Technical Papers

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BRIMACOMBE MEMORIAL LECTURE

J. Keith Brimacombe Memorial Lecture

Steel Research — Then, Now and Tomorrow: The Brimacombe Lecture .................................................................. 1 Alan W. Cramb

SAFETY & HEALTH

Safety Improvements & Innovations

Pilot Testing of Fire Protection in Extremely Corrosive Industrial Duct Environments ........................................... 11 David B. Fuller, Paul Su, William W. Doerr, J.C. Harrington, Jon M. Barna

Supporting Environmental, Health and Safety Programs Through a Best-in-Class CMMS/EAM Solution ........... 19 Jeromy Risner

New Philosophy and Strategies for HMI (Human-Machine Interface) Between the Operators and the Machines ....... 25 Marco Capitanio, Roberto Migliorati

ENVIRONMENTAL

Air Pollution Control

Technical and Economic Evaluation of Slag Dry Granulation ..................................................................................... 35 Terry E. Norgate, Dongsheng Xie, Sharif Jahanshahi

Challenges for Modeling Compliance With Short-Term SO2, NO2 and PM2.5 Ambient Standards ........................ 47 Robert J. Paine, David W. Heinold

Technological Apparatus for the Moderation of Meltshop Off-Gas ............................................................................ 55 Gioacchino Nardin, Antonella Meneghetti, Maria Elena Fabiani

The New Frustum Canopy Hood for Steel Meltshops ................................................................................................... 63 Marco Peter Cudicio, Michele Manazzone, Stefano Miani, Riccardo Gottardi

Predicting the Performance of Carbon Steel EAF Dust Processing Technology — A Case History ........................ 71 Larry M. Southwick

How to Make the Plants of Today Comply With the Requirements of Tomorrow .................................................... 81 Christian Fröhling, Peter Hemmling, Jens Kempken, William H. Emling

ENVIRONMENTAL/IRONMAKING

Environmental Technologies in the Blast Furnace

SVAI Gas Cleaning Options — A Solution for Every Problem .................................................................................. 87 Ian M. Craig, Martin P. Smith, Barry Featherstone, Alexander Fleischanderl, Andreas Klugsberger

Evaluate and Model the Efficiency of a Blast Furnace Gas Cleaning Plant Using Computational

Fluid Dynamics: Geometry Optimization of a Gravity Dust-Catcher ....................................................................... 97 David Winfield, David Paddison, Mark Cross, Nick Croft

Measures to Increase Efficiency and to Reduce CO2 Emissions in Iron and

Steelmaking in Germany and Europe ........................................................................................................................... 109 Hans Bodo Lüngen, Michael Peters, Peter Schmöle

Brazilian Potential of Biogas Use as Fuels in Metallurgy ............................................................................................ 121 Máximo Eleotério Martins, Isabela Cristina Filardi Vasques, Nayara da Silva Lima, Paulo Santos Assis

OxyCup® Furnace Operation at TISCO, China .......................................................................................................... 127

Michael Lemperle, H.-Jaan Rachner, Ralf Jennes

ENVIRONMENTAL/ELECTRIC STEELMAKING

EAF Environmental — Dust & Dioxins

A Mathematical Model for Carbothermic Reduction of Dust-Carbon Composite Agglomerates .......................... 143 Yuki Kuwauchi, Mansoor Barati

EAF Slag: A Product No Longer a Problem ................................................................................................................ 153 Loredana Di Sante, Filippo Cirilli, Nicola Angelucci

Development of EAF Dust Injection Technology at Aichi Steel ................................................................................. 163 Akira Tsubone, Tsuyoshi Momiyama, Masanori Inoue, Naoto Saito, Kazuyo Matsubae, Tetsuya Nagasaka

State of the Art Treatment of EAF Dust ....................................................................................................................... 173 Lifeng Zhang, Liyuan Sun, Shengqian Wang

Dioxins Minimization and Control in an EAF ............................................................................................................. 183 Maria Ilaria Pistelli, Daphne Mirabile, Marco Scotto D’Antuono, Enrico Malfa, Nicola Angelucci, Silvia Tosato, Paolo Giugliano

ENVIRONMENTAL/OXYGEN STEELMAKING

BOF Steelmaking Sustainability

Numerical Modeling of Flow Into Primary Dedusting System of 130t Converter .................................................... 195 Breno Totti Maia, Bruno Orlando de Almeida Santos, Fabrício Silveira Garajau, Hugo Leonardo de Freitas, Jose Geraldo Torres, Marcelo de Souza Lima Guerra, Roberto Parreiras Tavares, Rudolf Huebner

How Upgrades in Makeup Quality and Treatment Program Dramatically

Improved BOF Hood Uptime/Caster Mold Reliability ............................................................................................... 207 Jim Gleason

Development of Roll Type Continuous Slag Solidification Process ............................................................................ 211 Yuki Hagio, Koichi Hayashi, Hiroyuki Tobo

Cradle to Cradle at CSC: Through Integrated Recycling System and Industrial Symbiosis .................................. 217 Kuan-Nan Lin

COKEMAKING

Coke/Coal Raw Materials

Incorporation of Charcoal in Coking Coal Blend — A Study of the Effects on

Carbonization Conditions and Coke Quality ............................................................................................................... 225 Ka Wing Ng, Louis Giroux, Tony MacPhee, Ted Todoschuk

New Findings From the DMT Small-Scale Coking Test Retort Regarding

Coke Quality and Coke Oven Wall Safety .................................................................................................................... 237 Drazen Gajic, Manfred Kaiser

Bi-Reflectance Mapping and Automated Petrographic Analysis of Metallurgical Coke ......................................... 247 David E. Pearson, Richard A. Pearson

Cokemaking Alternative Technology

Coke Without Coal: More Than Half-Century of Production in Argentina ............................................................. 253 Jorge Madias, Mariano de Cordova

Coke Battery Pushing Emission Reduction — Improvements in Transfer Car Design at

U. S. Steel Canada Inc. – Lake Erie Works .................................................................................................................. 263 John Benson

Combining New Coke and Ironmaking Technologies to Reduce the Carbon Footprint in the Production of Steel ..... 267 Marka Jansen, Ian Cameron

Characterization of Mixtures of Sugarcane Bagasse and Charcoal for

Injection Through Tuyeres of Blast Furnaces .............................................................................................................. 277 Pedro Henrique Macêdo Leles, Samuel Trindade Viana, Paulo Santos Assis

Cokemaking Process Improvements

Coke Making Process Improvements Through Culture Change and Total Process Reliablity .............................. 293 Michael D. Kwalton, Ronald K. Burnette, Paul A. Borders

Commissioning of 565 kg, 18-Inch-Wide Pilot-Scale Movable Wall Coke Oven at Coal Science Laboratories ........ 303 Patrick Ellis, Allen Ellis, Hardarshan H. Valia

U. S. Steel Canada Lake Erie Works Stack Burner Project — Increase Stack Draft and Coke Production ......... 317 Baoquan Zhang

Sopreco®: Single-Oven Pressure Control System Installed in the New

Coke Oven Battery No. 3 at the Zentralkokerei Saar GmbH ..................................................................................... 323 Giovanni Siri, Luca Parodi

COKEMAKING/IRONMAKING

Coke Quality & Alternatives

Wood Pellets for Ironmaking From a Life Cycle Analysis Perspective ..................................................................... 331 Ka Wing Ng, Louis Giroux, Tony MacPhee, Ted Todoschuk

