Periodic Reporting for period 1 - CESAREF (Concerted European action on Sustainable Applications of REFractories)
Reporting period: 2022-10-01 to 2024-09-30
The CESAREF project addresses critical challenges in refractory materials within the context of the European Green Deal and the urgent need to reduce greenhouse gas emissions in energy-intensive industries. Refractory materials play a crucial role in high-temperature industrial processes, particularly in steelmaking, which significantly contributes to global CO2 emissions. As the steel industry transitions towards more sustainable practices, including hydrogen-based technologies, there is a pressing need for innovative refractory solutions that can withstand new operational conditions while improving energy efficiency and reducing environmental impact.
CESAREF brings together 8 academic partners, 9 industrial partners, and 9 associated partners to train 15 doctoral candidates in developing sustainable refractory solutions. The project aims to equip these researchers with the knowledge and skills necessary to contribute to the decarbonisation of energy-intensive industries, focusing on four key areas: efficient use of mineral resources and recycling, microstructure design for increased sustainability, anticipation of hydrogen steelmaking requirements, and enhancement of energy efficiency and durability.
By addressing these challenges, CESAREF aims to make significant contributions to the European Research Area in refractory materials, strengthening its global competitiveness. Expected impacts include developing new methodologies for efficient resource use and recycling, enhanced design and characterisation routes for improved process and material sustainability, and innovative environmental assessment tools for eco-design of refractory materials.
The project's interdisciplinary nature, combining materials science, engineering, and environmental assessment, positions it to contribute substantially to European Green Deal objectives. By training researchers with a holistic understanding of refractory materials and their applications in sustainable industrial processes, CESAREF aims to bridge the gap between academic research and industrial implementation, accelerating the adoption of innovative solutions for a low-carbon future in energy-intensive industries.
CESAREF brings together 8 academic partners, 9 industrial partners, and 9 associated partners to train 15 doctoral candidates in developing sustainable refractory solutions. The project aims to equip these researchers with the knowledge and skills necessary to contribute to the decarbonisation of energy-intensive industries, focusing on four key areas: efficient use of mineral resources and recycling, microstructure design for increased sustainability, anticipation of hydrogen steelmaking requirements, and enhancement of energy efficiency and durability.
By addressing these challenges, CESAREF aims to make significant contributions to the European Research Area in refractory materials, strengthening its global competitiveness. Expected impacts include developing new methodologies for efficient resource use and recycling, enhanced design and characterisation routes for improved process and material sustainability, and innovative environmental assessment tools for eco-design of refractory materials.
The project's interdisciplinary nature, combining materials science, engineering, and environmental assessment, positions it to contribute substantially to European Green Deal objectives. By training researchers with a holistic understanding of refractory materials and their applications in sustainable industrial processes, CESAREF aims to bridge the gap between academic research and industrial implementation, accelerating the adoption of innovative solutions for a low-carbon future in energy-intensive industries.
WP1 focused on improving the sustainable use of mineral resources and recycling in the refractory industry. Key results include the establishment of a robust database on refractory raw materials, the development of life cycle assessment methodologies for evaluating environmental impact, and the identification of strategies to enhance recycling loops. Progress was made in refining resource depletion indicators and optimizing production processes for eco-design.
WP2 advanced the microstructural design of refractories for improved sustainability. Research provided new insights into the structural and chemical evolution of materials under high temperatures, as well as the impact of thermal treatments on microcracks and stress distribution. Experimental techniques such as synchrotron radiation were used to analyse material transformations, leading to a better understanding of how microstructure influences macroscopic properties.
WP3 tackled the challenges of hydrogen-based steelmaking and its effects on refractory materials. The work included the development of a thermochemical database for refractories in hydrogen environments and studies on how hydrogen alters their mechanical and thermophysical properties. Research also explored site-specific configurations and the broader transferability of findings to other industrial processes aiming for net-zero emissions.
