TABLE OF CONTENTS AISTech 2011-Volume II ... - Steel Library

TABLE OF CONTENTS
AISTech 2011-Volume II
Author Index ........................................................................................................................................1377
COLD SHEET ROLLING
Cold Mill — Shape
Modeling Local Buckles and Predicting Limiting Values for Factors Causing Local Buckles in
Cold Rolling................................................................................................................................................1
Y. Liu, J. Fan, H. Zhang
Filtering Winding Effects From Control Systems in Cold Rolling Operations .................................13
J.L. Hinton, A.S. Malik, R. Grandhi
Improved Strip Edge Management and Shape Control Using Induction Work Roll Heating for
Light-Gauge Cold Rolling .......................................................................................................................25
N. Almstedt, D.C. Doerschuk, J.R. Fry
Reachability Conditions of Shape Targets in 20-High Cluster Mills..................................................35
M.E. Zipf, C.K. Godwin
Recent Development of Skinpass Mill and Tension Leveler................................................................49
E. Mukai
Pickling and Cold Mills
Automation and Drive Replacement for the CSN LLC Two-Stand Reversing Cold Mill................65
T.E. Richards, G. Sinders
Advanced On-Line Measuring Systems for Efficient Cold Strip Production....................................75
R. Holz, K. Hoen, W. Igelhorst, A. Kohlrausch
Improving Yield by Implementing an Automatic Slowdown Feature in a Cold Rolling Mill..........87
E. Rodriguez, A. Demagistris
Technology Packages for Quality and Yield Improvement in Cold Rolling Mills ............................95
G. Graessl, A. Maierhofer
New Power X-Hi Mill Technology for Stainless Steel and Silicon Steel Cold Rolling, and a Recent
In-Line Application................................................................................................................................103
M. Landy, A. Mauuary, O. Liétar, E. Chaillot, J.-L. Legoupil, V. Cronier, H. Dagn, D. Hawkins
Hybrid Water Mist Extinguishing System for Pickle Lines...............................................................111
F. Barstow, T. Euson

Roll Shapes
Determination of Corrosion Rates for Cold Rolling Coolant, Rolling Oil and Selected
Tramp Oils..............................................................................................................................................115
M.A. Nicholls, X. Cheng, R. Taylor, Q.M. Springstead
The Roll Shop Simulator.......................................................................................................................127
A. Gurrieri, C. Trevisan
Transitioning from Bare, Chrome-Plated or Rubber Rolls to Thermal Spray Carbides/Cermets
and Laser Overlays................................................................................................................................135
M.S. Brennan
Fundamentals of Roll Cooling and Control of Flatness at Primary Cold Reduction......................141
D. Lloyd
Premium Quality Rails..........................................................................................................................155
L. Maestrutti, L. Gori
Continuous Anneal
Use of a Novel Biodispersant to Enable Strip Quenching After Annealing With Less Than Optimal
Quality Water.........................................................................................................................................165
J. Gleason, K.C. Willis
Baosteel Flatness Control System Used on 6-High Skinpass Mill in 2030 New Continuous
Annealing Line .......................................................................................................................................173
J. Xu, S. Li
COLD SHEET ROLLING/GALVANIZING
Flat Rolled Processing Equipment
New Developments and Technologies for Strip Guiding Applications.............................................179
T. Dornseifer, J. Fryn, S. Devorich
Manual to Automatic Packing: A Case Study at Uttam Galva Steel Limited (UGSL)...................195
S.G. Tudekar, T. Kolkka, J. Rajagopalan
Study on the Design Electromagnet and Pole Shoes for Flexible Steel Strip Shape and Vibration
Control ....................................................................................................................................................213
T.I. Jang, Y.H. Kweon, C.H. Jee, Y.S. Jin

