Logistics services, slag and dust and sludge recycling, metal recovery

1. Engineered Solutions
for Electric Steelmakers
© 2014 Harsco Corporation, All Rights Reserved.

2. Harsco Corporation
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
1

3. Worldwide presence
Harsco Metals & Minerals
Operations at over 160 sites in 30 countries
Services: Logistics; Environmental Remediation, Material Recycling,
Metal & mineral recovery, Co-Product marketing

4. Safety Principles
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
3

5. Environmental Management
We maintain environmental standards and work to
ISO 14001 Environmental Management Systems
covering:
Airborne pollution control
Storage of hazardous materials
Spill prevention and clean up
Waste management
Fuel and energy conservation
4

6. Continuous Improvement
The Group Best Practices define our standard operating
practices across the globe.
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
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
5

7. Harsco EAF Services at a glance
6

8. Today’s Steelmaking Challenges
Minimise Raw Material Costs
Optimise Logistical Efficiency
Maintain Metal Product Quality
Achieving Environmental Sustainability
7

9. Helping steelmakers to optimise logistical efficiency and productivity
Scrap Management
Scrap processing
Product handling
Transportation
Meltshop services
Packaging
8

10. Scrap Management
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
9

11. ®
ScrapMaster Overview
Three integrated operating modules for cost-effective management of the entire scrap
supply chain, with full segregation and traceability
Incoming scrap
Scrap Handling
Scrap Chute loading
®
ScrapMaster
Management information reporting puts you in control
10

12. Scrap Basket Densification
Scrap Basket Densification is a service which
improves the density of the scrap in the basket.
The scrap is added to the basket before the
furnace charge.
By upgrading C-Fines which roll off the end of the
conveyor belt at metal recovery plants, valuable
scrap material can be utilized to make the scrap
charge denser and therefore improve the
efficiency of each heat.

13. 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

14. Scrap Processing
We process revert or external scrap according to your specific needs
and prepare scrap for internal re-use.
External or internal Scrap processing/upgrading
Baling
Shearing
Shredding
Drop-balling
Mobile Lancing operation
High volume cutting
13

15. Scrap Baling
Case Study:
Domestic Scrap Baling
Annual Volume of Scrap Processed: 51k tonnes/year
Baler Cycle Time:
Cutting Force:
Average Density of
Baled Scrap
2 minutes per batch,
each batch is 0.7 tonnes
2000 PSI
Up to 2.2 tons/m3
14

16. Scrap Shredding
Shredder, Argentina
- Unloading of incoming scrap
17,000 tonnes per month
- Sorting of unshreddable material (cylinders, gas tanks, etc)
- Scrap feeding to the Shredder Machine
- Transport to Basket preparation Yard for disposal
15

17. High-Volume Scrap Cutting
Multi-torch FerroCut® system delivers high productivity when cutting
Thick & heavy scrap - Cuts material up to 1.6metres thick
Tundish & Heavily contaminated skulls
Totally enclosed cutting bed and gas cleaning ensures environmental compliance
16

18. Case Study
ArcelorMittal Acindar, Argentina

19. Plant Overview
Metso Supplied
4000 HP
Erected in 2007
Capacity ; 200 KT / year
Loaded by an Equilibrium Crane
equipped with a 1,5 m3 grab
18

20. Densification
Scrap Densification:
Input Scrap:
0.27 T/m3
Shredded scrap:
0.9 T/m3
N. Baskets per heat:
Pre Shredder:
3
After Shredder:
1-2
Rejected:
19% of Input (0.65 T/m3) including non-ferrous for sale by AM
19

21. Densification
Data from AM Acindar
Example in 2009, without shredder VS with shredder;
Out Tonnes
In Tonnes ;
117 KT of raw material
95 KT of shredded scraps
+ 22 KT of rejected
Out Volume;
In volume ;
435 000 m3
106 000 m3
+ 34 000 m3
Scrap Volume reduced by 76%
20

22. Other Benefits
On site shredding
Reduced power requirement
Improved yield
Reduced electrode consumption
Alloy and flux consumption
Reduction in Missed specifications
Productivity increase
Reduced landfill
Approx. 2%
of
steelmaking
COSTS
Reduced refractory consumption
21

