| MONDAY | TUESDAY |

Wednesday, May 9
Morning Sessions

10 a.m. — Coke Producing — Coal Supply Issues - back to top
Room 101
Session Chairs: David Knapp, Glidewell Specialties Foundry; Thomas Berg, Sun Coke Co.

10 a.m.
Meeting Coal Quality Challenges for Global Coke Demand: A Supplier’s Perspective
D. Osborne, Anglo Coal, S. Gupta, The University of New South Wales, V. Sahajwalla, The University of New South Wales
Coal suppliers are under increasing pressure to meet global coking coal demand, as conventional high-quality coking coal reserves are declining and/or becoming increasingly difficult to mine. This study illustrates a coal supplier’s perspective on the potential of more recent coke blends, such as the Rangal coal measures in Queensland. There is a clear need to improve understanding of the implications of using new combinations of raw materials. This paper highlights the importance of global cooperation between the scientific community and other stakeholders, including coal suppliers, coke makers and iron makers.

10:30 a.m.
Train Transportation Coal Losses — A Wind Tunnel Study
J. Price, NRCAN; R. Leeder, Elk Valley Coal Corp; W. Hutny, NRCAN
Western Canadian coals are mined in the Rocky Mountains and transported by rail over long distances (>1,000 km) to ports and customers. The surface of the coal in the rail cars is treated with a dust suppressant; however, coal dust can still be lost during railing. CANMET Energy Technology Centre – Ottawa (CETC-O) and the Canadian Carbonization Research Association (CCRA) investigated factors affecting coal dust losses using a scaled model railcar in a wind tunnel. Several variables were evaluated at wind velocities up to 80 km/hour. As expected, increased apparent wind velocity (real wind plus train velocities) and smaller particle sizes increased coal dust losses. A study with a number of dust suppressants showed that latex and anionic polymer suppressants had better performance than oil and/or water, and commercial dust suppressants had varying performances. Reapplication of suppressant significantly reduced losses. The tests also showed that coal profiles with “slopes” in the front and rear of a railcar generated more coal losses than a flat coal surface, and the dimensions of the rear slope is important. Recommendations to reduce dust losses were made based on the results of the work.

10 a.m.— Iron Producing — Blast Furnace Hearth - back to top
Room 102
Session Chairs: Donald Krtanjek, Mittal Steel USA; Glenn Biever, Vesuvius USA

10 a.m.
The Theory and Practice of Blast Furnace Hearth Management at Corus Scunthorpe
R. Hood, Corus C&I
This presentation will discuss the ongoing management of the blast furnace hearths at Corus Scunthorpe, focusing on the core philosophies involved, the problems that arise, the monitoring systems used to identify problems, and the actions that may be taken to address those problems. Theoretical hearth behavior and conditions as interpreted through the monitoring systems are discussed, and they are compared with the physical evidence discovered during recent furnace relines.

10:30 a.m.
Simulation of the Hearth Draining Process and Thermal Stress of a Blast Furnace Hearth
Y. Zhang, Purdue University Calumet; C. Zhou, Purdue University Calumet; F. Huang, Mittal Steel USA; R. Deshpande, Purdue University Calumet; P. Chaubal, Mittal Steel USA
Detailed flows of hot metal and molten slag in the hearth during hearth draining are important for hot metal level control and hearth maintenance. In this paper, a transient, three-dimensional, multiphase computational fluid dynamics model is developed to simulate the hearth drainage of a blast furnace with multiple tapholes. This model can be used to analyze the liquid flow patterns inside a hearth, along with the liquid top profile at the end of a casting with different hearth drainage operation. The detailed liquid flow pattern, the detailed velocity distributions, and the temperature filed along with the thermal stress analysis will be very helpful to understanding the mechanism of hearth erosion.

11 a.m.
New Blast Furnace Hearth Erosion Computer Model Development and Application at U. S. Steel
K. Liu, U. S. Steel Corp.
A new blast furnace hearth erosion computer model has been developed and has been used for years at U. S. Steel blast furnaces. This paper describes a one-dimensional model that is frequently used at U. S. Steel blast furnaces to calculate the local erosion of the furnace hearth, and a two dimensional model that is used to evaluate the hearth erosion of an entire vertical cross-section of the furnace when a more detailed erosion profile is required. These models have been verified by core-drilling results, and proved to be a very effective tool in hearth erosion evaluation. The models used thermocouples inserted into the blast furnace from the cold face; based on the temperature history of these thermocouples, a heat conduction differential equation is solved to locate the 2,100°F isothermal. The numerical method that is used to solve the differential equation is a finite volume method. This paper presents a new way of solving an ill-posed conduction equation, which can overcome the inaccuracy and nonconvergence problems that some existing models face today.

11:30 a.m.
Blast Furnace Bottom and Hearth — Thermo-Mechanical Considerations
R. Van Laar, Danieli Corus BV, R. Van Oudenallen, Danieli Corus BV, V. Van Straaten, Danieli Corus BV
The blast furnace bottom and hearth are critical in determining campaign life. Various designs exist: under-hearth air-, water- or oil-cooling, under-hearth carbonaceous and ceramics courses, and hearth sidewall carbonaceous refractory materials. The refractory materials will be exposed to higher temperatures, and this will result in expansion and stresses. Various phenomena are described, and expansion considerations are qualified and quantified by finite element method calculations and refractory materials research.

10 a.m. — Iron Producing/Process Technology — Alternative Ironmaking I - back to top
Room 103
Session Chairs: James Simmons, Core Furnace Systems Corp.; Sara Hornby, Linde Gas LLC; Jack Oakey, Praxair

10:00 a.m.
Pig Iron Nuggets: How Good Are They?
S.K.Kawatra, Michigan Technological University
There is a great deal of interest in developing technologies that can replace the blast furnace for ironmaking.  One of the technologies is the iron nugget process (ITmk3), which is a single-step process for converting iron oxide pellets into metallic iron.  It has been believed that the iron nuggets were produced in single step; that is, under appropriate thermodynamic conditions, iron oxide pellets were converted into metallic iron. However, research work at Michigan Tech has shown that this is not correct. In reality, iron oxide pellets were first reduced to direct reduced iron (DRI), which were converted to transition direct reduced iron (TDRI), and finally transformed to pig iron nuggets. Hence, the final product from the iron nugget process contained some nuggets in the form of pig iron, but also included DRI with slag inclusions, and TDRI. This hypothesis was verified by laboratory experiments, and by examination of iron nuggets produced in a large-scale plant.

10:30 a.m.
Hi-QIP, a New Ironmaking Process
N. Ishiwata, JFE Steel Corp.; T. Matsui, JFE Steel Corp.; T. Higuchi, JFE Steel Corp.; H. Hiroha, JFE Steel Corp.; Y. Sawa, JFE Steel Corp.; K. Takeda, JFE Steel Corp.; A. Murao, JFE Steel Corp.
Hi-QIP (high-quality iron pebble) is a new coal-based process to produce high-quality iron. The iron pebbles, free from minerals, are made in a rotary hearth furnace directly from fine iron ore and coal. A feature of this process worthy of special mention is using a fine carbonaceous material layer on the rotary hearth as refractory, casting mold for melting iron and auxiliary reducing agents. The feature enables the melting of reduced iron in the rotary hearth furnace without any trouble, and permits fluctuation of mixing of raw material. Pilot plant tests were carried out. The operation lasted six days without any malfunction. The maximum productivity was 1.23 tons of metal/m2/day.

11 a.m.
Economic and Operating Benefits of the Hatch CRISP Process — A Logical Innovation in Electric Steelmaking
G. Traquair, Hatch; I. Gordon, Hatch; F. Wheeler, Hatch
The Hatch Continuous Reduced-Iron Steelmaking Process (CRISP) is an attractive investment for greenfield or incremental steelmaking capacity. Continuous steelmaking is the next logical innovation in electric steelmaking and builds on advancements made through continuous DRI and scrap charging, the continuous strip production (CSP) process and other lean manufacturing concepts. The project IRR for the CRISP concept in a “DR-friendly” location is estimated at greater than 40 percent, compared with an estimated 32 percent for a traditional hot-charged DRI-based electric furnace operation. The estimated benefits are low risk, and all the project components are of standard technologies and capabilities. The continuous electric furnace technology, a key element of the concept, has been proven in other metals applications.

11:30 a.m.
Sponge Iron Utilizations of High-ash Coal and Poor-quality Iron Ore for Making Quality Sponge Iron
P. Rana, Jindal Steel & Power Ltd.; V. Agrawal, Jindal Steel & Power Ltd.; V. Gujaral, Jindal Steel & Power Ltd.
Direct reduction through coal routes has been stabilized. The focus is now on optimizing the operation and production of quality sponge iron by using high-ash coal and poor-quality iron ore that are available in plenty. In the rotary kiln process, the quality of raw material plays a vital role in producing sponge iron of consistent quality. The challenge is to produce sponge iron at minimum cost without affecting quality. Jindal Steel & Power Ltd., India, used high-ash coal and poor-quality iron ore to make sponge iron of prime quality by modifying operating parameters, and making some changes in the facility and design of the system. This attempt met with considerable success and has led to the production of quality sponge iron at a low C/Fe ratio and low net specific energy consumption. This paper highlights the secrets of success behind the achievements and the initiatives taken to modify operations to get more than 99 percent kiln availability, 97 percent quality product and net specific energy consumption as low as 4.3 gcal/metric ton of DRI.

