Ricardo felipi

BOF Slag use as ballastBOF Slag use as ballast
ArcelorMittal Tubarão Experience
November, 2010
Authors:
Ricardo Filipe T. Moreira (Presenter)
Pedro Sérgio Bicudo Filho

ArcelorMittal Tubarão
General View
VitóriaVitória
Vila VelhaVila Velha CariacicaCariacica
Vitória, Vila Velha, Serra, Cariacica:
1,5 million hab.
SerraSerra

Production Flow Chart – 7.5 Mt Phase

2007
2008
Technical Development – New Applications 2009
Economic/Social/Environmental Gains
Centralization of By-products Management
Increase in residues generations
2002
Sustainability
Adding ValueAdding Value
By-products Management Evolution
Plant Start up
Implementation of CASP (by-products Storage Center)
Ever-growing inventories
“Erroneous” view of the market on Residues
Environmental characterizations
Qualification / R&D
Increase in residues generations
1983
1986
1990
1995
1998
1999

Synergy/Benchmarks for
Best Practices
Planning for Reuse and
Recycling
Monitoring of Key
Indicators
Monitoring of Key
Indicators
SUSTAINABILITYSUSTAINABILITY
By-products Management Main Actions
Integrated
Actions/cooperation with
Operational Areas
Partnerships with Research
Institutes/Universities/
Governmental
Agencies/Communities
Partnerships with Research
Institutes/Universities/
Governmental
Agencies/Communities
Technical and
Environmental
Qualification
Technical and
Environmental
Qualification
ByBy--productsproducts
ManagementManagement
Development of New
Markets/ Clients
Development of New
Markets/ Clients
Centralized Management
for Development,
Processing and
Applications

BOF Slag use as ballast – ArcelorMittal Tubarão Experience
Generation Index
2007 2008 2009
By-Products
Generation
kg/t CS 545 591 541
BF (51%) 277 kg/t CS
T.R.T
GBFS 255 kg/t HM
BOF (41%) 223 kg/t CS
Slag 120 kg/t CS
Scrap 42 kg/t CS
Sludge 23 kg/t CS
Sludge 6 kg/t HM
2007 2008 2009
By-Products Recovery
Index
% 98,9 99,7 98,8
Recovery Index 2009 Recovery Index Distribution
5%
65%
25%
4%
1%
Sales
Internal Recycling
Social Actions
Under processing
Storage

ByBy--Products IndexesProducts Indexes
BF Sludge StorageBF Sludge Storage
BF Sludge
T.R.T
Temporary Storage
(reduce moisture)
CERAMIC
INDUSTRY
BOF Fine Sludge StorageBOF Fine Sludge Storage
BOF Sludge Sinter Plant
2007 2008 2009
BF Sludge Storage k t 215 208 184
2007 2008 2009
BOF Fine Sludge Storage k t 210 208 166
Fine Sludge
Coarse Sludge Briquette Plant
LD Slag StorageLD Slag Storage Desulphurization slag (KR Process)
LD Slag
Slag of secondary refine
Slag of Steel shop cleanness
BOF Fine Sludge Storage k t 210 208 166
2007 2008 2009
LD Slag Storage k t 491 476 520
BOF Slag StorageBOF Slag Storage
(*) 2005 Storage = 955.000 t(*) 2005 Storage = 955.000 t
2009 – KR slag generation index adjustment

Matriz de decisão de projetos de co-produtos
Sinter EP Dust on red ceramic industry;
Desulphurization Slag (KR) on mortar composition;
Desulphurization Slag (KR) on cement industry;
BOF slag > 32 mm crushing process to allow road and concrete aggregate uses;
Raw Material Yard Cleanness (> 19 mm) crushing process to allow Sinter reuse;
FGD Heat Recovery Dust use on cement industry;
FGD Heat Recovery Dust use on agriculture;
Hydrocyclone BF Sludge to allow Sinter Recycling
On going By-products Development Projects