Reaction Behavior of Ferrocoke and Its Evaluation in a Blast Furnace .................................................................... 339 Tetsuya Yamamoto, Takeshi Sato, Hidekazu Fujimoto, Takashi Anyashiki, Kiyoshi Fukada, Michitaka Sato, Kanji Takeda, Tatsuro Ariyama

Evaluation of Alternatives to Raise the Blast Temperature at Lean Blast Furnace Top Gas Operation ............... 347 Tamoghna Mitra, Kimmo Kinnunen, Henrik Saxén

High-Temperature Performance Comparison of Lump Coal, Coal Briquette and Coke Used as COREX Fuel ....... 359 Qian Hui, Peng Xin

IRONMAKING

Ironmaking Plant Projects

Design, Construction, Commissioning and Operation of the New Blast Furnace No. 6 at AHMSA ...................... 363 Jaime Pena, Ricardo Gil Diaz, Scott Davis

OneSteel Whyalla Blast Furnace Campaign Extension .............................................................................................. 375 R. van Laar, J. Tsalapatis

The New BLT® High-Performance Chute Transmission Gearbox — Results of the

First 18 Months of Operation at Rogesa’s BF5 ............................................................................................................ 385 Dave Berdusco, Walter Hartig, Guy Thillen, Emile Lonardi, Lionel Hausermer

Ironmaking Computer Applications

Improving the Ironmaking Process With Expert Systems in Closed-Loop Operation ............................................ 395 Angelika Klinger, Thomas Kronberger, Martin Schaler, Bernhard Schürz

Influence of Process Variables on Blast Furnace Operational Limits: Ternium Siderar Experience .................... 407 G. Cegna, G. Puertas, O. Lingiardi, R. Musante

Validation of the Numerical Model for Blast Furnace Shaft Process ........................................................................ 417 Dong Fu, Yan Chen, Taifur Rahman, Chenn Q. Zhou, Yongfu Zhao, John D’Alessio, Kyle J. Ferron

Continuous Monitoring of Liquid Level and Thermal State in the Hearth Based on

Measurement of EMF on the Blast Furnace Shell ....................................................................................................... 429 Michael A. Alter, Joseph M. Brunner, Daniel J. Holmes

Blast Furnace Operations

Reaction Analysis of Continuous Desiliconization in the Hot Metal Runner at Kobe No. 3 Blast Furnace ........... 439 Takamitsu Nakasuga, Sei Kimura, Naoyuki Uchida, Tsuyoshi Mimura, Rikizo Tadai, Kenji Ito

Influence of Preliminary Metallization of Metallic Burden on Blast Furnace

Process and Performance Parameters .......................................................................................................................... 449 I.G. Tovarovskiy, Y.M. Gordon, A.E. Merkulov

The Impact of Design and Operating Parameters on Skull Formation in a Blast Furnace Hearth ........................ 457 Yongfu Zhao, Louis W. Lherbier, Jr., Dong Fu, Yan Chen, Chenn Q. Zhou, John G. Grindey

Productivity of 3 t/m3/day Over the Last Five Years at BF5 AHMSA Mexico ......................................................... 471

Fernando Liceaga, Miguel Villarreal, Joaquín Flores

Taphole Clay for High Productivity Operation of a Blast Furnace ........................................................................... 481 Won-keon Kim, Soon-il Yoon, Sang-ahm Lee

Blast Furnace Raw Materials

The Iron Ore Market 2012 ............................................................................................................................................. 489 Joseph J. Poveromo

The Rate Determining Step of the Oxidation of Natural Magnetite Concentrates ................................................... 503 Hyeon Jeong Cho, Christiaan Pistorius

Value in Use of the Dunite .............................................................................................................................................. 513 Enrique Somolinos, Javier Martinez

Sintering of Indian Iron Ores — Technical Considerations ....................................................................................... 521 Chandan Barman Ray, Bhaskar Roy, Tushar Kanti Mandal, Subhas Das

Alternate Ironmaking

Classification of Fine Ores Regarding Their Reducibility With Tests in a Lab-Scale

Fluidized Bed Reactor and Petrographical Analysis ................................................................................................... 531 Michael Skorianz, Heinrich Mali, Friedemann Plaul, Johannes Schenk, Christoph Thaler

Selection of Ironmaking Technology for Existing Specific Conditions of European Part of Russian Federation ....... 543 Yakov Gordon, Michiel Freislich, Rick Brown, Mitesh Patel, Greg Traquair

Inhibition of Reoxidation of Direct Reduced Iron ....................................................................................................... 553 Jaleel K. Ahmad

Online Raft Control and High Top Pressure Control in Blast Furnace to Maximize Productivity ........................ 559 Susanta Pramanik

Ironmaking Computer Applications

New Concept of the Auxiliary Fuel Injection Tuyeres of Blast Furnaces Developed by Numerical Simulations ...... 563 Breno Totti Maia, Bruno Orlando de Almeida Santos, Paulo Santos Assis, Marcelo de Souza Lima Guerra, Fabrício Silveira Garajau, José Eduardo Mautone Barros

Advances in the CFD Modelling of Raceway Injections .............................................................................................. 575 Christian Jordan, Christian Maier, Michael Harasek, Christoph Feilmayr, Stefan Schuster

State-of-the-Art PCI Technology for Blast Furnace Ensured by Continuous

Technological and Economical Improvement .............................................................................................................. 589 Robin Schott

IRONMAKING/ENERGY & UTILITIES

Blast Furnace Energy & Utilities

A Sensible Route to Energy Efficiency Improvement and CO2 Management in the Steel Industry ....................... 605 Michael D. Lanyi, Jin Cao, Joseph A. Terrible

Energiron Direct Reduction Process: The Forefront Technology .............................................................................. 615 Annamaria Volpatti, Barbara Franco, Alessandro Martinis

Flexible Gas Mixing Station Design and Operation for Natural Gas,

Coke Oven Gas and Blast Furnace Gas Mixtures ........................................................................................................ 625 David Pekor, Ramon Garcia, Michael Spada

Improved Blast Furnace Stove Operation With the Use of Oxygen-Enriched Combustion Air ............................. 631 Kim Michelsson, Mark Geach, Tommi Niemi, Peter M. Martin

IRONMAKING/REFRACTORY SYSTEMS

Ironmaking Refractories

Reliability of Casthouse Refractory System at No. 14 Blast Furnace, United States Steel Corporation ................ 641 Du H. Lee, Kenneth B. Wing

Laser Measurement System for Refractory Linings in Hot Torpedo-Ladles ............................................................ 647 Rolf Lamm

Campaign Life Extension at ROGESA Blast Furnaces by Co-Injection of PCI and Titanium Dioxide ................ 655 Walter Hartig, Djamschid Amirzadeh-Asl, Dieter Fünders

ELECTRIC STEELMAKING

EAF Electrical & Utilities

Modernization and Upgrade of a Static Var Compensator for an Electric Arc Furnace Application ................... 665 Andrew Owens, Anders J. Persson, Rolf Grünbaum, Bo L. Johansson

Providing Secure Ground Protection for Electric Arc Furnaces During Inrush Conditions .................................. 673 Dennis Boyd, Trevor Saunders, Mark Lanier, Larry Wright

Power Quality Compliance With SVC PLUS ............................................................................................................... 683 Magnus Geijer, Wolfgang Hoerger, Wolfgang Meusel, Gordon Wong

Electrode Consumption in a Modern High-Power Electric Steel Shop ..................................................................... 691 Christopher R. Armstrong, Timothy L. Bosserman, Kale E. Heibult, Kyle W. Vanover, James J. Fortier, Nicolas Lugo

