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