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By Paul Pugsley

The EMSpec sensor employs the principle of measuring the complex impedance of the target steel over a range of frequencies these impedance values in turn varies with transformation fraction of the steel. A full scale implementation of the Real Time Transformation Monitoring has been installed at a quality large European steel producer to show the benefits of such a system. A total of three EMSpec sensor heads have been installed between the exit Finishing Mill and the Down Coiler on a HSM. For the successful production of Dual Phase, TRIP and TWIP steels increased control of the cooling regime is demanded; the use of surface temperature measurements alone cannot guarantee to achieve the desired mechanical properties. The EMSpec sensor, which is engineered to withstand this harsh environment, in real time directly measures the percentage transformation of the steel in the cooling area, typically in the accelerated water cooling zone. Using the information from the sensors integrated into the mill model enhances the models ability to predict the transformation profile.

Aug 17, 2017

By Filippo Verlezza

The 3-roll technology is a recognized process applied to SBQ production. The main aim of this paper is to show the latest developments on this technology including other equipment´s that also contributes for a better performance on SBQ coils production.

Jul 30, 2018

By Robson Aguiar de Macedo

O estudo de ligas livres de Pb envolvendo o emprego de junções metálicas sob altas temperaturas tem recebido atenção especial, sendo desenvolvidas novas ligas com qualidade e desempenho adequados. Ligas Bi-Ag consistem em alternativas promissoras para a substituição das ligas de solda contendo Pb para tais aplicações, por isso devem ser melhor caracterizadas sob o aspecto de estruturas brutas de fusão. Assim, o presente trabalho objetiva investigar a liga hipoeutética Bi-1,5%Ag (%em peso) solidificada unidirecionalmente sob regime transitório de fluxo de calor. Será analisada a influência dos parâmetros térmicos de solidificação como velocidade de solidificação (VL), taxa de resfriamento (?) gradiente de temperatura (G) na microestrutura e na evolução de dureza da liga citada. Para determinação do perfil de dureza, foram realizados ensaios de dureza Vickers. Para obtenção e caracterização das microestruturas presentes no fundido Bi-1,5%Ag, fez-se o uso da microscopia ótica e da fluorescência de raios-x. Uma estrutura de dendritas facetadas de Bi circundadas pelo eutético Bi-Ag prevaleceu ao longo do lingote Bi-1,5%Ag. Verificou-se um aumento gradativo dos espaçamentos dendríticos primário (?1) e secundário (?2) à medida que a distância da base refrigerada foi aumentada. Em geral, os valores de dureza diminuíram para maiores valores de ?1 e ?2.

Aug 7, 2018

By Vitor Orlando Ferreira

The efficiency of an apparatus which uses a forced lubrication system, as well as the useful life of its components, is strongly related to the degree of contamination of lubricating oil. The presence of contaminants and the degradation of the oil itself cause it to release substances that fouling of the wall of the pipes. The cleaning and dialysis of the oil pipes, besides prolonging the life of the lubricant reduces wear of the components. There are several methods of cleaning in pipes, the problem is that some have abrasive characteristics, which could damage some types pipes. Among the non-abrasive methods stand the Flushing and Air scouring. Flushing uses the lubricating oil which circulates in temperatures alternating and high speeds, for generating turbulence to perform washing. The Air scouring method uses oil and filtered compressed air, injected into pipe, to generating higher flow, causing the power supply unit with fluid can work with lower power consumption and higher speeds, removing fouling of the pipe. The objective of this research is to evaluate the Reynolds number to correlate with the efficiency of cleaning the pipe. The method applied was the Air scouring and it was verified that the qualitative effects may occur when compared to Flushing. After testing, it was found that the chosen method brings significant changes in flow, and this flow regime varies considerably increasing the Reynolds number.

