JUSTech2011

Proceedings of the

Iron & Steel Technology ConferenceVolume II

2-5 May 2011

Indianapolis, Indiana

U.S.A.

Ronald E. Ashburn, Publisher

Christopher P. Brown, Graphic Artist

Carolyn A. Trobaugh, Production Assistant

Lisa C. Oldham, Technical Editor

TABLE OF CONTENTS

AISTech 2011-Volume II

Author Index 1377

COLD SHEET ROLLING

Cold Mill —Shape

Modeling Local Buckles and Predicting Limiting Values for Factors Causing Local Buckles in

Cold Rolling 1

Y. Liu, J. Fan, H. Zhang

Filtering Winding Effects From Control Systems in Cold Rolling Operations 13

J.L. Hinton, A.S. Malik, R. Grandhi

Improved Strip Edge Management and Shape Control Using Induction Work Roll Heating for

Light-Gauge Cold Rolling 25

N. Almstedt, D.C. Doerschuk, J.R. Fry

Reachability Conditions of Shape Targets in 20-High Cluster Mills 35

M.E. Zipf, C.K. Godwin

Recent Development of Skinpass Mill and Tension Leveler 49

E. Mukai

Pickling and Cold Mills

Automation and Drive Replacement for the CSN LLC Two-Stand Reversing Cold Mill 65

T.E. Richards, G. Sinders

Advanced On-Line Measuring Systems for Efficient Cold Strip Production 75

R. Holz, K. Hoen, W. Igelhorst, A. Kohlrausch

Improving Yield by Implementing an Automatic Slowdown Feature in a Cold Rolling Mill 87

E. Rodriguez, A. Demagistris

Technology Packages for Quality and Yield Improvement in Cold Rolling Mills 95G. Graessl, A. Maierhofer

New Power X-Hi Mill Technology for Stainless Steel and Silicon Steel Cold Rolling, and a Recent

In-Line Application 103

M. Landy, A. Mauuary, O. Lietar, E. Chaillot, J.-L. Legoupil, V. Cronier, H. Dagn, D. Hawkins

Hybrid Water Mist Extinguishing System for Pickle Lines Ill

F. Barstow, T. Euson

Roll Shapes

Determination of Corrosion Rates for Cold Rolling Coolant, Rolling Oil and Selected

Tramp Oils 115

M.A. Nicholls, X. Cheng, R. Taylor, Q.M. Springstead

The Roll Shop Simulator 127

A. Gurrieri, C. Trevisan

Transitioning from Bare, Chrome-Plated or Rubber Rolls to Thermal Spray Carbides/Cermets

and Laser Overlays 135M.S. Brennan

Fundamentals of Roll Cooling and Control ofFlatness at Primary Cold Reduction 141

D. Lloyd

Premium Quality Rails 155

L. Maestrutti, L. Gori

Continuous Anneal

Use of a Novel Biodispersant to Enable Strip Quenching After Annealing With Less Than OptimalQuality Water 165

J. Gleason, K.C. Willis

Baosteel Flatness Control System Used on 6-High Skinpass Mill in 2030 New Continuous

Annealing Line 173J. Xu, S. Li

COLD SHEET ROLLING/GALVANIZING

Flat Rolled Processing Equipment

New Developments and Technologies for Strip Guiding Applications 179

T. Domseifer, J. Fryn, S. Devorich

Manual to Automatic Packing: A Case Study at Uttam Galva Steel Limited (UGSL) 195S.G. Tudekar, T. Kolkka, J. Rajagopalan

Study on the Design Electromagnet and Pole Shoes for Flexible Steel Strip Shape and VibrationControl 213T.I. Jang, Y.H. Kweon, C.H. Jee, Y.S. Jin

GALVANIZING

Galvanizing — Importance of Steel Surface Interactions

New Continuous Hot-Dip Galvanizing Line DVL3 at Tata Steel, Netherlands 219

D. Cerrone, P. Podda, O. Lietar, A. Challaye

Influence of Annealing Process on the Selective Oxidation Behavior of Cold Rolled Dual-Phase

