Jean marie delbecq

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Presentation – Date - Ref. SLAG V&M STAR

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Seminário Internacional - Aplicação de Escória de Aciaria

Transcript of Jean marie delbecq

  • 1. SLAGV&M STAR Presentation Date - Ref.

2. SlagSlag is a byproduct of metalCommon components of slagsmelting, and hundreds of tons of itinclude:are produced annually in theSilicon oxidesprocess of refining metals andAluminum oxidesmaking alloys.Magnesium oxidesIn appearance, slag looks like aSulfur oxidesloose collection of aggregate withPhosphoruslumps of varying sizes.CalciumSlag is produced in a number of Ashways: LimestoneRepresents undesired impurities in themetals being smelted which float to thetop during smelting process.During smelting, metals oxidize and slagforms a protective crust of oxides on thetop of the metal being smelted. 3. Regulatory Status of Slag in U.S.The US Federal Register, Vol. 45, No.Reactivity standards were revised to98, May 19, 1980, lists therequire that any toxic gases generatedsubstances ruled hazardous by themust be in a quantity sufficient toUS Environmental Protectionpresent a danger to human health or theAgency (EPA).environment; slag generates onlyUS has four major hazardous wasteminute quantities and is thereforecharacteristics: Ignitability, exempted.Corrosivity, Reactivity, and Toxicity. Toxicity requirements set maximumSlag was tested by the U.S. EPA andleachate values at 100 times thefound to be non hazardous: drinking water standard, far higher than any slag could ever be expected to test.Retained heat from manufacturing orprocessing was dropped from theThe only furnace-related by-productstandard to avoid inclusion of slag in of the steel industry listed asthe Ignitability hazard class. hazardous is the electric-furnaceCorrosivity requirements wereemission control dust or sludge,changed to only include liquid wastesand the upper pH value raised to 12.5based on possible highor more, effectively excluding high pH concentrations of hexavalentsteel slag from the hazardouschromium, lead, and cadmium.classification. 4. Toxicity Characteristic Leaching Procedure(TCLP)Designed to determine the mobility of both organic andinorganic analytes present in liquid, solid, and multiphasicwastes.Used to determine if a waste meets the definition of EPtoxicity, which means it carries a hazardous waste codeunder RCRA (40 US CFR Part 261) of D004 through D052.If a solid waste fails the test for one or more of thesecompounds, the waste is considered to be a characteristichazardous waste (unless an exemption applies).Slag and sludge (which both vary in their components)contain multiple contaminants that require a TCLP. 5. TCLP: Maximum Concentration ofContaminants for Toxicity CharacteristicEPA HazardousRegulatedEPA HazardousRegulatedContaminant Waste CodeLevel (mg/l) (orWaste Code ContaminantLevel (mg/l) (or ppm)ppm)D004Arsenic (As)5 D033Hexachlorobutadiene0.5D005Barium (Ba)100D034Hexachloroethane3D018Benzene0.5D006Cadmium (Cd)1 D008Lead (Pb) 5D019Carbon 0.5D013Lindane0.4Tetrachloride D009Mercury (Hg) 0.2D020Chlordane 0.03D014Methoxychlor 10D021Chlorobenzene 100 D035Methyl ethyl ketone200D022Chloroform6D007Chromium (Cr) 5 D036Nitrobenzene2D023o-Cresol200 D037Pentachlorophenol100D024m-Cresol200D038Pyridine5D025p-Cresol200D010Selenium (Se) 