Annual Review 2020/2021 - SUSTAIN Steel

Annual Review
2020/2021

Contents

 sustainsteel.ac.uk
 04
 Introduction
 12
 Core Research
 @SustainSteel to the Hub
 Sustain Steel Welcome 04 Grand Challenges and
 Hub Overview 05 Themes 12
 info@sustainsteel.ac.uk Steel on the National Task Updates 16
 Agenda 08
 SUSTAIN Future Manufacturing Research Hub Industry Engagement 10
 Swansea University Bay Campus
 Fabian Way
 Crymlyn Burrows
 Skewen
 Swansea
 SA1 8EN
 32
 Hub Funded
 38
 Hub Activity
 Research
 Feasibility Studies 32 Facilities 38
 Early Career Events and Outreach 42
 Researcher Platform 36 Awards 44

 45
 Publications
 46
 Meet the Team

 Publications, Articles Management Team 46

 “Sustainability is the biggest challenge of our generation and the and Media 45 Strategic Advisory Board
 Operational Committee
 47
 48
 metallurgical sciences are ready to make their contribution” Investigators 49
 - Professor Dierk Raabe - Max-Planck-Institut Researchers 50

2 EPSRC Strategic University Steel Technology and Innovation Network Future Manufacturing Research Hub Annual Review 2020/2021 3

Welcome Hub Overview
 Dear Partners, members and future collaborators
 The SUSTAIN (Strategic University Steel Technology and Innovation Network) Future Manufacturing Research
 Hub is a £35M project funded by £10M of EPSRC funds as well as by Universities, Trade Bodies, Research and
 It gives us great pleasure to welcome you to the second
 Technology Organisations (RTO's) and Businesses over 7 years and aims to support the development of new,
 Annual Report for the SUSTAIN Future Manufacturing Hub, a
 smarter and more environmentally friendly options to ensure the future of steel manufacturing in the UK.
 programme based on two Grand Challenges, five Themes and
 13 Tasks. The Hub was launched in April 2019 as a National
 The Hub is based at Swansea University, with spokes at the University of Sheffield and WMG, University of
 Centre of Excellence for Steel, led by Swansea University in
 Warwick. Our headline industrial sponsors are British Steel, Celsa Steel UK, Liberty Steel, Sheffield Forgemasters
 collaboration with our Spoke partners Sheffield and Warwick
 and Tata Steel UK. The Hub currently has academic partnerships with Cardiff University, Durham University
 Universities and industrial partners British Steel, Celsa Steel
 and University College London.
 UK, Liberty Steel, Sheffield Forgemasters and Tata Steel UK.

 The SUSTAIN Team The Hub was launched during a period of uncertainty for UK
 Steel to provide a platform for novel research to deliver a net
 zero carbon and higher digital integration for the industry.
 This project focusses upon diverse areas such as Carbon
 Capture and Utilisation, the better use of waste products and
 heat energy, the development of novel sensing and analysis
 techniques, novel steel chemistries and processing and new
 digital techniques, both internally and externally within the
 greater supply chain.

 Steel is ubiquitous and a fundamental enabler of modern life.

 “Steel and concrete are The intricacy of modern steelmaking and the sheer volume
 of manufacture places steel in a pivotal position to drive the
 the working horses of the
 circular economy – not just for steel, but for all of the modern
 Anthropocene. But only materials that are used with it to achieve greater product
 steel offers the variety functionality. Drawing upon the knowledge and esteem of the
 partners, the Hub continues to advance research in areas that
 of reuse, repair and
 are germane to the continuation and growth of the industry
 remanufacture, which is in a circular, net zero carbon future economy. Our vision is
 at the base of the circular to provide a profitable, sustainable industry and supply chain
 with increased GVA, employment and sovereign capability for
 industrial economy.
 the UK's future needs.
 Scientific challenges for
 sustainable steel include Despite the COVID-19 pandemic, over the last two years we
 have witnessed the growth of an incredible collaborative
zero-carbon production and
 partnership between the steel industry and aligned academia.
 pure recovery technologies Working side by side to overcome the many formidable
 for molecules and alloys. challenges we face to enable a carbon free, truly sustainable
 future. We would like to thank each of our partners and
 Sustainable steel’s future
 collaborators for their continuous support to the SUSTAIN
 will come! ” Hub and look forward to new members joining the consortium
 - Dr Walter Stahel - Product Life Institute to drive a successful future for UK Steel.

 The SUSTAIN Team

 4 EPSRC Strategic University Steel Technology and Innovation Network Future Manufacturing Research Hub Annual Review 2020/2021 5

SUSTAIN in Numbers

44 6 6
 academics & new projects
 researchers funded by the
 working at universities hub in 20/21

 19 totalling
 aligned projects
 secured in 20/21 >12,000 website page
 views from

 £12.6m >3,500
 Task 9: TEM image
 Task 10: Subcoal™ showing reverted austenite
 in pellet form in a tempered martensite
 after processing matrix in a Super 13Cr steel

 in additional funding unique visitors

21 10
 industrial papers &
 
 engagement & 
 articles
 published
 workshop events Task 6: Optical surface
 measurements that
 quantitatively determine
 Facilities at WMG: graphite crystal orientation
 Alloy development have been developed

 >850 
 young people reached
 through supporting
 online outreach

>900 20
 attendees to
 project partners
 hub & supported Task 10: Blast furnace
 & collaborators Task 1: Biorefinery
 Tuyeres used to direct the
 events tubular reactor
 hot air into the furnace,
 and through which milled
 stack for algae
 reductants are added
 growth

6 EPSRC Strategic University Steel Technology and Innovation Network Future Manufacturing Research Hub Annual Review 2020/2021 7