Steel 223K.C. Yang, T.R. Chen, Y.S. Hwang

PLATE ROLLING

Advances in Plate Rolling Technology

Integrated Roll Shops for Heavy Plate Applications 233

G. Boselli, D. Quaglia, I. Grataroli, M. Cozzi

Advances in Coil-to-Plate Stretch Leveling Line Technologies 243

M.F. Italiano, R. Mercer, E.S. Orzel, A. Waigand, R.W. Williams, H. Zhao

NISCO Plate/Coil Mill Level 2 Force Model Improvements 253

B. Li, P. Zhu, D. Wang

The Latest Technology of the Heavy Plate Leveler 265

T. Aoyama

Automatic Slab and Thick Plate Surface Inspection 275

S. Burkhardt, J. Erxleben, K. Buchanan

PLATE ROLLING/METALLURGY — PROCESSING, PRODUCTS AND APPLICATIONS

Metallurgical Advancements in Plate Rolling

New Analysis- and Simulation-Features of the Microstructure Monitor and First Results from

Plate Mills 281

H.-U. Loffler

Sustainable Plate Manufacturing 289

S. Haine, R. Thackray, M. Steeper

ROD AND BAR ROLLING

Rod and Bar Rolling Technologies

Cemented Carbide Rolls for Rolling SBQ Bars 297

S.-E. Lundberg

EcoStar — A New Generation of Cost-Saving and Long-Life Rollers 311J. Pflppl, G. Shan, H. ThOne, F.G. Wimmer

Expanding the Free-Sized Rolling Range After Introducing a New 3-Roll Technology 317

K. Kawakami, N. Suetomi, A. Hayashi, Y. Ogata

Best Practices to Implement Complete Revamping of Obsolete Plants 331

M. Capitanio, R. Migliorati

Rod and Bar Quality Technologies

Development of a Three-Dimensional Mathematical Model for Real-Time Simulation of

Continuous Reheating Furnace Operations 341

J.E. Jenkins, C.K. Tran, J. Ward, J. Broughton

Quality Improvement in Replacing Universal Mills and Changing Pass Schedules 353K. Miyagawa

Technological Innovations for the KOCKS 3-Roll Reducing and Sizing Block 361O. Dewald, G. Ullrich, M. Kruse

Quality Assurance Improvement by Remodeling Inspection-Line Layout 369K. Honda, M. Ohno, Y. Otagaki, K. Isogami

Danieli CMS-Condition Monitoring System 379

D. Brandolisio, R. Chiozza

ROD AND BAR ROLLING/MATERIAL HANDLING

Rolling Mill Material Handling

Bar Code Identification of SDI Bars 389D.L. Anderson

Live Tracking of Billet Inventory 399K. Normofidi

ROLLS

Roll Shop Practices

Study of Contact Fatigue Phenomena Influence on Backup Rolls Rolling Campaign Duration and

Grinding Operations 405M. Paura, A. Di Schino, D. Stocchi, S. Lionetti, M. Calderini, S. Neri, S. Locci, R. Coletti

Roll Safety Roundtable

Backup Roll Failures 413K. Marsden

METALLURGY— STEELMAKING AND CASTING

Metallurgical Technology at the Caster

Measurement of Spray Cooling Nozzle Impact Pressure Footprints and Its Applications in

Continuous Casting 423M. Penno, H. Yin, R. Moravec, K. Blazek

Development and Application of a Quantitative Tool to Assess Casting Behavior 433G. Torga, D. Gonzalez Atchabahian, J. Scoccia, C. Capurro, C. Cicutti

Fluid Flow Behavior Delivered to a Tundish via a Dissipative Ladle Shroud (DLS) 441K. Morales-Higa, R.I.L. Guthrie, M. Isac, R.D. Morales

Analysis of Mold Flow Structure at ArcelorMittal Indiana Harbor No. 1 Slab Caster 453M.M. Yavuz, J. Thacker

