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 Steelmakers 1 Harsco’s Core Ideology 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 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 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 4 ? 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 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 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. 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 8 ? Scrap Management ? Scrap processing ? Product handling ? Transportation ? Meltshop services ? Packaging Helping steelmakers to optimise logistical efficiency and productivity 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 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 ® ® 11 ScrapMaster Value In Use Tangible 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 Processing 13 We 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 cutting Scrap Baling 14 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 Shredding 15 Shredder, Argentina 17,000 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 disposal 16 High-Productivity Scrap Breaking Latest drop-balling crane technology: ? Dual hoist system (25 % improvement in tonnage per hour in trials) ? Camera-guided targeting of the ball. High-Volume Scrap Cutting 17 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 18 Transport 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 breakouts Liquid Steel Transport Essential maintenance - Meltshop 19 ? Ladle and vessel lip cleaning Comprehensive 24/7 service throughout meltshop ? Tundish removal and transport Semi-finished Product Handling 20 Optimise 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 Handling 21 Controlled 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 handling Finished Product Logistics 22 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 ? Slitting and cutting 23 Helping steelmakers to optimise product quality 24 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 Product Quality Solutions 25 ? Visual inspection to identify and fix surface defects ? In-line bar sorting and repair facility e.g. splits, folds, poor cuts or outside required lengths Machine 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 flow Real time processing ? Slag handling/Metal recovery ? Slag recycling ? Dust & sludge metal recovery and recycling 26 Helping steelmakers to optimise the economic value of recycled by-products Metal Recovery 27 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 slag ? Upgrading of recovered metallics =>Coolant and degasser scrap production Steelmaking Scrap Value 28 Area Material Fe Content % Size (mm) Requirement Price ($/tonne) EAF Ladle Degassing Steel scrap Ladle coolant scrap Degasser coolant scrap 70 - 80 90 95+ 130 - 150 1 -3 tonne lumps 30 -130 12 -30 Size to allow compact charging. Free of deleterious materials Low residuals, free flowing Very low residuals, small size, free flowing 275 420 515 Slag Recycling 29 Transport Slag resold to third parties Metal RecoveryProcessing Slag Product Development 30 ? 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 Harsco’s solutions recycle by-products back into process, saving on raw materials 31 Raw Materials Iron Ore Scrap Carbon Lime/Doly Alloys By-products Î Sludge Î Millscale Î Slag Î Dust Î Fines By-Products Value in Use: Electric Steelmaking Example 32 Carbofer RecoFlux™ Performix Addition Rate (KGs/Tonne of Steel) Addition Rate (Tonnes per heat) Product Returned to Furnace (Tonnes) By Products Consumed (Tonnes) 15,750 15,000 2,813 15,00012,857 5,625 1.54 1.80 0.68 17.14 20.00 7.50 Raw Materials Savings Landfill Savings CO2 Emissions Savings Third Party Sales Customer’s Total Annual Savings 773,438 691,406 2,643,750 2,452,500 675,000 0 27,000 4,500 0 33,750 0 0 3,286,688 1,370,906 2,643,750 Usage Data Customer Savings ($) Annual tonnage: 750,000 33 Oily millscale and bag house dust are recovered, processed and re-injected into the furnace as a slag foaming agent 1) Proven increases in Fe yield (from dust & millscale) 2) Replaces carbon injection 3) Eliminates EAF dust disposal costs 4) Enrichment of Zn level in EAF dust allows marketing Carbofer® is a patented slag foaming agent 34 We deliver: ? Project evaluation ? Equipment selection procurement ? Project implementation ? Facilities commissioning and start up ? Personnel training ? Operations 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 Consulting & Project Management Services