Reducing the Effect of Electrode Water Cooling on Electrical Stability in an Arc Furnace ................................... 705 Gian Carlo Gattoni, Gianantonio Bernardi, Ben Bowman, David Coudert

EAF New Technologies

New Generation in Preheating Technology for Electric Arc Furnace Steelmaking ................................................. 717 Knut Rummler, Akif Tunaboylu, Dogan Ertas

iEAF® Technology: The Use of Offgas Analysis for Carbon and Temperature

Prediction in Electric Arc Furnaces .............................................................................................................................. 727 Steven Gillgrass, Vittorio Scipolo, Doug Zuliani, Paolo Clerici, Michele Pustorino

Implementation of the Chemical Energy Control Module at Nucor Yamato Steel EAF2 ....................................... 735 Ismael Valdez, Omar Quintanilla, Guillermo Fernández, Eugene Pretorius

An Advanced EAF Optimization Suite for 420-t Jumbo DC Furnace at

Tokyo Steel Using DANIELI Technology ..................................................................................................................... 745 Ananya Mukhopadhyay, Robert Coughlan, Marco Ometto, Romano Sellan

Industrial Application of Chemical Energy for Special Steel Grades and Processes ............................................... 757 Alexander Grosse, Klaus Libera, Robert Eriksson

ELECTRIC STEELMAKING/ENERGY & UTILITIES

EAF Start-Ups & Revamps

Startup of the VSB Metalshop: The First Consteel® EAF in Brazil ........................................................................... 767

Luís Gustavo de Oliveira Amaral Mello, Francesco Memoli, Nicola Rondini

Successful Start-Up and Benchmark Operating Results of 100 t FastArc® EAF at Kosco, Korea ......................... 777

Damiano Patrizio, Alberto Pesamosca

Increase Production in the EAFs in Ternium Guerrero, Mexico: Strategies and Actions ....................................... 783 Hugo Solis Tovar, Juan Carlos Rodrigues Goncalves, Ricardo Santos Padilla, Marco A. Herrera G., Fabian Castro Uresti

Increasing Energy Efficiency of the Electric Arc Furnace at Tenaris-Tamsa .......................................................... 793 Fernando Martell, Rafael Mendoza, Armando Llamas, Osvaldo Micheloud

Operational Results of PTI Slag Door System for EAF .............................................................................................. 805 Val Shver, Jaroslav Brhel, Christopher Farmer

Waste Heat Power Generation from EAFs, SAFs and Reheating Furnaces — A Comparison .............................. 811 Carsten Born, Ralf Granderath

OXYGEN STEELMAKING

BOF Operational & Productivity Improvements

Latest Developments in Magnesia-Carbon Bricks ....................................................................................................... 821 Gerald Buchebner, Ashraf Hanna, Volker Samm

Experience With Long BOF Campaign Life and TBM Bottom Stirring Technology at Meishan Steel in China ...... 829 Zhao Guoguang, Rainer Hüsken, Jürgen Cappel

Improved BOF Tapping Practice at AHMSA Mexico ................................................................................................. 841 Ashraf Hanna, Kerry Servos, Juan A. Carreon, Sergio Zapata, Hector Rios, Mario Orona

Comprehensive Electrics and Automation Solutions for Brazil’s Most Modern Steel Plant ................................... 851 Rudolf Hubmer, Stephan Hofinger, Josef Weiss, Reinhold Leitner

BOF Liquid Steel Chemistry Control

Phosphorus Equilibrium Between Liquid Iron and CaO-SiO2-MgO-FeO Slags ...................................................... 861 Andre N. Assis, Richard J. Fruehan, Seetharaman Sridhar

Oxygen Steelmaking Furnace Alloy Model at United States Steel Corporation ....................................................... 871 Yun Li, Samuel M. Smith, Naveen Gupta

Desulphurization Strategies in Oxygen Steelmaking ................................................................................................... 883 Bu ra ener, Rianer Hüsken, Jürgen Cappel

BOF Blow Practices & Endpoint Prediction

The Increasing Importance of BOF Endpoint Control When Using Higher-Phosphorous-Containing Hot Metal ..... 897 Doug Zuliani, Salim Khouri, Vittorio Scipolo

New Standard Development for Blowing at the BOF Converter by Using “Catch Carbon” Practice ................... 909 Dione Araújo Moreira, Hudson Asth, Paulo César Lemes Almeida, Mirelle Oliveira Spindola, Igor Vieira, Ronaldo Santos Sampaio

Investigation of the Bath Flow in Q-BOP in Water Model Experiment .................................................................... 917 Kenji Nakatani, Futoshi Ogasawara, Takashi Yamauchi, Goro Okuyama, Yuichi Uchida

Steel Expert Takes Command — Optimized Performance on BOF Converter ........................................................ 925 Stephan Hofinger, Rudolf Hubmer, Stephanie Schütt

Improving BF-BOF Performance and Safety Using Tenova’s Slop Detection System Technology ........................ 937 Igor Todorovic, Vittorio Scipolo

SPECIALTY ALLOY & FOUNDRY

Specialty Melting & Casting Process

Oxygen Control and Its Effect on Steel Cleanliness During Electroslag Remelting of NAK80 Die Steel ............... 947 Cheng-bin Shi, Xi-chun Chen, Han-jie Guo, Hao Ren

Practice of Process for Steelmaking of MnCr Gear Steel by 100t DC-LF-VD-CC Flow Sheet ............................... 959 Zhong Ding, Jun Lin

Recent Trends and Technologies in Ingot Casting ....................................................................................................... 965 Christian Redl, Stellan Hammarqvist

Specialty Steelmaking Quality

The New Integrated Level 2 Meltshop Management System at Latrobe Specialty Metals .................................... 973 Thomas E. Kantor, Greg Dowling, John R. Middleton

Role of Slag Basicity on Thermodynamic Partitioning of Chromium and Manganese in Ferritic Stainless Melts ..... 987 David Kundrat, Allen Wyatt, Hagan Fuchs

AlN Formation in High-Aluminum Content Fe-Al Alloys ........................................................................................ 993 June Bott, Hongbin Yin, Seetharaman Sridhar

Aluminum Deoxidization of H13 Hot Die Steel Through Inert Gas Protection Electroslag Remelting ............... 1005 Fei Wang, Xi-Chun Chen, Han-jie Guo

LADLE & SECONDARY REFINING

Liquid Steel Processing

Free Opening Performance Under Longer Residence Time of Steel Ladle at ArcelorMittal IHE Steelmaking ..... 1017 Eraj Siddique, Xin Zhang, James P. McCloskey, Yong M. Lee

The Effect of Silicon on the Desulfurization of Al-Killed Steels ............................................................................... 1027 Debdutta Roy, P.C. Pistorius, R.J. Fruehan

Starting a Tool to Improve Efficiency in Complex Secondary Steel Refining ........................................................ 1037 Bruno R. Coelho, Gustavo F. Machado, Ronaldo S. Sampaio, Alice G. Miranda, Sérgio L.S. Costa

Development and Implementation of an Online Process Model for the Control of

Steel Chemistry and Superheat During Secondary Steelmaking ............................................................................. 1045 Kamalesh Mandal, Erik Miller, Dan Pierce, Pete Loomis, Justin Novotny, George Gurley, Mark Pole

Automatic Ladle Gas Coupling Systems ..................................................................................................................... 1055 J. Kevin Cotchen, Rüdiger Ralf Eggert

Vacuum Processing

Focus on Vacuum Degassing ........................................................................................................................................ 1063 Riccardo Gottardi, Adam Partyka, Stefano Miani, Marco Volpe

