Polymer Technology - SEAISI treavelling Seminar 2015.ppt

Polymer Technology

2015 SEAISI Travelling Seminar30th March – 8th April 2015

Sustainable EAF Steelmaking through the Use of

Polymer Technology

Dr Zheshi Jin

Introduction

Commercial in Confidence

OneSteel have been developing innovative technologies to use recycled polymers as

alternative carbon units in steelmaking. These technologies hold promise of an

environmental and steelmaking win-win.

This presentation will introduce two key technologies: Polymer Injection Technology and

Polymer Composite Briquette. Polymer Injection Technology, developed in close

collaboration with the University of New South Wales, have become a standard process

in Australia since 2008 and have also been successfully implemented in a number of

overseas plants; Polymer Composite Briquette is in the final plant process validation

stage prior to being commercially implemented.

Carbon

Who is OneSteel


2000

CreationSpin-off from BHP

2005

Project

Magnet

2007SmorgonAcquisition

2010Moly-Cop

Acquisition

2011-2013

Mining Business

Doubled – 12mtpa

Domestic steel manufacturer& distributor

Internationalmining & materials company

Creation of iron export business

Domestic steelconsolidationGrinding mediaRecycling

Grinding mediaexpansion tonth&sth AmericaNo1 producer

South America

Mining Consumables in

Chile and Peru

Australasia

Mining Consumables in Australia

and Indonesia

Blast Furnance

Distribution in Australia and New

Zealand (Steel and Tube NZ)

EAF’s

Recycling in Australia and Asia

Arrium/OneSteel’s Global Footprint

North America

EAF

Mining Consumables in

Canada, USA, and Mexico

Northern

Territory

Western Australia

Southern Australia

Queensland

New South Wales

Victoria

Tasmania

Sydney Steel Mill600 ktpa

1 x EAF (80 t)

1 x Billet Caster (127 mm)

Waratah Steel Mill380 ktpa

1 x EAF (56 t)

1 x Billet Caster

1 x Ingot Casting Pit

AltaSteel Mill300 ktpa

1 x EAF (56 t)

1 x Billet Caster

1 x Ingot Casting Pit

Arrium/OneSteel’s

Steelmaking Capability

Laverton Steel Mill780 ktpa

1 x EAF (84 t)

1 x Billet Caster (150 mm)

Whyalla Steelworks1.3 Mtpa

2 x BOF (130 t)

1 x Combi Slab/Bloom

Caster (350/950 x 250 mm2)

1 x Billet Caster

Sydney Steel Mill

NSW, Australia

Start-up date 1992

Manufacturer Danieli

Type AC EBT

Transformer 66 MVA (Tamini)

Mean tapping

weight

80 tonnes

Shell diameter 5.5 m

Electrode

diameter

22 inch

(~560mm)

Chemical energy 2 BOC oxygen-

natural gas

burners

Fuchs combined

oxygen and

carbon door

lance

Annualised

production

600,000 t.p.a.

Operates under the tightest environmental requirements in the group due to its location being adjacent to residential

areas and recreational facilities in Sydney

Laverton Steel Mill

Melbourne, VIC, Australia

Start-up date 1988

Manufacturer Fuchs

Type AC OBT

Transformer 77 MVA (Tamini)

Mean tapping

weight

84 tonnes

Shell diameter 5.5 m, 0.95 m

offset

Electrode

diameter

24 inch

(600mm)

Chemical

energy

Danieli/More

Module System

3 oxygen-jet

injectors

3 carbon-jet

injectors

1 Lime-Jet

Annualised

production

780,000 t.p.a.

OneSteel Steelmaking Solutions Team

Paul O’Kane

� Principal Steel Manufacturing Technology Officer - chairs the Steelmaking and Rolling Best Practice Forum for Arrium Group

� Bachelor of Applied Science (Metallurgy).

