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Monday, August 31
8:00am Recent Developments in Thermomechanical Processing of Steels Clod Aranas, University of New Brunswick; Samuel Filgueiras Rodrigues, Federal Institute of Maranhao; Chiradeep Ghosh, Tata Steel Ltd.; Fulvio Siciliano, Dynamic Systems Inc. ; John Jonas, McGill University show more Description The use of thermomechanical control processing during hot rolling has played a significant role in improving the mechanical properties of steels in the past several decades. Accurate control of various metallurgical phenomena such as recrystallization, phase transformation and strain-induced precipitation has been the main target of steel industries around the world to push the properties of steels to their limit. Therefore, numerous physical and numerical simulations of hot rolling were developed to predict the microstructure and properties of steels during thermomechanical processing, which allows for quick optimization of manufacturing parameters. One of the most common techniques to physically simulate the actual hot rolling process in a laboratory scale is through hot torsion testing. In the present work, various grades of steels subjected to torsion simulation of hot strip and plate rolling were analyzed to determine the effect of deformation on the initiation of various metallurgical phenomena. The results show that high-temperature deformation can induce unusual metallurgical phenomena, such as dynamic phase transformation, which affects the final microstructure and mechanical properties of steels. These new findings can be employed to accurately control the volume fraction of phases in steels during cooling on the runout table after hot rolling. Time Monday, Aug 31 8:00AM - 9:00AM Location 26 B & C Speakers Clod Aranas University of New Brunswick Samuel Filgueiras Rodrigues Federal Institute of Maranhao Chiradeep Ghosh Tata Steel Ltd. Fulvio Siciliano Dynamic Systems Inc. John Jonas McGill University
9:30am Advancements in Tenova’s Offgas-Based Process Control Technology Platform Doug Zuliani, Tenova Goodfellow Inc.; Vittorio Scipolo, Tenova Goodfellow Inc. show more Description Tenova’s Intelligent EAF technology (i EAF®) is a multi-step road map for continuous improvement, cost saving and increased safety. The platform is tailored to the needs of each EAF and includes: hardware using NextGen® offgas analysis; advanced water detection software measuring H2 and H2O vapor to detect water leaks; performance savings models using real-time measurements for a robust control solution, avoiding imprecision/drift encountered when using incomplete measurements, assumptions and statistical models; and Industry 4.0 ongoing service and support program providing real-time monitoring of hardware and software. Time Monday, Aug 31 9:30AM - 10:00AM Location 14 Speakers Doug Zuliani Tenova Goodfellow Inc. Vittorio Scipolo Tenova Goodfellow Inc. Blast Furnace Data Validation Using Deep Learning as an Enabler for Autonomous Blast Furnace Cédric Schockaert, Paul Wurth; Fabrice Hansen, Paul Wurth S.A.; Franck Giroldini, Paul Wurth; Alexander Schmitz, Paul Wurth S.A. show more Description The first requirement in order to enable autonomous blast furnace is a high level of data quality and integrity. To meet these requirements, an unsupervised deep learning architecture, a LSTM AutoEncoder, has been implemented that captures the temporal and intervariable correlations from the data of a blast furnace. The application of the approach is multiple: 1) data validation and correction for data-driven model training, 2) live anomaly detection before feeding data-driven models, and 3) explainability of abnormal events in the process. This work has been validated on data from different blast furnaces and is integrated in Paul Wurth’s digital products. Time Monday, Aug 31 9:30AM - 10:00AM Location 25C Speakers Cédric Schockaert Paul Wurth Fabrice Hansen Paul Wurth S.A. Franck Giroldini Paul Wurth Alexander Schmitz Paul Wurth S.A. Characterization of Hypoperitectic Steels by Experimental Methods and Computational Thermodynamics: An Overview Christian Bernhard, Montanuniversitaet Leoben; Peter Presoly, Montanuniversitaet Leoben; Susanne Hahn, Primetals Technologies Austria GmbH; Sergiu Ilie, voestalpine Stahl GmbH show more Description An efficient pre-identification of hypoperitectic steel grades by experiments or thermodynamics is relevant to ensure surface quality, productivity and operational safety in the casting process. The potential of different laboratory experimental methods is critically evaluated in comparison with operational experience. Different predictive methods — such as simple empirical equations basing on statistical correlations — are discussed, whereby computational thermodynamics play the most important role. Nevertheless, the significance of the results of computational thermodynamics has always be seen critical, particularly, when — as in the example of advanced high-strength steel grades — higher contents of manganese, aluminum or silicon have to be considered. Time Monday, Aug 31 9:30AM - 10:00AM Location 1 Speakers Christian Bernhard Montanuniversitaet Leoben Peter Presoly Montanuniversitaet Leoben Susanne Hahn Primetals Technologies Austria GmbH Sergiu Ilie voestalpine Stahl GmbH CokeXpert Cloud: More Focus on Battery Lifetime and Personal Safety Davide Milanta, Paul Wurth; Wolfgang Kern, Paul Wurth show more Description In the framework of providing new tools in line with the current and upcoming needs in cokemaking, Paul Wurth has invested in the creation of a new “cloud” release of CokeXpert. This new release helps customers achieve a deeper understanding of the real status of coke oven batteries, combining measurements with visual observations, with the purposes to extend their lifetime and improve performance. In addition, new safety functionalities will ensure safe operations by means of a bidirectional exchange of information between personal protection equipment and CokeXpert. Time Monday, Aug 31 9:30AM - 10:00AM Location 25B Speakers Davide Milanta Paul Wurth Wolfgang Kern Paul Wurth Comprehensive Process Optimization for Electric Steelmaking Route Reinhold Leitner, Primetals Technologies Austria GmbH; Richard Stadlmayr, Primetals Technologies Austria GmbH; Rudolf Hubmer, Primetals Technologies Austria GmbH; Andreas Rohrhofer, Primetals Technologies Austria GmbH; Franz Hartl, Primetals Technologies Austria GmbH show more Description This paper figures out major benefits for installation of comprehensive upstream process optimization automation for mini-mills. The level 2 automation system covers applied optimization tools for raw material calculation and advanced scrap processing, dynamic model-based electric arc furnace melting and computer-assisted refining in ladle secondary furnace metallurgy followed by state-of-the-art level 2 automation for continuous casting machines. A fully automated tracking and identification system with high-temperature-resistant radio frequency identification ICE tag solution allows reliable product tracking and maintenance planning for teeming ladles and casting equipment. Furthermore, actual results of a recent implementation of process optimization systems at a U.S.-based meltshop are outlined. Time Monday, Aug 31 9:30AM - 10:00AM Location 6 Speakers Reinhold Leitner Primetals Technologies Austria GmbH Richard Stadlmayr Primetals Technologies Austria GmbH Rudolf Hubmer Primetals Technologies Austria GmbH Andreas Rohrhofer Primetals Technologies Austria GmbH Franz Hartl Primetals Technologies Austria GmbH Danieli Universal Endless - The First-Ever Universal Solution for Flat Products Is Now On-Stream Alessandro Pigani, Danieli show more Description In 2016, Shougang Jingtang United Iron & Steel Co. Ltd. (SGJT) ordered the world’s first DUE® plant. This new concept of thin-slab casting and rolling unifies in a single production line all the winning features that have been demonstrated up to now using either endless or coil-to-coil rolling in separate production lines, while eliminating the limiting factors of each. The SGJT’s DUE plant, presently in the commissioning stage, is designed to produce 2,100,000 tpy of high-value-added hot-rolled coils for a wide mix of steel grades and strip dimensions from 0.80 to 12.7 mm thick and 900 to 1,600 mm wide. Time Monday, Aug 31 9:30AM - 10:00AM Location 20 Speakers Alessandro Pigani Danieli Development of ASTM A709-50WF Heavy Plate for Fracture Critical Bridge Applications Dengqi Bai, SSAB Americas; Yufeng Wang, SSAB Americas; Liz Peterson, SSAB Americas; Chase Rawlinson, SSAB Americas; Chris Amsden, SSAB Iowa Inc. show more Description For some fracture critical applications, the requirements for the internal quality of steel plates, especially heavy-gauge plates, are very stringent. To ensure sound internal quality and performance, some grades require not only ultrasonic testing, but also through-thickness tensile testing (Z-test). One of the common defects in heavy-gauge hot-rolled steel plates is hydrogen embrittlement. When the hydrogen content in a steel plate reaches a certain level, it can cause microcracks, blisters and flaking. In the present study, the effects of rolling and cooling processes on hydrogen removal in a low-carbon microalloyed steel were analyzed. Time Monday, Aug 31 9:30AM - 10:00AM Location 25A Speakers Dengqi Bai SSAB Americas Yufeng Wang SSAB Americas Liz Peterson SSAB Americas Chase Rawlinson SSAB Americas Chris Amsden SSAB Iowa Inc. Development of Strategy for Sustaining, Enhancement and Cost Reduction at Severstal's Primary End Evgeniy Vinogradov, CherMK-Severstal; A. Kalko, Severstal, Cherepovets Steel Mills; S. Chikinov, Severstal, Cherepovets Steel Mills; A. Ivashov, Severstal, Cherepovets Steel Mills; D. Balahonov, Severstal, Cherepovets Steel Mills; M. Gurkin, Severstal, Cherepovets Steel Mills; E. Karunova, Severstal, Cherepovets Steel Mills; Yakov Gordon, Hatch Ltd.; Afshin Sadri, Hatch Ltd.; J. Busser, Hatch Ltd. show more Description Severstal produces 12 million tons of steel, 9.3 million tons of hot metal, 4.6 million tons of coke, 9.5 million tons of sinter and consumes 4.6 million tons of Kostamuksha pellets. Severstal’s strategy for primary end operation includes postponing the reline of 5,500 m3 blast furnace No. 5 (based on the results of semi-annual non-destructive testing measurements), construction of the new blast furnace No. 3 and new coke battery No. 11 with pressure-regulated ovens, coal stamp charging and coke dry quenching. Testing of waste extrusion briquetting is an ongoing project to improve sinter quality and increase sinter production. These allow for an increase in hot metal production and reduction of production costs. Time Monday, Aug 31 9:30AM - 10:00AM Location 26A Speakers Evgeniy Vinogradov CherMK-Severstal A. Kalko Severstal, Cherepovets Steel Mills S. Chikinov Severstal, Cherepovets Steel Mills A. Ivashov Severstal, Cherepovets Steel Mills D. Balahonov Severstal, Cherepovets Steel Mills M. Gurkin Severstal, Cherepovets Steel Mills E. Karunova Severstal, Cherepovets Steel Mills Yakov Gordon Hatch Ltd. Afshin Sadri Hatch Ltd. J. Busser Hatch Ltd. Dynamic Control of Top Blowing Gas Jet Velocity by Applying Actuation Gas Nobuhiko Oda, JFE Steel Corp.; Yumi Murakami, JFE Steel Corp.; Shingo Sato, JFE Steel Corp.; Goro Okuyama, JFE Steel Corp.; Takeshi Murai, JFE Steel Corp.; Naoki Kikuchi, JFE Steel Corp. show more Description Dynamic velocity control of the jet from a top-blowing lance is important because the preferable jet conditions for physical phenomena and metallurgical reactions change during blowing. This study investigated a new approach in which the jet velocity is controlled by applying actuation gas in 1/10-scale model experiments. The actuation gas paths were set in a plane vertical to the main nozzle, and the actuation gas flowrate was controlled independently from that of the main gas. Although the total flowrate was constant, the jet velocity from the nozzle increased with the actuation gas flowrate. Time Monday, Aug 31 9:30AM - 10:00AM Location 7 Speakers Nobuhiko Oda JFE Steel Corp. Yumi Murakami JFE Steel Corp. Shingo Sato JFE Steel Corp. Goro Okuyama JFE Steel Corp. Takeshi Murai JFE Steel Corp. Naoki Kikuchi JFE Steel Corp. From Refractory, to Tubular, to Spray-Cooled LMF Roofs Louis Valentas, Systems Spray-Cooled; Eric Chodl, Systems Spray-Cooled; Alan Sutliff, ArcelorMittal Indiana Harbor show more Description In the late 1990s, ArcelorMittal Indiana Harbor No. 3 (formerly LTV Steel) installed two 15-foot-diameter spray-cooled ladle metallurgy furnace roofs, replacing refractory brick roofs. These roofs were replaced with tubular roofs in the late 2000s and then switched back to the original spray-cooled roofs. New state-of-the-art spray-cooled roofs were implemented in 2017. This paper will review the original reasons for replacing the refractory roof, the change from spray-cooled to tubular and then back again to spray-cooled. The changes and improvements that were made along the way, including maintenance costs, water savings, lifetime, cleaner heats and safety, will be reviewed. Time Monday, Aug 31 9:30AM - 10:00AM Location 4 Speakers Louis Valentas Systems Spray-Cooled Eric Chodl Systems Spray-Cooled Alan Sutliff ArcelorMittal Indiana Harbor Important Updates to AIST Technical Report No. 13 - Guide for the Design and Construction of Mill Buildings Tim Bickel, CSD Structural Engineers; Steve Bohm, JNE Consulting show more Description AIST Technical Report No. 13 - Guide for the Design and Construction of Mill Buildings, was published in 1969 to provide owners, engineers and contractors with information about the considerations unique to mill buildings. The 6th edition is being prepared for release and includes many important updates, including: • Crane load cases and combinations to match current building code requirements. • Updated crane runway girder design criteria. • Expanded crane runway fabrication and erection tolerance requirements. • An expanded section with guidance on structural inspections and reinforcement. This presentation will further explain these updates and the benefits to building owners. Time Monday, Aug 31 9:30AM - 10:00AM Location 10 Speakers Tim Bickel CSD Structural Engineers Steve Bohm JNE Consulting Improvement of Centerline Segregation at U. S. Steel - Gary Works' No. 2 C Line Continuous Caster Ernesto Serrano, United States Steel Corporation; S. McCann, United States Steel Corporation; William Schlichting, United States Steel Corporation; M. Keel, United States Steel Corporation; C. Paynes, United States Steel Corporation; M. Liedtke, United States Steel Corporation; Thinium Natarajan, U. S. Steel Research and Technology Center; Marcellino Fornasier , Danieli; B. Flanigan, United States Steel Corporation; C.C. Tomazin, United States Steel Corporation; M. Knights, Danieli Officine Meccaniche show more Description Gary Works' C line caster was originally designed with the ability to change thickness and later upgraded to cast twin strands. Based on the improved internal quality results observed at U. S. Steel - Granite City Works' No. 1 Caster (formerly Bethlehem Steel's Sparrows Point caster) from the application of dynamic soft reduction (DSR), U. S. Steel - Gary Works' C line caster was modernized to be capable of DSR. Danieli Corp. was selected to engineer segment modernization for the dynamic gap control and integrate the control into their QCOOL, QCORE and QPULSE automation packages. Time Monday, Aug 31 9:30AM - 10:00AM Location 5 Speakers Ernesto Serrano United States Steel Corporation S. McCann United States Steel Corporation William Schlichting United States Steel Corporation M. Keel United States Steel Corporation C. Paynes United States Steel Corporation M. Liedtke United States Steel Corporation Thinium Natarajan U. S. Steel Research and Technology Center Marcellino Fornasier Danieli B. Flanigan United States Steel Corporation C.C. Tomazin United States Steel Corporation M. Knights Danieli Officine Meccaniche New High-Performance X-Ray Coating Weight Gauge for Metals Jean-Jacques Florent, Scantech SAS; Jan Gaudaen, Scantech SAS; Francois Legrand, Scantech SAS; Roland Gouel, Scantech Americas Inc. show more Description Productivity and quality of metallic coatings on metallic substrates depend heavily on the ability to control the coating thickness during manufacturing. The aim of the control is to minimize the quantity of coating metal used and the amount of out-of-tolerance product, hence reducing substantially production cost. An effective coating control requires an accurate, fast, continuous, non-contact, on-line coating thickness measurement. This paper outlines the performance of a new x-ray coating weight gauge design. This gauge uses a new compact head design and advanced state-of-the-art architecture/electronics and provides the best performance to meet these requirements. Time Monday, Aug 31 9:30AM - 10:00AM Location 16 Speakers Jean-Jacques Florent Scantech SAS Jan Gaudaen Scantech SAS Francois Legrand Scantech SAS Roland Gouel Scantech Americas Inc. Process Heating Assessments Using DOE’s Manufacturing Energy Assessment Software for Utility Reduction (MEASUR) Tool Suite Sachin Nimbalkar, Oak Ridge National Laboratory; Kristina Armstrong, Oak Ridge National Laboratory; Kiran Thirumaran, Oak Ridge National Laboratory; Wei Guo, Oak Ridge National Laboratory; Gina Accawi, Oak Ridge National Laboratory; Thomas Wenning, Oak Ridge National Laboratory; Arvind Thekdi, E3M Inc. show more Description Process Heating Assessment, part of the U.S. Department of Energy's Manufacturing Energy Assessment Software for Utility Reduction (MEASUR) Tool Suite is an upgraded version of the Process Heating Assessment and Survey Tool (PHAST). The PHAST tool has been used in many industrial plants in the U.S. and several other countries to identify energy use distribution, estimate energy losses, as well as analyze potential energy savings by using commonly recommended energy-saving measures. The upgraded PHAST is specifically designed to be used where it is necessary to consider multi-component charge load and account for a number of different areas of energy losses. Time Monday, Aug 31 9:30AM - 10:00AM Location 12 Speakers Sachin Nimbalkar Oak Ridge National Laboratory Kristina Armstrong Oak Ridge National Laboratory Kiran Thirumaran Oak Ridge National Laboratory Wei Guo Oak Ridge National Laboratory Gina Accawi Oak Ridge National Laboratory Thomas Wenning Oak Ridge National Laboratory Arvind Thekdi E3M Inc. Profile and Defect Detection Experiences on Section Mills Marco Appio, Danieli Automation S.p.A.; Luca Vitale, Danieli Automation S.p.A.; Angelo Lugnan , Danieli Automation S.p.A. show more Description In modern steel manufacturing plants, the possibility of ensuring a consistent surface quality of the rolled stock has now become a fundamental feature. Nowadays almost all rolling mills are equipped with laser section profile gauge but few of them have a surface defect detection system. The increasing requirement for a combined system for profile measuring and defect detection led Danieli Automation to develop an innovative solution to provide a complete production quality assurance package. A high-definition 3D surface reconstruction and accurate defect detection are obtained by the combination of high-speed cameras and technologically advanced machine vision mathematical algorithms. Time Monday, Aug 31 9:30AM - 10:00AM Location 13 Speakers Marco Appio Danieli Automation S.p.A. Luca Vitale Danieli Automation S.p.A. Angelo Lugnan Danieli Automation S.p.A. Recent Sustainability Developments in the Iron and Steel Industry Alicia Giglio, Hatch Ltd.; Janice Bolen, Hatch Ltd. show more Description An overview of some of the recent steel industry carbon emission reduction innovations will be provided, including: 1. Reduction in blast furnace production and the trend toward electric arc furnace steelmaking with scrap or direct reduced iron. 2. Hydrogen use in direct reduced iron processes with hydrogen created via green electricity. 3. Hydrometallurgical-based electrolysis of iron ore. 4. Molten oxide electrolysis (Boston Metals). 5. European developments under the ULCOS program (blast furnace top gas recycling, HISarna). 6. Chemical production from waste gases. 7. Slag use in the cement industry. Time Monday, Aug 31 9:30AM - 10:00AM Location 9 Speakers Alicia Giglio Hatch Ltd. Janice Bolen Hatch Ltd. SDI Heartland Temper Mill Stand Motor and Drive Replacement Thomas Richards, TMEIC; Gary Sinders, Steel Dynamics Inc. - Flat Roll Group Heartland Division; Neil Carpenter, TMEIC show more Description Steel Dynamics Inc. – Flat Roll Group Heartland Division had a problem on its temper mill. The stand bottom motor was on the verge of failure. Did it make sense to replace the DC motor with another DC motor when the drive was obsolete? Did it make sense to replace with an AC motor and drive for a mill that was all-DC? What happens if a new AC motor and drive are ordered and the DC motor fails in the interim? These are the questions that were faced. The paper will address the alternatives in detail, the challenges that were encountered, and how it worked out. Time Monday, Aug 31 9:30AM - 10:00AM Location 15 Speakers Thomas Richards TMEIC Gary Sinders Steel Dynamics Inc. - Flat Roll Group Heartland Division Neil Carpenter TMEIC Sustainable Recycling of Steel Manufacturing Wastewater Treatment Solid Wastes Via In-Process Dynamic Separation Naiyang Ma, ArcelorMittal show more Description In steel production, wastewater is constantly generated in various unit processes. The wastewater must be treated before the water can be reused internally or released to the environment. Existing wastewater treatment technologies are clean-water oriented, but solid wastes collected in the wastewater treatment processes are generally notorious nuances which are dirty, full of contaminants and sometimes hazardous. Sustainable recycling of the wastewater treatment solid wastes requires effective separation of beneficial components from undesirable ones. In-process dynamic separation has recently emerged as a promising technology for producing clean, dry and recyclable solid co-products in economic ways while wastewater is being cleaned. ArcelorMittal has studied this technology for significantly enhancing recyclability of steel manufacturing wastewater treatment solid wastes. Case studies at ArcelorMittal are presented in this article. Time Monday, Aug 31 9:30AM - 10:00AM Location 11 Speakers Naiyang Ma ArcelorMittal The Use of Unifuse™ Technology for EAF Duct Life Extension Pedro Amador, AZZ; Chris Hawk, AZZ show more Description As electric arc furnace (EAF) production processes have become more efficient, the water-cooled offgas ductwork technology has struggled to keep up. The result has been that the asset life of EAF water-cooled offgas ductwork is measured in months or a few years (within 1 to 5 years, most less than 3 years). ArcelorMittal Dofasco has had the same EAF offgas ductwork in operation and without failure for 15 to 17 years. This paper describes how this remarkable lifetime has been achieved. Time Monday, Aug 31 9:30AM - 10:00AM Location 19 Speakers Pedro Amador AZZ Chris Hawk AZZ
