Rail freight transportation is a system service where a multitude of players, participants and systems providers bear a high degree of responsibility for its attractiveness and performance. It shows high efficiency as transportation means, in terms of land use and energy consumption and low greenhouse gas emissions. However rail’s market share of freight transportation and its economic efficiency continues to be limited. Aimed at overcoming such uncertainty, this project addresses one of the most important key resources for further developing rail freight transportation: the optimization of the performance of the rail freight wagon. The continuous pressure on environmental issues and energy efficient transport is forcing the rail transportation sector to enhance the rail logistics services and to incorporate innovative solutions to improve load capacity to keep the “best-in-class” position and, therefore, acquiring a much privileged position beyond alternative terrestrial transport source, as truck transportation. Thus, aimed at optimizing rail freight transportation, the main objective of this project is to holistically address the aspects that may improve freight wagon performance: enhanced logistics, improved multimodal operative, higher load capacity, optimized filling/emptying time and flexibility to transport multi-products. This project aims to achieve such optimization by combining industrial expertise on the freight wagon design and construction, advanced materials for lightweight construction and logistics with the research capabilities to incorporate innovation solutions and optimize material performance.

STEPWISE is a solid sorption technology for CO2 capture from fuel gases in combination with water-gas shift and acid gas removal. The main objectives of the proposed STEPWISE project is to scale up the technology for the CO2 capture from Blast Furnace Gases (BFG) with three overall demonstration goals in comparison to state-of-the-art amine-based technologies: • Higher carbon capture rate – i.e. lower carbon intensity, 85% reduction • Higher energy efficiency – i.e. lower energy consumption for capture (SPECCA ), 60% reduction • Better economy – i.e. lower cost of CO2 avoided, 25% reduction The STEPWISE project will achieve this by the construction and the operation of a pilot test installation at a blast furnace site enabling the technology to reach TRL6 as the next step in the research, development and demonstration trajectory. Hence further reducing the risk of scaling up the technology. The STEPWISE project has the potential to decrease CO2 emissions worldwide by 2.1Gt/yr based on current emission levels. The conservative estimate is that by 2050, a potential cost saving of 750 times the research costs for this project will be realized each year every year, with a much larger potential. The overall objective is to secure jobs in the highly competitive European steel industry, a sector employing 360 thousand skilled people with an annual turnover of €170 billion.

ProcTwin aims to develop a demonstration platform to predict and visualize best use of multiple processing steps in a steel manufacturing chain. The methodology includes intelligent coupling of interconnected processing steps by numerical simulation, soft sensors, process data and distributed machine learning. Integrated numerical modelling that captures the interactions, relations, and feedback loops between various processing stations enables prediction for smart optimization of energy efficiency and product quality in the steel manufacturing. Continuous casting, reheating, hot metal working, quenching and leveling processes are examples that are controlled separately but strongly interconnected in terms of parameters. These processes serve as objective functions in two parallel use cases at Celsa (ES) and SSAB (SW). It is well known that process optimization can have a significant effect on reducing carbon footprint in steel production, and implementing new digital tools will enable a faster transition towards sustainable industry. ProcTwin is divided in clear work packages to reach the objectives: one is adaption of existing physically based numerical models of each process step to generate critical data that is impossible to measure or observe. Another is development of novel sensors and data integration for a secure and effective sharing industrial data. The innovative concept of ProcTwin is development of distributed machine learning to predict the process chains with large amounts of parameters. Lastly, these technologies will be combined through a demonstrator platform to model the manufacturing processes and enable control for increased product quality, energy efficiency and operator support.

INITIATE proposes a novel symbiotic process to produce urea from steel residual gases. The project will demonstrate a reduction in; primary energy intensity of 30%; carbon footprint of 95%; the raw material intensity of 40%; and waste production of 90%. Additional to this level of reduction, the concept represents a positive business case. INITIATE will demonstrate operating reliability and technology-based innovations in a real industrial setting at TRL7 by producing urea NH3 from steel residual gases as part of three test campaigns spanning six weeks each. The reduction in primary energy intensity, carbon footprint, raw material intensity and waste production will be assessed and verified on a regional and European level by advanced dynamic modelling and Life Cycle Assessment commiserated with ISO 14404 guidelines. The project will develop a commercial implementation roadmap for immediate deployment of INITIATE after project conclusion and for ensuring roll-out of INITIATE and similar symbiotic systems. Designing a robust and bankable first-of-a-kind commercial plant to produce urea from residual steel gases will allow implementation after project conclusion. Long term roll-out will be enabled by defining collaborative strategy for stakeholders alignment to implement INITIATE and similar symbiotic systems. Finally, effective and inclusive communication and dissemination of project results are maximized by organizing summer schools and creation of Massive Open Online Course. INITIATE will take advantage of a consortium spanning the full value chain, including major steel and urea industrial players (Arcelor Mittal, SSAB, Stamicarbon, NextChem), functional material suppliers (Johnson Matthey, Kisuma Chemicals), multi-disciplinary researchers (TNO, POLIMI, Radboud University) and experienced promoters of CCUS, circularity and symbiosis topics to public (CO2 Value Europe).

Currently, NG is normally substituted by hydrogen in upstream processes (both blast furnace and DRI), or limited application in finishing lines. Current downstream processes totally rely on NG burning as thermal source. Therefore, the massive usage of hydrogen in steel industry, as envisioned in the Carbon Direct Avoidance pathway of the ESTEP/EUROFER masterplan, requires a transformation of entire steelmaking process from liquid production process (UPSTREAM) to the rolling and finishing line (DOWNSTREAM). This research project is aimed at adopting hybrid heating technology (based on NG with progressive and increasing H2 utilization) in downstream processes. Thermal treatment and reheating processes, which are common to both BF and EAF route have a significant NG demand (about 50 Nm3/t of produced steel). also utilization for ladle preheating has a relevant NG demand (in the range 5-15 Nm3/t). In order to allow the shift from NG to H2 and consequently to reduce the environmental impact by using innovative combustion technologies (like flameless and oxyfuel combustion), impacts on steel quality, refractory and furnace must be assessed at high TRL (7). The general objective of this project is to exploit the hybrid heating technologies by evaluating the effects of the steel products, on the refractories and also on the combustion systems. Three Demo cases testing innovative multifuel burner and testing the limit of current systems at TRL 7 will facilitate the hydrogen transition of the steel sector. Achieved results will bring to a CO2 saving in the range 7.5-25Mt/year. Regarding the steel quality, the project activities will individuate the optimum processing parameters to ensure that primary scale and associated scale defects do not persist through to the final product.