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 Displaying page 1 of 20, items 1 to 25 of 490.

3 May 2015

Session: Ironmaking Across the Globe
(Ironmaking)
1 pm -

Current Status and Future Perspective of Japanese Ironmaking Technology for Environmental Solution (Confirmed)

Unscheduled

Koji Saito, Nippon Steel & Sumitomo Metal Corp.; Yasushi Kurita, Nippon Steel & Sumitomo Metal Corp.

The circumstances surrounding the iron and steel industry have changed greatly. While the increased demand for steel products has caused a rise in the price of raw materials such as iron ore and metallurgical coal and the quality of raw material has been deteriorating, there is a growing need for developing technology to give solutions for various environmental problems such as energy shortage, increase in CO2 and NOx emission and so on. This plenary lecture provides a summary of the developments of ironmaking technologies in Japan for environmental solution, along with some examples of the development result and practical application such as RCA (Reactive Coke Agglomerate), LCC (Lime Coating Coke), SCOPE21 (Super Coke Oven for Productivity and Environment Enhancement toward the 21st century), COURSE50 (CO2 Ultimate Reduction in Steelmaking Process by Innovative Technology for Cool Earth 50) project and so on.


Ironmaking in North America (Confirmed)

Unscheduled

Louis Lherbier, United States Steel Corporation; John Ricketts, ArcelorMittal

The North American Steel Industry is continuing the recovery from the 2008 financial crisis. There has been further consolidation of steel companies and reconfiguration or shutdown of operating plants to meet market requirements but control costs. The current state of NAFTA iron and coke making statistics will be reviewed. North American blast furnace iron makers continue to take advantage of low natural gas prices by increasing rates of natural gas injection or co-injecting natural gas with coal. There has also been some new developments in blast furnace monitoring and control using equipment like furnace top infrared camera, installation of computer models to monitor hearth condition and computer based expert systems. Alternate coke making technology continues to be investigated with pilot plant trials and plans for commercial scale plants. Some of the older coke making facilities have been rebuilt and brought into production. Iron ore developments include commercialization and start-up of plants to recover concentrate from iron ore tailings, building of new pellet plants and pellet plant expansions.


Ironmaking in Western Europe (Confirmed)

Unscheduled

Hans Bodo Luengen, Steel Institute VDEh; Michael Peters, ThyssenKrupp Steel Europe AG; Peter Schmöle, ThyssenKrupp Steel Europe AG

This presentation focuses on the evolution of iron making in Western Europe and highlights some aspects, like: Introduction into the development of hot metal production, progress of the structure of reductants and ore burden materials, sintering of iron ores, evaluation of constructional features and equipment of the blast furnaces and further outlook for the European iron making scenario. The integrated steel works in Western Europe operate modern plants for the production of a wide variety of high grade steel products. The blast furnace/converter route will remain dominant. One main focus is set on the future CO2 trading system based on benchmarks with non-reachable values as set by the European Commission.


The Past, the Present and the Prospects of Ironmaking in China (Confirmed)

Unscheduled

Shourong Zhang, Wuhan Iron & Steel Co. Ltd.; Xuegong Bi, Wuhan University of Science and Technology

The steel production had been a weak industry in Chinese history. In 1950, iron production in China was less than 0.1% of world. Many blast furnaces were built since 1950’s. In 1996, both iron and steel production in China surpassed 100 million tons. At the beginning of 21st century, large-scale modernized iornmaking and steelmaking facilities were installed, advanced technologies were introduced widely. The Chinese steel industry is taking a share about 1/2 of the world iron and steel production. In 2014, there are 18 steelworks with annual ironmaking capacity over 10 million tons in China. This paper gives a brief review of the development and prospects of ironmaking technology in China.


4 May 2015

Session: Safety & Environmental
(Cokemaking)
9:30 am -

Automation of Coke Oven Batteries at Hyundai Steel in Korea (Confirmed)

Unscheduled

Marcel Schulz, ThyssenKrupp Industrial Solutions; Klaus-Peter Leuchtmann, ThyssenKrupp Industrial Solutions; Chung Jin Hyung, Hyundai Steel Co.; Kang Yong Mook, Hyundai Steel Co.

This paper will describe the design and installation of lower level and upper level electrical, instrumentation, control, reporting and supervisory systems developed by ThyssenKrupp Industrial Solutions for a state of the art coke plant at Hyundai Steel in Korea. This paper describes the improvements and capabilities of these systems compared to out of date technologies.


