The Universal Database
EDSGN100 Section 18
Tyler Kurkiewicz
[email protected]
Paige Dumke
[email protected]
Samhita Kasuganti
[email protected]
Zack Hill
Team India
[email protected]
Recycling of Advanced High Strength Steel
Executive Summary
The objective of this project was to find a revolutionary way to modernize
and improve an old way of recycling steel. In this report are the details of one of
the most efficient and effective ways to do so, the Universal Database. Consisting
of an extensive network of labeled and stamped metal registered in a large
database, the Universal Database provides a way for car manufacturers and steel
producers to communicate what goes into the steel that is used in car parts.
Before recycling and shredding the car, the specific chemical properties of the
metal can be registered and the appropriate steps could be taken to recycle the
steel in the best possible manner.
Submitted to Professor Correll on April 30th, 2012
Table of Contents
1.0 Introduction ..................................................................................................... 2
2.0 Problem Statement .......................................................................................... 2
3.0 Customer Needs, Research, and Project Objectives ......................................... 3
4.0 Conceptual Designs .......................................................................................... 3
4.1 Concept Generation ...................................................................................... 3
4.2 Concept Screening ........................................................................................ 4
4.3 Concept Development .................................................................................. 5
4.4 Concept Selection ......................................................................................... 7
5.0 Detailed Design ................................................................................................ 8
6.0 Conclusions ...................................................................................................... 9
7.0 References ..................................................................................................... 10
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1.0 Introduction
ArcelorMittal is the biggest steel producing company in the world and is the market leader
in steel for use in the automotive and construction industry. The impressive company that has
its headquarters in Luxembourg, however, realizes the importance of looking to every corner of
the earth when looking to advance, refine, and improve their processes. Being only freshmen
in the engineering college at Penn State, our team was enthused when we were asked by
ArcelorMittal to help improve their steel recycling process. We were directed to attempt to
design a process to effectively recycle Advanced High Strength Steel from the automotive
market back into the steel production cycle.
This is a great request for students who are just beginning to focus their studies in
engineering, but the request was met with enthusiasm. Hours of brainstorming were in need,
but after a while, eight initial ideas were generated and entered the concept screening and
selection process. A couple different ideas were combined with one another and our final
concept, the Universal Database, was created. This database is a complex system that knows
the specific chemistry of each car part. This is made possible by stamping a specific serial
number or code onto each car part depending on their chemical makeup. Before the car then
proceeds to enter the car recycling process, each part can be scanned again so that its chemical
makeup can be made clear once again and the appropriate steps of recycling can be taken to
ensure the best results. This report contains more specific details on the Universal Database
and includes all the initial ideas, combined concepts, screening processes, and even pictures of
what it could entail if put into effect.
2.0 Problem Statement
The steel recycling process is flawed in that the steel they recycle often times contains
chemicals or different types of metals that they do not wish to have in their final product. We
need to discover a better method to seek out these unwanted chemicals and effectively recycle
the advanced high strength steel back into the production cycle. ArcelorMittal wants us to find
a better “cradle-to-cradle” process to not cause off-chemistry steel and to decrease alloy costs.
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3.0 Customer Needs, Research, and Project Objectives
Throughout this project, our main stakeholder we focused on was ArcelorMittal. While trying to
design effective ways to recycle Advanced High Strength Steel from the automotive market back into the
basic oxygen furnace steel production cycle, our two main criterions were accuracy and effectiveness.
But along with ArcelorMittal, we also kept in mind other stakeholders like the scrap dealers and
manufacturers, and their benefit in helping the company design an effective cradle-to-cradle process.
According to our team, the main customer need was to recycle scrap steel effectively (we consider
ArcelorMittal to be our customer). In order for this to take place, we need to have cooperation from the
scrap dealers and automotive manufacturers. Hence providing benefits to all of these stakeholders
became an important priority. For example, paying the car owners to return the car back to the
manufacturer after use would keep them happy.