GALVANIZING
Galvanizing — Importance of Steel Surface Interactions
New Continuous Hot-Dip Galvanizing Line DVL3 at Tata Steel, Netherlands...............................219
D. Cerrone, P. Podda, O. Lietar, A. Challaye
Influence of Annealing Process on the Selective Oxidation Behavior of Cold Rolled Dual-Phase
Steel .........................................................................................................................................................223
K.C. Yang, T.R. Chen, Y.S. Hwang
PLATE ROLLING
Advances in Plate Rolling Technology
Integrated Roll Shops for Heavy Plate Applications..........................................................................233
G. Boselli, D. Quaglia, I. Grataroli, M. Cozzi
Advances in Coil-to-Plate Stretch Leveling Line Technologies.........................................................243
M.F. Italiano, R. Mercer, E.S. Orzel, A. Waigand, R.W. Williams, H. Zhao
NISCO Plate/Coil Mill Level 2 Force Model Improvements.............................................................253
B. Li, P. Zhu, D. Wang
The Latest Technology of the Heavy Plate Leveler ............................................................................265
T. Aoyama
Automatic Slab and Thick Plate Surface Inspection..........................................................................275
S. Burkhardt, J. Erxleben, K. Buchanan
PLATE ROLLING/METALLURGY — PROCESSING, PRODUCTS AND APPLICATIONS
Metallurgical Advancements in Plate Rolling
New Analysis- and Simulation-Features of the Microstructure Monitor and First Results from
Plate Mills ...............................................................................................................................................281
H.-U. Löffler
Sustainable Plate Manufacturing .........................................................................................................289
S. Haine, R. Thackray, M. Steeper
ROD AND BAR ROLLING
Rod and Bar Rolling Technologies
Cemented Carbide Rolls for Rolling SBQ Bars..................................................................................297
S.-E. Lundberg

EcoStar — A New Generation of Cost-Saving and Long-Life Rollers .............................................311
J. Pöppl, G. Shan, H. Thöne, F.G. Wimmer
Expanding the Free-Sized Rolling Range After Introducing a New 3-Roll Technology.................317
K. Kawakami, N. Suetomi, A. Hayashi, Y. Ogata
Best Practices to Implement Complete Revamping of Obsolete Plants............................................331
M. Capitanio, R. Migliorati
Rod and Bar Quality Technologies
Development of a Three-Dimensional Mathematical Model for Real-Time Simulation of
Continuous Reheating Furnace Operations ........................................................................................341
J.E. Jenkins, C.K. Tran, J. Ward, J. Broughton
Quality Improvement in Replacing Universal Mills and Changing Pass Schedules .......................353
K. Miyagawa
Technological Innovations for the KOCKS 3-Roll Reducing and Sizing Block ..............................361
O. Dewald, G. Ullrich, M. Kruse
Quality Assurance Improvement by Remodeling Inspection-Line Layout......................................369
K. Honda, M. Ohno, Y. Otagaki, K. Isogami
Danieli CMS-Condition Monitoring System .......................................................................................379
D. Brandolisio, R. Chiozza
ROD AND BAR ROLLING/MATERIAL HANDLING
Rolling Mill Material Handling
Bar Code Identification of SDI Bars ....................................................................................................389
D.L. Anderson
Live Tracking of Billet Inventory.........................................................................................................399
K. Normofidi
ROLLS
Roll Shop Practices
Study of Contact Fatigue Phenomena Influence on Backup Rolls Rolling Campaign Duration and
Grinding Operations..............................................................................................................................405
M. Paura, A. Di Schino, D. Stocchi, S. Lionetti, M. Calderini, S. Neri, S. Locci, R. Coletti

