About

As raw materials, iron ore and scrap are forming the base of iron and steel production. Due to the transition from carbon-based to green steel production with hydrogen (H2), most current production units such as sinter plant, blast furnace (BF) and basic oxygen furnace (BOF) will be replaced by the direct reduction process (DR process), followed by the electric arc furnace (EAF). As a result, the current recycling routes for iron containing by-products (e.g. mill scale, dust, sludge) will be cut off and the demand for high-quality direct reduction pellets and scrap will rise, becoming a critical factor. New by-products from the gas treatment of the DR process and iron pellets sieving will emerge.

The specific potential of the TransZeroWaste project is to develop new recycling technologies for iron containing by-products, low-quality ores and those of new green steel production routes.’ These scrap-equivalent materials have a volume of up to 9 Mt/y in Europe and are currently recycled via CO₂ intensive BF-BOF route with sinter plants which provide separation of disturbing impurities. Since green steel process routes do not facilitate recycling or ensure adequate impurity separation, the following alternative technologies are developed to higher TRL in TransZeroWaste to ensure sufficient supply of raw materials in iron and steel production, even in the case of increasing demands:

   –   Hydrometallurgy de-oiling by-modified magnet separator and cleaning agent recovery

   –   Low CO₂ cold briquetting and pelletising

   –   Hot microwave pelletising with reduction potential

So far, knowledge of requirements for the reuse of these materials in the DR, EAF and downstream processes, as well as of their mutual influencing factors is lacking or still at low TRL. TransZeroWaste further develops these technologies, including pilot plants at industrial partners sites. Those technologies will be supported by the development of a decision support platform providing circularity, environmental and economic indicators for higher sustainability performances.

TransZeroWaste and its Innovative Actions address the following key objectives:

• Upgrading of low-quality iron ores by combining it with iron-rich by-products.

• Development of innovative techniques to produce high-quality pre-material for decarbonised future.

• Separation of disturbing components from by-products to replace scrap.

• Development of the technological basis and digital tools supporting the transition towards zero waste in the European steel industry.

All objectives are clearly related to the objectives of the Clean Steel Partnership. 

The developed TransZeroWaste technologies aim for the upgrade and use of low-quality iron ores and iron-containing by-products, focusing on impurity separation and reduction, as well as enhancing the valorisation potential of low-quality scrap equivalents while achieving a high recycling rate. Their further development will contribute to climate neutral and circular industrial value chains supporting transition towards low-CO₂ DR and EAF production routes, enhancing recycling potential to reduce the use of critical raw materials, and enabling the implementation of energy-efficient processes.

The development of a decision support platform modelling sustainability performances of steel production pathways supports the digital transition of the manufacturing sector. The project outcomes will thus help increase the resilience and competitiveness of the steel sector in Europe. As the transition to low-CO₂ DR and EAF routes leads to the shutdown of CO₂-intensive processes such as sinter plants, BF, and BOF— which currently support a high recycling rate— the recyclability and usability of low-grade ore and scrap would also be significantly reduced. Therefore, the TransZeroWaste technologies aim to provide solutions at TRL 8 to fill the gaps for recycling and upgrading for ore- and scrap-based green steel production. Considering sinter plant operation generating between 161 and 368 kg CO2/t sinter (Best Available Techniques), the replacement of sinter plant with low carbon technologies for the addressed 27 Mt/a raw materials could save between 4.3 and  9.9 Mt CO₂ /y. The replacement by TransZeroWaste technologies could provide the otherwise cut-off of recycling and upgrading as well as providing additional potential for low CO₂ zinc recovery.