Mill Scale is Our Business
Mineral Recycling (Saucon Resources) is offering Mill Scale from production sources in the U.S. For export or domestic use. Please contact us for analysis and current pricing information. Current allotments of materials are available. Spot purchases or potential long term contracts. All material we sell is produced in the USA, is screened clean and will meet standard specification boundaries.
Scales used to be considered a waste material by most steel producers in the U.S. When China entered the Worldwide steel market all available FE raw materials were considered potential supply options. These materials are a very good material for use in steel making and has many other uses and seen on Byproduct Uses. Many factories mix a few percentages of this material with their iron ore fines before they are sintered to help boost the iron content. Another main use is for cement production but for this purpose lower quality materials can be used.
Our company deals directly with producers here in the U.S. and has for many years. We move 7000 plus tons a month long term and from time to time we are involved in large export contracts. We can supply higher grade materials for steel making or lower grades for cement use. Please contact us for current availability.
Mill Scale As Used In Industrial Recycling
When we sometimes explain the materials we sell, I reference TV programs that explain steel manufacturing. When the TV program shows a red hot slab or plate of steel coming out of the steel mill’s furnace: Mill scale is basically the rust coating which forms on the poured steel or newly cast surface, it appears flaky and can be seen easily on the red hot surface. The materials are produced on the plate outer surface, profiles or sheets when it is produced by rolling the steel billets and hot iron in steel or rolling mills.
It seems like a hard brittle material which is mainly composed of mostly ferric, iron oxides and bluish black in color. Also produced during the hot rolling, conditioning and reheating operation for new steel production, initially the material adheres to the surface of the steel and also protects it from atmospheric corrosion. The scale is taken off by air blown or physical shaking, the material is then piled up or hauled away to storage areas.
Historically, it is collected and sold to the cement plants as iron requirement and additive agglomerate but now is seeing many more industrial applications. This byproduct is a very valuable metallurgical raw material as it contains about 65 to 70% iron. Due to its chemical, mineralogical and physical properties, the substance is also used as a raw material in the sintering process as well.
Generally, mill scale is a steel producing byproduct waste which is also used as prime material in many industries. There are many companies that handle industrial recycling process and deliver good quality materials. The quality materials are more valuable among the recycled materials and depending on the industry and application. Mill scale prices can vary from application to application.
Although, this material is a waste stream, with heavy depletion of a standard scrap many steel or Iron producers like to use scale to add ferrous (iron) units. Composition does depend on the type of steel being produced.
For the most part this byproduct contains a high amount of iron as well as low amount of alumina and silica. Hence, recycling it via sintering process. Hence, recycling it via the sintering process assist in saving the raw materials like limestone and iron ore. There are many studies investigated about the potential of steel mill by-product recycling in the sintering process. Except sinter productivity, some of the desired sinter properties can be achieved by using 40 to 50 kg of recycled materials per sinter ton.
Is your company looking recycled materials? Do you have a special materials need? Please CONTACT one of our professional team members to get started with any of your sourcing challenges. We would like the opportunity to be your company’s Mill Scale Supplier.
We will discuss mill uses both general mainstream uses and specific industrial applications.
Iron Oxide or scale refers to the substance that is formed due to oxidation of steel during operations like hot rolling, hot press, hot forming, heating/reheating, continuous casting, flame scarfing, conditioning, etc. Other than precious metals, all other metals are found in nature as oxides. The spontaneous corrosion of the surface of steel into ferrous oxide results in creation of scale. We will discus material uses in industry today and the future.
While discarded earlier as an unavoidable waste product generated during the steel manufacturing process, it is now possible to remove the scale by a combination of process waters and gravity separation, this generates a useful material.
Here are some of the basic Mill Scale Uses:
3. Cement clinker
5. Heat conservation
6. Generation of exothermic power
7. Iron Feedstock
11. Friction products
12. Colored Glass
13. Heavy concrete
14. Iron oxides
15. Iron salts
16. Melting charge
17. Mineral wool
19. Radiation shielding
21. Road construction
22. Sinter, Recycling material
23. Slag formers
24. Stone production
25. Tool steel
26. Water and soil treatment
27. Welding electrodes
28. Concrete weight aggregate
This byproduct can be mixed with copper during hot rolling and forging processes to manufacture the negative electrode or plates in alkaline batteries.
Mill scale can be utilized as catalysts in chemical processes requiring iron oxides to produce acetic acid.
One of the most prominent mill scale uses is Cement. Adding mill scale to the combustion area when manufacturing cement clinker converts unwanted and potentially-dangerous hydrocarbon gases into less volatile gas products. Further, it can be used as a raw material for manufacture of cement clinker by mixing it with feedstock materials before introduction of the raw material into the heated rotary kiln.
Composite counterweights, which are commonly used in industrial manufacturing processes and machines, consist of a waste-product or by-product of an industrial process that is bound with material of uniform mass. These ferrous byproducts can be used in the manufacture of counterweights. The product so prepared is then used in the finished machine or equipment.
Mill scale is being used in place of concrete as counterweights in washing machines. The material is mixed with water and used as filling material. These counterweights are used in the manufacturing process of basic metals as well as for production of general machinery and transportation equipment.
Use of mill scale for separation of volatile metals, iron, slag, and other impurities facilitates heat conservation and improves energy efficiency. Processing waste materials in an Electric Arc Furnace can help improve productivity and output and reduce wastage. Heat conservation helps avoid unnecessary wastage of resources when processing waste materials.
Generation of Exothermic Power
Combining waste products generated during the manufacturing process of heavy metals with mill scale will result in a low-density material that can injected into the furnace to create an exothermic reaction without excessive use of raw materials.
