Embed Size (px)
Citation preview
Sart-Tilman - LIEGE Zwijnaarde - GHENT
Annual Report
2008
ISSN 1370-7035 ….
CONTENTS
1Foreword 2
Companies affiliated to CRM 4
OrganizationSupervisory Board 6Iron and Steel Committee 7Departments 9
Income Data 10
Report on Research ActivitiesProduct Technology 12Finishing and Coating 16Sustainable Production 20Support to Regional and Federal Economy 24Guidance, Technological Watch 25
Publications 26
Conferences 28
Editor : Centre de Recherches Métallurgiques, Avenue Ariane 5, B - 1200 - BruxellesCentrum voor Research in de Metallurgie, Avenue Ariane 5, B - 1200 - BrusselCopyright : Centre de Recherches Métallurgiques, 2009
FOREWORD
2During the year 2008, CRM has managed more than 80 research projects reinforcing its strate-gic poles of activities: Recycling and Sustainable Production, Products Technology, Surface En-gineering, Technology Transfer and Guidance towards SME’s.
In the collective steel research programme, under the management of the CRM active membersArcelorMittal and Corus, the developments were mainly focusing on the following installationsor processes: sintering, blast furnace, by-products, electric arc furnace, hot and cold rolling,pickling and metallic coating. Other projects were aimed at the development of new genericsteels.
Several of these projects have reached the industrial stage and are discussed within the presentreport.
The contribution of CRM to the European research remains important and has largely contribu-ted to the development of new processes or products. CRM continues to support the RFCS pro-gramme, participating to many projects, more than 30 in 2008, and appointing experts to theproject evaluation sessions and to the technical committees.
CRM is also participating to the Walloon Marshall Plan and to the different calls for projects,being supported by its industrial members. The success rate has been quite high and new pro-jects have started in the field of construction, energy management and intelligent maintenance.
The project on “steel thixoforming” is progressing, the casting of small ingots having the wellsuited thixoformable microstructure has been successfully performed at Marichal Ketin. In theMirage project, co-ordinated by ArcelorMittal, CRM has contributed by manufacturing sand-wich panels, containing PCM for energy management in buildings.
The SME’s are demanding more and more support from the CRM team in charge of the techno-logy transfer and guidance activities. This activity, supported by the Walloon region, is still in-creasing with efficient co-ordination between the research centres active in metal and materialdevelopment, especially with our partners in PiMW (Walloon Pole of Material Engineering).
With the agreement of its members, CRM has pursued its policy for commercial exploitation ofsome of its inventions. CRM has finalised the development of a surface conversion treatmentcalled “Silicalloy”. A first industrial application was successful. The low cost nanocoating“Silicalloy” is applicable in continuous high productive lines on metals and galvanised pro-ducts. De Leuze S.A. has been licensed for the commercialisation of this Cr-free coating solution.
In other fields of application, the attractiveness of the CRM Tempcore® and MULPIC® coolingprocesses, for respectively the production of rebars and plates, remains high thanks to the outs-tanding partnerships with our members.
3Priority has been given to the improvement of safety in our laboratories and pilot lines. Thanksto the assistance of ArcelorMittal and Corus, the best safety tools have been implemented. Theencouraging result of this policy is one full year without accident. We would like to thank all per-sonnel members for this performance.
In these difficult times, CRM continues to accommodate its management. A high flexibility hasbeen put in place, facing the challenging situation and portfolio evolution, while ensuring highefficiency, cost control and on time delivery. Our main objective remains consisting in the gene-ration of innovative ideas that will be rapidly developed and implemented in industrial plants.
In the year 2008, CRM has participated to the creation of two patrimonial joint ventures withOCAS and AMLR, two research laboratories of ArcelorMittal.
In the “Metal Processing Centre” (MPC joint venture) at Zwijnaarde, the CRM has amalga-mated its main pilot assets operating in the field of rolling and thermal treatment with those ofOCAS research centre. The new company assets amount to 4.8 MEUR.
The “Surfaces and Advanced Material Coatings” (SAMCoat) JV consolidates in Liège the sur-face treatment installations of the CRM and AMLR centres. Its assets amount to 6.6 MEUR.
The establishment of these two joint ventures does not change the CRM organization and mana-gement, all the new assets in the CRM perimeter are serving our partners.
On October 24, 2008, CRM celebrated its 60th anniversary as well as the establishment of thetwo joint ventures. This event was an opportunity to review the recent accomplishments and thefuture prospects.
Jacques PELERINARCELORMITTAL S.A.
President CRM
Kris STEVENS Rob BOOMARCELORMITTAL FCWE CORUS Research,Development & technology
Vice-President CRM Vice-President CRM
Jean-Claude HERMANCRM
Managing Director
COMPANIES AFFILIATED TO CRM
On May 14, 2008
4
Active Members
ARCELORMITTAL S.A. – G.D LuxembourgCORUS GROUP plc – United Kingdom
and every one of their subsidiary companies in the iron and steel industry.
