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 Displaying page 1 of 2, items 1 to 25 of 35.

4 May 2015

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

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: EAF Operations
(Electric Steelmaking)
9:30 am -

Detection and Resolution of Adverse Melt Shop Conditions thru the use of the GrafTech ArchiTech System (Confirmed)

Unscheduled

Theodore Kurela, GrafTech International Holdings Inc.; Dennis Kenemuth, GrafTech International Holdings Inc.; Nicolas Lugo, GrafTech International Holdings Inc.

Analysis of adverse technical issues has traditionally relied on a snapshot of the state of the operation complemented with both the melt shop’s archived data and eyewitness accounts of adverse events. The GrafTech ArchiTech System is helping EAF shops solve problems faster by combining continuous analysis of information with statistically based alerts of process deviations. After one year of system implementation, a number of cases have been detected and communicated to melt shops worldwide. The objective of this paper is to examine a few of these cases; the early detection, statistical analysis, deviation reporting and the resulting countermeasures implemented.


Session: Environmental & Byproduct Management
(Oxygen Steelmaking)
9:30 am -

Beneficiation of BOF Steelmaking Converter Slag Fines with Weak Magnetic Separation (Confirmed)

Unscheduled

Naiyang Ma, ArcelorMittal

Weak magnetic separation coupled with selective particle size screening was adopted in treating steelmaking slag fines for beneficial recycling of the slag fines in previous research work, but it was found that the technology was not quite effective in treating BOF converter slag fines. Current research aims at increasing recycling ratio by optimizing operating parameters of a magnetic drum separator and by optimizing routes of processing the converter slag fines.


Session: Ladle Metallurgy Technology
(Ladle and Secondary Refining)
9:30 am -

Floating Chemistry Aims Model based on Grade, Reduction Ratio and Residuals (Confirmed)

Unscheduled

Kasra Normofidi, Quad Infotech Inc.; Praneeth Gorapalli, Quad Infotech Inc.

The chemical composition of steel has a direct impact on the mechanical properties of cast rolled steel products. Scrap quality is rarely guaranteed to be consistent and hence the molten steel requires alloying elements such as Vanadium, Manganese and Carbon to be added to the steel in the refining process. This is done to complement the chemical makeup of resident residual elements from the scrap so that the mechanical properties of the final product fall within the required ASTM specifications depending on shape, size and grade of the product. Quad Infotech has developed a system that allows the melt shop to define floating specifications for alloying elements that adjusts dynamically based on the composition of residual elements in the steel, the finished shape and size and of course the intended grade. The result is an optimized chemistry specification that coupled with controlled rolling and production process, minimizes the consumption of expensive alloying elements and hence reduces overall production costs.


Session: Mill Performance
(Cold Sheet Rolling)
9:30 am -

Adjustment of cold mill capability by intelligent modernization – latest references of SMS Siemag (Confirmed)

Unscheduled

Falk Töpfer, SMS Siemag AG; Jürgen Schanderl, SMS Siemag AG; Rüdiger Holz, SMS Siemag AG

Modernization of cold rolling mills is essential to fulfill market demands and to improve competitiveness. Intelligent concepts by SMS Siemag ensure getting maximum yield of existing mills. The first example deals with the modernization of the fifty year old tandem cold mill of OAO Severstal in Russia. Through the revamp the annual production will be increased and the product range will be enlarged focusing automotive grades. Existing single stand reversing mills can be enhanced by using the efficient Compact Cold Mill (CCM®) concept. SMS Siemag has two interesting CCM® extension projects of Pakistani and Bangladeshi customers under execution.


Session: EAF Energy Savings
(Energy and Utilities)
9:30 am -

A New Consteel Evolution With Irecovery: Better Performances In Steel Production With Heat Recovery For District Heating And Orc Turbine Power Generation (Confirmed)

Unscheduled

Cesare Giavani, Tenova S.p.A.; Nicola Monti, Tenova S.p.A.; Uggero De Miranda, Ori Martin S.p.A.; Roberto Bontempi, Ori Martin S.p.A.

