Download - OxiCup Zero Waste
SteelMill Foundry NE-Metalle OthersNon-ferrousOxyCup Process for Steel Mill Waste Oxides
ThyssenKrupp Stahl AG
Zero Waste - Zero Cost Conceptfor integrated Steel MillsOxyCup Process for Steel MillWaste Oxides
C. Bartels-v.Varnbüler, M. LemperleKüttner GmbH & Co. KG Essen, GermanyK. Kesseler, L. StahlThyssenKrupp Stahl AG, Duisburg, Germany
Zero Waste – Zero Cost Concept
SteelMill Foundry NE-Metalle OthersNon-ferrousOxyCup Process for Steel Mill Waste Oxides
ThyssenKrupp Stahl AG
Home scrap35,6 %
26,1 %8,8 %
Filterdust
Fe(II)chloride
BOF SlagsDe-S Slags
Runner Break out Rubble
Scale
Mill scale sludgeSludges
Total: 235 kg/t Raw Steel
0,8 %2,0 %
1,4 %1,5 %
23,8 %
Year 2000/2001
2 Fe-containing By-products and Wastes atThyssenKrupp Stahl AG
SteelMill Foundry NE-Metalle OthersNon-ferrousOxyCup Process for Steel Mill Waste Oxides
ThyssenKrupp Stahl AG
AmountFine Dust from Steel Plant 179.200 t/a 46,9 %Oily Mill Scale 44.300 t/a 11,6 %Sludge from Blast Furnace Top Gas Cleaning 21.000 t/a 5,5 %Total TKS 244.500 t/a 64,0 %
AmountBlast Furnace and Steel Plant Sludge 106.400 t/a 27,9 %Various Dusts and Sludges 31.100 t/a 8,1 %Total HKM 137.500 t/a 36,0 %
Total TKS and HKM 382.000 t/a
% of total
Residues at Hüttenwerke Krupp Mannesmann
Residues at ThyssenKrupp Stahl AG
% of total
3 Residues at ThyssenKrupp Stahl AG
SteelMill Foundry NE-Metalle OthersNon-ferrousOxyCup Process for Steel Mill Waste Oxides
ThyssenKrupp Stahl AG
ProductionlineProductionline
Sinterplant
Blast furnace
Steel Plant
Hot rollingmill
Productionflow
Utilisation besidethe main productionline
Utilisation in the main productionline
HotBriquetting
ESP Dust
Skulls/ rubble
BF top gas sludge
BOF dust (fine)
Skulls, Processed Slags
Mill scale sludge(oily)
Mill scale
Flue Dust
Former Former PracticePractice
BOF dust (coarse)
New New ConceptConcept
C-Brickmanufacturing
OxiCup shaftfurnace
Dumping and external use
Internal useBOF
New production wayMain production way
Zero Waste Concept4
SteelMill Foundry NE-Metalle OthersNon-ferrousOxyCup Process for Steel Mill Waste Oxides
ThyssenKrupp Stahl AGSelfreducing C-Brick
BF dust
BF sludge
BOF fine dust
Mill scale
Fe-Fines
Reduction agent
e.g. Coke breeze, Anthrazit, Petrolcoke
Cement Binder
H2O
5
SteelMill Foundry NE-Metalle OthersNon-ferrousOxyCup Process for Steel Mill Waste Oxides
ThyssenKrupp Stahl AGReduction of iron oxides in the shaft furnace
• Self-reducing bricks are charged together with coke and additives into the OxiCupshaft 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
6
SteelMill Foundry NE-Metalle OthersNon-ferrousOxyCup Process for Steel Mill Waste Oxides
ThyssenKrupp Stahl AG
CementH2O
Coke Gravel SkullsScrap C-Bricks
Top gasGas
cleaningZn-Sludge
Hot BlastCold Blast
Recuperator
O2
Hot metal Slag
Stockyard
Shaft Furnace
Gas-grid
Screening
Bunker System
Curing
Mixing
Pressing
7 Flow Scheme of Shaft Furnace Plant
SteelMill Foundry NE-Metalle OthersNon-ferrousOxyCup Process for Steel Mill Waste Oxides
