FOURNOS

In the FOURNOS project, we're addressing practical challenges in waste management by turning byproducts like fly ash into useful materials like basalt.

WHY?

Fly-Ash

Fly ash, a byproduct of waste incineration, poses a significant environmental and logistical challenge. In the Netherlands, waste-to-energy plants generate millions of tons of fly ash annually (PBL), which requires special handling and disposal. It contains toxic substances such as lead, arsenic, and mercury, making it harmful to the environment and us. These substances can lead to respiratory and cardiovascular issues, especially due to the fine particulate nature of fly ash which penetrates the respiratory system.

Basalt

The basalt market in Europe faces significant challenges due to high demand and limited supply, as basalt rock is scarce and difficult to extract. The production process is energy-intensive and environmentally damaging, contributing to significant carbon emissions (Technavio) (Mordor Intel) (IMARC). Although basalt is a sustainable alternative to materials like steel and fiberglass, its current production methods remain environmentally unfriendly (MarketsandMarkets) (Research & Markets).

Dumped Waste

In the Netherlands, residual waste streams like automotive shredder residue (ASR) and other energy-rich waste present significant challenges. ASR, a byproduct of car recycling, contains mixed materials that are difficult to process and often end up in landfills. This material includes plastics and metals that are energy-intensive to recycle. Additionally, certain energy-rich waste streams have too high an energy content for conventional incinerators, posing logistical and environmental difficulties (ARN) (Fortune Business Insights).

aggregate-preparation-plant-extraction-p

HOW?

MILESTONES

2018: DELFZIJL (IVER)

The project originated in Delfzijl, where CORE got involved into the restart of a factory, Ensartech. Within this factory the technology, also known as elementary retraction, could be implemented. Unfortunately during the research and engineering we had to conclude that the size of the factory and level of the gas scrubber present was insufficient to make a good business case.

2020: FOURNOS

FOURNOS was build to further validate and test the system that we started with in Delfzijl. The oven can go to 1600 degrees Celsius and allows us to test different waste mixtures. This is crucial, as we not only want to get rid of the fly-ash, but also make sure that the produced basalt is safe to use and doesn't leach.

BvOF 2021_1207_ACZ - nieuwe oven Team Core-1.jpg

2022: MAGMA

With Magma we wanted to take the basalt production to the next level. Whereas the older systems and projects focused merely on creating basalt for for instance ballast production, Magma allowed us to investigate the option of casting it into different shapes and sizes. For instance to test if we can create garden tiles with it, allowing for a better business case and higher end market.

2024: JTF PROJECT

The most recent step in the FOURNOS story is the start of a JTF (Just Transition Fund) project. We focus on re-engineering the factory from Delfzijl, with the intent to put it in the Moerdijk Harbour. The project focusses on testing out the individual process steps on pilot level and re-engineer the total installation.

DELFZIJL PROJECT

PARTNERS OF THE PROJECT

"GOS assisted CORE in the oven design for the factories and was the technical supplier who build FOURNOS and MAGMA"

Global Oven Systems, Son

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