Slab transport and logistics. Slag recycling and scrap recovery, dust and sludge processing and metal recovery. Scarfing, slab slitting and cutting.

1. Engineered Solutions
for Integrated Steelmakers
© 2014 Harsco Corporation, All Rights Reserved.

2. Harsco Corporation
Harsco is a global industrial services company
Listed on NYSE, S&P 400 index
Harsco is a global provider of industrial services and engineered products
Market leading positions in Metals & Minerals, Rail and Industrial products
Annual sales of more than $3bn covering 400 locations in over 50 countries
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3. Worldwide presence
Harsco Metals & Minerals
Operations at over 160 sites in 30 countries
Services: Logistics; Environmental Remediation, Material Recycling,
Metal & mineral recovery, Co-Product marketing,

4. Safety Principles
All occupational injuries & illnesses are preventable
Safety is everyone’s responsibility
Working safely is a condition of employment
Managers & supervisors are responsible for training all employees
to work safely
All operating exposures can be reasonably safeguarded
Preventing injuries & accidents contributes to business success
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5. Continuous Improvement
The Group Best Practices define our standard operating
practices across the globe.
Draws on best operating practice generated from Harsco’s 70-year
global operating experience.
Cover Safety, Asset Management, Operating Guidelines and Service
Quality. Continuously reviewed and updated
1) Unique knowledge-sharing mechanism that operates
across the global Harsco team
2) Providing the highest quality service that delivers the
lowest Total Cost of Ownership
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6. Harsco Integrated Steel Mill Services at a glance

7. Helping steelmakers to optimise logistical efficiency and productivity
Scrap Management
Scrap processing
Raw Materials handling
Product handling
Transportation
Meltshop services
Blast furnace services
Packaging
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8. Scrap Management
Optimise scrap reception, storage, menus and delivery to the furnace.
Handling of scrap arriving by road, rail and barge
Radioactivity Control, Quality Control
Collection and transport of internally arising scrap
Reception, storage and real time scrap inventory control
Load scrap baskets according to menus received electronically
from the meltshop
Transport baskets to the furnace on specialist vehicles
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9. ®
ScrapMaster Overview
Three integrated operating modules for cost-effective management of the entire scrap
supply chain, with full segregation and traceability
Incoming scrap
Scrap Handling
Scrap Chute loading
®
ScrapMaster
Management information reporting puts you in control
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10. Scrap Optimisation
®
ScrapMaster now integrates functionality from BOSS
(Blending Optimisation Software Suite)
Under license from Management Science Associates, Inc.
World leading optimisation program
Yield-based cost calculation
Actual scrap cost per tonne of steel
Value of the scrap inventory on a real-time basis
Minimises scrap charge cost, grade by grade
Based on specific grade production data entered by the
steelmaker
planned tonnage, scrap composition, prices,
availability and inventory