10 a.m. — Electric Steelmaking/Electrical Engineering — Electrical Control Systems for EAFs - back to top
Room 117
Session Chair: Tom Slovik, ABB Industrial Transformer; E. Shaw, Dofasco Inc.

10 a.m.
Experiences Implementing the Smart Furnace Control System
Ternium Hylsa Apodaca; G. Fernandez, AMI GE
This paper describes a new control application for full integration of the different EAF subsystems. It controls the electrical power input, burner system, oxygen lance, carbon injection system with slag condition feedback, exhaust gas control and offgas compensations for the burners and oxygen lance systems.

10:30 a.m.
Innovative Solutions for Differential Protection of Electric Arc Furnace Transformers
M. Bishop, Cooper Power Systems; D. Sharma, Nucor-Yamato Steel Co.; L. Kojovic, Cooper Power Systems
Current transformer (CT) saturation has been a recognized industry problem for reliable protective relay operation. If the CT characteristics are not properly selected for fault conditions, saturation will occur, and relays can fail to operate correctly. Differential protection systems for EAF transformers have not been applied in the past due to the lack of commercially available CTs for the secondary bus tubes and CT saturation problems due to the high current magnitudes, which often approach 100 kARMS. A novel differential protection system has been developed and deployed on two scrap metal electric arc furnaces (EAFs) at the Nucor-Yamato Steel facility in Blytheville, Ark., and have been in operation for more than a year. Two additional systems were recently installed at the Nucor Steel–Indiana plant. For each 90 MVA arc furnace transformer, the protection system consists of six RC current sensors and a muiltifunction relay that accepts the signals from the RC sensors. This paper presents an overview of each installation and reviews the performance of these systems, the first differential protection scheme for EAF transformers implemented in the United States.

11 a.m.
Continuous Success of DC EAF Power Supplies
R. Pai, ABB Switzerland; R. Stadler, ABB Switzerland; S. Tambe, ABB Switzerland; D. Sager, ABB Switzerland
DC power supplies are widely used in the steel and nonferrous industries. ABB continues to focus on DC technology while improving safety, reliability, efficiency, maintainability and performance. With increasing pressure from utilities for clean power consumers (low flicker, tighter power factor requirements, and minimum voltage imbalance), DC EAF technology continues to demonstrate advantages over AC EAFs. ABB’s new AC 800PEC controller provides optimized current regulation, and features an enhanced electrode regulation (ELREG) capability and a fast direct link to the SVC control (ArcComp) in order to achieve shorter power-on time and higher average power input, resulting in increased mill production.

11:30 a.m.
Preventing EAF Transformer Failures
A. Mariscal, AMI GE
This paper presents the methodology developed by AMI GE over 20 years to identify potential failure conditions in EAF transformers, and recommended practices on how to prevent them. This methodology has been applied in more than 20 high-power EAFs. Practical cases and results are discussed.

10 a.m. — Oxygen Steelmaking — BOF Environmental - back to top
Room 105
Session Chairs: Richard Browning, Praxair Inc.; Barry Schrader, Zaptech Corp.

10 a.m.
Solutions for Dusts and Sludges From the BOF Process
K. Sassen, DK Recycling und Roheisen GmbH; C. Moore, DK Recycling und Roheisen GmbH; C. Hillman, DK Recycling und Roheisen GmbH
During the production of 130 million tons of crude steel (EU 25) by the BOF process, approximately 1.7 million tons of BOF dust and 1.3 million tons of BOF sludge are generated. Although these residues contain notable amounts of iron, their use in integrated steel works is often limited due to environmental problems, negative impacts on productivity and problems during handling. The DK process has shown for more than 20 years that there is a sustainable solution for treating these residues on an industrial scale. This paper describes the processing of the residues via a sinter strand and a blast furnace, as well as production figures, improvements and an outlook for future projects.

10:30 a.m.
Turnkey Revamp of the LD (BOF) Steelmaking Plant at U. S. Steel Košice, Slovakia
W. Fingerhut, Siemens VAI
Modernization projects to increase production capacity often go hand in hand with significant improvements in the environmental situation — especially the air quality — at the plant. This was the objective when the liquid steel production of the No. 1 LD (BOF) shop at U. S. Steel Košice, Slovakia, was subjected to a major modernization overhaul. In January 2004, Siemens VAI was awarded the contract to implement the modernization project on a turnkey basis, which involved the installation of two new larger LD/BOF converters with Siemens VAI maintenance-free VAI-Con Link suspension system, two new energy- and maintenance-efficient LD/BOF converter primary offgas cooling systems with suppressed combustion, two new dry dedusting systems for LD (BOF) primary offgas cleaning, one common secondary dedusting system with two sets of converter doghouses, as well as the related electrical equipment, basic and process automation level 1 and level 2. The project was successfully completed in December 2005. This paper will give an overview of the project, in particular the installation of the LD/BOF converter primary offgas cooling and cleaning system, as well as the technological and operational highlights and results.

11 a.m.
Secondary Dedusting Systems With High-performance Gas Cooling and Explosion-proof Design
A. Hampel, Siemens VAI Metals Technologies GmbH & Co.
The scrap used for charging converters carries combustibles, and the amount of combustible content has continuously increased over the last several years. When hot metal is poured onto scrap, the thermal power emissions by the converter are exorbitant, with standard thermal power emissions now about 2 MW or more per ton of scrap. This leads to filter inlet temperatures that are too high, or to insufficient evacuation at the charging hood even when using emergency cooling air. Major secondary fugitive emissions at the charging hood and explosion in the offgas systems are the results. SIEMENS VAI has developed a system with offgas coolers that allows a high hot metal charging speed and more control of the thermal power emissions during charging, thereby avoiding a thermal overload of the plant and always enabling complete combustion of the combustibles in the scrap. Properly designed systems allow the use of cheaper scrap, which usually carries a higher content of combustibles.

10 a.m. — Continuous Casting — Strip Casting and Solidification Structure - back to top
Room 116
Session Chairs: Joydeep Sengupta, Dofasco Inc.; Jack Young, Hatch Ltd.

10 a.m.
The Castrip Process: An Update on Process Development at Nucor Steel’s First Commercial Strip Casting Facility
M. Schueren, Nucor Steel Corp.; P. Campbell, Nucor Steel Corp., W. Blejde, Castrip LLC, R. Mahapatra, Castrip LLC
Nucor Steel installed the world’s first commercial strip casting facility for plain carbon steel sheet at its Crawfordsville, Ind., facility in 2002. Since that time, the plant has produced nearly 400,000 tons of ultrathin cast strip (UCS). Products from the Crawfordsville plant are utilized for a range of applications, replacing cold rolled and hot rolled steel sheet. A majority of the shipments from the facility have been in a thickness range between 0.034 and 0.060 inch (0.85 to 1.5 mm).The paper discusses the major development challenges faced by the start-up team and provides an update on current casting strategies.

10:30 a.m.
Three-dimensional Frozen Meniscus and Hook Microstructure in Continuously Cast Ultralow-carbon Steel Slabs
B. Thomas, University of Illinois at Urbana-Champaign; S. Yu, POSCO; G. Lee, Pohang University of Science and Technology; H. Shin, POSCO; S. Kim, Pohang University of Science and Technology; D. Kim, POSCO
The complex shape of microstructural features near the corners of continuously cast steel slabs were investigated using special etching reagents and optical microscopy. Continuous hook defects originating along the characteristic pointed oscillation marks were revealed in longitudinal, transverse and diagonal cross-sections. The complete three-dimensional shape of the hooks, overflowed meniscus and oscillation marks was constructed and quantified from multiple photographs. The results clearly explain the complex features observed in the micrographs, and suggest their formation mechanism and the trends in casting conditions that govern their formation.

11 a.m.
Simulation of Austenite Grain Growth in the Continuous Casting
J. Reiter, University of Leoben; C. Bernhard, University of Leoben; H. Presslinger, Voest-Alpine GmbH
The formation of cracks on the surface of continuously cast semi-finished steels is basically attributed to the formation of precipitates, phases or segregates during cooling, particularly detrimental along austenite grain boundaries. Coarse columnar grains are known to increase the hazard of crack formation. Surface cracks are therefore often located below deep oscillation marks or surface depressions. Austenite grain growth is mainly influenced by the thermal history, the steel composition and the precipitation of nitrides and carbonitrides. The objective of the present work was the development of an austenite grain size prediction model for the slab casting of carbon steels and the implementation in a quality assurance system.

11:30 a.m.
Production of High-aluminum Steel Slabs
A. Roelant, Severstal NA; N. Minor, Severstal NA; K. James, Severstal NA; S. Street, Severstal NA; J. Tremp, Severstal NA
Transformation-induced plasticity (TRIP) behavior, exhibited by certain steel chemistries, has been known for several decades. However, until recently, the material has remained a laboratory curiosity. Lately, a market has begun to develop for TRIP steels. A technology hurdle for steel producers has been to transfer the product from laboratory to full-scale production. In 2006, Severstal NA started a program to fast-track the development of TRIP steel grades. Tactics developed during metallurgical workshops translated to successful production of high-aluminum TRIP slabs. These tactics, production history and subsequent quality evaluations are discussed in detail.

