The Danish steel recycling industry stands to be REVIVED through the potential of spray forming (SF). SF, with its world's largest plant located in Denmark, produces two remarkable products: a high-quality metal ingot and an overspray powder. In Denmark, steel recycling is currently insignificant. Scrap handling is limited to a fragmented sorting and is largely driven by an export-oriented market. The prevailing recycling method is that scrap is directed into a mixed waste stream. REVIVE offers recycling with an incentive for Danish manufacturing companies to sort highly alloyed steel scrap separately which consequently can be processed in a fashion where their intrinsic value is preserved and be returned as high-quality feedstock. 0175-00043B historically demonstrated that a unique Danish SF plant has immense recycling potential, reducing carbon emissions up to 60%. Drawing solely from green electricity and scrap material, its one-step process positions it as a groundbreaking solution that through REVIVE can be brought up to 90% emission reduction at scale. Scaling when operated exclusively on scrap introduces process and material fluctuations. The scale-up barrier is overcome via digital, robust, first-time-right recycling with an industry-leading 0.3 kg CO2 per kg. As the best-in-class technology, the Danish steel recycling industry is poised to thrive, making significant strides towards contributing to sustainable steel recycling practices.

As fossil fuels are phased out, the ongoing energy transition increases the need for power-to-X (PtX) systems providing anciliary services and converting fluctuating wind/solar power to high-value products such as clean fuels. Electricity constitutes up to 80% of the PtX product cost, therefore, high conversion efficiency is critical. The solid oxide electrolysis (SOE) technology has 40% higher fuel production efficiency than competing alternatives, however limited lifetime is a barrier to SOE commercialization. The ROAD2X consortium will address this barrier by maturing DynElectro’s newly patented (AC:DC) operation that increases SOE lifetime. Additionally, AC:DC operation improves impurity tolerance and enables dynamic operation, important for balancing renewable power production with power consumption. The project prepares AC:DC operated SOE technology for commercialization by 1) demonstrating robust long-term operation (1 year) of SOE cells and a stack 2) investigate the tested cells and stack to identify how AC:DC operation reduces SOE degradation and improves impurity tolerance 3) demonstrating dynamic operation with a 40 kW SOE system 4) designing a power-to-methanol systems with thermally integrated SOE modules. Notably, the generic AC:DC operation method can be used on existing SOE technology from leading manufacturers, which enables rapid implementation and scaling towards large PtX systems for clean fuel production.

Conventional manual manufacturing methods - hand lay-up and vacuum infusion - are to date predominantly used to produce large-scale Continuous Fiber Composite (CFC) structures for industries such as maritime, automotive, aerospace and wind energy. Conventional manufacturing is labor-intensive and compromises efficiency: manual production steps are posing a safety and quality deficiency risk. RoboPrint revolutionizes conventional manufacturing by establishing a fully automized and digitalized CFC 3D printing process - anticipated to become a game changer in industry demanding high-performance CFC structures by avoiding manual manufacturing limitations. CFC 3D printing enables production of complex geometries and fiber architectures otherwise not feasible with conventional methods. RoboPrint develops and integrates key enabling hardware and software technologies for 3D CFC printing on an industrial scale. On the digitalization side, RoboPrint develops a Digital Twin (DT) of the robotic CFC 3D printer, unifying thermomechanical modelling of the printing process with the virtual robotic printing sequences. Virtual 3D CFC printing enables optimization of the to-be-printed structure prior to physical printing. Interfacing the physical CFC 3D printer with its DT significantly reduces cost, time, safety risk and waste material compared to conventional methods. RoboPrint makes large-scale CFC 3D printing technology ready for demonstration in an industrially relevant environment.