ThyssenKrupp Stahl AGMixing of Waste Oxides8
SteelMill Foundry NE-Metalle OthersNon-ferrousOxyCup Process for Steel Mill Waste Oxides
ThyssenKrupp Stahl AG9 Vibrating Press
SteelMill Foundry NE-Metalle OthersNon-ferrousOxyCup Process for Steel Mill Waste Oxides
ThyssenKrupp Stahl AGBrick making
• Mixing and pressing of the different residues with coke breeze and cement
• 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
10
SteelMill Foundry NE-Metalle OthersNon-ferrousOxyCup Process for Steel Mill Waste Oxides
ThyssenKrupp Stahl AG
C-Bricks are cured in racks for approx.. 48 h
11 Curing racks
SteelMill Foundry NE-Metalle OthersNon-ferrousOxyCup Process for Steel Mill Waste Oxides
ThyssenKrupp Stahl AGOpen storage of C-Bricks
• 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
12
SteelMill Foundry NE-Metalle OthersNon-ferrousOxyCup Process for Steel Mill Waste Oxides
ThyssenKrupp Stahl AGSkulls
• Metallic revert materials ofunknown composition
• Steel plant skulls• Metal from slag processing• Metal from de-sulfurisation of hot metal• Ponded pig iron, salamander etc.
13
SteelMill Foundry NE-Metalle OthersNon-ferrousOxyCup Process for Steel Mill Waste Oxides
ThyssenKrupp Stahl AGOxiCup Shaft Furnace Hamborn14
SteelMill Foundry NE-Metalle OthersNon-ferrousOxyCup Process for Steel Mill Waste Oxides
ThyssenKrupp Stahl AGOxiCup Shaft Furnace
mHearth ø 2,4 Shaft ø 2,6
Height eff 8Height Hearth. 2,1
Working Vol. 42,5 m³
Production: t/m³24hC-Bricks 70% 10,5 Skulls/Scrap 23
15
SteelMill Foundry NE-Metalle OthersNon-ferrousOxyCup Process for Steel Mill Waste Oxides
ThyssenKrupp Stahl AGCast house of OxiCup Shaft Furnace
Pictures: TKS OxiCup Plant
16
SteelMill Foundry NE-Metalle OthersNon-ferrousOxyCup Process for Steel Mill Waste Oxides
ThyssenKrupp Stahl AGHot Metal from the Shaft Furnace
A tilting runner passes the hot metal to two positions for Torpedo cars. Slag is directly tapped in slag pots.
17
SteelMill Foundry NE-Metalle OthersNon-ferrousOxyCup Process for Steel Mill Waste Oxides
ThyssenKrupp Stahl AG
Basic Design:Charge material: 70% C-Bricks, 30% Skulls
Processed Residues 176.000 t/a 24,4 t/hProcessed Skulls 81.000 t/a 11,3 t/hHot Metal 165.000 t/a 22,9 t/hOperation time 7.200 h/a
18 Hamborn Shaft furnace, 2 Step Extension
SteelMill Foundry NE-Metalle OthersNon-ferrousOxyCup Process for Steel Mill Waste Oxides
ThyssenKrupp Stahl AG19 Shaft Furnace Hamborn, plant view
SteelMill Foundry NE-Metalle OthersNon-ferrousOxyCup Process for Steel Mill Waste Oxides
ThyssenKrupp Stahl AG
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
20 Advantages of OxiCup Process
SteelMill Foundry NE-Metalle OthersNon-ferrousOxyCup Process for Steel Mill Waste Oxides
ThyssenKrupp Stahl AG
Operation of Pilot plantOperation of Pilot plant19.07.1999 - 20.01.200017.09.2001 - today
Hot metal 130.000 t Stable operation with up to 85% C-Bricksproduction
Analysis: Charge composition:
Hot metalkg
Si 0,52 - 1,10 C-Bricks 2.800S 0,07 - 0,48 Skulls 1.200C 3,71 - 4,33 Coke 680
Gravel 205
