Technology Committees


Continuous Casting Technology Committee Activities

The CCTC had a virtual meeting 13 May 2020.
The CCTC hosted a meeting with 47 members in attendance. The committee discussed the status of the Continuous Casting training course, which is scheduled for 13–15 October 2020 in Cleveland, Ohio, USA. Committee members determined a few presentation topics that should be added to the existing lineup, such as electromagnetic stirring, mold water in addition to secondary cooling and oil usage as a mold lubrication.
The committee members then elected their officers for the 2020–2021 term. The new CCTC officers are:

  • Chair: Rudolf Moravec, ArcelorMittal Global R&D.

  • Vice chair: Yury Krotov, Steel Dynamics Inc. – Flat Roll Group Butler Division.

  • Papers chair: Ken Morales, AK Steel Research and Innovation Center.

  • Education co-chairs: Jeff Brower, Primetals Technologies USA LLC, and Bill Schlichting, U. S. Steel – Granite City Works.

  • Roundup co-chairs: Mark Masters, CMC Steel Alabama, and Ron O’Malley, Missouri University of Science and Technology.

The committee also had a follow-up discussion to their meeting in March 2020 on the operational impact and new practices that have come about as a result of the current COVID-19 pandemic.
Presentation:

  • “Vallourec’s CCM Revamp — Production and Quality Challenges,” by Mariana Modesto, Vallourec.

The CCTC and PTTC met jointly 11–12 February 2020, Mobile, Ala., USA.
The two committees reviewed the AIST Steel Industry Fatalities report. During the discussion, a suggestion was made for the creation of a safety app. Attendees gave examples of safety “toolbox talks” that take place at their facilities.
Rick Besich gave an update on AISTech 2020. He re-emphasized the role of session chair and papers chair.
The committees nominated officers for the upcoming term.
The CCTC and the PTTC then reviewed their respective roundups.
The CCTC recapped the 2019 Continuous Casting seminar, which was held in Memphis, Tenn., USA. The seminar had 94 attendees. This year’s Continuous Casting seminar will be held in Cleveland, Ohio, USA, with tours of ArcelorMittal Cleveland (slab) and TimkenSteel Corp. (bar).
The PTTC reviewed its 2019 Pipe and Tube seminar, which was held in Birmingham, Ala., USA. The event had 52 attendees. The next Pipe and Tube seminar will be held in the fall of 2021.
Presentations:

  • “Quantitative Assessment of Centerline Segregation in As-Cast Products,” by Sunday Abraham, SSAB Iowa Inc.

  • “Machine Design Overview of New SMS group Inc. Continuous Casters in the USA,” by Joseph Laughlin, SMS group Inc.

  • “Slab Quality Improvements for Line Pipe Applications,” by Rudolf Moravec and Rick Besich, ArcelorMittal USA.

The committees also held an open discussion on American Petroleum Institute (API) requirements.
The two groups then planned their fall 2020 and spring 2021 meetings. The CCTC will hold its fall 2020 meeting in conjunction with the Continuous Casting training conference, and its spring 2021 meeting in either San Antonio, Texas, USA, or Birmingham/Tuscaloosa, Ala., USA. The PTTC’s meetings are yet to be determined.
The next day the committees toured Berg Pipe Mobile and SSAB Alabama.

Rudolf Moravec (left) presented Greg Manfredi (right), SSAB Alabama, with a plaque of appreciation for hosting the CCTC and PTTC’s tour.
Frank Baumgardner (right) presented a plaque of appreciation to Paul Weber (left), Berg Pipe Co., for hosting a tour for the CCTC and PTTC.

The CCTC met 23 October 2019, Memphis, Tenn., USA.
The CCTC began its meeting by reviewing the 2019 Steel Industry Fatalities report, followed by a roundtable discussion.
Ken Morales, papers chair, led the discussion on the committee’s AISTech 2020 session development. The CCTC has scheduled seven sessions. Volunteers for session chairs were solicited. The committee then reviewed the instructions for papers chair and session chair.
The winner of the 2020 Continuous Casting Best Paper Award was selected. This award will be presented during AISTech 2020 in Cleveland, Ohio, USA.
The CCTC then reviewed the Continuous Caster Roundup, which was published in the July 2019 issue of Iron & Steel Technology.
The next Continuous Casting — A Practical Training Seminar will be held in October 2020 near Gallatin, Ky., USA, with tours of Nucor Steel Gallatin and North American Stainless.
The 2020 Continuous Casting South Korea Study Tour will take place 22–27 March. 