Steel on the National Agenda “ofTothe
 ensure the continual existence
 human race where science,
 technology and living standards
Dr Richard Curry continue to improve from
 generation to generation, we
The UK Steel Industry, once world leading in terms of must quickly transition to a truly
innovation, productivity and volume has been decimated
 circular economy where nothing
in recent decades by new entrants to the saturated global
linear economy. These new entrants, located in developing is wasted, resources are cycled
nations, have access to more favourable operational costs from generation to generation with
and lower national environmental targets that have applied
increasing pressure to the European and US producers,
 minimal loss. ”
reducing profit margins and potential for reinvestment and
growth. As the UK moves forward post-Brexit and COVID-19,
it is clear that there are vulnerabilities in many of these key be easy and will require a paradigm shift in thinking and
areas that not only force dependence upon imports for our attitude - focussing upon the domestic raw materials of the
own infrastructure, defence and consumables, but reduce future that we currently call ‘waste’ and making changes
our ability to control quality and maximise profitability from to the way we design and manufacture products that will
the high value goods we export. appear to be anathema to the current high efficiency, high
 productivity manufacturing processes.
The global environmental crisis together with the
diminishing availability and escalating prices of mined As the UK emerges from the COVID-19 pandemic, steel’s
elements that are key to modern technology, living standards sheer ubiquity, production volume and potential for
and renewable energy production are quickly showing that recycling, places the industry in a primary position to
we can no longer exploit our ‘consume and dispose’ habits lead the UK and rest of the world in a circular economy
that exemplify the linear economy to date. To ensure the revolution. The SUSTAIN project, funded by UKRI, British
continual existence of the human race where science, Steel, Celsa Steel UK, Liberty Steel, Sheffield Forge Masters
technology and living standards continue to improve from and Tata Steel UK together with support from the UK's
generation to generation, we must quickly transition to a leading material research laboratories and Trade Bodies,
truly circular economy where nothing is wasted, resources was created to lead the UK through this transition. With
are cycled from generation to generation with minimal loss. focus upon the main challenges to sustainability such as
This must be achieved on a foundation of carbon neutral the sequestration and reuse of waste heat and carbon
energy to ensure sustainability and prevent environmental emissions, reuse of hydrocarbon wastes and end of life
catastrophe. consumer goods, digital innovation, harsh environment
 sensor and measurement techniques and late stage
Due to its size, geography and history, the UK stands in a product differentiation, SUSTAIN aims to provide a
formidable position to lead the world in the transition to a national research platform to bring together the finest
true circular economy that must begin with the foundation UK academics, Research and Technology Organisations
industries as its nucleus. This must also include, influence (RTOs), Small and Medium Sized Enterprises (SMEs) and
and shape the supply chain, higher tier manufacturing tech companies to overcome these challenges through the
and tech industries to be truly circular in terms of future application of novel research to primary steel production
generations of society. However, this change will not and the greater supply chain.

 8 EPSRC Strategic University Steel Technology and Innovation Network Future Manufacturing Research Hub Annual Review 2020/2021 9

Industry Engagement Research Programme Structure

 The SUSTAIN Hub is split into two Grand Challenges, five Themes and nine main Tasks. Three
 additional Feasibility Studies have commenced, as well as a Task 0 which aims to monitor the impact
“developed
 Steel is a vital material in modern society. New grades are being
 every year to reduce the ‘in use’ carbon footprint of
 of the Hub as a whole.

products made from steel and supply our everyday needs in the
automotive, packaging, construction and engineering sectors.

SUSTAIN is helping to bring the steel industry and academia
together, to address the many challenges and opportunities for
this industry. How do we de-carbonise manufacturing processes?
What is the role for digital in a successful and sustainable 21st
century steel industry? How do we develop the next generation
of engineers and scientists to work in the industry? It’s been a
pleasure to meet such passionate and capable people through
SUSTAIN. I’m looking forward to the next steps in our journey
together.
 ”
- Byron Tucker - Tata Steel UK

 “SUSTAIN is a unique opportunity for the UK-based steel companies
 to have access to a wide variety of know-how and facilities across
 the Universities of Sheffield, Swansea and Warwick plus networked
 to other academic institutions. At one time our UK steel companies
 were mainly one large corporate organisation with its own corporate
 research facilities. This has long gone, but the advantage now
 is access to wider academic interests, state-of-the-art research
 equipment and collaborative knowledge groups. Activities of
 interest to Liberty Steel range from management of scrap supply,
 steelmaking controls, digital technologies and through to design of
 process and products using metallurgical principles.
 ”
 “Without the SUSTAIN initiative we would undoubtedly have fallen
 - Dr Simon Pike - Liberty Steel UK

 back into the trap of optimising steel properties per se instead of
 optimising steel properties per unit of environmental damage ”
 - Professor Sybrand van der Zwaag - TU Delft

 10 EPSRC Strategic University Steel Technology and Innovation Network Future Manufacturing Research Hub Annual Review 2020/2021 11

Core Research Grand Challenges and Themes

 SUSTAIN Grand Challenges and Themes

The SUSTAIN project aims to address two Grand Challenges:

Carbon Neutral Iron and Steelmaking Smart Steel Processing Theme 2:
 Zero Waste Steelmaking
Steel is ubiquitous in the modern developed world; This Grand Challenge aims to revolutionise the
its low cost and the highly developed industry that steel industry through the development of steels This theme concentrates on the reuse of domestic
produces it enable the standard of living we are with enhanced mechanical and physical properties, and industrial waste products within the steelmaking
accustomed to. From packaging to construction, develop increased functionality and utilise the recent process. The projects here focus on the substitution
transport and energy, steel plays a major part in developments in sensor technology and digital of fossil fuels with applicable landfill waste and the
our daily lives without us noticing. Although the systems. Focussing on production and supply reuse of end of life ferrous materials.
steelmaking process is highly efficient, for every chains, the Smart Steel Processing Grand Challenge
tonne of steel produced, twice the amount of CO2 is is introducing concepts such as blockchain and The UK currently exports approximately 10 M tonnes
liberated from fossil fuels to drive the process and its tracking technologies into a mature supply chain of scrap steel per year which could be recycled locally.
energy requirements. The first of SUSTAIN’s Grand and customer base that will explicitly describe the The main challenge in its reuse is the management
Challenges aims to develop innovative methods to manufacturing process and sourced materials on a of unknown elements inherited from a range of steel
eliminate the carbon footprint of the steelmaking product by product basis giving the end customer types, and well as non-ferrous and non-metallic
processes and provide a sustainable method of and government bodies full confidence in the contamination, introducing impurities.
production for a carbon neutral industry which product's performance, ethical raw material sourcing,
supports global needs. production and carbon footprint.

