CircSmeltSteel

The project CircSmeltSteel validates the use of metallurgical by-products as secondary sources in low carbon iron and steelmaking and clarifies the impact of steel quality on product properties meeting EU objectives on net zero manufacturing, sustainability, and competitiveness (Net-Zero Industry Act, Clean Industrial Deal, Steel and Metals Action Plan). The entire steelmaking chain is covered with upstream (primary/secondary metallurgy, casting) and downstream (hot and cold rolling/annealing). Two low-CO2 routes are considered with a system-level approach using by-products as secondary feedstock: the Electric Smelting Furnace (ESF, also called Smelter or Submerged Arc Furnace) and the Electric Arc Furnace (EAF), both at pilot and industrial scales. The steel produced will be evaluated under higher tramp element levels (nitrogen, phosphorous, sulphur, copper, molybdenum, tin), addressing the EU’s zero defects goal using mechanical testing (e.g., Gleeble, dilatometry). CircSmeltSteel is in line with the EU’s zero waste goal and industrial symbiosis, as ESF/EAF slags will be qualified as raw materials for other sectors. A skills development strategy including the Industry 5.0 paradigm will foster societal readiness for using low-quality materials in existing and new low-carbon steelmaking technologies. All data and models derived are integrated into a digital platform serving as an excellent data management strategy for R&D projects in the steel industry. An excellent consortium combines know-how in metallurgy, plant technology, process automation, and circularity with highly skilled scientific partners. CircSmeltSteel will raise awareness of the necessity of handling low-quality by-products for green hot metal and steel production and their scale-up to enable a resource-efficient, competitive economy. Business potential is enormous with ~80Mt annual by-product recycling (for ESF and EAF routes) and the capability to replace the sinter-BF route in integrated plants.