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Proceedings of the

Iron & Steel Technology Conference

Volume I

6-9 May 2013

Pittsburgh, PennsylvaniaU.S.A.

ASSOCIATION FORIRON& STEEL

\^ juimwi'idw

Ronald E. Ashburn, Publisher

Karen D. Hickey, Managing Editor

Christopher P. Brown, Lead Graphic Designer

Krista J. McGhee, Copy Editor/Graphic Design Assistant

A Publication of the Association for Iron & Steel Technology

TABLE OF CONTENTS

AISTech 2013 - Volume I

HOWE MEMORIAL LECTURE

Howe Memorial Lecture

The Power of Steelmaking— Harnessing High Temperature Reactions to

Transform Waste Into Raw Material Resources 1

V. Sahajwalla, M. Zaharia, I. Mansuri, R. Rajarao, R. Dhunna, F. Nur Yunos, R. Khanna, N. Saha-Chaudhury,

P. O 'Kane, A. Fontana, C. Skidmore, P. Vielhauer, D. O 'Connell, D. Knights

SAFETY AND HEALTH

Safety and Health

Innovative Approach to Industrial Lighting 19

Kent Lewis, Edgardo La Bruna, Amy Ford, John Sundy

Electrical Safety Myths and Misconceptions 27

James R. White

Hazard Protection Glass Design Specification for Use in Safeguarding Personnel AgainstMolten Metal Steam Eruptions 33

Charles E. Tomazin, Paul Ennis, Randall P. Roudabush, Carrie E. Davis, KirkA. Marchand

Achieving Operational Safety on Ladle Stirring With Automatic Gas Couplings 51

Christian Glossl, Wilfried Stroissnigg

The Synthesis of Standard Technologies to Create a Life Safety Solution

Applicable to the Steel Industry 57

ErnestJohnson, Tracey Countryman, Kevin Jackson, Christian Roth

ENVIRONMENTAL

Computational Fluid Dynamics (CFD) Modeling in Environmental Applications

CFD Modeling of a Flooded Disc Scrubber 63

Guangwu Tang, HongchangDang, Bin Wu, Theresa Obias, Jesse R. Santos, RichardE. Trzcinski, Chenn Q. Zhou

Water/Wastewater

Wastewater Treatment for the Coke Oven Batteries at U. S. Steel Canada Hamilton Works 73

MichaelA. Thomson, Meint Olthof, Sam Shelby Jr., Andrew Sebestyen, Ronald Sejevick, Robert Bowman,JavedIqbal, Roger Tristani

Efforts for Cooling Water Saving in a Steelmaking FacilityS. Cattarino, M. Colautti, S. Mansutti

87

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Unique Filter Design for Heavy Industry Cooling Water 99

Marcus N. Allhands

Application of a Mercury Variance Plan of Study: A Case Study 109

James Skubak, Mark Grabigel, Mark A. Amendola

ENVIRONMENTAL/COKEMAKING

Improvements in Byproduct Plants and Environmental

Investigation of Different Equipment Setups for Ammonia Wash and Desulfurization 123

Frank Sowa, Michael Wolf

Effective Energy Utilization at the NCE Coke Plant in Japan 137

Ryuji Sakata

Impact of Cokemaking Technology on a Steel Plant's Carbon Footprint 141

Chris Sharp, Yakov Gordon, Sining Liu, Paul Towsey, Ian Cameron

ENVIRONMENTAL/IRONMAKING

Ironmaking Environmental

Modern Blast Furnace Gas Cleaning—A Report of State-of-the-Art Technology 149

Franz Reufer, Christian Davidi

Characterization of Sinter Plant Emissions 159

Guilherme Correa Abreu, Luciana Correa Magalhaes, Bernardo Enne Correa da Silva, Salustiano M. Pinto,Rinaldo Henrique Pedrini, Marcos Edgardo Suringar, Glenn C. England, Bruce E. Dumdei, Marco De Moura

