steel mill services for integrated steelmakers
DESCRIPTION
Slab transport and logistics. Slag recycling and scrap recovery, dust and sludge processing and metal recovery. Scarfing, slab slitting and cutting.TRANSCRIPT
Engineered Solutions for Integrated Steelmakers
© 2014 Harsco Corporation, All Rights Reserved.
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Harsco is a global industrial services company
� Listed on NYSE, S&P 400 index
� Harsco is a global provider of industrial services and engineered products
� Market leading positions in Metals & Minerals, Rail and Industrial products
� Annual sales of more than $3bn covering 400 locations in over 50 countries
Harsco Corporation
Worldwide presence
Operations at over 160 sites in 30 countries
Services: Logistics; Environmental Remediation, Material Recycling, Metal & mineral recovery, Co-Product marketing,
Harsco Metals & Minerals
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� All occupational injuries & illnesses are preventable
� Safety is everyone’s responsibility
� Working safely is a condition of employment
� Managers & supervisors are responsible for training all employees
to work safely
� All operating exposures can be reasonably safeguarded
� Preventing injuries & accidents contributes to business success
Safety Principles
Continuous Improvement
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1) Unique knowledge-sharing mechanism that operates across the global Harsco team
2) Providing the highest quality service that delivers the lowest Total Cost of Ownership
� Draws on best operating practice generated from Harsco’s 70-year
global operating experience.
� Cover Safety, Asset Management, Operating Guidelines and Service
Quality. Continuously reviewed and updated
The Group Best Practices define our standard operating
practices across the globe.
Harsco Integrated Steel Mill Services at a glance
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� Scrap Management
� Scrap processing
� Raw Materials handling
� Product handling
� Transportation
� Meltshop services
� Blast furnace services
� Packaging
Helping steelmakers to optimise logistical efficiency and productivity
Scrap Management
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Optimise scrap reception, storage, menus and delivery to the furnace.
� Handling of scrap arriving by road, rail and barge
� Radioactivity Control, Quality Control
� Collection and transport of internally arising scrap
� Reception, storage and real time scrap inventory control
� Load scrap baskets according to menus received electronically
from the meltshop
� Transport baskets to the furnace on specialist vehicles
ScrapMaster Overview
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ScrapMaster
Management information reporting puts you in control
Three integrated operating modules for cost-effective management of the entire scrap supply chain, with full segregation and traceability
Scrap Chute loadingIncoming scrap Scrap Handling
®
®
Scrap Optimisation
� ScrapMaster now integrates functionality from BOSS (Blending Optimisation Software Suite)
� Under license from Management Science Associates, Inc.
� World leading optimisation program
� Yield-based cost calculation
� Actual scrap cost per tonne of steel
� Value of the scrap inventory on a real-time basis
� Minimises scrap charge cost, grade by grade
� Based on specific grade production data entered by the steelmaker
� planned tonnage, scrap composition, prices, availability and inventory
®
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Domestic Scrap Baling
Annual Volume of Scrap Processed: 51k tonnes/year
2000 PSI Cutting Force:
Baler Cycle Time: 2 minutes per batch, each batch is 0.7 tonnes
Up to 2.2 tons/m3Average Density of Baled Scrap
Case Study:
Scrap Baling
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Shredder, Argentina
17,000 tonnes per month
- Unloading of incoming scrap
- Sorting of unshreddable material (cylinders, gas tanks, etc)
- Scrap feeding to the Shredder Machine
- Load shredded scrap into trucks
- Transport to Basket preparation Yard for disposal
Scrap Shredding
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Multi-torch FerroCut® system delivers high productivity when cutting
� Thick & heavy scrap
� Tundish & Heavily contaminated skulls
Totally enclosed cutting bed and gas cleaning ensures environmental compliance
- Cuts material up to 1.6metres thick
High-Volume Scrap Cutting
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Optimise inventory value with on-site marking and tracking of semi-finished products.
� Item location tracking through RFID or Differential GPS
� Optimised transport reduces equipment fleet and operating hours=> lowest TCO
Semi-finished Product Handling
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Complete packaging solution for cold coils and coated sheet
� Supply of packaging materials
� Internal transfer of material between production processes
� Computerized identification and positioning systems
� Capacity to invest in automatic systems
Finished Product Packaging
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Transport and supply chain management solutions for finished products
� Tracking and identification of finished products to ensure traceability
� Stockyard management
� Internal transport service to road, rail or sea dispatch points.
Finished Product Logistics
� Scarfing
� Slitting and cutting
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Helping steelmakers to meet end-user requirements for product quality
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Specialised service delivering exceptional product surface quality
1) Skilled, experienced manual scarfers
2) Automated scarfing
� Patented MultiForm and ShallowCut torches perform various scarfing programs
from spot to full face with variable pass widths
� Cold or hot (850°C) scarfing; capacity to scarf up to 100,000 tons per month
� Eight installations operating worldwide with two scarfing hot slabs
Scarfing
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In-line inspection operating to the most stringent quality standards
� Automatic or manual in-line inspection stations;
� Finished products can be removed, repaired or rejected
� Dye penetration testing to identify surface defects.
