Facing the urgent challenges of climate change and the necessity for a transition towards more sustainable and efficient energy systems, the industrial sector, with the steel industry at the forefront, is compelled to significantly cut energy consumption and CO2 emissions. The steel sector, accounting for 9% of global anthropogenic CO2 emissions and consuming an average of ~5.2 MWh of primary energy per ton of steel produced, is at the heart of this challenge. The SYRIUS project, spanning 54 months, aims to revolutionize this landscape by integrating a 4.2 MWel Solid Oxide Electrolysis Cell (SOEC) for producing 100 kg/h of green hydrogen into a real Electric Arc Furnace (EAF) plant. Hydrogen will feed a 280tsteel/h – 84 MWth slab reheating furnace, demonstrating the potential to reduce steel reheating process CO2 emissions by 5,600 t/year during the project and up to 100% with full hydrogen feeding. By generating steam through furnace off-gas heat recovery, implementing by-product oxygen recovery in the furnace (allowing additional savings of 430 tCO2/year in SYRIUS and of 2% fuel input in future expansion) and analysing options for water recycle, SYRIUS seeks to minimize external energy consumption and sets industrial circularity at the project core. With a viable business case centred on process integration, SYRIUS aims to strongly enhance market opportunities in the short to medium term by driving industrial green hydrogen costs below 2.2 €/kg, surpassing the SRIA targets for 2030. By preserving end-product quality at competitive costs, reducing greenhouse gas emissions, lowering hydrogen costs, and creating new direct and indirect jobs, SYRIUS will play a pivotal role in enhancing the circularity of the EU steel sector. A first-of-its-kind TRL7 plant, ready to be scaled up, extended to other industries, and replicated globally thanks to the unique geographic coverage of the technology providers in the SYRIUS consortium, will showcase innovation in action.

The HEPHAESTUS project is built around one key, overarching objective: To develop a set of scalable and tuneable unit operations, to be built as integrated processing plant, featuring the capacity to treat multiple process wastes deriving from primary mineral and metallurgical (primary and secondary) streams. The unit operations are: - Clean-Tech electric furnace, to transform the EAF and AOD dust into metal alloy to be immediately remelted, process supported with streams of fines by-products from the mineral primary extractions (construction, aggregates and dimensional stone) - EZINEX process, to extract the zinc present in the dust of the furnace - Fibre drawing, for mineral wool manufacturing out of the process slag in molten state - Catalytic conversion of CO2 gas into methanol or formic acid - Ammonia-ammonium carbonate (AAC) and methanesulfonic acid (MSA) based hydrometallurgical processes, to produce a recyclable Fe-rich residue and to recover metals (e.g.e.g., ZnS) from EAF dust The project is targeting primarily small-scale applications (order of magnitude 10 k tons waste dust per year), to cope with the typically fragmented European process size. Such scale is matching the waste volumes and differentiation and granting positive environmental AND economic sustainability through the valorisation of different streams of by-products at low operational and capital expenditure, ensuring vast replicability and short ROI Project will be demonstrated in two pilot applications, in Greece and Italy, with the purpose of creating awareness on the business potential and to generate the conditions for a long-term exploitation, leading to meaningful reduction of wastes for the extractive and steel industries.

The typical lifetime of an industrial process plant is between 30 and 50 years. Technologies to enhance the operation and optimization of process plants can both guide the development of new state-of-the-art process plants and, perhaps more pertinently, can ensure that the large installed base of existing plants operates efficiently. The PRONTO Consortium partners are strongly convinced that for Europe to stay competitive, the overriding challenge is the efficient and sustainable operation of assets already installed and running at the present time. Production involves flows of material and energy over an extended area through the distributed and interconnected equipment of the process network. Process plants also generate complex information from disparate sources in the form of measurements from the process, mechanical and electrical sub-systems, and elsewhere. Efficient and sustainable operation of assets over a timescale of 30-50 years therefore requires sophisticated approaches for managing information and managing resources to ensure optimal operation. The research topics of PRONTO are (i) data analytics for assessment of the condition and performance of networks of equipment used for production in the process industries, (ii) optimization of use of resources in process networks taking account of real-time information about the condition and performance of the process equipment, and (iii) new concepts for process operation identified as having high potential for impact by industrial partners. The consortium partners include leading universities and well-known companies with high reputations for innovation. The consortium offers the early stage researchers training under the European Industrial Doctorate scheme by involving the non-academic sector extensively in joint supervision of the doctoral training with a strong emphasis on industrially-relevant PhD projects leading to practical demonstrations.