2010Proceedings of the

Iron & Steel Technology Conference

Volume I

May 3-6, 2010

Pittsburgh, PennsylvaniaU.S.A.

.—

W ASSOCIATIONFOR IRON& STEEL

\^ JkU4lll*m<UI

Ronald E. Ashburn, Publisher

Christopher P. Brown, Graphic Artist

Carolyn A. Trobaugh, Production Assistant

Lisa C. Oldham, Technical Copy Editor

CONTENTS

AISTech 2010-Volume I

Author Index 1365

AIME Keynote and J. Keith Brimacombe Memorial Lecture

AIME Keynote and J. Keith Brimacombe Memorial Lecture: Visualizing the Future in ManufacturingC.Q. Zhou 1

SAFETY AND HEALTH/PROJECT AND CONSTRUCTION MANAGEMENT

New Techniques in Project Safety

Pre-start Health and Safety Review (PSR) — A Third-Party Independent Review Conducted at

the Start of the Project in Preparation for Certification Upon Conclusion

C. Dupuis 15

SAFETY AND HEALTH/MATERIAL HANDLING

Material Handling Safety Innovations

Your Employees Use Fall Protection, But Are They Really Safe From Harm?

A.T. Galpin 19

Safety and Material HandlingV.Cantrell 31

ENVIRONMENTAL/OXYGEN STEELMAKING

Energy and Air Pollution Control

Waste Gas Cooling Plants with Evaporation CoolingJ. Kasalo 35

BOF Gas Cleaning: Second Generation of Dry-type ESP and Hydro Hybrid Filter TechnologyJ. Adams, T. WUbbels, H. Ester, K. Schmale, M. Meyn 53

Opportunities for Increasing Productivity and Lowering Operating Costs While Reducing GHGEmissions in SteelmakingD.J. Zuliani, V. Scipolo, J. Maiolo, C. Born 61

ENVIRONMENTAL/ENERGY AND UTILITIES

Process Heat Recovery for Energy Cost Reduction

Improved Temperature Uniformity in Batch Reheat Furnaces With Praxair's Dilute OxygenCombustion (DOC) SystemL. Cates, L. Rosen 73

Steel Mills: Energy Costs and the Green Planet

S.P. Pisano, A.G. Fennell ?9

Flue Gas Flow Optimization for Energy Efficiency and Clean Operations in Integrated Steel

Plants

A.J. Basu, V.B. Dutta, M. Pei 89

Tenova FlexyTech® TRGX Burner Modeling and TestingM. Ageno, A. Delia Rocca, M. Fantuzzi, V. Battaglia, E. Malfa, U. Zanusso 99

Lowering Exhaust Gas Losses and Emissions With Newly Developed Recuperative and

Regenerative Burners

J.G. Wuenning • 11

The Mill Revamping of Chubu Steel Plate

T. Mikie, H. Masaaki, M. Shizuo 115

ENVIRONMENTAL/ELECTRIC STEELMAKING

Reduction of GHG and EAF Dedusting Systems

Utilization of Waste Plastics in EAF Steelmaking: High-temperature Interactions between Slagand Carbonaceous Materials

V. Sahajwatla, S. Kongkarat, P. Koshy, R. Khanna, M. Zaharia, N. Saha-Chaudhury, P. O'Kane,C. Skidmore, D. Knights 127

Recovery of Phosphorus and Manganese From Steelmaking SlagY.-S. Jeong, H. Kubo, K.. Matsubae-Yokoyama, T. Nagasaka 137

Clean and Efficient— Optimization of EAF Dedusting SystemsT. Rummler, T. Doninger, V. Knoth, J. Belous, G. Briceno 147

Optimization of Offgas System Performance at Hamilton Specialty Bar

M. Trapp, J.A.T. Jones, S. Matson 159

ENVIRONMENTAL/IRONMAKING

Iron making Environmental Technologies

Achieving Carbon-free Emissions via the ENERGIRON DR Process

P.E. Duarte, A. Tavano, E. Zendejas 165

Operation Results of the New Waste Gas Treatment Facility at ROGESA's No. 2 Sinterplant—the EFA Process

