1. NOVEL WASTE
MINIMIZATION FOR STEEL
MANUFACTURING
N O V E M B E R 2 7 TH, 2 0 1 2
Adriano Arnini , Amir Fakhruddin Mohamed,
Anika Mohammed, Francis Bui,
Xiaobo Pan, Sonia Liscio
3. INTEGRATED STEEL MILL
WASTE MANAGEMENT PLAN
US Steel Canada
Steel-making Process
2
4. Objectives
1. Maximize the amount of waste utilized from
an integrated steel mill
2. Reduce the costs associated with waste
management
1.Background 2.Process Description
3
3.Reactor 4.Equipment 5.Hazards
6.Economics 7.Conclusions
5. US Steel Canada – Hamilton Works Plant
Formerly Stelco Inc.
Lake Ontario
Hamilton Harbor
Site chosen to
Hamilton Works
demonstrate concept
Steel production
capacity:
Google. (2012). Google Maps. Retrieved November 20,
2.6 Million tonnes/year 2012, from https://maps.google.ca/)
1.Background 2.Process Description
4
3.Reactor 4.Equipment 5.Hazards
6.Economics 7.Conclusions
6. Integrated Steel Mill Recycled
O2 Limestone Steel
Iron ore Pig Iron Molten Steel
Basic Oxygen
Coke
Blast
or Electric Arc
Furnace
Limestone Furnace
Blast Furnace Slag Steel Slag
Species Composition [%wt] Species Composition [%wt]
SiO2 35 SiO2 15
CaO 33 CaO 45
Al2O3 20 Al2O3 2
MgO 7 MgO 10
MnO 1 MnO 4
Fe2O3 1 Fe2O3 22
SO3 2
Trace Metals 1 Trace Metals 2
1.Background 2.Process Description
5
3.Reactor 4.Equipment 5.Hazards
6.Economics 7.Conclusions
8. The Proposal
Utilize two major waste streams from the steel mill
to make a significant value added product
Waste Streams: Product:
De-icing Fluid
Steel Slag Waste Pickle
Liquor
Source: Source:
http://www.betweenthelake http://www.environmentallever Source:
s.com/iron/fobf_7_5_03.ht age.com/industry/steel/Steel.h http://www.mto.gov.on.ca/english/transtek/roadtalk/r
m tml t16-4/index.shtml
1.Background 2.Process Description
7
3.Reactor 4.Equipment 5.Hazards
6.Economics 7.Conclusions
9. Background
Stelco Inc. initially proposes idea
Preliminary lab studies conducted
Results show idea is feasible
Revealed no major environmental concerns
US Steel Corp. purchases Stelco Inc.
Project suspended indefinitely
1.Background 2.Process Description
8
3.Reactor 4.Equipment 5.Hazards
6.Economics 7.Conclusions
14. Reaction Data Assumptions
Limited Access to Preliminary Research
Pilot studies required
Literature for Similar Reaction
Ideal batch reactor
0 to 31 Hours reaction
Less than 10mm particle size
Buffer time allotted
Varying particle size
oUp to 35mm
13
15. Product Quality
Minimize amount of heavy metals
pH = 9.5
Control with neat HCl
Retrieved from Dyer, J. A., Scrivner, N. C. and Dentel, S. K. (1998), A practical guide for determining the
solubility of metal hydroxides and oxides in water. Environ. Prog., 17: 1–8. doi: 10.1002/ep.670170112
1.Background 2.Process Description
14
3.Reactor 4.Equipment 5.Hazards
6.Economics 7.Conclusions
17. By-Product Specifications (Sediment)
Trace Trace (wt%)
Cr 10%
5% Fe Mn 0.04
Si 58% Al 0.020
14% Ni 0.03
Ti 0.009
S 9.0 E-04
Mg P 4.6 E-03
3% CN- 1.2 E-05
Ca As 1.5 E-05
10% Pb 0.004
Trace Metals
(ppm)
Forest Soil Cd <1
Cr 22
Compariso Ni 15
n Source: Pb 28
Bavrlic, K., & Quenselle, P.
