The University of Sheffield Advanced Manufacturing Research Centre (AMRC) has secured £1m funding to establish HyDecarb, a first of its kind, open access research capability dedicated to the decarbonisation of industrial natural gas.

Industrial heat is one of the most significant challenges in the race to net zero, accounting for nearly one fifth of global greenhouse gas emissions. In the UK, industrial processes contribute approximately twelve per cent of total emissions, the majority of which is heat related. While many sectors can turn to electrification, energy intensive industries such as foundries, glassmaking and steel face massive technical barriers where electricity is not yet a viable option.

The HyDecarb project, backed by the High Value Manufacturing (HVM) Catapult, provides a real world, industrial scale testbed for manufacturers to trial hydrogen fuel switching in a controlled environment. Designed to bridge the gap between laboratory research and full scale industrial adoption, the AMRC’s open access infrastructure removes the technical and financial barriers that have traditionally made the transition to low carbon energy too risky for individual manufacturers to attempt alone.

Matthew Cawood, head of castings at the AMRC, says the capability is a necessity for the survival of these sectors. He said: “High temperature industries have traditionally been the hardest to decarbonise, but finding a solution is now a necessity. By developing this capability at the AMRC, we are proving to our partners that they can slash emissions immediately without needing to reinvent their entire operation.

“We are providing the environment where businesses can meet environmental goals while keeping their production lines running and staying competitive. As a leading manufacturing R&D centre, our role is to de-risk this technology and drive its adoption across the UK manufacturing sector to meet the country’s net zero ambitions.”

DUAL INNOVATION APPROACH

At the heart of the HyDecarb project is a dual innovation approach that mimics the exact conditions found in ageing UK factories, allowing for accurate, real world testing:

· The furnace: A twenty-year-old industrial furnace will be overhauled by Therser UK and converted to operate on any blend of natural gas and hydrogen.

· The hydrogen source: To feed the furnace, the AMRC will integrate a gas decarbonisation unit from Sheffield based cleantech pioneer, Suiso, which generates a hydrogen/natural gas blend to power the furnace.

Suiso’s proprietary microwave pyrolysis technology decarbonises natural gas at the point of use by separating methane into hydrogen and solid carbon. By removing the carbon before combustion, the system enables industrial users to significantly reduce CO2 emissions while continuing to utilise existing gas infrastructure. The carbon is captured in a solid form rather than being released as atmospheric CO2.

This solid carbon is then upgraded by Suiso into high value activated carbon, used globally for water purification and air filtration. This circular approach turns a carbon liability into a commercial asset, a key factor in the AMRC’s selection of the technology.

Stuart McKnight, CEO of Suiso, said: “We are grateful to the AMRC for their confidence in our technology and for deploying it in their operations today and helping drive its adoption across the industries they support over time.

“This project marks a significant milestone in the transition to cost effective, low carbon industrial processes. Converting emissions into value is what we do at Suiso.”

SCALABLE ROUTE

Matthew Pound, sales director of Therser UK, said: “Working alongside the AMRC and Suiso, we are helping to create a practical, scalable route for energy intensive industries to reduce emissions, de-risk investment decisions and accelerate progress towards net zero manufacturing.

“By converting an existing industrial furnace to operate on hydrogen and natural gas blends, we are demonstrating how proven manufacturing assets can be adapted rather than replaced.”

The AMRC''s HyDecarb capability reinforces Sheffield’s position as the UK’s hub for green manufacturing. By lowering the barrier to entry for hydrogen adoption and making research accessible to all, the AMRC is ensuring that the region’s manufacturing ecosystem remains at the forefront of the global race to net zero.

The University of Sheffield Advanced Manufacturing Research Centre (AMRC) is a world leading research and innovation network with one hundred industrial partners including Rolls-Royce, Boeing, McLaren, Airbus and BAE Systems. It collaborates with industry and R&D experts to develop and de-risk innovative solutions for companies across the globe, leading manufacturing towards a smart, sustainable and resilient future.

It turns world leading research into practical improvements for industry, helping to boost businesses’ productivity and sharpen their competitive edge, while saving time, money and energy. The AMRC fosters collaborations and partnerships between industry, academia and government to deliver cutting edge research, development and innovation for better products and processes; while driving forward sustainable manufacturing technologies for net zero, creating the vital step changes needed in the low carbon transition.

The AMRC has specialist expertise in digital manufacturing, machine learning and artificial intelligence, composites, casting, automation and robotics, nuclear manufacturing, subtractive manufacturing, additive manufacturing, design and prototyping, and training. It has a global reputation for helping companies overcome manufacturing challenges and has become a model for collaborative research involving universities, academics and industry, worldwide.

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