Proceedings of the

Iron & Steel Technology Conference

Volume II

5-8 May 2014

Indianapolis, Indiana

U.S.A.

^+

ASSOCIATION FOR IRONS STEEL

AiUMIUVM

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 ofthe Association for Iron & Steel Technology

TABLE OF CONTENTS

AISTech 2014—Volume II

SPECIALTY ALLOY & FOUNDRY

Specialty Alloy & Foundry I

Development of High-Efficiency Refining Process in Stainless Steelmaking Plant at WakayamaSteelWorks 1343

Reita Saito, Hiroaki Yamazoe

Source and Transport Mechanism of Exogenous Inclusions in Vacuum-Poured Ingots: Part I—

Identification of Sources and Fluid Flow in Pony Ladle (Tundish) 1355

Tathagata Bhattacharya, Jason Fehr, Mike Wooddell, Bob Nester, Cory Chappell, Pallava Kaushik

Source and Transport Mechanism ofExogenous Inclusions in Vacuum Poured Ingots: Part II—

Fluid Flow and Solidification in the Mold 1373

Tathagata Bhattacharya, Jason Fehr

Review and Modeling of Energy Efficiency in American Steel Foundries 1385

Jianxun He, Siddhartha Biswas, Todd Sander, Simon Lekakh, Jeffrey Smith, Von Richards, Kent Peaslee

Specialty Alloy & Foundry II

Partial Substitution of Co for Ni in Stainless Steels 1397

Dennis Rodal, Ram Singh

Electro Slag Rapid Remelting (ESRR®) —A Novel Technology for the Production of High-Quality,

Near-Net-Shaped Billets and Blooms 1405

Michael Kubin, Alexander Scheriau, Matthias Knabl, Harald Holzgruber

The Use of Steel Mill Waste for Removal of Si in Recyclable Austenitic Stainless Steel 1411

Ricardo Baeta dos Santos, Jose de Oliveira, Estefano Vieira

LADLE & SECONDARY REFINING

Slag-Metal Interaction During Ladle Refining

Inert Gas Control Systems for the Steel Industry 1419

Richard Ardell, Florian Schmitt

Optimization of Argon Stirring at Hadeed Ladle Furnace by Application of Trustir Technology 1423

Narottam Behera, Ahmed Wohaishi, Rajesh Subramanian, Neeraj Tewari, Rama Bommaraju

Thermodynamic Evaluation ofthe Slag System CaO-MgO-Si02-Al203 1433

Wagner Bielefeldt, Antonio Vilela, Nestor Heck

Steel Desulfurization Using Sintered Synthetic Slag 1447

Jose Fldvio Viana, Marcus Motta

Simulations of Slag-Metal Entrainment in Ladle Metallurgy 1453

Anand Senguttuvan, Gordon Irons

Vacuum Treatment Technology & Process Control

Steam Ejector Versus Mechanical Vacuum Pumps 1465

Dieter Tembergen, Frank Dorstewitz, Kevin Cotchen

Advantageous Optimization of the VOD Process With Mechanical Vacuum Pumps 1479

Anke Teeuwsen, Graham Legge, Alessandro Villa, Guowei (Will) Deng

The Challenge of Using Mechanical Pump Systems for VOD Operation 1489

Markus Abel, Andrea Pezza, Willi Biihler, Jose David Martinez Cerezo

Ozkan DC Vacuum Tank Degasser Performance and SMS Concast Vacuum Pump Supermodule 1499

Mauro Milocco, Enver Soner, Fabio Trigatti, Giirkan Giirler

Start-Up of the 165-Ton Twin-Tank Vacuum Degasser With Dry Mechanical Vacuum Pumping

System for Nucor Hertford's Plate Mill 1513

Scott Andrews, Bryson Trumble, Adam Brooks, Lee Jackson, Francesco Memoli, Sergio A. Guzman,

Kyle J. Shoop

Experience With a Revamped VD-VOD System With Dry Mechanical Pumps 1523

Adam Partyka, Miguel Angel Iriarte, Riccardo Gottardi, Stefano Miani

Inclusion Control & Clean Steel Production I

Effective Internal Quality and Chemistry Controls for the Production of Sour Gas-Resistant

