Please note: the AISTech 2021 Technical Program is subject to change.
Presentations may be moved from in person to virtual based on author and company availability. Please check back regularly for updates.

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Monday, June 28
7:30am Artificial Intelligence and Data-Driven Modeling in Ironmaking – Potential and Limitations Dieter Bettinger, Primetals Technologies; Harald Fritschek, Primetals Technologies; Martin Schaler, Primetals Technologies; Petra Krahwinkler, Primetals Technologies; Adnan Husakovic, Primetals Technologies; Sonja Straszer, Primetals Technologies show more Description The revival of artificial intelligence (AI) promises to offer solutions in particular for complex systems that are difficult to model with classical methods. An overview of AI solutions in ironmaking is provided and their strengths and weaknesses are discussed. Topics such as the applicability for typical problem groups, pre-conditions regarding required data quality and completeness of data sets, reliability, and combination with classical approaches are covered. Further, the deployment and integration of black box models into control systems and the related stability are discussed. Time Monday, Jun 28 7:30AM - 8:00AM Speakers Dieter Bettinger Primetals Technologies Harald Fritschek Primetals Technologies Martin Schaler Primetals Technologies Petra Krahwinkler Primetals Technologies Adnan Husakovic Primetals Technologies Sonja Straszer Primetals Technologies Investigation on Softening/Hardening Mechanisms Occurring During the Hot Rolling Process by Means of Advanced, Self-Training Virtual Smart Sensors Alessandro Ferraiuolo, Marcegaglia Ravenna SpA show more Description Virtual sensors were developed that allow for the measurement of the evolution of microstructure in the longitudinal direction and the quantitative study of the softening phenomena that occur during the hot deformation or the static and dynamic recrystallization and the dynamic recovery as a function of the chemical composition and temperature. The innovative element of the paper is the development of a new methodology to control the hot rolling process microstructure evolution of high-strength steel strip/plate on-line by implementing virtual sensors based on self-training mathematical models. The validation of model predictions was carried out through laboratory and industrial tests. Time Monday, Jun 28 7:30AM - 8:00AM Speakers Alessandro Ferraiuolo Marcegaglia Ravenna SpA
8:00am IR Temperature Measurement to Monitor Induction Hardening Processes Daniel Schueftan, Advanced Energy; Janelle Coponen, Advanced Energy Industries show more Description The use of non-contact temperature measurement has become essential for controlling production processes in every step. In fact, high quality standards can only be guaranteed by precisely monitoring and controlling temperatures for even the smallest components. Process surveillance is one of the most important factors to guarantee the required product quality and profitability in induction hardening processes. In this session, attendees will learn how to achieve the desired hardness during induction hardening and tempering where a particular spot of the workpiece is heated up and subsequently quenched rapidly. Time Monday, Jun 28 8:00AM - 8:30AM Speakers Daniel Schueftan Advanced Energy Janelle Coponen Advanced Energy Industries
8:30am Data Driven Solutions and AI Simplifying Metals Complexity Enrico Plazzogna, Danieli Automation S.p.A show more Description An Intelligent Plant is a manufacturing organization strongly supported by digital assets (systems, sensors, equipment, etc.) which are fully integrated for the best and most efficient synergy between humans and machines. Processes are automatically and autonomously improved, and decision-making supported by data and statistics. Process performances and quality control are further optimized thanks to artificial intelligence. From one 3QPulpit the whole production can be safely and efficiently controlled by a few operators. 3QPulpit enriches, simplifies and empowers the operators’ experience, providing the right information at the right time by collecting Big Data directly from the plant, with full video monitoring so operators can safely navigate dangerous or inaccessible areas, even analyzing past events. The result is a sustainable plant where KPI indicators are measured, energy consumption is optimized, and quality is monitored and adjusted in order to produce more with less. Time Monday, Jun 28 8:30AM - 9:00AM Speakers Enrico Plazzogna Danieli Automation S.p.A Extremely Rapid Ablation and In-Situ EBSD Preparation Using a Femtosecond Laser in the FIB-SEM Andy Holwell, Carl Zeiss Microscopy Ltd.; Roger Barnett, Carl Zeiss Microscopy Ltd.; Tim Schubert, Aalen University show more Description When carrying out crystallography using electron backscatter diffraction (EBSD), the major time-limiting factor is sample preparation. The use of a femtosecond laser facilitates extremely fast sample machining and surface preparation with minimal sample damage, precisely locating, extracting and preparing specific regions of interest. The integration of a laser ablation chamber on the focused ion beam (FIB)-scanning electron microscopy (SEM) allows access to buried features and preparation of surfaces suitable for EBSD without time-consuming FIB milling. Several laser-prepared metal surfaces suitable for EBSD grain mapping will be shown. Total preparation time is under 5 minutes, enabling extremely rapid inclusion, grain and failure analysis workflows on the nanometer scale. Time Monday, Jun 28 8:30AM - 9:00AM Speakers Andy Holwell Carl Zeiss Microscopy Ltd. Roger Barnett Carl Zeiss Microscopy Ltd. Tim Schubert Aalen University
9:00am Correlative Light, Electron and In-Situ Raman Imaging of Modern and Historic Railway Tracks, Linking Wear and Corrosion Behavior to Microstructure and Composition Andy Holwell, Carl Zeiss Microscopy Ltd.; Roger Barnett, Carl Zeiss Microscopy Ltd. show more Description Rail track metallurgy has evolved to meet increasingly demanding requirements. The microstructure is engineered for high hardness, contact fatigue resistance and environmental durability. Mechanical and corrosion damage in worn 1930s and 1950s rails were compared against modern rail. In-situ Raman imaging was performed in a scanning electron microscope, correlated with light microscopy and energy-dispersive x-ray spectroscopy. The microstructure, oxides and inclusions in each rail were studied to assess their influence on mechanical damage, deformation and corrosion. Integrating a Raman microscope in the scanning electron microscope chamber uniquely allows rapid correlative workflows, overlay of spectra, and multimodal imaging in understanding corrosion and wear mechanisms. Time Monday, Jun 28 9:00AM - 9:30AM Speakers Andy Holwell Carl Zeiss Microscopy Ltd. Roger Barnett Carl Zeiss Microscopy Ltd. Mastering Fully Automated Steelmaking Richard Stadlmayr, Primetals Technologies; Christoph Stangl, Primetals Technologies show more Description Dynamic LD/basic oxygen furnace/electric arc furnace process control with assisted secondary refining and autonomous steel casting is state-of-the-art upstream technology. The idea of fully automated steelmaking shall raise meltshop automation to a level that enables operators to act primary as supervisors to execute steel production in a safe and reliable manner. Since there is no unified approach to close the gap between current plant-specific operation and the mid-term target of fully automated steelmaking, a digitalization road map draws a structured picture of required measures accompanied by an implementation order considering process development, IT and data infrastructure, meltshop transports and logistics, and maintenance aspects as one. Time Monday, Jun 28 9:00AM - 9:30AM Speakers Richard Stadlmayr Primetals Technologies Christoph Stangl Primetals Technologies
9:30am Shooter 4.0 – A Prototype for Intelligent and Autonomous Gunning Maintenance Nikolaus Mutsam, Mutsam Engineering; Gregor Lammer, RHI Magnesita; Ronald Lanzenberger, RHI Magnesita; Douglas Beish, BD & D Specialty Fabrication & Machine LLC show more Description This paper presents a system for fully automated, intelligent operation of a spray gunning manipulator. The prototype features motion tracking, autonomous gunning, an in-furnace camera for live monitoring and data analysis, automatic delivery of maintenance reports, and remote control via mobile app. Video and sensor data can be uploaded to a remote storage using an onboard internet connection. The data is used to analyze and optimize gunning. The prototype is retrofitted to an existing manipulator with the vision to getting machines of previous generations ready for the challenges of the Industry 4.0 era. Furthermore, integration into new machines is supported. Time Monday, Jun 28 9:30AM - 10:30AM Speakers Nikolaus Mutsam Mutsam Engineering Gregor Lammer RHI Magnesita Ronald Lanzenberger RHI Magnesita Douglas Beish BD & D Specialty Fabrication & Machine LLC Wet Flash Cooling: A Flexible and High-Performance Quenching Technology for Gen3 AHSS Stephane Mehrain, Fives; Sébastien Lemaire, Fives Stein show more Description The automotive steel market is driving today the development of a large variety of third-generation (Gen3) advanced high-strength steel (AHSS) grades with higher yield strength and improved formability. The most advanced Gen3 AHSS grades requires quenching with a precise control of the thermal cycle and an improved strip flatness. The Wet Flash Cooling technology reaches these goals, offering very high cooling rates with a fully flexible control of the operation. This paper summarizes the main challenges of quenching technologies to respond to the Gen3 AHSS production needs and describes the main features and industrial performances of the Wet Flash Cooling technologies. Time Monday, Jun 28 9:30AM - 10:30AM Speakers Stephane Mehrain Fives Sébastien Lemaire Fives Stein
10:30am Automatic Pilot For Strip Processing Lines Maxime Monnoyer, Fives KEODS; Etienne Menigault, Fives KEODS; Philippe Rocabois, Fives KEODS; Arnaud Ollagnier, Fives KEODS; Aldo Fiorini, Marcegaglia Ravenna SpA; Stefano Pantarotto, Marcegaglia Ravenna SpA; Alessandro Ferraiuolo, Marcegaglia Ravenna SpA show more Description Today management of galvanizing lines is generally based on manual presets or individual models for each process without comprehensive optimization of quality and productivity. Fives developed a process control solution using predictive metallurgical models combining physical laws, artificial intelligence and machine learning to automatically control key processes in a galvanizing line, aiming at reaching best compromise between quality yield, productivity and operational flexibility. The solution integrates incoming material properties, on-line measurements and final product quality targets, adjusts parameters of key process sections accordingly (furnace, zinc bath, wiping, skinpass) and optimizes transitions. Results from a recent case study will be highlighted. Time Monday, Jun 28 10:30AM - 11:00AM Speakers Maxime Monnoyer Fives KEODS Etienne Menigault Fives KEODS Philippe Rocabois Fives KEODS Arnaud Ollagnier Fives KEODS Aldo Fiorini Marcegaglia Ravenna SpA Stefano Pantarotto Marcegaglia Ravenna SpA Alessandro Ferraiuolo Marcegaglia Ravenna SpA Development and Successful Evaluation of an Atmosphere-Controlled Furnace for Direct Reduction Feedstock Studies Felix Firsbach, Lhoist Business Innovation Center; Michael Nispel, Lhoist Business Innovation Center; Bryan Souchon, Lhoist Business Innovation Center show more Description This paper describes the development of Lhoist’s atmosphere-controlled Vario-Furnace and its modification to conduct comparative metallurgical studies of iron ore feedstocks for direct reduction and blast furnaces, paving the way toward a CO2 emission-free steel industry. This furnace is designed to perform qualitative research on reduction behaviors of (iron ore) feedstock up to 500 g sample size in mixed-gas atmospheres (CO, CO2, H2, N2, O2, CH4, SOx) at temperatures up to 1,000°C. The setup, the gas flow optimization and the adaptation for metallurgical tests (reducibility, swelling, reduction-disintegration) are described, as well as the metallurgical results obtained on two types of industrial pellets. Time Monday, Jun 28 10:30AM - 11:00AM Speakers Felix Firsbach Lhoist Business Innovation Center Michael Nispel Lhoist Business Innovation Center Bryan Souchon Lhoist Business Innovation Center
11:00am Corrosion Behavior of Different Alloys in Zn and Al alloy Galvanizing Baths Tobias Simon, Kuhn Special Steel North America Inc.; Frank Wischnowski, Kuhn Special Steel North America Inc. show more Description In this study, different types of centrifugally cast and forged alloys are subjected to liquid metal (Zn and AlSi baths). Various samples were manufactured and introduced into test rig in galvanizing alloys (pure Zn and AlSi). The samples were examined and evaluated for mass loss and microstructure via optical and scanning electron microscopy. Test alloys were compared according to alloying elements. This work contributes to the understanding of the effect of alloying elements on liquid metal corrosion in various galvanizing baths. Here different alloy compositions are subjected to liquid metal test baths to simulate corrosion situations in Zn/Al/AlSi pots during continuous galvanizing. Time Monday, Jun 28 11:00AM - 11:30AM Speakers Tobias Simon Kuhn Special Steel North America Inc. Frank Wischnowski Kuhn Special Steel North America Inc. HIsarna: Benefits of an Innovative Smelting-Reduction Ironmaking Technology J.L.T. Hage, Tata Steel; Christiaan Zeilstra, Tata Steel; Johan Van Boggelen, Tata Steel; H.K.A. Meijer, Tata Steel; J. van der Stel, Tata Steel ; T. Peeters, Tata Steel show more Description HIsarna is a new coal-based smelting-reduction technology for ironmaking. Its benefits include: process intensification and high energy efficiency; a CCS-ready process gas; reduced emissions of dust, SOx and NOx; flexibility in raw materials; and increased circularity through reclaiming Zn from waste materials and/or Zn-coated scrap. Because HIsarna produces low-phosphorus and low-silicon hot metal, it reduces costs in steelmaking and opens opportunities for new products. The process also offers lower capex and opex compared to the blast furnace route. The HIsarna process offers the potential to replace a substantial part of the injected coal by biomass, natural gas or hydrogen. Time Monday, Jun 28 11:00AM - 11:30AM Speakers J.L.T. Hage Tata Steel Christiaan Zeilstra Tata Steel Johan Van Boggelen Tata Steel H.K.A. Meijer Tata Steel J. van der Stel Tata Steel T. Peeters Tata Steel
11:30am Cutting-Edge Process Technologies to Enhance Electrical Steel Performances Camille Moukarzel, Fives show more Description The booming electric vehicles market is driving the development of non-grain oriented electrical steels with high flux density and minimal core losses for the use in high-frequency electric motors, as well as high-energy-efficient grain-oriented electrical steels due to the need of charging infrastructure. The process routes for new high-performance grades require some advanced technologies such as ultrafast heating by transverse flux induction, high-temperature furnace operation, flexible and uniform cooling, and reliable furnace atmosphere control. This paper will describe these technologies which have been recently implemented on new lines and through upgrades of existing lines. Time Monday, Jun 28 11:30AM - 12:00PM Speakers Camille Moukarzel Fives Modernization of DRI Shaft Furnaces to Improve Performance and Product Quality Yakov Gordon, Hatch; N. A. Spirin, Ural Federal University show more Description Gas dynamics and gas distribution in shaft furnace play a crucial role in improvement of furnace productivity, product quality and reduction in natural gas rate. Optimum design parameters of gas distribution devices were investigated by means of mathematical modeling, pilot plant and industrial installation studies. New heat transfer co-current schematics of gas and material movement with self-reforming of natural gas in metallization zone was invented, patented and tested at the pilot plant. New shaft furnace design and improvements were proposed and new gas distribution deviCes were implemented, providing savings in fuel rate, increase in productivity and improvements in the quality of direct reduced iron. Time Monday, Jun 28 11:30AM - 12:00PM Speakers Yakov Gordon Hatch N. A. Spirin Ural Federal University
12:00pm Blast Furnace Data Validation Using Deep Learning as an Enabler for Autonomous Blast Furnace Cedric Schockaert, Paul Wurth; Fabrice Hansen, Paul Wurth & SMS digital; Franck Giroldini, Paul Wurth; Alexander Schmitz, Paul Wurth show more Description The first requirement in order to enable an autonomous blast furnace is high level of data quality and integrity. To meet these requirements, we have implemented an unsupervised deep-learning architecture, an LSTM AutoEncoder, that captures the temporal and intervariables correlations from the data of a blast furnace. The application of this approach is multiple: (1) Data validation and correction for data-driven model training, (2) Live anomaly detection before feeding data-driven models, and (3) Explainability of abnormal events in the process. This work has been validated on data from different blast furnaces and is integrated in Paul Wurth’s digital products. Time Monday, Jun 28 12:00PM - 12:30PM Speakers Cedric Schockaert Paul Wurth Fabrice Hansen Paul Wurth & SMS digital Franck Giroldini Paul Wurth Alexander Schmitz Paul Wurth Pomini Tenova Data Monitoring System - A 4.0 Industry Application Tailor-Made for Roll Grinding Machines Diego Brusetti, Tenova S.p.A.; Claudio Trevisan, Tenova S.p.A. show more Description The implementation of an effective 4.0 industry concept requires an advanced hardware and software package, enabling the monitoring of a comprehensive set of variables, properly identified and tracked to assess the functioning conditions of the equipment as well as the progress of the process. Pomini Tenova developed its own proprietary data monitoring package, in which the expertise of the original equipment manufacturer, of the grinding specialists and of the software engineering team have contributed to provide roll shop users with an advanced and effective tool, tailor-made around roll grinding specific necessities. Time Monday, Jun 28 12:00PM - 12:30PM Speakers Diego Brusetti Tenova S.p.A. Claudio Trevisan Tenova S.p.A.
12:30pm Development of Electrical Discharge Coating for Extended Textured Roll Campaigns Chris Childs, Sarclad; G. Evans, Sarclad Limited; T. Lowbridge, Sarclad Limited show more Description This paper describes the development of electrical discharge coating (EDC) of textured work rolls and summarizes the results obtained so far. Extending the life of textured rolls is important to steel mills for operational, financial and environmental reasons. Results of laboratory evaluations and industrial trials confirm that EDC produces a harder recast layer than alternative texturing methods and is a viable method of extending textured roll campaigns. Time Monday, Jun 28 12:30PM - 1:00PM Speakers Chris Childs Sarclad G. Evans Sarclad Limited T. Lowbridge Sarclad Limited Maintenance Becomes Smart: The Power of Digitizing Valuable Knowledge Stephan Weyer, Paul Wurth S.A.; Fabrice Hansen, Paul Wurth & SMS digital; Alexander Schmitz, Paul Wurth; Yves Reuter, Paul Wurth S.A. show more Description This paper puts maintenance of ironmaking technologies in the light of the digital age. It is addressed to all plant operators facing the challenge of optimizing existing processes in a meaningful way. It puts focus on the most important challenge: digitizing, sharing and linking valuable maintenance knowledge. Once this step becomes a success, advanced maintenance strategies will provide significant added value beyond the hype and thus ensure acceptance in practice. It will pave the way from fail and fix to prevent and predict. Time Monday, Jun 28 12:30PM - 1:00PM Speakers Stephan Weyer Paul Wurth S.A. Fabrice Hansen Paul Wurth & SMS digital Alexander Schmitz Paul Wurth Yves Reuter Paul Wurth S.A.
3:00pm Basic Actions to Prevent Continuous Casting Defects of Billets José Bacalhau, CBMM; Jose Bolota, LeanFox; Danilo Guzela, D. Di Napoli Guzela; Marcos Nogueira, ST3 Consulting show more Description This paper discusses the main operational features that must be considered to prevent defects of continuous casting of billets for microalloyed rebar grades. Microalloyed rebar grades are becoming popular since the quench and self-tempered (QST) rolling process cannot stand for most of the modern construction standards around the world. From several plants that successfully cast microalloyed rebar grades, the authors could summarize the best continuous casting practices to guide newcomers in the field of increasing microalloyed rebar billet production. Time Monday, Jun 28 3:00PM - 3:30PM Speakers José Bacalhau CBMM Jose Bolota LeanFox Danilo Guzela D. Di Napoli Guzela Marcos Nogueira ST3 Consulting
3:30pm Inclusion Shape Control Through Ca Treatment Keyan Miao, McMaster University; Muhammad Nabeel, McMaster University; Neslihan Dogan, McMaster University; Stanley Sun, ArcelorMittal Global R&D - Hamilton show more Description Ca injection is a common practice in steelmaking for inclusion modification; however, steel chemistry (S, Ca, Mn…) and casting speed can have a direct impact on the modification result. In this study, laboratory-scale experiments were conducted to investigate the influence of Ca and S on the evolution of the inclusion morphology under two sample cooling rates to simulate steel cooling at the caster. CaS-Oxide complex inclusion is one of the dominant inclusion types observed in the experiment. The CaS-Oxide inclusion morphologies were classified into three types. The mechanisms of the inclusion formation and evolution during steel process are discussed. Time Monday, Jun 28 3:30PM - 4:00PM Speakers Keyan Miao McMaster University Muhammad Nabeel McMaster University Neslihan Dogan McMaster University Stanley Sun ArcelorMittal Global R&D - Hamilton
4:00pm Study on Production Technology of Clean Steel in Phase II of Shougang Jingtang United Iron and Steel Co. Liu Jingang, Shougang Research Institute of Technology; Hao Ning, Shaugang Group Co., Ltd. ; Shi Shudong, Shougang Jingtang United Iron and Steel Co.; Yan Zhanhui, Shougang Jingtang United Iron and Steel Co.; Gao Chongguang, Shougang Jingtang United Iron and Steel Co.; Wang Guolian, Shougang Jingtang United Iron and Steel Co.; Yang Rongguang, Shougang Jingtang United Iron and Steel Co.; Chu Rensheng, Shaugang Group Co., Ltd. ; Li Zhanjun, Shaugang Group Co., Ltd. ; Li Haibo, Shaugang Group Co., Ltd. ; Zhu Guosen, Shaugang Group Co., Ltd. ; Ji Chenxi, Shaugang Group Co., Ltd. ; Zhu Zhiyuan, Shougang Group Co., Ltd. show more Description Using the process of "KR-converter - LF refining - VD vacuum refining - CC," the technology platform for a large converter to produce high-quality clean steel for medium thick plate has been developed, which meets the requirements for high-grade steel for medium thick plate. Sulfur content and phosphorus content are less than 0.001% and below 0.0065%, respectively, through the whole process control. Hydrogen content in the steel is reduced to less than 1.5 ppm by vacuum (<67 pa) degassing for 15 minutes. The inclusions meet the requirements of no more than 2.0 for all types of inclusions such as pipeline steel. Time Monday, Jun 28 4:00PM - 4:30PM Speakers Liu Jingang Shougang Research Institute of Technology Hao Ning Shaugang Group Co., Ltd. Shi Shudong Shougang Jingtang United Iron and Steel Co. Yan Zhanhui Shougang Jingtang United Iron and Steel Co. Gao Chongguang Shougang Jingtang United Iron and Steel Co. Wang Guolian Shougang Jingtang United Iron and Steel Co. Yang Rongguang Shougang Jingtang United Iron and Steel Co. Chu Rensheng Shaugang Group Co., Ltd. Li Zhanjun Shaugang Group Co., Ltd. Li Haibo Shaugang Group Co., Ltd. Zhu Guosen Shaugang Group Co., Ltd. Ji Chenxi Shaugang Group Co., Ltd. Zhu Zhiyuan Shougang Group Co., Ltd.
4:30pm Influence of Mold Powder Slag Composition on Formation of Oxide Particles in Steel Junya Ito, Shinagawa Refractories Co. Ltd.; Yukimasa Iwamoto, Shinagawa Refractories Co. Ltd.; Jim Gilmore, Shinagawa Advanced Materials Americas Inc.; Masanori Okada, Shinagawa Advanced Materials Americas Inc. show more Description In this study, diffusion of oxygen from molten mold powder slag into the casted steel surface was investigated experimentally to verify the oxide particle formation in the surface layer of the steel, which is expected to cause defects in the casting process. Small rectangular steel rods were submerged into various molten powder slags followed by microstructure observations of the interfacial area. As a result, formation of micron radius spherical particles composed of Si, Mn and O, and also the influence of the slag composition on the oxide particle formation, were confirmed. Time Monday, Jun 28 4:30PM - 5:00PM Speakers Junya Ito Shinagawa Refractories Co. Ltd. Yukimasa Iwamoto Shinagawa Refractories Co. Ltd. Jim Gilmore Shinagawa Advanced Materials Americas Inc. Masanori Okada Shinagawa Advanced Materials Americas Inc.
Tuesday, June 29
7:30am Why Both Hydrogen and Carbon are Key for Net Zero Steelmaking Carl De Maré show more Description Howe Memorial Lecture Time Tuesday, Jun 29 7:30AM - 8:30AM Location 202 Speakers Carl De Maré
8:30am Reimagining the Future Frank Diana, Tata Consultancy Services Ltd. show more Description AIME 150th Anniversary Keynote Lecture Time Tuesday, Jun 29 8:30AM - 9:30AM Location 202 Speakers Frank Diana Tata Consultancy Services Ltd.