(2010). Monitoring Forest Integrity
within the Credit River Watershed.
16 Meadowvale.
19. Plant Layout
WPL
Back-Up
Tanks
Reservoi
Reactors r
Loading
Area
HCL
Storag
e Shed
Main
Reservoi
r
Sedimen
t Pond
1.Background 2.Process Description
18
3.Reactor 4.Equipment 5.Hazards
6.Economics 7.Conclusions
20. Reactor Design
Batch reactor 2.0 m 1.0 m 2.0 m
Sloped walls
2.0 m
Capacity = 110m3
2.0 m
0.3 m
Dimensions
L = 7m
W = 5m
1.Background 2.Process Description
19
3.Reactor 4.Equipment 5.Hazards
6.Economics 7.Conclusions
22. Recirculation Process
Benefits
Increased mixing effect
Unites States Patent Office. (1976). Patent #3958952.
(Original work published 1974). Retrieved from
oResulting solution is
http://www.google.com/patents/US3958952?printsec=dra
wing#v=onepage&q&f=false
denser than solvent
Avoid clogging of the
plate with fines
Top View
Less movement of slag
reduces wear on lining
1.Background 2.Process Description
21
3.Reactor 4.Equipment 5.Hazards
6.Economics 7.Conclusions
23. Stop Logs
Stacked
Removable
Manual or Automatic
Stop Logs vs. Pumps
Gravity vs. electricity
oHorsepower is 6hp
http://www.internationalwastewater
oMinimal energy .com/Products/Gates.aspx
oMinimize operating cost
1.Background 2.Process Description
22
3.Reactor 4.Equipment 5.Hazards
6.Economics 7.Conclusions
26. Sediment Pond
Purpose
To settle the solids
Material
Carbon steel lined
with Reinforced
Polypropylene
Dimensions
40m x 14m x 5m
Capacity
2800m3
1.Background 2.Process Description
25
3.Reactor 4.Equipment 5.Hazards
6.Economics 7.Conclusions
27. Settling Rate & Drainage Time
Settling rate Drainage Time
The settling rate is 1 stop log = 7 minutes
0.1m/h
All solids will settle in
one week
1.Background 2.Process Description
26
3.Reactor 4.Equipment 5.Hazards
6.Economics 7.Conclusions
29. Main Reservoir
Purpose
To store
deicing fluid
Dimensions
51m x 60m x 3m
Capacity
9200m3
1.Background 2.Process Description
28
3.Reactor 4.Equipment 5.Hazards
6.Economics 7.Conclusions
30. Backup Reservoir
Purpose
When reservoir is full
& for maintenance
To store extra
production
Dimensions
28m x 28m x 3m
Capacity
2400m3
1.Background 2.Process Description
29
3.Reactor 4.Equipment 5.Hazards
6.Economics 7.Conclusions
31. Materials of Reservoirs
Body Lining
1. Vegetation 1. Reinforced
2. Fill Dirt polypropylene sheets
3. Steel Slag 2. Calcium bentonite clay
Vegetation
Fill Dirt
Slag
RPP
Clay
1.Background 2.Process Description
30
3.Reactor 4.Equipment 5.Hazards
6.Economics 7.Conclusions
32. Covering Structure
Purpose Covering Structure
To cover product
from rain
Dimension
125m x 155m
Area
19400m2
31
34. ECONOMICS
Comparison Between Existing and Proposed Plan
Cash Flow and Sensitivity Analysis
Current Market of De-icing Agents
Cost-saving Benefits
33
35. Replacing Regeneration Process
De-Icing Fluid Production: 11,000 tonnes per year
De-Icing Fluid Unit Price: $300 per tonne
Proposed Plan Current Process
Revenue from De- $3,300,000 Regeneration of ($15,800,000)
icing Fluid Waste Pickle Liquor
Cost of Neat Pickle ($16,800,000)
Liquor
Total Cost $13,500,000 Total Cost $15,800,000
Net Benefit: $2,300,000
1.Background 2.Process Description
34
3.Reactor 4.Equipment 5.Hazards
6.Economics 7.Conclusions
37. Sensitivity of Project
Internal Rate of Return vs.