Quality control and inspection
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Specialist machines designed to cut slab & plate to millimetre tolerances
� Fully automated twin axis cutting assemblies
� Specialist oxy fuel torches to minimise cut width and yield loss
� Multi-torch independently controlled machines
� Full on-board measurement systems
Cutting & Slitting
� Converting CO gases to ethanol
� Oily millscale sludge remediation
� Slag recycling/Metal recovery
� Dust & sludge agglomeration and briquetting/pelletizing
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Helping steelmakers to optimise the economic value of recycled by-products, and minimise the environmental impact of production
Coal
Micro Pellets
Electricity
CO gas Coke Ovens
Sinter plant
Blast Furnace
Iron Oxide Fines
Micro Pelletizing
plant
LANDFILL
BF Slag
GGBS
MineralRecovery
Scrap Upgrading
Cement
MR plant Fines
GGBFS
DesulphSlag Metal Recovery
BOS plant
Ethanol
CO2
LanzaTechProcess Sale
Mineral recovery
Briquetting plant
Dusts/Sludges
Lime/Dolomite Fines
Lime
Briquettes
Iron Ore
MR plant
Coke Breeze
MillscaleRollingMill
Dusts/SludgesBOSplant
Coke
Sinter
Resource recovery solutions: Ironmaking
:Raw Material
Waste materialProcess or product
Harsco Plant
Resource recovery solutions: Steelmaking
Raw Material
Waste materialProcess or product
Harsco Plant
Electricity
CO gas
BOS Plant
Metallurgical Additives
Ethanol
CO2
Slag
Metal recovery
Rolling Mill
Oxide recovery
Sludge
SludgeTreatment
MR plant
Mineral recovery
Scrap Upgrading
Oil recovery
Roadbase
Road products
Sale
Gasfermentation Sale
Co-Gen Plant
Scrap
Iron (from BF plant)
Dusts/Sludges
Fines Upgrading
Briquettes
MillscaleSuperfine
SaleCement feed
LANDFILL
OtherAggregate sale
Millscale
BriquettingPlant
Briquetting Plant
Off-gases produced by the BOF plant has a high calorific value. If it is not stored
or converted, it escapes into the atsmosphere as CO2 emissions. The current
alternative is to process the gas through a turbine to produce electricity (Co-Gen
plant), for internal re-use or sale to the grid.
CO gas to Ethanol
View LanzaTech video
LanzaTech
LanzaTech has developed an ethanol fuel production process that can be retrofitted
to industrial facilities using the carbon monoxide component of waste flue gases as a
nutrient source. They have developed a proprietary platform for producing lowest-
cost liquid biofuel at a much larger scale than any alternative technology. LanzaTech
has signed a partnership agreement with Harsco; Harsco is the service
provider, and LanzaTech provides the technology.
Ethanol can be used to fuel motor vehicles or aircraft. Richard Branson’s Virgin
Airlines has signed a deal with LanzaTech to fuel his aircraft with Ethanol-derived
aviation fuel by 2013.
References
• First BaoSteel demo plant in China commissioned in 2012.
Background
Further information:Bruce Barker
CO gas to Ethanol
Click here to view the animated process flow
Process Inputs Reactor Ethanol Re-useSeparation System End-product
Iron Oxide Fines
OxiFine product
Iron oxide fines (60% Fe product) used in the sinter plant. This represents a saving in steel production, as a replacement for iron ore pellets.
It also provides a zero waste solution for the steelmaker, to recycle C Fines from the metal recovery plant back into steelmaking rather than landfill disposal.
Vertical Shaft Impactor (VSI)
Further information: Chris [email protected]
™
• Developed for oil the industry (recovery of oil and clean sand)
• Harsco has applied the technology to oily sludge from millscale at steel mills
Oily Millscale sludge remediation
View video
The challenge of Oily Millscale Sludge
Oily millscale sludge generated by rolling mills is a hazardous waste. The presence of oil
in the millscale means that it produces emissions when burnt in the sinter plant.
Harsco Solution
Harsco offers a service using ultra-high pressure water treatment technology, which
separates the oil and millscale, producing a clean scale for recycling into steelmaking.
Further information:Jeremy Makepeace
Oily Millscale sludge remediation
MillScale
Oily Millscale sludge
Oil
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Slag tipping, cooling, digging, & transportation
� Digging and removal of air-cooled/granulated BF slag
� Hot slag hauling of BOS slag/Ladle slag
� Under furnace digging using specialized mobile equipment
� Controlled cooling of desulphurisation slag to minimise environmental impact
Slag Recycling
Slag management
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� Slag removal from the vessel
� Slag pit design
Specialized slag handling solutions
� Slag watering and cooling
� Slag pit digging
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Recycling recovered residual metallics to save on high-cost raw materials
� Separation and recovery of metallics from slag and debris
� Crushing and screening of de-metalised slag
� Upgrading of recovered metallics =>Coolant and degasser scrap production
Metal Recovery
Steelmaking Scrap Value
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Area MaterialFe Content %
Size (mm) Requirement Price ($/tonne)
Sinter Plant
BF
BOS
Ladle
Degassing
Low quality iron ore
High quality iron ore
Steel scrap
Ladle coolant scrap
Degasser coolant scrap
50 - 60
60 - 70
70 - 80
90
95
0 - 6
6 - 30
130 - 150
1 -3 tonne lumps
30 -130
12 -30
Small size
Consistent sizing and analysis
Size to allow compact charging. Free of deleterious materials
Low residuals, free flowing
Very low residuals, small size, free flowing
120
240
275
420
515
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� International centres of excellence in UK, Netherlands, NZ & USA
� Full testing facilities for supporting slag approval with government agencies
� Slag products successfully applied to- Road surfacing- Non-structural concrete - Cement manufacturing- Agriculture- Railway ballast- Construction fill- Ground stabilisation
Steel slag is re-used in many commercial applications
Slag Recycling
Agglomeration of steelmaking by-products
A range of briquetting or pelletizing solutions for processing and adding value to dust, sludge and millscale materials.
Key customer drivers:• landfill cost reduction• re-use valuable resources (Fe units) • reduction in raw material costs
Project Stages• Understanding customer objectives for end product • Business and process modelling• Compositional analysis and agglomeration trials• Decision on process technology solution and metrics• Design, build and operate plant
Further information: Daniel Devid [email protected]