Roll Safety Roundtable
Backup Roll Failures .............................................................................................................................413
K. Marsden
METALLURGY — STEELMAKING AND CASTING
Metallurgical Technology at the Caster
Measurement of Spray Cooling Nozzle Impact Pressure Footprints and Its Applications in
Continuous Casting................................................................................................................................423
M. Penno, H. Yin, R. Moravec, K. Blazek
Development and Application of a Quantitative Tool to Assess Casting Behavior .........................433
G. Torga, D. Gonzalez Atchabahian, J. Scoccia, C. Capurro, C. Cicutti
Fluid Flow Behavior Delivered to a Tundish via a Dissipative Ladle Shroud (DLS)......................441
K. Morales-Higa, R.I.L. Guthrie, M. Isac, R.D. Morales
Analysis of Mold Flow Structure at ArcelorMittal Indiana Harbor No. 1 Slab Caster..................453
M.M. Yavuz, J. Thacker
A Model for Slag Eyes in Steel Refining Ladles Covered With Thick Slag .....................................463
K. Krishnapisharody, G.A. Irons
Analysis of the Continuous Casting’s Stopper Rod Sticking.............................................................473
H.A.A. Lima, M.G. Rogana
METALLURGY — STEELMAKING AND CASTING/LADLE AND SECONDARY
REFINING/CONTINUOUS CASTING
Inclusions and Steel Properties, Inclusion Evaluation
Comparative Study of the Inclusion Size Determination by PDA-OES and Inclusion Extraction
Technique................................................................................................................................................481
M.M. Pande, M. Guo, R. Dumarey, S. Devisscher, B. Blanpain
How to Evaluate a Process for Clean Steelmaking and Quality Control .........................................493
P. Kaushik, H. Yin, H. Pielet, M. Lowry
The Effects of Nonmetallic Inclusions on Local Ductility ..................................................................507
K.-I. Yamamoto, H. Yamamura, D. Maeda, Y. Suwa
Steel Defect Arresting Device (S-DAD TM ) for Improving Steel Quality...........................................517
D. Janssen, J. Simoes, P. Desai
Inclusion Engineering
Wettability and Mechanical Properties Assessment of Nano TiO2 and Armco Iron System.........529
Z. Amondarain, L. Kolbeinsen, J.L. Arana

Modification of Inclusion Composition in Steel During Secondary Metallurgical Ladle Treatment
— A Comprehensive Process Simulation Model.................................................................................537
Q. Shu, O. Volkova, S. Lachmann, P.R. Scheller
Cleanliness Evaluation for 27SiMn Steels Produced by BOF→LF→Billet Casting Process .........549
L. Sun, L. Zhang, J. Li, A. Dong, Y. Chen, S. Yang
Development of Grain Refiner Alloys for Steels .................................................................................559
C. van der Eijk, F. Haakonsen, O.S. Klevan, Ø. Grong
Control of Inclusions During Steel Refining
Production of High-Strength Low-Alloy Bridge Steels ......................................................................567
Y. Chen, J.S. Li, L. Sun, S. Yang, A. Dong, L. Zhang
Inclusion Characterization of Titanium Stabilized Ultralow-Carbon Steels — Impact of Oxygen
Activity at Deoxidation..........................................................................................................................575
C. Lyons, P. Kaushik
Calcium Treatment of Molten Steel With an Innovative New Calcium Wire: Hi-Cal ® .................585
V.J. Jackisch, C.J. Jackson, J.L. Emerick
Modification of Inclusions and Inclusion Engineering
Formation and Modification of MgO-Al2O3-Based Inclusions in Alloy Steels ................................591
S. Yang, L. Zhang, L. Sun, J. Li, K. Peaslee
Decrease in MgO Content of Spinel Inclusions During Calcium Modification ...............................607
N. Verma, P.C. Pistorius, R.J. Fruehan, M. Lind, H. Oltmann, E. Pretorius, M. Potter
Thermodynamic and Experimental Study on the Modification of Non-Metallic Inclusions
Through the Contact With CaO-Al2O3-MgO Slags............................................................................617
S.K. Michelic, M. Hartl, C. Bernhard
Inclusion Compositions Before and After Calcium Treatment Measured Using Automated
Inclusion Analysis Methods ..................................................................................................................627
N. Verma, P.C. Pistorius, R.J. Fruehan, M. Lind
A Laboratory Study of Factors Affecting Sulfide Shape Control in Plate Grade Steels ................635
A. Dash, P. Kaushik
Effects of Calcium Treatment on Magnetic Properties of High-Efficient Nonoriented Silicon Steel
Sheets.......................................................................................................................................................651
F. Zhang, G. Li, B. Wang, Y. Zhang