9:30am Achieving Successful Laser Velocimeter Measurements for Unguided Products Using New Innovative Technology for Tension Control of Wire Rod in Hot Rolling Jerome Dapore, NDC Technologies Inc.; D. R. Parra Solís, Ternium; H. Santoyo Avilés, Ternium ; I. Chávez Mendoza, Ternium; J. J. Cerón Gonzalez, Ternium show more Description Laser doppler velocimetry (LDV) has been a long-proven method for accurately measuring the length and speed of products. But many applications involving the production of long, continuous cylindrical products pose measurement challenges. Products that cannot be well guided, move off-axis and move out of the measurement range make it difficult for traditional LDV-based gauges to keep the laser on the product’s surface. This results in hard-to-obtain and unreliable length and speed measurements. Cylindrical products that are small and/or have a severe curvature compound this measurement issue. This new patent-pending LDV technology is a breakthrough development for hot rolling long products. Time Tuesday, Jun 29 9:30AM - 10:00AM Location 207 C Speakers Jerome Dapore NDC Technologies Inc. D. R. Parra Solís Ternium H. Santoyo Avilés Ternium I. Chávez Mendoza Ternium J. J. Cerón Gonzalez Ternium Briquetting and Sintering - Competition or Synergy? Christophe Aubertot, Direxa Engineering LLC; Aitber Bizhanov, J.C. Steele & Sons Inc. show more Description The traditional sintering technology and the emerging technology of forming extruded briquettes (BREX) by stiff extrusion for preparation of raw materials for blast furnaces (BF) are compared, based on the results of scientific research and of the construction/commissioning of industrial lines. The presentation provides an analysis of energy efficiency and of the environmental impact. Looking at both technical and economic indicators, it shows the stiff extrusion technology to be quite competitive with the traditional method of agglomeration – sintering – and qualifies it as best available technology. The promising options for synergy between the two technologies are described. Time Tuesday, Jun 29 9:30AM - 10:00AM Location 201 A Speakers Christophe Aubertot Direxa Engineering LLC Aitber Bizhanov J.C. Steele & Sons Inc. Case Study: System Modifications Enhance Overall Ventilation Systems Ray Tedford, Schust show more Description Due to a less-than-optimal initial design, a steel mill client was replacing portions of ductwork every six months. This resulted in significant maintenance costs and impact on existing operations. The discussion will focus on this specific example to identify steps that every mill can take to help improve ventilation system performance. Topics such as typical problems that a mill may encounter and factors to consider will be explored, with the goal of minimizing ventilation system maintenance costs while improving air quality in the shop. Time Tuesday, Jun 29 9:30AM - 10:00AM Location 207 A Speakers Ray Tedford Schust CokeXpert Cloud: More Focus on Battery Lifetime and Personal Safety Davide Milanta, Paul Wurth Italia S.p.A. show more Description In the framework of providing new tools in line with the current and upcoming needs in cokemaking, Paul Wurth has invested in the creation of a new “cloud” release of CokeXpert. This new release helps customers in achieving a deeper understanding on the real status of coke oven batteries, combining measurements with visual observations, with the purpose of extending their lifetime and improving performance. In addition, new safety functionalities will ensure safe operations by means of a bidirectional exchange of information between personal protection equipment and CokeXpert. Time Tuesday, Jun 29 9:30AM - 10:00AM Location 209 B Speakers Davide Milanta Paul Wurth Italia S.p.A. Corrosion Behavior of Tundish Refractories by Molten Steel and Tundish Flux Ronald J. O'Malley, Missouri University of Science and Technology; Tyler Richards, Missouri University of Science and Technology; Jeffrey Smith, Missouri University of Science and Technology; Todd Sander, Missouri University of Science and Technology show more Description Interactions between dry vibratable tundish lining material, tundish flux and molten steel were explored using a laboratory-based crucible experiment. A periclase-based dry vibratable tundish lining material containing 30 wt.% olivine was selected for investigation. The flux used was one that is commercially available and was provided by industry sponsors. The steel grade investigated was low-carbon, aluminum-killed and calcium-treated with titanium addition. Cathodoluminescence imaging, secondary electron microscopy and energy-dispersive spectroscopy were performed to characterize the interactions. The linings are compared to determine the impact of material selection on lining corrosion, spinel formation and steel cleanliness. Time Tuesday, Jun 29 9:30AM - 10:00AM Location 205 B Speakers Ronald J. O'Malley Missouri University of Science and Technology Tyler Richards Missouri University of Science and Technology Jeffrey Smith Missouri University of Science and Technology Todd Sander Missouri University of Science and Technology Crane Rail Deformation Mapping Using Laser Scanner Point Cloud Michael Falk, Falk-PLI; Sagar Deshpande, Penn State University; Nathan Plooster, Falk PLI show more Description Proper alignments of runway rails of factory cranes are crucial for safe and reliable operation. A method is presented to estimate rail locations: head and web of rail. A standard rail template is compared to a slice of a rail point cloud at regular interval. Two-step matching is performed. The first step is to create a shortlist of candidate locations and the second step is a dense match between the template and the rail points. Root mean square error (RMSE) at each rail point is computed by comparing the nearest rail points and inflection points from the template. Lowest RMSE location is selected as the correct match. Time Tuesday, Jun 29 9:30AM - 10:00AM Location 209 C Speakers Michael Falk Falk-PLI Sagar Deshpande Penn State University Nathan Plooster Falk PLI Design and Application of an Optimum Roughing Mill Backup Roll Contour in a Hot Strip Mill Mustafa Saygili, Colakoglu Metalurji; Özkan Ozkan, Colakoglu Metalurji show more Description During hot strip rolling, roll working condition is heavy and complex in the roughing mill area due to big loads and high reductions. With the increasing competition in the market, the product mix is becoming more difficult at HSM-1850 of Colakoglu Metalurji. Rolls were frequently spalling and broken. After the application of improved backup roll contour instead of conventional flat contour, the non-uniform wear of work roll and backup roll were eliminated and the risk of roll spalling was reduced. Time Tuesday, Jun 29 9:30AM - 10:00AM Speakers Mustafa Saygili Colakoglu Metalurji Özkan Ozkan Colakoglu Metalurji Dynamic EAF Energy and Material Balance Model for On-Line Process Optimization Sunday Abraham, SSAB Americas; Yufeng Wang, SSAB Americas; Randy Petty, SSAB Americas; Tim Sprague, SSAB Americas; Tony Franks, SSAB Americas; Eric Brown, SSAB Americas show more Description A comprehensive and dynamic model has been developed for predicting key melting parameters. The model predicts temperature, carbon, oxygen, slag composition and offgas composition during the melting process. The temperature module is based on energies from electricity and chemical reactions. The carbon and oxygen module is based on scrap chemistry and supplied carbon and oxygen. The slag module is based on flux additions and oxidation reactions. From an established oxidation reaction hierarchy, the offgas module computes the volumes of CO and CO2. This paper discusses the implementation of the model for on-line process control and optimization at SSAB Americas. Time Tuesday, Jun 29 9:30AM - 10:00AM Location 204 Speakers Sunday Abraham SSAB Americas Yufeng Wang SSAB Americas Randy Petty SSAB Americas Tim Sprague SSAB Americas Tony Franks SSAB Americas Eric Brown SSAB Americas Gearboxes’ Service Life Increases Tenfold With Conventional Recirculating Oil System Upgrade Kyle Saxton, Saxton Industries; Jason Vicari, Cleveland-Cliffs - Indiana Harbor East; Tyler Minnick, Schaeffer Manufacturing Co. show more Description In 2011, the upgraded replacement of a conventional recirculating oil system doubled the service life of two gearboxes, from one to two years. The gearboxes continued to be used and monitored until one failed in May 2020. This means the modifications made in 2009 extended the service life of the boxes from one to 11 years, while also improving reliability, reducing lubricant usage, lowering life cycle repair and wastewater treatment costs, and lessening environmental impact. Rarely can the life cycle of a project be documented and its impact revealed. Time Tuesday, Jun 29 9:30AM - 10:00AM Location 205 C Speakers Kyle Saxton Saxton Industries Jason Vicari Cleveland-Cliffs - Indiana Harbor East Tyler Minnick Schaeffer Manufacturing Co. High-Throughput Casting Technology – Challenges and Solutions Juergen Mueller, SMS group GmbH; Christian Froehling, SMS group GmbH; Frank Seuffert, SMS group GmbH show more Description SMS group received an order from Steel Dynamics Inc. for the Sinton, Texas, single-strand high-production plant, having an annual capacity of 2.7 million metric tons. With a casting thickness of 130 mm, the required higher throughput is given and the production of thicker API grades becomes possible. Challenges for the subsequent high throughputs will be the steel flow control in the mold, minimization of bulging and the establishment of a uniform solidification in the strand guide. The continuous casting plant concept, with an overview of the technological highlights, will be presented. Time Tuesday, Jun 29 9:30AM - 10:00AM Location 208 A Speakers Juergen Mueller SMS group GmbH Christian Froehling SMS group GmbH Frank Seuffert SMS group GmbH Investigation of Carbon Deposition During Natural Gas and Oxygen Injection for the Direct Reduction Ironmaking Process Chenn Zhou, Purdue University Northwest; Tyamo Okosun, Purdue University Northwest; Yu Wang, Purdue University Northwest; Qurram Syed, Purdue University Northwest; Rui Liu, ArcelorMittal Global R&D; Cesar Velazquez, ArcelorMittal Lázaro Cárdenas; Joel Carmona, ArcelorMittal Lázaro Cárdenas; Elaine Chen, Voestalpine Texas LLC show more Description In the direct reduced iron (DRI) process, reducing gases are generated in a reformer and lose heat to the environment as they are transported to a shaft furnace. To maintain temperature, oxygen and natural gas are injected. In ideal operation, the natural gas combusts with the oxygen, yielding increased thermal energy. However, in existing operating scenarios, carbon formation around the natural gas ports has become a serious issue. In order to better understand this problem, a three-dimensional computational fluid dynamics model was developed to investigate flow phenomena, combustion characteristics and carbon deposition in this region of the DRI process. Time Tuesday, Jun 29 9:30AM - 10:00AM Location 201 B Speakers Chenn Zhou Purdue University Northwest Tyamo Okosun Purdue University Northwest Yu Wang Purdue University Northwest Qurram Syed Purdue University Northwest Rui Liu ArcelorMittal Global R&D Cesar Velazquez ArcelorMittal Lázaro Cárdenas Joel Carmona ArcelorMittal Lázaro Cárdenas Elaine Chen Voestalpine Texas LLC New High-Performance X-Ray Coating Weight Gauge for Metals Roland Gouel, Scantech Americas Inc.; Jean-Jacques Florent, Scantech SAS; Jan Gaudaen, Scantech SAS; Francois Legrand, Scantech SAS show more Description Productivity and quality of metallic coatings on metallic substrates depend heavily on the ability to control the coating thickness during manufacturing. The aim of the control is to minimize the quantity of coating metal used and the amount of out-of-tolerance product, hence reducing substantially production cost. An effective coating control requires an accurate, fast, continuous, non-contact, on-line coating thickness measurement. This paper outlines the performance of a new x-ray coating weight gauge design. This gauge uses a new compact head design, advanced state-of-the-art architecture/electronics and provides the best performance to meet these requirements. Time Tuesday, Jun 29 9:30AM - 10:00AM Location 207 B Speakers Roland Gouel Scantech Americas Inc. Jean-Jacques Florent Scantech SAS Jan Gaudaen Scantech SAS Francois Legrand Scantech SAS Novel Method for Stirring BOF Melts in Conjunction With Slag Splashing Anand Makwana, Air Products and Chemicals Inc.; Anup Sane, Air Products and Chemicals Inc.; Xiaoyi He, Air Products and Chemicals Inc.; Gregory Buragino, Air Products and Chemicals Inc. show more Description Basic oxygen furnace bottom stirring is used in many parts of the world because of the several benefits it brings to the operation. However, it is not prevalent in the U.S. because slag splashing is a common practice; and when used in conjunction with bottom stirring, it can cause poor reliability and blockage of the tuyeres. This paper discusses a newly developed tuyere that can help eliminate these issues while maintaining the advantages of stirring operation. The new tuyere achieves this objective by providing tuyere operational flexibility using advanced controls, thereby maintaining the stirring effectiveness of the tuyere for longer furnace campaigns. Time Tuesday, Jun 29 9:30AM - 10:00AM Location 205 A Speakers Anand Makwana Air Products and Chemicals Inc. Anup Sane Air Products and Chemicals Inc. Xiaoyi He Air Products and Chemicals Inc. Gregory Buragino Air Products and Chemicals Inc. Process and Physical Metallurgical Developments for High-Performance Niobium-Containing Pressure Vessel Steel Plates Steven Jansto, Research and Development Resources show more Description The end user in-service demands are becoming increasingly challenging in customer specifications for heavy plates specified in pressure vessels for petrochemical, chemical and cryogenic reactors. New-generation value-added low-carbon niobium-microalloyed pressure vessel high-strength steel materials have been developed for improved performance to fulfill this demand. Through the application of Nb-bearing plate steels, grain refinement results in a more homogeneous microstructure. Improved toughness at low temperature, excellent fatigue resistance and fracture toughness and excellent weldability result. These enhancements provide the engineering community with the opportunity to further improve their pressure vessel design and performance. Time Tuesday, Jun 29 9:30AM - 10:00AM Location 208 B Speakers Steven Jansto Research and Development Resources The Advantages of Wireless Condition Monitoring Over Route‐Based Monitoring for Developing a Successful Predictive Maintenance Strategy Ares Panagoulias, HydroAire Service Inc. show more Description One foundation of predictive maintenance is discovering incipient failures before significant damage occurs. The value of information provided by route‐based monitoring depend on the frequency of the route. Most route‐based data acquisition intervals are too infrequent to identify the inception of problems. Wireless condition monitoring (WCM) collects data at programmed high-frequency intervals. Based in the Industrial Internet of Things, this network of devices combines intelligent sensors and analytical applications that turn raw data into actionable information. WCM captures enough information to recognize incipient degradation and automatically sends alarms to alert specified personnel when monitored values exceed specified levels. Time Tuesday, Jun 29 9:30AM - 10:00AM Location 209 A Speakers Ares Panagoulias HydroAire Service Inc. Using Mathematical Modeling to Develop the Indexes Indicating Dependency of Arc Stability in the EAF on Charge Material Quality and Electrode Regulation Effectiveness T. Nagarajan, HEG Ltd.; Bipin Richharia, HEG Ltd.; Juan Ramon Fernandez, HEG Ltd.; Neeraj Shukla, HEG Ltd. show more Description In the electric arc furnace (EAF), the arc is non-linear and chaotic in the beginning of the melting and eventually becomes stable toward the end of melting. The degree of non-linearity is highly influenced by the sizing and quality of charge material. For the same quality of charge material and in flat bath, there could be a different level of arc stability depending on regulation system effectiveness. This model, which is based on thorough study in various EAFs, is finally aimed to derive the indexes that represent the effectiveness of system to achieve the best possible stable arc to deliver maximum power to the bath. Time Tuesday, Jun 29 9:30AM - 10:00AM Speakers T. Nagarajan HEG Ltd. Bipin Richharia HEG Ltd. Juan Ramon Fernandez HEG Ltd. Neeraj Shukla HEG Ltd.
10:00am A Fiber-Optic-Distributed Temperature Mapping Technique to Characterize Shell Solidification in Peritectic-Grade Steels Ronald J. O'Malley, Missouri University of Science and Technology; Damilola Balogun, Missouri University of Science and Technology; Muhammad Roman, Missouri University of Science and Technology; Laura Bartlett, Missouri University of Science and Technology; Jie Huang, Missouri University of Science and Technology; Rex Gerald, Missouri University of Science and Technology show more Description The quality of continuously cast steels is governed by events that occur during the initial stage of solidification in the mold, where the first layer of steel shell forms. In peritectic steels, solidification is influenced by the nature of the ferrite to austenite transformation, which is an antecedent for shell buckling and non-uniform growth during continuous casting of these steel grades. A dip test, which employs a copper mold instrumented with distributed fiber-optic sensors, has been developed to map closely spaced thermal features that are induced by the peritectic transformation. The magnitude of unevenness in shell thickness was also obtained. Time Tuesday, Jun 29 10:00AM - 10:30AM Location 208 A Speakers Ronald J. O'Malley Missouri University of Science and Technology Damilola Balogun Missouri University of Science and Technology Muhammad Roman Missouri University of Science and Technology Laura Bartlett Missouri University of Science and Technology Jie Huang Missouri University of Science and Technology Rex Gerald Missouri University of Science and Technology Addition of Scrap and DRI/HBI to the Blast Furnace — Technology to Overcome Top Temperature Limits and Reduce Greenhouse Gas Emissions Janice Bolen, McKinsey & Co. Inc.; Mitren Sukhram, Hatch; Ian Cameron, Hatch; Don Tu, Hatch; Jennifer Woloshyn, Hatch show more Description This paper is presented in three parts to describe how to overcome technical limitations of the blast furnace related to adding alternative iron units (AIUs), which are typically scrap and direct reduced iron/hot briquetted iron. First, the prior art regarding AIU additions is reviewed. From this, the energy shortfall as increasing amounts of AIUs are added the blast furnace is estimated. Lastly, stack injection of hot gas using electrically powered plasma torches is evaluated as a strategy to overcome this energy shortfall and enable greater AIU addition rates. The analysis focuses on North American blast furnace practice using an all-pellet burden and natural gas injection. Time Tuesday, Jun 29 10:00AM - 10:30AM Location 201 A Speakers Janice Bolen McKinsey & Co. Inc. Mitren Sukhram Hatch Ian Cameron Hatch Don Tu Hatch Jennifer Woloshyn Hatch Comprehensive Process Optimization for Electric Steelmaking Route Richard Stadlmayr, Primetals Technologies; Andreas Rohrhofer, Primetals Technologies; Franz Hartl, Primetals Technologies Austria GmbH show more Description This paper identifies major benefits for the installation of comprehensive upstream process optimization automation for mini-mills. The level 2 automation system covers applied optimization tools for raw material calculation and advanced scrap processing, dynamic model-based electric arc furnace (EAF) melting and computer-assisted refining in ladle metallurgy furnace secondary metallurgy followed by state-of-the-art level 2 automation for continuous casting machines. A fully automated tracking and identification system with high-temperature resistant radio frequency identification ICE tag solution allows reliable product tracking and maintenance planning for teeming ladles and casting equipment. Furthermore, actual results of a successful implementation of process optimization systems at an EAF-based meltshop are outlined. Time Tuesday, Jun 29 10:00AM - 10:30AM Speakers Richard Stadlmayr Primetals Technologies Andreas Rohrhofer Primetals Technologies Franz Hartl Primetals Technologies Austria GmbH Development of ASTM A709-50WF Heavy Plate for Fracture Critical Bridge Applications Yufeng Wang, SSAB Americas; Dengqi Bai, SSAB Americas; Chase Rawlinson, SSAB Alabama Inc.; Liz Peterson, SSAB Alabama Inc. ; Chris Amsden, SSAB Iowa Inc. show more Description For some fracture critical applications, the requirements for the internal quality of steel plates, especially heavy-gauge plates, are very stringent. To ensure sound internal quality and performance, some grades require not only ultrasonic testing, but also through-thickness tensile testing (Z-test). One of the common defects in heavy-gauge hot-rolled steel plates is hydrogen embrittlement. When the hydrogen content in a steel plate reaches a certain level, it can cause microcracks, blisters and flaking. In the present study, the effects of rolling and cooling processes on hydrogen removal in a low-carbon microalloyed steel were analyzed. Time Tuesday, Jun 29 10:00AM - 10:30AM Location 208 B Speakers Yufeng Wang SSAB Americas Dengqi Bai SSAB Americas Chase Rawlinson SSAB Alabama Inc. Liz Peterson SSAB Alabama Inc. Chris Amsden SSAB Iowa Inc. Evolution from EnviBATTM Pressure Regulation System to EnviBAT TM 2.0 Matt Kraeuter, Thyssenkrupp Industrial Solutions show more Description The risk of fugitive raw gas and dust emissions during the coking process has made coking plants an environmental challenge. Such emissions may take place around all openings of the battery. An advanced solution is the application of the single oven pressure regulation system EnviBAT that reduces the emissions from coke ovens. Time Tuesday, Jun 29 10:00AM - 10:30AM Location 209 B Speakers Matt Kraeuter Thyssenkrupp Industrial Solutions Getting Value From Your Operations and Maintenance Data – A Lesson From the Mining Industry Paul McRoberts, Rockwell Automation show more Description We’ve all been taught that the more data you collect, the more information you’ll have. However, many metals companies are finding a disconnect between the ease of buying sensors and collecting data – and actually using that data to inform operational decisions and equipment maintenance. This session will outline the work with a major global mining company to envision a new path forward. By leveraging the latest technological innovations and putting the right data in front of the right people, they’re reimagining the equipment maintenance process and mining value from their operations data. Time Tuesday, Jun 29 10:00AM - 10:30AM Location 205 C Speakers Paul McRoberts Rockwell Automation Heat Transfer Modeling and Adjustment From Radar Measurements in Reheating Steel Furnaces Patrik Ottosson, Radarbolaget; Fredrik Blomqvist, Radarbolaget; Daniel Andersson, Radarbolaget; Tomas Ekman, Linde Gas show more Description The scope of the paper includes a description of how radar expansion measurements in reheating steel furnaces enables adjustment of the heat transfer model. The novelty is to measure the absolute expansion of slabs through furnace walls. The method enables model adjustment without temperature loggers and enables on-line adaption/feedback without interfering production significantly. A system is fully implemented at Sandvik Material Technology and partially at SSAB. The systems are used to optimize heating, control temperature of slabs, and determine deviations between computed and measured expansion. Thereby, the model is faster adjusted due to furnace degradation, burning variations, fuel and atmosphere changes, and other causes. Time Tuesday, Jun 29 10:00AM - 10:30AM Speakers Patrik Ottosson Radarbolaget Fredrik Blomqvist Radarbolaget Daniel Andersson Radarbolaget Tomas Ekman Linde Gas Implementation of the Tiltable Sidewall Burner at Nucor Steel Tuscaloosa Inc.: Dynamically Adjustable Burner Angle to Optimize Scrap Melting and Reduce Refractory Wear Patrick Hansert, BSE America; Justin Novotny, Nucor Steel Tuscaloosa Inc.; Ryan Junkin, Nucor Steel Tuscaloosa Inc.; Michael Mayhall, Nucor Steel Tuscaloosa Inc.; Jake Franks, Nucor Steel Tuscaloosa Inc.; Phil Baker , Nucor Steel Tuscaloosa Inc.; Fatih Goekce, BSE show more Description As the second chemical energy package has been operating at Nucor’s B-furnace in Tuscaloosa for almost 2 years, it is time to review the project. It represented phase two of a partnership that started with its first electric arc furnace (EAF) back in 2016. When the decision was made to upgrade the EAF with the latest chemical energy package, Nucor decided to replace all sidewall burners with a Tiltable Virtual Lance Burner (T-VLB). The main benefits were reduced electrical energy consumption and better power-on times. Additionally, the simplistic and lightweight design of the burners made maintenance and replacement much easier than traditional burners. Time Tuesday, Jun 29 10:00AM - 10:30AM Location 204 Speakers Patrick Hansert BSE America Justin Novotny Nucor Steel Tuscaloosa Inc. Ryan Junkin Nucor Steel Tuscaloosa Inc. Michael Mayhall Nucor Steel Tuscaloosa Inc. Jake Franks Nucor Steel Tuscaloosa Inc. Phil Baker Nucor Steel Tuscaloosa Inc. Fatih Goekce BSE Innovative Surface Inspection System Deployment Liwei Zhang, ArcelorMittal Global R&D - East Chicago; Armelle Perrichon, ArcelorMittal Global R&D center – Maizières Process ; Luiz Alberto De Oliveira Martins, ArcelorMittal Global R&D center – Product Quality ; Brad Masters, AM/NS Calvert LLC; Brian Feagan, AM/NS Calvert LLC; Beth Isbell, AM/NS Calvert LLC show more Description Due to the growth of market competitiveness, which requires the product to be 100% checked, steel producers have increasingly turned to the use of commercially available on-line automated surface inspection systems (ASIS) for surface quality assurance and control. AM/NS Calvert has acquired a new surface inspection system so as to ensure products with superb surface quality to its customers. This paper presents the surface inspection system deployment. It starts with the surface inspection system functions and performance, then presents the use cases of surface inspection system, and finally discusses the steps and process on how to complete such deployments. Time Tuesday, Jun 29 10:00AM - 10:30AM Location 209 A Speakers Liwei Zhang ArcelorMittal Global R&D - East Chicago Armelle Perrichon ArcelorMittal Global R&D center – Maizières Process Luiz Alberto De Oliveira Martins ArcelorMittal Global R&D center – Product Quality Brad Masters AM/NS Calvert LLC Brian Feagan AM/NS Calvert LLC Beth Isbell AM/NS Calvert LLC Inspection of Hot-Rolled Heavy Plate by 3D Inspection Gregory Gutmann, ISRA Vision Parsytec Inc.; Dominik Recker, ISRA PARSYTEC GmbH show more Description Superior surface quality is of high importance for every steel manufacturing process step. The optical 2D inspection of rolled steel surfaces is state of the art and well established today. During rolling of heavy plates, the 2D inspection is very limited due to the heavy structure at the rolled surface. Defect depth is critical in grading plate. Inspection of the rolled surface by laser triangulation (3D) inspection offers fast and reliable detection and classification of surface defects, including depth, even during heavy plate rolling. Recent installations of the new 3D inspection system for heavy plate, including results, will be presented. Time Tuesday, Jun 29 10:00AM - 10:30AM Location 207 D Speakers Gregory Gutmann ISRA Vision Parsytec Inc. Dominik Recker ISRA PARSYTEC GmbH Installation of Vaicon Slag Stopper at U. S. Steel - Great Lakes Works Gerald Wimmer, Primetals Technologies ; Michael Maringer, Primetals Technologies; Ernesto Serrano, United States Steel Corporation; David Runner, United States Steel Corporation; Yun Li, United States Steel Corporation; Denis Vaillancourt, Primetals Technologies show more Description To improve efficiency and reduce conversion costs, U. S. Steel installed the pneumatic slag retention system from Primetals Technologies on the two 200-ton basic oxygen furnaces in the meltshop at Great Lakes Works. Expected benefits from this project include reduced slag carryover, improved alloy yield and increased steel quality. The Vaicon stopper went into operation in the summer of 2018. The paper describes the equipment, operational results and benefits achieved. In the last part of the paper, an outlook on a new generation of slag stopper is presented. Time Tuesday, Jun 29 10:00AM - 10:30AM Location 205 A Speakers Gerald Wimmer Primetals Technologies Michael Maringer Primetals Technologies Ernesto Serrano United States Steel Corporation David Runner United States Steel Corporation Yun Li United States Steel Corporation Denis Vaillancourt Primetals Technologies Material Flow How Concept for Wire Rod Coils Jagannathan Rajagopalan, Pesmel South Asia; Juha Suksi, Pesmel; Samu Katkanaho, Pesmel show more Description Wire rod coils for industrial and automobile application need extreme care for handling, tracking and storage. A conventional floor storage system could cause scratches and damage to the coils including detrimental mixing up of coils. Automatic storage and retrieval system using rack supported building concept (ASRS) with Internet of Things/Industry 4.0 could serve in protecting the coils with safe storage, easy tracking and handling with savings on unnecessary buildings and manpower/life cycle cost. Special coil packing methods are available for further protection. An easy way to automatically track, pack and store long product bundles is also explained. Time Tuesday, Jun 29 10:00AM - 10:30AM Location 207 C Speakers Jagannathan Rajagopalan Pesmel South Asia Juha Suksi Pesmel Samu Katkanaho Pesmel Modern Blast Furnace Top Gas Cleaning: Wet Separation Improvements at U. S. Steel – Great Lakes Works B2 Blast Furnace Jean-Luc Kuffer, Paul Wurth; Jim Quick, U. S. Steel - Great Lakes Works; Christian Davidi, Paul Wurth show more Description U. S. Steel - Great Lakes decided to replace an outdated venturi scrubber with a modern annular gap scrubber. The objective of the replacement was to improve gas quality and ensure safe and reliable operation of the B2 blast furnace during its next campaign. The new system was installed during the 2019 spring/summer outage of the furnace. This paper describes the scrubber technology, the project setup, as well as the concept of the erection and installation activities. Time Tuesday, Jun 29 10:00AM - 10:30AM Location 207 A Speakers Jean-Luc Kuffer Paul Wurth Jim Quick U. S. Steel - Great Lakes Works Christian Davidi Paul Wurth Physical Modeling for Product Development and Performance Optimization in Hot Dip Galvanizing Lines Ben Reed, Worthington Industries; Luis Fellipe Simoes, University of Pittsburgh; Dennis McHugh, Worthington Industries; C. Isaac Garcia, University of Pittsburgh show more Description Processing parameters for galvanizing lines require optimization when new steel alloy systems are considered or to improve product performance. The use of well-designed and reproducible laboratory computer-controlled physical simulations provides an excellent tool where more costly trial and error techniques can be eliminated. Recently, the continuous annealing line simulator at the University of Pittsburgh was used to investigate the mechanical properties of substrates annealed through a galvanizing line at different processing conditions. The corresponding results were successfully correlated to actual production results, with methodology now in regular use. Time Tuesday, Jun 29 10:00AM - 10:30AM Location 207 B Speakers Ben Reed Worthington Industries Luis Fellipe Simoes University of Pittsburgh Dennis McHugh Worthington Industries C. Isaac Garcia University of Pittsburgh Successful Conversion of Manual Cranes Into fully Automatic Cranes Ed LaBruna, Janus Automation show more Description Many customers in the metals industry have been discussing for the last years about converting existing manual cranes into fully automatic cranes and into automated storage and retrieval systems. This presentation discusses successful implementations and the key aspects regarding the justification of the projects, real benefits, safety, downtime and long-term benefits, including some unexcepted benefits not initially seen. Time Tuesday, Jun 29 10:00AM - 10:30AM Location 209 C Speakers Ed LaBruna Janus Automation The Future of Steel Ladle Refractory Monitoring Rich Shannon, Viper Imaging show more Description Refractory lining degradation exposes the ladle’s outer shell to excessive temperatures. Undetected, a molten metal breakout can occur – posing significant threat to personnel, equipment and production. Traditional monitoring methods had proved ineffective for the subject of this case study, so the electric arc furnace/argon oxygen decarburization engineer sought a solution providing continuous temperature monitoring. A system of thermal cameras and integrated software was implemented that communicates with the plant control system. Through thermal image data and software analysis including trend reporting, this system successfully assesses the extent of ladle wear. Thus, engineers are equipped for critical decision-making regarding ladle lining repair and renewal. Time Tuesday, Jun 29 10:00AM - 10:30AM Location 205 B Speakers Rich Shannon Viper Imaging The Impact of Data Analytics on Operations at MIDREX® Plants Brad Cantrell, Midrex Technologies Inc. show more Description Data analytics is not a new field. Scientific papers from the 1960s celebrated the future of data analysis. However, applying data analytics to certain applications has not in all cases resulted in the meaningful improvements expected. This paper explores the impact of data analytics on operations at MIDREX® plants and how modern computational developments are providing new opportunities for impactful insights. Time Tuesday, Jun 29 10:00AM - 10:30AM Location 201 B Speakers Brad Cantrell Midrex Technologies Inc.
