GO-4-0. December 14th 2016 JM Milazzo

Transcription

1 December 14th 2016 JM Milazzo

2 CONTENTS 1. Objective GO 4 0 Project 2. Consortium 3. Project Structure 4. Technical solutions 5. Market analysis 2

3 OBJECTIVE Reduce the need for landfill deposits by turning waste from metal industry into valuable products Sludge Dust Free C Sources Valorised Material Alloys FeMn Eramet Steel industry ArcelorMittal Recycling industry - Comet Free C =Carbon residue obtained from the catalytic cracking of organic residue (foam, rubber, textile, wood, plastic films, etc) contained in the shredder residue of metallic waste 3

4 OBJECTIVE AND TECHNICAL SOLUTION Reduce landfill deposit: Decrease quantities of deposit on landfill Economic environmental solution : Find out solution with lowest cost in Opex and Capex ( free C as Char C ) Pragmatic approach Cold treatment : Compare classical agglomeration with innovative tableting to agglomerate the sludge and dusts Hot treatment : Find out solution with lowest cost RHF,MHF,RK Saleable product: Agglomerate waste (sludge) from industrial producer into saleable product for market as Ore or Rich slag 4

5 CONSORTIUM & BUDGET Consortium ERAMET (coordinator Core Partner) Centre de Recherche Métallurgique ASBL (CRM) (Core Partner) ArcelorMittal (Associate Partner) Eurotab (Task Partner) COMET Traitements SA (Task Partner) Budget: 2M over 3 years (mid-2016 mid-2019) EIT Raw Material funding 5

6 SCHEMATIC STRUCTURE Schematic presentation of the main project steps Go / No Go 12/2016 Theoretical stage WP 0 : Feasibility study WP 2 : Specification of raw materials and final product quality Agglomeration tests Innovative compaction Remove impurities WP 3 : Waste pretreatment Pilot industrial scale 1,3 MW WP 4 : Industrial validation in a small industrial furnace May 16 Dec 16 Jan 17 Jan 18 April 17 Jan 19 Oct 18 Jun 19 0,1 Market aspects, 2,1 Collection and characterisation of secondary raw materials 3,1 Cold pre-conditioning optimisation 0,2 Technical analysis 3,2 High temperature pretreatment processes 0,3 Economic analysis 2,2 Definition of requirements for the use of self-reducing briquettes in melting furnaces 3,3 Preliminary melting trials 6

7 QUANTITIES INVOLVED IN GO 4 0 ~ Tty ~ T/y Case 1- stoechio 125% (C) Raw material ( Wet) (Eramet AM - Comet) Eramet : Sludge Dust Fines Arcelor Mittal Sludge BF Comet Char C Out put for mix All FeMn sludge ER + dusts + Ore Fines + Char + Sludge BF AM Case 3-125% ( C ) Raw material ( Wet) (Eramet AM - Comet) Eramet : Sludge Dust Fines Other Sludge from alloys group Arcelor Mittal Sludge BF Comet Char C out put for mix All FeMn sludge ER + dusts + Ore Fines + Char + Sludge BF AM + Other sludge 7 BERLIN GO-4-0

8 MAIN STREAM FOR GO 4 0 Raw material (Eramet AM Comet ) Eramet : Sludge Dust Minerai fin Arcelor Mittal Sludges Comet Char ~ T/an 1 ~ T/an Dry and Agglomeration (CRM Eurotab) Briquetting Tableting (2) Out put : Briquettes or tablette 3 Legend: Storage/ Process stage ~ Tan (1) ~ T/an (2) 2 Heat Treatment DRI (CRM) RHF MHF Rotary Kiln Sortie : DRI/HBI Transport materials ~ T/an 4 5 ~ T/an Process treatment a. 1+2 b c Product for EAF for external customer : Recyco, Befesa Output : FeMn Rich Slag Product for EAF external customer : Recyco, Befesa Output HCFeMn Rich Slag Rich slag for SAF Output HCSiMn 8 BERLIN GO-4-0 PROMETIA

9 GO 4 0 COMPOSITION SEALABLE PRODUCT Composition after cold treatment Agglomaration + Dryer Fe C Mn Mn/P Mn/Fe P (dry %) (dry %) (dry %) wt wt (dry %) Case 1 5,9 8,0 32, ,10 Case 3 5,1 6,8 31, ,09 Composition after Heat treatment Fe C Mn Mn/P Mn/Fe P (dry %) (dry %) (dry %) wt wt (dry %) Case 1 9,0 0,0 48, ,10 Cas 3 7,8 0,0 48, ,09 9 BERLIN GO-4-0 PROMETIA

