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By Ramon Valls Martin

A obtenção das propriedades magnéticas do rejeito do processamento do minério de ferro auxilia na determinação da viabilidade da recuperação do ferro residual. Também permite a otimização dos parâmetros operacionais do processo de concentração por separação magnética. Foram apresentados dois métodos de caracterização magnética: Método indutivo (histeresígrafo) e método de força magnética (balança de susceptibilidade). Estes métodos têm como vantagens o baixo custo e rapidez de execução. Apresentaram sensibilidade suficiente para a caracterização de amostras de resíduos com teores de ferro muito reduzidos.

Aug 16, 2017

By Andreas Rohrhofer

Reliable high end automation and process optimization systems are main factors for excellent product quality, safe operation and maximized plant performance in the steel industry and its designated environmental plants. Primetals Technologies introduces new automation packages for consequent safe and cost efficient production. Many areas within the steelplant interested to be monitored and measured automatically are not implemented in the automation system due to limited access or technical reasons. A wireless, self-organizing network facilitates wide ranging data transmission in previously inaccessible areas and opens up a wide range of new opportunities. With Fluid Guard a system to detect leakages with highest accuracy and reacts properly for all kind of water cooled circuits is available, improving the safety in steelmaking process. Lance Guard can be utilized for all fully automatic and semi-automatic lance appliances, but is especially suitable for the products of Primetals Sublance Standard/2.0 and LiquiRob applications, since these systems make seamless integration particularly simple. Manual lance appliances may also be tested and diagnosed. Environmental plants have become a main part in steelmaking plants. Highest performance in combination with optimized energy consumption is the main target in Primetals Technologies’ innovations in automation optimization packages for dedusting systems. A new approach for preventive maintenance and operator assistance is introduced with the Acoustic Expert System. In combination with the new Ask cloud based system, Primetals enables a 24/7 monitoring and a whole lifetime observation of any equipment within a steelplant. Furthermore it is now enabled to check the condition of the plant at a fingertip at any time.

Aug 17, 2017

By José Claudio Blanco

A medição de Planicidade sem contato (contactless) para Laminadores a Frio é efetuada com o sistema conhecido como SIFLAT. Os sensores utilizam tecnologia eddy current como medição precisa de amplitude entre o sensor e a chapa na qual será medida a planicidade. Os resultados convertido para valores de planicidade são de alta qualidade e precisão na mediação que serão posteriormente enviadas ao sistema de controle de planicidade. Este sistema é aplicado em laminadores de chapas a frio e linha de processo.

Aug 16, 2017

By Renan Bueno Wojciechowski, Yukio Shigaki

The quality of flat rolling process depends highly on multiple factors such as applied forces, materials involved for both strip and rolls, roll geometry and its positioning. To calculate the strip shape, a mathematical/numerical model can be applied, showing the final product and how the equipment behaves when changing some parameters. This is usually a time-consuming task for both user and computer, especially when it involves thin and hard strips. By coupling a quick rolling load calculation method as Bland-Ford and Finite Element Method (FEM) for roll stack deformation, it is possible to create an accurate and user-friendly rolling simulator. This paper presents the improvements done in the 3D FEM/multi-slab method and its actual capabilities by simulating two cases of a 6-High rolling mill. Different analysis in this equipment can be easily done in about 10 minutes by using the developed an electronic spreadsheet program interface and the folder generated with relevant results and logs. An operation manual and a commercial FE program plugins were made to aid construction of a completely new model. The code was created in a modularized way to assist the application of this simulator for other operational conditions.

Oct 1, 2019

By Alberto Lainati

The Bar Reducing and Sizing Technology has a core function in the value-chain for the production of rolled SBQ (Special Bar Quality) products. The EVO 2+4-roll is based on the compact combination of a 2-roll high-reduction module followed by a 4- roll low-reduction module for precise sizing. The EVO 2+4-roll mill, allows to gain significant technical and economical advantages in the hot- and post-rolling process routes: dimensional and surface accuracy, quick adaptability to processing variances and to small lots requirements, superior technological features of as-rolled product, competitive capex and opex. The EVO 2+4 unit has a very compact design, which makes it suitable both for new mills and upgrade applications.

Aug 17, 2017

By Eddy Dierckx

Modernization of flat rolling plants is essential to sustainably fulfill increasing market demands and to improve competitiveness. Intelligent modernizations ensure getting maximum prime yield of existing mills, even if they have gone through half a century of operation. Existing mills were designed based on former production, consumption and quality targets. Ever increasing requirements such as increase of productivity, change of product mix (e.g. new steel grades), reduction of energy consumption and improvement of product quality lead to the necessity to adapt the existing equipment to the new target. SMS group provides, besides the reliable equipment and automation solutions to successful upgrades of existing mills, also a systematic approach to develop technical and economical solutions together with our customers (conceptual engineering). This paper describes the SMS group approach to modernizations / upgrades, introduces powerful performance modules and provides a number of successful examples that have been implemented recently.

