Development of Refractory Coatings to support the Decarbonisation of the Steelmaking Process

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Background:In terms of global energy demand, according to the international energy authority, of the heating component 66% is industrial heat. This represents a staggering 20% of total demand. All of these processes utilise refractory [1] materials to contain and manage that heat. Steelmaking is no different. In fact, an integrated steel plant produces enough waste heat in a year to heat 500,000 homes. As such, to achieve net zero and solve the current energy crisis we must enhance industrial thermal efficiency through revolutionary approaches to the design and use of these refractory insulation materials. This is the primary goal and impact of this project.As TATA Steel moves towards its ambition of carbon neutral steelmaking by 2050 and a reduction of CO2 emissions of 30% in the UK by 2030[2], there is a need to transform the way sustainable steel is produced. Liquid Iron & Steel are both transported and processed in refractory coated vessels, examples being torpedoes, ladles, BOS (Basic Oxygen Steelmaking) vessels, tundishes, etc. At each process step, temperature loss occurs. The temperature deficit is addressed either through chemical heating processes, or adjustments made to scrap and alloy inputs to manage the final temperature. All of these steps increase energy requirements, have a resultant impact on the CO2 emissions and overall conversion cost of the final steel product; single degree changes across the operation can save hundreds of thousands of pounds per year.Project aims:The aim of the project is to study the Refractory coating systems, to both assess and reduce the energy losses and CO2 emissions of the steelmaking process. This will involve benchmarking, design studies, data analytics, thermal / finite element modelling, laboratory & plant scale trials and development of measurement systems (both contact & non-contact). It will also involve advanced refractory testing and collaboration with industrial, plant and research institutions will be required as it may provide wider opportunities to share learnings for the benefit of the global steel industry.[1] Refractory materials are designed to be resistant to decomposition by heat, pressure and chemicals, and to retain their mechanical properties at temperatures encountered in the modern manufacturing environment. The purpose of a refractory material is to contain heat whilst simultaneously protecting processing equipment. Typically, these materials are used as coatings for boilers, furnaces, incinerators etc and have multiple applications in the steel making process.[2] Tata Steel in Europe Sustainability Report 2019/2020 (https://www.tatasteeleurope.com/sustainability and https://www.tatasteeleurope.com/sites/default/files/TSE%20Sustainability%20report%202019-20%20%28EN%29.pdf)