BOF Slag use as ballastBOF Slag use as ballast
ArcelorMittal Tubarão Experience
November, 2010
Authors:
Ricardo Filipe T. ...
ArcelorMittal Tubarão
General View
VitóriaVitória
Vila VelhaVila Velha CariacicaCariacica
Vitória, Vila Velha, Serra, Cari...
Production Flow Chart – 7.5 Mt Phase
2007
2008
Technical Development – New Applications 2009
Economic/Social/Environmental Gains
Centralization of By-products ...
Synergy/Benchmarks for
Best Practices
Planning for Reuse and
Recycling
Monitoring of Key
Indicators
Monitoring of Key
Indi...
BOF Slag use as ballast – ArcelorMittal Tubarão Experience
Generation Index
2007 2008 2009
By-Products
Generation
kg/t CS ...
ByBy--Products IndexesProducts Indexes
BF Sludge StorageBF Sludge Storage
BF Sludge
T.R.T
Temporary Storage
(reduce moistu...
Matriz de decisão de projetos de co-produtos
Sinter EP Dust on red ceramic industry;
Desulphurization Slag (KR) on mortar ...
AGRICULTURE CONCRETE ARTEFACTS ARTIFICIAL REEFS
(concrete with BOF slag)
ROAD INFRASTRUCTURE
ACERITA®
Revsol – BOF Slag wi...
EFFLUENTS TREATMENT
Espirito Santo Federal University Studies
showing good results when using it as
filtering beds on dome...
ArcelorMittal Tubarão By-products Strategy
Environmental Policy
To adopt suitable management practices to efficiently use ...
Environmental Aspects
• TECAM Lab – 2004 (1st analysis)
• TECAM Lab – 2008 (2nd analysis)
Environmental Aspects
• VIÇOSA – 2006 (Agriculture)
Environmental Aspects
• Incaper 2007 (Agriculture)
(Instituto Capixaba de Pesquisa, Assistência Técnica e Extensão 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...
Environmental Aspects
• Falcão Bauer Eco-produto 2008
Environmental Aspects
• IEMA 2008 (Agriculture)
Environmental Aspects
• UFES 2008 (Wetlands)
Estudo realizado em parceria com a Universidade Federal do Espírito Santo (UF...
Environmental Aspects
• IPR/DNIT 2009 (road)
Environmental Aspects
• UFOP 2010 (ballast)
“Após o processo de
estabilização química foi
classificado como Classe II B
(N...
BOF Slag use as ballast – ArcelorMittal Tubarão Experience
Historical
• 1991 First Tests With LD Slag use as ballast (AMT ...
BOF Slag use as ballast – ArcelorMittal Tubarão Experience
BOF Slag Ballast - Technical specification under contract:
Phys...
BOF Slag use as ballast – ArcelorMittal Tubarão Experience
Main problems (cause and effect) reported by user
Grain size – ...
BOF Slag use as ballast – ArcelorMittal Tubarão Experience
Main problems (cause and effect) reported by user
emitter
Wheel...
BOF Slag use as ballast – ArcelorMittal Tubarão Experience
Look for good partnerships:
Working together with clients and R...
BOF Slag use as ballast – ArcelorMittal Tubarão Experience
Identifying Causes – Slag fines
Physical properties sample coll...
BOF Slag use as ballast – ArcelorMittal Tubarão Experience
Identifying Causes – Electrical current escape
Built a railroad...
BOF Slag use as ballast – ArcelorMittal Tubarão Experience
Identifying Causes – Electrical current escape
During rain
Afte...
BOF Slag use as ballast – ArcelorMittal Tubarão Experience
Identifying Causes – Electrical current escape
Lab Analysis – b...
BOF Slag use as ballast – ArcelorMittal Tubarão Experience
Identifying Causes – BOF slag ballast changing performance
40.0...
BOF Slag use as ballast – ArcelorMittal Tubarão Experience
Develop curing method
Lab tests Water through slag block – 0,17...
BOF Slag use as ballast – ArcelorMittal Tubarão Experience
Develop curing method
3 kinds of weathering configuration
- Spr...
BOF Slag use as ballast – ArcelorMittal Tubarão Experience
Develop curing method
Process measurement instruments
Sensor pr...
BOF Slag use as ballast – ArcelorMittal Tubarão Experience
Develop curing method
First results
Capacity (16 m²) CaO To CaO...
BOF Slag use as ballast – ArcelorMittal Tubarão Experience
Physical properties T 0 T 60
Develop curing method
Comparing ph...
BOF Slag use as ballast – ArcelorMittal Tubarão Experience
Develop curing method
Escória Arcelor Mittal Dormente de Aço
NO...
