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Recycling of Advanced High Strength Steel

The Dark Slayers AKA Team 7Ayan Bekzhanov - [email protected]

Abhiram Yalamanchili – [email protected] McCabe – [email protected] Woistman – [email protected]

mailto:[email protected]




Course: EDSGN 100, Section 10

Submitted to: Mr. Catanach on February 24th, 201

Table of Contents

Cover Page-------------------------------------- 1Table of Contents------------------------------ 2Executive Summary--------------------------- 3Introduction------------------------------------- 3Mission Statement----------------------------- 3Clarification of problem---------------------- 3Customer Requirements--------------------- 3Customer Needs Metrics Matrix----------- 4Literary Research------------------------------ 6Patent Research-------------------------------- 6Global Marketplace---------------------------- 7Concept Generation--------------------------- 7Concept Selection -------------------------- 8-9Calculations------------------------------------- 10Poster Design----------------------------------- 11BOF Functional Diagram---------------------- 12Final Design ------------------------------------- 13Conclusion --------------------------------------- 14References -------------------------------------- 15

Executive Summary

Our team’s goal was to design an efficient and viable method to separate and recycle different types of steel that ArcelorMittal recycles. Our endeavor was successful in the fact that our team

came up with many designs and theories that could be implemented in the real world.

Introduction

ArcelorMittal is the world’s largest steel producer. They annually produce 100 million tons of steel, and employ over 260,000 employees across 60 counties. In total, they produce around

10% of the entire world’s steel.

Mission Statement

ArcelorMittal requested us to design a process that will separate and recycle advanced high strength steel from the automotive market into a basic oxygen furnace. We were required to not adversely affect the steel quality, while also utilizing the alloys in the recycled steel to reduce the use and cost of new alloying elements. We were also made sure sure to not cause “off-chemistry heat”, which would render a batch unusable.

Clarification of Problem

ArcelorMittal is requesting a process that will recycle Advanced High Strength Steel from the automotive market into a basic oxygen furnace. We are required to not adversely affect the steel quality, while also utilizing the alloys in the recycled steel to reduce the use and cost of new alloying elements. We must also make sure to not cause “off-chemistry heat”, which will render a batch unusable.

Customer Requirements

In short, the customer requires a cost effective and environmentally friendly method of recycling steel. In order to meet our customer’s needs, we compiled the customer’s needs into the following categories:

Meet all SAE requirements Produce 125 million tons of steel per year Waste a maximum of 1.5 million tons of steel per year Produce 40 to 50 million tons of recycled steel per year Decrease production costs by 3%, to decrease consumer cost by 2% Remove 15 ounces of unwanted elements per pound of alloy A maximum of 1 product per 100 products has off-chemistry heat

Customer Needs Metrics Matrix

After identifying our customer’s needs, we grouped them into a needs metrics matrix as shown below.

Needs Metrics Matrix1 2 3 4 5 6 7

M

etric

Mee

ts a

ll SA

E re

quire

men

ts

Prod

uce

125

mill

ion

tonn

es o

f ste

el p

er y

ear

Max

imum

was

ted

stee

l is 1

.5 m

illio

n to

nes

Prod

uce

40 to

50

mill

ion

tonn

es o

f rec

ycle

d st

eel

per y

ear

Decr

ease

pro

ducti

on c

ost b

y 3%

, to

decr

ease

co

nsum

er p

rice

by 2

%Re

mov

e 15

oun

ces o

f unw

ante

d el

emen

ts p

er

A m

axim

um o

f 1 p

rodu

ct p

er 1

00 p

rodu

cts

ha

s off-

chem

istry

hea

t

Need2 Design a process to effectively recycle Advanced High

Strength (high alloy) Steel from the automotive market back into the basic oxygen furnace (BOF) steel production cycle.