10 a.m. — Coating and Process Lines — Process Lines II - back to top
Room 110

10 a.m.
The Conversion of the Mittal Steel USA – Cleveland Continuous Annealing Line Into a Hot-dip Galvanizing Line
D. Cerrone, Siemens Energy & Automation Inc.; C. Lewis, Mittal Steel USA
This paper will describe the project that was undertaken by Mittal Steel and Siemens VAI for the conversion of the continuous annealing line into a hot-dip galvanizing line at Mittal Steel USA – Cleveland Works. The presentation will begin by describing why converting the line was considered. The presentation will include a short description on how the scope of the project evolved and how the project total installed cost was developed. The results of the project are included.

10:30 a.m.
Review of Coreless Coating Pot and Induction Galvannealing Technologies
B. Rovins, Inductotherm Corp.; P. Knupfer, Inductotherm Coating Equipment, S.A.
Since the mid-1980s, coreless coating pots have been used in continuous galvanizing lines, particularly on lines producing Galvalume. Since the mid-1990s, high-frequency (100 kHz) induction heaters were introduced for the production of galvanneal. Now that sufficient time has passed, it is appropriate to recap the technical developments that have taken place as the technology has evolved. The presentation will review the implementation of the technology from the first installation through the present day, along with the advantages these technologies have provided the steel industry.

11 a.m.
Investigating Galvanneal Reactions on Pot Hardware Materials
M. Bright, Pyrotek Inc.
Over the past decade the use of galvannealed zinc-coated steel sheet (Zn – 0.135%Al) has increased dramatically for applications with stringent quality demands such as appliances and exposed automotive panels.  Significant research has been dedicated towards optimizing the coating composition and quality of these steel products.  However, minimal efforts have been focused on identifying the adverse impacts on galvanizing production hardware from this specific pot chemistry.  The differences in zinc reactivity as a function of aluminum concentration are only now being observed.  Utilizing SEM and EDS analysis, an overview of the Zn-Al metallurgical reactions on some common pot hardware materials following immersion in a galvanneal coating bath will be reviewed.

11:30 a.m.
Mechanism and Intensity of Zinc Coating Layer Formation by Electromagnetic Hot Dip Zinc Galvanizing
V. Buriak, Net Shape Cast Ltd.; A. Codutti, Danieli & C SpA; A. Kolesnichenko, Net Shape Cast Ltd.; A. Poloni, Danieli & C SpA; M. Pavlicevic, Danieli & C SpA
Electromagnetic hot-dip galvanizing is based on the upward passing of coated steel strip through zinc alloy that is partially levitated in an alternating magnetic field. In addition to numerous advantages that this coating technology gives (absence of a source of hard dross, no submerged roll or bearings, steady cleaning of coating alloy from oxides and inclusions), electromagnetic zinc galvanizing changes the process of coating formation. The intensity of the chemical reaction between Fe and Zn, which leads to the creation of more thin layers of intermetallic compounds, changes by imposition of an alternating magnetic field. The influence of MHD convection was investigated experimentally on the electromagnetic Gaflvanizer built by Net Shape Cast Ltd.

10 a.m. — Roll Technology — Roll Management Systems - back to top
Wabash Room 2
Session Chairs: Joseph Zuccarelli, Hitachi Metals America; Phil Everman, Nucor Steel Arkansas

10 a.m.
Roll Grinding — Products and Techniques for Reducing Grinding Costs
K. Pica, Saint-Gobain Abrasives; E. Reitz, Saint-Gobain Abrasives
This paper shares ways to lower the cost of grinding rolls. The main cost drivers to be discussed are increasing metal removal rates in grinding, acheiving good consistent roll finishes and decreasing abrasive costs. Among the subjects covered will be improvements that can be made in coolants and coolant systems, roll grinding programs and new abrasive technologies. Results to be presented were obtained through both internal testing and extensive external field testing on a variety of roll types. Case studies for both hot and cold mill roll grinding will be discussed, along with specific recommendations based on application.

10:30 a.m.
Custom-made Roll Shop Management Systems for Optimized Roll Organization
M. Smith, Waldrich Siegen GmbH & Co.; C. Chiang, Hcc/Kpm; D. Schmidt, Waldrich Siegen GmbH & Co.; K. Adamek, Waldrich Siegen GmbH & Co.
A professional roll shop management system (RSMS) is a database that manages an entire roll inventory and organizes the trouble-free flow of all rolls according to the requirements of the rolling mill. Connection to the mill computer or host systems guarantees the designated data transmission via standardized interfaces. Simple menu-driven data input eases planning by the operator. Comprehensive evaluation features provide detailed statistical analyses and quality documentation, which are especially important for roll shops that operate as service centers for their customers, the rolling mills.

11 a.m.
Roll Shop Management Software Integrated With RFID Technology
K. Hutchison, Automation Software & Engineering Inc.
RMSTrax is an enterprise solution for managing roll shops and their component lifecycles while providing decision-making tools for improved inventory control and maintenance scheduling. Incorporating industrialized tags and readers to withstand environmental challenges, RMSTrax uses RFID technology to track the status, location, and condition of rolls and chocks as they travel through the workflow. Efficient operation and management are achieved by integrating wireless handheld devices for mobility, mill-specific workflow rules, open architecture, enterprise-wide reporting, OSP, ERP, level 2, grinders and skate interfaces, and equipment productivity. Web-based reporting provides centralized procurement, real-time inventories, and costs per ton of roll usage aggregate from each mill.

11:30 a.m.
Roll Shop Management System
G. Bavestrelli, Techint SpA
Modern roll shops have a high degree of automation, allowing a single operator to supervise several grinding machines, as well as storing a lot of grinding information in centralized databases for each roll in the roll shop. This information is normally kept in database servers and is useful by itself, but it can be much more useful if it is organized well and correlated to mill production data. That is the purpose of a roll shop management system (RSMS). Such systems manage a lot of information about rolls, but also about chocks, bearings and grinding wheels, correlating grinding data to mill production data, to permit evaluation of the performance of rolls, chocks, bearings and wheels in the grinder and/or in the mill. Roll shop management systems also provide an inventory of all the rolls, chocks, bearings and wheels in the roll shop, and for each indicate the history and the current status. For chocks and bearings, such systems will also indicate when maintenance needs to be performed. The goal of an RSMS is therefore to move from the mere automation of a roll grinding machine to supporting the decisions made daily in the roll shop.

10 a.m. — Process Technology — Inclusion Analysis — Developing Technology - back to top
Room 111
Session Chair: Randy Stone, Heraeus Electro-Nite

10 a.m.
Computer-assisted Inclusion Rating
M. Savard, Clemex Technologies Inc., M. Dallaire, Clemex Technologies Inc

11 a.m.
Investigation on Nozzle Clogging During the Steel Billet Continuous Casting Process
X. Zuo, Norwegian University of Science & Technology; S. Niu, Shijiazhuang Iron & Steel Co. Ltd.; L. Zhang, Norwegian University of Science & Technology
This study investigates the reason and remedies for the clogging of the submerged entry nozzle (SEN) during billet continuous casting of mid-carbon steel. Clogging materials are analyzed using SEM and optical microscope. Inclusions in steel samples taken at ladles, tundish and billets are also investigated. The total oxygen on the entire section of the billet is measured. Steel cleanliness at unsteady casting states are studied, including cast start, ladle change, SEN change, cast end, and the special unsteady pouring period induced by SEN clogging. The industrial data of mold level fluctuation, casting speed, etc., for 24 hours are analyzed in detail. Fluid flow and inclusion motion and entrapment to the SEN surface are also simulated.

11:30 a.m.
Cracking Breakouts Susceptibility Function “CBSF” New Technique to Control the Productivity and Quality in Continuously Cast Steel Slabs
M. El-Bealy, Ain Shams University; A. Hussein, Ain Shams University
An extensive study has been conducted to theoretically elucidate the coupled effect of various casting and cooling conditions on the occurrence of interdendritic cracking breakouts in continuously cast steel slabs. The study combined previous industrial plants trials and the development of a mathematical model. The plant trials involved experimental measurements of casting and cooling conditions within the time period of interdendritic cracking breakouts. A one-dimensional mathematical model of heat flow, solidification, stress-strain, macrosegregation and interdendritic cracking has been developed. This model is necessary to compute the thermal fields, microstructure evolution, macrosegregation and stresses, and their strains within the solid shell and mushy zone. The interdendritic cracking phenomenon was simulated by using El-Bealy’s approach to characterize the interdendritic thermo-viscomechanical strains and the opening displacement between the dendrites “EIA.” In order to explain the incidence of this type of breakout, the effects of different casting and cooling conditions on the different slab design parameters affecting the frequency and severity of the interdendritic cracking breakouts were analyzed.