1D026Cresol200D0162,4-D10 D011Silver (Ag) 5D0271,4- 7.5D039Tetrachloroethylene0.7Dichlorobenzene D015Toxaphene0.5D0281,2- 0.5D040Trichloroethylene0.5DichloroethaneD0291,1- 0.7D0412,4, 5-Trichlorophenol 400DichloroethyleneD0422,4,6-Trichlorophenol 2D0302,4-Dinitrotoluene 0.13D012Endrin0.02D0172,4,5-TP (Silvex) 1D031Heptachlor0.008D043Vinyl Chloride 0.2 6. Slag Research1Over the past several years, the U.S. Steel SlagCoalition ("SSC"), a group of 63 companies thatproduce steel, process slag, or both, has undertaken acomprehensive study of the chemical composition ofslag generated during the steelmaking process and thepotential human health and ecological risks associatedwith possible exposure to such slag.Risk assessments developed during 1998 demonstratethat slag poses no meaningful threat to human healthor the environment when used in a variety ofresidential, agricultural, industrial, and constructionapplications. 7. Processors of Iron and Steel Slag in the AC Air-cooled blast furnace slagUnited StatesBOF Basic Oxygen Furnace steel slag. GG Ground Granulated Blast Furnace SlagOHF Open-Hearth Furnace steel slag ExpExpanded pelletized blast furnace slagEAF Electric Arc Furnace steel slagSlag processing company Plant location State Steel company servicedAC GG Exp BOF OHF EAFAMSIHolsopplePANorth American Hgans, Inc. XBarfield Enterprises, Inc.La Place LABayou Steel Corp.XBarfield Enterprises, Inc.Lone StarTXLone Star Steel Corp.XBeaver Valley SlagAliquippaPAOld slag pile siteX XBeaver Valley Slag (Thor Mill ) RoanokeVARoanoke Electric Steel, Inc. XBlackheart Slag Co. Muscatine (Montpelier) IAIPSCO Steel, Inc.XBorder Steel, Inc.El PasoTXBorder Steel, Inc. XBuffalo Crushed Stone, Inc. Woodlawn NYOld slag pile siteXBuzzi Unicem USA, Inc.New OrleansLAVarious foreignXCivil & Marine, Inc.Cape Canaveral FLVarious foreignXEdward C. Levy Co.Decatur (Trinity)ALNucor Steel Corp.XEdward C. Levy Co.Butler INSteel Dynamics Inc.XEdward C. Levy Co.Columbia CityINSteel Dynamics Inc.XEdward C. Levy Co.Crawfordsville INNucor Steel Corp.XEdward C. Levy Co.DetroitMISeverstal North America, Inc. XXEdward C. Levy Co.DetroitMIU.S. Steel Corp.XXEdward C. Levy Co.Canton OHThe Timken Co. XEdward C. Levy Co.DeltaOHNorth Star-Bluescope Steel Inc.XEdward C. Levy Co.HugerSCNucor Steel Corp.XEssroc Corp.Middlebranch OHMiscellaneous domestic and foreign XFlorida Rock Industries, Inc. TampaFLVarious foreignX 8. Processors of Iron and Steel Slag in theAC United States (Cont.) Air-cooled blast furnace slag BOFBasic Oxygen Furnace steel slag.GG Ground Granulated Blast Furnace SlagOHFOpen-Hearth Furnace steel slagExpExpanded pelletized blast furnace slagEAFElectric Arc Furnace steel slagSlag processing companyPlant location State Steel company serviced AC GG Exp BOF OHF EAFFritz Enterprises, Inc.FairfieldALU.S. Steel LLC XXGerdau Ameristeel Corp.Jacksonville FLGerdau Ameristeel Corp. XGerdau Ameristeel Corp.CharlotteNCGerdau Ameristeel Corp. XGlens Falls-Lehigh Cement Co.Cementon NYVarious foreign XHolcim (US) Inc. Birmingham (Fairfield) ALU.S. Steel LLCXHolcim (US) Inc. Gary INU.S. Steel LLCXHolcim (US) Inc. WeirtonWVWeirton Steel Corp. XLafarge North America Inc. ChicagoILIspat Inland Steel, Inc.XLafarge North America Inc. JoppaILIspat Inland Steel, Inc.XLafarge North America Inc. East Chicago INIspat Inland Steel, Inc. XLafarge North America Inc. Sparrows