Summaries of RFCS projects 2003-2012

Full list of co-financed projects

Research and Innovation EUROPEAN COMMISSION

Directorate-General for Research and Innovation Directorate G — Industrial Technologies Unit G5 — Research Fund for Coal and Steel

E-mail: [email protected]

Contact: Mario Iamarino

European Commission B-1049 Brussels

Tel. (32-2) 29 90337 Fax (32-2) 29 65987

E-mail: [email protected] [email protected] EUROPEAN COMMISSION

Summaries of RFCS projects 2003-2012

Full list of projects co-financed by the Research Fund for Coal and Steel research programme of the European Commission

Directorate-General for Research and Innovation 2012 R e s e a r c h F u n d fo r C o a l a n d S t e e l EUROPE DIRECT is a service to help you find answers to your questions about the European Union

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Cataloguing data can be found at the end of this publication. Luxembourg: Publications Office of the European Union, 2012

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FOREWORD

This volume is an exhaustive collection of summaries of RFCS projects covering – for the first time – the entire life of the programme, from the first contracts signed in 2003 up to 2012. With its renewed graphic layout and more compact format, it is intended to replace the traditional series of project synopses which used to focus on a limited time span, typically the most recent 4 years. The second appealing feature of this new edition is the presence of a direct link to the final project reports published on EU Bookshop and available for free download. It is believed that, thanks to this additional element, the new Summaries may become an excellent gateway for deep state‐of‐the‐art analysis for future research activities in the coal and steel sector.

The projects are presented per individual Technical Group and in chronological order. A Table of Content is provided with projects listed both in acronym alphabetical order and by reference number. In addition, the use of the Find function in Adobe Acrobat Reader is recommended to search by specific projects or by keywords.

CAL‐MOD RFCR‐CT‐2010‐00013 51 Table of Contents 1 CARBAIN RFSR‐CT‐2004‐00028 126 CARBOLAB RFCR‐CT‐2009‐00001 23 Projects listed in alphabetical order CARINA RFCR‐CT‐2010‐00011 50 CARSTEEL RFSR‐CT‐2003‐00046 112 CASTDESMON RFSR‐CT‐2003‐00003 79 CASTINCREM RFSR‐CT‐2004‐00010 81 CATIA RFSR‐CT‐2003‐00006 197 CCTPROM RFC2‐CT‐2006‐00005 41 CERCOT RFCP‐CT‐2006‐00011 42 Project Acronym Reference Number Page CERROD RFSR‐CT‐2012‐00012 107 CFB800 RFCR‐CT‐2005‐00009 46 6th Stainless Steel RFS1‐CT‐2008‐00020 123 Conference CHARGE&LOAD RFSR‐CT‐2006‐00025 131 ABETRAP RFCR‐CT‐2006‐00006 47 CHARMA RFSR‐CT‐2010‐00022 150 ACASOS RFSR‐CT‐2007‐00003 58 CHATTER RFSR‐CT‐2008‐00015 102 ACCLAIM RFCP‐CT‐2012‐00006 43 CHATTER RFSR‐CT‐2008‐00015 103 ACOUSVIBRA RFSR‐CT‐2003‐00025 165 CHILLUB RFSR‐CT‐2008‐00012 102 ACTRESS RFSR‐CT‐2006‐00024 131 CLEAN RFSR‐CT‐2004‐00022 113 AcTuM RFSR‐CT‐2008‐00006 85 CLEAN SELECTIVE RFCR‐CT‐2006‐00008 48 ADBLAST RFSR‐CT‐2010‐00030 183 CLEFCO RFCR‐CT‐2003‐00001 43 ADCTEC RFSR‐CT‐2006‐00034 203 CLOGGING RFSR‐CT‐2005‐00010 82 ADEMA RFCR‐CT‐2005‐00001 19 CLYCARGAS RFCR‐CT‐2005‐00007 46 ADMONI RFCR.CT.2003.00007 44 CO.CA.CO.R.K. RFCR‐CT‐2005‐00008 46 ADRIS RFCR‐CT‐2007‐00002 20 CO2freeSNG RFCR‐CT‐2009‐00003 35 Advanced Wiping RFSR‐CT‐2005‐00022 114 CO2RED RFSR‐CT‐2006‐00008 84 AFINOPRO RFSR‐CT‐2008‐00034 177 COALSWAD RFCR‐CT‐2008‐00004 22 AGAPUTE RFCR‐CT‐2004‐00006 45 COATHYDRO RFSR‐CT‐2010‐00038 209 AHSS‐PROFILE RFSR‐CT‐2011‐00018 137 COGASOUT RFCR‐CT‐2010‐00002 24 ALOAS RFSR‐CT‐2003‐00037 142 Cognitive Control RFSR‐CT‐2010‐00037 209 ANALCO RFSR‐CT‐2005‐00007 69 COHEADBAIN RFSR‐CT‐2005‐00031 129 Anti‐chatter CHD RFSP‐CT‐2006‐00009 93 COKARAC RFSR‐CT‐2004‐00002 56 ASEMIS RFSR‐CT‐2009‐00029 206 COMBITUBE RFSR‐CT‐2011‐00034 186 ASSOCOGS RFCR‐CT‐2003‐00008 44 COMBRI RFSR‐CT‐2003‐00018 165 ASTEX RFSR‐CT‐2005‐00028 128 COMBRI+ RFS2‐CT‐2007‐00031 160 ASYLECTRO RFSR‐CT‐2008‐00025 134 COMEX RFCR‐CT‐2012‐00003 27 ASYMMROLL RFSR‐CT‐2006‐00011 100 COMPFIRE RFSR‐CT‐2009‐00021 179 ATCORAS RFSR‐CT‐2011‐00015 119 COMTES700 RFCP‐CT‐2004‐00003 42 ATTEL RFSR‐CT‐2008‐00037 178 CONOPT SCRAP RFSR‐CT‐2005‐00003 67 AUSPLUS RFSR‐CT‐2010‐00019 136 CONOX RFSR‐CT‐2006‐00033 203 AUTOCHECK RFSR‐CT‐2003‐00045 199 Consistent BF RFSR‐CT‐2007‐00002 58 AUTOCOAT RFSR‐CT‐2009‐00014 117 CONSTAINSSA RFSR‐CT‐2004‐00026 125 AUTOCORR RFSR‐CT‐2009‐00015 148 CONSTOX RFSR‐CT‐2011‐00007 106 AUTODIAG RFSR‐CT‐2008‐00042 205 COOL RFCR‐CT‐2006‐00004 33 AUTOFATCOR RFSR‐CT‐2011‐00021 151 CORINOX RFSR‐CT‐2006‐00022 130 AVAS RFSR‐CT‐2003‐00043 199 CORSA RFSR‐CT‐2011‐00038 210 AVENTO RFCR‐CT‐2012‐00004 27 COSIMB RFSR‐CT‐2004‐00047 169 AWiCCo RFSR‐CT‐2005‐00020 99 COSSFIRE RFSR‐CT‐2006‐00028 171 BAINHARD RFSR‐CT‐2007‐00023 132 CP‐steels RFSR‐CT‐2006‐00021 130 Bainite Design RFSR‐CT‐2007‐00022 132 CRESTA RFSR‐CT‐2008‐00024 134 BATHFOAM RFSR‐CT‐2008‐00004 73 CRFREEROLLS RFSR‐CT‐2011‐00012 106 BATIMASS RFSR‐CT‐2012‐00033 190 CRYO RFSR‐CT‐2007‐00026 146 Beam‐blank MFC RFSP‐CT‐2005‐00008 79 CTLEUROPE RFC2‐CT‐2008‐00006 31 BIOGASS RFSR‐CT‐2012‐00035 191 CUT‐EDGE RFSR‐CT‐2004‐00021 112 BIOWAS RFSR‐CT‐2003‐00020 124 DCFC RFCR‐CT‐2011‐00004 51 BOFCom RFCR‐CT‐2006‐00010 48 DECAWIN RFSR‐CT‐2012‐00015 137 BOFDEDUST RFSP‐CT‐2007‐00045 195 DECFLAQ RFSR‐CT‐2004‐00050 200 BOFDYN RFSR‐CT‐2003‐00042 67 DECOBIOF RFSR‐CT‐2005‐00024 114 BOLT_ZnAlMg RFSR‐CT‐2012‐00014 120 DEFFREE RFSR‐CT‐2008‐00007 86 BRIDGEPLEX RFSR‐CT‐2004‐00040 167 DELOC RFSR‐CT‐2007‐00021 132 BRiFaG RFSR‐CT‐2008‐00033 176 DEMPOLIFE RFSR‐CT‐2005‐00002 57 C2H UPGRADE RFCR‐CT‐2003‐00009 31 DENOPT RFCR‐CT‐2007‐00008 49

3 DENSICHARGE RFCR‐CT‐2010‐00007 36 FATWELDHSS RFSR‐CT‐2010‐00032 183 DETAILS RFSR‐CT‐2006‐00032 172 FEATureFACE RFCR‐CT‐2012‐00001 26 DEVCAT RFCR‐CT‐2010‐00012 51 FECUNDUS RFCR‐CT‐2010‐00009 36 DIFISEK RFS2‐CT‐2003‐00048 157 FERRIGAL RFSR‐CT‐2008‐00019 116 DIFISEK+ RFS2‐CT‐2007‐00030 160 FIBLAS RFSR‐CT‐2006‐00029 171 DIRECT DEFECT TOOLBOX‐ RFSR‐CT‐2011‐00005 87 Fibre Laser Welded HSS RFS3‐CT‐2008‐00031 163 DDT FICEB RFSR‐CT‐2007‐00042 175 DISCCO RFSR‐CT‐2012‐00030 189 FIDESC4 RFSR‐CT‐2011‐00030 185 DISKX100PIPE RFS2‐CT‐2004‐00038 158 FINALPLATEFLATNESS RFSR‐CT‐2005‐00019 99 DiSTEEL RFSR‐CT‐2010‐00029 183 FIRESTRUC RFSR‐CT‐2003‐00030 166 DOT Application RFSP‐CT‐2004‐00006 65 FLANGE CORROSION RFSR‐CT‐2003‐00029 142 DP grades with improved RFSR‐CT‐2004‐00035 144 formability Flat strip control RFSR‐CT‐2010‐00015 118 DRYCOAL RFCP‐CT‐2004‐00002 41 FLEXCHARGE RFSR‐CT‐2007‐00008 71 DryConDis RFS2‐CT‐2004‐00036 157 FLEXGAS RFCR‐CT‐2007‐00005 34 DUCTAFORM RFSR‐CT‐2008‐00021 133 FLEXINJECT RFSR‐CT‐2008‐00001 59 DUPLEXTANK RFSR‐CT‐2009‐00025 180 FLEXPROMUS RFSR‐CT‐2010‐00017 119 DURADH RFSR‐CT‐2011‐00019 150 FLOMINET RFCR‐CT‐2008‐00005 23 DURATOOL RFSR‐CT‐2003‐00032 142 FLOWVIS RFSR‐CT‐2004‐00011 81 DYNAMO RFSR‐CT‐2012‐00009 107 FLOX‐COAL RFCR‐CT‐2005‐00010 47 EAFCAMERA RFSR‐CT‐2004‐00008 67 FLOX‐COAL‐II RFCR‐CT‐2011‐00005 52 EAFDYNCON RFSR‐CT‐2003‐00031 66 FLUXFLOW RFSR‐CT‐2003‐00027 80 EAF‐PROMS RFSR‐CT‐2006‐00005 69 FOMTM RFSP‐CT‐2012‐00007 79 ECLAIR RFCP‐CT‐2008‐00008 42 FOSUCOR RFSR‐CT‐2009‐00035 104 ECOBRIDGE RFSP‐CT‐2010‐00024 164 FRAMEUP RFSR‐CT‐2011‐00035 186 ECOCARB RFCR‐CT‐2008‐00007 34 FREEZE RFSR‐CT‐2006‐00038 204 ECONOSOX RFSR‐CT‐2004‐00003 56 FriendlyCoal RFCR‐CT‐2006‐00007 47 ECOPITCH RFCR‐CT‐2005‐00004 32 FRISCC RFSR‐CT‐2012‐00025 188 ECO‐Scrub RFCR‐CT‐2007‐00009 49 FS+ RFS2‐CT‐2007‐00032 160 ECOWATER RFCR‐CT‐2010‐00010 195 FULL‐REC 2 RFSP‐CT‐2003‐00007 65 EDAFFIC RFCR‐CT‐2008‐00002 22 FUSEIS RFSR‐CT‐2008‐00032 176 EDDYCAST RFSR‐CT‐2004‐00009 81 GEOASH RFCR‐CT‐2004‐00005 44 EDGECONTROL RFSR‐CT‐2007‐00015 101 GEOMOD RFCR‐CT‐2003‐00011 18 EEBIS RFSR‐CT‐2003‐00017 164 GEOSOFT RFCR‐CT‐2010‐00001 24 ELEM RFSR‐CT‐2008‐00039 178 GIPIPE RFSR‐CT‐2011‐00027 184 ELEXIR RFSR‐CT‐2007‐00020 131 GLOBALSHAPECONTROL RFSR‐CT‐2004‐00016 96 ELOTOP RFSR‐CT‐2010‐00016 118 GPHS RFSR‐CT‐2010‐00021 149 EMIMSAR RFCR‐CT‐2009‐00002 23 GRAINCONT RFSR‐CT‐2006‐00018 84 EMTECH RFCR‐CT‐2008‐00003 22 GREENEAF RFSR‐CT‐2009‐00004 74 ENCAVI RFS3‐CT‐2005‐00038 163 Hearth efficiency RFSR‐CT‐2007‐00001 58 ENCIO RFCP‐CT‐2011‐00003 42 HEAT RFSR‐CT‐2010‐00012 117 ENCOP RFSR‐CT‐2009‐00032 207 HELNOX‐BFG RFSR‐CT‐2012‐00010 107 ENFASS RFSR‐CT‐2011‐00020 150 HIDES RFSR‐CT‐2009‐00009 104 ENHANCED BF OPERATION RFSR‐CT‐2003‐00013 55 Hi‐FLOW RFSR‐CT‐2003‐00023 141 EOSC 2006 RFS1‐CT‐2006‐00002 65 HIGH‐PICK RFSR‐CT‐2005‐00021 113 EPCWCMS RFCR‐CT‐2003‐00003 17 HIJETROD RFSR‐CT‐2010‐00014 118 EPOSS RFSR‐CT‐2007‐00006 70 HILONG RFSR‐CT‐2012‐00028 189 ERAMAC RFSR‐CT‐2003‐00001 197 HINIST RFSR‐CT‐2005‐00004 68 ESE RFSR‐CT‐2007‐00037 173 HIPERC RFSR‐CT‐2005‐00027 127 ESTEP OPTIMET RFSR‐CT‐2007‐00024 133 HIPERCUT RFSR‐CT‐2012‐00027 188 ETHICS RFSR‐CT‐2008‐00038 178 HI‐PROF RFSR‐CT‐2005‐00033 145 ETIB RFSR‐CT‐2004‐00041 167 HISARNA B and C RFSR‐CT‐2011‐00002 60 eTipo RFSR‐CT‐2005‐00047 202 HISTWIN RFSR‐CT‐2006‐00031 172 EUROBUILD+ RFS2‐CT‐2007‐00029 159 HISTWIN2 RFSR‐CT‐2010‐00031 183 EUROFIBRES RFCR‐CT‐2009‐00004 35 HITUBES RFSR‐CT‐2008‐00035 177 EvalHD RFSR‐CT‐2012‐00040 212 HI‐VEL RFSR‐CT‐2006‐00026 146 EWRCOOL RFSR‐CT‐2004‐00015 96 HiVoSS RFS2‐CT‐2007‐00033 161 EXTUL RFSR‐CT‐2011‐00001 60 Hppm RFSR‐CT‐2007‐00018 115 FACTMON RFSR‐CT‐2003‐00041 198 HRENERGYCONTROL RFSR‐CT‐2010‐00008 104 FADLESS RFSR‐CT‐2009‐00027 181 HSM LUBRICATION RFSR‐CT‐2004‐00013 95 FAMEGA RFSR‐CT‐2003‐00021 111 HSS‐SERF RFSR‐CT‐2009‐00024 180 FATHOMS RFSR‐CT‐2005‐00042 170 HUGE RFCR‐CT‐2007‐00006 34

4 HUGE2 RFCR‐CT‐2011‐00002 37 LCS RFSR‐CT‐2006‐00035 203 HYBLAS RFSR‐CT‐2003‐00010 164 LIGPOWER RFCP‐CT‐2003‐00002 41 HYBRO RFSR‐CT‐2012‐00024 187 LINECOP RFSR‐CT‐2006‐00037 204 HYDRAMICROS RFSR‐CT‐2010‐00020 136 LINESPEC RFSR‐CT‐2007‐00041 174 HYDRAS RFSR‐CT‐2009‐00030 206 LOCAFI RFSR‐CT‐2012‐00023 187 HYDROSEP RFCR‐CT‐2006‐00003 33 LOCALHEAT RFSR‐CT‐2003‐00026 141 Hyprocom RFSR‐CT‐2007‐00016 101 LOWCARB RFCR‐CT‐2010‐00004 25 I2MSTEEL RFSR‐CT‐2012‐00038 212 LOWCNEAF RFSR‐CT‐2008‐00003 73 IAMTECH RFCR‐CT‐2004‐00001 18 LOWWEAR RFSR‐CT‐2006‐00010 99 ICCRACK RFSR‐CT‐2010‐00006 87 LPROLLCOAT RFSR‐CT‐2010‐00009 105 ICONSYS RFSR‐CT‐2012‐00037 211 LSSEMIQUAL RFSR‐CT‐2008‐00008 86 ICONTENS RFSR‐CT‐2011‐00016 120 LUBRIMOULD RFSR‐CT‐2009‐00006 87 IDEOGAS RFSP‐CT‐2006‐00001 55 LUBWORK RFSR‐CT‐2008‐00011 101 IERO RFSR‐CT‐2010‐00002 60 LUNA RFSR‐CT‐2009‐00012 135 IMGALVA RFSR‐CT‐2004‐00023 113 LWO+ RFS2‐CT‐2005‐00037 159 IMPCO RFSR‐CT‐2012‐00002 61 MAC D RFSR‐CT‐2011‐00024 152 IMPECABL RFCR‐CT‐2004‐00004 32 MACS+ RFS2‐CT‐2011‐00025 162 IMPHOS RFSR‐CT‐2006‐00006 70 MAGNETOHYDRO RFSR‐CT‐2007‐00012 85 IMPREX RFCR‐CT‐2008‐00001 21 MAGPRO RFSR‐CT‐2006‐00019 129 IMPROSOUND RFSR‐CT‐2004‐00012 95 MAGSEP RFSR‐CT‐2012‐00042 213 Improvement of line RFSR‐CT‐2005‐00052 115 MANNESTRAMP RFSR‐CT‐2004‐00025 125 productivity MARTIMPROP RFSR‐CT‐2006‐00023 131 Improvement of strip RFSR‐CT‐2003‐00011 94 guiding MASTERBILLET RFSR‐CT‐2008‐00005 85 ImPurgingAr RFSR‐CT‐2005‐00005 68 MAXICARB RFCR‐CT‐2006‐00002 33 IMSIMI RFSR‐CT‐2011‐00003 61 MECBAIN RFSR‐CT‐2012‐00017 138 IMSTEELLAD RFSR‐CT‐2003‐00008 66 MEMORACE RFSR‐CT‐2004‐00001 55 INAREIS RFSR‐CT‐2009‐00026 181 MEORU RFSR‐CT‐2004‐00004 56 INCLUSION RFSR‐CT‐2008‐00002 72 MEPMO RFSR‐CT‐2003‐00009 124 INCOOL RFSP‐CT‐2011‐00009 94 MERCURYCAP RFCR‐CT‐2007‐00007 49 INCOSTEEL RFSR‐CT‐2004‐00018 97 Metaldesign RFSR‐CT‐2005‐00030 128 INDUCWELD RFSR‐CT‐2005‐00040 170 METHODOWEAR RFSR‐CT‐2003‐00044 199 INDUSE RFSR‐CT‐2009‐00022 179 MICROAS 05 RFS1‐CT‐2005‐00025 123 InFaSo RFSR‐CT‐2007‐00051 176 MICROCONTROL RFSR‐CT‐2010‐00010 105 INFASO+ RFS2‐CT‐2012‐00022 163 MICRODAMAGE RFSR‐CT‐2008‐00027 135 INFERENCE RFCR‐CT‐2003‐00005 31 MICROFAT RFSR‐CT‐2005‐00034 145 INNOCARB RFSR‐CT‐2010‐00001 60 MICRO‐QUANT RFSR‐CT‐2006‐00017 129 INNOGLAST RFSR‐CT‐2007‐00036 173 MICROTOOLS RFSR‐CT‐2009‐00011 135 INNO‐HYCO RFSR‐CT‐2010‐00025 181 MICSIPE RFSR‐CT‐2008‐00018 116 INNOSOLID RFSR‐CT‐2012‐00011 89 MIHAR RFSR‐CT‐2003‐00040 125 INPREST RFSR‐CT‐2004‐00042 167 MINFIREX RFCR‐CT‐2010‐00005 25 INREQ RFCR‐CT‐2012‐00002 26 MINORTOP RFCR‐CT‐2003‐00004 43 INSAPTRANS RFS2‐CT‐2007‐00025 141 MINTOS RFCR‐CT‐2007‐00003 21 INSTAP RFSR‐CT‐2009‐00018 149 MISSTER RFCR‐CT‐2010‐00014 25 INTAB RFSR‐CT‐2005‐00041 170 MISTRETO RFSR‐CT‐2005‐00029 128 INTAB+ RFS2‐CT‐2009‐00019 161 MnAl‐steel RFSR‐CT‐2006‐00027 146 INTCLEANCON RFSR‐CT‐2011‐00004 75 MONSUPPORT RFCR‐CT‐2005‐00002 19 INTERCOOL RFSR‐CT‐2010‐00011 105 MONWIRE RFSR‐CT‐2012‐00041 213 IPCDS RFSR‐CT‐2003‐00038 198 MULTISAVE RFSR‐CT‐2011‐00036 210 IPRO RFSR‐CT‐2010‐00036 209 MU‐STEEL RFSR‐CT‐2010‐00033 208 IPSA RFSR‐CT‐2008‐00017 116 NAMOS RFSR‐CT‐2012‐00016 138 IPTINGOT RFSR‐CT‐2011‐00006 88 NANOBAIN RFSR‐CT‐2008‐00022 133 IRSIS RFSR‐CT‐2006‐00036 204 NASCENT RFSR‐CT‐2004‐00043 168 ISA‐PESR RFSR‐CT‐2004‐00027 126 NDTCASTING RFSR‐CT‐2007‐00013 85 JOINOX RFSR‐CT‐2012‐00034 191 NEMAEQ RFCR‐CT‐2006‐00001 20 JOINTEC RFSR‐CT‐2007‐00035 172 NEWEU RFS2‐CT‐2004‐00037 157 KINPCC RFSR‐CT‐2011‐00008 88 NEWGENHSS RFSR‐CT‐2009‐00013 148 KINSREP RFSR‐CT‐2008‐00028 147 NEWQP RFSR‐CT‐2011‐00017 137 KNOWDEC RFSR‐CT‐2009‐00031 207 NEXTEP RFSR‐CT‐2008‐00046 116 LADLIFE RFSR‐CT‐2009‐00003 74 NitrateBio Demo RFSP‐CT‐2007‐00047 195 LAREFMON RFSR‐CT‐2008‐00044 73 NODIOXCOMB RFCR‐CT‐2004‐00007 45 LASERHARD RFSR‐CT‐2006‐00012 100 NOEMI RFCR‐CT‐2012‐00005 37

5 NOVANNEAL RFSR‐CT‐2006‐00015 115 REDPAH RFCR‐CT‐2005‐00005 32 Nox‐RF RFSR‐CT‐2003‐00005 80 REFFIPLANT RFSR‐CT‐2012‐00039 212 NUSIMAG RFSR‐CT‐2004‐00024 125 REFORM RFSR‐CT‐2009‐00016 148 O‐Chess RFSR‐CT‐2007‐00049 205 REGTGF RFSR‐CT‐2003‐00036 81 ODS‐STEEL RFSR‐CT‐2006‐00020 130 REHOMI RFSR‐CT‐2004‐00030 127 OFFGAS RFSR‐CT‐2006‐00004 69 RELOTEMP RFSR‐CT‐2010‐00034 208 OMC RFSR‐CT‐2008‐00040 205 REPAIR RFSR‐CT‐2009‐00010 117 ONDECO RFSR‐CT‐2007‐00004 70 RFS‐CR‐03012 RFS3‐CT‐2005‐00015 93 OPCONSTAINLESS RFSR‐CT‐2007‐00007 71 ROBUST RFSR‐CT‐2007‐00043 175 OPTCOOLUB RFSR‐CT‐2006‐00014 100 ROBUSTFIRE RFSR‐CT‐2008‐00036 177 OPTDESLAG RFSR‐CT‐2010‐00005 75 ROBUSTIMPACT RFSR‐CT‐2012‐00029 189 OPTHEAT RFSR‐CT‐2006‐00007 84 Robustness RFSR‐CT‐2004‐00046 168 OPTIBOS RFSR‐CT‐2012‐00018 138 ROLLGAP SENSORS RFSR‐CT‐2009‐00008 103 OPTIFIN RFSR‐CT‐2007‐00014 101 ROLLINGHASS RFSR‐CT‐2008‐00023 134 OPTILUB RFSR‐CT‐2004‐00019 97 ROLLMARK RFSP‐CT‐2006‐00013 93 OPTI‐MINE RFCP‐CT‐2011‐00001 17 ROLLSTREM RFSR‐CT‐2012‐00045 108 OPTIPER RFSR‐CT‐2012‐00004 62 ROLLWITECH RFSR‐CT‐2010‐00007 104 OPTISHAMP RFSR‐CT‐2011‐00011 106 RUOSTE RFSR‐CT‐2012‐00036 191 OPTISTOVE RFSR‐CT‐2012‐00003 62 RUSTEEL RFSR‐CT‐2009‐00023 180 OPTISTRAIGHT RFSR‐CT‐2007‐00040 174 S+G RFSR‐CT‐2012‐00026 188 OPTITUBE RFSR‐CT‐2008‐00014 102 SAFETECH RFCR‐CT‐2003‐00010 18 OPUS RFSR‐CT‐2007‐00039 174 SAFETOWER RFSR‐CT‐2010‐00028 182 OxMaPro RFSR‐CT‐2008‐00016 103 SAFSS RFSR‐CT‐2010‐00026 182 OxyBurner RFCR‐CT‐2006‐00009 48 SARCO2 RFSR‐CT‐2011‐00033 186 OXYCORR RFCR‐CT‐2009‐00005 50 SB_Steel RFSR‐CT‐2010‐00027 182 OXYMOD RFCR‐CT‐2005‐00006 45 SBRI RFSR‐CT‐2009‐00020 178 PACROLP RFSR‐CT‐2003‐00002 94 SBRI RFSR‐CT‐2009‐00020 179 PACROLP‐II RFSR‐CT‐2009‐00007 103 Scale Control RFSR‐CT‐2005‐00016 98 PERMESS RFSR‐CT‐2005‐00045 201 SCRAP PROBE RFSP‐CT‐2008‐00041 196 PISAC RFSR‐CT‐2005‐00026 127 SECHALO RFS2‐CT‐2008‐00030 161 Seismic Design of Framed PLASTOTOUGH RFSR‐CT‐2005‐00039 169 RFS3‐CT‐2004‐00039 163 Buildings PLATEND RFSR‐CT‐2005‐00044 201 SEISRACKS RFSR‐CT‐2004‐00045 168 PLUGWATCH RFSR‐CT‐2012‐00005 75 SEISRACKS2 RFSR‐CT‐2011‐00031 185 PMAP RFSR‐CT‐2012‐00008 88 SELECTIVEROLLCOOLING RFSP‐CT‐2008‐00009 93 PRECASTEEL RFSR‐CT‐2007‐00038 173 SELSA RFSR‐CT‐2010‐00035 208 PrecHiMn RFSR‐CT‐2010‐00018 136 Semi‐Comp RFSR‐CT‐2004‐00044 168 PRECIOUS RFSR‐CT‐2003‐00034 166 SEMI‐COMP+ RFS2‐CT‐2010‐00023 162 PRECIPITATION RFSR‐CT‐2005‐00014 83 SensoCont RFSR‐CT‐2004‐00052 201 PRECO+ RFS2‐CT‐2011‐00026 162 SensorControPilot RFSP‐CT‐2007‐00046 195 PrECo‐Beam RFSR‐CT‐2006‐00030 171 SEQBRI RFSR‐CT‐2012‐00032 190 PREDINC RFSR‐CT‐2005‐00006 68 SHAPEHPM RFSR‐CT‐2003‐00039 95 PREMPROP RFSR‐CT‐2003‐00015 124 SHOCOM RFSR‐CT‐2005‐00001 57 PRESEG RFSR‐CT‐2003‐00022 80 SIMUSTEEL RFSR‐CT‐2005‐00046 202 PRESIDENCE RFCR‐CT‐2007‐00004 21 Sinter efficiency RFSR‐CT‐2006‐00039 57 PRESSPERFECT RFSR‐CT‐2012‐00021 153 SISCON RFSR‐CT‐2009‐00034 207 PREST RFSR‐CT‐2004‐00029 126 SLACON RFSR‐CT‐2012‐00006 76 PrimeForm RFSR‐CT‐2004‐00031 143 SLAGFERTILISER RFSR‐CT‐2011‐00037 210 PROMACH RFSR‐CT‐2007‐00027 147 SLAGFILMOWL RFSR‐CT‐2005‐00012 83 PROMS RFSR‐CT‐2003‐00016 66 SLASORB RFSP‐CT‐2009‐00028 196 PROSAFECOAL RFCR‐CT‐2007‐00001 20 SMARTBURN RFCR‐CT‐2008‐00009 50 PROSSUS RFS2‐CT‐2005‐00035 158 SMARTCOCO RFSR‐CT‐2012‐00031 190 PROTECT RFSR‐CT‐2010‐00004 74 SMARTFIRE RFSR‐CT‐2005‐00009 82 PROTUBEND RFSR‐CT‐2009‐00017 149 SOFTDETECT RFSR‐CT‐2004‐00017 97 RAINOW RFCR‐CT‐2005‐00003 19 SOLIMOULD RFSR‐CT‐2005‐00011 82 RAMSCI RFSP‐CT‐2007‐00048 196 SOLVSTIR RFSR‐CT‐2004‐00033 144 RAPCOAT RFSR‐CT‐2003‐00004 197 SOPLIQS RFSR‐CT‐2007‐00005 70 RATIO‐COAL RFCR‐CT‐2010‐00008 36 SPACE RFSR‐CT‐2005‐00023 114 REAL RFSR‐CT‐2005‐00043 201 SpeedFat RFSR‐CT‐2005‐00032 145 REC DC EAF RFSR‐CT‐2003‐00024 66 SPRINCOM RFSR‐CT‐2008‐00029 147 RECaL RFCR‐CT‐2012‐00008 52 SPRITCO RFCR‐CT‐2010‐00006 35 RECONI RFSR‐CT‐2011‐00039 211 SSIA RFSR‐CT‐2006‐00003 69

6 SSIF RFSR‐CT‐2004‐00048 169 SSSSS RFSR‐CT‐2004‐00014 96 STEELCLEANCONTROL RFSR‐CT‐2007‐00011 72 STEELRETRO RFSR‐CT‐2007‐00050 175 STEELTAC RFSR‐CT‐2011‐00022 151 StImprove RFSR‐CT‐2007‐00009 71 STRAINHARD RFSR‐CT‐2004‐00032 143 StrengthCONTROL RFSR‐CT‐2008‐00026 135 Stripvibrations reduction RFSP‐CT‐2007‐00017 111 STT RFSR‐CT‐2012‐00020 152 SUPSYSCC RFSR‐CT‐2009‐00033 207 SURFQUALDEV RFSR‐CT‐2003‐00047 199 SUSTAINTAP RFSR‐CT‐2012‐00001 61 SYNFAB RFSR‐CT‐2003‐00049 143 SYNPEX RFSR‐CT‐2003‐00019 165 TABASCO RFSR‐CT‐2011‐00028 184 TECPLAN RFSR‐CT‐2011‐00040 211 TESTRA RFSR‐CT‐2003‐00012 94 TESTTOOL RFSR‐CT‐2011‐00023 151 THINFILM RFSR‐CT‐2005‐00048 202 THINSTRIP RFSP‐CT‐2003‐00033 79 TOPOMETER RFSR‐CT‐2004‐00020 112 TOPROLLS RFSR‐CT‐2005‐00018 98 TOSICO RFSR‐CT‐2009‐00001 59 TOTOPTLIS RFSR‐CT‐2010‐00003 74 TRANSIENT RFSR‐CT‐2009‐00005 86 TREES RFSR‐CT‐2003‐00014 198 TRESOR RFSR‐CT‐2004‐00051 200 TUNDJUST RFSR‐CT‐2005‐00013 83 TUTEMP RFSR‐CT‐2004‐00034 144 TWIP4EU RFSR‐CT‐2012‐00019 152 UCG & CO2 STORAGE RFCR‐CT‐2010‐00003 24 UCoSiF RFSR‐CT‐2007‐00044 175 ULCF RFSR‐CT‐2011‐00029 184 ULCOS RFSR‐CT‐2004‐00005 56 ULCOS TGRBF RFSR‐CT‐2009‐00002 59 ULTRA DRY COOLING RFSR‐CT‐2010‐00013 118 ULTRAFINE RFSR‐CT‐2004‐00049 200 URIOM RFSR‐CT‐2007‐00010 72 VADPSHEETS RFSR‐CT‐2011‐00014 119 VALCOSS RFS2‐CT‐2005‐00036 158 VERAPS RFSR‐CT‐2003‐00035 166 WACOOL RFSR‐CT‐2005‐00017 98 WATERCHEM RFCR‐CT‐2003‐00006 17 WAVIMETER RFSR‐CT‐2006‐00016 115 WAVISURF RFSP‐CT‐2011‐00013 111 WINROLLS RFSR‐CT‐2008‐00013 102 WiSH RFS2‐CT‐2007‐00028 159 WORODEFS RFSR‐CT‐2011‐00010 106 ZEMUSIC RFSR‐CT‐2011‐00032 185 ZINC‐ALLOY RFSR‐CT‐2003‐00028 112 ZINCANA RFSR‐CT‐2008‐00043 206 ZINCOBOR RFSR‐CT‐2012‐00013 120

7 8 RFCR‐CT‐2007‐00007 MERCURYCAP 49 Table of Contents 2 RFCR‐CT‐2007‐00008 DENOPT 49 RFCR‐CT‐2007‐00009 ECO‐Scrub 49 Projects listed by reference number RFCR‐CT‐2008‐00001 IMPREX 21 RFCR‐CT‐2008‐00002 EDAFFIC 22 RFCR‐CT‐2008‐00003 EMTECH 22 RFCR‐CT‐2008‐00004 COALSWAD 22 RFCR‐CT‐2008‐00005 FLOMINET 23 RFCR‐CT‐2008‐00007 ECOCARB 34 RFCR‐CT‐2008‐00009 SMARTBURN 50 Reference Number Project Acronym Page RFCR‐CT‐2009‐00001 CARBOLAB 23 RFCR‐CT‐2009‐00002 EMIMSAR 23 RFC2‐CT‐2006‐00005 CCTPROM 41 RFCR‐CT‐2009‐00003 CO2freeSNG 35 RFC2‐CT‐2008‐00006 CTLEUROPE 31 RFCR‐CT‐2009‐00004 EUROFIBRES 35 RFCP‐CT‐2003‐00002 LIGPOWER 41 RFCR‐CT‐2009‐00005 OXYCORR 50 RFCP‐CT‐2004‐00002 DRYCOAL 41 RFCR‐CT‐2010‐00001 GEOSOFT 24 RFCP‐CT‐2004‐00003 COMTES700 42 RFCR‐CT‐2010‐00002 COGASOUT 24 RFCP‐CT‐2006‐00011 CERCOT 42 RFCR‐CT‐2010‐00003 UCG & CO2 STORAGE 24 RFCP‐CT‐2008‐00008 ECLAIR 42 RFCR‐CT‐2010‐00004 LOWCARB 25 RFCP‐CT‐2011‐00001 OPTI‐MINE 17 RFCR‐CT‐2010‐00005 MINFIREX 25 RFCP‐CT‐2011‐00003 ENCIO 42 RFCR‐CT‐2010‐00006 SPRITCO 35 RFCP‐CT‐2012‐00006 ACCLAIM 43 RFCR‐CT‐2010‐00007 DENSICHARGE 36 RFCR‐CT‐2003‐00001 CLEFCO 43 RFCR‐CT‐2010‐00008 RATIO‐COAL 36 RFCR‐CT‐2003‐00003 EPCWCMS 17 RFCR‐CT‐2010‐00009 FECUNDUS 36 RFCR‐CT‐2003‐00004 MINORTOP 43 RFCR‐CT‐2010‐00010 ECOWATER 195 RFCR‐CT‐2003‐00005 INFERENCE 31 RFCR‐CT‐2010‐00011 CARINA 50 RFCR‐CT‐2003‐00006 WATERCHEM 17 RFCR‐CT‐2010‐00012 DEVCAT 51 RFCR‐CT‐2003‐00007 ADMONI 44 RFCR‐CT‐2010‐00013 CAL‐MOD 51 RFCR‐CT‐2003‐00008 ASSOCOGS 44 RFCR‐CT‐2010‐00014 MISSTER 25 RFCR‐CT‐2003‐00009 C2H UPGRADE 31 RFCR‐CT‐2011‐00002 HUGE2 37 RFCR‐CT‐2003‐00010 SAFETECH 18 RFCR‐CT‐2011‐00004 DCFC 51 RFCR‐CT‐2003‐00011 GEOMOD 18 RFCR‐CT‐2011‐00005 FLOX‐COAL‐II 52 RFCR‐CT‐2004‐00001 IAMTECH 18 RFCR‐CT‐2012‐00001 FEATureFACE 26 RFCR‐CT‐2004‐00004 IMPECABL 32 RFCR‐CT‐2012‐00002 INREQ 26 RFCR‐CT‐2004‐00005 GEOASH 44 RFCR‐CT‐2012‐00003 COMEX 27 RFCR‐CT‐2004‐00006 AGAPUTE 45 RFCR‐CT‐2012‐00004 AVENTO 27 RFCR‐CT‐2004‐00007 NODIOXCOMB 45 RFCR‐CT‐2012‐00005 NOEMI 37 RFCR‐CT‐2005‐00001 ADEMA 19 RFCR‐CT‐2012‐00008 RECaL 52 RFCR‐CT‐2005‐00002 MONSUPPORT 19 RFS1‐CT‐2005‐00025 MICROAS 05 123 RFCR‐CT‐2005‐00003 RAINOW 19 RFS1‐CT‐2006‐00002 EOSC 2006 65 RFCR‐CT‐2005‐00004 ECOPITCH 32 6th Stainless Steel RFS1‐CT‐2008‐00020 123 RFCR‐CT‐2005‐00005 REDPAH 32 Conference RFCR‐CT‐2005‐00006 OXYMOD 45 RFS2‐CT‐2003‐00048 DIFISEK 157 RFCR‐CT‐2005‐00007 CLYCARGAS 46 RFS2‐CT‐2004‐00036 DryConDis 157 RFCR‐CT‐2005‐00008 CO.CA.CO.R.K. 46 RFS2‐CT‐2004‐00037 NEWEU 157 RFCR‐CT‐2005‐00009 CFB800 46 RFS2‐CT‐2004‐00038 DISKX100PIPE 158 RFCR‐CT‐2005‐00010 FLOX‐COAL 47 RFS2‐CT‐2005‐00035 PROSSUS 158 RFCR‐CT‐2006‐00001 NEMAEQ 20 RFS2‐CT‐2005‐00036 VALCOSS 158 RFCR‐CT‐2006‐00002 MAXICARB 33 RFS2‐CT‐2005‐00037 LWO+ 159 RFCR‐CT‐2006‐00003 HYDROSEP 33 RFS2‐CT‐2007‐00025 INSAPTRANS 141 RFCR‐CT‐2006‐00004 COOL 33 RFS2‐CT‐2007‐00028 WiSH 159 RFCR‐CT‐2006‐00006 ABETRAP 47 RFS2‐CT‐2007‐00029 EUROBUILD+ 159 RFCR‐CT‐2006‐00007 FriendlyCoal 47 RFS2‐CT‐2007‐00030 DIFISEK+ 160 RFCR‐CT‐2006‐00008 CLEAN SELECTIVE 48 RFS2‐CT‐2007‐00031 COMBRI+ 160 RFCR‐CT‐2006‐00009 OxyBurner 48 RFS2‐CT‐2007‐00032 FS+ 160 RFCR‐CT‐2006‐00010 BOFCom 48 RFS2‐CT‐2007‐00033 HiVoSS 161 RFCR‐CT‐2007‐00001 PROSAFECOAL 20 RFS2‐CT‐2008‐00030 SECHALO 161 RFCR‐CT‐2007‐00002 ADRIS 20 RFS2‐CT‐2009‐00019 INTAB+ 161 RFCR‐CT‐2007‐00003 MINTOS 21 RFS2‐CT‐2010‐00023 SEMI‐COMP+ 162 RFCR‐CT‐2007‐00004 PRESIDENCE 21 RFS2‐CT‐2011‐00025 MACS+ 162 RFCR‐CT‐2007‐00005 FLEXGAS 34 RFS2‐CT‐2011‐00026 PRECO+ 162 RFCR‐CT‐2007‐00006 HUGE 34 RFS2‐CT‐2012‐00022 INFASO+ 163

9 Seismic Design of RFS3‐CT‐2004‐00039 163 RFSR‐CT‐2003‐00039 SHAPEHPM 95 Framed Buildings RFSR‐CT‐2003‐00040 MIHAR 125 RFS3‐CT‐2005‐00015 RFS‐CR‐03012 93 RFSR‐CT‐2003‐00041 FACTMON 198 RFS3‐CT‐2005‐00038 ENCAVI 163 RFSR‐CT‐2003‐00042 BOFDYN 67 RFS3‐CT‐2008‐00031 Fibre Laser Welded HSS 163 RFSR‐CT‐2003‐00043 AVAS 199 RFSP‐CT‐2003‐00007 FULL‐REC 2 65 RFSR‐CT‐2003‐00044 METHODOWEAR 199 RFSP‐CT‐2003‐00033 THINSTRIP 79 RFSR‐CT‐2003‐00045 AUTOCHECK 199 RFSP‐CT‐2004‐00006 DOT Application 65 RFSR‐CT‐2003‐00046 CARSTEEL 112 RFSP‐CT‐2005‐00008 Beam‐blank MFC 79 RFSR‐CT‐2003‐00047 SURFQUALDEV 199 RFSP‐CT‐2006‐00001 IDEOGAS 55 RFSR‐CT‐2003‐00049 SYNFAB 143 RFSP‐CT‐2006‐00009 Anti‐chatter CHD 93 RFSR‐CT‐2004‐00001 MEMORACE 55 RFSP‐CT‐2006‐00013 ROLLMARK 93 RFSR‐CT‐2004‐00002 COKARAC 56 Stripvibrations RFSP‐CT‐2007‐00017 111 reduction RFSR‐CT‐2004‐00003 ECONOSOX 56 RFSP‐CT‐2007‐00045 BOFDEDUST 195 RFSR‐CT‐2004‐00004 MEORU 56 RFSP‐CT‐2007‐00046 SensorControPilot 195 RFSR‐CT‐2004‐00005 ULCOS 56 RFSP‐CT‐2007‐00047 NitrateBio Demo 195 RFSR‐CT‐2004‐00008 EAFCAMERA 67 RFSP‐CT‐2007‐00048 RAMSCI 196 RFSR‐CT‐2004‐00009 EDDYCAST 81 RFSP‐CT‐2008‐00009 SELECTIVEROLLCOOLING 93 RFSR‐CT‐2004‐00010 CASTINCREM 81 RFSP‐CT‐2008‐00041 SCRAP PROBE 196 RFSR‐CT‐2004‐00011 FLOWVIS 81 RFSP‐CT‐2009‐00028 SLASORB 196 RFSR‐CT‐2004‐00012 IMPROSOUND 95 RFSP‐CT‐2010‐00024 ECOBRIDGE 164 RFSR‐CT‐2004‐00013 HSM LUBRICATION 95 RFSP‐CT‐2011‐00009 INCOOL 94 RFSR‐CT‐2004‐00014 SSSSS 96 RFSP‐CT‐2011‐00013 WAVISURF 111 RFSR‐CT‐2004‐00015 EWRCOOL 96 RFSP‐CT‐2012‐00007 FOMTM 79 RFSR‐CT‐2004‐00016 GLOBALSHAPECONTROL 96 RFSR‐CT‐2003‐00001 ERAMAC 197 RFSR‐CT‐2004‐00017 SOFTDETECT 97 RFSR‐CT‐2003‐00002 PACROLP 94 RFSR‐CT‐2004‐00018 INCOSTEEL 97 RFSR‐CT‐2003‐00003 CASTDESMON 79 RFSR‐CT‐2004‐00019 OPTILUB 97 RFSR‐CT‐2003‐00004 RAPCOAT 197 RFSR‐CT‐2004‐00020 TOPOMETER 112 RFSR‐CT‐2003‐00005 Nox‐RF 80 RFSR‐CT‐2004‐00021 CUT‐EDGE 112 RFSR‐CT‐2003‐00006 CATIA 197 RFSR‐CT‐2004‐00022 CLEAN 113 RFSR‐CT‐2003‐00008 IMSTEELLAD 66 RFSR‐CT‐2004‐00023 IMGALVA 113 RFSR‐CT‐2003‐00009 MEPMO 124 RFSR‐CT‐2004‐00024 NUSIMAG 125 RFSR‐CT‐2003‐00010 HYBLAS 164 RFSR‐CT‐2004‐00025 MANNESTRAMP 125 Improvement of strip RFSR‐CT‐2003‐00011 94 RFSR‐CT‐2004‐00026 CONSTAINSSA 125 guiding RFSR‐CT‐2004‐00027 ISA‐PESR 126 RFSR‐CT‐2003‐00012 TESTRA 94 RFSR‐CT‐2004‐00028 CARBAIN 126 ENHANCED BF RFSR‐CT‐2003‐00013 55 OPERATION RFSR‐CT‐2004‐00029 PREST 126 RFSR‐CT‐2003‐00014 TREES 198 RFSR‐CT‐2004‐00030 REHOMI 127 RFSR‐CT‐2003‐00015 PREMPROP 124 RFSR‐CT‐2004‐00031 PrimeForm 143 RFSR‐CT‐2003‐00016 PROMS 66 RFSR‐CT‐2004‐00032 STRAINHARD 143 RFSR‐CT‐2003‐00017 EEBIS 164 RFSR‐CT‐2004‐00033 SOLVSTIR 144 RFSR‐CT‐2003‐00018 COMBRI 165 RFSR‐CT‐2004‐00034 TUTEMP 144 DP grades with RFSR‐CT‐2003‐00019 SYNPEX 165 RFSR‐CT‐2004‐00035 144 improved formability RFSR‐CT‐2003‐00020 BIOWAS 124 RFSR‐CT‐2004‐00040 BRIDGEPLEX 167 RFSR‐CT‐2003‐00021 FAMEGA 111 RFSR‐CT‐2004‐00041 ETIB 167 RFSR‐CT‐2003‐00022 PRESEG 80 RFSR‐CT‐2004‐00042 INPREST 167 RFSR‐CT‐2003‐00023 Hi‐FLOW 141 RFSR‐CT‐2004‐00043 NASCENT 168 RFSR‐CT‐2003‐00024 REC DC EAF 66 RFSR‐CT‐2004‐00044 Semi‐Comp 168 RFSR‐CT‐2003‐00025 ACOUSVIBRA 165 RFSR‐CT‐2004‐00045 SEISRACKS 168 RFSR‐CT‐2003‐00026 LOCALHEAT 141 RFSR‐CT‐2004‐00046 Robustness 168 RFSR‐CT‐2003‐00027 FLUXFLOW 80 RFSR‐CT‐2004‐00047 COSIMB 169 RFSR‐CT‐2003‐00028 ZINC‐ALLOY 112 RFSR‐CT‐2004‐00048 SSIF 169 RFSR‐CT‐2003‐00029 FLANGE CORROSION 142 RFSR‐CT‐2004‐00049 ULTRAFINE 200 RFSR‐CT‐2003‐00030 FIRESTRUC 166 RFSR‐CT‐2004‐00050 DECFLAQ 200 RFSR‐CT‐2003‐00031 EAFDYNCON 66 RFSR‐CT‐2004‐00051 TRESOR 200 RFSR‐CT‐2003‐00032 DURATOOL 142 RFSR‐CT‐2004‐00052 SensoCont 201 RFSR‐CT‐2003‐00034 PRECIOUS 166 RFSR‐CT‐2005‐00001 SHOCOM 57 RFSR‐CT‐2003‐00035 VERAPS 166 RFSR‐CT‐2005‐00002 DEMPOLIFE 57 RFSR‐CT‐2003‐00036 REGTGF 81 RFSR‐CT‐2005‐00003 CONOPT SCRAP 67 RFSR‐CT‐2003‐00037 ALOAS 142 RFSR‐CT‐2005‐00004 HINIST 68 RFSR‐CT‐2003‐00038 IPCDS 198 RFSR‐CT‐2005‐00005 ImPurgingAr 68

10 RFSR‐CT‐2005‐00006 PREDINC 68 RFSR‐CT‐2006‐00029 FIBLAS 171 RFSR‐CT‐2005‐00007 ANALCO 69 RFSR‐CT‐2006‐00030 PrECo‐Beam 171 RFSR‐CT‐2005‐00009 SMARTFIRE 82 RFSR‐CT‐2006‐00031 HISTWIN 172 RFSR‐CT‐2005‐00010 CLOGGING 82 RFSR‐CT‐2006‐00032 DETAILS 172 RFSR‐CT‐2005‐00011 SOLIMOULD 82 RFSR‐CT‐2006‐00033 CONOX 203 RFSR‐CT‐2005‐00012 SLAGFILMOWL 83 RFSR‐CT‐2006‐00034 ADCTEC 203 RFSR‐CT‐2005‐00013 TUNDJUST 83 RFSR‐CT‐2006‐00035 LCS 203 RFSR‐CT‐2005‐00014 PRECIPITATION 83 RFSR‐CT‐2006‐00036 IRSIS 204 RFSR‐CT‐2005‐00016 Scale Control 98 RFSR‐CT‐2006‐00037 LINECOP 204 RFSR‐CT‐2005‐00017 WACOOL 98 RFSR‐CT‐2006‐00038 FREEZE 204 RFSR‐CT‐2005‐00018 TOPROLLS 98 RFSR‐CT‐2006‐00039 Sinter efficiency 57 RFSR‐CT‐2005‐00019 FINALPLATEFLATNESS 99 RFSR‐CT‐2007‐00001 Hearth efficiency 58 RFSR‐CT‐2005‐00020 AWiCCo 99 RFSR‐CT‐2007‐00002 Consistent BF 58 RFSR‐CT‐2005‐00021 HIGH‐PICK 113 RFSR‐CT‐2007‐00003 ACASOS 58 RFSR‐CT‐2005‐00022 Advanced Wiping 114 RFSR‐CT‐2007‐00004 ONDECO 70 RFSR‐CT‐2005‐00023 SPACE 114 RFSR‐CT‐2007‐00005 SOPLIQS 70 RFSR‐CT‐2005‐00024 DECOBIOF 114 RFSR‐CT‐2007‐00006 EPOSS 70 RFSR‐CT‐2005‐00026 PISAC 127 RFSR‐CT‐2007‐00007 OPCONSTAINLESS 71 RFSR‐CT‐2005‐00027 HIPERC 127 RFSR‐CT‐2007‐00008 FLEXCHARGE 71 RFSR‐CT‐2005‐00028 ASTEX 128 RFSR‐CT‐2007‐00009 StImprove 71 RFSR‐CT‐2005‐00029 MISTRETO 128 RFSR‐CT‐2007‐00010 URIOM 72 RFSR‐CT‐2005‐00030 Metaldesign 128 RFSR‐CT‐2007‐00011 STEELCLEANCONTROL 72 RFSR‐CT‐2005‐00031 COHEADBAIN 129 RFSR‐CT‐2007‐00012 MAGNETOHYDRO 85 RFSR‐CT‐2005‐00032 SpeedFat 145 RFSR‐CT‐2007‐00013 NDTCASTING 85 RFSR‐CT‐2005‐00033 HI‐PROF 145 RFSR‐CT‐2007‐00014 OPTIFIN 101 RFSR‐CT‐2005‐00034 MICROFAT 145 RFSR‐CT‐2007‐00015 EDGECONTROL 101 RFSR‐CT‐2005‐00039 PLASTOTOUGH 169 RFSR‐CT‐2007‐00016 Hyprocom 101 RFSR‐CT‐2005‐00040 INDUCWELD 170 RFSR‐CT‐2007‐00018 Hppm 115 RFSR‐CT‐2005‐00041 INTAB 170 RFSR‐CT‐2007‐00020 ELEXIR 131 RFSR‐CT‐2005‐00042 FATHOMS 170 RFSR‐CT‐2007‐00021 DELOC 132 RFSR‐CT‐2005‐00043 REAL 201 RFSR‐CT‐2007‐00022 Bainite Design 132 RFSR‐CT‐2005‐00044 PLATEND 201 RFSR‐CT‐2007‐00023 BAINHARD 132 RFSR‐CT‐2005‐00045 PERMESS 201 RFSR‐CT‐2007‐00024 ESTEP OPTIMET 133 RFSR‐CT‐2005‐00046 SIMUSTEEL 202 RFSR‐CT‐2007‐00026 CRYO 146 RFSR‐CT‐2005‐00047 eTipo 202 RFSR‐CT‐2007‐00027 PROMACH 147 RFSR‐CT‐2005‐00048 THINFILM 202 RFSR‐CT‐2007‐00035 JOINTEC 172 Improvement of line RFSR‐CT‐2005‐00052 115 RFSR‐CT‐2007‐00036 INNOGLAST 173 productivity RFSR‐CT‐2007‐00037 ESE 173 RFSR‐CT‐2006‐00003 SSIA 69 RFSR‐CT‐2007‐00038 PRECASTEEL 173 RFSR‐CT‐2006‐00004 OFFGAS 69 RFSR‐CT‐2007‐00039 OPUS 174 RFSR‐CT‐2006‐00005 EAF‐PROMS 69 RFSR‐CT‐2007‐00040 OPTISTRAIGHT 174 RFSR‐CT‐2006‐00006 IMPHOS 70 RFSR‐CT‐2007‐00041 LINESPEC 174 RFSR‐CT‐2006‐00007 OPTHEAT 84 RFSR‐CT‐2007‐00042 FICEB 175 RFSR‐CT‐2006‐00008 CO2RED 84 RFSR‐CT‐2007‐00043 ROBUST 175 RFSR‐CT‐2006‐00010 LOWWEAR 99 RFSR‐CT‐2007‐00044 UCoSiF 175 RFSR‐CT‐2006‐00011 ASYMMROLL 100 RFSR‐CT‐2007‐00049 O‐Chess 205 RFSR‐CT‐2006‐00012 LASERHARD 100 RFSR‐CT‐2007‐00050 STEELRETRO 175 RFSR‐CT‐2006‐00014 OPTCOOLUB 100 RFSR‐CT‐2007‐00051 InFaSo 176 RFSR‐CT‐2006‐00015 NOVANNEAL 115 RFSR‐CT‐2008‐00001 FLEXINJECT 59 RFSR‐CT‐2006‐00016 WAVIMETER 115 RFSR‐CT‐2008‐00002 INCLUSION 72 RFSR‐CT‐2006‐00017 MICRO‐QUANT 129 RFSR‐CT‐2008‐00003 LOWCNEAF 73 RFSR‐CT‐2006‐00018 GRAINCONT 84 RFSR‐CT‐2008‐00004 BATHFOAM 73 RFSR‐CT‐2006‐00019 MAGPRO 129 RFSR‐CT‐2008‐00005 MASTERBILLET 85 RFSR‐CT‐2006‐00020 ODS‐STEEL 130 RFSR‐CT‐2008‐00006 AcTuM 85 RFSR‐CT‐2006‐00021 CP‐steels 130 RFSR‐CT‐2008‐00007 DEFFREE 86 RFSR‐CT‐2006‐00022 CORINOX 130 RFSR‐CT‐2008‐00008 LSSEMIQUAL 86 RFSR‐CT‐2006‐00023 MARTIMPROP 131 RFSR‐CT‐2008‐00011 LUBWORK 101 RFSR‐CT‐2006‐00024 ACTRESS 131 RFSR‐CT‐2008‐00012 CHILLUB 102 RFSR‐CT‐2006‐00025 CHARGE&LOAD 131 RFSR‐CT‐2008‐00013 WINROLLS 102 RFSR‐CT‐2006‐00026 HI‐VEL 146 RFSR‐CT‐2008‐00014 OPTITUBE 102 RFSR‐CT‐2006‐00027 MnAl‐steel 146 RFSR‐CT‐2008‐00015 CHATTER 102 RFSR‐CT‐2006‐00028 COSSFIRE 171