10:30am A Machine-Learning Approach for Steel Grade Detection in Hot Rolling Mills Pedro Emílio Gazola, GERDAU AÇOS LONGOS SA; H. S. O. dos Santos, GERDAU AÇOS LONGOS SA; M. Daroit, GERDAU AÇOS LONGOS SA; A. Locatelli, GERDAU AÇOS LONGOS SA show more Description During the loading of the reheating furnace, it is possible to have a billet with a steel grade different than expected misplaced and loaded. A possible solution for that problem is a machine-learning model that can identify the steel of the bar being rolled through the rolling stands motors current usage. Using an outlier detection technique, it was possible to identify patterns in the data for every steel grade, identifying when it did not match the expected in simulated data. Currently the model is working off-line and further testing will be realized during production for validating the model efficiency. Time Tuesday, Jun 29 10:30AM - 11:00AM Speakers Pedro Emílio Gazola GERDAU AÇOS LONGOS SA H. S. O. dos Santos GERDAU AÇOS LONGOS SA M. Daroit GERDAU AÇOS LONGOS SA A. Locatelli GERDAU AÇOS LONGOS SA Application of JetBurner Technology for a Small-Sized EAF Adam Partyka, INTECO; Juergen Jung, GKN Hoeganaes; Taras Gabriel, GKN Hoeganaes - Buzau Works; Martin Pavliš, INTECO PTI s.r.o. show more Description Utilization of chemical energy for melting process intensification has always been restricted in small-sized electric arc furnace (EAF). Limited shell dimensions and resulting minor volume greatly reduce heat transfer efficiency. INTECO PTI developed a compact type of burner and supersonic lance designed for furnaces with a capacity of less than 20 tons, which has been put into operation at the EAF at GKN Hoeganaes meltshop in Romania. The paper presents the achieved results and reveals details of operational parameters selection to minimize splashing and disturbance of electric arcs during melting. The installed equipment proved to be efficient in boosting the furnace productivity. Time Tuesday, Jun 29 10:30AM - 11:00AM Location 204 Speakers Adam Partyka INTECO Juergen Jung GKN Hoeganaes Taras Gabriel GKN Hoeganaes - Buzau Works Martin Pavliš INTECO PTI s.r.o. Cold-Bonded Briquette Testing Methodology and Standards Used for Traditional Furnace Feedstocks Mac Steele, J.C. Steele & Sons Inc.; Mark T. Ford, J.C. Steele & Sons Inc. show more Description Today there are requirements for alternative feedstocks to be introduced into furnaces around the globe. This paper explores the comparison of cold-bonded briquettes in comparison with feedstocks such as iron ore pellets (IOP), lump iron ore and coking coal. What is the best method for comparing performance of the briquettes in the furnace? Is it a tumble index, is it a shatter index, is it a completely new test or is it a combination of a few? At what point do the increased additives required to meet the mill’s existing raw material standards have a diminishing return on the furnace performance? Time Tuesday, Jun 29 10:30AM - 11:00AM Location 201 A Speakers Mac Steele J.C. Steele & Sons Inc. Mark T. Ford J.C. Steele & Sons Inc. Crane Girder Deformation Mapping Using Image Processing and Template Matching of Laser Scanner Point Cloud Michael Falk, Falk-PLI; Sagar Deshpande, Penn State University; Nathan Plooster, Falk PLI show more Description Repetitive loading of factory crane girders causes deformation and/or failure. In the presented method, LiDAR-points over one face of a girder are processed to create deformation maps of panels: web area between stiffeners and flanges. Web surface profiles at top, mid and bottom locations are created by matching a standard I-section template to point data. Root mean square error (RMSE) at each girder slice is computed by comparing the nearest girder points and inflection points from the template. The girder point with the lowest RMSE is selected as the correct match and three locations are identified. Time Tuesday, Jun 29 10:30AM - 11:00AM Location 205 C Speakers Michael Falk Falk-PLI Sagar Deshpande Penn State University Nathan Plooster Falk PLI Discovery of New Magnesia Source Extends Performance of Ladles in LMF and Vacuum Tank Degassing William Porter, PRCO America Inc. show more Description As the main raw material, the quality of fused magnesia directly affects the service life of magnesia carbon (MgO-C) refractory. A new source of fused magnesia with ultralow inclusions (SiO2 and Fe2O3) content and high CaO/SiO2 ratio (> 5.0:1.0) was introduced into MgO-C refractory, and the unique MgO-C refractory shows improved performance in the slagline of the ladle metallurgy furnace and vacuum tank degassing ladle for lower cost per ton of steel produced. This new MgO-C is now produced in a new refractory-producing plant in Mayfield, Ky., USA. Time Tuesday, Jun 29 10:30AM - 11:00AM Location 205 B Speakers William Porter PRCO America Inc. Dolime-Based EAF Hot Repair Material - Successful Product Improvements Felix Firsbach, Lhoist Business Innovation Center; Guillaume Bruel, Lhoist Business Innovation Center; Ian Houldsworth, Lhoist Western Europe; Jonathan Guest, Lhoist Western Europe; Souliyann Chunlamani, Lhoist Western Europe show more Description Dead-burnt dolime impregnated with iron oxide is an established and proven solution for electric arc furnace refractory hot repair for decades. The corrosion mechanisms in comparison to other refractory repairs are different, but with similar effects. With an optimized particle size distribution, densification and resistance to slag corrosion are increased. Sizing improvements bring the following advantages: minimizing porosity, maximizing contact for enhanced bonding and imparting flow characteristics. The results received via pyrometric cone equivalent tests, thermodynamic calculations and slag corrosion tests are presented. By optimizing the particle size distribution, it was possible to improve the corrosion resistance for a higher performance of Dolofrit®. Time Tuesday, Jun 29 10:30AM - 11:00AM Speakers Felix Firsbach Lhoist Business Innovation Center Guillaume Bruel Lhoist Business Innovation Center Ian Houldsworth Lhoist Western Europe Jonathan Guest Lhoist Western Europe Souliyann Chunlamani Lhoist Western Europe Effect of Through-Thickness Microstructural Homogeneity on Fatigue Performance of Structural Steels in Air and Hydrogen Environments Douglas Stalheim, DGS Metallurgical Solutions Inc.; Andrew Slifka, NIST; Enrico Lucon, NIST; Pello Uranga, CEIT and University of Narrava; Dong-Hoon Kang, Hyundai Steel Technical Research Center show more Description Strength and ductility properties of structural steels for a given microstructure are driven by the average ferrite grain/packet size and by the homogeneity of that ferrite grain/packet size in the final product. Fatigue performance in air for applications of wind towers, bridges, high-rise buildings and in high-pressure gaseous hydrogen for various pipeline systems is critical to the end-use design. To evaluate the effect of through-thickness ferrite grain size and homogeneity on fatigue performance, samples with differences in average ferrite grain size and homogeneity were produced and fatigue tested in both air and high-pressure gaseous hydrogen. Time Tuesday, Jun 29 10:30AM - 11:00AM Location 208 B Speakers Douglas Stalheim DGS Metallurgical Solutions Inc. Andrew Slifka NIST Enrico Lucon NIST Pello Uranga CEIT and University of Narrava Dong-Hoon Kang Hyundai Steel Technical Research Center Environment Defines Productivity: Emission Control System Modifications Using Fluid Dynamic Study of Building Ventilation at Sinobras Meltshop, Brazil Milton Lima, Sinobras; Jim Belous, Bender Corp. show more Description Fluid dynamic modeling (FDM) was used to develop solutions for eliminating fugitive emissions from the meltshop building and to increase the annual liquid steel production. Secondary emission control (SEC) system performance was simulated by an inverted 1:100 scale plexiglaxs model of the entire meltshop, utilizing the negative buoyancy effects of saline solution in water. Test results show that with the installation of the additional scavenger exhaust at the east side of the meltshop and overall increase of the system capacity by 50% allows for the elimination of fugitive emissions and increase of annual production by 50%. Time Tuesday, Jun 29 10:30AM - 11:00AM Location 207 A Speakers Milton Lima Sinobras Jim Belous Bender Corp. Finishing End Areas and Technologies Antonio Ambra, AIC North America Corp. show more Description Overview of different technologies and applications on finishing end areas, including material tracking, counting, packing and robotic tagging, reports, and stock handling automatic systems. Time Tuesday, Jun 29 10:30AM - 11:00AM Location 207 C Speakers Antonio Ambra AIC North America Corp. HD mold 2021 – Update Chad Donovan, SMS group Inc.; Jason Arzberger, SMS group Inc.; Curtis Bish, SMS group Inc.; Joseph Laughlin, SMS group Inc.; Stephan Six, SMS group GmbH show more Description HD mold was one of the original fiber optic-based continuous caster mold temperature measuring systems introduced to the North American steel industry several years ago. As the installed base for HD mold has increased in North America, much has been learned to improve the system's reliability and better understand the capabilities of this product. Specifics related to data collection and its potential uses will be presented. Other topics of discussion will include advancements related to hardware, software and manufacturing that have opened doors to allow for greater measuring density. Time Tuesday, Jun 29 10:30AM - 11:00AM Location 208 A Speakers Chad Donovan SMS group Inc. Jason Arzberger SMS group Inc. Curtis Bish SMS group Inc. Joseph Laughlin SMS group Inc. Stephan Six SMS group GmbH Ladle Hot Spot Detection — A Novel and Robust Approach to Eliminate False Positives in Infrared Thermal Image Analysis Javier Barreiro, ANT Automation LLC; Miguel Simiand, ANT Automation; Ignacio Salinas, ANT Automation show more Description Refractory-lined ladles are used in the steel shop. The refractory lining gets degraded over time and produces excessive temperature in the outer shell. Infrared cameras are used to detect high temperatures and alert abnormal conditions. Different situations can generate high temperatures on the ladle surface not necessarily related to refractory degradation such as spills or splashes, which triggers false notifications. False alarms can reduce staff alertness and real situations can go unnoticed. This approach performs a novel space-temporal temperature analysis of the ladle surface to classify the events into categories using an artificial intelligence model trained with previous measurements. Time Tuesday, Jun 29 10:30AM - 11:00AM Location 205 A Speakers Javier Barreiro ANT Automation LLC Miguel Simiand ANT Automation Ignacio Salinas ANT Automation Revolutionary Endless Strip Production up to 20 mm – Precise and Uniform HSLA Steel Andreas Jungbauer, Primetals Technologies; K. Baumgartner, Primetals Technologies Austria GmbH; T. Lengauer, Primetals Technologies Austria GmbH; S. Grosseiber, Primetals Technologies Austria GmbH show more Description Increased quality demands for thick gauges of high-strength, low-alloy (HSLA) (API) steels along the total strip length call for production in real endless operation. When it comes to ultrathin, high-quality strip, recent innovations enable manufacture in the range from 0.8 up to 20 mm in fully endless operation. The mechanical and material properties of HSLA (API) steels are reached by applying strict deformation and temperature control. Pass schedules and resulting metallurgical properties as well as specific technological solutions of reference plants will be discussed is this paper. Time Tuesday, Jun 29 10:30AM - 11:00AM Location 207 D Speakers Andreas Jungbauer Primetals Technologies K. Baumgartner Primetals Technologies Austria GmbH T. Lengauer Primetals Technologies Austria GmbH S. Grosseiber Primetals Technologies Austria GmbH Rising and Failure of Gas-Based Direct Reduction Processes Yakov Gordon, Hatch show more Description The first industrial application of direct reduced iron (DRI) production was Wiberg-Soderfors' DRI shaft furnace process. The history of development and implementation of various gas-based direct reduction processes was studied. The strength and weakness of this processes were evaluated. It was shown that the economics of the direct reduction process depends on cost of raw material and reducing agent, reliability of equipment and strict application of direct reduction principles. This paper evaluates the successes and failures of DRI gas-based processes. Time Tuesday, Jun 29 10:30AM - 11:00AM Location 201 B Speakers Yakov Gordon Hatch Robotic Workstation for Safe Ladle Sliding Gate Maintenance Gianluca Maccani, Polytec USA, BM Group Polytec S.p.A. show more Description Steel mills need to reduce as much as possible the scrap steel produced during the transaction between grades, using different technologies related to the necessity to guarantee an error-proof tracking system to prevent potentially catastrophic mistakes. The presented technologies used to track the billets in the casting machines are related to automation. Time Tuesday, Jun 29 10:30AM - 11:00AM Location 209 A Speakers Gianluca Maccani Polytec USA, BM Group Polytec S.p.A. Side Pull Detection Techniques for Wire Rope Hoists Steven Lubeck, Laser-View Technologies Inc. show more Description A wire rope hoist on an overhead crane operated under a side-pulled condition presents a safety risk, can produce accelerated wear and can damage a hoist that is not designed for such use. Damage to a hoist can be costly, reduce productivity with unnecessary downtime and can result in unsafe conditions. Improper use of a hoist due to side pulling poses a significant hazard to operators as a load is lifted. This presentation compares strengths and weaknesses of available overhead monitoring systems, their general methods of operation, and capabilities. Time Tuesday, Jun 29 10:30AM - 11:00AM Location 209 C Speakers Steven Lubeck Laser-View Technologies Inc.
11:00am AI-Based Models of Emissions at the Stack From Industrial Furnaces Alessandro Della Rocca, Tenova S.p.A.; Michele Roveda, Tenova S.p.A.; Nicolò Giso, Tenova S.p.A. show more Description By means of machine-learning algorithms, predictive models of gas emissions from reheating furnaces at the stack are created based on process data: temperatures, air and fuel flowrates, pressures, oxygen content, etc. Those models are not aimed to replicate, even with a very good approximation, measurements of NOx or CO2 performed by the dedicated gas analyzers. The target is to create virtual sensors able to correlate the scheduled production to the pattern of process conditions and to predict the concentration of any gas released, thus allowing to organize the production schedule according to a forecast of the environmental impact. Time Tuesday, Jun 29 11:00AM - 11:30AM Location 207 A Speakers Alessandro Della Rocca Tenova S.p.A. Michele Roveda Tenova S.p.A. Nicolò Giso Tenova S.p.A. Digital Technologies for Continuous Casting Gianluca Maccani, Polytec USA, BM Group Polytec S.p.A.; Vittore Girardin, Polytec USA, BM Group Polytec S.p.A. show more Description Operator safety, product quality and productivity improvement are cornerstones of Industry 4.0. The continuous casting machine area is a work environment with risks. Human intelligence combined with smart robotics can increase safety averting operator from hot areas and improve the process quality and the traceability of semi-finished products. Powerful machine vision systems implemented on robots and managed by user-friendly interfaces allow an upgrade to what is called 4.0. Data collection and artificial intelligence with autonomous machine learning is another important opportunity to upgrade to steelmaking 4.0. Time Tuesday, Jun 29 11:00AM - 11:30AM Location 208 A Speakers Gianluca Maccani Polytec USA, BM Group Polytec S.p.A. Vittore Girardin Polytec USA, BM Group Polytec S.p.A. Key Challenges for Efficient Descaling J. Lee, Primetals Technologies UK Ltd. ; John Hinton, Primetals Technologies show more Description Whenever hot steel is exposed to oxygen-bearing gases, it reacts to form scale. During high-temperature steel production, its influence on the surface state extends throughout processing. The dynamic local environmental creates transient conditions that result in complex cycles of scale growth, deformation and removal. This presents a considerable challenge to the steel producer when aiming for process consistency. This paper focuses on key challenges that require an appreciation of the interaction of complex variables across different length scales. These will include the scale-metal interface metallurgy and setup of the descaling system. Time Tuesday, Jun 29 11:00AM - 11:30AM Speakers J. Lee Primetals Technologies UK Ltd. John Hinton Primetals Technologies Optimization of Electrode Consumption in EAF for Different Operating Conditions T. Nagarajan, HEG Ltd.; Bipin Richharia, HEG Ltd.; Juan Ramon Fernandez, HEG Ltd.; Manendra Sharma, HEG Ltd. show more Description Graphite electrodes contribute about 10-20% of the conversion cost in an electric arc furnace (EAF). Although few empirical relations between electrode consumption and the EAF operational factors have been presented in research in the past, factors such as arc stability, efficiency of the foamy slag, water cooling, etc., are not taken into consideration. In this study, the variations in electrode consumption and its pattern within the furnace and between various other furnaces for different operating conditions are thoroughly researched to achieve best practices to optimize the electrode consumption. This will include discovery of “severity factor" of oxidizing environment of furnace representing its influence on electrode consumption. Time Tuesday, Jun 29 11:00AM - 11:30AM Speakers T. Nagarajan HEG Ltd. Bipin Richharia HEG Ltd. Juan Ramon Fernandez HEG Ltd. Manendra Sharma HEG Ltd. Optimizing Material Handling Rob Loomis, InVekTek LLC show more Description This presentation discusses how advanced crane controls can increase the overall throughput of the entire plant. Time Tuesday, Jun 29 11:00AM - 11:30AM Location 209 C Speakers Rob Loomis InVekTek LLC Power Cooling – Advanced Strip Cooling Technology for Hot Strip Mills for Maximum Metallurgical Flexibility, High Cooling Rates and for Saving of Alloying Elements Konrad Krimpelstaetter, Primetals Technologies; Lukas Pichler, Primetals Technologies ; Ruediger Doell, Primetals Technologies ; Klaus Weinzierl, Primetals Technologies show more Description Primetals Technologies has introduced a new strip cooling technology for hot strip mills with increased impact pressure to achieve higher strip cooling rates. The automation system with its advanced models is an important and integral part of the solution. With this type of equipment, steel producers can produce new steel grades with higher strength at lower material costs. The lower material costs mainly arise from saving of alloys by applying higher cooling rates. This paper describes this technology and explains different positions of Power Cooling in a hot strip mill supporting different production strategies and benefits. Time Tuesday, Jun 29 11:00AM - 11:30AM Location 207 D Speakers Konrad Krimpelstaetter Primetals Technologies Lukas Pichler Primetals Technologies Ruediger Doell Primetals Technologies Klaus Weinzierl Primetals Technologies The Development of a Modern BF Hearth Sidewall Observation Management Eric Schaub, Paul Wurth Deutschland GmbH show more Description Chemical composition and physical properties of hearth carbon change over the service life of a blast furnace. In addition, other phenomena like heat resistances can create unnoticeable changes in the hearth sidewall lining, too (e.g., skulls, brittle layers). Without identifying such changes, it is very difficult to calculate the realistic hearth lining wear profiles with a 2D or 3D mathematical finite element model. Paul Wurth has developed so-called multi-point thermocouple sensor probes that allow for the detection of such kind of changes. In this paper, Paul Wurth will present examples of typical installations, recent experiences and application of this technology. Time Tuesday, Jun 29 11:00AM - 11:30AM Location 205 B Speakers Eric Schaub Paul Wurth Deutschland GmbH Yield Stress in Ferritic Steels Influenced by Grain Boundary Walls Thomas L. Altshuler, Advanced Materials Laboratory Inc. show more Description Accepted theories explaining the cause for the unique upper and lower yield points in hypoeutectic plain carbon steels are considered inadequate. Atomic force microscopy revealed that grain boundaries between adjoining grains in these steels consist of brittle, probably cementite (Fe3C), walls enclosing the grains. These walls inhibit the movement of dislocations between adjoining grains until the walls fracture. Experiments show this may be the primary cause of a sharp upper yield point at the elastic line followed by rapid drop in stress below the Lüders region. Thereafter, the stress rises elastically into the Lüders plastic deformation region. Time Tuesday, Jun 29 11:00AM - 11:30AM Location 208 B Speakers Thomas L. Altshuler Advanced Materials Laboratory Inc.
