Project duration: 01 January 2020 – 31 December 2021

Objective

The project aims to involve society in a process of social commitment in order to highlight that the coexistence between industry and the natural, social, educational and cultural environment is positive and desirable for society, since it improves the quality of life of the population, contributes to social and economic development at the local level, promotes sustainable practices and promotes the natural environment.

The solution (technology)

The project proposes a set of activities to involve the targeted audience through a SOCIAL ENGAGEMENT process to learn, to interest and to motivate through different education modules designed to start breaking the barriers of stereotypes and misinformation surrounding the raw materials industry, to strengthen ties with the local communities and, finally, to incite enthusiasm and passion for the Raw Materials-related topics.

The social impact of the activities will be assessed to foster the replication and transference of the most successful experiences to other Raw Materials Industry though a Good Practices Guidelines, that will be shared with EIT Community.

Partnership

• Atlantic Copper S.L.U., Spain (Lead Partner)
• Consiglio Nazionale delle Ricerche (CNR), Italy
• Fundación Atlantic Copper, Spain
• Magnesitas Navarras S.A., Spain
• National Technical University of Athens (NTUA), Greece
• Outotec Oy, Finland
• Technische Universiteit Delft (Delft University of Technology), Netherlands

For more information, please visit the project web page.

Project duration: 1 January 2018 – 31 March 2021

Objective

Deep understanding of the resource base is the most important economic leverage to optimize mining operations. Developments in seismic techniques (hardware and software) have substantially changed ore exploration approaches, making high-resolution seismic surveys more affordable.

New leading edge acquisition and processing technology have increased the capabilities of seismic imaging. Now, massive data acquisition programs are attainable. Research carried out within environmental seismic noise interferometry, depth migration, and seismic tomography opens a variety of options, increasing imaging possibilities and resolution power of seismic data. Careful assessment of these new possibilities requires an ideal large-scale data acquisition program and strong research efforts in developing new data analysis procedures, taking into account the different possibilities of such a unique seismic database.

The solution (technology)

SIT4ME improves this knowledge combining controlled-source seismic with seismic noise recording above and underground, generating a high, locally ultra-high resolved 3D image. Deep mining customers benefit most as drilling is expensive and potential field geophysics lacks resolution. Upscaling concerns methodology, soft- and hardware.

Partnership

• Spanish National Research Council (CSIC), Spain (Lead partner)
• Boliden Mineral AB, Sweden
• DMT GmbH & Co. KG, Germany
• Technische Universität Bergakademie Freiberg (TUBAF), Germany
• Uppsala University, Sweden

For more information, please visit the official website of the project.

01 March 2018 – 28 May 2021

Objective

Companies operating in the recovery of non-ferrous metals (especially the lead, zinc and copper producers) generate solid waste in the form of the metallurgical slags as a by-product of their processes. About 240,000 t of the waste slags from lead and zinc industry are produced each year just in Poland, and in Europe, this kind of waste is produced in the amount of several million tons. Those slags are mostly hazardous for the natural environment and require storage in the properly secured landfills. The slag producers bear the costs of building the landfills as well as the environmental fees for the waste storage. The non-ferrous metals producers are looking for an efficient method to eliminate the metallurgical waste slags from the process cycle according to the “zero-waste” strategy.

The primary objective of this project is to upscale a technology to recover metals from waste slags produced by lead/zinc and copper industry. These slags are potential sources of valuable base metals, which can be recovered in the form of marketable products. Additionally, after the process, the slag can be transformed into a non-hazardous material which can be used in the building sector as aggregate, i.e. for road construction or other applications. The results of the project will create solid grounds for making a decision about building the slag valorization installations at each of the important metallurgical waste slag producers and to integrate them with the main base metal production equipment.

The solution (technology)

The project will provide a ready for implementation solution for the growing challenge of waste management in the companies which produce white slag by complete transformation of its volume into construction material, thus eliminating the environmentally hazardous material, and at the same time providing additional profit to the companies thanks to the recovery of base (Zn, Pb, Cu) and by-product (Ag, Sb, Sn) metals which are contained therein.