3 Keep the steel quality the same throughout the process x5 Be the leader in all major global steel markets x x x x15 Convert the linear cradle-to-grave process into a cyclical

“cradle-to-grave” process17 Lower the amount of steel consumed. x x19 Recycle as much steel as possible. x x20 Factory processes 2 types of materials that need to be

processed.21 Factory processes the alloys that are part of the scrap stream. x22 Factory processes unwanted alloys in steel producing. x26 Pieces of metal with different composition have different

properties.x

29 Steel is free from cause off-chemistry. x x30 The proposed process allows for a cheaper production of

steel.x x

34 A system must be implemented to prevent off-chemistry heat. x x35 Another system must be implemented to separate high grade

steel from low grade steel.37 Increase alloy contents of steel if cost reduction is required. x x

38 Create a model to utilize the scrap during scrap charge for heats requiring alloy additions.

x

39 Use chemistries for a heat of AHSS and line pipe (see additional information) to demonstrate the model.

40 Include the weight of pure alloy that will be needed in addition to what is coming from scrap.

x x

45 Submit the technical report on the web48 Create CAD drawings49 Create systems diagrams50 Create a prototype of the design51 Create a list of the design concepts

Literary Research

Steel Recycling Institute1

This website has a lot of great information on how the recycling process works, and explains what objects have recyclable steel in them. It also shows the different rates that recycled steel sells for.

Facts About Steel Recycling2

This website shows many helpful facts about recycling steel and how recycling works. It also details some of the products created with recycled steel.

Recycling Process3

This website has an animated presentation detailing how scrap steel is received, shredded, separated, and then recycled. It helped us understand the different amount of steps and coordination that goes into steel recycling.

Eddy Current Separator4

This website explains how eddy current separators work and their importance in the separation of metals for recycling. It allowed us to understand the necessity to incorporate one into our process.

Patent Search

Google Patents5 was a great resource to search for patents involving methods of steel recycling including material separation/sorting, and melting. We were careful to avoid all forms of patent infringement in our design.

Global Marketplace

Recycling steel is something that is being used in all places throughout the world. There is a Bureau of International Recycling that lays out the different ways in being able to handle and recycle steel. For example, they provide various different techniques pertaining to how steel can be recycled. Media separation is one technique that is used, where a shredder is used to separate iron metal from the other materials within the steel. To separate these other materials even further, methods such as liquid floating systems and electrical currents are used to separate the other materials within the steel. This recycled steel can be used in various different applications, such as construction, transportation, and households. The Bureau of International Recycling is made up of various different board members of different ethnic backgrounds. The chairman is from the United Kingdom, while other members are from India, China, France, USA, Sweden, Russia, Jordan, and Germany. Therefore, this all shows that recycling steel is an important part of not just the United States, but the world as a whole.

Concept Generation

Our professor gave us some topics to brainstorm about pertaining to recycling steel and what other factors are included with the idea of recycled steel. All four of us brainstormed on our own about each topic and came up with ideas that could solve the problems that were given to us. The nine questions that were posed to us were: how to separate the components of the steel, how we could make our recycling environmentally friendly, how to better identify steel from the supplier, how to get more cars to be recycled, how to make cars easier to disassemble, how to better separate car parts, how to better sort steel in the steel recycling plants, and the advantages of using a shredder for recycling. After we individually brainstormed our ideas, we came together and compared and contrasted our ideas that we came up with. From there, we took our best options and ran them through a concept selection process in order to find the best ideas for each problem.

Concept Selection

Separation of materialsSelection Criteria

Magnetic seperation

Chemical Reactions

Centrifuge (Densities) Boiling Point

Effectiveness 0 0 + 0Price 0 - 0 -Maintainence

0 - 0 -

Time 0 - 0 0Advance? Yes Yes Yes Yes

Green Energy SourcesSelection Criteria

Renewable Energy BOF into "standby" mode

Environmentally Friendly Machinery

Effectiveness 0 0 0Price 0 + -Maintainence 0 0 -Time 0 0 0Advance? Yes Yes Yes

Supplier Identifying SteelSelection Criteria

Communicating with Supplier

Incentivise the Supplier

Effectiveness 0 +Price 0 -Maintainence 0 0Time 0 0Advance? No Yes

How to Get Cars to RecycleSelection Criteria

Asking Car Companies Give Away Scrap Cars

Rebate for Consumer

Advertisements/Events for Car Recycling

Effectiveness 0 + +Price 0 - -Maintainence 0 0 0Time 0 + +Advance? Yes Yes Yes

Making Car Easier To DisassembleSelection Criteria

Easily Removable Parts

Less Small Components

Effectiveness 0 0Price 0 0Maintenance 0 0Time 0 0Advance? Yes Yes

Separating Car PartsSelection Criteria

Centrifuge (Densities)