Aug 17, 2017

By Francisco Morganti

The market requirements which strip processing lines have to deal with have altered significantly within the last decades. Particularly, the production has to be economical and ecological efficient and processing lines have to cover a broad product portfolio. Already existing plants either directly or indirectly are competing with new plants, which are equipped with the latest technologies. The “Special Strip Processing Equipment” is designed to be integrated easily and within small downtime phases in existing lines. All single machines can be delivered in short time “ready-to-perform” with a tested and proved automation system. Thus, the competitiveness of existing lines can be increased immediately with less effort. To find out which machines can be reasonably implemented SMS group offers an “Efficiency Check”. A special proceeding is used by experts to find out quickly which machines will have the largest effect on the efficiency of the line while demanding at the same time the smallest expense.

Aug 17, 2017

By Claudio Fabbro

The increasing demand of wire rod high carbon grades for both small and large sizes are challenging the wire rod producers to enhance new technologies by combining high plant productivity and efficiency of superior quality finished products with extreme process flexibility. The possibility to change process route according to the final application of the rolled steel grade and to simplify production planning is one of the most important keys to success that distinguishes the mill plants developed by Danieli. This paper will focus on the most important metallurgical and process targets and on the in-line heat treatment technologies representing the core of Danieli know-how on high carbon grades production.

Jul 30, 2018

By Gergö Rimaszéki

Due the fast growing of pig iron and steel in the last years associate with some mineral resources changes (Hematite?Itabirite), has been checking the sinter feed degradation. The typical sinter feed (0.15;-6.3 mm) has become limited and the rapid growing production resulted in more and more fine ore (< 150 µm) availability in the market. The sinter plant operators are facing several new challenges since the mixing and granulation- and the sintering behavior of the fines containing mixtures often differs from the traditional sinter feed´s behavior. The utilization of fines in the sinter plants might increase the process water consumption required for the mixing and granulation process or even the solid fuel consumption, which effects the operational cost of the plant significantly. The current study presents an overview about Outotec´s laboratory facilities and competence regarding the mixing and granulation of fines in different equipments. The usage of high intensity mixers (HIM) – vertical and horizontal as well – showed to be the most effective, based in cold agglomeration tests in small scale, in case of fine ore handling. Permeability and particle size distribution curves are used to evaluate and demonstrate the efficiency of the different equipments. Outotec´s ”Know-How” with the different type of mixer and the modern laboratory facilities provide an excellent opportunities to optimize the mixing and granulation procedure and utilize up to 100 % pellet feed

Aug 17, 2017

By Laurent Dorel

Surface quality monitoring is primarily implemented in the last steps of steel manufacturing before shipment to the end user. However, an increasing trend for also addressing this topic in the upstream stages, such as hot rolling plant, is tackled by Primetals Technologies to give steel producers the key to a global optimized yield management, and efficient “lessons learned” processes. After the last developments of SIAS Next Gen platform, including High Resolution and Near Infra-Red, some site results will be exposed on the very specific high constraints lines such as ESP Endless Strip Production and Plate Mills, and highlights the related most interesting aspects for our customers.

Aug 17, 2017

By Karl Berger, Roman Schneeweis, Dietrich Mathweis

With increasing demands from customers to provide flat strip with tighter tolerances on material properties, particularly flatness of e.g. martensitic steel grades (M1500), it has become necessary to develop strategies to improve flatness without influencing the tensile properties for such hard steel grades. Usual skin pass mills are not capable to apply sufficient tension and roll force for these kinds of material to improve the flatness. Therefore, alternatives had to be searched for. This paper describes skin pass - / temper – rolling methods from the classical one to new alternatives in order to satisfy the demanding market of higher material properties and idle running mills in rolling plants.

Oct 1, 2019

By Danilo Gonçalves de Oliveira

A linha de Decapagem e Laminação a Frio da ArcelorMIttal Vega vem recebendo constantes investimentos para aumento da sua capacidade produtiva sendo o mais recente a instalação do quarto tanque de decapagem química realizada em março de 2015. Para que esse investimento trouxesse o resultado esperado, eram esperadas melhorias de desempenho no processo de Laminação a Frio. O presente trabalho expõe a metodologia empregada para identificar os projetos necessários e os expressivos resultados obtidos com a sua condução ao longo do ano de 2014.

Aug 16, 2017

By Carlos Alexandre Gonçalves de Moura

O trabalho se baseia na redução do retorno parcial de aço por temperatura na Aciaria LD com foco em análise estatísticas do processo, melhorias no projeto alinhado ao plano de manutenção dos componentes mecânicos e elétricos do sistema de aquecimento de panelas. Para análise do problema foi elaborado um estudo utilizando Lean Six Sigma através do DMAIC, analisando as condições de processo, procedimento operacional e plano de manutenção dos equipamentos. Como resultado do trabalho obteve-se uma redução em 58% no retorno parcial em panelas de aquecedor.

Jul 30, 2018

By André Oliveira

The present paper describes state-of-the-art Pulverized Coal Injection technology with focus to Dynamic Distribution guaranteeing highest accuracy on equal distribution and being thus one of the key factors enabling constantly highest injection rates. As an alternative to the construction of a new plant, existing plants may be modernized and upgraded to latest technology. Two recent examples are presented. As a conclusion, two case studies of return on investment are showing that the PCI technology, both for new facilities as well as for upgrades, is very profitable and mandatory for high blast furnace operation effectiveness.

