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Extreme energyfree valorisation of copper metallurgical waste in heating elements and semiconductive nanoceramic enamels (Waste3)
Start date: Oct 1, 2011, End date: Sep 30, 2014 PROJECT  FINISHED 

Background The Waste3 project targets the environmental problem of waste slag produced by pyrometallurgical processes during primary extraction of copper. For each kilo of copper obtained, 2.2 kg of slag is produced, amounting to 5.56 millions tonnes/yr of slag in Europe. Despite its high iron content, this slag is currently disposed of in landfills, further processed as inert material, or used as an abrasive in industrial processes. However, this last option is not a sustainable solution, because the granules derived from the slag and used as an abrasive are themselves disposed of after re-use. However, because it is composed of iron oxides and silicates, the slag has semi-conductive and mild ferromagnetic properties and could be used to produce innovative advanced materials for heating applications, substituting materials with much higher embodied energy, and bringing environmental benefits. Objectives The Waste3 project's aim is to convert primary copper metallurgical waste into heating elements and semi-conductive enamels for residential applications. To do this, a small-scale pilot production line, able to process 200 kg/day of slag, will be constructed. The project also aims to develop from the slag new materials for residential use, in particular: Tubular heat-resistant elements for ovens and small electrical appliances; Floor elements for residential heating, to substitute conventional wall-mounted elements; and Plates or auxiliary heating elements for microwave heating of food. Thirdly, the project will establish a separation process to recover iron-silicate and oxide rich granules, and to convert them into one of the aforementioned products. Expected results: The technology proposed by Waste3 will allow an iron-rich industrial waste to be converted into safe products for construction and electrical appliances. Expected environmental benefits: Production of a test series of new products containing more than 80% of copper metallurgical waste by weight; Substitution of higher embodied energy materials, such as molybdenum disilicide, in heating elements; Development of high-performance and energy-saving materials, such as electrical systems for residential heating; and An increase in the efficiency of microwave ovens through the use of the newly generated materials.Expected technical improvements: Lower cost heating elements, because of the much lower raw material costs, availability of pre-milled products and the low-energy processing; High abrasion and wear resistance, particularly important for coverings and floor applications; Safe installation in environments where there is risk of explosion, because of the antistatic properties of the coverings; Rapid heating of the new materials with low applied currents; Good thermal shock resistance deriving from the moderate thermal conductivity of the materials, allowing rapid heating, or fast cooking when used in microwave ovens; and Lower costs and higher productivity in finishing operations.
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