# of results per page:  
select

Filter Results



By Date   By Time
select

 
select

By Topic
select

By Committee
select

 

Program Schedule



 
Change page:  
 Displaying page 1 of 20, items 1 to 25 of 482.

4 May 2015

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

Automation of Coke Oven Batteries at Hyundai Steel in Korea

Unscheduled

Matt Kraeuter, ThyssenKrupp Industrial Solutions; Marcel Schulz, ThyssenKrupp Industrial Solutions

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 This paper describes the improvements and capabilities of these systems compared to out of date technologies.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

Unscheduled

Kornelia Voelski, Paul Wurth Italia S.p.A; Antonio Esposito, Paul Wurth Italia S.p.A; Fabio Cerutti, Paul Wurth Italia S.p.A; Björn Otten, Paul Wurth Italia S.p.A

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

Unscheduled

Satoshi Ishikawa, 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

Iakov Gordon, Hatch Ltd; John Busser, Hatch Ltd; Cameron Ian, 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 Organisation

Unscheduled

Kornelia Voelske, Paul Wurth Italia S.p.A.; Alessandro Molinari, Paul Wurth Italia S.p.A.; Klaus Nowitzki, Paul Wurth Italia S.p.A.

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 Spirint, 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 application to operation

Unscheduled

Shinroku Matsuzaki, Nippon Steel & Sumitomo Metal Corporation; Masahiro Ito, Nippon Steel & Sumitomo Metal Corporation; Kenji Kawahara, Nippon Steel & Sumitomo Metal Corporation

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

Unscheduled

Alois Altendorfer, Siemens VAI Metals Technologies

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 AM Dofasco

Unscheduled

Mike Pomeroy, ArcelorMittal Dofasco

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 5 Running the 3rd campaign with an accumulated 40 million tons of hot metal and a high productivity of 3.40.

Unscheduled

Luis Alberto Castro Castro, AHMSA; Juan Alfredo Borrego Villarreal, AHMSA

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 # 1 - 1st campaign: Historical Results, Main Issues on its Reline, Technological Updates, First Results of Second Campaign and Perspectives

Unscheduled

Claudio Cesar da Costa, ArcelorMittal Tubarão; Ernandes de Souza Belonia Filho, 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 #6 Blast Furnace Hearth Campaign Extension

Unscheduled

Frank Huang, ArcelorMittal USA LLC

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

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

Unscheduled

Guoliang Zhang, University of Science & Technology Beijing; Shengli Wu, University of Science & Technology Beijing; Bo Su, 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

Unscheduled

Yoshitaka Katahira, 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 No.4 Sintering Machine Putting into Production in 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

Unscheduled

Alessandro Martinis, Danieli Centro Metallics; Pablo Duarte, Tenova HYL

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.


DRI Processing with Blast Furnace, EAF or Jet Process – A Comprehensive Overview

Unscheduled

Gerald Wimmer, Siemens VAI Metals Technologies GmbH; Markus Abel, Siemens VAI Metals Technologies GmbH; Wolfgang Sterrer, Siemens VAI Metals Technologies GmbH; Krzysztof Pastucha, Siemens VAI Metals Technologies GmbH

Several new DRI production facilities have been put in operation in the last years, mainly driven by new raw material sources and decreasing gas prices due to the shale gas boom in the US. For processing of DRI several processes exist: melting with electrical energy in an EAF, substituting part of iron ore in blast furnace or melting in converter equipped with Jet Process. Detailed description of these processes will be given followed by a summary of the core equipment required. Figures from references plants and calculations will be used to compare the different processes of DRI processing and highlight their advantages, disadvantages, limits and potential areas of application.


Economics & Value in use of DRI in USA

Unscheduled

Angelo Manenti, TENOVA Core

In this paper will be outlined the economic advantages of using DRI vs PIG iron and high grade scrap in steel production in USA and it will give some guidelines on how to evaluate the value in use of DRI for raw material purchasers and melt shop managers.


Evaluation of Silica Content and Metallization Degree of Pellets for Direct Reduction on its Value in Use (Confirmed)

Unscheduled

Michel Leite, Vale S.A.; Eider Dutra, Vale S.A.; Sandra Guerra, Vale S.A.

Direct reduction and electric arc furnace is an important route for steel production in the world. The DRI production in 2013 was 75.2 Mt, which 63.2% was produced by Midrex Process, 24.2% by coal-based and 15.4% by Hyl/Energiron. The metallic charge of direct reduction is mainly compound by iron ore agglomerate in the form of pellets and the direct reduction of iron ore occurs without melting and using natural gas as reducing agent. As a consequence, this process is widely used in countries where the cost of natural gas is low. Pellets chemical and metallurgical specifications are very important for direct reduction process and steel refining in electric arc furnace. This characteristics impacts on reactors productivity and consumptions of natural gas, electricity, flux and electrodes and consequently on steel cost production. This paper presents a discussion about the impacts of silica content and metallization degree of pellets for direct reduction and value in use. A mathematical model which simulates steel production by direct reduction and electric arc furnace route has been developed using mass and heat balance and also empirical correlations from literature.


Strategies for Implementing Direct Reduction Technologies in an Integrated Steel Plant (Confirmed)

Unscheduled

Ian Cameron, Hatch Ltd.; Nishit Patel, Hatch Ltd.; Yakov Gordon, Hatch Ltd.

Hatch assessed the merits of producing direct reduced iron (DRI) in an integrated steel works using coke oven gas and CO-rich basic oxygen furnace gas as a fuel/reductant in a gas-based DRI shaft furnace. Strategies to produce DRI with waste gases only and with a natural gas supplement will be described. DRI usage opportunities in the iron and steelmaking process areas will be presented including the impact on steel production and the plant energy balance. Commentary on various integrated steel plant arrangements that favor the implementation of DRI technology will be provided.