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Program Schedule
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7 May 2012
Session: J. Keith Brimacombe Memorial Lecture
(Brimacombe Memorial Lecture)8 am - 8:45 am (RM Building A - Level Four Concourse A412)
Steel Research — Then, Now and Tomorrow (Confirmed)
8 am
Alan Cramb, Illinois Institute of Technology
J. Keith Brimacombe was an innovator; he believed that knowledge transmittal, from universities to industry and from industry to universities, was the key to work that had impact. Keith, his colleagues and students did fundamental work, but always for a reason that had practical implication. His group’s work in the laboratory or on the computer ended up solving a problem in a plant or giving direction to a process. In this paper, the role of research that is focused on process improvement (know how) will be compared to research that is fundamental in nature (know why). The role and importance of both types of research in the steel industry in our past, our present and in the future will be discussed (know why and how). Based on this comparison, potential future interactions between universities and industry that could lead to radical process innovation will be suggested, as that will lead us to know what must be done next.
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Session: International Alliance Lecture
(International Alliance Lecture)8:50 am - 9:30 am (RM Building A - Level Four Concourse A412)
International Alliance Lecturer (Confirmed)
8:50 am
G.K. Basak, Joint Plant Committee - Ministry of Steel, India
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Session: EAF Environmental — Dust and Dioxins
(Environmental/Electric Steelmaking)9:30 am - 12 pm (RM Building A - Level Three Concourse A305)
Chairs: Christer Carlsson - ABB Inc., Patrick Jablonski - Nucor Steel, Fernando Martinez - AMI GE
A Mathematical Model for Carbothermic Reduction of Dust-Carbon Composite Agglomerates (Confirmed)
9:30 am
Yuki Kuwauchi, University of Toronto; Mansoor Barati, University of Toronto
Recycling of dust using a rotary hearth furnace (RHF) has gained considerable attention in the past two decades for the sustainable production of steel with less environmental impact. In order to further promote the recycling of electric arc furnace dust and carbonaceous wastes using the RHF process, a mathematical model was developed to predict the reaction behavior of dust-reductant composites. The reduction kinetics of zinc and iron oxides, as well as the behavior of volatile matter in the reductant were considered. The modeling approach and some calculation results specific to the dust-related reactions will be presented.
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EAF Slag: A Product No Longer a Problem (Confirmed)
10 am
Loredana Di Sante, Centro Sviluppo Materiali S.p.A.; Filippo Cirilli, Centro Sviluppo Materiali S.p.A.; Nicola Angelucci, Tenaris Dalmine
Steelmaking slag has been used as a road construction material, competing with natural materials. In EAF slag, after cooling, a fraction of chromium may exist as CrO3. Since hexavalent chromium is soluble in water, the slag produced during the steel process requires a leaching test before landfill or reuse. Here, the leaching behavior of a Cr-bearing EAF slag has been studied in order to propose to the construction market this kind of material. Laboratory and industrial experimentations show that significant cooling rates are highly effective in order to nullify Cr leaching and to guarantee the mechanical characteristics to use this slag for civil applications.
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Development of EAF Dust Injection Technology at Aichi Steel (Confirmed)
10:30 am
Akira Tsubone, Aichi Steel Corp.; Tsuyoshi Momiyama, Aichi Steel Corp.; Masanori Inoue, Shin-Ei Kinzuku Co. Ltd.; Naoto Saito, Tohoku University; Kazuyo Matsubae, Tohoku University; Tetsuya Nagasaka, Tohoku University
In the EAF steelmaking industry, dust treatment is one of the most serious issues due to its high costs and environmental burden. Without solving this critical problem, it is difficult to realize sustainable recycling of steel and zinc. Dust injection technology is a potential solution because it might enable the enrichment of zinc and promote significant reductions in the amounts of regenerated dust. In this study, the effects of dust injection technology on the quantity and the quality of the regenerated dust have been extensively investigated, including the chemical speciation of zinc in the regenerated dust.