Point MDInternational Steel Group Inc.XLafarge North America Inc. Cleveland (Cuyahoga Co.) OHInternational Steel Group Inc. XLafarge North America Inc. LordstownOHOld slag pile siteXLafarge North America Inc. McDonald OHYoungstown Sheet and Tube Co.XLafarge North America Inc. Salt Springs (Youngstown)OHYoungstown Sheet and Tube Co.XLafarge North America Inc. Warren OHWCI Steel Inc. XLafarge North America Inc. West Mifflin PAU.S. Steel LLC (ET Works)XLafarge North America Inc. West Mifflin (Brown Reserve) PAOld slag pile site XLafarge North America Inc. WhitehallPAVarious foreign XLafarge North America Inc. SeattleWAVarious foreign XLafarge North America Inc. WeirtonWVWeirton Steel Corp.XLehigh CementEvansville PAVarious foreign XLevy Co., Inc., TheBurns Harbor INInternational Steel Group Inc. XX 9. Processors of Iron and Steel Slag in theACAir-cooled blast furnace slag United States (Cont.) BOFBasic Oxygen Furnace steel slag.GGGround Granulated Blast Furnace Slag OHFOpen-Hearth Furnace steel slagExp Expanded pelletized blast furnace slag EAFElectric Arc Furnace steel slagSlag processing companyPlant location State Steel company servicedAC GG Exp BOF OHF EAFLevy Co., Inc., TheEast Chicago INInternational Steel Group Inc.XLevy Co., Inc., TheGary INU.S. Steel LLCXXMountain Enterprises, Inc. AshlandKYAK Steel Corp.XMultiServBirmingham ALStructural Metals Corp.XMultiServTuscaloosa ALNucor Steel Corp.XMultiServBlythevilleARNucor Steel Corp.XMultiServBlytheville (Armorel)ARNucor-Yamato Steel Co. XMultiServPueblo CORocky Mountain Steel Mills XMultiServWilton (Muscatine) IAIPSCO Steel, Inc.XMultiServEast Chicago INIspat Inland Steel, Inc. XMultiServIndiana Harbor INInternational Steel Group Inc. XMultiServGhentKYGallatin Steel Co. XMultiServSparrows Point MDInternational Steel Group Inc.XXMultiServAhoskie (Cofield)NCNucor Steel Corp.XMultiServCanton OHRepublic Engineered Products LLC XMultiServMansfieldOHAK Steel Corp. XMultiServWarren OHWCI Steel Inc. XMultiServBraddock (Mon Valley)PAU.S. Steel/Republic Technologies XMultiServButler PAAK Steel Corp. XMultiServCoatesvillePAInternational Steel Group Inc. XMultiServKoppel PAKoppel Steel Co. (NS Group, Inc.)X 10. Processors of Iron and Steel Slag in theACAir-cooled blast furnace slag United States (Cont.) BOFBasic Oxygen Furnace steel slag.GGGround Granulated Blast Furnace Slag OHFOpen-Hearth Furnace steel slagExp Expanded pelletized blast furnace slag EAFElectric Arc Furnace steel slagSlag processing companyPlant location State Steel company serviced AC GG Exp BOF OHF EAFMultiServSteelton PAInternational Steel Group Inc.XMultiServMidlothian TXTXI Chaparral Steel Co. XMultiServGeneva (Provo) UTGeneva Steel Holdings Corp.6 XXMultiServSeattleWANucor Steel Corp. XRinker Materials Corp. MiamiFLVarious foreign XSt. Lawrence Cement, Inc.Camden NJVarious foreign XSt. Marys Cement, Inc. DetroitMIVarious foreign XStein, Inc.Sterling ILSterling Steel, Inc.XStein, Inc.AshlandKYAK Steel Corp. XXStein, Inc.ClevelandOHInternational Steel Group Inc. XXStein, Inc.LoraineOHRepublic Engineered Products LLC XXTitan Florida, Inc.Medley FLVarious foreign XTube City IMS Corp.Birmingham ALNucor Steel Corp. XTube City IMS Corp.NewportARArkansas Steel Assoc. XTube City IMS Corp.Rancho Cucamonga CATAMCO Steel XTube City IMS Corp.PortageINBeta Steel Corp.XTube City IMS Corp.NorfolkNENucor Steel Corp. XTube City