14 Jan Opigeo develops the “Stillmetal” process for the production in Europe of ferroalloys and materials for the circular economy

Ferroalloys are a vital raw material for the steel industry, but they require highly energy-intensive production processes. In fact, much of the ferroalloy production is located in areas of the world where access to sources and regulation of supplies are more favorable and therefore suffer a less preponderant impact than European countries, with effects on competition. However, in 2024 the European Union expressed its opinion on the decision to extend the safeguard measures to ferroalloys as well.
The aim is to protect European producers and shield them from low-cost imports, especially from a China that is also competitive in this sector.

OPIGEO already started an experimental activity called “STILLMETAL” in 2022 to demonstrate the validity of a ferroalloy production process for European steel industries, valorizing their slag from melting and today in 2025 it has a prototype plant started up at Acciaierie Venete.

The plant is able to process the ladle slag in the molten state through the aluminothermic reduction of its silica content. The final products obtained through the pyrometallurgical process are an Fe-Si ferroalloy and a residual slag. The composition of the residual slag is designed to maximize its value. All the energy required is provided by the exothermic aluminothermic reaction.

The solution, therefore, presents all the characteristics of a low environmental impact process that guarantees, in a circular economy perspective, the reuse of waste and its conversion into high value-added materials.

Despite its complex composition, ladle slag retains significant potential for valuable elements and energy, making its valorization essential for sustainable resource management.

STILLMETAL (acronym for “SusTaInable sLag process to obtain a valuabLe METAL”) is a collaborative project between Opigeo, Italghisa, Zerocento and the European Institute of Innovation and Technology (EIT) RawMaterials.

The initiative focuses on slag valorization, aiming to transform steelmaking by-products into valuable materials.

Thermodynamic modelling enables precise control over reaction pathways and product composition, optimizing the process for industrial applications.

The work demonstrates the potential of ladle slag to be converted into useful resources. The proposed approach reduces environmental impact while supporting circular economy principles, thus contributing to the sustainability goals of the steel industry.

1st Prototype plant installed in Acciaierie Venete (PD).