in the North American Iron and Steel Industry
And Reported Capital Expenditures
Joann Cantrell, publications
manager/editor, Iron &Steel Technology (email@example.com)
expansions and reported capital expenditures for 2004 and 2005
are presented in alphabetical order by company.
Compliant or Safety Leadership?
David L. Witschorke,
safety coordinator — meltshop, TXI Chaparral Steel, Midlothian,
a culture that places as much importance on safety practices
as steel quality and budgets is the key to moving a safety
program to a new level. This article discusses why safety
practices should reflect this commitment, and why OSHA standards
should be the minimum.
of Health and Safety Practices and Initiatives With Equipment and Process Improvements at Dofasco’s
Marty Smith, health
and safety field coordinator — No. 2 blast furnace rebuild
and slag processing, Dusanka Foebel, health and safety coordinator,
Rick Chaykowski, coach — No. 4 blast furnace, Bob Prociuk,
coach — No. 3 blast furnace, and Chris Bielec, coach
— hot rail, Dofasco Inc., Hamilton, Ont., Canada (firstname.lastname@example.org)
furnace operating practices, combined with equipment development
and the implementation of safety-related initiatives, have
reduced the severity and number of injuries associated with
blast furnace operation. This integration is bringing Dofasco
closer to an accident-free workplace.
Application of Low-NOx Technology to Reheating Furnaces —
Environmental and Efficiency Advantages
David G. Schalles and
John C. Dormire, Bloom Engineering Co. Inc., Pittsburgh, Pa.
article discusses the latest techniques to reduce NOx emissions.
Several unique burner configurations are presented, along
with a review of various furnace configurations. Fuel efficiency
and CO emission considerations are also discussed.
Hazard Risk Analysis and NFPA 70E
Ron Widup, executive
vice president and general manager, Shermco Industries Inc.,
Irving, Texas (email@example.com)
article presents updated information on the 2004 edition of
NFPA 70E, explains various methods for determining incident
energy levels at electrical equipment and offers information
for determining the proper level of personal protective equipment.
The latest developments in arc-blast research are also discussed.
Slag Granulation System — Environmental Process Control
Patrick Leyser and Christian
Cortina, Paul Wurth SA, Luxembourg (firstname.lastname@example.org)
designs of plants for granulating with hot or cold water are
discussed, together with the resulting improvements in the
granulation process, sand product and emissions.
Application of Broken Bag Detector Technology for Compliance,
Operation and Maintenance Under the Steelmaking EAF NSPS and
the Iron and Steel Foundry NESHAP
Joseph C. Wesselman (left),
corporate environmental director, IPSCO Enterprises Inc., Lisle,
Ill.; and Charles W. Askins (right), chairman and president,
AG Environmental Services Inc., Farmington, N.Y. (email@example.com,
discusses the practical installation of broken bag detection
technology for cost-effective compliance with the latest emission
standards. A review of the current status of these rules and
their application to EAFs and melting furnaces is provided.
Shape Simulation Software for the Continuous Cold Rolling Process
Liu, Jalal Biglou and Jian Fan, Quad Engineering Inc., Toronto,
Ont., Canada; and J.J. Fitzpatrick and Brian D. Nelson, Dofasco
Inc., Hamilton, Ont. Canada
Software to simulate strip shape in a fully continuous cold
rolling process is being developed through a joint effort
of Quad Engineering Inc. and Dofasco Inc. The first phase
of the model development is completed and is described in
this paper. In this phase, three underlying models were developed.
The first model is a strain rate–based finite difference
three-dimensional (3-D) strip deformation model, in which
the 3-D strain rate field and stress field are determined.
Based on this, the lateral spread and roll force transverse
distribution are calculated by integrating the strain rate
and stress. The second model calculates the roll stack deflection
and work roll 3-D flattening. This model also considers the
inter-roll contact length variation and the condition of kiss
rolling. The strip 3-D deformation model and roll deformation
model were coupled together using an iterative procedure.
The third model is an analytical model to simulate the stress
unloading process after the roll bite and to determine the
tension distribution between stands and after the last stand.
Shapemeter readings are predicted by merging the above three
models. The model is tuned and verified using the shape data
collected from Dofasco’s CPCM (coupled pickling line
and cold mill). A graphical user interface was developed to
integrate the models into a user-friendly software package.
For the next phase, the following models are being developed:
an empirical roll surface roughness loss model, a 3-D roll
thermal profile model, a 3-D stress unloading and a strip
buckling model. These models will be integrated into the existing
program to develop a comprehensive cold rolling simulation
software package capable of shape and flatness prediction
for a fully continuous cold rolling mill.
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