11:30am Better Control and Improved Accuracy of the Hot Rolling Process by Modern Encoder Solutions Peter Haarhoff, Johannes Hübner Fabrik elektrischer Maschinen GmbH show more Description In hot rolling mills, there are still outdated encoder and switch attachments that are not suitable anymore for the requirements of modern rolling process. Combinations of cam switches and absolute encoders connected with distribution gear are inaccurate and difficult to adjust. This technical paper shows on the basis of three different case study examples how to improve by changing to state-of-the-art encoder technology. These case studies illustrate higher precision and lower costs at positioning of screwdowns, better control accuracy at positioning of side guides and optimized reliability of looper position measurement. Time Tuesday, Jun 29 11:30AM - 12:00PM Speakers Peter Haarhoff Johannes Hübner Fabrik elektrischer Maschinen GmbH Design and Evaluation of a Lab Size Vacuum Sampling Method for Simulating the Twin-Roll Strip Casting Process Yizhou Du, Missouri University of Science and Technology; Ronald J. O'Malley, Missouri University of Science and Technology; Mario Buchely, Missouri University of Science and Technology; Mingzhi Xu, Georgia Southern University show more Description A new sampling method has been developed to produce less-than-2-mm-thick strips that simulate the solidification conditions of the direct twin-roll casting process (CASTRIP®). Using this newly developed sampling method, high-Si steel samples were produced. Using secondary dendrite arm spacing, the sample solidification cooling rate is calculated to be approximately 1,700 K/second. The dendrite structures and calculated solidification cooling rates are shown to be similar to those observed in the commercial CASTRIP process. The sampling method is useful for rapid prototyping and evaluation of new alloys for the vertical twin-roll strip casting process. Time Tuesday, Jun 29 11:30AM - 12:00PM Location 208 A Speakers Yizhou Du Missouri University of Science and Technology Ronald J. O'Malley Missouri University of Science and Technology Mario Buchely Missouri University of Science and Technology Mingzhi Xu Georgia Southern University Effects of Steel Chemistry and Reheating Temperature on Prior Austenite Grain Size Dengqi Bai, SSAB Americas; Eric Lynch, SSAB Americas; Hanok Tekle, Missouri University of Science and Technology; Jacob Mineart, SSAB Americas R&D show more Description In modern microalloyed steels, Ti and Nb are often added to control the as-reheated prior austenite grain size, the temperature window for controlled rolling, and for precipitation strengthening. In addition to the effects of Ti and Nb, slab reheat temperature also has a strong effect on the as-reheated prior austenite grain size. In the present study, the combined effects of steel chemistry and slab reheat temperature on the as-reheated prior austenite grain size were investigated. Time Tuesday, Jun 29 11:30AM - 12:00PM Location 208 B Speakers Dengqi Bai SSAB Americas Eric Lynch SSAB Americas Hanok Tekle Missouri University of Science and Technology Jacob Mineart SSAB Americas R&D Ladle Bottom Design for Optimized Steel Flow and Metallic Yield Douglas Galesi, Saint-Gobain Performance Ceramics and Refractories; Haysler Lima, Saint-Gobain Performance Ceramics and Refractories; Vladnilson Ramos, Saint-Gobain Performance Ceramics and Refractories show more Description During the steelmaking process, the steel is drained from the ladle into the tundish. In the final stages of ladle draining, two fluid phenomena occur: the vortex and drain formation, resulting in a reduction in metallic yield. Through a new methodology of ladle bottom refractory casting, with a characteristic shaping profile, a reduction of the vortex depth and a reduction of negative effects of the drain formation were obtained, which allowed a 75% decrease of the total losses. The studies were conducted on a 1:14 scale in a physical model compared to an industrial steel ladle. Time Tuesday, Jun 29 11:30AM - 12:00PM Location 205 B Speakers Douglas Galesi Saint-Gobain Performance Ceramics and Refractories Haysler Lima Saint-Gobain Performance Ceramics and Refractories Vladnilson Ramos Saint-Gobain Performance Ceramics and Refractories Measuring Flatness of Rolled Strips Under Tension in Hot Rolling Mills Mark Zipf, SMS group Inc.; Olaf Jepsen, SMS group GmbH; Frank Gorgels, SMS group GmbH; Patrick Siemann, SMS group GmbH show more Description The gap in the market for measuring systems for hot-rolled strip under tension has now been closed with a new product developed by SMS group and brings the proven X-Shape technology, which is based on VDeh-Betriebsforschungsinstitut (BFI) flatness measurement concept to the hot rolling process. In cooperation with BFI and ArcelorMittal, the prototype has been installed and operated at ArcelorMittal’s hot rolling mill in Eisenhüttenstadt. The measuring system offers a detailed insight into the effects of flatness in the finishing mill when rolling with tension, as well as the effects of the laminar cooling. Time Tuesday, Jun 29 11:30AM - 12:00PM Location 207 D Speakers Mark Zipf SMS group Inc. Olaf Jepsen SMS group GmbH Frank Gorgels SMS group GmbH Patrick Siemann SMS group GmbH Retractable Roofs: Traveling Crane Technologies in Sports Cory Lindh, Uni-Systems Engineering; Andrew Agosto, Uni-Systems Engineering; Mark Silvera, Uni-Systems Engineering show more Description Retractable roofs and other kinetic sports architecture features have heritage in, and further advance, the hoist and drive technology developed by the overhead traveling crane and material handling industries. This case study describes how AIST TR-06 has contributed to the design of the custom mechanization within these applications, as well as how innovative technologies – including alternative drive arrangements, tolerance-accommodating structural releases, custom independent suspension systems, and more sophisticated controls systems – have enabled the reliable motion of increasingly complex systems, including some of the largest moving structures in the world Time Tuesday, Jun 29 11:30AM - 12:00PM Location 209 C Speakers Cory Lindh Uni-Systems Engineering Andrew Agosto Uni-Systems Engineering Mark Silvera Uni-Systems Engineering Transforming Metal Production by Maximizing Revenue Generation With Operational AI Crick Waters, Falkonry Inc.; Beverly Klemme, Falkonry Inc.; Raj Talla, Falkonry Inc.; Prerna Jain, Falkonry Inc. ; Nikunj Mehta, Falkonry Inc. show more Description Only recently have signal processing and machine learning been packaged into a production-ready software solution for commercial use at scale. This paper reveals how an operational artificial intelligence solution is applied against multi-variate time series data to learn, detect and predict operating conditions in continuous casting operations. The solution applies a system of signal acquisition, feature extraction and machine learning to sensor data resulting in alerts to operations of conditions that precede equipment failure. These alerts allow operations to schedule necessary maintenance interventions, thus avoiding unexpected downtime events and thereby increasing annual production output without new capital investment. Time Tuesday, Jun 29 11:30AM - 12:00PM Location 209 A Speakers Crick Waters Falkonry Inc. Beverly Klemme Falkonry Inc. Raj Talla Falkonry Inc. Prerna Jain Falkonry Inc. Nikunj Mehta Falkonry Inc. Value Creation of Dolime Compared to MgO Alternatives for EAF Application Felix Firsbach, Lhoist Business Innovation Center; Eric Perrin, Lhoist Business Innovation Center; Michael Nispel, Lhoist Business Innovation Center; John Beatty, Lhoist North America; William Johnson, Lhoist North America show more Description For electric arc furnace application, MgO is key to managing the lifetime of refractories for achieving the highest productivities and controlling the viscosity of the slag to guarantee good slag foaming and proper metallurgical behavior at the same time. This paper investigates the potential added value of different MgO sources (i.e., raw and calcined dolomite, raw and calcined magnesite, and recycled MgO from refractories) according to their dissolution kinetics into the slag. This affects the ability to saturate the steelmaking slag with MgO, which influences the chemical erosion of the refractories and impacts the foaminess and the metallurgical properties of the slag. Time Tuesday, Jun 29 11:30AM - 12:00PM Speakers Felix Firsbach Lhoist Business Innovation Center Eric Perrin Lhoist Business Innovation Center Michael Nispel Lhoist Business Innovation Center John Beatty Lhoist North America William Johnson Lhoist North America
2:00pm 100% H2 DRI From Nuclear Process Heat John Kutsch, Thorium Energy Alliance show more Description Coupling reactor technology into direct reduction steel by high-temperature steam electrolysis, hydrogen-making from natural gas is a wasteful process that is also not economical at higher gas costs. Molten salt reactor (MSR) is uniquely suited to provide the very high temperatures (600+C working temperatures) that are needed to both generate significant amounts of hydrogen, oxygen (a feed for basic oxygen furnaces) and electricity needed for advanced steel production. Studies by TEA and Idaho National Laboratory have shown that this new generation of MSR would be the most effective to provide carbon free, inherently safe, clean, non-proliferating energy. Time Tuesday, Jun 29 2:00PM - 2:30PM Location 201 B Speakers John Kutsch Thorium Energy Alliance Advanced Cooling Technology to Improve High-Strength Plate-Steckel Mill Steel Production Dengqi Bai, SSAB Americas; Ian Robinson, Primetals Technologies ; Joachim Kilato, Primetals Technologies; Chase Rawlinson, SSAB Alabama Inc. show more Description This paper describes a recent plate-Steckel mill modernization project applying the MULPIC® cooling technology coupled with existing conventional laminar cooling to produce high-strength plate and coil. A description is given of the automation control scheme implemented to give accurate temperature control as well as the advantages of intermediate cooling during the holding phase to improve mill productivity. The paper demonstrates the importance of the advanced model-based automation coupled with sophisticated adaptation. Insights are provided by predictions of the plate temperature and microstructural evolution during cooling. Typical performance results are given, which demonstrate the accuracy that was achieved. Time Tuesday, Jun 29 2:00PM - 2:30PM Location 207 C Speakers Dengqi Bai SSAB Americas Ian Robinson Primetals Technologies Joachim Kilato Primetals Technologies Chase Rawlinson SSAB Alabama Inc. An Accelerated Installation and Commissioning Plan to Upgrade an Aging Static VAR Compensator for an Electric Arc Furnace Application VISVESVARAN Subramanian, Primetals Technologies USA LLC; Anil Kanagala, Primetals Technologies USA LLC show more Description Static VAR compensators play a vital role in providing power quality compliance and network stability to electric arc furnaces. Considering a typical life cycle of 20 years, upgrading aging SVC equipment ensures maximum meltshop production. Recent increase in production demand from meltshops has challenged maintenance supervisors with fewer and shorter downtimes available for equipment upgrades and servicing. This paper presents an executed plan where a conventional SVC installation and commissioning schedule was compressed from two months to just 11 days. This paper details the execution plan, risk analysis, challenges encountered and remedial measures taken to ensure on-time start-up. Time Tuesday, Jun 29 2:00PM - 2:30PM Location 202 B Speakers VISVESVARAN Subramanian Primetals Technologies USA LLC Anil Kanagala Primetals Technologies USA LLC Approach to Successful Production of Very-Low-Carbon High-Strength Galvanized Dual-Phase Steels Through a CSP Flex Mill Shobhit Bhartiya, Big River Steel; V.S.Y. Injeti, Big River Steel; Chirag Mahimkar, Big River Steel; MAT Bishop, Big River Steel; Matthew Enloe, CBMM North America Inc.; Amar De, Big River Steel; Denis Hennessy, Big River Steel show more Description Very-low-carbon, microalloyed chemistry is utilized for the development of high-strength dual-phase (DP) steels with enhanced formability. Clean steel practices, in combination with suitable chemistry and casting powder selection, resulted in excellent mechanical properties and formability characteristics of DP steels along with excellent surface finish. The enhanced balance of strength and formability is attributed to the optimization of the microstructure through refinement, uniformity and balancing microconstituents mechanical response. In this contribution, production strategy and formability characterization of DP steels with tensile strengths of 780 MPa and above relevant to automotive body structure applications will be discussed. Time Tuesday, Jun 29 2:00PM - 2:30PM Location 208 B Speakers Shobhit Bhartiya Big River Steel V.S.Y. Injeti Big River Steel Chirag Mahimkar Big River Steel MAT Bishop Big River Steel Matthew Enloe CBMM North America Inc. Amar De Big River Steel Denis Hennessy Big River Steel Bath Level Management in the Consteel DC Electric Arc Furnace Paul Turner, Heraeus Electro-Nite Co. LLC; Pat Quiney, Nucor Steel-Hertford County; Kaleb Fitch, Nucor Steel-Hertford County; Leonard Meads, Heraeus Electro-Nite Co., LLC show more Description The hot heel and endpoint bath level are important factors for optimal furnace efficiency when operating an electric arc furnace (EAF), even more so for the operation of a Consteel DC EAF. A new bath level management system was implemented into practice at Nucor Steel-Hertford County (NSHC) with the goal of improved control over these aspects of the process. Without costing any additional process time, NSHC operators are able to monitor the steel bath level throughout the Consteel EAF process. In addition to improving operational control of the Consteel EAF, noticeable process gains were realized as well. Time Tuesday, Jun 29 2:00PM - 2:30PM Location 204 Speakers Paul Turner Heraeus Electro-Nite Co. LLC Pat Quiney Nucor Steel-Hertford County Kaleb Fitch Nucor Steel-Hertford County Leonard Meads Heraeus Electro-Nite Co., LLC Descaling of Medium C and High Si, Mn Steels Ronald J. O'Malley, Missouri University of Science and Technology; Richard Osei, Missouri University of Science and Technology; Simon Lekakh, Missouri University of Science and Technology; Lesli Peterson, Spraying Systems Co.; Oldair Sasso, Spraying Systems Co. show more Description Descaling of slabs exiting reheat furnaces prior to hot rolling is an important step to improve surface quality in the steelmaking process. An induction heating system with a controlled atmosphere that replicates the combustion atmosphere in a commercial slab reheat furnace was used to oxidize high-Si, Mn and medium-C steels. High-pressure water jet descaling was performed following scale formation using a laboratory setup that mimicked the industrial descaling process. Effects of nozzle impact factor (N/mm2) on scale removability for the different steels were investigated. The critical values of impact factor required for scale removal are discussed. Time Tuesday, Jun 29 2:00PM - 2:30PM Location 207 D Speakers Ronald J. O'Malley Missouri University of Science and Technology Richard Osei Missouri University of Science and Technology Simon Lekakh Missouri University of Science and Technology Lesli Peterson Spraying Systems Co. Oldair Sasso Spraying Systems Co. Fine-Scale Details Within the Roll Clusters of 20-High/Sendzimir Mills, Part 1: Microstatic Interactions Mark Zipf, SMS group Inc. show more Description The roll clusters of 20-high/Sendimir mills are assemblies of solid rolls, backing bearings, arbors and support saddles, all seated to the housing’s precision bores. The static locations/contact mechanics of these components/bores form the roll cluster’s longitudinal and transverse geometries. For stability and proper function, these geometries must adhere to a series of necessary conditions and precise tolerances. This paper examines fine-scale imperfections in the roll cluster’s geometry influence precision; light-gauge shape control performance, which may exceed the capabilities of conventional roll grinding practices; cluster setup strategies; and the available dynamic shape actuation. Time Tuesday, Jun 29 2:00PM - 2:30PM Location 207 B Speakers Mark Zipf SMS group Inc. How U.S. Steelmaking Became a Green Industry and What Lies Ahead Francesco Memoli, Tenova Inc. show more Description U.S. steelmaking is the smallest contributor of CO2 emissions per ton of steel produced in the world, doing its part to prevent climate change and global warming. This is the result of a combination of economic, financial and technological factors that contributed to make U.S. steelmaking a benchmark for green steel production. This paper proves with scientific data the current situation, the technologies that are at the base of such results and the challenges ahead in keeping the industry on this path to be an example for the rest of the world. Time Tuesday, Jun 29 2:00PM - 2:30PM Location 207 A Speakers Francesco Memoli Tenova Inc. Improvement of Centerline Segregation at United States Steel Corporation’s Gary Works No. 2 C Line Continuous Caster Thinium Natarajan, U. S. Steel Research and Technology Center; William Schlichting , United States Steel Corporation ; Ernesto Serrano, United States Steel Corporation; S. McCann, United States Steel Corporation; M. Fornasier, Danieli & C. S.p.A.; M. Knights, Danieli & C. S.p.A.; C. C. Tomazin, United States Steel Corporation; B. Flanigan, United States Steel Corporation; M. Liedtke, United States Steel Corporation; C. Paynes, United States Steel Corporation; M. Keel, United States Steel Corporation show more Description Gary Works' C line caster was originally designed with the ability to change thickness and later upgraded to cast twin strands. Based on the improved internal quality results observed at U. S. Steel - Granite City No. 1 Caster (formerly Bethlehem’s Steel Sparrow Point caster) from the application of dynamic soft reduction (DSR), U. S. Steel - Gary Works' C line caster was modernized to be capable of DSR. Danieli Corp. was selected to engineer segment modernization for the dynamic gap control and integrate the control into their QCOOL, QCORE and QPULSE automation packages. Time Tuesday, Jun 29 2:00PM - 2:30PM Location 205 B Speakers Thinium Natarajan U. S. Steel Research and Technology Center William Schlichting United States Steel Corporation Ernesto Serrano United States Steel Corporation S. McCann United States Steel Corporation M. Fornasier Danieli & C. S.p.A. M. Knights Danieli & C. S.p.A. C. C. Tomazin United States Steel Corporation B. Flanigan United States Steel Corporation M. Liedtke United States Steel Corporation C. Paynes United States Steel Corporation M. Keel United States Steel Corporation Managing the Impact, Assessment and Application of Solutions for Combustible Dust Mitigation and Control in Modern Manufacturing Environments Simon Shipp, AUMUND Corp. show more Description Given recent events at the port in Beirut, and updates in domestic legislation, combustible dust mitigation and material control can not be ignored. This paper reviews and explains NFPA 652 legislative demands and the process of combustible dust hazard analysis. The paper also provides technology insights from real-world installations and practical experience in handling difficult, hot and dusty materials without risk. The paper was schedule for AISTech 2020, but in the light of recent events it has become essential for owners and operators to increase awareness, and ownership of the combustible dust management task. Time Tuesday, Jun 29 2:00PM - 2:30PM Location 209 B Speakers Simon Shipp AUMUND Corp. Mathematical Modeling of Residence Time Distribution in a Twin-Strand Slab Caster Tundish Donghui Li, University of Toronto; Kinnor Chattopadhyay; Chad Cathcart, Stelco Inc.; Fernando Guerra, University of Toronto & Stelco Inc. show more Description The residence time of liquid steel inside the continuous casting tundish and fraction of dead volume affect the probability of the non-metallic inclusion flotation and removal, as well as the final steel product quality. In order to optimize the flow patterns using different flow control devices, a computational fluid dynamics model was developed to predict the resistance temperature device curves using a user-defined scalar model, and the dead volume percentages were then calculated for different casting conditions. The removal rate of non-metallic inclusions was also predicted by developing a discrete phase model to compute the inclusion trajectories and residual ratio of inclusions. Time Tuesday, Jun 29 2:00PM - 2:30PM Speakers Donghui Li University of Toronto Kinnor Chattopadhyay Chad Cathcart Stelco Inc. Fernando Guerra University of Toronto & Stelco Inc. Panel Discussion: What We Learned Over the Past Year and How it Applies in the Future Al Varga; David Mysko, Hatch; Barry Felton, Cleveland-Cliffs Burns Harbor show more Description Panel Discussion: What We Learned Over the Past Year and How it Applies in the Future Time Tuesday, Jun 29 2:00PM - 5:00PM Location 202 A Speakers Al Varga David Mysko Hatch Barry Felton Cleveland-Cliffs Burns Harbor Real Intelligence – A Novel Approach to EAF Optimization Jeremy Jones, CIX Inc.; Mark Trapp, CIX Inc. show more Description Recently there has been a strong effort to integrate artificial intelligence (AI) into manufacturing operations and this is best suited to heavily automated operations with repetitive operating cycles. In electric steelmaking, the number of variations that occur from one heat to another makes it difficult to apply AI effectively. As an alternative, the authors propose the use of real intelligence (RI) – a suite of tools based on process fundamentals. These tools screen process data in real time, enabling the operator to make better process decisions. The authors will demonstrate how these tools can be implemented to assist the operator. Time Tuesday, Jun 29 2:00PM - 2:30PM Location 209 A Speakers Jeremy Jones CIX Inc. Mark Trapp CIX Inc. Reduced Fuel Gas Usage With Improved Reheat Furnace Pressure Control Mark Ferra, REXA show more Description Reheat furnaces need a stable internal pressure to optimize burner combustion. In 2019, a major steel producer in northwestern Pennsylvania replaced an existing pneumatic actuator due to poor reliability and pressure control. The new electrohydraulic actuator with patented technology can react (4-5 Hz) to small, varying changes in the control signal with a repeatability of <0.1% travel position. This approach vastly improves the positioning accuracy of the flue gas stack damper, which allows hot gases to exit the furnace. By stabilizing the pressure in the furnace, the combustion efficiency was improved with an annual fuel savings of US$103,000 per year. Time Tuesday, Jun 29 2:00PM - 2:30PM Location 201 A Speakers Mark Ferra REXA Restricted No-Fly Zone Management for Overhead Cranes Steven Lubeck, Laser-View Technologies Inc. show more Description In a steel production environment, overhead crane operators are forced to avoid obstacles, such as equipment and structures, while transporting loads through production. While careful and diligent operation of an overhead crane can avoid accidental collisions, it is common for an operator to be distracted in a busy and noisy mill environment. Such collisions can present safety risks, and result in costly damage, often leading to downtime. This presentation compares strengths and weaknesses of common techniques available for restricted zone overhead crane monitoring systems, their general methods of operation, and capabilities. Time Tuesday, Jun 29 2:00PM - 2:30PM Location 209 C Speakers Steven Lubeck Laser-View Technologies Inc. Safe, Fast and Cost-Effective Caster Roll Change at SDI Butler Tobin Smith, Steel Dynamics Inc. - Flat Roll Group Butler Division; John Hook, Hook Industrial Sales; Herb Pattison, Hook Industrial Sales show more Description Steel Dynamics Inc. - Flat Roll Group Butler Division designed a unique system for changing rolls in the caster bending and straightener units. The innovative new design reduces pinch point and roll handling hazards while also greatly reducing roll change time and equipment damage. Multiple devices were developed to make the process safer and less labor-intensive, including a hydraulic motor-activated "crawler" that provides exceptional control, a roll track and installation system that complements multiple roll position angles, as well as roll transportation equipment. Time Tuesday, Jun 29 2:00PM - 2:30PM Location 208 A Speakers Tobin Smith Steel Dynamics Inc. - Flat Roll Group Butler Division John Hook Hook Industrial Sales Herb Pattison Hook Industrial Sales Spray-Cooled BOF Hoods at U. S. Steel - Gary Works: 28 Years Louis Valentas, Systems Spray-Cooled; Troy Ward, Systems Spray-Cooled show more Description In 1993, U. S. Steel - Gary Works #1 BOP installed spray-cooled basic oxygen furnace removable hood panels for its #3 vessel (Mary Furnace) to replace the existing problematic high-pressure tubular cooling system. Hood panels for Evelyn and Daisy Furnaces (vessels #1 and #2) were later installed in 1996. The purpose of this paper is to review the original reasons for replacing the conventional water-cooling system, to include design principles and operation of spray-cooled equipment. The changes and developments that were made over the last 28 years, including maintenance costs, lifetime, safety and repairs, will be reviewed. Time Tuesday, Jun 29 2:00PM - 2:30PM Location 205 A Speakers Louis Valentas Systems Spray-Cooled Troy Ward Systems Spray-Cooled The Modular Roll Shop System, Extendable and Flexible Jared Joergens, Maschinenfabrik Herkules GmbH & Co. ; Robert Curler, Herkules North America show more Description The Modular Roll Shop System keeps track of all the roll shop materials such as rolls with their profiles and performance in the mill, chocks, bearings and wheels. The system is used to analyze all the data collected in the roll shop to be able to understand the right parameters in terms of grinding procedure and mill cycles to be able to save money in the daily production to acquire competitiveness in the market. The modular roll shop system, together with one of its components, the History Data Viewer System and the Process Timeline, is able to virtualize the roll grinding process to enable the operator to understand every single roll grinding pass. Time Tuesday, Jun 29 2:00PM - 2:30PM Location 205 C Speakers Jared Joergens Maschinenfabrik Herkules GmbH & Co. Robert Curler Herkules North America Top Gas Recycling Revisited to Reduce Blast Furnace CO2 Emissions Mitren Sukhram, Hatch; Ian Cameron, Hatch; Kyle Lefebvre, Hatch; Ben Ellis, BHP; Xinliang Liu, BHP; Tom Honeyands, University of Newcastle; Nicholas Aubry, Hatch Ltd. show more Description Blast furnace (BF) top gas recycling (O2BF) was tested by the ULCOS program to reduce CO2 emissions using the LKAB experimental blast furnace. During tests, the carbon rate was reduced by about 25%. Hatch and BHP re-visited the O2BF concept to assess if additional technologies could be implemented to further reduce CO2 emissions beyond what was achieved. Using a two-stage heat and mass balance model, viable operating conditions were established for a low-carbon-rate operation, significantly less than what was achieved in the ULCOS trials. Details of the enabling technologies to reach such low CO2 emission rates will be presented. Time Tuesday, Jun 29 2:00PM - 2:30PM Speakers Mitren Sukhram Hatch Ian Cameron Hatch Kyle Lefebvre Hatch Ben Ellis BHP Xinliang Liu BHP Tom Honeyands University of Newcastle Nicholas Aubry Hatch Ltd.
