Howe Memorial Lecture
Monday, May 7 • 8–9 a.m.

From Liquid to Solid: Key Issues in the Future of Steel Casting
A.W. Cramb, Rensselaer Polytechnic Institute
The development of continuous casting revolutionized the production of steel and was a necessary condition for the development of the minimill for bar and rod production and for the “thin slab” flat product plants that are now common in North America. While integrated steel plants also implemented continuous casting within their facilities, current trends are toward in-line processing plants that are enabled by close coupling of steelmaking, casting and rolling. Latest developments in casting have led to direct strip casting — the first truly near-net-shape steel casting operation for flat products.

Challenges in casting development are to match the productivity of a rolling mill to the productivity of casting and to produce a casting with a surface quality that allows the cast surface to become the product surface. Thus, a major issue of modern casting is to create defect-free cast surfaces at very high casting speeds. To understand and potentially solve this problem, one must answer two fundamental questions concerning the formation of solid steel: “How does solidification start?” and “How fast can solid form?” This lecture will focus on the current status and the future of continuous casting by considering these two questions.

Monday, May 7
Morning Sessions

9:30 a.m. — Coke Producing — Coke Plant Technology - back to top
Room 101
Session Chairs: John Shell, Indianapolis Coke; Dave Knapp, Glidewell Specialties Foundry

9:30 a.m.
Dawes Lane Coke Ovens, Corus UK — Recovery From Catastrophic Loss of Services
N. Willerton, Corus
On Feb. 1, 2006, a forklift truck collided with a conveyor support stanchion at the Scunthorpe Works. The structure supported the two steam supply mains to the Dawes Lane Coke Ovens and the export gas main, in addition to other services. All were severed, apart from the gas main, which was left unsupported for a considerable length. After approximately 10 hours, an unproven system of operation was used to protect the batteries. Mobile steam generation was used to restore steam supply after 82 hours, and normal battery operations resumed one month after the incident.

10 a.m.
Optimizing Heat Recovery Coke Plant Siting
M. Barkdoll, Sun Coke Co.
This paper provides an update on the status of Sun Coke Co.’s heat recovery coke plants in Haverhill, Ohio, and Vitoria, Brazil. Also included is the status of future Sun Coke plants both in the United States and internationally.

10:30 a.m.
Managing Tar and Liquor Quality
F. Passamani, CST Arcelor Brasil; E. Antonio da Silva, Nalco Brasil; H. Chumienski, Nalco; P. Buaiz Silvares, CST Arcelor Brasil; R. Jose da Silva, CST Arcelor Brasil
Tar and flushing liquor must be removed from coke oven gas. Not only are they at the beginning of the gas cleaning circuit, but their impact on operating costs, gas cleaning performance and environmental loading throughout most of the gas cleaning plant cannot be overstated. This paper discusses factors that affect the tar and flushing liquor quality and focuses on changes in operating practices coupled with specialty chemical enhancement technology. Changes in the liquor and tar qualities will be reviewed, and the impact on coke oven operation, primary gas cooling and the waste treatment operation will be presented.

11 a.m.
Refractory Repair Strategies for Battery Life Extension
E. Goffi, Fosbel Inc.
This paper will focus on current repair strategies and new innovations in the coke plant repair service market. Topics will include battery ranking systems and life prediction models, as well as new innovations in both fused silica and conventional brickworks replacement for end-flue and throughwall repairs.

11:30 a.m.
Coke Oven Gas Condensate — Hazardous Waste Issues
T. Robertson, Environmental Quality Management Inc.
Proper characterization, classification and determination are critical when determining if materials are subject to regulation as a hazardous waste. Making this determination is a complex task, and it is a central component of hazardous waste management regulations. Over the years, there has been substantial confusion and continuing controversy regarding appropriate classification and management of waste streams associated with the manufacture of coke and coke oven gas byproducts. This paper demonstrates that, with careful and diligent management, coke oven gas condensate may be excluded from the realm of solid waste management, be exempt from the realm of hazardous waste management, be characteristically hazardous waste and be subject to numerous NESHAPs.

9:30 a.m. — Iron Producing — Blast Furnace Operations - back to top
Room 102
Session Chairs: Surjit Singh, Mittal Steel USA; Art Cheng, Severstal NA

9:30 a.m.
CST Arcelor Brasil No. 2 Blast Furnace — 10 Million Tons
R. Rezende, Companhia Siderurgica Tubarao; J. Novaes, Companhia Siderurgica Tubarao; C. Klein, Companhia Siderurgica Tubarao; J. Gushiken, Companhia Siderurgica Tubarao; E. Santos, Companhia Siderurgica Tubarao
This paper shows the main results and operational practices of the No. 2 blast furnace at CST Arcelor Brasil during eight years of operation. This equipment reached 10 million tons in December 2005. Throughout the campaign, improvements have been made to the burden distribution, and some operational changes have solved problems such as high temperatures in the wall of the hearth and Cu-staves. Those actions have stabilized the operation/temperature in the hearth and enabled the company to maximize its production.

10 a.m.
The No. 2 Blast Furnace Casthouse at Dofasco
C. Bell, Dofasco Inc.; E. Wende, Dofasco Inc.; F. VanLaar, Dofasco Inc.; J. Augstman, Dofasco Inc.; and W. Struiksma, Dofasco Inc.

10:30 a.m.
New Challenge in the Casthouse Operation at ThyssenKrupp Steel
W. Wiese, ThyssenKrupp Steel AG; M. Peters, ThyssenKrupp Steel AG; P. Schmole, ThyssenKrupp Steel AG; P. Ruther, ThyssenKrupp Steel AG
ThyssenKrupp Steel operates four blast furnaces with a hot metal capacity of up to 12 million tons per year in total. To minimize costs in the casthouse operation and to optimize the tapping performance for hot metal and slag, measures were taken to optimize the taphole conditions and to prolong the life of the refractory lining of the troughs. In addition to choosing an optimized refractory material, ThyssenKrupp Steel undertook extensive technical measures in the total casthouse area with the aim of improving economical efficiency, especially in the fields of casthouse practices and tapping techniques, improved instrumentation for tapping, introduction of long tapping sequences, improvements of the lining strategy for the runner systems, and adaptation of techniques and organization for the casthouse area. The improvements for the casthouses of the large Schwelgern No. 1 and No. 2 furnaces, and the strategic ideas for further improvements in the future, are shown.

11 a.m.
How Do You Mend a Broken Hearth?
F. Kielbowich, Hamilton Steel GP Inc.; S. Duran, Hamilton Steel GP Inc.; S. Hutchinson, Hamilton Steel GP Inc.; D. Rivard, Hamilton Steel
Hamilton Steel No. 5 blast furnace experienced premature hearth wall troubles five years into an anticipated 12­ -year campaign. These issues included hearth wall gaps between the shell plate and wall ranging from 3 to 14 inches, bulging of the shell plate and breakout at the west iron notch. The issues began in the fall of 2004, escalating into serious deterioration of the hearth wall and iron notch thermocouple temperatures by the spring of 2005. This paper will describe the sequence of events leading to the initial discovery of the problems, investigations undertaken to define the magnitude of the issues, countermeasures implemented to continue operation, and finally repairs performed in November 2006.

11:30 a.m.
Ternium-Siderar Blast Furnace No. 2: End of Campaign
R. Musante, Ternium Siderar; E. Velo, Ternium Siderar; J. Zubimendi, Ternium Siderar; R. Ametrano, Ternium Siderar; O. Lingiardi, Ternium Siderar
Blast furnace No. 2 at Ternium-Siderar operated from Sept. 13, 1995, until Oct. 27, 2006, when a blowdown was performed to carry out a major repair and technological update. During the 11 years and 44 days it was in operation, it produced 22.7 million metric tons of hot metal, representing 9,377 t/m3 of inner volume. The salamander casting was successful and was achieved 8 hours after the shutdown of the furnace, casting 220 tons of hot metal. The hearth does not show typical “elephant foot” wear, but rather a bowl type, as predicted by the wear model for this hearth. Although the hearth showed marked erosion at the bottom, the campaign could have been extended. The decision to shut down the blast furnace to carry out the major repair was a response to an opportunity relating to the company’s future expansion plans.

9:30 a.m. — Iron Producing — Sintering - back to top
Room 103
Session Chairs: James Simmons, Core Furnace Systems Corp.; Thomas Dohnal, Wheeling Pittsburgh Steel

9:30 a.m.
Development of an On-line Moisture Measuring System for Sinter Plants
K. Lee, RIST
This paper presents research into an on-line method to measure the amount of moisture contained in an ore that is later used as raw material for sinter. Several on-line methods for measuring the amount of moisture were analyzed and compared, and a neutron method determined to be most suitable for the sinter plant was designed and adopted. Many experiments were conducted to find the most suitable calibration line for sinter plants in order to minimize measuring errors, and a program was developed in which the change in the amount of moisture can be closely observed.

10 a.m.
Sintering Properties of Marra Mamba Iron Ores
L. Hsieh, China Steel Corp.
In the sinter pot tests of individual iron ores, Marra Mamba ores demonstrated many distinctive properties. Compared with hematite and pisolitic ores, Marra Mamba ores presented the highest permeability in sintering, medium productivity, lowest tumbler strength, smallest size of sinter, and required the highest coke rate and moisture. In the sintering of blending ores, the effects of increasing Marra Mamba ore on the sintering properties (including the productivity, TI, coke rate, sinter’s mean size and suitable moisture in the raw mix) were reflected by the differences between Marra Mamba ore and replaced ores in the sintering of individual iron ores.