 These Grand Challenges are split into five Themes:

 Theme 1: Theme 3:
 Emissions Management and Utilisation Data Driven Innovation

 This theme focusses on carbon capture and usage To be transformative, the industry will have to be
 of large sources of CO2 and management of other disruptive. The goal of this task is to ultimately
 harmful gaseous and particulate emissions. generate disruptive technologies for 21st Century
 supply chains and business models.
 The first challenge is demonstrating a robust
 recovery and separation process to extract CO2 from New approaches to process modelling and optimised
 a range of output gas streams. Then, the re-use of fast-algorithm techniques will be used to allow
 the captured CO2 will be investigated at laboratory real-time simulation and prediction of complex
 scale, before upscaling to industry. thermodynamic, kinetic and mechanical processes.

 12 EPSRC Strategic University Steel Technology and Innovation Network Future Manufacturing Research Hub Annual Review 2020/2021 13

Core Research Grand Challenges and Themes

 Progress reports by Task

 As documented, the majority of the core SUSTAIN The introduction of four new Tasks (T0, T10, T11
 Tasks are underway and making good progress, with and T12) has occurred over the last year, three of
 most PDRA positions recruited and lab work, despite which appear under the Feasibility Studies section.
 ongoing COVID-19 restrictions, having commenced. Although in the very early stages of development,
 T7 has an ongoing PhD recruitment drive thereby T0 will identify and nurture common challenges and
 Theme 4: delaying commencement in time for this Review. focus groups across the whole SUSTAIN activity
 Smart Low Energy Production landscape, including GCRA, Platform and Feasibility
 funds. The objective is to then evaluate the resulting
 This theme focusses on using smart techniques, scientific industrial impact.
 enhanced material properties and non-carbon
 sourced reactants to reduce the net carbon usage
 and energy required throughout the steelmaking
 process.

 Thermal energy lost as heat throughout the steel
 manufacturing process is considered together with
 both the use of new novel materials to convert
 conducted and radiated heat into useful electrical
 energy, as is the performance and durability of
 existing and future refractory materials.

 Theme 5:
 New Processes for New Products

 This theme looks at the potential of using novel
 chemistries, processes and measurements to
 produce new products or improve the efficiency and
 consistency of existing high value steels.

 One area of focus is microstructural monitoring during
 processing, whilst the other looks at the development of
 ultra-high-performance steel for improved processing
 efficiency, reduced process energy requirements, ultra
 high strength for equivalent lighter weight products
 and novel processes which enable late differentiation
 of the steel into a range of diverse products.

14 EPSRC Strategic University Steel Technology and Innovation Network Future Manufacturing Research Hub Annual Review 2020/2021 15

Core Research Theme 1

 Carbon dioxide capture processes:
 The large absorber rig is currently being prepared and subsequent methanol to DME step. This will be
 to commence testing. There have however been carried out on a laboratory-based sub-pilot plant. The
 Task 1: Emissions Control delays in acquiring a new compressor power source DME unit will first be optimised using commercial
 with pressure drop. Additional parts to allow for Vulcanol before progressing to using our own CO2-
 automation of the larger rig are currently on order for derived methanol. This will allow us to streamline
 immediate installation when delivered. and expedite the overall process development.
 Start date: October 2020 Expected end date: October 2023
 Pls: Professor Andrew Barron, Professor Peter Styring, Dr Enrico Andreoli Carbon dioxide thermochemical conversion: Carbon dioxide electrochemical conversion:
 Researchers: Dr George Dowson, Dr Waqas Hassan Tanveer As a result of the literature reviews, it has become clear The design, assembly and calibration of a bench scale
 that the most beneficial route to commercialisation CO2 electrolyser has been completed. Self-supported
 Project partners: Swansea University, University of Sheffield
 will be through CO2-to-DME, using renewable energy copper-based gas diffusion electrodes have been
 as the input (eDME). Work has begun to redesign a prepared and are undergoing tests for operational
Project Abstract Industry context
 reactor to perform the CO2 to methanol conversion stability.
The aim of Task 1 is to reduce carbon emissions from The future of the steel industry depends on the
steelmaking processes by capturing and converting integration of production units where the resource
the emitted carbon dioxide into high value-added use is optimised for profitability and sustainability.
products. The development of this technology is Blast furnace and coke oven gases contain CO2 which,
essential as the steelmaking processes in their on removal, can help deliver purified components
current form will continue to generate CO2 for some including carbon monoxide and hydrogen. Whilst
time. Complementary Tasks within the SUSTAIN Hub the production of steel is of core importance to
are developing lower carbon technologies to further the industry, integrated steelworks could make
drive the industry towards a net zero future. There additional income from by-product streams, including
is a real opportunity for the overall cost of carbon the conversion of CO2 to value-added products.
capture and sequestration to be offset via valuable Thermochemical and electrochemical conversion of
products made from the captured CO2. CO2-derived CO2 to hydrocarbons and oxygenates (e.g. ethylene,
chemicals and fuels are of particular interest to us DME) and algae biorefinery conversion of CO2 to
for their added value and in some cases large market lipids and proteins are crucial to this approach.
scale merit, demonstrating the potential for a future
circular economy based on CO2 recycling.
 Progress to Date Above: (a) Schematic representation of CO2 fed
Key findings: Carbon dioxide capture materials: electrolyser setup. (b) Snapshot of the actual Above: Self-supported gas diffusion electrodes for
 Amine-based (triazine-based cross-linked testing station. CO2 electrolysis. (a) Photo of a copper mesh before
Synthesis of CO2 capture materials completed at and after the copper foam deposition. Microscopy
 polyethyleneimine) materials have been successfully
gram scale for testing in dynamic breakthrough images showing the general structure (b) of the
 synthesised, characterised and prepared at gramme
system Planned Impact: microscopic structures of foams (c-e) using
 scale for testing in the Thermal Pressure Swing different deposition conditions.
 Providing the UK steel industry with designed
 Adsorption Unit. Experiments to characterise
 Lab scale CO2 electrolyser for production of scalable options for carbon dioxide valorisation
 the materials for dynamic CO2 breakthrough are
 hydrocarbons operational underway at the Research Centre for Carbon Solution
 (RCCS), at Heriot-Watt University in collaboration Additional Task 1 activities: Collaboration with The green hydrogen production unit has now been
Protocol for preparing self-supported gas with Dr Susana Garcia with a research paper awaiting Reducing Industrial Carbon Emissions (RICE): running 12 months at Hanson UK, replacing some of
diffusion electrodes for robust CO2 conversion submission once this data has been received. Carbon Dioxide Biorefinery - The biorefinery the natural gas used to process slag for aggregate.
completed demonstrator is currently being installed at Vale’s
 Ionic liquids supported cellulose materials are Clydach Nickel Refinery. Progress has also been Pressure Swing Adsorption Unit (PSA) - A PSA unit
 Biorefinery demonstrator deployed at Vale currently being optimised through the use of made in assembling the bioreactor in the polytunnel. is under development for the separation of CO2 from
 Instrumental Gas Analysis. The data for these ionic Assembly of one section of the Perspex tubing industrial emissions and process gasses. The PSA
eDME identified as the primary fuel target as a liquids will be evaluated and analysed to design housing the growing algae has been completed design has been finalised and a prototype is under
 enhanced materials which are capable of capturing with commissioning and testing due to commence construction.
ground transport alternative to the steel works
 CO2 over a range of waste gas concentrations. shortly.

