The ferrous recycling industry

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1 Recycling-ferrous This presentation contains general suggestions. SSAB hereby expressly disclaims any liability for their suitability for individual applications. It is the responsibility of the user of this brochure to adapt the recommendations contained herein to the requirements of individual applications

2 The ferrous recycling industry World crude steel production ~40% of the world crude steel production comes from ferrous scrap Scrap: consumption, trade, and apparent domestic supply, 2003 (million metric tons) Country Consumption - Imports + Exports = Apparent Domestic Supply European Union (15) Other Europe CIS NAFTA Central and South America Africa Asia Oceania World

3 European ferrous recycling industry Scrap consumption in 2004 was about 103 million tons in the EU ESG, the European Shredder Group had 212 shredding plants in 2004 The actual number of shredders in whole Europe is most likely at least double 400 shredders or more?

4 The EU scrap price index No time for production disturbances

5 The iron and steel recycling loop COLLECTE D SCRAP MUNICIPAL SCRAP INDUSTRIA L SCRAP DISMANTLED CARS LOCAL AND CENTRAL SCRAP YARDS FRAGMENTATION PLANTS IMPORT EXPORT STEEL MILLS/FOUNDRIES

6 Schematic flow of recycling plant Handling and sorting Scrap delivery Shredding Baling and cutting

7 Possibilities for HARDOX Scrap delivery Containers Shredding Hammermill-type shredders Hammers Disc caps Liner plates Shear type shredders Knives Anvils Handling and sorting Buckets Grapples Conveyor side liners Baling and cutting Balers Liner plates Mobile demolition shears Structure and teeth

8 Recycling Generic Flow grapple crusher hopper conveyor system chute shredder container

9 Recycling Shredder Knifes and Anvils - sliding wear resistance, - high strength, - good toughness, - homogenous mechanical properties, -> HARDOX

10 Recycling Teeth or Striker Bars - impact wear resistance, - good support required, -> HARDOX 600

11 Recycling Hoppers - impact wear resistance, - possibility to reduce weight, -> HARDOX 450

12 Recycling Crushers - Hammers - impact wear resistance, - sliding wear resistance, - toughness, -> HARDOX

13 Recycling Crushers - Lining Plates - impact wear resistance, - bendability, - weldability -> HARDOX 450

14 Recycling Crushers - Anvils - sliding wear resistance, - weldability, -> HARDOX 500

15 Recycling Crushers - Screens - sliding wear resistance, - weldability, -> HARDOX 500

16 Scrap supply system (Cyclone) Scrap supply system (Cyclone) Technical data: The Cyclone is lined with tiles made of wear plate. Different materials are used like hard faced plates, HARDOX etc. Dimensions and quantities Plant height: 5-6m Diameter: 2.5m Number of tiles: 189 pieces Maximum tile size: 1200x215mm Material: HARDOX 450, 10mm Operating Condition: Annual revision. Tiles are now cutted with water jet to give better wear resistance at the edges.

17 Mobile Metal Scrap Baler Steel grade: Hardox 400 Thickness range: mm Previous material: AR400 Service life: 12 months Competitive advantage: Availability of plate Volume: 30 ton / year Manufacturing steps Cutting method - Gas cutting; Welding method - MAG Status: Success

18 Residue compactor Steel grade: Hardox 450 Thickness range: 3 to 6 mm Type of application: Mobile residue compactor-container. Manufactured entirely in Hx450, 3,2mm. Increase in service life and reduction of weight. Previous material Mild steel Manufacturing steps Cutting method - Gas cutting; Bending method - Roll bending; Bending method Press brake bending; Welding method - Normal Welding Status Success Comments Customer has repeated order

19 Knife holder of scrap shears Description The Knife holders are bolted to the stand H A R D O X Technical data: The blade holders have been manufactured from tempered steel and coated with 30CrNiMoV6. Due to the brittleness it was switched to Hardox 400. Since then there has been no fractures of the knife holder. Dimensions and quantities: Thickness t = 135mm Size: 131 x 220mm The life of a blade holder is about 3-5 years. The total requirement is approximately 500 units per year.