11 RFSR‐CT‐2008‐00015 CHATTER 103 RFSR‐CT‐2010‐00001 INNOCARB 60 RFSR‐CT‐2008‐00016 OxMaPro 103 RFSR‐CT‐2010‐00002 IERO 60 RFSR‐CT‐2008‐00017 IPSA 116 RFSR‐CT‐2010‐00003 TOTOPTLIS 74 RFSR‐CT‐2008‐00018 MICSIPE 116 RFSR‐CT‐2010‐00004 PROTECT 74 RFSR‐CT‐2008‐00019 FERRIGAL 116 RFSR‐CT‐2010‐00005 OPTDESLAG 75 RFSR‐CT‐2008‐00021 DUCTAFORM 133 RFSR‐CT‐2010‐00006 ICCRACK 87 RFSR‐CT‐2008‐00022 NANOBAIN 133 RFSR‐CT‐2010‐00007 ROLLWITECH 104 RFSR‐CT‐2008‐00023 ROLLINGHASS 134 RFSR‐CT‐2010‐00008 HRENERGYCONTROL 104 RFSR‐CT‐2008‐00024 CRESTA 134 RFSR‐CT‐2010‐00009 LPROLLCOAT 105 RFSR‐CT‐2008‐00025 ASYLECTRO 134 RFSR‐CT‐2010‐00010 MICROCONTROL 105 RFSR‐CT‐2008‐00026 StrengthCONTROL 135 RFSR‐CT‐2010‐00011 INTERCOOL 105 RFSR‐CT‐2008‐00027 MICRODAMAGE 135 RFSR‐CT‐2010‐00012 HEAT 117 RFSR‐CT‐2008‐00028 KINSREP 147 RFSR‐CT‐2010‐00013 ULTRA DRY COOLING 118 RFSR‐CT‐2008‐00029 SPRINCOM 147 RFSR‐CT‐2010‐00014 HIJETROD 118 RFSR‐CT‐2008‐00032 FUSEIS 176 RFSR‐CT‐2010‐00015 Flat strip control 118 RFSR‐CT‐2008‐00033 BRiFaG 176 RFSR‐CT‐2010‐00016 ELOTOP 118 RFSR‐CT‐2008‐00034 AFINOPRO 177 RFSR‐CT‐2010‐00017 FLEXPROMUS 119 RFSR‐CT‐2008‐00035 HITUBES 177 RFSR‐CT‐2010‐00018 PrecHiMn 136 RFSR‐CT‐2008‐00036 ROBUSTFIRE 177 RFSR‐CT‐2010‐00019 AUSPLUS 136 RFSR‐CT‐2008‐00037 ATTEL 178 RFSR‐CT‐2010‐00020 HYDRAMICROS 136 RFSR‐CT‐2008‐00038 ETHICS 178 RFSR‐CT‐2010‐00021 GPHS 149 RFSR‐CT‐2008‐00039 ELEM 178 RFSR‐CT‐2010‐00022 CHARMA 150 RFSR‐CT‐2008‐00040 OMC 205 RFSR‐CT‐2010‐00025 INNO‐HYCO 181 RFSR‐CT‐2008‐00042 AUTODIAG 205 RFSR‐CT‐2010‐00026 SAFSS 182 RFSR‐CT‐2008‐00043 ZINCANA 206 RFSR‐CT‐2010‐00027 SB_Steel 182 RFSR‐CT‐2008‐00044 LAREFMON 73 RFSR‐CT‐2010‐00028 SAFETOWER 182 RFSR‐CT‐2008‐00046 NEXTEP 116 RFSR‐CT‐2010‐00029 DiSTEEL 183 RFSR‐CT‐2009‐00001 TOSICO 59 RFSR‐CT‐2010‐00030 ADBLAST 183 RFSR‐CT‐2009‐00002 ULCOS TGRBF 59 RFSR‐CT‐2010‐00031 HISTWIN2 183 RFSR‐CT‐2009‐00003 LADLIFE 74 RFSR‐CT‐2010‐00032 FATWELDHSS 183 RFSR‐CT‐2009‐00004 GREENEAF 74 RFSR‐CT‐2010‐00033 MU‐STEEL 208 RFSR‐CT‐2009‐00005 TRANSIENT 86 RFSR‐CT‐2010‐00034 RELOTEMP 208 RFSR‐CT‐2009‐00006 LUBRIMOULD 87 RFSR‐CT‐2010‐00035 SELSA 208 RFSR‐CT‐2009‐00007 PACROLP‐II 103 RFSR‐CT‐2010‐00036 IPRO 209 RFSR‐CT‐2009‐00008 ROLLGAP SENSORS 103 RFSR‐CT‐2010‐00037 Cognitive Control 209 RFSR‐CT‐2009‐00009 HIDES 104 RFSR‐CT‐2010‐00038 COATHYDRO 209 RFSR‐CT‐2009‐00010 REPAIR 117 RFSR‐CT‐2011‐00001 EXTUL 60 RFSR‐CT‐2009‐00011 MICROTOOLS 135 RFSR‐CT‐2011‐00002 HISARNA B and C 60 RFSR‐CT‐2009‐00012 LUNA 135 RFSR‐CT‐2011‐00003 IMSIMI 61 RFSR‐CT‐2009‐00013 NEWGENHSS 148 RFSR‐CT‐2011‐00004 INTCLEANCON 75 DIRECT DEFECT RFSR‐CT‐2009‐00014 AUTOCOAT 117 RFSR‐CT‐2011‐00005 87 TOOLBOX‐DDT RFSR‐CT‐2009‐00015 AUTOCORR 148 RFSR‐CT‐2011‐00006 IPTINGOT 88 RFSR‐CT‐2009‐00016 REFORM 148 RFSR‐CT‐2011‐00007 CONSTOX 106 RFSR‐CT‐2009‐00017 PROTUBEND 149 RFSR‐CT‐2011‐00008 KINPCC 88 RFSR‐CT‐2009‐00018 INSTAP 149 RFSR‐CT‐2011‐00010 WORODEFS 106 RFSR‐CT‐2009‐00020 SBRI 178 RFSR‐CT‐2011‐00011 OPTISHAMP 106 RFSR‐CT‐2009‐00020 SBRI 179 RFSR‐CT‐2011‐00012 CRFREEROLLS 106 RFSR‐CT‐2009‐00021 COMPFIRE 179 RFSR‐CT‐2011‐00014 VADPSHEETS 119 RFSR‐CT‐2009‐00022 INDUSE 179 RFSR‐CT‐2011‐00015 ATCORAS 119 RFSR‐CT‐2009‐00023 RUSTEEL 180 RFSR‐CT‐2011‐00016 ICONTENS 120 RFSR‐CT‐2009‐00024 HSS‐SERF 180 RFSR‐CT‐2011‐00017 NEWQP 137 RFSR‐CT‐2009‐00025 DUPLEXTANK 180 RFSR‐CT‐2011‐00018 AHSS‐PROFILE 137 RFSR‐CT‐2009‐00026 INAREIS 181 RFSR‐CT‐2011‐00019 DURADH 150 RFSR‐CT‐2009‐00027 FADLESS 181 RFSR‐CT‐2011‐00020 ENFASS 150 RFSR‐CT‐2009‐00029 ASEMIS 206 RFSR‐CT‐2011‐00021 AUTOFATCOR 151 RFSR‐CT‐2009‐00030 HYDRAS 206 RFSR‐CT‐2011‐00022 STEELTAC 151 RFSR‐CT‐2009‐00031 KNOWDEC 207 RFSR‐CT‐2011‐00023 TESTTOOL 151 RFSR‐CT‐2009‐00032 ENCOP 207 RFSR‐CT‐2011‐00024 MAC D 152 RFSR‐CT‐2009‐00033 SUPSYSCC 207 RFSR‐CT‐2011‐00027 GIPIPE 184 RFSR‐CT‐2009‐00034 SISCON 207 RFSR‐CT‐2011‐00028 TABASCO 184 RFSR‐CT‐2009‐00035 FOSUCOR 104 RFSR‐CT‐2011‐00029 ULCF 184

12 RFSR‐CT‐2011‐00030 FIDESC4 185 RFSR‐CT‐2011‐00031 SEISRACKS2 185 RFSR‐CT‐2011‐00032 ZEMUSIC 185 RFSR‐CT‐2011‐00033 SARCO2 186 RFSR‐CT‐2011‐00034 COMBITUBE 186 RFSR‐CT‐2011‐00035 FRAMEUP 186 RFSR‐CT‐2011‐00036 MULTISAVE 210 RFSR‐CT‐2011‐00037 SLAGFERTILISER 210 RFSR‐CT‐2011‐00038 CORSA 210 RFSR‐CT‐2011‐00039 RECONI 211 RFSR‐CT‐2011‐00040 TECPLAN 211 RFSR‐CT‐2012‐00001 SUSTAINTAP 61 RFSR‐CT‐2012‐00002 IMPCO 61 RFSR‐CT‐2012‐00003 OPTISTOVE 62 RFSR‐CT‐2012‐00004 OPTIPER 62 RFSR‐CT‐2012‐00005 PLUGWATCH 75 RFSR‐CT‐2012‐00006 SLACON 76 RFSR‐CT‐2012‐00008 PMAP 88 RFSR‐CT‐2012‐00009 DYNAMO 107 RFSR‐CT‐2012‐00010 HELNOX‐BFG 107 RFSR‐CT‐2012‐00011 INNOSOLID 89 RFSR‐CT‐2012‐00012 CERROD 107 RFSR‐CT‐2012‐00013 ZINCOBOR 120 RFSR‐CT‐2012‐00014 BOLT_ZnAlMg 120 RFSR‐CT‐2012‐00015 DECAWIN 137 RFSR‐CT‐2012‐00016 NAMOS 138 RFSR‐CT‐2012‐00017 MECBAIN 138 RFSR‐CT‐2012‐00018 OPTIBOS 138 RFSR‐CT‐2012‐00019 TWIP4EU 152 RFSR‐CT‐2012‐00020 STT 152 RFSR‐CT‐2012‐00021 PRESSPERFECT 153 RFSR‐CT‐2012‐00023 LOCAFI 187 RFSR‐CT‐2012‐00024 HYBRO 187 RFSR‐CT‐2012‐00025 FRISCC 188 RFSR‐CT‐2012‐00026 S+G 188 RFSR‐CT‐2012‐00027 HIPERCUT 188 RFSR‐CT‐2012‐00028 HILONG 189 RFSR‐CT‐2012‐00029 ROBUSTIMPACT 189 RFSR‐CT‐2012‐00030 DISCCO 189 RFSR‐CT‐2012‐00031 SMARTCOCO 190 RFSR‐CT‐2012‐00032 SEQBRI 190 RFSR‐CT‐2012‐00033 BATIMASS 190 RFSR‐CT‐2012‐00034 JOINOX 191 RFSR‐CT‐2012‐00035 BIOGASS 191 RFSR‐CT‐2012‐00036 RUOSTE 191 RFSR‐CT‐2012‐00037 ICONSYS 211 RFSR‐CT‐2012‐00038 I2MSTEEL 212 RFSR‐CT‐2012‐00039 REFFIPLANT 212 RFSR‐CT‐2012‐00040 EvalHD 212 RFSR‐CT‐2012‐00041 MONWIRE 213 RFSR‐CT‐2012‐00042 MAGSEP 213 RFSR‐CT‐2012‐00045 ROLLSTREM 108

13 14

Technical Group Coal 1

Coal mining operation, mine infrastructure and management, unconventional use of coal deposits

The scope of TGC1 includes:

• Modern techniques for surveying deposits

• Integrated mine planning

• Highly efficient, largely automated excavation and mining technologies corresponding to the geological characteristics of EU hard coal deposits

• Appropriate support technologies

• Transport systems

• Power supply services, communication and information, transmission, monitoring and process control system

• Health and safety in mines, gas control, ventilation and air conditioning, occupational health safety

• Reduction of green house emissions from coal deposits

• Return to the mine of mining waste, fly ash, desulphurization, other forms of waste

• Refurbishment of waste heaps and the industrial use of residues from coal production and consumption

• Protection of water tables and the purification of mine drainage water

• Protection of surface installation against the effects of subsidence in the short and long term

• CO2 geological storage

• Upgrading coal deposits; coal bed methane, enhanced coal bed methane, underground gasification, others

15 16 Summaries of RFCS projects 2003-2012 TGC1 : Coal mining operation, mine infrastructure and management, unconventional use of coal deposits

RFCP-CT-2011-00001 OPTI-MINE

Full Title Demonstration of process optimization for increasing the efficiency and safety by integrating leading edge electronic information and communication technologies (ICT) in coal mines Info Type of Project Pilot&Demonstration Duration (months) 36 Total Budget 4590053 € Start Date 1/07/2011 EU Contribution 2295028 € End Date (actual) 30/06/2014 State Research in progress Summary Increasing cost pressure requires optimized operation processes in coal mining. OPTI-MINE integrates and demonstrates newest ICT developments, many originating from earlier RFCS projects, to increase efficiency of mining operations and safety by holistic process optimisation: Five European mines in five different countries, two ICT system integrators and two universities demonstrate and assess the reliability and the impact on cost effectiveness, safety and environment within industrial scale demonstrations of different focus. The scientifically proven results and a strong dissemination programme will boost the use of these integrated ICT systems in European mines and strengthen European mining technology on global markets. Partners Organization Country Responsible RAG ANTHRAZIT IBBENBÜREN GMBH DEUTSCHLAND Ing. Thomas MISZ (Project Coord.) ASOCIACION PARA LA INVEST. Y EL DESAR. INDUSTRIAL DE ESPAÑA Ing. Angel RODRIGUEZ LÓPEZ PREMOGOVNIK VELENJE, d.d. SLOVENIJA MSc Bostjan SKARJA DMT-GESELLSCHAFT FÜR LEHRE UND BILDUNG MBH DEUTSCHLAND Prof. Dr.- Ing. Christoph DAUBER HULLERAS DEL NORTE, S.A. ESPAÑA Ing. José Raul GONZALEZ RUIZSANCHEZ KOMPANIA WEGLOWA S.A. POLAND Dr.-Eng. Marek SZARAFINSKI MINETRONICS GMBH DEUTSCHLAND Dipl.-Ing. Christoph MÜLLER OKD, A.S. CZECH REPUBLIC Ing. Richard PAVLIK SILESIAN UNIVERSITY OF TECHNOLOGY - POLITECHNIKA SL POLAND Prof. Jan PALARSKI

RFCR-CT-2003-00003 EPCWCMS

Full Title Enhancing the performance of mine communication, warning and condition monitoring systems Info Type of Project Research Duration (months) 36 Total Budget 2236231 € Start Date 1/09/2003 EU Contribution 1341739 € End Date (actual) 31/08/2006 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA23196:EN Summary In today’s coal mines many different components of plant are working together in complex interaction. Although many processes are already partly or fully automated, very often mine workers still have to manually intervene to direct the operation of plant, frequently impeded by poor visibility and high noise levels. Efficient operational control of the mining functions is not always possible under these conditions, with resulting production losses and costly maintenance work. Accidents associated with plant-worker interaction may occur more likely and emergency warnings may go unnoticed. Essentially, there is a need to greatly improve available communication, warning and condition monitoring systems. Partners Organization Country Responsible DMT GmbH & Co KG DEUTSCHLAND Dipl.-Ing. Rainer RELLECKE (Project Coord.) ASOCIACION PARA LA INVEST. Y EL DESAR. INDUSTRIAL DE ESPAÑA Mr José Luis GARCIA-SIÑERIZ MARTÍNEZ HULLERAS DEL NORTE, S.A. ESPAÑA Mr Esteban Gerardo RODRIGUEZ REYERO MINES RESCUE SERVICE LTD UNITED KINGDOM Mr Stuart C. BENNETT

RFCR-CT-2003-00006 WATERCHEM

Full Title Optim. of mine water discharge by monitoring & modelling of geochemical processes & develop. of measures to protect acquifers & active mining areas from mine water contamination Info Type of Project Research Duration (months) 42 Total Budget 3421209 € Start Date 1/09/2003 EU Contribution 2052726 € End Date (actual) 28/02/2007 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA23456:EN Summary Mining has been discontinued in many coal deposits in Europe. Extended pumping carried out during exploitation, is no longer required but the effects on surface and ground water quality will continue over long periods of time. The present research project aims at investigating the: -new hydrogeological and hydrochemical regime of the area -generation mechanisms of pollutants -tracing techniques and monitoring systems -methods to seal active mine areas or contaminated areas -mathematical models to predict the effects of the proposed methods The collaboration of associates from several European countries ensures propagation and optimization of the results. Partners Organization Country Responsible DEUTSCHE STEINKOHLE A.G. DEUTSCHLAND Mr Josef PASTOR (Project Coord.) ASOCIACION PARA LA INVEST. Y EL DESAR. INDUSTRIAL DE ESPAÑA Mr Jesus Maria SUSO LLAMAS DMT GmbH & Co KG DEUTSCHLAND Dr. Christoph KLINGER HULLERAS DEL NORTE, S.A. ESPAÑA Mr Alfredo MENENDEZ DIAZ MINES RESCUE SERVICE LTD UNITED KINGDOM Dr. Robert R. JOZEFOWICZ PUBLIC POWER CORPORATION S.A. HELLAS Dr. Dimitrios DIMITRAKOPOULOS THE UNIVERSITY OF NOTTINGHAM UNITED KINGDOM Dr. David J. REDDISH WHITE YOUNG GREEN ENVIRONMENTAL Ltd UNITED KINGDOM Mr Keith WHITWORTH

17 Summaries of RFCS projects 2003-2012 TGC1 : Coal mining operation, mine infrastructure and management, unconventional use of coal deposits

RFCR-CT-2003-00010 SAFETECH

Full Title Optimisation of surveillance,technical equipment & procedures to prevent workers from danger attribute to fire, hazardous or toxic gases, firedamp or climatic conditions Info Type of Project Research Duration (months) 42 Total Budget 3267686 € Start Date 1/09/2003 EU Contribution 1960611 € End Date (actual) 28/02/2007 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA23353:EN Summary In underground coal mines controlling and surveillance of firedamp or toxic gases, the ventilation, climate control and the early fire indication are some of the most important problems facing miners and mining companies. The aim of the proposed project is to improve the safety taking into account the competitiveness of coal production by: · improving the quality of surveillance of underground ambient air · determining the flow characteristics of firedamp, · reducing the thermal strain for workers, · developing technical methods and equipment for controlling and diagnosis of sensitive electrical equipment. Partners Organization Country Responsible DEUTSCHE STEINKOHLE A.G. DEUTSCHLAND Mr Joerg LEHMANN (Project Coord.) ASOCIACION PARA LA INVEST. Y EL DESAR. INDUSTRIAL DE ESPAÑA Mr José Luis GARCIA-SIÑERIZ MARTÍNEZ CHARBONNAGES DE France FRANCE Dipl.-Ing. Jean-Luc ZIMMER DMT GmbH & Co KG DEUTSCHLAND Mr Jörg WALASIAK HULLERAS DEL NORTE, S.A. ESPAÑA Dr. Albino GONZALEZ GARCIA S.A. HULLERA VASCO-LEONESA ESPAÑA Ing. José Luis FERNANDEZ EGUIBAR INSTITUT NATIONAL DE L'ENVIRONNEMENT INDUSTRIEL E FRANCE Mr Alain CZYZ MINES RESCUE SERVICE LTD UNITED KINGDOM Dr. Robert R. JOZEFOWICZ THE UNIVERSITY OF NOTTINGHAM UNITED KINGDOM Dr. Ian Stuart LOWNDES

RFCR-CT-2003-00011 GEOMOD

Full Title Geotechnical modelling, classification & exploration for safe & efficient mine layout & tunnel support design Info Type of Project Research Duration (months) 36 Total Budget 2545614 € Start Date 1/09/2003 EU Contribution 1527368 € End Date (actual) 31/08/2006 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA22964:EN Summary The main aim of the Project is to develop improved tools for the design of coal mine support systems and layouts. Three groups of tools are to be developed, namely: a) Numerical modelling techniques which can be applied to the study of dynamic rock behaviour, such as rock bursts, and the design of support systems in complex geometries, using 3D strain-softening models. New constitutive models will be developed where necessary. b) A rockbolting system design method based upon rock classification, and c) A seismic method for predicting ground conditions ahead of an advancing tunnel so as to allow dynamic, pro-active support variation. Partners Organization Country Responsible ROCK MECHANICS TECHNOLOGY Ltd UNITED KINGDOM Dr. David Norman BIGBY (Project Coord.) DMT GmbH & Co KG DEUTSCHLAND Dr. rer. Nat. Rüdiger MISIEK DEUTSCHE STEINKOHLE A.G. DEUTSCHLAND Dipl.-Ing. Rudolf RENGERS GEOCONTROL S.A. ESPAÑA Dr. José Miguel GALERA THE UNIVERSITY OF NOTTINGHAM UNITED KINGDOM Dr. Ian Stuart LOWNDES

RFCR-CT-2004-00001 IAMTECH

Full Title Increasing the efficiency of roadway drivages through the application of advanced information, automation and maintenance technologies Info Type of Project Research Duration (months) 40 Total Budget 3029283 € Start Date 1/07/2004 EU Contribution 1817569 € End Date (actual) 31/10/2007 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA23881:EN Summary The proposed research has the target of improving the efficiency of Roadway Drivages, one of the key factors in the productivity of modern high-performance Coal Mines, through the extensive use of the latest advances in Information, Communication, Automation and Maintenance Technologies, applied to: - Providing on-line support and expert’s diagnostics during large assembly-disassembly works and maintenance activities, using simultaneous video, audio and data transmissions. - The introduction of novel roof-support and support placement technologies. It is estimated that the combination of the above technologies will produce a rise of 8-10% in productivity, by increasing operational efficiency and machinery availability. Partners Organization Country Responsible ASOCIACION PARA LA INVEST. Y EL DESAR. INDUSTRIAL DE ESPAÑA Ing. Angel RODRIGUEZ LÓPEZ (Project Coord.) DMT GmbH & Co KG DEUTSCHLAND Dr.-Ing. Martin SCHMID INSTYTUT TECHNIKI GORNICZEJ KOMAG POLAND Prof. Teodor WINKLER MINES RESCUE SERVICE LTD UNITED KINGDOM Mr David BRENKLEY RAG Aktiengesellschaft DEUTSCHLAND Mr Uwe POLLEI SANDVIK MINING AND CONSTRUCTION GMBH OESTERREICH Dipl.-Ing. Egmont LAMMER

18 Summaries of RFCS projects 2003-2012 TGC1 : Coal mining operation, mine infrastructure and management, unconventional use of coal deposits

RFCR-CT-2005-00001 ADEMA

Full Title Advances in exploration methods and applications Info Type of Project Research Duration (months) 36 Total Budget 3228216 € Start Date 1/07/2005 EU Contribution 1936930 € End Date (actual) 30/06/2008 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA24217:EN Summary “ADEMA” is a cohesive, ambitious programme that is designed to address deficiencies in underground exploration and geological definition. An interdisciplinary approach is a key feature, with significant innovations sought in seismic interpretation and validation, coal seam radio imaging, microseismic monitoring and drill/core parameter use. The programme has a strong application focus and will secure significant production cost and safety benefits. The research is targeted deliberately at improving critical geological knowledge in a range of situations; coal mine business risk control, geological repository definition for carbon storage schemes, underground coal gasification well drilling activities, and in enhanced coalbed methane recovery schemes. Partners Organization Country Responsible UK COAL MINING LTD UNITED KINGDOM Mr John WILSON (Project Coord.) GEOCONTROL S.A. ESPAÑA Dr. José Miguel GALERA GLOWNY INSTYTUT GORNICTWA POLAND Dr. Adam LURKA HERIOT-WATT UNIVERSITY UNITED KINGDOM Prof. Brian SMART MINES RESCUE SERVICE LTD UNITED KINGDOM Mr David BRENKLEY SEISMIC IMAGE PROCESSING LTD UNITED KINGDOM Mrs Beatrice McGLEN TNO, NEDERLANDSE ORG. VOOR TOEGEPAST NATUURWE NEDERLAND Drs. Henk PAGNIER

RFCR-CT-2005-00002 MONSUPPORT

Full Title Development of more economical innovative support systems for gateroads under the influence of rock stresses Info Type of Project Research Duration (months) 36 Total Budget 2882817 € Start Date 1/07/2005 EU Contribution 1729690 € End Date (actual) 30/06/2008 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA24461:EN Summary Focus is on improved monitoring of support systems. This can be achieved by joint research developing and testing monitoring systems under rock stress and investigating the virtue of support. Development and testing of new monitoring devices should be as close to practice as possible. It will be combined with application of new means of support. For immediate evaluation, online data transfer is required. Particularly during the first phase after driving, the effect of support measures will be monitored by new suitable systems. A common European format for recording and interpretation of monitoring data contributes to better competitiveness of European coal. Partners Organization Country Responsible DMT GmbH & Co KG DEUTSCHLAND Dipl.-Geol. Stephan PETERS (Project Coord.) GEOCONTROL S.A. ESPAÑA Dr. José Miguel GALERA GLOWNY INSTYTUT GORNICTWA POLAND Dr. Stanislaw PRUSEK RAG Aktiengesellschaft DEUTSCHLAND Dr. Nikolaos POLYSOS ROCK MECHANICS TECHNOLOGY Ltd UNITED KINGDOM Dr. David Norman BIGBY UK COAL MINING LTD UNITED KINGDOM Mr David MOORE

RFCR-CT-2005-00003 RAINOW

Full Title Researching the applications of innovative open wireless technologies Info Type of Project Research Duration (months) 36 Total Budget 3275993 € Start Date 1/07/2005 EU Contribution 1965597 € End Date (actual) 30/06/2008 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA24182:EN Summary This proposal defines an ambitious, highly integrated programme of work to research, develop and exploit emerging technologies of open standard wireless systems and autonomous ‘smart’ sensor networks in a range of critical underground applications. The project will focus on basic research activities, the behaviour and application of low-powered open infrastructure wireless components, smart sensors and radio frequency identification (RFID) devices. Applications focus will include distributed monitoring systems, personnel location, materials tracking, integrated voice and data delivery, health monitoring of mine workers and improvements to rescue communications. The research addresses fundamental requirements for improved monitoring and operational efficiency in underground activities. Partners Organization Country Responsible RAG Aktiengesellschaft DEUTSCHLAND Mr Uwe POLLEI (Project Coord.) ASOCIACION PARA LA INVEST. Y EL DESAR. INDUSTRIAL DE ESPAÑA Mr Jorge DEL VALLE DMT GmbH & Co KG DEUTSCHLAND Dipl.-Ing. Rainer RELLECKE INSTYTUT TECHNIK INNOWACYJNYCH EMAG POLAND MSc. Eng. Przemyslaw WISZNIOWSKI MINES RESCUE SERVICE LTD UNITED KINGDOM Mr David BRENKLEY ROCK MECHANICS TECHNOLOGY Ltd UNITED KINGDOM Dr. David Norman BIGBY

19 Summaries of RFCS projects 2003-2012 TGC1 : Coal mining operation, mine infrastructure and management, unconventional use of coal deposits

RFCR-CT-2006-00001 NEMAEQ

Full Title New mechanisation and automation of longwall and drivage equipment Info Type of Project Research Duration (months) 36 Total Budget 3809157 € Start Date 1/07/2006 EU Contribution 2285493 € End Date (actual) 30/06/2009 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA24974:EN Summary Complete automation, together with the optimised mechanisation of longwall workings and roadway drivages, are key important factors for improving mine productivity. Maximised coal production can be assured by minimising human machine attendance mistakes, reducing labour costs and increasing machine running time and equipment reliability. The strategic focus of the project is the development of full automatic shearer face equipment. This will take into account the development of software for the design of cutting tools with a minimum of pick wear and machine down time. New designs of cutting drums will lead to improved tool cutting (pick) loading efficiency with less fine coal and dust production. Innovative methods of maintenance and planned repair of the machines will maximise the running time of longwall and drivage equipment. The research will result in considerably improved productivity within European Coal mines. Partners Organization Country Responsible RAG Aktiengesellschaft DEUTSCHLAND Dipl.-Ing. Hans-Joachim KUBIK (Project Coord.) ASOCIACION PARA LA INVEST. Y EL DESAR. INDUSTRIAL DE ESPAÑA Mr Jorge DEL VALLE INSTYTUT TECHNIK INNOWACYJNYCH EMAG POLAND MSc. Eng. Przemyslaw WISZNIOWSKI EMBIGENCE GMBH DEUTSCHLAND Dipl.-Ing. Christoph MÜLLER INSTYTUT TECHNIKI GORNICZEJ KOMAG POLAND M. Sc. Eng. Dariusz JASIULEK MINES RESCUE SERVICE LTD UNITED KINGDOM Dr. Colin TALBOT ROCK MECHANICS TECHNOLOGY Ltd UNITED KINGDOM Dr. Lorraine KENT TECHNISCHE UNIVERSITAET CLAUSTHAL DEUTSCHLAND Dipl.-Ing. Axel WEISSENBORN

RFCR-CT-2007-00001 PROSAFECOAL

Full Title Increased productivity and safety of European coalmines by advanced techniques and planning tools enabling an improved strata control of the face-roadway junction Info Type of Project Research Duration (months) 36 Total Budget 3293615 € Start Date 1/07/2007 EU Contribution 1976170 € End Date (actual) 30/06/2010 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA25090:EN Summary Longwall face ends are the most vulnerable areas of hard coal mines for injuries and production delays. They are also the most difficult to support. Recently several major falls of ground and major face-end/roadway deformations have occurred in European mines showing that such incidents are often caused by misjudgement of faulted zones, failing ribs and inappropriate support measure choices at the planning stage. The project focuses on the development of reliable planning tools and advanced support techniques for faceroadway junctions to enable strata control of this critical location. This will have a considerable impact on the productivity and safety of European Coal mines. Partners Organization Country Responsible RAG Aktiengesellschaft DEUTSCHLAND Mr Frank LÜTTIG (Project Coord.) ASS. POUR LA RECHERCHE ET LE DEV. DES METHODES ET P FRANCE Dr. Faouzi HADJ HASSEN DMT GmbH & Co KG DEUTSCHLAND Dr. Andreas K.M. HUCKE GEOCONTROL S.A. ESPAÑA Mr Agustín MUÑOZ NIHARRA GLOWNY INSTYTUT GORNICTWA POLAND Dr. Stanislaw PRUSEK GOLDER ASSOCIATES (UK) Ltd UNITED KINGDOM Dr. David Norman BIGBY KOMPANIA WEGLOWA S.A. POLAND Mr Janusz IMIELA ROCK MECHANICS TECHNOLOGY Ltd UNITED KINGDOM Dr. Lorraine KENT UK COAL MINING LTD UNITED KINGDOM Mr David MOORE

RFCR-CT-2007-00002 ADRIS

Full Title Advanced drivage and roadheading intelligent systems Info Type of Project Research Duration (months) 36 Total Budget 3612890 € Start Date 1/07/2007 EU Contribution 2167734 € End Date (actual) 30/06/2010 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA25077:EN Summary The goal of this proposal is the development of novel, fully automated, self steering, more efficient systems for performing the preparatory works needed to access coal seams, including drivage, roadheading, as well as mounting chambers for longwall face equipment. Activities will include the design, modification and construction of several types of machines as well as their automatic steering and possibly self-steering systems, which will be performed by a well balanced, interdisciplinary consortium of Research institutions, Machinery manufacturers and Mining Companies, thus guaranteeing the proper balance between the theoretical and practical aspects of the work. Partners Organization Country Responsible ASOCIACION PARA LA INVEST. Y EL DESAR. INDUSTRIAL DE ESPAÑA Dr. Samir NABULSI (Project Coord.) DMT GmbH & Co KG DEUTSCHLAND Dipl.-Ing. Dietmar PLUM GOLDER ASSOCIATES (UK) Ltd UNITED KINGDOM Dr. David Norman BIGBY HULLERAS DEL NORTE, S.A. ESPAÑA Mr César CORDERO ESCOSURA INSTYTUT TECHNIKI GORNICZEJ KOMAG POLAND Dr. Dariusz PROSTANSKI MINES RESCUE SERVICE LTD UNITED KINGDOM Mr John FORD RAG Aktiengesellschaft DEUTSCHLAND Dipl.-Ing. Peter ACHILLES ROCK MECHANICS TECHNOLOGY Ltd UNITED KINGDOM Dr. Lorraine KENT TALLERES ZITRÓN SA ESPAÑA Mr Roberto ARIAS

20 Summaries of RFCS projects 2003-2012 TGC1 : Coal mining operation, mine infrastructure and management, unconventional use of coal deposits

RFCR-CT-2007-00003 MINTOS

Full Title Improving mining transport reliability Info Type of Project Research Duration (months) 36 Total Budget 2413736 € Start Date 1/07/2007 EU Contribution 1448242 € End Date (actual) 30/06/2010 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA25098:EN Summary The proposal addresses a range of novel approaches to improving the performance, reliability and environmental aspects of operating transport systems underground in deep, extensive coal mines with complex networks. The use of alternative motive power provisions for transport vehicles will be investigated, by examining the potential for using alternative fuels, including fuel cells. The study also encompasses transport logistics and the potential merits of using advanced management information and machine diagnostic systems. In addition, the safety and health aspects of machine fires, exhaust emissions and whole body vibration are included. Partners Organization Country Responsible MINES RESCUE SERVICE LTD UNITED KINGDOM Mr Stuart C. BENNETT (Project Coord.) ASOCIACION PARA LA INVEST. Y EL DESAR. INDUSTRIAL DE ESPAÑA Mr Pedro MORILLO INSTYTUT TECHNIK INNOWACYJNYCH EMAG POLAND MSc. Eng. Przemyslaw WISZNIOWSKI GLOWNY INSTYTUT GORNICTWA POLAND Dr. Stanislaw PRUSEK INSTYTUT TECHNIKI GORNICZEJ KOMAG POLAND Prof. Teodor WINKLER KOMPANIA WEGLOWA S.A. POLAND Mr Andrzej PAKURA RITTAL GMBH & CO KG DEUTSCHLAND Dipl.-Ing. Martin ROSSMANN

RFCR-CT-2007-00004 PRESIDENCE

Full Title Prediction and monitoring of subsidence hazards above coal mines Info Type of Project Research Duration (months) 36 Total Budget 4366865 € Start Date 1/07/2007 EU Contribution 2620118 € End Date (actual) 30/06/2010 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA25097:EN Summary Mining Subsidence Engineering is one of the most important topics in relation with coal mining. Although its occurrence, prediction and control are well known, this project will apply various innovative techniques to an old problem. These new techniques can been subdivided considering if they will be applied to the evaluation of long term stability of roadways, longwalls or shafts (Laser Scanner survey and other geophysical non destructive techniques) for subsidence prediction; or if its application is to the subsidence control at surface (digital photogrammetry, INSAR, seismicity). In this field all these monitoring techniques will be linked, by GPS, to a GIS so a good land management, minimizing subsidence harzards, above existing coal mined areas will be achieved. As a consequence of this project a better protection of the environment in coal areas and an improvement of the competitive position of European coal can be assured. Partners Organization Country Responsible GEOCONTROL S.A. ESPAÑA Mr Carlos HERRERO GARCÍA (Project Coord.) ASOCIACION PARA LA INVEST. Y EL DESAR. INDUSTRIAL DE ESPAÑA Mr Juan Carlos CATALINA ASS. POUR LA RECHERCHE ET LE DEV. DES METHODES ET P FRANCE Dr. Faouzi HADJ HASSEN DMT GmbH & Co KG DEUTSCHLAND Dipl.-Ing. Rainer KUCHENBECKER INSTYTUT TECHNIK INNOWACYJNYCH EMAG POLAND MSc. Eng. Jacek JUZWA GOLDER ASSOCIATES (UK) Ltd UNITED KINGDOM Dr. David Norman BIGBY MINES RESCUE SERVICE LTD UNITED KINGDOM Dr. Robert R. JOZEFOWICZ RAG Aktiengesellschaft DEUTSCHLAND Dipl.-Ing. Volker SPRECKELS ROCK MECHANICS TECHNOLOGY Ltd UNITED KINGDOM Dr. Lorraine KENT UK COAL MINING LTD UNITED KINGDOM Mr David MOORE

RFCR-CT-2008-00001 IMPREX

Full Title Improved extraction ratios for deep coal mines Info Type of Project Research Duration (months) 36 Total Budget 2399428 € Start Date 1/07/2008 EU Contribution 1439656 € End Date (actual) 30/06/2011 State Research technically completed; publication in hand Summary The objective of this Project is to research, identify and develop practical means by which coal recovery ratios in European deep mines can be improved significantly in a safe and efficient manner. To ensure more sustainable use of European coal reserves and reduce reliance upon imported energy, it is necessary to devise means of extracting efficiently significant tonnages of the extensive areas of coal which are left around (and between) longwall panels and of improving the deep mined coal industry’s ability to maximise its extraction of thick coal seams, large tonnages of which are currently abandoned in the goaf. Partners Organization Country Responsible GOLDER ASSOCIATES (UK) Ltd UNITED KINGDOM Dr. David Norman BIGBY (Project Coord.) DMT GmbH & Co KG DEUTSCHLAND Dr.-Ing. Juergen te KOOK GLOWNY INSTYTUT GORNICTWA POLAND Dr. Stanislaw PRUSEK KATOWICKI HOLDING WEGLOWY S.A. POLAND Msc Eng. Janusz CZARNECKI ROCK MECHANICS TECHNOLOGY Ltd UNITED KINGDOM Dr. David Norman BIGBY TECHNISCHE UNIVERSITAET CLAUSTHAL DEUTSCHLAND Dipl.-Ing. Elisabeth CLAUSEN UK COAL MINING LTD UNITED KINGDOM Mr David MOORE THE UNIVERSITY OF NOTTINGHAM UNITED KINGDOM Dr. Rodney STACE

21 Summaries of RFCS projects 2003-2012 TGC1 : Coal mining operation, mine infrastructure and management, unconventional use of coal deposits

RFCR-CT-2008-00002 EDAFFIC

Full Title Early detection and fighting of fires in belt conveyors Info Type of Project Research Duration (months) 36 Total Budget 2204019 € Start Date 1/07/2008 EU Contribution 1322412 € End Date (actual) 30/06/2011 State Research completed, report published on EU Bookshop at (link not yet available) Summary Incidents and accidents involving conveyor belt fires continue causing major infrastructure damage and production loses to mining companies, not only in Europe, but all around the world. Research activities proposed within EDAFFIC will deal with the specific topics of fire in conveyor belts and related ventilation issues. A multidisciplinary and comprehensive approach is proposed, in which all aspects related with conveyor belt fires will be adressed, including, but not limited to, prevention, early detection, combustion process, new belt materials, firefighting, ventilation use in firefighting or managing smoke, inertization, environmental hazards and occupational safety, etc. Partners Organization Country Responsible ASOCIACION PARA LA INVEST. Y EL DESAR. INDUSTRIAL DE ESPAÑA Ing. Angel RODRIGUEZ LÓPEZ (Project Coord.) CENTRUM BADAN I DOZORU GORNICTWA PODZIEMNEGO POLAND MSc. Malgorzata RYSZKA DMT GmbH & Co KG DEUTSCHLAND Mr Heinrich PETERSMANN INSTYTUT TECHNIK INNOWACYJNYCH EMAG POLAND Dr. Wladyslaw MIRONOWICZ HULLERAS DEL NORTE, S.A. ESPAÑA Mr César CORDERO ESCOSURA MINES RESCUE SERVICE LTD UNITED KINGDOM Mr John FORD UK COAL MINING LTD UNITED KINGDOM Mr Stewart JOBLING

RFCR-CT-2008-00003 EMTECH

Full Title Mine emergency support technologies Info Type of Project Research Duration (months) 36 Total Budget 3665712 € Start Date 1/07/2008 EU Contribution 2199428 € End Date (actual) 30/06/2011 State Research technically completed; publication in hand Summary Recent mine incidents, both within the EU and elsewhere, have highlighted the role that emergency support systems and technologies have in ensuring the survival of the mine workforce. The large, deep complex mines of the European Union are presenting increasing challenges for the industry. There are currently deficiencies in situational awareness and supporting communication and evacuation measures available after a major accident. Crucially required technical progress in these fields will significantly enhance EU incident provision and emergency preparedness. This will both help to ensure that the workforce is protected and secure the infrastructure of coal production. Partners Organization Country Responsible MINES RESCUE SERVICE LTD UNITED KINGDOM Mr David BRENKLEY (Project Coord.) ASOCIACION PARA LA INVEST. Y EL DESAR. INDUSTRIAL DE ESPAÑA Mr Pedro MORILLO CENTRALNA STACJA RATOWNICTWA GORNICZEGO SA POLAND MSc.Eng. Miroslaw BAGINSKI DMT GmbH & Co KG DEUTSCHLAND Dipl.-Ing. Rainer RELLECKE INSTYTUT TECHNIK INNOWACYJNYCH EMAG POLAND Dr. Wladyslaw MIRONOWICZ EMBIGENCE GMBH DEUTSCHLAND Dipl.-Ing. Christoph MÜLLER GEOCONTROL S.A. ESPAÑA Mr Fernando PORTUGUES SALGADO HULLERAS DEL NORTE, S.A. ESPAÑA Mr Juan José FERNANDEZ DIAZ MINETRONICS GMBH DEUTSCHLAND Dipl.-Ing. Christoph MÜLLER RAG Aktiengesellschaft DEUTSCHLAND Dipl.-Ing. Ulrich KIMMIT UK COAL MINING LTD UNITED KINGDOM Mr Stewart JOBLING

RFCR-CT-2008-00004 COALSWAD

Full Title Investigation of adsorption and swelling behaviour of coal to determine the feasibility of CO2 sequestration and CH4 production enhancement Info Type of Project Research Duration (months) 36 Total Budget 1764112 € Start Date 1/07/2008 EU Contribution 1058467 € End Date (actual) 30/06/2011 State Research in progress Summary The COALSWAD project is focused on a reliable estimation of CO2 sequestration capacity and CH4 production rate in coal. Topics investigated : • Adsorption behaviour of coal as function of rank; • Competitive adsorption behaviour of CH4, CO2, N2 and O2 on moisture-equilibrated coal; • Swelling and shrinkage properties of coal and their influence on adsorption data; • Calculation of absolute adsorption data. The results of this project will help to decide if CO2 sequestration in coal effectively supports reaching the CO2 emission reduction target. Moreover they are essential for environmental protection and should be transferable to other European regions. Partners Organization Country Responsible FRAUNHOFER GESELLSCHAFT ZUR FOERDERUNG DER AN DEUTSCHLAND Dr. Eva SCHIEFERSTEIN (Project Coord.) DMT GmbH & Co KG DEUTSCHLAND Dipl.-Geol. Ralph SCHLÜTER GREEN GAS DPB a.s. CZECH REPUBLIC Dr.-Ing. Petr HEMZA INSTITUT FÜR NICHTKLASSISCHE CHEMIE e.V. DEUTSCHLAND PD Dr. Habil. Reiner STAUDT ÖSTERREICHISCHE AKADEMIE DER WISSENSCHAFTEN OESTERREICH Prof. Dr. Peter LAGGNER UNIVERSITEIT LEIDEN NEDERLAND Dr. Jörg MATYSIK

22 Summaries of RFCS projects 2003-2012 TGC1 : Coal mining operation, mine infrastructure and management, unconventional use of coal deposits

RFCR-CT-2008-00005 FLOMINET

Full Title Flooding management for underground coal mines considering regional mining networks Info Type of Project Research Duration (months) 36 Total Budget 1925484 € Start Date 1/07/2008 EU Contribution 1155291 € End Date (actual) 30/06/2011 State Research technically completed; publication in hand Summary The proposal wants to develop numerical models to forecast impacts of regional mine water rebound on mine water, groundwater and surface waters. Optimisation of the mine water management will allow to better protect the environment. The research is also dedicated to industrial interest using the mine water rise for opportunities to recover renewable energy in form of electricity and geothermal heat. The numerical models will be extended to include density and temperature terms to become a practical planning tools for these activities. One additional application is the forecast on risks originating from mine gases pressuried by the rising mine water. The variety of model applications will demonstrate the capability of the proposed methodology for regional mine water rebound in interconnected underground hard coal mines. Partners Organization Country Responsible DMT GmbH & Co KG DEUTSCHLAND Dr. Christoph KLINGER (Project Coord.) ASOCIACION PARA LA INVEST. Y EL DESAR. INDUSTRIAL DE ESPAÑA Mr Jesus Maria SUSO LLAMAS GLOWNY INSTYTUT GORNICTWA POLAND Dr. Grzegorz GZYL HULLERAS DEL NORTE, S.A. ESPAÑA Ms Belen GARZON SUCAR INSTITUT NATIONAL DE L'ENVIRONNEMENT INDUSTRIEL E FRANCE Mr Arnaud CHARMOILLE

RFCR-CT-2009-00001 CARBOLAB

Full Title Improving the knowledge of carbon storage and coal bed methane production by "in situ" underground tests Info Type of Project Research Duration (months) 48 Total Budget 4122752 € Start Date 1/07/2009 EU Contribution 2473652 € End Date (actual) 30/06/2013 State Research in progress Summary The proposal aims to improve the practical knowledge of the physical and chemical processes involved in the Enhanced Coal Bed Methane (ECBM) technique, by means of a series of “in situ” tests of CO2 injection and CBM production, in a specially conditioned test area in a underground coal mine, in order to obtain high-quality data for: − Development of improved models that simulate the mechanical, physical and chemical behaviour of coal and gases, − Identification and sizing of the physical parameters to be monitored during and after the injection experiments. − Long term risk assessment of the CO2 storage Partners Organization Country Responsible HULLERAS DEL NORTE, S.A. ESPAÑA Dr. Noel CANTO TOIMIL (Project Coord.) ASOCIACION PARA LA INVEST. Y EL DESAR. INDUSTRIAL DE ESPAÑA Mr José Luis GARCIA-SIÑERIZ MARTÍNEZ BRGM FRANCE Dr. Isabelle CZERNICHOWSKI-LAURIOL GLOWNY INSTYTUT GORNICTWA POLAND MSc. Eng. Jacek SKIBA INSTITUT NATIONAL DE L'ENVIRONNEMENT INDUSTRIEL E FRANCE Mr Zbigniew POKRYSZKA

RFCR-CT-2009-00002 EMIMSAR

Full Title Enhanced miner-information interaction to improve maintenance and safety with augmented reality technologies and new sensors Info Type of Project Research Duration (months) 36 Total Budget 3347542 € Start Date 1/07/2009 EU Contribution 2008526 € End Date (actual) 30/06/2012 State Research in progress Summary European mines will become increasingly dependent on the availability of efficient access to information, knowledge and know how in the near future. Mine personnel will obtain important benefits from the availability of systems providing “Human-Technical Interaction” in the harsh environmental conditions underground, not only in advanced maintenance activities, but also as informational and navigational aids, both in normal and emergency situations. The research will develop, implement and demonstrate “Augmented Reality” devices and applications, enhanced marker systems and real-time location systems that will improve the interaction of mine personnel with computer-stored information and knowledge in several fields of work, and condition-oriented preventive maintenance, which will be achieved through the development of novel sensors for online monitoring of critical parts of AFC and plough systems. Partners Organization Country Responsible ASOCIACION PARA LA INVEST. Y EL DESAR. INDUSTRIAL DE ESPAÑA Mr Juan Carlos CATALINA (Project Coord.) DMT GmbH & Co KG DEUTSCHLAND Dipl.-Ing. Dietmar PLUM INSTYTUT TECHNIK INNOWACYJNYCH EMAG POLAND MSc. Eng. Przemyslaw WISZNIOWSKI INSTYTUT TECHNIKI GORNICZEJ KOMAG POLAND Prof. Teodor WINKLER MINES RESCUE SERVICE LTD UNITED KINGDOM Dr. David GIBSON RAG Aktiengesellschaft DEUTSCHLAND Dipl.-Ing. Johannes QUINKENSTEIN RITTAL GMBH & CO KG DEUTSCHLAND Dipl.-Ing. Martin ROSSMANN SANDVIK MINING AND CONSTRUCTION GMBH OESTERREICH Dipl.-Ing. Egmont LAMMER

23 Summaries of RFCS projects 2003-2012 TGC1 : Coal mining operation, mine infrastructure and management, unconventional use of coal deposits

RFCR-CT-2010-00001 GEOSOFT

Full Title Geomechanics and control of soft mine floors and sides Info Type of Project Research Duration (months) 36 Total Budget 3269320 € Start Date 1/07/2010 EU Contribution 1961593 € End Date (actual) 30/06/2013 State Research in progress Summary European collieries suffer from severe floor and side deformation due to depth, tectonic stress and the soft strata around the seams, which are vulnerable to degradation over time, particularly when wet. This has major economic and safety implications for the industry. The project will develop and apply improved means of measuring, representing and analysing this behaviour and its interaction with mine support, both in the laboratory and in the field. Its objectives are to improve our understanding of the phenomena and develop enhanced design and construction solutions utilising stress control, sprayed linings, improved cuttable reinforcement and/or closed support structural sections. Partners Organization Country Responsible GOLDER ASSOCIATES (UK) Ltd UNITED KINGDOM Dr. Lorraine KENT (Project Coord.) BECKER-WARKOP Sp. Z.o.o. POLAND Msc. Eng. Leszek ZYREK GEOCONTROL S.A. ESPAÑA Mr Mario FERNÁNDEZ PÉREZ GLOWNY INSTYTUT GORNICTWA POLAND Dr. Sylwester RAJWA POLUDNIOWY KONCERN WEGLOWY SA POLAND Msc. Eng. Wojciech KAMINSKI UK COAL MINING LTD UNITED KINGDOM Mr David MOORE THE UNIVERSITY OF NOTTINGHAM UNITED KINGDOM Dr. Rodney STACE

