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By Paolo Demetlika

In this paper it is shown how the “Zero Operator” concept on the casting floor has been reached by adoption of a standard 6 axis industrial anthropomorphic robot coupled with the most innovative machine vision technology. This has been achieved by automating all the operations related to the ladle and tundish activities, including shroud manipulation, powder addition, ladle nozzle identification, nozzle opening by lancing, temperature measurement and chemical sampling. Q–Robot CAST family products are the result of the successful alliance between industrial robotics and the most advanced technology in process automation. This led, for each production area, to the introduction of flexible automation in dangerous places, even where some degree of human intervention is still necessary. By using anthropomorphic robots, human operators can be reassigned to safer environments. Furthermore, robots are suited to deal with repetitive and labor intensive tasks thus guaranteeing a high process quality.

Oct 30, 2017

By Patrick E. Connell

During the ABM Conference of 2015 the latest design and process features of the new 3-roll RSB® generation were presented together with a unique Size Control System SCS® for a real time closed loop control to produce an extraordinary quality SBQ – day in, day out. In the past two years, Kocks has focused on improving the repeatability of the rolling process and developed technology to enhance the performance of its equipment. These developments include Fast Remote Control (FRC), Stands Adjustable Under Load (AUL) implementation of closed loop Size Control System (SCS), and finally a state of the art laser Gauge (4D Eagle) that pulls all of these developments into a complete package of quality. Gauges used in the past generally operated with the “shadow” measuring system. The latest gauge developments are based on the “light section” method. This method is more suitable to provide real time measurement parameters of the rolled bar. Placed close to the last rolling stand, the “light section” gauge is capable of measuring around the complete diameter with a clear definition of the bar stage in relation to the axes of the rolls. It is also capable of making these measurements using a very high measurement frequency. Following requirements of the market, requiring the highest gauge measuring frequencies which display the bar in the most accurate way even at the highest rolling speeds, the “4D Eagle” gauge was developed. This paper describes all the process features and parameters of this impressive and unique newly developed gauge as well as the other described technical improvements.

Oct 30, 2017

By Jeremy Fletcher

In today’s world, the requirement of Steel Producers to revamp and modernize their blast furnaces on-time, safely and with the latest technology is paramount. In addition they must meet the detailed design, construction and safety legislation and regulations, which can be different for the various countries around the world. Siemens MT is renowned for its ability to perform Blast Furnace rebuilds, relines and modernisations within extremely tight time frames and in a safe manner. Modular Blast Furnace construction concepts have been perfected to minimise project duration and plant downtime for furnace rebuilds. Safety and certainty are the keys for success. Siemens MT are constantly introducing new technologies into the market place including cyclone gas cleaning and triple external cone gas scrubber, along with step changes in technology such as dry gas cleaning and dry slag granulation. The economic environment and the continuing requirement for improved environmental performance, drive many of these innovations. This paper describes some of the latest rebuild reference projects of Siemens MT, along with the latest technical innovations installed on these furnaces, and some of the construction methodology used for a safe and secure rebuild.

Aug 1, 2018

By Matteo Tomba

Today’s steel market is characterised by high competitiveness and tight profit margins; therefore, the operational costs of rolling mills must be as low as possible, while ensuring a final product of the highest quality standards. PERT SRL is an engineering company with a long-term experience in the international steel market, specialised in the design and supply of highly innovative and bespoke solutions for siderurgical and environmental plants. Because of its strong commitment to deliver excellent products and services, and its ability to innovate and adapt to the fastchanging market requirements, PERT has studied a new generation of BI-SUPPORT rolling stands, designed to be used in rolling mill plants for the production of rebars, rounds and sections in special quality bars (SBQ) steel grade, wire rod, light and medium section, suitable also for special steel plants. This paper will provide a deep insight into the key technical and economic features that have revolutionised the rolling technology for long products, such as the absence of spindles and piping on board, the considerably reduced number of spare parts required, a ring gap regulation system, and the compact dimensions, which lead to significant savings in investments and production costs; at the same time, the BI-SUPPORT stands guarantee excellent standards to the final product, an increase in plant productivity and a general improvement in the plant management.

Aug 16, 2017

By Raúl Daniel López

Un objetivo de seguridad y calidad en los moldes de la colada continua de Siderar fue la de tener un menisco estable y controlado. A lo largo de los distintos periodos de inversiones y mejoras, el control de nivel de Siderar logro como objetivo contener su variación de nivel de acero en el molde en un rango de variación menor a +/-2 mm y con una velocidad de cambio inferior a 1,5 m/segundos. Esta etapa trajo una relativa mejora en los aspectos mencionados (calidad y continuidad operativa) pero el hecho de tener como sistema de medición de nivel un sistema radiactivo (fuente Co60 y contador de centelleo) mantenía serias limitaciones en ambos rubros dado que este sistema no diferencia la interface escoria /polvo colador con el menisco de acero. Este trabajo tratará de mostrar y contar las tareas de desarrollo y aplicación de esta nueva tecnología, hoy vigente en la nueva Colada Continua N° 2 (CCD2) y en etapa de puesta en marcha de la CCD1.

