The process industry is continuously looking for new ways to improve resource efficiency due to high dependence on resources (energy, raw materials and utilities). In large scale production even small changes in using raw materials and in energy can significantly improve process efficiency. The MORSE approach is to adopt new software tools for model-based predictive control, multi-criterial through process optimisation and quality management with overall process coordination. The application of these new software tools will lead to process improvements - reducing the use of raw material and energy while increasing the high quality and production rates. The Morse project aims to further develop and to integrate a set of software tools that have partly already been validated in different process steps in steel industries. These software prototype tools and models were developed and evaluated by six R&D partners of the consortium in collaboration with three process industry partners. With the enhanced Morse tools companies of the process industry will be enabled to optimise the use of raw materials and energy by coordinated prediction and control of resource input and product quality along the entire process route from raw material and energy intake to customer delivery. The mission of the Morse project is to develop model-based, predictive raw material and energy optimisation tools for the whole process route. This approach will be demonstrated in steel industry, to increase yield and product quality in production of high-strength carbon steels, stainless steels and cast steels.

H2-enriched direct reduction (DR) is the key decarbonisation technology for integrated steelworks mentioned in pathways of all major steel producers. Natural gas driven DR is established in industry mostly outside Europe but there are no experiences with high H2 enrichment > 80%. H2 based reduction is no principal issue but endothermic and the influences on morphology, diffusion and effective kinetics are not known. Also properties and movement of particles in the reactor are not know and issues like sticking cannot be excluded. Probably, temperature distribution and flow of solids and gas will be clearly different. No reliable prognosis is possible yet, in particular with regard to local permeability, process stability and product quality of industrial size furnaces with higher loads on the particles and larger local differences. Many activities are initiated for first industrial demonstration of H2-enriched DR but they will not close many of these knowledge gaps. MaxH2DR provides missing knowledge and data of reduction processes. A world-first test rig determines pellet properties at conditions of industrial H2 enriched DR furnaces and a physical demonstrator shows the linked solid and gas flow in shaft furnaces. This will be combined with digitals models including the key technology DEM-CFD to provide a hybrid demonstrator able to investigate scale-up and to optimise DR furnace design and operating point. This sound basis will be used to optimise the process integration into existing process chains. Simulation tools will be combined to a toolkits that covers impacts of product properties on downstream processes as well as impacts on gas and energy cycles. Thus, promising process chains, sustainable and flexible, will be achieved for different steps along the road to decarbonisation. The digital toolkits will support industrial demonstration and implementation and strengthen digitisation and competitiveness of the European steel industry.

EAF steelmaking is the key technology for decarbonised steelmaking, either in scrap-based plant by modification of existing processes for further decarbonisation, or as new EAF installations in decarbonised integrated steel works to (partly) replace the classical BF-BOF production. At same time the EAF is the most important example for modular and hybrid heating, already now combining electric arc heating with burner technologies. Consequently, it was selected as main focus of GreenHeatEAF for the Call „Modular and hybrid heating technologies in steel production“. GreenHeatEAF develops and demonstrates the most important decarbonisation approaches at EAFs including the use of hydrogen to replace natural gas combustion in existing or re-vamped burners or innovative technologies like CoJet. Furthermore, decarbonisation of EAF steelmaking by solid materials like DRI/HBI and renewable carbon sources like biochar is tackled. Technologies to re-optimise the heating management with maximum heat recovery of off-gas and slag employing new sensor and soft-sensor concepts as well as extended digital twins are developed: as result the extended CFD and flowsheeting models, and monitoring and control tools will prognose the influences of the different decarbonisation measures on EAF and process chain to support upcoming decarbonisation investments and to enable the control of decarbonised hybrid heating with maximum energy efficiency. GreenHeatEAF combines trials in demonstration scale, e.g. in combustion- and EAF-demo plants, with validations in industrial scale and digital optimisations with high synergy. Thus, it completely follows the Horizon Twin Transition and Clean Steel Partnership objectives and the target to progress decarbonisation technologies from TRL 5 to 7. This synergic concept of GreenHeatEAF supports implementation and digitisation to speed up the transition of the European steel industry to highly competitive energy-efficient decarbonised steel productio

In context of the transition to low-carbon, green and sustainable steel production in Europe, disruptive technologies to reduce the environmental footprint as close to zero as possible, seamless digitalisation of production processes, and skilled people to co-design and understand the transformation process are necessary. DiGreeS will address these needs by implementing an integrated digitalisation approach across the steel value chain, enabling better use of process data collected and ensuring the involvement of human experience for easier industrial integration. The aim of DiGreeS is to develop a user-friendly digital platform for networked production based on novel and soft sensors and related approaches and models to support efficient feedstock verification and real-time control of electric arc furnace crude steel production, increasing process yield while improving the quality of intermediate and final steel products. In this context, the potential of artificial intelligence techniques will be fully exploited to support the optimal use of industrial data, and different scenarios specific to each use case will be modelled. The digital platform will be implemented and verified in industrial process lines of the three use cases: scrap/secondary raw material verification, optimisation of the electric arc furnace processes and optimisation of the levelling of steel sheets. DiGreeS aims to improve the quality of crude steel and finished products, optimize scrap usage, and improve energy efficiency in the steel production process. DiGreeS has the potential to save up to €800 million in costs annually and reduce CO2 emissions from the steelmaking industry by up to 6 million tonnes per year.

The DESTINY project aims to realize a functional, green and energy saving, scalable and replicable solution, employing microwave energy for continuous material processing in energy intensive industries. The target is to develop and demonstrate a new concept of firing granular feedstock for materials transformation using full microwave heating as alternative and complement to the existing conventional production. The DESTINY system is conceived as cellular kilns in mobile modular plant, with significant advantages in terms of resource and energy efficiency, flexibility, replicability and scalability with reduced environmental footprint. The DESTINY concept will be proved in a demo site located in Spain, covering high energy demanding sectors of strategic interest as Ceramic (Pigments), Cement (Calcined clay) and Steel (Sinter, Iron Pellets/DRI, ZnO), to validate the critical parameters of the developed technology in relevant environment (TRL 6). It will be implemented with 2 feeding modules and 1 mobile microwave kiln module and product treatment. Influence of the DESTINY solutions in terms of stability, process efficiency and characteristics of raw materials, intermediate/sub/final products will be investigated to improve performance of the industrial processes addressed and guarantee the required quality of products. Numerical simulation tools will be used to drive the design and support the testing activities The industrialization and sustainability of DESTINY high temperature microwave technology will be assessed through the evaluation of relevant KPIs, with Life Cycle Methodologies. With the final aim of ensuring a large exploitation and market penetration for DESTINY, technology-based solutions business model, economic viability and replicability analysis will be conducted. For guaranteeing industrial transferability appropriate exploitation and dissemination activities have been defined during and even after the end of the project.