Continuous Casting Technology Committee Activities
The CCTC met 17 October 2013, Memphis, Tenn., USA
The 9th annual Continuous Casting — A Practical Training Seminar was reviewed. The expansion to two-and-a-half days was successful, with 120 attendees. The panel discussion was a popular feature. Next year’s training seminar will be held on 20–23 October 2014 in Indianapolis, Ind., USA.
Seven CCTC sessions are scheduled for AISTech 2014, with parallel sessions on Tuesday morning and Wednesday afternoon. Session topics were selected, and CCTC members were encouraged to contact Ron O’Malley if interested in becoming a session chair.
Rick Besich discussed the 2014 Continuous Casting Best Paper Award and noted that the award subcommittee had selected “Stopper Rod Dithering Trials at ArcelorMittal Dofasco No. 1 Continuous Caster,” by Stephen Daeyoung Chung, Joydeep Sengupta and Mehrnoosh Afnan. This award will be presented at AISTech 2014 during the CCTC meeting.
Presentations were given by Bill Schlichting, U. S. Steel – Gary Works; Rudolf Moravec, ArcelorMittal Indiana Harbor; David Wise, Evertz Technology; Jeff Brower, Siemens Industry Inc.; and Chad Donovan, SMS Millcraft.
The CCTC met in New Orleans, La., on 20–21 February. The committee was given a tour of ArcelorMittal La Place steelmaking operations on Thursday morning, 21 February. The 2013 Continuous Casting Best Paper Award will be presented to Nick Gregurich, Garrett Flick, Rudolf Moravec and Kenneth Blazek for their paper entitled, “In-Depth Analysis of Continuous Caster Machine Behavior During Casting With Different Roll Gap Taper Profiles,” during the CCTC meeting on Monday, 6 May at AISTech 2013 in Pittsburgh, Pa. The CCTC officer elections for the 2013–2015 term are: Ron O’Malley, chair; Richard Besich, vice chair; Shahrooz Nafisi, papers chair; Rudolf Moravec, APB Slab Caster chair; Ian Deeks, APB Shape Caster chair; Jeff Brower, education chair; and Dewey Humes, Eric Rosenow and Ian Bakshi, caster roundup subcommittee. The AIST Association-Level Award candidates were discussed, along with the award guidelines and requirements. CCTC members can contact Ron O’Malley to nominate an individual for consideration. Jeff Brower, education chair, discussed the possibility of extending this year’s training seminar to two and one-half days. The 2013 Continuous Casting Training Seminar program was scheduled to be finalized in mid-March. This year’s caster training seminar will be held on 14–17 October 2013 in Memphis, Tenn., with Nucor Steel–Memphis as the host plant. Two presentations were given during the CCTC meeting: “Dynamic Soft Reduction on Bloom,” by Philip Ponikvar, Siemens; and “Liquid Core Detection Method,” by Bryan Petrus, University of Illinois.
The CCTC met on 16 October 2012 in Pittsburgh, Pa., before the 2012 Continuous Casting — A Practical Training Seminar. CCTC producer members reviewed/approved slab caster and shape caster parameter definitions for the AIST Process Benchmarker (APB) on 15 October. The continuous casting training seminar was well attended, with 122 participants. Richard Besich, CCTC papers chair, presented abstracts for AISTech 2013, from which the CCTC developed six session topic themes: New Technology, Quality — Internal and Surface, Mold Level Control — FEA, Computer Models, Bar/Bloom, and Caster Refractory.
Ron O’Malley announced the Continuous Casting Best Paper Award winner: “In-Depth Analysis of Continuous Caster Machine Behavior During Casting With Different Roll Gap Taper Profiles,” by Nicholas Gregurich, Garrett Flick, Rudolf Moravec and Kenneth Blazek, ArcelorMittal Global Research and Development. This award will be presented at the CCTC meeting at AISTech 2013 in Pittsburgh. The next CCTC meeting will be held on 20–21 February 2013, with a tour of ArcelorMittal LaPlace steelmaking operations.
