EUROPEAN STEEL TECHNOLOGY AND APPLICATION DAYS 2017 - ESTAD 2017

In 2015, Mitsubishi-Hitachi Metals Machinery and Siemens VAI Metals Technologies established a new joint-venture company for the metals industry under the name Primetals Technologies. As one of its strategic core values, Primetals Technologies tackles the challenges faced by the metals industry that include raw-material price and quality volatility, excess steel capacity that has an impact on...

The previous three industrial revolutions were all triggered by technical innovations. Currently, Industry 4.0 is a popular term to describe the imminent changes of the industrial landscape, particularly in the iron and steel production and consequently in the refractory industry.The full digitization of industry promises significant efficiency gains. This development has already started to...

The flat steel feed stock for final fabrication of steel products is mainly covered by cold rolled and final annealed or galvanized strips. Depending on the thickness and surface demands, also conventional batch processes can serve a certain but truly very limited ratio. The Arvedi ESP Technology is giving new impulses into this market. With this game changing technology it is suddenly...

This paper provides a short overview of recent steel market developments considering the global steel oversupply and recessions in some emerging economies. The enormous Chinese overcapacity combined with their lower demand is a major reason for the deterioration on the steel market. The general steel demand also declines due to slow growth or even reductions in technology fields like ship...

**Climate issues are inseparably linked with energy and industrial topics.** For (European) steel industry and in particular for voestalpine, this refers one the one hand to our **customers and markets** (nearly two thirds of Group revenue are generated with the segments energy and mobility), and on the other hand―equally important―to our **production processes and products,** which are...

Hot work tool steels have been developed, employing combined precipitation of carbides and intermetallic particles. Synergistic precipitation hardening effects were used to reduce the necessary carbide content. An appropriate minimum of nickel and aluminium additions were determined to precipitate intermetallic NiAl particles, maintaining the materials characteristics. Material and...

In November 2015 voestalpine Stahl Linz started up its secondary metallurgy No. 4. This facility consists out of a ladle furnace, a RH vacuum degasser and a trimming stand and is located in the east of the steel plant just opposite to the slab caster CC 7. Already in the early phase of a feasibility study it was decided that this secondary metallurgy will be an investment for the `high end´...

The AOD process is primarily used for stainless steel making since conventional BOF converters lead to high loss of Cr and other alloy elements due to oxidation. During the different operational stages, namely decarburization, reduction and desulphurization, an O2/Ar mixture is fed into the converter via submerged tuyeres that can be located either in the side wall or the bottom. The O2/Ar...

After a short decision making process voestalpine Stahl Linz decided in June 2013 about their largest foreign investment project for the installation of a 2.0 MTPY Midrex HBI plant in Corpus Christi, Texas/USA. A consortium of Primetals USA LLC and Midrex Technologies was awarded for the supply of Equipment, Engineering and Technical Services of the Direct Reduction plant as green-field...

Today, one of the main goals in optimization of the iron and steel making processes is the consideration of environmental protection and energy saving in every plant area. Not only the processing from iron ore, reducing agents and additives has to be taken into consideration but also the handling and conveying of the materials between the different process steps. This paper provides some...

Actual improvements in rolling e.g. in relation to power requirements, energy consumption and final material properties demand powerful and robust simulation tools for process optimization, pre-setting calculations or automation. The semi-industrial rolling equipment of the institute of Metal Forming of TU Bergakademie Freiberg is used during the period of simulation development as well as for...

**Abstract** In this work, we present a novel inspection technique for surface defects on cold and hot steel products during production. Common approaches for cold steel products are based on 2D images, which are highly influenced by the surface texture and thus lead to high false alarm rates on hot surfaces. Automated detection of defects on hot surfaces is of special interest, though,...

Si bearing automotive steels manufactured from the Compact Strip Production (CSP) are used for making the surface critical Wheel & Rim application. A lot of scale issues are encountered in these grades making it very difficult to meet the urgent needs of the customer and it also leads to a lot of downgrading at Tata Steel’s premises. A cross functional project was undertaken at Tata Steel’s...

Due the increasing requirements for an integrated system for dimensional measuring and defect detection, Danieli Automation has recently developed an innovative defect detection algorithm. Based on the data grabbed by the same high speed cameras also used for profile dimensional control, it builds a complete production quality assurance package. A high density and accurate 3D surface of the...

It is well known now that the ingot defects like hot tears or cracks are rooted at the first beginning of the solid shell birth. Damages result from the competition between hydrostatic pressure within the turbulent flow of the liquid zone and the solidifying skin under tensile stresses and strains state. In addition, the thermal energy extracted from the cast product by the mold has huge...

The changed chemical composition of modern advanced high-strength steel (AHSS) grades has certain influences on the pickling process. Especially the higher contents of silicon and manganese have a critical impact on the process, which leads to problems in conventional pickling lines. The most significant challenges are sludge occurrence, varying pickling times, changed visual appearance,...

The article focuses on the hot rolling of large diameter bars (round bars of 500mm) using either continuous casted blooms or ingots. This kind of product is often manufactured by forging an ingot. The forging process is able to applied large deformation and thus to ensure a good metallurgical microstructure (small grain size, no porosities or micro-cracks…). However, this process has two main...

Fire hazard in the steel industry is not a new topic and the steel industry is taking any possible efforts to lower the fire hazard in its production plants. Fire hazard is present in several different forms, but fires induced and intensified by mineral oil based lubricants are notorious and feared. For hydraulic fluids several alternatives are available, but for lubricating greases fire...

Outotec is a pioneer in rotary kiln direct reduction with coal offering the well-proven SL/RN and the more recent SL/RN-Xtra technologies. The SL/RN-Xtra technology uses hot offgas from the rotary kiln to pre-harden green pellets on a travelling grate, before they are fed to the rotary kiln. This not only increases energy efficiency of the process, but also the production rate of the standard...

The sustainability of the electric steelmaking route is affected by several factors, such as the electric energy consumption, the waste production, the CO2 emission, as well as by the consumption of freshwater and the amount of wastewater. The improvement of the water management in the electric steelworks can lead to a reduction of their water footprint and impact on the surrounding...

The need for more effective and flexible roll-gap lubrication technologies in hot- and cold-rolling mills is steadily increasing due to ever-greater requirements placed on the rolling process and the final products. This paper focuses on two innovative technologies for highly efficient roll-gap lubrication for hot and cold rolling. For cold rolling mills, MQL® (a new generation of roll gap...

POSCO has developed CEM® (Compact Endless cast and rolling Mill) process, which is based on high casting speed with 6~8m/min and endless rolling from mold meniscus to down coiler. Mechanical design improvement and high speed technology development have been achieved through various efforts such as the mold pool flow control, water cooling in the caster and the mold level hunting control. For...

Rising energy demand and steadily decreasing quality of raw materials due to the global resource depletion are great challenges to the steel production today. The FINEX® Process has been developed jointly by POSCO, Korea and PRIMETALS Technologies Austria, to provide the iron making sector with the capability to lower hot metal production costs, environmental pollutions and to increase the...

Inline measurement of mechanical and magnetic properties of steel strip with contactless, non-destructive techniques offers considerable potential for further technological optimization and new applications. This is achieved by the PropertyMon system from Primetals Technologies employing state-of-the-art methods for indirect measurements using electromagnetic signals. By measuring the...

Electromagnetic, mechanical or gas stirring can improve thermal, mechanical and chemical mixing. Bottom gas stirring is the dominant method. Physical modeling has been extensively employed in the past 40 years to describe mixing phenomena due to bottom gas stirring in metallurgical ladles. The opacity of the steel/slag system and its scale are two factors that impose limitations to fully...

Over the last 25 years the thin slab casting and rolling process has been gaining a major market share in the production of hot rolled strip, progressively eroding the areas previously of exclusive domain of conventional mills. This is mainly thanks to the competitiveness of the process over conventional ones, and to the growing ability of this technology to cover the majority of market...

Explosions due to the entrapment of water by molten iron, steel, or slag pose a very serious safety risk in the industry, and can occur during any of the several molten stage processes involved in iron & steel making. Although prevention of these explosions is the primary objective, understanding the overpressure resulting from an explosion is important for worker protection, and to the...

An electrical steel with 1.24wt.% Si was hot rolled, hot band annealed and cold rolled (CR) to a rolling reduction of 78%. The as-CR specimen was subsequently annealed at the temperature range between 500°C and 900°C, and Vickers microhardness tests was performed on these specimens to determine the recrystallization (RX) temperature. Recrystallization was found to start at the temperature of...

The process of liquid steelmaking is characterised by a large throughput of resources and energy. It is performed along a chain of different batch processes performed consisting of several aggregates for heating and metallurgical refining of the liquid steel melt. The objective of the production process is to deliver liquid steel melts with narrow quality targets regarding temperature and...

Coke oven gas (COG), as a kind of high heat value source, was projected to be injected into free board of the COREX melter gasifier. In this paper, a static model had been created based on mass and heat balances. The model was capable of calculating the temperature of free board, the quantity of COG injected and top gas. The results showed that the COG injection into free board can adjust its...

A series of measurement systems have been developed by CRM during last years. This covers measurements from entry to exit of galvanising line. These measurements cover: oxide thickness measurement for oxydo-reduction control inside furnace, the shape of the strip inside furnace to control heat buckles, the position of wipers and the shape and vibrations of strip at bath level to control zinc...

Strip biting is considered the most critical moment for hot rolling. Rolling could be done only if it is succeeded; otherwise the strip cannot be threaded into the mill stand and cobble will be happened due to material accumulation. The possibility of having such problem will be increased while using RGL (Roll Gap Lubrication) during the strip head biting. Based on an empirical experience,...

The many new steels being developed to address the light-weighting car initiative put new demands on the thermal processing equipment in order to obtain the desired mechanical properties. Higher annealing temperatures, faster cooling rates, tighter control of the cooling curve, better strip shape and more uniform tempering are needed. Interestingly, many of these demanding requirements are...

