Circular Steam: Decarbonisation of filter cleaning technologies

Why is there a need for this type of research?

DEECOM is a patented superheated steam process developed to clean polymer-contaminated filters, with recent extensions into composite and polymer recycling. It operates by exposing the contaminated part to superheated steam and subjecting it to repeated cycles of pressurisation and decompression. However, the process is energy intensive, as the production of high-temperature steam over multiple hours requires large volumes of water, gas, and electricity to achieve the requisite cleaning. The demand for superheated steam, combined with the limited use of heat recovery systems in commercial applications, means that DEECOM is not operating at its full low-carbon potential. There is, therefore, a need to explore alternative and more sustainable methods of steam generation and energy recovery.

Through Circular Steam, we will undertake an options analysis to identify lower-carbon-footprint and highly efficient heat recovery technologies that can be integrated into the DEECOM process. The study will compare the utilisation of a highly efficient, modern, low- or zero-carbon fuel boiler with a novel alternative: pulsed steam inflow using a hydrogen steam generator. Following initial data collection and pilot tests, the deployment of these technologies will be evaluated.

This options analysis will be supported by further innovations to maximise heat recovery from superheated steam passing through the outflow line. This steam is heavily contaminated with recyclate from polymer breakdown on the filter; therefore, additional reprocessing to remove these recyclates will also be explored.

Upon successful completion of the options analysis, the project will develop a pathway for commercial-scale application of these technologies, including techno-economic and life-cycle assessments (TEA and LCA). Data for this will be collected from the various partners through inventories and by using techniques such as thermal imaging to obtain additional information on the processes.

What this research will change

This project will enable facilities such as the partner, Longworth, to identify technologies with high decarbonisation potential and develop a roadmap for their application and integration. These technologies will be essential for decarbonising filter cleaning and other contamination-removal industries, boosting UK trade while contributing to the UK government’s net-zero targets.

Role of the Brunel Composites Centre in this research

Brunel Composites Centre (BCC) will be extensively involved in the project from start to finish. BCC will collect data from the various project partners to understand the studied processes and to obtain information on inputs and recoverable energy. This data will be used to perform techno-economic and life-cycle assessments of the proposed subprocesses and processes. BCC will play an active role throughout these studies.

Project Partners

• Brunel University London (Brunel Composites Centre)
• B & M Longworth (Edgworth) Ltd.
• Steamology Motion Ltd.
• Centre for Process Innovation (CPI) 
• Biorenewables Development Centre (BDC)