While trying to design an effective recycling method, a lot of research was done about the different
possibilities as to how the scrap metal can be prepared for useful recycling, the general steel making
process, the different chemical and physical properties of steel, the recyclable properties of steel, and
the Basic Oxygen Furnace (BOF) and the Electric Arc Furnace (EAF). We did most of this research as a
class and made presentations to teach everyone else. Once we had our basic knowledge, we began
brainstorming. One or two of our initial concepts were based on the various chemical and physical
properties of steel. But, our main objective was to design an effective method to recycle scrap steel for
the cradle-to-cradle process, so we tried to design more based off of accuracy and effectiveness. These
two criterions were the most important to us and the concepts that we brainstormed were developed
based off of these criterions.
4.0 Conceptual Designs
After clearly defining the problem statement and researching ArcelorMittal’s needs as
well as the business of steel, we preceded into our next step, which was conceptual design.
Our concept design process consisted of four steps: Generation, Screening, Development, and
Selection. The process required our team to collaborate our many ideas and continue to build
upon each other’s ideas repeatedly until we came up with our final design, “the Universal
Database.”
4.1 Concept Generation
When we first started to generate ideas, we each came up with one initial concept
individually. Then, we brought each of our own ideas to the table and tried to generate even more ideas
after seeing what each other was thinking. Some our ideas were crazy and even seemed impossible, but
the flow of creativity allowed for even better ideas to be formed. After our initial brainstorm, we settled
with a final list of eight concepts to move onto the next round. The table below describes our eight
initial concepts, which we labeled alphabetically, “A-H”.
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Initial Concepts Generation Chart
Color ArcelorMittal will color code their steel directly after it comes out of the BOF. The steel will be dyed
A
Coding according to the chemical make up. The steel will be easily identified after it leaves AM and gets made into
parts at manufacturers. When the steel returns to AM, it can be sorted before it gets thrown into the BOF.
AM will imprint a barcode or serial number into the steel after it is processed. AM would need to develop a
Scanner
scanner for this or have people check the steel manually after it comes back from being used. It will then
B
Code
be sorted according to the number.
When carbon is reacted with oxygen, it creates carbon dioxide. If AM were to conduct this chemical
Chemical reaction, they could eliminate the carbon and take away everything else that is left, which would be
C
Reactions considered an off-chemistry alloy. Then, reversing the process would turn the carbon dioxide back into
carbon, and AM would have more pure steel to recycle.
D
Universal
Database
E Grinding
Chemical
F Propertie
s
ManufacG
turers
H
EAF
After AM creates the steel, they would mark it according to its chemical makeup and enter that information
into a database. When the steel is purchased by the automotive makers, the database info will be sent with
it. When the cars are created, the steel along with what and where it was used will be entered into the
database as well. Then, when steel returns back to AM, it can be referenced with the database and sorted.
Before the steel is thrown into the BOF, AM should grind down the steel to its elemental form, so that the
alloys can be separated under a microscope. Then the elements can be formed back together and then
melted down for pure steel.
The steel will go through a process of being slowly heated, so that the alloys will melt off at different times,
according to their chemical properties. This will make it easier to remove the alloys from the steel before it
gets melted.
Government regulations will be put into effect that will make it required to send your cars back to the
manufacturer before it goes to the scrap yard so that they can take it apart and separate the steel.
Right now, AM uses the BOF for most of its processes. Simply using the EAF more will allow them to recycle
more steel and get more from it. The EAF uses higher temperature to boil off impurities as well.
4.2 Concept Screening
After developing our initial eight ideas, we needed to put them through the screening
process. This is done to weed out any ideas that are not worth developing on or are just not as great as
the others. Before creating our concept screening chart we needed to decide what criteria we were
going to compare them to. We decided on eight different criterions which you will find in the left
column. We then compared each of our concepts to a reference concept, which is the process that
ArcelorMittal currently has in place at their facilities. We used a simple scale of pluses, minuses, and
zeros. Anything that received a “0” meant it was basically the same as the reference. If anything
received a “+” or “-“, that meant it was either better or worse than the reference. The concepts that
had the best net score at the end of the screening were moved onto the next the round.
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Concept Screening Matrix:
4.3 Concept Development
The four concepts that we decided to continue with were the Color Coding, Scanner
Code, Universal Database, and Manufacturers. After looking at these concepts, we decided that
combing the Scanner Code and Universal Database concepts (BD) would create an even better solution.