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State of the Art in the Treatment of EAF Dust in North America (Confirmed)
11 am
Lifeng Zhang, University of Science and Technology Beijing
EAF dust is a product of the melting of steel scrap in an electric arc furnace. When automobile scrap is remelted in an electric arc furnace (EAF), about 1–2% of the charge, or an average of 17.5 kg dust per tonne of steel produced, is converted into a dust. In the United States, approximately 700,000–800,000 tonnes of EAF dusts are generated each year. In the current paper, technologies for recycling EAF dust were reviewed, including glassification, solidification/stabilization, Waelz kiln technology, MDRT rotary kiln furnace process, cupola furnace process, rotary hearth furnace process, PIZO channel induction furnace process, microwave heating, direct carbonation and leaching process.
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Dioxins Minimization and Control in a EAF (Confirmed)
11:30 am
Ilaria Pistelli, Centro Sviluppo Materiali S.p.A.; Enrico Malfa, Centro Sviluppo Materiali S.p.A.; Daphne Mirabile, Centro Sviluppo Materiali S.p.A.; Marco Scotto, Centro Sviluppo Materiali S.p.A.; Nicola Angelucci, Tenaris Dalmine; Paolo Giugliano, Tenaris Dalmine; Silvia Tosato, Tenaris Dalmine
Thermal treatment of material containing organic matter and chlorine are potential dioxin sources. In this study, not only the EAF process but also the offgas duct pathway are studied, in more than a hundred analyses, in order to individuate dioxin risk zones. By taking into consideration all dioxin formation mechanisms (i.e., the presence of precursor, “fire trace” and De Novo synthesis), a method for easily and immediately warning about critical EAF process steps and offgas points is set up. Moreover, a correlation curve (in agreement with the Clausius Clapeyron equation) between dioxin production and the main process conditions are defined, permitting a strict minimization and control of dioxin production.
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Session: Coke/Coal Raw Materials
(Cokemaking)9:30 am - 12 pm (RM Building A - Level Three Concourse A301)
Chairs: Toni Brayton - U. S. Steel, Robert Carlin - DTE Energy Services, Shiju Thomas - U. S. Steel Research and Technology Center
Incorporation of Charcoal in Coking Coal Blend — A Study of the Resulting Effects on Carbonization Conditions and Coke Quality (Confirmed)
9:30 am
Ka Wing Ng, CanmetENERGY; Louis Giroux, CanmetENERGY; Tony Macphee, CanmetENERGY; Ted Todoschuk, ArcelorMittal Dofasco Inc.
Incorporation of biomass materials in coking coal blends is one of the potentially effective approaches for reducing GHG emissions in blast furnace ironmaking. Experimental work in the pilot-scale movable wall coke oven at CanmetENERGY was performed to examine the effect of charcoal addition to coal blends on carbonization conditions and on properties of resultant bio-coke. Charcoal addition significantly reduced the oven wall pressure during coking. Moreover, the ash content and particle size of the charcoal added to the coal blend play important roles on the properties of resultant bio-coke. In this paper, details of the experimental results obtained will be presented and discussed.
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Potential of Columbian Coals to Produce High-Grade LAM Coke (Confirmed)
10 am
Surya Kishore Gurram, Global Ispat Koksna Industrija Ltd.
One of the important coal sources being developed for GIKIL is coal from Columbia. To understand its potential in producing a high-grade LAM coke, experiments have been conducted at GIKIL in various combinations of Columbian coal with other source coals of GIKIL, such as Czech and American coals. The experiments have been conducted with two-component, three-component and four-component blends to find the optimum combination of Columbian coal to achieve the required coke quality. This paper describes these research efforts in depth and concludes the potential for its use in blends to produce a LAM coke of CSR above 62% in combination with other source coals.
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New Findings From the DMT Small-Scale Coking Test Retort Regarding Coke Quality and Coke Oven Wall Safety (Confirmed)
10:30 am
Drazen Gajic, DMT GmbH & Co. KG; Manfred Kaiser, DMT GmbH & Co. KG
For a long time, DMT has determined coke quality and carbonization behavior data both from coal and coal blend carbonization tests, in a 10 kg retort and a semi-technical coke oven. Those test results have been validated in industrial coking plants. Using model calculations, DMT is now able to scale up the coking behavior with a high reliability from the retort test results to the industrial coke oven scale, comprising the indices MICUM M40/M10, IRSID I40/I10 and the internal gas pressure. Recent work is in progress to determine the impact of oxidation and weathering on the coke quality, particularly on the CRI and CSR values.
