SPIRE
Brokerage event
October 22nd
2013
SUSTAINABLE PROCESS
INDUSTRY
EUROPEAN INDUSTRIAL
COMPETTIVENESS TROUGH
RESOURCE AND ENERGY EFFICIENCY
Project Idea Presentation
Tenaris idea – Horizon 2020 SPIRE Call 7
07. October 2013
Tenaris
Global industrial System
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Project Idea Concept
By-products of the steelmaking industry shall be considered as a secondary
raw material source due to their high content of iron and other metal oxides.
Today metallurgical treatment/extraction methods, such as pyro-metallurgical
processes, are aimed to recover the metal oxides contained in different
mediums: from ores to waste.
In Steel industry most of these are devoted to the recover of Zn from filter
dusts, thus representing an example of a waste stream generated by an
industrial sector and recovered by another one.
The project concept is to extend this approach to the recovery of other
valuable metals, including Fe contained in industrial by-products or waste.
This will contribute to the 2030 target reduction (up to 20%) of the nonrenewable primary raw material intensity.
The plasma technology (electrical arc furnace), presently limited to the
treatment of dusts from high alloyed steel production, can be widely employed
and further developed to effectively recover raw materials in an economic and
eco efficient way.
This responds to SPIRE KA 4.3: Technologies for (pre)treatment of
process and waste streams (gaseous, liquids, solids) for re-use and
recycling
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Project Idea Concept
eCo2SMelt = ecological-economical Stainless steel Melting
Scale
Sludge
Scale
Dust
Dust
Fe-Alloys fine
Briquette
ZnO
to Zn smelter
Black slag
Black slag
Scrap
substitute
EAF
in reducing
conditions
White slag (lime)
(glass, ceramic, refractory)
Valuable
/ inert slag
Inert
slag
to cement
Fe-Alloys to EAF
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Metal oxide (non-ferrous)
C-based residuals (petro-chemical)
Si-based residuals
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Idea Impact
The plasma technology can treat a large variety of waste
streams:
 The by-product coming form steel industry:
 slag, scale, dust, sludge
 Nonferrous waste:





Incinerator ashes
Catalyst for vanadium (V, Ni, Mo. Co)
Mn-sludge
Ni-dust from FeNi-production
Fayalite slag
 Residuals containing C (i.e. chemical and petro-chemical
industry)
 Residual containing Si (i.e. ceramic, refractory and glass
industries)
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Idea Impact
The project the idea is related to the SPIRE 7 call topics:
• development of new approach for the design and scale up of
industrial process for metals recovery from waste solids (TRL 7)
• integration with the currently existing plant/technology taking
into account the links with primary process
• prove industrial relevance and feasibility of proposed technology
by demonstration activities in industrial environment
The expected impact are:
• significant improvement of the resource efficiency increasing the
recovery of material up to 40% by:
•
•
•
maximum flexibility in the materials charged
tailor made according to the production size as well as market
requirements.
energy recovery from flue gas (steam o electrical energy generation)
• cross sectorial technology transfer
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Existing Project Consortium
1.
Tenaris: installation and operation of an electrical arc
reduction furnace - EARF (industrial size demo plant)
for Fe-alloy recovery from different EAF steel and
rolling mill waste streams and from metals containing
wastes/by-products generated by other process
industries
2.
Centro Sviluppo Materiali: process development and
modelling for the recovery of iron and valuable metals
3.
Tenova: engineering and plant supplier
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Looking for partners…
1. Companies with residual containing valuable
metals, C and/or Si (chemical, petrochemical, ceramic, glass, non-ferrous, ….)
2. Final user of recovered valuable metals and
slag (non-ferrous, cement, …)
3. Company with LCA capability for process
and product environment impact analysis
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Contact details
Tenaris Dalmine
Piazza Caduti 6 luglio 1944 1, I-24040 Dalmine, Italy
- Caterina Epis, Institutional Relations Manager
Tel. +39 035 5603505
Mail: cepis@tenaris.com
- Fabio Praolini, Environment Regional Manager
Tel. +39 035 5603374
Mail: fpraolini@tenaris.com
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