An integrated process optimization system for MIDREX DR Plants has jointly been developed by Primetals Technologies and MIDREX Technologies. This system was installed for the first time at the MIDREX DR plant Module 2 of Qatar Steel. The new product quality prediction models achieve high prediction accuracy – hours before the measured data are available. This supports quick decision-making to...

Driven by the global megatrend of CO2 reduction and improvement of energy efficiency there is also shift of energy systems ongoing which will also influence the way of steel production in Europe. The EU roadmap for a low carbon economy suggested even a reduction of CO2 emissions of 80% between time period from 2005 to 2050. New CO2 lean iron making technologies like natural-gas based...

The meaning of numerical simulations of metallurgical reactors has increased during the last years. The simulations offer detailed information about the process and new insights into regions, which are typical difficult to examine. For the simulated remelting processes the growth direction of the dendrites is most important. The correlation between liquidus isothermal and growth direction...

Natural gas burners are prevailing tools for a wide range of metallurgical operations. The field of usage is extensive and includes, i.e., melting of scrap in EAF, heating of slabs in pre-heating furnaces or post combustion in off-gas treatment plants. Since the invention of the Bunsen burner in 1857 the design of natural gas burners have changed substantially. Modern day burner designs like...

Since the end of the 1980s, thin slab casting and rolling plants, in particular CSP® plants are well established for the production of hot strip. By introducing the endless operation mode, a new generation of casting and rolling plants was created. CEM®, the compact endless casting and rolling mill, is the innovative solution introduced to the market by the Korean steelmaker POSCO and the...

The performance of a flat product rolling mill is directly related to the design concept and performance of the upstream reheating furnace(s), both in terms of productivity but ever more importantly for final rolled quality and yield increase purposes. Many such production plants are also located near residential areas and thus as very demanding emissions reductions laws are set, steel...

Outokumpu Stainless Tornio Work is an integrated steel plant, which features production of molten ferrochrome at the same site. The refining of the molten ferrochrome is conducted in an ferrochrome converter, which is essentially a modified argon-oxygen decarburisation (AOD) converter. The process control of the ferrochrome converter is based on composition samples and temperature...

The Surface Roughness Meter (SRM), developed by CRM and commercialised by Amepa, has been enhanced by additional waviness measurement. SRM, deployed nowadays at more than 40 installations around the world, is used in several industrial lines and interest is more and more increasing from automotive and high quality surface products manufacturers and users. These applications, including...

The demand for increasing energy efficiency and CO2 reduction is one of the global megatrends of our time. Although the steel industry suffers from a volatile economic environment, the steel plants are interested to find opportunities for sustainable cost reduction and put efforts into healthy solutions for the environmental. Integrated steel plants are trying to cut electrical power and...

Module-E, one of the largest MIDREX direct reduction plant in the world with more than 2.5 MT iron oxide consumption. The oxides used in its Shaft Furnace (SF) is in pellet shape of size 6 to 18 mm diameters. However, during palletization process at suppliers’ locations, and transportation afterward, undersized pellets are generated. In the plant, undersized materials are screened off from...

For every single final product you can get a carbon foot print, which is dominated by raw materials and production processes. The steel industry is looking to minimize its carbon footprint by self-defining reasons not only for environmental aspects, but also to cut own energy costs. There were significant results reached by optimizing each process step and also in trying to link single process...

Flow Phenomena and mixing characteristics of the molten metal bath have been investigated according to the bottom bubbling gas conditions. The mixing time of the bath was affected from the location of gas bubbling plugs on the bottom of the ladle and numbers(from 1 to 3 plugs). For the same number of bottom bubbling plugs, the bottom bubbling in the center of the ladle showed the shortest...

3rd generation advanced high-strength steel (AHSS) grades are complex materials with special chemical compositions and multiphase microstructures. The annealing and galvanizing process of these grades is different and places new demands on the plant technology. One of them is the prevention of surface faults. Bare spots can occur due to a higher content of alloying elements like silicon or...

Beside computational intensive methods like CFD or FEM, reduced modelling approaches for technical process may be more practical, especially in production environments. A modelling approach, which can be applicable for industrial processes to predict the heating of products, semi-finished materials or raw materials, will be shown. To derive such models many different approaches, depending on...

In the context of the reconstruction and modernization of Arcelor Mittal coking plant at Gijon works, Paul Wurth has been awarded with the engineering, supply of key equipment as well as erection and commissioning supervision services for the rebuild of two coke oven batteries and the modernisation of the adjacent by-product and relevant waste water treatment plants. In particular, for the...

Over the last years, waste heat recovery in steel industry attracted more and more attention. Environmental regulations, public funding as well as required revamps of old dedusting systems lead steel plant operators to discuss and to evaluate possibilities of recovering waste heat. The development of a waste heat recovery plant requires extensive knowledge as well as long experience of the...

The increased demand for higher precision and lower tolerances of rolled steel products poses an enormous challenge for the development of roll materials. New high speed steel grades **HSS** offer a solution in many cases for hot strip mills, strip casters or plate mills because of their extreme wear and heat resistance as well as superior surface properties. For ***early roughing...

In the Tata Steel IJmuiden BOS plant (Netherlands) the Hot Metal pouring process is completely automated. After the connection of the torpedo above the HM pit by the loco driver all movements of torpedo’s and transfer cars are done by computers. Interlocks with loading cranes, avoid overfilling Hot Metal ladles, damaging the torpedo tracks and recognition of the torpedo number are guarded by...

"Energy efficiency" is of great importance at the present time. But first of all, there are too many numbers and figures in the issue of energy efficiency in steel production. Usually there are many differences between the theoretical, technical or even weighted values. For the Steel industry it is important to identify areas of action and to establish the link to the policy framework on the...

It becomes more important to properly prepare raw coal blend for cokemaking since required coke quality has been increasing. In particular, because coal size adjustment is an important operation which strongly affects coke strength, various control technologies for coal size have been developed. General coal size design has been almost based on the well-known Sovaco method. In the method,...

CRM has developed a very precise method to measure the shape and vibrations just above the wipers on galvanising lines. Based on mirror-principle, this method allows to reach 0.1mm precision in position and 50Hz in vibrations and is adjustable to a wide range of wipers. The measurements done can be used to control the shape and vibrations of strip leading so to a better coating homogeneity and...

The shaft furnace is a scrap melting furnace which produces high calorie gas and thus plays an important part as an energy supplier in a steel works. In shaft furnace operation, the coke rate is reduced or the exhaust gas calorie is increased corresponding to the energy balance in the steel works. Because the coke rate and exhaust gas calorie are determined by coke gasification reactivity, the...

The steel market is experiencing a difficult conjuncture: on the one hand steel producers minimize their investments while optimizing their over- production, on the other hand suppliers reduce their internal human resources and capacity in order to overcome the instability of the new era. A return to the steel production levels of the past is not expected in the short term. Research,...

Nowadays, energy efficiency represents the main challenge in iron & steel industries. The key aspect for the achievement of this crucial specification is constituted by the optimization of the involved billets reheating and rolling processes. In particular, the major difficult is the need of a concurrent and coordinated optimization of the reheating furnaces and of the rolling mill stands. For...

The target of this work has been to in detail measure the conditions inside the roll gap during hot and cold rolling. For this purpose rolling was done using an instrumented work roll. The purpose was to measure contact length, contact force distribution, friction coefficient and heat transfer coefficient. The work roll used three contact sensors, two for measuring the contact loads and one...

Steel industry is an energy-intensive sector, in particular for the electrical energy consumption. The utilized energy composes a significant part of production costs and has a significant impact on the electricity network. The increasing utilization of variable renewable energy sources, such as solar or wind, lead to key role for the energy-intensive industries demand side flexibility. Thus,...

Coal weathering is regularly surveyed by cokemakers in order to avoid coke quality deterioration as a result of coal rheological properties decrease. Usual Gieseler fluidity and dilatation rheological tests are sensitive to weathering, but require values of initial and oxidized coal, which makes these tests difficult to be used. For this reason, three promising weathering detection tests were...

Flatness is one of the most important qualities of plates. Most plates just after the rolling or cooling process, however, do not satisfy the flatness demand for customers. As the most particular flatness defects, edge wave and center buckle are well-known. In order to satisfy flatness limits, roller leveler is widely applied. In the roller leveling, the plastic deformation ratio that...

In this work, the use of a low-carbon steel AISI 1005 (Wr. N. 1.0303) is proposed as a substitute of CuZn39Pb3 brass in order to produce fashion accessories by hot forming. The heating process of the billets for hot forming has been carried out at 1050°C through a single heating step inside an induction furnace or by double step inside muffle and induction furnaces. The surface quality of the...

For flat steel production, the surface quality and the knowledge of surface defects is crucial to deliver a high quality product to the customer. Therefore, since end of 1990th as the first commercial systems came up, automatic surface inspection systems (ASIS) have been established as tightly integrated tool for surface quality supervision and the data provided by the systems are now more...

Effects of the slags on the total oxygen contents and Ds formation in bearing steel were investigated by vacuum induction furnace experiments. The optimal middle basicity slags for VD treatment was selected in the range the CaO to SiO2 content ratio of 3~4, and the CaO to Al2O3 ratio of 1.6~1.8, resulting in lower total oxygen contents and less Ds inclusions. Evolution of inclusions in bearing...

Pulverized coal injection (PCI) is now commonly used in iron making blast furnaces to produce reductants and to generate heat in the raceway. The advantage of using this important auxiliary fuel is that it replaces the expensive metallurgical coal and, therefore, helps in lowering the operating cost of the blast furnace. The optimization of the PCI practice has led to high rates of pulverized...

Muffle furnaces are most often used in wire drawing mills. In most cases, protective gas(es) is fed into the muffle tube. This shielding gas can be hydrogen, nitrogen, cracked ammonia or endogas. Some of these gases are very aggressive and will shorten the life of the muffle tubes significantly. In the annealing furnaces, the temperature is usually between 800 and 1,120°C. These aggressive...

