Recycling of Advanced High Strength Steel
The Dark Slayers AKA Team 7Ayan Bekzhanov - [email protected]
Abhiram Yalamanchili – [email protected] McCabe – [email protected] Woistman – [email protected]
Page 1
Course: EDSGN 100, Section 10
Submitted to: Mr. Catanach on February 24th, 201
Table of Contents
Cover Page-------------------------------------- 1Table of Contents------------------------------ 2Executive Summary--------------------------- 3Introduction------------------------------------- 3Mission Statement----------------------------- 3Clarification of problem---------------------- 3Customer Requirements--------------------- 3Customer Needs Metrics Matrix----------- 4Literary Research------------------------------ 6Patent Research-------------------------------- 6Global Marketplace---------------------------- 7Concept Generation--------------------------- 7Concept Selection -------------------------- 8-9Calculations------------------------------------- 10Poster Design----------------------------------- 11BOF Functional Diagram---------------------- 12Final Design ------------------------------------- 13Conclusion --------------------------------------- 14References -------------------------------------- 15
Page 2
Executive Summary
Our team’s goal was to design an efficient and viable method to separate and recycle different types of steel that ArcelorMittal recycles. Our endeavor was successful in the fact that our team
came up with many designs and theories that could be implemented in the real world.
Introduction
ArcelorMittal is the world’s largest steel producer. They annually produce 100 million tons of steel, and employ over 260,000 employees across 60 counties. In total, they produce around
10% of the entire world’s steel.
Mission Statement
ArcelorMittal requested us to design a process that will separate and recycle advanced high strength steel from the automotive market into a basic oxygen furnace. We were required to not adversely affect the steel quality, while also utilizing the alloys in the recycled steel to reduce the use and cost of new alloying elements. We were also made sure sure to not cause “off-chemistry heat”, which would render a batch unusable.
Clarification of Problem
ArcelorMittal is requesting a process that will recycle Advanced High Strength Steel from the automotive market into a basic oxygen furnace. We are required to not adversely affect the steel quality, while also utilizing the alloys in the recycled steel to reduce the use and cost of new alloying elements. We must also make sure to not cause “off-chemistry heat”, which will render a batch unusable.
Customer Requirements
In short, the customer requires a cost effective and environmentally friendly method of recycling steel. In order to meet our customer’s needs, we compiled the customer’s needs into the following categories:
Meet all SAE requirements Produce 125 million tons of steel per year Waste a maximum of 1.5 million tons of steel per year Produce 40 to 50 million tons of recycled steel per year Decrease production costs by 3%, to decrease consumer cost by 2% Remove 15 ounces of unwanted elements per pound of alloy A maximum of 1 product per 100 products has off-chemistry heat
Page 3
Customer Needs Metrics Matrix
After identifying our customer’s needs, we grouped them into a needs metrics matrix as shown below.
Needs Metrics Matrix1 2 3 4 5 6 7
M
etric
Mee
ts a
ll SA
E re
quire
men
ts
Prod
uce
125
mill
ion
tonn
es o
f ste
el p
er y
ear
Max
imum
was
ted
stee
l is 1
.5 m
illio
n to
nes
Prod
uce
40 to
50
mill
ion
tonn
es o
f rec
ycle
d st
eel
per y
ear
Decr
ease
pro
ducti
on c
ost b
y 3%
, to
decr
ease
co
nsum
er p
rice
by 2
%Re
mov
e 15
oun
ces o
f unw
ante
d el
emen
ts p
er
A m
axim
um o
f 1 p
rodu
ct p
er 1
00 p
rodu
cts
ha
s off-
chem
istry
hea
t
Need2 Design a process to effectively recycle Advanced High
Strength (high alloy) Steel from the automotive market back into the basic oxygen furnace (BOF) steel production cycle.
