SPIRE
Brokerage event
October 22nd
2013
SPIRE 7 – 2015:
Recovery technologies for metals and other
minerals
Project Idea Presentation
Organizations
THIS PROPOSAL IS SUPPORTED BY ESTEP, BUT ACTUALLY CARRIED BY THE PARTNERS
LISTED BELOW;
 ESTEP is the Steel Community's European Steel
Technology Platform
 voestalpine Group is a major European steel
producer.
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Concept
Two high grade secondary raw materials (Zn-Oxide, Fe-slag) are produced, which are used as feed specifically
tailored to the process requirements of consequent metal production (in addition, also cement production and
construction aggregates are options for the Fe-slag).
Comparative advantages of the process are wide
range for dust grain size and metals content of input
material, absence of pre-treatment requiremenets, no
mechanical parts, reaction speed, reduced energy
consumption, small scale units for on-site operation.
The technology enables industrial sites to process onsite their dusts economically into products with high
economic value.
Benefits along value chains: Landfilling is reduced
and also process efficiencies and economics of metal
recyclers (e.g. secondary cast iron produers can be
disburdened from Zn-inputs) and final metals
producers are improved.
Zn-depleted
Fe-rich slag
This project idea will adress call tpoic SPIRE 7 -2015 „Recovery
technologies for metals and other minerals“
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Option to design the demonstrator to be able to host
also a thermochemical process involving the
fractioned extraction of phosphate and heavy metals
from sewage sludge ash at high temperatures under
reducing conditions
Idea Impact - call topic
Proof of economic and industrial feasibility: Laboratory pilot plant is operating successfully (Project 1.2
“RecoDust” under the Austrian K1-NET COMET). Scale up to near industrial scale demonstrator with
industrial site integration is thus well prepared. In case of inclusion of sewage sludge ash extraction the FP 7
“RecoPhos” will be the starting point.
Potential for reducing dependency from imports: For Zinc Europe has an import dependence of 65%. At the
same time Zinc present in industrial dusts which are recovered at high cost or largely not at all has a
potential to reduce around 5%-points and reduce recycling-cost cost significantly as well environmental
impact. Increased Fe-recovery will increase steel making yields and thus Fe-imports. P-content in the
sewage sludge produced in Europe could replace roughly up to 20 or 30% of the phosphate imports into the
EU.
Significant impact on the resource efficiency of industrial sectors: Process efficiency of metal recovery chain
is significantly increased and thus resource use. Hitherto landfilled low-concentration metal bearing dusts
are rendered processable.
Enhanced sustainable industrial processes, shorter time to market and higher production capacity: See
above. Recovery costs for Zinc from dusts and P from sewage sludge will fall significantly.
Cross-sectorial technology transfer: One basic installation design can support different reaction processes
and can thus be applied both to metals recovery and P-recovery.
Cross-sectorial character of the idea: Sectors where residuals have their origin (e.g. steel, sewage works)
are enabled on-site to beneficiate their residuals. These materials can then be directly used by the existing
primary metal producing sectors e.g. (metals, phosphorous). The project aims to bring together residual
owners, equipment producers, metal producers, chemical industries (maybe Cement producers) to
accelerate value chain optimisation across these sectors.
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Idea impact - SPIRE Roadmap
„Expected outcomes for the SPIRE stakeholders“ for W2R
taken from SPIRE Roadmap page 87f.
Relevance to project idea
The development projects show that the material losses in the selected
existing recycling processes can be reduced by 70%.
Not material losses in recycling processes are
being addressed, but their chemical and
energy efficiency improved. In addition,
hitherto unused sources of materials for thise
procrsses will be mobilised..
Development of efficient pre-processing technologies for complicated
waste streams enable economically viable recovery of selected scarce
minor compounds.
Adressed.
Collection efficiencies for mobile phones and other small electronic
appliances improved by 50 % compared with current efficiencies.
Not addressed.
At least 5 new cross-sectorial waste valorisation concepts developed by
2025.
Addressed.
By 2020 modelling tools and crosssectorial databases for more holistic and
systematic analysis of the viability of recycling opportunities developed.
Indirectly addressed, because life cycle
evaluation will be part of the project.
By 2025 novel integrated modelling concept demonstrated.
Not addressed. If feasible project could be linked
up to a respective modelling project.
By 2025 novel recycling process concepts for at least 5 different
(complicated) waste streams demonstrated.
Addressed.
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Existing Project Consortium
• No consortium for the SPIRE-call formed at this stage.
• Core of the SPIRE consortium will be formed from
members of the consortia operating the existing labpilots:
• for RecoDust download “factsheets” under
http://www.ffg.at/comet-compentence-centres-excellenttechnologies-k1-centres
• for RecoPhos see
http://www.recophos.org/c/mid,1361,Consortium/
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Looking for partners…
1.
2.
3.
4.
5.
6.
To provide input materials, owners of residual metal-bearing dusts.
P-containing sewage slag owners.
To design, build and maintain the demonstrator, industrial
equipment manufacturers.
To establish the life cycle based evaluation, institutions with
respective know-how. Ideally this could be linked to another SPIRE
project.
To establish integrated road testing of the secondary raw materials
produced, metal (and maybe Cement) producers.
To control possible effects on possible use of slags as final
products, building industry.
If feasible, link or cooperation with another SPIRE project devoted
to modeling.
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Contact details
Bernhard Kohl
voestalpine AG / G-U
Email: bernhard.kohl@voestalpine.com
Deskphone: 0043 (0)50304 15 3077
Mobilephone: 0043 (0)664 6156087
Address: voestalpine-Straße 1, A-4020 Linz, Austria
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voestalpine Group
As a steel-based technology and capital goods group and a world leader in the manufacture,
processing, and development of sophisticated steel products, voestalpine supplies technologyintensive sectors, such as the automotive, railway, aviation, and energy industries.
voestalpine products are manufactured in 500 Group companies and locations in more than 50
countries and on all five continents.
Key figures (2011/12):
Revenue: € 12.1 bn
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EBITDA: € 1.3 bn
Employees: ~ 46,000