Purity improvement of scrap metal

Project Information

PURESCRAP

Grant agreement ID: 101092168

DOI

10.3030/101092168

EC signature date 24 November 2022

Start date 1 January 2023

End date 31 March 2027

Funded under

• Digital, Industry and Space

Total cost

€ 6 181 056,25

EU contribution

€ 4 997 059,75

Coordinated by

SWERIM AB
Sweden

Periodic Reporting for period 2 - PURESCRAP (Purity improvement of scrap metal)

Reporting period: 2024-07-01 to 2025-06-30

Summary of the context and overall objectives of the project

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.

Work performed from the beginning of the project to the end of the period covered by the report and main results achieved so far

The initial task to investigate the needs from the steelworks and the requirements from the scrap sorting facility was completed during the first year(2023). The following configuration of the sensor systems was then performed during 2024. The factory acceptance tests of the sensors were then reported in D2.4 and the ICT infrastructure in D2.7.

The two sensor stations has been installed in two separate testlines:
• A testline for the shredded sensor station was constructed at Stena Recycling. Here the sensors have been tested with various kinds of shredded ferrous scrap. Selected batches have been sent to VASD for melt to provide reference analysis of the sensor results.
• A testline for the heavy scrap sensor station was constructed at Swerim. It can handle 1 m long samples and enables tests of the heavy scrap sensor station as well as serving as a stand-alone analysis station. Needs for improvement in the detection of object position has been identified and work with modifications is ongoing to realise complete scrap batch analysis.
The installations in the testlines enabled the on-Site Acceptance Tests of the sensors which is reported in D3.1. The sensor station for shredded scrap is further moved and mounted at the production line in the shredder facility of Stena Recycling.

Achievements are also in activities supporting the development of the sensor solutions. The market analysis reported in deliverable D6.1 show that there is a need and potential for the PURESCRAP solution. Following the first draft of the exploitation plan (D6.2.) the replication potential has been reported in D6.4.

The KPI’s of the project have been monitored and reported in the intermediate KPI monitoring report D3.5. First 4 scrap batches analysed by the shredded sensor station have been melted to give a first reference analysis for the sensors. The batches weighted 600 – 900 kg and iron were added to a total melt of ca 5 ton. The final composition of three batches passed the specifications for EN 10263-4 (<0.025 m.% P, <0.25 m.% Cu) while the steel produces in the fourth bag exceeded the Cu-limit by only 0.07 m.%.

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.

Progress beyond the state of the art and expected potential impact (including the socio-economic impact and the wider societal implications of the project so far)

The sensor stations that are installed are unique in that they are operating in a full-scale scrap processing. The sensor station for shredded scrap is installed in a shredder plant with throughput up to 150 ton/hour. The analysis station for heavy scrap handles large sized scrap material with sizes up to 1m. 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.

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. That will have impact on the quality of the produced scrap material and the improved resource efficiency of the steelmaking process.

The work is still in the phase where sensor systems are being tested, but not yet ready to be used as process control instruments. So far it is seen that the sensor systems handle the environment and provides stable signals. Remaining is the adaption of the models for quantitative analysis.

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.

PURESCRAP sensor stations (heavy and shredded)

Components of the test station for shredded scrap