Control of Inclusions During Steel Continuous Casting
Formation of Intragranular Acicular Ferrite in C-Mn Steel by Ti-Al Complex Deoxidization ....661
C. Yang, M. Jiang, Z. Hu, N. Lu, X. Wang
Effect of Nozzle Clogging on Surface Flow and Vortex Formation in the Continuous
Casting Mold ..........................................................................................................................................669
S.-M. Cho, S.-H. Kim, R. Chaudhary, B.G. Thomas, H.-J. Shin, W.-R. Choi, S.-K. Kim
Process Diagnosis on ULC Steels Cleanliness and Redesign of the Tundish
at ArcelorMittal LC...............................................................................................................................681
R.D. Morales, J. Delgado-Pureco, R. Lule, S. Morales, F. Lopez
Surface Tension and Temperature Effect on Entrapment of Bubbles and Particles in Continuous
Casting of Steel.......................................................................................................................................697
S.-M. Lee, S.-J. Kim, H.-G. Lee
Analytical and Numerical Approach for Inclusion Removal in the Continuous Casting
Tundish ...................................................................................................................................................705
H. Arcos-Gutierrez, J. de J. Barreto, S. Garcia-Hernandez
Fluid Flow and Steel Cleanliness in a Continuous Casting Tundish and Mold...............................717
S. Yang, L. Zhang, J. Li, F. Lu, K.D. Peaslee
METALLURGY — PROCESSING, PRODUCTS AND APPLICATIONS
Microstructural Characterization
Qualitative and Quantitative Techniques for Evaluating Manganese Segregation in Advanced
High-Strength Steels at ArcelorMittal Dofasco’s No. 1 Continuous Caster.....................................731
J. Sengupta, J. Casey, D. Crosbie, B.D. Nelson, G. Kladnik, N. Gao
Microtexture Evolution on Grain-Oriented Electrical Steel .............................................................741
M.-C. Tsai, Y.-S. Hwang
Mechanical Behavior
The Development and Manufacture of Ultrathin Cast Strip Steel Products With High Residual
Element Levels via the CASTRIP ® Process.........................................................................................751
D.G. Edelman, P.C. Campbell, C.R. Killmore, K.R. Carpenter, H.R. Kaul, J.G. Williams,
W.N. Blejde
Grain Refinement of Austenitic Manganese Steels.............................................................................763
F. Haakonsen, J.K. Solberg, O.S. Klevan, C. van der Eijk
Thermal Processing
Model of Microalloy Precipitation During Continuous Casting and Refining ................................773
K. Xu, B.G. Thomas, M.S. Dyer, J.G. Speer, D.K. Matlock

Influence of V(C,N) Precipitation Potential on Recovery Annealing Response of Microalloyed
Sheet Steel...............................................................................................................................................785
J. Raines, D.K. Matlock, J.G. Speer, R.J. Glodowski
Direct Steel Sheet Production From Solid Pig Iron — Gaseous Decarburization of White
Cast Iron .................................................................................................................................................795
J.-O. Park, Y. Sasaki
Slag Module for 3D Visualization of Ternary Phase Diagrams Tutorial .........................................799
W. Zhao, H. Abramowitz, E. Johnsen, M.A. Roller
Product Metallurgy
On-Line Quality Data Warehouse for Metallurgy .............................................................................811
V. Sklenar, V. Zitko, J. Knobloch, P. Cermak
Successful Development of a New Steel Product — Importance of Process Modeling and Dynamic
Logistics Simulation...............................................................................................................................819
S. Kumar, J. McGinty, V. Hernandez, S.-E. Lundberg
The Development of Wind Turbine Bolts Steels in China Steel Corp. .............................................833
S.-C. Lin, J.-F. Tu
ENERGY AND UTILITIES
EAF Energy Optimization
Realization of the Coexistence of Energy Savings and Environmental Measures in the EAF-
Concept of ECOARC TM ........................................................................................................................845
Y. Sato
Optimization of Reheat Furnaces
Rugged, Verifiable, In-Situ Oxygen Analyzers for Combustion Optimization in Steel Reheat
Operations ..............................................................................................................................................857
Y.H. Boltz, E.S. Boltz, D.B. Knight, K. Taylor
Recent Cost Reduction Developments in the Heating of Steel...........................................................863
S.J. O’Connor, A.G. Fennell
Control Method for Low Oxygen Concentration of Waste Gas is HSM Reheating Furnace ........873
H.-H. Cheng, Y.-L. Hsu, C.-M. Liao, T.-S. Huang, C.-H. Wang
Process Control and Automation Systems Advancements for Reheat Furnaces.............................883
G.R. Hurd, E. Rodriguez, J. Kaufman, J. Ward, H.C. Wu