Sorting Out the Hazards of Anhydrous Taphole Clays 169

Ryan A. Hershey, James W. Stendera, Glenn G. Biever

ENVIRONMENTAL/ELECTRIC STEELMAKING

Innovation in EAF Ventilation

Enhanced Capture of Mercury in Baghouse by Using Novel Filtration Media and Filter Design 175Vishal Bansal, Robert W. Taylor, Pete Maly, Michael Johnson, Bryan Yetter

NOx Sources and Production in a Consteel Electric Arc Furnace 185

Stephen Tullis, Ali Korabi, Ian Deeks

Low-Cost Offgas Combustion Enhancement to Improve Fume/Heat Control System Performance 193Dejan Zrelec

Development of the Direct Evacuation Control System for Modern Electric Arc Furnaces 205J. Belous, M. Marz

Optimization of Building Ventilation for Gerdau Beaumont Meltshop

Using Physical Fluid Dynamic ModelingJ. Belous, R. Anawate, J. Lahita

213

ENVIRONMENTAL/OXYGEN STEELMAKTNG

Oxygen Steelmaking Sustainability Programs

Flammability Limits for Oxygen Steelmaking Offgas Mixture and

Their Implementation in a Steelmaking Shop 225

Yun Li, Gabriel Trefa

Flexible BF/BOF Technologies Designed to Produce Steel in the Most Efficient, Productive and

Cleanest Way Possible When Using a Diverse Raw Materials and Energy Mix 239

D.J. Zuliani

COKEMAKING

Cokemaking New Technologies

A Review on Stamped Charging of Coals 253

Jorge Madias, Mariano de Cordova

Methodology for Cokemaking Technology Selection for Operating Conditions and

Expansion of Iron and Steel Works 263

Yakov Gordon, Rick Brown, John Busser, Michiel Freislich, Ian Cameron

Coal and Coke Quality

Predictive Model for Blending Coking Coals Part 1: Western Canadian Coals 273

Ross Leeder, Ka WingNg, Louis Giroux, Tony MacPhee, Cornelis Kolijn

Relationship Between CSR/CRI and Coal Properties via Principal Component Analysis Approach 283

Ka Wing Ng, Louis Giroux, Tony MacPhee, Barry Ryan, John Price, Ross Leeder

The Petrography of Metallurgical Coke 293

DavidE. Pearson, RichardA. Pearson, Yuekan Jiao, Hee Kyoung Park

Influences on Bulk Density and Its Effect on Coke Quality and Internal Gas Pressure 307

Drazen Gajic

Cokemaking Process Control

Coke Wet Quenching Moisture Reduction Aid 321

N. Morrison, U. Turunc, N. Arumugam

Reliable and Maintenance-Free, Radio-Based Positioning System for Coke Plant

Battery Cars at U. S. Steel Canada, Hamilton Works 329

Thomas Boric, Edgardo La Bruna, Fernando Marsonet

1

Retrofitting Coke Oven Pressure Control Without Stopping Production 335

Giovanni Siri, WinfriedFaust, Leon Herrell

Coke Size and Shape Characterisation for Bed Permeability Estimation 343

Ka Wing Ng, Louis Giroux, Tony MacPhee, Ted Todoschuk, Cornells Kolijn

The Improvements of the Coal Moisture Control System in a Cokemaking Plant 355

Der-Her Wang, Ming-Tzai Hung, Chao-Wen Chen

IRONMAKTJVG

Blast Furnace Operations

The Best Way to Blow-In of Blast Furnace: Definition, Philosophy, Theory and Practical Approach 367

MichaelA. Alter, Charles C. McGovern

Curse to Cure—The Utilization of Titanium-Bearing Products in Blast Furnace Ironmaking 381

Stuart Street, Charles Copeland, Elizabeth Worral

Development of Channeling Prediction System for a Blast Furnace 405

Jia-Shyan Shiau, Chi-Chung Wang, Chung-Ken Ho, Che-Hsiung Tung

Raw Materials

Blast Furnace Value-In-Use Model and Its Application for Iron Ore Processing 413Michiel Freislich, Harry Brunger, Leigh Harris, Yakov Gordon