10:30 a.m.
MEROS® Sinter Offgas Cleaning — Meeting Future Environmental Demands Now
T. Plattner, Siemens VAI Metals Technologies GmbH & Co.; R. Neuhold, Siemens VAI Metals Technologies GmbH & Co.; A. Fleischanderl, Siemens VAI Metals Technologies GmbH & Co.
Environmental authorities all over the world have addressed their attention to sinter plants. New regulations in Europe and a special focus on SO2 and NOx in Asia and the United States demand new approaches for sinter gas-cleaning concepts. Maximized Emission Reduction Of Sintering (MEROS) is a new dry-type gas-cleaning process that removes pollutants from the offgas stream of sinter plants far more efficiently than conventional processes. The technology is based on counter-current injection of additives, gas conditioning, dust recirculation and fabric filter dust removal. In 2005, a demonstration plant was installed to investigate physical-chemical effects on removal efficiency of various gas compounds, while also optimizing process parameters. Operation results will be presented. The start-up of the world’s first commercial MEROS gas-cleaning plant is scheduled for August 2007.

11 a.m.
Visibility Control of the Main Stack Plume at CST Arcelor Brasil Sinter Plant: A Scientific Approach
A. Ferreira,CST Arcelor Brasil; E. Harano, CST Arcelor Brasil; J. Mendes, CST Arcelor Brasil; G. Abreu, CST Arcelor Brasil; H. Oliveira, CST Arcelor Brasil; M. Andrade, Companhia Siderurgica de Tubarao
Even after significant investments were made to control emissions, the visibility of the main stack plume at the CST Arcelor Brasil sinter plant remained a factor, as it was difficult to measure and control. Therefore, a study supported by Federal University of Espírito Santo was carried out, serving as a guide for controlling the visibility of the plume, and basically consisted of a theoretical approach to the visibility phenomenon. Based on statistical analysis, the study aimed at determining the relationships between the process parameters (inputs and operational) and emissions.

9:30 a.m. — Electric Steelmaking/Process Technology — EAF Process Technology - back to top
Room 111
Session Chairs: Gary Bresson, Miller & Co.; James Fortier, Showa Denko Carbon; Euan Evenson, Praxair Inc.

9:30 a.m.
Developments Toward an Intelligent Electric Arc Furnace at CMC Texas Using Goodfellow EFSOPTM Technology
J. Maiolo, Tenova Goodfellow; C. Williams, CMC Group; C. Li, Tenova Goodfellow; M. Boutazakhti, Tenova Goodfellow
Tenova Goodfellow Inc., formerly Techint Goodfellow Technologies Inc., has developed the Goodfellow Expert Furnace System Optimization Process (EFSOPTM), which uses real-time analysis of EAF offgases to optimize, dynamically, the chemical energy usage within the electric arc furnace. The benefits of the Goodfellow EFSOP system are safety, increased process knowledge, lower conversion costs and increased productivity. In December 2005, Tenova Goodfellow installed and commissioned its Goodfellow EFSOP system for CMC Steel at their Seguin, Texas, meltshop to optimize the operation of their 120-ton EAF. Subsequent to the initial EFSOP installation and working toward continuous improvement in offgas-based optimization and control, Tenova Goodfellow has partnered with CMC Steel Texas to begin development of an intelligent control system for the EAF. In addition to offgas composition and furnace operating parameters, the program uses continuous offgas temperature and fourth-hole static pressure measurements to calculate dynamically a gas-phase mass and energy balance for the EAF. This balance is in turn used to elucidate important steelmaking information, such as rate of air in-leakage into the furnace; rate of decarburization from the bath; rate of oxidation and rate of water in-leakage into the offgas. This paper will outline the path to EAF optimization and the benefits achieved at CMC Texas. Progress toward Tenova’s Intelligent Furnace (iEAF) development will also be discussed.

10 a.m.
Tools for Foaming Slag Operation During EAF Steelmaking
R. Krump, Voestalpine Mechatronics GmbH; C. Sedivy, Voestalpine Mechatronics GmbH
Modern EAF steelmaking involves the foaming slag operation. A stationary foam operation can be maintained only by adjustment of the blowing parameters according to the real situation in the furnace. With an automatic slag management system, it is possible to detect the actual situation quantitatively and control the carbon addition in order to achieve perfect foaming conditions with reduced carbon consumption. To avoid carryover slag at furnace tapping, the tapping process can be optimized by use of an infrared slag detection system.

10:30 a.m.
Laser Off-Gas Analysis with Closed Loop Control Improves EAF Optimization
J. Von Scheele, Linde AG; S. Hornby, Linde Gas LLC; M. Gartz, Linde AG Germany; H-J. Krassnig, Stahl – und Walzwerk Marienhutte Ges. MbH
Laser offgas analysis technology has been used in EAFs since 2002. This paper will present the addition of closed-loop control and water laser analysis to the Lindarc® offgas analysis system, which already offers CO, CO2, O2 and temperature analysis. Detailed results of the latest installations will be presented, as well as results from prior installations, to show how changes to the system have increased optimization capability of the expanded Lindarc laser offgas analysis system.

11:30 a.m.
Foaming Slag in More Dimensions — A New Detection Method for Electric Arc Furnace Control
T. Matschullat, Siemens AG; W. Wichert, Lechstahlwerke GmbH; D. Rieger, Siemens AG
The Industrial Solutions and Services (I&S) Group and the Corporate Technology (CT) department of Siemens AG have developed a new method of measuring the changes in the level of foaming slag in arc furnaces over time and in the various parts of the furnace. The method is based on the measurement of structure-borne noise at the furnace shell. Highly sensitive acceleration sensors fitted to the walls of the furnace provide signals that enable spatial mapping of the foaming slag. A series of tests carried out on a 70-metric-ton arc furnace at Lech-Stahlwerke GmbH showed a very high match with visually determined levels of slag. The prototype for on-line detection, installed in March 2006, gives the operator the opportunity to influence the process into a more stable operation of foaming slag.

9:30 a.m. — Electric Steelmaking — Radiation, Mediation and Improvement - back to top
Room 117
Session Chairs: Harriet Dutka, The Timken Co.; Allen Wyatt, SGL Carbon LLC

9:30 a.m.
Timken Faircrest Radiation — It Could Happen to You
B. Weisburn, TheTimken Corp.; K. Kushner, The Timken Co.; A. Black, The Timken Co.; T. Webb, The Timken Co.; H. Dutka, The Timken Co.
The Faircrest Steel Plant had operated for nearly 20 years and felt comfortable that the radiation detection program in place was adequate enough to protect the company from the possibility of melting a radioactive source. However, on May 4, 2004, all of that thinking changed when the plant melted a Cs-137 source. A review of the events associated with this incident, along with a description of the changes to the company’s radiation detection program, will be presented.

10:30 a.m.
International Perspective on Radioactive Contaminated Scrap Metal
R. Turner, River Metals Recycling

11 a.m.
Source Melt Response
B. Melchios, Energy Solutions
This paper will cover source metals emergency response, remediation and radioactive materials.

9:30 a.m. — Oxygen Steelmaking — BOF Tapping and Carryover Control - back to top
Room 105
Session Chairs: William Howanski, Mittal Steel USA; Greg Meszaros, U. S. Steel Corp.

9:30 a.m.
Recent Developments in the Application of Refractory Darts for BOF Slag Control at Mittal Sparrows Point
W. Howanski, Mittal Steel USA; T. Kalep, IFGL Inc.; T. Swift, SPEC Inc.
The minimizing of BOF slag carryover into the steel ladle can have significant operational and economic benefits.  The immediate impact is upon the total aluminum consumption required for deoxidation, as well as improved alloy recovery.  Additionally, reduced phosphorus reversion is achieved.  Other downstream benefits such as improved ladle refractory performance and LTS stir lance stir life can also be associated with the dedicated employment of a refractory dart to minimize BOF slag carryover.

Recent efforts at Mittal Steel - Sparrows Point plant highlight the progress and development of the refractory dart slag control programs. The results of various trials utilizing alternative dart head designs and the benefits derived will be identified.  Finally, the introduction of infrared camera technology in combination with a refractory dart practice will be discussed.

10 a.m.
Improvement in Performance of the Tapping System at Port Talbot Steelworks
M. Cormier, RHI Canada Inc; M. Berger, RHI-AG
For North American integrated steel plants, it is increasingly important to adapt the taphole system at the BOF to the most important needs of the meltshop. These are: increase productivity, improve process quality and lower production costs per ton of steel. A new CFD optimized taphole system has been successfully tested at Corus Port Talbot. The tailored taphole geometry provided longer life by reducing the wear of the taphole and also provided a more stable tapping time, which improved the controllability of the process. In addition, a better bundled steel stream during tapping improved the steel quality by avoiding N pickup. Furthermore, a solid surround block concept, combined with a well-proven taphole repair system, has significantly shortened the downtime per taphole repair.

