Peittoon kierrätyspuisto, Tuhkasta timantteja II - Liiketoimintaa teollisista sivutuotteista ja uusiutuvasta energiasta, 10.12.2013 Pori.

1. Jätemuovi – haitallisesta hiilipohjaisesta materiaalista arvokkaaksi metallurgisen
koksin, koksaamokaasun, vedyn ja hiilivetypohjaisen öljyn raaka-aineeksi
TkT Jyrki Heino
Nippon Steel
LABORATORY OF PROCESS METALLURGY
DEPARTMENT OF PROCESS AND ENVIRONMENTAL ENGINEERING

2. The history of Harjavalta industrial area
1944 Copper factory is moved from Imatra to Harjavalta.
1945 The start up of the Outokumpu copper factory

3. The history of Harjavalta industrial area
1945 The start up of the Outokumpu copper factory
1947 The start up of the Kemira sulphuric acid plant
Year 1950

4. 1949 Start up of first Outokumpu copper flash smelter
1956 First licensed Outokumpu copper flash smelter
starts up in Ashio, Japan
1959 Start up of first Outokumpu nickel flash smelter
1995 Start up of AGA hydrogen plant
1995 Start up of Direct Outokumpu Nickel (DON)
process
1999 Outokumpu out sources industrial maintenance,
transport, sanitation, industrial sanitation and
guarding to partnership companies

5. Type II industrial system
Concentrate, silica sand
FLOW SHEET OF COPPER SMELTER
Feed mixture
Flue dust
Bag
filter
Oxygen
and air
SCREENING AND
GRINDING
Bag
filter
Steam
CONCENTRATE
DRYING
WHB
FLASH SMELTING
FURNACE
PRESSURE
FILTER
Slag concentrate
Slag
Matte
Scrap, anode scrap
THICKENER
Silica sand,
coke, reverts
SLAG GRINDING
WHB
EP
CONVERTER
Ni drying
HEAT
EXCHANGER
Ni Electric
furnace bins
ANODE CASTING
Propane, air
ANODE
FURNACE
Waste slag
Bag
filter
Air and oxygen
SLAG COOLING
Blister
SLAG
CONCENTRATOR
Acid
plant
EP
Cu-ANODE

6. = More
than 55 licences in five continent
The first ever copper flash smelting process
started in Harjavalta, Finland at 1949
Outotec 2012

7. Copper and nickel flash smelters as an important part of
Harjavalta industrial eco-park
YARA SUOMI OY
MAINTENANCE
KEMIRA OYJ
Mainpartner Oy
GAS PRODUCTION
Insta Automation Oy
SECURITY
Air Liquide Finland Oy ABB Oy Services
ISS Security Oy
Oy AGA Ab
POWER SUPPLY
Suomen Teollisuuden
Energiapalvelut STEP Oy
BOLIDEN
HARJAVALTA OY
PLANNING AND PROJECTS
Outotec (Finland) Oy
Insta Automation Oy
NORILSK NICKEL
HARJAVALTA OY
CANTEEN
Amiga and Fazer
VR CARGO
THE PORI PORT
OY HACKLIN LTD
Boliden Harjavalta Oy
CLEANING OF
FACILITIES
SOL Palvelut Oy
INDUSTRIAL
CLEANING
Lassila & Tikanoja Oyj
WASTE WATER
TREATMENT
Aquflow Oy Oy
INTERNAL
TRANSPORTATION
Valtasiirto Oy
16.12.2013
LUVATA PORI OY
OUTOTEC (FINLAND) OY
7
Boliden Harjavalta Oy 2012)

8. The product and company diversity progress 1945 - 2013
YEAR COMPANY
PRODUCTS
1945
Outokumpu
Anode copper
2013
Boliden Harjavalta Oy
Anode copper, nickel matte, sulphuric acid, and sulphuric
dioxide in smelters of Harjavalta plant. Cathode copper, gold,
silver, platinum and palladium concentrate, copper sulphate,
nickel sulphate, copper telluride, and selenium in electrolysis of
Pori plant
Norilsk Nickel Harjavalta Oy
Nickel cathodes, nickel briquettes, nickel powders, nickel fine
powder, nickel solutions, nickel chemicals, ammonium
sulphate, copper sulphide, and cobalt sulphate solution
SP Minerals Oy
Screened granulated nickel slag for sand blasting and roofing
felt production
Kemira Oyj
Aluminium sulphate
YARA
Urea phosphate, different kinds of fertilizers, urea
AGA
Gaseous oxygen, hydrogen and nitrogen, liquid oxygen,
nitrogen, and argon
STEP Oy
Process steam, high temperature steam, process energy,
district heating energy, raw water, salt-free and precipitated
water, electric energy, and compressed air

