Overview
A true collaboration of the best minds in industry, research and government, working together for a low-carbon heavy industry.
Our approach is problem-solving research that can be adopted by industry. Our collaborative structure means that our teams of researchers are strongly aligned with industry to focus research on the practical challenges that companies face to de-risk the technology pathways to decarbonise heavy industry.
INDUSTRY-LED RESEARCH PROGRAMS
Process Technologies
Program 1 accelerates the reduction of industrial processes’ carbon footprint through development and evaluation of innovative technologies, including producing green iron and steel products from magnetite and hematite/goethite ores, green alumina production, and low-carbon lime and cement.
MILESTONES
1.1 Producing green iron products from magnetite
This research stream is developing technologies, data and demonstration facilities at sufficient scale to reduce the carbon intensity of green iron and steel production using magnetite ores. Work being undertaken includes:
- Process and computational fluid dynamics (CFD) models and technoeconomic assessments to assess low-carbon processing routes, including partial to full replacement of natural gas with hydrogen and electrically generated heat in pellet induration (the thermal treatment process that hardens pellets for use in a blast furnace or direct reduction process) or direct reduction.
- Experimental assessment of the application of electrical energy sources to pellet induration or direct reduction.
- Prototype development and demonstration of preferred technologies such as hybrid burners for pellet induration and hydrogen direct reduction.
- Life cycle assessment of preferred technology options for products such as green pellets (blast furnace and direct reduction grade) and hydrogen direct reduced iron (DRI).
- Testing of low-carbon pellet production and mineral carbonation processes.
1.2 Producing green iron products from hematite/goethite ores
This research stream is developing technologies, data and demonstration facilities at sufficient scale to reduce the carbon intensity of green iron and steel production using hematite/geothite ores. Work being undertaken includes:
- Technoeconomic evaluation of the quantum and type of renewable energy available in the relevant regional areas.
- Experimental assessment of beneficiation processing routes to produce feed suitable for direct reduction and/or alternative electric ironmaking routes, using low-carbon fuel and energy input, including:
- agglomerated product (pellet, briquette) for blast furnace and/or shaft direct reduction processes
- concentrated fines for fluidised bed direct reduction processes
- a feed to a fluidised bed reduction process (e.g. hot briquetted iron)
- feed for pig iron production in electric smelting furnace (DRI, hot briquetted iron).
- Demonstration of preferred processing routes for:
- beneficiation
- agglomeration
- DRI production
- pig iron production.
- Testing of preferred processing routes.
1.3 Low-carbon high-temperature alumina calcination
This research stream is developing low-carbon heat input approaches and technologies for the high-temperature (>1000ºC) calcination component of alumina production through:
- Prototype development and demonstration of a plausible low-carbon technology option using both experiments and CFD modelling.
- Modelling, testing and demonstration of a promising low-carbon technology options, such as hydrogen or electrification, for alumina calcination.
- De-risking of technology upscaling by establishing a significant database and validated numerical models of preferred low-carbon technology for alumina calcination.
1.4 Low-carbon heat for the hydrometallurgical process component of alumina refining
Low-carbon heat input approaches and technologies for the low-temperature hydrometallurgical component of alumina production (i.e. the production of low-carbon steam <300ºC) using approaches such as:
- Scoping studies and program development for electrification, fuel replacement, variable renewable energy (VRE) integration or solar thermal technology options.
- Scoping studies and program development for thermal storage at an alumina refinery to firm renewable energy supplies and produce steam.
- Modelling and testing the use of a low-carbon technology options, such as hydrogen or mechanical vapour recompression, for steam generation.
- Identifying the most promising routes to a low-carbon Bayer process (refining bauxite to produce alumina) and developing a feasibility study for a large-scale demonstration of viable routes to ~50% CO2
- Demonstration of the application of preferred technology options to an alumina refinery.
1.5 Low-carbon construction materials
This research stream is undertaking:
- Process flow and technoeconomic assessment to prioritise new low-carbon construction materials, using:
- Calcined clays (LC3)
- Carbonated gangue
- Red mud.