A Model for Slag Eyes in Steel Refining Ladles Covered With Thick Slag 463

K. Krishnapisharody, G.A. Irons

Analysis of the Continuous Casting's Stopper Rod Sticking 473

H.A.A. Lima, M.G. Rogana

METALLURGY— STEELMAKING AND CASTING/LADLE AND SECONDARY

REFINING/CONTINUOUS CASTING

Inclusions and Steel Properties, Inclusion Evaluation

Comparative Study of the Inclusion Size Determination by PDA-OES and Inclusion Extraction

Technique 481

M.M. Pande, M. Guo, R. Dumarey, S. Devisscher, B. Blanpain

How to Evaluate a Process for Clean Steelmaking and Quality Control 493P. Kaushik, H. Yin, H. Pielet, M. Lowry

The Effects ofNonmetallic Inclusions on Local Ductility 507

K.-I. Yamamoto, H. Yamamura, D. Maeda, Y. Suwa

Steel Defect Arresting Device (S-DAD) for Improving Steel Quality 517

D. Janssen, J. Simoes, P. Desai

Inclusion Engineering

Wettability and Mechanical Properties Assessment of Nano TiC>2 and Armco Iron System 529

Z. Amondarain, L. Kolbeinsen, J.L. Arana

Modification of Inclusion Composition in Steel During Secondary Metallurgical Ladle Treatment

— A Comprehensive Process Simulation Model 537

Q. Shu, O. Volkova, S. Lachmann, P.R. Scheller

Cleanliness Evaluation for 27SiMn Steels Produced by BOF—LF-^Billet Casting Process 549

L. Sun, L. Zhang, J. Li, A. Dong, Y. Chen, S. Yang

Development of Grain Refiner Alloys for Steels 559

C. van der Eijk, F. Haakonsen, O.S. Klevan, 0. Grong

Control of Inclusions During Steel Refining

Production of High-Strength Low-Alloy Bridge Steels 567

Y. Chen, J.S. Li, L. Sun, S. Yang, A. Dong, L. Zhang

Inclusion Characterization of Titanium Stabilized Ultralow-Carbon Steels — Impact of Oxygen

Activity at Deoxidation 575

C. Lyons, P. Kaushik

Calcium Treatment of Molten Steel With an Innovative New Calcium Wire: Hi-Cal® 585

V.J. Jackisch, C.J. Jackson, J.L. Emerick

Modification of Inclusions and Inclusion Engineering

Formation and Modification of MgO-AhOa-Based Inclusions in Alloy Steels 591

S. Yang, L. Zhang, L. Sun, J. Li, K. Peaslee

Decrease in MgO Content of Spinel Inclusions During Calcium Modification 607

N. Verma, P.C. Pistorius, R.J. Fruehan, M. Lind, H. Oltmann, E. Pretorius, M. Potter

Thermodynamic and Experimental Study on the Modification of Non-Metallic Inclusions

Through the Contact With CaO-Al203-MgO Slags 617

S.K. Michelic, M. Hartl, C. Bernhard

Inclusion Compositions Before and After Calcium Treatment Measured Using AutomatedInclusion Analysis Methods 627

N. Verma, P.C. Pistorius, R.J. Fruehan, M. Lind

A Laboratory Study of Factors Affecting Sulfide Shape Control in Plate Grade Steels 635

A. Dash, P. Kaushik

Effects of Calcium Treatment on Magnetic Properties of High-Efficient Nonoriented Silicon Steel

Sheets 651

F. Zhang, G. Li, B. Wang, Y. Zhang

Control of Inclusions During Steel Continuous Casting

Formation of Intragranular Acicular Ferrite in C-Mn Steel by Ti-Al Complex Deoxidization ....661

C. Yang, M. Jiang, Z. Hu, N. Lu, X. Wang

Effect of Nozzle Clogging on Surface Flow and Vortex Formation in the Continuous

Casting Mold 669

S.-M. Cho, S.-H. Kim, R. Chaudhary, B.G. Thomas, H.-J. Shin, W.-R. Choi, S.-K. Kim

