METALLURGY AND FOUNDRY ENGINEERING – Vol. 34, 2008, No.

Mohammad Hassan Joulazadeh*

ENVIRONMENTAL FRIENDLY CONSUMPTION OF SCRAP TIRES

IN EAF’S TO SAVE POWER & CARBON

1. INTRODUCTION

The Islamic Rep. of Iran began to produce steel about 40 years ago. Figure 1 shows
crude steel production trend in Iran. Iran produced 10,2 mmt crude steel in 2007. EAF steel-
making routes share is 77.5%, for the 4th development plan this share will increase up to
85%. Iranian steelmaking inputs are DRI (65%), HM (20.5%) and Scrap (14.5%) which
differ from world steelmaking inputs. Carbon is one of the most utilized compounds in EAF
steelmaking and plays a significant role in the process as follows.

Fig. 1. Iranian crude steel production trend

– Source of energy in the steel bath via reaction with oxygen

2C+O2 → 2CO (1)

* M.Sc.: Persia Metal Co. Consultant, Esfahan, Islamic Republic of Iran; e-mail: [email protected]

13
 – Source of energy above the bath via post combustion with oxygen
CO + O2 → CO2 (2)
– Recovery of iron from the slag via the reaction
FeO + C → Fe + CO (3)
– Slag foaming materials.
– Fundamental alloying element.

The amount of charge carbon used depends on several factors including.

– Carbon content of scrap charge.
– Desired tapping carbon
– Projected oxygen gas consumption.
– The economics of iron yields versus C cost [1].

In the past carbon bearing materials were charged into EAF to ensure that the melt-in
carbon level was about that desired in the final product. Carbon bearing materials used
normally for EAF are metallurgical, petroleum, fluid coke, anthracite coal and artificial
graphite. Iranian EAF units mostly used coke or coal as carbon bearing materials usually,
these materials imported from abroad. The price of coke and clean coal varies between 300–
350 $/t. On the other hand about 8 millions passenger car and truck tires scrapped each year
usually spread in land. In this situation ESCo decided to improve the environment by recy-
cling scrap tires instead of burying them in landfills and reduce steelmaking cost. ESCo first
pondered waste tire as a recyclable material in 2004. Since then, these resources have been
in use as a partial steel scrap and coke replacement within EAF steelmaking. While use of
tires in EAFs is a new market in IRI, this practice was is standard in US and France in 2000,
in Japan 1998. Now in Japan, some 15% of all used tires are consumed by EAFs. In the US
in 2005, 1.34 million (18880 tons) waste tires were consumed by EAF [2]. This research is
related to the melting of scrap metal in various Iranian EAF, using whole used tires as an
additional source of heat and carbon. Some of worldwide steel companies such as West
Siberian I&S works & Nippon Steel use scrap tires in oxygen blown vessels successfully.

2. ENVIRONMENT AND SCRAP TIRES

In 2006 more than 1.3 billion scrap tires were generated in the US, Japan, Russia, Iran
and they discard 300 [2], 130, 50 & 8 million truck and passenger car tires per year respec-
tively. Scrap tires are a significant problem worldwide and their disposal presents environ-
mental and safety hazards including fire, overflowing landfills and pollution of the atmo-
sphere. Disposal of scrap tires in tire piles is non-acceptable practice because of the risks
posed by tire fire and because tire piles can provide habitats for disease vector such as mos-
quitoes [3]. Tire stock piles host snakes and small mammals such as rats, opossum, skunks
and raccoons. The greatest risk associated with scrap tire stockpiles is their possible igni-
tion. Once ignited, stock pile fires tend to spread rapidly generating massive quantities of
smoke and contaminated water. In recent years 7 scrap tire stock piles fired in the Tehran,
Qazvin, Eslam Shahr, Karaj and Yazd cities of Iran. It is reported that in 1983 a 7 million

14
tire fire in Rhinehart Virginia is-
sued a cloud of smoke with air
pollution deposited in three
states. In 1999 a lighting strike
ignited tire fire in Westley, Cali-
fornia [4]. ESCo took environ-
mental responsibilities very se-
riously and tried to help and to
solve environmental problems
and get economical and ecologi-
cal benefits from scrap tires. For
this purpose ESCo began to use Fig. 2. A view of ESCos scrap tires storage
its scrap tires collected in sto-
rage, in the EAF. Figure 2 presents a view of ESCo’s scrap tires storage. The scrap automo-
tive tires are so plentiful that they have a near zero cost.