10 a.m. — Sensors and Instrumentation — Sensors and Instrumentation - back to top
Room 108
Session Chairs: Barry Brusey, Dofasco Inc.; Steve Sontag, GE Sensing

10 a.m
Monitoring Product Quality With Sheet Profile Testing
W. Mellander, Harford Industries, S. Harford, Harford Industries
The Epac Division of Harford Industries has developed a strip steel profile gauge as an off-line instrument to be used in the rugged mill environment rather than in a lab. Critical data can be monitored from the mill floor for quick decisions. This instrument simultaneously measures and displays the top, bottom and gauge (thickness) profiles of the strip sample. A gamma test reads four points at each end of the sample strip. A touchscreen PC with wireless capability controls all operational functions and displays. The skates can be saved to a database and viewed in multiple areas of the plant for additional quality analysis and archiving.

10:30 a.m.
Torpedo Car Hot Spot Sensing
A. Barreiro, VAI-Ingdesi Automation; E. LaBruna, VAI-Ingdesi Automation; M. Romeo, VAI Ingdesi Automation, J. Ingersoll, VAI Ingdesi, L. Arlenghi, VAI Ingdesi Automation
The purpose of this system is to perform the automatic detection of hot spots on torpedo cars in order to avoid dangerous and costly accidents due to possible leaks. The system is based on a group of infrared cameras and artificial vision algorithms to achieve a reliable detection of hot spots as the torpedo cars pass by the camera station. The Web-based system also generates alarms and historical data for every torpedo car that goes through the detection process, avoiding equipment failure (e.g., refractory bricks breaking down) and the associated costly production downtime.

11 a.m.
Furnace Water Lead Detection and Reduced Conversion costs Efforts at Aceria Compacta de Bizkaia, spain, Using the Goodfellow EFSOP System
M. Khan, Tenova Goodfellow; K. Nikkanen, Tenova Goodfellow; J. Gavina, Aceria Compacta de Bizkaia
Tenova Goodfellow Inc., formerly Techint Goodfellow Technologies Inc. (Techint), 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 May 2006, Tenova Goodfellow installed and commissioned two EFSOP systems for Aceria Compacta de Bizkaia (ACB), Spain. The main objectives of this installation were to detect furnace water leaks for safety reasons and reduce EAF conversion costs. A water leak detection and alarm system has been developed using the EFSOP system based on offgas fingerprints of the ACB furnaces. The detection of a furnace water leak relies on the ability of the EFSOP system to accurately and quickly measure H2 and CO concentrations of the furnace offgas. Examination of the offgas chemistry has also led to the development of new burner practices and changes to the charged carbon practice to improve furnace efficiency. ACB has benefited from the EFSOP system in terms of reduced consumption of electrical energy, charged and injected carbon, and natural gas, and improved yield and productivity. The consumption reduction benefits alone have resulted in a savings of more than US$1/tls. This paper will outline the EAF optimization and benefits at ACB and discuss the water leak detection system.

11:30 a.m.
IMPOC® Online Mechanical Properties Measurement Reducing Processing and Material Problems
S. Devorich, EMG Automation Inc.; M. Gilbert, EMG Automation Inc.; A. Jordan, EMG Automation GmbH
The Impulse Magnetic Process Online Controller (IMPOC) system has been applied in industrial applications since 1998 for the on-line measurement of yield point and tensile strength. The system has become a standard QA tool for leading steel producers to reduce destructive material testing and material rework. The IMPOC system has been successfully used for process optimization in annealing lines and galvanizing lines. This paper concentrates on those applications and the benefits for the quality management process. The paper also briefly covers EMG’s newest application, which is the common use of IMPOC and SORM (on-line roughness measurement system) for closed-loop control of a temper mill and for the optimum calculation of the setup rolling force value.

10 a.m. — Computer Applications — Computer Applications - back to top
Room 107
Session Chairs: James Hendrickson, Mittal Steel USA; David J. Moore, WCI Steel

10 a.m.
Laser Plus Oy Improves Quality Assurance Process with the Laser Technology: Automated Specimen Manufacturing System for Material Testing Productionn
R. Nurkkala, Laserplus Oy; H. Saariluoma, Laserplus Oy; V. Immonen, Laserplus Oy
An automated specimen manufacturing system (ASMS) was developed especially for the manufacture of metals specimens. Using the latest laser technologies, the ASMS enables the manufacture of test specimens faster and more profitably than manual methods. The ASMS process includes automatic test sheet loading, test sheet identification, laser marking, laser cutting, sorting of specimens and scrap removal phases. The totally integrated automation (PLC/CNC/PC/HMI) is controlled with a product information database as a part of the quality assurance process. Based on the modular design, the ASMS handles stainless, carbon steel and aluminum products, including hot and cold rolled strip coils, plates and sheets with various capacity requirements. Laserplus Oy has delivered the first stainless steel application of the ASMS to Outokumpu Stainless Oy in Finland. The ASMS in unmanned operation is fully incorporated into the production line at the Tornio plant with the specified capacity.

10:30 a.m.
Supply Chain Management (SCM) for Steel Producers With a Focus on Cold Mill Complexes
M. Finset, Danieli Automation
Danieli Automation presents a new supply chain management (SCM) approach with a totally integrated data system for steel producers, with focus on the latest cold mill complex implementations and results. System integration with automatic gathering of production data and key performance data significantly improves the plant’s manageability and increases working capital performance. Keeping all order and production data in one system has significantly reduced the IT management. The SCM supports the plant in its operations for order management, material acquisition, scheduling optimization, tracking, quality, tests, certification and shipping, while getting the maximum efficiency with its tightly integrated modules supported by user-configurable steelmaking rules.

11 a.m.
Numerical Prediction of Dynamic Behaviors of Coupled Heat, Mass and Momentum Transfer Processes in the Lower Part of Blast Furnace
M. Kuwabara, Nagoya University; Y. Kashihara, JFE Steel Corp.; J. Yang, Nagoya University; M. Sano, Nagoya University
The effects of nonuniform flows of solid, gas and liquid on thermal features of the melting zone of the blast furnace are discussed on the basis of a simple yet convenient mathematical dynamic model. In this model, the lower part of the furnace is divided into several regions, each having peculiar characteristics. A set of simultaneous ordinary differential equations for heat and mass transfer processes is numerically calculated in order to predict possible abnormal cooling of a furnace or to investigate ways to reactivate the furnace. Typical computing time to predict transitional behaviors over several hours is reduced to several seconds.

11:30 a.m.
Increasing the Productivity of the Hot Strip Mill Voestalpine Stahl Linz
R. Konnerth, Siemens VAI; E. Weberberger, Voest-Alpine Stahl GmbH; W. Seyruck, Voest-Alpine Stahl gmbH; G. Mitter, Siemens VAI

10 a.m. — Cranes — Cranes - back to top
Room 104
Session Chairs: James Salisbury, Dofasco Inc.; Mike Urbassik, Eaton Electrical

10 a.m.
Steel Coil Lifting Using Synthetic Slings
J. Boesten, DSM Dyneema
DSM Dyneema has developed a type of sling that outperforms all other slings in steel coil lifting. A three-year joint development with a sling company and a stevedore in Europe resulted in a lower weight sling, fewer injuries, fewer worker compensation claims, faster rigging, higher safety and greater cost savings. This paper focuses on the development of the sling, assuring safe use, and discard criteria.

10:30 a.m.
Under the Hook: A Closer Look
T.J. Medcalf, Carolina Crane Inspections
This paper will assist plant engineering and maintenance personnel in implementing equipment maintenance and inspection programs to ensure that manufacturer recommendations and OSHA regulations are adhered to. These minimum requirements are established to prevent equipment failure, which may endanger personnel, property and assets of the company. The use of nondestructive testing methods at regularly scheduled intervals through a documented inspection program and in accordance with applicable codes, standards and specifications, conducted by certified inspection personnel can be a cost-effective maintenance tool. It can provide early detection of mechanical deficiencies that can affect the safe operation of below-the-hook material handling equipment. OSHA standards clearly state that the equipment owner/operator must establish maintenance programs based on the severity of use, facility design, wear characteristics and equipment conditions based on past operating experience. Included in this discussion will be an overview of acceptance and rejection criteria from applicable codes and specifications concerning the proper maintenance, repair and operation of material handling equipment used in the steel manufacturing industry.

11 a.m.
Effective Crane Standards
T. Berringer, Cavotec Gantrex, Inc.

10 a.m. — Maintenance Processes — Reliability Achievement Awards - back to top
Wabash Room 3
Session Chairs: John Schlobohm, Castrol; Dennis Smith, CHL; Peter Havelka, MPI

10 a.m.
Steelmaking Dust Collector Three-piece Auger Conversion to One-piece: A Way to Save on Environmental and Maintenance Costs
R. Bradford, Stelco Inc.
With increasing focus on reliable environmental efficiency and cost savings in manpower, the one-piece screw design was a proven way to save time and efficiently capture the effluents of the steelmaking process. Due to the drastic cost of a complete system redesign, there was a need to assess the existing system. Taking into consideration its original design and capacity, with the expectations of today’s standards, a basic anaylsis of the system was performed. The repetitive failures that caused the most downtime was the primary focus of the analysis. Pinpointing major repetitive failures led to a more proactive stance in becoming more reliable and efficient.