11. Scrap Baling
Case Study:
Domestic Scrap Baling
Annual Volume of Scrap Processed: 51k tonnes/year
Baler Cycle Time:
2 minutes per batch,
each batch is 0.7 tonnes
Cutting Force:
2000 PSI
Average Density of
Baled Scrap
Up to 2.2 tons/m3
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12. Scrap Shredding
Shredder, Argentina
- Unloading of incoming scrap
17,000 tonnes per month
- Sorting of unshreddable material (cylinders, gas tanks, etc)
- Scrap feeding to the Shredder Machine
- Load shredded scrap into trucks
- Transport to Basket preparation Yard for disposal
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13. High-Volume Scrap Cutting
Multi-torch FerroCut® system delivers high productivity when cutting
Thick & heavy scrap - Cuts material up to 1.6metres thick
Tundish & Heavily contaminated skulls
Totally enclosed cutting bed and gas cleaning ensures environmental compliance
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14. Semi-finished Product Handling
Optimise inventory value with on-site marking and tracking of semi-finished
products.
Item location tracking through RFID or Differential GPS
Optimised transport reduces equipment fleet and operating hours=> lowest TCO
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15. Finished Product Packaging
Complete packaging solution for cold coils and coated sheet
Supply of packaging materials
Internal transfer of material between production processes
Computerized identification and positioning systems
Capacity to invest in automatic systems
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16. Finished Product Logistics
Transport and supply chain management solutions for finished products
Tracking and identification of finished products to ensure traceability
Stockyard management
Internal transport service to road, rail or sea dispatch points.
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17. Helping steelmakers to meet end-user requirements for product quality
Scarfing
Slitting and cutting
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18. Scarfing
Specialised service delivering exceptional product surface quality
1) Skilled, experienced manual scarfers
2) Automated scarfing
Patented MultiForm and ShallowCut torches perform various scarfing programs
from spot to full face with variable pass widths
Cold or hot (850° scarfing; capacity to scarf up to 100,000 tons per month
C)
Eight installations operating worldwide with two scarfing hot slabs
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19. Quality control and inspection
In-line inspection operating to the most stringent quality standards
Automatic or manual in-line inspection stations;
Finished products can be removed, repaired or rejected
Dye penetration testing to identify surface defects.
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20. Cutting & Slitting
Specialist machines designed to cut slab & plate to millimetre tolerances
Fully automated twin axis cutting assemblies
Specialist oxy fuel torches to minimise cut width and yield loss
Multi-torch independently controlled machines
Full on-board measurement systems
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21. Helping steelmakers to optimise the economic value of recycled byproducts, and minimise the environmental impact of production
Converting CO gases to ethanol
Oily millscale sludge remediation
Slag recycling/Metal recovery
Dust & sludge agglomeration and briquetting/pelletizing
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22. Resource recovery solutions: Ironmaking
:
Raw Material
Waste material
Process or product
Harsco Plant
CO2
LanzaTech
Process
Ethanol
Sale
Micro
Pelletizing
plant
Coke Breeze
Coke Ovens
Briquetting
plant
CO gas
Dusts/Sludges
BOS
plant
Electricity
Blast
Furnace
Coal
Dusts/Sludges
Millscale
Rolling
Mill
Coke
Mineral
Recovery
Micro Pellets
Sinter plant
Lime/
Dolomite Fines
LANDFILL
Sinter
Iron Oxide Fines
Briquettes
Lime
Iron Ore
Cement
GGBFS
GGBS
BF
Slag
Mineral recovery
Desulph
Slag
BOS plant
MR plant
Metal Recovery
Scrap
Upgrading
MR plant
Fines

23. Resource recovery solutions: Steelmaking
Raw Material
Waste material
Process or product
Briquetting
Plant
Harsco Plant
CO2
Millscale
Co-Gen Plant
Gas
fermentation
Ethanol
Sale
Cement
feed
CO gas
Dusts/
Sludges
Rolling Mill
Sale
Sludge
Superfine
BOS Plant
Road
products
Electricity
Briquetting
Plant
Metallurgical
Additives
Sludge
Treatment
Sale
Roadbase
Oxide
recovery
LANDFILL
Briquettes
Mineral recovery
Iron (from BF plant)
Scrap
Slag
MR plant
Metal recovery
Scrap Upgrading
Fines Upgrading
Millscale
Other
Aggregate
sale
Oil recovery

24. CO gas to Ethanol
Background
Off-gases produced by the BOF plant has a high calorific value. If it is not stored
or converted, it escapes into the atsmosphere as CO2 emissions. The current
alternative is to process the gas through a turbine to produce electricity (Co-Gen
plant), for internal re-use or sale to the grid.
LanzaTech
LanzaTech has developed an ethanol fuel production process that can be retrofitted
to industrial facilities using the carbon monoxide component of waste flue gases as a
nutrient source. They have developed a proprietary platform for producing lowestcost liquid biofuel at a much larger scale than any alternative technology. LanzaTech
has signed a partnership agreement with Harsco; Harsco is the service
provider, and LanzaTech provides the technology.
Ethanol can be used to fuel motor vehicles or aircraft. Richard Branson’s Virgin
Airlines has signed a deal with LanzaTech to fuel his aircraft with Ethanol-derived
aviation fuel by 2013.
References
• First BaoSteel demo plant in China commissioned in 2012.
View LanzaTech video
Further information:
Bruce Barker
bbarker@harsco.com