The Continuous Casting Technology Committee (CCTC) met during AISTech 2012 on Monday, 7 May. The CCTC 2012–2013 officer elections were completed with the following results: Paul Laskey, chair; Ron O’Malley, vice chair; Richard Besich, papers chair; Rudolf Moravec, APB chair; Jeff Brower and Bill Schlichting, education co-chairs; Eric Rosenow and Ian Bakshi, roundup co-chairs. The 2012 Best Paper Continuous Casting Award was presented to Pallava Kaushik, Hongbin Yin, Howard Pielet and Michael Lowry for their paper entitled, “How to Evaluate a Process for Clean Steelmaking and Quality Control.” Brower provided an update on the 2012 Continuous Casting — A Practical Seminar program, which is scheduled for 16–18 October 2012 in Pittsburgh, Pa. United States Steel Corporation – Edgar Thompson Works will be the host plant.
The AIST Process Benchmarker will develop two separate benchmarking modules for continuous casting. Moravec is developing the parameters for the Slab Caster module; O’Malley and Ian Deeks are APB co-chairs for developing the Shape Caster module. Both modules should be completed by August 2012. The North American Continuous Caster Roundup will be expanded to include South America to follow the direction of both the Electric Steelmaking Technology Committee and the Oxygen Steelmaking Technology Committee. Schlichting, CCTC past chair, was elected to serve a two-year term as the AIST Division IV director, succeeding Darrell Sturgill, CCTC past chair. An APB Module Producer-Only meeting will be held from 2 to 4 p.m. on Monday, 15 October. On Tuesday, 16 October, the CCTC will meet from 8 a.m. to 4 p.m. prior to registration at Continuous Casting — A Practical Training Seminar in Pittsburgh, Pa.
The Continuous Casting Technology Committee (CCTC) and the Sensors Subcommittee met in Columbia, S.C., on 21–22 February 2012. The CCTC AIST Process Benchmarker (APB) development meeting was held on Tuesday night, 21 February, with Rudolf Moravec, CCTC APB chair, discussing the possible benchmarking parameters that could be established. The APB reporting spreadsheet was discussed and key variables for benchmarking will be implemented. The CCTC met on Wednesday, 22 February, for further discussion on specific parameter guidelines for the variety of casting processes. The meeting began with a review of the 2011 Steel Industry Fatalities report, followed by a safety roundtable discussion. Ron O’Malley, CCTC papers chair, presented the AISTech 2012 paper sessions. A total of eight sessions for casting have been scheduled for AISTech 2012. O’Malley asked the session chairs to contact authors in their session for assistance. Jeff Brower, CCTC education chair, updated the committee on this year’s Continuous Casting — A Practical Training Seminar, which will be held on 16–18 October in Pittsburgh, Pa. The final program details are being completed.
The 2012 Continuous Casting Award for Best Paper will be given to Pallava Kaushik, Hongbin Yin, Howard Pielet and Michael Lowry for their paper, “How to Evaluate a Process for Clean Steelmaking and Quality Control,” at the CCTC meeting during AISTech on Monday, 7 May in Atlanta, Ga. Ron O’Malley was recognized for being this year’s recipient of the 2012 AIST Benjamin F. Fairless Award (AIME) and the 2012 AIST Distinguished Member and Fellow Award. Both awards will be presented to him at this year’s President’s Award Breakfast on Tuesday, 8 May at AISTech 2012. CCTC officer elections for 2012–2013 will include Paul Laskey as chair, Ron O’Malley as vice chair, Richard Besich as papers chair, Rudolf Moravec as APB chair and Jeff Brower as education chair. Bill Schlichting will succeed Darrell Sturgill as the AIST Division IV director after AISTech 2012. The following presenters concluded the meeting: Bill Porter of VGH/Petronix Sensors, “Roll Gap Checker, Met Length Measurement”; Tom Piccone of U. S. Steel Research, “Upgrade of Mold Thermocouple System at Edgar Thompson Slab Caster”; Rudolf Moravec of ArcelorMittal, “Sensors for a Better Understanding of Steelmaking/Casting Processes”; Matt Hankinson, “MTS Linear Position Sensors”; and Bill Smith, “LAP Laser Projection and Non-Contact Measurement.” The next CCTC meeting will be at AISTech 2012 on Monday, 7 May at noon.
