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By Pedro Henrique Vasconcellos Apipe

O objetivo do trabalho consistiu em estudar os modos de transmissão de calor existentes em um conjunto mecânico composto por um rolo de extração e mancais de contato rolante em decorrência do movimento de um tubo laminado sobre o mesmo na planta da Vallourec Brasil. A motivação para o estudo surgiu na avaliação de como os fenômenos térmicos presentes resultariam na distribuição de temperatura através da superfície do conjunto e qual a sua relação com a disponibilidade desse equipamento. Para isso a análise desenvolvida foi baseada no emprego da dinâmica dos fluidos computacionais (CFD), associada a imposições subsidiárias durante a definição das condições de contorno do problema. Como resultado a distribuição de temperatura através da superfície do conjunto foi determinada, sobretudo na pista interna do rolamento e na região na qual se encontra o sistema de refrigeração. Desse modo conclui-se que embora o sistema de refrigeração dissipe uma grande quantidade de calor a sua eficiência não é satisfatória. Fato esse descrito pela presença de temperaturas superiores as necessárias para a ocorrência do fenômeno de ponto de gota.

Jul 31, 2018

By Kátia Cristina Gouveia

O objetivo deste trabalho foi determinar a TTDF do aço ASTM A36 com diferentes graus de encruamento após ensaios de impacto Charpy, sob diversas metodologias. Não se notaram diferenças no comportamento do material quando se avaliam os valores de TTDF obtidos pela medição da expansão lateral dos corpos de prova, nem considerando o valor da TTDF na qual o material apresenta 50% de fratura frágil, usando as metodologias de avaliação visual das faces de fratura dos corpos de prova, embora os valores sejam divergentes dos valores obtidos pelos métodos analíticos. A avaliação das faces de fratura dos corpos de prova por microscopia eletrônica de varredura permitiu visualizar que nas regiões onde visualmente considerou-se que havia apenas fratura frágil, também haviam regiões típicas de fratura dúctil. Conclui-se que a metodologia mais indicada é aquela que considera a TTDF como a temperatura na qual a energia absorvida é a média dos patamares superior e inferior, pois é um método simples, de fácil reprodutibilidade e que melhor refletiu a tendência de comportamento do material nos diferentes graus de encruamento estudados.

Aug 7, 2018

By Igor Martins dos Santos

O nitrogênio waste, que é chamado assim por ser mais impuro, devido à existência de uma porcentagem aproximada de 2% mais de oxigênio no mesmo, utilizado exclusivamente no processo de “Slag Splash” na Aciaria, possui um contrato fechado de volume para fornecimento (7.000 Nm³/h, à pressão de 30 bar), o qual estava sendo utilizada aproximadamente a metade do mesmo (3.500 Nm³/h). Como no processo produtivo da CSA, é utilizado o nitrogênio de baixa pressão (16 bar) em grande quantidade (21.600 Nm³/h, sendo aproximadamente 5.600 Nm³/h acima do contrato de fornecimento), foi feito um projeto para interligar as duas linhas de nitrogênio através de aproximadamente 420 metros de tubulação, com sistema de controle integrado e analisador de oxigênio para garantir a concentração mínima de 1% de oxigênio no Nitrogênio de baixa pressão, devido à necessidade de algumas áreas. Nos primeiros seis meses após implantação, foi contabilizado uma economia de aproximadamente R$4.0 milhões (aproximadamente 3.100 Nm³/h de consumo).

Oct 30, 2017

By Daniel Hiroshi Taira Anese

O objetivo desse trabalho consiste no estudo do grau de sensitização do aço UNS S31803 envelhecido a 700ºC por ensaios de reativação potenciodinâmica de duplo loop (DL-EPR). Para isso corpos de prova do aço em estudo foram solubilizados a 1175ºC e envelhecidos a 700ºC em tempos entre 10 min e 360 h. Corpos de prova metalográficos foram utilizados para caracterização microestrutural que foi realizada por meio de técnicas de estereologia quantitativa a partir de imagens de elétrons retroespalhados e análises magnéticas usando o ferritoscópio. Os ensaios DL-EPR foram conduzidos em solução 2M H2SO4 + 0,5M NaCl + 0,01M KSCN à 30ºC em amostras polidas. Observou-se que o comportamento eletroquímico do aço UNS S31803 possui forte influência da microestrutura, já que o grau de sensitização (GS) aumenta com o aumento do tempo de envelhecimento, devido à formação de fases intermetálicas que empobrecem as regiões adjacentes em Cr e Mo.

