1101 17th Street, NW

Suite 1300
Washington, DC 20036-4700

www.steel.org

A Feasibility Study for Recycling

Used Automotive Oil Filters in a Blast Furnace
AISI Contract TRP-9

Project No. 0041

January 2002

By

Metserv
Ralph M. Smailer, Principal Investigator
Gregory L. Dressel, Investigator
Jennifer Hsu Hill, Investigator

Metserv
9800 A McKnight Road
Suite 310
Pittsburgh, PA 15237-6006
Tel: (412) 348-0015
Fax: (412) 348-0017
E-mail: [email protected]
AISI Contract TRP-9
Project No. 0041
A Feasibility Study for Recycling Used Automotive Oil Filters in a Blast Furnace

Table of Contents

1.0 Executive Summary 4

2.0 Introduction 5
2.1 The Blast Furnace Process 6
3.0 Used Oil Filters 7
3.1 Generation Rate 7
3.2 Geographic Distribution of Used Oil Filters 9
3.3 Filter Composition 9
3.3.1 Gross Filter Weights 9
3.3.2 Steel Coatings 10
3.3.3 Fuels 11
3.3.4 Used Oil Filter Components 11
3.3.5 Oil Filter Dry Material Weight Percentages 12
3.4 Energy Values for Contained Oil and Filter Media 13
3.5 Current Methods of Processing of Used Oil Filters 13
3.6 Present Disposal of Used Oil Filters 14
3.6.1 Recycling at Steel Plants and Foundries 14
3.6.2 Individual State Laws Governing Oil Filter Recycling 15
4.0 Blast Furnace 16
4.1 Blast Furnace Geographical Distribution 16
4.2 Current Operating Practice 16
4.2.1 Fuel 17
4.2.2 Iron Ore 17
4.2.3 Metallics 17
4.2.4 Fluxes 18
4.2.5 Production 18
4.2.6 Hot Metal Chemistry 18
4.2.7 Slag Chemistry 19
4.2.8 Gas Cleaning 19
4.2.9 Waste Water Cleaning 19
4.3 Recycling of Used Oil Filters to the Blast Furnace 19
4.3.1 Material Handling and Storage 23
4.3.2 Size Requirements 23
4.3.3 Effect on Blast Furnace Process 24
4.3.3.1 The Chemistry of Motor Oil in the Blast Furnace 24
4.3.3.1.1 Composition and Properties of Motor Oil 26
4.3.3.1.2 Distillation of Oil in the Blast Furnace 30
4.3.3.1.3 Reactions of Oil in the Blast Furnace 30
4.3.3.2 Fuel Value Recovered 33

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AISI Contract TRP-9
Project No. 0041
A Feasibility Study for Recycling Used Automotive Oil Filters in a Blast Furnace

4.3.3.3 Top Gas Chemistry 34

4.3.3.4 Metallics Recovered 34
4.3.3.5 Slag Chemistry 35
4.3.3.6 Hot Metal Chemistry 35
4.3.3.7 Burden Permeability 35
4.3.4 Process Flow Diagram 35
4.3.5 Effect on Gas Cleaning 37
4.3.6 Effect on Blast Furnace Gas Heating Value 38
5.0 Capital Cost Considerations 39
5.1 Storage 39
5.2 Handling and Charging 39
5.3 Processing of Oil Filters 39
5.4 Top Gas Cleaning 40
5.5 Waste Water Cleaning 40
6.0 Operating Cost Considerations 41
6.1 Hot Metal Production 41
6.2 Slag Production 42
6.3 Top Gas Production 42
6.4 Fuel Requirements 42
6.5 Flux Requirements 42
6.6 Iron Yield 42
6.7 Gas Cleaning 41
6.8 Waste Water Treatment 43
7.0 Analysis 44
7.1 Operational Considerations 44
7.2 Cost/Benefit Review 45
8.0 Review with Blast Furnace Operators 47
8.1 Past Experiences with Oily Charge Materials 47
8.2 Perceived Problems with Charging Oil Filters 47
9.0 Future Work 49
10.0 Conclusions 50
11.0 Acknowledgements 51
12.0 Appendix 52
13.0 References 59
14.0 Resumes 61

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AISI Contract TRP-9
Project No. 0041
A Feasibility Study for Recycling Used Automotive Oil Filters in a Blast Furnace

A Feasibility Study for Recycling Used Automotive Oil Filters in a Blast Furnace

1.0 Executive Summary

This feasibility study has indicated that of the approximately 120,000 tons of low
residual steel available to be recycled from used oil filters (UOF’s), a maximum blast
furnace charge of 2% (40 lb/NTHM) of the burden may be anticipated for short term use
of a few months due to limited availability of the UOF’s. The oil contained in the most
readily processed UOF’s being properly hot drained and crushed is approximately 12%
to 14% by weight. This oil (and filter media) charged (about 10 lb/NTHM) will be
pyrolized into lighter hydrocarbons of 98% of the oil and media charge weight, resulting
in additional fuel gas of 68% (7 lb/NTHM) and a condensable hydrocarbon fraction of
30% (7 lb/NTHM), with the remaining 2% (1 lb/NTHM) resulting as carbon being added
into the burden.

Based upon the writer’s collected information and assessment of the calculations on
the pyrolysis of the motor oil, there does not appear to be any operational problems
relating to the recycling of UOF’s to the blast furnace. Any free draining of oil in the
transportation, handling, and storage of UOF’s prior to their charging must be contained.
Although, the EPA does not consider UOF’s hazardous, five states have enacted
legislation banning the placement of UOF’s into state landfills.

Upon reviewing the preliminary study work with steel plant personnel, it was learned
that one USA blast furnace operator has been routinely charging UOF’s at about 100
tons to 200 tons per month for many years. The current cost of these UOF’s is about
$30 per gross ton delivered to the company’s plant. Discussions with the company’s
operating and scrap purchasing personnel have indicated no adverse effect to their blast
furnace operation or in the handling and storage of the UOF’s with their specification of
“no free flowing oil”. The remaining oil content in these UOF’s is not presently known.

The following sections will provide detailed information regarding the generation rate
of used oil filters, their geographical disposition, and their potential quantities available
for recycling. Although the contained oil quantities are a relatively small percentage of
the blast furnace burden, extensive analysis and calculations have been done to indicate
the most probable result of the pyrolysis of the oil within the blast furnace. There does
not appear to be any toxic consideration as a result of this pyrolysis within the blast
furnace. However, a hydrocarbon condensate in the “gasoline” fraction will condense in
the blast furnace scrubber water and may require additional processing in the water
treatment system to remove the light oils from the condensate.

Used oil filters represent an additional source of high quality iron units that may be
effectively added to the charge of a blast furnace for beneficial value to the operator and
to the removal of this resource from landfills.

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AISI Contract TRP-9
Project No. 0041
A Feasibility Study for Recycling Used Automotive Oil Filters in a Blast Furnace

2.0 Introduction

This study is the result of a solicitation by the American Iron & Steel Institute for
“A Feasibility Study for Recycling Used Automotive Oil Filters in a Blast Furnace” as
dispatched by e-mail 11 May 2001. In the AISI, “Steel Technology Road Map”, March,
1998, section 3.2.3 AUTOMOTIVE, there is a commentary on recycling of automotive
scrap. Oil filters represented the greatest potential source of currently un-recycled
automotive steel scrap. The Steel Technology Roadmap indicated potential iron units of
65,000 tons from oil filters to be available. This is contrasted with more than 12,000,000
tons of shredded steel scrap from automobiles in 1994.1

There has been considerable work done over the past ten years concerning the
potential for recycling of used automotive oil filters. Professor K. D. Peaslee of the
University of Missouri-Rolla, Department of Metallurgical Engineering, has done a
significant amount work over many years regarding the potential for recycling of used
automotive oil filters. Much of this work is summarized in a current technical bulletin. 2

A study by “The Convenient Automotive Services Institute” 3 showed that based

on their testing of used oil filters, that the results indicated filters to be non-hazardous
with respect to EPA classifications.

This AISI feasibility study has relied mainly on published work and information
gathering via the Internet to obtain the background information regarding the generation
rate and location of used oil filters (UOF’s) in the United States. This information is
presented in detail in the following sections of the study. A 100% recycling rate of
current UOF’s has the potential for 120,000 tons of steel to be available for recycling.
This is to be placed in perspective to the approximately 50,000,000 tons/year of blast
furnace iron production in the United States. Therefore, in the writer’s opinion, the most
likely maximum charging rate of UOF’s to the blast furnace would be less than 2% of the
burden.

Section 3.3 Composition, then focuses on the oil content of the UOF’s along with
any potential metals contamination. The results show the metal to be a high quality, low
residual source of iron units. Particular emphasis is placed on the pyrolysis of oil as the
UOF’s enter the blast furnace and become heated within the burden. This study will
show that 98% of the oil entering the blast furnace in the UOF will leave with the top gas
as both fuel gas and a condensable hydrocarbon fraction.

Communications with blast furnace operating personnel were conducted to

determine any actual operating experience with UOF’s, or their perceived potential
problems concerning the charging of used oil filters to the blast furnace. The

1
AISI, “Steel Technology Roadmap”, March 1998, section 2.2.3 A UTOMOTIVE, pg 77.
2
Technical Bulletin, “The Future of Used Oil Filter Recycling in Missouri: An Evaluation of Potential
Processes, Product Quality, Recycling Locations, and Economics”, February 15, 1997, K.D. Peaslee and
D.E. Roberts, II, University of Missouri-Rolla, Department of Metallurgical Engineering.
3
“Report of the Findings on the Waste Classification of Used Automotive Oil Filters”, The Convenient
Automotive Services Institute, April 1991.

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AISI Contract TRP-9
Project No. 0041
A Feasibility Study for Recycling Used Automotive Oil Filters in a Blast Furnace

discussions with the US Steel operators identified that they have been charging UOF’s
at the Gary Works for many years as indicated in section 8.0.

A qualitative cost benefit analysis is presented by the writers to assist the

assessment of the potential value for recycling UOF’s to the blast furnace in section 7.0.
The section 9.0 “Future Work” is directed toward enhancing the recovery of UOF’s for
beneficial recycling to the blast furnace.

2.1 The Blast Furnace Process

As an aid to assist persons who may not be familiar with the iron blast furnace, a
pictorial representation of the blast furnace process has been downloaded from the AISI
web site4 as shown below in Figure 1.

Figure 1: The blast furnace process4

4
“The Process,” From “An Introduction to Blast Furnace Technology”, ATSI Engineering Services,
http://www.steel.org/learning/howmade/blast_furnace.htm, 12/17/2001.

Metserv Page 6 of 69 January 2002

AISI Contract TRP-9
Project No. 0041
A Feasibility Study for Recycling Used Automotive Oil Filters in a Blast Furnace

3.0 Used Oil Filters

3.1 Generation Rate

Used oil filters are generated from a number of sources. Light duty pickup
trucks, derivatives thereof and automobiles generate the most oil filters. Other
applications producing used oil filters would be medium and heavy duty trucks,
stationary internal combustion engines, off road vehicles, motorcycles, construction
machinery, hydraulic power generation units, railroad locomotives, aircraft and auxiliary
power units.

A used oil filter is produced every time an oil filter in use is replaced with a new
filter. Very few oil lubrication filters are cleaned and reused. The current state of the art
filters are designed to trap particles as small as 8 to 10 microns in a fibrous media that
precludes flushing and regeneration. 5

A quick examination of automobile maintenance instructions shows that under

normal driving conditions, oil changes are recommended every 7500 miles and an oil
filter change is recommended every other oil change. However under “severe”
circumstances such as driving in a dusty area, towing a trailer, frequent idling or driving
4 miles or less in freezing weather the recommended change interval for both the oil and
oil filter is 3000 miles. Most commercial oil change facilities recommend an oil and filter
change every 3000 miles, even to the point of putting a reminder sticker on the
windshield.

Certain cars today have oil change indicators lights built into the instrument
cluster. An algorithm based on the number of engine starts, total engine revolutions,
miles driven, and etc., since the last oil change flashes a signal when an oil change is
needed. However, in order to keep the warranty in force, a driver needs to follow the
written recommendations included with the owner’s manual.

Lubricant analysis for predictive analysis of oil changes and engine conditions
has become a useful tool for railroads, automotive and trucks fleets and aircraft
businesses. On a regular basis, a sample of oil is taken from an internal combustion
engine and checked for viscosity, physical appearance, metal content, water, and
coolant contamination. 6 A major consumer of lubricating oil may set up a complete
laboratory while private analysis service for individual automobile owners are available
through the oil companies.7 While widespread adoption of this method would lead to
better prediction of a used oil filter generation rate, however cost and inconvenience
would preclude the normal owner of a motor vehicle from this service.

5
“AC Delco – Parts Information-Oil Filters-Ultraguard Gold,”
http://www.acdelco.com/pi_filt_oil_gold_feature.htm, 9/24/01
6
F.E. Lockwood and R. Dailey, “Lubricant Analysis,” Friction, Lubrication and Wear Analysis, 1992,
ASM Handbook, Vol. 18, pp. 299-312
7
“Online Sample Report, Oil Sampling Guidelines, ” http://www.thetakgroup.com/pennzoil-
quakerstate/pqs/login.asp, 10/25/01

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AISI Contract TRP-9
Project No. 0041
A Feasibility Study for Recycling Used Automotive Oil Filters in a Blast Furnace

On the one hand, the commercial oil change facilities are advocating more
frequent oil changes while on the other hand, there will be a large percentage of drivers
who greatly extend the mileage or time between oil filter changes.

In the USA and Puerto Rico in 1999 there were 222,564,582 registered motor
vehicles.8 This total includes all automobiles, trucks and motorcycles in private and
public service. The Oil Filter Recycling Council estimates that approximately
440,000,000 used oil filters will be generated in the USA in year 2001 while historical
trends indicate about a 1% increase per year; 9 this is roughly two oil filter changes for
every registered motor vehicle in the USA. The generation of 440,000,000 oil filters per
year seems reasonable given the number of registered motor vehicles and the fact that it
is impossible for one person to operate more than one vehicle at a time.

From 1998 to 1999 the oil filter-recycling rate increased from 33 to 50% as
indicated in a survey of filter recyclers.10 For year 2001 the Oil Filter Recycling Council
estimated a recycling rate of between 40 to 50%. 11 The recycling rate is dependent on
state laws and growth of oil change facilities sending filters to recyclers. The recycling
rate is expected to exhibit continued growth.

To predict the number of used oil filters generated for recycling in a blast furnace
up to the year 2005, one needs the total annual oil filter units of production and the
increase in recycling rates. A production rate increase of 1% per year is known. For
the purposes of this study, a 5% per year increase in recycling is assumed.

Table 1: Used Oil Filters Available for Recycling 2001 to 2005

Year Total New Oil Filter Oil Filter Recycling Oil Filter Units
Units Rate Available for
Recycling
2001 440,000,000 50 % 220,000,000
2002 444,400,000 55 % 244,400,000
2003 448,800,000 60 % 269,300,000
2004 453,300,000 65 % 294,700,000
2005 457,900,000 70 % 320,500,000

According to this prediction an increase of 46% by 2005 is expected in the

number of oil filter units generated for recycling.

In all 50 states and Puerto Rico disposal of motor oil on or in the ground is illegal.
Used oil filters are classified by the EPA as a non-hazardous material if they are not
terne plate (coated with a mixture of tin and lead). As a result all commercially available

8
“State Motor Vehicle Registration 1999 Table MV-1, ”
http://wwwcf.fhwa.dot.gov/ohim/hs99/tables/mv1.pdf, 10/25/2001
9
Brent Hazelett, ”Private Communications,” Oil Filter Manufacturers Council, September 25, 2001.
10
“Recycle Rate for Used Oil Filters.” http://www.filtercouncil.org/news/May2000.html, (Filter
Manufacturers Council, FMC PR 01-00, May 4, 2000).
11
Brent Hazelett, ”Private Communications,” Oil Filter Manufacturers Council, September 25, 2001.

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AISI Contract TRP-9
Project No. 0041
A Feasibility Study for Recycling Used Automotive Oil Filters in a Blast Furnace

oil filters are now provided with a galvanized or tinplate coating. Depending on state
laws, a “do it yourselfer” or oil change facility can dispose of properly drained used oil
filters in a landfill. Future improvements in oil filter recycling rates may be dependent on
eliminating landfills as a place of oil filter disposal and economic incentives for recycling
oil filters.

3.2 Geographic Distribution of Used Oil Filters

Wherever there are internal combustion engines, there are used oil filters. The
U.S. Department of Transportation compiles statistics on motor vehicle registrations by
state including Puerto Rico. By using the assumption of two oil filter changes per year
as was previously discussed and a 50 % recycling rate, one can estimate the number of
recyclable oil filters generated yearly in each state as shown in Appendix 1.

Crushing and separation of non-metallic elements reduces the average weight of

a used oil filter from 10 oz to 8.81 oz. Based on 2 oil filter changes per year,
222,564,582 registered motor vehicles with an average steel weight in an oil filter of 8.81
oz there would be a maximum of 122,550 tons of steel available for blast furnace
melting.

3.3 Filter Composition

3.3.1 Gross Filter Weights

New oil filter weights vary considerably depending on the size of the filter. Listed
below are some designations and gross weights for oil filters, Table 2. The gross weight
includes all components including steel, filter media material and rubber.

Table 2: New Oil Filter Weights

Information Source Oil Filter Designation Gross Weight (oz, g)

Oil Filter Manufacture Average Filter (estimate) 10 oz, 283 g
Council 12
ArvinMeritor 13 Small Filter 7.87 oz, 223 g
ArvinMeritor 14 Medium Filter 12.59 oz, 357 g
Delphi 15 Small Filter 8.29 oz, 235 g
Delphi 16 Large Filter 15.70 oz, 445 g
Average Gross Weight 10.89 oz, 308.6g

Since there are over 100 different types of commercially available oil filters, a
weighted average weight would involve determining both the amount sold in each
category and individual weights. For purposes of this feasibility study a simple average

12
Brent Hazelett, ”Private Communications,” Oil Filter Manufacturers Council, September 25, 2001.
13
Nishaj Attassery, “Private Communications,” 16 Oct 2001, Email Letter, ArvinMeritor
14
Ibid
15
Mike Whitman, “Private Communications,” 12 Oct 2001, Fax Memo, Delphi Corporation
16
Ibid

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AISI Contract TRP-9
Project No. 0041
A Feasibility Study for Recycling Used Automotive Oil Filters in a Blast Furnace

of the above gross weights will be used as the basis for calculation. The gross average
weight includes all oil filter components for new filters.