The Continuous Casting Technology Committee (CCTC) met in Merrillville, Ind., on 10 October 2011. There were 40 CCTC members in attendance. Review of the 2011 Steel Industry Fatalities Report was followed by a safety roundtable discussion. Roundup co-chairs Eric Rosenow and Ian Bakshi reviewed possible revisions for the 2012 North American Continuous Caster Roundup. Committee participation was solicited to further develop the roundup statistics before the 1 April 2012 deadline. The AIST Process Benchmarker (APB) was presented to the CCTC. The committee nominated Rudolf Moravec, ArcelorMittal USA Research, to serve as the CCTC benchmarking chair. Bill Schlichting, U. S. Steel – Gary Works, and Ron O’Malley, Nucor Steel–Decatur, will assist Moravec in developing the benchmarking statistical guidelines. The caster benchmarking format will be presented at the next CCTC meeting in February 2012. Ron O’Malley, CCTC papers chair, presented AISTech 2012 paper sessions, which include three separate sessions, two joint committee sessions and three parallel sessions during the conference. Caster-related paper abstracts continue to be submitted and will be considered by the CCTC.
Six presentations were given, involving caster maintenance issues:
"Benefits of In-Chain Caster Measurement” by Paul Laskey.
"Caster Roll Vibration Measurement” by Bill Porter.
“Machine Taper Change and Strand Measurement” by Rudolf Moravec.
"Improvements in a Slab Caster Instrumented Mold” by Sebastian Capote
"Operational Machine Loading, Wear and Tear: Causes, Effects and
Mitigation” by Bruce Kozak.
"Caster Alignment Issues” by Michael Falk.
The next CCTC meeting will be held on 22–23 February 2012 in Columbia, S.C. This will be a joint committee meeting with the Sensors Subcommittee. The meeting topic will be “Caster Sensor Technology.”
The Continuous Casting Technology Committee (CCTC) met on 2 May 2011 in Indianapolis, Ind. There were 64 members in attendance with current CCTC membership at 132 members. The committee reviewed the 11 fatalities so far in 2011 and followed this with a safety roundtable discussion. The CCTC officer elections were confirmed for 2011–2012: Bill Schlichting, chair; Paul Laskey, vice chair; Ron O’Malley, papers chair; Rudolf Moravec, membership chair; Jeff Brower and Bill Schlichting, education co-chairs; and Eric Rosenow and Ian Bakshi, roundup co-chairs. The 2011 Continuous Casting Best Paper Award was presented to Bruce Forman, Mehmet Yavuz, Tomas Tsai and Jeff Thacker for their paper, “Optimization of a Submerged Entry Nozzle Design to Reduce Non-Metallic Inclusions in Line Pipe Steel.” The CCTC recognized Dave Beck of ChemTreat Inc. for his efforts with the Caster Roundup as he now enjoys retirement. Pierre Dauby presented Best Paper selection guidelines for this year’s papers. Steve Swoope and Bill Schlichting appointed the Best Paper selection committee: Ron O’Malley, Rudolf Moravec, Jack Young, Pierre Dauby and Bill Schlichting. Schlichting thanked Swoope for his efforts this past year as the committee chair. The next CCTC meeting will be on Tuesday, 11 October before the Casting Training Seminar registration in Merrillville, Ind.
The Continuous Casting Technology Committee (CCTC) and the Safety & Health Technology Committee (SHTC) met jointly on 22–24 Feb in Jacksonville, Fla. The current CCTC membership stands at 129 members, and the current SHTC membership is at 47 members. A review of the 2010 and 2011 Steel Industry Fatalities Statistics started the meeting. Butch Collins, SHTC Roundup chair, discussed the origin of the Steel Industry Fatalities Statistics form, which is now used by most Technology Committees to start their safety discussions. Chad McClimans, SHTC education chair, updated this report dating back to 2006. A safety roundtable discussion followed, with emphasis on argon ladle hookups and possible automatic practices. Steve Swoope, CCTC chair announced that the AISTech 2011 Continuous Casting Award for Best Paper will go to Bruce Forman, Mehmet Yavuz, Tomas Tsai and Jeff Thacker for their paper entitled, “Optimization of a Submerged Entry Nozzle Design to Reduce Non-Metallic Inclusions in Line Pipe Steel.” This award will be presented at the CCTC meeting at AISTech 2011 on Monday, 2 May at noon. The AISTech 2012 Call for Papers was reviewed and approved by both committees. Bill Schlichting, CCTC papers chair, discussed the paper sessions scheduled for AISTech 2011. Session chairs were reminded to contact their session authors for support.
