Resource Recovery Solutions Brochure

1 Harsco Metals Recovery Resource Solutions 01 Harsco Metals Recovery Resource SolutionsResource Recovery Solutions Harsco HouseRegent Park299 Kingston RoadLeatherheadSurrey KT22 7SGTel +44 (0) 1372 381400Fax +44 (0) 1372 381420Email resourcerecoverysolutions@harsco.comwww.harscometals.comTransforming the value of steelmaking by-products through innovative resource recovery solutions Harsco Metals 03Harsco Metals provides specialist solutions in resource recovery, logistics and product quality to the global metals industry. Our approach is based on solving the specific challenges facing individual customers – each contract is entirely bespoke. We also fully recognize that many of the issues relating to by-product recycling or efficient production flows are common to most producers, and we draw on our unique global scale to apply best operating practice when designing solutions. With operations at more than 160 locations in over 30 countries, Harsco Metals has followed the footprint of the steel industry worldwide. This has enabled us to gain unrivalled depth and breadth of knowledge, as well as providing the scale to develop new process technologies focused on enhancing value to our customers.Our long-term approach to customer relationships is underpinned by our belief that safety is paramount and our aim is to create an injury-free workplace. Harsco Metals is also engaged in a systematic process of continuous improvement of our operations along ‘lean’ principles, providing leverage on cost efficiencies throughout the entire life of the customer relationship. Globally Engineered SolutionsRecovery Resource Solutions4 Harsco Metals Recovery Resource Solutions Harsco Metals 5A growing number of steel producers have embraced the goal of zero waste. Harsco Metals enables these strategies by providing economically and environmentally viable solutions for recycling by-products.According to the World Steel Association, every tonne of steel produced generates 200kg of by-products via the EAF route and approximately double this figure by the BF/BOF route. The economics of landfill often make it a prohibitively expensive option, especially considering the alternative route of recycling.For the steelmaker, resource recovery translates into greater efficiency. Harsco Metals’ resource recovery processes achieve high yield rates in metal recovery. We have also developed numerous external markets for residual by-products after the metal has been extracted, including applications across the construction, cement, agriculture and shipyard industries. Towards zero wasteBy-products produced (kg) per tonne of crude steel produced SLAGDUST & SLUDGE0 50 100150200250300350400450500BF BoFEAFWorld Steel AssociationRaw materialsMetal productsRecyclingAgriculture Construction Cement ShipyardsMaterial analysisProcess requirementsEnvironmental impactTechnical solutionBy-productsMetalrecoveryMetals producer Harsco Metals has helped Hadeed Iron & Steel (Saudi Arabia) implement a zero waste policy across multiple by-product streams. SteelPhalt recycles 100% of the steel slag produced by 3 different steel mills in the Rotherham (UK) area, into roadmaking applications. At AK Steel Ashland (USA), Harsco Metals is processing dusts for recycling ferrous units back into steelmaking as briquettes. Harsco Metals 7Recovery Resource Solutions6 Harsco MetalsThe benefits of resource recovery extend beyond economics. The environmental impact is greatly reduced: by less landfill, less quarrying of natural aggregates, less pollution due to the reduced need for transportation, and reduced CO2 emissions through more energy efficient processes.The solutions we develop for resource recovery don’t just extract the economic value of by-products. They also protect the environment and the surrounding community, thereby contributing towards sustainable steelmaking. At ArcelorMittal’s Carinox stainless steel plant, Harsco Metals has developed an innovative solution to address the environmental hazard posed by uncontrolled slag dust emissions. Stainless steel slag fines necessitate tight environmental controls on slag handling and storage. After taking readings of local wind patterns and dust concentrations in the surrounding residential area, Harsco Metals designed a solution in collaboration with our customer and the Belgian Environmental Protection Agency which complied with the agreed emission limits. Having installed customised hoods to cover each slag pit bay, dust levels are controlled via water sprayed from hood nozzles. The entire area is monitored by dust sensors laid out at strategic points and the dust readings recorded on the system are verified by the EPA.Harsco Metals makes annual sales of over nine million tonnes of processed slag to end-users in more than 25 countries. Improving sustainability, reducing environmental impact The stainless slag pits at ArcelorMittal’s Carinox plant are entirely covered by dust hoods. These hoods are complemented by water sprayed above the pit for dust containment. The aerial view of the site at Carinox shows the areas monitored by the dust measurement system.8 Harsco Metals Recovery Resource Solutions Harsco Metals 9Over the many years that Harsco Metals has been providing resource recovery solutions, we have been at the forefront of developing process technologies that maximise metal recovery yields and produce a residual product which can be safely recycled.We work closely with our customers to design solutions that integrate the recycled product into the production flow. One example of this is Carbofer®, a slag foaming agent sourced from millscale, dusts and sludge recovered on site. These materials are blended with lime and carbon inside a purpose-built plant to produce a free-flowing powder injected directly into the furnace.At Terni in Southern Italy Harsco Metals has developed an integrated solution which recovers highly valuable Ni and Cr units within a variety of dusts, scales and other by-products generated by ThyssenKrupp stainless steel mill. The smelted end product is a Ni- and Cr-rich alloy which is returned into steelmaking at Terni. The solution has improved the sustainability of steelmaking operations, as well as successfully reducing the cost of raw materials and landfill.Innovative solutions for resource recovery Under the Carbofer® process, a slag foaming agent is directly injected into the EAF furnace. The Plasminox® process technology recovers Ni and Cr elements from stainless steel dust, sludge and scale.At Gadsden, Alabama, Harsco Metals is working in partnership with the EPA on one of the largest sustainable remediation projects in the USA10 Harsco Metals Recovery Resource Solutions Harsco Metals 11SlagHarsco