20 Exhaust elbow Steel grade: Hardox 450 Thickness range: 10 to 30 mm Industry segment: Recycling Description of the application: Ferrous recycling plant, where non-metallic elements are separated from ferrous elements by means of forced air. The non-metallic elements are expelled through this tube, causing wear in the elbow, where the particles hit directly. Service life: 1-2 years Competitive advantage: Service life Manufacturing steps Cutting method - Gas cutting; Bending method - Roll bending Status: Success

21 Holder in scrap shear by Hardox 500 Thickness range: 30 to 60 mm Industry segment: Recycling Type of application: Press Description of the application: The holder is working in big scrap shear and is holding/pressing the scrap when shearing. Because of high demand for accuracy, the edges of the plates has to be milled. Previous material: Higher alloyed, air quenched steel Service life: 10 years (estimation) Competitive advantage: Service life Volume: ca 20 tons Manufacturing steps Cutting method - Gas cutting; Welding method - Normal Welding; Status: Success

22 Scrap shreddar -nobs made by Hardox 500 Steel grade: Hardox 500 Thickness range: mm Description of the application: Nobs for a scrap shredder made of 40 mm Hardox500 Previous material: S355 Service life: 3 to 4 times longer than S355 Competitive advantage: Service life Manufacturing steps Cutting method - Gas cutting Status: Success Reason for failure or success: Extended service life

23 Grabble HARDOX 450 Devise for measuring radiactive levels in scrap (HARDOX 500/15 mm)

24 Scrap tipper box Steel grade: Hardox 450 Thickness range: 3 to 6 mm Industry segment: Transport Description of the application: Scrap tipper light box Manufacturing steps Cutting method - Gas cutting; Cutting method - Plasma cutting; Bending method - Pressbrake bending; Welding method - Normal Welding Status: Success Reason for failure or success: Lighter and stronger Comments: botton plate 4mm, rest of parts in 3,2

25 The hammermill-type shredder

26 Metal scrap processing Sucessful trial: -The sandwich hammer made by Hardox 500 tested in scrap processing -There is 16 hammers (120x515x569), netto weight 167 kg as one set. Previos life time for hammers measured in scrap volumes: S690Ql 1600 tons Hardox tons Original 12%Mn steel 7000 tons New adwance 12%Mn steel 9700 tons Hardox 500 (sandwich) tons 26

27 Scrap delivery Containers Three main reasons why to use HARDOX wear plate in containers Increase Payload Wear life Impact resistance 3,2 4 mm HARDOX 450 Find more info about containers in TechSupport #2 and #3

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30 Scrap handling and sorting HARDOX 400/450 HARDOX 500 WELDOX 700 HARDOX 450

31 Hardox 450 in scrap baskets

32 Baling presses HARDOX 450 or HARDOX 500 "The newer materials are hard all the way through, and not just at the top, we are now using a steel with the trade name HARDOX 500 that has a Brinell hardness of 500. The material we used before had a hardness factor of only 300. Joseph Szany, waste division sales manager for Lindemann Recycling Equipment, Charlotte, N.C. USA.

33 Slitting baler Steel grade Hardox 450, 10 to 30 mm Description of the application The 12mm Hardox450 was used to line a slitting line baler. This baler catches and recoils the slitting line scrap. Previous material Mild Steel Service life >3 years Competitive advantage Service life Manufacturing steps Cutting method - Gas cutting; Welding method - Normal Welding Status Success

34 Mobile baling press and shear Advantage HARDOX Lower dead weight lowers the transportation costs Maintains or even increase wear life

35 Scrap shears Stamper protected by high-strength, exchangeable wear plates HARDOX 500 or HARDOX 550

36 Demolition Shears HARDOX 400 HARDOX HiTuf HARDOX 500 HARDOX 600

37 Shredder Wear Parts Liner plates in car shredder Materials and limitations: Manganese steel plate Swelling causes misalignment and bad fitting Hazardous smoke when welding and cutting HARDOX wear plate Thickness limitations Cracking risk Cost of cutting

38 Scrap milling

39 Manganese steel The competition for shredder wear parts Water quenched from 1050 C to retain carbon in solution, the soft core has a strength of 849 MPa, fracture elongation of 40% and a Brinell hardness of 200, but due to the deformation hardening mechanisms the hardness will rise. But Manganese steel does not work well in sliding wear. Hazardous smoke when welding and cutting. Difficult machining properties due to the fact that the material hardens during the operation.

