EcoShred-SCRAPTUNING

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1 EcoShredSCRAPTUNING New shredder technology for EAF scrap charging

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3 NEW TREATMENT TECHNOLOGY Increases the flexibility of scrap charging YOUR CHALLENGE Scrap is a raw material that is traded worldwide and whose importance for future steelmaking is growing continuously. Globally rising recycling rates, in particular of automobile scrap but also electrical waste, on the one hand increase the scrap types offered on the market, yet on the other hand these scrap types can only be used for the production of highquality steels to a certain extent. The increasing complexity and intermeshing of electronic systems in automobile construction aggravate this problem. In addition, major price fluctuations and a volatile availability of clean scrap grades force steel producers to employ a cost and qualitydriven purchasing strategy. Tramp elements in the scrap such as lead, copper, zinc, tin, oils and plastic materials are increasingly causing problems when charged in electric arc furnaces. On the one hand, the analysis specifications for highquality steels limit the Fig. 1: Shredder input. use of certain scrap grades, while on the other hand the dioxins and furans produced by the tramp elements of the scrap place stricter requirements on highly effective wastegas cleaning concepts. In order to secure the future competitiveness of electricsteel producers, the raw material basis for highquality steel grades must therefore be safeguarded to an adequate degree at moderate prices. The valueadded arising from the EcoShred process through the treatment of heavily contaminated capital scrap into scrap types with a defined lump size and minimal copper contents amounts to approx. 25 /t, depending on the location and allowing for the conversion costs. OUR SOLUTION In a Joint Venture with Messrs. SICON GmbH/Hilchenbach, Germany, SMS Siemag offers the EcoShred treatment concept for complex recycling scrap, setting new standards for steelmakers in terms of scrap composition and purity requirements. With this method, undesired accompanying substances are reduced to a minimum by various process stages. Online analyzers allow the specific setting of the scrap composition for the discontinuous or continuous addition of scrap. Furthermore, the process stages that are aligned with each other reduce tramp elements such as plastic materials from endoflife vehicles and rubber residues from old tires that cause major problems in the cleaning of waste gas and are responsible for the formation of dioxins. With lower scrap procurement costs and higher addedvalue through the removal of tramp elements in the scrap, a processing line combined with an electric arc furnace thus leads to short payback periods. Also part of the process is the possibility of a full recovery of metallic elements from the shredder residues plus their utilization according to the VW SICON process. 3

4 SMS SIEMAG EcoShredScrapTuning THE HIGHLIGHTS OF THE ECOSHRED PROCESS 1. Higher profitability The aim of EcoShred is high profitability. Compared with shredder solutions from competitors, the specific electric power consumption is optimized. The major operating costs are under control at all times. With its intelligent control system, EcoShred always operates at an optimum throughput rate and power input. Wear costs are lower than those of competitor machines. The selection of a suitable wear material and especially the integrated discharging of wearintensive constituents as part of the process result in a higher service life of the wear parts and thus in shorter maintenance and repair downtimes. 2. Homogeneous scrap quality In contrast with today's customary shredder installations, EcoShred has been optimized to produce homogeneous scrap with a higher bulk density, which results for example in a singlebucket strategy and, of course, in lower conversion costs. More and more complex shredder input material, brought about by rising amounts of electronic components, makes today's standard manual sorting operations a risk for the quality of shredded scrap. Unpredictable quality variations either restrict the usability of shredded scrap or increase the cost of buying out scrap because larger amounts of highquality scrap are needed. With its improved process control system, EcoShred produces scrap with a defined composition and a copper content of <0.2%. In addition, a significantly lower amount of inert material increases the metallurgical yield. This effect is made possible through a more intensive impact effect in the rotor space of the EcoShred installation which, in combination with the novel type AirSort wind sifter, permits much better cleaning than other wellknown units. Fig. 2: Shredded scrap. 3. Online scrap analysis The perfect separation of constituents detrimental to production on the one hand and a permanent analysis of the shredded scrap on the other hand allow clearly improved usability of shredded scrap. The cost efficiency of electric arc furnace operation is significantly raised. The elements of the shredded scrap (Cu, Mn, Fe, Cr, Ni, Ti, Co, Ca, Si, Al) are continuously analyzed and evaluated. EcoShred integrates the online analyzer into the overall control system. Scrap of insufficient quality is automatically discharged. Network communication between the machine operator and the crane driver leads to a further improvement of the operational reliability. 4. Emission control With EcoShred, uncontrolled explosions and emission values above the statutory limit values are a thing of the past, irrespective of the input material. 4