Improving Temperature Control at the RHOB ......................................................................................................... 1073 Qiujin Li, William Flanagan

Comparison of the RH and Tank Degassing Processes ............................................................................................. 1083 Dieter Tembergen, Thomas Eichert, Jan Meier-Kortwig, J. Kevin Cotchen

Slag Entrainment Behavior in the Vacuum Chamber of RH Degasser ................................................................... 1097 Fang Jiang, Guoguang Cheng

Operational Results of the Latest Vacuum Plant Installations ................................................................................. 1105 Andrea Pezza, Markus Abel, Michel Hein

Engineering Aspect and Results for VHD Technology .............................................................................................. 1115 Christian Redl, Matthias Pfennig, Johannes Obitz, Dieter Brück

LADLE & SECONDARY REFINING/METALLURGY —

STEELMAKING & CASTING

Ladle & Secondary Refining

Mathematical Model of Multiphase Flow in Argon Stirred Ladle and a

New Technique for Prediction of the Mixing Time .................................................................................................... 1125 Lucas Costa, Roberto Tavares, Bernardo Braga, Diego Lima, Helbert Lino

Interaction Between Gas and Liquid Phase in an RH Vacuum Degasser ............................................................... 1135 Fengsheng Qi, Liu Yang, Baokuan Li

Novel Modeling Concept for Vacuum Tank Degassing ............................................................................................. 1143 Vivek Thapliyal, Simon N. Lekakh, Kent D. Peaslee, David G.C. Robertson

Clean Steel

Transient Phenomena of Inclusions in Alloy Steels During the RH-VD-CC Process ............................................. 1151 Shufeng Yang, Lifeng Zhang, Qiangqiang Wang, Yongfeng Chen

Desulphurization of Liquid Steel in Ladle Furnace ................................................................................................... 1161 V. Hernandez, S. Kumar

Formation and Evolution of Inclusions in Al-Ti-Mg-Deoxidized Steel .................................................................... 1171 Ying Ren, Yongfeng Chen, Xiaogang Yang, Shufeng Yang, Lifeng Zhang, Xiaoming Ding, Jingshe Li, Shusen Li, Fenggang Liu

Improvement in Sampling Process Precision by Means of an Inert Atmosphere Sampling

System at ArcelorMittal Indiana Harbor East No. 2 Steel Producing ..................................................................... 1179 William Souronis, Paul A. Turner, Robert Rote

A Study of Ca-Modification Process in Al-Killed Steels ............................................................................................ 1195 S. Nafisi, J. Jordan, C. D’Souza, L. Collins, T.J. Drake

CONTINUOUS CASTING

Continuous Cast Internal Quality

In-Depth Analysis of Continuous Caster Machine Behavior During Casting With

Different Roll Gap Taper Profiles ............................................................................................................................... 1207 Nick Gregurich, Garrett Flick, Rudolf Moravec, Kenneth Blazek

Simulated and Experimental Study of Segregation in Continuously-Cast High Carbon Bloom Steel ................. 1221 T.A. Tran, R.P. Thackray

Characteristics and a Novel Quantitative Model of Macrosegregation in

Continuously Cast High-Carbon Steel Billets ............................................................................................................ 1229 Zibing Hou, Guoguang Cheng

A Review of the Rhomboidity Problem in Billet Casting .......................................................................................... 1241 Jorge Madias

Mold Powder Technology

High-Temperature Mold Powder Viscosity: Basic Experimental Procedure and Quantitative Analysis ............ 1251 Nathan J. Howell, Yong M. Lee, Hongbin Yin, Kenneth E. Blazek

A Novel Approach for Coupling Slag Infiltration to Metal Flow, Solidification and

Mold Oscillation on a 3D Model for Continuous Casting of Slabs ........................................................................... 1259 Pavel E. Ramirez Lopez, Ulf Sjöström, Peter D. Lee, Kenneth C. Mills, Björn Jonsson, Jesper Janis

Performance of Three to Five Poise Mold Powders With an Exothermic Addition ............................................... 1269 Dan Larson, Takayuki Suzuki, Asish K. Sinha, Elizabeth Borges

Kinetic Study of the Devitrification of Mold Powder Slags ...................................................................................... 1279 Yadira G. Maldonado, F. Andrés Acosta, A. Castillejos, Brian G. Thomas

Caster Process Modeling & Simulation

Calibration of Thermal Models of Continuous Casting of Steel ............................................................................... 1291 Lance C. Hibbeler, Melody M. Langeneckert, Junya Iwasaki, Inwho Hwang, Ron J. O’Malley, Brian G. Thomas

Continuous Enhancements of the Evraz Superheat Model Control for Slab Casting ............................................ 1303 Shaojie Chen, Colin D’Souza, Dave Evans, Kendal Dunnett, Jim Burns, Garry Sylvestre, Chris Cannon

Transient Turbulent Flow Simulation With Water Model Validation and Application to Slidegate Dithering ..... 1317 Rui Liu, Brian G. Thomas, Bruce Forman, Hongbin Yin

Thermal Stress Cracking of Sliding Gate Plates ........................................................................................................ 1329 Hyoung-Jun Lee, Seong-Mook Cho, Seon-Hyo Kim, Brian G. Thomas, Sang-Woo Han, Tae-In Chung, Joo Choi

CONTINUOUS CASTING/PROJECT & CONSTRUCTION MANAGEMENT

Caster Start-Ups, Upgrades & New Concepts

CSP® Flex — New CSP

® Concepts for Future Market Requirements ..................................................................... 1339

Christian Bilgen, Christoph Klein, Christian Klinkenberg, Jürgen Müller

The Evolution of the Thin-Slab Caster Concept: Latest TSC Technology to

Produce Over 330 t/Hour per Strand .......................................................................................................................... 1349 Andrea Carboni

Operational Results of the World’s Most Modern Bow Type Caster With Vertical Mold for the

Production of 355-mm-Thick Slabs for Demanding Quality Requirements ........................................................... 1361 Martin Hadler, Ewald Reisenberger, Andreas Eichinger, Christian Fürst, Johannes Unter, Peter Hodnik

Presentation of Innovative 250/350 mm Continuous Caster in Salzgitter ............................................................... 1371 Markus Schäperkötter, Peter Müller, Steffen Roßius, Christian Geerkens, Martin Becker, Holger Beyer-Steinhauer

Development of the High-Speed Thin-Slab Casting Technology of POSCO ........................................................... 1383 Byung-jin Min, Geon Shin, Sang-hyeon Lee

Siemens VAI’s WinLink® Technology ........................................................................................................................ 1395

Colombo Ezio, Zanelli Ugo

CONTINUOUS CASTING/MAINTENANCE & RELIABILITY

Caster Maintenance & Upgrade Concepts

Development of the New Sealing System on a Roller Bearing in a Continuous Caster Roll .................................. 1399 Kazuhiko Ohno, Kenta Izaki, Makoto Naito, Shinji Tanaka

Arvedi ESP — First Results and Business Cases ....................................................................................................... 1409 Andreas Jungbauer, Josef Lanschuetzer, Wersching Günther, Windner Georg, Bumberger Armin

New Developments and Versatility of EcoStar Roller Enhancements ..................................................................... 1417 Daryl L. Charlier, Jeffery K. Brower

Spray Cooling: Staying Cool in Hot Places ................................................................................................................. 1425 Stanley Smith, Troy D. Ward

