AISTech 2012 – Technical Papers - Steel Library
AISTech 2012 – Technical Papers - Steel Library
AISTech 2012 – Technical Papers - Steel Library
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<strong>Technical</strong> <strong>Papers</strong><br />
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BRIMACOMBE MEMORIAL LECTURE<br />
J. Keith Brimacombe Memorial Lecture<br />
<strong>Steel</strong> Research — Then, Now and Tomorrow: The Brimacombe Lecture .................................................................. 1<br />
Alan W. Cramb<br />
SAFETY & HEALTH<br />
Safety Improvements & Innovations<br />
Pilot Testing of Fire Protection in Extremely Corrosive Industrial Duct Environments ........................................... 11<br />
David B. Fuller, Paul Su, William W. Doerr, J.C. Harrington, Jon M. Barna<br />
Supporting Environmental, Health and Safety Programs Through a Best-in-Class CMMS/EAM Solution ........... 19<br />
Jeromy Risner<br />
New Philosophy and Strategies for HMI (Human-Machine Interface) Between the Operators and the Machines ....... 25<br />
Marco Capitanio, Roberto Migliorati<br />
ENVIRONMENTAL<br />
Air Pollution Control<br />
<strong>Technical</strong> and Economic Evaluation of Slag Dry Granulation ..................................................................................... 35<br />
Terry E. Norgate, Dongsheng Xie, Sharif Jahanshahi<br />
Challenges for Modeling Compliance With Short-Term SO2, NO2 and PM2.5 Ambient Standards ........................ 47<br />
Robert J. Paine, David W. Heinold<br />
Technological Apparatus for the Moderation of Meltshop Off-Gas ............................................................................ 55<br />
Gioacchino Nardin, Antonella Meneghetti, Maria Elena Fabiani<br />
The New Frustum Canopy Hood for <strong>Steel</strong> Meltshops ................................................................................................... 63<br />
Marco Peter Cudicio, Michele Manazzone, Stefano Miani, Riccardo Gottardi<br />
Predicting the Performance of Carbon <strong>Steel</strong> EAF Dust Processing Technology — A Case History ........................ 71<br />
Larry M. Southwick<br />
How to Make the Plants of Today Comply With the Requirements of Tomorrow .................................................... 81<br />
Christian Fröhling, Peter Hemmling, Jens Kempken, William H. Emling
ENVIRONMENTAL/IRONMAKING<br />
Environmental Technologies in the Blast Furnace<br />
SVAI Gas Cleaning Options — A Solution for Every Problem .................................................................................. 87<br />
Ian M. Craig, Martin P. Smith, Barry Featherstone, Alexander Fleischanderl, Andreas Klugsberger<br />
Evaluate and Model the Efficiency of a Blast Furnace Gas Cleaning Plant Using Computational<br />
Fluid Dynamics: Geometry Optimization of a Gravity Dust-Catcher ....................................................................... 97<br />
David Winfield, David Paddison, Mark Cross, Nick Croft<br />
Measures to Increase Efficiency and to Reduce CO2 Emissions in Iron and<br />
<strong>Steel</strong>making in Germany and Europe ........................................................................................................................... 109<br />
Hans Bodo Lüngen, Michael Peters, Peter Schmöle<br />
Brazilian Potential of Biogas Use as Fuels in Metallurgy ............................................................................................ 121<br />
Máximo Eleotério Martins, Isabela Cristina Filardi Vasques, Nayara da Silva Lima, Paulo Santos Assis<br />
OxyCup ® Furnace Operation at TISCO, China .......................................................................................................... 127<br />
Michael Lemperle, H.-Jaan Rachner, Ralf Jennes<br />
ENVIRONMENTAL/ELECTRIC STEELMAKING<br />
EAF Environmental — Dust & Dioxins<br />
A Mathematical Model for Carbothermic Reduction of Dust-Carbon Composite Agglomerates .......................... 143<br />
Yuki Kuwauchi, Mansoor Barati<br />
EAF Slag: A Product No Longer a Problem ................................................................................................................ 153<br />
Loredana Di Sante, Filippo Cirilli, Nicola Angelucci<br />
Development of EAF Dust Injection Technology at Aichi <strong>Steel</strong> ................................................................................. 163<br />
Akira Tsubone, Tsuyoshi Momiyama, Masanori Inoue, Naoto Saito, Kazuyo Matsubae, Tetsuya Nagasaka<br />
State of the Art Treatment of EAF Dust ....................................................................................................................... 173<br />
Lifeng Zhang, Liyuan Sun, Shengqian Wang<br />
Dioxins Minimization and Control in an EAF ............................................................................................................. 183<br />
Maria Ilaria Pistelli, Daphne Mirabile, Marco Scotto D’Antuono, Enrico Malfa, Nicola Angelucci,<br />
Silvia Tosato, Paolo Giugliano<br />
ENVIRONMENTAL/OXYGEN STEELMAKING<br />
BOF <strong>Steel</strong>making Sustainability<br />
Numerical Modeling of Flow Into Primary Dedusting System of 130t Converter .................................................... 195<br />
Breno Totti Maia, Bruno Orlando de Almeida Santos, Fabrício Silveira Garajau, Hugo Leonardo de Freitas,<br />
Jose Geraldo Torres, Marcelo de Souza Lima Guerra, Roberto Parreiras Tavares, Rudolf Huebner<br />
How Upgrades in Makeup Quality and Treatment Program Dramatically<br />
Improved BOF Hood Uptime/Caster Mold Reliability ............................................................................................... 207<br />
Jim Gleason
Development of Roll Type Continuous Slag Solidification Process ............................................................................ 211<br />
Yuki Hagio, Koichi Hayashi, Hiroyuki Tobo<br />
Cradle to Cradle at CSC: Through Integrated Recycling System and Industrial Symbiosis .................................. 217<br />
Kuan-Nan Lin<br />
COKEMAKING<br />
Coke/Coal Raw Materials<br />
Incorporation of Charcoal in Coking Coal Blend — A Study of the Effects on<br />
Carbonization Conditions and Coke Quality ............................................................................................................... 225<br />
Ka Wing Ng, Louis Giroux, Tony MacPhee, Ted Todoschuk<br />
New Findings From the DMT Small-Scale Coking Test Retort Regarding<br />
Coke Quality and Coke Oven Wall Safety .................................................................................................................... 237<br />
Drazen Gajic, Manfred Kaiser<br />
Bi-Reflectance Mapping and Automated Petrographic Analysis of Metallurgical Coke ......................................... 247<br />
David E. Pearson, Richard A. Pearson<br />
Cokemaking Alternative Technology<br />
Coke Without Coal: More Than Half-Century of Production in Argentina ............................................................. 253<br />
Jorge Madias, Mariano de Cordova<br />
Coke Battery Pushing Emission Reduction — Improvements in Transfer Car Design at<br />
U. S. <strong>Steel</strong> Canada Inc. <strong>–</strong> Lake Erie Works .................................................................................................................. 263<br />
John Benson<br />
Combining New Coke and Ironmaking Technologies to Reduce the Carbon Footprint in the Production of <strong>Steel</strong> ..... 267<br />
Marka Jansen, Ian Cameron<br />
Characterization of Mixtures of Sugarcane Bagasse and Charcoal for<br />
Injection Through Tuyeres of Blast Furnaces .............................................................................................................. 277<br />
Pedro Henrique Macêdo Leles, Samuel Trindade Viana, Paulo Santos Assis<br />
Cokemaking Process Improvements<br />
Coke Making Process Improvements Through Culture Change and Total Process Reliablity .............................. 293<br />
Michael D. Kwalton, Ronald K. Burnette, Paul A. Borders<br />
Commissioning of 565 kg, 18-Inch-Wide Pilot-Scale Movable Wall Coke Oven at Coal Science Laboratories ........ 303<br />
Patrick Ellis, Allen Ellis, Hardarshan H. Valia<br />
U. S. <strong>Steel</strong> Canada Lake Erie Works Stack Burner Project — Increase Stack Draft and Coke Production ......... 317<br />
Baoquan Zhang<br />
Sopreco ® : Single-Oven Pressure Control System Installed in the New<br />
Coke Oven Battery No. 3 at the Zentralkokerei Saar GmbH ..................................................................................... 323<br />
Giovanni Siri, Luca Parodi
COKEMAKING/IRONMAKING<br />
Coke Quality & Alternatives<br />
