Solving issues in carbon-neutral iron and steel making processes with diverse input materials of varying quality (Clean Steel Partnership) (RIA)

Expected Outcome:The topic enables a fast and reliable transition to innovative technology pathways for carbon-neutral iron and steel making by tackling fundamental problems and boundary conditions with a system-level approach. This approach will target input materials, processes, and iron /steel output quality, considering the needs to reduce production costs, find alternative materials and solutions, improve process/energy efficiency and achieve at least the traditional product quality.

Iron and steel making plants constitute complex systems where the product quality is bound to a large set of variables. Variations in feedstock composition, along with reductant choice and mix, introduce noticeable variations in process metallurgy, its kinetics and thermodynamics, with influence on the morphology of the intermediates and consequent impact on the next phases of production, and lifetime, quality, safety and reliability of the finished product.

The strong dependence of the final steel quality on the variable quality of the raw materials and the balance of the production process, has to be taken into account under the consideration of costs, energy availability, sustainability, overall and specific energy efficiency, CO2 emissions and strategic resources (in particular strategic raw materials[1]).

Projects are expected to contribute to at least three of the following outcomes:

• Validate innovative carbon-neutral iron and steel making solutions within a system-level approach and in consideration of diverse materials with varying quality (raw input materials and reductants mix) and energy needs. Address high-risk factors at macroscopic and microscopic level through detailed characterisation of the physical and chemical interactions that could compromise the optimal functioning of the processes;
• Solve system-level issues within at least two low-CO2 production routes;
• Define solutions and provide concepts to address possible modifications or material substitutions in innovative installations for low CO2 iron and steel production;
• Improve low-CO2 steel production reliability to target high-quality products: i) clarify the effect of material and process variables, and overall system aspects; ii) clarify the influence of changing crude steel quality on the properties of the produced steel, with the purpose to achieve quality and extended lifespan of products; iii) clarify the impact of diverse input materials with varying quality on the residue characteristics and on its potential valorisation and use;
• Provide an impact analysis covering the materials and energy balance of identified solutions, viability and byproducts.

Scope:The topic calls for collaborative approach between academia, industry (including SMEs) and research organizations with the purpose to support: i) understanding, validating, and solving essential problems to allow maturity of innovative technologies in the industrial investment panorama for future carbon-neutral iron and steel making, ii) accelerating a reliable transition to climate neutrality in view of the end of the free ETS allowances by providing solutions optimized for different scenarios, and iii) fulfilling the Commission Recommendation 2024/774[2] on a Code of Practice on industry-academia co-creation for knowledge valorisation.

Proposals should address at least four of the following points:

• De-risk and extend operational windows of low CO2 iron- and steel making technologies considering system-level scenarios;
• Target the heterogeneity of available reductants and feedstock materials, their different physical states and the mixed use of them. In this context, the sustainability of the process to produce them should be considered, along with the requirements for various grades of purity;
• Achieve high-quality steel products characterized by increased tolerances of contents of contaminants, originating from low quality raw materials. Adapt the micro-structure and control application-specific properties by acting on material preparation, processes and process technologies. Include the development of detection / measurement systems and multi-scale models as needed;
• Analyse, micro- and/or nano-characterise, and compare low-carbon production of liquid iron and/or crude steel combining the use of direct reduced iron (DRI) with varying qualities and raw materials from primary and secondary sources to push for closing material cycles;
• Couple the analysis with needs for plant design optimisation and measures to mitigate risks during operation;
• Define pre-processing needs of primary and secondary iron containing materials for iron and steelmaking targeting low environmental impact. Analyse the effects on the production process and product metallurgy;
• Consider analytical research infrastructures. Data should be supporting simulations- and modelling needs in line with FAIR (Findability, Accessibility, Interoperability and Reusability) principles. Interoperability of data sharing should be addressed;
• Consider effects of solutions indicated in the outcomes of the proposed project on specific regional or country level conditions, including cross-sectorial scenarios, such as energy availability, water use and recovery of water and other resources from the steelmaking process to use in other industrial sectors and vice versa, where applicable;
• Use tools such as, but not limited to, life cycle assessment (LCA) or life cycle costing (LCC) to create benchmarks for progress measurement towards carbon neutrality;
• Aim at taking advantage of pilot plants in Europe to create correlations between real-world processes and laboratory-based research.

Multidisciplinary research activities should address at least one of the following:

• Introduce sensors or develop new ones, especially able to work in very high temperature environments. They may include a soft and integrated set of sensors. Use fast digital techniques for data collection, processing and analysis. Develop enhanced models with different levels of resolution and integrate Machine Learning (ML)/AI for comprehensive understanding of process mechanisms;
• Use input from finalised/ongoing research in heat recovery via heat exchange technologies that could contribute to reduction of external energy use;
• Develop concepts for on-site hydrogen production techniques at very low cost.

Proposals submitted under this topic should include a business case and exploitation strategy, for at least one process route, as outlined in the introduction to this Destination. If more than one process route is part of the project, the selection of the preferred one should be duly justified.

Additionally, a strategy for skills development to target innovative solutions should be presented, associating social partners when relevant.

The actions should envisage clustering activities with other projects funded under this topic. Cross-projects co-operation should include consultations and joint activities on cross-cutting issues and share of results not bound to intellectual property, as well as participating in joint meetings and communication events. To this end proposals should foresee a dedicated work package.

Projects (if selected for funding and if relevant) could consider clustering activities with one project funded under topic HORIZON-CL4-INDUSTRY-2025-01-DIGITAL-61.

In this topic, the integration of the gender dimension (sex and gender analysis) in research and innovation content is not a mandatory requirement.

This topic implements the European co-programmed Clean Steel Partnership.

[1] https://www.consilium.europa.eu/en/infographics/critical-raw-materials/

[2] https://eur-lex.europa.eu/legal-content/EN/TXT/PDF/?uri=OJ:L_202400774