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Bi-Reflectance Mapping and Automated Petrographic Analysis of Metallurgical Coke (Confirmed)
11 am
David Pearson, Pearson Coal Petrography Inc.; Rich Pearson, Pearson Coal Petrography Inc.
An automated method of measuring the bireflectance of metallurgical coke has been developed and used to characterize many single cokes, as well as coke blends of European, North American, Asian and Australian origin. Bi-reflectance (maximum–minimum reflectance) maps provide pattern-distribution structure that aid textural identification, while cross-plots of maximum reflectance versus bi-reflectance are used to identify and classify the varieties of fused and unfused coal, and vapor-deposited carbon, both confirmed through cluster discriminant analysis. Statistical pattern-recognition analysis of bi-reflectance maps is aimed at replacing coke petrographic point-counting, and although successfully demonstrated, it is not yet commercially implemented.
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Decision-Making Tool for Optimum Coal Blend Regarding Commercial, Technical and Operational Constraints for an Integrated Steel Plant
11:30 am
F. Breseghello, USIMINAS
This work presents an integrated decision-making tool capable of finding the best global distribution of different coal types for coke production. It aims at minimum overall cost, ensuring the blast furnace requirements, considering commercial, technical and operational constraints. The tool was developed in GUSEK, based on GLPK solver — which uses coke quality prediction and byproducts generation equations — and in Microsoft Excel VBA, for a user-friendly interface. It also includes logistical issues, providing the smallest inventory possible. The free optimizer platform is desirable for scalability purposes, making it possible to deal with more complex logistic and supplier problems.
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Session: Plant Projects
(Ironmaking)9:30 am - 12 pm (RM Building A - Level Three Concourse A302)
Chairs: Dale Combs - Severstal Dearborn, Al Dzermejko - Magneco/Metrel, Inc., John Mroz - Berry Metal Co.
Design, Construction, Commissioning and Operation of the New Blast Furnace No. 6 at AHMSA (Confirmed)
9:30 am
Jaime Pena, AHMSA; Ricardo Diaz, AHMSA; Scott Davis, Paul Wurth Inc.
The blow-in of No. 6 blast furnace at AHMSA took place on 8 April 2011. Within three months of operation, the furnace was already exceeding the rated nominal production capacity of 4,000 MT/day. The furnace features a belt conveyor-type charging system, Bell-Less Top®, the latest design of hydraulic guns and drills, casthouse emissions system, GCI injection system with provisions for natural gas injection, and a new gas cleaning plant with an axial cyclone, AGE scrubber and demister. This paper will highlight the design features of the furnace, the furnace construction at the site, furnace operation and production output results.
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OneSteel Whyalla Blast Furnace Campaign Extension (Confirmed)
10 am
Reinoud van Laar, Danieli Corus BV; John Tsalapatis, OneSteel
OneSteel operates a single blast furnace at their Whyalla plant. The fourth furnace campaign started in 2004 and comprised a cooling system which included advanced copper stave and cast-iron stave coolers in the upper bosh and stack, copper cooling plates and silicon carbide refractory in the lower bosh with high-alumina blocks in the tuyere-band area. Water leaks in several coolers started to be observed in late 2007, later followed by bosh refractory lining and cooling plate failures. There were ongoing lower bosh shell and expansion joint hotspots following the lining failure. A 64-day repair was executed in 2011 in order to prolong the furnace campaign life to at least 2020. This repair included a new tuyere-band area design and a “Hoogovens” bosh design with machined copper cooling plates and graphite. Two new rows of copper stave coolers have been installed in the belly. This paper addresses the history, the design solution and the campaign extension repair.