Wood Pellets for Ironmaking From a Life Cycle Analysis Perspective ..................................................................... 331<br />
Ka Wing Ng, Louis Giroux, Tony MacPhee, Ted Todoschuk<br />
Reaction Behavior of Ferrocoke and Its Evaluation in a Blast Furnace .................................................................... 339<br />
Tetsuya Yamamoto, Takeshi Sato, Hidekazu Fujimoto, Takashi Anyashiki, Kiyoshi Fukada, Michitaka Sato,<br />
Kanji Takeda, Tatsuro Ariyama<br />
Evaluation of Alternatives to Raise the Blast Temperature at Lean Blast Furnace Top Gas Operation ............... 347<br />
Tamoghna Mitra, Kimmo Kinnunen, Henrik Saxén<br />
High-Temperature Performance Comparison of Lump Coal, Coal Briquette and Coke Used as COREX Fuel ....... 359<br />
Qian Hui, Peng Xin<br />
IRONMAKING<br />
Ironmaking Plant Projects<br />
Design, Construction, Commissioning and Operation of the New Blast Furnace No. 6 at AHMSA ...................... 363<br />
Jaime Pena, Ricardo Gil Diaz, Scott Davis<br />
One<strong>Steel</strong> Whyalla Blast Furnace Campaign Extension .............................................................................................. 375<br />
R. van Laar, J. Tsalapatis<br />
The New BLT ® High-Performance Chute Transmission Gearbox — Results of the<br />
First 18 Months of Operation at Rogesa’s BF5 ............................................................................................................ 385<br />
Dave Berdusco, Walter Hartig, Guy Thillen, Emile Lonardi, Lionel Hausermer<br />
Ironmaking Computer Applications<br />
Improving the Ironmaking Process With Expert Systems in Closed-Loop Operation ............................................ 395<br />
Angelika Klinger, Thomas Kronberger, Martin Schaler, Bernhard Schürz<br />
Influence of Process Variables on Blast Furnace Operational Limits: Ternium Siderar Experience .................... 407<br />
G. Cegna, G. Puertas, O. Lingiardi, R. Musante<br />
Validation of the Numerical Model for Blast Furnace Shaft Process ........................................................................ 417<br />
Dong Fu, Yan Chen, Taifur Rahman, Chenn Q. Zhou, Yongfu Zhao, John D’Alessio, Kyle J. Ferron<br />
Continuous Monitoring of Liquid Level and Thermal State in the Hearth Based on<br />
Measurement of EMF on the Blast Furnace Shell ....................................................................................................... 429<br />
Michael A. Alter, Joseph M. Brunner, Daniel J. Holmes<br />
Blast Furnace Operations<br />
Reaction Analysis of Continuous Desiliconization in the Hot Metal Runner at Kobe No. 3 Blast Furnace ........... 439<br />
Takamitsu Nakasuga, Sei Kimura, Naoyuki Uchida, Tsuyoshi Mimura, Rikizo Tadai, Kenji Ito<br />
Influence of Preliminary Metallization of Metallic Burden on Blast Furnace<br />
Process and Performance Parameters .......................................................................................................................... 449<br />
I.G. Tovarovskiy, Y.M. Gordon, A.E. Merkulov
The Impact of Design and Operating Parameters on Skull Formation in a Blast Furnace Hearth ........................ 457<br />
Yongfu Zhao, Louis W. Lherbier, Jr., Dong Fu, Yan Chen, Chenn Q. Zhou, John G. Grindey<br />
Productivity of 3 t/m 3 /day Over the Last Five Years at BF5 AHMSA Mexico ......................................................... 471<br />
Fernando Liceaga, Miguel Villarreal, Joaquín Flores<br />
Taphole Clay for High Productivity Operation of a Blast Furnace ........................................................................... 481<br />
Won-keon Kim, Soon-il Yoon, Sang-ahm Lee<br />
Blast Furnace Raw Materials<br />
The Iron Ore Market <strong>2012</strong> ............................................................................................................................................. 489<br />
Joseph J. Poveromo<br />
The Rate Determining Step of the Oxidation of Natural Magnetite Concentrates ................................................... 503<br />
Hyeon Jeong Cho, Christiaan Pistorius<br />
Value in Use of the Dunite .............................................................................................................................................. 513<br />
Enrique Somolinos, Javier Martinez<br />
Sintering of Indian Iron Ores — <strong>Technical</strong> Considerations ....................................................................................... 521<br />
Chandan Barman Ray, Bhaskar Roy, Tushar Kanti Mandal, Subhas Das<br />
Alternate Ironmaking<br />
Classification of Fine Ores Regarding Their Reducibility With Tests in a Lab-Scale<br />
Fluidized Bed Reactor and Petrographical Analysis ................................................................................................... 531<br />
Michael Skorianz, Heinrich Mali, Friedemann Plaul, Johannes Schenk, Christoph Thaler<br />
Selection of Ironmaking Technology for Existing Specific Conditions of European Part of Russian Federation ....... 543<br />
Yakov Gordon, Michiel Freislich, Rick Brown, Mitesh Patel, Greg Traquair<br />
Inhibition of Reoxidation of Direct Reduced Iron ....................................................................................................... 553<br />
Jaleel K. Ahmad<br />
Online Raft Control and High Top Pressure Control in Blast Furnace to Maximize Productivity ........................ 559<br />
Susanta Pramanik<br />
Ironmaking Computer Applications<br />
New Concept of the Auxiliary Fuel Injection Tuyeres of Blast Furnaces Developed by Numerical Simulations ...... 563<br />
Breno Totti Maia, Bruno Orlando de Almeida Santos, Paulo Santos Assis, Marcelo de Souza Lima Guerra,<br />
Fabrício Silveira Garajau, José Eduardo Mautone Barros<br />
Advances in the CFD Modelling of Raceway Injections .............................................................................................. 575<br />
Christian Jordan, Christian Maier, Michael Harasek, Christoph Feilmayr, Stefan Schuster<br />
State-of-the-Art PCI Technology for Blast Furnace Ensured by Continuous<br />
Technological and Economical Improvement .............................................................................................................. 589<br />
Robin Schott
IRONMAKING/ENERGY & UTILITIES<br />
Blast Furnace Energy & Utilities<br />
A Sensible Route to Energy Efficiency Improvement and CO2 Management in the <strong>Steel</strong> Industry ....................... 605<br />
Michael D. Lanyi, Jin Cao, Joseph A. Terrible<br />
Energiron Direct Reduction Process: The Forefront Technology .............................................................................. 615<br />
Annamaria Volpatti, Barbara Franco, Alessandro Martinis<br />
Flexible Gas Mixing Station Design and Operation for Natural Gas,<br />
Coke Oven Gas and Blast Furnace Gas Mixtures ........................................................................................................ 625<br />
David Pekor, Ramon Garcia, Michael Spada<br />
Improved Blast Furnace Stove Operation With the Use of Oxygen-Enriched Combustion Air ............................. 631<br />
Kim Michelsson, Mark Geach, Tommi Niemi, Peter M. Martin<br />
IRONMAKING/REFRACTORY SYSTEMS<br />
Ironmaking Refractories<br />
Reliability of Casthouse Refractory System at No. 14 Blast Furnace, United States <strong>Steel</strong> Corporation ................ 641<br />
Du H. Lee, Kenneth B. Wing<br />
Laser Measurement System for Refractory Linings in Hot Torpedo-Ladles ............................................................ 647<br />
Rolf Lamm<br />
Campaign Life Extension at ROGESA Blast Furnaces by Co-Injection of PCI and Titanium Dioxide ................ 655<br />
Walter Hartig, Djamschid Amirzadeh-Asl, Dieter Fünders<br />
ELECTRIC STEELMAKING<br />
EAF Electrical & Utilities<br />
Modernization and Upgrade of a Static Var Compensator for an Electric Arc Furnace Application ................... 665<br />
Andrew Owens, Anders J. Persson, Rolf Grünbaum, Bo L. Johansson<br />
Providing Secure Ground Protection for Electric Arc Furnaces During Inrush Conditions .................................. 673<br />
Dennis Boyd, Trevor Saunders, Mark Lanier, Larry Wright<br />
Power Quality Compliance With SVC PLUS ............................................................................................................... 683<br />
Magnus Geijer, Wolfgang Hoerger, Wolfgang Meusel, Gordon Wong<br />
Electrode Consumption in a Modern High-Power Electric <strong>Steel</strong> Shop ..................................................................... 691<br />
Christopher R. Armstrong, Timothy L. Bosserman, Kale E. Heibult, Kyle W. Vanover, James J. Fortier, Nicolas Lugo<br />