RFCR-CT-2010-00002 COGASOUT

Full Title Development of novel technologies for predicting and combating gas outbursts and uncontrolled emissions in thick seam coal mining Info Type of Project Research Duration (months) 36 Total Budget 3641260 € Start Date 1/07/2010 EU Contribution 2184756 € End Date (actual) 30/06/2013 State Research in progress Summary The objective of this project is to develop and test novel technologies for the prediction and combating of gas outbursts and uncontrollable gas emissions in coal mines which operate in thick and/or steeply dipping thick seams. This in turn will significantly enhance the potential to recover thick seam reserves within the EU. The objectives will be achieved through a programme of field experimentation, monitoring and theoretical development combined with numerical simulation methods. Coal mine Velenje and Hullera Vasco-Leonesa will host fieldwork and research will lead to the development of a risk assessment methodology which can be implemented worldwide. Partners Organization Country Responsible IMPERIAL COLLEGE OF SCIENCE, TECHNOLOGY AND MEDI UNITED KINGDOM Prof. Sevket DURUCAN (Project Coord.) ASOCIACION PARA LA INVEST. Y EL DESAR. INDUSTRIAL DE ESPAÑA Mr Pedro MORILLO PREMOGOVNIK VELENJE, d.d. SLOVENIJA Dr. Simon ZAVSEK DMT GmbH & Co KG DEUTSCHLAND Dr. Joachim BRANDT GLOWNY INSTYTUT GORNICTWA POLAND Dr. Adam LURKA HORNONITRIANSKE BANE PRIEVIDZA A.S. SLOVAKIA Ing. Stanislav PAULIK S.A. HULLERA VASCO-LEONESA ESPAÑA Ing. Concepcion CASADO SULE K-UTEC AG SALT TECHNOLOGIES DEUTSCHLAND Dr. Volkmar SCHMIDT MINES RESCUE SERVICE LTD UNITED KINGDOM Mr Stuart C. BENNETT

RFCR-CT-2010-00003 UCG & CO2 STORAGE

Full Title Study of deep underground coal gasification and the permanent storage of CO² in the affected areas Info Type of Project Research Duration (months) 30 Total Budget 3067971 € Start Date 1/07/2010 EU Contribution 1840783 € End Date (actual) 31/12/2012 State Research in progress Summary The objective of the proposal is to evaluate the potential of deep lying coal seams (>1200m, like those in Bulgaria) for the development of UCG and to show that the UCG in deep coal can reuse the same boreholes with technical modifications, for the injection and permanent storage of CO2. Storage options are the adjacent stressed coal and the overlying/underlying strata or the abandoned UCG cavity itself. Initial estimates suggest that at 1600m, all the CO2 produced during gasification could be re-injected and stored in liquid form. State-of-the-art geo-mechanic, hydrogeological and UCG cavity growth models will be developed and validated for application to possible future demonstration sites in Bulgaria and elsewhere. Partners Organization Country Responsible OVERGAS INC. AD BULGARIA Eng Nikolay HRISTOV (Project Coord.) CENTRE FOR RESEARCH AND TECHNOLOGY HELLAS HELLAS Dr. Nikolaos KOUKOUZAS DMT GmbH & Co KG DEUTSCHLAND Dipl.-Geol. Ralph SCHLÜTER HELMHOLTZ ZENTRUM POTSDAM DEUTSCHES GEOFORSC DEUTSCHLAND Dr. Thomas KEMPKA GEOLOGICAL INSTITUTE - BULGARIAN ACADEMY OF SCIEN BULGARIA PhD Aleksey BENDEREV INSTITUTO SUPERIOR TECNICO PORTUGAL Dr. Vidal NAVARRO TORRES UNIVERSITY OF LEEDS UNITED KINGDOM Dr. Yong SHENG

24 Summaries of RFCS projects 2003-2012 TGC1 : Coal mining operation, mine infrastructure and management, unconventional use of coal deposits

RFCR-CT-2010-00004 LOWCARB

Full Title Low carbon mine site energy initiatives Info Type of Project Research Duration (months) 36 Total Budget 3876689 € Start Date 1/07/2010 EU Contribution 2326014 € End Date (actual) 30/06/2013 State Research in progress Summary Carbon emissions caused by mining-related activities has never been more topical with increasing environmental, social and political awareness of climate change. Reducing CO2 and methane (CH4) emissions are equally important issues. Coal mining contributes to 8% of global anthropogenic methane emissions, and CH4 is 21 times more potent than CO2 in trapping heat. This project is designed to investigate and develop modern technologies and techniques that can significantly reduce the coal mining industry’s carbon footprint in terms of both emissions (CO2, CH4), operational energy consumption (CO2), whilst remaining technically and commercially competitive. Partners Organization Country Responsible UNIVERSITY OF EXETER UNITED KINGDOM Dr. Gareth KENNEDY (Project Coord.) ASOCIACION PARA LA INVEST. Y EL DESAR. INDUSTRIAL DE ESPAÑA Mr José Luis GARCIA-SIÑERIZ MARTÍNEZ PREMOGOVNIK VELENJE, d.d. SLOVENIJA MSc Matjaz KAMENIK GLOWNY INSTYTUT GORNICTWA POLAND Prof. Antoni KIDYBINSKI HULLERAS DEL NORTE, S.A. ESPAÑA Mr César CORDERO ESCOSURA KOMPANIA WEGLOWA S.A. POLAND MSc. Eng. Grzegorz LAGODZINSKI MINES RESCUE SERVICE LTD UNITED KINGDOM Mr Malcom PURVIS THE UNIVERSITY OF NOTTINGHAM UNITED KINGDOM Dr. Rodney STACE UNIVERSIDAD DE OVIEDO ESPAÑA Prof. Salvador ORDONEZ GARCIA

RFCR-CT-2010-00005 MINFIREX

Full Title Minimising risk for and reducing impact of fire and explosion hazards in underground coal mining Info Type of Project Research Duration (months) 36 Total Budget 2554212 € Start Date 1/07/2010 EU Contribution 1532528 € End Date (actual) 30/06/2013 State Research in progress Summary Fires and explosions are still major cause of injuries and even fatalities in underground coal mining although the safety in European coal mines has reached a fairly high standard. But also operation downtimes and productions losses are caused by fires and thus affect competitiveness of the coal mining companies. MINFIREX aims at minimising the risks for fires and explosions by developing strategies to prevent fires and explosions and developing innovative detection measures and fire fighting methods especially for hidden fires as well as developing an innovative active extinguishing system ensuring effective protection against propagation of fires or explosions. Partners Organization Country Responsible DMT GmbH & Co KG DEUTSCHLAND Mr Harald SCHILLEGGER (Project Coord.) ASOCIACION PARA LA INVEST. Y EL DESAR. INDUSTRIAL DE ESPAÑA Mr José Luis GARCIA-SIÑERIZ MARTÍNEZ INSTYTUT TECHNIK INNOWACYJNYCH EMAG POLAND Dr. Stanislaw TRENCZEK HULLERAS DEL NORTE, S.A. ESPAÑA Dr. Albino GONZALEZ GARCIA INSTYTUT TECHNIKI GORNICZEJ KOMAG POLAND Dr. Zbigniew SZKUDLAREK MINES RESCUE SERVICE LTD UNITED KINGDOM Dr. Colin TALBOT UK COAL MINING LTD UNITED KINGDOM Mr Stewart JOBLING

RFCR-CT-2010-00014 MISSTER

Full Title Mine shafts: improving security and new tools for the evaluation of risks Info Type of Project Research Duration (months) 36 Total Budget 3006853 € Start Date 1/07/2010 EU Contribution 1804111 € End Date (actual) 30/06/2013 State Research in progress Summary Mine shafts consitute a key element of mining by being: - crucial for access to underground workings; - necessary for the proper functioning of mining operations; - a remaining trace of former mining activity on surface

Therefore, the safety of the whole "mine shaft life cycle" must be ensured (from design to closure), for active mining activity, staff and public safety and land use reasons. The project aims to develop innovative cost-effective tools to: - enhance the understanding of hazards that may affect mining shafts; - optimize safety conditions for active shafts maintenance and disused shafts treatments. Partners Organization Country Responsible INSTITUT NATIONAL DE L'ENVIRONNEMENT INDUSTRIEL E FRANCE Mr Romuald SALMON (Project Coord.) DMT GmbH & Co KG DEUTSCHLAND Dipl.-Ing. Rainer KUCHENBECKER GEOCONTROL S.A. ESPAÑA Mrs Virginia PORTAL CABEZUELO GLOWNY INSTYTUT GORNICTWA POLAND Dr. Stanislaw PRUSEK KOMPANIA WEGLOWA S.A. POLAND MSc. Eng. Grzegorz LAGODZINSKI MINES RESCUE SERVICE LTD UNITED KINGDOM Mr Malcom PURVIS THE UNIVERSITY OF NOTTINGHAM UNITED KINGDOM Dr. Rodney STACE

25 Summaries of RFCS projects 2003-2012 TGC1 : Coal mining operation, mine infrastructure and management, unconventional use of coal deposits

RFCR-CT-2012-00001 FEATureFACE

Full Title Electromagnetic coal face environmental observation and recognition for feats in process optimization and occupational health and safety Info Type of Project Research Duration (months) 36 Total Budget 3585251 € Start Date 1/07/2012 EU Contribution 2151151 € End Date (actual) 30/06/2015 State Research in progress Summary Positioning of mining machines under harsh conditions while enabling safety for the Miners costs considerably time and money. Observation of complete machine environments using simultaneously several electromagnetic technologies enables for the first time reliable and accurate object-localization underground. Combined with Information and Communication Technology (ICT) it increases the efficiency of mine production and development and contributes to process optimization. Productivity enhancement is achieved by high accuracy and reliable geometric environmental scanning for machine positioning and movement sequences, leading to less waste, energy consumption, wear, downtimes, coal preparation effort, fire hazard and cost and higher coal yield. Safety enhancement is achieved by introducing a human localization device for proximity detection and collision avoidance with machinery reducing accidents and fatalities. FEATureFACE additionally complies with the upcoming EU-machinery-directive regarding the required functional safety, which can currently not be fulfilled with state-of-the-art technologies. The full-range consortium involves two coal producers and will develop, test and implement the world’s first failsafe machine environment detection solution for roadheaders, loaders and shearers. FEATureFACE aims at a breakthrough by combining strengths and compensating weaknesses of each single technology. Partners Organization Country Responsible RHEINISCH-WESTFÄLISCHE TECHNISCHE HOCHSCHULE AA DEUTSCHLAND Prof. Dr. Karl NIENHAUS (Project Coord.) AUSTRIAN CENTER OF COMPETENCE IN MECHATRONICS G OESTERREICH Mr Reimar PFEIL BECKER MINING SYSTEMS AG DEUTSCHLAND Prof. Andreas SEELIGER EICKHOFF BERGBAUTECHNIK GMBH DEUTSCHLAND Dipl.-Ing. Thomas HUERMANN INDURAD GMBH DEUTSCHLAND Dr. Reik WINKEL LINZ CENTER OF MECHATRONICS GMBH OESTERREICH Dr. Thomas BUCHEGGER OKD, A.S. CZECH REPUBLIC Ing. Richard PAVLIK RAG Aktiengesellschaft DEUTSCHLAND Mr Armin MOZAR SANDVIK MINING AND CONSTRUCTION GMBH OESTERREICH Dipl.-Ing. Egmont LAMMER

RFCR-CT-2012-00002 INREQ

Full Title Enhanced effectiveness and safety of rescuers involved in high risk activities by designing innovative rescue equipment systems Info Type of Project Research Duration (months) 36 Total Budget 3312628 € Start Date 1/07/2012 EU Contribution 1987577 € End Date (actual) 30/06/2015 State Research in progress Summary The INREQ project addresses directly the safety and operational efficiency of mine rescue teams. It will develop special prototype and experimental rescue equipment to increase their safety, work comfort and effectiveness. This includes several new tools and a system for monitoring biometric and working conditions, with data transfer via a dedicated communication system to the rescue centre. Special attention will be paid to exposure of rescuers to hyperthermia. This will include comprehensive body temperature measurement, transfer of information and providing local air conditioning. The rescue equipment to be developed within INREQ will be directly applicable in a wide variety of rescue actions; for example where miners are cut off from evacuation routes as a result of infrastructure damage and rock falls. One outcome of the project will be a development of effective rescue equipment for rescue tunneling through rock fall debris. The rescue equipment will consist of carefully designed, but inter-related sub-systems, including; an improved lightweight rescue conveyor, equipped with a self-propelled platform to facilitate its forward relocation as the rescue proceeds, an improved rescue support system, and a mobile air conditioner to deliver vital cooled air to the rescuers’ working zone. Also a device for driving the rescue tunnels in solid rock is planned to be designed. In this case two types of devices will be developed. One of them will be based on hydro cutting technology, which will be a prototype device and the other one using low energy will be developed as an experimental device. Partners Organization Country Responsible INSTYTUT TECHNIKI GORNICZEJ KOMAG POLAND Dr. Andrzej DRWIEGA (Project Coord.) ASOCIACION PARA LA INVEST. Y EL DESAR. INDUSTRIAL DE ESPAÑA Dr. Samir NABULSI CENTRALNA STACJA RATOWNICTWA GORNICZEGO SA POLAND Mr Adam NOWAK DMT GmbH & Co KG DEUTSCHLAND Dipl.-Ing. Rainer RELLECKE GEOCONTROL S.A. ESPAÑA Mr Fernando PORTUGUES SALGADO GOLDER ASSOCIATES (UK) Ltd UNITED KINGDOM Dr. Lorraine KENT I.CO.P. SpA ITALIA Mr Enzo RIZZI

26 Summaries of RFCS projects 2003-2012 TGC1 : Coal mining operation, mine infrastructure and management, unconventional use of coal deposits

RFCR-CT-2012-00003 COMEX

Full Title Complex mining exploitation : optimizing mine design and reducing the impact on human environment Info Type of Project Research Duration (months) 36 Total Budget 3787333 € Start Date 1/07/2012 EU Contribution 2272400 € End Date (actual) 30/06/2015 State Research in progress Summary This project focuses on: -mine exploitation with over- or under-lying old mine and the potential resulting hazards -the reduction of the impact of mining exploitation on human environment in such conditions For mining in subsided coal seams, work begun under the Presidence RFCS Project. A draft methodology was developed to design mine layouts in these cases. The work under this Project will: -apply this methodology to the workings at the target mines -closely monitor their condition on drivage and face retreat -improve the methodology based on the experience gained The Project will need to develop improved geotechnical numerical modelling techniques to better represent the condition of subsided rock and to couple large scale stress distribution modelling with small scale support system modelling to predict roadway support behaviour in these complex conditions. Secondly, stress and strain caused by deep exploitation may affect old shallow mines. The Upper Silesia Basin is largely concerned. Mining seismicity is a specific case. The problem with mining seismicity is worldwide, in EU it is still occurring in Upper Silesia Coal Basin and in German mines. Ground vibration resulting from mining seismic events can be dangerous according to reactivation of old shallow exploitation. It can cause discontinuous effect in near surface soils or even land collapses. Moreover, it can trigger slope instabilities in open pits, like in Belchatow lignite mine in Poland were mining seismic events have reached magnitude greater than 4. To protect in an efficient manner the building assets, we need to be able to predict the effect of ground movements on building assets. Recent works (Burland 97, Deck 06, Caudron 08) show that the transfer mechanism of the strains from the ground to the building is dependent of some complex and non-linear soilstructure interactions. This project will answer the need to evaluate and reduce the vulnerability of buildings subjected to those hazards. Partners Organization Country Responsible INSTITUT NATIONAL DE L'ENVIRONNEMENT INDUSTRIEL E FRANCE Dr. Marwan AL HEIB (Project Coord.) CENTRE FOR RESEARCH AND TECHNOLOGY HELLAS HELLAS Dr. Nikolaos KOUKOUZAS DMT GmbH & Co KG DEUTSCHLAND Mr Paul ALTHAUS GEOCONTROL S.A. ESPAÑA Mr Mario FERNÁNDEZ PÉREZ GLOWNY INSTYTUT GORNICTWA POLAND Prof. Grzegorz MUTKE GOLDER ASSOCIATES (UK) Ltd UNITED KINGDOM Dr. Lorraine KENT UK COAL MINING LTD UNITED KINGDOM Mr David MOORE THE UNIVERSITY OF NOTTINGHAM UNITED KINGDOM Dr. Alec MARSHALL

RFCR-CT-2012-00004 AVENTO

Full Title Advance tools for ventilation and methane emmissions control Info Type of Project Research Duration (months) 36 Total Budget 3268736 € Start Date 1/07/2012 EU Contribution 1961242 € End Date (actual) 30/06/2015 State Research in progress Summary European coal mines are in general deeper than other mines, which increase the risks of high methane emissions and outbursts, having also higher rock temperature. For both reasons, ventilation air flows are considerably higher in European mines, this being an important cost factor that affects the overall competitiveness of the European coal industry: the energy requirement for these ventilation needs is estimated in about 200 billion kWh per year, only in the main surface fans. The situation is worsening, as most coal fields to be mined in the next years are located at greater depths. Some of the fatal accidents registered in European mines in the last years are connected with the new and increased risks being found as the mines go deeper. Usual practice in most European mines is to provide a large air flow excess in order to guarantee safe conditions. This flow is maintained continuously, although it is only required in very specific points and at certain moments, depending in any case on the specific conditions and working procedures of each mine. The project has two basic aims: i) To develop new concepts on ventilation monitoring systems, taking into account the new risks appearing in the current and future production fields, in order to improve the safety and climatic conditions at the working areas, with special attention to the actions to be taken after severe methane incidents. ii) To reduce the costs involved in ventilation, analysing different aspects such as the dynamic regulation of air flow (”Ventilation On Demand”), and new systems of fan control for better efficiency and reliability. The activities planned in the project represent a new approach to the problems of ventilation and methane control at European level, when compared to the current practices. The participation of a balanced consortium of organizations from five different countries -including Romania for first time in theprogram- enables to cover a variety of mining conditions across Europe. Partners Organization Country Responsible ASOCIACION PARA LA INVEST. Y EL DESAR. INDUSTRIAL DE ESPAÑA Mrs Marta FERNANDEZ ORDAS (Project Coord.) DMT GmbH & Co KG DEUTSCHLAND Dipl.-Ing. Rainer RELLECKE INSTYTUT TECHNIK INNOWACYJNYCH EMAG POLAND Dr. Stanislaw TRENCZEK GLOWNY INSTYTUT GORNICTWA POLAND Dr.-Eng. Henryk KOPTON HULLERAS DEL NORTE, S.A. ESPAÑA Ing. Albino GONZALEZ GARCIA INST.NAT.DE CERC- DEZVOLTARE PENTRU SEC.MINIERA SI ROMANIA Mr Constantin LUPU KOMPANIA WEGLOWA S.A. POLAND Dr.-Eng. Marek SZARAFINSKI THE UNIVERSITY OF NOTTINGHAM UNITED KINGDOM Dr. Ian Stuart LOWNDES

27 28

Technical Group Coal 2

Coal preparation, conversion and upgrading

The scope of TGC2 includes:

• Coal preparation techniques

• Cokefaction

• Coal gasification

• Hydrogen

• Synfuels

29 30 Summaries of RFCS projects 2003-2012 TGC2 : Coal preparation, conversion and upgrading

RFC2-CT-2008-00006 CTLEUROPE

Full Title Promotion of European coal to liquids R&D activities Info Type of Project Accompanying measure (studies) Duration (months) 18 Total Budget 326927 € Start Date 1/07/2008 EU Contribution 196156 € End Date (actual) 31/12/2009 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA25002:EN Summary This Type 2 accompanying measure will promote and disseminate the scope and achievements of the ECSC and RFCS projects on coal-to-liquids (CTL) R, D&D to those major coal- and oil shale-using new member states of the EU, Poland, Czech Republic and Estonia, in which there is significant potential for an uptake of CTL technology and where industry is now starting to reconsider the development of CTL processes. It will provide a to technical and economic state of the art review of CTL activities, past and present, based on ECSC and RFCS projects, together with comment on environmental issues plus an impact assessment of current CTL R&D capabilities within EU industry, institutes and academia. Partners Organization Country Responsible IEA COAL RESEARCH LIMITED UNITED KINGDOM Dr. Andrew MINCHENER (Project Coord.) FUELCONSULT GMBH DEUTSCHLAND Dr. Bernhard BONN GLOWNY INSTYTUT GORNICTWA POLAND Prof. Krzysztof STANCZYK SEVEN - STREDISKO PRO EFEKTIVNI VYUZIVANI ENERGIE o. CZECH REPUBLIC Dipl.-Eng. Bohuslav MALEK TALLINNA TEHNIKAULIKOOL*TALLINN UNIVERSITY OF TEC ESTONIA Prof.Dr. Andres SIIRDE

RFCR-CT-2003-00005 INFERENCE

Full Title On-line measurement of coal quality parameters by inference of sensor information Info Type of Project Research Duration (months) 52 Total Budget 2062262 € Start Date 1/09/2003 EU Contribution 1237357 € End Date (actual) 31/12/2007 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA23897:EN Summary Ash and moisture content of the coal and its handleability are important quality parameters. To maintain high standards it is essential to get knowledge of key parameters throughout the whole preparation process. There are few measuring instruments because they are expensive and need much maintenance. On the other hand many signals from different sensors are available which contain inherent information about single product streams. By an intelligent data processing system quality parameters can be infered from a combination of signals. For the inference of handleability the size distribution is a key parameter, for which sensors have yet to be developed. Also for the subsequent utilisation in power plants the size distribution is very important. For a continuous optimisation of the pulverised fuel preparation on-line measuring devices have to be integrated into the milling circuit. Partners Organization Country Responsible DMT GmbH & Co KG DEUTSCHLAND Dr. Franz VERFUSS (Project Coord.) EMC ENVIRONMENT ENGINEERING LTD UNITED KINGDOM Mr Shihui ZHOU SOCIETE NATIONALE D'ELECTRICITE ET DE THERMIQUE SA FRANCE Mr Daniel RAMPELBERG THE UNIVERSITY OF NOTTINGHAM UNITED KINGDOM Prof. Nick J. MILES UNIVERSITY OF TEESSIDE UNITED KINGDOM Dr. Jianyong ZHANG

RFCR-CT-2003-00009 C2H UPGRADE

Full Title Upgrading of high moisture, low rank coals to hydrogen and methane Info Type of Project Research Duration (months) 42 Total Budget 2792444 € Start Date 1/09/2003 EU Contribution 1675468 € End Date (actual) 28/02/2007 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA23584:EN Summary The project proposed aims to develop a new integrated process for upgrading high moisture, low rank brown coals to three product streams: (1) A fuel gas mainly consisting of methane and hydrogen, which is called ‘HyMet gas’. This gas can be used as a substitute for natural gas for high efficient power generation with fuel cells as well as for gas turbines with very low CO2 emissions due to the high hydrogen content. (2) By- products of the process are precalcinated feed for a cement kiln and a pure CO2 gas stream facilitating CO2 removal from this process. First experiments show the feasibility of the new process. Within the proposed project the basic development will be done to assess the technological viability. Furthermore the economic advantages compared to conventional brown coal utilisation as well as design parameters of a pilot plant will be delivered. Partners Organization Country Responsible UNIVERSITAET STUTTGART DEUTSCHLAND Dr. Roland BERGER (Project Coord.) BRANDENBURGISCHE TECHNISCHE UNIVERSITÄT COTTBU DEUTSCHLAND Prof. Dr.-Ing. Hans-Joachim KRAUTZ CENTRE FOR RESEARCH AND TECHNOLOGY HELLAS HELLAS Prof. Emmanuel KAKARAS INGENIEURBURO THOMAS WEIMER DEUTSCHLAND Dr. Thomas WEIMER NATIONAL TECHNICAL UNIVERSITY OF ATHENS HELLAS Prof. George ANDROUTSOPOULOS PUBLIC POWER CORPORATION S.A. HELLAS Dipl.-Ing. Abraham MIZAN SCS TECHNOLOGY VERFAHRENSTECHNIK GMBH OESTERREICH Dipl.-Ing. Leo SEIRLEHNER UNIVERSIDAD COMPLUTENSE DE MADRID ESPAÑA Prof. Dr. José CORELLA UNIVERSITY OF ULSTER UNITED KINGDOM Prof. P.C. EAMES VATTENFALL EUROPE MINING AG DEUTSCHLAND Dipl.-Ing. Ralf MASSOW ZENTRUM FÜR SONNENENERGIE- UND WASSERSTOFF-FO DEUTSCHLAND Dr. Rer. Nat. Michael SPECHT

31 Summaries of RFCS projects 2003-2012 TGC2 : Coal preparation, conversion and upgrading

RFCR-CT-2004-00004 IMPECABL

Full Title Improving environmental control and battery life through integrated monitoring systems Info Type of Project Research Duration (months) 48 Total Budget 1479333 € Start Date 1/07/2004 EU Contribution 887600 € End Date (actual) 30/06/2008 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA24226:EN Summary The principal aims are to reduce environmental emissions from EU coking plants and to prolong the life and productivity rates of existing coke plants, whilst minimising operational expenditure, in terms of both improved energy utilisation and lower maintenance costs. These will be achieved through collaboration in development and application of a number of novel techniques designed for monitoring all critical areas of battery condition/operations. These include: • Development of an automated system for mapping the condition of oven chambers • Development of a system for inspection/cleaning of regenerators • Development of automated flue temperature monitor • Plant installation of tiebar strain and oven top deflection measurement systems • Evaluation of carbon deposition, its effects and eradication Partners Organization Country Responsible TATA STEEL UK LIMITED UNITED KINGDOM Dr. Ruth POULTNEY (Project Coord.) ARCELORMITTAL MAIZIERES RESEARCH S.A. FRANCE Mr Jean-Paul GAILLET DMT GmbH & Co KG DEUTSCHLAND Dr. Friedrich HUHN THE UNIVERSITY OF NOTTINGHAM UNITED KINGDOM Prof. John W. PATRICK

RFCR-CT-2005-00004 ECOPITCH

Full Title Development of a new generation of coal-derived environmentally-friendly pitches Info Type of Project Research Duration (months) 36 Total Budget 2015084 € Start Date 1/07/2005 EU Contribution 1209050 € End Date (actual) 30/06/2008 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA24193:EN Summary This proposal deals with the development of coal-tar based pitches of low toxicity. It is aimed to both, to guarantee the pitch supply for the steel industry and to reduce the environmental impact derived from the use of coal-tar pitches. Economical aspects in relation with the implementation of the new technology and the potential impact of the results are taken into account. Apart from the coverage of the needs of traditional pitch user industries, it is also intended to develop pitches with potential applications in new carbon materials for energy and high technology applications, such as supercapacitors associated to fuel cells. The project has been built on the basis of a multidisciplinar consortium, which includes expertise from different research organizations and universities, under the umbrella of three industries which cover the range from pitch makers to end pitch users. This will guarantee the full exploitation of the results. The contribution of five countries, geographically well distributed, will ensure a good dissemination of results. Furthermore, the development of these new pitches will offer the opportunity to upgrade a low value product of the coal conversion process and hopefully, the opportunity to develop a new pitch which may compete with the well established Japanese AR-24, produced by Mitsubishi. Partners Organization Country Responsible AGENCIA ESTATAL CONSEJO SUPERIOR DE INVESTIGACIO ESPAÑA Prof. Rosa MENENDEZ LOPEZ (Project Coord.) CARBONE SAVOIE FRANCE Dr. Serge LACROIX IMPERIAL COLLEGE OF SCIENCE, TECHNOLOGY AND MEDI UNITED KINGDOM Prof. Rafael KANDIYOTI INDUSTRIAL QUIMICA DEL NALON S.A. ESPAÑA Dr. Juan José FERNANDEZ-RODRIGUEZ LABORATORIO NACIONAL DE ENERGIA E GEOLOGIA IP PORTUGAL Dr. Ibrahim GULYURTLU POLITECHNIKA WROCLAWSKA - WROCLAW UNIVERSITY O POLAND Prof. Jacek MACHNIKOWSKI

RFCR-CT-2005-00005 REDPAH

Full Title Reduction of polycyclic aromatic hydrocarbon (PAH) emissions from coking plants Info Type of Project Research Duration (months) 42 Total Budget 1930920 € Start Date 1/09/2005 EU Contribution 1158552 € End Date (actual) 28/02/2009 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA24965:EN Summary European steel production relies on reliable coke supply, which can be achieved only if European coke is produced in environmental friendly conditions. However, using existing coking techniques, the European proposal for new PAH emission standards (benz(a)pyrene at 1 ng/m3) cannot be achieved. Since more than half of PAH emissions from modern coking comes from door leakages the most effective strategies for reducing PAH emissions with existing coke ovens are: - to reduce the original rate of PAH formation in the oven (dependent on the initial coking blend), - to implement a better control of gas pressure inside the oven. Further, PAH emissions can be used to help monitor the condition of door seals. Regarding future regulation, it is also important to identify in the surrounding areas of coking plants the sources of emissions in order to quantify the contributions from coking to the total PAH concentration in ambient air. This integrated project includes laboratory and pilot scale investigations as well as tests at industrial scale for validation. Partners Organization Country Responsible THE UNIVERSITY OF NOTTINGHAM UNITED KINGDOM Prof. Colin E. SNAPE (Project Coord.) ARCELORMITTAL MAIZIERES RESEARCH S.A. FRANCE Mr Etienne PETIT AGENCIA ESTATAL CONSEJO SUPERIOR DE INVESTIGACIO ESPAÑA Dr. Ramon ALVAREZ INSTYTUT CHEMICZNEJ PRZEROBKI WEGLA - INST. FOR CH POLAND Dr. Aleksander SOBOLEWSKI THE MONCKTON COKE & CHEMICAL COMPANY LTD UNITED KINGDOM Mr Iain ARCHIBALD

32 Summaries of RFCS projects 2003-2012 TGC2 : Coal preparation, conversion and upgrading

RFCR-CT-2006-00002 MAXICARB

Full Title Maximising carbon utilisation through improved raw material selection and process control Info Type of Project Research Duration (months) 42 Total Budget 3071461 € Start Date 1/07/2006 EU Contribution 1842876 € End Date (actual) 31/12/2009 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA25047:EN Summary The principal aims of the project are to deliver a critical requirement for improved flexibility of carbon sources available to EU cokemakers and to optimise process operations for maximised coke productivity and reduced environmental emissions. The work is essential to address rapidly rising coal/coke costs and increasingly restricted availability of traditionally used supplies. The aims will be achieved through an integrated series of laboratory, pilot scale and plant trials designed to: • Develop novel coal characterisation techniques for initial selection of suitable blend components. • Evaluate alternative carbon additives, including biomass and recycled products. • Optimise blend preparation and process operations for maximised coke productivity and yield. • Generate mathematical modelling methods for improved blend formulation and coke quality prediction. • Assess the environmental and economic impact of proposed changes in blend types and process operations. Partners Organization Country Responsible TATA STEEL UK LIMITED UNITED KINGDOM Dr. Ruth POULTNEY (Project Coord.) ARCELORMITTAL MAIZIERES RESEARCH S.A. FRANCE Dr. Paul PERNOT AGENCIA ESTATAL CONSEJO SUPERIOR DE INVESTIGACIO ESPAÑA Dr. Ramon ALVAREZ DMT GmbH & Co KG DEUTSCHLAND Dipl.-Ing. Friedhelm STRELOW TECHNISCHE UNIVERSITÄT BERLIN DEUTSCHLAND Prof. Dr.-Ing. Halit Z. KUYUMCU THE UNIVERSITY OF NOTTINGHAM UNITED KINGDOM Prof. Colin E. SNAPE VOESTALPINE STAHL GMBH OESTERREICH Dipl.-Ing. Karl PILZ

RFCR-CT-2006-00003 HYDROSEP

Full Title Hydrogen separation in advanced gasification processes Info Type of Project Research Duration (months) 36 Total Budget 2515813 € Start Date 1/07/2006 EU Contribution 1509487 € End Date (actual) 30/06/2009 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA25071:EN Summary This proposal addresses the development of new membranes and adsorbents to reduce the costs of adapting integrated gasification combined cycle (IGCC) processes for hydrogen separation with CO2 capture. The current available technology, physical solvent processes such as Rectisol and Selexol, can only operate close to ambient temperatures and are best at high partial pressures. A range of high capacity carbon-based adsorbents based on activated phenolic resins and nitrogen-containing precursors, such as polyacrylonitrile (PAN), will be developed and tested for CO2 capture. Promising membrane configurations, encompassing metal, ceramics and polymers will be developed and tested to determine the effectiveness of the hydrogen separation processes at realistic operating conditions. Process designs and modelling will be conducted incorporating the new membranes materials and CO2 adsorbents. Partners Organization Country Responsible THE UNIVERSITY OF NOTTINGHAM UNITED KINGDOM Prof. Colin E. SNAPE (Project Coord.) ARTISTOTLE UNIVERSITY OF THESSALONIKI HELLAS Prof. George SAKELLAROPOULOS CENTRE FOR RESEARCH AND TECHNOLOGY HELLAS HELLAS Dr.-Ing. George SKODRAS AGENCIA ESTATAL CONSEJO SUPERIOR DE INVESTIGACIO ESPAÑA Dr. Fernando RUBIERA CENTRO SVILUPPO MATERIALI SPA ITALIA Dr. Eros Luciano FARACI ELCOGAS SA ESPAÑA M.Sc. Pedro CASERO CABEZON INSTITUTO NACIONAL DE ENGENHARIA, TECNOLOGIA E IN PORTUGAL Dr. Ibrahim GULYURTLU TECHNIP K.T.I. SPA ITALIA Dr. Gaetano IAQUANIELLO MAST CARBON TECHNOLOGY Ltd UNITED KINGDOM Dr. Oleksandr KOZYNCHENKO MAST CARBON INTERNATIONAL Ltd UNITED KINGDOM Dr. Oleksandr KOZYNCHENKO

RFCR-CT-2006-00004 COOL

Full Title Coke oven operating limits Info Type of Project Research Duration (months) 36 Total Budget 1595507 € Start Date 1/07/2006 EU Contribution 957304 € End Date (actual) 30/06/2009 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA24972:EN Summary The objective of this research project is to define the safe limits of coke oven battery operating conditions compatible with a long service life in terms of thermal and mechanical stresses. For this purpose a 3D thermo-mechanical model of the heating walls taking into account the assembly of bricks and joints will be developed. Different sources of stresses on the oven walls will be investigated : thermal load, coking pressure, pushing force. Theoretical (model) and experimental investigations will be carried out at laboratory scale, in pilot oven and in coke plants to evaluate swelling pressure and pushing force for different carbonisation parameters. As a result, the maximum acceptable production rate in safe conditions for the battery service life will be defined. Partners Organization Country Responsible ARCELORMITTAL MAIZIERES RESEARCH S.A. FRANCE Mr Daniel ISLER (Project Coord.) INSTYTUT CHEMICZNEJ PRZEROBKI WEGLA - INST. FOR CH POLAND Dr. Aleksander SOBOLEWSKI ILVA S.P.A. ITALIA Dr. Aldo BOVE RAUTARUUKKI OYJ FINLAND Mr Olavi KERKKONEN UNIVERSITE D'ORLEANS FRANCE Prof. Alain GASSER

33 Summaries of RFCS projects 2003-2012 TGC2 : Coal preparation, conversion and upgrading

RFCR-CT-2007-00005 FLEXGAS

Full Title Near zero emission advanced fluidised bed gasification Info Type of Project Research Duration (months) 36 Total Budget 2536420 € Start Date 1/07/2007 EU Contribution 1521852 € End Date (actual) 30/06/2010 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA25125:EN Summary In the 1970’s and 1980’s the developments of fluidised bed gasification technologies stopped at pilot/demonstration scale for economic reasons but it grew the interest in its use with biomass for many reasons (fuel flexibility, wide range operation scales suitability, do not require fine grinding difficult with biomass). In this project the way to overcoming the potential disadvantages of fluidised bed gasification and its use to process biomass/waste together with coal (at different operation scales and applications) and the technology for CO2 capture/reduction will be investigated. The effects of different fuels, composition and gasification medium on the quality of the producer gas will be also evaluated. Particular focus is on novel technologies for gasification coupled with CO2 sequestration and for producing hydrogen rich syngas from coal and biomass/waste. Partners Organization Country Responsible CONSIGLIO NAZIONALE DELLE RICERCHE ITALIA Mr Francesco MICCIO (Project Coord.) ANSALDO ENERGIA S.p.A. ITALIA Dr. Maria Luisa PELIZZA BIOMASSE KRAFTWERK GÜSSING GMBH & CO KG OESTERREICH Mr Markus KOCH CENTRO DE INVESTIGACIONES ENERGÉTICAS MEDIOAMBI ESPAÑA Dr. José Maria SANCHEZ HERVAS INSTITUTE OF CHEMICAL PROCESS FUNDAMENTALS ACAD CZECH REPUBLIC Dr. Miroslav PUNCOCHAR IMPERIAL COLLEGE OF SCIENCE, TECHNOLOGY AND MEDI UNITED KINGDOM Dr. Marcos MILLAN LABORATORIO NACIONAL DE ENERGIA E GEOLOGIA IP PORTUGAL Dr. Ibrahim GULYURTLU REPOTEC - RENEWABLE POWER TECHNOLOGIES UMWELT OESTERREICH Mr Harald TREMMEL TECHNISCHE UNIVERSITAET WIEN OESTERREICH Prof. Hermann HOFBAUER

RFCR-CT-2007-00006 HUGE

Full Title Hydrogen oriented underground coal gasification for Europe Info Type of Project Research Duration (months) 36 Total Budget 3139846 € Start Date 1/07/2007 EU Contribution 1853308 € End Date (actual) 30/06/2010 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA25044:EN Summary The project explores the technology for hydrogen production through underground gasification of coal in a dynamic geo-reactor. The process will be controlled through purposed dynamic changes in temperature and pressure of the reactants and products. The project addresses CBM usage and CO2 sequestration in coal deposits. The environmental fingerprint of the technology on air, water and strata stability will be evaluated. The locations of demonstration plants will be chosen through computer modelling and simulation. Large scale production of hydrogen from coal is crucial for coal mining industries and will serve the needs of energy, chemistry and transportation sectors of Europe. Partners Organization Country Responsible GLOWNY INSTYTUT GORNICTWA POLAND Prof. Krzysztof STANCZYK (Project Coord.) INSTITUTE OF CHEMICAL PROCESS FUNDAMENTALS ACAD CZECH REPUBLIC Dr. Olga SOLCOVA INSTITUT SCIENTIFIQUE DE SERVICE PUBLIC BELGIQUE Ir. Hoang Luong TRAN KOMPANIA WEGLOWA S.A. POLAND Dr.-Eng. Marek SZARAFINSKI NATIONAL MINING UNIVERSITY UKRAINE Prof. Volodymyr BONDARENKO PGE GORNICTWO I ENERGETYKA KONWENCJONALNA SA POLAND Mr Jacek GADOWSKI POLTEGOR INSTYTUT - INSTYTUT GORNICTWA ODKRYWK POLAND Prof. Jerzy BEDNARCZYK SILESIAN UNIVERSITY OF TECHNOLOGY - POLITECHNIKA SL POLAND Prof. Jan PALARSKI TECHNISCHE UNIVERSITEIT DELFT NEDERLAND Dr. Hans BRUINING UCG PARTNERSHIP LTD UNITED KINGDOM Dr. Michael GREEN UNIVERSITAET STUTTGART DEUTSCHLAND Ms Anja SCHUSTER

RFCR-CT-2008-00007 ECOCARB

Full Title Reduction of emissions and energy utilisation of coke oven underfiring heating systems through advanced diagnostics and control Info Type of Project Research Duration (months) 42 Total Budget 2490112 € Start Date 1/07/2008 EU Contribution 1494068 € End Date (actual) 31/12/2011 State Research completed, report published on EU Bookshop at (link not yet available) Summary The project aims are to reduce emissions and maximise energy efficiency of coke oven underfiring heating using intelligent diagnostics and individual wall heating control. These will be achieved by developing data-driven diagnostics techniques to detect faults, such as blocked nozzles and through-wall leakage, in the heating flues and integrated with an innovative automatic individual wall heating control system, and hence reduce NOx, SO2, CO, CO2, particulates emissions and increase energy efficiency. The project addresses the competitive and environmentally friendly conversion of coal. The technology implementation will be easily transferable to any European cokemaking plant. Partners Organization Country Responsible TATA STEEL UK LIMITED UNITED KINGDOM Dr. Mansour SAIEPOUR (Project Coord.) ARCELORMITTAL MAIZIERES RESEARCH S.A. FRANCE Mr Daniel ISLER UHDE GmbH DEUTSCHLAND Mr Ulrich KOCHANSKI UNIVERSITY OF NEWCASTLE UPON TYNE UNITED KINGDOM Prof. Anthony Julian MORRIS VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Dr.-Ing. Frank MINTUS

34 Summaries of RFCS projects 2003-2012 TGC2 : Coal preparation, conversion and upgrading

RFCR-CT-2009-00003 CO2freeSNG

Full Title Substitute natural gas from coal with internal sequestration of CO2 Info Type of Project Research Duration (months) 36 Total Budget 1661353 € Start Date 1/07/2009 EU Contribution 996812 € End Date (actual) 30/06/2012 State Research in progress Summary The conversion of coal into so-called Substitute Natural Gas (SNG) will reduce dependencies on Non-European Natural Gas resources. However, capacities of existing gas grids limit the allowable plant size. An innovative steam gasification technology - promises competitive Coal-to-SNG plants in the medium-scale power range between 50 to 500 MW - reduces CO2 production inherently by 1/3 The consortium will up-scale gasification, methanation and sequestration technologies that have been developed successfully for the conversion of biomass and will evaluate the technical and economical application of this concept for coal by means of gasification and methanation tests at an existing gasification plant. Partners Organization Country Responsible FRIEDRICH-ALEXANDER UNIVERSITAT DEUTSCHLAND Prof. Dr.-Ing. Jürgen KARL (Project Coord.) DVGW DEUTSCHE VER. DES GAS-UND WASSERFACHES-TE DEUTSCHLAND Dr.-Ing. Frank GRAF HIGHTERM RESEARCH GMBH DEUTSCHLAND Mr Markus ZANKL NATIONAL TECHNICAL UNIVERSITY OF ATHENS HELLAS Prof. Emmanouil KAKARAS TECHNISCHE UNIVERSITAET GRAZ OESTERREICH Prof. Dr.-Ing. Jürgen KARL

RFCR-CT-2009-00004 EUROFIBRES

Full Title Development of carbon precursors from anthracene oil-based pitches for carbon fibre preparation Info Type of Project Research Duration (months) 42 Total Budget 1879655 € Start Date 1/07/2009 EU Contribution 1127793 € End Date (actual) 31/12/2012 State Research in progress Summary This proposal deals with the development of carbonaceous precursors from anthracene oilbased pitches for their use in the preparation of isotropic carbon fibres and graphitic fibres. The development of these precursors will represent innovative and strategic achievements for the European Community, as it will allow the acquisition of the knowledge and technology necessary to obtain raw materials for carbon fibre preparation. Such know-how is currently the reserve of the American and Japanese industries. The project has as its main objective the preparation of precursors in a continuous regime, which are suitable for obtaining isotropic and graphitic fibres. This will provide representative data for subsequent scaling up. The activation of carbon fibres will provide another market alternative. Partners Organization Country Responsible AGENCIA ESTATAL CONSEJO SUPERIOR DE INVESTIGACIO ESPAÑA Dr. Marcos GRANDA (Project Coord.) IMPERIAL COLLEGE OF SCIENCE, TECHNOLOGY AND MEDI UNITED KINGDOM Dr. Marcos MILLAN INDUSTRIAL QUIMICA DEL NALON S.A. ESPAÑA Dr. Juan José FERNANDEZ-RODRIGUEZ UNIVERSITY OF LEEDS UNITED KINGDOM Dr. Aidan WESTWOOD POLITECHNIKA WROCLAWSKA - WROCLAW UNIVERSITY O POLAND Prof. Jacek MACHNIKOWSKI

RFCR-CT-2010-00006 SPRITCO

Full Title Generation of swelling pressure in a coke, transmission on oven walls and consequences on wall degradation Info Type of Project Research Duration (months) 42 Total Budget 1942334 € Start Date 1/07/2010 EU Contribution 1165400 € End Date (actual) 31/12/2013 State Research in progress Summary Coal swelling pressure is one of the major causes of coke oven degradation. The aim of the present project is to progress in the knowledge of the swelling pressure generation phenomena, to develop advanced methodologies to measure phenomena and their consequences on ovens, and to develop a prediction model of wall pressure. A global approach from gas pressure generation in the plastic coal to the resulting stress on the oven walls is proposed. Coupling of pressure development in the oven chamber and thermo mechanical behaviour of heating walls will allow quantifying the effect of swelling pressure on oven walls degradation. Partners Organization Country Responsible ARCELORMITTAL MAIZIERES RESEARCH S.A. FRANCE Mr Daniel ISLER (Project Coord.) AGENCIA ESTATAL CONSEJO SUPERIOR DE INVESTIGACIO ESPAÑA Dr. Ramon ALVAREZ INSTYTUT CHEMICZNEJ PRZEROBKI WEGLA - INST. FOR CH POLAND Dr. Aleksander SOBOLEWSKI THE UNIVERSITY OF NOTTINGHAM UNITED KINGDOM Prof. Colin E. SNAPE UNIVERSITE D'ORLEANS FRANCE Prof. Alain GASSER

35 Summaries of RFCS projects 2003-2012 TGC2 : Coal preparation, conversion and upgrading

RFCR-CT-2010-00007 DENSICHARGE

Full Title Improving the use of alternative raw materials in coking blends through charge densification Info Type of Project Research Duration (months) 36 Total Budget 2872353 € Start Date 1/07/2010 EU Contribution 1723413 € End Date (actual) 30/06/2013 State Research in progress Summary The principal aim is to improve use of alternative materials in coking coal blends by delivering technological solutions to increase oven charge bulk density for European plants, through an integrated series of trials supported by process development and mathematical modelling to: • Investigate charge pre-treatment/densification methods to increase use of alternative materials in coking blends at existing plants. • Evaluate the influence of alternative raw materials, blends and pre-treatment processes on charge bulk density, carbonisation, coke oven operating conditions, coke quality and yield. • Assess the economic and environmental feasibility of alternative materials and pre-treatment technologies for industrial coke production. Partners Organization Country Responsible TATA STEEL UK LIMITED UNITED KINGDOM Dr. Ruth POULTNEY (Project Coord.) ARCELORMITTAL MAIZIERES RESEARCH S.A. FRANCE Mr Daniel ISLER AGENCIA ESTATAL CONSEJO SUPERIOR DE INVESTIGACIO ESPAÑA Dr. Ramon ALVAREZ DMT GmbH & Co KG DEUTSCHLAND Dr. Erwin PILARCZYK INSTYTUT CHEMICZNEJ PRZEROBKI WEGLA - INST. FOR CH POLAND Dr. Aleksander SOBOLEWSKI TECHNISCHE UNIVERSITÄT BERLIN DEUTSCHLAND Prof. Dr.-Ing. Halit Z. KUYUMCU THE UNIVERSITY OF NOTTINGHAM UNITED KINGDOM Prof. Colin E. SNAPE VOESTALPINE STAHL GMBH OESTERREICH Dipl.-Ing. Karl PILZ

RFCR-CT-2010-00008 RATIO-COAL

Full Title Improvement of coal carbonization through the optimization of fuel in coking coal blends Info Type of Project Research Duration (months) 36 Total Budget 2014497 € Start Date 1/07/2010 EU Contribution 1089501 € End Date (actual) 30/06/2013 State Research in progress Summary The main objective of the project is an improvement of coal carbonization process through the optimization of fuel in coking coal blends. The dependence between petrographic properties of coal, alternative fuels addition and coke quality will be determined. New method of prognosis of metallurgical coke quality based on reactive/inert ratio of coal fuel blends will be proposed. An innovative monitoring, control and optimization system for preparation of coking fuel blends will be designed and implemented. A number of tests demonstrating the system feasibility and effectiveness at full scale industrial process will be provided. Partners Organization Country Responsible UNIWERSYTET SLASKI POLAND Dr. Iwona JELONEK (Project Coord.) AGENCIA ESTATAL CONSEJO SUPERIOR DE INVESTIGACIO ESPAÑA Dr. Angeles BORREGO KOMBINAT KOKSOCHEMICZNY ZABRZE SA POLAND Eng. Stella ROSIAK THYSSENKRUPP STEEL EUROPE AG DEUTSCHLAND Mr Heike EICKHOFF TRINECKE ZELEZARNY a.s. CZECH REPUBLIC PhD Stanislav CZUDEK USTAV GEONIKY AV CR, V.V.I. CZECH REPUBLIC Ing. Alena KOZUSNIKOVA

RFCR-CT-2010-00009 FECUNDUS

Full Title Advanced concepts and process schemes for CO² free fluidised and entrained bed co-gasification of coals Info Type of Project Research Duration (months) 36 Total Budget 2877029 € Start Date 1/07/2010 EU Contribution 1726218 € End Date (actual) 30/06/2013 State Research in progress Summary The need to efficiently convert/upgrade coal and renewable fuels and to drastically reduce CO2 emissions calls for research in improving technologies of solid fuels to energy conversion. The project aims at integrating gasification schemes for the co-gasification of coal, biomass and wastes with processes for CO2 separation and capture. Fluidised bed and entrained flow gasification processes will be considered thanks to their flexibility and effectiveness for carrying out thermal conversion of different feedstock. Seven work-packages are foreseen dealing with management, outcomes dissemination, tailoring gasification schemes for integration with CO2 separation, development of materials for gas cleaning, char upgrading, and CO2 separation. Partners Organization Country Responsible CONSIGLIO NAZIONALE DELLE RICERCHE ITALIA Mr Francesco MICCIO (Project Coord.) CENTRO DE INVESTIGACIONES ENERGÉTICAS MEDIOAMBI ESPAÑA Dr. José Maria SANCHEZ HERVAS ELCOGAS SA ESPAÑA Dr. Pilar COCA LLANO INSTITUTE OF CHEMICAL PROCESS FUNDAMENTALS ACAD CZECH REPUBLIC Prof. Dr. Karel SVOBODA IMPERIAL COLLEGE OF SCIENCE, TECHNOLOGY AND MEDI UNITED KINGDOM Dr. Marcos MILLAN LABORATORIO NACIONAL DE ENERGIA E GEOLOGIA IP PORTUGAL Dr. Ibrahim GULYURTLU UNIVERSITA DEGLI STUDI DI SALERNO ITALIA D. Diego BARLETTA TECHNISCHE UNIVERSITAET WIEN OESTERREICH Prof. Hermann HOFBAUER

36 Summaries of RFCS projects 2003-2012 TGC2 : Coal preparation, conversion and upgrading

RFCR-CT-2011-00002 HUGE2

Full Title Hydrogen oriented underground coal gasification for Europe - Environmental and Safety Aspects Info Type of Project Research Duration (months) 36 Total Budget 2074641 € Start Date 1/07/2011 EU Contribution 1244785 € End Date (actual) 30/06/2014 State Research in progress Summary The project is focused on safety and environmental aspects of underground coal gasification. Underground trial will be performed in mine testing two borehole system and reactive barriers usage. The most serious environmental concerns related to UCG will be investigated that is contamination of underground aquifers and potential leakage of poisonous and explosive gases into the surrounding strata. The work will be focused on finding practical solutions of possible leakages prevention by use of reactive barriers. Complex system of environmental telemetric monitoring will be built and tested. Also technical and ecological risk assessment will be performed. Partners Organization Country Responsible GLOWNY INSTYTUT GORNICTWA POLAND Prof. Krzysztof STANCZYK (Project Coord.) LUBELSKI WEGIEL "BOGDANKA" SA POLAND Ph.Eng. Boleslaw KOZEK INSTITUTE OF CHEMICAL PROCESS FUNDAMENTALS ACAD CZECH REPUBLIC Dr. Olga SOLCOVA INSTITUT NATIONAL DE L'ENVIRONNEMENT INDUSTRIEL E FRANCE Dr. Régis FARRET KOMPANIA WEGLOWA S.A. POLAND Dr.-Eng. Marek SZARAFINSKI SILESIAN UNIVERSITY OF TECHNOLOGY - POLITECHNIKA SL POLAND Prof. Jan PALARSKI UCG ENGINEERING LTD UNITED KINGDOM Dr. Michael GREEN

RFCR-CT-2012-00005 NOEMI

Full Title Nitrogen oxides emissions minimization through improvement of vertical heat distribution inside heating flues Info Type of Project Research Duration (months) 42 Total Budget 1231394 € Start Date 1/07/2012 EU Contribution 738836 € End Date (actual) 31/12/2015 State Research in progress Summary The primary sources of NOx emissions in coke plants are waste heat gases. These emissions depend on underfiring gas and heating pattern. New heating designs with multi-stage heating and waste gas recirculation allow reducing NOx formation but can only be applied in new constructions. Improvement of existing batteries in terms of heat distribution and NOx emissions will be proposed. Coke oven gas dilution and possible design modifications will be studied. Mathematical and physical models will be used to determine the best possible ways to improve the heating pattern before implementation at industrial scale. Benefits will be assessed by performing industrial measurements. Partners Organization Country Responsible ARCELORMITTAL MAIZIERES RESEARCH S.A. FRANCE Mrs Juliette DELINCHANT (Project Coord.) BIURO PROJEKTOW KOKSOPROJEKT Sp. Z.O.O. POLAND Mr Wiktor HUMMER

37 38

Technical Group Coal 3

Coal combustion, clean and efficient coal technologies, CO2 capture

The scope of TGC3 includes:

• Clean and efficient coal combustion

• Integration of the coal chain, from mining to the final product (electricity, heat, hydrogen, coke)

• Carbon management strategy

• Reduction of the environmental impact of installations using EU coal, lignite and oil shave

