Logan W. Spangler
U. S. Steel; Fairfield Tubular Steel Operations
This summer I had the honor and opportunity to intern with U. S. Steel at the Fairfield Tubular Steel Operation (FTSO) in Fairfield, Ala., as an operations intern. Working in operations gave me the incredible opportunity to see all parts of the steelmaking process here at FTSO. My focus this summer was on the ladle metallurgy furnace (LMF) and the continuous caster.
At the LMF, I helped collect data for the implementation of a new software that will eventually change how the argon stir is controlled. Right now, the LMF operator chooses a standard cubic feet per minute (SCFM) of argon to control stir. However, recently a new sensor was commissioned that measures the ladle vibration. This new sensor will allow FTSO to move into controlling the argon stir via vibration, 
as this vibration index gives a more comprehensive view of what is happening inside the ladle. It also helps the operator account for stopped or leaking plugs, ensuring a more consistent stir. My responsibility for this project was to take a short video of the steel inside the ladle. I then correlated the open eye of the steel seen in the videos with a stir rate (SCFM), vibration index and backpressures of both plugs. Using all the data points, I was able to analyze the best vibration index ranges for each desired stir profile. I was also able to analyze how the LMF was able to remove sulfur from the steel. Combining this data with the vibration sensor index created a detailed analysis of what is needed within the steel to maximize the efficiency of the desulfurization process.
At the continuous caster, I was able to assist with a trial of a set of new ladle shrouds and lower ladle nozzles. This test was to determine if these new shrouds and nozzles were able to effectively lower the nitrogen pickup in the steel as it moved from the ladle to the tundish. My job was to take a photo of the inside of the ladle shroud in between heats, as well as the lower nozzle. I analyzed how the number of heats on a shroud and nozzle set contributed to the nitrogen pickup, using these photos as a supplement.
I am extremely grateful the opportunity to intern with U. S. Steel at FTSO this summer. Being able to work alongside everyone at this plant to complete meaningful projects was truly an honor. I look forward to applying the skills and knowledge I gained here to help improve the steel industry in the future.