Reducing the Effect of Electrode Water Cooling on Electrical Stability in an Arc Furnace ................................... 705<br />
Gian Carlo Gattoni, Gianantonio Bernardi, Ben Bowman, David Coudert<br />
EAF New Technologies<br />
New Generation in Preheating Technology for Electric Arc Furnace <strong>Steel</strong>making ................................................. 717<br />
Knut Rummler, Akif Tunaboylu, Dogan Ertas
iEAF ® Technology: The Use of Offgas Analysis for Carbon and Temperature<br />
Prediction in Electric Arc Furnaces .............................................................................................................................. 727<br />
Steven Gillgrass, Vittorio Scipolo, Doug Zuliani, Paolo Clerici, Michele Pustorino<br />
Implementation of the Chemical Energy Control Module at Nucor Yamato <strong>Steel</strong> EAF2 ....................................... 735<br />
Ismael Valdez, Omar Quintanilla, Guillermo Fernández, Eugene Pretorius<br />
An Advanced EAF Optimization Suite for 420-t Jumbo DC Furnace at<br />
Tokyo <strong>Steel</strong> Using DANIELI Technology ..................................................................................................................... 745<br />
Ananya Mukhopadhyay, Robert Coughlan, Marco Ometto, Romano Sellan<br />
Industrial Application of Chemical Energy for Special <strong>Steel</strong> Grades and Processes ............................................... 757<br />
Alexander Grosse, Klaus Libera, Robert Eriksson<br />
ELECTRIC STEELMAKING/ENERGY & UTILITIES<br />
EAF Start-Ups & Revamps<br />
Startup of the VSB Metalshop: The First Consteel ® EAF in Brazil ........................................................................... 767<br />
Luís Gustavo de Oliveira Amaral Mello, Francesco Memoli, Nicola Rondini<br />
Successful Start-Up and Benchmark Operating Results of 100 t FastArc ® EAF at Kosco, Korea ......................... 777<br />
Damiano Patrizio, Alberto Pesamosca<br />
Increase Production in the EAFs in Ternium Guerrero, Mexico: Strategies and Actions ....................................... 783<br />
Hugo Solis Tovar, Juan Carlos Rodrigues Goncalves, Ricardo Santos Padilla, Marco A. Herrera G., Fabian Castro Uresti<br />
Increasing Energy Efficiency of the Electric Arc Furnace at Tenaris-Tamsa .......................................................... 793<br />
Fernando Martell, Rafael Mendoza, Armando Llamas, Osvaldo Micheloud<br />
Operational Results of PTI Slag Door System for EAF .............................................................................................. 805<br />
Val Shver, Jaroslav Brhel, Christopher Farmer<br />
Waste Heat Power Generation from EAFs, SAFs and Reheating Furnaces — A Comparison .............................. 811<br />
Carsten Born, Ralf Granderath<br />
OXYGEN STEELMAKING<br />
BOF Operational & Productivity Improvements<br />
Latest Developments in Magnesia-Carbon Bricks ....................................................................................................... 821<br />
Gerald Buchebner, Ashraf Hanna, Volker Samm<br />
Experience With Long BOF Campaign Life and TBM Bottom Stirring Technology at Meishan <strong>Steel</strong> in China ...... 829<br />
Zhao Guoguang, Rainer Hüsken, Jürgen Cappel<br />
Improved BOF Tapping Practice at AHMSA Mexico ................................................................................................. 841<br />
Ashraf Hanna, Kerry Servos, Juan A. Carreon, Sergio Zapata, Hector Rios, Mario Orona<br />
Comprehensive Electrics and Automation Solutions for Brazil’s Most Modern <strong>Steel</strong> Plant ................................... 851<br />
Rudolf Hubmer, Stephan Hofinger, Josef Weiss, Reinhold Leitner
BOF Liquid <strong>Steel</strong> Chemistry Control<br />
Phosphorus Equilibrium Between Liquid Iron and CaO-SiO2-MgO-FeO Slags ...................................................... 861<br />
Andre N. Assis, Richard J. Fruehan, Seetharaman Sridhar<br />
Oxygen <strong>Steel</strong>making Furnace Alloy Model at United States <strong>Steel</strong> Corporation ....................................................... 871<br />
Yun Li, Samuel M. Smith, Naveen Gupta<br />
Desulphurization Strategies in Oxygen <strong>Steel</strong>making ................................................................................................... 883<br />
Buğra Şener, Rianer Hüsken, Jürgen Cappel<br />
BOF Blow Practices & Endpoint Prediction<br />
The Increasing Importance of BOF Endpoint Control When Using Higher-Phosphorous-Containing Hot Metal ..... 897<br />
Doug Zuliani, Salim Khouri, Vittorio Scipolo<br />
New Standard Development for Blowing at the BOF Converter by Using “Catch Carbon” Practice ................... 909<br />
Dione Araújo Moreira, Hudson Asth, Paulo César Lemes Almeida, Mirelle Oliveira Spindola,<br />
Igor Vieira, Ronaldo Santos Sampaio<br />
Investigation of the Bath Flow in Q-BOP in Water Model Experiment .................................................................... 917<br />
Kenji Nakatani, Futoshi Ogasawara, Takashi Yamauchi, Goro Okuyama, Yuichi Uchida<br />
<strong>Steel</strong> Expert Takes Command — Optimized Performance on BOF Converter ........................................................ 925<br />
Stephan Hofinger, Rudolf Hubmer, Stephanie Schütt<br />
Improving BF-BOF Performance and Safety Using Tenova’s Slop Detection System Technology ........................ 937<br />
Igor Todorovic, Vittorio Scipolo<br />
SPECIALTY ALLOY & FOUNDRY<br />
Specialty Melting & Casting Process<br />
Oxygen Control and Its Effect on <strong>Steel</strong> Cleanliness During Electroslag Remelting of NAK80 Die <strong>Steel</strong> ............... 947<br />
Cheng-bin Shi, Xi-chun Chen, Han-jie Guo, Hao Ren<br />
Practice of Process for <strong>Steel</strong>making of MnCr Gear <strong>Steel</strong> by 100t DC-LF-VD-CC Flow Sheet ............................... 959<br />
Zhong Ding, Jun Lin<br />
Recent Trends and Technologies in Ingot Casting ....................................................................................................... 965<br />
Christian Redl, Stellan Hammarqvist<br />
Specialty <strong>Steel</strong>making Quality<br />
The New Integrated Level 2 Meltshop Management System at Latrobe Specialty Metals .................................... 973<br />
Thomas E. Kantor, Greg Dowling, John R. Middleton<br />
Role of Slag Basicity on Thermodynamic Partitioning of Chromium and Manganese in Ferritic Stainless Melts ..... 987<br />
David Kundrat, Allen Wyatt, Hagan Fuchs<br />
AlN Formation in High-Aluminum Content Fe-Al Alloys ........................................................................................ 993<br />
June Bott, Hongbin Yin, Seetharaman Sridhar<br />
Aluminum Deoxidization of H13 Hot Die <strong>Steel</strong> Through Inert Gas Protection Electroslag Remelting ............... 1005<br />
Fei Wang, Xi-Chun Chen, Han-jie Guo
LADLE & SECONDARY REFINING<br />
Liquid <strong>Steel</strong> Processing<br />
Free Opening Performance Under Longer Residence Time of <strong>Steel</strong> Ladle at ArcelorMittal IHE <strong>Steel</strong>making ..... 1017<br />
Eraj Siddique, Xin Zhang, James P. McCloskey, Yong M. Lee<br />
The Effect of Silicon on the Desulfurization of Al-Killed <strong>Steel</strong>s ............................................................................... 1027<br />
Debdutta Roy, P.C. Pistorius, R.J. Fruehan<br />
Starting a Tool to Improve Efficiency in Complex Secondary <strong>Steel</strong> Refining ........................................................ 1037<br />
Bruno R. Coelho, Gustavo F. Machado, Ronaldo S. Sampaio, Alice G. Miranda, Sérgio L.S. Costa<br />
Development and Implementation of an Online Process Model for the Control of<br />
<strong>Steel</strong> Chemistry and Superheat During Secondary <strong>Steel</strong>making ............................................................................. 1045<br />
Kamalesh Mandal, Erik Miller, Dan Pierce, Pete Loomis, Justin Novotny, George Gurley, Mark Pole<br />
Automatic Ladle Gas Coupling Systems ..................................................................................................................... 1055<br />
J. Kevin Cotchen, Rüdiger Ralf Eggert<br />
Vacuum Processing<br />
Focus on Vacuum Degassing ........................................................................................................................................ 1063<br />
Riccardo Gottardi, Adam Partyka, Stefano Miani, Marco Volpe<br />
Improving Temperature Control at the RHOB ......................................................................................................... 1073<br />
Qiujin Li, William Flanagan<br />