60
Variation of Factors
Internal Rate of Return (IRR) in %
50
40 Total Capital
Investment
Revenue
30
Maintenance
20
MARR
10
0
-50 -40 -30 -20 -10 0 10 20 30 40 50
Variation in %
36
38. Current Market for De-icing Agents
Ontario usage
500,000 to 600,000
tonnes of salt per year
De-icing trucks
City of Hamilton already
purchasing new liquid
application trucks
Fixed Automated Spray Technology. (n.d.). Retrieved November 18, 2012, from
http://www.ibigroup.com/Pages/Project.aspx?ProjectId=430&DisciplineId=3&PracticeId=50&pageNam
Infrastructure in place e=AreaOfPractice.aspx&backString=AreaOfPractice.aspxxDisciplineID=3ppracticeID=50ppage=
Fixed Automated Spray
Technology (F.A.S.T)
1.Background 2.Process Description
37
3.Reactor 4.Equipment 5.Hazards
6.Economics 7.Conclusions
39. City of Hamilton – Cost of Materials
Road salt De-icing fluid
Unit price: $50 per tonne Unit Price: $300 per tonne
Annual Usage: Annual Usage:
26,000 tonnes per year 2,730 tonnes per year
Total cost: $1,300,000 Total cost: $830,000
Savings of $470,000
1.Background 2.Process Description
38
3.Reactor 4.Equipment 5.Hazards
6.Economics 7.Conclusions
40. Cost Savings & Benefits
Environmentally friendly material
Zero release of ferrocyanide
Introduction of calcium ions in soil
Corrosion reduction
Reduced chloride release
Socioeconomic benefits
Vehicular accident reduction (F.A.S.T)
1.Background 2.Process Description
39
3.Reactor 4.Equipment 5.Hazards
6.Economics 7.Conclusions
41. RECOMMENDATIONS &
CONCLUSIONS
Market Expansion
International Implementation
Paramagnetic Iron Oxide Recovery
40
42. Recommendations
Market Expansion
Scale-up production
Solid product
Global Implementation
Minimizing footprint
Top steel producers & calcium chloride consumers
Alternate uses for calcium chloride solution
Alternate Use for Sediment
Paramagnetic iron oxide recovery Magnetite
Potential source of greater revenue
1.Background 2.Process Description
41
3.Reactor 4.Equipment 5.Hazards
6.Economics 7.Conclusions
43. Conclusions
Maximized amount of waste used
Converted to a marketable product
Cost savings of $2,300,000/year
Novel, simple, energy-efficient
Adaptable to steel mills world-wide
42
44. Acknowledgements
Henry Miyamoto
Jill Lam
Donald Kirk
Graeme Norval
Rosanna Kronfli
Lydia Wilkinson
43
57. Solubility of Heavy Metals
Retrieved from Dyer, J. A., Scrivner, N. C. and Dentel, S. K. (1998), A practical guide for determining the solubility of metal
hydroxides and oxides in water. Environ. Prog., 17: 1–8. doi: 10.1002/ep.670170112
56
58. Production Schedule
Reactor Sediment Reservoir
Pond
• 1 Week • 1 Week • 10 000
of Mixing of tonnes
• Recirculation Settling produced
process • Sediment
• 1 Week removed
during
of maintenance
Settling
• Vacuum
Pumped
2 Batch Reactors per week
Staggered Production
4 Reactors in total
57
59. HCl Price
Current price of HCl $250
Maximum HCl price when regeneration process
becomes preferred: $284
58
61. Total Capital Investment
Total Capital Investment
A. Direct Cost
1. Equipment $ 2,415,834.91
2. Instrumentation and Controls $ 238,989.58
3. Electrical Installations $ 183,838.14
4. Building Including Services $ 128,686.70
5. Yard Improvements $ 367,676.28
6.Service Facilities $ 367,676.28
B. Indirect Cost
1. Engineering and Supervision $ 551,514.42
2. Construction Cost $ 1,295,945.66
3. Contingencies $ 888,648.45
4. Startup Expense $ 999,729.51