� 32 years experience in the steel-making industry

� Various positions in BHP/OneSteel including Operations Superintendent BHP Newcastle, Manager MeltshopSmorgon Steel Group and General Manager MultiServ, who were responsible for servicing a steel-making plant in Port Kembla, Australia

� The Leader of PIT implementation teams for Sydney, Laverton , USA, UMC and Celsa UK

Andrea Fontana

� Technical Superintendent, Meltshops

� Bachelor Chemical Engineering

� 19 years experience in the steelmaking industry.

� Started at Danieli, Italy, and worked for seven years and commissioned a variety of melt shop equipment as Project Manager . Joined OneSteel in 2000

� Current focus is steelmaking best practice for all Meltshops in Arrium Group

� Key member of PIT implementation teams for Laverton , UMC and Celsa UK

Zheshi Jin

� Principal Research Officer

� PhD in Materials Science & Engineering

� 20 years experience in Australian steel manufacturing industry.

� Joined BHP/OneSteel in 1994 and commissioned major projects in a variety areas including metallic/organic coatings and EAF offgas/dust treatment

� Current focus is R&D on steelmaking best practice, with specific focus on steelmaking emissions control

� Key member of PIT implementation team for Celsa UK

Daniel Miles

� Manager Steelmaking Solutions

� Bachelor of Metallurgical Engineering (Hons), MBA

� 25 years experience in Australian steel manufacturing industry.

� Experience in wide areas including R&D, Technical metallurgy, Operations, Corporate Strategy and Business Development and Sales and Marketing

� Current focus is on the commercialization of PIT and UNSW partnership

Polymer Injection

Technology

Foamy Slag – Key to modern

EAF steelmaking

� Longer arc = higher input of electrical energy

� Improved heat transfer from arc to steel

� Decreased heat losses to sidewalls

� Reduced electrode and refractory consumption

� Improved FeO reduction:ability to recover ironunits from the slag intothe molten bath

Evaluation of Slag Foaming

& FeO Reduction

The foaming efficiency of the slag is measured by the volume of the slag over time – or a Vt/V0 test.

• Volume ratio of slag: Vt/V0

• Vt: foamed slag volume at time t

• V0: initial dense slag volume

• Percentage of reacted FeO in slag

• FeO% = (nCO + 2nCO2) / nFeO × 100%

• nCO : CO mole numbers until time t

• nCO2: CO2 mole numbers until time t

• nFeO: initial FeO mole numbers in slag

Polymer Injection technology

Improved Slag Foaming

t=120 sec t=180sec t=240sect= 0 sec

100%

Co

ke

t= 0 sec t=120 sec t=180sec t=240sec

Po

lym

er

Ble

nd

Slag Foaming Volume Analysis

A combination of rubber and coke produces a superior foaming slag volume than coke alone


Laboratory Work at UNSW

• Established feasibility of carbon and polymer blends as foaming agents.

• Patented in major industrial countries

• Results reported in previous papers and conferences.

Prof. Veena Sahajwalla,

Rate of CO, CO2 gas generation (mL/sec) with reaction time following interaction of EAF slag with MC, HDPE/Rubber-coke Blends.*

Gas Generation CO and CO2

(Infrared)

0

1

2

3

4

5

0 300 600 900 1200 1500 1800

Rate

of

tota

l g

as g

en

erati

on

(m

L/s

ec)

Time, sec

100% MC

MC-Rubber Blend

MC-HDPE Blend

* V. Sahajwalla, M. Zaharia, M. Rahman, R. Khanna, N. Saha-Chaudhury, P. O’Kane, J. Dicker,C. Skidmore and D. Knights, “Recycling Rubber Tyres

and Waste Plastics in EAF Steelmaking”, Steel Research int. 82 (2011) No. 5, pp. 566-572

The rate of gas

generation following the

interaction of HDPE-

Coke blend was seen to

be the fastest, followed

by the rate of gas

generation from rubber-

coke blends, while the

lowest rate was seen

when coke represented

the carbon material.