W. Hartig, F. Reufer 175

Low-cost Hot Metal: The Future of Blast Furnace IronmakingM. Geerdes, R. van Laar, R. Vaynshteyn 185

Environmental Benefits of Natural Gas Direct Reduction

J.T. Kopfle, G.E. Metius 193

Reduction of Blast Furnace Ironmaking Carbon Footprint Through Process IntegrationK.W. Ng, L. Giroux, T. MacPhee, T. Todoschuk 199

ENVIRONMENTAL

Resource Reduction and Air Pollution Control

Advanced Technologies for Residue Treatment — Successful Start-up of the PRIMUS® Plant of

Dragon Steel in Taiwan

1. Both, M. Houbart, J.-L. Roth 209

Ultra Low-NOx Flat Flame Burner Application for Steel Reheat Furnaces

J. Feese, F. Lisin 217

Addressing Climate Change —A Novel Greenhouse Gas Carbon Abatement Process (G-CAP1M)for the Iron and Steel IndustryS. Kumar, M. Freislich, D. Mysko, LA. Westfall, S. Bachenheimer 227

New Process and Application for Biogas in MetallurgyP. Santos Assis, M.E. Martins, A.L. de Oliveira Moreira, RA. da Silva Junior, T. Freitas Pipano 249

Vapor Pressure Measurements of Zinc and Lead Chlorides From Slag SystemY. Zhang, Z. Fu, Y. Wang, S. Li 255

New Zinc Recovery Process From EAF Dust by Lime Addition

R. Chairaksa, Y. Inoue, K. Matsubae-Yokoyama, T. Hiraki, T. Nagasaka 271

COKEMAKING

Technical Advancements in Cokemaking

Application of New Coke Oven Battery Technologies on the World Market

M. Reinke 283

Coke Oven Gas Desulfurization — State of the Art

T. NSthe, D. Schuster, H. Thielert 291

Effect of Blending Rangal Coal on High-temperature Behavior of Cokes

S. Gupta, B.-C. Kim, V. Sahajwalla 303

Study of the Use of Steel Industry Fuel on Coking OperationsS.J. McKnight, S. Thomas, E. Bengier, J. Bielich, T. Helinski 317

Battery Preservation

Influence of Wall Surface Unevenness on Coke-pushing Force

T. Nakagawa, T. Arima, K. Fukuda, S. Nomura, M. Sugiura, M. Sakaida, K. Kato 327

Heat Recovery Cokemaking Technologies

Comparison of Byproduct and Heat-Recovery Cokemaking TechnologiesP.S. Towsey, I. Cameron, Y. Gordon 333

Manufacturing and Characteristics of Modern Silica Brick Material for Coke Ovens

F. Brunk, U. Kochanski 345

Cokemaking Process Improvements and Repairs

Brick Rubble Removal From the Base of an On-line Battery Stack at ArcelorMittal Dofasco

B. Doleman, T. Maurice 351

The Design and Installation of a Video Camera Line-up System for Oven Machines at DTE

Energy Services, EES Coke Battery No. 5, Detroit, MichiganR. Shriver, D. Schweitzer 365

IRONMAKING

Blast Furnace Controls

The Gimbal Top Goes On-line, A New Era for Blast Furnace ChargingP.Whitfield, I.M.Craig 373

Analysis of the Economy and Emissions of Blast Furnace Operation With Top Gas Recycling

H. Helle, H. Ghanbari, M. Helle, F. Pettersson, H. Sax<5n 379

A New Architecture of Control and Operation Information System —PRM in the New Campaignof a Blast Furnace

J.-M. Chang 387

Raw Materials

Raw Materials for the Blast Furnace

C.B. Ray, A. Mukherjee, S. Chakraborty 395

Next Generation Sintering Technologies: Latest Developments to Achieve Real Cost-efficiency in