3. PRERESEARCH

Before using worn-out tires in EAF, research was done to determine results for using
old tires in other industrial fields. Cement kilns, boilers, pulp and paper mills were used for
discarding tires. Except for cement kilns, old tires are not readily acceptable for use as ener-
gy source [5]. Size and steel belts and beads of tires can be problematic for some scrap tires
uses, but belts and beads are valuable raw materials for steel mill using EAF. In this research
in the first step ESCos scrap tires storage was visited and the number, type and weight of
them determined. The weight of them varied between 5 up to 1000 kg. For the calculation of
steel bead weight, 7 pieces of passenger car tires were completely burned and it was found
that scrap tires contain 10% bead. Steel grade of bead was C67. The heat of combustion of
scrap tire was 8334 kcal/kg.

3.1. Trials in 6 tons capacity EAF

Initial trials were done in the melt shop employing a 6 Mg AC EAF for casting parts
manufacturing. The EAF powered by a 2.8 MVA transformer. All scraps and fluxes are
delivered via a single basket. Produced steel grades are shown in the Table 1. The details of
heats parameters are illustrated in Table 2. As shown in the Table 2 approximately 16 kg
scrap tire/t is consumed. S content of steels was lower then limited value. Coke and pig iron
charges (as carbon sources) were eliminated. Electrical energy consumption was reduced as
compared to nominal and actual rate by 10 & 12% respectively. As shown in Figure 3 actual
electric energy consumption decreased from 448 to 388 kWh/Mg steel. Carburizing of steel
(up to 1% C) was done by scrap tires. Production cost was lowered by 4–5 €/Mg. In the flue
gas CO, NOx and SO2 content was lower than permitted range (measured by the Testo
350XL). Table 3 shows comparison of flue gas composition analyzed and allowed. The heat
results of EAF (6t) did not reveal any difference between carbon from coke, coal, pig iron
and that from scrap whole tires. In this step of research more than 300 Mg casting parts was
manufactured and totally 4.5 Mg of scrap tires consumed, which corresponds to two passen-
ger car tires/t charged. The used tires were charged as whole to scrap basket near the bottom

15
of metallic charge. Steel scrap is added onto the tires, which compresses tires and decreases
the space occupied by them. Figure 4 presented charging of scrap tires in scrap bucket.
Adding of scrap tires to molten steel is dangerous and not recommended.
Table 1. Steel grades heats produced with charging scrap tires
Grade C Mn Si P≤ S ≤ Cr Ni Mo
20GL 0.15–0.25 1.20–1.50 0.20–0.42 0.040 0.040 ≤0.30 ≤0.30
GS-45 0.20–0.25 0.60–1.00 0.35–0.60 0.030 0.030 ≤0.40 ≤0.40
25L 0.22–0.30 0.30–0.75 0.20–0.42 0.040 0.045 ≤0.30 ≤0.30
30L 0.27–0.34 0.30–0.75 0.20–0.42 0.040 0.040 ≤0.30 ≤0.30
35L 0.32–0.40 0.40–0.90 0.20–0.42 0.040 0.045 ≤0.30 ≤0.30
45L 0.42–0.50 0.40–0.90 0.20–0.42 0.040 0.045 ≤0.30 ≤0.30
WS-140 0.67–0.75 0.72–0.78 0.47–0.53 0.030 0.030 2.22–2.28 ≤0.30 0.30–0.40
WS-170 0.80–0.90 0.70–1.20 0.30–0.60 0.045 0.045 2.00–2.40 ≤0.50 0.30–0.45
38KhGN 0.35–0.43 0.8–1.10 0.20–0.42 0.040 0.040 0.50–0.80 0.70–1.00
30KhN2M 0.27–0.34 0.30–0.60 0.17–0.37 0.020 0.020 0.60–0.90 1.30–1.70 0.20–0.30
30Kh 0.65–0.75 0.40–0.90 0.20–0.42 0.035 0.035 0.80–1.10 ≤0.40
GS-20Mn5 0.17–0.23 1.00–1.50 ≤0.60 0.020 0.015 ≤0.30 ≤0.40 ≤0.15
6KhGNM2 0.50–0.60 1.00–1.20 0.40–0.60 0.040 0.040 2.40–2.60 0.70–0.90 0.40–0.60

