AISTecn2010

Proceedings of the

Iron & Steel Technology ConferenceVolume II

May 3-6,2010

Pittsburgh, PennsylvaniaU.S.A.

Ronald E. Ashburn, Publisher

Christopher P. Brown, Graphic Artist

Carolyn A. Trobaugh, Production Assistant

Lisa C. Oldham, Technical Copy Editor

CONTENTS

AISTech 2010-Volume II

Author Index 1371

CONTINUOUS CASTING

Slab Improvements and More

Analysis of Ti-, Mg- and Zr-bearing Inclusions in Ultra-low and Low Carbon Steels

S.R. Story, N. Gupta, G.S. Casuccio, M.S. Potter 1

Technological Upgrades of Slab Casting Plants: The Danieli Davy Distington Experience for Plant

Renovations and Performance ImprovementsCP. Piemonte, J. Lester, B. Kozak 11

Slab Caster Revamping—The Approach to Excel in the Market

0. Schulz, K. Engel, M. Haslinger, F. Derflinger 23

CONTINUOUS CASTING/METALLURGY — STEELMAKING AND CASTING

Slab — Impact Slivers and Non-Mets Via Nozzle/Mold

Improvement of the Periodical Mold Level Fluctuation in a Slab Caster and Relevant Sliver

Defects on Hot-rolled Coils

K.-W. Huang, M.-H. Chen, C.-H. Hung, T.-F. Yeh, T.-C. Cheng 35

Nozzle Design for ArcelorMittal Dofasco's No. 1 Continuous Caster for Minimizing Sliver Defects

M.M. Yavuz, J. Sengupta 41

Optimization of a Submerged Entry Nozzle Design to Reduce Nonmetallic Inclusions in Line PipeSteel

B.R. Forman, M.M. Yavuz, T.H. Tsai, J.A. Thacker 53

Effects of FC Mold on Slab and Final Product Qualities at Low ThroughputsJ. Song, H. Yang, X. Leng, J.-E. Eriksson, H. Hackl 63

Slab— Heat Transfer Technology — Improvements

Experimental Study on Heat Transfer Behavior Through the Mold Flux Film Between the

Solidifying Shell and Mold

S. Mineta, T. Kajitani, H. Yamamura 71

A Novel Steady-state Technique for Measuring the Heat Extracted by Secondary Cooling SpraysC.A. Hernandez, A.H. Castillejos, F.A. Acosta, X. Zhou, B.G. Thomas 81

The Sophisticated Air Mist Nozzle for Secondary Cooling of the Continuous Caster

S. Kubori, N. Kaguchi 93

Optimization of Surface Quality Through Mold Thermal MonitoringS. Carless, A. Westendorp, A. Karaperman, J. Brockhoff 105

Effect of Melting and Casting Parameters on the Hot Ductility Behavior ofNb-bearing Beams,

Billets and Slabs

S.G. Jansto 115

The Effect of Hydrogen on Mold Heat Removal in Continuous CastingT.J. Piccone, S.M. Smith 127

Slab— Brake Technology and Modeling and New Roll Concepts

Water Modeling of Stirring and Braking Processes in a Slab Caster Mold

H. Yang, F. Tehranchi, J.-E. Eriksson, J. Song 135

Development of Self-braking Nozzle for Steel Slab Continuous Casting Process

L.Zhang 147

Increasing Casting Speed Without Mold Level Hunting Risk Using Switching Control

T. Passenbrunner, P. Ortner, L. del Re, P. Colaneri 161

Improving Centerline Segregation Control on X70 Products

X. Chen, S. Abraham, G. Franco, J. Asante, C. D'Souza, K. Dunnett 175

Correlation Between F-value and Sliver Index for Ultra-low Carbon Steel Grades at ArcelorMittal

Dofasco's No. 1 Continuous Caster

J. Sengupta, E. Dillon, J. Dixon 181

The Nature of Internal Defects in Continuously Cast Steel and Their Impact on Final Product

QualityR. Pierer, C. Bernhard 193

HOT SHEET ROLLING

Hot Mills — New Developments and Modernizations

Strategies for Flexible Hot Mill Modernizations — Concepts for Modernization and Extension of

Hot Strip Mills

R. Burger, R. Schuster 205

Modernization of Hot Strip Mills — Concepts, Implementations and Results

S. Kramer, S. Berger, W. Fuchs 219

Arvedi ESP (Endless Strip Production) First Thin Slab Endless Casting and Rolling Results