Sinter Production

A Fulgencio, C. Aichinger, E. Fehringer, H. Stiasny, J, Reidetschlager, S. HOtzinger 405

AHMSA's Blast Furnace No. 4 Operation with Low-grade Raw Materials for HighestProductivityR. Gil, 0. Villasana, W. Teubl 417

IRONMAKING/REFRACTORY SYSTEMS

Blast Furnace Equipment and Refractories

High-conductivity Copper in the Blast Furnace

T. Shellhammer, R. Walsh 437

Severstal L-Blast Furnace Hearth Refractories Findings and Repair at Sparrows Point

R.E. Fash, J.O. Barrett, R. Timmer, R. Hansen, F. van Laar, G. Ritterman, B. Stackhouse 453

ArcelorMittal Dofasco No. 2 Blast Furnace Stove RepairsD. Carreau, F. van Laar, G. Atlija 469

Reducing Refractory Cost Using New Al203-SiC-C Bricks for Hot Iron TransportP. Dejiang, H. Zhongyang, W.N. Porter, Q. Yu 481

Eddy-free Tuyeres for a Blast Furnace

A. MacRae 489

Tuyere Life Improvements and Operating Enhancements on Great Lakes B-2 Blast Furnace

S.E. Yaniga, W.P. Francis 499

IRONMAKING

New [ronmaking Process

SIMETAL Corex®: Prepared For Present and Future Ironmaking ChallengesC. BOhm, U. Schmidt, K. Wieder, W. Grill 509

Ironmaking Technology Selection for Site-specific Conditions

Y. Gordon, M. Freislich, J. Els 519

Utilization of Non-DR Grade/BF Grade Low-Fe Pellets for Direct Reduction and MeltingApplicationS. Mukherjee, P.P. Joshi 529

Blast Furnace Campaigns

JSW Steel No. 3 Blast Furnace: An Introduction to India's Largest Blast Furnace

M. Eden, C. Sharpe, C. Clark 541

The New TATA Steel "H" Blast Furnace: Design Concept, Project Development and OperatingResults

R.P. Singh, S.K. Roy, R. Cirelli, F. Fabiola, C. Castagnola 553

30 Million Tonnes in the Hearth of Blast Furnace No. 5 at AHMSA Mexico

F. Liceaga, G. Vidales, R. Mata 555

Advanced Inside-furnace Monitoring Techniques Implemented on the New Large Blast Furnace

ofShagangZ. Gao, J. Liu, T. Gao 565

Hot Blast Stoves

Don't Let Your Money Go Up the Chimney

P.M. Martin, M. Fletcher 573

The Future of Hot Blast Stoves

R. van Laar, J. Barel 587

Thermal Efficiency Optimization of the Hot Stove SystemP.-H. Lin, W.-T. Yau, J.-H. Tsai 597

Numerical Simulation of the Effects of High Radiative Coating on Heat Transfer Process in

Regenerator of BF Hot Stove

H. Zhou, H. Zhang, J. Wang, H. Bai, D. Li, Y. Wen, Z. Dan, Y. Zong 607

Injection of Fuels at Tuyeres

Development of a Virtual Reality Blast Furnace Package Using CFD

B. Wu, D. Ratko, R. Ren, Y. Hu, L. Jin, C. Q. Zhou 617

CFD Simulation of Co-injection of Plastic Particles and Oil Into a Blast Furnace RacewayM. Harasek, C. Jordan, C. Feilmayr, S. Schuster 629

Direct Injection of Biofuel in Blast Furnace IronmakingK.W. Ng, L. Giroux, T. MacPhee, T. Todoschuk 643

Proven Practice and Future Prospects of Blast Furnace Reductant InjectionJ. Plooij, D. Bergsma, E. Tesselaar 653

Combustion Rate Evaluation for Tires Blends Considering Their Injection Into the Blast Furnace

TuyeresB.C. Pinheiro, R.S. Assis Barros, P.S. Assis 661

IRONMAKING/COMPUTER APPLICATIONS

Blast Furnace Models and Studies

Numerical Investigation and Optimization of a Venturi Scrubber

B. Wu, D. Zheng, N. Chen, D. Lu, C. Q. Zhou 667

Physical and Mathematical Modeling of Transient Thermal and Liquid Flow Inside a Blast