Energy Management
Identifying Energy Efficiency Opportunities for Steel Industry — The Production Energy
Optimization Concept............................................................................................................................895
R. Steele, F. Mielli
The Challenge of Heat Recovery in Integrated Steel Plants..............................................................901
C. Born, R. Granderath
Strategic Energy/CO2 Model for ArcelorMittal Burns Harbor ........................................................913
A. Kirk, H. Pielet, M. Atkinson, H. Silva
Preparing Your Company for the Future Energy Management Systems Requirements Like ISO
50001........................................................................................................................................................923
E. La Bruna, G. Zafred
ELECTRICAL APPLICATIONS
Sensor Systems
Wireless Technology — A Revolution in Temperature, Oxygen and Carbon Measurements in
Molten Metal ..........................................................................................................................................931
D.G. Janu, R.R. Rote, T.W. Junker
Development and Experience with In-Chain Caster Measuring Systems........................................943
R. Cowlishaw
Drives
Selection of Induction Motor Drives for Reversing Hot Mill Roller Tables ....................................953
N.A. Price, P. Jackson, S. Kodama
Large-Capacity Motor Drives...............................................................................................................965
R. Tessendorf, H. Hosoda, K. Fukuma, Y. Baba
Challenges in Reliable Electrical Testing of Rotating Machines.......................................................977
H.W. Penrose
STATCOM for Maintaining Power Quality in a Grid Feeding a Steel Plant..................................983
R. Grünbaum, J.-P. Hasler, A. Owens, J. Rasmussen
SINAMICS High-Efficiency Drive Technology for Rolling Mills .....................................................993
P. Bhooplapur, H. Wiechmann

COMPUTER APPLICATIONS
Software Applications
Automatic Slab Quality Grading Successfully Implemented at Continuous Caster at Shougang
Corp., QianGang, in Three Months ...................................................................................................1001
H.G. Peintinger
Integration of Automation Solutions of Casting and Rolling for Better Control
of Product Quality................................................................................................................................1007
A. Mukhopadhyay, B. Šarler, A. Polo, M. Ometto
Integrated Steelmaking Plant Process Automation and Optimization...........................................1021
J. Knobloch, T. Ochmann, T. Bartonek, L. du Preez, S. Fouche
Make-to-Stock Finish-to-Order: Responsive and Cost-Effective Steelmaking..............................1033
S. Wilson
Hot and Cold Rolling Applications
Surface Defect Detection Using 3D Imaging for Commercial Automated Surface Inspection
System Performance Improvement....................................................................................................1041
B. Chen, L. Zhang, H.A. Long
New Edger with Optimum Automation for the Hot Strip Mill at ThyssenKrupp Steel Europe in
Bochum .................................................................................................................................................1047
G. Schneider, D. Ehlert, T. Koch, M. Korzi
Comprehensive Strip Temperature and Microstructure Control Revolutionizes Hot Strip Mill
Automation ...........................................................................................................................................1051
K. Weinzierl, H.U. Löffler, M. Rößiger, U. Houben
An Effective Interstand Cooling in Hot Strip Mill ...........................................................................1061
D. Hajduk, J. Knobloch, M. Raudenský
Legacy Systems — Upgrade or Replace?
Replacement of Mill Floor Data Collection System at United State Steel Corporation — Great
Lakes Works.........................................................................................................................................1069
M. McCabe, B.J. Bonner
Advanced or Novel Automation Technology
Development of Next-Generation Level 2 Model as Metallurgical System....................................1075
B. Li, D. Wang, P. Zhu

