The number one problem for EAF Sheet Steel operations in producing high quality sheet steel for the automotive industry is copper content. Copper content above 0.10% Cu in sheet steel produces surface defects. Copper is therefore diluted 3 fold in the sheet steel product by adding pig iron and/or direct reduced iron to scrap steel product melted down in the Electric Arc Furnace. Typical Shredded scrap steel product coming out of a scrap yard with a shredder contains 0.30%Cu – 0.35%Cu. Shredded automobiles make up about 25% - 33% of the shredded scrap steel coming out of scrap yards with shredders.
Copper contamination in shredded scrap steel comes almost exclusively from motors ( alternators, generators, small motors, etc ) and wiring in automobiles being shredded. There are as many as 21 motors in a new automobile. Few supply chain shredded steel scrap yards measure the copper content of their shredded scrap steel they sell at $400 - $500 / ton and deliver to EAF Sheet Steelmaking operations. EAF Steel operations also don't even measure the Cu content of the shredded scrap steel they purchase.
Local and International EAF Sheet Steel Manufacturers, having trouble sourcing high-quality scrap steel.
Steel Scrap Metal Yards, looking to provide higher quality product to your buyers.
International Ports of Entry, aiming to process scrap steel at the height of the supply chain.
The In-Flight Scrap Cu Reduction System is a portable, semi-trailer mounted modular system that is transported to the site of operation. The equipment is completely mobile and can be set up and placed into operation within 24hrs of arriving on site. The system consists of mobile modular units that are positioned next to each other end to end and connected by conveyor belts. The copper content of the shredded scrap steel feed is reduced as a result of passing through the processing system.
The In-Flight Scrap Cu Reduction System incorporates magnetic and other physical separation equipment to reduce the Cu content of shredded scrap steel prior to being melted down in EAF furnaces producing sheet steel and other steel products. The technology does the work as it is uniquely housed on a mobile platform which can be located at desired positions or trial physical locations to test what location is best for EAF, shredder steel scrap yards, or international ocean ports of entry where shredded steel is being loaded or unloaded from ocean ships.
The EAF sheet steelmaking industry is changed forever by taking advantage of the synergy of the 2 Technology Breakthroughs described as follows:
The first Technology Breakthrough occurs as the technology transitions the upgrading of shredded scrap steel and reducing Cu content normally conducted at shredder steel scrap yards to now being conducted at the front end of EAF steel operations. EAF operations can finally remove the frustration of receiving out of spec high level Cu shredded scrap steel shipments from shredder scrap yards. The second Technology Breakthrough occurs as EAF operations, shredder steel scrap yards, and international ocean ports of entry can take advantage of the mobile In-Flight scrap Cu reduction systems which can be moved and operated at different locations at each property site to optimize the overall operation of the system.
The patent pending In-Flight Cu removal system flowsheet shown above is unique as it is a mobile system set up to run and remove copper from shredded scrap steel at unloading stations next to train cars, ocean going vessels, barges, or shredded scrap steel stockpiles near these locations. These mobile systems replace stationary Cu removal operations and reduce material handling of the unloaded shredded scrap steel and conveying of the unloaded shredded scrap steel long distances to the stationary Cu removal plants. The separate mobile systems are mounted on semi trailers and pulled into place by separate semitrucks to the EAF steel making operations or shredder steel scrap yards. Each trailer mounted modular system has a self contained diesel mounted generator to supply electrical power. Mobile material handlers having grapple hooks remove shredded scrap steel from train cars, ships or piles and load it into a mobile feeder system equipped with a hopper to load shredded scrap steel to the first mobile Cu separation system at a constant rate of 100tph – 125tph. As a result of processing, a first low Cu shredded scrap steel product is produced and a second lower feed rate shredded scrap steel product is produced. The first and second shredded scrap steel may be combined, if desired. A third by-product stream of separated Cu containing material is produced using an optional automated robotic Cu removal system or a manual hand picking station for copper removal. A separated non-ferrous stream is also produced which can be sold to a nonferrous separation plant or can be sent to a landfill.
Smart Scrap designs process from conception to installation:
Step 1: Site Visit
Step 2: Material Analysis
Step 3: Proposed Solution
Step 4: Design and Build
Step 5: Installation
Copyright © 2022 Smart Scrap Cu Reduction Systems, LLC - All Rights Reserved.