Presentations:

  • “Oxygen Lance Sharing With Safety,” by Scott Martin, Nucor Steel–Arkansas.

  • “Caster Job Risk Assessment at Nucor Steel Gallatin,” by Andrea  Aller, Nucor Steel Gallatin.

  • “X-Pact Width Control,” by Nick Romeo, SMS group.

  • “Nucor Tuscaloosa Manipulator,” by Dan Green, Nucor Steel Tuscaloosa Inc.

  • “ArcelorMittal Burns Harbor Caster Safety Overview,” by Rudolf Moravec, ArcelorMittal R&D.

Attendees had a choice to tour either Nucor Steel–Arkansas or Nucor Steel Memphis Inc. after the meeting. Upon conclusion of the tour, a panel discussion and reception were held.

The CCTC met 6 May 2019, Pittsburgh, PA, USA.
The following officers were elected:

Chair: Rudolf Moravec, ArcelorMittal Global R&D – East Chicago

Vice chair: Yury Krotov, Steel Dynamics Inc. – Flat Roll Group Butler

Papers chair: Ken Morales, AK Steel Research and Innovation Center

Education co-chairs: Jeff Brower, Primetals Technologies, and Bill Schlichting, U. S. Steel – Granite City Works

Roundup co-chairs: Mark Masters, CMC Steel Alabama, and Ronald J. O’Malley, Missouri University of Science and Technology

The CCTC, LSRTC and RSTC met jointly 13–14 February 2019, Jacksonville, Fla., USA.
CCTC and LSRTC Highlights:
The CCTC and LSRTC met jointly while the RSTC met separately in the morning on 13 February. Later that afternoon, the three committees convened for technical presentations. 
The CCTC and LSRTC opened their meeting with a review of the Steel Industry Fatalities report. It was noted that the number of fatalities was down, even with a high production level. Discussion included overhead cranes, man lifts, demolition and construction projects.
The CCTC and LSRTC reviewed their respective AISTech 2019 technical sessions, and session chairs were reminded of their responsibilities.
Jimmy Barrett gave some comments on the most recent Secondary Steelmaking Refractories training conference. Seventy-five people attended the conference, including 35 from steel-producing companies representing 17 different facilities.
The next Secondary Steelmaking Refractories conference will take place in San Antonio, Texas, USA, on 14–17 October 2019, with a tour of CMC Steel Texas.
Jeff Brower discussed the Continuous Casting training seminar. This year the seminar will take place in Memphis, Tenn., USA, on 21–24 October 2019 with tours of Nucor Steel Memphis Inc. (bar) and Nucor Steel–Arkansas (sheet).
Nominations for CCTC and LSRTC officers for the 2019–2020 term were discussed.
The Continuous Casting Roundup was reviewed. Ron O’Malley will email the roundup to the CCTC to enter their 2018 data. This roundup will be published in the July 2019 issue of Iron & Steel Technology.
The CCTC discussed locations for its next International Study Tour. Possible locations included South Korea and France.
RSTC Highlights:
The RSTC began its meeting by reviewing the 2018 Steel Industry Fatalities report, followed by a roundtable discussion. 
The committee finalized its technical session lineup for AISTech 2019.
Mike Anderson shared his experiences from the 2018 AIST Leadership Conference. 
Nominations for RSTC officers for the 2019–2020 term were discussed.
The AIST Digital Transformation Task Force meeting at AISTech 2019 will be held on Wednesday, 8 May. Rakesh Dhaka will represent the RSTC.
The RSTC’s Fall 2019 meeting will be held either in conjunction with the training seminar in San Antonio or at another tour site in September 2019. This will be determined during the RSTC’s meeting at AISTech 2019.
The Refractory Systems Best Paper Award was discussed. The award will be presented during the RSTC meeting at AISTech 2019.
The following presentations were given when the three committees gathered in the afternoon:

  • “Steel Cleanliness Analysis at Nucor Steel–Berkeley,” by Abhishek Bhansali, Nucor Steel–Berkeley.

