Ricardo felipi

BOF Slag use as ballast BOF Slag use as ballast ArcelorMittal Tubarão Experience

November, 2010

Authors:Ricardo Filipe T. Moreira (Presenter)Pedro Sérgio Bicudo Filho

ArcelorMittal TubarãoGeneral View

VitóriaVitóriaVila VelhaVila Velha CariacicaCariacica

Vitória, Vila Velha, Serra, Cariacica: 1,5 million hab.

SerraSerra

Production Flow Chart – 7.5 Mt Phase

2007

2008

Technical Development – New Applications 2009

Economic/Social/Environmental Gains

Centralization of By-products Management

Increase in residues generations 2002

Sustainability

Adding ValueAdding Value

By-products Management Evolution

Plant Start up

Implementation of CASP (by-products Storage Center)

Ever-growing inventories

“Erroneous” view of the market on Residues

Environmental characterizations

Qualification / R&D

Increase in residues generations

1983

1986

1990

1995

1998

1999

Synergy/Benchmarks for Best Practices Planning for Reuse and

Recycling

Monitoring of Key Indicators

Monitoring of Key Indicators

SUSTAINABILITYSUSTAINABILITY

By-products Management Main Actions

Integrated Actions/cooperation with

Operational Areas

Partnerships with Research Institutes/Universities/

Governmental Agencies/Communities

Partnerships with Research Institutes/Universities/

Governmental Agencies/Communities

Technical and Environmental Qualification

Technical and Environmental Qualification

ByBy--productsproducts

Management Management

Development of New Markets/ Clients

Development of New Markets/ Clients

Centralized Management for Development, Processing and

Applications

BOF Slag use as ballast – ArcelorMittal Tubarão Expe rience

Generation Index

2007 2008 2009By-ProductsGeneration kg/t CS 545 591 541

BF (51%) 277 kg/t CST.R.T

GBFS 255 kg/t HM

BOF (41%) 223 kg/t CS

Slag 120 kg/t CS

Scrap 42 kg/t CS

Sludge 23 kg/t CS

Sludge 6 kg/t HM

2007 2008 2009By-Products Recovery

Index % 98,9 99,7 98,8

Recovery Index 2009 Recovery Index Distribution

5%

65%25%

4%1%

Sales

Internal Recycling

Social Actions

Under processing

Storage

ByBy--Products IndexesProducts Indexes

BF Sludge StorageBF Sludge StorageBF Sludge

T.R.T

Temporary Storage

(reduce moisture)

CERAMICINDUSTRY

BOF Fine Sludge StorageBOF Fine Sludge StorageBOF Sludge Sinter Plant

2007 2008 2009

BF Sludge Storage k t 215 208 184

2007 2008 2009

BOF Fine Sludge Storage k t 210 208 166Fine Sludge

Coarse Sludge Briquette Plant

LD Slag StorageLD Slag Storage Desulphurization slag (KR Process)

LD Slag

Slag of secondary refine

Slag of Steel shop cleanness

BOF Fine Sludge Storage k t 210 208 166

2007 2008 2009

LD Slag Storage k t 491 476 520

BOF Slag StorageBOF Slag Storage(*) 2005 Storage = 955.000 t(*) 2005 Storage = 955.000 t

2009 – KR slag generation index adjustment

Matriz de decisão de projetos de co-produtos

Sinter EP Dust on red ceramic industry;

Desulphurization Slag (KR) on mortar composition;

Desulphurization Slag (KR) on cement industry;

BOF slag > 32 mm crushing process to allow road and concrete aggregate uses;

Raw Material Yard Cleanness (> 19 mm) crushing process to allow Sinter reuse;

FGD Heat Recovery Dust use on cement industry;

FGD Heat Recovery Dust use on agriculture;

Hydrocyclone BF Sludge to allow Sinter Recycling

On going By-products Development Projects

AGRICULTURE CONCRETE ARTEFACTS ARTIFICIAL REEFS(concrete with BOF slag)

ROAD INFRASTRUCTURE

ACERITA®

Revsol – BOF Slag with expansion higher than 3% (PTM 130 Method).