Large-Diameter Slewing Ring Bearing Storage Methods: Comparisons and Cost Effectiveness ......................... 1439 Joseph J. Fitzgerald

Technological and Automation Upgrade for CSP® Plant TKSE Bruckhausen ...................................................... 1449

Wolfgang Gruber, Reinhold Leitner, Walter Pitzer

CONTINUOUS CASTING/REFRACTORY SYSTEMS

Ladle & Tundish Refractory Materials & Designs

Study and Application of Forsterite Dry Vibration Material for Tundish .............................................................. 1459 Minglian Gan, Yong Chen, Zhongyang He, Shifeng Song, Junfeng Lou

Dry and Inorganic Tundish Coating Refractory ........................................................................................................ 1465 William N. Porter, Kyösti Ruotanen, Dirk Pörzgen

MAG-QC — Tundish Metering Nozzle Quick Changer ........................................................................................... 1473 Vladimir Mathias de Abreu

Research and Application of Magnesia-Based Retaining Block of a Tundish Gas Curtain .................................. 1479 Hongtao Meng, Yun Wang, Zhongyang He, Yong Chen, Xingyuan Luo

Improvement of Ladle Slidegates ................................................................................................................................ 1487 Harukiyo Tokuda, Takashi Miki, Kenichi Harada, Koji Kawarada

Use of Dry Refractory Liners in Continuous Caster Tundishes: Characterization and Quality Aspects ............ 1497 Stelvio Buoro, Giorgio Romanelli

HOT SHEET ROLLING

Hot Mills — Upgrading for the Future

Hot Strip Mill — Streamlining for Increasing the Capacity and Improving Quality ............................................ 1507 Horst Janssen, Ernst-Ulrich Becker

Danieli Contributions to the Development of Thin-Slab Casting and Rolling Process: From

“First Generation” Plants to the Recent “World Record Breaking” Applications ................................................ 1511 Carlo P. Piemonte, Alessandro Pigani

Modernizations of the Beeckerswerth Hot Strip Mill for Manufacturing High Strength

Grades With Special Requirements ............................................................................................................................ 1517 Gabriel Kolek, Michael Bössler, Andreas Zaum

Increasing Productivity and Rolling Quality Through Optimized Mill Window Geometry ................................. 1523 Jochen Corts

HOT SHEET ROLLING/COLD SHEET ROLLING/ROLLS

Roll Gap Lubrication & Strip Profile

Improved Roll-Gap Lubrication to Reduce Energy Consumption and to Extend the Material Product Mix ..... 1533 Konrad Krimpelstatter

Effect of Non-Uniform Roll Cooling on Hot Bands Crown and Flatness in Finishing Stands .............................. 1537 E. Nikitenko

Increasing Web Speed and Eliminating Tracking Problems in an Electro-Tinning

Line With the PARALIGN Roll Alignment Report ................................................................................................... 1545 Chiu Yen Woo

Superior Profile Control Technology With Edge-Oriented Shifting ........................................................................ 1551 Tanehiro Kikkawa

HOT SHEET ROLLING/METALLURGY — PROCESSING, PRODUCTS &

APPLICATIONS/COMPUTER APPLICATIONS

Hot Rolled Product Quality & Improvements

Thermomechanical Simulation of Hot Rolled Q&P Sheet Steels ............................................................................. 1561 David B. Futch, Grant A. Thomas, John G. Speer, Kip O. Findley

A Strip Crown Model Based on the Finite Element and Response Surface Methods ............................................ 1569 Derek E. Slaughter, Thomas G. Ranger, James E. Atkinson, Christopher Backel, Robert Oldroyd

Real-Time Metallurgically Based Estimator of Microstructure and Tensile Properties of

Hot Rolled Strips On-Line Coil Quality Estimator (CQE) ....................................................................................... 1581 Maurizio Lubrano, Paolo Emilio Di Nunzio, Giovanni Zangari, Roberto Venturini

The Effect of Hot Mill Processing Temperature Variations on Final Coil Properties of Hot Rolled Steels ......... 1591 Michael J. Ryan, Stephen G.R. Brown, Peter J. Evans, Hiram Mullan

The Impact of Tapered Work Rolls in the Finishing Mill During Hot Rolling ....................................................... 1601 Mohammed Tahir, Jesper Holmberg

HOT SHEET ROLLING/ENERGY & UTILITIES

Fuel for Thought

Flameless Oxyfuel Slab Reheating Experiences ......................................................................................................... 1611 Anders Lugnet, Jonas Engdahl, Jorma Päätalo, Tony Palermo

Novel Application of Organic Rankine Cycle (ORC) Technology for Waste Heat Recovery

From Reheat Furnace Evaporative Cooling System .................................................................................................. 1625 Ahmet Durmaz, Ralph Pugh, aban Yazici, Kasim Erdo an, Abbas Kosan

CFD Modeling of Complete Reheating Furnaces ...................................................................................................... 1635 Valerio Battaglia, Enrico Malfa, Massimiliano Fantuzzi

Development of Compact Regenerative Burners in Hot Rolling Mills .................................................................... 1645 Motoki Takada, Koichi Taksahi, Toshiaki Amagasa, Tomoaki Tadama, Hiroyuki Nakashima

The Revolution in Heat Transfer Technology is Won, Forced Draft Burners Move Aside and

the Thermal Kinetic Energizer Now Takes Center Stage ......................................................................................... 1657 Carl Mörsner, Anthony Nathan

COLD SHEET ROLLING

Cold Mills & Equipment

Danieli Cold Mill Complex Turboflo® and Pickling Coupled to 6-High Mini Tandem

Mill for Automotive Applications ................................................................................................................................ 1667 Michele Turchetto, Tommaso Settimo, Luciano Vignolo

Pickling Line/Tandem Cold Mill With Electrical and Automation Systems From

SMS Siemag Successfully Commissioned at MMK ................................................................................................... 1673 Detlef Ehlert, Michael Bühren, Joachim Schaumann, Keshav Kumar Gaur

Automatic and Online Oil Film Monitoring ............................................................................................................... 1683 Klaus J. Peters

Coil-to-Coil Joining With Laser Welding in Particular for “Sophisticated Steel Grades” .................................... 1689 Ralf Wallmeyer, Manfred Neumann

Equipment for Product Features

A Method for the Determination of Shape Actuator Capabilities Envelopes in 20-High Cluster Mills ............... 1697 Mark E. Zipf

Multivariable Directions in the Improvement of Shape Actuator Performance ..................................................... 1711 Mark E. Zipf

Laboratory Evaluation of a New Method to Reduce Ridge Buckles in Cold Rolled Strip ..................................... 1727 Yuli Liu, Hui Zhang, Mike Levick, Ying Zhou

Mill Control Systems

On a New Slip-Stick Rolling Model With Non-Circular Roll Bite Containing Multiple Characteristic Zones ... 1739 Remn-Min Guo

Up-to-Date Cold Strip Production in Continuously and Discontinuously Operating Cold Mills ......................... 1749 Karl Hoen, Rüdiger Holz, Falk Töpfer

Development of Pass Schedule Software Using a Slip-and-Stick Non-Circular Arc Force Model ........................ 1759 Remn-Min Guo

New Rolling Method of Reversing Cold Rolling Mill ................................................................................................ 1771 Tanehiro Kikkawa

Pickling and Tandem Cold Rolling Technologies for Severstal North America in Dearborn, Michigan ............. 1781 Yoichi Kai, Mark R. Blankenau, John M. Tomasaitis, Larry Flowers, Motoyuki Fujii, Shunsaku Kasai, Toshihide Shinoda

