The TransZeroWaste Project unveiled its transformative approach to iron ore processing at the recent AMPERE 2023 conference. With a focus on advancing low-carbon technologies in industrial applications, TransZeroWaste’s innovative “hot microwave pelletising” technology addresses the dual challenges of low-quality iron ore and mill scale upgrading, all while reducing carbon emissions—a vital step for the future of the European steel industry.
Tackling the Challenge of low-quality Iron Ores with Microwaves
As the demand for high-quality iron resources grows and the steel industry pivots away from carbon-intensive processes, upgrading low-quality iron ores becomes critical. Conventional sintering is energy-intensive and leaves a large carbon footprint, creating an urgent need for alternative methods. TransZeroWaste responds with an innovative hot microwave pelletising process designed to boost the iron grade of low-quality ores while optimizing energy use. This microwave-based technique offers significant benefits over traditional methods, including faster processing times, greater energy efficiency, and modular scalability for integration into existing industrial setups.
Technology Behind TransZeroWaste: Modular Microwave Processing Units
The project introduces a modular microwave processing system that facilitates seamless integration with existing infrastructures. Unlike traditional heating systems, microwave technology allows precise, real-time tuning of heat intensity and feedstock speed, ensuring efficiency in energy consumption. The setup comprises cellular kilns for material transformation, allowing the processing of granular feedstock using microwave energy. By using microwave generators that adapt based on the material flow and power needs, the system ensures optimal heat distribution at high temperatures. This configuration enables smaller, more flexible solutions, making it feasible for companies to implement this low-carbon technology without substantial investment.
Beyond Efficiency: Environmental Benefits and a Path to Zero Waste
The environmental impact of TransZeroWaste’s microwave pelletising is groundbreaking. By eliminating the need for carbon-heavy sintering processes, the technology aims to reduce emissions by an estimated 4.3 to 9.9 million tons of CO₂ per year. The project has the potential to upgrade up to 27 million tons of materials annually using low-carbon methods, positioning itself as a pivotal solution for the European steel industry’s shift toward a zero-waste future. Moreover, the process is adaptable for a range of iron-rich materials, including mill scale—a byproduct often disregarded in conventional processing.
Building on the Success of the DESTINY Project
TransZeroWaste builds upon insights gained from the DESTINY Project (H2020), which first explored microwave heating as a scalable alternative in industrial processes. Through DESTINY’s research, microwave energy was proven effective in heating materials with high efficiency, showing that modulating internal wavelengths could yield optimal results even in high-volume operations. Leveraging this knowledge, TransZeroWaste applies the same principles with enhanced electromagnetic field distribution for larger-scale applications, ensuring a viable path for industrial-scale adoption.
Looking Ahead: A Sustainable Future for the Steel Industry
By spearheading the hot microwave pelletising technology, the TransZeroWaste Project not only addresses current inefficiencies in iron ore processing but also lays the groundwork for the European steel industry’s journey toward a sustainable, carbon-free, zero-waste future. With a solution that reduces reliance on sintering while making effective use of microwave energy, TransZeroWaste exemplifies the types of innovations essential for achieving environmental targets in heavy industry sectors.
Through its pioneering work, TransZeroWaste highlights the importance of investing in scalable, energy-efficient solutions that can be integrated with minimal financial and logistical barriers, making low-carbon technologies accessible and feasible for widespread industrial implementation. As a model of innovation and environmental stewardship, TransZeroWaste stands as a beacon of sustainable progress within the AMPERE 2023 community and beyond.