BOF Slag use as ballast – ArcelorMittal Tubarão Experience
BOF slag ballast advantages
Resiliency Modulus
Natural rock = 3...
BOF Slag use as ballast – ArcelorMittal Tubarão Experience
ArcelorMittal Tubarão BOF slag ballast production flow
Slag
gen...
BOF Slag use as ballast – ArcelorMittal Tubarão Experience
On going Actions
Final report results presented to client (rail...
BOF Slag use as ballast – ArcelorMittal Tubarão Experience
Conclusion:
- ArcelorMittal Tubarão BOF slag
can be used as bal...
BOF Slag use as ballastBOF Slag use as ballast
ArcelorMittal Tubarão Experience
November, 2010
Authors:
Ricardo Filipe T. ...
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Ricardo felipi

  1. 1. BOF Slag use as ballastBOF Slag use as ballast ArcelorMittal Tubarão Experience November, 2010 Authors: Ricardo Filipe T. Moreira (Presenter) Pedro Sérgio Bicudo Filho
  2. 2. ArcelorMittal Tubarão General View VitóriaVitória Vila VelhaVila Velha CariacicaCariacica Vitória, Vila Velha, Serra, Cariacica: 1,5 million hab. SerraSerra
  3. 3. Production Flow Chart – 7.5 Mt Phase
  4. 4. 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
  5. 5. 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 ManagementManagement Development of New Markets/ Clients Development of New Markets/ Clients Centralized Management for Development, Processing and Applications
  6. 6. BOF Slag use as ballast – ArcelorMittal Tubarão Experience Generation Index 2007 2008 2009 By-Products Generation kg/t CS 545 591 541 BF (51%) 277 kg/t CS T.R.T GBFS 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 2009 By-Products Recovery Index % 98,9 99,7 98,8 Recovery Index 2009 Recovery Index Distribution 5% 65% 25% 4% 1% Sales Internal Recycling Social Actions Under processing Storage
  7. 7. ByBy--Products IndexesProducts Indexes BF Sludge StorageBF Sludge Storage BF Sludge T.R.T Temporary Storage (reduce moisture) CERAMIC INDUSTRY BOF Fine Sludge StorageBOF Fine Sludge Storage BOF Sludge Sinter Plant 2007 2008 2009 BF Sludge Storage k t 215 208 184 2007 2008 2009 BOF Fine Sludge Storage k t 210 208 166 Fine 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 t 2009 – KR slag generation index adjustment
  8. 8. Matriz de decisão 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
  9. 9. 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 Tubarão BOF slag road use since 2009 BOF Slag use as aggregate on asphalt composition BOF Slag Applications Viçosa Federal University and INCAPER studies show AM Tubarão 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 Falcão 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.
  10. 10. EFFLUENTS TREATMENT Espirito Santo Federal University Studies showing good results when using it as filtering beds on domestic sanitary effluents treatment (wetlands) BOF Slag Applications CEMENT 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 Gabion Hillside protection Rockfill aiming Tetrapods Recovery of stone-quarry Rip Raps Hillside protection
  11. 11. ArcelorMittal Tubarão By-products Strategy Environmental Policy To adopt suitable management practices to efficiently use natural resources, reduce emissions into the atmosphere and water bodies, and recycle industrial wastes. Continuous Development of Partnerships New Technologies Research and Development Continuous Improvement Breaking of ParadigmsSustainability
  12. 12. Environmental Aspects • TECAM Lab – 2004 (1st analysis) • TECAM Lab – 2008 (2nd analysis)
  13. 13. Environmental Aspects • VIÇOSA – 2006 (Agriculture)
  14. 14. Environmental Aspects • Incaper 2007 (Agriculture) (Instituto Capixaba de Pesquisa, Assistência Técnica e Extensão Rural)
  15. 15. Environmental Aspects • IEMA 2007 (ballast)
  16. 16. 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) 1º Mês 2º Mês 3º Mês 8º Mês Implantação Litoral Serra Fase final de licenciamento ambiental no IBAMA-DILIC. Os estudos foram concluídos e está programada reunião com IBAMA em Brasília até o final de dezembro.