• Reduction in emissions from coal utilization

• Clean and efficient coal technologies

• CO2 capture

• Co-combustion of coal with solid waste or biomass

• Zero emissions and high efficient power generation

• CHP from coal

• Coal contribution to global energy security

39 40 Summaries of RFCS projects 2003-2012 TGC3 : Coal combustion, clean and efficient coal technologies, CO2 capture

RFC2-CT-2006-00005 CCTPROM

Full Title Clean coal technology R, D&D promotion and dissemination Info Type of Project Accompanying measure (studies) Duration (months) 18 Total Budget 290353 € Start Date 1/07/2006 EU Contribution 186902 € End Date (actual) 31/12/2007 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA23583:EN Summary This Type 2 accompanying measure will complement and provide added value for coal utilisation R, D&D activities managed by the European Commission, under the ECSC and RFCS programmes. This will be achieved by promoting and disseminating the scope and achievements of the ECSC and RFCS projects on coal-fired power generation R, D&D, to the major coal using new member and candidate states of the EU. It will also promote the rationale for the strategic priorities and mode of operation of the RFCS programme, to encourage a more informed cooperation between the R,D&D organisations within the EU-15 and Poland, Czech Republic, Rumania and Bulgaria. Activities will include demonstrating the value of coal utilisation R, D&D towards establishing a sustainable energy mix for Europe while ensuring that EU coal based stakeholders can remain competitive within a global context. This will involve interaction with strategic decision makers, stakeholders and R&D organisations of the EU-15 and the four designated countries through promotion and dissemination via brochures, web based links and workshops. Partners Organization Country Responsible IEA COAL RESEARCH LIMITED UNITED KINGDOM Dr. Andrew MINCHENER (Project Coord.) INSTITUTUL DE STUDII SI PROIECTARI ENERGETICE SA ROMANIA Dr. Carmencita CONSTANTIN SEVEN - STREDISKO PRO EFEKTIVNI VYUZIVANI ENERGIE o. CZECH REPUBLIC Dipl.-Eng. Bohuslav MALEK SILESIAN UNIVERSITY OF TECHNOLOGY - POLITECHNIKA SL POLAND Dr. Andrzej SZLEK

RFCP-CT-2003-00002 LIGPOWER

Full Title More efficient cleaning concepts for stepping up availability of lignite-fired power plants Info Type of Project Pilot&Demonstration Duration (months) 52 Total Budget 2312896 € Start Date 1/09/2003 EU Contribution 925158 € End Date (actual) 31/12/2007 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA23869:EN Summary As a domestic raw material, lignite plays an important and indispensable role as a competitive energy source in the power generation mix of many European countries. The specific properties of this energy source lead to low ash softening and melting temperatures resulting in fouling and slagging in the boiler during combustion. The mixing of the coal charge and adapted control of the firing process alone do not prevent that the lignite-based power generation is still affected by massive availability restrictions due to fouling. Such restrictions can only be reduced by using highly efficient cleaning equipment. Therefore, the objective of this project is to test, under demonstration conditions, improved cleaning equipment and new heating surfaces suited for more efficient cleaning measures. These measures will enhance the availability and competitiveness of this energy source and help maintaining its vital role in European power supply. Partners Organization Country Responsible RWE POWER AG DEUTSCHLAND Mr Georg WIECHERS (Project Coord.) ALSTOM POWER SYSTEMS GmbH DEUTSCHLAND Dr. Georg-Nikolaus STAMATELOPOULOS PUBLIC POWER CORPORATION S.A. HELLAS Dipl.-Ing. Abraham MIZAN RWE NPOWER PLC UNITED KINGDOM Dr. Gerry RILEY

RFCP-CT-2004-00002 DRYCOAL

Full Title Commercial-scale testing of a fluidized-bed drying plant for highly efficient lignite-fired power plants Info Type of Project Pilot&Demonstration Duration (months) 54 Total Budget 6184654 € Start Date 1/10/2004 EU Contribution 2473862 € End Date (actual) 31/03/2009 State Research technically completed; publication in hand Summary In many European countries, lignite is of outstanding importance to power generation. As a domestic energy source, it offers long- term security of supply and guarantees economically efficient power generation in the base load range. The decrease in CO2 emissions and the preservation of resources are vital incentives to continue improving the present state-of-the-art of lignite-based power plant technology. To achieve this, the use of a pre-drying plant for moist lignite as well as its integration into a dry lignite-fired power plant can make an important contribution with a further efficiency increase of 4 – 6 % points. For this reason, RWE Rheinbraun has been developing and successfully optimising the predrying process for many years. Before their first commercial-scale application, drying as well as dry lignite combustion will have to be tested on a commercial scale. For major sub-activities of this project, financial support is requested by this Application. As competent European power plant operators and suppliers, the participants ensure project implementation geared towards the interests of industry, while representing – at the same time – potential users of this process for efficient lignite-based power generation. Partners Organization Country Responsible RWE POWER AG DEUTSCHLAND Mr Claus MOSER (Project Coord.) ALSTOM POWER SYSTEMS GmbH DEUTSCHLAND Dr. Georg-Nikolaus STAMATELOPOULOS BOT ELEKTROWNIA BELCHATOW SPOLSKA AK POLAND Mr Krzysztof PRZEGALINSKI NATIONAL TECHNICAL UNIVERSITY OF ATHENS HELLAS Prof. Emmanuel KAKARAS PUBLIC POWER CORPORATION S.A. HELLAS Mr Constantin CHALOULOS VATTENFALL EUROPE GENERATION AG & CO. KG DEUTSCHLAND Dr. Thomas BRUNNE

41 Summaries of RFCS projects 2003-2012 TGC3 : Coal combustion, clean and efficient coal technologies, CO2 capture

RFCP-CT-2004-00003 COMTES700

Full Title Component test facility for a 700 °C power plant Info Type of Project Pilot&Demonstration Duration (months) 90 Total Budget 15189984 € Start Date 1/07/2004 EU Contribution 6075994 € End Date (actual) 31/12/2011 State Research technically completed; publication in hand Summary The objective is to design, manufacture, erect and operate a Component Test Facility (CTF) to test high temperature durable new materials needed to realise a coal based power plant with efficiencies above 50%. High efficiencies safe resources and avoid emissions. A share of up to 20 % of (CO2 neutral) biomass can be added to the fuel resulting in a further avoidance of anthropogenic CO2. The real European consortium of major utilities and manufacturers ensures in itself the dissemination of the results in Europe and worldwide. The project will contribute to increase the competitiveness of the European power industry. Partners Organization Country Responsible VGB POWERTECH e.V. DEUTSCHLAND Mr Christian STOLZENBERGER (Project Coord.) ALSTOM POWER SYSTEMS GmbH DEUTSCHLAND Dr. Georg-Nikolaus STAMATELOPOULOS BURMEISTER & WAIN ENERGY A/S DANMARK Mr Oluf KROGH DONG ENERGY GENERATION AS*DANKRAFT AS ELSAM IN DANMARK Mr Joergen BUGGE HITACHI POWER EUROPE GmbH DEUTSCHLAND Dr. Friedrich KLAUKE SIEMENS AG DEUTSCHLAND Dr. Heiner EDELMANN

RFCP-CT-2006-00011 CERCOT

Full Title CO2 emission reduction through combustion optimisation technologies at coal-fired power plants Info Type of Project Pilot&Demonstration Duration (months) 36 Total Budget 3250225 € Start Date 1/07/2006 EU Contribution 1300090 € End Date (actual) 30/06/2009 State Unknown type of status (CSX) Summary This project is devoted to the development and full-scale validation of technologies for reducing CO2 emissions in pulverised coal power plants, by means of increased efficiency and fuel flexibility strategies. The approach to be used relies on the following complementary scopes: - Adaptation and industrial application of a novel combustion control based on in-furnace monitoring, which was successfully developed in a previous ECSC project for Nox optimisation. - Development of a novel burner with higher fuel flexibility capabilities. Fuel scenarios to be considered include combustion of different types of coals and coal/biomass cofiring. Partners Organization Country Responsible ENDESA GENERACION SA ESPAÑA Dr. Juan Carlos BALLESTEROS APARICIO (Project Coord) ANSALDO CALDAIE S.p.A. ITALIA Ing. Alessandro SAPONARO CENTRE FOR RESEARCH AND TECHNOLOGY HELLAS HELLAS Dr. Panagiotis GRAMMELIS ECOENERGIA Sp ZOO POLAND M. Sc. Eng. Jan SIWINKSI INGENIERIA ENERGETICA Y DE CONTAMINACION S.A. ESPAÑA Dr. Francisco RODRIGUEZ BAREA

RFCP-CT-2008-00008 ECLAIR

Full Title Emission free chemical looping coal combustion process Info Type of Project Pilot&Demonstration Duration (months) 54 Total Budget 6421724 € Start Date 1/07/2008 EU Contribution 2270771 € End Date (actual) 31/12/2012 State Research in progress Summary Chemical-looping combustion (CLC) for coal is a zero-emission technology, combining very low efficiency penalty (2-3%) and low CO2 capture cost, about 10€/ton CO2. Key issues for coal-CLC are: adequate technical solutions to reactors/surrounding systems; oxygen-carrier performance/behaviour and interaction with fuel; actual demonstration of technology. The proposal involves scale-up to 1-MWth pilot and experimental/theoretical work to provide basis for design and optimization. This includes investigation of oxygen-carrier interaction with fuel and long-term stabilility; development of tools/models to identify best reactor design and process layout; solutions for emission control; testing in 1-MWth plant and technical, environmental and economical assessment including 450-MW unit. Partners Organization Country Responsible ALSTOM BOILER France FRANCE Ms Corinne BEAL (Project Coord.) L'AIR LIQUIDE SA FRANCE Mr Christophe CLAEYS ALSTOM SWITZERLAND LTD SUISSE Dr. Michal BIALKOWSKI AGENCIA ESTATAL CONSEJO SUPERIOR DE INVESTIGACIO ESPAÑA Dr. Juan ADANEZ CHALMERS TEKNISKA HÖGSKOLA AB SVERIGE Prof. Anders LYNGFELT STIFTELSEN SINTEF NORGE Dr. Rune BREDESEN TECHNISCHE UNIVERSITÄT DARMSTADT DEUTSCHLAND Prof. Bernd EPPLE VATTENFALL RESEARCH AND DEVELOPMENT AB SVERIGE Dr. Marie ANHEDEN

RFCP-CT-2011-00003 ENCIO

Full Title European network for component integration and optimisation Info Type of Project Pilot&Demonstration Duration (months) 72 Total Budget 23886488 € Start Date 1/07/2011 EU Contribution 9554596 € End Date (actual) 30/06/2017 State Research in progress Summary The key goal of ENCIO is to concentrate all scientific and technological efforts to make the 700°C technology ready for deployment in coal fired power plants. ENCIO is an important step before the erection of a 700°C power plant can start. This step consists of the installation of a test facility in Fusina, at an ENEL power plant in Italy. The project will focus on practical investigations, aiming at proving manufacturing, welding, repair and life-time concepts for thickwalled components. ENCIO can be seen as perfect transition from pilot towards demo features. 42 Partners Organization Country Responsible Summaries of RFCS projects 2003-2012 TGC3 : Coal combustion, clean and efficient coal technologies, CO2 capture

VGB POWERTECH e.V. DEUTSCHLAND Mr Christian STOLZENBERGER (Project Coord.) CENTRO SVILUPPO MATERIALI SPA ITALIA Dr Paolo FOLGARAIT ENEL PRODUZIONE S.p.A. ITALIA Eng. Leonardo ARRIGHI ENEL INGEGNERIA E RICERCA S.p.A. ITALIA Ing. Sauro PASINI HITACHI POWER EUROPE GmbH DEUTSCHLAND Dr. Friedrich KLAUKE

RFCP-CT-2012-00006 ACCLAIM

Full Title Advanced coal chemical-looping combustion, aiming at highest performance Info Type of Project Pilot&Demonstration Duration (months) 30 Total Budget 3200765 € Start Date 1/07/2012 EU Contribution 1591434 € End Date (actual) 31/12/2014 State Research in progress Summary Chemical-looping combustion (CLC) for coal is a zero-emission technology, combining very low efficiency penalty (2-3%) and low CO2 capture cost, potentially as low as 10 €/ton CO2. Key issues for coal-CLC are: adequate technical solutions to reactors/surrounding systems; oxygen-carrier performance/behaviour and interaction with fuel; actual demonstration of technology. The proposal builds on the great advances made in the ÉCLAIR project and the unique CLC solid fuel pilots developed and built. ÉCLAIR has clearly demonstrated the feasibility of the technology, but also that it would be an important advantage if process performance could be further improved. Such improvement primarily concerns the incomplete gas conversion and the corresponding need for oxypolishing of CO2 product gas. The proposal focuses on options to improve gas conversion with either new oxygen carriers, or with more advanced fuel reactor design. A number of oxygen carrier materials expected to give radical improvements in performance are known, but have not been sufficiently tested. The programme involves prequalification tests of such materials under sustained continuous operation in smaller chemical-looping combustors, 1-10 kW. Best candidates will be further tested in 100 kW and 1 MW pilots. Advanced fuel reactor designs will be investigated in cold flow model experiments combined with use of validated models in order to assess options to improve gas conversion. Proposal also involves update and review of downstream gas treatment and full-scale power plant design, as well as studies of the fate and influence of sulphur and nitrogen in the fuel, depending on oxygen carrier. The project is expected to have very great impact because it aims at demonstrating significant advances of the chemical-looping technology for solid fuel. Thus, it is expected to demonstrate how the potential for very fundamental reductions of energy penalty and CO2 capture costs can be realized. Partners Organization Country Responsible CHALMERS TEKNISKA HÖGSKOLA AB SVERIGE Prof. Anders LYNGFELT (Project Coord.) ALSTOM BOILER France FRANCE Ms Corinne BEAL BASF SE DEUTSCHLAND Dr. Philipp GRUENE AGENCIA ESTATAL CONSEJO SUPERIOR DE INVESTIGACIO ESPAÑA Dr. Juan ADANEZ STIFTELSEN SINTEF NORGE Dr. Rune BREDESEN TECHNISCHE UNIVERSITÄT DARMSTADT DEUTSCHLAND Prof. Bernd EPPLE TECHNISCHE UNIVERSITAET WIEN OESTERREICH Dr. Tobias PRÖLL

RFCR-CT-2003-00001 CLEFCO

Full Title Advanced CFB for clean and efficient coal power Info Type of Project Research Duration (months) 40 Total Budget 2231760 € Start Date 1/09/2003 EU Contribution 1339056 € End Date (actual) 31/12/2006 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA23875:EN Summary To fulfil the needs of development of the Once Through Supercritical (OTSC) Circulating Fluidized Bed (CFB) technology comprehensive understanding of CFB combustion processes must be achieved. This promotes boiler designers to meet the requirements of utility boilers to secure boiler performance and reliability at OTSC operation. In particular, more distinct understanding of combustion behaviour in OTSC CFB application during multifuel operation is needed to meet the additional requirements of the boiler control algorithms. The strategic importance and attractiveness of the OTSC CFB design is based on capability on multifuel operation that makes it possible to decrease CO2 emissions remarkably compared to current designs down to level of 500 – 600 kgCO2/ MWhel, depending on the degree of fuel substitution. The important aim of the proposed work is also to promote scale-up of the design of an OT CFB plant up to 600 MWe size. Partners Organization Country Responsible TEKNOLOGIAN TUTKIMUSKESKUS VTT*TECHNIC. RESEARC FINLAND Dr. Jouni HAMALAINEN (Project Coord.) CENTRE FOR RESEARCH AND TECHNOLOGY HELLAS HELLAS Prof. Emmanuel KAKARAS CHALMERS TEKNISKA HÖGSKOLA AB SVERIGE Prof. Filip JOHNSSON FOSTER WHEELER ENERGIA OY FINLAND Dr. Timo HYPPÄNEN

RFCR-CT-2003-00004 MINORTOP

Full Title Minimisation of impact of nitrogen oxide reduction technologies on operation and performance Info Type of Project Research Duration (months) 48 Total Budget 2115359 € Start Date 1/09/2003 EU Contribution 1269214 € End Date (actual) 31/08/2007 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA23861:EN Summary Numerous technologies have been developed to control NOX emissions but new limits effective from 2008 will require a combination of such measures, which may impact negatively on plant availability, environmental performance and efficiency. Such problems have not been clearly defined nor solutions found. This industrially focussed proposal will examine a range of problems, including carbon-in-ash, deposition and corrosion and the need to use renewable fuels. It will involve a combination of modelling and lab- pilot- and industrial-scale testing. A set of guidelines will be developed to advise plant operators and manufactures on best practise for meeting the revised targets. Partners Organization Country Responsible RWE NPOWER PLC UNITED KINGDOM Dr. Michael WHITEHOUSE (Project Coord.) ENERGY RESEARCH CENTRE OF THE NETHERLANDS NEDERLAND Dr. Ir. Rob KORBEE EMC ENVIRONMENT ENGINEERING LTD UNITED KINGDOM Mr Michael WHITEHOUSE INSTITUTO SUPERIOR TECNICO PORTUGAL Dr. Mario COSTA KEMA NEDERLAND BV NEDERLAND Dr. Kees GAST RUHR-UNIVERSITÄT BOCHUM DEUTSCHLAND Prof. Dr.-Ing. Viktor SCHERER UNIVERSITY OF LEEDS UNITED KINGDOM Dr. Bernard GIBBS 43 Summaries of RFCS projects 2003-2012 TGC3 : Coal combustion, clean and efficient coal technologies, CO2 capture

RFCR-CT-2003-00007 ADMONI

Full Title Development of advanced monitoring methodes to improve boiler availability and performance Info Type of Project Research Duration (months) 40 Total Budget 1698392 € Start Date 1/09/2003 EU Contribution 1019035 € End Date (actual) 31/12/2006 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA22994:EN Summary Taxation, legislation and market competition increasingly promotes using coal and renewable energy sources more efficiently and with wide range. National and international emission regulations, concerning especially the level of greenhouse gas emissions, and the introduction of emission trading systems can play important role in the future’s energy business sector. This may lead to an increase in the use of solid biomass based fuels also in Pulverised Coalfired plants. Co-firing, however, poses new challenges for power plant operators. Particularly, the nature of biomass ash causes boiler fouling, which in turn decreases boiler efficiency. In order to increase fuel flexibility and achieve the most economical way for power generation, many operation parameters must be taken into account. Advanced on-line methods for ash behaviour and deposition formation monitoring as well as on-line process performance calculation methodologies are developed in this project. These can be implemented into power plant control systems for operators’ support. Partners Organization Country Responsible TEKNOLOGIAN TUTKIMUSKESKUS VTT*TECHNIC. RESEARC FINLAND Mr Markku ORJALA (Project Coord.) CENTRE FOR RESEARCH AND TECHNOLOGY HELLAS HELLAS Prof. Emmanuel KAKARAS FUNDACION CIRCE- CENTRO DE INVESTIGACION DE RECU ESPAÑA Dr. Cristobal CORTES GRACIA EVN AG OESTERREICH Ing. Alois OTTER FORTUM POWER AND HEAT OY FINLAND Mr Pertti MIELONEN TECHNISCHE UNIVERSITEIT DELFT NEDERLAND Prof. Dr.-Ing. Hartmut SPLIETHOFF CRANFIELD UNIVERSITY UNITED KINGDOM Mr John OAKEY

RFCR-CT-2003-00008 ASSOCOGS

Full Title Assessment of options for CO2 capture and geological sequestration Info Type of Project Research Duration (months) 45 Total Budget 2941793 € Start Date 1/09/2003 EU Contribution 1765076 € End Date (actual) 31/05/2007 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA23873:EN Summary The reduction in overall CO2 emissions to atmosphere is a major goal of the Community. However, technical options for CO2 capture from coal-fired power plants are not readily available. This project will improve understanding of the engineering (and hence financial) practicality of the three main technologies being assessed for CO2 capture (pre-gasification, oxy-fuel combustion and sorption from flue gas) and analyse one of the most potentially attractive mechanisms for economic sequestration (enhanced coal-bed methane). Its successful completion will lead to a significant improvement in the ability of plant operators to assess the viability of abatement options potentially available to them. Partners Organization Country Responsible E.ON UK plc UNITED KINGDOM Dr. Robin IRONS (Project Coord.) ARTISTOTLE UNIVERSITY OF THESSALONIKI HELLAS Prof. George SAKELLAROPOULOS CERAMICS & REFRACTORIES TECHNOLOGICAL DEVELOPM HELLAS Dr. Christos DEDELOUDIS CENTRE FOR RESEARCH AND TECHNOLOGY HELLAS HELLAS Dr.-Ing. George SKODRAS IMC GEOPHYSICS LTD UNITED KINGDOM Mr Peter JACKSON THE UNIVERSITY OF NOTTINGHAM UNITED KINGDOM Prof. Colin E. SNAPE UNIVERSITAET STUTTGART DEUTSCHLAND Prof. Dr. Klaus R.G. HEIN

RFCR-CT-2004-00005 GEOASH

Full Title Understanding and mastering coal fired ashes geopolymerization process in order to turn potential into profit Info Type of Project Research Duration (months) 36 Total Budget 1203141 € Start Date 1/11/2004 EU Contribution 721884 € End Date (actual) 31/10/2007 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA23891:EN Summary The project deals with the geopolymerization of (co)-combustion fly ashes of various origins. The research takes into account the potential geopolymerization of Si and Al-bearing solid residues as a new method of solidification/stabilization of wastes, in particular inorganic solid wastes, with emphasis on the long-term stability. Moreover, based on fundamental increased knowledge expected from the study, the proposed programme will also consider the actual potentialities of ashes-based geopolymers in term of environmental and economical constrains. Partners Organization Country Responsible INSTITUT SCIENTIFIQUE DE SERVICE PUBLIC BELGIQUE Dr. Diano ANTENUCCI (Project Coord.) ASOCIACION DE INVESTIGACION Y COOPERACION IND. AN ESPAÑA Prof. Constantino PEREIRA CORDI-GEOPOLYMERE S.A. FRANCE Prof. Dr. Ralph DAVIDOVITS AGENCIA ESTATAL CONSEJO SUPERIOR DE INVESTIGACIO ESPAÑA Dr. Feliciano PLANA LLEVAT TECHNISCHE UNIVERSITEIT DELFT NEDERLAND Dr. Henk VAN NUGTEREN UNIVERSIDAD DE SEVILLA ESPAÑA Prof. Constantino FERNANDEZ PEREIRA

44 Summaries of RFCS projects 2003-2012 TGC3 : Coal combustion, clean and efficient coal technologies, CO2 capture

RFCR-CT-2004-00006 AGAPUTE

Full Title Advanced gas purification techn. for co-gasification of coal,refinery by-products,biomass & waste,targeted to clean power produced from gas & steam turbine generator set fuel cells Info Type of Project Research Duration (months) 42 Total Budget 2569812 € Start Date 1/12/2004 EU Contribution 1541887 € End Date (actual) 31/05/2008 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA24967:EN Summary In AGAPUTE proposal, the accent is put on the best techno-economical ways to purify dust- and tar-loaded hot gas exiting different pressurized gasifiers which convert selectively coal and mixtures thereof into fuels dedicated to be burnt either in gas turbines (CO + H2 + CH4) or in fuel cells (H2) for electricity production, the exceeding heat released from the global process being additionally recovered in gas or steam turbines (like in IGCC and future hitech fuel cell plants). Main components to be removed physically or chemically or to be diluted through interlinked processing units are resp. : tars, nitrogen-based compounds (NH3,HCN,N2,NOx), halogens (Cl,F,Br), sulphur-based compounds (H2S,COS,CS2), heavy metals (mainly Al,Cd,Zn,Pb,Hg), carbon-based compounds (CH4,CO,CO2), fine particulates, solid residues (bottom- and fly-ash). Partners Organization Country Responsible CENTRO SVILUPPO MATERIALI SPA ITALIA Dr. Antonello DI DONATO (Project Coord.) AGENCIA ESTATAL CONSEJO SUPERIOR DE INVESTIGACIO ESPAÑA Prof. Ana Maria MASTRAL ELCOGAS SA ESPAÑA Dr. Pilar COCA LLANO IMPERIAL COLLEGE OF SCIENCE, TECHNOLOGY AND MEDI UNITED KINGDOM Prof. Rafael KANDIYOTI INSTITUTO NACIONAL DE ENGENHARIA, TECNOLOGIA E IN PORTUGAL Dr. Ibrahim GULYURTLU THE UNIVERSITY OF NOTTINGHAM UNITED KINGDOM Prof. Colin E. SNAPE UNIVERSITAT POLITECNICA DE CATALUNYA (UPC) ESPAÑA Dr. Luis PUIGJANER UNIVERSIDAD POLITECNICA DE MADRID ESPAÑA Prof. Carmen CLEMENTE

RFCR-CT-2004-00007 NODIOXCOMB

Full Title Zero "dioxin" releases in coal combustion and coal/organic waste co-combustion processes Info Type of Project Research Duration (months) 48 Total Budget 2868020 € Start Date 1/12/2004 EU Contribution 1720811 € End Date (actual) 30/11/2008 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA25059:EN Summary The total efficiencies of the preventive measure of the dioxins/furans formation make up the major objective, but this is unlikely to be achieved completely without further appropriate preventive measures. The application of this precaution principle into complementary curative measures is appropriate: adsorption of “dioxin” on active carbons and cokes will complement advanced fine dust filtration. To be successful, this challenge goes through several main key steps: 1) – Dechlorination of internal combustor gases and flue gases; 2) – Advanced inhibitions of the catalytically active sites on fly ash external surface area; 3) – Dioxin adsorption by the best and most cost-effective carbon based compounds; 4) – Integrated chemical and physical (advanced fine dust filtrations) treatments tests in pilots , macro-pilot and industrial plants; 5) – Modelling and testing VOC’s and Dioxin formation and adsorption; 6) – Modelling of flue gas filtration. On the basis of its well proven economical viability, this innovative sustainable project will be later developed and enforced in a preliminary convincing demonstration step . Partners Organization Country Responsible INSTITUT SCIENTIFIQUE DE SERVICE PUBLIC BELGIQUE Ir. Pierre LANDUYT (Project Coord.) ASOCIACION DE INVESTIGACION Y COOPERACION IND. AN ESPAÑA Prof. Luis SALVADOR MARTINEZ ARTISTOTLE UNIVERSITY OF THESSALONIKI HELLAS Prof. George SAKELLAROPOULOS CENTRE FOR RESEARCH AND TECHNOLOGY HELLAS HELLAS Dr.-Ing. George SKODRAS AGENCIA ESTATAL CONSEJO SUPERIOR DE INVESTIGACIO ESPAÑA Dr. Jesus BLANCO CENTRO SVILUPPO MATERIALI SPA ITALIA Dr. Eros Luciano FARACI ENDESA GENERACION SA ESPAÑA Eng. Antonio GIMENEZ ALONSO ENERVAC-FLUTEC Ltd HELLAS Dr. Athanasios KATSANEVAKIS INGENIERIA ENERGETICA Y DE CONTAMINACION S.A. ESPAÑA Dr. Francisco RODRIGUEZ BAREA SIOEN-NORDIFA S.A. BELGIQUE Ir. Bernard COLSON UNIVERSITY OF NEWCASTLE UPON TYNE UNITED KINGDOM Prof. Keith Mark THOMAS

RFCR-CT-2005-00006 OXYMOD

Full Title Development and experimental validation of a mathematical modelling methodology for oxy-fuel combustion for CO2 capture in large power plants Info Type of Project Research Duration (months) 40 Total Budget 2156685 € Start Date 1/07/2005 EU Contribution 1294011 € End Date (actual) 31/10/2008 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA24248:EN Summary One promising technology for the improvement of the use of coal as a clean energy source and the use of CO2 capture is the Oxy- Fuel Boiler Technology. Computerised mathematic models are used for development and design of coal-fired boilers. Further development of the models is needed to support the demand of mathematic modelling for Oxy-Fuel combustion that will occur in Europe the coming five years. The objective for the proposed project is to develop and by experiments validate a mathematical modelling methodology for Oxy- Fuel combustion to be used in process layout, operation and optimisation of a CO2 free power plant. Partners Organization Country Responsible VATTENFALL RESEARCH AND DEVELOPMENT AB SVERIGE Mr Leif BRANDELS (Project Coord.) CHALMERS TEKNISKA HÖGSKOLA AB SVERIGE Prof. Filip JOHNSSON FLUENT EUROPE LIMITED UNITED KINGDOM Dr. Christopher CAREY DOOSAN BABCOCK ENERGY LTD UNITED KINGDOM Mr Ragi PANESAR NATIONAL TECHNICAL UNIVERSITY OF ATHENS HELLAS Prof. Emmanouil KAKARAS UNIVERSITAET STUTTGART DEUTSCHLAND Dr. Uwe SCHNELL 45 Summaries of RFCS projects 2003-2012 TGC3 : Coal combustion, clean and efficient coal technologies, CO2 capture

RFCR-CT-2005-00007 CLYCARGAS

Full Title Clean syngas from carbonaceous materials gasification for highly efficient electric energy generation Info Type of Project Research Duration (months) 36 Total Budget 2500804 € Start Date 1/07/2005 EU Contribution 1500482 € End Date (actual) 30/06/2008 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA25055:EN Summary The principal aim of this project is the production of syngas from gasification of low grade coal and biomass to be directly used for highly efficient electric energy production (direct combustion in gas turbine, fuel cells). A gas tar free is required in both applications. The objective of the present project is to establish the efficiency of different gasification conditions and catalytic tar cracking technologies to obtain the required gas purity. Theoretical solutions will be validated by means of appropriate experimental campaigns. Partners Organization Country Responsible CENTRO SVILUPPO MATERIALI SPA ITALIA Dr. Antonello DI DONATO (Project Coord.) ENEL INGEGNERIA E RICERCA S.p.A. ITALIA Eng. Claudio ZEPPI TECHNIP K.T.I. SPA ITALIA Dr. Gaetano IAQUANIELLO LABORATORIO NACIONAL DE ENERGIA E GEOLOGIA IP PORTUGAL Dr. Ibrahim GULYURTLU SOCIETÀ TECNOLOGIE AVANZATE CARBONE S.P.A. - SOTA ITALIA Eng. Enrico MAGGIO TECNATOM S.A. ESPAÑA Mr Andrés SANCHEZ BIEZMA UNIVERSITY OF NEWCASTLE UPON TYNE UNITED KINGDOM Prof. Keith Mark THOMAS THE UNIVERSITY OF NOTTINGHAM UNITED KINGDOM Dr. Edward LESTER

RFCR-CT-2005-00008 CO.CA.CO.R.K.

Full Title Coal catalytic co-gasification in an innovative rotary Kiln gasifier Info Type of Project Research Duration (months) 36 Total Budget 2098332 € Start Date 1/07/2005 EU Contribution 1259000 € End Date (actual) 30/06/2008 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA25043:EN Summary Aim of this proposal is to demonstrate the opportunity to produce a clean syngas by means of a pioneering approach to co- gasification of coal/biomass or coal/waste (e.g. tyres, RDF- Refuse Derived Fuel-, etc.). The novelty consists principally of a new conception rotary kiln gasifier and of an innovative catalytic gasification. The innovative gasifier combines the high mixing of a fluidised bed gasifier without the need of a fine fixed feed granulometry and without the problem of a high carry over of the latter. The use of syngas produced in microturbines/internal combustion engines or, after the hydrogen extraction, in fuel cells, will be investigated and the clean-up section suitable for each application will be defined. This proposal foresees the construction of a small – scale gasifier (5-15 kg/h) for obtaining all the fundamental parameters and technical/economic information for a further demonstration project. Partners Organization Country Responsible CENTRO SVILUPPO MATERIALI SPA ITALIA Dr. Claudio LEPORATI (Project Coord.) ANSALDO ENERGIA S.p.A. ITALIA Dr. Maria Luisa PELIZZA ENEL INGEGNERIA E RICERCA S.p.A. ITALIA Eng. Claudio ZEPPI LABORATORIO NACIONAL DE ENERGIA E GEOLOGIA IP PORTUGAL Dr. Ibrahim GULYURTLU SOCIETÀ TECNOLOGIE AVANZATE CARBONE S.P.A. - SOTA ITALIA Eng. Alberto PETTINAU THE UNIVERSITY OF NOTTINGHAM UNITED KINGDOM Prof. Colin E. SNAPE UNIVERSIDAD DE ZARAGOZA ESPAÑA Dr. Jesus ARAUZO PÉREZ

RFCR-CT-2005-00009 CFB800

Full Title Utility scale CFB for competitive coal power Info Type of Project Research Duration (months) 36 Total Budget 3396235 € Start Date 1/09/2005 EU Contribution 2037743 € End Date (actual) 31/08/2008 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA24357:EN Summary The development of the unregulated electricity markets has forced the power producers into a new situation. Increased competition brings power producers more aspects to be taken into account. Improved competitiveness is the key issue in order to maintain or increase profitability of power generation. In addition, the age profile of the existing power plants results in a high demand for new power production capacity within the next years. The replacement or the modernisation of the old power plants utilising modern technology with high steam parameters and high efficiencies would contribute to the saving of the resources and to the reduction of all kind of emissions. This would definitely improve public acceptance of coal-fired power plants. However, new investments must be able to compete decades forward in order to secure competitive power production. The principal objective of the proposed project is to scale up CFB technology up to utility scale (600 - 800 MWe) to meet the future requirements of power plant operators at deregulated energy markets. Partners Organization Country Responsible TEKNOLOGIAN TUTKIMUSKESKUS VTT*TECHNIC. RESEARC FINLAND Dr. Jouni HAMALAINEN (Project Coord.) CENTRE FOR RESEARCH AND TECHNOLOGY HELLAS HELLAS Dr. Nikolaos KOUKOUZAS FUNDACION CIRCE- CENTRO DE INVESTIGACION DE RECU ESPAÑA Dr. Cristobal CORTES GRACIA ENDESA GENERACION SA ESPAÑA Dr. Juan Carlos BALLESTEROS APARICIO FOSTER WHEELER ENERGIA OY FINLAND Dr. Timo HYPPÄNEN SIEMENS AG DEUTSCHLAND Dipl.-Ing. Andre SCHRIEF

46 Summaries of RFCS projects 2003-2012 TGC3 : Coal combustion, clean and efficient coal technologies, CO2 capture

RFCR-CT-2005-00010 FLOX-COAL

Full Title Development of a pilot-scale flameless oxidation burner for ultra low NOx combustion of pulverised coal Info Type of Project Research Duration (months) 36 Total Budget 2996203 € Start Date 1/06/2005 EU Contribution 1797722 € End Date (actual) 31/05/2008 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA24188:EN Summary The project aims at proving the concept of flameless combustion of coal with the objective of delivering burner designs that are ready for demonstration. In order to achieve these objectives established methods for R&D in combustion research are used: • Proof of the concept by experimental investigations at bench scale • Modelling and simulation to provide suitable tools for up-scaling the burners and designing suitable boilers. • Pilot scale testing of the scaled up burners • Design of industrial applications and assessment of the feasibility of the new technology Partners Organization Country Responsible UNIVERSITAET STUTTGART DEUTSCHLAND Ms Anja SCHUSTER (Project Coord.) ELECTRICITE DE France FRANCE Dr. Pierre PLION ELEKTROWNIA OPOLE SA POLAND M.Sc. Edward KINAL INSTYTUT ENERGETYKI POLAND Dr.Eng. Tomasz GOLEC INSTITUT NATIONAL DES SCIENCES APPLIQUEES DE ROUE FRANCE Dr. David HONORE DOOSAN BABCOCK ENERGY LTD UNITED KINGDOM Mr Gerard HESSELMANN NATIONAL TECHNICAL UNIVERSITY OF ATHENS HELLAS Prof. Emmanouil KAKARAS RHEINISCH-WESTFÄLISCHE TECHNISCHE HOCHSCHULE AA DEUTSCHLAND Prof. Dr.-Ing. Reinhold KNEER WS WÄRMEPROZESSTECHNIK GmbH DEUTSCHLAND Dr. Joachim G. WÜNNING

RFCR-CT-2006-00006 ABETRAP

Full Title Abatement of emissions of trace pollutants by FGD from co-combustion and environmental characteristics of by- products Info Type of Project Research Duration (months) 36 Total Budget 2324489 € Start Date 1/07/2006 EU Contribution 1394693 € End Date (actual) 30/06/2009 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA25083:EN Summary The project focuses on three main topics: a) The assessment of the environmental characteristics of all the solid residues (ash, slag or FGD gypsum) produced in power plants burning coal alone or coal combined with other secondary fuel, taking into account the 2003/33/CE Directive on waste disposal recently put in force. According to this standard, the classification of several combustion by-products traditionally treated (disposed) as an inert or non-hazardous waste or with industrial applications in many EU member states, will have to be revised; b) The evaluation of the abatement capacity for trace pollutant emissions of wet FGD facilities, also trying new additives, and c) the leachability of these pollutants from the end by- product, studying if necessary possible remediation actions in order to facilitate the reuse of the FGD gypsum. The study is carried out in several EU power plants under (co-) combustion strategies equipped with FGD facilities. In addition, the project can also be useful in relation to the advent of new emission regulations in coal power plants. Partners Organization Country Responsible ENDESA GENERACION SA ESPAÑA Dr. Juan Carlos BALLESTEROS APARICIO (Project Coord.) CENTRE FOR RESEARCH AND TECHNOLOGY HELLAS HELLAS Dr. Nikolaos KOUKOUZAS AGENCIA ESTATAL CONSEJO SUPERIOR DE INVESTIGACIO ESPAÑA Dr. Xavier QUEROL KEMA NEDERLAND BV NEDERLAND Dr. Rudolf MEIJ THE UNIVERSITY OF NOTTINGHAM UNITED KINGDOM Dr. Mercedes MAROTO-VALER UNIVERSIDAD DE SEVILLA ESPAÑA Prof. Constantino FERNANDEZ PEREIRA

RFCR-CT-2006-00007 FriendlyCoal

Full Title Cost effective and environmental friendly oxyfuel combustion of hard coals Info Type of Project Research Duration (months) 36 Total Budget 2364382 € Start Date 1/07/2006 EU Contribution 1418630 € End Date (actual) 30/06/2009 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA25000:EN Summary The FriendlyCoal proposal focuses on advanced boiler concepts for CO2-free hard coal fired power plants with oxyfuel technology. The main challenge of this technology is the high combustion temperature from the combustion with pure oxygen. The commonly discussed concept to overcome this problem is the recirculation of significant amounts of CO2. The focus of this project is to compare this commonly discussed concept with a newly invented concept - the inversely staged combustion. The project includes the burner and boiler design for an 300 MWth hard coal fired power plant and in particular the testing of a newly design 3 MW burner. Partners Organization Country Responsible TECHNISCHE UNIVERSITAET MUENCHEN DEUTSCHLAND Prof. Dr.-Ing. Hartmut SPLIETHOFF (Project Coord) AE&E AUSTRIA GmbH & CoKG OESTERREICH Dr. Paul RENETZEDER DANMARKS TEKNISKE UNIVERSITET DANMARK Prof. Anker DEGN JENSEN ENEL INGEGNERIA E RICERCA S.p.A. ITALIA Ing. Giancarlo BENELLI SIEMENS AG DEUTSCHLAND Dr.-Ing. Joachim FRANKE TECHNISCHE UNIVERSITAET GRAZ OESTERREICH Dr. Ulrich HOHENWARTER

47 Summaries of RFCS projects 2003-2012 TGC3 : Coal combustion, clean and efficient coal technologies, CO2 capture

RFCR-CT-2006-00008 CLEAN SELECTIVE

Full Title Intelligent monitoring and selective cleaning control of deposits in pulverised coal boilers Info Type of Project Research Duration (months) 36 Total Budget 2073614 € Start Date 1/07/2006 EU Contribution 1244169 € End Date (actual) 30/06/2009 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA25084:EN Summary The scientific objective of this proposal is to develop an integrated On-line tool to locally monitor and detect slagging and fouling in the whole boiler including convective and radiative part in order to allow selective cleaning of the heat exchangers. The main elements of the integrated tool will be: • Utilisation of process data like flow rates, temperatures etc. of the power plant, existing signals of the heat flux sensors of the Teruel power station (Spain) and acoustic pyrometry measurements of the furnace exit temperature (distribution) • New fouling sensors for convective heat exchangers • 3-dimensional CFD-modelling of the combustion, fluid flow and heat transfer in the radiative and convective heat exchangers of the boiler and calculation of ash deposition to indicate areas of ash deposition • Combination of the CFD-modelling with thermodynamic modelling of the water steam cycle Partners Organization Country Responsible TECHNISCHE UNIVERSITAET MUENCHEN DEUTSCHLAND Prof. Dr.-Ing. Hartmut SPLIETHOFF (Project Coord) CENTRE FOR RESEARCH AND TECHNOLOGY HELLAS HELLAS Dr. Nikolaos KOUKOUZAS FUNDACION CIRCE- CENTRO DE INVESTIGACION DE RECU ESPAÑA Dr. Cristobal CORTES GRACIA CLYDE BERGEMANN GmbH MASCHINEN UND APPARATEB DEUTSCHLAND Dipl.-Ing. Stephan SIMON ENERGY RESEARCH CENTRE OF THE NETHERLANDS NEDERLAND Dr. Ir. Rob KORBEE ENDESA GENERACION SA ESPAÑA Dr. Juan Carlos BALLESTEROS APARICIO

RFCR-CT-2006-00009 OxyBurner

Full Title Development of advanced large scale low NOx oxy-fuel burner for PF combustion Info Type of Project Research Duration (months) 36 Total Budget 1444391 € Start Date 1/07/2006 EU Contribution 866634 € End Date (actual) 30/06/2009 State Research completed, report published on EU Bookshop at (link not yet available) Summary A promising technology for improvement of use of coal as a clean energy source and CO2 capture is Oxy-Fuel Combustion. Important research activities in this field are in progress. However, works performed so far has mainly dealt with investigations on process feasibility, its potential contribution to CO2 reduction and process optimisation. Detailed investigations on burner design are lacking. Proposed project therefore seeks to develop an advanced low NOx oxy-fuel burner concept for Lignite and Sub-Bituminous Coals, which is economic, efficient and clean. Results from proposed 30 MW oxy-fuel plant of Vattenfall will also be available for up- scaling the burner concept. Partners Organization Country Responsible UNIVERSITAET STUTTGART DEUTSCHLAND Mr Jörg MAIER (Project Coord.) L'AIR LIQUIDE SA FRANCE Mrs Emmanuelle BROMET ALSTOM POWER SYSTEMS GmbH DEUTSCHLAND Dipl.-Ing. Frank KLUGER NATIONAL TECHNICAL UNIVERSITY OF ATHENS HELLAS Prof. Emmanouil KAKARAS VATTENFALL EUROPE GENERATION AG & CO. KG DEUTSCHLAND Mr Norbert JENTSCH

RFCR-CT-2006-00010 BOFCom

Full Title Application of the biomass, oxyfuel and flameless combustion for the utilisation of pulverised coals for electricity generation Info Type of Project Research Duration (months) 42 Total Budget 1622372 € Start Date 1/07/2006 EU Contribution 973423 € End Date (actual) 31/12/2009 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA25128:EN Summary This project will combine the three most advantageous new technologies for the future reduction of CO2 emissions from pulverized coal fuel fired power plants and simultaneously maintain high efficiencies and low emissions and be able to use a wide variety of (European) coals. These three techniques include the combination of Biomass-Oxyfuel-Flameless Combustion. Biomass co-firing has a CO2 neutral characterisitic, Oxy-Coal firing plus flue gas recirculation will result in increased flue gas CO2 levels which can more easily be separated and sequestrated and Flameless Combustion has the advantage of extremely high efficiencies in combination with uniform heat transfer and very low emissions. A combination of these three technologies, especially for coal, has not been investigated before. Partners Organization Country Responsible ENERGY RESEARCH CENTRE OF THE NETHERLANDS NEDERLAND Ir. Willem VAN DE KAMP (Project Coord.) INSTYTUT ENERGETYKI POLAND Dr.Eng. Tomasz GOLEC INSTITUTO SUPERIOR TECNICO PORTUGAL Dr. Joao TOSTE AZEVEDO RWE NPOWER PLC UNITED KINGDOM Dr. Michael WHITEHOUSE TECHNISCHE UNIVERSITAET CLAUSTHAL DEUTSCHLAND Prof. Dr.-Ing. Roman WEBER

48 Summaries of RFCS projects 2003-2012 TGC3 : Coal combustion, clean and efficient coal technologies, CO2 capture

RFCR-CT-2007-00007 MERCURYCAP

Full Title High capacity sorbents and optimization of existing pollution control technologies for mercury capture in industrial combustion systems Info Type of Project Research Duration (months) 36 Total Budget 2479480 € Start Date 1/10/2007 EU Contribution 1487687 € End Date (actual) 30/09/2010 State Research completed, report published on EU Bookshop at (link not yet available) Summary This proposal addresses the global problem of mercury (Hg) emissions from coal-fired plants and the current position of conventional air pollution control devices (APCDs) only providing partial solution for oxidized Hg capture, particularly for low-rank coals. Our previous work has shown that (1) low-cost gasification chars have superior mercury capture performance than current benchmark carbons; and (2) manganese oxide compounds sorb mercury and also act as catalysts to promote mercury oxidation, that can then be subsequently captured in existing APCDs. Accordingly, the two-fold objective is to further develop low-cost injection sorbents, and maximize mercury oxidation and its subsequent capture in existing APCDs. Fundamental studies will be followed by extensive testing in pilot and full scale systems to evaluate the performance of the developed materials under actual plant conditions. Partners Organization Country Responsible THE UNIVERSITY OF NOTTINGHAM UNITED KINGDOM Dr. Mercedes MAROTO-VALER (Project Coord.) CENTRO DE INVESTIGACIONES ENERGÉTICAS MEDIOAMBI ESPAÑA Dr. Alberto BAHILLO AGENCIA ESTATAL CONSEJO SUPERIOR DE INVESTIGACIO ESPAÑA Dr. M. Rosa MARTINEZ-TARAZONA ENERGY RESEARCH CENTRE OF THE NETHERLANDS NEDERLAND Dr. Ir. Jacob H.A. KIEL ENEL INGEGNERIA E RICERCA S.p.A. ITALIA Dr.-Ing. Gennaro DE MICHELE HULLERAS DEL NORTE, S.A. ESPAÑA Mr Luis DIAZ FERNANDEZ JOHNSON MATTHEY PLC UNITED KINGDOM Dr. Dave THOMPSETT UNIVERSITAET STUTTGART DEUTSCHLAND Dipl.-Ing. Kevin BRECHTEL

RFCR-CT-2007-00008 DENOPT

Full Title Optimisation of SCR-DeNOx catalyst performance related to deactivation and mercury oxidation Info Type of Project Research Duration (months) 36 Total Budget 1887164 € Start Date 1/07/2007 EU Contribution 1061839 € End Date (actual) 30/06/2010 State Research completed, report published on EU Bookshop at (link not yet available) Summary DENOPT addresses the topic “Efficient protection of the environment and improvement of coal as clean energy source” focusing on the improvement of SCR DeNOx performance related to deactivation and mercury oxidation. The goal of the project is to develop novel catalyst materials and improve regeneration processes to reduce ammonia consumption and improve catalyst lifetime. In parallel it is aimed to improve mercury oxidation to achieve an overall mercury removal rate higher than 90% incorporating a multi pollutant control strategy combining SCR, ESP and FGD. Furthermore a 3D-CFD model will be developed predicting NOx reduction, mercury oxidation and being sensitive to catalyst deactivation. Partners Organization Country Responsible UNIVERSITAET STUTTGART DEUTSCHLAND Dipl.-Ing. Kevin BRECHTEL (Project Coord.) ENBW KRAFTWERKE AG DEUTSCHLAND Dr. Sven UNTERBERGER ENEL INGEGNERIA E RICERCA S.p.A. ITALIA Dr.-Ing. Gennaro DE MICHELE E.ON NEW BUILD & TECHNOLOGY GmbH DEUTSCHLAND Dipl.-Ing. Jürgen BRANDENSTEIN PORZELLANFABRIK FRAUENTHAL GMBH OESTERREICH Dipl.-Ing. Kurt OREHOVSKY RECOM SERVICES GMBH DEUTSCHLAND Dr. Xiaohai HAN REACTION ENGINEERING INTERNATIONAL USA Dr. Constance SENIOR

RFCR-CT-2007-00009 ECO-Scrub

Full Title Enhanced capture with oxygen for scrubbing of CO2 Info Type of Project Research Duration (months) 39 Total Budget 2591775 € Start Date 1/07/2007 EU Contribution 1555064 € End Date (actual) 30/09/2010 State Research completed, report published on EU Bookshop at (link not yet available) Summary The project aims to develop a scheme for retrofitting carbon capture to existing boilers. It uses a novel combination of techniques employed in conventional CO2 capture, such as oxygen enrichment and post-combustion solvent scrubbing, together with measures to increase efficiency, reduce steam consumption and generate power requirements without significantly reducing net boiler electricity generating capacity. The project inlcudes development of the process, module integration and optimisation for a range of plant types and fuels. Fundamental studies also address many issues relevant to conventional capture, so the fundamental work has wide applicability to new plant and extends ongoing carbon capture research. Partners Organization Country Responsible RWE NPOWER PLC UNITED KINGDOM Dr. Gerry RILEY (Project Coord.) ARTISTOTLE UNIVERSITY OF THESSALONIKI HELLAS Prof. George SAKELLAROPOULOS CENTRE FOR RESEARCH AND TECHNOLOGY HELLAS HELLAS Dr. Panagiotis GRAMMELIS AGENCIA ESTATAL CONSEJO SUPERIOR DE INVESTIGACIO ESPAÑA Mr José Manuel ANDRES GIMENO ENERGY RESEARCH CENTRE OF THE NETHERLANDS NEDERLAND Ir. Willem VAN DE KAMP PUBLIC POWER CORPORATION S.A. HELLAS Dipl.-Ing. Leandros GEORGOULIS RWE POWER AG DEUTSCHLAND Dr. Matthias KRUMBECK UNIVERSITY OF LEEDS UNITED KINGDOM Dr. Bernard GIBBS

49 Summaries of RFCS projects 2003-2012 TGC3 : Coal combustion, clean and efficient coal technologies, CO2 capture

RFCR-CT-2008-00009 SMARTBURN

Full Title Intelligent control and optimisation of power station boilers firing pulverised coal and coal/biomass blends Info Type of Project Research Duration (months) 36 Total Budget 1467226 € Start Date 1/07/2008 EU Contribution 880337 € End Date (actual) 30/06/2011 State Research technically completed; publication in hand Summary This proposal is concerned with the development of innovating, monitoring control and optimisation systems to improve the performance of burners and boilers fired by pulverised coal and coal/biomass blends. As a consequence CO2, NOx and SO2 emissions will be reduced and the project will also enhance the ability of utility boilers to burn coal/biomass mixtures. The proposed systems are: - A system for monitoring and control of individual burners using low cost sensors and artificial intelligence. - A combustion optimisation system for an arch-fired boiler using 'local' automatic gas sampling systems. - Optimisation of a flue gas desulphurisation plant. Partners Organization Country Responsible UNIVERSITY OF GLAMORGAN UNITED KINGDOM Prof. Steven WILCOX (Project Coord.) GAS NATURAL SDG ESPAÑA Mr Jesús María GONZALEZ GARCÍA INSTYTUT ENERGETYKI POLAND Dr.Eng. Tomasz GOLEC INDRA SISTEMAS SA ESPAÑA MSc. Ana Isabel GALVEZ UNIVERSIDAD DE ZARAGOZA ESPAÑA Prof. Javier BALLESTER CASTANER

RFCR-CT-2009-00005 OXYCORR

Full Title Boiler corrosion under oxy-fuel conditions Info Type of Project Research Duration (months) 36 Total Budget 1956218 € Start Date 1/09/2009 EU Contribution 1173730 € End Date (actual) 31/08/2012 State Research in progress Summary Oxy-fuel combustion is a promising technology for improvement of coal utilisation as a clean energy source and for CO2 capture. Works performed so far have dealt with investigations on process feasibility and optimisation. Combustion in O2/recycled flue gas (RFG) atmosphere has the following consequence: higher concentrations of CO, SO2/SO3, HCl and fine particles inside the furnace, thus higher corrosion potential. Henceforth the proposed project aims at determining critical corrosion parameters during oxy-coal combustion, investigation of high and low temperature corrosion, characterization of fly ash produced in the process and its deposition on plant elements as well as results assessment for highly efficient (600 – 700°C- range steam temperature) full-scale application. Partners Organization Country Responsible UNIVERSITAET STUTTGART DEUTSCHLAND Mr Jörg MAIER (Project Coord.) ALSTOM BOILER DEUTSCHLAND GmbH DEUTSCHLAND Dipl.-Ing. Frank KLUGER ENEL INGEGNERIA E RICERCA S.p.A. ITALIA Dr. Eng. Nicola ROSSI SWEREA KIMAB AB SVERIGE Mr Peter VIKLUND OUTOKUMPU STAINLESS AB SVERIGE Dr. Rachel PETTERSSON VATTENFALL RESEARCH AND DEVELOPMENT AB SVERIGE Dr. Pamela HENDERSON