Jul 31, 2018

By Karollyne Gomes de Castro Monsores

Os materiais poliméricos são sensíveis a radiação ultravioleta, acarretando mudanças em suas propriedades. Sob esta perspectiva, o presente estudo expôs o polietileno de baixa densidade (PEBD) a radiação ultravioleta por 150 e 300 horas. A avaliação físico-química e a caracterização mecânica foram realizadas para verificar as mudanças macromoleculares produzidas por tal radiação e confirmadas por exame visual. Diante dos resultados, confirmou-se a ocorrência de degradação, através da presença de ruptura de cadeias, além da produção de reticulação, e um sutil decréscimo da cristalinidade. O ensaio de tração confirmou a fragilização produzida pela radiação. O desempenho balístico das placas fixadas por adesivo a base de etilcianoacrilato produziram delaminação, ao contrário do observado nas placas fixadas por silicone.

Oct 30, 2017

By Bernardo Siqueira

This paper presents a unique stirred milling technology, Outotec HIGmill™, a modern, flexible and energy efficient grinding solution for fine and ultra fine grinding being tested in an industrial scale level. The test was performed at an iron ore pellet producing plant in Sweden (for confidentiality reasons, it will be referred to only as “the client”) where a pilot HIGmill™ unit (HIG25) was installed parallel to a conventional regrind circuit to compare its performance to the existing ball mill. By using a continuous test run procedure and evaluating the parameters of F80, P80, mill shaft rotation speed and power drawn it was determined its grinding capabilities, operational flexibility and energy efficiency. Outotec HIGmill™ outperformed the existing ball mill in the plant proving its capabilities to grinding finer, with steeper particle size distribution (PSD) and much higher energy efficiency. The tests performed showed that, with further refining of its operation, it is capable of consistently deliver the required PSD with up to 30% higher grinding efficiency.

Aug 16, 2017

By Klaus Pronold

Once installed rolling mills can look forward to a long life. Around 40% of the 140 conventional hot strip mills presently in operation were built between 1960 and 1970. 17 of the 29 CSP®-plants were commissioned before the year 2000 and have automation platforms that are obsolete and/or have outdated rolling technology. Keeping pace with the market requirements is an ongoing challenge for producers of flat steel. It is a real balancing act keeping production facilities performing at necessary levels, safeguarding the investment and keeping outage periods to a minimum. To overcome these demanding factors and strike the right balance allowing for the production of higher grade steel that meets the current market price the installation of mechanical equipment as well as automation platforms and process technology must meet the latest technology standards. Being discussed in this paper are the different motives for modernizations along with their impact on project handling and commissioning philosophies. Experience gained during recent modernization projects in the field of flat steel rolling relating to Steckel / plate mills or current CSP® modernizations will be shared and demonstrate that each modernization has its own individual solution. Specific strategies are explained to help optimize production, increase plant agility and maximize the return on investment.

Aug 17, 2017

By Gilvandro Bueno

Os controles dos processos de cominuição estão normalmente associados à redução de granulometria e geração de superfície específica, usualmente utiliza-se peneiramento para medição de granulometria e permeabilímetro de Blaine para superfície específica, estes métodos são largamente utilizados para este fim. O método on line por difratômetros a laser também pode ser empregado para estas medições na indústria, como se trata de uma tecnologia recentemente adaptada para ao processo de Pelotização, foi necessário validar o equipamento e determinar equações de correlação de leitura com os equipamentos existentes. O trabalho consistiu em realizar uma série de amostragens cujas amostras foram analisadas no equipamento industrial a laser, em seguida analisadas em laboratório. As equações de correlações obtidas foram inseridas no equipamento industrial de medição on line por laser tornando a leitura familiar aos obtidos pelas análises de laboratório, onde foi possível garantir confiabilidade para tomadas de decisões.

