Decarbonising the Production of Large Scale Forgings and Castings

Sheffield Forgemasters specialises in the manufacture of large scale, high quality, cast and forged components. The company has a 200 year history in metal production and forming, supplying products to a range of market sectors including, defence, oil and gas, renewables and power generation. The company represents the UK's sole capability for supplying major nuclear vessel forgings for both civil and defence applications

The production of large scale cast and forged product uses carbon based fuels in multiple stages of the manufacturing process. The largest contributor to carbon emissions is related to the burning of natural gas for a variety of heating applications. Other emissions and sources of carbon are associated with cutting and burning operations, in addition to a range of consumables used.

The principal objective of the project is to address the decarbonisation of energy intensive manufacturing processes at Sheffield Forgemasters, in order to align the company to the national ambition of achieving net zero carbon emissions by 2050\. Primary manufacturing routes, focusing on key processes such as steel making and heat treatment, will be investigated to identify opportunities for decarbonisation. The company's reliance on natural gas means opportunities for fuel switching to carbon free equivalents, e.g., Hydrogen, will be explored. In addition, opportunities to remove oxyacetylene and propane fuels used in cutting operations will also be considered.

The proposed decarbonisation solutions will also examine the potential impact of process changes on products from a quality and engineering performance view point. The results of the study will be used to inform decisions on future capital investment and form the basis for future technology deployment and development projects. The study will identify the possible modifications required to be made to company's infrastructure to enable fuel switching, building a case for the industrial use of carbon-free alternative fuels which can be potentially be deployed to other industrial markets and sectors

The project represents the starting point for a comprehensive decarbonisation strategy at Sheffield Forgemasters. The project will be delivered in partnership with the Material Processing Institute who has extensive experience in high temperature, energy intensive industries. Primarily working with the steel industry, The Materials Processing Institute, like Sheffield Forgemasters, have a strong track record of participating in and leading multi-partner technology projects. The Institute has experience in furnace performance and plant audit in collaborations working to decarbonise foundation industries.