2:30pm 100% In-Process Compositional Testing Using X-Ray Fluorescence Alex Thurston, Olympus Scientific Solutions show more Description Advances in x-ray fluorescence (XRF) technology have led to better in-process compositional analysis solutions. For instance, in-line XRF systems can now maintain a duty cycle consistent with continuous production lines in robust industrial environments. New XRF technologies can also analyze and evaluate more elements than before, including the quantification of magnesium, aluminum, silicon, phosphorus and sulfur within seconds. Metals analysis compatibility allows manufacturers of various alloy grades to verify product material by both grade specification and chemistry. XRF technologies can be integrated into a manufacturing line on automated or stationary equipment using modern connectivity and power requirements. Time Tuesday, Jun 29 2:30PM - 3:00PM Location 205 B Speakers Alex Thurston Olympus Scientific Solutions 7 Steps to a More Effective Safety Communication Program and Safety Culture — What Every Steel Manufacturer Must Consider Dan Konstantinovsky, RH Blake show more Description Forward-thinking steel manufacturers understand that having a safe workplace isn't just the right thing to do, it's critical to business success. A key component of a successful safety program is effective communication. This presentation will identify the seven key steps every industrial firm should take to help make communications more effective and better engage the hearts and minds of their employees. Key components of this presentation include capturing employee insight with voice of the customer research, how to develop a safety communications content plan, why certain safety communications programs fail and seven safety communications best practices. Time Tuesday, Jun 29 2:30PM - 3:00PM Location 209 B Speakers Dan Konstantinovsky RH Blake An Assessment of Ultralow-NOx Combustion Technology for the Steel Industry Justin Dzik, Fives North American Combustion show more Description Environmental regulations are constantly changing based on the varying global landscape. Considerations on combustion systems' pollution impact will need to be made to stay in compliance with governmental regulations. There have been many low-NOx technologies that have been implemented on a variety of steel processes. This paper will give a brief history and evolution of low-NOx approaches and present the current best offering for ultralow-NOx burners, as well as a look forward to emerging technologies. Time Tuesday, Jun 29 2:30PM - 3:00PM Location 201 A Speakers Justin Dzik Fives North American Combustion Blast Furnace Flame Temperature Calculation Improvements John Busser, Hatch show more Description Tuyere zone blast furnace reactions are reviewed from an energy standpoint. Simplified mass and energy balances are outlined to improve the accuracy of flame temperature calculations. Time Tuesday, Jun 29 2:30PM - 3:00PM Speakers John Busser Hatch Crane Safety - We've Done the Thinking So You Don't Have To Kevin Hoffmeyer, Whiting Corp. show more Description Learn how a crane manufacturer implements an integrated approach to crane safety. From inception through design, to production, usage and maintenance, safety is built into each step of the process to ensure a reliable crane that is safe to operate, maximizes uptime and requires less to maintain. Time Tuesday, Jun 29 2:30PM - 3:00PM Location 209 C Speakers Kevin Hoffmeyer Whiting Corp. Developing a Framework for a Process Digital Twin Using Unity 3D Chenn Zhou, Purdue University Northwest; John Moreland, Purdue University Northwest; Kyle Toth, Purdue University Northwest; Syed Khaleelullah, Purdue University Northwest; Aoya Sun, Purdue University Northwest; Bernard Chukwulebe, ArcelorMittal Global R&D - East Chicago; Charles Romberger, ArcelorMittal Global R&D - East Chicago; Alexander Samardzich, ArcelorMittal Global R&D - East Chicago; Luis Raygadas, Purdue University Northwest; Nicolas Gregurich, Cleveland-Cliffs Burns Harbor show more Description As part of Industry 4.0, digital twin solutions have become increasingly important. Some examples have focused on data-driven models, where data is shown primarily in tablature or graph format, and in others computer-aided design modeling is used to show a virtual version of a piece or an array of equipment to show a whole process visually. The project will utilize Unity to allow multiple ways to see data for a process and allow interactivity. The final goal of the finished work will allow the digital twin work with a combination of off-line data sets, live cloud data and user inputs. Time Tuesday, Jun 29 2:30PM - 3:00PM Location 209 A Speakers Chenn Zhou Purdue University Northwest John Moreland Purdue University Northwest Kyle Toth Purdue University Northwest Syed Khaleelullah Purdue University Northwest Aoya Sun Purdue University Northwest Bernard Chukwulebe ArcelorMittal Global R&D - East Chicago Charles Romberger ArcelorMittal Global R&D - East Chicago Alexander Samardzich ArcelorMittal Global R&D - East Chicago Luis Raygadas Purdue University Northwest Nicolas Gregurich Cleveland-Cliffs Burns Harbor Evaluation of Mechanical Behavior Shifting of API 5L X70M Skelp Through Accelerated Cooling and Spiral Forming Processes Ashish Singh, Nucor Steel-Arkansas; Jacob Lewis, Nucor Steel Tuscaloosa Inc.; Qiulin Yu, Nucor Steel Tuscaloosa Inc.; Matt Montgomery, Nucor Steel Tuscaloosa Inc. ; PN Mahida, Welspun Pipes Inc. show more Description The direct quenching and accelerated cooling (DQ-AcC) of Nucor Steel Tuscaloosa Inc. has been used to produce API 5L X70M skelp successfully for both straight- and spiral-seam welded pipe mills at Welspun Pipes. Compared to the conventional laminar flow cooling that produces ferrite-pearlite microstructure, DQ-AcC results in uniform acicular ferrite and upper bainite through-thickness, which enhances strength and toughness significantly. To understand the losses of yield strength and toughness due to strain softening, mechanical behavior shifting of API 5L X70M skelp through accelerated cooling and spiral forming processes is examined. Time Tuesday, Jun 29 2:30PM - 3:00PM Location 207 C Speakers Ashish Singh Nucor Steel-Arkansas Jacob Lewis Nucor Steel Tuscaloosa Inc. Qiulin Yu Nucor Steel Tuscaloosa Inc. Matt Montgomery Nucor Steel Tuscaloosa Inc. PN Mahida Welspun Pipes Inc. Expansion and Modernization of 230-kV Meltshop Substation Using Digital Substation Technologies Ramesh Khajjayam, Primetals Technologies USA LLC; Anil Kanagala, Primetals Technologies USA LLC; Tim Burttram, Big River Steel show more Description This paper presents the principles, implementation and execution methodology of expansion and modernization of an existing 230-kV substation to add two additional bays for a new meltshop expansion. The paper presents the benefits of IEC 61850 and the digital twin solutions used in implementation. The paper further presents the improvements made from phase 1 to accommodate various lessons learned from the existing system design. Time Tuesday, Jun 29 2:30PM - 3:00PM Location 202 B Speakers Ramesh Khajjayam Primetals Technologies USA LLC Anil Kanagala Primetals Technologies USA LLC Tim Burttram Big River Steel Fine-Scale Details Within the Roll Clusters of 20-High/Sendzimir Mills, Part 2: Microdynamic Interactions Mark Zipf, SMS group Inc. show more Description Precision automatic gauge control (AGC) applications involving high-strength and specialty alloys are well suited for 20-high cluster/Sendzimir mills, especially when the exit strip’s thickness deviations are expected to operate near or within the measurement uncertainty (noise level) of the gauging system. In these cases, fine-scale imperfections in the mill housing, backing assemblies, bearings and rolls become active agents of performance degradation that are beyond the dynamic bandwidth of the roll gap actuation/AGC system. This paper explores the nature of these fine-scale interactions and the influence of their respective geometric, grinding and runout tolerances. Time Tuesday, Jun 29 2:30PM - 3:00PM Location 207 B Speakers Mark Zipf SMS group Inc. Hydrogen and Steel Production: On-Site Containerized Hydrogen Production From Natural Gas and Biogas Angelo Manenti, Metal Consulting; Stewart Stewart, BAYOTECH show more Description Hydrogen is being progressively utilized as a clean fuel in both transportation and power generation. It has already been used in steel production for many years in heat treatments (i.e., hydrogen annealing). Currently, there is a big push to increase the use of hydrogen also as a reductant in direct reduced iron production, and in general to decarbonize the steel industry to reduce greenhouse gas emissions. This paper identifies the potential use of hydrogen in the steel production and analyzes a new compact and containerized H2 production technology that allows steelmakers to efficiently produce on-site hydrogen from natural gas and/or biogas. Time Tuesday, Jun 29 2:30PM - 3:00PM Location 201 B Speakers Angelo Manenti Metal Consulting Stewart Stewart BAYOTECH Latest Technologies for CBN High-Speed Grinding and High-Performance SMART control Jochen Muenker, Georg North America Inc. show more Description Cubic boron nitride is the second-hardest material in the world after diamonds, and has superior grinding performance. Advantages of digital twin technology include virtual commissioning and training independent of the real machine. Time Tuesday, Jun 29 2:30PM - 3:00PM Location 205 C Speakers Jochen Muenker Georg North America Inc. New Flat-Rolled Steel Plant for Sinton, Texas, Utilizes Advanced CSP Technology With High-Throughput Single-Strand Caster and 84-Inch-Wide Hot Strip Mill for 3.0 Million Tons Per Year Keith Watson, SMS group Inc.; Frank Brenner, SMS group GmbH; Alfred Metzul, SMS group GmbH; Glenn Pushis, Steel Dynamics Inc.; Tom Wilcox, Steel Dynamics Inc.; Bill Seres, Steel Dynamics Inc.; Ron Bohna, Steel Dynamics Inc. show more Description Steel Dynamics Inc. is building a new plant for new products based on 76-inch-wide high-strength steel grades. Next-generation CSP® technology, coupled pickling tandem rolling line and continuous galvanizing line from SMS group are the basis of the plant. The plant concepts and core technologies will be presented. Targeted products will be outlined. Time Tuesday, Jun 29 2:30PM - 3:00PM Location 207 D Speakers Keith Watson SMS group Inc. Frank Brenner SMS group GmbH Alfred Metzul SMS group GmbH Glenn Pushis Steel Dynamics Inc. Tom Wilcox Steel Dynamics Inc. Bill Seres Steel Dynamics Inc. Ron Bohna Steel Dynamics Inc. Prediction and Validation of Macrosegregation in Large Steel Slab Samples Using a New Mesoscale Model and XRF Measurements Yi Feng, McMaster University; Joydeep Sengupta, ArcelorMittal Global R&D - Hamilton; Brian Thomas, Colorado School of Mines; Miha Založnik, Université de Lorraine; André Phillion, McMaster University show more Description The occurrence of centerline segregation in continuously cast steel slabs has been predicted using a new 3D mesoscale solute transport model in combined with a 1D macroscale heat transfer model. The 3D mesoscale model considers the effects of solute partitioning as well as solute transport at the scale of casting. The predictions are validated against large-scale measurements of solute distribution via x-ray fluorescence. The influence of processing parameters on centerline segregation is examined through a parametric study. The results are useful for alleviating macrosegregation during the continuous casting of advanced high-strength steel grades. Time Tuesday, Jun 29 2:30PM - 3:00PM Speakers Yi Feng McMaster University Joydeep Sengupta ArcelorMittal Global R&D - Hamilton Brian Thomas Colorado School of Mines Miha Založnik Université de Lorraine André Phillion McMaster University Revamp of BOF Converters at AK Steel-Middletown Works Using Vaicon Link 2.0 Converter Vessel Suspension System Gerald Wimmer, Primetals Technologies ; Denis Vaillancourt, Primetals Technologies ; Steve Torok, AK Steel; Georg Unterrainer, Primetals Technologies show more Description AK Steel-Middletown Works determined to change their two 225-ton basic oxygen furnace (BOF) vessels. One BOF vessel and trunnion ring were previously fabricated with a bracket support system. After a thorough technical analysis, AK Steel chose to revamp the vessel and trunnion ring to accommodate the Vaicon Link 2.0 suspension system. The first vessel was installed in 2017, the second vessel is fully pre-assembled on-site and ready for installation. The paper describes the principles of the suspension system, the project execution and results from an inspection after 17 months of operation. Time Tuesday, Jun 29 2:30PM - 3:00PM Location 205 A Speakers Gerald Wimmer Primetals Technologies Denis Vaillancourt Primetals Technologies Steve Torok AK Steel Georg Unterrainer Primetals Technologies Review of Centrifugal Fan Design Decisions Over the Past 25 Years of Operation Dan Banyay; Sean Graham, New York Blower Co.; Steve Back, New York Blower Co.; Mike Schlemmer, New York Blower Co. show more Description This paper reviews the design and operational decisions that were made in 2005 during the replacement of a double-width, double-inlet 75-inch-diameter, 9,000 lb., dual-speed, centrifugal fan wheel for a Q-BOP blast furnace due to excessive cracking in the wheel. The original centrifugal fan showed excessive cracking after 10 years of speed cycling duty. The replacement fan has been operating for more than 10 years and shows no signs of fatigue cracking. This paper reviews the original analysis, decisions by the plant personnel and evaluates the process against a present-day analysis. Time Tuesday, Jun 29 2:30PM - 3:00PM Location 207 A Speakers Dan Banyay Sean Graham New York Blower Co. Steve Back New York Blower Co. Mike Schlemmer New York Blower Co. Subscription for EAF Optimization Tony Klippel, Gerdau Long Steel North America; Carlos De Los Santos, AMI Automation; Jamie Hansen, AMI Automation show more Description A new technology and service agreement provides Gerdau Long Steel North America with a comprehensive subscription to optimize its entire base of electric arc furnaces (EAFs) and ladle metallurgy furnaces (LMFs). The ability to rapidly upgrade all plants would not have been possible using a traditional business approach. The new business approach is all-inclusive, providing the equipment, the technical know-how, the continuous remote monitoring, and support to ensure the highest efficiency EAF and LMF performance using an Industry 4.0 digital business approach with aligned outcomes. This new subscription approach ensures that Gerdau Long Steel North America will always have the latest optimization technology on its EAFs. Time Tuesday, Jun 29 2:30PM - 3:00PM Location 204 Speakers Tony Klippel Gerdau Long Steel North America Carlos De Los Santos AMI Automation Jamie Hansen AMI Automation The Casting Machine of the Future: New Automation and Digital Technologies Improve Operations Len Kosatka, Rockwell Automation show more Description Continuous casting is a demanding process and operators are constantly trying to achieve optimum speed, quality and yield while avoiding undue equipment stress. Often, these operators are working with outdated control systems, which produce limited information and reduce machine performance and reliability. As a result, many companies are relying on operator experience and know-how instead of operations data to make decisions. But what happens as these operators retire? This presentation will share advanced automation architectures that integrate power and process for better control, visualization, and troubleshooting. Applications of digital technologies like artificial intelligence will also be explored. Time Tuesday, Jun 29 2:30PM - 3:00PM Location 208 A Speakers Len Kosatka Rockwell Automation
3:00pm A Review of the Economic and Environmental Fundamentals of Selecting Heat Recovery for Combustion Systems in the Steel Industry Dennis Quinn, Fives North American Combustion show more Description Cost savings through reduction in fuel consumption, heat transfer increases, total NOx emissions reduction and carbon emissions reduction are all relevant considerations when evaluating heat recovery in industrial combustion systems. This paper investigates the evaluation of these considerations to facilitate the reader in making trade-off decisions. The objective is to arm the reader with additional tools to assist in making the best equipment decisions for their process. Time Tuesday, Jun 29 3:00PM - 3:30PM Location 201 A Speakers Dennis Quinn Fives North American Combustion Advances in Metals Cutting Technology Ed LaBruna, Janus Automation; Antonio Pensotti, Fimi show more Description Increased requirements for better performance and quality results combined with new products and specifications have pushed equipment manufacturers to find new technologies. This presentation discusses some of the new technological approaches to metal sheet cutting. The combination of mechatronic approach of new mechanical equipment designs combined with state-of-the-art automation systems provides new advantages in this area. Real case applications for sheet metal process lines will be presented including heavy plates from 3 to 25 mm in thickness. Slitting, cut-to-length and leveling machines advancements will be discussed including the benefits and limitations of the different approaches. Time Tuesday, Jun 29 3:00PM - 3:30PM Location 207 B Speakers Ed LaBruna Janus Automation Antonio Pensotti Fimi Blast Furnace Energy Balance — A Sensible Heat Approach John Busser, Hatch show more Description Simplified mass and energy balances are outlined, showing the importance of sensible heat in the blast furnace process. Chemical heat inputs are reviewed in terms of sensible heat requirements. Time Tuesday, Jun 29 3:00PM - 3:30PM Speakers John Busser Hatch CANCELLED: Pragmatic Implications for Cybersecurity in Industrial Environments Rafal Los, Lightstream Managed Services show more Description Cybersecurity presents serious implications for industrial companies - with the impact coming to nearly every area of corporate risk as well as safety. While technologists preach the immediate importance of a cybersecurity focus, the lack of maturity ensures that budgets and goals are still misaligned. The continued challenge is to implement pragmatic approaches to cybersecurity challenges that balance budget, innovation and risk while minimizing the negative impact to the company. This presentation will discuss an approach to cybersecurity and compliance risk that focuses on practical mitigation and avoidance. Time Tuesday, Jun 29 3:00PM - 3:30PM Location 209 A Speakers Rafal Los Lightstream Managed Services Digital Dynamic Managed Services: Achieving the Next Level of Performance in Caster Maintenance Christoph Häusler, SMS group show more Description The foundation of a win-win project for a caster operator and its original equipment manufacturer service supplier is a trustful and open cooperation. Both parties have to virtually merge and work with one common goal of maximizing the total cost of ownership. For this, maximum skilled personnel, suitable quality of repairs and spares, and well-optimized workflows have to be in place. If this foundation is given, the new possibilities of digitalization open new potentials of further improvements. Based on more than 50 years of experience in caster maintenance services and cooperation lasting for decades, this paper gives details of this successful several symbioses. Time Tuesday, Jun 29 3:00PM - 3:30PM Location 208 A Speakers Christoph Häusler SMS group Hydrogen-Based DRI EAF Steelmaking - Fact or Fiction? Sara Hornby, Global Strategic Solutions Inc. show more Description This paper will present a provocative rumination of the challenges to be considered and overcome before hydrogen-based direct reduced iron (DRI) steelmaking becomes a reality, or not. Considerations such as technology needs (H2 generation, DRI carbon content, electric arc furnace needs and overall carbon balance) and economic viability (as understood currently) will be posed and discussed, along with the impact of carbon taxes. Time Tuesday, Jun 29 3:00PM - 3:30PM Location 201 B Speakers Sara Hornby Global Strategic Solutions Inc. Improving Overall Robustness of a Power Transformer Used in Steel Mills Through Advanced Design and Rigorous Manufacturing Process Jeff Mason, Virginia Transformer show more Description The life of a transformer is influenced by its design. Power transformers are forecasted to work for a period of 20-25 years of in-service life, during which the transformer may see faults that generate short circuits. These external short circuits generate asymmetrical short-circuit currents that are higher in magnitude than the service currents and lead to destructive short-circuit forces. This presentation will dive into what tools an engineer can use to improve the overall robustness of design and the coordination of improved manufacturing tolerances, material tolerances, material stresses during tests and temperature limits of components. Time Tuesday, Jun 29 3:00PM - 3:30PM Location 202 B Speakers Jeff Mason Virginia Transformer Improving performances and reliability – New Technologies for Meltshop cranes Lorenzo Bacchetti, Danieli & C. Officine Meccaniche S.p.A.; Massimiliano Svetina, Danieli Corporation show more Description Presentation of the latest technologies applied to process cranes in steelmaking plants to improve their performances and operations reliability. Since today’s cranes are highly interconnected with the main process of steel plants, new technical solutions are required to guarantee and enhance the functioning of plants around the clock. Maintaining the focus on operator’s and plant’s safety, the presentation will range from redundancy systems on gearboxes, motors and inverters used to reduce machines downtime, to the latest technologies applied to meltshop cranes for cycles and operations standardization. Time Tuesday, Jun 29 3:00PM - 3:30PM Location 209 C Speakers Lorenzo Bacchetti Danieli & C. Officine Meccaniche S.p.A. Massimiliano Svetina Danieli Corporation Increased Safety and Performance of BOF Relining at Ternium Brasil Leonardo Demuner, Ternium Brasil; Gerald Wimmer, Primetals Technologies ; Bernhard Voraberger, Primetals Technologies ; Willian Correa, Ternium Brasil show more Description Until 2019, Ternium Brazil did the relining of their 340-metric-ton basic oxygen furnace converters through the removable converter bottom. This relining process generated an operational risk for Ternium due to the sensitive area of the refractory bottom joint. In an extensive study, different relining processes were evaluated in order to improve the operational and personal safety of the relining process and in parallel to reduce the relining time. Based on the study results, a new relining machine with winch suspended working platform and elevator was developed together with Primetals Technologies, and was implemented and successfully started up in October 2019. Time Tuesday, Jun 29 3:00PM - 3:30PM Location 205 A Speakers Leonardo Demuner Ternium Brasil Gerald Wimmer Primetals Technologies Bernhard Voraberger Primetals Technologies Willian Correa Ternium Brasil Investigation of Optimal Continuous Casting Condition for Superior Steel Cleanliness Bikram Konar, EVRAZ North America; Jyoti Saroop, EVRAZ North America; Shaojie Chen, EVRAZ North America show more Description The quality of the continuously cast steel products depends on mold-fluid (liquid steel) flow pattern (MFFP), which depends on casting parameters: mold width, casting speed and argon flowrate. During changes in these parameters, suboptimal MFFPs cause meniscus turbulences, increasing non-metallic inclusions (NMI) and deteriorating product cleanliness. MFFP measurements by nail dip method and computational fluid dynamics simulations have been performed to reveal the detrimental effects of the casting parameters. The MFFPs are then correlated to NMI types and locations along the slab width. A novel parameter map is proposed to aid casting control and optimization for superior steel cleanliness. Time Tuesday, Jun 29 3:00PM - 3:30PM Speakers Bikram Konar EVRAZ North America Jyoti Saroop EVRAZ North America Shaojie Chen EVRAZ North America Ironmaking, Reinvented: Gas-Based Hot Metal Process for a Clean Steelmaking Era Francesco Memoli, Tenova Inc.; Paolo Stagnoli, Tenova S.p.A. show more Description The integrated steelmaking route is facing its hardest challenge ever: voices are raising to close blast furnaces and basic oxygen furnace (BOF) shops for good. The demand for industry decarbonization is guiding nations' policies and traditional steelmakers around the world are struggling to balance between company profitability and carbon emissions. Now, the gas-based hot metal process, capable of producing liquid pig iron starting from high-carbon hot direct reduced iron pellets, can revolutionize the field, maintaining BOF shops for the highest quality steel production. This paper presents the different projects currently under development and the impact in terms of greenhouse gas reduction, exceeding Paris Agreement goals. Time Tuesday, Jun 29 3:00PM - 3:30PM Location 207 A Speakers Francesco Memoli Tenova Inc. Paolo Stagnoli Tenova S.p.A. Limiting Bainite Formation by Refinement in Nb-Microalloyed Hot-Rolled Sections Yan Wang, Gerdau; Bryan Williams, Gerdau; Taylor Giddens, Gerdau; Douglas Stalheim, DGS Metallurgical Solutions Inc.; Matthew Enloe, CBMM North America Inc. show more Description Production of high-strength niobium-microalloyed structural sections is achieved by rolling above traditional temperatures employed in thermomechanical processing. Niobium intended to retard static recrystallization and favor grain refinement during hot rolling, concurrent with reductions in manganese and vanadium contents, has been employed to achieve target ferrite-pearlite microstructures and achieve mechanical property targets. Niobium, in combination with other additions that retard primary ferrite formation (Mn, Cr, Mo), is balanced in subject alloys to ensure the desired microstructure upon air cooling from finish rolling temperatures and is partially compensated by a reduction in austenite grain size. Time Tuesday, Jun 29 3:00PM - 3:30PM Location 208 B Speakers Yan Wang Gerdau Bryan Williams Gerdau Taylor Giddens Gerdau Douglas Stalheim DGS Metallurgical Solutions Inc. Matthew Enloe CBMM North America Inc. Managing Heat Stress-Related Injuries and Illness in the Iron and Steel Industry Rupkatha Bardhan, Murray State University; Melina Eaker, Murray State University; William Ryan Gaskins, Murray State University; Jacob Crissup, Murray State University show more Description Heat-related injuries and illnesses are common among iron and steel industry workers, who are frequently exposed to extreme heat at work. Heat stroke is a serious heat illness can cause fatality. This project (currently in study) will involve students pursuing a career in occupational safety and health to investigate sources of heat stress in iron and steel industry employees, and provide effective ways to manage heat stress through assessment, control and training. The successful completion of the project will also help in identifying environmental conditions that contribute to heat stress and recommending preventive measures for maintaining worker safety and health. Time Tuesday, Jun 29 3:00PM - 3:30PM Location 209 B Speakers Rupkatha Bardhan Murray State University Melina Eaker Murray State University William Ryan Gaskins Murray State University Jacob Crissup Murray State University Performance and Results of the 2.5-Million-Tons-Per-Year EAF at Tosyali Algerie Andrea Grasselli, Tenova show more Description The electric arc furnace (EAF) at Tosyali Algerie is the most productive EAF in the world using direct reduced iron (DRI). Fed by hot DRI and metal scrap, it has a capacity of 2.5 million metric tons per year. This EAF, designed and supplied by Tenova in 2018, started up few months later and has so far produced millions of metric tons, reaching stable productivity levels above 300 mtph. This paper presents the latest performance and results of the installation. Time Tuesday, Jun 29 3:00PM - 3:30PM Location 204 Speakers Andrea Grasselli Tenova Prediction of Damage During Different Hot Rolling Schedules of Medium-Carbon V-Microalloyed Steel Ronald J. O'Malley, Missouri University of Science and Technology; Shouvik Ganguly, Missouri University of Science and Technology; Simon Lekakh, Missouri University of Science and Technology; Mario Buchely, Missouri University of Science and Technology; F. Okanmisope, Missouri University of Science and Technology ; K. Chandrashekhara, Missouri University of Science and Technology ; J. Heerema, Missouri University of Science and Technology show more Description The ability to predict conditions that induce irreversible damage in hot-rolled material is vital for product quality. In the current work, parameters for Johnson-Cook strength and damage models were determined using high-temperature mechanical testing on medium-carbon vanadium-microalloyed steels. Finite element models were developed for two hot rolling bar schedules, considering both square to round and round to round continuous casting and hot rolling processes. The experimentally determined material models were implemented along with the industrial hot rolling parameters. Using simulation results, the locations of regions with a high probability of damage initiation were predicted. Time Tuesday, Jun 29 3:00PM - 3:30PM Location 207 D Speakers Ronald J. O'Malley Missouri University of Science and Technology Shouvik Ganguly Missouri University of Science and Technology Simon Lekakh Missouri University of Science and Technology Mario Buchely Missouri University of Science and Technology F. Okanmisope Missouri University of Science and Technology K. Chandrashekhara Missouri University of Science and Technology J. Heerema Missouri University of Science and Technology Prediction of Inclusion GSV: A Quality Control Tool for Inclusion SEM Analysis Mohammad Abdulsalam, Carnegie Mellon University; Bryan Webler, Carnegie Mellon University show more Description One of the most widely used techniques for non-metallic inclusion analysis is scanning electron microscopy along with energy-dispersive spectroscopy (SEM/EDS). The compositional quantification and grayscale values (GSV) are some of the features measured in SEM/EDS analysis. This study utilizes regression models to predict the GSV of an inclusion from its composition. Discrepancies between predicted and measured GSVs can help identify false positives or erroneous readings due to contaminants or improper filtering, providing an automated quality control tool on inclusion SEM analysis. Time Tuesday, Jun 29 3:00PM - 3:30PM Location 205 B Speakers Mohammad Abdulsalam Carnegie Mellon University Bryan Webler Carnegie Mellon University Production of X70 Discrete Plate Using MULPIC Dengqi Bai, SSAB Americas; Ian Robinson, Primetals Technologies ; Chase Rawlinson, SSAB Alabama Inc.; Kenneth Hodges, SSAB Alabama Inc. show more Description In late 2019, an advanced runout table cooling system was installed at the SSAB Alabama Inc. rolling mill. The purpose of this upgrade was to expand SSAB’s capabilities of offering advanced high-strength steels in wider thickness ranges. Since the installation, an optimized rolling practice with the application of accelerated cooling has been developed for 0.750-inch X70 plate. Plates produced with this practice have been successfully converted to pipes with satisfactory mechanical properties. Time Tuesday, Jun 29 3:00PM - 3:30PM Location 207 C Speakers Dengqi Bai SSAB Americas Ian Robinson Primetals Technologies Chase Rawlinson SSAB Alabama Inc. Kenneth Hodges SSAB Alabama Inc. Understanding Interaction between Residual Stress in BackUp Rolls and Modern Mill Loading Conditions Konstantin Redkin, WHEMCO Inc.; Christopher Hrizo, WHEMCO; H. Zeigler, WHEMCO Inc. show more Description Development of Advanced High Strength Steels (AHSS) and rolling practices to produce wider and lighter gages promote both increased mill loading and increased rolling accident frequency. Mill rolls’ performance requirements and damage tolerance are pushed to extreme levels continuously challenging roll manufacturers. Proposed complex finite element analysis of backup rolls to predict microstructural evolution and associated transformational-thermal stresses during roll manufacturing will be discussed, taking into account superimposed actual mill loading conditions. Proposed approach can be expanded to design rolls for actual or theoretical rolling production schedules for hot and cold mills, including non-ferrous applications, using forged or cast rolls. Time Tuesday, Jun 29 3:00PM - 3:30PM Location 205 C Speakers Konstantin Redkin WHEMCO Inc. Christopher Hrizo WHEMCO H. Zeigler WHEMCO Inc.