Aug 1, 2018

By Bart de Graaff, Victor van Straaten, Edo Engel

The hot blast system is key ancillary plant equipment with respect to safe and stable operations during a long blast furnace campaign. Hot blast stove designs have been optimized to such an extent that in some cases, their lifetimes have surpassed the campaign lengths of the associated blast furnaces by a substantial margin, with the exception of the burner and a few critical areas. This article presents recent developments with respect to designing, building new and operating existing hot blast systems for a long lifetime and at optimized performance. These developments include fundamental improvements such as dome combustion designs as well as increasingly comprehensive packages for inspection, assessment and maintenance techniques. Examples of such techniques are burner replacement with the hot blast system at operating temperature, improved double shell approaches and TOFD measurement applications.

Oct 1, 2019

By Liao Jianfeng

The Baosteel Zhanjiang 5,050m3 blast furnaces have been built with highly independent integration and innovation technologies and represented the state of the art of the world’s huge BFs. The proper of BF1 and BF2 is designed with long-campaign technology; both BFs share the same set of stockhouse, water and PCI systems; the BCQS serial-hopper no-bell top, TRT and blower are all local equipment as applied; four top-combustion stoves systems are matched; the BFG is cleaned by fully dry process; and the automation control system for the main process is self integrated. The BFs have been started up and performing with sound indicators. Their smooth proceedings symbolize China’s huge blast furnace ironmaking technology ascending a new high.

Oct 30, 2017

By Alessandro Molinari

In recent times, coke oven machines are acquiring a more prominent role in the coke making process. Apart from the traditional handling of the coal and coke flow, nowadays these machines are also deeply involved in all environmental and process control aspects. Paul Wurth coke oven machines have been developed by Schalke to meet the most recent requirements in terms of emissions control, automation, instrumentation, operability and maintainability. In CSP, Ceará, the new coke making plant represents the status of the art of the technologies applied to the whole coking process; starting from the Coke Oven Batteries and the Gas Treatment Plant developed by Paul Wurth up to the Coke Machines supplied by Schalker Eisenhütte, whose technology is now part of Paul Wurth coke making products portfolio. Present paper describes the plant configuration focusing on Coke Oven Machines and the key factors which are guarantying the success of the project.

Aug 16, 2017

By Diego José Inforzato

Hot tensile data were correlated with creep data, in Aluminum Alloy AL7475-T7351, as part of a broader research program, aiming at the validation of a methodology that proposes an equivalence between the two kind of results, for metallic materials in general. The methodology is based on a criterion that establishes correlation among the following parameters from each test: the strain rate, ultimate tensile stress, and time to reach the ultimate tensile stress, in tensile tests, are equivalent respectively to the: minimum strain rate, applied stress and rupture time, in creep tests, for a given test temperature. The present material was tested at 3 temperatures: 133,166 and 193ºC, using 3 nominal tensile strain rates in the hot tensile tests: 3.2x10-6, 1.6x10-4 and 6.4x10-3 s-1 and 9 applied stress levels in the creep tests, varying from 140 to 400 MPa. The conversion of the hot tensile data to creep-like data allowed performing the analysis of all the results together according to the traditional creep relations proposed by different authors, namely: Norton, Arrhenius, Zener-Hollomon and Monkman-Grant, with the determination of the corresponding parameters in each case. The equivalence between hot tensile and creep data is also confirmed for this aluminum alloy.

Aug 8, 2018

By Jorge Luiz Ribeiro de Oliveira

A indústria siderúrgica na América do Sul tem sido desafiada desde a crise econômica mundial do final de 2008, como as demais siderúrgicas ao redor do mundo. O cenário de continua degradação das matérias primas, em especial o minério de ferro e a necessidade de reduzir custos, considerando que cerca de 70% do mesmo está relacionado à produção de gusa, atuando em direção oposta, torna este desafio maior ainda. Operar um Alto Forno com elevadas taxas de injeção de carvão (mais que 180 kg/t de gusa) e baixo taxa de combustíveis (menor que 490 kg/t de gusa), considerando a elevação da taxa de geração de escória devido a matéria prima em degradação (~300 kg/t de gusa) torna-se obrigatório ter estabilidade operacional por meio de boas práticas operacionais suportado por adequado sistema de manutenção centrado em confiabilidade (RCM). Este trabalho objetiva mostrar como a ArcelorMittal planta de Tubarão está enfrentando esta situação, visando atingir os objetivos citados anteriormente.

