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Materials Processing Institute (MPI)

Materials Processing Institute (MPI)

6 Projects, page 1 of 2
  • Funder: UK Research and Innovation Project Code: EP/S019111/1
    Funder Contribution: 5,176,330 GBP

    Resource Efficiency is essential for reducing the environmental impact of manufacturing. Progress in achieving it has been slow, but a rapidly changing international context, including Brexit, is giving new emphasis to Industrial Strategy in the UK which creates a unique window of opportunity. This transformational Programme aims to locate resource efficiency at the heart of a visionary industrial strategy; it will create new world-leading competitive advantage for UK manufacturing by addressing four fundamental barriers to progress: - to break out of lock-in to resource inefficiency, novel methods and tools will be developed to enumerate and characterise all today's options to design and manufacture material goods; - to create clarity about the environmental impact of new manufacturing strategies, a ground-breaking Physical Resources Observatory will be developed to access and interpret more and better global resource data; - to target manufacturing innovations for Resource Efficiency and accelerate their implementation, the features of an effective Innovation Pipeline will be characterised, tested and deployed with a portfolio of promising emerging manufacturing technologies; - to give new priority to Resource Efficiency in Industrial Strategy, new metrics and decision-framing will be developed and tested in the Living Lab of the Programme's industrial consortium. The Programme brings together nine internationally-leading academic groups and a consortium of subscribing industrial partners. The management strategy, designed for flexibility, aims to integrate existing methods from diverse disciplines to address the application of Resource Efficiency while stimulating exploration of new methodological opportunities where existing approaches are inadequate. The value of the investment in the Programme will be maximised through an International Advisory Panel to support connections and awareness, a consortium executive committee to determine priorities for strategic analysis, and a supervisory board to ensure financial and legal compliance. The programme will deliver impact via quarterly strategic analysis reports on resource issues, a programme of policy influence led by an experienced Policy Champion, technological innovations, an annual UK Forum on Resource Efficiency, commercial and open-access software tools, researcher training and multi-channel communications.

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  • Funder: UK Research and Innovation Project Code: EP/V061798/1
    Funder Contribution: 4,049,200 GBP

    The Materials Made Smarter Centre has been co-created by Academia and Industry as a response to the pressing need to revolutionise the way we manufacture and value materials in our economy. The UK's ability to manufacture advanced materials underpins our ambitions to move towards cleaner growth and a more resource efficient economy. Innovation towards a net zero-carbon economy needs new materials with enhanced properties, performance and functionality and new processing technologies, with enhanced manufacturing capability, to make and deliver economic and societal benefit to the UK. However, significant technological challenges must still be overcome before we can benefit fully from the transformative technical and environmental benefits that new materials and manufacturing processes may bring. Our capacity to monitor and control material properties both during manufacture and through into service affect our ability to deliver a tailored and guaranteed performance that is 'right-first-time' and limit capacity to manage materials as assets through their lifetime. This reduces materials to the status of a commodity - a status which is both undeserved and unsustainable. Future materials intensive manufacturing needs to add greater value to the materials we use, be that through reduction of environmental impact, extension of product life or via enhanced functionality. Digitalisation of the materials thread will help to enhance their value by developing the tools and means to certify, monitor and control materials in-process and in-service improving productivity and stimulating new business models. Our vision is to put the UK's materials intensive manufacturing industries at the forefront of the UK's technological advancement and green recovery from the dual impacts of COVID and rapid environmental change. We will develop the advanced digital technologies and tools to enable the verification, validation, certification and traceability of materials manufacturing and work with partners to address the challenges of digital adoption. Digitisation of the materials thread will drive productivity improvements in materials intensive industries, realise new business models and change the way we value and use materials.