 16 EPSRC Strategic University Steel Technology and Innovation Network Future Manufacturing Research Hub Annual Review 2020/2021 17

Core Research Theme 2

 Progress to Date
 Progress has included commissioning and testing recent developments have included the development
 new methods for studying ultra-fast (100ms of in situ image analysis (ultra-fast digital imaging

 Task 2: Waste Reprocessing timescale), high temperature (>1000ºC) processes
 in extreme environments (oxidising/reducing) with
 and fast thermal imaging). After a period where travel
 was not possible, a visit has been made to Cardiff
 a focus on in situ metrology wherever possible. To University and a discussion held about initial char
 achieve this, ultra-fast pyrolysis has been combined samples produced from their drop tube furnace.
 with sophisticated time of flight GCMS to study the These chars have experienced different residence
 Start date: June 2020 Expected end date: June 2023
 volatile fraction of fossil fuel and non-fossil fuel times at high temperature and we are studying
 Pls: Professor Peter Holliman, Dr Richard Thackray
 (e.g. non-recyclable waste, plastics, biomass and the balance between solid and volatile matter by
 Researchers: Dr Eurig Wyn Jones modified biomass) to begin to build a library of data combining the DTF with pyrolysis GCMS.
 PhD students: Fawas Ojobowale and to understand the presence and influence of
 Project partners: Swansea University, University of Sheffield, Tata Steel UK, N&P Recycling heteroatoms. Ex situ sample analysis has also been The Sheffield EngD project has been advertised and
 started to examine sample heterogeneity. Processing the start date for the successful applicant will be
Project Abstract methods to both prepare samples for analysis and September 2021.
Blast furnace ironmaking uses fossil fuel carbon (e.g. to co-mix materials have also been developed. More
coke and coal) to provide energy and to reduce iron
oxide to liquid iron. In this task, life cycle analysis will Planned Impact:
be combined with experimental testing to investigate
 To displace fossil fuel carbon from
using non-fossil fuel carbonaceous waste to displace
 ironmaking to reduce CO₂ emissions
fossil fuel carbon within the ironmaking process. By Left: Ultra-fast
using non-fossil fuel sources of carbon we aim to pyrolyser with
reduce net carbon dioxide emissions and so help to pressure reactor
decarbonise the overall process.

Key findings:
We have shown that:
Non-renewable waste can be milled to different
particle sizes

 Thermal analysis can study the kinetics of
 thermal processes for fossil fuel and non-fossil
 fuel carbon

Ultra-fast pyrolysis GCMS can study the sort of
ultra-fast thermal processes found in a blast
furnace
 Right: dTG data for
 mixed carbon sample
 Slow motion imaging can help to understand
 at different heating
 ultra-fast thermal processes rates

In collaboration with Cardiff University we can
study the chars produced from a drop tube
furnace using pyrolysis GCMS
 Above: Examples of non-recyclable waste

 18 EPSRC Strategic University Steel Technology and Innovation Network Future Manufacturing Research Hub Annual Review 2020/2021 19

Core Research Theme 2

 Progress to Date
 We have extensively engaged with industry partners We have been characterising the as-cast and
 (i.e. steelmakers) and beyond (metal recyclers, heat-treated steel samples using the advanced

 Task 3: Scrap Utilisation trading bodies, independent consultancy, etc) to
 identify the impurity levels for different categories of
 characterisation techniques at WMG, with a focus
 on the existence forms of impurity Cu and its
 steel scraps and for different steel grades. This has evolution due to heat-treatment. We have advanced
 been used to help design the research matrix. understanding on the co-existence of CuS and
 manganese silicate oxides and of CuS and (Fe,Mn)S
 Start date: December 2019 Expected end date: December 2022
 We have carried out a critical review of the current and its evolution due to the heat treatment at 1200°C.
 Pls: Dr Zushu Li, Professor Claire Davis, Dr Richard Thackray
 metallurgical understanding about the behaviour
 Researchers: Dr Ishwar Kapoor of various residual elements, individually and The Sheffield PhD/EngD project associated with
 Project partners: WMG University of Warwick, University of Sheffield, British Steel, Celsa Steel UK, synergistically at high (>1200°C) and low temperatures the task has been advertised and the successful
 Liberty Steel, Sheffield Forgemasters, Tata Steel UK (1200°C) and low temperatures (

