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February
2008
Vol. 5, No. 2
Electric Steelmaking Technologies
About the Cover
CMC Steel Texas’ Don Miller (left) and Don Skloss (right, facing) at the 120-short-ton AC EAF. In 2007, the furnace was completely rebuilt in 17 days, including the following new equipment: foundation piers, tilt platform, upper and lower shells, and gantry roof lift design. Since the start-up last February, the EAF has broken records for production and efficiency in four consecutive months. In the last quarter of 2007, the EAF melted in excess of a quarter million tons, an all-time record for CMC Steel Texas. The rebuilt furnace was engineered, fabricated and installed by Superior Machine Co. Photo courtesy of CMC Steel Texas (photographer: Lynn Glenwinkle).
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27
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Timken Faircrest Radiation — It Could Happen To You
Thomas G. Webb (pictured), process improvement specialist — steelmaking, C. Andrew Black, manager — technical services — alloy steel, Kenneth J. Kushner, manager — health and safety, and Bruce E. Weisburn, senior reliability analyst, The Timken Co., Canton, Ohio (tom.webb@timken.com, andrew.black@timken.com, ken.kushner@timken.com, bruce.weisburn@timken.com); and Harriet G. Dutka, CMC Steel South Carolina, Cayce, S.C. (formerly plant manager of Timken Faircrest) (harriet.dutka@cmc.com)
When the Timken Faircrest steel plant melted a Cs-137 radioactive source in 2004, a monumental cleanup took place. A review of the events associated with the incident and the impact on the company’s radiation detection program are presented. |
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32
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EAF Energy and Material Balance Modeling
Sunday Abraham (left) and Shaojie Chen (right), IPSCO Inc., Regina, Sask., Canada (sabraham@ipsco.com, schen@ipsco.com)
This paper outlines a study performed at IPSCO to develop an energy efficiency model for the EAF scrap melting and refining processes. The model was further developed to include on-line control of key steps, thereby demonstrating the potential for significant cost savings in EAF steelmaking. |
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43
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Maintenance at Minimills — Effective, but Also Efficient?
Martin Fleischer (top left), managing director, Johannes Greinacher (top right), managing director, Badische Stahl-Engineering GmbH, Kehl, Germany (martin.fleischer@bse-kehl.de, johannes.greinacher@bse-kehl.de); Michel Hamy (bottom left), managing director, and Ralph Ridder (bottom right), managing director, Badische Stahlwerke GmbH, Kehl, Germany (michel.hamy@bsw-kehl.de, ralph.ridder@bsw-kehl.de)
This paper presents key results of the Maintenance Cost Management project carried out by Badische Stahl-Engineering, which shows that maintenance can be improved without losing efficiency or falling into a productivity trap. |
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49
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Preventing EAF Transformer Failures
Antonio Mariscal (left) and Fernando Martinez (right), AMIGE, Monterrey, México (antonio.mariscal@amige.com, fernando.martinez@amige.com)
This paper presents a methodology developed by AMIGE to identify potential failure conditions in EAF transformers and recommended practices on how to prevent them. Practical cases and results are discussed. |
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57
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Improving Liquid Steel Production at Rocky Mountain Steel
by Installing a High-capacity Electric Arc Furnace With SIEMENS VAI ULTIMATE EAF Technology
Dave Ellis (left), manager — melting and casting, and Ja’net Ogle (right), process metallurgist — meltshop, Rocky Mountain Steel Mills, Pueblo, Colo. (ellisd@rmsm.com); John Chakany and Thomas Daum, SIEMENS Energy & Automation, Metals Technologies Division, Canonsburg, Pa. (daum.thomas@siemens.com); and Markus Abel, SIEMENS VAI, Willstaett-Legelshurst, Germany (markus.abel@siemens.com)
Rocky Mountain Steel began to optimize its liquid steel production by using one high-capacity EAF in 2004. Highlights of the project, such as schedule, design, manufacturing, installation and start-up, are presented. |
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70
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Improving the System Life of Basic Oxygen and Electric Arc Furnace Hoods, Roofs and Side Vents
Lawrence C. Boyd Jr. (left), director — core programs, Energy Industries of Ohio, Independence, Ohio (boyd@energyinohio.com), and Vinod K. Sikka (right), Oak Ridge National Laboratory, Oak Ridge, Tenn. (sikkavk@ornl.gov)
The service life of typical carbon steel components in BOF/EAF hood and roof systems adversely impacts overall system performance by requiring continual maintenance shutdowns. The use of alternative AlBr components can lead to less maintenance and greatly increased service life. |
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