  17. 17. Environmental Aspects • Falcão Bauer Eco-produto 2008
  18. 18. Environmental Aspects • IEMA 2008 (Agriculture)
  19. 19. Environmental Aspects • UFES 2008 (Wetlands) Estudo realizado em parceria com a Universidade Federal do Espírito Santo (UFES) e a ArcelorMittal Tubarão, para avaliação de Escória de Aciaria (LD) como leito cultivado e leito filtrante no pós- tratamento de efluentes sanitários, “O estudo concluiu com a contribuição para a redução dos seguintes parâmetros: correção de pH, turbidez, DBO, DQO, NTK, fósforo, dureza e matéria orgânica, e teve como objetivo o tratamento natural dos efluentes, visando assim o bem estar e a qualidade de vida da comunidade”
  20. 20. Environmental Aspects • IPR/DNIT 2009 (road)
  21. 21. Environmental Aspects • UFOP 2010 (ballast) “Após o processo de estabilização química foi classificado como Classe II B (Não Perigoso – Inerte)”
  22. 22. BOF Slag use as ballast – ArcelorMittal Tubarão Experience Historical • 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 0,00 20.000,00 40.000,00 60.000,00 80.000,00 100.000,00 120.000,00 140.000,00 160.000,00 180.000,00 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 Amount of Tubarão LD Slag used as ballast Over 1 million tons
  23. 23. BOF Slag use as ballast – ArcelorMittal Tubarão 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/m³ 2.800 kg/m³(√) BOF Slag Ballast - Particle size distribution Sieve size % passing by mass 75 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 300 m Related to FeM content on BOF slag – máx 2%
  24. 24. BOF Slag use as ballast – ArcelorMittal Tubarão Experience Main problems (cause and effect) reported by user Grain size – Slag fines Drainage problems on railway Concrete effect on ballast Grain size – Slag fines ArcelorMittal Tubarão Control Slag Generation Storage ( ~ 2 years) Process Screening Product (slag ballast) Inspection Dispatch Inspection Grain size analysis “Each batch” Focus on screening process (wrong action AMT & Railway operator) Controle de Despacho de escória de lastro Material Estocado na Área de Carregamento Controle de Despacho de escória de lastro Material Estocado na Área de Carregamento
  25. 25. BOF Slag use as ballast – ArcelorMittal Tubarão Experience Main problems (cause and effect) reported by user emitter Wheel on track - electrical current consumption – correct position Slag Ballast causing electrical current consumption Wrong signal position receiver ArcelorMittal Tubarão Control Slag Generation Storage ( ~ 2 years) Process Metallic removal Product (slag ballast) Inspection Dispatch Inspection Focus on metallic removal process (wrong action AMT & Railway operator)
  26. 26. BOF Slag use as ballast – ArcelorMittal Tubarão Experience Look for good partnerships: Working together with clients and Research Institutes; Client Railroad Operator Client Railroad Operator
  27. 27. BOF Slag use as ballast – ArcelorMittal Tubarão Experience Identifying Causes – Slag fines Physical properties sample collected on railway: Physical properties of LD slag ballast characterization results; - High weight per cubic meter; (higher than natural stone) - No clay lumps; - Los Angeles Abrasion Loss from 15% to 30% (limit < 40%) - Soft and friable pieces = 11% to 1% (limit < 5%) Chemical properties: - CaO content analysis – from 1.5% to 6.15%; - Expansion effect even after 2 years storage (~ 5 mts high); - Internal stretches due to expansion effect causing structure damage – fines generation; Main Action: Develop method to reduce CaO content at LD slag ballast; ?
  28. 28. BOF Slag use as ballast – ArcelorMittal Tubarão Experience Identifying Causes – Electrical current escape Built a railroad simulator at Mario Carvalho Station; - Highest problem occurrence at EFVM railroad; Measurement equipment to check electrical resistance and pluviometer (data logger)
  29. 29. BOF Slag use as ballast – ArcelorMittal Tubarão Experience Identifying Causes – Electrical current escape During rain After rain VoltagebetweentracksVoltagebetweentracks Main problem occurring just after rain period Problem increase due to bad drainage system – slag fines
  30. 30. BOF Slag use as ballast – ArcelorMittal Tubarão Experience Identifying Causes – Electrical current escape Lab Analysis – ballast box to simulate water action on slag After 11 water cycles Water PH reduction (12 to 10) CaO dissolution Electrical resistance Electrical conductivity Main Action: Develop method to reduce CaO content at LD slag ballast;
  31. 31. BOF Slag use as ballast – ArcelorMittal Tubarão Experience Identifying Causes – BOF slag ballast changing performance 40.000,00 60.000,00 80.000,00 100.000,00 120.000,00 140.000,00 160.000,00 180.000,00 Everything OK Problems – Why? ?0,00 20.000,00 40.000,00 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 ? What changed on AMT process BOF Slag Storage over 1 million tons (2000) - old stock piles BOF slag Storage = 955.000 tons (2005) BOF Slag Storage = 545.000 tons (2007) Increase stockpiles height ACTION = Develop curing method for BOF slag ballast Storage Period reduction