10:30 a.m.
VAI-CON®-Tap: The Missing Link in Converter Steelmaking
R. Hubmer, Siemens VAI; K. Herzog, Siemens VAI; G. Staudinger, Siemens VAI; P. Juza, Siemens VAI
Modern steelmaking processes demand ever-shorter tap-to-tap times at increasing steel quality levels. In the majority of process steps, a high level of automation of the LD (BOF) process has been achieved: lance movements, oxygen blowing, tapping alloying, blow endpoint determination and slag carryover prevention have been very successfully put into fully automatic operation. Siemens VAI has introduced technological packages and automation solutions for the above-mentioned process steps through the implementation of the SteelExpert process model family, including DYNACON dynamic blow end control, and technological packages, such as VAI-CON® Car, VAI-CON® Tilting Drive Control and VAI-CON® SlagStopper including IRIS slag detection. The latest development to complete the VAI-CON® family is VAI-CON® -Tap — the missing link to allow automatic tapping of the converter. VAI-CON-Tap coordinates converter tilting and drive position, ladle car position movement and VAI-CON® Stopperslag stopper activation to allow for a fully automatic tapping process.

11 a.m.
Application of a Thermographic Slag Detection System at Baosteel
J. Zhou, Baoshan Iron & Steel Co. Ltd.; J. Li, Baoshan Iron & Steel Co. Ltd.
The development of Baosteel converter combined blowing is reviewed, along with the present technologies: tuyere system alteration, adjusting the content of converter slag, and re-access of porous brick by enriched oxygen. The principle and the main instrument of the thermographic slag detection system are introduced. By analyzing the thickness of the slag in the ladle, the best match of a thermographic slag detection system and a converter can be found.

9:30 a.m. — Continuous Casting — Mold Monitoring and Heat Transfer - back to top
Room 116
Session Chair: Jeff Brower, Siemens VAII; George Lawson, Mittal Steel USA

9:30 a.m.
Mold Expert 2.0 — New and Improved Features for Mold Monitoring
O. Lang, Vatron; K. Morwald, Siemens VAI; A. Pesek, Siemens VAI
The first version of the MoldExpert included routines for sticker detection, heat flux monitoring and friction monitoring. For the MEX 2006, additional features are integrated. With the mold level analyzer, the quality of mold level control can be evaluated. Moreover, the data are checked for characteristic disturbances (bent rolls, mold level hunting) and clogging/unclogging phenomena. The hot area detection algorithms help to detect static and dynamic hot spots. Improved algorithms for breakout prediction reduce the number of false alarms. To make inspection of process data more convenient, long-term data storage is organized according to individual heats, and the data can be visualized with the long-term viewer.

10 a.m.
Observations on Mold Corner Temperatures Measured Using Thermocouples
E. Serrano, U. S. Steel Corp.; T. Piccone, U. S. Steel Corp.; T. Natarajan, U. S. Steel Corp.; I. Sohn, U. S. Steel Corp.
During examination of alarm case data from the sticker detection systems at different U. S. Steel casters, it was discovered that the thermocouple measurements in the vicinity of the mold corners often have unusual patterns, including oscillatory behavior. Examples of such behavior will be discussed, together with the casting conditions under which they are observed, a description of the relationships between thermocouples at different locations near the mold corners, and possible mechanisms responsible for the observed behavior.

10:30 a.m.
Investigating Mold Heat Transfer in Thin Slab Casting in CON1D
A. Kamperman, Corus RD&T; A. Hamoen, Corus RD&T; W. van der Knoop, Corus RD&T; M. Santillana, Corus RD&T; B. Thomas, University of Illinois at Urbana-Champaign
The one-dimensional heat transfer model, CON1D, is being applied to investigate the thin-slab casting process. To account for the multidimensional thermal behavior around the cooling channels of the funnel mold, a three-dimensional finite element model, developed using ABAQUS, is applied to find correction factors that enable CON1D to accurately predict temperature at thermocouple locations. The model calculations have been validated using an extensive database of plant process parameters obtained from the Corus direct sheet plant in IJmuiden, including measurements of mold powder consumption, oscillation mark shape, mold temperature and heat removal. The improved CON1D model will be used to extrapolate the standard practice to higher casting speeds and new mold designs.

11 a.m.
Detection of Mold Events Using Thermocouple Measurements
I. Sohn, U. S. Steel Corp.; T. Piccone, U. S. Steel Corp.; T. Natarajan, U. S. Steel Corp.
As casters push the boundaries of safe and stable casting, it is important to provide operators with sensors that can provide adequate warnings about problems in the mold. In this paper, work being done at different U. S. Steel facilities utilizing thermocouple measurements to detect mold events is described. In particular, the focus will be on issues like longitudinal face cracks, tube breaks and mold flux studies.

11:30 a.m.
Innovative Methods and Probe for Continuously Measuring Liquid Steel Temperature and Slag Thickness
Z. Yuan, McGill University; F. Mucciardi, McGill University; S. Yue, McMaster University
A new on-line method of monitoring the slag thickness on a steel melt locates the interface between the slag and the steel by capitalizing on the thermal emissivity difference between molten steel and slag. This technique can also be used to locate the interface in many systems that contain two immiscible phases. In addition, a new method for continuously monitoring liquid steel/slag temperatures has been developed. This method combines a common infrared temperature measurement system with an innovative protecting “Tube” (the Thermopump) to yield a piece of equipment that measures the temperature of a liquid at some distance below the free surface. Moreover, this technique can also be used to monitor temperatures continuously in other harsh environments. A probe that can continuously monitor steel/slag temperatures, and at the same time can monitor slag thickness, has been conceptualized and designed. A commercial prototype of the probe was designed, manufactured and tested in the lab, and was to be tested in a plant tundish by the end of 2006. Lab and plant test results are discussed in this paper. Also presented are details on how to monitor liquid steel/slag temperature and slag thickness by using this new Thermopump probe.

9:30 a.m. — Sheet Rolling — Sheet Rolling - back to top
Room 110
Session Chairs: Eric Thokar, Danieli Corp.; Charles Varga, Quaker Chemical Corp.

9:30 a.m.
Elastohydrodynamic Lubrication in Rolling Geometries
I. Burton, DA Stuart Co.
Elastohydrodynamic lubrication is one of the most researched topics in tribology. Much of this research is not specific to the rolling condition; rather, it has focused on bearing design. Its importance in steel rolling cannot be ignored and is paramount to maximizing mill speed and production. Research will be presented that explores effects of viscosity, chemical-structure relationships and pressure viscosity coefficients to maximize the EHD effect. A case study will also be discussed.

10 a.m.
Validation of an Accurate and Rapid New Model for Strip Crown
A. Malik, Wright State University; R. Grandhi, Wright State University
Validation of a new, rapid model for mill deflection and strip crown on both cluster-type and noncluster-type rolling mills is presented. The validated method offers several advantages over traditional models in on-line use. It includes continuity of elastic foundations, noniterative solution when using predetermined foundation moduli, continuous third-order displacement fields, simple stress-field determination, the ability to calculate mill vibration characteristics, and comparatively faster solution time. Consistent with the most advanced existing methods, the new method can accommodate roll crowning, roll bending, roll shifting and roll crossing mechanisms. Validation is provided using large-scale, finite-element studies using the commercial package ABAQUS.

10:30 a.m.
Automatic Surface Inspection as a Productivity Tool for Hot and Cold Mill Shops
J. Legoupil, VAI Clecim Siemens VA

11 a.m.
Latest Solutions for High-output Coupled or Continuous Cold Rolling Mills
S. Martin, Siemens VAI; S. Mauuary, Siemens VAI; O. Germain, Siemens VAI; P. Gippet, Siemens VAI; B. Sokoloff, Siemens VAI
Due to ever-increasing market pressure, steel producers have to rationalize their equipment and reduce their cost per ton to fulfill the high demand and to generate more profit. With high productivity and low operating cost, the coupled or continuous lines are now the standard for new or revamped tandem cold mills. To help its customer improve their production level and quality, Siemens VAI supplies integrated solutions, from equipment to automation. This paper will describe the benefits that have been achieved by customers using Siemens VAI’s most up-to-date solutions for high-productivity mills.

11:30 a.m.
An Innovative Solution Minimizing the Thickness Variations in Cold Rolling
L. Broussard, Converteam SAS
On tandem cold rolling mills, thickness performances can be altered due to some modifications of the first stand rolling conditions. It is not always possible to detect these perturbations early enough to compensate for them by traditional controllers. Converteam Inc. developed an innovative, patented solution able to eliminate such perturbations. This paper presents the implementation of the solution and the results reached on an installation.

9:30 a.m. — Long Products Rolling — Long Products I - back to top
Room 108
Session Chairs: Tom Gallagher, SinterMet LLC; David Light, Carter Steel Co.

9:30 a.m.
Economic Production on Bar and Wire Rod Mills
H. Mueller, SMS Meer
The Multiline Loop, combined with an 8-stand block and FRS® Flexible Reducing Sizing mill for quality steel wire rod, allows mill utilization in excess of 90 percent and thermomechanical rolling for the complete size range from 0.2 to 1 inch (5–25 mm). The PSM 3-roll Precision Sizing Mill for SBQ mills has the unique feature of roll setting with hydraulic AGC for extra-close bar tolerances. The HSD® High-Speed Delivery system is suitable for operating speeds of 9,000 feet/minute (46 m/second) with a design speed of 10,000 feet/minute (50 m/second) in rebar mills. The VCC® Vertical Compact Coiler is available for twist-free coiling, speeds up to 7,000 feet/minute (35 m/second), sizes 0.25–1.25 inches (6–32 mm) rebar, rounds, squares, hexagon and flats.

