Technology Committees


Oxygen Steelmaking Technology Committee Activities

The OSTC met 14–15 February 2018, Southgate, Mich., USA. On 14 February, the OSTC members in attendance had the opportunity to tour either the Fiat-Chrysler Sterling Stamping Plant or the Warren Stamping Plant. Included in the tours was a visit to the coil storage area, the blanking and stamping facilities, and the quality assurance laboratories.
On 15 February 2018, the OSTC held its business meeting followed by technical presentations on maintenance and reliability practices in the basic oxygen furnace.
The status of the OSTC’s AISTech 2018 technical sessions was reviewed, and an update was given on the revision to Technical Report No. 32, Design and Construction of BOF Vessels.
Nominations were taken for 2018–2019 OSTC officers.
The OSTC Korea/Taiwan BOF Study Tour was discussed, which was held in March 2018.
The first technical presentation was given by James Kelly, who discussed winterization of the BOF at ArcelorMittal Burns Harbor. Kelly detailed the procedures and practices in securing the water lines during frigid temperatures.
Klaus Lazzaro of the SMS group presented advancements in gearing design and maintenance for BOF vessels, detailing how tapered sleeves with hydraulic mounting devices minimize issue in gear alignment during disassembly and reassembly.
Neal Pyke from ArcelorMittal Dofasco G.P. discussed how automation controls can have many benefits but, if not monitored, can create hidden failure modes.

The OSTC met 11–12 October 2017, Hammond, Ind., USA. The OSTC was given a tour of ArcelorMittal Riverdale’s BOF facility and the ladle and casting facilities on 11 October, followed by the OSTC business meeting on 12 October.
The OSTC held a safety contact roundtable discussion, which served as an opportunity for members to share safety-related improvements and events so all could benefit.
Mark Borsody, OSTC papers chair, discussed the abstracts selected for the OSTC sessions for AISTech 2018. The committee will hold five paper sessions plus the annual BOF Operators Panel Discussion. Volunteers were taken for session chairs as well.
As a wrap-up to AISTech 2017, volunteers were taken to evaluate nominations for the 2018 AIST Charles Herty Award, which honors the best BOF paper from the conference.
The OSTC then discussed options in organizing a Korea/Taiwan BOF Study Tour. Being planned for March 2018, the study tour would include three BOF facilities in Korea and two facilities in Taiwan. Producer member support will be sought in order for the tour to be conducted.
The meeting ended with six technical presentations on oxygen lances and lance tip designs:

  • Pushing the Limits of the Lance,” by Neal Pyke, ArcelorMittal Dofasco G.P.

  • Balancing Lance Tip Life and Slag FeO,” by Yun Li, U. S. Steel Research and Technology Center.

  • Improved Cooling Systems, Supersonic Nozzles With Ideal Contour,” by Christian Oehler, Saar-Metallwerke GmbH.

  • New Lance Concepts,” by Louis Valentas, Berry Metal Co.

  • Twisted Lance Tips and Parabolic Nozzles,” by Steve Gillgrass, Tallman Bronze.

  • BOF Lance Tip Performance at Algoma,” by Kamal Ughadpaga, Algoma Steel.

Karim Alshurafa (left) presented a plaque of appreciation to Nicholas Furdeck (right) for hosting the OSTC’s tour of ArcelorMittal Riverside on 11 October.
 

The OSTC met 9 May 2017, Nashville, Tenn., USA.

The following officers were elected:

  • Chair: Karim Alshurafa, SMS USA LLC

  • Vice chair: Neal Pyke, ArcelorMittal Dofasco Inc.

  • Papers chair: Mark Borsody, Carbide Industries Inc.

 
 
Karim Alshurafa (right) presented a plaque of appreciation to Jeff Stipec (left), area manager, Steelmaking, U. S. Steel – Mon Valley Works, for hosting the OSTC’s tour of the Edgar Thomson Plant.

The OSTC met 7–8 February 2017, Pittsburgh, Pa., USA. The meeting began on 7 February 2017 with a plant visit to U. S. Steel – Mon Valley Works, Edgar Thomson Plant, which was the original Carnegie Steel Co. facility. The attendees visited the basic oxygen furnace as well as the continuous casting operations floor and witnessed the process of exchanging tundishes. The tour concluded with a question-and-answer session with U. S. Steel personnel.
On 8 February 2017, the attendees met at the AIST world headquarters in Warrendale, Pa., USA. Future meeting locations were discussed. The OSTC will be looking to visit supplier facilities to gain a better understanding of the raw materials used in the BOF process. Potential technical topics for presentation were also discussed, such as iron ore quality; short-term, unpredictable iron chemistry (low temperature, high silicon, high titanium, etc.); and other steelmaking challenges.
The OSTC’s AISTech 2017 technical sessions were reviewed. Four sessions and one panel discussion have been organized on oxygen steelmaking technology. 
Karim Alshurafa, OSTC papers chair, announced the 2017 Charles Herty Award winner. The award will be presented during the OSTC meeting at AISTech 2017. 
The OSTC members discussed potential BOF Study Tour regions. A few tour routes were proposed and the OSTC will evaluate two options: Korea and northern Europe. 
The meeting concluded with a series of technical presentations on predicting and controlling slag eruptions during oxygen blowing. Representatives from ArcelorMittal Dofasco Inc.; U. S. Steel – Mon Valley Works, Edgar Thomson Plant; and Cappel Stahl Consulting; as well as James Kelly, independent consultant, presented on how to anticipate and limit slag eruptions during the oxygen blow. 

