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BOF Slag use as ballast BOF Slag use as ballast ArcelorMittal Tubarão Experience
November, 2010
Authors:Ricardo Filipe T. Moreira (Presenter)Pedro Sérgio Bicudo Filho
ArcelorMittal TubarãoGeneral View
VitóriaVitóriaVila VelhaVila Velha CariacicaCariacica
Vitória, 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 Tubarão Expe rience
Generation Index
2007 2008 2009By-ProductsGeneration kg/t CS 545 591 541
BF (51%) 277 kg/t CST.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 2009By-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
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 t
2009 – KR slag generation index adjustment
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
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.
EFFLUENTS TREATMENTEspirito 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-quarryRip Raps
Hillside protection
ArcelorMittal Tubarão 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
• VIÇOSA – 2006 (Agriculture)
Environmental Aspects
• Incaper 2007 (Agriculture)(Instituto Capixaba de Pesquisa, Assistência Técnic a 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; 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 SerraFase final de licenciamento ambiental no
IBAMA-DILIC. Os estudos foram concluídos e está
programada reunião com IBAMAem Brasília até o final de dezembro.
Environmental Aspects
• Falcão Bauer Eco-produto 2008
Environmental Aspects• IEMA 2008 (Agriculture)
Environmental Aspects
• UFES 2008 (Wetlands)
Estudo realizado em parceria com a Universidade Fed eral 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 sani tários,
“O estudo concluiu com a contribuição para a redução dos segu intes parâmetros: correçãode pH, turbidez, DBO, DQO, NTK, fósforo, dureza e matéria org ânica, 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)
“Após o processo de estabilização química foi
classificado como Classe II B
(Não Perigoso – Inerte)”
BOF Slag use as ballast – ArcelorMittal Tubarão Expe rience
Historical
• 1991 First Tests With LD Slag use as ballast (AMT and ra ilroad 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 (grai n 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
BOF Slag use as ballast – ArcelorMittal Tubarão Expe rience
BOF Slag Ballast - Technical specification under con tract:
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 Ωm
Related to FeM content on BOF slag – máx 2%
BOF Slag use as ballast – ArcelorMittal Tubarão Expe rience
Main problems (cause and effect) reported by user
Grain size – Slag fines
Drainage problems on railway
Concrete effect on ballastGrain size – Slag fines
ArcelorMittal Tubarão Control
Slag Generation
Storage
( ~ 2 years)
ProcessScreening
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
BOF Slag use as ballast – ArcelorMittal Tubarão Expe rience
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)
ProcessMetallic removal
Product
(slag ballast) Inspection
Dispatch
Inspection
Focus on metallic removal process
(wrong action AMT & Railway operator)
BOF Slag use as ballast – ArcelorMittal Tubarão Expe rience
Look for good partnerships:
Working together with clients and Research Institut es;
Client
Railroad Operator
Client
Railroad Operator
BOF Slag use as ballast – ArcelorMittal Tubarão Expe rience
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 a t LD slag ballast;
?
BOF Slag use as ballast – ArcelorMittal Tubarão Expe rience
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)
BOF Slag use as ballast – ArcelorMittal Tubarão Expe rience
Identifying Causes – Electrical current escape
During rain After rain
Vol
tage
bet
wee
n tr
acks
Vol
tage
bet
wee
n tr
acks
Main problem occurring just after rain period
Problem increase due to bad drainage system – slag fines
BOF Slag use as ballast – ArcelorMittal Tubarão Expe rience
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 a t LD slag ballast;
BOF Slag use as ballast – ArcelorMittal Tubarão Expe rience
Identifying Causes – BOF slag ballast changing perfo rmance
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 OKProblems – 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 st ock 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
BOF Slag use as ballast – ArcelorMittal Tubarão Expe rience
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)
BOF Slag use as ballast – ArcelorMittal Tubarão Expe rience
Develop curing method3 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
BOF Slag use as ballast – ArcelorMittal Tubarão Expe rience
Develop curing method
Process measurement instruments
Sensor protectionWet sensor Temperature sensor
Data logger back up (each 3 minutes)
CO2 measurement
pluviometer
BOF Slag use as ballast – ArcelorMittal Tubarão Expe rience
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 sensornot wet
Base sensornot wet
Target to achieve 3% of CaO content – good results ( comparing to natural stone performance)
After ballast weathering treatment – slag was screen ed 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;
BOF Slag use as ballast – ArcelorMittal Tubarão Expe rience
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
BOF Slag use as ballast – ArcelorMittal Tubarão Expe rience
Develop curing method
Escória Arcelor Mittal Dormente de Aço
NOVA;
4835,855000
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
Re
sist
ivid
ad
e (
Ωm
)
Gustavo; 977,78
2 Anos;
1553,69
0
1000
2000
3000
4000
5000
Entre eletrodos
Re
sist
ivid
ad
e (
Ωm
)
BOF not treated slag
Simulator data
(Just after built)
Close to 300 Ωm (AREMA)
Problem to railway user
BOF slag simulator
(after 2 years) Low electrical resistivity
problem of BOF slag ballast solved
BOF Slag use as ballast – ArcelorMittal Tubarão Expe rience
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 red uced 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
BOF Slag use as ballast – ArcelorMittal Tubarão Expe rience
ArcelorMittal Tubarão BOF slag ballast production flow
Slag generation
Slag first processingScreening
Metallic removal
Slag second processingScreening
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
BOF Slag use as ballast – ArcelorMittal Tubarão Expe rience
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;
BOF Slag use as ballast – ArcelorMittal Tubarão Expe rience
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;
BOF Slag use as ballast BOF Slag use as ballast ArcelorMittal Tubarão Experience
November, 2010
Authors:Ricardo Filipe T. Moreira (Presenter)Pedro Sérgio Bicudo Filho
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