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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