Aug 15, 2017

By John Ross Middleton

Based upon 30 years+ experience in the Development, Implementation and Ongoing Support of Computer based Melt Shop Management Systems in about 40 plants in the UK, Europe and the USA, consideration of the overall facilities of a state of the art, comprehensive, Integrated Melt Shop System covering Melting and Secondary processes for all grades of steels and superalloys; the scope of functionality of these systems, covering Raw Materials and Consumables Procurement and Inventory Management, Laboratory Management, Melt Shop Scheduling, Furnace Charge and Additions Optimisation, Level 1.5 to Level 2.5 Materials Optimisation and Process Control Calculations, Process Data Recording, Management of Ladles, Furnace Bodies, Vessels and Moulds, Comprehensive Management Reporting and Integration with Corporate ERP Systems. The second section of the paper reviews the key ‘Success Factors’ to achieve rapid, successful implementation, comprehensive, fast response user support, continuing system improvement and maintaining ‘perfect fit’ of system to operations in an ever changing future technical, operations and business environment.

Jul 29, 2018

By Christoph Aichinger

A smart combination – Primetals Technologies developed the Circular Pelletizing Technology (CPT), which is a combination of the well-proven travelling-grate pelletizing technology with the design of a circular dip rail cooler of modern sinter plants. The overall space requirement and the installed weight for a CPT plant is significantly less compared to conventional technologies and by that CPT is a very attractive alternative for new projects.

Aug 16, 2017

By Patrick Edward Connell

The next generation of the well-established 3-roll Reducing & Sizing Block (RSB), the RSB SCS® is the latest milestone in reducing and sizing technology for SBQ products. It offers enhanced bar quality, improved productivity, mill availability and economy as well as a simplified, safe and environmentally friendly operation. A newly developed modular drive concept of the RSB SCS® grants a smaller footprint in the layout, a reduced oil-lubrication volume and a simplified maintenance schedule. Intelligent engineering leads furthermore to reduced hydraulic functions of the RSB SCS®, which ensures a safe and environmentally friendly rolling. Another integral part of the RSB SCS® is an innovative stand changing concept, which allows automatic stand changing within three minutes. The new RSB SCS® also includes a Fast Remote Control (FRC) which enables the immediate adjustment of the roll gap against the rolling force (under load) within milliseconds. Size changes along the free-size range can also be made within the traditional billet gaps in less than five seconds. At the core of the future-oriented RSB SCS® is a real-time closed-loop control system called Size Control System (SCS®) acting with 3-roll stands adjustable under load (AUL) and / or the heavy duty stands. These features remarkably further improve the rolled tolerances and their reproducibility, and at the same time simplify the operation by means of an automated optimization of the process parameters for the rolled bars.

Aug 16, 2017

By Sebastien Flament

More and more Hot Strip Mills are facing defects on their products that lead to a rejection of complete product batches by their customers. Several of those defects are induced by excessive work roll degradation. This paper is focussed on the understanding of work roll corrosion and oxidation mechanisms in a hot strip mill. Several laboratory trials (Hot rolling simulator, cyclic oxidation) have highlighted important factors influencing corrosion of work rolls as well as helping the understandings of oxidation of a work roll in the roll bite and along the roll circumference in a stand. The attention is focussed on several elements present in water used in HSM for direct roll cooling (e.g. chloride, bactericides, sulphates, phosphates) and their effect on roll surface degradation. The second part of this paper is focused on the understanding of work roll oxidation along the roll circumference. The effects of roll composition, roll temperature, water composition and water temperature have been studied in order to understand the oxidation/corrosion mechanisms in a HSM.

Aug 16, 2017

By Bernhard Hiebl

Global trends that are constantly challenging the iron and steel producers are related to worsening of the iron ore grades, higher substitution rates of main iron ores to cheaper raw materials due to economic pressure and increased environmental standards. Changing the raw materials in an operating plant can significantly influence the sintering or pelletizing process. Adjusting all process parameters to regain stable and high productive operation takes considerable time and causes production losses. Furthermore changes in raw materials lead to variations in the process gas flows and emission concentrations.Therefore SVAI developed two models for numerical simulation of sintering process and pelletizing process. Amongst others the models are based on Ergun equation and include chemical reactions of the related process. For already operating plants the simulations shall predict changes of the process parameters when raw materials are exchanged or when operational parameters are varied. Furthermore the simulations give advantageous information for the design of green field plants and allow the simulation of different plant configurations.The objective of this paper is to demonstrate what the latest developments are in these numerical simulations and what Siemens VAI is doing to overcome the remaining challenges in this field.