In the past decades, all possible strengthening mechanisms have been fully exploited to tailor the mechanical properties of steels. Nowadays, it is becoming difficult to move further and meet the continuously increasing properties requirements, as the physical limits have been almost reached in bulk metals. Multilayer metallic materials produced by roll-bonding can be a viable solution to...

The current market is seeing an increase in the demand of added value products including the production of high strength plates which ideally must keep the use of high cost alloys to a minimum. Applications such as oil and gas pipelines, offshore structures and shipbuilding, require good control of both mechanical properties and the final shape of the plates. The production of such plate is...

After years of meltshop trials, the final technical solution for a Mechanical Pumping System for Vacuum treatment in Steelmaking has been finalized by SMS group and the pump manufacturing company Flowserve/SiHi. The result of trials and validation processes of the technology are presented in this paper outlining the optimal solution for a series of installations for specific technical...

In 2012 Tata Steel Ltd, commenced construction of an integrated iron and steel plant in Kalinganagar Orissa, India. The first phase of the project included steelmaking facilities, coke plant, sinter plant and blast furnace number 1. A contract had been awarded to Primetals Technologies in January 2007 to design and supply the new 14m hearth diameter blast furnace and additional facilities as...

In order to optimize the conduction of steel billets reheating furnaces, advanced multivariable process control techniques are needed so as to guarantee a suitable handling of all furnace conditions. The final goal is the achievement of energy efficiency while preserving product quality: a profitable tradeoff between energy saving, environmental impact decreasing and throughput maximization...

For the present investigation, the same steel grade has been produced with two different deoxidation practices namely Al and Al-Si killing. There has been reported that deoxidation with Si reduces costs and decreases castability issues associated with Al. Material from both practices has been characterised in the "as cast" and "forged and rolled" conditions. The differences in terms of...

One of the global trends that are constantly challenging the iron and steel industry is related to the generation of fines, slurry, sludge and scales, summed up as ferrous by-products. The recycling of those by-products is commonly practiced in many steel plants. These materials normally cannot be used directly in the primary processes. The most common application is to add ferrous by-products...

Surface quality monitoring is primarily implemented in the last steps of steel manufacturing before shipment to the end user. However, an increasing trend for also addressing this topic in the upstream stages, such as hot rolling plant, is tackled by Primetals Technologies to give steel producers the key to a global optimized yield management, and efficient “lessons learned” processes. ...

For fast rotating equipment (bearings, pumps, motors, gears, etc) various condition monitoring techniques, predominantly vibration analysis, allow predictive maintenance practices to be applied. For slow rotating equipment (1 rpm) the situation is quite different. Our approach how to monitor such equipment is covered in the first part of the paper. Vibration monitoring is typically not...

Besides modern equipment and sophisticated process automation systems effective steel production requires a production management system which is coordinating the production processes on the shop floor and integrating those with the commercial processes. Implementation time has direct influence on the return of investment of such a system. The product driven project methodology, a new...

Here we present the HiNSPECT, a brand new machine based on shape-from-shadow technique, which aims at marking defective areas product surfaces with high accuracy within the zero-defects tolerance policy. Special lightning and innovative algorithms concur to highlight the defects with their pseudo-3D depth. Irregularities, such as scratch marks or inclusions, can be neatly seen in real-time...

Flatness is an essential property for the quality of heavy plates. To achieve the flatness required by the customer, levelling machines are used for many types of plates. Today, flatness is described by means of the deviation of the plate topography from a 1 or 2 m ruler according to DIN EN 10029. This measurement method does not provide any further information about the type of flatness...

The thin solidifying shell in the meniscus region of continuous caster deforms due to severe contraction of steel during solidification for near peritectic composition of steel and there is potential risk of cracking and in the extreme cases, breakout of shell. The main purpose of the present study was to contribute an improved understanding of peritectic transformation through high...

Louisville | Cincinnati | Evansville | Columbus | Indianapolis Improving Reliability for Steel Mill Furnace Rolls Author: Jeremy Rydberg Atlas was approached by a major steel manufacturer and asked to develop methods to improve overall reliability of steel mill furnace rolls. To accomplish this it was determined we would need to develop methods to inspect new, used and failed...

Recently, in an environment in which the fluctuations of coking coal price increase, in order to produce high strength coke at a low production cost, it is required that the blending technology applied to various kinds of coal. The dilatation of coal is one of the significant factors determining coke strength. It is known that in the case of blended coal that contains semi-soft coking coals,...

In a competitive environment, innovative products which need very minimal investments can help in improving OPEX and thereby helping staying competitive. This paper presents some of such innovative products which SMS group has developed by focusing on energy costs, asset utilization, productivity and material costs. X Pact® FEOS X Pact® FEOS is a furnace energy optimization system for...

Laser-induced breakdown spectroscopy (LIBS) is a promising method for fast and quantitative element analysis of complex materials. We report on LIBS measurements of multi-component oxide materials and the compositional analysis of materials by a calibration-free (CF) method. This CF-LIBS method relies on modeling of the optical emission of laser-induced plasma assuming local thermodynamic...

This paper presents the work carried out by CRM Group in view to measure on-line the cleanliness of steel strip at the exit of the cleaning section of galvanizing lines. The applied method is based on the LIBS principle (Laser Induced Breakdown Spectroscopy) and allows a simultaneous measurement of the iron fines and of the carbon pollution. A short comparison with existing measuring systems...

The renewable biomass can be applied in the steel industry mainly by means of injection, gasification and mixing or embedding into raw materials, and contribute in such a way to the CO2 emission mitigation. Previous studies on the biomass usage in cokemaking concluded that a maximum amount of raw biomass in coal blend is limited to some 1.5 – 2.0 % due to deterioration of coke quality. To...

3D-Measurements for slabs and heavy plate are now available and close the gap in the production chain. The measuring systems described in this presentation must be seen as high-tech solutions in the field of casting and rolling technology. The measuring systems were developed taking into consideration the harsh casting and rolling mill environment in which they are to be used, with the aim of...

The efficiency of the iron and steel production becomes increasingly a very important factor for any producer in the world. Looking at the overall costs for steel production, the source and quality of iron ore is the most important factor, which influences the overall efficiency downstream to the steel making process. By improving the iron ore quality the entire processing chain benefits...

For demands of production increasing of advanced high strength steel (hereinafter AHSS), steel manufacturers face short production capacity of pickling line. Primetals Technologies Japan, Ltd (herein after PTJ) have proposed *i* Box pickling tank to improve production capacity, which is most advanced, maintenance easy and saving energy. Since *i* Box pickling tank need storage tanks of acid...

Steel production is responsible for roughly 8% of the global CO2 emissions and due to its projected growing worldwide demand, this figure can be expected to grow further. As modern steel production has been optimized over the last decades close to its thermodynamic and –chemical limits, considerable reduction of CO2 emission and energy demand by process optimization are considered difficult to...

The European steel industry identified digitization as a key enabling technology not only for maintaining its world-wide leading role with respect to product quality, but also for pushing the limits and raising efficiency, reliability and quality to a next level. Recently, many steel companies updated and overhauled existing infrastructures and prepared for being “BigData-ready” and to apply...

Traditional approaches to blast furnace gas cleaning using wet scrubbers are being challenged by the re-emergence of dry gas cleaning technologies based on the success of the same in other parts of the iron and steel network. The wet gas cleaning of blast furnace gases offers a proven solution to the handling of the process gases removing dust and certain trace contents in the gas in a...

In mid of 2015 Acroni, a Slovenian steel producer belonging to the Slovenian Steel Group (SIJ), has awarded Primetals Technologies with an order to supply a new 95 metric ton AOD converter and dedusting system to its steel works in Jesenice. Less than 2 years later, in April 2017 the new process route will be brought into operation resulting in an increase in annual liquid steel production...

Modern information and communication technologies like Business Intelligence, Big Data or Cloud Computing will help predict the possibility to increase productivity, quality and flexibility within the manufacturing industry and thus to understand advantages within the competition. From the first introduction of Q3Intelligence more than 10 years ago, Danieli Automation has always focused on...

Primetals Technologies had developed a new mash seam welder (Cross Seam Welder, CSW) based on MSW features including low cost and compactness, enhancing its compatibility with Continuous Rolling of Steel Sheets at Thicknesses up to 6.5 mm. The first order and second order for the CSW were received form JFE Steel Corporation, where they were installed in the Continuous Pickling Line. These...

During the steel making process, huge quantities of gas are produced, stored and used as fuel later on in the process. It is the case of the Coke Oven Gas (COG), the Blast Furnace Gas (BFG), the Basic Oxygen Furnace Gas (BOFG) and the Corex Gas. Those gases contains high percentages of Carbon Monoxide (CO), which is very toxic at low concentrations and also odorless and colorless, which makes...

JFE Steel Corporation produces around 0.6 million tons of Cr base ferrite stainless steel per year at the Chiba Works. Recently, the demand of ultra-low carbon grade of Cr base ferrite stainless steel is increasing for using automotive exhaust system parts and so on. In the case of producing ultra-low carbon Cr base ferrite stainless steel, the bottle neck of the production line is Vacuum...

Iron and steel making requires a wide range of different raw materials significantly influencing process performance which demands a continuous optimization of process routes also with respect to energy efficiency as well as environmental emissions. Steadily changing raw material prices and qualities, market situations and product variations are challenging integrated steel plant operators in...

Pickling lines are often considered as a bottleneck of steel production. Increasing the throughput has been the declared goal of many research projects. Yet, high quality pickling results depend on a complicated mixture of constraints like careful choice of pickling speed, suited entry temperature and a good estimate about how many scale resides on the strip surface. In this paper, a technique...

In the past decades, the requirements in respect of environmental protection and the regulations by the environmental protection authorities, respectively have become ever stricter worldwide. And the possibilities to prove and measure harmful substances have been improved significantly. Moreover, the harmful effects on health of many substances have been evaluated and detected only in the...