Influence of Coke Breeze Positioning on the Sintering Behavior of Pellets andRaw Material Bed With Embedded Pellets 423Takahide Higuchi, Yuji Iwami, Yosuke Kuriki, Koichi Nushiro, Michitaka Sato, Nobuyuki Oyama

Guidelines for Selecting Pellet Plant Technology 435M. Huerta, I. Cameron, K. O'Leary, J.M. Mourao, U.V. Medeiros

Characterization of Different Lump Ore Brands According to Industrial-Scale ProcessConditions by Means of Reducibility Testing and Morphological Investigation 447M.B. Hanel, H Mali, J.F. Schenk, F. Hauzenberger, C. Thaler, H. Stocker, M. Skorianz

Refractory Applications

Finite Element Analysis (FEA) Applied to Hot Blast System Design 457Attilio M. Colangelo

Advanced Stoves Operation at voestalpine Stahl Donawitz With SIMETAL BF VAIron 471Arno Habermann, Alexander Marout, Harald Fritschek, Thomas Kronberger, Martin Schaler

Accommodating Iron-to-Carbon Interface Issues in the Blast Furnace Hearth 481Albert J. Dzermejko

Design Improvement and Repair ofInternal Combustion Chamber Stoves 497Hani El Kassas, Martin Gantenberg, Eric Schaub, Johannes Miinzer

j

Comparison of Different Systems of Hot Blast Stoves 509

Martin Gantenberg, Eric Schaub, RalfAllmannsdorfer, Alexander Klima

Alternate Ironmaking

Process Development of a New DRI Technology for Oolitic Iron Ores 519

V. Hernandez, K. Peake, A. Dalvi, R. Brown, J. Olurin, T. O 'Farrell, M. Zhou, B. Liu, I. Cameron

Technological Solutions for Intensive Production of Low-Silicon Hot Metal in

Blast Furnace Processing Vanadium Containing Titania-Magnetite 527

Sergei Zagainov, Sergei Filatov, Yakov Gordon, Olga Sobianina

Comparison Between Some Processes for Production of Hot Metal 537

Marcio Fernandes da Cunha Rodrigues, Junio Augusto Rodrigues Pasqual, Paulo Santos Assis

The Calderon Unique Process for Making Direct Iron and Steel 551

A. Calderon

Injection

Fundamental Evaluation of Natural Gas Co-Injection With Coke Oven Gas or Coal 559

Louis W. Lherbier Jr., Michael F. Riley

Numerical Simulation of the Co-Injection of Natural Gas and Pulverized Coal in Blast Furnace 573

Yan Chen, Dong Fu, Chenn Q. Zhou

Brazilian Potential of Biogas Use as Fuels in Metallurgy: Process, Management and Costs 581

Kerlly Oliveira Calixto, Carolina Avila Martins, Maximo Eleoterio Martins, Paulo Santos Assis

CFD-Simulation of the Blast Furnace Process: Injection of Heavy Oil and

Plastic Particles Into the Raceway 595

C. Maier, C. Jordan, C. Feilmayr, C. Thaler, M. Harasek

Effect of Blocking Oxygen Burner on Temperature Distribution in the Freeboard of

COREX Melter Gasifier by Introducing a Three-Dimensional Mathematical Model 609

Kaiping Du, Shengli Wu, Mingyin Kou, Jing Sun

Equipment and Devices

No-Bell Top Proves Its Reliability in Service 619

M. Schwob, F.-J. Irnich, S. Buzga

Accurate and Flexible NDT Measurements of Copper and Cast Iron Stave

Thicknesses in the Blast Furnace 629

Afshin Sadri, Barry Hyde, BradDempsie, Koorosh Mirkhani

Development and Application of Blast Furnace Burden Surface Profile Visualization Technology 637

Zhengkai Gao, Jianliang Zhang, Yuanxing Zhu, Chuanhui Li, Lei Wan, Tai Gao

Torpedo Ladle Positioning System Using Artificial Vision System 643

Mariano Zecchi, Edgardo La Bruna

Dry Slag Granulation - The Environmentally Friendly Way to Making Cement 649

Ian J. McDonald, Andrea Werner

Blast Furnace Modeling

Model for Real-Time Prediction of Cohesive Zone Shape and Location Inside a Blast Furnace 657M. Guha, S. Rai, M.K. Agarwal, R. V. Ramna