Hand Sort

Effectiveness 0 0Price 0 0Maintenance 0 +Time 0 -Advance? Yes Yes

How Steel Recycling Plants SortSelection Criteria

Communicating with Suppliers

Magnetic separation

Chemical Reactions Centrifuge (Densities)

Boiling Point

Effectiveness

0 0 0 + 0

Price + 0 - 0 -Maintainence

+ 0 - 0 -

Time - 0 - 0 0Advance? No Yes Yes Yes Yes

Shredder ApplicationsSelection Criteria

Easier to Handle Easier to Transport

Easier to Sort

Effectiveness 0 0 0Price 0 0 0Maintainence 0 0 0Time 0 0 0Advance? Yes Yes Yes

Calculations

As a part of our project, we were instructed to perform calculations for how much AHSS (or high alloyed steel) can be added to create Line Pipe and LCAK (Low Carbon Aluminum Killed) steel without causing off-chemistry. The calculations that we performed are shown below.

Chemical Analysis of each type of steelC Mn Cr Al Cb 440,000 lb heat

AHSS 0.0017 0.015 0.002 0.0012 0.0002 0.15 scrap percentage chargedLCAK 0.0004 0.002 0.001 0.0004 0.00004 66000 scrap weight

Line Pipe 0.0005 0.015 0.001 0.0004 0.00003

Mass Balance Equationslbs each element allowed in heat of LCAK

and Line Pipe LCAK 176 880 440 176 17.6

Line Pipe 220 6600 440 176 13.2Percentage added due to oxidation 300% 200%

lbs each element after blown LCAK 176 2640 880 176 17.6

Line Pipe 220 19800 880 176 13.2

lbs element contained in scrap (if 100%)AHSS 112.2 990 132 79.2 13.2

Percentage added due to oxidation 300% 200%

Adjusted element in scrap according to how much is oxidzed

AHSS 112.2 2970 264 79.2 13.2

Percent added from AHSS to not cause off chemistry in LCAK production 88.9% 88.9%

lbs of different elements in AHSS added to make LCAK without causing off chemistry N/A 2640 235 N/A N/A

lbs of AHSS total added to make LCAK 58667

Percent added from AHSS to not cause off chemsitry in LCAK production N/A 100% 100% N/A N/A

lbs of different elements in AHSS to make Line Pipe without causing off chemistry N/A 2970 264 N/A N/A

lbs of AHSS total added to make Line Pipe 66000

Poster Design

As part of our project, we were instructed to design a poster. It is below:

BOF Functional Diagram

For our project, we were instructed to create a function BOF diagram. It is below:

Final Design

Conclusion

Lance

Input/output piping

Input/output piping

46 feet tall12 foot radius

From this project, we gained a better understanding of the importance of steel recycling and what goes on in a basic oxygen furnace. ArcelorMittal gave us a task that would typical be a task for people who are actually employed by ArcelorMittal, which is pretty interesting considering we are undergraduate students. This project gave us the opportunity to be faced with an actual problem that is happening in our world today. Before this project, we had very little knowledge on the importance of recycling steel, and how we can recycle steel. From this project, we have gained a better understanding of this concept, which can only help us later on in life. Additionally, we were able to gain a better knowledge on how a basic oxygen furnace works and how we can better improve the sustainability of the basic oxygen furnace. An opportunity like the one ArcelorMittal gave to us does not come up every day, so we were grateful that we could help them on their project.

References

1. http://www.recycle-steel.org/ 2. http://earth911.com/recycling/metal/steel/facts-about-steel-recycling/ 3. http://www.schnitzersteel.com/metals_recycling_process.aspx 4. http://www.cogelme.com/eng/e-eddy-current-metal-separator.htm

http://www.cogelme.com/eng/e-eddy-current-metal-separator.htm

http://www.schnitzersteel.com/metals_recycling_process.aspx

http://earth911.com/recycling/metal/steel/facts-about-steel-recycling/

http://www.recycle-steel.org/

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