GALVANIZING

Galvanizing of Advanced High-Strength Steels

Recent Trends in Hot Dip Galvanizing of Advanced High-Strength Steel at ThyssenKrupp Steel Europe ........ 1791 Martin Norden, Marc Blumenau, Rudolf Schönenberg

A Kinetic Oxidation Model for High-Strength Steel ................................................................................................. 1799 Young-Min Kim, In-Ho Jung, Suk-Kyu Lee, Jong-Sang Kim

Industrial Use of Pre-Oxidation During Continuous Hot-Dip Coating of (High) Alloyed Steels .......................... 1807 Marc Blumenau, Christopher Oliver Gusek, Martin Norden, Rudolf Schönenberg

Advances in Galvanizing Line Process Technologies

Strip Lateral Control With Electromagnetic Steering Device .................................................................................. 1815 Yusuke Ishigaki, Yoshiaki Nishina, Yoichi Yoshinaga

Development of Improving of Surface Qualities of Hot-Dip Galvanized

Product by Electromagnetic Strip Stabilizers ............................................................................................................ 1823 Yuichi Ozawa, Yoshiaki Nishina, Yusuke Ishigaki, Kazuhisa Kabeya

The New ThyssenKrupp-Laser-Welding-Machine at HDGL No. 7 ......................................................................... 1831 Clemens Trachternach, Gerhard Alber

Crack Initiation and Propagation of Galvanized Coatings Under Bending Loads ................................................ 1839 Yuttanant Boonyongmaneerat, Petch Jearanaisilawong, Suwat Ploypech

Review on Wiping: A Key Process Limiting CGL Productivity ............................................................................... 1847 Frank E. Goodwin, Michel Dubois

PLATE ROLLING

Moving Plate Rolling Forward

New Danieli Wide Plate Mill at Jiang Yin Xing Cheng Special Steel Works, P.R. of China ................................. 1861 Giorgio Ximeris, Emanuele Bozzetto, Enrico Crisà, William Tami

Elimination of Full Face and Edge Cracking in Hot-Charge Plate Rolling ............................................................ 1867 V. Hernandez, S. Kumar

Advanced Strategies for Leveling for High-Strength Heavy Plate Production ....................................................... 1879 Detlef Ehlert, Matt Korzi, Thomas Koch, Gerhard Horn, Roman Dehmel

State-of-the-Art Automated Ultrasonic Material Testing Systems, Modularity and Practical Applications ....... 1887 O. Ruzek, H. Ballmann

Research on Newly Developed Martensitic Stainless Steel Plate Used in Hydropower Station ............................ 1899 Liu Shangtan, Hu Junhui, Wang Qingliang, Huang Zheyi, Ji Renfeng, Shen Rong, Chen Qinping

PLATE ROLLING/METALLURGY —

PROCESSING, PRODUCTS & APPLICATIONS

Plate Products

Strengthening Mechanisms in Microalloyed Martensitic Plate Steels ..................................................................... 1905 Shane C. Kennett, Kip O. Findley

Development of TMCP Steel Plates for Hydraulic Supports Used in Mining Machinery ..................................... 1917 Xianying Xue, Haijun Chen, Hong Lei, Weizhao Song

Direct Heat Treatment After Hot Rolling of a High-Strength and High-Toughness Plate Steel ........................... 1923 Zhang Aiwen, Zhang Qingfeng, Jiao Sihai

ROD & BAR ROLLING

Rolling Mill Innovations

Innovation in Automatic Billet Conditioning Using Advanced Optical Surface Crack

Recognition System and High-Pressure Grinding Machines .................................................................................... 1933 Daniel Aegerter, Jan Gummersbach

Rod and Bar Mill Developments Over the Past Fifteen Years ................................................................................. 1945 T.M. Shore

Latest Improvements to Increase Reliability and Productivity on Multi-Slitting Processes ................................. 1957 Andrea Zanon, Tiziano De Giorgio, Emanuele Iogna Prat, Mauro Odorico, Renzo Pesamosca

50 m/s in Cooling Bed to Enhance Profitability in Rebar Production ..................................................................... 1965 Luigi Tambosco, Andrea Taurino

Another Step Foward to the Best Quality Wire Rod With Better Productivity and Higher Efficiency ............... 1971 F. Mulinaris, N. Redolfi, A. Taurino

Rolling Mill Advancements

Thermomechanical Processing for Quality Products in High Speed Rod Rolling Mills ........................................ 1979 B.V. Kiefer, W.P. Krejdovsky

Microstructure Simulator for Long Product Mills .................................................................................................... 1989 Michael Kruse, Matthias Schuck

Laying Head Upgrade ................................................................................................................................................... 1995 Robert E. Greuter

Non-Oxidizing Reheating Rotary Hearth Furnace .................................................................................................... 1997 Jim Feese, Felix Lisin

Rolling Mill Maintenance & Reliability

Protecting Bearings in Rolling Mills ........................................................................................................................... 2005 Howard M. Lockhart

Planning, Implementation and Commissioning of a Heavy-Duty 3-Roll Reducing and

Sizing Block at Republic Steel, Lackawanna, N.Y. .................................................................................................... 2019 David A. Boettger, W. Jürgen Ammerling, Sergio A. Filippini

An Integrated System for Minimizing the Downtime for Dimensional Changes in Bar Rolling Mills ................. 2033 Sven-Erik Lundberg

Comprehensive Control of a Reheating Furnace ....................................................................................................... 2053 Pavel Skopec, Jan Knobloch, Tomas Vyhlidal, Goran Simeunovic, Michal Svantner, Milan Honner

Flexible Groove Sequences for Hot Rolling a Number of Materials ........................................................................ 2065 Christian Overhagen, Paul Josef Mauk

Quenched and Tempered Bar ...................................................................................................................................... 2075 Jacob Selzer

PIPE & TUBE

Pipe & Tube Innovations

Lubrication of a Seamless Pipe Sizing Mill ................................................................................................................. 2083 James DiLonardo, Carl Kennedy

ROLLS

Roll Shop

Automatic Roll Loaders for Intelligent Roll Shops .................................................................................................... 2091 Giovanni Bavestrelli

Roll Shop Auxiliaries and Complete Roll Shops ........................................................................................................ 2101 Davide Quaglia, Francesco Auteri, Giovanni Boselli, Paolo Gaboardi

Advances in Roll Scanning Technology — A New Method for Eddy Current Defect Detection ........................... 2109 Robert A.C. Northern

Mill Roll Technology

New Roll Grinding Technologies for 20-High Cluster Mills ..................................................................................... 2117 Paolo Gaboardi, Giovanni Boselli, Mark E. Zipf, Michael Brewster, Claudio Trevisan, Thomas Andersson, Andrea Tognoni, Davide Quaglia

Development of New Materials Based on On-Site and Laboratory Evaluation Methods for

Understanding Work Roll Surface Degradation ........................................................................................................ 2129 Gisèle Walmag, Sébastien Flament, Jurgen Malbrancke, Geneviève Moreas, Mario Sinnaeve

The Production of Customer-Tailored ICDP Rolls by Using Alloying and Graphite Control Strategies ............ 2141 Michael Brandner, Alex Mayr, Tommy Nylen

Thermal Load and Fatigue of Rolls in Hot Rolling ................................................................................................... 2149 Jaroslav Horsky, Miroslav Raudensky, Tomas Luks

Cold Rolling of Metal Foils by Means of Ceramic Work Rolls ................................................................................ 2159 Christian Overhagen, Paul Josef Mauk

