Dusts, scale, slags, sludges... Not wastes, but sources of profits
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11/10/03
9:20 PM
Page 769
The 2001 Howe Memorial Lecture Published by permission of the Iron & Steel Society
Dusts, Scale, Slags, Sludges. . . Not Wastes, But Sources of Profits
PETER J. KOROS
Historically, the steel industry has focused on the need for and the many benefits of recycling steel that is discarded either in its own or in its customers’ manufacturing processes, as well as in recovery and reuse of steel scrap that arises after the product has served its intended purpose. In fact, modern steelmaking relies on the use of recycled iron units for at least half of its production. The other side of the story is the fate of the non-steel by-products (e.g., oxide dusts, sludges, scales, slags, spent refractories and the contained “low grade” energy units that are generated as natural adjuncts to iron and steelmaking processes). These valuable by-products often are classified as “wastes” and are discarded to landfills, at significant cost, although in reality they offer significant potential for cost savings or profit if reintroduced into the industrial arena via well planned programs. Examples of such instances will be presented, including energy credit issues, in the hope of pointing the way for future expansion of benefits from these opportunities. Peter J. Koros, the Iron and Steel Society’s 77th Howe Memorial Lecturer (2001), is Principal of Koros Associates, Inc. (Pittsburgh, PA), a consultancy he founded following retirement from the former LTV Steel Company where he worked for nearly 41 years, retiring as Senior Research Consultant. He earned the Bachelor of Science degree in Metallurgical Engineering from Drexel University, and his master’s and doctoral degrees in Metallurgy from the Massachusetts Institute of Technology (MIT). In 1958, he joined Jones and Laughlin Steel (which became LTV Steel Company), where he held positions in research (Director, Process Metallurgy), Technical Services and Quality Control, with most activities focused on steelmaking and related areas. He was responsible for J&L’s development work in injection technology for desulfurization of hot metal and steel, was the inventor of the patented co-injection concept now in use worldwide, and had the lead role in LTV Steel’s programs for degalvanizing scrap and for recovery and utilization of by-product oxides. He led the AISI Opt-In program for degalvanizing scrap and the LTV-USS pilot program for processing “by-product” oxides. Koros has authored more than 75 publications and presentations, and holds eight U.S. patents, the latest issued in 2000. Dr. Koros was elected a Distinguished Member and Fellow of the ISS in 1984 and a Fellow of ASM International in 1988. Other honors include the ISS Distinguished Service Award (1998), ISS Electric Furnace Honorable Mention Citation (1987), International Magnesium Association Design and Applications Award (1978), AISI Gold (1977) and Silver (1969) Medals, ISS Herty (1963), McKune (1963), and Toy (1962) Awards. Koros served on the Technical Advisory Committee of the AISI-DOE Direct Stee
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