Periodic Reporting for period 1 - CAESAR (CirculArity Enhancements by Low quality Scrap Analysis and Refinement)
Periodo di rendicontazione: 2022-06-01 al 2023-11-30
The main expected outcome of CAESAR will be the demonstration at full-size industrial scale of integrated scrap upgrading, sorting and characterisation technologies, untapping volumes of low-quality scrap streams in Europe and generating valorisation routes for all the non-ferrous fractions obtained, towards zero waste.
Today, the European Union’s steel sector is a modern industry with its main customer base found within the EU home markets, particularly in high-end segments. The main competitive strength is based on high quality products, product innovation and technological development, efficiency, and skilled manpower. However, challenges remain to keep the EU steel sector both competitive at a global level and climate-neutral, in line with the European Green Deal and the CleanSteel Partnership’s vision.
The scrap usage in the steel sector is a common practice to improve the process’ sustainability, as it decreases the use of virgin raw materials i.e. iron ore and boosts the circular economy by using waste produced in the steel process and other value chains. Pre-consumer scrap i.e. directly reusable scrap generated in steelmaking, represents roughly 45% of the total scrap used worldwide, whereas 55% of the scrap utilised comes from other processes and contains various type of pollutant (inert materials, other metals, plastics, etc.). This is called post-consumer scrap.
The current trend in the EU scrap market points at a slight decrease in the pre-consumer scrap (due to production i.e. yield, improvement, meaning less scrap production by tonne of steel) and an increase in the short- and long-term of the post-consumer scrap stream, due to an increase in steel consumption. At the same time, the scrap demand from the steelmaking industry is sharply increasing as producing steel from scrap (by increasing either EAF production share or the scrap ratio at BOF) drastically reduces CO2 emissions and energy consumption. Unfortunately, the quality of the scrap needed to meet high-quality steels standards limits dramatically the use of post-consumer scrap, with End Of Life (EOL) products’ streams that are growing not only in volumes but in complexity (containing
unwanted minor elements such as plastics, fibres, metals, etc.) and decreasing in quality.
To increase the steel scrap recycling capacity and energy efficiency, while keeping EU competitive and safe in terms of raw materials imports, energy consumption and climate change impact, innovative technologies to “clean” the scrap before it reaches the steel furnaces need to be implemented. To this aim, CAESAR’s focus is to reduce impurities in post-consumer scrap before melting together better classified scrap, to increase the use of scrap, achieving the same quality of the finished product.
Today, the European Union’s steel sector is a modern industry with its main customer base found within the EU home markets, particularly in high-end segments. The main competitive strength is based on high quality products, product innovation and technological development, efficiency, and skilled manpower. However, challenges remain to keep the EU steel sector both competitive at a global level and climate-neutral, in line with the European Green Deal and the CleanSteel Partnership’s vision.
The scrap usage in the steel sector is a common practice to improve the process’ sustainability, as it decreases the use of virgin raw materials i.e. iron ore and boosts the circular economy by using waste produced in the steel process and other value chains. Pre-consumer scrap i.e. directly reusable scrap generated in steelmaking, represents roughly 45% of the total scrap used worldwide, whereas 55% of the scrap utilised comes from other processes and contains various type of pollutant (inert materials, other metals, plastics, etc.). This is called post-consumer scrap.
The current trend in the EU scrap market points at a slight decrease in the pre-consumer scrap (due to production i.e. yield, improvement, meaning less scrap production by tonne of steel) and an increase in the short- and long-term of the post-consumer scrap stream, due to an increase in steel consumption. At the same time, the scrap demand from the steelmaking industry is sharply increasing as producing steel from scrap (by increasing either EAF production share or the scrap ratio at BOF) drastically reduces CO2 emissions and energy consumption. Unfortunately, the quality of the scrap needed to meet high-quality steels standards limits dramatically the use of post-consumer scrap, with End Of Life (EOL) products’ streams that are growing not only in volumes but in complexity (containing
unwanted minor elements such as plastics, fibres, metals, etc.) and decreasing in quality.
To increase the steel scrap recycling capacity and energy efficiency, while keeping EU competitive and safe in terms of raw materials imports, energy consumption and climate change impact, innovative technologies to “clean” the scrap before it reaches the steel furnaces need to be implemented. To this aim, CAESAR’s focus is to reduce impurities in post-consumer scrap before melting together better classified scrap, to increase the use of scrap, achieving the same quality of the finished product.