Pressure-Vessel-Quality Steels 1535

Amar De, Raul Torres, Mario Chavez, Ruben Garcia, Gustavo Campos, Jose Fernandez, Jorge Nieto

Ladle Technology & Process Control

Experience With Unique IR Vision System at GKN Hoeganaes LRF 1545

George Kychakoff, Randall Stone, Chris Glover, Christopher Addison

Back Pressure Correlation — A Method to Determine Gas Flow Status at LMF 1551

Hoyong Hwang, Yong Lee, Andrew O'Loughlin, Erik Strobel

Technical Advances in Ladle Gate Design 1563

Richard Ardell, Reinhard Enrengruber

Physical Ladle Tracking 1567

Federico Ahualli, Juan Sagasti, Steven Meyer, Francesco Memoli

A New Vibration Ladle Slag Detection System 1577

Jiantao Yang, Lu Tian, An Fei

LADLE & SECONDARY REFINING/METALLURGY— STEELMAKING & CASTING

Kinetics in Secondary Steelmaking

On the Formation of Coarse Niobium Particles in Microalloyed HSLA Steels 1587

Shahrooz Nafisi, Aaron Den Boer, Laurie Collins

Effect of Nickel, Copper and Chromium on Stacking Fault Energy of FCC Iron 1599

Krista Limmer, David Van Aken, Julia Medvedeva

Formation Mechanism of CaO-CaS Inclusions in Pipeline Steels 1607

Ying Ren, Lifeng Zhang, Shusen Li, Wen Yang, Yi Wang

Inclusion Control & Clean Steel Production II

Effect of RE Oxide Grain Refinement on the Heat-Treated Properties of 1030 Steel 1619

Robert Tuttle

Effect of Slidegate Opening on Mold Flow Structure 1631

Kadir Giirsoy, Mehmet Yavuz

Improving Steel Cleanliness Through Deoxidation Practice on EAF Tapping 1641

Rafael Giacomin, Takeshi Fujii, Antonio Barreto, Taciana Braz, Laurent Chesseret

Continuous Slab Casting Superheat Control at SSAB Mobile 1647

Yufeng Wang, Sunday Abraham, Rick Bodnar, Stephen Richardson, Chase Rawlinson

CONTINUOUS CASTING

Mold Powder

Latest Enhancements in Mold Powder Thickness Control as a Result of a New Propulsion System

Implemented in Flux Feeding 1659

Federica Mantovani, Stefano Spagnul, Mitja Padovan, Andrea Bianco

A Model for Slag Solidification 1669

Dmitri Nassyrov, In-Ho Jung

Caster Modeling

Innovative Approach to Improve the Thermal Performance of Beam Blank Molds Through

FE Modeling 1681

Enzo Franceschinis, John Beaton, Gianni Del Forno

Simulation of the Centerline Segregation Generated in a Tapered Face Mold by the Formation

of Bridging 1695

Takemasa Murao, Toshiyuki Kajitani, Hideaki Yamamura, Koichi Anzai, Katsunari Oikawa, Tomoki Sawada

DynaPhase: On-Line Calculation of Thermodynamic Properties During Continuous Casting* 1705

Walt Antos, Susanne Hahn

Successes and Challenges of Upgrading a Complete Mold Level Control System at North Star

BlueScope Steel 1713

Glen Meiring, Craig Hawkins, PatrickArnulf, Xavier Rabec

Methodology of Water Modeling and Submerged Entry Nozzle (SEN) Design for Bloom Casting With

Mold Electromagnetic Stirring (MEMS) 1727

Andrea Brighton, Peter Glaws, Nicholas Valentine, James Dorricott, Lawrence Heaslip, Rodolfo Morales,

Derek Chalmers

Cast Upgrades/New Concepts/Controlling Devices

Casting of Flat Products— Latest Developments for Modernization and New Installations* 1737

Walt Antos, Oliver Schulz, Florian Waltenberger

The Surface Quality of Casting Defect Detection System 1747

Lu Tian, Shenglan Chen

Restoring a Classic Caster— Making the Caster You Have Better 1759

Chad Donovan

Strategies Against Reoxidation of Liquid Steel in Billet Casting With Metering Nozzle 1771