Aug 2, 2018

By Thomas Höfler, Michael Auinger, Bernhard Linder

Gas-fired pusher furnaces are commonly used to heat steel slabs before hot rolling. Temperatures well above 1000 °C combined with an oxidizing atmosphere containing H2O, CO2 and O2 result in rapid oxidation of most steel grades. The resulting oxide scale and the chemistry of the metal-scale-interface are major determining factors for the occurrence of hot rolling defects. To better understand these phenomena, lab-scale trials were performed with two different steel grades in an electric tube furnace in the temperature range 1000-1250 °C, using an atmosphere of about 20 % H2O, 7 % CO2 and 3 % O2. Humidification of the gas was achieved by evaporation, using a custom thermostat with standard laboratory glassware. The resulting samples were prepared metallographically, using cold mounting under vacuum with taper section angles, and analyzed using light microscopy and SEM/EDS. The scale structure of the Si alloyed steel was highly dependent on the oxidation temperature due to the formation of eutectic liquid phases of FeO, Fe2SiO4 and FeAl2O4. Below the eutectic temperature, the scale of the Si steel appeared to be made up of three distinct areas: The external scale consisting solely of Fe oxides, the internal scale containing Fe2SiO4 and FeAl2O4, and an internal oxidation zone with SiO2 and Al2O3 in a mostly plain Fe matrix. Comparisons of the experimental results with simulations of the internal oxidation showed good qualitative agreement.

Oct 1, 2019

By Rodrigo Ribeiro de Andrade, Túlio César Nogueira, Ed Juarez Mendes Taiss, Nilton José Lucinda de Oliveira

The objective of this study was to determine the effects of an eventual slab central macro-segregation in microalloyed steels with low Mn content (0.80%) and high Nb content (0.08 to 0.10%) on the kinetics of recrystallization of austenite during its rolling, on its critical temperatures, that is, of non-recrystallization (Tnr), start Ar3 and finish Ar1 of ferrite transformation and its response to a simulated industrial thermomechanical processing. The determination of the austenite recrystallization kinetics was made through isothermal double compression tests using a dilatometer, while the critical temperatures were determined through hot torsion tests in a Gleeble® 3800. It was found that austenite recrystallization kinetics, Ar3 and Ar1 temperatures did not present significant changes for the samples extracted both at ¼ of the thickness and at the core of the plate, indicating that, as expected, the central segregation in this type of steel was not intense to the point of affecting this phenomenon. The Tnr values determined for the samples extracted in the core of the plate were, on average, 30°C lower than those obtained from specimens extracted at ¼ thickness, which suggests that a significant portion of the carbonitrides present in the core of the slab are eutectic and coarse, not having completely dissolved during the reheating of the specimens. This occurred despite the fact that the austenitization temperature adopted in this treatment theoretically leads to the total dissolution of Nb, as seems to have occurred in the case of specimens extracted at ¼ of thickness, where carbonitrides have a finer size.

Oct 1, 2019

By Ulrich Sommers

The Intelligent Furnace (I-Furnace) by SMS group is a smart furnace process and production optimization model. The combination of various tools leads to an optimized heat treatment and production process. It combines a mathematical/physical model to control the furnace with EMG’s IMPOC system for online strength measurement and a newly developed annealing microstructure model to predict material properties. This paper reports about the revamping of an existing galvanizing line, where a mathematical/physical control model has been implemented in combination with an online quality measurement system. This way, the process improvement of continuous galvanizing lines and the quality management of a range of steels including AHSS will be demonstrated. Furthermore, it gives information about the development of the annealing microstructure model to predict material characteristics. Eventually, the I-Furnace will be presented according to the current development and reference status.

Oct 30, 2017

By Emanuelle Garcia Reis, Gustavo de Sousa, Rodney Pardo Alves

Gerdau Ouro Branco´s plate mill started the operation in 2016 with high level technology. In general, national and international plate markets are every day more rigorous about final product quality. Suppliers must be aware about dimensional accuracy, surface quality and flatness of the plates, independent of the quality standards. To guarantee the best service to this increasingly demanding and competitive market, it is extremely important to guarantee the original project conditions executing the right maintenance of the rolling mill main components. In order to maintain the product quality and avoid the production and maintenance cost increase, it is important to find ways to control the mill and the main process variables, through daily measurements of the equipment performance. This paper aims to present the influence of the main equipment variables that affect the mill operational stability and how to control and evaluate the mill performance.