  •  “An Update on Steel-Refractory Interactions Research at the PSMRC,” by Ron O’Malley, Missouri University of Science and Technology. 

  • “CFP: Clean Flow Port SEN Design for Flow Optimization,” by Josef Riccio, Krosaki USA.

  • “Physical Water Modeling of Slab SENs to Improve Steel Cleanness and Clogging by Assessing In-Mold Fluid Flow and Associated Turbulence,” by Andy Smith, Materials Processing Institute.

  • “Steel Interactions With Refractory Focus: Ladle to Mold,” by Gregor Arth, RHI Magnesita.

The next day, the three committees toured CMC Steel  Florida.

The CCTC, LSRTC and RSTC toured CMC Steel Florida on 14 February. Ty Hall, works manager, and Bill Rider, plant engineer, accepted a plaque of appreciation from Ron O’Malley, AIST first vice president from Missouri University of Science and Technology (left to right): Helmut Oltmann, LSRTC chair; Hall; O’Malley, Rider; and Ian Deeks, CCTC chair.

The CCTC met 10 October 2018, Detroit, MI, USA.
Yury Krotov, papers chair, discussed AISTech 2019 technical session development. As of the meeting, the CCTC had 36 papers accepted into the technical program. 
Volunteers were solicited for session chairs, and the instructions for papers chair and session chair were reviewed.
The Continuous Casting Best Paper Award winner was selected. This award will be presented at AISTech 2019 in Pittsburgh, Pa., USA.
The position of Caster Roundup chair was discussed, as the position had become vacant. Mark Masters and Ron O’Malley volunteered to take on this role.
Plans for the 2019 Continuous Casting — A Practical Training Seminar were discussed. The CCTC is looking at either Memphis, Tenn., USA, or Birmingham, Ala., USA, with both a flat product and long product tour site.
The following presentations were given:

  •  • “INTECO Mold Level Master,” by Klaus Von Eynatten, INTECO Atec Automation GmbH. The presentation discussed a stopper rod mechanism/electromechanical servo actuator to minimize hydraulics on the casting platform. It is designed to plug and play with current systems, minimizing changes.

  •  • “JENDCO — Mold Level Technology,” by John R. Matschner, JENDCO Corp. This discussion focused on the technology’s ability to analyze source current state and rate of decay to determine lifetime.

  •  • “Accurate Mold Powder Thickness Measuring and Mold Level Measuring With One Radiometric Sensor,” by Craig Oaks, SMS Concast. Oaks discussed a new design that measures mold powder and steel level.

The CCTC met 7 May 2018, Philadelphia, PA, USA.
The following officers were elected:

  • Chair: Ian Deeks, Nucor Steel–South Carolina

  • Vice chair: Rudolf Moravec, ArcelorMittal Global R&D – East Chicago

  • Papers chair: Yury Krotov, Steel Dynamics Inc. – Flat Roll Group Butler

  • Education co-chairs: Jeff Brower, Primetals Technologies, and Bill Schlichting, United States Steel Corporation

The CCTC and MSCTC met 6–7 February 2018, Florence, S.C., USA. 
The CCTC and MSCTC reviewed safety statistics and had an excellent discussion focusing on the causes and the age breakdown of fatalities.
AISTech 2018 sessions were finalized. The CCTC has eight sessions and MSCTC has six sessions. The group discussed upcoming deadlines for AISTech 2018, as well as the roles of the session chair and papers chair.
The Continuous Casting Best Paper award and the Kent D. Peaslee Memorial Award (a joint-committee award between the MSCTC and the Ladle & Secondary Refining Technology Committee)were discussed.
Both committees went through nominations for the upcoming 2018–2019 officer rotation.
Rudolf Moravec, ArcelorMittal Global R&D, reviewed the most recent Caster Study Tour, which was held in Japan in November 2017.
The following technical presentations were given:

  • “HD Scan Macrosegregation,” by Joe Laughlin, SMS group.

  • “Elemental Segregation Analysis in Continuous Steel Castings Using Micro-XRF,” by Kenny Witherspoon, I-XRF.

