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All information included in this presentation, including copyright and trademarks, is expressly reserved and no part of these materials may be reproduced or distributed outside of the customer’s organization in any form without Harsco’s prior written consent.
Engineered Solutions for Integrated Steelmakers
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Our Core Purpose
To build teams that win with integrity anywhere in the world
Our Core Values
1. Uncompromising integrity and ethical business practices
2. People – the “A Team”
3. Continuous improvement
4. Value creation discipline
Harsco’s Core Ideology
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Harsco Metals is part of Harsco Corporation (NYSE listed: HSC)
Harsco is a global provider of industrial services and engineered products
Market leading positions in each of its chosen segments:
Infrastructure, Metals, Minerals, and Rail
Annual sales of more than $3bn covering 400 locations in over 50 countries
Harsco Corporation
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Harsco’s Partnership with the Steelmaker
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Integrity is absolute
Shared knowledge is our greatest asset
Working together builds success
Human life is priceless
In always keeping our promises
We believe
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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
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We employ qualified Environmental professionals in our major operations 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
We are committed to certification of all our remaining operations worldwide by the end of 2010.
Environmental Management
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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
Sites are measured and monitored on compliance.
The manual draws on best operating practice generated from Harsco’s 100-year global operating experience.
Database contents cover Safety, Asset Management, Operating Guidelines and Service Quality. Continuously reviewed and updated in line with latest operating experience.
The Group Best Practice manual defines Harsco Metals standard operating practices across the globe.
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Today’s Steelmaking Challenges
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Minimise Raw Material Costs
Optimise Logistical Efficiency
Maintain Metal Product Quality
Achieving Environmental Sustainability
Minimise Raw Material Costs
Optimise Logistical Efficiency
Maintain Metal Product Quality
Achieving Environmental Sustainability
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Scrap ManagementScrap processingRaw Materials handlingProduct handling
TransportationMeltshop servicesBlast furnace servicesPackaging
Helping steelmakers to optimise logistical efficiency and productivity
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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
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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
®
®
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ScrapMaster Value In Use
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Tangible cost savings and value enhancement
Meltshop productivity
Metal purity
Secondary metallurgy
®
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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 calculationActual scrap cost per tonne of steelValue of the scrap inventory on a real-time basisMinimises 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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Annual Volume of Scrap Processed: 50,000 tonnes/year
2900 PSI Cutting Force:
Shear Cycle Time: 7.5 minutes per batch, each batch is 1.4 tonnes.
0.05 tonnes/m3 (in)1.20 tonnes/m3 (out)
Average Scrap Density
Case Study: Shredding Rails
Scrap Shearing
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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, Argentina17,000 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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On-site scrap screening/quality controlProcessed in a screening plant - remove any contaminants or waste materials
Return processed scrap to the yard ready for charging into the furnace
Segregated
Contaminants
Scrap after
processing
Scrap Screening
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High-Productivity Scrap Breaking
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Latest drop-balling crane technology:
Dual hoist system (25 % improvement in tonnage per hour in trials)
Camera-guided targeting of the ball.
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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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We process excess liquid iron in environmentally controlled conditions, recovering the cooled iron for re-use
1. Optimal pit design allows for minimum fume generation and maximum productivity
2. Fume control hoods for environmental protection
3. Once solidified, plated iron can be broken for internal recycling or external sale
Iron Ponding
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We manage and optimize storage and delivery of bulk raw materials for ironmaking
Handling, stocking, & screening of iron ore, coke, lime & sinter
Transport with specialist vehicles
Operation of large wharf cranes to unload material from bulk carriers
Bulk Raw Materials Management
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Comprehensive maintenance service for conveyor belts & components
Targeted early upgrading of parts to avoid production downtime
Sophisticated condition monitoring & global best practice maintenance program ensures:
Predictive problem resolution
Maximum reliability
Maximum availability
Conveyor Belt Maintenance
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Transport of liquid steel ladles from furnace to caster
Ladle transport in specialist tailored vehiclesUp to 400 tonne capacity, seven axle, elevating pallet carriers Infra-red camera monitors the ladle shell temperature to prevent breakouts
Liquid Steel Transport
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Blast furnace runner cleaning
Coke Oven Inlet de-graphitising
Coke Oven Cleaning
Comprehensive 24/7 service throughout the Blast Furnace and Coke Ovens, with a direct link to the production process.
Torpedo lip cleaning
Torpedo wrecking
Essential maintenance – Blast Furnace
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Refractory removal and relining
Ladle and vessel lip cleaning
Comprehensive 24/7 service throughout meltshop, with a direct link to the production process.
Tundish removal and transport
BOS meltshop cleanup
Essential maintenance – Meltshop
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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 materialsInternal transfer of material between production processesComputerized identification and positioning systemsCapacity 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
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ScarfingSlitting and cutting
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Helping steelmakers to optimise product quality
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Specialised service delivering exceptional product surface quality
1) Skilled, experienced manual scarfers
2) Androfer robotic scarfer
Patented MultiForm and ShallowCut torches perform various scarfing programs from spot to full face with variable pass widthsCold or hot (850°C) scarfing; capacity to scarf up to 100,000 tons per monthEight 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 rejectedDye 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
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Slag handling/Metal recoverySlag recyclingDust & sludge metal recovery and recycling
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Helping steelmakers to optimise the economic value of recycled by-products
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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 slagUpgrading of recovered metallics =>Coolant and degasser scrap production
Metal Recovery
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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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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
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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
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By-Products Value in Use: Integrated Steelmaking Example
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Sludge Dewatering
RecoFlux™ Briquetting Micro Pelletising
Performix
Addition Rate (KGs/Tonne of Steel)
Addition Rate (Tonnes per heat)
Product Returned to Furnace (Tonnes)
By Products Consumed (Tonnes) 53,333 45,500 98,000 15,000
80,0000 50,000 100,000 30,000
0.00 6.00 3.75 7.50 2.25
0.00 20.00 12.50 7.5025.00
Raw Materials Savings
Landfill Savings
CO2 Emissions Savings
Third Party Sales
Customers Total Annual Savings
0 3,687,500 4,200,000 14,100,0005,644,800
0 3,600,000 2,047,500 04,410,000
0 24,000 0 00
160,000 0 0 00
160,000 7,311,500 6,247,500 14,100,00010,054,800
Usage Data
Customer Savings ($)
80,000
Annual tonnage: 4 million
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Harsco has experience of more than ten plants worldwide with total capacity of over 1,500,000 tonnes per annum
Briquettes for recycling via BF and BOF
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- Final product improves sinter plant productivity- Use of a homogenous sinter bed mix and reduced disposal costs
Pelletising recycles by-products back into the sinter plant
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External sale
Dehydrate
PROCESSING
50% humidity
25% humidity
Filter Cake
Filter Cake Stockyard management
Recycle to the meltshop
Processing Sludge into useable filter cake
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Consulting & Project Management Services
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We deliver:
Project evaluationEquipment selection procurementProject implementationFacilities commissioning and start upPersonnel trainingOperations support
We have developed a project management model which covers all phases of the project life cycle and delivers predictable outcomes.
- Disciplined procedures and experienced project managers ensure best results- Backed up by Group Best Practice sharing across the globe