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Steel Alerts Vol.5 No.3
Steel Alerts Vol.5 No.3
STEEL ALERTS
Vol. 5 No. 3, 2008
The PIZO Process was developed for the upgrading of oxide materials from the
metals industry. This paper discusses the operation of a demonstration facility
while processing BOF sludge and EAF dust to produce zinc, iron and slag
products.
Two new cooling towers were started up at CSI using zero liquid discharge water
chemistry. The most significant benefit of the new technology is that cost savings
and performance were not at the expense of water conservation or environmental
protection.
Marcus N. Allhands
1
Iron & Steel Technology, Vol. 5 No. 4, 2008 pp 139-147
A new quench tower was constructed at Arcelor Mittal Dofasco’s No. 1 Coke
Plant, while plant operations continued in the same area. Safe construction of a
new tower required a reduction in coking rate to provide a window for
construction access, which presented the opportunity for major overhaul of some
older equipment and facilities.
In the fall of 2006, Corus IJmuiden’s No. 7 BF was stopped for a hearth reline and
several repairs. This paper discusses the decommissioning of the furnace and the
blow-in, as well as preliminary process results.
The use of oxyfuel technology at Ovako’s Hofors Works has led to increased
throughput, fuel savings and reduced emissions. This paper describes background,
solutions and results of Ovako’s oxyfuel reheating installations.
2
Due to the increasing costs of natural gas, pulverized coal, fed pneumatically to
the heat zone of existing reheat furnaces, has become an economical alternative.
Benefits include fuel savings, no significant increase in scaling or surface
inclusions, and easily controlled emissions.
Dr. R. K. Sinha
Developments in bar and rod mill equipment and mill layout designs continue to
provide rolling mill operators with new ways to improve productivity and product
quality. Advanced rolling equipment such as the Reducing/Sizing Mill, now being
applied to both rod and bar mill configurations, enables significant improvements
in mill utilization, while simultaneously enhancing the size tolerance of the
finished product and providing the capability to do thermo mechanical rolling for
metallurgical advantages. Other developments in the rolling line, such as high
speed guides, new water box cooling nozzles, high speed shears and intelligent
pinch rolls and new laying head features provide additional operational
improvements. Handling of the finished rod products after rolling through to
shipping has also benefited from equipment developments, such as ring
distributors, coil handling systems and coil compactors. For bar mills, new
3
cooling bed designs, along with stackers, bundlers and tiers provide for reliable
operations with improvements in productivity.
Although pure iron is a weak material, steels cover a wide range of the strength
spectrum from low yield stress levels (around 200 MPa) to very high levels
(approaching 2000 MPa). These mechanical properties are usually achieved by
the combined use of several strengthening mechanisms, and in such
circumstances it is often difficult to quantify the different contributions to the
strength. These results should then be helpful in examining the behavior of more
complex steels.
Like other metals, iron can be strengthened by several basic mechanisms, the
most important of which are:
. Work hardening
. Solid solution strengthening by interstitial atoms
. Solid solution strengthening by substitutional atoms
. Refinement of grain size
. Dispersion strengthening, including lamellar and random dispersed structures.
12. Modeling and Simulation of the Fluid Flow in Continuous Slab Casting
Mould
Fluid flow inside a continuous slab casting mould has been investigated using
both water model experiments and numerical simulation methods. First the k- E
model is used to obtain a time-averaged velocity field to learn about the basic
flow pattern; then the LES method is performed to analyze instantaneous flow
behavior. Simulation results have been compared and validated by experimental
data; Results show that flow patterns in the mould change with time, and that the
jet swing interacts with recirculation zones.
4
In casting the control model relation between casting speed and frequency plays
an important role in the optimisation of process parameters and the improvement
of lubrication condition. The mould friction between mould and strand can
directly describe the powder lubrication situation in a mould. In the present
research, based on the slab continuous caster equipped with hydraulic oscillators,
the transient friction forces were obtained by the differences between the
monitored driving forces of casting and the calculated driving forces of no casting
at same oscillation parameters. According to the trends of friction force with
different control models, the characteristics and disadvantages of the traditional
positive control model, and the improved positive control model and the inverse
control model are discussed. This experimental study contributes to studying the
frictional behaviour in mould under different control models, as well as selecting
reasonable control model for high speed continuous casing.