40 Replace with HARDOX? With persistence and a little help from your application engineer this might work

41 Market potential Average scrap consumption in Europe is 100 million metric tons each year Approximately 45% are being shredded 45 million tons scrap that passes a shredder Shredders wear parts, about 1 kg per ton shredded scrap Hammers take up 80% tons hammer wear part If each hammer weighs approximately 200 kg hammers consumed each year in Europe.

42 Knifes HARDOX 600, HARDOX Extreme For milling electric waste such as cables, synthetic material etc

43 Steel scrap baler Steelgrade: Hardox 400 Thickness range: 10 to 30 mm; 60 to 90 mm Industry segment: Recycling Type of application: Baler Description of the application Hardox400 was used to reline this scrap baler. Most of the liners are 15mm and 12mm but the ram is 75 mm plate Previous material: Hardox400 Volume: 12 ton Manufacturing steps: Cutting method - Gas cutting; Welding method - MAG Status: Success

44 Liner in a scrap press Description: Quality: HARDOX 450 or 500 Origin quality: HARDOX 400 Function: lining in a scrap press Processed material: various steel scrap Advantages: Longer life time Bild bitte hier einfügen Production: Operating hours: 8-16 hours per working day Operating temperature: depending on the scrap about 70 degrees Exchange: about 1 ½ to 2 years

45 Compressing and cutting bales Hardox 500 This machine is both cutting and compressing the bales. The cutting is necessary to make the bales sharper and easier for transportation. The cutting edges in Hardox 600 have a service life of months without cracks. With the original cutting edges with Tool Steel the cracks occurs because Tool Steel don t have impact toughness. And in these compress machines enter very different kind of materials: metal, rocks, etc 45

46 Aluminum-Shredder Material: 500 HARDOX Advantages: long life, good toughness Bild bitte hier einfügen Size: 50x311x311mm Cutting: gas under water Life time: approx 3 months Competition material: Unknown. Operating temperature: normally at 60 C. Problem: Shredder Repairs are often outdoors in very cold places. Danger of cracking due to bad preheating Dimensions and quantities: Weight: 28 kg net. Quantity: 30 pieces per quarter

47 Lining in scrap recycling machine Description: Name: lining for scrap recycling machine Material: HARDOX 450, 15mm Advantages: life time Technical data: Plasma-cut, drilled Dimensions and quantities: 15x150x3300, 40 strips per year, 2,500 kg per year

48 Liner to scrap shredder Technical data: HARDOX 500 was used from the beginning. Rotational speed: 600 revolutions per minute. Bild hier einfügen Processing: pre-heating to C before cutting Dimensions and quantities: 75x2100x4150, about 400 tones

49 Bucket used for recycling Steelgrade Hardox 400 Thickness range 3 to 6 mm Industry segment Recycling Description of the application All the bucket is manufactured by Hardox 400 in 4, 5 and 6 mm. Cutting edges in Hardox 400 in 25 mm and 30 mm. Previous material Mild Steel Competitive advantage Service life Manufacturing steps Cutting method - Gas cutting; Status Success. Less weight and stronger bucket.

50 For further information on performance, production recommendations and selection of materials, please get in touch with your local technical SSAB contact. SSAB SE Oxelösund, Sweden, T techsupport@ssab.com, This presentation contains general suggestions. SSAB hereby expressly disclaims any liability for their suitability for individual applications. It is the responsibility of the user of this brochure to adapt the recommendations contained herein to the requirements of individual applications

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