Jorge Madias, Alberto Moreno

Q-PULSE, the New Tool to Determine the End of Solidification Point in Continuous Casting 1779

Marcellino Fornasier, Stefano Baf, Luigi Orsettig, Gabriele Schiavone

Revisiting the Standard Operating Practices Related to Slab Casting Fundamentals 1787

William Emling, Dewey Humes, Joseph Laughlin

CONTINUOUS CASTING/METALLURGY — STEELMAKING & CASTING

Inclusions — Caster Clogging & Final Product

Continuous Casting of High-Carbon Alloy Steel Billets With Modulated Stirring at a Later Stage of

Solidification 1801

Len Beitelman, Chris Curran, David Domanski, Ian Deeks, Neil Hopkins

Thermodynamic Evaluation of Inclusion Formation and Nozzle Clogging During Slab Casting 1815

Kinnor Chattopadhyay, Sina Mostaghel, Sunil Kumar

Three-Dimensional Determinations of the Non-Metallic Inclusions in Different Ferroalloys 1823

Yanyan Bi, Andrey Karasev, Par Jonsson

Fused Quartz Tundish Nozzles Stop Clogging and Clean Existing Clog, Eliminating Ladle Shroud

Removal 1831

Joerg Peter, Dan Fisher

Effect of Steel Cleanliness on the Clogging of the Submerged Entry Nozzle During the Casting of

Titanium-Bearing Stainless Steels 1849

Guoyu Qian, Guoguang Cheng

Cast Modeling — Mold Fluid Flow & Solidification

Impact of Argon Injection Through Tundish Upper Nozzle on Mold Fluid Flow at ArcelorMittal

Dofasco's No. 1 Continuous Caster 1857

Joydeep Sengupta, Stephen Chung

Numerical Investigation of Slag Entrainment in Continuous Casting Molds 1865

Kenneth Swartz, Lance Hibbeler, Brendan Joyce, Brian Thomas

Effect ofLadle, Tundish and Mold Design on Melt Flow Parameters 1881

Simon Lekakh, David Robertson

SEN Structure to Improve Steel Quality for Small-Size Molds 1893

Hiroyasu Niitsuma, Koji Moriwaki, Masanori Ogata

The Influences of EMBr on the Flow and Solidification of Molten Steel in the CSP Mold Using

Different Submerged Entry Nozzle Angles 1901

Xiaofeng Zhang, Qing Liu, Lusha Zhang, Changping Nie, Kun Dou

CONTINUOUS CASTING/REFRACTORY SYSTEMS

Caster Tundish Innovations

Product Development and Flow Optimization in the Tundish by Modeling and Simulation 1911

Gemot Hackl, David Wappel, Daniel Meurer, Marcos Tomas, Richard Komanecky

Investigation of Stopper Rod Tip Wear on a Thin-Slab Caster 1921

Madeline Rembold, Oscar Chahin, Neal Ross, Bob Williams, Ron O'Malley

Developments and Improvements to the CasTemp Continuous Temperature Measurement in

Liquid Steel 1933

Philip Hughes-Narborough

Reduced Non-Metallic Inclusions in Steel Using Next-Generation Disposable Tundish Lining 1943

William Porter, Kybsti Ruotanen

Fluid Flow-Related Transport Phenomena in Continuous Casting Electromagnetic FC-Mold Strands 1951

Qiangqiang Wang, Yubin Li, Lifeng Zhang, Wen Yang, Yanlong Li, Chen Gao

HOT SHEET ROLLING

New Considerations for Hot & Cold Sheet Rolling

Aligning Rolls Using Gyroscope and Optical Technology in Conjunction 1965

Eric Elder, Benjamin Koontz

A Model for Strip Profile and Roll Crown During Flat Rolling in Hot and Cold Mills With SpecialEmphasis on Innovative Work Roll Materials 1973

Christian Overhagen, Paul JosefMauk

High-Performance Solutions for Rolling ofAdvanced High-Strength Steel Grades in Hot Strip Mills* 1983

Jennifer Grzyb, Julian Thoresson, Reinhard Karl, Sieglinde Ehgartner, Klaus Wseinzierl