  32. 32. BOF Slag use as ballast – ArcelorMittal Tubarão Experience Develop curing method Lab tests Water through slag block – 0,17 mm / sec Around 7 minutes to wet 1 slag ballast block; Water Quantity? Time cycle? Lab tests Water through slag column Around 1 minute to wet 2 m height. weathering method : 10 min water on + 30 min water off (steam formation)
  33. 33. BOF Slag use as ballast – ArcelorMittal Tubarão Experience Develop curing method 3 kinds of weathering configuration - Spread storage (30 cm height) - Cone storage (2 meters height) - AMT old storage (4 meters height) cone storage Spread storage AMT old storage
  34. 34. BOF Slag use as ballast – ArcelorMittal Tubarão Experience Develop curing method Process measurement instruments Sensor protectionWet sensor Temperature sensor Data logger back up (each 3 minutes) CO2 measurement pluviometer
  35. 35. BOF Slag use as ballast – ArcelorMittal Tubarão Experience Develop curing method First results Capacity (16 m²) CaO To CaO T45 CaO T60 Spread storage 8 tons 8,03 2,80 1,5 Cone storage 25 tons 8,03 3,11 1,7 AMT old storage 50 tons 8,03 Base sensor not wet Base sensor not wet Target to achieve 3% of CaO content – good results (comparing to natural stone performance) After ballast weathering treatment – slag was screened and 25 % was removed (grain size less than 32 mm) After curing process Ballast slag was tested under physical properties The fine slag part will be used on road application (low expansion) high demand;
  36. 36. BOF Slag use as ballast – ArcelorMittal Tubarão Experience Physical properties T 0 T 60 Develop curing method Comparing physical properties – Final Results T0 = Not treated slag T60 = Treated Slag under cone storage (60 days) Lab analysis occurred 30 days after treating process Maximum grain size 75 mm 75 mm Los Angeles 11,5% 11,43% Water absorption 1,74% 0,81% Porosity 4,21% 2,03% Soft and friable pieces 11,51% 0% Fine grain size problem of BOF slag ballast solved
  37. 37. BOF Slag use as ballast – ArcelorMittal Tubarão Experience Develop curing method Escória Arcelor Mittal Dormente de Aço NOVA; 4835,85 5000 6000 m) Brita Dormente de Aço 5000 6000 BOF slag – steel sleepers (resistivity) Natural stone – steel sleepers (resistivity) BOF treated slag Simulator data (Just after built) Gustavo; 266,67 2 anos; 1493,56 0 1000 2000 3000 4000 5000 Entre eletrodos Resistividade(Ωm) Gustavo; 977,78 2 Anos; 1553,69 0 1000 2000 3000 4000 5000 Entre eletrodos Resistividade(Ωm) BOF not treated slag Simulator data (Just after built) Close to 300 m (AREMA) Problem to railway user BOF slag simulator (after 2 years) Low electrical resistivity problem of BOF slag ballast solved
  38. 38. BOF Slag use as ballast – ArcelorMittal Tubarão Experience BOF slag ballast advantages Resiliency Modulus Natural rock = 33,11 MPa Typical railway section ballast (40 cm height) Resiliency Modulus BOF slag = 63,00 MPa Typical railway section ballast (40 cm height) Results Indicates that ballast thickness can be reduced around 25% using BOF treated slag as ballast – cost reduction First results indicate that ballast life cycle can be improved using BOF treated slag as ballast (around 40%)– on going study
  39. 39. BOF Slag use as ballast – ArcelorMittal Tubarão Experience ArcelorMittal Tubarão BOF slag ballast production flow Slag generation Slag first processing Screening Metallic removal Slag second processing Screening Metallic removal Slag treatment (water into cone stockpiles) 6 boxes = 4.500 tons/each box Around 10.000 tons/monthAround 10.000 tons/month Slag bins to avoid ground contact contamination
  40. 40. BOF Slag use as ballast – ArcelorMittal Tubarão Experience On going Actions Final report results presented to client (railway operator); Brazilian standard for BOF slag use as ballast draft; Dynamic simulator with BOF slag ballast; Next Actions Site test on EFVM; Return of Regular use (Commercial relationship) at EFVM;
  41. 41. BOF Slag use as ballast – ArcelorMittal Tubarão Experience Conclusion: - ArcelorMittal Tubarão BOF slag can be used as ballast after a curing process (CaO reduction < 3%). - Ballast thickness can be reduced when using BOF slag; Conclusion: - Attention on process changing; - Stay close to clients; - Look for good partnerships; - Keep always researching;
  42. 42. BOF Slag use as ballastBOF Slag use as ballast ArcelorMittal Tubarão Experience November, 2010 Authors: Ricardo Filipe T. Moreira (Presenter) Pedro Sérgio Bicudo Filho

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