Research and development

Development of an Innovative Cast Steel for Hydrogen Service

Project implemented by a consortium:

Leader: PGO S.A.
Consortium member: Sieć Badawcza Łukasiewicz – Górnośląski Instytut Technologiczny

Project objective

Within the R&D Module, the aim is to develop and test an innovative product—cast steel for hydrogen service—manufactured using a dedicated, integrated cast-steel production process.

Project activities and outcomes

In the R&D Module, research will be conducted to develop material and process solutions that ensure increased resistance of the cast steel to hydrogen embrittlement. This will result in longer service life at elevated pressures and stable mechanical properties across a wide temperature range in equipment intended for hydrogen service.

Target groups / Applications

Products manufactured using the new technology will be applied in the following industries:

gas sector,
power/energy sector

Project value: PLN 15,359,886.71
Co-financing from European Funds: PLN 8,669,058.18

Development of an innovative technology for forming preforms and long products using universal CNC machines, and the launch of renewable energy use by constructing a photovoltaic installation of approx. 600 kWp.

Project objective

Within the R&D Module, the project aims to develop an innovative technology for forming preforms and elongated products using universal CNC machines, which will then be implemented in the business operations of PGO S.A., Kuźnia Glinik Branch in Gorlice.

The outcome of the Green Transition Module will be the transformation of the Gorlice Branch toward sustainable development and a circular economy.

Project activities and outcomes

R&D Module: Research will be carried out to develop a technology for manufacturing axisymmetric products and semi-finished products of arbitrary geometry, while simultaneously achievin

a reduction in forging time by approximately 20%,

a reduction in electricity consumption by approximately 20%,

a reduction in material costs by approximately 5%.

Green Transition Module: A photovoltaic installation will be built, enabling the Kuźnia Glinik Branch in Gorlice to begin using renewable energy for its own needs, covering around 5.5% of total demand.

Target groups / Applications

Products manufactured using the new technology will be applied in the following sectors:

automotive,

agricultural machinery,

railway,

defense.

Project value: PLN 14,283,622.27
Co-financing amount: PLN 5,562,972.47

“An innovative, ATD thermal analysis-based, technology for the production of high-quality self-feeding cast iron for the production of a new generation of castings with improved quality parameters.”

Project objective

Development of a new automated cast iron melting technology based on cooling curve analysis. Development of a new automated cast iron melting technology based on cooling curve analysis.

Its application will enable us to eliminate disadvantages of casting technologies that are currently applied in the world, taking particular account of the elimination of degraded Chunky graphite as well as risers and feeders.

Effects

Expanding the range of products by grey and ductile cast iron castings with increased quality parameters:

• minimised content of degraded Chunky graphite,
• reduced porosity,
• increased strength,
• increased yield strength,
• increased elongation.

Applicability

Products manufactured according to the new technology will be applied in the following industries:

• automotive,
• agricultural machinery,
• shipbuilding,
• energy.

Performance date: 01 September 2017 – 31 August 2020

Project value: PLN 37,049,906,12

Co-financing amount: PLN 15 541 090,29

"Demonstration of technology for manufacturing innovative steel castings for extreme operating conditions" using an AOD converter."

Project objective

Obtaining a new technology enabling the production of low- and high-alloy steels with increased strength and impact resistance parameters. Producing super alloys based on nickel and new grades of high-alloy cast steel with duplex and superduplex nitrogen. The AOD converter technology will enable us to start post-furnace processing (secondary metallurgy).

Effects

The unique features of the product are, primarily, their increased strength and impact resistance under extreme conditions of use.

• At temperatures below -60^oC,
• under extreme pressure conditions at depths below 3,000 m,
• in highly invasive working environments, for example with high salinity,
• in systems using extremely aggressive media (such as acids, crude oil, high-pressure steam).

Applicability

Products manufactured according to the new technology will be applied in the following industries:

• modern energy,
• offshore wind energy,
• railway transport,
• extraction operations in the oil & gas industry, both on land and on the seabed,
• broadly-defined industrial fittings.

Performance date: 01 March 2017 – 31 August 2020

Project value: PLN 48,154,602.36

Co-financing amount: PLN 19,261,840.94