G. Arvedi, F. Mazzolari, A. Jungbauerl, G. Hohenbichler, G. Holleis 231

Adding Value to the Hot Rolled Coil Business at Burns Harbor by Reducing the Number of

Unplanned Roll Changes While Sharing Technical Experiences on the ArcelorMittal GroupA.L. Costa, T.M. Mayrosh, F.R. Gonzalez 241

HOT SHEET ROLLING/ROLLS

Hot Mills — Rolls and Lubrication

Work Roll Temperature and Thermal Crown Measurement to Improve Roll Cooling EfficiencyM.B. Assar, B.J. Warnock, J.A. Cox, A.F. Costa, J.T. Sims, W.E. Mellander 253

SIROLL HM Work Roll Lubrication for Electrical Energy Reduction and Strip Surface

ImprovementA. Seilinger, R. Schuster, F.-X. Schmoller, G. Grasser 261

Reducing Carbon Footprints with Green Hot Mill Lubricants

J.E. Murphy, R. Wu 269

HSS Work Rolls for Hot Mill Finishing Stands: Keys to Success

S. Mario 279

HOT SHEET ROLLING/COMPUTER APPLICATIONS

Information Technology for Hot Strip Rolling

Productivity Optimization at Duferco Farrell's 60" Hot Strip Mill

R.N. Bilkie, E.P. Horan 293

Bar Width Change in Finishing Stands of the Hot Strip Mill

E. Nikitenko 309

Mill Level 2 Model in Improvement of Product Quality and ProductivityB. Li 317

Quality Performance Report Improves Mill OperationW. Filipczyk, J. McMillen 327

COLD SHEET ROLLING/ROLLS

What If? The Future of Hexavalent Chromium Part I

Use of High Chrome Rolls in Cold Mills

R. Schleiden, J. Ballani 339

Implementation of In-service Key Parameters of HSS Work Roll Grade Dedicated to Advanced

Cold RollingC. Gaspard, C. Vergne, D. Batazzi, T. Nylen, P.H. Bolt, S. Mul, K.M. Reuver 347

Spun Cast Semi-HSS Rolls in Cold Mill ApplicationsA. Tremea, F. Bellicini, H. Fenandez, D. Agazzani 359

COLD SHEET ROLLING

Cold Rolling Technologies I

Chemical Removal of Internal Scale From HCI Pickle Liquor PipelineM.A. Nicholls, J. Wong 371

SIROLL CM-upgrading of Cold Rolling Tandem Mills to Continuous OperationG. Finstermann, M. Landy 381

PLTCM Network Topologies0. Gocan, G. Xinan 393

Strip Cleanliness, Extracting New Data From the Rolling Oil TGA Burn-off CurveM.A. Nicholls 409

Cold Rolling Technologies II

Integrated New Downstream Facilities at Acciaieria Arvedi, ItalyM. Turchetto 417

Advanced Technologies for Skin Passing of Stainless Steel and Carbon Steel

S. Willems 425

Fit for the Future by Modernization — Latest Solutions for Tandem Cold Mills

R. Holz, F. Topfer, K. Hoen 435

Taking Batch Annealing Optimization to the Next LevelM.W. McDonald 447

Efficient Coolant Removal From Metal Strip on Cold Mill/Temper Mill

B. Schaming, J. Mondabaugh 461

GALVANIZING/TINPLATE AND ELECTROGALVANIZING

Advances in Zinc Coating Processing

Simulation of Strip Lateral Dynamics on Continuous Processing LinesY. Ishigaki, K. Kabeya 469

A Method for Roll Alignment by Means of Inertial Technology Using PARALIGN®T.M. Coombes 481

Improving the Galvanizing Process — Electromagnetic Strip Stabilization and ComplementarySolutions: eMASS, eWIPE, eBACSA. Jordan, S. Dombrowski, S. Devorich 485

Graphical Tool for Bottleneck Identification and Productivity Improvements in Galvanizing Lines

K. Wright, M. Roberts 499

New Electrolytic Tinning Line and Tin-free Steel Line for BAOSTEEL, China

K. Keiji, N. Yoshifumi, C. Shenghe, W. Wen 507

GALVANIZING

Advances in Hot-dip Coating Processing

Numerical Investigation of Air Knives with Multiple-impinging Slot Jets in Continuous Hot-dipGalvanizingP. Tamadonfar, J.R. McDermid, A.N. Hrymak, F.E. Goodwin 517