10 a.m.
Rolling with a One-pass Family and Minimum Downtime Large-diameter SBQ
S. Filippini, Kocks Pittsburgh Co.; W. Ammerling, Friedrich Kocks GmbH
Most large-diameter SBQ bars are produced in traditional 2-high mills that have many times been adapted to finish this range of products. However, fierce competition among producers makes it difficult for them to realize conversion costs compatible with accepted market prices. The development of the 3-roll technology has led to the introduction of the reducing and sizing block (RSB), which ideally meets all the requirements of a modern mill. The RSB, which usually replaces the last finishing 2-high stands of a rolling mill, offers the production of high-quality bars with the highest possible yield, maximum mill availability and unlimited production flexibility. This paper shows that the RSB is the optimal rolling unit for finish rolling of high-quality, large-diameter bars.

10:30 a.m.
New Welding Technology for Banding Machines at Nucor, Berkeley - Beam Mill
S. McCarthy, Nucor Steel, J. Crenshaw, Nucor Steel, C. Andersen, Nucor Steel

11 a.m.
Cost Reduction for Concrete Reinforcing Steel Bar Production for Wire Rod, Bar and Spooler Line According to New International Standard Requirements
F. Toschi, Danieli & C. SPA

11:30 p.m.
Adaptive Dimension Models for Optimization of Long Products Rolling
R. Lindkvist, ABB Corporate Research; A. Daneryd, ABB Corporate Research; M. Olsson, ABB Process Automation
This paper presents the ADMTM tool for optimization and simulation of multistand profile rolling. Today, mill settings are largely determined by trial-and-error experience gained over a long period of time by senior mill workers and with little structured support by, for example, an expert system based on consistent rolling models. Mill availability and yield can improve when production speed and energy requirements can be simulated and optimized, and when bar dimension, roll load sharing and groove utilization can be controlled. The ADM tool gives the mill floor worker the parameter settings to reach these optimal conditions in an easy-to-use HMI and with computing response within the minute. Cornerstones are state-of-the-art optimization and on-line model learning techniques along with unique simplified mechanical and physical models.

9:30 a.m. — University and Industry Relations — Student Presentations I - back to top
Room 113

9:30 a.m. — Computer Applications — Modeling - back to top
Room 107
Session Chairs: Paul Martin, Dofasco Inc.; Alesksandar Fabijanic, Nucor Steel Corp.

9:30 a.m.
Influence of Structure and Parameters of a Machine on Its Technical Productivity
V. Kravchenko, Priazov State Technical University
This paper shows that the following factors have considerable influence on a machine’s technical productivity and on the variation coefficient: level of the machine’s complexity balanced by its productivity; coefficients of readiness; theoretical productivity ratio of the first and the subsequent machines, and also a machine’s structure. Recently developed mathematical software describing the operational process as a system of machines with various functional purposes and service life allows one to estimate technical productivity, taking into account the above mentioned factors. Mathematical software can be used for the analysis and synthesis of metallurgical machine complexes.

10 a.m.
Model-based Evaluation of Sustainability Indicators in Integrated Steelmaking: A Case Study
C. Ryman, MEFOS; C. Grip, SSAB Tunnplat AB; M. Larsson, MEFOS
The complex structure of the energy and mass flows in steelmaking has resulted in many attempts to describe the process dynamics by models. Swedish steelmaker SSAB Tunnplåt has a good deal of experience in using optimization models for planning and decision-making related to energy and material utilization. Sustainable development is development aimed at improving the quality of life for everyone, and is a factor of increasing importance in the industry. This paper shows how optimization models can be used for systematic analysis and optimization of sustainability indicators such as energy efficiency, greenhouse gas emissions, and selected material and cost consumption rates.

10:30 a.m.
Hot Mill Furnace Optimization With BetaPlanner for Optimal Mill Scheduling
J. Roelandt, Advanced Information Systems
BetaPlanner is a scheduling application that allows automatic building of slab schedules for mill processing lines based on various physical and logistic constraints. In 2001, AIS implemented the BetaPlanner hot charging scheduling solution at a major steel company in Central Europe. After a successful implementation of the SteelPlanner products, this company now wants to further improve the hot charge solution by closely synchronizing the level 3 and level 2 systems of the reheating furnaces. The steel plant has three furnaces of different type and capacity. The furnace optimizer has a full thermal model that is closely compatible with the level 2 furnace monitoring system. The optimizer takes into account the simulated temperature at charging time and ensures that mill or furnace bottlenecks are discovered and resolved. The implementation is planned for May 2007.

11:30 a.m.
Application of the Furnace Automation System
M. Ki, POSCO
POSCO has been applying a furnace automation system at its newly built continuous galvanizing line. The furnace automation system is a mathematical model that automatically controls strip temperature while considering line condition and coil information. Generally, strip temperature is controlled by operators. In this case, if the operators don’t have enough experience, strip temperature control would fail and cause a great deal of product loss. To provent these losses, this automatic system has been applied. As a result, product defects have fallen off and operator workloads have been reduced.

9:30 a.m. — Maintenance Processes — Equipment Reliability - back to top
Room 109
Session Chairs: Colleen Reeves, Dubric Industries Inc.; Jerry Oberlander, U. S. Steel Corp.

9:30 a.m.
160” Plate Mill – Descaling Pumps Worthington 6WC135 5 Stage Barrel Pumps Cost Reductions through Life Cycle Improvements
J. Steiger, HydroAire Inc.
Three Worthington 6WC-135 five-stage pumps have been in service since the 1970s to provide descaling water to the 160-inch plate mill at Burns Harbor, Ind. In the past, all the pumps have exhibited high noise levels along with abnormally high vibrations and well above normal maintenance problems. This paper discusses the improvements that have extended the run times of these pumps from approximately one year to five years and led to a decreased life cycle cost. The pumps now operate with a low-flow recirculation system and have been upgraded with five vane heavy shrouded CA-6NM impellers, “A” and “B” gaps recommended by Dr. Makay, 1W/N rotor balance, and Lomakin grooves on the 420F stationary wear rings and bushings.

10 a.m.
Online Fault Analysis of DC Motors
Author D.L. McKinnon, PdMA Corp.
For many years, technology forced the electrical testing of DC motors to be performed with a de-energized motor. However, recent advancements allow the testing of DC motors to be performed while the motor is still running, eliminating any interruption to operation. This paper includes the presentation of case studies of various DC motor anomalies, along with discussion of the application of this new approach to DC motor testing. This updated knowledge will allow maintenance staff to better prioritize the predictive and preventive maintenance work requests during short scheduled outages.

10:30 a.m.
Roll and Overlay Technologies to Improve Operational Performance
J. Brower, Siemens VAI Services LLC; D. Strathy, Siemens VAI Services LLC
Advancements within the metals industry have increased the focus on product operational efficiencies and quality while promoting a reduction of maintenance downtime and expense. Improving component reliability and properly maintaining the product net shape in benders, zones and segments is critical in each of these efforts. This paper will focus on modified roll designs and base material enhancements that combat the extreme operational environments within any caster. Additionally, roll life can be significantly increased through the use of engineered overlays. By targeting roll erosion, corrosion, wear and thermal fatigue, this session also details the variations of overlay materials, process controls and technologies developed for all types of continuous casting machines. Cost-effective roll maintenance solutions will be introduced with the support of benchmark data.

11 a.m.
Valve Stands — Paranoid to Perception
J. Bapat, Forbes Marshall

11:30 a.m.
Mathematical Model of the Failures Rate Parameter of a Machine as a System of Various Service Life Elements
V. Kravchenko, Priazov State Technical University
A mathematical model of the failures rate parameter of a machine as a system of various service life elements is developed. The method can be used to obtain the integrated parameter of the machine failure quantity and considers the variability of the restoration process. The failures rate parameter is the ratio of elements failure quantity in time unit to tested elements quantity, provided that all the failed elements are replaced with serviceable elements (new or repaired). For ordinary failure rates with limited consequences, the failures rate parameter is connected with failures frequency by means of Volter integrated equation of the second type.

9:30 a.m. — Environmental Technology — General Environmental Issues - back to top
Room 106
Session Chairs: P. Sheehan, Sponseller Group, Inc.; A. Hall, Wheatland Tube Co.

9:30 a.m.
The EPA’s Urban Air Toxics Strategy and Minimills
H. Alexander, Business Environment Inc.
The Clean Air Act as amended in 1990 included a list of 188 key air contaminants known as hazardous air pollutants, or HAPs. Different from the older, shorter list of so-called “criteria pollutants,” which included familiar contaminants like carbon monoxide and particulates, the list of HAPs focused on toxic air contaminants. Hence the alternative term, “air toxics.” The CAA required the Environmental Protection Agency (EPA) to examine the list of HAPs and to create a sublist inclusive of species it believed posed the greatest threat to urban areas. That sublist became known as the Urban HAPs. The resultant regulatory program became known as the Urban Air Toxics Strategy. This paper analyzes that strategy and its impacts on air permits of minimills in both urban and rural settings. Explanations of how the EPA plans to implement that strategy through MACT standards, GACT standards and the Flexible GACT Process are included.