Comparison of the RH and Tank Degassing Processes ............................................................................................. 1083<br />
Dieter Tembergen, Thomas Eichert, Jan Meier-Kortwig, J. Kevin Cotchen<br />
Slag Entrainment Behavior in the Vacuum Chamber of RH Degasser ................................................................... 1097<br />
Fang Jiang, Guoguang Cheng<br />
Operational Results of the Latest Vacuum Plant Installations ................................................................................. 1105<br />
Andrea Pezza, Markus Abel, Michel Hein<br />
Engineering Aspect and Results for VHD Technology .............................................................................................. 1115<br />
Christian Redl, Matthias Pfennig, Johannes Obitz, Dieter Brück<br />
LADLE & SECONDARY REFINING/METALLURGY —<br />
STEELMAKING & CASTING<br />
Ladle & Secondary Refining<br />
Mathematical Model of Multiphase Flow in Argon Stirred Ladle and a<br />
New Technique for Prediction of the Mixing Time .................................................................................................... 1125<br />
Lucas Costa, Roberto Tavares, Bernardo Braga, Diego Lima, Helbert Lino<br />
Interaction Between Gas and Liquid Phase in an RH Vacuum Degasser ............................................................... 1135<br />
Fengsheng Qi, Liu Yang, Baokuan Li<br />
Novel Modeling Concept for Vacuum Tank Degassing ............................................................................................. 1143<br />
Vivek Thapliyal, Simon N. Lekakh, Kent D. Peaslee, David G.C. Robertson
Clean <strong>Steel</strong><br />
Transient Phenomena of Inclusions in Alloy <strong>Steel</strong>s During the RH-VD-CC Process ............................................. 1151<br />
Shufeng Yang, Lifeng Zhang, Qiangqiang Wang, Yongfeng Chen<br />
Desulphurization of Liquid <strong>Steel</strong> in Ladle Furnace ................................................................................................... 1161<br />
V. Hernandez, S. Kumar<br />
Formation and Evolution of Inclusions in Al-Ti-Mg-Deoxidized <strong>Steel</strong> .................................................................... 1171<br />
Ying Ren, Yongfeng Chen, Xiaogang Yang, Shufeng Yang, Lifeng Zhang, Xiaoming Ding, Jingshe Li, Shusen Li,<br />
Fenggang Liu<br />
Improvement in Sampling Process Precision by Means of an Inert Atmosphere Sampling<br />
System at ArcelorMittal Indiana Harbor East No. 2 <strong>Steel</strong> Producing ..................................................................... 1179<br />
William Souronis, Paul A. Turner, Robert Rote<br />
A Study of Ca-Modification Process in Al-Killed <strong>Steel</strong>s ............................................................................................ 1195<br />
S. Nafisi, J. Jordan, C. D’Souza, L. Collins, T.J. Drake<br />
CONTINUOUS CASTING<br />
Continuous Cast Internal Quality<br />
In-Depth Analysis of Continuous Caster Machine Behavior During Casting With<br />
Different Roll Gap Taper Profiles ............................................................................................................................... 1207<br />
Nick Gregurich, Garrett Flick, Rudolf Moravec, Kenneth Blazek<br />
Simulated and Experimental Study of Segregation in Continuously-Cast High Carbon Bloom <strong>Steel</strong> ................. 1221<br />
T.A. Tran, R.P. Thackray<br />
Characteristics and a Novel Quantitative Model of Macrosegregation in<br />
Continuously Cast High-Carbon <strong>Steel</strong> Billets ............................................................................................................ 1229<br />
Zibing Hou, Guoguang Cheng<br />
A Review of the Rhomboidity Problem in Billet Casting .......................................................................................... 1241<br />
Jorge Madias<br />
Mold Powder Technology<br />
High-Temperature Mold Powder Viscosity: Basic Experimental Procedure and Quantitative Analysis ............ 1251<br />
Nathan J. Howell, Yong M. Lee, Hongbin Yin, Kenneth E. Blazek<br />
A Novel Approach for Coupling Slag Infiltration to Metal Flow, Solidification and<br />
Mold Oscillation on a 3D Model for Continuous Casting of Slabs ........................................................................... 1259<br />
Pavel E. Ramirez Lopez, Ulf Sjöström, Peter D. Lee, Kenneth C. Mills, Björn Jonsson, Jesper Janis<br />
Performance of Three to Five Poise Mold Powders With an Exothermic Addition ............................................... 1269<br />
Dan Larson, Takayuki Suzuki, Asish K. Sinha, Elizabeth Borges<br />
Kinetic Study of the Devitrification of Mold Powder Slags ...................................................................................... 1279<br />
Yadira G. Maldonado, F. Andrés Acosta, A. Castillejos, Brian G. Thomas
Caster Process Modeling & Simulation<br />
Calibration of Thermal Models of Continuous Casting of <strong>Steel</strong> ............................................................................... 1291<br />
Lance C. Hibbeler, Melody M. Langeneckert, Junya Iwasaki, Inwho Hwang, Ron J. O’Malley, Brian G. Thomas<br />
Continuous Enhancements of the Evraz Superheat Model Control for Slab Casting ............................................ 1303<br />
Shaojie Chen, Colin D’Souza, Dave Evans, Kendal Dunnett, Jim Burns, Garry Sylvestre, Chris Cannon<br />
Transient Turbulent Flow Simulation With Water Model Validation and Application to Slidegate Dithering ..... 1317<br />
Rui Liu, Brian G. Thomas, Bruce Forman, Hongbin Yin<br />
Thermal Stress Cracking of Sliding Gate Plates ........................................................................................................ 1329<br />
Hyoung-Jun Lee, Seong-Mook Cho, Seon-Hyo Kim, Brian G. Thomas, Sang-Woo Han, Tae-In Chung, Joo Choi<br />
CONTINUOUS CASTING/PROJECT & CONSTRUCTION MANAGEMENT<br />
Caster Start-Ups, Upgrades & New Concepts<br />
CSP ® Flex — New CSP ® Concepts for Future Market Requirements ..................................................................... 1339<br />
Christian Bilgen, Christoph Klein, Christian Klinkenberg, Jürgen Müller<br />
The Evolution of the Thin-Slab Caster Concept: Latest TSC Technology to<br />
Produce Over 330 t/Hour per Strand .......................................................................................................................... 1349<br />
Andrea Carboni<br />
Operational Results of the World’s Most Modern Bow Type Caster With Vertical Mold for the<br />
Production of 355-mm-Thick Slabs for Demanding Quality Requirements ........................................................... 1361<br />
Martin Hadler, Ewald Reisenberger, Andreas Eichinger, Christian Fürst, Johannes Unter, Peter Hodnik<br />
Presentation of Innovative 250/350 mm Continuous Caster in Salzgitter ............................................................... 1371<br />
Markus Schäperkötter, Peter Müller, Steffen Roßius, Christian Geerkens, Martin Becker, Holger Beyer-Steinhauer<br />
Development of the High-Speed Thin-Slab Casting Technology of POSCO ........................................................... 1383<br />
Byung-jin Min, Geon Shin, Sang-hyeon Lee<br />
Siemens VAI’s WinLink ® Technology ........................................................................................................................ 1395<br />
Colombo Ezio, Zanelli Ugo<br />
CONTINUOUS CASTING/MAINTENANCE & RELIABILITY<br />
Caster Maintenance & Upgrade Concepts<br />
Development of the New Sealing System on a Roller Bearing in a Continuous Caster Roll .................................. 1399<br />
Kazuhiko Ohno, Kenta Izaki, Makoto Naito, Shinji Tanaka<br />
Arvedi ESP — First Results and Business Cases ....................................................................................................... 1409<br />
Andreas Jungbauer, Josef Lanschuetzer, Wersching Günther, Windner Georg, Bumberger Armin<br />
New Developments and Versatility of EcoStar Roller Enhancements ..................................................................... 1417<br />
Daryl L. Charlier, Jeffery K. Brower<br />
Spray Cooling: Staying Cool in Hot Places ................................................................................................................. 1425<br />
Stanley Smith, Troy D. Ward
Large-Diameter Slewing Ring Bearing Storage Methods: Comparisons and Cost Effectiveness ......................... 1439<br />
Joseph J. Fitzgerald<br />
Technological and Automation Upgrade for CSP ® Plant TKSE Bruckhausen ...................................................... 1449<br />
Wolfgang Gruber, Reinhold Leitner, Walter Pitzer<br />