Used on unpaved roads, yards recovery and landfill.

Acerita – Treated BOF Slag with expansion less than 3% (PTM 130 Method)

sub-base and base of paved roads. BOF Slag High support strenght allows layer thickness reduction on projects.

Federal Road Department Standards created for ArcelorMittal Tubarão BOF slag road use since 2009

BOF Slag use as aggregate on asphalt composition

BOF Slag Applications

Viçosa Federal University and INCAPER studies show AM Tubarão

BOF slag efficiency when used as soil corrective. Under Federal Agricultural Agency analysis to issue License for

commercial use.

Experimental Coffe planting - Incaper

This application was certified on 2008 by Falcão Bauer Quality Institute based on its technical performance and as an eco-product due to its social and environmental benefits.

(concrete with BOF slag)

Provide new applications for BOF Slag use under sea as rockfill aiming,

tetrapods construction and seashore protection.

On going discussions with Local City Halls and Environmental State Agency to

define project start up.

EFFLUENTS TREATMENTEspirito Santo Federal University Studies

showing good results when using it as filtering beds on domestic sanitary

effluents treatment (wetlands)

BOF Slag Applications

CEMENT INDUSTRY

It reduces CO2 emissions at clinker production. About 3000 t/month are designated to cement production

Obtained from BOF slag processing in plants with crushing, screening, metallic separation

and free lime reduction aiming to attend grain size and other ballast specifications.

BALLAST

Another applications

Landfill Gabion

Hillside protection

Rockfill aiming

Tetrapods Recovery of stone-quarryRip Raps

Hillside protection

ArcelorMittal Tubarão By-products Strategy

Environmental PolicyTo adopt suitable management practices to efficiently use natural

resources, reduce emissions into the atmosphere and water bodies, andrecycle industrial wastes.

Continuous

Development of Partnerships

New Technologies

Research and Development

Continuous Improvement

Breaking of ParadigmsSustainability

Environmental Aspects

• TECAM Lab – 2004 (1st analysis)

• TECAM Lab – 2008 (2nd analysis)


• VIÇOSA – 2006 (Agriculture)


• Incaper 2007 (Agriculture)(Instituto Capixaba de Pesquisa, Assistência Técnic a e Extensão Rural)

Environmental Aspects• IEMA 2007 (ballast)


• ECOS 2008 (Artificial Reefs)

T1 - 1:1:4(cement; sand; BOF slag 0 a 19mm)

T2 - 1:2:3 (cement; sand; BOF slag 0 a 19mm)

T3 - 1:2:3 (cement; sand; BOF slag 5 a 19mm)

T4 - 1:2:23(cement; sand; natural stone)

1º Mês 2º Mês

3º Mês 8º Mês

Implantação Litoral SerraFase final de licenciamento ambiental no

IBAMA-DILIC. Os estudos foram concluídos e está

programada reunião com IBAMAem Brasília até o final de dezembro.


• Falcão Bauer Eco-produto 2008

Environmental Aspects• IEMA 2008 (Agriculture)


• UFES 2008 (Wetlands)

Estudo realizado em parceria com a Universidade Fed eral do Espírito Santo (UFES) e a ArcelorMittal Tubarão, para avaliação de Escória de Aciaria (LD) como leito cultivado e

leito filtrante no pós- tratamento de efluentes sani tários,

“O estudo concluiu com a contribuição para a redução dos segu intes parâmetros: correçãode pH, turbidez, DBO, DQO, NTK, fósforo, dureza e matéria org ânica, e teve como objetivo otratamento natural dos efluentes, visando assim o bem estar e a qualidade de vida dacomunidade”


• IPR/DNIT 2009 (road)


• UFOP 2010 (ballast)

“Após o processo de estabilização química foi

classificado como Classe II B

(Não Perigoso – Inerte)”


Historical

• 1991 First Tests With LD Slag use as ballast (AMT and ra ilroad operator) partnership;

• 1998 Technical specification to BOF Slag developed. AMT and railroad operator.