9. Material and energy
change of Harjavalta
Industrial Eco Park
STEP
ADVANTAGES
NN
Environmental and recycling benefits
YARA
Better energy efficiency
Better product diversity when different
companies can concentrate to their
own core know-how areas
Marketing and logistic benefits
Improved safety activity
NN = Norilsk
Nickel
Imago factors
Positive co-operation factor based on
cultural differences

11. Environmental load of Finnish ferrous and nonferrous
metallurgical industry – Future challenges
 In ferrous industry main raw materials are oxide ores and in nonferrous
industry sulphide ores
 Earlier sulphur dioxide was main problem in nonferrous metal manufacture;
now the main problem is a huge amount of unutilised solid wastes
 High electric energy demand in electrolysis of copper, nickel and zinc and
ferrochromium and stainless steel manufacture
 The main problem of ore based ferrous industry is CO2 emissions
 Specific CO2 emissions (tons per produced ton of steel) of Finnish steel
industry are one of the lowest in the world
 The major problem when using more steel scrap as a raw material will be the
contamination of steel by tramp elements
 Utilisation of some dusts, slimes and sludge from ferrous industry is waiting
for economical solutions

12. Harjavalta industrial park as
an example of an industrial
ecosystem when developing
environmental friendliness of
carbon steel
Basic principle: “The primary production
chain of the ore based steel making is
not disturbed (Pöyliö et al. 2002)”
=> So, there is ahead a mega jump in
technological, economic and ecological
efficiency by totally eliminating waste
streams and fully exploiting synergies
with other related industrial technologies.
(Szekely 1996)
Heino 2006

13. Industrial ecology applied to carbon steel manufacture
More efficient use of own iron residues
(dusts, scales and sludge = waste oxides)
Use of iron residues from other industries
(Scrap, slags, roasting residues)
Use of secondary or bio based energy
sources and reducing agents (Plastics, tar,
heavy oil, tyres, wood, etc.)
More efficient use of slags in cement
industry, in road construction and agriculture
to replace virgin raw materials
Low heat energy utilization in district
heating, in greenhouses or somewhere else
in the surrounding community.
Coke oven gas can be converted into H2,
which can be fed into fuel cell battery for
automobile or chemical industry
Utilisation of carbon monoxide as a raw
material of formic acid manufacture
Better energy efficiency with the aid of
energy integration included pinch
technology, etc.

14. EFFICIENT FUEL FOR A BLAST FURNACE (EFBF)
01.09.2011 - 31.08.2015
T. Fabritius, S. Gornostayev, J. Heino., S. Huttunen, T. Kokkonen, and R. Mattila
INTRODUCTION
Natural reserves of coking coal are limited and the standards for blast furnace iron
making are becoming increasingly strict, encouraging steel producers to implement
environmentally friendly and economical processes.
The production of high quality coke requires a better control of its properties (e.g.,
reactivity and strength) as well as sustainable and economic management of coke
oven gases (H2 ~ 58.5% and CH4 ~ 23.8% as a main utilisable components).
Because of the limited source of coking coal, it must be found new ways to
substitute the virgin raw material with other appropriate renewable or secondary
organic compounds.
Without large investments costs to extra treatment plant twaste plastics charged in
coke ovens can be used as a secondary source of hydrogen, a fuel, a reductant, a
carburization agent and a structural support used in a BF thus substituting virgin coal
and thus decreasing carbon dioxide emissions.
LABORATORY of PROCESS METALLURGY
DEPARTMENT of PROCESS and ENVIRONMENTAL ENGINEERING

15. INTRODUCTION TO PLASTIC COKE RESEARCH IN EFBF
 Without large investments costs to extra treatment plant waste
plastic can be processed in coke ovens to be used in blast furnace as
structural support, carbon based reductant, carburization agent, and
fuel for the hot iron metal.
 By-products of coking process (H2, hydrocarbon oil, and CH4) can be
used in other more valuable purposes.
 Virgin coal will be substituted and CO2 emissions reduced.

16. PLASTIC COKE RESEARCH
 To study how coking process proceeds when coking coal without and
with varying amounts of plastics.
 To investigate coking process when changing the amount of the
plastics among the coking coal.
 To produce different type of plastic-free and plastic-bearing coke for
analysing and testing.
 To investigate how plastics and their amount affect the porosity and
strength of the coke and to define is there any maximum limit to the
amount of the plastics.
 To measure the coke gas composition when coking coal without and
with varying amounts of plastics.