Dave Beck, Caster Roundup chair, presented the 2011 Caster Roundup, which was converted to metric values where applicable. The CCTC recognized Mr. Beck’s efforts the past three years in updating the Caster Roundup. The CCTC thanked Mr. Beck for his years of committee dedication and wished him good fortune in his retirement. The committee selected Eric Rosenow and Ian Bakshi as the Caster Roundup co-chairs. The AIST Process Benchmarking was presented to explain the committee’s options available for future benchmarking. AIST’s Ironmaking Technology Committee will lead the benchmarking program so that other Technology Committees will have a framework to follow. The CCTC Producer-Only Subcommittee will be chaired by Bill Schlichting. This subcommittee will have a conference call before AISTech 2011 to develop Key Performance Indicators to make benchmarking statistics viable for participants. The SHTC will work on developing an active AIST website to further communicate safety performances and innovations. An update on this benchmarking program will be given to Technology Committees at AISTech 2011. Bill Rider, GerdauAmeristeel Jacksonville meltshop superintendent, provided a joint committee tour of the plant, followed by a question-and-answer session.
The Continuous Casting Technology Committee (CCTC) met on Monday, 3 May during AISTech 2010, with 56 members in attendance. Current CCTC membership is at 113 members. Bill Schlichting reviewed the 2010 Steel Industry Fatalities Statistics, discussing the eight recorded fatalities so far this year. A safety round table discussion followed with plant safety incidents, near misses, and corrective actions taken that improved the overall plant safety performance. Election of the CCTC officers for 2010–2011 term resulted in the following: Steve Swoope, chair; Ray Miller, vice chair; Bill Schlichting, papers chair; Paul Laskey, membership chair; Jeff Brower, education chair; and Dave Beck, Caster Roundup chair. Darrell Sturgill was recognized as the new AIST Technology Division IV board of directors representative for the 2010–2012 term. The CCTC thanked Ron O’Malley as the past Division IV representative. The 2010 Best Paper Award was presented to Ron Kostyo, Marc Burty, James Bradley, Didier Dubois and Milan Alavanja for their paper, “Sliver Reduction at ArcelorMittal Burns Harbor Steel Producing: An Operational Perspective.” Jeff Brower updated the committee on this year’s Caster Training Seminar, to be held in Birmingham, Ala., on 12–14 Oct 2010. A tour of U. S. Steel Fairfield will conclude this two-day, single-track training seminar. Dave Beck presented the 2010 North American Caster Roundup to the CCTC for final review. The Caster Roundup was published in the July issue of Iron & Steel Technology. The Refractory Systems Technology Committee (RSTC) asked the CCTC to complete a survey. Further clarification will be needed, and an RSTC member will be asked to make a presentation at the next CCTC meeting. Two confirmed presentations for the next CCTC meeting will involve electromagnetic stirring: Len Beitelman will discuss its relevance to billet/bloom casting, and Pierre H. Dauby will discuss its relevance to slab casting. The next CCTC meeting will be on Tuesday, 12 Oct in Birmingham, Ala., before the Caster Training Seminar registration. Bill Schlichting was presented the CCTC chair plaque for his continued participation with the Continuous Casting Technology Committee.