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Evaluating High-Intensity Mixers as a Solution to Improve Sinter Quality in a Depleted Sinter Feed Environment (Confirmed)
10:30 am
Gustavo Moreira, Federal University of Minas Gerais; Gabriela Soares, Federal University of Minas Gerais; Ronaldo Sampaio, RSConsultants
To deal with the depletion of rich sinter feed sources for sintering, the Brazilian integrated steel industry started to increase the proportion of rich pellet feed in their existing sintering process. ArcelorMittal Monlevade and Gerdau Açominas successfully implemented the HPS (Hybrid Pellet Sinter) process. This paper presents a metallurgical and economic study aimed at discovering a simpler method to better mix pellet feed with sinter feed for use in the existing sintering machines of USIMINAS, which is the use of high-intensity mixers. USIMINAS now has its own iron ore sources, but it will come mainly from the concentration of poor itabirites that result in very fine ore concentrate. The value-in-use method was utilized to define the most convenient proportion of sinter feed and the concentrate to use at existing blast furnaces.
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The New High-Performance Chute Transmission Gearbox — Results of the First 18 Months of Operation at ROGESA’s BF5 (Confirmed)
11 am
Dave Berdusco, Paul Wurth Inc.; Walter Hartig, AG der Dillinger Hüttenwerke; Emile Lonardi, Paul Wurth S.A.; Guy Thillen, Paul Wurth S.A.; Lionel Hausermer, Paul Wurth S.A.
At the Dillingen plant in Germany, Rogesa installed the prototype of the new high-performance chute transmission gearbox (CTGHP) on their largest blast furnace (No. 5). This technologically advanced chute drive system is based on 40 years of experience in BLT charging technology and modern simulation tools. The result is a cost-effective design ensuring reduced maintenance and increased lifetime potential. This first industrial application has been in successful operation since October 2010. This paper highlights technical advantages of the CTGHP and provides an analysis on the effect of BF No. 5’s burden distribution on the operational performance during this initial period.
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Method of Repair for Blast Furnace Copper Staves With Water Connection Pipe/Weld or Plug Weld Leaks (Confirmed)
11:30 am
Todd Smith, Berry Metal Co.; Derek Dengel, Berry Metal Co.; Kenneth Wing, United States Steel Corporation; Brian Thompson, United States Steel Corporation
Blast furnaces throughout the world have experienced pipe attachment or plug weld leaks with drilled and plugged copper staves. Studying these failures, they occur, on average, at 5 1/2 years of service. To avoid replacing the staves after a short campaign, it is desirable to repair these circuits. This repair method permits reestablishing water cooling with the copper surfaces of the stave. The repair can be performed during a short outage. This technology will be presented showing a summary of failure mechanisms and a unique repair method to extend the life of drilled and plugged staves.
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Session: Blast Furnace Injections
(Ironmaking)9:30 am - 12 pm (RM Building A - Level Three Concourse A303)
Chairs: Hugh Crosmun - Carmeuse Lime and Stone, Inc., Bruce Stackhouse - RG Steel
Continuous Monitoring of Liquid Level and Thermal State in the Hearth Based on Measurement of EMF on the Blast Furnace Shell (Confirmed)
9:30 am
Daniel Holmes, ArcelorMittal; Michael Alter, ArcelorMittal
Electro Motive Force (EMF) is a sensitive tool that has been correlated to two main blast furnace parameters, the total liquid level and thermal state of the furnace hearth. Since 2007, ArcelorMittal has successfully installed EMF systems on the hearth shells of most ArcelorMittal blast furnaces in North and South America. The EMF trends are being utilized by operators for casting practice control and decision making on furnace thermal condition with varying success.
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Improving the Ironmaking Process With Expert Systems in Closed-Loop Operation (Confirmed)
10 am
Thomas Kronberger, Siemens VAI Metals Technologies GmbH; Angelika Klinger, Siemens VAI Metals Technologies GmbH; Martin Schaler, Siemens VAI Metals Technologies GmbH; Bernhard Schurz, Siemens VAI Metals Technologies GmbH
This paper gives a brief description of the blast furnace automation package, the SIMETAL VAiron Expert System, and summarizes the typical benefits. SIMETAL Vairon Expert is part of the VAiron level 2 systems for sinter plants, blast furnaces and COREX® plants. Main features of these expert systems are the process diagnostics, suggestion of corrective actions and possibility of on-line (closed-loop) operation of the plant. In the knowledge system platform, information and trends of the plant operation are combined, textual explanations for diagnostics are generated and corrective actions for the plant operation are suggested to the operator. The operator gains detailed understanding of complex plant situations. On the basis of a recent Mexican project, actual saving figures are presented.