Cokemaking: PT Krakatau POSCO’s Gas Treatment Plant in Cilegon, Indonesia (Confirmed)

Unscheduled

Fabio Cerutti, Paul Wurth Italia S.p.A; Antonio Esposito, Paul Wurth Italia S.p.A; Björn Otten, DMT GmbH & Co. KG; Mario Petzsch, DMT GmbH & Co. KG

PT Krakatau POSCO’s Gas Treatment Plant (GTP) belongs to Indonesia’s first ever cokemaking plant. The installation is the result of a long and consolidated experience in the cokemaking field and combines know-how and experience of Paul Wurth and DMT. Based on the latest technologies and specific design know-how, this state-of-the-art project has been executed in close, trustful cooperation with the Customer. The GTP has been successfully commissioned in October 2013. The paper highlights the main technology features applied in this project for the different processes and gives an overview about GTP commissioning and start-up within a Greenfield coke making plant.


Construction and Operation of NSSMC Kashima 1E Coke Oven Battery (Confirmed)

Unscheduled

Satoshi Ishikawa, Nippon Steel & Sumitomo Metal Corporation; Kakunari Suzuki, Nippon Steel & Sumitomo Metal Corporation; Hideyuki Kunimasa, Nippon Steel & Sumitomo Metal Corporation; Yuji Komai, Nippon Steel & Sumitomo Metal Corporation; Ryosuke Iki, Nippon Steel & Sumitomo Metal Corporation

NSSMC selected Europe maker who can construct a coke battery of 7-meters height and adopted the same size as the existing battery in order to operate using the same locomotive. Main improving points over the existing battery are uniformity heating wall to height direction and length direction, expansion control to width direction and length direction, NOx reduction structure, and rise of rigidity of heating wall. We started groundwork in April 2009, although there was the construction discontinuation by the Great East Japan Earthquake in March 2011, we start up in October 2011, and are continuing the operation stable till now.


Criteria to Evaluate Cokemaking Strategy for an Integrated Steel Plant (Confirmed)

Unscheduled

Yakov Gordon, Hatch; John Busser, Hatch Ltd.; Ian Cameron, Hatch Ltd.

Recent pre-feasibility and feasibility studies performed by Hatch concluded that the selection of By-product or Heat Recovery Coke Oven technology must be made on a case-by-case basis as many different factors can affect the ultimate technology choice. A selection methodology has been previously developed which includes considerations such as available lands, energy sources/consumers, the specific steel plant configuration, environmental performance and the capital costs. The choice of technology also has a significant impact on a steel plant’s carbon footprint. Case studies shall be presented from a mass and energy balance viewpoint to illustrate key differences between the two cokemaking technologies and that will better define the effects on the overall steel plant carbon footprint and energy balance, especially the power and fuel balances. Yield and energy recovery differences key to the evaluation process shall be resolved and explained.


Recent Experience in Commissioning Two Full Sets of Coke Oven Machines: Plant Features and Project Organization (Confirmed)

Unscheduled

Alessandro Molinari, Paul Wurth Italia S.p.A.; Davide Zarcone, Paul Wurth Italia S.p.A.; Klaus Nowitzki, Schalker Eisenhütte Maschinenfabrik GmbH

For PT Krakatau POSCO’s new cokemaking plant (Cilegon, Indonesia) with coke oven batteries designed by Paul Wurth, Schalker Eisenhütte Maschinenfabrik has supplied and commissioned two full sets of Coke Oven Machines. The application of most modern technologies guarantees fast and efficient handling processes, long service life and reduced emissions during pushing operations. In October 2013, the entire plant has been put in operation. This paper describes commissioning and start-up of the two sets of machines (each with a charging car, pusher machine, coke transfer car, quenching car, locomotive) and highlights the corresponding sequences in the frame of a Greenfield project.


Session: Ironmaking Modeling I-Prediction & Control
(Ironmaking)
9:30 am -

Analysis of Transient Processes in Blast Furnace

Unscheduled

V. Moikin, Hatch; Yakov Gordon, Hatch; N. Spirin, Hatch

The kinetic-dynamic mathematical model was used to evaluate transient processes in blast furnace. The influence of variation in the value and sign of individual control parameter as well as combined influence of several control parameters was evaluated. It was found that transient process has a monotonous character only when metallic burden load is changed. When moisture of the blast, is changed – the transient process is an oscillatory character and is oscillatory and alternating-sign character in the case of variation in oxygen enrichment or natural gas injection. Good correlation of the findings with actual operating results of blast furnace and literature data is demonstrated. Incorporation of the dynamics characteristics into the control system positively affects blast furnace performance.