• 1998 Beginning of Regular use (Commercial relationship) at EFVM;

2006 User start to complain about railway problems (grai n size problems and wrong signals from electrical conductivity of slag)

• 2007 Railway operator Stop using• 2007 Railway operator Stop using

0,00

20.000,00

40.000,00

60.000,00

80.000,00

100.000,00

120.000,00

140.000,00

160.000,00

180.000,00

1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006

Amount of Tubarão LD Slag used as ballast

Over 1 million tons


BOF Slag Ballast - Technical specification under con tract:

Physical properties Technical Specification

BOF Slag results

Soft and friable pieces < 5% 3% ( √)

Pulverulent material < 1% 0.5 % ( √)

Clay lumps < 0.5% no ( √)

Los Angeles Abrasion Loss < 40% 15% ( √)

Weight (kg) per cubic meter > 1.400 kg/m³ 2.800 kg/m³ (√)

BOF Slag Ballast - Particle size distribution

Sieve size % passing by mass

75 mm 100 %

63 mm 90 to 100%

38 mm 25 to 60 %

19 mm 0 to 10%

13 mm 0 to 5 %

BOF Slag Ballast - Electrical resistance

minimum resistance of 300 Ωm

Related to FeM content on BOF slag – máx 2%


Main problems (cause and effect) reported by user

Grain size – Slag fines

Drainage problems on railway

Concrete effect on ballastGrain size – Slag fines

ArcelorMittal Tubarão Control

Slag Generation

Storage

( ~ 2 years)

ProcessScreening

Product

(slag ballast) Inspection

Dispatch

Inspection

Grain size analysis

“Each batch”Focus on screening process

(wrong action AMT & Railway operator)

Controle de Despacho de escória de lastro

Material Estocado na Área de Carregamento

Controle de Despacho de escória de lastro

Material Estocado na Área de Carregamento


Main problems (cause and effect) reported by user

emitter

Wheel on track - electrical current consumption – correct position

Slag Ballast causing electrical current consumption

Wrong signal position

receiver

ArcelorMittal Tubarão Control

Slag Generation

Storage

( ~ 2 years)

ProcessMetallic removal

Product

(slag ballast) Inspection

Dispatch

Inspection

Focus on metallic removal process

(wrong action AMT & Railway operator)


Look for good partnerships:

Working together with clients and Research Institut es;

Client

Railroad Operator

Client

Railroad Operator


Identifying Causes – Slag fines

Physical properties sample collected on railway:

Physical properties of LD slag ballast characterization results;

- High weight per cubic meter; (higher than natural stone)

- No clay lumps;

- Los Angeles Abrasion Loss from 15% to 30% (limit < 40%)

- Soft and friable pieces = 11% to 1% (limit < 5%)

Chemical properties:

- CaO content analysis – from 1.5% to 6.15%;

- Expansion effect even after 2 years storage (~ 5 mts high);

- Internal stretches due to expansion effect causing structure damage – fines generation;

Main Action: Develop method to reduce CaO content a t LD slag ballast;

?


Identifying Causes – Electrical current escape

Built a railroad simulator at Mario Carvalho Station;

- Highest problem occurrence at EFVM railroad;

Measurement equipment to check electrical resistance and pluviometer (data logger)



During rain After rain

Vol

tage

bet

wee

n tr

acks

Vol

tage

bet

wee

n tr

acks

Main problem occurring just after rain period

Problem increase due to bad drainage system – slag fines



Lab Analysis – ballast box to simulate water action on slag

After 11 water cycles

Water PH reduction (12 to 10)

CaO dissolution

Electrical resistance

Electrical conductivity

Main Action: Develop method to reduce CaO content a t LD slag ballast;


Identifying Causes – BOF slag ballast changing perfo rmance

40.000,00

60.000,00

80.000,00

100.000,00

120.000,00

140.000,00

160.000,00

180.000,00

Everything OKProblems – Why?

?0,00

20.000,00

40.000,00

1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006

?What changed on AMT process

BOF Slag Storage over 1 million tons (2000) - old st ock piles

BOF slag Storage = 955.000 tons (2005)

BOF Slag Storage = 545.000 tons (2007)

Increase stockpiles

height

ACTION = Develop curing method for BOF slag ballast

Storage

Period reduction


Develop curing method

Lab tests Water through slag block – 0,17 mm / sec

Around 7 minutes to wet 1 slag ballast block;

Water Quantity? Time cycle?