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Influence of Process Variables on Blast Furnace Operational Limits: Ternium Siderar Experience (Confirmed)
10:30 am
Gabriel Puertas, Ternium Siderar; Gustavo Cegna, Ternium Siderar; Oscar Lingiardi, Ternium Siderar; Roberto Musante, Ternium Siderar
Frequent and deep changes in the global market affect the operating conditions of blast furnaces, pushing them to operate close to the known limits in many cases. This paper analyzes how certain process variables affect the productivity and operational limits based on the experience developed in recent years in Ternium Siderar. The analysis includes energy balance results and industrial data.
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A CFX-Based Modeling of Blast Furnace Considering Layered Cohesive Zone
11 am
Baoyu Guo, University of New South Wales
A CFX-based mathematical model is developed to describe the flow-heat transfer-chemical reaction behaviors of gas-solid-liquid phases in an ironmaking blast furnace, where the layered cohesive zone is considered explicitly. The typical in-furnace phenomena of an operating blast furnace are simulated in terms of multiphase flow, temperatures, gas composition and reduction degree, etc. The effect of different model geometry is investigated by means of comparing the predictions from slot model and sector model. The results indicate that the treatment of layered cohesive zone can naturally predict the in-furnace phenomena of a layered-burden blast furnace. The sector model gives significantly different predictions than the slot model. This model offers a cost-effective and easily transferable tool to understand and optimize blast furnace operation.
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Validation of the Numerical Model for Blast Furnace Shaft Process (Confirmed)
11:30 am
Chenn Zhou, Purdue University Calumet
A computational fluid dynamics (CFD) model was applied to simulate the gas flow, solid burden descent and chemical reactions in a blast furnace. Optimization of the gas and burden distribution by the CFD model can lower the furnace fuel rate. In this work, the operational data of a U. S. Steel blast furnace is provided to conduct the CFD simulation. Validation of the CFD results is achieved by comparing the simulation results with the plant measurements. The top gas temperature distribution, compositions, pressure drop, actual coke rate, etc., are compared. The detailed CFD results are analyzed to gain insight into the actual furnace operation.
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Session: BOF Benchmarking — Panel Discussion
(Oxygen Steelmaking)9:30 am - 12 pm (RM Building A - Level Three Concourse A313)
Chairs: HansJoerg Junger - RHI Canada, Kamal Ughadpaga - ESSAR Steel Algoma Inc.
Development of the AIST Process Benchmarker for Oxygen Steelmaking (Confirmed)
9:30 am
Patrick Gallagher, Management Science Associates Inc.; Noah Wolf-Johnston, Management Science Associates Inc.
The APB is a Web-based analytical platform and service for benchmarking operational performance metrics for the Technology Committees of AIST. The goal of the service is to increase technical networking between participating AIST member companies and to provide a valuable source of relevant performance benchmark information. This paper will discuss the technology, methodology and approaches used in developing the APB and will provide case studies of how different Technology Committees are using the system.
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Panel Discusion: BOF Benchmarking (Confirmed)
10 am
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Session: Steel Process
(Ladle & Secondary Refining)9:30 am - 12 pm (RM Building A - Level Three Concourse A314)
Chairs: Greg Brasel - Carbide Industries LLC, Chad Clark - Gallatin Steel, Helmut Oltmann - Nucor Steel
Free Opening Performance of Steel Ladle at ArcelorMittal Indiana Harbor East Steelmaking (Confirmed)
9:30 am
Eraj Siddique, ArcelorMittal; Xin Zhang, ArcelorMittal; James McCloskey, ArcelorMittal; Yong Lee, ArcelorMittal
To improve the productivity and final product mix, liquid steel has been transferred from one shop to another in ArcelorMittal Indiana Harbor Steel Producing facilities. Among many difficulties during liquid steel transfer, longer residential time of steel in the ladle led to a drastic decrease the free open rate. In order to counter the imminent problems, key variables affecting the free open were investigated. This paper will discuss the performance of free open rate for different ladle sands and methods to improve the free open rate.
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