Analysis of Edge Buildup on Aluminized Steel Strip Using Computational Fluid Dynamics (CFD)and MetallographyA. Elnenaey, C.R. Shastry 527

The Influence of Temperature and Aluminum Content on Galvannealed CoatingX. Yu, H.Zhang 537

Mechanical Properties and Development of Hot-dip Coated Solid Solution Strengthened LowCarbon Steels for Automobiles

G. Cheng, Y. Xie, L. Chen 549

PLATE ROLLING

Optimization of Plate Mill Heating and Rolling

Modern Process Models to Improve Product Quality on Plate Mills

R. D611, W. Nothegger 555

Modernization of the Heavy-plate Rolling Mill at DongkukD. Ehlert, K. Pronold, F. Mehlich 565

Maximized Asset Reliability and Performance Connected to PDA InspectionJ. Kurosky, K. Knaphus, M. Inns, J. Marquez 577

The Plate Mill as a Metallurgical Tool

J. Lee, M. Steeper, M. Landy 583

Quality Improvements in the Plate Mill

Two Hundred Years ofRolling on the BrandywineR.P. Smith Jr 589

A Targeted Approach to Optimizing a Plate Mill

D. Bambury, S. Martin, J. Grzyb, D. Rosburg 605

New Developments in Drive Trains for Roughing and Plate Mills

C. Sundermann, W. Malan, E. Jung, R. Gehle 615

Tenova FlexyTech® Regenerative Flameless Burners

M. Ageno, M. Fantuzzi, A. Landi, U. Zanusso 627

Descale System DesignS. DeMar 639

Shape Improvement in Cut-to-length Line With an In-line Quarto Skinpass Mill

M. Derijcke, J.J. Servanton, R. Hequet 651

ROD AND BAR ROLLING/PROJECT AND CONSTRUCTION MANAGEMENT

Long Product Projects

Project Management Models for Long Product Rolling Mills

A. Lainati, M. Arena 661

Cash for Clunkers in the Reheat Furnace World

P. Arribalzaga, R. DaRocha 669

Staying Ahead of the Curve— Beating the Commissioning Schedule for Continuous Slab Casters

G. Paulon, B.A. Kozak, P. Franco, D. Passantino, M. Foraasier 677

The 750,000 Stpy SBQ Rolling Mill, Part of the Complete Minimill at Nucor Steel Memphis Inc.,USA

L. Maestrutti, L. Gori, R. Cecutti 687

Drive Selection for Rolling Mills

E. Thorstenson 695

ROD AND BAR ROLLING

Rolling Mill Advancements

New Stands for New Duties

E. Krieg, L. Cavaletti, M. Fabro 701

Quench and Tempering: An Unfamiliar Process in North America

M. Allen 707

Quenched and Self-tempered Rebar — Process Overview, Layouts, Operational Parameters and

Cost SavingsS.-E. Lundberg 717

"The House of the World's Longest Billet" The New Micromill Danieli (Ml.DA®) at CMC Steel

Arizona: An Innovative Process for the Most Competitive Production of Rebar Product

K. Keller, C. Travaglini, E. Cavinato, P. Losso 727

Totally Controlled Safety System With Zero Impact on Productivity for a Bar Rolling Mill

M. Capitanio 735

Improvement of Wire Rods Processing TechnologyA. Takamori, T. Idesako 751

ROLLS

Roll Inspection Systems

Mechanical Study for Reducing Shell/Core Bond Separation of Duplex Cast Work Rolls for a Hot

Strip Mill

Y. Liu, J. Fan, M. Levick 757

Interpretation of UT and EC Results in Roll TestingML Brandner, R.J.W.M. van Kollenburg 771

METALLURGY — STEELMAKING AND CASTING

Continuous Casting Metallurgy

Solidification and Dendrite Growth of Stainless Steel During Continuous CastingL. Zhang 781

Entrapment of Inclusions in Continuous Casting Billet: Industrial Observation and ModelingY. Wang, X. Zuo, L. Zhang, S. Li, A. Dong, L.N.W. Damoah 793

Development of a Validated 3-D Thermal Model for ArcelorMittal Dofasco's No. 2 Continuous

Caster Mold to Evaluate Design Improvements for High-speed CastingN. Bontems, J. Sengupta, M. Trinh, A. Bally 807

One Year Casting Experience for Rounds of High-quality Steel Grades at Nucor MemphisC. Travaglini, N. Kapaj, M. Sattolo 817