14. Effect of barite on mineralogical composition and structure of iron ore sinter
Barite containing iron ore samples were sintered in a down draft sinter pot aiming
at producing sinters having 0·5-5·5 mass%BaO. The influence of barite on
maximum sintering temperature, extent of sulphur removal and FeO content in
sinter was studied. Qualitative and quantitative phase analyses were carried out
using electroprobe microanalyser (EPMA) while the different developed phases
were identified with X-ray diffraction (XRD) techniques. The structure of sintered
samples was microscopically examined. In sinter, the extent of sulphur removed
slightly increases with BaO content up to 1·5 mass%, followed by a considerable
increase in 2·5 mass%BaO containing sinter. The sintering temperature decreases
with the increase in BaO content giving a maximum decrease in 2·5 mass%BaO.
The increase in BaO content up to 1·5 mass% slightly decreases the magnetite
content followed by a sharp decrease of 2·5 mass%. Barium ferrite was not
detected in sinters containing up to 1·5 mass%BaO and most of BaO was directed
to the slag. In 2·5 mass%BaO containing sinter, eutectic and needle structures of
barium ferrite solid solutions were developed. The eutectic structure decreased
while the needle structure increased in number and size of samples containing
>2·5 mass%BaO.
15. Experimental and operational thermal studies on blast furnace cast steel
staves
5
The operating conditions of cast steel staves at Masteel blast furnace have been
simulated to generate the temperature distribution under different operating
conditions. The influence of the temperature and velocity of cooling water as well
as the gas temperature of blast furnace on the temperature distribution of the cast
steel stave was obtained. The main cause of stave damage is discussed. The result
shows that cast steel staves possess better heat transfer ability and a lower
temperature distribution field than nodular cast iron staves, but their performance
is much less satisfactory than that of copper staves.
16. Characterisation of iron ore sinter and its behaviour during non-isothermal
reduction conditions
Egyptian iron ore sinter with low contents of barite (0·5 wt-%BaO) and alumina
(0·7 wt-%Al2O3) was prepared by the down draft sinter pot technique and
physically and chemically characterised. The sinter is mainly composed of
unassimilated hematite, precipitated hematite and magnetite phases and glassy
calcium silicate (slag). Manganese was concentrated in magnetite phase forming a
solid solution of 'magnetite-jacobsite spinel'. Calcium ferrites were not detected in
the sinter due to its low basicity (CaO/SiO2≈1). The sinter was non-isothermally
reduced with carbon using a heating up reduction technique with the facility of
following the high temperature phenomena during the reduction process. High
temperature properties were determined from the results of X-ray observations,
reduction rate profile and the gasification rate. The results obtained indicated that
the reduction of sinter started at 823 K, then at >1073 K and the reduction rate
increased due to the interaction between the carbon gasification and gaseous
reduction processes. The retardation reduction, smelting reduction and meltdown
of metallic iron phenomena occur at 1323, 1473 and 1680 K respectively, which
simulate the high temperature region of the blast furnace for iron production.
17. Sintering and heating reduction processes of alumina containing iron ore
samples
6
containing ≤1·5%Al2O3, SFCA was dissociated at higher temperatures to porous
magnetite and silicate melt. In samples containing ≥2·5%Al2O3, SFCA was stable
and its quantity increased with increasing alumina content. The non-isothermal
reduction of sinter samples was carried out using a heating reduction technique
with the facility of following up the high temperature phenomena during
reduction process. X-ray observations, reduction rate profile and the gasification
rate were used for the determination of high temperature properties of samples. In
the gas-solid reduction region, Al2O3 increased the reduction rate (RDR) at the
initial stage up to 1073 K and the RDR increases with increasing Al2O3 content up
to 2·5%. At >1073 K, the RDR was relatively slower due to the presence of
primary low melt slag containing alumina. For sinter containing >2·5%Al2O3, the
lowering in RDR and total reduction degree (TRD) starts to decrease with
increasing Al2O3 content as a result of the formation of SFCA phase which has a
good reducibility and as a consequence of the decrease in the quantity of the
primary low melt slag containing alumina. No more than 2·5%Al2O3 in the slag
results in a harmful effect on the high temperature properties while higher
alumina content in sinter leads to the formation of SFCA which improves the high
temperature reduction properties.