3 Keep the steel quality the same throughout the process x5 Be the leader in all major global steel markets x x x x15 Convert the linear cradle-to-grave process into a cyclical
“cradle-to-grave” process17 Lower the amount of steel consumed. x x19 Recycle as much steel as possible. x x20 Factory processes 2 types of materials that need to be
processed.21 Factory processes the alloys that are part of the scrap stream. x22 Factory processes unwanted alloys in steel producing. x26 Pieces of metal with different composition have different
properties.x
29 Steel is free from cause off-chemistry. x x30 The proposed process allows for a cheaper production of
steel.x x
34 A system must be implemented to prevent off-chemistry heat. x x35 Another system must be implemented to separate high grade
steel from low grade steel.37 Increase alloy contents of steel if cost reduction is required. x x
Page 4
38 Create a model to utilize the scrap during scrap charge for heats requiring alloy additions.
x
39 Use chemistries for a heat of AHSS and line pipe (see additional information) to demonstrate the model.
40 Include the weight of pure alloy that will be needed in addition to what is coming from scrap.
x x
45 Submit the technical report on the web48 Create CAD drawings49 Create systems diagrams50 Create a prototype of the design51 Create a list of the design concepts
Literary Research
Page 5
Steel Recycling Institute1
This website has a lot of great information on how the recycling process works, and explains what objects have recyclable steel in them. It also shows the different rates that recycled steel sells for.
Facts About Steel Recycling2
This website shows many helpful facts about recycling steel and how recycling works. It also details some of the products created with recycled steel.
Recycling Process3
This website has an animated presentation detailing how scrap steel is received, shredded, separated, and then recycled. It helped us understand the different amount of steps and coordination that goes into steel recycling.
Eddy Current Separator4
This website explains how eddy current separators work and their importance in the separation of metals for recycling. It allowed us to understand the necessity to incorporate one into our process.
Patent Search
Google Patents5 was a great resource to search for patents involving methods of steel recycling including material separation/sorting, and melting. We were careful to avoid all forms of patent infringement in our design.
Global Marketplace
Page 6
Recycling steel is something that is being used in all places throughout the world. There is a Bureau of International Recycling that lays out the different ways in being able to handle and recycle steel. For example, they provide various different techniques pertaining to how steel can be recycled. Media separation is one technique that is used, where a shredder is used to separate iron metal from the other materials within the steel. To separate these other materials even further, methods such as liquid floating systems and electrical currents are used to separate the other materials within the steel. This recycled steel can be used in various different applications, such as construction, transportation, and households. The Bureau of International Recycling is made up of various different board members of different ethnic backgrounds. The chairman is from the United Kingdom, while other members are from India, China, France, USA, Sweden, Russia, Jordan, and Germany. Therefore, this all shows that recycling steel is an important part of not just the United States, but the world as a whole.
Concept Generation
Our professor gave us some topics to brainstorm about pertaining to recycling steel and what other factors are included with the idea of recycled steel. All four of us brainstormed on our own about each topic and came up with ideas that could solve the problems that were given to us. The nine questions that were posed to us were: how to separate the components of the steel, how we could make our recycling environmentally friendly, how to better identify steel from the supplier, how to get more cars to be recycled, how to make cars easier to disassemble, how to better separate car parts, how to better sort steel in the steel recycling plants, and the advantages of using a shredder for recycling. After we individually brainstormed our ideas, we came together and compared and contrasted our ideas that we came up with. From there, we took our best options and ran them through a concept selection process in order to find the best ideas for each problem.