METALLURGY— PROCESSING, PRODUCTS AND APPLICATIONS

High-strength Steels

Improvement in Strip Temperature Control for High-strength Steel in a Radiant Tube Furnace

M. Deka, K.W. Johnson, S. Pandkar, F.M. Martins, J.F. Carr 825

Rating Inclusions in an As-cast Carbon Steel

M. Faraji, R. Thackray, I. Todd, P. Tsakiropoulos 841

Development of Nano-size Precipitation Strengthening Hot-rolled Automobile Steels

C.-Y. Huang, H.-W, Yen, Y.-T. Pan, J.-R. Yang 849

Implementation Experience of Danieli-CQETM at Hot Strip Mill

A. Mukhopadhyay, A. Polo 859

Property Control

Microstructure and Mechanical Properties Comparison of Direct Quenched vs. Reaustenitized

and Quenched Plate

N.C. Muckelroy, K.O. Findley 869

A Non-Destructive Inspection System for Measuring Mechanical-technological Properties of Steel

Grades

N. GstOttenbauer, K.L. Feiste, J. Reisinger, G. Ossberger 879

The UGR Process: The Danieli Innovative Process for a Low-cost Production of Seismic Concrete

Reinforcement Steel

F. Toschi, C. Fabbro 889

Effects of Continuous Cast Section Size on the Torsional Fatigue of 1050 Steel

R.L. Cryderman 897

Introduction of R&D Group in Iron & Steel I

Value Creation Through R&D at ArcelorMittal

R.C. Sussman 909

Recent Steel Research at the Department of Ferrous Metallurgy of RWTH Aachen University

W. Bleck, G. Hessling, H.H. Dickert 919

Introduction of R&D Group in Iron & Steel II

The McMaster Steel Research Center: A Model for Industry-University Collaboration

G.A. Irons, J.G. Thomson 931

General

Developments on a Web-based Metal Technology and Metal Information Network

B. Li 935

Detection of Internal Defects Prior to Value-added Processes to Minimize Final Product Surface

Defects

J.S. Monks 947

Intercritically Austempered Steel

R. Aristizabal, A. Haglund, A.P. Druschitz, M. Ostrander 955

Expert 5i—Quality Software Modules in the EPROMI Architecture for Increased Steel

Production EfficiencyR. Brunelli, C. Hope 965

Introduction of R&D Group in Iron & Steel III

CIVS — Center for Innovation Through Visualization and Simulation

C.Q. Zhou, J. Moreland 973

The Working Group "Continuous Casting: Metallurgy and Materials (M2CC)" at Leoben

University, Austria

C. Bernhard, R. Pierer, S.C. Michelic 977

Inauguration of IRIS, Institute of Research of Iron and Steel, for Sha Steel in China

T. Emi 987

The McGill Metals Processing Center: A University-Industry Partnership for Process MetallurgyR.I.L. Guthrie, M. Isac 993

Grain Refinement and Precipitates

Investigation Into an HSM Finishing Stand Defect Which Generated FeO-type Lamination

M.R. Blankenau, O.V. Kostrubsky, R.H. Radzilowski 997

Effect of Cerium on the Inoculation of Acicular Ferrite in Hot-rolled Fe-Mn-Al-Si-C Steel

M.C. McGrath, D.C. Van Aken, V.L. Richards 1007

Production of Fine Grained As-rolled Structural Plate Steels

D.G. Stalheim, R. Glodowski 1019

Fine Grain Practice—Revisited

R.J. Glodowski 1027

Microalloy Precipitation in Hot Charged Slabs

M.S. Dyer, J.G. Speer, D.K. Matlock, A.J. Shutts, S. Jansto, K. Xu, B.G. Thomas 1035

ENERGYAND UTILITIES

Energy Cost Savings, Strategies and Procedures

Oxygen-Enhanced Ladle Preheating Systems: Improved Tap-to-tap Cycle Time and OperatingCost Reductions

J. Kelly, F. Dentella, A. Recanati, J. Visus, E. Miclo

Description of a Simulation Method for Evaluating the Thermal Properties of Insulation Materials

Used on an Evaporative Skid Cooling System in Reheat Furnaces

P. Hughes, T. Skolnik

A Multi-faceted Approach to Reducing Electricity Costs in the Steel IndustryB.E. Zak