Twelve per cent chrome ferritic (non-stabilised) stainless steel cast at the
continuous caster at Columbus Stainless exhibited notable differences in the width
change between consecutive heats. The reason for these differences is related to
the fact that the steel is in a dual phase region between austenite and ferrite during
the solidification stages of the continuous casting process. A model was
developed and is currently used as a production tool to predict the width change
of a 12% chrome ferritic heat before it is cast based on heat composition. The
strand width is altered based on the model predictions by changing the secondary
cooling pattern. It was uncertain if the current model is the best suited for this
application and a study was carried out using different but more advanced data
mining techniques in an attempt to improve the existing model. It was found that
advanced data mining techniques could not improve the original rule based
model.
7
Geometric quantities of rolled products can be measured online in the
manufacturing process using laser measurement technology. Examples of laser
inspection systems, which are in routine use in rolling mills, their performance,
and the operational experience will be discussed. One to three-dimensional
geometric quantities are measured, such as the thickness of cold rolled sheets, the
cross-sectional profile of rails and flatness defects of heavy plates. The features of
the laser method will be compared to those of conventional measuring methods.
Precision and measurement capability achieved under production conditions will
be described.
21. Prospects for the Control of Solidification Structures from the Viewpoints of
Weld, Hot-workability and Near Net Shape Casting
8
investment casts were often found by the magnetic particle testing. It was
considered that the cracks were caused with this position being hot spots. The
cracking was improved by changing the size of sprues for molten steel not to hit
the corners to prevent hot spots. As a summary, for high alloys, solidification
process still depends on the way of try and error and experience base. Therefore
far more investigations are expected to predict how molten steels solidify
avoiding any defects and deterioration of every property.
In the chill zone of the alloy casting, many fine grains nucleate on the surface and
many dendrites grow their preferred growth direction. Therefore, it is rare that a
“typical” dendritic structure can be observed near the chill zone. Usually, the
solidified structure exhibits a quite complex pattern. In this study, the observed
shape of dendrite will be investigated. Using Al-20mass%Cu alloy, unidirectional
solidification with constant temperature gradient and growth velocity was
performed. Then the solidified structure was observed on a cross section, which
was intentionally inclined from the heat flow direction. The spatial relationship
between dendrite and plane for observation has been defined using three angles, θ,
φ and β. The solidified patterns were analyzed as a function of these angles. 3D-
CAD model for solidified pattern has been developed assuming that secondary
dendrite arms form plates. Solidified patterns agree quite well with 3D-CAD
model.
23. Relation between the Traces of Nucleation on the Surface and Grain in the
Condition of Continuous Casting of Steel
9
increased with increasing cooling rate. The effective nucleation ratio was defined
as the ratio between the number of grains and that of discs. The effective
nucleation ratio obtained was a few percent and indicated small dependence on
cooling rate in the range of this study.
24. Analysis of the Crystallization of Mold Flux for Continuous Casting of Steel
In continuous casting of steel, mold fluxes are used to prevent surface defects,
such as longitudinal cracks. The crystallization of mold flux promotes mild
cooling of the steel shell, but crystallization behavior has been still uncertain.
Therefore, this study has been carried out to analyze the crystallization processes
of mold flux. Mold flux used in this study has high tendency for crystallization.
Quenched specimens were heat-treated in various conditions and characterized.
Glassy specimen heat-treated in the electric furnace over 550°C for 180 min
crystallized. These crystalline were confirmed to be cuspidine by XRD analysis.
The number of grains decreased and the average grain size increased with rise of
temperature of heat treatment. The growth velocity also increased with rise of
temperature. In-situ observation by the laser microscope revealed that the glassy
specimen crystallized in a moment over 600°C and the surface of the specimen
turned to be rough. This may lead to mild cooling in the mold.
The Sn-10%Pb alloy has been solidified under the imposition of a direct current
and a static magnetic field perpendicular each other for the excitation of an
electromagnetic force in the local region of the sample to clarify the effect of
operating parameters on the solidified structure. The electromagnetic force
induced by the simultaneous imposition of the direct current and the static
magnetic field does not excite the nucleation in this investigation. And the
solidified structures obtained under the different intensities of the direct current
and the static magnetic field are compared each other for optimization of the
electromagnetic field in this process. Increase in the direct current is preferable
for the refined structure formation under the constant magnetic field intensity.
Under the constant product of the direct current and the static magnetic field,
refining effect of the solidified structure is the same level under the certain value
of the magnetic field. Over this critical magnetic field, the refining effect
decreases because the melt flow caused by the imposed electromagnetic force is
suppressed by the interaction between the magnetic field and the fluid motion.
