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OxyCup Process for Steel Mill Waste Oxides

Steel Mill

Foundry

Non-ferrous NE-Metalle

Others

Zero Waste - Zero Cost Concept for integrated Steel Mills OxyCup Process for Steel Mill Waste Oxides

C. Bartels-v.Varnbüler, M. Lemperle Küttner GmbH & Co. KG Essen, Germany K. Kesseler, L. Stahl ThyssenKrupp Stahl AG, Duisburg, Germany

ThyssenKrupp Stahl AG Zero Waste ­ Zero Cost Concept

OxyCup Process for Steel Mill Waste Oxides

Steel Mill

Foundry

Non-ferrous NE-Metalle

Others

Year 2000/2001

35,6 % Home scrap

1,4 % 1,5 % 0,8 % 2,0 %

Runner Break out Rubble Fe(II)chloride Sludges Mill scale sludge

23,8 % BOF Slags De-S Slags

8,8 % Scale 26,1 % Filterdust Total: 235 kg/t Raw Steel ThyssenKrupp Stahl AG

2

Fe-containing By-products and Wastes at ThyssenKrupp Stahl AG

OxyCup Process for Steel Mill Waste Oxides

Steel Mill

Foundry

Non-ferrous NE-Metalle

Others

Residues at ThyssenKrupp Stahl AG

Amount Fine Dust from Steel Plant Oily Mill Scale Sludge from Blast Furnace Top Gas Cleaning 179.200 t/a 44.300 t/a 21.000 t/a % of total 46,9 % 11,6 % 5,5 %

Total TKS

244.500 t/a

64,0 %

Residues at Hüttenwerke Krupp Mannesmann

Amount Blast Furnace and Steel Plant Sludge Various Dusts and Sludges 106.400 t/a 31.100 t/a % of total 27,9 % 8,1 %

Total HKM

137.500 t/a

36,0 %

Total TKS and HKM

382.000 t/a

ThyssenKrupp Stahl AG

3

Residues at ThyssenKrupp Stahl AG

OxyCup Process for Steel Mill Waste Oxides

Steel Mill

Foundry

Non-ferrous NE-Metalle

Others

Productionline

Former Practice New Concept

Mill scale

Sinterplant

ESP Dust C-Brick Dumping and manufacturing external use

Flue Dust Blast furnace BF top gas sludge Skulls/ rubble OxiCup shaft BOF furnace

Internal use

Hot Briquetting

Steel Plant BOF dust (fine) Skulls, Processed Slags Mill scale sludge (oily)

BOF dust (coarse)

Hot rolling mill

Main production way Production New production way flow

Utilisation beside the main productionline

Utilisation in the main productionline

ThyssenKrupp Stahl AG

4

Zero Waste Concept

OxyCup Process for Steel Mill Waste Oxides

Steel Mill

Foundry

Non-ferrous NE-Metalle

Others

Reduction agent e.g. Coke breeze, Anthrazit, Petrolcoke H2O Cement Binder

BF dust BF sludge BOF fine dust Mill scale

Fe-Fines

ThyssenKrupp Stahl AG

5

Selfreducing C-Brick

OxyCup Process for Steel Mill Waste Oxides

Steel Mill

Foundry

Non-ferrous NE-Metalle

Others

· Self-reducing bricks are charged together with coke and additives into the OxiCup shaft furnace · Reduction of the iron oxides starts at 1000°C and is completed at 1400°C forming sponge iron · Reduced iron and slag components are melted in the following and leave the furnace continuously via a siphon system · Iron and slag are comparable to blast furnace qualities · All of the zinc and most of the alkalis leave the furnace as dust and are concentrated in the filter cake downstream the scrubber system ThyssenKrupp Stahl AG

6 Reduction of iron oxides in the shaft furnace

OxyCup Process for Steel Mill Waste Oxides

Mixing

Steel Mill

Foundry

Cement

Non-ferrous NE-Metalle

Others

H2O

Pressing

Curing

Screening Bunker System

Coke Gravel

Skulls Scrap

C-Bricks

Stockyard

Top gas Gas cleaning Gas-grid Zn-Sludge

Shaft Furnace

Hot Blast

Cold Blast

Recuperator O2 Hot metal Slag

ThyssenKrupp Stahl AG

7

Flow Scheme of Shaft Furnace Plant

OxyCup Process for Steel Mill Waste Oxides

Steel Mill

Foundry

Non-ferrous NE-Metalle

Others

ThyssenKrupp Stahl AG

8

Mixing of Waste Oxides

OxyCup Process for Steel Mill Waste Oxides

Steel Mill

Foundry

Non-ferrous NE-Metalle

Others

ThyssenKrupp Stahl AG

9

Vibrating Press

OxyCup Process for Steel Mill Waste Oxides

Steel Mill

Foundry

Non-ferrous NE-Metalle

Others

·

Mixing and pressing of the different residues with coke breeze and cement

·

·

10

The pressed bricks are discharged from the mould on pallets made from wood. There are about 200 kg of bricks per pallet. Cycle-time is about 20 to 30 seconds ThyssenKrupp Stahl AG

