Ferrous Scrap

Most ferrous scrap is recycled in steelmaking processes by melting the scrap in either a basic oxygen or an electric arc furnace. However, a significant market exists for cast-iron products, which are also made by melting ferrous scrap. In 1991, world production of cast irons was estimated at nearly 3.9 X 10 t at over 14,000 iron foundries (15). 

Total merchant shipments of DRI and HBI in 1993 reached 5.1 x 10 t. The primary DRI exporting countries were Venezuela, Russia, Malaysia, Trinidad, and India. The price of merchant HBI in 1993 was in the range of 125 to 167/1 on a deUvered basis. Although there are expectations that the value of merchant DRI should some day stand on its own, the historic price has been tied to the price of ferrous scrap. A general mle of thumb has been that the value of merchant DRI is comparable to prime scrap (No. 1 Bundles or No. 1 Bushelings) in industrial countries, and comparable to imported shredded scrap in developing countries (see RECYCLING, FERROUS METALS). 

Primary consumers for ferrous scrap are the iron and steel mills and foundries. Minor consumers iaclude ferroalloy producers, copper producers for use ia copper precipitation (see Recycling, nonferrous metals), and the chemical iadustry. The steel iadustry consumes about three-fourths of the total. Scrap consumption for ferroalloy production, copper precipitation, and the chemical iadustry total less than one million t. The United States is the leading exporter of ferrous scrap, exporting almost nine million t ia 1994, valued at about 1.3 biUioa. Total value of domestic scrap purchases and exports ia 1994 was 8 biUioa (2). 

A comprehensive history of ferrous scrap recycling ia the United States beginning ia 1646 has beea pubUshed (3). Some selected eveats of iaterest iaclude the first opea-hearth steel produced (1868) the first commercial direct-arc electric furnace steel produced ia the United States (1906) the first large iaduction furnace iastaHed ia the United States (1914) the first basic oxygen steel produced ia the United States (1954) the rise of continuous casters and scrap-based minimills (1965) the first thin-slab continuous caster at a minimill (1989) U.S. exports and imports of ferrous scrap at record highs (1990) and the end of production of open-hearth steel (1991). 

The avadabihty of prompt iadustrial scrap is directiy related to the level of iadustrial activity. Producers geaeraHy do aot accumulate prompt iadustrial scrap because of storage requiremeats and iaventory control costs. Thus, it is rapidly available to the scrap consumer or the ferrous scrap iadustry. Prompt iadustrial scrap comes from imported steel as well as domestic steel mill products. Obsolete scrap, also known as old or post-coasumer scrap, is widely used. Treads ia aew steelmaking capacity and the reduced proportions of premium scrap iadicate that use of obsolete scrap should be expected to iacrease. 

Shredding operations may also include apphances (white goods) which are being recycled in increasing quantities at least partiy because of the banning of apphances from landfills in many states. The recycling rate for apphances in 1994 was 70% compared to 62% in 1993 when 1.4 million t of ferrous scrap was recovered from 36 million apphances. The recycling rate was 55% in 1992 (10,11). 

Constmction and dem olition (C D) debris is a potentiahy large source of recyclables. However, as of 1995, generation rates and ferrous scrap content were not weh estabUshed and estimates were highly variable. Eerrous materials in C D debris are typicahy reinforcing bars, wire mesh, and stmctural steel. Some of the scrap is sold for recycling once concrete is effectively removed and the scrap is sized to specification (17). 

Table 1. Ferrous Scrap and Pig Iron in the Steel Industry, 1994 ...

The most comprehensive set of descriptions of ferrous scrap are pubHshed by ISRI. Individual steel mill and foundry consumers usually foUow the ISRI specifications, although many also incorporate specific requirements tailored to the needs of the consuming faciHty. 

Scrap from municipal refuse may be in the form of source-separated steel cans, a mixed ferrous fraction, metal magnetically separated from mixed waste or incinerator ash, and C D debris. An ASTM specification (E1134-86) was developed in 1991 for source-separated steel cans. The Steel Recycling Institute has a descriptive steel can specification entitled "Steel Can Scrap Specifications". PubHshed standards for municipal ferrous scrap also include ASTM E701-80, which defines chemical and physical test methods, and ASTM E702-85 which covers the chemical and physical requirements of ferrous scrap for several scrap-consurning industries. 

A. J. Stone and P. H. Meyst, Ferrous Scrap Materials Manual ICRI Report No. 517, Iron Casting Research Institute (ICRI), Columbus, Ohio, Mar. 

R. D. Burlingame, Ferrous Scrap Fxplained Luria Brothers Co., Inc., Cleveland, Ohio, 1981. 

The Commission is working on establishing end-of-waste criteria for a number of specific recyclable materials including metal scrap of copper, aluminum and iron, waste paper, waste glass, compost, and plastics. Based on the results of two frontrunner studies, ferrous scrap and aluminum scrap in 2010, the first... 

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