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By Kyle T. Chomyn

Multi-disciplinary engineering analysis and advanced modeling techniques were used to identify and develop low cost design modifications to improve a blast furnace hot blast air distribution main that experienced frequent refractory failures. Piping flexibility analysis helped identify the root causes of refractory damage and determine the need for new expansion joints. Finite element analysis was used to optimize a custom-designed elbow-to-elbow tie-rod system, which ensures thermal expansion loads are not placed on connecting piping. Heat transfer coefficients through the elbows were estimated using computational fluid dynamics (CFD) flow modeling. The cast refractory design was changed to a more reliable brick refractory design. Excessive draft was occurring during furnace back-drafting, so the system was assessed using CFD, and a passive flow-reduction spool was designed. This firstprinciples engineering design approach allowed for optimization and verification, ensuring that the new design addressed the root cause of the previous deficiencies.

Aug 17, 2017

By Clebson Joel Mendes de Oliveira

Sulfur control in steel have been challenging process experts since the discovering of it deleterious effect on most of steel product properties. To separate this slag from hot metal is mandatory to complete desulfurization process. The preferred method is to skim hot metal surface physically removing the contaminated slag, attributing to the operator the evaluation of skimming efficiency. Thus, we present a new lower cost system using image processing methods foreseeing a future full automation skimming process.

Aug 16, 2017

By Noan Tonini SImonassi

As fibras naturais extraídas das folhas do curauá estão entre as mais fortes fibras naturais utilizadas como reforço de compósitos poliméricos para aplicações em engenharia. Tais compósitos, até agora, são limitados em relação às propriedades mecânicas e energia de impacto. Assim o objetivo do presente trabalho é de investigar a possibilidade da melhora da resistência à tração bem como a energia de impacto dos compósitos de matriz poliéster reforçados com fibras de curauá com variados parâmetros de processamento. Os parâmetros observados foram a quantidade de fibras com diâmetro fino e pressão aplicada durante o processamento. Utilizando 60% de fração volumétrica de fibras finas (diâmetro médio variando de 50 à 80 µm) contínuas e alinhadas foi possível se obter resistência à tração superior 200 MPa. Ainda, aplicando-se 30 MPa de pressão durante a cura foram obtidos mais de 270 MPa de resistência a tração. Já para resistência a impacto Izod, uma resistência de 340 J/m foi obtido pelos corpos de prova com entalhe feito em sentido perpendicular ao alinhamento das fibras.

Oct 30, 2017

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 Vitor Guarnier Domiciano

A necessidade de melhorar as propriedades dos refratários monolíticos para resistir às condições operacionais cada vez mais severas e instáveis das casas de corrida de Alto-Forno tem sido um grande desafio para os fornecedores de refratários de maneira a garantir a segurança dos canais de corrida e sua disponibilidade para operação. Este trabalho apresenta as propriedades de novos concretos refratários Al2O3-SiC-C (aplicados por vibração ou bombeamento/projeção a úmido) desenvolvidos para resistir ao severo mecanismo de corrosão que ocorre na linha de gusa de canais principais e que exige constante atenção dos operadores das casas de corrida. Testes realizados com os novos concretos refratários em canais de corrida principais de diferentes Altos-Fornos de grande produtividade revelaram uma significativa diminuição da velocidade de desgaste do revestimento refratário na linha de gusa oferecendo uma condição operacional segura e confiável às casas de corrida.

Aug 16, 2017

By Kurt Herzog

State-of-the-art automation information technology and connectivity enables the digitalization of steel production that goes far beyond conventional automation of industrial production. Initiatives have been started around the globe to foster digitalization like IIoT (Industrial Internet of Things) in the US, Industrie 4.0 in Germany or China 2025. Primetals Technologies is actively driving the digitalization shaping the future of steel production. Intelligent combination of sensor technology combined with digital models as well as quality and production planning and control systems leads to new dimensions in product quality and production cost reduction. New diagnostic ways allow intuitive fault tracing or processing to support faster maintenance. Digital assistants support both operation and maintenance using context-oriented or self-learned information.

