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



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



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



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


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


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



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


ThyssenKrupp Stahl AGMixing of Waste Oxides8


ThyssenKrupp Stahl AG9 Vibrating Press


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



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

11 Curing racks


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


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


ThyssenKrupp Stahl AGOxiCup Shaft Furnace Hamborn14


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


ThyssenKrupp Stahl AGCast house of OxiCup Shaft Furnace

Pictures: TKS OxiCup Plant

16


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



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


ThyssenKrupp Stahl AG19 Shaft Furnace Hamborn, plant view



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



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



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



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



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



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



Further Information:

[email protected]

26 Further Information

Documents

OxiCup Zero Waste