Electric Steelmaking Solutions Brochure

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 Electric Steelmakers1Harsco’s Core IdeologyOur Core PurposeTo build teams that win with integrity anywhere in the worldOur Core Values1. Uncompromising integrity and ethical business practices2. People – the “A Team”3. Continuous improvement4. Value creation discipline2Harsco 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 countriesHarsco CorporationHarsco’s Partnership with the Steelmaker3? Integrity is absolute? Shared knowledge is our greatest asset? Working together builds success? Human life is priceless? In always keeping our promisesWe believe4? 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 successSafety Principles5We 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 conservationWe are committed to certification of all our remaining operations worldwide by the end of 2010.Environmental ManagementContinuous Improvement 61) Unique knowledge-sharing mechanism that operates across the global Harsco team2) 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. Today’s Steelmaking Challenges7? 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 Sustainability8? Scrap Management? Scrap processing? Product handling? Transportation? Meltshop services? PackagingHelping steelmakers to optimise logistical efficiency and productivityScrap Management9Optimise 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 vehiclesScrapMaster Overview10ScrapMasterManagement information reporting puts you in controlThree integrated operating modules for cost-effective management of the entire scrap supply chain, with full segregation and traceability Scrap Chute loadingIncoming scrap Scrap Handling®®11ScrapMaster Value In UseTangible cost savings and value enhancement? Meltshop productivity? Metal purity? Secondary metallurgy®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®Scrap Processing13We 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 cuttingScrap Baling14Domestic Scrap BalingAnnual Volume of Scrap Processed: 51k tonnes/year2000 PSI Cutting Force:Baler Cycle Time: 2 minutes per batch, each batch is 0.7 tonnesUp to 2.2 tons/m3Average Density of Baled ScrapCase Study: Scrap Shredding15Shredder, Argentina17,000 tonnes per month - Unloading of incoming scrap - Sorting of unshreddable material (cylinders, gas tanks, etc) - Scrap feeding to the Shredder Machine - Transport to Basket preparation Yard for disposal16High-Productivity Scrap BreakingLatest drop-balling crane technology: ? Dual hoist system (25 % improvement in tonnage per hour in trials)? Camera-guided targeting of the ball.High-Volume Scrap Cutting17Multi-torch FerroCut® system delivers high productivity when cutting? Thick & heavy scrap? Tundish & Heavily contaminated skullsTotally enclosed cutting bed and gas cleaning ensures environmental compliance- Cuts material up to 1.6metres thick 18Transport 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 breakoutsLiquid Steel TransportEssential maintenance - Meltshop19? Ladle and vessel lip cleaningComprehensive 24/7 service throughout meltshop? Tundish removal and transportSemi-finished Product Handling20Optimise 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 Semi-finished Product Handling21Controlled 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 handlingFinished Product Logistics22Transport 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? Slitting and cutting23Helping steelmakers to optimise product quality24Specialist 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 systemsCutting & SlittingProduct Quality Solutions25? Visual inspection to identify and fix surface defects?In-line bar sorting and repair facility e.g. splits, folds, poor cuts or outside required lengthsMachine 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 flowReal time processing? Slag handling/Metal recovery? Slag recycling? Dust & sludge metal recovery and recycling26Helping steelmakers to optimise the economic value of recycled by-productsMetal Recovery27Recycling 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 productionSteelmaking Scrap Value 28Area MaterialFe Content % Size (mm) Requirement Price ($/tonne)EAFLadleDegassingSteel scrap Ladle coolant scrapDegasser coolant scrap70 - 809095+130 - 150 1 -3 tonne lumps 30 -13012 -30Size to allow compact charging. Free of deleterious materialsLow residuals, free flowingVery low residuals, small size, free flowing275420515Slag Recycling29TransportSlag resold to third partiesMetal RecoveryProcessingSlag ProductDevelopment30? 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 stabilisationSteel slag is re-used in many commercial applicationsSlag RecyclingHarsco’s solutions recycle by-products back into process, saving on raw materials31Raw MaterialsIron OreScrap Carbon Lime/DolyAlloys By-productsÎ SludgeÎ MillscaleÎ SlagÎ DustÎ FinesBy-Products Value in Use: Electric Steelmaking Example32Carbofer RecoFlux™ PerformixAddition Rate (KGs/Tonne of Steel)Addition Rate (Tonnes per heat)Product Returned to Furnace (Tonnes)By Products Consumed (Tonnes)15,750 15,000 2,81315,00012,857 5,6251.54 1.80 0.6817.14 20.00 7.50Raw Materials SavingsLandfill SavingsCO2 Emissions Savings Third Party Sales Customer’s Total Annual Savings 773,438 691,406 2,643,7502,452,500 675,000 027,000 4,500 033,750 0 03,286,688 1,370,906 2,643,750Usage DataCustomer Savings ($)Annual tonnage: 750,00033Oily millscale and bag house dust are recovered, processed and re-injected into the furnace as a slag foaming agent1) Proven increases in Fe yield (from dust & millscale)2) Replaces carbon injection3) Eliminates EAF dust disposal costs4) Enrichment of Zn level in EAF dust allows marketingCarbofer® is a patented slag foaming agent 34We deliver:? Project evaluation? Equipment selection procurement? Project implementation? Facilities commissioning and start up? Personnel training? Operations supportWe 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 globeConsulting & Project Management Services