3.3.2 Steel Coatings

Coated steels are used in oil filters. Tin plate or galvanized steels are used for
the can, top and bottom plates and center tube.17 18Wix, Delphi, Fram and ArvinMeritor
reported using tin plate and uncoated steels in their filters.19 20 21 22A coating of 0.25 lb.
tin per base box is usually specified for oil filter applications. 23 A base box is 31360
square inches. The tin coating is always applied to both sides of a sheet for an oil filter
application. This would mean that approximately 0.125 lb tin is present every 31360
square inches of surface area. This works out to a 15 micro inch thick tin coating on
each side.

If galvanized steel is specified for an oil filter the coating weight is usually 0.10 oz
per square foot of surface area for one side. 24 This means the zinc coating thickness is
275 micro inches per side. Zinc is electrolytically applied to both sides for oil filter
applications.

The cans for oil filters are made using a drawn and iron process. Steel thickness
will be reduced around 20% during the drawing operation. Likewise the coating
thickness is reduced 20 % at the same time. The amount of thickness reduction and
associated steel elongation is highly dependent on the design of the irons and dies used
in the process. Stamped parts such as the top and bottom plates will not experience
thickness reduction.

An earlier study melted crushed oil filters in an induction furnace. 25 Reported

residual tin levels ranged from 0.026 to 0.035 wt. %. No values were reported for zinc
due to the fact that zinc will volatilize during air or vacuum melting operations. Zinc
causes problems due to re-condensation causing accumulation within the blast furnace
operation. 26

If an oil filter manufacturer uses galvanized steel for the can it is possible to
roughly estimate the weight of the zinc coating. Based on known zinc coating weights
per square foot, the weight of zinc may be determined, as shown in Appendix 4. The
information used to estimate the surface area of the can was obtained from a study of oil
filter construction and quality. 27 The estimate is based on the calculated surface area for

17
“Tin Plate,” http://www.weirton.com/products/tin/tinplate.html , 24 Sep 2001
18
“Weirzin,” http://www.weirton.com/products/galv/weirzin.html, 24 Sep 2001
19
Brent Hazellet, “Private Communications,” Oil Filter Manufacturers Council, 18 Oct 2001
20
Mike Whitman, “Private Communications,” 13 Oct 2001, Phone Message, Delphi Corporation
21
Scott Jacobs, “Private Communications,” 24 Oct 2001, Email Letter, Fram Brand, Honeywell Corp.
22
Nishaj Attassery, “Private Communications,” 16 Oct 2001, Email Letter, ArvinMeritor
23
Edward Adamczyk, “Private Communications,” Weirton Steel, Phone Message, 11 Oct 2001.
24
Ibid
25
Kent D. Peaslee, “Recycling Used Automotive Filters,” Journal of Metals, February, 1994, pg. 46
26
Harold E. McGannon, ed., The Making Shaping and Treating of Steel, (Pittsburgh: United States Steel,
1971), pg. 456
27
“Engine Oil Filter Study,” http://www.scuderiaciriani.com/rx7/oil_filter_study/, 11 Oct 2001.

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AISI Contract TRP-9
Project No. 0041
A Feasibility Study for Recycling Used Automotive Oil Filters in a Blast Furnace

both the inside and outside of the can, and the thickness reduction due to drawing and
original zinc coating weight.

Data was given for the cartridge cylinder dimensions in the study. The cartridge
is the filtration media element inside the can. Surrounding the filter media cartridge is
the can. By increasing the filter cartridge diameter and height by 10 and 20 %
respectively, the surface area of the can cylinder can be readily calculated.
Based on this calculation, an average filter using a zinc coating on the can will
contain 0.00369 lbs Zn (0.059 oz, 1.67 g). This would result in a minimum zinc content
of 0.54% in the average filter.

3.3.3 Fuels

When a filter is removed from an engine it contains oil. While there are various
methods for draining the filter prior to and after removal, some residual oil will always
remain as shown in Table 3. As measured by ArvinMeritor and Delphi, oil filters can hold
anywhere from 8 oz. (227 ml) to 22 oz (624 ml).28 29An average oil filter will contain
around 16 oz (liquid) of oil. 30 Just after removal, an improperly drained filter will contain
70 % of its original oil volume. Even after properly hot-draining a filter, studies have
shown that approximately 40% of the weight of a used filter remains due to used oil (6 to
8 ounces).31 Proper draining and crushing of used oil filters will remove up to 88 % of
the oil in a used filter. 32

Table 3: Estimates of Oil Contained in an Average Used Oil Filter

Filter Condition Oil Volume Oil Weight 33

Full 16 oz. (454 ml) 14.69 oz.
Improperly Drained 11.2 (331 ml) 10.27
Properly Hot Drained 6.4 (189 ml) 5.87
Drained and Crushed 1.9 (56 ml) 1.74

3.3.4 Used Oil Filter Components

The main parts of a disposable spin-on oil filter are the can, base plate, center
tube, top and bottom plates, springs, filter media cartridge and rubber gasket. In some
filters a dusting of Teflon is blown onto the rubber gasket. Corrosion proof TiO 2 based
paint is used to coat the outside of the filter for protection from the elements and brand
identification.

28
Nishaj Attassery, “Private Communications,” 16 Oct 2001, Email Letter, ArvinMeritor
29
Mike Whitman, “Private Communications,” 17 Oct 2001, Phone Message, Delphi Corporation
30
Brent Hazelett, ”Private Communications,” Oil Filter Manufacturers Council, September 25, 2001.
31
Ibid.
32
Kent D. Peaslee, “Recycling Used Automotive Filters,” Journal of Metals, February 1994, pg. 44.
33
Note: Lubricating Oil Specific Gravity can vary from 0.856 to 0.913. For purposes of this study a value
of 0.88 will be used. “Material Data Safety Sheet,” Havoline Motor Oil,
http://www.equivatexacomsds.com/rd/getsinglemsds.asp?ID=191113, 18 Sep 2001.

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AISI Contract TRP-9
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A Feasibility Study for Recycling Used Automotive Oil Filters in a Blast Furnace

(1) The Filter Body or Can is a container for filter parts, which is made of steel
specifically designed to withstand the normal automotive operating environment
as well as start-up pressure surges. Weirton Steel lists the use of tinplate and
galvanized sheet steel for this application. 34

(2) The Base Plate is a thick metal plate which supports the filter and provides
secure engine mounting for easy spin on installation. This is normally made from
an uncoated hot or cold rolled low carbon steel.

(3) The Center Tube provides support to the filtering media. The center tube is
usually made out of tin plate or galvanized steel and perforated with holes to
allow the passage of oil.

(4) The Top and Bottom Plates are a metal disks positioned on the top and bottom of
the filter media. The plates are used to slightly compress and keep the filtration
media in proper position. They are usually made from tin plate or galvanized
steel.

(5) Springs are used in the anti backflow valve. The combination valve assembly
includes a pressure relief (bypass) valve to assure oil flow to the engine if the
filter should plug from extended use beyond the recommended service life or
when the weather is cold and the oil is thick and flows slowly. They are normally
made from plain carbon steel.

(6) The Filter Media Cartridge is the component of the system, in which the oil is
actually filtered to remove the particulate contamination. Almost all filter media is
made out of paper with a very small percentage made from synthetic fibers.

(7) The Gasket is the resilient rubber material (nitrile rubber) that provides a positive
seal between the filter and engine mount.

3.3.5 Oil Filter Dry Material Weight Percentages

A previous study determined the component weight on a percentage basis for

light duty and heavy-duty oil filters, Table 4. 35

34
Weirton Steel Internet Site
35
Kent D. Peaslee and Darrell E. Roberts, “Characterization of used automotive oil filters for recycling,”
Resources, Conservation and Recycling 19 (1997), pg 86.

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AISI Contract TRP-9
Project No. 0041
A Feasibility Study for Recycling Used Automotive Oil Filters in a Blast Furnace

Table 4: Oil Filter Dry Component Weight Content

Oil Filter Light Duty Heavy Duty Average Weight of

Component Filter Filter Percentage for Component
all Filters For an Average
Oil Filter –
10.89 oz
Can 31 % 32% 32 % 3.48 oz
Base Plate 32 22 27 2.94
Center Tube 7 10 9 0.98
Top/Bottom 9 7 8 0.87
Plates
Springs 5 4 5 0.54
Filter Media 12 20 16 1.74
Rubber 3 2 3 0.34

By adding up the weights for the steel components one finds that the weight of
steel in an average oil filter is 8.81 oz (249.8 g).

3.4 Energy Values for Contained Oil and Filter Media

An energy value used by a major electrical provider is 133,000 Btu per gallon
for used motor oil.36 At a specific gravity of 0.88 this is approximately 18,000 Btu/lb of
used motor oil. Energy values for dry paper (filter media) typically average around
10,000 Btu/lb.37 Due to the small weights involved, energy values for the paint on the oil
filter and nitrile rubber gasket are minimal and will not be considered in this study.

3.5 Current Methods of Processing of Used Oil Filters

Used oil filters obtained by recyclers are generally crushed into pucks, shredded,
or made into scrap bales. In many scrap-processing operations, a shredder, which

includes a hammermill, both shreds and pounds the pieces into mill nuggets.38 Oil flows
out of the shredder into a collector box. A magnetic drum is used to separate the ferro-
magnetic metallic parts from the paper element and rubber gasket. The metal parts can
then be screened into 1 in, 2 in, 3 in, 4 in or larger fragments. 39 40The paper is then sold

36
Santee Cooper Electric Utility, “GOFER, Give Oil For Energy Recovery,”
http://www.scgofer.org/about.html, November 12, 2001
37
Wisconsin Energy Bureau. “Paper Pellets for Industrial Fuel,” www.wifocusonenergy.com, November
11,2001.
38
Bill Vajdek, “Private Communications,” American Resource Recovery, Ltd., Maywood, IL, November
15, 2001
39
Tammi Jones, “Private Communications,” Commercial Filter Recycling, Los Angeles, California,
October 27, 2001.
40
Gregory C. Potter, “Private Communications,” Oil Filter Recyclers, Inc. Easton, IL, November 13, 2001.

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to a waste heat generator. Apparent metallic bulk density after shredding is reported to
be about 37 lb/ ft 3.

Scrap baling is another method of processing used oil filters. Several scrap
processors use this method to supply used oil filter metallics to EAF shops. Apparent
bulk density for scrap bales was reported around 60 to 80 lb/ ft 3. Scrap bundles may be
as small as 1ft³ up to 2 ft³. This material would be too large for charging to a blast
furnace.

Another method is crushing the filters in a hydraulic press to form a “puck”. One
operator then “cooks” the pucks to drive off the remaining oil. 41 All dimensions of a filter
are reduced by about 50 % so the maximum dimension may range from 2 in up to 8 in.
Bulk density is around 40 to 45 lb/ ft 3 for this material. Another scrap dealer compresses
the filters into 45 lb, 10 in diameter cylinders with hemispherical tops.42

As an estimate, uncrushed filters may have an average cylinder size height of 4.5
in and a diameter of 3.5 inches at a weight of 10.89 oz. This gives a specific density for
an average filter of 27.2 lb/ft3. If the dry filters are put into steel barrel with an assumed
40 % void space, the apparent bulk density would be 16.3 lb/ ft3.

For charging to a blast furnace, used oil filters would need to be screened to
accommodate operators, unless size control is a part of the process. The scrap yard
processors indicated that it would be possible to give blast furnace operators a specified
size range of oil filters.

3.6 Present Disposal of Used Oil Filters

3.6.1 Recycling at Steel Plants and Foundries

An oil filter is considered recycled when the metal portion of the filter is melted by
a steel producer or iron foundry and reused for new products. 43 The US Army has done
research into the disposal of used oil filters and the Steel Recycling Institute provided the
following list, to the US Army, of primary steel or foundry companies as possible sources
for melting used oil filters:44

Bayou Steel, Baton Rouge Louisiana

Birmingham Steel, Birmingham, Alabama
Lukens Steel, Allentown, Pennsylvania
Structural Metals, Austin, Texas
US Steel, Pittsburgh, PA
Wheeling-Pittsburgh Steel, Wheeling, WV
Structural Metals, Seguin, Texas

41
Jim Nickerson, “Private Communications,” Nickro Recycling Inc., Pittsburg, TX, November 13, 2001.
42
Terry Jones, “Private Communications,” Bernell Recycling, Ranch Cucamonga, CA, November 14,
2001.
43
Brent Hazelett, “Private Communications,” Oil Filter Manufacturers Council November 9, 2001.
44
“Disposal of Terne-Plated and Non Terne-Plated Oil Filters,” http://chppm-
www.apgea.army.mil/hwmp/Factsheets/OilFilters.html, January, 2001.

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TAMCO, Ranch Cucamonga, California

U.S. Foundry & Manufacturing, Medley, FL

The 2001 recycling rate at 220,000,000 UOF’s, or 50% is in the range of 87,000
tons to 115,000 tons depending on the residual oil content of Hot Drained and Crushed
UOF’s and Hot Drained UOF’s only. These recycled UOF’s are melted in iron foundry
cupolas and electric arc furnace steelmaking plants, with a small amount, at about 2,000
tons melted in the blast furnace (see section 8.1).

3.6.2 Individual State Laws Governing Oil Filter Recycling45

Disposal of drained non terne-plated oil filters in landfills is an acceptable

disposal method in most states. However, terne plate oil filters were quickly eliminated
from commerce because of the lead contribution. Even so, some states are in the
process of revising their regulations to make landfilling of used oil filters illegal. In fact,
five states generally prohibit the non-hazardous disposal of used oil filters in landfills:
Texas, Rhode Island, Florida, California and Minnesota.

A summary of the relevant rules encompassing used oil filter disposal by state is
given in Appendix 4.

45
“Used Filter Management Regulations,” Oil Filter Manufacturers Council, http://filtercouncil.org/regs/

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4.0 Blast Furnace

4.1 Blast Furnace Geographical Distribution

As of October 21, 2001 there are 19 separate steel plants with at least one
operating blast furnace as detailed in Table 5.

Table 5: USA Blast Furnace Locations 46

Steel Company Location of Blast Furnace

Acme Steel Co. Chicago, IL
AK Steel Corp Ashland, KY
AK Steel Corp Middletown, OH
Bethlehem Steel Corp. Burns Harbor, IN
Bethlehem Steel Corp. Sparrows Point, MD
Geneva Steel Vineyard, UT
Ispat Inland East Chicago, IN
LTV Cleveland, OH
LTV East Chicago, IN
National Steel Corp. Ecorse, MI
National Steel Corp Granite City, IL
Rouge Steel Corp. Dearborn, MI
US Steel Group Braddock, PA
US Steel Group Fairfield, AL
US Steel Group Gary, IN
Republic Technologies Lorain, OH
WCI Steel Inc Warren, OH
Weirton Steel Corp. Weirton, WV
Wheeling-Pittsburgh Steel Steubenville OH
Corp.

Most of the listed steel plants have multiple blast furnaces. Due to economic
surges and declines the steel plants will “light up” or “bank” blast furnaces as needed.
For calculations purposes in this study one blast furnace is always assumed to be able
to accept used oil filters at the various steel plants.

4.2 Current Operating Practice

In North American blast furnace practice, the coke and iron ore represent about
85% of the operating costs of a net ton of hot metal (NTHM). The availability of
significant quantities of relatively low priced, imported coke results in an approximate

46
“Blast Furnace Roundup,” Iron and Steelmaker, Vol. 28, No. 8, August 2001, pp. 75-77.

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equal cost sharing between the iron ore and the balance of imported coke and domestic
coke for the operating costs of the blast furnace.

4.2.1 Fuel

The dominant fuel to the blast furnace is coke. Other fuels are also utilized to
both enhance productivity and also to reduce fuel cost. These include injection of
pulverized coal or granulated coal, and the routine practice of heavy oil or tar injection
into the hot blast at the tuyers of the blast furnace. The air blast is preheated in the blast
furnace stoves to approximately 2,000°F, to create the combustion reaction within the
raceway of the blast furnace producing heat and releasing CO and H into the burden for
chemical reduction.

The coke is added with the burden charging equipment to the top of the furnace
and performs a vital role in maintaining a good permeability of the burden to facilitate a
high volume and uniformly distributed flow of gases through the burden with a minimal
pressure drop.

Besides the fuel value in the coke, the coke also provides many necessary
mechanical and physical characteristics to facilitate the free flow of gases through the
burden and to physically support the weight of the charge.

4.2.2 Iron Ore

Iron oxide pellets provide the dominant source of iron units into the blast furnace.
Fluxed sinter, which may provide a means of recycling steel plant iron bearing wastes,
as well as steel making slag, both contribute additional iron units to the burden.

In many blast furnace operations, it is common practice to charge metallic iron

bearing scrap along with the burden into the top of the furnace. Such metallic items are
normally “B” scrap derived from processing steel making slag, compressed steel
turnings and/or borings, direct reduced iron products such as HBI and DRI.

The most likely operating candidate for consideration of used oil filters into the
blast furnace would be an operation that currently has stockhouse bins allocated to the
charging of metallic materials.

4.2.3 Metallics

The majority of the metallic output from an iron blast furnace is derived from the
charging of iron ore in both lump and pellet form. Fine iron ores, and other plant waste
iron oxides may be agglomerated in a sintering process. In making the ingredients for
the sinter plant, additional fluxing agents may be deliberately added so as to incorporate
the flux materials within the sintered iron oxide charge.

