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Monday, May 16
8:00am Modern Tools for Steelmaking Research and Optimization P. Chris Pistorius, Carnegie Mellon University show more Description Modern steelmaking is a highly competitive, data-rich industry, supported by deep fundamental data on process thermodynamics and kinetics. In my view, the role of steelmaking research is to support steelmaking process metallurgy, to identify gaps in our knowledge, and to fill those gaps. In this presentation, I shall highlight some such examples from my own research in steel refining. Kinetic modeling of steel-slag-refractory-inclusion reactions has been successful in predicting the changes in steel and inclusion compositions during ladle refining. In contrast with the kinetic models using a few mass transfer coefficients, detailed flow modeling is needed to understand the interaction between argon bubbles, steel and slag. These models remain incomplete, because of at best partial quantification of turbulent flow and the large range of length scales. As a final example, combining tools for data visualization and analysis with metallurgical fundamentals can provide clear answers on the quantitative effect of process variables. The common thread of these examples is that all combine metallurgical fundamentals with modern tools of calculation, microscopy, and data analysis, to quantify steelmaking. Time Monday, May 16 8:00AM - 9:00AM Location Spirit of Pittsburgh Ballroom Speakers P. Chris Pistorius Carnegie Mellon University
9:30am A New “All-in-One” Acid Regeneration Plant Dedicated to Small-Scale HCl Waste Streams Andreas Zoellner, John Cockerill; Jörg Bollmann, John Cockerill show more Description While acid regeneration systems for bigger pickling installations are state of the art in the steel industry, small-capacity waste acid streams are generally not regenerated due to economic reasons. John Cockerill has developed SARA® to address precisely this environmentally unacceptable situation. The fluidized bed ARP SARA offers a modular design that guarantees its clients the optimal solution for all their individual process requirements. With an acid recovery rate of up to 99%, SARA is closing the loop on acid regeneration also for installations with volumes between 10 and 30 m³ per day and reaches HCl and dust emission values under 10 mg/Nm³. Time Monday, May 16 9:30AM - 10:00AM Location 320 Speakers Andreas Zoellner John Cockerill Jörg Bollmann John Cockerill An Examination of the Underlying Physics and Mechanics of Herringbone and Diagonal/Cross-Buckle Flatness Distortions Mark E. Zipf, SMS group Inc. show more Description Herringbone and diagonal/cross-buckle flatness distortions form when a region of near flat (or lightly center-buckled) strip is subjected to planar shearing, which forms an angled compressive stress that exceeds the local buckling threshold. The shearing stems from mechanical misalignment, straightening of cambered strip or specific asymmetries in the shape actuation. The manifest buckling forms as a highly ordered, self-assembling checkerboard pattern (i.e., orthogonal buckling modes) that achieves a minimum energy equilibrium. This paper examines the underlying physics of this class of flatness defect, along with what rolling techniques, mill setups and actuation strategies provide a means of resolution. Time Monday, May 16 9:30AM - 10:00AM Location 307 Speakers Mark E. Zipf SMS group Inc. Collection Main Pressure Control Preventive Maintenance Mark Ferra, REXA Inc. show more Description The best alarm is one that isn’t needed thanks to predictive maintenance. During normal operation, the crossover valve becomes coated in tar entrained from the coke oven gases, increasing the required torque to turn the valve. Left unchecked, the tar builds up with the potential to damage the valve and cause unnecessary downtime. REXA electro-hydraulic actuators enabled the end user to use predictive maintenance to alert the control room when the actuator exceeds normal torque output. Valve cleaning can be scheduled. Actuator unscheduled shutdowns due to tar buildup are eliminated with improved positioning accuracy compared to the replaced actuator. Time Monday, May 16 9:30AM - 10:00AM Location 319 Speakers Mark Ferra REXA Inc. Danieli's Technological Solutions on Wirerod: A Winning Combination to Enhance Rolling Speed, Stability and Tolerance Jozi Shuli, Danieli & C. Officine Meccaniche S.p.A.; Federico Tortul, Danieli & C. Officine Meccaniche S.p.A. show more Description The last few years have seen the consolidation of the endless casting and rolling process in the field of construction steels, which has led Danieli to consider new grades, especially wire rod. The endless configuration enhances the rolling quality and tolerance stability at very high speed for extra-small-size wire rod. Given the illustrated benefits plus those related to the continuous process, more and more customers are asking for MIDA plants. Recently Danieli reached an agreement with the Bashundhara Group for the first plant worldwide which will produce low- and high-carbon smooth wire rod. Time Monday, May 16 9:30AM - 10:00AM Location 401 Speakers Jozi Shuli Danieli & C. Officine Meccaniche S.p.A. Federico Tortul Danieli & C. Officine Meccaniche S.p.A. Decarbonization at Nucor Steel Seattle Inc. Using Tallman Supersonic Carbon Injectors Aaron Strelbisky, Tallman Technologies Inc. ; Michael Strelbisky, Tallman Technologies Inc. ; Kelly Kurisu, Nucor Steel Seattle show more Description While electric arc furnaces (EAFs) have an advantage in decarbonization based on their scrap charges, direct sources of carbon use still represent a significant opportunity for improvement and reduction of greenhouse gas emissions. Nucor Steel Seattle has installed/commissioned the Tallman Supersonic Carbon Injection system (TSCi™) for use in their EAF. TSCi is an injection system with the primary aim of improving injection carbon delivery by increasing material delivery efficiency using supersonic methods. Results from the installation and commissioning of TSCi at Nucor Steel Seattle and optimization efforts will be reported. Time Monday, May 16 9:30AM - 10:00AM Location 406 Speakers Aaron Strelbisky Tallman Technologies Inc. Michael Strelbisky Tallman Technologies Inc. Kelly Kurisu Nucor Steel Seattle Decarbonizing the Steelmaking Industry Through Gas-Based Direct Reduction Jorge Martinez, Tenova HYL show more Description For the decarbonization of the steelmaking industry, there are two main routes. One consists of the progressive conversion of the blast furnace (BF)-basic oxygen furnace (BOF) to direct reduced iron (DRI)-electric arc furnace (EAF) facilities. The second alternative is the production of hot metal (HM) by installing a gas-based direct reduction plant feeding DRI to an open-slag bath furnace (DRI-OSBF). This allows the integrated mill steelmaker to optimize investment costs by keeping its downstream facilities in operation while replacing only the BF ironmaking installation. For either route, the reduction of CO2 emissions can be further enhanced by the partial use of hydrogen (H2) for DRI production. Time Monday, May 16 9:30AM - 10:00AM Location 308 Speakers Jorge Martinez Tenova HYL Digital Transformation in Action: Customer Use Case Len Kosatka, Rockwell Automation show more Description Metals companies around the global are taking on digital initiatives to improve competitiveness. This presentation will share the strategic road map Rockwell Automation developed with an industry leader in aluminum and copper manufacturing to improve data quality, worker productivity, equipment reliability, safety and the cost of conversion. Critical success factors and the company’s plan for making these big changes during a global pandemic will also be discussed. Time Monday, May 16 9:30AM - 10:00AM Location 315 Speakers Len Kosatka Rockwell Automation Experience With Operation and Maintenance of the Spray-Cooled EAF Roof at Ovako Hofors Scott Ferguson, Systems Spray-Cooled; Louis Valentas, Systems Spray-Cooled; Markus Abel, tripleS GbR show more Description In order to increase the availability and safety of its 100 mton electric arc furnace (EAF), the Swedish steel producer Ovako Hofors decided to replace its tubular water-cooled EAF roof with a spray-cooled roof. The EAF roof and the auxiliary equipment were successfully installed and commissioned in 2018. The spray-cooled technology has now been in operation for four years. The first rebuild of the hot-face was completed during the spring of 2021. The paper will both describe the project, but also the Ovako Hofors experience coming from the operation and maintenance of the equipment during the last 4 years of being in service. Time Monday, May 16 9:30AM - 10:00AM Location 403 Speakers Scott Ferguson Systems Spray-Cooled Louis Valentas Systems Spray-Cooled Markus Abel tripleS GbR Improving Combustion Heating Energy and Emissions via Retrofit Ceramic Inserts Bradley Nakanishi, Saint-Gobain; Thomas Briselden, Saint-Gobain; Pierre Gougeon, Saint-Gobain Research Paris; Catherine Goulas, Saint-Gobain Research Paris; Christophe Kulej, Saint-Gobain Research Paris show more Description Steel reheating in, for example, continuous annealing lines often relies on radiant tube combustion. This paper will review the benefits of retrofit ceramic technologies and their application to industrial radiant tube heating. Such technologies reduce energy consumption and CO2 emissions by up to 30% while substantially lowering NOx emissions versus conventional installations. Modern retrofit ceramic devices feature twisted tapes, twisted channels and other designs tailored to enhance combustion. Through illustrative case studies, the paper will summarize how advanced combustion modeling combined with industrial ceramic forming technologies provide high-performance solutions for managing flame efficiency and emissions. Time Monday, May 16 9:30AM - 10:00AM Location 402 Speakers Bradley Nakanishi Saint-Gobain Thomas Briselden Saint-Gobain Pierre Gougeon Saint-Gobain Research Paris Catherine Goulas Saint-Gobain Research Paris Christophe Kulej Saint-Gobain Research Paris Improving Metallurgical Vessels Efficiency Using Coating Technology Angelo Cristante, Reno Refractories Inc.; Manoj Kumar Mahapatra, University of Alabama at Birmingham; James Mark Frost, Reno Refractories, Inc. show more Description Coating technology can reduce corrosion wear and improve the metallurgical production process and safety. The corrosion resistance of blast furnace trough refractories against slag and pig iron was compared between coated and non-coated refractory samples. The refractories were coated either with SiC or carbon coating products. In addition, two steel samples, one with coating and another without were fired to decarburization temperature. Comparison analysis was carried using an optical camera, image analysis software, scanning electron microscopy-energy-dispersive x-ray spectroscopy, and x-ray diffraction. The coated refractories are expected to show higher corrosion resistance and lower slag adherence. Coated steel is expected to maintain its microstructural properties. Time Monday, May 16 9:30AM - 10:00AM Location 408 Speakers Angelo Cristante Reno Refractories Inc. Manoj Kumar Mahapatra University of Alabama at Birmingham James Mark Frost Reno Refractories, Inc. Industrial Policy and Partnership Viewpoints on the Effects of Decarbonization Rob Ivester, NIST Manufacturing Extension Partnership show more Description This paper presents industrial policy and partnership viewpoints on the effects of decarbonization. Time Monday, May 16 9:30AM - 10:00AM Location 407 Speakers Rob Ivester NIST Manufacturing Extension Partnership New Laminar Cooling Technology Enables Baosteel HSM 2050 to Produce New High-Quality Steel Grades and Formats Naoto Migakida, Primetals Technologies; Alois Seilinger, Primetals Technologies; Ye Wen, Primetals Technologies; Xiaozhen Yang, Baoshan Iron & Steel Co., Ltd. ; Jianfeng Wu, Baoshan Iron & Steel Co., Ltd. show more Description A strip cooling line revamp for Baoshan Iron & Steel’s (Baosteel) hot strip mill included a new laminar and turbo laminar cooling system. This enables Baosteel to extend its product range up to a thickness of 19 mm for high toughness line pipe grades at low temperature, and dual-phase and multi-phase steel grades in a thickness range of 2 to 8 mm. Despite the massive disruption of the COVID-19 pandemic, all equipment was delivered on time. Significant parts of the project were executed remotely, including advisory service. Because of this effort, the restart date moved 48 hours earlier than planned. Time Monday, May 16 9:30AM - 10:00AM Location 306 Speakers Naoto Migakida Primetals Technologies Alois Seilinger Primetals Technologies Ye Wen Primetals Technologies Xiaozhen Yang Baoshan Iron & Steel Co., Ltd. Jianfeng Wu Baoshan Iron & Steel Co., Ltd. Software for Dimensional and Wear Control of Lance Tip Face and Nozzles - WRL Breno Maia, Lumar Metals North America; Willian Lima, Lumar Metals North America; Thiago Pinto Wandekoken, Lumar Metals North America; Marco Antônio de Souza Leite Cuadros, GainTech; Gustavo Maia de Almeida, Instituto Federal do Espírito Santo; Caio Santos, GainTech; Paulo Vasconcellos Leal Silva, Instituto Federal do Espirito Santo; Hewerton Folli, Instituto Federal do Espirito Santo show more Description The lance tip and the nozzles contained in them are largely responsible for primary refining steels in basic oxygen furnaces. Over the lance life, they wear out. They demand inspections and an active look at their effects on metallurgical heat parameters and operational safety, avoiding water leaks. Based on image collection and analysis, the development of software called WRL is capable of carrying out current measurements of the lance tip face and nozzles and determining the main dimensions variations, evaluating the wear severity. Inspection times of lance currently in hours are now minutes and with greater precision and speed in interpreting information. Time Monday, May 16 9:30AM - 10:00AM Location 318 Speakers Breno Maia Lumar Metals North America Willian Lima Lumar Metals North America Thiago Pinto Wandekoken Lumar Metals North America Marco Antônio de Souza Leite Cuadros GainTech Gustavo Maia de Almeida Instituto Federal do Espírito Santo Caio Santos GainTech Paulo Vasconcellos Leal Silva Instituto Federal do Espirito Santo Hewerton Folli Instituto Federal do Espirito Santo Studying Characteristics of the Passivation Film Developed Under Load in Salt Solution for High-Manganese TRIP (Fe39Mn20Co20Cr15Si5Al) Alloy Pranshul Varshney, University of Alabama; Nilesh Kumar, University of Alabama show more Description The nature of passivation film developed on metallic materials surface governs the corrosion and stress corrosion cracking behavior in electrochemical environments. In this work, the characteristics of passivation film developed under stress have been evaluated for high-manganese transformation-induced plasticity (TRIP) Fe39Mn20Co20Cr15Si5Al1 (at.%) alloy. The passivation film was developed by subjecting the dogbone-shaped tensile specimen to uniaxial tension in 3.5 wt.% NaCl solution at room temperature followed by electrochemical impedance spectroscopy and x-ray photoelectron spectroscopy to assess the film characteristics. In this presentation, a relative comparison will be made between the films developed under the load and no-load conditions. Time Monday, May 16 9:30AM - 10:00AM Location 310 Speakers Pranshul Varshney University of Alabama Nilesh Kumar University of Alabama Wear-Resistant Copper Staves — An Update Edward Long, Primetals Technologies; Dave Osborne, Primetals Technologies; Colin Morrison, Primetals Technologies show more Description Since the installation of the first wear-resistant staves in February 2013, Primetals Technologies continues to develop and monitor its wear prevention solutions for copper staves. There are currently three sites globally featuring installation of the latest wear resistance designs. Operational data demonstrates that the inserts remain in place with no apparent wear developing. Reduced heat losses from the blast furnace to the cooling system has also been observed, delivering an additional, potential fuel-saving benefit. This paper will describe the new stave features and how the innovative, class-leading design has been developed to overcome commonly experienced stave issues. Time Monday, May 16 9:30AM - 10:00AM Location 317 Speakers Edward Long Primetals Technologies Dave Osborne Primetals Technologies Colin Morrison Primetals Technologies
10:00am Advanced Analytics in Steelmaking Marek Lukacin, U. S. Steel Kosice; Juraj Sabol, U. S. Steel Kosice; Robert Vandlik, U. S. Steel Kosice show more Description Thanks to advancing computing power and storage technology, industrial companies are integrating artificial intelligence (AI) into their processes. USSK has started to experiment with such models in 2017 and its goal is to aid human decision and standardize practices through usage of AI-based models. USSK's steelmaking is a case in point with a suite of models developed in-house spanning desulfurization of hot metal, scrap blending, endpoint prediction and alloys usage in secondary metallurgy. This presentation will show both technical aspects of such data transformation as well as softer elements such as change management. Time Monday, May 16 10:00AM - 10:30AM Location 318 Speakers Marek Lukacin U. S. Steel Kosice Juraj Sabol U. S. Steel Kosice Robert Vandlik U. S. Steel Kosice Burns Harbor Stove Repairs Using Monolithic Materials Jesse Carreau, Allied Mineral Technical Services LLC; Bob Byerman, Cleveland-Cliffs Burns Harbor; B. Eschbach, Cleveland-Cliffs Burns Harbor; B. Hansen, Allied Mineral Technical Services, LLC; F. van Laar, Allied Mineral Technical Services, LLC show more Description The failure of refractory systems in a fast-paced industry creates demand for reliable repairs that offer the shortest timeline. Therefore, innovative solutions must improve the refractory design and installation methods to repair older, traditional refractory systems promptly. An alternative design with monolithic materials was successfully implemented at Burns Harbor in 2020 and 2021 in hot blast stoves D1 and D3. The C4 stove at Burns Harbor is currently under repair by various in-place castable pours forming the combustion chamber walls and dome. A post-construction analysis will demonstrate the validity and feasibility of the design. Time Monday, May 16 10:00AM - 10:30AM Location 408 Speakers Jesse Carreau Allied Mineral Technical Services LLC Bob Byerman Cleveland-Cliffs Burns Harbor B. Eschbach Cleveland-Cliffs Burns Harbor B. Hansen Allied Mineral Technical Services, LLC F. van Laar Allied Mineral Technical Services, LLC Coke Oven Machines Fit for the Next Decade Wolfgang Kern, SMS group Inc. show more Description In the next decade, coke oven plants will continue to face various organizational and technical challenges. Increasing political pressure, new laws, and restrictions concerning the environment, health and safety in workplaces as well as CAPEX budgets and lifetimes of existing coke oven batteries and machines are growing challenges and concerns for cokemakers worldwide. The presentation will give an insight into the solutions Paul Wurth is implementing to face these challenges, for example by the use of new technologies, but also by the constant search for new methodologies in the design and supply of coke oven machines and related equipment. Time Monday, May 16 10:00AM - 10:30AM Location 319 Speakers Wolfgang Kern SMS group Inc. Danieli’s Leveler: The Latest Generation for Extended Capability Range Enrico Zambon, Danieli Germany GmbH; Marco Mossutti, Danieli Automation S.p.A.; Alexander Meyer, Danieli Germany GmbH; Enrico Crisa, Danieli & C. Officine Meccaniche S.p.A. show more Description Modern plate market requirements in terms of extended plate thickness and yield strength ranges represent a limitation for many steel producers to offer a top-quality flat plate due to insufficient capacity of their existing leveling machines. Looking to this technical challenge, Danieli developed its new leveler generation EVO/6, based on multi-cassette technology. Supported by technological packages such as the MULTIMOTOR™ and updated level 2 automation models, the EVO/6 is suitable for typical plate thickness of hot-rolled material ranging 3/16 inch to 3-4 inches, as well as heat-treated plates, delivering plate flatness within the most stringent ASTM and EN standards. Time Monday, May 16 10:00AM - 10:30AM Speakers Enrico Zambon Danieli Germany GmbH Marco Mossutti Danieli Automation S.p.A. Alexander Meyer Danieli Germany GmbH Enrico Crisa Danieli & C. Officine Meccaniche S.p.A. Direct Reduction: Dealing With an Uncertain Future Todd Astoria, Midrex Technologies Inc. show more Description The steel industry is being faced with exciting opportunities: New fuels, the mitigation of greenhouse gas emissions, new technologies, and new raw materials are all leading to discussions and ideas that would not have been possible even a few short years ago. Unfortunately, new opportunities also cause new uncertainties that can complicate decisions that have long investment timelines. The direct reduction of iron ore using the MIDREX® Process can help mitigate these uncertainties by providing unparalleled flexibility for raw materials, fuels and product offerings. Time Monday, May 16 10:00AM - 10:30AM Location 308 Speakers Todd Astoria Midrex Technologies Inc. Eliminating CO2, Energy and Quality Inefficiencies Through Application of AI Falk-Florian Henrich, PhD, Smart Steel Technologies GmbH; Michael Peintinger, Smart Steel Technologies GmbH show more Description The increasing pressure to address CO2, energy and quality inefficiencies can best be approached through innovative production routes and technologies such as artificial intelligence (AI) and machine learning. In this regard, only exact data will allow steelmakers to charge for their conversion efforts and to succeed in future audits. Hence, very precise AI-based models for the existing and future processing chains are mandatory, computing the exact energy input and CO2 output per product. Smart Steel Technologies’ approach shows proper state-of-the-art AI models for each process and across production processes and displays results of successful automated avoidance of inefficiencies across the whole value chain. Time Monday, May 16 10:00AM - 10:30AM Location 315 Speakers Falk-Florian Henrich, PhD Smart Steel Technologies GmbH Michael Peintinger Smart Steel Technologies GmbH Evaluating the Onset of Hot Tearing in High-Strength and Lightweight Steels Using Controlled Deformation Testing Simon Lekakh, Missouri University of Science and Technology; Ronald J. O'Malley, Missouri University of Science and Technology; Mario Buchely, Missouri University of Science and Technology; Laura Bartlett, Missouri University of Science and Technology; Soumava Chakraborty, Missouri University of Science and Technology; Katelyn Kiser, Missouri University of Science and Technology; Viraj Athavale, Missouri University of Science and Technology; Krista Limmer, DEVCOM Army Research Laboratory, U.S. Army Research Laboratory; Katherine Sebeck, DEVCOM Ground Vehicle Systems Center, U.S. Army Research Laboratory; Daniel Field, DEVCOM Army Research Laboratory, U.S. Army Research Laboratory show more Description The onset of hot tearing in X70, Cr-Ni-Mo and Fe-Mn-Al steels was evaluated using controlled deformation testing (CDT). The CDT device consisted of a cylindrical phenolic resin-bonded sand mold with an electrical cylinder that was computer controlled to apply a tensile force to the steel shell during solidification. Solidification structure and strain rates were controlled to mimic the continuous casting process. Sulfur prints and macroetching of the resulting castings were used to identify hot tearing and evaluate the solidification structure. Resulting hot tears and microsegregation were evaluated utilizing scanning electron microscopy and energy-dispersive x-ray spectroscopy. Time Monday, May 16 10:00AM - 10:30AM Location 316 Speakers Simon Lekakh Missouri University of Science and Technology Ronald J. O'Malley Missouri University of Science and Technology Mario Buchely Missouri University of Science and Technology Laura Bartlett Missouri University of Science and Technology Soumava Chakraborty Missouri University of Science and Technology Katelyn Kiser Missouri University of Science and Technology Viraj Athavale Missouri University of Science and Technology Krista Limmer DEVCOM Army Research Laboratory, U.S. Army Research Laboratory Katherine Sebeck DEVCOM Ground Vehicle Systems Center, U.S. Army Research Laboratory Daniel Field DEVCOM Army Research