The OSTC toured the U. S. Steel – Mon Valley Works, Edgar Thomson Plant on 7 February 2017.
 
 
 
Chad Cathcart, U. S. Steel Canada – Lake Erie Works, presented the facility’s practices for utilizing lower-grade scrap.

The OSTC met 21 September 2016, Hamilton, Ont., Canada.  The meeting began with a tour of the KOBM stream at ArcelorMittal Dofasco Inc., hosted by Neal Pyke, who provided an overview of the facility and its history of steelmaking. Operation of the KOBM at ArcelorMittal Dofasco is extremely automated, with specific checkpoints during the process for operator oversight. The automation system controls the process once the hot metal is charged into the furnace and the furnace is uprighted for the blow. The system controls the process through the tapping of the heat. The attendees also toured the ladle metallurgy facilities and the continuous casting pulpit. 
The OSTC held its business meeting and technical discussion the following day. A safety roundtable discussion was held. Pyke then reviewed the potential oxygen steelmaking technical sessions for AISTech 2017. 
Volunteers were identified to evaluate the 2017 Charles Herty Award nominees for best oxygen steelmaking paper from AISTech 2016.
Mike Strelbisky discussed potential options for a 2017 BOF Study Tour in Western or Northern Europe. 
The business meeting concluded with Shank Balajee discussing the AIST Process Benchmarker® BOF Mini-Module parameters showing the benchmarking of BOF operations in the industry. 
Four technical presentations on scrap utilization practices were given by Essar Steel Algoma, ArcelorMittal Indiana Harbor, U. S. Steel Canada and ArcelorMittal Dofasco Inc. 

Karim Alshurafa (right), OSTC vice chair, presented a plaque of appreciation to Neal Pyke (left) for hosting the OSTC’s tour of ArcelorMittal Dofasco Inc.
The OSTC service plaque was presented to Nenad Radoja
(left to right): Karim Alshurafa, Jerry Moscoe, Radoja and
Neal Pyke.

The OSTC met 17 May 2016, Pittsburgh, PA, USA.

The following officers were elected:

  • Chair: Jerry Moscoe, ArcelorMittal Indiana Harbor No. 4 Steel Producing

  • Vice chair: Karim Alshurafa, SMS USA LLC

  • Papers chair: Neal Pyke, ArcelorMittal Dofasco Inc.

  • Membership chair: Mark Borsody, Carbide Industries

The OSTC met 9–10 february 2016, Southgate, Mich., USA. On 9 February, the members were given a plant tour of AK Steel Corp. – Dearborn Works, hosted by Tim Halls and Tim Cauchie. Kamal El-Rassi, Thomas Henry, Louise Doyle and Gregory Szkudlarek also assisted as tour guides. The tour consisted of a visit to the operating floor of the BOF shop, the overlook of the secondary refining area, and a visit to the operating pulpit of the continuous caster. That evening, the OSTC joined the AIST Detroit Member Chapter for the chapter’s February dinner meeting and a presentation by Alta Equipment Co.
A summary was given of the five Oxygen Steelmaking Technologies sessions for AISTech 2016. Session chairs were advised of their responsibilities in communicating with the authors. Session schedules were reviewed and adjusted to provide a complete program. Any papers that were cancelled were replaced with substitutes.
The OSTC vice chair announced the results of the Charles Herty Award Subcommittee’s review of the award candidates. The award will be presented at AISTech 2016.
The OSTC has been active in holding international study tours. In September 2015, a group of 23 delegates from Japan were hosted by members of the OSTC for a study tour of North American steelmaking facilities. This was a reciprocal tour to the OSTC Japan tour in 2014. Additionally, the OSTC began discussions on its next international visit. The committee is considering either the U.K./Sweden/Finland or a visit to Eastern European steelmaking facilities. More discussion will be held at the next OSTC meeting.
The following technical presentations on ladle refractory maintenance were given:

  • AK Steel Corp. – Dearborn Works Steel Ladle Refractory Maintenance,” by Matt Paddon of RESCO. Paddon provided a detailed presentation of changes that have taken place over the years at Dearborn and how data is being tracked for the ladles. Some of the parameters being measured and monitored are heats per lining, heats per day, pre-heat temperatures, ladle metallurgy furnace arrival temperatures and steel residence time. Attention to heat line-up and type of heat being produced are part of the program. The goal is to achieve 120 average heats per ladle lining in 2016.