State-of-the-art automation information technology and connectivity enables the digitalization of steel production that goes far beyond conventional automation of industrial production. Initiatives have been started around the globe to foster digitalization like IIoT (Industrial Internet of Things) in the US, Industry 4.0 in Germany or China2025. Primetals Technologies is actively driving the...

The SMS group vacuum converter technology combines the advantages of the AOD converter and the VOD technologies. In the vacuum converter process, the final decarburization step of stainless steel grades and ferroalloys takes place under vacuum. The dilution of oxygen by inert gases known from the AOD process is largely omitted. Use of SMS group´s vacuum converter technology ensures the...

The installation of a spark arrester prior to the EAF’s off-gas filter has become common practice for prolonging filtering bag lifetime as carbon injection was increased. The Axial Cyclone efficiency has been optimized by sophisticated CFD programs in recent projects to achieve sufficient abatements starting from 125 microns whilst simultaneously maintaining pressure drops to below 1"...

Modern EAFs require enhanced Safety and improved, consistent Performances; these features should be linked together, if possible. Both modern well-designed furnaces and more dated ones can benefit from the latest technology and equipment for removing operators from hazardous places, thus leaving dangerous activities to automated systems, while other technologies can read actual performances...

The Special Bar Quality family comprises a wide range of steel grades, mainly requested by the automotive, energy and engineering sectors, for applications where significant performances are required (eg. stresses, temperatures, working cycles, etc.). To meet these requirements it is necessary to reach a precise control of both the mechanical characteristics and metallurgy structures along the...

The challenging and competitive market situation caused by worldwide excess capacity forces more and more steel producers into the market of high-quality, high-price products in order to increase their profits. Compared to commodity grades high-quality products pose substantial demands on the quality management, which has to address extremely tight production tolerances across the entire...

When the scrap charge in EAF melts, the heat transfer between the arc and side panels increases until slag foaming is started or arc length is reduced. However, the slag accumulated on the side panels acts as a kinetic barrier between the arc and cooling water. Previously, only estimates of the cause of slag has been obtained due to lack of reference measurement. In this work side panel...

Modeling Metals production becomes more challenging due to the constant increase of diversification on one hand and higher quality requirements on the other. At the same time globalization drives the metals industries towards modern ERP “standards” that by default are designed for assembly production. All attempts to model metals production by BoMs are failing as soon as the constantly...

Mechanical properties of steel wire rod are mainly influence by chemical composition and cooling rate of Morgan Stelmor cooling system, especially for high strength wire rod. Since the chemical composition will slightly fluctuate among different heats, it will accordingly cause the variation of mechanical properties. Although it can be compensated by cooling process adjustment manually,this...

The steel production via the EAF route produces free lime containing dust. In the case of carbon steel production, the main dust recycling process is the Waelz furnace, allowing the recovery of zinc but not of Fe. In the case of stainless steel production, the recovery of valuable alloying elements (a.o. nickel, chromium, and molybdenum) can be achieved by recycling the dust in the form of...

Technological solutions, to utilize process gases from the iron and steel industry, to allow other production facilities , e.g. chemical industry, to use such energy sources, is becoming more and more attractive. One possible way, to convert the available energy from carbon and hydrogen-rich off-gases, such as coke oven gas, blast furnace top gas, direct reduction gas and also converter BOF...

State-of-the-art process control systems are currently utilized with the intention to optimize the production process for certain individual aggregates (e.g. blast furnace, sinter plant, etc.) based on locally and temporally limited information. Following the spirit of Industry 4.0, the idea of holistic optimization models goes one step further by enhancing the performance of a plant through...

For Electric Arc Furnaces (EAF) high performance and productivity can be reached by fully utilized equipment and products and with the associated process knowhow for a mostly uniformed and safer operation. The furnace components, also associated with supporting products have to be designed for a maximum power input, utilization and safe operation. Cycle times during power off and power on...

A modernization project was undertaken by Kroman Celik Sanayii A.S. in order to improve their product quality, consistency and shape of the coil package, reduce maintenance and delays in rod mill, thereby increasing utilization and productivity. The project involved installation of a new Morgan Intelligent Pinch Roll and High Speed Laying Head, modifications to the existing controlled cooling...

Numerical simulation methods such as Computational Fluid Dynamics (CFD) and Finite Element Analysis (FEA) are increasingly used in the steel industry to provide quick and economical tools for problem-solving and design. Game engines such as Unity 3D have become important tools for developing interactive applications such as serious games and training applications. However, little work has been...

In the Electric Arc Furnace (EAF) chemical and electrical energy is used for melting and superheating of scrap and DRI/HBI. Although the fluid-dynamic and thermodynamic phenomena during the different furnace steps are qualitatively known, some of these effects may cause process problems. To serve as an example, a free-burning electric arc not covered by foamy slag overheats the furnace walls...

The concept and benefits of retrofitting a cold blast mixer with plasma torches to heat hot blast air will be described. A ‘hot mixer’ would top-up hot blast temperatures achieved during the stove firing cycle and eliminate the need for cold blast air mixing. The technology is scalable; implementation of just a few plasma torches will reduce coke consumption and GHG emissions. Candidate...

European steel is decisively driven by product quality and customer demand. Industry 4.0 is yet a blurry term, nowadays being praised for bringing disruptive advantages for modern manufacturing industries in the next decades. Many people are overwhelmed by the diversity invoked by the word Industry 4.0 and although many applications are emerging, practical examples are rarely described or...

PERT has developed and patented a new concept for the composite rolls for long product rolling mills, called LLR Rolls (Long – Life Rolling Rolls). LLR Rolls, allows mounting of cast iron, HSS or carbide rings on a shaft made of special alloyed steel, in order to increase the grooves working life and to decrease, consequently, the plant downtimes for stands changing operations. The...

Industry follows only the agriculture sector as main water consumer, as water is fundamental for all process steps from the cooling to the washing stages, from the product formulation to the mass separation. In particular, steelworks use significant amount of water in cooling and washing systems. However, higher freshwater cost and environmental regulation pressurise industry toward an...

It is analysed some titaniferous magnetite deposits of Russia. The results of laboratory, industrial and calculation (by means of mathematical models) researches of physical, chemical and thermophysical processes at oxidizing roasting (agglomeration) of the titaniferous raw materials are considered. The rating of influence of metallurgical properties (reducibility, durability, softening and...

Data mining process has proved to be very valuable for addressing industrial issues such as understanding defect crisis. However, for the methodology to be successful, several key criteria have to be fulfilled: * Data has to be relevant and well prepared * Rigorist mathematical, statistical and modeling methodologies have to be used to assess result robustness. * As many process knowledge...

Thanks to the extremely high stiffness of BSS Sizing Stands, we introduce the concept of “sizing stands” not only in special steel rolling mills (SBQ or alloyed steel), where the tolerance of the final products must be very tight, but also in rebar or wire rod rolling mills. This means a very high final product quality and a better product marketability, in fact the quality improvement does...

With the objective to further optimize the Electric Arc Furnace process, Vallourec Star installed the ZoloSCAN Laser Off Gas Analyzer in late 2015. Being one of the most efficient EAFs in North America, the integration of the off gas sensor with the AMIGE SmartFurnace system, required precise algorithms and reliable technology in order to provide consistent results. With a design that allows...

During production of ethylene, propylene and butadiene at SABIC olefin plants, coke is deposited on furnace tubes. Deposited coke layer increases with time which reduces furnace efficiency. Hence, removal of coke through de-coking process-stage is frequently required followed by landfilling of collected waste coke. Moreover, HADEED imports carboneous additives or recarburizers to be added...

The recycling and treatment of radioactively contaminated scraps, mostly from the nuclear industry, are becoming more and more prominent issues facing the iron and steel sector. A proposed treatment route of steel containing radionuclides is with the Electric Arc Furnace (EAF). However, a deep understanding of the behavior of radionuclides (mostly cesium and strontium) during arc melting has...

The generation of renewable electrical energy will not fulfil the electrical energy consumption at any time. Therefore there will be “surplus” electrical energy in the electrical energy system that must be used to gain grid stability. The PtL technology consumes that “surplus” electrical energy and incorporates simultaneously the substantial usage of CO2 as feedstock for its conversion to...

MES systems constitute the central information and management platform for the entire process sequence of a plant and its ancillary equipment in the metal-producing industry. It is linked with the automation systems of all plants and it receives status information, production data and process data. In the SMS group X-Pact® MES 4.0 modules, comprehensive technological control systems ensure...

**Abstract** Proper understanding and control of accumulation, drainage and heat transfer of hot metal and slag in BF hearth is essential for a stable and efficient blast furnace operation. Abnormal drainage behavior may lead to high liquid build up in the hearth. Operation problems normally be encountered if the liquid levels in the hearth exceed a critical limit when hearth coke and...

In the world, the rail production is on a growing trend as a consequence of the market interest to high-speed and heavy-haul transports. A confirmation to this come from the main international standards having been up-to-dated or re-issued after 2010, in USA, Europe, Russia, India and China. In 2014, the rail production in the world was approximately 12 million tons (Mt), of which 8 were...

Maintenance is gaining more and more attention in the steel industry as companies realize that it is critical to monitor the condition of assets to increase plant availability and reduce the risk of an unplanned shutdown. Due to global overcapacities, modernization investments have been reduced, pushing plant equipment to its maximum lifecycle level. To reduce unplanned shutdowns, increase...

Coupling the blast furnace with direct reduction processes may increase the BF productivity and flexibility, and contribute to CO2 emission mitigation at an integrated steelworks. Charging of HBI into blast furnaces will be realised this year in Europe. Another way is injection of DRI / LRI via tuyères. In this case, the briquetting step and long residence times in the shaft could be...

Today the possibility to run EAFs at optimal energy efficiency is limited due to lack of information on the scrap melting progress and steel temperature inside the furnace. This paper describes results from a research project with the aim to improve the estimation of these essential parameters through taking advantage of new experimental measurement techniques (sound, vibrations, harmonic...

