Modelling and optimal design of refractories for high-temperature industrial applications for a low carbon society

Project Information

RE-FRACTURE2

Grant agreement ID: 955944

DOI

10.3030/955944

Project closed

EC signature date 16 July 2020

Start date 1 January 2021

End date 31 December 2024

Funded under

• EXCELLENT SCIENCE - Marie Skłodowska-Curie Actions

Total cost

€ 1 471 290,48

EU contribution

€ 1 471 290,48

Coordinated by

UNIVERSITA DEGLI STUDI DI TRENTO
Italy

Periodic Reporting for period 2 - RE-FRACTURE2 (Modelling and optimal design of refractories for high-temperature industrial applications for a low carbon society)

Reporting period: 2023-01-01 to 2024-12-31

Summary of the context and overall objectives of the project

The steel industry contributes to global CO2 emissions due to the energy-intensive processes involved in molten steel handling and processing. A critical aspect of steel production is refractory materials, which must withstand extreme thermal and chemical conditions. However, current refractory designs present inefficiencies, leading to energy waste, limited lifespan, and environmental impact. It is thus essential to develop advanced computational models that allow for the design of more efficient and durable refractory components.
Reducing the environmental footprint of steel production will significantly contribute to global efforts to combat climate change. Developing improved refractory materials will save energy, reduce waste, and lower CO2 emissions. Training researchers in cutting-edge computational modelling and simulation techniques will foster innovation, ensuring Europe remains a leader in sustainable industrial practices.
This project plays a vital role in making the steel industry more sustainable by achieving these objectives, aligning with global efforts to transition towards a low-carbon economy while maintaining industrial competitiveness and innovation.

Work performed from the beginning of the project to the end of the period covered by the report and main results achieved so far

This research project focused on developing advanced computational models for refractory materials to enhance their performance in high-temperature industrial applications, particularly in steel production. Refractories, known for their exceptional thermal and chemical stability, are crucial for handling molten steel and other high-temperature materials. However, optimizing their design for efficiency and sustainability has remained a challenge.
Through groundbreaking computational simulations, this project modelled refractory behaviour across their full working temperature range. These advancements have led to significant improvements in the design of critical components such as refractory nozzles, plates, ladles, and tundish slide gate systems. The results demonstrate the potential for substantial energy savings, reduced waste, lower CO2 emissions, and enhanced safety in steel production processes.
Additionally, the project trained a new generation of researchers in applying modelling and simulation tools for refractory design. These experts are now equipped to drive innovation in materials science, ensuring that the industry continues to balance technological advancements with environmental sustainability.
The research outcomes contribute to a more sustainable steel industry by improving refractory components’ resilience to extreme thermal and mechanical stresses and developing innovative solutions for handling molten materials. As a result, new refractory materials can be produced with lower energy consumption, improved safety, and extended lifespan, significantly reducing the environmental footprint of steel manufacturing.

Progress beyond the state of the art and expected potential impact (including the socio-economic impact and the wider societal implications of the project so far)

The RE-FRACTURE2 project has successfully advanced beyond the state of the art, helping to create a new group of European researchers with solid academic backgrounds and a deep understanding of industrial demands. This project has also made them more aware of energy-saving techniques and reducing waste, which is essential today. These researchers are ready to handle complex industrial projects focusing on a circular economy. The goal is to make things more innovative, use fewer materials, reuse and recycle more, and reduce waste. PhD students worked on research projects, expanding their expertise into previously unexplored areas. By the end, they were able to set up manufacturing systems that save time in design and production, which means less cost and better, more reliable products. The project also encouraged knowledge sharing between the industry and universities, with many workshops, seminars, and direct teamwork. This approach has been essential for the European steel industry, which is facing challenges like CO2 emissions and competition from developing countries. RE-FRACTURE2 is helping Europe stay competitive globally by focusing on training and research that support a shift toward a low-carbon economy. Apart from the technical outcomes, the project also had a broader impact. It trained young researchers to improve industrial production and create new high-temperature processes. It helped keep the steel components market strong and boosted EU scientists' skills. The project also created jobs in areas of high-temperature applications within the EU. It helped EU manufacturers become more competitive in the global steel market. By reducing the use of raw materials and energy, it helped cut down greenhouse gas emissions.
Most importantly, it created a new generation of designers who are more conscious about the environment and resource efficiency. Overall, RE-FRACTURE2 has made a real difference in science and industry. It has prepared young researchers to lead in sustainable manufacturing and ensured Europe remains at the forefront of innovation while protecting the environment.

Field picture of a slide gate.