10 GO 4 0 PRODUCT = RICH SLAG FOR SAF OR ORE EAF Case 1 Case 3 = Case 1 With other sludge + 40 kt/y Dryer and agglomeration Dryer and agglomeration Market 2 for EAF 136 kt/y Zn =15% Mn = 32% 23 kt/y FeMn, Rich Slag 56 kt/y Market 3 for SAF for SiMn 136 kt/y Mn 32% Market 3 for SAF for SiMn Zn =0% Mn = 48% 82 kt/y Heat treatment ( MHF, RK, RHF) Market 2 for EAF Zn =0% Mn = 48% 82 kt/y 23 kt/y FeMn, Rich Slag 56 kt/y 10

11 COLD TREATMENT Agglomeration techniques Tablet without blend Innovative Classical Roll-press «Tablet» mm Sintering: 1-10mm Pelletising: Max 0,2mm Briquetting: 0-6mm Extrusion: 0-6mm Eirich mixer: <1mm 11

12 COLD TREATMENT The agglomeration technique used is dependent on: Thermodynamic properties of the agglomerate. Raw materials particle size. Agglomerate size required. Binder project Go Test without Binder innovative agglomeration Cold and hot strength. Reactivity. Porosity. Cost ---- Reduce all cost for treatment innovative agglomeration 12

13 COLD PRE-TREATMENT INNOVATIVE PROCESS WITHOUT BINDER Compact forming EUROTAB - Technology Tabletting Double punch w or w/o dwell time Tabletting Powder with properties / behavior upon compaction An optimal kinematic Pressure, speed, dwell time,... Tablet performances adapted to application Single punch w or w/o refrigeration 13

14 HOT PRE-TREATMENT PRE-TREATMENT TECHNOLOGIES The rotary hearth furnace continuous furnace concept.. Multiple hearth Furnace- Vertical Calciner, several circular hearths Rotary kiln Hot gases pass along the kiln in counter-current or co current 14

15 FEASIBILITY STUDY - METHODOLOGY By-product MIX reference cold treatment DRI Hot treatment Value on market Evalutaion Opex and Capex Deliverable 12/2016 Estimation Bankability Project Evolution project Step 1 : Chemistry Calculation with thermodynamic model Step 2 : Mix Definition Step 3 : Market study Step 4 : Sealable mix and volumes Step 5 : Evaluation Opex and Capex - Step 6 : Bankability Assessment Methodology Step 1 2 Mix reference Step 5 Step 6 Sealable mix Market input Step 4 Step 3 15

16 FEASIBILITY PROFITABLE MARKET Simple approach Market value + Save on Deposit cost Operational cost ( Opex + Capex) 0 CP consulting /t CRM and partners 16

17 MARKET STUDY RICH SLAG OR POOR ORE Market value + Save on Deposit cost Operational cost ( Opex + Capex) 0 CP consulting /t average 126 /t CRM and partners Market = Rich slag for SAF (submerged Arc Furnace) -SiMn Market or SA ore for EAF ( Electric Arc Furnace) Rich slag value = 70 % * DMTU * % Mn + Added Value Save on Deposit = ER 100 /t - AM Range DMTU = tonnages of manganese content calculated with 9% humidity for ore (figures given in Dry Metric Ton Units: 1 DMTU Mn = 10 kg manganese). 17

18 MARKET STUDY - VALUE Market value + Save on Deposit cost Operational cost ( Opex + Capex) 0 CP consulting 100 /t -250 / t CRM and partners Dryer and agglomeration Case 1 Dryer and agglomeration Heat treatment ( MHF, RK, RHF) Value 44 /t market 2 EAF external Mn = 32% Value -2 /t market 3 SiMn Mn=32% Value 10 /t - market 3 for SiMn Mn=48% Value 65 /t market 2 EAF external Mn=48% Save on deposit 126 /t Save on deposit 126 /t Save on deposit 126 /t Save on deposit 126 /t Global value 171 /t Case 1.1 Global Value 124 /t Case 1.2 Global value 136 /t Case 1.3 Global Value 191 /t Case

19 BANKABILITY OF THE PROJECT Market value + Save on Deposit cost Operational cost ( Opex + Capex ) 0 CP consulting 100 /t -250 / /t CRM and partners Cold treatment Hot treatment = DRI Market value /t Bankability All cases 8 are profitable 20 cases are profitable 4 are not profitable 126 /t landfill cost Treatment Cost : Opex and capex /t 19

20 Thank you for your attention 20