10 a.m.
VOC Treatment Technology at BET
K.E. Jee, POSCO

10:30 a.m.
The Use of Steelmaking Slag for Mineralogical Sequestration of Carbon Dioxide
S. Lekakh, University of Missouri-Rolla; K. Peaslee, University of Missouri-Rolla; V. Richards, University of Missouri-Rolla; C. Rawlins, University of Missouri-Rolla
Steelmaking processes rely heavily on carbon-containing fuels, leading to substantial carbon dioxide emissions. In 2000, the U.S. steel industry produced approximately 1.75 tons CO2 for every ton of steel shipped. However, steelmaking processes also use calcium and magnesium oxide–containing minerals for slag generation, which have a high CO2 sequestration potential. This paper reviews an experimental study at UMR using steelmaking slag to sequestrate carbon dioxide while simultaneously accelerating the slag stabilization process. Thermogravimetric measurements and a two-stage slurry reactor are used to study reaction kinetics. The degree of slag carbonization is reported for slag component minerals and industrial slags under wet and dry conditions.

11 a.m.
Life Cycle Greenhouse Gas Emission Comparison of Steel Products With Other Materials
C. Buterbaugh, University of Missouri-Rolla; M. McGrath, University of Missouri-Rolla; K. Peaslee, University of Missouri-Rolla; Z. Voss, University of Missouri-Roll, J. Novotny, University of Missouri-Rolla, J. Brunner, University of Missouri-Rolla

Accurate life cycle studies, based on credible supporting data for the energy and environmental impacts of different materials used in construction and manufacturing, are important to both steel producers and users of steel products. With the advances in steelmaking technology, it important that life cycle inventories (LCI) and life cycle assessments (LCA) be based on current energy efficient and environmentally friendly technologies. This paper reports on a study done under a FeMet Design Grant by undergraduate students at the University of Missouri-Rolla to provide up-to-date and accurate LCI and LCA studies comparing steel products with other materials.

11:30 a.m.
Technology to Produce Low-activation Steel for the Reduction of Radioactive Waste
M. Kinnno, Fujita Corp.; Y. Matsushima, Nippon Steel Technoresearch Corp.; M. Sakakibara, Nippon Steel Technoresearch Corp.; A. Hasegawa, Tohoku University; S. Kitamura, Tohoku University
When a nuclear power plant is shut down, a large amount of steel scrap is generated. Since this scrap is radioactive waste with low energy levels, its disposal cost is very high. Such scrap can be recycled if its radioactive element content is reduced. By analyzing commercial steel bars in Japan, the harmful element was confirmed to be Co, and its content varies from 10 to 130 ppm. Mass balance calculations in steelmaking processes were carried out and measured the slag/metal partition ratio in order to develop a technology to produce low-activation steel.

Monday, May 7
Afternoon Sessions

2 p.m. — Coke Producing — Coal Technology - back to top
Room 101
Session Chairs: Hardarshan Valia, Coal Science Inc.; Frank Jere, DTE Energy Services Inc.; Mike Best, U. S. Steel Corp.

2 p.m.
Effect of Coal Pretreating Technology on Coke Strength
H. Uematsu, Nippon Steel Corp.; M. Naito, Nippon Steel Corp.; T. Arima, Nippon Steel Corp.; S. Nomura, Nippon Steel Corp.; K. Kato, Nippon Steel Corp.
In Japan, improvement of coke quality is strongly demanded. Improvement of coke quality generally leads to an increase in the blending ratio of noncaking or slightly-caking coal in a coal charge without deteriorating coke strength. Nippon Steel has developed dry coal charging processes such as CMC and DAPS (Dry-cleaned and Agglomerated Precompaction System) for cokemaking. A new cokemaking plant (SCOPE 21 type) is now under construction at Nippon Steel Oita works. This paper describes the R&D behind coal pretreating technologies for improving coke quality.

2:30 p.m.
Influence of Coal Blend and Charging on the Productivity of the Ruukki Coke Ovens
O. Kerkkonen, Rautaruukki Oyj
In this paper, the process factors affecting blend charge and coke output will be presented. The regional focus of Ruukki’s coal supply changed significantly, and this resulted in unforeseen blend size scatter and oven sticking. A blend bulk density rig was constructed, and production trials with oil and petroleum coke were run. Due to increased blend changes, it was difficult to achieve the targeted oven productivity. Maximized blend bulk density favored high coke output per oven, but at the same caused problems in blend charging.

3 p.m.
Use of Higher Levels of Canadian Coal in Blends With a High Percentage of Semi-soft Coals, Part 1: Lab and Pilot-scale Studies
Y. Suzuki, Nippon Steel Corp.; K. Kato, Nippon Steel Corp.; R. Leeder, Elk Valley Coal Corp.; C. Kolijn, Elk Valley Coal Corp.; A. Dobashi, Nippon Steel Chemical Co. Ltd.; T. Arima, Nippon Steel Corp.; K. Ikeda, Nippon Steel Corp.
Laboratory and pilot-scale coking work was carried out at both the NSC Research Centre in Tokyo and CANMET facilities in Ottawa to investigate the use of higher levels (e.g., up to 40 percent) of various Canadian coking coals in blends containing high levels of semisoft coal (e.g., 30 percent). The NSC work was conducted in a fixed-wall 100-kg-capacity pilot oven, and the CANMET work was conducted in a Carbolite 350-kg-capacity movable-wall pilot oven. Coking results from the two facilities were the same or showed similar trends. A number of Canadian coals of varying rank were investigated at different levels of substitution for Australian HCC coking coals. The lab and pilot results indicated that at least two of the Canadian coals could be used to produce coke of similar or better properties. Maintaining overall blend plastic properties was shown to be important for maintaining coke strength. Based on these results, one coal was selected for an industrial trial.

3:30 p.m.
Automatic Combustion Control of CST’s Coke Oven Batteries
L. Mello, CST Arcelor Brasil; N. Biccas, CST Arcelor Brasil; G. Goncalves, CSTArcelor Brasil; C. Dandrea, CST Arcelor Brasil; A. Torres, CST Arcelor Brasil
The objective of automatic combustion control is to guarantee the operational stability of coke batteries based on control of the coking time. This control is guided by a mathematical model in which the inputs are process variables and raw materials parameters; outputs are combustion parameters. Coking time out of specification can cause a lack of thermal input, or, on the other hand, extreme thermal input to the battery, with reduction of useful life of the ovens. This paper presents the evolution of the performance of the burning process, providing stability to the coking time.

4 p.m.
Web-based Data Gathering, Automatic Reporting and Schedule Generation for Coke Plant Automation
A. Barreiro,VAI Ingdesi; E. LaBruna, VAI Ingdesi; M. Gallo, VAI Ingdesi, J. Veiras, VAI Ingdesi
This Web-based application automatically collects all the relevant data from the field and automatically generates production, process, quality and EPA reports. The system includes wireless portable devices that allow environmental inspectors to collect data directly in the field. The Web-based eVision technology requires no additional licensing costs for increasing the number of users or adding variables to the system. This complete data acquisition system combined with local HMIs has given each operator access to an interactive, automatically generated schedule, and thus virtually eliminates erroneous data entry and wasteful storage of paper records.

2 p.m. — Iron Producing — Blast Furnace Campaign - back to top
Room 102
Session Chairs: Robert Bean, Danieli Corus; Robert Jason, Mittal Steel USA

2 p.m.
Investigation of Influential Parameters on BF Operations and Wear Conditions of No. 5 Blast Furnace After Its Inner Volume Enlargement
W. Hartig, AG der Dillinger Huttenwerke; R. Lin, AG der Dillinger Huttenwerke
ROGESA operates two blast furnaces for HM production and one blast furnace in standby at the Dillinger site. The No. 5 blast furnace was rebuilt in 1997 to increase its inner volume from 2,631 m³ to 3,067 m³. The hearth lining design and the cooling system had to be adapted. After about eight years of operation, serious wear was detected in the hearth lining and a part of the shaft cooling. Consequently, an interim repair was necessary and carried out during December 2005 and January 2006. This paper describes the operation performance and the wear conditions of No. 5 blast furnace after its enlargement, especially regarding the following aspects: the influence of coke quality on the BF operation and campaign life; hearth design, choice of refractory, and the cooling system in the hearth and at the shaft; and the measures taken against short-term temperature increase, especially the use of titanium-bearing materials.

2:30 p.m.
The 2006 Reline of the Corus IJmuiden No. 7 Blast Furnace
R. Molenaar, Corus Staal BV; L. Bol, Corus Staal BV; T. Bakker, Corus Staal BV
A major reline of IJmuiden’s No. 7 blast furnace was executed in the second half of 2006. The scope of the maintenance and project activities included the replacement of the hearth refractory, the replacement of the hot blast main and the bustle main, and the exchange of the charging system from a bell/movable armour to a bell-less PW system. This paper will describe the blowdown, soaking, excavation, repair, blow-in and first operational experiences.

