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Program Schedule
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6 May 2013
Session: Howe Memorial Lecture
(Howe Memorial Lecture)8 am - 8:45 am (RM Spirit of Pittsburgh Ballroom B)
Chairs: Ron Ashburn - AIST
The Power of Steelmaking — Harnessing High-Temperature Reactions to Transform Waste Into Raw Material Resources (Confirmed)
8 am
Veena Sahajwalla, University of New South Wales
This presentation describes the opportunities available to iron and steelmakers to utilize waste streams — ranging from polymeric materials to agricultural wastes — as raw materials. The potential to implement such novel recycling solutions is generally not available to many other materials industries because they operate at relatively lower temperatures. Recycling waste polymeric materials in steelmaking is one solution for end-of-life products which currently present a serious burden in landfills, as is the case with some plastics. Specifically, the lecture will present a fundamental understanding of different plastic wastes, as well as agricultural waste and tires, and their transformations and chemical reactions at high temperatures. Plant results from EAF steelmaking in Sydney, Australia, where recycling waste is now standard practice, will also be included.
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Session: International Alliance Lecture
(International Alliance Lecture)8:45 am - 9:30 am (RM Spirit of Pittsburgh Ballroom B)
Chairs: Ron Ashburn - AIST
The Indian Steel Scenario - Changing Technological Phase (Confirmed)
8:45 am
A.C.R. Das, Industrial Advisor to the Steel Ministry, Government of India
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Session: Computational Fluid Dynamics (CFD) Modeling in Environmental Applications
(Environmental)9:30 am - 12 pm (RM 405)
Chairs: Vern Martin - Flow Care, Paul Sheehan - SNC Lavalin America, Dejan Zrelec - Tenova Goodfellow
Five-Dimensional CFD Modeling as an Effective Design Tool to Simulate and Compare Alternative Green Ventilation Configurations for the Construction and Operation of Hot Process Buildings (Confirmed)
9:30 am
Edmund Baltuch, Air-Therm Inc.; Siegmar Baltuch, Air-Therm Inc.
Natural ventilation in iron and steel is key to proper mill function. There are a number of ventilator designs available that will affect the type of building structure required, project costs and design performance — all of which is difficult to rectify or reengineer once implemented. This research and the applied results demonstrate that computational fluid dynamic simulation allows 5-dimensional observation, analysis and optimization at significantly lower cost than previously possible. Results have been fully implemented on a number of steel mill applications, and the authors continue to study, optimize and innovate as new tools become available to provide the best possible engineered solutions for particular applications.
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Computational Fluid Dynamic (CFD) Modeling for Hood Design (Confirmed)
10 am
Brian Bakowski, SNC – Lavalin America, Inc.; Robert Albert, SNC – Lavalin America, Inc.
Over the last several years, computational fluid dynamic (CFD) software and computing technology has advanced to the point where engineers can simulate real-world conditions within a virtual world. In the case of steel mills, this virtual world is created to match the dynamic environment of the mill. By utilizing CFD technology, engineers can create the steel mill within a virtual world and assign variables to reflect these real-world conditions. Additionally, changes to these real-world conditions can also be modeled, such as a hood over a process which emits particulate. The hood would be modeled to include the desired geometry and volume and modifying the parameters until the desired capture efficiency was achieved, effectively “right sizing” the hood and emission control system. This paper reviews the process and benefits of CFD modeling.
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CFD Modeling of a Flooded Disc Scrubber (Confirmed)
10:30 am
Bin Wu, Purdue University – Calumet; Theresa Obias, Purdue University – Calumet; Jesse Santos, Purdue University – Calumet; Rich Trzcinski, Purdue University – Calumet; Jim Keith, Purdue University – Calumet; Chenn Zhou, Purdue University – Calumet
At an integrated steel mill, a sintering plant is operated to produce sinter for the iron production process. The flue gas generated during this process is cleaned by a Flooded Disc Scrubber that uses a high-velocity gas flow moving across a liquid surface to atomize the liquid into droplets in order to collect particulates in the gas stream. This current Flooded Disc Scrubber system has been experiencing a significant decrease in overall efficiency, primarily a reduction in the particulate capture. In order to identify the cause of this deficiency, a 3-D CFD model had been developed to understand the current operation. Parametric studies of operating conditions had also been conducted to improve particle removal efficiency and prevent excessive ductwork vibration.
