Advanced Pilot Plants - A Cost Effecive Step in Process Development

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1 Advanced Pilot Plants - A Cost Effecive Step in Process Development Göran Carlsson CEO Swerea 12/6/07 MEFOS June 11, 2013

2 Content The global picture and killing a myth Global challenges influencing R&TD The role of a pilot-plant June 11, 2013 Future Circular Materials Expo 2

3 Kg/cap Steel comsumption of today Source: OECD GDP/cap June 11, 2013 Future Circular Materials Expo 3

4 Crude steel production, mmt Global crude steel prodction Gloriuos +5%/yr Pityful +1%/yr China +6%/yr Source: WSA June 11, 2013 Future Circular Materials Expo 4

5 Crude steel production, mmt Global crude steel production 1800,0 1600,0 Total 1400,0 1200,0 1000,0 800,0 Iron ore based 600,0 400,0 200,0 0,0 Source: WSA Scrap based June 11, 2013 Future Circular Materials Expo 5

6 Crude steel production, mmt Global crude steel production years mmt 200 Source: WSA June 11, 2013 Future Circular Materials Expo 6

7 Scrap based steelmaking, mmt Steel production analysis 2012 Average life time for a steel construction: 20 years Crude steel production 1993: 730 mmt Steel scrap used in steelmaking 2012: ~ 680 mmt - internally reused ~ 110 mmt - steel scarp ~ 570 mmt Steel scarp yield > 90 % 600,0 500,0 400,0 300,0 200,0 Growth last 20 years: 240 mmt Annular growth rate: 5 % 100,0 0, June 11, 2013 Future Circular Materials Expo 7

8 Crude steel production, mmt Iron ore based steelmaking 1200,0 Oxygen steelmaking Iron ore and coal prices Iron ore (blue) Coal (red) 1000,0 800,0 600,0 400,0 200,0 0, Source: WSA, OECD June 11, 2013 Future Circular Materials Expo 8

9 What s going on globally and influencing Swerea MEFOS activities Competition for raw materials Energy cost and GHG Environment and sustainability New materials for lighter constructions Competence~Integrity~Service June 11, 2013 Future Circular Materials Expo 9

10 Sourcing of raw materials New raw materials - usually lower grades Secondary raw materials - recovery from e.g. dust, sludge, scale, slag, tales Tertiary materials - development of alternative materials June 11, 2013 Future Circular Materials Expo 10

11 June 11, 2013 Future Circular Materials Expo 11 The pilot plants - some successful results

12 The DC-furnace Furnace Heat size Furnace inner diameter, lined Electrode diameter Inner hole diameter ca 5 tonnes 1.8 m 250 mm 70 mm - Titania slag smelting - VILD-process - FeVMn slag processing, - Zn recovery from EAF dust - FeCrNi Steel industry (Cr, Ni) - Direct MC ferroalloys - Mn-slag from residue - Silicon processes - FeNi from Ni-ore and dust - FeNiMo/V2O3 catalyst smelting - AshArc ABB treatment of flyash June 11, 2013 Future Circular Materials Expo 12

13 Reduction of V-rich slag June 11, 2013 Future Circular Materials Expo 13

14 Results from test campaigns V-recovery % Energy cons MWh/ton slag Flexibility Reductants LD-slag >90% 1.3 Excellent C, C+FeSi, C+Al, C+SiC >90% 0.9 Excellent SiC LUVA-slag >90% 1.2 Excellent C, C+FeSi, C+Al >90% 0.9 Excellent SiC June 11, 2013 Future Circular Materials Expo 14

15 Hot Slag Reduction Plant trials - tapping Plant trials - Injection Metal and slag products Pilot trials - Kaldo Pilot trials - Injection June 11, 2013 Future Circular Materials Expo 15

16 The VILD project Final results An Industry Process and Inspiration Price 2011 by the Swedish Recycling Industry June 11, 2013 Future Circular Materials Expo 16

17 Universal converter -All kinds of converter processes -Kaldo process -MCFeMn by dec Heat size 6 tonnes Rotating speed 6-30 rpm Furnace diameter, lined m Furnace volume, lined 3.8 m 3 Oxygen gas flow 0.5 m 3 n/sec -Mn-steel process -Clinkering of Mn-sludge -Mineral smelting (Pb-Zn) -Wastes from metal industry -Al recovery from dross June 11, 2013 Future Circular Materials Expo 17

18 The Kaldo process - developed by Boliden at Swerea MEFOS Lead Kaldo Copper Kaldo followed by electronic Kaldo and also Silver Kaldo Tin Kaldo June 11, 2013 Future Circular Materials Expo 18

19 Pickling sludge to substitue fluorspar June 11, 2013 Future Circular Materials Expo 19

20 Recycling of ladle slag to BOF BOF slag Lime - low sulphur - low water Lime - low sulphur - low water Hot metal Crude Steel Refined Steel Slag 12/6/07 Construction material Raw material for cement Paddoc material Fertilizer June 11, 2013

21 Recycling of ladle slag to BOF BOF slag Ladle slag Lime Hot metal Crude Steel Refined Steel Slag Quicker slag forming Better off-gas cleaning 12/6/07 Construction material Raw material for cement Paddoc material Fertilizer June 11, 2013

22 The Swerea Group one step further Process metallurgy Metal working Heating Swerea MEFOS Swerea IVF Production technique Ceramics Textiles Corrosion Materials properties Analysis Swerea KIMAB Sweden's strongest R&TD-team on Industrial Recycling of Material Swerea SICOMP Plastic Composites 12/6/07 June 11, 2013 Swerea SWECAST Castings Foundry

23 Final remarks Top class pilot plant facilities in combination with strong simulation tools and measuring technique is a strong platform for advanced R&TD Powerful research teams, on international level and with a combination of industrial and academic experience, are a must Interntional networking is essential in order to stay in the forefront. Competence~Integrity~Service June 11, 2013 Future Circular Materials Expo 23