Aug 7, 2018

By Rossana Bezerra de Azevedo Vasconcelos Seabra de Melo

O presente estudo apresenta um método de avaliação de desempenho de operadores nas análises químicas que caracterizam o minério de ferro. São eles: Ferro total (Fe), sílica (SiO2), alumina (Al2O3), manganês (Mn), fósforo (P) e perda por calcinação (PPC). O desempenho é avaliado em termos de precisão e veracidade. Estes dois indicadores primários são combinados num secundário denominado de indicador de “confiabilidade metrológica”. O método foi aplicado nos laboratórios da Mina (no estado do Pará) e do Porto (no estado do Maranhão) de uma empresa mineradora onde foi possível: 1) conhecer o desempenho de cada laboratório assim como conhecer o desempenho de cada operador; 2) identificar os pontos fortes (identificar o procedimento que leva a melhores desempenhos) e oportunidades de melhorias (atuar nas causas, capacitar); 3) equalizar a forma de executar cada uma das tarefas com as melhores práticas identificadas; 4) proporcionar oportunidade de desenvolvimento técnico dos profissionais envolvidos no processo. O desempenho neste indicador tornou-se critério avaliação de aptidão para executar análises.

Aug 2, 2018

By Carlos Martins Viana

Neste trabalho, foram sintetizados e caracterizados nanofios de prata que posteriormente foram usados para produção de uma tinta condutora cuja, caracterização elétrica foi medida através de valores de tensão versus corrente. A primeira fase do trabalho consiste na obtenção dos nanofios pelo método poliol. Nesta fase, fez-se uma análise da estrutura dos fios, com o objetivo de verificar a uniformidade (forma e tamanho). Para estudos da estrutura utilizou-se a microscopia ótica (MO) e microscopia eletrônica de varredura (MEV). Também utilizou-se a espectroscopia de Ultravioleta-Visível (Uv-Vis) para identificação dos nanofios no produto obtido. A segunda fase, consiste no desenvolvimento da tinta condutora, onde nanofios foram redispersados em uma mistura de solventes e CTAB em banho de ultrassom, para obtenção de valores de tensão superficial e viscosidade. Por fim, medidas de corrente contínua da tinta, permitiram a construção da curva tensão versus corrente, da qual se obteve o valor da resistência elétrica. Através da curva foi possível comprovar o caráter condutor da tinta e pela linearidade da curva, verificou-se que a tinta produzida é considerada um material ôhmico.

Aug 16, 2017

By Edgar Apaza Huallpa

Os aços inoxidáveis duplex (AID), apresentam em geral uma microestrutura composta de austenita e ferrita em proporções aproximadamente iguais. Para ter o controle dos processos de fabricação e desempenho é importante conhecer sua evolução microestrutural, devido à precipitação de fases intermetálicas como sigma (s) e chi (?), que causam grave deterioração das propriedades mecânicas do material. Neste trabalho foi estudada a evolução da fase sigma (s) durante tratamentos térmicos em temperaturas intermetálicas (800°C-900°C) de amostras do aço inoxidável duplex tipo SAF2205 (DIN 1.4462/UNS 31803). Foi observada uma gradual redução da intensidade do sinal do ruído de Barkhausen com o aumento do tempo de tratamento térmico, indicando uma redução na fração de fase ferromagnética. Para tempos de tratamento de 24 horas, o sinal de Ruído de Barkhausen está quase totalmente inserido dentro do ruído de fundo da medida, indicando haver uma fração volumétrica bastante reduzida de ferrita. Por meio da produção de amostras padrão para calibração, essa pode ser uma via de avaliação não destrutiva de componentes submetidos em campo a temperaturas nas quais se formam fases intermetálicas.