The affiliated companies in the Benelux countries are :
ARCELORMITTAL Belval & Differdange S.A. (ex. ProfilARBED) - G.D. LuxemburgARCELORMITTAL Bettembourg S.A. (ex.TrefilARBED) - G.D. LuxemburgARCELORMITTAL Dudelange S.A. (ex. GALVALANGE) - G.D. LuxemburgARCELORMITTAL France S.A. (ex-USINOR) – G.D. LuxemburgARCELORMITTAL Luxembourg (ex-ARBED) - G.D. LuxemburgARCELORMITTAL Rodange & Schifflange (ex. ARES) - G.D. LuxemburgARCELORMITTAL STAINLESS BELGIUM N.V. (ex-Ugine & ALZ) - BelgiumARCELORMITTAL STEEL BELGIUM S.A. (ex. SIDMAR) – BelgiumCOCKERILL SAMBRE S.A. (ARCELORMITTAL Group) - BelgiumCORUS STAAL B.V - The NetherlandsINDUSTEEL BELGIUM (ARCELORMITTAL Group) - BelgiumSEGAL S.A. (CORUS Group plc) - Belgium
5
Associated Members
AIR LIQUIDE INDUSTRIES BELGIUM S.A. – BelgiumÅKERS BELGIUM S.A. – BelgiumAMEPA GmbH – GermanyCARMEUSE S.A. – BelgiumCARRIERES ET FOURS A CHAUX DUMONT-WAUTIER S.A. - BelgiumCARSID – BelgiumCBMM Technology Suisse S.A. – SwitzerlandCMI S.A. – BelgiumCOMET TRAITEMENTS S.A – BelgiumCONVERTEAM S.A. – FranceCUMERIO – BelgiumCYTEC S.A. – BelgiumDE LEUZE S.A. – BelgiumDREVER INTERNATIONAL S.A. – BelgiumDUFERCO CLABECQ S.A. – BelgiumDUFERCO LA LOUVIERE S.A. – BelgiumFONDERIES MARICHAL KETIN & Cie S.A. – BelgiumLE FOUR INDUSTRIEL BELGE S.A. – BelgiumGONTERMANN-PEIPERS GmbH – GermanyHERAEUS ELECTRO-NITE INTERNATIONAL N.V. - BelgiumHERSTAL S.A. – BelgiumINDUCTOTHERM S.A. – BelgiumINSTITUT BELGE DE LA SOUDURE asbl – BelgiumINTERNATIONAL MANGANESE INSTITUTE - FranceIRM Group S.A. – BelgiumMAGOTTEAUX INTERNATIONAL S.A. – BelgiumMULTISERV S.A. – BelgiquePAUL WURTH S.A. - G.D. LuxemburgPRAYON S.A. – BelgiumPRÜFTECHNIK DIETER BUSCH A.G. – GermanySIEMENS VAI METALS TECHNOLOGIES GmbH - AustriaTECHSPACE AERO S.A. – BelgiumTHY-MARCINELLE S.A. – BelgiumTI GROUP AUTOMOTIVE SYSTEMS (BELGIUM) S.A. - BelgiumUMICORE S.A. – BelgiumWHEELABRATOR ALLEVARD – France
ORGANIZATION
on May 14, 2008
6
Supervisory Board
PresidentJacques PELERIN, General Manager Country Wallonia, ARCELORMITTAL
Vice-PresidentsKris STEVENS, Vice-President – Progress Academy, ARCELORMITTAL FCWERob BOOM, Director R&D, Strategy & Competence, CORUS Research, Development & Technology
AdministratorsGeorges ALLO, Conseiller Scientifique, SPF Economie, PME, Classes Moyennes et EnergieMichel BEGUIN, Managing Director, ARCELORMITTAL Liège ResearchAndré BOCK, Senior Vice-President, ARCELORMITTALJacques CHARLES, Vice-President Research & Development,
ARCELORMITTAL STAINLESS FRANCEPinakin CHAUBAL, Process Program Manager, ARCELORMITTAL Research S.A.Jean-Pierre COHEUR, Professeur, Université de LiègeJozef DILEWIJNS, Professor, Universiteit GentChris ELLIOT, Director Technical Construction & Industrial, CORUS RESEARCHCarlos ESPINA, Vice-President, ARCELORMITTAL Research & DevelopmentRobert JOOS, Directeur Général, Groupement de la SidérurgieHerwig JORISSEN, Secretaris-Generaal, Centrale der Metaalbewerkers van BelgiëVincent LECOMTE, Directeur Général, S.A. des Fonderies Marichal, Ketin & CiePaul LIAKOS, Secrétaire Général, ACV-Metaal/CSC-MétalGreg LUDKOVSKY, Vice-President of Global R&D, ARCELORMITTAL R&DFrançois MUDRY, GM Scientific Advisor, ARCELORMITTAL R&DMargriet NIP, Director Product & Market Development, CORUS Strip Products IJmuidenSven VANDEPUTTE, General Manager, ARCELORMITTAL R&D Industry GentAn VAN DE VEL, Scientific Relation Manager, UMICORE RESEARCHWim VAN RIJSWIJK, Manager Packaging Steel Programme, CORUS RD&TJosé VERDIN, Représentant Centrale de l’Industrie du Métal de Belgique
Observers
Yvon MASYN, Innovatie door Wetenschap en Technologie in VlaanderenPierre VILLERS, Inspecteur Général ff, Direction Générale des Technologies, de la Recherche
et de l’Energie de la Région Wallonne Jean-Claude HERMAN, Directeur Général, CRM
AuditorDominique JACQUET-HERMANS
on January 1 , 2009
7
Iron and Steel Committee
Members
ARCELORMITTAL GroupJ.P. ALLEMAND, ARCELORMITTAL RESEARCH S.AM. BABBIT, ARCELORMITTAL RESEARCH S.AM. BEGUIN, ARCELORMITTAL RESEARCH S.AJ. CHARLES, ARCELORMITTAL STAINLESS FRANCE S.A.P. CHAUBAL, ARCELORMITTAL RESEARCH S.A.C. ESPINA, ARCELORMITTAL RESEARCH S.AJ. HOFFMANN, ARCELORMITTAL LUXEMBOURG S.A.J.-M. STEILER, ARCELORMITTAL RESEARCH S.A.S. VANDEPUTTE, ARCELORMITTAL R&D INDUSTRY GENT
CORUS GroupR. BOOM, CORUS STAAL B.V.C. ELLIOT, CORUS CONSTRUCTION AND INDUSTRIAL, UKM. NIP, CORUS STRIP PRODUCTS NLW. VAN RIJSWIJK, CORUS RD&T
CRMJ.-C. HERMANCh. MARIQUE
8
DEPARTMENTS
on March 9, 2009
9
Report on Research Activities
PRODUCT TECHNOLOGY
12 The interactions between process and product areone of the key aspects that drive the actions andcompetences of CRM.
Two major axes of development characterize theactivities of this department: Innovation and optimization in process. Basic metallurgy study of new product
concepts.
