From lab scale to industrial application
Large volumes of grinding sludge are generated every year during the grinding and machining of steel. Rich in iron, this residual material is difficult to recycle and is therefore often incinerated or sent to landfill. Swedish company Anferra has developed a process that can instead recover valuable materials from the sludge and turn them into new raw materials. Together with RISE, the company is now working to take the technology from laboratory scale towards industrial application.
Anferra’s process can recover iron chloride for water treatment, hydrogen, and a solid fraction containing alloying metals. This makes it possible to retain materials that would otherwise be lost and return them to industrial value chains as new raw materials. It is a practical example of industrial symbiosis.
Anferra began working with RISE in 2024 to further develop the technology. Since then, the collaboration has expanded to include several areas of expertise.
– When we started working with RISE, we had already shown that the chemistry worked at lab scale. The next challenge was to turn that into a robust process that could be scaled up. RISE has played an important role, both through its technical expertise and by giving us access to equipment and facilities where we can test the process at a larger scale, says Ebba Adolfsson, co-founder and CEO of Anferra.
The collaboration has also resulted in several development projects, with funding from organisations including Vinnova and the Swedish Energy Agency.
– RISE has helped us move beyond isolated laboratory experiments and towards a more industrial approach to development, including scale-up, filtration, material selection and process analysis. They have also supported us in securing public funding, both by identifying relevant calls and by taking part in projects with the expertise and infrastructure needed to deliver them, says Ebba Adolfsson.
From laboratory chemistry to a pilot plant
David Blomberg Saitton, Business Developer at RISE, is one of the people working closely with Anferra on the technical development. The work has gradually shifted from studying individual process steps to preparing a containerised pilot plant at RISE Processum in Örnsköldsvik. Moving beyond the laboratory also brings new requirements related to occupational health and safety.
– We have developed a detailed understanding of the process and tested several of its individual steps. We have also prepared technical documentation for the construction of the pilot-scale process and worked on the basis for occupational safety assessments and ATEX classification, says David Blomberg Saitton.
ATEX classification is used to assess the risk of explosions in environments where flammable gases, vapours or dust may be present. It affects the requirements placed on both equipment and the working environment.
The project is now moving into its next phase, with construction of the pilot plant due to begin. During pilot operation, data will be collected and analysed to deepen understanding of the process and support further development and commercialisation.
What will matter most once the pilot is up and running?
– Our main priority is to demonstrate that the process remains stable and reproducible at pilot scale. We also want to verify a high level of iron recovery, ensure that the iron chloride meets the required quality, and gather reliable data on factors such as cycle times, energy use and water consumption. That will provide the foundation for the next step: an industrial demonstration plant, says Ebba Adolfsson.
In just over two years, the work has progressed from small-scale experiments to preparations for a physical pilot plant. The next challenge will be to see how the technology performs as volumes increase and operating conditions become more representative of an industrial setting. The pilot results will provide Anferra with the data needed to move towards a demonstration plant and, ultimately, industrial deployment.
