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ScrapMaster is a trademark of Harsco Corporation. All rights reserved. BOSS is a trademark of Management Science Associates, Inc. All rights reserved. This presentation is intended for customers of Harsco Corporation. All information included in this presentation, including copyright and trademarks, is expressly reserved and no part of these materials may be reproduced or distributed outside of the customers organization in any form without Harscos prior written consent.
Core Purpose
To build teams that win with integrity anywhere in the world
Customers Employees Shareholders Suppliers Value Creation Value Capture Value Selling Be the Best Sustainable Superior Performance (20-Mile March) Ethical in Thought, Word and Deed Disciplined Thought, Disciplined Action and Disciplined People Transparency Safety Personal Accountability and Responsibility Customers Targeted Market BHAG Envisioned Future
Core Values
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Continuous Improvement
Continuous Improvement Discipline through Lean and Six Sigma Methods Business Transformation
Europe N. Am Rest of Asia China India M.E. Africa CIS S. Am Oceania 0 50 100 150
EAF BOS
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70% of steelmaking costs are raw materials Scrap makes up a large proportion of this
Estimated Scrap input cost $204 million/year $374 million/year 3 million tonne BOS plant 1 million tonne EAF plant
Best-in-Class scrap management allows the Steelmaker to: Downgrade/reject merchant scrap loads Reduce scrap yard landfill costs Minimise scrap stocks Optimize scrap charges
=> EAF delays waiting for scrap => Incorrect weights charged => Low yields => Increased slag volumes => Missed specifications => Increased refractory wear => Greater flux, O2, power consumption
Financial impact:
1 minutes lost production time approx $3000 10oC Cooling requirement approx $440 per heat +100 ppm [O] at tap approx $51 per heat
Optimum scrap mix is charged each and every time on time the correct weight, the correct quality, zero delays Full inspection, including state of the art radiation detection for all purchased scrap Proactive reporting of scrap deliveries to enable cash recovery associated with OOS loads, rejected loads and contaminated loads Real time IT control for internal and purchased scrap with full stock tracking and reporting system Full traceability and accountability of scrap throughout site so that potential for fraud can be eliminated
ScrapMaster
Four integrated operating modules for cost-effective management of the entire scrap supply chain, with full segregation and traceability.
Scrap handling
ScrapMaster
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Optimizing
ScrapMaster Value
Save on external scrap purchasing Realise the maximum value of internal scrap Charge the optimum scrap mix on time, every time Monitor the entire scrap charge history
The unique video review function in ScrapMaster allows the furnace manager to monitor exactly what scrap was loaded at what time, in case of any problem with a particular heat.
Scrap Optimization
ScrapMaster now integrates BOSS (Blending Optimization Software Suite) functionality Under license from Management Science Associates, Inc. World leading optimization program Yield-based cost calculation Actual scrap cost per tonne of steel Value of the scrap inventory on a real-time basis Minimises scrap charge cost, grade by grade Based on specific grade production data entered by the steelmaker planned tonnage, scrap composition, prices, availability and inventory
BOSS References
Essar Steel Algoma ArcelorMittal PST AK Steel ATI Carpenter Technology Universal Stainless MetalTek International McConway Torley Sparrows Point Scrap Processing The Federal Metal Co Waukesha Foundry WCI Steel
Canada USA USA USA USA USA USA USA USA USA USA USA
Integrated EAF Stainless Steel Stainless Steel EAF Stainless Steel Special Steels Special products Integrated Special products Special products Integrated
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BOSS Functions
Single heat optimization Multi heat optimization Campaign optimization Scrap buy planning Inventory management Results feedback and interpretation
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Scrap Grade Name Steel Grade Name Scrap Type Chemical Analysis
Restrictions
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Inventory Data
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Solution Information
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Successful Optimizing
Factors for Optimization Accuracy Input scrap analysis is critical
Regular melt tests and spectrographic analysis of scrap required to build database Update model as more and more information is gathered
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Scrap Analysis
Accurate chemical analysis data is required for scrap materials Need to begin population of scrap database To start process, need melt tests of each scrap Ongoing testing of scrap will be required to populate database with a large number of samples to improve model accuracy
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Optimization Improvement
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Feedback Data Receive Scrap
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Analyse Chemical Data
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Continuous Feedback
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Update Scrap Analysis
Process Improvement
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Melting EAF
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Results (history)
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Quantifying the cost of production constraints (e.g. sulfur composition of the heat) Lowest cost liquid steelmaking Optimized use of scrap available Use data for informed scrap purchasing and negotiation Planned scrap buy Full control of scrap cost Tangible savings
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