Energy Efficient, Low CO2 Refractories for the Foundation Industries

PSR是集装箱玻璃行业耐火材料和工程玻璃空调系统的领先制造商，该行业的大部分业务是出口销售。PSR属于多个基础行业(陶瓷和玻璃)，其运营是能源密集型的。目前的耐火材料制造方法包括长烧成周期，人们认为通过缩短烧成周期可以实现显著(10%)的节能和相应的二氧化碳排放减少。该项目旨在找到一种经济高效的解决方案，以降低陶瓷耐火材料制造过程中的能源消耗。将研究添加掺杂剂使材料致密化，以实现更低的温度或更短的时间，从而减少能源消耗和二氧化碳排放。基于文献回顾，我们认为可以实现10%的节省。添加了掺杂剂的耐火材料的研究将通过化学、物理和热机械试验进行研究。该项目将通过与合作伙伴的知识转移和共同创造新概念的机会，使PSR受益；通过这种产业界和学术界的合作伙伴关系转移最佳实践；并提高制造过程的能源效率。此外，如果这项技术得到更广泛的许可/应用，英国和全球耐火材料行业可能会节省成本。在全球耐火材料行业的相关产品中，节省10%的能源和二氧化碳，估计每年将节省0.5-5公吨二氧化碳，即使吸收有限：-2010年，仅中国耐火材料行业就排放了5500万吨二氧化碳(Hu&Kavan，2014)。如果PSR能够将每个烧成周期减少10%，我们相信这是可以实现的，这将减少PSR的直接二氧化碳排放，降低能源成本，提高能源效率、环境可持续性和生产率。最重要的是，一旦进一步开发，这项技术将被授权给全球耐火材料市场的相关部分，每年节省0.5-5公吨二氧化碳(保守估计)。

PSR is a leading manufacturer of refractories and engineered glass conditioning systems for the container glass industry, where exports sales account for much of the business. PSR falls within multiple foundation industries (ceramics & glass), where its operations are energy intensive.Current refractories manufacturing methods include long firing cycles where it is believed that substantial (\>10%) energy savings and corresponding reduction in CO2 emissions could be achieved by reducing the lengths of firing cycles.This project aims to find a cost-effective solution to reduce energy consumption in the manufacturing process of ceramic refractories. The addition of dopants to densify the material will be investigated to enable firing at lower temperatures or for shorter times, reducing energy consumption and CO2 emissions. Based on a literature review we believe that \>10% savings are achievable. Study of refractories with dopant additions will be studied by chemical, physical and thermo-mechanical testing.This project will benefit PSR through knowledge transfer with partners, and opportunities to co-create new concepts; transfer best practice through this industry - academia partnership; and improve the energy efficiency of the manufacturing processes. Furthermore, there are potential savings across the UK and global refractories industries if this technology were licensed / applied more widely. A 10% energy and CO2 saving across the relevant products within the global refractories industry, would save an estimated 0.5-5 MT / year, even with only limited uptake:- China's refractories industry alone emitted 55MT CO2 in 2010 (Hu & Kavan, 2014).If PSR were able to reduce each firing time cycle by 10%, which we believe achievable, this would reduce direct PSR's CO2 emissions, lowering energy costs and improving energy efficiency, environmental sustainability and productivity. Most importantly, this technology, once further developed, will then be licensed to relevant parts of the global refractories market, saving 0.5-5 MT CO2 / yr (conservative estimates).