Furnace Hearth During the Tapping Period

E.T. Bispo dos Santos, J.I. Gushiken, L.A. Wasem, C.A. da Silva, LA. da Silva, F. Mansur,

V. Seshadri 679

Burden Descending and Redistribution in a Blast Furnace

D. Fu, F. Huang, F. Tian, C.Q. Zhou 693

Characterization of the State of LKAB Experimental BF Hearth

L.O. Sundqvist, N. Eklund, J.-O. Wikstrom 701

Investigation of Related Factors of Blast Furnace Slag Fluidity and Its ApplicationJ.-S. Shiau, C.-K. Ho, S.-H. Liu 711

Development of Burden Distribution Technology at U. S. Steel Canada's Hamilton Works 'E'

Blast Furnace

Y. Zhao, J.C. Capo, S.J. McKnight, J. D'Alessio, K.J. Ferron, P.F. Badgley, Z. Gao, T. Gao 723

ELECTRIC STEELMAKING/ENERGY AND UTILITIES

Heat Recovery in Electric Arc Furnaces

New Approaches to Meltshop Offgas Heat RecoveryJ.A.T. Jones, P. Safe 735

Heat Recovery for the EAF of Georgsmarienhiitte, GermanyH. Schliephake, C. Born, R. Granderath, F. Memoli, J. Simmons 745

ELECTRIC STEELMAKING

New EAF Start-ups and EAF Revamping

Formation of an Impromptu EAF Process Team at CMC Steel Texas

B. VanderWaal, S. Matson, J. Jetkiewcz 753

/EAF® Technology: Recent Developments and Results at TenarisDalmine, ItalyP. Galbiati, P. Giugliano, V. Scipolo, S. Gillgrass, P. Clerici, M. Pustorino 761

Single Charge EAF Modification: Installation and ExperienceB. Butcher, Y. Krotov, B. Laroy, K. Vanover, S. Meyer 771

Start-up and Results of the EAF Consteel® Plant of Celsa Nordic — Mo I Rana (Norway)C. Giavani, M. Guzzon, F. Picciolo 783

EAF Foamy Slag in Stainless Steel Production: Industrial Experiences and Further DevelopmentJ. Reichel, L. Rose, J.K. Cotchen, M.A. Damazio, H.B. Loss, E.M. Pinto 793

EAF Chemical Energy and Process Control

Numerical Modeling of Scrap Heating by Burners

K. Mandal, G.A. Irons 801

Oxygen/Carbon Injection System at Charter Steel Cleveland Facility, Project Description and

Operational Results

R, Zeien, A. Mucci, M. Iacuzzi, S. Marcuzzi 811

Optimization Results at Ferriere Nord Using EFSOP® Technology

M Missio,N. Boin, M. Khan 819

EAF Optimization: Efficient Use of Energy in the Electric Arc Furnace

A. Wyatt, H. Fuchs, D. Kundrat, H. Schaefer 829

Jets in Steelmaking Units: The Source of Information About Physical and Chemical

Transformation Into the Steel Melt

0. Shlik 841

EAF Scrap, Steel and Slag Reactions and Modeling

Thermodynamic Modeling to Improve Foamy Slag Practice in the EAF

L. Trueba Jr., E. Schmidt, R. Corbari, M. Kan 859

Effect of Preheating Temperature on the Melting and Decarburization Behavior of DRI in

Steelmaking SlagE. Sharifi, M. Barati, M.D. Johnston 875

A Study on Supersonic Coherent Jet Characteristics Using Computational Fluid DynamicsM. Alam, J. Naser, G. Brooks 885

Kinetics of Reduction of FeO in EAF Steelmaking Slag by Metallurgical Coke and Waste Plastics

Blends

J.R. Dankwah, V. Sahajwalla, P. Koshy, N.M. Saha-Chaudhury, P. O'Kane, C. Skidmore,