Laboratory, U.S. Army Research Laboratory Hydrogen-Based Annealing Technologies for High-Alloyed Steel Strips Open Various Market Segments Sascha Eppensteiner, EBNER Industrieofenbau GmbH show more Description High-alloyed flat products have various applications in different market segments. Depending on the application, different properties are required and therefore different heat treatment concepts are necessary to achieve the target in the most cost-efficient way. This paper reviews heat treatment applications of continuous bright annealing lines operating under pure hydrogen atmosphere. It will give an overview of challenges in the process and introduce use cases in different market segments, e.g., classical austenitic, ferritic, martensitic grades with a focus on highest productivity; precision strips with a focus on ultrathin gauges; and Ni-base alloys with a focus on highest peak metal temperatures. Time Monday, May 16 10:00AM - 10:30AM Location 310 Speakers Sascha Eppensteiner EBNER Industrieofenbau GmbH Improvement of Performances of Cold Heading Quality Wire Rod Produced by HBIS Chengsteel Works Antonello Di Salvo, DITH; Giuseppe Pratolongo, DITH; Antonio Mollo, DITH; Baohua Wang, HBIS Chengsteel show more Description The SWRCH22A 6.5-mm wire rod, delivered by HBIS Chengsteel, sometimes showed unsatisfactory performances in terms of productivity and rejection rate during the production of the hex-washer self-drilling screw. Extensive metallurgical investigations have been performed to identify the causes of surface defects and premature breakages during the cold drawing process. The work demonstrated that surface defects were associated with unsteady casting conditions while the poor cold drawability and premature breakages were induced by dynamic strain aging. This paper describes the investigations made and countermeasures that have been adopted to improve wire rod production for specific cold heading applications. Time Monday, May 16 10:00AM - 10:30AM Location 401 Speakers Antonello Di Salvo DITH Giuseppe Pratolongo DITH Antonio Mollo DITH Baohua Wang HBIS Chengsteel Linde’s Innovative Method to Improve Energy Efficiency in the EAF Valmiro Sa, Linde; Sumant Warty, Linde; Izaias Marques, Linde; Vitor Zanotelli, White Martins Gases Industriais S.A. ; Gustavo Pelisser, Gerdau S.A.; Joyce Vieira, Gerdau S.A. show more Description Steelmakers continue to strive for improvements in the use of chemical energy into electric arc furnaces (EAFs). Linde has developed an innovative method that provides real-time dynamic control in achieving effective energy optimization. Improved efficiency is derived, not only in burner melting phase, but also during refining. This technology can also be successfully deployed as a decarbonization strategy to improve energy utilization in EAFs. Industrial-scale demonstration to validate this state-of-the-art solution applied to EAF steelmaking is discussed. Operational efficiency and benefits achieved from this technology are presented. Time Monday, May 16 10:00AM - 10:30AM Location 406 Speakers Valmiro Sa Linde Sumant Warty Linde Izaias Marques Linde Vitor Zanotelli White Martins Gases Industriais S.A. Gustavo Pelisser Gerdau S.A. Joyce Vieira Gerdau S.A. Quality Optimization of Hot-Dip Galvanized Strip Using Model Predictive Control Berend Brasjen, Tata Steel Europe; C.J. Boeder, Tata Steel ; M. Bsibsi, Tata Steel ; J. Ponsioen, Tata Steel ; R. Speets, Tata Steel ; R. Verhoef, Tata Steel show more Description Over the past decade, Tata Steel Netherlands has developed a non-linear model predictive temperature controller for its continuous annealing and hot-dip galvanizing lines. The controller has demonstrated its capability to increase productivity, improve temperature accuracy and reduce energy consumption. In order to take the next step toward product quality control, the controller is linked to a material property model so that the predicted process temperatures can be directly translated into projected final product properties. This enables the rectification of product quality deviations that may result from prior processing steps, and thus further increases overall product quality and homogeneity of product properties. Time Monday, May 16 10:00AM - 10:30AM Location 402 Speakers Berend Brasjen Tata Steel Europe C.J. Boeder Tata Steel M. Bsibsi Tata Steel J. Ponsioen Tata Steel R. Speets Tata Steel R. Verhoef Tata Steel Research and Development Efforts Towards Technological Solutions Joe Cresko, U.S. Department of Energy - Advanced Manufacturing Office show more Description This paper details research and development efforts towards technological solutions. Time Monday, May 16 10:00AM - 10:30AM Location 407 Speakers Joe Cresko U.S. Department of Energy - Advanced Manufacturing Office Turn-Up and Turn Down Analysis at Roughing Mill Vertical Scalebreaker Nicolas Legrand, ArcelorMittal; Rajat Bathla, Cleveland-Cliffs Burns Harbor show more Description This work identifies origins and corrective actions of slab turn-up issues at the roughing mill vertical scalebreaker. Most past turn-up analysis was made in horizontal rolling conditions but very few in vertical conditions. Simulations can reproduce turn-ups observed on the industrial line and identify corrective actions: a drastic decrease of turn-up was obtained by changing the passline height. Roll edger misalignment was identified to be another possible source of turn-up. The analysis is concluded by defining geometrical tolerances to avoid/mitigate turn-ups. Time Monday, May 16 10:00AM - 10:30AM Location 306 Speakers Nicolas Legrand ArcelorMittal Rajat Bathla Cleveland-Cliffs Burns Harbor VTLG Laser Thickness Gauge in Challenging Boundary Conditions of 20-High Mill for Stainless Steel Elke Roller, Vollmer GmbH show more Description The VTLG is a strip thickness gauge that operates on the principle of laser triangulation. Challenging boundary conditions caused by cold rolling mills (i.e., dense oil mist, reflectivity, strip breakage) can be viewed as pitfalls of such optical systems. However, a more recent installation of the VTLG on a 20-high mill for stainless steel proved the possibility of achieving µm accuracy for thickness measurement when faced with challenging conditions. The capability and strategic implementation of this VTLG installation is an exceptional example of how optical systems can offer a reliable and precise solution in cold rolling applications. Time Monday, May 16 10:00AM - 10:30AM Location 307 Speakers Elke Roller Vollmer GmbH Water Management and Treatment for the Integrated Steel Plant Peter Klut, Danieli Corus; Bart De Graaff, Danieli Corus; Antoine van Hoorn, Danieli Corus BV show more Description Minimizing intake of fresh water and avoiding discharge of pollutants to the aqueous environment has become top priority for the steel industry. This article presents common water management strategies for ironmaking plants and their specific technical challenges based on a systematic description of the main pollution sources and causes, using real-life examples. This includes the relationship between burden materials, operating conditions and effluent quality. Origin and removal of specific components, such as cyanide and heavy metals, are emphasized. Also, the important connection between gas cleaning and water treatment is discussed and advanced treatment options for coke plant effluents are evaluated. Time Monday, May 16 10:00AM - 10:30AM Location 320 Speakers Peter Klut Danieli Corus Bart De Graaff Danieli Corus Antoine van Hoorn Danieli Corus BV
10:30am A Kinetic Model for Argon Oxygen Decarburization (AOD) Operation in Stainless Steelmaking Process In-Ho Jung, Seoul National University; Marie-Aline Van Ende, Seoul National University show more Description Accurate prediction of temperature and carbon content in the argon oxygen decarburization (AOD) process is critical to the process control for maximum de-C rate and minimum Cr oxidation. A kinetic AOD process model has been developed based on the effective equilibrium reaction zone approach, which couples accurate FactSage thermodynamic databases and mass transfer for complex chemical reactions. The accuracy of the model to predict the temperatures and compositions of steel, slag and gas during the operation have been proven in plants. The model can be used for the optimization of the current operation and the construction of the smart factory in stainless steelmaking. Time Monday, May 16 10:30AM - 11:00AM Location 318 Speakers In-Ho Jung Seoul National University Marie-Aline Van Ende Seoul National University Aligning Production to Available Energy With an Energy Consumption Forecast Stefan Albers, PSI Metals show more Description With increasing share of renewable energy, energy availability will become more volatile. To respect resulting energy consumption constraints from energy providers, to contribute to grid stability and reduce energy costs, we need to forecast energy consumption cross-line in the production planning and scheduling process. This requires product and process specific forecasting models for all operations. PSImetals applies these models to forecast and optimize cross-line schedules respecting energy availability constraints. This paper outlines deriving the forecasting models from production and EMS data. It summarizes first results of implementation in scheduling and energy balancing of a cold rolling mill. Time Monday, May 16 10:30AM - 11:00AM Location 315 Speakers Stefan Albers PSI Metals Best Practices to Reduce the Iron and Steel Industry’s CO2 Emissions by 2030 Alisha Giglio, SINAI Technologies; Britt MacKinnon, Hatch; Mitren Sukhram, Hatch; Ian Cameron, Hatch; Richard Elliott, Hatch; Sa Ge, Hatch; Nicholas Aubry, Hatch show more Description Steelmaking is a carbon-intensive activity, and breakthrough technologies are being developed to address the steel industry’s aspirations for carbon neutrality by 2050. As the industry pursues the goal of sustainable steelmaking, more efficient operation of existing infrastructure will be critical to achieving the emissions reductions targets set by national and international policy initiatives in the near term. Valuable lessons can be learned from the industry’s top performers, and these best practices can be readily applied to existing basic oxygen furnace/blast furnace or direct reduced iron/electric arc furnace operations. This paper provides an overview of the currently available decarbonization efforts and the optimal strategy for reducing emissions. Time Monday, May 16 10:30AM - 11:00AM Location 407 Speakers Alisha Giglio SINAI Technologies Britt MacKinnon Hatch Mitren Sukhram Hatch Ian Cameron Hatch Richard Elliott Hatch Sa Ge Hatch Nicholas Aubry Hatch Design, Construction and Start-Up of the Continuous Galvanizing Line #3 at Steel Dynamics Inc. – Flat Roll Group Columbus Division — The 10th Galvanizing Line of Steel Dynamics Inc. Brandon Ensor, Steel Dynamics Inc. - Flat Roll Group Columbus Division; Andrew Howard, Steel Dynamics Inc. - Flat Roll Group Columbus Division; Jeff Roach, Steel Dynamics Inc. - Flat Roll Group Columbus Division; Jeff Baumann, Steel Dynamics Inc. - Flat Roll Group Columbus Division; Tom Herb, Steel Dynamics Inc. - Flat Roll Group Columbus Division; Madhu Ranade, Steel Dynamics Inc. show more Description For a quantum increase in production of value-added products at Columbus, Steel Dynamics Inc.'s board authorized a modern #3 continuous galvanizing line (CGL) for producing 400,000 tons per year of galvanized and Type 1 aluminized products (up to 72 inches wide and 0.012-0.157 inch thick). The line was designed for ease of operation and maintenance, fast payback, and a built-in flexibility for future upgrades. The #3 CGL produced its first prime coil on 9 July 2020, 19 months after issuing contracts. There were no recordable injuries or COVID-19 infections. The line has performed well — exceeding its design capacity 8 months after the start-up. Time Monday, May 16 10:30AM - 11:00AM Location 403 Speakers Brandon Ensor Steel Dynamics Inc. - Flat Roll Group Columbus Division Andrew Howard Steel Dynamics Inc. - Flat Roll Group Columbus Division Jeff Roach Steel Dynamics Inc. - Flat Roll Group Columbus Division Jeff Baumann Steel Dynamics Inc. - Flat Roll Group Columbus Division Tom Herb Steel Dynamics Inc. - Flat Roll Group Columbus Division Madhu Ranade Steel Dynamics Inc. Economical and environmentally friendly alternative to Phosphate and Chromate pretreatments Hunaid Nulwala, LumiShield Technologies show more Description The push for sustainable, cost-effective, high-performance coatings systems is driving paint and alloy development innovation. However, pretreatment of metals has shown incremental progress over the past few decades. LumiShield has optimized the growth of adherent aluminum oxide thin films on conductive substrates to produce a corrosion-resistant layer. The adherent aluminum oxide coatings have been applied to a range of steel and aluminum alloys and zinc, galvanized, and nickel-plated steel. The aluminum oxide-coated metals offer significant enhancements in corrosion protection. The chemistry is non-toxic, does not contain any heavy metals or phosphates, and is scale-up ready. Time Monday, May 16 10:30AM - 11:00AM Location 402 Speakers Hunaid Nulwala LumiShield Technologies Fundamentals for Developing Nanoprecipitation-Strengthened Thick-Gauge HSLA 550 Steel Through a Flex CSP Mill C. M. Enloe, CBMM North America Inc.; V.S.Y. Injeti, Big River Steel, a U. S. Steel Company; Amar De, Big River Steel, a U. S. Steel Company; Venkata Natarajan, Big River Steel, a U. S. Steel Company; Chirag Mahimkar, Big River Steel, a U. S. Steel Company; Aaron Meyer, Big River Steel, a U. S. Steel Company show more Description In continuous strip processing, low tunnel furnace temperature, combined with significantly short residence time, positively modifies the evolution of carbonitride precipitates in austenite and minimizes over coarsening of austenite grains prior to hot rolling. Such operational advantages were utilized in developing lean yet high-performing high-strength, low-alloy (HSLA) 550 steels. A lean, low-carbon base chemistry was adopted for the development of microalloyed HSLA 550 steels up to a thickness of 16 mm. Hot rolling was designed to achieve excellent low-temperature toughness and superior cold bendability suitable for roll-forming operations. Ti or Ti+Nb additions were appropriately chosen for grain refinement and significant nanoprecipitation strengthening. Time Monday, May 16 10:30AM - 11:00AM Location 316 Speakers C. M. Enloe CBMM North America Inc. V.S.Y. Injeti Big River Steel, a U. S. Steel Company Amar De Big River Steel, a U. S. Steel Company Venkata Natarajan Big River Steel, a U. S. Steel Company Chirag Mahimkar Big River Steel, a U. S. Steel Company Aaron Meyer Big River Steel, a U. S. Steel Company Improving Blast Furnace Efficiency and Reducing Carbon Emissions With Blast Furnace Oxygen Pulsing Technology Ross Edmond, Primetals Technologies Ltd. ; Rainer Klock, thyssenkrupp AT.PRO tec GmbH; Bartosz Smaha, thyssenkrupp Steel Europe AG; Hauke Bartusch, VDEh-Betriebsforschungsinstitut GmbH show more Description The SIP oxygen pulsing technology was commissioned in late 2020 on the 40-tuyere thyssenkrupp Steel Europe Schwelgern BF1 in Germany, and demonstrated immediate improvements in eta-CO. The technology reduced the total fuel rate and also allowed an increase in the ratio of pulverized coal injectionto coke. These results demonstrate both a reduction in Opex as well as a reduction in the carbon emissions from the blast furnace, within a very short payback period. This paper will discuss the technology and the learnings from the Schwelgern BF1 operations with oxygen pulsing. Time Monday, May 16 10:30AM - 11:00AM Location 317 Speakers Ross Edmond Primetals Technologies Ltd. Rainer Klock thyssenkrupp AT.PRO tec GmbH Bartosz Smaha thyssenkrupp Steel Europe AG Hauke Bartusch VDEh-Betriebsforschungsinstitut GmbH Induction Reheating for Slab, Bar and Billet Conversion David Cernava, Inductotherm Group show more Description This presentation reviews seven examples of induction reheating of steel slabs, bar and billets for conversion into finished products. The benefits of using induction reheating as compared to the alternative method of carbon fuel burning are shown. Also, induction reheating, which uses electromagnetic technology, is explained along, with the various equipment and processing parameters currently being used in the steel industry. Time Monday, May 16 10:30AM - 11:00AM Location 306 Speakers David Cernava Inductotherm Group Operational Results of the Chemical Energy Package Revamp in Two 110-Ton-Capacity EAFs at ArcelorMittal Acindar Thiago Pinto Wandekoken, Lumar Metals North America; Paulo Hopperdizel, Lumar Metals; Nerea Mendonza , ArcelorMittal Acindar show more Description ArcelorMittal Acindar, a steel company focused on increasing efficiency and cost reduction of the steelmaking process using scrap as charge and feeding direct reduced iron continuously, planned to revamp the chemical energy package on its two 110-ton-capacity electric arc furnaces (EAFs) with the goal of decreasing the consumption of injected carbon and oxygen and achieving better foaming slag. This revamp consisted of a new EAF chemical package supplied from Lumar Metals. The papers shows the results of carbon, oxygen, electric energy consumption reduction and better foaming slag. Time Monday, May 16 10:30AM - 11:00AM Location 406 Speakers Thiago Pinto Wandekoken Lumar Metals North America Paulo Hopperdizel Lumar Metals Nerea Mendonza ArcelorMittal Acindar Prediction Model of Hot-Rolled Coil Temperature and Phase Transformation Applied Local Heat Flux Considering Coil Shape Yuta Sano, Kobe Stell, Ltd.; Keiichi Yamashita, Kobe Stell, Ltd.; Masanori Kobayashi, Kobe Stell, Ltd. ; Hiroharu Takahashi, Kobe Stell, Ltd. ; Koki Fukushima, Kobe Stell, Ltd. show more Description In the production of high-tensile steels, the coil cooling process of hot-rolled strip is the significant process because the properties of these steels before cold rolling process is determined and it is related to the cold rollability. This paper introduces the prediction model of the coil temperature installed phase transformation. The two-dimensional model of the radial and axial directions cylindrical coordinate system were used, and a local heat flux model was applied based on the coil shape measurement. In addition, combining with a simple phase transformation prediction model, it has become possible to predict the phase transformation rate. Time Monday, May 16 10:30AM - 11:00AM Location 310 Speakers Yuta Sano Kobe Stell, Ltd. Keiichi Yamashita Kobe Stell, Ltd. Masanori Kobayashi Kobe Stell, Ltd. Hiroharu Takahashi Kobe Stell, Ltd. Koki Fukushima Kobe Stell, Ltd. Strip Steering Control – A Cutting-Edge Technology for Hot Strip Mills Olaf Norman Jepsen, SMS group; Dr. Christian Mengel, SMS group; Dr. Michael Breuer, SMS group show more Description The new X-Roll® guide system improves mill stability and quality, especially when rolling thin gauges or high-strength grades. The new sideguiding system on the finishing mill’s entry area is introduced and explained with operational examples. New developments of the roll alignment control strategies based on roll force and mill stand entry guide force measurement will be presented, including a camera-based measuring system that generates direct process feedback of the strip position. At the downcoiler area, a new guiding system offers the benefits of smooth operation to avoid edge damages together with an increased operation time. Time Monday, May 16 10:30AM - 11:00AM Speakers Olaf Norman Jepsen SMS group Dr. Christian Mengel SMS group Dr. Michael Breuer SMS group Successful Operation of an Anti-Chatter Solution at ArcelorMittal Dofasco's Tandem Cold Mill Georg Keintzel, Primetals Technologies; Konrad Krimpelstaetter, Primetals Technologies; Simon Mittlboeck, Primetals Technologies; Adam Junkin, Primetals Technologies Austria GmbH show more Description Primetals Technologies has developed a unique anti-chatter system to eliminate third-octave mill chatter. It represents a high-dynamic hydraulic solution that brings in damping and stabilizes the rolling process. The first permanent industrial application of this trendsetting technology – called ChatterBlock Expert – is successfully in operation at the CPCM No. 1 of ArcelorMittal Dofasco. It demonstrates that it can effectively suppress gauge chatter and that chatter-critical products can now be rolled at significantly higher speeds and increased productivity without any quality degradation. The industrial solution and impressive results from its operation will be presented in the paper. Time Monday, May 16 10:30AM - 11:00AM Location 307 Speakers Georg Keintzel Primetals Technologies Konrad Krimpelstaetter Primetals Technologies Simon Mittlboeck Primetals Technologies Adam Junkin Primetals Technologies Austria GmbH The New Age of HBI Sean Boyle, Midrex Technologies Inc.; Johannes Rothberger, Primetals Technologies; Christian Boehm, Primetals Technologies; Robert Millner, Primetals Technologies; Wolfgang Sterrer, Primetals Technologies; Adam Merki, Primetals Technologies Austria GmbH show more Description Direct reduction offers a tremendous emission reduction compared to prevailing ironmaking processes. The decarburization pressure will increase the demand for pig iron and hot briquetted iron (HBI). Due to the avoidance of re-oxidation and reduced fines generation, HBI is the preferred way for a merchant material. It can be produced at locations with low-cost energy and raw materials available and shipped without certain precautions. This paper talks about HBI benefits and market, and new plants recently started up or contracted (e.g., Mikhailovsky HBI with a planned start-up in 2024). The main technical features of this plant and other upcoming HBI plants are described. Time Monday, May 16 10:30AM - 11:00AM Location 308 Speakers Sean Boyle Midrex Technologies Inc. Johannes Rothberger Primetals Technologies Christian Boehm Primetals Technologies Robert Millner Primetals Technologies Wolfgang Sterrer Primetals Technologies Adam Merki Primetals Technologies Austria GmbH The Role of Ti(C,N) in Retarding Dissolution of Graphite Refractory Thomas Britt, Carnegie Mellon University; P. Chris Pistorius, Carnegie Mellon University show more Description Blast furnace campaign life is often limited by excessive wear of carbonaceous hearth refractory. Charging titanium-containing ores has been seen to extend the hearth life, likely due to Ti(C,N) skull formation. Though industry has well-established charging practices for remediation and prevention, the dissolution of graphite into molten Fe has not been measured when the liquid contains Ti(C,N). The dissolution of graphite into molten baths of Fe-C, Fe-C-Ti, and Fe-C-Ti-N will be presented, along with proposed mechanisms by which Ti(C,N) protects graphite. Time Monday, May 16 10:30AM - 11:00AM Location 408 Speakers Thomas Britt Carnegie Mellon University P. Chris Pistorius Carnegie Mellon University Welding With No Heat-Affected Zone: No Stress Riser Paul Cheng, FuseRing.com show more Description Industry can make high grade metal, i.e., HY130, bainitic/pearlitic rail but the problem is joining. FuseRing Solid State is a one-shot, autogenous and automated process. There is no heat-affected zone, and it is fine-grained base to base; with no fusion line. FuseRing technique is not friction welding. There is no stress riser regardless of thickness. The weld resists embrittlement. It is ideal for hydrogen pipeline. Global manufacturers are making extra long, extra hard rail sections but they are still being joined using a 50-year-old technology - flash butt and thermite with soft dips either side of the weld. FuseRing is a fundamentally different process; heat penetration is in millimeters on either side of the weld face. Time Monday, May 16 10:30AM - 11:00AM Location 401 Speakers Paul Cheng FuseRing.com Zero Liquid Discharge Technology for TMZ’s 500-ktpy Cold Mill Complex Lorenzo Marino, Danieli & C. Officine Meccaniche S.p.A. show more Description This paper shows how to achieve optimal water cycle management by zeroing primary water needs through the reuse of treated production process wastewater. After a number of positive experiences of water recovery in other steel sector applications, this case refers to a cold complex, where many chemical products are deployed. Today’s technology allows for water to be fully recovered into the process, while discharge is limited to solid waste. Process description and data collected from the water recovery plant will show how to reach a 100% zero liquid discharge process. Time Monday, May 16 10:30AM - 11:00AM Location 320 Speakers Lorenzo Marino Danieli & C. Officine Meccaniche S.p.A.