Wire surfaces undergo many transformations on their way to the finished product. They are a very important key factor for the strength and quality of the wire. Fine steel wires have a small diameter such as 80 to 150 μm, however they have to resist high strength up to 3900 MPa during their application. During their production, any kind of surface damage has to be avoided. Another important...

Zinc enters the steel production through the feeding of galvanized steel scrap into the electric arc furnace (EAF). Based on the process conditions, the zinc oxide gets reduced, evaporates as metallic zinc, reoxidizes to zinc oxide in the offgas and gets collected in the filter house. Beside zinc, which represents the main component, elements like lead, iron, cadmium, sodium, potassium,...

The paper describes the converting to a new generation of descaling nozzles in a conventional hot strip mill for steel. There are descaling stations behind the reheating furnace, on the roughing mill stands and in front of the finishing mill. Before the converting, there had been three high pressure pumps in operation to supply the descaling stations. The new descaling nozzles had been tested...

The intensive use of automation solutions, process models as well as expert systems is well established in converter steelmaking. and It is widely recognized that automated procedures have a positive influence on productivity, product quality and operational safety. The combination of existing technologies, new support systems and the beneficial use of information management tools empower the...

In iron making dialogue, a salamander is referred to all liquid and solidified materials in the hearth of a blast furnace which cannot be removed through the taphole. Taphole locations are designed in a way that a pool or sump of liquid hot metal remains in the bottom of the hearth. The resulting salamander has multi purposes. Primarily it provides a buffer to retard bottom refractory wear,...

Electric Arc Furnaces (EAF) used for steel production are characterized by high and strongly erratic consumption of reactive power, substantial harmonic generation, as well as asymmetrical loading of its three phases. As conventional generation are being replaced by renewables the power systems will become more sensitive to these disturbances. To compensate for these adverse effects Static var...

Evolving market conditions in today’s world – increased variability, volatility and complexity – require more agility than ever for metals supply chains. The bottom line is that future supply chain ROI maximization will not so much be driven by unit cost minimization but by the pro-motion and protection of flow of materials and information. This implies revisiting today’s MRP and ERP systems...

BOF bottom gas purging has been established as inevitable technology for high quality demands at decreasing conversion cost levels. The trend for applying raw materials with higher variations in phosphorus at the same or increasing product quality levels increases the need for reliable, save and long-term available inert gas purging. Higher converter lifetime at decreasing converter refractory...

This paper shows an overview on state of the art chemical injection systems at the EAF. Modern injection solutions, lower consumption costs, increased productivity and safety. These systems are easily upgradable to any EAF. Within a short shut down time, the installation of modern combined injection systems will lead to huge productivity and process improvements. The chemical injection...

A methodology has been developed for improving the operational efficiency and cost competitiveness of steel plants. The salient features of this methodology which is implemented working closely with steel plant personnel, includes internal benchmarking, comparison with best practice (similar class) after normalization of key performance indicators (KPIs), fundamental process analysis including...

Pohang No. 4 Blast furnace, inner volume 5600m3, was relined and blowed in at 8th October 2010. The first failure in copper stave cooling channel was found on 20th. June 2014, 44months after blow-in, in belly. When the copper stave cooling channel in blast furnaces had been damaged in POSCO, cooling plates were installed from the outside of furnace shell to recover cooling function in the...

In June 2010, after almost three years of intensive preparation work and intense technical discussions, PRIMETALS TECHNOLOGIES (PT) received an order from Allegheny Technologies Incorporated (ATI) to design, engineer and supply a new, fully integrated hot-rolling mill on a process-turn-key basis which included a water treatment plant. PRIMETALS successfully executed this project by using the...

We performed a numerical analysis for simulating packed bed structures containing non-spherical elements and the liquid trickle flow characteristics of such structures. Fully-Lagrangian numerical simulation methods can track all motion information for solid or liquid elements at each point in time. We performed individual packing behavior calculations for non-spherical elements, based on DEM...

IMS Messsysteme GmbH has developed the first width measurement system based on radar technology for hot rolling mills. In contrast to laser radiation or light, radar waves are insensitive to steam and dust. Therefore, the system allows for width measurement under harsh environmental conditions, where the use of other measurement technologies is difficult or not possible at all. As the...

Steelmakers strive for a high degree of effectiveness combined with efficient energy. Equally important are productivity of the process and the quality of the product. Hellenic Halyvourgia, Greece (HLV) and SMS group have developed a completely new and unique process for scrap preheating: the SHARC furnace (shaft arc furnace) process. This process minimizes energy consumption to a minimum...

This work was a continuous development and multidisciplinary. Through the blowing process survey data and process parameters being were conducted developments , enhancements and adjustments at lance tip hot face parameters with Slagless technology , as well as blow process parameters, reestablishment system " autopilot " blow and mitigating actions for slopping. The main results are Increased...

The utilization of production facilities in an optimum way, with reliable due date fulfillment, reducing raw material and energy consumption, are challenges iron and steel companies are facing in their business every day. By using an APS Advanced Planning and Scheduling System such goals can be achieved to increase the competitiveness of iron and steel producers. A sophisticated APS...

During the last years CRM has developed a dynamic on/off-line model for the EAF process. Contrary to calculations using statistical inputs, CRM model uses a fundamental set of calculations based on thermodynamics and kinetics that takes dynamically into account furnace operating data. The purpose of the on-line application is to provide the operator with a better estimation of the melting...

With increasing computing power, data storage capacity, advanced algorithms and innovative sensor technolo-gies it is today possible to approach the BOF process from another point of view: machine learning models and Data-driven Prediction Models (DdPM). These approaches process large amounts of data to predict the BOF process conditions, e.g. temperature, carbon and phosphorus content of the...

BOF, due to operational conditions and location, suffer variations in the parameters whose effects on the liquid bath are usually neglected. The present paper investigated mainly two aspects: inner BOF pressure and oxygen temperature in the stagnant reservoir. The results shown that oxygen temperature changes properties like density and velocity but has small influence on jet penetration. The...

The blast furnace - converter route is dominant in European steelmaking. Investments are being made to modernise hot metal production plants in Europe. The coking plants, sinter units and blast furnaces are powerful and environmentally friendly. In view of the demands for massive reductions in CO2 emissions in Europe, however, it will be necessary to work on solutions regarding whether, and...

Lubrication is a key parameter for improving the finishing mill process in hot rolling. The lubrication changes the contact interface between the work rolls and the hot strip. The lubrication can reduce the rolling force, the rolling torque, the energy consumption, the work rolls consumption and the work rolls degradation. Lubrication is also a lever to optimize finishing mill capability. The...

The scrap used as charge material in the Electric Arc Furnace (EAF) is characterised by a high variability in yield, chemical composition, bulk density and melting behaviour. This is essential to be considered in context with online monitoring and control of the EAF process. The objective of the Pilot & Demonstration project AdaptEAF, funded within the European Research Fund for Coal and Steel...

An early breakage of the copper stave cooling pipe is a serious issue in ironmaking worldwide. This breakage of the copper stave caused unstable operation and shortened service life. Pohang No.4 BF experienced a leakage of coolant into the furnace caused by rapid wear of copper stave. It was found that the main causes of the breakage are high productivity operation ever since blow-in and blast...

Numerical flow simulations have constantly evolved in the last decades and nowadays play an important role in the development of modern converters. The flow inside the converter is highly complex and comprises a whole lot of physical phenomena like supersonic flow, chemical reactions, heat transfer and the flow of gas bubbles in the liquid melt. Due to numerical reasons, not all flow processes...

Yield and economy during hot rolling of flat products depend on developing high capacity components fulfilling further increasing customers demands for cost and resource effective production of steel strip and plate material. The paper gives an overview of the latest developments for high capacity components and tools of SMS group for conventional hot strip mills, CSP® plants and heavy plate...

Industrie 4.0 is slowly but surely arriving in the melt shops. Furnaces are being equipped with more and more sensors, digital models are increasing the degree of automation, and information is being shared between different aggregates within the plant. Because the electrode control system plays a key role in electric steelmaking, it naturally assumes an important position in the melt...

To decrease time in defect crisis solving in roughing mill in ArcelorMittal Dofasco, a very robust vision system, RollScope, has been installed in stand in front of lower roll. The RollScope developed by CRM allows to take images of roll surface using a water column to avoid vapour and waste disturbances. This water column acts so as a guide light resulting in very good quality of images of...

ArcelorMittal Atlantique et Lorraine BF-2 5th campaign started in 1992 was concluded in 2015 with a total hot metal production of 26 million tons. The furnace was stopped for 129 days, from August to December 2015 for a relining aiming to revamp the top charging system, the hearth, the casting house and the gas cleaning. In terms of top charging system, existing Bell-top with movable armor...

Indoor positioning of steel ladles using beacons ------------------------------------------------ ---------- In recent years significant progress has been achieved in the field of Bluetooth technology. While the Bluetooth functionality is well-known since the 1990s, it was recently that new application scenarios have occurred originating from the energy saving Bluetooth version BLE...

The steel scrap melting rate in an electric arc furnace (EAF) is directly related to energy consumption and furnace productivity. In this paper, the melting time of steel bars of varying size in a liquid steel bath has been predicted using computational fluid dynamics (CFD) simulation. A three-dimensional CFD model has been developed with detailed consideration of fluid flow and the melting...

Oxygen blowing is the main operation in the steel refining process in BOF (Basic Oxigen Furnance) steelmaking. This blow is made by an oxygen injection lance through supersonic nozzles, which must be designed for the specific operating conditions, such as flow and oxygen pressures, height in relation to the metal bath, lance height, etc.. Bad design of these nozzles directly influences the...

In the field of down coiler technology in hot strip mills PRIMETALS Technologies has developed new innovative products which remove a head-ache by substantially simplifying operation and maintenance work and considerably reducing operation and maintenance costs. Contrary to conventional wear plates where the passing strip always cuts into the plates along the same line, wear on Primetals’...

In order to enhance the reaction rate between the slag and the metal, the formation of metal droplets in the slag phase (metal emulsion) is an effective measure. In this paper, the formation behavior of metal droplets by the bubble rupture of the gas injected into the metal phase was investigated. To extract the metal droplets, the water soluble chloride (KCl-LiCl-NaCl) and oxide (Na2B4O7)...