23. Other Benefits with Harsco
Since the arrival of Harsco new scrapyard solution
The downgraded heat indicator has been reduced to a 20% of the
historical value, thanks to the use of ScrapMaster™.
Minutes of delay have been reduced from an average of 1 to 0,1
min/heat.
22

24. Harsco Customised Scrap Solutions
Harsco provide a customised solution for each project based on individual
requirements
Scrap logistics is tailored to the import scrap transport; road, rail, barge, ship
Scrap handling operations are modelled utilising simulation software to
optimise logistic solutions
Scrap handling equipment is selected based on optimised simulation of
operation to minimise capital expenditure while achieving customer delivery
requirements
Logistics operations are supported by sophisticated inventory management
systems that can be combined with optimisation technology
Additional scrap processing and densification equipment can be added to
remove non-ferrous materials and provided product to match steelmakers
requirements

25. Liquid Steel Transport
Transport of liquid steel ladles from furnace to caster
Ladle transport in specialist tailored vehicles
Up to 400 tonne capacity, seven axle, elevating pallet carriers
Infra-red camera monitors the ladle shell temperature to prevent breakouts
24

26. Essential maintenance - Meltshop
Comprehensive 24/7 service throughout meltshop
Ladle and vessel lip cleaning
Tundish removal and transport
25

27. Semi-finished Product Handling
Optimise inventory value with on-site marking and tracking of
semi-finished products.
Barcode or RFID tag marking
Item location tracking through RFID or Differential GPS
26

28. Semi-finished Product Handling
Controlled cooling and handling of billets and blooms
- Controlled cooling: customised cooling hoods for slow cooling option
- Specially adapted wide span multi-fork lift truck for controlled product handling
27

29. Finished Product Logistics
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
28

30. Helping steelmakers to meet end-user requirements for product quality
Slitting and cutting
29

31. Cutting & Slitting
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
30

32. Product Quality Solutions
In-line bar sorting and repair facility
Visual inspection to identify and fix surface defects
e.g. splits, folds, poor cuts or outside required lengths
Real time processing
Machine sits over the advancing cooling table
at the exit to the rolling mill.
Non-conforming bars are identified, removed,
repaired and re-injected back into the
production flow
31

33. Helping steelmakers to optimise the economic value of recycled by-products
Slag handling/Metal recovery
Slag recycling
Dust & sludge metal recovery and recycling
32

34. Current resource recovery solutions: EAF
Raw Material
Waste material
Process or product
Process
Plant
Harsco Plant
EAF Dust
Rolling Mill
Sludge
Sludge
treatment
plant
Electricity
Coolant
scrap
Fines
Metallurgical
Additives
Scrap Basket
Densification
Scrap
Road products
Ladle Slag
Sale
Asphalt
LANDFILL
Mineral recovery
Coal
DRI
Iron Ore
Millscale
EAF Slag
MR plant
Metal recovery
Fines Upgrading
Aggregate
sale
Oxide
recovery
Oil
Separation

35. Slag Recycling overview
Transport
Processing
Slag Product
Development
Metal Recovery
Slag resold to third parties
34

36. Slag management
Comprehensive slag tapping and tipping service
Slag removal from the vessel
Slag watering and cooling
Slag pit design
Slag pit digging
35

37. Metal Recovery
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
36

38. Steelmaking Scrap Value
Area
EAF
Material
Steel scrap
Fe Content %
70 - 80
Size (mm)
130 - 150
1 -3 tonne lumps
Ladle
Degassing
Ladle coolant
scrap
90
30 -130
Degasser
coolant scrap
95+
12 -30
Requirement
Size to allow compact
charging. Free of
deleterious materials
Low residuals, free flowing
Very low residuals, small
size, free flowing
Price
($/tonne)
275
420
515
37

39. Slag Recycling
Steel slag is re-used in many commercial applications
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
38

40. Oily Millscale sludge remediation
The challenge of Oily Millscale Sludge
Oily millscale sludge generated by rolling mills is a hazardous waste, making landfill an
expensive option.
Harsco Solution
Harsco offers a service using ultra-high pressure water treatment technology, which
separates the oil and millscale, producing a clean scale.
• Developed for oil the industry (recovery of oil and clean sand)
• Harsco has applied the technology to oily sludge from millscale at steel mills
View video
Further information:
Jeremy Makepeace
jmakepeace@harsco.com