  • “Micro-XRF analysis of Metals,” by Mike Beauchaine, Bruker.

  • An analysis of the round-robin testing for centerline evaluation performed by the IQRS subcommittee was given by Sunday Abraham, SSAB Americas, and Joydeep Sengupta, Arcelor­Mittal Dofasco G.P.

  • Ron O’Malley, Missouri University of Science and Technology, talked about recent inclusion research at the Peaslee Steel Manufacturing Research Center.

The next day, the group toured Nucor Steel–South Carolina.

1. Kenny Witherspoon presented during the CCTC and MSCTC joint meeting on 6 February 2018. 2. Scott Story (right) presented a plaque of appreciation to Ian Deeks (left) for hosting the tour of Nucor Steel–South Carolina on 7 February 2018.

The CCTC met 18 October 2017, Fort Wayne, Ind., USA. The CCTC reviewed the 2017 Steel Industry Fatalities report, followed by a roundtable discussion. Committee members were reminded how they can reach out to fellow CCTC members.
Yury Krotov, papers chair, discussed the CCTC’s AISTech 2018 technical session development. The CCTC has 38 abstracts over eight sessions. The instructions for papers chair and session chair were reviewed.
The recipient of the 2018 AIST Continuous Casting Best Paper Award was announced. This award will be presented at the CCTC meeting during AISTech 2018 in Philadelphia, Pa., USA.
The 2017 Continuous Caster Roundup was reviewed. Any facility updates should be sent to Eric Rosenow, roundup chair.
Jeff Brower and Bill Schlichting reviewed Continuous Casting — A Practical Training Seminar, which had 92 participants. A recap of the course can be found on pages 192–193 of this issue. The 2018 Continuous Casting training seminar will be held on 8–11 October 2018 in Memphis, Tenn., USA, with Big River Steel serving as tour host.
Ron O’Malley, study tour chair, reviewed the program for the 2017 Japan Caster Study Tour, which was held in November.
The following technical presentations were given:

  • How Torch Cutting and Deburring Affect Billet Quality, by Enrico D’Ottavi, ALBA.

  • Imaging-Based Surface Inspection of Cast Products,” by Enrique Frixione, OG Technologies.

  • Billet Inspection at Nucor Steel–South Carolina,” by Ian Deeks, Nucor Steel–South Carolina.

Steel Dynamics Inc. – Structural and Rail Division’s caster operations provided the attendees with an excellent tour.
A panel discussion and reception followed the plant tour. Jeff Brower, Primetals Technologies, served as moderator, with the following panelists: Rudolf Moravec, ArcelorMittal Global R&D; Bill Schlichting, SKW North America; Rick Besich, ArcelorMittal Indiana Harbor; Ian Deeks; and Ian Bakshi, KME America.

 
 
Ian Deeks (right) presented Richard Besich (left) with the CCTC service plaque.

The CCTC met 8 May 2017, Nashville, Tenn., USA.

The following officers were elected:

  • Chair: Ian Deeks, Nucor Steel–South Carolina

  • Vice chair: Rudolf Moravec, ArcelorMittal Global R&D – East Chicago

  • Papers chair: Yury Krotov, Steel Dynamics Inc. – Flat Roll Group Butler

  • Education co-chairs: Jeff Brower, Primetals Technologies, and Bill Schlichting, SKW North America

  • Roundup chair: Eric Rosenow, NALCO Water, An Ecolab Company

The CCTC met 22 February 2017, Scottsdale, Ariz., USA. The CCTC reviewed the 2016 Steel Industry Fatalities report, followed by a safety roundtable discussion.
Rudolf Moravec, papers chair, reviewed the CCTC’s AISTech technical sessions, which encompass six sessions and two joint sessions for a total of 43 presentations. The roles of session chair and papers chair were reviewed.
Committee officers for 2017–2018 were discussed and elections will take place during the CCTC meeting at AISTech 2017.
The Continuous Casting Best Paper Award winner was announced. This award will be presented at AISTech 2017 during the CCTC meeting.
The 2017 Caster Japan Study Tour will be held on 5–11 November 2017. The program for the tour, which is  awaiting approval from the ISIJ, was presented.
Continuous Casting — A Practical Training Seminar will be held on 16–19 October 2017 in Fort Wayne, Ind., USA. Steel Dynamics Inc. – Structural and Rail Division will be the host plant. The CCTC requested a program change for this seminar that would move the committee meeting to Wednesday morning during the training seminar.
The CCTC’s fall meeting topic/theme will be discussed during the committee’s meeting at AISTech 2017.
The following presentations on caster production optimization were given:

  • “Productivity Improvements at Nucor Darlington,” by Ian Deeks, Nucor Steel–South Carolina

  • “Maximizing Production at CMC Arizona,” by Gilbert Hutton, Commercial Metals Company – Arizona.