AGRICULTURE CONCRETE ARTEFACTS ARTIFICIAL REEFS
(concrete with BOF slag)
ROAD INFRASTRUCTURE
ACERITA®
Revsol – BOF Slag with expansion higher than 3% (PTM 130 Method).
Used on unpaved roads, yards recovery and landfill.
Acerita – Treated BOF Slag with expansion less than 3% (PTM 130 Method)
sub-base and base of paved roads. BOF Slag High support strenght allows layer
thickness reduction on projects.
Federal Road Department Standards created for ArcelorMittal Tubarão BOF slag road
use since 2009
BOF Slag use as aggregate on asphalt composition
BOF Slag Applications
Viçosa Federal University and
INCAPER studies show AM Tubarão
BOF slag efficiency when used as soil
corrective. Under Federal Agricultural
Agency analysis to issue License for
commercial use.
Experimental Coffe planting - Incaper
This application was certified on 2008 by
Falcão Bauer Quality Institute based on its
technical performance and as an eco-product
due to its social and environmental benefits.
(concrete with BOF slag)
Provide new applications for BOF Slag
use under sea as rockfill aiming,
tetrapods construction and seashore
protection.
On going discussions with Local City
Halls and Environmental State Agency to
define project start up.

EFFLUENTS TREATMENT
Espirito Santo Federal University Studies
showing good results when using it as
filtering beds on domestic sanitary
effluents treatment (wetlands)
BOF Slag Applications
CEMENT INDUSTRY
It reduces CO2 emissions at clinker
production. About 3000 t/month are
designated to cement production
Obtained from BOF slag processing in plants
with crushing, screening, metallic separation
and free lime reduction aiming to attend
grain size and other ballast specifications.
BALLAST
Another applications
Landfill Gabion
Hillside protection
Rockfill aiming
Tetrapods
Recovery of stone-quarry
Rip Raps
Hillside protection

ArcelorMittal Tubarão By-products Strategy
Environmental Policy
To adopt suitable management practices to efficiently use natural
resources, reduce emissions into the atmosphere and water bodies, and
recycle industrial wastes.
Continuous
Development of
Partnerships
New
Technologies
Research and
Development
Continuous
Improvement
Breaking of
ParadigmsSustainability

Environmental Aspects
• TECAM Lab – 2004 (1st analysis)
• TECAM Lab – 2008 (2nd analysis)

• VIÇOSA – 2006 (Agriculture)

• Incaper 2007 (Agriculture)
(Instituto Capixaba de Pesquisa, Assistência Técnica e Extensão Rural)

• IEMA 2007 (ballast)

• ECOS 2008 (Artificial Reefs)
T1 - 1:1:4
(cement; sand; BOF slag 0 a 19mm)
T2 - 1:2:3
T3 - 1:2:3
T4 - 1:2:23
(cement; sand; natural stone)
1º Mês 2º Mês
3º Mês 8º Mês
Implantação Litoral Serra
Fase final de licenciamento ambiental no
IBAMA-DILIC.
Os estudos foram concluídos e está
programada reunião com IBAMA
em Brasília até o final de dezembro.

• Falcão Bauer Eco-produto 2008

• IEMA 2008 (Agriculture)

• UFES 2008 (Wetlands)
Estudo realizado em parceria com a Universidade Federal do Espírito Santo (UFES) e a
ArcelorMittal Tubarão, para avaliação de Escória de Aciaria (LD) como leito cultivado e
leito filtrante no pós- tratamento de efluentes sanitários,
“O estudo concluiu com a contribuição para a redução dos seguintes parâmetros: correção
de pH, turbidez, DBO, DQO, NTK, fósforo, dureza e matéria orgânica, e teve como objetivo o
tratamento natural dos efluentes, visando assim o bem estar e a qualidade de vida da
comunidade”

• IPR/DNIT 2009 (road)

• UFOP 2010 (ballast)
“Após o processo de
estabilização química foi
classificado como Classe II B
(Não Perigoso – Inerte)”