RFCR-CT-2010-00011 CARINA

Full Title Carbon capture by means of indirectly heated carbonate looping process Info Type of Project Research Duration (months) 42 Total Budget 2458416 € Start Date 1/07/2010 EU Contribution 1475050 € End Date (actual) 31/12/2013 State Research in progress Summary Standard carbonate looping promises low energy penalties for post-combustion CO2-capture and is particularly suited for retrofitting existing power plants. The heat for calcination can be provided by supplementary coal firing with oxygen leading to energy penalties and additional investment costs for air separation. The objective of this project is to investigate and test a new concept with an indirectly heated calciner using heat pipes, offering even higher plant efficiency and lower CO2 avoidance costs than the oxy-fired standard carbonate looping process. The work programme includes design of the heat exchanger system with heat pipes, process cycle calculations, testing in 1MWth scale, and up-scaling studies for real plants. Partners Organization Country Responsible TECHNISCHE UNIVERSITÄT DARMSTADT DEUTSCHLAND Prof. Bernd EPPLE (Project Coord.) FISIA-BABCOCK ENVIRONMENT GMBH DEUTSCHLAND Dr.-Ing. Ulrich PRIESMEIER GROSSKRAFTWERK MANNHEIM AG DEUTSCHLAND Dr.-Ing. Karl-Heinz CZYCHON HIGHTERM RESEARCH GMBH DEUTSCHLAND Dr. Andreas SCHWEIGER LHOIST RECHERCHE ET DEVELOPPEMENT SA BELGIQUE Dr. Thierry CHOPIN TECHNISCHE UNIVERSITAET GRAZ OESTERREICH Dipl.-Ing. Christoph BAUMHAKL FRIEDRICH-ALEXANDER UNIVERSITAT DEUTSCHLAND Prof. Dr.-Ing. Jürgen KARL

50 Summaries of RFCS projects 2003-2012 TGC3 : Coal combustion, clean and efficient coal technologies, CO2 capture

RFCR-CT-2010-00012 DEVCAT

Full Title Development of high performance SCR-catalysts related to different fuel types Info Type of Project Research Duration (months) 36 Total Budget 2359856 € Start Date 1/07/2010 EU Contribution 1415913 € End Date (actual) 30/06/2013 State Research in progress Summary The DEVCAT proposal addresses the topic of “technological improvements targeting enhanced efficiency of coal fired power plants” related to an efficient reduction of NOx-, SO3- and Hgemissions. The goal of the project is to develop special SCR-DeNOx-catalysts for coal, bio-fuel and co-combustion with respect on efficient NOx-reduction, high mercury oxidation and low SO2- SO3-conversion. Therefore based on the further development of existing catalyst technology, innovative catalyst designs for bio-fuel applications or the use of nano-technology is applied. With respect to modified SCR-technology, also the effect on downstream air pollution control devices like FGD systems is investigated. Furthermore a 3D-CFD model is used and improved for the modelling of the SCR-system. Partners Organization Country Responsible UNIVERSITAET STUTTGART DEUTSCHLAND Dipl.-Ing. Barna HEIDEL (Project Coord.) ENBW KRAFTWERKE AG DEUTSCHLAND Dr. Harald THORWARTH ENEL INGEGNERIA E RICERCA S.p.A. ITALIA Ing. Sauro PASINI E.ON NEW BUILD & TECHNOLOGY GmbH DEUTSCHLAND Dipl.-Ing. Jürgen BRANDENSTEIN PORZELLANFABRIK FRAUENTHAL GMBH OESTERREICH Dipl.-Ing. Kurt OREHOVSKY RECOM SERVICES GMBH DEUTSCHLAND Dr. Xiaohai HAN

RFCR-CT-2010-00013 CAL-MOD

Full Title Modelling and experimental validation of calcium looping CO²-capture process for near-zero CO²-emission power plants Info Type of Project Research Duration (months) 36 Total Budget 2007455 € Start Date 1/10/2010 EU Contribution 1204473 € End Date (actual) 30/09/2013 State Research in progress Summary The Calcium Looping (CaL) process is a post-combustion CO2 capture route. This project aims to develop advanced simulation tools for industrial process application. Issues of sorbent attrition, sulphation and reactivation are assessed. Kinetic parameters are incorporated to a sorbent model, providing the basis for the CFD carbonator, regenerator models. CFD models are validated against bench-scale experimentation results. Their input will be used for a process and steam cycle model regarding reference plants and leading to design rules. Synergy with the cement industry is beneficial. A techno-economic analysis and basic engineering of such systems will bring the process close to commercialization. Partners Organization Country Responsible UNIVERSITAET STUTTGART DEUTSCHLAND Dipl.-Ing. Mariusz ZIEBA (Project Coord.) CENTRE FOR RESEARCH AND TECHNOLOGY HELLAS HELLAS Dr. Panagiotis GRAMMELIS CONSIGLIO NAZIONALE DELLE RICERCHE ITALIA Dr. Riccardo CHIRONE ENBW KRAFTWERKE AG DEUTSCHLAND Dr. Sven UNTERBERGER ENEL INGEGNERIA E RICERCA S.p.A. ITALIA Dr. Cristiana LA MARCA TITAN CEMENT COMPANY AE HELLAS Mr Emmanuel CHANIOTAKIS POLITECHNIKA WROCLAWSKA - WROCLAW UNIVERSITY O POLAND Prof. Halina PAWLAK KRUCZEK

RFCR-CT-2011-00004 DCFC

Full Title Efficient conversion of coal to electricity - direct coal fuel cells Info Type of Project Research Duration (months) 36 Total Budget 2030301 € Start Date 1/07/2011 EU Contribution 1218181 € End Date (actual) 30/06/2014 State Research in progress Summary Direct electrochemical conversion of coal to electricity offers very significant increases in efficiency with consequent reductions in CO2 emissions coupled with facilitated sequestration possibilities. Our recent laboratory tests have shown that Direct Carbon Fuel Cells (DCFC) can exceed commercial MCFC performance levels. Here we seek to apply DCFC technologies to coal conversion. We will develop these coal DCFCs increasing scale, improving cell design, seeking new active and conductive structure and surface promoted catalysts, addressing durability, investigating coal source and optimising coal processing for this application. Performance will be evaluated throughout the project and recommendations made for a commercial-scale demonstrator. Partners Organization Country Responsible THE UNIVERSITY COURT OF THE UNIVERSITY OF ST ANDRE UNITED KINGDOM Prof. John IRVINE (Project Coord.) AGENCIA ESTATAL CONSEJO SUPERIOR DE INVESTIGACIO ESPAÑA Dr. Ana ARENILLAS DANMARKS TEKNISKE UNIVERSITET DANMARK Dr. Peter HOLTAPPELS PANEPISTIMIO DYTIKIS MAKEDONIAS - UNIVERSITY OF WE HELLAS Prof. George MARNELLOS

51 Summaries of RFCS projects 2003-2012 TGC3 : Coal combustion, clean and efficient coal technologies, CO2 capture

RFCR-CT-2011-00005 FLOX-COAL-II

Full Title Development of scale-up methodology and simulation tools for the demonstration of PC-FLOX burner technology in full-scale utility boilers Info Type of Project Research Duration (months) 36 Total Budget 2690872 € Start Date 1/07/2011 EU Contribution 1614524 € End Date (actual) 30/06/2014 State Research in progress Summary This project aims to develop a scale-up methodology and simulation tools which are required for the implementation of Pulverised- Coal Flameless Oxidation (PC-FLOX) burners in utility plants. Substantial pilot (0.5 MWth) experimental investigation will be the backbone in order to support the development and validation of scale-up methodology and CFD FLOX-specific sub-models. To develop simulation tools, these CFD FLOX-specific sub-models will be integrated into commercial CFD codes. A CFD modelling, experimental results and industrial partners’ expertise will lead to the development of the scale-up methodology for full-scale PC- FLOX burners. A CFD study and techno-economic analysis of utility plants operated with PC-FLOX burners will be carried out. Partners Organization Country Responsible UNIVERSITAET STUTTGART DEUTSCHLAND Dipl.-Ing. Mariusz ZIEBA (Project Coord.) DOOSAN POWER SYSTEMS LTD UNITED KINGDOM Mr Greg SIMS ENBW KRAFTWERKE AG DEUTSCHLAND Dr. Sven UNTERBERGER INSTYTUT ENERGETYKI POLAND Dr. Bartosz SWIATKOWSKI INSTITUT NATIONAL DES SCIENCES APPLIQUEES DE ROUE FRANCE Dr. David HONORE PGE GORNICTWO I ENERGETYKA KONWENCJONALNA SA POLAND Dr. Inz. Krzysztof FUZOWSKI RHEINISCH-WESTFÄLISCHE TECHNISCHE HOCHSCHULE AA DEUTSCHLAND Prof. Dr.-Ing. Reinhold KNEER WS WÄRMEPROZESSTECHNIK GmbH DEUTSCHLAND Dr. Joachim G. WÜNNING

RFCR-CT-2012-00008 RECaL

Full Title Novel calcium looping CO2 capture process incorporating sorbent reactivation by recarbonation Info Type of Project Research Duration (months) 36 Total Budget 2697943 € Start Date 1/07/2012 EU Contribution 1618765 € End Date (actual) 30/06/2015 State Research in progress Summary This project will develop a new sorbent regeneration technique for postcombustion Calcium Looping CO2 capture systems, that could reduce to near zero the net sorbent requirements and further reduce operating cost and energy penalties. The novel method (patent application in 2011) is based on the re- carbonation of carbonated particles with pure CO2, and the use of solids purges for flue gas desulfurization. An intense R&D programme is proposed to close existing gaps of knowledge, design, build and test the concept in an existing large calcium looping pilot (1.7MWt) as well as to conduct process simulation and economic estimations at large scale. Partners Organization Country Responsible ENDESA GENERACION SA ESPAÑA Mr Andrés SANCHEZ-BIEZMA SACRISTAN (Pr. Coord.) AGENCIA ESTATAL CONSEJO SUPERIOR DE INVESTIGACIO ESPAÑA Dr. Juan Carlos ABANADES GARCIA HULLERAS DEL NORTE, S.A. ESPAÑA Mr Luis DIAZ FERNANDEZ THE CHANCELLOR, MASTERS AND SCHOLARS OF THE UNIV UNITED KINGDOM Dr. John DENNIS UNIVERSITAET STUTTGART DEUTSCHLAND Dipl.-Ing. Mariusz ZIEBA

52

Technical Group Steel 1

Ore agglomeration and ironmaking

The scope of TGS1 includes:

• Ore agglomeration, sintering and pelletising processes

• New and improved iron-ore reduction processes (including DRI & C-free reduction)

• Ironmaking processes and operations including slag treatment

• Standardisation of testing and evaluation methods

• Maintenance and reliability of production lines

• Reduction of emissions, energy consumption and improvement of the environmental impact

• Instrumentation, modelling and control of processes

53 54 Summaries of RFCS projects 2003-2012 TGS1 : Ore agglomeration and Ironmaking

RFSP-CT-2006-00001 IDEOGAS

Full Title Industrial demonstration of hot gas injection at the blast furnace Info Type of Project Pilot&Demonstration Duration (months) 64 Total Budget 4511967 € Start Date 1/03/2006 EU Contribution 1359570 € End Date (actual) 30/06/2011 State Research technically completed; publication in hand Summary This proposal is part of the ULCOS Program and is focused on carbon saving at the blast furnace with an objective of 25%. It aims at testing at a real blast furnace (EKO Stahl BF1) nitrogen-free operation and hot reducing gas injection into the shaft. The objectives are: - optimise the gas flow rate injected at the wall and its distribution inside the shaft - assess the furnace behaviour under these conditions (thermal control, raceway formation, cohesive zone, pressure field, hearth, coke quality damages) - assess the productivity increase of nitrogen-free operation - demonstrate high rates of natural gas at the blast furnace. Partners Organization Country Responsible ARCELORMITTAL MAIZIERES RESEARCH S.A. FRANCE Mr Dominique SERT (Project Coord.) AKTIEN-GESELLSCHAFT DER DILLINGER HÜTTENWERKE AG DEUTSCHLAND Dr.-Ing. Rongshan LIN ARCELORMITTAL EISENHÜTTENSTADT GmbH DEUTSCHLAND Dr.-Ing. Jörg HUNGER CENTRE DE RECHERCHES METALLURGIQUES ASBL BELGIQUE Mr Gérard DANLOY ILVA S.P.A. ITALIA Dr.-Ing. Vincenzo DIMASTROMATTEO LUOSSAVAARA-KIIRUNAVAARA AB (LKAB) SVERIGE Mr Peter SIKSTRÖM RAUTARUUKKI OYJ FINLAND Dr. Lawrence HOOEY TATA STEEL NEDERLAND TECHNOLOGY BV NEDERLAND Ir. Jan van der STEL THYSSENKRUPP STEEL EUROPE AG DEUTSCHLAND Dr. Bernd KORTHAS VOESTALPINE STAHL GMBH OESTERREICH Dipl.-Ing. Thomas BÜRGLER

RFSR-CT-2003-00013 ENHANCED BF OPERATION

Full Title Enhanced blast furnace operation and service life by improved monitoring and control of the hearth and uniformity Info Type of Project Research Duration (months) 42 Total Budget 2315055 € Start Date 1/09/2003 EU Contribution 1389033 € End Date (actual) 28/02/2007 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA23455:EN Summary The evaluation of various blast furnace measurement data will be improved, to enhance life, monitoring and control of hearth and uniformity. Therefore a set of novel and ingenious techniques will be developed, verified and applied. Blast furnace stability, more uniform metal quality and a lower fuel rate will be achieved by the investigation of symmetric operation. Combined with the analysis of the blast furnace hearth and dead man, this will lead to a protection of the refractory lining, the prolongation of the blast furnace’s life and optimised tapping echniques. Productivity, safety, security and environmental aspects will be raised additionally. Partners Organization Country Responsible VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Dr. rer. nat. Günter HARP (Project Coord.) ABO AKADEMI UNIVERSITY FINLAND Prof. Henrik SAXEN AKTIEN-GESELLSCHAFT DER DILLINGER HÜTTENWERKE AG DEUTSCHLAND Dr.-Ing. Rongshan LIN ARCELORMITTAL ESPAÑA SA ESPAÑA Mr Diego CARRASCAL ARCELORMITTAL MAIZIERES RESEARCH S.A. FRANCE Mr Dominique SERT AGENCIA ESTATAL CONSEJO SUPERIOR DE INVESTIGACIO ESPAÑA Dr. Javier MOCHON MUÑOZ RAUTARUUKKI OYJ FINLAND Ms Päivi MANNILA TATA STEEL UK LIMITED UNITED KINGDOM Dr. George CLIXBY

RFSR-CT-2004-00001 MEMORACE

Full Title Improvement of the raceway monitoring under modern blast furnace operating conditions Info Type of Project Research Duration (months) 45 Total Budget 1256925 € Start Date 1/07/2004 EU Contribution 754155 € End Date (actual) 31/03/2008 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA24388:EN Summary The functioning of the raceway presently appears as the limiting factor for the increase of the coal injection rate at the blast furnace. In order to further reduce the coke rate by 15 to 20 kg/thm with reference to the best results presently obtained in Europe, this project aims at investigating the impact of the coal injection on the raceway behaviour, and on the corresponding gas distribution within the furnace. With this objective, new measuring techniques will be developed and/or implemented in order to measure the raceway characteristics on one side, and to enable the control of the injection condition per tuyere on the other side. These techniques will be applied on actual blast furnaces for the examination of the raceway behaviour under high PCI operation. They will also be used for the investigation of the raceway functioning on physical models and at pilot scale under coal (and other reducing agents) injection conditions. The obtained results will be implemented in a mathematical model of the heat exchanges in the raceway. Partners Organization Country Responsible ARCELORMITTAL MAIZIERES RESEARCH S.A. FRANCE Dr. Eric LECTARD (Project Coord.) AGENCIA ESTATAL CONSEJO SUPERIOR DE INVESTIGACIO ESPAÑA Mr Alberto ISIDRO SWEREA MEFOS AB SVERIGE Mr Pär HAHLIN RHEINISCH-WESTFÄLISCHE TECHNISCHE HOCHSCHULE AA DEUTSCHLAND Prof.Dr.-Ing. Dieter G. SENK

55 Summaries of RFCS projects 2003-2012 TGS1 : Ore agglomeration and Ironmaking

RFSR-CT-2004-00002 COKARAC

Full Title New characterisation test of the coke behaviour at high temperatures Info Type of Project Research Duration (months) 42 Total Budget 1250249 € Start Date 1/07/2004 EU Contribution 750150 € End Date (actual) 31/12/2007 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA23748:EN Summary The behaviour of coke in the blast furnace is still a main concern. However, the tests currently available for coke characterization do not correctly reflect the actual stresses suffered by coke in the blast furnace. The objective of the project consists in the setup of new laboratory tests to characterize the coke behaviour at high temperature under blast furnace conditions. The validity of these tests will be demonstrated by comparing the characteristics of the cokes resulting from the tests with the cokes sampled at the blast furnace tuyeres. The tests will be designed in order to allow the ironmaking industry to better characterize coke quality on a routine basis. Partners Organization Country Responsible CENTRE DE RECHERCHES METALLURGIQUES ASBL BELGIQUE Mr Gérard DANLOY (Project Coord.) ARCELORMITTAL MAIZIERES RESEARCH S.A. FRANCE Dr. Eric HESS TATA STEEL NEDERLAND TECHNOLOGY BV NEDERLAND Mr Bart van der VELDEN THYSSENKRUPP STEEL EUROPE AG DEUTSCHLAND Dr.-Ing. Klaus MÜLHEIMS

RFSR-CT-2004-00003 ECONOSOX

Full Title Modelling the pollutants formation and behaviour during sintering of iron ores Info Type of Project Research Duration (months) 42 Total Budget 868384 € Start Date 1/07/2004 EU Contribution 521031 € End Date (actual) 31/12/2007 State Research completed, report published on EU Bookshop at (link not yet available) Summary A mathematical model able to predict the CO, NOx and SOx emissions in different sintering lay-outs will be developed. This will provide ironmaking companies with a useful tool for environmental optimisations of the sintering conditions, but also for evaluating the environmental and sintering performances of different concepts (like EOS or Top-Layer Sintering) when applied to their own working conditions. The necessary basic knowledge not yet available will be acquired by laboratory or sinter pot experiments. The model will be calibrated/validated by comparing its calculated emissions with the ones measured as well in pot trials as in different sinter plants. Partners Organization Country Responsible CENTRE DE RECHERCHES METALLURGIQUES ASBL BELGIQUE Mr Bernard VANDERHEYDEN (Project Coord.) ARCELORMITTAL MAIZIERES RESEARCH S.A. FRANCE Mr Philippe RUSSO VOESTALPINE STAHL DONAWITZ GmbH & Co KG OESTERREICH Mr Wolfgang SCHWEIGER

RFSR-CT-2004-00004 MEORU

Full Title Minimising environmental emissions by optimised reductant utilisation Info Type of Project Research Duration (months) 42 Total Budget 1796006 € Start Date 1/07/2004 EU Contribution 1077603 € End Date (actual) 31/12/2007 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA24995:EN Summary The project seeks to minimise the environmental emissions of blast furnace operation by measuring and controlling the products of incomplete combustion of hydrocarbon injectants. The quantity and source of carbonaceous carryover materials in top gas dust will be evaluated and related to key blast furnace operating parameters. Laboratory, pilot and plant scale investigations will be carried out to support the development of new techniques to quantitatively determine the type and origin of carbon (from coke, char and soot) in carryover materials. Ultimately, on-line monitoring and control of carbon carryover will be achieved to minimise environmental emissions from the process. Partners Organization Country Responsible TATA STEEL UK LIMITED UNITED KINGDOM Dr. Colin J. ATKINSON (Project Coord.) CENTRO SVILUPPO MATERIALI SPA ITALIA Dr. Antonello DI DONATO IMPERIAL COLLEGE OF SCIENCE, TECHNOLOGY AND MEDI UNITED KINGDOM Prof. Rafael KANDIYOTI RAUTARUUKKI OYJ FINLAND Mr Olavi KERKKONEN VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Dr. rer. nat. Günter HARP

RFSR-CT-2004-00005 ULCOS

Full Title ULCOS New Blast Furnace Process Info Type of Project Research Duration (months) 60 Total Budget 8551812 € Start Date 1/07/2004 EU Contribution 5131088 € End Date (actual) 30/06/2009 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA24085:EN Summary The central objective of this project is to develop a new blast furnace process route able to operate with very low CO2-emissions, based on drastically reduced consumption of carbon containing input materials. The programme initially will cover a period of 5 years, starting with mathematical modelling and laboratory as well as technical scale investigations, which are necessary to get a suitable process concept for a CO2 reduced ironmaking process. The results of that work are basis for small scale blast furnace tests which will give the first experimentally proven data for the CO2 reduction potential of the new process as well as process data for a technical process evaluation. The results shall lead to the selection and the base preparatory work for the largesize pilot demonstration unit for the new CO2 reduced ironmaking process, which is objective of a future project. Partners Organization Country Responsible 56 THYSSENKRUPP STEEL EUROPE AG DEUTSCHLAND Ms Alexandra HIRSCH (Project Coord.) AKTIEN-GESELLSCHAFT DER DILLINGER HÜTTENWERKE AG DEUTSCHLAND Dr.-Ing. Rongshan LIN Summaries of RFCS projects 2003-2012 TGS1 : Ore agglomeration and Ironmaking

L'AIR LIQUIDE SA FRANCE Dr. Michel DEVAUX ARCELORMITTAL MAIZIERES RESEARCH S.A. FRANCE Dr. François HANROT CENTRE DE RECHERCHES METALLURGIQUES ASBL BELGIQUE Mr Olivier ANSSEAU ILVA S.P.A. ITALIA Dr.-Ing. Vincenzo DIMASTROMATTEO KÜTTNER GmbH & Co. KG DEUTSCHLAND Dipl.-Ing. Wolfram KÜTTNER LUOSSAVAARA-KIIRUNAVAARA AB (LKAB) SVERIGE Mr Mats HALLIN PAUL WURTH S.A. LUXEMBOURG Dipl.-Ing. Guy THILLEN TATA STEEL NEDERLAND TECHNOLOGY BV NEDERLAND Ir. Jan van der STEL TATA STEEL UK LIMITED UNITED KINGDOM Mr C.R. BENNINGTON SIEMENS VAI TECHNOLOGIES LTD UNITED KINGDOM Mr Michael EDEN VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Dr. rer. nat. Günter HARP VOESTALPINE STAHL GMBH OESTERREICH Dipl.-Ing. Thomas BÜRGLER

RFSR-CT-2005-00001 SHOCOM

Full Title Short term CO² mitigation for steelmaking Info Type of Project Research Duration (months) 36 Total Budget 2402677 € Start Date 1/07/2005 EU Contribution 1441605 € End Date (actual) 30/06/2008 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA24989:EN Summary This proposal aims at lowering the environmental impact of steelmaking, by reducing greenhouse gas emission, and saving energy and natural resources. The expected reduction at short term is around 10% waiting for higher reduction coming from ULCOS results. The means are:  the use of charcoal, a renewable source of carbon, in large blast furnaces, either by addition in the coal blend, or by injection through the tuyeres  the enhancement of coke reactivity, to decrease the reserve zone temperature and the carbon need of the blast furnace  the intensive use of wastes as reductant for the BF, through gasification and injection of the produced gas  the addition of waste plastics into the coal blend. Partners Organization Country Responsible ARCELORMITTAL MAIZIERES RESEARCH S.A. FRANCE Dr. François HANROT (Project Coord.) AGENCIA ESTATAL CONSEJO SUPERIOR DE INVESTIGACIO ESPAÑA Dr.-Ing. Miguel FERNANDEZ RHEINISCH-WESTFÄLISCHE TECHNISCHE HOCHSCHULE AA DEUTSCHLAND Prof.Dr.-Ing. Dieter G. SENK VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Dr. rer. nat. Günter HARP VOESTALPINE STAHL GMBH OESTERREICH Dipl.-Ing. Thomas BÜRGLER

RFSR-CT-2005-00002 DEMPOLIFE

Full Title Determination of factors influencing dead man position and evaluation of its impact on blast furnace life time Info Type of Project Research Duration (months) 42 Total Budget 1991409 € Start Date 1/07/2005 EU Contribution 1194846 € End Date (actual) 31/12/2008 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA24976:EN Summary Relining a blast furnace is a costly affair, due to the actual relining cost and production loss. The campaign life is currently limited by the hearth refractory wear. The objective of this project is to increase that refractory lifespan. Online measurements at the blast furnace will be improved. New models describing the state of the blast furnace hearth will be developed. The dissection of a hearth will be used to validate both models and measurements. This will improve understanding of the wear mechanisms and subsequently lead to better process control and a longer life span of the blast furnace hearth. Partners Organization Country Responsible TATA STEEL NEDERLAND TECHNOLOGY BV NEDERLAND Ir. Jan van der STEL (Project Coord.) ARCELORMITTAL MAIZIERES RESEARCH S.A. FRANCE Dr. Sami-Alex ZAÏMI CENTRE DE RECHERCHES METALLURGIQUES ASBL BELGIQUE Mr Olivier HAVELANGE SWEREA MEFOS AB SVERIGE Dr. Dong Yuan SHENG TATA STEEL NEDERLAND TECHNOLOGY BV - IJMUIDEN TEC NEDERLAND Mr Mark HATTING THYSSENKRUPP STEEL EUROPE AG DEUTSCHLAND Dr.-Ing. H. Peter RÜTHER VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Dr. Oliver MIELENZ

RFSR-CT-2006-00039 Sinter efficiency

Full Title Enhanced sinter efficiency by optimised quality control Info Type of Project Research Duration (months) 42 Total Budget 1751893 € Start Date 1/07/2006 EU Contribution 1051136 € End Date (actual) 31/12/2009 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA25086:EN Summary The overall aim of this research project is to enhance the sinter efficiency by optimisation of the sinter mix homogeneity and permeability based on chemical inline-monitoring and on-strand permeability test devices. One of the two main objectives of the project is the development of an inline-monitoring test device which is able to detect the chemical composition of a sinter raw mix on a conveyor belt in situ. Two different measurement techniques, XRF and PGNAA are investigated in this project The other main objective deals with the development und installation of on-strand permeability measurements. Therefore the pre and post ignition permeability is investigated and compared with each other. Both objectives have in common that the monitoring devices are used to control the sinter process to enhance the sinter quality and productivity. Partners Organization Country Responsible THYSSENKRUPP STEEL EUROPE AG DEUTSCHLAND Dr. Stefan WIENSTRÖER (Project Coord.) TATA STEEL NEDERLAND TECHNOLOGY BV NEDERLAND Dr. Eng Maria MARTINEZ PACHECO VOESTALPINE STAHL DONAWITZ GmbH & Co KG OESTERREICH Dipl.-Ing. Manfred ZAHN VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Dr.-Ing. Thorsten HAUCK

57 Summaries of RFCS projects 2003-2012 TGS1 : Ore agglomeration and Ironmaking

RFSR-CT-2007-00001 Hearth efficiency

Full Title Improvement of hearth drainage efficiency and refractory life for high BF productivity and a well adjusted reductant injection rate at varying coke quality Info Type of Project Research Duration (months) 42 Total Budget 3558656 € Start Date 1/07/2007 EU Contribution 2135194 € End Date (actual) 31/12/2010 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA25121:EN Summary Blast furnace stability and productivity will be improved under the aspects of high reductant injection rates and varying coke qualities. BF lifetime, security and environmental aspects will be raised additionally. To optimise the tapping strategy and to lower the fuel rate, the hearth drainage efficiency will be investigated with a new deadman porosity parameter, innovative non radioactive tracer tests, new radar and ultrasound measurements, novel analysis techniques and upgraded simulations of fluid flows in the hearth. Investigations of thermal stresses in refractory and dissection analyses of revamped hearths will improve lining design for campaign prolongation. The estimated annual savings are up to 0.7 M€/year for each BF in the EU. Partners Organization Country Responsible VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Dr.-Ing. Thorsten HAUCK (Project Coord.) ABO AKADEMI UNIVERSITY FINLAND Prof. Henrik SAXEN AKTIEN-GESELLSCHAFT DER DILLINGER HÜTTENWERKE AG DEUTSCHLAND Dr.-Ing. Rongshan LIN ARCELORMITTAL EISENHÜTTENSTADT GmbH DEUTSCHLAND Dr.-Ing. Jörg HUNGER ARCELORMITTAL ESPAÑA SA ESPAÑA Mr Luis Fernando SANCHO MENDEZ ARCELORMITTAL MAIZIERES RESEARCH S.A. FRANCE Dr. Sami-Alex ZAÏMI AGENCIA ESTATAL CONSEJO SUPERIOR DE INVESTIGACIO ESPAÑA Dr. Javier MOCHON MUÑOZ CENTRO SVILUPPO MATERIALI SPA ITALIA Dr. Eros Luciano FARACI LUCCHINI S.p.A. ITALIA Ing. Antonio GRANATA SWEREA MEFOS AB SVERIGE Dr. Dong Yuan SHENG RAUTARUUKKI OYJ FINLAND Dr. Lawrence HOOEY OULUN YLIOPISTO*UNIVERSITY OF OULU FINLAND Mr Timo FABRITIUS

RFSR-CT-2007-00002 Consistent BF

Full Title Consistent blast furnace operation whilst using low cost raw materials Info Type of Project Research Duration (months) 54 Total Budget 2685901 € Start Date 1/07/2007 EU Contribution 1611540 € End Date (actual) 31/12/2011 State Research technically completed; publication in hand Summary The proposed reserach will deliver solutions, how to conserve consistent blast furnace operation also in situations, when low cost raw materials, usually of lower quality, shall be used. Operational trials will explore ferrous fines and nut coke charging, correlated with coal injection rates. New online inspectionmethods will demonstrate changed material properties between charging and raceway. Scientific knowledge will proceed. Competitiveness for ironmaking will be increased. The research will contribute to the RFCS programme within the R&D area "Application of developed know-how and optimisation of the operating conditions in conventional routes" of the Strategic Research Agenda of ESTEP. Partners Organization Country Responsible VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Dipl.-Ing. Stefan BÖHNISCH (Project Coord.) ARCELORMITTAL ESPAÑA SA ESPAÑA Mr Luis Fernando SANCHO MENDEZ AGENCIA ESTATAL CONSEJO SUPERIOR DE INVESTIGACIO ESPAÑA Dr. Javier MOCHON MUÑOZ SCUOLA SUPERIORE DI STUDI UNIVERSITARI E DI PERFEZI ITALIA Dr. Valentina COLLA SALZGITTER FLACHSTAHL GmbH DEUTSCHLAND Dr. Manfred KETTLER TATA STEEL UK LIMITED UNITED KINGDOM Dr. George CLIXBY THYSSENKRUPP STEEL EUROPE AG DEUTSCHLAND Dr. Carl Ulrich WIETERS

RFSR-CT-2007-00003 ACASOS

Full Title Alternate carbon sources for sintering of iron ore Info Type of Project Research Duration (months) 42 Total Budget 1548822 € Start Date 1/07/2007 EU Contribution 929293 € End Date (actual) 31/12/2010 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA25151:EN Summary New alternate carbon sources for sintering (Acasos) will be investigated with the aim to substitute coke breeze. Therefore Acasos, i.e. biomass, deposited carbon rich dust, BF-dust and alternate sources as petroleum coke and anthracite will be indentified, characterised and economically evaluated for replacing coke breeze. On this basis innovative pre-treatment process, i.e. grinding, separation and agglomeration processes, will be investigated to adapt and optimise the properties of Acasos. Influences on sinter performance and quality will be determined at sinter-pot tests. Based on this Acasos will be applied in industrial scale to determine replacement factors and influences on the sintering process and emissions. Partners Organization Country Responsible VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Dipl -Ing Roland PIETRUCK (Project Coord.) ARCELORMITTAL BREMEN GMBH DEUTSCHLAND Dr. Joachim JANZ ILVA S.P.A. ITALIA Dr. Aldo BOVE TATA STEEL UK LIMITED UNITED KINGDOM Dr. Mohammad ZANDI VOESTALPINE STAHL GMBH OESTERREICH Dr. Herbert SCHMID

58 Summaries of RFCS projects 2003-2012 TGS1 : Ore agglomeration and Ironmaking

RFSR-CT-2008-00001 FLEXINJECT

Full Title Flexible injection of alternative carbon material into the blast furnace Info Type of Project Research Duration (months) 42 Total Budget 1875402 € Start Date 1/07/2008 EU Contribution 1125242 € End Date (actual) 31/12/2011 State Research technically completed; publication in hand Summary The project contributes to a sustainable use of natural resources by increased use of alternative carbon sources as BF injectants, improved competitiveness of the European steel producers and a possibility to decrease CO2 emission. Materials (e.g. plastics, dusts, sludge) are treated in an air-grinder to improve their suitability for BF injection and the effect on product properties is evaluated. By tests and theoretical support, two injection layouts for BF application are compared and the limits of additions to a PC system are evaluated. Additional raceway measurement technique during experimental BF tests is used to improve verification of raceway simulation. Partners Organization Country Responsible SWEREA MEFOS AB SVERIGE Dr. Lena SUNDQVIST ÖQVIST (Project Coord.) LUOSSAVAARA-KIIRUNAVAARA AB (LKAB) SVERIGE Mr Nicklas EKLUND SSAB EMEA AB SVERIGE M.Sc. Bo SUNDELIN VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Dipl.-Ing. Michael HENSMANN VOESTALPINE STAHL GMBH OESTERREICH Dr. Stefan SCHUSTER

RFSR-CT-2009-00001 TOSICO

Full Title New measurement and control techniques for total control in iron ore sinter plants Info Type of Project Research Duration (months) 42 Total Budget 2409197 € Start Date 1/07/2009 EU Contribution 1445518 € End Date (actual) 31/12/2012 State Research in progress Summary Target is a breakthrough in sinter control and clear improvement of fuel utilisation. For “Total Sinter Control” all process steps are covered. Highlights are: - online measurement of mix composition including free carbon - influence of grain size and segregation on melting zone - efficiency of special fuels (e.g. recycling materials, carbon fines, charcoal, lignite) - innovative advisory systems - automatic charging and process stability control - total sinter fuel and quality control basing on o carbon content in sinter mix and in electrofilter dust o efficiency of special fuels o gas analysis All achievements are verified on industrial scale. Partners Organization Country Responsible VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Dr.-Ing. Thorsten HAUCK (Project Coord.) AKTIEN-GESELLSCHAFT DER DILLINGER HÜTTENWERKE AG DEUTSCHLAND Dr.-Ing. Rongshan LIN ARCELORMITTAL ESPAÑA SA ESPAÑA Eng Aurelio GUTIERREZ AGENCIA ESTATAL CONSEJO SUPERIOR DE INVESTIGACIO ESPAÑA Dr. Javier MOCHON MUÑOZ ILVA S.P.A. ITALIA Dr.-Ing. Piero PULITO SCUOLA SUPERIORE DI STUDI UNIVERSITARI E DI PERFEZI ITALIA Dr. Valentina COLLA TATA STEEL NEDERLAND TECHNOLOGY B.V. NEDERLAND Ms Elisa S. M. BOT

RFSR-CT-2009-00002 ULCOS TGRBF

Full Title ULCOS top gas recycling blast furnace process Info Type of Project Research Duration (months) 36 Total Budget 8029041 € Start Date 1/03/2009 EU Contribution 4817425 € End Date (actual) 29/02/2012 State Research in progress Summary The objective of this project is the next step in the development of a new blast furnace route to operate with very low CO2 emissions. The project is the succession of the ULCOS New Blast Furnace process RFCS project launched in 2005 and aims at preparing this process for industrial application. After the design of the experiments and the engineering, three options of the new technology will be tested and/or optimised at the experimental blast furnace and evaluated. The results will allow selecting the best process and technology options for an industrial size demonstration unit, which will be the object of a future project. Partners Organization Country Responsible TATA STEEL NEDERLAND TECHNOLOGY B.V. NEDERLAND Ir. Jan van der STEL (Project Coord.) AKTIEN-GESELLSCHAFT DER DILLINGER HÜTTENWERKE AG DEUTSCHLAND Dr.-Ing. Rongshan LIN L'AIR LIQUIDE SA FRANCE Ms Anne BERTHELEMOT ARCELORMITTAL MAIZIERES RESEARCH S.A. FRANCE Mr Dominique SERT CENTRE DE RECHERCHES METALLURGIQUES ASBL BELGIQUE Mr Olivier ANSSEAU ILVA S.P.A. ITALIA Dr.-Ing. Vincenzo DIMASTROMATTEO KÜTTNER GmbH & Co. KG DEUTSCHLAND Dipl.-Ing. Wolfram KÜTTNER LUOSSAVAARA-KIIRUNAVAARA AB (LKAB) SVERIGE Mr Nicklas EKLUND SWEREA MEFOS AB SVERIGE Mr Bror-Erik SKÖLD PAUL WURTH S.A. LUXEMBOURG Dipl.-Ing. Guy THILLEN RAUTARUUKKI OYJ FINLAND Mr Miika SIHVONEN RHEINISCH-WESTFÄLISCHE TECHNISCHE HOCHSCHULE AA DEUTSCHLAND Prof.Dr.-Ing. Dieter G. SENK SSAB TUNNPLÅT AB SVERIGE M.Sc. Nils EDBERG THYSSENKRUPP STEEL EUROPE AG DEUTSCHLAND Ms Alexandra HIRSCH VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Dr.-Ing. Jörg ADAM VOESTALPINE STAHL GMBH OESTERREICH DI Thomas BUERGLER

59 Summaries of RFCS projects 2003-2012 TGS1 : Ore agglomeration and Ironmaking

RFSR-CT-2010-00001 INNOCARB

Full Title Innovative carbon products for substituting coke on BF operation Info Type of Project Research Duration (months) 42 Total Budget 2575225 € Start Date 1/07/2010 EU Contribution 1545136 € End Date (actual) 31/12/2013 State Research in progress Summary Based on positive experiences with charging self reducing iron oxide carbon briquettes into a blast furnace, carbon briquettes shall be developed for coke substitution. To get reasonable mechanical briquette strength, undersized BF coke fractions as base material shall be used together with alternative carbon fines like e.g. low volatile coal or lignite coke together with a binder. For further decrease in coke consumtion activated carbon material shall be charged into the ferrous layer. Due to high reactivity against CO² that carbon will participate in the solution loss reaction producing CO and decrease the thermal reserve zone temperature in the blast furnace. The expected benefits are increased indirect reduction and decreased direct reduction as well as reduced energy consumption. Here two different technologies for application to blast furnace operation are traced: the activation of nut coke and the agglomeration of active pet coke. Partners Organization Country Responsible VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Dipl -Ing Roland PIETRUCK (Project Coord.) DK RECYCLING & ROHEISEN GmbH DEUTSCHLAND Dr. Carsten HILLMANN LUOSSAVAARA-KIIRUNAVAARA AB (LKAB) SVERIGE Mr Nicklas EKLUND SWEREA MEFOS AB SVERIGE Dr. Lena SUNDQVIST ÖQVIST THYSSENKRUPP STEEL EUROPE AG DEUTSCHLAND Dr. Horst MITTELSTÄDT UNIWERSYTET SLASKI POLAND Dr. Iwona JELONEK VOESTALPINE STAHL GMBH OESTERREICH DI Thomas BUERGLER

RFSR-CT-2010-00002 IERO

Full Title Iron production by electrochemical reduction of its oxide for high CO² mitigation Info Type of Project Research Duration (months) 36 Total Budget 3962766 € Start Date 1/07/2010 EU Contribution 1834616 € End Date (actual) 30/06/2013 State Research in progress Summary The present proposal aims at developing a breakthrough technology to produce steel without any direct CO2 emissions. The solution consists in using electricity directly to decompose iron oxide into metal and oxygen. The proposal is following up on the ULCOS program, during which the key phenomena controlling the efficiency of the electrochemical reaction have been identified. The work packages are focused on understanding the physics and chemistry of these phenomena in order to propose the design at the scale of an industrial individual cell of an optimised technology demonstrating a very high level of CO2 mitigation. Partners Organization Country Responsible ARCELORMITTAL MAIZIERES RESEARCH S.A. FRANCE Mr Hervé LAVELAINE DE MAUBEUGE (Pr. Coord.) ELECTRICITE DE France FRANCE Mr Alain HITA FUNDACION TECNALIA RESEARCH & INNOVATION ESPAÑA Ms Mónica SERNA NORGES TEKNISK-NATURVITENSKAPELIGE UNIVERSITET NORGE Prof. Geir Martin HAARBERG STIFTELSEN SINTEF NORGE Mrs Karen Sende OSEN TATA STEEL NEDERLAND TECHNOLOGY BV NEDERLAND Dr. Sieger VAN DER LAAN UNIVERSIDADE DE AVEIRO PORTUGAL Prof. Jorge FRADE

RFSR-CT-2011-00001 EXTUL

Full Title Investigations of measures for extension of BF tuyere life time Info Type of Project Research Duration (months) 42 Total Budget 1354331 € Start Date 1/07/2011 EU Contribution 812599 € End Date (actual) 31/12/2014 State Research in progress Summary The damage of blast furnace tuyeres happens up to 80 times a year at normal BF operation. Each single tuyere damage effect a stoppage of the whole BF for several hours. Energy and money is spent without any benefit in form of HM production. To ensure its competitiveness and sustainability, the European steel industry must reduce those unplanned BF stoppages. The objective is to define practical measure for BF operators for the extension of tuyere life time. Partners Organization Country Responsible VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Dr.-Ing. Jörg ADAM (Project Coord.) ISD DUNAFERR DUNAI VASMU Zrt. HUNGARY Mr Imre TITZ THYSSENKRUPP STEEL EUROPE AG DEUTSCHLAND Mr Andrej JOHNEN VOESTALPINE STAHL GMBH OESTERREICH Dr. Stefan SCHUSTER

RFSR-CT-2011-00002 HISARNA B and C

Full Title Hisarna experimental campaigns B and C Info Type of Project Research Duration (months) 42 Total Budget 11212004 € Start Date 1/07/2011 EU Contribution 6727202 € End Date (actual) 31/12/2014 State Research in progress Summary HIsarna is a new Ironmaking concept developed under FP6-ULCOS, characterised by very low CO2 emissions and direct use of coal and ore. It combines previous developments known as CCF and HIsmelt. The main objective within the proposed project is to gain a detailed understanding of the process principles and hardware performance and thus knowledge towards the robustness of the process concept. After design of experiments and related engineering, trials are to be performed in the Hisarna experimental plant in IJmuiden. These trials should eventually provide information for a next scale up of the process. Partners Organization Country Responsible TATA STEEL NEDERLAND TECHNOLOGY BV NEDERLAND Ir. Koen MEIJER (Project Coord.) 60 AKTIEN-GESELLSCHAFT DER DILLINGER HÜTTENWERKE AG DEUTSCHLAND Prof. Dr.-Ing. Karl-Hermann TACKE ARCELORMITTAL MAIZIERES RESEARCH S.A. FRANCE Mr Jean Pierre BIRAT Summaries of RFCS projects 2003-2012 TGS1 : Ore agglomeration and Ironmaking

ILVA S.P.A. ITALIA Dr.-Ing. Michele ZAGARIA KÜTTNER GmbH & Co. KG DEUTSCHLAND Dipl.-Ing. Wolfram KÜTTNER LUOSSAVAARA-KIIRUNAVAARA AB (LKAB) SVERIGE Mr Peter SIKSTRÖM PAUL WURTH S.A. LUXEMBOURG Mr Paul GOEDERT SAARSTAHL AG DEUTSCHLAND Dr. Christian GÜNTHER SSAB EMEA AB SVERIGE Mr Jonas LÖVGREN THYSSENKRUPP STEEL EUROPE AG DEUTSCHLAND Dr. Zoltan TASZNER VOESTALPINE STAHL GMBH OESTERREICH Dipl.-Ing. Christoph FEILMAYR

RFSR-CT-2011-00003 IMSIMI

Full Title Improved sinter mix preparation while using challenging raw materials Info Type of Project Research Duration (months) 42 Total Budget 2494056 € Start Date 1/07/2011 EU Contribution 1496434 € End Date (actual) 31/12/2014 State Research in progress Summary Iron ores show a downward trend of their quality (finer particles, broader size distribution, lower grades and higher fluctuation of properties). To ensure its competitiveness and sustainability, the European steel industry must use such ores together with recycled materials at the sinter plant, while improving sinter quality and productivity at lowest possible environmental impact and energy consumption. The objective of this project is to allow an optimal use of challenging input materials in such a difficult context, by an advanced control of all preparation phases (mixing, granulation, etc.) and a better understanding of their impact on the sintering process. Partners Organization Country Responsible CENTRE DE RECHERCHES METALLURGIQUES ASBL BELGIQUE Mr Frédéric VAN LOO (Project Coord.) ARCELORMITTAL MAIZIERES RESEARCH S.A. FRANCE Dr. Jean-François DOUCE TATA STEEL NEDERLAND TECHNOLOGY B.V. NEDERLAND Dr. Ir. Willemijn HUSSLAGE UNIVERSITE DE LIEGE BELGIQUE Prof. Eric PIRARD VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Dipl -Ing Roland PIETRUCK VOESTALPINE STAHL GMBH OESTERREICH Dr. Herbert SCHMID

RFSR-CT-2012-00001 SUSTAINTAP

Full Title Blast furnace sustained tapping practice Info Type of Project Research Duration (months) 42 Total Budget 2877812 € Start Date 1/07/2012 EU Contribution 1726687 € End Date (actual) 31/12/2015 State Research in progress Summary The key objective of this proposal is to optimise the blast furnace tapping practice. The innovative approach is the combination of direct liquid level and flow measurements and the characterisation of drainage regimes. This will result in a better understanding of the hearth processes and in improved casting rules based on actual measurements. The proposed applications will contribute to a stable and thus more efficient blast furnace process in terms of operational safety, energy consumption and economy. Partners Organization Country Responsible TATA STEEL NEDERLAND TECHNOLOGY B.V. NEDERLAND Ir. Jan van der STEL (Project Coord.) AKTIEN-GESELLSCHAFT DER DILLINGER HÜTTENWERKE AG DEUTSCHLAND Dr.-Ing. Rongshan LIN ARCELORMITTAL MAIZIERES RESEARCH S.A. FRANCE Mr Benoît LECACHEUX CENTRE DE RECHERCHES METALLURGIQUES ASBL BELGIQUE Mr Claudio OJEDA LUOSSAVAARA-KIIRUNAVAARA AB (LKAB) SVERIGE Mr Nicklas EKLUND SWEREA MEFOS AB SVERIGE Dr. Lena SUNDQVIST ÖQVIST SALZGITTER FLACHSTAHL GmbH DEUTSCHLAND Dr. Tatjana MIRKOVIC VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Dr.-Ing. Yalcin KAYMAK

RFSR-CT-2012-00002 IMPCO

Full Title Improved coal combustion under variable blast furnace conditions Info Type of Project Research Duration (months) 42 Total Budget 2481011 € Start Date 1/07/2012 EU Contribution 1488607 € End Date (actual) 31/12/2015 State Research in progress Summary High pulverised coal injection (PCI) rates for minimisation of coke consumption are state of the art in blast furnace (BF) operation. Increasing need for flexible production rate with changing operational conditions and limited availability of matching coal types causes constraints for high PCI rates and results in higher total carbon © consumption. The overall project objective is to reduce the coke consumption also under these difficult new conditions by increased injection of conventional PC or new carbon products at the same time as the total rate of reducing agents is minimised. Additionally, some plants are restricted not only in supply of coals of stable and desirable quality, but also in oxygen capacity or injection system layout. The project will contribute to improved competiveness of European steel industry by reduced costs and ecological footprint of carbon with respect to air. The flexibility will be improved by customizing new carbon products for injection available on the market at the same time as need for high rank coking coals can be decreased. The objectives are reached by implementation of monitoring methods for injection-material quality, which improves BF heat level control and stability. The injection lances are modified for enhanced blast oxygen supply to coal plume, increasing the conversion efficiency of injected carbon material, minimising fines accumulation in lower zone of the BF and allowing minimum coke rates. Modification of lance design and necessary adjustments of blast parameters shall be carried out with the restriction at the actual BF plant in mind, without demands for major investments in the injection facilities. Decreased use of metallurgical coke and high rank coking coals by replacing them with low rank coals or new carbon materials harmonize with ESTEP priorities of adaptation of the ironmaking process to lower quality materials. Partners Organization Country Responsible SWEREA MEFOS AB SVERIGE Dr. Lena SUNDQVIST ÖQVIST (Project Coord.) LUOSSAVAARA-KIIRUNAVAARA AB (LKAB) SVERIGE Mrs Gunilla HYLLANDER SSAB EMEA AB SVERIGE Mr Björn JANSSON THYSSENKRUPP STEEL EUROPE AG DEUTSCHLAND Ms Alexandra HIRSCH 61 VOESTALPINE STAHL DONAWITZ GmbH & Co KG OESTERREICH Mr Hugo STOCKER Summaries of RFCS projects 2003-2012 TGS1 : Ore agglomeration and Ironmaking

VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Dipl.-Ing. Michael HENSMANN

RFSR-CT-2012-00003 OPTISTOVE

Full Title Optimisation of blast furnace hot stove operation Info Type of Project Research Duration (months) 42 Total Budget 1916301 € Start Date 1/07/2012 EU Contribution 1149781 € End Date (actual) 31/12/2015 State Under process of signature Summary European steelmaking rely on relatively old plant that often experience problems with hot stove performance and operation. This project aims at developing and optimising techniques that makes the operation more efficient and stable thus reducing emissions, cost and energy demand. Stove oxygen enrichment , preheating of fuel/air, automated stove control concept and general guidelines for characterisation and optimisation of hot stoves will be developed to help European steelmakers improve its operations and increase its competitiveness. All techniques will be developed through a combination of theoretical work, pilot scale trials and industrial scale trials. A proper evaluation of the different techniques are ensured by thoroughly analysing the effect on the whole steelmaking production system. The results will be delivered as general guidelines and can in practice be applied by all European steel plants. Partners Organization Country Responsible SWEREA MEFOS AB SVERIGE Mr Magnus LUNDQVIST (Project Coord.) DK RECYCLING & ROHEISEN GmbH DEUTSCHLAND Dr. Jürgen SCHLIMBACH SSAB EMEA AB SVERIGE Mr Erik OLSSON VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Mr Sebastian KOTZICH

RFSR-CT-2012-00004 OPTIPER

Full Title Optimisation of permeability bars to customise sinter plants on changing demands Info Type of Project Research Duration (months) 42 Total Budget 1560357 € Start Date 1/07/2012 EU Contribution 936214 € End Date (actual) 31/12/2015 State Research in progress Summary Most sinter plants use permeability bars (rakes) to effectively raise productivity. However, still very few knowledge exists about their influences on the process. Consequently, they can hardly be adapted to changing conditions. Aim of „OptiPer“ is to completely understand the influences of permeability bars on the local processes, productivity and quality. A unique set of well-coordinated operational trials at several plants will be performed and analysed by measurements and innovative models. A generally applicable optimisation strategy will be developed and guidelines for adaption to changing conditions/demands (raw materials, production, quality). Special attention will be paid on vertical permeability bars. Partners Organization Country Responsible VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Ms Lisa Dorothée MÜLLER (Project Coord.) ARCELORMITTAL ESPAÑA SA ESPAÑA Mr Javier RODRIGUEZ SOMOANO AGENCIA ESTATAL CONSEJO SUPERIOR DE INVESTIGACIO ESPAÑA Dr. Javier MOCHON MUÑOZ THYSSENKRUPP STEEL EUROPE AG DEUTSCHLAND Dipl.-Ing. Thorsten STÜRMER VOESTALPINE STAHL DONAWITZ GmbH & Co KG OESTERREICH Dipl.-Ing. Roland MAYERHOFER

62

Technical Group Steel 2

Steelmaking Processes

The scope of TGS2 includes:

• Electric arc furnace processes

• Physico-chemical metallurgy of liquid steel and slag

• Recycling of steel scrap

• Secondary metallurgy techniques

• Standardisation of testing and evaluation methods

• Maintenance and reliability of production lines

• Reduction of emissions, energy consumption and improvement of the environmental impact

• Instrumentation, modelling and control of processes

63 64 Summaries of RFCS projects 2003-2012 TGS2 : Steelmaking processes

RFS1-CT-2006-00002 EOSC 2006

Full Title 5th European oxygen steelmaking conference 2006 Info Type of Project Accompanying measure (confere Duration (months) 0 Total Budget 375400 € Start Date 26/06/2006 EU Contribution 20000 € End Date (actual) 28/06/2006 State Research completed; no publication Summary The objective of the present proposal is the organisation and hosting of an European conference in the field of oxygen steelmaking and secondary metallurgy. The European Oxygen Steelmaking Conference (EOSC) series is organised in turn by one of the European Metallurgical Societies and Associations. As such it represents the most comprehensive expert knowledge in steelmaking. Past of the EOSC venues were: • 1993: Neuss, D • 1997: Taranto, I • 2000: Birmingham, UK • 2003: Graz, A The Steel Institute VDEh is pleased to announce that it will organize the 5th European Oxygen Steelmaking Conference to be held in Aachen, 26 – 28 June 2006. The scope of the conference is to provide a forum for researchers, specialists and engineers from the European Union and abroad to discuss and to inform themselves about latest process and plant technology developmens, research projects and results, operation related questions of metallurgy, automation and process control and process integrated environmental protection aspects in all areas of basic oxygen steelmaking. Within this frame the diffusion of results gained on research projects by the European Commission Steel RTD Programme is assured. Partners Organization Country Responsible STAHLINSTITUT VDEh DEUTSCHLAND Dr.-Ing. Hans Bodo LÜNGEN

