engineered solutions for integrated steelmakers...scrap management 9 optimise scrap reception,...

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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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Page 1: Engineered Solutions for Integrated Steelmakers...Scrap Management 9 Optimise scrap reception, storage, menus and delivery to the furnace. Handling of scrap arriving by road, rail

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

Page 2: Engineered Solutions for Integrated Steelmakers...Scrap Management 9 Optimise scrap reception, storage, menus and delivery to the furnace. Handling of scrap arriving by road, rail

1

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

Page 3: Engineered Solutions for Integrated Steelmakers...Scrap Management 9 Optimise scrap reception, storage, menus and delivery to the furnace. Handling of scrap arriving by road, rail

2

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

Page 4: Engineered Solutions for Integrated Steelmakers...Scrap Management 9 Optimise scrap reception, storage, menus and delivery to the furnace. Handling of scrap arriving by road, rail

Harsco’s Partnership with the Steelmaker

3

Integrity is absolute

Shared knowledge is our greatest asset

Working together builds success

Human life is priceless

In always keeping our promises

We believe

Page 5: Engineered Solutions for Integrated Steelmakers...Scrap Management 9 Optimise scrap reception, storage, menus and delivery to the furnace. Handling of scrap arriving by road, rail

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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

Page 6: Engineered Solutions for Integrated Steelmakers...Scrap Management 9 Optimise scrap reception, storage, menus and delivery to the furnace. Handling of scrap arriving by road, rail

5

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

Page 7: Engineered Solutions for Integrated Steelmakers...Scrap Management 9 Optimise scrap reception, storage, menus and delivery to the furnace. Handling of scrap arriving by road, rail

Continuous Improvement

6

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.

Page 8: Engineered Solutions for Integrated Steelmakers...Scrap Management 9 Optimise scrap reception, storage, menus and delivery to the furnace. Handling of scrap arriving by road, rail

Today’s Steelmaking Challenges

7

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

Page 9: Engineered Solutions for Integrated Steelmakers...Scrap Management 9 Optimise scrap reception, storage, menus and delivery to the furnace. Handling of scrap arriving by road, rail

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Scrap ManagementScrap processingRaw Materials handlingProduct handling

TransportationMeltshop servicesBlast furnace servicesPackaging

Helping steelmakers to optimise logistical efficiency and productivity

Page 10: Engineered Solutions for Integrated Steelmakers...Scrap Management 9 Optimise scrap reception, storage, menus and delivery to the furnace. Handling of scrap arriving by road, rail

Scrap Management

9

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

Page 11: Engineered Solutions for Integrated Steelmakers...Scrap Management 9 Optimise scrap reception, storage, menus and delivery to the furnace. Handling of scrap arriving by road, rail

ScrapMaster Overview

10

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

®

®

Page 12: Engineered Solutions for Integrated Steelmakers...Scrap Management 9 Optimise scrap reception, storage, menus and delivery to the furnace. Handling of scrap arriving by road, rail

ScrapMaster Value In Use

11

Tangible cost savings and value enhancement

Meltshop productivity

Metal purity

Secondary metallurgy

®

Page 13: Engineered Solutions for Integrated Steelmakers...Scrap Management 9 Optimise scrap reception, storage, menus and delivery to the furnace. Handling of scrap arriving by road, rail

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

®

Page 14: Engineered Solutions for Integrated Steelmakers...Scrap Management 9 Optimise scrap reception, storage, menus and delivery to the furnace. Handling of scrap arriving by road, rail

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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

Page 15: Engineered Solutions for Integrated Steelmakers...Scrap Management 9 Optimise scrap reception, storage, menus and delivery to the furnace. Handling of scrap arriving by road, rail

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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

Page 16: Engineered Solutions for Integrated Steelmakers...Scrap Management 9 Optimise scrap reception, storage, menus and delivery to the furnace. Handling of scrap arriving by road, rail

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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

Page 17: Engineered Solutions for Integrated Steelmakers...Scrap Management 9 Optimise scrap reception, storage, menus and delivery to the furnace. Handling of scrap arriving by road, rail

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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

Page 18: Engineered Solutions for Integrated Steelmakers...Scrap Management 9 Optimise scrap reception, storage, menus and delivery to the furnace. Handling of scrap arriving by road, rail

High-Productivity Scrap Breaking

17

Latest drop-balling crane technology:

Dual hoist system (25 % improvement in tonnage per hour in trials)

Camera-guided targeting of the ball.