Large scale test facilities at Ghent and Liegeallow to cover processing steps from metalsolidification and casting to rolling and thermaltreatment.
The equipment located in Ghent is managed sinceend of 2008 inside a joint venture withArcelorMittal-OCAS called “MPC” (MetalProcessing Centre).
Casting
Using the pilot casters available at Liege, a newway to produce high resistance steel is exploredin the frame of two RFCS projects withArcelorMittal (Flat carbon and Stainless steels).The basic concept is to inject in the liquid metal,
just before the casting mould, dispersoïdicelements acting as inoculants to refine thesolidification structure.
Successful trials have been conducted with thisHollow Jet Nozzle technology to add ferro-cerium powder in a resulphurized DP steelgrade.
Very fine sulpho-oxides of cerium (averagesize: 1.4 µm) homogeneously distributed in theas-cast structure have been observed.
During reheating and rolling, these precipitatesreduce the growth of the austenite phases andpromote the formation of very fine acicularferrite phase in the final hot rolled product.
Hot Rolling
Let us recall the availability of a uniquecontinuous hot rolling pilot line located inGhent and allowing to test and simulate a largevariety of operating conditions and industriallay-outs.
After an adaptation of the hot rolling pilotline, several continuous trials have been
13performed with different asymmetrical rollingconfigurations.
A comparison has been made by changing theroll diameters for both dual- and single-drive lay-out. For all the tested configurations, a significantreduction of the rolling force has been observedand the model for calculating rolling forces inasymmetric mode has been adapted.
The assessment of the work roll performancesduring hot rolling is another important field ofactivity conducted with the support of rollmakersaffiliated to CRM (Marichal Ketin and Äkersmore particularly). The study of different rollmaterials on the pilot rolling line is made easierthanks to the use of the “inserts” technique.Several roll qualities can be compared undersimilar working conditions.
Long-term test campaigns simulating the firststand of the hot strip finishing mill haveallowed to more precisely identify theinfluence of two important operatingparameters:- a higher initial roughness of the work
roll after grinding positively affects the
formation of an adherent roll oxide layerthat reduces the roll degradation,
- the application of a pure oil lubrication isnot only beneficial to lower the rollingforce but also to significantly decreasethe work roll wear.
A new project has been launched inside theEuropean RFCS programme to investigatethe roll degradation in the roughing mill. Anadapted version of the on-line measuring unitcalled “Rollscope” and previously developedfor the finishing mill has been implementedby CRM in the roughing mill ofArcelorMittal Dunkirk.
The prevention of the steel oxidation duringreheating and rolling is an essential issue toreduce production cost and improve theproduct quality. In line with one of thepriorities of the Strategic Research Agendaof the European Steel Technology Platform(ESTEP), a new RFCS project aims to selectpossible protective means able to reduce thescale formation during reheating and rolling.
In order to reduce the scatter observed inthe material properties (mainly the
14 mechanical strength) of hot coiled strip as wellover the strip length as over the width, it is aimedto develop a new flexible and width-adaptablecooling device located before or at the coilerlevel. It will allow to adjust the cooling strategybased on the results of on-line iterativesimulations and measurements of strip tensileproperties. This development is conducted in theframe of a European RFCS project.
Cold rolling
New cooling techniques for enhancing theprocessing performances during cold rollingare investigated in a RFCS projectconducted in collaboration withArcelorMittal. Pilot trials realized on theARSA cold rolling mill at Maizières withthe HTRC technology (High TurbulenceRoll Cooling) have confirmed a highcooling performance of HTRC even with avery low water pressure of 0.5 bar. Theenergy consumption can be reduced bymore than 90% compared to conventionalnozzle cooling systems.
Surface cleanness in cold rolling is animportant issue for final product qualityaspects. Simulations on the formation andadherence of wear debris in relation with thelubricant parameters are conducted on thededicated plate out / wash-off simulator builtby CRM. In the frame of this RFCS projectcoordinated by Corus, the application of theremote LIBS technology for measuring on-line the sheet surface contamination is alsorealized. This LIBS unit has been acquiredthanks to the support of EFRD (EuropeanFund for Regional Development) and theWalloon Region.
The original method recently developed todetermine the quantity and homogeneity ofan oil film, plated out on a metal surface, hasproven its efficiency and reliability. Stable orunstable emulsions can be quickly measuredin a range between 0.02 g/m2 and 5 g/m2. Thetechnique is based on the use of fluorescence,UV lighting and a CCD camera.
15Thermal treatment and annealing
The controlled production of advanced highstrength steels implies a detailedquantification of the complex multi-phasemicrostructures, an objective pursued in theframe of a RFCS project involving alsoCorus and ArcelorMittal. CRM developed aquantitative assessment of banding due tomacro-segregation for steels like DP or TRIPgrades. The metallographic procedure relieson a mathematical treatment of the electronicimage. The surface occupied by onerepresentative phase is progressively eroded.This progressive erosion is made along andacross the rolling direction and shows afaster evolution across the rolling directionwhen banding is present. It leads to define ananisotropy index, helpful to better classifythe different steel grades.