As we moved on to further develop these concepts so that we could make an educated decision on
which was the best, we came up with a few more ideas. One we thought was worth to further develop
and compare it with the concepts we have already developed. This concept solution was called
Spectrometer, which we labeled as “I”. Below, are the final four concepts we had in place before we
went on to make our final decision.
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A. Color Coding:
This concept requires ArcelorMittal to color code their steel directly after it comes out of the
BOF. The steel will be dyed according to the chemical makeup of the steel. The steel then will be easily
identified after it leaves AM, gets sent off to the buyer, made into parts, and is eventually recycled back
to AM. AM can use the colors to sort the steel before they throw it all into the BOF.
BD. Universal Database/Scanner Code:
After AM creates the steel, they will have a barcode or serial numbers inscribed into the steel
according to its chemical makeup and enter that information into a database. When the steel is
purchased by the automotive makers, the information in the database would be sent to them along with
the steel. The automotive makers would then keep track of what type of steel is used for each part of
their car, in each specific model and make of the car. After they are done transforming the steel into
the shape they need, they will then reapply the serial number/barcode. They would also upload that
information to the database. The universal database would be made available to not only AM, but to
the automotive makers and scrap dealers as well. A password and username would be needed though.
This way, everyone involved in each part of the cycle can know what type of steel they are dealing with.
Then, when the cars come back or are traded in, the car dealers or AM, or wherever the car
ends up, will be checked with the database. This will help AM to identify the steel and eliminate any
unwanted alloys. It will also be fairly cost effective. It is a good solution without being too expensive.
G. Manufacturers:
When the public scraps their car, they should be required to first send it to the manufacturers so
that they can go through the car and take out the steel. The will be government regulated so that it is
required. This solution is quick, easy, and cost effective, but may not achieve the goal of eliminating off
chemistry heats as well as other solutions.
I. Spectrometer:
One method that can be used by AM is the Mass Spectrometer. Mass Spectrometer uses the
magnetic properties of elements and detects them. The basic principal of the Spectrometer is: If
something is moving and you subject it to a sideways force, instead of moving in a straight line, it will
move in a curve - deflected out of its original path by the sideways force. There is a four step process
consisting of ionization and deflection of ions. By putting in the scrap steel into the spectrometer we
can separate the steel from the impurities because they cannot be magnetized. Even if they are
magnetized, there is another simple process steel can go through to become magnetized. In the fourth
step of the spectrometer process, the electromagnet is placed specifically to separate the various
components of the steel. Since we know the exact composition of steel, we can use the elements
required and recycle the unrequired ones. Even though this method can prove to be effective, it may
turn out to be very expensive and it would go against our criteria of being cost effective.
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4.4 Concept Selection
Now that we had our top four concept ideas fully developed, we needed to create a
Concept Selection Chart so that we could score the concepts effectively. To do this, we first need to
figure out weights for our criterion so that we could get weighted scores for our concepts. To do this,
we created an Analytical Hierarchy Process (AHP) Chart. This chart helped us rate our criterion.
AHP Chart:
Our top two criterions were Accuracy and Effectiveness. We used these criterions to then score
our final four concepts. We rated the concepts on a scale of 1-5 for each criterion and then multiplied
that number by the weight of each criterion. This gave us our weight score for each criterion. After
adding up the sum for each concept, they were ranked. The number on solution was the one we were
going to develop and present to ArcelorMittal.
Concept Selection Matrix:
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5.0 Detailed Design
Our highest scoring concept was the universal database (BD). This final concept was a
combination of two of our first concepts that we generated. Every part that is put into production on a
vehicle will be stamped with a number, specific to the type of metal it is made out of. Every number will
be recorded in an online database that will be provided to the scrap dealers and car dismantlers.
Scanners will be provided to each company that has the databases programed into them. These
scanners will be able to read the identification numbers on parts. It will read the number on the part
and display the type of metal that it is. The scrap deal will then be able to sort the piece into the correct
pile for further recycling.