Despite continuous progress in roll development and improved rolling conditions, the control of work roll performances remains a major concern for the hot strip mill. One shortcoming is objective information and knowledge about the roll degradation and the origin. To address this situation, several hot rolling mills introduced a work roll evaluation procedure that is performed at the end of...

In recent years, efforts in the field of ironmaking research have been focused on the process optimization to reach new objectives in terms of low reducing agent operation. As a consequence, mathematical models have become key tools, including advanced numerical methods, to describe accurately physical phenomena occurring in the blast furnace. However, little attention has been paid so far...

With the increasing number of high productive EAF, and the variability in raw materials and product demand, the need for a system capable of adapting to the operation conditions in real time is essential. With state of the art technology, the AMIGE SmartFurnace system, featuring optimization tools like the DigitARC PX3 Electrode Regulation System and the ZoloSCAN Laser Off Gas Analyzer, has...

In the present work, an analysis of geometric parameters of tip nozzles in operation was developed and extrapolations for futures situations were proposed. The main trigonometric relationships to evaluate the possibility of jet coalescence were determined. The results showed that the Primary Circle Diameter (PCD) is not affected only by the geometry of the nozzle, tips with up to 04 (four)...

With the ILTEC Technology, Mettop´s patented water-free cooling solutions, it is possible to overcome the disadvantages of water by using an alternative cooling medium, namely the ionic liquid IL-B2001. The main characteristics, which makes IL-B2001 so favourable, are the neglectable vapour pressure, the wide liquidus range and the not flammable, non-explosive and atoxic behaviour. Since it...

Pair Cross mill(hereinafter PC mill) was developed widely to control the shape and crown of rolled strips for high productivity and saving energy. Recently, the demand for harder and thinner hot rolled strip, such as high strength steel or dual phase type high strength steel, has been increasing. In such production for harder and thinner hot rolled strip, higher reductions and larger rolling...

DK Recycling & Roheisen operates its blast furnace No. 3 with zinc loads higher than any other blast furnace in the world, because the metallic feed consists of iron and zinc containing residues of the steel industry. During the last year, the phenomena of the furnace lifting itself more than 200 mm out of its foundation could be observed. This led to dramatic consequences in operation and...

Dr.-Ing. Jens Kempken, Dipl.-Ing. Thomas Hüper, Dr. Martin Blaesner Key words: Process, product, performance, optimization, quality management, expert know how, automation, digitisation, A competitive landscape pressurizes the steel producers business, zero defect requirements from customers forces the producers for additional efforts in process control and quality management. The so...

Threading is a critical phase in hot rolling both in the finishing and the roughing mill. To avoid threading refusals which cause loss of productivity and steel yield, some constrains are applied on the process: no lubrication or only on the strip body, limitation of thickness reduction, high slab temperature at the furnace exit… However, we had no means to estimate the threading risk for each...

Hans Peintinger Managing Director QuinLogic GmbH, Aachen Smart factory, high flexibility, short time to market & efficiency in industrial scale are key words of Industry 4.0. The growing quality requirements in high end products are same time an enormous challenge, which are very often in competition with efficiency targets and market driven cost cutting measures. This paper...

Environmental protection has become more important in the iron and steel making industry during the last few decades. Stricter environmental protection measures are now required to comply with regulations set by government agencies. Dry dedusting systems (DDS) represent the latest technology for cleaning the primary gas of basic oxygen furnaces (BOF). Due to increasing economic pressure on the...

Blast furnace No. 3 at Zaporizhstal in Zaporozhye is rebuilt in 2016-2017. The Ukrainian company is targeting for increased production and availability by the use of new technology. Zaporizhstal awarded the contract of the Top Charging Unit to Danieli Corus, after comparing all available technologies. Main focus of DC is availability and maintainability of equipment. The DC product is a...

In metallurgical plants you will find lots of areas with dust, smoke gases and easily accessible liquid steel. To carry out manual work in this environment is very dangerous and should be avoided. Nowadays more and more manipulators and robotic solutions are used to substitute tasks in hazardous areas. One example for such a dangerous work is tap-hole-opening in electric arc...

The primary control tool of the BOF process lies on the adjustment of the oxygen blow parameters. The best process conditions involve several variables, like oxygen flow rate, distance bath lance (DBL), number of holes for the oxygen blow, among other factors. Through a visual inspection of the jet penetration and the volume of stagnant zones, the behavior of each configuration tested was...

Harder grades and better surface quality in longer rolling campaigns are the todays challenges in the hot rolling finishing mill. One of the key factors to achieve these objectives is the application of roll gap lubrication. It is essential to have a high performance, robust and highly efficient industrial lubrication installation. During the last years, also the economic aspect has gained...

A real-time liquid level measurement system was installed at Dillinger Hütte Blast Furnace No 5. The method is mainly based on strain gauges along a vertical line on the lower BF shell and an analytical deformation model of the hearth. The method, developed by TMT and CRM, indicates both the total slag level and the pig iron level inside the BF hearth. The liquid level measurement allows to...

Semi-finished steel and Special alloy products need to be cut for further processing. In most cases (e. g. for cold cutting of bright bars, etc.), shortest-possible cutting cycles, precise and clean cuts are a must. 2 cutting technologies, abrasive cutting and cold circular sawing, meet these requirements. For certain material grades, however, cold circular sawing is the more economic solution...

After 7 years and 14 installations worldwide of the Condoor (aka Texas Tailgate), the results achieved and the lessons learned leading to the present technical solution are presented, in 3 major steps summing up hundreds of technical improvements, each born from steelmaker experiences and requirements. Not all stories have been positive but each experience, especially when shared by the...

For several decades, researchers did many hypotheses on the unique behaviour of ICDP in rear finishing stands. All those hypotheses will be discussed to make the clear link between the role of graphite, the mechanical and structural properties of ICDP that make this grade so unique. The aim is to highlight which properties are required to bear the specific degradation and incidents occurring...

Treatment of hot metal in a Basic Oxygen Furnace (BOF) is a highly exothermic, complex, oxidising-refining process in order to remove hot metal impurities (mainly carbon and phosphorus) from iron and to achieve an optimal end temperature for further treatment of the crude steel. End-point control of the BOF process is in general based on static charge calculations and observation of...

Hot Blast Stove Technology has been developed to such an extent that low cost hot metal production for over 30 years without major repairs has become achievable, making the decision for a campaign length between 5 to over 30 years a design choice for the plant owner/operator. Some of the earlier examples of designs capable of such long campaign lengths are currently close to the 50th year...

Cost competiveness and productivity management achieved safely and meeting high quality standards are paramount to the success of steelmaking in the current market. In recent years, a tool to perform three phase power system analysis of alternating current electric arc furnaces – SGL PRO ARC – was developed and successfully deployed to optimize mast control systems and electrical operating...

Today’s steel producers face the dual challenge of ensuring on-time delivery and ever demanding product requirements while also running a lean operation. Every day the management of a long rolling plant requires continuous optimization of both operating and business practices. Utilizing the evolution in technology (data collection, communication, internet of things, control techniques and...

Primetals Technologies Japan, Ltd. has developed the contact-type inline strip shape meter (Looper Shape Meter, hereinafter LSM) and has been marketing it for hot strip mills, where continuous inline strip shape measurement is long-awaited. The LSM consists of seven segmented rolls aligned in the width direction. Low hysteresis is obtained by applying torque meters at each segment. An internal...

Thermocouples are often installed in the blast furnace hearth, for use in estimating the remaining refractory thickness. However, a wide variety of thermocouple arrangements are used. Using a thermal assessment approach combining non-destructive testing (AU-E) and thermocouple data, the selection of thermocouple locations within a furnace hearth was investigated. 2D transient thermal...

The purpose of this document is to describe the new technology developed increase the safety, reduce the manpower needed in dangerous areas, increase the traceability and reduce the risk of mistakes in the production. The integration, made in different steps, both in automation and robotics side introduce the concept of the industry 4.0, the digitalization of the information shared with the...

Abstract A steel making factory with a DC EAF and LF requires a reliable and stable supply system to allow the correct and efficient operation of the overall plant. Not always these conditions can be fully guaranteed giving rise to the need of more flexible operating modes for the steel making factory, foreseeing the operation in different configurations: synchronous mode with the main public...

The technological knowledge of BOF process represents an important key to improve metallurgical results. In a challenging and competitive market, operational stability and innovation are necessary to achieve excellent quality and suitable costs. In order to study the combined blowing (top and bottom blow) through cold physical model, in similarity with thyssenkrupp 330 tons converter, visual...

The continuous increase of the production steel in the last decades, caused the adjusted in steel plants in adapt in the new demand the acquiring manufactured steel. This study aimed to analyze the reactors ranging 6-350 tons of steel cast correlated their dimensional parameters and with the help of the tool data extrapolation, to propose the furnace of 800 tons. Ultimately, were checked the...

The slagdoor is the part of the electric furnace for the slag bleeding occurs. This door is closed by a metal door that rises at the time of casting slag, dropping back to its initial position to continue the process of steelmaking. During the casting, the erosion or attrition of the refractories lining that cover the sidewalls of the furnace takes places, so it is necessary to apply a...

Rolling of thin strips in a finishing mill of Endless Strip Production (ESP), Compact Strip Production (CSP) and Hot Strip Mill (HSM) with an outstanding thickness performance and stability has increased requirements to the tension and thickness control concept of finishing mills. To fulfill these requirements Primetals Technologies developed in the first step a new control concept for...

During initial blow-in of the blast furnace the hearth refractory system could experience high temperatures. Over time, skull formation on the hot face of refractory results in temperature reduction within the hearth refractory. Such temperature fluctuation may generate undesirable refractory cracking and/or gap formation, particularly around ramming mixture. These flaws could increase the...