10:00am 30+ Year Campaign of IJmuiden Blast Furnace No. 6 Frank Kerkhoven, Tata Steel Netherlands; J. Stuurwold, Tata Steel Netherlands; G. Tijhuis, Tata Steel Netherlands; Reinoud van Laar, Danieli Corus show more Description Blast Furnace No. 6 of Tata Steel in IJmuiden was blown-in in April 1986 after a full reline with improvements to the lining-cooling system and top charging. The hearth design from the 1970s was changed on minor points and the air cooling of the bottom and spray cooling of the sidewall remained. After 16 years, the hearth refractory was replaced, but the bosh and stack were not repaired. Currently, after more than 33 years since the original blow-in, the furnace is still performing very well from the point of view of productivity, efficiency and reliability. The excellent design of the furnace is only one aspect that made this possible. Other important aspects are good instrumentation, excellent process control and comprehensive asset management. Time Monday, Aug 31 10:00AM - 10:30AM Location 26A Speakers Frank Kerkhoven Tata Steel Netherlands J. Stuurwold Tata Steel Netherlands G. Tijhuis Tata Steel Netherlands Reinoud van Laar Danieli Corus A Novel Phenomenological Kinetic Model of Nanobainite Steels to Characterize the Dynamics of the Autocatalytic Nucleation Process Minal Shah, CSIR-National Metallurgical Lab; Suchandan Kumar Das, CSIR-National Metallurgical Lab show more Description A kinetic model is proposed in the present work, which formulates the dynamic nature of autocatalysis. The change in Gibbs free energy due to carbon partitioning will alter the autocatalytic nucleation with bainite transformation. The autocatalytic nucleation of bainite transformation in steels will be assisted by the presence of dislocations in austenite formed near transformed bainite. The model also evaluates the activation energy due to dislocation barrier, which is arising by solid solution strengthening of austenite. The autocatalytic factor increases with a reduction in the transformation temperature due to the increased value of the internal energy of the shear stress of the dislocation. Time Monday, Aug 31 10:00AM - 10:30AM Location 14 Speakers Minal Shah CSIR-National Metallurgical Lab Suchandan Kumar Das CSIR-National Metallurgical Lab Artificial Intelligence and Data-Driven Modeling in Ironmaking – Potential and Limitations Petra Krahwinkler, Primetals Technologies Austria GmbH; Sonja Strasser, Primetals Technologies Austria GmbH; Dieter Bettinger, Primetals Technologies Austria GmbH; Harald Fritschek, Primetals Technologies Austria GmbH; Martin Schaler, Primetals Technologies Austria GmbH; Adnan Husakovic, Primetals Technologies Austria GmbH show more Description The revival of Artificial Intelligence (AI) promises to offer solutions in particular for complex systems that are difficult to model with classical methods. Selected AI solutions in ironmaking are provided, their strengths and weaknesses are discussed: Topics as the applicability for typical problem groups, preconditions regarding required data quality as well as completeness of data sets, reliability, and the combination with classical approaches are covered. Furthermore, the deployment and integration of black box models into control systems and the related stability are discussed. Time Monday, Aug 31 10:00AM - 10:30AM Location 25C Speakers Petra Krahwinkler Primetals Technologies Austria GmbH Sonja Strasser Primetals Technologies Austria GmbH Dieter Bettinger Primetals Technologies Austria GmbH Harald Fritschek Primetals Technologies Austria GmbH Martin Schaler Primetals Technologies Austria GmbH Adnan Husakovic Primetals Technologies Austria GmbH Digital Transformation: Why Projects Fail, Potential Best Practices and a Road Map for Success Jeffrey Botsch , Rockwell Automation show more Description The metals industry will invest US$55B in smart manufacturing digital solutions by 2020. However, many companies are finding they lack the leadership, infrastructure and worker skills to successfully implement digital transformation projects. The problem isn’t isolated to heavy industries: a Gartner study showed that across market segments, 85% of big data projects fail. This paper proposes a set of actionable ideas to help metals companies plan, implement and sustain digital transformation initiatives. The presenters will share their work with a major metals company in North America to perform an operational assessment, align divisional and corporate needs, and define a digital transformation strategy. Time Monday, Aug 31 10:00AM - 10:30AM Location 13 Speakers Jeffrey Botsch Rockwell Automation EOF Automation Celso Barão, BC show more Description The EOF is a basic oxygen furnace (BOF) characterized by concept of pre-heating solid charge based on energy of previous heat. This work consisted of the development and implantation of mathematical models. The system of equations considers all metallic charges with respective chemical compositions and it defines the amount of energetic or cooling, besides the quantity of lime. Initially, the development went to knowledge of process, given the excellence and originality of the EOF, which is different than the BOF. After process automation, significant gains in productivity, increase in metal yield and lower consumption of refractories were achieved. Time Monday, Aug 31 10:00AM - 10:30AM Location 7 Speakers Celso Barão BC Evaluation of the System Dynamics and the Compliance Standards for Large Industrial Motor Starting Poojit Lingam, Primetals Technologies USA LLC; Anil Kanagala, Primetals Technologies USA LLC; Visvesvaran Subramanian, Primetals Technologies USA LLC show more Description Large motors are ubiquitous in a steel plant. Many of these motors require direct on-line (DOL) starting without speed or torque control. DOL applications create dynamic transients during starting. Using an example of a 10,000 hp motor from a recently executed project, this paper presents the study of the standard power quality compliance requirements, evaluation of the dynamic transients for various system initial states and the effects of these transients on the system. The paper also presents the procedure used for evaluation. Examples of compensation solutions evaluated and the final solution selected is presented along with the criteria used for selection. Time Monday, Aug 31 10:00AM - 10:30AM Location 15 Speakers Poojit Lingam Primetals Technologies USA LLC Anil Kanagala Primetals Technologies USA LLC Visvesvaran Subramanian Primetals Technologies USA LLC Getting Value From Your Operations and Maintenance Data – A Lesson From the Mining Industry Paul McRoberts, Rockwell Automation show more Description We’ve all been taught that the more data you collect, the more information you’ll have. However, many metals companies are finding a disconnect between the ease of buying sensors and collecting data – and actually using that data to inform operational decisions and equipment maintenance. This paper will outline how Rockwell Automation worked with a major global mining company to envision a new path forward. By leveraging the latest technological innovations and putting the right data in front of the right people, they’re reimagining the equipment maintenance process and mining value from their operations data. Time Monday, Aug 31 10:00AM - 10:30AM Location 19 Speakers Paul McRoberts Rockwell Automation Heat Treatment and Austenitization Temperature Effect on Ultrahigh-Strength Steel Daniel M. Field, U.S. Army Combat Capabilities Development Command Army Research Laboratory; Krista R. Limmer, U.S. Army Combat Capabilities Development Command Army Research Laboratory; Johnathan S. Montgomery, U.S. Army Combat Capabilities Development Command Army Research Laboratory; Daniel J. Magagnosc, U.S. Army Combat Capabilities Development Command Army Research Laboratory; Kyu C. Cho, U.S. Army Combat Capabilities Development Command Army Research Laboratory show more Description The effect of heat treatment on the microstructure, strength and toughness of an ultrahigh-strength (>250 ksi) steel was investigated. A thermodynamic approach was used to design the heat treatments based on the segregation developed during solidification. This methodology was utilized to produce refinement of the prior austenite grain size leading to superior properties. The cleavage energy was shown to correlate to both the prior austenite grain size according to an inverse root relationship, as well as to the high-angle boundary misorientation between the martensite laths. Time Monday, Aug 31 10:00AM - 10:30AM Location 25A Speakers Daniel M. Field U.S. Army Combat Capabilities Development Command Army Research Laboratory Krista R. Limmer U.S. Army Combat Capabilities Development Command Army Research Laboratory Johnathan S. Montgomery U.S. Army Combat Capabilities Development Command Army Research Laboratory Daniel J. Magagnosc U.S. Army Combat Capabilities Development Command Army Research Laboratory Kyu C. Cho U.S. Army Combat Capabilities Development Command Army Research Laboratory Implementations of Proximity Warning Systems for the Steel Industry Edgardo La Bruna, Janus Automation show more Description The metals industry moves large and heavy loads using cranes, transfer cars, forklifts and haulers. This environment creates many potential dangerous situations that can put personnel and equipment at risk of accidents. The proximity warning system is an effective, low-implementation-cost and low-maintenance-cost method to reduce such risks. This papers presents several real user cases of the implementation of proximity warning systems in the metals industry. Time Monday, Aug 31 10:00AM - 10:30AM Location 16 Speakers Edgardo La Bruna Janus Automation Lessons Learned From the Commissioning and Support of Mechanically Pumped Degassing Systems Worldwide Anke Teeuwsen, Edwards Vacuum; Frank Shi, Edwards Technologies Trading (Shanghai) Co. Ltd; Leonardo Bonifacio, Edwards Vacuum SpA; Aditya Agrawal, Edwards India Pvt. Ltd. show more Description During the past 15 years, the use of dry vacuum pumps has increased markedly. Original installations in foundry billet operations that were relatively light-duty have progressed to the high-volume continuous caster operations seen today. These operations require that the pumping equipment runs continuously during campaigns with no time allowed for service or maintenance. These demands on pumping system design and reliability currently dominate conversations in the industry. Time Monday, Aug 31 10:00AM - 10:30AM Location 4 Speakers Anke Teeuwsen Edwards Vacuum Frank Shi Edwards Technologies Trading (Shanghai) Co. Ltd Leonardo Bonifacio Edwards Vacuum SpA Aditya Agrawal Edwards India Pvt. Ltd. Life Cycle Assessment Study of a Novel Slag Practice for Titanium-Stabilized Stainless Steels Refining Rodrigo Lencina, Imerys France; Chen Yuxin, Imerys China; Emmanuelle Henry-Lanier, Imerys France show more Description The study compares the environmental impacts of stainless steel slags formed using two different materials: a new calcium aluminate flux and fluorspar. Life cycle assessment is used as the methodology, analyzing all life cycle stages of the fluxes production processes, from extraction of raw materials to the end of life of the waste generated. Results show that slag practice using calcium aluminate flux has lower impact for most of the indicators considered in the study, such as greenhouse gas emissions and air pollution. In conclusion, the analysis showed the potential of calcium aluminate fluxes to reduce the environmental impacts during slag conditioning. Time Monday, Aug 31 10:00AM - 10:30AM Location 11 Speakers Rodrigo Lencina Imerys France Chen Yuxin Imerys China Emmanuelle Henry-Lanier Imerys France Managing the Impact, Assessment and Application of Solutions for Combustible Dust Mitigation and Control in Modern Manufacturing Environments Simon Shipp, Aumund Corp. show more Description The presentation explains the significance and requirement to mitigate and manage combustible dust risks in modern manufacturing environments. The presentation reviews practical and legislative demands and provides solutions and considerations for operators, managers and owners. Contrasting technology applications from other industries and providing recommendations for application in metallurgy processes, the material offers useful and alternate perspectives to a real and potentially highly dangerous issue. Time Monday, Aug 31 10:00AM - 10:30AM Location 25B Speakers Simon Shipp Aumund Corp. Operational Results and Experience of HTT Oxymo Burners/Oxygen Injectors With Moving Flame and Oxygen Jets Installed in the Electric Arc Furnace at Stahl und Walzwerk Marienhütte Jaroslav Brhel, HTT Engineering spol. s r.o.; Thomas Griessacher, Stahl und Walzwerk Marienhütte GmbH show more Description Chemical energy represents significant heat input to modern electric arc furnaces and its efficiency has major impact on furnace productivity and operational cost. HTT Oxymo burners enable controlled wide-range motion of the flame and supersonic oxygen jet inside of the furnace area, while the burner body remains static and sealed in the furnace wall. This technology has been installed in a 45-ton highly productive furnace at Marienhütte Graz in Austria, where it replaced fixed supersonic burners/injectors. The paper describes this new installation, technology principles and practical operational results. Time Monday, Aug 31 10:00AM - 10:30AM Location 6 Speakers Jaroslav Brhel HTT Engineering spol. s r.o. Thomas Griessacher Stahl und Walzwerk Marienhütte GmbH Peritectic Behavior Detection in the Fe-C-Mn-Al-Si Steel System Using Fiber Optic Temperature Mapping Muhammad Roman, Missouri University of Science and Technology; Damilola Balogun, Missouri University of Science and Technology; Rex E. Gerald II, Missouri University of Science and Technology; Laura Bartlett, Missouri University of Science and Technology; Jie Huang, Missouri University of Science and Technology; Ronald O'Malley, Missouri University of Science and Technology show more Description Peritectic behavior is often avoided through chemistry adjustment to avoid surface defects and breakouts in continuous casting. However, the combined effects of C, Mn, Al and Si on the boundaries for peritectic behavior are still disputed. A controlled solidification experiment was developed to characterize the effects of composition on the uniformity of shell growth during solidification using a copper chill mold with an embedded fiber optic temperature sensor. The spatially distributed sensor employs optical frequency domain reflectometry to measure temperatures with a 0.6 mm spatial resolution and a 20 ms measurement period to map closely spaced temperature features caused by the peritectic reaction. Time Monday, Aug 31 10:00AM - 10:30AM Location 1 Speakers Muhammad Roman Missouri University of Science and Technology Damilola Balogun Missouri University of Science and Technology Rex E. Gerald II Missouri University of Science and Technology Laura Bartlett Missouri University of Science and Technology Jie Huang Missouri University of Science and Technology Ronald O'Malley Missouri University of Science and Technology Power Cooling — Advanced Strip Cooling Technology for Hot Strip Mills for Maximum Metallurgical Flexibility, High Cooling Rates and for Saving of Alloying Elements Lukas Pichler, Primetals Technologies Austria GmbH; Konrad Krimpelstaetter, Primetals Technologies Austria GmbH; Rüdiger Döll, Primetals Technologies Germany GmbH; Klaus Weinzierl, Primetals Technologies Germany GmbH show more Description Primetals Technologies introduced a new strip cooling technology for hot strip mills with increased impact pressure to achieve higher strip cooling rates. The automation system with its advanced models is an important and integral part of the solution. With this type of equipment, steel producers are capable of producing new steel grades with higher strength at lower operation costs. The lower operation costs mainly arise from saving of alloys by applicable high cooling rates. This paper describes this technology and explains different locations of power cooling on a hot strip mill, supporting different production strategies and benefits. Time Monday, Aug 31 10:00AM - 10:30AM Location 20 Speakers Lukas Pichler Primetals Technologies Austria GmbH Konrad Krimpelstaetter Primetals Technologies Austria GmbH Rüdiger Döll Primetals Technologies Germany GmbH Klaus Weinzierl Primetals Technologies Germany GmbH Reduced Fuel Gas Usage With Improved Reheat Furnace Pressure Control Mark Ferra, REXA show more Description Reheat furnaces need a stable internal pressure to optimize burner combustion. In 2019, a major steel producer in northwest Pennsylvania replaced an existing pneumatic actuator due to poor reliability and pressure control. The new electrohydraulic actuator with patented technology can react (4-5 Hz) to small, varying changes in the control signal with a repeatability of <0.1% travel position. This approach vastly improves the positioning accuracy of the flue gas stack damper, which allows hot gases to exit the furnace. By stabilizing the pressure in the furnace, the combustion efficiency was improved with an annual fuel savings of US$103,000 per year. Time Monday, Aug 31 10:00AM - 10:30AM Location 12 Speakers Mark Ferra REXA Searching New Horizons: The Hydrogen Revolution in Steelmaking Paolo Argenta, Tenova S.p.A.; Francesco Memoli, Tenova Inc. show more Description Several megatrends are driving society toward sustainable economic models. In the case of energy-intensive industries such as steelmaking, the evolution toward climate neutrality will mean major investments in new industrial processes that entail the use of alternative feedstock sources. In this scenario, Tenova has developed and improved technologies able to significantly reduce energy consumption and the environmental footprint of steel production, with a very particular focus on hydrogen-based solutions. This paper outlines the SALCOS and HYBRIT projects, at the forefront of steelmaking innovation, and the role of the gas-based reduction process in these innovative routes. Time Monday, Aug 31 10:00AM - 10:30AM Location 9 Speakers Paolo Argenta Tenova S.p.A. Francesco Memoli Tenova Inc. Streamlining Material Handling for Increased Plant Capacity Rob Loomis, InVekTek LLC show more Description Most mills depend on cranes as the primary tool for material handling. Crane controls haven't changed much over the years. The simple fact is cranes are still 100% the responsibility of the operator. And operator turnover is exasperating the plants' need to increase capacity and improve efficiency. New enhanced controls enable even experienced crane operators to transfer material 20% faster and safer, reducing collisions by 80%. And with new operators, the performance gains are even greater. If increasing plant capacity is a priority, take a look at your cranes. Without control technology, increasing productivity comes at the expense of safety. Time Monday, Aug 31 10:00AM - 10:30AM Location 10 Speakers Rob Loomis InVekTek LLC Understanding Slab Bowing Problem in the Slab Yard Hongbin Yin, ArcelorMittal show more Description As more and more hot rolling mills convert from pusher-type reheat furnace to walking beams, the requirement for slab dimensions becomes stricter. Bowed slabs, which were tolerated in pusher furnaces in the past, bear the risk of being scraped before charging to the walking beam furnace. In order to understand the slab bowing phenomenon, a number of experiments were carried out with thermal couples, thermal vision camera and timed snapshot camera, as well as scheduled manual measurements to track the slab bowing process over time within the slab stack. Effort also paid to the grade effects on the amount of bowing. This paper summarizes the results. Time Monday, Aug 31 10:00AM - 10:30AM Location 5 Speakers Hongbin Yin ArcelorMittal
10:30am Alloy and Process Modification for High-Hardness Steels David Salley, Center for Advanced Vehicular Systems - Mississippi State University; Will Williams, Center for Advanced Vehicular Systems - Mississippi State University; Haley Doude, Center for Advanced Vehicular Systems - Mississippi State University; Wil Whittington, Center for Advanced Vehicular Systems - Mississippi State University; Daniel M. Field, U.S. Army Combat Capabilities Development Command Army Research Laboratory; Krista R. Limmer, U.S. Army Combat Capabilities Development Command Army Research Laboratory; Kevin Doherty, U.S. Army Combat Capabilities Development Command Army Research Laboratory; Hongjoo Rhee, Mississippi State University show more Description Multiple high-hardness steel (HHS) alloys were produced to investigate reducing hydrogen embrittlement (HE) susceptibility to prevent delayed cracking. The alloys were produced in-house as 50-lb. heats and hot rolled to 0.5-in. plates for comparison against a commercially available steel. Manufacturing simulations were also run on a Gleeble thermal-mechanical simulator to identify better processing parameters. Testing was performed to evaluate correlations between mechanical properties, microstructure and hydrogen embrittlement performance. The findings in this study have implications for reducing HE susceptibility in HHS steels. Time Monday, Aug 31 10:30AM - 11:00AM Location 25A Speakers David Salley Center for Advanced Vehicular Systems - Mississippi State University Will Williams Center for Advanced Vehicular Systems - Mississippi State University Haley Doude Center for Advanced Vehicular Systems - Mississippi State University Wil Whittington Center for Advanced Vehicular Systems - Mississippi State University Daniel M. Field U.S. Army Combat Capabilities Development Command Army Research Laboratory Krista R. Limmer U.S. Army Combat Capabilities Development Command Army Research Laboratory Kevin Doherty U.S. Army Combat Capabilities Development Command Army Research Laboratory Hongjoo Rhee Mississippi State University Auto Adaptive Vibration Monitoring Utilizing Edge Computing in Rolling Mill Applications David Kober, IBA America LLC show more Description With a successful data analytics strategy in regards to vibration monitoring, maintenance- and repair-related information can be derived automatically and auto adapt to changing process conditions. The purpose of this discussion is to characterize a common-sense approach using strategic data analytics practices to leverage auto adapting condition monitoring by classifying the dynamically changing process conditions that exist in rolling mill applications. Utilizing systems that exist on the edge, the technologies that are available on both the IT and OT realm can be leveraged efficiently and immediately with strategic coordination. The focus will center around practical rolling mill application examples. Time Monday, Aug 31 10:30AM - 11:00AM Location 13 Speakers David Kober IBA America LLC Bayesian Approach to Pyrometry During Intercritical Annealing of Advanced High-Strength Steel Fatima Suleiman, University of Waterloo; Kaihsiang Lin, University of Waterloo; Roger Tsang, University of Waterloo; Thomas Larrick, Williamson Corp.; Kyle Daun, University of Waterloo show more Description Measuring steel strip temperature through pyrometry requires detailed knowledge of the spectral emissivity. Unfortunately, precise estimates of the spectral emissivity are elusive because it varies with wavelength, temperature, surface roughness and oxidation. This study presents a Bayesian pyrometry methodology in which temperature and spectral emissivity are unknown stochastic variables that are inferred together. Additional information about the spectral emissivity is incorporated into the inference through maximum likelihood priors. While standard pyrometry methods provide a point estimate of surface temperature, Bayesian techniques infer the posterior probability density, which will allow galvanizers to better assess the reliability of the pyrometrically inferred temperature. Time Monday, Aug 31 10:30AM - 11:00AM Location 16 Speakers Fatima Suleiman University of Waterloo Kaihsiang Lin University of Waterloo Roger Tsang University of Waterloo Thomas Larrick Williamson Corp. Kyle Daun University of Waterloo CFD Study of an Energiron Reactor Fed With Different Concentrations of Hydrogen Dario Pauluzzi, Danieli; Ashton Hertrich Giraldo, Danieli; Alberto Zugliano, Danieli & Officine Meccaniche S.p.A.; Daniela Dalle Nogare, Danieli; Alessandro Martinis, Danieli & Officine Meccaniche S.p.A. show more Description Climate change is one of the defining challenges of our era and the iron and steel sector is responsible for approximately 7% of global CO2 emissions. Innovative hydrogen-based technologies are being developed to decrease the carbon footprint of tomorrow’s steelmaking plants; in this context, Energiron is a mature direct reduction technology that maximizes the efficient use of hydrogen for direct reduced iron (DRI) production. This paper presents a computational fluid dynamics analysis of an Energiron reactor operating with different levels of hydrogen; the resulting momentum, species and enthalpy balances for both the DRI and the gas phases are described and analyzed. Time Monday, Aug 31 10:30AM - 11:00AM Location 9 Speakers Dario Pauluzzi Danieli Ashton Hertrich Giraldo Danieli Alberto Zugliano Danieli & Officine Meccaniche S.p.A. Daniela Dalle Nogare Danieli Alessandro Martinis Danieli & Officine Meccaniche S.p.A. Commencing and Improving the Production of IF Steel Slabs at Chengsteel, HBIS Jacques De Vos, DITH; Jia Huang Hong, HBIS Chengsteel; Giuseppe Pratolongo, DITH; Antonello Di Salvo, DITH show more Description The starting situation at the beginning of the project consisted in short interstitial-free (IF) casting sequences mostly with the replacement of submerged-entry nozzle (SEN) during or after each heat, due to clogging by alumina inclusions with consequent slab downgrade. After completing the project, the 2-strand continuous caster was able to cast, mostly replacing the SEN once, the maximum number of IF steel heats per sequence that the steelmaking cycle could supply. This paper describes the investigations made and countermeasures adopted for lengthening IF casting sequences and strongly increasing the ratio of slabs suitable for exposed automotive applications. Time Monday, Aug 31 10:30AM - 11:00AM Location 5 Speakers Jacques De Vos DITH Jia Huang Hong HBIS Chengsteel Giuseppe Pratolongo DITH Antonello Di Salvo DITH Crane Safety Project - Overload Protection Systems for Cranes in Demanding Environments Stefan Dahlman, Gigasense AB show more Description This paper describes a crane safety Ppoject that explains the level of functional safety the overload protection system shall fulfill, and how the different system components are designed. According to functional safety standard EN ISO 13849-1, Automatic Cranes, cranes for transportation of molten steel and cranes in nuclear power plants shall fulfill minimum Performance Level d, Category 3. This paper presents a project from quote to delivery. Time Monday, Aug 31 10:30AM - 11:00AM Location 10 Speakers Stefan Dahlman Gigasense AB Development of High-Efficiency Recuperator by New Heat Transfer–Promoting Device at the Continuous Annealing Line Ryo Kamura, JFE Steel Corp.; Koji Iwata, JFE Steel Corp.; Kunitoshi Oyama, JFE Steel Corp. show more Description In iron works, many heat recuperators that exchange between exhaust gas and combustion air are utilized in order to advance energy saving at the continuous annealing line (CAL). This paper will present an investigation of the importance of improving heat transfer performance of the recuperator by promoting turbulence of outer surface recuperator. A new heat transfer-promoting device was developed that advances heat transfer and satisfies the allowable pressure loss and reduces the quantity of fuel gas by about 4%. Time Monday, Aug 31 10:30AM - 11:00AM Location 12 Speakers Ryo Kamura JFE Steel Corp. Koji Iwata JFE Steel Corp. Kunitoshi Oyama JFE Steel Corp. Development of the PyroLIBS Sensor: Direct and Real-Time Measurement of Molten Material Composition Bijan Shahriari, Hatch Ltd. show more Description The PyroLIBS sensor utilizes the principles of laser-induced breakdown spectroscopy to provide real-time and direct measurement of melt chemistry. The sensor provides faster analysis compared to melt sampling and more accurate analysis compared to indirect methods (e.g., gas stream analyzers and galvanic potential sensors). This paper outlines the collaboration between Hatch and the National Research Council of Canada in the development and commercialization of this sensor for ironmaking and steelmaking applications. Results and steps forward will be shared (lab testing, in-plant piloting and commissioning). Time Monday, Aug 31 10:30AM - 11:00AM Location 25C Speakers Bijan Shahriari Hatch Ltd. Functionalization of Supersonic Oxygen Lance for EAF Masashi Yamaguchi, Taiyo Nippon Sanso Corp.; Yasuyuki Yamamoto, Taiyo Nippon Sanso Corp.; Yoshiyuki Hagihara, Taiyo Nippon Sanso Corp. show more Description Supersonic oxygen lance is an important tool for power reduction in the electric arc furnace (EAF) process. SCOPE-Jet was launched in 2001 as a supersonic oxygen lance for EAF. In recent years, the combination with post-combustion has enhanced power reduction effect. In addition, the SCOPE-Jet is being enhanced. One modification is a burner that applies the self-induced oscillation phenomenon to SCOPE-Jet to realize wide-area heating. The other is a burner that can form a