25. CO gas to Ethanol
Click here to view the animated process flow
Process Inputs
Reactor
Separation System
End-product
Ethanol Re-use

26. Iron Oxide Fines
™
OxiFine product
Vertical Shaft Impactor (VSI)
Iron oxide fines (60% Fe product) used in the sinter plant.
This represents a saving in steel production, as a
replacement for iron ore pellets.
It also provides a zero waste solution for the steelmaker, to
recycle C Fines from the metal recovery plant back into
steelmaking rather than landfill disposal.
Further information: Chris Byrne
cbyrne@harsco.com

27. Oily Millscale sludge remediation
The challenge of Oily Millscale Sludge
Oily millscale sludge generated by rolling mills is a hazardous waste. The presence of oil
in the millscale means that it produces emissions when burnt in the sinter plant.
Harsco Solution
Harsco offers a service using ultra-high pressure water treatment technology, which
separates the oil and millscale, producing a clean scale for recycling into steelmaking.
• Developed for oil the industry (recovery of oil and clean sand)
• Harsco has applied the technology to oily sludge from millscale at steel mills
View video
Further information:
Jeremy Makepeace
jmakepeace@harsco.com

28. Oily Millscale sludge remediation
Oily Millscale sludge
Oil
MillScale

29. Slag Recycling
Slag tipping, cooling, digging, & transportation
Digging and removal of air-cooled/granulated BF slag
Hot slag hauling of BOS slag/Ladle slag
Under furnace digging using specialized mobile equipment
Controlled cooling of desulphurisation slag to minimise environmental impact
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30. Slag management
Specialized slag handling solutions
Slag removal from the vessel
Slag watering and cooling
Slag pit design
Slag pit digging
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31. Metal Recovery
Recycling recovered residual metallics to save on high-cost raw materials
Separation and recovery of metallics from slag and debris
Crushing and screening of de-metalised slag
Upgrading of recovered metallics =>Coolant and degasser scrap production
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32. Steelmaking Scrap Value
Area
Sinter Plant
Material
Fe Content
%
Size (mm)
Requirement
Price
($/tonne)
Low quality
iron ore
50 - 60
0-6
Small size
120
BF
High quality
iron ore
60 - 70
6 - 30
Consistent sizing and
analysis
240
BOS
Steel scrap
70 - 80
Size to allow compact
charging. Free of
1 -3 tonne lumps deleterious materials
275
Ladle
Ladle coolant
scrap
90
30 -130
Degasser
coolant scrap
95
12 -30
Degassing
130 - 150
Low residuals, free
flowing
420
Very low residuals, small
size, free flowing
515
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33. Slag Recycling
Steel slag is re-used in many commercial applications
International centres of excellence in UK, Netherlands, NZ & USA
Full testing facilities for supporting slag approval with government
agencies
Slag products successfully applied to
- Road surfacing
- Non-structural concrete
- Cement manufacturing
- Agriculture
- Railway ballast
- Construction fill
- Ground stabilisation
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34. Agglomeration of steelmaking by-products
A range of briquetting or pelletizing solutions for processing and
adding value to dust, sludge and millscale materials.
Key customer drivers:
• landfill cost reduction
• re-use valuable resources (Fe units)
• reduction in raw material costs
Project Stages
• Understanding customer objectives for end product
• Business and process modelling
• Compositional analysis and agglomeration trials
• Decision on process technology solution and metrics
• Design, build and operate plant
Further information: Daniel Devid
ddevid@harsco.com