11:00am A Practical Analysis of Benefits of AC Drives Over DC Drives in Cold Rolling Mills Navneet Singh, Digi Drives Pvt. Ltd.; Samir Bansal, Digi Drives Pvt. Ltd.; Ravinder Kumar, Avon Ispat & Power Ltd.; Manish Kumar, Digi Drives Pvt. Ltd. show more Description This paper presents a practical study to document the direct and indirect benefits of AC drives over DC drives in cold rolling mills, including energy, efficiency, power quality, uptime, productivity and manpower. The study is based on practical data collected, compared and analyzed both pre- and post-upgrade of a 4-high cold mill. Time Monday, May 16 11:00AM - 11:30AM Location 307 Speakers Navneet Singh Digi Drives Pvt. Ltd. Samir Bansal Digi Drives Pvt. Ltd. Ravinder Kumar Avon Ispat & Power Ltd. Manish Kumar Digi Drives Pvt. Ltd. AI Application to Detect Product Anomalies in a Hot Roll Mill Marcelo Saparrat, TecnoAp show more Description In the hot rolling process, different types of steel for various products are rolled according to certain process values, setting the control system according to the product to be achieved. Occasionally, due to tracking or identification problems, a slab being rolled is not that which is indicated in the control system; this means that it may have very different mechanical properties than expected and, if not detected in time, this incorrect product could reach a customer. This case is an artificial intelligence application that consists of a model with the ability to detect such situations and warn the operators during the operation. Time Monday, May 16 11:00AM - 11:30AM Location 306 Speakers Marcelo Saparrat TecnoAp Blast Furnace Tuyere Monitoring Powered by Artificial Intelligence Marc Weydert, Paul Wurth S.A.; Pierre Van Dorpe, Paul Wurth S.A.; Steve Czarnuch, Paul Wurth S.A.; Aissatoundiay Ba, Paul Wurth S.A. show more Description The Paul Wurth Tuyere Phenomena Detection System (TPDS) is a camera-based system for continuous monitoring of the blast furnace (BF) tuyere, injection lance, injectant and raceway zone widely installed on high-injection rate blast furnaces. Recent advances in machine learning, in particular in the domain of machine vision, allow improving TPDS substantially by introducing novel monitoring and anomaly detection methods applied to multi-modal data acquired from the BF. This work presents how these artificial intelligence techniques enable robust automated detection of region of interests, continuous injection status classification or detection of hazardous process conditions such as tuyere blockages. Time Monday, May 16 11:00AM - 11:30AM Location 317 Speakers Marc Weydert Paul Wurth S.A. Pierre Van Dorpe Paul Wurth S.A. Steve Czarnuch Paul Wurth S.A. Aissatoundiay Ba Paul Wurth S.A. Combining Time Series and Chemical Composition Data for Early Longitudinal Crack Detection at the Continuous Caster Davi Sala, UGent-imec; Andy Van Yperen-De Deyne, ArcelorMittal; Azarakhsh Jalalvand , UGent-imec; Erik Mannens, UGent-imec show more Description Detecting longitudinal cracks early in the continuous casting process is vital to prevent quality issues further down the production line. The most common approaches for detection are rule-based systems that look for temperature drops during casting. This notion is extended using a big data approach by combining two years of historical data, joining both temporal (thermocouples) and static data (chemical composition, process information, etc.). Multiple state-of-the-art models are trained and evaluated on thousands of automatically extracted features from the temporal data. Early results show that the inclusion of chemical information next to the thermocouple data can greatly improve detection rates. Time Monday, May 16 11:00AM - 11:30AM Location 316 Speakers Davi Sala UGent-imec Andy Van Yperen-De Deyne ArcelorMittal Azarakhsh Jalalvand UGent-imec Erik Mannens UGent-imec Digitalization — Companion for a New Way of Operating Metals Plants Alexander Thekale, Primetals Technologies; Martin Kerschensteiner, Primetals Technologies; Wladimir Schistka, Primetals Technologies show more Description The growing range of digitalization technologies and methods provide new opportunities to continuously increase quality, throughput and process stability in metals industry. Apart from established applications like process or quality analysis, there is much more, especially regarding plant operation. Digital assistants and experts, for example, can significantly support operators in their daily work so that they can focus on what really matters and can act appropriately. The more digital assistants, the more the operator becomes a supervisor of their plant. This also changes the needs of how they operate their plant, and thus, new concepts for control stations are necessary. Time Monday, May 16 11:00AM - 11:30AM Location 315 Speakers Alexander Thekale Primetals Technologies Martin Kerschensteiner Primetals Technologies Wladimir Schistka Primetals Technologies Digitalized Automation and Logistics for Steel Plants With Industry 4 Jagannathan Rajagopalan, Pesmel South Asia and Pesmel North America ; Samu Katkanaho, Pesmel OY; Sami Koivuluoma, Pesmel show more Description In steel mills, storage and buffering functions are often isolated manual operations and there is no overall control of the material flows. Capital tied to raw materials and intermediate products is excessive. Automated material handling systems integrated to production processes could achieve maximum efficiency with shortened lead times, best transition planning, real-time tracking, and full traceability and accurate sorting and shipping of products with the best return on investment. This paper discusses the building blocks of digital and modern plant logistics with benefits of automation in plant logistics. Time Monday, May 16 11:00AM - 11:30AM Location 403 Speakers Jagannathan Rajagopalan Pesmel South Asia and Pesmel North America Samu Katkanaho Pesmel OY Sami Koivuluoma Pesmel Image Analysis and Data Integration to Facilitate Remote and Automated BOF Tapping Frank Kemeny, Nupro Corporation show more Description Manual tapping of steel can be inconsistent and potentially unsafe, with less-than-optimal results. Tapping from a remote location can improve safety and automated tapping can further improve consistency and provide optimum results. The benefits of remote and optimized furnace tapping are numerous, and may include improved safety, lower treatment costs, decreased tap times, lower consumption of reagents and decreased processing time. Remote and automated furnace tapping both require an effective tapping guidance system, integrating image analysis, historical data, and current plant information. The various components required and their integration in the tapping guidance system are described. Time Monday, May 16 11:00AM - 11:30AM Location 318 Speakers Frank Kemeny Nupro Corporation Improve Blast Furnace Safety, Operational Stability and Hearth Wall Preservation With Tailored Taphole Clay Technologies Tomás Moreira de Oliveira, RHI Magnesita; Aloísio Simões Ribeiro, RHI Magnesita; William Headrick Jr., RHI Magnesita; Felipe Nonaka, RHI Magnesita show more Description Blast furnace demands during taphole plugging continuously challenge refractory suppliers to develop innovative solutions tailored to individual tapholes of individual blast furnaces. This paper presents taphole clay solutions implemented in blast furnaces, focusing on safety, operational stability and hearth wall preservation. Innovative technologies have been developed for special applications such as: consecutive taps, crack sealing, hot spots, taphole length recovery and ecofriendly refractories in addition to continuous improvement of materials for standard applications. The implementation of these taphole clays in the market have contributed to better blast furnace operation and campaign extension for customers. Time Monday, May 16 11:00AM - 11:30AM Location 408 Speakers Tomás Moreira de Oliveira RHI Magnesita Aloísio Simões Ribeiro RHI Magnesita William Headrick Jr. RHI Magnesita Felipe Nonaka RHI Magnesita Maximizing Scrap Recycling by Designing Cu Tolerant Steel Compositions Henry Geerlings, Colorado School of Mines; Lionel Promel, Colorado School of Mines show more Description Residual elements from scrap steel recycling, most notably copper, are known to result in hot shortness during thermomechanical processing and casting. As the concentration of copper and other residuals in steel scrap streams increases, Electric Arc Furnace (EAF) scrap recycling heats commonly use pig iron to dilute residuals below current limits. Our work focuses on establishing residual element tolerant compositions and concomitant processing windows that can simultaneously mitigate issues from residuals during thermomechanical processing and, if possible, use these residuals to improve properties, yielding a more sustainable steel manufacturing pathway with a substantially smaller carbon footprint. Time Monday, May 16 11:00AM - 11:30AM Location 310 Speakers Henry Geerlings Colorado School of Mines Lionel Promel Colorado School of Mines New Heavy Plate Mill Project at Nucor Steel Brandenburg Enrico Zambon, Danieli Germany GmbH; Paulo Da Costa, Danieli & C. Officine Meccaniche S.p.A.; Lorenzo Lusina, Danieli & C. Officine Meccaniche S.p.A.; Marco Mossutti, Danieli Automation S.p.A. show more Description Danieli’s 175-inch-wide heavy plate/Steckel allows for flexible production of heavy and light plates and jumbo coils. The consolidated global tendency toward green power generation investments, especially hydro and wind power, offers new development opportunities for the steel plate market. Heavy plates of 3- to 14-inch final rolled thickness are interesting products for plate mills to remain innovative and competitive. Based on an energy-efficient electric arc furnace meltshop, the mill combines the advantages of plate/Steckel rolling for medium thin plates, as well as 60 short tons of jumbo coiled plates with 36-inch ingot rolling. Time Monday, May 16 11:00AM - 11:30AM Speakers Enrico Zambon Danieli Germany GmbH Paulo Da Costa Danieli & C. Officine Meccaniche S.p.A. Lorenzo Lusina Danieli & C. Officine Meccaniche S.p.A. Marco Mossutti Danieli Automation S.p.A. Operational Results of Lumar Metals Chemical Energy Package Revamp at JSPL Angul, India, in 250-Ton-Capacity EAF Charging Hot Metal and DRI Thiago Pinto Wandekoken, Lumar Metals North America; Paulo Hopperdizel, Lumar Metals; Raju PSJKK, Lumar Metals; Atul Dubey, Jindal Steel & Power Ltd.; Rakesh Sinha, Jindal Steel & Power Ltd.; P. V. Rammurthy, Jindal Steel & Power Ltd. show more Description JSPL Angul, India, a steel company with plant capacity of 6.0 millions tons per year, has a blast furnace and direct reduced iron plant, steel meltshop with one 250-ton-capacity basic oxygen furnace and one 250-ton-capacity electric arc furnace (EAF). During January 2019, JSPL planned to implement a chemical energy package revamp on the EAF to increase the productivity. This revamp consisted in a new EAF chemical package supplied by Lumar Metals. The paper shows the project development and operational results. Time Monday, May 16 11:00AM - 11:30AM Location 406 Speakers Thiago Pinto Wandekoken Lumar Metals North America Paulo Hopperdizel Lumar Metals Raju PSJKK Lumar Metals Atul Dubey Jindal Steel & Power Ltd. Rakesh Sinha Jindal Steel & Power Ltd. P. V. Rammurthy Jindal Steel & Power Ltd. The Roadmap From BOF Toward EAF Operation — A Concept Study for an Exemplary European Integrated Plant Felix Firsbach, Badische Stahl-Engineering; Per Lückhoff, Badische Stahl-Engineering; Patrick Hansert, Badische Stahl-Engineering; Peter van der Velden, Badische Stahl-Engineering show more Description The global steel industry is moving from the blast furnace (BF)-basic oxygen furnace (BOF) route to hydrogen-based direct reduction and electric steelmaking to reduce CO2 emissions and serve the growing demand for green steel. Badische evaluated operational and metallurgical differences between BOF and the electric arc furnace (EAF) and the challenges experienced when switching to EAF: • What does it mean to operate an EAF 24/7? • What are realistic figures of continuous operation for the existing high-quality steel grades including raw materials? • How can such a process be implemented into an existing steel plant or meltshop building? • What are the requirements for the EAF and logistics? Time Monday, May 16 11:00AM - 11:30AM Location 407 Speakers Felix Firsbach Badische Stahl-Engineering Per Lückhoff Badische Stahl-Engineering Patrick Hansert Badische Stahl-Engineering Peter van der Velden Badische Stahl-Engineering
11:30am Commencing and Improving the Production of IF Steel Slabs at Chengsteel, HBIS Antonello Di Salvo, DITH; Giuseppe Pratolongo, DITH; Jacques De Vos, DITH; Hong Jia Huang, HBIS Chengsteel show more Description The starting situation at the beginning of the project consisted in short IF casting sequences mostly with the replacement of the 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, May 16 11:30AM - 12:00PM Location 316 Speakers Antonello Di Salvo DITH Giuseppe Pratolongo DITH Jacques De Vos DITH Hong Jia Huang HBIS Chengsteel Introduction to the Molten Oxide Electrolysis (MOE) Technology for CO2-Free Ironmaking Stephan Broek, Boston Metal show more Description Discussed is the breakthrough molten oxide electrolysis (MOE) technology for CO2-free ironmaking that was invented by MIT. In an electrolysis process, iron ore is directly reduced to molten iron only using electricity. Because no carbon is used there are no Scope 1 greenhouse gas emissions. Only Scope 2 emissions are attributed to the process and if renewable energy is used then Scope 2 emissions are also zero. The presentation will review the principles of the process, how iron ore is used, the main characteristics of the MOE iron, and how it is being scaled up for industrial use. Time Monday, May 16 11:30AM - 12:00PM Location 407 Speakers Stephan Broek Boston Metal Modernization of Existing Hot Stoves Using Advanced Technology of Kalugin Top-Fired Stoves Mikhail Kalugin, Kalugin JSC show more Description Many designs of stoves used for blast furnaces cannot provide complete gas combustion during operation. Kalugin has developed and successfully implements an advanced and economically efficient technology of top-fired stoves meeting today’s high environmental requirements. Modernization of existing stoves can be performed with different options from replacement of existing burner design to full replacement of stoves. This paper gives a comprehensive assessment of various modernization options based on productivity, capital expenditures, project implementation period and reduction in harmful emissions, which enables to choose the best option for modernization of existing facilities to improve productive efficiency and significantly reduce adverse environmental impacts. Time Monday, May 16 11:30AM - 12:00PM Location 317 Speakers Mikhail Kalugin Kalugin JSC Operational Results and Experience of Burners/Oxygen Injectors With Moving Flame and Oxygen Jets Installed in the Electric Arc Furnace of Stahl und Walzwerk Marienhütte Jaroslav Brhel, HTT Engineering spol. s r.o.; Thomas Griessacher, Stahl und Walzwerk Marienhütte GmbH show more Description Stahl und Walzwerk Marienhütte GmbH in Graz operates a highly productive electric arc furnace. The furnace capacity is 45 tons and plant produces more than 400,000 tons per year with this single unit. HTT OxymoTM burner system was installed in this EAF in 2019 and operation has been optimized in following years. This new technology enable a controlled and wide range motion of the oxygen gas flames and supersonic oxygen jet inside of the furnace area, while the burner body remains static and sealed in the furnace wall. The paper describes principles of this new technology and the latest practical operational results. Time Monday, May 16 11:30AM - 12:00PM Location 406 Speakers Jaroslav Brhel HTT Engineering spol. s r.o. Thomas Griessacher Stahl und Walzwerk Marienhütte GmbH
2:00pm 5 Key Steps to Driving Safety Program Adoption Through Internal Communications — What Every Steel Manufacturer Must Consider Dan Konstantinovsky, RH Blake show more Description Leading steel manufacturers uniquely understand that having a safe workplace isn't just the right thing to do, it's critical to sustainable business success. A key component of a successful safety program is effective communication. This presentation will identify the five key steps that steel manufacturing leadership and communicators should take to help make communications more effective and better engage the hearts and minds of their employees. Key components of this presentation include capturing employee insight with voice of the customer research, how to develop a safety communications content plan and why certain safety communications programs fail (and how to avoid). Time Monday, May 16 2:00PM - 2:30PM Location 319 Speakers Dan Konstantinovsky RH Blake A Foundation for Data Analytics in Manufacturing Using ibaPDA and Open-Source Machine-Learning Tools Marcelo Cardoso, Gerdau show more Description The Gerdau Long Steel North America Fort Smith plant has expanded use of the ibaPDA system from the initial data acquisition for troubleshooting functionality to a central component of a data analytics platform. With the upgrade to a historical data server, the ibaPDA system provides the data lake foundation as well as the first level of analytics for data cleaning, filtering, and process variable aggregation. Process events triggered upon data ingestion are used to automatically execute statistical analyses or machine-learning models implemented using open-source libraries for automatic notifications, anomaly detection and process diagnostics. The integration with video cameras further expanded troubleshooting capabilities. Time Monday, May 16 2:00PM - 2:30PM Location 311 Speakers Marcelo Cardoso Gerdau Addressing Operating Cost, Productivity and Emissions Challenges Associated With Dirty, Oily Scrap at Metalfer Steel Mill, Serbia Vittorio Scipolo, Tenova Goodfellow Inc.; Nikola Zlatkovic, Metalfer Steel Mill; Prashant Bihare, Tenova Goodfellow Inc. show more Description Dirty, oily scrap leading to heavy CO and H2 emissions is always problematic and a real challenge for many steelmakers. Tenova’s intelligent electric arc furnace solutions, NextGen® hybrid/extractive offgas analysis and comprehensive process control models, were employed to optimize and dynamically control the chemical injection system and successfully lower CO emissions and fume system heat load, while achieving outstanding performance results for increased productivity and reduced electrical (10%), natural gas (30%) and power-on time. Despite Covid-19 limitations, project results will show how Tenova’s Industry 4.0-compliant technology enabled an effective remote internet-based support for installation and process optimization for Metalfer Steel Mill, Serbia. Time Monday, May 16 2:00PM - 2:30PM Location 320 Speakers Vittorio Scipolo Tenova Goodfellow Inc. Nikola Zlatkovic Metalfer Steel Mill Prashant Bihare Tenova Goodfellow Inc. Alternative Caster Mold Water Treatment for Leaky Closed System James Gleason, Suez; Matthew Clardy, Suez Water Technologies & Solutions show more Description This paper will discuss an alternative treatment program for a closed mold system on a continuous caster in the Eastern United States. The alternative program was necessitated when water losses from the system became so excessive that a typical anodic inhibition program (nitrite) became too expensive to maintain. Mild steel corrosion rates and reactive iron climbed as a result. The alternative program decreased mild steel corrosion rates by 90% and dramatically reduced iron levels as well, minimizing the potential for corrosion byproducts to precipitate on copper mold surfaces. Time Monday, May 16 2:00PM - 2:30PM Location 316 Speakers James Gleason Suez Matthew Clardy Suez Water Technologies & Solutions Asset Optimization — Capabilities Shown on a Use Case in Continuous Casting Christoph Häusler, SMS group; Andre Peschen, SMS group; Benjamin Zimmerman, SMS group Inc.; Fabrice Hansen, SMS Digital show more Description A lot is said to be asset optimization or smart maintenance. Many projects are still at the beginning. This presentation shows by means of a converted use case in the field of continuous casting plants how smart maintenance can function. In this practical example, various applications were introduced (among others: condition monitoring, mobile maintenance management system, digital documentation, digital twin, predictive maintenance application, etc.), connected and optimized to form an asset optimization complex. Time Monday, May 16 2:00PM - 2:30PM Location 315 Speakers Christoph Häusler SMS group Andre Peschen SMS group Benjamin Zimmerman SMS group Inc. Fabrice Hansen SMS Digital Autonomous Maintenance Lyle Bufogle, Consultant show more Description Autonomous maintenance (AM) is the operator portion of Total Productive Maintenance, Lean Manufacturing, Toyota Production System, and World-Class Manufacturing. AM is the operators’ activities to monitor, inspect, clean, tighten, lubricate, maintain and improve the normal conditions of equipment. AM prevents equipment deterioration and increases maintenance efficiency. The main objective of AM is to maximize production capacity by reducing the number and duration of equipment breakdowns. “Operator care” allows more time for skilled maintenance technicians to perform proactive and restoration activities. AM includes 5S and Visual Management to organize work areas. AM improves worker engagement and operations-maintenance collaboration. Time Monday, May 16 2:00PM - 2:30PM Location 404 Speakers Lyle Bufogle Consultant Autonomous Trimming and Sampling of Wire Rod Coil Head and Tail Antonio Ambra, AIC; Jens Nylander, AIC North America Corp. show more Description The rolling process has been refined and improved over the past several decades and today there are technological marvels worldwide. However, regardless of all the wonderous technologies such as high-speed rolling equipment, artificial technology and digital twins, rolling mills must regularly trim and sample the finished coiled products, and in almost all cases, this is a 100% manual operation. To address this, AIC has developed a fully autonomous trimming and sampling robot, the TrimBot. TrimBot is a trimming and sampling system that can operate within any existing vertical or horizontal coil handling system while offering perfect results and accuracy on every coil. Time Monday, May 16 2:00PM - 2:30PM Location 401 Speakers Antonio Ambra AIC Jens Nylander AIC North America Corp. Configuration of Charging and Teeming Cranes: The Features That Make the Difference Lorenzo Bacchetti, Danieli & C. Officine Meccaniche S.p.A. show more Description This paper will present concepts and standard features for charging/ladle cranes. The paper will include practices in using planetary gearboxes, safety reevings, emergency brakes, redundancy functions, visual pickup confirmation and safety pickup verification algorithms. Time Monday, May 16 2:00PM - 2:30PM Location 405 Speakers Lorenzo Bacchetti Danieli & C. Officine Meccaniche S.p.A. Coping With New Requirements Due to the Increased Use of High-Strength Steels Jochen Muenker, GEORG North America show more Description High-strength steels developed and commercialized in recent years are designed to provide physical properties (especially higher strength and best formability) together with decreased thickness range. Particularly automotive companies, with the ever-increasing demand for lightweight requirements without compromising safety requirements, demand these steel compositions. Such steel grades are expected to dominate the material share in automobile in the foreseeable future. Time Monday, May 16 2:00PM - 2:30PM Location 307 Speakers Jochen Muenker GEORG North America Flexible Tundish Configuration for Stainless Steel Producers Johan Richaud, Vesuvius; Abhishek Chakraborty, Vesuvius India Ltd.; Devashish Nagori, Vesuvius India Ltd.; Rakesh Tiwari, Vesuvius India Ltd.; Dr. Arnab Kundu, Jindal Steel Hisar Ltd.; Dr. Arijit Saha Podder, Jindal Steel Hisar Ltd.; Rajesh Saxena, Jindal Stainless Limited; Jagmohan Sood, Jindal Stainless Limited show more Description Stainless steels cover a wider range of cost and quality requirements than low-alloy grades, and a unique tundish configuration cannot be optimized for production of such varied steel products. A tundish flow computational fluid dynamics-based study has been undertaken, considering a flexible selection of flow modifiers, including a special yield-enhanced tundish working lining. This enables stainless producers to independently select a configuration suited for either maximizing yield or improving quality, based on the unique techno-commercial needs of the grade. The flow modifiers are designed for flexible tundish configurations with minimal modifications and within the standard tundish preparation time. Time Monday, May 16 2:00PM - 2:30PM Location 310 Speakers Johan Richaud Vesuvius Abhishek Chakraborty Vesuvius India Ltd. Devashish Nagori Vesuvius India Ltd. Rakesh Tiwari Vesuvius India Ltd. Dr. Arnab Kundu Jindal Steel Hisar Ltd. Dr. Arijit Saha Podder Jindal Steel Hisar Ltd. Rajesh Saxena Jindal Stainless Limited Jagmohan Sood Jindal Stainless Limited Hot Repairing MgO-C Self-Flow Castable for BOF Converter With Zero Fume Emission Carlos Pagliosa, RHI Magnesita; Vanderlúcio Madalena, RHI Magnesita; José Alvaro Sardelli, RHI Magnesita; Marcelo Borges, RHI Magnesita; Victor Carlos Pandolfelli, Federal University of São Carlos show more Description A self-flow MgO-C castable was conceived to be delivered as a ready-to-use product. Some challenges were overcome such as the development of a very low-viscosity binder, grain size distribution to avoid segregation, fast curing time, and a new sort of dispersant. Hot repair is performed at any temperature of basic oxygen furnace (BOF) bricks and applied by throwing a super sac or a bag directly to the damage area. Trials were conducted at steel shops and the performance was similar to the resin-bonded material, but with zero fume and non-pollutant emission. After installation, the BOF converter is ready to resume operation in 30-45 minutes. Time Monday, May 16 2:00PM - 2:30PM Location 408 Speakers Carlos Pagliosa RHI Magnesita Vanderlúcio Madalena RHI Magnesita José Alvaro Sardelli RHI Magnesita Marcelo Borges RHI Magnesita Victor Carlos Pandolfelli Federal University of São Carlos Hot-Rolled Plate Surface Quality Evaluation and Assessment for End User Applications Steven Jansto, Research and Development Resources; Hari Muthuswami, FOERSTER Instruments Inc.; Michael Cooke, SSAB Iowa Inc.; Annelise Scierka, Nucor Steel Tuscaloosa Inc.; Jacob Lewis, Nucor Steel Brandenburg; Tanya Ros-Yanez, Cleveland-Cliffs Research & Innovation Center; Andrew Smith, SSAB Alabama; Andy Roubidoux, EVRAZ NA show more Description This session relates to ASTM A06 Section 9 and ASTM A941, and the evolving expectation of surface quality in regards to plate product. The connection of the steel producer and end user continues to support efforts for a deeper understanding of the hot-rolled plate surface quality and standard requirements appropriate for a given application within the supply chain. Session will highlight common hot-rolled surface imperfections, with follow up Q&A on how best to define the imperfections. Time Monday, May 16 2:00PM - 2:30PM Location 402 Speakers Steven Jansto Research and Development Resources Hari Muthuswami FOERSTER Instruments Inc. Michael Cooke SSAB Iowa Inc. Annelise Scierka Nucor Steel Tuscaloosa Inc. Jacob Lewis Nucor Steel Brandenburg Tanya Ros-Yanez Cleveland-Cliffs Research & Innovation Center Andrew Smith SSAB Alabama Andy Roubidoux EVRAZ NA Hydrogen Production and Supply Methods for Decarbonizing Iron and Steel Making Anup Sane, Air Products; Michelle Schoonover, Air Products and Chemicals Inc. show more Description As the steel industry makes strides towards decarbonizing iron and steel production, use of low and no carbon hydrogen along with carbon capture from off-gas streams will be essential to this effort. Hydrogen can be used to decarbonize ironmaking by replacing carbon as a reductant and to decarbonize steelmaking by replacing natural gas as a fuel. In the next several years, producing, storing, and supplying hydrogen with low carbon intensity at large scales (> 100s MT/day) and capturing carbon dioxide will be key in supporting these decarbonizing efforts for the steel industry. This presentation will inform about the existing production and supply modes for hydrogen, including how they are being decarbonized to produce low and no carbon hydrogen at scale, and what other technologies are available for gas separation and carbon capture. Time Monday, May 16 2:00PM - 2:30PM Location 407 Speakers Anup Sane Air Products Michelle Schoonover Air Products and Chemicals Inc. Modeling the Impacts of Nuisance Elements on Blast Furnace Operation Chenn Zhou, Purdue University Northwest; Tyamo Okosun, Purdue University Northwest; Samuel Nielson, Purdue University Northwest; Stuart Street, Cleveland-Cliffs Inc.; Gerard Louwerse, Tata Steel Europe; Jan van der Stel, Tata Steel Europe show more Description Computational modeling techniques for blast furnace simulation have been developed by Purdue University Northwest researchers to study furnaces operated by member companies of the Steel Manufacturing Simulation and Visualization Consortium. Presently, further understanding of the impacts of nuisance elements such as zinc, potassium and sodium on the furnace is desired. These elements can react with reducing gases, reducing the efficiency of operation, and their circulation within the furnace under certain conditions can also result in material buildup. This research will discuss modifications to existing computational fluid dynamics models to track nuisance element chemical reactions and concentrations