The EAF process reach different results during the different production periods depending by variabilities in operating practices applied, equipment’s efficiencies, scraps charged and hot heel present. A mathematical tool for continuous monitoring of process performances and technological phenomena in EAF has been developed in collaboration between Feralpi Group and CSM to monitor steel/slag...

What makes automotive steel, really automotive? Is now-a-days automotive steel, the same as future automotive steel? And, can we reduce production costs and still achieve automotive quality? Producing steel strip with the highest material properties and surface aspects are NOT enough; CONTROL is the key aspect Danieli equipment has been developed together with: > Yieh Phui (PR China) –...

Sustainable steel making comprises the efficient utilization of the byproducts generated during the technological process. The general byproduct generated during the converter steelmaking process is the off gas, which contains a huge amount of physical –temperature and chemical – CO and H2 energy. The efficient utilization of both types of energy is the target of this research. The amount of...

Based on in-depth investigation of blast furnace slags composition and viscosity it was found that the conditions of blast furnace synthetic and industrial slags could be characterized by slag index “a”: a = (k1CaO + k2MgO + k3TiO2)/(k4SiO2+k5Al2O3+k6FeO+k7MnO). Here coefficients k1, k2, k3, k4, k5 , k6 , k7 characterize known values of coulomb forces in ion structure of multi-component...

Due to the ongoing trend towards fully automated processing lines the development of process controls is highly desirable. In the field of roller leveling a process control has to ensure a constant flatness of the processed strip. A direct measurement of the remaining curvature after leveling is difficult as the strip is suspended to external forces such as gravity or tensile stresses....

The experiences to optimize and control the single steps of steelmaking process as EAF LF and continuous casting has shown that a through process approach is necessary to take into account the previous and subsequent process steps as constrains for optimization. In this way Feralpi Siderurgica has developed a new approach of through process modelling and monitoring coupling simulation...

Considerable amounts of slag and dust are produced in integrated – iron ore based – steelmaking as well as in EAF – scrap based – steelmaking. These by-products still contain considerable amounts of metals in metallic and oxide form and are nowadays only partly processed and recycled, the rest has to be landfilled. Typical solutions are internal recycling via the sinter plant and the blast...

Results of the analysis of physical-chemical properties of sinter and pellets are presented. It was shown that at BF transition to operation with high proportion of non-fluxed pellets in furnace charge, it is necessary to change the basic parameters of the slag mode as well as furnaces loading practice. Results of calculation for BF of OJSC “MMK” operation with high proportion of non-fluxed...

Induration of magnetite pellet is a complex physicochemical process involving oxidation, sintering and the heat transfer phenomena. Often, these phenomena happen simultaneously and influence each other while being exposed to high temperature in the induration furnace, which might results in the formation of duplex structure within the pellet having the core of magnetite and shell of oxidized...

For cleaning of primary gases from BOF-process, the well approved wet scrubbing technology is worldwide the most applied technology. Most of these installations are running for more than 20-30 years. They were originally designed for compliance with environmental regulations much less stringent and complex than nowadays. The revamp, upgrade and retrofit of these systems to fulfil actual...

Primetals and Tangshan have achieved a great performance in project execution to enable a fast development of Tangshan’s new #2 Cold Rolling Mill Complex dedicated to the most valuable products in cold rolled, annealed and coated coils. The project was not limited to equipment delivery and line start-up but included challenging steps in production while considering the three processes,...

Industrial furnaces are subject to extreme heat stress, chemical reactions and abrasive reactions. At the bosh and stack levels of blast furnaces, cooling staves are subject to severe abrasive wear. The staves if worn may cause water leaks, chilling of the furnace and/or catastrophic explosion. Thus, techniques have been developed to monitor the remaining stave thickness so that timely...

ArcelorMittal USA Indiana Harbor plant is making large quantity of high Al TRIP and DP grades to meet the needs from automobile industry for high strength and high deformability steel products. During steelmaking process of these high Al TRIP and Dual Phase steel grades, it has been observed that the nitrogen behaves very differently from regular Al-killed steels. Nitrogen will drop along the...

Yield and economy during cold rolling of flat products depend on developing high capacity components fulfilling further increasing customers demands for cost and resource effective production of steel strip material. The paper gives an overview of the latest developments for high capacity components and tools of SMS group for cold rolling tandem mills and cold reversing mills. The SMS...

JFE Steel Corporation developed a technology (“Super-SINTERTM OXY” ) for injection of hydrogen-based gas fuel and oxygen in sintering machines, which makes it possible to greatly increase sinter productivity and sinter strength in the sintering process, and successfully applied this technology to a commercial sinter plant. 　In ordinary sintering process, after coke breeze is mixed with iron...

In Germany, 43 million tons of steel were produced in 2015, together with about 14 million tons of iron and steel slag as a by-product; about 2 million tons of which are slag from the electric arc furnace. This slag is predominantly used in road construction and earthworks in Germany; because of its significantly superior physical properties it partly substitutes natural rocks in these fields....

In hot and cold rolling mills self-exited vibrations are a very common problem. These vibrations lead to chatter marks on rolls and strip, if no countermeasures are applied. Usually rolling speed is reduced significantly in an automated way, each time self-exited vibration comes up. A reduced productivity is always the result. A new actuator is presented in this paper that allows the active...

Intensive operation of blast furnace allows an increase in production of hot metal and profitability of Iron & Steel Works. However, blast furnace structural integrity could be sacrificed if no measures are taken to protect refractory lining and to build stable accretion. NTMK-EVRAZ is a unique and advanced blast furnace operation with titania load of about 45-50 kg TiO2/thm. Successful...

More than 40 Million tons of steel were produced in Germany in 2015. Therefore the total amount of iron and steel slags is about 13 Million tons every year. The black slag from electric steel making (EAF-slag: approx. 2 Million tons every year in Germany) produced during the scrap melting process in the electric arc furnace can be used in the construction of roads and in other high-grade...

Since the development of basic oxygen furnace (BOF) the modelling of the process reflects a huge field of activity due to the accelerated increase of BOF steel plants. The optimization of the BOF process is focussed, amongst others, also on the thermodynamic and kinetic modelling. With the program MatLab® a new BOF model has been developed. One of the main topics is the description of the...

Ignition of sinter raw mix has a major influence on the efficiency and productivity of the sintering process. Basically, the operation of an ignition hood consists in setting hood temperature and controlling lambda ratio so as to adjust oxygen content in exhaust gas and ensure an efficient ignition of the solid fuel contained in the raw mix. Operators are facing the problems of generation of...

Noticed the strong national and international industrial activity, more specifically concerning the steel production and the model of oxygen converter adopted on the different types of primary refining process, this work applies to relevant models, revaluating since the more rudimentary techniques till the current technologies. Then they will present the methods in which resulted the study of...

By mass, slag is the largest residue in iron and steelmaking. Due to excellent properties as a construction material slag is rising in popularity as a resource. Before slag can be used there are some restrictions that must be fulfilled of which the leaching of chromium is one. For slag to be considered inert material the leaching limit for chromium is at 0.5 mg/kg. The leaching of slag is...

Pellet production is an intensive energy process. Although, pelletizing it is a highly energy optimized process, producers are facing restriction due to restrictive environmental standards in the whole world. In order to deliver solution to this relevant topic, Outotec is developing in small scale the low NOx burner since 2012, and the expressive results are reached. In 2014 using CFD...

Grinding and drying as well as pulverized coal injection is today state-of-the-art in Küttner's product portfolio. Over decades improvements and developments have been made for the benefit of our clients. The aim was always to increase the injection rate by reducing the coke rate at the same time. Overall ironmaking cost should be reduced by keeping a predictable and safe blast furnace...

In cold strip rolling, the amount of wear generated in the contact zone influences the surface quality of the final product, and, by influencing the coefficient of friction between work roll and strip, the force and power requirements of the mill. Most of this wear is expected to be generated from the strip, as the rolls are generally much harder. In order to study the generation of wear...

To achieve minimal coke rates in blast furnace operation it is crucial to obtain optimal burning of additional fuels like e.g. pulverized coal (PC). However, there are operating conditions, where an optimal burning is not possible and it is beneficial to shut down the PC supply on one or more injection lances. The frequent case of raceway blockages can lead to reduced wind throughput on the...

State of the art sinter coolers are working based on the cross flow cooling principle. Thus, only a part of the thermal energy can be used for heat recovery application. The other part of the cooling air is brought unused to the environment. Furthermore, environmental regulation regarding dust emission and intelligent usage of exergy are getting stronger. Therefore Primetals Technologies...

Safety and environmental considerations have significantly increased the demand for Advanced High Strength Steels for automotive applications. Primetals Technologies has incorporated various advanced technologies in the latest supplied Continuous Pickle Line coupled with Tandem Cold Mills (PL-TCM) to satisfy the increased process demands to produce these harder and thinner steels, achieve the...

An increased environmental consciousness, more stringent environmental regulations and a raise of raw material costs have characterized the last few years. All these factors affect the industrial chain management and in the case of the steel industry lead to an intensification of the effort to find solutions allowing increasing waste and by-product reuse. The paper presents part of the work...

To further reduce process times and increase availability at the LD converters in the high-performance steel mill of voestalpine Stahl GmbH in Linz, Austria, the old hydraulic sublance manipulators were replaced with three new robotic sublance systems by Primetals Technologies Austria GmbH. The main criteria for the project were: high availability of >98 %, short cycle times in sublance-probe...

The use of biomass in metallurgical coke production has been identified as one of the main possibilities to introduce a renewable carbon source to the process chain of blast furnace based steel production, thereby decreasing the CO2 emissions produced by the steel industry. In this study, multiple grades of bio-cokes are prepared by combining charcoal produced from pine chips at a high...

The increasing demand of ever higher hardness and thinner steel, for example “advanced high strength steel” in the automotive industry, “tin plate” and “electrical (silicon) steel”, has accelerated in recent years. Particularly in the cold rolling field, harder- and thinner-strip rolling techniques have become urgent requirements which must be dealt with. The HYPER UC-MILL, which was newly...