10
26. Peritectic Transformation in Low Carbon Steels Containing High
Phosphorus Concentration
The effects of the addition of titanium and boron on the austenite grain refinement
in as-cast S45C carbon steel have been investigated and the results have been
discussed based on a Fe-TiB2 pseudo-binary phase diagram. The molar ratio of
the added titanium and boron was fixed at 1: 2 and the estimated molar percent of
the added TiB2 was varied from 0 to 0.5. The average austenite grain diameter
decreased from 1 900 to 250 µm as the TiB2 addition increased from 0 to 0.2
mol%, when the cooling rate was 0.02 K/s. The austenite grain diameter,
however, did not exhibit further decrease when the TiB2 addition increased from
0.2 to 0.5 mol%. The lower limit grain diameter of 250 µm was very close to the
secondary dendrite arm spacing, which was not affected by the addition of
titanium and boron. When the cooling rate of the molten steel increased, the grain
size and the dendrite arm spacing decreased. For all cooling rates, the lower limit
grain size was very close to the secondary dendrite arm spacing. Metallographic
observations revealed that one austenite grain included many dendrite arms when
titanium and boron was not added, while with the addition of these elements one
11
dendrite arm included several austenite grains having the dimension of the
dendrite arm diameter. It was suggested that TiB2 particles and other inclusions
such as TiC and Fe2B were formed in the inter-dendritic positions during and after
solidification and they controlled the grain boundary migration in the inter-
dendritic positions.
28. Evolution of Columnar γ Grain in Low Carbon Steel and Its Refinement by
Additional Elements in Thin Slab Casting Simulator
The evolution of as-cast γ grain in low carbon steel has been investigated using
thin slab cast simulator developed in NIMS (National Institute for Materials
Science). Fine columnar γ grain evolved from the surface to the center of the
ingot was obtained, and second dendrite arm spacing and γ grain size of the ingot
along with the distance from the surface showed a good agreement with those of
commercially produced 50 mm thick slab by a thin slab caster. Thus, we
succeeded to simulate the macro-structure and micro-structure of the thin slab
produced by practical thin slab continuous casting process. The γ grain size for
the present cooling rate of approximately 4 K/s showed a relatively good
agreement with the estimated value by the previously predicted line of
dγ=1.52T−0.5 for low carbon steels based on the Classical Grain Growth Model
(CGGM). Phosphorus, one of the typical impurities in steel, well known as the
strong b.c.c. stabilizer, was added to low carbon steel aiming at the refinement of
γ grain by the suppression of its growth. The γ grain size was drastically reduced
to about a half of normally cast one even with a little addition of phosphorus
lower than 0.05 mass%. It was probably caused by the retardation of γ phase birth
by the phosphorus segregation in the inter-dendritic region and the retardation of
completion of δ/γ transformation which leads to pinning of the γ grain growth.
The effect of crystal multiplication at the mold wall during casting process, so-
called “Big Bang” phenomenon, on the macrostructure of Al-Si alloy was
examined. Conventional casting experiments were carried out and the degree of
the crystal multiplication at the mold wall was evaluated by simulating the
macrostructures similar to the experimentally observed ones using a cellular
automaton method. The degree of the crystal multiplication decreased with
increase in superheat of the molten alloy at the pouring. The reason of this can be
12
attributed to the remelting of suspended crystals formed due to the crystal
multiplication by superheated melt.
31. Equilibrium Constants and Nitrogen Activity in Liquid Metals and Iron
Alloys
Jerzy Siwka
In the initial period of steel production with nitrogen as an alloy addition, from
among the three thermodynamic factors, i.e. chemical composition, temperature
and pressure, use was made of the first and the second factor only. Consideration
given to the third factor created conditions for the realization of the “old” idea of
steel ennoblement using nitrogen. An experimental setup for the investigation of
the equilibrium state of chemical reactions in the gaseous phase–liquid metal
system in the pressure range from 0.001 to 3.2 MPa and at temperatures not
exceeding 2423 K has been constructed and is presented in this paper. This setup
relies on the levitation metal melting technique, whereby the ceramic crucible is
eliminated and does not take part in the reaction phenomena. Intensive induction
mixing of the liquid metal and the rapid cooling of samples in the experiment
period provide the reproducibility of a given state through chemical analysis of
the frozen samples of metal. The solubility of nitrogen in liquid iron, chromium,
nickel, cobalt, vanadium and iron alloys in the pressure range 0.001 to 3.2 MPa at
various temperatures, was determined. The determined characteristics made it
13
possible to develop a thermodynamic model describing the solubility of nitrogen,
temperature and chemical composition in a wide range of variation of these
factors. The established nitrogen–nitrogen interaction reduces the effectiveness of
nitrogen introduced to the liquid steel.
