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2011 January Issue
Full Table of Contents
Process Control & Automation Technologies
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About the Cover
MIG welding for a Jeep® Wrangler frame at Tower International’s Plymouth, Mich., facility. Tower International is a leading integrated global manufacturer of engi-neered structural metal components and assemblies. The company supplies the automotive industry with body-structure stampings, frames and other chassis structures, as well as complex welded assemblies for small and large cars, crossovers, pickups and SUVs.
Photo courtesy of Tower Automotive.
Full magazine available in the Members Only Area |
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Technical Features Table of Contents |
| 37 |
Visualizing the Future in Steel Manufacturing
Chenn Q. Zhou, director, Center for Innovation through Simulation and Visualization, professor and head, Department of Mechanical Engineering, Purdue University Calumet, Hammond Ind. (czhou@purdue.edu)
Virtual environments provide a unique and effective tool for understanding complex physical processes, and thus enable significant improvements quickly and cost-efficiently. Examples of advanced computer simulation and visualization technologies in steel manufacturing are presented.
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| 52 |
Development of Burden Distribution Technology at U. S. Steel Canada’s Hamilton Works ‘E’ Blast Furnace
Yongfu Zhao (top row, left), Jerry C. Capo (top row, right) and Steven J. McKnight (middle row, left), United States Steel Corporation Research & Technology Center, Munhall, Pa. (yzhao@uss.com); John D’Alessio (middle row, center), Kyle J. Ferron (middle row, right) and Peter F. Badgley (bottom row, left), U. S. Steel Canada – Hamilton Works, Hamilton, Ont., Canada (JDAlessio@uss.com); Zhengkai Gao (bottom row, center), University of Science & Technology Beijing, Beijing, China (okgzk@126.com); and Tai Gao (bottom row, right), Shenwang Pioneer Tech. Corp., Beijing, Beijing, China (swcx@swcx.com)
A burden distribution computer simulation model was developed and implemented to design a new charging practice at U. S. Steel Canada’s Hamilton Works. Results included improved furnace stability and productivity, significant savings in coke cost and a significant reduction in CO2 emissions.
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63 |
Easy Access to Everything — Or How the Web Can Bring It All Together
Raymond P. Gauvreau, process automation engineer — metals, TM GE Automation Systems LLC, Salem, Va.
(ray.gauvreau@tmeic-ge.com)
This paper demonstrates how to use existing Web technology to build a unifying environment to manage and maintain modern steel mill equipment, control systems and production over a single plant-wide network.
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70 |
Advancement and Innovation in AC Drives Technology Allow Full Automation of a Large-Diameter Ingot Reversing Rolling Mill
Robert Majka, software engineer, Quad Automation Inc., Toronto, Ont., Canada (rmajka@quadautomation.com)
A blooming mill was challenged with the task of converting 11,000-pound ingots into 4- and 5-inch round billets while maintaining complete control from the main operator pulpit. The solution involves linking each part of the process while increasing hands-free operation.
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77 |
In-Process Measurement of Organic Coating Thickness Using a Full-Spectrum Infrared Sensor
Christopher Burnett (left), technical product manager, Thermo Fisher Scientific, Mount Airy, Md. (christopher.burnett@thermofisher.com); Andreas Quick (center), R&D manager — gauging, and Bernd Harand (right), measurement engineering, Thermo Fisher Scientific, Erlangen, Germany (andreas.quick@thermofisher.com, bernd.harand@thermofisher.com)
Technology that provides reliable measurement of organic coating thickness in real time now exists. This measurement information can be used to control the primer and paint coating heads to improve coating uniformity, reduce paint usage and eliminate scrap/rework.
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82 |
Cast in Time and Quality: Energy Savings Through Integrated Heat Temperature Forecast and Scheduling Model
Heinz-Josef Ponten (left), director — deliveries, and Sebastian Grob, senior consultant, PSI Metals GmbH, Düsseldorf, Germany (hjponten@psi.de, sgrob@psi.de); and Bernd Kleimt (right), head of department — process automation steelmaking, VDEh-Betriebsforschungsinstitut (BFI), Düsseldorf, Germany (bernd.kleimt@bfi.de)
An integrated system of heat schedule prediction and temperature development was designed to control the energy consumption of a heat. The adjustment of the BOF tapping temperature or the energy input in the ladle furnace is optimized according to the current workload.
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166 |
Considerations for the Design of Gas Stirring in Ladle Metallurgy
K. Krishnapisharody and G.A. Irons, Steel Research Centre, McMaster University, Hamilton, Ont., Canada (krishnk@mcmaster.ca, ironsga@mcmaster.ca)
This paper is concerned with the design and operational aspects of gas stirring conditions in ladle metallurgy. A previous mathematical model for the features resulting from steel-slag interactions is validated with available experimental data from industrial steel ladles, and the utility of the model for process analysis is discussed. The treatment is generalized by employing similarity analysis. This methodology is used to correlate design parameters such as freeboard allowance, aspect ratio and placement of gas injectors with permissible gas flowrates. The analysis aids operators in selecting process conditions. It can also be used to make proper comparisons between ladle stations and to benchmark operations. |
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