IMS Corp.Perth AmboyNJGerdau Ameristeel Corp. XTube City IMS Corp.Sayreville NJGerdau Ameristeel Corp. XTube City IMS Corp.Middletown OHAK Steel Corp. XXTube City IMS Corp.Mingo Junction OHWheeling Pittsburgh Steel Corp.XX 11. Processors of Iron and Steel Slag in the AC Air-cooled blast furnace slag United States (Cont.) BOFBasic Oxygen Furnace steel slag. GG Ground Granulated Blast Furnace Slag OHFOpen-Hearth Furnace steel slag ExpExpanded pelletized blast furnace slag EAFElectric Arc Furnace steel slagSlag processing companyPlant location State Steel company serviced AC GG Exp BOF OHF EAFTube City IMS Corp.YoungstownOH V&M Star (North Star, Inc.) XTube City IMS Corp.Sand SpringsOK Sheffield Steel Corp. XTube City IMS Corp.Cayce SC SMI/CMC Steel Group XTube City IMS Corp.Knoxville TN Gerdau Ameristeel Corp. XTube City IMS Corp.SeguinTX SMI/CMC Steel Group XTube City IMS Corp.PetersburgVA TXI Chaparral Steel Co. XTube City-IMS, IMS DivisionAxisAL IPSCO Steel, Inc. XTube City-IMS, IMS DivisionFort SmithAR MacsteelXTube City-IMS, IMS DivisionNewport AR Arkansas Steel Assoc. XTube City-IMS, IMS DivisionKingman AZ North Star Steel Inc. XTube City-IMS, IMS DivisionClaymontDE CitiSteel USA, Inc. XTube City-IMS, IMS DivisionCartersvilleGA Gerdau Ameristeel Corp. XTube City-IMS, IMS DivisionWilton (Muscatine)IA Gerdau Ameristeel Corp. XTube City-IMS, IMS DivisionKankakeeIL Nucor Steel Corp. XTube City-IMS, IMS DivisionPeoriaIL Keystone Steel & Wire Co. XTube City-IMS, IMS DivisionLaplace LA Bayou Steel Corp. XTube City-IMS, IMS DivisionJackson MI MacsteelXTube City-IMS, IMS DivisionMonroeMI Macsteel (Quanex) XTube City-IMS, IMS DivisionSt. PaulMN Gerdau Ameristeel Corp. XTube City-IMS, IMS DivisionJackson MS Nucor Steel Corp. XTube City-IMS, IMS DivisionCharlotte NC Gerdau Ameristeel Corp. X 12. Processors of Iron and Steel Slag in the AC Air-cooled blast furnace slag United States (Cont.) BOF Basic Oxygen Furnace steel slag. GG Ground Granulated Blast Furnace Slag OHF Open-Hearth Furnace steel slag ExpExpanded pelletized blast furnace slag EAF Electric Arc Furnace steel slagSlag processing companyPlant locationStateSteel company serviced AC GG Exp BOF OHF EAFTube City-IMS, IMS DivisionPerth Amboy NJ Gerdau Ameristeel Corp. XTube City-IMS, IMS DivisionSayrevilleNJ Gerdau Ameristeel Corp. XTube City-IMS, IMS DivisionAuburnNY Nucor Steel Corp. XTube City-IMS, IMS DivisionMarionOH Marion Steel Co.XTube City-IMS, IMS DivisionMcMinnville OR Cascade Steel Rolling Mills, Inc. XTube City-IMS, IMS DivisionPortlandOR Oregon Steel Mills Inc. XTube City-IMS, IMS DivisionBethlehem PA Old slag pile site XXUniversal Stainless & Alloy ProductsTube City-IMS, IMS DivisionBridgeville PA XInc.Tube City-IMS, IMS DivisionMidland PA J&L Specialty Products, Inc.XTube City-IMS, IMS DivisionMonroeville PA Old slag pile siteXTube City-IMS, IMS DivisionNew CastlePA Ellwood Quality Steels Co.XTube City-IMS, IMS DivisionPark Hill (Johnstown) PA Old slag pile siteXTube City-IMS, IMS DivisionPricedale PA Old slag pile siteXTube City-IMS, IMS DivisionReading PA Carpenter Technology Corp.XTube City-IMS, IMS DivisionDarlingtonSC Nucor Steel Corp. XTube City-IMS, IMS DivisionGeorgetownSC Georgetown Steel Corp.XTube City-IMS, IMS DivisionJackson TN Gerdau Ameristeel Corp. XTube City-IMS, IMS DivisionBeaumontTX Gerdau Ameristeel Corp. XTube City-IMS, IMS DivisionJewettTX