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  • Funder: UK Research and Innovation Project Code: EP/V011804/1
    Funder Contribution: 4,437,440 GBP

    Historically, the discovery, development and application of metals have set the pace for the evolution of human civilisation, driven the way that people live, and shaped our modern societies. Today, metals are the backbone of the global manufacturing industry and the fuel for economic growth. In the UK, the metals industry comprises 11,100 companies, employs 230,000 people, directly contributes £10.7bn to the UK GDP, and indirectly supports a further 750,000 employees and underpins some £200bn of UK GDP. As a foundation industry, it underpins the competitive position of every industrial sector, including aerospace, automotive, construction, electronics, defence and general engineering. However, extraction and processing of metals are very energy intensive and cause severe environmental damage: the extraction of seven major metals (Fe, Al, Cu, Pb, Mn, Ni and Zn) accounts for 15% of the global primary energy demand and 12% of the global GHG emission. In addition, metals can in theory be recycled infinitely without degradation, saving enormous amounts of energy and CO2 emission. For instance, compared with the extraction route, recycling of steel saves 85% of energy, 86% GHG emission, 40% water consumption and 76% water pollution. Moreover, metals are closely associated with resource scarcity and supply security, and this is particularly true for the UK, which relies almost 100% on the import of metals. The grand challenge facing the entire world is decoupling economic growth from environmental damage, in which metals have a critical role to play. Our vision is full metal circulation, in which the global demand for metallic materials will be met by the circulation of secondary metals through reduce, reuse, remanufacture (including repair and cascade), recycling and recovery. Full metal circulation represents a paradigm shift for metallurgical science, manufacturing technology and the industrial landscape, and more importantly will change completely the way we use natural resources. Full metal circulation means no more mining, no more metal extraction, and no more primary metals. We will make the best use of the metals that we already have. We propose to establish an Interdisciplinary Circular Economy Centre, CircularMetal, to accelerate the transition from the current largely take-make-waste linear economy to full metal circulation. Our ambition is to make the UK the first country to realise full metal circulation (at least for the high-volume metals) by 2050. This will form an integral part of the government's efforts to double resource productivity and realise Net Zero by 2050. We have assembled a truly interdisciplinary academic team with a wide range of academic expertise, and a strong industrial consortium involving the full metals supply chain with a high level of financial support. We will conduct macro-economic analysis of metal flow to identify circularity gaps in the metals industry and to develop pathways, policies and regulations to bridge them; we will develop circular product design principles, circular business models and circular supply chain strategies to facilitate the transition to full metal circulation; we will develop circular alloys and circular manufacturing technologies to enable the transition to full metal circulation; and we will engage actively with the wider academic and industrial communities, policy makers and the general public to deliver the widest possible impact of full metal circulation. The CircularMetal centre will provide the capability and pathways to eliminate the need for metal extraction, and the estimated accumulative economic contribution to the UK could be over £100bn in the next 10 years.

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  • Funder: UK Research and Innovation Project Code: EP/S022732/1
    Funder Contribution: 4,666,530 GBP

    Understanding and characterising the behaviour of fluids is fundamental to numerous industrial and environmental challenges with wide-ranging societal impact. The CDT in Fluid Dynamics at Leeds will provide the next generation of highly trained graduates with the technical and professional skills and knowledge needed to tackle such problems. Fluid processes are critical to both economic productivity and the health and environmental systems that affect our daily lives. For example, at the microscale, the flow of liquid through the nozzle of an ink-jet printer controls the quality of the printed product, whilst the flow of a coolant around a microprocessor determines whether or not the components will overheat. At the large scale, the atmospheric conditions of the Earth depend upon the flow of gases in the atmosphere and their interaction with the land and oceans. Understanding these processes allows short term weather forecasting and long term climate prediction; both are crucial for industry, government and society to plan and adapt their environments. Fluid flows, and their interactions with structures, are also important to the performance of an array of processes and products that we take for granted in our everyday lives: gas and water flow to our homes, generation of electricity, fuel efficiency of vehicles, the comfort of our workplaces, the diagnosis and treatment of diseases, and the manufacture of most of the goods that we buy. Understanding, predicting and controlling Fluid Dynamics is key to reducing costs, increasing performance and enhancing the reliability of all of these processes and products. Our CDT draws on the substantial breadth and depth of our Fluid Dynamics research expertise at the University of Leeds. We will deliver an integrated MSc/PhD programme in collaboration with external partners spanning multiple sectors, including energy, transport, environment, manufacturing, consultancy, defence, computing and healthcare, who highlight their need for skilled Fluid Dynamicists. Through a combination of taught courses, team projects, professional skills training, external engagement and an in-depth PhD research project we will develop broad and deep technical expertise plus the team-working and problem-solving skills to tackle challenges in a trans-disciplinary manner. We will recruit and mentor a diverse cohort from a range of science and engineering backgrounds and provide a vibrant and cohesive training environment to facilitate peer-to-peer support. We will build strengths in mathematical modelling, computational simulation and experimental measurement, and through multi-disciplinary projects co-supervised by academics from different Schools, we will enable students to undertake a PhD project that both strengthens and moves them beyond their UG discipline. Our students will be outward facing with opportunities to undertake placements with industry partners or research organisations overseas, to participate in summer schools and study challenges and to lead outreach activities, becoming ambassadors for Fluid Dynamics. Industry and external engagement will be at the heart of the CDT: all MSc team projects will be challenges set and mentored by industry (with placements embedded); each student will have the opportunity for user engagement in their PhD project (from sponsorship, external supervision and access to facilities, to mentoring); and our partners will be actively involved in overseeing our strategic direction, management and professional training. Many components will be provided by or with our partners, including research software engineering, responsible innovation, commercial awareness and leadership.