10:30 a.m.
Equipment Reliability Improvement at Dofasco’s DSG Galvanizing Line
M. Hendsbee, Dofasco, Inc.

11:00 a.m.
Utilizing 3D Survey to Improve Caster Component Alignment
F. Hancock, CitiSteel USA

11:30 a.m.
Getting the Best of Both Worlds in Reversing Mill Recoilers at Nucor Steel-Berkeley
J. Curtis, Nucor Steel Corp.; S. Matovic, Horsburgh & Scott; C. Bender, NSK Corp.

10 a.m. — Project and Construction Management — Construction Management - back to top
Room 109

10 a.m.
The Rise of the Nonwelded Hydraulic Piping System
S. Adams, Tube-Mac Industries
In the last few years, the chronic lack of skilled labor has brought to light the need to develop a reliable, cost-effective method of joining larger-diameter, high-pressure piping systems. Traditional methods of joining smaller diameter (1/4–3/4 inch) by compression or flare fittings are accepted by contractors and maintenance departments. The problem, until recently, has been larger-diameter pipe (3/4–4 inches), which was traditionally welded, and is now being addressed by mechanically attached fittings (MAFs) such as swaged or flared fittings. The benefit is a much lower skill level requirement, making the availability of skilled labor a non-issue.

10:30 a.m.
Factory Acceptance Testing
R. England, Matrix Technologies Inc.
Accurate simulation conditions for factory acceptance testing (FAT) are essential when implementing new computer process control and information systems. The conditions for the system’s testing begin with defined test procedures and include proper setup and configuration of the hardware components, as well as utilizing accurate test simulation software and data. This presentation will examine the management and implementation of software factory acceptance testing. The management aspect will look at scheduling resources, equipment and space requirements, and the tasks and costs associated with equipment setup, power and communications. This presentation will also include a look at the technical aspects of executing the testing, including preparation of procedures, simulation code requirements, viewing and recording test results, and simulation data input for real-time testing.

11:00 a.m.
Using GIS Technology for Document and Asset Management
K. Armstrong, ATSI Engineering Services
Today’s workforce is expected to accomplish more and more in their standard work day. Streamlining the daily workflow process of how you perform your job can save time, which ultimately saves money.

A typical steel plant can have thousands of important documents from drawings, specs, and photos, to vendor cut-sheets, operations & maintenance manuals that need to be accessed on a daily basis. The time spent searching for these documents could be better utilized performing other vital job tasks. Organizing all of these documents into a workable environment that allows quick and easy access can be a daunting task. Using Geographical Information System (GIS) technology can take all of those documents from your desks, flat files and file cabinets to your fingertips with a click of a mouse.

This paper will focus on ATSI’s process using GIS technology to integrate thousands of documents into a single efficient application that allows team members, managers and decision makers simple and efficient access to all of their files from a desktop computer or mobile device. Early estimates show that using GIS technology for simple asset and document management and retrieval can save an average worker 25% of their time. Looking to the future, this technology will prove to be a breakthrough in cost efficiency for the steel industry.

10 a.m. — Environmental Technology — Effluent Control - back to top
Room 106

10 a.m.
Applications of Automatic Screen Filters in the U.S. Steel Industry
M. Allhands, Orival Inc.
Water has, is and always will be an integral part in the iron and steelmaking process. Water is used for various cooling and cleaning purposes. Water reuse is essential in today’s market. Scale pits are used to remove heavy particles, but filters are necessary to remove light suspended particles. Automatic self-cleaning screen filters are used in many mill applications, but good design is required to meet expectations. This overview will look at a variety of those applications in a number of mills and describe the appropriate use of such filters.

10:30 a.m.
PIZO Furnace Demonstration Operation for Processing of EAF Dust
J. Bratina, Heritage Technology Group; K. Lenti, Heritage Technology Group
Heritage has developed a new technology (PIZO Process) for the processing of oxide materials from the metals industry to produce valuable products.  Construction of a one ton per hour demonstration facility for this process was completed in early 2006.  This paper provides a discussion of the operation of this demonstration facility while processing BOF sludge and EAF dust to recover zinc, iron and slag products.  The facility was operated from January 2006 until September 2006.

11 a.m.
Wasteload Allocation and TMDLs
H. Alexander, Business Environment Inc.
The federal Clean Water Act requires the establishment of so-called “total maximum daily loads” (TMDLs) for water quality limited streams. Many consider NPDES permitting and wasteload allocation in streams subject to TMDLs difficult and confusing. Actually, there is an underlying logical process that can be easily understood. This paper lucidly explains that process. Included are easy-to-follow numerical examples. Also included are key equations and helpful conversion factors to be used in practice by industrial personnel negotiating NPDES permits with regulatory authorities. The paper further provides uncomplicated definitions and explanations of key terms or concepts such as water quality-based effluent limitations (QUE-bells); the 7-day, 10-year low flow (7Q10) of a stream; why the geometric mean is preferred and can be used instead of the arithmetic mean or “average” when multiple pieces of data are available; and the reasonable potential to violate an effluent limitation.

11:30 a.m.
Zero Liquid Discharge (ZLD) Cooling Tower Treatment at CSI
J. Reed, California Steel Industries Inc.; J. Kubis, Water & Enviro Tech Co. Inc.; D. Duke, Water & Enviro Tech Co. Inc.
Two new cooling towers were started up using zero liquid discharge (LCD) water chemistry at CSI to eliminate environmental discharge costs and reduce water use. High total dissolved solids (TDS) chemistry that results from ZLD required new scale and corrosion inhibition technology to protect the equipment and permit improved maintenance and operating expense. Galvanized tubes and mild steel in the towers show outstanding corrosion protection, as well as control of “white rust” and scale in 25,000 TDS tower water. New technology that produces inhibitor chemistry from source water silica permits operation at high TDS without scale or corrosion. It also costs less than chemical treatment.

Wednesday, May 9
Afternoon Sessions

2 p.m. — Iron Producing — Blast Furnace Modeling and Analysis - back to top
Room 102
Session Chairs: Albert Dzermejko, Magneco Metrel

2 p.m.
Mathematical Model to Predict Potential Damage to Blast Furnace Cooling Staves Based on Measured Thermocouple Data
D. Radakovic, U. S. Steel Corp.; K. Liu, U. S. Steel Corp.
A method of evaluating the condition of blast furnace cooling staves has been developed in which measured thermocouple readings are used to predict the thermal stress in the stave body. A finite element computer model was developed for the U. S. Steel Edgar Thomson Works No. 3 blast furnace copper stack staves using the ABAQUS Standard V6.4 finite element software. The analysis indicated that, for high heat flux conditions in which the stave thermocouple temperature rises above 320°F, the copper cooling staves undergo permanent deformation in the areas adjacent to the fixing bolt locations. The magnitude of the plastic strain, however, was predicted to be very low relative to the total potential elongation of the ductile copper. Generally, this model can be used as a tool to estimate the potential damage that occurs as a result of measured stave temperature excursions.

2:30 p.m.
Model of Radial Distributions in the Blast Furnace Shaft
S. Kodukula, Abo Akademi University; N. Saxen, Abo Akademi University
A mathematical model was developed to estimate the radial distribution of the ore-to-coke (O/C) ratio in the blast furnace shaft on the basis of molar flow and energy balance equations. It utilizes the radial distribution of the gas, measured either above or below the burden surface, or both, to estimate the thermal flow ratios in concentric rings of the shaft. From this, the O/C distribution is estimated under the assumption that a thermal reserve zone of a given temperature exists in the furnace. The model, which also predicts the radial distribution of temperature and pressure in the shaft, has been evaluated using measurements from industrial blast furnaces.

3 p.m.
Method and Results of Numerical Modeling of Physicochemical Processes in Radial Annular Cross-sections Along the Blast Furnace Height
Y. Gordon, Hatch Associates; V. Bolshakov, Iron & Steel Institute, Ukraine; I. Tovarovskiy, Iron & Steel Institute, Ukraine
The system of discrete material and thermal balances in the radial annular cross-sections for 12 vertical zones is used to describe the heat and mass transfer processes of iron ore reduction. The temperature increase in vertical zones starts from the initial temperature interval of 400°C for the first zone and further with 100°C intervals for the other 11 zones with material descend and transformation from the solid to the liquid phase. The temperature of the melt is the bottom boundary of the last zone. The furnace cross-section is divided for 10 ring zones. Thus, all volume of a burden column is divided for 10 x 12 = 120 zones. The area of the rings is the same, and each ring represents the positioning of the bell-less top spout. The heat and material balances are calculated for each individual zone as a part of the overall heat and material balance for the whole furnace. The balance equations include the calculations of reduction process and boundary temperature for each zone. The results of quantitative analysis of the blast furnace performance under the various conditions are demonstrated.