* J. Dankwah, P. Koshy, N. Saha-chaudhury, P. O’Kane, C. Skidmore, D. Knights) and V. Sahajwalla, “Reduction of FeO in EAF Steelmaking Slag by Metallurgical Coke and Waste Plastics Blends” ISI(J International, Vol 51(3), 2011, pp. 498-507

Gas Generation

(Gas Chromotgraphic)

The Benefits – Reduction in Inject

Carbon Consumption and Cost

� Improved slag foaming results in a reduction in the amount of carbon injectant consumed per heat

� The chemical composition of rubber tyre crumb is similar to high grade anthracite (87-90% fixed carbon and low ash)

� In most regions, rubber crumb can be purchased at a lower price than that of coke / anthracite

� Rubber properties are better than coke

� Doesn’t absorb moisture

� Not washed like coke so lower potential chlorine

� Not as fine and does not break down during transport and storage

(less loss to bag house and less wear on injection pipes)


The Benefits – Improved Yield

� Laboratory studies have shown that a blend of polymer and coke is able to reduce the slag rapidly, attaining over 80% reduction in less than 400 seconds; in comparison by 400 seconds the reduction by 100% coke is much less (only about 6%)

� This is a result of the extra reducing gases (CH4 and H2) generated with the addition of polymers

� With the blend of rubber/coke, the hydrogen contained in the rubber helps maintain cyclic carbon gasification reactions to obtain high rate of slag FeO reduction.

� Improved reduction of slag FeO results in improved yield


The Benefits – Reduced Electrical

Consumption and Improved Productivity

� The improved slag foaming results in:

� Superior insulation of molten bath

� Improved shrouding of the electrodes

� Longer arc

� This results in:

� Reduced Power on time

� Improved active power

� Reduced electrode wear

� Reduced electrical energy consumption


The Benefits – Environmental

• Reduced carbon footprint through reduced CO2 emissions as a result of the potential to reduce electricity consumption produced by coal-fired power stations

• The technology reduces carbon per tonne of steel produced by 8-11kg (based on results from Australian mills) partially mitigating against potential cost of carbon trading schemes

• In addition rubber that is often diverted to landfill are recycled into value-added steel products

• High temperature reactions in slag layer – therefore no noxious fumes or foul odours around EAF.

• Reduced dioxin emissions


Summary of Benefits

Benefit Area SSM LSM USA 1 Asia 1 Asia 2 Europe 1

Reduction in Electrical consumption(KWh per billet tonne)

2.8% 2.4% 1.7% 5.1% 3.8% 1.6%

Reduction in inject carbon(kilograms per heat)

12.0% 16.2% 6.3% 12.0% 12.0% 8.4%

Yield improvement 0.30% 0.27% 0.24% 0.20% 0.17%

Increase in productivity(Tonnes per minute of POT)

3.0% 1.9% 2.7% 2.8% 1.8%

Reduction in inject oxygen(cubic metres per billet tonne)

2.3% 1.9% 0.7% 1.6% 5.6%

Reduction in Natural Gas(cubic metres per billet tonne)