RFSP-CT-2003-00007 FULL-REC 2

Full Title Hydrometallurgical continuous treatment of ZnO enriched powders for metal zinc production Info Type of Project Pilot&Demonstration Duration (months) 24 Total Budget 1460000 € Start Date 1/09/2003 EU Contribution 584000 € End Date (actual) 31/08/2005 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA22989:EN Summary Through extensive experimentation on a demonstration plant the aim of the project is to generate the criteria and design equations to develop at industrial scale a continuous hydro metallurgical process conceived for the treatment of powders produced from an existing industrial pyro metallurgical treatment of EAF dusts which arise from the production of plain carbon steels and stainless steels. These powders, consisting of a mixture of oxides rich in ZnO, are treated to obtain, as final product, metal zinc at a production rate of 500 kg/day, as well as marketable secondary raw materials. The corresponding ecological hydro metallurgical plant is composed of a series of reactors for dissolution of powders, purification of the solution and final electrolysis to obtain metal zinc suitable for use in galvanizing lines. The hydro metallurgical plant is located at ThyssenKrupp Acciai Speciali Terni Steelworks in Terni. The technical feasibility and economic convenience of the whole pyro-metallurgical and hydro-metallurgical chain of the Full-Rec technology will be assessed in view of its industrial exploitation. Partners Organization Country Responsible CENTRO SVILUPPO MATERIALI SPA ITALIA Dr.ssa Loredana DI SANTE (Project Coord.) ASO SIDERURGICA S.R.L. ITALIA Dr. Silvano PANZA TECHINTSpA ITALIA Ing. Marcello POZZI THYSSENKRUPP ACCIAI SPECIALI TERNI SpA ITALIA Dr.-Ing. Daniele MORONI

RFSP-CT-2004-00006 DOT Application

Full Title Application of direct optical temperature measurement in steelmaking process Info Type of Project Pilot&Demonstration Duration (months) 36 Total Budget 789975 € Start Date 1/07/2004 EU Contribution 315990 € End Date (actual) 30/06/2007 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA23736:EN Summary The main target of this pilot project is to implement and test the new measurement system for continuous determination of steel melt temperature in converter during the oxygen blowing process. The new system will be tested and optimised during long-term plant trials at BOF converters under various operational conditions. Based on the results obtained from the project, significant improvements in productivity, energy and material consumption of the converter process are expected. Partners Organization Country Responsible AKTIEN-GESELLSCHAFT DER DILLINGER HÜTTENWERKE AG DEUTSCHLAND Dr.-Ing. Helmut LACHMUND (Project Coord.) VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Dr.-Ing. Herbert KÖCHNER

65 Summaries of RFCS projects 2003-2012 TGS2 : Steelmaking processes

RFSR-CT-2003-00008 IMSTEELLAD

Full Title Investigations and measures to reduce emissions and energy consumption during preheating of steel ladles Info Type of Project Research Duration (months) 40 Total Budget 1775447 € Start Date 1/09/2003 EU Contribution 1065268 € End Date (actual) 31/12/2006 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA23175:EN Summary Steel ladles are preheated after relining to stabilize the lining material and to avoid thermal shock during the first tapping after relining. The preheating procedure is associated with high energy consumption and the emission of unburned hydrocarbons. The unburned hydrocarbons include a considerable amount of polycyclic aromats, known as being strongly carcinogenic. The projects aims are the optimisation of the preheating-procedure, the reduction of energy consumption, the optimisation of the combustion and the development of measures to reduce emissions. Especially the reduction of emissions will improve the working quality considerably. Partners Organization Country Responsible VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Dr.-Ing. Wolfgang ADLER (Project Coord.) CENTRO SVILUPPO MATERIALI SPA ITALIA Dr. Mario TONELLI GERDAU INVESTIGACION Y DESARROLLO EUROPA S.A. ESPAÑA Dr. Gonzalo ALVAREZ DE TOLEDO THYSSENKRUPP ACCIAI SPECIALI TERNI SpA ITALIA Ing. Vinicio DE ANGELIS THYSSENKRUPP NIROSTA GMBH DEUTSCHLAND Dipl.-Ing. Uwe de FRIES

RFSR-CT-2003-00016 PROMS

Full Title Cost efficient metallurgy for the production of novel ultra high strength deep drawable steel grades with high Mn contents from 10 to 25 wt.-% Info Type of Project Research Duration (months) 36 Total Budget 934489 € Start Date 1/09/2003 EU Contribution 560693 € End Date (actual) 31/12/2006 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA22991:EN Summary The proposal addresses a current need for novel ultra high-strength deep-drawable steels with high manganese contents of up to 25 wt.-% and extremely improved properties for light-weight construction. The aim is the selection and development of suitable technologies of primary and secondary metallurgy for the production of these steels and the determination of tolerable contents of critical tramp and trace elements. The proposal objectives will be achieved by a combination of theoretical investigations, laboratory development and larger-scale trials. Partners Organization Country Responsible SALZGITTER MANNESMANN FORSCHUNG GmbH DEUTSCHLAND Dr.-Ing. Christian REDEKER (Project Coord.) SWEREA MEFOS AB SVERIGE Mr Ralph NYSTRÖM TECHNISCHE UNIVERSITAET CLAUSTHAL DEUTSCHLAND Prof. Dr.-Ing. Karl-Heinz SPITZER

RFSR-CT-2003-00024 REC DC EAF

Full Title Monitoring system for controlling and reducing the electrode consumption in DC EAF plants Info Type of Project Research Duration (months) 36 Total Budget 1050400 € Start Date 1/09/2003 EU Contribution 630240 € End Date (actual) 31/08/2006 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA23889:EN Summary In modern high-powered DC EAF plants operating with large electrodes, discontinuous electrode consumption events such as electrode breakage or tip drops remain a problem and have a clear impact on final steel costs. Mastering this problem implies a better knowledge of the involved phenomena. Therefore, an optical system for electrode monitoring after the melting of each scrap basket will be installed at the single shell DC EAF of ProfilARBED Esch-Belval. The measurement of the progressive electrode consumption (on tip and side) and the observation of crack formation, joint openings, tip drops and electrode breakages will allow establishing the relationships with electrode grade, nipple type or nipple screwing technique as well as with furnace operating parameters. Using the available data, existing calculation model for electrode consumption will be updated and improved. Additional pilot tests in a 1t DC EAF will allow focusing enlarged investigations on well–controlled parameters. Guidelines to reduce the electrode consumption will be established. Moreover, the applicability of the electrode monitoring system will also be tested at the twin-shell DC EAF of ProfilARBED Differdange. Partners Organization Country Responsible CENTRE DE RECHERCHES METALLURGIQUES ASBL BELGIQUE Mr Jean BORLEE (Project Coord.) CENTRO SVILUPPO MATERIALI SPA ITALIA Dr.ssa Loredana DI SANTE ProfilARBED S.A. LUXEMBOURG Dr. Jean-Claude BAUMERT VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Dr.-Ing. Bernd KLEIMT

RFSR-CT-2003-00031 EAFDYNCON

Full Title Dynamic control of EAF burners and injectors for oxygen and carbon for improved and reproducible furnace opertion and slag foaming Info Type of Project Research Duration (months) 42 Total Budget 1545849 € Start Date 1/09/2003 EU Contribution 927509 € End Date (actual) 28/02/2007 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA23920:EN Summary The objective of the project is to develop dynamic control functions for the wall mounted oxygen and carbon injectors as well as for the oxy-fuel burners of the EAF. The setpoints for each individual injector shall be determined depending on a signal for foamy slag detection, exhaust gas analysis values and dynamic model calculations. An optical distance sensor inside the burners shall detect the actual scrap load in front of each burner to control its operation duration and the oxygen to natural gas ratio. Dynamic and automatic control of burners and injectors shall ensure their optimal operation in a reliable and reproducible way with stable slag foaming. Expected results are a decrease of tap-to-tap time and consumption of electrical energy and oxygen. The aim tap analysis can be adjusted more accurately, the safety of furnace operation is improved, and the operator working time in front of the furnace can be reduced. 66 Partners Organization Country Responsible Summaries of RFCS projects 2003-2012 TGS2 : Steelmaking processes

VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Dr.-Ing. Bernd KLEIMT (Project Coord.) CENTRE DE RECHERCHES METALLURGIQUES ASBL BELGIQUE Mr Pierre NYSSEN GEORGSMARIENHÜTTE GmbH DEUTSCHLAND Dr.-Ing. Ingo KOLM ProfilARBED S.A. LUXEMBOURG Dr. Jean-Claude BAUMERT GERDAU INVESTIGACION Y DESARROLLO EUROPA S.A. ESPAÑA Mr Santiago LANDA LAZCANO

RFSR-CT-2003-00042 BOFDYN

Full Title Dynamic end point in BOF through a fast and simultaneous determination of the steel/slag composition Info Type of Project Research Duration (months) 40 Total Budget 1102151 € Start Date 1/09/2003 EU Contribution 661290 € End Date (actual) 31/12/2006 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA24032:EN Summary The project aims at shortening the tap to tap time in oxygen steel plants in order to increase their productivity while reaching a very high hitting ratio at turndown. The main target of this proposal is to develop a completely new method for controlling the BOF process by using an original in- blow heterogeneous sampler and a dedicated laser analytical method. Associated with a metallurgical model, the data obtained with the heterogeneous samplers could lead to dynamically assess the state of the refining progress and to define the corrective actions in order to allow a safe direct tapping practice. This new process control method could also find interesting applications in the EAF steel making. The new analytical methodology dedicated to heterogeneous samples could equally profit to other steel making steps such as secondary metallurgy ..… Partners Organization Country Responsible CENTRE DE RECHERCHES METALLURGIQUES ASBL BELGIQUE Mr Michel WAUTERS (Project Coord.) ARCELORMITTAL MAIZIERES RESEARCH S.A. FRANCE Dr. Michel HEMMERLIN HERAEUS ELECTRO-NITE INTERNATIONAL NV BELGIQUE Ing. Johan KNEVELS SWEREA KIMAB AB SVERIGE Dr. Arne BENGTSON

RFSR-CT-2004-00008 EAFCAMERA

Full Title Control by camera of the EAF operations in airtight conditions Info Type of Project Research Duration (months) 42 Total Budget 969780 € Start Date 1/07/2004 EU Contribution 581868 € End Date (actual) 31/12/2007 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA24986:EN Summary The aim of this project is to develop a visualisation tool that is able to control an electric arc furnace working in airtight conditions - defined as closing the slag door and injecting oxygen and carbon through wall-mounted injectors. The system will assist the operator in assessing the optimal time for charging the second basket and to detect un-melted scrap and skulls on the walls during the flat bath phase. A dedicated burner/ endoscope/ camera module and processing package will be industrialised in two industrial furnaces (DC and AC). A previous ECSC project has made preliminary use of an infrared camera combined with an endoscope and shown that this arrangement is able to view into an EAF through flames and dust; the device could be located in an EAF burner. Partners Organization Country Responsible CENTRE DE RECHERCHES METALLURGIQUES ASBL BELGIQUE Mr Pierre NYSSEN (Project Coord.) ARCELORMITTAL BELVAL & DIFFERDANGE S.A. LUXEMBOURG Mr Jacques HOFFMANN MORE S.r.l. ITALIA Mr Giancarlo ANTONELLI TATA STEEL UK LIMITED UNITED KINGDOM Dr. M. Stuart MILLMAN

RFSR-CT-2005-00003 CONOPT SCRAP

Full Title Control and optimisation of scrap charging strategies and melting operations to increase steel recycling ratio Info Type of Project Research Duration (months) 42 Total Budget 1854704 € Start Date 1/07/2005 EU Contribution 1112822 € End Date (actual) 31/12/2008 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA25095:EN Summary The general aim of the project is to allow the best and most economic use of scrap in steelmaking operations. At the EAF, systems for the on-line monitoring of the scrap charge and for the optimisation of its melting conditions will be developed and implemented in industrial plants. Both aspects are indeed highly significant with regard to furnace efficiency, iron recovery and energy use. Another main axis of work will be to increase the use of lower scrap qualities (including “problem” scrap such as more contaminated scrap qualities with plastics, rubber and other materials), both for the EAF and BOF in order to comply with future legislation regarding steel recycling ratios, such as the “end of life vehicle” directive Directive' as well as existing directives on packaging and coated scrap. Partners Organization Country Responsible CENTRE DE RECHERCHES METALLURGIQUES ASBL BELGIQUE Mr Michel WAUTERS (Project Coord.) ARCELORMITTAL BELVAL & DIFFERDANGE S.A. LUXEMBOURG Mr Marco PICCO CENTRO SVILUPPO MATERIALI SPA ITALIA Dr. Piero FRITTELLA SWEREA MEFOS AB SVERIGE Dr. Jonas ALEXIS NLMK LA LOUVIERE S.A. BELGIQUE Dr.-Ing. Bernard POIZOT TATA STEEL UK LIMITED UNITED KINGDOM Mr Alan SCHOLES

67 Summaries of RFCS projects 2003-2012 TGS2 : Steelmaking processes

RFSR-CT-2005-00004 HINIST

Full Title Mastering of P-ESR technology for high nitrogen steel grades for high value applications Info Type of Project Research Duration (months) 42 Total Budget 1076922 € Start Date 1/07/2005 EU Contribution 646153 € End Date (actual) 31/12/2008 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA25095:EN Summary Electro Slag Remelting is the technology for obtaining high purity and soundness steels in large ingots. It is also promising for designing and producing high nitrogen high performance steels when the process is run at high pressure. The aim of the project is to develop new and improved methods for production of both martensitic and austenitic special steels with high nitrogen content (up to 1%) for highly stressed and high temperature applications. The project, carried out both at laboratory and industrial scale, will benefit of specifically developed simulative and process control tools, and will generate a set of microstructural, chemical, and mechanical characterisations of steels containing high content of Nitrogen. Specific industrial testing will be carried out too concerning thermomechanical transformation of ingots to verify the whole manufacturing cycle conditions. Partners Organization Country Responsible CENTRO SVILUPPO MATERIALI SPA ITALIA Dr.-Ing. Andrea CAROSI (Project Coord.) ENERGIETECHNIK ESSEN GmbH DEUTSCHLAND Dipl.-Ing. Volkher DIEHL VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Dr.-Ing. Bernd KLEIMT MATERIÁLOVÝ A METALURGICKÝ VÝZKUM s.r.o. CZECH REPUBLIC Prof. Dr. Vlastimil VODAREK

RFSR-CT-2005-00005 ImPurgingAr

Full Title Improvement of purging plugs performances by investigations on the materials, process analysis and continuous monitoring Info Type of Project Research Duration (months) 48 Total Budget 906380 € Start Date 1/07/2005 EU Contribution 543828 € End Date (actual) 30/06/2009 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA24987:EN Summary The object of the research proposal is the purging plugs for ladle Ar blowing. The objective is to improve the plugs selection and management in order to enhance their performances. The work programme is based on a multidisciplinary approach that involves steel maker, purging plugs producer and researcher working on refractory materials and technology and on measuring methodologies and system applied to the steel making environment. The activity forecast both on plant and laboratory trials. Trials on plant want to characterise standard and enhanced ladle practices, standard and new purging plugs, with respect the plugs performances. During these trials plug refractory wear measurements are carried out. Laboratory trials forecast refractory investigations to characterise materials transformations during the use of the plugs and to better establish the correlations between process and wear of the refractory. Overall results will be used to set a model of general application of the correlations between the process and the behaviour of the plugs. Partners Organization Country Responsible CENTRO SVILUPPO MATERIALI SPA ITALIA Dr. Mario TONELLI (Project Coord.) CALDERYS ITALIA SRL ITALIA Dr. Renzo PARODI THYSSENKRUPP ACCIAI SPECIALI TERNI SpA ITALIA Mr Massimo PROIETTI CERQUONI VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Dr. Christian DANNERT

RFSR-CT-2005-00006 PREDINC

Full Title Prediction of inclusions in the slabs from the process characteristics Info Type of Project Research Duration (months) 42 Total Budget 1570504 € Start Date 1/07/2005 EU Contribution 942302 € End Date (actual) 31/12/2008 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA24992:EN Summary Non metallic inclusions are present in all continuously casted steels. They can affect the physical and mechanical characteristics of products and, consequently, their service properties. The development of a model capable to predict the type, number and severity of the non metallic endogenous inclusions during production will be essential to introduce corrective actions immediately, with the consequent saving and optimization of the resource consumption and environmental benefit. This project will use innovative techniques based on the objective experience extracted from past data for obtain this objective. Partners Organization Country Responsible ARCELORMITTAL ESPAÑA SA ESPAÑA Mr Luis Fernando SANCHO MENDEZ (Pr. Coord.) ILVA S.P.A. ITALIA Dr. Nicola DELRE POLITECNICO DI MILANO ITALIA Prof. Walter NICODEMI RHEINISCH-WESTFÄLISCHE TECHNISCHE HOCHSCHULE AA DEUTSCHLAND Prof.Dr.-Ing. Dieter G. SENK SCUOLA SUPERIORE DI STUDI UNIVERSITARI E DI PERFEZI ITALIA Dr. Valentina COLLA AALTO-KORKEAKOULUSAATIO (AALTO UNIVERSITY FOUN FINLAND M Sc Jukka LAINE UNIVERSIDAD DE OVIEDO ESPAÑA Prof. Francisco ORTEGA FERNANDEZ

68 Summaries of RFCS projects 2003-2012 TGS2 : Steelmaking processes

RFSR-CT-2005-00007 ANALCO

Full Title On-line determination of the CO/CO2 concentration in the OG system in BOF converter Info Type of Project Research Duration (months) 42 Total Budget 1228207 € Start Date 1/07/2005 EU Contribution 736924 € End Date (actual) 31/12/2008 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA24460:EN Summary A great problem when using gas analysis data based in off-line gas analyzers for controlling the gas extraction system is the long time delays associated with the measurements. The objective of this project is a development of dynamic models of the gas extraction system to optimise existing control systems and investigate alternative systems for an on-line measurement of the concentration of COx and O2. With this control it could act over the OG system: deciding to send the gas to the torch or gasometer, depending on the proportion of CO, CO2 and O2, and the development of blow control schemes based on gas analysis. Partners Organization Country Responsible ARCELORMITTAL ESPAÑA SA ESPAÑA Mr Luis Fernando SANCHO MENDEZ (Pr. Coord.) SWEREA MEFOS AB SVERIGE Mr Johan ERIKSSON RHEINISCH-WESTFÄLISCHE TECHNISCHE HOCHSCHULE AA DEUTSCHLAND Prof.Dr.-Ing. Dieter G. SENK SCUOLA SUPERIORE DI STUDI UNIVERSITARI E DI PERFEZI ITALIA Dr. Valentina COLLA

RFSR-CT-2006-00003 SSIA

Full Title Strengthened scrap impact area in BOF converters Info Type of Project Research Duration (months) 42 Total Budget 1539162 € Start Date 1/07/2006 EU Contribution 923498 € End Date (actual) 31/12/2009 State Research completed, report published on EU Bookshop at (link not yet available) Summary Excessive wear of the scrap impact area in BOF vessels has become a major problem for European steelmaker as a consequence of enhancing product quality and higher productivity. The objective of this project is to develop and assess a variety of innovative care techniques and innovative techniques for use of higher wear resistant refractory for the scrap impact area and for different types of BOF vessels. With these techniques it will be possible to continue high scrap rate operations, use heavy internal scrap of known composition and maintain or increase converter campaign life. Converter operations will also become safer. Partners Organization Country Responsible SWEREA MEFOS AB SVERIGE Mr Johan ERIKSSON (Project Coord.) RHI AG OESTERREICH Dr. Gerald BUCHEBNER RAUTARUUKKI OYJ FINLAND Mr Simo ISOKÄÄNTÄ SSAB EMEA AB SVERIGE Mr Hakan WAHLBERG VOESTALPINE STAHL GMBH OESTERREICH Dr. Herbert MIZELLI

RFSR-CT-2006-00004 OFFGAS

Full Title Improved EAF process control using on-line offgas analysis Info Type of Project Research Duration (months) 36 Total Budget 2716188 € Start Date 1/07/2006 EU Contribution 1629711 € End Date (actual) 30/06/2009 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA25048:EN Summary In this project, continuous analysis of EAF off-gas is used to develop comprehensive mass and energy monitoring of the EAF process in order to increase productivity. In particular, the following topics will be implemented in order to enhance EAF productivity: implementation of on-line energy monitoring, monitoring of decarburisation of the melt, decrease of heat load on the dedusting system by optimal combustion and heat transfer to the scrap in the furnace vessel, decrease of lancing time and tap-to-tap time. Continuous chemical analysis of EAF off-gas will be realized at the primary dedusting system with special emphasis on long-term availability. Partners Organization Country Responsible RHEINISCH-WESTFÄLISCHE TECHNISCHE HOCHSCHULE AA DEUTSCHLAND Prof.Dr.Ing. Herbert PFEIFER (Project Coord.) CENTRE DE RECHERCHES METALLURGIQUES ASBL BELGIQUE Mr Pierre NYSSEN CENTRO SVILUPPO MATERIALI SPA ITALIA Dr. Filippo CIRILLI DEUTSCHE EDELSTAHLWERKE GMBH DEUTSCHLAND Dipl.-Ing. Hans-Peter JUNG STAHL- UND WALZWERK MARIENHÜTTE GMBH OESTERREICH Dipl.-Ing. Axel GRABMEIER O.R.I. MARTIN - ACCIAIERIA E FERRIERA DI BRESCIA SpA ITALIA Ing. Uggero DE MIRANDA TENOVA SpA ITALIA Dr.-Eng. Mauro BIANCHI FERRI THYSSENKRUPP NIROSTA GMBH DEUTSCHLAND Dipl.-Ing. Helge MEES VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Dr.-Ing. Bernd KLEIMT

RFSR-CT-2006-00005 EAF-PROMS

Full Title Cost efficient metallurgy for the production of novel ultra high strength deep drawable steel grades with high Mn contents from 10 to 25 wt.-% by using EAF steel making route Info Type of Project Research Duration (months) 28 Total Budget 652769 € Start Date 1/09/2006 EU Contribution 391661 € End Date (actual) 31/12/2008 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA24225:EN Summary The proposal addresses a current need for novel ultra high-strength deep-drawable steels with high manganese contents of up to 25 wt.-% and extremely improved properties for light-weight construction. The aim is the selection and development of suitable technologies and routes of metallurgy using steel production in the EAF and the related aspects of secondary metallurgy for the production of these steels. The proposal objectives will be achieved by a combination of some specific theoretical investigations, laboratory development and of larger-scale trials.

Partners Organization Country Responsible 69 SALZGITTER MANNESMANN FORSCHUNG GmbH DEUTSCHLAND Dr. Joachim KROOS (Project Coord.) Summaries of RFCS projects 2003-2012 TGS2 : Steelmaking processes

SWEREA MEFOS AB SVERIGE Mr Pär HAHLIN TECHNISCHE UNIVERSITAET CLAUSTHAL DEUTSCHLAND Prof. Dr.-Ing. Karl-Heinz SPITZER

RFSR-CT-2006-00006 IMPHOS

Full Title Improving phosphorus refining Info Type of Project Research Duration (months) 42 Total Budget 1498546 € Start Date 1/07/2006 EU Contribution 899127 € End Date (actual) 31/12/2009 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA25005:EN Summary Phosphorus removal is required to produce high quality BOS steel. However, current phosphorus process control strategies are based on end point steady-state models, which do not account for the intensely dynamic processes that are involved in phosphorus removal. Consequently, there are often large variations in heat-by-heat performance indicating that existing control schemes for phosphorus are not secure and should be improved to avoid production interrupts and reduce flux costs. The project aims at improving current phosphorous refining strategies by introducing additional dynamic aspects into the control scheme including enhanced slag formation practices and advanced lance control routines. If successful, the project would be expected to result in improved conservation of resources (slag-making fluxes and lower temperature losses), and a positive environmental impact (reduced BOS slag generation). Partners Organization Country Responsible TATA STEEL UK LIMITED UNITED KINGDOM Dr. M. Stuart MILLMAN (Project Coord.) SWEREA MEFOS AB SVERIGE PhD. Donald MALMBERG SSAB TUNNPLÅT AB SVERIGE Msc. Mats BRÄMMING TATA STEEL NEDERLAND TECHNOLOGY BV NEDERLAND Dr. Abha KAPILASHRAMI

RFSR-CT-2007-00004 ONDECO

Full Title On-line control of desulphurisation and degassing through ladle bubbling under vacuum Info Type of Project Research Duration (months) 36 Total Budget 948193 € Start Date 1/07/2007 EU Contribution 568916 € End Date (actual) 30/06/2010 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA25091:EN Summary The objective of the project is using appropriate sensors to qualify the stirring state, to develop innovative signal processing, to obtain representative indices and use them as input in an on-line desulphurisation model, adjust the process and contribute to improvement of degassing performance (H, N removal). Stakes: reduction in products non-quality (S, H, N), robust production process for future steels in low sulphur, increase in competitiveness and increased productivity (decrease of treatment cost). The project will in gaining time that will be the source of energy savings. Safety risks will be decreased for less operator’s exposure to the process. Partners Organization Country Responsible ARCELORMITTAL MAIZIERES RESEARCH S.A. FRANCE Mrs Michèle NADIF (Project Coord.) AKTIEN-GESELLSCHAFT DER DILLINGER HÜTTENWERKE AG DEUTSCHLAND Dr.-Ing. Helmut LACHMUND VOESTALPINE STAHL GMBH OESTERREICH Dr. Roman RÖSSLER

RFSR-CT-2007-00005 SOPLIQS

Full Title Optimisation of sampling at liquid steel state and correlative inclusions assessment of liquid steel for the improvement of high performance steel grades production process Info Type of Project Research Duration (months) 36 Total Budget 1026340 € Start Date 1/07/2007 EU Contribution 615804 € End Date (actual) 30/06/2010 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA25039:EN Summary Development of high performance steel grades conducts to more and more severe cleanliness / inclusions populations requirements. Steelmakers have a real need to control during steelmaking inclusions populations at the liquid state. It was established that inclusions present in liquid steel samples are not often representative of inclusions actually present in the liquid - moreover solid– steel. In this way wrong cleanliness evaluations conduct to quality troubles and customers' claims. The benefits estimated for total European steels production is 32M€/year. So, proposal's aims are to determine the most representative liquid steel sampling parameters to optimise the correlative inclusions populations assessment. Partners Organization Country Responsible ASCOMETAL S.A.S. FRANCE Dr.-Ing. Fabienne RUBY-MEYER (Project Coord.) KUNGLIGA TEKNISKA HÖGSKOLAN - THE ROYAL INSTITUTE SVERIGE Dr. Anders TILLIANDER RIVA ACCIAIO SPA ITALIA Ing. Paolo ROSSI GERDAU INVESTIGACION Y DESARROLLO EUROPA S.A. ESPAÑA Mr Rafael PIZARRO

RFSR-CT-2007-00006 EPOSS

Full Title Energy and productivity optimised EAF stainless steel making by adjusted slag foaming and chemical energy supply Info Type of Project Research Duration (months) 42 Total Budget 1476421 € Start Date 1/07/2007 EU Contribution 885853 € End Date (actual) 31/12/2010 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA25082:EN Summary Objective of the project is to increase energy efficiency and productivity during EAF stainless steel making by slag foaming and adjusted use of all available energy sources. By means of different slag conditioning techniques and foaming additives foamy slag practise shall be established in dependence on available injection technologies, tapping procedures and decarburisation requirements resulting from post treatment technology (AOD, VOD). Based on slag foaming advantages, energy efficiency during EAF stainless steel production shall be increased by using the mainly exothermic chemical reactions, higher power input by high impedance operation and adjusted utilisation of both chemical and electrical energy in dependence on melting time. The proposed research is in complete accordance with the strategy priority “Direct and alternative input of energy in the electric arc furnace” and is specially supported by the ESTEP Working Group 1 “Profit“. 70 Partners Organization Country Responsible VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Dipl.-Ing. Gerald STUBBE (Project Coord.) Summaries of RFCS projects 2003-2012 TGS2 : Steelmaking processes

ACRONI, PODJETJE ZA PROIZVODNJO JEKLA IN JEKLENIH IZ SLOVENIJA Dr. Anton JAKLIC BGH EDELSTAHL SIEGEN GmbH DEUTSCHLAND Dipl.-Ing. Michael SEDLMEIER SWEREA MEFOS AB SVERIGE Dr. Johan BJÖRKVALL OUTOKUMPU STAINLESS AB SVERIGE BSc. Lasse LILJEDAHL GERDAU INVESTIGACION Y DESARROLLO EUROPA S.A. ESPAÑA Mr Santiago LANDA LAZCANO

RFSR-CT-2007-00007 OPCONSTAINLESS

Full Title Resource-saving operation and control of stainless steel refining in VOD and AOD process Info Type of Project Research Duration (months) 36 Total Budget 1386292 € Start Date 1/07/2007 EU Contribution 831775 € End Date (actual) 30/06/2010 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA25087:EN Summary The objective of the project is to improve the operation and control of stainless steel refining within the VOD and the AOD process with respect to the main metallurgical operations. This shall be achieved by detailed investigations with CFD based process models, and by application of dynamic models for on-line observation and control of the process. Furthermore a detailed investigation of operation parameters with emphasis on the slag behaviour shall be performed, and new VOD operation practices regarding lance injection of scale FeO and EAF slag with high chromium contents shall be developed. Expected benefits are a reduced consumption of alloys, reducing agents, slag formers and process gases. Stainless steel production will be optimised regarding energy consumption and amount of slag to be deposited or recycled. The well-aimed control of decarburisation reaction will reduce the risk of potentially dangerous steel and slag overflow. Partners Organization Country Responsible VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Dr.-Ing. Bernd KLEIMT (Project Coord.) KOBOLDE & PARTNERS AB SVERIGE Dr.-Eng. Rutger GYLLENRAM KUNGLIGA TEKNISKA HÖGSKOLAN - THE ROYAL INSTITUTE SVERIGE Dr. Anders TILLIANDER OUTOKUMPU STAINLESS AB SVERIGE M Sc. Gunnar LINDSTRAND SMS MEVAC GmbH DEUTSCHLAND Dipl.-Ing. Dieter TEMBERGEN ACRONI, PODJETJE ZA PROIZVODNJO JEKLA IN JEKLENIH IZ SLOVENIJA Dr. Anton JAKLIC

RFSR-CT-2007-00008 FLEXCHARGE

Full Title Cost and energy effective management of EAF with flexible charge material mix Info Type of Project Research Duration (months) 42 Total Budget 2223918 € Start Date 1/07/2007 EU Contribution 1334351 € End Date (actual) 31/12/2010 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA25094:EN Summary Objective of the project is the set-up of an innovative methodology to manage in an effective way the EAF charged with the variable materials mix guarantying the required steel quality, the cost to produce crude steel and the environmental constrains having in mind the volatility of scrap quality-price ratio and the pressures arising from CO2 trading legislation. Thus the projects will address the issues of maximising the use of low quality scrap in the charge mix, will investigate the use of the scrap substitutes, like Direct Reduced Iron (DRI) and Hot Briquette Iron (HBI), as alternative to high quality scrap and will optimize the energy input required to melt down the charged materials. The development of new operation procedures and control tools will be supported by especially designed laboratory, pilot and industrial tests. Partners Organization Country Responsible CENTRO SVILUPPO MATERIALI SPA ITALIA Dr. Enrico MALFA (Project Coord.) CENTRE DE RECHERCHES METALLURGIQUES ASBL BELGIQUE Mr Marcel DORMANN FERALPI SIDERURGICA S.p.A. ITALIA Ing. Francesco MAGNI GEORGSMARIENHÜTTE GmbH DEUTSCHLAND Dr.-Ing. Ingo KOLM SWEREA MEFOS AB SVERIGE Dr. Erik SANDBERG OVAKO BAR AB SVERIGE Mr Risto PONKALA GERDAU INVESTIGACION Y DESARROLLO EUROPA S.A. ESPAÑA Mr Santiago LANDA LAZCANO VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Dr.-Ing. Bernd KLEIMT

RFSR-CT-2007-00009 StImprove

Full Title Improvement of ladle stirring to minimise slag emulsification and reoxidation during alloying and rinsing Info Type of Project Research Duration (months) 36 Total Budget 1011155 € Start Date 1/07/2007 EU Contribution 606693 € End Date (actual) 30/06/2010 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA25068:EN Summary The objective of this research project is to improve steel metallurgy and quality by minimising slag emulsification and reoxidation during stirring in secondary metallurgy. Advanced monitoring of stirring processes will be applied to assess their impact on necessary metallurgical applied operation. In addition, the duration of melt treatments will be shortened, the dissolution of alloying additions will be improved and the amount of ladle stirring gas will be reduced. Interaction of stirring process parameters with steel metallurgy will be clarified. This will allow to perform dynamic stirring throughout the whole necessary treatment time. Partners Organization Country Responsible VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Dr.-Ing. Herbert KÖCHNER (Project Coord.) KUNGLIGA TEKNISKA HÖGSKOLAN - THE ROYAL INSTITUTE SVERIGE Prof. Dr. Du SICHEN SAARSTAHL AG DEUTSCHLAND Dr. Peter VALENTIN AALTO-KORKEAKOULUSAATIO (AALTO UNIVERSITY FOUN FINLAND Dr. Seppo LOUHENKILPI

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RFSR-CT-2007-00010 URIOM

Full Title Upgrading and utilisation of residual iron oxide materials for hot metal production Info Type of Project Research Duration (months) 42 Total Budget 1563498 € Start Date 1/07/2007 EU Contribution 938099 € End Date (actual) 31/12/2010 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA25081:EN Summary The proposed project focuses on development of innovative pyrometallurgical technologies for recycling especially of residuals from stainless steel making. One part deals with the briquetting of stainless steel residuals and direct recycling into the EAF. The other part deals with the development of the innovative inductive heated coke bed technology as a key process for recycling especially stainless steel residuals in parallel to the EAF with a complete recovery of alloying elements for steelmaking, zinc for non ferrous metals use and slag usable for building applications as an approach for a zero waste technology in stainless steel making. To lower the electric energy demand the inductive heated coke bed shall be charged by molten material as well as preheated coke. For the experimental investigations an existing flash melter shall be used for charging the molten material. The charged coke shall be treated in a special coke preheater. The inductive heated coke bed technology seems not only to be coupled with a flash melting unit but also applicable to the low shaft furnace/cupola process like that one operated by TKS for steel works residues. This will broaden the application of the process to stainless steel residual processing. The need for agglomerated material for the shaft furnace process is the link to the briquetting investigations planned within this project. The proposed research is in complete accordance with the priority “sustainable use of resources” of the Strategic Research Agenda of ESTEP with high relevance for the RFCS programme and is specially supported by the ESTEP Working Group 1 “Profit“. Partners Organization Country Responsible VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Dipl.-Ing. Gerald STUBBE (Project Coord.) BÖHLER EDELSTAHL GmbH & Co. KG OESTERREICH Mr Michael EBNER CENTRO SVILUPPO MATERIALI SPA ITALIA Dr.ssa Ilaria PISTELLI TRIBOVENT VERFAHRENSENTWICKLUNG GmbH OESTERREICH DI Alfred EDLINGER

RFSR-CT-2007-00011 STEELCLEANCONTROL

Full Title Development of steel grade related slag systems with low reoxidation potential in ladle and optimised ladle glaze technique for improving steel cleanliness Info Type of Project Research Duration (months) 36 Total Budget 1377999 € Start Date 1/07/2007 EU Contribution 826800 € End Date (actual) 30/06/2010 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA25076:EN Summary The technical objective of this project is to investigate the interaction between deoxidised steel (low- and high-alloyed steel grades) melts and oxidic materials during the process of ladle metallurgy. Finally steel grade specific slag systems and the ladle glaze technique will be optimised in view of low reoxidation potentials and a low tendency for uncontrolled inclusion formation. In this way steel cleanliness can be improved through lower amounts of non-metallic inclusions, which has a beneficial impact on productivity and quality of steel products. The formation and modification of inclusion by ladle slags, ladle lining and ladle glaze will be studied in detail. These aspects will be investigated on selected steel grades both under process and laboratory conditions. Through the close cooperation between industrial partners and universities optimised slag compositions and treatment strategies will be developed and verified in practice. European steelworks will finally profit from these project results. Partners Organization Country Responsible TECHNISCHE UNIVERSITÄT BERGAKADEMIE FREIBERG DEUTSCHLAND Prof. Dr.-Ing. Piotr R. SCHELLER (Project Coord.) KUNGLIGA TEKNISKA HÖGSKOLAN - THE ROYAL INSTITUTE SVERIGE Prof. Dr. Du SICHEN SSAB EMEA AB SVERIGE Mrs Mia ALMCRANTZ THYSSENKRUPP NIROSTA GMBH DEUTSCHLAND Dr.-Ing. Jörg-Friedrich HOLZHAUSER UDDEHOLM TOOLING AB SVERIGE Dr. Mselly NZOTTA

RFSR-CT-2008-00002 INCLUSION

Full Title Innovative methodology for through process inclusion level forecasting of engineering steel Info Type of Project Research Duration (months) 36 Total Budget 1128550 € Start Date 1/07/2008 EU Contribution 677130 € End Date (actual) 30/06/2011 State Research in progress Summary The project objective is to develop a tool of "intelligent manufacturing" based on statistical inclusion analysis. The intelligent manufacturing is based on the correlation among the inclusion taken during steelmaking route and inclusions on the product and this fact will allow to control the subsequent rolling operation, helping the operator to make the best coupling of inclusion characteristics and leel of rolling. The statistical methodology selected is the extreme value statistic, which allows the description of an inclusion family in terms of maximum defect measured. Partners Organization Country Responsible COGNE ACCIAI SPECIALI SpA ITALIA Dr. Elena BALDUCCI (Project Coord.) CENTRO SVILUPPO MATERIALI SPA ITALIA Dr. Filippo CIRILLI GERDAU INVESTIGACION Y DESARROLLO EUROPA S.A. ESPAÑA Mr Jacinto ALBARRAN SANZ VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Dipl -Ing Norbert LINK

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RFSR-CT-2008-00003 LOWCNEAF

Full Title Optimised production of low C and N steel grades via the electric steelmaking route Info Type of Project Research Duration (months) 42 Total Budget 1698420 € Start Date 1/07/2008 EU Contribution 1019052 € End Date (actual) 31/12/2011 State Research technically completed; publication in hand Summary The main objective of the project is to develop a through-process control strategy for a reliable, simultaneous achievement of low steel carbon and nitrogen levels within electric steelmaking under minimum energy and material costs with optimal productivity. This shall be achieved by investigation of relevant operational parameters and modelling of pick-up and removal of C and N within all aggregates of the process route. Regarding EAF, focus will be laid on the use of alternative iron materials (pig iron, DRI/HBI) to lower C and N contents at tapping. The control system will be applied on-line at five electrical steelmaking plants with different process routes and aggregates (EAF,LF,VD) for various steel products (wire, beam blanks, sectionals, SBQ, slabs). Partners Organization Country Responsible VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Dr.-Ing. Bernd KLEIMT (Project Coord.) ARCELORMITTAL OLABERRIA S.L. ESPAÑA Dr. José Luis RENDUELES VIGIL CENTRE DE RECHERCHES METALLURGIQUES ASBL BELGIQUE Mr Pierre NYSSEN PEINER TRÄGER GmbH DEUTSCHLAND Mr Matthias SCHÖRING RIVA ACCIAIO SPA ITALIA Dr.-Ing. Nicola VENERI GERDAU INVESTIGACION Y DESARROLLO EUROPA S.A. ESPAÑA Mr Asier ARTEAGA

RFSR-CT-2008-00004 BATHFOAM

Full Title Control of slag and refining conditions in the BOF Info Type of Project Research Duration (months) 42 Total Budget 1838043 € Start Date 1/07/2008 EU Contribution 1102826 € End Date (actual) 31/12/2011 State Research technically completed; publication in hand Summary Control of slag foaming the BOF has always been problematic. With increased pressure on process yields and productivity, combined with increased demands for accurate control of refining in the process it is important to develop a process control tool that can control slag foaming and thus consistently achieve the optimum performance from both a perspective of slopping control as well as refining in the BOF. The project aims to use static and dynamic process data from many sources in the process and relate them to process performance by using advanced statistical analysis tools. This will be used, combined with data from analytical models for the BOF refining reactions, to develop a process control system that pro-actively controls slag formation in the BOF. If successful the project should result in improved productivity and process yields, as well as reduced flux consumption and dust emissions from the plants. Partners Organization Country Responsible TATA STEEL UK LIMITED UNITED KINGDOM Ir. Johan VAN BOGGELEN (Project Coord.) ARCELORMITTAL ESPAÑA SA ESPAÑA Mr Luis Fernando SANCHO MENDEZ ARCELORMITTAL MAIZIERES RESEARCH S.A. FRANCE Dr. Jean-Christophe HUBER KUNGLIGA TEKNISKA HÖGSKOLAN - THE ROYAL INSTITUTE SVERIGE Prof. Dr. Du SICHEN POLITECNICO DI MILANO ITALIA Prof. Walter NICODEMI VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Dr.-Ing. Bernd KLEIMT

RFSR-CT-2008-00044 LAREFMON

Full Title Enhanced reliability in ladle refining processes (VD, VOD and LF) by improved on-line process monitoring and control Info Type of Project Research Duration (months) 36 Total Budget 1283954 € Start Date 1/12/2008 EU Contribution 770372 € End Date (actual) 30/11/2011 State Research technically completed; publication in hand Summary The main objective of this project is to develop and apply an enhanced on-line monitoring and control system for reliable operation of different ladle refining processes (VD, VOD and LF). Joint application of new thermal imaging based evaluation of stirring efficiency and improved dynamic process models will lead to reliable control and improved performance of the main metallurgical operations during ladle refining. Expected benefits are improved quality and cleanness of liquid steel and reduced treatment times, leading to lower energy losses and improved productivity. Regarding vacuum degassing, the well-aimed control of stirring will lessen the problems with slag foaming and slopping, and will reduce the risk of potentially dangerous slag overflow. Partners Organization Country Responsible VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Dr.-Ing. Herbert KÖCHNER (Project Coord.) ARCELORMITTAL RUHRORT GMBH DEUTSCHLAND Mr Jürgen KRUCK GERDAU INVESTIGACION Y DESARROLLO EUROPA S.A. ESPAÑA Mr Asier ARTEAGA VOESTALPINE STAHL DONAWITZ GmbH & Co KG OESTERREICH Dr. Gerald KLÖSCH

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RFSR-CT-2009-00003 LADLIFE

Full Title Enhanced steel ladle life by improving the resistance of lining to thermal, thermomechanical and thermochemical alteration Info Type of Project Research Duration (months) 36 Total Budget 1241458 € Start Date 1/07/2009 EU Contribution 744875 € End Date (actual) 30/06/2012 State Research in progress Summary Ladle refractory wear is an important concern for steelmakers, not only for the material cost but also for its influence on plant productivity and safety. This project aims at enhancing ladle lining life, helping steelmakers in decisions about materials to use and in scheduling of maintenance operations. This will be achieved by model based soft sensors and laboratory work. The wear of ladle lining is mainly due to its cyclic interaction with steel and slag during its normal operation. The understanding of the chemical, thermo-chemical and thermo-mechanical reactions in the metal-slag-refractory system is the key to reach the planned goal. Partners Organization Country Responsible GERDAU INVESTIGACION Y DESARROLLO EUROPA S.A. ESPAÑA Mr Asier ARTEAGA (Project Coord.) CENTRO SVILUPPO MATERIALI SPA ITALIA Dr. Mario TONELLI LUCCHINI S.p.A. ITALIA Mr Luca TRILLINI VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Dr.-Ing. Guido MITTLER

RFSR-CT-2009-00004 GREENEAF

Full Title Sustainable EAF steel production Info Type of Project Research Duration (months) 36 Total Budget 2031872 € Start Date 1/07/2009 EU Contribution 1219124 € End Date (actual) 30/06/2012 State Research in progress Summary The objective is to study the EAF cycle in order to investigate the partial or total substitution of coal and natural gas with charcoal and biogas produced from pyrolysis of biomass (agricultural and forest residues). The char is used as powder or in suitable size in the basket. For each of these use the following phases: preparation starting from pyrolysis process, mechanical preparation, briquetting if necessary, transport and use in EAF will be analysed. The biogas is used for EAF burners. The characteristics of char and biogas, and the related pyrolysis process, is tailored in order to match the requirements for their utilisation in EAF. Partners Organization Country Responsible FERRIERE NORD S.P.A. ITALIA Dr. Loris BIANCO (Project Coord.) CENTRO SVILUPPO MATERIALI SPA ITALIA Dr. Filippo CIRILLI DEUTSCHE EDELSTAHLWERKE GMBH DEUTSCHLAND Dipl.-Ing. Hans-Peter JUNG IMPERIAL COLLEGE OF SCIENCE, TECHNOLOGY AND MEDI UNITED KINGDOM Dr. Marcos MILLAN STAHL- UND WALZWERK MARIENHÜTTE GMBH OESTERREICH Dipl -Ing Hans-Jörg KRASSNIG RHEINISCH-WESTFÄLISCHE TECHNISCHE HOCHSCHULE AA DEUTSCHLAND Dr.-Ing. Lukas VOJ TECNOCENTRO ENG SRL ITALIA Dr. Giacomo Matteo RICCI

RFSR-CT-2010-00003 TOTOPTLIS

Full Title Multi-criteria through-process optimisation of liquid steelmaking Info Type of Project Research Duration (months) 42 Total Budget 1632592 € Start Date 1/07/2010 EU Contribution 979555 € End Date (actual) 31/12/2013 State Research in progress Summary Main project objective is the development of a through-process integrated approach for process chain optimisation in liquid steelmaking. Real-time monitoring and predictive models, elaborating process and sensor data from different aggregates, shall be integrated for a through-process multi-criteria optimisation of material and energy input regarding quality, productivity and costs. A dynamic and optimised modification of the planned process route for a heat will be suggested in case of detected deviations in quality relevant parameters. The system shall be applied at two BOF and one EAF steelmaking plant with different routes and secondary metallurgy equipment, to ensure the concept transferability to further plants. Partners Organization Country Responsible CENTRO SVILUPPO MATERIALI SPA ITALIA Dr. Maria MURRI (Project Coord.) ARCELORMITTAL ESPAÑA SA ESPAÑA Mr Javier RODRIGUEZ SOMOANO LUCCHINI S.p.A. ITALIA Dr. Marco BIANCHI PEINER TRÄGER GmbH DEUTSCHLAND Mr Matthias SCHÖRING VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Dr.-Ing. Bernd KLEIMT

RFSR-CT-2010-00004 PROTECT

Full Title Processes and technologies for environmentally friendly recovery and treatment of scrap Info Type of Project Research Duration (months) 42 Total Budget 3277463 € Start Date 1/07/2010 EU Contribution 1966477 € End Date (actual) 31/12/2013 State Research in progress Summary Recycling of coated scrap is currently limited by formation of problematic by-products, such as zinc containing dust and hazardous air emissions. A proposed innovative stand alone process for preheating and surface cleaning of scrap is expected to significantly improve the recyclability of such scrap sources, thus widening the scrap base, simplifying recycling of in-house by-products and reducing hazardous emissions. The process utilizes chlorine containig waste, such as automotive shredder residues, in separate oxygen combustion enabling minimisation of flue gases. The coatings are removed in gas phase and collected in dedicated recovery system rendering the possibility for recovery of valuable metals. 74 Partners Organization Country Responsible Summaries of RFCS projects 2003-2012 TGS2 : Steelmaking processes

SWEREA MEFOS AB SVERIGE Dr. Mikael LARSSON (Project Coord.) ENGITEC TECHNOLOGIES SPA ITALIA Dr. Massimo MACCAGNI IVL SVENSKA MILJÖINSTITUTET AB SVERIGE Mr Anders BJÖRK SICON GMBH DEUTSCHLAND Dipl.-Ing. Gabriel LESINSKY SSAB TUNNPLÅT AB SVERIGE MSc Leif NILSSON SCUOLA SUPERIORE DI STUDI UNIVERSITARI E DI PERFEZI ITALIA Dr. Valentina COLLA STENA METALL A/S DANMARK Mr Erik RASMUSSEN STENA METALL SERVICE AB SVERIGE Mr Christer FORSGREN UNIVERSITÄT SIEGEN DEUTSCHLAND Prof Dr Ing Hab Wolfgang KRUMM

RFSR-CT-2010-00005 OPTDESLAG

Full Title Increased yield and enhanced steel quality by improved deslagging and slag conditioning Info Type of Project Research Duration (months) 36 Total Budget 1030338 € Start Date 1/07/2010 EU Contribution 618203 € End Date (actual) 30/06/2013 State Research in progress Summary The project objective is to improve the deslagging process during two process steps of liquid steelmaking, i.e. after hot metal desulphurisation and before secondary steelmaking, by applying image sensors to control deslagging operations. Aim is to increase the yield by minimising the metallic losses, and to minimise the amount of remaining slag after deslagging. Furthermore, based on new information from image analysis about the efficiency of deslagging, a dynamic control of the following slag conditioning process shall be developed, to ensure optimal conditions for subsequent metallurgical processes. Thus the quality of the liquid steel shall be improved. Partners Organization Country Responsible VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Dr.-Ing. Herbert KÖCHNER (Project Coord.) SWEREA MEFOS AB SVERIGE Mr Lars-Erik FROM SAARSCHMIEDE GMBH FREIFORMSCHMIEDE DEUTSCHLAND Dr. Bernhard DONTH SSAB TUNNPLÅT AB SVERIGE Mr Magnus ANDERSSON

RFSR-CT-2011-00004 INTCLEANCON

Full Title Intelligent cleanness controls in secondary steelmaking by advanced off- and online process models Info Type of Project Research Duration (months) 42 Total Budget 1407643 € Start Date 1/07/2011 EU Contribution 844586 € End Date (actual) 31/12/2014 State Research in progress Summary This project will develop new off-line and on-line models and will apply them for advanced industrial control strategies and practices in secondary metallurgy, in order to guarantee highest steel cleanness levels for high quality steels, with focus on case hardening and microalloyed grades. The application of on-line control strategies, based on a combination of through-process models and new monitoring and control techniques for stirring during ladle metallurgy processes, should enable the reliable achievement of improved quality and castability. This will lead to an increased yield due to a lower number of heats to be downgraded due to quality problems. Partners Organization Country Responsible FUNDACION TECNALIA RESEARCH & INNOVATION ESPAÑA Mr Juan PALACIOS (Project Coord.) DEUTSCHE EDELSTAHLWERKE GMBH DEUTSCHLAND Dipl.-Ing. Hans-Peter JUNG GERDAU INVESTIGACION Y DESARROLLO EUROPA S.A. ESPAÑA Ms Tamara RODRÍGUEZ DURAN VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Dipl.-Ing. Roger KOITZSCH

RFSR-CT-2012-00005 PLUGWATCH

Full Title Stirring plug monitoring system for improvement of plug availability and stirring performance Info Type of Project Research Duration (months) 36 Total Budget 1919343 € Start Date 1/07/2012 EU Contribution 1151605 € End Date (actual) 30/06/2015 State Research in progress Summary The aim of this research proposal is the development and installation of online monitoring systems for stirring plugs in steel ladles in order to determine and predict their availability and performance for stirring processes. This is realised by interaction of suitable measurement techniques for refractory temperatures, numerical simulations of process induced changes in stirring plugs during operation, plant trials with stirring plugs differing in composition and geometry and software engineering. Actual information of wear status, stirring plug availability and their performance avoids non-stirring events, provides accurate stirring procedures and therewith supports a trouble-free steel production. Partners Organization Country Responsible VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Mr Birgit PALM (Project Coord.) CENTRO SVILUPPO MATERIALI SPA ITALIA Dr. Mario TONELLI DEUTSCHE EDELSTAHLWERKE GMBH DEUTSCHLAND Mr Leandro SCHÖTTLER GERDAU INVESTIGACION Y DESARROLLO EUROPA S.A. ESPAÑA Mr Asier ARTEAGA THYSSENKRUPP ACCIAI SPECIALI TERNI SpA ITALIA Mr Massimo PROIETTI CERQUONI

75 Summaries of RFCS projects 2003-2012 TGS2 : Steelmaking processes

RFSR-CT-2012-00006 SLACON

Full Title Control of slag quality for utilisation in the construction industry Info Type of Project Research Duration (months) 42 Total Budget 1833659 € Start Date 1/07/2012 EU Contribution 1100196 € End Date (actual) 31/12/2015 State Research in progress Summary During steelmaking, slag is generated in different kinds of processes. Processed slag can be used as building material if certain quality criteria are met. Slag quality is defined by mechanical properties and by environmental behaviour of slag. Maximum concentrations of leachable substances in the slag eluate, for example fluoride, molybdenum, chromium and vanadium, have been fixed to define slag quality. Slag quality and the possibilities of slag utilisation can be improved by: a) immobilisation of these leachable substances and b) recycling of washing/cooling water from slag treatment with elimination of leachable components. The project aims at ensuring and increasing the utilisation of steelmaking slags in the construction industry by improving the quality of slag. For this purpose, new techniques have to be developed to immobilise the critical elements and separate remaining leachable substances (e.g. fluoride, molybdenum, chromium and vanadium) from the washing/cooling water and to condition these separated substances for disposal or reuse. The elimination of leachable substances in a closed-loop process helps to avoid the entry of leachable substances into the environment and supports the resource-efficient utilisation of steelmaking slags. Partners Organization Country Responsible FEhS - INSTITUT FÜR BAUSTOFF-FORSCHUNG e.V. DEUTSCHLAND Dr.-Ing. Dirk MUDERSBACH (Project Coord.) CENTRO SVILUPPO MATERIALI SPA ITALIA Dr. Filippo CIRILLI RIVA ACCIAIO SPA ITALIA Eng Stefano BARAGIOLA GERDAU INVESTIGACION Y DESARROLLO EUROPA S.A. ESPAÑA Dr. Iňigo UNAMUNO VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Dr. Barbara WENDLER