Development of Visualizing System of Blast Furnace Operation and Operational Application (Confirmed)

Unscheduled

Atsushi Inayoshi, Nippon Steel & Sumitomo Metal Corp.; Shinroku Matsuzaki, Nippon Steel & Sumitomo Metal Corp.; Masahiro Ito, Nippon Steel & Sumitomo Metal Corp.

It is indispensable to stabilize the blast furnace operation in order to increase productivity, decrease the reduction agent ratio, and target the abatement of carbon dioxide emissions from blast furnaces. To support the stability of blast furnace operations, an online system that visualizes the state of operations by using the large amount of data of the stave temperature and the shaft pressure of the blast furnace was developed. This two- or three-dimensional visualizing system enables a clear and objective understanding of the spatial and time series of the fluctuation of the shaft pressure and the filling structure of the charging material. In addition, by calculating and visualizing the spatial and timewise change of data, which is two-dimensional visualization, the fluctuation in the state of the blast furnace could be grasped quickly and quantitatively. This paper reports an example of applying the visualization system to the operation of the blast furnace.


DR Optimization System — First Commissioning Report and New Developments Regarding the Metallization and Carbon Prediction Models (Confirmed)

Unscheduled

Alois Altendorfer, Siemens VAI Metals Technologies GmbH; Greg Hughes, Midrex Technologies, Inc.; Angelika Klinger, Siemens VAI Metals Technologies GmbH

The DR Optimization System known as SIMPAX is an integrated process optimization system for a MIDREX DR Plant developed by Siemens VAI and MIDREX Technologies. Recently a completely new version of the DR Optimization System was launched and commissioned at Qatar Steel. This paper describes the experiences and challenges of the first commissioning and highlights the newly developed solutions for handling the errors inherent in some of the measuring devices used by the optimization program. Significant improvements over the previous version of this system are identified and the positive results are documented.


Stable Blast Furnace Operation by the Application of Predictive Process Models

Unscheduled

Jan van der Stel, Tata Steel R&D; H. Jak, Tata Steel Mainland Europe; T. Bell, Tata Steel Long Products; J. Raleigh, Tata Steel Strip UK; T. Peeters, Tata Steel R&D; K. Andreev, Tata Steel R&D

The development of blast furnace iron making models has a long history at Tata Steel in Europe. These models have been developed to understand the blast furnace processes. The models appeared to be a major tool for blast furnace process optimization. The coke rate could be drastically lowered and productivity could be increased to unprecedented levels, especially with the help of high coal injection rates and high oxygen enrichment levels. Almost every aspect of blast furnace ironmaking has been explored by the model development. There are steady state models, like heat and mass balance, hearth management, liquid and particle flow, burden distribution and dynamic models such as hot metal quality and temperature. The internal state of the blast furnace can be visualized, by a thermal map, the reduction degree of the burden and the position and shape of the cohesive zone. The models developed have helped to standardize the control decisions for operators and management and have lead to a better-controlled blast furnace operation which improved the stability of the process.


Use of Process Models for Thermal Control at ArcelorMittal Dofasco

Unscheduled

Mike Pomeroy, ArcelorMittal Dofasco Inc.

A presentation of the use of process models for thermal control at ArcelorMittal Dofasco, particularly recent Blast Furnace expert system deployment. Aspects of the use in the field at ArcelorMittal Dofasco and implementation will be discussed as well as means for evaluating efficacy of thermal models.


Session: Blast Furnace Operations I-Campaign Life and Productivity
(Ironmaking)
9:30 am -

AHMSA Blast Furnace No 5: Running the Third Campaign With an Accumulated 40 Million Tons of Hot Metal and a High Productivity (Confirmed)

Unscheduled

Luis Alberto Castro Castro, A.H.M.S.A.; Gustavo Vidales Perches, A.H.M.S.A.; Juan Alfredo Borrego Villarreal, A.H.M.S.A.; Werner Teubl, BFT Blast Furnace Technical Assistance; Juan Carlos Bortoni, A.H.M.S.A.

Blast furnace 5 started the 3rd campaign in August 1994 after a relining and reengineering to increase the production from originally 4.500t/day (productivity 2.08) to 5.500t/day (productivity 2.48). The blast furnace 5 has been operated continually since it was blown in 1994, adjusting operations, process control and maintenance practices and upkeep of stack refractory in partial maintenance by manual shotcrete and robot gunning through all campaign; the furnace hearth was emptied and chilled in 2012 in order to repair the wall and tap areas to reinforce the wall thickness with a refractory concrete. Further on some facilities like the charging system and scrubber were modernized and replaced in 2013 and in 2014 the drilling machines and clay guns (new hydraulics machines) were installed in both cast floors in order to increase facilities power to drain the furnace hearth in the best way. A new fourth stove was built to bring more energy to the blast furnace process. The sum of all theses new facilities brought us the opportunity to reach 7,500t/day (productivity 3.40).


