Secondary Steelmaking


Schedule

8–10 October 2024 • Holiday Inn & Suites Nashville Downtown – Broadway • Nashville, Tenn., USA

Tour of GKN Hoeganaesa

Tuesday, 8 October 2024

7 a.m.

Registration and Breakfast

8 a.m.

Keynote Presentation
Kerry Williams, GKN-Hoeganaes Corp.

8:30 a.m. 

Introductions, Jimmy Barrett, Allied Mineral Products Inc.

8:45 a.m.

Raw Materials, Bricks and Shapes, Monolithics
Ruth Engel, Refractory Consulting Services
The seminar will begin by presenting the raw materials used in the manufacture of refractories, why they are used, their availability and expected characteristics. These raw materials will then be combined to make bricks and their effect on physical properties will be discussed. This discussion will be extended to castables, where additional parameters like installation and dry-out will be considered.

9:45 a.m.

Break

10 a.m. 

Brick Manufacturing
Korey Skala, HWI, A Member of Calderys
A process overview of refractory brick manufacturing, including unfired and fired brick production, from raw materials to packaged products.

10:45 a.m.

Break

11 a.m.

Ladle Construction Design and Insulation
Rob Doty, IMACRO Inc.
This presentation features a wide-ranging discussion about the many options in ladle refractory design. The basics of heat transfer will then be covered from molten steel through layers of refractories to steel ladle shells, followed by insulation choices, how they affect ladle shell temperatures and refractory expansion dynamics.

Noon

 Lunch

1 p.m.

Ladle Pre-Heat and Handling
Rafael Bruch, Gerdau Long Steel North America Midlothian Mill

1:45 p.m.

Break

2 p.m.  

Ladle Free Opens
Jamie Lash, AJF Inc.
This presentation will cover typical sand blends, methods of delivery and diagnosis of failures. It will introduce developing technology and safety aspects throughout the industry.

2:45 p.m. 

Break

3 p.m. 

Tundish Refractory
Filipe Fabri, Vesuvius USA
This session will present the different refractories that control the liquid steel flow, how they interact with steel, how they can impact on quality, how to evaluate different designs through modeling, and the latest technologies and trends in the market, from flow control systems to automation and robotics

4–5:30 p.m.

Panel Discussion and Reception
Moderator: Jimmy Barrett, Allied Mineral Products Inc.
Panelist: Rob Doty, IMACRO Inc. and Abhishek Bhansali, Nucor Steel–Berkeley

Wednesday, 9 October 2024

7 a.m.

Breakfast

8 a.m.

Secondary Steelmaking Process – LMF
Abhishek Bhansali, Nucor Steel–Berkeley
This presentation provides an overview of the fundamental metallurgical processes and operational aspects involved in secondary steelmaking, with a specific emphasis on the ladle metallurgy furnace. Additionally, it addresses the practical challenges that arise during these processes. The presentation then delves into the impact of slags on refractory wear. Finally, the presentation concludes by discussing the significance of steel cleanliness and calcium treatment.

9 a.m. 

Ladle Thermal Imaging — Infrared Systems Supporting Secondary Processing Refractories
Thomas Connors, Connors Industrials Inc.
This presentation will provide films of secondary processing activities with infrared data indicating operational and refractory benefits.

9:30 a.m.

Break

9:45 a.m. 

Refractory Materials Testing and Product Selection
Rakesh Dhaka, United States Steel Corporation
Discussion of various test methods to evaluate different refractory materials for steelmaking applications

10:15 a.m.

Laser Technology in Steelmaking Vessels
Sean Guy, Process Metrix
Overview of lidar technology and how it can help make the steelmaking process more efficient and safe

10:45 a.m.

Break   

11 a.m.

Refractory Best Practices for Steel Ladles and Furnaces​
Karen Uffalussy, Resco Products​
This presentation will cover recommended refractory practices for brick, monolithics, and castables for ladles and furnaces of various types. This will include suggested best practices, do's and don'ts, guidelines versus real life use discussion, and a handful of examples.

Noon

Lunch

1 p.m.

Ladle Breakout Failure Investigation
Dave Ehrhart, RHI Magnesita

1:45 p.m. 

Flow Control Products
Josh Kaser, RHI Magnesita
This presentation will provide an understanding of the basics involved in flow control of steel at the caster. The main focus of this presentation will center around the isostatic refractories and their purposes.

2:30 p.m.

Break

2:45 p.m.

EAF Refractory Products
Mike Clark, HWI, A Member of Calderys
This presentation shall cover the design of both brick and monolithic refractory products used in electric arc furnace applications. Wear mechanisms will be explained, as well as methods to prevent such mechanisms through optimization of refractory systems and steelmaking process improvements.

3:30 p.m.

EAF Deltas
Paul Thibodeau, Allied Mineral Products
Design and function of an electric arc furnace delta.

5 p.m.

Adjourn

Thursday, 10 October 2024

7 a.m.

Breakfast

8 a.m.

Plant Tour of GKN Hoeganaes

Noon

Return From Plant Tour and Conference Adjourn