higher-velocity oxygen jet and shorten the melting time by injecting high-temperature oxygen generated in the pre-heating device into the SCOPE-Jet. Time Monday, Aug 31 10:30AM - 11:00AM Location 6 Speakers Masashi Yamaguchi Taiyo Nippon Sanso Corp. Yasuyuki Yamamoto Taiyo Nippon Sanso Corp. Yoshiyuki Hagihara Taiyo Nippon Sanso Corp. JinXi Blast Furnace No. 9 Refractory Wear Evaluation Based on AU-E and Physical Measurements Afshin Sadri, Hatch Ltd.; Li Jian Wei, Heibei JinXi Iron & Steel Group Co. Ltd.; Sun Ya Ping, Heibei JinXi Iron & Steel Group Co. Ltd.; Mitchell Henstock, Hatch Ltd.; Wai Lai Ying, Hatch Ltd. ; Jesson Ma, Hatch Ltd. show more Description The wear and erosion of the refractory lining and cooling elements in blast furnaces are the main reason for termination of their campaign life. This paper presents the results of combined AU-E inspection and thermal analysis of refractory lining in Blast Furnace No. 9 at JinXi steel plant in Tangshan, China. In June 2019, BF No. 9 was relined, which provided the rare opportunity to compare the results of the AU-E inspection with actual physical refractory thickness measurements. In addition, the condition of the refractory was observed and noted during this investigation. Time Monday, Aug 31 10:30AM - 11:00AM Location 26A Speakers Afshin Sadri Hatch Ltd. Li Jian Wei Heibei JinXi Iron & Steel Group Co. Ltd. Sun Ya Ping Heibei JinXi Iron & Steel Group Co. Ltd. Mitchell Henstock Hatch Ltd. Wai Lai Ying Hatch Ltd. Jesson Ma Hatch Ltd. Modeling and Design of Quenching and Tempering Process for Alloy Steel Pipes Zhichao (Charlie) Li, DANTE Solutions Inc.; Justin Sims, DANTE Solutions, Inc. ; B. Lynn Ferguson, DANTE Solutions Inc. show more Description High-quality steel pipes are often quench-hardened for superior mechanical properties. The process includes austenitizing, spray quenching and tempering. During spray quenching, the quenching rate is affected by the type of quenchant, nozzle design, flowrate, spray zone and spray time, etc. In this article, the austenitizing, spray quenching and tempering process of one alloy steel pipe are modeled using DANTE, a commercial finite element heat treat software. The modeling results include hardness, phase fractions, residual stresses and distortion. Using modeling, different processes are designed to obtain bainite or tempered martensite phases. Time Monday, Aug 31 10:30AM - 11:00AM Location 14 Speakers Zhichao (Charlie) Li DANTE Solutions Inc. Justin Sims DANTE Solutions, Inc. B. Lynn Ferguson DANTE Solutions Inc. New EAF Dust Treatment Process for Co-Production of Metallic Zinc and Calcium-Ferrite Shunsuke Koide, Hoei Metal Co. Ltd.; Hitoshi Mizuno, Hoei Metal Co. Ltd.; Kazuyoshi Yamaguchi, Hoei Metal Co. Ltd. & Tohoku University; Fumio Tanno, Hoei Metal Co. Ltd.; Tetsuya Nagasaka, Tohoku University show more Description In the EAF steelmaking industry, dust treatment is one of the most serious issues worldwide due to its high costs and environmental burden, and thus this critical problem must be solved for sustainability of steel industry. A bench-scale investigation has been conducted in which CaO and coal-added EAF dust was heated at around 1,000°C to convert ZnFe2O4 into ZnO and Ca2Fe2O5, and formed ZnO was reduced. Evaporated zinc was collected as crude ZnO and after the halogens removal process, ZnO was supplied to carbothermic reduction process under reduced pressure. Finally, high-purity metallic zinc was successfully recovered. Time Monday, Aug 31 10:30AM - 11:00AM Location 11 Speakers Shunsuke Koide Hoei Metal Co. Ltd. Hitoshi Mizuno Hoei Metal Co. Ltd. Kazuyoshi Yamaguchi Hoei Metal Co. Ltd. & Tohoku University Fumio Tanno Hoei Metal Co. Ltd. Tetsuya Nagasaka Tohoku University Novel Method for Stirring BOF Melts in Conjunction With Slag Splashing Anand Kumar Makwana, Air Products; Anup Sane, Air Products; Xiaoyi He, Air Products; Gregory Buragino, Air Products show more Description Basic oxygen furnace bottom stirring is a well-known process with documented benefits, including higher yield, improved metallurgical properties and increased efficiency. Bottom stirring is commonly used outside of the U.S.; however, it is not common in the U.S. mainly due to the poor reliability and difficulty avoiding blockage of the stirring elements due to slag splashing practices which extend refractory campaigns over 10,000 heats. This paper presents a newly developed tuyere design and stirring practice that will allow long campaign life with slag splashing while maintaining the stirring operation. Time Monday, Aug 31 10:30AM - 11:00AM Location 7 Speakers Anand Kumar Makwana Air Products Anup Sane Air Products Xiaoyi He Air Products Gregory Buragino Air Products Predicting the Peritectic Transformation as a Function of Steel Composition Bryan Webler, Carnegie Mellon University show more Description This paper documents work to predict the effect of alloy composition on the peritectic transformation. The occurrence of the peritectic transformation can be identified from experimental data and computational thermodynamics calculations, with regression models used to predict behavior for new compositions. Potential advanced high-strength steel compositions require levels of alloying elements outside the range of previous efforts. Here, Thermo-Calc was used to determine when the peritectic transformation occurs over a range of alloy compositions. New regression approaches were used to build models. Results were compared to previous correlations, as well as targeted experiments using differential scanning calorimetry. Time Monday, Aug 31 10:30AM - 11:00AM Location 1 Speakers Bryan Webler Carnegie Mellon University Productivity and Performances Enhancing in OMK for X70 Arctic Via Thin-Slab Rolling Fed by EAF Romano Sellan, Danieli; Marcellino Fornasier , Danieli; Bojan Vucinic , Danieli; Oliver Rott, Danieli Germany; Kislica Vyacheslav, Vyksa Steel Works; Muntin Alexander, Vyksa Steel Works show more Description The pioneer experience started in 2008 at OMK’s new thin-slab plant (the first facility worldwide producing X-70 for arctic applications via EAF-LRF-VD) has entered a new chapter. The EAF revamping boosted productivity up to +25% with the latest chemical packages supported by a closed automation process loop. The roll-diagram upgrade in the TSC and the commissioning of Q-Pulse enhance the internal quality for MC grades, while mold MM-EMS installation will grant surface quality at the top level and cope with increased productivity. An upgrade of the runout table cooling enables significant cost reduction due to increased cooling rates and strength of the rolled products. Time Monday, Aug 31 10:30AM - 11:00AM Location 20 Speakers Romano Sellan Danieli Marcellino Fornasier Danieli Bojan Vucinic Danieli Oliver Rott Danieli Germany Kislica Vyacheslav Vyksa Steel Works Muntin Alexander Vyksa Steel Works Rapid Corbel Repair Technologies Alan Bowser, Fosbel Inc. show more Description Effective coke battery production and maintenance requires a balance between coke production and refractory preservation. This presentation will focus on Corbel technologies that optimize oven availability, reduce maintenance downtime and extend battery life. These Corbel technology repairs restore the structural stability, thermodynamic integrity and proper heating of the oven wall. Time Monday, Aug 31 10:30AM - 11:00AM Location 25B Speakers Alan Bowser Fosbel Inc. Vacuum Converter Provides Superb Stainless Steel and Ferroalloy Refining Power for Highly Demanding Applications Uwe Thiedemann, SMS group; Miroslaw Paluszak, SMS group; Tim Kleier, SMS group show more Description For the production of sophisticated steel grades, a vacuum converter (VacCon) provides numerous advantages. The VacCon integrates advantages of an argon oxygen decarburizer (AOD) combined with abilities of a vacuum oxygen decarburizer. High productivity of the highest purity steel can be achieved. The new process enables the production of stainless, acid- and heat-resistant steel, and high-alloy special steel. Refining of ferromanganese and ferrochrome to low-carbon grades are additional applications. The production of the lowest carbon, nitrogen and hydrogen levels is possible with significantly reduced argon consumption compared to the conventional AOD process. Conventional AOD plants can be modified to incorporate the advantages of the new VacCon process. Time Monday, Aug 31 10:30AM - 11:00AM Location 4 Speakers Uwe Thiedemann SMS group Miroslaw Paluszak SMS group Tim Kleier SMS group WCM – World-Class Maintenance Walter Marrochi, Ternium Mexico show more Description Ternium adopted the World-Class Maintenance Model as its asset management. This model consists of a structured methodology that allows a metric of the maturity of the process, focuses on critical equipment and large losses. A three-year plan is generated, with the objectives of: 20% availability increase. 15% cost reduction. 15% improvement of labor productivity. 20% reduction of working capital. Risk control to achieve zero serious accidents and incidents. Time Monday, Aug 31 10:30AM - 11:00AM Location 19 Speakers Walter Marrochi Ternium Mexico
11:00am AI Application to Front-End Bending Prediction Marcelo Saparrat, TECNOAP; Fernando Monti, Ternium Mexico; José Ibarra, Ternium Mexico show more Description During the passes of the slab in the reversing mill, there is sometimes a curvature defect in the tip of the sheet being processed. This defect, due to the form it presents, is colloquially known as "ski." Depending on its direction and magnitude, it can cause the slab to hit the frame of the next stage or to be inserted into the conveyor rollers, with its consequent damage to the equipment and production stoppage. An artificial intelligence-based prediction model will be presented, with more than 200 process variables that take in account the underlying physical complexities that cause this phenomenon. Time Monday, Aug 31 11:00AM - 11:30AM Location 13 Speakers Marcelo Saparrat TECNOAP Fernando Monti Ternium Mexico José Ibarra Ternium Mexico Application of Oxygen-Enriched Combustion in an Industrial Reheating Furnace Using CFD Bethany Worl, Purdue University Northwest; Francisco Martinez, Purdue University Northwest; Armin Silaen, Purdue University Northwest; Kurt Johnson, ArcelorMittal Global R&D; Larry Fabina, ArcelorMittal Burns Harbor; Kelly Tian, Praxair; Joe Maiolo, Praxair; Chenn Zhou, Purdue University Northwest show more Description An important part of the hot rolling process is the reheating of steel products to target temperature using the combustion of natural gas in a furnace. To increase energy efficiency of this reheating process, oxygen enrichment can be used with high entrainment of reaction product gases to distribute the combustion reaction area. The modeling of various configurations was undertaken using computational fluid dynamics to use oxygen enrichment or oxy-fuel in order to avoid changes in the furnace zone temperatures while reducing fuel usage. Effects on the combustion, temperature distribution, species and heat transfer to the steel product are under study. Time Monday, Aug 31 11:00AM - 11:30AM Location 12 Speakers Bethany Worl Purdue University Northwest Francisco Martinez Purdue University Northwest Armin Silaen Purdue University Northwest Kurt Johnson ArcelorMittal Global R&D Larry Fabina ArcelorMittal Burns Harbor Kelly Tian Praxair Joe Maiolo Praxair Chenn Zhou Purdue University Northwest Applications and Practices of Integrated Intelligent Management and Control Platform for Ironmaking Area Gang Wang, CISDI Chongqing Information Technology Co. Ltd.; Tao Deng, CISDI Chongqing Information Technology Co. Ltd.; Jinsong Wang, CISDI Chongqing Information Technology Co. Ltd.; Hao Xie, CISDI Information Technology Co. Ltd.; Xiaodong Sun, CISDI Information Technology Co. Ltd.; Xianming Li, Shaoguan Iron & Steel Group Co. Ltd. show more Description Based on the Internet of Things and big data analysis, the intelligent integrated control center for upstream-BF (ironmaking included) has been built for data processing and production control on procedures from stockyard to sintering, coking and ironmaking. Those procedures can be integrated for production control by intelligent decision-making and models. The production, technical and management staff can apply this center platform for the intelligent control of production and for intelligent monitor pre-alarms, analysis and diagnosis, and decision-making. All upstream-BF procedures are operated with an enhanced stability and improved quality control level. In the meanwhile, energy consumptions can be reduced and economic indicators are remarkably increased. Time Monday, Aug 31 11:00AM - 11:30AM Location 25C Speakers Gang Wang CISDI Chongqing Information Technology Co. Ltd. Tao Deng CISDI Chongqing Information Technology Co. Ltd. Jinsong Wang CISDI Chongqing Information Technology Co. Ltd. Hao Xie CISDI Information Technology Co. Ltd. Xiaodong Sun CISDI Information Technology Co. Ltd. Xianming Li Shaoguan Iron & Steel Group Co. Ltd. Campaign Life Extension of Blast Furnace Offgas System Sergio Nascimento Leal, Gerdau Açominas S.A.; Jorge Luiz de Oliveira, Gerdau Açominas S.A. ; Maher Al-Dojayli, Formerly of Hatch Ltd.; Hamid Ghorbani, Hatch Ltd.; Ricardo Jose Maia, Hatch Ltd.; Camilla Lopes, Hatch Ltd.; Yang Zhou, Hatch Ltd.; Mark Allan, Hatch Ltd.; Sunil Kumar, Hatch Ltd.; Chad Van der Woude, Hatch Ltd. show more Description During 33 years of operation, Gerdau’s Blast Furnace #1 offgas system experienced high metal loss, significant dust buildup due to process issues, and buckling damages due to high-temperature events. This paper presents the fitness-for-service assessment that developed strategies for: short-term local repairs without production interruptions and long-term repairs for campaign life extension until next planned major maintenance shutdown. These strategies include external reinforcements, refractory lining, operational controls and a health monitoring plan. The plant successfully performed the repairs and was able to continue the operation without production interruptions, resulting in major financial benefits and improved safety conditions. Time Monday, Aug 31 11:00AM - 11:30AM Location 26A Speakers Sergio Nascimento Leal Gerdau Açominas S.A. Jorge Luiz de Oliveira Gerdau Açominas S.A. Maher Al-Dojayli Formerly of Hatch Ltd. Hamid Ghorbani Hatch Ltd. Ricardo Jose Maia Hatch Ltd. Camilla Lopes Hatch Ltd. Yang Zhou Hatch Ltd. Mark Allan Hatch Ltd. Sunil Kumar Hatch Ltd. Chad Van der Woude Hatch Ltd. Crane Remote Driving: Applications in Meltshop Area Lorenzo Bacchetti, Danieli; Luca Argiolas, Danieli & Officine Meccaniche S.p.A. show more Description This presentation discusses engineering and commissioning of a charging crane remote control, with first operation feedback. The crane operator is no longer exposed to electric arc furnace (EAF) scrap-charging hazards: the control is performed from a safe control room with increased ergonomics. The crane is no longer commanded from joysticks, but guided from touch screens. One single operator is supervising the activities of the EAF crane and the EAF. A smart CCTV-camera system automatically interacts with the crane and the technological process, giving the operator an enhanced vision of the action. Time Monday, Aug 31 11:00AM - 11:30AM Location 10 Speakers Lorenzo Bacchetti Danieli Luca Argiolas Danieli & Officine Meccaniche S.p.A. Heating Value and Waste Gas Flow-Controlled Exhaust Gas Post-Combustion for a 150-Ton RH-TOP Degasser at Big River Steel Helmut Biehl, SMS Mevac GmbH; Volker Wiegmann, SMS Mevac GmbH; Jochen Schlüter, SMS Mevac GmbH; Michele Vachon, Big River Steel; Jonathan Youngblood, Big River Steel show more Description Big River Steel started up in Osceola, Ark., USA, in 2016. The entire plant was supplied by SMS group. A 150-ton RH-TOP unit was selected for producing steels with ultralow carbon contents, achieved during the decarburization process. Meanwhile, considerable amounts of CO are generated. U.S. federal regulations require that combustible process gases have to be burnt with a heating value of at least 200 BTU/scf. To follow that regulation, a new flare stack burner concept was developed to combust CO-containing exhaust gases and reduce the environmental impact in the form of CO2 emissions. Time Monday, Aug 31 11:00AM - 11:30AM Location 11 Speakers Helmut Biehl SMS Mevac GmbH Volker Wiegmann SMS Mevac GmbH Jochen Schlüter SMS Mevac GmbH Michele Vachon Big River Steel Jonathan Youngblood Big River Steel High-Carbon DRI for the Production of High-Purity Pig Iron Francesco Memoli, Tenova Inc.; Jorge Martinez, Tenova HYL show more Description The world’s iron and steel producers need a paradigm change for the future to fulfill environmental regulations and to cope with raw material availabilities and final product qualities. The ENERGIRON® technology has been characterized by innovation and this paper outlines the novel Tenova High Purity Pig Iron (HPPI) production process that starts with the reduction of iron-oxide pellets in a gas-based DR module and follows with high-carbon-DRI melting in an electric furnace, specifically designed to produce pig iron, thus reducing carbon footprint in about 50% for ironmaking of integrated steel mills while keeping the BOF and downstream facilities unchanged. Time Monday, Aug 31 11:00AM - 11:30AM Location 9 Speakers Francesco Memoli Tenova Inc. Jorge Martinez Tenova HYL How JSW Dolvi Evolved Since 1998 to Become One of the Most Productive CSP® Plants in the World Georg Padberg, SMS group GmbH; Atluri Ratnaprasad, JSW Steel Ltd., Dolvi Works; Vurity Saibabu, JSW Steel Ltd., Dolvi Works; Ralf Bauer, SMS group GmbH; Michael Pander, SMS group GmbH; Luc Neumann, SMS group GmbH show more Description The first CSP plant in India went into operation in Dolvi, Maharashtra, in 1998. It started up with a vertical caster (274-inch metallurgical length) and a 6-stand hot rolling mill for the production of hot-rolled coils up to 61.4 inches wide. In 2003, the first major upgrade was the commissioning of a 2nd caster (370"). In 2015, the first caster's upgrade included strand guide extension and liquid core reduction. In 2017, automation upgrade incorporated electromagnetic brake and delta speed. This increased productivity to 3.6 mst, which was initially 1.3 mst. This helped JSW's goals of improving quality, productivity, reducing costs and introduction of new steel grades. Time Monday, Aug 31 11:00AM - 11:30AM Location 5 Speakers Georg Padberg SMS group GmbH Atluri Ratnaprasad JSW Steel Ltd., Dolvi Works Vurity Saibabu JSW Steel Ltd., Dolvi Works Ralf Bauer SMS group GmbH Michael Pander SMS group GmbH Luc Neumann SMS group GmbH Hydrogen-Based Annealing Technologies for High-Alloyed Steel Strips Open Various Market Segments Sascha Eppensteiner, EBNER Industrieofenbau GmbH show more Description High-alloyed steel strip products have a variety of challenging applications in different market segments. Depending on the final application, different properties are required and therefore various heat treatment concepts are necessary. This paper reviews versatile applications of continuous bright annealing lines operating under hydrogen atmosphere, gives an overview of challenges in the process, and introduces recently implemented use cases of such lines in different market segments, such as: • Classical austenitic, ferritic and martensitic grades with a focus on highest production rates. • Precision strips with a focus on ultrathin gauges. • Ni-base alloys with a focus on highest peak metal temperatures. Time Monday, Aug 31 11:00AM - 11:30AM Location 25A Speakers Sascha Eppensteiner EBNER Industrieofenbau GmbH Investigation of Peritectic Behavior of Steel Using a Thermal Analysis Technique Sunday Abraham, SSAB Iowa Inc. show more Description Thermal analysis experiments were conducted during solidification of steel in a laboratory setting to investigate the effects of C, Si, Cr and Mo on peritectic reactions during solidification. The results from the thermal analysis experiments were compared to predictions by four peritectic equations. Time Monday, Aug 31 11:00AM - 11:30AM Location 1 Speakers Sunday Abraham SSAB Iowa Inc. Maintenance and Operations Improvement Process Lyle Bufogle, McConway & Torley show more Description McConway & Torley is the sole remaining facility making steel in Pittsburgh. Improvement initiatives center on lean manufacturing and reliability. Efforts begin with a steering team, plus four OpEx teams concentrating on planning and scheduling, CMMS, MRO Warehousing, and reliability. Lean TPM efforts include 5S, autonomous maintenance, SQDC Noticeboards, Gemba, Kaizen, focused improvement projects and performance evaluation. Maintenance was reorganized to transition to proactive from reactive maintenance. Predictive maintenance targets failure modes use ultrasound, thermography and vibration analysis. Lubrication, upskilling and contractor management practices are being upgraded. Objectives for change and improvement are challenging and are well-supported by management. Time Monday, Aug 31 11:00AM - 11:30AM Location 19 Speakers Lyle Bufogle McConway & Torley Mastering Fully Automated Steelmaking Richard Stadlmayr, Primetals Technologies Austria GmbH; Christoph Stangl, Primetals Technologies Austria GmbH; Peter Pinter, Primetals Technologies Austria GmbH show more Description Today dynamic ladle degasser/basic oxygen furnace/electric arc furnace process control with assisted secondary refining and autonomous steel casting is state-of-the-art upstream technology. The idea of fully automated steelmaking extends the meltshop automation to a level that enables the operator to act primarily as supervisor to execute steel production in a safe manner. Since there is no unified approach to close the gap between current plant-specific operation and the mid-term target of fully automated steelmaking, a digitalization road map draws a structured picture of required measures accompanied by an implementation order considering process development, IT and data infrastructure, meltshop logistic topics, and maintenance aspects as one. Time Monday, Aug 31 11:00AM - 11:30AM Location 6 Speakers Richard Stadlmayr Primetals Technologies Austria GmbH Christoph Stangl Primetals Technologies Austria GmbH Peter Pinter Primetals Technologies Austria GmbH Nucor Gallatin Pre-Assembled Tunnel Furnace: Meeting the Demand of Quality Construction With Saving in Installation Time Alessandro Venanzini, Danieli Centro Combustion; Fabrizio Pere, Danieli Centro Combustion; Narayan Raut, Danieli Corp. show more Description In a market where time is money and any rework at site may cost a fortune and delay the overall completion, the “pre-assembly” concept has become a necessity. Danieli Centro Combustion is executing a pre-assembled tunnel furnace for Nucor Steel Gallatin. The whole assembly of furnace equipment (structure, refractory, piping) is done in the workshop prior to shipment at site. 3D engineering by Danieli Centro Combustion and pre-assembly are mutually beneficial concepts that will ensure no additional time from order to commissioning and add the benefits of quality, workmanship and accuracy long desired by industry for turnkey projects. Time Monday, Aug 31 11:00AM - 11:30AM Location 20 Speakers Alessandro Venanzini Danieli Centro Combustion Fabrizio Pere Danieli Centro Combustion Narayan Raut Danieli Corp. Optimal Model Re-training in Steelmaking Process Estimation Using Machine Learning Algorithms Marco Luccini, Tenova Goodfellow Inc.; Elena Uchiteleva, Tenova Goodfellow Inc. show more Description Optimal re-training of an estimation and prediction model based on past data is an extensively researched topic. Specifically, with the recent surge in number of connected sensors and Internet-of-Things (IoT) devices, a large quantity of process data is suddenly available to help improve process models. In this contribution, the application of a Machine Learning model to estimate steelmaking process variables in an EAF is presented, with the application of re-training solutions to maintain optimal process estimation accuracy over time and to adapt to process changes. Time Monday, Aug 31 11:00AM - 11:30AM Location 14 Speakers Marco Luccini Tenova Goodfellow Inc. Elena Uchiteleva Tenova Goodfellow Inc. State-of-the-Art Converter Technology: Proven Features for Longest BOF Lifetime Günther Staudinger, Danieli Corus; Michael Skorianz, Danieli Corus; Joachim Lehner, voestalpine Stahl GmbH show more Description In basic oxygen furnace steelmaking, there is an increasing requirement for converter vessel and refractories to increase their lifetimes in parallel as a system. This article presents developments and recent implementations of: > Maximum inner reaction volume within an existing plant space. > Suspension system with further improved vertical lamella elements and a new horizontal suspension element based on flat lamella plates to compensate thermal expansion of the vessel by elastic deformation. > Highly creep-resistant shell material, converter air and water cooling. > Second generation of temperature monitoring system Q–Temp. > DCMS-Danieli Conditioning Monitoring System (e.g., tilting drive gear components). Time Monday, Aug 31 11:00AM - 11:30AM Location 7 Speakers Günther Staudinger Danieli Corus Michael Skorianz Danieli Corus Joachim Lehner voestalpine Stahl GmbH Successful Operation of Sulfur Recovery Unit at New Byproduct Plant at Tata Steel Deepak Kumar, Tata Steel Ltd.; Rajesh Kumar, Tata Steel Ltd.; Abhijit Roy, Tata Steel Ltd. show more Description Coke oven gas, which is produced during the carbonization process, contains H2S and the separation of sulfur from the gas is required to protect the environment from its adverse consequences. A desulfurization plant by Claus reactor was implemented for the first time at Tata Steel's Jamshedpur Plant in 2014. Since then, stable operation by controlling the operating parameters like temperature of sour gas, various ratios, temperature of the Claus kiln, reactor, etc., through daily management has helped in sustained production of elemental sulfur. Various maintenance-related issues faced have been overcome by proper design modifications. This paper describes the various learnings from the operation. Time Monday, Aug 31 11:00AM - 11:30AM Location 25B Speakers Deepak Kumar Tata Steel Ltd. Rajesh Kumar Tata Steel Ltd. Abhijit Roy Tata Steel Ltd.