ArcelorMittal Tubarão BF No. 1 First Campaign: Historical Results, Main Issues on Its Reline, Technological Updates, First Results of Second Campaign and Perspectives (Confirmed)

Unscheduled

Claudio Cesar da Costa, ArcelorMittal Tubarão; Ernandes de Souza Belonia Filho, ArcelorMittal Tubarão; Luiz Wasem, ArcelorMittal Tubarão; Emerson Ribeiro, ArcelorMittal Tubarão; Salustiano Pinto Jr., ArcelorMittal Tubarão

The first campaign of Blast Furnace #1 of ArcelorMittal Tubarão started on November 30th, 1983 and finished in April 17, 2012, having produced 93.9 million tons in 28,4 years, a total of 10,367 days nonstop. The relining involved investment of around 180 million dollar and about 17,000 tons of plant components and material, which were scheduled to be done in approximately 100 days. This paper will discuss the findings in the reline, 1st campaign historical results, main reline issues, technological updates, first results of second campaign and future perspectives.


Cleveland No. 6 Blast Furnace Hearth Campaign Extension

Unscheduled

Frank Huang, ArcelorMittal USA

In September 2009, when ArcelorMittal Cleveland Blast Furnace No. 6 (C6) was preparing for restart after a business plan outage, very deep erosion on the hearth bottom was found. Based on the core-drills, in the central region the erosions had gone through the ceramic pads, carbon blocks, and even graphite beams for the passive cooling. In order to meet the business plan, C6 was restarted without hearth relining. It was operated for four years continuously and safely. In this paper, the innovative operational methodologies for protecting the hearth bottom are presented along with the detailed hearth inspections after it was blown-down for reline in September 2013.


Longevity Technology Research and Practice of Baosteel No. 3 BF (Confirmed)

Unscheduled

Renliang Zhu, Baoshan Iron and Steel Co. Ltd.; Guo Jun Sun, Baoshan Iron and Steel Co. Ltd.; Chengcheng Lin, Baoshan Iron and Steel Co. Ltd.

Baosteel No.3 BF put into production on September 20,1994, and shut down to overhaul on September 1,2013. Generation furnace run for nearly 19 years. It still hold residual iron after the blast furnace shut down. Put anatomical investigations on the hearth, combinate the measures and the operation of number three blast furnace maintenance industry longevity adjustment system, summarizes the various factors that affect the longevity of the blast furnace operation, focusing on exploring large blast furnace technology and operations longevity industry system.


Operating Experiences at JSPL, BF-II (India) — Achieving Higher Performance Indicators With Inferior Raw Materials (Confirmed)

Unscheduled

Hemant Upadhyay, Jindal Steel & Power Ltd.; Arvind Kumar Bhagat, Jindal Steel & Power Ltd.

Modern steel making demands superior quality and quantity hot metal at lowest cost. Efforts have been continuously made for BF process optimization, to improve the energy efficiency, productivity, cost competitiveness and campaign life of a blast furnace. The BF2 at JSPL India, over the years has set-up many milestones, surpassing productivity beyond 3.0 t/m3WV/day with high hot blast temperature >1200 deg C and pulverized coal injection > 200 Kg/tHM, in-spite of not having the best raw materials in industry. This paper deals with the experiences and difficulties faced during the stabilization and operation of that furnace. The various steps taken, process modifications done and parameter tuning like coke quality derivation for different PCI rates, O2 enrichment stabilization & control, PCI stabilization & control, burden distribution & charging control and raw material quality control are described.


Session: Sintering I
(Ironmaking)
9:30 am -

Chemistry, Structure and Quality of Iron Ore Sinter (Confirmed)

Unscheduled

Liming Lu, CSIRO Mineral Resources Flagship

High quality sinter is required to sustain the extreme operating conditions and productivity of modern blast furnaces. This paper will first review the relationship between sinter chemistry, structure and quality, and then examine the effect of sinter chemistry including Al2O3, MgO and SiO2, CaO/SiO2, on the structure and quality of sinters prepared from the same blend components. The mechanisms leading to weak sinter strength will also be discussed in detail.


