1. Section 006 Team 3 Anthony Pinter Chase Huckestein Tim Finnegan Chris McElroy

2. Table of Contents 1. Project Conceptualization 2. Problem Definition 3. Steel 4. Types of Steel 5. Design Attributes 6. Weighted Objective Tree 7. Specifications 8. Morphological Table 9. Comparing Alternatives 10. Final Design Selection 11. Final Design Selection 12. Final Design Mock-up

3. Project Conceptualization We recognize the need to design a process that will accurately analyze and sort scrap metal

4. Problem Definition  ArcelorMittal is experiencing problems with the chemical composition of the scrap metal they are using to make recycled steel The recent increase in AHS steel use is causing off-chemistry heats of steel and costing ArcelorMittal money  A process is needed that will prevent off- chemistry heats and allow ArcelorMittal to reutilize the alloys present the AHS steel scrap to maximize profit.

5. Steel  Steel is an mixture consisting of iron, carbon, and a variety of other elements called alloys 1 Steel is much stronger and flexible then pure iron  Fabrication of steel: Iron is melted down and inserted into a basic oxygen furnace with carbon and other alloys Once properly mixed, the mixture is cast into long slabs These slabs are then extruded into sheet metal, which are rolled into bales  Steel can be heat treated to strengthen it further 1. http://en.wikipedia.org/wiki/Steel

6. Types of Steel Alloy Compositions Advanced High Strength Steel Low Carbon Aluminum Killed Steel Line Pipe Carbon 0.17%0.04%0.05% Chromium 0.2%0.1% Columbium 0.02%0.004%0.003% Manganese 1.5%0.2%1.5% Aluminum 1.2%0.04%  Advanced High Strength Steel (AHSS) Lightweight alloy that consists of several elements to improve strength and flexibility Used in automobiles  Low Carbon Aluminum Killed Steel (LCAK) Steel deoxidized with Al Consumes some of the oxygen added to the furnace to lower temperature  Line Pipe Used to transport natural gas, oil and water 2 2. http://www.ingaa.org/cms/112.aspx

7. Design Attributes  Recycling Process: Efficient ○ Little to no jamming Self-lubricating parts ○ Fast process >100 tons per hour Cheap ○ Easy to purchase and install ArcelorMittal or scrapper can purchase and install Minimize space requirements ○ Recoup purchase costs in <5 years Government subsidies Accurate ○ Low scanning error rate <2% error ○ Capable of typing a variety of metals Correctly identify alloys contained in metal

8. Weighted Objective Tree ProjectObjectivesConstraintsFeatures

9. Specifications  The process should be able to process over 50 tons of scrap per hour  The process should have an error rate of less then 1%  The process should be able to process a variety of different scrap  The process should have minimal jams  The process should be as easy to install as possible  The installer should be able to recoup costs in less then 5 years  The process should be able to be installed at either ArcelorMittal or the scrapyards  The process should be constructed from recycled materials

10. Morphological Table FeaturesOption 1Option 2Option 3 Low error rate Automated metal scanner Laboratory analysis On-site chemical testing Process >50 tons per hour Manually move scrap as needed Automated conveyors belts Cranes and magnets to move scrap Minimize stoppages and jams Self-lubricated parts Manually lubricated parts No additional measures taken Minimize space requirements Horizontal process Multiple stations spread across the warehouse Vertical process

11. Constraints/ Objectives Weight (%) Automated scanner, automated conveyors, self- lubricated, vertical process Laboratory analysis, automated conveyors, manually lubricated, station set-up On-site testing, cranes, self- lubricated, horizontal process Automated scanner, manually moved, no additional measures, vertical process C: Little to no jamming X C: Fast process C: Easy to purchase and install C: Recoup cost in <5 years C: Low scanning rate error X C: Type a variety of metals O: Efficient300.6 | 18%0.4 | 12% O: Cheap300.7 | 21%0.3 | 9% O: Accurate400.4 | 16%0.6 | 24% Totals:55%45%

12. Final Design Selection  Large metal shredder Self-lubricates at regular intervals to reduce jamming  System of conveyor belts Takes shredded scrap into analyzer Automatically sorts scrap according to analyzer results  Metal analyzer determines metal composition of each piece of scrap quickly and effectively Error rate of 1% or less to minimize costs

13. Final Design Selection  Entire process starts high and ends low to conserve space, minimize cost and enable either ArcelorMittal or the scrapyards to implement the process  Maximizes use of recyclable materials in construction to reduce environmental impact  Keeps lead and other harmful materials out of the steel cycle  Minimizes cost associated with sorting Designed to recoup costs in less then 5 years Government subsidies and grants available because this increases the recycling of a limited resource

14. Design Mock-up

15. Questions?