11:30am Approach to Successful Production of Very-Low-Carbon, Highly Formable Dual-Phase Steels Through the Continuous Galvanizing Line of the Flex Mill at Big River Steel Shobhit Bhartiya, Big River Steel; Siddhartha Biswas, Big River Steel ; Mat Bishop, Big River Steel; Josh Vandyke, Big River Steel; Denis Hennessey, Big River Steel; Amar De, Big River Steel show more Description At Big River Steel, a very-low-carbon chemistry for the development of family of high-strength, highly formable dual-phase (DP) steels was undertaken to produce highly stretchable, higher-strength dual-phase steels with possibly the lowest carbon equivalence in the industry. A clean steel practice combined with a suitable choice of chemistry has resulted in excellent mechanical properties and forming characteristics of high-strength DP steels (780 MPa and above). In this article, production strategy and advanced material characterization of DP steels with tensile strength of 600 MPa and above will be discussed. Time Monday, Aug 31 11:30AM - 12:00PM Location 25A Speakers Shobhit Bhartiya Big River Steel Siddhartha Biswas Big River Steel Mat Bishop Big River Steel Josh Vandyke Big River Steel Denis Hennessey Big River Steel Amar De Big River Steel Assessment of the Peritectic Behavior in the Continuous Casting Mold Franz Ramstorfer, Ternium Brazil; Leonardo Martins Demuner, Ternium Brazil; Oliver Lang, Primetals Technologies Austria GmbH; Christian Ortner, Primetals Technologies Austria GmbH; Martin Schuster, Primetals Technologies Austria GmbH show more Description Knowing the intensity of peritectic behavior of steel grades during solidification in the mold is essential for adjusting casting parameters in order to cast peritectic steel grades defect-free under stable casting conditions. The peritectic behavior of various steel grades from the whole production spectrum was measured using the Peritectic Expert of the MoldExpert system, which determines the peritectic behavior based on temperature measurements in the mold copper plates and expresses it as a dimensionless peritectic index. Based on these measurements, an analytic correlation between chemical composition and peritectic index for characterizing steel grades could be found. Time Monday, Aug 31 11:30AM - 12:00PM Location 1 Speakers Franz Ramstorfer Ternium Brazil Leonardo Martins Demuner Ternium Brazil Oliver Lang Primetals Technologies Austria GmbH Christian Ortner Primetals Technologies Austria GmbH Martin Schuster Primetals Technologies Austria GmbH Blast Furnace Campaign Extension by Recovering Cooling Capability of the Furnace Body and Increasing Cost Competitiveness by Low-Grade Coke Operation at Pohang No. 1 Blast Furnace Cheolgi Min, POSCO; Taejun Kim, POSCO show more Description Pohang No. 1 Blast Furnace is the oldest and smallest blast furnace in POSCO, which started its third campaign in 1993 and is operating steadily. This paper introduces recovering cooling capability of the old blast furnace to extend the campaign and the increasing cost-competitiveness of the small blast furnace by low-grade coke operation. For recovering cooling capability, a cooling water induction device was developed outside the shell and prevented damage to the body refractories by increasing body press-in hole. Pohang No. 1 Blast Furnace also succeeded in reducing the cost difference with large blast furnace through the low-grade coke operation. Time Monday, Aug 31 11:30AM - 12:00PM Location 26A Speakers Cheolgi Min POSCO Taejun Kim POSCO Crane Rail Measurement by Image Processing Laser Scanner Point Cloud Mike Falk, Falk PLI show more Description Overhead cranes run on runway rails in factories and warehouses around the world. Proper alignments of runway rails are crucial to their safe operation. We present a method to determine features such as rail’s head and web by processing laser scanner point-cloud. The point-cloud of rail is converted to voxels data structure. Similarly, virtual points of standard rail dimensions are converted to voxels. Fast-Fourier transform image matching is employed to match the standard rail to rail cross-section at regular interval. Highly correlated cross-sections are shortlisted and conjugate locations of the standard rail are identified on the matching cross-section. Time Monday, Aug 31 11:30AM - 12:00PM Location 19 Speakers Mike Falk Falk PLI Electrometallurgical Steelmaking by Molten Oxide Electrolysis Alexander Fleischanderl, Primetals Technologies Austria GmbH; Thomas Kuehas, Primetals Technologies; Adam Rauwerdink , Boston Metal; Rich Bradshaw , Boston Metal show more Description To achieve the Paris Climate Agreement goal of reducing CO2 emissions 80% by 2050, substantial changes to iron and steel production technologies are required. One visionary innovation is based on carbon-free direct steelmaking with molten oxide electrolysis (MOE). Developed by Boston Metal in cooperation with Primetals Technologies, the goal is to reduce the fed iron oxide, using “green” electrons instead of carbon-based fuels. The only products from the process are liquid metal and the byproducts electrolyte (slag) and oxygen. This paper describes the process of the MOE technology, the current development status and an outlook of the first industrial demonstrations. Time Monday, Aug 31 11:30AM - 12:00PM Location 9 Speakers Alexander Fleischanderl Primetals Technologies Austria GmbH Thomas Kuehas Primetals Technologies Adam Rauwerdink Boston Metal Rich Bradshaw Boston Metal Full Hydraulic Solution – The Advanced Fourth-Generation Pair Cross Mill Longze He, Primetals Technologies Japan Ltd.; Akira Sako, Primetals Technologies Japan Ltd.; Jiro Hasai, Primetals Technologies Japan Ltd.; Takao Owada, Primetals Technologies Japan Ltd. show more Description Pair Cross (PC) technology was developed by Primetals Technologies for hot-rolled strip profile control. Since operation of the world’s first PC mill in 1984, more than 150 stands have been supplied worldwide and contributing to high-quality strips. The PC mill kept evolving since it was born to correspond to the constantly developing needs of steel market. Lately, the fourth-generation PC mill was launched with full hydraulic control system for better maintainability, meanwhile keeping the high performance of profile control consistent. This paper will introduce the structure and new advanced functions, such as automatic chock position zeroing and automatic leveling compensation. Time Monday, Aug 31 11:30AM - 12:00PM Location 20 Speakers Longze He Primetals Technologies Japan Ltd. Akira Sako Primetals Technologies Japan Ltd. Jiro Hasai Primetals Technologies Japan Ltd. Takao Owada Primetals Technologies Japan Ltd. Improved Stability in Control of Sinter Feed Basicity by Using GEOSCAN Real-Time On-Belt Analysis Luke Balzan, Scantech International show more Description The scope of this paper is to introduce by case study the use of on-line analysis to improve the stability of basicity control in the iron sintering process. GEOSCAN has been used for on-line analysis in various industries for many years, and has been recently applied for iron sintering, where elemental analysis allows for the real-time calculation of basicity ratios. Data is fed to the plant for feedback control based on results. The paper discusses improvements observed by two customers who have implemented this technology and is written collaboration with the users and equipment supplier. Time Monday, Aug 31 11:30AM - 12:00PM Location 25C Speakers Luke Balzan Scantech International Industry 4.0 Boosts the Steel Industry Into a New Era of Digitalization and Smart Technology Hong Dai, CISDI Engineering Co. Ltd. Consulting Business Division; Xiangjun Zuo, CISDI Engineering Co. Ltd. Consulting Business Division show more Description This paper expounds Industry 4.0’s significance and influence on steel's digital and intelligent development. It details the trending appeal of digital and intelligent transformation and upgrades for the global steel industry. A large-sized steel works is taken as an example for introducing thoughts and effects of Industry 4.0 on its tailored services, intelligent manufacturing, big data-based management and supply chain integration. Against the backdrop of Industry 4.0 strategy, the practicable top-down and stepwise measures and paths are proposed for building a future-oriented Industry 4.0 steel works, with expertise in intelligent equipment, digital factory and industrial internet. Time Monday, Aug 31 11:30AM - 12:00PM Location 13 Speakers Hong Dai CISDI Engineering Co. Ltd. Consulting Business Division Xiangjun Zuo CISDI Engineering Co. Ltd. Consulting Business Division Side-Pull Detection Techniques for Wire Rope Hoists Steven Lubeck, Laser-View Technologies Inc. show more Description A wire rope hoist on an overhead crane operated under a side-pulled condition presents a safety risk, can produce accelerated wear and can damage a hoist that is not designed for such use. Damage to a hoist can be costly, can reduce productivity with unnecessary downtime and can result in unsafe conditions. Improper use of a hoist due to side-pulling poses a significant hazard to operators as a load is lifted. This presentation compares strengths and weaknesses of available overhead monitoring systems, their general methods of operation and capabilities. Time Monday, Aug 31 11:30AM - 12:00PM Location 10 Speakers Steven Lubeck Laser-View Technologies Inc.
2:00pm A Modified Johnson-Cook Model Incorporating the Effect of Grain Size on Flow Stress Shouvik Ganguly, Missouri University of Science and Technology; Mario Buchely, Missouri University of Science and Technology; K. Chandrashekhara, Missouri University of Science and Technology; Simon Lekakh, Missouri University of Science and Technology; Ronald O'Malley, Missouri University of Science and Technology show more Description The mechanical properties of steel are influenced by grain size, which can change through nucleation and growth at elevated temperatures. However, the classic Johnson-Cook model that is widely used in hot deformation simulations does not consider the effect of grain size. In this study, the Johnson-Cook model was modified to incorporate the effects of austenite grain size on flow stress. A finite element model was employed to characterize the effects of grain size on the flow stress for different steel grades over a range of temperatures (900ºC to 1,200ºC). Simulation results show good agreement with experimental observations. Time Monday, Aug 31 2:00PM - 2:30PM Location 25A Speakers Shouvik Ganguly Missouri University of Science and Technology Mario Buchely Missouri University of Science and Technology K. Chandrashekhara Missouri University of Science and Technology Simon Lekakh Missouri University of Science and Technology Ronald O'Malley Missouri University of Science and Technology An Accelerated Installation and Commissioning Plan to Upgrade an Aging Static VAR Compensator for an Electric Arc Furnace Anil Kanagala, Primetals Technologies USA LLC; Visvesvaran Subramanian, Primetals Technologies USA LLC show more Description Static VAR Compcnsators play a vital role in providing power quality compliance and network stability to electric arc furnaces. Considering a typical life cycle of 20 years, upgrading aging SVC equipment ensures maximum meltshop production. Recent increase in production demand from meltshops has challenged maintenance supervisors with fewer and shorter downtimes available for equipment upgrades and servicing. This paper presents an executed plan where a conventional SVC installation and commissioning schedule was compressed from two months to just 11 days. This paper details the execution plan, risk analysis, challenges encountered and remedial measures taken to ensure on-time start-up. Time Monday, Aug 31 2:00PM - 2:30PM Location 15 Speakers Anil Kanagala Primetals Technologies USA LLC Visvesvaran Subramanian Primetals Technologies USA LLC An Automated Coil Grading System Implemented at ArcelorMittal Columbus Coating Line Michael Peintinger, QuinLogic LLC; Marcelo Silveira Anjos, ArcelorMittal; Peter Hollingsworth, ArcelorMittal; Michael Salmond , QuinLogic LLC show more Description This paper presents a solution, aligned with Industry 4.0, to utilize data in real time to improve the quality evaluation of coated steel products. The proposed system ensures the on-time delivery of a high-quality product to customers. The technology used in this solution is a coil grading software from QuinLogic LLC that uses automated surface inspection system and process data, supported by ArcelorMittal grading criteria, to ensure a real-time decision on coil quality. The system is also used as a feedback tool to improve problem solving and enhance coil quality through processing pipeline. Time Monday, Aug 31 2:00PM - 2:30PM Location 14 Speakers Michael Peintinger QuinLogic LLC Marcelo Silveira Anjos ArcelorMittal Peter Hollingsworth ArcelorMittal Michael Salmond QuinLogic LLC Application of Decision Tree-Based Twin Support Vector Machines to Classify Dephosphorization in BOF Steelmaking Jovan Phull, University of Toronto; Juan Egas, University of Toronto; Sandip Barui, University of South Alabama; Sankha Mukherjee, University of Toronto; Kinnor Chattopadhyay, University of Toronto show more Description Ensuring high quality of steel by removing phosphorus in the basic oxygen furnace (BOF) is essential. Herein, dephosphorization in BOF steelmaking was analyzed based on slag chemistries and tapping temperatures of 16,000 heats from two BOFs, using unsupervised machine learning (tree-based twin support vector machines and K-means clustering). The extent of dephosphorization was quantified using lp (logarithm of the ratio of %P in slag to %P in steel). Instead of predicting the final values of lp, this study focused on the classification to different categories ("High", "Moderate", "Low" and "Very Low") of l_p based on slag chemistries and tapping temperatures. Time Monday, Aug 31 2:00PM - 2:30PM Location 7 Speakers Jovan Phull University of Toronto Juan Egas University of Toronto Sandip Barui University of South Alabama Sankha Mukherjee University of Toronto Kinnor Chattopadhyay University of Toronto Ball Spalling in Rolling Element Bearings: Decrease in Rolling Contact Fatigue Life Due to Inferior Microstructure and Manufacturing Processes Elizabeth Brazitis, NSK Corp.; Mark Wolka, NSK Corp.; Graham Keep, NSK Corp. show more Description Ball failure due to fatigue is an atypical mode of failure in a rolling element bearing. A recent full-scale bench test resulted in ball spalling well below the calculated bearing life. Subsequent metallurgical analysis of the spalled balls found inferior microstructure and manufacturing methods. Microstructural analysis revealed significant carbide segregation in the steel, which resulted from substandard steelmaking practices. In addition, the grain flow of the balls revealed a manufacturing anomaly that produced a stress riser in the material. The inferior rolling elements caused at least an 80% reduction in rolling contact fatigue life. Time Monday, Aug 31 2:00PM - 2:30PM Location 19 Speakers Elizabeth Brazitis NSK Corp. Mark Wolka NSK Corp. Graham Keep NSK Corp. Coke Quality Derived From Petrographic Analysis of Sapozhnikov Semi-Cokes Jackie (Hee Kyoung) Park, Pearson Coal Petrography; David E. Pearson, Pearson Coal Petrography; Richard A. Pearson, Pearson Coal Petrography; Yuekan Jiao, Pearson Coal Petrography show more Description Automated bireflectance image mapping of basal sections of semi-coke residues from Sapozhnikov plastometry are used here to determine anisotropy quotient (AQ) for each pixel. On the same sample, final contraction (X) and plastic layer thickness (Y) are used to determine the slope of Y/X, the Sapozhnikov quotient (SQ). A cross-plot of logarithmic SQ as abscissa with linear AQ defines a matrix of coke strengths and coke types. Semi-coke blends are recognized by the presence of high- or low-rank encapsulites, and/or by AQ distributions in cumulative probability plots, that cut across those of single-origin semi-cokes. Time Monday, Aug 31 2:00PM - 2:30PM Location 25B Speakers Jackie (Hee Kyoung) Park Pearson Coal Petrography David E. Pearson Pearson Coal Petrography Richard A. Pearson Pearson Coal Petrography Yuekan Jiao Pearson Coal Petrography Data-Driven Study to Develop Corrosion-Resistant Zn-Mg-Al-Sn Coating Alloys With Low Melting Temperature Rohit Bardapurkar, Colorado School of Mines; Sridhar Seetharaman , Colorado School of Mines; John Speer, Colorado School of Mines; Christopher K. H. Borg, Citrine Informatics show more Description To achieve corrosion protection, Zn-based coatings are commonly applied on sheet steels. In the case of advanced high-strength steels, the relatively high application temperature of the coatings (460°C for hot-dip galvanizing) may affect the substrate microstructure and resulting mechanical properties. New coatings with significantly lower melting temperature and acceptable corrosion resistance would offer new flexibility for substrate processing. In this study, machine learning algorithms trained on existing corrosion data are used to optimize the synthesis of novel coating alloys. The machine learning models are used to predict corrosion current, corrosion potential and melting temperature of the coatings in high-dimensional Zn-Mg-Al-Sn alloy composition space. Time Monday, Aug 31 2:00PM - 2:30PM Location 24 Speakers Rohit Bardapurkar Colorado School of Mines Sridhar Seetharaman Colorado School of Mines John Speer Colorado School of Mines Christopher K. H. Borg Citrine Informatics Decreased Sinter Process Variation at BlueScope Steel Using Real-Time Feed Composition Nick Di Giorgio, BlueScope Steel; David Pinson, BlueScope Steel; Garry Noble, Thermo Fisher Scientific show more Description BlueScope Steel traditionally controlled sinter chemistry via a feedback SPC scheme utilizing four hourly x-ray fluorescence product chemistries. While stable sinter chemistry could be achieved with consistent bed blending, variations in practice or contamination often resulted in long periods of instability. To improve sinter chemical stability, a Thermo Fisher CB Omni Fusion on-line analyzer was installed to measure the sinter plant feed and to shorten the control loop. Limestone and manganese ore are now automatically adjusted using continuous proportional integral derivative control. This has halved sinter chemistry variability, optimized transitions across blended beds and yielded benefits downstream at the blast furnace. Time Monday, Aug 31 2:00PM - 2:30PM Location 26A Speakers Nick Di Giorgio BlueScope Steel David Pinson BlueScope Steel Garry Noble Thermo Fisher Scientific Effects of Alloy Elements in Advanced High-Strength Steels on the Efficiency of Nitrogen Removal in a Tank Degasser Dai Tang, Nucor Steel-Decatur LLC; P. Chris Pistorius, Carnegie Mellon University show more Description Advanced high-strength steels (AHSS) generally have high alloy contents such as manganese, aluminum and silicon, which change the nitrogen removal rate during tank degassing. Alloying elements affect nitrogen removal in two ways. Thermodynamically, they change nitrogen solubility: manganese increases nitrogen solubility, while aluminum and silicon decrease nitrogen solubility. Kinetically, manganese increases the interfacial reaction rate, whereas aluminum and silicon decrease the rate. The net effect is that the activity coefficient of nitrogen in typical AHSS is similar to that in low-carbon aluminum-killed steel, but with a much lower interfacial reaction rate constant: gas-based nitrogen removal in a tank degasser is not feasible. Time Monday, Aug 31 2:00PM - 2:30PM Location 1 Speakers Dai Tang Nucor Steel-Decatur LLC P. Chris Pistorius Carnegie Mellon University Emerging Temporary Power Supports Sustainability Steve Birtch, Aggreko show more Description Steel producers have made significant progress in sustainability and reducing impacts of steelmaking on the environment, particularly in energy and utility decisions. This presentation covers sustainability drivers, the effects on energy and utilities in manufacturing, and how emerging temporary power/utility technologies support environmental and cost-saving goals. Deployment of temporary utilities including microgrids and right-sized utilities address demand, reduce fuel consumption, increase reliability, and reduce operational costs. Improvements from 5% to 15% can be achieved. Effective deployment of temporary utilities frees up capital for high-return investments. Temporary utility solutions allow producers to adopt best practices and make informed choices. Time Monday, Aug 31 2:00PM - 2:30PM Location 12 Speakers Steve Birtch Aggreko Evaluation of Mechanical Behavior Shifting of API 5L X70 Skelp Through Accelerated Cooling and Spiral Forming Processes Qiulin Yu, Nucor Steel Tuscaloosa Inc.; Jacob Lewis, Nucor Steel Tuscaloosa Inc.; Matt Montgomery, Nucor Steel Tuscaloosa Inc.; PN Mahida, Welspun Pipes Inc.; Ashish Singh, Welspun Pipes Inc. show more Description Direct quenching and accelerated cooling (DQ-AcC) at Nucor Steel Tuscaloosa Inc. has been used to produce API 5L X70 skelp successfully for both straight- and spiral-seam welded pipe mills at Welspun Pipes. Compared with the conventional laminar flow cooling that produces ferrite-pearlite microstructure, DQ-AcC results in uniform acicular ferrite and upper bainite across thickness, which significantly enhances strength and toughness. To understand the losses of yield strength and toughness due to strain softening, mechanical behavior shifting of API 5L X70 skelp through accelerated cooling and spiral forming processes is examined. Time Monday, Aug 31 2:00PM - 2:30PM Location 23 Speakers Qiulin Yu Nucor Steel Tuscaloosa Inc. Jacob Lewis Nucor Steel Tuscaloosa Inc. Matt Montgomery Nucor Steel Tuscaloosa Inc. PN Mahida Welspun Pipes Inc. Ashish Singh Welspun Pipes Inc. HBI: The Benefits and Sourcing of Steel’s Most Versatile Metallic Vincent Chevrier, Midrex Technologies Inc. show more Description Hot briquetted iron (HBI) is used in electric arc furnaces to produce high-quality steel products that could not be made with high residual element in scrap. Blast furnaces also benefit from HBI to reduce CO2 emissions. As demand continues to grow, HBI production must increase. Since most of the HBI capacity is not available for merchant sale, investing in direct reduction plants is now feasible. To determine the best locations for these plants, this paper will review where iron ore and natural gas are produced and the location of the steelmaking facilities that could use the product. Time Monday, Aug 31 2:00PM - 2:30PM Location 9 Speakers Vincent Chevrier Midrex Technologies Inc. In-Plant Observations and Thermomechanical Modeling of Different Vessel Types Applying an Insulation Layer Lionel Rebouillat, Pyrotek; Shengli Jin, Montanuniversitaet Leoben show more Description Multi-layered refractory linings of vessels used in ironmaking, steelmaking and the mineral processing industries are submitted to various wear mechanisms caused by a combination of thermal, mechanical and chemical stresses, and operational factors. The development of new models for thermomechanical analyses helps to better understand the interactions in-between the different refractory layers and the steel shell of the vessels. The designs of refractory linings in steel ladle, torpedo car and rotary kiln are analyzed with in-plant observations and thermomechanical modeling. The benefits of an insulation layer are detailed in terms of refractory lining performances and process improvement. Time Monday, Aug 31 2:00PM - 2:30PM Location 16 Speakers Lionel Rebouillat Pyrotek Shengli Jin Montanuniversitaet Leoben JFE Fukuyama's Modern Greenfield Sinter Plant With Waste Gas Recirculation, Gas Cleaning and Leaching Plant Alexander Fleischanderl, Primetals Technologies Austria GmbH; Michaela Böberl, Primetals Technologies Austria GmbH; Edmund Fehringer, Primetals Technologies Austria GmbH; Andreas Steinwandter, Primetals Technologies Austria GmbH show more Description The greenfield 387 m² sinter plant for JFE's Fukuyama site comprises a modern sinter plant including a waste gas recirculation system, circular cooler, material handling, MEROS® gas cleaning system and a byproduct leaching plant. The design ensures minimum environmental impact. Part of the waste gas is recirculated to minimize its flow and to reduce coke consumption. The excess waste gas is treated by a MEROS gas cleaning plant to reduce SOx by 97% and dioxins to <0.1 ng/Nm³. The leaching system, the first of its kind, treats the solid byproduct to minimize operation and landfill cost. Valuable components are recycled while the cleaned wastewater is discharged to the sea. Time Monday, Aug 31 2:00PM - 2:30PM Location 11 Speakers Alexander Fleischanderl Primetals Technologies Austria GmbH Michaela Böberl Primetals Technologies Austria GmbH Edmund Fehringer Primetals Technologies Austria GmbH Andreas Steinwandter Primetals Technologies Austria GmbH Latest Advances and Trends in the Operation and Maintenance of Automotive Paint Shops Luis Edgardo Llanes, Asesoria Industrial Especializada show more Description Paint shop facilities at automotive plants have had a few main modifications from the process viewpoint, although they have been impacted by new regulations, new standards and better materials applications. Applied technologies and new modified processes are arising for better surface finishing. A revision of the “full dip” E-Coat painting process, as well as painting process of units, cure ovens, painting automation and environment emissions and tendencies, concludes the discussion with a brief benchmark and analysis made for the modification of state-of-the-art facilities, with a high impact in savings, less environmental impact and better flexibility. Time Monday, Aug 31 2:00PM - 2:30PM Location 22 Speakers Luis Edgardo Llanes Asesoria Industrial Especializada Measuring Flatness of Rolled Strips Under Tension in Hot Rolling Mills Frank Gorgels, SMS group GmbH; Olaf Jepsen, SMS group GmbH; Patrick Siemann, SMS group GmbH show more Description The gap in the market for measuring systems for hot-rolled strip under tension has now been closed with a new product developed by SMS group and brings the proven X-Shape technology, which is based on the market-leading VDeh-Betriebsforschungsinstitut (BFI) flatness measurement concept, to the hot rolling process. In cooperation with BFI and ArcelorMittal, the prototype has been successfully installed and operated at ArcelorMittal’s hot rolling mill in Eisenhüttenstadt. The measuring system offers a detailed insight into the effects of flatness in the finishing mill when rolling with tension, as well as the effects of the laminar cooling. Time Monday, Aug 31 2:00PM - 2:30PM Location 20 Speakers Frank Gorgels SMS group GmbH Olaf Jepsen SMS group GmbH Patrick Siemann SMS group GmbH New Corrosion Test Method for Improved Performance Ladle Purge Plug Quentin Robinson, Vesuvius Research; Philipp Hunger, Vesuvius Research show more Description A method was developed for corrosion testing of steel ladle purge plugs. This new corrosion test uses a purge plug inserted into a “pony ladle.” The process of heating the molten metal in a furnace, transferring molten metal to the ladle, purging, draining of the ladle and oxygen lancing is repeated multiple times to mimic how a purge plug is used in steel mills. A significantly improved corrosion resistance was measured for the OptiClean purge plug compared to other purge plugs. These laboratory findings were confirmed in industrial trials. Time Monday, Aug 31 2:00PM - 2:30PM Location 4 Speakers Quentin Robinson Vesuvius Research Philipp Hunger Vesuvius Research Non-Contact Sensors in Caster Operations Steven Lubeck, Laser-View Technologies Inc. show more Description Engineers involved with caster lines continue to increase their use of non-contact sensors for real-time monitoring of conditions of the cast strand. Live monitoring permits processes both upstream and downstream to be