Aug 8, 2018

By Luiz Cláudio von Sperling Cotta

Os precipitadores eletrostáticos são equipamentos responsáveis pelo despoeiramento dos gases de processo que atravessam o forno de grelha móvel. O processo de sinterização no forno gera uma grande quantidade de particulado que são retidos por estes equipamentos, portanto têm grande importância no processo da Samarco e para qualidade do ar nas comunidades do entorno. A eficiência dos precipitadores é monitorada através da emissão de particulado no topo das chaminés. Neste estudo foram analisados os fatores elétricos e dimensionais que afetam a eficiência de despoeiramento e, portanto, os mecanismos que recolhem as partículas. Foi também avaliado o balanço de massas do equipamento e a capacidade de coleta de particulado de cada campo do precipitador eletrostático. Desta forma foi realizada a otimização do tempo entre batimentos de placas e ajustes lógicos para a diminuição de entradas de ar falso no precipitador. As ações resultaram em aumento da eficiência do funcionamento do equipamento, com redução do baseline de emissão de particulado. Resultados adicionais foram identificados através da redução de manutenção de válvulas duplas, maior controle operacional.

Aug 1, 2018

By Marcus Vinicius Laudares Mendonça

SMS calculates and improves tooth and flank profiles individually to realise a homogeneous pressure distribution over the complete load flank. With a tooth profile and flank profile according to AGMA, ISO or DIN standard the contact pressure varies along the load flank. To realize a homogeneous distribution of the contact pressure and to avoid a premature mesh, SMS improves the tooth profile and flank profile in three steps. First SMS is doing a preliminary calculation and design according ISO, DIN or AGMA standard, with safety factors based on more than 125 years of experience. Second SMS calculates and checks the local contact pressure at the load flank under consideration of shaft, gearing and housing deformation, as well as the bearing behaviour. Finally SMS calculates and designs an improved tooth profile and flank profile to receive a homogeneous contact pressure at the load flank. The result is an increase of the torque transmitting capacity of up to 30% of the SMS advanced gears with the same outer dimensions than traditional gears.

Aug 17, 2017

By Afonso Cardoso da Silva, Romeu Thomaz Viana Jr, Emanuelle Garcia Reis, José Herbert Dolabela da Silveira

The Gerdau Ouro Branco Mill, three years after the implementation of its new plate mill, has started to develop high complexity products. The plate mill’s learning curve has been increasingly challenging since products are being developed to their highest grades. This work aims to present the first results of the development of steels of the strength class of 510 MPa produced by TMCP (Thermomechanical Controlled Processing) followed by accelerated cooling. These results show the potential and advantage of the accelerated cooling process regarding to obtain products of high mechanical strength and high toughness, associated with a low equivalent carbon.

Oct 1, 2019

By Benito Barbabela Silva, Michel Garant, Mathieu Dubé

Pellets market challenging scenario has stimulated pelletizing experts to pursue innovative alternatives to process development in order to increase pellets competitiveness vis-à-vis sinter. When it comes to indurating process, pelletizing productivity is still limited and its OPEX inflated by the lower input of carbon into mixes due to quality impairment caused by magnetite formation in pellets core. This obstacle led to the rethinking of carbon distribution strategy within the green balls. To achieve such purposes, COREM through its precompetitive research program dedicated to its members, has proposed the layered pellets®, a two-stage balling technology. Balling in disc and pot-grate tests in COREM’s pilot plant were carried out to proof the concept, support the arising technology and evaluate its potential. According to first results, while CCS strongly improved, tumble and abrasion indexes as well dynamic LTD must be further investigated. Tests on four classes of equivalent carbon content pellets to evaluate layering strategy gave very good perspectives concerning the increase of productivity, and the reduction of fuel consumption and GHG emissions.

Oct 1, 2019

By Uwe König

Traditionally quality control of iron ore sinter, its raw materials and raw mixtures has relied on time-consuming wet chemistry. The mineralogical composition that defines the properties is often not monitored. XRD analysis in combination with Rietveld quantification and statistical data evaluation using Partial Least-Square Regression (PLSR) has been successfully established to determine the mineralogical composition and process parameters such as the FeO (Fe2+) content and basicity of iron sinter within an analysis time of less than 8 minutes per sample. Both methods take the full XRD pattern into account and can be simultaneously applied on the same measurement. In addition the Rietveld method was used to quantify the phase content of raw mixtures to monitor the composition of blending beds.