C. Working Capital $ 1,190,166.39
60
62. Total Capital Investment
Plant Initial Investment Detailed Spreadsheet 1/2
A. Direct Cost
1. Equipment Unit Cost Quantity Unit Installation Total Unit Cost
HCl Units
Semi Bulk Tanks/Totes $ 455.00 12 tote $ 5,460.00
Metering Pump $ 3,485.00 2 per pump $ 1,394.00 $ 9,758.00
Spill Skid $ 765.50 2 per skid $ 1,531.00
Waste Pickle Liquor Units
Low Carbon Steel Tanks $ 67,400.00 3 per tank $ 30,330.00 $ 293,190.00
HDPE Liner $ 7.00 435 per m2 $ 0.33 $ 3,188.55
Centrifugal Pump $ 28,200.00 4 per pump $ 11,280.00 $ 157,920.00
Concrete Berm $ 260,000.00 1 per berm $ 260,000.00
Reactor Units
Low Carbon Steel Tanks $ 53,900.00 4 per tank $ 24,255.00 $ 312,620.00
HDPE Liner $ 7.00 516 per m2 $ 1.33 $ 4,298.28
Double Piston Diaphragm Pump $ 89,300.00 5 per pump $ 35,720.00 $ 625,100.00
Settling Pond Unit
Reinforced Polypropylene Liner $ 10.00 1100 per m2 $ 0.38 $ 11,418.00
Low Carbon Steel Body $ 304,200.00 1 per body $ 136,890.00 $ 441,090.00
Conveyor Belt $ 118,200.00 1 per belt $ 118,200.00
Reservoir Units
Calcium Bentonite $ 300.00 25 per tonne $ 7,500.00
Reinforced Polypropylene Liner $ 10.00 4950 per m2 $ 0.38 $ 51,381.00
Sump Pump $ 20,500.00 1 per pump $ 8,200.00 $ 28,700.00
Auxiliary Units
Pipe $ 36.88 330 per feet $ 16.60 $ 17,647.08
Level Indicator Controller $ 1,450.00 7 per controller $ 10,150.00
pH Controller $ 1,500.00 4 per controller $ 6,000.00
Pressure Indicator Controller $ 1,694.00 4 per controller $ 6,776.00
HDPE Pipe Reducer $ 18.00 4 per reducer $ 72.00
Check Valves $ 300.00 1 per valve $ 300.00
Butterfly Valves $ 750.00 18 per valve $ 13,500.00
3-way Valve $ 600.00 1 per valve $ 600.00
Magmeter $ 1,455.00 1 per magmeter $ 1,455.00
Flow Control Valve $ 420.00 1 per valve $ 420.00
Filter $ 560.00 22 per filter $ 420.00 $ 21,560.00
Solenoid Valves $ 2,000.00 3 per valve $ 6,000.00
Purchased Equipment Subtotal $ 1,838,381.40 $ 2,415,834.91
61
63. 2. Instrumentation and Controls
Normal Solid-fuild Chemical Processing 13% of Purchased-equipment $ 238,989.58 $ 238,989.58
3. Electrical Installations
Electrical-installations cost 10% of Purchased-equipment $ 183,838.14 $ 183,838.14
4. Building Including Services
Solid-fuild Expansion at an existing site 7% Purchased-equipment $ 128,686.70 $ 128,686.70
5. Yard Improvements
Approximates 20% of Purchased-equipment $ 367,676.28 $ 367,676.28
6.Service Facilities
Approximates 20% of Purchased-equipment $ 367,676.28 $ 367,676.28
Subtotal $ 3,702,701.89
Total Capital Investment
Plant Initial Investment Detailed Spreadsheet 1/2
B. Indirect Cost Cost Total Cost
1. Engineering and Supervision
Approximates 30% purchased-equipment $ 551,514.42 $ 551,514.42
2. Construction Cost
Contractor's Fee 5% $ 185,135.09 $ 185,135.09
Construction 10% of fixed capital $ 1,110,810.57 $ 1,110,810.57
3. Contingencies
Approximates 8% of fixed capital $ 888,648.45 $ 888,648.45
4. Startup Expense
Approximates 9% of fixed capital $ 999,729.51 $ 999,729.51
Subtotal $ 3,735,838.05
C. Fixed Capital Investment $ 7,438,539.94
D. Working Capital (10-20% of Total Capital Investment) $ 1,190,166.39
E. Total Capital Investment $ 8,628,706.33
62
64. Production Annual Cost
Total Production Cost
Detailed Plant Annual Operating Cost Spreadsheet
A. Manufacturing Cost
Direct Production Cost Quantity Unit Unit Cost Total Cost
1. Raw Materials
