Plastic-Derived Steel Reducing Agents (SRA)

Waste Type:

Plastic

Main Circular Economy Strategy:

Plastic - Digital Tools & Smart Systems

KEYWORDS

PLASTICS, REUSE, SECONDARY MATERIALS

Summary

Feralpi, within the OnlyPlastic project, replaced part of the coal and anthracite used in its Electric Arc Furnace with recycled post-consumer plastics introducing them as Steel Reducing Agents through a specialized injection system .

Description

In alignment with the OnlyPlastic project, Feralpi developed and implemented an innovative approach to partially replace traditional fossil-based reducing agents—such as coal and anthracite—in its Electric Arc Furnace (EAF) operations: • Plastic-Derived Steel Reducing Agents (SRA)

Environmental Perspective

Feralpi’s adoption of plastic-derived SRAs in steel production delivers significant environmental advantages:
◼ Reduction in CO₂ Emissions: Replacing fossil-based carbon sources with hydrogenrich recycled plastics contributes directly to the reduction of iron oxides, substantially lowering CO₂ emissions associated with traditional carbon-intensive reduction processes.
◼ Enhanced Energy Efficiency: Implementation of plastic-derived SRAs resulted in approximately 3% reduction in specific electrical consumption of the Electric Arc Furnace, thereby reducing overall energy use and associated greenhouse gas emissions.
◼ Circular Use of Plastic Waste: Converts post-consumer plastic waste from a disposal challenge into a valuable industrial input, supporting circular economy principles and significantly reducing plastic waste sent to landfills or incineration.
◼ Reduction of Fossil Resource Dependency: Less reliance on coal and anthracite significantly reduces the environmental impacts related to fossil fuel extraction and usage, contributing to broader sustainability goals within the steel industry. Through this initiative, Feralpi effectively demonstrates how circular economy practices can significantly reduce both environmental impacts and resource intensity in heavy industrial processes.

Economic Perspective

The implementation of plastic-derived SRAs offers substantial economic benefits to Feralpi:
◼ Cost Reduction in Production Inputs: SRAs derived from recycled plastics are more cost-effective than traditional fossil-based carbon sources, resulting in lower raw material costs and enhanced production efficiency.
◼ Energy Cost Savings: Achieved a measurable reduction in electricity consumption (~3% less), providing direct cost savings through reduced energy expenditures in the steelmaking process.
◼ Infrastructure Investments and ROI: Although initial investments in specialized injection systems, infrastructure upgrades, and polymer storage facilities were required, the ongoing savings in raw material and energy costs deliver a positive longterm return on investment.
◼ Market Competitiveness and Regulatory Compliance: Improved environmental performance and lower carbon footprint strengthen Feralpi’s market position and facilitate compliance with evolving regulations regarding emissions and resource use, providing strategic competitive advantages.
◼ Circular Economy Branding: Enhanced company reputation as an environmentally proactive manufacturer, potentially attracting customers and partners committed to sustainability, further enhancing market positioning and business opportunities. Overall, adopting plastic-derived SRAs significantly contributes to economic efficiency and competitive positioning through resource cost reduction and improved operational effectiveness.