Advanced Technology of Process Control for Compact Hot Strip Mills 1993

Kazutoshi Kitagoh, Naohiro Kubo, Jingjung Zhang, Shuguang Kang

Optimizations & Improvements for Hot Mills

Effect of Backup Rolls Wear on Hot Band Flatness and Crown 2005

Eugene Nikitenko

Work Roll Cooling Operation and Design Optimization Based on Mathematical Modeling and Heat

Transfer Principles 2013Sunil Kumar, Victor Hernandez

Enhanced Accuracy of Descaling Nozzle Arrangements With New, Complementary Measurement

Methods** 2025

Jiirgen Frick

Integrated Approaches to Enhance Width Performance at Hot Strip Mill 2029

Yuefa Xiao, Roberto Costa, David Ganske, Patrick Trippel

Application Results of Mill Stabilizer Device for Reduction ofMill Vibration in Hot Finish Rolling 2043

Hideaki Furumoto, Kanji Hayashi, Takao Owada, Shinya Kanemori, Frank Beddings

Strength Evaluation and Toughening of Drive Spindle of Hot Strip Mill 2053

Satoru Akutsu, Tatsuaki Inoue, Terumasa Onishi

New Designs & Concepts for Hot Sheet Mills

Results of Danieli New 4.0-MTPY Semi-Continuous Hot Strip Mill at Baosteel Meishan 2059

Catalin Fusulan, Paolo Bobig, Federico Perotti, Matteo Remy Bulfone, S.K. Bhaumik, G. Bhaumik, G. Mow

High-Performance Hot Strip Mill — Introduction of Technologies Applied to the New No. 2 Hot StripMill at USIMINAS in Cubatao 2071

Taro Sato, Jiro Hasai, Frank Beddings

Next Arvedi ESP Installations in China— High-Quality, Ultrathin Strip to Enter New Market

Segments* 2081

Andreas Jungbauer, Sergey Bragin, Robert Linsbod

Total Mill Technologies

Improvement ofProduct Quality and Plant Availability With SMS Siemag Integrated Plant

Monitoring System 2091

Wolfgang Spies, DetlefEhlert, Alfred Metzul, Martin Bldsner

Accelerating Threats to Supply Chain: Globalization, Climate Change, Natural Disasters,

Transportation, IT Security and Financial Stability 2099

James Bright

The Challenges and Solutions to Integrate Multi-Facility/Buildings Disparate Management Systems

Across a Steel Mill Plant 2109

Nathan Slider

Accelerated Depreciation Policy to Promote Energy Efficiency in the Brazilian Steel Industry 2113

Gustavo Moura, Sammuel Aleixo, Joao Paulo Barbosa

Advantages of Using 3D Virtualization in the Metals Industry 2133

Edgardo La Bruna, Mariano Zecchi

HOT SHEET ROLLING/COLD SHEET ROLLING/COMPUTER APPLICATIONS

Computer Applications for Rolling Mills

On the Optimization Procedure of Rolling Mill Design—A Combined Application of Rolling Models 2143

Remn-Min Guo

A Method to Characterize Multi-Pass Frequency Content and Improve AGC Performance 2161

Mark Zipf

Advanced Model-Based Controls for Steel and Aluminum Hot Strip Mills 2177

Gerald Hearns, Yaohou Li, Chris Fryer

Re-Examination of Generalized Rolling Model Using von Karman Equation on Elastic Foundation With

Work-Hardening Curves 2185

Remn-Min Guo

HOT SHEET ROLLING/METALLURGY — PROCESSING, PRODUCTS & APPLICATIONS

Hot Sheet Rolling Metallurgy

Optimization of Thermo-Mechanical Rolling for the Production of API 5L Steel Strips FromThin Slab 2201

Catalin Fusulan, Mauro Guagnelli, Paolo Bobig

Implementation of High-Turbulence Roll Cooling at ArcelorMittal Dofasco's Hot Strip Mill 2213

Zafer Koont, Andrei Ianos, Gas Gebara, Patrick Van Poecke, Hugo Uijtdebroeks, John Fitzpatrick

The Importance of Hot Rolling Microstructural Evolution Obtained by Hot Torsion Tests With