Aug 17, 2017

By Patrick Hansert

Safety was always in the focus of Badische Stahlwerke, however at the same time productivity has to increase as well in order to compete in a tough world market. In 2015 BSW produced over 2.2 Mio tons with two EAFs, leading to tap-to-tap times in average of under 40 minutes. Our philosophy has always been, that our most important success factor are the people: therefore we have to improve the working conditions as much as we can. Starting in 2012 Badische developed a robot that can support this goal. The first step was to use it for temp/sample taking, but the unit had to become a multi-tasker. Only 2 years later the first automated cartridge changer was installed at a customer site in Scandinavia, in late 2015 then the next tool was implement: tool changer allows now to use also a camera to check the condition inside of the heat after tapping. More tools are designed currently and will be implemented shortly. This paper describes the current installations and experiences as future applications.

Aug 17, 2017

By Andrea Taurino

Innovation means implementing a new product or a product that has undergone significant improvement over time, in terms of method, form and performance. Innovation encompasses all the scientific, technological, organizational, financial and commercial steps that need to be taken to put it into operation. Innovation combined with research and development makes it possible to perfect the product with consistency over time. Taking inspiration from the bases developed by the Austrian economist Joseph A. Schumpeter back in 1911, Danieli came up with the concept of “Innovaction” – a combination of Innovation and Action, to refer to the development and advancement of various products for the steelmaking industry, including the loop laying head for wire rod.

Aug 17, 2017

By Maurizio Massimo

Danieli developed the “3Q” suite of process control technologies to address three critical principles: delivering the highest product Quality, in the required Quantity, with Quickness of response required for today’s casting machines. Ever increasing market demands for productivity and slab quality necessitate the latest advances/improvements in equipment design, process technology, and control software for all types of slab casters, and Danieli boasts a unique experience that extends from ultra high-speed thin slab casters to extra high-thickness conventional slab casters. The “3Q” system is monitored and controlled by a unique, intelligent HMI incorporating. Touch screen technology and Operator Assistant tablets. Operator Assistant is a tablet based system that guides the operator through the plant process, so that in the event of a process change or an alarm the operator is automatically presented with the choice of possible solutions / actions. The comprehensive range of technological packages cover all aspects of caster design and automation control, from feeding of liquid steel into the tundish to the final slab leaving the caster.

Aug 17, 2017

By Gerd Weyand

Gontermann-Peipers GmbH (GP) Germany developed a new, high alloyed steel grade for the manufacturing of back-up rolls. The advanced GP double pour casting processes provide highest flexibility in being quite open in rolls work layer chemistry and hence microstructure with no influence on core respectively neck properties. GP took the process advantage to provide a brand new back-up roll grade with remarkably reduced roll wear while operating with textured work rolls. In the meantime several successful trials have been made with this new roll grade on different Skin Pass Mills. As a result the performance of back-up roll and thus availability of mill will be improved while specific costs for mill will drop. This quite new back-up roll grade has recently been launched. As next step increasing the field of applications is under progress.

Aug 17, 2017

By Raúl Daniel López

Ternium-Siderar steelmaking has been focused in permanent improvements and process optimization. At present the Slab Continuous Caster N°1 has been totally transformed after 20 years of uninterrupted work. The authors of this paper summarize and comment on aspects which were the main changes and place emphasis largely on those technological developments in which they have been active during that period. Productivity and quality have been our goals during the last 20 years; it has led us to improve process and to achieve better control tools. In the development of this presentation, the authors will put special emphasis on the explanation of those works that were made following their own experiences through the technical personnel who belong to the staff of the company.

Jul 30, 2018

By Levi de Oliveira Bueno

Constant stress testing was used for characterization of creep behavior of a 1Cr0.5Mo steel plate in the ex-service condition. The tests were performed on creep machines equipped with Andrade-Chalmers type profiles, high sensitivity SLVC transducer extensometry, high stability temperature controllers, and facilities for monitoring the creep curves with an automatic data logging system. Ten creep machines of this type were used in this research, in an experimental work that lasted for one year. Three temperature levels were selected: 538, 565 and 593°C, with stress in the range from 52 to 224 MPa producing rupture times varying from 5 to about 3950h. The creep curves were all followed with great scrutiny using data logger scanning rates which enabled storing thousands of readings in each case. The experimental analysis involved measurements of minimum creep rate, rupture time and final elongation at rupture. The data were analyzed according to the classical phenomenological / physical relations (Norton, Arrhenius, Zenner-Hollomon, Monkman-Grant) and also considering five traditional parameterization methodologies (Larson-Miller, Orr-Sherby-Dorn, Goldhoff-Sherby, Manson- Haferd and Manson-Succop). Comparisons are presented among the possibilities of data extrapolation from five different methodologies. Comparison is also made with creep results obtained on a similar plate of the same material in the virgin condition.

Aug 16, 2017