17. The coal-to-coke transformation takes place as follows:
The heat is transferred from the heated brick walls into
the coal charge with the following consequences:
1. From about 375°C to 475°C, the coal decomposes
to form plastic layers near each wall.
2. At about 475°C to 600°C, there is a marked
evolution of tar, and aromatic hydrocarbon
compounds, followed by resolidification of the
plastic mass into semi-coke.
3. At 600°C to 1100°C, the coke stabilization phase
begins. This is characterized by contraction of coke
mass, structural development of coke and final
hydrogen evolution.
4. When the plastic layers have met at the center of
the oven, the entire mass has been carbonized.
Source: Shelton Iron and Steel Co

18. Source: Kawasaki Steel

19. Plastic as a secondary raw material of coke
Source: Nippon Steel

20. Source: Nippon Steel

21. EXPERIMENTAL
 Metallurgical coke was prepared in laboratory scale coke ovens by coking three
common coals (RI, EV and BU) without and with most widely used plastic polyethylene (HDPE, (C2H4)n).
 Plastics and coals were grinded to < 5 mm.
 In mini coking process samples were warmed up to 1200 ºC.
 Coke compression strength was measured by Zwick 100 kN Tensile test machine.
 Image analysis by optical microscopy was performed to study textures and
porosity of coke.
 ASAP 2020 Pore size analyser was used to measure porosity and surface area
(BET) of coke

22. Laboratory scale coke oven battery with nine coke ovens

23. Tools and methods for advanced studies of coke
Optical microscopy and image analysis
Digital
camera
Recognition of textures (mosaic, isotropic, banded) and pores.
Mattila O., Salmi P. Wavelet-based image analysis method to study the
properties of coke (2008) Scanmet III Conf., Sweden, p. 237-244.

24. Cold compression strength (kN/m2) of coke as a function of PE plastic 0 – 12,5 % addition in RI coal

25. RESEARCH RESULTS
 No significant changes were observed in the cold strength results from 0 up
to 5% of HDPE plastics addition to the three different coals BU, EV and RI.
 Below 5% HDPE plastics addition in RI coal the increase of mosaic texture at
the expense of isotropic texture compensates for the weakening effect of
increased porosity. Also rounded macro pores observed in texture analysis,
decrease the weakening effect.
 Mosaic carbon texture in coke is usually less reactive with carbon dioxide
compared to isotropic carbon texture, thus improving the CRI and CSR
values of coke to be used in blast furnace.
 The cold compression strength results of coke manufactured by adding the
most common plastic (HDPE) to Riverside coal were very encouraging.
 Estimations are both coal-specific and plastic-specific and should be made

26. Eco-efficient features of Finnish metallurgical industry
 Conservation of energy and intelligent use of non-fossile energy
sources and minimizing the impact on the environment; air, water, soil
 ASM Historical Landmark Award for the Outokumpu Flash Smelting
Process in 2002
 About 50 % of the World copper and 30 % of nickel is produced by
Flash Smelting method developed in Harjavalta Finland by
Outokumpu (nowadays Outotec)
 13 BAT´s = Best Available Technologies developed by Outotec rated
by the EU to their energy-efficiency and low emissions
 Ruukki as a leader in the Dow Jones Sustainability index among
carbon steel manufactures (Cleantechfinland 2011)
 Outokumpu Tornio Stainless steel plant having the lowest carbon
footprint of world stainless steel manufactures (Outokumpu 2010)
Mäkinen 2006 and Outotec 2012

27. Pekka Tervonen, TkT, eMBA
Johtaja
Puh: +358 40 6739519
pekka.tervonen@oulu.fi

28. Centre for Environment and Energy (CEE)
1. CEE:n toiminnan painopisteet ovat ilma, vesi, energia ja resurssitehokkuus
sekä edellisiä poikkileikkaavana teemana mittaustekniikka.
2. Visiona on olla ekoinnovatiivisten ratkaisujen haluttu yhteistyökumppani.
3. Strategiana on kehittää ympäristö- ja energia-alaa yhdistävä
osaamiskeskittymä, joka yhdistää nopeasti alan huippuosaamisen tutkimus-,
kehitys- ja innovaatiotoiminnan hankkeisiin, yhteistyöverkostot ja
rahoituskanavat.
4. CEE yhdistää läpinäkyvästi valitun alan huippututkimuksen ja yritysosaamisen
Oulussa ja yhteistyöverkkojen kautta valtakunnallisesti ja kansainvälisesti.
Tämä luo kestävän pohjan tutkimus- ja yritysyhteistyölle.
5. Toimintafilosofia on ohjelmapohjainen verkostomalli, mikä mahdollistaa
nopean ja proaktiivisen tutkimusyhteisöjen ja yritysten yhteistyön.