to better quantify their impacts. Time Monday, May 16 2:00PM - 2:30PM Location 317 Speakers Chenn Zhou Purdue University Northwest Tyamo Okosun Purdue University Northwest Samuel Nielson Purdue University Northwest Stuart Street Cleveland-Cliffs Inc. Gerard Louwerse Tata Steel Europe Jan van der Stel Tata Steel Europe Nuclear Hydrogen Pathway Enabling DRI Green Steel: An Update John Kutsch, Thorium Energy Alliance show more Description The key to 100% H2 direct reduced iron steel from mine to metal is economically implementing the major systems need to get to US$1/kg hydrogen. This talk will provide an update on the Caldera Pea Ridge Mine Green Steel Project. It will report on the final engineering plans and the groundwork taking place to reopen the mine. The presentation will benefit the entire steel industry and will allow the membership to incorporate learning about economically scaling hydrogen production to full industrial scale needed for processing millions of kilos of ore to metal into their plans for future integrated steel systems. Time Monday, May 16 2:00PM - 2:30PM Location 308 Speakers John Kutsch Thorium Energy Alliance Panel Discussion: Transforming the BOF for Carbon Neutrality Chad Cathcart, Stelco Inc.; Sara Hornby, Global Strategic Solutions, Inc. (GS2i); Andreas Schneider, DILLINGER and ROGESA & ZKS; Tom Kuhl, ArcelorMittal Dofasco; Traci Forrester, Cleveland-Cliffs, Inc. show more Description Steel and metals manufacturing are reliant on fossil fuels as carbon is the primary element necessary for the reduction of iron ore and a critical alloying element in steel. Without carbon, we do not have steel. Global steel production, which contributes significantly to the emission of CO2 to the atmosphere, also recognizes the importance in pursuing a carbon-neutral industry. The integrated steelmaking route (BF/BOF), which remains an essential process to satisfy global market demand, especially for automotive manufacturing, presents a significant potential to achieve carbon neutrality. Cutting-edge technologies such as smelting reduction, carbon capture and utilization, and hydrogen-based DRI are still emerging from research, development and deployment. Many of the world’s largest steel companies are exploring the possibilities of these technologies. This moderated panel discussion will bring together global leaders in BOF steel production to discuss their path towards carbon neutrality. Topics for discussion will include (1) Each company’s overall vision for BOF carbon neutrality (2) Applications for coke substitutes such as natural gas, hydrogen gas, etc. (3) Status and timelines on CCUS applications and (4) Reinforcing the importance for BOF steel production Time Monday, May 16 2:00PM - 5:00PM Location 318 Speakers Chad Cathcart Stelco Inc. Sara Hornby Global Strategic Solutions, Inc. (GS2i) Andreas Schneider DILLINGER and ROGESA & ZKS Tom Kuhl ArcelorMittal Dofasco Traci Forrester Cleveland-Cliffs, Inc. Raw Material and Technology Considerations For Low-C EAF Steelmaking Jeremy Jones, CIX Inc. show more Description Much attention is being placed on electric arc furnace (EAF) technology as a means of transitioning to lower-carbon-footprint steelmaking. As one begins to evaluate the opportunities that the EAF brings to this endeavor, one quickly realizes that the future of EAF technology is closely entwined with the selection of raw materials that are utilized to make the steel. In fact, it is impossible to separate the two topics when attempting to develop low-C steelmaking solutions. This paper identifies issues to evaluate and identify questions that should be asked as one embarks on the journey to a carbon-neutral 2050. Time Monday, May 16 2:00PM - 2:30PM Location 406 Speakers Jeremy Jones CIX Inc. Transient Analysis of Flow in a Multi-Strand Delta-Shaped Tundish Pavan Shivaram, RHI Magnesita; Pedro Domingos, RHI Magnesita; Richard Komanecky, RHI Magnesita; Guido Peloquin, RHI Magnesita show more Description The flow within a tundish is of critical importance for a caster. For a multi-strand caster tundish in particular, the differences between the strands could lead to product quality variations and other concerns. A complete cycle of a ladle exchange process is studied using transient computational fluid dynamics analysis. Steady state, tundish drain and refill during ladle exchange, and eventual attainment of steady state are all studied. Different impact pots are studied for a comparison of their influence on the differences between the strands. Time Monday, May 16 2:00PM - 2:30PM Location 309 Speakers Pavan Shivaram RHI Magnesita Pedro Domingos RHI Magnesita Richard Komanecky RHI Magnesita Guido Peloquin RHI Magnesita Various Strategies for the Distribution of Reductions in the Finishing Stands of a Hot Rolling Mill Eugene Nikitenko, U. S. Steel Research and Technology Center show more Description The distribution of reductions (drafts) between finishing stands can serve various purposes. It can be used to improve flatness, thereby assisting roll bending and shifting. Drafts can be optimized to increase the length of slabs that can be rolled without overloading the elements of the rolling stand and without overheating the main motors. The specific distribution of reductions makes it possible to lengthen the work roll campaign, which is often limited by the wear of the cast iron rolls used in the last few finishing stands. The paper discusses the results of the analysis of the three strategies outlined above. Time Monday, May 16 2:00PM - 2:30PM Location 306 Speakers Eugene Nikitenko U. S. Steel Research and Technology Center
2:30pm A Digital Transformation: Modernizing Your Asset’s Safety Program Landon Pearson, Steel Dynamics Inc ; Charles Droessler, LJB Inc show more Description Protecting steel mill workers involves the use of numerous safety procedures and programs — risk assessments, personal protective equipment requirements, hazard identification, asset inventories and design/training/inspection records are only a few examples. When data from various safety components is not well compiled, it becomes difficult to effectively utilize the information collected. This paper showcases how Steel Dynamics Inc. – Flat Roll Group Butler Division uses a dynamic, web-based interactive map to manage the findings from a walking-working surface assessment. The tool allows ongoing inspections to be scheduled, assigned and completed digitally using a workflow application, while a dashboard tracks compliance and achievement of program objectives. Time Monday, May 16 2:30PM - 3:00PM Location 319 Speakers Landon Pearson Steel Dynamics Inc Charles Droessler LJB Inc Benefits of Laser Deposit Welding in Descale Pump Application Ken Babusiak, Hydro, Inc show more Description Laser deposit welding (LDW) of wear surfaces in descale pumps can provide significant benefits. This upgrade provides a very hard wear surface and no longer requires a sacrificial component. Using LDW, impeller rings can be eliminated, removing the risk of a ring failure. LDW technology significantly deters the opening of critical wear ring clearances, maintaining rotor stability and performance for a much longer period of time. Superior material hardness also protects against damage during transient events. Hydro’s presentation will focus on the benefits and application of LDW in descale pumps with a case study showing practical application of the concept. Time Monday, May 16 2:30PM - 3:00PM Location 404 Speakers Ken Babusiak Hydro, Inc Detecting Unsafe Lifting Practices on Wire Rope Hoists Steven Lubeck, Laser-View Technologies show more Description A wire rope hoist on an overhead crane is an important tool in steel production that is often misused, creating a safety risk and increasing potential downtime. Standard wire rope hoists are designed for vertical lifting only. Side loading, or side pulling, presents a safety risk, and can accelerate wear and damage a hoist. When bridging at elevation, this action is referred to as snag. Bridging in a direction that would make side pull/snag worse can also be prevented. This presentation discusses methods of dealing with hoist side pull, snag and the related bridge controls to prevent such hazards. Time Monday, May 16 2:30PM - 3:00PM Location 405 Speakers Steven Lubeck Laser-View Technologies Digital Scrap Yard Lorenzo Bacchetti, Danieli & C. Officine Meccaniche S.p.A.; Luca Argiolas, Danieli & C. Officine Meccaniche S.p.A. show more Description Evolution of the scrap yard management in steel plants happens through process digitalization and reduction of human interactions. This paper will include description of main functions, including digital scrap acceptance, advanced yard management with tracking, volumes detection and melting process optimization. Time Monday, May 16 2:30PM - 3:00PM Location 315 Speakers Lorenzo Bacchetti Danieli & C. Officine Meccaniche S.p.A. Luca Argiolas Danieli & C. Officine Meccaniche S.p.A. Highest Yields and Lowest Conversion Costs for Stainless Steel Operations Markus Hagedorn, ABP Induction Systems GmbH; Gerald Wimmer, Primetals Technologies Austria GmbH; Christopher Carstens, ABP Induction LLC; Marco Rische, ABP Induction Systems GmbH; Denis Vaillancourt, Primetals Technologies USA LLC show more Description Due to the absence of exothermic oxygen reactions, artificial slag formation or electric arc plasma, alloy yields of inductive melting are 96-100%. Melt production from newly developed induction furnaces increases up to 800,000 t/year to feed large argon oxygen decarburization converters. However, even small units are economically attractive, e.g., to increase the yield of nickel or ferroalloys. Metallurgic and thus economical benefits are described, referencing to running applications and recent improvements: (1) Induction furnace as sole primary melting furnace, (2) Primary melting shared between the electric arc furnace and induction furnace, and (3) Melting of alloys (e.g., FeCr; Ni; FeMn, FeMo) and their addition into carbon melt. Time Monday, May 16 2:30PM - 3:00PM Location 310 Speakers Markus Hagedorn ABP Induction Systems GmbH Gerald Wimmer Primetals Technologies Austria GmbH Christopher Carstens ABP Induction LLC Marco Rische ABP Induction Systems GmbH Denis Vaillancourt Primetals Technologies USA LLC Improved API X80 Heavy-Gauge Large-Diameter Pipe Mechanical Property Stability Through Cost-Effective Optimized Niobium Metallurgy Performance Doug Stalheim, DGS Metallurgical Solutions; Jose Bacalhau, CBMM; Jiang Jinxing, Nanjing Iron and Steel Company, LTD; Huo Chunyong, Tubular Goods Research Institute ; Zhang Yongqing, CITIC Metal; David Han, International Welding Technical Center show more Description Today’s market for API pipeline steels requires higher strength and fracture toughness performance in heavier gauges and larger pipe diameters. Meeting basic average mechanical properties of strength, Charpy V-notch test and drop weight tear test performance has been achieved by many with newer powerful plate mills and cooling systems. However, stability/standard deviations of plate/pipe strength and toughness along with pipe seam/girth weld toughness continues to be challenging. Nanjing Iron and Steel successfully improved base metal plate strength and toughness stability that translated into improved pipe strength and toughness stability including pipe seam/girth welds with an optimum 0.075% niobium content and plate processing for the application. Time Monday, May 16 2:30PM - 3:00PM Location 402 Speakers Doug Stalheim DGS Metallurgical Solutions Jose Bacalhau CBMM Jiang Jinxing Nanjing Iron and Steel Company, LTD Huo Chunyong Tubular Goods Research Institute Zhang Yongqing CITIC Metal David Han International Welding Technical Center Interpretable Deep Learning Techniques and Meta Information for Automated Decision Making in Ironmaking Plants Dieter Bettinger, Primetals Technologies; Georgios Koutroulis, Pro2Future GmbH; Petra Krahwinkler, Primetals Technologies; Belgin Mutlu, Pro2Future GmbH; Martin Schaler, Primetals Technologies; Christian Tauber, Primetals Technologies; Matej Vukovic, Pro2Future GmbH; Stefan Thalmann, University of Graz show more Description Modeling complex processes like ironmaking is a demanding task. Approaches based on machine learning and especially deep learning (DL) offer a considerable option. Using the latest artificial intelligence (AI) achievements, a multi-step time series DL framework was developed to forecast key performance indicators, e.g., the silicon content and temperature of hot metal from a blast furnace. However, DL methods are often seen as black boxes, which hinder their contribution to expand process knowledge as well as their integration into control systems. Enhancing the DL model with advanced, explainable AI techniques and meta information makes them more transparent, enabling optimized decision-making in ironmaking. Time Monday, May 16 2:30PM - 3:00PM Location 317 Speakers Dieter Bettinger Primetals Technologies Georgios Koutroulis Pro2Future GmbH Petra Krahwinkler Primetals Technologies Belgin Mutlu Pro2Future GmbH Martin Schaler Primetals Technologies Christian Tauber Primetals Technologies Matej Vukovic Pro2Future GmbH Stefan Thalmann University of Graz Iron-Air Batteries - The Catalyst for Steelmaking Decarbonization Vincent Chevrier, Form Energy show more Description Form Energy is pioneering a multi-day energy storage technology: the iron-air battery. Besides being safe, reliable and low cost, the technology is designed to be scalable by sourcing iron already available at a global scale. This need for net-zero-emission iron will open a new market for iron- and steelmakers. Iron-air batteries will be the catalyst that will accelerate the development of new technologies for green steel production as the electrical grid decarbonizes. Time Monday, May 16 2:30PM - 3:00PM Location 308 Speakers Vincent Chevrier Form Energy Predicting Grain Size in SBQ Bars When Using a Kocks Reducing Sizing Block Patrick Connell, Kocks Pittsburgh Co; Glyn Ellis, Kocks Pittsburgh Co; Michael Kruse, Friedrich Kocks Gmbh show more Description Kocks intends to present the predictable metallurgical benefits of using a Kocks reducing sizing block (RSB) in combination with low-temperature rolling and the Kocks microstructure simulator. The information to be provided is a combination of existing data from similar applications as well as data from partially implemented installations. A combination of mechanical, process and metallurgical benefits will be presented. Time Monday, May 16 2:30PM - 3:00PM Location 401 Speakers Patrick Connell Kocks Pittsburgh Co Glyn Ellis Kocks Pittsburgh Co Michael Kruse Friedrich Kocks Gmbh Proceedings Computational Analysis of Surface Wave Fluctuation Utilizing Electromagnetic Braking in a Continuous Caster Armin Silaen, Purdue University Northwest; Chenn Zhou, Purdue University Northwest; Mauro Ferreira, Nucor Corp.; Wesley Rollings, Nucor Corp.; Saswot Thapa, Purdue University Northwest show more Description The flow dynamics at the meniscus level of the mold have an important impact on operational conditions and quality of cast products during continuous casting. Abrupt mold surface velocity variation brings asymmetry on the surface directed flow, therefore forming internal and surface defects in the final cast products. The local turbulent flow can be dampened instantaneously with the use of electromagnetic forces, known as electromagnetic brake (EMBr). The impacts of EMBr on the surface velocity, mold powder entrapment rates, and the surface fluctuation heights at different mold widths and casting speeds are analyzed to provide a better knowledge and understanding. Time Monday, May 16 2:30PM - 3:00PM Location 316 Speakers Armin Silaen Purdue University Northwest Chenn Zhou Purdue University Northwest Mauro Ferreira Nucor Corp. Wesley Rollings Nucor Corp. Saswot Thapa Purdue University Northwest Progress on the Pathway to Cost-Effective, Zero-Carbon Hydrogen Dave Wolff, Nel Hydrogen show more Description In January 2021, Nel Hydrogen announced a goal to reach US$1.50/kg green hydrogen supply by 2025. The goal includes all fixed and variable costs to make hydrogen – a true breakthrough in terms of CAPEX and OPEX. By achieving the goal of US$1.50/kg green hydrogen by water electrolysis, Nel Hydrogen will make fossil-derived hydrogen redundant, particularly for applications where green hydrogen provides unique advantages for the end product. Steel is such an application. This paper will discuss progress to date in achieving the goal, challenges mastered and issues to come. Time Monday, May 16 2:30PM - 3:00PM Location 407 Speakers Dave Wolff Nel Hydrogen Scrap Supply Chains and Residual Impacts: Benchmarking Price Implications Today and Into the Future Sridhar Seetharaman , Arizona State University ; Travis Lowder, National Renewable Energy Laboratory; Bhaskar Yalamanchili, Gerdau show more Description This paper will seek to benchmark the relationship between the portion of residuals in scrap (principally copper) and prices for select steel grades. It updates a Yalamanchili et al. 1999 paper that was one of the first to offer a quantitative metric for this relationship. The paper will rely principally on a literature review and interviews with scrap suppliers and steelmakers; it will also contain original analysis on how residual quantities in the scrap supply chain and scrap prices could change into the future given certain trends. Time Monday, May 16 2:30PM - 3:00PM Location 406 Speakers Sridhar Seetharaman Arizona State University Travis Lowder National Renewable Energy Laboratory Bhaskar Yalamanchili Gerdau Studying the Flow and Thermal Dynamics in a Small Single-Strand Tundish Pavan Shivaram, RHI Magnesita; Pedro Domingos, RHI Magnesita; Richard Komanecky, RHI Magnesita; Alexandre Resende, RHI Magnesita; Jeremy Stickan, RHI Magnesita; Preston Barrett, RHI Magnesita show more Description The flow within a tundish is of critical importance for a caster. Unfavorable flow and thermal conditions can lead to poor quality, disruptions and even termination of cast. The flow and thermal dynamics within a small single-strand tundish are studied using computation fluid dynamics analysis. Some unusual and interesting dynamics were observed with a potential for temperature-related disruptions. Modifications to the tundish furniture were investigated, showing promising improvements to the temperature distribution. The analysis included steady-state and transient ladle exchange scenarios. Time Monday, May 16 2:30PM - 3:00PM Location 309 Speakers Pavan Shivaram RHI Magnesita Pedro Domingos RHI Magnesita Richard Komanecky RHI Magnesita Alexandre Resende RHI Magnesita Jeremy Stickan RHI Magnesita Preston Barrett RHI Magnesita Time Series AI for Anomaly Detection and Diagnosis in Steel Production Crick Waters, Falkonry Inc.; Raj Talla, Falkonry Inc. ; Prerna Jain, Falkonry Inc. ; Keval Bhanushali, Falkonry Inc. show more Description Artificial intelligence (AI) and machine learning (ML) techniques have been used to solve complex operations problems. Applying ML and AI for anomaly detection and diagnosis at scale, however, has been a significant challenge. This paper discusses how Falkonry's Operational AI platform leverages ML/AI for automated detection and diagnosis of equipment in steelmaking. This methodology is scalable across use cases without the need for data scientists. Precedent detection of novel equipment conditions provides insight to maintenance operations that would otherwise have been missed. Such insights lead to proactive maintenance interventions, thus avoiding loss of production due to unexpected downtime events. Time Monday, May 16 2:30PM - 3:00PM Location 311 Speakers Crick Waters Falkonry Inc. Raj Talla Falkonry Inc. Prerna Jain Falkonry Inc. Keval Bhanushali Falkonry Inc. Toward Lights-Out Factory: Improved Roughing Mill Operation by Camber-Free Rolling Reduces Strip Steering Challenge in the Finishing Mill of SSAB Borlänge, Sweden, and Paves Way to Fully Automatic Flat Rolling Klaus Pronold, SMS group; Eberhard Becker, SMS group; Siegfried Latzel, SMS group; Mats Thurgren, SSAB show more Description This paper follows a strategy to eliminate the need of humans and steering of the hot strip mill as the first camber-free rolling technology was implemented in the hot mill at SSAB Borlänge, Sweden. 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 that can be achieved by this technology. These results will be presented as well as future steps to ultimately eliminate permanent human interventions for hot sheet rolling paving the path toward lights-out operation. Time Monday, May 16 2:30PM - 3:00PM Location 306 Speakers Klaus Pronold SMS group Eberhard Becker SMS group Siegfried Latzel SMS group Mats Thurgren SSAB Upgrading Steel Dynamics Inc. - Flat Roll Group Columbus Division’s Continuous Pickling and Cold Rolling Operation for Increased Throughput and Production of Advanced High-Strength Steels Jeff McLain, Steel Dynamics Inc. - Flat Roll Group Columbus Division; Byron McNair, Steel Dynamics Inc. - Flat Roll Group Columbus Division; Anthony Wills, Steel Dynamics Inc. - Flat Roll Group Columbus Division; Brent Adams, Steel Dynamics Inc. - Flat Roll Group Columbus Division; Cody Dyar, Steel Dynamics Inc. - Flat Roll Group Columbus Division show more Description Steel Dynamics authorized a strategy to increase production of value-added products at its Columbus Division with a new #3 continuous galvanizing line (CGL) and extensive upgrades to #1 CGL. To support this strategy, existing continuous pickle-tandem cold mill (PLTCM) complex capability had to be upgraded. This upgrade was carried out in steps, with minimal interruptions to ongoing production. Innovative techniques were used for design, equipment choice, installation, and commissioning of the new entry-end and state-of-the-art laser welder. With the use of strict safety and health protocols, the PLTCM upgrade was completed successfully without any OSHA recordable injuries or COVID-19 infections. Time Monday, May 16 2:30PM - 3:00PM Location 307 Speakers Jeff McLain Steel Dynamics Inc. - Flat Roll Group Columbus Division Byron McNair Steel Dynamics Inc. - Flat Roll Group Columbus Division Anthony Wills Steel Dynamics Inc. - Flat Roll Group Columbus Division Brent Adams Steel Dynamics Inc. - Flat Roll Group Columbus Division Cody Dyar Steel Dynamics Inc. - Flat Roll Group Columbus Division Using the Right Pulse-Jet Technology to Reduce Environmental Impact Raymond Tedford, Schust show more Description Steel producers are under pressure to reduce energy costs and their carbon footprint. This presentation will show how reducing differential pressure across a baghouse can deliver significant energy savings, thus lowering the environmental impact. Traditional on-line cleaning pulse-jet baghouses have demanded more, not less, energy. This presentation will illustrate how it is possible for an enhanced cleaning system to use less compressed air energy than conventional on-line cleaning. Stable differential pressure is achieved using segment isolation rather than isolating a large compartment. Time Monday, May 16 2:30PM - 3:00PM Location 320 Speakers Raymond Tedford Schust
3:00pm Advanced Cast Product Quality Testing by HD Scan Bo Usko, SMS group Inc.; Bill Emling, SMS group; Joe Laughlin , SMS group; Tamara Gusarova, SMS group show more Description As-cast slab sample inspections through HD scan technology have beneficial results, opposed to the subjective processes available today. This ultrasonic measurement technique can detect defects such as segregations, cracks and inclusions. The first industrial reference was installed at Tata IJmuiden, Netherlands, in December 2018. Tata and SMS group worked together on progress of the HD scan and its benefits for optimizing the casting process. Results of etching versus HD scan were evaluated, showing the benefits of the HD scan capabilities. Additional benefits were realized through sample preparation time, safety and timely sample results. This technology can be integrated with Industry 4.0 solutions. Time Monday, May 16 3:00PM - 3:30PM Location 316 Speakers Bo Usko SMS group Inc. Bill Emling SMS group Joe Laughlin SMS group Tamara Gusarova SMS group Automatic Scrap Bucket Handling by Charging Crane at ABS Meltshop Lorenzo Bacchetti, Danieli & C. Officine Meccaniche S.p.A.; Francesca Foschiani, Danieli & C. Officine Meccaniche S.p.A. show more Description This paper presents a solution for fully automatic bucket handling by a charging crane in ABS meltshop, Italy. The presentation will cover the new technologies used to ensure a safety pick-up of the scrap bucket from transfer cars, and consequently its deposit. Additionally, the technologies for the meltshop machines' remote driving and supervision are discussed, comparing them to previously adopted technologies. The paper will also cover the safety features included to allow the fully automated execution of the charging cycle. Time Monday, May 16 3:00PM - 3:30PM Location 405 Speakers Lorenzo Bacchetti Danieli & C. Officine Meccaniche S.p.A. Francesca Foschiani Danieli & C. Officine Meccaniche S.p.A. Development of High-Toughness Steel Plates for Offshore Pipelines Ricardo Faria, Gerdau Ouro Branco; Daniel Matsubara, Gerdau Ouro Branco show more Description Large-diameter pipes applied in offshore transportation lines have special toughness requirements due to the elevated internal and external pressures associated with deep sea environments. In this scenario, the plate fabrication becomes very challenging, as it must ally high thickness with elevated tensile strength and toughness, demanding specific process controls. This work shows technical aspects of the steel design in terms of chemical composition and rolling practices to assure high toughness at low temperatures. Mechanical characterizations were performed by tensile tests, Charpy, drop weight tear testing, crack tip opening displacement and correlation with microstructural features. Time Monday, May 16 3:00PM - 3:30PM Location 402 Speakers Ricardo Faria Gerdau Ouro Branco Daniel Matsubara Gerdau Ouro Branco Direct Rolling Scheduling Is Like Tightrope Walking Between Casting and Rolling Peter Knoop, PSI Metals; Andréa de Sá, PSI Metals show more Description Compact strip production (CSP)/endless strip production (ESP) lines integrate casting, heating and rolling into a single process, reducing energy consumption (around 40%) and thus decreasing costs. To create a schedule for such lines, it is necessary to consider both casting and rolling process constraints. The challenge is that those constraints are different and some of them are even contradicting. This paper describes the direct rolling scheduling software solution developed by PSI that is capable of finding an optimum balance between casting and mill constraints by a multi-criteria objective function. It supports the human schedulers with state-of-the-art data analytics, fast schedule generation and graphical schedule editors. Time Monday, May 16 3:00PM - 3:30PM Location 315 Speakers Peter Knoop PSI Metals Andréa de Sá PSI Metals Edge Analytics in Energy Management: Power Monitoring of Steel Plants David Kober, iba America show more Description The presentation outlines a method of leveraging an open ecosystem for data acquisition and data analysis on an edge device in relation to energy management: An approach that provides consistent data to all stakeholders interested (maintenance, engineering, scheduling, quality, R&D, data scientists, etc.) in transforming this immense amount of data into useful and actionable information. This occurs while concurrently preparing the data for artificial intelligence and machine-learning models. The method will be demonstrated by a real-world case study of a power quality monitoring system for a steel facility to efficiently monitor, maintain and optimize the transportation of energy. Time Monday, May 16 3:00PM - 3:30PM Location 311 Speakers David Kober iba America How 3D Laser Scan Is Adding Value and Performance to Refractory Lining Inside the Steel Industry Aloísio Simões Ribeiro, RHI Magnesita; Felipe Nonaka, RHI Magnesita; Julia Macedo, RHI Magnesita; Bruno Guimarães, RHI Magnesita; Victor Morais, RHI Magnesita; Haylander Avila, RHI Magnesita show more Description In order to meet steel industry demands related to safety and performance increasing, refractory suppliers are continuously challenged to develop innovative and integrated solutions to fulfill customers’ needs. This paper aims to present the new portable 3D laser scanning technology that is being used to add a new concept for refractory linings inspection in several steel equipment – during hot conditions and after campaign. Blast furnace runner campaign has enhanced its performance by 15%, steel ladle campaigns are now constantly monitored during hot measures and refractory post-mortem analysis are being performed with high accuracy by this new methodology. Time Monday, May 16 3:00PM - 3:30PM Location 408 Speakers Aloísio Simões Ribeiro RHI Magnesita Felipe Nonaka RHI Magnesita Julia Macedo RHI Magnesita Bruno Guimarães RHI Magnesita Victor Morais RHI Magnesita Haylander Avila RHI Magnesita How Soon We Forget Danny Smith, SafeStart(R) show more Description How many important things have you forgotten? That’s a great setup to the punchline, “I don’t know – I forgot!” But what if it’s a critical new skill set that mitigates specific risks like those experienced during a pandemic? How do we avoid complacency drift’s trap and develop skills that become habitual? Time Monday, May 16 3:00PM - 3:30PM Location 319 Speakers Danny Smith SafeStart(R) Level Control: Performance Module for Quality Improvement Ronald Wilmes, SMS group; Lothar Schaps, SMS group show more Description This paper offers a presentation of the properties, characteristics and advantages of the technological control modules of the SMS group's full automatic mold level control system for quality improvement (minimization of casting level fluctuations, detection and elimination of vibrations through transient bulging), as well as an integrative conversion concept of an existing plant. It provides a demonstration of the quality improvements resulting from the application of the various control modules on the basis of operating results. The paper includes presentation of a step-by-step modernization and conversion concept based on an example of the integration of this system into an existing plant during regular plant shutdowns. Time Monday, May 16 3:00PM - 3:30PM Location 310 Speakers Ronald Wilmes SMS group Lothar Schaps SMS group New Process for Hazardous Contaminated Steel Scrap to Produce Clean EAF Feedstock Felix Firsbach, Badische Stahl-Engineering; Jan-Henk Wijma, Purified Metal Company; Gonzalo Damm, Purified Metal Co. show more Description Steel scrap contaminated with hazardous components like asbestos, mercury or hexavalent chrome is widely available worldwide. The processing is not permitted in ordinary steel plants due to legislation for hazardous emissions control. Purified Metal Co. built the first plant in Delfzijl, Netherlands, which is able to treat hazardous ferrous waste. Metallurgical and operational experiences of first industrial campaigns, with asbestos and Cr(VI) scraps are described. The products are neutralized purified metal blocks with chemically known composition and carbon content of 3 wt.