PROJECT AND CONSTRUCTION MANAGEMENT
Project Facility Improvements
Mill Bay Crane Runway 110T-120T Upgrade ..................................................................................1087
W.E. Vanni, J. Fong, C. Folkman, R. Brooks
What’s New in Fall Protection, Hazard Analysis and Rescue Planning.........................................1095
A.T. Galpin
Modern Approaches and CFD Simulation in the Ventilation of Hot Process Buildings ..............1107
S.U. Baltuch, E.G. Baltuch
International Sourcing of Ironmaking Plants and the New Approach of TKCSA for the
Management of Its Construction and Commissioning.....................................................................1117
H. Eichelkraut, J.T. Marins, P.C. Guillaume, B. Scheuer
Field Data-Based Mathematical Simulation and Optimization of a Complex Construction
Activity..................................................................................................................................................1127
J.P. Modak, D.K. Parbat, S.P. Mishra
Project Management Best Practices
Design of a Greenfield Integrated Steel Plant Using Dynamic Computer Simulation..................1139
R.W. Sindrey, M. Patel
MAINTENANCE AND RELIABILITY
Maintenance Planning and Management
Protecting Intellectual Property — Patent or Trade Secret? ..........................................................1147
A.T. Stein, J.F. Marsh, R.E. Gaum
Creating and Sustaining a Culture of Reliability .............................................................................1157
R.K. Brooks, G.R. Hutto
The Weld Cladding of Foot and Top Segment Rolls to Improve Roll Life ....................................1165
P. Collins, S. Hunt, D. Le Jeune
Mechanical
The Timken ADAPT Bearing for Slab Support Rolls in Continuous Casters...............................1175
N.A. Los, J.H. Rhodes, G. Daberger
Rolling Mill Main Drive Spindles.......................................................................................................1183
J. Mackel

Reliability Achievement Awards
Reliability Achievement Bronze Award: Spares Consolidation at USS-POSCO Industries........1193
T.D. Kuzmicky, M.T. Brevig
Reliability Achievement Silver Award: ArcelorMittal Burns Harbor Hot Strip Mill Achieves
Nearly $2.3 Million in Savings Through the World-Class Equipment Reliability Program........1203
S. Piech
Reliability Achievement Gold Award: Reliability-Based Approach to the Combustion
Process...................................................................................................................................................1213
D. DaSilva, F. Blanco
Environmental, Energy Savings and Safety
Steel Process Fans — Energy Efficiency Upgrades: The Right Way, the Only Way....................1225
D. Banyay
Electrical Maintenance Practices That Impact Safety .....................................................................1229
M. Moore
MAINTENANCE AND RELIABILITY/LUBRICATION AND HYDRAULICS
Monitoring and Measurement
Test Methods for Hydraulic Media....................................................................................................1233
A.K. Guven
The Future of Green Bearing Protection...........................................................................................1241
K.V. Wong
Application of the Intelligent Lubrication System on the 4300mm Heavy Plate Hot
Rolling Line ..........................................................................................................................................1251
D. Wang, P. Wang, Z. Ding, H. Zhao
Gearboxes See Double the Life by Replacing Conventional Recirculating Oil System ................1263
K.J. Saxton, J.C. Vicari, J. Curto, R.P. Ellis, A.M. Minnick
REFRACTORY SYSTEMS
Refractory Technologies
Introduction of Slidegate Plate Technology Contributing to Reducing Environmental
Burden...................................................................................................................................................1271
Y. Shin, T. Iwaguchi, T. Fushimi
Mathematics Modeling of Thermal Shock in Refractory Linings...................................................1279
A.V. Zabolotsky

Optimum Lining Performance for Particular Process Slags in Metallurgical Vessels Supported by
Thermomechanical Modeling .............................................................................................................1289
M. Kirschen, R. Lanzenberger, B. Petritz, T. Prietl
Insulating Firebrick — Maximizing Energy Savings in Iron and Steel Applications Through
Product Selection .................................................................................................................................1299
A. Wynn, E. Magni, M. Marchetti, S. Chernack, C. Johnson
State-of-the-Art Cold Setting Working Lining Mixes for Tundish.................................................1309
R. Komanecky, B. Petritz, R. Sorger
MATERIAL HANDLING/PACKAGING, SHIPPING AND TRANSPORTATION METHODS
Material Handling Improvements
Enhancing Personnel Safety Through RFID Technology and a Personnel Safety System...........1317
J.W. Franz
Environmentally Friendly Solutions for Coil Handling in Process and Storage Areas ................1325
M.K. Baach
Designing SAFE Instruction: The Use of 3D Animation for Safety Training In a Forklift Safety
Module ..................................................................................................................................................1333
S. Weppel
CRANES
Smart Crane Control — Improving Productivity, Safety and Traceability ..................................1341
J. Rowe
Reduce Maintenance Time and Save Costs for Hot Metal Crane...................................................1347
F.-T. Lin
Modern Crane Works Safety Technology .........................................................................................1355
I.L.A. Horst
Analysis of 30 Years of Using a Runway Beam.................................................................................1367
J.G. de Araújo Silva, L.F. Loureiro Ribeiro