In the first of a series of interviews, Sk.ru discovers what makes innovators tick in the less glamorous but no less critical field of metallurgy.
Recycling steelmaking slag the EcoSlag way. Photo: Amir Shakurov
EcoSlag is a Moscow-based firm that produces, as its name suggests, environmentally friendly crushed aggregate out of steelmaking slag. Doubts about the marketability of the product evaporate upon the realization that the product is one of the most commonly used construction materials in the world.
EcoSlag’s Amir Shakurov sat down with sk.ru on the sidelines of an industry event held recently at the Skolkovo Hypercube named “An Innovation Lift in Metallurgy,” presenting startup technology to big market players.
According to Pavel Morozov of Skolkovo’s Energy-Efficient Cluster, EcoSlag is a model startup insofar as its “science and business competencies are brought together organically.”
“At the same time, the startup came to us complete with a big client in OMC (United Metallurg Company). These kinds of stories are always more intriguing for us because they have already proven the existence of demand for their innovation," he said.
Sk.ru: Can you explain your innovation?
Amir Shakurov: “The innovation is specifically about recycling molten steelmaking slag by controlled cooling and solidification in a crystallization drum. This could bring about wholesale changes in the approach of steelworkers to the processes of utilizing the waste they produce, because with this technology it’s possible to get a ready-made building material in the form of crushed aggregate in just five minutes. This is the most widely used material used in construction, so it is always in great demand.”
What's wrong with existing methods?
“We need to get rid of the existing, tired and ineffectual methods of recycling slag with long-term storing in slag heaps, which exacerbate the ecological conditions in towns and regions, in favor of a more ecologically friendly and energy-efficient way to process molten slag into a quality product that meets the standards of the construction industry.
It’s also necessary to change the outlook of not only the steelworkers themselves, but of the environmental and legal organs of the Russian Federation, because today, according to the Federal Law No. 89 “On consumer and industrial waste,” slag is assigned a 4th-class hazard level, while in the EU, the term “slag” is understood simply as a byproduct of iron production.”
The EcoSlag process: Molten slag at 1,600 degrees Celsius is poured into the crystalizer drum for processing. The solidified slag then exits the drum at 1,000 degrees Celcius and undergoes extra cooling on the conveyer belt, after which the end product falls to 100-200 degrees Celcius.This multistage cooling process is what makes it environmentally friendly. Photo: Amir Shakurov
What ambitions do you have for EcoSlag?
“We believe that molten steelmaking slag is a byproduct of steelmaking, which, like with liquid steel, requires special methods of solidifying with the aim of making a quality product, but at the same time that has a more complex chemical and mineral makeup, so unlike the processes for crystalizing liquid steel, coming up with a process to solidify slag is quite a difficult task.
The solution we’re offering is angling for inclusion in a list of the Best Available Technology, and I think that this will happen in the near future. Our significant scientific-technological groundwork in the sphere of molten slag and the thermodynamics of its solidification helps to find a multi-layered solution for every steel plant taking into account its geographical location, the furnace it uses, the branded gauge of founded steel and possible customers for slag products.
Our aim is to equip all existing steel plants with the industrial technology and machinery to processing of liquid slag without waste-dumping or storage. At the same time, we offer a maximally simple, automated and safe production process for quality building materials via solidification of molten mass in a crystallization drum.
We are in the metal waste utilization services market. We plan to enter the market, and claim a firm foothold there with a novel approach to solving complex tasks in metallurgy and construction.”
The end product, with a pen included for scale. Photo: Amir Shakurov
How will the average person on the street be affected by the innovation?
“The person on the street, of course, won’t directly feel the effect, but in changing the process of utilizing waste, in changing the life cycle of products, we are first and foremost improving the environment in which this person lives. Secondly, we are raising the quality and reliability of the construction materials from which roads and buildings are built – the things that people use on an everyday basis. Thirdly, we are conserving resources for the future of humanity. For all these reasons I think the world should care about a solution to this problem.”
What difficulties have you experienced in the innovation process?
“Steel slag is a multicomponent system that in a liquid state is an ionic solution, but in a solid structure acquires mineralogical phases corresponding to the original chemical composition of the melt and the conditions of solidification. In some processes, a fine dust forms that is a source of environmental pollution. From the theory we know that this can be prevented by thermal stabilization, but the theory does not provide specific values for the high-speed cooling required to achieve this. One of the most difficult challenges was to determine the optimal values for the cooling rate at which the slag is not subject to further degradation. We managed to solve this problem theoretically, and then conducted pilot testing in the lab that confirmed we achieved the cooling rate of 40-55 degrees Celsius per second. This not only stabilized the rubble from the ladle slag, but it produced a quality additive for steel instead of burnt lime, which brings a substantial economic benefit to the enterprise.”
Amir Shakurov.
What was the most exciting moment in the innovation phase?
“The most amusing moment was the first hot test of the technology and the equipment, which, at the most crucial moment, seconds before the discharge of the 1,600 degree Celsius molten slag, suddenly stopped and ceased turning. If liquid slag continues to be poured into the machine without it rotating, it can freeze up the system, which will then require major repair. This would hold up the testing for a long, long time and, most worryingly, destroy the faith of the steelworkers in the efficiency of our machine and the technology as a whole. At that moment my heart literally skipped a beat. There’s no way in this world that I expected that to happen. It turned out that the automated system switched off the engine. The problem was solved in a few seconds and the host testing was a success, but I’ll remember this moment for the rest of my life.”
Is there any difference in the way the technology might be adopted in other markets abroad?
“This problem is relevant not only for Russia, but for the entire world, because slag forms at all steel plants regardless of their geographical location.”
What made you an innovator?
“In 2012, a group of scientists from the Federal State Unitary Enterprise I.P. Bardin Central Research Institute for Ferrous Metallurgy, together with two firms - OMC Steel and Energoterm System – fulfilled a state order of the Ministry of Education and Science on the development of technology and equipment for processing liquid waste. But after its completion, we never commercialized the innovation.
So in 2014 we registered the company EcoSlag Recycling to deal specifically with the implementation in metallurgy of broad solutions for recycling liquid slag and producing a quality product for the construction industry.
At the end of 2014, Skolkovo announced the opening of a steel sector. We applied for participant status, and this month we became a resident of the Skolkovo Foundation.
Being a startup in such a large industry as steelmaking isn’t easy, but I think that in today's economy we can offer competitive solutions and enter the market. We hope to soon find strategic partners and co-investors who can provide us not only the financial support we need, but also to increase our chances of gaining market share.
I think that if a person or a team has the desire to work and achieve its goals, then you will find nothing is impossible. Our team consists of highly motivated enthusiasts who have already more than once proved their effectiveness. I believe that we will achieve a lot together.”