% which can be used as feedstock for electric arc furnaces. Time Monday, May 16 3:00PM - 3:30PM Location 406 Speakers Felix Firsbach Badische Stahl-Engineering Jan-Henk Wijma Purified Metal Company Gonzalo Damm Purified Metal Co. Operational Results of Hot Charging DRI Brian Voelker, Midrex Technologies Inc.; Sean Boyle, Midrex Technologies Inc. show more Description In electric arc furnace (EAF) steelmaking, hot transport/hot charging is an effective means of lowering the cost per ton of liquid steel by reducing power and electrode consumption, as well as increasing EAF productivity. MIDREX® shaft furnaces can be equipped with one of the three systems to transfer HDRI (hot DRI) to a meltshop: HOTLINK®, Hot Transport Conveyor (HTC) and Hot Transport Vessel (HTV). This paper will look at the development, history and operational results of this innovation and will delve into advantages and disadvantages of each method and explain the key factors that should go in to selecting the best options for steelmakers. Time Monday, May 16 3:00PM - 3:30PM Location 308 Speakers Brian Voelker Midrex Technologies Inc. Sean Boyle Midrex Technologies Inc. Optimizing Blast Furnace Stoves With Fast Stoichiometric Combustion Control Robert Bambeck, Bambeck Systems; Robin Roberts, Bambeck Systems; Emmaline Mazzei, Cleveland-Cliffs Indiana Harbor; Trenton Tagessen, Cleveland-Cliffs Indiana Harbor show more Description Blast furnace stoves combustion is optimized by implementing a stoichiometric combustion control. Required is a very fast laser analyzer across the stove flue gas to the stack and a control that holds the air-to-fuel ratio precisely at the perfect relationship at all firing conditions. The analyzer uses a quantum cascade laser (QCL), which uniquely measures in the mid-inferred wavelengths. CO is the process variable with its fundamental absorption wavelength in the mid-inferred. This paper discusses the QCL analyzer, the control strategy and the application of the technology installed at Cleveland-Cliffs' blast furnace #4 at Indiana Harbor. Time Monday, May 16 3:00PM - 3:30PM Location 320 Speakers Robert Bambeck Bambeck Systems Robin Roberts Bambeck Systems Emmaline Mazzei Cleveland-Cliffs Indiana Harbor Trenton Tagessen Cleveland-Cliffs Indiana Harbor Regenerative Burner Systems With Hydrogen Fuel for Decarbonization of High-Temperature Processes Justin Dzik, Fives North American Combustion; Mark Hannum, Fives North American Combustion, Inc. show more Description As the world looks to decarbonize, all indicators currently point to increased cost of fired thermal input for industrial processes. To minimize, there will be premiums placed on energy recovery. These demands are most clear in high-temperature (>2,00°F) processes. Regenerative burner systems are the means to recover the energy in the flue gases. Once energy recovery is maximized, then the transition to carbon-neutral fuel, such as hydrogen, can be performed, while minimizing additional impacts. This paper will discuss the advantages of regenerative burner systems, system engineering and performance impacts of hydrogen as a carbon-neutral fuel. Time Monday, May 16 3:00PM - 3:30PM Location 407 Speakers Justin Dzik Fives North American Combustion Mark Hannum Fives North American Combustion, Inc. Slab and Billet Grinding and Deburring Solutions Norbert Asamer, BRAUN Maschinenfabrik GmbH show more Description According to the newest trends, continuously cast products require full precise surface treatment or deburring at the front and/or tail ends before the next process steps. BRAUN has developed a highly flexible surface grinding and deburring grinding machines for applications which are too difficult for conventional deburring techniques. The paper describes the key features and advantages of BRAUN’s machine design and the operational results from the first already completed projects. Time Monday, May 16 3:00PM - 3:30PM Location 306 Speakers Norbert Asamer BRAUN Maschinenfabrik GmbH Study of the Temperature and of the Slag Properties Effects on Hot Metal Dephosphorization Efficiency Elton Volkers do Espírito Santo, Instituto Federal do Espírito Santo; Inamara Amanda Souza Santos, Instituto Federal do Espírito Santo; Késsia Gomes Paradela, Instituto Federal do Espírito Santo; José Roberto de Oliveira, Instituto Federal do Espírito Santo; Caio Vaccari Silva, Instituto Federal do Espirito Santo show more Description In the present work, an analysis of the dephosphorizing efficiency of a standard mixture M1 and other five mixtures is proposed. In those mixtures, temperature and slag properties (mixing mass and CaO granulometry) were varied. Experiments were carried at a temperature of 1,400°C and simulations were performed in FactSage 7.2 and surface images of the crucible were analyzed through Quantikov 15.86. The standard mixture M1 yields better efficiency than the other variations proposed. The results corroborate the equation used to calculate the dephosphorizing factor (FDeP), calculated to correlate slags thermodynamical properties and dephosphorization efficiency. Time Monday, May 16 3:00PM - 3:30PM Speakers Elton Volkers do Espírito Santo Instituto Federal do Espírito Santo Inamara Amanda Souza Santos Instituto Federal do Espírito Santo Késsia Gomes Paradela Instituto Federal do Espírito Santo José Roberto de Oliveira Instituto Federal do Espírito Santo Caio Vaccari Silva Instituto Federal do Espirito Santo Sublances: New Conceptions for Best Performances Breno Maia, Lumar Metals North America; Willian Lima, Lumar Metals North America; Bruno Santos (in memoriam), Lumar Metals North America; Haroldo Xavier, Ternium Brasil; Alenísio Alexandre Alves Nogueira, Lumar Metals show more Description The sublance has become an essential equipment in the primary refining of steel. Great attention is paid to the quality of the samples and their impacts on the quality of the steel produced. This paper discusses improvements in the final end of this equipment with the objective of increasing the life of the equipment and reducing the number of occurrences of cleaning of skulls and increasing the connection confiability of the sensors. Time Monday, May 16 3:00PM - 3:30PM Location 404 Speakers Breno Maia Lumar Metals North America Willian Lima Lumar Metals North America Bruno Santos (in memoriam) Lumar Metals North America Haroldo Xavier Ternium Brasil Alenísio Alexandre Alves Nogueira Lumar Metals Successful Story of a Rolling Mill Full Upgrade, Challenges and Results Antonio Ambra, AIC; David Zapata, Chicago Heights Steel show more Description This paper presents a description of the challenges an obsolete rolling mill faces with automation and with controlling the key performance indicators, steps made to fully upgrade it in minimal stopping time, and a description of the obtained results. Time Monday, May 16 3:00PM - 3:30PM Location 401 Speakers Antonio Ambra AIC David Zapata Chicago Heights Steel The Evolution of Continuous Annealing and Processing Lines for the Production of Electrical Steels Stefano Martines, Tenova; Christian Wuppermann, Tenova LOI Thermprocess show more Description The market demands for electrical steel is currently driven by strong initiatives toward electro-mobility and large infrastructural projects to optimize power networks toward extended capacities of renewable energies. Therefore, new steel grades with thin and ultrathin gauges have been developed to improve the efficiency of components containing non-grain oriented and grain-oriented electrical steel. The production of these advanced silicon steel grades has highest demands on heat treatment and processing lines. In the present study, the recent Tenova developments in technology for silicon strip heat treatment and processing are described. Time Monday, May 16 3:00PM - 3:30PM Location 307 Speakers Stefano Martines Tenova Christian Wuppermann Tenova LOI Thermprocess Titanium Nitride Nucleation and Growth During Steel Solidification P. Chris Pistorius, Carnegie Mellon University; Bryan Webler, Carnegie Mellon University; Peter Wilkerson, Carnegie Mellon University show more Description Titanium nitride is an unavoidable yet potentially dangerous inclusion in several types of industrially produced steel. These hard inclusions can grow to be large and have sharp edges. Inclusions with these properties can concentrate stress and propagate cracks in steel, hampering mechanical properties. This work investigated TiN inclusions in lollipops, slab crops, and samples remelted under controlled conditions in the laboratory. Lower solidification rates produced larger TiN, but substantial differences were observed between remelted and plant samples despite similar cooling rates. Results were connected to the mechanisms governing the TiN growth, which must be understood to ensure steel cleanliness. Time Monday, May 16 3:00PM - 3:30PM Location 309 Speakers P. Chris Pistorius Carnegie Mellon University Bryan Webler Carnegie Mellon University Peter Wilkerson Carnegie Mellon University
3:30pm Advanced Technology in High-Temperature Annealing of Grain-Oriented Electrical Steel Marius Kreuzeder, EBNER Industrieofenbau GmbH show more Description The sharp rise in global electricity demand will necessitate the expansion of the electrical grid in the coming decades. Due to sustainability and climate goals, the required efficiency and quality level for grain-oriented electrical steel is permanently increasing. During an ideal high-temperature heat treatment process the target is to achieve a perfect GOSS-structure throughout the entire charge, which is only feasible with highest uniformity of temperature within the coils. The talk reviews an advanced heat treatment technology for high-temperature annealing of grain-oriented material, which results in significant reduction in processing time, outstanding material quality and lowest media consumptions. Time Monday, May 16 3:30PM - 4:00PM Location 310 Speakers Marius Kreuzeder EBNER Industrieofenbau GmbH Asset Performance Management for Metals Michael Tay, Rockwell Automation show more Description In the steel industry, maintenance costs account for 10-15% of total production cost. And unplanned downtime in heavy industry can account for as much as 20% of productive capacity. Without a doubt, equipment maintenance has a huge impact on a company’s bottom line. The good news? Thoughtful, innovative maintenance practices are more available than ever before. This session will focus on the Maintenance Maturity Model and share current and future technology enablers and best practices for three maintenance approaches: preventative, condition-based and predictive. Time Monday, May 16 3:30PM - 4:00PM Location 404 Speakers Michael Tay Rockwell Automation Building Sustainable Mini Cold Rolling Complexes Navneet Singh, Digi Drives Pvt. Ltd.; Deepak Khanna, Digi Drives Pvt. Ltd. show more Description This paper encourages budding entrepreneurs to set up a cold flat steel complex with minimal CAPEX and small gestation period. Leveraging green technologies fulfills all criteria - especially addressing the upward supply chain and downstream high quality, low OPEX and user-friendly distribution network sensitized to end user requirements. A brief case study demonstrates wealth creation for the entrepreneur and competitive bespoke product for the end user, paving the path for a sustainable future. Time Monday, May 16 3:30PM - 4:00PM Location 307 Speakers Navneet Singh Digi Drives Pvt. Ltd. Deepak Khanna Digi Drives Pvt. Ltd. Control of the Tundish Superheat by Modeling the Temperature Loss After the Final Secondary Refinement Process Step Using a Machine-Learning Approach Franz Ramstorfer, Ternium Brasil; Leonardo Martins Demuner, Ternium Brasil; Bruno Suveges Cerchiari , Ternium Brasil show more Description Maintaining the tundish superheat in a certain temperature range is essential for the stability of the continuous casting process, quality of the casted product and the caster productivity. The final adjustment of the steel temperature in the ladle at the last station of the secondary refinement process is therefore key for adjusting the tundish superheat. In the present work, the temperature loss was modeled based on secondary refinement parameters, ladle condition and casting parameters using various machine-learning techniques. Moreover, the model was integrated as a real-time calculation in the level 2 on-line process control system. Time Monday, May 16 3:30PM - 4:00PM Location 309 Speakers Franz Ramstorfer Ternium Brasil Leonardo Martins Demuner Ternium Brasil Bruno Suveges Cerchiari Ternium Brasil Conversion of Manual Cranes in Fully Automatic Cranes at Nucor Steel Gallatin Ed LaBruna, Janus Automation show more Description This presentation discusses the entire process to convert a manual crane shipping bay into a fully automatic storage and retrieval system, including the simulation, consideration for the conversion in an operative area, interaction in areas on the ground for manual operations, logistics optimization and overall ground safety. Time Monday, May 16 3:30PM - 4:00PM Location 405 Speakers Ed LaBruna Janus Automation Effect of Plate Rolling Strategy and Nb Microalloying in the HAZ Performance After Welding Doug Stalheim, DGS Metallurgical Solutions; Pello Uranga, CEIT and University of Navarra, Tecnun ; Daichi Izumi, JFE Steel Corp.; Nobuyuki Ishikawa, JFE Steel Corp.; David Jarreta, CBMM Asia; David Martin, CBMM Asia; Nerea Isasti, CEIT and University of Navarra; Jose M. Rodriguez-Ibabe, CEIT and University of Navarra show more Description The definition of hot rolling parameters to achieve the most suitable combination of final microstructure and precipitation is a key factor to control mechanical properties of welded plates. In this work, several Ti-Nb microalloyed steels were rolled following standard and optimized rolling strategies, resulting in different microstructures and precipitation states in the hot-rolled plates. Both simulated and real welding treatments were applied to the plates and the mechanical properties measured. The correlation between hot rolling parameters, precipitate population, microstructural features and mechanical performance was evaluated. High mechanical performance of welded plates was achieved for the optimized rolling conditions. Time Monday, May 16 3:30PM - 4:00PM Location 402 Speakers Doug Stalheim DGS Metallurgical Solutions Pello Uranga CEIT and University of Navarra, Tecnun Daichi Izumi JFE Steel Corp. Nobuyuki Ishikawa JFE Steel Corp. David Jarreta CBMM Asia David Martin CBMM Asia Nerea Isasti CEIT and University of Navarra Jose M. Rodriguez-Ibabe CEIT and University of Navarra Evaluation of Stirring and Flux Type Influence on Hot Metal Desulfurization Efficiency Elton Volkers do Espírito Santo, Instituto Federal do Espírito Santo; Inamara Amanda Souza Santos, Instituto Federal do Espírito Santo; Késsia Gomes Paradela, Instituto Federal do Espírito Santo; José Roberto de Oliveira, Instituto Federal do Espírito Santo; Marcelo Lucas Pereira Machado, Instituto Federal do Espírito Santo; Caio Vaccari Silva, Instituto Federal do Espirito Santo; Flaviani Marculano Marchesi, Instituto Federal do Espirito Santo show more Description Desulfurization parameters such as stirring and flux type are fundamental to reach the low sulfur levels required nowadays. Therefore, this paper aims to determine their influence on desulfurization efficiency. Two types of stirrers were tested as well as the following fluxes: standard flux, sodalite, aluminum dross, fluorspar and B2O3. The tests were performed at 1,350°C in an inert atmosphere. The liquid and solid phases formed in the mixtures were determined by the software Factsage 7.0 and the desulfurization factor (FDeS) was developed. The stirrer with the highest stirring energy and the mixtures containing B2O3 generated the best results. Time Monday, May 16 3:30PM - 4:00PM Speakers Elton Volkers do Espírito Santo Instituto Federal do Espírito Santo Inamara Amanda Souza Santos Instituto Federal do Espírito Santo Késsia Gomes Paradela Instituto Federal do Espírito Santo José Roberto de Oliveira Instituto Federal do Espírito Santo Marcelo Lucas Pereira Machado Instituto Federal do Espírito Santo Caio Vaccari Silva Instituto Federal do Espirito Santo Flaviani Marculano Marchesi Instituto Federal do Espirito Santo Forward Dressing: Toward a More Dynamic and Effective Material Allocation and Production Process Alessandro Stenico, PSI Metals GmbH; Marc Schwarzer, PSI Metals GmbH show more Description Order dressing is the business process that derives from the sales order the ideal settings for each manufacturing step required until the final product. However, when an input material significantly deviates from the ideal status, the remaining production plan needs to be dynamically adapted. Forward dressing is a service that, for deviating input materials, generates material-specific instructions for the downstream manufacturing steps in order to fulfill the order targets. The advantages of applying forward dressing in metals production management include minimizing unallocated or downgraded material, avoiding production delays, maximizing throughput, and compensating quality deviations with material-specific process parameters. Time Monday, May 16 3:30PM - 4:00PM Location 315 Speakers Alessandro Stenico PSI Metals GmbH Marc Schwarzer PSI Metals GmbH Increased Dependability in Mechanical Conveying of DRI Hot Charge Gaetano Coraggio, Magaldi Technologies; N. Bassano, MAGALDI POWER S.p.A.; C. Mantellino, MAGALDI POWER S.p.A. show more Description Charging hot direct reduced iron (DRI) into the furnace from a distance is normally performed with a sprocket-driven mechanical chain conveyor in inert atmospheres up to 700 degrees C. These systems are historically a maintenance headache as they suffer greatly due to the high temperatures and abrasive nature of the material and dust. To solve these heat- and atmospheric-related issues and increase plant efficiency and uptime, a new DRI containment conveyor system utilizing a sealed shell, steel pans and looped mesh system has been developed and tested. The results of the testing and details of the system are to be presented. Time Monday, May 16 3:30PM - 4:00PM Location 308 Speakers Gaetano Coraggio Magaldi Technologies N. Bassano MAGALDI POWER S.p.A. C. Mantellino MAGALDI POWER S.p.A. Integrated Temperature Model for Superior Hot Strip Production – First Results From SDI Sinton Klaus Pronold, SMS group; Kai Grybel, SMS group; Christoph Hassel, SMS group; Patrick Dickel, SMS group GmbH show more Description In an effort to improve hot rolling process models, prediction accuracy, and technological control performance efficiency a new cross-functional model, meta model, takes an integrated temperature approach. Hot rolling involves various consecutive process steps, which affects the mechanical properties of the product; for example, yield strength, tensile strength and low-temperature behavior. The result of the rolling process is influenced by the chemical composition of the steel and the temperature guidance during rolling. This new development is part of the new Steel Dynamics Inc. - Flat Roll Group Southwest-Sinton Division plant being commissioned in 2022, and future-oriented concepts and latest results from commissioning will be presented. Time Monday, May 16 3:30PM - 4:00PM Location 306 Speakers Klaus Pronold SMS group Kai Grybel SMS group Christoph Hassel SMS group Patrick Dickel SMS group GmbH New Field Results on Ultrasonic Mold Thermal Mapping for Quality Improvement and Initial Solidification Diagnostics Stefano Miani, Ergolines Lab srl - Trieste; Giovanni Schiavon, Ergolines Lab srl - Trieste; Stefano Spagnul, Ergolines Lab srl - Trieste; Isabella Mazza, Ergolines Lab srl - Trieste show more Description Ergolines developed an ultrasonic thermal mapping (UT-MAP) system that provides a real-time temperature map of the copper mold. The ultrasonic sensors are installed on the water jacket, requiring minimal machining and the measurement is contactless. A dedicated UT-MAP software displays the real-time temperature trends and meniscus thermal profiles with dedicated process control tools. From field data installations, UT-MAP demonstrates its ability to detect anomalies in the thermal profile as sticking events and heat transfer variations. By analyzing the UT-MAP historical temperature data, the metallurgist can optimize casting practice and process variables, leading to reproducible casting conditions and improved steel quality. Time Monday, May 16 3:30PM - 4:00PM Location 316 Speakers Stefano Miani Ergolines Lab srl - Trieste Giovanni Schiavon Ergolines Lab srl - Trieste Stefano Spagnul Ergolines Lab srl - Trieste Isabella Mazza Ergolines Lab srl - Trieste Numerical Modeling of Hydrogen Application in a Reheating Furnace Armin Silaen, Purdue University Northwest; Chenn Zhou, Purdue University Northwest; Chukwunendum Uzor, Purdue University Northwest; Emily Higley, Purdue University Northwest; John Rosser, Purdue University Northwest; Kelly Tian, Linde; Joe Maiolo, Linde; Lawrence Fabina, Cleveland-Cliffs Burns Harbor show more Description The current practice in the steel industry is to use methane as fuel in reheat furnaces. The combustion of methane generates greenhouse gases such as carbon dioxide and carbon monoxide. There is a need for research into alternative fuels to be used in reheat furnaces to reduce greenhouse. This study investigates how using hydrogen as fuel in a reheat furnace impacts flame pattern, slab heating profile, heat flux into slab, scale thickness, slab thermal stress, and carbon and NOx emissions. The computational fluid dynamics simulations used in this study provide insights into the use of hydrogen as fuel in reheat furnaces. Time Monday, May 16 3:30PM - 4:00PM Location 407 Speakers Armin Silaen Purdue University Northwest Chenn Zhou Purdue University Northwest Chukwunendum Uzor Purdue University Northwest Emily Higley Purdue University Northwest John Rosser Purdue University Northwest Kelly Tian Linde Joe Maiolo Linde Lawrence Fabina Cleveland-Cliffs Burns Harbor Phenol-Free Magnesia Carbon/Alumina Magnesia Carbon Refractories for Ladle Lining Seungseok Choi, Wonjin Worldwide; JeongWoo Lee, Wonjin Worldwide; Dongbaek Kim, Wonjin Worldwide; Namjun Park, Wonjin Worldwide show more Description Resin-bonded unfired bricks, such as magnesia carbon, are the most popular refractory products for the steelmaking industry. Novolac-type phenolic resin is the bonding agent for such unfired bricks for most refractory producers, thanks to its ease of use and reduced level of hazard compared to the ordinary bonding agent, pitch. Although resin-bonded bricks are cured at over 200℃ during manufacturing, remaining resin components emit odor and hazardous gases during use. To remove such unfavorable components, new phenol-free bonded bricks are studied and tested. Time Monday, May 16 3:30PM - 4:00PM Location 408 Speakers Seungseok Choi Wonjin Worldwide JeongWoo Lee Wonjin Worldwide Dongbaek Kim Wonjin Worldwide Namjun Park Wonjin Worldwide ProcessXpert: A New Generation of Knowledge-Based Blast Furnace Expert System Fabrice Hansen, SMS Digital; Juraj Micak, Paul Wurth S.A.; Franck Giroldini, Paul Wurth S.A show more Description ProcessXpert is a knowledge-based blast furnace process optimization model for continuous monitoring of blast furnace operation. This model is built based on the SACHEM expert system, using proven expertise of more than 30 years of experiences. The model provides multiple phenomena detection. On top of phenomena detection, the model provides hot metal temperature and silicon prediction for short- and mid-term horizon and appropriate fuel rate recommendation, with possible combination of machine-learning approaches. The present paper highlights the advantages and the recent developments on the ProcessXpert model, which is a part of Paul Wurth’s level 2 solution – BFXpert™. Time Monday, May 16 3:30PM - 4:00PM Location 317 Speakers Fabrice Hansen SMS Digital Juraj Micak Paul Wurth S.A. Franck Giroldini Paul Wurth S.A Safety Guarding Ergonomics and ROI Chris Allen, Belt Conveyor Guarding show more Description The topic of the presentation is to emphasize the importance of safety guarding ergonomics and its return on investment. Key topics will be discussed include: - OSHA/MSHA machine guarding standards and how to apply them to equipment. - Principles of fixed guarding. - Explanation of how companies can make their guarding ergonomic and maintenance-friendly. - Demonstration of cost effects of injuries due to non-ergonomic guarding. - Providing a useful tool to estimate direct and indirect costs caused by poor ergonomics. Time Monday, May 16 3:30PM - 4:00PM Location 319 Speakers Chris Allen Belt Conveyor Guarding Steel Production Experience in Using Pig Iron and Hot Briquetted Iron in the Electric Arc Furnace at Steel Dynamics Kamalesh Mandal, Steel Dynamics Inc.; William Lee, Steel Dynamics Inc.; Don Bryant, Steel Dynamics Inc.; Evan Wright, Steel Dynamics Inc.; Madhu Ranade, Steel Dynamics Inc.; Ron Bohna, Steel Dynamics show more Description Steel Dynamics Inc.'s more than 9 million tons/year of sheet steel production from its Columbus, Butler and Sinton electric arc furnaces serve appliance, automotive, construction, HVAC, energy, agriculture and service center markets with hot rolled, cold rolled, pickled, galvanized, Galvalume®, aluminized, and painted products. The company successfully produces advanced products with low residuals, particularly low copper, by using an optimized mix of prime scrap, hot briquetted iron (HBI) and pig iron. This presentation will cover production experience at the Columbus mill in using 10-30% pig iron and 3-10% HBI in the charge mix and will also cover design features in the new Sinton mill for increased use of HBI. Time Monday, May 16 3:30PM - 4:00PM Location 406 Speakers Kamalesh Mandal Steel Dynamics Inc. William Lee Steel Dynamics Inc. Don Bryant Steel Dynamics Inc. Evan Wright Steel Dynamics Inc. Madhu Ranade Steel Dynamics Inc. Ron Bohna Steel Dynamics The Tenova Hydrogen SmartBurner for Reheating: Analysis of the Industrial Results in TenarisDalmine Alessandro Della Rocca, Tenova S.p.A.; Mattia Bissoli, Tenova S.p.A.; Davide Astesiano, Tenova S.p.A.; Guido Jochler, RINA S.p.A.; Fabio Praolini, Tenaris S.p.A. show more Description This paper presents the Tenova SmartBurner technology: TSX (recuperative flameless for reheating applications) and TRKSX (self-recuperative flameless for heat treatment) ready-to-use H2 as fuel up to 100%. In both cases, NOx in the operative range from 100% NG to 100% H2 is well below the next future limits: <80 mg/Nm3 at 5% of O2 with furnace at 1,250°C and air above 500°C. The ongoing development will be completed with the installation on TenarisDalmine's furnace. A propaedeutic analysis of the effect of atmosphere generated by the combustion of a NG/H2 mixture on main TenarisDalmine products will be also analyzed. Time Monday, May 16 3:30PM - 4:00PM Location 401 Speakers Alessandro Della Rocca Tenova S.p.A. Mattia Bissoli Tenova S.p.A. Davide Astesiano Tenova S.p.A. Guido Jochler RINA S.p.A. Fabio Praolini Tenaris S.p.A. Utilizing Advanced Simulation Techniques to Improve Hood Design Brian Bakowski, SLR Consulting show more Description Capturing airborne contaminants such as particulate emissions is a requirement under the maximum available control Technology (MACT) standards for the steel industry. As particulate escapes the building, it is qualitatively measured as opacity by certified opacity readers. As part of the MACT Standard, the owner’s permit will then specify an opacity limit, such as no more than 20% for a 6-minute average. This standard then requires the owner to capture has much particulate inside the building to avoid non-compliance with the standards. This paper examines methods to increase capture efficiency of local hoods using the latest simulation technology. Time Monday, May 16 3:30PM - 4:00PM Location 320 Speakers Brian Bakowski SLR Consulting Visual Tracking on Continuous Casting Gianluca Maccani, Polytec USA Corp.; Anna Zoppirolli, BM Group Polytec S.p.A. show more Description Instead of detecting the billets position using a single-point sensor and relying just on the automation, methods that are proven not fully reliable in different conditions, this new concept introduces machine vision in order to detect by images the position of the billets in a way more similar to the human eye. This system is virtually not affected by any failure (billets that falls from the transfer car, false positives or negatives form sensors, etc.), achieving higher general reliability. Time Monday, May 16 3:30PM - 4:00PM Location 311 Speakers Gianluca Maccani Polytec USA Corp. Anna Zoppirolli BM Group Polytec S.p.A.
