SUSTAINABLE PROCESSINDUSTRYEUROPEAN INDUSTRIAL COMPETTIVENESS TROUGHRESOURCE AND ENERGY EFFICIENCY

SPIRE Brokerage eventOctober 22nd 2013

Project Idea PresentationTenaris idea – Horizon 2020 SPIRE Call 707. October 2013

SPIRE-7

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Tenaris Global industrial System

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Project Idea ConceptBy-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 non-renewable 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 ConcepteCo2SMelt = ecological-economical Stainless steel Melting

Scale

Valuable / inert slag

White slag (lime)

Black slag

Fe-Alloys fine

Dust

SludgeScale

Dust

Black slag

Fe-Alloys to EAF

Briquette

eCo2SMelt = ecological-economical Stainless steel Melting

Scale

Valuable / inert slag

White slag (lime)

Black slag

Fe-Alloys fine

Dust

SludgeScale

Dust

Black slag

Fe-Alloys to EAF

Briquette

ScaleScale

Valuable / inert slag

White slag (lime)White slag (lime)

Black slag

Fe-Alloys fine

Dust

Black slag

Fe-Alloys fine

Dust

SludgeScale SludgeScale

Dust

Black slag

Dust

Black slag

Fe-Alloys to EAF

BriquetteBriquette

Metal oxide (non-ferrous)C-based residuals (petro-chemical)

Si-based residuals (glass, ceramic, refractory)

EAF in reducing conditions

Scrap substitute

Inert slag to cement

ZnO to Zn smelter

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Idea ImpactThe 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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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

Idea Impact

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Existing Project Consortium1. 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, petro-chemical, 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 detailsTenaris DalminePiazza 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