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Session: Cokemaking New Technologies
(Cokemaking)9:30 am - 12 pm (RM 401)
Chairs: Rob Carlin - DTE Energy, Matt Kraeuter - ThyssenKrupp, Rick Lyons - AK Steel Corp.
A Review on Stamped Charging of Coals (Confirmed)
9:30 am
Jorge Madias, Metallon; Mariano DeCordova, Metallon
As coking coals become more expensive and of relative availability, coke producers have developed alternatives for the introduction of cheaper coals in the blend. This includes differentiated grinding, use of additives, and compacted charging. This paper reviews the evolution of this technology since its first application in the 1980s for Sarre coals, to current developments in China and India. The pros and cons of this charge preparation technique and its implications on battery operation are discussed, for both byproducts ovens and non-recovery/heat recovery ovens.
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MIDREX’s Unique Solution to Utilize Coke Oven Gas for Producing Direct Reduced Iron (Confirmed)
10 am
Gary Metius, Midrex Technologies Inc.
Hundreds of coke producing ovens are in operation around the world, the byproduct of which is an offgas (COG) that has a rich chemical composition for producing direct reduced iron. COG is most often used to produce electricity, providing energy for other applications within an integrated steel works, as a fuel in the steel works, or as a feedstock for chemicals production at adjacent facilities. MIDREX and its partner PRAXAIR have developed a unique system to condition COG so that its inherent chemical value can be optimized for production of DRI. MIDREX is erecting a pilot plant to prove the system at its research and technology center. This paper discusses the system and its application.
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Methodology for Cokemaking Technology Selection for Operating Conditions and Expansion of Iron and Steel Works (Confirmed)
10:30 am
Yakov Gordon, Hatch; Rick Brown, Hatch; John Busser, Hatch; Michiel Freislich, Hatch Australia; Ian Cameron, Hatch
Selection of cokemaking technology within an iron and steel works is complicated, involving analysis of coal quality, coke demand and supply, environmental regulations, and the plant energy balance. The methodology involves coal blend selection, preparation, charging, cokemaking and quenching technology selection to meet the blast furnaces’ coke quality requirements and the energy balance for the entire works. Hatch’s mass and energy balance, OPEX, CAPEX, energy/CO2 and financial models provide clients with NPV/IRR (net present value/internal rate of return) ranking and sensitivity analysis to assist in selecting the best strategy among byproduct or heat recovery ovens, charging and quenching systems for replacement or expansion programs.
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Thermal Model of Heat Transfer in Coke Plant (Confirmed)
11 am
Lucas Silva, Universidade Federal de Ouro Preto; Alisson De Castro, Gerdau Acominas; Guilherme Silva, Gerdau Acominas; Erick Braga, Gerdau Acominas; Niloy Nath, Rajarshi Shahu College of Engineering; Paulo Assis, Universidade Federal de Ouro Preto
Equations that describe the thermal behavior in a coke oven has been derived and solved by using a numerical method. In a two-dimension model, were analyzed the temperature profile of refractory wall, the heat transfer by conduction in the refractory wall and conduction between the refractory wall and the coal. In the coal/coke body were considered the conduction in the solid part, convection of gases and steam and radiation in the interstices (pores and fissures). The main objective of this modeling is predict the
time required for complete coking and the amount of heat needed in order to avoid the waste of energy.
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Recent Trends in Heat Recovery Cokemaking (Confirmed)
11:30 am
John Quanci, SunCoke Energy; Jonathan Perkins, SunCoke Energy; Michael Brommer, SunCoke Energy
In 1998, the SunCoke Energy Indiana Harbor Coke plant started the first Horizontal Heat Recovery (HHR) Cokemaking process, which produces steam and power from waste flue gas. HHR technology has greatly expanded in the last decade and is expected to increase with rising demand for reliable power sources, excellent environmental performance, low capital, low operating cost and ability to improve existing steel plant energy integration through combination of HHR and by-product cokemaking technologies. Compared to a by-product oven, a modern HHR oven has higher temperatures, extended coking time, and deeper coal beds resulting in higher quality, larger size coke--resulting in improved blast furnace productivity and increased PCI usage. With no wall pressure limit, HHR allows greater flexibility to use low cost, low quality, high expanding coals. HHR technology continues to advance by driving to smaller footprint, even lower capital, improved coke yield, lower coal costs, rate flexibility, lower emissions, improved oven life and increased power recovery.