76

Technical Group Steel 3

Casting

The scope of TGS3 includes:

• Continuous casting and near net shape casting techniques with or without direct rolling for flat and long products

• Chemistry and physics of solidification

• Ingot casting

• Maintenance and reliability of production lines

• Reduction of emissions, energy consumption and improvement of the environmental impact

• Standardisation of testing and evaluation methods

• Instrumentation, modelling and control of processes

77 78 Summaries of RFCS projects 2003-2012 TGS3 : Casting

RFSP-CT-2003-00033 THINSTRIP

Full Title Industrial realisation of the production of thin strip in a casting rolling line Info Type of Project Pilot&Demonstration Duration (months) 36 Total Budget 696664 € Start Date 1/09/2003 EU Contribution 278666 € End Date (actual) 31/08/2006 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA23351:EN Summary This project aims to substitude cold strip for deep drawing applications by hot strip for economic, time-saving and ecological reasons. For that a thin slab casting and direct rolling line shall be used. Ferritic rolling is a suitable rolling method for the necessary thin hot strips. Starting with an ELC-grade two main processing routes shall be tested, which are high finishing rolling and coiling temperatures to get a soft and ductile hot strip for direct application and low finishing rolling and coiling temperatures to get a strained thin hot strip for direct annealing and hot dip galvanising. Partners Organization Country Responsible THYSSENKRUPP STEEL EUROPE AG DEUTSCHLAND Dr. Hans-Peter SCHMITZ (Project Coord.) TECHNISCHE UNIVERSITÄT BERGAKADEMIE FREIBERG DEUTSCHLAND Prof Dr -Ing Rudolf KAWALLA

RFSP-CT-2005-00008 Beam-blank MFC

Full Title Direct casting of small sections beam-blanks thanks to meniscus free casting technology Info Type of Project Pilot&Demonstration Duration (months) 48 Total Budget 1467150 € Start Date 1/07/2005 EU Contribution 586860 € End Date (actual) 30/06/2009 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA25057:EN Summary The aim of this demonstration project is to show, through pilot trials, that beam blanks for the production of small sections can be cast continuously close to the final shape using Meniscus Free Casting technology. The pilot caster at Arcelor Research will be used to optimise the process in terms of productivity, production costs and quality. Substantial savings are expected for the casting operations due to streamlined process and the simplicity of the installation. Additional cost reductions of at least 15 €/ton are expected for the rolling operations due to hot charging and the reduction of the number of rolling passes. The installations associated with the process will be very compact, leading to further savings on investment costs. Partners Organization Country Responsible ARCELORMITTAL MAIZIERES RESEARCH S.A. FRANCE Mr Martin BEAUVAIS (Project Coord.) ARCELORMITTAL BELVAL & DIFFERDANGE S.A. LUXEMBOURG Dr. Pierre HUBSCH

RFSP-CT-2012-00007 FOMTM

Full Title Application of fibre optical thermal monitoring at CC-billet mould for improved product quality Info Type of Project Pilot&Demonstration Duration (months) 42 Total Budget 855824 € Start Date 1/07/2012 EU Contribution 427912 € End Date (actual) 31/12/2015 State Research in progress Summary Aim is to develop and operate a better control of initial solidification at meniscus level to enhance surface quality of as-cast products. An innovative sensor system based on fibre optical mould temperature sensors will be used which was initially developed in the previous RFCS research project MasterBillet. This system will be further developed to identify irregular casting conditions with particular reference to mould powder feeding, slag rim formation and irregularities in initial solidification. The developed system will be put into practice at a billet mould and corrective actions to assurance a better quality of as cast product will be validated. Partners Organization Country Responsible VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Dr. rer. nat. Torsten LAMP (Project Coord.) GERDAU INVESTIGACION Y DESARROLLO EUROPA S.A. ESPAÑA Dr. Iňigo UNAMUNO

RFSR-CT-2003-00003 CASTDESMON

Full Title Improvement, control & prediction of cast & rolled products through development & application of novel engineering monitoring techniques Info Type of Project Research Duration (months) 50 Total Budget 1994997 € Start Date 1/09/2003 EU Contribution 1196998 € End Date (actual) 31/10/2007 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA23853:EN Summary The project will develop improved means of defining, monitoring and assessing the effects of caster design, condition and operation on slab, bloom and rolled product quality in order to enable better control of the process and to provide the required data for quality prediction. The project will determine the effects of mould taper, wear, metal level, heat transfer and friction as well as secondary cooling and strand guide alignment under steady state and dynamic conditions; relationships with product quality data will be established together with means of predicting and controlling caster condition. Partners Organization Country Responsible TATA STEEL UK LIMITED UNITED KINGDOM Dr. Gerard STEPHENS (Project Coord.) ARCELORMITTAL EISENHÜTTENSTADT GmbH DEUTSCHLAND Dipl.-Ing. Bertram SEHER ARCELORMITTAL ESPAÑA SA ESPAÑA Mr Luis Fernando SANCHO MENDEZ CENTRO SVILUPPO MATERIALI SPA ITALIA Dr.-Ing. Arianna GOTTI FORSCHUNGS- UND QUALITÄTSZENTRUM BRANDENBURG DEUTSCHLAND Dipl.-Ing. Ramona KLÖPPEL FUNDACION TECNALIA RESEARCH & INNOVATION ESPAÑA Mr Martin OJANGUREN OTAZUA VOESTALPINE STAHL DONAWITZ GmbH & Co KG OESTERREICH Dipl.-Ing. Markus FORSTHUBER VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Dipl -Ing Norbert LINK

79 Summaries of RFCS projects 2003-2012 TGS3 : Casting

RFSR-CT-2003-00005 Nox-RF

Full Title Minimizing Nox emissions from reheating furnaces Info Type of Project Research Duration (months) 42 Total Budget 2554141 € Start Date 1/09/2003 EU Contribution 1532485 € End Date (actual) 28/02/2007 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA23202:EN Summary This project will investigate NOx reduction in laboratory and pilot furnaces for both air and oxyfuel combustion with the support of CFD combustion modelling. The objective is to reduce NOx emissions from steel reheating furnaces while maintaining dood fuel efficiency and low CO levels for both air combustion and oxyfuel combustion. There are many potential ways to reduce NOx for older steel reheating furnaces, including low NOx burners, internal flue gas recirculmation, chemical scrubbing and oscillating combustion. This project will give recommendations for the best techniques to reduce NOx emissions. Partners Organization Country Responsible SWEREA MEFOS AB SVERIGE Dr. John NISKA (Project Coord.) L'AIR LIQUIDE SA FRANCE Dr. Rémi TSIAVA CENTRO SVILUPPO MATERIALI SPA ITALIA Dr. Enrico MALFA FUNDACION TECNALIA RESEARCH & INNOVATION ESPAÑA Mr Jesus DE LA QUINTANA INSTITUTO DE SOLDADURA E QUALIDADE PORTUGAL Dr. Joao Fernando GOMES TENOVA SpA ITALIA Ing. Chim. Marco DANERI VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Dr.-Ing. Heinz-Peter GITZINGER VOESTALPINE STAHL GMBH OESTERREICH Dr. Bernhard KAUFMANN

RFSR-CT-2003-00022 PRESEG

Full Title Prediction of rolled product properties by correlation with as-cast structure & rolled product, plant process variables, plant process variables including modelling of segregation Info Type of Project Research Duration (months) 42 Total Budget 1962853 € Start Date 1/09/2003 EU Contribution 1177712 € End Date (actual) 28/02/2007 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA23309:EN Summary The aim of the proposal is to relate centreline segregation severity and distribution to the rolled product quality. This will be achieved by combining plant measurements, modelling and metallurgical assessment and taking an integrated view of the casting and subsequent rolling processes via slab, bloom and billet routes for both long and flat products. Partners Organization Country Responsible TATA STEEL UK LIMITED UNITED KINGDOM Mr Brian BARBER (Project Coord.) ARCELORMITTAL ESPAÑA SA ESPAÑA Mr Luis Fernando SANCHO MENDEZ CENTRO SVILUPPO MATERIALI SPA ITALIA Dr. Irene LUZZO HELSINKI UNIVERSITY OF TECHNOLOGY - TEKNILLINEN KO FINLAND M Sc Jukka LAINE SWEREA KIMAB AB SVERIGE Dr. Jacek KOMENDA SCUOLA SUPERIORE DI STUDI UNIVERSITARI E DI PERFEZI ITALIA Dr. Valentina COLLA VOESTALPINE STAHL DONAWITZ GmbH & Co KG OESTERREICH Dipl.-Ing. Markus FORSTHUBER

RFSR-CT-2003-00027 FLUXFLOW

Full Title Enhanced steel product quality & productivity by improved flux performance in the mould through optimising the multiphase flow conditions & special regard to melting & entrapment Info Type of Project Research Duration (months) 42 Total Budget 1770935 € Start Date 1/09/2003 EU Contribution 1062560 € End Date (actual) 28/02/2007 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA23182:EN Summary Optimum melting of flux and behaviour of the molten flux pool as well as the avoidance of flux entrapment are important requirements to be achieved simultaneously for a stable casting process and a high product quality. The aim of the project performed by steel producers (TKN, Aceralia, Sidenor, Cogne) and research institutions (BFI and CSM) is to provide concrete information on the necessary optimum constructive and process engineering measures to adjust the flow conditions in the mould in order to fulfil these requirements. This research will cover flat and long products as well as carbon and stainless steels. The outcome of this research are important benefits for a great number of European steel producers concerning improved productivity and quality as well as a safe casting process saving resources. Partners Organization Country Responsible VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Dipl.-Ing. Sigurd RÖDL (Project Coord.) ACERALIA CORPORACION SIDERURGICA S.A. ESPAÑA Mr Luis Fernando SANCHO MENDEZ COGNE ACCIAI SPECIALI SpA ITALIA Dr. Armando POLI CENTRO SVILUPPO MATERIALI SPA ITALIA Dr. Michele DE SANTIS GERDAU INVESTIGACION Y DESARROLLO EUROPA S.A. ESPAÑA Mr Javier CIRIZA THYSSENKRUPP NIROSTA GMBH DEUTSCHLAND Dr.-Ing. Jörg-Friedrich HOLZHAUSER

80 Summaries of RFCS projects 2003-2012 TGS3 : Casting

RFSR-CT-2003-00036 REGTGF

Full Title Improvement of top gas fired reheating and direct reduction furnaces for high temperature using innovative regenerative burners Info Type of Project Research Duration (months) 40 Total Budget 1219192 € Start Date 1/09/2003 EU Contribution 731515 € End Date (actual) 31/12/2006 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA24029:EN Summary Due to needed high temperature in reheating and direct reduction furnaces natural gas or oil are used in general. These are expensive fuels and at the same time steel works byproduct gases like top gas are often not used but flared. Flame temperature of top gas normally does not reach the required level for reheating and direct reduction processes. Therefore a combined preheating of combustion air and top gas by the use of ceramic regenerators will be developed and tested. Therewith waste gas is exhausted locally instead of streaming throughout the complete furnace and local temperatures inside the furnace will become adjustable more precisely. Partners Organization Country Responsible VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Dr.-Ing. Wolfgang ADLER (Project Coord.) AKTIEN-GESELLSCHAFT DER DILLINGER HÜTTENWERKE AG DEUTSCHLAND Dipl.-Ing. Klaus EBERWEIN CENTRO SVILUPPO MATERIALI SPA ITALIA Dr. Umberto ZANUSSO

RFSR-CT-2004-00009 EDDYCAST

Full Title Multiplexed eddy-current arrays for the detection of corner cracks on as cast products in the inspection yard & at the exit of continuous casting Info Type of Project Research Duration (months) 54 Total Budget 1039110 € Start Date 1/07/2004 EU Contribution 623466 € End Date (actual) 31/12/2008 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA24181:EN Summary Despite several previous attempts, detection of transverse corner cracks at the exit of continuous casting is not operational. Gains of 15M€/y may be expected for European steel production with very positive environmental aspects, through the reduction of the size of cold slab inspection yard, and possible direct hot charging in the hot mills. This proposal aims to investigate the recent multiplexed eddy-current array technology, beginning with a laboratory study and field tests on cold products to determine the most appropriate solution. Then with tests on hot slabs and billets at the exit of continuous casting will be conducted. Partners Organization Country Responsible ARCELORMITTAL MAIZIERES RESEARCH S.A. FRANCE Dr. Philip MEILLAND (Project Coord.) AKTIEN-GESELLSCHAFT DER DILLINGER HÜTTENWERKE AG DEUTSCHLAND Dr.-Ing. Helmut LACHMUND GERDAU INVESTIGACION Y DESARROLLO EUROPA S.A. ESPAÑA Mr Juan José LARAUDOGOITIA THYSSENKRUPP STEEL EUROPE AG DEUTSCHLAND Dr. Wolfram WEBER

RFSR-CT-2004-00010 CASTINCREM

Full Title Cast product improvement by "through process" inclusion assessment and removal Info Type of Project Research Duration (months) 45 Total Budget 1256036 € Start Date 1/07/2004 EU Contribution 753621 € End Date (actual) 31/03/2008 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA23898:EN Summary Improved steel cleanness is essential for higher quality steels. Despite extensive research, carry-through or agglomeration of inclusions during casting leads to poor steel quality. Much work has focused on steelmaking, yet there remains limited understanding of inclusion interactions at the submerged entry nozzle, leading to defects. This project will: Relate inclusion behaviour with stable and unstable casting parameters, including application of novel techniques. Extend CFD modelling capabilities to inclusion agglomeration in complex, unstable, and two-phase flows. Develop recommendations for improved performance and practical systems related to stopper accretions, nozzle blockage, nozzle gas pressures and inclusion removal in tundish and mould. Partners Organization Country Responsible TATA STEEL UK LIMITED UNITED KINGDOM Mr Alan SCHOLES (Project Coord.) ASCOMETAL S.A.S. FRANCE Mr Joël MANCINI GERDAU INVESTIGACION Y DESARROLLO EUROPA S.A. ESPAÑA Mr Santiago LANDA LAZCANO VOESTALPINE STAHL DONAWITZ GmbH & Co KG OESTERREICH Dr. Axel SORMANN VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Dipl.-Ing. Sigurd RÖDL

RFSR-CT-2004-00011 FLOWVIS

Full Title Measurement, prediction and control of steel flows in the casting nozzle and mould Info Type of Project Research Duration (months) 48 Total Budget 1357913 € Start Date 1/07/2004 EU Contribution 814748 € End Date (actual) 30/06/2008 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA24205:EN Summary The project will study the improvement of steel surface and internal quality by the development of measuring and predictive tools in the tundish nozzle and casting mould. Correlation and application of the developed tools with plant data to generate guidelines for quality improvement will be carried out. This will be achieved by further development of technologies to measure and visualise steel flow patterns in the casting nozzle (started under contract 7215.PP/045) combined with measurements of flow velocities and thermal conditions in the mould (following on from 7210.PP142) and correlation with plant data and process measurements. Partners Organization Country Responsible TATA STEEL UK LIMITED UNITED KINGDOM Mr Stuart R. HIGSON (Project Coord.) SWEREA MEFOS AB SVERIGE Mr Ulf SJÖSTRÖM 81 SAARSTAHL AG DEUTSCHLAND Dr. Peter VALENTIN Summaries of RFCS projects 2003-2012 TGS3 : Casting

GERDAU INVESTIGACION Y DESARROLLO EUROPA S.A. ESPAÑA Mr Javier CIRIZA VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Dr. rer. nat. Torsten LAMP

RFSR-CT-2005-00009 SMARTFIRE

Full Title Real-time intelligent diagnostics and optimisation of reheating furnace performance Info Type of Project Research Duration (months) 42 Total Budget 2056119 € Start Date 1/07/2005 EU Contribution 1233672 € End Date (actual) 31/12/2008 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA24174:EN Summary The overall project aims are to improve reheating furnace operation, maintenance and product quality by improved diagnostics, monitoring and control of process parameters. This will be achieved by developing an innovative flame analysis system and determination of combustion and furnace diagnostics using databases and statistical and physical models. These approaches will be amalgamated into a new prototype diagnostics, warning and suggestion (DWS) system. The DWS methodology will be used in at least two partner countries to optimise reheating furnace operation and reheated stock. Thus, the competitiveness and efficiency of the EU steel industry will be improved. Partners Organization Country Responsible TATA STEEL UK LIMITED UNITED KINGDOM Mr Graham ANDREWS (Project Coord.) ACERALIA CORPORACION SIDERURGICA S.A. ESPAÑA Mr Luis Antonio RODRIGUEZ LOREDO SWEREA MEFOS AB SVERIGE Dr. Bo LEDEN UNIVERSITY OF GLAMORGAN UNITED KINGDOM Prof. Steven WILCOX VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Dr.-Ing. Guido MITTLER

RFSR-CT-2005-00010 CLOGGING

Full Title New strategies for clogging prevention for improved productivity and steel quality Info Type of Project Research Duration (months) 36 Total Budget 1858335 € Start Date 1/07/2005 EU Contribution 1115001 € End Date (actual) 30/06/2008 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA24177:EN Summary Clogging is still a problem to solve. To achieve a break through in this project a new basic knowledge will be elaborated as a basis for the development of new strategies for clogging prevention like new feeding system designs in conjunction with innovative gas injection, prediction and control of clogging. This will be done in an integrated approach concerning chemical and physical phenomena in conjunction with an extensive operational data base using advanced or newly developed investigation and measurement methods. The obtained results will be verified by operational data and trials with a view to a final implementation of the new strategies in the operational praxis. Partners Organization Country Responsible VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Dipl.-Ing. Sigurd RÖDL (Project Coord.) ARCELORMITTAL ESPAÑA SA ESPAÑA Mr Luis Fernando SANCHO MENDEZ COMDICAST AB SVERIGE Dr. Sven EKEROT KUNGLIGA TEKNISKA HÖGSKOLAN - THE ROYAL INSTITUTE SVERIGE Dr. Margareta ANDERSSON RIVA ACCIAIO SPA ITALIA Dr.-Ing. Nicola VENERI RHEINISCH-WESTFÄLISCHE TECHNISCHE HOCHSCHULE AA DEUTSCHLAND Prof.Dr.-Ing. Dieter G. SENK SCUOLA SUPERIORE DI STUDI UNIVERSITARI E DI PERFEZI ITALIA Dr. Valentina COLLA VOESTALPINE STAHL GMBH OESTERREICH Dr. Guangmin XIA

RFSR-CT-2005-00011 SOLIMOULD

Full Title Enhanced as-cast product quality by optimised mould taper design Info Type of Project Research Duration (months) 42 Total Budget 1286510 € Start Date 1/07/2005 EU Contribution 771905 € End Date (actual) 31/12/2008 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA24176:EN Summary The aim of this project is to investigate how the taper in combination with shrinkage, operational parameters and other mould conditions (wear and distortion) affects as-cast product quality for different semis formats, namely billets and slabs. The achievement of this objective will provide crucial information for the optimisation of mould design and operational parameters, looking for the as-cast product quality improvement. Plant trials will be supported by mathematical modelling concerning early solidification and the interaction between solidified shell and mould. This is a collaborative work between Sidenor I+D, Centro Sviluppo Materiali (CSM), Corus UK Ltd and Betriebsforschungsinstitut (BFI). Partners Organization Country Responsible GERDAU INVESTIGACION Y DESARROLLO EUROPA S.A. ESPAÑA Dr. Iňigo UNAMUNO (Project Coord.) CENTRO SVILUPPO MATERIALI SPA ITALIA Dr. Maria Rita RIDOLFI TATA STEEL UK LIMITED UNITED KINGDOM Mr Andrew CHOWN VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Dr.-Ing. Oliver BREITFELD

82 Summaries of RFCS projects 2003-2012 TGS3 : Casting

RFSR-CT-2005-00012 SLAGFILMOWL

Full Title Optimising slag film properties and determination of operational windows for lubrication, mould heat transfer and shell formation Info Type of Project Research Duration (months) 42 Total Budget 2046240 € Start Date 1/07/2005 EU Contribution 1227745 € End Date (actual) 31/12/2008 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA24988:EN Summary The objective of this project is to optimise the lubrication within the mould and heat transfer from the shell to the mould via the definition of operational windows for the mould powder and numerical simulation of fluid flow at the meniscus and the effects of stresses and deformation on the forming shell. The operational windows will be defined through a correlation of slag and slag film properties, observed surface defects, caster and casting operational parameters and numerical simulation and model predictions. Achievement of the objectives will result in an improvement in as-cast surface quality. Partners Organization Country Responsible TATA STEEL UK LIMITED UNITED KINGDOM Dr. Bridget STEWART (Project Coord.) CENTRO SVILUPPO MATERIALI SPA ITALIA Dr. Antonello DI DONATO GEORGSMARIENHÜTTE GmbH DEUTSCHLAND Dr.-Ing. Ingo KOLM SWEREA KIMAB AB SVERIGE M.Sc. Carl-Ake DÄCKER OUTOKUMPU STAINLESS AB SVERIGE MSc. Appell ANDERS GERDAU INVESTIGACION Y DESARROLLO EUROPA S.A. ESPAÑA Dr. Iňigo UNAMUNO VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Dr.-Ing. Oliver BREITFELD

RFSR-CT-2005-00013 TUNDJUST

Full Title Innovative tundish management for final steel thermal and chemical adjustment Info Type of Project Research Duration (months) 36 Total Budget 1235681 € Start Date 1/07/2005 EU Contribution 741409 € End Date (actual) 30/06/2008 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA24348:EN Summary The research aim is to found possible/feasible actions on tundish casting for thermal/chemical adjustments: - thermal heating via chemical reactions at bath-insulating powder interface; - steel composition adjustment where mixing conditions are favourable; As a matter of fact, typical drawbacks when performing in ladle these metallurgy operations are: - time lag before tapping can increase bath re-oxidation affecting steel cleanliness ; - alloying elements re-oxidised, are lost in inclusions with failure of target composition. The work, carried out by CSM (Co-ordinator), CAS, BFI and KEP, is supported by modelling tools (CFD /physical), laboratory tests and operational plant trials on carbon and stainless steels. Partners Organization Country Responsible CENTRO SVILUPPO MATERIALI SPA ITALIA Dr. Michele DE SANTIS (Project Coord.) COGNE ACCIAI SPECIALI SpA ITALIA Dr. Armando POLI DEUTSCHE EDELSTAHLWERKE GMBH DEUTSCHLAND Dipl.-Ing. Hans-Peter JUNG VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Dr.- Ing. Carsten TSCHEUSCHNER

RFSR-CT-2005-00014 PRECIPITATION

Full Title Precipitation behaviour of microalloyed steels during solidification and cooling Info Type of Project Research Duration (months) 42 Total Budget 1911068 € Start Date 1/07/2005 EU Contribution 1146641 € End Date (actual) 31/12/2008 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA24204:EN Summary The objective of this research proposal is to extend significantly the area of knowledge of the precipitation of nitrides, carbides and complex particles during solidification and cooling of microalloyed steel grades and to investigate their effect on as-cast surface quality. The proposed work will include the investigations into the effect of the solidification and cooling rates on precipitation, strain induced precipitation of particles and their interaction with strain induced ferrite and modified steel chemistries that result in fewer surface defects and reduced microstructural banding. To achieve the overall objective, the approach to the project is threefold; industrial plant based, numerical modelling and laboratory and pilot plant based. Partners Organization Country Responsible TATA STEEL UK LIMITED UNITED KINGDOM Dr. Shahid RIAZ (Project Coord.) ARCELORMITTAL MAIZIERES RESEARCH S.A. FRANCE Mr Yann LE PAPILLON SWEREA KIMAB AB SVERIGE Dr. Stanislaw ZAJAC RHEINISCH-WESTFÄLISCHE TECHNISCHE HOCHSCHULE AA DEUTSCHLAND Prof.Dr.-Ing. Dieter G. SENK GERDAU INVESTIGACION Y DESARROLLO EUROPA S.A. ESPAÑA Dr. Gonzalo ALVAREZ DE TOLEDO VOESTALPINE STAHL DONAWITZ GmbH & Co KG OESTERREICH Dr. Axel SORMANN

83 Summaries of RFCS projects 2003-2012 TGS3 : Casting

RFSR-CT-2006-00007 OPTHEAT

Full Title Quality improvement by metallurgical optimised stock temperature evolution in the reheating furnace including microstructure feedback from the rolling mill Info Type of Project Research Duration (months) 42 Total Budget 2549660 € Start Date 1/07/2006 EU Contribution 1529796 € End Date (actual) 31/12/2009 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA25001:EN Summary The overall project aims are to optimise product quality, reheating furnace operation and material yield by improved monitoring and control of the reheating furnace and rolling mill. This will be achieved by heating according to new heating curves optimised with respect to the microstructure of the steel, handling of stops and changes of steel grades in the rolling mill. The new heating curve will be developed through a combination of laboratory experiments, industrial trials and theoretical modelling approach for the microstructure, stock temperature and energy consumption. The new heating strategies will be implemented in four partner countries to optimise the furnace and rolling mill operation. Thus, the competitiveness and efficiency of the EU steel industry will be improved. Partners Organization Country Responsible VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Dr.-Ing. Rolf KLIMA (Project Coord.) ARCELORMITTAL SESTAO S.A. ESPAÑA Mr Juan I. LANGARA FUNDACION TECNALIA RESEARCH & INNOVATION ESPAÑA Mr Jon BARCO INSTITUT ZA KOVINSKE MATERIALE IN TEHNOLOGIJE SLOVENIJA Dr. Anton JAKLIC SWEREA MEFOS AB SVERIGE Dr. Bo LEDEN AB SANDVIK MATERIALS TECHNOLOGY SVERIGE M.Sc. Ebrahim MOOSAVI GERDAU INVESTIGACION Y DESARROLLO EUROPA S.A. ESPAÑA Mr José Manuel LLANOS FUNDACION TECNALIA RESEARCH & INNOVATION ESPAÑA Dr. Felix PENALBA DIAZ

RFSR-CT-2006-00008 CO2RED

Full Title CO2 reduction in reheating furnaces Info Type of Project Research Duration (months) 48 Total Budget 2481055 € Start Date 1/07/2006 EU Contribution 1488633 € End Date (actual) 30/06/2010 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA25004:EN Summary The objective of this project is to demonstrate the capability of new technology, such as regenerative and oxyfuel combustion system based on flameless oxidation to allow a step change in environmental impact of steel reheating furnaces reducing at the same time the CO2 and NOx emissions in comparison with conventional furnaces equipped with central recuperator and flame burners. To reach this goal regenerative and oxyfuel combustion systems will be tested in pilot and industrial furnaces and investigated with the support of CFD combustion modelling. The effect of new combustion systems on the product quality will also be analysed. The project will give recommendation for the best practice to install and operate with high reliability the new combustion systems in reheating furnaces for different type of gas gaseous fuels with high reliability Partners Organization Country Responsible CENTRO SVILUPPO MATERIALI SPA ITALIA Dr. Enrico MALFA (Project Coord.) AGA AB SVERIGE Mr Tomas EKMAN ARCELORMITTAL ESPAÑA SA ESPAÑA Mr Luis Antonio RODRIGUEZ LOREDO FERALPI SIDERURGICA S.p.A. ITALIA Ing. Francesco MAGNI SWEREA MEFOS AB SVERIGE MSc. Anders RENSGARD TENOVA SpA ITALIA Ing. Maurizio SENAREGA VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Dr.-Ing. Wolfgang ADLER

RFSR-CT-2006-00018 GRAINCONT

Full Title Grain size control in steel by means of dispersed non-metallic inclusions Info Type of Project Research Duration (months) 36 Total Budget 1676679 € Start Date 1/07/2006 EU Contribution 1006007 € End Date (actual) 30/06/2009 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA24993:EN Summary The goal of the project is to create a ground for an industrial technology utilising the promising concept of grain size control by means of dispersoidic inoculants placed into the steel microstructure. The project objectives are to create and improve the basic knowledge of grain refining ferroalloys and to develop and establish a new addition technique applicable for steel continuous casting. The new opportunities for grain size control will have an impact on the development of entirely novel steel grades and products. The project involves partners that have been selected for their specific knowledge and prior work in the field. Partners Organization Country Responsible KUNGLIGA TEKNISKA HÖGSKOLAN - THE ROYAL INSTITUTE SVERIGE Dr. Margareta ANDERSSON (Project Coord.) ARCELORMITTAL MAIZIERES RESEARCH S.A. FRANCE Dr. Thierry IUNG COMDICAST AB SVERIGE Dr. Sven EKEROT CENTRE DE RECHERCHES METALLURGIQUES ASBL BELGIQUE Mr Paul NAVEAU AALTO-KORKEAKOULUSAATIO (AALTO UNIVERSITY FOUN FINLAND Prof. Dr. Lauri HOLAPPA

84 Summaries of RFCS projects 2003-2012 TGS3 : Casting

RFSR-CT-2007-00012 MAGNETOHYDRO

Full Title Improvement to steel cleanness, castability and surface quality through the application of magneto- hydrodynamics during pouring and solidification Info Type of Project Research Duration (months) 42 Total Budget 1904900 € Start Date 1/07/2007 EU Contribution 1142940 € End Date (actual) 31/12/2010 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA25123:EN Summary The objective of this research is to improve steel cleanness, including improvement to the size and distribution of non-metallics in the as-cast semi to improve downstream processing and final properties, using conventional single M-EMS and modern multimode M-EMS and technologies to control segregation. In addition, the project is aimed at the optimisation of M-EMS parameters to both minimise powder/slag entrapment and reduce power consumption for both long and flat products. The novel application of electromagnetics to control the meniscus and flow in the SEN will also be investigated. To support the industrial trials, there will be an extensive programme of pilot plant casts and an extensive programme of numerical and physical modelling. Partners Organization Country Responsible TATA STEEL UK LIMITED UNITED KINGDOM Dr. Shahid RIAZ (Project Coord.) ARCELORMITTAL MAIZIERES RESEARCH S.A. FRANCE Dr. Jean-François DOMGIN GERDAU INVESTIGACION Y DESARROLLO EUROPA S.A. ESPAÑA Dr. Gonzalo ALVAREZ DE TOLEDO AALTO-KORKEAKOULUSAATIO (AALTO UNIVERSITY FOUN FINLAND Dr. Seppo LOUHENKILPI VOESTALPINE STAHL DONAWITZ GmbH & Co KG OESTERREICH Dipl.-Ing. Karin ROCKENSCHAUB VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Dr. Ralph STRIEDINGER

RFSR-CT-2007-00013 NDTCASTING

Full Title Innovative non-contact, non-destructive sensors for automatic detection of surface and internal defects in hot continuously cast products Info Type of Project Research Duration (months) 42 Total Budget 1780199 € Start Date 1/07/2007 EU Contribution 1068120 € End Date (actual) 31/12/2010 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA25092:EN Summary The quality of slabs is the basis of good quality for all other steel products in the downstream production process. The automatic on-line detection and logging of surface, subsurface and internal defects for the controlling and optimization of the scarfing process and for use during continuous casting is important. An EMAT/EMAT Phased-Array-System and a LASER/EMAT- System will be developed to detect these defects. The Conoscopic-Holography-System can currently only find repetitive longitudinal defects and this system needs to be further developed. The control of downstream processes for tracing steel through the mill will be also bringing big advantages to the steel industry. Partners Organization Country Responsible VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Dipl.-Phys Ing. Dietmar OBERHOFF (Project Coord.) ARCELORMITTAL ESPAÑA SA ESPAÑA Mr Luis Fernando SANCHO MENDEZ SCUOLA SUPERIORE DI STUDI UNIVERSITARI E DI PERFEZI ITALIA Dr. Valentina COLLA TATA STEEL UK LIMITED UNITED KINGDOM Mr Stuart R. HIGSON

RFSR-CT-2008-00005 MASTERBILLET

Full Title Mastering billet casting through integration of innovative mould sensoring and on line billet surface quality monitoring Info Type of Project Research Duration (months) 36 Total Budget 1565787 € Start Date 1/07/2008 EU Contribution 939472 € End Date (actual) 30/06/2011 State Research technically completed; publication in hand Summary The aim of the proposal is the development of two equipments with innovative sensors able to improve the control of casting conditions for each billet. The first instrument is for the measure of the liquid steel level in the mould and the layer thickness of casting powders; the second is for the measure of the thermal field of high part mould. Associating them to the automatic inspection of the surface of each billet and appropriate elaboration will allow the definition of the rules for rigorous control of the casting conditions. The system will recognize the anomalous casting conditions and will indicate to the operational worker the actions to carry out in order to correct the found anomalies to guarantee a as cast product of better quality. The attended results are a grinding decreasing, energy savings and an improvement of the working environment. Partners Organization Country Responsible CENTRO SVILUPPO MATERIALI SPA ITALIA Dr. Franco MACCI (Project Coord.) O.R.I. MARTIN - ACCIAIERIA E FERRIERA DI BRESCIA SpA ITALIA Ing. Uggero DE MIRANDA GERDAU INVESTIGACION Y DESARROLLO EUROPA S.A. ESPAÑA Dr. Iňigo UNAMUNO VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Dr. rer. nat. Torsten LAMP

RFSR-CT-2008-00006 AcTuM

Full Title Active tundish metallurgy Info Type of Project Research Duration (months) 42 Total Budget 2108929 € Start Date 1/07/2008 EU Contribution 1265358 € End Date (actual) 31/12/2011 State Research technically completed; publication in hand Summary The project objective is to develop active tundish process by applying tailored covering slag with high capacity to efficiently absorb macro- and microinclusions from different steels. Thorough investigation of interfacial phenomena controlling inclusion removal and dissolution into tundish slag are performed to guide the slag section. Optimized flow patterns for inclusion removal in steady state and transient conditions are studied by water modelling and CFD simulation. Refractory materials are evaluated in accordance with the steel and inclusion chemistry and quality requirements. Steel grades are selected for theoretical examination and experimental trials, particularly to reduce cleanness problems and increase sequence length. 85 Partners Organization Country Responsible Summaries of RFCS projects 2003-2012 TGS3 : Casting

AALTO-KORKEAKOULUSAATIO (AALTO UNIVERSITY FOUN FINLAND Dr. Marko KEKKONEN (Project Coord.) DEUTSCHE EDELSTAHLWERKE GMBH DEUTSCHLAND Dipl.-Ing. Hans-Peter JUNG FUNDACION TECNALIA RESEARCH & INNOVATION ESPAÑA Ms Mónica SERNA OVAKO BAR OY AB FINLAND Mr Kari VÄLIMAA GERDAU INVESTIGACION Y DESARROLLO EUROPA S.A. ESPAÑA Ms Tamara RODRÍGUEZ DURAN TATA STEEL UK LIMITED UNITED KINGDOM Mr William LAW TECHNISCHE UNIVERSITÄT BERGAKADEMIE FREIBERG DEUTSCHLAND Prof. Dr.-Ing. Piotr R. SCHELLER

RFSR-CT-2008-00007 DEFFREE

Full Title Integrated models for defect free casting Info Type of Project Research Duration (months) 42 Total Budget 1874435 € Start Date 1/07/2008 EU Contribution 1124661 € End Date (actual) 31/12/2011 State Research technically completed; publication in hand Summary The objective is to generate a new modelling based optimization and quality control system for continuous casting. The new concept can be used for off-line process design and optimization but also for on-line quality control. The traditional concepts have several drawbacks and it is dif-ficult to find a comprehensive process optimization and design system. The new concept is based on fundamental features obtained from mathematical models and on calculated safety ranges for them. The outcome of this approach provides steel industry with a new innovative ap-proach for controlling the continuous casting process and therefore achieving higher outcome, quality and yield. Partners Organization Country Responsible AALTO-KORKEAKOULUSAATIO (AALTO UNIVERSITY FOUN FINLAND Ms Heli KYTÖNEN (Project Coord.) COGNE ACCIAI SPECIALI SpA ITALIA Dr. Elena BALDUCCI CENTRO SVILUPPO MATERIALI SPA ITALIA Dr. Michele DE SANTIS ISD DUNAFERR DUNAI VASMU Zrt. HUNGARY Mr Robert JOZSA NLMK LA LOUVIERE S.A. BELGIQUE Mr Guy MARTIN VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Dipl.-Ing. Sigurd RÖDL

RFSR-CT-2008-00008 LSSEMIQUAL

Full Title Reduction in surface cracking in as-cast low sulphur and calcium treated steels Info Type of Project Research Duration (months) 42 Total Budget 1417420 € Start Date 1/07/2008 EU Contribution 850452 € End Date (actual) 31/12/2011 State Research technically completed; publication in hand Summary The objective of this proposal is to attempt to understand why certain low and very low sulphur content and calcium treated steels are more prone to longitudinal broad face, transverse broad face and corner and network type cracking in the as-cast surface. From this understanding the objective is to develop the casting practice and/or ‘tune’ the steel chemistry to ensure defect free semis with the consequence of improved hot charging capability and/or reduced surface rectification requirements. To achieve the overall objective there are several sub-objectives, each designed to complement the programme and these form the Work Packages. Partners Organization Country Responsible TATA STEEL UK LIMITED UNITED KINGDOM Dr. Shahid RIAZ (Project Coord.) ARCELORMITTAL BELVAL & DIFFERDANGE S.A. LUXEMBOURG Mr Nicolas CAILLET RIVA ACCIAIO SPA ITALIA Ing. Mauro NEGRO RHEINISCH-WESTFÄLISCHE TECHNISCHE HOCHSCHULE AA DEUTSCHLAND Prof.Dr.-Ing. Dieter G. SENK VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Dipl.-Ing. Sigurd RÖDL

RFSR-CT-2009-00005 TRANSIENT

Full Title Effect of transients on quality of continuously cast product Info Type of Project Research Duration (months) 42 Total Budget 2277097 € Start Date 1/07/2009 EU Contribution 1366258 € End Date (actual) 31/12/2012 State Research in progress Summary Transient conditions in continuous casting occur during ladle changeover, flying tundish changes, casting speed changes, linking, start and end of casts, During these periods strand quality, both surface and internal, is affected. For the first time, the understanding of the causes of transient conditions and their effects on quality will be addressed. Process and quality data from transient events will be collected, particularly by plant trials. Data analysis, innovative metallurgical investigations and innovative modelling of transient events will be performed. A guidebook of new practices and downgrade rules will be produced to reduce the quality problems associated with transient events. Partners Organization Country Responsible TATA STEEL UK LIMITED UNITED KINGDOM Dr. Gerard STEPHENS (Project Coord.) ARCELORMITTAL RUHRORT GMBH DEUTSCHLAND Mr Dieter KIRSCH RIVA ACCIAIO SPA ITALIA Dr. Marco PIANEZZOLA GERDAU INVESTIGACION Y DESARROLLO EUROPA S.A. ESPAÑA Mss Izaskun ALONSO SCUOLA SUPERIORE DI STUDI UNIVERSITARI E DI PERFEZI ITALIA Dr. Valentina COLLA FUNDACION TECNALIA RESEARCH & INNOVATION ESPAÑA Mr Juan PALACIOS VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Dr. rer. nat. Torsten LAMP

86 Summaries of RFCS projects 2003-2012 TGS3 : Casting

RFSR-CT-2009-00006 LUBRIMOULD

Full Title Identification of optimal mould lubrication conditions through an innovative hot and cold simulation method Info Type of Project Research Duration (months) 42 Total Budget 1905569 € Start Date 1/07/2009 EU Contribution 1143341 € End Date (actual) 31/12/2012 State Research in progress Summary This proposal aims to enhance the as-cast surface quality of carbon and stainless steels by optimising flux type and behaviour under proper operating conditions. The approach is based on reliable phenomena representation, supported by physical/numerical modelling and laboratory techniques. These techniques will make it possible to predict the performance of commercially available powders on different casters, as well as enhancing knowledge of mould flux infiltration and heat transfer mechanisms. Hot measurement methods will be coupled with a dedicated cold models simulating the shell/mould gap. The expected know-how deliverable is a new method for mould powder choice tailored on industrial needs. Partners Organization Country Responsible COGNE ACCIAI SPECIALI SpA ITALIA Dr. Marco MASSAZZA (Project Coord.) CENTRO SVILUPPO MATERIALI SPA ITALIA Dr. Umberto MARTINI SWEREA KIMAB AB SVERIGE Mr Carl-Ake DÄCKER GERDAU INVESTIGACION Y DESARROLLO EUROPA S.A. ESPAÑA Dr. Iňigo UNAMUNO TATA STEEL UK LIMITED UNITED KINGDOM Dr. Bridget STEWART VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Dipl.-Ing. Roger KOITZSCH

RFSR-CT-2010-00006 ICCRACK

Full Title Intercolumnar cracking and its relationship to chemistry and applied strain Info Type of Project Research Duration (months) 42 Total Budget 2257364 € Start Date 1/07/2010 EU Contribution 1354418 € End Date (actual) 31/12/2013 State Research in progress Summary The objective aims at the reduction of intercolumnar (IC) cracking in continuously cast semis through a programme of work to establish the levels of strain (and strain rates) associated with intercolumnar cracks and to correlate these with the chemistry of the steel being cast and the casting process parameters. Both routine and novel plant engineering monitoring will be used to determine the levels of strain through the caster. A critical supportive aspect of the programme is a numerical simulation of strain at the solid-liquid interface. The work is planned for slab, bloom and billet in carbon and stainless steel grades. Partners Organization Country Responsible TATA STEEL UK LIMITED UNITED KINGDOM Dr. Shahid RIAZ (Project Coord.) ARCELORMITTAL MAIZIERES RESEARCH S.A. FRANCE Mr Nicolas TRIOLET COGNE ACCIAI SPECIALI SpA ITALIA Dr. Marco MASSAZZA CENTRO SVILUPPO MATERIALI SPA ITALIA Dr. Andrea DE VITO LUCCHINI S.p.A. ITALIA Dr. Marco BIANCHI GERDAU INVESTIGACION Y DESARROLLO EUROPA S.A. ESPAÑA Dr. Gonzalo ALVAREZ DE TOLEDO VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Dr.- Ing. Carsten TSCHEUSCHNER

RFSR-CT-2011-00005 DIRECT DEFECT TOOLBOX-DDT

Full Title Development of a toolbox for direct defect prediction and reduction through the characterisation of the meniscus-slag bed behaviour and initial shell solidification in CC Info Type of Project Research Duration (months) 42 Total Budget 2481352 € Start Date 1/07/2011 EU Contribution 1488811 € End Date (actual) 31/12/2014 State Research in progress Summary This project seeks to directly determine the transient occurrence of defects and process problems during slab casting. Direct-defect prediction is possible through numerous plant-trials and liquid-metal experiments to characterise the heat-transfer and dynamic behaviour of the slag-bed and meniscus (particularly, at the meniscus corner where initial solidification occurs). Microstructural evolution including the formation of defects (cracks) will be observed through novel “in-situ experiments” and steel properties are addressed through high-temperature measurements. Expertise acquired will be used to develop numerical models that predict metalslag-argon flows, heat-transfer, mould-oscillation, solidification, stress-strain, shell microstructural evolution and the explicit formation of defects. This will provide the steelmakers with a new set of tools to improve the casting practice. Partners Organization Country Responsible SWEREA MEFOS AB SVERIGE Mr Thomas JONSSON (Project Coord.) SWEREA KIMAB AB SVERIGE Mr Carl-Ake DÄCKER SSAB TUNNPLÅT AB SVERIGE PhD Patrik WIKSTRÖM TATA STEEL NEDERLAND TECHNOLOGY B.V. NEDERLAND Mr D. VAN DER PLAS THE UNIVERSITY OF MANCHESTER UNITED KINGDOM Prof. Peter LEE

87 Summaries of RFCS projects 2003-2012 TGS3 : Casting

RFSR-CT-2011-00006 IPTINGOT

Full Title Innovative process technology for ingot casting by application of simulation and measuring techniques Info Type of Project Research Duration (months) 42 Total Budget 2049802 € Start Date 1/07/2011 EU Contribution 1229880 € End Date (actual) 31/12/2014 State Research in progress Summary Systematic research for ingot casting has been strongly neglected in Europe during the last decade irrespective the fact that about 8 % of the world steel tonnage are still produced the ingot casting route. Moreover special steel products and their necessary steel grades, as for example tool steel, can only be produced by ingot casting in larger volumes. New technologies for CO2 reduction and resource savings demands the development of new special steel products where especially customer demands on clean steel quality of the ingot production is very high and further increasing. The proposal is addressing this by a through process optimisation with new simulation techniques, measuring and process technology concerning mould filling, solidification and application of mould powders. Partners Organization Country Responsible SWEREA KIMAB AB SVERIGE Mr Carl-Ake DÄCKER (Project Coord.) BUDERUS EDELSTAHL GMBH DEUTSCHLAND Dr.-Ing. Frank HIPPENSTIEL PROSIMET SPA ITALIA MSc Marco ALLONI GERDAU INVESTIGACION Y DESARROLLO EUROPA S.A. ESPAÑA Mr José Manuel LLANOS UDDEHOLM TOOLING AB SVERIGE MSc. Ewa SJÖQVIST PERSSON VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Dipl.-Ing. Roger KOITZSCH

RFSR-CT-2011-00008 KINPCC

Full Title Kinetics of precipitation during continuous casting of plate steels Info Type of Project Research Duration (months) 36 Total Budget 928289 € Start Date 1/07/2011 EU Contribution 556973 € End Date (actual) 30/06/2014 State Research in progress Summary The objective of the proposal is to establish methods for the prediction of precipitation during continuous casting of microalloyed plate steels. As surface cracks are induced by precipitate particles, this is a precondition for understanding the causes of cracking and thus for the minimization of such defects. A quantitative description of the effect of strains and stresses on precipitation is needed and will be developed. Laboratory investigations will be performed and thier results translated into mathematical approaches using the MatCalc tool. This will be complementedby industrial studies on continuously cast slab material of representative microalloyed plate steels. Partners Organization Country Responsible AKTIEN-GESELLSCHAFT DER DILLINGER HÜTTENWERKE AG DEUTSCHLAND Prof. Dr.-Ing. Karl-Hermann TACKE (Project Coord.) POLITECNICO DI MILANO ITALIA Dr.-Ing. Carlo MAPELLI TECHNISCHE UNIVERSITAET WIEN OESTERREICH Prof. Dr. Ernst KOZESCHNIK VOESTALPINE STAHL GMBH OESTERREICH Dr. Guangmin XIA

RFSR-CT-2012-00008 PMAP

Full Title Influence of composition and continuous casting parameters on the precipitation of microalloyed particles of B microalloyed steel grades and Mn alloyed steel grades Info Type of Project Research Duration (months) 42 Total Budget 1220551 € Start Date 1/07/2012 EU Contribution 732331 € End Date (actual) 31/12/2015 State Research in progress Summary The overall objective of the PMAP project is to reduce the rejection and the requirements for surface repair due to cracking defects of the continuously cast semis by optimization of microalloying steel composition and related casting parameters. This objective will be accomplished by the extension of the knowledge on precipitation of B, Nb, V (C,N) in the CC process and its effects on as- cast surface and internal crack sensitivity. It will focus on interaction among those precipitates with MnS inclusions during solidification and cooling and on their influence on austenite decomposition temperature and kinetics for high Mn steels grades, including microalloyed TRIP steel chemistries. Combined influence of those parameters with thermo-mechanical billet history will be considered studying the strain induced precipitation during bending and straightening CC operations. The Boron segregation during solidification and the B effects on austenite/ferrite transformation low ductility zone will be studied in combination with precipitation of MnS and other microalloying elements, where Mn content varies from 0.6 to 30 wt.-%. The approach to the project is threefold: industrial tests, laboratory and pilot plant experimental work, and numerical modelling. Mathematical/thermodynamic modelling is to be extended and applied on prediction and improvement of experimental and industrial routes. The dissolution technique together with electron microscopy will be used to evaluate precipitation on industrial samples and to simulate the industrial process in the lab. Partners Organization Country Responsible GERDAU INVESTIGACION Y DESARROLLO EUROPA S.A. ESPAÑA Dr. Gonzalo ALVAREZ DE TOLEDO (Project Coord.) SWEREA KIMAB AB SVERIGE Dr. Jacek KOMENDA RHEINISCH-WESTFÄLISCHE TECHNISCHE HOCHSCHULE AA DEUTSCHLAND Prof.Dr.-Ing. Dieter G. SENK TATA STEEL UK LIMITED UNITED KINGDOM Dr. Shahid RIAZ

88 Summaries of RFCS projects 2003-2012 TGS3 : Casting

RFSR-CT-2012-00011 INNOSOLID

Full Title Investigation of innovative methods for solidification control of liquid steel in the mould Info Type of Project Research Duration (months) 42 Total Budget 1293873 € Start Date 1/07/2012 EU Contribution 776324 € End Date (actual) 31/12/2015 State Research in progress Summary The objective aims at controlling the heat transfer in the mould in order to improve product quality and process stability with special regard to the meniscus and the mould corners. The work will include the modification of the primary cooling as well as the modification of the cooper surface geometry. Based on pilot plant trials, physical and numerical modelling operational measures will be derived and tested in operational trials. An additional outcome of the numerical modelling will be an online-model for the primary cooling control. Partners Organization Country Responsible VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Dr.- Ing. Carsten TSCHEUSCHNER (Project Coord.) SALZGITTER FLACHSTAHL GmbH DEUTSCHLAND Dr.-Ing. Peter MÜLLER TATA STEEL UK LIMITED UNITED KINGDOM Dr. Shahid RIAZ VOESTALPINE STAHL GMBH OESTERREICH Dr. Guangmin XIA

89 90

Technical Group Steel 4

Hot and cold rolling processes

The scope of TGS4 includes:

• Reheating furnaces

• Hot and cold rolling

• Thermal treatments

• Standardisation of testing and evaluation methods

• Maintenance and reliability of production lines

• Reduction of emissions, energy consumption and improvement of the environmental impact

• Instrumentation, modelling and control of processes

91 92 Summaries of RFCS projects 2003-2012 TGS4 : Hot and cold rolling processes

RFS3-CT-2005-00015 RFS-CR-03012

Full Title Stay for applied steel thermal and straightening processes research Info Type of Project Accompanying measure (training) Duration (months) 3 Total Budget 6750 € Start Date 1/09/2005 EU Contribution 6750 € End Date (actual) 30/11/2005 State Research completed; no publication Summary 1. As a researcher, it would be profitable to learn from the experience of working in one of Europe's leading private-sector institutes for applied research and development in the field of steel technology. This involves gain knowledge with training activities on the data-warehouse, control, data analysis, etc. of the processes’ pilot plants related to my research line during my thesis production, in fields closed to the profile straightening. 2. Take part of the strategies’ design to intend to improve the processes concerning the Project, changing the present configuration based (along with other parameters) on the result obtained in the numerical simulations required, in a continue feedback (testwork-numerical simulation). 3. Knowledge generation to be consolidated in papers. Our intend is the publication of article between the Universidad de La Rioja and BFI from the results obtained during the stay period. The Universidad de La Rioja and its candidate are committed to that publications or other information disclosure wont infringe possible intellectual property rights and wont compromise the protection (such as patentability) of any results, inventions or know-how from third parties. Partners Organization Country Responsible VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Dr. Axel MAAG (Project Coord.) UNIVERSIDAD DE LA RIOJA ESPAÑA Dr. Alpha PERNIA ESPINOZA

RFSP-CT-2006-00009 Anti-chatter CHD

Full Title Controlled hydraulic damper to prevent chatter in cold rolling Info Type of Project Pilot&Demonstration Duration (months) 24 Total Budget 632679 € Start Date 1/07/2006 EU Contribution 253072 € End Date (actual) 30/06/2008 State Unknown type of status (CSX) Summary The project aims at installing and testing an innovative mechanical device, called Controlled Hydraulic Damper, to prevent 3rd octave chatter in cold rolling of thin steel strip. It would provide adequate passive damping to the stands, so that the roll-ability limits due to chatter (rolling speed, achievable strip thickness or maximal reduction) are widened. The proposal includes vibration analysis, numerical simulation, design and construction of the device, installation and validation of the anti-chatter device in industrial conditions. Savings of 8.5 M€/year can be expected for the European production of cold rolled packaging steel. Partners Organization Country Responsible ARCELORMITTAL MAIZIERES RESEARCH S.A. FRANCE Mr Rémi BONIDAL (Project Coord.) ARCELOR PACKAGING INTERNATIONAL SA FRANCE Mr Laurent VERMOT DES ROCHES SIEMENS VAI METALS TECHNOLOGIES SAS FRANCE Mr Stéphane GOUTTEBROZE

RFSP-CT-2006-00013 ROLLMARK

Full Title Roll mark detection on the tandem mill Info Type of Project Pilot&Demonstration Duration (months) 36 Total Budget 1515830 € Start Date 1/07/2006 EU Contribution 606332 € End Date (actual) 30/06/2009 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA24999:EN Summary Roll marks created by the cold rolling are tiny defects only revealed by a manual stone brushing. But enhanced by the coating they create unacceptable defects on the galvanised or painted surface. Benefits would results from automatic detection early after tandem mill, saving about 9 M€/y (defects, claims). Today no surface inspection system is able to reach the goal. Human inspection is performed after stone brushing on a limited area of strip. The project aims to develop a technique suitable to detect on-line roll marks at tandem mill exit and assess its detection performances in industrial environment. Partners Organization Country Responsible ARCELORMITTAL MAIZIERES RESEARCH S.A. FRANCE Dr. Thierry JACQUOT (Project Coord.) ARCELORMITTAL BELGIUM NV BELGIQUE Mr Jean SCHELINGS SR-INSTRUMENTS OY FINLAND Mr Seppo PYÖRRET TEKNOLOGIAN TUTKIMUSKESKUS VTT*TECHNIC. RESEARC FINLAND Dr. Jouni TORNBERG