29. CEE – yritysosaamisen ja huippututkimuksen integraatio

30. CIRU –platform/CEE (Juha.roininen@oulu.fi)
 CIRU – Platform auttaa teollisuusyrityksiä kehittämään prosessejaan ja hyödyntämään
niissä syntyviä sivuainevirtoja.
 Asiantuntemuksemme perustuu tieteelliseen tutkimukseen termodynamiikan,
minerologian, kemiallisten analyysien, reaktiokinetiikan ja virtausmallinnuksen alueilla.
 Voimavaroinamme on koko tekninen osaaminen ja erityisenä tavoitteenamme on yhdistää
toimintaamme myös tuotteistaminen kaikkine osa-alueineen.
 Tässä työssä huomioimme myös yhteiskunnallisen vaikuttamisen, josta esimerkkinä on
muotoilu aspektin tuominen mukaan aliarvostettujen materiaalivirtojen tuotteistamiseen
yhtenä työkaluna hyväksyttävyyden saavuttamiseksi ekologisille toimintamalleille.
 Toimintamme peruslähtökohtia on tarpeiden tunnistaminen, avoimuus, yhteistyö sekä
innovaatioiden edistäminen tutkimuksen avulla.
 Yhteistyö suurteollisuuden ja julkisten toimijoiden kanssa toimii erinomaisesti
 Työmme tavoite on lisätä toimijoiden kannattavuutta ja ekologisuutta korkealaatuisella
tieteellisellä osaamisella ja erityisesti PK sektorin toimijat ovat erittäin toivottuja
osallistumaan tähän yhteistyöhön.
 Tule mukaan parantamaan maailmaamme ja ota yhteyttä meihin tulevaisuuden tekijöihin.

31. Sources of information
CENTRE FOR ENVIRONMENT AND ENERGY (2013) <http://www.oulu.fi/english/CEE>
Cleantechfinland (2011) <http://www.cleantechfinland.com/news/ruukki_achieves_industry leader_position_in_ dow_jones_
sustainability_indexes/>. 21.9.2011
Heino, J. (2006) Harjavalta industrial park as an example of an industrial ecosystem when developing environmental friendliness of carbon steel.
Doctoral dissertation. Acta Universitatis Ouluensis, C Technica 254. 163 p. (In Finnish)
Heino, J., Gornostayev, S., Kokkonen, T. Huttunen, S. Fabritius, T. Waste plastic – From harmful carbon based material to valuable raw material
of metallurgical coke, coke oven gas, hydrogen, and hydrocarbon oil. Annual World Conference on Carbon, 17-22 June, 2012, Krakow, Poland.
Oral presentation and paper in conference proceedings.
Heino, J., Gornostayev, S., Kokkonen, T., Turpeinen, E., Huuhtanen, M., Suopajärvi, H., Huttunen, S. Fabritius, T. & Keiski, R. (2013) Waste
plastic as an additional raw material of metallurgical coke to produce hydrogen as by-product. Poster in 2nd International Symposium of Green
Chemistry 2013 in France.
Kawasaki Steel. <URL:http://www.kawasaki-steel-21st-cf.or.jp/chapter_2/index.html> 24.10.2002
Mäkinen, J. (2006) Eco-efficient Solutions in the Finnish Metallurgical Industry. Challenges of Eco-efficiency seminar.
Outokumpu. (2010) The energy and low-carbon programme. Outokumpu leading the way. <URL:http://www.outokumpu.com/51623.epibrw/> 8 p.
Outotec (2012) <URL:http ://www.outotec.com/pages/Page____40893.aspx?epslanguage=EN>
Nippon Steel news June 2004
Pöyliö, E., Makkonen, H., Laitila, L., Heino, J., Hiltunen, A. & Härkki, J. (2002) Optimal recycling of the iron based steelmaking dusts, scales and
sludge. Recycling and waste treatment in mineral and metal processing: Technical and economic aspects. Luleå, 16.6 – 20.6.2002. Luleå
University of Technology, MEFOS and the Mineral, Metals & Materials Society. Volume 2, pp. 129 –137.
Szekely, J. (1996) Steelmaking and industrial ecology - Is steel a green material? ISIJ International 36(1996)1, pp. 121 - 132.
Yonesawa K. Longitudinal vision of steelmaking industries from an environmental standpoint in Japan through course 50 project. SCANMET III 3rd International Conference on Process Development in Iron and Steel making, 8-11, June 2008, Luleå, Sweden, vol. 1, pp. 49-58.