Concept Selection
Page 7
Separation of materialsSelection Criteria
Magnetic seperation
Chemical Reactions
Centrifuge (Densities) Boiling Point
Effectiveness 0 0 + 0Price 0 - 0 -Maintainence
0 - 0 -
Time 0 - 0 0Advance? Yes Yes Yes Yes
Green Energy SourcesSelection Criteria
Renewable Energy BOF into "standby" mode
Environmentally Friendly Machinery
Effectiveness 0 0 0Price 0 + -Maintainence 0 0 -Time 0 0 0Advance? Yes Yes Yes
Supplier Identifying SteelSelection Criteria
Communicating with Supplier
Incentivise the Supplier
Effectiveness 0 +Price 0 -Maintainence 0 0Time 0 0Advance? No Yes
How to Get Cars to RecycleSelection Criteria
Asking Car Companies Give Away Scrap Cars
Rebate for Consumer
Advertisements/Events for Car Recycling
Effectiveness 0 + +Price 0 - -Maintainence 0 0 0Time 0 + +Advance? Yes Yes Yes
Page 8
Making Car Easier To DisassembleSelection Criteria
Easily Removable Parts
Less Small Components
Effectiveness 0 0Price 0 0Maintenance 0 0Time 0 0Advance? Yes Yes
Separating Car PartsSelection Criteria
Centrifuge (Densities)
Hand Sort
Effectiveness 0 0Price 0 0Maintenance 0 +Time 0 -Advance? Yes Yes
How Steel Recycling Plants SortSelection Criteria
Communicating with Suppliers
Magnetic separation
Chemical Reactions Centrifuge (Densities)
Boiling Point
Effectiveness
0 0 0 + 0
Price + 0 - 0 -Maintainence
+ 0 - 0 -
Time - 0 - 0 0Advance? No Yes Yes Yes Yes
Shredder ApplicationsSelection Criteria
Easier to Handle Easier to Transport
Easier to Sort
Effectiveness 0 0 0Price 0 0 0Maintainence 0 0 0Time 0 0 0Advance? Yes Yes Yes
Calculations
Page 9
As a part of our project, we were instructed to perform calculations for how much AHSS (or high alloyed steel) can be added to create Line Pipe and LCAK (Low Carbon Aluminum Killed) steel without causing off-chemistry. The calculations that we performed are shown below.
Chemical Analysis of each type of steelC Mn Cr Al Cb 440,000 lb heat
AHSS 0.0017 0.015 0.002 0.0012 0.0002 0.15 scrap percentage chargedLCAK 0.0004 0.002 0.001 0.0004 0.00004 66000 scrap weight
Line Pipe 0.0005 0.015 0.001 0.0004 0.00003
Mass Balance Equationslbs each element allowed in heat of LCAK
and Line Pipe LCAK 176 880 440 176 17.6
Line Pipe 220 6600 440 176 13.2Percentage added due to oxidation 300% 200%
lbs each element after blown LCAK 176 2640 880 176 17.6
Line Pipe 220 19800 880 176 13.2
lbs element contained in scrap (if 100%)AHSS 112.2 990 132 79.2 13.2
Percentage added due to oxidation 300% 200%
Adjusted element in scrap according to how much is oxidzed
AHSS 112.2 2970 264 79.2 13.2
Percent added from AHSS to not cause off chemistry in LCAK production 88.9% 88.9%
lbs of different elements in AHSS added to make LCAK without causing off chemistry N/A 2640 235 N/A N/A
lbs of AHSS total added to make LCAK 58667
Percent added from AHSS to not cause off chemsitry in LCAK production N/A 100% 100% N/A N/A
lbs of different elements in AHSS to make Line Pipe without causing off chemistry N/A 2970 264 N/A N/A
lbs of AHSS total added to make Line Pipe 66000
Poster Design
Page 10
As part of our project, we were instructed to design a poster. It is below:
BOF Functional Diagram
Page 11
For our project, we were instructed to create a function BOF diagram. It is below:
Final Design
Page 12
Conclusion
Page 13
Lance
Input/output piping
Input/output piping
46 feet tall12 foot radius
From this project, we gained a better understanding of the importance of steel recycling and what goes on in a basic oxygen furnace. ArcelorMittal gave us a task that would typical be a task for people who are actually employed by ArcelorMittal, which is pretty interesting considering we are undergraduate students. This project gave us the opportunity to be faced with an actual problem that is happening in our world today. Before this project, we had very little knowledge on the importance of recycling steel, and how we can recycle steel. From this project, we have gained a better understanding of this concept, which can only help us later on in life. Additionally, we were able to gain a better knowledge on how a basic oxygen furnace works and how we can better improve the sustainability of the basic oxygen furnace. An opportunity like the one ArcelorMittal gave to us does not come up every day, so we were grateful that we could help them on their project.
References
Page 14
1. http://www.recycle-steel.org/ 2. http://earth911.com/recycling/metal/steel/facts-about-steel-recycling/ 3. http://www.schnitzersteel.com/metals_recycling_process.aspx 4. http://www.cogelme.com/eng/e-eddy-current-metal-separator.htm
Page 15