Other RFCS research conducted withArcelorMittal and Corus aim at developingnew high resistance steel grades by:
- exploiting the formation of a hot rolledtempered martensite through the application
of a quench & tempering cycle in existing hot rolling lines (quench before coiling and tempering in the coil). High tensile strength can be reached while keeping a good elongation level.
- favouring the formation of ultra-fine bainiticstructure while limiting the consumption ofalloying elements such as niobium. Gainingmore basic knowledge in this field isnecessary, as the influence of alloyingelements on the bainitic hardenability hasnot been studied yet as extensively as themartensitic hardenability.
- applying a high magnetic field to influencethe recrystallisation and phasetransformation of steel during annealing (acollaboration with the University of Liège -Supras laboratory). Depending on the steelgrade, it has been shown that an increasingmagnetic field alters the martensiticstructures, promotes the presence of ahigher ferrite fraction after quenching andsoftens the microstructure.
FINISHING AND COATING
16 The activities of this department are clusteredaround some major fields covering the surfacepreparation of metallic products (pickling,degreasing), the annealing, the metallic coatingand the post-conditioning treatments.
The development of new coatings concepts andadvanced materials are also part of the activitiesas well as the detailed characterization andanalysis of the produced materials.
Unique pilot installations and characterizationequipment are available to support these actions.
It has to be especially pointed out that thecontinuous annealing and galvanizing pilot lineof CRM is integrated since the end of 2008 in ajoint venture with ArcelorMittal Research Liege,nicknamed “SAMCOAT” (Surfaces AdvancedMetallic Coatings).
Pickling
To support the projects conducted in this areaaiming to optimize strip surface quality and topartially or totally replace the use of acidspecies for removing oxides layer from
steel strip, a small simulator has been built thatcomplements the large scale equipmentavailable on the CASTL line. Let us recall thatthe CASTL line has been erected with thefinancial support of EFRD and the WalloonRegion.
Hot dip galvanization
For an efficient galvanizing of high strengthsteels, an appropriate control of the annealingfurnace atmosphere has to be carried outcombining a high dew point in a first sectionand a sufficiently high level of hydrogen in asecond one.
A new process window has been searched foraiming to replace the injection of water vaporby a partial reduction of the hydrogen amount. Ithas been shown that the benefit of a higheroxidation potential is only kept when thehydrogen level in the furnace is higher than 1%.It is due to the action of the steel carbon thatrapidly diffuses to the free surface and reducesthe amount of active water vapor.
Dross growth on rolls and hardwareimmersed in zinc bath is associated with the
17occurrence of stringent defects on galvanizedstrip.
To identify the build-up mechanisms, pilot linetests at CRM and industrial campaigns havebeen performed. Samples of various materialshave been placed on roll flanges and supports forthe duration of a full galvanizing campaign (GIor GA). At the same time, samples have beenplaced in static situation and removed from timeto time in order to gather some kinetic data.
Dross build-up has appeared depending on thehydrodynamic situation in the bath (higher is thelocal zinc velocity, bigger is the build-up).
Most probable evolution is, firstly, thenucleation of Fe2Al5 small germs on the rolls,then followed by a continuous Fe and Al feedingof those crystals supplied by the saturated flowof zinc along the roll. When the bigger crystalshave reached a sufficient size, the transport of Aland Fe towards the substrate surface is blocked,preventing underneath crystals growth.
As shown during several test campaigns, thisdross build-up is quite independent of the base
material. Even non-wetting materials (likegraphite or WC layers) are sensitive but theformed dross layer is easier to be removed fromthese materials.
A new wiping concept has beenexperimented on the continuous pilot line ata speed of 70m/min.
Based on a pair of thin metallic foils supportedby mechanical actuators and located at the exitof the zinc bath, it aims to progressively squeezethe liquid coating down to a few microns. Theobjective is to a find an alternative toconventional gas wiping limited by splashing athigh line speed.
The wiping efficiency has not reached theexpected level (~90/93% compared to the aimed97%) due to very small dross particles ratherrapidly entrapped between the foil and the strip.It has also failed to reach the expected fewmicrons thin coating. This problem of dross willrequire to develop a specific solution to allowthe further development of this new foilconcept.
18 Surface conversion treatment
Aiming a full chromium- and VOC-freecoating, a new system called “Silicalloy” hasbeen developed by CRM thanks to thefinancial support of the Walloon Region andthe collaboration with CoRi (Belgian CoatingResearch Institute).
This efficient, fast, green and low costtreatment, can be applied with a roll coater onsteel or metallic strip. The formed layer is avery thin (100nm) hybrid coating made of silicaand polymers. The combined structures providehardness and flexibility. The other advantagesof the coating are its transparency andhydrophobicity, that are key aspects for specificapplications of finished products. As far ascorrosion is concerned, this coating offersperformances similar to those of the bestconventional passivation products. Thecommercial valorisation and application of thisnew concept will be performed by DeleuzeS.A., a company affiliated to CRM, through adevelopment project of the “Marshall plan”supported by the Walloon Region and inpartnership with CMI, CoRI and FUNDP.
The development of another post-treatmentof the galvanized sheet aiming theincorporation of particles in the zinc coatinglayer before it gets solidified has beenpursued with the support of the WalloonRegion (“Sandwind” project).
Once the strip emerges from liquid zinc bath, thezinc excess is removed by gas wipers and thenthe strip is covered with a thin zinc film thatsolidifies at some distance upwards. The processtakes profit of the section where the coating isstill liquid to incorporate particles by jet sprays.By this method, significant improvements can beobtained in terms of reflectivity, surface aspect,friction, wear and resistance, ….