4:00pm Campaign Life Extension of Blast Furnace Offgas System Chad Van der Woude, Hatch; Hamid Ghorbani, Hatch; Jorge Luiz de Oliveira, Gerdau Açominas S.A. ; Sunil Kumar, Hatch Ltd.; Mark Allan, Hatch Ltd.; Yang Zhou, Hatch Ltd.; Camilla Lopes, Hatch Ltd.; Ricardo Jose Maia , Hatch Ltd.; Maher Al-Dojayli, Hatch Ltd.; Sergio Nascinmento Leal, Gerdau Açominas S.A. show more Description During the 33 years of operation, an operator's blast furnace 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, May 16 4:00PM - 4:30PM Location 404 Speakers Chad Van der Woude Hatch Hamid Ghorbani Hatch Jorge Luiz de Oliveira Gerdau Açominas S.A. Sunil Kumar Hatch Ltd. Mark Allan Hatch Ltd. Yang Zhou Hatch Ltd. Camilla Lopes Hatch Ltd. Ricardo Jose Maia Hatch Ltd. Maher Al-Dojayli Hatch Ltd. Sergio Nascinmento Leal Gerdau Açominas S.A. Design Features and Innovations of Modern Electrical Arc Furnaces Eneko Sedano, Sarralle Steel Melting Plant; Jon Serrano, Sarralle Steel Melting Plant show more Description This paper will be discussed the design features of the new DC electric arc furnace. During this project, particular attention has been dedicated to safety features with automatic and robot-assisted operations as well as to achieve and a very low impact on the power grid in terms of flickers and harmonics, while using a variety of raw materials (scrap, DRI, HBI, PI, GPI) permitting the production of blast furnace steel qualities also. Electrical impact reduction and flicker technology used in the design phase will be also reviewed in detail. Time Monday, May 16 4:00PM - 4:30PM Location 315 Speakers Eneko Sedano Sarralle Steel Melting Plant Jon Serrano Sarralle Steel Melting Plant Development and Application of Waste Gas Model on 210-Ton Converter Yanhui Sun, University of Science and Technology Beijing; Pan Gao, University of Science and Technology Beijing/Research Institute of Technology, Shougang Group; Haibo Li, Shougang Group Co., Ltd.; Bin Chen, Shougang Group Co., Ltd.; Tengfei Jiang, Beijing Shougang Co., Ltd. ; Guibin Huang, University of Science and Technology Beijing show more Description Compared with the sublance model, the waste gas model has the characteristics of high intelligence and high efficiency, so in recent years, it has been increasingly used as a new method of judging the end of the converter blowing. The waste gas model was developed on the 210-ton converter at Shougang Group, which achieved the effect that the hit rate of C content at the end of the blowing reached 99% and the hit rate of T reached 87%. Time Monday, May 16 4:00PM - 4:30PM Speakers Yanhui Sun University of Science and Technology Beijing Pan Gao University of Science and Technology Beijing/Research Institute of Technology, Shougang Group Haibo Li Shougang Group Co., Ltd. Bin Chen Shougang Group Co., Ltd. Tengfei Jiang Beijing Shougang Co., Ltd. Guibin Huang University of Science and Technology Beijing Development of Exothermic Granule Mold Powder With Improved Thermal Insulation by Adding Metallic Material Shoji Takahashi, Shinagawa Refractories Co. Ltd.; Junya Ito, Shinagawa Refractories Co. Ltd.; Masanori Okada, Shinagawa Advanced Materials Americas Inc.; Jim Gilmore, Shinagawa Advanced Materials Americas Inc. show more Description In the continuous casting of steel, improving the insulation property of the mold powder is effective for reducing inclusion defects and surface cracking. To improve on this effect, a spray-dried granule type with an exothermic reaction utilizing metal oxidation has been developed. To demonstrate the influence of exothermicity on thermal insulation in the mold, a simulation test measuring the temperature of molten iron covered with mold powder samples has been developed and conducted in the laboratory. The results are applied for the optimization of exothermicity in products. The exothermic granule type has achieved improved steel quality and stable casting operation. Time Monday, May 16 4:00PM - 4:30PM Location 316 Speakers Shoji Takahashi Shinagawa Refractories Co. Ltd. Junya Ito Shinagawa Refractories Co. Ltd. Masanori Okada Shinagawa Advanced Materials Americas Inc. Jim Gilmore Shinagawa Advanced Materials Americas Inc. Dynamic No-Fly Zones; Overhead Cranes vs. Moving Obstacles Steven Lubeck, Laser-View Technologies show more Description In steel production, overhead cranes are used in conjunction with other material handling equipment, such as jib and gantry cranes. Operators are forced to avoid interfering with these systems while transporting loads. Often, the overhead and gantry crane work together in production cells. No-fly zoning around moving obstacles is more difficult than fixed boundaries and requires controls and sensors that communicate between the crane and the related equipment. Such collisions can present safety risks and result in costly damage and downtime. This presentation discusses common techniques available for dynamically restricting overhead crane position when operated around other moving obstacles. Time Monday, May 16 4:00PM - 4:30PM Location 405 Speakers Steven Lubeck Laser-View Technologies Environmental and Production Improvements in Plate Production by Digitalization of Cooling Technologies John Hinton, Primetals Technologies; Ian Robinson, Primetals Technologies show more Description The use of in-line plate cooling technology is proven to produce high-strength steel grades. State-of-the-art plate cooling technology offers great flexibility in allowing a wide product portfolio for a steel producer. Advanced process automation enables tight tolerances across all performance indicators. More recently, the focus has turned to minimizing environmental impacts and processing costs. For example, a reduction in post processing requirements and careful management of water consumption. This paper considers the implications and opportunities for this technology, from further optimization to ongoing digitalization, condition monitoring and process optimization through digital twin. Time Monday, May 16 4:00PM - 4:30PM Location 320 Speakers John Hinton Primetals Technologies Ian Robinson Primetals Technologies Melting Behavior of Conventional and Hydrogen-Reduced DRI in a Simulated EAF Steel Bath Ronald J. O'Malley, Missouri University of Science and Technology; Joe Govro, Missouri University of Science and Technology; Laura Bartlett, Missouri University of Science and Technology; Soumava Chakraborty, Missouri University of Science and Technology; Amogh Meshram, Arizona State University; Yuri Korobeinikov, Arizona State University ; Sridhar Seetharaman , Arizona State University ; Viraj Athavale, Missouri University of Science and Technology; A. Meena, Missouri University of Science and Technology ; K. Phillips, Missouri University of Science and Technology ; J. Smith, Missouri University of Science and Technology ; A. Emdadi, Missouri University of Science and Technology show more Description The melting behavior of conventional carbon-bearing direct reduced iron (DRI), hot briquetted iron (HBI), and carbon-free DRI produced by hydrogen reduction has been investigated in a simulated electric arc furnace (EAF) melting environment. A testing apparatus was created to document the melting rates under various bath conditions in slag and steel. The data acquired is compared to established melting mechanisms and models. The results of this investigation sheds light on the potential process effects of melting hydrogen-produced DRI in the EAF. Time Monday, May 16 4:00PM - 4:30PM Location 308 Speakers Ronald J. O'Malley Missouri University of Science and Technology Joe Govro Missouri University of Science and Technology Laura Bartlett Missouri University of Science and Technology Soumava Chakraborty Missouri University of Science and Technology Amogh Meshram Arizona State University Yuri Korobeinikov Arizona State University Sridhar Seetharaman Arizona State University Viraj Athavale Missouri University of Science and Technology A. Meena Missouri University of Science and Technology K. Phillips Missouri University of Science and Technology J. Smith Missouri University of Science and Technology A. Emdadi Missouri University of Science and Technology New Cold Mill Complex in Ukraine — Technologies and Achieved Performances Marco Girardi, Danieli & C. Officine Meccaniche S.p.A.; Cristian Bini, Danieli Wean United show more Description The complex will produce 1.6 Mtpy of cold-rolled quality strip products: more than 600,000 tons will be galvanized coils, with another 170,000 tons polymer coated. The project includes the construction of a cold rolling continuous tandem mill combined with a pickling line, as well as two strip processing lines for zinc, zinc aluminum and polymer coatings. The installed technologies will ensure Metinvest will be able to produce in an environmentally sustainable way at competitive production costs, with emissions much lower than today's standards. The first coil will be produced by Q3 2024. Time Monday, May 16 4:00PM - 4:30PM Location 307 Speakers Marco Girardi Danieli & C. Officine Meccaniche S.p.A. Cristian Bini Danieli Wean United NOx Emission From the Hot Blast System: Formation, Effects, and the Possibilities for Its Reduction Bart De Graaff, Danieli Corus; Jan de Weerdt, Danieli Corus BV; Yuriy Lytvynyuk, Danieli Corus BV show more Description NOx formation has a two-fold impact on the hot blast system: NOx is a pollutant (subject to emission regulations) and causes intercrystalline stress corrosion (affecting shell lifetime and potentially causing dangerous situations). Predicting and understanding the fundamentals of NOx formation and its control within allowable limits has great added value. Such predictions provide useful insights for designing new stoves as well as for finding improved operating conditions within existing systems. This paper compares a one-dimensional, pre-mixed flame combustion model based on Cantera and full-scale computational fluid dynamics with combustion model for their applicability for analyzing specific situations and control measures. Time Monday, May 16 4:00PM - 4:30PM Location 317 Speakers Bart De Graaff Danieli Corus Jan de Weerdt Danieli Corus BV Yuriy Lytvynyuk Danieli Corus BV Optimized Tool Use of Saw Blades on Cold Circular Saws Through the Use of a Condition Monitoring System Andreas Kellner, framag Industrieanlagenbau GmbH; Reinhard Pollhamer, framag Industrieanlagenbau GmbH; Heimo Huemer, framag Industrieanlagenbau GmbH show more Description Cold circular saws are used in a wide variety of applications in the steel industry. In order to be able to meet the extremely high requirements regarding performance, cutting quality and service life, framag has developed a novel condition monitoring system to monitor the saw blade. With the help of this system, it is possible for the operator to obtain precise information about the condition of the saw blade at any time in order to select optimum cutting parameters, but also to be able to plan tool changes in advance. This contribution deals with the sensor technology, data evaluation and rollout of this condition monitoring system. Time Monday, May 16 4:00PM - 4:30PM Location 311 Speakers Andreas Kellner framag Industrieanlagenbau GmbH Reinhard Pollhamer framag Industrieanlagenbau GmbH Heimo Huemer framag Industrieanlagenbau GmbH Panel Discussion: A Pathway to Making Your Reheat Furnaces Green while Improving Capacity and Reducing Energy Consumption Dave Wolff, Nel Hydrogen; Armin Silaen, Purdue University Northwest; Justin Dzik, Fives North American Combustion; Mark Hannum, Fives North American Combustion, Inc. ; Anup Sane, Air Products show more Description Panel Discussion Time Monday, May 16 4:00PM - 5:00PM Location 407 Speakers Dave Wolff Nel Hydrogen Armin Silaen Purdue University Northwest Justin Dzik Fives North American Combustion Mark Hannum Fives North American Combustion, Inc. Anup Sane Air Products Panel Discussion: Challenges with Respect to Raw Materials Angelo Manenti, Metal Consulting; Madhu Ranade, Steel Dynamics Inc. show more Description Panel discussion on the challenges of raw materials for use in the electric arc furnace. Time Monday, May 16 4:00PM - 5:00PM Location 406 Speakers Angelo Manenti Metal Consulting Madhu Ranade Steel Dynamics Inc. Production of Steel Heavy Plates up to 100 mm by TMCP With Accelerated Cooling at NLMK DanSteel Eugene Goli-Oglu, NLMK DanSteel; Zibrandt Greisen, NLMK DanSteel show more Description This paper contains investigations of microstructure and mechanical properties of industrial samples of low-carbon microalloyed steel heavy plates of quality S420M and S420ML according to EN 10025-4:2019 and used for offshore wind foundations. The chemical composition and process parameters of TM+ACC heavy plates used were developed by the authors. The technology is fully implemented at NLMK DanSteel. The authors describe the specifics of designing the chemical composition and selecting the technological parameters for the thermomechanical processing. Time Monday, May 16 4:00PM - 4:30PM Location 402 Speakers Eugene Goli-Oglu NLMK DanSteel Zibrandt Greisen NLMK DanSteel Safety's Flux Capacitor Danny Smith, SafeStart(R) show more Description If you had a workplace time machine, what insights would your future-self provide? Most leaders would want to use this opportunity to improve the outcome reliability in common problem areas such as safety, performance, employee engagement and culture. The great news is that reliable outcomes don’t require seeing into the future. A human factors framework model can provide a prescriptive approach to addressing deficiencies in organizations. Participants will learn the common challenges associated with human factors — within both individuals and organizations. Time Monday, May 16 4:00PM - 4:30PM Location 319 Speakers Danny Smith SafeStart(R) Steel Production Assistance System (SPAS) That Uses Measurement Data From an Ultrafast Laser Scanner to Optimize Safety, Yield and Refractory Performance of the Metallurgical Vessel Rolf Lamm, Minteq International GmbH; Stefan Kirchhoff, Minteq International GmbH show more Description The Steel Production Assistance System (SPAS) uses data from a new developed laser measuring system specially designed for extreme hot environment. By immersion of a laser scanner into a hot vessel (converter, electric arc furnace, ladle, torpedo) the system is collecting millions of data points that can be used not only to evaluate the refractory thickness of the linings, but the data also serve as the basis for various calculations that lead to increased safety, optimization of process flows and increased yields in steel production. Time Monday, May 16 4:00PM - 4:30PM Location 408 Speakers Rolf Lamm Minteq International GmbH Stefan Kirchhoff Minteq International GmbH Thermodynamic Simulation of Precipitation Hardening Stainless Steel Ana Laura Hernandez Sustaita, Universidad Autónoma de Nuevo León; Luis Aldolfo Leduc-Lezama, Universidad Autónoma de Nuevo León; Edgar Iván Saldaña, Universidad Autónoma de Nuevo León; Martha P. Guerrero Mata, Universidad Autónoma de Nuevo León show more Description The forging industry, dedicated to the processing and casting of steels, makes use of sophisticated thermodynamic tools for analysis and design in order to improve its alloys. It is well known that material properties and behavior are strongly dependent on chemical composition. However, it is expensive and time consuming to carry out experiments for each new alloy. Therefore, this presentation shows the development of a heat-treated stainless steel precipitation hardening grade. Using ThermoCalc, it was found that even slightly different chemical compositions can have an impact on transformation temperatures, amount and type of precipitates affecting the final mechanical properties. Time Monday, May 16 4:00PM - 4:30PM Location 310 Speakers Ana Laura Hernandez Sustaita Universidad Autónoma de Nuevo León Luis Aldolfo Leduc-Lezama Universidad Autónoma de Nuevo León Edgar Iván Saldaña Universidad Autónoma de Nuevo León Martha P. Guerrero Mata Universidad Autónoma de Nuevo León
4:30pm AI Crane Safety Technology Paul Thurber, Everguard; Sundeep Ahluwalia, Everguard show more Description We will introduce sensor-based (CV & RTLS) technologies powered by Sentri360. These are proven solutions using artificial intelligence to aid in the prevention of crane incidents and associated losses. Time Monday, May 16 4:30PM - 5:00PM Location 405 Speakers Paul Thurber Everguard Sundeep Ahluwalia Everguard Aspects of Boundary Lubrication in Advanced High-Strength Steel Rolling Bas Smeulders, Quaker Houghton show more Description Boundary lubrication is important in controlling roll forces in cold rolling. Friction is reduced by molecule adsorption, and local adhesion is minimized by chemical reactions at the contacting surfaces. Pilot mill trials on advanced high-strength steel showed clear differences in roll force between lubricant emulsions only varying in boundary lubrication properties. The coefficient of friction in these trials was analyzed with an advanced "tribological roll bite model." The friction was shown to include contributions of elastohydrodynamic lubrication, micro-plasto-hydrodynamic lubrication, sliding boundary friction and unprotected friction, the latter varying between the lubricants. The method assists lubricant development based on understanding of lubrication mechanisms. Time Monday, May 16 4:30PM - 5:00PM Location 307 Speakers Bas Smeulders Quaker Houghton Condition Evaluation as Basis for Digitalization – Use Cases and New Analysis Christoph Häusler, SMS group; Benjamin Zimmerman, SMS group Inc.; Johannes Leipold, SMS group show more Description New analyses are constantly being developed to analyze the condition of machines in even greater detail in order identify the phenomena that were previously undetectable (e.g., spindle knocking). New methods of sensor technology open up new possibilities, even in components that were previously difficult to monitor (e.g., acoustic emission). The new methods of digitization and big data analytics are accelerators for moving from pure condition monitoring to condition evaluation, respectively, predictive asset health (e.g., novelty detection). This presentation shows practical examples that these technologies have left the concept stage and have already proven their industrial suitability in practical operation. Time Monday, May 16 4:30PM - 5:00PM Location 311 Speakers Christoph Häusler SMS group Benjamin Zimmerman SMS group Inc. Johannes Leipold SMS group Electrical Energy Reduction for Air Pollution Control Systems: Further Improvements on Two American Plants With Smooth Fluid-Dynamic Solutions From the Quenching Tower to the New, Patented Stack Marco Peter Cudicio, Danieli & C. Officine Meccaniche S.p.A.; Alberto Feruglio, Danieli & C. Officine Meccaniche S.p.A. show more Description Air pollution control systems' electrical energy demand is typically in the range of 20–28 kWh/ton. It is strictly related to the system given flowrate and pressure drop, the first one often being determined by the authorities or a dispersion model. From the DOB to the patented silent stack without mineral wool, the pressure drop reduction in selected parts of the plant can bring energy savings between 30 and 50%. The paper describes two installations in the U.S. whose start-up is expected by mid-2022, whose benefits include less CO2 emitted, in the range of 4,000 tpy. Time Monday, May 16 4:30PM - 5:00PM Location 320 Speakers Marco Peter Cudicio Danieli & C. Officine Meccaniche S.p.A. Alberto Feruglio Danieli & C. Officine Meccaniche S.p.A. Enhanced Dynamic Response to Impact for Hot Rolling Mills Bernardo Sainz, AMI Automation; Rommel Villarreal, AMI Automation show more Description One fundamental characteristic of a rolling mill is the speed response of the main drive for two reasons: the speed adjustment and the impact response. Different methods have been applied to avoid the problems of a low-speed response, for example adding some lead speed before impact and removing it after impact. To have a better impact response, it is necessary to increase the speed regulator response leading to torque oscillations and resonance when running in idle. This paper shows other methods, where feedforward compensations assist the speed regulator to have an enhanced impact response and avoid problems of torque oscillations. Time Monday, May 16 4:30PM - 5:00PM Location 306 Speakers Bernardo Sainz AMI Automation Rommel Villarreal AMI Automation High-Performance Plate Production at the New Steckel Plate Mill at Shandong Iron & Steel in Rizhao, China Klaus Pronold, SMS group; Alexander Reske, SMS group; Liu Huibao, SMS group; Stephan Mosbleck, SMS group GmbH; Weihua Sun, Shandong Iron & Steel Group Rizhao Co. Ltd. show more Description A key facility 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. Latest digitalization solutions improving product quality over the whole production process including the new thick-slab caster will discussed here as well. Plant concept, capability and production results will be presented. Time Monday, May 16 4:30PM - 5:00PM Location 402 Speakers Klaus Pronold SMS group Alexander Reske SMS group Liu Huibao SMS group Stephan Mosbleck SMS group GmbH Weihua Sun Shandong Iron & Steel Group Rizhao Co. Ltd. Improving Gearbox Service Life Mike Allega, The Timken Company show more Description Gearboxes are vital components in metals processing facilities and their performance is influenced by many factors. These include installation, condition monitoring, lubrication system maintenance and inspections. In addition, performance can be improved through the repair process by identifying and addressing primary damage modes. This paper will discuss common issues and guidelines to improve reliability throughout the life of the gearbox. Time Monday, May 16 4:30PM - 5:00PM Location 404 Speakers Mike Allega The Timken Company New BOF Solution — Ternium Brazil Bruno Cezar Calazans de Andrade, Ternium Brasil; Antônio Augusto de Rezende Martins, Ternium Brasil; Bruno Nery Stoco, Ternium Brasil; Rúbia Teodoro Silva, Ternium Brasil; Leôncio Machado de Rezende, Ternium Brasil; Gilson Rangel Souto, Ternium Brasil; Eduardo Valbão Bastos, Ternium Brasil; Maria Luiza Gonçalves Pereira, Ternium Brasil; Simão Pedro de Oliveira, Ternium Brasil; Gilvan Nascimento de Souza, Ternium Brasil; Leonardo Martins Demure, Ternium Brasil show more Description In July 2020, the project equipment supplier sold its first converter lining in South America to Ternium Brasil. The lining surpassed the previous record by 16%, without restrictions operating and low-mass hot repair under 0.20 kg/t. A key factor for the result achieved is the supplier and customer partnership, because the appropriate choice of refractories used, combined with the best practices of the client and management of key variables of the process, such as slag analysis, particularly the CaO/SiO2 ratio, MgO and FeO contents, level of oxidation of the bath, temperature, and maintenance techniques, provided this impressive result. Time Monday, May 16 4:30PM - 5:00PM Location 408 Speakers Bruno Cezar Calazans de Andrade Ternium Brasil Antônio Augusto de Rezende Martins Ternium Brasil Bruno Nery Stoco Ternium Brasil Rúbia Teodoro Silva Ternium Brasil Leôncio Machado de Rezende Ternium Brasil Gilson Rangel Souto Ternium Brasil Eduardo Valbão Bastos Ternium Brasil Maria Luiza Gonçalves Pereira Ternium Brasil Simão Pedro de Oliveira Ternium Brasil Gilvan Nascimento de Souza Ternium Brasil Leonardo Martins Demure Ternium Brasil Numerical Simulation of Flow Modifier Effect on Fluid Flow Pattern, Wall Shear Stress and Inclusion Removal in a Two-Strand Tundish Xuefeng Bai, University of Science and Technology Beijing; Zhijie Guo, University of Science and Technology Beijing; Yanhui Sun, University of Science and Technology Beijing; Hongjun Shen, CISDI Engineering Co. Ltd. show more Description A mathematical model was developed to investigate the influence of flow modifier on fluid flow pattern, wall shear stress and inclusion removal in a two-strand tundish. A baffle with upward holes effectively eliminated the short-circuiting and smoothed the steel flow in the outlet zone. The six RTD indexes and inclusion removal rate were both greatly increased. A turbulence inhibitor decreased the velocity at the free surface, thereby lowering the possibility of slag entrapment. Meanwhile, the maximum flow-induced shear stress at the rear wall near the ladle shroud was decreased, while the inclusion removal was significantly promoted. Time Monday, May 16 4:30PM - 5:00PM Speakers Xuefeng Bai University of Science and Technology Beijing Zhijie Guo University of Science and Technology Beijing Yanhui Sun University of Science and Technology Beijing Hongjun Shen CISDI Engineering Co. Ltd. Ranking and Managing Occupational Hazards in the Workplace: A Case Study of the Iron and Steel Manufacturing Industry Dr. Ephraim Massawe, Southeastern Louisiana University show more Description Iron and steel factory workers are at risk of exposure to multiple hazards. Tools currently in existence rank and risk one particular hazard. A single tool to rank multiple hazards will provide an opportunity to prioritize resources for prevention and control. Currently, no single tool exists to rank the risks and severity of multiple hazards such as physical, biological, and ergonomic. This presentation features a framework of this tool for a steel rolling mill. It includes key elements of the risk factors, such as frequency of tasks and exposures, injury rates, days away from work, and other risk factors. Time Monday, May 16 4:30PM - 5:00PM Location 319 Speakers Dr. Ephraim Massawe Southeastern Louisiana University Simulation of Simultaneous Two-Phase Precipitation Kinetics by Cluster Dynamics Model Kun Xu, Anhui University of Technology show more Description The multi-phase precipitation frequently occurs in the complex metal systems, which significantly influences their microstructure and properties. In this paper, the original single-phase cluster dynamics model is expanded to the simultaneous two-phase precipitation case, and the population balance equations with complete mass conservation are carefully proposed. The new model is then applied to simulate the precipitation behaviors during the aging process of the Fe-Cu-Ni ternary alloy, and the calculated results are verified to agree well with the atom probe experimental data. Time Monday, May 16 4:30PM - 5:00PM Location 310 Speakers Kun Xu Anhui University of Technology