3:30pm A Holistic Approach Toward the Next Level of Safe EAF Operation Danny Schreiber, Badische Stahlwerke GmbH; Andreas Volkert, Badische Stahlwerke GmbH; Ralf Schweikle, BSE; Sven Fuchs, BSE; Patrick Hansert, BSE America; Cara Riedel, Badische Stahl-Engineering GmbH show more Description This paper will not only show the latest tool geared toward the goal of zero accidents, but will also demonstrate a full circle of inventions that are in operation at BSW. The latest tool at BSW's plant in Kehl, Germany, is called the taphole manipulator (THM), which launched in January 2020. As BSW's personnel are its most important asset, BSW thrives to do everything possible to keep them safe. This paper will show a full circle of equipment implemented to do so. Time Tuesday, Jun 29 3:30PM - 4:00PM Location 209 B Speakers Danny Schreiber Badische Stahlwerke GmbH Andreas Volkert Badische Stahlwerke GmbH Ralf Schweikle BSE Sven Fuchs BSE Patrick Hansert BSE America Cara Riedel Badische Stahl-Engineering GmbH Analyzing Sensitivity of Fractional Centerline Segregating Rating to Image Adjustments Ahmad van der Breggen, EVRAZ North America show more Description For high-strength, low-alloy steel produced for pipelines, centerline segregation is viewed as one of the important metrics for steel quality. When analyzing the sensitivity of a previously published fractional rating method, some effects on ratings were found that suggest that some extremes of image adjustment from default scanner settings were incompatible with the algorithm. This paper standardizes the acquisition of images to continue on the path toward an objective, automated rating method that is robust and independent of image quality. The error introduced by acceptable image adjustments and reasonable histograms is estimated, and problems introduced by sample preparation are discussed. Time Tuesday, Jun 29 3:30PM - 4:00PM Speakers Ahmad van der Breggen EVRAZ North America Application of Oxygen-Enriched Combustion in an Industrial Reheating Furnace Using CFD Bethany Worl, Cleveland-Cliffs; Francisco Martinez, Purdue University Northwest; Armin Silaen, Purdue University Northwest; Kurt Johnson, ArcelorMittal Global R&D; Larry Fabina, Cleveland-Cliffs; Joe Maiolo, Linde; Kelly Tian, Praxair Inc.; Chenn Zhou, Purdue University Northwest show more Description An important part of the hot rolling process is the reheating of steel products to target temperature using combustion of natural gas in a furnace. To increase energy efficiency of this reheating process, oxygen enrichment can be used with high entrainment of reaction product gases to distribute the combustion reaction area. The modeling of various configurations was undertaken using computational fluid dynamics to use oxygen enrichment or oxy-fuel in order to avoid changes in the furnace zone temperatures while reducing fuel usage. Effects on the combustion, temperature distribution, species and heat transfer to the steel product are under study. Time Tuesday, Jun 29 3:30PM - 4:00PM Location 207 D Speakers Bethany Worl Cleveland-Cliffs Francisco Martinez Purdue University Northwest Armin Silaen Purdue University Northwest Kurt Johnson ArcelorMittal Global R&D Larry Fabina Cleveland-Cliffs Joe Maiolo Linde Kelly Tian Praxair Inc. Chenn Zhou Purdue University Northwest Coal Rheology - The Effect of Rank and Sample Preparation on Test Results Ted Todoschuk, ArcelorMittal Dofasco G.P.; Louis Giroux, Natural Resources Canada show more Description Coal rheology is a critical parameter for determining the coking and caking ability of metallurgical coals for cokemaking. The effect of particle size on the resultant fluidity and dilatation results will be governed by the rank of the coal during sample preparation due to hardness (HGI) differences. For this study, various rank U.S. Appalachian metallurgical coals were prepared using the standard ASTM methods, and rheology results were determined. In addition, rheology was also measured on sized subsets to determine the effect of size and rank on the overall rheology results. Size limits for the ASTM standards are suggested. Time Tuesday, Jun 29 3:30PM - 4:00PM Speakers Ted Todoschuk ArcelorMittal Dofasco G.P. Louis Giroux Natural Resources Canada Crane Remote Driving: Applications in Meltshop Area Lorenzo Bacchetti, Danieli & C. Officine Meccaniche S.p.A.; Luca Argiolas, Danieli & Officine Meccaniche S.p.A. show more Description Presentation of engineering and commissioning of Charging Crane Remote control, with first operation feedback. Crane operator is no longer exposed to EAF scrap charging hazards: the control is performed from a safe control room with increased ergonomics. Crane is not command anymore from joysticks, but from guided from touch Screens. One single operator is supervising the activities of EAF Crane and EAF. A smart CCTV-camera system automatically interacts with crane and technological process giving to the operator an enhanced vision of the action. The successful experience of remoting the control of EAF charging crane in meltshop at ABS, Italy. Time Tuesday, Jun 29 3:30PM - 4:00PM Location 209 C Speakers Lorenzo Bacchetti Danieli & C. Officine Meccaniche S.p.A. Luca Argiolas Danieli & Officine Meccaniche S.p.A. Data-Driven Study of Desulfurization During Ladle Treatment and Its Impact on Steel Cleanliness P. Chris Pistorius, Carnegie Mellon University; Stephano Piva, Carnegie Mellon University show more Description During steelmaking processing, large amounts of data are collected, including chemical composition, amount of additions, temperature measurements and amount of argon stirring. In this paper, ladle furnace time-series data from 258 heats of medium-carbon, Si-bearing, Al-killed steel are analyzed to calculate desulfurization steel mass transfer coefficients, compare their values with empirical correlations and discuss the deviations. Other kinetic phenomena are also discussed in this work, such as Al fade due to steel-slag reactions, Mg pickup in alumina inclusions and the effect of steel chemical composition into post-Ca treatment oxide inclusion composition. Time Tuesday, Jun 29 3:30PM - 4:00PM Location 205 B Speakers P. Chris Pistorius Carnegie Mellon University Stephano Piva Carnegie Mellon University Digital Transformation: Why Projects Fail, Potential Best Practices and a Road Map for Success Len Kosatka, Rockwell Automation show more Description The metals industry has invested US$55 billion in smart manufacturing digital solutions by 2020. However, many companies are finding they lack the leadership, infrastructure and worker skills to successfully implement digital transformation projects. The problem isn’t isolated to heavy industries: a Gartner study showed that across market segments, 85% of big data projects fail. This paper proposes a set of actionable ideas to help metals companies plan, implement and sustain digital transformation initiatives. The discussion will share the work with a major metals company in North America to perform an operational assessment, align divisional and corporate needs, and define a digital transformation strategy. Time Tuesday, Jun 29 3:30PM - 4:00PM Location 209 A Speakers Len Kosatka Rockwell Automation Main Considerations for a Successful Automation Upgrade Ed LaBruna, Janus Automation show more Description This paper discuss some of the main aspects to consider for a successful automation upgrade in the metals industry, including real implementation cases in the meting and rolling sector. Some of the aspects are related to setting expectations, a comprehensive functional specification, quality of the existing information, factory acceptance testing, site acceptance testing and commissioning strategies. Time Tuesday, Jun 29 3:30PM - 4:00PM Location 202 B Speakers Ed LaBruna Janus Automation MIDREX H2 - The Road to CO2-Free Iron and Steelmaking Robert Millner, Primetals Technologies; Johannes Rothberger, Primetals Technologies; Wolfgang Sterrer, Primetals Technologies; Hanspeter Ofner, Primetals Technologies; Barbara Rammer, Primetals Technologies; Christian Boehm, Primetals Technologies Austria GmbH; Vincent Chevrier show more Description The iron and steel industry must reduce CO2 emissions drastically during the next 30 years. The EU target is an 80% reduction by 2050, which can only be achieved by different production processes. To prepare, many steel producers plan to integrate a direct reduction (DR) plant in their existing steel works. This paper describes the Midrex H2 plant configuration for stepwise increase up to 100% H2 input. An overview about currently ongoing H2 plant projects based on Midrex shaft furnace technology will be given. Furthermore, a feasibility and case study of a DR plant operation based on H2 will be presented. Time Tuesday, Jun 29 3:30PM - 4:00PM Location 201 B Speakers Robert Millner Primetals Technologies Johannes Rothberger Primetals Technologies Wolfgang Sterrer Primetals Technologies Hanspeter Ofner Primetals Technologies Barbara Rammer Primetals Technologies Christian Boehm Primetals Technologies Austria GmbH Vincent Chevrier Modernization and Customization of a Copper Plate Mill Descale System Steve DeMar, Hauhinco show more Description In 2019, a descale system for a 110-year-old plate mill in Germany was upgraded to the latest technology in customizable descaling. This paper will cover general features of the rolling mill and production criteria; the original descale system and condition of the water hydraulic equipment; engineering solutions in the new system and methods of reducing energy and water consumption, including adjustable descale zone, distance and pressure control; and the new descale system scope of supply, installation and commissioning, and overall project timeframe. Net improvements since production resumed will be summarized. Time Tuesday, Jun 29 3:30PM - 4:00PM Location 207 C Speakers Steve DeMar Hauhinco Non-Contact Sensors in Caster Operations Steven Lubeck, Laser-View Technologies Inc. show more Description Engineers involved with caster lines continue to increase their use of non-contact sensors for real-time monitoring of conditions of the cast strand. Live monitoring permits processes both upstream and downstream to be adjusted to optimize production, assure quality, optimize yield and reduce scrap. Laser-based sensors are capable of providing dimensional size and profile feedback. Several types of laser sensors can measure displacement, position and proximity. The harsh environmental conditions plays a role in determining the right sensor for the job. This presentation examines the advantages of non-contact laser-based sensors, along with suggestions for successful implementation at the caster. Time Tuesday, Jun 29 3:30PM - 4:00PM Location 208 A Speakers Steven Lubeck Laser-View Technologies Inc. Product Yield Improvement in Non-Continuous Rolling Mills Ruediger Holz, Danieli Germany GmbH; Jay Kremm, Danieli show more Description Non-continuous cold rolling mills, such as reversing mills or stand-alone tandem mills, are the optimal solution in terms of investment cost and operating flexibility for a limited production capacity. On the other side, material losses at strip head and tail end due to out-of-thickness tolerance lengths are increasing operating costs. Newly developed technologies, such as Yield Boost and Mega Coil, for the threading of strip head and tail in close roll gap mode and the processing of heavier coils are aimed at improving product yield and plant capacity. Time Tuesday, Jun 29 3:30PM - 4:00PM Location 207 B Speakers Ruediger Holz Danieli Germany GmbH Jay Kremm Danieli Surface Characteristics of High-Manganese TRIP (Fe39Mn20Co20Cr15Si5Al1) Steel Pranshul Varshney, University of Alabama; Nilesh Kumar, University of Alabama show more Description Steel is a widely used engineering material. It suffers extensive corrosion. The electrochemical behavior of high-manganese transformation-induced plastically deformed (TRIP) steel Fe39Mn20Co20Cr15Si5Al1 (at.%) in 3.5 wt.% NaCl solution was studied. The linear polarization test reveals corrosion current density as 8.05 x 10-8 A/cm2, lower than 410 stainless steel (8.96 x 10-6 A/cm2) and shows better uniform corrosion resistance. The electrochemical impedance spectroscopy reveals stable surface film formation. Further experiments are underway for detailed surface characterization. Time Tuesday, Jun 29 3:30PM - 4:00PM Location 208 B Speakers Pranshul Varshney University of Alabama Nilesh Kumar University of Alabama The EAF for Integrated Plants Jens Apfel, Primetals Technologies show more Description EAF Ultimate is designed for all kinds of raw material scenarios. One-bucket charging even for 100% scrap, low electrical energy consumption, improved chemical power input and safety improvements are its key features. Modern and smart automation tools like an automated sand filling system, automated charging system, T+S manipulator, offgas measurement or an automated taphole opener ensure safety and delay reduced productivity. Current performance figures including maintenance costs and lifetime information of all major equipment parts will be shown, together with mechanical solutions to make brownfield implementations possible and workable. Time Tuesday, Jun 29 3:30PM - 4:00PM Location 204 Speakers Jens Apfel Primetals Technologies The Path for Electric Steelmaking and Renewable Energy in the United States Francesco Memoli, Tenova Inc. show more Description The United States is the region of the world where electric steelmaking is most developed, with 70% of the entire steel production being made with electric arc furnaces, with tremendous benefits in terms of reduction of the carbon footprint of our industry. Meanwhile, in the last 10 years, renewable energy has more than doubled its volume, surpassing coal for the first time since 1885, with 11.5 quadrillion Btu. New meltshops entirely fed by renewable electricity have been conceived and will soon be a reality. This paper analyzes challenges and opportunities for a carbon-free steel industry based on renewable. Time Tuesday, Jun 29 3:30PM - 4:00PM Location 201 A Speakers Francesco Memoli Tenova Inc. Using DSI as Low-Cost Emissions Control Jon Norman, United Conveyor Corp. show more Description Applications for dry sorbent injection (DSI) as a flexible and low-capital-cost method for air emissions control in the steelmaking industry will be discussed. DSI can be applied to any process where acid gas emissions, including HCl, SO2, SO3, or mercury must be controlled, such as blast furnaces, ladle metallurgy furnaces, coke manufacturing, etc. An overview of the technology will be given, with specific details relative to sorbents used, pollutant removal performance and effects on waste disposal. Example applications will also be presented, along with high-level capital and operating cost information. Time Tuesday, Jun 29 3:30PM - 4:00PM Location 207 A Speakers Jon Norman United Conveyor Corp.