Tests have successfully been carried out on thegalvanizing pilot line of CRM and evidencedthe possibility to operate continuously whilemanaging the powder flow and the coatingadherence.
A new project (“nicknamed “Clearzinc”)and dealing with the development of newprotective coating concepts, possibly free of
19zinc, has been launched at the end of 2008 inthe frame of the EFRD programme 2007-2013, supported by the Walloon Region.
Product characterization
In the frame of a RFCS project, consisting toset up methodologies of hydrogenmeasurements in coated steels, CRM isdealing with sample preparation beforehydrogen analysis.
Different issues are treated: the impact of thecoating removal and machining of samples, thepossible hydrogen runaway resulting fromstorage, the incidence of the storage cryogenicmedium or of other chemical species used in thesample preparation, …
The results are quantified in terms of desorptioncurves obtained on a sophisticated home-mademeasurement unit, allowing to clearly identifythe impact of the different processingparameters.
In order to comply with more and morestringent specifications of the customers on
final products and to reach a fast and earlydetermination of these properties, sensorsallowing an on-line monitoring andcharacterization of the product surfacemorphology are proposed by the “AdvancedTechniques” department of CRM.
Waviness is one of the properties, especiallyimportant for the automotive sector. It requires adedicated development as mostly not eye-nakedvisible before painting of coated or uncoatedproducts.
Based on the on-line microscopy conceptdeveloped by CRM for the determination of theroughness profile on moving products, anadapted equipment has been designed in theframe of a RFCS project. It combines a highspeed camera, an adapted lighting unit,synchronization techniques and a new imageprocessing approach. Correlation with staticlaboratory measurements is encouraging andopens the way for industrial tests in Corus-Segaland ArcelorMitttal Avilès.
SUSTAINABLE PRODUCTION
20 In the upstream processes (sintering, blastfurnace, steelmaking), the expertise of CRMcovers a large range of activities from thedevelopment and implementation ofmetallurgical models and sensors to theoptimization of existing processes or theintroduction of new concepts.
It is completed by a high competence inenvironmental questions and by-productsrecycling and valorisation.
Sintering of iron ores
An important programme deals with thecontrol of the sintering process.
The “SuPerMagnag” sensor, implemented atArcelorMittal Gent to continuously provide amapping of the upper layer sinter quality hasbeen intensively exploited to assess its diagnosisand process control ability. A new sensorsupport has been designed, aiming at anoptimised robustness and reliability. It iscurrently in its final implementation phase. Thisconfiguration will allow, through continuouslong-term campaigns, to enhance the control on
the process and to reduce sinter heterogeneitiesand production costs.
In combination with this sensor application,CRM has pursued the development and theindustrial implementation of its sinter model asa complementary process control tool.
Blast furnace operations
CRM has successfully developed a robusttechnique to determine the liquid level evolutioninside the blast furnace hearth, measuring thedeformation of the hearth shell. The sensor canbe placed onto the hearth shell in less than threehours.
It was demonstrated on several blast furnacesthat the evolution of the new level indicatorgives a reliable information consistent with thetapping sequences. It can be used for improvedscheduling of the tapping operation and toprevent incidents like slag level reaching thetuyeres.
21 The European project “ULCOS” aiming todrastically reduce the CO2 emissions hasreached the second phase of developmentaiming to validate and demonstrate, at alarger industrial scale, the concept of theblast furnace operating with an importantrecycling of the top gas.
EAF Steelmaking
The development of a dynamic model of theEAF operations is progressing.
Contrarily to a statistical approach, the CRMmodel is based on a fundamental set ofcomputations integrating thermodynamics andkinetics aspects and taking into account thecyclic furnace data in real time. The mainpurpose of the on-line application is to providethe operator with a better estimation of thecharge melting state and of the liquid steeltemperature. This, in turn, will enable lower taptemperature and reduced energy consumption.The model has already been successfully usedfor off-line simulations of different furnaces andscenarios (e.g. various operating patterns).
Its first on-line application was carried out inArcelorMittal Esch-Belval. The deployment ofthe model is being pursued in otherArcelorMittal plants.
The accuracy of the model predictions isconstantly improved, taking into account theuneven arc distribution in AC furnace or bydeveloping in close collaboration withArcelorMittal Esch-Belval and Differdange (DCfurnaces) improved monitoring systems for anenhanced post-combustion rate (Off-gasmeasurements), for a tighter control on theburners or for a better appraisal of the scrapcharacteristics. Several of these actions areconducted in the frame of RFCS projects.
Environmental aspects
By-product recycling and valorization
CRM is notably equipped with a pilot rotaryhearth furnace (capacity : up to 100 kg/h).
In the frame of a project supported by the “Polesof Competitivity” of the Walloon region(Marshall Plan)
22 nicknamed Phoenix and coordinated by COMETTraitements, the treatment of organic matterscontained in the shredding residues of metalliccomponents is aimed at through a novel lowtemperature and emission processing. CRM ischarged to study the valorisation in the steelindustry of the carbon compounds issued fromthis new process. The equipment available atCRM will be complemented by a new mixer anda briquetting unit suited to condition thesecarboneous by-products together with iron-bearing products for feeding the RHF with self-reducing briquettes.
Improved air quality
During the 4 last years CRM has successfullycoordinated the Interreg III Euregio “Meuse-Rhin” programme on advanced techniques forfine dust abatement supported by the WalloonRegion. The other partners were RWTHAachen, Hogeschool Zuyd Heerlen and CMKHasselt.
The project consortium has in particular studiedthe possibility to comply with stricterenvironmental regulations by improving the
collection efficiency of dedusting systemsalready in place, without the need of expensiveadditional abatement means.
The concept tested at CRM is to agglomeratefine dust particles by applying powerfulultrasounds to the dust laden fumes in order tofacilitate the subsequent capture of the sogenerated clusters.