D. Knights 895

Development and Improvement of New Technologies for EAF

Radiation Protection — An Investment for the Future

T. Doninger, T. Rummler, J. Belous, J. Apfel, P. Hansert 905

Robotic Solutions for EAF— First Performance Review

M. Abel, M. Hein, M. Huck, K. Pastucha, A. Priesner 913

Operational Benefits and Design Considerations for a Stationary Electric Furnace for Continuous

SteelmakingT. Koehler, K. Wallace, F. Wheeler, F. Atkinson, Y. Gordon, D. Rudge, T. Ma 919

ELECTRIC STEELMAKING/ELECTRICAL APPLICATIONS

EAF Power Control and High-Voltage Equipment

Asymmetrical Power Control of AC-EAFs by Structure-borne Sound Evaluation

B. Dittmer, K. KrUger, D. Rieger, T. Matschullat, A. DObbeler 937

Secondary System Mechanical Resonance in New Tall-shell SDI-Butler Arc Furnaces: Detection

and Solutions

R.E. Gerhan, Y. Krotov, N. Lugo 947

Fault Tolerant SVC ArcComp System for DC Arc Furnaces

S. Tambe, A. Kumar 959

Line Differential Protection Systems Using Low-power Current Sensors Applied to EAF Circuits

L. Kojovic, M.T. Bishop, T.R. Day, D. Sharma 967

The ArCOS Furnace Automation Concept— Much More Than a Simple Electrode Control

SystemC. Sedivy, C. Koubek, R. Krump 979

STATCOM for Powerful Flicker Reduction From Electric Arc Furnace OperationR. Griinbaum, A. Owens, M. Dahlblom, J.-P. Hasler, T. Larsson, L. Owen 985

OXYGEN STEELMAKING/COMPUTER APPLICATIONS

BOF Modeling and Process Control

Dynamic Modeling of the BOF for Endpoint Prediction Using EFSOP* Technology Results and

Implementation at Riva Taranto

A. Ceriani, G. Aprile, V. Scipolo, O. Davis, P. Clerici, M. Pustorino 997

Innovative Drop-in Sensor System at Essar Steel AlgomaK. Alshurafa, K. Ughadpaga, S. Briglio, S. Asam, R. Stone 1005

Cast in Time and Quality: Energy Savings Through Integrated Heat Temperature Forecast and

Scheduling Model

H.-J. Ponten, B. Kleimt, S. Grob, M. Heesen 1013

Time-based Scheduling System for Steelmaking and Continuous Casting Production

S. Kekec, M.C. Altigiil, H. Yildirim 1027

OXYGEN STEELMAKING

BOF Production and Processing

Avoiding Sloppy BOS Process Behavior

M. Bramming, B. Bjorkman 1037

Quick Direct Tap at United States Steel Corporation's Gary Works Q-BOP ShopY. Li, A. Monson, J. Novotny, R. Rote 1049

Production Improvement of No. 2 BOSP at ESAI

K. Ughadpaga, S. Briglio, G. Mohammed 1063

Experimental Remarks on Supersonic Jet Behavior in High-temperature, Reactive Ambient in

Connection to SteelmakingW.J. Mahoney 1071

Effects of Some Operational Parameters Upon Degasification Rate, Mixing Time, Splashing and

Skull Development in a Combined-blow Converter During Steelmaking Refining: A PhysicalModel ApproachL.P. Almeida, V. Maggioni, W.V. Gabriel, C.A. da Silva, l.A. da Silva, V. Seshadri 1081

Development of a Comprehensive Model for Oxygen SteelmakingN. Dogan, GA. Brooks, M.A. Rhamdhani 1091

SPECIALTY ALLOY AND FOUNDRY

Specialty Steelmaking

Strategies for Use of Superheated Steam During Steel Refining in Converters

C.-J. Rick 1103

Oscillation Measurement and Multiphase Flow Simulation of the AOD Process

H.-J. Odenthal, U. Falkenreck, E. Hovestaedt, E. Jipnang, M. Reifferscheid, D. Rosenthal,J. Schlueter, U. Thiedemann 1115