Fujico’s CPC/HSS Roll Performance at CMC’s Arizona Micro-Mill and in North America ............................... 2169 Gene E. Lee, Felix Lopez

METALLURGY — STEELMAKING & CASTING

Clean Steel & Inclusions

Activity of SiO2 in SiO2-Al2O3-CaO Slags in Equilibrium With Fe-Al Melts .......................................................... 2177 Jiwon Park, Seetharaman Sridhar, Richard J. Fruehan

Effect of S Concentration on Inclusions Entrapment in Solidified Shell ................................................................. 2185 Hiroyuki Ohno, Yuji Miki

Experimental Investigation Into the Influence of Ti on the Clogging of ULC Steels in Continuous Casting ...... 2191 Christian Bernhard, Guangmin Xia, Martin Egger, Andreas Pissenberger, Susanne K. Michelic

Assessing Inclusion Removal in a Steelmaking Ladle: Plant Assessment and Modeling ....................................... 2201 Angelo Máximo Fernandes Marins, Wiclef Humberto Vieira Martins, Carlos Antônio da Silva, Itavahn Alves da Silva, Joaquim Gonçalves Costa Neto, Varadarajan Seshadri

METALLURGY — STEELMAKING &

CASTING/COMPUTER APPLICATIONS

Modeling & Verification

Effect of Silicon on Hot Shortness ............................................................................................................................... 2213 Erica E. Sampson, Seetharaman Sridhar

Modern Approaches and CFD Modeling of Hot Process Building Air Induction Optimization .......................... 2225 Siegmar U. Baltuch, Edmund G. Baltuch

Model of Gas Flow Through Upper Tundish Nozzle Refractory and Initial Bubble Size ..................................... 2235 Rui Liu, Brian G. Thomas

Determination of Flow Instabilities Inside a Continuous Casting Mold by Particle Image

Velocimetry and Computational Fluid Dynamics ...................................................................................................... 2247 Carlos Vinícius de Carvalho, Luiz Flávio Pereira Costa, Luiza Pessoa Moreira, Gabriel Romeu T. Santos, Carlos Antônio da Silva, Itavahn Alves da Silva, Varadarajan Seshadri

Online Quality Prediction Based on Learning ........................................................................................................... 2259 Vladimir Sklenar

METALLURGY — PROCESSING, PRODUCTS & APPLICATIONS

Hot Rolled Products & Applications

Impact of Non-Polygonal Ferrite Microstructures on Technological Properties of CSP®

Processed Low-Carbon Micro-Alloyed Steels ............................................................................................................ 2269 Carl-Peter Reip, Ingo Schuster, Erich Hovestädt, Reinhard Flender, Matthias Frommert

Advanced Analysis and Quantification of Hot Rolled Strip Microstructures by EBSD ........................................ 2281 Matthias Frommert, Joachim Konrad, Carl-Peter Reip

Processing & Performance of Steel Products

Importance of Advanced High-Strength Steels and Electronic Units on the Recycling of Automobiles: A Review ... 2293 Kyle Bevans, Matthew Chott, Brandon Ensor, Jamie Fitzgerald, Stephanie Martin, Kent Peaslee, Scott Pisarik, Luke Walker, Matthew Wilson, Lifeng Zhang

Investigation on Composition and Processing Parameters of Cu/P-Bearing

Corrosion-Resistant Automobile Sheet ....................................................................................................................... 2305 Lu Zhixin, Luo Shinian, Tong Gang

The Induction Heat Treatment Process and the Materials Performance of DIB STAM 1470 .............................. 2317 Jui-Fan Tu, Shou-Chi Lin

Rolling Quality Under Your Control! How 2 Million Coils Fit Into Your iPad ..................................................... 2325 Hans Gerhard Peintinger

CONTINUOUS CASTING/METALLURGY — STEELMAKING & CASTING

Continuous Cast Surface Quality

Further Study of the “Blown Grain” Condition ........................................................................................................ 2333 Rudolf Miši ko, Martin Fujda, Sandra Fedáková, Dagmar Fedáková, E.S. Szekeres

Modification of the Microstructure in the Near-to-Surface Layer of

Continuously Cast Billets of Low-Carbon Steel ......................................................................................................... 2341 Jaroslow Marcisz, Bogdan Garbarz, Artur Zak

Improved Determination of the Effect of Alloying Elements on the Peritectic Range in Low Alloyed Cast Steel .... 2351 Robert Shepherd, Ingo Knopp, Heinz-Gunter Brass

Addressing Transverse Cracking Problem in Slab Casting ...................................................................................... 2359 S. Kumar, V. Hernandez

Caster Mold Sensing & Control

The Pulsative Electromagnetic Casting Technique for Slab Casting ....................................................................... 2373 Masahiro Tani, Kazuhisa Tanaka, Shinichi Fukunaga, Takehiko Toh, Masafumi Zere

Dynamic Argon Control ............................................................................................................................................... 2381 Bruce R. Forman, Yong M. Lee

Development of the Third-Generation FC Mold by Numerical and Water Model Simulations ........................... 2393 Hongliang Yang, Martin Sedén, Nils Jacobson, Jan-Erik Eriksson, Helmut Hackl

Radio-Frequency Sensor for Liquid Steel Level and Flux Powder Thickness

Measurements in Continuous Casting Mold .............................................................................................................. 2401 Franco Macci, Fernando Menchetti, Giuseppe Virone, Riccardo Tascone, Massimo Luni, Maurizio Zanforlin

New Concept of Ledge-Type Eddy Current Level Sensor and Practical Results at SSAB Tunnplat ................... 2413 Michel Dussud, Robert Johansson

ENERGY & UTILITIES

Energy Savings Practical Applications

Development of New Combustion Control System Based on Fuel Gas Humidity at Continuous Annealing Line ... 2421 Koji Iwata, Kenta Karube, Shinji Tanaka

ELECTRICAL APPLICATIONS

Electrical Safety & Upgrades

Electrical Arc Flash Safety and Risk Management ................................................................................................... 2427 Tim Cotter, Louis Hapeshis

Changes to NFPA 70E 2012 ......................................................................................................................................... 2433 James R. White

New Approach for Intelligent Motor Control Centers .............................................................................................. 2439 Terry L. Schiazza, Fabio Mielli

Energy Saving Drives for Hot Strip Mills ................................................................................................................... 2447 Ralph Pugh, Hasan Ramanli, Tayfun Altuntop, Serkay Özalici, Marcelo Lara

Sensor System Technologies

Overcoming Mechanical Issues in Obtaining Stable Length and Speed

Measurements in Steel Mills and Billet Caster Applications .................................................................................... 2459 Les Jensen

Synopsis of a Modern X-Ray Thickness Gauge ......................................................................................................... 2465 Jean-Jacques Florent, Jan Gaudaen, Roland Gouel

Study and Application of Cold Rolling Strip Walking Detection System ................................................................ 2479 He Jianfeng

Electrical System Improvements

Basic Concepts for an Integrated Steel Process Control System .............................................................................. 2487 Dave Hreha, Fabio Mielli

Effective and Flexible Rolling Mill Automation Upgrades ....................................................................................... 2495 Jens P. Riedel, Rainer Ohnmeiss, Helmar Jungfer

High-HP DC Drive Replacement or Digital Front End (DFE) Upgrade on Rolling Mills ..................................... 2503 Bob Hamlin, Ron Devoe

Application of Large Capacity Voltage Source Inverter to Cylindrical Rotor Synchronous Motor .................... 2507 Katsuhiko Fukuma, Hiromi Hosoda, Kentaro Suzuki, Thomas Richards, Gary Sinders, Marcelo Lara

