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  • 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