When the metal is originally made into billets,
slabs, rods, or sheets at the metal manufacturer it will
be stamped with the specific number for the type of
metal it is. This will add a final step into the steel
making process. While the metal is cooling off on roller
table the metal will go into a press. The press will have
a stamp in it similar to the one on the right. It will
punch a number into the metal piece. Then the metal
will continue cooling off.
When the metal is received by the car
manufactures they will know exactly what the metal is
by the number on it. They can then cut, shape, form, and weld the
metal into whatever they need for the car. After the piece is made
they can stamp another number onto the part based on the metal
it was made from. This process will make an additional step in the
car part manufacturing process. As in the original manufacturing of
the metal, the car part will need to be stamped again. The number
will stay on the part through the entire life of the car.
When the car has reached the end of its life it will be sent
into a scrap yard or straight into the recycling yard. The workers can scan the parts as they disassemble
the car. Each piece will show a code on the scanner that will tell the worker what kind of metal it is. They
can then sort the metal and let it continue on through the recycling process. The batches of recycled
metal will now only have one specific type of metal in them. This will make the new metals that are
made by the recycled material better as there will be no unwanted burn offs or off chemistry.
This new process of recycling will take a little bit of time to be implemented. The actual process
of stamping pieces of metal will be very easy to implement. Adding a small step to the end of the
manufacturing process will not be too much to ask of production companies. A stamp will be easy to put
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onto a piece of metal. The most amount of time will be waiting for the new
cars to get to the end of their life cycle and be returned into the basic
oxygen furnace to be recycled into new metal.
Number
49519ab
99dfv98
519efvf
51r8g19
51grg8r
efrg968
Type
carbon steel
spring steel
weathering
steel
maraging steel
stainless steel
tool steel
This method is very sustainable. When new metals are introduced
into car a part all that is needed is a new number be put into the database.
The numbers will synchronize with all of the scanners via satellite once a year. It is not crucial that the
scanners be updated right away because the cars will take on average ten to fifteen years to go back
into the recycling process.
6.0 Conclusions
The solution that we have is innovative and effective, but like any solution there will be some
draw backs. The largest of ours is the time that is taken to dismantle an entire car into all of its pieces.
After a car has gone through its life there will be dirt, mud, grease, and all sorts of road grime getting in
the way of tearing apart the car. Our learning experience during this project was looking more into the
end of the concept. We looked mostly into the actual steel manufacturing process and how to recycle
steel starting from there. We did not take into account the time it would take to dismantle an entire car.
In the beginning of the project our team was met with a lot of awe. A multibillion dollar
company was asking a group of freshman engineering students to develop an idea for recycling steel.
But we soon realized that no matter what age, people can have great and innovative ideas. We
approached the project enthusiastically and with every aspect of our knowledge. In the end we came up
with a design that will effectively and accurately recycles the steel back into the basic oxygen furnace.
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7.0 References
ArcelorMittal. "CURRENT PROJECT." SEDTAPP. Web. 30 Apr. 2012.
<http://www.sedtapp.psu.edu/design/design_projects/edsgn100/sp12/index.html>.
"Basic Oxygen Furnace: Process Description." Heat Treat Consortia Home. Web. 30 Apr. 2012.
<http://www.heattreatconsortium.com/MetalsAdvisor/iron_and_steel/process_description
s/raw_metals_preparation/steelmaking/basic_oxygen_furnace/basic_oyxgen_furnace_pro
cessdescription.htm>.
"Electric Arc Furnace: Process Description." Heat Treat Consortia Home. Web. 30 Apr. 2012.
<http://www.heattreatconsortium.com/MetalsAdvisor/iron_and_steel/process_description
s/raw_metals_preparation/steelmaking/electric_arc_furnace/electric_arc_furnace_process
_description.htm>.
"The Mass Spectrometer." Chemguide: Helping You to Understand Chemistry. 2010. Web. 30
Apr. 2012. <http://www.chemguide.co.uk/analysis/masspec/howitworks.html>.
"Recycled Scrap Steel." Armco Metals. 17 Apr. 2012. Web. 30 Apr. 2012.
<http://www.armcometals.com/Recycled%20Materials>.
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