3 p.m.
The No. 5 Blast Furnace Campaign Life Extension at JFE’s West Japan Works, Fukuyama Area
M. Sakurai, JFE Steel Corp.; T. Watanabe, JFE Steel Corp.; Y. Fukumoto, JFE Steel Corp.
The second campaign of Fukuyama blast furnace No. 5 was blown in on Feb. 19, 1986. with NKK movable armor, improved refractories and cooling system. Its hearth diameter was 14 m, and its working volume was 3,923 m3. The second campaign lasted nearly 19 years and produced 63 million metric tons of hot metal. Throughout the second campaign, bosh stave repair and replacement, installation of staves to plate-cooled shaft and taphole repair were performed. In this paper, the campaign history of BF No. 5 and those technologies implemented to extend furnace life will be introduced.

4 p.m.
The 2003 Reline and Upgrading of Rogesa Blast Furnace No. 4
F. Reufer, Paul Wurth Umwelttechnik GmbH; W. Hartig, AG der Dillinger Huttenwerke
In order to increase the production capacity of the Rogesa blast furnace No. 4 from 5,000 to 6,400 metric tons/day to meet the steelmaking requirements at Dillinger Hüttenwerke AG and Saarstahl AG, the furnace shell was replaced. This enlarged the working volume to 2,358 m3, and the hearth diameter was increased from 10.0 to 11.2 m. In addition to the enlargement of the furnace a significant portion of the total investment was committed to the introduction of equipment for improved environmental control. BF No. 4 was blown-in on Sept. 25, 2003, after a shutdown period of 89 days.

4:30 p.m.
The Concept of Permanent Lining for the Prolongation of Blast Furnace Campaign Life
S. Zhang, Wuhan Iron and Steel Corp.
Based on the experience of extending blast furnace campaign life at Wuhan Iron and Steel Corp., China, the author presents the concept of permanent lining for the prolongation of blast furnace campaign life. The permanent lining of a blast furnace is characterized as a lining that is kept stable throughout the entire campaign life of a blast furnace, even when the campaign life extends to 20 years or more, without any intermediate repair. This paper describes the principle for the buildup of a permanent lining for a blast furnace and the practice at Wuhan Iron and Steel Corp.

2 p.m. — Iron Producing — Pellets - back to top
Room 103
Session Chairs: Lee English, Cleveland-Cliffs Inc.; Barry Felton, Mittal Steel USA

2 p.m.
Pelletizing and Pellet Quality at Cleveland-Cliffs Operations
E. Schmutz, Cleveland-Cliffs Inc.; K. Oja, Cleveland-Cliffs Inc.
Pellet quality at Cleveland-Cliffs is reviewed with emphasis on sizing, compression and metallurgical properties. Efforts to continuously improve these properties will be discussed.

2:30 p.m.
QCM’s Direct Reduction Grade Pellet Quality Development
J. Poveromo, Quebec Cartier Mining Co.; S. Miller, Quebec Cartier Mining Co.; A. Audet, Quebec Cartier Mining Co.; S. Beaudin, Quebec Cartier Mining Co.
QCM’s pellet plant started up in 1977 with the specific objective to produce DR-grade pellets along with BF pellets. Shipments were made mainly in North America until the 1990s, when QCM accelerated efforts to produce a world-class DR-grade pellet. Successful initiatives in the areas of reduction in gangue content, elimination of clustering, and maximization of reducibility and metallization led QCM to be considered a reference pellet for DR quality by key Midrex plant operators early in this millennium. More recent accomplishments include increasing pellet size while maintaining superior physical properties. Research continues on silica reduction, optimal coating practices and increased reducibility.

3 p.m.
A Characterization Test for DR Pellets Reflecting the Higher Temperature Observed in Modern DR Furnace Operation
G. Paquet, Corem; A. Audet, Quebec Cartier Mining Co.; M. Garant, Corem; S. Morris, Iron Ore Co. of Canada
Over the last several years, the bustle gas temperature of the DR furnace was significantly increased as a result of DR pellet coating, which reduces clustering in the furnace. A new pyrometallurgical test was developed at COREM to better reproduce the actual operating conditions of the DR furnace. This test, called RC for Reducibility–Clustering, allows for the evaluation of both the reducibility index and the clustering properties in one single test. Results of development work show that the RC test reproduces well the texture and metallization of commercial DRI with good repeatability. The results of a study on the impact of temperature, coating material and procedure are also presented.

3:30 p.m.
Mechanical Strength of Reduced Iron Ore Pellets Sampled From the LKAB Experimental Blast Furnace
C. Stillberg; A. Dahlstedt, LKAB; A. Brannmark, LKAB; G. Hyllander, LKAB
Sufficient strength of iron burden materials throughout reduction is instrumental to efficient blast furnace operation. For almost a decade, LKAB has employed an experimental blast furnace. Pellet properties are manifested by the blast furnace operation and, although the burden has been regularly sampled and pellet strength analyzed, the test results have been treated with some skepticism, as they are found to vary and seem sensitive to process disturbances. In a recent campaign, an ambitious sampling program was undertaken to investigate how to more efficiently interpret the results and how process conditions influence pellet degradation. Results are compared to standard laboratory tests.

4 p.m.
Silica and Aluminum: A Method to Predict the Associated Costs When Organic Binders Are Substituted for Bentonite in DRI Pellets
J. Schmitt, Akzo Nobel
In pellet-making processes, organic binders have demonstrated the ability to produce pellets with lower gangue contents, though their usage is oftentimes limited because of high perceived costs at the pellet plant. Akzo Nobel has developed a model based on an integrated iron/steel plant which contradicts this perception and demonstrates savings totaling millions of dollars when the overall impact and effects of an organic binder are considered.

4:30 p.m.
SeqiOlivine Improves the Sintering and Pelletizing Performance of Iron Ore
A. Fredriksson, Minelco AB
SeqiOlivine is a brand-new product of olivine for metallurgical industry. To verify the applicability of SeqiOlivine as additives to iron ore sintering and pelletizing processes, comparative laboratory tests and industrial trials were carried out. The results indicted that, compared with the use of the reference olivine materials, the use of SeqiOlivine can increase the productivity in both iron ore sintering and pelletizing processes. The reducibility of final products can be improved too, to some extent. Furthermore, the energy consumption can be decreased in the pelletizing process due to a better grindability of SeqiOlivine than that of the reference one.

2 p.m. — Iron Producing/Environmental Technology — Blast Furnace Environmental Technology - back to top
Room 104
Session Chairs: Hugh Crosmun, Carmeuse Lime; Robert Albert, S/D Engineers Inc.

2 p.m.
Blast Furnace Dust Characterization from the Dust Catcher and Some Experiments for its Use
P. Assis, UFOP-Escola de Minas; H. Marques, UFOP-Escola de Minas; R. Azevedo, Gerdau Acominas; C. Assis, Redemat
This paper presents data from the powder generated as waste in a blast furnace cyclone. The sample was collected in a small blast furnace (120 m3) in a city near Ouro Preto. This came from the dried gas cleaning. The sample was processed in a physical laboratory, then was analyzed using a scanning electronic microscope, so that the grains and some chemical elements could be seen. A picnometer was utilized for determining its density. The data regarding the waste was used to choose the best way for its agglomeration, with the selected agglomeration medium. Some pellets were produced and characterized in order to determine their properties. After this initial research, it was proved that the powder can be agglomerated, and the mini blast furnaces (with a capacity less than 500 tons hot metal per day) in Brazil could solve the problem of disposing that waste.

2:30 p.m.
Sustainable Compliance and Clean Bulk Solids Handling
J. Fischer, Air Control Science Inc.
Controlling dust and particulates from the conveyance and storage of raw materials has plagued steelmakers since the Industrial Revolution. Today, with heightened concern for workers’ health, global competitive pressure to run more efficiently, and government regulations, the stakes are much too high to continue with the trial and error methods of dust and spillage control of the past. This paper will cover how to apply best available control technology (BACT) from around the world in a three-phase approach. The results create sustainable, clean, EPA-and OSHA-compliant bulk handling in BOF material handling, coal preparation, blast furnace stock houses, sinter plants, and pellet handling in the iron ore and steel industries.

3 p.m.
Fine Charcoal Agglomeration and Its Feasibility for Blast Furnace Usage and for Energy Generation
C. Okuhara, Gerdau Acominas; T. Falco, Gerdau Acominas; P. Assis, Universidade Federal de Ouro Preto; D. Avelar Lucena, UFOP
This paper analyzes the charcoal pellets produced from charcoal wastes and verifies the influence of certain variables on reduction and oxidation. For this evaluation, a combustion index was defined based on combustion time, temperature and mass of material. In an effort to characterize the pellets, the moisture, volatile materials, ash and fixed carbon were determined so that calorific power, density, porosity and compression strength could also be found. Finally, the pellets produced from the waste were analyzed for their energy equivalence and the possibility of using the material for charging into the blast furnace throat. In this way, a new use for this waste has been proposed with a certain degree of success, not only as a substitute fuel in a vapor generator, but also as part of the blast furnace charge along with lump iron ore.

3:30 p.m.
Gas Cleaning Systems in Ironmaking Blast Furnaces
G. Streit, ATSI Inc.
Ironmaking blast furnaces produce iron, slag and blast furnace gas. The gas has a fuel value, but it must be conditioned and cleaned before it is useful. Traditionally, the gas passes through a gravity settling chamber, a wet scrubber with a variable throat venturi, and finally a mist eliminator or gas cooler. Blast furnaces experience an increase in production and efficiency at higher top pressures. Because of this increase in production and efficiency, over the years blast furnace operations have increased the top pressures at which they operate. Top pressures in the range of 15–30 psi are becoming more common. With this increase in pressure, alternate technologies should be investigated when designing the blast furnace gas conditioning systems.

