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3 May 2015

Session: Ironmaking Across the Globe
(Ironmaking; ICSTI)
1 pm - 4 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 W. Lherbier, Jr., United States Steel Corporation; John Ricketts, ArcelorMittal Global R&D

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.

Developments in Ironmaking in South America (Confirmed)

1:30 pm

Jorge Luiz Ribeiro Ribeiro de Oliveira, ArcelorMittal Tubarão; Francisco Coutinho Dornelas, ArcelorMittal Tubarão; Erick Torres Bispo dos Santos, ArcelorMittal Tubarão; Jorge Adelino de Faria, ArcelorMittal Tubarão; Edson Luiz Massonori Harano, ArcelorMittal Tubarão

The South America Steel Industry is being challenged since the last 2008 financial crisis, as the others plants around the world. The scenario of ferrous raw material continuously being downgrading and the necessity to reduce production cost to be competiitive, providing that around 70% of crude steel cost is related to hotmetal, are in the opposite direction and makes the challenge be tougher. The aim of this lecture is to show the main ongoing actions at ArcelorMittal Brazil in order to achieve such goals. To operate a blast furnace with high coal injection (more than 180kg/t of HM) and low few rate (less than 490 kg/t), facing the slag rate increasing due to raw material downgrading as mentioned before ( ~300 kg/t) is mandatory to have operational stability through good operational practices and reliability centred maintenance in a world class level. To purse such objectives, the steel industry need to have a qualified workforce, training and developing them properly and continuously and be able to attract and retain talent people.

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

2 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)

2:30 pm

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

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 — Status Quo and Future Trends (Confirmed)

3 pm

Hans Bodo Lüngen, 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.

Ironmaking in South Korea – Beyond the Blast Furnace (Confirmed)

3:30 pm

Hoo-Guen Lee, POSCO; Sang-Ho Yi, POSCO

Steelmakers in Korea have been facing great challenges toward innovation and development to overcome the constraints in the blast furnace (BF) process. FINEX® has been developed to provide the ironmaking sector with the capability to lower environmental pollution, especially CO2 emissions, and flexibility in terms of operation and the choice of materials. FINEX is a new technology combining gas-based direct reduction in a series of fluidized-bed reactors and a reduction smelting in a melter-gasifier. Commenced in April 2007, the first 1.5 MTPA commercial plant has demonstrated its competitiveness as an alternative ironmaking route. Another 2.0 MTPA advanced FINEX plant was recently added at Pohang Works. The second commercial plant has been in satisfactory operation since its blowing-in in January 2014.

4 May 2015

Session: Howe Memorial Lecture
(Howe Memorial Lecture)
8 am - 9 pm (RM 26B/26C)

Role of Engineering Consultancy in the Transformation of a Technology Idea to a Working Process Plant (Confirmed)

8 am

Yakov Gordon, Hatch Ltd.

Engineering consultancy is viewed to be associated with implementation of steel plant projects. In this lecture, an attempt is made to highlight the role of engineering consultancy during different stages of technology development and implementation. When compared to the days of Professor Howe, consulting engineering in modern times is no different. Retained by a developer or consumer of new technology, engineering consulting employs fundamentals of metallurgical process analysis, plant design and engineering principles to establish core plant, utilities and infrastructure. This is backed up with financial analysis and assessment of technology and financial risks. Case studies for scale-up, evaluation and selection of new technology for specific site conditions are presented to highlight the importance of engineering consultancy.

Session: Coke Oven Battery Construction and State-of-the-Art Technology in Cokemaking
(Cokemaking; ICSTI)
9:30 am - 12 pm (RM 21)

Chairs: John Angsman - Wingate Alloys, 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

Giovanni Siri, Paul Wurth Italia S.p.A.; Alessandro Molinari, 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.

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

10:30 am

Giovanni Siri, Paul Wurth Italia S.p.A; 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

John Busser, Hatch Ltd.; Yakov Gordon, 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.

Using Modern Coke Oven Technology at the New Hyundai Steel Coke Plant (Confirmed)

11:30 am

Marcel Schulz, ThyssenKrupp Industrial Solutions AG; Klaus-Peter Leuchtmann, ThyssenKrupp Industrial Solutions AG; Jin Hyung Chung, Hyundai Steel Co.; Yong Mook Kang, 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 23)

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 Europe R&D; Hans Jak, Tata Steel Ijmuiden; Trevor Bell, Tata Steel Long Products; James Raleigh, Tata Steel Strip Products UK; Tim Peeters, Tata Steel Europe R&D; Kirill Andreev, Tata Steel Europe 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, Scientific-industrial Innovative Enterprise TOREX; Vitaliy Moikin, Research Institute of Heat Exchange in Metallurgy "VNIMT"; Vladislav Lavrov, 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 Application to Operation (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 Co.; 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

Yanglong Li, University of Science & Technology Beijing; Shusen Cheng, University of Science & Technology Beijing; Jianmin Gao, Jiuquan Iron & Steel (Group) Co., Ltd.; Chuan Chen, University of Science & Technology Beijing

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 & 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 #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

D. (Frank) Huang, ArcelorMittal Global R&D; Marcelo Andrade, ArcelorMittal Global R&D; John Ricketts, ArcelorMittal Global R&D; Osama Hassen, ArcelorMittal Cleveland; Phillip Pergi, ArcelorMittal Cleveland; Dennis Cronin, ArcelorMittal Cleveland; Bruce Stackhouse, ArcelorMittal Cleveland

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.

Improvements in Control Process and Hearth Maintenance in BF No. 5 at AHMSA (Confirmed)

10:30 am

Luis Alberto 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

Guo Jun Sun, Baoshan Iron and Steel Co. Ltd.; Renliang Zhu, 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., Javier Martinez - Pasek Minerales, Bernard Vanderhayden - CRM group

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

9:30 am

Liming Lu, CSIRO Mineral Resources Flagship; Natalie Ware, CSIRO Mineral Resources Flagship; Sarath Hapugoda, CSIRO Mineral Resources Flagship; Tirsha Raynlyn, 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.

Mineralization of Iron Ore Fines in the Process of CAP (Confirmed)

11:30 am

Tao Jiang, Central South University; Guanghui Li, Central South University; Zhengwei Yu, Central South University; Yuanbo Zhang, Central South University; Qian Li, Central South University

The composite agglomeration process (CAP) is an innovative method for preparing blast furnace burden. In CAP, the pelletizing feeds are prepared into 8- to 16-mm green balls, and the matrix feeds are granulated to 3- to 8-mm particles. Subsequently, these two feeds are mixed and roasted together in a sintering machine. Therefore, the mixture structure of CAP has an obvious difference from that of sintering and pelletizing. In this study, a mineralization model of CAP was designed theoretically, and the sintering pot results indicated that the theoretical model was perfectly realized by segregation of fluxes and coke breeze in the two feeds. Therefore, the qualified burden can be attained by using CAP.

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

Chairs: Henry Gaines - Midrex Technologies Inc., Narayan Govindaswami - Consultant

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

9:30 am

Angelo Manenti, Tenova Core Inc.

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.