Sustainable Curing: exploring alternative technologies for painted steel products
Lead Research Organisation:
Swansea University
Department Name: College of Engineering
Abstract
Background:
Tata Steel UK is one of the largest producers of pre-painted steel in Europe and produces top range products which are specified throughout Europe, primarily for use in the construction industry. To maintain this position, the organisation is constantly trying to improve the current product range, either through the development of best-in-class coatings for the construction industry, improved offerings in service or through added functionality. Tata's premium coated products can offer maintenance free warranties of up to 40 years and this technology is based on decades of experience formulating paints sourced from fossil fuels as their feedstock. With ever increasing focus on sustainability credentials and the circular economy, Tata Steel UK have a clear carbon reduction strategy. Part of this strategy requires alternative curing technologies from the current gas fired ovens which will reduce the overall embodied carbon of the pre-finished steel products. It is envisaged as part of this research, suitable pilot line capability will be developed to prove the chosen curing technology before scaling up to full manufacturing capability. Such alternative curing technologies could include, but are not limited to, Ultra Violet (UV), Electron Beam (EB), Induction curing, Infra Red (IR).
This research project will help shape the sustainability future of the UK business by fundamentally changing the method of manufacturing.
Project aims:
- Work in conjunction with our key paint supplier to fully understand the current paint formulation and how the paint formulation will need to be adapted depending on the curing method
- Assess the impact of the different curing process technologies on the various different polymers
- Analyse materials via external and accelerated testing.
- Use analytical techniques such as UV, ATR FTIR and Raman spectroscopy to determine the mechanism and rates of organic coating degradation and erosion.
- Look to enhance the pilot line to evaluate the preferred curing process technologies and provide recommendations to the business as to the suitability of the various options.
Tata Steel UK is one of the largest producers of pre-painted steel in Europe and produces top range products which are specified throughout Europe, primarily for use in the construction industry. To maintain this position, the organisation is constantly trying to improve the current product range, either through the development of best-in-class coatings for the construction industry, improved offerings in service or through added functionality. Tata's premium coated products can offer maintenance free warranties of up to 40 years and this technology is based on decades of experience formulating paints sourced from fossil fuels as their feedstock. With ever increasing focus on sustainability credentials and the circular economy, Tata Steel UK have a clear carbon reduction strategy. Part of this strategy requires alternative curing technologies from the current gas fired ovens which will reduce the overall embodied carbon of the pre-finished steel products. It is envisaged as part of this research, suitable pilot line capability will be developed to prove the chosen curing technology before scaling up to full manufacturing capability. Such alternative curing technologies could include, but are not limited to, Ultra Violet (UV), Electron Beam (EB), Induction curing, Infra Red (IR).
This research project will help shape the sustainability future of the UK business by fundamentally changing the method of manufacturing.
Project aims:
- Work in conjunction with our key paint supplier to fully understand the current paint formulation and how the paint formulation will need to be adapted depending on the curing method
- Assess the impact of the different curing process technologies on the various different polymers
- Analyse materials via external and accelerated testing.
- Use analytical techniques such as UV, ATR FTIR and Raman spectroscopy to determine the mechanism and rates of organic coating degradation and erosion.
- Look to enhance the pilot line to evaluate the preferred curing process technologies and provide recommendations to the business as to the suitability of the various options.
Planned Impact
The CDT will produce 50 graduates with doctoral level knowledge and research skills focussed on the development and manufacture of functional industrial coatings. Key impact areas are:
Knowledge
- The development of new products and processes to address real scientific challenges existing in industry and to transfer this knowledge into partnering companies. The CDT will enable rapid knowledge transfer between academia and industry due to the co-created projects and co-supervision.
- The creation of knowledge sharing network for partner companies created by the environment of the CDT.
- On average 2-3 publications per RE. Publications in high impact factor journals. The scientific scope of the CDT comprises a mixture of interdisciplinary areas and as such a breadth of knowledge can be generated through the CDT. Examples would include Photovoltaic coatings - Journal of Materials Chemistry A (IF 8.867) and Anti-corrosion Coatings - Corrosion Science (IF 5.245), Progress in Organic Coatings (IF 2.903)
- REs will disseminate knowledge at leading conferences e.g. Materials Research Society (MRS), Meetings of the Electrochemical Society, and through trade associations and Institutes representing the coatings sector.
