HORIZON EUROPE
ExpectedOutcome:Projects are expected to contribute to one or more of the following outcomes:
Implementation of highly efficient technologies for recovering metal (iron and non-ferrous metals) and mineral fractions from in-plant steelmaking residues. The recovery technology should condition the composition and properties of the residue such as, but not limited to, slag, sludge, scale, filter dust, sinter waste produced by blast furnace / basic oxygen furnace (BF / BOF) and electric arc furnace (EAF) routes, but also by next-generation iron and steelmaking such as, but not limited to, the direct reduction / electric arc furnace (DR / EAF) pathway including the melting and reduction of low-grade iron ore. Two possible ways are envisioned: the first one is based on cooling and mechanical steps, such as, but not limited to, wet or dry granulation followed by phase separation; the second one relies on dedicated processes to enable a direct recycling of residues in existing production processes or in standalone pyro-metallurgic melting and reduction or hydrometallurgical / biohydrometallurgical units. Such knowledge and results should support the valorisation of residues in...
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ExpectedOutcome:Projects are expected to contribute to one or more of the following outcomes:
Implementation of highly efficient technologies for recovering metal (iron and non-ferrous metals) and mineral fractions from in-plant steelmaking residues. The recovery technology should condition the composition and properties of the residue such as, but not limited to, slag, sludge, scale, filter dust, sinter waste produced by blast furnace / basic oxygen furnace (BF / BOF) and electric arc furnace (EAF) routes, but also by next-generation iron and steelmaking such as, but not limited to, the direct reduction / electric arc furnace (DR / EAF) pathway including the melting and reduction of low-grade iron ore. Two possible ways are envisioned: the first one is based on cooling and mechanical steps, such as, but not limited to, wet or dry granulation followed by phase separation; the second one relies on dedicated processes to enable a direct recycling of residues in existing production processes or in standalone pyro-metallurgic melting and reduction or hydrometallurgical / biohydrometallurgical units. Such knowledge and results should support the valorisation of residues in the present value chain and/or in innovative applications. If appropriate, residues could be chemically and structurally characterised at micro-scale level via characterisation (also multi-modal) performed at analytical research infrastructures, which would allow obtaining relevant statistical information;Describe and/or modify the composition and properties of residues such as, but not limited to, slags and/or sludge produced by next-generation steelmaking such as, but not limited to the DR / EAF pathway. Such knowledge and results should support the valorisation of the residues in the present value chain and/or in innovative applications. If appropriate, residues could be chemically and structurally characterised at micro-scale level via characterisation (also multi-modal) performed at analytical research infrastructures, which would allow obtaining relevant statistical information;Enhanced utilisation of low-quality scrap by new technologies and by new iron/steel making routes (such as smart BF-BOF routes to be line with decarbonisation targets), targeting high quality of the finished product and reduced CO2 emissions. The aim is to remove scrap impurities (tramp elements) such as, but not limited to, copper before melting, for example through scrap yard management and charge preparation for quality upgrading, or after the melting in liquid phase, through, but not limited to, metallurgical methods;Technologies to broaden the types of ore grades utilized in different processes. The aim is to establish processes that allow for upgrade of low-grade iron ores and other iron-bearing materials to make them suitable for, but not limited to, cold bonded agglomeration, pelletisation, or direct use in existing steelworks.
Scope:In the medium-term scenario, new technologies will enter in the iron and steelmaking production process, e.g., higher amount of scrap in basic oxygen furnaces (BOF), more electric arc furnace (EAF) based steelmaking, as well as more directly reduced production capacity are foreseen. Therefore, it is necessary to consider the influence of the feedstock quality, of the new production technologies and of the composition of the by-products generated on the present model of circular economy for both, economic, and environmental aspects.
Recycling of steel scrap (no matter if it is home-scrap, industrial scrap, or post-consumer scrap), the increased consumption of scrap, the recovery of iron from residues and the use of low-quality iron ore materials are vital to diminish the need for additional primary resource extraction and hence to decrease the environmental impact of steel manufacturing. This is also contributing to a wise and sustainable management approach of iron resources. Applying circular economic principles to product design (thus, designing for remanufacture and recycling) will allow ferrous and non-ferrous metals, such as copper, to be more easily separated and recycled.
Proposals should consider higher utilisation of low-quality iron-bearing materials, in particular, but not limited to, low-quality scrap with higher amounts of unwanted elements (residual and alloying elements, such as Cu, Sn, Sb, As and Bi, but also Cr, Mo, B) that prevent the production of many steel grades and a higher utilisation of internal residues; all focused on the recycling of its metal contents. Where appropriate for the study proposed, analytical research infrastructures, such as synchrotron facilities, should be considered as capable of providing large amount of statistically relevant data. The aim is to obtain a sustainable vision of reduced virgin raw materials use.
Moreover, the existing recycling and reuse solutions for today’s steel industry will be affected and new solutions need to be developed to maintain a sustainable development of the steel industry in the future. Projects should aim at the selection and integration of best available and applicable technologies supported by digital smart tools. These are key elements to improve and adapt circular economy solutions for the long-term goal towards zero waste increasing the use of scrap, the materials recycling rate and the residue valorisation by targeting to achieve the same quality of the finished product and at the same time reducing CO2 emissions due to lower energy need with respect to iron-ore.
Multidisciplinary research activities should address one or more of the following:
New technologies for reduce / reuse / recycle of residues and by-products in the next generation iron ore and steelmaking process: Increasing reuse and recycling of steelmaking and foundry slags;Recycling and valorisation of dusts, and sludges;Recovering iron and metal-fractions from in-plant residues;Conditioning processes for the use of residues and low-quality iron ore grades, like agglomeration or pelletisation;Implementing Circular Economy and Industrial Symbiosis for long-term goal towards zero- waste. Sustainable and efficient scrap management and recycling aiming high-grade steel production with increased scrap rates including: Improved mechanical scrap preparation coupled with scrap analyses at various levels;Continuous analysis and monitoring of the scrap bulk composition using sensor systems with accompanied model-supported Big Data analytics and Artificial Intelligence (AI) techniques for scrap classification;Scrap yard management and charge preparation for quality upgrading;Optimised and more flexible primary and secondary steelmaking processes considering enhanced scrap rates. This topic implements the co-programmed European Partnership on Clean Steel.
Specific Topic Conditions:Activities are expected to start at TRL 4 and achieve TRL 5-6 by the end of the project – see General Annex B.
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