Core Research Theme 3

 For the blockchain demonstrator, initiative research Due to COVID-19, project partners were severely
 ideas have been proposed: blockchain will be used to affected with a large number of key staff furloughed.
 build a trusted distributed network of stakeholders; As a contingency, we adapted our approach by re-
 Semantic technologies will be used to facilitate aligning our existing SC research projects. A joint
 Task 4: Digital Steel Innovation Hub (DSIH) the sharing of product information and enhance project between SUSTAIN, Transforming Construction
 semantic interoperability. and ESRC Productivity was formed to explore the
 concept of SC productivity across different sectors.
 WMG Data Science As a result, a large-scale survey was developed. The
 Start date: September 2019 Expected end date: October 2023 The existing state-of-the art robotic simulator research output will be made available in the form
 Pls: Professor Janet Godsell, Professor Giovanni Montanna, containing one robotic hand to two robotic hands has of industry reports and a peer-reviewed academic
 Professor Arnold Beckmann been extended. Cooperation between two robotic journal paper.
 Researchers: Dr Zakiah Suhaimi, Dr Sagar Uprety, Dr Qiushi Cao hands to pick and place a bar using stated inputs has
 been implemented. The implementation of camera October 2020: Re-engaged with Liberty Steel as
 PhD students: David Ireland
 input-based learning algorithms for robotic hand furlough reduced. The project has been re-scoping
 Project partners: WMG University of Warwick, Swansea University, British Steel, Celsa Steel UK, manipulation is ongoing. and the focus shifted to steel demand from aerospace
 Sheffield Forgemasters, Liberty Steel, Tata Steel UK, nChain customers (e.g. Boeing) to the Bolton Air Service
 Supply Chain: MSc projects Centre and then to the Stocksbridge site. Detailed
Project Abstract 2019/2020: Four company-based projects were research design was developed and the approach
T4 aims to create a data-driven step-change Key findings: received, three are complete, one is pending. could be adopted by other steel companies.
improvement in the competitiveness of UK steel 2020/2021: Currently working with Liberty Steel on
 A novel hybrid approach that combines
supply chains (SCs). It will utilise recent developments project ‘Evaluation of inventory control management’. Relaunch of SC programme
in technologies to both harness and analyse data
 statistical AI and symbolic AI can be proposed
 March 2021: With the current climate, it is quite
that can improve the value-added and productivity of to facilitate and automate predictive
 Company case studies challenging for all companies to commit to the case
products, processes, and UK steel industry SC. The maintenance in steelmaking
 January 2020: Organised a workshop with all studies. To give some flexibility to industrial partners,
project will explore how the adoption of industrial industrial partners and agreed to have a 2-stage case a new SC programme with three-phase activities was
digital technologies (IDTs) could improve steel SC The programmed RDF data generator can be study approach: relaunched. The activities include IDT assessments,
productivity and sustainability. Deep reinforcement used to generate simulation data regarding developing an IDT adoption roadmap, and case-study
 Stage 1 - Liberty Steel and Forgemasters
learning algorithms will be developed to train multiple steelmaking process interventions.
 Stage 2 - Tata Steel and British Steel
robotic agents to collaboratively solve tasks such as
object manipulation using direct input from mounted The robotic manipulation task of lifting a long/
cameras. In addition, the project will assess the heavy bar in the air can be made more sample
use of a demonstrator tool in enabling real-time efficient using Hierarchical reinforcement
predictive maintenance and facilitating product- learning, which breaks down task into two sub-
related knowledge and data sharing among different
 tasks; gripping the bar, then lifting it to a target
stakeholders.
 location
Industry context
T4 has been working with a number of industrial Progress to Date
partners to provide them with the opportunity of Computer Science
identifying rapidly promising data-driven innovations. Regarding the real-time predictive maintenance
Several exploratory meetings have been organised demonstrator, several Stream Reasoning techniques
to look at potential future synergies on blockchain have been studied, C-SWRL and C-SPARQL have
applications (Swansea, nChain, and Celsa Steel UK) been chosen as rule language and query language to
and the use of intelligent robots for automation in the perform reasoning; A RDF data generator has been Top left: existing state-of-the-art simulations wherein a
steel industry (WMG and Tata Steel UK). programmed to generate RDF data streams. These single agent picks a object and places it at a target
 RDF data streams are treated as simulation data
 to be injected into knowledge models for stream Bottom left: our simulation where two agents collaborate
 Planned Impact: to push a long bar to target location
 reasoning; a high-level Industry 4.0 ontology has been
To improve competitiveness of UK steel supply
 chains in a sustainable and value-adding way selected as a foundational ontology. This ontology Above: A novel architecture for real-time predictive
 will be specialised into the steelmaking domain. maintenance

 22 EPSRC Strategic University Steel Technology and Innovation Network Future Manufacturing Research Hub Annual Review 2020/2021 23

Core Research Theme 3

 Task 5: Intelligent Steelmaking

 Start date: October 2020 Expected end date: December 2023
 Pls: Dr Richard Thackray, Dr Michael Auinger
 Researchers: Dr Aurash Karimi, Dr Uchenna Kesieme
 Project partners: University of Sheffield

Project Abstract Industry context
Many existing process models for steel production do The context to industry is to make use of existing
not allow for process alignment and are too complex (old) programmes and develop new fast modelling
for meaningful real-time predictive use. The primary routines for fast predictions. Depending on the interest
aim of Task 5 is to take a different view on steel of the industrial partner, this can be relevant for
production in its entirety by not seeking to improve optimising day-to-day process strategies or develop
product qualities but by focussing on decreasing mitigation scenarios for unwanted production stops
energy usage and building links over the entire or equipment breakdown.
process chain. This will be achieved by development
and optimisation of process level models supported Progress to Date
by experimental verification, analysis of process The PDRAs have been recruited and are in place
data and by benchmarking current process routes since late 2020.
to quantitatively assess how efficiently industry
currently uses both energy and materials. The project team is now operational and we have
 designed and circulated a questionnaire to the
 SUSTAIN industrial partners to re-evaluate their
Planned Impact: modelling interests which might have changed,
Delivery of coherent process level model and or become more specific during the past year. A
assessments for fast and efficient optimisation literature review for fast process optimisation for
of the process chain with respect to cost, energy ladle metallurgy has been finished and preliminary
flow and material usage data from industry for part of the LCA analysis has
 been shared with the team. Above: Schematic reaction zone model for a blast furnace

 Key findings:
 Inventory of Existing Process and Efficiency Flows
 Left: Schematic view of
 the digital process model,
 based on the Reaction Analytics of Process Data
 Zone approach

 Optimisation of the Building Blocks

 Life Cycle Assessment to Quantify Efficiency Gains

 24 EPSRC Strategic University Steel Technology and Innovation Network Future Manufacturing Research Hub Annual Review 2020/2021 25

Core Research Theme 4

 to provide a richer information set including a
 novel optical technique for measuring graphite
 orientation (figure 2) which has been shown to
 Task 6: Thermal Efficiency have an effect on thermal conductivity in other
 systems [1]. In parallel we have conducted
 laboratory oxidation experiments which
 Start date: January 2020 Expected end date: January 2023 measured the decarbonisation kinetics of the
 Pls: Professor Cameron Pleydell-Pearce, Dr Karen Perkins, Dr Hollie Cockings, graphite/phenolic based binder that occur during
 Dr Matthew Carnie pre-heating and between use cycles. We are in
 the process of correlating these observations
 Researchers: Dr Matthew Burton, Dr Michael Dowd, Dr Ria Mitchell
 with characterisation methods to understand the
 PhD students: Geraint Howells structural sensitivities of the kinetics. Towards
 Project partners: Swansea University, British Steel, Celsa Steel UK, Liberty Steel, Sheffield the end of the task we will look at more complex
 Forgemasters, Tata Steel UK, Vesuvius PLC liquid metal/slag interactions with refractories.