- Process modelling and experimental assessment to develop options to overcome barriers and lower cost of implementation.
- Evaluation of potential for conversion of byproducts, wastes, ore beneficiation residues and captured mineral carbonates from relevant industrial processes.
- Experimental studies of potential pathways to low-carbon coproducts using materials sourced from other Cooperative Research Centre testing programs
- Development of improved engineering design modelling tools, employing further experiments for model development and validation.
- Life-cycle assessment with updated technoeconomic and business case assessments of preferred low-carbon technology options.
Cross-Cutting Technologies
Program 2 provides opportunities for partners in multiple sectors to research shared challenges such as access to and integration of low-carbon energy, how to best mitigate CO2 derived from the processes themselves, and opportunities for circular economy initiatives.
The program is developing and demonstrating novel technologies that have economic potential to lower carbon intensity through low-carbon energy, heat, fuels, oxidants and reductants, and carbon, capture, utilisation and storage (CCUS).
MILESTONES
2.1 Integrating variable renewable energy sources into existing industrial processes
This research stream is developing technology to manage variable sources of renewable electrical energy within a process. Work includes:
- Assessing potential to add value to relevant partner industrial plants through increased capacity to accommodate turn up/turn down of energy loads.
- Developing and evaluating appropriate tools for assessing technoeconomic feasibility of new dynamic operating strategies or processes to accommodate variable energy.
- Experimentation and modelling to demonstrate enhancement using new strategies or processes.
- Pre-feasibility plans to demonstrate these innovations in a partner’s plant, including developing digital twin capabilities.
- Designing demonstration in a partner’s plant, including prototype optimisation.
- Demonstrating variable low-carbon energy integration in a plant.
2.2 Technology to accommodate use of multiple energy sources
This stream seeks to develop new technology and methods to accommodate multiple variable energy sources (including storage) with flexibility to balance availability, and switch between them, while minimising cost and CO2 emissions. Work includes:
- Identifying preferred options for hybridisation or other approaches to manage inherent variability in renewable energy supply within a process or technology.
- Developing small-scale prototype designs for promising options and conducting technoeconomic assessments of viability.
- Demonstrating technical feasibility of promising concepts at laboratory scale.
- Developing plans to upscale promising technologies, including further improvements to, or additional data for, each technology.
- Testing to de-risk upscaling.
- Developing improved engineering design modelling tools, employing further experiments for model development and validation.
2.3 Integrated capture and re-use of CO₂ in industrial processes
This stream will assess and advance technology readiness levels of carbon capture and storage, as well as CO2 utilisation technology. Carbon usage may include conversion to fuels, use in the agriculture sector, as a feedstock for plastics via commodity products such as methanol, and via mineral carbonation to produce alternative construction materials.
Work includes:
- Reviewing, with technoeconomic assessment, combinations of commercial and emerging CO2 capture and re-use technologies, to select priority options for Australian industries.
- Evaluating integration of priority options into existing partner processes, including experimentation and modelling to de-risk priority options.
- Developing a prototype for novel enhancement of partner technology.
- Developing improved prototype and validated models of novel technology.
2.4 Blending of alternative low-carbon fuels for current industrial processes
This stream is developing and adapting technology to accommodate new blends of low-carbon fuels into existing industrial processes to reduce carbon emission. Work includes:
- Identifying, via technoeconomic assessment, priority options for low-carbon fuels and other heat sources for partners.
- Developing novel technological concepts to unlock target sources of alternative fuels or other heat sources from experiments and modelling.
- Proof-of-concept demonstration and CFD modelling of novel approaches.
- Further improving novel burner technology and gathering experimental evidence on a variety of alternative fuels, heat sources and conditions.
- Assessing performance, emissions, impact on process and net carbon reduction, and developing validated models for new or improved technologies.
- Assessing, via models, the design of adaptation strategies in existing plants.
- Developing plans to demonstrate blending in commercial plants.
- Supporting the development of designs and implementation for commercial demonstration.
- Demonstrate and assess the technical viability of fuel blending and its effect on existing processes.