Decreasing iron ore quality, higher substitution rates of main iron ores to cheaper raw materials due to economic pressure and increased environmental standards are constantly challenging the iron and steel producers. Changing the raw materials in an operating plant can significantly influence the sintering process. Adjusting all process parameters to regain stable and high productive...

Although its chemistry rich in valuable raw materials: carbon content up to 60% and iron content of up to 30 %, blast furnace sludge cannot be recycled into the sintering process, because of its Zn content which is detrimental for Blast Furnace operation. Without an economically viable solution to the problem, millions of tonnes of sludge goes to landfill, creating costs for steelmakers who...

The aim of the BOF (Basic Oxigen Furnace) process is to convert carbon-rich liquid hot metal from the blast furnace to low-carbon steel, which may be refined in the secondary steelmaking shop. Fluxes are needed in this process to remove impurities from the liquid hot metal and form an appropriate slag which could be easily separated from the steel. These fluxes could require low melting points...

At thyssenkruppCSA, a positive heat balance at BOF process is faced, mainly because of low utilization of scrap and plant design. A singular logistic concept for hot metal transport between blast furnace and steel plant was stablished to optimize handling, transport and energy. An average addition of 75kg of iron ore pellets/t steel is necessary for the BOF-340t heat balance. In order to...

Hot Blast Stove Systems are an important equipment of a Blast Furnace plant. During the last years, performance requirements and operation practice for the Hot Blast Systems have changed, with a big influence on the BF operation. Therefore it is necessary to keep the Hot Blast System, including the Hot Blast Stoves, in proper condition in order to maintain the production capacity of the Blast...

Rolling of hard and thin strips is still a challenge for steel industry. For such a configuration, the rolling force could drastically increase and might exceed the tandem mill limit. Flexible lubrication has been developed at ArcelorMittal to cope with the aforementioned issue. It enables controlling effectively the friction condition inside the roll-bite through lubrication process with...

The purpose of Sinter plants is to heat iron ore fines along with fluxes and coke fines or coal, to produce a semi-molten mass that solidifies into porous pieces of sinter with the necessary size and strength characteristics for feeding into the blast furnace. Fluxes used in the sintering process need to have an appropriate granulometric distribution and TI (tumbler index) to avoid generation...

In this hard days for Brazil steel market, all steel shops want to achieve the same goal, work with : productivity, low costs and high performance. In this scenario the Slagless technology (which is applied into BOF converter) was important to reach this targets.After use has been reduced the number of times of nozzle exchange in more than 04 times. Was reduced too, the time to remove lance...

Primetals Technologies has made an important Research & Development effort on laser welder field. The last step of its program was the evolution of its laser welder range by implementing the Solid state technology with laser cutting and welding. Since this step, twelve welders have been manufactured by Primetals Technologies. After more than six years of industrial feedback, the results...

The sharp decline in iron and steel prices has led producers to focus more and more on existing plants and costs of production in recent years. Focus has been on optimizing plant performance to increase productivity in existing plants and decrease energy and maintenance costs (Total variable cost). In addition changing of input materials to the worse and stricter environmental legislation...

Reducing agents are considered to be the major portion of hot metal production cost in blast furnace (BF) ironmaking. In addition, lower energy consumption, lower CO2 emission and waste recycling are strongly needed from both economic and environmental perspectives. Therefore, the iron and steel industry is prompted to sustainable develop “coke free, zero waste and green processes” for future...

The application of post-combustion to avoid skull formation on BOF lances was tested in industrial trials. The main findings are that no negative impact on the metallurgical targets (i.e. carbon, temperature and phosphorus at end of blow as well as iron–oxide in the slag) could be observed. The technology is capable of avoiding the buildup of lance skull and consequently increasing the average...

Blast furnace slag with its tapping temperature of around 1,500°C and a approximately 400 million tons yearly worldwide production is a huge largely unused energy potential. Current state-of-the-art practice is to granulate blast furnace slag in wet-granulation plants without utilization of the thermal energy. However new dry slag granulation technologies are in development to cool the molten...

Sinter is one of the most significant iron carrying raw materials in the blast furnace process. The properties of sinter such as the reducibility and the reduction degradation index (RDI) affect the efficiency of the ironmaking process directly. However, sinter is an agglomerate with complex mineralogical features and a high degree of inhomogeneity. This work aims to characterize the surface...

In 2014, SMS group received the order to modernize Severstal’s fifty years old four stand tandem mill (TCM) in Cherepovets. Main aims are to increase the capacity and strip quality as well as to prepare the mill for a later coupling to a new pickling line (PL). Additionally reduced off-gauge length, raised availability and increased automation rate are required to improve the yield. In a...

Demands for cold rolled tin-plated or galvanized steel sheet products are increasing rapidly in Turkey supported by its economic expansion. A cold rolling complex project for Tosyali-Toyo Celik Anonim Sirketi has now started in Turkey to meet the demands. Primetals Technologies supplies PL-TCM, Tin-CAL and 2-std. Temper DCR Mill for the complex. This paper will introduce the latest...

Based on the investigation results of carbon brick damage of 4BF at Baosteel, this paper discussed the viewpoint that maintaining a stable solidified iron layer(protecting layer) on hot surface of carbon brick is the key for prolong campaign life of hearth and expounded the importance of ensuring higher heat transfer effect of carbon brick construction system. The paper expatiated the...

There is one challenge known to all metallurgists: how much of each ferroalloy to add during steelmaking process in order to ensure the required chemistry of the steel at the lowest possible cost. As ferroalloys participate in numerous chemical reactions, the final absorption of the added elements depends on many factors, which measurements are rough or even unknown. The decision on the exact...

Sinter-Cooler process aims to cool down material at sinter-strand outlet to safely transport it to blast furnaces. In a context of high productivity of sinter-strands, good operation of this process is a key feature to avoid productivity loss and fire issues on conveyor belts. Numerical model was developed to find optimal operating conditions to be applied by operators to maximize capacity of...

As a technology for heavy reduction cold rolling of hard materials such as stainless steel and electrical steel, the Advanced 20Hi Split Housing ZR-Mill (HZ-Mill) has been developed as a 20Hi Cluster mill with a split inner housing, replacing the conventional large-scale mono-block type 20Hi ZRM. In the HZ-Mill, workability can be improved by increasing a roll clearance between the work rolls,...

Altering qualities of raw materials for iron making demand changing treatment before using them in metallurgical aggregates. The conventional iron ore sintering process is only suitable for materials down to a particle size of about 0.2 mm. Currently, it is possible to achieve a maximum fine ore amount of up to 180 to 200 kg/t sinter. In this study, the influence of ultra-fine iron ores (< 0.1...

Pulverized coal injection (PCI) and natural gas (NG) injection at the blast furnace are used to inject fuel into the reaction to maintain temperature control and chemistry of the charge. The reliability of the lances to perform repeatable and be retracted for ease of maintenance is critical for production efficiency at the blast furnace. Upgrading from 300 series lance to a more highly alloyed...

For the process of obtaining steel, pig iron produced in the blast furnace must be treated by a series of transformations called refining. Torpedo ladles carry melted pig iron at temperatures around 1500-1650°C form the blast furnace to the steel mill through a railroad. Generally, the refractory lining of the torpedo has three layers with silicon carbide bricks in the working lining which is...

With the steady increase in computation power numerical simulations offer new possibilities for the design and optimization of industrial facilities. In the highly competitive business of iron making with rapidly increasing requirements in metallurgic plant design numerical models can be highly beneficial in the development process. In this paper a coupled approach of numerical simulations to...

UHT has delivered and commissioned the world’s largest GRANSHOT® metal granulation unit to TATA Steel’s new steel plant in Kalinganagar, Odisha. The delivery enables a seamless industrial route for excess blast furnace iron with a granulation capacity of 300 ton/h. The GRANSHOT® unit is engineered for tapping directly from the torpedo to enable easy metal transfer between the blast furnace...

The new developed “LaCam Explorer” measuring system shows a unique way to measure refractory lining thickness and 3D-profile in hot steel casting ladles **from inside** the ladle. The Laser-measuring system has an innovative, yet simple and rugged design that allows immersion of a laser head into a hot Steel Casting Ladle with surrounding temperatures of more than 1100 °C and surface...

**First successful flying roll change installation for increased production yield** Pushing the horizon of stainless steel continuous cold rolling mill performance on the edge of perfect strip quality level, not compromising with the highest yield and productivity ratios, has been given a new milestone by Primetals Technologies. After a first reference of X-HI® technology tandem mill on...

1. Copper staves are being used widely as blast furnace body cooling components. Blast furnace production and life-time sustainability is directly related with the durability of the copper staves. Copper staves protects the refractory and furnace shell from the heat load and adverse mechanical effects due to the formation of an accretion layer. Since the stave maintenance and replacement is...

Chatter is one of the most crucial phenomenons in strip rolling, especially in the very fast operating process steps like cold rolling. Bringing mills to the maximum of their operational possibilities without entering the “chatter” areas is not only a challenging task for all producers of Aluminum and Steel strip and sheet but must also be supported comprehensively by the plant manufacturers....

The rapid growing iron and steel productions in the recent years resulted in a continuously demand for new iron ore resources. On the other hand the availability of the typical sinter feed (1-6.3 mm) has become limited and the rapid growing production resulted in more and more fine ore (< 150 μm) availability in the market. The sinter plant operators are facing several new challenges since the...

The efficiency of a batch annealing bay is to a large extent dependent on which coils are combined to create the stacks. At Tata Steel IJmuiden a smart stack building algorithm is in use to optimize productivity. However, over the past few years the throughput of the batch annealing bay has become more volatile as more steel was shifted to the hot dip galvanizing lines. Especially when...

Ten years back SMS group has launched its X-Shape flatness measurement system for cold rolling mills. The core component of X-Shape is the flatness measuring roll developed by SMS group. Its outer appearance can hardly be distinguished from a conventional deflector roll, but it is the sophisticated technology inside that makes the difference. Main features are - state-of-the-art,...