Influence of Fluidity of Liquid Phase of Iron Ore on Sintering Indexes (Confirmed)

Unscheduled

Bo Su, University of Science & Technology Beijing; Shengli Wu, University of Science & Technology Beijing; Guoliang Zhang, University of Science & Technology Beijing; Zhigang Que, University of Science & Technology Beijing; Tiankai Song, University of Science & Technology Beijing; Hailong Xue, University of Science & Technology Beijing

As foundation of bonding process of iron ores during sinter, liquid phase plays important role on improvement of sinter quality. Sinter pot tests using 16 blending ores with different fluidity of liquid phases (FLP) from 0.5~1.9 were carried out. The results showed that with the increase of FLP, yield increased linearly from 58.5 % to 64.2 %, solid fuel consumption decreased linearly from 65.0 kg/t to 59.2 kg/t, sintering time and MS of sinter increased when FLP˂1.2 but decreased later, productivity maintained at about 30 t/m2∙d when FLP˂1.2. So the suitable zone of FLP in the sintering process is 1.2~1.5.


Liquidus Composition on the FeOx-Rich Side of the FeOx-CaO-SiO2 (Confirmed)

Unscheduled

Yoshitaka Katahira, Tokyo Institute of Technology; Miyuki Hayashi, Tokyo Institute of Technology; Takashi Watanabe, Tokyo Institute of Technology

To make high strength sinters with good reducibility using poor quality iron ores with high gangue content, the phase diagram of the involved system is required to control the generation of melt in the sintered ore. However, since the oxygen partial pressure changes during the sintering reaction, it is necessary to obtain the phase diagram corresponding to appropriate oxygen partial pressure. In this study, liquidus compositions of the FeOx-CaO-SiO2 slag system coexisting with FeOx were measured. Samples charged into Pt crucibles were held at 1573K. Liquidus compositions of slags obtained were evaluated by EPMA analysis.


The Practice of Putting No. 4 Sintering Machine Into Production at Baosteel (Confirmed)

Unscheduled

Luowen Ma, Baoshan Iron and Steel Co. Ltd.; Xuming Wang, Baoshan Iron and Steel Co. Ltd.

Baosteel have to build a new sinterting machine which has 600 square meters in order to respond to the future growth of blast furnace demand in sinter and the new stricter rules of energy saving and environmental protection.At the same time it will reduce the negative effects on operation and quality of the sinter product with the degradation on the quality of raw materials.This production line adopts advanced technology, mature, stable and reliable process equipment .It will must be improve the competitiveness of Baosteel sintering system and to achieve cleaner, low consumption, low cost and high efficiency iron making target.


Use of Halide Solution to Improve the RDI and RI of Sinter: An Experience at JSPL (Confirmed)

Unscheduled

Sanjay Srivastava, Jindal Steel & Power Ltd.; Brij Badhadra, Jindal Steel & Power Ltd. ; D.P. Ray, Jindal Steel & Power Ltd.; Man Singh Raghuwanshi, Jindal Steel & Power Ltd.

The reduction-degradation index (RDI) of sinter is an important parameter to estimate the quality of sinter in low temperature zone (450-550oC) of blast furnace. Hence, it is of great importance to reduce the RDI of sinter which improve the permeability of blast furnace burden column for a stable and smooth performance resulting high yield and low consumption. In the last few years, many researchers have studied and reported the method for improving sinter quality by adding halide solution on to surface of the manufactured sintered ore. Some sinter producers also established from practices that spraying CaCl2 solution on to the sinter surface will reduce the RDI (reduction-Degradation Index) of sinter. A study on the RDI and RI (reducibility index) of sinter, which was sprinkled with different concentrations of CaCl2 solution was carried out at Jindal Steel & Power Ltd., Raigarh. The laboratory results showed that up to a certain percentage the RDI and RI of sinter decrease with the increase of Cl- concentration. With comprehensive consideration of the RDI and RI of sinter, when the concentration of Cl- reaches an optimum level (say X%), the RDI of sinter will be significantly reduced and at the same time RI will not be affected. On the basis of the laboratory results, the same has been implemented successfully for the existing sinter plant. The experience thus gained has been explained in this paper.


Session: Direct Reduction Ironmaking I-Use and Value of DRI
(Ironmaking)
9:30 am -

Characteristics of Hot, High-Carbon DRI: ENERGIRON Results and Performances in Operating Plants (Confirmed)

Unscheduled

Alessandro Martinis, Danieli Centro Metallics

ENERGIRON Direct Reduction Technology has recently focused on the innovative production of High Carbon Hot DRI to be pneumatically transported into adjacent EAFs, causing dramatic improvements in the overall steelmaking process. In the details, this paper has the aim to present the recent DR technology developments maximizing the energy of the DRI product, that can now be used at temperatures above 600°C with a carbon content up to 3.5%, as confirmed by ENERGIRON plant data presented in detail in the paper. These improved DRI characteristics allow to reduce the overall energy consumption and thus to increase the efficiency in the steel production.