2.5 Technologies to lower carbon emissions through synergistic production of industrial chemicals and fuels
This stream is developing new and adapting current technologies that provide synergies between carbon emission reduction and production of valuable chemicals and fuels. Work includes:
- Identifying options for synergistic processes, products, chemicals or fuels.
- Technoeconomic assessment of options for synergistic processes, products, chemicals or fuels.
- Experimental assessment of priority options for low-carbon synergistic processes, products, chemicals or fuels through.
- Testing and developing preferred technology options for low-carbon production.
- Developing improved engineering design modelling tools and employing further experiments for model development and validation.
- Life-cycle assessment with updated technoeconomic and business case assessments of preferred low-carbon technology options.
Facilitating Transformation
Technology alone is not sufficient to decarbonise heavy industry. Program 3 assesses how to facilitate the low-carbon transition, and ensure industry adoption of HILT CRC’s technologies. It investigates multidimensional and complex issues such as effective policy and regulatory enablers, development of green markets and trade of low-carbon products, and enabling facilities and infrastructure.
MILESTONES
3.1 Developing supporting frameworks for emerging low-carbon technologies
Following reviews of existing industry roadmaps and regional plans for the low-carbon transition, this research stream is undertaking:
- Life-cycle assessments of current production operations
- State and national reviews of heavy industry carbon production positions
- Technology development and low-carbon production roadmaps for low-carbon scenario planning including in regional hub development.
- Development of low-carbon transition pathways for industry including input into Australian Government sectoral plans.
- Ongoing assessment of impacts of policy and technology developments on industry low-carbon transition pathways, including emissions and economic implications.
3.2 Assessing barriers and policy enablers for the production and trade of low-carbon products and commodities
Following preliminary assessments of the supply and value chains for green products, this stream is developing:
- Detailed assessments of opportunities in the supply and value chain for low-carbon products and commodities.
- Policy and regulatory assessment of green product domestic and export markets.
- Recommendations for certification frameworks for low-carbon products and commodities.
- Review of the trade policy implications for green products and green energy development in Australia.
- Analysis to identify where in the supply chain of low-carbon products and commodities Australia has comparative advantage.
- Frameworks to assess low-carbon policy impacts and inform ongoing policy development.
- Low-carbon trade analysis to inform industry.
- Analysis and recommendations for developing demand for low-carbon products and commodities.
3.3 Enabling facilities and infrastructure
Following an assessment of the role of industrial hubs in heavy industry decarbonisation, this stream is undertaking:
- A stakeholder engagement plan and consultation with First Nations organisations.
- Assessment of the infrastructure requirements of a sustainable and secure energy supply for heavy industry, including regional development opportunities.
- Assessment of supporting infrastructure requirements for heavy industry decarbonisation, outside of energy needs, including regional development opportunities.
- Frameworks for industry-government collaboration on shared infrastructure, considering models for co-investment/ownership.
- Ongoing assessment and recommendations for optimal regional development and strategies to unlock investment in infrastructure.
- Assessment of requirements for social license to inform industry.
Research Strategy & FOCUS
Our research strategy was developed in close consultation with our partners across the heavy industrial sector in Australia and overseas. The strategy identifies outputs, pathways and focus areas that drive the development of projects and contribute to the planning for infrastructure.
PATHWAYS TO DECARBONISE HEAVY INDUSTRY
HILT CRC has mapped decarbonisation pathways and areas where technology can be deployed and have a significant impact on decarbonisation. The figure below shows individual technologies and pathways for the decarbonisation of HILT CRC’s sectors, as well as the linkages between them.
RESEARCH FOCUS AREAS 2023 TO 2027
Our research focus areas, detailed in the figure below, fall into five focus areas:
- Beneficiation to improve ores and make them more suitable for decarbonised processes.
- Reactor technology needed to progress decarbonised processes.
- Energy technology – recognising the criticality of supply and integration of low-carbon energy and fuels for heavy industry decarbonisation.
- Circularity, including carbon capture, utilisation and storage (CCUS).
- Facilitating transformation to address the non-technical barriers to decarbonisation.
