The core targets of Stellantis’ future strategy include slashing carbon emissions to achieve carbon net zero. Reducing the manufacturing carbon footprint, in particular in the foundries, is important to achieve these aims. Stellantis are actively investigating ways in which they can support the reduction of the embodied carbon of their vehicles.
Coke is used in foundries mainly for three reasons: chemical reduction, heat source, and a mechanical support:
- Coke is rich in carbon, which allows the reduction of metallic oxides (such as iron oxide) into pure metal. This chemical reaction is essential in the production of cast iron and steel.
- High calorific value: it burns at very high temperatures and provides the heat needed to melt metals.
- Mechanical structure: in the form of solid pieces, coke helps maintain good gas circulation, while serving as a physical support for the metal charge, preventing the collapse of the melting bed.
Fossil coke is derived from bituminous coal. It is produced from pyrolysis of coal at high temperature, and has a very high carbon content, typically in the range of 85% to over 90% by weight.
The motivation of this challenge is to replace a part of the fossil coke by biocoke, produced from pyrolysis of biomass, to reduce carbon footprint and dependence on fossil coke supply, and to promote localised production.
The proposed solution must cover a process or approach which produces biocoke at suitable quality for foundries, from an initial biomass source or directly from biocarbon.
This opportunity is only open to UK registered organisations.
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The proposed solution must cover a process or approach which produces biocoke at suitable quality for foundries, from an initial biomass source or directly from biocarbon.
The biocoke must be in the form of briquettes and must meet foundries specification: high carbon content (≥85%), low ash content (<10%), Lower Heating Value (LHV) 28MJ/kg, Higher Heating Value (HHV) 30MJ/kg, mechanical strength to support the weight of the metal above, and a minimum piece size to allow the passage of gases and fluids.
The maturity level of the proposed solution must be ≥ TRL5 including:
- Demonstration of the process in an operational experimental pilot, resulting in the production of biocoke briquettes
- Chemical analyses results of the briquettes (see technical requirements)
- Mechanical strength test results or foundry test results (see technical requirements)
The solution should be commercially deployable ideally within 1 year.
The process should be harmless for humans and environment, considering viable control measures.
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The solution must:
- Produce biocoke at suitable quality for foundries, from an initial biomass source or directly from biocarbon
- Comply with EU regulations for pollutants emissions
- Meet the following Stellantis High-Quality Criteria:
- No harm: prove no negative environmental, social or economic impact by preparatory analysis, collaboration with local communities, robust planification & regular monitoring.
- No leakage: avoid displacing or creating emissions by preparatory analysis, collaboration with communities and robust planification
If the solution starts from biomass as input material, this biomass must not cause competition with food.
For further technical and functional requirements, visit the Innovation Exchange site at the link below.
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- Solutions that do not comply with the Stellantis High-Quality Criteria of No harm and No leakage.
- Solutions where the source of biomass is in competition with food.
- Solutions focused only on the biomass pyrolysis step to generate biocarbon.
- Solutions which have not demonstrated results to produce biocoke (i.e. should be TRL5 or above for this application).
- Solutions from organisations that are not registered in the UK.
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Successful applicants will be given an opportunity to pitch to Stellantis. The applications will be reviewed by technical experts in foundry at Stellantis. Selected solutions may be co-developed towards commercial adoption through co-development, pilot studies or other arrangement depending on mutual agreement between Stellantis and the solution provider.
The benefits package for a successful applicant may also include:
- Support from Innovate UK Business Connect
- Support in the development of a prototype or pilot
- Technical support
- Invitation to attend or present at Innovate UK Business Connect events
- A potential business collaboration
- Investor introductions (if investment is required)
- Support if any Innovate or similar competitions are relevant.