Engineered Solutions for Integrated Steelmakers

© 2014 Harsco Corporation, All Rights Reserved.

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Harsco is a global industrial services company

� Listed on NYSE, S&P 400 index

� Harsco is a global provider of industrial services and engineered products

� Market leading positions in Metals & Minerals, Rail and Industrial products

� Annual sales of more than $3bn covering 400 locations in over 50 countries

Harsco Corporation

Worldwide presence

Operations at over 160 sites in 30 countries

Services: Logistics; Environmental Remediation, Material Recycling, Metal & mineral recovery, Co-Product marketing,

Harsco Metals & Minerals

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� 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

Continuous Improvement

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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

� Draws on best operating practice generated from Harsco’s 70-year

global operating experience.

� Cover Safety, Asset Management, Operating Guidelines and Service

Quality. Continuously reviewed and updated

The Group Best Practices define our standard operating

practices across the globe.

Harsco Integrated Steel Mill Services at a glance

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� Scrap Management

� Scrap processing

� Raw Materials handling

� Product handling

� Transportation

� Meltshop services

� Blast furnace services

� Packaging

Helping steelmakers to optimise logistical efficiency and productivity

Scrap Management

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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

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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

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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

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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 Baling

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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

- Load shredded scrap into trucks

- Transport to Basket preparation Yard for disposal

Scrap Shredding

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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

High-Volume Scrap Cutting

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Optimise 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 TCO

Semi-finished Product Handling

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Complete 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 systems

Finished Product Packaging

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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.

Finished Product Logistics

� Scarfing

� Slitting and cutting

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Helping steelmakers to meet end-user requirements for product quality

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Specialised service delivering exceptional product surface quality

1) Skilled, experienced manual scarfers

2) Automated scarfing

� 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 slabs

Scarfing

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In-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 inspection

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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

� Converting CO gases to ethanol

� Oily millscale sludge remediation

� Slag recycling/Metal recovery

� Dust & sludge agglomeration and briquetting/pelletizing

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Helping steelmakers to optimise the economic value of recycled by-products, and minimise the environmental impact of production

Coal

Micro Pellets

Electricity

CO gas Coke Ovens

Sinter plant

Blast Furnace

Iron Oxide Fines

Micro Pelletizing

plant

LANDFILL

BF Slag

GGBS

MineralRecovery

Scrap Upgrading

Cement

MR plant Fines

GGBFS

DesulphSlag Metal Recovery

BOS plant

Ethanol

CO2

LanzaTechProcess Sale

Mineral recovery

Briquetting plant

Dusts/Sludges

Lime/Dolomite Fines

Lime

Briquettes

Iron Ore

MR plant

Coke Breeze

MillscaleRollingMill

Dusts/SludgesBOSplant

Coke

Sinter

Resource recovery solutions: Ironmaking

:Raw Material

Waste materialProcess or product

Harsco Plant

Resource recovery solutions: Steelmaking

Raw Material

Waste materialProcess or product

Harsco Plant

Electricity

CO gas

BOS Plant

Metallurgical Additives

Ethanol

CO2

Slag

Metal recovery

Rolling Mill

Oxide recovery

Sludge

SludgeTreatment

MR plant

Mineral recovery

Scrap Upgrading

Oil recovery

Roadbase

Road products

Sale

Gasfermentation Sale

Co-Gen Plant

Scrap

Iron (from BF plant)

Dusts/Sludges

Fines Upgrading

Briquettes

MillscaleSuperfine

SaleCement feed

LANDFILL

OtherAggregate sale

Millscale

BriquettingPlant

Briquetting Plant

Off-gases produced by the BOF plant has a high calorific value. If it is not stored

or converted, it escapes into the atsmosphere as CO2 emissions. The current

alternative is to process the gas through a turbine to produce electricity (Co-Gen

plant), for internal re-use or sale to the grid.

CO gas to Ethanol

View LanzaTech video

LanzaTech

LanzaTech has developed an ethanol fuel production process that can be retrofitted

to industrial facilities using the carbon monoxide component of waste flue gases as a

nutrient source. They have developed a proprietary platform for producing lowest-

cost liquid biofuel at a much larger scale than any alternative technology. LanzaTech

has signed a partnership agreement with Harsco; Harsco is the service

provider, and LanzaTech provides the technology.

Ethanol can be used to fuel motor vehicles or aircraft. Richard Branson’s Virgin

Airlines has signed a deal with LanzaTech to fuel his aircraft with Ethanol-derived

aviation fuel by 2013.

References

• First BaoSteel demo plant in China commissioned in 2012.

Background

Further information:Bruce Barker

bbarker@harsco.com

CO gas to Ethanol

Click here to view the animated process flow

Process Inputs Reactor Ethanol Re-useSeparation System End-product

Iron Oxide Fines

OxiFine product

Iron oxide fines (60% Fe product) used in the sinter plant. This represents a saving in steel production, as a replacement for iron ore pellets.

It also provides a zero waste solution for the steelmaker, to recycle C Fines from the metal recovery plant back into steelmaking rather than landfill disposal.

Vertical Shaft Impactor (VSI)

Further information: Chris Byrnecbyrne@harsco.com

™

• Developed for oil the industry (recovery of oil and clean sand)

• Harsco has applied the technology to oily sludge from millscale at steel mills

Oily Millscale sludge remediation

View video

The challenge of Oily Millscale Sludge

Oily millscale sludge generated by rolling mills is a hazardous waste. The presence of oil

in the millscale means that it produces emissions when burnt in the sinter plant.

Harsco Solution

Harsco offers a service using ultra-high pressure water treatment technology, which

separates the oil and millscale, producing a clean scale for recycling into steelmaking.

Further information:Jeremy Makepeace

jmakepeace@harsco.com

Oily Millscale sludge remediation

MillScale

Oily Millscale sludge

Oil

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Slag 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 impact

Slag Recycling

Slag management

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� Slag removal from the vessel

� Slag pit design

Specialized slag handling solutions

� Slag watering and cooling

� Slag pit digging

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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

Metal Recovery

Steelmaking Scrap Value

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Area MaterialFe Content %

Size (mm) Requirement Price ($/tonne)

Sinter Plant

BF

BOS

Ladle

Degassing

Low quality iron ore

High quality iron ore

Steel scrap

Ladle coolant scrap

Degasser coolant scrap

50 - 60

60 - 70

70 - 80

90

95

0 - 6

6 - 30

130 - 150

1 -3 tonne lumps

30 -130

12 -30

Small size

Consistent sizing and analysis

Size to allow compact charging. Free of deleterious materials

Low residuals, free flowing

Very low residuals, small size, free flowing

120

240

275

420

515

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� 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

Agglomeration of steelmaking by-products

A range of briquetting or pelletizing solutions for processing and adding value to dust, sludge and millscale materials.

Key customer drivers:• landfill cost reduction• re-use valuable resources (Fe units) • reduction in raw material costs

Project Stages• Understanding customer objectives for end product • Business and process modelling• Compositional analysis and agglomeration trials• Decision on process technology solution and metrics• Design, build and operate plant

Further information: Daniel Devid ddevid@harsco.com