Oct 30, 2017

By Pietro Palma

Universal cardan joints are widely used in drivetrains of rolling mills for steel and aluminum making, as well as for non ferrous alloy industry. Working conditions are extremely tough due to high alternating or pulsating rolling torques in the roughing stands and high torques and speeds in the finishing stands. Overloads and lubrication along with oxide and slag are also critical issues that contribute to create severe working conditions. For a constant and reliable power transmission rolling mills performance and uptime rely on Universal cardan Joints which are the most critical equipment of the drivetrain. Fatigue assessment of the most important components of the Universal cardan Joint is therefore definitely vital for the mill in order to avoid failures and consequently downtimes. Considering the component’s dimensions and weight and in addition the time needed in order to reproduce full scale tests, a new approach to study the Universal cardan joint’s main components fatigue behavior has been investigated. It consists in reproducing the local stress condition of the main joint components on small scale specimens that can be tested by conventional laboratory fatigue machines. The aim of this study is to analyze the most critical stress concentration areas in the universal cardan joints highlighting how a universal cardan joint Wöhler curve can be determined through laboratory tests of small scale specimens.

Aug 16, 2017

By Andreas Rohrhofer

Reliable high end automation and process optimization systems are main factors for excellent product quality, safe operation and maximized plant performance in the steel industry and its designated environmental plants. Primetals Technologies introduces new automation packages for consequent safe and cost efficient production. Many areas within the steelplant interested to be monitored and measured automatically are not implemented in the automation system due to limited access or technical reasons. A wireless, self-organizing network facilitates wide ranging data transmission in previously inaccessible areas and opens up a wide range of new opportunities. With Fluid Guard a system to detect leakages with highest accuracy and reacts properly for all kind of water cooled circuits is available, improving the safety in steelmaking process. Lance Guard can be utilized for all fully automatic and semi-automatic lance appliances, but is especially suitable for the products of Primetals Sublance Standard/2.0 and LiquiRob applications, since these systems make seamless integration particularly simple. Manual lance appliances may also be tested and diagnosed. Environmental plants have become a main part in steelmaking plants. Highest performance in combination with optimized energy consumption is the main target in Primetals Technologies’ innovations in automation optimization packages for dedusting systems. A new approach for preventive maintenance and operator assistance is introduced with the Acoustic Expert System. In combination with the new Ask cloud based system, Primetals enables a 24/7 monitoring and a whole lifetime observation of any equipment within a steelplant. Furthermore it is now enabled to check the condition of the plant at a fingertip at any time.

Aug 17, 2017

By Márcia M. S. M. Pereira, Hervé Tavernier, Gérson T. Ferreira, Caio Nogueira Araujo Diniz, Fabio Luiz Lourenço, Wagner C. Moreira, Vinicius Cunha Aranda

Pós fluxantes desempenham um papel significativo na qualidade do aço durante o processo de lingotamento contínuo. Os pós fluxantes são escórias sintéticas usadas para lubrificar o molde durante o lingotamento contínuo do aço. Para que isso ocorra, o fluxante deve apresentar as seguintes funções: isolamento químico e térmico do aço, absorção de inclusões não metálicas do aço, lubrificação do molde e controle da transferência de calor entre o aço e o molde. O desempenho de cada função está relacionado às propriedades químicas e físicas do pó fluxante, que são dependentes de sua composição química e sua composição mineral, devido a sua relação com a taxa de fusão do material. A fim de garantir uma produção eficiente e de alta qualidade durante o lingotamento de um aço ultra baixo carbono, os pós fluxantes A e B foram investigados de acordo com diferentes propriedades físico-químicas. Diversos experimentos laboratoriais foram realizados para comparar o desempenho dos materiais A e B, visando à diminuição de captura da escória pelo aço no molde: avaliação do comportamento de fusão e fluidez, composição química e viscosidade. As temperaturas de processo foram avaliadas através de testes estatísticos, visando caracterizar o fluxo de calor e o trabalho de fricção durante lingotamento. Os testes industriais preliminares, realizados na Ternium Brasil, foram conduzidos com o objetivo de analisar o comportamento do pó fluxante durante a operação de lingotamento contínuo em relação a alguns aspectos operacionais e fornecer informações sobre sua influência na qualidade superficial do aço. Os resultados mostraram que, aumentando a viscosidade do fluxante, o consumo de pó tornou-se menor, levando a um maior trabalho de fricção e menor fluxo de calor no molde. No entanto, o comportamento da camada de escória mostrou que, apesar do aumento da força de atrito no molde, a espessura da escória foi adequada e não houve relatos de defeitos superficiais durante o uso do material fluxante de maior viscosidade.