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Session: Blast Furnace Operations
(Ironmaking)9:30 am - 12 pm (RM 402)
Chairs: Jason Entwistle - United States Steel Corporation, Nick Morgan - United States Steel Corporation, Bruce Stackhouse - ArcelorMittal USA
The Best Way to Blow-In of Blast Furnace: Definition, Philosophy, Theory and Practical Approach (Confirmed)
9:30 am
Michael Alter, ArcelorMittal Burns Harbor; Charles McGovern, ArcelorMittal Burns Harbor
A classification of blow-ins of blast furnaces is offered. Proposed definitions of the end of blow-in and the best blow-in are based on the knowledge of heat exchange and reduction processes in a blast furnace. The comparative effectiveness of injecting nitrogen, natural gas, coke oven gas, oxygen and water vapor in the blow-in period is presented. The blow-in slag optimization principles and choice of burden materials are described. A comparison of "traditional" and accelerated Lipetsk blow-in is provided.
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Significant Operational Changes to IH7 Blast Furnace From 2003 Through 2012 (Confirmed)
10 am
Daniel Holmes, ArcelorMittal USA; James E. Bobek, ArcelorMittal USA; Donald Zuke, ArcelorMittal USA
As with most blast furnaces in recent history, significant changes have been made to the furnace operation of IH7 due to changing economic factors and technology advances. This paper outlines some of the major changes undertaken on the blast furnace since 2003, including the operational transition from a plate-cooled to a stave-cooled furnace, major distribution changes using a Paul Wurth rotating top, stove oxygen injection, cash-focused operations in 2008 and 2009, and the use of lower-cost raw materials due to escalating iron ore pricing.
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Curse to Cure — The Utilization of Titanium-Bearing Products in Blast Furnace Ironmaking (Confirmed)
10:30 am
Stuart Street, Severstal Dearborn; Charles Copeland, Severstal Dearborn; Elizabeth Worral, Severstal Dearborn
The utilization of titanium-bearing products in blast furnace ironmaking has a rich and complex history. This paper briefly reviews some of the history of titanium in blast furnace ironmaking. Based on the review, the authors propose a hypothesis for the evolution of titanium from being viewed by ironmakers as a curse to a cure. The paper also covers more recently developed targeted strategies for using titanium-bearing products, including those developed at Severstal Dearborn, such as focused charging and doped taphole clay. The authors also discuss whether polytherapy strategies have been overlooked as an influence on the interpretation of industrial results when treating hearth erosion issues with titanium-bearing products.
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The Impact of Titanium on Skull Formation in the Blast Furnace Hearth (Confirmed)
11 am
Yongfu Zhao, U. S. Steel Research and Technology Center
Titanium-bearing materials are often charged from the furnace top or added through tuyeres to protect the blast furnace hearth. In most previous studies, the minimum titanium requirement was calculated on the basis of thermodynamics, and the hot metal temperature was used as the reference temperature for calculation. The present work combines thermodynamics, heat transfer, fluid flow dynamics and solidification analysis. The mechanism of titanium promoting skull formation in a blast furnace hearth is explained by changes occurring in the boundary layer between the hot metal and carbon brick. Instead of using the actual hot metal temperature as reference, the temperature in the boundary layer is utilized to calculate the titanium content required for Ti-TiC equilibrium. It is also found that hot metal silicon promotes titanium precipitation.
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Development of Channeling Prediction System for a Blast Furnace (Confirmed)
11:30 am
Jia-Shyan Shiau, China Steel Corp.; Chi-Chung Wang, China Steel Corp.; Chung-Ken Ho, China Steel Corp.; Che-Hsiung Tung, China Steel Corp.
Visualization technology comprised mainly of pressure distribution was developed to predict blast furnace (BF) channeling phenomena in this study. The real-time data of BF shaft pressure was used to create a 3D visual model by neural network algorithms, and 3D real-time BF pressure changes were observed. The root mean square deviation (RMSD) of BF shaft pressure was used as an index to set up the predicting criteria of channeling occurrence with the opening of the BF AGE (Annular Gap Element), and the predicting system based on the criteria was built. The criteria for the channeling alarm were both of the RMSD of BF shaft pressure at L7 (seventh level) calculable, and AGE opening greater than 60%. Results showed that BF operation can be adjusted to avoid the occurrence of channeling.