CONTINUOUS CASTING/REFRACTORY SYSTEMS<br />
Ladle & Tundish Refractory Materials & Designs<br />
Study and Application of Forsterite Dry Vibration Material for Tundish .............................................................. 1459<br />
Minglian Gan, Yong Chen, Zhongyang He, Shifeng Song, Junfeng Lou<br />
Dry and Inorganic Tundish Coating Refractory ........................................................................................................ 1465<br />
William N. Porter, Kyösti Ruotanen, Dirk Pörzgen<br />
MAG-QC — Tundish Metering Nozzle Quick Changer ........................................................................................... 1473<br />
Vladimir Mathias de Abreu<br />
Research and Application of Magnesia-Based Retaining Block of a Tundish Gas Curtain .................................. 1479<br />
Hongtao Meng, Yun Wang, Zhongyang He, Yong Chen, Xingyuan Luo<br />
Improvement of Ladle Slidegates ................................................................................................................................ 1487<br />
Harukiyo Tokuda, Takashi Miki, Kenichi Harada, Koji Kawarada<br />
Use of Dry Refractory Liners in Continuous Caster Tundishes: Characterization and Quality Aspects ............ 1497<br />
Stelvio Buoro, Giorgio Romanelli<br />
HOT SHEET ROLLING<br />
Hot Mills — Upgrading for the Future<br />
Hot Strip Mill — Streamlining for Increasing the Capacity and Improving Quality ............................................ 1507<br />
Horst Janssen, Ernst-Ulrich Becker<br />
Danieli Contributions to the Development of Thin-Slab Casting and Rolling Process: From<br />
“First Generation” Plants to the Recent “World Record Breaking” Applications ................................................ 1511<br />
Carlo P. Piemonte, Alessandro Pigani<br />
Modernizations of the Beeckerswerth Hot Strip Mill for Manufacturing High Strength<br />
Grades With Special Requirements ............................................................................................................................ 1517<br />
Gabriel Kolek, Michael Bössler, Andreas Zaum<br />
Increasing Productivity and Rolling Quality Through Optimized Mill Window Geometry ................................. 1523<br />
Jochen Corts<br />
HOT SHEET ROLLING/COLD SHEET ROLLING/ROLLS<br />
Roll Gap Lubrication & Strip Profile<br />
Improved Roll-Gap Lubrication to Reduce Energy Consumption and to Extend the Material Product Mix ..... 1533<br />
Konrad Krimpelstatter
Effect of Non-Uniform Roll Cooling on Hot Bands Crown and Flatness in Finishing Stands .............................. 1537<br />
E. Nikitenko<br />
Increasing Web Speed and Eliminating Tracking Problems in an Electro-Tinning<br />
Line With the PARALIGN Roll Alignment Report ................................................................................................... 1545<br />
Chiu Yen Woo<br />
Superior Profile Control Technology With Edge-Oriented Shifting ........................................................................ 1551<br />
Tanehiro Kikkawa<br />
HOT SHEET ROLLING/METALLURGY — PROCESSING, PRODUCTS &<br />
APPLICATIONS/COMPUTER APPLICATIONS<br />
Hot Rolled Product Quality & Improvements<br />
Thermomechanical Simulation of Hot Rolled Q&P Sheet <strong>Steel</strong>s ............................................................................. 1561<br />
David B. Futch, Grant A. Thomas, John G. Speer, Kip O. Findley<br />
A Strip Crown Model Based on the Finite Element and Response Surface Methods ............................................ 1569<br />
Derek E. Slaughter, Thomas G. Ranger, James E. Atkinson, Christopher Backel, Robert Oldroyd<br />
Real-Time Metallurgically Based Estimator of Microstructure and Tensile Properties of<br />
Hot Rolled Strips On-Line Coil Quality Estimator (CQE) ....................................................................................... 1581<br />
Maurizio Lubrano, Paolo Emilio Di Nunzio, Giovanni Zangari, Roberto Venturini<br />
The Effect of Hot Mill Processing Temperature Variations on Final Coil Properties of Hot Rolled <strong>Steel</strong>s ......... 1591<br />
Michael J. Ryan, Stephen G.R. Brown, Peter J. Evans, Hiram Mullan<br />
The Impact of Tapered Work Rolls in the Finishing Mill During Hot Rolling ....................................................... 1601<br />
Mohammed Tahir, Jesper Holmberg<br />
HOT SHEET ROLLING/ENERGY & UTILITIES<br />
Fuel for Thought<br />
Flameless Oxyfuel Slab Reheating Experiences ......................................................................................................... 1611<br />
Anders Lugnet, Jonas Engdahl, Jorma Päätalo, Tony Palermo<br />
Novel Application of Organic Rankine Cycle (ORC) Technology for Waste Heat Recovery<br />
From Reheat Furnace Evaporative Cooling System .................................................................................................. 1625<br />
Ahmet Durmaz, Ralph Pugh, Şaban Yazici, Kasim Erdoğan, Abbas Kosan<br />
CFD Modeling of Complete Reheating Furnaces ...................................................................................................... 1635<br />
Valerio Battaglia, Enrico Malfa, Massimiliano Fantuzzi<br />
Development of Compact Regenerative Burners in Hot Rolling Mills .................................................................... 1645<br />
Motoki Takada, Koichi Taksahi, Toshiaki Amagasa, Tomoaki Tadama, Hiroyuki Nakashima<br />
The Revolution in Heat Transfer Technology is Won, Forced Draft Burners Move Aside and<br />
the Thermal Kinetic Energizer Now Takes Center Stage ......................................................................................... 1657<br />
Carl Mörsner, Anthony Nathan
COLD SHEET ROLLING<br />
Cold Mills & Equipment<br />
Danieli Cold Mill Complex Turboflo ® and Pickling Coupled to 6-High Mini Tandem<br />
Mill for Automotive Applications ................................................................................................................................ 1667<br />
Michele Turchetto, Tommaso Settimo, Luciano Vignolo<br />
Pickling Line/Tandem Cold Mill With Electrical and Automation Systems From<br />
SMS Siemag Successfully Commissioned at MMK ................................................................................................... 1673<br />
Detlef Ehlert, Michael Bühren, Joachim Schaumann, Keshav Kumar Gaur<br />
Automatic and Online Oil Film Monitoring ............................................................................................................... 1683<br />
Klaus J. Peters<br />
Coil-to-Coil Joining With Laser Welding in Particular for “Sophisticated <strong>Steel</strong> Grades” .................................... 1689<br />
Ralf Wallmeyer, Manfred Neumann<br />
Equipment for Product Features<br />
A Method for the Determination of Shape Actuator Capabilities Envelopes in 20-High Cluster Mills ............... 1697<br />
Mark E. Zipf<br />
Multivariable Directions in the Improvement of Shape Actuator Performance ..................................................... 1711<br />
Mark E. Zipf<br />
Laboratory Evaluation of a New Method to Reduce Ridge Buckles in Cold Rolled Strip ..................................... 1727<br />
Yuli Liu, Hui Zhang, Mike Levick, Ying Zhou<br />
Mill Control Systems<br />
On a New Slip-Stick Rolling Model With Non-Circular Roll Bite Containing Multiple Characteristic Zones ... 1739<br />
Remn-Min Guo<br />
Up-to-Date Cold Strip Production in Continuously and Discontinuously Operating Cold Mills ......................... 1749<br />
Karl Hoen, Rüdiger Holz, Falk Töpfer<br />
Development of Pass Schedule Software Using a Slip-and-Stick Non-Circular Arc Force Model ........................ 1759<br />
Remn-Min Guo<br />
New Rolling Method of Reversing Cold Rolling Mill ................................................................................................ 1771<br />
Tanehiro Kikkawa<br />
Pickling and Tandem Cold Rolling Technologies for Severstal North America in Dearborn, Michigan ............. 1781<br />
Yoichi Kai, Mark R. Blankenau, John M. Tomasaitis, Larry Flowers, Motoyuki Fujii, Shunsaku Kasai, Toshihide Shinoda<br />
GALVANIZING<br />
Galvanizing of Advanced High-Strength <strong>Steel</strong>s<br />
Recent Trends in Hot Dip Galvanizing of Advanced High-Strength <strong>Steel</strong> at ThyssenKrupp <strong>Steel</strong> Europe ........ 1791<br />
Martin Norden, Marc Blumenau, Rudolf Schönenberg<br />
A Kinetic Oxidation Model for High-Strength <strong>Steel</strong> ................................................................................................. 1799<br />
Young-Min Kim, In-Ho Jung, Suk-Kyu Lee, Jong-Sang Kim
