Process-adapted material characterization for ferrous metal recovery from residues arising in scrap cutting operations

The transformation of Europe’s steel industry represents a flagship initiative of industrial decarbonization. In pursuit of a 55 % by mass reduction in process-related CO₂ emissions by 2030 relative to 1990 levels, the sector is progressively transitioning towards secondary production pathways, with a particular emphasis on the establishment of electric arc furnace technology. This technological transition entails a fundamental change in the industry’s raw material base, as iron and steel scraps increasingly substitute for primary ores. Projections indicate a doubling of scrap demand over the coming decade.

This study explores the largely untapped potential of so-called shear sands − predominantly fine-grained residues generated during the cutting and downsizing of scrap using hydraulic shears, comprising for approximately 2 % by mass of the processed material stream. These residues are subjected to comprehensive mechanical processing and characterization, followed by a subsequent separation into distinct fractions. The primary objective is the mechanical recovery of ferrous scrap to elucidate its resource potential for integration into secondary production routes.

The findings demonstrate the feasibility of directly recovering a ferrous scrap fraction corresponding to approximately 27 % by mass of the original material. Additional fractions are likewise obtained and systematically characterized. Coarse fractions (>1 mm) are examined through visual and gravimetric methods, while fine fractions (<1 mm) are subjected to chemical analysis to identify patterns of elemental enrichment and depletion.

This investigation confirms that the recovery of shear sands can make a meaningful contribution to securing raw material for the transformation of Europe’s steel industry.