FISC is working with industry to help them solve problems relating to six key themes. In this case study partner The Henry Royce Institute is using thermodynamic modelling to investigate the corrosive effects of hydrogen fuelling (as opposed to natural gas) on different refractory materials.

FISC theme: Process Optimisation
Designing and improving systems to minimise process variability, maximise resource utilisation and identify best practice. Data gathered will be analysed to help improve operations, but also to identify best practice across the foundation industries and transfer knowledge that aids the competitiveness of the UK.


What problem/s does industry have?
Industry wants and needs to decarbonise but needs a cost effective and sustainable method of exploring how using lower carbon materials and processes might affect their business.

There are concerns that using alternative fuels like hydrogen might corrode refractory materials (the materials used to line furnaces, kilns and other devices exposed to high temperatures).

How is FISC helping solve the problem/s?
Through collaboration FISC and its partner The Henry Royce Institute (Royce) at The University of Manchester partnered with the UK's largest manufacturer of shaped refractories, DSF Refractories & Minerals Ltd, to investigate the corrosive effects of hydrogen fuelling (as opposed to natural gas) on different refractory materials.

Hydrogen firing in glass melt furnaces changes the combustion atmosphere. As the glass melts high levels of water vapour concentrate that might react with refractory blocks in the furnace.

In partnership with Glass Futures and the Materials Processing Institute, Royce used thermodynamic modelling to study the physical processes and the chemical reactions occurring on several different refractory materials in consultation with DSF.

Two typical glass melt compositions were studied, a soda lime silicate melt and a special borosilicate glass. The results of these calculations informed guidelines for the selection of refractory types to optimise furnace operating conditions.

How does this benefit industry?
It means DSF have information relating to the high temperature evaporation from two typical glass melt compositions and how it will affect existing and new lining compositions allowing them to focus practical testing on the most suitable materials.

"The calculations succeeded in giving us the quantitative effect of oxy-hydrogen combustion on sodium borate vapourisation from the glass and the effect of this on existing and new lining compositions. We are very happy with the quality and speed of the work, enabling us to move on the practical testing of these materials." Trevor Wilson, Area Sales Manager, DSF Refractories & Minerals Ltd

Based near Buxton, DSF is one of the Peak District's largest employers with around 150 staff drawn from neighbouring towns and villages. Innovation like this is enabling the company to secure and grow its future supporting its employees some of whom have 25 to 50 years of service.

This modelling approach and knowledge offers a lower cost and more sustainable way for industry to optimise process conditions and inform future investments.

Read the full Royce case study HERE or find out more about Royce's work as part of FISC's EconoMISER project HERE.

If you'd like FISC to support you with your industrial problems please drop us an email at info@ukfisc.org

Published: 17-04-2025