Project Abstract Industry context The development of thermoelectric materials
 Fig 1: 3D high resolution X-Ray Computed Tomography data
Task 6 aims to develop understanding of technologies The steel industry is one of the UKs largest emitters builds on previous work within the SPECIFIC® of an Al2O3 – Carbon refractory structure segmented to
that reduce heat loss through improved insulation and of waste heat; a typical steel works emits ~ 20 PJ/ IKC that has developed novel manufacturing reveal (a) all constituents and (b) the aggregate structures.
maximise waste heat recovery through both thermo- yr from cooling water alone. If 25% of that heat was techniques for castable ‘near-net’ materials
electric generation and heat storage materials. This recoverable at 5% efficiency, savings could be £10M/ (figure 3) [2]. Early research focussed on: 1)
relies on understanding key materials and associated year (based on £0.15/kWh electricity price). Therefore the development of a tube geometry test bed
processes. The project focusses primarily on two main there is commercial and environmental impetus for to test prototype generators in more complex
technologies, refractory materials and heat storage reducing heat loss and recovering industrial waste geometries and 2) exploration of earth abundant,
and energy generation. Initially the technologies are heat. In secondary liquid steel processing alone, each non-toxic and cost competitive systems suitable
progressing in parallel with the intention to integrate 1°C improvement in thermal efficiency saves ~£2m for widespread adoption in the steel industry. The
these highly complementary technologies towards per annum. Further, the temperature of steel through test bed is ready and a number of P and N type
the end of the task. The project is continuously process is the most important parameter to control material options have been explored. The doping
expanding its scope through complementary funding to produce high quality steel. Improved efficiency will of these systems is being optimised to improve
and will soon initiate work in the area of process reduce demand on the National Grid and consumption device efficiency. In parallel we are investigating
metrology and control, heat storage and the impact of fossil fuels for power generation, subsequently earth abundant half-Heusler compounds. We
of emissivity on radiative heat transfer. reducing the CO2 footprint of steelmaking. intend to determine the high temperature stability
 of the devices and examine the potential to
 Key findings: Progress to Date develop self-powered temperature sensors for Fig 2: Optical surface measurements that quantitatively
 Key research has focussed on: 1) the development
 High resolution multimodal imaging steelmaking ladles. determine graphite crystal orientation have been developed.
 of advanced characterisation approaches for
 techniques have been developed that provide refractory lining materials and 2) the development of
 The task is now set to expand through
 novel insight into refractory structure thermoelectric materials through a novel ‘near-net’
 complementary funding sources to examine a
 manufacturing process. These will be complemented
 wider range of potential technologies including
 The techniques have helped develop by studies on heat transfer efficiency at metal
 heat storage and radiative heat transfer efficiency
 structure – property, and structure – process surfaces and heat storage technologies.
 of metals. The work in this task has been well
 relationships for refractories in service complemented by the feasibility studies at
 The refractory characterisation has been approached
 Durham University and UCL and we are looking
 Novel castable thermoelectric systems have with increasing complexity. First we developed and
 to work together to progress our complementary
 been created that permit integration with refined acquisition and segmentation approaches
 technologies.
 complex geometries for X-Ray Computed Tomography (XCT) data of
 carbon bonded refractory structures. The table in Fig 3: The manufacturing method for cast near net shape
 Planned Impact: thermoelectric devices and schematic of how this can be
 figure 1 shows how these have developed to match applied to more complex geometries.
 Soon the task will expand to include heat The project aims to reduce waste heat production
 the product, whilst the images illustrate how we can through insulation, process control and efficiency
 storage materials and systems for steelmaking References
 show structure segmentation. We then developed and thermal energy harvesting [1] Lu. Yang et al. Materials Chemistry and Physics, Volume 257 (2021) 123702
 and heat transfer efficiency in furnace
 correlative complementary microscopy techniques [2] M. Burton et al. Advanced Energy Materials, Volume 9 (2019) Issue 26 1900201

 26 EPSRC Strategic University Steel Technology and Innovation Network Future Manufacturing Research Hub Annual Review 2020/2021 27

Core Research Theme 5

 out for sensitivity to different steel samples and microstructure changes can be monitored by the EM
 calibration of the developed COMSOL FE model. A signal and modelling is being carried out to determine
 canister design has also been finalised by Dr Russ the low magnetic field permeability changes. Further
 Task 8: Smart Sensors for Real-Time Measurement Hall, with input from Primetals Technology Limited
 and Dr Frank Zhou and is under construction. Once
 tests will be carried out on a different steel grade
 (from Liberty Steel). Consideration, with University
 complete the array will be installed in the furnace- of Manchester, will then be needed on how to move
 roller table and trials will commence. from a non-deployable laboratory sensor to a sensor
 Start date: August 2019 Expected end date: August 2022 design suitable for use in an industrial furnace. High
 Pl: Professor Claire Davis High temperature annealing of two rod grades, temperature magnetic property measurements
 provided by British Steel, in a laboratory high for full BH behaviour are also being pursued in
 Researchers: Dr Frank Zhou
 temperature EM sensor have been performed collaboration with the University of Manchester via
 Project partners: WMG University of Warwick, University of Manchester, Primetals Technology
 to support development of microstructure – laboratory testing of a high temperature Epstein
 Limited, British Steel, Liberty Steel magnetic signal relationships. The results show the frame they have developed.

Project Abstract Industry context
 Planned Impact:
Improved monitoring of steel production allows for The production of advanced high strength steel
greater digitilisation and control, leading to more grades is challenging as tight process parameter
 EM sensor arrays for real-time in-situ monitoring, characterisation and control of
 steel microstructures during steel processing for a range of grades and applications
efficient, less energy intensive manufacturing. control is required to achieve the complex
Improved monitoring of processes is a key part to microstructures and real-time feedback is desired.
sustainability, growth and modernisation for the steel Commercial sensor systems are available for cold
industry. Great improvements have been made for strip steel monitoring, where sensor signals are
 Right: Sensor heads
real-time monitoring and feedback control but several correlated to mechanical properties. Currently
 for the sensor array
areas have been highlighted where insufficient the only commercial system for hot strip steel and COMSOL model.
information is currently available requiring new microstructural monitoring is the EMspec system, The model was
and improved sensing approaches. One area is produced by Primetals Technology Limited using used to optimise the
 sensor array design
microstructural monitoring during processing and University of Manchester licensed technology, with
 (sensor head size and
electromagnetic (EM) sensors are ideal candidates. relationships between microstructure, magnetic spacing)
The project is focusing on development of new EM parameters and sensor signal developed at WMG.
sensors and signal-microstructure relationships for There is a need to extend knowledge and application
use in steel processing. to non-strip steel geometries and grades.