4:00 p.m.
Global Warming and the Steel Industry
E. Anderson, E.A. Anderson Engineering, Inc.

2 p.m. — Electric Steelmaking/Computer Applications — EAF Process Control - back to top
Room 111
Session Chairs: Jack Murray, Emerson Process Management; Ray Figas, SGL Carbon LLC

2 p.m.
EAF Energy and Material Balance Modeling
S. Chen, IPSCO Inc.; S. Abraham, IPSCO Inc.
The EAF steelmaking process is increasingly becoming the dominant route of steelmaking. In the drive to save cost and conserve energy without compromising productivity, steelmakers are searching for the optimum way of melting scrap in the EAF. While the fundamentals of scrap melting and refining processes in the EAF are well studied and understood, these processes are difficult to optimize due to the heterogeneity of the EAF steelmaking environment and the complexity of interaction between different phases. As a result, the control of input materials and energy consumption are based on the judgment of the EAF operators. This paper outlines the study performed at IPSCO to develop an energy efficiency model for the EAF scrap melting and refining processes. The model comprises two parts; one part deals with optimizing the consumption of carbon at a given oxygen level for maximum energy output in the EAF; the second part deals with supplying as much chemical fuels (natural gas, oxygen and carbon) as possible to reduce electrical consumption and melting time. This modeling work has demonstrated the potential for significant cost savings in the EAF steelmaking. The understanding of the energy and material interaction in the EAF has enabled the authors to develop an on-line model for the control of key steps in the EAF melting and refining processes.

2:20 p.m.
Application of CFD Modeling to the Design of Fume Control Systems in the Steel Industry
T. Plikas, Hatch Ltd.; J. woloshyn, Hatch Ltd.; D. Johnson, Hatch Ltd.

3 p.m.
Integrated Process Director: A Real-time Integration Between EAF Fumes and Injection
S. Miani, Concast Technologies; R. Gottardi, Concast AG; M. Volpe, Concast Technologies
In an EAF’s energy balance, the heat losses attributable to the fumes are always indicated with a question mark, due to a lack in estimating the temperature, the chemical composition and the real flow-rate, especially in real time. Reliable tracking of the EAF energy balance is now possible, allowing real-time feedback on the input vectors (injectors). Particularly, the real-time analysis of the fumes, based on laser technology, allows mutual feedback with CO, O2, H2O, temperature and the injectors using a fuzzy engine software. The behavior of a medium-size EAF is analyzed in depth.

3:30 p.m.
The VM2 EAF Remote Scoreboard: Four Years of Experience
F. Martinez, AMI GE; E. Garza, AMI GE
This paper presents and describes the new Web-based technology Scoreboard for remote EAF process monitoring. Users can access key and detailed EAF operating data as it is being generated from any location through a secure Internet connection. The system has been evolving during the last four years and is being used in furnaces all over the world. Results and experiences are presented.

4 p.m.
Charge Optimization in EAF Steelmaking: Recent Developments
S. Olund, Danieli Automation; L. Morsut, Danieli Automation; R. Coughlan, Danieli Automation
The cost of raw materials is a considerable part of the total production cost in steelmaking. This is especially true for stainless steelmaking. However, for carbon steels, considerable savings can be generated via the optimization of the EAF charge. In some recent projects, new, innovative charge calculation models have been developed. The least-cost charge calculator (LCC) optimizes the total set of charge recipes for multiple heats as well for single heats, based on the heat lineup. A highly interactive user interface allows the user to check and modify the calculation results. Real-time or actual material inventories are considered in the calculations. When the buckets are filled, the data can be used to decide the amount of scrap materials that will need to be purchased in order to maintain sufficient inventories. Once the total charge is decided, an additional bucket filling calculation can be used to distribute the materials to be charged across the buckets remaining to be filled.

2 p.m. — Electric Steelmaking — EAF Meltshop Operations - back to top
Room 117
Session Chairs: Scott Ertl, Charter Steel; Jeremy Jones, Nupro Corp.

2 p.m.
Siemens VAI Ultimate EAF: Various Operational Results
M. Abel, Siemens VAI Metal Technologies GmbH; M. Hein, Siemens VAI Metals Technologies GmbH, Siemens VAI Metal Technologies GmbH
Following the introduction of Ultimate technology — the new generation of electric arc furnaces from VAI Fuchs — in 2005, the first operational results of this technology are presented through a review of the performances of several installations worldwide. The first example is the 120-ton EAF supplied to NSMMZ in Revda, Russia, a steel plant of the MAXI Group. Due to various restrictions inside the plant, the EAF operated according to the Ultimate philosophy with a reduced tap weight of 90 tons for the first six months after start-up. The second example is the first of two 180-ton EAFs supplied to the steel plant MMK in Magnitogorsk, Russia, designed to produce 4 millions tons of steel per year. This EAF is using up to 35 percent hot metal. The third and last example is the 250-ton EAF supplied to the steel plant Colakoglu in Gebze, Turkey, which uses the world’s largest transformer for an AC EAF application, with a rated power of 240 MVA. Finally, new Ultimate EAF installations, to be started within the next year, are revealed.

2:30 p.m.
Maintenance at Minimills — Effective and Efficient
M. Hamy, Badische Stahlwerke GmbH, R. Ridder, Badische Stahlwerke GmbH, J. Greinacher, Badische Stahl-Engineering GmbH, M. Fleischer, Badische Stahl-Engineering GmbH
This paper presents the key results of the Maintenance Cost Management (MCM) project carried out by Badische Stahl-Engineering (BSE), which shows that maintenance can be improved without losing efficiency or falling into a productivity trap. Answers will be provided to questions that typically arise in the implementation of such a cultural change: How should efficiency in maintenance be measured? How should the maintenance be organized — centralized or decentralized? How many people are needed on a shift? Which procedures and methods are applicable in maintenance?

3 p.m.
New Developments in Scrap Handlers
C. Lannes, Sennebogen LLC
This presentation will cover the development of new material handlers for scrap and other bulk materials within a steel mill. These material handlers, generally rubber-tired, can be diesel or electric driven. The latest ones will reduce operating costs by up to 70 percent when compared to diesel-driven units. These results were obtained by studying more than 1,000 units in operation. By using such technology as well as improving the layout of the scrap yard, further cost savings can be expected.

3:30 p.m.
A Revolutionary Approach to Consistently Obtain the Cleanest and Most Representative Steel Samples From Molten Metal
T. Junker, Minco - Midwest Instrument Co.; A. Reilly, Minco - Midwest Instrument Co.
Sampling probe designs have continuously improved over the past several years, but now there is a revolutionary new system to further enhance the quality of analysis on all steel samples sent to the chemical lab. Minco’s ProAS (Professional Argon Sampling) system purges argon into the sampling chamber prior to immersion, and then, once immersed and the capping system melts off, the argon purge continues to eliminate all foreign contamination before a clean representative sample is extracted under vacuum from the molten metal bath. The benefits of Minco’s ProAS system include, but are not limited to, improved chemical analysis on all critical grades (especially stainless steel and ultralow-carbon grades), lower operating costs through savings on alloy additions, reduced oxidation of the sample, reduced sample preparation time, and reduced testing by providing a solid, clean representative sample with every immersion.

4 p.m.
Novel Industrial Trials Demonstrating the Use of Plastics for EAF Slag Foaming
M. Rahman, University of New South Wales; J. Dicker, University of New South Wales; R. Khanna, University of New South Wales; V. Sahajwalla, University of New South Wales
A series of successful trials, in which a plastic and coke mix was used to generate foaming slag in an industrial EAF, is detailed in this paper. Due to the high impurity content of coke, other forms of carbon have been considered as injectants; graphite is relatively expensive, so attention has now turned to plastics (hydrocarbon polymers). A previous paper proved the ability of plastic/coke mixes to foam slag in a laboratory furnace. Data from these industrial trials shows decreases in electrical energy consumption and power-on times, implying that furnace efficiency has improved with the use of plastics.

4:30 p.m.
Siemens VAI Minimill Technology — Next-generation Long Products Plant
R. Perez, Fuchs De Mexico SA de CV; T. Narholz, VAI Fuchs Germany
VAI Fuchs and VAI Pomini developed a new concept for meltshops based on the ULTIMATE electric arc furnace. The performance of this next-generation melting tool has an impact on plant layout, plant logistics, electrics and automation, and all other process steps as well as the balance of plant. The ultrahigh power input requires electric competence, which can be handled by SIEMENS Metals. Through Siemens VAI minimill technologies, investors can now rely on a single source for electric steelmaking, billet casting, rolling mill and electric power distribution, leaving no open questions throughout the complete lifecycle of the plant. This paper deals with these topics and provides an overview of the latest plant reference, including some operational results that confirm the concept that will lead steelmakers to new levels of performance.

