SUSTAINABLE PROCESSINDUSTRYEUROPEAN INDUSTRIAL COMPETTIVENESS TROUGHRESOURCE AND ENERGY EFFICIENCY
SPIRE Brokerage eventOctober 22nd 2013
Project Idea PresentationTenaris idea – Horizon 2020 SPIRE Call 707. October 2013
SPIRE-7
2WWW.SPIRE2030.EU
Tenaris Global industrial System
3WWW.SPIRE2030.EU
Project Idea ConceptBy-products of the steelmaking industry shall be considered as a secondary raw material source due to their high content of iron and other metal oxides.
Today metallurgical treatment/extraction methods, such as pyro-metallurgical processes, are aimed to recover the metal oxides contained in different mediums: from ores to waste. In Steel industry most of these are devoted to the recover of Zn from filter dusts, thus representing an example of a waste stream generated by an industrial sector and recovered by another one.
The project concept is to extend this approach to the recovery of other valuable metals, including Fe contained in industrial by-products or waste. This will contribute to the 2030 target reduction (up to 20%) of the non-renewable primary raw material intensity.
The plasma technology (electrical arc furnace), presently limited to the treatment of dusts from high alloyed steel production, can be widely employed and further developed to effectively recover raw materials in an economic and eco efficient way.
This responds to SPIRE KA 4.3: Technologies for (pre)treatment of process and waste streams (gaseous, liquids, solids) for re-use and recycling
4WWW.SPIRE2030.EU
Project Idea ConcepteCo2SMelt = ecological-economical Stainless steel Melting
Scale
Valuable / inert slag
White slag (lime)
Black slag
Fe-Alloys fine
Dust
SludgeScale
Dust
Black slag
Fe-Alloys to EAF
Briquette
eCo2SMelt = ecological-economical Stainless steel Melting
Scale
Valuable / inert slag
White slag (lime)
Black slag
Fe-Alloys fine
Dust
SludgeScale
Dust
Black slag
Fe-Alloys to EAF
Briquette
ScaleScale
Valuable / inert slag
White slag (lime)White slag (lime)
Black slag
Fe-Alloys fine
Dust
Black slag
Fe-Alloys fine
Dust
SludgeScale SludgeScale
Dust
Black slag
Dust
Black slag
Fe-Alloys to EAF
BriquetteBriquette
Metal oxide (non-ferrous)C-based residuals (petro-chemical)
Si-based residuals (glass, ceramic, refractory)
EAF in reducing conditions
Scrap substitute
Inert slag to cement
ZnO to Zn smelter
5WWW.SPIRE2030.EU
Idea ImpactThe plasma technology can treat a large variety of waste streams:
The by-product coming form steel industry: slag, scale, dust, sludge
Nonferrous waste: Incinerator ashes Catalyst for vanadium (V, Ni, Mo. Co) Mn-sludge Ni-dust from FeNi-production Fayalite slag
Residuals containing C (i.e. chemical and petro-chemical industry)
Residual containing Si (i.e. ceramic, refractory and glass industries)
6WWW.SPIRE2030.EU
The project the idea is related to the SPIRE 7 call topics: • development of new approach for the design and scale up of
industrial process for metals recovery from waste solids (TRL 7)• integration with the currently existing plant/technology taking
into account the links with primary process• prove industrial relevance and feasibility of proposed
technology by demonstration activities in industrial environment
The expected impact are:• significant improvement of the resource efficiency increasing
the recovery of material up to 40% by:• maximum flexibility in the materials charged• tailor made according to the production size as well as market
requirements. • energy recovery from flue gas (steam o electrical energy generation)
• cross sectorial technology transfer
Idea Impact
7WWW.SPIRE2030.EU
Existing Project Consortium1. Tenaris: installation and operation of an electrical arc
reduction furnace - EARF (industrial size demo plant) for Fe-alloy recovery from different EAF steel and rolling mill waste streams and from metals containing wastes/by-products generated by other process industries
2. Centro Sviluppo Materiali: process development and modelling for the recovery of iron and valuable metals
3. Tenova: engineering and plant supplier
8WWW.SPIRE2030.EU
Looking for partners…1. Companies with residual containing valuable metals,
C and/or Si (chemical, petro-chemical, ceramic, glass, non-ferrous, ….)
2. Final user of recovered valuable metals and slag (non-ferrous, cement, …)
3. Company with LCA capability for process and product environment impact analysis
9WWW.SPIRE2030.EU
Contact detailsTenaris DalminePiazza Caduti 6 luglio 1944 1, I-24040 Dalmine, Italy
- Caterina Epis, Institutional Relations Manager Tel. +39 035 5603505 Mail: [email protected]
- Fabio Praolini, Environment Regional Manager Tel. +39 035 5603374 Mail: [email protected]