HCl 12 totes/year $ 455.00 $ 5,460.00
Waste Pickle Liquor
Steel Slag
2. Operating Labor 2 operator/year $ 56,600.00 $ 113,200.00
3. Utilities
Electricity 46250 kW-hr/year $ 0.08 $ 3,700.00
Fuel - Petro 17500 liter/year $ 1.30 $ 22,750.00
4. Maintenance and Repairs
0.05 of FCI $ 371,927.00
5. Operating Supplies
0.15 of Main&Rep $ 55,789.05
6. Laboratory Charges
0.15 of Op&Labor $ 16,980.00
Direct Production Cost $ 589,806.05
Fixed Costs
Insurance
0.007 of FCI $ 52,069.78
Plant-overhead costs
0.6 of Op&Labor $ 67,920.00
Manufactuing Cost Total $ 709,795.83
B. General Expenses
Administrative costs
0.15 of Op&Labor $ 16,980.00
Total Product Cost $ 726,775.83
63
65. Top Steel Producers vs.
Top Calcium Chloride Consumers
Country Steel Production
[million tons]
China 626.7
Japan 109.6
United States 80.5
India 68.3
Russia 66.9
South Korea 58.4
Germany 43.8
Source: Badkar, M. (2011, July 26). The
10 Biggest Steel Producing Countries In Source: IHS Chemical. (2012). Calcium
The World. Retrieved from Business Chloride. Retrieved November
Insider: 2012, from IHS Chemical Web Site:
http://www.businessinsider.com/countrie http://www.ihs.com/products/chemical/pl
s-that-produce-the-most-steel-2011- anning/ceh/calcium-chloride.aspx
7?op=1
64
66. Alternate Uses Of Calcium Chloride Solution
Source: http://www.calciumchloride.com/market.shtml
65
67. Paramagnetic Iron Oxide Recovery
Magnetite
• 3 Fe(OH)2 → Fe3O4 + 2 H2O + H2
Separation
• Wet low intensity magnetic separators
Source:
http://www1.southafricacrusher.com/optional
Potential Iron in Solid Waste: 2,300 tonne/year -equipment/low-intensity-magnetic-
separator.php
Alternative Price Revenue
($/tonne) ($/ year)
Magnetic Iron Oxide Recovery $320 $736,000
Sintering Plant $120 $276,000
Difference $200 $460,000
Source: (Iron Ore: Market Outlook to 2020, 7th edition 2012, 2012)
66
69. Process Equipment Materials
Equipment Body Lining Advantages
Reactor A242 Steel HDPE -A242 highly resistant to
atmospheric corrosion
(Brockenbrough, 2006)
- HDPE chemically inert to
reactants & products and
highly resistant to wear;
widely used with abrasive
slurries (Gabriel, 2001)
Settling Pond A242 Steel Reinforced PP -RPP highly resistant to UV
exposure (Western
Environmental Liner, 2009)
Reservoir 1st layer : Steel Slag 1st layer : Reinforced PP -RPP resistant to UV
2nd layer: Fill Dirt Lining Sheets exposure
3rd layer: 2 nd layer: Calcium bentonite - Clay is a self-healing pond
Vegetation clay sealant to provide extra
safety against leaks (Moine-
Ledoux, 2000)
Stop logs Carbon Steel HDPE -HDPE lining chemically inert
- With EPDM seals and epoxy to reactants & products
painted steel guides -EPDM weathering, UV and
chemically resistant (Rubber-
Cal, 1999)
-Epoxy paint protects steel
from corrosion by chloride
ions
68
70. Secondary Equipment Materials
Piping Body Lining Advantages
WPL A242 Steel HDPE -A242 highly resistant to atmospheric corrosion
HCl -HDPE chemically inert to reactants & products and
Recirculation highly resistant to wear; widely used with abrasive
De-icing fluid slurries
Flush (Water)
Piping
Pumps Body Lining Advantages
Diaphragm Carbon Natural -Steel provides structural strength
(Recirculation) Steel Rubber -Natural Rubber excellent resistance to severe
Centrifugal abrasion, chemically resistant and low cost (Soft
Metering Natural Rubber, 2012)
Sump
Valves Body Lining Advantages