2 p.m. — Oxygen Steelmaking — Blowing, Stirring and Slag Formation - back to top
Room 105

2 p.m.
Stirring Strategies to Meet the Highest Metallurgical Requirements in the BOF Process
H. Lachmund, AG der Dillinger Huttenwerke; R. Bruckhaus, AG der Dillinger Huttenwerke
The influence of the arrangement of bottom stirring nozzles on flow conditions was investigated, taking into account both the flow conditions and the interactions between the oxygen jet and the heterogenous plume. Variatons in the geometry of the oxygen lance tips improved metallurgical results in combination with the lime addition model. The degree of dephosphorization was improved by variation of stirring conditions during and after the blow with a properly adjusted slag composition, particularly with regard to MgO content. In addition, the poststirring treatment led to a decrease in dissolved oxygen content, thereby lowering the amount of aluminium for deoxidation and increasing the oxide cleanliness. For steel grades with a controlled nitrogen content, the influence of blowing oxygen purity as well as bottom stirring strategy was analyzed.

2:30 p.m.
Kinetics of Iron Oxide Formation Under the Condition of Oxygen Top Blowing for Dephosphorization of Hot Metal in the Basic Oxygen Furnace
S. Nabeshima, JFE Steel Corp.; H. Matsuno, JFE Steel Corp.; A. Matsui, JFE Steel Corp.; Y. Kishimoto, JFE Steel Corp.
At JFE Steel’s West Japan Works (Fukuyama District), hot metal is dephosphorized in the basic oxygen furnace (BOF). In order to improve dephosphorization efficiency, it is important to increase the activity of oxygen at the slag-metal interface. As both oxygen blowing and reduction by the carbon in the metal affect the activity of oxygen at the slag-metal interface, the effect of oxygen blowing conditions on iron oxide formation was investigated in laboratory-scale experiments. Based on the experimental results, a kinetic model that enables prediction of iron oxide behavior in the BOF was developed. Top blowing conditions for dephosphorization were optimized using this model.

3 p.m.
Strategies to Achieve Low Phosphorus Content for Customer Applications
G. Kleinschmidt, SMS Demag Inc.; J. Schlueter, SMS Demag Inc.; U. Falkenreck, SMS Demag Inc.; J. Kempken, SMS Demag Inc.
Increasing phosphorus charge, by either reuse of BOF slag in the blast furnace or iron ore supply from Asian or Australian origin, may result in P content in hot metal between 0.100 and 0.300 percent. Counter to this are the requests for reduced final phophorous content in steel, especially for structural grades serving line pipe and offshore applications, down to 0.006 percent. In this paper, some aspects regarding the mechanism of dephosphorization strategies for different types of converter vessels will be discussed. The question of bottom purging will be highlighted. Technical and commercial limits for the slag chemistry, as well as the slag amount, will be investigated. The strategy for dephosphorization has to be answered downstream, at the application of the final product. From this point of view, the drawbacks on the conversion costs need clarification for each region and for each steel mill.

3:30 p.m.
Theoretical and Practical Aspects of Lance Skulling and Slag Formation in BOF Vessels
N. Prasad, IIT Kanpur; K. Shukla, IIT Kanpur; B. Deo, IIT Kanpur; M. Malathi, IIT Kanpur; R. Boom, IIT Kanpur
The phenomenon of lance skulling is investigated by morphological studies done on samples collected from several plants. A heat transfer model, incorporating the effect of hot spots, correlates the changes in lance cooling water temperature with lance height and the thickness of the lance skull. The mechanism of slag foaming is also investigated, and the height of foam is calculated using new models for droplet velocity and bubble velocity calculation. Both lance skulling and slag foaming are intimately connected with the kinetics of lime dissolution and iron oxide reduction. A kinetic model is developed for iron oxide reduction. Lance skulling and slag foaming can be predicted.

4 p.m.
Behavior of Spitting During Blowing of a BOF
T. Inaba, Kobe Steel Ltd.; Y. Kanzaki, Kobe Steel Ltd.; K. Semura, Kobe Steel Ltd.; M. Nakamura, Kobe Steel Ltd.
One of the most serious problems is the skull adhering to the lance and the buildup of metal in the BOF mouth caused by spitting during blowing. To make the behavior of spitting clear, the authors researched the relationship between the attained height of particles from the bath surface and the particle size of metal. The particle size of metal observed at various sites of the BOF can be explained by the balance of power to act on particles in the exhaust gas.

2 p.m. — Ladle and Secondary Refining/Process Technology — Vacuum Degassing - back to top
Room 106
Session Chairs: Leslie Niemi, Affival Inc.; Bruce Barker, National Recovery Systems; Les Niemi, Affival, Inc.

2 p.m.
Steel Degassing Vacuum Systems — Operation, Design and Maintenance Considerations
J. Cotchen, SMS Demag Inc.; C. Braum, Universal Service Technologies Inc.
Vacuum systems for liquid steel degassing need to operate reliably even though they are subject to adverse and sometimes severe conditions. Even under normal circumstances, large amounts of dust are created, which can quickly foul the vacuum pump, no matter the type. For this reason, steelmakers need to be aware of how design, operation and maintenance must all be considered so that these systems will perform as required in the intervals between maintenance. Based on the authors’ experience, this paper discusses those factors that influence a vacuum system’s operation. Common problems, techniques and solutions are discussed to provide a holistic approach to assure the reliability of steam ejector, mechanical and hybrid vacuum systems.

2:30 p.m.
Effect of Different Configurations of Gas Injection Systems in an RH Degasser on Melt Circulation and Decarburization Kinetics
H. Pujatti, UFMG; A. Nascimento, UFMG; R. Tavares, Federal University of Minas Gerais; L. Neves, UFMG; T. Almeida, UFMG
In the present work, a physical model of an RH degasser was used to study the effects of different configurations of gas injection systems on melt circulation and decarburization kinetics. A new technique, based on image analysis, was proposed to estimate the melt circulation rate. Different regions for gas injection were tested. The decarburization reaction of liquid steel was simulated by a reaction involving CO2 and caustic solutions.

3 p.m.
Applications and Advancements for Vacuum Degassing
R. Kane, Core Furnace Systems Corp.; J. Simmons, Core Furnace Systems Corp.; K. Shoop, Core Furnace Systems Corp.
A vacuum degassing system provides an added value to the steelmaking process. A reliable vacuum degassing system is very important for the production of higher-quality grades of steel that end-user industries require. This paper will describe recent vacuum degasser technological advancements, and will discuss recent installations and operation results of several applications.

3:30 p.m.
A Gap Analysis of Decarburization Models for RH Degassers
S. Street, Severstal North America Inc.; A. Roelant, Severstal North America Inc.; E. Worral, Severstal North America Inc.
Ultralow-carbon (ULC) steels are used extensively in the automotive industry due to their combination of strength and formability. At Severstal NA, ultralow-carbon levels are achieved through the use of a Ruhrstahl-Heraeus (R-H) degasser unit. An opportunity for process improvement in producing ULC steels resides with accurate real-time prediction of carbon content during RH decarburization. Improved process capability through tighter carbon ranges and reduced processing time is offered via a robust process model. Severstal NA has undertaken efforts to improve the accuracy of its decarburization model. Upon implementation, a disparity was observed between the model and plant data when under abnormal vessel conditions. Limited information exists in the public domain discussing these issues. A gap analysis of existing published decarburization models and actual plant processing is discussed.

4 p.m.
Optimization of Multifunctional Lance Technique in an RH Degasser
J. Tandon, Essar Steel Ltd.; R. Robey, SMS Mevac; A. Kumar, Essar Steel Ltd.; D. Majumdar, Essar Steel Ltd.
RH vacuum degassing equipment with a capacity of 1.2 million tons/year was commissioned at Essar Steel in June 2006. This unit allows decarburizing the liquid steel to a level of 20–30 ppm C and deoxidizing to an oxygen level of 25 ppm for the production of ULC grades with short treatment time. To facilitate higher decarburization rates, temperature control in processed steel and less turnaround time, the RH degasser provisions include a top oxygen lance, Al heating facility and on-line RH vessel heating capability. Interstitial-free steel, extra-deep-drawing and other grades having very low C, H2 and N2 are produced while maintaining high productivity rates.

4:30 p.m.
Gas-stirred Ladle: Multi-phase-species Mathematical Model
M. Al-Harbi, University of Leicester; S. Gao, University of Leicester; H. Atkinson, University of Leicester
A multi-phase-species (steel/gas/slag and dissolved elements like Al, O and S) mathematical model based on fundamental transport equations has been developed. This model was used to study the steelmaking refining process. In this approach, a computational fluid dynamics (CFD) analysis was used to predict the flow pattern of the gas-stirred ladle system, and the mass mixture fractions at the steel/slag interface. A thermodynamic analysis package, MTDATA, from the National Physical Laboratory, was linked to the model to predict the mass transaction at the steel/slag interface due to the refining process. The model’s predicted results of the desulfurization rate during the vacuum degassing process were compared to data from the literature, and a good agreement was found. Real plant data will be used to validate this simulation model.

2 p.m. — Continuous Casting — Caster Configurations and Practices I - back to top
Room 116
Session Chairs: George Moulden, Mittal Steel USA; Jack Bean, J.B. Martin Co.; Tony Rumler, Siemens VAI

2 p.m.
Medium-thick-slab Casting Technology — Bridging the Gap Between Conventional and Thin-slab Casting
A. Wagner, Siemens VAI; J. Watzinger, Siemens VAI; K. Moerwald, Siemens VAI
Medium-thick-slab casting technology is presented for the production of slabs with thicknesses rangi