The Continuous Casting Technology Commttee (CCTC) met in Decatur, Ala., with 31 of its members and two members from the Metallurgy — Steelmaking & Casting Technology Committee (MSCTC) in attendance. The Nucor Steel–Decatur OSHA VPP Star status safety program was outlined by Tim Reeves and George Stephenson. The CCTC reviewed the Safety & Health Technology Committee’s Steel Industry Fatality Statistics for 2009 and 2010 YTD. The SHTC provided two 3-year graphs (2006–2009) that displayed the reason and type of steel industry fatalities. The AISTech 2009 Best Paper Award will be given to ArcelorMittal Burns Harbor for thei paper, “Sliver Reduction at ArcelorMittal Burns Harbor: An Operation Perspective.” There is a total of six casting sessions at AISTech 2010, four of which will be held jointly with the MSCTC. The Continuous Casting Training Seminar will have a two-day single-session format and will be held in Birmingham, Ala., on 12–14 Oct 2010. The CCTC officer rotation for 2010–2011 will be as follows: Steve Swoope, chair; Ray Miller, vice chair; Bill Schlichting, papers chair; Paul Laskey, membership chair; Dave Beck, Caster Roundup chair; and Jeff Brower, education chair. Darrell Sturgill will replace Ron O’Malley as AIST Division IV board of directors representative for the 2010–2012 term. The 2010 North American Caster Roundup will be published in the July issue of Iron & Steel Technology. CCTC recognized the efforts of Dave Beck, CCTC Roundup Chair, for his efforts in compiling new plant data. Presentations were made by Michael Badger, Philip Ponikvar and Ron O’Malley. Discussions for moving the Town Hall Forum from Wednesday morning to Wednesday afternoon at AISTech 2011 ended in a unanimous affirmative vote. The CCTC then toured Nucor Steel–Decatur’s steelmaking and casting departments.
The Continuous Casting Technology Committee (CCTC) met in Charleston, S.C., on 13 Oct 2009, prior to the Casting Training Seminar. Bill Schlichting, CCTC chair, welcomed the 27 committee members and two guests in attendance. CCTC membership stands at 121 members. Hans Schade volunteered to take the meeting minutes. The meeting agenda included prior meeting minutes, AIST Anti-Trust Guidelines, staff announcements, AIST’s 2009 Steel Industry Fatality Statistics compiled by the Safety & Health Technology Committee, and a preliminary compilation of paper selections and scheduled sessions for AISTech 2010. The CCTC then discussed MS&T’09, which was scheduled for 26–29 Oct 2009, in Pittsburgh, Pa. Mr. Schlichting and Ray Miller, CCTC Safety co-chair, were scheduled to represent the CCTC at the AIST Leadership Development Conference in Charlotte, N.C., held in conjunction with the annual Safety & Health Conference and the AIST Southeast Member Chapter fall meeting. A review of the 2009 Steel Industry Fatality Statistics started an open discussion on safety. Mr. Miller gave a safety-related PowerPoint presentation on behavior and “at risk” factors. Mr. Schlichting provided a review of a U. S. Steel – Gary Works fatality in which a crane maintenance shift manager fell from a crane deck. RFID technological advancements were discussed. The Material Handling Technology Committee, as well as the Packaging, Shipping & Transportation Methods Technology Committee, will have presentations regarding safety improvements made with RFID technology in high-traffic areas at their winter meetings. Any confirmed improvements will be communicated with other AIST committees. The 2009 Best Casting Paper Award selection committee was nominated: Ray Miller, Bruce Kozak, Jack Young, Jeff Brower and Phil Ponikvar will nominate this year’s Best Paper Award winner. Mr. Miller, CCTC papers chair, presented a schedule for the CCTC sessions at AISTech 2010. The CCTC will sponsor six sessions covering the following topics: CSP/thin slab machines; quality improvements on thick slab casters; heat transfer; brake technologies; and concurrent sessions on innovations in slab casting and in billet/bloom/beam blank technologies. The CCTC requested a joint session with the Safety & Health Technology Committee with papers detailing safety-related issues. Dave Beck, CCTC membership chair, has compiled a revision to the 2003 Casting Roundup. The Continuous Casting Roundup is set to be published in the March 2010 issue of Iron & Steel Technology. The next CCTC meeting will be in Decatur, Ala., on 10–11 Feb 2010, with a tour of Nucor Steel–Decatur.