Tuesday, May 17
10:00am An Application of Performance-Based Design Techniques for Fire Protection of a Batch Annealing Process John Wade, GSE, Inc.; Robert Cloutier, University of South Alabama; Partha Sarker, Gulf States Engineering, Inc. show more Description Design of fire protection systems for any part of a steel mill is a study in performance-based design. For a typical installation, the applicable system requirements will be dictated by a combination of the local adopted prescriptive fire codes, protection of hazards, input from the insurance carrier and various industry standards. This paper proposes to describe a typical approach for performance-based design of fire systems for the protection of a batch annealing process for steel coil, where annealing takes place under a hydrogen bath and where the furnaces are fired with natural gas. Time Tuesday, May 17 10:00AM - 10:30AM Location 319 Speakers John Wade GSE, Inc. Robert Cloutier University of South Alabama Partha Sarker Gulf States Engineering, Inc. Development and Testing of Flameless Burner Fed by NG/H2 Mix Pietro Della Putta, SMS group S.p.A.; Umberto Zanusso, SMS group S.p.A.; Jimmy Fabro, SMS group S.p.A.; Mario Fabro, SMS group Inc.; Filippo Cirilli, Rina Consulting CSM; Irene Luzzo, Rina Consulting CSM show more Description The worldwide push for renewable and “green” energy usage is well publicized. One of the first official acts was the presentation of the European Green Deal by the EU in December 2019, which describes the road map to achieve zero emissions of greenhouse gases. The use of hydrogen as an energy carrier instead of traditional fossil sources (e.g., coal and natural gas) should be considered as a primary option, especially if it is produced from renewable sources through electrolysis. This paper covers the development, testing and results of the SMS group ZeroFlameHY2 burners that can use hydrogen with low environmental impact. Time Tuesday, May 17 10:00AM - 10:30AM Location 407 Speakers Pietro Della Putta SMS group S.p.A. Umberto Zanusso SMS group S.p.A. Jimmy Fabro SMS group S.p.A. Mario Fabro SMS group Inc. Filippo Cirilli Rina Consulting CSM Irene Luzzo Rina Consulting CSM Development of a CALPHAD-Based Steel Property Model Library for Martensite, Pearlite and Bainite Paul Mason, Thermo-Calc Software Inc.; Jiayi Yan, Thermo-Calc Software AB; Johan Jeppsson, Thermo-Calc Software AB; Qing Chen, Thermo-Calc Software AB show more Description CALPHAD tools have long been used to predict thermodynamic, phase equilibria and kinetic transformations for different steels. This presentation describes CALPHAD models for the prediction of martensite, pearlite and bainite. The martensite model calculates the Ms temperature based on modeling the transformation barrier and martensite fractions are based on the fraction of athermal martensite calculated using an analytical equation. The pearlite model describes the thermodynamics and kinetics of pearlite formation from austenite using a criteria where either growth rate or Gibbs energy dissipation rate is maximized. The bainite model describes the thermodynamics and isothermal kinetics of bainite transformation from austenite. Time Tuesday, May 17 10:00AM - 10:30AM Location 310 Speakers Paul Mason Thermo-Calc Software Inc. Jiayi Yan Thermo-Calc Software AB Johan Jeppsson Thermo-Calc Software AB Qing Chen Thermo-Calc Software AB Development of Highly Efficient Fluidized Lime for Hot Metal Desulfurization Based on Thermodynamic Calculations and Industrial Validation Felix Firsbach, Badische Stahl-Engineering; Joyce Aderhold, Lhoist; Leomar Marcon, Lhoist; Christopher Pust, Lhoist; Martin Boike, Lhoist; William Johnson, Lhoist show more Description Desulfurization is a critical step before converting hot metal to steel. Increasing sulfur inputs while decreasing sulfur targets is difficult and more challenging with approaches like introducing carbon-neutral biomass into blast furnaces. Lhoist investigated improving hot metal desulfurization with innovative blends (Flucal®). Based on carryover slag analyses and enhanced fluidized lime, a theoretical final slag was calculated with Thermo-Calc regarding sulfur capacity and viscosity. Special focus was set on intensified agitation and reduction of fluorine content. Three new receipts where identified and industrially verified. The sulfur removal efficiency was improved 11.7%, treatment time was decreased 10% and splashing was minimized. Time Tuesday, May 17 10:00AM - 10:30AM Location 318 Speakers Felix Firsbach Badische Stahl-Engineering Joyce Aderhold Lhoist Leomar Marcon Lhoist Christopher Pust Lhoist Martin Boike Lhoist William Johnson Lhoist Evaluation of Thermo-Calc and FactSage Predictions in Liquid Steelmaking Processes Bryan Webler, Carnegie Mellon University; Andrew Huck, Carnegie Mellon University; Stephano Piva, Carnegie Mellon University show more Description Two commonly used commercial software packages for liquid steel processing calculations are Thermo-Calc and FactSage. Each makes equilibrium calculations with Gibbs energy models of phases, e.g., liquid metal for steel and liquid oxide for slag. New developments and database updates in these packages motivated examination of their predictions relevant to steelmaking processes. These updates include revisions to the Gibbs energy models of both the liquid metal and liquid oxide phases. In this work, predictions from both software packages related to slag/metal equilibria in the ladle and vacuum refining processes were made and compared to some available plant and laboratory data. Time Tuesday, May 17 10:00AM - 10:30AM Location 311 Speakers Bryan Webler Carnegie Mellon University Andrew Huck Carnegie Mellon University Stephano Piva Carnegie Mellon University High-Performance Roll End Hubs for Maximum Rolling Mill Availability Jim Fraser, Voith; Peter Grawenhof, Voith show more Description With industrywide focus on attaining competitive advantages in metals rolling, mill owners constantly pursue high-technology innovations to achieve maximized mill performance. Mechanical driveline reliability is closely related to this objective. The roll end hub is a key component in rolling mill drivelines. This paper explains the design and function of roll end hubs and provides an update on the performance of an innovative type introduced in 2016. Time Tuesday, May 17 10:00AM - 10:30AM Location 307 Speakers Jim Fraser Voith Peter Grawenhof Voith Influence of Raceway Shape on Species Concentration Eva-Maria Wartha, TU Wien/K1-MET GmbH; Markus Bösenhofer, TU Wien/K1-MET GmbH; Franz Hauzenberger, Primetals Technologies Austria GmbH; Hugo Stocker, voestalpine Stahl Donawitz GmbH; Christoph Feilmayr, voestalpine Stahl GmbH; Michael Harasek, TU Wien show more Description An entire utilization of alternative reducing agents inside the raceway zone is favorable to increase the coke replacement ratio in blast furnaces and utilize waste products in the ironmaking process. The extreme conditions prohibit measurements, but computational fluid dynamics incorporating validated models can help to understand the processes occurring in the raceway zone. An accurate prediction of the raceway size and shape is essential to correctly predict the thermo-chemical processes and resulting species distribution. This paper will demonstrate this based on a laboratory test setup and, furthermore, identify interstitial fluid effects to be essential to accurately predict the raceway shape. Time Tuesday, May 17 10:00AM - 10:30AM Location 317 Speakers Eva-Maria Wartha TU Wien/K1-MET GmbH Markus Bösenhofer TU Wien/K1-MET GmbH Franz Hauzenberger Primetals Technologies Austria GmbH Hugo Stocker voestalpine Stahl Donawitz GmbH Christoph Feilmayr voestalpine Stahl GmbH Michael Harasek TU Wien Ladle-to-Mold Refractory Design Optimization for the New Caster at Nucor Steel Gallatin John Rogler, Vesuvius; Neil Sutcliffe, Nucor Corp.; Giovanna Busolin, Danieli; Marcellino Fornasier, Danieli; Johan Richaud, Vesuvius show more Description The upgrade of Nucor Steel Gallatin thin-slab plant to an ultramodern Quality Strip Production (QSP) mill by Danieli producing high value-added products requires ladle-to-mold flow optimization. Water and computer modeling simulations have been undertaken to overcome the challenges associated with high mass flowrates. Controlling turbulence in the tundish, enhancing steel temperature distribution throughout the tundish, improving mold meniscus stability for throughputs up to 7 tons/minute and reducing standing wave height have been the focus for Nucor, Danieli and Vesuvius technology teams. The refractory design has been customized to ensure optimal caster yield and to achieve higher quality casting. Time Tuesday, May 17 10:00AM - 10:30AM Location 408 Speakers John Rogler Vesuvius Neil Sutcliffe Nucor Corp. Giovanna Busolin Danieli Marcellino Fornasier Danieli Johan Richaud Vesuvius Lances for Vacuum Degassing – Applications and Failure Analysis Breno Maia, Lumar Metals North America; Willian Lima, Lumar Metals North America show more Description Lances for reactors that work under vacuum, in general, have great durability and low maintenance interventions. For this reason, "orphan" equipment can be considered similar to some diseases and medications. They are necessary and, due to their operational stability, they are not remembered. This article is intended to perform an analysis of the application of vacuum degassing lances and a failure analysis. Time Tuesday, May 17 10:00AM - 10:30AM Location 309 Speakers Breno Maia Lumar Metals North America Willian Lima Lumar Metals North America Mitigation of Harmonics Generated by Arc Furnace Using C-Type and Single-Tuned Filter Sarat Keswar, Primetals Technologies USA LLC; Anil Kanagala, Primetals Technologies USA LLC; Hiranya Pathak, Primetals Technologies USA LLC show more Description The current in an arc furnace is highly unpredictable and contains a continuous spectrum of integer and interharmonic distortion, due to which designing a passive filter bank to compensate the harmonics generated by an arc furnace becomes extremely challenging. This paper discusses the challenges faced in designing a filter to compensate harmonics generated by the arc furnace and also discusses a scenario that evaluates avoiding parallel resonance when mill loads and the arc furnace are fed from the same source. Time Tuesday, May 17 10:00AM - 10:30AM Location 401 Speakers Sarat Keswar Primetals Technologies USA LLC Anil Kanagala Primetals Technologies USA LLC Hiranya Pathak Primetals Technologies USA LLC Modeling of Isothermal Reduction of Hematite Pellets Using Hydrogen Joe Govro, Missouri University of Science and Technology; Amogh Meshram, Arizona State University; Yuri Korobeinikov, Arizona State University ; Soumava Chakraborty, Missouri University of Science and Technology ; Sridhar Seetharaman , Arizona State University ; Ronald J. O'Malley, Missouri University of Science and Technology show more Description Reducing CO2 emissions from the iron-making process can significantly contribute towards the goals of the United States to fight climate change. Using hydrogen as a reducing agent instead of carbon can drastically reduce the carbon footprint of steel production. Pure hydrogen gas diluted in nitrogen was used to reduce iron ore pellets at different temperatures and feed gas ratios. The porosity of the pellets was studied using SEM-greyscale analysis. A 2D-axisymmetric model was developed using COMSOL Multiphysics with porosity defined as a function of reduction. The model was found to fit the experimental data with more than 95% accuracy. The observed results are discussed. Time Tuesday, May 17 10:00AM - 10:30AM Location 308 Speakers Joe Govro Missouri University of Science and Technology Amogh Meshram Arizona State University Yuri Korobeinikov Arizona State University Soumava Chakraborty Missouri University of Science and Technology Sridhar Seetharaman Arizona State University Ronald J. O'Malley Missouri University of Science and Technology Modern Fluid Power Safety Controls for the Steel Industry Eric Cummings, ROSS Controls; Chris Brogli, ROSS Controls show more Description Pneumatic and hydraulic controls are widely used throughout the steel industry due to their high reliability and suitability to the extreme environments present in many applications. When modern safety systems are implemented on new or updated equipment, the sophisticated electrical controls of safety programmable logic controllers are utilized to provide fail-safe control systems. Pneumatic and hydraulic safety devices provide the output safety function to meet current ANSI and ISO standards for machine safety. OSHA accepts these control reliable systems for use as alternative measures for production related activities. This presentation reviews applications using modern safety systems for lockout and alternative measures. Time Tuesday, May 17 10:00AM - 10:30AM Location 404 Speakers Eric Cummings ROSS Controls Chris Brogli ROSS Controls New Breakthroughs in the Modeling of Tundish Stopper Rods Hongbin Yin, ArcelorMittal Global R&D; Bruce Forman, ArcelorMittal Global R&D; Y. Lee, ArcelorMittal Global R&D show more Description The similarity criteria for a full-scale water model and a continuous caster have been known for more than 30 years. However, traditional modeling techniques lack an important boundary condition that needs to be included when simulating the low-pressure region around a stopper rod tip. This paper will explore how the missing boundary condition was discovered, and how ArcelorMittal R&D implemented new modeling techniques that accurately predict the true stopper rod flow and pressure distributions using their computational fluid dynamics and full-scale water model. Time Tuesday, May 17 10:00AM - 10:30AM Location 316 Speakers Hongbin Yin ArcelorMittal Global R&D Bruce Forman ArcelorMittal Global R&D Y. Lee ArcelorMittal Global R&D Solution for External Holes on Tubes Surface X20Cr13 Ivan Diniz, Vallourec show more Description A great challenge for Vallourec is to avoid external holes on tubes surface that affect the wall thickness, causing scrap in X20Cr13 grade. The piercer is the source of the problem concerning external holes on tubes surface. In Brazil, it is manufactured grade X20Cr13 using high-cobalt alloy guide shoes. Sticking of X20Cr13 was observed on the guide shoe surface and external holes on tubes surface after rolling. A low-cost technical solution was the key to regain the profitability of this product. Time Tuesday, May 17 10:00AM - 10:30AM Location 402 Speakers Ivan Diniz Vallourec Utilizing SCR Power Controllers to Improve the Industrial Heat Treat Process Through Predictive Maintenance and Intelligent Power Control Tony Busch, Control Concepts Inc. show more Description This paper examines how silicon-controlled rectifiers (SCRs) have a major influence on temperature regulation and improve the industrial heat treat process utilizing intelligent power control and predictive maintenance. Exactly how digital SCR power controllers are superior to their analog predecessors and how they improve industrial furnace operations will be addressed in the paper. The results were obtained by not so much by a study, but by field experience from the OEM and Weiss Industrial, the manufacturer's representative for an unnamed brand of SCR power controllers. A discussion of how to incorporate SCRs into an industrial network and their applications is provided. Time Tuesday, May 17 10:00AM - 10:30AM Location 315 Speakers Tony Busch Control Concepts Inc. Zero-Carbon Emission Hot Rolling of Direct Application Sheet With Real Endless Strip Production Lukas Preuler, Primetals Technologies; Andreas Jungbauer, Primetals Technologies; G. Schwarz, Primetals Technologies Austria GmbH; T. Lengauer, Primetals Technologies Austria GmbH; B. Kradel, Primetals Technologies Germany GmbH show more Description Raw material, energy consumption and recently also CO2 emissions are the main drivers for steel production costs. The energy-saving and ultra-compact endless strip production (ESP), with liquid steel supplied from an electric arc furnace featuring optimized melting technology, helps to reduce the operation costs. Arvedi ESP is known for 45% lower energy consumption compared to conventional casting and rolling plants. Direct application products of ESP allow for cold rolling, annealing and related emissions to be omitted. This mini-mill of the future has been started up at Fujian Dingsheng Iron & Steel. Time Tuesday, May 17 10:00AM - 10:30AM Location 306 Speakers Lukas Preuler Primetals Technologies Andreas Jungbauer Primetals Technologies G. Schwarz Primetals Technologies Austria GmbH T. Lengauer Primetals Technologies Austria GmbH B. Kradel Primetals Technologies Germany GmbH
10:30am Asset Tracking: Choosing the Correct Technology Philip Levin, Cleveland-Cliffs Inc. show more Description As an industry, we are attempting to track everything, from a bag of alloys, to a slab, to a coil from manufacturing to a customer. Some technologies are better than others, depending on the item to be tracked. This paper will include a basic discussion of the different flavors of radio frequency identification, optical character recognition, and vision systems and their use. Further discussion will take place on the infrastructure needed to support this effort. Time Tuesday, May 17 10:30AM - 11:00AM Location 315 Speakers Philip Levin Cleveland-Cliffs Inc. Development of a New Sustainable Tundish-to-Mold Shroud Johan Richaud, Vesuvius; Fabienne Ruby-Meyer, Ascoval; Jonathan Foulon, Ascoval; Martin Kreierhoff, Vesuvius; Romuald Mazurier, Saarstahl Ascoval show more Description With the growing environmental constraints, Ascoval and Vesuvius have focused on extending casting sequence length of high-quality steels. A new shroud has been developed to increase casting duration with limited addition of zirconia and without energy-consuming pre-heating requirement and to reduce steel downgrade by improving the semi-cast quality. The new long-life shroud will allow a reduction of the number of tundish skulls with fewer first and last blooms downgrades and rejection. The special port has been adapted to improve bloom internal quality. These enhancements are permitting Ascoval to reduce the CO2 emission and to reduce refractory annual consumption. Time Tuesday, May 17 10:30AM - 11:00AM Location 408 Speakers Johan Richaud Vesuvius Fabienne Ruby-Meyer Ascoval Jonathan Foulon Ascoval Martin Kreierhoff Vesuvius Romuald Mazurier Saarstahl Ascoval Diversified Mechanical Vacuum Pump Solutions for VD/VOD Anke Teeuwsen, Edwards GmbH; Aditya Agrawal, Edwards India Pvt. Ltd. ; Frank Shi, Edwards Technologies Trading (Shanghai) Co.Ltd show more Description Today mechanical vacuum pump systems are state of the art for new refining stations. The advantages over steam ejectors are well-known. There are various options in both mechanical pump size/model and systems concept, as the design requirements are diverse: Footprint, productivity, production flow, available service/maintenance/operations personnel, as well as process specification. Small degassers require disproportionally larger performance per ton of produced steel. The mega trend of green steel will lead to ever-larger vacuum degassing/vacuum oxygen decarburization stations requiring different solutions than the prior Ruhrstahl-Heraeus systems. This paper will give insights into field experience of various global installations and conclude the factors for optimal selection of the individual vacuum solution. Time Tuesday, May 17 10:30AM - 11:00AM Location 309 Speakers Anke Teeuwsen Edwards GmbH Aditya Agrawal Edwards India Pvt. Ltd. Frank Shi Edwards Technologies Trading (Shanghai) Co.Ltd Dry Furnace: A New Step Toward Decarbonization Narayan Raut, Danieli Corp.; Elisa Salamone, Danieli Centro Combustion S.p.A.; Alessandro Venanzini, Danieli Centro Combustion show more Description Following indications for a strong greenhouse gas emissions reduction, and referring to funds allocated by the government for innovative systems with low carbon dioxide emissions, Danieli Centro Combustion has finalized the study for the “Dry Plus” furnace concept. Based on the dry skids concept and the absence of cooling water, this walking-beam-type furnace is designed to abate CO2 emission. Its advantages are not limited to CO2 reduction, though: in fact, specific consumption improvements, the absence of a water-treatment plant, increased billet heating quality, maintenance time reduction, OpEx diminution and lower erection times are additional benefits of this new technology. Time Tuesday, May 17 10:30AM - 11:00AM Location 407 Speakers Narayan Raut Danieli Corp. Elisa Salamone Danieli Centro Combustion S.p.A. Alessandro Venanzini Danieli Centro Combustion Effect of Mold Powder Residue on Thin-Cast Slab Scale Structure Evolution During Reheating and Descaling Richard Osei, Missouri University of Science and Technology; Dmitry Tsvetkov, Steel Dynamics Inc. - Flat Roll Group Columbus Division; Anthony Bader, Steel Dynamics Inc. - Flat Roll Group Columbus Division; Simon Lekakh, Missouri University of Science and Technology; Ronald J. O'Malley, Missouri University of Science and Technology show more Description Mold powder is an essential part of the continuous casting process as it provides strand lubrication and controls mold heat transfer. Also, the chemical makeup of mold powder can modify the surface of a cast slab, forming complex scale structures during casting and reheating. Such surface scale modification can potentially affect descaling. In this study, an industrial steel grade sample were collected and characterized to report scale evolution. Industrial descaling practice was simulated in the laboratory. Effect of surface condition on scale structure and descaling efficiency is discussed. The results prove useful information for improving steel quality. Time Tuesday, May 17 10:30AM - 11:00AM Location 306 Speakers Richard Osei Missouri University of Science and Technology Dmitry Tsvetkov Steel Dynamics Inc. - Flat Roll Group Columbus Division Anthony Bader Steel Dynamics Inc. - Flat Roll Group Columbus Division Simon Lekakh Missouri University of Science and Technology Ronald J. O'Malley Missouri University of Science and Technology Fully Automated In-Line Strand Condition Monitoring for Enhanced Roll Gap Measurement and Control in Continuous Casting Grant McBain, Sarclad; Will Smailes, Sarclad show more Description Sarclad has developed an improved monitoring device that can be fitted as an integral part of the caster’s dummy bar chain. This allows more frequent monitoring and analysis of the caster condition, providing data at the start of every cast sequence. Critically, this can be done with no delay to production, which is key in high-productivity plants. This paper details the design improvements implemented and reviews the measures taken to ensure accurate data capture in the harsh environment of a live continuous casting machine. Findings include live plant utilization of the equipment, presented in the form of a case study. Time Tuesday, May 17 10:30AM - 11:00AM Location 316 Speakers Grant McBain Sarclad Will Smailes Sarclad Hydrogen-Ready Energiron: The Way to Zero GHG Emissions Dario Pauluzzi, Danieli & C. Officine Meccaniche S.p.A.; Ashton Hertrich Giraldo, Danieli & C. Officine Meccaniche S.p.A.; Alessandro Martinis, Danieli & C. Officine Meccaniche S.p.A.; Luca Tommasi, Danieli & C. Officine Meccaniche S.p.A. show more Description Today’s technology offers plants with very high energy efficiency. But to be aligned with the objective of the Paris Agreement, limit the global temperature rise to well below 2°C above pre-industrial levels, and make a further step toward CO2 emissions reduction, a dramatic shift is required in primary steelmaking. It is believed that fuel selection is the key of the future. ENERGIRON®, jointly developed by Tenova and Danieli and based on hydrogen use for decades, targets a future with zero GHG emissions starting today: Hydrogen is an additional fuel option inside a proven plant design. Time Tuesday, May 17 10:30AM - 11:00AM Speakers Dario Pauluzzi Danieli & C. Officine Meccaniche S.p.A. Ashton Hertrich Giraldo Danieli & C. Officine Meccaniche S.p.A. Alessandro Martinis Danieli & C. Officine Meccaniche S.p.A. Luca Tommasi Danieli & C. Officine Meccaniche S.p.A. Improving Safety Conditions in the EAF Fernando Diaz, Tenaris; Vladimir Guinez, Tenaris show more Description Electric steelmaking can be a dangerous environment, so this paper sets a very strong target: No man around the furnace. The paper will discuss early water leak detection, remote furnace tapping, remote furnace sealing, automatic additions, furnace plancher confinement, revision of the furnace with camera, functional safety, safety in loading and refrigerated panel tracking. Time Tuesday, May 17 10:30AM - 