Basic oxygen steel making slag contains a sufficient quantity of metallic steel
droplets contained within the slag to make recovery worthwhile. The recovery of this
metal from steel making slag is often referred to as “B scrap”. Depending upon

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A Feasibility Study for Recycling Used Automotive Oil Filters in a Blast Furnace

operational characteristics at different plants, many blast furnaces routinely charge

metallic Fe along with the iron oxide burden. Some of the metallic Fe is in the form of
scrap metals, which have been prepared and processed so as to have high density and

free flowing characteristics for the furnace charge. The addition of metallic materials into
the blast furnace usually represents a minor portion of the charge, commonly less than
20% to 2%.

4.2.4 Fluxes

Limestone has been the traditional fluxing agent to the blast furnaces along with
gravel containing silica. In some operations, the limestone and silica are substituted by
fluxed sinter, fluxed pellets, or a portion of steel making slag components recycled to the
blast furnace.

The charging of UOF’s to the blast furnace does not appear to indicate any
change to current flux practices. This is because the UOF’s do not contain any
appreciable quantities of either acidic or basic oxides that would offset the chemical
balance of the blast furnace slag.

4.2.5 Production

The average production rate of USA blast furnaces is about 1.5 million tons per
year each. At 90% of calendar days available for production, this would average 4,570
tons per day for a typical blast furnace.

The above-mentioned “B” scrap (metallic droplets recovered from steel making
slag) is commonly utilized in a range of 40-80 lb/NTHM, or about 2% to 4% of the
metallic output. The study assumes a reasonable upper limit for the charging of UOF’s
to the blast furnace of 2%, or 40 lb/NTHM.

4.2.6 Hot Metal Chemistry

The average blast furnace would produce slag at the rate of about 4,570
NTHM/d. A typical hot metal chemistry is shown in Table 6.47

Table 6: Hot Metal Chemistry

C 4.50%
Fe 94.29%
Si 0.60%
P 0.049%
Mn 0.51%
S 0.052%

47
D. Wakelin, “The Making, Shaping, and Treating of Steel “, 11th Edition, Ironmaking Volume, p751,
AISE Steel Foundation, 1999.

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4.2.7 Slag Chemistry

The average blast furnace can be expected to produce about 1,020 t/day. Slag
would have the approximate chemistry as shown in Table 7.48

Table 7: Slag Chemistry

SiO 2 37.73%
Al2 O3 8.99%
CaO 39.73%
MgO 10.45%
MnO 0.97%
S 1.45%

The slag produced is generally at a rate of 450 lb/NTHM.

4.2.8 Gas Cleaning

The blast furnace top gas leaves the furnace at a temperature of approximately
300°F to 400°F. The gas is directed into a dust collector where in the lager particles of
dust are trapped before the gas is further directed into a high intensity wet scrubber for
removing the bulk of the particulate.

Any products of combustion and reduction reaction water will be condensed

within the venturi scrubber at a scrubbing water temperature of approximately 80°F.

4.2.9 Waste Water Cleaning

The major use of contact process water is in the scrubber system of the venturi
scrubber. Approximately 3,200 gal/NTHM of water is re-circulated in the process. This
water is directed first to a thickener, with 96% of water re-circulated back to the process
after passing through a cooling tower or heat exchanger. Effluent water from the
process of about 70 gal/NTHM goes to a wastewater treatment plant for processing to
meet environmental criteria for discharge.

4.3 Recycling of Used Oil Filters to the Blast Furnace

At a 100 % recycling rate, 122,500 tons of steel from used oil filters are available
for recycling and if 19 blast furnaces are available, this would mean that each steel plant
would melt 6447 tons of oil filters per year. The average annual production rate of 36
listed blast furnaces is 1.49 million tons. This average includes currently banked blast
furnaces. On this basis, an average blast furnace could expect used oil filters to
constitute less than 0.43 % of the total hot metal output depending on yield. Based on
the current 50% recycle rate, steel from used oil filters would constitute less than 0.22 %
of the annual hot metal output.

Averages can be misleading so perhaps it is better to look at a worst-case

scenario. In the Western States recycling scenario, only one steel plant has blast

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furnaces operating west of the Mississippi River. Geneva Steel located in Vineyard,
Utah has three blast furnaces but only No. 2 with an annual production rate of 1.3 million
tons is listed as currently operating as of October 21, 2001. Oil filters from Hawaii,
Alaska, Washington, Oregon, California (California has 12 % of the total registered
motor vehicles in the USA), Idaho, Nevada, Arizona, Montana, Wyoming, Colorado and
New Mexico could be shipped to Geneva Steel. This would be a total of 86,739,696
units or 19.5 % of the total used filters generated in the USA each year at a 100 %
recycling rate. The gross weight of the filters would be 27,106 tons while the steel
content would be 23,881 tons. The steel charge weight of used oil filters would
constitute less than 1.84 % of the annual hot metal output. At a recycling rate of 50 %
the steel content of used oil filters would make up less than 0.92 % of the annual hot
metal output.

In Table 8, the charging weights and percentages of the itemized oil filter
components are calculated for an even distribution to 19 blast furnaces. A skewed
distribution-charging pattern of oil filters obtained from the Western States to only one
blast furnace is used as a worst-case scenario. Table 8 is based on a 50 % recycling
rate using current rates of oil filter generation.

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A Feasibility Study for Recycling Used Automotive Oil Filters in a Blast Furnace

Table 8: Charging Weights and Percentages of Used Average Oil Filter Components at a 50 %
Recycling Rate Based on Current Oil Filter Generation Data

Oil Filter Estimated Annual Annual Annual Annual

Component Unit Weight Charging Charging Charging Charging
per Filter Weight for 19 Percentage for Weight for Percentage for
Blast Furnaces 19 Blast Western States Western States
(222,564,582 Furnaces at an Scenario Scenario, One
oil filters average 1.49 (43,369,848 oil Blast Furnace
recycled) million tons filters at 1.3 million
apiece recycled) tons
(ton) (%) (ton) (%)
(oz) (weight)
Can 3.48 24204 0.0855 4716 0.3628
Base Plate 2.94 20448 0.0722 3985 0.3065
Center Tube 0.98 6816 0.0241 1328 0.1022
Top/Bottom 0.87 6051 0.0214 1179 0.0907
Plates
Springs 0.54 3756 0.0133 732 0.0563
Total Steel 8.81 61275 0.2164 11940 0.9185
Components
Tin Content if 0.03 209 0.0007 41 0.0031
Present48
Minimum Zinc 0.059 410 0.0014 80 0.0062
Content if
Present
Filter Media 1.74 12102 0.0427 2358 0.1814
Rubber 0.34 2365 0.0084 461 0.0354
Assembled Filter 10.89 75742 0.2675 14759 1.1353
Oil-Full 14.69 102157 0.3609 19907 1.5313
Oil -Improperly 10.27 71443 0.2524 13922 1.0709
Drained
Oil-Properly Hot 5.87 40841 0.1443 7958 0.6122
Drained
Oil-Drained and 1.74 12130 0.0428 2364 0.1818
Crushed

Table 9 utilizes a predicted 70 % recycling rate based on a compounded 1 %

annual increase in new oil filter sales and a 5% yearly increase in the recycling rate
between 2001 to the end of 2005.

48
Assumed 0.030 % Sn in melted steel components, which exhibited a 76 % metallic yield.

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AISI Contract TRP-9
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A Feasibility Study for Recycling Used Automotive Oil Filters in a Blast Furnace
Table 9: Charging Weights and Percentages of Used Average Oil Filter Components at a 70 %
Recycling Rate Based on Future Growth

Oil Filter Estimated Unit Annual Annual Annual Annual

Component Weight per Charging Charging Charging Charging
Filter Weight for 19 Percentage for Weight for Percentage for
Blast Furnaces 19 Blast Western States Western States
(320,506,035 Furnaces at an Scenario Scenario, One
oil filters average 1.49 (63,183,173 oil Blast Furnace
recycled) million tons filters at 1.3 million
apiece recycled) tons
(ton) (%) (ton) (%)
(oz) (weight)
Can 3.48 34855 0.1231 6871 0.5286
Base Plate 2.94 29446 0.1040 5805 0.4465
Center Tube 0.98 9815 0.0347 1935 0.1488
Top/Bottom 0.87 8714 0.0308 1718 0.1321
Plates
Springs 0.54 5409 0.0191 1066 0.0820
Total Steel 8.81 88239 0.3117 17395 1.3381
Components
Tin Content if 0.03 300 0.0011 59 0.0046
Present49
Minimum Zinc 0.059 591 0.0021 116 0.0090
Content if
Present
Filter Media 1.74 17428 0.0616 3436 0.2643
Rubber 0.34 3405 0.0120 671 0.0516
Assembled 10.89 109072 0.3853 21502 1.6540
Filter
Oil-Full 14.69 147112 0.5196 29001 2.2309
Oil-Improperly 10.27 102882 0.3634 20282 1.5601
Drained
Oil-Properly 5.87 58813 0.2077 11594 0.8919
Hot Drained
Oil-Drained 1.74 17468 0.0617 3443 0.2649
and Crushed

The writers recognize that it is not cost effective to consider shipping oil filters
from remote distances to a blast furnace, unless economic incentives are provided to
facilitate overcoming the transportation cost disadvantage. The major advantage for
blast furnace operators using UOF’s would be the low cost of quality iron units.

A further review of geographic availability of UOF’s has been calculated for an

Indiana/Chicago blast furnace and a Pittsburgh/Youngstown regional blast furnace. For
the Indiana/Chicago region, the availability of UOF’s from Iowa, Illinois, Indiana,
Michigan, and Wisconsin would equal 31.2 million UOF’s. The yield calculation of steel
at this collection rate would equal 12,300 tons, which divided by an average blast
furnace size of 1.5 Mtpy would equal 0.82% of the charge, or 16 lbs UOF/NTHM. The
Indiana/Chicago region is the AISI designation for steel plants in that area.

49
Assumed 0.030 % Sn in melted steel components, which exhibited a 76 % metallic yield.

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In a similar fashion, a consideration for states adjoining a Pittsburgh/Youngstown

regional blast furnace would include Connecticut, Ohio, Delaware, Maryland, New York,
New Jersey, and Pennsylvania; for a total of 43.5 million UOF’s. The calculation again
would indicate a total of 17,100 tons of UOF’s for an average 1.5 Mtpy blast furnace.
This would be a charging rate of 1.1% of the burden or 23 lb UOF/NTHM.

4.3.1 Material Handling and Storage

The typical blast furnace requires approximately 2 tons of solid charged materials
for each net ton of hot metal (NTHM) produced. A nominal blast furnace operation will
handle 9,000 t/day of bulk materials.

The blast furnace raw materials are normally delivered to the site in railroad cars
which are then unloaded either directly into material bins by bottom discharge, or
through a series of conveyor belt transfer into the blast furnace stockhouse bins.

The potential recycling of used automotive filters into the blast furnace will
require that the UOF’s be compatible with the overall bulk material handling system.
This includes factors such as free flowing through gates and bins, sizing compatible with
bin flow and gate control devices, screens, and sufficient density to avoid being removed
from the top of the furnace by the velocity of the top gases.

A major consideration is the degree to which oil may be discharged from used oil
filters while being stored in bins prior to entering the furnace. Any oil that may leak from
the filters into the bin poses a potential problem of dripping from the bottom of the bins
(which are only designed to contain solids, not liquids) and may find its way into the
drainage system beneath the stockhouse. This would create additional problems of
wastewater treatment to remove any contained used motor oil from the drainage
collection system.

Communications between buyers and suppliers of UOF’s in the supply chain

should be able to properly address any concerns over freely draining oil.

4.3.2 Size Requirements

The blast furnace material handling systems can accommodate maximum

particle sizes up to about 6 in x 6 in. However, the actual size of materials charged must
be carefully considered with respect to the sizing of other materials on the burden. This
sizing requirement is essential to maintain good burden permeability for the free flow of
process gasses through the burden. Discussions with blast furnace operators have
indicated that the preferred maximum size for scrap materials would be represented by
approximately 2 in x 3 in or the pressed form of scrap known as “hockey puck” of about
3 in x 4 in diameter.

UOF’s, which have been properly drained, still contain about 40% by weight
motor oil. Additionally the low bulk density at about 16.3 lb/ft3 would occupy excessive
volume in the skip-charging car to the furnace. Excess oil leaking from the filters would
cause significant oil contamination problems in the material handling system.

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The properly drained and crushed UOF’s would represent the least cost
processing for recycling to the blast furnace, although it still contains approximately 13%
oil in the filter media. Further observation will be required to see whether or not such
crushed and drained UOF’s would continue to leak amounts of oil that would considered
excessive by the blast furnace operator.

UOF’s, which have been shredded and the non-metallic materials removed,
would have oil content of less than 2% (mainly surface adhering oil) but would be too low
in density to remain within the furnace due to the high top gas velocity. Additional
compressing of shredded oil filter metallics would be required to achieve the density
necessary for blast furnace operations, although this entails additional processing costs.

4.3.3 Effect on Blast Furnace Process

As previously discussed, due to regional availability and materials blending

requirements, it is expected that approximately 2% maximum of the burden (40
lb/NTHM) would be the most likely rate to be considered. Some blast furnace operators
routinely charge as much as 200 lb/ton of high quality iron units in the form of HBI (Hot
Briquetted Iron). The actual charging rate for UOF’s would need to be arrived at in
discussions with potential operators of the blast furnace.

4.3.3.1 The Chemistry of Motor Oil in the Blast Furnace

This feasibility study for recycling used oil filters in the iron blast furnace was
based upon two main factors: the recovery of iron units from the steel container, and the
potential recovery of energy from the contained motor oil. The only fuel routinely added
to the top of a blast furnace is coke. Coke, as a result of the pyrolysis of coal in coke
oven plants, does not have any appreciable remaining volatility. Other fuels used in the
blast furnace include tar, fuel oil, granulated and pulverized coal, and natural gas: all of
which are injected along with the hot blast through the tuyeres.

No references could be found regarding previous charging of oil or other

hydrocarbons into the top of an iron blast furnace. The writers have constructed a
schematic representation of the blast furnace indicating probable time, temperature and
gas composition relationships based upon their own calculations and some references in
the literature as shown in Figure 2. 50 51

Also shown in Figure 2, the box shape, which represents a UOF, entering the top
of the furnace, undergoing pyrolysis, and ultimately melting into the liquid iron bath at
around 7 hours schematically represents the position of used oil filters in the blast
furnace as a function of time.

50
R. Jeschar, A Theoretical Model Coupling Kinetics of Ore Reduction and Coke Gasification in Cocurrent
and Countercurrent Reactors, Fifth International Iron and Steel Congress, Washington, April 6-9, p 992,
Iron & Steel Society, 1986.
51
A. Poos, and N. Pongjis, 1994 Turkdogan Symposium Proceedings, Application of Process Models for
the design of an Optimized Blast Furnace Process, p 45, Iron & Steel Society, 1994.

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400°F (200°C)
0 Hours
750°F (400°C)
1 Hours
1110°F (600°C)

2 Hours
1470°F (800°C)
70 ft 3 Hours
1560°F (850°C)
4 Hours
1650°F (900°C)

5 Hours
1830°F (1000°C)
6 Hours

2190°F (1200°C)
7 Hours
30 ft
2820°F
Tuyere (1550°C)
8 Hours

Tap Hole

= Used Oil Filter

Item 0 Hr 1 Hr 2 Hr 3 Hr 4 Hr 5 Hr 6 Hr 7 Hr 8 Hr
Temp°F 400 750 1110 1470 1560 1650 1830 2190 2820
CO % 24 24 30 32.2 34 41.2 43.6 39.6 40
CO2% 21 21 15 12.9 11.2 4.1 1.8 .4 0
H2% 2.5 2.5 2.5 2.4 2.3 2.2 2.1 2 2
N2% 52.5 52.5 52.5 52.5 52.5 52.5 52.5 58 58
Total 100 100 100 100 100 100 100 100 100

CO/CO 2 1.0 1.0 2.0 2.5 3 10 25 90 100

PSIG 12 15.1 18.2 21.3 24.5 27.6 30.7 33.9 37

Figure 2: Schematic representation of blast furnace time and temperature relationships,

approximate.

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A Feasibility Study for Recycling Used Automotive Oil Filters in a Blast Furnace

4.3.3.1.1 Composition and Properties of Motor Oil

Fresh Motor Oils typically contain C18 to C32 paraffinic, napthenic and aromatic
hydrocarbons with boiling points starting around 620 °F. 52 The ingredients of three
different brands of motor oil are given in Table 10.

53
Table 10: Ingredients of Fresh Motor Oil

Brand Weight % Range Ingredients

Havoline Motor 75-94.99 Hydro treated heavy paraffinic distillate
Oil 3-8.99 Solvent refined hydro treated middle distillate
10W-30 <1 Proprietary Additives
Quaker State HD <90 Hydro treated heavy paraffinic distillate
SAE Motor Oil <90 Solvent-dewaxed heavy paraffinic distillate
All Grades 10-20 Detergent/Inhibitor system
<1 Pour point depressant
Pennzoil Multi- 75-80 Base Lubricating Oils
Grade Motor Oil 5-15 Detergent/Inhibitor system
All Grades 5-15 Viscosity index improver
<1 Pour point depressant
<1 Antifoam Additive

Table 10 shows that fresh motor oil consists of primarily paraffins, which are non-
cyclic, saturated hydrocarbons. The effects of additives were not considered in this
study since they make up a small percentage of the oil.

An analysis of the composition of used motor oil is shown in Table 11. Used Motor Oils
contain heavy polycyclic aromatic hydrocarbons (PAHs), which are aromatics with two or
more rings. The structure of some of the PAHs is shown in Appendix 7.

Some PAHs are known carcinogens although for many others the effects are not
determined. Shown in Table 12, is the concentration of various PAHs found in a sample
of motor oil. The total PAH concentration in this sample is low, 0.17%, and most of the
PAHs have high boiling points, and so will remain in the furnace until they have broken
down. Table 13 shows the metal content of used oil, and Table 14 shows the nitrogen
and sulfur content.