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 Rodrigo Fina Ferreira, Jacek Kolacz, Luciana Gois, Neymayer Pereira Lima

The recent developments on the sensor detectors together with the higher capacity of the machines, due the high-speed computing recent advances, have made possible extending the application in the mining industry. The use of x-ray fluorescence, x-ray transmission and radiometric sensor based sorting can selectively remove gangue minerals in different size fractions for different minerals. This paper summarizes the potential application of SBS for an iron ore in three size fractions aiming to increase the %Fe after the removal of particles with main gangue minerals associated. Pilot plant tests were carried out with samples of iron ore in different size fractions and different content of hematite and gangues. The use of x-ray transmission sensor showed the possibility to increase the %Fe from about 63% to above 68% for particles below 80mm and 45mm, after the removal of low density particles. The presence of fines on the feed affected the performance of the SBS X-rays transmission machine, especially for the fine fraction feed. The mineralogical determination, carried out to know the association between hematite and gangue minerals, and the density of the particles on the feed, can be used to preview the quality of products of the x-transmission sorting process.

Oct 3, 2019

By Emanuele Osto

In late 2013, the installation of the world's first application of a break-through technology for rail hardening was started at Baogang Iron & Steel (Group) Co. Ltd. in Inner Mongolia, China, one of world's leading rail producers. The "Injector Dualphase Rail Hardening" (idRHa+) system was developed by Primetals Technologies and Centro Sviluppo Materiali S.p.A. (RINA-CSM) a Technical Center headquartered in Rome, Italy. Baogang was a key partner, providing its large expertise of premiumrail producer, including its experience with existing offline technologies. With a design based on thermal, mechanical and metallurgical models, idRHa+ can apply customized cooling protocols, so to obtain the desired microstructure and hardness distribution across the rail head, with a high degree of accurateness and operation flexibility. idRHa+ can be installed in inline or offline configurations. During 2014, the system was successfully commissioned at rail mill #2 in the city of Baotou, Inner Mongolia, and entered the regular commercial production. This paper gives an overview of the key concepts behind idRHa+'s design, the progression of its commissioning and testing till the ramp-up to consistent industrial operation. Derived from idRHa+ research and experience, other water-cooling technologies are available for different applications such as: quenching & tempering of medium-large sections, control of distorsion of merchant bars, quenching of stainless grades for improving the resistance to corrosion.

Aug 16, 2017

By Marcos Paulo da Silveira, Carolina Conter Elgert, Messias Prado de Almeida, Rafael Stella Galdino

Microalloyed steels have been intensely studied as an alternative to increase strength by grain refinement and/or precipitation hardening. Long steel products have a wide range of opportunities to apply well-defined principles of controlled rolling (CR) in order to increase strength and toughness with reduced costs. To evaluate the effect of microalloying elements as Nb and Ti with thermomechanical treatment, three conditions were tested: DIN 16MnCrS5 with hot rolling (HR), DIN 16MnCrS5 with Nb and CR and DIN 16MnCrS5 with Nb+Ti and CR. Austenitic grain size, obtained by direct quenching after rolling, has shown a decrease 32% with Nb addition, and 29% when Nb and Ti was added. Controlled rolling generated higher grain refinement and pancacked grains near the surface. When comparing ferritic grain size, controlled rolling plus niobium and titanium additions resulted in significant reduction of 35%. Yield strength increased 15% with microalloying and CR and more than 270% in impact toughness, even at -40°C.

Oct 1, 2019

By Sander Mul, Michael Brandner, Armin Paar

Graphitic HSS roll grades such as ESW’s brand VANIMO can be considered as the latest developments for the last finishing stands in hot strip mills. These roll grades are developed on the basis of the alloying concept of (Carbide Enhanced) Indefinite Chill work roll materials. During the development of VANIMO, the amounts and types of carbide forming elements were increased and adjusted into the direction of cast HSS roll grades. The microstructure of graphitic HSS roll grades therefore consists of tempered martensite, cementite and several different carbide types as well as a well-defined amount of free graphite. The main purpose of graphitic HSS roll grades is to combine the high surface quality of Indefinite Chill alloys as well as the high wear resistance of HSS roll grades. Several systematic steps were taken to increase the wear performance from Carbide-Enhanced Indefinite Chill grades to the more advanced VANIC grade and further on to the highest alloyed roll grade VANIMO. In every development step, the surface quality of the roll grades was carefully monitored. The decision to invest in new testing equipment at ESW’s plant was driven by the wish to see microstructural effects of different alloys in a macroscopic dimension. Usually samples are taken from cast rolls and investigation is done in comparably small areas compared to the total surface of a roll. Rolling of strip is done with the entire barrel, so effects of alloy and microstructure can appear anywhere on the barrel surface. To ensure better understanding and deeper knowledge about influences of alloying trials we decided to install the last version of LRI (Lismar Roll Inspection). LRI includes the latest technology of Eddy Current with an enormous resolution. Depending on the formation of carbide precipitations, carbide network as well as matrix and free graphite, the EC test can detect smallest differences. The possibility to analyze the different results of EC and UT surface wave inspection will be discussed. A few examples of surface effects in the mill application will be discussed and improvement strategies explained.