Brick making

OxyCup Process for Steel Mill Waste Oxides

Steel Mill

Foundry

Non-ferrous NE-Metalle

Others

C-Bricks are cured in racks for approx.. 48 h

ThyssenKrupp Stahl AG

11

Curing racks

OxyCup Process for Steel Mill Waste Oxides

Steel Mill

Foundry

Non-ferrous NE-Metalle

Others

· Open storage area at Thyssen, Duisburg. · The bricks produced can be stored outside for an unlimited time. They are not eluable and even get harder with time. · Brick shape optimal for bulk handling ThyssenKrupp Stahl AG

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Open storage of C-Bricks

OxyCup Process for Steel Mill Waste Oxides

Steel Mill

Foundry

Non-ferrous NE-Metalle

Others

· Metallic revert materials of unknown composition · Steel plant skulls · Metal from slag processing · Metal from de-sulfurisation of hot metal · Ponded pig iron, salamander etc. ThyssenKrupp Stahl AG

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Skulls

OxyCup Process for Steel Mill Waste Oxides

Steel Mill

Foundry

Non-ferrous NE-Metalle

Others

ThyssenKrupp Stahl AG

14

OxiCup Shaft Furnace Hamborn

OxyCup Process for Steel Mill Waste Oxides

Steel Mill

Foundry m 2,4 2,6

Non-ferrous NE-Metalle

Others

Hearth ø Shaft ø

8 Height eff Height Hearth. 2,1 Working Vol. 42,5 m³

Production: t/m³24h C-Bricks 70% 10,5 Skulls/Scrap 23

ThyssenKrupp Stahl AG

15

OxiCup Shaft Furnace

OxyCup Process for Steel Mill Waste Oxides

Steel Mill

Foundry

Non-ferrous NE-Metalle

Others

Pictures: TKS OxiCup Plant

ThyssenKrupp Stahl AG

16

Cast house of OxiCup Shaft Furnace

OxyCup Process for Steel Mill Waste Oxides

Steel Mill

Foundry

Non-ferrous NE-Metalle

Others

A tilting runner passes the hot metal to two positions for Torpedo cars. Slag is directly tapped in slag pots.

ThyssenKrupp Stahl AG

17

Hot Metal from the Shaft Furnace

OxyCup Process for Steel Mill Waste Oxides

Steel Mill

Foundry

Non-ferrous NE-Metalle

Others

Basic Design: Charge material: 70% C-Bricks, 30% Skulls Processed Residues Processed Skulls Hot Metal Operation time 176.000 81.000 165.000 7.200 t/a t/a t/a h/a 24,4 t/h 11,3 t/h 22,9 t/h

18

Hamborn Shaft furnace, 2 Step Extension

ThyssenKrupp Stahl AG

OxyCup Process for Steel Mill Waste Oxides

Steel Mill

Foundry

Non-ferrous NE-Metalle

Others

ThyssenKrupp Stahl AG

19

Shaft Furnace Hamborn, plant view

OxyCup Process for Steel Mill Waste Oxides

Steel Mill

Foundry

Non-ferrous NE-Metalle

Others

Processing of all wastes from the main processes BF, BOF, HSM Thus optimized process calculation and smoother operation Higher direct tapping rates and less down-grading and return melts Extensive use of clean high zinc containing scrap. Better purchase conditions No more use of De-S metals in the converter. Much cheaper De-S in the hot metal ladle. Less skull formation. Higher Fe yield High flexibility by varying the processed materials

ThyssenKrupp Stahl AG

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Advantages of OxiCup Process

OxyCup Process for Steel Mill Waste Oxides

Steel Mill

Foundry

Non-ferrous NE-Metalle

Others

Operation of Pilot plant 19.07.1999 - 20.01.2000 17.09.2001 - today Hot metal production Analysis: Hot metal Si S C 0,52 - 1,10 0,07 - 0,48 3,71 - 4,33 C-Bricks Skulls Coke Gravel Blast 39,72 36,41 1,49 0,94 Oxygen Top gas kg 2.800 1.200 680 205 17.000 Nm³/h @ 520 °C 1.500 Nm³/h CO H2 32,4 % 3,5 % 130.000 t Stable operation with up to 85% C-Bricks

Charge composition:

Slag SiO2 CaO Fe Basicity

ThyssenKrupp Stahl AG

21

Operation of Pilot Plant

OxyCup Process for Steel Mill Waste Oxides

Steel Mill

Foundry

Non-ferrous NE-Metalle

Others

Brickmaking

Basic Data Investment Brick Making Facility Production 12.500.000 US$ 235.160 t/year

Operating Cost (Workforce, Electricity, Maintenance, et.) Capital Cost (Decrepitation 10 Years, Interest 8%) Total Cost Brickmaking per ton of Bricks

6,87 $/t 7,44 $/t 14,31 $/t

Production of C-Bricks

t/a US$/t mat US$/a US$/t

Brick making H2O Cement 8 % Cokebreeze Residues

235.160

14,31 0,00 60,00 55,00 0,00

3.365.140 0 969.600 1.430.000 0 5.764.740

17.000 16.160 26.000 176.000 235.160 Total cost Bricks per year Bricks shipped to OxiCup

15,06 0,00 0,00 4,34 6,40 0 25,80 US$/t 223.402 t/a

ThyssenKrupp Stahl AG

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Brick making

OxyCup Process for Steel Mill Waste Oxides

Hot Metal from OxiCup Shaft Furnace

(excluding civil work and infrastructure)

Steel Mill

Foundry

Hot Metal

Non-ferrous NE-Metalle

Others

175.374 tons per ye ar 14.614 tons per month

Operating Cost

Cost US$ per Yea r Workforce Electricity Ox ygen 150 m3/t RE 864.000 720.000 1.315.302 -4.087.959 578.733 843.750 400 kg/t RE 30 kg/ t HM 2 US$/t 50 US$/t 140.299 263.060 959.186

US$ / t HM 4,93 4,11 7,50 -23,31 5,14 4,81 0,80 1,50 5,47

Top Gas Credit (1850 m³/t HM * 4.500 kJ/m³ * 2,8 US$/GJ) Consuma ble s incl. Re fra ctory, Quality Mainte na nce Sla g Sludge

Total Operating Cost Charge Material

C-Bricks Ste el Pla nt Skulls De -S-Skulls Coke Gra ve l Charging Ma terial 216.347 t 42.000 t 42.000 t 17% 1.305 t 25,87 US$/t 40 US$/t 0 US$/t 120 US$/t 10 US$/t

5.597.795 1.680.000 0 6.127.083 13.050 13.417.928

31,92 9,58 0,00 34,94 0,07 76,51 81,98

22.500.000

Total Cost Capital Cost (Gernan conditions)

De pre ciation 10 Ye ars Intere st 8%

14.377.114

Inve stment Shaft Furna ce Plant: US$

17,96

Hot Metal Cost ex Shaft Furnace T ilting Runner

99,94

ThyssenKrupp Stahl AG

23

Hot Metal from OxiCup Shaft Furnace

OxyCup Process for Steel Mill Waste Oxides

Steel Mill

Foundry

Non-ferrous NE-Metalle

Others

Abstract of Feasibility Study for OxiCup Furnace Plant

Investment Cost (Civil w orks and infrastructure not considered)

Brickmaking Facility Shaft Furnace Plant 12.500.000 US$ 22.500.000 US$

Total Basic Data

Treated Waste materials Hot Metal Production Top Gas Production (4.500 kJ/m³) Production of Zn Filter Cake

35.000.000 US$

176.000 mt/y 175.374 mt/y 324.441.160 m³/y 6.577 mt/y

Production OxiCup Shaft Furnace

Production Cost Hot Metal Capital Cost (Germ an conditions) 81,98 US$/t HM 17,96 US$/t HM

Total Cost

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99,94 US$/t HM

ThyssenKrupp Stahl AG

Abstract of Feasibility Study for OxiCup Furnace Plant

OxyCup Process for Steel Mill Waste Oxides

Steel Mill

Foundry

Non-ferrous NE-Metalle

Others

Optimization of sinter plant and its emission Processing of waste from affiliated companies Customer service by taking back machining wastes. Processing of shredder light fraction and waste plastics Processing of stainless steel plant dusts Supplement hot metal in times of BF-relining by scrap melting Further reduction of Zn- and Alkali - load into Blast Furnace Realization of waste free steel mill (Zero waste-zero cost - concept) Feasible Ore based HM production in small scale

ThyssenKrupp Stahl AG

25

Further Potential

OxyCup Process for Steel Mill Waste Oxides

Steel Mill

Foundry

Non-ferrous NE-Metalle

Others

Further Information: [email protected]

ThyssenKrupp Stahl AG

26

Further Information

Information

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Microsoft PowerPoint - Zero Waste-Zero Costs.ppt