The chemistry of used motor oil is highly variable. To assist the reader in this
regard, Table 15: Compositions of Used Oil and Other Fuels, has been partially
reproduced to illustrate a sampling of Virgin Lube, Used Gasoline Engine Oil, and Used
Diesel Engine Oil.

52
Robert A. Meyers. Environmental Analysis and Remediation, v. 6. John Wiley & Sons, New York,
1998. p. 3669
53
Internet

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A Feasibility Study for Recycling Used Automotive Oil Filters in a Blast Furnace

The time of acquisition of used motor oil samples for chemical analysis that is
referenced in a later section is not known. Although the early references to toxicology of
used motor oil make an inferred relationship to studies involving fresh water trout
species and PAH’s compounds (polycyclic aromatic hydrocarbons), the very high lead
content may also be a toxicity factor. This is discussed in section 4.3.3.1.1, composition
of properties in motor oil.

The lead content shown in Table 15 at 47.2 ppm to 57 ppm is markedly lower
than that shown in

Table 13 at 18500 ppm (1.85%). A possible explanation may be associated with

the phase out of leaded gasoline for non-leaded gasoline and its effect on used motor oil
samples for chemical analysis before this transition.

54
Table 11: Hydrocarbon Group Analysis of used motor oil .
Hydrocarbon Group Weight %
Saturates 76.6-86.3
Aromatics 4.1-12.9
Polars 0.8-3.8
Asphaltenes 0
Volatiles 3.2

55
Irwin, Roy J. et al. Environmental Contaminants Encyclopedia, Used Motor Oil Entry. National Park
Service, 1997. http://nature.nps.gov/toxic/oilused.pdf.

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54
Table 12: Concentrations of PAHs found in one sample of motor oil

Compound Conc. (ppm)

Low molecular weight PAHS
- Naphthalene 52.0
- Acenapthylene 1.5
- Acenapthene 3.7
- Fluorene 67.0
- Phenanthrene 200.0
- Anthracene 22.0
High Molecular Weight PAHs
- Fluoranthene 55.0
- Pyrene 120.0
- Benz(a)anthracene 38.0
- Chrysene 45.0
- Benzofluoranthenes 46.0
- Benzo(e)pyrene 32.0
- Benzo(a)pyrene 15.0
- Perylene 1.1
- Indo(1,2,3-cd)pyrene 14.0
- Dibenz(ah)anthracene 1.5
- Benzo(ghi)perylene 72.0
Alkylated PAHs
- C-1 naphthalene 31.0
- C-2 naphthalene 60.0
- C-3 naphthalene 80.0
- C-4 naphthalene 52.0
- C-1 phenanthrene 300.0
- C-2 phenanthrene 300.0
- C-3 phenanthrene 140.0
- C-4 phenanthrene 35.0
Total PAH concentration 1783

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54
Table 13: Metal Content of Used Oil

Component Conc. (ppm)

Aluminum 15
Copper 18
Iron 220
Lead 18500
Silicon 17
Antimony 6
Sodium 59
Calcium 688
Barium 177
Zinc 1360
Magnesium 410

54
Table 14: Non-Metal Inorganic Content of Used Oil

Component Conc. (wt %)

Nitrogen 0.09
Sulfur 0.29-0.54

Table 15: Compositions of Used Oil and Other Fuels 55

Component Used Gasoline Used Diesel Virgin Lubeª

Engine Oilª Engine Oilª
Ash, wt% 0.54 0.46 0.14
Sulfur, wt% 0.36 0.25 0.36
Nitrogen, wt% 0.04 0.02 0.02
Barium, ppm 2.7 3.4 <1.0
Beryllium, ppm <0.02 <0.02 <0.02
Cadmium, ppm 1.5 2.4 <0.25
Chromium, ppm 3.2 3.9 <2
Lead, ppm 47.2 57 <20
Nickel, ppm 1 1.8 <1.2
Zinc, ppm 1,162 1,114 1,210
Halogens, ppm 350 234 <200

55
D.J. Graziano and E.J. Daniels, Assessment of Opportunities to Increase the Recovery and Recycling
Rates of Waste Oils. Energy Systems Division Argonne National Laboratory, Contract W-31-109-Eng-38,
for the United States Department of Energy, pg 54, August 1995.

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4.3.3.1.2 Distillation of Oil in the Blast Furnace

With the use of the thermal profile and the pressure profile given in Figure 2,
flash calculations for the distillation of the oil, as in Appendix 4, were performed to
calculate the vapor-liquid equilibrium properties of the oil in each temperature section.

The NIST Chemistry Web Book 56 provided Antoine Equation 57 parameters for
calculating saturated pressure. Table 16 lists the Antoine equation parameters available
for various paraffins and pyrene. Since Antoine parameters were only available for the
paraffins listed, the flash calculations were done using only these components plus
pyrene since it is a PAH that is reported to have a higher concentration. The calculation
using only these components should give an adequate understanding since the boiling
points should be similar.

Table 16: Antoine parameters for various hydrocarbons (Appendix 4: eq.2)

Species A B C
C18 H38 4.332 2068.96 -111.927
C21 H44 5.92073 3571.218 -19.953
C23 H48 6.557 4200.069 1.864
C26 H54 6.5763 4224.36 -30.387
C27 H56 6.256 3654.27 -86.045
Pyrene 2.68713 1086.824 -262.849

Flash Calculations show that at 0 hours and 400°F, all of the oil will be in liquid
form, at 1 hour and 750°F, 99.8% of the oil will be vaporized and 0.2% of the oil will be in
liquid form and go down to the next stage during hour 2. At that point the remaining oil
will then be vaporized. Therefore the oil will remain in the 1-hour stage until it has
decomposed into products with boiling points below 400°F, which would include
hydrocarbons with 11 or less Carbons, or it will react to form products that act as
petroleum coke. The products of these reactions will be discussed further in the next
section.

4.3.3.1.3 Reactions of Oil in the Blast Furnace

When petroleum fractions are heated to temperatures over 660°F, thermal

decomposition will proceed at significant rates.58 Paraffins have the least thermal
stability and very severe thermal cracking of heavy hydrocarbons can result in
condensation reactions of ring compounds, yielding a high fraction of coke. 58 Thermal
decomposition, which is also referred to as cracking or pyrolysis, involves free radical
reactions consisting of the following steps: (1) Initiation - the introduction of free radicals

56
“NIST Chemistry Web Book”,
“http://WebBook.nist.gov/cgi/cbook.cgi?ID=C593453&Units=SI&Mask=4.”.
57
J.M. Smith and H.C. Van Ness. “Introduction to Chemical Engineering Thermodynamics”. McGraw-
Hill, Inc. New York, 1987.
58
James Speight. The Chemistry and Technology of Petroleum 3 rd ed. Marcel Dekker, Inc., New York,
1999.

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into the system which typically involves the cleavage of a C-C bond in heavy paraffins.
(2)Propagation – a series of reactions that converts reactants to products while leaving
the radical concentrations unchanged. (3) Termination – the combination of radicals to
give stable products.59

The primary reactions that occur during free radical reactions of hydrocarbons
are decomposition reactions such as: 58

CH 3 − CH 2 − CH 2 − CH 3 
→ CH 3 − CH = CH 2 + CH4 .

The secondary reactions are those where the primary product form higher
molecular weight products, i.e.:58

CH 2 = CH 2 + CH2 = CH 2 
→ CH 3 CH 2 CH = CH 2 ,
or

R - CH = CH 2 + R ′ − CH = CH 2 
→ Cracked Residuum + coke + other products .

Table 17 lists experimental results of pyrolysis of partially hydrogenated gas oil,

which is the closest available comparison to used motor oil as far as molecular weight,
composition and boiling point range, although the motor oils would contain a higher
percentage of paraffins.

Table 17: Results of the pyrolysis of partially hydrogenated gas oil with a temperature profile
60
between 1292-1526°F

Reaction Products Wt % related

to feed
Cracked gas ≤ C4 62
Pyrolysis gasoline (C 5 to Tboil < 392 °F) 27.7
Pyrolysis Fuel Oil (Tboil ≥ 392 °F) 9.0
Coke and Tar 0.9

Figure 3 outlines the results given in Table 17, and shows the final destination of
the products. About 90% of the products would have boiling points below 400°F and
would therefore leave the top of the furnace. Of this, about 28 wt % of the feed (gasoline
fraction) will condense in the scrubber at 80°F and 62 % (Gas fraction) is not
condensable at that temperature and will be used as fuel gas. The gasoline fraction
contains 9 wt % (of the feed) oil as benzene and toluene. Benzene is considered toxic in
exposure levels above 25 ppm for an 8 hour shift, and toluene above 300 ppm.
Benzene has been identified as a carcinogen. The remaining products consist of 9 wt %
(of the feed) of fuel oil with tboil> 392°F and 0.9 wt% of coke. The fuel oil should undergo

59
Lyle F. Albright, et al. Pyrolysis: Theory and Industrial Practice. Academic Press, New York, 1983.
Iron can act as a catalyst to produce surface carbon.6
60
Nowak et al. Chem Tech. v. 31 p. 496-500, 1979.

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further cracking to form more volatile products and coke. The deposit of coke may
contain high boiling point PAHs in the form of tars, and ordered or disordered carbon,
formed in the gas phase or on a surface. Any such PAH in the coke will be destroyed in
the high temperature zones of the process. Iron can act as a catalyst to produce surface
carbon.

Cracked gas ≤ C4
(62.1 %)
+ Gasoline
Gasoline (C 5 to Tboil < 392 °F) Fuel Gas == 30.3%
67.9%
Condensed in scrubber
(27.7% )
(80 °F)
Oil
charged
into BF Pyrolysis
at top
100%
Fuel Gas Gasoline
5.8% 2.6%

Fuel Oil (Tboil ≥ 392 °F) Further Pyrolysis into lighter

(9.3%) hydrocarbons and coke
+

Coke
+ Coke 1.8%
(0.9%)
0.9% Coke

Figure 3: Flow diagram outlining the pyrolysis of Gas Oil shown in Table 15

Figure 4 outlines the production of coke in the pyrolysis of hydrocarbons. The

hydrocarbons are first broken down into lighter hydrocarbons and heavier hydrocarbons.
The lighter hydrocarbons can be further decomposed to gases. The heavier
hydrocarbons can undergo polymerization to form high molecular weight hydrocarbons
which then react to form carbon and tar. Many of the PAHs should form coke 61.

During the pyrolysis reactions, the 9.3% of pyrolyized fuel oil in the burden at 1 hour
will undergo further pyrolysis into lighter hydrocarbons and coke, approximating a
distribution of 5.8% as fuel gas, 2.6% as gasoline, and 0.9% as additional coke.

The calculations indicate that for 100% of the weight of used oil charged into the top
of the blast furnace into the burden, all of the oil will remain as a liquid until reaching the
1-hour zone of about 750°F. Within the burden at this temperature zone, about 90% of
the charged oil will vaporize, undergo pyrolysis and exit the blast furnace with the top

61
G.F. Froment, Coke formation in the thermal cracking of hydrocarbons. Reviews in Chemical
Engineering. V. 6, n4, p293-328, 1990.

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gas. The overall result of charging oil into the top of the blast furnace is decomposed as
follows:
Oil Input =100.0%
Fuel Gas = 67.9%
Condensate (Gasoline) = 30.3%
Coke = 1.8%

The heavier hydrocarbons oils with 12 or more carbons, about 10%, will undergo
progressive pyrolysis in the lower and higher temperature zones of the burden until
lighter hydrocarbons leave the top of the burden and the heavier hydrocarbons are
converted to coke, at about 2% of the oil charge weight.

f.r.r. f.r.r.
Initial hydrocarbon lighter hydrocarbons products (gases)

+
heavier hydrocarbons

cyclized intermediates

f.r.r. polymerization

high molecular weight condensation tars

hydrocarbons
(-) surface (+) surface

soot surface carbon

Figure 4: Flow Diagram for the production of coke. Any hydrocarbon can yield catalytic carbon in
59
the presence of some materials. (f.r.r. = Free-radical reactions)

4.3.3.2 Fuel Value Recovered

Table 18 represents calculated values for the composition of the products of

pyrolysis of used motor oil in the blast furnace. The weight distribution of the
components of the major products is an approximation used by the writers based on the
best available information and calculations. Although the actual weight percentages in

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the final products of the pyrolysis reaction are very small, it was felt that it might be
useful to future work, or analysis of greater concentrations of oil input to the blast
furnace to provide a comprehensive review of the pyrolysis products.

The calculations in Table 18 were utilized to obtain an average molecular weight for
fuel gas and the “gasoline” fraction. For the case illustrated at a 2% charge of UOF’s to
the burden, the fuel gas weighing 7 lb would occupy 71 scf at a molecular weight of 35.7
lb. In a similar calculation, the gasoline fraction that will condense at a weight of 3 lb
would occupy a volume of 10.5 scf in the gas phase at a molecular weight of 102.8 lb.
These values are shown in the material balance of Figure 6.

Table 18: Calculated results of the composition of the products of pyrolysis of used motor oil to
obtain average molecular weights

Products Wt % Mol. Wt. Product Fraction Mol. Wt. Fraction

Propylene 15.3 42.1 0.225 9.5

Ethylene 27.4 28.1 0.404 11.4
Butadiene 4.4 54.1 0.065 3.5
C1 to C4 (avg.) 20.8 37.0 0.306 11.3
Fuel Gas 67.9
Avg. Mol. Wt. 35.7

Benzene 4.4 78.1 0.145 11.3

Toluene 4.4 92.1 0.145 13.3
C5 to C10 (avg.) 21.5 110.2 0.710 78.2
Gasoline 30.3
Avg. Mol. Wt. 102.8

Coke
Carbon 1.8 12 1.00 12
Input Motor Oil 100.0

As a simplifying assumption, the authors have chosen to equate the heating

value of the fuel gas equivalent to methane (CH4) with a heating value of 1,000 Btu/Ft3.

4.3.3.3 Top Gas Chemistry

Because of the very small contribution to the total gas volume made by the fuel
gas, which is equivalent to 1.2 weight% of the total top gas volume, it is not felt to be
practical to develop a detailed chemistry for the overall top gas.

4.3.3.4 Metallics Recovered

Metallics (Fe) will be recovered at a rate of nearly 100% of the Fe in the charged
materials. Therefore the metallics recovered from UOF’s would be equal to the weight
fraction of Fe in the weight of the UOF. For the drained and crushed UOF in the
illustrated case, a value of 76% of the weight of the UOF is indicated.1

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4.3.3.5 Slag Chemistry

There is no quantifiable change in slag chemistry as there are virtually no oxide

minerals present in the UOF’s.

4.3.3.6 Hot Metal Chemistry

As mention in section 3.3.2 Steel Coatings, coated steels are used in oil filters.
Steel provided to the manufacturer of oil filters is approximated by 50% uncoated, 25%
galvanized (zinc coated) and 25% tin plate. An earlier study referenced in this same
section showed an analysis on melting a charge of 100% UOF’s resulting in a residual
tin level from 0.026 to 0.035 weight%. However, it is not presently known if this
represents a mixture of both coated and uncoated filters.

Therefore a 40 lb UOF/t burden charge at a 76% metallic yield would result in

34.4 lb Fe/NTHM. This 30.4 lb of Fe derived from the UOF would contain 0.008 lb/tin
(Sn). This gives a calculated increase to the tin content of the hot metal of 0.04 ppm, an
insignificant amount. To summarize, the effect of adding UOF’s to the BF burden at a
charging rate of 40 lb UOF/NTHM results in no significant change to hot metal chemistry.

4.3.3.7 Burden Permeability

The crushed and drained oil filter appears to have dimensions approximating 3 in
to 4 in diameter by about 1 in high as observed in Peaslee.1 An observation of Figure 3
in the previously referenced work would indicate that a crushed and drained filter should
be reasonably free flowing in bulk, and of a large enough particle size so as not to
provide restrictions to gas flow in the burden or subsequent decrease in burden
permeability. This comment is the opinion of the authors and will need verification by
blast furnace operators and/or trials.

4.3.4 Process Flow Diagram

In order to help clarify and identify to the reader the overall effect of the charging
of UOF’s to the iron blast furnace, two process flow diagrams have been constructed.
The first, Figure 5 shows the blast furnace material balance for a conventional practice.

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BURDEN TOP GAS

A C

SLAG
D

BLAST
B

E
HOT METAL

A lb C scf lb
Iron bearing burden Dry top gas 53,718 4376
Pellets 65% Fe 1828 (23.4% CO, 21.2% CO2, 2.5% H2, bal.N2)
Fluxed sinter 51% Fe 1368
Steelmaking slag 28% Fe 52 Moisture 3521 168

Fuel Coke 920 Flue dust and sludge 87

D lb
Moisture Moisture 132 Slag 546
B scf lb (38% SiO2, 9% Al2O3, 42% CaO, 10% MgO)
Blast Dry air 34,584 2655 (1.3% S)
Enriching oxygen 1227 104 E lb
Moisture 1028 49 Hot metal 2000.0
(4.5% C, 0.48% Si, 0.59% Mn, 0.029% S)
Fuel Tar 6.6 gal 69 (0.060% P)

Figure 5: Blast furnace material balance for a conventional practice 62

A revised material balance for the blast furnace has been calculated from the
information shown in Figure 5, for the addition of a 2% charge of UOF’s added to the
burden. A comparison of the material balance shows a very small effect on the overall
material balance from the addition of this 2% UOF charge.

62
From: D. H. Wakelin, Blast Furnace Material and Energy Balance. The Making, Shaping and Treating of
Steel, 11th Edition, Ironmaking Volume, p734, sec 10.3.5, 1999.