Oct 1, 2019

By Andreas Cestonaro

Roll grade evolution in plate mill applications is traditionally following the development in hot strip mills. New grades normally find their way into service only after being successfully implemented in hot strip production. The majority of the plate mills worldwide are using work roll grades that have been invented before the 1980’s. But today the demands in the mills are pushed by sophisticated product mixes and longer rolling campaigns. The result of this development is a higher wear rate on the work rolls and as a consequence roll hardness is increased and advanced roll materials are used. The backup rolls are also affected by this. The wear rate is higher and the mechanical impact in terms of contact pressure and work hardening is increasing. This paper outlines the results of the roll grade development at Gontermann-Peipers and introduces new materials for work and backup rolls for plate mills.

Jul 30, 2018

By Edo Engel

Hot Blast Stove Technology has been developed to such an extent that low cost hot metal production for over 30 years without major repairs has become achievable, making the decision for a campaign length between 5 to over 30 years a design choice for the plant owner/operator. Some of the earlier examples of designs capable of such long campaign lengths are currently close to the 50th year of their running campaign. These examples are found especially in Europe and North America. Along the duration of these campaigns, repairs to subsystems such as burners, hot blast outlets etc. may be required. Depending on a plant’s up and down stream production capacities, the repairs may have to take place in the shortest possible time frame to minimize production loss. This article discusses an approach for intermediate repairs, executed while keeping the majority of the system at operating temperature.

Oct 30, 2017

By Armando Vazquez

Steel Dynamics Inc. (SDI) and Tenova Goodfellow Inc. (TGI) have successfully commissioned the first hybrid extractive/laser system for continuous and full spectrum analysis (CO, CO2, O2, H2 and H2O vapor) on two twin shell furnaces at Butler, Indiana. NextGen® technology using off-gas analysis as a main tool for EAF practice optimization is a proven effective method for improving plant productivity. Significant benefits attributed to the NextGen® system are operational cost reductions through the use of real-time dynamic control of chemical energy and improved environmental conditions through reduced GHG emissions. Additionally, the implementation of Tenova’s Water Leak Detection Technology® has shown results as an effective tool for operators to identify in real-time the presence of water during both reducing and oxidizing conditions. This paper will include project details, trials and results and will also outline the latest hardware developments and multipoint capabilities

Oct 30, 2017

By Andrea Pezza

The steel market is experiencing a difficult conjuncture: on the one hand steel producers minimize their investments while optimizing their over- production, on the other hand suppliers reduce their internal human resources and capacity in order to overcome the instability of the new era. A return to the steel production levels of the past is not expected in the short term. Research, development and plant concept optimization is one recipe to drive the future of the steel business. This article describes a new concept for a VOD plant developed as a result of thorough investigation and assessment of all possible solutions. A joint and tight cooperation with the final customer was necessary to reaching important results. This article consists of the contributions from the plant suppliers in terms of their experience and feedback, as well as the final user’s. The final customer, voestalpine Giesserei Linz GmbH, and the plant supplier, Primetals Technologies, are both worldwide players and highly focused on reaching best quality and innovation.

Oct 30, 2017

By Rodrigo Fina Ferreira

This paper presents a mineral liberation study on two iron ore samples from the Quadrilátero Ferrífero, in Brazil: compact itabirite of low-grade metamorphism (CI) and friable itabirite of high-grade metamorphism (FI). The quartz liberation spectrum for both samples have been obtained through QEMSCAN analyses, carried out for several comminution degrees, to compare the liberation characteristics and to evaluate the evolution of the quartz’s liberation degree after fragmentation. The results have shown significant differences in liberation spectrum between the itabirite samples studied. The liberation process of FI was easier than of CI, due its high porosity and larger crystal size compared with CI, which has shown more complex mineral assemblages with low porosity and smaller crystals. The quartz liberation spectrum has shown that grinding at P95 of 0.210 mm for the FI sample, and of 0.045 mm for CI sample, should result in satisfactory liberation for subsequent concentration step.

Aug 1, 2018

By Paul Riches

Today’s steel producers face the dual challenge of ensuring on-time delivery and ever demanding product requirements, while also running a lean operation. Every day the management of a long rolling plant requires continuous optimization of both operating and business practices. Imagine a long rolling facility, where individual pieces of equipment communicate with each other, where sensor information can be used not only for control purposes but to also monitor the condition of the equipment, where models are used to verify the process is within working limits and the equipment raises alerts to operators when it requires maintenance! Utilizing the ongoing evolution in technology though data collection, communication, internet of things, control techniques and smart sensors, there is now more information available than ever before. The collection and analysis of this information will both advance control and monitoring of plant performance; revolutionizing long rolling mill plants worldwide and optimizing the entire value chain, along with improved and more flexible production.

Oct 30, 2017