The bench-scale test results obtained at CRMwith dusts from different origins show theapplicability of this concept to a wide range ofindustrial processes (up to 50% improvementfor PM2.5 collection by bag filters).
Tests with fuel engine fumes have shown thatthe technique can also be efficient onnanoparticles.
A market study realized by CIDE-SOCRAN hasshown a real potentiality for this concept withpossible applications in medium-sized boilersfor collective heating systems or electricitygeneration.
SUPPORT TO REGIONAL AND FEDERAL ECONOMY
23CRM is actively contributing to the researchprogrammes launched by the Federal andRegional Belgian Authorities in partnership withother research centres, universities and industrialresearch laboratories.
Beside dedicated and thematic RD projects, theseactions aim to promote the innovation towardsthe industry and support the development of newcompetences.
In line with the “Poles of Competitivity” ofthe Walloon Region (nicknamed “MarshallPlan”), CRM contributes to several projects :
- The thixo-casting/forming of steel grades(“THIXOACIER”) to manufacture componentsthrough a “near net shape” approach iscoordinated by Marichal Ketin.
Casting trials, both in the CRM pilot installationand in the foundry of Marichal Ketin, haveshown that a fully globular microstructure ondedicated steel grades can be achieved by usingthe water cooled Hollow Jet Nozzle with ironpowder injection.
Forming tests have confirmed that this type ofglobular structure, when sufficiently reheated toobtain 20% of liquid fraction inside the structure,exhibits a thixotropic behaviour, i.e. it requires avery low forming force to be shaped at the finaldimensions.
- The project “MIRAGE”, coordinated byArcelorMittal, aims at developing innovativesteel products notably for the construction.
The CRM contribution is focused on the designof novel steel panels characterized by an“intelligent thermal behaviour” in order to bettermeet the daily heating-cooling cycles of abuilding. The basic concept is to use “PhaseChange Materials” (PCM) that are fixed inside aresin on the backside of the steel panels. Whenthe temperature is high, PCM accumulate heatand so prevent uncomfortable overheating. Theaccumulated heat is released during the nighttime. Prototype steel panels have been prepared(in collaboration with CoRI) and thecharacterisation of their thermal behaviour isperformed by a dedicated test called T-History.
24 - A similar concept is applied to developnew house furniture and finishing products. It isinvestigated in a collaborative project“RETERMAT” supported by the WalloonRegion and associating several Belgian researchcentres CRM, CSTC (Construction),CENTEXBEL (Textile) and CERTECH(Chemical).
- Another application of PCM is searchedfor in the project “EverFire”, launched in theframe of the Walloon programme “EnergyWall”,and aiming to develop renewable energy sourcesand high energy efficiency. Conducted incollaboration with the Belgian research centre forCeramic (BCRC), the objective is to develop aheat accumulator for medium temperature levels(400 to 800°C) to be installed in domestic hearth.
CRM is also active in the development ofsensors and analytical measurementtechniques for process control.
Using the LIBS technology, acquired thanks tothe support of EFRD and Walloon region,different industrial applications are explored.
- With the financial support of IWT, astudy is carried out for the remote analysis ofsemis in steelmaking and foundries.
Laboratory test, at 3 meter distance, on hotsamples from different steel grades, have shownthat the LIBS method can successfully analysetheir chemical composition without the need for aspecific calibration at high temperature.
Similar results prove the feasibility of thetechnology with cast iron, even containing a highlevel of alloying elements, up to a temperature of300°C, requested by the foundry process.
A second example of application concerns themeasurement of lead in solder for the electronicindustry. No fast analytical method applicable onvery thin components is today available, theexisting methods need very long specificcalibration procedures. Tests carried out at CRMshow that the LIBS method is a powerfulalternative way allowing a quasi non-destructiveanalysis on very small components, withoutspecific preparation.
GUIDANCE, TECHNOLOGICAL WATCH
25The CRM’s activity in providing a technicalsupport to small and medium companies iscontinuing thanks to the support of the WalloonRegion. It takes profit of the expertise andequipments available at CRM in wear, tribology,metal forming, fracture mechanics, fatigue,corrosion, surface and structure analysis,... TheISO 9001 certification covering all the CRMactivities and the ISO 17025 accreditation for agreat number of tests and calibration help toreinforce the CRM actions
As an example of the activities realised in 2008,let us mention :
- The analysis of the breakage of a weldedmetallic frame in galvanized steel. Detailedmetallographic examinations have revealedthat the main causes were attributed toexcessive fatigue sollications amplified bycorrosion problems and unadapted weldingconditions. A new welding mode has beendefined to solve the problem.
- The setting of a quality control approach forthe manufacturing of aluminum wheel rim.The on-site application of hardness
measurements allows to regularly control theinternal quality of the moulds used to cast thewheel rim.
- The support to an expertise study on thefracture origin of a springing bar used inprivate car. Detailed examinations haveconfirmed that the rupture was due to a shockresulting from a crash and not to fatigueproblems caused by eventual pre-existinginternal defects.
- The identification of the breakage of a rollsupporting shaft placed in a continuousannealing furnace. Rotary bending has led toa fatigue fracture initiated on surface defectscaused by a bad machining of the shaft.
