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November
2006
Vol. 3, No. 10
Oxygen Steelmaking Technologies
About the Cover
The 240-metric-ton RH-TOP unit (single vessel) at EKO Stahl, Eisenhuettenstadt (Arcelor Group) with hydraulic ladle lifting.
Photograph courtesy of SMS Mevac GmbH.
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Merger Mania and Steel Demand Euphoria: A Review of the IISI 40th Annual conference, Buenos Aires, Argentina |
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31
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Improvements in the BOF Process at Algoma Steel Inc.
Sid Hilderley, superintendent steelmaking and refining, Lorenzo Greco, FLS charge and melt steelmaking, Egan Wong, senior process specialist, and Kamal Ugahadpaga, quality engineering specialist, Algoma Steel Inc. (shilderl@algoma.com, ewong@algoma.com); and Jorge O. Petroni (pictured), technical sales director, Ultracore Corp. (formerly process consultant, Exiros Tenaris, jpetroni@ultracore.com)
In 2004, Algoma Steel initiated a project to reduce the oxidation levels in its BOF. The results were major aluminum savings, improved steel yield, improved
turndown performance and better steel quality for downstream steel refining. The process enhancements that facilitated the lower oxidation levels are discussed. |
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36
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Optimizing BOF Slag Control Through the Application of Refractory Darts
William S. Howanski (left), division process manager, Mittal Steel USA – Sparrows Point, Sparrows Point, Md. (bill.howanski@mittalsteel.com); Tom Kalep, applications manager, MonoCeramics Inc., Benton Harbor, Mich. (tkalep1@aol.com); and Tom Swift (right), president, SPEC Inc., Baltimore, Md. (steelprocess@aol.com)
This paper describes the refractory dart slag control program employed at Mittal Steel USA – Sparrows Point. The benefits of various alternative dart head designs are identified, and the use of infrared camera technology is shown to have a complementary effect. |
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45
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The Utilization of
High-phosphorous Hot Metal in BOF Steelmaking
Bernard O. Chukwulebe (left), senior research engineer, Mittal Steel USA R&D Center, East Chicago. Ind. (bernard.chukwulebe@mittalsteel.com); Anatoliy N. Klimushkin (center), director, Central Plant Laboratory, and Grigoriy V. Kuznetsov (right), deputy manager — steelmaking, Central Plant Laboratory, Mittal Steel Temirtau, Temirtau, Kazakhstan (anatoliy.klimushkin@mittalsteel.com, grigoriy.kuznetsov@mittalsteel.com)
This article describes the fluxing practices, results obtained and challenges faced in the effort to refine high-phosphorous hot metal in the BOF vessel at Mittal Steel Temirtau. |
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54
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BOF Shell Barrel Growth Simulation
En-Sheng Chen (pictured), consultant, Thermomechanical Designs, Round Rock, Texas (thermomech@yahoo.com); Joseph B. Boyce, plant engineer, Jerry Tucker, BOF maintenance manager, and Kelan Nowak, project engineer, Mittal Steel USA – Burns Harbor, Burns Harbor, Ind. (joseph.boyce@mittalsteel.com, gerald.tucker@mittalsteel.com, kelan.nowak@mittalsteel.com)
When the No. 3 BOF vessel at Mittal Steel Burns Harbor experienced noticeable shell growth in its
barrel section, the size of the air gap between the
BOF shell and its trunnion ring was reduced. A methodology to simulate and predict the shell growth was thus developed to help determine the time frame for the shell and trunnion ring replacement or repair. |
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63
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Condition Monitoring Using Acoustic Emission Monitoring: The Development of Aquilla AE PRO, a Fixed System
Ian Taylor (top left) and Kevin Peacock (top right), Corus Northern Engineering Services, Teesside, U.K. (ian.taylor@corusgroup.com, kevin.peacock@corusgroup.com); Paul Kitson (bottom left), knowledge group leader, and Winfield Stewart (bottom right), senior research engineer, Corus Research Development & Technology, Grangetown, U.K. (paul.kitson@corusgroup.com, winfield.stewart@
corusgroup.com)
This article tracks condition monitoring by Corus over the last two decades, culminating in the birth of Aquilla AE Pro and the savings realized by its use at Scunthorpe and other locations. |
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72
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Mn Control at KOBM Steelmaking
Dongsheng Liao (left), senior technology coordinator — steelmaking technology, Stanley Sun (center), principal researcher, and Neal Pyke (right), technology coordinator — steelmaking technology, Dofasco Inc., Hamilton, Ont., Canada (liao_dongsheng@dofasco.ca, stanley_sun@dofasco.ca, neal_pyke@dofasco.ca)
Manganese control at the KOBM can be challenging for various grades of steel, especially IF grades. Dofasco has developed a new practice to effectively control manganese during KOBM steelmaking, which has led to a significant reduction in the frequency of manganese off-analysis. |
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103
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Steel Strips — The Long and
Winding Road
Roderick I.L. Guthrie, MacDonald professor and director, McGill Metals Processing Centre, McGill University, Montreal, Canada (rod@mmpc.mcgill.ca)
Sheet steel products are ubiquitous, enjoying a dominant share of the appliance and transportation sectors. Apart from unmatched strength/weight ratios, another reason for the dominance of steel over plastic and aluminum sheet has been the fiercely competitive nature of the steel industry itself, and the many players involved. For a steelmaker, high steel yields and high productivity are prerequisites to survival within the global marketplace. Over the years, the methods of steel sheet production have undergone major transformations, as the industry moved away from rolling ingots produced by static castings, to rolling slabs produced by continuous casting, then to thin slabs by continuous casting, and most recently to the direct (continuous) casting of thin strips. To match the production capabilities of a conventional slab caster, producing slabs at 1.4 m/minute and 200 mm thick, a net-shape caster producing 1-mm-thick strip of an equivalent width would have to run 200 times faster, or 4.7 m/second. To date, casting velocities of about 2 m/second, or 120 m/minute, are being reached! |
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