Industrial Use of Pre-Oxidation During Continuous Hot-Dip Coating of (High) Alloyed <strong>Steel</strong>s .......................... 1807<br />
Marc Blumenau, Christopher Oliver Gusek, Martin Norden, Rudolf Schönenberg<br />
Advances in Galvanizing Line Process Technologies<br />
Strip Lateral Control With Electromagnetic Steering Device .................................................................................. 1815<br />
Yusuke Ishigaki, Yoshiaki Nishina, Yoichi Yoshinaga<br />
Development of Improving of Surface Qualities of Hot-Dip Galvanized<br />
Product by Electromagnetic Strip Stabilizers ............................................................................................................ 1823<br />
Yuichi Ozawa, Yoshiaki Nishina, Yusuke Ishigaki, Kazuhisa Kabeya<br />
The New ThyssenKrupp-Laser-Welding-Machine at HDGL No. 7 ......................................................................... 1831<br />
Clemens Trachternach, Gerhard Alber<br />
Crack Initiation and Propagation of Galvanized Coatings Under Bending Loads ................................................ 1839<br />
Yuttanant Boonyongmaneerat, Petch Jearanaisilawong, Suwat Ploypech<br />
Review on Wiping: A Key Process Limiting CGL Productivity ............................................................................... 1847<br />
Frank E. Goodwin, Michel Dubois<br />
PLATE ROLLING<br />
Moving Plate Rolling Forward<br />
New Danieli Wide Plate Mill at Jiang Yin Xing Cheng Special <strong>Steel</strong> Works, P.R. of China ................................. 1861<br />
Giorgio Ximeris, Emanuele Bozzetto, Enrico Crisà, William Tami<br />
Elimination of Full Face and Edge Cracking in Hot-Charge Plate Rolling ............................................................ 1867<br />
V. Hernandez, S. Kumar<br />
Advanced Strategies for Leveling for High-Strength Heavy Plate Production ....................................................... 1879<br />
Detlef Ehlert, Matt Korzi, Thomas Koch, Gerhard Horn, Roman Dehmel<br />
State-of-the-Art Automated Ultrasonic Material Testing Systems, Modularity and Practical Applications ....... 1887<br />
O. Ruzek, H. Ballmann<br />
Research on Newly Developed Martensitic Stainless <strong>Steel</strong> Plate Used in Hydropower Station ............................ 1899<br />
Liu Shangtan, Hu Junhui, Wang Qingliang, Huang Zheyi, Ji Renfeng, Shen Rong, Chen Qinping<br />
PLATE ROLLING/METALLURGY —<br />
PROCESSING, PRODUCTS & APPLICATIONS<br />
Plate Products<br />
Strengthening Mechanisms in Microalloyed Martensitic Plate <strong>Steel</strong>s ..................................................................... 1905<br />
Shane C. Kennett, Kip O. Findley<br />
Development of TMCP <strong>Steel</strong> Plates for Hydraulic Supports Used in Mining Machinery ..................................... 1917<br />
Xianying Xue, Haijun Chen, Hong Lei, Weizhao Song<br />
Direct Heat Treatment After Hot Rolling of a High-Strength and High-Toughness Plate <strong>Steel</strong> ........................... 1923<br />
Zhang Aiwen, Zhang Qingfeng, Jiao Sihai
ROD & BAR ROLLING<br />
Rolling Mill Innovations<br />
Innovation in Automatic Billet Conditioning Using Advanced Optical Surface Crack<br />
Recognition System and High-Pressure Grinding Machines .................................................................................... 1933<br />
Daniel Aegerter, Jan Gummersbach<br />
Rod and Bar Mill Developments Over the Past Fifteen Years ................................................................................. 1945<br />
T.M. Shore<br />
Latest Improvements to Increase Reliability and Productivity on Multi-Slitting Processes ................................. 1957<br />
Andrea Zanon, Tiziano De Giorgio, Emanuele Iogna Prat, Mauro Odorico, Renzo Pesamosca<br />
50 m/s in Cooling Bed to Enhance Profitability in Rebar Production ..................................................................... 1965<br />
Luigi Tambosco, Andrea Taurino<br />
Another Step Foward to the Best Quality Wire Rod With Better Productivity and Higher Efficiency ............... 1971<br />
F. Mulinaris, N. Redolfi, A. Taurino<br />
Rolling Mill Advancements<br />
Thermomechanical Processing for Quality Products in High Speed Rod Rolling Mills ........................................ 1979<br />
B.V. Kiefer, W.P. Krejdovsky<br />
Microstructure Simulator for Long Product Mills .................................................................................................... 1989<br />
Michael Kruse, Matthias Schuck<br />
Laying Head Upgrade ................................................................................................................................................... 1995<br />
Robert E. Greuter<br />
Non-Oxidizing Reheating Rotary Hearth Furnace .................................................................................................... 1997<br />
Jim Feese, Felix Lisin<br />
Rolling Mill Maintenance & Reliability<br />
Protecting Bearings in Rolling Mills ........................................................................................................................... 2005<br />
Howard M. Lockhart<br />
Planning, Implementation and Commissioning of a Heavy-Duty 3-Roll Reducing and<br />
Sizing Block at Republic <strong>Steel</strong>, Lackawanna, N.Y. .................................................................................................... 2019<br />
David A. Boettger, W. Jürgen Ammerling, Sergio A. Filippini<br />
An Integrated System for Minimizing the Downtime for Dimensional Changes in Bar Rolling Mills ................. 2033<br />
Sven-Erik Lundberg<br />
Comprehensive Control of a Reheating Furnace ....................................................................................................... 2053<br />
Pavel Skopec, Jan Knobloch, Tomas Vyhlidal, Goran Simeunovic, Michal Svantner, Milan Honner<br />
Flexible Groove Sequences for Hot Rolling a Number of Materials ........................................................................ 2065<br />
Christian Overhagen, Paul Josef Mauk<br />
Quenched and Tempered Bar ...................................................................................................................................... 2075<br />
Jacob Selzer
PIPE & TUBE<br />
Pipe & Tube Innovations<br />
Lubrication of a Seamless Pipe Sizing Mill ................................................................................................................. 2083<br />
James DiLonardo, Carl Kennedy<br />
ROLLS<br />
Roll Shop<br />
Automatic Roll Loaders for Intelligent Roll Shops .................................................................................................... 2091<br />
Giovanni Bavestrelli<br />
Roll Shop Auxiliaries and Complete Roll Shops ........................................................................................................ 2101<br />
Davide Quaglia, Francesco Auteri, Giovanni Boselli, Paolo Gaboardi<br />
Advances in Roll Scanning Technology — A New Method for Eddy Current Defect Detection ........................... 2109<br />
Robert A.C. Northern<br />
Mill Roll Technology<br />
New Roll Grinding Technologies for 20-High Cluster Mills ..................................................................................... 2117<br />
Paolo Gaboardi, Giovanni Boselli, Mark E. Zipf, Michael Brewster, Claudio Trevisan, Thomas Andersson, Andrea Tognoni,<br />
Davide Quaglia<br />
Development of New Materials Based on On-Site and Laboratory Evaluation Methods for<br />
Understanding Work Roll Surface Degradation ........................................................................................................ 2129<br />
Gisèle Walmag, Sébastien Flament, Jurgen Malbrancke, Geneviève Moreas, Mario Sinnaeve<br />
The Production of Customer-Tailored ICDP Rolls by Using Alloying and Graphite Control Strategies ............ 2141<br />
Michael Brandner, Alex Mayr, Tommy Nylen<br />
Thermal Load and Fatigue of Rolls in Hot Rolling ................................................................................................... 2149<br />
Jaroslav Horsky, Miroslav Raudensky, Tomas Luks<br />
Cold Rolling of Metal Foils by Means of Ceramic Work Rolls ................................................................................ 2159<br />
Christian Overhagen, Paul Josef Mauk<br />
Fujico’s CPC/HSS Roll Performance at CMC’s Arizona Micro-Mill and in North America ............................... 2169<br />
Gene E. Lee, Felix Lopez<br />
METALLURGY — STEELMAKING & CASTING<br />
Clean <strong>Steel</strong> & Inclusions<br />
Activity of SiO2 in SiO2-Al2O3-CaO Slags in Equilibrium With Fe-Al Melts .......................................................... 2177<br />
Jiwon Park, Seetharaman Sridhar, Richard J. Fruehan<br />