 Left: High
 Key findings: Progress to Date temperature
 The new EM sensor array concept has been laboratory EM
 A four EM sensor head array system has modelled and optimised design determined (sensor sensors (showing
 been designed and built and is sensitive to sensor coils, left,
 head size/number/spacing). The design was carried and after high
 changes in steel microstructure out in collaboration with long term partners at the temperature
 University of Manchester (feedback and discussions potting, right)
 A COMSOL FE model for the sensor array with Professor Tony Peyton). Consideration of the
 has been developed allowing sensitivity of potential industrial applications (narrow strip mill at
 sensor signal to microstructure and sample Liberty Steel and wire/rod mill at British Steel) and
 geometry to be determined laboratory demonstration run out table was taken into Right: EM sensor
 account for geometry constraints. The final sensor signal (green) and
 array design was passed to Dr Stephen Dickinson temperature (blue)
 In-situ high temperature laboratory EM with time for in-situ
 (Organised Technology Limited) for construction
 sensor measurements for annealing of EM tests showing the
 (funded within a High Value Manufacturing Catapult change in EM signal
 rod samples has shown that pearlite
 project to upgrade the WMG furnace-roller table which is related to
 spheroidisation and recrystallisation spheroidisation of
 containing an EMspec system). The sensor array
 behaviour can be continuously monitored has been completed and experimental tests carried
 pearlite

 28 EPSRC Strategic University Steel Technology and Innovation Network Future Manufacturing Research Hub Annual Review 2020/2021 29

Core Research Theme 5

 Progress to Date
 A critical review has been undertaken on the control of process route has been devised that will allow
 Sv (austenite interfacial area per unit volume) through systematic changes in the austenite interfacial area

 Task 9: Late Stage Product Definition and thermomechanical processing for the selected steel
 grades. Through experimental analysis of the cast
 per unit volume. The transformation behaviour will
 therefore be studied as a function of Sv. This will

 Integration to cast, and in-cast variations in composition of the
 Super 13Cr steel, a range of steel compositions have
 allow a separation of the effects of composition from
 thermomechanical process conditions.
 been determined that will allow the effect of a) high
 Mn content (with otherwise target composition), b) The PhD position has been advertised but has not
 Start date: October 2020 Expected end date: October 2023
 high Ni content (with otherwise target composition) received any eligible applications yet. The reports
 Pls: Professor Mark Rainforth, Professor Eric Palmiere, Dr Martin Strangwood
 and c) both high Mn and high Ni. These casts are of effects of pre-conditioning on austenite stability,
 Researchers: Dr Peng Gong being produced in-house. A thermomechanical thermodynamics and kinetics are being reviewed.
 Project partners: University of Sheffield, Liberty Steel, British Steel, Tata Steel UK

Project Abstract Industry context
Efficiency in steel production requires relatively Efficiency in steel production requires minimal
minimal changes in the upstream procedures with changes in the upstream procedures (i.e. steelmaking)
product differentiation occurring during the latter with product differentiation occurring during the
stages of processing. The austenite transformation latter stages of processing. Efficiency in product use
to various transformation products is probably the requires design of high-quality steels with appropriate
single most important factor in determining the mechanical properties and life-time durability. This
final properties of most steels. The role of local activity considers both of these aspects, focusing
segregation is also critical in the transformation on different steel grades and product portfolios but
and subsequent heat treatment. The ability to exert utilising the strength of UK metallurgical research Right: TEM image showing
greater control over the transformation gives the to provide new products and processes to position reverted austenite in a
 tempered martensite matrix
ability to have greater control of the transformation the industry at the forefront of development. This
 in a Super 13Cr steel.
product and subsequent final properties of the steel. project has generic applicability across all the steel
This applies across all steel types, whether long manufacturers in SUSTAIN.
products, strip or sections.

 Key findings:
 The carbon content in reverted
 austenite is a linear function of
 the tempering temperature

 A subsequent second temper
 results in redistribution of both
 carbon and nickel

 The second temper results in
 austenite that is much more
 resistant to strain induced
 transformation, as a result of Planned Impact:
 solute redistribution Above: Carbon content in reverted austenite for The research will lead to adjustments in the hot rolling and heat treatment
 single and double tempered samples schedules to improve properties and deliver a more consistent product

 30 EPSRC Strategic University Steel Technology and Innovation Network Future Manufacturing Research Hub Annual Review 2020/2021 31

