The overall aim of Real-Time-Mining is to develop a real-time framework to decrease environmental impact and increase resource efficiency in the European raw material extraction industry. The key concept of the proposed research promotes the change in paradigm from discontinuous intermittent process monitoring to a continuous process and quality management system in highly selective mining operations. Real-Time Mining will develop a real-time process-feedback control loop linking online data acquired during extraction at the mining face rapidly with an sequentially up-datable resource model associated with real-time optimization of long-term planning, short-term sequencing and production control decisions. The project will include research and demonstration activities integrating automated sensor based material characterization, online machine performance measurements, underground navigation and positioning, underground mining system simulation and optimization of planning decisions, state-of-the art updating techniques for resource/reserve models. The impact of the project is expected on the environment through a reduction in CO2-emissions, increased energy efficiency and production of zero waste by maximizing process efficiency and resource utilization. Currently economically marginal deposits or difficult to access deposits will be become industrial viable. This will result in a sustainable increase in the competitiveness of the European raw material extraction through a reduced dependency on raw materials from non-EU sources.

In the European process industries large amounts of energy and resources are used to produce millions of tonnes of materials each year. Especially in metal making processes, metallic scraps from end of life goods are recycled and used as secondary raw materials in the processes. Usage of scrap is both ecologically and commercially beneficial, since it reduces the depletion of natural resources like virgin ores and avoids landfills with waste material. Today even more important is that the energy consumption and the CO2 emissions of the reduction processes of metal ores can be reduced or even totally avoided when using recycled materials as feedstock. However, the metal production facilities are facing an increasing variability in material and energy feedstock. To cope with this challenge, existing metal production plants need to be retrofitted with appropriate sensors for scrap analysis and furnace operation, to cope with the varying conditions of the feedstock regarding materials and energy. Furthermore, the selection of the optimal feedstock in terms of material and energy efficiency has to be improved by application of appropriate process control and decision support tools. Also solid scrap preheating systems can increase the energy efficiency of the melting processes. To monitor and control the process behaviour in an optimal way, model-based software tools have to be developed and applied. The main objective of the REVaMP project is to develop, adapt and apply novel retrofitting technologies to cope with the increasing variability and to ensure an efficient use of the feedstock in terms of materials and energy. This will be exemplarily demonstrated within three different use cases from the metal making industry. Due to the industrial relevance, the use cases were chosen from electric and oxygen steelmaking, aluminium refining and lead recycling. The performance of the different technologies will be assessed, and the benefits will be quantified.

Specific raw materials become increasingly important to manufacture high level industrial products. Especially electronic equipment contains precious metals and a series of strategic raw materials. To date the material specific recycling is focused on mass stream concepts such as shredder processes and metallurgy to extract the high-value metallic constituents, i.e. copper, gold, silver. However, a series of critical elements cannot be recovered efficiently or is even lost in dust or residual fractions. The goal of ADIR is to demonstrate the feasibility of a key technology for next generation urban mining. An automated disassembly of electronic equipment will be worked out to separate and recover valuable materials. The concept is based on image processing, robotic handling, pulsed power technology, 3D laser measurement, real-time laser material identification (to detect materials), laser processing (to access components, to selectively unsolder these; to cut off parts of a printed circuit board), and automatic separation into different sorting fractions. A machine concept will be worked out being capable to selectively disassemble printed circuit boards and mobile phones with short cycle times to gain sorting fractions containing high amounts of valuable materials. Examples are those materials with high economic importance and significant supply risk such as tantalum, rare earth elements, germanium, cobalt, palladium, gallium and tungsten. A demonstrator will be developed and evaluated in field tests at a recycling company. The obtained sorting fractions will be studied with respect to their further processing and recovery potential for raw materials. Refining companies will define requirements and test the processing of sorting fractions with specific material enrichments. An advisory board will be established incorporating three telecommunication enterprises.

Circular economy will be one of the main drivers to significantly reduce CO2 in the refractory industry, as the energy-intensive primary raw material production has by far the highest impact on the product's carbon footprint. So far, automated sorting solutions could not consolidate in refractory recycling because the development is extremely complex and requires combination of different sensor technologies. The ReSoURCE project will innovate the full process chain of refractory recycling with an AI-supported multi sensor sorting equipment as its core technology. Combining laser-induced breakdown spectroscopy, hyper spectral imaging with optimized pre-processing and automated ejection will lay the foundation to set a new state of the art for refractory sorting starting of particle sizes down to below 1 mm. The continuous monitoring of the economic and ecologic benefits by techno-economic and life cycle assessment will ensure the green and digital transformation of the refractory recycling value chain. Reaching the ReSoURCE objectives will lead to massive annual CO2 reductions (up to 800 kilo tonnes) and energy savings (up to 760 GWh) in the European Union. Naturally usage of secondary raw materials is related to a reduction of extractive processing in the raw material mines (reduction of 1 million ton). Simultaneously, it will give access to currently unexploited raw material sources within the European, therewith strengthening EUs resilience by fostering refractory material autarky, particularly as some of the refractory base materials are listed on the EU's critical raw material list (bauxite, graphite). The two demonstrators to be build in course of the ReSoURCE project, will ensure the straight-forward exploitation and implementation of this revolutionising recycling process chain in the European industry.