south african metal casting conference … · sg iron foundries need reliable and consistent...
TRANSCRIPT
SOUTH AFRICAN
METAL CASTING CONFERENCE
MARCH 2017
JAMES DURRANS & SONS
Company Summary
Established 1863
100% family owned (6th generation)
205 employees
2016: Revenue 60 Million UK£
• Carbon Raisers, Carbon for Friction Materials
• Refractory Coatings, Exothermic Sleeves, Lubricants
• Production: 8 Sites
• Sales: in more than 40 countries
• Markets: foundry/automotive, steel and chemical industries
Brancepeth Scunthorpe
PenistoneBilston
UK Manufacturing Sites
International Locations
Low S and N
Carbon Raiser
Procarb SGElectrode-
Graphite
3D Microscopic Images
Raw Material:
Green Waxy Coke produced exclusively by…….
……. one of the world‘s largest energy groups, specialist in liquefying of coal……..through the
Fischer-Tropsch-Synthisis
……..calcination of green waxy coke by James Durrans -> Procarb SG
The cooperation with Sasol enables James Durrans to offer a completely new range of Carbon Raiser products.
THE CURRENT VALUE CHAINOF PROCARB SG
Sasol – James Durrans – SG Iron Foundries
Procarb SG – Origin of Raw Material
The source of Procarb SG is the Fischer–Tropsch–Process, various chemical reactions that converts coal or natural gas via a mixture of Carbon onoxide and hydrogen into liquid hydrocarbons.
Liquid Hydrocarbons are
distilled into various HC
fractions, one of which is waxy
oil. This is the origin of the
Green Waxy Coke.
Green Waxy Coke is then
calcined in a Shaft Kiln to
remove the volatile matter,
resulting in the product named
Procarb SG.
Sasolburg
Tentative Shaft Calcination Plant for Procarb SG
Environmental Permit pending, expected April 2017
Current Value Chain of Procarb SG
2. Calcination in the
shaft furnace
Sasol
5. Global Sales
NEW Value Chain of Procarb SG, planned for 2018
2. Global Sales
1. Building of a shaft calcining facility
(including screening and packaging) in
Sasolburg
SG Iron foundries need reliable and consistent sources of low sulphur recarburiser!
• To date the only real choice for a highly soluble and low sulphur Carbon Raiser were the energy
intensive Graphitised Petroleum Cokes (GPC)
Procarb SG provides a step change in technology as:
• It is a highly soluble and ultra low sulphur Carbon
• Lower environmental impact vs. the GPC alternatives.
WHY?
• Typical GPC products are made from crude oils with sulphur contents of 4%
• Procarb SG is manufactured from the already low in sulphur ‘waxy coke’ material
• Unlike GPC, there is no need to electro-thermally heat waxy coke > 2.000°C to vaporise the
entrapped sulphur
• Avoiding electro-thermal heating reduces the overall energy consumption by around 80%
(typically 0.5 vs 2.5 MWh/t)
This dramatic improvement reduces the foundries environmental foot print whilst enabling them to still
utilise the highly soluble and ultra low sulphur materials critical in the production of SG Iron.
Procarb SG – environmental benefits
Procarb SG – environmental benefits
Production of Procarb SG:
• 95% less CO2 emissions compared to GPC production
• No emissions of SO2
• No electrical heating of raw material required
Another step forward on the way to a „green(er)“ foundry!
Carbon Recovery:
Trim Addition of pure Electrode Graphite vs. Procarb SG
% C-content
before C trim
addition
% C-content
after C trim addition
Comparison of Carbon recovery:
Trim Additions of Electrode Graphite vs Procarb SG
Thank you for your attention!
Any questions?