Innovative by
multi-partner projects
At Dillinger, innovation always takes center stage, not only internally and with our customers, but also through participation in multi-partner projects. These projects are designed to bring together the necessary expertise, laboratory and plant technology to enable synergy effects for faster new and further developments.
Motivation
Cooperation in multi-partner projects makes it possible to address development needs and ideas in which not only we, but also other institutes, companies and society are interested. Such projects would either take too long or overtax our own resources if they were developed exclusively internally.
Partners
In line with all compliance regulations, we combine our steel and process know-how as well as our industrial plant and laboratory technology with specialized universities, research institutes and industrial companies from various sectors in order to integrate the specific spectrum of expertise in each case. If necessary, we also make use of public funding.
Current projects
TransZeroWaste
Upgrading of low-quality iron ores and mill scale with low carbon technologies
Considering the ambitious pollutant emission reductions expected of the steel sector in the coming years, development of novel solutions to address the transition to clean steel production and the switch to more environmentally friendly production technologies are of fundamental importance. Due to the transition from carbon-based iron and steel production to green steel production with hydrogen (H2), most current production units such as sinter plant, blast furnace (BF) and basic oxygen furnace (BOF) will in the future be replaced by the direct reduction process (DR process) followed by the electric arc furnace (EAF). In consequence, a complete replacement of the existing highly efficient internal recycling via sinter plant by new developments is needed.
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Within the TransZeroWaste project new technologies are being developed to assist in this regard and promote the reuse of steel residues in the production process, namely through the hydrometallurgical removal of impurities from oily mill scale and sludge, together with pelletization, briquetting and microwave treatment of currently discarded iron containing materials. In addition, upgrading of low-grade ore in combination with suitable Fe-baring by-products will be included in the project’s development activities.
Material investigation and pre-trials on lab-scale of all iron-baring by-products of BF-BOF- and EAF-route in combination with a Material Flow Analysis (MFA) of two distinct sites steel production plants, before and after the transition incorporating the novel TransZeroWaste technologies, thorough literature research and thermochemical calculations form the basis for the ongoing developments. One of the sites (AG der Dillinger Hüttenwerke – Dillinger) operates a BF-BOF integrated steel plant with transformation to DR- ore-based-EAF-route, while the other (CELSA) operates a scrap based EAF adding DR for e.g. recycling of scale.
Meanwhile, based on these findings and ongoing pre-trials on lab-scale, the optimization of layout and construction of the projects pilot plants have been started. One of the pilot plants, the microwave kiln for removal of unwanted residuals such as e.g. zinc from the iron-containing scale, dust, sludge, etc. will be installed and operated at Dillinger during the project for adjustment and testing under industrial environment conditions.
Further information on the project
The projects partners LUXEMBOURG INSTITUTE OF SCIENCE AND TECHNOLOGY (LIST), VDEH-BETRIEBSFORSCHUNGSINSTITUT GMBH (BFI), COMPANIA ESPANOLA DE LAMINACION SL (CELSA BARCELONA), K1-MET GMBH (K1-MET), UNIVERSITAT POLITECNICA DE VALENCIA (UPV), INNCEINNMAT SL (CEINNMAT), AKTIEN-GESELLSCHAFT DER DILLINGER HUTTENWERKE (DILLINGER), INSTITUTO DE SOLDADURA E QUALIDADE (ISQ), ESTEP PLATEFORME TECHNOLOGIQUE EUROPEENNE DE L’ACIER (ESTEP), PROIGMENES EREVNITIKES & DIAHIRISTIKES EFARMOGES (AMSOLUTIONS), SIEC BADAWCZA LUKASIEWICZ – INSTYTUTMETALURGII ZELAZA IM. STANISLAWASTASZICA (IMZ), AGENCIA ESTATAL CONSEJO SUPERIOR DE INVESTIGACIONES CIENTIFICAS (CSIC), provide an efficient cooperation to join research and industrial expertise and facilities.
EnWaRec
Holistic approach for cooling water circuits
Energy-intensive industries such as steelmaking are indispensable for the European economy, as they supply numerous key value chains. The transformation of the iron and steel industry from CO2-intensive production to low-CO₂ hydrogen-based steelmaking is embedded within ecological, technical, and political frameworks that significantly influence the realization of decarbonization.
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The use of direct reduction plants (DR) introduces new process streams that result e.g. in high-temperature condensate and substantial energy input into the gas scrubbing water, with temperatures reaching up to 80 °C. This increases the demand for cooling water to meet operational temperature requirements and comply with regulatory discharge limits. Climate change exacerbates water stress, reducing water availability and increasing salinity levels. Combined with higher water temperatures, this further intensifies the need for freshwater. Due to challenging water compositions, elevated temperatures, severe corrosion and scaling, high salinity, and abrasive particles, no energy or water recovery from these streams is currently practiced.
About the Project
To address these challenges, EnWaRec is developing a holistic approach for cooling water circuits, incorporating heat, power, and water recovery, energy and water reuse, and tailored water treatment. Monitoring sensors that measure scaling and corrosion potential form the basis for targeted dosing of treatment chemicals, applicable at temperatures up to 80 °C. Microturbines utilize the potential energy of water streams for sludge drying or to power membrane distillation. Software tools determine the optimal locations for installing heat exchangers and microturbines to maximize energy recovery.
Objectives and Expected Outcomes for Dillinger
For Dillinger, the focus in the project is on the continuous casting plant CC6. In the secondary cooling zone, water is sprayed directly onto hot steel through nozzles to achieve controlled cooling. During this process, the water absorbs not only large amounts of energy but also significant quantities of contaminants such as scale and casting powder. These impurities must be removed through complex treatment to prevent nozzle clogging and minimize the water’s corrosion potential.
A precise representation of the water circuit as a digital twin is therefore essential. It enables timely countermeasures and early detection of potential issues.
Dillinger, through its “Steel Plant Technology & Research” and “Steel Plant Production-Oriented Maintenance” departments, together with project partners, has defined the following objectives:
- Selection and further development of inline probes for measuring corrosion rates and scaling tendencies in the process water circuit of the continuous casting plant;
- Development of a digital representation of the water circuit (digital twin);
- Development of concepts for demand-driven chemical dosing and circuit maintenance based on inline measurements;
- Feasibility study on heat recovery using heat exchangers;
- Integration of measurement systems into the CC6 water circuit at Dillinger;
- Operational trials of the developed concepts;
- Economic evaluation based on operational trials and adjustment of the developed operating concepts;
- Implementation of an adapted inline monitoring system that indicates the need for chemical dosing and circuit maintenance.
Further information on the project