Partnership

• Institute of Non-Ferrous Metals (IMN), Poland (Lead partner)
• Baterpol S.A., Poland
• BERZELIUS Stolberg GmbH, Germany
• Küttner GmbH & Co. KG, Germany
• Rheinisch-Westfaelische Technische Hochschule Aachen, (RWTH Aachen), Germany
• Flemish Institute for Technological Research NV (VITO), Belgium

Project duration: 1 January 2021 – 31 December 2023

Objective

Wire and Arc Additive Manufacturing (WAAM) presents unique opportunities to create, repair and extend life of large industrial equipment. In-situ microstructure control methodologies will be implemented in WAAM to improve the lifetime of industrial components. Inline multiparametric non-destructive testing will allow real-time defect detection during WAAM. One spin-off company, two case studies and two functional prototypes will be delivered.

The solution (technology)

Wire and Arc Additive Manufacturing (WAAM) presents unique opportunities for production, repair, refurbishment and life extension of large industrial equipment by melting and solidification of any given wire(s) using an electrical arc as heat source. Two challenges exist: 1) due to process thermal cycles, certain alloy families can be susceptible to the formation of large grain size microstructures which are typically associated with poor mechanical properties; and 2) the process can lead to the formation of defects, such as pores and lack of fusion, that may be detrimental to the part’s in-service performance. Solving the poor mechanical properties of the as-built parts is performed by thermomechanical treatments aiming at homogenising the microstructure, i.e., decrease grain size and, eventually, dissolve any detrimental phases that have formed. However, this is a time- and energy-consuming effort, which leads to an increase in production time and costs. Assessing the presence of defects is usually performed after the parts are built. If upon NDT inspection, defects are found, depending on their volumetric fraction, morphology and type, the material can be considered as waste. Hence, the need for inline and offline reliable detection methods is fundamental.

We propose to tackle these challenges in a comprehensive way by performing direct microstructural engineering of the deposited material via newly developed and validated WAAM process variants. These will encompass the introduction of inoculating agents to promote grain refinement but also the of use in-situ hot forging to promote material hardening, as well as, decrease its waviness, roughness and, more importantly, the likelihood for pore formation. An optimization of the thermal cycles, which influences the solid-state transformations of the deposited materials will also be implemented. Furthermore, a multiparametric non-destructive system for inline monitoring will be developed to identify defects that may occur during parts production. These ambitious goals aim at decreasing production time, material waste while increasing process efficiency during WAAM. Moreover, two case studies will be conducted: one will focus on the repair of damaged or obsolete industrial equipment (C-steel), while the other will concentrate on reducing lead-times by replacing forged components (Inconel). It is expected that the implementation of these new WAAM variants in conjunction with the use of the NDT multiparametric system can lead to an extension of the lifetime of repaired equipment by 20% or to a substantial lead time reduction (factor 5-10) which reduces or completely eliminates the need for stock-keeping, thus significantly decreasing the industry associated carbon footprint.

This work will be supported by numerical simulation tools which will be experimentally validated via advanced materials characterization. On top of these process innovations and their industrial implementation a life cycle assessment platform for companies already using or interested in adopting WAAM will be developed and made available. Moreover, lifelong learning initiatives will be implemented within the framework of this project.

Partnership

• The French National Centre for Scientific Research (CNRS-UB), France
• EIT Raw Materials GmbH, Germany
• Norwegian University of Science and Technology (NTNU), Norway
• NOVA.ID.FCT – Associação para a Inovação e Desenvolvimento da FCT, Portugal
• OCAS N.V., Belgium
• Université de Bordeaux, France
• New University of Lisbon – Faculty of Sciences and Technology (FCT NOVA) (Lead Partner), Portugal

Project duration: 1 January 2019 – 31 December 2021

Objective

Today, most mines are still using large amounts of paper-based information or isolated excel files. Instead of voice-over IP, 4G, email, and messenger services, the supervisors in many underground mines provide tasks to the operator by driving to the different workplaces or by two-way radio. Machines are used even though they urgently require planned maintenance as a lack of diagnostics.