3:30 p.m.
Prediction of the Inner Profile of a Blast Furnace Hearth
F. Huang, Mittal Steel USA; P. Chaubal, Mittal Steel USA; C. Zhou, Purdue University Calumet; Y. Zhang, Purdue University Calumet; R. Deshpande, Purdue University Calumet
Hearth wear and the inner profile are highly dependent on the liquid iron flow pattern, refractory temperatures and temperature distributions at the hot face (the interface between the liquid iron and refractory or the skull). A methodology has been established to estimate the hearth erosion and its inner profile based on the hearth temperature measurements. This new method couples the three-dimensional computational fluid dynamics hearth model with one-dimensional thickness estimation according to the detailed thermal flow paths. It has been applied to the prediction of the hearth inner profiles of the Mittal Steel Indiana Harbor No. 7 blast furnace at different time periods. The details of the methodology and simulation results will be discussed.

4 p.m.
Calculation of Coke Replacement Ratio
R. Jason, Mittal Steel USA; F. Huang, Mittal Steel USA
Determining the replacement ratio of coke with an injection fuel is very important to choosing the injection fuel and adjusting the blast furnace operation. The replacement ratio of coke with an injection fuel depends on four aspects: chemical compositions of injection fuel, heating value of injection fuel, the gas utilization of the blast furnace, and the coke quality. A new method has been established to determine the replacement ratio of coke with injection fuel rate based on these four aspects. This new method can accurately determine the replacement ratio of coke with any kind of injection fuel. The calculated replacement ratios match the industrial operation data very well.

4:30 p.m.
Numerical Analysis of the Coke Combustion Inside Raceway
M. Gu, Purdue University Calumet; C. Zhou, Purdue University Calumet; P. Chaubal, Mittal Steel USA; F. Huang, Mittal Steel USA; N. Selvarasu, Purdue University Calumet
In a blast furnace, the injected coal and coke are combusted simultaneously under the same environment. Analysis of the coke combustion in the raceway will provide fundamental insights and lay a foundation for simulating the combustion process in the raceway, including injected fuel(s) and coke combustion. In this paper, a three-dimensional, multiphase reacting computational fluid dynamics model is developed to simulate coke combustion in a raceway. The interreaction between the coke combustion and raceway size is considered. Parametric studies are conducted to investigate the impacts of tuyere operation and the effects of coke particle size, coke reactivity, and porosity of the active coke zone on the raceway size and coke combustion.

2 p.m. — Iron Producing/Process Technology — Alternative Ironmaking II - back to top
Room 103
Session Chairs: Jeff Myers, Midrex Technologies Inc.; Jerry Nelesen, National Recovery Systems Inc.; William Slye, Praxair Inc.

2 p.m.
Techniques for the Utilization of Low-quality Iron Ore Feeds for Shaft Furnace Direct Reduction
G. Hoffman, Midrex Technologies Inc.; J. McClelland, Midrex Technologies Inc.; J. Ripke, Midrex Technologies Inc.
Iron oxide pellets and lump ore are in tight supply for direct reduction. Given the strong steel market, iron ore prices have surged until new capacity becomes available. Both old DR plants and new projects may have to use lower-quality raw materials, which may impact the quality of the DRI or HBI product. A new engineering approach has been developed to allow the use of lower-quality iron oxides in shaft furnace direct reduction applications. This paper discusses the nature of these techniques and the impact on issues such as productivity, processing temperature, burden sticking, increased fines generation, pressure drop and DRI strength.

2:30 p.m.
Reduction Kinetics of coarse Hematite in Pressurized Fluidized Beds
B. Weiss, S. Schuster, F. Winter, H. Mali and J.L. Schenk, Montanuniversitat Leoben
Reduction processes based on fluidized bed technology have been gaining an important role in ironmaking. The FINMET® process and the FINEX® process are multi-staged fluidized bed reactor systems for the reduction of iron ore fines, operating at elevated pressures. For process optimization and further improvement, fundamental knowledge of the reduction kinetics under industrial operating conditions is required. A laboratory-scale, pressurized fluidized bed reactor was developed and operated at process conditions similar to the FINMET and FINEX processes. With this unit, the reduction progress depending on the residence time can be elevated. To describe the reduction kinetics, a mathematical model was developed based on the experimentally evaluated reduction behavior. The degree of reduction can be calculated for every stage at any time during the process.

3 p.m.
Gasification and the MIDREX® Direct Reduction Process
R. Cheeley, Midrex Technologies Inc.
Much of the expansion in the steel industry is occurring in China, India, and other locations that do not have an abundance of low-cost natural gas. This typically precludes the use of natural gas-based direct reduction for making iron. One option for making direct reduced iron (DRI) in these locations is to combine a gasification plant with a MIDREX® direct reduction plant. The gasification plant can use coal, pet coke or refinery bottoms to generate a synthesis gas that is an acceptable reducing gas source for producing DRI in a MIDREX plant.

3:30 p.m.
Upgrading of Highveld Electric Iron Furnaces to Partially Open Bath Smelting
J.M.A. Geldenhuis, Nucor Steel, J. Els, Hatch, K. Sutherland, Highveld Steel and Vanadium Corp. Ltd.; B. Marshall, Highveld Steel and Vanadium Corp. Ltd., C. Walker, Hatch; B. Wasmund, Hatch
Highveld Steel and Vanadium operates a rotary-kiln, electric furnace (RKEF) smelter in South Africa to smelt a vanadium bearing titaniferous magnetite ore for the production of pig iron and vanadium products. Hatch has been working with Highveld to improve the operation by converting the submerged arc furnaces to partially open bath smelting mode (POB). Initial positive trial results obtained on Furnace 3 in 2003 lead to the successful conversion of Furnace 5 to POB during 2005. Results of both the initial trials on Furnace 3 and the results of the first year of operation on Furnace 5 are presented and discussed. Significant benefits associated with the open bath operation include improvements in furnace productivity, vanadium recoveries, iron and slag chemistry, raw material consumption and iron yield.

4:30 p.m.
Operations at the HIsmelt Kwinana Plant
N. Goodman, HIsmelt Corp. Pty. Ltd.

2 p.m. — Iron Producing — Blast Furnace Cooling - back to top
Room 104
Session Chairs: Keki Nanavati, Cleveland-Cliffs Inc.; A. Cheng, Severstal North America, Inc.

2 p.m.
Blast Furnace Cooling — North America Perspective
P. Sortisio, ATSI; A. Cheng, Severstal North America Inc.

2:30 p.m.
Efficient Blast Furnace Cooling for a Long Campaign
I. Carmichael, Paul Wurth; N. Mousel, Paul Wurth

3 p.m.
Blast Furnace Cooling Panel Discussion
Panel Facilitators: K. Nanavati, Cleveland-Cliffs Inc.; F. Rorick, Rorick Inc.
Panelists:
R. Jason, senior process engineer, Mittal Steel USA – Cleveland
P. Ruether, manager, Thyssen Krupp
A. Petrucelli, ironmaking technology reliability coach, Dofasco Inc.
R.J. Van Laar, engineering technologist, Corus Group plc
B. Felton, process and technology manager, Mittal Steel USA – Burns Harbor
S. Hutchinson, area manager blast furnace and PCI, Hamilton Steel

2 p.m. — Electric Steelmaking — EAF Process and Operations - back to top
Room 117
Session Chairs: Brett McGee, C/G Electrodes LLC; Scott Swanson, C/G Electrodes LLC

2 p.m.
Combustion of Organic Wastes for Their Utilization in Electric Arc Furnace Steelmaking
N. Saha-Chaudhury, University of New South Wales; M. Zaharia, University of New South Wales; J. Lee, University of New South Wales; D. Knights, Onesteel Market Mills; E. Pretorius, Nucor Steel Corp.; S. Darma, University of New South Wales; R. Khana, University of New South Wales; P. O’Kane, Onesteel Market Mills; V. Sahajwalla, University of New South Wales
This article highlights the energy benefits that are achieved using different mixtures of organic waste materials. Due to the fact that these types of materials have high calorific values and combustion of hydrocarbons releases chemical energy, they may be regarded as attractive raw materials and can act as a source of energy in EAF steelmaking. Combustion of coke/waste plastic and coke/rubber mixtures was investigated. Previous works reported the slag foaming phenomenon while using waste plastics. This study reports on the fundamental understanding of combustion of organic waste materials.

2:30 p.m.
The Latest Evolution in EAF Gunning Practice
V. Morais, Magna Refractories Inc.; N. Gangutia, Magna Magnesitas Navarras, S.A.; G. Bonnet, Magna Magnesitas Navarras, S.A.
Capacity and productivity are increasing throughout the steel industry, and new, reliable gunning techniques are needed. The evolution of gunning practices has occurred in two ways: the gunning materials themselves have been redesigned over the years (grain size distribution, additives, raw materials, chemistry), and the application methods have changed. This article focuses on the evolution of application methods. Following a review of various gunning methods (which are not exclusive from one another) — from the most primitive manual shovelling to the most advanced light mobile robot gunning — the author will compare the economics of each method and make a qualitative comparison following the SWOT diagram: strength, weakness, opportunity, threat. The author will conclude that a spectacular evolution has occurred in gunning because it is a piece in the value chain of steel production that is absolutely necessary. It must be reliable, consistent, efficient, safe and of course economically sound.