Development and Application of Discrete Element Charging Burden Model for Blast Furnace 665Chung-Ken Ho, Shan-Wen Du, Chi-Seng Chou, Che-Hsiung Tung

Evaluation of Using Tire Waste Into Charcoal or Coke Blast Furnaces 675Alex M.A. Campos, Amanda Crisiina Goncalves, Natalia Chaves Almeida, Gemirson de Paula Reis,Carlos Frederico Campos Assis, Paulo Santos Assis

Other Burden Materials

Use of Hot Briquetted Iron Made From Low-Grade Iron Ore Pellets in a Blast Furnace 685Thomas Battle, Urvashi Srivastava, Mark Boedecker

Circular Pelletizing Technology — A Revolutionary Solution 691Christoph Aichinger, Andre Fulgencio, BernhardHiebl, Reinhard Redl, Hans Stiasny

ELECTRIC STEELMAKING

EAF Performance Improvements I

Next-Generation EAF Optimization at ArcelorMittal Dofasco Inc 697Marshall Khan, Suresh Mistry, Vittorio Scipolo, Stanley Sun, Stephen Waterfall

Evraz Pueblo Best Practice Operation With SIMETAL EAF Ultimate Technology—Seven Years of Records in the Making 707Dave Ellis, Valerie Varick, Markus Abel, Thomas Daum

Determination of the Intrinsic Value of Ore-Based Metallics 717JeremyA. T. Jones

EAF Optimization and Energy Recovery

Meltshop Yield and Heat Size Improvements at ArcelorMittal Indiana Harbor — Long Carbon 725MuraliM. Collur, Bruce A. Webb, Randy R. King, IderaldoL.B. Cruz, Fred A. Jaicks, Marssal V. Victorino,Jim L. Bulfer, BUI A. Cravens, Nick A. Mundo, Don K. White

Electric Arc Furnace Process Optimization at ArcelorMittal Point Lisas 735Alexandre Rail, AshrafHanna, Ronnie Partapsingh, Matthias Madey

Productivity Benefits in the Electrical Steelmaldng Process by Means of Reactive Power Compensation 745A. Owens, A.J. Persson, R. Griinbaum

Green Technologies for Higher Energy Efficiency in Electric Steelmaking 753Martin Fleischer, Jorg Schwdrer, Jan Liickhoff

Novel Solutions for Arc Furnaces

Benefits of EAF Bottom Purging Systems 761

Marcus Kirschen, AshrafHanna, Karl-Michael Zettl

Safe and Productive Electric Arc Furnace 769

Stefano Miani, Alessandro Fornasaro, Luca Gemo, Mauro Milocco

Breakthrough Technology for Real-Time Water Detection in EAF Steelmaking 781

Doug Zuliani, Vittorio Scipolo, Ovidiu Negru, Marshall Khan

EAF Performance Improvements II

DC EAF Modernization With Siemens Metals Technologies Fin-Type Anode 791

Thomas Handrich, Michel Huck, Markus Abel, Peter Petrov

How Changes in Scrap Mix Affect the Operation of Consteel® EAF 795

Francesco Memoli, Jeremy A.T. Jones, Federico Picciolo

OXYGEN STEELMAKING

BOF Productivity

Application of Thermodynamic Analysis for Developing Strategies to

Improve BOF Steelmaking Process Capability 809

Kinnor Chattopadhyay, Sunil Kumar

Slag Splashing Practices and Basic Oxygen Furnace Lining Recommendations 821

AshrafHanna, Thomas Kollmann, Hans Joerg Junger, Alexander Cepak

Steel Shop Themodynamic and Logistic Model Development as a Process EngineeringStudent Training Method at V&M do Brasil 829

Stephano Papadopoli Tonelli Piva, Andre Amaral, Dione Moreira Araujo, Ronaldo Santos Sampaio

