TransZeroWaste - Upgrading of low-quality iron ores and mill scale with low carbon technologies

Initial situation:

Conversion of the steel industry from coal to H2 as a reducing agent by 2030 makes it necessary to change production units:

  • Current: sinter plant –> blast furnace –> basic oxygen furnace
  • After transformation: pelletizing –> Direct reduction with hydrogen (DR) –> Electric arc furnace (EAF)

Existing recycling routes via sintering plants will be cut off, e.g. for coarse rolling and foundry scale or fine iron ore fraction from pellet screening. Furthermore, there are no recycling options for oily fine mill scale.

Project targets:

  • Upgrading low-grade iron ore by combining it with iron-rich by-products,
  • Development of innovative techniques to produce high quality pre-material for decarbonised future production routes,
  • Separation of disturbing components from byproducts to replace scrap,
  • Development of the technological basis and digital tools supporting the transition towards zero waste in the European steel industry.

Innovative approaches:

  • Use of microwaves for hot agglomeration of upgraded iron ore as well as for separation of interfering components such as oil or zinc,
  • Process development for cold agglomeration,
  • Innovative de-oiling of currently disposed or thermal treated materials with high iron content as mill / casting scale,
  • Upgrading and utilisation of low-grade iron ore with iron contents below 60 % in combination with iron-rich materials like scale for use in future DR-EAF process routes,
  • Decision support tool to identify the most sustainable processing routes of low-quality iron ore and high iron content by-products,
  • Digital mapping of material flows before, during and after the transition of the steel industry.
  • Demonstration of the developed processes in operational tests on the TRL8.

Benefits for the industry:

  • The outcomes of the TransZeroWaste could contribute to the upgrade of 27 million t/a materials and to the avoided greenhouse gas emissions of sinter plants, corresponding to 4,3 to 9,9 Mt CO2/a,
  • Proven technical solutions for the transformation,
  • Decision support tool to determine the most sustainable processing routes for low-grade iron ore and by-products with a high iron content.

The BFI develops processes for oil removal using magnetic separators and for cold agglomeration such as pelletising and briquetting.

About TransZeroWaste:

The project is funded by the European Union. Views and opinions expressed are however those of the author(s) only and do not necessarily reflect those of the European Union or  HaDEA. Neither the European Union nor the granting authority can be held responsible for them.

Project duration: 12/2022 – 11/2026

Further information about the project: TransZeroWaste

Publications:

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