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 Displaying page 1 of 23, items 1 to 25 of 562.

3 May 2015

Session: Ironmaking Across the Globe
(Ironmaking; ICSTI)
1 pm - 3:30 pm (RM 26B/26C)

Chairs: Pinakin Chaubal - ArcelorMittal Steel, Conrad Fisher - Steel Dynamics Inc., Mike Riley - Praxair Inc.

Ironmaking in North America (Confirmed)

1 pm

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

North American blast furnace ironmakers continue to take advantage of low natural gas prices by increasing rates of natural gas injection or co-injecting natural gas with coal. There have also been some new developments in blast furnace monitoring and control using equipment like furnace top infrared cameras, installation of computer models to monitor hearth condition, and computer-based expert systems. Alternate cokemaking technology continues to be investigated with pilot plant trials and plans for commercial-scale plants. Some of the older cokemaking 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.

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

1:30 pm

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

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 solutions for various environmental problems such as energy shortage, increase in CO2 and NOx emission, and so on. This lecture provides a summary of the developments of ironmaking technologies in Japan toward environmental solutions, along with some examples of the results and practical application such as Reactive Coke Agglomerate (RCA), Lime Coating Coke (LCC), Super Coke Oven for Productivity and Environment Enhancement toward the 21st century (SCOPE21), CO2 Ultimate Reduction in Steelmaking Process by Innovative Technology for Cool Earth 50 (COURSE50) and so on.

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

2 pm

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

Steel production had been a weak industry in Chinese history. In 1950, iron production in China was less than 0.1% of the world's total. Many blast furnaces were built since the 1950s. In 1996, both iron and steel production in China surpassed 100 million tons. At the beginning of the 21st century, large-scale modernized iornmaking and steelmaking facilities were installed, and advanced technologies were introduced widely. The Chinese steel industry now has about 1/2 of the world iron and steel production. In 2014, there were 18 steel works 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.

Ironmaking in Western Europe (Confirmed)

2:30 pm

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 ironmaking in Western Europe and highlights some aspects, such as: 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 a future outlook for the European ironmaking 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.

4 May 2015

Session: Safety & Environmental
(Cokemaking; ICSTI)
9:30 am - 12 pm (RM 23)

Chairs: Rob Carlin - DTE Energy Services, Wehnua Zheng - ACRE

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

9:30 am

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

NSSMC selected a European company to construct a coke battery 7 m high and adopted the same size as the existing battery in order to operate using the same locomotive. Main improvements over the existing battery are uniformity in the heating wall to height direction and length direction, expansion control to width direction and length direction, NOx reduction structure, and rise of rigidity of the heating wall. Groundwork was started in April 2009, although construction was interrupted by the Great East Japan Earthquake in March 2011. Start-up was in October 2011, and operation has continued since then.

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

10 am

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 the most modern technologies guarantees fast and efficient handling processes, long service life and reduced emissions during pushing operations. In October 2013, the entire plant was put into 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.

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

10:30 am

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 the 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 was successfully commissioned in October 2013. This 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 cokemaking plant.

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

11 am

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

Recent pre-feasibility and feasibility studies performed by Hatch concluded that the selection of byproduct 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 previously developed selection methodology includes considerations such as available lands, energy sources/consumers, the specific steel plant configuration, environmental performance and 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. Yield and energy recovery differences key to the evaluation process shall be resolved and explained.

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

11:30 am

Marcel Schulz, ThyssenKrupp Industrial Solutions AG; Klaus-Peter Leuchtmann, ThyssenKrupp Industrial Solutions AG; 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.

Session: Ironmaking Modeling I — Prediction & Control
(Ironmaking; ICSTI)
9:30 am - 12 pm (RM 25A)

Chairs: Kazuya Kunitomo - Kyushu University, Keqian Liu - U. S. Steel Research and Technology Center, Chenn Zhou - Purdue University Calumet

Stable Blast Furnace Operation by the Application of Predictive Process Models (Confirmed)

9:30 am

Jan van der Stel, Tata Steel R&D; Hans Jak, Tata Steel Mainland Europe; Trevor Bell, Tata Steel Long Products; James Raleigh, Tata Steel Strip UK; Tim Peeters, Tata Steel R&D; Kirill Andreev, Tata Steel R&D

The development of blast furnace ironmaking models has a long history at Tata Steel in Europe. The models are a major tool for blast furnace process optimization. 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 led to a better-controlled blast furnace operation, which has improved the stability of the process.

Analysis of Transient Processes in Blast Furnace (Confirmed)

10 am

Yakov Gordon, Hatch Ltd.; Nikolai Spirin, Ural Federal University; Vladimir Shvidkii, Ural Federal University; Yuriy Yaroshenko, Ural Federal University; Boris Bokovikov, Ural Federal University; Vitaliy Moikin, Ural Federal University

A kinetic-dynamic mathematical model was used to evaluate transient processes in a blast furnace. The influence of variation in the value and sign of individual control parameters, as well as the combined influence of several control parameters, was evaluated. It was found that the transient process has a monotonous character only when the metallic burden load is changed. When moisture of the blast is changed, the transient process has an 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 a blast furnace and literature data is demonstrated. Incorporation of the dynamic characteristics into the control system positively affects blast furnace performance.

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

10:30 am

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 visualization 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.