33. Analysis of Drainage Rate Variation of Molten Iron and Slag from Blast
Furnace during Tapping
Despite its importance in practical blast furnace (BF) operation, the dominant
factors to control drainage rate or tapping time have not been well studied. In
most cases, short tapping time has been attributed to rapid tap hole diameter
enlargement. On the other hand, the experiential tendency about positive
correlation between furnace hearth bottom temperature and drainage rate has been
widely recognized.In order to examine the dominant factors to control the liquid
drainage rate or tapping time at BF, a simulative calculation model is introduced,
where the liquid drainage path consists of coke particles packed layer (coke filter)
and tapping hole and the overall drainage rate is determined as one of smaller
14
fluid rate in coke filter or tapping hole. For calculating the fluid rate in coke filter,
a hypothesis that liquid iron and slag in coke filter is driven toward the tap hole
entry point consuming the coke particles, whose extent depends on molten iron C
saturation degree and FeO fraction in molten slag, was introduced.
Increasing the Al2O3 content in the blast furnace slag, the blast furnace operations
tend to make troubles such as excess accumulation of molten slag in the blast
furnace hearth and increasing pressure drop at the lower part of the blast furnace.
So, it will be important to keep good slag fluidity at the blast furnace operations
such as, drainage of tapping and keeping good permeability.
In order to clarify the effect of high Al2O3 slag fluidity on the blast furnace, high
Al2O3 slag (20%) test operations of experimental blast furnace have been carried
out. Investigation results of the test operation are as follows;
1) Slag MgO improves the hearth drainage rate at high Al2O3 slag operation.
2) Permeability of the dripping zone is improved by decreasing slag CaO/SiO2, at
high Al2O3 slag operation of the blast furnace.
3) It was verified that the slag drainage phenomena were able to described by the
fluid model.
4) The optimum composition of high Al2O3 slag of the blast furnace is high MgO
and low CaO/SiO2.
Wall shear stress due to flow of the molten steel in the tundish is one of the factor
for erosion of refractory walls which decides sequence length of a tundish. The
flow-induced shear stress on the wall of a six strand curved type billet caster
tundish has been computed by a 3-D mathematical model. The location of
predicted peak wall shear stress was found to be same as observed in the plant
after a sequence. Different design parameters of the tundish such as wall
inclination angle, curvature radius, and tundish width are studied by analyzing the
flow-induced wall shear stress. The role of a pouring chamber is assessed with
respect to the wall shear stress. It was found that vigorous circulation around the
inlet stream from shroud plays a major role in deciding the extent of the wall
shear stress. Use of pouring chamber resulted in lesser wall shear stress than that
of a bare tundish. The peak shear stress was found to be decreasing as any of the
15
design parameters increased within a range. A modification in design parameter
of the tundish can reduce the wall shear stress, thus may help to improve the
sequence life of the tundish.
The effect of temperature on oxygen activity in steel was studied in plant trials
where temperature and oxygen activity were measured at two depths and at the
same time during different parts of ladle refining. The results show that large
temperature gradients exist towards the surface of the steel melt for the sampling
occasion when no slag is present on the steel surface, as can be expected. It was
also observed that the oxygen activity is higher in the lower measurement position
than in the upper during the majority of the ladle refining. This is explained by the
oxygen activity's temperature dependence. By using the data from this study and
previously reported plant trials it was shown that Si–SiO2 or Al–Al2O3
equilibrium controls the oxygen activity.
The mechanism by which crystallization of mold flux reduces the heat transfer
between the steel shell and the mold has been investigated from the viewpoint of
physical properties and characteristics of mold flux and air gap on the basis of a
heat transfer model involving conduction and radiation processes. It has been
found that, in mold fluxes for medium carbon steel, the reflectivity of the
crystalline slag layer formed in mold flux film is an efficient factor for further
reducing the total heat flux in the film. The heat transfer reduction based on this
finding would be possible according to the following mechanism: Crystallization
of mold flux film increases the reflectivity of the crystalline slag layer in the film
owing to enhanced scattering of light by introduction of crystal grain boundaries,
and thereby more radiation energy returns from the crystalline slag layer to the
steel, leading to reduction in the total heat flux across the film.