The solution (technology)

The solution to this problem, proposed in the SmartHub project, is the Industrial Internet of Things (IIoT). IIoT is embedding intelligence in industrial machines allowing them to be more efficient, self-correcting, safer, and connected, relieving mundane tasks from operators enabling them to focus on the system. Still, many companies don’t have enough digital capabilities. Traditionally, that meant they either had to build those capabilities themselves or buy them by seeking support from a qualified partner. Building digital capabilities is expensive and time-consuming. And purchasing them or partnering is often slowed by cultural gaps and miscommunications which seldom lead to real-world solutions.
SmartHuB offers mines, machine manufacturers and suppliers to gather, transmit, ingest disparate, real-time and historical data onto a scalable and fast-analysis platform to generate valuable insights, providing a toolkit for data analytics applications for fixed and mobile assets, covering machinery and equipment in mining processes including Room&Pillar and continuous mass-transport as well as a predictive analytics platform, which can use real-time and historical data from machinery and equipment as well as contextual information about weather and the environment to optimize operations for equipment operators and managers.

Partnership

• Indurad GmbH, Germany (Lead Partner)
• AGH University of Science and Technology, Poland
• DMT GmbH & Co. KG, Germany
• FLSmidth A/S, Denmark
• LTU Business AB, Sweden
• Mine Master Spółka, Poland
• Sachtleben Bergbau GmbH & Co.KG, Germany
• Südwestdeutsche Salzwerke AG, Germany
• Tallinn University of Technology, Estonia
• talpasolutions GmbH, Germany
• VKG Kaevandused OÜ, Estonia

Project duration: 1 January 2019 – 31 December 2020

Objective

SmartPlaCE@Schools will develop creative learning material on Circular Economy concepts and business models for high school education, using gamification methods. As the follow-up of FosterERM@Schools, this project will also develop a virtual environment hosting the downloadable Risk&Race@schools game, together with a range of complementary learning materials. In addition, the platform will capture feedback from schools on their needs and experiences.

The solution (technology)

SmartPlaCE@Schools will develop creative learning materials on Circular Economy concepts and business models for high school education. For dissemination purposes, it will set up a Europe-wide digital platform that will host a downloadable version of the serious game, Risk&Game@Schools, developed as an educational tool suitable for teenagers, as well as a range of learning materials focused on circular economy concepts and business models, and linked to the high school curriculum. Apart from a valuable source of information and course materials for teachers, the interactive platform will be able to involve students in active learning using gamification methodology, supporting teachers in using this tool and in capturing feedback from schools and teachers on their needs and experiences.

The use of the platform will help young adults to be aware of the complexity and interrelation of raw materials with environmental sustainability issues, equip them to debate issues and motivate them to take responsibility. Furthermore, the platform will be designed to show options to pursue careers in science and technology by strengthening the connections between the educational training period and job opportunities. Synergies with existing platforms, such as the RM@schools virtual centre and other European initiatives, such as etwinning.net, will be exploited where possible.

Partners

• Vlaamse Instelling voor Technologisch Onderzoek NV (VITO), Belgium (Lead Partner)
• Consiglio Nazionale delle Ricerche (CNR), Italy
• TalTech University, Estonia
• Wuppertal Institut fuer Klima, Umwelt, Energie GmbH (Wuppertal Institute),
• bvse Associations Sekundärrohstoffe und Entsorgung e.V., Germany

For more information, please visit the project web page.

Project duration: 1 January 2018 – 30 June 2020

Objective

SO4Control is a mine water management concept that combines environmental and economic advantages into a process concept for utilisation of internal process circulations. The concept enables significant reductions in concentrations of regulated compounds in the discharge as well as in the consumption of process chemicals. In addition, with enhanced raw material usage, substantial new income can be generated with the recovery of additional side products.

The solution (technology)

The process concept offers an innovative and sustainable way of enhancing the overall feasibility of an industrial scale operation. The solution provided is modular meaning that can be tailored depending on the need of each customer. The first module is enhanced leaching design and optimisation, which creates process solutions with a controlled amount of sulphate in the process waters and broader possibilities for additional side product recovery. The second piece is advanced membrane technologies, which enable cost-effective concentration of metal sulphates in the discharged water to be used as such or via biological sulphate reduction. The third phase is the biological sulphate reduction tailored to be very energy efficient also in the cold conditions in Scandinavia. The concept entails also the recovery of sulphur as either a commercial side product or a recyclable process chemical. The last phase is the recovery of a valuable side product from the effluent from the biological process.