The Italian steelmaker Ori Martin is making the revamping of the first European Consteel, installed in 1998 in Brescia and still working with good performances, that now, after 16 years of continuous operation, needs to be revamped increasing productivity and reducing consumptions. Ori Martin decided as well to install, at the Consteel outlet on the EAF primary off-gas line, a heat recovery system which will be able to produce steam with a waste heat boiler by using the thermal energy still exiting from the melting unit. The paper describes the improvements that will be done in the new Consteel Evolution and the new iRecovery system that will deliver thermal energy to the city of Brescia heat district grid during winter time and that will feed an ORC turbo-generator to produce electric energy for Ori Martin internal use. The new installation will let Ori Martin to have one of the most environmental friendly and energy efficient steel melting system in the world.


Session: Electrical Application Case Studies
(Electrical Applications)
9:30 am -

California Steel 5 Stand Tandem Mill Modernization (Confirmed)

Unscheduled

Thomas Richards, TMEIC; Trina Tran, California Steel Industries; Gary Gepitulan, TMEIC

California Steel recently modernized their 5 Stand Tandem Mill. Level 1, HMI, and Level 2 were replaced. Virtual Machine technology was widely employed to simplify maintenance and reduce administration costs. This paper will discuss the justification, implementation, results and techniques utilized to phase in the new equipment without any impact to production.


Session: Applications of Information Technology
(Computer Applications)
9:30 am -

Engineering Tools for the Steel Mill Environment (Confirmed)

Unscheduled

Mark Leer, CHL Systems

The purpose of this paper is to the use of various Engineering Tools applicable to the steel mill environment. It will discuss both 2D and 3D CAD systems and how these are used in the design and improvement of steel mill equipment. It will also discuss application of 2D simulation tools and 3D simulation (FEA, Motion Analysis, and Thermal Analysis) at they apply to the steel mill environment. Real world examples of application of all of these tools will be presented.


Optimizing Capacity and Growing Your Business through Supply Chain Virtualization (Confirmed)

Unscheduled

Gary Marzec, Northrop Grumman

Virtual supply chain partner relationships are popping up all over the steel industry; with customers generally leading the way toward a paperless relationship with suppliers. More importantly the network is expanding to include raw material producers, service centers, toll processors, freight companies, foreign ports and warehouses. All connected, disconnected and connected again as business opportunities may require. For example, a metal producer has a good opportunity with a new customer at a location remote from their current operation. They could choose to build a processing facility close to the customer’s location. However, it may be a better bet to choose an existing service center near the customer’s facility, ask about their available line time and establish a virtual partnership. Northrop Grumman, working with steel industry customers, has developed tools to make the optimization of capacity though virtualization work, for any supply chain configuration customers may challenge them to create. Web applications administered in the cloud and offered as Software as a Service provides the basis of this virtualization idea. Add in e-Communication capabilities to allow various business systems to talk to each other and the reality of today’s virtualized community is established.


Session: Steelmaking & Casting Refractory Technology
(Refractory Systems)
9:30 am -

Ladle Refractory Cost Reduction (Confirmed)

Unscheduled

Junichi Nakamura, Godo Steel, LTD

Billets for wire rods and shaped steel are produced by electric furnace in Godo Steel. Magnesia-carbon (MC) brick and alumina-magnesia-carbon(AMC) brick are used in a ladle working lining, but lifetime of ladle refractory become shortened as low carbon wire rods increase. A result of controling slag composition in the slow corrosion area of MC brick on operation range, lifetime of ladle refractory is extended and the costs have been successfully reduced. This paper presents measures that have extended lifetime of the ladle refractory.


Novel Refractory Plate Sealing Technology (Confirmed)

Unscheduled

James Ovenstone, Vesuvius Advanced Ceramics (China) Co. Ltd.; Linna Sun, Vesuvius Advanced Ceramics (China) Co. Ltd.

A coating material for sealing the joint between moving, adjoining refractory surfaces at high temperature has been developed. The coating utilizes a specially coated expandable graphite with a high intumescence onset temperature. The results from different steel plant trials with MTSPs/MTNPs have shown clear benefits to this patented technology, including extended plate life, gouging elimination, and improved argon backpressure., while at the same time lubricating the sliding action during tube change and protecting the plate from oxidation. The following paper describes the key aspects of the technology, the advantages it offers, and some recent field results from steel plants.


Session: Cranes
(Cranes)
9:30 am -

Optimal Crane Maintenance Functional Structure (Confirmed)

Unscheduled

Charles Totten, T&M Equipment Co.