16
ISIJ Int., Vol. 48 (2008), No. 4 pp. 467-474
Low carbon steel was oxidized over the temperature range 1050–1250°C in O2–
CO2–H2O–N2 gas mixtures. The oxidation times were 15–120 min, and the scales
were 130–2000 µm thick. The experimental parameters were chosen to
approximate scale formation under conditions similar to those of reheating
furnaces in hot strip mills. In the hydraulic descaling tests, two modes of scale
removal were observed. In the first mode, observed in classical three-layer scales
that developed an inner porous layer with low or medium porosity, the horizontal
undercutting occurred at the boundary of the inner porous layer and dense scale.
The second mode was observed in classical three-layer scales that developed an
inner porous layer with high porosity, and in crystalline scales. In the second
mode, the horizontal undercutting occurred at the first plane of large pores
relative to the scale/steel interface. A rise in the concentration of free oxygen
resulted in an increase in thickness of the residual scale at 1050°C. At 1100°C and
1150°C, the increase in residual scale thickness with increasing free oxygen was
significant in the initial 60 min of oxidation; after this period of time the
differences in the thickness of the residual scale became smaller. At higher
temperatures, the influence of free oxygen in the residual scale thickness was
small at 1200°C and negligible at 1250°C. In general, the experiments showed
that scale morphology controlled the removability of scale.
It is well-known that the solute drag effect due to dissolved Nb and the pinning
effect due to NbC in Nb microalloyed steel cause retardation of the grain growth
during austenitisation and of the transformation during cooling. These effects
strongly depend on the austenitisation-temperature. But there is little numerical
research on both effects simultaneously so far. In this study the mobility
behaviour during austenite (γ) to ferrite (α) transformation was investigated by
phase field modelling, showing that the α/γ boundary velocity during cooling
increases with increasing austenitisation-temperature. These phenomena are
caused by both pinning and solute drag effects. The effect of pinning decreases as
the austenitisation-temperature increases because NbC dissolves with
austenitisation treatment at high temperature. On the other hand, the strength of
the solute drag effect is the highest for intermediate austenitisation-temperature,
where the α/γ boundary velocity during cooling is in the intermediate range, and
the strength is determined by the effects of both the concentration of dissolved Nb
atoms and the α/γ boundary velocity. These features are quantitatively discussed
from the simulation results.
17
40. Physicochemical processes with coal particles in liquid-phase reduction. I
The reducing agent used in slag melt is coal, which enters the melt at
temperatures of 1450–1500° C. The coal undergoes coking here, with heating at
30–50 K/s or more. The hydrogen, oxygen, and nitrogen in the coal’s organic
mass enter the gas phase, along with some of the carbon and sulfur. The
remainder of the carbon and the mineral components of the ash remain in the coke
residue and subsequently participate in the processes occurring in the bath:
combustion with the blast oxygen; and reduction by the metal oxides in the slag
melt.
A. E. Batraeva, E. N. Ishmetev
18
43. Kinetics of the two-phase zone of binary alloys, taking account of external
perturbations
T. B. Ibadullaev, V. A. Arutyunov
19
The mold is a key component of continuous-casting machines. It determines the
dimensions of the solidifying crust and the billet as a whole. The productivity of
the machine and the time between repairs depend on the working life of the mold.
Mold malfunctioning is most often due to wear and buckling of the working
walls, as well as unsealing of the joint between the wide and narrow mold faces in
composite molds. These factors are largely determined by the thermal operation
of the mold, which, in turn, is associated with the parameters of water cooling.
A. P. Krivenko, A. N. Levchenkov
O. G. Gorbunev, D. P. Kukui
In expanding the range of rolled products at existing mills, the product range
becomes more universal. At small-bar mills, the range is expanded to intermediate
and large bar; at intermediate-bar mills, the range is extended to small bar. With
decrease in profile cross section at linear mills, the lack of scope for further
extension of the grooves usually poses problems. In that case, the initial billet
cross section is reduced, and the number of passes in the cogging cell is retained;
this entails changing the groove configuration and the stock of rollers and
auxiliary equipment, and the productivity of the cogging cell is reduced. Another
method is to increase the number of passes in this cell, which again entails
modification of the roller grooves.