Slag Blast 17.000 Nm³/h@ 520 °C
SiO2 39,72 Oxygen 1.500 Nm³/hCaO 36,41Fe 1,49 Top gas CO 32,4 %Basicity 0,94 H2 3,5 %
21 Operation of Pilot Plant
SteelMill Foundry NE-Metalle OthersNon-ferrousOxyCup Process for Steel Mill Waste Oxides
ThyssenKrupp Stahl AG
BrickmakingBasic Data
Investment Brick Making Facility 12.500.000 US$
Production 235.160 t/year
Operating Cost (Workforce, Electricity, Maintenance, et.) 6,87 $/tCapital Cost (Decrepitation 10 Years, Interest 8%) 7,44 $/t
Total Cost Brickmaking per ton of Bricks 14,31 $/t
Production of C-Brickst/a US$/t mat US$/a US$/t
Brick making 235.160 14,31 3.365.140 15,060,00
H2O 17.000 0,00 0 0,00Cement 8 % 16.160 60,00 969.600 4,34Cokebreeze 26.000 55,00 1.430.000 6,40Residues 176.000 0,00 0 0
235.160Total cost Bricks per year 5.764.740 25,80 US$/t
Bricks shipped to OxiCup 223.402 t/a
22 Brick making
SteelMill Foundry NE-Metalle OthersNon-ferrousOxyCup Process for Steel Mill Waste Oxides
ThyssenKrupp Stahl AG
Hot Metal from OxiCup Shaft Furnace Hot Metal 175.374 tons per year
14.614 tons per month(excluding civil work and infrastructure)
Operating CostCost US$ per Year
Workforce 864.000 4,93
Electricity 720.000 4,11
Oxygen 150 m3/t RE 1.315.302 7,50
Top Gas Credit (1850 m³/t HM * 4.500 kJ/m³ * 2,8 US$/GJ) -4.087.959 -23,31
Consumables incl. Refractory, Quality 578.733 5,14
Maintenance 843.750 4,81
Slag 400 kg/t RE 2 US$/t 140.299 0,80Sludge 30 kg/ t HM 50 US$/t 263.060 1,50
Total Operating Cost 959.186 5,47
Charge Material
C-Bricks 216.347 t 25,87 US$/t 5.597.795 31,92Steel Plant Skulls 42.000 t 40 US$/t 1.680.000 9,58De-S-Skulls 42.000 t 0 US$/t 0 0,00Coke 17% 120 US$/t 6.127.083 34,94Gravel 1.305 t 10 US$/t 13.050 0,07
Charging Material 13.417.928 76,51
Total Cost 14.377.114 81,98
Capital Cost (Gernan conditions) Investment Shaft Furnace Plant: US$ 22.500.000Depreciation 10 Years Interest 8% 17,96
Hot Metal Cost ex Shaft Furnace Tilting Runner
US$ / t HM
99,94
23 Hot Metal from OxiCup Shaft Furnace
SteelMill Foundry NE-Metalle OthersNon-ferrousOxyCup Process for Steel Mill Waste Oxides
ThyssenKrupp Stahl AG
Investment Cost (Civil w orks and infrastructure not considered)
Brickmaking Facility 12.500.000 US$
Shaft Furnace Plant 22.500.000 US$
Total 35.000.000 US$
Basic DataTreated Waste materials 176.000 mt/y
Hot Metal Production 175.374 mt/y
Top Gas Production (4.500 kJ/m³) 324.441.160 m³/y
Production of Zn Filter Cake 6.577 mt/y
Production OxiCup Shaft FurnaceProduction Cost Hot Metal 81,98 US$/t HM
Capital Cost (German conditions) 17,96 US$/t HM
Total Cost 99,94 US$/t HM
Abstract of Feasibility Study for OxiCup Furnace Plant
24 Abstract of Feasibility Study for OxiCupFurnace Plant
SteelMill Foundry NE-Metalle OthersNon-ferrousOxyCup Process for Steel Mill Waste Oxides
ThyssenKrupp Stahl AG
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
25 Further Potential
SteelMill Foundry NE-Metalle OthersNon-ferrousOxyCup Process for Steel Mill Waste Oxides
ThyssenKrupp Stahl AG
Further Information:
26 Further Information