Polymer Technology
2015 SEAISI Travelling Seminar30th March – 8th April 2015
Sustainable EAF Steelmaking through the Use of
Polymer Technology
Dr Zheshi Jin
Introduction
Page 2Commercial 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
Page 3Commercial in Confidence
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
Page 4
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
Page 5
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.
Page 6
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.
Page 7
OneSteel Steelmaking Solutions Team
Page 8
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
Page 9
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
Page 10
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
Page 11
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
Page 12
Slag Foaming Volume Analysis
A combination of rubber and coke produces a superior foaming slag volume than coke alone
Page 13Commercial in Confidence
Laboratory Work at UNSW
Page 14
• 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.
Page 15
* 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)
Page 16
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)
Page 17Commercial in Confidence
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
Page 18Commercial in Confidence
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
Page 19Commercial in Confidence
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
Page 20Commercial in Confidence
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
Page 21
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
Page 22
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
Page 23
Building Capability
of Young Engineers
Page 24
� 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
Page 25
Environmental Results
Dioxins
Page 26Commercial in Confidence
� 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
Environmental Results
Page 27Commercial in Confidence
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
Environmental Results
Dioxins SSM
Page 28Commercial in Confidence
Sulfur – no pick up in the steel
Page 29Commercial in Confidence
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
Page 30Commercial in Confidence
� 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
Page 31Commercial in Confidence
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.
Page 32
Polymer Composite
Briquette
Polymer Composite Briquette
of recycled PE and coke fines
Page 33
Page 34
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
Polymer Composite Briquette
Plant trial results
Page 35
Electrical Energy consumption – 15 kWh/bt saving
Polymer Composite Briquette
Plant trial results
Page 36
Power on time – 0.8min reduction
Polymer Composite Briquette
Plant trial results
Page 37
Charge carbon consumption – 18% reduction with same tap C% and oxy
Polymer Composite Briquette
Plant trial results
Page 38
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
Page 40
Preparation of feed for the demonstration facility
Emission test results
Meet all requirements
Page 41
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
Page 44Commercial in Confidence