ELECTRICAL APPLICATIONS

Sensors

VIP 08 Flatness Measurement and Control SystemA. Selent 1069

In-Process Measurement of Organic Coating Thickness Using a Full Spectrum Infrared Sensor

C. Burnett, A. Quick, B. Harand 1085

Innovative Design of New Laser-based Thickness Gauges for Inline Measurement of StripThickness

A. Schultz, J. Mitchell 1091

.1047

,1055

1065

Power Distribution

Innovative Methods for Integrating Utility and Production Automation SystemsM.E. Rourke 1097

Drives and Control

Synchronous and Induction Motors for Main Drive ApplicationsR. Tessendorf 1107

Hybrid DC-DC-AC Main Drive for ILVA, Taranto Finishing Mill

M.A. DeCarli, B. Jones, A. Giordano 1121

Advanced and Reliable Drive Systems for the Rolling Mill IndustryG. Bodden 1129

An Industrial Power System Management for High-quality Uninterrupted Power Supply at Tata

Steel

A. Kar, D.M. Chowdhary, R. Jeloka 1139

COMPUTER APPLICATIONS

Software Applications

Revamping MES and L3 Systems in the Iron and Steel IndustryC. Fisher, P. Lagae, M. Mecozzi, E. La Bruna 1149

Easy Access to Everything — Or How the Web Can Bring It All TogetherR.P. Gauvreau 1157

A Lean Supply Chain Manufacturing Model

G. Marzec, J. Hauge 1167

Process Integration as a Tool for Decision-makers in the Steel IndustryC. Ryman 1177

PROJECT AND CONSTRUCTION MANAGEMENT

Project Tools and Techniques

Strategic Demolition Impact Analysis — A Plan for Aging Infrastructure

N.Fox 1187

Utilizing High Definition 3-D Laser Scanning Technology to Obtain As-built Information to

Streamline Retrofit ImprovementsK.A. Armstrong 1197

Role of the Industrial Engineer in Today's Steel Producing Environment

W.J. Zehe 1203

Achieving Project Excellence

United States Steel Corporation Fairfield Works Coal Grinding FacilityK.C. Wong, R. McCabe, G. Saul 1213

MAINTENANCE AND RELIABILITY

Reliability Projects

Optimizing Indirect Production Cost

M. McGee 1227

Danieli Maintenance Management SystemD. Brandolisio 1231

Running Your Maintenance Department as a Business

R.A. Frascarelli 1245

Requirements on Standard Tests of Radial Shafts Seals for the Heavy IndustryA. Koch, H.-W. GUnther, G.J. Wiistenhagen 1255

Reliability Achievement Award

Electric Arc Furnace Tap ChangersC. Birkbeck, C. Schwabe, S. Ryan 1263

Maintenance Technologies and Tools

Decreasing MTTR Using Split Seal TechnologyE.J. Rogalski 1275

Caster Nozzle Protection

M.N. Allhands 1281

Advances in Bearing Reclamation

E. Wineland, R. Burdan, J. Oberlander 1287

Rotary Seals for Heavy-duty Applications — Technology Meets Customer RequirementsA. Koch, B. Baas, G.J. Wtlstenhagen 1291

LUBRICATION AND HYDRAULICS

Fluids and Systems

Mitigation of Triboelectric Charging in Industrial Hydraulic and Lubricating Fluids — Case

Studies in the Primary Metals Market SegmentM.Mahapatro 1297

Factors to Consider in the Selection of a Mill Grease

T. Vasiliw, H. Faci 1305

Novel Polyalkylene Glycol Based Hydraulic Fluids

G. Khemchandani, M. Greaves 1313

Care and Maintenance ofHydraulic Fluids

J. Schlobohm 1323

Application of an Intelligent Centralized Lubrication System in the Iron and Steel IndustryD. Wang, J. Zhao, K. Zhang, Y. Zhang, H. Zhao 1333

MATERIAL HANDLING

Material Handling Improvements

Optimized Material Flow in Plate Plants by Integration of Scheduling and Warehouse

ManagementH. Henning, J. Hackmann, I. Kunin, M. Diestel 1341

Automated Material Tracking via RFID TechnologiesJ.R. Franz 1345

Regulatory Impact on Diesel Engine Emissions

S. Weyant 1355

CRANES

Material Handling Improvements

AC Variable Frequency Drive with Static Stepless Simulation Software Outperforms Traditional

Static Stepless Crane Control

A.S. Kureck 1359

World-class Crane and Runway System for the 21st Century

C.A.Totten 1365