Oct 1, 2019

By Armando Vazquez Arredondo

Tenova Goodfellow Inc. has successfully installed the proprietary EFSOP® (Expert Furnace System Optimization Process) system in over 80 installations worldwide. For over 15 years, the EFSOP® System has successfully achieved its main objective of improving performance and operating costs through the reduction of electricity, oxygen, methane, injected and charge carbon use. Using the off-gas information provided by the EFSOP® System, Tenova Goodfellow Inc. has now developed a solution for detecting abnormal water events within the EAF steelmaking process. When water form enters the EAF, it immediately forms into water vapor (H2Ogas) and a proportion of the resulting water vapour will further react and dissociate to H2. Effective water detection technology must be capable of detecting BOTH forms of water; H2Ogas & H2. Tenova Goodfellow has the technology to measure in real time and simultaneously H2Ogas & H2. This paper will provide a summary on how the EFSOP Water Detection Technology® is used during the EAF operation. Details regarding the technology, software, alarm rate and information on sensibility water trial tests will be provided within this paper.

Aug 16, 2017

By Rudolf Hubmer

In October 2013 JSW Steel decided to place an order to Primetals Technologies Austria (former Siemens VAI Metals Technologies) for the installation of a comprehensive Level 2 process optimization system for more than 20 existing production facilities of various suppliers. For SMS-I new L2 systems are provided for two hot metal pretreatment stations, three hot metal desulphurization stations, three ladle furnaces, two 1-strand slab casters, a ladle tracking system as well as a shop supervisory system. Additionally the existing L2 system for one 1-strand slab caster is being upgraded in the course of the project. In SMS-II new L2 systems for the 7 hot metal desulphurization stations, 4 ladle furnaces, 1 new RH vacuum degasser, ladle tracking system and a shop supervisory system are supplied. Despite of the challenging time schedule the commissioning of the single facilities started within less than 12 month after contract effectiveness. The installed Level 2 process optimization systems together with the achieved results are described in this paper.

Aug 16, 2017

By Francisco Morganti

The market requirements which strip processing lines have to deal with have altered significantly within the last decades. Particularly, the production has to be economical and ecological efficient and processing lines have to cover a broad product portfolio. Already existing plants either directly or indirectly are competing with new plants, which are equipped with the latest technologies. The “Special Strip Processing Equipment” is designed to be integrated easily and within small downtime phases in existing lines. All single machines can be delivered in short time “ready-to-perform” with a tested and proved automation system. Thus, the competitiveness of existing lines can be increased immediately with less effort. To find out which machines can be reasonably implemented SMS group offers an “Efficiency Check”. A special proceeding is used by experts to find out quickly which machines will have the largest effect on the efficiency of the line while demanding at the same time the smallest expense.

Aug 17, 2017

By Jean-François Stumper, Mario Moser, Mark Kruessmann, Volker Langer, Daniel Bastos Martins Cruz, Claude Meisch

The latest generation of probes and casthouse machines provide a wealth of data that has not been available a few years ago. The evaluation of this data gives direct feedback to improve the blast furnace efficiency, the equipment maintenance and design and it allows the early detection of critical or deviating process situations. A stable operation with lower operation and maintenance costs are the final customer benefits.