- The multi-partners guidance “Surface andMaterial” involving Materia Nova, CoRI andCRM has organized on June 6, 2008 athematic day on “Corrosion resistance –Investigation means and protective coatings”.More than 40 people have joined the meetingheld at CRM Liege. All the information isavailable on the internet site: http:/www.gis-surfaces.be
PUBLICATIONS
26
Product Technology
P. NAVEAU, J.P. FISCHBACH, V. FLORES, J.M. DAMASSE, J.M. BOULET,B. GOURNAY,Industrial tests of the Hollow Jet Nozzle on the ArcelorMittal Isbergues slab caster,La Revue de Métallurgie, CIT, October 2008, Vol. 10, p. 513
G. LANNOO, I. TOLLENEER, J. MALBRANCKE,Asymmetric rolling in a hot strip mill : Opportunities and metallurgical effect,La Revue de Métallurgie, CIT, November 2008, Vol. 11, p. 562
L. BARBE, K. VERBEKEN,Microstructural characterization of dual phase steels by means of electron microscopy,Ceramic Transactions, June 1-6, 2008, Vol. 200, p. 71.
G. WALMAG, X. VANDEN EYNDE, M. SINNAEVE, R. ERNST,Mechanisms of work rolls degradation in HSM,Proceedings of ABRASION 2008, 3rd International Conference on Abrasion Wear ResistantAlloyed White Cast Iron for Rolling and Pulverizing, August 24-27, 2008, Trento, Italy.
G. WALMAG, X. VANDEN EYNDE, M. SINNAEVE, V. LECOMTE,Mechanisms of work rolls degradation in HSM,Proceedings of AISTech Conference, May 5-8, 2008, Pittsburgh, USA.
Sustainable Production
M. DORMANN, B. VANDERHEYDEN, D. STEYLS,Advanced technique to reduce the emissions of particulate matter,La Revue de Métallurgie, CIT, December 2008, Vol. 12, pp. 586-595.
P. NYSSEN, C. MATHY, M.S. MILLMAN, D. TOLAZZI, L. LONDERO, C. CANDUSSO, J.C.BAUMERT, M. BRIMMEYER, D GUALTIERI, D. RIGONI,Direct Observation of the Melting Process in an EAF with a Closed Slag Door,Proceedings of 9th European Electric Steelmaking Conference, Jagiellonian University, Krakow,Archives of Metallurgy and Material, May 2008, Issue 2, pp. 464-468.
C. MATHY, P. NYSSEN, M. BRIMMEYER, D. GUALTIERI, D. RIGONI, J.C. BAUMERT,Innovative technique for reliable operations and blow-back prevention of EAF annular burners,combined burners and injectors,Proceedings of 9th European Electric Steelmaking Conference, Jagiellonian University, Krakow,Archives of Metallurgy and Material, May 2008, Issue 2, pp. 469-473.
27
M. WAUTERS, P. ALBART, P. NYSSEN, J.-C. BAUMERT, M. PICCO, C. WEILER,Automated Assessment of Scrap Quality before Loading into an EAF,Proceedings of 9th European Electric Steelmaking Conference, Jagiellonian University, Krakow,Archives of Metallurgy and Material, May 2008, Issue 2, pp. 345-351.
G. DANLOY, S.A. ZAÏMI, T. CAMPOS, D. POMEROY, M. BENNANI,R. PEREZ-CHUST, B. LECACHEUX, D. HUANG,Blast Furnace Models Development and Application in ArcelorMittal Group,Proceedings of International Symposium on Recent Progress on Mathematical Modelling inIronmaking, Tokyo, Japan, October 16-17, 2008.
Application of Metals
G. WALMAG, P. NAVEAU, A. RASSILI, M. SINNAEVE,A new Processing route for as-cast thixotropic steel,Proceedings of 10th International Conference – Semi-solid processing of alloys and composites,Aachen-Liège, September 16-18, 2008.
CONFERENCES
28
Product Technology
J.F. NOVILLE, J. SMAL, J.C. HERMAN,Cooling to Optimise Properties of Hot Rolled Steel,SMEA Conference, University of Sheffield, UK, June 17-18, 2008.
H. UIJTDEBROEKS, D. ESPINOSA, B. VERVAET,Influence of Roll Lubrication and Roll Cooling on Product Quality,SMEA Conference, University of Sheffield, UK, June 17-18, 2008.
C. MARIQUE, J.C. CHARBONNIER,European Steel Response to World Challenges : The Strategic Agenda of ESTEP,SMEA Conference, University of Sheffield, UK, June 17-18, 2008.
L. BARBÉ, K. VERBEKEN,Microstructural characterization of dual phase steels by means of electron microscopy,Conference on texture of materials (ICOTOM15), Pittsburgh, Pennsylvania, USA,June 1-6, 2008.
C. MARIQUE,Updating the SRA priorities in scale free processing and intelligent manufacturing,Mirror Group, ESTEP (European Steel Technology Platform), Brussels, June 24, 2008.
G. WALMAG, X. VANDEN EYNDE, M. SINNAEVE, R. ERNST,Mechanisms of work rolls degradation in HSM,ABRASION 2008, 3rd International Conference on Abrasion Wear Resistant Alloyed White CastIron for Rolling and Pulverizing, Trento, Italy, August 24-27, 2008.
G. WALMAG, X. VANDEN EYNDE, M. SINNAEVE, V. LECOMTE,Mechanisms of work rolls degradation in HSM,AISTech Conference, May 5-8, 2008, Pittsburgh, USA.
Finishing and Coating
C. GEORGES, T. STUREL,Effects of hydrogen on materials,International Hydrogen Conference, Moran, Wyoming, USA, September 7-10, 2008.
J. CRAHAY, J.C. HERMAN,Top quality galvanised products against high zinc prices: a new challenge for steel,International Seminar on Coated Steels (ISCS 2008), Jamshedpur, India, February 14-16, 2008.
L. BORDIGNON,Galvanising of hot rolled strips: mechanism and parametric study,International Seminar on Coated Steels (ISCS 2008), Jamshedpur, India, February 14-16, 2008.