1.9% – 1.7% – – –

FeO% reduction 3.0% 2.5% 2.4% 2.0% 1.5%

Increase in Active Power (MW) 1.0% 0.8% 0.95% 2.0% 0.87%

Total inject per billet tonne (kg/t) 5.2 9.8 9.2 12.0 15.8 4.1

Oxygen to total inject ratio 3.4 2.8 5.3 3.6 1.8 6.9

Milestones achieved in Australia

February 2015

� 73,676 heats tapped using Polymer Injection

Technology at SSM &LSM

� 26,479 t of coke consumption replaced

� 2,124,618 equivalent used car tyres consumed

Awards

� 2007 Certificate of Recognition from AIST

� 2008 Finalist – European Environment Agency Royal Awards –

Sustainable Technology Transfer 2008

� 2008 NSW Green Globe Awards, Industry Award – Environmental

Sustainability

� 2011 Finalist – NSW Green Globe Awards, Waste and Recycling Award

� 2012 Winner – CRC Australian Collaboration Innovation Awards

� 2012 Finalist – World Steel Association Steelie Awards, Innovation of

the Year 2012

� 2012 Finalist – Premier’s NSW Export Awards

� 2012 One of eight innovations by Society of Manufacturing Engineers –

Innovations That Could Change the Way We Manufacture 2012

� 2013 Finalist – Eureka Prize for Commercialisation of Innovation

� 2014 Research & Development Excellence Award, Engineers Australia

Building Capability

of Young Engineers

� Another key achievement of the polymer technology development has been the building capability of young engineers through the close relationship with the University of New South Wales.

� As well as sponsoring PhD students over the years, OneSteel also have a scholarship program with UNSW for undergraduates. OneSteel sponsors two students in second, third and fourth year.

� These students are given projects at the plants during summer vacation with set objectives that deliver tangible benefits back to the business. They are well supervised and present the results to the Sydney Steel Mills Meltshop and Rolling Mill lead teams.

� This develops the students and exposes them to business drivers and practical application of knowledge to deliver outcomes. OneSteel can assess their development opportunities and assist them grow professionally.

Commercialisation

� Completed commercialisation at UMC, Thailand, 2011

� Commercialised at SeAH BeSteel (4 EAFs), Korea, April 2014

� Completed implementation at Celsa UK, October 2014

� In agreement for implementation at Celsa Nordic in July 2015 followed by Celsa Barcelona

� In discussions with a number of steelmakers in Asia and the Middle East for potential implementations

Environmental Results

Dioxins


� Tests of stack dioxin emissions conducted at four plants

� 4 times at Site 1: September 2007, November 2007, May 2008, July 2008

� Once at Site 2: February 2008

� Once at Site 3: August 2008

� Once at Site 4: July 2014

� Coke and rubber/coke blend used within 36 hours of each other to ensure valid results, except at Site 3, where the tests were a week apart



Dioxin

emissions

Site 1 Site 2 Site 3 Site 4

Data point 1 75% 26% 17% >100%

Data point 2 45%

Data point 3 5%

Data point 4 6%

Site 1 Site 3 Site 4

Volatile Organic

Compounds

-75% -40% -85%

Carbon Monoxide 12% -37% -21%

Sulphur dioxide 14% 21% -87%

Nitrogen Oxides 2% -6% 15%

Positive percentage values are percentage decreases

� The results from various sites have shown that rubber injection always reduced dioxin emissions and didn’t cause any material impact on other emissions such as heavy metals, combustion gases, sulphur dioxide and VOCs, any variations were all well within the respective emissions limits

� It is the experience of OneSteel that scrap quality and blend, as well as operational delays, have a major impact on air emission results; the scrap blend at Site 3 was altered between tests


Dioxins SSM


Sulfur – no pick up in the steel


Sulfur in steel at Sydney Steel Mill (annual average)

100% Coke injected Rubber / Coke injected

2007 0.0213%S 0.0219%S

2008 0.0226%S 0.0224%S

Component Rubber

Ash 2.4%

C 85.9%

H 8%

Sulfur 2%

Moisture 0.8%

� The sulfur content in tire rubber is about 2%. There is no reversion into steel, though, as all reactions happen in the slag layer.

� OneSteel has conducted specific campaigns at SSM to check sulfur pickup in the steel when injecting a rubber/coke blend, and compared the results with coke only injected heats.

� Found no statistical difference in the sulfur content in the steel.

Hydrogen – no pick up in steel and

improved slag reduction


� Gas bubbles generated from the polymers will react in the slag layer, and get consumed.