Aug 16, 2017

By Rossana Bezerra de Azevedo Vasconcelos Seabra de Melo

O presente estudo apresenta um método de avaliação de desempenho de operadores nas análises químicas que caracterizam o minério de ferro. São eles: Ferro total (Fe), sílica (SiO2), alumina (Al2O3), manganês (Mn), fósforo (P) e perda por calcinação (PPC). O desempenho é avaliado em termos de precisão e veracidade. Estes dois indicadores primários são combinados num secundário denominado de indicador de “confiabilidade metrológica”. O método foi aplicado nos laboratórios da Mina (no estado do Pará) e do Porto (no estado do Maranhão) de uma empresa mineradora onde foi possível: 1) conhecer o desempenho de cada laboratório assim como conhecer o desempenho de cada operador; 2) identificar os pontos fortes (identificar o procedimento que leva a melhores desempenhos) e oportunidades de melhorias (atuar nas causas, capacitar); 3) equalizar a forma de executar cada uma das tarefas com as melhores práticas identificadas; 4) proporcionar oportunidade de desenvolvimento técnico dos profissionais envolvidos no processo. O desempenho neste indicador tornou-se critério avaliação de aptidão para executar análises.

Aug 2, 2018

By Nicolás Ariel Zabala

During the make-up and break-out of the connections, threaded joints are exposed to intense mechanical and tribological solicitations. The connection performance is influenced by its geometry, material properties, surface treatments and thread compound. The aim of this work is to evaluate and characterize the tribological behavior of different thread compounds applied on manganese phosphated carbon steel under low speed and high pressure sliding contact. Four thread compounds were evaluated: one containing lead, zinc and graphite; other lead-free, containing copper and finally, the last two lead-free and containing non-metallic solids. The tribological behavior was analyzed by a block-on-ring tribotest. During the test, load varied linearly between 250 N and 7000 N; loading and unloading lasted 14 sec and were performed in opposite directions of rotation to simulate the make-up and break-out operations. Friction force and load as a function of time were registered. Upon completion of the test, wear surfaces were analyzed by SEM, optical microscopy and energy dispersive spectroscopy. The obtained results show that the lead and zinc containing thread compound displayed the best behavior, showing a wear reduction of approximately 20%. These results are in line with previously known oilfield experience. Average COF values around 0.15 were measured and no significant differences between dopes were observed; indicating that the wear behavior was influenced by the additive package.

Jul 31, 2018

By Karl Berger

The paper gives a comprehensive overview of the historical development of various metal rolling technologies and also describes the influence to industrial and socio-economic developments. The rolling of steel, in particular of rails, beams, rebar, strip and plate has enabled the large scale transport and travel, the building of bridges and buildings, the manufacturing of ships and cars. All this has changed the face of the world significantly. Further the paper approaches technological highlights in the design, manufacturing, drive and control of modern mills and the various types developed to create industrial economic units for the different markets and customers’ requirements. An outlook of future challenges is as well discussed in the paper. Various solution approaches for the rolling technologies, from continuous improvement of existing plants to more radical new concepts like endless rolling, near net-shape casting and rolling are approached. A positive conclusion is drawn that rolling technologies will remain a valuable area for engineers with scientific and economic challenges, but also a clear vision for positive contribution to further industrial and social development.