Lab tests Water through slag column Around 1 minute to wet 2 m height.

weathering method : 10 min water on + 30 min water off (steam formation)


Develop curing method3 kinds of weathering configuration

- Spread storage (30 cm height)

- Cone storage (2 meters height)

- AMT old storage (4 meters height)

cone storage

Spread storage

AMT old storage



Process measurement instruments

Sensor protectionWet sensor Temperature sensor

Data logger back up (each 3 minutes)

CO2 measurement

pluviometer



First results

Capacity (16 m²) CaO To CaO T45 CaO T60

Spread storage 8 tons 8,03 2,80 1,5

Cone storage 25 tons 8,03 3,11 1,7

AMT old storage

50 tons 8,03 Base sensornot wet

Base sensornot wet

Target to achieve 3% of CaO content – good results ( comparing to natural stone performance)

After ballast weathering treatment – slag was screen ed and 25 % was removed (grain size less than 32 mm)

After curing process Ballast slag was tested under physical properties

The fine slag part will be used on road application (low expansion) high demand;


Physical properties T 0 T 60


Comparing physical properties – Final Results

T0 = Not treated slag

T60 = Treated Slag under cone storage (60 days)

Lab analysis occurred 30 days after treating process

Maximum grain size 75 mm 75 mm

Los Angeles 11,5% 11,43%

Water absorption 1,74% 0,81%

Porosity 4,21% 2,03%

Soft and friable pieces 11,51% 0%

Fine grain size problem of BOF slag ballast solved



Escória Arcelor Mittal Dormente de Aço

NOVA;

4835,855000

6000

m)

Brita Dormente de Aço

5000

6000

BOF slag – steel sleepers (resistivity) Natural stone – steel sleepers (resistivity)

BOF treated slag

Simulator data

(Just after built)

Gustavo; 266,67

2 anos;

1493,56

0

1000

2000

3000

4000

5000

Entre eletrodos

Re

sist

ivid

ad

e (

Ωm

)

Gustavo; 977,78

2 Anos;

1553,69

0

1000

2000

3000

4000

5000

Entre eletrodos

Re

sist

ivid

ad

e (

Ωm

)

BOF not treated slag

Simulator data

(Just after built)

Close to 300 Ωm (AREMA)

Problem to railway user

BOF slag simulator

(after 2 years) Low electrical resistivity

problem of BOF slag ballast solved


BOF slag ballast advantages

Resiliency Modulus

Natural rock = 33,11 MPa

Typical railway section ballast (40 cm height)

Resiliency Modulus

BOF slag = 63,00 MPa

Typical railway section ballast (40 cm height)

Results Indicates that ballast thickness can be red uced around 25% using BOF treated slag as ballast – cost reduction

First results indicate that ballast life cycle can be improved using BOF treated slag as ballast (around 40%)– on going study


ArcelorMittal Tubarão BOF slag ballast production flow

Slag generation

Slag first processingScreening

Metallic removal

Slag second processingScreening

Metallic removal

Slag treatment(water into cone

stockpiles)

6 boxes = 4.500 tons/each box

Around 10.000 tons/monthAround 10.000 tons/month

Slag bins to avoid ground contact contamination


On going Actions

Final report results presented to client (railway operator);

Brazilian standard for BOF slag use as ballast draft;

Dynamic simulator with BOF slag ballast;

Next Actions

Site test on EFVM;

Return of Regular use (Commercial relationship) at EFVM;


Conclusion:

- ArcelorMittal Tubarão BOF slag can be used as ballast after a curing process (CaO reduction < 3%).

- Ballast thickness can be reduced when using BOF slag;

Conclusion:

- Attention on process changing;

- Stay close to clients;

- Look for good partnerships;

- Keep always researching;

BOF Slag use as ballast BOF Slag use as ballast ArcelorMittal Tubarão Experience

November, 2010

Authors:Ricardo Filipe T. Moreira (Presenter)Pedro Sérgio Bicudo Filho

Technology

Ricardo felipi