Butterfly PVC EPDM -PVC is low cost and mechanically strong (Curbell
Solenoid Plastics, 2012)
Check -EPDM provides chemically and UV resistant seal
Flow Control
3-way
69
71. Equipment Sizing
Table 13: Process Equipment Sizing 1 of 2
Product Mass Density Actual % Volume Design Width Depth Height Comments Stop Logs
[kg] [kg/m3] Volume Volume [m] [m] [m] [m]
[m3] [m3]
Reactor WPL 107000 1450 74.3 0.74
(1 unit) HCl 378 1490 0.25 0.00 Holds half a 7x0.3048
Water 0.00 1000 0.00 0.00 batch of raw 3x0.1524
materials
Slag 37000 3750 9.88 0.10
Total 84.4 100 5 6.875 4
Settling Liquid 4210000 1380 304 0.11
Pond Holds 1 yr solids 14x 0.3048
Solids 3990000 2020 1980 0.72 + 2 liquid 4x0.1524
batches
Total 2280 2740 40 13.9 5
Reservoi Liquid 10500000 1380 7600 0.83
r Holds 1 yr of
Solids 0.00 0.00 0.00 0.00 product -
Total 7600 9120 60 51 3
70
72. Equipment Sizing Continued
Table 14: Process Equipment Sizing 2 of 2
HCl Supply Mass Balance Vol. with OD [m3] Dimensions [m] of Design Vol. [m3] Comments
Vol. [m3] OD
Radius= 0.5 &Height
0.51 0.61 =1 Holds 2 batches
455.69 535 (Total) - - Holds 3 weeks of WPL
Radius = 3 & Height
WPL Supply - 178 (1/3 of Total) =7 198 Holds 1 week of WPL
Back-Up
Reservoir - 9120/4 = 2280 28 x 28 x 3 2352 Holds ¼ of main reservoir
71
Notes de l'éditeur
IntroductionTeam name & membersToday we will be presenting a novel, and innovative waste management plan for the steel manufacturing industry
Our plan for this afternoon will be to:First, talk about the current waste management plan at a typical steel mill andSecondly we will be presenting ourproposal to minimize wastes and in more detail we will talk about our the key unit and also the settling and storage sites that we have proposedFollowing the technical details we will be going over the plant economics and will close off with a few recommendations for our proposal
First off you might be wondering:what exactly are we trying to do? 1. Minimize the amount of waste produced at an integrated steel mill2. Reduce the costs associated with waste managementAnd so the proposal that will be presented today is an innovative approach to try to accomplish these two objectives
To demonstrate our plan we have chosen a local steel mill, the Hamilton Works plant formerly known as StelcoThe plant in Hamilton has an annual production capacity of 2.6M tonnes of steel product which represents approx. 2% of the world’s production of crude steel
So, what wastes are we dealing with and where do they come from?To identify the wastes, I’ll briefly go over the basic steel making process… To make steel:1. Raw materials (IO,C,LS) charged into blast furnace2. Blast furnace heats these materials to approx. 1500°C where 2 products are formed: pig iron (later used to make steel) and a by-product called blast furnace slag3. Even though BFS is a byproduct, not a waste because 100% of it can be used in other applicationsConcrete aggregateRoad baseMake cement4. Back to the main process, pig iron that is produced is sent to another furnace. Depending on the plant, it is either the BO or EAF where o2,LS, and RecySteel is added.5. Again 2 products are formed: molten steel and another byproduct called Steel Slag. Unlinke BFS, steel slag has limited uses and generally just accumulates on site for use as a fill or railroad ballast. For this reason Steel slag will be a waste that we will have to deal with.