V. P. Piptyuk, S. E. Samokhvalov
Treatment of the intermediate product using a ladle–furnace unit helps ensure the
required quality of the steel produced. The growing use of such equipment
testifies to its flexibility and promise. However, it is clear from operational
20
experience, the results of foreign studies, and our research that the efficiency of
treatment in a ladle–furnace unit may be increased, along with the energy and
resource conservation in the process. Recommendations for optimization of ladle–
furnace technology must be based not only analysis and refinement of the
parameters but also on additional research.
49. Optimizing the coking coal employed at OAO NTMK to ensure competitive
CSR and CRI values of coke
A. V. Kushnarev, A. A. Kirichkov
The prediction of steel and coke production to 2010 proposed at the Fourth
European Coke and Iron making Congress (Paris, 2000) assumes that the smelting
of hot metal will increase from 500 million t in 1999 to 675 million t in 2010,
while coke production for this purpose will rise from 260 to 285 million t/yr.
According to the proceedings of the European Summit on Coke (Dusseldorf,
Germany, April 2006), hotmetal production has grown from 500 to 785 million
t/yr over the past 15 years, while the coke/hot-metal ratio has fallen from 0.72 in
1995 to 0.60 in 2005. Growth in world steel output is also expected to continue.
Of total steel production, blast-furnace and converter processes account for
65.3%, and electrosmelting for 31.8%. The dominant technology in steel
production involves coke production, a blast furnace, and an oxygen converter.
Accordingly, coke-free production (the Midrex, Corex, D 105, Romelt, and other
processes) are not likely to offer serious competition to blast-furnace production
in the first half of the twenty- first century. The blast-furnace process is constantly
being improved and still has great potential.
A. A. Butkarev, A. P. Butkarev
21
51. Growth kinetics of the ingot shell in the mold with pulsed-continuous cooling
22
TITLE INDEX
23
25. Mobility Analysis of the Austenite to Ferrite Transformation in Nb 17
Microalloyed Steel by Phase Field Modelling
26. Modeling and Simulation of the Fluid Flow in Continuous Slab Casting 04
Mould
27. New Developments in Bar and Rod Mill Technology 03
28. Numerical Simulation of Flow-induced Wall Shear Stress to Study a 15
Curved Shape Billet Caster Tundish Design
29. Online laser measurement technology for rolled products 07
30. Optimizing the coking coal employed at OAO NTMK to ensure 21
competitive CSR and CRI values of coke
31. Ovako, Hofors Works — 13 Years’ Experience of Using Oxyfuel for 02
Steel Reheating: Background, Solutions and Results
32. Pattern of Solidified Structure on the Inclined Observation Plane 09
33. Peritectic Transformation in Low Carbon Steels Containing High 11
Phosphorus Concentration
34. Phosphorus distribution between phases in smelting high-carbon 18
ferromanganese in the blast furnace
35. Physicochemical processes with coal particles in liquid-phase reduction. 18
I
36. PIZO Furnace Demonstration Operation for Processing EAF Dust 01
37. Prospects for the Control of Solidification Structures from the 08
Viewpoints of Weld, Hot-workability and Near Net Shape Casting
38. Refinement of Austenite Grain in Carbon Steel by Addition of Titanium 11
and Boron
39. Refinement of Solidified Structure using DC Electromagnetic Field 10
40. Reheat Furnace Fuel Switching 02
41. Relation between the Traces of Nucleation on the Surface and Grain in 09
the Condition of Continuous Casting of Steel
42. Replacement of the No. 1 Coke Plant Quench Tower at ArcelorMittal 02
Dofasco
43. Rolling and splitting of reinforcing steel in linear mills 20
44. Simulation of natural-gas combustion in a blast-furnace tuyere 19
45. Sintering and heating reduction processes of alumina containing iron ore 06
samples
46. The 2006 Reline of Corus IJmuiden Blast Furnace No. 7 02
47. The Mechanisms for Improving Strength of Iron and Steel 04
48. The Use of Steelmaking Slag for Mineralogical Sequestration of Carbon 01
Dioxide — Aqueous Processing
49. Thermal operation of molds in continuous-casting machines with 19
cooling channels of different shape
50. Using universal heat-insulating mixtures in intermediate ladles 20
51. Zero Liquid Discharge (ZLD) Cooling Tower Treatment at CSI 22
24