3 p.m.
Sustainability by Having Zero Accidents and Zero Downtime
M. Flores-Magari, Coyne Textile Services
Selecting the right type of protective apparel is no longer a simple choice of style and price. There are choices to be made, with a clear understanding of the hazardous exposure to molten metals (such as zinc in galvanizing), radiant heat, flash fires and electric arc flash. Garments and safety accessories are now designed for specialized applications. New emphasis by OSHA on protection against electric arcs is creating additional challenges. As the results of new studies and research become available, even more products will be introduced, and new requirements for protecting workers will be established. When the most effective personal protective equipment is used, it is more likely that there will be zero accidents and zero downtime due to health and safety issues.

3:30 p.m.
Recycling Ladle Slag as Slag Former for EAF Steelmaking – A Study of Foaming Behavior
M. Guzzon, Politecnico di Milano; C. Mapelli, Politecnico di; V. Sahajwalla, University of New South Wales; F. Memoli, Tenova Metal Making; N. Saha-Chaudhury, University of New South Wales; M. Pustorino, Tenova Melt Shops

Several steel plants, in Italy and the rest of Europe, recycle the slag proceeding from the secondary metallurgy as slag former for their electric arc furnaces. In this paper, the results of this nonstandard practice are analyzed and related to the characteristics of the EAF slag resulting from this recycling. An interesting effect has been found on the characteristics of foaming velocity, slag basicity and slag density. Slag foaming studies were conducted in the laboratories of UNSW, Sydney, Australia, using the high-temperature visualization facility. The studies have established the differences in the slag foaming phenomenon between the electric arc furnace slag formed with usual components (lime, dololime, etc.) and the slag formed with the nonstandard mix (lime and recycled ladle slag). Using a model of isothermal solubility developed by Politecnico di Milano University, Italy, the other EAF slag properties — in particular the density and the basicity — are correlated to the saturation of silicates, aluminates and other complex components of the secondary metallurgy slag into the EAF slag. The results of these studies confirm that this particular type of ladle slag recycling is viable, as it does not affect the EAF foaming properties, and in some cases it is even more favorable than the standard practice.

4 p.m.
Improving Liquid Steel Production at Rocky Mountain Steel by Installing a High-capacity Electric Arc Furnace Utilizing SIEMENS VAI's Ultimate EAF Technology
D. Ellis, RMSM
In 2004, Rocky Mountain Steel decided to optimize their liquid steel production in order to increase productivity, to increase efficiency by replacing the two existing electric arc furnaces with one high-capacity EAF, and also to improve the environmental situation by installing a new baghouse and ducts. The new high-capacity EAF features elements of SIEMENS VAI's Ultimate EAFtTechnology, such as a single-bucket charge, current conducting electrode arms, oxygen management by refined combined burners (RCBs) with carbon injection, and a new process automation system for level 1 and level 2. The overall project also included modification to the existing building, installation of a new canopy hood, offgas ducts and baghouse. The project was successfully completed in November 2005. Highlights of the project, such as schedule, design, manufacturing, installation and start-up, as well as operational and technical highlights of the installed equipment, will be presented in this paper.

4:30 p.m.
The Practice of Carbon Injection and Postcombustion to Achieve Metallic Yield Recovery in the Electric Arc Furnace: The Experience of Amsteel Mills
L. Fook Guan, Amsteel Mills SDN BHD; F. Memoli, Tenova; C. Wai Meng, Amsteel Mills SDN BHD; P. Chung Kuan, Amsteel Mills SDN BHD; O. Negru, Tenova Goodfellow
Amsteel Mills SDN BHD is an 800,000-metric-tons-capacity steel plant located in Malaysia and belonging to the Lion Group, which is the first steel producer in southeast Asia with more than 4 million metric tons of flat and long products. Amsteel operates one scrap-based EAF with an 87-metric-ton heat size capacity, which was equipped in the end of 2005 with a modern oxy-carbon injection system and an additional postcombustion burner system. Besides the expected benefits arising from the reduction of power-on time and overall energy consumption, Amsteel has experienced a constant and consistent metallic yield recovery through a very efficient carbon powder injection practice. This paper describes the results achieved during a year of production and the operational practices that take into account a very careful analysis of the EAF slag, monitoring its composition at the beginning and the end of the flat bath period. The results in yield recovery are thus related to the reduction of the iron oxides in the slag and the amount of carbon powder used for the injection.

2 p.m. — Specialty Steelmaking — Melting and Finishing of Stainless Steel - back to top
Room 113
Session Chairs: Stephen Lukes, Carpenter Specialty Alloys; John Bustnes, Tinfos Jernverk A/S

2:30 p.m.
Control of Chromium Slagging in Stainless Steelmaking at EAF
L. Voj, RWTH Aachen, V. Risonarta, RWTH Aachen, I. Wagenknecht, RWTH Aachen, H. Pfeifer, RWTH Aachen
In EAF steelmaking, oxygen is blown into the melt to oxidize carbon. However, during carbon oxidation, chromium is also oxidized and chromium oxidation is an economical loss for stainless steelmaking at EAF. By using off-gas analysis, additional information of off-gas composition can be used to monitor: the efficiency of oxygen injection (1), and the decarburization of the melt (2). The latter defines the end of oxygen injection with minimum excess oxygen to avoid excess chromium slagging in EAF. In order to avoid excess chromium slagging, oxygen lancing must be stopped after having reached the critical carbon content in melt.

This paper will present result of off-gas measurement in the EAF, thermodynamic modeling, and strategies for oxygen injection to reach a defined content of carbon and chromium in steel melt

3 p.m.
Development of Alloy Addition Apparatus for the Reduction of Melt Reoxidation in Stainless Steelmaking Ladle at POSCO
D. Kim, POSCO; J. Park, POSCO; K. Lee, POSCO; J. Kim, POSCO
An alloy addition apparatus, ACASIA® (A Challenging Alloy Addition System in Inert Atmosphere), for the prevention of melt reoxidation in a ladle was developed. In order to reduce the reoxidation in stainless steel melt during alloy addition in a 10-ton ladle, a carrier gas with Ar was used without submerging the alloy addition tube. The content of nitrogen pickup was decreased in ferritic stainless steel melt after ladle treatment. In plant tests using ACASIA, not only the oxygen partial pressure between the melt and alloy addition tube, but also the content of nitrogen pickup, were significantly decreased in a 90-ton ferritic stainless steel melt compared to the conventional process.

3:30 p.m.
The Practice and Analysis of Power Consumption in and EAF With Dephosphorized Hot Metal Charging for Melting Stainless Steel
F. Zhu, Baoshan Iron & Steel Co. Ltd.; H. Chi, Baoshan Iron & Steel Co. Ltd.; Y. Hu, Baoshan Iron & Steel Co. Ltd.; X. Jiang, Baoshan Iron & Steel Co. Ltd.; W. Mao, Baoshan Iron & Steel Co. Ltd.
The main factors affecting power consumption in an EAF are theoretically analyzed. It is pointed out that the effective way to reduce power consumption is to optimize the power supply regime, to use oxygen in reason, to optimize the hot metal charging rate and to shorten the tap-to-tap time of the EAF process. At Baosteel Stainless Steel Branch, it is shown that, when the hot metal charging rate reaches 50 percent in an EAF, power consumption will be reduced to 320 kWh/metric ton.

2 p.m.
Repair of a BOF Trunnion Ring and Llamellas Units at Ternium Siderar Plant
S. Lopes, Ternium Siderar; N. Balbis, Ternium Siderar; O. Biga, Ternium Siderar; A. Montaldo, Ternium Siderar
Ternium Siderar is a flat products facility located in San Nicolas, Argentina. This steel plant has operated with three BOF converters of 200 tons each since its start-up in 1973. The converter’s original design was developed by GHH. The vessel’s support is made by 10 lamellas that link the body with a trunnion ring. In October 2005, the No. 2 converter suffered a burn-through in the slagline under the trunnion shaft zone. The damage inflicted to the equipment was very important: a hole of 300 mm diameter in the vessel, a quarter trunnion ring was destroyed and two lamellas were cut off by the steel flow. In view of the fact that Siderar’s staff never saw this level of damage, and in the absence of spare lamellas, Siderar asked for technical assistance from SMS Demag. This paper describes the converter’s reparation process, especially the damaged lamellas. This work also includes the strategy adopted in order to put the converter back in operation in less than 45 days.

2:30 p.m.
BOF Postcombustion Oxygen Lances as a Production and Maintenance Tool
L. Valentas, Berry Metal Co.; J. Jones, Berry Metal Co.; J. Barbus, Berry Metal Co.

3 p.m.
BOF Hood Systems Operations and Maintenance Considerations
M. Nousak, Middough Consulting Inc.; J. Janssen, Middough Consulting Inc.
With the advent of slag splashing, refractory lining life no longer dictates the scheduling of downturns for BOF vessels. Rather, the repair and maintenance of BOF supporting infrastructure has become the basis for extended maintenance downturns. At many BOF shops, hood reliability, repair and maintenance has become the primary consideration in vessel outage planning. Operating practices have also evolved and changed the parameters that were the basis of the original hood design. This paper will discuss typical BOF hood designs and hood cooling systems and how vessel operations may impact hood performance and life. Maintenance practices that prolong hood life will be discussed, as well as how maintenance planning and scheduling can provide more reliable operation during a vessel campaign.

