PRocess Innovations for the Mineral industry focusing on ROasting and Calcination Kiln technologies and supported by novel pre- and post-processing

Abstract

PRIM-ROCK addresses process efficiency through a multifaceted strategy addressing industrial processes from input to output, supported by an ambitious digital framework and transversal supporting activities. In particular, advanced techniques for the pre-processing of the raw material will be deployed to enhance its efficiency according to the requirements of the process, supplemented by simulations and decision support systems to increase the operational limits of flexibility in the feedstock domain. Additionally, the process intensification component of the project will design, develop, and validate innovative and efficient processes, as well as optimizing the existing ones. The aim is to develop a portfolio of technologies to a higher resource efficiency and lower level of GHG emissions of extractive industries. The project will focus on improving the resource efficiency of the calcination and roasting processes, that are commonly used in the mineral and cement industries. To this end, process simulations in collaboration with AI data-driven models will be utilized and a digital twin for each process will be developed. Finally, waste reduction and re-utilization strategies will be investigated targeting to the realtime processes’ adjustment capabilities to feedstock changes and tighter processing control solutions. All these components will be supplemented by transversal supporting activities, such as technoeconomic assessment, LCA, standardization etc. The PRIM-ROCK solutions will be demonstrated in 3 different ASPIRE sectors, namely Minerals (magnesite, laterite), Cement (limestone) and Non-ferrous metals (sphalerite, chalcopyrite). The consortium is composed of 7 SMEs along with 6 RTDs, 3 universities and 5 large enterprises, working together to achieve over 30% resource efficiency enhancement in each use-case, 770ktCO2 averted, productivity increase in the range 9-16% and more that 1,360 new jobs by 2033.