Table 2. Details of some heat parameters

Final En.Con. Scrap Tire Final Heat
C% Grade
(C%) (kWh/t) (kg) (S% ) #
0.37 0.32–0.40 387.6 59 0.022 35 L 20748
0.66 0.65–0.75 387 76 0.026 WS-140 20751
0.72 0.65–0.75 333.5 125 0.015 WS-140 20760
0.37 0.32–0.40 389.9 90 0.027 35 L 20762
0.70 0.65–0.75 416.8 125 0.010 WS-140 20763
0.31 0.27–0.34 312.8 80 0.022 30 L 20765
0.30 0.32–0.40 457 100 0.022 35 L 20766
0.49 0.42–0.50 345.9 100 0.027 45 L 20767
0.69 0.65–0.75 407.6 135 0.015 WS-140 20768
0.83 0.75–0.85 384 150 0.011 WS-170 20771
0.66 0.65–0.75 467.7 150 0.015 WS-140 20773
0.29 0.27–0.34 404.7 110 0.018 30 L 20774
0.73 0.65–0.75 390.2 160 0.020 WS140 20789
0.28 0.27–0.34 374.4 100 0.020 30 L 20790
0.45 0.42–0.50 420.7 130 0.026 45 L 20791
0.37 0.35–0.42 353.6 120 0.025 38 KhGN 20792
0.45 0.42–0.50 360 130 0.015 45 L 20793
0.43 0.42–0.50 317.5 130 0.022 45 L 20795
0.71 0.65–0.75 381.8 160 0.015 WS140 20796
0.36 0.32–0.40 397.8 110 0.020 35 L 20798
0.36 0.32–0.40 322.6 100 0.021 35 L 20806
0.27 0.22–0.30 341.7 70 0.024 25 L 20809
0.36 0.32–0.40 360 100 0.026 35 L 20812
0.40 0.42–0.50 338.5 120 0.021 45 L 20813
0.22 0.20–0.25 453.6 150 0.025 GS-45 20815
0.04 0.42–0.50 391.4 100 0.029 45 L 20817
0.36 0.32–0.40 346 100 0.021 35 L 20829

16
 kWh/Mg

Fig. 3. Influence of scrap tires

used on electrical energy consumption

Table 3. CO, NOx and SO2 content of flue gas

Heat # Heat # Heat # Heat # Heat # Heat # Heat # Heat # Heat # Heat # Allowed
Unit Gas
20930 20929 20922 20921 20844 20817 20815 20796 20774 20738 Range
87 297 178 180 435 110 144 114 129 128 435 PPM CO
11.79 42 72 87 84 0.5 36 158 128 126 350 PPM NOX
16.7 9.5 25 6.8 56 0 15 11 19 19 800 PPM SO2

Fig. 4. Charging of scrap tires in scrap basket

3.2. Performance of Used Tires in 40 Mg AC EAF

After observing successful results in 6 Mg capacity AC EAF, we decided to perform this

work in a high capacity EAF in IAS Co. This plant has two 40 Mg AC EAF, two ladle stirring
station and a 4 strand billet CCM. The EAF is powered by two 30 MVA transformers and
a co-jet slag door burner device equipped with post combustion oxygen port. It makes

17
between 14–15 heats per day. 20 heats were made with 11571 and 00601 steel grades.
Metallic materials were charged into EAF in 2 or 3 baskets. The first basket contained more
used tires than the second one, and the second more than third. For safety purpose after each
tapping 40–50% of required lime was charged on the bottom of EAF. Scrap tires were put in
the middle of each basket. Once the steel scrap charge was molten, pure oxygen was inject-
ed by lance to create decarburization and post combustion of the excess CO. Scrap tires
added with the iron bearing charge give additional energy by exothermic reactions [6].