5 Fig. 3: Problems with emissions. EcoShred offers various solutions, from conventional dedusting with a wet scrubber to a completely dry dedusting system. In all cases, the operation of an EcoShred plant stands for environmentfriendly operation with low and controlled emissions. The acceptance of scrap treatment is thus improved and the approval procedure is simplified. 5. Metal recovery and ASR treatment Increasing nonferrous metal contents in the shredder prematerial convert shredder residues (automobile shredder residues, ASR) into a source of raw materials. Fig. 4: Gamma Tech Analyzer. 5

6 SMS SIEMAG EcoShredScrapTuning EcoShred integrates the unique VWSICON process which permits complete recycling of the shredder residues. Thanks to the VWSICON process, ASR no longer constitute a nuisance. The costefficient treatment in combination with the complete recovery of the nonferrous metals leads to a further improvement of the overall profitability of the shredder process. 6. Layout planning Good scrap logistics play a decisive role in the high performance of the EcoShred plants. SICON and SMS Siemag are responsible for the entire layout and logistics planning and integrate the EcoShred plant into the steelworks premises, thus ensuring optimum use of the plant. sıcon 75 sıcon 100 sıcon 120 Basic Process + Eddy Current + FinesTuning Detection and separation of nonferrous metals up to < 1.5 mm (1/16 ) Automated system for offline or inline downstream separation Basic Process + Eddy Current + FinesTuning + Varisort Varisort SensorSorter, equipped with the highlysensitive multichannel metal search coil Highest separation accuracy by means of 16/8/6.4 mm nozzle grid Operating widths from 512 mm (20 ) to 3072 mm (121 ) Separation of stainless steel, cables and all nonferrous metals remaining in SICON 75 Basic Process + Eddy Current + FinesTuning + Varisort + Copper/cable separation Combines the SICON 75 and SICON 100 processes with copper separation Ground copper material with a purity of up to 95% Generation of a completely metalfree plastic and fiber fraction for further recycling. of Zorba 90 % purity of Zorba 90 % purity of Zurik 80 % purity of Zorba 95 % purity of Zurik 90 % purity of Copper No % purity sıcon 120+ In addition to the complete metal separation, SICON 120+ is able to recover the plastic materials for recycling with the innovative Polyfloat system. Fig. 5: Classification of the SICON scrap tuning SICON75, SICON 100 ; SICON

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8 MEETING your EXPECTATIONS For further information, please contact: SMS SIEMAG AG Mathias Lüttenberg VES Fundamentals and Models Melting & Reduction EduardSchloemannStrasse Düsseldorf, Germany Phone: Telefax: mathias.luettenberg@smssiemag.com SMS SIEMAG AG Alexander Bergs VHA Technical Sales Steelmaking/Mechanical EduardSchloemannStrasse Düsseldorf, Germany Phone: Telefax: alexander.bergs@smssiemag.com H3/309E 500/03/13. Ky. Printed in Germany The information provided in this brochure contains a general description of the performance characteristics of the products concerned. The actual products may not always have these characteristics as described and, in particular, these may change as a result of further developments of the products. The provision of this information is not intended to have and will not have legal effect. An obligation to deliver products having particular characteristics shall only exist if expressly agreed in the terms of the contract.