  • “High-Speed Billet/Bloom Casting and Quality Optimization,” by Dewey Humes, Primetals Technologies USA LLC.

  • “InfoSight Mold Powder Distribution System at AK Steel Mansfield,” by Jon Ekvail, InfoSight.

  • “Redesign of the Bender at ArcelorMittal Burns Harbor,” by Rudolf Moravec, ArcelorMittal Global R&D – East Chicago.

Gilbert Hutton (right), works manager, Commercial Metals Company – Arizona, was presented with a plaque of appreciation from Rick Besich (left), CCTC chair, for hosting a tour for the CCTC during its meeting on 22 February 2017.

The CCTC met 20 October 2016, Memphis, TN,  USA. The CCTC reviewed the 2016 Steel Industry Fatalities report, followed by a safety roundtable discussion.
Rudolf Moravec, papers chair, discussed AISTech 2017 session development. The CCTC has eight sessions scheduled. Session chairs were selected, and the roles of papers chair and session chair were reviewed.
The 2017 AIST Continuous Casting Best Paper Award winner was selected. This award will be presented at
AISTech 2017.
Eric Rosenow provided an update on the AIST Continuous Caster Roundup. Those who wish to make additions or updates to statistics should contact Rosenow.
Jeff Brower discussed Continuous Casting — A Practical Training Seminar, which will be held in Fort Wayne, Ind., USA, on 16–19 October 2017.
Presentations on ladle free open performance were given by ArcelorMittal Indiana Harbor and ArcelorMittal Burns Harbor.

Ian Deeks (right) presented the CCTC service plaque to
Rick Besich (left).

The CCTC met 16 May 2016, Pittsburgh, PA, USA.

The following officers were elected:

  • Chair: Rick Besich, ArcelorMittal Indiana Harbor

  • Vice chair: Ian Deeks, Nucor Steel–South Carolina

  • Papers chair: Rudolf Moravec, ArcelorMittal Global R&D

Rick Besich (left), CCTC chair, presented a plaque of appreciation to Bill Rider (right), superintendent steelmaking, Gerdau Long Steel North America Jacksonville Mill, for hosting the CCTC’s tour of the facility. 

The CCTC met 17–18 February 2016, Jacksonville, Fla., USA.  The 2015–2016 Steel Industry Fatalities statistics were reviewed, followed by a safety roundtable discussion.
Rudolf Moravec discussed the CCTC’s technical sessions for AISTech 2016. Seven sessions are scheduled. The roles of session chair and papers chair were reviewed.
The Continuous Casting Best Paper Award will be presented at AISTech 2016.
Continuous Casting — A Practical Training Seminar will be held on 17–20 October 2016 in Memphis, Tenn., USA, with Nucor Steel Memphis Inc. serving as host plant.
An update was given on AIST Study Tours:

  • Rudolf Moravec reviewed the 2015 Germany Caster Study Tour.

  • The 2016 United Kingdom Specialty Alloy Study Tour will be held on 19–25 June 2016.

  • The 2016 Italy EAF Study Tour will be held on 13–19 November 2016.

  • The CCTC will explore the possibility of a 2017 Japan Caster Study Tour.

The following technical presentations were given:

  • “Overview of Gerdau Jacksonville Steelmaking Operations,” by Bill Rider of Gerdau Long Steel North America Jacksonville Mill.

  • “Mold Feeder Technology,” by Darrell Sturgill of Imerys Metalcasting Solutions.

  • “Sensor Technology in Casting,” by John Rogler of Vesuvius.

  • “Long Products Casting,” by Todd Mannering of Nucor Steel Memphis Inc.