Hallie Charapp, Shannon Harrop, Max Kennedy and Kyle Miller

INTRODUCTION

We recognize the need to design a new process to identify, separate and store the high alloyed scrap from the rest of the scrap from the automotive junk yard.

TABLE OF CONTENTS

Introduction Background Specifications Weighted Objective Tree Brainstorming Decision Matrix Flow Chart Sustainability

STEEL RECYCLING

Steel is North America's most recycled material Use of steel scrap to make new steel conserves energy,

reduces emissions and conserves natural resources Each year, steel industry recycles more than 18 million

tons of steel from cars Use of AHSS reduces a vehicle’s structural weight by as

much as 25% and can cut CO2 emissions by up to 15% more than any other automotive material.

Automobiles maintain a recycling rate of nearly 100 percent1

BACKGROUND Steel

composition of different metals

the strongest alloy

“cradle to grave” --> “cradle to cradle”

ArcelorMittal delivered automotive scrap

stays separate from other scraps such as ore

lollipop sampling

spectrometer tests the makeup of scrap metal (inefficient)

Our task:

new solution to effectively identify, transport and store the high alloyed steel

ensure there is no off chemistry when making recycled steel

decrease the cost of production while increasing revenue (if possible)

BACKGROUND CONT’D

Recycling steel

separate (AHSS) from scrap

AHSS burned in basic oxygen furnace

metal slag drains out

other gases leave furnace

alloy compounds added to AHSS in airtight vacuum to create necessary percentage of metals to create LCAK steel.

SPECIFICATIONS Avoid off-chemistry

-system must maximize the amount of highest alloyed steel that can be added to a heat of standard LCAK steel without off-chemistry

- keep AHSS separate throughout whole process- Use reliable composition evaluation techniques

Cheap

- Not cause a dramatically increased cost for ArcelorMittal

- Avoid outsourcing and paying other companies

Separates AHSS

- Separate and identify the AHSS from the automobile scraps

- Keep scrap composition in specified range (C 0.17% Cr 0.2% Cb 0.02% Mn 1.5% Al 1.2%)

SPECIFICATIONS CONT’DSafe/reliable

- Process works effectively every time

- Does not cause increased danger risks

Accurate

-Proper composition measurement techniques are used, Spectrometer

- The average results of multiple tests are used

- Proper sample sizes of metal are used (small strips)

Time efficient

- Avoid taking lollipop samples of every small piece of metal, but remain accurate

-Short, fast transportation

MORPHOLOGICAL CHART  Ideas  

Separation Car Co. Labels parts Junkyard separates parts Separate by Comp. only

Identification Car Co. identifies comp. Outsource parts to other Co. to identify

ArcelorMittal Identifies comp.

Accuracy Multiple Spectrometer measurements

Additional x-ray measurements

 

Sample Size Melt parts into large sample Take average of a couple parts’ comp.

Cut parts into small strips

Storage Large piles of separate parts

Small containers of similar composition metals

Train cars divided by part/composition

DECISION MATRIX

  A B C

Composition Testing

(.24) * .6 (.24)*.2 (.24)*.2

Ease of Separation

(.24)* .4 (.24)*.4 (.24)*.2

Transportation (.12) * .7 (.12)* .1 (.12)* .2

Cost (.12) * .5 (.12)* .25 (.12) *.25

Reliability (.16)* .33 (.16)* .33 (.16)*.33

Totals ***.4368*** .2388 .2028

A: -Car Co. Labels Parts by comp. -Junkyard Separates by label-A.M. Re-Measures and Uses

B: -Junkyard Separates Parts-Couple samples from small piles analyzed by another Co. for comp. - Crates with parts sent to A.M. labeled by comp.

C: -Junkyard separates parts-Small piles melted into large slabs analyzed by another Co. for comp.-Slabs sent to A.M. labeled by comp.

Cost Analysis

SUSTAINABILITY Environmental

- Our design does not dramatically alter the steel making process, which is good for current research and development programs

-The North American steel industry has been actively investing in research into new processes for making steel that reduce or eliminate CO2 emissions2

Economic

-Cost will increase slightly for car companies to label the compositions and for junkyards to separate individual parts

- ArcelorMittal does not have to spend time and money to analyze the incoming parts

- Overall, the new steel will be made more accurately and with more AHSS; the cost of the final products will increase—

ArcelorMittal makes more profit

SUSTAINABILITY CONT’D Social

- Design allows job opportunities in the car companies and junkyard companies

- Having more AHSS, along with the accurate steel-making process, allows for safer construction

- Labeling regulations create order and consistency in the industry

REFERENCES

[1] (http://www.recycle-steel.org/)

[2] (http://www.recycle-steel.org/Sustainability/Energy%20Reduction/CO2%20Breakthrough.aspx)

QUESTIONS