High-impact Computer Integrated Meltshop Management Systems — Effective Implementationwith Sustained Success

J.R. Middleton 1131

Cost Optimization in the Production of Stainless and Special Steels in the AOD Converter byUsing Oxidic AlloysK. Pastucha, J. Spiess, S. Dimitrov, C. Bruckner 1143

Operating Principle and Plant Design of the VD/VOD Facility at ThyssenKrupp Acciai SpecialiTerni (TK AST) for the Production of Superferritic Stainless Steel

J.K. Cotchen, T. Eichert, D. Tembergen, J. Triplat 1151

LADLE AND SECONDARY REFINING/REFRACTORY SYSTEMS

Refractories and Slidegates

Slidegate MythologyP.D. King 1163

Highly Durable Refractory Slide Nozzle Plate for Continuous Casting of Steel

Y. Uchida, M. Takenami, K.. Akamine, J. Yoshitomi, T. Kayama 1173

Improving Ladle Stir Reliability and Service Life Using New Design Purge PlugF. Wang, B. Liu, W.N. Porter, Q. Yu, T. Goodwin 1181

Increasing the Refractory Wear Profde Control on the Steel Ladles at V&M do Brazil

H.G. Asth, L.F. Silva, G.J. Cruz, G. Bastos, L.P. Almeida, R.S. Sampaio 1189

LADLE AND SECONDARY REFINING

Ladle and Secondary Refining Operations

Steel Liquidus Temperature Estimation From Thermodynamic Calculations

T.J. Piccone 1203

Thermodynamic Modeling of the CaF2-Containing Slags and Its Applications to SteelmakingProcess

I.-H.Jung 1211

On-line Monitoring of Ladle StirringX. Xu, G. Brooks, W. Yang 1221

Influence of Plume Eye Area on Surface Reaction Rate of Oxygen-water System Under Bottom

Bubbling Condition

N. Maruoka, F. Lazuardi, H. Shibata, S.-Y. Kitamura 1231

Degassers

Steel Degassing Operations Using Mechanical Vacuum Pump Systems

R. Gottardi, A. Partyka, S. Miani, M. Volpe 1243

Degassing 101

J.K. Cotchen 1253

Hydrogen and Nitrogen Control and Breakout Warning Model for Casting Nondegassed Steel

S. Abraham, S. Chen, C. D'Souza, J. Asante, A. Cook, G. Franco, K. Dunnett, S. Nafisi 1261

CONTINUOUS CASTING

CSP/Thin Slab Casting

Water Treatment Chemistry Impact on CSP Mill Product Quality and Production Rate

G. Gurley, J.S. Strasser, J.L. Hatcher 1275

Mold Flow Modeling of ArcelorMittal Riverdale and POSCO Thin Slab Casters

M.M. Yavuz, M.J. Cho, S.M. Lee, K. Neale 1291

Near-net-shape Casting of Steel— Belt Casting TechnologyJ. Schlueter, J. Wans, J. Bausch, H.-J. Hecken 1303

CONTINUOUS CASTING/METALLURGY —STEELMAKING AND CASTING

Beam Blank, Billet and Bloom Casting Innovations

Effect of Ladle Shroud Alignment on Steel Quality in a 4-strand Delta-shaped Tundish

K. Chattopadhyay, M. Isac, R.I.L. Guthrie 1311

Quality Improvement in Bloom for SBC Steel

T. Honda, D. Kaneko, S. Kurasako 1321

Mold Technology for the Future

A.N. Grundy, M. Hogenschurz, F. Kawa, B, Kttndig 1333

Advanced Revamping Solutions for Long Product CastingU. Zanelli 1343

Study on the Influence of Secondary Cooling Water Coverage Area of Bloom Surface on CoolingEffect in Continuous Casting of Gearing Steel

X. Zhang, Q. Liu, L. Meng, Q. He, Z. Dou 1353