Page 19: Engineered Solutions for Integrated Steelmakers...Scrap Management 9 Optimise scrap reception, storage, menus and delivery to the furnace. Handling of scrap arriving by road, rail

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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

Page 20: Engineered Solutions for Integrated Steelmakers...Scrap Management 9 Optimise scrap reception, storage, menus and delivery to the furnace. Handling of scrap arriving by road, rail

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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

Page 21: Engineered Solutions for Integrated Steelmakers...Scrap Management 9 Optimise scrap reception, storage, menus and delivery to the furnace. Handling of scrap arriving by road, rail

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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

Page 22: Engineered Solutions for Integrated Steelmakers...Scrap Management 9 Optimise scrap reception, storage, menus and delivery to the furnace. Handling of scrap arriving by road, rail

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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

Page 23: Engineered Solutions for Integrated Steelmakers...Scrap Management 9 Optimise scrap reception, storage, menus and delivery to the furnace. Handling of scrap arriving by road, rail

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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

Page 24: Engineered Solutions for Integrated Steelmakers...Scrap Management 9 Optimise scrap reception, storage, menus and delivery to the furnace. Handling of scrap arriving by road, rail

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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

Page 25: Engineered Solutions for Integrated Steelmakers...Scrap Management 9 Optimise scrap reception, storage, menus and delivery to the furnace. Handling of scrap arriving by road, rail

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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

Page 26: Engineered Solutions for Integrated Steelmakers...Scrap Management 9 Optimise scrap reception, storage, menus and delivery to the furnace. Handling of scrap arriving by road, rail

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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

Page 27: Engineered Solutions for Integrated Steelmakers...Scrap Management 9 Optimise scrap reception, storage, menus and delivery to the furnace. Handling of scrap arriving by road, rail

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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

Page 28: Engineered Solutions for Integrated Steelmakers...Scrap Management 9 Optimise scrap reception, storage, menus and delivery to the furnace. Handling of scrap arriving by road, rail

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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

Page 29: Engineered Solutions for Integrated Steelmakers...Scrap Management 9 Optimise scrap reception, storage, menus and delivery to the furnace. Handling of scrap arriving by road, rail

ScarfingSlitting and cutting

28

Helping steelmakers to optimise product quality

Page 30: Engineered Solutions for Integrated Steelmakers...Scrap Management 9 Optimise scrap reception, storage, menus and delivery to the furnace. Handling of scrap arriving by road, rail

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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

Page 31: Engineered Solutions for Integrated Steelmakers...Scrap Management 9 Optimise scrap reception, storage, menus and delivery to the furnace. Handling of scrap arriving by road, rail

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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

Page 32: Engineered Solutions for Integrated Steelmakers...Scrap Management 9 Optimise scrap reception, storage, menus and delivery to the furnace. Handling of scrap arriving by road, rail

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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

Page 33: Engineered Solutions for Integrated Steelmakers...Scrap Management 9 Optimise scrap reception, storage, menus and delivery to the furnace. Handling of scrap arriving by road, rail

Slag handling/Metal recoverySlag recyclingDust & sludge metal recovery and recycling

32

Helping steelmakers to optimise the economic value of recycled by-products

Page 34: Engineered Solutions for Integrated Steelmakers...Scrap Management 9 Optimise scrap reception, storage, menus and delivery to the furnace. Handling of scrap arriving by road, rail

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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

Page 35: Engineered Solutions for Integrated Steelmakers...Scrap Management 9 Optimise scrap reception, storage, menus and delivery to the furnace. Handling of scrap arriving by road, rail

Steelmaking Scrap Value

34

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

Page 36: Engineered Solutions for Integrated Steelmakers...Scrap Management 9 Optimise scrap reception, storage, menus and delivery to the furnace. Handling of scrap arriving by road, rail

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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

Page 37: Engineered Solutions for Integrated Steelmakers...Scrap Management 9 Optimise scrap reception, storage, menus and delivery to the furnace. Handling of scrap arriving by road, rail

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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

Page 38: Engineered Solutions for Integrated Steelmakers...Scrap Management 9 Optimise scrap reception, storage, menus and delivery to the furnace. Handling of scrap arriving by road, rail

By-Products Value in Use: Integrated Steelmaking Example

37

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

Page 39: Engineered Solutions for Integrated Steelmakers...Scrap Management 9 Optimise scrap reception, storage, menus and delivery to the furnace. Handling of scrap arriving by road, rail

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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

Page 40: Engineered Solutions for Integrated Steelmakers...Scrap Management 9 Optimise scrap reception, storage, menus and delivery to the furnace. Handling of scrap arriving by road, rail

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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

Page 41: Engineered Solutions for Integrated Steelmakers...Scrap Management 9 Optimise scrap reception, storage, menus and delivery to the furnace. Handling of scrap arriving by road, rail

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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

Page 42: Engineered Solutions for Integrated Steelmakers...Scrap Management 9 Optimise scrap reception, storage, menus and delivery to the furnace. Handling of scrap arriving by road, rail

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