Mathematical Modeling 2225

Marcelo Pereira Machado, Mario Roberto Tasca, Fernanda Martins

The Deformation and Migration Behavior of Inclusions During Multi-Pass Hot Rolling Processes 2231

Junliang Ge, Shusen Cheng, Jing Guo, Chongming Chang, Yueqiang Zheng, Jipeng Li

Precipitation Strengthening of Nanoscale Cementite in 0.17% Carbon Steel During Ultrafast

Cooling (UFC) 2239

Bin Wang, Zhenyu Liu, Zhaodong Wang, Guodong Wang, Devesh Misra

Investigation of the Anisotropic Mechanical Property Phenomenon in SPFH590 Hot Rolled

Steel Strips 2247

Ming-Yen Tsai, Ching-Yuan Huang

COLD SHEET ROLLING

Pickling Lines

State-of-the-Art Pickling Line Tandem Cold Mills — Insight Into Latest References* 2255

Mark Landy, Gerlinde Djumlija, Gerhard Finstermann, Wolfgang Kutschar, Alain Challaye, Stephane Georges

New PL-TCM (Pickling and Tandem Cold Strip Mill) in Vietnam 2267

Takeshi Kumai, Tanehiro Kikkawa

The Most Advanced PLTCM With New iBox Design and 6-Stand UCM-Mill For High-Strength

Automotive Steel 2277

Akihiro Yamamoto, Kosei Tsuji, Woowsang Jeong, Janghyeon Lee

Eco Pickled Surface (EPS) Technology Update: Commercial Experience and Design Evolution to

Enhance Performance 2287

Christopher Liefer, Alan Mueth, Kevin Voges

Dalnox Bright® and Ecological Pickling: Danieli's New Solutions for the Stainless Steel Strip Market

Restarting 2297

Jon Roman, Luciano Vignolo, Alessandra Primavera, Simone Guanin, S. Luperi, L. Lattanzi

Annealing, Strip Inspection, Tension Leveling

CFD Simulation ofBatch Annealing Process to Evaluate the Effects of Increased Impeller Speed 2305

Yuli Liu, Jian Fan, Shan Lui

New PRO-TEC CAL —Ultrahigh-Strength Steels for the Automotive Industry 2315

Jeffrey Stechschulte, Keith Watson, Michael Cottin, Bernward Nutt, Caesar Sasse, Jean-Pierre Crutzen

Influence of the Coil Temperature Uniformity in BAF on the Thickness Variation of Cold

Rolled Strips 2321

Li Wen Wu, Shiung-Sung Lin

Teamwork at Its Best With Marcegaglia: High-Quality Production After Record-Time Horizontal

Strip Annealing Furnace Upgrade 2331

Artesiano Marcello, Cesare Laviosa, Stefano Pantarotto

The Improvement on the Strip Deviation of the Horizontal Degreasing Section of CAL 2343

Li Wang, Geng Yang

Cold MUl —Control

Implementing an Accurate, Reliable Measurement System for Improving Mass Flow Automatic

Gauge Control in Rolling Mills and Related Process Applications 2347

Jerome Dapore

Newly Developed Universal Crown Control Mill "HYPER UCM" for Rolling of High-Strength Steel 2353

Daisuke Yamada, Hajime Higuchi, Shinichi Yasunari, Ichiro Maeno, Toyotsugu Masuda

Metallurgical Analysis of Annealed Steel Strip by Transverse Flux Induction Heating (TFIH) 2359

Emmanuel Palard, Ivan Longombre, Pierre Dousselin

Pickling & Cold Mills— General

Preventing Fires in Pickle Lines 2369

Michael J. Swahn. Richard Heagerty, Christopher Birchfield

Reversing Cold Mills — Trend-Setting All-Rounder for a Wide Range of Applications 2377

Michael Peretic, Karl Hoen, Riidiger Holz, Jiirgen Schanderl

Modification in Bath Heating Technique for Increased Efficiency of Pickling Line 2385

Suman Kant Thakur, Apoorva Kumar Marik, Partha Pratim Sengupta, Shashi Shekhar Mohanty

Three-Stand PLTCM: Technology and Field Results From the Latest Danieli Cold Rolling

