Solutions for Stainless Steelmakers 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 Stainless 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 servicesHelping 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 vehiclesValue to Steelmaker- Best use of internal arisings- Lower secondary metallurgy costsScrapMaster 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®13We process revert or external scrap according to your specific needs and prepare scrap for internal re-use.? External or internal Scrap processing? OxyCutting? Mobile Lancing hood solution Value to SteelmakerMinimise scrap purchasing costs and upgrade scrap to the required qualityScrap Cutting14Domestic 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: Value to SteelmakerHigher scrap density results in reduced furnace charge cycle timesScrap Baling15Value to SteelmakerTransport 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- Avoidance of a breakout and its costs – safety, material, production downtime - Preserves ladle refractories- Lowest Total Cost of Ownership for the millLiquid Steel Transport16? Refractory removal and relining? Ladle and vessel lip cleaningComprehensive 24/7 service throughout meltshopValue to Steelmaker- Minimal production downtime - Service tailored to suit production parameters and schedule? Tundish removal and transport? EAF meltshop cleanupEssential maintenance - Meltshop17Optimise 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 Value to Steelmaker- Improved cash flow- Zero lost items targetSemi-finished Product Handling18Transport 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 pointsValue to Steelmaker- Full tracking of products until delivery- Careful handling protects products in transportFinished Product Logistics19Complete packaging solution for cold coils and coated sheetValue to Steelmaker- No damage in handling or transport- Preserves product quality? Supply of packaging materials? Internal transfer of material between production processes? Computerized identification and positioning systems? Capacity to invest in automatic systemsFinished Product Packaging? Grinding? Slitting and cutting20Helping steelmakers to optimise product qualitySlab Grinding21? Semi-automated & manual grinding of surface defects? Throughput & surface quality tailored to individual customer requirements? Visual inspection for quality controlFor face & edge grinding:22Specialist 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- Exact Cutting to end-user specification - Minimise revert scrap wasteValue to SteelmakerCutting & Slitting? Slag handling/Metal recovery? Slag recycling? Dust & sludge metal recovery and recycling23Helping steelmakers to optimise the economic value of recycled by-products24Slag RecyclingTransportSlag resold to third partiesMetal RecoveryProcessingSlag ProductDevelopment25Recycling 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 productionValue to Steelmaker- Maximise scrap Fe unit yield - Upgraded products to suit production requirementsMetal Recovery26? 5 High Grade plants worldwide? Plants range from 22tph to 70tph? Processes typically include? Pre-screening and crushing? Milling and grinding with rod and ball mills? Gravity concentration? Fines de-wateringHigh Grade Plants27? Maximise profit per ton of slag processed by optimising:? recovery of metallic content? the efficiency of our plants (minimum cost per ton processed)? the utilisation of the metal-free slag as a raw material in other industries? Value for our customers? Run the most efficient plants in the market? minimise unplanned stoppages, resulting in best availability and utilisation ratings? maximise throughput per hour without sacrificing safety or qualityOperating principles28? Stainless Steel slag replaces limestone in asphalt? Leachate issues resolved by encapsulation in Bitumen? Produces 120,000 TPY asphalt from EAF and AOD stainless steel slag? Currently sells all suitable slag generated in the Sheffield area (carbon and stainless) into the road construction marketSteelPhalt UK29? AOD slag falls to dust upon cooling due to a phase change in the slag. The resulting material is difficult to handle and is an environmental issue Benefits of Borax? By adding ‘Borax’ at the decant stage, the slag is stabilised and doesn’t go through the phase change? The Borax also improves metal segregation and means the slag is saleable as an aggregateWithBoraxWithoutBoraxBorax30Slag Pot Double DecantingValue to Steelmaker? Recycling of Pot Top slag into asphalt surface course market ? Higher yield of metal recovery p/t through HG Plant? Pot Top contains less metal due to density differential? AOD slag Trial produced: 33% Pot top and 67% Pot BottomPot BottomPot TopSlag Pot tipping procedure developed for Stainless Slag31By-products from stainless steel operations can be processed to recover the valuable Ni and Cr componentsPlasminox by-product recycling32A high yield Fe/Ni/Cr alloy is produced that can be re-used at EAFAn inert slag and Zn enriched dust is also producedDusts and sludges are mixed with flux and reductantthen smelted in a plasma furnacePlasminox by-product recycling33We 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