- A bespoke training package on the formulation, function, use, degradation and end of life that will embed the latest research and will be available to industry partners for employees to attend as CPD and for other PGRs demonstrating added value from the CDT environment.
Wealth Creation
- Value added products and processes created through the CDT will generate benefits for Industrial partners and supply chains helping to build a productive nation.
- Employment of graduates into industry will transfer their knowledge and skills into businesses enabling innovation within these companies.
- Swansea University will support potential spin out companies where appropriate through its dedicated EU funded commercialisation project, Agor IP.
Environment and society
- Functionalised surfaces can potentially improve human health through anti-microbial surfaces for health care infrastructure and treatment of water using photocatalytic coatings.
- Functionalised energy generation coatings will contribute towards national strategies regarding clean and secure energy.
- Responsible research and innovation is an overarching theme of the CDT with materials sustainability, ethics, energy and end of life considered throughout the development of new coatings and processes. Thus, REs will be trained to approach all future problems with this mind set.
- Outreach is a critical element of the training programme (for example, a module delivered by the Ri on public engagement) and our REs will have skills that enable the dissemination of their knowledge to wide audiences thus generating interest in science and engineering and the benefits that investments can bring.
People
- Highly employable doctoral gradates with a holistic knowledge of functional coatings manufacture who can make an immediate impact in industry or academia.
- The REs will have transferable skills that are pertinent across multiple sectors.
- The CDT will develop ethically aware engineers with sustainability embed throughout their training
- The promotion of equality, diversity and inclusivity within our cohorts through CDT and University wide initiatives.
- The development of alumni networks to grow new opportunities for our CDT and provide REs with mentors.
Knowledge
- The development of new products and processes to address real scientific challenges existing in industry and to transfer this knowledge into partnering companies. The CDT will enable rapid knowledge transfer between academia and industry due to the co-created projects and co-supervision.
- The creation of knowledge sharing network for partner companies created by the environment of the CDT.
- On average 2-3 publications per RE. Publications in high impact factor journals. The scientific scope of the CDT comprises a mixture of interdisciplinary areas and as such a breadth of knowledge can be generated through the CDT. Examples would include Photovoltaic coatings - Journal of Materials Chemistry A (IF 8.867) and Anti-corrosion Coatings - Corrosion Science (IF 5.245), Progress in Organic Coatings (IF 2.903)
- REs will disseminate knowledge at leading conferences e.g. Materials Research Society (MRS), Meetings of the Electrochemical Society, and through trade associations and Institutes representing the coatings sector.
- A bespoke training package on the formulation, function, use, degradation and end of life that will embed the latest research and will be available to industry partners for employees to attend as CPD and for other PGRs demonstrating added value from the CDT environment.
Wealth Creation
- Value added products and processes created through the CDT will generate benefits for Industrial partners and supply chains helping to build a productive nation.
- Employment of graduates into industry will transfer their knowledge and skills into businesses enabling innovation within these companies.
- Swansea University will support potential spin out companies where appropriate through its dedicated EU funded commercialisation project, Agor IP.
Environment and society
- Functionalised surfaces can potentially improve human health through anti-microbial surfaces for health care infrastructure and treatment of water using photocatalytic coatings.
- Functionalised energy generation coatings will contribute towards national strategies regarding clean and secure energy.
- Responsible research and innovation is an overarching theme of the CDT with materials sustainability, ethics, energy and end of life considered throughout the development of new coatings and processes. Thus, REs will be trained to approach all future problems with this mind set.
- Outreach is a critical element of the training programme (for example, a module delivered by the Ri on public engagement) and our REs will have skills that enable the dissemination of their knowledge to wide audiences thus generating interest in science and engineering and the benefits that investments can bring.
People
- Highly employable doctoral gradates with a holistic knowledge of functional coatings manufacture who can make an immediate impact in industry or academia.
- The REs will have transferable skills that are pertinent across multiple sectors.
- The CDT will develop ethically aware engineers with sustainability embed throughout their training
- The promotion of equality, diversity and inclusivity within our cohorts through CDT and University wide initiatives.
- The development of alumni networks to grow new opportunities for our CDT and provide REs with mentors.
Studentship Projects
| Project Reference | Relationship | Related To | Start | End | Student Name |
|---|---|---|---|---|---|
| EP/S02252X/1 | 01/10/2019 | 31/03/2028 | |||
| 2744818 | Studentship | EP/S02252X/1 | 01/10/2022 | 30/09/2026 | Christopher Linyard-Tough |