3:30 p.m.
Improving the System Life of Basic Oxygen and Electric Arc Furnace Hoods, Roofs and Side Vents
L. Boyd, Energy Industries of Ohio; V. Sikka, Oak Ridge National Laboratory
The service life of typical carbon steel components in BOF/EAF hood and roof systems adversely impacts overall system performance by requiring continual shutdowns for maintenance. A U.S. Department of Energy project evaluated alternatives to traditional carbon steel construction of these components. Aluminum bronze (AlBr) was identified as an attractive alternative. An AlBr skirt was installed on a BOF at the Lorain, Ohio, facility of Republic Engineered Products in October 2004. This is believed to be the first such application of this material in BOF service. To date, this skirt has required no maintenance for process-related failures and has a projected life of at least five years. This paper will describe the project and review the impressive results obtained.

4 p.m.
Development of a Lance Clamping Device for the BOF at the Rourkela Steel Plant of SAIL
K. Pandey, RDCIS, SAIL; A. Sahu, RDCIS, SAIL; G. Roy, RDCIS, SAIL; T. Dutta, RDCIS, SAIL
An innovative design for a lance clamping device for the basic oxygen furnace (BOF) has been developed and implemented in an integrated steel plant. The compact mechanism of clamping has been designed using taper rollers for guiding the lance. Clamping and declamping of the lance are automatic. Heat-resistant materials have been used for the equipment and the structural components. The design facilitates lance adjustment even in the clamped condition during blowing. On completion of oxygen blow, the lance is automatically declamped and lifted. The newly designed clamping device has facilitated smooth blowing, consistent steel chemistry and improved lining life of the converter.

2 p.m. — Ladle and Secondary Refining — Ladle Metallurgy and Refining - back to top
Room 106
Session Chairs: Chad Clark, Gallatin Steel; Randall Rose, WCI Steel Inc.; Stewart Robinson, Carbide Industries LLC

2 p.m.
Spout and Eye Formation on the Bath Surface in Ladle Metallurgy Practice
K. Krishnapisharody, McMaster University; G. Irons, McMaster University
Experimental data on the spout formation in gas-stirred baths have been used to derive a simple model of unconfined gas-liquid plumes suitable for steel ladle practice. The model predicts the gas and liquid fractions and velocities as simple functions of operating variables. To achieve optimal performance, the use of these correlations as a tool in some design aspects, as well as in devising stable operating practices of industrial ladles, is presented. These include estimates of necessary freeboards to contain splashes and permissible operational limits of gas flowrates to avoid ladle-eye/wall interactions. Furthermore, implications of the dual porous plug practice are discussed.

2:30 p.m.
CFD Analysis of the Behavior of the Slag/Steel Interface in an Argon Gas-stirred Ladle
B. Li, Purdue University Calumet; C. Zhou, Purdue University Calumet; P. Chaubal, Mittal Steel USA; H. Ying, Mittal Steel USA; S. Balajee, Mittal Steel USA
The ladle metallurgy furnace (LMF) is fully responsible for the processes of alloy and temperature homogenization, deoxidation, desulfurization and inclusion removal. Efficiency of desulfurization at the LMF for advanced high-strength steels depends essentially on the interaction between slag and steel created by argon stirring. Computational fluid dynamics (CFD) studies have been conducted to analyze the transient three-phase flows in an argon gas bottom stirring ladle with one and two off-center porous plugs. The behavior of the slag/steel interface — such as deformation, surface renewal velocity and wave formation frequency of slag layer — have been displayed with the effects of operation parameters. The interface area between the steel phase and slag phase is also estimated based on the distribution of slag volume fraction.

3 p.m.
Monitoring Ladle Eye Dynamics Using Multivariate Statistical Methods
J. MacGregor, McMaster University; K. Krishnapisharody, McMaster University; K. Graham, McMaster University; G. Irons, McMaster University
Despite the importance of ladle metallurgy to the overall steelmaking process, very little has been achieved in the way of advanced ladle control. Limited sensors are available to monitor heat progress, and current control methods involve manual procedures. This paper details a vision-based sensor for analyzing ladle eye dynamics in realvtime using a multivariate image analysis (MIA) technique based on principal component analysis (PCA). Predictive capabilities of the models were demonstrated using cold model data over a wide range of operating variables. Application and implications of process control to industrial systems are discussed.

3:30 p.m.
Improvements to the Porous Plug System at SDI Butler
K. Kinsey, Steel Dynamics Inc.; L. Leins, Steel Dynamics Inc.; T. Gephart, Steel Dynamics Inc.; Y. Krotov, Steel Dynamics Inc.
A porous plug system was installed at SDI Butler for steel desulfurization at the LMF stations with the goal of switching over from top lance to the new system to achieve cost savings and better flexibility in steel processing. Over the years, various optimizations have been attempted with mixed success. Recent improvements made to the system enabled high desulfurization rates with the reduction of sulfur levels from 0.030–0.050 to 0.003 percent with the argon flow in the range of 40–70 scfm. Optimizations made to the porous plug system included the installation of a second plug, separation of the funnel/probe delivery and argon delivery system, and the design and installation of a new flow regulation and control system. Some of the challenges included ladle brick erosion and porous plug maintenance.

4 p.m.
Clarification of the Mechanism of Aluminothermic Reduction of MgO
M. Kuwabara, Nagoya University; J. Yang, Nagoya University
The mechanism of aluminothermic reduction of MgO was studied by use of a high-temperature optical microscope (HTOM). The reduction rate was increased with increasing temperature and carrier gas flowrate. It was found that the reduction proceeded after penetration of molten aluminum into the magnesium oxide phase. The penetration began at 1,273 K, and it was accelerated above 1,373 K. The reduction began to take place violently from 1,473 K. In-situ observation of the melting process of aluminum particles showed that the thermal stress could break up the alumina film, through which molten aluminum flew out.

2 p.m. — Continuous Casting — Mold Coatings, Flux Feeding and Oscillation - back to top
Room 116
Session Chairs: Steve Thomas, Gallatin Steel; Richard Besich, Ispat Inland; Brian Thomas, University of Illinois at Urbana-Champaign

2 p.m.
New Developments and the Versatility of High-hardness Nickel-alloy Coatings for Mold Liners
M. Powers, Siemens VAI Services LLC; J. Brower, Siemens VAI Services LLC; K. Rapp, Siemens VAI Services LLC
Enhanced coating technologies play a critical role in improving product quality, cost and the lifetime of continuous caster molds. This paper details current mold liner coating alternatives and the operational limitations of high-hardness broadface and narrowface applications. Benchmark performances will be examinded from conventional, medium-thickness, high-speed, funnel-style (CSP) and beam-blank molds. By altering the basic properties of well-established traditional coatings, tthe versatility and benefits for each coating application are detailed, from providing transitional hardness and varying coating thickness, to altering the hot face geometry, and the homogeneous layering of coating designed to increase reliability. This paper is a follow-up to a 2005 presentation on high-hardness alternative mold coatings and is intended to introduce the audience to refined liner reconditioning and process control mechanisms.

2:30 p.m.
Model of Thermal-Fluid Flow in the Meniscus Region During an Oscillation Cycle
B. Thomas, University of Illinois at Urbana-Champaign; J. Arana, University of Basque Country; J. Barco, Labein Technicia; C. Ojeda, Labein Technicia
In the continuous casting of steel, heat flow, solidification and fluid flow in the liquid slag in the meniscus region during each oscillation cycle control the infiltration of molten slag into the gap between the steel shell and the mold hot face. This also affects the formation of oscillation marks, subsurface hooks and other defects. To improve understanding of these phenomena, a computational model has been developed to quantify the pressure, flow, solidification and thermal oscillations that control slag rim formation, consumption, meniscus shape and the formation of oscillation marks. These results show how surface defects and quality problems in the cast product form, so that solutions can be found.

3:00 p.m.
Influence of Different Oxides on the Behavior of Continuous Casting Fluxes
E. Benavidez, Universidad Tecnologica Nacional; E. Brandaleze, Instituto Argentino de Siderurgia; A. Martin, Instituto Argentino de Siderurgia, J Madias, Instituto Argentino de Siderurgia, C.G. Oliver, Centro Atomico Bariloche
The knowledge of the physical and chemical properties, as well as the behavior of the mold fluxes during melting, is important in order to improve continuous casting operations. Lubrication and control of heat transfer in the mold are the more relevant functions of these materials. Values of physical properties like viscosity and surface tension at melting range temperatures are required, as much as the thermal behavior under process conditions. In this paper, experimental viscosity values are reported in the melting range temperatures and calculated by means of the Riboud model. The evolution of crystalline phases is carried out by the DRX technique during heating and cooling. Finally, the percentage of crystal phases is determined by the inclined plane and SEM techniques. The study includes the influence of different types of oxide additions on the physical properties and also on the development of crystal phases.

3:30 p.m.
Slab Surface Optimization Utilizing Fixed Minimum Negative Strip Time
B. Kozak, SMS Demag Inc.; D. Mojumdar, Essar Steel Ltd.; P. Chaudhari, ESSAR Steel Ltd.
In the first week of May 2006, the No. 3 slab caster at Ess