WP4 concentrated on enhancing energy efficiency and durability in steel manufacturing through digital tools. Progress included the development of novel monitoring sensors to track refractory performance, improved modelling techniques for simulating thermal behaviour, and experimentation to validate findings in industrial settings. Decision-support tools were created to optimize refractory use and steel ladle management, contributing to reduced energy consumption and improved sustainability.
WP2 advanced the microstructural design of refractories for improved sustainability. Research provided new insights into the structural and chemical evolution of materials under high temperatures, as well as the impact of thermal treatments on microcracks and stress distribution. Experimental techniques such as synchrotron radiation were used to analyse material transformations, leading to a better understanding of how microstructure influences macroscopic properties.
WP3 tackled the challenges of hydrogen-based steelmaking and its effects on refractory materials. The work included the development of a thermochemical database for refractories in hydrogen environments and studies on how hydrogen alters their mechanical and thermophysical properties. Research also explored site-specific configurations and the broader transferability of findings to other industrial processes aiming for net-zero emissions.
WP4 concentrated on enhancing energy efficiency and durability in steel manufacturing through digital tools. Progress included the development of novel monitoring sensors to track refractory performance, improved modelling techniques for simulating thermal behaviour, and experimentation to validate findings in industrial settings. Decision-support tools were created to optimize refractory use and steel ladle management, contributing to reduced energy consumption and improved sustainability.
The CESAREF project has delivered several advancements beyond the state of the art in the field of refractory materials for energy-intensive industries. One major innovation involves the integration of Life Cycle Assessment (LCA) methodologies into the design and recycling of refractories, allowing for a comprehensive evaluation of their environmental impact. This approach has identified new recycling routes and eco-design strategies, significantly enhancing resource efficiency and reducing waste in steel production.
CESAREF has also advanced the microstructural design of refractory materials, applying cutting-edge characterization techniques and numerical modelling to optimize thermomechanical properties. Innovations in digitalization, such as the use of advanced digital twins and real-time monitoring systems, have been developed to predict refractory performance and enhance operational efficiency. The project has introduced reduced-order models and deep autoencoders to manage the thermal behaviour of steel ladles more effectively, thereby improving energy efficiency and reducing CO2 emissions.
To ensure further uptake and success of these advancements, several key needs must be addressed. The continued development and refinement of predictive models and decision support systems are essential for integrating these innovations into real-time industrial applications. Further optimization of the algorithms and the inclusion of heuristic methods are required to manage the complexity of large-scale operations effectively. Moreover, the integration of these digital tools into existing industrial processes demands a robust data infrastructure, including reliable data acquisition systems and secure, scalable cloud-based platforms.
Industry collaboration remains critical for the practical adoption of these innovations. Enhanced partnerships between academia and industry will support the deployment of novel refractory solutions across different sectors, including cement and glass production. Training initiatives that build interdisciplinary expertise in digitalization, materials science, and sustainability are crucial for preparing the next generation of researchers and engineers.
CESAREF has also advanced the microstructural design of refractory materials, applying cutting-edge characterization techniques and numerical modelling to optimize thermomechanical properties. Innovations in digitalization, such as the use of advanced digital twins and real-time monitoring systems, have been developed to predict refractory performance and enhance operational efficiency. The project has introduced reduced-order models and deep autoencoders to manage the thermal behaviour of steel ladles more effectively, thereby improving energy efficiency and reducing CO2 emissions.
To ensure further uptake and success of these advancements, several key needs must be addressed. The continued development and refinement of predictive models and decision support systems are essential for integrating these innovations into real-time industrial applications. Further optimization of the algorithms and the inclusion of heuristic methods are required to manage the complexity of large-scale operations effectively. Moreover, the integration of these digital tools into existing industrial processes demands a robust data infrastructure, including reliable data acquisition systems and secure, scalable cloud-based platforms.
Industry collaboration remains critical for the practical adoption of these innovations. Enhanced partnerships between academia and industry will support the deployment of novel refractory solutions across different sectors, including cement and glass production. Training initiatives that build interdisciplinary expertise in digitalization, materials science, and sustainability are crucial for preparing the next generation of researchers and engineers.