Decarburizing C + O2 → CO + 1.35 kWh / kg. C (4)

Post combustion CO + O2 → CO2 + 6.0 kWh / kg. C (5)

Total C + O2 → CO2 + 7.35 kWh / kg. C (6)

A general trend observed for EAF processes is an increase in oxygen and carbon injec-
tions. Results of this work were as follows:
– Coke is replaced by scrap tires and coke consumption completely eliminated.
– Average scrap tires consumption was 14.1 kg/t.
– Electric power consumption decreased by 10% (from 580 to 530 kWh/Mg) and pro-
duction cost lowered by 5 €/t. CO, SO2 and NOx content of stack gas was within
allowed range.
– Similar results were obtained in Malayer alloy steel company with 25 t EAF (17 MVA).

3.3. Dioxins Formation & Emissions

Of the various pollutants generated in EAF steelmaking processes, dioxins are by far
the most toxic. The problem of dioxins emissions is particularly critical in EAF units where
large quantities of externally purchased scrap (with the omnipresent organic & chloride
compounds) are melted to produce steel [7]. Poly Chloral Dibenzol Dioxins are chemical
compounds of chlorine. A dioxin is any compound that contains the dibenzo-p- dioxin nu-
cleus. A furan is any compound that contains the dibenzofuran nucleus [8]. The general
formulas are shown in Figure 5. According to information from Rubber Manufacturers
Association, tires contain nearly undetectable level of chlorine and do not from dioxins in
high temperature processes [5]. No influence on measured concentration of dioxins and
furan in the gaseous phase in smokestack emissions of EAF steelmaking with scrap tire
charge mix was found [6]. A number of factors influence the amount of dioxins which may
be formed in a given EAF steelmaking process, including temperature, pH, catalyst and
reactions kinetics. The effect of temperature on formation of halogenated dioxins and furan
is well recognized. A mathematical relationship between temperature and DXN formation
has been proposed to calculate the theoretical amount of dioxins that can be expected (7).

y = 0.025t 2 e−3[(t − 200) / 200] (7)

where y is dioxin concentration (ppb) and t is temperature (oC).

18
 Fig. 5. General formulas of Dioxin (2, 3, 7, 8) & Furan (2, 3, 7, 8) [8]

This relationship graphically represented in Figure 6, shows that dioxin formation

peaks at 200oC and decreases unsymmetrically with increasing temperature [8]. If metallic
charge of EAF contains some chlorine, in order to minimize the reforming of dioxin, rapid
cooling of the process off gas to below 200oC is the most effective means [7]. Quality con-
trol of scrap or dust inputs depends on the process used. UNEP recommends an emission
factor of 10 μg TEQ/tls. If controls are put on scrap to exclude cutting oils and heavily
contaminated scrap, and gas cleaning with secondary combustion and fabric filtration are
used, emissions below 0.1 μg TEQ/tls can be achieved. Selection and sorting to prevent
the addition of material that is contaminated with organic matter or precursors can redu-
ce the potential for dioxin formation. The use of optimum combustion conditions and oxy-
gen injection in the upper part of a furnace to ensure complete combustion of furnace gases
may be necessary to achieve this. As the regulation values in EAF units in Japan are 0.5 ng
TEQ/Nm3 or less for a newly built furnace, 5 ng TEQ (Toxic Equivalency)/Nm3 or less for
an existing furnace. The temperature of the gas entering the bag house has strong effect on
dioxin content discharged to atmosphere (see Fig. 7). When the temperature is kept below
80oC, a dioxin content of less than 1 ng TEQ/Nm3 can be achieved [9].

Fig. 6. Dioxine concentration versus temperature [8]

19
 DXN (ng-TEQ/m3[N])

Temperature (oC)

Fig. 7. Scatter plot of temperature of the inlet of dust collectors and DXN conc. in EAF flue gases [9]

