The Next Generation of Iron Production
Turning Waste Fines and Low-Grade Ore Into Steel-Ready Iron
Market Reality for Steel and Mining Producers
Scrap availability is tightening, and scrap quality is increasingly inconsistent. Demand for pig iron and HBI is rising, particularly for EAF steelmaking, while high-quality steel production requires dense, consistent iron units.
At the same time, steelmakers pay to remove fines and waste, then buy replacement iron at market prices. Mining fines and low‑grade ore are sold at significant discounts despite strong iron demand.
Pig Pucks
A New Class of Steel‑Ready Iron
Alterna’s Pig Pucks are a pig-iron-class, steel-ready iron unit designed as a drop-in product for existing steelmaking processes — produced from waste fines and low‑grade materials.
A Standardized, High-Performance Iron Unit
- Near pig iron density
Significantly reducing re-oxidation and improving material stability. - Adjustable carbon content
Optimized for EAF or BOF operations - High metallized iron content
Ideal for high-quality steel production - Low impurities
Reducing downstream processing needs - No binders
Improving steel quality and furnace efficiency - Produced on-site or locally
Eliminating logistics cost and supply risk - IMO shippable
Enabling safe storage and transport
The E-Cyclor
Waste inputs. Efficient processing. Superior iron outputs.
Waste fines and low‑grade materials are processed through Alterna’s E‑Cyclor system, a reactor designed specifically for fines, to produce pig‑iron‑class Pig Pucks.
The E‑Cyclor System
- Processes steel mill fines and mining fines directly
- Requires no pelletizing, sintering, or binders
- Operates at low temperature and low pressure
- Supports flexible energy and reductant inputs
What This Means for Your Operation
1
High uptime and continuous operation
2
Low operating burden and resource use
3
Compact footprint and easy integration
4
Reduced operational risk
Turning Waste
Into Iron Value
Waste fines that typically incur disposal costs can be converted into pig‑iron‑class outputs, producing market-valued iron units on-site or locally.
The result is a shift from material liability to revenue-generating product, with minimal capital required for the customer.
Where the E‑Cyclor System Is Deployed
Steel Mills
- Convert waste fines into steel‑ready Pig Pucks
- Offset scrap, HBI, and imported pig iron
- Eliminate hauling and disposal costs
EAF Operations
- Supplement scrap with dense iron units
- Improve melt stability for high‑quality steels
- Control carbon for optimized furnace performance
Mining Operations
- Upgrade iron ore
- Monetize waste piles
- Increase revenue per tonne with minimal capex
Let’s Start the Conversation
Every operation has a different material profile, cost structure, and set of constraints. A conversation with Alterna is the fastest way to evaluate how the E-Cyclor system and Pig Puck production could integrate into your existing operations and create value from underutilized materials.
