HERCULES introduces a novel breakthrough approach towards thermal energy storage of surplus renewable energy via a hybrid thermochemical/sensible heat storage with the aid of porous media made of refractory redox metal oxides and electrically powered heating elements. The heating elements use surplus/cheap renewable electricity (e.g. from PVs, wind, or other sources) to charge the metal oxide-based storage block by heating it to the metal oxide reduction temperature (i.e. charging/energy storage step) and subsequently (i.e. upon demand) the fully charged system transfers its energy to a controlled airflow that passes through the porous oxide block which initiated the oxidation of the reduced metal oxide. It is an exothermic process thus a hot air stream is produced during this step which can be used to provide exploitable heat for industrial processes. The proposed research will be conducted by an interdisciplinary consortium constituting leading research centers, universities, innovative SMEs, and large enterprises including ancillary service providers and technology end-users.

Scrap-based production of Steel using Electric Arc Furnace (EAF) with possibility of 100 % scrap charges, offers a Circular Economy-based solution to reduce CO2 emissions when compared to the integrated Blast Furnace (BF) + Basic Oxygen Furnace (BOF) route (1.81 tCO2/tsteel for BOF vs 0.23tCO2/tsteel for EAF). However, EAF production of sheet steel is currently not a reality due to the effect of undesired residual elements in the scrap. The aim of CiSMA is to introduce scrap-based EAF steel products into mass-market sheet metal consumer goods with high-quality requirements, currently served with BOF steel (96 % of the market). First, by generating fundamental knowledge on how residual elements, and Copper in particular, interact with sheet Steel and its performance. This will be done combining state-of-the-art methodologies with specialized resources, such as Synchrotron, to design Steel grades and determine safe residual thresholds. Next, scrap as a raw material will be studied together with methodologies to improve its quality and maximize the use of low-quality scrap, through the use of techniques that separate undesired inclusions from the main stream of steel. Finally, by generating a toolbox of enabling technologies to introduce recycled sheet metal in the industry: 1) fast characterization tests for quality control, 2) online test methodologies that can be applied in the press floor, and 3) the development of Machine Learning-enhanced Finite Element Modelling and Digital Twin that allow adapting production processes to feedstock with high variability. These developments will be showcased in applying four steel compositions into two pilot trials for mass-market applications: automotive and white goods. These trials will ensure that the material and production route developed can be readily accepted by the market, demonstrate the developed toolset of enabling technologies, and quantify the environmental improvements achieved compare to the current product.

The flexolighting programme is focussed on research and innovations on materials, processes and device technology for OLED lighting with the intention of building a supply chain within Europe. The aim is to realise OLED devices over a large area/surface with high brightness, high uniformity and long life time. A demonstrator will be built and delivered at the end of the project. The main targets are (i). Cost of the lighting panels should be less than Euro 1 per 100 lumens. (II). high luminous efficiency, in excess of 100 lm/W with improved out-coupling efficiency. (ii). white light life-time of at least 1000 hours at 97% of the original luminance of 5000 cdm-2.(iii). The materials and the devices therefrom will allow for differential aging of the colours, thus maintaining the same colour co-ordinates and CRI over its use. (iv). Attention will be paid to recyclability and environmental impact of the materials and the OLED lighting systems. Flexolighting project will also ensure European industrial leadership in lighting. The introduction of OLED Lighting technology is held back by the current cost of the systems, life-time and poor uniformity of luminance on large area panels. The programme aims to combine existing state of the art OLED materials technology (Thermally activated fluorescent materials (TADF) and phosphorescent emitters and world class transport materials) with new developments in processing technologies (Organic Vapour Phase Deposition (OVPD) and printing technologies) to develop new next of generation low cost OLED lighting systems to move forward to scale up and full scale production on novel planarized flexible steel substrates with cost effective conformal encapsulation method. The transparent top contacts made of thin metallic films, conducting polymers or graphene monolayer with metal tracks to reduce the series resistance will be employed in inverted top emitting OLED structures to deliver 100 lumens per Euro.

Refractory materials are key enablers for high temperature industries such as Iron & Steelmaking (I&S). Refractories are sophisticated materials designed and optimized to sustain severe operation conditions inducing complex combinations of thermo-mechano-chemical damage mechanisms. Nevertheless, refractory material consumption has been reduced over the last 50 years from more than 35 kg of refractories per ton of steel to about 10 kg/t in the European steel industry, while keeping safety of the utmost importance. The movement of the I&S industry towards Net-Zero emissions and digitalized processes through disruptive, breakthrough technologies will be achieved through the use of Hydrogen. The biggest challenge for the refractory industry is to continue to meet the performance expectations while, at the same time, moving to a more sustainable production direction. The complexity and urgency of these technology changes, highlighted by the European Green Deal, requires a Concerted European Action on Sustainable Applications of REFractories (CESAREF). A consorted and coordinated European network with steel, refractory, raw material producers and key academic poles will tackle the following key topics: • Efficient use of raw materials and recycling, • Microstructure design for increased sustainability, • Anticipation of hydrogen steelmaking, • Energy efficiency and durability. While creating new developments in the I&S and refractory industries, the network will train highly skilled doctoral candidates capable of communicating and disseminating their acquired knowledge. CESAREF will create a core team across the European refractory value chain, accelerating the drive towards the European refractory industries push towards sustainable materials and processes, as well as Net-Zero emission Steel production. This will help to create and secure sustainable employment in the European refractory and I&S industries.

Each year the EU steel sector generates several million tons of metal and mineral containing residues that are currently largely under-exploited and are often sent to landfills with an enormous waste of resources that could replace virgin materials. ReMFra main objective is the development and validation of highly efficient pyrometallurgic melting and reduction demonstration plant at relevant industrial scale for recovering metals and minerals contained in a wide range of steelmaking residues. The ReMFra process will allow to valorise steelmaking residues, such as filter dust, scale, sludge and slags, to obtain pig iron, iron rich oxides, a highly concentrated zinc oxide and an inert slag. ReMFra comprises two main parts to be developed, improved and tested at industrial scale: Plasma Reactor and RecoDust. The first will be dedicated to recover the coarse residues (scale, sludge, slag), while the second will focus on fine-grained dusts. The project will allow the improvement of iron yield using recovered pig iron instead of new pig iron and replacing the iron ore with the iron rich oxide. The recovery of concentrated ZnO and inert slag as by-products will provide a significant source of income and will contribute to the overall carbon neutrality. To reach the full circularity, the process foresees the use, as reducing agent, of secondary carbon sources (i.e. waste plastics). Energy recovery solutions will also be integrated in the metal recovery process starting from enabling the use of molten pig iron. ReMFra consortium comprises: 5 steelmaking companies, 4 RTOs as technology providers with large experience in steel sector, 1 university and the European Steel Technology Platform. To conclude, ReMFra is expected not only to enable technological advances in the demonstrators involved but will also contribute to the development of new standards, training programmes, adaptation and certification of industrial processes thus facilitating the replication of the project.