28 29
Sustainable Production
P. NYSSEN, C. MATHY, M.S. MILLMAN, D. TOLAZZI, L. LONDERO, C. CANDUSSO, J.C.BAUMERT, M. BRIMMEYER, D. GUALTIERI, D. RIGONI,Direct Observation of the Melting Process in an EAF with a Closed Slag Door,9th European Electric Steelmaking Conference, Jagiellonian University, Krakow,May 19-21, 2008.
C. MATHY, P. NYSSEN, M. BRIMMEYER, D. GUALTIERI, D. RIGONI, J.C. BAUMERT,Innovative technique for reliable operations and blow-back prevention of EAF annular burners,combined burners and injectors,9th European Electric Steelmaking Conference, Jagiellonian University, Krakow,May 19-21, 2008.
M. WAUTERS, P. ALBART, P. NYSSEN, J.-C. BAUMERT, M. PICCO, C. WEILER,Automated Assessment of Scrap Quality before Loading into an EAF,9th European Electric Steelmaking Conference, Jagiellonian University, Krakow,May 19-21 2008.
G. DANLOY, J. VAN DER STEL, B. KORTHAS, F. MÜLLER, H. JAK, D. SERT,J. BORLEE, V. DIMASTROMATTEO, M. HALLIN, N. EKLUND, N. EDBERG,L. SUNDQVIST, B.E. SKÖLD, R. LIN, A. FEITERNA, C. FEILMAYR,A. HABERMANN, A. BERTHELEMOT, M. GRANT,Evaluation of the ULCOS Blast furnace process at LKAB Experimental BF in Luleå,Scanmet III Conference, New Technologies, Luleå, Sweden, June 9, 2008.
J. BORLEE, J. VAN DER STEL, B. KORTHAS, F. MÜLLER, H. JAK, G. DANLOY, D. SERT,V. DIMASTROMATTEO, M. HALLIN, N. EKLUND, N. EDBERG, L. SUNDQVIST,B.E. SKÖLD, R. LIN, A. FEITERNA, C. FEILMAYR, A. HABERMANN, A. BERTHELEMOT,M. GRANT,Developments and evaluation of the ULCOS Blast furnace process at LKAB Experimental BF inLuleå,Scrap Substitutes & Alternative Ironmaking V Symposium, Baltimore, USA, November 2-4, 2008.
J. BORLEE, G. DANLOY, BERTHELEMOT, D. SERT, J. VAN DER STEL, H. JAK,V. DIMASTROMATTEO, M. HALLIN, N. EKLUND, M.PETTERSON, G. ZUO, N. EDBERG,B.E. SKÖLD, R. LIN, A. FEITERNA, B. KORTHAS, F. MÜLLER, C. FEILMAYR,A. HABERMANN,The trials of the ULCOS new blast furnace concept,STAHL 2008 Annual Conference, Düsseldorf, Germany, November 13-14, 2008.
G. DANLOY, S.A. ZAÏMI, T. CAMPOS, D. POMEROY, M. BENNANI,R. PEREZ-CHUST, B. LECACHEUX, D. HUANG,Blast Furnace Models Development and Application in ArcelorMittal Group,ISIJ Conference, Tokyo, Japan, October 2008.
30
G. DANLOY, J. VAN DER STEL, P. SCHMÖLE,Heat and mass balance in the ULCOS Blast Furnace - Poster presentation,4th ULCOS Seminar, Essen, Germany, October 1-2, 2008.
G. DANLOY,Modelling of the blast furnace internal state with MOGADOR - Poster presentation,4th ULCOS Seminar, Essen, Germany, October 1-2 2008.
Application of Metals
D. SOMMER, V. TUSSET,Material Control laboratory (Join laboratories for determination of Chemical composition,Mechanical properties - Metallography analysis),CETAS – Meeting CRM Liège January 29-30th , 2008.
V. TUSSET, O. LEMAIRE, G. MONFORT, A. DUPONT,Le strumentazione portatili Spectrometria OES & FRX,Associazione Italiana di Metallurgia, L'analisi chimica dei materiali metallici- Milano, Novembre12-13, 2008.
V. TUSSET,L‘analisi di Carbonio, Zolfo, Azoto, Ossigeno, Idrogeno (C,S,N,O,H,)Associazione Italiana di Metallurgia, L'analisi chimica dei materiali metallici- Milano, Novembre12-13, 2008.
V. TUSSETEvolution CETAS (Commission Européenne d’Etude et d’Application de Travaux de l ’Analyse enSidérurgie),CETAS/Jernkontoret Nordic Chemists' and Metallographers' Conference 2008 Sigtuna, Sweden,November 26-27, 2008.
G. MONFORT, J.F. NOVILLE, V. TUSSET,Optimization of LIBS measurements for on-line applications in harsh industrial environments,LIBS2008- 5th International Conference on Laser-induced Breakdown Spectroscopy, Berlin,Germany, September 22-26, 2008.
G. WALMAG, P. NAVEAU, A. RASSILI, M. SINNAEVE,A new Processing route for as-cast thixotropic steel,10th International Conference – Semi-solid processing of alloys and composites, Aachen-Liège,September 16-18, 2008.
Centre de Recherches Métallurgiques asbl
Centrum voor Research in de Metallurgie vzw
Avenue du Bois Saint-Jean, 21Domaine Universitaire du Sart Tilman (P59)
B-4000 LIEGETEL. : +32-(0)4-2546 211FAX +32-(0)4-2546 464
E-mail : [email protected]
Technologiepark 903cB-9042 ZWIJNAARDE (GENT)TEL. : +32-(0)9-2645 764FAX +32-(0)9-2645 834
E-mail : [email protected]
http://www.crm-eur.com
