A significant milestone has been achieved within the MECALO project with the successful testing of spray-agglomerated silicon carbide (SiC) in a pilot-scale silicon production campaign at Elkem’s Sicalo Si pilot facility.
The material, developed and produced by GLATT within MECALO, was evaluated during a campaign carried out in April 2026, where more than 600 kg of spray-agglomerated SiC was introduced into the pilot furnace under realistic operating conditions.
Transforming fines into valuable furnace feedstock
One of the key challenges in silicon production is the efficient use of fine materials, which are often difficult to feed directly into industrial furnaces. MECALO addresses this challenge by converting fine particles into robust agglomerates that can be handled, transported and processed in a similar way to conventional raw materials.
The spray-agglomerated SiC tested during the campaign represents an important example of how innovative material processing can contribute to improved resource efficiency and circularity in metallurgical processes.
Positive performance under industrially relevant conditions
Throughout the pilot campaign, the agglomerates were subjected to all key process steps, including transport, storage, weighing, blending, charging and continuous furnace operation.
The results demonstrated that the material performed well under operational conditions. The agglomerates contributed to a more open and permeable furnace charge, supporting improved gas flow and favourable process conditions inside the furnace. Importantly, no indications were observed that fines generation during heating negatively affected charge permeability.
Previous high-temperature testing had already highlighted the potential of the material to enhance gas permeability within the charge blend, and the pilot campaign provided further confirmation of these promising characteristics.
Towards industrial implementation
The successful qualification of the spray-agglomerated SiC marks an important step towards the industrial deployment of MECALO-developed materials.
Notably, during the campaign, approximately 60% of the reductant input was supplied through the GLATT spray-agglomerated SiC, demonstrating the material’s capability to operate at significant substitution levels.
Based on the positive outcomes achieved, the material has been identified as a suitable candidate for upcoming demonstration campaigns, where even higher substitution rates will be explored.
These results highlight the potential of MECALO innovations to support more sustainable and resource-efficient silicon production processes while contributing to the broader transition towards greener metallurgical industries.