Effect of S Concentration on Inclusions Entrapment in Solidified Shell ................................................................. 2185<br />
Hiroyuki Ohno, Yuji Miki<br />
Experimental Investigation Into the Influence of Ti on the Clogging of ULC <strong>Steel</strong>s in Continuous Casting ...... 2191<br />
Christian Bernhard, Guangmin Xia, Martin Egger, Andreas Pissenberger, Susanne K. Michelic
Assessing Inclusion Removal in a <strong>Steel</strong>making Ladle: Plant Assessment and Modeling ....................................... 2201<br />
Angelo Máximo Fernandes Marins, Wiclef Humberto Vieira Martins, Carlos Antônio da Silva,<br />
Itavahn Alves da Silva, Joaquim Gonçalves Costa Neto, Varadarajan Seshadri<br />
METALLURGY — STEELMAKING &<br />
CASTING/COMPUTER APPLICATIONS<br />
Modeling & Verification<br />
Effect of Silicon on Hot Shortness ............................................................................................................................... 2213<br />
Erica E. Sampson, Seetharaman Sridhar<br />
Modern Approaches and CFD Modeling of Hot Process Building Air Induction Optimization .......................... 2225<br />
Siegmar U. Baltuch, Edmund G. Baltuch<br />
Model of Gas Flow Through Upper Tundish Nozzle Refractory and Initial Bubble Size ..................................... 2235<br />
Rui Liu, Brian G. Thomas<br />
Determination of Flow Instabilities Inside a Continuous Casting Mold by Particle Image<br />
Velocimetry and Computational Fluid Dynamics ...................................................................................................... 2247<br />
Carlos Vinícius de Carvalho, Luiz Flávio Pereira Costa, Luiza Pessoa Moreira, Gabriel Romeu T. Santos,<br />
Carlos Antônio da Silva, Itavahn Alves da Silva, Varadarajan Seshadri<br />
Online Quality Prediction Based on Learning ........................................................................................................... 2259<br />
Vladimir Sklenar<br />
METALLURGY — PROCESSING, PRODUCTS & APPLICATIONS<br />
Hot Rolled Products & Applications<br />
Impact of Non-Polygonal Ferrite Microstructures on Technological Properties of CSP ®<br />
Processed Low-Carbon Micro-Alloyed <strong>Steel</strong>s ............................................................................................................ 2269<br />
Carl-Peter Reip, Ingo Schuster, Erich Hovestädt, Reinhard Flender, Matthias Frommert<br />
Advanced Analysis and Quantification of Hot Rolled Strip Microstructures by EBSD ........................................ 2281<br />
Matthias Frommert, Joachim Konrad, Carl-Peter Reip<br />
Processing & Performance of <strong>Steel</strong> Products<br />
Importance of Advanced High-Strength <strong>Steel</strong>s and Electronic Units on the Recycling of Automobiles: A Review ... 2293<br />
Kyle Bevans, Matthew Chott, Brandon Ensor, Jamie Fitzgerald, Stephanie Martin, Kent Peaslee, Scott Pisarik,<br />
Luke Walker, Matthew Wilson, Lifeng Zhang<br />
Investigation on Composition and Processing Parameters of Cu/P-Bearing<br />
Corrosion-Resistant Automobile Sheet ....................................................................................................................... 2305<br />
Lu Zhixin, Luo Shinian, Tong Gang<br />
The Induction Heat Treatment Process and the Materials Performance of DIB STAM 1470 .............................. 2317<br />
Jui-Fan Tu, Shou-Chi Lin<br />
Rolling Quality Under Your Control! How 2 Million Coils Fit Into Your iPad ..................................................... 2325<br />
Hans Gerhard Peintinger
CONTINUOUS CASTING/METALLURGY — STEELMAKING & CASTING<br />
Continuous Cast Surface Quality<br />
Further Study of the “Blown Grain” Condition ........................................................................................................ 2333<br />
Rudolf Mišičko, Martin Fujda, Sandra Fedáková, Dagmar Fedáková, E.S. Szekeres<br />
Modification of the Microstructure in the Near-to-Surface Layer of<br />
Continuously Cast Billets of Low-Carbon <strong>Steel</strong> ......................................................................................................... 2341<br />
Jaroslow Marcisz, Bogdan Garbarz, Artur Zak<br />
Improved Determination of the Effect of Alloying Elements on the Peritectic Range in Low Alloyed Cast <strong>Steel</strong> .... 2351<br />
Robert Shepherd, Ingo Knopp, Heinz-Gunter Brass<br />
Addressing Transverse Cracking Problem in Slab Casting ...................................................................................... 2359<br />
S. Kumar, V. Hernandez<br />
Caster Mold Sensing & Control<br />
The Pulsative Electromagnetic Casting Technique for Slab Casting ....................................................................... 2373<br />
Masahiro Tani, Kazuhisa Tanaka, Shinichi Fukunaga, Takehiko Toh, Masafumi Zere<br />
Dynamic Argon Control ............................................................................................................................................... 2381<br />
Bruce R. Forman, Yong M. Lee<br />
Development of the Third-Generation FC Mold by Numerical and Water Model Simulations ........................... 2393<br />
Hongliang Yang, Martin Sedén, Nils Jacobson, Jan-Erik Eriksson, Helmut Hackl<br />
Radio-Frequency Sensor for Liquid <strong>Steel</strong> Level and Flux Powder Thickness<br />
Measurements in Continuous Casting Mold .............................................................................................................. 2401<br />
Franco Macci, Fernando Menchetti, Giuseppe Virone, Riccardo Tascone, Massimo Luni, Maurizio Zanforlin<br />
New Concept of Ledge-Type Eddy Current Level Sensor and Practical Results at SSAB Tunnplat ................... 2413<br />
Michel Dussud, Robert Johansson<br />
ENERGY & UTILITIES<br />
Energy Savings Practical Applications<br />
Development of New Combustion Control System Based on Fuel Gas Humidity at Continuous Annealing Line ... 2421<br />
Koji Iwata, Kenta Karube, Shinji Tanaka<br />
ELECTRICAL APPLICATIONS<br />
Electrical Safety & Upgrades<br />
Electrical Arc Flash Safety and Risk Management ................................................................................................... 2427<br />
Tim Cotter, Louis Hapeshis<br />
Changes to NFPA 70E <strong>2012</strong> ......................................................................................................................................... 2433<br />
James R. White
New Approach for Intelligent Motor Control Centers .............................................................................................. 2439<br />
Terry L. Schiazza, Fabio Mielli<br />
Energy Saving Drives for Hot Strip Mills ................................................................................................................... 2447<br />
Ralph Pugh, Hasan Ramanli, Tayfun Altuntop, Serkay Özalici, Marcelo Lara<br />
Sensor System Technologies<br />
Overcoming Mechanical Issues in Obtaining Stable Length and Speed<br />
Measurements in <strong>Steel</strong> Mills and Billet Caster Applications .................................................................................... 2459<br />
Les Jensen<br />
Synopsis of a Modern X-Ray Thickness Gauge ......................................................................................................... 2465<br />
Jean-Jacques Florent, Jan Gaudaen, Roland Gouel<br />
Study and Application of Cold Rolling Strip Walking Detection System ................................................................ 2479<br />
He Jianfeng<br />
Electrical System Improvements<br />
Basic Concepts for an Integrated <strong>Steel</strong> Process Control System .............................................................................. 2487<br />
Dave Hreha, Fabio Mielli<br />
Effective and Flexible Rolling Mill Automation Upgrades ....................................................................................... 2495<br />
Jens P. Riedel, Rainer Ohnmeiss, Helmar Jungfer<br />
High-HP DC Drive Replacement or Digital Front End (DFE) Upgrade on Rolling Mills ..................................... 2503<br />
Bob Hamlin, Ron Devoe<br />
Application of Large Capacity Voltage Source Inverter to Cylindrical Rotor Synchronous Motor .................... 2507<br />
Katsuhiko Fukuma, Hiromi Hosoda, Kentaro Suzuki, Thomas Richards, Gary Sinders, Marcelo Lara<br />
Investigation of HAGC System Performance With Various Circuitry Design ....................................................... 2519<br />
Remn-Min Guo, Tony Manias<br />
Electromagnetic Devices for Limiting Currents for Starting Large Motor and Fault Currents .......................... 2531<br />
Prafulla R. Deo, Tushar P. Shah<br />