One steel plant's Crane Repair department managed to improve safety, reduce breakdowns, increase service life of the components like gearing, hoist drums, blocks and wheel assemblies and re-rail the entire plant runways with Flash butt welded joints, and reduce cost of the plant's cranes, thus getting crane reliability and availability to very high levels by the simple method of keeping accurate records, learning failure modes, getting information from the data and continuously improving. The functional structural will be described.


Session: Coke Quality & Blast Furnace Performance
(Cokemaking)
2 pm -

Fundamental Coke Kinetic Studies Using a Coke Analogue (Confirmed)

Unscheduled

Apsara Jayasekara, University of Wollongong; Raymond Longbottom, University of Wollongong; Brian Monaghan, University of Wollongong

Coke kinetic studies are in part limited by the complexity and heterogeneity of coke. To address these issues, a coke analogue with simpler carbon structure, controllable mineralogy and porosity has been developed. The analogue’s gasification kinetics in CO2 has been studied using thermogravimetric analysis. Three kinetic reaction control regimes were identified. These regimes are chemical reaction control (1123-1298 K), mixed control (1298-1423 K) and mass transfer control (1423-1623 K). These control regimes closely follow what has been established for the kinetic behaviour of industrial coke and support the use of the coke analogue in the study of coke reactivity.


Session: Sintering II
(Ironmaking)
2 pm -

Evaluation of Hydration Characteristics of the Lime Used for Iron Ore Sintering Based on the Constant-temperature Calorimetric Method (Confirmed)

Unscheduled

Li Zhang, Baoshan Iron & Steel Co., Ltd; Shengli Wu, University of Science and Technology, Beijing; Yongzhong Zhang, Baoshan Iron & Steel Co., Ltd; Maojun Zhou, Baoshan Iron & Steel Co., Ltd

The Constant-temperature Calorimetric Method has been used to test 4 kinds of lime from the sintering plant. It showed that the Method can precisely test the hydration heat and hydration speed of the lime and avoid the shortage of the tradition ways, and the results were consistent with that of the sintering pot test. Meanwhile, it was found that the hydration properties of the 4 kinds of lime were markedly different, and the hydration speed is influenced by the impurities and the microstructure of the lime. In this case, the increasing of the MgO and the Al2O3 content can reduce the hydration speed of the lime, and the lime with the smaller crystal grain size has a larger hydration speed.


Session: Ironmaking Environmental Developments II
(Ironmaking)
2 pm -

Optimised Waste Gas Recirculation Lay-outs for Environment-friendly and Energy Efficient Sintering of Iron Ores (Confirmed)

Unscheduled

Bernard Vanderheyden, CRM Group; Frédéric van Loo, CRM Group; Cécile Mathy, CRM Group; Jean-Christophe Pierret, CRM Group

Process-integrated pollution control techniques like selective waste gas recirculation at the sinter plant are interesting not only from the environmental viewpoint, but also because they allow saving energy by in situ heat recovery. Nevertheless, contrary to purely end-of-pipe solutions, these process-integrated techniques also influence the sintering process itself and might consequently be detrimental to productivity and/or to sinter quality. As the optimal waste gas recirculation lay-out may depend on local conditions (raw materials used, available space, production constraints, more pressure on one specific pollutant…), it is sometimes difficult to directly extrapolate results obtained with one commercially available layout at one sinter plant to any other case. CRM has therefore recently upgraded its optimisation toolbox (mathematical model of the sintering process and sinter pot, both allowing simulation of waste gas recirculation) to assist steelmakers or equipment builders in the selection and sizing of the most suitable option for one specific sinter plant (new or to be revamped). The model may assess the impact of waste gas recirculation layouts on processing time and sintering degree, temperature at the discharging of the sinter strand and of sinter cooler respectively, and profiles of waste gas characteristics in the wind boxes and at stack (flow rate, temperature and composition, including CO, NO and SO2). The calculations may be complemented by sinter pot trials for checking sinter quality aspects and for the assessment of the waste gas recirculation impact on some other pollutant emissions (fine dust, VOCs…). The presented toolbox has already been used for several real industrial applications to support the selection, pre-engineering and economical assessment of original waste gas/hot air recirculation layouts.