11:00AM Location 319 Speakers Fernando Diaz Tenaris Vladimir Guinez Tenaris Interpreting X-Ray Absorption and Diffraction Contrast for Massive Non-Destructive 3D Grain Mapping of Steel and Other Alloys in Laboratory-Computed Tomography and X-Ray Microscopy Andy Holwell, ZEISS Research Microscopy Solutions; Hrishikesh Bale, ZEISS Research Microscopy Solutions show more Description Conventional computed tomography or x-ray microscopy is limited to microstructural imaging via material density differences. As such, single-phase polycrystalline materials (e.g., alloys) do not exhibit absorption contrast to reveal underlying grain microstructure. For 3D microstructural crystallography, metallurgists must use synchrotron crystallography or electron backscatter diffraction in electron microscopy. This paper will show how laboratory-based diffraction contrast tomography (DCT) can extract 3D crystallographic information from single-phase polycrystalline samples non-destructively. DCT scans collect x-ray diffraction patterns which are deconvoluted for reconstruction, providing grain maps carrying information on grain morphology, orientation, size and centroid position, for studies of grain growth, tensile testing and anisotropy. Time Tuesday, May 17 10:30AM - 11:00AM Location 310 Speakers Andy Holwell ZEISS Research Microscopy Solutions Hrishikesh Bale ZEISS Research Microscopy Solutions Lifetime-Extended Steel Mill Rollers Produced by Laser Cladding Thomas Schlaefer, LaserBond Ltd. ; Christiane Schulz, University of South Australia; Colin Hall, University of South Australia; Tahnee Bathurst, LaserBond Ltd.; Brian Probets, LaserBond Ltd. show more Description Rollers in the steel mill are subject to extreme wear and, depending on the type of rollers, also to high-temperature corrosion. Under given conditions, monolithic economic steel rolls provide only limited lifetime. One possibility for extending the lifetime of such rollers lies within the application of wear- and corrosion-resistant coatings. This presentation will focus on the utilization of the LaserBonds® laser cladding process as a surfacing technology, which allows the economic production of surface engineered rollers in the steel mill industry and the increase in lifetime that can be achieved. Time Tuesday, May 17 10:30AM - 11:00AM Location 307 Speakers Thomas Schlaefer LaserBond Ltd. Christiane Schulz University of South Australia Colin Hall University of South Australia Tahnee Bathurst LaserBond Ltd. Brian Probets LaserBond Ltd. Potential for Increased Scrap Melting in a BOF Geoffrey Brooks, Swinburne University of Technology; M. Akbar Rhamdhani, Swinburne University of Technology; Nirmal Madhavan, Swinburne University of Technology; Bapin Rout, Tata Steel; Aart Overbosch, Tata Steel show more Description Maximizing the amount of scrap in the basic oxygen furnace (BOF) is a feasible solution to effectively utilize the chemical energy. The present study focuses on analyzing the dependency of input scrap quantity on energy consumption and greenhouse gas emissions. The results indicate that if the present industrial limit of post-combustion ratio % is raised from 22% to 50%, then achieving ~35% scrap in the feed is feasible. The paper includes a discussion on present industrial limitations that prevent increasing scrap above 30% of the total feed and possibilities for optimizing the oxygen steelmaking process. Time Tuesday, May 17 10:30AM - 11:00AM Location 318 Speakers Geoffrey Brooks Swinburne University of Technology M. Akbar Rhamdhani Swinburne University of Technology Nirmal Madhavan Swinburne University of Technology Bapin Rout Tata Steel Aart Overbosch Tata Steel Replacement of Aging Low-Voltage Power Distribution Equipment Marshall Cook, Siemens Industry Inc.; Ryan Dial, Siemens Industry Inc. show more Description This paper discusses the replacement of aging low-voltage power distribution circuit breakers with new, modern breakers, including arc flash reduction, remote operation, remote racking and human-machine interface integration. Time Tuesday, May 17 10:30AM - 11:00AM Location 401 Speakers Marshall Cook Siemens Industry Inc. Ryan Dial Siemens Industry Inc. Review of the State-of-the-Art Technologies in the Electric Arc Furnace Ashraf Hanna, RHI Magnesita; Karim Badr, RHI Magnesita; Dave Ehrhart, RHI Magnesita show more Description This article will cover a generic review of the state-of-the-art ongoing OEM technologies in electric arc furnaces and the various efforts conducted to maximize the productivity, improve the process control, and reduce CO2 emissions and the energy needs. The added value of customizing the furnace shells and pre-heating the metallic feed inputs will also be highlighted. The article will finally shed some light on the auxiliary technologies that support process improvement and cost reduction in electric arc furnaces. Time Tuesday, May 17 10:30AM - 11:00AM Location 406 Speakers Ashraf Hanna RHI Magnesita Karim Badr RHI Magnesita Dave Ehrhart RHI Magnesita Role of Microstructure and Texture Synergy on Low-Temperature Toughness of Heavy-Gauge Line Pipe Steels Jing Su, EVRAZ North America; Michael Gaudet, EVRAZ North America; Muhammad Rashid, EVRAZ North America; Muhammad Arafin, EVRAZ North America show more Description With the increasing demand for using line pipes in harsh service environments, much research has been devoted to developing heavy-gauge pipe steels with improved low-temperature toughness. Alloying and thermomechanical processing affect both microstructure and texture. There is still a lack of understanding of the joint effects of microstructure and texture on toughness and strength. As the pipe gauge becomes heavier, the through-thickness microstructure heterogeneity plays an additional role in mechanical properties. Here, different roughing and finishing conditions were applied to generate a series of microstructures and textures in X70 line pipe steels and their synergic effects on toughness was investigated. Time Tuesday, May 17 10:30AM - 11:00AM Location 402 Speakers Jing Su EVRAZ North America Michael Gaudet EVRAZ North America Muhammad Rashid EVRAZ North America Muhammad Arafin EVRAZ North America Selective Slag Systems for Steel Inclusion Cleanliness Eloy Martinez Rehlaender, SvMet Engineering S.A. show more Description Inclusion steel cleanliness is achieved by proper process steps from tapping of liquid steel to casting. Steel plant conditions are dynamic in nature in terms of temperature, oxygen levels at tap, sulfur contents at tap and a variety of factors during secondary steelmaking. So is natural that a system that is intended to control and modulate steel inclusion cleanliness should be dynamic as well. A selective slag system that can “modulate” and target different slag compositions has been tested in a number of steel plants from small electric arc furnaces (54 tons) to large basic oxygen furnace vessels (335 tons) with good success. Time Tuesday, May 17 10:30AM - 11:00AM Location 311 Speakers Eloy Martinez Rehlaender SvMet Engineering S.A. Structural Analysis and Failure Prediction of Direct Reduced Iron P. Chris Pistorius, Carnegie Mellon University; Grant Kenny, Carnegie Mellon University show more Description In this work, a comprehensive study of the internal structure of commercially produced direct reduced iron (DRI) is considered. Utilizing high-resolution Micro-CT analysis, this study aims to link structural features and defects to their effect on the ultimate compressive strength and failure of DRI. Specific structural features and defects may therefore be incorporated into existing predictions of the compressive strengths of DRI based on computed stiffness values from semi-non-destructive cyclic load tests. Time Tuesday, May 17 10:30AM - 11:00AM Location 308 Speakers P. Chris Pistorius Carnegie Mellon University Grant Kenny Carnegie Mellon University
11:00am A Safe Approach to Ladle Slidegate Maintenance Gianluca Maccani, Polytec USA Corp.; Anna Zoppirolli, BM Group Polytec S.p.A. show more Description A robotic cell automatically manages the sliding gate maintenance in order to increase safety, operational accuracy and stability, and to optimize process time control. It's equipped with an extraction/insertion tool, refractory nozzle extraction tool, tool to remove fixed plate, nozzle cleaning tool, graphite spraying tool and a lance tool. Time Tuesday, May 17 11:00AM - 11:30AM Location 309 Speakers Gianluca Maccani Polytec USA Corp. Anna Zoppirolli BM Group Polytec S.p.A. Anomaly Detection of the Continuous Casting Strand Guide by Monitoring the Withdrawal Force Using Machine Learning Franz Ramstorfer, Ternium Brasil; Leonardo Martins Demuner, Ternium Brasil; Gabriel Yoshiharu Sato, Ternium Brasil show more Description In the present work, a methodology for detecting anomalies in continuous casting was developed based on the monitoring of the total strand withdrawal force. The anomaly detection is based on the comparison of the actual total withdrawal force with a reference value, calculated by an artificial neural network, which was trained and optimized using the most relevant casting parameters of actual production data. Using this methodology, process or machine anomalies, which call for a visual inspection and therefore a machine downtime, can be detected more rapidly and therefore product quality problems or extensive machine downtime may be avoided. Time Tuesday, May 17 11:00AM - 11:30AM Location 316 Speakers Franz Ramstorfer Ternium Brasil Leonardo Martins Demuner Ternium Brasil Gabriel Yoshiharu Sato Ternium Brasil CO2 Reduction Options for High-Temperature Heating in the Iron and Steel Industry Michael Cochran, Bloom Engineering Co. Inc.; Keenan Cokain, Bloom Engineering Co. Inc.; Scott Brown, Bloom Engineering Co. Inc. show more Description There are many high-temperature steel applications where low-carbon alternative fuels could be used, including, but not limited to, reheat furnaces, ladle heating and processing lines. While many are looking at hydrogen as a potential low-carbon alternative fuel to use for industrial heating, there are other options available to reduce the amount of CO2 being released. Some of these other reduction options include switching to biofuels, the use of efficiency increasing technology such as regenerative burners, or moving from direct combustion to electric heating. Time Tuesday, May 17 11:00AM - 11:30AM Location 407 Speakers Michael Cochran Bloom Engineering Co. Inc. Keenan Cokain Bloom Engineering Co. Inc. Scott Brown Bloom Engineering Co. Inc. Crude Coke Oven Gas System Replacement at Aging Coke Oven Batteries for Lifetime Extension and Emission Reduction Cesare Laviosa, Paul Wurth Italia S.p.A. show more Description An important part of a steel plant is the coke oven. In order to extend the lifetime and to meet environmental regulations, coke oven operators need to monitor plant performance and equipment condition. The presentation will provide an inside view on the planning and methodology of replacing a complete coke oven gas raw gas system to extend the life of the coke oven while also improving the emission situation by further implementing the coke oven plant with the SOPRECO® system during the planning and replacement phase. It will also highlight how these improvements will further contribute to lower emissions. Time Tuesday, May 17 11:00AM - 11:30AM Speakers Cesare Laviosa Paul Wurth Italia S.p.A. Key Attributes to Consider for Optimum Fracture and Fatigue Performance of API Grade Pipeline Steels in Gaseous Hydrogen Applications Doug Stalheim, DGS Metallurgical Solutions; Andrew Slifka, NIST; Enrico Lucon, NIST; Matthew Connolly, NIST; Pello Uranga, CEIT and University of Navarra, Tecnun show more Description In general, fracture and fatigue performance of API-grade pipeline steels degrade in the presence of pressurized hydrogen gas. Similarly, various through-thickness microstructural characteristics correlate with the degradation in mechanical properties. However, there are key microstructural attributes and evaluation methods as it relates to fracture and fatigue performance in gaseous hydrogen that can be used as guides to identify these through-thickness microstructural characteristics that yield stable or improved fracture and fatigue performance with increasing hydrogen pressure. This paper will tie in microstructural evaluation methods that can be used as guides to fracture and fatigue performance in gaseous hydrogen applications. Time Tuesday, May 17 11:00AM - 11:30AM Location 402 Speakers Doug Stalheim DGS Metallurgical Solutions Andrew Slifka NIST Enrico Lucon NIST Matthew Connolly NIST Pello Uranga CEIT and University of Navarra, Tecnun Modeling of Lime Dissolution in BOF Slags Using Gibbs Energy Minimization Daniel Marian Ogris, K1-MET GmbH; Ernst Gamsjäger, Institute of Mechanics, Montanuniversität Leoben show more Description A sharp-interface multi-component diffusion model is developed for the dissolution of CaO-containing additives in metallurgical slags. The solution of the partial differential equations is numerically approximated by means of a finite-difference scheme with an uneven mesh at the solid-liquid interface. The boundary conditions at the solid-liquid interface between the dissolving oxide particle and the liquid slag are calculated via a newly developed Gibbs energy minimization routine. Diffusion processes in the liquid slag are identified as the rate controlling mechanisms by comparing the numerical results of the sharp-interface model to experimental observations stemming from high-temperature laser scanning confocal microscopy. Time Tuesday, May 17 11:00AM - 11:30AM Location 318 Speakers Daniel Marian Ogris K1-MET GmbH Ernst Gamsjäger Institute of Mechanics, Montanuniversität Leoben Non-Contact Laser Sensors in Slab Handling Steven Lubeck, Laser-View Technologies show more Description Handling slabs through rolling, heat treatment, size control and yard storage involves position and size control. Producers continue to increase their use of non-contact sensors for real-time monitoring of size and position to optimize processes. Laser sensors are capable of providing length, width and plate profile, in addition to yard position as a slab yard crane stores or locates a slab. The harsh environmental conditions plays a role in determining the right sensor for the job. This presentation examines the advantages of noncontact laser-based sensors, along with suggestions for successful implementation. Time Tuesday, May 17 11:00AM - 11:30AM Location 315 Speakers Steven Lubeck Laser-View Technologies Nucor Steel-Decatur Pickle Line #2 Drive and Motor Replacement Thomas Richards, TMEIC Corp. Americas; Rich Erickson, Nucor Corp.; Lee McCreless, Nucor Corp. show more Description The drives on Nucor Steel Decatur LLC’s Pickle Line #2 were obsolete. The smaller drives were AC drives. The larger motors and drives were all DC and Nucor wished to make it an exclusively AC line. This paper describes the decisions that were made, the implementation strategy and the project results. Time Tuesday, May 17 11:00AM - 11:30AM Location 401 Speakers Thomas Richards TMEIC Corp. Americas Rich Erickson Nucor Corp. Lee McCreless Nucor Corp. Performance and Results of Linde CoJet Technology at Gerdau Long Steel North America Midlothian Mill Hamzah Alshawarghi, Linde; Rafael Bruch, Gerdau Long Steel North America Midlothian Mill show more Description In September 2019, Gerdau Long Steel North America decided to implement Linde’s CoJet technology in their electric arc furnaces (EAFs) at its Midlothian plant. The main objective to pursue this change was to reduce power consumption, increase productivity and reduce maintenance time by considering the non-water-cooled CoJet injectors. Gerdau Long Steel North America Midlothian Mill operates two EAFs. As a first step, all sidewall lances were replaced in EAF A with CoJet injectors. After evaluating performance of running with CoJets for about one year, the company decided to convert the EAF B to a CoJet system as well. This paper will present the performance benefits and results achieved. Time Tuesday, May 17 11:00AM - 11:30AM Location 406 Speakers Hamzah Alshawarghi Linde Rafael Bruch Gerdau Long Steel North America Midlothian Mill Roll Shop Case Study at a German Steelmaker: Facts and Figures Prove the Superiority of Herkules Roll Grinder's Control and Measuring Technology Jared Jörgens, Maschinenfabrik Herkules; Robert Curler, Herkules North America; Thorsten Mehlhorn, Maschinenfabrik Herkules show more Description This case study will present figures that show and explain how a German leading steel maker is saving up to 20% on roll stock removal and 10% on measuring time per grind, while achieving a 98% availability of the roll grinder. In detail, the presentation will explain how the intelligent real-time HCC/KPM roll grinder control and its unique features such as the “speed profiling Z-axis” and simultaneous measurement “in process” with parallel correction of the grinding process save roll stock removal and grinding time. Time Tuesday, May 17 11:00AM - 11:30AM Location 307 Speakers Jared Jörgens Maschinenfabrik Herkules Robert Curler Herkules North America Thorsten Mehlhorn Maschinenfabrik Herkules The New Generation of Q-Level+: Advanced Steel Level Combined With Flux Level Control Marcellino Fornasier, Danieli; Gabriele Donati, Danieli Automation S.p.A.; Luigi Orsettig, Danieli Automation S.p.A.; Martin Stepanek, VÚHŽ Inc.; Cristiano Pezzutto, Danieli Automation show more Description Consistent control of liquid steel in the mold at high casting speeds is fundamental to secure thin-shell casting stability and superior surface strip quality. The fast response of the VUHZ eddy current sensor allowed for early diagnostics of disturbances, enhancing the level controller capability. Danieli’s Q-LEVEL+ system identifies and counteracts level disturbances, reducing them at the early stage and maintaining a rather low standard deviation level. Coupling the eddy current and radioactive sensors readings allows for the feedback of control to the mold flux feeding system, granting constant layer thickness as experienced at Hoa Phat’s Danieli QSP in Vietnam. Time Tuesday, May 17 11:00AM - 11:30AM Location 310 Speakers Marcellino Fornasier Danieli Gabriele Donati Danieli Automation S.p.A. Luigi Orsettig Danieli Automation S.p.A. Martin Stepanek VÚHŽ Inc. Cristiano Pezzutto Danieli Automation Variety of Technologies Applied for Anti-Clogging Submerged-Entry Nozzle Toshio Horiuchi, Shinagawa Refractories Co. Ltd.; Hiroyasu Niitsuma, Shinagawa Refractories Co. Ltd.; Ryota Okazaki, Shinagawa Refractories Co. Ltd.; Yukio Ohkawa, Shinagawa Refractories Co. Ltd.; Takayuki Matsunaga, Shinagawa Refractories Co. Ltd.; Masakazu Iida, Shinagawa Refractories Co. Ltd.; Xiaodong Li, Shinagawa Advanced Material Americas Inc. show more Description Preventing alumina clogging of the submerged-entry nozzle is one of the most important factors for achieving stable production and excellent steel quality. Suitably engineered stable microstructure of gas blowing material enables a steady gas injection without fluctuation until the end of casting. Unique inner liner materials that have higher wettability to molten steel results in an ideal surface condition. Novel port design forms an optimized outlet flow without stagnation. This report describes these various technologies for clogging suppression and successful results in reducing steel defects. Time Tuesday, May 17 11:00AM - 11:30AM Location 408 Speakers Toshio Horiuchi Shinagawa Refractories Co. Ltd. Hiroyasu Niitsuma Shinagawa Refractories Co. Ltd. Ryota Okazaki Shinagawa Refractories Co. Ltd. Yukio Ohkawa Shinagawa Refractories Co. Ltd. Takayuki Matsunaga Shinagawa Refractories Co. Ltd. Masakazu Iida Shinagawa Refractories Co. Ltd. Xiaodong Li Shinagawa Advanced Material Americas Inc.
11:30am Green Steel Production Using Advanced Melting Furnace Technology Kyle Chomyn, Hatch; Terrence Koehler, Hatch Ltd; Sa Ge, Hatch Ltd show more Description The future of steelmaking requires significant process changes for the reduction of carbon emissions. One approach uses direct reduced iron (DRI) with an electric arc furnace; however, this poses challenges when using lower-grade ores/pellets and with hydrogen-DRI. This paper describes a higher yield/efficiency method, using an electric melting furnace to convert DRI more effectively into pig iron for use in the steel shop. The melting furnace leverages advanced furnace technology developed over 60+ years for iron/ferro-nickel applications. This approach eases the shift to green steelmaking by using existing facilities and pellet supply chains, while providing higher yields and reduced life cycle costs. Time Tuesday, May 17 11:30AM - 12:00PM Location 407 Speakers Kyle Chomyn Hatch Terrence Koehler Hatch Ltd Sa Ge Hatch Ltd Line Pipe Material Consideration for Transport of High-Pressure Hydrogen Aquiles Perez, EC&A Solutions Eng ; Richard Hill, Microalloying International show more Description High-pressure hydrogen (above 3,000 psi) pipeline materials must be designed to withstand potential hydrogen damage mechanisms (e.g., hydrogen embrittlement/fatigue resistance reduction through the design life of the system). Currently, there are approximately 1,600 miles of hydrogen pipelines operating in the U.S. transporting low energy density at pressures between 500 and 1,200 psi. These pipelines follow the requirements detailed in ASME B31.12 for hydrogen service up to 3,000 psi. Limitations for transporting hydrogen at higher pressures are due to a lack of testing and understanding of the material boundaries. Time Tuesday, May 17 11:30AM - 12:00PM Location 402 Speakers Aquiles Perez EC&A Solutions Eng Richard Hill Microalloying International Logistics of Converting an Ungrounded (IT) vs. Grounded (TN) Power for a 34.5kV to 480V System Alec Glenn, AM/NS Calvert LLC; David Stockin, E&S Grounding Solutions; Dan Boresch, Phase-X Engineering, Inc. show more Description This paper will share technical information regarding the conversion of an existing 34.5kV/480V ungrounded (IT) system to a grounded (TN) system in a hot strip mill. During normal operations, ungrounded (IT) systems have demonstrated increased failures and systems errors for variable frequency drive and motor controllers compared to grounded systems. A properly grounded electrical system can reduce the error and failure rates of equipment, but also allow for a safer environment for persons should an electrical fault occur. Results obtained include an analysis of the protection system reliability and power quality both before and after the change from ungrounded to grounded. Time Tuesday, May 17 11:30AM - 12:00PM Location 401 Speakers Alec Glenn AM/NS Calvert LLC David Stockin E&S Grounding Solutions Dan Boresch Phase-X Engineering, Inc. Modeling of the Process Kinetics and Thermodynamics of Industrial Steelmaking Based on CALPHAD Thermodynamics Paul Mason, Thermo-Calc Software Inc.; Nicholas Grundy, Thermo-Calc Software AB; Ralf Rettig, Thermo-Calc Software AB; Lina Kjellqvist, Thermo-Calc Software AB; Johan Jeppsson, Thermo-Calc Software AB; Ake Jansson, Thermo-Calc Software AB show more Description The Process Metallurgy Module within Thermo-Calc can be used to simulate the kinetics and thermodynamics of full-scale industrial steelmaking processes and can be applied to all relevant liquid steelmaking processes. It is based on the thermodynamic database TCOX, to model the interactions between liquid steel and slag during steelmaking and refining. The latest version (TCOX11) contains the most important elements in steels and slags (Fe-Al-C-Ca-Co-Cr-Cu-F-Gd-K-La-Mg-Mn-Mo-N-Na-Nb-Ni-O-P-S-Si-Ti-V-W-Y-Zr) and H and Ar in the gas phase. Kinetics are modeled using the effective equilibrium reaction zone approach. In this presentation, applications to steelmaking practices for existing and new grades will be described. Time Tuesday, May 17 11:30AM - 12:00PM Location 311 Speakers Paul Mason Thermo-Calc Software Inc. Nicholas Grundy Thermo-Calc Software AB Ralf Rettig Thermo-Calc Software AB Lina Kjellqvist Thermo-Calc Software AB Johan Jeppsson Thermo-Calc Software AB Ake Jansson Thermo-Calc Software AB Process Guidance: Process Optimization, Condition Monitoring, Quality Evaluation, Metallurgical Parameter Administration and Operator Guidance Integrated in One System Ronald Wilmes, SMS group; Georg Nowark, SMS group; Lothar Schaps, SMS group; Uwe Plociennik, SMS group GmbH show more Description The increasing variety of products in continuous casting requires steel grades dependent on adaptation of the parameter settings. This demands the biggest possible support for the operator by the plant automation. X-Pact® Process Guidance is able to provide this support. It combines: a) The product tracking, on-line quality evaluation, condition monitoring and optimization of the casting process, through integrated mathematical process models. b) Steel-grade-based allocation of all metallurgical parameters and their automatic adaptation in case of a grade change. c) Guidance of the operator, especially in critical casting situations. The achieved improvements will be presented based on a plant modernization. Time Tuesday, May 17 11:30AM - 12:00PM Location 310 Speakers Ronald Wilmes SMS group Georg Nowark SMS group Lothar Schaps SMS group Uwe Plociennik SMS group GmbH Taken Fom the Field - Metallurgical Results and Equipment Technology by the Example of a Recently Commissioned 120 st VD Plant Alexander Stueckelschwaiger, Inteco melting and casting technologies GmbH; Zachary Stroman, Nucor NSSC; Christian Redl, Inteco melting and casting technologies GmbH; Christian Buchmaier, Inteco melting and casting technologies GmbH