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November
2005 |
Mittal
Steel USA – Sparrows Point: A Dedicated Producer of
Quality, Flat Rolled Steels
Norman L. Samways,
Ph.D., technical consultant, Pittsburgh, Pa.
Investments
of more than $1 billion over the last 10 years have made Sparrows
Point highly competitive. Recent facilities include a $300-million
cold mill complex and a caster rebuild to produce wide slabs
for plates. |
Productivity
Improvement at Stelco Hamilton With Limited Hot Metal
Robert Cameron, retired,
George Cuthill, information systems analyst, Ian Deeks, manager
— primary and steelmaking technology, and Rick Minion,
retired, Stelco Hamilton, Hamilton, Ont., Canada (george.cuthill@stelco.ca,
ian.deeks@stelco.ca)
In
the last few years, Stelco Hamilton has shifted from a hot
metal–rich operation to being hot metal poor. This article
describes how the steel-to-hot-metal ratio has been continuously
improved in order to maximize steelmaking productivity.
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Productivity
and Cost Improvements Using a Real-time Slag Conditioning Practice
at U. S. Steel Gary Works
G.A. Meszaros (left),
research specialist, U. S. Steel Research & Technology Center,
Monroeville, Pa. (gmeszaros@uss.com); G.E. Goldsmith, process
quality manager — steel producing, I.M. Nickerson, quality
engineer — No. 2 caster, and M.J. McCoy, technical coordinator
— ironmaking, U. S. Steel Gary Works, Gary, Ind. (ggoldsmith@uss.com,
inickerson@uss.com, mmccoy@uss.com)
A
real-time ladle slag conditioning practice based on a split
addition before and after degassing of ultralow-carbon grades
was implemented to improve control of slag oxidation potential.
A method to qualify suppliers based on overall slag conditioning
cost and emission performance is also reviewed. |
Optimum
Vessel Tapping
Frank L. Kemeny, president,
David I. Walker, director — research and development,
and Jeremy A.T. Jones, director — engineering and operations,
Nupro Corp., Lewiston, N.Y. (fkemeny@nuprocorp.com, dwalker@nuprocorp.com,
jjones@nuprocorp.com)
Several tools have been developed and integrated to provide
a guidance system for optimum vessel tapping. This guidance
system, in turn, has created the opportunity for improved yield,
reduced skimming operations, heat-specific slag conditioning
and therefore reduced costs. |
The
Presence of Titanium in Hot Metal and Its Effects on Desulfurization
Stuart Street, senior
metallurgist, SeverStal North America Inc., Dearborn, Mich.
(sstreet@severstalna.com); Randall P. Stone, senior product
applications manager, Heraeus Electro-Nite Co., Langhorne, Pa.
(rstone@electro-nite.com); and Peter J. Koros, principal, Koros
Associates Inc., Pittsburgh, Pa. (koros.associates@att.net)
The presence of titanium in hot metal has traditionally been
a problem for steelmakers for several reasons. This issue, and
related effects on testing the hot metal, are examined in detail
with reference to the literature and plant and laboratory experience. |
Sharing
Hot Metal at Mittal Steel USA
Jack Finlayson, division
manager — iron producing, Mittal Steel USA – Indiana
Harbor, East Chicago, Ind. (jack.finlayson@mittalsteel.com);
Robert Jason, practice engineer, Mittal Steel USA –
Cleveland, Cleveland, Ohio (robert.jason@mittalsteel.com);
Dale E. Heinz, division manager — primary operations,
and Barry Felton, IPO process and technology manager, Mittal
Steel USA – Burns Harbor, Burns Harbor, Ind. (dale.heinz@mittalsteel.com,
bfelton@intlsteel.com); and Gary Norgren, division manager
— primary operations, Mittal Steel USA – Riverdale,
Riverdale, Ill. (gary.norgren@mittalsteel.com)
Mittal
Steel USA operates numerous integrated steel mills throughout
North America. The challenges associated with coordinating
iron and hot metal movement among various plants are described. |
Economic
Optimization of BOF Raw Materials Consumption in a Volatile
Scrap Market and With Limited Hot Metal Availability
Tom Russo, senior manager
— primary operations, Mittal Steel USA – Sparrows
Point, Sparrows Point, Md. (tom.russo@mittalsteel.com); Tim
Miller, research supervisor (retired), Jack Repasch, research
consultant, and Naren Sheth, senior research engineer, Mittal
Steel R&D, Bethlehem, Pa.; and Mark Trapp, plant manager,
U.S. Pipe, Burlington, N.J.
Increasing demand for product, limited hot metal capacity and
high scrap prices present a dilemma for BOF steelmakers. A number
of steelmaking tools have been developed by Mittal Steel USA
to manage the ratio of hot metal to scrap and total production
of a BOF under such conditions. |
Replacement
of a BOF Suspension Lamella Unit at U. S. Steel Edgar Thomson
Plant
W. Todd Zeisler, senior
engineer, and J. Kevin Cotchen, senior process engineer —
steelmaking, SMS Demag Inc., Pittsburgh Pa. (todd.zeisler@sms-demag.net,
kevin.cotchen@sms-demag.us); Fred W. Hemingway, project manager,
and William J. Pruss Jr., plant engineering manager, U. S.
Steel Edgar Thomson Plant, Braddock, Pa. (fhemingway@uss.com,
bpruss@uss.com)
In
2004, a burn-through in a BOF vessel at U. S. Steel Edgar
Thomson Works completely severed a lamella and damaged an
adjacent unit. The repair process, including the initial assessment
of damage, and the
ensuing operational strategy are described. |
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