During the first period, the project focused on the specifications of the pilot, CFD simulations to design an optimal prototype cell and development of the process parameters as well as designing the overall system. Regarding the use of alternative raw materials, the period was centered on the characterization of bauxite residue samples from the Bayer Process.
During the second period, the development of the numerical 3D CFD model has been achieved and successfully applied to design the cell while finalizing the design of the overall system and the sub-components (3D and 2D drawings) in order plan the erection of the pilot in the building that has been built specifically to host the pilot. Laboratory trials on bauxite residues and other alternative materials were pushed further in order to assess the current efficiency (70% à 130°C).
During the 3rd period, the efforts were focused on 2 main items: finalizing the design of the equipment and the commissioning of the pilot. After the basic design, we focused on the detailed design of each sub-component such as the P&ID, the instrument and motor list, the valve list and so on. During the first phase of the commissioning, many experiments have been conducted in order to define the best materials for the cell, as well as the best electrolysis parameters.
During the fourth period, a huge effort has been put towards the safe operation of the pilot with the completion of an ATEX and HAZOP analysis. Several trials on the cell to produce iron plates have been carried out. Changes were made to the initial process design and parameters to enhance gas management and improve the quality of the iron plates. These modifications involved reducing the cathode size, decreasing the flow rate of the electrolyte, and lowering the concentration of hematite. In the last year, a total of six trials have been carried out with the graphite mini-cathode, resulting in the production of intact iron plates for the first time. Overall, these adjustments have proven to be effective in optimizing the gas management system and enhancing the quality of the final product.
Finally, an exploitation roadmap has been defined with the partners and some of this exploitation work will also be performed within the scope of a follow-up EU project as well as more complex studies on raw materials which are promising but couldn't be fully finalized.
SIDERWIN is highly promising as during the fourth and final period, the project managed to produce a first 1.25M2 of intact iron plate after the adjustments of the initial cell design and process parameters. A data driven predictive model, and an optimization tool have been developed.
Whilst the technology is currently working, and optimisations are still needed, current cost estimates and revenue projections show that with further research and the right exploitation of available flexibility in its production process this is a promising sustainable way of producing steel.