adjusted to optimize production, assure quality, optimize yield and reduce scrap. Laser-based sensors are capable of providing dimensional size and profile feedback. Several types of laser sensors can measure displacement, position and proximity. The harsh environmental conditions play a role in determining the right sensor for the job. This presentation examines the advantages of non-contact laser-based sensors, along with suggestions for successful implementation at the caster. Time Monday, Aug 31 2:00PM - 2:30PM Location 5 Speakers Steven Lubeck Laser-View Technologies Inc. Optimization of Parameters of Blast Furnace Smelting Under Conditions of Plant Operation With Limited Supply of Coke, Natural Gas or Iron-Bearing Materials Michael Alter, ALTER Blast Furnace Consulting show more Description Based on extended theoretical and actual plant operational experiences, the author discusses the strategy of selecting main blast furnace parameters (hot blast pressure, temperature and volume; oxygen, natural gas and steam injection; and top pressure level) with a charging mode and scheduled shutdowns in real conditions of the flow of raw materials and fuel. Recommendations can be provided based on real-life situations. Time Monday, Aug 31 2:00PM - 2:30PM Location 25C Speakers Michael Alter ALTER Blast Furnace Consulting Shape Up! The New Merchant Bar Mill at Nucor Steel Kankakee Inc. Mario Fabro, SMS group Inc. show more Description The new rolling mill will allow Nucor Steel Kankakee Inc. to expand its product range into larger merchant bar sizes for the growing regional market. Taking advantage of the latest technology, this new mill aims at being the industry market leader. State-of-the-art solutions targeting extreme flexibility and reduced changeover times will allow the just-in-time rolling philosophy needed to withstand the market cycles. This presentation will cover the project development and start-up of the facility. Time Monday, Aug 31 2:00PM - 2:30PM Location 21 Speakers Mario Fabro SMS group Inc. Smart Ladle: AI-Based Tool for Optimizing Casting Temperature Armin Silaen, Purdue University Northwest; Chenn Zhou, Purdue University Northwest; Nicholas Walla, Purdue University Northwest; Eugene Pretorius, Nucor Steel-Berkeley; Yury Krotov, Steel Dynamics Inc. - Flat Roll Group Butler Division; Bin Chen, Purdue University Northwest show more Description From the basic oxygen furnace/electric arc furnace to the caster, the ability to quantify and respond to the variables that affect steel casting temperature is crucial for achieving consistent casting quality and maximizing productivity. Deviations from the optimum steel casting temperature can require adjustment to casting speed, which impacts productivity and potentially also harm product quality. This work will use a deep-learning network to develop quantifiable relationships between the casting temperature and various factors during the ladle refining process to enable predictions of casting temperature and precise adjustments to steel temperature prior to the ladle reaching the casting stage of the production process. Time Monday, Aug 31 2:00PM - 2:30PM Location 13 Speakers Armin Silaen Purdue University Northwest Chenn Zhou Purdue University Northwest Nicholas Walla Purdue University Northwest Eugene Pretorius Nucor Steel-Berkeley Yury Krotov Steel Dynamics Inc. - Flat Roll Group Butler Division Bin Chen Purdue University Northwest Smart Products, Assistance Tools and Service Solutions for Digital Production in EAF-Based Meltshops Richard Stadlmayr, Primetals Technologies Austria GmbH; Hannes Beile, Primetals Technologies Germany GmbH; Jens Apfel, Primetals Technologies Germany GmbH; Thomas Reindl, Primetals Technologies Austria GmbH; Brigitte Laimer, Primetals Technologies Austria GmbH show more Description Digital electric arc furnace (EAF) production means the seamless interaction of the installed equipment and any new feature and digital assistance system, which are added during a continuous plant modernization and step-by-step upgrade activities. Digital EAF steelmaking starts with automated scrap handling and preparation, followed by a fully automated melting process. Autonomous transport systems for ladles and materials guarantee a safe handling and the precise execution of the defined process logistics. Powerful tools for the process analysis and business intelligence systems allow a deep insight into the physical production and provide required information for important decisions and life cycle measures at a glance. Time Monday, Aug 31 2:00PM - 2:30PM Location 6 Speakers Richard Stadlmayr Primetals Technologies Austria GmbH Hannes Beile Primetals Technologies Germany GmbH Jens Apfel Primetals Technologies Germany GmbH Thomas Reindl Primetals Technologies Austria GmbH Brigitte Laimer Primetals Technologies Austria GmbH Study on Inclusion Evolution Through Si/Mn Deoxidation in Medium-Carbon Steels Katharina Kirchheimer, Montanuniversitaet Leoben; Ronald Schnitzer, Montanuniversitaet Leoben; Gerald Klösch, voestalpine Stahl Donawitz GmbH; Josef Fasching, voestalpine Stahl Donawitz GmbH; Christian Bernhard, Montanuniversitaet Leoben; Susanne K. Michelic, Montanuniversitaet Leoben show more Description Highly stressed medium-carbon steels with demands for increased lifetime properties are sensitive regarding the final cleanness level. Size, composition and morphology of non-metallic inclusions are essentially influenced by the applied deoxidation practice. An improved deoxidation procedure for these steels substituting classical Al by Mn and Si is studied using laboratory tests in a so-called Tammann furnace and accompanying plant trials. The formed inclusion landscape and their modification over time is analyzed using manual and automated scanning electron microscopy/energy-dispersive x-ray spectroscopy measurements. Additionally, material tests (thermal-mechanical simulator, deformation dilatometer, fatigue test) are performed, enabling a comparison of the relation between inclusion and material properties for various scenarios. Time Monday, Aug 31 2:00PM - 2:30PM Location 3 Speakers Katharina Kirchheimer Montanuniversitaet Leoben Ronald Schnitzer Montanuniversitaet Leoben Gerald Klösch voestalpine Stahl Donawitz GmbH Josef Fasching voestalpine Stahl Donawitz GmbH Christian Bernhard Montanuniversitaet Leoben Susanne K. Michelic Montanuniversitaet Leoben The Modular Roll Shop System — Extendable and Flexible Guido Matarazzo, Herkules show more Description The Modular Roll Shop System, extendable and flexible, is the new Industry 4.0 technological product developed by Herkules Group to keep tracking of all the roll shop materials such as rolls with their profiles and performance in the mill, chocks, bearings and wheels. The Modular Roll Shop System is the instrument necessary to analyze all the data collected in the roll shop to be able to understand the right parameters in terms of grinding procedure and mill cycles to be able to reduce production costs to acquire competitiveness on the market. Time Monday, Aug 31 2:00PM - 2:30PM Location 10 Speakers Guido Matarazzo Herkules
2:30pm An Integrated Approach to Steel Cleanliness Evaluation of Aluminum-Killed Steel Produced Using CSP Technology Cody Dyar, Steel Dynamics Inc. - Flat Roll Group Columbus Division; Dmitry Tsvetkov, Steel Dynamics; Pat Lueckenhoff, Steel Dynamics Inc. - Flat Roll Group Butler Division; Anthony Bader, Steel Dynamics Inc. - Flat Roll Group Columbus Division; Pete Loomis, Steel Dynamics Inc. - Flat Roll Group Columbus Division show more Description In recent years, the use of scanning electron microscopy/energy-dispersive x-ray spectroscopy statistical analysis to compare evolution of inclusions for various grade families has been well documented. This paper aims to present the effects of ladle metallurgy furnace and caster practices on inclusion distribution and population throughout full casting sequences. Samples for analysis were collected from two industrial mini-mills. Ladle, tundish and strip samples were collected from heats throughout multiple casting sequences for evaluation of data generated through automated feature analysis (AFA). Joint ternary diagrams generated from AFA were evaluated to synthesize the morphology of inclusions throughout the practices. Time Monday, Aug 31 2:30PM - 3:00PM Location 3 Speakers Cody Dyar Steel Dynamics Inc. - Flat Roll Group Columbus Division Dmitry Tsvetkov Steel Dynamics Pat Lueckenhoff Steel Dynamics Inc. - Flat Roll Group Butler Division Anthony Bader Steel Dynamics Inc. - Flat Roll Group Columbus Division Pete Loomis Steel Dynamics Inc. - Flat Roll Group Columbus Division Artificial Neural Networks to Predict Hydrogen Content in Steels at Secondary Refining in Ternium Brazil Raquel Souza Correa, Universidade Federal de Minas Gerais; Daniel Carvalho, Ternium Brazil show more Description Hydrogen content control in steel is vital for the steel melt plant operations, as it may be responsible for accidents and undesirable steel properties. Hydrogen content prediction through mathematical modeling is fundamental for steel melt plants. A relationship between hydrogen content and materials addition made through different process phases is complex. Artificial neural networks (ANNs) proved to be an efficient tool to support these predictions compared to regression models. ANNs indicated that the quantity of each material is an important factor for hydrogen pickup as well as the sequence of each addition and weather conditions. Time Monday, Aug 31 2:30PM - 3:00PM Location 7 Speakers Raquel Souza Correa Universidade Federal de Minas Gerais Daniel Carvalho Ternium Brazil Blast Furnace Gas to Boiler Pressure Control Mark Ferra, REXA show more Description Blast furnace gas is often used as a fuel for a boiler at the power house. REXA’s patented hydraulic actuation technology is able to react (3-5 Hz) to small, constantly varying changes in control signal with a repeatability of <0.1% travel position. A steel producer in India replaced the existing pneumatic actuator due to poor pressure control. With the REXA actuator positioning a 69-inch butterfly valve, the fluctuation of pressure from the setpoint was reduced from 45 MMWC to 12 MMWC, and always within control limits. Steam generation increased 13% due to improved combustion. Time Monday, Aug 31 2:30PM - 3:00PM Location 12 Speakers Mark Ferra REXA BOF Gas Cleaning System Upgrades for Increased Efficiency and Off–Gas Quality Matthias Meyn, Danieli Corus; Peter Klut, Danieli Corus; Ruud Herold, Danieli Corus; Edo Engel, Danieli Corus show more Description In BOF steelmaking, conditions and composition of the gas produced is varies from the start to the end of a blow. During the blow, gas with high temperature (≥ 950 °C), loaded with dust (70 – 200 g Nm³) and typically composed of approx. 90% CO and 10% CO2 is produced at the BOF mouth. This gas has to be cooled and cleaned (down to a dust level of < 20 mg/Nm³) before further processing downstream. Process equipment is installed above and alongside the converter mouth to enable energy recovery as well as collection and recycling of the dust produced. This article presents a newly developed technology based on annular gap scrubbers for converter off–gas cooling and cleaning with minimum maintenance requirement and increased efficiency when compared to traditional systems based on flap venturi scrubbers. In addition, an improved three-stage mist eliminator design is discussed. Both these developments are the result of applying technology developed for and proven in blast furnace ironmaking within the context of basic oxygen steelmaking. Time Monday, Aug 31 2:30PM - 3:00PM Location 11 Speakers Matthias Meyn Danieli Corus Peter Klut Danieli Corus Ruud Herold Danieli Corus Edo Engel Danieli Corus Challenges and Opportunities for Smart Tools in Digitalized Rolling Mills Alexander Thekale, Primetals Technologies Germany GmbH; Karola Gurrath, Primetals Technologies Germany GmbH show more Description The ever-increasing necessity of digitalizing work processes and the availability of ever-larger amounts of data are changing the working requirements in the steel industry. Innovative software tools are used in order to meet this development and to facilitate the work of today and tomorrow. The visualization of data plays a key role here. This presentation will show different requirements, challenges and application possibilities for these tools. Furthermore, examples will be shown of how existing tools for rolling mill automation support the development, commissioning and maintenance of automation software. Moreover, the tools enable state-of-the-art data analysis techniques, visualization and optimization of processes. Time Monday, Aug 31 2:30PM - 3:00PM Location 13 Speakers Alexander Thekale Primetals Technologies Germany GmbH Karola Gurrath Primetals Technologies Germany GmbH Coal Rheology — The Effect of Rank and Sample Preparation on Test Results Ted Todoschuk, ArcelorMittal Dofasco G.P.; Louis Giroux, Natural Resources Canada show more Description Coal rheology is a critical parameter for determining the coking and caking ability of metallurgical coals for cokemaking. The effect of particle size on the resultant fluidity and dilatation results will be governed by the rank of the coal during sample preparation due to hardness (HGI) differences. For this study, various rank U.S. Appalachian metallurgical coals were prepared using the standard ASTM methods, and the rheology results were determined. In addition, rheology was also measured on sized subsets to determine the effect of size and rank on the overall rheology results. Size limits for the ASTM standards are suggested. Time Monday, Aug 31 2:30PM - 3:00PM Location 25B Speakers Ted Todoschuk ArcelorMittal Dofasco G.P. Louis Giroux Natural Resources Canada Comprehensive Tool to Bring Total Cost of Ownership in Design During Project Conceptualization Stage at Engineering and Projects at Tata Steel Niraj Ranjan Kumar, Tata Steel Ltd.; Rajat Kumar, Tata Steel Ltd.; Ch Ramesh Babu, Tata Steel Ltd.; A D Kothari, Tata Steel Ltd.; D N Jha, Tata Steel Ltd.; R R Jha, Tata Steel Ltd. show more Description A comprehensive tool was utilized during engineering and designing of a system by Tata Steel’s Engineering and Projects Department to include the total cost of ownership during design stage of project conceptualization. This includes total life cycle costing of the system by incorporating energy-efficient, environmentally friendly technologies and optimizing product quality to reduce the overall cost considering the economic life of the system. Various new and energy-efficient technologies were explored through innovative methods to bring down the life cycle cost by providing engineering solutions to the system. Incorporation of total cost of ownership during the design stage has resulted in designing of the system with overall cost effectiveness of up to 35% during life cycle of the system. Time Monday, Aug 31 2:30PM - 3:00PM Location 21 Speakers Niraj Ranjan Kumar Tata Steel Ltd. Rajat Kumar Tata Steel Ltd. Ch Ramesh Babu Tata Steel Ltd. A D Kothari Tata Steel Ltd. D N Jha Tata Steel Ltd. R R Jha Tata Steel Ltd. Decoupled Flatness and Contour Control in the Last Stands of a Hot Strip Mill During Rolling Klaus Loehe, Primetals Technologies Germany GmbH; Niklas Petrasch, thyssenkrupp Steel Europe AG show more Description Flatness and contour errors (profile/wedge) during the rolling of hot slabs are closely connected but are conventionally treated as different problems and independent controls are designed. Flatness is controlled in the last and profile in the first stands to reduce flatness problems, leading to very slow control speed. This problem is solved with a newly designed decoupling controller considering several stands. This allows contour and flatness to be set independently of each other in the last stands, enabling a very high control speed due to the proximity to the measuring device. Measurements will be presented showing control results. Time Monday, Aug 31 2:30PM - 3:00PM Location 20 Speakers Klaus Loehe Primetals Technologies Germany GmbH Niklas Petrasch thyssenkrupp Steel Europe AG Development of Cycloid-Type Charging Device for Improving Sintering Ore Manufacturing Efficiency Kyung Hun Kim, POSCO show more Description In this paper, the development of cycloid charging device to improve the manufacturing efficiency of sintering ore is introduced. The cycloid curve is the highest efficiency curve for converting the potential energy into kinetic energy. This curve was applied to the charging device to increase the spray distance of the mix materials. Cycloid-type charging devices help to improve the vertical segregation by increasing the horizontal speed of mix materials. The increase of sintering productivity was confirmed through the application of a cycloid-type charging device, and the bonding ratio was also decreased by improving the yield of sinter. Time Monday, Aug 31 2:30PM - 3:00PM Location 26A Speakers Kyung Hun Kim POSCO Development of Electrical Discharge Coating for Extended Textured Roll Campaigns Chris Childs, Sarclad; Gareth Evans, Sarclad; Tom Lowbridge, Sarclad show more Description This paper describes the development of electrical discharge coating (EDC) of textured work rolls and summarizes the results obtained so far. Extending the life of textured rolls is important to steel mills for operational, financial and environmental reasons. Results of laboratory evaluations and industrial trials confirm that EDC produces a harder recast layer than alternative texturing methods and is a viable method of extending textured roll campaigns. Time Monday, Aug 31 2:30PM - 3:00PM Location 10 Speakers Chris Childs Sarclad Gareth Evans Sarclad Tom Lowbridge Sarclad Digital Substations and Process Bus for Steel Mills – Overview and Quantitative Assessment Poojit Lingam, Primetals Technologies USA LLC; Tim Burttram, Big River Steel; Hiranya Pathak, Primetals Technologies USA LLC; Ramesh Khajjayam, Primetals Technologies USA LLC show more Description While digital substations have seen an increase in popularity in the past few years, their adoption has been restricted only to the utilities. This paper explores the finer details of digital substations and provides a comprehensive evaluation of process bus technology for steel mills. A cost benefit analysis is presented along with lessons learned and future applications. A centralized protection design is introduced and modern protection designs are explored. Safety, cost, scalability and integration into Industry 4.0 systems are evaluated for small-, medium- and large-scale substations. Time Monday, Aug 31 2:30PM - 3:00PM Location 15 Speakers Poojit Lingam Primetals Technologies USA LLC Tim Burttram Big River Steel Hiranya Pathak Primetals Technologies USA LLC Ramesh Khajjayam Primetals Technologies USA LLC Grain Boundary Cementite Walls in Steel: A More Complete Picture of Yielding Thomas L. Altshuler, Advanced Materials Laboratory show more Description The unique upper and lower yield points in hypoeutectoid steels differ from other body-centered cubic metals. Current explanations about this phenomenon are incomplete. Atomic force microscopy revealed that the boundaries between adjoining grains in the AISI 1018 consist of cementite (Fe3C) walls enclosing each grain. These walls inhibit the movement of dislocations between grains until the walls fracture, which is believed to be the primary cause of a sharp upper yield point followed by a lower yield point. Time Monday, Aug 31 2:30PM - 3:00PM Location 25A Speakers Thomas L. Altshuler Advanced Materials Laboratory High-Performance Plate Production at the New Steckel Mill at Shandong Iron & Steel in Rizhao, China Wolfgang Spies, SMS group GmbH; Alexander Reske, SMS group GmbH; Peter Rainer, SMS group GmbH; Huibao Liu, SMS Siemag Technology (Beijing) Co. Ltd.; Stephan Mosbleck, SMS group GmbH; Weihua Sun, Shandong Iron & Steel Group Rizhao Co. Ltd. show more Description An important part of the new flat steel production complex at Shandong Iron & Steel in Rizhao, China, is a 3.5-m-wide Steckel plate mill. Its dimension exceeds all previous installations in capacity, flexibility and performance. This plant also features a digitalization level for product quality control as part of the production facility, which also includes a new thick-slab caster for this mill. The plant concept, capability and production results will be presented. Time Monday, Aug 31 2:30PM - 3:00PM Location 23 Speakers Wolfgang Spies SMS group GmbH Alexander Reske SMS group GmbH Peter Rainer SMS group GmbH Huibao Liu SMS Siemag Technology (Beijing) Co. Ltd. Stephan Mosbleck SMS group GmbH Weihua Sun Shandong Iron & Steel Group Rizhao Co. Ltd. Impact of Lip Adjustment on Wiping Efficiency Michel Dubois, John Cockerill Metals show more Description The impact of the lip shape and adjustment is addressed by 2D computational fluid dynamics modeling. The effect on the coating weight and the nitrogen dilution by ambiance is also studied. It is shown that the shape of the tip has a significant effect of the behavior of the air jet in atmosphere. Similarly, the quality of the channel (convergent, divergent or parallel) impacts both the coating weight and the dilution of nitrogen. This means that the quality of the maintenance in industrial line is as important as the initial design in order to ensure efficient wiping. Time Monday, Aug 31 2:30PM - 3:00PM Location 24 Speakers Michel Dubois John Cockerill Metals Investigation of Carbon Deposition During Natural Gas and Oxygen Injection for the Direct Reduction Ironmaking Process Tyamo Okosun, Purdue University Northwest; Yu Wang, Purdue University Northwest; Qurram Syed, Purdue University Northwest; Elaine Chen, ArcelorMittal Global R&D; Rui Liu, ArcelorMittal Global R&D – East Chicago; Cesar Velazquez, ArcelorMittal Global R&D; Joel Carmona, ArcelorMittal Global R&D; Chenn Zhou, Purdue University Northwest show more Description In the direct reduction ironmaking (DRI) process, reducing gases are generated in a reformer and lose heat to the environment as they are transported to a shaft furnace. To maintain temperature, oxygen and natural gas are injected. In an ideal operation, the natural gas combusts with the oxygen, yielding increased thermal energy. However, in existing operating scenarios, carbon formation around the natural gas ports has become a serious issue. In order to better understand this problem, a three-dimensional computational fluid dynamics model was developed to investigate flow phenomena, combustion characteristics and carbon deposition in this region of the DRI process. Time Monday, Aug 31 2:30PM - 3:00PM Location 9 Speakers Tyamo Okosun Purdue University Northwest Yu Wang Purdue University Northwest Qurram Syed Purdue University Northwest Elaine Chen ArcelorMittal Global R&D Rui Liu ArcelorMittal Global R&D – East Chicago Cesar Velazquez ArcelorMittal Global R&D Joel Carmona ArcelorMittal Global R&D Chenn Zhou Purdue University Northwest New Cold Mill Complex in Turkey — Technologies and Achieved Performances Ruediger Holz, Danieli; Cristian Bini, Danieli show more Description The new cold mill complex in operation at Yıldız Demir Çelik features the latest technologies to produce 1.5 million tons per year of high-quality cold-rolled, tempered and coated coils, satisfying most demanding end users. Innovative rolling mill technologies like OSRT, ultralow hysteresis HAGC and latest processing technologies like the new-generation wiping system have been applied with performance levels that are even exceeding the expectations in terms of strip flatness and thickness control (both in steady-state and transient phases) and zinc layer control at high-speed thin coating. Time Monday, Aug 31 2:30PM - 3:00PM Location 22 Speakers Ruediger Holz Danieli Cristian Bini Danieli Novel Methodology of Modeling Iron Ore Induration Furnaces Claire Velikonja, Hatch Ltd.; Jayant Borana, Hatch Ltd.; Oghenebrorhie Emuophedaro, Hatch Ltd.; Umesh Shah, Hatch Ltd.; Manuel Huerta, Hatch Ltd.; Janice Bolen, Hatch Ltd.; Jennifer Woloshyn, Hatch Ltd.; Yakov Gordon, Hatch Ltd.; Tom Plikas, Hatch Ltd. show more Description Induration furnaces are used to produce iron pellets for blast furnaces and their performance is sensitive to operational and design changes. The challenge of modeling these machines is that as geometric complexity and predictability increases, the model is less representative of a range of machines. In this work, a three-dimensional model of the pellet bed has been combined with a one-dimensional model of the gas flow network for easy deployment to a wide range of process gas flow configurations. The model was validated against reference plant operating data and then used to improve the operational efficiency of an induration furnace. Time Monday, Aug 31 2:30PM - 3:00PM Location 14 Speakers Claire Velikonja Hatch Ltd. Jayant Borana Hatch Ltd. Oghenebrorhie Emuophedaro Hatch Ltd. Umesh Shah Hatch Ltd. Manuel Huerta Hatch Ltd. Janice Bolen Hatch Ltd. Jennifer Woloshyn Hatch Ltd. Yakov Gordon Hatch Ltd. Tom Plikas Hatch Ltd. NSK - Improving Bearing Life in Continuous Casters Tim Schofield, NSK Corp. show more Description Since the beginning of continuous slab casting, there has been a focus on improving bearing life to reduce the maintenance cost of caster segments. Heavy loads, slow speeds and high temperatures lead to roll deflection and heavy wear that are detrimental to bearing life. NSK has introduced the NUB series cylindrical roller bearing as an optimized countermeasure to this challenging environment. This paper will introduce the ways in which the NUB series counters the extreme conditions of the continuous caster to improve segment maintenance intervals and how these countermeasures performed under actual operating conditions. Time Monday, Aug 31 2:30PM - 3:00PM Location 19 Speakers Tim Schofield NSK Corp. Optimization of Blast Furnace Operation by Using One-Third-Scale Experimental Burden Distribution Simulator and Mathematical Modeling Kosho Matsuda, Nippon Steel Corp.; Hiroshi Mio, Nippon Steel Corp.; Hiroshi Sakai, Nippon Steel Corp.; Kaoru Nakano, Nippon Steel Corp.; Seiji Nomura, Nippon Steel Corp. show more Description Burden distribution is one of the most important controlling factors for the blast furnace operation. However, it is quite difficult to grasp the phenomena of the burden distribution in a working blast furnace. Therefore, a one-third-scale experimental burden distribution simulator was built to investigate the effect of the charging conditions. The effect of nut coke mixed condition was examined in the burden simulator and the obtained data was applied to the mathematical model for blast furnace to evaluate the operation. It was found that the nut coke distribution has strong impact on the blast furnace operation. Time Monday, Aug 31 2:30PM - 3:00PM Location 25C Speakers Kosho Matsuda Nippon Steel Corp. Hiroshi Mio Nippon Steel Corp. Hiroshi Sakai Nippon Steel Corp. Kaoru Nakano Nippon Steel Corp. Seiji Nomura Nippon Steel Corp. Quantitative Flow Measurements in an Inert Gas Shrouded Tundish Kinnor Chattopadhyay, University of Toronto; Donghui Li, University of Toronto show more Description Inert gas shrouded tundishes often tend to develop distinct flow patterns, which lead to the formation of "exposed eye" in the tundish. In the present study, quantitative flow measurements have been performed in reduced-scale water model tundishes using high-speed videography and particle image velocimetry. Different gas injection techniques have been considered and bubble size distribution, bubble trajectories, steel surface velocity at the open eye, and overall flow fields are reported. A computational fluid dynamics model of an inert gas shrouded tundish was developed and validated against water model experiments. Time Monday, Aug 31 2:30PM - 3:00PM Location 1 Speakers Kinnor Chattopadhyay University of Toronto Donghui Li University of Toronto Recarburization With Lignite Special Coke From Germany Chris Wood, Minmet Carbons Inc.; Andreas Kuphal, Rheinbraun Brennstoff GmbH show more Description Lignite special coke (LSC) is produced in Germany and used extensively in Europe for recarburization into the ladle at tap or into the ladle metallurgy furnace (LMF) with stirring. LSC has a high specific surface and melts rapidly. Any nitrogen attaches to CO bubbles and sulfur is chemically bound to the ash and ends up in the slag. LSC is ideally suited to mills producing long products like wire rod where nitrogen control is critical. Fixed carbon is 90% but pricing is 40-50% lower. For North American mills wanting to diversify away from China-produced GPC, LSC is a good money-saving alternative. Time Monday, Aug 31 2:30PM - 3:00PM Location 4 Speakers Chris Wood Minmet Carbons Inc. Andreas Kuphal Rheinbraun Brennstoff GmbH Refractories Containing Silicon Carbide (SiC): A Review Paulo Santos Assis, Universidade Federal de Ouro Preto; Edna Mônica da Silva, Universidade Federal de Ouro Preto; Alisson Lara de Carvalho, Universidade Federal de Ouro Preto show more Description Industrial development has been accompanied by the development of new materials including refractories that have allowed processes requiring high temperatures to be economically and technically viable, reducing premature wear on equipment and energy consumption. Silicon carbide (SiC) has properties such as high thermal stability, thermal shock resistance and high temperature resistance, which favor its application to the refractory industry. This works aims to present the main applications of silicon carbide in the refractory industry, as well as the physical and chemical phenomena related to the performance of refractory containing SiC. Time Monday, Aug 31 2:30PM - 3:00PM Location 16 Speakers Paulo Santos Assis Universidade Federal de Ouro Preto Edna Mônica da Silva Universidade Federal de Ouro Preto Alisson Lara de Carvalho Universidade Federal de Ouro Preto Simulation of the Impact of Various EAF Process Parameters on Electrode Oscillation and Stress Nathanael May, GrafTech International; Josh Clark, GrafTech International show more Description Graphite electrodes are used by electric arc furnace steel producers to melt and refine charge material by passing large currents, typically between 50 and 140 kA, through them. The dynamic and intensive steelmaking process means that electrodes must survive mechanical, thermal and chemical stressors. GrafTech has developed multi-physics models to provide insight into factors that affect electrodes. This presentation will show the simulated effect of current, current interruption, electrode column length and electrode pitch circle diameter on forces that electrodes experience during operation. These factors will influence the probability that an electrode will be mechanically overloaded high in the column. Time Monday, Aug 31 2:30PM - 3:00PM Location 6 Speakers Nathanael May GrafTech International Josh Clark GrafTech International The Casting Machine of the Future: New Automation and Digital Technologies Improve Operations Scott Thoreson , Rockwell Automation show more Description Continuous casting is a demanding process and operators are constantly trying to achieve optimum speed, quality and yield while avoiding undue equipment stress. Often, these operators are working with outdated control systems, which produce limited information and reduce machine performance and reliability. As a result, many companies are relying on operator experience and know-how instead of operations data to make decisions. But what happens as these operators retire? This presentation will share advanced automation architectures that integrate power and process for better control, visualization and troubleshooting. Applications of digital technologies such as artificial intelligence will also be explored. Time Monday, Aug 31 2:30PM - 3:00PM Location 5 Speakers Scott Thoreson Rockwell Automation