Metals extracts the full metallic value from steel slag through magnetic separation, and we operate metal recovery processing plants in more than 50 locations around the globe. After conditioning, screening and crushing, slag possesses many properties which make it superior to natural aggregates for a number of applications. The chemistry of steel slag varies depending on the steel grade being produced, and selecting the right application is key due to expansivity (free lime) and the leaching properties of slag. Our approach is to develop aggregate solutions entirely adapted to local market conditions. This reflects state or national regulations specifying the physical or mechanical properties of permitted materials, as well as additional factors such as the expected service life. Through our extensive global network, Harsco Metals has developed slag applications in industries such as construction, cement, environmental services, and shipyards.Dust and sludge Many integrated steelmakers recycle their particulate by-products to the sinter plant. However, because of the low volume and poor handling characteristics of the materials, this often results in variations in the composition and homogeneity of the sinter bed with implications for sinter plant productivity. Harsco Metals uses blending and micro-pelletising processes to convert individual by-products into a single homogenized mix, ensuring a consistent feed material. For electric steelmakers, EAF dust is an important opportunity for resource recovery. Harsco Metals’ Carbofer® process produces a slag foaming agent sourced from millscale, dusts and sludge recovered on site. These materials are blended with lime and carbon inside a purpose-built plant to produce a free-flowing powder injected directly into the furnace. ScaleFerrous oxides from the caster or rolling mill represent high quality scrap for re-use in steel production. These can be recycled on their own or agglomerated with other by-products, depending on the specification required, to maximise recovery and minimise any impact on production. Creating value from by-productsEAF example of Resource Recovery potential savings (typical values from 1 million tonnes per year steel production) Raw material savingsLandfill savingsCO2 savingsThird party salesTotalScrap($)Aggregates($)Carbofer($)Total($)5,671,8750005,671,87505,500,000550,0006,050,0001,031,2503,700,00036,00045,0004,812,2506,703,1259,200,00036,000595,00016,534,125 Asphalt aggregates discharged from temperature-controlled bins at SteelPhalt (UK). 9 different by-products are blended at Dunkerque (Belgium) to produce a homogenised feed into the sinter bed. Millscale is also used at Dunkerque to regulate Fe levels in the blend. Processed slag aggregate is used for efficient drainage of synthetic turf football pitches, as in this example in Portugal for our customer Global Stadium. Harsco Metals 1312 Harsco Metals Recovery Resource SolutionsWhen introducing recycled products into the production process, steelmakers apply the same exacting standards that they require from suppliers of raw materials. There is still an overriding necessity for a stable chemistry and other specific parameters, such as a consistent humidity rate or precise pellet size.Specializing in slag, dust, sludge and millscale by-products, Harsco Metals has developed and implemented resource recovery solutions for steelmakers across the globe. With a deep understanding of the physical, mechanical and chemical properties of recycled materials, we are trusted by our customers to provide the right blend of materials to match their specifications.Quality assurance is integral to our service. We maintain rigorous control procedures at every stage of the recovery process in order to ensure that the quality of the recycled product is never compromised. Sample testing of products is carried out routinely throughout the recovery process to ensure compliance with required characteristics, both for recycled products that are to be used within steelmaking and for materials that will be used externally for other applications.Uncompromising quality Stockpiled finished product briquettes. Compression testing of the briquette for strength. Taking a sample of the crushed briquette for moisture testing. Material arrives from hopper into the dryer to reduce moisture content.In the last 20 years Harsco Metals has built and operated over 20 plants to assist the steel industry in recovering value from dust, sludge and scale14 Harsco Metals Recovery Resource SolutionsWe believe in the value of building long-term customer relationships that are based on a commitment to creating sustained and measurable value, along with best practice operational benefits. We provide a completely bespoke service, tailoring –every solution to exact product specifications and seamlessly integrated with the production schedule.Our solutions are complete and comprehensive, –from material analysis to product recycling.We provide solutions that are flexible, with the –ability to recycle products internally or source external markets.Stringent quality assurance procedures ensures –the suitability of recycled products into the production process.A robust and professional management structure –ensures smooth operations from start up, along with the support of a global asset management system for optimal maintenance and cost-effective utilisation of equipment and plant.We possess proven expertise in environmental –regulations, ensuring that every solution is fully compliant.We constantly invest in technology, research and –development to maintain our status as market leaders and innovators. We have patents covering 20 technologies filed in over 30 countries.Why choose Harsco MetalsHarsco Metals has long experience in the use of flame technologies on semi-finished steel products, for precision cutting or surface conditioning applications to the most exacting specifications. Harsco Metals has patented process technologies for scarfing automation, and our expert staff are skilled in manual surface conditioning.We provide Logistics Solutions engineered to optimise the supply chain and contribute towards the metal producer’s goal of On-Time-In-Full. Our expertise in mobile equipment allied with computer modelling of the movement of vehicles and goods allows seamless integration with the metals production flow. This is backed up by item tracking using RFID or GPS, and video monitoring technologies.Our Resource Recovery solutions support the goal of zero waste. By-products are processed or blended to meet the specific chemical, mechanical and physical properties required of the final recycled product. Recovery of metallic units is optimised, using a range of patented process technologies.