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BURDEN TOP GAS

A C

SLAG
D

BLAST
B

E
HOT METAL

A lb C scf lb
Iron bearing burden Dry top gas 53,546 4362
Pellets 65% Fe 1782 (23.4% CO, 21.2% CO2, 2.5% H2, bal.N2)
Fluxed sinter 51% Fe 1368 Fuel Gas 71 7
Steelmaking slag 28% Fe 52 Moisture 3521 168
Used Oil Filters* 76% Fe 40 Gasoline Fraction 10.5 3
Fuel Coke 919 Flue dust and sludge 87
*UOF (Oil, paper) 24% D lb
Moisture Moisture 132 Slag 543
B scf lb (38% SiO2, 9% Al2O3, 42% CaO, 10% MgO)
Blast Dry air 34,584 2655 (1.3% S)
Enriching oxygen 1227 104 E lb
Moisture 1028 49 Hot metal 2000
(4.5% C, 0.48% Si, 0.59% Mn, 0.029% S)
Fuel Tar 6.6 gal 69 (0.060% P)

Figure 6: Blast furnace material balance for a 2% recycle rate of used oil filters in the burden63

4.3.5 Effect on Gas Cleaning

Recycling of UOF’s is not expected to result in any significant complication in the

cleaning of the particulates in the blast furnace top gas. The received materials would
be as crushed and/or densified oil filters with or without internal components. As such,
these solids would not disintegrate until well below the upper surface of the burden. The

63
As calculated by the writer.

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filtered media contained within an oil filter could be an off gas problem if the filter were
not compacted within the steel container.

Any filter material entering the burden within the UOF, would be trapped until
much deeper into the burden where the temperatures would be sufficient for full
pyrolysis of the cellulose material of the filter. Both the pyrolysis of motor oil and of the
filter media would occur simultaneously. Therefore, additional particulate contamination
of the top gas stream does not appear to be a problem.

As pointed out in section 4.3.3.1, The chemistry of Motor Oil in the Blast Furnace,
98.2% of the amount of oil charged into the furnace with the UOF will leave in the top
gas in the vapor phase. The lighter hydrocarbons will remain as fuel gas equal to about
67.9% of the original charged oil weight. The other 30.3% of the somewhat higher
hydrocarbon fraction, referred to as “gasoline”, will condense in the water scrubbing
system.

Once the gasoline fraction is condensed, 14% of this fraction will be benzene and
14% toluene with the balance in the C5 to C10 range. Detailed examination of the water
treatment plant will be required to determine if additional actions need to be taken to
remove these constituents prior to discharge.

4.3.6 Effect on Blast Furnace Gas Heating Value

About 67.9 % of the oil entering the top of the furnace will undergo pyrolysis and
be converted into lighter hydrocarbons, approximating an average heating value of
methane, CH4. As such, this fuel gas would have a heating value of approximately
1,000 Btu/ft3.

Although this fuel gas, equivalent to methane, appears to be a potentially large

increase in heating value, it must be remembered that the total oil charged to the furnace
is a relatively small percentage, approximating only about 13 weight percent for each
fraction of the blast furnace burden occupied by UOF’s, i.e. approximately 13% oil from
the 2% UOF’s charged to the blast furnace the equivalent of 0.26% methane entering
the top gas stream.

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5.0 Capital Cost Considerations

The capital cost associated with charging UOF’s into the blast furnace cannot be
quantitatively expressed until a determination is made as to the weight fraction of burden
that UOF’s will occupy. As previously mentioned, the authors of this study have
subjectively indicated an approximate 2% of the burden as being a potential target figure
for charging UOF’s into the blast furnace. The following capital cost considerations will
be based upon this approximation, but once more definitive charging percentages can
be determined, more accurate cost effects could be developed.

5.1 Storage

The majority of blast furnace burden materials are delivered to the stockhouse by
railroad. These materials are delivered in iron ore cars where by they may be emptied
by means of a rotary car dumper, or in bottom dump hopper cars for discharging directly
into receiving bins. Transfer cars are used to deliver additional materials to the
stockhouse.

The receipt of UOF’s into a storage location will need to accommodate some
amount of oil leakage from the material. Considerations for protected storage to avoid
contamination with rainwater by the used motor oil may be appropriate. The potential
amount of oil that may drain from previously drained and crushed UOF’s is not presently
known and will need to be evaluated to determine the criteria for an engineering solution
for the storage requirements.

The most important criteria in this regard is to keep any free draining oil from
entering sumps and drains associated with the storage facility. Communication and
cooperation between the suppliers and the buyers can be a major factor to reduce
and/or control any free draining oil.

5.2 Handling and Charging

As long as the overall size of UOF’s are below 6 in x 6 in and preferably less than
below 4 in x 6 in, and preferably in the range of 3 in x 4 in, the normal bulk material
handling system should be relatively unaffected. UOF’s in the drained and crushed form
would be reasonably free flowing in normal blast furnace materials handling systems.

5.3 Processing of Oil Filters

One case study for an originator of UOF’s is the New York City Department of
Sanitation Bureau of Motor Equipment. 64 On an annual basis the New York Department
of Sanitation diverted 50 tons of filters from disposal to recycling. The overall cost per
ton of export (UOF’s) was $100/ton. The recycling program avoided a solid disposal
cost of approximately $5,000.00, but the recycling company charged $48,024.00 for a
net program increase of $43,024.00. However it is stated that there is a reduced cost
and liability associated with hazardous waste disposal and minimizing the volume of
waste disposed.

64
Recycling Oil and Fuel Filters, www.nycwasteless.com/citysense/initiaves/dosfilters.htm, 2000.

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The above example shows that the immediate cost of recycling oil filters is
significantly higher than landfill. Due to environmental considerations, landfill of UOF’s
may not be feasible in the future.

However, the approximately $100/ton of UOF’s charged by the recycler may

contain sufficient incentive to develop a direct recycling program with a consumer of the
end product i.e. a steel mill. The fees charged by the recycling company could be a
significant means for properly preparing the UOF’s for size and residual oil to meet the
requirements of recycling in the blast furnace.

5.4 Top Gas Cleaning

Charging of UOF’s would not result in any capital costs associated with the dry
particulate cleaning of the top gas.

5.5 Waste Water Cleaning

This study has indicated that approximately 30% of the residual oil contained in the
UOF’s will be pyrolyized into a condensate that would be condensed by the scrubber
wash water at an operating temperature of 80°F. An analysis of this aspect was not
included in the scope of work for this study and may be developed in a later study, if
deemed appropriate.

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6.0 Operating Cost Considerations

Because UOF’s are not a regular part of the blast furnace burden, there is no
published market price for this material. US Steel has indicated that UOF’s are currently
delivered FOB their Gary Works at $30 per gross ton. A metallic yield of 80% would
result in low residual iron units at about $35.60 per net ton Fe. The following cost
considerations will be of a qualitative approach to indicate where additional costs and/or
benefits may be obtained and or examined in more detail in the future.

6.1 Hot Metal Production

Charging metallics to a blast furnace will significantly increase productivity. If

metallics are added, the only energy required is melting energy. Whereas, when iron
oxides are charged, the energy of chemical reduction is required to separate the iron
oxide into the metallic iron as well as the heat energy to bring the reaction products to
tapping temperature. Many blast furnace operators significantly increase the metallic
charge to one operating blast furnace when another blast furnace in the same plant must
be taken off line for repair or relining. This is also done on an intermittent basis to
balance out production requirements from a single blast furnace before starting a second
blast furnace.

A technical paper prepared by AK Steel 65 in 1994 is a useful reference as to blast

furnace productivity benefits derived from several process improvements. Although this
technical paper included a metallic charge involving hot briquetted iron, the productivity
relationship may be extrapolated to a consideration of UOF’s.

The AK Steel experience showed a relationship of an increase in the production

of the blast furnace in NTHM/day being increased by the amount of tons/day of HBI
Charged. This particular HBI material demonstrated an increased production rate Y, of
Y=0.928X +4846.6: with 4846.6 being the initial production rate in tons per day prior to
charging HBI, and X being the amount of HBI charged in tons per day. The coefficient
0.928 is approximately equal to the total Fe content of the HBI charged, of which 92% is
expected to be in the metallic form, as shown in Figure 7 of the AK Steel reference.

From the above relationship, we may assume that an increase in blast furnace
productivity may be approximated by utilization of the metallic Fe content of the charged
material on the same basis as AK’s experience with the HBI. The use of this relationship
in a calculation for crushed and drained UOF’s having a demonstrated yield of 76%
would result in a production increase for an average blast furnace producing 4,920
NTHM/day of approximately 1.4% with a charging rate of UOF’s of 2% of the burden. 66

65
D.A. Kercsmar, et al., Sustained Production in Excess of 9 Tons Per Day/100 ft 3 WV at Middletown’s No.
3 Blast Furnace, Iron & Steelmaker, p 33, July 1994.
66
K.D. Peaslee & D.E. Roberts, II, “ The Future of Used Oil Filter Recycling in Missouri: An Evaluation
of Potential Processes, Product, Quality, Recycling Locations, & Economics”, Missouri Department of
Natural Resources, p 19, February 15, 1997.

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A Feasibility Study for Recycling Used Automotive Oil Filters in a Blast Furnace

However, this production rate increase of 1.4% in NTHM/d for a 2% charge of

UOF’s may be increased or decreased depending upon the energy required for the
pyrolysis of the contained oil within the UOF.

6.2 Slag Production

Expectations are that there would be no increase or decrease in operating costs

related to slag production.

6.3 Top Gas Production

The used motor oil contained in the UOF’s will undergo a distillation such that for
each 100% of oil entering the furnace, 67.9% would exit the top gas as fuel gas and
30.3% would exit as a gasoline fraction in the vapor phase. In the demonstration case of
a 2% UOF charge to the burden, or 40 lb UOF’s/NTHM, for the case of drained and
crushed filters this would represent a 13% weight of oil or 5.2 lb/ton of motor oil that
would be released into the top gas as 3.5 lb/ton fuel gas and 1.6 lb of gasoline in the
vapor phase. The 3.5 lb/NTHM of CH4 would be equivalent to approximately 378 scf. At
a natural gas energy value of $2.50/1,000 scf, this would represent a value increase in
the fuel gas of $0.94/NTHM credit.

The C5 and higher hydrocarbons in the gasoline fraction will be condensed in the
scrubber.

6.4 Fuel Requirements

Estimations indicate that a 2% charge of UOF’s (40 lb UOF/NTHM) would

contribute about 0.72lb coke/NTHM. If one is to assume an average coke price
delivered to the skip of the blast furnace at $120/t coke, a credit of $0.043/NTHM may be
estimated as a benefit.

6.5 Flux Requirements

There is no anticipated increase or decrease in costs associated with flux and/or

slag.

6.6 Iron Yield

Iron yield is estimated to be recovered at the rate of 100% of the contained Fe in

the UOF’s charged to the blast furnace. At the example rate of 2% of the burden
charged as UOF’s (40 lb UOF/NTHM) the yield, as previously described, is estimated to
be 76%. Therefore the 40 lb UOF/NTHM would yield 30.4 lb Fe/NTHM. Because the
pricing structure for UOF’s delivered to the blast furnace is not currently known, it is not
possible to calculate an estimated benefit for the additional 30.4 lb Fe/NTHM resulting
from UOF’s charged to the blast furnace.

6.7 Gas Cleaning

There is no change to operating costs for the dry portion of the top gas cleaning
operation.

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AISI Contract TRP-9
Project No. 0041
A Feasibility Study for Recycling Used Automotive Oil Filters in a Blast Furnace

6.8 Waste Water Treatment

Some additional process water/waste water treatment costs will increase due to
the vapor fraction in the hydrocarbon range referred to as “gasoline”, C5 to C10 will
condense in the gas cleaning system within the scrubber. This will result in
hydrocarbons within the gasoline fraction to be removed from the process water and the
wastewater stream for prior to discharge.

The quantity of this gasoline fraction is estimated to be 1.6 lb/NTHM for a 40 lb

UOF/NTHM charge. This would contain 0.23 lb of benzene and 0.23 lb of toluene per
NTHM.

The cost of wastewater treatment has not been included within the scope of work for
this study. Therefore, it is not known at this time whether or not the condensate would
be removed within the normal process water/wastewater treatment plant for a modern
blast furnace, or not.

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AISI Contract TRP-9
Project No. 0041
A Feasibility Study for Recycling Used Automotive Oil Filters in a Blast Furnace

7.0 Analysis

In section 4.3 Recycling of Used Oil Filters to the Blast Furnace, calculations were
made to show the recycling capability of 19 blast furnaces in the U.S. consuming all
available filters as well as one western blast furnace consuming all filters west of the
Mississippi as an extreme hypothetical case. Under conditions that assume a future
growth of oil filter recycling and increased production of oil filters, and a 70% recycling
rate in the year 2005 results in an average charge of only 0.3% of steel components
from the UOF’s recycled to the average blast furnace. This would obviously be too small
an amount for an operator to deal with, and so the calculations showed an increase
concentration going to one furnace as an example at a steel-charging rate of 1.3% to the
burden.

Another way to look at the potential for balancing UOF generation rate against BF
capacity on a regional basis may be demonstrated by the following example. In this
case, two regional markets Chicago and Pittsburgh have been selected.

In the case of the Chicago market, and assuming 100% UOF recycling from the
adjoining states of Iowa, Illinois, Indiana, Michigan, and Wisconsin, a total of 31.2 million
UOF’s at an average weight of 0.79 lb would result in 12,300 tons of UOF’s (including
the oil) for recycle to one Chicago blast furnace. This would be an equivalent charging
rate of 0.82% UOF’s to one blast furnace at a rate of 1.5 Mtpy.

If a regional market centered on Pittsburgh were considered, then UOF’s obtained

from the states of New York, Connecticut, New Jersey, Pennsylvania, Maryland,
Delaware, and Ohio, would be 43.5 million UOF’s at a 100% recycling rate. This number
of filters times 0.79 lb/UOF equals 17,100 tons UOF per year. This would represent a
charging rate of 1.1% UOF’s/NTHM.

The overall usage rate within this study encompassed an average of 2% crushed
and drained UOF’s, per NT HM. The writer’s opinion is that this may represent a
reasonable average charging rate upon which to base the calculations for this study.
Actual operations may significantly change this average charging rate to a smaller
fraction or a much greater fraction depending upon the operating philosophy. However,
operating at a rate greater than 2% UOF’s/NTHM would necessarily mean an
intermittent operation as the availability of UOF’s would be limited.

7.1 Operational Considerations

The writers have assumed that the used oil filters, having been first properly hot
drained and then subsequently crushed, would represent a reasonable, least cost supply
of UOF’s to the blast furnace. Any filter media remains within the crushed and drained
UOF, will act as a sponge to inhibit further draining of oil. Additional examination of
crushed and drained UOF’s in bulk will be required to evaluate whether or not such UOF
processing will relieve the problems of oil contamination from material handling and
storage considerations at the blast furnace storage and stockhouse.

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AISI Contract TRP-9
Project No. 0041
A Feasibility Study for Recycling Used Automotive Oil Filters in a Blast Furnace

Charging of crushed and drained UOF’s to the blast furnace at a bulk density of
50 lb/ft3 is a metallic charging practice that may be similar to other scrap charges used in
the blast furnace. In section 4.3.3.1 The Chemistry of Motor Oil in the Blast Furnace, a
detailed approach to the behavior of motor oil in entering the upper zone of the blast
furnace with the charged materials has been shown. Motor oil has a high boiling point,
such that it would remain liquid at 400°F, thereby entering the burden within the drained
and crushed UOF. During the next one to two hours as temperatures increase from
750°F to 1100°F, the motor oil would pyrolyize into lighter hydrocarbons which would
leave the burden with the top gas and heavier hydrocarbons which would undergo
further pyrolysis until becoming coke. The resulting coke from the pyrolysis of the motor
oil would represent about 2% of the weight of motor charged into the furnace. Although
some concerns have been expressed about the possibility of polycyclic aromatic
hydrocarbons (PAH’s) because of the possibility of connection to known carcinogens,
this risk appears to be exceedingly small as these heavier PAH’s would be pyrolyized in
the higher temperature zones of the furnace.

The lighter weight fractions of the motor oil input to the furnace would be
discharged from the blast furnace as fuel gas, 67.9% of the weight of motor oil charged,
and a “gasoline” fraction representing 30.3% of the weight of motor oil charged which
would condense in the wet scrubber of the off gas system. The absolute quantities of
“gasoline” condensate at a charging rate of 2% UOF’s/NTHM would be1.6 lb/NTHM.

The effect of this 1.6 lb “gasoline” fraction lb/NTHM may have on the process
water and wastewater treatment is outside of the scope of this study. If subsequent
study of this water treatment issue would indicate it to represent a significant cost item,
then the processing of UOF’s to the blast furnace would require shredding of the filters
by the processor and briquetting of the shredded material into “bricks” or “pucks”. There
are some UOF processors within the United States that do shredding of the UOF’s. This
has been commented in section 3.5 Processing.

In the event that a UOF shredding operation would be required, the resulting
metallic units recovered form this process would have no adverse affect on blast furnace
operations and, could be handled as any other metallic charged to the blast furnace.

7.2 Cost/Benefit Review

At this stage of the feasibility study, it is not possible to accurately quantify additional
costs and/or benefits to derived in a $/NTHM of hot metal produced. The best approach
at this stage is to identify, in a qualitative manner, the areas that will be expected to see
either an increase cost or a benefit to be derived from the charging of UOF’s to the blast
furnace.

Table 19, Relative Cost vs. Benefit of Charging Used Oil Filters to the Blast Furnace,
has been constructed to show these relationships, in the writer’s opinion, which may
result from the charging of UOF’s to the blast furnace.

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AISI Contract TRP-9
Project No. 0041
A Feasibility Study for Recycling Used Automotive Oil Filters in a Blast Furnace

Table 19: Relative Cost vs. Benefit of Charging Used Oil Filters to the Blast Furnace
Item Higher Cost Benefit
Storage +
Iron Ore +
Metallics +
Fluxes 0 0
Coke +
Production +
Hot Metal Analysis 0 0
Slag Production 0 0
Slag Analysis 0 0
Gas Cleaning 0 0
Water Treatment +
Fuel Value +
Maintenance ? ?