The Continuous Casting Technology Committee (CCTC) met on Monday, 4 May at AISTech 2009. There were 51 members in attendance. The CCTC presented the 2008 Continuous Casting Award for Best Paper to Lifeng Zhang, Yufeng Wang, Xiangjun Zuo, Shusen Li and Wei Jin for their paper entitled, “Transport of Fluid Flow and Inclusions in Continuous Casting.” Steve Swoope, papers chair, reviewed the CCTC sessions scheduled at AISTech 2009. He asked each session chair to evaluate as many papers in CCTC sessions as possible so that an informed decision could be made as part of the Best Paper Nominating Committee. Darrell Sturgill, CCTC chair, discussed year-to-date fatality statistics for 2009. The plan to have two CCTC Safety co-chairs was approved by this group. The following CCTC officers were elected for 2009–2010: Bill Schlichting, chair; Steve Swoope, vice chair; Raymond Miller, papers chair and Safety co-chair; Jeff Brower, education chair; J.C. Raies, Safety co-chair; and Dave Beck, membership chair. The CCTC mission statement was reviewed and approved. The Continuous Casting Roundup was set for completion by 31 Jul 2009. Dave Beck, Jeff Brower, Ron O’Malley, Allen Horrex, Ray Miller, Steve Thomas, Ian Bakshi, Bruce Kozak, Jorg Peter, Frank Papay, Trevor Shellhammer and Mike Rennard are some of the CCTC members who have contributed to updating this roundup. A conference call on 19May helped to narrow the plant facilities from which information was still needed. Jeff Brower discussed the fall training seminar scheduled for 13–15 Oct 2009, in Charleston, S.C. CCTC member Jeff Powers will serve as the committee host while touring Nucor Steel–Berkeley. The next CCTC meeting will be held before the 2009 Continuous Casting Training Seminar in Charleston, S.C., in October. Presentation topics will include two caster safety projects (Ray Miller and J.C. Raies); sticker and breakout detection systems (Ron O’Malley and Bill Schlichting); centerline and soft reduction (Bruce Kozak), and cold weather hazards (presenter TBD). The CCTC winter 2010 meeting site will be Nucor Steel–Decatur, with host Ron O’Malley.
The Continuous Casting Technology Committee (CCTC) met on 24–26 Feb in Memphis, Tenn. The committee toured Nucor Steel–Memphis on Thursday morning, seeing the meltshop, ladle furnace, caster and rolling mill. Tuesday afternoon’s Producer-Only meeting was postponed. There were 31 members in attendance. On Wednesday, the attendees were welcomed by the CCTC chair, Darrell Sturgill. The CCTC membership is at 166 members, with nine new members since the previous meeting in October 2008. A safety round table discussion followed, which reviewed steel industry fatalities in 2008. Bill Emling suggested that the committee discuss each fatality. This conversation created a dialogue to consider electing two CCTC safety co-chairs, one a producer and one a supplier. A motion to create non-rotating safety co-chairs was approved by the committee. Steve Thomas of Gallatin Steel and J.C. Raies of Dover Hydraulics were elected to these new positions. Nominations were then accepted for the CCTC chair, which has to be filled by a producer member. Raymond Miller, TMK-IPSCO Koppel Tubulars; Jeff Powers, Nucor Steel–Berkeley; Scott Andrews, Nucor Steel–Hertford County; Mike Jones, Severstal Warren; and Mike Panzeri, Severstal Sparrows Point were nominated for committee chair or papers chair for 2009–2010. Steve Swoope was nominated for vice chair; Dave Beck was nominated for membership chair; and Jeff Brower and Bill Schlichting were nominated for education co-chairs. CCTC officer voting will take place on Monday, 4 May during AISTech 2009 in St. Louis, Mo. The 2008 Continuous Casting Award for Best Paper will be presented at this meeting to Lifeng Zhang, Yufeng Want, Xiangjun Zuo and Wei Jin for their paper entitled, “Transport of Fluid Flow and Inclusions in Continuous Casting Strands.” Dave Beck has updated 75% of the 2003 Caster Roundup, and Jeff Brower volunteered to complete the update for 2009. Bill Sadler, Todd Mannering and Matt Ashby presented an overview of Nucor Steel–Memphis and served as the tour hosts. Technical presentations with the theme “Casting Quality with Maintenance” were made by Jay Ondrovic, Castrip LLC; Jeff Brower, Siemens VAI; Bill Emling, SMS Demag; and Jeff Blankenship, MRSI. The next Continuous Casting Training Seminar will be 13–15 Oct 2009, in Charleston, S.C. A tour of Nucor Steel–Berkeley will be scheduled. Steve Swoope reviewed the five CCTC technical sessions scheduled for AISTech 2009. It was recommended to form a Best Paper subcommittee to review as many CCTC presentations as possible. The CCTC topics for the AISTech 2010 Call for Papers were reviewed and revised.