SCRAP SHREDDER AND ANALYZER

Section 006 Team 3Anthony Pinter

Chase HuckesteinTim FinneganChris McElroy

Table of Contents1. Project Conceptualization2. Problem Definition3. Steel4. Types of Steel5. Design Attributes6. Weighted Objective Tree

7. Specifications8. Morphological Table9. Comparing Alternatives10. Final Design Selection11. Final Design Selection12. Final Design Mock-up

Project Conceptualization

We recognize the need to design a process that will accurately analyze and

sort scrap metal

Problem Definition ArcelorMittal is experiencing problems with

the chemical composition of the scrap metal they are using to make recycled steelThe 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.

Steel Steel is an mixture consisting of iron, carbon,

and a variety of other elements called alloys1

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

Types of SteelAlloy Compositions

Advanced High

Strength Steel

Low Carbon

Aluminum Killed Steel

Line Pipe

Carbon 0.17% 0.04% 0.05%

Chromium 0.2% 0.1% 0.1%

Columbium 0.02% 0.004% 0.003%

Manganese 1.5% 0.2% 1.5%

Aluminum 1.2% 0.04% 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 water2

2. http://www.ingaa.org/cms/112.aspx

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

Weighted Objective TreeProject Objectives Constraints Features

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

Morphological TableFeatures Option 1 Option 2 Option 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

requirementsHorizontal process

Multiple stations

spread across the warehouse

Vertical process

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

installC: Recoup cost in <5

yearsC: Low

scanning rate error

X

C: Type a variety of

metals

O: Efficient 30 0.6 | 18% 0.4 | 12%O: Cheap 30 0.7 | 21% 0.3 | 9%

O: Accurate 40 0.4 | 16% 0.6 | 24%Totals: 55% 45%

Final Design Selection Large metal shredder

Self-lubricates at regular intervals to reduce jamming

System of conveyor beltsTakes shredded scrap into analyzerAutomatically sorts scrap according to analyzer

results Metal analyzer determines metal

composition of each piece of scrap quickly and effectivelyError rate of 1% or less to minimize costs

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 sortingDesigned to recoup costs in less then 5 yearsGovernment subsidies and grants available because

this increases the recycling of a limited resource

Design Mock-up

Questions?