With the present knowledge base, it may be expected that additional cost may be
incurred relative to UOF storage and in water treatment resulting from the condensation
of “gasoline fraction” hydrocarbon phases in the gas cleaning scrubber water for
treatment. An unknown factor is whether or not the additional hydrocarbon vapors may
result in additional maintenance problems, and/or possible oil leakage from the UOF’s
that may require additional maintenance considerations.

On the benefit side, there exists a reduction in iron ore pellet requirements, the
potential for reduced metallics costs, an increase in the production rate and less coke
due to charging metallics, a higher fuel value in the blast furnace top gas, and an
unknown cost/benefit relationship relative to maintenance.

At this stage of the feasibility study, it appears that there is potential incentive to
determine what is required to conduct additional industrial trials for the recycling of
UOF’s to the blast furnace. To assist in this aspect, the section 8.0 Review with Blast
Furnace Operators, which follows, will serve to highlight the past experiences that have
been brought to the attention of this feasibility study by operators solicited by AISI and
the writer.

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AISI Contract TRP-9
Project No. 0041
A Feasibility Study for Recycling Used Automotive Oil Filters in a Blast Furnace

8.0 Review with Blast Furnace Operators

William Obenchain of the AISI provided the writer with blast furnace operator
contacts at Bethlehem Steel, Dofasco, Ispat Inland, USS and WCI Steel.

8.1 Past Experiences with Oily Charge Materials

During the review of this feasibility study with blast furnace personnel at US
Steel, it was learned that USS reported continuing experience in charging UOF’s into
their iron blast furnace at the Gary Works. This work has been underway for at least five
or six years. The current cost of the UOF’s is about $30 per gross ton delivered to the
Gary Works.

USS has been receiving approximately 100 tons to 200 tons of UOF’s per month.
These are delivered by dump truck at about 20 tons per load. The UOF’s are dumped
onto the scrap blending concrete pad. A front-end loader is used to distribute the UOF’s
throughout the scrap (B scrap, and other steel plant metallics) for blending.

The blended metallic charges are then loaded by front-end loader into a transfer
car to be discharged into the metallic/scrap bin at the stock house. The skip car is
loaded by a material gathering conveyor, which receives all burden materials from the
stockhouse for delivery into the skip car.

The UOF’s are blended with scrap at a rate of 100 tons to 200 tons UOF’s per
30,000 tons to 40,000 tons of scrap per month or about 0.3% to 0.5% UOF in the scrap
blend. At a concentration of 0.5% UOF in the scrap blend, and assuming a 400 lb scrap
per NTHM charging rate, this would represent a UOF charging rate of 0.1% in the overall
burden.

The discussion USS personnel indicated that no problems had been experienced
with respect to oil draining from the UOF’s and that because the scrap is blended on a
concrete pad, any potential drainage would be contained. Additionally, there were no
known operational problems with respect to the blast furnace operations or its top gas
treatment and water treatment. The charging rate at 0.1% in the overall burden is a very
small amount and may be insufficient to disclose potential problems if larger amounts
may be charged.

8.2 Perceived Problems with Charging Oil Filters

The other blast furnace operators representing Bethlehem Steel, Dofasco, Ispat
Inland and WCI Steel all expressed concerns relating to the contained oil. The initial
concerns are that any free flowing oil from the filters may be a material storage and
handling problem resulting in contamination of the ground and/or ground water.

Communications between buyers and suppliers of UOF’s in the supply chain should
be able to properly address any concerns over freely draining oil.

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AISI Contract TRP-9
Project No. 0041
A Feasibility Study for Recycling Used Automotive Oil Filters in a Blast Furnace

The next major concern expressed by all of these operators was the extent to which
oil would vaporize in the top of the furnace. The concern is that the vaporized oil would
condense and contaminate the scrubber wash water system.

Other concerns expressed were the potential difficulties based on the final size of the
oil filter in charging with a Paul Worth top and also with potential problems in conveyor
charging systems due to concerns on poor material flowability.

One operator indicated that they have optimized the blast furnace process to a
controlled temperature of the top gas. They did not think it would be worthwhile to re-
optimize furnace practices for a small percentage of a material that could potentially
cause problems.

Most operators felt that the UOF’s would need to be priced at a low level relative to
other metallics, or they would not be interested in interrupting normal material balances
to the process.

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AISI Contract TRP-9
Project No. 0041
A Feasibility Study for Recycling Used Automotive Oil Filters in a Blast Furnace

9.0 Future Work

The only remaining concern of blast furnace operators not answered in the feasibility
study is with respect to the effect of the vaporized oil components on the operating cost
and capital cost of the top gas cleaning system to comply with all regulations.

At the time this study was authorized, it was not known that US Steel at Gary Works
had a continuing program of charging UOF’s into their blast furnaces.

Due to the fact that US Steel does have operating experience with recycling UOF’s
into the blast furnace, consideration may be given to conducting a study of the
operational results at that blast furnace site. This has the benefit of not incurring any
significant cost to conduct a demonstration for the feasibility of this concept. However, it
must be consistent with US Steel’s policies and procedures regarding any proprietary or
confidential operating practices and procedures.

If an analysis of the USS Gary experience can be shared with other blast furnace
operators, then the potential for significant additional recycling of UOF’s to the blast
furnace may readily occur.

The other significant aspect to be developed is the requirement for proper

preparation of UOF’s for shipment, delivery and storage to the BF operators. This
analysis would need to obtain information from originating scrap yards as well as
material receiving and handling operations at the steel works.

It will be necessary to collect additional information with respect to motor oil that may
drain from crushed and drained UOF’s during transportation and storage prior to
charging into the blast furnace. In the event that free draining of motor oil from the
UOF’s is found to be in excess of steel plant requirements, then consideration needs to
be given toward the shredding and separation of oil and filter media from the steel
components, and the compaction and/or briquetting of the shredded steel components
for blast furnace charging.

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AISI Contract TRP-9
Project No. 0041
A Feasibility Study for Recycling Used Automotive Oil Filters in a Blast Furnace

10.0 Conclusions

This feasibility study has identified the major parameters to be considered in

recycling of used automotive oil filters to the iron blast furnace. Properly hot drained oil
filters do not represent a federal environmental hazardous waste, although several
states have legislation prohibiting the landfilling of used oil filters. The present weight of
steel contained in used oil filters (UOF’s) for recycling is about 122,000 t/yr.

The least cost delivery of UOF’s to the blast furnace would be properly hot draining
followed by crushing of the filter. This is expected to result in approximately 13% oil
remaining in the filter media within the crushed filter. The chemistry of the used oil,
when charged in to the top of the blast furnace, indicates that about 98% of the weight of
this oil would be removed from the furnace in the blast furnace top gas as both fuel gas
and as a condensable “gasoline fraction” that would condense in the scrubber water.
The fuel gas is a positive benefit, but it is not known to what extent the condensable
“gasoline fraction” would represent additional water treatment costs.

In the event that a 13% contained oil in crushed and drained UOF’s is excessive,
then a UOF processing route that encompasses shredding of the filter, separation of
filter media, collection of used motor oil for its recycling, and compaction of the shredded
metal may be required to provide a charge material to the blast furnace. This
subsequently shredded and compacted charged material should, in the writer’s opinion,
have no detrimental effect to the recycling of this material through the blast furnace with
respect to top gas chemistry or any contamination of the hot metal chemistry, but it
would incur additional cost.

The charging of metallic iron units to the top of the blast furnace is a routine practice
in the industry. To be acceptable to the blast furnace operator, recycling of steel from
used oil filters must be conducted in a way that will not cause environmental remediation
costs and/or operational problems, which outweigh the potential cost benefits of
recycling this material.

Due to the fact that used oil filters are presently being recycled in the blast furnaces
at US Steel, Gary Works, a study of this practice would benefit the industry. Such a
study would need to be consistent with the policies and confidentiality requirements of
US Steel. The current cost of the UOF’s is about $30 per gross ton delivered to the
Gary Works.

The analysis conducted in this study has been mainly oriented to the use of a 2%
charge of UOF’s to the blast furnace burden. The US Steel practice at 0.1% UOF’s may
be too low to indicate any potential problems. However, on a geographically distributed
basis, there may not be nearly enough total volume of UOF’s generated to charge more
than about 0.5 weight percent of the burden to a blast furnace. In this case, provided
transportation costs are not excessive, sufficient blast furnace capacity exists to recycle
all UOF’s that may be reasonably delivered to the steel plant.

Currently electric furnace steel plants as well as iron foundries consume significant
amounts of the existing recycled UOF’s.

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AISI Contract TRP-9
Project No. 0041
A Feasibility Study for Recycling Used Automotive Oil Filters in a Blast Furnace

Future work should be directed to establishing the criteria for processing of UOF’s to
be acceptable to the blast furnace from a size, density and residual oil content basis.
Additionally, a more detailed assessment of wastewater treatment costs may be required
to properly accommodate the condensable fraction of the vaporized oil species.

There is strong indication that additional states may enact legislation banning the
disposal of UOF’s into landfills. This will result in increased cost to the public for
disposal of these necessary maintenance activities on their automobile, unless beneficial
recycling can be organized. Through a combination of developing the requirements of
UOF’s for blast furnace recycling, publicity to the originating sources of UOF’s, and
development of an appropriate and responsible transportation link; the recycling of
UOF’s into the blast furnace may be mutually beneficial to the environment and to the
steel industry.

11.0 Acknowledgements

The writers would like to acknowledge participation and advice from the following
companies and their personnel.

Bethlehem Steel Fred Rorick

Dofasco Randy Fischer
Ispat Inland Wendell Carter
US Steel Ed O’Donnell
Jon Burgo
Ted Weitzel
WCI Steel Bill Sherwood
Wheeling-Pittsburgh Steel Ed Asbury
Kvaerner, Pittsburgh Neil Goodman

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AISI Contract TRP-9
Project No. 0041
A Feasibility Study for Recycling Used Automotive Oil Filters in a Blast Furnace

12.0 Appendix

Appendix 1: State Motor Vehicle Registrations 199967

STATE All STATE All

Vehicles Vehicles

Alabama 4,006,454 Nebraska 1,589,184

Alaska 586,393 Nevada 1,185,875

Arizona 3,751,417 New Hampshire 1,098,554

Arkansas 1,839,611 New Jersey 6,208,305

California 26,782,040 New Mexico 1,607,151

Colorado 3,953,175 New York 10,899,573

Connecticut 2,819,692 North Carolina 5,769,173

Delaware 626,315 North Dakota 720,799

Dist. of Col. 236,987 Ohio 10,476,193

Florida 11,625,429 Oklahoma 2,984,763

Georgia 7,059,719 Oregon 3,079,568

Hawaii 737,409 Pennsylvania 9,209,429

Idaho 1,170,422 Rhode Island 766,220

Illinois 9,571,901 South Carolina 3,073,091

Indiana 5,604,559 South Dakota 807,722

Iowa 3,175,168 Tennessee 4,489,504

Kansas 2,274,030 Texas 14,237,616

Kentucky 2,703,894 Utah 1,601,854

Louisiana 3,547,570 Vermont 535,278

Maine 946,408 Virginia 5,928,621

Maryland 3,942,270 Washington 4,969,440

Massachusetts 5,436,298 West Virginia 1,398,578

Michigan 8,457,526 Wisconsin 4,458,578

Minnesota 4,136,503 Wyoming 544,119

Mississippi 2,348,984 0

Missouri 4,461,573 Total 220,461,056

Montana 1,020,121 Puerto Rico 2,103,526

Total Vehicles Including 222,564,582

P.R.

67
“State Motor Vehicle Registration 1999 Table M V-1, ”
http://wwwcf.fhwa.dot.gov/ohim/hs99/tables/mv1.pdf, 10/25/2001

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AISI Contract TRP-9
Project No. 0041
A Feasibility Study for Recycling Used Automotive Oil Filters in a Blast Furnace

Appendix 2: Estimate of Oil Filter Can Zinc Coating Weight

Oil Filter Zinc Coating Weight
Oil Filter Brand Trade Name Manufacturer Filter Cartridge Filter Cartridge Filter Cartridge Shell Backplate Filter Can Zinc Coating
Length Outside Diameter Inside Diameter Thickness Thickness Surface Area Weight
20 % elongation
(in) (in) (in) (in) (ft^2) (lb)
AC Delco Duraguard AC Delco 4.626 3.375 1.375 0.015 0.1 0.937 0.00468
F2
Car and Driver SF-1A Champion 4 3.25 1.625 0.012 0.102 0.780 0.00390
Deutsch D539 Champion 4 3.25 1.625 0.012 0.102 0.780 0.00390
Fram Extra Guard Fram 4.125 3 1.375 0.015 0.089 0.742 0.00371
PH 8A
Fram Tough Fram 4.125 3 1.625 0.015 0.187 0.742 0.00371
Guard
TG8A
Fram Double Fram 4.125 3 1.625 0.015 0.187 0.742 0.00371
Guard
DG 8A
Mobil 1 M1-301 Champion 4.25 3.25 1.625 0.022 0.138 0.829 0.00414
Mopar 4105409 Champion 2.375 2.675 1.675 0.01 0.115 0.381 0.00191
Mopar 5281090 Purolator 2.675 3.25 1.625 0.01 0.115 0.522 0.00261
Mopar 3549957 Champion 3 3.25 1.625 0.012 0.102 0.585 0.00292
Mopar 3549957 Purolator 3.125 3.25 1.625 0.01 0.115 0.609 0.00305
Mopar 53020311 Fram 4.25 3.2 1.625 0.014 0.11 0.816 0.00408
Purolator Premium Purolator 4.1 3.2 1.625 0.015 0.14 0.787 0.00394
Plus
L34875
Motorcraft Long Lasting Purolator 4.125 3.25 1.625 0.011 0.12 0.804 0.00402
FL-1A
NAPA 1515 Gold DANA 4 3.25 1.625 0.014 0.104 0.780 0.00390
Pennzoil PZ-1 Fram 4.125 3 1.375 0.015 0.089 0.742 0.00371
Purolator Premium Purolator 4.125 3.25 1.625 0.011 0.115 0.804 0.00402
Plus
L30001
Purolator Pure One Purolator 4.125 3.25 1.625 0.011 0.115 0.804 0.00402
PL30001
STP S-O1 Champion 4 3.25 1.625 0.012 0.102 0.780 0.00390
Wix 51515 DANA 4 3.25 1.625 0.014 0.104 0.780 0.00390

Average Wt. 0.00369

Zinc Coating Weight 0.10 oz / sq. ft.

Filter Can Area Cartridge Outside Diameter Area x PI + 10 % x Cartridge Height + 20 %

Appendix 3: Rules Summary for Used Oil Filter Disposal

State Oil Filter Disposal Rules

Alabama Federal Guidelines: Non-terne plated used oil filters are exempt
from hazardous waste regulations if the used oil filter is:
a) punctured through its dome end or its anti-drain back valve and
hot-drained; or
b) hot-drained and crushed; or
c) dismantled and hot-drained; or
d) hot-drained using an equivalent method to remove used oil.
Definitions: Terne is an alloy of lead and tin that was used in
some heavy duty filters in the past. Hot draining is defined as
draining the oil filter at near engine operating temperature and
above 60 degrees Fahrenheit for a recommended 12 hours.

If these conditions are not met, the filters must be tested or

assumed to be hazardous waste and managed accordingly.
Alaska Federal Guidelines: See Alabama
Arizona Federal Guidelines: See Alabama

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A Feasibility Study for Recycling Used Automotive Oil Filters in a Blast Furnace

Arkansas Federal Guidelines: See Alabama

California In California used oil filters are considered non-hazardous if:
1. They are drained of free flowing oil, which includes removal
of any barrier to free- flowing oil, crushing, opening,
puncturing, or in any other manner that removes oil.
2. They are processed for metal reclamation (recycling).
3. They are stored and transferred in a closed, rainproof
container that is designed to keep spilled oil inside the
container. Drums of filters need to be labeled “drained used
oil filters” and must indicate the initial date of accumulation on
each container.

Storage Limits:
1. Less than 1 ton – 1 year
2. 1 ton or more-180 days

Call CA Dept of Toxic Substances for other rules.