Hub funded research Feasibility studies

 Feasibility Studies Task 10: Drop-tube Furnace to Investigate Novel
 Reductants for the Decarbonisation of Ironmaking
In Summer 2020, the Hub launched its First Call for This first call was open to UK academics eligible to
Feasibility Studies, initially offering funding for three receive EPSRC funding, for a maximum duration of Start date: December 2020 Expected end date: May 2021
feasibility studies to conduct novel research which six months, and a maximum value of £50,000 (80% PI: Dr Julian Steer
aligned with the Hub’s two Grand Challenges: Carbon FEC). Three new Tasks (10 - 12) were funded in this
 Project partners: Cardiff University, Tata Steel UK
Neutral Iron and Steelmaking and Smart Steel round.
Processing. Research proposals had to be aligned to Project Abstract the raceway region characterised
and complement the current research programme. Due to restrictions, the entire call was conducted Blast furnace Ironmaking utilises Key findings:
 by short residence times and high
 virtually, using Webinars and a Virtual Sandpit session coal injection alongside coke heating rates. Comparable sample burnouts
This Call was designed to attract new partners to the held via Zoom meetings and Meeting Mojo (thanks to in the process, and this project
project which may have potential to lead to further KTN for arranging the use of this platform). The Hub have been measured in some
 investigates the technical A range of blend compositions
collaborations and future funding bids and is our was pleased with the level of engagement received Subcoal™/injection coal blends
 feasibility of using alternative have been tested at different
primary mechanism to introduce new academic from the community in this new virtual environment reductants as a substitute residence times to establish how
collaborators and develop additional research - from the submitted applications to everyone who for carbon units. The project Subcoal™ blends have similar
 they compare to the standard coals
spokes. gave their time to support this activity, the response investigates the opportunities and carbon contents to typical
 and the partially burnt residues will
 was impressive and encouraging. issues surrounding the use of an injection blends
 also be tested, to compare the char
 alternative commercial reductant gasification reactivity. A kinetics
 called Subcoal™. This material is study has been run to understand Initial work suggests
 a mixture of paper and plastics and compare its behaviour in comparable performance of
 produced from residential waste combustion, gasification and different Subcoal™ deliveries
 which is non-recyclable and would pyrolysis conditions; this has
 otherwise be landfilled. Due to its been carried out to help establish Pyrolysis of Subcoal™ blends
 higher hydrogen content, it has the conditions for evaluation in a results in higher hydrogen
 potential to reduce CO2 emissions fluidised bed gasifier. and methane contents in the
 associated with the process by
 decomposition gas mixture
 substituting some of the mined Industry context
 coal and utilising biomass derived After discussion with Tata Steel
 paper/cardboard material. UK, it was raised that sample
 Top: Paper
 composition variability, due to the and plastic
 Progress to Date very mixed nature of this material, collection
 Incorporating a new reductant would be an important variable and
 into a blast furnace could lead to measure. It was also stressed processing
 to process stability issues with that the project output needs to
 serious consequences on the be in a format that production can
 production of Iron. So far, work relate too, so standard proximate
 has concentrated on investigating analysis tests will be used
 the incorporation of paper/plastics alongside other academic output.
 in the form of the commercial As a result, samples of separate Bottom:
 Subcoal™ product, blended with delivery batches of Subcoal™ have Subcoal™
 typical coals used for blast furnace been obtained from N&P recycling. in pellet
 form after
 injection. Over 60 samples have These have been incorporated in processing
 been tested in a drop tube furnace, the test plan and are in the process
 to mimic, as closely as possible, of being evaluated.

 32 EPSRC Strategic University Steel Technology and Innovation Network Future Manufacturing Research Hub Annual Review 2020/2021 33

Hub funded research Feasibility studies

 Task 11: Ultra-High Temperature Reliable Electronics Task 12: Techno-economic Feasibility of Net-Zero
 Development (UHTRED) Emission Solutions for Metal Heating (THERMOS)
 Start date: November 2020 Expected end date: October 2021
 Start date: September 2020 Expected end date: February 2021
 PI: Dr Yukun Hu
 Pls: Dr Alton Horsfall and Dr Andrew Gallant
 RA's: Xiaoyuan Cheng and Xiyao Sun
 PhD students: Jonathan Hammler
 Project partners: University College London, Warwick Manufacturing Group, Air Products and SWERIM
 Project partners: Durham University

 Project Abstract energy consumption of the steel
Project Abstract This study will focus on the industry. Today’s best practice Key findings:
In the steel industry, operating temperatures above metal heating process and values for heating a tonne of Pure NH3 is hard to ignite in air,
400°C are commonplace and monitoring materials the proposed sustainable net- steel to temperature for rolling but H2 and NH3 mixture can ignite
and systems in these conditions is essential. zero emission solutions, which or forging is still above 1.0 GJ/ and combust stably with 1% H2
However, semiconductor-based transistors involve hydrogen and ammonia tonne. If no disruptive innovation
are unsuitable for use in extreme temperature gas. The project will investigate to the existing heating process
 The flame temperature of H2 and
environments. if the UK could introduce carbon- is put in place, steelmakers will
 free heating for furnaces at all its
 NH3 mix combustion increases
 likely struggle to achieve further
 rolling mills. with H2 fraction
This study will explore the use of materials, reduction in energy consumption
designs and circuit models based around and CO2 emission.
 The project will analyse Even in the absence of a suitable
microscale vacuum channel transistors. The target
 combustion behaviour and scale Progress to Date catalyst, due to moderate
is to produce device and circuit designs which are
capable of operating over a wide temperature formation using computational WP1: Combustion behaviour temperature, the reaction of NH3,
range, from 25 to 1000°C. fluid dynamics and reaction under different environments H2 and air mainly produces N2
 kinetics models. A furnace has been investigated based on and H2O
Progress to Date ‘digital twin’ will be used to the burner designed provided by
Identification of suitable materials for the demonstrate the proposed net- AirProducts. Both H2O and O2 promote scale
manufacture of the transistors has been completed. zero emission solutions. The WP2: A mixed gas emissivity formation at high temperatures
The current intention is to utilise Ir on HfO2, however work will provide new insights model has been developed (>700°C), and the excess O2
close-coupled multi-physics simulations are being into the transition pathway of which can be incorporated into should be reduced as much as
utilised to fully optimise the work function offsets reheating furnaces that might be the integrated furnace model to possible in the oxyhydrogen
and the effect on the transistor characteristics. systemic weaknesses in a green calculate mixed gas emissivity in
 combustion environment
 steel economy. real-time.
Simulations of the initial lateral channel structure WP3: A scale formation model
 Key findings: Industry context is being developed using neural-
has confirmed the operation of the transistor
under the required operating conditions. A revised Viable, manufacturable structure identified The metal heating facility, such network algorithms, with training
structure to mitigate the issues of gate control as a reheating furnace, is an and test data obtained from
in the channel has been devised and are being indispensable thermal facility literature of steel scale formation.
 Transistor characteristics under a range of
incorporated in to the model. in steel production. The energy WP4: Time needed to incorporate
 suitable operational conditions
 consumption of heating still the results and models developed
Initial steps towards design toolkit for circuit accounts for about two thirds in WPs 1-3, as a digital-twin of
 First logic primitive circuits simulated
development now completed and further of the rolling process and about the pilot-scale furnace provided
optimisation based on the simulation data is 20% of the energy consumption by Swerim to investigate the Above: Transient temperature contours of
underway. of steel production, which directly technical feasibility of the H2/NH3 mixture firing with air
 affects the production cost and proposed heating solutions.
 34 EPSRC Strategic University Steel Technology and Innovation Network Future Manufacturing Research Hub Annual Review 2020/2021 35