Session: Ironmaking/Computer Modeling (Jt)
(Ironmaking; Computer Applications)
2 pm -

Drain Rate and Liquid Level Simulation in Blast Furnance Hearth (Confirmed)

Unscheduled

Hemant Upadhyay, Jindal Steel & Power LTD; Tarun Kumar Kundu, Indian Institute of Technology

Proper understanding and control of drainage of hot metal and slag from hearth is essential for a stable and efficient blast furnace operation. Therefore it is important for furnace operators to understand the mechanisms governing hearth drainage. Unfortunately, it is very difficult to carry out any direct measurement because of the hostile conditions in the blast furnace hearth, with high temperature and chemically aggressive liquids. Hence the estimation of drain rate and liquid level in hearth has to be simulated based on the operating parameters available. Models, suggested by previous researchers, though give good estimates, have some deficiencies. They either require huge infrastructure or involve a lot of parameters, whose values are not readily available. To solve this problem and provide the furnace operator a tool to examine and control the tapping with easily available process parameters, a mathematical model is prepared, at JSPL India, which simulates the casting practice with fairly accurate results. Here blast furnace hearth is considered as a pressurized vessel with liquid supply from top and a drain (taphole) at bottom. The fluid flow from the tap hole is dynamic and depends on a number of parameters. Those parameters were studied over a large number of actual castings and their relationship established in term of tunable flow factors. A set of modeling equations are used to represent the variation of flow rate, mass content and fluid level in hearth. Based on these calculations, the slag-out time (ts) and tapping closure time (tc) are predicted and a real time view of liquid levels in blast furnace hearth is provided. During the trials, conducted at JSPL Raigarh India, the model has achieved a match rate of 95% for slag-out time (ts) and 88% for tapping closure time (tc). Though there is still scope of improvement, the results are well within acceptable range and at present model is used for process control.


Session: Annealing & Rolling Theory
(Cold Sheet Rolling)
2 pm -

Optimizing Strip Speed Measurements for Mass Flow-AGC & Elongation Control with Laser Velocimeters – A Case Study (Confirmed)

Unscheduled

Goetz Bering, Polytec GmbH; Peter Nawfel, Polytec Inc

In order to compete in the global Steel Markets, manufacturers seek out ways to increase yield, improve quality and reduce operating costs. Mass Flow – AGC & Elongation Control have become standard control techniques used in rolling to achieve these goals. Within these control philosophies, Laser Velocimeters are well known for improving Mass Flow-AGC/Elongation by offering a more accurate strip speed measurement as compared to contact methods, especially during acceleration/deceleration transition events in mill speed. This paper outlines a case study to illustrate best practices for selecting and configuring a sensor system, installing and optimizing the measurement signal and integration to control systems.


Session: SBQ Rolling
(Rod and Bar Rolling)
2 pm -

Possibilities and Limitations of Free Size Rolling with Respect to Size and Temperature Variations of Different Materials (Confirmed)

Unscheduled

Christian Overhagen, University of Duisburg-Essen; Paul Josef Mauk, University of Duisburg-Essen

Free Size Rolling (FSR) is a modern pass design concept, which allows rolling of different finished round sections in close tolerances, utilizing a special design of the final passes. In this paper, an analysis of FSR is presented by a computer-simulation of the rolling process in rod and bar mills which utilize FSR. The simulation allows calculations of process parameters during rolling in the two- and three roll processes, including section shapes influenced by interstand tensions and elastic deformations. The results obtained will indicate, up to which extend adjustments of section faults are possible with FSR.


Upgrading an Existing Bar Mill for SBQ Production by Retrofitting a High-performance Abrasive Cut-off Machine (Confirmed)

Unscheduled

Norbert Asamer, BRAUN Machine Technologies, LLC

Abrasive cutting is the ideal cutting technology for upgrading of existing rolling mills, especially for long products. An increased flexibility, a high degree of automation and in particular an improved quality of the cut products are substantial advantages of abrasive cut-off machines. For the production of value-added products, such as SBQ, the utilization of perfect tuned, state-of-the-art abrasive cut-off machines is essential to achieve the required product quality. This paper demonstrates, why a customer decided to install a high-performance abrasive cut-off ma-chine in addition to the existing cold shear, by having perfect flexibility for rolling both SBQ and deformed bars.


5 May 2015

Session: Blast Furnace Cohesive Zone
(Ironmaking)
10 am -

Behaviour of Different Ferrous Materials in the Blast Furnace Cohesive Zone (Confirmed)

Unscheduled

Chin Eng Loo, University of Newcastle

The properties of the cohesive zone in an ironmaking blast furnace are dependent on the softening and melting behavior of the ferrous feed. Laboratory assessment of this property involves the reduction of a small bed of material under an applied compressive load. Bed contraction, pressure drop across the bed and reduction degree are determined during a test. In this study, beds were quenched at different temperatures to provide information of bed structural and composition changes. This paper highlights the differences in the behavior of pellets, sinter and lump ore in a softening and melting test.