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Session: Raw Materials
(Ironmaking)9:30 am - 12 pm (RM 403)
Chairs: Mike Best - United States Steel Corporation, Keki Nanavati - Cliffs Natural Resources, Joe Poveromo - RMI Global
Blast Furnace Value-in-Use Model and Its Application for Iron Ore Processing (Confirmed)
9:30 am
Michiel Freislich, Hatch Australia; Harry Brunger, Hatch Australia; Leigh Harris, Hatch Australia; Yakov Gordon, Hatch
The selection of iron ore for a blast furnace is traditionally influenced by a number of factors that determine the economics and practicalities of a successful operation. Hatch has developed a sophisticated value-in-use model enabling iron ore producers to investigate the impact of replacing existing burden with a new ore during blast furnace operation, and the corresponding cost implications to the steel product. This paper presents a case study showing the impacts of various ore grades in a typical integrated steel works and analyzes the impact on production cost if a price on carbon is introduced. Estimates show that the addition of a carbon price will significantly affect the value-in-use of various ore types.
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Influence of Coke Breeze Positioning on the Sintering Behavior of Pellets and Raw Material Bed With Embedded Pellets (Confirmed)
10 am
Takahide Higuchi, JFE Steel Corp.; Yuji Iwami, JFE Steel Corp.; Yosuke Kuriki, JFE Steel Corp.; Koichi Nushiro, JFE Steel Corp.; Nobuyuki Oyama, JFE Steel Corp.
In the sintering process, effective usage of coke breeze is important to improve productivity. The influence of coke breeze positioning on the pellet strength and sintering behavior was investigated by crushing test and x-ray CT scan. Coating coke breeze was effective to the pellet strength due to maintaining of the contacting points of mixture fine, promoting the combustion and suppressing the pore generation in the pellet. In addition, the surrounding temperature of the pellet increased, and a large void was generated under the pellet. Based on the simulation, it was found that the combustion heat amounts were effectively transported to the area under the pellet.
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Guidelines for Selecting Pellet Plant Technology (Confirmed)
10:30 am
Manuel Huerta, Hatch; Ian Cameron, Hatch; Kevin O'Leary, Hatch; Jose Mourao, Hatch Brazil; Urano Medeiros, Hatch Brazil
As greater amounts of fine iron ore concentrates enter the marketplace, new investments in pelletizing capacity are inevitable. When investors assess the two well-proven pelletizing technologies, the straight grate and grate kiln, the most appropriate choice is not immediately evident. Certain technical, market and site-specific factors will favor one technology over the other. Hatch has compared the merits of both technologies regarding plant construction; type of ore processed; energy consumption and fuel flexibility; required plant capacity; operating and capital costs and environmental performance. A technology assessment checklist that investors should consider when making a new investment decision is presented.
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Characterization of Different Lump Ore Brands According to Industrial-Scale Process Conditions by Means of Reducibility Testing and Morphological Investigation (Confirmed)
11 am
Martina Hanel, Montanuniversitaet Leoben; Heinrich Mali, Montanuniversitaet Leoben; Johannes Schenk, Montanuniversitaet Leoben; Franz Hauzenberger, Siemens VAI Metals Technologies GmbH; Christoph Thaler, voestalpine Stahl Donawitz GmbH & Co KG; Hugo Stocker, voestalpine Stahl Donawitz GmbH & Co KG; Michael Skorianz, Montanuniversitaet Leoben
Within this research work, lump ores of different mineralogical types have been investigated for their applicability in diverse reduction aggregates concerning reducibility and mechanical properties in conventional lab testing facilities combined with microscopic investigations and specific surface area analysis. Raw and reduced ore brands of limonite, hematite and magnetite have been characterized in terms of morphological properties and mineralogical evolution due to reduction. It could be pointed out that the reduction temperatures concomitant to variations of the gas mixture have different consequences on the reduction progress, depending on the mineralogy and structure of the ore feed material. Additionally, a coherency of reduction rate and mechanical properties is described within this research work.
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Iron Ore Market 2013 (Confirmed)
11:30 am
Joseph Poveromo, Raw Materials & Ironmaking Global Consulting
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Session: EAF Performance Improvements I
(Electric Steelmaking)9:30 am - 12 pm (RM 406)
Chairs: Stephan Ferenczy - Steel Dynamics Inc., Robert Lockington - Siemens, Stewart Robinson - Carbide Industries LLC
Next-Generation EAF Optimization at ArcelorMittal Dofasco Inc. (Confirmed)
9:30 am
Marshall Khan, Tenova Goodfellow Inc.; Suresh Mistry, Tenova Goodfellow Inc.; Vittorio Scipolo, Tenova Goodfellow Inc.; Stanley Sun, ArcelorMittal Dofasco Inc.; Stephen Waterfall, ArcelorMittal Dofasco Inc.
