Research & Development

“He who moves not forward goes backward,” Johann-Wolfgang von Goethe (German writer, 1749-1832) said once.

And the Roman philosopher and poet Lucius Annaeus Seneca (4 BC – 65 AD) is quoted as saying, “To want to progress is the largest part of progress.”

“The pace of scientific progress today is so fast that somebody might be declaring that a thing cannot be done altogether, when he is already interrupted by somebody else, who has just done that very thing,” said Albert Einstein (German-American physicist, 1879-1955).

We would like to join the many intelligent individuals who have recognized that progress is an important factor for making the world a better place. To that end, we strive to make a contribution in this regard through our constant involvement in many R&D projects. In cooperation with universities and other industry partners, we regularly provide our expertise and know-how in order to jointly achieve overriding objectives. Below are just some of the projects we have participated in:

2013-2015

PROJECT „REGRAN“

The project focuses on developing an innovative engineered fuel as granulate consisting of shredder residues derived from end-of-life vehicle recycling (ReGran) with defined properties suited specifically for gasification. The mixed fuel granulate are to be produced using a heated trough mixer and thus represents an alternative production process compared to the energy-intensive pelletization process. In order to reduce the energy requirement, a concept is being developed in the project to utilize industrial waste heat for heating up the mixer by means of induction. The project is a joint venture between SICON and Universität Siegen, Faculty for Energy and Process Engineering and is supported by ZIM (Central Innovation Program for Medium-sized Enterprises).

2010-2014

PROJECT „PROTECT“

The low-carbon galvanized steels normally used in automotive bodies and appliances are a source of high-quality scrap feed for both BOF and EAF steel production. The aim of this project was to develop a new method to preheat and remove coatings on steel scrap prior to melting as a standalone concept, decoupling the preheating from the off-gas streams from the melting furnace. As energy carrier for the concept energy containing difficult waste streams are to be used.
As part of this project a new method has been developed to promote synergetic use of low-value energy rich waste, combined with cleaning and preheating of zinc-containing steel scrap. In all scrap preheating applications, the exhaust gases generated can contain difficult compounds which need a dedicated gas cleaning system to handle these. The increased emission of harmful dust and hazardous air emission is regardless of the fuel used since these are originated from the impurities and organic coating on the scrap itself. Zinc coating on steel is used to increase the corrosion resistance of the steel. The low-carbon galvanized steels normally used in automotive bodies and appliances are a source of high quality scrap feed for both BOF and EAF steel production. Although there have been development of technology for removal of the galvanized coatings, the protracted delays in achievement of an economically viable solution have forced most BOF operators to implement alternative methodologies to maintain environmental compliance (EAF operations, with higher dust disposal cost, benefit to some extent from the value of the contained zinc units). PROTECT project focus on developing methods for efficient separation of energy containing waste streams into valuable feed be used in scrap preheating and surface cleaning application. Tests conducted in the project have shown that it is possible to separate waste (plastic, rubber etc.) fractions into various streams useful streams, to thermo-chemically convert these into a syngas, through separate combustion, use the exhaust gases generated preheat scrap and remove coatings, through a dedicated gas cleaning and recovery system recover valuables. Theoretical evaluation shows that the concept is positive both from environmental and economic standpoint.
PROTECT has been supported by the European Commission and has been performed by the partners SICON, MEFOS, SSAB, Engitec, Stena Metall AB, University of Siegen, IVL AB, SSUP and Stenal Metall A/S.

2009-2013

PROJECT „SHREDDERSAND 1“

So-called shredder sands are produced during the processing of residues generated, for instance, in the patented VW-SICON process during the comminution of end-of-life vehicles, household appliances, and mixed scrap. A process was developed to recover fine-grain shredder sands (less than 1mm in size) during the course of the BMBF-funded joint project “Shredder Sand” with project partners Volkswagen AG, SICON GmbH, Recylex GmbH and the Institute of Mineral and Waste Processing, Waste Disposal and Geomechanics (IFAD) of Technische Universität Clausthal (TU Clausthal). At the same time, a method was developed that also separates the mineral or siliceous material flow in addition to the other product flows. Thanks to the cooperation of IFAD with the Recycling Work Group of the Department of Building Materials at the F.A. Finger-Institute for Building Material Sciences of Bauhaus-Universität Weimar and the Building Materials Technology Department of BAM Federal Institute for Materials Research and Testing, it was possible to identify an innovative and high-grade application route for this mineral material flow from shredder sands. To this end, a new process is used for generating swelling granulates (light-weight aggregrate) from heterogeneous fine-grain building and demolition wastes. This requires the preceding processing step of the shredder sands based on the process developed in the “Shredder Sand” project. The process and the resulting opportunities have already been presented in the magazine entitled “Recycling”. During the course of the multi-stage process, organic components are separated from the shredder sands (< 1 mm) by means of flotation and wet separation table. Afterwards, the iron concentrate is separated in the magnet stage such that it can be reused by the industry as input material. Copper concentrates which are also circulated back to the industry are then generated in the downstream milling and screening steps.

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