ricardo felipi

BOF Slag use as ballast BOF Slag use as ballast ArcelorMittal Tubaro Experience

November, 2010

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

ArcelorMittal TubaroGeneral View

VitriaVitriaVila VelhaVila Velha CariacicaCariacica

Vitria, 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 Tubaro Experience

Generation Index

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

BF (51%) 277 kg/t CS T.R.TGBFS 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 Distribution5%

65%25%

4% 1%

SalesInternal RecyclingSocial ActionsUnder processingStorage

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 t2009 KR slag generation index adjustment

Matriz de deciso 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 Tubaro BOF slag road use since 2009

BOF Slag use as aggregate on asphalt composition

BOF Slag Applications

Viosa Federal University and INCAPER studies show AM Tubaro

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 Falco 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 ApplicationsCEMENT 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 GabionHillside protection

Rockfill aimingTetrapods Recovery of stone-quarry

Rip Raps Hillside protection

ArcelorMittal Tubaro 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)

Environmental Aspects VIOSA 2006 (Agriculture)

Environmental Aspects Incaper 2007 (Agriculture)(Instituto Capixaba de Pesquisa, Assistncia Tcnica e Extenso Rural)

Environmental Aspects IEMA 2007 (ballast)

Environmental Aspects 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)

1 Ms 2 Ms

3 Ms 8 Ms

Implantao Litoral SerraFase final de licenciamento ambiental no

IBAMA-DILIC. Os estudos foram concludos e est

programada reunio com IBAMAem Braslia at o final de dezembro.

Environmental Aspects Falco Bauer Eco-produto 2008

Environmental Aspects IEMA 2008 (Agriculture)

Environmental Aspects UFES 2008 (Wetlands)

Estudo realizado em parceria com a Universidade Federal do Esprito Santo (UFES) e a ArcelorMittal Tubaro, para avaliao de Escria de Aciaria (LD) como leito cultivado e

leito filtrante no ps- tratamento de efluentes sanitrios,

O estudo concluiu com a contribuio para a reduo dos seguintes parmetros: correode pH, turbidez, DBO, DQO, NTK, fsforo, dureza e matria orgnica, e teve como objetivo otratamento natural dos efluentes, visando assim o bem estar e a qualidade de vida dacomunidade

Environmental Aspects IPR/DNIT 2009 (road)

Environmental Aspects UFOP 2010 (ballast)

Aps o processo de estabilizao qumica foi

classificado como Classe II B(No Perigoso Inerte)

BOF Slag use as ballast ArcelorMittal Tubaro ExperienceHistorical

1991 First Tests With LD Slag use as ballast (AMT and railroad 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 (grain size problems and wrong signals from electrical conductivity of slag)

2007 Railway operator Stop using 2007 Railway operator Stop using

0,0020.000,0040.000,0060.000,0080.000,00

100.000,00120.000,00140.000,00160.000,00180.000,00

1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006

Amount of Tubaro LD Slag used as ballastOver 1 million tons

BOF Slag use as ballast ArcelorMittal Tubaro Experience

BOF Slag Ballast - Technical specification under contract:

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/m 2.800 kg/m()

BOF Slag Ballast - Particle size distribution

Sieve size % passing by mass75 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 300mRelated to FeM content on BOF slag mx 2%

BOF Slag use as ballast ArcelorMittal Tubaro Experience

Main problems (cause and effect) reported by user

Grain size Slag fines

Drainage problems on railway

Concrete effect on ballastGrain size Slag fines

ArcelorMittal Tubaro Control

Slag Generation

Storage( ~ 2 years)

ProcessScreening

Product(slag ballast) Inspection

DispatchInspection

Grain size analysisEach batchFocus on screening process

(wrong a