This material is a waste product that is rich in iron making one of mill scale uses a FE additive. This material can be mixed with industrial waste and by products to create iron feedstock for the manufacturing process. Mill scale can be processed through leaching, roasting, and other processes.
Refining ferro-alloys involves addition of oxidizing agents that will combine with the impurities and rise to the surface. Or, the slag will separate or get diffused as gas by products. Mill scale is a suitable agent for oxidation to remove impurities from alloys.
Magnetic carrier additives can enhance the performance and efficacy of mixed fertilizers. Mill scale is used as the magnetizing synergist agent to provide additional nutrients to the crop. Mill scale is also used as a de-siliconization agent that is an integral part of the phosphate fertilizer production process.
Mill scale can also be used in the manufacture of water-treatment chemicals that are used in agricultural, forestry, fishing, and scientific activities related to research and development.
Mill scale is used as a source of iron for manufacture of iron and steel from scrap materials. The submerged arc furnace produces very little slag, which facilitates use of mill scale as reducing agents to produce alloy metal with very little slag and impurities.
More Mill Scale Uses
Friction Products Like Brakes.
Auto brakes rely on friction to bring the vehicle to a halt. In products that use sponge iron as the principal material for generating friction, mill scale can be used to replace up to half of the sponge iron without compromising on efficacy or performance of the friction material. This makes mill scale a useful raw material for the manufacture of a wide range of equipment including industrial machines as well as consumer goods.
Colored glass is made primarily by using slag contents that contain iron, manganese, and other metals that causes the glass to have the desired hue. Small amounts of mill scale can be used as a replacement for iron-based colorants during the glass manufacturing process.
This type of concrete does not require additional thickeners and is manufactured by mixing cement, a heavy aggregate and water. Mill scale can be combined with feedstock and used as a part of the heavy aggregate material that differentiates this type of concrete from standard concrete.
Heating mill scale and iron oxide will result in production of iron oxide pigments of shades of red, brown, or black. Further addition of mill scale and heating the resulting mixture will result produce iron oxide black pigment.
Leaching of mill scale at high temperatures in a high-pressure environment can lead to recovery of ferric oxide, which can then be used for various industrial applications and processes.
Mill scale can be kept in containers that are then used as electric furnace melting charge controllers.
Mineral wool requires use of fluxing materials during its production process. Mill scale can be used as one such material.
Iron Oxide Paint
Paint manufacturing requires use of iron oxide paint pigments. Mill scale can be used in the cores to help achieve the right balance and proportion of iron, which is the most significant component of the pigment.
Shielding material consists of building material combined with a shielding component that makes it possible for the material to reflect or absorb electromagnetic radiation. Since ferrous materials can be used for shielding, dry mill scale can be used to manufacture materials that are capable of blocking electromagnetic radiation.
Refractory material is made by crushing dolomite and mixing it with a flux suspension liquid or paint. Mill scale can be used as flux material that is combined with the liquid binder and ultimate used to produce the refractory material.
For building roads that offer greater adhesion between the tire and the surface, greater ability to withstand abrasive contact, and even conduction of surface heat, mill scale can be added to the building material as an additional component to enhance safety, quality, and durability of the surface of the road.
Mill scale is a byproduct that can be used for sintering iron and zinc ore. The scale is mixed with a fuel and an agglomeration agent is used to create the mixture. The sinter bed is then heated to bring the process to its conclusion.
For foaming slag to be truly effective, the foam must be created up to a certain height on top of the molten steel material. Introducing mill scale will ensure the foam is of the amount and volume that will ensure the molten steel is completely protected by the foaming slag.
Mill scale is an ideal raw material for manufacturing high-content stone with magnetite ore for use in high-grade food, medical, and military equipment. This stone has very little impurities and undergoes a stringent purification process.
Removing carbon in specific parts of tool steel molds where free carbon may impair safety or strength can be done by introducing an oxidizing agent like scale. This material offers greater control over the overall content of free carbon along with the ability to vary carbon content in different parts of the metal product or article which is a very specific example of mill scale uses.
Water and Soil Treatment
Contaminated soil or ground water containing halogen compounds can be purified by use of iron-based purification particles. Mill scale is an effective purification material that can be introduced into the contamination-removal process.
Electric arc welding electrodes are made of an alkali meal oxide that is combined with metal compounds like oxides of iron, manganese, aluminum or silicon dioxide. Mill scale is an effective source of iron oxides for the manufacture of electrodes that are used in the welding process.
Heavy Weight Aggregates
Heavy concrete and mortar require fine aggregate particles with metal iron as its primary constituent one of the major mill scale uses. The heavy weight aggregate is manufactured by mixing materials like mill scale of specific diameters, pig iron particles, and granulated slags.
Mill scale uses are multiple, this byproduct is versatile and can be used for coloring, binding, heat transfer, lubrication, viscosity adjustment, and as agents for binding or absorbing gases or liquids. If your company or organization requires mill scale or other Fe related materials please contact us. Saucon Resources has Multiple resources for supplying mill scale. If you are in an industry that is suited to mill scale uses contact us.
Available Scales, Oxides and Raw Materials:
As mill Scale Suppliers, we can arrange and facilitate contracts for materials produced in the U.S. for volumes of 500 to 5000 net tons per month. Looking for Material Prices? Contact our Team for up to date quotes.
Mill scale allotment available of 30,000 mt +/_ 10%.
Pig Iron Briquettes, 90% FE+ 500-5000 tons per month.
Iron Fines produced in the U.S. FE content +70% , 3000 MT per month
Cement Companies: we have several materials suited for your industry and in large volumes.
Mill Scale and other recycled minerals & byproducts for re-use in industrial applications.
4800 Stecker St