Installation 2389

Jon Roman, Massimiliano Svetina, Luciano Vignolo, Michele Turchetto

Advanced Chromium-Free Coating for Electrical Steels 2399

Kang-Yung Peng

GALVANIZING

New Developments in Metallic-Coated Sheet Steel Processing

Development of Surface Defects Prevention Technology in Continuous Galvanizing Line: The Defects

Originated From Zn Oxides Adherence in the Snout 2407

Yoshinori Omatsu, Akira Tetsuya Kazama Iwata, Yoshiyuki Umegaki, Takahiko Oshige

Near-Roll Dross Particle Interactions in a Galvanizing Bath 2417

Amir Kargar, Andrew Hrymak, Frank Goodwin

Advanced Electrolytic Tinning Line With Insoluble Anode System 2427

Takuya Araikawa. Tong Wen. Zltang Dang Fang, Shinsuke Hamaguchi. Keiji Kan\io, Yoshifumi Ninomiya.

Shouichi Yamamoto. Ryoh Yamamoto

Danieli Wiping Process Evolution: From New 3rd Air Knives Generation to One Integrated

Technological Package Able to Produce Tight Coating Weight Tolerances at Higher Processing

Speed and Reduced Operating Costs 2437

L Vignolo, G. Caporal, F. Vecchiet. F. Guastini. A. De Luca. M. Minen

Development of Al-Si-Based Coatings for Hot Stamping Application 2449

Sanjeev Shukla, Sanicsh Kumar. Shashi Shekliar Mohanty

New Spraying Process Development on the Inlet Deflector Roll of the Recoiling Line

CaiHeng

2457

PLATE ROLLING

Plate Rolling Technologies

Application of Hot Rolling Lubrication on a Reversing Coil/Plate Mill 2463

Qiulin Yu, Amy Beard

Enhancing the Competitiveness of Plate Mills— Services That Can Make a Big Difference From

a Small Investment* 2475

Jennifer Gryzb, Michael Clark, Joseph Lee, Mark Chalmers, Sandip Samanta, Ian Robinson

Shandong Taishan Steel Group Co. Ltd.— Technological Upgrade of Steckel Mill 2489

Wolfgang Spies, Bernward Reif

Functional Safety of an Electrical and Automation Control System Applied to a Plate Rolling

Mill Plant 2505

Maria Elena Fabiani, Adriano Totis, Emanuele Caisutti

Modernization of Steckel and Plate-Steckel Mills for 1-Inch X80 and Other High-Strength Products* 2519

Jennifer Grzyb, Michael Clark, Joseph Lee, Mark Chalmers, Sandip Samanta, Ian Samanta, Ian Robinson

Overview of Heat Treat Leveler for ArcelorMittal Burns Harbor 2531

Hiroyuki Uematsu, Keizo Abe

Author Index 2545

* The following papers in Volume II of the AISTech 2014 Proceedings appear courtesy of the companies listed alongside

them:

DynaPhase: On-Line Calculation of Thermodynamic Properties During Continuous Casting— Siemens VAI Metals

Technologies GmbH

Casting of Flat Products— Latest Developments for Modernization and New Installations — Siemens VAI Metals Technologies

GmbH

High-Performance Solutions for Rolling of Advanced High-Strength Steel Grades in Hot Strip Mills — Siemens VAI Metals

Technologies GmbHNext Arvedi ESP Installations in China — High-Quality, Ultrathin Strip to Enter New Market Segments— Siemens VAI Metals

Technologies GmbH

State-of-the-Art Pickling Line Tandem Cold Mills — Insight Into Latest References — Siemens VAI Metals Technologies

GmbH

Enhancing the Competitiveness of Plate Mills— Services That Can Make a Big Difference From a Small Investment — Siemens

VAI Metals Technologies GmbHModernization of Steckel and Plate-Steckel Mills for 1-Inch X80 and Other High-Strength Products— Siemens VAI Metals

Technologies GmbH

**The following paper was originally presented at the 2014 European Scale Oxide Conference, Institute of Materials,

Minerals and Mining (IoM), London:

Enhanced Accuracy of Descaling Nozzle Arrangements With New, Complementary Measurement Methods — Lechler Inc. and

the Institute of Materials, Minerals and Mining