2012 Granulated Metal Product From Direct Tapped Furnace

Paper presented at ATS-JSI Conference, 17-18 December, 2012, Paris, France.
since 2003, direct tapping of the hot metal from the

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plasma shaft reduction furnace to the GRANSHOT
granulation unit, Fig 2.
Granulated metal product from
direct tapped furnace - experience
from operation at BEFESA Sweden
Mr Vesterberg, Per (UHT Kista Sweden)
Dr Beskow, Kristina (UHT Kista Sweden)
Mr Rick, Carl-Johan, (UHT Kista Sweden)
Mr Ruh, Andreas (BEFESA Steel Services GmbH,
Duisburg, Germany)
RECYCLING OF STAINLESS STEEL DUST

European stainless steel producers generate some
20-30 kg dust per tonne produced stainless steel.
When recycling this material it is important to find a
suitable product shape for users. Traditional forms of
solidification of recycled material involve casting,
cooling, crushing and sieving. Crushing and screening
of high carbon brittle materials generates fines and
dust that is problematic both at the producer and at
the final product user. The metal recycling industry is
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a growing area for applying the GRANSHOT
granulation process for solidification. This industrial
process is already proven in iron and ferroalloy Fig 2.Hot liquid metal directly enters the granulation tundish.
applications, where it directly produces metal granules
ready for handling, packaging and transport. Granulation at ScanDust is made at a rate of 1.5
tonnes/min, Table 1. After the dewatering and drying
operation, the metal granules exit the unit within 1
minute. The final product is transported to a storage
silo and packed for transport, ready for shipment back
to the stainless steel plant from where the dust
originated or it is to be sold on the open market [1].
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Table 1. Data for GRANSHOT unit at BEFESA ScanDust.
Plant design capacity ~ 144 tonnes/day
Granulation rate 1.5 tonnes/min
Heat size 12 tonnes
Water cooling capacity 4 MW
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GRANSHOT METAL GRANULATION
The granulation process is a method for rapid
solidification of metals in water. The process is based
on the heat exchange between the liquid hot metal
and cooling water.
The hot liquid metal is tapped into a preheated tundish
and from the tundish the hot metal hits a spray-head
of refractory material, placed in the centre over the
granulation tank. The spray-head splits the metal
Fig1.Within 1 min recycled stainless steel dust, is granulated
at BEFESA ScanDust, Landskrona, Sweden. stream into droplets that are evenly distributed over
the tank water surface, Fig 3. The hot metal solidifies
BEFESA SCANDUST OPERATIONS partly in-flight before penetrating the water surface.
The BEFESA ScanDust plant in southern Sweden, Further cooling takes place as the granules sink
Landskrona has an output of 30,000 tonnes of downwards in the granulation water tank transferring
recovered metal per year, Fig 1. This plant features, heat to the counter flowing cooling water.
UHT – Uvån Hagfors Teknologi AB, Kista/Stockholm, Sweden.

www.uht.se, contact: Per Vesterberg, mob +46-73-275 2336, [email protected]
Paper presented at ATS-JSI Conference, 17-18 December, 2012, Paris, France.
Granules for Simplified Logistics

The main fraction lies in the size range between 5-25
mm with a typical deformed spherical shape, having a
3
bulk density over 3.5 tonnes/m . The size distribution
of the granules will vary slightly with metal
composition, hot metal temperature and granulation
rate. The granule size, weight and shape make the
product excellent for bulk handling. It can easily be
handled by conveyor belts, vibrating feeders, magnet,
baskets and front-end loader, Fig 4. The free flow
properties also make it suitable for silo storage and as
a continuous process addition, for example through
th
the 5 hole of the EAF.
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Fig 3.In the GRANSHOT process the hot liquid metal hits a
refractory target and the drops are cooled by water.
o
The solidified granules, at T< 100 C, are discharged
from the lower end of the tank by an air and water
ejector on to a dewatering screen, Fig 1. The solution
with spray-head and ejector allows for an industrial
high capacity operation, currently up to 300 tonnes/hr.
After dewatering the metal granules can if requested,
as at BEFESA, be further dried in a rotary dryer.
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There are several GRANSHOT implementations in
the recycling industry but the majority is for
ferroalloys, as for ERAMET Doniambo, BHP-Billiton,
SNNC, VALE and AngloAmerian, XSTRATA. There Fig 4.Granulated recycled stainless steel dust being packed.
are also pig iron being granulated at ArcelorMittal
Ideal Metallurgical Properties
Saldanha, SSAB, Voestalpine and ESSAR Steel.
The granules are free from oxides and slag, also inert
RESULTS AT BEFESA
while heated. The high specific surface area results in
The final composition of granulated stainless steel good preheating properties, quick melting and
process dust is determined by the ingoing raw dissolution when added into a liquid melt. This is
materials, a typical composition is shown in Table 2. combined with a high density that enables the
granules to penetrate the slag layer.
Table 2. Typical composition of granulated material.
SUMMARY
Fe C Cr Ni Mo Si
Weight
BEFESA ScanDust has by applying direct tapping and
0.5– 0.2– ®
% 55–65 4–6 15–20 3–10 GRANSHOT metal granulation as solidification of the
3 0.5
recycled stainless steel dust achieved several
important results in their operation.
Rapid & Safe Operation
Granulation and drying of granules take 1 minute as  Safe and industrial process, with high solidification
compared to the earlier casting, cooling, crushing and capacity, 90 t/hr and solutions up to 300 t/hr exists.
handling operations, which were also hazardous to  Close to 100% metallic yield and almost no fines.
the staff.
 30% cost reduction by direct tapping from the
Close to 100% Metallic Yield furnace and the use of granulation process.
By granulating the recycled stainless steel dust, close  Metal granules have ideal logistical properties for
to 100% metallic yield and almost no fines is achieved producer, transporter and the end-users.
in the solidification. This is appreciated by BEFESA
and the end-users of the granulated material.  The shape and absence of moisture, slag and
oxides makes metal granules well suited in any
30% Cost Reduction downstream metallurgical process.
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Direct tapping to the GRANSHOT unit and the simple REFERENCES
handling of the granules have reduced the cost at
BEFESA ScanDust with some 30% as compared to [1] Beskow K, et al, The sustainability of valuable
the earlier casting in moulds, crushing and the metals – recycling of residues from stainless steel
extensive material handling that was necessary. production, Baosteel BAC 2010 conference, China.
UHT – Uvån Hagfors Teknologi AB, Kista/Stockholm, Sweden.

www.uht.se, contact: Per Vesterberg, mob +46-73-275 2336, [email protected]

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Paper presented at ATS-JSI Conference, 17-18 December, 2012, Paris, France.

since 2003, direct tapping of the hot metal from the

RECYCLING OF STAINLESS STEEL DUST

UHT – Uvån Hagfors Teknologi AB, Kista/Stockholm, Sweden.

Granules for Simplified Logistics

UHT – Uvån Hagfors Teknologi AB, Kista/Stockholm, Sweden.

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