4:00pm AI Application to Front-End Bending Prediction Marcelo Saparrat, TecnoAp; Fernando Monti, Ternium S.A. de CV; José Ibarra, Grupo Open show more Description During the passes of the slab in the reversing mill, there is sometimes a curvature defect in the tip of the sheet being processed. This defect, due to the form it presents, is colloquially known as SKI. Depending on its direction and magnitude, it can cause the slab to hit the frame of the next stage or to be inserted into the conveyor rollers, with its consequent damage to the equipment and production stoppage. This paper will expose the underlying physical complexities that cause this phenomenon and how a solution to this problem was structured using artificial intelligence capabilities. Time Tuesday, Jun 29 4:00PM - 4:30PM Location 207 C Speakers Marcelo Saparrat TecnoAp Fernando Monti Ternium S.A. de CV José Ibarra Grupo Open Characteristics and Thermodynamics of Nozzle Clogging in Ti-Stabilized Ultra-Pure Stainless Steels Xuefeng Bai, University of Science and Technology Beijing; Zirong Zhao, University of Science and Technology Beijing; Xiaoshuai Hao, University of Science and Technology Beijing; Yanhui Sun, University of Science and Technology Beijing show more Description Characteristics of the deposits on the submerged entry nozzle wall in Ti-stabilized ultrapure stainless steels were investigated by cross-sectional and acid dissolution methods. The deposit profile could be divided into three major layers: eroded refractory, initial adhesive layer and loose multi-phase deposits. The initial adhesive layer comprised two sublayers: (i) the Al2O3–ZrO2 composite layer and (ii) the dense Al2O3-based deposit layer. The loose multi-phase deposits were composed mainly of MgO·Al2O3, CaO·Al2O3 and CaO·TiO2. Furthermore, the phase stability diagrams in high-Cr steels and equilibrium precipitations of inclusions during solidification were calculated to study the formation of deposits in the clogging. Time Tuesday, Jun 29 4:00PM - 4:30PM Speakers Xuefeng Bai University of Science and Technology Beijing Zirong Zhao University of Science and Technology Beijing Xiaoshuai Hao University of Science and Technology Beijing Yanhui Sun University of Science and Technology Beijing Computational Studies and Optimization of Inclusion Removal in a Steel Ladle Abhishek Bhansali, Nucor Steel-Berkeley; Armin Silaen, Purdue University Northwest; Chenn Zhou, Purdue University Northwest; Xipeng Guo, Purdue University Northwest; Joel Godinez, Purdue University Northwest; Nicholas Walla, Purdue University Northwest; Helmut Oltmann, Nucor Steel-Berkeley; Vivek Thapliyal, Nucor Steel-Berkeley; Eugene Pretorius, Nucor Steel-Berkeley show more Description In a steel refining ladle, the properties of manufactured steel can be notably weakened due to the presence of excessive inclusions. Stirring via gas injection through a porous plug is often used as part of the steel refining process to reduce these inclusions. In this paper, 3D computational fluid dynamics is used to analyze transient multi-phase flow and inclusion removal in a gas-stirred ladle. The effects of gas stirring with bubble-inclusion interaction is analyzed using volume of fluid approach for multi-phase flow modeling while the effects of bubble coalescence and breakup are modeled via discrete phase model and inclusions modeled via population balance model. Time Tuesday, Jun 29 4:00PM - 4:30PM Location 205 B Speakers Abhishek Bhansali Nucor Steel-Berkeley Armin Silaen Purdue University Northwest Chenn Zhou Purdue University Northwest Xipeng Guo Purdue University Northwest Joel Godinez Purdue University Northwest Nicholas Walla Purdue University Northwest Helmut Oltmann Nucor Steel-Berkeley Vivek Thapliyal Nucor Steel-Berkeley Eugene Pretorius Nucor Steel-Berkeley Crane Close-Loop Anti-Sway Systems Ed LaBruna, Janus Automation show more Description In today's dynamic labor market, training and a focus on avoiding distractions is vital in reducing accidents, product and equipment damage; and enhancing operation performance. A state-of-the-art closed-loop anti-sway system can dramatically help in those areas. Real implementation cases in the steel industry will be discussed, showing not only the benefits but also the challenges. Time Tuesday, Jun 29 4:00PM - 4:30PM Location 209 C Speakers Ed LaBruna Janus Automation Digital Substations and Process Bus for Steel Mills – Overview and Quantitative Assessment Ramesh Khajjayam, Primetals Technologies USA LLC show more Description While digital substations have seen an increase in popularity in the past few years, their adoption has been restricted only to the utilities. This paper explores the finer details of digital substations and provides a comprehensive evaluation of process bus technology for steel mills. A quantitative assessment methodology is presented along with lessons learned and future applications. A centralized protection design is introduced, and modern protection designs are explored. Safety, cost, scalability and integration into Industry 4.0 systems are discussed. Time Tuesday, Jun 29 4:00PM - 4:30PM Location 202 B Speakers Ramesh Khajjayam Primetals Technologies USA LLC Effective Utilization Techniques for Coal Having High Maximum Fluidity Based on Unique Permeation Distance Evaluation Yusuke Dohi, JFE Steel Corp.; Kiyoshi Fukada, JFE Steel Corp.; Tetsuya Yamamoto, JFE Steel Corp.; Takashi Matsui, JFE Steel Corp.; Izumi Shimoyama, JFE Steel Corp.; Hiroyuki Sumi, JFE Steel Corp.; Mikiya Nagayama, JFE Steel Corporation; Daisuke Igawa, JFE Steel Corporation; Issui Akishika, JFE Steel Corporation show more Description Caking coal with high maximum fluidity, which is essential for making high-strength coke, is limited in reserves. Therefore, some effective and practical utilization techniques were developed for coal having high fluidity based on unique permeation distance evaluation. High-fluidity coal with longer permeation distance lowers coke strength. This study investigates some influencing factors of permeation distance. Through the investigation, some measures for controlling permeation distance and mitigating the adverse effects of high-fluidity coal with long permeation distance on coke strength were clarified. Time Tuesday, Jun 29 4:00PM - 4:30PM Speakers Yusuke Dohi JFE Steel Corp. Kiyoshi Fukada JFE Steel Corp. Tetsuya Yamamoto JFE Steel Corp. Takashi Matsui JFE Steel Corp. Izumi Shimoyama JFE Steel Corp. Hiroyuki Sumi JFE Steel Corp. Mikiya Nagayama JFE Steel Corporation Daisuke Igawa JFE Steel Corporation Issui Akishika JFE Steel Corporation Heating Value and Waste Gas Flow-Controlled Exhaust Gas Combustion for a 150-ton RH-TOP Degasser at Big River Steel Jochen Schlueter, SMS group GmbH; Volker Wiegmann, SMS group GmbH; Helmut Biehl, SMS group GmbH; Michele Vachon, Big River Steel; Jonathan Youngblood, Big River Steel show more Description Big River Steel started production in 2016. The customer selected an RH-TOP degasser mainly with the objective of producing ultralow-carbon steels by performing an efficient decarburization process. This process generates considerable amounts of CO. U.S. federal regulations require the burning of combustible process gases with a heating value of at least 200 BTU/SCF. To comply with this regulation, a new type of flare stack burner has been developed, which combusts CO-containing exhaust gases and reduces the environmental impacts in the form of CO2 emissions. Time Tuesday, Jun 29 4:00PM - 4:30PM Location 207 A Speakers Jochen Schlueter SMS group GmbH Volker Wiegmann SMS group GmbH Helmut Biehl SMS group GmbH Michele Vachon Big River Steel Jonathan Youngblood Big River Steel Impact of Surface Machining on Stress Corrosion Cracking Resistance of AISI 316L Tube Fitting Nuts in an Offshore Environment Zhe Ren, Case Western Reserve University show more Description To understand the effect of surface machining on the resistance of AISI 316 L compression fitting nuts to stress–corrosion cracking (SCC) in offshore environment, AISI 316 L nuts surface-machined by different methods were tested in a salt-spraying chamber. Under constant testing conditions, significantly different SCC resistance was observed depending on how the nuts had been machined. Microstructural analysis of the nuts' cross-sections and statistical evaluation of the nut surface-crack density indicate that machining by a “form” tool yields a crack density one order of magnitude lower than machining by a “single-point” tool. Time Tuesday, Jun 29 4:00PM - 4:30PM Location 208 B Speakers Zhe Ren Case Western Reserve University Industrial Perspective of Digital Twin Development and Applications for Iron and Steel Processes Yale Zhang, Hatch; Mitren Sukhram, Hatch; Ian Cameron, Hatch show more Description Iron- and steelmaking are processes that produce steel from iron ore and/or scrap, which involves various levels of complexity - from continuous to batch operation; from physical deformation to chemical reactions; and from reduction to oxidation; just to name a few. Every day plant managers, process engineers and operators must make timely decisions to address production, quality and cost issues that are often contradicting each other, while adhering to a high standard of safety and environmental requirements. It is not an easy task, even with assistance of today’s advanced process control systems. Time Tuesday, Jun 29 4:00PM - 4:30PM Location 201 A Speakers Yale Zhang Hatch Mitren Sukhram Hatch Ian Cameron Hatch Lightweight Work Roll Flattening Model for Severe Rolling Conditions Brian Braho, Braho Machinery LLC; Robert Paul Schaeffer, Braho Machinery LLC show more Description Rolling models assuming a circular deformed roll profile have been successfully used for many years. They are known to have deficiencies on hard materials, thin gauges and low reductions. Modern numerical models with fully elastic roll deformation are a solution, but the computational cost is too high to have widespread use. A simplified model is presented that captures the essential elements of the fully elastic deformed roll shape, and can be applied on Bland-Ford-style rolling calculations. Time Tuesday, Jun 29 4:00PM - 4:30PM Location 207 B Speakers Brian Braho Braho Machinery LLC Robert Paul Schaeffer Braho Machinery LLC Searching New Horizons: The Hydrogen Revolution in Steelmaking Francesco Memoli, Tenova Inc.; Paolo Argenta, Tenova S.p.A. show more Description Several megatrends are driving society toward sustainable economic models. In the case of energy-intensive industries such as steelmaking, the evolution toward climate neutrality will mean major investments in new industrial processes that entail the use of alternative feedstock sources. In this scenario, Tenova has developed and improved technologies able to significantly reduce energy consumption and the environmental footprint of steel production, with a very particular focus on hydrogen-based solutions. This paper outlines the SALCOS and HYBRIT projects, at the forefront of steelmaking innovation, and the role of the gas-based reduction process in these innovative routes. Time Tuesday, Jun 29 4:00PM - 4:30PM Location 201 B Speakers Francesco Memoli Tenova Inc. Paolo Argenta Tenova S.p.A. Systematic Application of AI to Quality Optimization From Steelmaking to Galvanizing Falk-Florian Henrich, Smart Steel Technologies; Otmar Jannasch, Smart Steel Technologies GmbH; Hossam Shafy, Smart Steel Technologies GmbH; Jan Daldrop, Smart Steel Technologies GmbH; Selim Arikan, Smart Steel Technologies GmbH; Martin Rückl, Smart Steel Technologies GmbH show more Description Excess capacity and margin pressure force steelmakers to adopt new technologies such as artificial intelligence (AI) and machine learning to further increase prime production at minimized costs. Current quality-oriented applications of AI are either restricted to simple, punctual problems that have been solved through conventional optimization by advanced steelmakers in the past, or restricted to mere prediction of quality outcomes. At best, ad hoc online recommendations are provided to operators. Smart Steel Technologies' systematic AI-based approach avoids quality deviations from the outset instead of predicting them. Results from production are presented ranging from the meltshop to the galvanizing line. Time Tuesday, Jun 29 4:00PM - 4:30PM Location 209 A Speakers Falk-Florian Henrich Smart Steel Technologies Otmar Jannasch Smart Steel Technologies GmbH Hossam Shafy Smart Steel Technologies GmbH Jan Daldrop Smart Steel Technologies GmbH Selim Arikan Smart Steel Technologies GmbH Martin Rückl Smart Steel Technologies GmbH The Widest ESP Line for U. S. Steel – Full Digitalization Possibilities Andreas Jungbauer, Primetals Technologies; Klaus Jax, Primetals Technologies Austria GmbH; A. Maierhofer, Primetals Technologies Germany GmbH; A. Haschke, Primetals Technologies Germany GmbH; B. Voglmayr, Primetals Technologies Austria GmbH; Adnan Cosic, Primetals Technologies Austria GmbH; Klaus Frauenhuber, Primetals Technologies Austria GmbH; Michael Weinzinger, Primetals Technologies Austria GmbH; M. Ringhofer, Primetals Technologies Austria GmbH; Roman Winkler, Primetals Technologies Austria GmbH show more Description U. S. Steel combines its integrated steelmaking process with the widest ESP line ever built to produce advanced high-strength steel grades that assist automotive customers in meeting fuel efficiency standards and Primetals Technologies offers newest digitalization possibilities. Through-Process Optimization (TPO) enables the control and optimization of the production and product quality across the entire process chain. By collecting the right data with Through-Process Quality Control (TPQC) out of all automation systems, measurement systems, smart sensors and even from operators, data are transformed into valuable information, key performance indicators, decisions, advices and actions, enabling a higher level of production and product quality. Time Tuesday, Jun 29 4:00PM - 4:30PM Location 207 D Speakers Andreas Jungbauer Primetals Technologies Klaus Jax Primetals Technologies Austria GmbH A. Maierhofer Primetals Technologies Germany GmbH A. Haschke Primetals Technologies Germany GmbH B. Voglmayr Primetals Technologies Austria GmbH Adnan Cosic Primetals Technologies Austria GmbH Klaus Frauenhuber Primetals Technologies Austria GmbH Michael Weinzinger Primetals Technologies Austria GmbH M. Ringhofer Primetals Technologies Austria GmbH Roman Winkler Primetals Technologies Austria GmbH
4:30pm Building a Credible Greenhouse Gas Abatement Plan in the Steel Industry Alisha Giglio, Hatch; Gino DeVilla, Hatch show more Description The global impact of climate change is placing increasing pressure on energy- and emission-intensive sectors such as the steel industry. Investors, governments, employees and community stakeholders are demanding firms build credible plans for improving the environmental sustainability of their operations. Leveraging subject matter expertise across the steel value chain, and drawing from experts in renewable energy and sustainable financing, an approach will be shared to building and communicating a credible greenhouse (GHG) abatement plan for steel producers. A high-level assessment of applicable GHG-abating technologies will be presented, along with a first-pass analysis of potentially cash-positive actions. Time Tuesday, Jun 29 4:30PM - 5:00PM Location 207 A Speakers Alisha Giglio Hatch Gino DeVilla Hatch Condition Based-Risk Inspection Program for Structural Assets Scott Sambuco, Orbital Engineering Inc. show more Description Condition Based-Risk Inspection (RBI) is a maintenance process used to examine structural assets in industrial plants. RBI is a decision-making methodology for optimizing inspection plans. RBI Assessment Model is a tool for ranking plant structures on both condition and risk. This program quantitatively establishes individual repair priorities with consideration for the importance of both individual and combined deficiencies and the probability of failure that may result. It examines the Health & Safety, Environment and business risk of ‘active’ and ‘potential’ damage or failure mechanisms to assess and rank failure probability and consequence. The ranking optimizes inspection frequencies and inspection types. Time Tuesday, Jun 29 4:30PM - 5:00PM Location 209 C Speakers Scott Sambuco Orbital Engineering Inc. Hydrogen Generation Prepared for Iron and Steel Revolution David Wolff, Nel Hydrogen show more Description Reducing the carbon intensity of the iron and steel industry depends in part on cost-effective hydrogen generation as a reducing atmosphere for DRI and annealing, and fuel gas for burner systems. Presentation will discuss approaches that are being taken to reduce hydrogen generation CAPEX and OPEX. Time Tuesday, Jun 29 4:30PM - 5:00PM Location 201 B Speakers David Wolff Nel Hydrogen Innovative Roll Profile Design for Thin-Strip Cold Rolling Mills Navneet Singh, Digi Drives Pvt. Ltd.; Satish Kumar Tripathi, Yogiji Technoequip Pvt. Ltd.; Vidyadhar Kelkar, Span Associates; Manish Kumar, Digi Drives Pvt. Ltd.; Amit Sharma, Digi Drives Pvt. Ltd. show more Description This paper presents a roll profile design to achieve greater reductions on a cold rolling mill to produce much lighter gauges in fewer passes without compromising strip shape. This study is based on the simulation of roll separating force applied on models with different roll profiles and analyzes the stress distribution across the rolls and the strip. The study also includes the thermal analysis of YOGIJI-DIGI-supplied 6-high reversing cold rolling mills with more pass reduction for similar incoming thickness compared to other mills and the significance of strip, coolant and roll temperatures in the cold rolling process. Time Tuesday, Jun 29 4:30PM - 5:00PM Location 207 B Speakers Navneet Singh Digi Drives Pvt. Ltd. Satish Kumar Tripathi Yogiji Technoequip Pvt. Ltd. Vidyadhar Kelkar Span Associates Manish Kumar Digi Drives Pvt. Ltd. Amit Sharma Digi Drives Pvt. Ltd. Microstructural and Plastic Deformation Study of a Multi-Phase Advanced High-Strength Steel Nilesh Kumar, University of Alabama; AFM Monowar Hossain, University of Alabama show more Description Multi-phase (MP) steels fall under the category of advanced high-strength steel. In this study, the microstructure and mechanical properties of a hot-rolled MP steel were examined using advanced microstructural and mechanical properties characterization tools. The microstructural analysis revealed presence of bainite and martensite/retained austenite micro-constituents. The elastic behavior, strength and ductility were determined from tensile test results. The fractography of the fractured surface of the tensile specimens revealed ductile fracture of the alloy. Using digital image correlation, a continuous increase in longitudinal strain was noted in the necked region whereas it plateaued outside the necked region. Time Tuesday, Jun 29 4:30PM - 5:00PM Location 208 B Speakers Nilesh Kumar University of Alabama AFM Monowar Hossain University of Alabama On-Line Monitoring System to Detect Anomaly of Rolls in Rolling Mills Yuki Okano, TMEIC; Hiroyuki Imanari, TMEIC; Kazuyuki Maruyama, TMEIC; Yukihiro Yamasaki, TMEIC show more Description Rolling rolls are used under harsh conditions such as large loads and thermal stresses. If a roll spall occurs during rolling, it damages equipment and rolled materials severely, which leads to a long and hard recovery. An on-line monitoring system has been developed to detect roll anomaly in a hot strip mill. The system calculates the roll eccentricity value for each roll and alarms a risk of roll spall to the operators when the value is largely changed. This paper will show actual results and discuss the basic ideas of the system. Time Tuesday, Jun 29 4:30PM - 5:00PM Location 207 D Speakers Yuki Okano TMEIC Hiroyuki Imanari TMEIC Kazuyuki Maruyama TMEIC Yukihiro Yamasaki TMEIC Toward a Lime Magnetite Pellets-Based Feedstock for Ironmaking Geoffrey Brooks, Swinburne University of Technology; Suneeti Purohit, CSIRO; Mark Pownceby, CSIRO; Akbar Rhamdhani, Swinburne University of Technology; Keith Vining, CSIRO show more Description Lime magnetite pellets (LMPs) have previously been reported as a potentially novel feedstock for lower-carbon-footprint blast furnace (BF) and shaft direct reduced iron (DRI) ironmaking operations. In this paper, the authors use a combined theoretical and experimental approach to analyze the technical issues and economic feasibility of commercializing the LMP process. The issues and opportunities associated with the subsequent use of LMPs in BF or DRI plants as a substitute for existing iron ore pellets and sinters are presented. The economic constraints of implementing the LMP process are also discussed. Time Tuesday, Jun 29 4:30PM - 5:00PM Speakers Geoffrey Brooks Swinburne University of Technology Suneeti Purohit CSIRO Mark Pownceby CSIRO Akbar Rhamdhani Swinburne University of Technology Keith Vining CSIRO
Wednesday, June 30
10:30am Analysis of Inclusion Clusters Using Machine-Learning Tools Mohammad Abdulsalam, Carnegie Mellon University; Bryan Webler, Carnegie Mellon University; M. Jacobs, Carnegie Mellon University show more Description Behavior of non-metallic inclusions is critical for steel processing. One of the main concerns is inclusion agglomeration, which can lead to large clusters in the solid product. Scanning electron microscopy (SEM) coupled with energy-dispersive spectroscopy (EDS) has been a prominent technique for inclusion characterization. This study utilizes the output generated from SEM/EDS analysis along with machine-learning tools to provide an automated method for inclusion cluster identification. The approach was to analyze multiple cross-sections from a steel sample, thereby examining inclusions from a detailed three-dimensional perspective. The aim was to relate the three-dimensional analysis to the two-dimensional cross-sections. Time Wednesday, Jun 30 10:30AM - 11:00AM Location 205 B Speakers Mohammad Abdulsalam Carnegie Mellon University Bryan Webler Carnegie Mellon University M. Jacobs Carnegie Mellon University Effects of Reduction and Carburization on Strength of Direct Reduced Iron P. Chris Pistorius, Carnegie Mellon University; Geonu Kim, Carnegie Mellon University show more Description Direct reduced iron (DRI), as a feedstock in ironmaking and steelmaking, must maintain strength and integrity during processing, transportation, and use to avoid any operational issues and loss of material as fines. This study is designed to find associations among physical properties, structural changes, and phases in direct reduced iron during reduction and carburization. The results show that carburization changes DRI strength little, whereas the gas atmosphere has a significant effect (depending on the concentrations of water vapor, hydrogen and carbon monoxide). Time Wednesday, Jun 30 10:30AM - 11:00AM Location 201 B Speakers P. Chris Pistorius Carnegie Mellon University Geonu Kim Carnegie Mellon University How to Improve the Quality of Inbound Scrap Thomas Saccamozzone, Eriez show more Description Steel mills buy shredded ferrous scrap from various scrap processors around the country. Many steel mills have a copper requirement which is sometimes difficult to achieve. The Shred-1 Ballistic Separator uses magnets coupled with a high-speed belt to pull the high-quality ferrous (low copper) away from the copper-bearing material (less magnetic). The copper content in this material is typically between 0.16% and 0.17%. Typical scrap yards produce a ferrous product that contains about 0.033-0.035%. Time Wednesday, Jun 30 10:30AM - 11:00AM Location 202 A Speakers Thomas Saccamozzone Eriez Integrated Overall Quality Management Joachim Gnauk, PSI Metals show more Description The traditional model of a quality management system (QMS) primarily works locally and only integrates with L2 systems, leaving room for improvement in the age of Industry 4.0. An end-to-end approach is presented; a fully integrated quality management system (QMS) leading to a better control of material and process characteristics. A fully integrated QMS system can can take into account numerous data points resulting in traceable and controllable intermediate and final quality decisions. This integrated QMS is able to perform an overall quality control, statistical process controls and automatically react on quality issues. This paper discusses the modes of operation and the internal structure of a quality management system and presents an example of a successful implementation at a large Asian steel producer. Time Wednesday, Jun 30 10:30AM - 11:00AM Location 209 A Speakers Joachim Gnauk PSI Metals Non-Linear Bending Control for Temper Mills Brian Braho, Braho Machinery LLC; Robert Paul Schaeffer, Braho Machinery LLC show more Description Although proper bending force is critical to maintaining good strip shape, temper mill bending control is often relatively simplistic. This paper presents the sources of bending-related shape defects and solutions used to overcome them. Time Wednesday, Jun 30 10:30AM - 11:00AM Location 208 B Speakers Brian Braho Braho Machinery LLC Robert Paul Schaeffer Braho Machinery LLC Optimization of Parameters of Blast Furnace Smelting Under Conditions of Plant Operation With Limited Supply of Coke, Natural Gas or Iron-Bearing Materials Michael Alter, Alter Blast Furnace Consulting show more Description Based on extended knowledge and actual plant operational experiences, the author discusses the strategy of selecting main blast furnace parameters (blast pressure, temperature and volume; oxygen, natural gas and steam injection; and top pressure level) along with a charging mode and scheduled one of blast furnace shutdowns in real situations of the flow of raw materials and fuel. Optimizing productivity and coke consumption cut by top pressure reduction on 50-100 kPa is the preferable move versus decreasing hot blast oxygen enrichment 5-8%. Total pressure drop during operational changes should maintain established. Optimization can be arranged based on real-life situations. Time Wednesday, Jun 30 10:30AM - 11:00AM Location 201 A Speakers Michael Alter Alter Blast Furnace Consulting Quantitative Assessment of Centerline Segregation and Other Internal Defects in As-Cast Products Sunday Abraham, SSAB Americas show more Description The internal quality of as-cast products can have a significant impact on the performance of the finished products. The internal quality of as-cast products is dependent on the nature of defects such as radial cracks, spot inclusions, porosities and centerline segregation. In the steel industry, the severity of these defects has always been determined by a visual assessment. To improve the continuous casting process for superior internal quality and enhance properties of products, such as line pipe grades, SSAB Americas has developed a quantitative technique for the assessment of centerline segregation, spot inclusions and radial cracks in as-cast products. Time Wednesday, Jun 30 10:30AM - 11:00AM Location 207 D Speakers Sunday Abraham SSAB Americas Safety-Certified Positioning and Anti-Collision System at Steel Mill Cranes Peter Haarhoff, Johannes Hübner Fabrik elektrischer Maschinen GmbH; Thomas Brandenburger, Johannes Hübner Fabrik elektrischer Maschinen GmbH show more Description Modern and automated electric overhead traveling cranes or hoist systems require safe position monitoring and anti-collision systems. Also personal and equipment below the load has to be protected in a safe way. This technical paper shows on the basis of three different examples how to improve by changing to state-of-the-art encoder technology:  Higher precision and lower costs at positioning of ladles.  More safety for personal and equipment.  First available safety-certified positioning and anti-collision system at steel mill cranes – independent from fog, dust or other influences. Time Wednesday, Jun 30 10:30AM - 11:00AM Speakers Peter Haarhoff Johannes Hübner Fabrik elektrischer Maschinen GmbH Thomas Brandenburger Johannes Hübner Fabrik elektrischer Maschinen GmbH Steel Dynamics Inc. (SDI) - New billet welder and Spooler Line Mirko Dorigo, Danieli show more Description The US steel producer Steel Dynamics Inc. awarded Danieli the contract for a new billet welder and spooler line on July 2017 to be installed at its Columbia City, Indiana facility. The new equipment is capable of processing 240,000 tpy of rebar from #3 to #8 and smooth rounds from 3/8” to 1-1/16” in compact coils up to 5 tons. The combination of billet welding and spooling technologies will maximize yield because of the endless production process. The plant was started-up in December 2018. Time Wednesday, Jun 30 10:30AM - 11:00AM Location 207 C Speakers Mirko Dorigo Danieli Sustainable Recycling of Steel Manufacturing Wastewater Treatment Solid Wastes via In-Process Dynamic Separation Naiyang Ma, ArcelorMittal USA Research LLC show more Description In steel production, wastewater is constantly generated in various unit processes. Existing wastewater treatment technologies are clean water-oriented, but solid wastes collected in the wastewater treatment processes are generally dirty, full of contaminants and sometimes hazardous. Sustainable recycling of the wastewater treatment solid wastes requires effective separation of beneficial components from undesirable ones. In-process dynamic separation has recently emerged as a promising technology for producing clean, dry and recyclable solid co-products in economical ways. In this paper, a recent study of this technology is reported. Time Wednesday, Jun 30 10:30AM - 11:00AM Location 207 A Speakers Naiyang Ma ArcelorMittal USA Research LLC The Smart, Connected Plant: The Power of Proactive, Unified Security and Communications Jeff Bogdan, Motorola Solutions show more Description Those in the iron and steel industry understand the importance of instant, reliable communication, equipped with the features to keep teams safe and efficient. But 81% of manufacturers are still using more than one device to communicate on the job and many struggle to integrate their communications and security systems. Motorola Solutions' integrated ecosystem unifies voice, video, data and analytics on one single platform. Providing communication between any device, on any network, from any location and with any user, these solutions pull in real-time security data for intelligence at every moment to detect, analyze, communicate and respond to both everyday incidents and critical emergencies. Time Wednesday, Jun 30 10:30AM - 11:00AM Location 205 C Speakers Jeff Bogdan Motorola Solutions Using Video Cameras in Combination With Proximity Warning System to Improve Safety Ed LaBruna, Janus Automation show more Description This paper discuss the benefits of implementing a combined system using video cameras and proximity warning systems to not only warn about close proximity but also tracking those near interactions between equipment and personnel. Time Wednesday, Jun 30 10:30AM - 11:00AM Location 202 B Speakers Ed LaBruna Janus Automation Virtual Reality Simulator for Portable Fire Extinguisher Training Chenn Zhou, Purdue University Northwest; John Moreland, Purdue University Northwest; Kyle Toth, Purdue University Northwest; Angela Hiller, ArcelorMittal; Justin Heffron, Purdue University Northwest; Jeff Mitchell, Cleveland-Cliffs - Burns Harbor; Chenhao Zhang, Purdue University Northwest; Robbie Britton, Cleveland-Cliffs Burns Harbor; Stephen Borzych, Cleveland-Cliffs Burns Harbor show more Description Fires are an ever-present hazard in the steel industry. Fire extinguishers are only helpful if workers are sufficiently trained to assess when and how to use them. This paper discusses the development of a virtual reality (VR) fire safety simulator to provide interactive training to steel industry workers. The simulator introduces trainees to the PASS method (Pull, Aim, Squeeze, Sweep), and lets them put out fires using a VR headset and controllers. The simulator includes realistic fire behaviors and combines interactive 3D models with 360-degree videos to provide a realistic, immersive and engaging training tool. Time Wednesday, Jun 30 10:30AM - 11:00AM Location 209 B Speakers Chenn Zhou Purdue University Northwest John Moreland Purdue University Northwest Kyle Toth Purdue University Northwest Angela Hiller ArcelorMittal Justin Heffron Purdue University Northwest Jeff Mitchell Cleveland-Cliffs - Burns Harbor Chenhao Zhang Purdue University Northwest Robbie Britton Cleveland-Cliffs Burns Harbor Stephen Borzych Cleveland-Cliffs Burns Harbor