Nucor Steel Corp. XTube City-IMS, IMS DivisionLongviewTX LeTourneau Steel GroupXTube City-IMS, IMS DivisionPlymouthUT Nucor Steel Corp. XTube City-IMS, IMS DivisionSaukville WI Charter Steel XTube City-IMS, IMS DivisionWeirton WV Weirton Steel Corp. X 13. Slag Use in U.S.In 1997, iron and steel slag consumption totaled approximately21.4 million tons valued at about $147 million.Of this total, BF slag accounted for approximately 65 percent ofthe tonnage and was worth about $118 million.Steel slag accounted for the remainder.The physical shape of slag particles make steelmaking slag asuperior material for use as a construction aggregate, currentlythe major use of steelmaking slag.Natural aggregates, such as limestone, sand, and gravel products,compete with slag for use as a construction aggregate.Because slag is a renewable mineral resource, its use reduces theconsumption of natural resources by the construction industry. 14. Slag Use in US(continued)Major uses of steelmaking slag:Railroad ballastAggregate in bituminous mixes such as: Neutralization of mine drainage andpavement surfaces, bases, surfaceindustrial dischargetreatments, seal coats, slurry coats,Agricultural uses, such as soiland cold patch.remineralization and conditioning, pHConcrete aggregate and as an supplement/liming agent, fertilizeringredient in cement Controlled, granular fills, such as thoseAnti-skid aggregate (snow and icefor unpaved parking and storage areas,control aggregate) pipe and tank backfill, berm construction, and other industrial andSurfacing of stabilized shoulders, banks construction activityand other select material Construction aggregate or a fluxingBank stabilization (erosion control agent at steel millsaggregate) Landfill daily cover materialGabions and riprap Landscape aggregateAggregate base courses and sub-bases Trench aggregate/drain fieldsUnpaved driveways, surface roads, andwalkways Sand blast gritMineral wool (home and appliance Roofing granulesinsulation)Bulk filler (e.g., paints, plastics, adhesives) 15. Youngstown, OhioThe V&M - Youngstown facility includes: An 85-ton electric arc furnace; A 3-strand continuous caster of 8 3/4" or 11 1/4 rounds; A walking beam reheat furnace; and A 6-stand retained mandrel mill (MPM).Site Statistics27.05 acres owned112.93 acres leased29.2 acres under roof 16. V&M STAR Youngstown, OHMini-mill with a 830,000 short ton per yearcapacity.Produce high quality seamless steel pipe for theoil and gas industries.Annual output capacity is approximately 610,000tons of finished tubular products, of which 66%are Oil Country Tubular Goods (OCTG).Produced approximately 34,744 tons of slag in2009, which is sold to a third part for processing.Slag produced per month is approximately 10-12% of liquid steel tons. 17. Slag ProcessingTube City IMS serves as the third part processor forthe V&M STAR Youngstown facility.After slag is poured off EAF it is transported to acooling pit and watering area.The slag is then sorted, all large pieces of steel areremoved with a magnetic crane, and then runthrough a separator which sorts the slag accordingto sizes.The sized slag is then sold to outside companies formany different applications.All slag processed is sold to an outside company, nowaste is generated.At V&M STAR the mTon of Slag per mTon of LiquidSteel Produced = .12 18. 