  • “ArcelorMittal Dofasco Steel Ladle Lining Strategy,” by Neal Pyke of ArcelorMittal Dofasco Inc. Pyke provided an overview of the steelmaking operation. He elaborated on how data has been tracked since 1997, specifically for the larger KOBM ladles. The ladle brick program is comprehensive and is monitored in real time to allow for maintenance schedule changes and early maintenance if necessary.

  • “ArcelorMittal Indiana Harbor No. 4 SP Steel Ladle Refractory Maintenance,” by Jerry Moscoe of

  • ArcelorMittal Indiana Harbor. Moscoe provided an overview of the ladle management system and how data is monitored.

  • “Refractory Overview and State of the Industry,” by Korey Skala of RHI US Ltd. Skala gave a comprehensive overview of the entire history of refractory development of the years since the Bessemer converter days. He discussed the various types of ladle brick and their specific uses and zones in the ladles, as well as the current market and state of the refractory industry worldwide focusing on the effect that China’s steel capacity has on the market. He concluded by summarizing the challenges the refractory industry is facing.

Nenad Radoja (right) presented Tim Halls (left) with a plaque of appreciation for hosting the OSTC’s tour of AK Steel Corp. – Dearborn Works on 9 February 2016.
 
 
Nenad Radoja (left) presented the OSTC service plaque to Jamie Lash (right).

The OSTC met 5 May 2015, Cleveland, Ohio, USA.
The following officers were elected:

  • Chair — Nenad Radoja, Connors Industrial Inc.

  • Vice chair — Jerry Moscoe, ArcelorMittal Indiana Harbor

  • Papers chair — Karim Alshurafa, SMS USA LLC

  • Membership chair — Neal Pyke, ArcelorMittal Dofasco Inc.

Meeting Highlights:
The OSTC Japan Study Tour was reviewed by Mike Strelbisky. He also provided an overview of the upcoming reciprocal tour being arranged for Japanese BOF producers to visit North American steel producers. The tour will be held on 5–9 September 2015 and will include five BOF facilities and four EAF facilities. Concurrent with the proposed Japanese North American  Study Tour will be a technical exchange between the Japanese delegates and representatives from the AIST Oxygen Steelmaking and Electric Steelmaking Technology Committees. The next OSTC International Study Tour is currently being planned and will include visits to either the three BOF facilities in the United Kingdom or the three BOF facilities in Scandinavia.

The OSTC met 28–29 January 2015, Fort Wayne, Ind., USA. The meeting began on the afternoon of 28 January 2015 with a unique tour for the oxygen steelmakers. The OSTC took the opportunity to tour the Iron Dynamics Inc. (IDI) and the Flat Rolled Division of Steel Dynamics Inc. in Butler, Ind., USA. The tour gave the BOF operators and suppliers a perspective on how liquid iron that is similar in quality to blast furnace iron can be made from DRI and a submerged arc furnace and then utilized by an EAF facility to make flat rolled sheet. Conrad Fisher, IDI plant manager, provided the tour of the submerged arc furnace which included the opportunity to witness the furnace tap. Kyle Vanover, EAF metallurgist, and Ricky Rollins, melting manager, provided the tour at the Flat Rolled Division, which included the charging of hot metal in the EAF, a tap, the LMF stations, the thin-slab continuous casters and mold repair area.  
The business meeting and technical discussion occurred on 29 January 2015. James Lash, OSTC chair, opened the meeting and asked the 33 attendees to introduce themselves. Karim Alshurafa, OSTC membership chair, detailed his efforts in recruiting additional BOF operators to the committee. He also asked for the OSTC members to reach out to individuals not on the committee to encourage their participation for the benefit of the industry.
Jerry Moscoe, papers chair, reviewed the OSTC sessions for AISTech 2015. Five sessions are currently planned, including an Operator’s Panel Discussion on Shop Floor Implementation of New Technology. Open paper slots and potential presenters were also identified.
Mike Strelbisky provided a review of the 2014 BOF Japan Study Tour, which included visits to six facilities and a joint ISIJ/AIST technical discussion. Strelbisky then discussed the status of a reciprocal study tour by Japanese BOF operators to North America. Because of shutdowns and logistics, a couple of options are being offered to the Japanese operators for their visit — one option includes AISTech 2015 in May, and the other option would include the fall 2015 OSTC meeting and tour.
Following those discussions, the technical presentations began, which were focused on practices and procedures for alloying during tap. Presenters included: 

  • Ricky Rollins and Chase Ault, who provided an overview of SDI and its Butler operations and alloy practices.

  • Steve Snell of Hickman Williams & Co., who discussed microalloying of advanced high-strength sheet (AHSS) steel.

  • Neal Pyke, who  presented the ArcelorMittal Dofasco KOBM tap and alloy/flux procedures.

  • Vince Clemans presented the tapping practices at ArcelorMittal Burns Harbor. 

Next OSTC Meeting:  Wednesday, 6 May 2015 during AISTech 2015 in Cleveland, Ohio, USA