In Area 1, K1-MET focuses on two main topics. These are increased efficiency for more product output in metallurgical processes, and circularity for closing material cycles. A closed material loop is a circular process in which an output can be used and then converted into a new product again.

In primary iron and steel metallurgy, the sintering process is the first treatment step of iron ore, which should be further used in a low-carbon direct reduction process. A sinter plant heats and agglomerates fine iron ore particles at high temperature. Direct reduction uses natural gas or hydrogen to produce iron without releasing massive carbon dioxide (CO₂) into the atmosphere, making it more environmentally friendly.

Another part of Area 1 deals with alternative reducing agents in the blast furnace and during treatment of copper recycling materials. A blast furnace is a large industrial plant that produces liquid iron (hot metal) during a reduction and smelting process. Reducing agents are used in the blast furnace to remove the oxygen from the iron oxides. The main state-of-the-art reducing agent in the blast furnace is carbon (in the form of coke). K1-MET is looking for more sustainable alternatives.

In secondary metallurgy, methods such as ladle furnace and Ruhrstahl-Heraeus vacuum degassing are investigated regarding increased steel cleanness. A ladle furnace ensures quality and consistency of the molten steel before it is casted into semi-finished products. Vacuum degassing removes unwanted gases from molten steel by placing the steel melt in a sealed chamber with no surrounding air (vacuum).

Additionally, process efficiency and product quality are to be improved in the field of continuous casting and electro slag remelting. Continuous casting is a method to produce solid metal semi-products. A molten metal is poured into a mold and is cooled and solidified continuously. Electro slag remelting is applied to refine steels and various alloys, resulting in high-quality semi-products by using highly reactive slags to remove impurities from the steel.

In the field of circularity, Area 1 addresses the treatment of waste materials and by-products to recover valuable materials for recycling in the processes. By-products, such as slags or dusts, are secondary materials produced during the steel making process.

Finally, a fundamental research project investigates methods to define properties of metallurgical slags from iron and steelmaking.

One project from the nonferrous sector explores the treatment of copper-containing waste materials in terms of product output and sustainability.

• Strengthen sustainability and circularity in metallurgy
• Increasing product output and quality during steel refining and casting
• Closing material loops by returning used or waste materials to production
• Saving energy by enhanced use of primary and secondary raw materials