Historical
• 1991 First Tests With LD Slag use as ballast (AMT and railroad operator) partnership;
• 1998 Technical specification to BOF Slag developed. AMT and railroad operator.
• 1998 Beginning of Regular use (Commercial relationship) at EFVM;
2006 User start to complain about railway problems (grain size problems and wrong signals
from electrical conductivity of slag)
• 2007 Railway operator Stop using• 2007 Railway operator Stop using
0,00
20.000,00
40.000,00
60.000,00
80.000,00
100.000,00
120.000,00
140.000,00
160.000,00
180.000,00
1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006
Amount of Tubarão LD Slag used as ballast
Over 1 million tons

BOF Slag Ballast - Technical specification under contract:
Physical properties Technical
Specification
BOF Slag results
Soft and friable pieces < 5% 3% (√)
Pulverulent material < 1% 0.5 % (√)
Clay lumps < 0.5% no (√)
Los Angeles Abrasion Loss < 40% 15% (√)
Weight (kg) per cubic meter > 1.400 kg/m³ 2.800 kg/m³(√)
BOF Slag Ballast - Particle size distribution
Sieve size % passing by mass
75 mm 100 %
63 mm 90 to 100%
38 mm 25 to 60 %
19 mm 0 to 10%
13 mm 0 to 5 %
BOF Slag Ballast - Electrical resistance
minimum resistance of 300 m
Related to FeM content on BOF slag – máx 2%

Main problems (cause and effect) reported by user
Grain size – Slag fines
Drainage problems on
railway
Concrete effect on ballast
Grain size – Slag fines
ArcelorMittal Tubarão Control
Slag
Generation
Storage
( ~ 2 years)
Process
Screening
Product
(slag ballast)
Inspection
Dispatch
Inspection
Grain size analysis
“Each batch”
Focus on screening process
(wrong action AMT & Railway
operator)
Controle de Despacho de escória de lastro
Material Estocado na Área de Carregamento
Controle de Despacho de escória de lastro
Material Estocado na Área de Carregamento

Main problems (cause and effect) reported by user
emitter
Wheel on track - electrical current consumption – correct position
Slag Ballast causing electrical current consumption
Wrong signal position
receiver
ArcelorMittal Tubarão Control
Slag
Generation
Storage
( ~ 2 years)
Process
Metallic removal
Product
(slag ballast)
Inspection
Dispatch
Inspection
Focus on metallic removal process
(wrong action AMT & Railway operator)

Look for good partnerships:
Working together with clients and Research Institutes;
Client
Railroad Operator
Client
Railroad Operator

Identifying Causes – Slag fines
Physical properties sample collected on railway:
Physical properties of LD slag ballast characterization results;
- High weight per cubic meter; (higher than natural stone)
- No clay lumps;
- Los Angeles Abrasion Loss from 15% to 30% (limit < 40%)
- Soft and friable pieces = 11% to 1% (limit < 5%)
Chemical properties:
- CaO content analysis – from 1.5% to 6.15%;
- Expansion effect even after 2 years storage (~ 5 mts high);
- Internal stretches due to expansion effect causing structure damage – fines
generation;
Main Action: Develop method to reduce CaO content at LD slag ballast;
?

Identifying Causes – Electrical current escape
Built a railroad simulator at Mario Carvalho Station;
- Highest problem occurrence at EFVM railroad;
Measurement equipment to check electrical resistance and
pluviometer (data logger)

During rain
After rain
VoltagebetweentracksVoltagebetweentracks
Main problem occurring just after rain period
Problem increase due to bad drainage system – slag fines

Lab Analysis – ballast box to simulate water action on slag
After 11 water cycles
Water PH reduction (12 to 10)
CaO dissolution
Electrical resistance
Electrical conductivity
Main Action: Develop method to reduce CaO content at LD slag ballast;

Identifying Causes – BOF slag ballast changing performance
40.000,00
60.000,00
80.000,00
100.000,00
120.000,00
140.000,00
160.000,00
180.000,00
Everything OK
Problems – Why?
?0,00
20.000,00
40.000,00
1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006
?
What changed on AMT process
BOF Slag Storage over 1 million tons (2000) - old stock piles
BOF slag Storage = 955.000 tons (2005)
BOF Slag Storage = 545.000 tons (2007)
Increase
stockpiles
height
ACTION = Develop curing method for BOF slag ballast
Storage
Period reduction