Oct 1, 2019

By Ricardo Rodrigues Grizotti, Laudelino Cota Fonseca Junior, Marcio Basilio Xaviere

O projeto tem por objetivo desenvolver a padronização e implantação de um Modelo de Governança de Planejamento e Gestão de Estoques de MRO (Manutenção, Reparo e Operação) bem como um Modelo de Reposição baseado em políticas e modelos quantitativos, estatístico suportado de ferramental sistêmico desenvolvido no ERP SAP da companhia que incorpora Práticas de Planejamento e Gerenciamento, para melhor determinação dos Estoques e Nível de Serviços dos Materiais de Natureza MRO visando a otimização e balanceamento dos níveis de estoque com aumento do nível de serviço; redução do stockout; oportunizar a otimização dos tamanho dos lotes de compras para cada SKU; otimização das políticas de reabastecimento para cada classe de SKU e desenvolver indicadores e desempenho para monitoramento e controle do processo de planejamento e gestão dos estoques de MRO. O desenvolvimento, construção e implantação do projeto foi pautado e realizado através do uso da Metodologia Lean Six Sigma e suas ferramentas advindas do DMAIC - (“Define”, “Measure”, “Analyse”, “Improve” e “Control”), como uma estratégia gerencial planejada, com foco nos resultados de qualidade e financeiros, com o objetivo de promover mudanças significativas na empresa, buscando sempre melhorias nos processos, produtos e serviços oferecidos aos clientes.

Oct 1, 2019

By Jens Kempken

A competitive landscape pressurizes the steel producers business, zero defect requirements from customers forces the operators for additional efforts in process control and quality management. The so called quality related cost, which include also rework, cost for downgrading or even scabbing of material is already a remarkable lever in a plants profitability breakdown. The introduction of advanced state of the art grades in the product portfolio requires already a budgeting for the expenses for R&D and quality management. PQA has been developed as a process and quality management software solution next to existing level 2 or level 3 automation systems. It is focusing on the analysis of process data, equipment information, in line quality measurement devices and trend analysis to obtain an answer whether the process is according to definition and expectation and whether the intermediate or final product can be shipped for further processing as prime material. Advanced analytics which are linked to an expert know how based configuration identifies deficiencies in the production and processing process. An intelligent, state of the art quality rating system evaluates tolerable deviations. PQA comprises the software platform including the database, data configurator and collector from the different sources in the production process and units. The core element of the platform is the knowledge based expert know how package defining process and quality determining fundamentals. The paper describes the structure of the software package, it gives insights on the expert know how package, process and quality evaluation and points out the customer benefits, cost reduction, improvement yield, customer satisfaction increase. The link to recent operational references is given.

Oct 30, 2017

By Ramon Augusto Moretti, Henrique da Rocha Severino, Renato Nascimento de Castro, Fernando Cesar Sousa

Rolling stand 12 (LTx) of long steel, installed in the company A, Piracicaba - SP unit, had presented high levels of vibration, which affected its internal components, such as: shaft, gears and bearings, generating downtime. To evaluate this equipment a study was proposed by the following engineering techniques: Conventional Vibration Analysis, Operational Deflection Shape (ODS) and numerical simulation by the Finite Element Method (FEM). In the Conventional Vibration Analysis, high levels of vibration were observed during manufacturing process, especially when the material reaches the equipment. Impacts generate high values in acceleration, on average 80 m/s² peak to peak. In the moment of impact, misalignment of internal components was observed by ODS. Field results were correlated to those obtained by the Finite Element Method, which allowed to calibrate FEM model. Thus, the most effective structural modification already numerically evaluated was implemented in the system. Afterwards, new measurements by vibration and ODS techniques were performed, and attenuation of vibrational levels and operational mode, which overloaded the internal components rolling stand, were verified.