Improvement of Blast Furnace Performance by Applying a High-Efficiency Expert System (Confirmed)

11 am

Xuegong BI, Wuhan University of Science and Technology; Peng Li, Wuhan University of Science and Technology; Jindong Zhou, Wuhan University of Science and Technology; Wei Peng, Wuhan University of Science and Technology; Kuangnian He, Shaogang Iron and Steel Group Co. Ltd.; S Zhong, Shaogang Iron and Steel Group Co. Ltd.; X Zhong, Kunlun Information Science and Technology Company; D Bai, Shaogang Iron and Steel Group Co. Ltd.; W Pan, Shaogang Iron and Steel Group Co. Ltd.; K Liu, Shaogang Iron a

The price and quality of iron ores have been varying frequently and dramatically worldwide for many years, bringing about great difficulties in blast furnace operation. In order to help operators steer the furnace under this unfavorable condition, a new concept was proposed for developing a low-cost and high-efficiency expert system and applied to the development of the ES of a 3,200 m3 blast furnace in Southern China. This system has been working trouble-free since September 2012. Due to its implementation, productivity increased by 0.247 THM/m3·d, and comprehensive coke rate decreased by 21 kg/THM.

General Mathematical Model of Adjusting Blast Volume of Blast Furnace Tuyeres (Confirmed)

11:30 am

Yang-long Li, University of Science & Technology Beijing; Shusen Cheng, University of Science & Technology Beijing; Jianmin Gao, Jiuquan Iron & Steel (Group) Co. Ltd

A general mathematical model was build for adjusting blast parameters of a tuyere. Illustrated by a Chinese BF with a volume of 5,500 m3, the blast volume, velocity and kinetic energy of each tuyere were analyzed when the lengths or areas of the tuyeres were adjusted. The blast velocity and kinetic energy of the adjusted tuyeres would be decreased by increasing the length of them. The blast velocity or kinetic energy of the adjusted tuyeres could be enhanced when the number of decreased-area tuyeres was over a critical value. This model is beneficial for uniformity of hearth gas flow and stable work.

Session: Blast Furnace Operations I — Campaign Life and Productivity
(Ironmaking; ICSTI)
9:30 am - 12 pm (RM 25B)

Chairs: Oscar Lingiardi - Ternium Siderar, Charles McGovern - ArcelorMittal Burns Harbor, Trevor Shellhammer - Shellhammer Consulting

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

9:30 am

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 No. 1 of ArcelorMittal Tubarão started on 30 November 1983 and finished in 17 April 2012, having produced 93.9 million tons in 28.4 years, a total of 10,367 days non-stop. The relining involved an investment of around $180 million 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 during the reline, first campaign historical results, main reline issues, technological updates, first results of the second campaign and future perspectives.

Cleveland No. 6 Blast Furnace Hearth Campaign Extension (Confirmed)

10 am

Frank Huang, ArcelorMittal USA; Marcelo Andrade, ArcelorMittal USA; Osama Hassen, ArcelorMittal USA; Phillip Pergi, ArcelorMittal; Dennis Cronin, ArcelorMittal Steel

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.

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

10:30 am

Luis Alberto Castro Castro, AHMSA; Gustavo Vidales Perches, AHMSA; Juan Alfredo Borrego Villarreal, AHMSA; Werner Teubl, BFT Blast Furnace Technical Assistance; Juan Carlos Bortoni, AHMSA

Blast furnace No. 5 has 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 campaigns. 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, 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 power to drain the furnace hearth. A new fourth stove was built to bring more energy to the blast furnace process. The sum of all these new facilities led to the opportunity to reach 7,500 t/day (productivity 3.40).

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

11 am

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 was put into production on 20 September 1994 and was shut down for overhaul on 1 September 2013. It still held residual iron after the blast furnace was shut down. Anatomical investigations were made on the hearth, combining the measurements and the operation of No. 3 blast furnace maintenance longevity adjustment system. This paper summarizes the various factors that affect the longevity of the blast furnace operation, focusing on exploring large blast furnace technology and operations longevity system.

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

11:30 am

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

Modern steelmaking 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 achieved many milestones, surpassing productivity beyond 3.0 t/m3WV/day with high hot blast temperature >1,200°C and pulverized coal injection >200 Kg/tHM, in spite of not having the best raw materials in the industry. This paper deals with the experiences and difficulties faced during the stabilization and operation of that furnace. The various steps taken, process modifications and parameter tuning — such as coke quality derivation for different PCI rates, and O2 enrichment stabilization and control — are described.

Session: Sintering I
(Ironmaking; ICSTI)
9:30 am - 12 pm (RM 25C)

Chairs: Hugh Crosmun - Carmeuse Lime & Stone Inc., Enrique Somolinos - Pasek Minerales, Bernard Vanderhayden - CRM group

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

9:30 am

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)

10 am

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 a foundation of the bonding process for iron ores during sinter, the liquid phase plays an important role in 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, and productivity was maintained at about 30 t/m2∙d when FLP˂1.2. Thus the suitable zone of FLP in the sintering process was determined to be 1.2~1.5.

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

10:30 am

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.

A study on the reduction-degradation index (RDI) and reducibility index (RI) of sinter, which was sprinkled with different concentrations of CaCl2 solution, was carried out at Jindal Steel & Power Ltd., Raigarh, India. 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 is explained in this paper.

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

11 am

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

Baosteel has build a new sinterting machine of 600 m2 in order to respond to the future growth of blast furnace demand in sinter and the new stricter rules of energy savings 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 improve the competitiveness of Baosteel's sintering system and achieve cleaner, low-consumption, low-cost and high-efficiency iron making targets.

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

11:30 am

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 the 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 1,573 K. Liquidus compositions of slags obtained were evaluated by EPMA analysis.

Session: Direct Reduction Ironmaking I — Use and Value of DRI
(Ironmaking; ICSTI)
9:30 am - 12 pm (RM 26A)

Economics and Value-in-Use of DRI in the USA (Confirmed)

9:30 am

Angelo Manenti, Tenova Core

This paper will outline the economic advantages of using DRI instead of pig iron and high-grade scrap in steel production in the United States. It will give some guidelines on how to evaluate the value-in-use of DRI for raw material purchasers and meltshop managers.