Systematic KOBM Process Control Based on Offgas Information 839

Dongsheng Liao, Stanley Sun, Kevin Boylan, Mike Sohm, Neal Pyke

BOF Chemistry

Strategic Planning for Desulphurization in Integrated Steel Plants 851S. Kumar, J. McGinty, K. Chattopadhyay, V. Hernandez, Y. Gordon

Low-Cost Scrap Does Not Low-Cost Steel Make 865Sara A. Hornby

Effect of Blow Parameters in the Mixing Time Using Physical Model of BOF Converter 875

Breno Totti Maia, Ronan Almeida Faustino, Gustavo Abreu, Bernardo Costa, Roberto Parreiras Tavares

Phosphorus Removal in Oxygen Steelmaking: A Comparison Between Plant and Laboratory Data 889A.N. Assis, R.J. Fruehan

Blow Practices and Endpoint Prediction

Advanced Blowing and Stirring Conditions in the BOF Process 897

Hans-Jurgen Odenthal, Pavlo Grygorov, Markus Reifferscheid, Jochen Schliiter

Introducing the BOF Blowing Process Model— A Tool for Practice Improvement 911

Diancai Guo, Darrell Swickard, James Bradley

A Novel Data-Driven Prediction Model for BOF Endpoint 923

Jochen Schluter, Hans-Jiirgen Odenthal, Norbert Uebber, HendrikBlom, Katharina Morik

OXYGEN STEELMAKING/MAINTENANCE AND RELIABILITY

BOF Maintenance

Life Extension of BOF Lower Hood at U. S. Steel Canada's Lake Erie Works

via Engineering and Design Changes 929

Samar K. Saha, DavidJ. Radakovic, Thomas A. Walden

Innovative Solutions to Drive Sustainability — An Overview of Latest Developments bySiemens VAI Metals Technologies 939

Andreas Flick, Gerard Fliegel

SPECIALTY ALLOY AND FOUNDRY

Melting and Casting of Specialty Steels and Alloys

Process Optimisation Model for FeMn and SiMn Production 951

E. Jipnang Njamen, P. Monheim, H.J. Oterdoom, H.J. Odenthal, J. Schluter

Riser Sleeves 959

Tyler J. Schnieter

Automatic Ingot Mold Cleaning and Its Value for Ingot Casting 967Michael Pillwax, Heinz Rumpler, LeonhardPaar

Design and Application of Advanced Semi-Automated Ingot Teeming Systems 975Christian Redl, Stellan Hammarqvist

Evolution of Secondary Inclusions During Electroslag Remelting Process 983Cheng-bin Shi, Han-jie Guo, Xi-chun Chen, Xiao-lin Sun

LADLE AND SECONDARY REFINING

Inclusion Engineering and Clean Steels Plenary Talks

An Overview of Steel Cleanliness From an Industry Perspective 993E.B. Pretorius, H.G. Oltmann, B.T. Schart

Methods of Quantifying Non-Metallic Inclusions and

Assessing Steel Cleanliness — Part I

Effect of Submerged Entry Nozzle Design on the Distribution of Inclusions in Cast Products 1027

C. Capurro, J. Copola, S. Ferro, C. Cicutti

Correction of Matrix Effects on Microanalysis ofCalcium Aluminate Inclusions 1037

P. Chris Pistorius, Arshey Patadia, Jeeyoung Lee

The Behavior of Inclusion Components in High-Aluminum and High-Silicon Steels 1045

Wouter Tiekink, Aart Overbosch, PieterBroersen, Rob Kooter, Bert van Arendonk, Marco Rijnders

Improvement of the Sampling Methodology for the Cleanliness Measurement in the Liquid Steel Stage 1051

F. Ruby-Meyer, S. Evrard, M. Vergauwens, P. Balland

Use of an Inverse Algorithm for 2D to 3D Particle Size Conversion and

Its Application to Non-Metallic Inclusion Analysis in Steel 1061

Simon N. Lekakh, Vivek Thapliyal, Kent Peaslee

Development of an Inclusion Characterization Methodology for Improving Steel Product Cleanliness....