Develop curing method
Lab tests Water through slag block – 0,17 mm / sec
Around 7 minutes to wet 1 slag ballast block;
Water Quantity? Time cycle?
Lab tests Water through slag column
Around 1 minute to wet 2 m height.
weathering method : 10 min water on + 30 min water off (steam formation)

3 kinds of weathering configuration
- Spread storage (30 cm height)
- Cone storage (2 meters height)
- AMT old storage (4 meters height)
cone storage
Spread storage
AMT old storage

Process measurement instruments
Sensor protectionWet sensor Temperature sensor
Data logger back up (each 3 minutes)
CO2 measurement
pluviometer

First results
Capacity (16 m²) CaO To CaO T45 CaO T60
Spread storage 8 tons 8,03 2,80 1,5
Cone storage 25 tons 8,03 3,11 1,7
AMT old
storage
50 tons 8,03 Base sensor
not wet
Base sensor
not wet
Target to achieve 3% of CaO content – good results (comparing to natural stone performance)
After ballast weathering treatment – slag was screened and 25 % was removed (grain size less than
32 mm)
After curing process Ballast slag was tested under physical properties
The fine slag part will be used on road application (low expansion) high demand;

Physical properties T 0 T 60
Comparing physical properties – Final Results
T0 = Not treated slag
T60 = Treated Slag under cone storage (60 days)
Lab analysis occurred 30 days after treating process
Maximum grain size 75 mm 75 mm
Los Angeles 11,5% 11,43%
Water absorption 1,74% 0,81%
Porosity 4,21% 2,03%
Soft and friable pieces 11,51% 0%
Fine grain size problem of BOF slag ballast solved

Escória Arcelor Mittal Dormente de Aço
NOVA;
4835,85
5000
6000
m)
Brita Dormente de Aço
5000
6000
BOF slag – steel sleepers (resistivity) Natural stone – steel sleepers (resistivity)
BOF treated slag
Simulator data
(Just after built)
Gustavo; 266,67
2 anos;
1493,56
0
1000
2000
3000
4000
5000
Entre eletrodos
Resistividade(Ωm)
Gustavo; 977,78
2 Anos;
1553,69
0
1000
2000
3000
4000
5000
Entre eletrodos
Resistividade(Ωm)
BOF not treated slag
Simulator data
(Just after built)
Close to 300 m
(AREMA)
Problem to railway user
BOF slag simulator
(after 2 years)
Low electrical resistivity
problem of BOF slag ballast solved

BOF slag ballast advantages
Resiliency Modulus
Natural rock = 33,11 MPa
Typical railway section ballast (40 cm height)
Resiliency Modulus
BOF slag = 63,00 MPa
Typical railway section ballast (40 cm height)
Results Indicates that ballast thickness can be reduced around 25% using BOF
treated slag as ballast – cost reduction
First results indicate that ballast life cycle can be improved using BOF treated slag as
ballast (around 40%)– on going study

ArcelorMittal Tubarão BOF slag ballast production flow
Slag
generation
Slag first processing
Screening
Metallic removal
Slag second processing
Screening
Metallic removal
Slag treatment
(water into cone
stockpiles)
6 boxes = 4.500 tons/each box
Around 10.000 tons/monthAround 10.000 tons/month
Slag bins to avoid ground contact
contamination

On going Actions
Final report results presented to client (railway operator);
Brazilian standard for BOF slag use as ballast draft;
Dynamic simulator with BOF slag ballast;
Next Actions
Site test on EFVM;
Return of Regular use (Commercial relationship) at EFVM;

Conclusion:
- ArcelorMittal Tubarão BOF slag
can be used as ballast after a curing
process (CaO reduction < 3%).
- Ballast thickness can be reduced
when using BOF slag;
Conclusion:
- Attention on process changing;
- Stay close to clients;
- Look for good partnerships;
- Keep always researching;

Ricardo felipi

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