3:00pm Analysis of Inclusion Clusters Using Machine Learning Tools Mohammad Abdulsalam, Carnegie Mellon University; M. Jacobs, Carnegie Mellon University; Bryan Webler, Carnegie Mellon University show more Description Behavior of non-metallic inclusions is critical for steel processing. One of the main concerns is inclusion agglomeration, which can lead to large clusters in solid product. Scanning electron microscopy (SEM) coupled with energy-dispersive spectroscopy (EDS) has been a prominent technique for inclusion characterization. This study utilizes the output generated from SEM/EDS analysis along with machine learning tools to provide an automated method for inclusion cluster identification. The approach was to analyze multiple cross-sections from a steel sample, thereby examining inclusions from a detailed three-dimensional perspective. The aim was to relate the three-dimensional analysis to the two-dimensional cross-sections. Time Monday, Aug 31 3:00PM - 3:30PM Location 3 Speakers Mohammad Abdulsalam Carnegie Mellon University M. Jacobs Carnegie Mellon University Bryan Webler Carnegie Mellon University Calculation of Replacement Rate Based on the Chemical Composition and Calorific Value of Biomasses Alex Campos, Universidade Federal de Ouro Preto; Paulo Santos Assis, Universidade Federal de Ouro Preto show more Description Injection of pulverized materials is a technique used in most blast furnaces around the world. Some characteristics are necessary for the material to be injected. However, biomass is an economical and environmentally friendly alternative to substitute part of the coal used. An important variable is the replacement ratio, which is the reduced amount in the coke rate per unit mass of the injected material. There are some mathematical models for calculating the replacement ratio based on chemical and thermal properties. This work aims to calculating the replacement rate of biomasses using formulas available in the literature based on chemical and thermal properties. Time Monday, Aug 31 3:00PM - 3:30PM Location 25C Speakers Alex Campos Universidade Federal de Ouro Preto Paulo Santos Assis Universidade Federal de Ouro Preto Choosing an Electrical Supplier Thomas Richards, TMEIC; Gary Gepitulan, TMEIC show more Description Choosing an electrical supplier for a project is a decision with long-lasting implications. Whether it is a modernization or a new project, the considerations are very similar. What criteria are important to consider and why? What criteria have been used on actual projects and how did those criteria work out? What criteria were not used but later wished had been considered? This paper will examine actual projects, the criteria considered, how the criteria worked out and any additional criteria that should have been considered. Time Monday, Aug 31 3:00PM - 3:30PM Location 21 Speakers Thomas Richards TMEIC Gary Gepitulan TMEIC Configuring and Tuning "U" and "W" Radiant Tubes for Optimum Performance Dennis Quinn, Fives North American Combustion Inc. show more Description For a wide variety of applications where indirect heat is required, as opposed to direct firing, radiant tubes can provide a dependable answer. “W” and “U” style radiant tubes dominate the current installed base of radiant tubes. Like any industrial heating technique, radiant tube applications require proper selection, calibration and tuning to maximize production rates, minimize maintenance, and optimize energy use and consumption. Realizing the operational ideal for radiant tube applications requires knowing the fundamentals, the ability to recognize common issues, and taking advantage of different methods/available technologies. This paper explores techniques for optimizing radiant tube heating applications. Time Monday, Aug 31 3:00PM - 3:30PM Location 12 Speakers Dennis Quinn Fives North American Combustion Inc. Corrosion Behavior of Different Alloys in Zn and Al Alloy Galvanizing Baths Tobias Simon, Kuhn Special Steel North America Inc.; Frank Wischnowski, Kuhn Special Steel North America Inc. show more Description In this study, different types of centrifugally cast and forged alloys are subjected to liquid metal (Zn and AlSi baths). Different samples were manufactured. Samples were introduced into test rig in galvanizing alloys (pure Zn and AlSi). Samples were examined and evaluated: mass loss and microstructure via optical and scanning electron microscopy. Test alloys were compared according to alloying elements. This work contributes to the understanding of the effect of alloying elements on liquid metal corrosion in various galvanizing baths. Here different alloy compositions are subjected to liquid metal test baths to simulate corrosion situations in Zn/Al/AlSi pots during continuous galvanizing. Time Monday, Aug 31 3:00PM - 3:30PM Location 24 Speakers Tobias Simon Kuhn Special Steel North America Inc. Frank Wischnowski Kuhn Special Steel North America Inc. Danieli Endless Casting and Rolling: Energy-Saving Technology for the Rebar Market Andrea De Luca, Danieli; Federico Tortul , Danieli; M. Cimolino, Danieli & Officine Meccaniche S.p.A.; S. Ronco, Danieli Automation S.p.A show more Description In the last decade, MIDA technology featuring the Danieli patented Endless Casting and Rolling process has achieved important goals in energy savings and transformation efficiency. With this technology, gas reheating furnaces have been removed from the production process of rebar, making it pollution-free and sustainable. Nowadays, the MIDA solutions cover a wide range of production from 150,000 tpy to 2,000,000 tpy with NANO, COMPACT, JUMBO and Twin mill configuration and products with straight bars, spooled coils, wire rod and is prepared to meet the ever-increasing market demands. Time Monday, Aug 31 3:00PM - 3:30PM Location 5 Speakers Andrea De Luca Danieli Federico Tortul Danieli M. Cimolino Danieli & Officine Meccaniche S.p.A. S. Ronco Danieli Automation S.p.A Development of a CALPHAD-Based Steel Property Model Library for Martensite and Pearlite Paul Mason, Thermo-Calc Software; Johan Jeppsson, Thermo-Calc Software; Jiayi Yan, Thermo-Calc Software; Qing Chen, Thermo-Calc Software show more Description A new martensite temperature model calculates the martensite start temperature (Ms) based on modeling the transformation barrier. The partitionless equilibrium temperature T0 is calculated using a CALPHAD database. The model also gives temperatures corresponding to 50%, 90%, and 99% transformations where martensite fractions are based on the fraction of athermal martensite calculated using an analytical equation [Huyan et al. (2016)]. A new pearlite property model describes the thermodynamics and kinetics of pearlite formation from austenite. Growth rate and lamellar spacing of pearlite are determined by a criteria where either growth rate or Gibbs energy dissipation rate is maximized. Time Monday, Aug 31 3:00PM - 3:30PM Location 25A Speakers Paul Mason Thermo-Calc Software Johan Jeppsson Thermo-Calc Software Jiayi Yan Thermo-Calc Software Qing Chen Thermo-Calc Software Development of Long-Life Slag Pot by Optimizing Stiffness Structurally for Temperature Distribution Kosuke Kozai, JFE Steel Corp.; Makoto Naito, JFE Steel Corp.; Yoshichika Sato, JFE Steel Corp.; Kunitoshi Oyama, JFE Steel Corp. show more Description The slag pot, which transports slag produced during the steelmaking, process does not lay refractories on the inner surface in order to separate slag more easily. Therefore, since the temperature greatly differs between the part in contact with slag and other parts, the lifetime of the slag pot is limited by deformation and crack due to thermal stress. By optimizing stiffness structurally for temperature distribution, a slag pot was developed that can reduce thermal stress by 28%. More than two years of continuous evaluation confirmed that there was hardly any deformation. Time Monday, Aug 31 3:00PM - 3:30PM Location 16 Speakers Kosuke Kozai JFE Steel Corp. Makoto Naito JFE Steel Corp. Yoshichika Sato JFE Steel Corp. Kunitoshi Oyama JFE Steel Corp. Effects of Reduction and Carburization on Strength of Direct Reduced Iron Geonu Kim, Carnegie Mellon University; P. Chris Pistorius, Carnegie Mellon University show more Description Direct reduced iron (DRI), as a primary feedstock in ironmaking and steelmaking, must maintain strength and integrity during processing, transportation, and use to avoid any operational issue and loss of materials. Mechanical properties and structural changes of direct reduced iron during production should be understood. This study is designed to find associations among physical properties, structural changes, and inner phases of direct reduced iron developed during reduction and carburization. Also, diverse gas-based DRI productions such as CO-based, H2-based (fossil-free), and industrial (MIDREX and HYL) processes are compared in terms of DRI mechanical properties and structures. Time Monday, Aug 31 3:00PM - 3:30PM Location 9 Speakers Geonu Kim Carnegie Mellon University P. Chris Pistorius Carnegie Mellon University Efficient Purification of Ferrosilicon Alloy by Using Oxidative Slag Agent Yanhui Zhang, University of Science & Technology Beijing; Yaqiong Li, University of Science & Technology Beijing; Lifeng Zhang, Yanshan University show more Description A novel approach was developed to remove the Al and Ca impurities from the ferrosilicon alloy by using the single SiO2 or Fe2O3 slag agent efficiently. Combined with scanning electron microscopy/energy-dispersive x-ray spectroscopy (SEM-EDS), inductively coupled plasma atomic emission spectroscopy (ICP-AES) and electron microprobe analysis (EPMA) were used to analyze samples. After refining, the impurity phases of Al and Ca in ferrosilicon alloys decreased sharply and the corresponding removal efficiencies yielded 88.28% and 98.70%, respectively. Meanwhile, secondary pollution of ferrosilicon alloy also can be avoided. Time Monday, Aug 31 3:00PM - 3:30PM Location 4 Speakers Yanhui Zhang University of Science & Technology Beijing Yaqiong Li University of Science & Technology Beijing Lifeng Zhang Yanshan University Gas Cleaning and Waste Heat Recovery Solutions for Integrated Steel Plants and Mini-Mills — State-of-the-Art Technologies and Latest References Alexander Fleischanderl, Primetals Technologies Austria GmbH; Thomas Steinpazer, Primetals Technologies Austria GmbH; Paul Trunner, Primetals Technologies Austria GmbH show more Description Today, steel mills are forced to comply with the most stringent environmental regulations. Two practical examples for achieving ultralow emission levels and best-in-class energy efficiency are presented. The installation of a new electric arc furnace at a steel plant in Italy, including a state-of-the art gas cleaning system and a novel type of waste heat recovery solution with record execution time, is discussed. The latest innovations for wet- and dry-type ultralow emission gas cleaning for basic oxygen furnace shops are introduced. A novel concept for top-gas recovery turbine arrangement for a blast furnace as well as operational achievements are presented. Time Monday, Aug 31 3:00PM - 3:30PM Location 11 Speakers Alexander Fleischanderl Primetals Technologies Austria GmbH Thomas Steinpazer Primetals Technologies Austria GmbH Paul Trunner Primetals Technologies Austria GmbH High-Fluxed Sintering Practice at Tata Steel - A Method to Handle Indian Iron Ore Fines Arunkumar Chelladurai, Tata Steel Ltd.; Srijith Mohanan, Tata Steel Ltd.; Vipul Mohan Koranne, Tata Steel Ltd.; Asadi Srinivas Reddy, Tata Steel Ltd. show more Description Blast furnace burden mixed with olivine pellets offered an opportunity to produce sinter using a new chemistry regime at high flux regime and permitted flexibility in the ore mix, resulting in a change of sinter properties at Tata Steel. Acidic/olivine pellets are meant to meet the flux requirements of the blast furnace through sinter. The ore mix ratio of sources A and B to sintering was switched over to reduce the input of finer size fraction and high alumina, which resulted in the improvement of sinter quality like RDI and RI. Time Monday, Aug 31 3:00PM - 3:30PM Location 26A Speakers Arunkumar Chelladurai Tata Steel Ltd. Srijith Mohanan Tata Steel Ltd. Vipul Mohan Koranne Tata Steel Ltd. Asadi Srinivas Reddy Tata Steel Ltd. IEC Technical Specification for AC Adjustable-Speed Rolling Mill Motors Ronald Tessendorf, Tessendorf Enterprises; Sumiyasu Kodama, TMEIC; Noboru Morita, Motor & Carbonbrush Lab. Co. Ltd. show more Description The author presented a paper at AISTech 2014 outlining the need for a main drive AC motor standard. In 2016, IEC Working Group (WG) 34 was formed with the task of producing the document. The original WG members were Australia, Germany, India, Japan, Korea and the United States. Technical Specification IEC TS 60034-34 Specific requirements for AC adjustable speed rolling mill motors was issued after extensive WG discussions and consideration of comments from IEC member countries. This paper will highlight some of the differences from the original proposed concepts and summarize the final results. Time Monday, Aug 31 3:00PM - 3:30PM Location 15 Speakers Ronald Tessendorf Tessendorf Enterprises Sumiyasu Kodama TMEIC Noboru Morita Motor & Carbonbrush Lab. Co. Ltd. Improvement of Steel Plate Temperature Control Accuracy in Accelerated Cooling Takahiro Ohara, Kobe Steel Ltd.; Keiichi Yamashita, Kobe Steel Ltd.; Kensuke Uenishi, Kobe Steel Ltd.; Taketsugu Osaka, Kobe Steel Ltd. show more Description In plate cooling, the flow behavior of cooling water on plate, which is one of influential factors on the heat transfer, varies with the water flow density and plate width. In order to improve accuracy of plate temperature control, a heat transfer model was developed that considers flow behavior of cooling water on plate. The developed heat transfer model was optimized based on multi-point plate temperature measurements, including temperature measurements on upper and lower surfaces of recuperated process after cooling. As a result of applying this model to actual cooling control, highly accurate plate temperature control has been achieved. Time Monday, Aug 31 3:00PM - 3:30PM Location 23 Speakers Takahiro Ohara Kobe Steel Ltd. Keiichi Yamashita Kobe Steel Ltd. Kensuke Uenishi Kobe Steel Ltd. Taketsugu Osaka Kobe Steel Ltd. Latest Technologies for CBN High-Speed Grinding and High-Performance SMARTcontrol Jochen Münker, GEORG North America Inc. show more Description Cubic boron nitride (CBN) is the second hardest material in the world after diamonds, and has superior grinding performance. Advantages of digital twin technology include virtual commissioning and training independent of the real machine. Time Monday, Aug 31 3:00PM - 3:30PM Location 10 Speakers Jochen Münker GEORG North America Inc. Machine Learning–Based On-Line Model for Slag Conditioning in Ladle Furnaces in Ternium Mexico Alejandro Zambrano, ECON Tech; Julio Lara, Ternium Mexico; Nelson Sánchez, ECON Tech; José Lara, Ternium Mexico show more Description This paper shows the implementation of a machine learning-based on-line model for slag conditioning in ladle furnaces. The model calculates the lime and aluminum additions in order to achieve a slag target chemical composition and is based on a weighted k-Nearest Neighbor algorithm to calculate an initial approximation of additions, and then a mass balance within an optimization algorithm to adjust the final additions. The model was validated with process data from two ladle furnaces, and the results demonstrate that better control of the final slag chemical composition from heat to heat can be achieved. Time Monday, Aug 31 3:00PM - 3:30PM Location 13 Speakers Alejandro Zambrano ECON Tech Julio Lara Ternium Mexico Nelson Sánchez ECON Tech José Lara Ternium Mexico Machine Learning–Based Predictive Quality Jérémy Coppe, PSI Metals North America; Elena Samuylova, Mechanica AI; Emeli Dral, Mechanica AI show more Description Up to 4% of metals production is scrapped despite the highest standards related to quality. Most defects are related to the early stages of the production process (casting and milling) but mostly only discovered at the finishing stages of the product. Machine learning-based predictive quality can predict up to 75% of defects during metals production, most of which could be avoided, thereby reducing the scrap production of the plant drastically. This paper describes how such models can be achieved and maintained and how they can be embedded in the operational quality management of a metals production plant. Time Monday, Aug 31 3:00PM - 3:30PM Location 14 Speakers Jérémy Coppe PSI Metals North America Elena Samuylova Mechanica AI Emeli Dral Mechanica AI Modeling of the Dynamic-Bulging-Induced Surface Level Fluctuations in Continuous Casting Zhengtao Xu, University of Illinois Urbana-Champaign; Zhelin Chen, University of Illinois Urbana-Champaign; Lu Chen, University of Illinois Urbana-Champaign; Bryan Petrus, Nucor Steel-Decatur LLC; Madison Milligan, Nucor Steel-Decatur LLC; Daniel Stephens, Nucor Steel-Decatur LLC; Joseph Bentsman, University of Illinois Urbana-Champaign; Brian G. Thomas, Colorado School of Mines show more Description Mold level fluctuations cause flow instability, strand surface cracks and even breakouts in severe cases. Dynamic unsteady bulging caused by periodic squeezing of the strand far below the mold is an important cause of mold level fluctuations. This phenomenon is calculated by a computational model. A stopper position-based flow model is used to calculate the steel flowrate through the submerged-entry nozzle. Together with a steady bulging model based on thermomechanical analysis, a geometric model is used to calculate the dynamic bulging shape evolution. These models are combined and applied to investigate mold level fluctuations under real casting conditions. Time Monday, Aug 31 3:00PM - 3:30PM Location 1 Speakers Zhengtao Xu University of Illinois Urbana-Champaign Zhelin Chen University of Illinois Urbana-Champaign Lu Chen University of Illinois Urbana-Champaign Bryan Petrus Nucor Steel-Decatur LLC Madison Milligan Nucor Steel-Decatur LLC Daniel Stephens Nucor Steel-Decatur LLC Joseph Bentsman University of Illinois Urbana-Champaign Brian G. Thomas Colorado School of Mines Pickling Line and Tandem Continuous Mill at Ternium Pesquería Facility With a 5-Stand, 6-High Configuration Jorge Salinas, Ternium Mexico show more Description The main equipment that the process has are laser welding machine, three loopers, scalebreaker, jet pickling tanks, inspection station and COGNEX system. Sidetrimmer (flying width change). Type of mill: UCMW(S) carousel with two tension reels. The principals goals are to simulate production programs; validate materials for thin thicknesses before processing; reduced re-welds; optimization using Cognex; and good performance in thickness, flatness and productivity. Time Monday, Aug 31 3:00PM - 3:30PM Location 22 Speakers Jorge Salinas Ternium Mexico Real Intelligence – A Novel Approach to EAF Optimization Mark Trapp, Continuous Improvement Experts Inc.; Jeremy Jones, Continuous Improvement Experts Inc. show more Description In recent years there has been a strong effort to integrate artificial intelligence (AI) into manufacturing operations. In heavily automated operations with repetitive operating cycles, this may be possible. However, in a process such as electric arc furnace (EAF) steelmaking, the process variations make it difficult to apply AI effectively. As an alternative, the authors propose the real intelligence — the use of effective tools based on a sound understanding of process fundamentals to allow the operator to make better decisions in real time. As greater EAF automation is implemented, the operator role must change from equipment operation to frontline process optimization. Time Monday, Aug 31 3:00PM - 3:30PM Location 6 Speakers Mark Trapp Continuous Improvement Experts Inc. Jeremy Jones Continuous Improvement Experts Inc. Remanufacturing Process and Improvement in Fatigue Life of Rolling Bearings by UNSM Shirmendagva Darisuren, Designmecha; Inho Cho, Designmecha; Junho Lee, Designmecha; A. Amanov, Sun Moon University; S.W. Yim, POSCO show more Description This study proposes a sustainable bearing remanufacturing process using the ultrasonic nanocrystal surface modification (UNSM) technique. The proper maintenance and usage of repaired bearings can increase their life to be equal to or greater than that of new bearings. Rolling contact fatigue tests performed on UNSM-treated new and used specimens polished after 4×106 cycles reveal that UNSM-treated new specimens exhibit the longest fatigue life compared to other specimens. This study verifies the proposed complete fatigue recovery process, which can increase the fatigue life of used bearings to a level greater than that of new bearings. Time Monday, Aug 31 3:00PM - 3:30PM Location 19 Speakers Shirmendagva Darisuren Designmecha Inho Cho Designmecha Junho Lee Designmecha A. Amanov Sun Moon University S.W. Yim POSCO Toward Man-Less Factory: Improved Roughing Mill Operation by Camber-Free Rolling Reduces Strip Steering Challenge in the Finishing Mill of SSAB Borlänge, Sweden Mats Thurgren, SSAB Borlänge; Wolfgang Spies, SMS group GmbH; Siegfried Latzel, SMS group GmbH; Klaus Pronold, SMS group GmbH; Eberhard Becker, SMS group GmbH show more Description Following a strategy to eliminate the need of man and steering of the hot strip mill, the first camber-free rolling technology was implemented at SSAB Borlänge, Sweden, in the hot strip mill. Camber in strip is considered the most important source of cobbles in the finishing mill and root cause for steering corrections and control. Results show tremendous improvement can be achieved by this technology. Results will be presented as well as future steps to ultimately eliminate human intervention for hot sheet rolling. Time Monday, Aug 31 3:00PM - 3:30PM Location 20 Speakers Mats Thurgren SSAB Borlänge Wolfgang Spies SMS group GmbH Siegfried Latzel SMS group GmbH Klaus Pronold SMS group GmbH Eberhard Becker SMS group GmbH Understanding the Dynamics of Slag Evolution and Its Influence on Hot Metal Refining in a BOF Process Bapin Rout, Tata Steel Netherlands; Elisabeth Beunder, Tata Steel Netherlands; Aart Overbosch, Tata Steel Netherlands; Willem van der Knoop, Tata Steel Netherlands; Jianjun Sun, Tata Steel Netherlands; Frank N. H. Schrama, Tata Steel Netherlands show more Description Control and understanding of the slag evolution path is important for the optimal performance of the basic oxygen furnace (BOF) process. Variables such as scrap, flux additions, lance movement and O2 flow influence the slag evolution that controls hot metal refining. At Tata Steel, a modified sublance probe was used to take slag and metal samples from a 330-metric-ton converter at different refining periods. The dynamic evolution of slag chemistry, weight and mineralogy were estimated and the influence of the process variables on slag formation and its effect on hot metal refining are discussed with the help of a dynamic BOF model. Time Monday, Aug 31 3:00PM - 3:30PM Location 7 Speakers Bapin Rout Tata Steel Netherlands Elisabeth Beunder Tata Steel Netherlands Aart Overbosch Tata Steel Netherlands Willem van der Knoop Tata Steel Netherlands Jianjun Sun Tata Steel Netherlands Frank N. H. Schrama Tata Steel Netherlands Use of High-Strength Carbon-Containing Briquettes (CC-BREX) for Lowering the Coke Rate in Blast Furnaces Prateek Mathur, Tata Steel Ltd. show more Description By improving the reactivity of carbon with the associated iron oxides, it is possible to lower the temperature of the start of the Boudouard reaction. This can be achieved by having carbon innately dispersed within the agglomerate, thereby increasing the contact area. This is not possible using conventional agglomerates that burn carbon as a heat source for creating slag bonds. In a trial at Tata Steel's C-Blast Furnace, carbon-containing BREX (CC-BREX) was used successfully at 3, 5 and 7% in the burden. A reduction of 25-27kg/thm in coke rate was achieved for the best case. Time Monday, Aug 31 3:00PM - 3:30PM Location 25B Speakers Prateek Mathur Tata Steel Ltd.