� There is no discernible increase to the hydrogen level in the steel as a result of injecting rubber into the slag

� The presence of hydrogen and some fixed carbon in a carbonaceous material is essential to initiate and maintain cyclic carbon gasification reactions to obtain a high rate of slag FeO reduction. This essential requirement is fulfilled when coke is blended with rubber, which contains about 8% of hydrogen


Basic overview of the

implementation process

� Review your steelmaking KPI’s

� Perform volume and chemical analysis of your coke and rubber options

� Rubber sourcing and accreditation

� Work with you to gain regulatory approval if required

� Material handling system

� Training and development of employees

� Management of a controlled trial

� Coordination of environmental testing through specialised consultants if required.

Polymer Composite

Briquette

Polymer Composite Briquette

of recycled PE and coke fines

Progress – plant trials

� Small scale trials at SSM in July 2011 using briquettes produced from a standard industrial extruder at APR, Adelaide

� Preliminary trials at LSM in 2012 using briquettes produced at QCM, Pt Kembla (OzRock process)

� Trial of 10t QCM briquettes at LSM in November 2012� Reduction in electrical energy consumption of 10kWh/cht

� Reduction in power on time by 1.2min

� Reduction in charge carbon consumption of 11.5%

� 20t briquettes produced in Italy in July 2014 from a commercial compression briquetting process� 10t trialled at LSM in January 2015

� Reduction in electrical energy consumption of 12.4kWh/cht

� Reduction in power on time of 0.8min

� Reduction in charge carbon consumption of 18%

� Remaining 10t will be trialled in March 2015 at LSM together with stack monitoring and workplace health tests


Plant trial results

Electrical Energy consumption – 15 kWh/bt saving


Plant trial results

Power on time – 0.8min reduction


Plant trial results

Charge carbon consumption – 18% reduction with same tap C% and oxy


Plant trial results

Tap and arrival temperature

Biochar - Crucible Technology

� Technology developed to produce

carbon and gas from biomass

especially wood and other waste

materials or polymer products

� Demonstration plant operating at

Vales Point

� ~0.5 t/hr throughput

� Continuous automated process for multiple biomass feed sources

� Completed 72 hours campaign of stable automated operation

� In the process of obtaining EPA

special exemption for the products –

char and gas as normal standard

fuels

� Ready for commercialisation

39

Feed for Biochar

Preparation of feed for the demonstration facility

Emission test results

Meet all requirements

Pollutants/Species Group 6 limit CBC results

Total particulates 50 <3

Fluorine 50 3.2

Heavy metals 1 0.027

Mercury 0.1 <0.002

Cadmium 0.1 <0.001

Dioxins 0.1 0.00095

VOCs 40 0.02

SO3 100 5.4

H2S 5 0.46

Chlorine 200 0.02

All units mg/m3, except for dioxins ng/m3Test date: 7th January 2015 at Vales Point

42

� Typical composition

� Fixed carbon: typically about 50-70%

� Very low ash (1%) and low S (<0.03%)

� Inherent moisture 4%

� Remainder VM

� Size � +4mm 1.3%

� - 4mm +1 mm 11.2%

� -1mm + 0.5mm 37.3%

� -0.5mm +0.212mm 46.8%

� -0.212mm 3.4%

42

Biochar

42

4343

Biochar

0

0.5

1

1.5

2

2.5

3

3.5

0 50 100 150 200 250 300 350 400

Vo

lum

e R

ati

o :

Vt/

Vo

Time - Sec

OST Bio Char + OST Rubber + OST Slag

43

Summary

� Polymer Injection Technology is a commercialized sustainable steelmaking technology

� Partial substitution of coke or anthracite with a polymer source (e.g. rubber)

� Low capital requirements

� Proven records of commercial implementations

� OneSteel continues to research and develop

� Polymer sources

� Polymer blends

� New technologies

� OneSteel is developing engineering technology for commercial applications of Polymer Composite Briquette and Biochar as alternative low cost carbon units in EAF steelmaking


Polymer Technology - SEAISI treavelling Seminar 2015.ppt

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