1069

Sunday Abraham, Justin Raines, Rick Bodnar

Impact of Inclusions and Impurities on Product Performance

Effect of Rare Earth Oxides in Plain Carbon Steels 1085

R. Tuttle

The Effects ofInclusions on Fatigue Performance of Steel Alloys 1095

K.O. Findley, R.L. Cryderman, A.B. Nissan, D.K. Matlock

Inclusions and Their Behavior in Ultrahigh-Strength Steels 1105

Mark A. Rhoads, Jon R. Groh, XishanXie

Effect of Oxygen on the Interfacial Tension of Liquid Fe 1117

Joonho Lee, Yunkyum Kim, Joongkil Choe, MajidAbbasi

Methods of Quantifying Non-Metallic Inclusions and

Assessing Steel Cleanliness — Part II

Development and Application of a Remelt Method for Rapid Collection and Observation of Inclusions....

1123

Howard M. Pielet, Scott Schuldt

Three-Dimensional Investigation of Large-Size Inclusions and Clusters in Steels by

Using Electrolytic Extraction Technique 1139

Andrey Karasev, Yanyan Bi, Par G. Jonsson

In-Situ Observation of the Formation and Interaction Behavior of the Oxide/OxysulfideInclusions on a Liquid Iron Surface 1147

Pengcheng Yan, Muxing Guo, Bart Blanpain

Fundamentals for the Formation of Mg-Al-Ti-O Compound Inclusions in Steel 1159

Ying Ren, Shusen Li, Lifeng Zhang, Shufeng Yang, Wen Yang

1

Slaft-Metal Interactions and Steel Cleanliness

The New Continuous Casting Machine at ArcelorMittal Temirtau (Kazakhstan)

Dogan Ertas, Paolo Turolo

LADLE AND SECONDARY REFINING/CONTINUOUS CASTING

Controlling Non-Metallic Inclusions and Impurities During

Steelmaking. Refining and Continuous Casting — Part I

A Thermodynamic Model and Database of Oxysulfide Inclusions Containing Ca-Mn-Si-Al-O-S 1179

Rongxun Piao, Dae-Hee Woo, Hae-Geon Lee, Youn-Bae Kang

Kinetic Model to Predict the Change in Chemical Composition of Inclusions During Ladle Treatment 1191

A. Harada, N. Maruoka, H. Shibata, S. Kitamura

Control of Ca-Containing Inclusions in Al-Killed Steel Grades 1201

Scott R. Story, Riadl. Asfahani

Slag-Metal Interactions and Steel Cleanliness

Mold Slag Entrainment Mechanisms in Continuous Casting Molds 1215

Lance C. Hibbeler, Brian G. Thomas

Model Studies on Slag Metal Entrainment in Gas-Stirred Ladles 1231

A. Senguttuvan, G.A. Irons

LADLE AND SECONDARY REFINING/METALLURGY —

STEELMAKING AND CASTING

Controlling Non-Metallic Inclusions and Impurities During

Steelmaking. Refining and Continuous Casting — Part II

Inclusion Engineering and the Metallurgy of Calcium Treatment 1243

Sunday Abraham, Rick Bodnar, Justin Raines

Tundish Design at Steel Dynamics Butler Flat Rolled Division for Improved Steel Cleanliness 1259Anthony Bader, Kyle Vanover, Amy Woods

Controlling Non-Metallic Inclusions and Impurities During

Steelmaking. Refining and Continuous Casting — Part III

Inclusion Control Model in Ladle Metallurgy Furnace 1273Jorgelina Perez, Gordon A. Irons

Effect of Ce Addition on the Formation Behavior of Inclusions in Stainless Steel Melts 1285Joo Hyun Park, Sun KukKwon

Characterization of Non-Metallic Inclusions and Micro-Porosity in Steel:

Forged Ingots, Centrifugal and Net Shape CastingsJianxun He, Kent Peaslee, Von Richards

1293

Comparison of Three Approaches to Al-Si Deoxidized Steel and Al-Killed Steel 1301

Jia Tan, P. Chris Pistorius

Inclusion Characterization and Cleanliness Assessment for High-Strength, Low-Alloy Steels 1313

Paul Chao-Peng Wu, Yindong Yang, Guifang Zhang, Alex McLean