3:30pm An investigation on the inline direct quenching parameters on the microstructure and hardness uniformity of an abrasion-resistant steel plate Hamed Hoseiny, Primetals Technologies Ltd.; Andrew Harvey, Primetals Technologies Ltd. show more Description In the production of steel plate, powerful in-line cooling machines with direct quench (DQ) capability offer the steel producer great flexibility. A wide range of final structure property relationships can be targeted in the as-rolled product. A key feature is the potential reduction in processing stages; however, final performance levels must still be achieved. This paper considers the pertinent process parameters that can limit the in-line DQ process window, such as temperature, geometry and capacity. The current performance and challenges in widening the process window compared to traditional process routes are reviewed. Time Monday, Aug 31 3:30PM - 4:00PM Location 23 Speakers Hamed Hoseiny Primetals Technologies Ltd. Andrew Harvey Primetals Technologies Ltd. Canadian Steel Producer Installs New Tar Electrostatic Precipitators on COG James Reynolds, Hamon Research-Cottrell; Patrick Doonan, Hamon Research-Cottrell show more Description The paper will discuss the problems with the 40-year-old tar electrostatic precipitators (ESPs) and how the new tar ESPs solved those problems. Problems to be overcome were corrosion, poor flow distribution, plugging and poor performance. The new ESP equipment incorporates modern-day rigid electrodes and high-frequency transformer/rectifiers to increase performance and 316L stainless steel collection internals. Three units were installed in the summer of 2019 and performance met the plants requirements via third-party testing. Time Monday, Aug 31 3:30PM - 4:00PM Location 11 Speakers James Reynolds Hamon Research-Cottrell Patrick Doonan Hamon Research-Cottrell Coupling Molten Salt Reactor to Direct Reduction Steel via High-Temperature Steam Electrolysis John Kutsch, Thorium Energy Alliance show more Description Direct reduced iron (DRI) steel production based on steam methane reformation hydrogen is not as efficient and doesn't produce true DRI because CO2 is left in the system. Work at Idaho National Lab shows that high-temperature steam electrolysis systems coupled to molten salt reactors creates carbon-free hydrogen for under US$1.80/kg, making it economically advantageous to produce true DRI steel via this method. It has been proposed to present exact flow sheets, processes and cost analysis used by several national labs to come to the conclusion that this hydrogen supply based on this system would make the most economical, highest-grade steel. Time Monday, Aug 31 3:30PM - 4:00PM Location 9 Speakers John Kutsch Thorium Energy Alliance Development of Nanobainitic Steels With Accelerated Kinetics and Tensile Strength of 1.7-2.0 GPa Minal Shah, CSIR-National Metallurgical Lab; Swapan K Das, CSIR-National Metallurgical Lab; Sandip Ghosh Chowdhury, CSIR-National Metallurgical Lab show more Description Nanobainite steels with medium carbon ~0.5 wt.% are produced in the present work with faster kinetics and without the addition of cobalt and aluminum. Nanobainitic steel of 1.7-2.0 GPa ultimate tensile strength is used in application of wear resistance, ball bearing and gears. Kinetics of bainitic transformation was investigated by emphasizing on influence of alloying elements to produce nanobainitic steel. Reduction of carbon in the alloy accelerates the kinetics of transformation as it increases the driving force for bainitic transformation and it reduces activation energy of the dislocation barrier determined using a kinetic model. The activation energy of the dislocation barrier has a direct relation on austenite strength at the transformation temperature. Time Monday, Aug 31 3:30PM - 4:00PM Location 25A Speakers Minal Shah CSIR-National Metallurgical Lab Swapan K Das CSIR-National Metallurgical Lab Sandip Ghosh Chowdhury CSIR-National Metallurgical Lab Discovery of New Magnesia Source Extends Performance of Ladles in LMF and Vacuum Tank Degassing Tianqing Li, Puyang Refractories Co. Group; Baikuan Liu, Puyang Refractories Co. Group; Qixiu Zuo, Puyang Refractories Co. Group; Jie Gao, Puyang Refractories Co. Group; Runtang Feng, Puyang Refractories Co. Group; Shiqiang Li, Puyang Refractories Co. Group; Bill Porter, PRCO America LLC show more Description As the main raw material, the quality of fused magnesia directly affects the service life of magnesia carbon (MgO-C) refractory. A new type of fused magnesia with ultralow inclusion (SiO2 and Fe2O3) content and high CaO/SiO2 ratio (more than 5) was introduced into MgO-C refractory, and the unique MgO-C refractory showed good performance in the slagline of the ladle metallurgy furnace and vacuum tank degassing ladle. The composition and microstructure of the used MgO-C refractory were investigated and its degradation mechanisms were proposed. Time Monday, Aug 31 3:30PM - 4:00PM Location 4 Speakers Tianqing Li Puyang Refractories Co. Group Baikuan Liu Puyang Refractories Co. Group Qixiu Zuo Puyang Refractories Co. Group Jie Gao Puyang Refractories Co. Group Runtang Feng Puyang Refractories Co. Group Shiqiang Li Puyang Refractories Co. Group Bill Porter PRCO America LLC Estimation of Coal Charge Bulk Density: Factors Impacting Bulk Density and Its Effect on the Carbonization Process for Stamp-Charge Coke Ovens Asadi Srinivas Reddy, Tata Steel Ltd.; Adity Ganguly, Tata Steel Ltd.; Ashutosh Bhushan, Tata Steel Ltd.; Amitabh Shankar, Tata Steel Ltd.; Ranjan Kumar Singh, Tata Steel Ltd.; R.V. Ramna, Tata Steel show more Description Stamp charging enables cokemakers to improve charge bulk density for better coke quality. Several factors impact the density, e.g., coal moisture, crushing fineness, stamping energy, etc. Also, density impacts quality and oven performance. Hence it is important to understand variations of density. A new method is developed to estimate the charge density for individual oven based on the amount of coke discharged with load cells installed in a dry quenching bucket lifting crane. Density is estimated with coal moisture and volatile content. The results are helpful to understand the factors influencing density and its impact on quality and oven performance. Time Monday, Aug 31 3:30PM - 4:00PM Location 25B Speakers Asadi Srinivas Reddy Tata Steel Ltd. Adity Ganguly Tata Steel Ltd. Ashutosh Bhushan Tata Steel Ltd. Amitabh Shankar Tata Steel Ltd. Ranjan Kumar Singh Tata Steel Ltd. R.V. Ramna Tata Steel Evaluation of the Iron Content in Non-Metallic Inclusions in Steel for (Sub)-Microscopic Steel Cleanness Description Alexander Mayerhofer, Montanuniversitaet Leoben; Peter Presoly, Montanuniversitaet Leoben; Christian Bernhard, Montanuniversitaet Leoben; Susanne K. Michelic, Montanuniversitaet Leoben show more Description Increasing customer demands for higher steel quality will require improved (sub-)micro cleanness descriptions in the near future. Due to the challenging analysis of matrix elements in non-metallic inclusions, the iron content of particles was often neglected in chemical evaluations up until now. Starting to close this gap of information, a systematic approach was developed, including statistic particle prediction, sample production on laboratory scale and subsequent analysis evaluating the iron content in particles (<1 µm) by scanning electron microscopy/energy-dispersive x-ray spectroscopy measurements. This enables a detailed (sub-)micro cleanness description for steels ensuring the determination of correct compositions and an improved understanding of particle morphology for smallest sizes. Time Monday, Aug 31 3:30PM - 4:00PM Location 3 Speakers Alexander Mayerhofer Montanuniversitaet Leoben Peter Presoly Montanuniversitaet Leoben Christian Bernhard Montanuniversitaet Leoben Susanne K. Michelic Montanuniversitaet Leoben High-Throughput Casting Technology — Challenges and Solutions Jürgen Müller, SMS group GmbH; Christian Fröhling, SMS group GmbH; Frank Seuffert, SMS group GmbH show more Description SMS group received an order from Steel Dynamics Inc. for the Sinton, Texas, USA, single-strand high-production plant, having an annual capacity of 2.7 million metric tons (3 million short tons). With a casting thickness of 130 mm, the required higher throughput is given and the production of thicker API grades becomes possible. Challenges for the subsequent high throughputs will be the steel flow control in the mold, minimization of bulging and the establishment of a uniform solidification in the strand guide. The continuous casting plant concept, with an overview of the technological highlights, will be presented. Time Monday, Aug 31 3:30PM - 4:00PM Location 5 Speakers Jürgen Müller SMS group GmbH Christian Fröhling SMS group GmbH Frank Seuffert SMS group GmbH Intelligent Prediction Methodology and Simulation Model Concerning Optimizing Byproduct Energy Scheduling and Utilization in Iron- and Steelmaking Enterprises Dabin Wang, CISDI R&D Co. Ltd.; Hu Kun, CISDI R&D Co. Ltd. show more Description In steel works, byproduct energy generated in iron- and steelmaking process accounts for approximately 40% of the total energy involved, which is mainly converted into the form of gases and steam. In this paper, prediction methodology of energy production and consumption is applied for energy scheduling to help improve system stability. Furthermore, the integrated optimization model for energy conversion among byproduct gases, steam and electricity generation is proposed to improve energy utilization efficiency, which considers the influence of energy loss in pipeline transport and power plant efficiency by simulating energy flow inside the pipeline network as well as simulating operating characteristics of the gas boiler and steam turbine. Time Monday, Aug 31 3:30PM - 4:00PM Location 12 Speakers Dabin Wang CISDI R&D Co. Ltd. Hu Kun CISDI R&D Co. Ltd. Investigation of Grounding Failures in Transformers and Evaluation of Best Practices Hiranya Pathak, Primetals Technologies USA LLC; Ramesh Khajjayam, Primetals Technologies USA LLC show more Description Typical industrial transformer grounding design includes grounding of the tank, neutral and the control cabinet. The transformer core acts as a magnetic medium to channel the flux and is also grounded. Core grounding may not be seen as a requirement by process or safety. Improper grounding may lead to increased dielectric stresses, leading to internal transformer failures or line-to-ground faults. Investigations of transformer failures due to improper grounding are presented along with solutions to such problems. This paper also presents aspects of transformer grounding, focused on the core ground in order to improve the insulation system, protective relaying and safety. Time Monday, Aug 31 3:30PM - 4:00PM Location 15 Speakers Hiranya Pathak Primetals Technologies USA LLC Ramesh Khajjayam Primetals Technologies USA LLC New Approach to Classify Phosphorus Partition in BOF Steelmaking Using PCA-Based Twin Support Vector Machines Sankha Mukherjee, University of Toronto; Sandip Barui, University of South Alabama; Kinnor Chattopadhyay, University of Toronto show more Description Controlling endpoint phosphorus in basic oxygen furnace steelmaking is critical. Herein, a principal component analysis (PCA)-based twin-support vector machines (TWSVM) algorithm is proposed to predict categories of phosphorus partition based on slag chemistries, slag basicities, O2 blowing time and tapping temperature. PCA is implemented for data dimensionality reduction. Quantile-based and K-means clustering techniques have been applied initially to categorize data with different degrees of phosphorus partition. For comparison, multiple linear regression model, support vector machines (SVM) with polynomial and radial basis kernels, least square SVM and least square TWSVM are also considered. Time Monday, Aug 31 3:30PM - 4:00PM Location 7 Speakers Sankha Mukherjee University of Toronto Sandip Barui University of South Alabama Kinnor Chattopadhyay University of Toronto New Flat-Rolled Steel Plant for Sinton, Texas: Advanced CSP Technology With Single-Strand Caster and 84-Inch-Wide Hot Strip Mill for 3 Million Tons Per Year Glenn Pushis, Steel Dynamics Inc.; Tom Wilcox, Steel Dynamics Inc. - Flat Roll Group Butler Division; Ron Bohna, Steel Dynamics Inc. - Flat Roll Group Columbus Division; Bill Seres, Steel Dynamics Inc. - Flat Roll Group Sinton; Frank Benner, SMS group GmbH ; Alfred Metzul, SMS group GmbH ; Keith Watson, SMS group Inc. show more Description Steel Dynamics Inc. is set to build a new plant for new products based on 76-inch-wide high-strength steel grades. Next-generation CSP® technology, coupled pickling tandem rolling line and continuous galvanizing line from SMS group are basis of the plant. The plant concepts and core technologies will be presented. Targeted products will be outlined. Time Monday, Aug 31 3:30PM - 4:00PM Location 21 Speakers Glenn Pushis Steel Dynamics Inc. Tom Wilcox Steel Dynamics Inc. - Flat Roll Group Butler Division Ron Bohna Steel Dynamics Inc. - Flat Roll Group Columbus Division Bill Seres Steel Dynamics Inc. - Flat Roll Group Sinton Frank Benner SMS group GmbH Alfred Metzul SMS group GmbH Keith Watson SMS group Inc. Numerical Investigation of DC Electric Arc Behavior Under the Consideration of Electrode Movement Yuchao Chen, Purdue University Northwest; Yu Wang, Purdue University Northwest; Armin Silaen, Purdue University Northwest; Chenn Zhou, Purdue University Northwest show more Description An electric arc is a phenomenon of gas discharge; that is, an instantaneous spark generated by current passing through certain insulating media. In the present study, a simple configuration of the free-burning arc was validated using a comprehensive computational fluid dynamics model. Simulation results are in good agreement with former experimental data. Investigation of the electric arc was conducted indirectly through corresponding flow fields including temperature field, velocity field and current density field. A novel method to model the electrode movement was adopted and related investigations were also conducted to evaluate the impact of electrode lifting/setback on arc performance. Time Monday, Aug 31 3:30PM - 4:00PM Location 6 Speakers Yuchao Chen Purdue University Northwest Yu Wang Purdue University Northwest Armin Silaen Purdue University Northwest Chenn Zhou Purdue University Northwest On-Line Model for Refractory Wear of Submerged-Entry Nozzle During Continuous Casting José Lara, Ternium Mexico; Leandro Martorello, Ternium Mexico; Ricardo Santos, Ternium Mexico; Carlos Muñoz, Ternium Mexico; Manuel Beirana, Ternium Mexico; Fabián Castro, Ternium Mexico; Rodrigo Lescas, Ternium Mexico show more Description The wear of refractory submerged-entry nozzles (SEN) impact strongly in safety, quality and cost of continuous casting machines. It could limit productivity, especially for thin-slab casters. In the present work, an on-line model of the SEN wearing is developed to notify the continuous casting personnel about the wearing profile along the sequence. This provide relevant information about remaining casting time in safe conditions to prevent the SEN breakout due to excessive wearing, reducing exposure of operators to unsafe conditions involved after such an undesirable event. The model also allows simulating different strategies to optimize the SEN wear performance. Time Monday, Aug 31 3:30PM - 4:00PM Location 14 Speakers José Lara Ternium Mexico Leandro Martorello Ternium Mexico Ricardo Santos Ternium Mexico Carlos Muñoz Ternium Mexico Manuel Beirana Ternium Mexico Fabián Castro Ternium Mexico Rodrigo Lescas Ternium Mexico On-Line Monitoring System to Detect Anomaly of Rolls in Rolling Mills Yuki Okano, TMEIC; Hiroyuki Imanari, TMEIC; Kazuyuki Maruyama, TMEIC; Yukihiro Yamasaki, TMEIC show more Description Rolling rolls are used under harsh conditions such as large loads and thermal stresses. If a roll spall occurs during rolling, it damages equipment and rolled materials severely, which leads to long and hard works to recovery. An on-line monitoring system has been developed to detect roll anomaly in a hot strip mill. The system calculates the roll eccentricity value for each roll and alerts the operators of a risk of roll spall when the value is largely changed. The presentation will show the actual results and discuss the basic ideas of the system. Time Monday, Aug 31 3:30PM - 4:00PM Location 20 Speakers Yuki Okano TMEIC Hiroyuki Imanari TMEIC Kazuyuki Maruyama TMEIC Yukihiro Yamasaki TMEIC Optimizing Sinter Chemistry to Counter Alumina Effect Chandra Shekhar Verma, Jindal Steel & Power Ltd. show more Description Sinter strength decreases with increasing alumina content due to its refractory nature and requires more heat input to fuse. It goes between the grain boundaries of the bond and makes it weaker. The ultimate aim of this study is to produce strong sinter even with high Al2O3 without hampering productivity. The study includes mineralogy test of iron fines and sinter to find out the distribution of different phases. The study concludes with the establishment of B4 and Al2O3/SiO2 ratio between 1.52 and 1.57 and 0.63 and 0.67, respectively, and achieved a tumbler index of +76 with a productivity of 1.60-1.63 T/M2/hour. Time Monday, Aug 31 3:30PM - 4:00PM Location 26A Speakers Chandra Shekhar Verma Jindal Steel & Power Ltd. Pomini Tenova Data Monitoring System: An Industry 4.0 Application Tailor-Made for Roll Grinding Machines Alfredo Brambilla, Tenova Inc.; Diego Brusetti, Tenova S.p.A.; Claudio Trevisan, Tenova S.p.A. show more Description The implementation of an effective Industry 4.0 concept requires an advanced hardware and software package, enabling the monitoring of a comprehensive set of variables, properly identified and tracked to assess the functioning conditions of the equipment as well as the progress of the process. Pomini Tenova developed their own proprietary Data Monitoring Package, in which the expertise of the OEM, of the grinding specialists and of the software engineering team have contributed to provide roll shop users with an advanced and effective tool, tailor made around roll grinding specific necessities. Time Monday, Aug 31 3:30PM - 4:00PM Location 10 Speakers Alfredo Brambilla Tenova Inc. Diego Brusetti Tenova S.p.A. Claudio Trevisan Tenova S.p.A. Quantitative Measurements of Bubble Formation and Bubble Size Distribution in a CC Mold During Gas Injection Through the Stopper Rod Using Full-Scale Physical Modeling Donghui Li, University of Toronto show more Description Injecting bubbles through the stopper rod is one of the effective ways to reduce submerged-entry nozzle port clogging and also modify the mold flow pattern. In order to reduce the pinhole defects forming from the micro-argon bubbles entrapped by the solidifying dendrites, larger argon bubbles are preferred because of higher rise velocity. In the paper, different bubble injection methods viz. single-point injection, multi-point injection and using porous plugs at the tip of stopper rod were studied in a full-scale water model mold system. The results of bubble size distribution, bubble trajectories, bubble count and resulting flow field are presented. Time Monday, Aug 31 3:30PM - 4:00PM Location 1 Speakers Donghui Li University of Toronto Software as a Service in the Metals Industry — Challenges, Requirements and Opportunities Reinhold Leitner, Primetals Technologies Austria GmbH; Daniel Fuchshuber, Primetals Technologies Austria GmbH; Christoph Stangl, Primetals Technologies Austria GmbH show more Description The idea of software as a service is becoming more widely accepted throughout all industries. The benefits of IT systems that are always up to date, continuously supported by experts and providing functional extensions to the newest developments and technologies, are invaluable. Now the first full-featured process optimization system “as-a-service” subscription license model is available, taking the idea one step further and ensuring that higher-level automation systems will never be outdated anymore. This paper describes the challenges and requirements to engineer and implement modern process optimization systems ready for agile software-as-a-service business models and the opportunities this transition brings for both customers and suppliers. Time Monday, Aug 31 3:30PM - 4:00PM Location 13 Speakers Reinhold Leitner Primetals Technologies Austria GmbH Daniel Fuchshuber Primetals Technologies Austria GmbH Christoph Stangl Primetals Technologies Austria GmbH Study on the Formation Mechanism of Gas Gap in Blast Furnace Hearth Zhongping Zou, CISDI Engineering Co. Ltd.; Jun Xu, CISDI Engineering Co. Ltd.; Min Chen, CISDI Engineering Co. Ltd. Iron & Steel Business Division show more Description This paper analyzes the blast furnace’s production data and investigation results on the damage and comes to reckon that part of the hearth’s heat transfer systems contains the gas gap. It further expounds the hazardous effect of the gas gap on the hearth’s service life from heat transfer theoretical calculations. By means of the gas gap simulation calculation, it proposes the formation mechanism of the gap and recommends prevention and control measures for extending the hearth service life. Time Monday, Aug 31 3:30PM - 4:00PM Location 25C Speakers Zhongping Zou CISDI Engineering Co. Ltd. Jun Xu CISDI Engineering Co. Ltd. Min Chen CISDI Engineering Co. Ltd. Iron & Steel Business Division The Next Generation of Proactive Maintenance Dave Cutnaw, SKF USA Inc. show more Description Optimizing a rotating equipment maintenance program can seem overwhelming. However, advantages gained from reduced unplanned downtime, increased productivity, better spare parts management, higher profitability and lower total cost of ownership of a machine’s life cycle make it worth the effort. With a case study from the steel industry to illustrate the benefits, this discussion will outline steps to take proactive maintenance to the next level using a novel pay-for-performance strategic maintenance model that can boost productivity, cut unplanned downtime and maximize profitability. Learn how to break the cycle of unplanned machine failure with a comprehensive approach to enhance rotating equipment performance. Time Monday, Aug 31 3:30PM - 4:00PM Location 19 Speakers Dave Cutnaw SKF USA Inc. Toward Man-Less Factory: Higher Level of Automation at New Multi-Purpose Reversing Cold Rolling Mill at Bilstein, Germany Wolfgang Spies, SMS group GmbH; Markus Gümpel, SMS group GmbH; Wolfgang Franken, SMS group GmbH; Falk Töpfer, SMS group GmbH show more Description Bilstein built a new high-performance, multi-purpose reversing mill for ultrahigh-strength steel grades with a new category of automation level. Its features include full process automation, fully automatic coil logistics including supply and delivery, optimized power consumption control of the plant, and full control of environmental pollution including noise. Preparations are implemented for IT 4.0 applications such as artificial intelligence and pattern recognition. Plant concept, functional features and first results will be presented. Time Monday, Aug 31 3:30PM - 4:00PM Location 22 Speakers Wolfgang Spies SMS group GmbH Markus Gümpel SMS group GmbH Wolfgang Franken SMS group GmbH Falk Töpfer SMS group GmbH Transverse Flux Induction Heating Technology Emmanuel Patard, Fives Celes; Tony Kezer, Fives Celes; Kevin Bertermann, Fives ST Corp. show more Description A unique transverse flux technology developed by Fives for rapid strip heating will be introduced. Conventional heating rates of around 70˚C/second are often insufficient for the complex heating and cooling cycles required to process advanced high-strength steel and ultrahigh-strength steel in strip processing lines. Transverse flux induction heating technology is a proven alternative for very rapid heating up to 400°C/second. The main function of the technology is as a booster for the continuous annealing line and continuous galvanizing line, as well as stainless and silicon steel processing lines to optimize steel grade metallurgical properties while reducing greenhouse gas emissions. Select case studies will be reviewed. Time Monday, Aug 31 3:30PM - 4:00PM Location 24 Speakers Emmanuel Patard Fives Celes Tony Kezer Fives Celes Kevin Bertermann Fives ST Corp.