Oct 1, 2019

By Wagner Duarte Flores

A demanda por tubos de aço com rigorosos requisitos de propriedades mecânicas tem crescido devido à exploração de reservas de petróleo e gás natural em regiões remotas e em ambientes hostis. Um grande desafio para as siderúrgicas é prever as alterações de propriedades mecânicas que ocorrem durante a conformação chapa/tubo, associadas ao encruamento e ao efeito Bauschinger, visando atender às especificações no tubo. Nesse estudo, foi avaliado o efeito da conformação chapa/tubo nas propriedades mecânicas do aço API X60 (TMCP). Para tal, foram realizados ensaios de tração, de impacto Charpy e de CTOD, em amostras de chapa e de tubo, e análise metalográfica, além de simulação do efeito Bauschinger por meio de ensaio cíclico compressão-tração. Os resultados dos ensaios de tração, tanto com os corpos de prova plate type quanto com round bar, apresentaram aumento da tensão limite de escoamento e redução da ductilidade, devido ao encruamento. Nos corpos de prova que sofreram aplainamento, esse aumento foi menos pronunciado, justificado pela ocorrência do efeito Bauschinger. A simulação do efeito Bauschinger confirmou a indicação de queda do limite de escoamento devido ao ciclo reverso de deformação. A tenacidade não foi fortemente afetada após a conformação do tubo.

Aug 16, 2017

By Renan Oss Giacomelli

The adhesion of multifunctional coatings on soft substrates is of paramount importance in the tribological behavior of this important class of surface treatment. In particular, scratch and indentation tests have been extensively used in order to assess this property. In this paper, the adhesion of a-C:H diamond-like carbon films deposited on nitrided low carbon steel was evaluated by indentation and scratch tests. The coatings were produced by PECVD onto 1020 steel substrates with two different surface finishing: ground (Sq = 0.184 µm) and polished (Sq = 0.002 µm). Indentation tests using a Rockwell diamond indenter were conducted and the adhesion evaluated by measuring the spalling region on images obtained by using optical microscopy. The analysis of the spalling regions produced semi-quantitative results, eliminating the subjective qualitative analysis proposed by the standard method VDI 3198. In addition, scratch tests were performed using the same indenter and a comparison between the two techniques was established.

Jul 31, 2018

By Andrea Donadon

This article introduces the Danieli Total Asset Management System, which involves 360 degrees service methods and equipment. Danieli Condition Monitoring System and Danieli Torque Monitoring System are fundamental to evaluate the conditions of the working components in heavy duty transmissions. The first one monitors the vibrations and the lubrication fluid conditions with the purpose to identify the presence of malfunctions, by detecting any variation of the signals from the standard values. The second one monitors the transmitted torque for each spindle and gearbox, with the aim of detecting any anomaly in torque distribution and magnitude, and evaluating the residual life of the mechanical parts, on the base of a dedicated fatigue damage algorithm. All these features are useful in avoiding serious damages to machines, facilities and people, but allow also planning the maintenance and overhaul activities with efficiency, in order to achieve the best plant availability and reliability. The data analysis is made by the IntelliCMS software, which interfaces with plant and Danieli operators and includes the possibility to cooperate by remote connections, simplifying service activities and support. All these features allow providing new full service programs, where the client is totally supported in maintenance, overhauls and substitutions. This is the best way to ensure the most efficient, high quality and reliable after sales assistance.

Aug 16, 2017

By Francois Mignard

With a limited global steel production growth, automotive application market shows interesting volumes and trends especially in emerging countries. The recent period has again enabled Siemens VAI to confirm a position amongst leading suppliers of new plants serving high-end steel production in particular for unexposed and exposed automotive material. With a series of recent plant references in operation and under construction, relevant answers to such sustained level of performances are highlighted along the downstream processes. Designed for a wide range of applications, Siemens VAI processing lines includes advanced technological and state-of–the art equipment, among them, Solid state laser welder, Pickling Tunnel tanks, Skin pass mill and Tension leveller, Side trimmer with dynamic width adjustment, and new generation of Automatic surface inspection systems. With a continuous aim of driving improvements, Siemens VAI has also developed Global Quality Monitoring solutions notably through advanced software which provide just-in-time warnings and assist steel makers in the daily operation of their lines. As lifecycle partner, Siemens VAI offers solutions and services in metallurgical expertise from metallurgical modelling, through physical simulation on rolling, annealing and galvanizing processes, and enables Siemens to accompany our customers along with their project definition till fulfilment of highest market requirements.

Jul 30, 2018