More on our systems and process
The mobile screening device shown above represents our modular Cu reduction modules. 100-125tph of shredded scrap steel is fed into the initial feeder module equipped which meters out a constant 100tph of material to the separation modules.
The mobile modules are mounted on specially designed semi-truck trailers which are moved into position at the train, ship, barge or truck shred unloading site. Hydraulic jacks are activated to raise the modules off the trailer tires to provide a stable working base on which to operate the system, as shown above. Material is transferred to and from each module with conveyor belts mounted parallel or perpendicular to the flow of material, as shown above. Electrical power is provided to each module by diesel generators mounted on each module.
No personnel are needed to operate the system other than individuals loading shredded scrap steel into the feeder module. Web cameras are mounted above each module to stream live pictures back to control rooms to show the operating status of each module.
Our Cu reduction systems have been proven at pilot scales of 1tph, 10tph, 100tph, and 1000tph where separation tests were conducted in which test results showed 85%-90% of the initial feed rate produced a shredded scrap steel product with the remaining 10-15% containing 0.30%-0.35%Cu. These excellent operating results provide a total system payback of 3-4 months at EAF sheet steel operations as a result of large scale OPEX cost reductions provided by reductions in pig iron addition and yield gains achieved at each EAF furnace steelmaking line.
The above map highlights steel plants throughout the world and showcases markets for installation/utilization of our Smart Scrap Cu Reduction Systems technology. You are able to view and interact with this tool in real time from our resources page here.
Please contact us if you cannot find an answer to your question. We're here to help!
What levels of copper reduction can we expect to see by running shredded scrap steel through your Smart Scrap Cu Reduction Systems equipment and flowsheet at 100 tph?
-When you run typical U.S. produced shredded scrap steel having an average of 0.30%Cu – 0.35%Cu. If the average copper content is above 0.35%Cu, you will see an average Cu reduction of 0.10%Cu – 0.15%Cu when you run the higher Cu content shredded scrap steel through our system.
How long will it take to set up your mobile modular equipment and start running it?
-Typical set up time to start running shredded scrap steel through our copper reduction system using diesel generators to provide the electrical power and put the conveyor systems in place is 12 – 24 hrs.
Do you provide a process guarantee?
-The equipment providers have suggested to us that they will provide an equipment buy-back guarantee.
Why should we consider purchasing a mobile plant design versus a stationary plant design to reduce copper in shredded scrap steel?
1. Stationary plant design infrastructure costs for a typical 250tph system can be as high as $2.5M This cost is avoided in a mobile plant design.
2. No environmental permits are required when you run a portable plant vs a stationary plant.
3. Mobile plants require much less material handling as compared to stationary plants, which provides $ millions in savings per year.
How can you explain your incredible system payback of 4 months for an EAF operation that produces 1 -2 MTPY sheet steel?
-Payback calculations are made by calculating the reduced additions of pig iron /DRI to each EAF heat with lower Cu concentrations coming from shredded scrap steel added. Have the plant metallurgists run the Opex cost calculations with lower Cu content coming from the shredded scrap steel produced with the Smart Scrap Cu Reduction System. Shredder scrap yards can calculate paybacks using $25/ton - $50/ton premiums received by selling low copper shredded scrap steel.
How can CO2 emission reductions be claimed by using lower Cu shredded scrap steel in EAF steel production?
-Section 3 greenhouse gas emissions are reduced by using less pig iron or DRI in EAF steelmaking when lower Cu content shredded scrap steel in used.
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