At this stage, an extensive mapping of the European scrap market with emphasis of exportation out of EU has been provided. It was based on the analysis of scrap data from relevant European, national and regional reports. Information have been collected by each partner about the scrap business in its own country from recycling national organisations or from the customs administration of each country or Eurofer. As well a report describing the various scrap characterization methods has been established.
Several large size low-quality scrap samples (E1, E3, E40, HMS, WEEEs) have been bought on the market by the industrial partners. Considering the strong heterogeneity of scrap piles, specific sampling procedures have been established and shared. Some melting trials have been performed directly by the plant at Sestao and Dunkerque. In the same time, smaller size samples have been / will be sent for characterisation via melting trials and other characterisation means at the RTOs premises.
In parallel, metal recycler partners (Reydesa and Rolanfer) are working on the optimization of the primary treatment with support of R&D centers. Online XRF characterization is also under investigation at Reydesa plant. Some advanced cleaning technologies (Aspartel technology and BHS rotoshredder) are tested at intermediate size. Results analysis are ongoing.
Similarly, characterization technologies are currently tested at pilot plant at Tomra and ArcelorMittal facilities. Finally, the separation scheme of residues have been determined.
For all the activities, the data that will be necessary to establish the LCA are recorded and shared among the consortium.
Several large size low-quality scrap samples (E1, E3, E40, HMS, WEEEs) have been bought on the market by the industrial partners. Considering the strong heterogeneity of scrap piles, specific sampling procedures have been established and shared. Some melting trials have been performed directly by the plant at Sestao and Dunkerque. In the same time, smaller size samples have been / will be sent for characterisation via melting trials and other characterisation means at the RTOs premises.
In parallel, metal recycler partners (Reydesa and Rolanfer) are working on the optimization of the primary treatment with support of R&D centers. Online XRF characterization is also under investigation at Reydesa plant. Some advanced cleaning technologies (Aspartel technology and BHS rotoshredder) are tested at intermediate size. Results analysis are ongoing.
Similarly, characterization technologies are currently tested at pilot plant at Tomra and ArcelorMittal facilities. Finally, the separation scheme of residues have been determined.
For all the activities, the data that will be necessary to establish the LCA are recorded and shared among the consortium.
Replacement of pre-consumer scrap with high quality clean scrap grades: deep cleaning of post-consumer scrap as developed in CAESAR would allow increased usage of these low grades at BOF and in flat product EAF.
Concerning progressive replacement of pig iron with post-consumer grades, an action is to increase the scrap load at the BOF for which enhanced scrap cleaning activity performed in CAESAR is necessary. Several steelmakers have expressed ambition to shut of BF. This will increase the use of scrap in flat steel production as, for EAF, scrap ratio is only limited by intrinsic scrap quality what is the topic of CAESAR.
To reduce the environmental impact by minimizing CO2 emission up, increase the use of scrap.
WP4 contributes to develop novel technologies for onsite characterization of ferrous materials to help standardization of charge managing practice through determination of scrap chemical analysis and volume determination. Integration of stochastic modelling and onsite characterisation in systematic procedures will support charges managing.
Replicability of the demonstration plant in most of EU steel shops: the project focusses on different components that allow easier replication than fully integrated systems. Within ArcelorMittal, the most representable sites for a state-of-the-art scrap handling procedure are included.
Concerning progressive replacement of pig iron with post-consumer grades, an action is to increase the scrap load at the BOF for which enhanced scrap cleaning activity performed in CAESAR is necessary. Several steelmakers have expressed ambition to shut of BF. This will increase the use of scrap in flat steel production as, for EAF, scrap ratio is only limited by intrinsic scrap quality what is the topic of CAESAR.
To reduce the environmental impact by minimizing CO2 emission up, increase the use of scrap.
WP4 contributes to develop novel technologies for onsite characterization of ferrous materials to help standardization of charge managing practice through determination of scrap chemical analysis and volume determination. Integration of stochastic modelling and onsite characterisation in systematic procedures will support charges managing.
Replicability of the demonstration plant in most of EU steel shops: the project focusses on different components that allow easier replication than fully integrated systems. Within ArcelorMittal, the most representable sites for a state-of-the-art scrap handling procedure are included.