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  • Funder: UK Research and Innovation Project Code: EP/V026402/1
    Funder Contribution: 2,259,080 GBP

    The UK Foundation Industries (Glass, Metals, Cement, Ceramics, Bulk Chemicals and Paper), are worth £52B to the UK economy, produce 28 million tonnes of materials per year and account for 10% of the UK total CO2 emissions. These industries face major challenges in meeting the UK Government's legal commitment for 2050 to reduce net greenhouse gas emissions by 100% relative to 1990, as they are characterised by highly intensive use of both resources and energy. While all sectors are implementing steps to increase recycling and reuse of materials, they are at varying stages of creating road maps to zero carbon. These roadmaps depend on the switching of the national grid to low carbon energy supply based on green electricity and sustainable sources of hydrogen and biofuels along with carbon capture and storage solutions. Achievement of net zero carbon will also require innovations in product and process design and the adoption of circular economy and industrial symbiosis approaches via new business models, enabled as necessary by changes in national and global policies. Additionally, the Governments £4.7B National Productivity Investment Fund recognises the need for raising UK productivity across all industrial sectors to match best international standards. High levels of productivity coupled with low carbon strategies will contribute to creating a transformation of the foundation industry landscape, encouraging strategic retention of the industries in the UK, resilience against global supply chain shocks such as Covid-19 and providing quality jobs and a clean environment. The strategic importance of these industries to UK productivity and environmental targets has been acknowledged by the provision of £66M from the Industrial Strategy Challenge Fund to support a Transforming Foundation Industries cluster. Recognising that the individual sectors will face many common problems and opportunities, the TFI cluster will serve to encourage and facilitate a cross sectoral approach to the major challenges faced. As part of this funding an Academic Network Plus will be formed, to ensure the establishment of a vibrant community of academics and industry that can organise and collaborate to build disciplinary and interdisciplinary solutions to the major challenges. The Network Plus will serve as a basis to ensure that the ongoing £66M TFI programme is rolled out, underpinned by a portfolio of the best available UK interdisciplinary science, and informed by cross sectoral industry participation. Our network, initially drawn from eight UK universities, and over 30 industrial organisations will support the UK foundation industries by engaging with academia, industry, policy makers and non-governmental organisations to identify and address challenges and opportunities to co-develop and adopt transformative technologies, business models and working practices. Our expertise covers all six foundation industries, with relevant knowledge of materials, engineering, bulk chemicals, manufacturing, physical sciences, informatics, economics, circular economy and the arts & humanities. Through our programme of mini-projects, workshops, knowledge transfer, outreach and dissemination, the Network will test concepts and guide the development of innovative outcomes to help transform UK foundation industries. The Network will be inclusive across disciplines, embracing best practice in Knowledge Exchange from the Arts and Humanities, and inclusive of the whole UK academic and industrial communities, enabling access for all to the activity programme and project fund opportunities.

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