Jul 30, 2018

By Raíza da Silva Juvenal, Suelen Silva Rocha, Artur Ângelo Alcântara de Assis, Jorge Luiz Valença Mariz

Um estudo de viabilidade econômica deve considerar parâmetros e incertezas inerentes a um projeto para produzir resultados econômicos consistentes, fornecendo ao investidor uma ferramenta de tomada de decisão. O presente estudo objetivou efetuar inicialmente a avaliação econômica convencional do cenário realista de uma mineração de agregados em fase de implantação localizada em Pernambuco, cujo Valor Presente Líquido (VPL) obtido foi R$ 24.006.309,20, o que representa um resultado positivo. Através da metodologia de Monte Carlo foi efetuada uma análise de risco considerando incertezas em 100.000 cenários, nos quais nove variáveis assumiram valores estocásticos dentro dos domínios definidos, produzindo assim uma distribuição estatística do VPL ao invés de um único número, sendo ainda efetuada uma análise de sensibilidade para identificar e quantificar as variáveis que mais impactam no resultado da avaliação. Por fim, os dois fatores mais influentes identificados na análise de sensibilidade inicial foram isolados e submetidos a uma nova análise de risco em outros 100.000 cenários. Foi concluído que o projeto é economicamente viável e que a probabilidade de gerar lucro aos investidores é de 99,77%, embora a probabilidade do VPL ser igual ou maior que o previsto pelo método convencional seja de 49,98%.

Oct 3, 2019

By Anand Kumar Agrawal, Kinzel Klaus Peter, Lorenzo Micheletti, Cristiano Castagnola, Horst Kappes, Andre Oliveira, Björn Rösner, Philippe Bermes

Blast furnaces are widely employed today for iron production all around the world, with a total production of around 1.2 billion tons per year. Its operating principle, which relies on usage of coke to reduce the ore, to ensure the permeability in the reaction vessel, to maintain its flexibility of operation and acceptability for varying qualities of iron ores. The blast furnace route is widely considered as the most economic and efficient route of iron production, however it is based on fossil energy carriers. The blast furnace route has undergone significant developments in terms of energy efficiency in the last decades, which led to a substantial reduction in the use of fossil reduction materials. Being an energy intensive process, competitiveness and cost saving in the blast furnace plant was always strongly related to the saving of energy and hence reduction of CO2 emissions. In addition to this, EU emissions trading system (EU ETS) as a cornerstone of the EU's policy in response to climate change has set new “challenges” for iron production in Europe. Paul Wurth has always been deeply involved in the development of energy saving technologies for blast furnaces. In the following a review of energy saving achievements developed in the last decades will be presented and the potential of available CO2 saving technologies will be summarized. Additionally, an outlook about the potential of future technologies, concepts and their impact on the blast furnace and the steel plant’s energy balance will be discussed. Finally, the replacement of carbon by hydrogen as reduction agent in the steel plant will be reviewed, with special focus on a comparison of costs and incentives.

Oct 1, 2019

By Wallace Ernesto Sant’Anna Ramos

Dentre as diversas tecnologias utilizadas para desinfecção da água uma das mais utilizadas em todo mundo são as Monocloraminas. O presente trabalho visa mostrar as vantagens e benefícios de se utilizar uma tecnologia combinada mais limpa, verde e eficaz para controle microbiológico sem causar danos ao meio ambiente, além de ser mais segura e confiável, para o processo e o ser humano.

Sep 25, 2017

By Detlef Ehlert

Energy efficiency is coming to the center of attention in the metallurgical and rolling mill industry due to increasing energy costs, limited resources and political requirements. Also, a green image and energy efficient production is a clear competitive advantage. SMS Siemag, being familiar with automation and measurement equipment, provides an energy data management system which gives transparency over the energy consumptions. All energy relevant media including electricity, gas, water, compressed air and further more can be recorded. The system is manufacturer-independent and allows the use of already installed measuring technology with the possibility of subsequent extension. So potentials for improvement can be recognized and energy savings can be estimated and proven after the implementation of the measures. Being familiar with the processes in the metallurgical and rolling plants, the system by SMS Siemag allows the assignment of the energy data to the production and plant data. Only by this connection, the data can be reduced to key performance indicators allowing authoritative evaluation of energy efficiency. The results are clearly represented on dashboards and support the continuous improvement process. The system also supports the energy controlling with an automatic reporting system, cost center assignment and in support with certification according to ISO 50001.

Jul 30, 2018