Development of fossil free casting powders

Purpose and goal

The project will develop fossil-free casting powders based on biochar and clarify its impact on process and product. By developing fossil-free casting powders the environmental impact of the casting processes can be reduced and contribute to the transition to a climate-neutral steel production. New modeling techniques will be used to model the melting process of casting powder and to develop tools to assess the performance of casting powder and provide new opportunities for process optimization and increase the pace of development of casting powders.

Expected effects and result

The project will increase the understanding of the properties of biochar and how they affect the casting powder performance in both continuous casting and casting. A successful introduction of fossil-free casting powder will have the effect that more casting powders in the future can be replaced with fossil-free alternatives, which contributes to a climate-neutral casting process. New tools for process optimization and to assess casting powder performance and will strengthen the steel industry by optimizing casting processes and improving yields and product quality.

Planned approach and implementation

The approach is an iterative process where existing casting powders form the basis for the development of casting powders based on biochar. The properties of casting powders are evaluated at high and low temperatures and selected fossil-free casting powders will be evaluated in casting plant trials. Different varieties of biochar will be mapped based on suitability and availability for future production. Models for flowability and sintering behaviour of casting powders are developed based on characterization data and are tested in case studies based on the casting processes.