COMPUTER APPLICATIONS<br />
Application-Driven Quality & Cost Improvements<br />
The Development and Technology of the AIST Process Benchmarker (APB) ........................................................ 2539<br />
Patrick J. Gallagher, Noah D. Wolf-Johnston<br />
Innovation for Quality Assurance — Automatic Creation of QA Rules From Claims Data ................................. 2557<br />
Norbert Holzknecht, Jens Brandenburger, Stephan Keil, Fredrich Luecking<br />
MOREintelligence: An Innovative Multi-Dimensional Data Anaylsis System for Metallurgical Processes ........ 2565<br />
Denis Cappellari, Ugo de Siervo, Gregory Guttman<br />
Results of Foaming Slag and Scrap Meltdown Control SIMELT CSM/FSM Based on<br />
Structure-Borne Sound in Electric Arc Furnace Operation ..................................................................................... 2577<br />
Thomas Matschullat, Detlef Reiger, Björn Dittmer, Klaus Krüger, Arno Döbbeler, Helge Mees
COMPUTER APPLICATIONS/MATERIAL HANDLING<br />
Material Handling Technology<br />
The Case for the Eriez ® CleanStream Process ....................................................................................................... 2591<br />
Thomas Saccamozzone<br />
Improved Converter Process Control ......................................................................................................................... 2595<br />
G. Wimmer, M. Hiebler, M. Thumfart, F. Hartl<br />
A Review of Emerging Trends in Mobile and Wireless Technology for<br />
Maintenance and Reliability in the <strong>Steel</strong> Industry ..................................................................................................... 2605<br />
Brian Hagaman<br />
Benefits of Advanced Configuration and Simulation Study ..................................................................................... 2611<br />
Teemu Kolkka, Jagannathan Rajagopalan, Juhn Suksi<br />
PROJECT & CONSTRUCTION MANAGEMENT<br />
Project Management Techniques<br />
Conversion at the Luna Plant in ABS, Italy: 45 Days From Last Rectangle to First Round Bloom Cast ............ 2621<br />
Nicola Santangelo, Luigi Morsut<br />
The 2.3 Mt/Y Most Modern Production Facilities in the Mediterranean Area for<br />
Flat Products at MMK Metalurji ................................................................................................................................ 2627<br />
Alessandro Pigani, Luciano Vignolo, Carlo Piemonte, Paolo Burin<br />
Project Management in the 21st Century Electronic Project Management ............................................................ 2633<br />
Dominick DeSalvo, Peter Mansmann, Laura Goetsch, David A. Scotti<br />
Comparison and Integration of the Ukrainian Project Life Cycle Process With a<br />
Western Front End Loading Process .......................................................................................................................... 2647<br />
Neil Tannyan<br />
MAINTENANCE & RELIABILITY<br />
Continual Improvement Ideas<br />
Remote Operational Monitoring and Control of Auxiliary Process Units and Electrical Systems ....................... 2655<br />
Michael E. Rourke<br />
MORGOIL Bearing Technological Upgrade in TERNIUM-SIDERAR Hot Strip Mill ........................................ 2663<br />
Andres Esteban, Gabriel F. Royo, Peter N. Osgood<br />
A VPP Success Story: Making OSHA 10 Work for You ........................................................................................... 2671<br />
Amber Norris, David Reinhold<br />
Mechanical Condition Monitoring and Analysis Applications in the <strong>Steel</strong> Industry ............................................. 2675<br />
Gabriel F. Royo, Ernesto Perez Rios
Reliability Achievement Awards<br />
Reliability Achievements in the <strong>Steel</strong> Industries ........................................................................................................ 2685<br />
Colleen Reeves<br />
Reliability Achievement Bronze Award: Caster Hydraulic Pusher Table Cylinder Upgrade .............................. 2687<br />
Bill Bennett<br />
Reliability Achievement Silver Award: Improving Mill Performance Through Roll Shop Process Control ...... 2691<br />
John E. Cox III<br />
Reliability Achievement Gold Award: Gear Boxes See Double the Life by<br />
Replacing Conventional Recirculating Oil System .................................................................................................... 2701<br />
Kyle J. Saxton, Jason C. Vicari, James Curto, Richard P. Ellis, Ashley M. Minnick<br />
Personnel & Technology Developments<br />
Combined Utilization of Condition Monitoring and Real-Time Numeric Simulation for a<br />
Condition Forecast Oriented Maintenance Strategy ................................................................................................. 2707<br />
Karl Nienhaus, Christian Bernet, Markus Schütz, Ralph Baltes<br />
The Performance Culture ........................................................................................................................................ 2715<br />
Mark Broussard<br />
Development of Intelligent Machine Condition Monitoring and Diagnostic System at CSC ................................ 2725<br />
Chih-Chung Wang, Chung-Ho Kuo, Chen-Sen Ouyang, Chien-Wei Lee, Chun-Chuan Chao<br />
Safer Lock-Out Tag-Out With Permanent Electrical Safety Devices — Electrically Safe<br />
Work Conditions Based Upon NFPA 70E and OSHA .............................................................................................. 2735<br />
Philip B. Allen<br />
Development of Non-Destructive Crack Inspection Technique for Conveyance Roll Using Vibro-Thermography .. 2741<br />
Yoshiaki Nishina, Daisuke Imanishi, Youichi Yoshinaga<br />
New Ideas for All Areas of the Plant<br />
EAF Equipment Redesign for Maximum Operational Performance and Extended Component Life ................. 2749<br />
Robert Strain, Kirk Rounds<br />
Maintenance Strategy Implemented in the New ThyssenKrupp CSA Plant in Brazil ........................................... 2755<br />
Ricardo Pascotto, Dalber Da Silva, Clauduio Viana, Franz Kolmbauer, Klaus Stohl, Karl Trnka<br />
Nip Pressure Measurement System ............................................................................................................................. 2763<br />
Edward J. Schaming<br />
Collaborative Mobile Maintenance Method for Reclaimer ...................................................................................... 2771<br />
KwanHee Lee<br />
LUBRICATION & HYDRAULICS<br />
Lubrication & Hydraulics<br />
Improved Gear Spindle Longevity in a Cold Reduction Mill Operation ................................................................. 2781<br />
Dan Housel, John Kurosky, Tim Crimmins
Effective Lubrication Solutions for <strong>Steel</strong> Mill Equipment ........................................................................................ 2787<br />
Nael Zaki, Anuj Mistry, James Sidow<br />
REFRACTORY SYSTEMS<br />
<strong>Steel</strong>making & Refractory Technology<br />
The Technology, Benefits and Measurement of the ELBY Ladle Bottom ........................................................... 2795<br />
Andy Toner, John Boeing, Jim Caprio, Albert Dainton<br />
New Magnesia-Alumina-Carbon Brick Technology for <strong>Steel</strong> Processing Vessels .................................................. 2801<br />
David E. Shewmon, Israel Peretz<br />
Calcium Corrosion of a Zirconia Slidegate Refractory ............................................................................................. 2807<br />
Javier Pascual, J.E. Shoff, Christoph Bauer, Martin Wiesel, Stacey Tate<br />
The Longevity Technology of Refractory Linings of AOD Refining Furnaces in Baosteel ................................... 2815<br />
Hebing Chi, Shi Lli, Donggang Li, Jihe Wei<br />
CRANES<br />
Crane Technology Improving Maintenance & Safety<br />
Expert Operator Control for Increasing Safety, Productivity and Operability of Cranes .................................... 2821<br />
Khalid Sorensen<br />
Safer Vibration Readings of Overhead Cranes in a <strong>Steel</strong> Manufacturing Environment ....................................... 2829<br />
George R. Kredel<br />
Material Handling: Focus on Safety With the Customization of Lifting Devices and Plant-Wide Evaluations ...... 2835<br />
John Novak, Kirk Rounds, Larry Arnold, Jim Davis<br />
Extending Wireless Technology for Remote Control of Crane Brakes,<br />
Equipment Monitoring and Encoder Feedback ......................................................................................................... 2847<br />
Randy Creech
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