MECALO project: Revolutionizing the production of sustainable critical raw materials in the EU using renewable hydrogen

Innovations and Initiatives Infrastructure and Communication

Posted by NewAdmin on 2025-01-16 13:00:30 |

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The Horizon Europe-funded MECALO project is at the forefront of transforming the production of critical raw materials (CRMs) crucial for European industries.

By utilizing renewable hydrogen and pioneering carbon-looping technologies, MECALO aims to achieve CO2-neutral production of Silicon (Si) and Manganese (Mn), representing a major advancement toward sustainable industrial practices. This initiative supports the European Union’s Critical Raw Materials Act, which seeks to ensure a secure and sustainable supply of CRMs while contributing to climate neutrality goals.

Addressing Europe’s Dependence on Critical Raw Materials:
Silicon and manganese are vital for Europe’s clean technology initiatives and the goal of climate neutrality by 2050. However, Europe is heavily dependent on imports for these materials, with China accounting for 76% of the global silicon supply. Norway is Europe’s leading supplier, providing 33% of silicon, while France and Norway together supply only 5% of ferromanganese. This reliance underscores the need for Europe to enhance its CRM production capabilities to reduce dependency on external sources and strengthen resilience in critical industries.

MECALO's Vision for CO2-Neutral Production:
MECALO’s main objective is to establish a sustainable, CO2-free model for producing silicon and manganese. The project’s innovative approach includes:

• Renewable hydrogen integration: Using hydrogen produced from renewable energy to replace fossil carbon in metallurgical processes, significantly lowering CO2 emissions.
• Carbon-looping technology: Developing processes that minimize fossil fuel use, achieving up to a 95% reduction in CO2 emissions during the production of Si and Mn.

Through these innovations, MECALO plans to replace 9 million tonnes of coal imports annually with 15 billion Nm³ of hydrogen by 2050, cutting 33 million tonnes of CO2 emissions each year. This approach could also serve as a model for decarbonizing other energy-intensive industries across Europe.

Challenges in Decarbonizing Critical Industries:
Many metallurgical processes, such as those used to produce silicon and manganese, rely on carbothermic reduction, which generates CO2 as a by-product. While hydrogen offers a promising alternative, its lower reductant efficiency presents challenges for certain metals. MECALO’s innovative approach overcomes these challenges, paving the way for sustainable CRM production without requiring the development of entirely new production technologies.

A Collaborative Effort for a Sustainable Future:
Funded by the Horizon Europe Framework Programme (2021-2027), the MECALO project brings together 15 partners from eight EU member states and associated countries. The consortium includes:

• Four research centres
• Four small and medium-sized enterprises (SMEs)
• Five industrial partners
• Two additional entities

Coordinated by SINTEF, the project spans the entire CRM value chain, ensuring a comprehensive approach to achieving its ambitious goals. By combining the expertise of research institutions and industry leaders, MECALO is set to deliver transformative outcomes that will bolster Europe’s global position in the CRM market.

The MECALO project officially began with a meeting in Trondheim, Norway, on October 28-29, 2024. During this event, project partners outlined their roles and laid the foundation for the 42-month initiative. They also visited SINTEF’s cutting-edge laboratories to explore the technologies central to achieving MECALO’s objectives.

A Path to Sustainable CRM Production:
The MECALO project reflects the EU’s commitment to fostering sustainable innovation and securing a resilient future for critical industries. By prioritizing CO2-free production and leveraging renewable hydrogen, MECALO tackles pressing challenges in CRM production while aligning with Europe’s climate neutrality targets. Through collaboration and groundbreaking research, the project not only reduces environmental impact but also strengthens Europe’s industrial independence.

As MECALO progresses, it lays the groundwork for a cleaner, more sustainable future in the production of critical raw materials, ensuring Europe’s continued competitiveness and environmental responsibility on the global stage.

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