Colorado Federal Guidelines: See Alabama
Connecticut 1. Oil must be removed from the filter by puncturing and gravity
draining for at least 24 hours or by crushing the filter. A
combination of crushing and draining is preferred.
2. The drained oil must be collected and recycled
3. The oil filter can be disposed of in a permitted solid waste
landfill.
Generators and collectors of used oil filters must obtain a permit.
Delaware Federal Guidelines: See Alabama
D.C. Federal Guidelines: See Alabama
Florida Used oil filters generated by commercial entities may not be land
filled in Florida. A commercial generator of used oil filters must
Florida, Continued have the filters managed by a registered processor or must register
with the Dept. of Environmental as a used oil filter processor.
Contact FL Dept. of Env. Protection, Hazardous Waste Mgmt.
Section for more information.
Georgia Federal Guidelines: See Alabama
Hawaii Very Similar to Federal Guidelines. See Alabama
Idaho Federal Guidelines: See Alabama
Illinois Used oil filters that are drained and crushed are shipped to a
recycling facility would be considered scrap metal, not waste.
Uncrushed and undrained oil filters are managed as a special
waste. See IL Environmental Protection Agency for more
information.
Indiana Federal Guidelines: See Alabama
Iowa Federal Guidelines: See Alabama
Kansas Federal Guidelines: See Alabama
Kentucky Very Similar to Federal Guidelines. See Alabama
Louisiana Federal Guidelines: See Alabama

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A Feasibility Study for Recycling Used Automotive Oil Filters in a Blast Furnace

Maine Federal Guidelines: See Alabama

Maryland Federal Guidelines: See Alabama
Massachusetts Very Similar to Federal Guidelines: See Alabama
Michigan Very Similar to Federal Guidelines: See Alabama
Minnesota Used oil filters are prohibited from solid waste disposal.
Minnesota requires business generators of used oil filters to either:
1. recycle the used oil filter; or
2. dispose of the filter as hazardous waste
Contact MN Pollution Control Agency, Policy and Planning Div.
for more information.
Mississippi Federal Guidelines: See Alabama
Missouri Similar to Federal Guidelines: See Alabama. The Department
does not require used oil generators to distinguish between terne-
plated and non-terne plated oil filters.
Montana Similar to Federal Guidelines. Contact Air & Waste Mgmt. Bureau
Nebraska Federal Guidelines: See Alabama
Nevada Federal Guidelines: See Alabama
New Hampshire Federal Guidelines: See Alabama
New Jersey Federal Guidelines: See Alabama
New Mexico Federal Guidelines: See Alabama
New York Federal Guidelines: See Alabama
North Carolina Federal Guidelines: See Alabama
North Dakota Federal Guidelines: See Alabama
Ohio Federal Guidelines: See Alabama
Oklahoma Federal Guidelines: See Alabama
Oregon Federal Guidelines: See Alabama
Pennsylvania Federal Guidelines: See Alabama
Puerto Rico Federal Guidelines: See Alabama
Rhode Island Rhode Island regulates oil filters generated by corporate entities as
hazardous waste. Used oil filters, exclusive of satellite storage,
may not be stored on-site for more than 90 days. Filters may not
be land filled in Rhode Island. See Dept. Env. Mgmt., Compliance
/ Inspection Div.
South Carolina Federal Guidelines: See Alabama
South Dakota Similar to Federal Guidelines. Contact SCDHEC, Bureau of Land
& Waste Mgmt. Division of Mining & Solid Waste Mgmt.
Tennessee Similar to Federal Guidelines. Contact TN Department of
Environmental Conservation, Solid Waste Assistance
Texas The Texas rule provides cradle to grave management for used oil
filters. Used oil filters are banned from Texas landfills. The
generator must remove all free- flowing oil from the filters and
make arrangements for filter removal and processing. See
TNRCC, Waste Permits Div., I&HW Permits, Used Oil Recycling
Program
Utah Federal Guidelines: See Alabama

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Vermont Similar to Federal Guidelines: See Alabama

Virginia Federal Guidelines: See Alabama
Washington Federal Guidelines: See Alabama
West Virginia Federal Guidelines: See Alabama
Wisconsin Similar to Federal Guidelines: See Alabama
Wyoming Similar to Federal Guidelines: See Alabama

Appendix 4: Flash Calculation

Let L equal the moles of liquid with mole fractions {x i}, and let V be the moles of vapor
with mole fractions {y i}. The material balance equations are written as
L +V =1
z i = x i L + y iV ( i = 1, 2, K, N )
where {zi} are the overall mole fractions. Eliminating L from the equations, we get
z i = x i (1 − V ) + y i V ( i = 1, 2, K, N ) Eq. 1
Raoult’s law for vapor-liquid equilibrium is given by
yi = K i xi
where Ki is the “K-value” and is given here by
K i = Pi sat / P
Psat is calculated using the Antoine Equation given by
B
log 10 P sat = A − Eq. 2
T +C
Substituting x i=yi/Ki in Eq. 1 and solving for y i gives
zi K i
yi = (i = 1, 2,K , N ) Eq. 3
1 + V ( K i − 1)

since ∑y i = 1 , the sum of Eq. 2 gives

zi K i
∑ 1 + V (K
i − 1)
=1 Eq. 4
i

Since T, P, and {zi} are known, the only unknown in Eq. 3 is V. The solution is
obtained iteratively.

In order to determine if it is possible to do a flash calculation, first perform a bubble

pressure, Pb, and dew pressure calculation, Pd. The bubble pressure is the pressure
where the mixture will start to boil and the dew pressure is the pressure where the
mixture will start to condense at a particular temperature. In order to do the flash
calculation the pressure needs to be between Pd and Pb. Pb is calculated using
Pb = ∑ xi Pi sat
i
with {x i}={zi}. Pd is calculated using

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1
Pd =
∑ yi / Pi sat
i
with {y i}={zi}.

Appendix 5: Sample Flash Claculation

For T = 750 °F = 671.9 K

P=15.1 psig=1.92 bar

First using values of zi and Pisat shown below, the Bubble Pressure of the oil at 750 °F is
calculated:
Pb = ∑ z i Pi sat
i

= 0.19 * 4.337 + 0.18 * 2.772 + 0.19 * 2.105 + 0.18 * 0.980 + 0.19 * 1.043 + 0.07 *1.071
= 2.17 bar
The Dew Pressure for the oil is also calculated:
1
Pd =
∑ yi / Pi sat
i

1
=
0.19 / 4.337 + 0.18 / 2.772 + 0.19 / 2.105 + 0.18 / 0.980 + 0.19 / 1.043 + 0.07 / 1.071
= 1.59 bar
Since the pressure, P=1.92 bar, is between the bubble pressure and the dew pressure, the
flash calculation can be performed. If the pressure was greater than the bubble pressure
than the mixture would be all vapor and if the pressure was less than the dew pressure,
the mixture would be all liquid.

i zi Pisat(bar) Ki yi xi
K i = Pi sat / P
Component (overall B (vapor (liquid
A−
composition,
arbitrarily P sat = 10 T +C
composition) composition)
set) (T in Kelvin) zi K i y
yi = xi = i
1 + V ( K i − 1) Ki
C18 H38 0.19 4.337 2.256 0.1902 0.0843
C21 H44 0.18 2.772 1.442 0.1801 0.1249
C23 H48 0.19 2.105 1.095 0.1900 0.1736
C26 H54 0.18 0.980 0.510 0.1797 0.3525
C27 H56 0.19 1.043 0.543 0.1897 0.3496
pyrene 0.07 1.071 0.557 0.0699 0.1254

The value of V, the fraction of the mixture that is vaporized, is obtained iteratively by
using the MS Excel “Goal Seek” function to change V in order to set

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A Feasibility Study for Recycling Used Automotive Oil Filters in a Blast Furnace

∑y i =1
i
“Goal Seek” calculated V to be 0.998 so 99.8% of the oil is vaporized in that section at
750 °F.

Appendix 6: Symbol Table

PAH Polycyclic aromatic hydrocarbon

A, B, C Empirical parameters for the Antoine Equation (Appendix 4, eqn2)
L Moles of liquid
V Moles of vapor
xi Liquid mole fraction for component i
yYi Vapor mole fraction for component i
zi Overall mole fraction for component i
P Pressure
Pisat Saturated pressure for component i
Pb Bubble pressure
Pd Dew pressure

Appendix 7: Typical Aromatic Hydrocarbons

Figure 7: Some typical aromatics from hydr ocarbon pyrolysis.57 Molecules with 2 or more rings are
known as polycyclic aromatic hydrocarbons (PAH)

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13.0 References
1
AISI, “Steel Technology Roadmap”, March 1998, section 2.2.3 A UTOMOTIVE, pg 77.
2
Technical Bulletin, “The Future of Used Oil Filter Recycling in Missouri: An Evaluation of Potential
Processes, Product Quality, Recycling Locations, and Economics”, February 15, 1997, K.D. Peaslee and
D.E. Roberts, II, University of Missouri-Rolla, Department of Metallurgical Engineering.
3
“Report of the Findings on the Waste Classification of Used Automotive Oil Filters”, The Convenient
Automotive Services Institute, April 1991.
4
“The Process,” From “An Introduction to Blast Furnace Technology”, ATSI Engineering Services,
http://www.steel.org/learning/howmade/blast_furnace.htm, 12/17/2001.
5
“AC Delco – Parts Information-Oil Filters-Ultraguard Gold,”
http://www.acdelco.com/pi_filt_oil_gold_feature.htm, 9/24/01
6
F.E. Lockwood and R. Dailey, “Lubricant Analysis,” Friction, Lubrication and Wear Analysis, 1992,
ASM Handbook, Vol. 18, pp. 299-312
7
“Online Sample Report, Oil Sampling Guidelines, ” http://www.thetakgroup.com/pennzoil-
quakerstate/pqs/login.asp, 10/25/01
8
“State Motor Vehicle Registration 1999 Table MV-1, ”
http://wwwcf.fhwa.dot.gov/ohim/hs99/tables/mv1.pdf, 10/25/2001
9
Brent Hazelett, ”Private Communications,” Oil Filter Manufacturers Council, September 25, 2001.
10
“Recycle Rate for Used Oil Filters.” http://www.filtercouncil.org/news/May2000.html, (Filter
Manufacturers Council, FMC PR 01-00, May 4, 2000).
11
Brent Hazelett, ”Private Communications,” Oil Filter Manufacturers Council, September 25, 2001.
12
“State Motor Vehicle Registration 1999 Table MV-1, ”
http://wwwcf.fhwa.dot.gov/ohim/hs99/tables/mv1.pdf, 10/25/2001
13
Brent Hazelett, ”Private Communications,” Oil Filter Manufacturers Council, September 25, 2001.
14
Nishaj Attassery, “Private Communications,” 16 Oct 2001, Email Letter, ArvinMeritor
15
Ibid
16
Mike Whitman, “Private Communications,” 12 Oct 2001, Fax Memo, Delphi Corporation
17
Ibid
18
“Tin Plate,” http://www.weirton.com/products/tin/tinplate.html, 24 Sep 2001
19
“Weirzin,” http://www.weirton.com/products/galv/weirzin.html , 24 Sep 2001
20
Brent Hazellet, “Private Communications,” Oil Filter Manufacturers Council, 18 Oct 2001
21
Mike Whitman, “Private Communications,” 13 Oct 2001, Phone Message, Delphi Corporation
22
Scott Jacobs, “Private Communications,” 24 Oct 2001, Email Letter, Fram Brand, Honeywell Corp.
23
Nishaj Attassery, “Private Communications,” 16 Oct 2001, Email Letter, ArvinMeritor
24
Edward Adamczyk, “Private Communications,” Weirton Steel, Phone Message, 11 Oct 2001.
25
Ibid
26
Kent D. Peaslee, “Recycling Used Automotive Filters,” Journal of Metals, February, 1994, pg. 46
27
Harold E. McGannon, ed., The Making Shaping and Treating of Steel, (Pittsburgh: United States Steel,
1971), pg. 456
28
“Engine Oil Filter Study,” http://www.scuderiaciriani.com/rx7/oil_filter_study/, 11 Oct 2001.
29
Nishaj Attassery, “Private Communications,” 16 Oct 2001, Email Letter, ArvinMeritor
30
Mike Whitman, “Private Communications,” 17 Oct 2001, Phone Message, Delphi Corporation
31
Brent Hazelett, ”Private Communications,” Oil Filter Manufacturers Council, September 25, 2001.
32
Ibid.
33
Kent D. Peaslee, “Recycling Used Automotive Filters,” Journal of Metals, February 1994, pg. 44.
34
Note: Lubricating Oil Specific Gravity can vary from 0.856 to 0.913. For purposes of this study a value
of 0.88 will be used. “Material Data Safety Sheet,” Havoline Motor Oil,
http://www.equivatexacomsds.com/rd/getsinglemsds.asp?ID=191113, 18 Sep 2001.
35
Weirton Steel Internet Site
36
Kent D. Peaslee and Darrell E. Roberts, “Characterization of used automotive oil filters for recycling,”
Resources, Conservation and Recycling 19 (1997), pg 86.

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37
Santee Cooper Electric Utility, “GOFER, Give Oil For Energy Recovery,”
http://www.scgofer.org/about.html, November 12, 2001
38
Wisconsin Energy Bureau. “Paper Pellets for Industrial Fuel,” www.wifocusonenergy.com, November
11,2001.
39
Bill Vajdek, “Private Communications,” American Resource Recovery, Ltd., Maywood, IL, November
15, 2001
40
Tammi Jones, “Private Communications,” Commercial Filter Recycling, Los Angeles, California,
October 27, 2001.
41
Gregory C. Potter, “Private Communications,” Oil Filter Recyclers, Inc. Easton, IL, November 13, 2001.
42
Jim Nickerson, “Private Communications,” Nickro Recycling Inc., Pittsburg, TX, November 13, 2001.
43
Terry Jones, “Private Communications,” Bernell Recycling, Ranch Cucamonga, CA, November 14,
2001.
44
Brent Hazelett, “Private Communications,” Oil Filter Manufacturers Council November 9, 2001.
45
“Disposal of Terne-Plated and Non Terne-Plated Oil Filters,” http://chppm-
www.apgea.army.mil/hwmp/Factsheets/OilFilters.html, January, 2001.
46
“Used Filter Management Regulations,” Oil Filter Manufacturers Council, http://filtercouncil.org/regs/
47
“Blast Furnace Roundup,” Iron and Steelmaker, Vol. 28, No. 8, August 2001, pp. 75-77.
48
D. Wakelin, “The Making, Shaping, and Treating of Steel “, 11th Edition, Ironmaking Volume, p751,
AISE Steel Foundation, 1999.
49
Assumed 0.030 % Sn in melted steel components, which exhibited a 76 % metallic yield.
50
Assumed 0.030 % Sn in melted steel components, which exhibited a 76 % metallic yield.
51
R. Jeschar, A Theoretical Model Coupling Kinetics of Ore Reduction and Coke Gasification in Cocurrent
and Countercurrent Reactors, Fifth International Iron and Steel Congress, Washington, April 6-9, p 992,
Iron & Steel Society, 1986.
52
A. Poos, and N. Pongjis, 1994 Turkdogan Symposium Proceedings, Application of Process Models for
the design of an Optimized Blast Furnace Process, p 45, Iron & Steel Society, 1994.
53
Robert A. Meyers. Environmental Analysis and Remediation, v. 6. John Wiley & Sons, New York,
1998. p. 3669
54
Internet
55
Irwin, Roy J. et al. Environmental Contaminants Encyclopedia, Used Motor Oil Entry. National Park
Service, 1997. http://nature.nps.gov/toxic/oilused.pdf.
56
D.J. Graziano and E.J. Daniels, Assessment of Opportunities to Increase the Recovery and Recycling
Rates of Waste Oils. Energy Systems Division Argonne National Laboratory, Contract W-31-109-Eng-38,
for the United States Department of Energy, pg 54, August 1995.
57
“NIST Chemistry Web Book”,
“http://WebBook.nist.gov/cgi/cbook.cgi?ID=C593453&Units=SI&Mask=4.”.
58
J.M. Smith and H.C. Van Ness. “Introduction to Chemical Engineering
Thermodynamics”. McGraw-Hill, Inc. New York, 1987.
59
James Speight. The Chemistry and Technology of Petroleum 3 rd ed. Marcel Dekker, Inc., New York,
1999.
60
Lyle F. Albright, et al. Pyrolysis: Theory and Industrial Practice. Academic Press, New York, 1983.
Iron can act as a catalyst to produce surface carbon.6
61
Nowak et al. Chem Tech. v. 31 p. 496-500, 1979.
62
G.F. Froment, Coke formation in the thermal cracking of hydrocarbons. Reviews in Chemical
Engineering. V. 6, n4, p293-328, 1990.
63
From: D. H. Wakelin, Blast Furnace Material and Energy Balance. The Making, Shaping and Treating of
Steel, 11th Edition, Ironmaking Volume, p734, sec 10.3.5, 1999.
64
As calculated by the writer.
65
Recycling Oil and Fuel Filters, www.nycwasteless.com/citysense/initiaves/dosfilters.htm, 2000.
66
D.A. Kercsmar, et al., Sustained Production in Excess of 9 Tons Per Day/100 ft 3 WV at Middletown’s No.
3 Blast Furnace, Iron & Steelmaker, p 33, July 1994.
67
K.D. Peaslee & D.E. Roberts, II, “ The Future of Used Oil Filter Recycling in Missouri: An Evaluation of
Potential Processes, Product, Quality, Recycling Locations, & Economics”, Missouri Department of
Natural Resources, p 19, February 15, 1997.

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13.0 Resumes

Gregory L. Dressel, P. Eng.

768 Country Club Drive
Pawleys Island, SC 29585 USA
______________________________________________________________________
Phone +1 843-237-8337
Fax +1 843-237-8337

[email protected]
Summary:

Manager and engineer operating a variety of steel melt shops. Well experienced in the management and
startup of melt shops using scrap, hot metal and DRI cast into slabs, thin slabs, billets, blooms and beam
blanks.