Partnership

• Terrafame Group Oy, Finland (Lead Partner)
• Aalto-Korkeakoulusaatio (Aalto University), Finland
• DMT GmbH & Co. KG, Germany
• LTU Business AB, Sweden
• Miljötekniskt Center AB (MTC), Sweden
• RISE Research Institutes of Sweden Holding AB, Sweden
• Skyscape Ltd, the UK
• Spinverse Innovation Management Oy, Finland
• Sulfator Ltd, Finland
• Teknologian tutkimuskeskus VTT (Technical Research Centre of Finland Ltd. VTT), Finland

Project duration: 1 January 2016 – 31 December 2018

Objective

This project aims at implementing a long-term self-sustainable excellence network dedicated to providing services to customers for the implementation of innovative, sustainable business and cooperation models for recycling and/or exploitation of raw materials from end-of-life products, as well as supporting companies and to facilitate the exploitation of European secondary resources via collaboration (software, databases, competences, infrastructures, instrumentation, best practices, etc.) implementing industrial symbiosis and the circular economy.

The solution (technology)

Offering guidance to local and regional authorities in planning new industrial parks or revitalizing existing areas for higher level of resource efficiency and harmonised national waste strategies.

Partnership

• Teknologian tutkimuskeskus VTT (Technical Research Centre of Finland Ltd. VTT), Finland (Lead Partner)
• Aalto-Korkeakoulusaatio (Aalto University), Finland
• Fundación Tecnalia Research & Innovation, Spain
• Instytut Metali Niezelaznych, IMN (Institute of Non-Ferrous Metals), Poland
• IVL Svenska Miljoeinstitutet AB (IVL Swedish Environmental Research lnstitute), Sweden
• Katholieke Universiteit te Leuven (KU Leuven), Belgium
• Lappeenranta University of Technology, Finland
• Luleå University of Technology (LTU), Sweden
• Outotec Oy, Finland
• Rheinisch-Westfaelische Technische Hochschule Aachen (RWTH Aachen) Germany
• Vlaamse Instelling voor Technologisch Onderzoek NV – (Flemish Institute for Technological Research NV VITO), Belgium

For more information, please visit project website.

Project duration: 1 January 2021 – 31 December 2023

Objective

Additive manufacturing (AM) holds potential for revolutionizing electromechanical industry. Bottleneck is the availability of materials. We aim at upscaling soft magnetic powders for AM. Electrical machine (EM) and drive industry, with a value of 6.3 B€ in Europe, is among potential end-users. Consortium combines powder and EM experts. Parts of powder products are validated by CRF and Siemens. Powder commercialization is led by Elkem.

The solution (technology)

The SOMA project is answering to electric mobility (e-mobility) demand for more optimized electromechanical devices with enhanced performance, lower material consumption and life cycle cost. This demand is pushing the manufacturers and research community to explore non-conventional designs and manufacturing methods. Additive manufacturing technologies are opening up new possibilities for realizing novel magnetic circuit designs. Earlier studies have shown that by tailoring material compositions together with optimized processing parameters and particularly, with post-treatments, high performance soft magnetic components can be manufactured by laser powder bed fusion (L-PBF). Further, it has been shown that through topology optimization, the weight of an electrical machine can be decreased significantly without compromising the other key characteristics. The SOMA project is focused on the upscaling of soft magnetic alloys tailored for additive manufacturing with minimized amount of critical raw materials. Furthermore, SOMA will demonstrate a manufacturing route where the restrictions of conventional manufacturing methods do not apply enabling groundbreaking changes in designs and consequently leading to lightweight and material efficient solutions for, e.g., future e-mobility.

Partnership

• Technical Research Centre of Finland Ltd. VTT (Lead Partner), Finland
• Siemens AG, Germany
• Gemmate Technologies, Italy
• Elkem AS Technology Kristiansand, Norway
• Research Center Fiat, Italy

Learn more about the project here.