Add spray roaster backup slideMoving along the production line the molten steel is further refined, casted, and rolled into various shapes that make up the steel products.When the steel cools an oxide layer is formed and to ensure good surface quality the oxide layer must be removed. Typically a 30% Hydrochloric acid solution called pickle liquor is used in an acid bath. After the steel has been immersed in the bath, the resulting solution is called waste pickle liquor.Currently steel mills all over the world employ a regeneration process to recycle the waste pickle liquor but this process can be costly depending on the price of neat HCl and is also very energy intensive. Even though there is a process to regenerate the waste pickle liquor, this area presents itself as an opportunity for cost savings.So how are we minimizing the wastes and reducing the costs?
Our plan is to utilize the steel slag and waste pickle liquor to make a de-icing fluid that is used to prevent ice formation on roads.
Stelco hadinitially proposed the ideaand they also performed preliminary lab studies.The results they had obtained confirmed the feasibility of the idea however in 2007, Stelco went into receivership and from then on the project was suspended.This is where our team comes in. Glacius Inc. has chosen to further pursue this project by developing a process to turn steel slag and waste pickle liquor to produce a de-icing fluid. I will now pass it on to my colleague Sonia who will describe the process in more detail.
Say what is on the slide – emphasis on the fact that its not main production of steel mill and needs to be a process that can make money without causing too much problems.
WPL from mill collects in tanksSteel slag from mill collects in stock pileSet 1 begins – consists of 2 batch reactorsWPL gets added (pumped), then steel slag gets added (wheel loader and slag shute)Undergoes mixing process – recirculation – for 1 weekEnd of week cycle settles for 1 weekSimultaneously Set 2 is loading and undergoes mixing processTo filter solid/liquid, Set 1 is drained to sediment pond, sediment vacuum pump, sent to steel mill (high in iron content)End of week 3, sediment pond is drained into reservoir Process repeatsEnd of year, sediment collected in sediment pond is removed
Show what is created through the reaction(Fairly straight forward)Acid/Base ReactionsExothermic = heat will be releasedSince open to atmosphere – maximum change in temperature will be approx. 200C
Even though Stelco performed preliminary research on reaction, we do not have access to this information and could not design accordingly.We had to base our design on research from other studies in literature. – give magnitudeAccording to this data for a similar reactor at ideal conditions will take anywhere from 0 to 31 hours to react. However this is according to a particle size as small as 1 to 10mmSince pilot studies for this reaction are still required, buffering time is allotted in the design to allow a particle size from up to 35mm to react
State final compositions – 30wt%De-icing strength - approx. -25oC
Sediment is mostly iron and silicate – some trace metals-ideal for use in steel millCompare soil for understanding of concentrations
Here I will go through the plant layout listing off the components and equipment
State it is a batch reactor and that it is open to atmosphere - say that this design is to accommodate how we are discharging the productExplain the purpose of the sloped walls - to make sure the solids always settle towards the bottomGo over the total capacity that the reactor can holdList dimensionsMentions the 0.3m is for the distributor plate and you will talk about it in the next slide?