University Level Education:

1977 B.S. The Pennsylvania State University, University Park, PA, USA. Metallurgical Engineering.
1991 MS The University of Massachusetts, Amherst, MA, USA. Engineering Management

Current Employment:

1994 to 2000: Dressel Technologies, Independent Consulting and Management

Assignments
Year Client Location Job Description
2001 Secret Client (2) USA Steelmaking Operations Work
2000-2001 SMS DEMAG, Pittsburgh, PA USA Commissioning Consultant in
Start Up of Stainless Melt Shop
2000 Secret Client (1) USA Steelmaking Operations Work
2000 The Recovery Group, Boston, Hunedoara, Romania Operational Assessment of
MA State Owned Steel Plant
2000 Concast Standard, Wettingen Abu Zaabal Military Factory AC EAF and Melt Shop
Switzerland Cairo, Egypt Management and Startup
1999-2001 Iron and Steel Society Iron and Steelmaker Magazine Writer and Coordinator of Skull
Session, Monthly Q & A
Column
1999 Pyromet, Johannesburg, USA DRI Use in Submerged Arc
Republic of South Africa Furnace Process Engineering
1999 Concast Standard, Wettingen Charter Steel, Saukeville , WI DC EAF Operations and
Switzerland USA Process Improvements
1999 Concast Standard, Wettingen Namheng Steel, Lop Buri Melt Shop Problem Solving
Switzerland Thailand
1999 EMC International, Inc SIDERPERU, Chimbote, Ladle Furnace Startup and
Pittsburgh, PA Peru Management Support. BOF melt
support
1998-1999 Iron and Steel Society Iron and Steelmaking Magazine Wrote and published series
titled, “Use of Direct Reduced
Iron in Electric Arc Furnaces”
1998 DAI Management Assoc. Inc AllMet Direct Reduced Iron Project work on EAF Dust
Facility, Blytheville, AR recycling facility
1998 Concast Standard, Wettingen Guangzhou Iron and Steel Technical and operational
Switzerland China supervision of a DC EAF in
startup phase

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Year Client Location Job Description

1998 Kvaerner Metals Clecim Tung Ho Steel Ladle Furnace Operations and
Saint Chamond, France Miaoli, Taiwan, R.O.C Metallurgy Improvements
1997-1998 Concast Standard, Zurich Southern Steel Berhad, Penang, Technical and operational
Switzerland Malaysia supervision of a twin shell DC
EAF and AC Ladle Furnace in
startup phase
1997 Kvaerner Metals, Pittsburgh, PA, Wheeling Pittsburgh Steel, Process engineering and operator
USA Steubenville, OH, USA training on a CAS OB ladle
metallugy unit

1997 Concast Standard, Zurich, Daye Steel, Huangshi, China Technical and operational
Switzerland supervision of a DC EAF in startup
phase
1996-1997 Namheng Steel, Lopburi, Thailand Namheng Steel, Lopburi, Thailand Management of a DC EAF, AC LF
and billet melt shop in start up
phase
1996 Gallatin Steel, Ghent, KY USA Gallatin Steel, Ghent, KY USA EAF operational training in shop
using DC EAF and Thin Slab
Caster
1996 Kvaerner Metals, St. Chamond, Essar Steel, Surat, India Performance testing of a DC EAF
France using 80 % HBI as a raw material.
SPC training
1996 Kvaerner Metals, Sheffield, Hadeed, Saudi Arabia Engineering Calculations for DRI
England feed rates and EAF Practices
1996 Dressel Technolo gies, Pawleys AISE Automation Conference, Presentation of a paper on melt
Island, SC, USA Nashville, TN, USA shop simulation
1995-1996 ABB Industrie, AG, Baden, Shanghai No. 3 Steel Works, Technical and operational
Switzerland Shanghai, China supervision of two DC EAF’s in
startup phase
1994-1995 Kvaerner Metals, Pittsburgh, PA, Essar Steel, Surat, India Management of two DC EAF’s
USA and AC Ladle Furnaces in startup
phase using 80% HBI
1994-1995 Caribbean Ispat Limited, Trindad Caribbean Ispat Limited, Trindad Steelmaking and SPC Training and
and Tobago, West Indies and Tobago, West Indies Quality Consulting in EAF shop
using 90 % DRI
1994 Van Deilen Industries, Van Deilen Industries, Conceptual engineering for a micro
Lambertville, MI, USA Lambertville, MI, USA steel plant
1994 Dressel Technologies, Dressel Technologies, Established Dressel Technologies
Pawleys Island, SC, USA Pawleys Island, SC, USA as a metallurgical and steel plant
management consulting firm
Former Employers:
1993 to 1994 Florida Steel, Jacksonville, Fl, USA Melt shop process engineer

1987 to 1993 Georgetown Steel, Georgetown, SC, USA. Management of billet caster process engineering
and quality control in a carbon steel melt shop using 50 % direct reduced iron (DRI). Supervision of
various operational personnel. Shop produced a large quantity of high carbon wire rod products.

1980 to 1987 National Steel Research Center, Weirton, WV, USA. Technical management of a number of
steelmaking and slab continuous casting research projects. Supervision of technical personnel.

1978 to 1980 Weirton Steel, Weirton, WV, USA. Operational management of a vacuum degasser and
continuous slab caster operations. Supervision of operational personnel.

Professional License:
State board certified professional engineer, PA and WV.

References and Publications:

Available upon request

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AISI Contract TRP-9
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JENNIFER H. HILL
[email protected]

Graduate Student

Campus Address:
Carnegie Mellon University
Department of Chemical Engineering
5000 Forbes Avenue
Pittsburgh, PA 15213
(412) 268-3039

Home Address:
105 Heston Drive
Cranberry Township, PA 16066
(724) 772-9018

OBJECTIVE To obtain an industrial position in research and development that uses my engineering
skills and knowledge about advanced process control and modeling.

EDUCATION Carnegie Mellon University, Pittsburgh, PA

Ph.D. Chemical Engineering, Expected March 2002
Thesis: Robust Adaptive Control with Unknown Disturbances.
Advisor: B. Erik Ydstie
GPA: 3.33/4.00

Pennsylvania State University, State College, PA

B. S. Chemical Engineering with Honors, 1997
GPA: 3.89/4.00 Ranking: 2/110

Franklin Regional High School, Murrysville, PA, 1993

EXPERIENCE AND
QUALIFICATIONS

Ph.D. Research Project: (8/97-Present)

Carnegie Mellon University Pittsburgh, PA
• Developed feedforward adaptive control algorithm for a Kodak satellite as Ph.D.
Qualifier Project.
• Developed a robust adaptive stopping algorithm that prevents parameter drift and
bursting.
• Developed an adaptive optimization algorithm for a silicon reactor.
• Experience with adaptive control, identification, dynamic modeling and model
predictive control algorithms.

Process Control Research Consultant: (5/99-1/01)

PPG Industries Pittsburgh, PA
• Implemented an Extended Horizon Self Tuning Controller for furnace crown
temperature control, which improved efficiency of furnace control.
• Developed furnace bottom temperature model and adaptive predictive controller.
• Conducted control experiments to obtain PID tuning parameters for reheat
temperature control.

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A Feasibility Study for Recycling Used Automotive Oil Filters in a Blast Furnace

Undergraduate Research Project: (1/96 - 5/97)

Penn State Department of Chemical Engineering State College, PA
• Studied effect of shear stress on aortic smooth muscle cells for honors thesis.
• Developed new experimental setup for my project.

Student Engineer: (5/95 - 8/95)

Calsicat (Division of Mallinckrodt Chemical) Erie, PA
• Tested the activity of experimental catalysts using micro-reactors.
• Analyzed products using gas chromatography, UV spectroscopy, and analytical
chemistry

RELATED
COURSES Mathematical Techniques in Chemical Engineering Engineering Design
Process Systems Engineering and Optimization Process Control
Computational Methods for Large Scale Processes Reactor Design
Linear Systems and Control Thermodynamics
Fluid Dynamics Kinetics
Chemical Plant Design Polymer Science

COMPUTER SKILLS:
Pro II/Provision, MATLAB, Fortran, C, GAMS, LaTex, Unix, Windows

CONFERENCE PRESENTATIONS:
• Hill, Jennifer and Erik Ydstie. “Robust Adaptive Control: How to Stop the
Estimator to Prevent Bursting”. 2001 AIChE Annual Meeting, Reno, NV,
November 2001.
• Hill, Jennifer and Erik Ydstie. “Parameter Estimation and Robust Adaptive
Control”. 2000 AIChE Annual Meeting, Los Angeles, CA, November 2000.
• Hsu, Jennifer and Erik Ydstie. “Robust Adaptive Control with Unknown
Disturbances”.
1999 AIChE Annual Meeting, Dallas, TX, November 1999.
PUBLICATIONS:
• Hill, Jennifer and Erik Ydsite. “Adaptive Control without Parameter Projection
and Unknown Sign of the High Frequency Gain”. Submitted to International
Journal of Adaptive Control and Signal Processing.
• Hill, Jennifer, Erik Ydstie, and Yu Jiao. “Adaptive Control of an Industrial Float
Glass Process”. Submitted to IFAC World Congress, 2002.
• Hill, Jennifer, Erik Ydstie, and Yu Jiao. “Adaptive Predictive Control of Glass
Temperature”. To be submitted to Automatica.

PROFESSIONAL AFFILIATIONS: American Institute of Chemical Engineers (AIChE)

AWARDS:
• Carnegie Mellon University Graduate Fellowship (1997-2002)
• Penn State Engineering Society Scholarship (1993-1997)
• Penn State Academic Excellence Scholarship (1993-1997)
• Graduated Penn State University with Highest Distinction (1997)

REFERENCES: Available on Request

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. Metserv
9800 A McKnight Road
Suite 310
Pittsburgh, PA 15237-6006
Tel: (412) 348-0015
Fax: (412) 348-0017
E-mail: [email protected]

NAME Smailer, Ralph M

CITIZENSHIP United States of America

PROFESSIONAL EXPERIENCE

1999 to Present Director, Metallurgical Services – METSERV

Provides consulting services related to Conceptual Engineering of
EAF Steelplants, Steelplant Feasibility and Modernization Studies,
Process Simulation and Logistics Studies, Direct Reduction (of iron
ore) Process Plant Studies, the marketing of Hot Briquetted Iron
(HBI) to the steel industry, technology assessment of Pressurized
Fluid Bed Combustion (PBFC) of carbonacaeous materials for
power generation, and as a manufactures representative of Industrial
Fans and Dust Collection Baghouses.

1980-1998 Vice President, Process Technology - Kvaerner Metals

Responsible for the technical management of many projects,
including RH vacuum degassing, ladle metallurgy, HYL III direct
reduction process plants, iron ore pellet plants, steel strip processing
lines, steelmaking feasibility studies, and other projects relating to
mineral processing, iron and steelmaking, industrial furnaces and
chemical industry process plants. He has also been actively involved
in technology assessment and acquisition, and has served as Patent
Administrator for the Pittsburgh office.

Also respons ible for technology assessment, development and

acquisition of new technology and enhancement of existing
technologies in the fields of mineral processing, iron and
steelmaking, industrial furnaces, and chemical engineering. Duties
include coordination wit h worldwide Kvaerner Metals offices,
licensees; technical collaboration with other companies;
management of Process Technology Department having a senior
technical staff to provide sales support, proposals, process
engineering, hot commissioning, and satis faction of performance
guarantees on proposals and/or contracts; and administration of
patent and licensing activities.

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General Manager, Process Technology - Kvaerner Metals

Responsible for technical coordination, sales support, process
engineering, and commissioning for industrial furnaces in the fields

of aluminum heating and melting, steel heating, and electric arc

melting, refining furnaces, and ladle metallurgy facilities. Also
directed sales and technology of the Arc Furnace Department.

Manager, Arc Furnaces - Kvaerner Metals

Developed new/enhanced electric arc furnace product line. Duties
included updating the design basis to provide an enhanced electric
arc furnace design, negotiating license agreement with Daido Steel
Company, Tokyo for their Ladle Furnace Process; directing sales and
marketing activities to enter market dominated by well known and
successful competitors; negotiating supplemental license agreement
with NKK Corporation, Tokyo, for their NK-AP Process; receiving
acceptance of Japanese technology supply to USA steel plant
customers; and winning contracts.

Business Development Specialist - Kvaerner Metals

Responsible for re-introduction of the FIOR (Fluid Bed Iron Ore
Reduction) direct reduction process to the worldwide marketplace.
Duties included negotiating technical cooperation agreement with
FIOR de Venezuela to provide direct reduced iron steelmaking
technology to their worldwide customers for the FIOR DRI/HBI
product; developing procedures that were adopted by the
International Maritime Organization for the code of safe shipment of
DRI cargoes worldwide; assisting in the sales and marketing of the
proprietary FMC formed cokemaking process; and evaluating
several new technologies for potential new product lines.

Also responsible for engineering analysis and development

engineering directed to the enhancement of the FIOR process to
improve fluid bed processing of iron ore for longer term availability
of the process plant between turnarounds.

1964 - 1980 Supervisor - Manufacturing Technology - Lukens Steel Company

Assigned to direct start-up of $4 million continuous material
handling system for use with direct reduced iron feeding to arc
furnaces. Duties included directing operating, maintenance, and
technical efforts; obtaining project productivity and cost goals; and
developing Closed Loop computer control of electric arc furnace to
give desired steel temperature. Also negotiated and controlled
purchase of Technical Assistance contract with Daido Steel

Metserv Page 66 of 69 January 2002

AISI Contract TRP-9
Project No. 0041
A Feasibility Study for Recycling Used Automotive Oil Filters in a Blast Furnace

Company Ltd., Japan, and assisted in coordination of training

program, and implementation of ultra-rapid-melting practices for the
electric arc furnace
.

Supervisor, Manufacturing Technology - Lukens Steel Company

Assigned to a 3- member corporate planning committee, which was
responsible for technology in order to obtain a 30% increase in
steelmaking capacity. A resulting $60 million, 5-year plan was
developed based upon up rating of existing arc furnaces. $10 million
was appropriated in December, 1977.

Supervisor, Hot Briquetting Facility for Steel Turnings - Lukens

Steel Company
Responsible for developing technical concept for a hot briquetted
steel turnings based product with chemical properties engineered for
steelmaking. Duties included technical evaluation of 100,000
tons/year facility to make hot briquetted turnings product.

Research Engineer, Process, in Electric Furnace Operations – Luken

Steel Company
Responsible for steelmaking development activities of 2 electric
furnaces at 100 tons and 2 at 150 tons. Duties included development
and coordination of major production trials involving the use of
directly reduced iron products in electric furnace steelmaking, rapid
refining, and low sulfur steel production.

1962 to 1964 Metallurgical Investigator - LTV Steel Company (J & L Steel)

Responsible for the installation and start- up of a 400-ton vacuum
degassing facility Duties included assisting in evaluating
metallurgical practices. Was also responsible for developing a liquid
metal sampling procedures for dissolved gas analysis for an open
hearth shop, 400 ton, oxygen blown, hot metal practice.

Metallurgical Investigator, Trainee (in the area of blast furnaces) –

LTV Steel Company
Responsible for developing computer program for start- up, and
burden calculations for raw material feed to blast furnace.

Metserv Page 67 of 69 January 2002

AISI Contract TRP-9
Project No. 0041
A Feasibility Study for Recycling Used Automotive Oil Filters in a Blast Furnace

Technical Publications

“Modeling for DRI Value in Steelmaking”, Smailer R M, Sheftel VM, Holmes R L; Steel
Times International, September, 1999

“Modeling for DRI Value in Steelmaking”, Smailer R M, Sheftel VM, Holmes R L;

Advanced Technology Symposium - Scrap Alternatives ;Iron and Steel Society, Trinidad,
West Indies, February 28 – March 3, 1999

“Charge Mix Optimization”, Cates L E, Sheftel V M, Smailer R M; 56th Electric Furnace

Conference, Iron & Steel Society, New Orleans, LA, November 15 – 18, 1998

“The Evolution of Technical Equipment and Process Development in Support of Electric

Furnace Production”, Smailer RM; AIME 50th Electric Furnace Conference, Atlanta,
Georgia, November, 1992

“The Significance of Electric Furnace Steel in Replacing Traditional Technologies”,

Smailer RM, Pekor DF, Pittsburgh Coal Conference, October 14-18, 1991

“The Use of Natural Gas in the FIOR Process”, Smailer RM, Triplett DW, Gas Research
Conference on “Natural Gas Use in the Production of Virgin Iron Units”, Chicago,
Illinois, April 23, 1987

“FIOR Today - Operations and Products”, Whipp, RH, Smailer RM, Kulberg HA, Arab
Steel 127, p. 44-72, 1985.

“Development of the NK-AP Ladle Refining Process:, Smailer RM, Ikegami Y, Iron and
Steel Engineer, 62 (11), p. 29-33, November 1985

“Phosphorus Control in DRI Steelmaking”, Smailer RM, Electric Furnace ’83, Mexico
City, Mexico, June 12-15, 1983, Instituto Latinoamericano del Fierro y El Acero, 1983

“Hot Briquetting of FIOR Fines”, Smailer RM, Whipp RH, Kuby OA, Malakouti N
SME-AIME Fall Meeting and Exhibit, Society of Mining Engineers of AIME, 1981

“FIOR - 300,000 Tons by Water”, Molina MA, Smailer RM, Direct Reduction ’80
Conference, July 27-30, 1980, Instituto Latinoamericana del Fierro y El Acero, 1980

“Handling Storage, and Shipment of Direct Reduced Iron”, Jensen HB, Smailer RM, 39th
Ironmaking Conference, Iron and Steel Society of AIME, Warrendale, Pennsylvania, p.
430-436, 1980

“Transportation and Storage of Direct Reduced Iron”, Smailer RM, Jensen HB, (Chapter
for AIME book on Direct Reduction of Iron, 1980)

Metserv Page 68 of 69 January 2002

AISI Contract TRP-9
Project No. 0041
A Feasibility Study for Recycling Used Automotive Oil Filters in a Blast Furnace

“Practical Aspects of Electroslag Re- melting Technology”, Mitchell A, Smailer RM,

International Metals Reviews, v4, n5-6, p. 231-264

“Utilization of Direct Reduction Iron in Electric Steelmaking”, Smailer RM, Jensen HB,
Scott WW, Jr., Electric Furnace Conference Proceedings, Volume 32, p. 29-36, 1975

“Utilization of Direct Reduction Iron in Electric Steelmaking”, AISE Annual Meeting,

New York, NY 1974

“Utilization of Direct Reduction Iron in Electric Steelmaking”, Smailer RM, Jensen HB,
Scott WW, Jr., UNIDO (United Nations Industrial Development Organization) Third
Interregional Symposium Iron Steel Industry, Brazil, October 1973

“Operating Benefits of Continuously Charging Pre-reduced Ore Briquettes to a 150-T

Electric Furnace”, Smailer RM, Price JA, Metallurgical Society AIME, National Open
Hearth and Basic Oxygen Steel Conference Proceedings, v53, Detroit Meeting, p 38-43,
April 6-8, 1970

“Vacuum Degassing of Specialty Plate Steel”, McMichael RC, Smailer RM, Edwards
DY, Blast Furnace Steel Plant, March 1969

“Development of Operating and Metallurgical Practice for Lukens 150-Ton Vacuum

Degassing Unit”, Fogelman EL, Wilt HW, Smailer RM, Journal of Metals v18, n5, p
623-627, May 1966

Book: Direct Reduced Iron: Technology and Economics of Production and Use,
Stephenson, Robert H; Smailer, Ralph M., Iron and Steel Society AIME, Warrendale,
Pennsylvania, 1980

Patents:
Patent No. 3,809,986, “Combination Iron and Iron Oxide Briquetting for
Steelmaking”

Honors and Awards:

McFarland Award for Achievement in Metallurgy, Penn State Chapter, ASM

International, 1993

Centennial Fellow, College of Earth and mineral Science, Pennsylvania State

University, 1996

Metserv Page 69 of 69 January 2002