SPIRE 7 – 2015: Recovery technologies for metals and other minerals

1. SPIRE-7 SPIRE Brokerage event October 22nd 2013 SPIRE 7 – 2015: Recovery technologies for metals and other minerals Project Idea Presentation

2. 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.

3. 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 on-site 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 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 This project idea will adress call tpoic SPIRE 7 -2015 „Recovery technologies for metals and other minerals“

4. 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.

5. Idea impact - SPIRE Roadmap

6. 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 lab-pilots: • for RecoDust download “factsheets” under http://www.ffg.at/comet-compentence-centres-excellent-technologies-k1-centres • for RecoPhos see http://www.recophos.org/c/mid,1361,Consortium/ 6

7. Looking for partners… • 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.

8. 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

9. 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 technology-intensive 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 EBITDA: € 1.3 bn Employees: ~ 46,000