State material: Body: Carbon Steel Lining: HDPE (High Density Polyethylene)Thickness of Materials HDPE lining 5mm Steel Lining ????Slag Chutes: A242 Steel (weathering steel) - made for atmospheric conditions
Top to bottom recirculationSimilar to a Percolating TankThe liquid lies underneath the solidsThe liquid rises through the solid and the solid dissolves into liquid-0.5hp diaphragm pump-1 day turnover rateShow visual of distributor plateShow visual of patent design on filter units - the slots in the cylinder will allow liquid to flow through and not solid - each unit has a 4in diameter - 10 on short edge - 50 on long edge List benefits of this style of mixing shown above
Jill wanted a side view showing how the liquid is expelled when different logs are openedExplain what a stop log is - planks that are stack on top of each other - are removable to control the flow of liquid through the system - can either be manual or automaticCompare a stop log to a pump - it will take 50 sec to drain a 1ft log - state the pump size equivalent to drainage time of 1ft log - go over objectives - minimizes energy therefore minimizing capital cost - therefor it is less expensive - gravity is free and electricity is not - less maintenance cause solids would ruin pump
Section break;Highlight the objectives
This is where the sediment pond located in the plant
We’re also using stop logs at the sediment pondRPP - UV resistant
Solids such as silicate, Mg, Ca, Fe and trace metalsThe range of size is from 1-10mmFor the solids to settle, we calculated that the settling rate is 0.1m/hWith this rate, all solids should settle in one week before it gets transferred into the reservoir
A storage unitComparison???
Since environment canada has labeled hamilton as one of the concerned areas, and our plant is located near the water table, we have put extra thought to prevent our product from leaking into the water. Thus, this is the reason we have 5 different layers for the reservoirSlag – will be the main body of reservoir The fill dirt – to mitigate leachate from permeating into the ground water. The vegetation - encourage the binding of the fill dirt and thus reduce the incidence of erosion in case of heavy rain. The calcium bentonite clay is a self-healing material, so it will prevent any holes from forming.RPP - UV resistant
Cover product from heavy rain which will dilute our productIt will be used all the time, not during the rain onlyIt doesn’t look like a tent, it’ll look more like a dome due to googlesketchup limitation
I’m gonnaadress the major hazards in the plant and how are we mitigating themNeat hydrochloric acid spillPlastic spill pallets under each toteWheel-loader hits reactor during loading Dig a trench & angled towards the sedimentation pondWaste pickle liquor storage tank leakage/failureWe’re going to seal this area with the dikes which have the same capacity of all 3 reactors
Annual Production, Unit PriceComparison between the current regeneration process and our proposed de-icing venture
Two critical points in our sensitivity analysisRevenue decreases by 15 %And total capital investment increases by 20%
Ontario usage: huge market demand for de-icing agentsNew liquid de-icing trucks: new trend for de-icing agentsExisting implementation of fluid de-icing technology: spray before snowfall, decrease ice formation on roads
Cost savings example in city of Hamilton40% raw material savingCity of Hamilton can save up to $470,000
City of Hamilton exampleFerrocyanide is an additive in road salt which prevents aggregation of salt crystals. This can dissociate into cyanide ions which makes the soil toxic absorbed by soil and aquatic environment.Calcium ions can increase permeability of soil to air and water. Extremely beneficial to regions like Niagara falls where agriculture is its main venture.Reduced chlorine release onto road structures which in turn reduces corrosion.Liquid de-icers can be applied before snow storms to prevent ice formation.
Scale-up production with neat HCl and Lime available on-siteSolidify product using evaporative equipment – look into alternative secondary storage (Ties-in with previous point) – Large reservoirs redundant alternative stockpile or immediate shipping once settling time satisfiedTop steel producers also top calcium chloride consumers. China and North America top contenders. Top producers such as Brazil where deicing fluid not in great demand can use calcium chloride solution in other industrial applications such as petroleum, food and highway maintenance. Due to basicity and high chloride levels in reactor, iron oxides in sediment exist predominantly as magnetite, a saleable product. Used as an aggregate for heavy concrete in nuclear plants, heavy media in coal plants and in the manufacture of electronic recording media. Sells at $300/tonne and steel mill stands to gain a net benefit of up $500 000 per annum