Case Studies
Case Studies
These case studies demonstrate cost-effective upgrades, successful installations, and proven operational results.
Case Study 1
Gold Mine Tailings Paste Backfill, USA
Problem:
A gold mine had reclaimed tailings with approximately 18% moisture and variable particle sizes. They needed a feeder that could handle this difficult, inconsistent material and meter it at a constant rate into a batch mixer without bridging or stalling.
Solution:
Steele supplied two E Series Even Feeders — one triple 124E and one double 124E — fitted with a large 120 cubic yard hopper loaded by a front-end loader. The two feeders work in tandem, cycling on and off to deliver a consistent, even flow to the batch mixer.
Result:
Reliable, low-maintenance operation confirmed. The machines are estimated to process 50 million tonnes of bulk raw material over their service life.
Case Study 2
Blast Furnace Dust & Smelter Sludge to Briquettes, West Bengal, India
Problem:
A pig iron manufacturer operating two blast furnaces was paying market rates for iron ore and coke while generating large volumes of blast furnace dust and LD sludge — fine, wet waste with no productive outlet.
Solution:
Steele engineered a stiff extrusion line to convert the waste streams into cold-bonded briquettes using 6% Portland cement as a binder. The process involved high-intensity mixing, vacuum de-airing, and extrusion at 15–18 tonnes per hour. No heating or firing required.
Result:
Briquettes replaced 40% of iron ore feed within the first year, rising to 100% within 12 months. Coke consumption dropped 24% — from 680kg to 520kg per hot metal tonne — due to residual carbon in the waste. All-in production cost under $12 per tonne.
Case Study 3
Steel Mill By-Product Recovery, CAP Acero, Chile
Problem:
Steel mills globally generate large volumes of fine dusts, sludges, and residues that accumulate in stockpiles — material with high iron and carbon content that cannot be economically returned to the melt cycle without conditioning.
Solution:
Steele partnered with TMS International to develop the Extruded Product Services (EPS) process, powered by Steele stiff extrusion. A dedicated on-site EPS plant was built at CAP Acero in Concepción, Chile, converting fine mill waste into standardised furnace feedstock tailored to each mill’s melt recipe.
Result:
Full-scale commercial plant operational since 2019. Steelworks waste converted to usable feedstock with minimal binder and no heat or firing required, reducing material costs and CO₂ emissions simultaneously.
Case Study 4
Steel Mill By-Product Recovery, Five Plants, India
Problem:
Steel and ferro alloy producers across India were generating significant volumes of LD sludge, blast furnace dust, baghouse dust, mill scale, DRI fines, sinter fines, and coke fines — all with recoverable value but no reliable processing pathway.
Solution:
Steele installed five stiff extrusion plants across India — at Rourkela, Raigarh, Jamshedpur, Joda, and Visakhapatnam — through a partnership with Green Sustainability Services (GSS). Each plant processes iron, carbon, and flux-rich fines back into agglomerated feedstock for blast furnace, steel, and ferro alloy operations.
Proven Metal Recovery With Simple, Reliable Equipment
If your mills are accumulating mountains of minus 3mm fines with varying moisture levels, then you’re in our sweet spot and we should talk.
For more information on Steele by-product management for iron and steel mills, talk to your regional Steele sales representative or call +1.704.872.3681.