Process Diagnosis on ULC Steels Cleanliness and Redesign of the Tundish

at ArcelorMittal LC 681

R.D. Morales, J. Delgado-Pureco, R. Lule, S. Morales, F. Lopez

Surface Tension and Temperature Effect on Entrapment of Bubbles and Particles in Continuous

Casting of Steel 697

S.-M. Lee, S.-J. Kim, H.-G. Lee

Analytical and Numerical Approach for Inclusion Removal in the Continuous CastingTundish 705

H. Arcos-Gutierrez, J. de J. Barreto, S. Garcia-Hernandez

Fluid Flow and Steel Cleanliness in a Continuous Casting Tundish and Mold 717

S. Yang, L. Zhang, J. Li, F. Lu, K.D. Peaslee

METALLURGY— PROCESSING, PRODUCTS AND APPLICATIONS

Microstructural Characterization

Qualitative and Quantitative Techniques for Evaluating Manganese Segregation in Advanced

High-Strength Steels at ArcelorMittal Dofasco's No. 1 Continuous Caster 731

J. Sengupta, J. Casey, D. Crosbie, B.D. Nelson, G. Kladnik, N. Gao

Microtexture Evolution on Grain-Oriented Electrical Steel 741

M.-C. Tsai, Y.-S. Hwang

Mechanical Behavior

The Development and Manufacture of Ultrathin Cast Strip Steel Products With High Residual

Element Levels via the CASTRIP® Process 751

D.G. Edelman, P.C. Campbell, C.R. Killmore, K.R. Carpenter, H.R. Kaul, J.G. Williams,

W.N. Blejde

Grain Refinement of Austenitic Manganese Steels., 763

F. Haakonsen, J.K. Solberg, O.S. Klevan, C. van der Eijk

Thermal Processing

Model of Microalloy Precipitation During Continuous Casting and Refining 773

K. Xu, B.G. Thomas, M.S. Dyer, J.G. Speer, D.K. Matlock

Influence of V(C,N) Precipitation Potential on Recovery Annealing Response of MicroalloyedSheet Steel 785

J. Raines, D.K. Matlock, J.G. Speer, R.J. Glodowski

Direct Steel Sheet Production From Solid Pig Iron — Gaseous Decarburization of White

Cast Iron 795

J.-O. Park, Y. Sasaki

Slag Module for 3D Visualization of Ternary Phase Diagrams Tutorial 799

W. Zhao, H. Abramowitz, E. Johnsen, M.A. Roller

Product Metallurgy

On-Line Quality Data Warehouse for Metallurgy 811

V. Sklenar, V. Zitko, J. Knobloch, P. Cermak

Successful Development of a New Steel Product — Importance of Process Modeling and DynamicLogistics Simulation 819

S. Kumar, J. McGinty, V. Hernandez, S.-E. Lundberg

The Development of Wind Turbine Bolts Steels in China Steel Corp 833

S.-C. Lin, J.-F. Tu

ENERGY AND UTILITIES

EAF Energy Optimization

Realization of the Coexistence of Energy Savings and Environmental Measures in the EAF-

Concept ofECOARC 845

Y. Sato

Optimization of Reheat Furnaces

Rugged, Verifiable, In-Situ Oxygen Analyzers for Combustion Optimization in Steel Reheat

Operations 857

Y.H. Boltz, E.S. Boltz, D.B. Knight, K. Taylor

Recent Cost Reduction Developments in the Heating of Steel 863

S.J. O'Connor, A.G. Fennell

Control Method for Low Oxygen Concentration of Waste Gas is HSM Reheating Furnace 873H.-H. Cheng, Y.-L. Hsu, C.-M. Liao, T.-S. Huang, C.-H. Wang

Process Control and Automation Systems Advancements for Reheat Furnaces 883G.R. Hurd, E. Rodriguez, J. Kaufman, J. Ward, H.C. Wu