4:00pm Advanced Bulk Material Transfer Technology Embedded In Equipment Gregory Clark, Tassco show more Description Advanced design technology, next-generation abrasive resistant materials and cutting-edge manufacturing techniques are combined to provide the best-available technology in bulk material transfer systems. Advanced design technology for the precision flow of bulk material through transfer systems, provides assurance of: • Meeting design capacity. • Minimized: o Pluggage risk. o Accumulated material residing inside chutework. o Material impact, degradation, dust generation, spillage. • Maximized: o Performance. o Safety. o Service life. Time Monday, Aug 31 4:00PM - 4:30PM Location 25C Speakers Gregory Clark Tassco Application of Machine Learning for Defective Coils Prediction Gina Verbanac , Danieli Automation S.p.A.; Luca Cestari, Danieli Automation S.p.A.; Gabriele Costante, Università degli Studi di Perugia; Paolo Valigi , Università degli Studi di Perugia; Riccardo Forti, Acciai Speciali Terni; Giacomo Disarò, Acciai Speciali Terni show more Description Availability of data from connected processes and breakthrough innovations in computing tools create exciting perspectives for artificial intelligence (AI) applications in metals industry. Acciai Speciali Terni, in partnership with Danieli Automation and the University of Perugia, decided to embrace this opportunity combining long-standing process expertise with a modern digital infrastructure and machine learning algorithms to extract actionable correlations from collected data. The initial step of this digital transformation process was focused on a predictive quality use case, with the target to highlight the correlations between the process parameters of the recently upgraded CC3 caster and surface defects identified on coils after rolling. Time Monday, Aug 31 4:00PM - 4:30PM Location 13 Speakers Gina Verbanac Danieli Automation S.p.A. Luca Cestari Danieli Automation S.p.A. Gabriele Costante Università degli Studi di Perugia Paolo Valigi Università degli Studi di Perugia Riccardo Forti Acciai Speciali Terni Giacomo Disarò Acciai Speciali Terni Cutting-Edge Technology for HSM – Strip Steering Control Olaf Jepsen, SMS group GmbH; Christian Mengel, SMS group GmbH; Michael Breuer, SMS group Inc. show more Description Stability of the hot strip mill rolling process remains a main topic when it comes to processing thin and hard materials. Strip steering, especially at the end of rolling and tail-out rips, are a main source of unscheduled downtimes in a hot strip mill. Thus, the main focus of the paper is the new X-Roll® Guide System to improve mill stability and quality. The system provides reproducible conditions for the threading process and during rolling. Steering control has a direct benefit on the availability of the mill. New developments of the roll alignment control strategies will be presented. Time Monday, Aug 31 4:00PM - 4:30PM Location 20 Speakers Olaf Jepsen SMS group GmbH Christian Mengel SMS group GmbH Michael Breuer SMS group Inc. Development and Production of the Largest Beam Blank in the World in Submerged Casting Marcellino Fornasier , Danieli; Przemyslaw Pardela, Danieli; Richaud Johan, Vesuvius France; Hilgenhoener Enno , Vesuvius Germany; Pierluigi Armenante , Danieli show more Description The new 12-m-radius combi caster can produce three beam blank sections and mini-slabs. The largest beam blank section produced measures 1,300 x 510 x 140 mm with a linear weight of approximately 2,700 kg/m. The 550 x 280 mm mini-slab can be produced on four strands utilizing two twin-molds. The continuous casting machine is equipped with advanced Danieli technological packages, such as the Q-INMO oscillator or Danieli Liquid Pool Control System for secondary cooling optimization. Submerged casting practice is subject to continuous development with special consideration given to the submerged-entry nozzle, which was designed by advanced numerical simulation, focusing on maximizing productivity without compromising quality. Time Monday, Aug 31 4:00PM - 4:30PM Location 5 Speakers Marcellino Fornasier Danieli Przemyslaw Pardela Danieli Richaud Johan Vesuvius France Hilgenhoener Enno Vesuvius Germany Pierluigi Armenante Danieli Development of Intermix Practice at Vallourec's Continuous Casting Mariana Pessoa, Vallourec Soluções Tubulares do Brasil; Osvaldo Ferreira, Vallourec Soluções Tubulares do Brasil; Laurent Chesseret, Vallourec Soluções Tubulares do Brasil; Thiago Oliveira, Vallourec Soluções Tubulares do Brasil; Carlos Silva, Universidade Federal de Ouro Preto; Luis Germano, Vallourec Soluções Tubulares do Brasil show more Description Intermix practice is the mixture among different steel grades in the same tundish at continuous casting. The main objectives are increase casting sequences and reduce yield loss due to head and tail crop at caster, crucial for the reduction of production cost. The present work shows the fully implementation of intermix practice at Vallourec's continuous casting in terms of planning, production and validation. Intermix pilot tests were performed in a tundish water model (five-factor Design of Experiment), industrial trials were validated, and the automatic bar optimization was implemented and standardized in the level 2 system. Time Monday, Aug 31 4:00PM - 4:30PM Location 1 Speakers Mariana Pessoa Vallourec Soluções Tubulares do Brasil Osvaldo Ferreira Vallourec Soluções Tubulares do Brasil Laurent Chesseret Vallourec Soluções Tubulares do Brasil Thiago Oliveira Vallourec Soluções Tubulares do Brasil Carlos Silva Universidade Federal de Ouro Preto Luis Germano Vallourec Soluções Tubulares do Brasil Effects of Methane Injection on Carbon Formation in MIDREX Hot Briquetted Iron (HBI) Michelle Godoy, Colorado School of Mines; Christopher Harris, voestalpine; Wolfgang Sterrer, voestalpine; Victor Romo, voestalpine; Emmanuel De Moor, Colorado School of Mines show more Description The use of direct reduced iron (DRI) in electric arc furnaces (EAFs) is increasing dilute residuals from scrap, notably copper. The carbon amounts in DRI may increase thermal efficiency in the EAF. Characterization of carbon formation in DRI and HBI (hot briquetted iron) is therefore important and was performed with an investigation of reaction thermodynamics and kinetics. Carbon contents of DRI and HBI from voestalpine’s MIDREX facility in Corpus Christi, Texas, were determined with x-ray diffraction, Mössbauer spectroscopy, and Leco carbon/sulfur analysis. A range of process conditions was determined for optimal carbon formation. Time Monday, Aug 31 4:00PM - 4:30PM Location 9 Speakers Michelle Godoy Colorado School of Mines Christopher Harris voestalpine Wolfgang Sterrer voestalpine Victor Romo voestalpine Emmanuel De Moor Colorado School of Mines Galvanneal Furnace Analysis and Control Methods Wang Lu, Baosteel-NSC Automotive Steel Sheets Co. Ltd. show more Description The recent rapid developments in the automobile industry have demanded the extensive use of galvannealed (GA) steel sheets. In particular, the development of lightweight automobiles is putting increasingly higher requirements on the strength of GA steel sheets. The galvanneal furnace, which is used for processing galvannealed steel sheets, is typically composed of the induction heating section, holding section and fog cooling section. This paper describes the structural characteristics of each component of the galvanneal furnace, and analyzed temperature control methods of the galvanneal furnace that are important for the successful production of high-strength GA steel sheets for automotive applications. Time Monday, Aug 31 4:00PM - 4:30PM Location 24 Speakers Wang Lu Baosteel-NSC Automotive Steel Sheets Co. Ltd. Influence of Mold Powder Slag Composition on the Formation of Oxide Particles in Steel Junya Ito, Shinagawa Refractories Co. Ltd.; Yukimasa Iwamoto, Shinagawa Refractories Co. Ltd.; Jim Gilmore, Shinagawa Advanced Materials Americas Inc.; Masanori Okada, Shinagawa Advanced Materials Americas Inc. show more Description In this study, diffusion of oxygen from molten mold powder slag into the cast steel surface was investigated experimentally to verify the oxide particle formation in the surface layer of the steel, which is expected to cause defects in the casting process. Small rectangular steel rods were submerged into various molten powder slags followed by microstructure observations of the interfacial area. As a result, formation of micron radius spherical particles composed of Si, Mn and O, and also the influence of the slag composition on the oxide particle formation, were confirmed. Time Monday, Aug 31 4:00PM - 4:30PM Location 3 Speakers Junya Ito Shinagawa Refractories Co. Ltd. Yukimasa Iwamoto Shinagawa Refractories Co. Ltd. Jim Gilmore Shinagawa Advanced Materials Americas Inc. Masanori Okada Shinagawa Advanced Materials Americas Inc. Inspection of Hot-Rolled Heavy Plate by 3D Inspection Dominik Recker, ISRA Parsytec GmbH; Greg Gutmann, ISRA VISION Parsytec Inc. show more Description Superior surface quality is of high importance for every steel manufacturing process step. The optical 2D inspection of rolled steel surfaces is state of the art and well established today. However, during rolling of heavy plates, 2D inspection is very limited due to the heavy structure at the rolled surface. Defect depth is critical in grading plate. Inspection of the rolled surface by laser triangulation (3D) inspection offers fast and reliable detection and classification of surface defects, including depth, even during heavy plate rolling. Recent installations of the new 3D inspection system for heavy plate including results will be presented. Time Monday, Aug 31 4:00PM - 4:30PM Location 23 Speakers Dominik Recker ISRA Parsytec GmbH Greg Gutmann ISRA VISION Parsytec Inc. LaserBond Composite Carbide Steel Mill Rolls Thomas Schlaefer, LaserBond Ltd; Christiane Schulz, University of South Australia; Peter Mutty, LaserBond; Colin Hall, University of South Australia show more Description Applying extreme wear and high-temperature corrosion-resistant alloys to the working face of steel mill rolls dramatically extends service life, resulting in substantial reductions in maintenance costs and a friendlier alternative for environment. Steel mill rolls are subjected to aggressive operating conditions where a combination of factors including extreme temperatures, abrasion, fretting, water cooling and corrosion all combine to reduce service life. LaserBond Composite Carbide Rolls are an alternative to traditional steel mill rolls, offering benefits in industry where environmental awareness and downward cost pressures are a fact of everyday life. Time Monday, Aug 31 4:00PM - 4:30PM Location 19 Speakers Thomas Schlaefer LaserBond Ltd Christiane Schulz University of South Australia Peter Mutty LaserBond Colin Hall University of South Australia Maceral Separation and Its Use in Cokemaking Debjani Nag, Tata Steel Ltd.; Rashmi Singh, Tata Steel Ltd.; P S Dash, Tata Steel Ltd. show more Description Coking potential of coal significantly depends on the maceral composition of coal. Macerals in coal are of different types: reactive and inert. These macerals differ in their physical and chemical properties. Different methodology has been used to separate the reactive macerals in a non-coking coal. The enriched coal is characterized in order to understand the change in coking potential by different techniques. It is then used in the making of metallurgical coke by proper blend design with other coals. Enriched coal enhances the properties of metallurgical coke. This shows a path of utilization of non-coking coal in metallurgical cokemaking. Time Monday, Aug 31 4:00PM - 4:30PM Location 25B Speakers Debjani Nag Tata Steel Ltd. Rashmi Singh Tata Steel Ltd. P S Dash Tata Steel Ltd. Neural Networks on Predicting Non-Linear Material Properties Joshua Todd, Nucor Corp. show more Description For predicting material properties, such as yield strength, simple models fit a characteristic set of data using linear regression. Complex models account for metallurgy, requiring a thorough understanding to produce new models. Inaccuracy and difficulty face each method, respectively. A method of extracting product data and constructing neural networks to reliably predict arbitrary measurable properties was developed by studying a niobium grade of sheet steel. A high-level interface expanded its application to a range of products, allowing predictions of yield strength to a standard deviation of ±1 ksi for single-grade and ±2.5 ksi for multiple-grade models. Time Monday, Aug 31 4:00PM - 4:30PM Location 14 Speakers Joshua Todd Nucor Corp. Overcurrent Protection, Short-Circuit Current Ratings and the New UL Standard for VFDs: What You Need to Know Nikunj Shah, Siemens Industry Inc. show more Description This presentation discusses different types of overcurrent protective devices (OCPD), their behavior in circuit protection and differences among them. It provides thorough understanding of requirements of motor branch circuit protection according to different codes/standards for industrial control panels and variable frequency drives (VFDs). Short-circuit current ratings (SCCR) are defined and their determination in a system is discussed. Proper OCPD sizing to obtain a desired SCCR in compliance with UL/NEC/IEC requirements is also reviewed. As a bonus, the new UL standard UL61800-5-1 for VFDs is discussed, as well as its differences from UL508C and the benefits users experience under the new standard. Time Monday, Aug 31 4:00PM - 4:30PM Location 15 Speakers Nikunj Shah Siemens Industry Inc. Q-SYM² and Q-ASC: ABS Scrap Yard Management, Assisted Scrap Classification and Digital Integration Into the Steel Process Luca Argiolas, Danieli & Officine Meccaniche S.p.A.; Lorenzo Bacchetti, Danieli show more Description After one year of automatic scrap management, feedback from the scrap yard manager and process data comparison are presented. Q-SYM² is Danieli's technology for automated scrap yard management. It ensures the reliability of the data, such as scrap inventory, entry and exit volume inventory, bucket charging recipes, scrap bucket stratification, and complete scrap tracking, from the truck to the electric arc furnace (EAF). A complete scrap receipt, containing per each scrap layer the scrap automatic classification, weight, volume, density, position in the bucket, is handed over to EAF furnace control system for cost reduction during melting and optimized receipt management. Time Monday, Aug 31 4:00PM - 4:30PM Location 6 Speakers Luca Argiolas Danieli & Officine Meccaniche S.p.A. Lorenzo Bacchetti Danieli Role of Cooling Rate on the Substructure of Eutectic M7C3 Carbides in Hypereutectoid Fe-Cr-C Alloy 8Cr13MoV Jie Zhang, University of Science & Technology Beijing; Jing Li, University of Science & Technology Beijing; Wei Yan, University of Science & Technology Beijing; Chengbin Shi, University of Science & Technology Beijing; Yindong Yang, University of Toronto show more Description The control of primary M7C3 carbides is significant for improving the performance of hypoeutectic Fe-Cr-C alloy. In this paper, the growth mechanism of primary M7C3 carbides and the effect of cooling rate on primary M7C3 carbides in 8Cr13MoV were ascertained by electron backscatter diffraction and scanning electron microscopy. The results showed that the morphology of primary M7C3 carbides was multiple granular instead of overall blocky. Increasing the cooling rate enabled refining the size of carbide grains, changing the morphology of carbide grains and promoting the generation of eutectic carbides, despite not changing the agglomeration and coalescence behaviors of carbide grains. Time Monday, Aug 31 4:00PM - 4:30PM Location 25A Speakers Jie Zhang University of Science & Technology Beijing Jing Li University of Science & Technology Beijing Wei Yan University of Science & Technology Beijing Chengbin Shi University of Science & Technology Beijing Yindong Yang University of Toronto Study on the Application of FEA in BF Crude Gas Piping Design Daji Zou, CISDI Engineering Co. Ltd.; Ze Yang, CISDI Engineering Co. Ltd.; Zhongping Zou, CISDI Engineering Co. Ltd.; Le Qi, CISDI Engineering Co. Ltd. show more Description This paper shows the importance of finite element analysis (FEA) for optimization of the blast furnace crude gas piping design, taking an example of a blast furnace’s engineering. It reveals the position and level of stress concentration in the piping system and how to decrease the stress level effectively by FEA. It proposes optimized piping parameters to create a natural compensation on the piping system and to control the deformation of different sections of piping and the stress level within an appropriate range. As a result, the piping system can be ensured to work safely and reliably. The optimized design has been proved by the operational blast furnace. Time Monday, Aug 31 4:00PM - 4:30PM Location 21 Speakers Daji Zou CISDI Engineering Co. Ltd. Ze Yang CISDI Engineering Co. Ltd. Zhongping Zou CISDI Engineering Co. Ltd. Le Qi CISDI Engineering Co. Ltd. Study on the Effect of Compound Additives on Sinter Quality Li Xin, North China University of Science and Technology; Hongwei Li, North China University of Science and Technology; Liu Ran, North China University of Science and Technology; Hongyang Li, North China University of Science and Technology; Xiaojie Liu, North China University of Science and Technology; Liu Song, North China University of Science and Technology show more Description On the basis of adding 12 kinds of additives to sinter, the influence of additives on sinter quality was analyzed. Five kinds of additives (B2O3, CaCl2, NaCl, NaNO3, CaCl2) with the best indexes were selected as composite additives. Sintering tests were carried out according to different proportions, and some metallurgical properties were tested. It was concluded that the sintering scheme with the proportions of B2O3 (30%), NaCl (15%) and NaNO3 (9%), CaCl2 (46%) could improve the sinter quality and metallurgical properties. Time Monday, Aug 31 4:00PM - 4:30PM Location 26A Speakers Li Xin North China University of Science and Technology Hongwei Li North China University of Science and Technology Liu Ran North China University of Science and Technology Hongyang Li North China University of Science and Technology Xiaojie Liu North China University of Science and Technology Liu Song North China University of Science and Technology The Characteristics of Sulfur in Blast Furnace Gas and Desulfurization Technology Jian Xie, CISDI R&D Co. Ltd.; Jingchuan Wu, CISDI R&D Co. Ltd. show more Description As one of the most important secondary energy sources for iron and steel enterprises, blast furnace gas (BFG) has the broadest application in the whole process of iron and steel smelting. The problem of sulfur pollution in BFG has gradually been recognized in recent years. In this paper, the sources and behaviors of sulfur in BFG have been analyzed, and the technical solutions for BFG desulfurization and related experimental results are also explained. With this technology, the sulfur dioxide emissions from blast furnace smelting process are expected to be reduced by 100 to 400 g/t Fe. It is of great significance for realizing green ironmaking. Time Monday, Aug 31 4:00PM - 4:30PM Location 11 Speakers Jian Xie CISDI R&D Co. Ltd. Jingchuan Wu CISDI R&D Co. Ltd. Welding of High-Strength Steel Grades With X-Pro® Laser Welder in Continuous Strip Processing Lines Jens Szonn, SMS group GmbH; Christian Dornscheidt, SMS group GmbH; Jens Artel, SMS group GmbH; Caesar Sasse, SMS group GmbH show more Description In the entry section of continuous strip processing lines, strips of different characteristics need to be connected. Especially modern third-generation advanced high-strength steel grades are often difficult to weld. The X-Pro® laser welder by SMS group allows welding of these materials. This paper presents the benefits of the X-Pro laser welder, e.g., the patented inductive heating system, the automatic weld parameter calculation and the quality assurance system. Furthermore, the application of a modern solid-state laser source instead of a conventional carbon dioxide source will be shown, as well as the suitability of the compact design for revamps. Time Monday, Aug 31 4:00PM - 4:30PM Location 22 Speakers Jens Szonn SMS group GmbH Christian Dornscheidt SMS group GmbH Jens Artel SMS group GmbH Caesar Sasse SMS group GmbH
4:30pm AI Application to Melting Temperature Prediction in an Electric Arc Furnace Marcelo Saparrat, TECNOAP; Fernando Monti, Ternium Mexico; José Ibarra, Ternium Mexico show more Description In an electric arc furnace, high temperatures and the presence of slag covering the molten steel prevent having an on-line continuous temperature measurement system: only few measurements at the end of melting are performed using a robot equipped with a thermocouple. This represents a challenge that can be addressed using mathematical models in combination with machine learning techniques to predict temperature of the molten steel using process variables that can be measured. An artificial intelligence-based bath temperature prediction model will be presented that takes into account the underlying physical complexities driving the melting process. Time Monday, Aug 31 4:30PM - 5:00PM Location 6 Speakers Marcelo Saparrat TECNOAP Fernando Monti Ternium Mexico José Ibarra Ternium Mexico Application of Soft Reduction to Improve Internal Quality of Fine-Punched Steel Zhiping Chen, Central Research Institute, Baosteel Iron & Steel Co. Ltd.; Chenhui Wu, Northeastern University; Nailiang Cheng, Central Research Institute, Baosteel Iron & Steel Co. Ltd.; Cheng Ji, Northeastern University; Miaoyong Zhu, Northeastern University show more Description The band structure of fine-punched plate is the main factor of punching performance, which is closely related to the internal quality of the slab, especially the central segregation. According to the Mannesmann standard, it is stable and controllable below the segregation of 2.2. However, the original slab segregation coincidence rate ≤2.2 was only 13%. For typical grades, the soft reduction and secondary cooling control were focused. After several rounds of tests, significant results have been achieved. The typical steel grades have a low to 2.2 compliance rate of more than 80%, and the hot-rolled strip band structure rating has also been significantly improved. Time Monday, Aug 31 4:30PM - 5:00PM Location 1 Speakers Zhiping Chen Central Research Institute, Baosteel Iron & Steel Co. Ltd. Chenhui Wu Northeastern University Nailiang Cheng Central Research Institute, Baosteel Iron & Steel Co. Ltd. Cheng Ji Northeastern University Miaoyong Zhu Northeastern University Artificial Intelligence Services in Steel Production — On Premise and in the Cloud Sonja Strasser, Primetals Technologies Austria GmbH; Gerald Hohenbichler, Primetals Technologies Austria GmbH; Manuel Sattler, Primetals Technologies Austria GmbH; Petra Krahwinkler, Primetals Technologies Austria GmbH; Johann Reidetschlaeger, Primetals Technologies Austria GmbH show more Description Physics-based metallurgical models have been used for decades in the steel industry. Advanced methods of machine learning and data sciences allow combining the strength of pure data models and proven physics models and exploiting their benefits. Expert know-how in steel is being integrated with data science expertise to provide the next level of digital services for the metals industry. This paper focuses on practical examples how to use artificial intelligence in steel production to gain deeper insight, develop new control schemes, find root causes, improve deviation forecasting, and to optimize operations, quality results and predictive maintenance. Time Monday, Aug 31 4:30PM - 5:00PM Location 13 Speakers Sonja Strasser Primetals Technologies Austria GmbH Gerald Hohenbichler Primetals Technologies Austria GmbH Manuel Sattler Primetals Technologies Austria GmbH Petra Krahwinkler Primetals Technologies Austria GmbH Johann Reidetschlaeger Primetals Technologies Austria GmbH CAE Simulation and Study on Revamping Dust Catcher for Blast Furnace Tian Hui, CISDI Engineering Co. Ltd.; Zhongping Zou, CISDI Engineering Co. Ltd.; Yu Zhong, CISDI Chongqing Information Technology Co. Ltd.; Xu Can, CISDI Engineering Co. Ltd.; Yu Donglong, CISDI Engineering Co., Ltd. show more Description This paper analyzes a blast furnace’s revamp process for the gravity dust catcher with introduction of the cyclone dust removal principle. Computational fluid dynamics is adopted for simulation calculations of the entire flow field and solid particle movement. It studies the influential law of different velocities, cyclone plate quantities and dimensions on the separation efficiency and on the gas flow track’s distribution. The simulation gets to the optimized structural parameters of the dust catcher. The revamped dust catcher has seen a great improvement of the dust removal efficiency and a remarkable reduction of investment cost and less rebuild work. The revamp expertise for the primary dedusting system can relieve the dust loads on the secondary gas cleaning system of the blast furnace. Time Monday, Aug 31 4:30PM - 5:00PM Location 11 Speakers Tian Hui CISDI Engineering Co. Ltd. Zhongping Zou CISDI Engineering Co. Ltd. Yu Zhong CISDI Chongqing Information Technology Co. Ltd. Xu Can CISDI Engineering Co. Ltd. Yu Donglong CISDI Engineering Co., Ltd. Effect of Surface Roughness of MgO on Dissolution Behavior Into Slag Cheol Min Yoon, Yonsei University; Dong Joon Min, Yonsei University show more Description MgO is a principal constituent of refractories in the steelmaking process, so to minimize the corrosion of MgO into slag, numerous previous studies about the dissolution behavior of the MgO have been reported to understand the corrosion of refractories. Nevertheless, in present study, the dissolution reaction between high-alumina-content slag and MgO is observed, and the MgAl2O4 spinel growth according to the surface roughness of MgO is evaluated. Through these results, the rate constant and activation energies of the MgO dissolution and the spinel growth rate according to surface properties of the MgO can be obtained. Time Monday, Aug 31 4:30PM - 5:00PM Location 3 Speakers Cheol Min Yoon Yonsei University Dong Joon Min Yonsei University Effects of Interaction of CO2, H2O and K on Coke Thermal Strength Hongwei Li, North China University of Science and Technology; Li Xin, North China University of Science and Technology; Liu Ran, North China University of Science and Technology; Hongyang Li, North China University of Science and Technology; Shuhui Zhang, North China University of Science and Technology; Lyu Qing, North China University of Science and Technology show more Description The test studies the effects of the interaction of CO2 H2O and K on coke thermal strength at different temperatures and different conditions in the high-temperature zone of a blast furnace. The results show that temperature has a great effect on the deterioration of coke. The weight loss of coke is the highest in N2+CO+CO2+H2O+K atmosphere at the same temperature. K has a certain influence on the thermal strength of coke. The simultaneous effect of CO2 and H2 is stronger than that of CO2 or H2 alone. The interaction in CO2+H2+K atmosphere promotes the reaction with coke, resulting in the worst coke strength. Time Monday, Aug 31 4:30PM - 5:00PM Location 25B Speakers Hongwei Li North China University of Science and Technology Li Xin North China University of Science and Technology Liu Ran North China University of Science and Technology Hongyang Li North China University of Science and Technology Shuhui Zhang North China University of Science and Technology Lyu Qing North China University of Science and Technology In-situ densification of iron oxide dust during iron ore sintering Deepak Sahu, CSIR-IMMT; N. B. Ballal, Indian Institute of Technology – Bombay; Tushar Mamodia, Indian Institute of Technology – Bombay; Somnath Basu, Indian Institute of Technology – Bombay show more Description The variation in sinter quality across the height during sintering of iron ore is typically attributed to the higher rate of heat loss from the top layer and slower cooling rate towards the bottom. However, recent experiments carried out using a pot sintering apparatus indicate a systematic migration of moisture as well as fine dust particles from top to the bottom layer during the process. Re-condensation of moisture and accumulation of dust particles caused formation of a dense layer below the combustion zone. Layers with higher concentration of accumulated dust also showed better shatter strength after sintering. Time Monday, Aug 31 4:30PM - 5:00PM Location 26A Speakers Deepak Sahu CSIR-IMMT N. B. Ballal Indian Institute of Technology – Bombay Tushar Mamodia Indian Institute of Technology – Bombay Somnath Basu Indian Institute of Technology – Bombay Integrated Overall Quality Management Joachim Gnauk, PSI Metals; Vladimir Berenzon, PSI Metals; Jörg Hackmann, PSI Metals; Kai Huang, PSI Metals; Xiao Qiang Liu, PSI Metals show more Description Traditional quality management systems (QMS) regard local processes and often act on level 2 automation systems. A novel type of integrated QMS was developed as part of, and fully integrated in, an existing and continuously developing L3 production management system. In contrast to former software products, the high integration allows not only the standard functionality of conventional QM installations but also a transparent elaboration of quality targets and indicators, as well as traceability and control of intermediate and final quality decisions. This paper explains the mode of operation and internal structures and references a large Asian steel producer case study. Time Monday, Aug 31 4:30PM - 5:00PM Location 14 Speakers Joachim Gnauk PSI Metals Vladimir Berenzon PSI Metals Jörg Hackmann PSI Metals Kai Huang PSI Metals Xiao Qiang Liu PSI Metals Lubrication Fundamentals for Rolling Element Bearings Brian Ray, The Timken Co.; Cory Langhoff, The Timken Co. show more Description This presentation introduces lubrication fundamentals for rolling elements bearings. The target audience are people new to industry or anyone wanting to refresh their knowledge on lubrication basics. Topics covered will include the main functions of a lubricant, how lubrication impacts bearing performance and guidance on how to select the proper lubricant for general industrial applications. The key characteristics of a lubricant will first be established, covering both oil and grease. Then suggestions will be provided on the proper lubricant selection and the best means for lubricant delivery to rolling element bearings with an emphasis on grease. Time Monday, Aug 31 4:30PM - 5:00PM Location 19 Speakers Brian Ray The Timken Co. Cory Langhoff The Timken Co. Major Challenges and Strategies for Blast Furnace Operation in Higher PCI at Slag Rate Mohanraj N, JSW Steel Ltd.; Lokendraraj Singh, JSW Steel Ltd.; Naveen Singh, JSW Steel Ltd.; Srinivas Rao, JSW Steel Ltd.; Dasu AVRP, JSW Steel Ltd. show more Description A study revealed that slag rate is the most important limiting factor for increasing the pulverized coal injection (PCI) rate in the blast furnace. There is no global reference of large blast furnaces (UV >4,000 cum m) operating with high PCI rate (>200 kg/thm) at high slag rate (~400 kg/thm). Since JSW BFs operate with a high slag rate of ~400 kg/thm, increasing the PCI rate from ~150 kg/thm to beyond 200 kg/thm was a major challenge. This paper explains the challenges and strategies for the ramp up of PCI rate >180 kg/thm from 150 kg/thm at 400 kg/thm slag rate for a medium to large BF. Time Monday, Aug 31 4:30PM - 5:00PM Location 25C Speakers Mohanraj N JSW Steel Ltd. Lokendraraj Singh JSW Steel Ltd. Naveen Singh JSW Steel Ltd. Srinivas Rao JSW Steel Ltd. Dasu AVRP JSW Steel Ltd. New NOF and Post Zinc Pot Cooler for Automobile Sheet Galvanizing Line Revamp Baisong Yang, Chongqing CISDI Thermal & Environmental Engineering Co. Ltd.; Guoqiang Zhang, Cold Strip Work Angang Steel Co. Ltd.; Junyou Liu, Cold Strip Work Angang Steel Co. Ltd. show more Description High-temperature aluminum silicate fiber block can provide a long-life and stable solution for furnace insulation, with extended overhaul period for 2 to 4 times, resolving the problem of frequent furnace breakdown for maintenance. Optimized combustion control system for galvanizing line breakdown, combined with afterburners located in fume duct outside the furnace, can precisely control furnace O2 contents, realize lower furnace temperature, keep positive pressure in the furnace and purge H2 inside the furnace within a safe time frame. Zinc pot tower cooling rollers and anti-fingerprint cooling rollers are designed with interlayer water cooling with high efficiency, which can eliminate zinc residue damage to the cooling roller surface. Time Monday, Aug 31 4:30PM - 5:00PM Location 24 Speakers Baisong Yang Chongqing CISDI Thermal & Environmental Engineering Co. Ltd.