Tenova Goodfellow Inc. has installed the next generation of its proprietary EFSOP® system (NEXTGEN) on the twin-shell EAFs at ArcelorMittal Dofasco Inc. The objectives were to significantly improve EAF performance and operating costs for both scrap-based and hot metal-based operations through the reduction of electricity, oxygen, methane, injected and charge carbon. The NEXTGEN control system paces the EAF according to the dynamic determination of the "total net energy" defined as the sum of the electrical energy input + chemical energy input – the total energy losses, all adjusted in real time for their respective utilization efficiencies. This innovation enables true dynamic optimization of total process energy (both chemical and electrical), thereby facilitating the highest energy utilization.
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Applications and Operating Results of Solid Materials (Carbon, Fluxes, Aluminum, Polymer) Pneumatic Injection Technologies Into the EAF (Confirmed)
10 am
Simone Marcuzzi, MORE SRL; Massimo Iacuzzi, MORE SRL; Giovanni Londero, MORE SRL; Andrea Fontana, OneSteel Manufacturing
The electric arc furnace continues to evolve into a highly efficient melting unit. In recent years, there has been an increased demand for the pneumatic injection of solid materials into the EAF to improve the melting process. Pneumatic injection has been demonstrated to be an improvement compared to the practice of charging materials via the buckets, conveyor belts and/or roof openings, which result in poorer efficiency and higher maintenance/operational costs. Besides the description of the use of carbon, lime and dolo-lime pneumatic injection in the furnace, this paper will provide an overview of the latest innovative material injection processes, such as aluminum for stainless steel production, and polymer injection technology, which has demonstrated increased volume and foaminess of the slag.
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Process Optimization at Nucor Steel in Crawfordsville, Ind. (Confirmed)
10:30 am
Dan Brisson, Nucor Steel-Indiana; Tony Bryan, Nucor Steel-Indiana; Carl Schwabe, Nucor Steel-Indiana; Gerry Gillen, Nucor Steel-Indiana
In early 2012, Nucor Steel–Indiana had some of the highest kWh/ton numbers when compared to other Nucor mills of a similar size. A concerted effort between furnace operators and other Nucor divisions brought about a significant improvement in EAF efficiencies within a few short months. A number of things contributed to the overall improvements: adjustments to a new regulation system, scrap recipe and scrap layering changes, a new slag model, and development of a metrics system with a scorecard. Ultimately, the furnace operators have embraced the changes and brought about the improvements. An update will be presented on recent progress.
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Evraz Pueblo Best Practice Operation With SIMETAL EAF Ultimate Technology — Seven Years of Records in the Making (Confirmed)
11 am
Dave Ellis, Evraz Rocky Mountain Steel; Markus Abel, Siemens VAI Metals Technologies GmbH; Denis Vaillancourt, Siemens Industry Inc.; Thomas Daum, Siemens Industry Inc.; Valoree Varick, EVRAZ Inc. NA
In October 2012 it was seven years since Evraz Pueblo started up its new SIMETAL EAF Ultimate.
With the start-up of the Ultimate EAF, which features technological highlights like single bucket charge, high-performance electrical power input, high-efficiency oxy-fuel burner technology with carbon injection, new environmental dust evacuation system, as well as modern basic automation and process optimization system, Evraz Pueblo has achieved new records in terms of productivity and quality in almost every year since the first heat. This paper will describe the technical aspects of how operational excellence and expertise combined with accompanying equipment technology enables an operation to achieve productivity and also quality parameters that were not possible before the installation of the new furnace.
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Determination of the Intrinsic Value of Ore-Based Metallics (Confirmed)
11:30 am
Jeremy Jones, Tenova Core
Many steelmakers have attempted to develop models that show the value-in-use for various scrap and scrap substitute materials. In most cases, these models fall short of their objective because they consider only the metallic Fe contribution to steelmaking. It has been recognized that the utilization of pig iron and DRI/HBI can have an effect on both EAF productivity and operating costs beyond the effect of the iron content contributed to the liquid steel. The most difficult parameter to place a value on is dilution of residuals by the virgin iron alternative scrap materials. This paper investigates the cost of residuals in the scrap by evaluating the cost differences between high- and low-residual materials. This information can then be added into value-in-use models to capture the added value of low-residual raw materials for steelmaking.
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