Integrated Steelmaker 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 Integrated Steelmakers1Our 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 disciplineHarsco’s Core Ideology2Harsco 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? Raw Materials handling? Product handling? Transportation? Meltshop services? Blast furnace 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®®ScrapMaster Value In Use11Tangible 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®13Annual Volume of Scrap Processed: 50,000 tonnes/year2900 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 DensityCase Study: Shredding RailsScrap Shearing14Domestic 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 Baling15Shredder, 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 disposalScrap Shredding16On-site scrap screening/quality control? Processed in a screening plant - remove any contaminants or waste materials? Return processed scrap to the yard ready for charging into the furnaceSegregatedContaminantsScrap after processingScrap ScreeningHigh-Productivity Scrap Breaking17Latest drop-balling crane technology: ? Dual hoist system (25 % improvement in tonnage per hour in trials)? Camera-guided targeting of the ball.18Multi-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 High-Volume Scrap Cutting19We process excess liquid iron in environmentally controlled conditions, recovering the cooled iron for re-use1. Optimal pit design allows for minimum fume generation and maximum productivity2. Fume control hoods for environmental protection3. Once solidified, plated iron can be broken for internal recycling or external saleIron Ponding20We 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 carriersBulk Raw Materials Management21Comprehensive 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 availabilityConveyor Belt Maintenance22Transport 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 Transport23? Blast furnace runner cleaning? Coke Oven Inlet de-graphitising? Coke Oven CleaningComprehensive 24/7 service throughout the Blast Furnace and Coke Ovens, with a direct link to the production process.? Torpedo lip cleaning? Torpedo wreckingEssential maintenance – Blast Furnace24? Refractory removal and relining? Ladle and vessel lip cleaningComprehensive 24/7 service throughout meltshop, with a direct link to the production process.? Tundish removal and transport? BOS meltshop cleanupEssential maintenance – Meltshop25Optimise 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 TCOSemi-finished Product Handling26Complete packaging solution for cold coils and coated sheet? Supply of packaging materials? Internal transfer of material between production processes? Computerized identification and positioning systems? Capacity to invest in automatic systemsFinished Product Packaging27Transport 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? Scarfing? Slitting and cutting28Helping steelmakers to optimise product quality29Specialised service delivering exceptional product surface quality1) Skilled, experienced manual scarfers2) Androfer robotic scarfer? Patented MultiForm and ShallowCut torches perform various scarfing programs from spot to full face with variable pass widths? Cold or hot (850°C) scarfing; capacity to scarf up to 100,000 tons per month? Eight installations operating worldwide with two scarfing hot slabsScarfing30In-line inspection operating to the most stringent quality standards? Automatic or manual in-line inspection stations;? Finished products can be removed, repaired or rejected? Dye penetration testing to identify surface defects.Quality control and inspection31Specialist 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 & Slitting? Slag handling/Metal recovery? Slag recycling? Dust & sludge metal recovery and recycling32Helping steelmakers to optimise the economic value of recycled by-products33Recycling 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 productionMetal RecoverySteelmaking Scrap Value 34Area MaterialFe Content % Size (mm) RequirementPrice ($/tonne)Sinter PlantBFBOSLadleDegassingLow quality iron oreHigh quality iron ore Steel scrap Ladle coolant scrapDegasser coolant scrap50 - 6060 - 7070 - 8090950 - 66 - 30130 - 150 1 -3 tonne lumps 30 -13012 -30Small size Consistent sizing and analysisSize to allow compact charging. Free of deleterious materialsLow residuals, free flowingVery low residuals, small size, free flowing12024027542051535Slag 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 impactSlag Recycling36? 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 RecyclingBy-Products Value in Use: Integrated Steelmaking Example37Sludge DewateringRecoFlux™ Briquetting Micro PelletisingPerformixAddition 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 15,00080,0000 50,000 100,000 30,0000.00 6.00 3.75 7.50 2.250.00 20.00 12.50 7.5025.00Raw Materials SavingsLandfill SavingsCO2 Emissions SavingsThird Party SalesCustomers Total Annual Savings 0 3,687,500 4,200,000 14,100,0005,644,8000 3,600,000 2,047,500 04,410,0000 24,000 0 00160,000 0 0 00160,000 7,311,500 6,247,500 14,100,00010,054,800Usage DataCustomer Savings ($)80,000Annual tonnage: 4 million38Harsco has experience of more than ten plants worldwide with total capacity of over 1,500,000 tonnes per annumBriquettes for recycling via BF and BOF 39- Final product improves sinter plant productivity- Use of a homogenous sinter bed mix and reduced disposal costsPelletising recycles by-products back into the sinter plant40External saleDehydratePROCESSING50% humidity25% humidityFilter CakeFilter Cake Stockyard managementRecycle to the meltshopProcessing Sludge into useable filter cakeConsulting & Project Management Services41We 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 globe