Periodic Reporting for period 1 - PURESCRAP (Purity improvement of scrap metal)
Reporting period: 2023-01-01 to 2024-06-30
The objective of the project PURESCRAP is to increase the use of low-quality scrap grades (post-consumer scrap) in the steel industry by deploying and applying best available technologies to reduce impurities. It has the following specific objectives:
1. Reduce the impurities in low-quality scrap grades (post-consumer scrap) by new detection technologies.
2. Enhance the uptake of post-consumer scrap to produce high-quality steel grades.
3. Improve the scrap characterisation by new detection technologies.
4. Reduction of CO2 emissions
Sensors are installed at the recycling plant operated by Stena Recycling. The scrap is there produced in two main categories – shredded and heavy (cut) scrap. These originates from the shredding and the cutting operation and both material streams are addressed by the PURESCRAP project with a similar approach but separate technical solution.
The output material will be produced in batches of 5-20 tonnes. The sensors will provide information on the chemistry, size and shape of the scrap. Each batch will then have a complete chemical analysis including average composition and spread and also the size distribution of the material. This will enable the steelworks to more efficiently plan the charges and combine scrap batches to match the desired metal quality.
The sensor stations will also be used to gain insight in the material flows at the scrap processing facility. Direct feedback from adjustments of shredder and magnet will be obtained and the processes can then be optimised for improved impurity removal
There are several technical challenges that needs to be addressed. The scrap has large variations in size and shape, and the occurrence of surface contaminations and coatings makes analysis of the bulk material difficult. Equally important to having a potent technical solution is that it is useable both by the individual operators and also adaptable to different scrap processing actors. Both the technical and societal aspects are addressed within the PURESCRAP project.
The ambition is to enable an increased use of post-consumer scrap by 40% and thus increase the resource efficiency of the Electric Arc Furnace by 140 kg/ton.
1. Reduce the impurities in low-quality scrap grades (post-consumer scrap) by new detection technologies.
2. Enhance the uptake of post-consumer scrap to produce high-quality steel grades.
3. Improve the scrap characterisation by new detection technologies.
4. Reduction of CO2 emissions
Sensors are installed at the recycling plant operated by Stena Recycling. The scrap is there produced in two main categories – shredded and heavy (cut) scrap. These originates from the shredding and the cutting operation and both material streams are addressed by the PURESCRAP project with a similar approach but separate technical solution.
The output material will be produced in batches of 5-20 tonnes. The sensors will provide information on the chemistry, size and shape of the scrap. Each batch will then have a complete chemical analysis including average composition and spread and also the size distribution of the material. This will enable the steelworks to more efficiently plan the charges and combine scrap batches to match the desired metal quality.
The sensor stations will also be used to gain insight in the material flows at the scrap processing facility. Direct feedback from adjustments of shredder and magnet will be obtained and the processes can then be optimised for improved impurity removal
There are several technical challenges that needs to be addressed. The scrap has large variations in size and shape, and the occurrence of surface contaminations and coatings makes analysis of the bulk material difficult. Equally important to having a potent technical solution is that it is useable both by the individual operators and also adaptable to different scrap processing actors. Both the technical and societal aspects are addressed within the PURESCRAP project.
The ambition is to enable an increased use of post-consumer scrap by 40% and thus increase the resource efficiency of the Electric Arc Furnace by 140 kg/ton.
The initial task to investigate the needs from the steelworks and the requirements from the scrap sorting facility is completed. This started the configuration of the sensor systems consisting of camera, LiDAR, XRF, and LIBS. The design of the sensors and the integrated sensor stations is complete and reported in deliverables D2.1 and D2.2. Current activities are to finalize the sensor manufacturing and install them in the two pilots (one for the shredded and one for the heavy scrap). The two pilots are both constructed as two steps where the first step is to prove the system with a separate material handling before installing the sensor stations in the production line of the recycling facility.
Achievements are also in activities supporting the development of the sensor solutions. The set of KPI’s are defined. The market analysis is ready showing that there is a need and potential for the PURESCRAP solution. This is reported in the public deliverable D6.1 Also the first draft of the exploitation plan is ready and reported in the public deliverable D6.2.
The task for assessment of social impact aims at ensuring that the technical solution is accepted by the users, including the workers at the recycling plants. A first set of interviews have been conducted where the acceptance of the PURESCRAP solution was monitored and input for the development was received.
Achievements are also in activities supporting the development of the sensor solutions. The set of KPI’s are defined. The market analysis is ready showing that there is a need and potential for the PURESCRAP solution. This is reported in the public deliverable D6.1 Also the first draft of the exploitation plan is ready and reported in the public deliverable D6.2.
The task for assessment of social impact aims at ensuring that the technical solution is accepted by the users, including the workers at the recycling plants. A first set of interviews have been conducted where the acceptance of the PURESCRAP solution was monitored and input for the development was received.
The main project results with impact on the steel making process will be achieved when sensors are installed at the recycling facility and its performance can be evaluated in terms of analysis accuracy. This will have impact on the quality of the produced scrap material and the improved resource efficiency of the steelmaking process.
Main results so far are the deliverables of the initial definitions, requirements and conceptual designs done in WP1. The deliverables reporting on the market analysis and potential for the PURESCRAP solution is of importance for the project but is also a useful overview for other projects related to ferrous scrap and steelmaking. The functional configuration of the sensor stations is complete and reported which is of importance for making the final important step of installing the sensors in the pilots. The two sensor stations provide unique opportunities for scrap analysis as they aim to bring a complete information of the scrap batches delivered to the steel plants.
Main results so far are the deliverables of the initial definitions, requirements and conceptual designs done in WP1. The deliverables reporting on the market analysis and potential for the PURESCRAP solution is of importance for the project but is also a useful overview for other projects related to ferrous scrap and steelmaking. The functional configuration of the sensor stations is complete and reported which is of importance for making the final important step of installing the sensors in the pilots. The two sensor stations provide unique opportunities for scrap analysis as they aim to bring a complete information of the scrap batches delivered to the steel plants.