Energy Management

Identifying Energy Efficiency Opportunities for Steel Industry—The Production EnergyOptimization Concept 895

R. Steele, F. Mielli

The Challenge of Heat Recovery in Integrated Steel Plants 901

C. Born, R. Granderath

Strategic Energy/C02 Model for ArcelorMittal Burns Harbor 913A. Kirk, H. Pielet, M. Atkinson, H. Silva

Preparing Your Company for the Future Energy Management Systems Requirements Like ISO

50001 923

E. La Bruna, G. Zafred

ELECTRICAL APPLICATIONS

Sensor Systems

Wireless Technology — A Revolution in Temperature, Oxygen and Carbon Measurements in

Molten Metal 931

D.G. Janu, R.R. Rote, T.W. Junker

Development and Experience with In-Chain Caster Measuring Systems 943

R. Cowlishaw

Drives

Selection of Induction Motor Drives for Reversing Hot Mill Roller Tables 953

N.A. Price, P. Jackson, S. Kodama

Large-Capacity Motor Drives 965

R. Tessendorf, H. Hosoda, K. Fukuma, Y. Baba

Challenges in Reliable Electrical Testing of Rotating Machines 977H.W. Penrose

STATCOM for Maintaining Power Quality in a Grid Feeding a Steel Plant 983

R. Grtinbaum, J.-P. Hasler, A. Owens, J. Rasmussen

SINAMICS High-Efficiency Drive Technology for Rolling Mills 993

P. Bhooplapur, H. Wiechmann

COMPUTER APPLICATIONS

Software Applications

Automatic Slab Quality Grading Successfully Implemented at Continuous Caster at ShougangCorp., QianGang, in Three Months 1001

H.G. Peintinger

Integration of Automation Solutions of Casting and Rolling for Better Control

of Product Quality 1007

A. Mukhopadhyay, B. Sarler, A. Polo, M. Ometto

Integrated Steelmaking Plant Process Automation and Optimization 1021

J. Knobloch, T. Ochmann, T. Bartonek, L. du Preez, S. Fouche

Make-to-Stock Finish-to-Order: Responsive and Cost-Effective Steelmaking 1033

S. Wilson

Hot and Cold Rolling Applications

Surface Defect Detection Using 3D Imaging for Commercial Automated Surface InspectionSystem Performance Improvement 1041

B. Chen, L. Zhang, H.A. Long

New Edger with Optimum Automation for the Hot Strip Mill at ThyssenKrupp Steel Europe in

Bochum 1047

G. Schneider, D. Ehlert, T. Koch, M. Korzi

Comprehensive Strip Temperature and Microstructure Control Revolutionizes Hot Strip Mill

Automation 1051

K. Weinzierl, H.U. Lflffler, M. Rofliger, U. Houben

An Effective Interstand Cooling in Hot Strip Mill 1061

D. Hajduk, J. Knobloch, M. Raudensky

Legacy Systems — Upgrade or Replace?

Replacement of Mill Floor Data Collection System at United State Steel Corporation — Great

Lakes Works 1069

M. McCabe, B.J. Bonner

Advanced or Novel Automation Technology

Development of Next-Generation Level 2 Model as Metallurgical System 1075

B. Li, D.Wang, P. Zhu

PROJECT AND CONSTRUCTION MANAGEMENT

Project Facility Improvements

Mill Bay Crane Runway 110T-120T Upgrade 1087W.E. Vanni, J. Fong, C. Folkman, R. Brooks

What's New in Fall Protection, Hazard Analysis and Rescue Planning 1095A.T. Galpin

Modern Approaches and CFD Simulation in the Ventilation of Hot Process Buildings 1107S.U. Baltuch, E.G. Baltuch

International Sourcing of Ironmaking Plants and the New Approach of TKCSA for the

Management of Its Construction and Commissioning 1117H. Eichelkraut, J.T. Marins, P.C. Guillaume, B. Scheuer

Field Data-Based Mathematical Simulation and Optimization of a Complex Construction