Session: Specialty Alloy - Part I
(Specialty Alloy and Foundry)
10 am -

High-Performance Abrasive Cut-off Machines for Forging Applications (Confirmed)

Unscheduled

Christian Lieberknecht, BRAUN Machine Technologies, LLC; Gerhard Richter, BRAUN Maschinenfabrik GmbH

Forged products need to be cut to remove the product ends, to take samples, or to cut the products to length before further processing. Abrasive cutting has proven to be the ideal technology for these operations, irrespective of the type of forge used or the cutting temperature. BRAUN is a supplier of fully-automated cutting facilities, complete with material transport and aligning systems including product marking machines and cooling beds. In order to meet the demands of the forging plants around the world, state-of-the-art abrasive cut-off machines are designed for cutting wheel diameters of up to 78 inch.


Latest Developments in Abrasive Cutting and Grinding of Large-Scale Casted Parts (Confirmed)

Unscheduled

Matthew Foerster, BRAUN Machine Technologies, LLC; Gerhard Richter, BRAUN Maschinenfabrik GmbH

Prior to further processing of semi-finished steel products, it must be ensured that the surface of the workpieces is free from scale and flaws. Additional to this hot or cold cutting of ESR and conventionally cast ingots large forgings from open-die presses and flat products such as slabs or plates require a perfect cutting surface. For both application BRAUN provides a state-of-the-art-solution either with its high-pressure grinding technology or its abrasive cutting technology.


Session: Technological Methods for Improving the Hot Sheet Rolling Process
(Hot Sheet Rolling)
10 am -

New Control Technique for Reducing the Likelihood of Cobbles in the Tandem Rolling of Hot Metal Sheet (Confirmed)

Unscheduled

John Pittner, University of Pittsburgh

This paper presents the results of an investigation into the use of a new advanced control technique to reduce the likelihood of a cobble in a tandem hot mill. The investigation considered a reduction in the work piece temperature due to skid chill which induced a change in phase of the work piece. Simulations done at the University of Pittsburgh have demonstrated the capability of the controller to significantly reduce the changes in mass flow during the change in phase and thus reduce the likelihood of a cobble. The success of this work has further demonstrated the likelihood of future success of the new control method for various other operational situations and product mixes.


Session: Clean Steel - Characterization Techniques
(Metallurgy - Steelmaking and Casting)
10 am -

Optimizing the Speed and Quality of Automated Inclusion Analysis (Confirmed)

Unscheduled

Dai Tang, Carnegie Mellon University; P. Chris Pistorius, Carnegie Mellon University

Automated analysis of inclusions, using scanning electron microscopy with microanalysis, is a widely used quality control tool. Close attention to set-up of the instrument can improve analysis quality and rate. Two important set-up parameters are considered here. First, inclusions are detected by their lower brightness in back-scattered electron images; through both measurements and simulation, it is shown how the choice of brightness threshold (below which features are recognized as possible inclusions) affects analysis speed (through false-positives) and quality (through failure to detect inclusions of certain compositions if the threshold is set too high). Second, beam current and accelerating voltage affect the X-ray count rate (and so determine the analysis time required to achieve acceptable signal-to-noise ratios in the X-ray spectrum). It is shown that analyses can be performed at 10 kV accelerating voltage (instead of the more commonly used 20 kV) with no loss in speed, and significantly improve the analysis accuracy by reducing Fe matrix distortion.


Session: Non-Metallic Inclusions
(Metallurgy - Processing, Products and Applications)
10 am -

Effect of Rare Earth Oxides on the Rolling Performance of Grain Refined 1030 (Confirmed)

Unscheduled

Robert Tuttle, Saginaw Valley State University

Rare earth oxides have been found to produce grain refinement in steels through their ability to assist in the nucleation of dendrites during solidification. Previous experimental work has centered on small scale experiments or properties from castings or ingots. Little has been done to determine if these inclusions have an effect on the rolling performance of steels. This paper covers a set of experiments were rare earth treated and untreated 1030 steel was rolled at 10%, 25%, and 50% cold work. The rolling performance, microstructure, and resulting mechanical properties are being reported. No significant difference in rolling performance was observed.