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Mechanical Extrusion Technology as A Decarbonisation Catalyst for Sustainable non-ferrous Energy Intensive Industries.

Objective

The European non-ferrous metals sector relies on rigid, gas-fired melting furnaces. This fossil dependency causes severe energy inefficiencies, high carbon emissions, material losses to oxidation, and an inability to adapt to renewable energy grids. The project transitions recycling from thermal melting to electrified solid-state screw extrusion. Using shear friction to plasticize scrap below its melting point, the approach bypasses the latent heat of fusion to drastically reduce energy demand. The architecture relies on four technical pillars. First, a feedstock conditioning system uses multi-sensor arrays and microwave heating to remove organic contaminants without combustion. Second, a 350kW solid-state extruder module consolidates scrap into dense profiles, integrating heat pipes to recover internal friction heat. Third, an energy management system transforms the extruder into a grid asset, using digital twins to modulate torque in sub-seconds and match renewable energy generation. Finally, a sectoral framework delivers lifecycle assessments and standardized brownfield retrofit blueprints. Pilot validation occurs across interconnected nodes. An extrusion hub in Norway executes deep electrification trials, while a conditioning hub in Greece processes complex swarf. Remote testing uses live data from a Bulgarian foundry to control the Norwegian pilot, directly fulfilling the call objective to phase out fossil fuels and integrate renewables. Expected outcomes include over 60 percent reduction in specific energy consumption, the complete elimination of scope 1 emissions and toxic fumes, and the recovery of material yields lost to oxidation, providing sub-second load flexibility. The consortium comprises eighteen partners across seven countries. This includes five small and medium enterprises and three large enterprises, uniting research organisations and policy bodies to cover the entire secondary metals value chain.

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Programme(s)

Topic(s)

Funding Scheme

HORIZON-IA - HORIZON Innovation Actions

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Call for proposal

(opens in new window) HORIZON-CL5-2026-02

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Coordinator

SINTEF AS
Net EU contribution
€ 1 175 000,00
Address
STRINDVEGEN 4
7034 Trondheim
Norway
Region
Norge Trøndelag Trøndelag
Activity type
Research Organisations
Links
Total cost
€ 1 175 000,00

Participants (17)