Activity 1127J.P. Modak, D.K. Parbat, S.P. Mishra

Project Management Best Practices

Design of a Greenfield Integrated Steel Plant Using Dynamic Computer Simulation 1139

R.W. Sindrey, M. Patel

MAINTENANCE AND RELIABILITY

Maintenance Planning and Management

Protecting Intellectual Property — Patent or Trade Secret? 1147

A.T. Stein, J.F. Marsh, R.E. Gaum

Creating and Sustaining a Culture of Reliability 1157

R.K. Brooks, G.R. Hutto

The Weld Cladding of Foot and Top Segment Rolls to Improve Roll Life 1165

P. Collins, S. Hunt, D. Le Jeune

Mechanical

The Timken ADAPT Bearing for Slab Support Rolls in Continuous Casters 1175N.A. Los, J.H. Rhodes, G. Daberger

Rolling Mill Main Drive Spindles 1183

J. Mackel

Reliability Achievement Awards

Reliability Achievement Bronze Award: Spares Consolidation at USS-POSCO Industries 1193

T.D. Kuzmicky, M.T. Brevig

Reliability Achievement Silver Award: ArcelorMittal Burns Harbor Hot Strip Mill Achieves

Nearly $2.3 Million in Savings Through the World-Class Equipment Reliability Program 1203

S. Piech

Reliability Achievement Gold Award: Reliability-Based Approach to the Combustion

Process 1213

D. DaSilva, F. Blanco

Environmental, Energy Savings and Safety

Steel Process Fans — Energy Efficiency Upgrades: The Right Way, the Only Way 1225

D. Banyay

Electrical Maintenance Practices That Impact Safety 1229

M. Moore

MAINTENANCE AND RELIABILITY/LUBRICATION AND HYDRAULICS

Monitoring and Measurement

Test Methods for Hydraulic Media 1233A.K. Guven

The Future of Green Bearing Protection 1241

K.V. Wong

Application of the Intelligent Lubrication System on the 4300mm Heavy Plate Hot

Rolling Line 1251

D. Wang, P. Wang, Z. Ding, H. Zhao

Gearboxes See Double the Life by Replacing Conventional Recirculating Oil System 1263

K.J. Saxton, J.C. Vicari, J. Curto, R.P. Ellis, A.M. Minnick

REFRACTORY SYSTEMS

Refractory Technologies

Introduction of Slidegate Plate Technology Contributing to Reducing Environmental

Burden 1271Y. Shin, T. Iwaguchi, T. Fushimi

Mathematics Modeling of Thermal Shock in Refractory Linings 1279A.V. Zabolotsky

Optimum Lining Performance for Particular Process Slags in Metallurgical Vessels Supported byThermomechanical Modeling 1289M. Kirschen, R. Lanzenberger, B. Petritz, T. Prietl

Insulating Firebrick — Maximizing Energy Savings in Iron and Steel Applications ThroughProduct Selection 1299

A. Wynn, E. Magni, M. Marchetti, S. Chernack, C. Johnson

State-of-the-Art Cold Setting Working Lining Mixes for Tundish 1309R. Komanecky, B. Petritz, R. Sorger

MATERIAL HANDLING/PACKAGING, SHIPPING AND TRANSPORTATION METHODS

Material Handling Improvements

Enhancing Personnel Safety Through RFID Technology and a Personnel Safety System 1317

J.W. Franz

Environmentally Friendly Solutions for Coil Handling in Process and Storage Areas 1325

M.K. Baach

Designing SAFE Instruction: The Use of3D Animation for Safety Training In a Forklift SafetyModule 1333

S. Weppel

CRANES

Smart Crane Control — Improving Productivity, Safety and Traceability 1341

J. Rowe

Reduce Maintenance Time and Save Costs for Hot Metal Crane 1347

F.-T. Lin

Modern Crane Works Safety Technology 1355

I.L.A. Horst

Analysis of 30 Years of Using a Runway Beam 1367

J.G. de Araujo Silva, L.F. Loureiro Ribeiro