Decarbonising the Production of Large Scale Forgings and Castings

谢菲尔德锻造公司专门从事大规模，高质量，铸造和锻造部件的制造。该公司在金属生产和成型方面拥有200年的历史，为包括国防，石油和天然气，可再生能源和发电在内的一系列市场部门提供产品。该公司代表了英国唯一一家为民用和国防应用提供主要核船舶锻件的能力。大规模铸造和锻造产品的生产在制造过程的多个阶段使用碳基燃料。碳排放的最大贡献者与各种加热应用的天然气燃烧有关。除了使用的一系列消耗品外，其他碳排放和碳源与切割和燃烧操作有关。该项目的主要目标是解决谢菲尔德锻造集团能源密集型制造过程的脱碳问题，以使该公司与到2050年实现净零碳排放的国家目标保持一致。将调查以炼钢和热处理等关键工艺为重点的初级制造路线，以确定脱碳的机会。该公司对天然气的依赖意味着将探索将燃料转换为氢等无碳当量的机会。此外，还将考虑去除切割操作中使用的氧乙炔和丙烷燃料的机会。拟议的脱碳解决方案还将从质量和工程性能的角度检查工艺变化对产品的潜在影响。这项研究的结果将用于未来资本投资的决策，并构成未来技术部署和发展项目的基础。该研究将确定公司基础设施可能需要进行的修改，以实现燃料转换，为工业使用无碳替代燃料建立一个案例，该案例可以潜在地部署到其他工业市场和部门。该项目代表了谢菲尔德锻铸集团全面脱碳战略的起点。该项目将与材料加工研究所合作交付，该研究所在高温，能源密集型行业拥有丰富的经验。材料加工研究所与谢菲尔德锻造集团一样，主要与钢铁行业合作，在参与和领导多合作伙伴技术项目方面有着良好的记录。该研究所在为基础工业脱碳的合作中，在炉子性能和工厂审计方面具有丰富的经验。

Sheffield Forgemasters specialises in the manufacture of large scale, high quality, cast and forged components. The company has a 200 year history in metal production and forming, supplying products to a range of market sectors including, defence, oil and gas, renewables and power generation. The company represents the UK's sole capability for supplying major nuclear vessel forgings for both civil and defence applicationsThe production of large scale cast and forged product uses carbon based fuels in multiple stages of the manufacturing process. The largest contributor to carbon emissions is related to the burning of natural gas for a variety of heating applications. Other emissions and sources of carbon are associated with cutting and burning operations, in addition to a range of consumables used.The principal objective of the project is to address the decarbonisation of energy intensive manufacturing processes at Sheffield Forgemasters, in order to align the company to the national ambition of achieving net zero carbon emissions by 2050\. Primary manufacturing routes, focusing on key processes such as steel making and heat treatment, will be investigated to identify opportunities for decarbonisation. The company's reliance on natural gas means opportunities for fuel switching to carbon free equivalents, e.g., Hydrogen, will be explored. In addition, opportunities to remove oxyacetylene and propane fuels used in cutting operations will also be considered.The proposed decarbonisation solutions will also examine the potential impact of process changes on products from a quality and engineering performance view point. The results of the study will be used to inform decisions on future capital investment and form the basis for future technology deployment and development projects. The study will identify the possible modifications required to be made to company's infrastructure to enable fuel switching, building a case for the industrial use of carbon-free alternative fuels which can be potentially be deployed to other industrial markets and sectorsThe project represents the starting point for a comprehensive decarbonisation strategy at Sheffield Forgemasters. The project will be delivered in partnership with the Material Processing Institute who has extensive experience in high temperature, energy intensive industries. Primarily working with the steel industry, The Materials Processing Institute, like Sheffield Forgemasters, have a strong track record of participating in and leading multi-partner technology projects. The Institute has experience in furnace performance and plant audit in collaborations working to decarbonise foundation industries.