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

背景：就全球能源需求而言，根据国际能源权威机构的数据，供热组件中66%是工业用热。这相当于总需求的20%。所有这些过程都使用耐火材料[1]来容纳和管理热量。炼钢就不一样了。事实上，一家综合钢铁厂一年产生的废热足以为50万户家庭供暖。因此，为了实现净零排放并解决当前的能源危机，我们必须通过革命性的方法来设计和使用这些耐火隔热材料来提高工业热效率。这是该项目的主要目标和影响。随着塔塔钢铁朝着2050年碳中和炼钢和2030年在英国减少30%二氧化碳排放的目标迈进[2]，有必要改变可持续钢铁的生产方式。液态铁和钢都是在耐火涂层容器中运输和加工的，例如鱼雷，钢包，BOS（碱性氧气炼钢）容器，中间包等。在每个工艺步骤中，都会发生温度损失。通过化学加热过程或调整废料和合金投入以管理最终温度来解决温度不足。所有这些步骤都增加了能源需求，对最终钢铁产品的二氧化碳排放和整体转化成本产生了影响;整个操作过程中的单一温度变化每年可以节省数十万磅。项目目标：该项目的目的是研究耐火涂层系统，以评估和减少炼钢过程中的能源损失和二氧化碳排放。这将涉及基准测试、设计研究、数据分析、热/有限元建模、实验室和工厂规模试验以及测量系统的开发（接触式和非接触式）。它还将涉及先进的耐火材料测试，并将需要与工业，工厂和研究机构合作，因为它可能提供更广泛的机会来分享知识，以造福全球钢铁行业。[1]耐火材料被设计成抵抗热、压力和化学品的分解，并在现代制造环境中遇到的温度下保持其机械性能。耐火材料的目的是容纳热量，同时保护加工设备。通常，这些材料用作锅炉、熔炉、焚化炉等的涂层，并在炼钢过程中具有多种应用。[2]塔塔钢铁在欧洲的可持续发展报告2019/2020（https：www.tatasteeleurope.com/sustainability and https：//www.tatasteeleurope.com/sites/default/files/TSE%20Sustainability%20report%202019-20%20%28EN%29.pdf）

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)