11:00am A New Generation of Fast and Technically Advanced “Through the Coil Eye” Wrapping Machines Based on Robot Technology Jan Persson, Lamiflex Inc show more Description The MultiWrapper is a dual blocker roller system with a small footprint that requires no capital expenditure and low maintenance, and is ergonomically sound for operators. A wrapping time of approximately 3 minutes makes it the fastest in the industry. Film overlap and tension can easily be adjusted and programmed to optimize the right amount of packaging for each steel coil. The twin blocker roller system limits crane loading time. The MultiWrapper, with its robot arms, can be upgraded to perform more tasks than the actual wrapping. Time Wednesday, Jun 30 11:00AM - 11:30AM Location 202 A Speakers Jan Persson Lamiflex Inc Evolution of Non-Metallic Inclusions in Highly Alloyed Steels During Ladle Refining Andrew Huck, Carnegie Mellon University; Bryan Webler, Carnegie Mellon University show more Description Oxide, sulfide and nitride inclusions in steel, both unintended and by design, can significantly affect processing and properties. Thermodynamic models have been established that fit observed inclusion evolution in ladle refining for conventional steelmaking, but it is unknown if these models will transfer to higher alloy steels with additional elements and different processing steps. This work will focus on inclusion evolution in a martensitic heat-resistant steel (>10 elements added) that is processed via electric arc furnace, argon oxygen decarburization and electroslag remelting before being forged and compare these results to FactSage equilibrium and kinetic models. Time Wednesday, Jun 30 11:00AM - 11:30AM Location 205 B Speakers Andrew Huck Carnegie Mellon University Bryan Webler Carnegie Mellon University Filtering Out Failures: A Productive Conversion Experience for a Steel Mill Stan Shmia, De Nora Water Technologies show more Description A midwestern U.S. steel mill maintains 21 pressure filters for water filtration of hot strip mill contact water and continuous casting machine spray return contact water. The filter media of the perforated sheet metal underdrains was, by design, in direct contact with the metal underdrain openings. Over time, the underdrain would become deformed, allowing sand media particles to pass through. Media intrusion, which required a disruptive shutdown to fix, was significantly impacting mill efficiency and product quality. This paper will discuss the details of the mill’s problem and how converting to a different underdrain design addressed it. Time Wednesday, Jun 30 11:00AM - 11:30AM Location 207 A Speakers Stan Shmia De Nora Water Technologies Fundamentals of Alloy and Processing Design for the Successful Production of Ferritic, TiC-Strengthened Ultrahigh-Strength 100-ksi (Yield Strength) Hot-Rolled Steel With Low-Temperature Toughness Through a Flex Mill V.S.Y. Injeti, Big River Steel; Chirag Mahimkar, Big River Steel; Amar De, Big River Steel; Venkata Natarajan, Big River Steel ; Denis Hennessy, Big River Steel ; Jay Martin , Big River Steel show more Description A low-carbon Ti-Nb-microalloyed steel chemistry was designed for the production of ultrahigh-strength hot-rolled steels with 100 ksi minimum yield strength and low-temperature toughness suitable for automotive, agricultural and machinery component applications. Ultrahigh strength was achieved through ferrite grain refinement and very fine TiC precipitation strengthening only. Alloy design and processing approaches were tailored to the dynamics of a continuous hot strip producing line with no interruption to regular production routine. Hot-rolled coils up to 8 mm have been successfully produced so far with enhanced low-temperature toughness and cold bendability. Time Wednesday, Jun 30 11:00AM - 11:30AM Location 208 B Speakers V.S.Y. Injeti Big River Steel Chirag Mahimkar Big River Steel Amar De Big River Steel Venkata Natarajan Big River Steel Denis Hennessy Big River Steel Jay Martin Big River Steel Gas Cleaning and Waste Heat Recovery Solutions for Integrated Steel Plants and Mini Mills – State-of-the-Art Technologies and Latest References Thomas Steinpazer, Primetals Technologies; Paul Trunner, Primetals Technologies; Alexander Fleischanderl, Primetals Technologies show more Description Today steel mills are forced to comply with the most stringent environmental regulations. Two practical examples for achieving ultralow emission levels and best-in-class energy efficiency are presented: the installation of a new electric arc furnace at a steel plant in Italy including a state-of-the art gas cleaning system and a novel type of waste heat recovery solution with record execution time are discussed. Latest innovations for wet- and dry-type ultralow emission gas cleaning for basic oxygen furnace shops are introduced. A novel concept for top gas recovery turbine arrangement for a blast furnace as well as operational achievements are presented. Time Wednesday, Jun 30 11:00AM - 11:30AM Speakers Thomas Steinpazer Primetals Technologies Paul Trunner Primetals Technologies Alexander Fleischanderl Primetals Technologies HBI: Steel’s Most Versatile Metallic in the Transition to the Hydrogen Economy Sean Boyle, Midrex Technologies Inc. show more Description The conversion to hydrogen ironmaking will take time because of the unavailability of green hydrogen at necessary volumes/costs, and the large capital requirements to convert from the blast furnace (BF) to the direct reduction-electric arc furnace route. During this transition phase, other ways to reduce CO2 emissions must be explored in integrated steel plants. Hot briquetted iron (HBI) can be used in the BF/basic oxygen furnace (BOF) to supplement scrap, increase productivity and lower CO2 emissions. Merchant HBI can be produced in large-scale operations at a location where logistics and reducing gas (including hydrogen) can be advantageous and transported in the right amount to existing steelmaking complexes as a flexible metallic source. Time Wednesday, Jun 30 11:00AM - 11:30AM Location 201 B Speakers Sean Boyle Midrex Technologies Inc. Investigation on Flying Tundish Change and Separation Plate Using Micro-X-Ray Fluorescence at ArcelorMittal Dofasco's No. 1 Continuous Caster Jackie Leung, ArcelorMittal Global R&D - Hamilton; Manh Kha Trinh, ArcelorMittal Dofasco G.P. show more Description To optimize productivity, steel grades of different chemistries are often cast sequentially. This can include flying tundish changes and grade separation plates inserted into the mold. Although these practices aim to separate the grades, some mixing is still possible. A unique imprint of the crater shape in the as-cast slab is formed as a result. Micro-x-ray fluorescence, in addition to several other innovative tools and techniques, was used to reveal and analyze the crater shape from multiple slabs. This paper reviews findings from the extensive investigation carried out at ArcelorMittal Dofasco and proposes an explanation of the imprint’s formation. Time Wednesday, Jun 30 11:00AM - 11:30AM Speakers Jackie Leung ArcelorMittal Global R&D - Hamilton Manh Kha Trinh ArcelorMittal Dofasco G.P. Machine Learning for Blast Furnace Productivity Improvement at Jindal Steel and Power Angul Anil Gandhi, Qualicent Analytics, Inc.; Ritesh Mishra, Jindal Steel and Power Ltd.; Aniruddha Fadnis, Qualicent Analytics, Inc. ; Richa Jaiswal, Jindal Steel and Power Limited; Sambit Mishra, Jindal Steel and Power Limited; Amitava Sircar, ABS Technical Services show more Description The process inside a blast furnace remains a complex one, influenced by many factors simultaneously and with deep interactions among the influencing factors. This process complexity is enabling better quality hot metal, but the complexity comes at a cost – intractable conditions of furnace behavior leading oftentimes to lower productivity. It is in this context of complexity and the availability of numerous data streams that we highlight in this presentation the use of machine learning to improve productivity at the newly commissioned blast furnace at JSPL at Angul in India. Time Wednesday, Jun 30 11:00AM - 11:30AM Location 201 A Speakers Anil Gandhi Qualicent Analytics, Inc. Ritesh Mishra Jindal Steel and Power Ltd. Aniruddha Fadnis Qualicent Analytics, Inc. Richa Jaiswal Jindal Steel and Power Limited Sambit Mishra Jindal Steel and Power Limited Amitava Sircar ABS Technical Services Next-Generation Scrap Management Technology Giovanni Bavestrelli, Tenova; Marco Corbella, Tenova; Renato Girelli, Tenova show more Description In recent years, Tenova set out to assist its customers in creating a cyber-physical factory by integrating the enabling technologies of Industry 4.0 in the steelmaking process. An important part of this initiative is the optimization of the scrap management process, with the goal to reduce waste, costs and energy consumptions as well as improve the quality of the product, the uptime of the equipment, and the overall productivity and efficiency of the plant. The presentation describes the various solutions introduced as well as their benefits and the lessons learned during the project implementation. Time Wednesday, Jun 30 11:00AM - 11:30AM Location 209 A Speakers Giovanni Bavestrelli Tenova Marco Corbella Tenova Renato Girelli Tenova Shape Up! The New Merchant Bar Mill at Nucor Steel Kankakee Inc. Mario Fabro, SMS group Inc. show more Description The new rolling mill will allow Nucor Steel Kankakee Inc. to expand its product range into larger merchant bar sizes for the growing regional market. Taking advantage of the latest technology, this new mill aims at being the industry market leader. State-of-the-art solutions targeting extreme flexibility and reduced changeover times will allow the just-in-time rolling philosophy needed to withstand the market cycles. This presentation will cover the project development and start-up of the facility. Time Wednesday, Jun 30 11:00AM - 11:30AM Location 207 C Speakers Mario Fabro SMS group Inc. Smart Safety Guard — Improving Safety Through Real-Time People Localization Fabrice Hansen, Paul Wurth & SMS digital; Nicolas Schlesser, Paul Wurth S.A.; D. Jakubowski, Paul Wurth S.A.; Yves Reuter, Paul Wurth S.A. show more Description Part of Paul Wurth’s commitment is to help customers improve their health and safety standards. From time to time, dangerous situations may appear around blast furnaces. This paper presents a real-time localization tool combining two technologies: Bluetooth Low Energy and Mesh Network. This non-intrusive, almost wireless, solution provides a clear live visualization of workers’ positions to interpret that nobody is in a risky environment at any given time through a user-friendly interface with various functionalities such as geofencing and automatic alarms. In response to the current pandemic, contact tracing is possible through the newly included COVID module. Time Wednesday, Jun 30 11:00AM - 11:30AM Location 209 B Speakers Fabrice Hansen Paul Wurth & SMS digital Nicolas Schlesser Paul Wurth S.A. D. Jakubowski Paul Wurth S.A. Yves Reuter Paul Wurth S.A. State of the Art in Electro-Welded Tube Manufacturing Equipment Ed LaBruna, Janus Automation; Antonio Pensotti, Fimi show more Description This presentation discusses the state-of-the-art equipment used to produce electro-welded tubes. In a very competitive and constantly demanding environment for higher performance, flexibility and quality, machine equipment providers have made substantial improvements to cope with those requirements. The main areas covered in the presentation are coil processing, electro-welded tube mills, strip join, threading and drilling units, milling cutoff units tube finishing lines and cold conforming lines, including hydro testing, end fencing, packing, cutting and handling equipment. Real case implementation will be presented including the main benefits and limitation of the technologies used. Time Wednesday, Jun 30 11:00AM - 11:30AM Location 207 D Speakers Ed LaBruna Janus Automation Antonio Pensotti Fimi The Next-Generation Surface Quality Management System Gregory Gutmann, ISRA Vision Parsytec Inc.; Michael Hoenen, ISRA PARSYTEC GmbH show more Description Surface quality is one of the most important quality characteristics of advanced flat steel products. Most quality management systems can deal with thresholds for gauge data or measurements like chemical composition and mechanical properties, but they are lacking the possibility to decide on surface quality. ISRA’s Surface Quality Management System defines the detailed, customer order-specific quality corridor for each production step from slab to finished product and realizes the surface quality part. It enables reliable quality decisions in each production step. The Central SIS Monitor guarantees that the surface quality is measured correctly. Time Wednesday, Jun 30 11:00AM - 11:30AM Location 202 B Speakers Gregory Gutmann ISRA Vision Parsytec Inc. Michael Hoenen ISRA PARSYTEC GmbH Use of Insight Data Management Software to Improve Reliability at NLMK Indiana James Gleason, Suez; Ehren Plew, NLMK Indiana; Terry Black, NLMK Indiana show more Description This paper will describe the ongoing use of a proprietary data management system (Insight) at a Midwestern mini-mill. Insight is a communication and troubleshooting system designed to monitor facility performance in real time. Insight began utilization with respect to U.S. Environmental Protection Agency audits. Previous manual data collection wasn't traceable. There were potential problems and penalties associated with maintenance of the previous data collection system. An iPad fleet was configured with the Insight app to make data collection throughout the mill easier and reliable. An explosion in data points allows for trend analysis in all operating areas. A reduction in operating hours has already been realized. Document security and traceability have been strengthened. Time Wednesday, Jun 30 11:00AM - 11:30AM Location 205 C Speakers James Gleason Suez Ehren Plew NLMK Indiana Terry Black NLMK Indiana
11:30am An Assessment of State-of-the-Art Offgas Sensor Technology for Process Control in Steel Combustion Furnaces Ken Grieshaber, OnPoint Solutions LLC; Eric Huelson, OnPoint Solutions LLC show more Description TDLAS has grown in popularity in recent years, replacing extractive offgas measurement systems. Electric arc furnace and basic oxygen furnace steelmakers utilize TDLAS to report combustion gases such as CO and CO2 while also measuring water vapor levels to assess leaks in water-cooled furnace equipment. In reheat furnaces, TDLAS has been deployed in multiple heating zones to correct zone stoichiometry, temperature and CO levels. During early adoption, questions arose pertaining to accuracy and robustness in a steel environment. This paper provides TDLAS integration strategies, operating data and value for process optimization. The use of TDLAS with machine-learning technology will be shown. Time Wednesday, Jun 30 11:30AM - 12:00PM Location 202 B Speakers Ken Grieshaber OnPoint Solutions LLC Eric Huelson OnPoint Solutions LLC Blast Furnace Gas to Boiler Pressure Control Mark Ferra, REXA show more Description Blast furnace gas is often used as a fuel for a boiler at the power house. REXA’s hydraulic actuation technology is able to react (3-5 Hz) to small, constantly varying changes in control signal with a repeatability of <0.1% travel position. A steel producer in India replaced the existing pneumatic actuator due to poor pressure control. With the REXA actuator positioning a 69-inch butterfly valve, the fluctuation of gas pressure from the process setpoint was reduced from 45 MMWC to 12 MMWC, and always within control limits. Boiler steam generation increased 13% due to improved combustion. Time Wednesday, Jun 30 11:30AM - 12:00PM Location 201 A Speakers Mark Ferra REXA Digital Optimization of Refractory Maintenance Nikolaus Mutsam, Mutsam Engineering; Franz Pernkopf, Graz University of Technology; Gregor Lammer, RHI Magnesita show more Description Refractory condition monitoring and maintenance are key to extending the lifetime of a vessel lining and therefore increase steelmaking efficiency. An approach for optimizing refractory maintenance by employing statistics and machine-learning methods is presented. The scope of this work is to provide intelligent decision support for planning and performing maintenance on refractory material in order to improve its lifetime. This challenge is tackled by contriving a recommendation system for refractory maintenance, e.g., for proposing hot repair intervals, based on historic process data and lining measurements. Time Wednesday, Jun 30 11:30AM - 12:00PM Speakers Nikolaus Mutsam Mutsam Engineering Franz Pernkopf Graz University of Technology Gregor Lammer RHI Magnesita High-Carbon DRI for the Production of High-Purity Pig Iron Jorge Martinez, Tenova HYL; Francesco Memoli, Tenova Inc. show more Description The world’s iron and steel producers need a paradigm change for the future to fulfill environmental regulations and to cope with raw material availabilities and final product qualities. The ENERGIRON® technology has been characterized by innovation and this paper outlines the novel Tenova High Purity Pig Iron production process that starts with the reduction of iron-oxide pellets in a gas-based direct reduction module and follows with high-carbon-direct reduced iron melting in an electric furnace, specifically designed to produce pig iron. The carbon footprint is thereby reduced by about 50% for ironmaking of integrated steel mills, while keeping the basic oxygen furnace and downstream facilities unchanged. Time Wednesday, Jun 30 11:30AM - 12:00PM Location 201 B Speakers Jorge Martinez Tenova HYL Francesco Memoli Tenova Inc. Increase Productivity, Minimize Waste and Lower Production Costs With Manufacturing Operations Management Solution Sam Malizia, Prisma Integration show more Description Manufacturing operations management (MOM) systems institute the rules necessary to maintain production value and ensure that everyone and everything operates accordingly. MOM systems manage continuous improvement of inventory, production, quality control, and scrap reduction around strategic objectives such as cost reduction, product innovation, sustainability, quality and regulatory compliance. The MOM system described in this work manages the entire genealogy for a single product, providing real-time tracking through the entire manufacturing process. This scalable system provides a set of modular functions, based on best practices, which can be selected and customized according to the specific needs of the customer. Time Wednesday, Jun 30 11:30AM - 12:00PM Location 209 A Speakers Sam Malizia Prisma Integration MES Implementation in the Tubular Sector Ed LaBruna, Janus Automation show more Description In a very competitive and changing market, companies compete to obtain market share with innovation, customer satisfaction and productivity. A manufacturing execution system tool is critical to help in some of those areas. This presentation describes real implementation in the tubular sector, including production, tracking, quality and shipping modules. Time Wednesday, Jun 30 11:30AM - 12:00PM Location 207 D Speakers Ed LaBruna Janus Automation Rolling Mill Bearing Lubrication Improvement Using Properly Sized Vacuum Dehydrator Richard Trent, Hy-Pro Filtration; Scott Howard, Hy-Pro Filtration; Aaron Hoeg, Hy-Pro Filtration show more Description This paper will share technical information regarding mitigating and controlling water and solid contamination buildup during normal operations of the rolling mill lube oil system. During normal operations, water spray enters the bearing through labyrinth seals, increasing water and solid contamination buildup in the oil. A properly sized vacuum dehydrator controls dirt level and maintains water content below saturation, which eliminates the need to decant free water off the reservoir. Results obtained include elimination of water and oily waste dump to the holding pond and extended life of the bearing and lubricant. Time Wednesday, Jun 30 11:30AM - 12:00PM Location 205 C Speakers Richard Trent Hy-Pro Filtration Scott Howard Hy-Pro Filtration Aaron Hoeg Hy-Pro Filtration Smart Ladle: AI-Based Tool for Optimizing Casting Temperature Chenn Zhou, Purdue University Northwest; Nicholas Walla, Purdue University Northwest; Zhankun Luo, Purdue University Northwest; Bin Chenn, Purdue University Northwest; Yury Krotov, Steel Dynamics Inc. show more Description From the basic oxygen furnace/electric arc furnace to the caster, the ability to quantify and respond to the variables that affect steel casting temperature is crucial for achieving consistent casting quality and maximizing productivity. Deviations from the optimum steel casting temperature can require adjustment to casting speed, which impacts productivity and can also harm product quality. This work will use a deep-learning network to develop quantifiable relationships between the casting temperature and various factors during the ladle refining process to enable predictions of casting temperature and precise adjustments to steel temperature prior to the ladle reaching the casting stage of the production process. Time Wednesday, Jun 30 11:30AM - 12:00PM Location 205 B Speakers Chenn Zhou Purdue University Northwest Nicholas Walla Purdue University Northwest Zhankun Luo Purdue University Northwest Bin Chenn Purdue University Northwest Yury Krotov Steel Dynamics Inc. The State of the Art in Magnetic Drum Separators for Scrap Thomas Saccamozzone, Eriez show more Description This paper will discuss a rare earth scrap drum as an efficient means of recovering weakly magnetic slag. The strong magnetic field allows for a very clean separation of the slag. The drums pull more of the slag whether homogeneous or diverse. It has strong magnetic forces from edge to edge protection, saving time and producing a very clean product. In addition, this rare earth scrap drum provides separation of ferro magnetics, including large pieces in the slag industry. It can remove weakly magnetic pieces of ferrous, allowing for a greater recovery. Time Wednesday, Jun 30 11:30AM - 12:00PM Location 202 A Speakers Thomas Saccamozzone Eriez The successful implementation of 5-strand rolling at DeAcero Ramos Arizpe (Mexico) Alberto Voltolina, Danieli Corp.; Kevin Barbee, Danieli Corporation show more Description Just three days after hot startup, the mill had already demonstrated its full potential by rolling at 70% of its maximum capacity, meaning a very fast ramp-up learning curve. The rolling mill is designed to produce rebar from #3 to #16 on the QTB-Quenching and Tempering line for bars, smooth rounds and squares from 1/2” to 2”, merchant bars, angles, channels, flats and T-profiles. The process technology provides split-rolling of rebar on five strands. The paper presents this 5-strand process, explaining the technological features and the mechanical and automation equipment involved in this new innovative rolling method. Time Wednesday, Jun 30 11:30AM - 12:00PM Location 207 C Speakers Alberto Voltolina Danieli Corp. Kevin Barbee Danieli Corporation Upgrades in Environmental Technology for the Liquid Phase of Integrated Steelmaking Michael Skorianz, Danieli Corus; Peter Klut, Danieli Corus; Matthias Meyn, Danieli Corus; Victor van Straaten, Danieli Corus show more Description Around the world, the steel industry is under increased pressure to improve environmental performance, e.g., by mitigating emissions and optimizing energy recovery and consumption. While this may often be an imposed requirement, many of the measures related to improving a plant’s environmental performance introduce economic benefits at the same time. This article covers a number of recent developments in this respect, such as possibilities for energy optimization across the plant, increased revert processing, dry gas cleaning technology for the blast furnace, efficiency improvement, and NOx emission reduction for the hot blast system and upgrades for the basic oxygen furnace gas cleaning system. Time Wednesday, Jun 30 11:30AM - 12:00PM Speakers Michael Skorianz Danieli Corus Peter Klut Danieli Corus Matthias Meyn Danieli Corus Victor van Straaten Danieli Corus Wearable Sensing Devices and the Internet of Things for Worker Safety and Health Management in the Steel Manufacturing Industry Ibukun Awolusi, University of Texas at San Antonio; Brenda Campbell, University of Texas at San Antonio; Jennifer Mondragon, The University of Texas at San Antonio; Aliu Akinsemoyin, The University of Texas at San Antonio show more Description Steel manufacturing is one of the most hazardous industries in which employees are continuously exposed to dangerous hazards and austere working conditions. More safety management improvements can be achieved by deploying emerging technologies such as wearable sensing devices (WSDs) and the Internet of Things (IoT) to predict and prevent illnesses, injuries, and fatalities. The main purpose of this research is to evaluate the applications of IoT-based WSDs for worker safety and health management in steel manufacturing. It is anticipated that the implementation of these technologies will reduce injuries and illnesses, thereby improving safety performance and productivity in steel manufacturing. Time Wednesday, Jun 30 11:30AM - 12:00PM Location 209 B Speakers Ibukun Awolusi University of Texas at San Antonio Brenda Campbell University of Texas at San Antonio Jennifer Mondragon The University of Texas at San Antonio Aliu Akinsemoyin The University of Texas at San Antonio
12:00pm Auto Adaptive Vibration Monitoring Utilizing Edge Computing in Rolling Mill Applications David Kober, iba America show more Description With a successful data analytics strategy in regard to vibration monitoring, maintenance and repair-related information can be easily derived automatically and auto adapt to dynamically changing process conditions. The purpose of this discussion is to characterize a common-sense approach using strategic data analytics practices to leverage auto adapting condition monitoring by considering the dynamically changing process conditions that exist in rolling mill applications. Utilizing systems that exist on the edge, the technologies that are available in the IT and OT realms can be leveraged efficiently with strategic coordination. The focus will center around practical rolling mill application examples. Time Wednesday, Jun 30 12:00PM - 12:30PM Location 205 C Speakers David Kober iba America CANCELED: New Developments in the Iron Carbide Process – A Viable Alternative for EAF Steelmaking in the Global Energy Transition Eric Eccleston, TechnipFMC; Sanjeev Sekhri, TechnipFMC show more Description The Iron Carbide Process is a viable alternative to conventional direct reduced iron (DRI) processes producing virgin iron units. As a feedstock for electric arc furnace steelmaking, iron carbide has several advantages, including energy savings, steel chemistry, production yield, handling properties and the potential to achieve the lowest carbon emissions per unit of steel produced. This paper outlines the history and development of the Iron Carbide Process technology, and details recent process development efforts by TechnipFMC aimed at optimized heat integration, further improvements in carbon emissions performance, and re-establishment of the Iron Carbide Process as a viable, commercial-scale alternative to conventional DRI processes. Time Wednesday, Jun 30 12:00PM - 12:30PM Location 201 B Speakers Eric Eccleston TechnipFMC Sanjeev Sekhri TechnipFMC CANCELLED: Numerical Study of Heat Transfer for Microwave-Assisted Reduction of Hematite Prasenjit Singha, Indian Institute of Technology, Madras; Sunil Yadav, Indian Institute of Technology, Madras; Soumya Ranjan Mohanty; Ajay Kumar Shukla, Indian Institute of Technology, Madras show more Description In this paper, the temperature distribution during microwave-assisted heating of the hematite ore pellets was predicted by using the numerical simulations. Hematite rectangular pallets 25 cm x 25 cm in size were considered to be heated for 1, 2 and 3 minutes using a microwave-assisted furnace. Numerical simulations were performed to simulate the heat transfer in a 2-dimensional hematite slab on application of the convective and the radiative boundary conditions. The resulting temperature profile can be used as a guiding tool for optimizing the microwave-assisted carbothermal reduction process of hematite. Time Wednesday, Jun 30 12:00PM - 12:30PM Location 201 A Speakers Prasenjit Singha Indian Institute of Technology, Madras Sunil Yadav Indian Institute of Technology, Madras Soumya Ranjan Mohanty Ajay Kumar Shukla Indian Institute of Technology, Madras Development of ARMSS: Augmented Reality Maintenance and Safety System Chenn Zhou, Purdue University Northwest; Yury Krotov, Steel Dynamics Inc.; John Moreland, Purdue University Northwest; Na Zhu, Purdue University Northwest; Myriam Chanoluisa, Purdue University Northwest; Luis Raygadas-Lara, Purdue University Northwest; Garrett Page, Steel Dynamics Inc. show more Description This paper describes development and pilot implementation of an Augmented Reality Maintenance and Safety System (ARMSS) for steel industry workers. An augmented reality headset displays digital information such as images and video, projected on see-through lenses in front of the wearer. Using this capability, the system delivers workers with hazard information, step-by-step instructions, and animated guides for maintenance and safety procedures. The visuals are displayed on top of the equipment and the surrounding environment, directing the worker to the correct locations. The system also verifies a user’s understanding through a built-in feedback system. Time Wednesday, Jun 30 12:00PM - 12:30PM Location 209 A Speakers Chenn Zhou Purdue University Northwest Yury Krotov Steel Dynamics Inc. John Moreland Purdue University Northwest Na Zhu Purdue University Northwest Myriam Chanoluisa Purdue University Northwest Luis Raygadas-Lara Purdue University Northwest Garrett Page Steel Dynamics Inc. How Artificial Intelligence Simplifies Automated Optical Surface Inspection Deployment and Operation in the Metals Industry Jochen Koenig, Schenk Vision; Chris Miller, Schenk Vision; Mark Cornell, Schenk Vision show more Description While automated optical inspection (AOI) of metal surfaces has grown increasingly powerful and versatile, the deployment into day-to-day operations can be difficult, particularly as engineering staffing is reduced. It has become important to focus the development at AOI manufacturers on tools and methods toward the goal of making AOI systems hands-off for day-to-day operation and simplify their initial deployment as much as possible. This is done utilizing various forms of artificial intelligence, which automate tasks like adjusting light levels, detection levels and defect classification. This article will introduce how these functions generally work and showcase studies of their usage. Time Wednesday, Jun 30 12:00PM - 12:30PM Location