Oct 1, 2019

By Walter Valery, Kristy Duffy, Alex Jankovic, Peter Holtham

Hatch’s Mine to Process Optimization projects integrate mining and processing strategies, minimizing operating costs and maximizing overall profit. The methodology involves ore characterization, blast audits, plant surveys, analysis of historical data, and integrated modelling and simulation of mining and processing. Blast designs are tailored according to ore type and the downstream process is optimized for the changed feed. This approach has increased throughput and minimized costs for many operations worldwide. The implementation of this methodology at an iron ore operation that faced challenges with increasing mining strip ratio and ore body mineralogy changes is presented in this paper. The larger stripping ratio increased mining costs and constrained the run-of-mine (ROM) delivery to the process plant. Process performance was affected as the ore mineralogy shifted from predominantly hematite to include greater proportions of magnetite. The project objective was to minimize overall cost per ton mined and processed and maximize profit. Tailoring the blast designs according to ore type and process optimization increased the throughput of all process lines. This provided the potential to shut down one of the five processing line, aligning the mine and plant capacity and significantly reducing the processing costs.

Oct 3, 2019

By Hui-bin Wu, Rui Yuan, Yang Gu, Peng-cheng Zhang, Zheng-zhi Zhao

The corrosion behavior of three kinds of medium-Cr rolled steel pipeline steels in carbon dioxide collecting and transporting environment at different temperatures was studied. The results shew that the 5Cr sample was most affected by temperature. When the temperature rised from 30 °C to 90 °C, the corrosion rate increased from 0.12 mm/a to 1.87 mm/a, which was increased 15.6 times. The corrosion rate of 7Cr steel at 30 °C was similar to that of 5Cr steel. However, as the temperature increased, the corrosion rate rised slowly, increasing by 2.4 times at 90 °C. The corrosion rate of 9Cr steel was not obvious with temperature, and it was always below 0.06 mm/a. The thickness of the corrosion product film of the three samples gradually increased below 70 °C, and suddenly increased above 70 °C. This was related to the negative temperature coefficient of the solubility of FeCO3, and the thickening of the product film also affected the ion exchange of the cathodic reaction. An increase in the Cr content contributed to grain refinement and increased the proportion of the small-angle grain boundaries. More fine grains mean an increase in the total length of the grain boundaries, which could provide a diffusion channel for the free Cr element; on the other hand, the low-angle grain boundary structure was more orderly, with a lower free volume and lower interface energy. Under the combined effect of both, 9Cr steel and 7Cr steel had high volta potential and better corrosion

Oct 1, 2019

By Silvio Cecchini

State-of-the Art Mould Level Control Solutions for continuous casting applications face different challenges. On the one hand, technological phenomena such as clogging and unclogging, unsteady bulging or waving can create unpredicted meniscus disturbances by completely changing the casting channel geometry and the flow behaviour of liquid steel to the mould. On the other hand, from the viewpoint of caster operations, long lifetime, quick interchange-ability and integration capability into existing systems must be achieved. In the present contribution, the overall development of INTECO TBR’s mould level master – a comprehensive mould level control solution for all continuous casting applications – will be introduced. The basis for the presented system is a development over several years which includes investigations of all critical components such as shroud, stopper, stopper mechanism, servo actuator and mould level control program. These investigations finally resulted in a new-ly developed control algorithm for a highly dynamic servo actuator. The control algorithm with its basic functionality such as the prevention, identification and removal of clogging impacts with the associated automation functions to reduce their influence onto the overall mould level control performance will be presented. The scientific basis, the resulting control functions and their related automation implementation will also be illustrated. Finally, a patented control algorithm and control functionality for unsteady bulging and waving effects with the associated automation functions to reduce their influence onto the overall mould level control performance.

Aug 16, 2017