Investigation of HAGC System Performance With Various Circuitry Design ....................................................... 2519 Remn-Min Guo, Tony Manias

Electromagnetic Devices for Limiting Currents for Starting Large Motor and Fault Currents .......................... 2531 Prafulla R. Deo, Tushar P. Shah

COMPUTER APPLICATIONS

Application-Driven Quality & Cost Improvements

The Development and Technology of the AIST Process Benchmarker (APB) ........................................................ 2539 Patrick J. Gallagher, Noah D. Wolf-Johnston

Innovation for Quality Assurance — Automatic Creation of QA Rules From Claims Data ................................. 2557 Norbert Holzknecht, Jens Brandenburger, Stephan Keil, Fredrich Luecking

MOREintelligence: An Innovative Multi-Dimensional Data Anaylsis System for Metallurgical Processes ........ 2565 Denis Cappellari, Ugo de Siervo, Gregory Guttman

Results of Foaming Slag and Scrap Meltdown Control SIMELT CSM/FSM Based on

Structure-Borne Sound in Electric Arc Furnace Operation ..................................................................................... 2577 Thomas Matschullat, Detlef Reiger, Björn Dittmer, Klaus Krüger, Arno Döbbeler, Helge Mees

COMPUTER APPLICATIONS/MATERIAL HANDLING

Material Handling Technology

The Case for the Eriez® CleanStream™ Process ....................................................................................................... 2591

Thomas Saccamozzone

Improved Converter Process Control ......................................................................................................................... 2595 G. Wimmer, M. Hiebler, M. Thumfart, F. Hartl

A Review of Emerging Trends in Mobile and Wireless Technology for

Maintenance and Reliability in the Steel Industry ..................................................................................................... 2605 Brian Hagaman

Benefits of Advanced Configuration and Simulation Study ..................................................................................... 2611 Teemu Kolkka, Jagannathan Rajagopalan, Juhn Suksi

PROJECT & CONSTRUCTION MANAGEMENT

Project Management Techniques

Conversion at the Luna Plant in ABS, Italy: 45 Days From Last Rectangle to First Round Bloom Cast ............ 2621 Nicola Santangelo, Luigi Morsut

The 2.3 Mt/Y Most Modern Production Facilities in the Mediterranean Area for

Flat Products at MMK Metalurji ................................................................................................................................ 2627 Alessandro Pigani, Luciano Vignolo, Carlo Piemonte, Paolo Burin

Project Management in the 21st Century Electronic Project Management ............................................................ 2633 Dominick DeSalvo, Peter Mansmann, Laura Goetsch, David A. Scotti

Comparison and Integration of the Ukrainian Project Life Cycle Process With a

Western Front End Loading Process .......................................................................................................................... 2647 Neil Tannyan

MAINTENANCE & RELIABILITY

Continual Improvement Ideas

Remote Operational Monitoring and Control of Auxiliary Process Units and Electrical Systems ....................... 2655 Michael E. Rourke

MORGOIL Bearing Technological Upgrade in TERNIUM-SIDERAR Hot Strip Mill ........................................ 2663 Andres Esteban, Gabriel F. Royo, Peter N. Osgood

A VPP Success Story: Making OSHA 10 Work for You ........................................................................................... 2671 Amber Norris, David Reinhold

Mechanical Condition Monitoring and Analysis Applications in the Steel Industry ............................................. 2675 Gabriel F. Royo, Ernesto Perez Rios

Reliability Achievement Awards

Reliability Achievements in the Steel Industries ........................................................................................................ 2685 Colleen Reeves

Reliability Achievement Bronze Award: Caster Hydraulic Pusher Table Cylinder Upgrade .............................. 2687 Bill Bennett

Reliability Achievement Silver Award: Improving Mill Performance Through Roll Shop Process Control ...... 2691 John E. Cox III

Reliability Achievement Gold Award: Gear Boxes See Double the Life by

Replacing Conventional Recirculating Oil System .................................................................................................... 2701 Kyle J. Saxton, Jason C. Vicari, James Curto, Richard P. Ellis, Ashley M. Minnick

Personnel & Technology Developments

Combined Utilization of Condition Monitoring and Real-Time Numeric Simulation for a

Condition Forecast Oriented Maintenance Strategy ................................................................................................. 2707 Karl Nienhaus, Christian Bernet, Markus Schütz, Ralph Baltes

The Performance Culture™ ........................................................................................................................................ 2715 Mark Broussard

Development of Intelligent Machine Condition Monitoring and Diagnostic System at CSC ................................ 2725 Chih-Chung Wang, Chung-Ho Kuo, Chen-Sen Ouyang, Chien-Wei Lee, Chun-Chuan Chao

Safer Lock-Out Tag-Out With Permanent Electrical Safety Devices — Electrically Safe

Work Conditions Based Upon NFPA 70E and OSHA .............................................................................................. 2735 Philip B. Allen

Development of Non-Destructive Crack Inspection Technique for Conveyance Roll Using Vibro-Thermography .. 2741 Yoshiaki Nishina, Daisuke Imanishi, Youichi Yoshinaga

New Ideas for All Areas of the Plant

EAF Equipment Redesign for Maximum Operational Performance and Extended Component Life ................. 2749 Robert Strain, Kirk Rounds

Maintenance Strategy Implemented in the New ThyssenKrupp CSA Plant in Brazil ........................................... 2755 Ricardo Pascotto, Dalber Da Silva, Clauduio Viana, Franz Kolmbauer, Klaus Stohl, Karl Trnka

Nip Pressure Measurement System ............................................................................................................................. 2763 Edward J. Schaming

Collaborative Mobile Maintenance Method for Reclaimer ...................................................................................... 2771 KwanHee Lee

LUBRICATION & HYDRAULICS

Lubrication & Hydraulics

Improved Gear Spindle Longevity in a Cold Reduction Mill Operation ................................................................. 2781 Dan Housel, John Kurosky, Tim Crimmins

Effective Lubrication Solutions for Steel Mill Equipment ........................................................................................ 2787 Nael Zaki, Anuj Mistry, James Sidow

REFRACTORY SYSTEMS

Steelmaking & Refractory Technology

The Technology, Benefits and Measurement of the ELBY™ Ladle Bottom ........................................................... 2795 Andy Toner, John Boeing, Jim Caprio, Albert Dainton

New Magnesia-Alumina-Carbon Brick Technology for Steel Processing Vessels .................................................. 2801 David E. Shewmon, Israel Peretz

Calcium Corrosion of a Zirconia Slidegate Refractory ............................................................................................. 2807 Javier Pascual, J.E. Shoff, Christoph Bauer, Martin Wiesel, Stacey Tate

The Longevity Technology of Refractory Linings of AOD Refining Furnaces in Baosteel ................................... 2815 Hebing Chi, Shi Lli, Donggang Li, Jihe Wei

CRANES

Crane Technology Improving Maintenance & Safety

Expert Operator Control for Increasing Safety, Productivity and Operability of Cranes .................................... 2821 Khalid Sorensen

Safer Vibration Readings of Overhead Cranes in a Steel Manufacturing Environment ....................................... 2829 George R. Kredel

Material Handling: Focus on Safety With the Customization of Lifting Devices and Plant-Wide Evaluations ...... 2835 John Novak, Kirk Rounds, Larry Arnold, Jim Davis

Extending Wireless Technology for Remote Control of Crane Brakes,

Equipment Monitoring and Encoder Feedback ......................................................................................................... 2847 Randy Creech