4. CONCLUSIONS

This research has shown that scrap tires can be used as a substitute for carbon in
the EAF steelmaking process. Used tires can replace coke in EAF at least up to the level
14.5 kg/Mg.
The replacement ratio is 1.6 kg tire/kg coke. The tires are added to the scrap as a source
of chemical energy.Replacing coal and coke consumption of used tires in EAF’s resulted in
the following:
1. Coke and coal charge are eliminated completely in EAF (6, 25 & 40 Mg) steelmaking
process.
2. Rolling mills scale or oxygen gas are injected into EAFs while the scrap tires are burn-
ing so than combustion is complete and clean.
3. Bead wires (10% of tire weight) become a part of steel charge. Since the steel and other
materials of tires are consumed, there is no ash or other waste.
4. Scrap tires are used as carbon source for low, medium and high carbon content steel as
well as heat and wear resistant steels in EAF .
5. Consumption of scrap tires in EAF can provide a net decrease in electrical and chemi-
cal energy. In this research electrical energy consumption is reduced by 10–20%.
6. The stack gas analysis has shown that the concentrations of CO, NOx & SO2 were
within permitted range.
7. No adverse impact on emissions and reduced NOx emission. S content of steel products
was lower than 0.026%.
8. Carburizing power of truck and bus tires is better than passenger car tires.
9. Adding of scrap tires to molten steel is not recommended.
10. The final cost of steel is lowered by 5 €/Mg.
11. In Iran annually 8 million passenger car and truck tires are discarded. In existing EAFs
it is possible to use 11 millions scrap tires (110000 Mg). Iran will produce 29 million
tons of crude steel in 4th development plan. In this case 40 millions passenger car tires
or equal weight truck tires can be used in EAF steelmaking process.

20
12. Mechanical, physical and chemical properties of steel products as well as gas content
and absence of casting failures were approved by quality control department.
13. Using scrap tires is not recycling but it is considered as beneficial use. It is better to
recover the energy from a tire rather than landfill it.
14. Scrap tires have a heat of combustion value of 6668 to 8355 kcals/kg & contain less
ash and S than most types of coals.
15. Shredding of tires is very expensive. In this research whole tires were charged into the
EAF.
16. EAF can also accept large sized tires as bus, grader, mining and road machinery, bull-
dozer & farm tires. In this respect a whole loader tires of 250 kg were charged into 40 Mg
EAF.
17. The low cost technique promotes environmental safety without affecting the steel quality.
18. According to information from Rubber Manufacturers Association, tires contain near-
ly undetectable levels of chlorine and do not form dioxin in high temperature process
as EAF steelmaking. Dioxin formation peaks at 200oC and decreases unsymmetrically
with increasing temperature. Tires have virtually no Hg. In Japan, dioxins limited va-
lues are 0.5 ng TEQ/Nm3 or less for a newly built EAF and 5 ng TEQ/Nm3 or less for
an existing EAF.

Acknowledgments
This project is supported by ESCo. The Author would like to thank the managing di-
rector Mr. B. Sobhany, deputy managing director Mr. R.G. Ebrahimi and R&D team of
ESCo who cooperated and helped to conduct this work. Thanks are also extended to manag-
ing directors of Merat Poolad, Iran & Malayer Alloy Steel companies for their kind cooper-
ation to implement this environmental friendly research.

REFERENCES

[1] Jones J.A.T.: Carbon Utilization in the EAF, 1998, EAF conference proceeding, p. 599
[2] Rubber Manufacturing Association: Scrap tire markets in the U.S. 2005 Edition, Washington DC, 2006,
p. 10
[3] EPA Management of Scrap Tires – Tire Derived Fuel, April 2005,EPA530-F-05-006 p. 1
[4] EPA Management of Scrap Tires – Tire fires
[5] Stebbing L.P.E.: Using scrap tires as a Chemical fuel source in the EAF. AISE, 2002, p. 3
[6] Clauzade/Aliapur C.: End of life tires in EAF-s: An industrial success story. 2006, p. 1
[7] Lehner J.: Low cost solutions for the removal of Dioxin from EAF off gas.Steel Times Int. September 2003,
pp. 40–45
[8] EPA-454/R-97-003: Locating and Estimating Air Emissions from Sources of Dioxins and Furans. U.S. En-
vironment Protection Agency. Research Triangle Park, North Carolina 27711 May 1997, pp. 172–173(4)
[9] Yamakawa H., Isakara K. et al.: Study on dioxin reduction & behavior of it in EAF. La Revue de Metallur-
gie, 2002 January, pp. 23–30

Received
October 2008

21