Engineered Solutions for Electric 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

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We maintain environmental standards and work to ISO 14001 Environmental Management Systems covering:

� Airborne pollution control

� Storage of hazardous materials

� Spill prevention and clean up

� Waste management

� Fuel and energy conservation

Environmental Management

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 EAF Services at a glance

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Today’s Steelmaking Challenges

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� Minimise Raw Material Costs

� Optimise Logistical Efficiency

� Maintain Metal Product Quality

� Achieving Environmental Sustainability

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� Scrap Management

� Scrap processing

� Product handling

� Transportation

� Meltshop 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 Basket Densification

Scrap Basket Densification is a service which improves the density of the scrap in the basket. The scrap is added to the basket before the furnace charge.

By upgrading C-Fines which roll off the end of the conveyor belt at metal recovery plants, valuable scrap material can be utilized to make the scrap charge denser and therefore improve the efficiency of each heat.

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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Scrap Processing

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We process revert or external scrap according to your specific needs and prepare scrap for internal re-use.

� External or internal Scrap processing/upgrading

� Baling

� Shearing

� Shredding

� Drop-balling

� Mobile Lancing operation

� High volume cutting

Scrap Baling

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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 Shredding

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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

- Transport to Basket preparation Yard for disposal

High-Volume Scrap Cutting

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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

Case Study

ArcelorMittal Acindar, Argentina

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Plant Overview

� Metso Supplied

� 4000 HP

� Erected in 2007

� Capacity ; 200 KT / year

� Loaded by an Equilibrium Crane equipped with a 1,5 m3 grab

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Densification

� Scrap Densification:

Input Scrap: 0.27 T/m3 � Shredded scrap: 0.9 T/m3

� N. Baskets per heat:

Pre Shredder: 3 � After Shredder: 1-2

� Rejected:

19% of Input (0.65 T/m3) including non-ferrous for sale by AM

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Densification

Data from AM Acindar

Example in 2009, without shredder VS with shredder;

In Tonnes ;

117 KT of raw material

Out Tonnes

95 KT of shredded scraps

+ 22 KT of rejected

In volume ;

435 000 m3

Out Volume;

106 000 m3

+ 34 000 m3

Scrap Volume reduced by 76%

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Other Benefits

� On site shredding

� Reduced power requirement

� Improved yield

� Reduced electrode consumption

� Alloy and flux consumption

� Reduction in Missed specifications

� Productivity increase

� Reduced landfill

� Reduced refractory consumption

Approx. 2%of

steelmaking

COSTS

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Other Benefits with Harsco

� Since the arrival of Harsco new scrapyard solution

� The downgraded heat indicator has been reduced to a 20% of the

historical value, thanks to the use of ScrapMaster™.

� Minutes of delay have been reduced from an average of 1 to 0,1min/heat.

� Harsco provide a customised solution for each project based on individual requirements

� Scrap logistics is tailored to the import scrap transport; road, rail, barge, ship

� Scrap handling operations are modelled utilising simulation software to optimise logistic solutions

� Scrap handling equipment is selected based on optimised simulation of operation to minimise capital expenditure while achieving customer delivery requirements

� Logistics operations are supported by sophisticated inventory management systems that can be combined with optimisation technology

� Additional scrap processing and densification equipment can be added to remove non-ferrous materials and provided product to match steelmakers requirements

Harsco Customised Scrap Solutions

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Transport of liquid steel ladles from furnace to caster

� Ladle transport in specialist tailored vehicles

� Up to 400 tonne capacity, seven axle, elevating pallet carriers

� Infra-red camera monitors the ladle shell temperature to prevent breakouts

Liquid Steel Transport

Essential maintenance - Meltshop

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� Ladle and vessel lip cleaning

Comprehensive 24/7 service throughout meltshop

� Tundish removal and transport

Semi-finished Product Handling

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Optimise inventory value with on-site marking and tracking of semi-finished products.

� Barcode or RFID tag marking

� Item location tracking through RFID or Differential GPS

Semi-finished Product Handling

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Controlled cooling and handling of billets and blooms

- Controlled cooling: customised cooling hoods for slow cooling option

- Specially adapted wide span multi-fork lift truck for controlled product handling

Finished Product Logistics

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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

� Slitting and cutting

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Helping steelmakers to meet end-user requirements for product quality

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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

Product Quality Solutions

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� Visual inspection to identify and fix surface defects

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In-line bar sorting and repair facility

e.g. splits, folds, poor cuts or outside required lengths

Machine sits over the advancing cooling table at the exit to the rolling mill.

Non-conforming bars are identified, removed, repaired and re-injected back into the production flow

Real time processing

� Slag handling/Metal recovery

� Slag recycling

� Dust & sludge metal recovery and recycling

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Helping steelmakers to optimise the economic value of recycled by-products

Current resource recovery solutions: EAF

Raw Material

Waste materialProcess or product

Harsco Plant

Electricity

Metallurgical Additives

EAF Slag

Metal recovery

LANDFILL

EAF Dust

Coal

Iron Ore

DRIMR plant

Mineral recovery

Fines Upgrading

Aggregate sale

Asphalt

Road products Sale

Ladle Slag

ProcessPlant

Scrap

Scrap BasketDensification

Fines

Coolantscrap

Rolling Mill

Oxide recovery

Sludge

Sludge treatment plant

Oil

Separation

Millscale

Slag Recycling overview

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Transport

Slag resold to third parties

Metal RecoveryProcessing

Slag ProductDevelopment

Slag management

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� Slag removal from the vessel

� Slag pit design

Comprehensive slag tapping and tipping service

� Slag watering and cooling

� Slag pit digging

Metal Recovery

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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

Steelmaking Scrap Value

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Area MaterialFe Content %

Size (mm) Requirement Price ($/tonne)

EAF

Ladle

Degassing

Steel scrap

Ladle coolant scrap

Degasser coolant scrap

70 - 80

90

95+

130 - 150

1 -3 tonne lumps

30 -130

12 -30

Size to allow compact charging. Free of deleterious materials

Low residuals, free flowing

Very low residuals, small size, free flowing

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

• 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, making landfill an

expensive option.

Harsco Solution

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

separates the oil and millscale, producing a clean scale.

Further information:Jeremy Makepeace

jmakepeace@harsco.com