3RD PARTY SLAG SALES - 20099-Jan2,191 tons 9-Jul 1,163 tonsRobert Janson637Gwinn Brothers238Foster Trucking512Murphy Trucking 123Youngstown Iron250Ray Brothers113Lakeside 2109-Feb2,216 tons 9-Aug 2,767 tonsMurphy Trucking551Youngstown Iron 320Foster Trucking253Ray Brothers292Ray Brothers 229Larson Trucking 265Rt#5 Sand & Gravel 212Lee Gardner 172Simak Trucking170Robert Janson 1249-Mar6,051 tonsRay Brothers1,491Murphy Trucking 1,361 9-Sep 2,279 tonsRt#5 Sand & Gravel405 Gwinn Brothers827JDS Landscape 374 Ray Brothers500Gwinn Brothers325 Simak Trucking250Simak 309 Robert Janson 1539-Apr4,076 tons 9-Oct 2,912 tonsRay Brothers 818Youngstown Iron 826Don Kennedy817Gwinn Brothers738Murphy Trucking217Ray Brothers451NJM Excavating 176JDS Landscaping 148Rt#5 Sand & Gravel 134Robert Janson 1029-May2,414 tons 9-Nov 3,961 tonsRay Brothers 296Total Waste Logistics1,419Gwinn Brothers 282Ray Brothers 691Rt#5 Sand & Gravel 202Gwinn Brothers 355Murphy Trucking170Simak Trucking 307Robert Janson2889-Jun3,099 tonsRay Brothers 6519-Dec 1,615 tonsGwinn Brothers 498Gwinn Brothers532Rt#5 Sand & Gravel 253Simak Trucking301Murphy Trucking124Ray Brothers262Youngstown Iron 250TOTAL TONS FOR 2009 = 34,744 19. 2008 Pilot StudyV & M Star pilot study to reduceWaste streams were mixed withwaste and increase recycling effortsfly ash, steel furnace slag, andwas successfully completed in 2008. cement to create a strong basematerial to use during roadOhio EPA was involved in andimprovement operations withinapproved of pilot study.the facility.Waste streams (mill scale and Since the pilot study, a 600 footsludge) that are generated during section of this road base materialproduction of seamless pipe werewas utilized at the Youngstownincorporated into a road base facility.material. V&M STAR EnvironmentalThe objectives of the pilot study Department has requestedincluded: providing sufficientcontinued installation of the roadstrength to support heavy equipment,base material throughout theflexibility to prevent cracking,plant in upcoming years as adurability for long service life, and feasible alternative to off-sitestability to bind and secure anydisposal, potentially increasingresidual metals, oil, and/or grease the average waste recycling ratepresent in the mill scale and sludge. to greater than 90%. 20. 2008 Pilot Study (cont.)Slag roadwayinstallation 21. 2008 Pilot Study (cont.) Completed slag roadway 22. Sludge Pad 23. Sludge pad 24. AwardsV&M STAR Ohio received the 2009 Steel ManufacturesAssociation Recycling Award for the road way project.Additionally, the facility is in the final selection process forthe Ohio Environmental Stewardship Award. 25. Comparison of V&M Slag Analytical to Regulated Level(ppm)2010 Analytical Regulated LevelArsenicND 5Barium.266 100CadmiumND 1Lead ND 5Selenium ND 1Silver ND 5 26. Contact Information: Soil SolutionsSenior Project Manager: Timothy C. JonesSoil Solutions, LLC21 Highcroft WayHopkinton, MA 01748Phone: 508-497-0030Fax: 508-497-0031Email: [email protected]: http://www.soilsolutions.info/index.htm 27. For More Information:National Slag Association http://www.nationalslag.org/Slag Cement Associationhttp://www.slagcement.org/American Iron and Steel Institutehttp://www.steel.org//AM/Template.cfm?Section=HomeThe Steel Manufactures Associationhttp://www.steelnet.org/ 28. References1. Information developed by the National Slag Association Environmental Committee