RFSP-CT-2008-00009 SELECTIVEROLLCOOLING

Full Title Industrial implementation of a selective roll cooling system for big rolls with multiple groves in long product rolling based on advanced cooling technology Info Type of Project Pilot&Demonstration Duration (months) 36 Total Budget 1049431 € Start Date 1/07/2008 EU Contribution 419772 € End Date (actual) 30/06/2011 State Research technically completed; publication in hand Summary The general aim of this pilot and demonstration program is to demonstrate that the cooling of big grooved work rolls can strongly be improved by the use of advanced cooling technology and a selective cooling strategy. The main objectives are to improve the performance of big grooved rolls and to reduce the required coolant flow and pressure. By this to increase the production rate and to reduce energy cost, raw materials and recycled flow rate. The new selective cooling systems will be based on preliminary trials, performed in the framework of the RFCS research program “Effective work roll cooling”[1]. Partners Organization Country Responsible CENTRE DE RECHERCHES METALLURGIQUES ASBL BELGIQUE Mr Hugo UIJTDEBROEKS (Project Coord.) ARCELORMITTAL BELVAL & DIFFERDANGE S.A. LUXEMBOURG Mr Antoine SNYERS TATA STEEL UK LIMITED UNITED KINGDOM Dr. Christian ONISA

93 Summaries of RFCS projects 2003-2012 TGS4 : Hot and cold rolling processes

RFSP-CT-2011-00009 INCOOL

Full Title Intensive cooling in cold rolling Info Type of Project Pilot&Demonstration Duration (months) 42 Total Budget 1249595 € Start Date 1/07/2011 EU Contribution 624797 € End Date (actual) 31/12/2014 State Research in progress Summary The objective of this pilot and demonstration project is the industrialisation of the intensive, high turbulent, Water Pillow Cushion (WPC) cooling technology in cold rolling mills for work roll cooling and strip cooling. The implementation is based on preliminary trials, performed in the RFCS research project “OPTCOOLUB” [1]. This innovative project aims to improve cooling performance in order to suppress temperature related defects, to enhance lubrication efficiency and to increase rolling speed. The intensive WPC cooling technology will also create the opportunity to minimise energy costs, the amount of recycled flow rate and oil contamination in the coolant. Partners Organization Country Responsible CENTRE DE RECHERCHES METALLURGIQUES ASBL BELGIQUE Mr Bart VERVAET (Project Coord.) ARCELORMITTAL MAIZIERES RESEARCH S.A. FRANCE Dr. Makhlouf HAMIDE TATA STEEL NEDERLAND TECHNOLOGY BV NEDERLAND Ir. Leon JACOBS

RFSR-CT-2003-00002 PACROLP

Full Title The prediction and avoidance of cracking in long product hot rolling Info Type of Project Research Duration (months) 46 Total Budget 1835773 € Start Date 1/09/2003 EU Contribution 1101464 € End Date (actual) 30/06/2007 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA23890:EN Summary The project is aimed at an improved understanding of the causes of crack initiation and growth during hot rolling of long products, a frequent occurrence for low ductility steels such as freecutting and stainless steels. One target is to achieve crack free rolling of alternatives to leaded steels, a priority in view of the ELVD directive. Constitutive material models including the effects of damage at high temperatures and strain rates will be developed and incorporated into FEM models, and validated by Laboratory testing, but also by use of Works-based defect detection techniques. Defect free Process regime maps will be developed. Partners Organization Country Responsible TATA STEEL UK LIMITED UNITED KINGDOM Dr. Didier FARRUGIA (Project Coord.) ASCOMETAL S.A.S. FRANCE Mrs Joëlle DEMURGER CENTRO DE ESTUDIOS E INVESTIGACIONES TECNICAS ESPAÑA Dr. José Maria RODRIGUEZ IBABE CENTRO SVILUPPO MATERIALI SPA ITALIA Dr. Juan Hector BIANCHI SWEREA MEFOS AB SVERIGE Mr Jan-Olov PERÄ OVAKO BAR OY AB FINLAND Lic. Tech. Martti VEISTARO GERDAU INVESTIGACION Y DESARROLLO EUROPA S.A. ESPAÑA Mr José Manuel LLANOS

RFSR-CT-2003-00011 Full Title Improvement of strip guiding and related effects in cold rolling of high strength steel grades Info Type of Project Research Duration (months) 42 Total Budget 1088545 € Start Date 1/09/2003 EU Contribution 653127 € End Date (actual) 28/02/2007 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA23606:EN Summary The development of new high strength steels (TRIP, Dual Phase etc…) on cold mills significantly increases strip guiding troubles and related effects (degraded strip flatness, roll changes …). This project first aims at developing mathematical models accounting for physical phenomena involved in these strip guiding troubles. In a second time, these models associated with rolling trials will be derived in practical recommendations to improve cold mill productivity and product quality. The related benefits would be : - to facilitate the development of high strength steels by the possibility to achieve higher reductions without guiding troubles or flatness degrading effects. - to advise equipment purchases required for strip guiding control on continuous tandem mills. Partners Organization Country Responsible ARCELORMITTAL MAIZIERES RESEARCH S.A. FRANCE Mr Patrick SZCZEPANSKI (Project Coord.) ARCELORMITTAL EISENHÜTTENSTADT GmbH DEUTSCHLAND Mr Hagen KOTHE VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Dr. Mohieddine JELALI

RFSR-CT-2003-00012 TESTRA

Full Title Temperature and straigthness at straigthening of sections and rails Info Type of Project Research Duration (months) 42 Total Budget 1111618 € Start Date 1/09/2003 EU Contribution 666970 € End Date (actual) 28/02/2007 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA25088:EN Summary The removal of hot straightened sections from stacked piles and the cutting of long straightened rails to delivery length severely affect the straightness of the products. Restraightening and adapting the production process to the cooling conditions have negative effects on productivitiy. The objective of this project is to determine the fundamental correlations between the straightening temperature and the straightening process by detailed analyses of straightness deviations an the basis of experimental investigations on operational and pilot plants as well as computer-based model simulations. Based on this knowledge measures will be derived that will ensure the starightness of sections or rails even if the straightening process takes place at elevated temperatures. Partners Organization Country Responsible VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Dipl -Ing Frank GORGELS (Project Coord.) PEINER TRÄGER GmbH DEUTSCHLAND Dipl.-Ing. Arved HAASLER 94 UNIVERSIDAD DE LA RIOJA ESPAÑA Prof. Joaquín ORDIERES MERE VOESTALPINE SCHIENEN GmbH OESTERREICH Dr.-Ing. Birgit EISENKOLB Summaries of RFCS projects 2003-2012 TGS4 : Hot and cold rolling processes

RFSR-CT-2003-00039 SHAPEHPM

Full Title Reduction of shape defects & yield losses by advanced online-adaptation of control systems & new operating strategies in heavy plate rolling mills Info Type of Project Research Duration (months) 48 Total Budget 1428517 € Start Date 1/09/2003 EU Contribution 857110 € End Date (actual) 31/08/2007 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA25089:EN Summary SHAPEHPM provides new operating strategies, ski-end control and optimised set-up adaptation for ski & control for camber/thickness profile to reduce shape defects and yield losses. The innovative approach encompasses a new topometrical measurement system TopPlan to collect data on plan view shape and ski, advanced FE modelling and rules to predict shape defects, and the development and use of advanced online models for in-bar ski control. To compensate the deficits of conventional models and control methods, Iterative Learning Control will be applied as a new idea for a pass to pass set-up adaptation of in-bar ski-control and of camber control that takes into account cross thickness profile. The concept will be optimised by runs of a real time HPM-simulator built up by online-models to predict shape and ski. The benefit could be yield saving in the plate mills of the order of 1%. Partners Organization Country Responsible VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Dr. Ulrich MÜLLER (Project Coord.) SWEREA MEFOS AB SVERIGE PhD Annika NILSSON RAUTARUUKKI OYJ FINLAND Lic. Tech. Agne BOGDANOFF TATA STEEL UK LIMITED UNITED KINGDOM Dr. Andrew RICHARDSON

RFSR-CT-2004-00012 IMPROSOUND

Full Title Improvement of central soundness in long products from a through process control of solidification and reheating and rolling parameters Info Type of Project Research Duration (months) 36 Total Budget 1279958 € Start Date 1/07/2004 EU Contribution 767975 € End Date (actual) 30/06/2007 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA23588:EN Summary This project aims to improve central soundness in rolled long products and thus to increase significantly the current range of rolled sizes made via continuous casting route in one heat. The main goal is to integrate the solidification and reheating and rolling processes giving rise to a through process control of all the parameters involved. Thus, this project will treat solidification and rolling as an integrated process. The study will develop a new methodology for central porosity evaluation as well as will integrate new and existing models in the area of solidification and rolling. Partners Organization Country Responsible GERDAU INVESTIGACION Y DESARROLLO EUROPA S.A. ESPAÑA Mr José Manuel LLANOS (Project Coord.) ASCOMETAL S.A.S. FRANCE Mrs Joëlle DEMURGER CENTRO SVILUPPO MATERIALI SPA ITALIA Dr. Michele DE SANTIS SWEREA MEFOS AB SVERIGE Mr Jan-Olov PERÄ AB SANDVIK MATERIALS TECHNOLOGY SVERIGE Dr. Bo ROGBERG

RFSR-CT-2004-00013 HSM LUBRICATION

Full Title New lubrication technology for the hot strip mill Info Type of Project Research Duration (months) 42 Total Budget 1339873 € Start Date 1/07/2004 EU Contribution 803924 € End Date (actual) 31/12/2007 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA24192:EN Summary Current hot rolling lubrication, based on the use of emulsion (0.2 to 1 mgr of oil mixed in water), causes many problems in term of control, consistency and reproducibility of the results and maintenance. The guaranty of a high and constant quality of the emulsion is not achieved, consequently the lubrication efficiency shows a high scattering. The main objective of this project is to develop a new concept of hot rolling lubrication in order to apply pure oil thanks to atomisation or injection. Particular attention is given to the efficiency and consistency of the results, to a minimization of the maintenance problems and reduction water pollution due to loss in water. Thanks to such a system, natural oil can be applied. These oils are low cost, efficient and less polluting. First laboratory continuous pilot trials are very promising in term of efficiency, safety and maintenance needs. Partners Organization Country Responsible CENTRE DE RECHERCHES METALLURGIQUES ASBL BELGIQUE Mr Bart VERVAET (Project Coord.) ARCELORMITTAL MAIZIERES RESEARCH S.A. FRANCE Mr Guy HAURET SOLLAC ATLANTIQUE SA FRANCE Mr Denis AVEDIAN THYSSENKRUPP STEEL EUROPE AG DEUTSCHLAND Dipl.-Phys. Roland WUNDERLICH

95 Summaries of RFCS projects 2003-2012 TGS4 : Hot and cold rolling processes

RFSR-CT-2004-00014 SSSSS

Full Title Optimised through process shape of stainless steel wide strip Info Type of Project Research Duration (months) 54 Total Budget 1744196 € Start Date 1/07/2004 EU Contribution 1046517 € End Date (actual) 31/12/2008 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA24249:EN Summary The project aim is to eliminate the principal sources of poor shape within the stainless steel strip production route (hot mill, Sendzimir Mill, vertical bright annealer (VBA), tension leveller, etc), taking account of interactions between the various hot/cold mill processes. Strip condition will be monitored through the production route, to quantify shape changes occurring at each stage, influences of process variables/engineering condition of plant, interactions between successive processes, and hence optimum strip entry/exit shape for each individual process. Modelling of shape development during rolling and tension levelling will establish sensitivities/key engineering priorities. New shape control systems will be devised/implemented on-line, incorporating influences/mutual interactions of mill flatness actuators, incoming strip flatness, and integration with gauge control. The work will be undertaken by Corus (co-ordinator) and AvestaPolarit, UK; MEFOS and LuCoil Steel AB, Sweden; BFI, IMS and TKN, Germany. Partners Organization Country Responsible VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Dr.-Ing. Jan POLZER (Project Coord.) IMS Messsysteme GmbH DEUTSCHLAND Mr Jörg BUSCH LUCOIL STEEL AB SVERIGE PhD. Prof. Carl Erik GRIP SWEREA MEFOS AB SVERIGE MSc. Olof WIKLUND OUTOKUMPU STAINLESS LTD UNITED KINGDOM Mr Andrew BACKHOUSE TATA STEEL UK LIMITED UNITED KINGDOM Dr. Andrew RICHARDSON THYSSENKRUPP NIROSTA GMBH DEUTSCHLAND Mrs Helge VOLLMANN

RFSR-CT-2004-00015 EWRCOOL

Full Title Effective roll cooling Info Type of Project Research Duration (months) 42 Total Budget 1906889 € Start Date 1/07/2004 EU Contribution 1144134 € End Date (actual) 31/12/2007 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA23866:EN Summary The objective of the project is to establish the most appropriate roll cooling conditions needed to combat the effects of roll surface deterioration, taking due account of the cyclic heating and cooling conditions as well as the mechanical properties of the roll itself. To deliver optimum performance of the mill this project sets out to determine how to best preserve the original roll surface from the perspective of the work roll cooling. Partners Organization Country Responsible TATA STEEL UK LIMITED UNITED KINGDOM Mr Andy HEELEY (Project Coord.) BRNO UNIVERSITY OF TECHNOLOGY - VYSOKE UCENI TECH CZECH REPUBLIC Dr. Miroslav RAUDENSKY COGNE ACCIAI SPECIALI SpA ITALIA Mr William TEGGI CENTRE DE RECHERCHES METALLURGIQUES ASBL BELGIQUE Mr Hugo UIJTDEBROEKS CENTRO SVILUPPO MATERIALI SPA ITALIA Dr.-Ing. Filippo DIONISI VICI Fundación INASMET ESPAÑA Dr. Felix PENALBA DIAZ GERDAU INVESTIGACION Y DESARROLLO EUROPA S.A. ESPAÑA Mr José Manuel LLANOS UNIVERSITY OF BRISTOL UNITED KINGDOM Dr. Christopher TRUMAN VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Dr.-Ing. Burkhard SCHMIDT

RFSR-CT-2004-00016 GLOBALSHAPECONTROL

Full Title Flatness set-up in hot strip mills tailored to the demands of next step processes and final customers Info Type of Project Research Duration (months) 42 Total Budget 1578443 € Start Date 1/07/2004 EU Contribution 947065 € End Date (actual) 31/12/2007 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA25119:EN Summary The claim to produce flat products in hot strip rolling lines strictly tailored to the demands of next step processes and final customers has been tackled for long only in terms of enhanced local flatness of the strip in the line. Thus the core aim of the project is the development of a co-ordinated flatness set-up system, based on an “Adaptive Flatness Predictor”, which optimises all actuator set points relevant for the evolution of flatness downstream from the exit of the finishing train to the cold coil and takes into account all process and actuator constraints inclusive the special conditions of edge masking. Basis for the development of the co-ordinated flatness set-up system will be the performance of rolling trials at a pilot line, field investigations at HSMs and structured data analysis to identify the parameters of a hybrid model of flatness evolution downstream the complete line. These investigations will lead to a decision support system, which generates optimal set-up modifications to gain a flat cold coil satisfying customer requirements. Partners Organization Country Responsible VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Dr. Ulrich MÜLLER (Project Coord.) ARCELORMITTAL ESPAÑA SA ESPAÑA Mrs Susana PEREGRINA MARQUEZ SWEREA MEFOS AB SVERIGE MSc. Olof WIKLUND SSAB EMEA AB SVERIGE Mr Bengt BROLUND TECHNISCHE UNIVERSITÄT BERGAKADEMIE FREIBERG DEUTSCHLAND Prof Dr -Ing Rudolf KAWALLA UNIVERSIDAD DE OVIEDO ESPAÑA Dr. Daniel F. GARCIA

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RFSR-CT-2004-00017 SOFTDETECT

Full Title Intelligent soft-sensor technology and automatic model-based diagnosis for improved quality, control and maintenance of mill production lines Info Type of Project Research Duration (months) 36 Total Budget 1862138 € Start Date 1/07/2004 EU Contribution 1117283 € End Date (actual) 30/06/2007 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA23893:EN Summary SOFTDETECT develops software sensors for the prediction of quality and process parameters (e.g., thermal state, thickness quality and chatter marks) during processing. This builds up the basis for control performance diagnosis, automatic fault-detection and diagnosis of causes. Human-machine interfaces will be provided to indicate early warnings, using advanced data analysis, modelling and visualisation techniques. SOFTDETECT provides a contribution for hot and cold-rolled strip producers to increase quality and reduce production costs to face the trend towards products with tight thickness and flatness tolerances, as well as surface-critical material such as that used for exposed automotive applications. The benefits of the project will be demonstrated at TKAST’s HSM, ACERALI’s TCM, and RASSELSTEIN’s Temper Mill (NWW 4). All methods and components of SOFTDETECT, thus specifically validated, are aimed at being used together as a comprehensive system to enhance the mill performance from the walking furnace till the exit of the temper mill. Partners Organization Country Responsible VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Dr.-Ing. Jan POLZER (Project Coord.) ACERALIA CORPORACION SIDERURGICA S.A. ESPAÑA Dr. José Luis RENDUELES VIGIL CENTRO SVILUPPO MATERIALI SPA ITALIA Dr. Fabio SANFILIPPO IMS Messsysteme GmbH DEUTSCHLAND Mr Jörg BUSCH THYSSENKRUPP RASSELSTEIN GMBH DEUTSCHLAND Mr Paul MICHELS THYSSENKRUPP ACCIAI SPECIALI TERNI SpA ITALIA Dr.-Ing. Luca ONOFRI UNIVERSIDAD DE OVIEDO ESPAÑA Mr Alberto DIEZ GONZALEZ

RFSR-CT-2004-00018 INCOSTEEL

Full Title In-line quality control of hot wire steel. Towards innovative contactless solutions and data fusion Info Type of Project Research Duration (months) 54 Total Budget 2453177 € Start Date 1/07/2004 EU Contribution 1471906 € End Date (actual) 31/12/2008 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA24184:EN Summary INCOSTEEL project aims to optimise in-line detection of surface defects produced in the manufacture of of hot wire steel. Material assessment is carried out at 1200ºC, when wire passes at a speed of 120 m/s. Existing systems present some limitations regarding detection and characterisation of several types of common defects (mainly, longitudinal ones). The project proposes the use of more advanced electromagnetic and ultrasonic techniques and sensors (multifrequency eddy current techniques and EC array sensors and EMATs) to deal with this problem. Models based on Finite Elements will be used for designing techniques and sensors (reducing the number of prototypes to develop). Partners Organization Country Responsible TECNATOM S.A. ESPAÑA Mrs Carmen PEREZ (Project Coord.) GERDAU INVESTIGACION Y DESARROLLO EUROPA S.A. ESPAÑA Mr José Manuel LLANOS TECHNISCHE UNIVERSITÄT BERGAKADEMIE FREIBERG DEUTSCHLAND Prof Dr -Ing Rudolf KAWALLA UNIVERSITÄT KASSEL DEUTSCHLAND Dr. Rene MARKLEIN

RFSR-CT-2004-00019 OPTILUB

Full Title Optimisation of rolling lubricants for improved operation of cold rolling mills Info Type of Project Research Duration (months) 42 Total Budget 1918154 € Start Date 1/07/2004 EU Contribution 1150893 € End Date (actual) 31/12/2007 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA23866:EN Summary The goal of this project is to propose methods for improved operation of cold rolling mills by optimised use of cold rolling emulsions. The optimisation will cover as well the economical, the ecological and the technical operation of the mill. This will be achieved by developing methods for recovery and recycling of the oil from used rolling emulsions, by developing reliable function tests for evaluation of the applicability of new or reconditioned rolling oils, by analysing surface contaminations formed by degraded and recovered oils and finally by developing on-line analysis methods for the monitoring of the working rolling oil emulsion. Partners Organization Country Responsible THYSSENKRUPP STEEL EUROPE AG DEUTSCHLAND Dr. Martin RAULF (Project Coord.) HYDRO ALUMINIUM DEUTSCHLAND GmbH DEUTSCHLAND Dr. Gerhard KUDERMANN IVL SVENSKA MILJÖINSTITUTET AB SVERIGE Mr Östen EKENGREN LUXCONTROL SA LUXEMBOURG Dr. Mohammed CHTAIB SWEREA MEFOS AB SVERIGE PhD Nils-Göran JONSSON SAPA AB SVERIGE Mr Arne BERG SSAB TUNNPLÅT AB SVERIGE Mr Lars-Henrik ÖSTERHOLM VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Dr.-Ing. Burkhard SCHMIDT VOESTALPINE STAHL GMBH OESTERREICH Dr. Hubert DUCHACZEK YKI, YTKEMISKA INSTITUTET AB SVERIGE Dr. Karin PERSSON

97 Summaries of RFCS projects 2003-2012 TGS4 : Hot and cold rolling processes

RFSR-CT-2005-00016 Scale Control

Full Title Control of scale during steel processing Info Type of Project Research Duration (months) 42 Total Budget 1817016 € Start Date 1/07/2005 EU Contribution 1090210 € End Date (actual) 31/12/2008 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA24261:EN Summary Scale is a perennial cause of defects on rolled products, either directly or as a result of persistent ghost marks. This project builds on previous work to determine optimum processing conditions for special steels (notably ferritic and austenitic stainless steels, micro-alloy strip steels and plate grades), by characterising furnace scale, residual scale after hydraulic descaling and scale present after primary rolling. A simplified empirical scale growth model will facilitate interpolation between different steel types and furnace atmospheres. An FE model of scale growth and deformation will predict scale development during reheating, descaling and rolling. The model work will be tested against laboratory and pilot plant trials. Partners Organization Country Responsible TATA STEEL UK LIMITED UNITED KINGDOM Dr. Bridget STEWART (Project Coord.) CENTRO SVILUPPO MATERIALI SPA ITALIA Dr. Nicoletta ZACCHETTI SWEREA MEFOS AB SVERIGE Dr. John NISKA OULUN YLIOPISTO*UNIVERSITY OF OULU FINLAND Prof. Dr. Pekka MÄNTYLÄ VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Dr.-Ing. Christian BÜHNER

RFSR-CT-2005-00017 WACOOL

Full Title Width-adaptable optimized controlled-cooling systems (WACOOLs) for the production of innovative advanced HSS grades and the study of strip shape changes while cooling Info Type of Project Research Duration (months) 48 Total Budget 1969698 € Start Date 1/07/2005 EU Contribution 1181819 € End Date (actual) 30/06/2009 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA25062:EN Summary Efficient production of Advanced High Strength Steels (AHSS) require important and parallel improvement of the rolling process and especially of the cooling systems. The microstructures and the resultant mechanical properties of steel depend on the cooling patterns and the steel chemistry. The prediction of TTT-diagrams and other curves obtained from continuous cooling required for planning the industrial production of AHSS grades will be performed. Symmetrically or asymmetrically controllable as well as edge-masking types of width-adaptable and water-efficient laminar-flow cooling systems will be developed and implemented at 3 HSMs. To complement the strip-cooling & transformation phenomena, an investigation of the strip shape changes, by means of both mathematical modeling and AI techniques, all along the cooling path between finishing mill and down coiler will be undertaken with a view to reducing rejects. Partners Organization Country Responsible CETTO AG DEUTSCHLAND Dr.Rer.Nat. Scaria MANNANAL (Project Coord.) ACERALIA CORPORACION SIDERURGICA S.A. ESPAÑA Mr Luis Antonio RODRIGUEZ LOREDO ASTURFEITO S.A. ESPAÑA Mr José Luis GONZALEZ GARCIA ILVA S.P.A. ITALIA Dr. Massimiliano PAGLIARO SCUOLA SUPERIORE DI STUDI UNIVERSITARI E DI PERFEZI ITALIA Dr. Valentina COLLA TATA STEEL NEDERLAND TECHNOLOGY B.V. NEDERLAND Dr. Ir. Jaap VAN DER LUGT THYSSENKRUPP STEEL EUROPE AG DEUTSCHLAND Dipl.-Phys. Jürgen DREVERMANN

RFSR-CT-2005-00018 TOPROLLS

Full Title Damage resistant and roughness retaining work rolls for cold rolling and temper rolling Info Type of Project Research Duration (months) 48 Total Budget 2943354 € Start Date 1/07/2005 EU Contribution 1766012 € End Date (actual) 30/06/2009 State Research completed, report published on EU Bookshop at (link not yet available) Summary The ‘optimal work roll’ for cold rolling and temper rolling depends on mill-specific factors (mill lay-out, rolling practices, product mix). A concerted approach is proposed to investigate and physically describe the evolution of roll damage, residual stresses and roll surface roughness during rolling, taking into account the synergy between roll-related and mill-specific factors. A decision tool to tailor roll properties to the mill, including the aspect of environment protection, will be developed. Prototypes of rolls with superior properties will be developed and tested. Simultaneously, roll inspection methods and procedures will be improved to eliminate the safety risk of exploding rolls. Partners Organization Country Responsible TATA STEEL NEDERLAND TECHNOLOGY BV NEDERLAND Dr. Petrus Henk BOLT (Project Coord.) AKERS BELGIUM S.A. BELGIQUE Dr Claude GASPARD ARCELORMITTAL MAIZIERES RESEARCH S.A. FRANCE Mr Maxime LAUGIER CENTRE DE RECHERCHES METALLURGIQUES ASBL BELGIQUE Mr Olivier LEMAIRE CENTRO SVILUPPO MATERIALI SPA ITALIA Dr.ssa Roberta VALLE LISMAR ENGINEERING B.V. NEDERLAND Ir. Frans STORK

98 Summaries of RFCS projects 2003-2012 TGS4 : Hot and cold rolling processes

RFSR-CT-2005-00019 FINALPLATEFLATNESS

Full Title Optimisation of final plate flatness by set-up coordination for subsequent manufacturing processes Info Type of Project Research Duration (months) 48 Total Budget 1894199 € Start Date 1/07/2005 EU Contribution 1136519 € End Date (actual) 30/06/2009 State Research technically completed; publication in hand Summary Nowadays the flatness performance of plate manufacturing lines is still tackled in terms of enhanced local flatness of the plates in the line. The aims of this project are to optimise local flatness approaches and to progress from this basis by taking the flatness requirements of the subsequent production quantitatively into account in form of a co-ordinated flatness set-up system. This system will integrate all sub models including models of transfer conditions from process stage to process stage and perform a line through process flatness prediction. Based on this a line set-up optimiser connecting local stage rules by a line optimisation strategy will generate the best fitting actions relevant to the evolution of flatness. Partners Organization Country Responsible VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Dr. Ulrich MÜLLER (Project Coord.) ARCELORMITTAL ESPAÑA SA ESPAÑA Mr Luis Antonio RODRIGUEZ LOREDO SWEREA MEFOS AB SVERIGE MSc. Olof WIKLUND RAUTARUUKKI OYJ FINLAND Mr Pasi LUOTO TATA STEEL UK LIMITED UNITED KINGDOM Dr. Steve HENDERSON THYSSENKRUPP STEEL EUROPE AG DEUTSCHLAND Dr. Wolfram WEBER

RFSR-CT-2005-00020 AWiCCo

Full Title Advanced width and camber control Info Type of Project Research Duration (months) 48 Total Budget 1867705 € Start Date 1/07/2005 EU Contribution 1120623 € End Date (actual) 30/06/2009 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA25042:EN Summary Aim of the AWiCCo project is the optimisation of the hot rolled strip geometry regarding width and camber. For this a modern shape control system shall be developed. One component will be a process comprehensive (roughing and finishing mill) width control, taking all regulating possibilities influencing the width into account. The second component will be a camber control for the roughing mill. In this connection a new side guiding system for a continuous control of the camber and wedge generation shall be designed. An interaction analysis will show the interdependencies of those controllers and the possibility of merging. An improved finished product concerning the desired finished strip geometry shall be achieved. Partners Organization Country Responsible VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Mr Roger LATHE (Project Coord.) ARCELORMITTAL ESPAÑA SA ESPAÑA Mr Luis Antonio RODRIGUEZ LOREDO SWEREA MEFOS AB SVERIGE M Sc Jan LEVEN RAUTARUUKKI OYJ FINLAND MSc. Juha JOKISAARI UNIVERSIDAD DE OVIEDO ESPAÑA Prof. Francisco ORTEGA FERNANDEZ VOESTALPINE STAHL GMBH OESTERREICH Dipl.-Ing. Wolfgang SEYRUCK

RFSR-CT-2006-00010 LOWWEAR

Full Title Controlling wear and surface cleanliness during cold rolling Info Type of Project Research Duration (months) 42 Total Budget 2000054 € Start Date 1/07/2006 EU Contribution 1200033 € End Date (actual) 31/12/2009 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA25074:EN Summary Excessive iron fines generation during rolling is of nuisance, both in the mill and in subsequent production steps. The aim of the project is to control the iron fines and oil residues generated during a cold rolling process. To achieve that objective, research is focused on three poles: • Establish full understanding on the underlying wear mechanisms. • Determine the parameters that influence dirt generation during rolling and capture the quantitative effects in a physically based model. • Development of an online measurement method to determine the amount of generated dirt. The expected returns are important cost savings in the mill, increase in batch-annealing capacity and a general increase in client satisfaction. Partners Organization Country Responsible TATA STEEL NEDERLAND TECHNOLOGY BV NEDERLAND Ir. Leon JACOBS (Project Coord.) ARCELORMITTAL ESPAÑA SA ESPAÑA Dr. José Luis RENDUELES VIGIL ARCELORMITTAL MAIZIERES RESEARCH S.A. FRANCE Ir. Cécile PESCI CENTRE DE RECHERCHES METALLURGIQUES ASBL BELGIQUE Mr Bart VERVAET SWEREA MEFOS AB SVERIGE PhD Nils-Göran JONSSON TECHNISCHE UNIVERSITÄT BERGAKADEMIE FREIBERG DEUTSCHLAND Prof Dr -Ing Rudolf KAWALLA VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Dr.-Ing. Jochen KURZYNSKI

99 Summaries of RFCS projects 2003-2012 TGS4 : Hot and cold rolling processes

RFSR-CT-2006-00011 ASYMMROLL

Full Title Using asymmetrical rolling for increased production and improved material properties Info Type of Project Research Duration (months) 42 Total Budget 1592905 € Start Date 1/07/2006 EU Contribution 955744 € End Date (actual) 31/12/2009 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA25061:EN Summary This project will investigate the possibilities to use asymmetrical rolling in existing mills in order to decrease loads, increase reductions and improve strip geometry and material properties. The project involves tests in pilot and industrial mills, FE-modelling and metallurgical analysis. Models for rolling forces, rolling torques and long bow will be developed since it is needed for the pass schedule design. Different asymmetrical designs will be investigated such as single/twin drive, different sized work rolls. The level of shear for different geometries will be investigated in laboratory scale. Microstructure will be evaluated both for laboratory test and full scale trials. Partners Organization Country Responsible SWEREA MEFOS AB SVERIGE PhD Annika NILSSON (Project Coord.) CENTRE DE RECHERCHES METALLURGIQUES ASBL BELGIQUE Mr Jurgen MALBRANCKE CENTRO SVILUPPO MATERIALI SPA ITALIA Dr. Ilaria SALVATORI TECHNISCHE UNIVERSITÄT BERGAKADEMIE FREIBERG DEUTSCHLAND Prof Dr -Ing Rudolf KAWALLA VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Mr Roger LATHE

RFSR-CT-2006-00012 LASERHARD

Full Title Laser treatment of profiled rolls Info Type of Project Research Duration (months) 42 Total Budget 1306438 € Start Date 1/07/2006 EU Contribution 783863 € End Date (actual) 31/12/2009 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA25064:EN Summary A laser heat source can melt a surface layer, up to 1 mm in depth, typically less than the abrasive wear depth for a rolling campaign. Due to the rapid cooling a significant increase in the hardness is produced without affecting the substrate metallurgy. A protective layer can be so applied on selected areas of a roll as part of the dressing procedure. This project would develop adequate laser based strategies to treat profiled rolls, determining the optimum applications (weld depths, speeds and areas) and applicable roll grades, and additionally, determine the efficiency of the process in technical and economical terms. Partners Organization Country Responsible TATA STEEL UK LIMITED UNITED KINGDOM Dr. Chris HEASON (Project Coord.) ASOCIACION DE INVESTIGACION METALURGICA DEL NOR ESPAÑA Dr. Alberto FERNANDEZ CELSA ATLANTIC S.L. ESPAÑA Mr José R. NAYA RODRIGUEZ INNSE CILINDRI SRL ITALIA Eng. Alberto TREMEA INSTITUTO DE SOLDADURA E QUALIDADE PORTUGAL Dr. Helena GOUVEIA GERDAU INVESTIGACION Y DESARROLLO EUROPA S.A. ESPAÑA Mr José Manuel LLANOS UNIVERSITA DEGLI STUDI DI TRENTO ITALIA Prof. Massimo PELLIZZARI VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Dr.-Ing. Jochen KURZYNSKI

RFSR-CT-2006-00014 OPTCOOLUB

Full Title New cooling techniques for enhanced roll bite lubrication during cold rolling of high strength steels and thin packaging steels Info Type of Project Research Duration (months) 42 Total Budget 1609006 € Start Date 1/07/2006 EU Contribution 965405 € End Date (actual) 31/12/2009 State Research completed, report published on EU Bookshop at (link not yet available) Summary The current trend of cold tandem mills of combining higher rolling speed, larger reduction, harder steel grades significantly increases problems of cooling and lubrication degradation. This project aims at improving cooling performances to make better lubricant properties in cold rolling. Physical models associated to tests of new cooling techniques (combination of different types or arrangements of nozzles, high turbulence cooling techniques) will be derived in practical recommendations to improve cold mills productivity and product quality. The expected benefits for the European steel industry are estimated to 15M€/year through the possibility to achieve higher rolling speeds and reductions, to decrease oil consumption (by 5%) and oil cost (by 15%), and to reduce water consumption and recycled coolant quantities (positive environmental aspect). Partners Organization Country Responsible ARCELORMITTAL MAIZIERES RESEARCH S.A. FRANCE Dr. Nicolas LEGRAND (Project Coord.) ARCELORMITTAL ESPAÑA SA ESPAÑA Mr Guillermo VECINO BRNO UNIVERSITY OF TECHNOLOGY - VYSOKE UCENI TECH CZECH REPUBLIC Dr. Miroslav RAUDENSKY CENTRE NATIONAL DE LA RECHERCHE SCIENTIFIQUE FRANCE Dr. Pierre MONTMITONNET CENTRE DE RECHERCHES METALLURGIQUES ASBL BELGIQUE Mr Hugo UIJTDEBROEKS LECHLER GMBH DEUTSCHLAND Mr Jochen MUNZ VOESTALPINE STAHL GMBH OESTERREICH Dr. Dieter PAESOLD

100 Summaries of RFCS projects 2003-2012 TGS4 : Hot and cold rolling processes

RFSR-CT-2007-00014 OPTIFIN

Full Title Optimisation of finishing processes for eliminating rectification of plate and section products Info Type of Project Research Duration (months) 42 Total Budget 1194543 € Start Date 1/07/2007 EU Contribution 716726 € End Date (actual) 31/12/2010 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA25080:EN Summary The project is aimed at an improved understanding of the evolution of microstructure, material properties, internal stress/strain fields, flatness and squareness, during hot rectification and cooling of plates and sections, establishing the sensitivities of product condition at entry to cold rectification. Hot rectification and cooling processes will be optimised to achieve required mechanical and dimensional properties, thereby reducing or eliminating the need for cold rectification. Warm rectification will also be considered as a mean to increase throughput and reduce mechanical work on finished products. Regime maps will be developed covering key products and grades, and selectively tested in industrial conditions. Partners Organization Country Responsible TATA STEEL UK LIMITED UNITED KINGDOM Dr. Didier FARRUGIA (Project Coord.) AKADEMIA GORNICZO-HUTNICZA IM. STANISLAWA STASZI POLAND Prof. Maciej PIETRZYK CENTRO DE ESTUDIOS E INVESTIGACIONES TECNICAS ESPAÑA Dr. Isabel GUTIERREZ SANZ RIVA ACCIAIO SPA ITALIA Dr. Marco PIANEZZOLA

RFSR-CT-2007-00015 EDGECONTROL

Full Title Minimised yield losses by innovative integrated edge-drop, width and shape control based on soft-sensor technology and new actuators in cold rolling mills Info Type of Project Research Duration (months) 42 Total Budget 1808963 € Start Date 1/07/2007 EU Contribution 1085378 € End Date (actual) 31/12/2010 State Research completed, report published on EU Bookshop at (link not yet available) Summary This project will bring European steel producers a major step forward to delivering near rectangular cold strips to their final customers and thus minimising their own yield losses by avoiding/reducing side trimming and strip breaks on critical and highly demanding products. Potential actuators to control edge drop and width in cold rolling will be evaluated combining innovative (i.e. portable and integrated) measurement systems on industrial mills, (3D model-based) soft-sensors for online estimation, and model predictive control. The expected benefits for the European steel industry are estimated to an average of 20 M€/year1 through the possibility to produce strips with tight geometrical tolerances and to reduce yield, with positive environmental aspect. Partners Organization Country Responsible VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Dr. Mohieddine JELALI (Project Coord.) ARCELORMITTAL EISENHÜTTENSTADT GmbH DEUTSCHLAND Dr.-Ing. Jürgen BATHELT ARCELORMITTAL ESPAÑA SA ESPAÑA Mr Guillermo VECINO ARCELORMITTAL MAIZIERES RESEARCH S.A. FRANCE Dr. Nicolas LEGRAND SWEREA MEFOS AB SVERIGE MSc. Patrik SIDESTAM

RFSR-CT-2007-00016 Hyprocom

Full Title Development of an innovative hybrid procedure for combining tension-levelling and skin pass rolling Info Type of Project Research Duration (months) 42 Total Budget 1287748 € Start Date 1/07/2007 EU Contribution 772649 € End Date (actual) 31/12/2010 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA25093:EN Summary Main objective is the development of an innovative strip finishing procedure by combining tension levelling and skin pass rolling into one production step and thus to shorten the process chain. During former RFCS-projects [R1, R2] it could be proved that the mechanical characteristics of strip material mainly adjusted during the skin pass rolling process are possible to be achieved as well during a pure tension levelling process by variation of applied tension and bending load. The realisation of the desired surface texture requires an additional superposed deformation under pressure introduced simultaneously in those strip sections where the yield strength of the material already is met by the applied tension-bending procedure. Using the new facility it will be possible to adjust material mechanical and surface roughness properties independently. Thus the new technique fundamentally contributes to the common development to require steel grades with highest surface quality and simultaneous highest available deformation resources. Partners Organization Country Responsible VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Dipl.-Ing. Volker DIEGELMANN (Project Coord.) BILSTEIN GmbH & Co KG DEUTSCHLAND Dipl.-Ing. Gerald Otto ZWICKEL INSTITUTO DE SOLDADURA E QUALIDADE PORTUGAL Dr. Helena GOUVEIA SUNDWIG GmbH DEUTSCHLAND Dipl.-Ing. Udo WEIRAUCH UNIVERSIDAD DE LA RIOJA ESPAÑA Dr. Eliseo VERGARA

RFSR-CT-2008-00011 LUBWORK

Full Title Increase of cold rolling performance by new lubricant and innovative work roll concepts Info Type of Project Research Duration (months) 42 Total Budget 1464064 € Start Date 1/07/2008 EU Contribution 878439 € End Date (actual) 31/12/2011 State Research technically completed; publication in hand Summary New approaches for work roll materials, surface treatment and coatings, new emulsions and additives enables increased productivity and surface cleanliness in steel cold rolling. Laboratory, pilot tests and finally first examinations nearing industrial rolling process will prove applicability of new technologies and decreases risks associated with industrial testing. Examination on impact on strip surface and surface cleanliness as well as consequences for care and control of emulsions circuits will be included in this research work. The platform of positive results already achieved for aluminium hot rolling with oil free emulsions will benefit well on the steel research work. Partners Organization Country Responsible VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Dipl -Ing Tilo REICHARDT (Project Coord.) 101 CENTRE DE RECHERCHES METALLURGIQUES ASBL BELGIQUE Mrs Diana ESPINOSA Summaries of RFCS projects 2003-2012 TGS4 : Hot and cold rolling processes

HYDRO ALUMINIUM DEUTSCHLAND GmbH DEUTSCHLAND Dr. Gerhard KUDERMANN LUXCONTROL SA LUXEMBOURG Dr. Mohammed CHTAIB THYSSENKRUPP STEEL EUROPE AG DEUTSCHLAND Dr. Martin RAULF VOESTALPINE STAHL GMBH OESTERREICH Dr. Hubert DUCHACZEK YKI, YTKEMISKA INSTITUTET AB SVERIGE Dr. Karin PERSSON

RFSR-CT-2008-00012 CHILLUB

Full Title Advanced method to improve work roll life time and surface quality of hot rolled strip by new coupled oil free lubrication and chilling Info Type of Project Research Duration (months) 47 Total Budget 1423894 € Start Date 1/07/2008 EU Contribution 854336 € End Date (actual) 31/05/2012 State Research in progress Summary CHILLUB will gain detailed knowledge of heat transfer mechanism of strip surface before and the mechanism of friction and roll fatigue in the roll bite when applying new coupled oil free lubricant (water soluble) with strip cooling (chilling) during hot rolling. Research work is primarily related to work roll deterioration and strip surface quality. Secondary the suppressing of scale formation is examined. Objectives of the investigations are: - Increase work roll life time - Improving strip surface quality - Enlarged process window when rolling high strength steels. Results are integrated into set-up and control models revealing into an industrial prototype. Partners Organization Country Responsible TATA STEEL NEDERLAND TECHNOLOGY B.V. NEDERLAND Mr Harry VAN STEDEN (Project Coord.) BRNO UNIVERSITY OF TECHNOLOGY - VYSOKE UCENI TECH CZECH REPUBLIC Dr. Miroslav RAUDENSKY CENTRE DE RECHERCHES METALLURGIQUES ASBL BELGIQUE Mr Bart VERVAET THYSSENKRUPP STEEL EUROPE AG DEUTSCHLAND Mr Christian MUELLER VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Dipl -Ing Tilo REICHARDT

RFSR-CT-2008-00013 WINROLLS

Full Title Work rolls in the roughing mills: roll grade and process optimisation to save energy and roll cost of use Info Type of Project Research Duration (months) 48 Total Budget 2273616 € Start Date 1/07/2008 EU Contribution 1364169 € End Date (actual) 30/06/2012 State Research in progress Summary This project objective is to improve the robustness of the rolling process in the roughing mill by decreasing the roll consumption and increasing the process reliability. A first axis will be the observation of the working roll during its lifetime and the comparison of observations with models to understand the degradation mechanisms. Then, the influence of process parameters such as roll cooling and roll preparation before rolling will be investigated to define the optimized rolling conditions. The final axis will be the development of an optimized new work roll grade based on the specifications obtained from the other axis. Partners Organization Country Responsible ARCELORMITTAL MAIZIERES RESEARCH S.A. FRANCE Ms Minouche MOHAMMADI TEHRANI (Project Coord.) AKERS BELGIUM S.A. BELGIQUE Dr Claude GASPARD CENTRE DE RECHERCHES METALLURGIQUES ASBL BELGIQUE Mr Jurgen MALBRANCKE

RFSR-CT-2008-00014 OPTITUBE

Full Title Improvement of the internal wall surface of seamlesss tubes by optimisation and anticipating management of the mandrel bar operation and supervision of the internal tool process Info Type of Project Research Duration (months) 63 Total Budget 1313723 € Start Date 1/07/2008 EU Contribution 788234 € End Date (actual) 30/09/2013 State Research in progress Summary This project aims to optimise the internal wall surface of seamless tubes. Systems to measure internal tool condition and process forces will provide a database for correlation analysis and on-line prediction-based processing and anticipating maintenance. Hybrid correlation & Finite Element Models will predict the internal wall surface quality based on internal tool condition evolution and tool process parameters. New wear resistant tool materials/coatings and enhanced process lubrication will be introduced to optimise internal tool surface and process parameters. A supervision system will integrate the on-line information and an anticipating strategy to handle internal tool processes and maintenance proposals e. g. of the time to replace the tool. The system will be demonstrated at a push bench tube line of Benteler. Partners Organization Country Responsible VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Mr Hagen KRAMBEER (Project Coord.) BENTELER STAHL/ROHR GmbH DEUTSCHLAND Mr Leonhard ROSE COMTES FHT a.s. CZECH REPUBLIC Ph.D. Michal ZEMKO ROVALMA SA ESPAÑA Eng. Isaac VALLS ANGLES

102 Summaries of RFCS projects 2003-2012 TGS4 : Hot and cold rolling processes

RFSR-CT-2008-00015 CHATTER

Full Title Global adaptive model for prediction, characterization and damping of vibrations in hot strip mills Info Type of Project Research Duration (months) 36 Total Budget 1879635 € Start Date 1/07/2008 EU Contribution 1127781 € End Date (actual) 30/06/2011 State Research in progress Summary This project proposes a novel global approach to solve vibrations problems during hot rolling of strip, detecting and eliminating conditions that drive to their appearance and developing control strategies for their effective damping. The main approach is to develop models that evaluate the probability of appearance of vibrations at any stand according to rolling conditions foreseen by process models for the next bar to enter the mill. If probability is high, process models will be told to generate a different mill set up that changes the conditions of those stands. Additional measure and damping strategies will complete the strategy. Partners Organization Country Responsible CETTO AG DEUTSCHLAND Dr.Rer.Nat. Scaria MANNANAL (Project Coord.) ARCELORMITTAL ESPAÑA SA ESPAÑA Mr Luis Antonio RODRIGUEZ LOREDO SCUOLA SUPERIORE DI STUDI UNIVERSITARI E DI PERFEZI ITALIA Dr. Valentina COLLA THYSSENKRUPP STEEL EUROPE AG DEUTSCHLAND Dipl.-Phys. Jürgen DREVERMANN TECHNISCHE UNIVERSITAET CLAUSTHAL DEUTSCHLAND Prof. Dr.-Ing. Hans-Peter BECK UNIVERSIDAD DE OVIEDO ESPAÑA Dr. Ignacio ALVAREZ GARCIA

RFSR-CT-2008-00016 OxMaPro

Full Title Oxidation Management in hot rolling processes Info Type of Project Research Duration (months) 42 Total Budget 2619191 € Start Date 1/07/2008 EU Contribution 1571515 € End Date (actual) 31/12/2011 State Research technically completed; publication in hand Summary The European Steel Platform (ESTEP) has called for determined research and development activity into the area of ‘scale-free’ processing and is specifically recommending this project. OXMAPRO aims to develop novel integrated routes involving the use of coatings in reheating and hot rolling, new methods of scale/coating detection and process control and optimisation of descaling practices to produce the best surface quality for each steel. These new concepts and processes will be highly transferable across steel grades. The project will focus on strip, rail, rod, bar and plate for yellow goods. It will involve laboratory, pilot plant and industrial plant trials. Partners Organization Country Responsible TATA STEEL UK LIMITED UNITED KINGDOM Dr. Shahid RIAZ (Project Coord.) ARCELORMITTAL MAIZIERES RESEARCH S.A. FRANCE Ir. Cécile PESCI CENTRE DE RECHERCHES METALLURGIQUES ASBL BELGIQUE Mrs Isabelle TOLLENEER HOESCH HOHENLIMBURG GmbH DEUTSCHLAND Dipl.-Ing. Holger ADLUNG GERDAU INVESTIGACION Y DESARROLLO EUROPA S.A. ESPAÑA Mr José Manuel LLANOS VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Dr.-Ing. Rolf KLIMA

RFSR-CT-2009-00007 PACROLP-II

Full Title The prediction and avoidance of cracking in long product hot rolling. Phase II. Info Type of Project Research Duration (months) 42 Total Budget 1514966 € Start Date 1/07/2009 EU Contribution 908980 € End Date (actual) 31/12/2012 State Research in progress Summary The project is aimed at minimising ductility break-ups on “apparently sound” as-cast free cutting semis (blooms/billets), which are prone to surface cracking during reheating/rolling. Influence of multiscale geometric and microstructural heterogeneities (e.g. chilled region, inclusions) and their sensitivities to adverse stress-strain states will be determined. This project will bring further innovation to the recently completed PACROLP RFCS project establishing via advanced mechanical and pilot testing, state of the art characterisation, and multiscale modelling, the sensitivities of micro-macro cracking to industrial processing conditions. Defect free regime maps will be developed covering key products and grades, and selectively tested in industrial conditions. Partners Organization Country Responsible CENTRO DE ESTUDIOS E INVESTIGACIONES TECNICAS ESPAÑA Dr. José Maria RODRIGUEZ IBABE (Project Coord.) ASS. POUR LA RECHERCHE ET LE DEV. DES METHODES ET P FRANCE Dr. Marc BERNACKI CENTRO SVILUPPO MATERIALI SPA ITALIA Dr. Juan Hector BIANCHI GERDAU INVESTIGACION Y DESARROLLO EUROPA S.A. ESPAÑA Mr José Manuel LLANOS TATA STEEL UK LIMITED UNITED KINGDOM Dr. Didier FARRUGIA

RFSR-CT-2009-00008 ROLLGAP SENSORS

Full Title Advanced roll gap sensors for enhanced hot and cold rolling processes Info Type of Project Research Duration (months) 42 Total Budget 2050913 € Start Date 1/07/2009 EU Contribution 1230548 € End Date (actual) 31/12/2012 State Research in progress Summary To achieve higher product quality and productivity on rolling mills, it becomes necessary to get a profound knowledge of friction, heat transfers and lubrication in the roll gap. An approach is proposed to develop innovative roll gap sensors to measure simultaneously at the roll-strip interface thermal and mechanical conditions and oil film thickness: different sensor designs are evaluated and compared in hot and cold rolling using laboratory, pilot and industrial mill tests. Finally the sensors, combined with modelling and mill measurements, are used to increase mills productivity (lower roll surface degradation) and to improve product quality (better strip thickness). Partners Organization Country Responsible ARCELORMITTAL MAIZIERES RESEARCH S.A. FRANCE Dr. Nicolas LEGRAND (Project Coord.) 103 BRNO UNIVERSITY OF TECHNOLOGY - VYSOKE UCENI TECH CZECH REPUBLIC Dr. Jaroslav HORSKY Summaries of RFCS projects 2003-2012 TGS4 : Hot and cold rolling processes

COMMISSARIAT A L'ENERGIE ATOMIQUE FRANCE Dr. Pierre FERDINAND CENTRE NATIONAL DE LA RECHERCHE SCIENTIFIQUE FRANCE Dr. Pierre MONTMITONNET SWEREA MEFOS AB SVERIGE PhD Nils-Göran JONSSON THYSSENKRUPP STEEL EUROPE AG DEUTSCHLAND Mr Ditmar PIESACK THE UNIVERSITY OF SHEFFIELD UNITED KINGDOM Prof Robert DWYER-JOYCE

RFSR-CT-2009-00009 HIDES

Full Title Innovative high temperature descaling techniques Info Type of Project Research Duration (months) 42 Total Budget 1142360 € Start Date 1/07/2009 EU Contribution 685416 € End Date (actual) 31/12/2012 State Research in progress Summary The aim of HIDES is to develop and assess new innovative high temperature mechanical descaling techniques for optimising surface quality, heat loss and energy usage for a range of low to high alloyed steel (Si, Cr, Ni) for long (rail/rod) and flat products. This will be achieved via a combination of laboratory pilot scale testing, detailed surface and microstructural characterisation, thermo-mechanical modelling and plant trials. The effectiveness of innovative concepts such as high temperature steel shot mechanical descaling will be assessed against other concepts such as high pressure/low flow (400 bars +) and conventional high pressure water (HPW) descaling techniques. Partners Organization Country Responsible CENTRE DE RECHERCHES METALLURGIQUES ASBL BELGIQUE Mr Philippe POUTEAU (Project Coord.) KARLSRUHER INSTITUT FÜR TECHNOLOGIE (KIT) DEUTSCHLAND Prof. Dr.-Ing. Volker SCHULZE TATA STEEL UK LIMITED UNITED KINGDOM Dr. Didier FARRUGIA WHEELABRATOR ALLEVARD SA FRANCE Mr Tony PREZEAU

RFSR-CT-2009-00035 FOSUCOR

Full Title Future-oriented supervision of the cold rolling process in reversing mills Info Type of Project Research Duration (months) 42 Total Budget 1406453 € Start Date 1/07/2009 EU Contribution 843872 € End Date (actual) 31/12/2012 State Research in progress Summary Key criteria for the productivity of a mill stand and the quality of the finished product are the pass schedule design and the geometry of the used rolls. Current systems use empirically determined rules for the description of process parameters such as strip flatness and strip quality. The geometry of the rolls is also determined empirically. Within the framework of this project the empirically determined rules and procedures are to be replaced. This is to be achieved by intelligent and consistent use of all available information as well as the development of new calculation models. The main objectives are the optimized utilization of the rolling mill potential and the improvement of the strip quality. A further objective is the use of CVC technology in existing 20-high mills. Partners Organization Country Responsible VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Mr Roger LATHE (Project Coord.) SWEREA MEFOS AB SVERIGE M Sc Jan LEVEN THYSSENKRUPP NIROSTA GMBH DEUTSCHLAND Dipl.-Ing. Jörg KAZMIERSKI

RFSR-CT-2010-00007 ROLLWITECH

Full Title Application of novel wireless technologies to improve rolling performances Info Type of Project Research Duration (months) 36 Total Budget 1665860 € Start Date 1/07/2010 EU Contribution 999517 € End Date (actual) 30/06/2013 State Research in progress Summary This project aims at developing integrated wireless micro sensors which can be placed in almost any part of a rolling mill, allowing for new measurement locations in the mill. As a result monitoring and control can be extended and improved. To facilitate continuous measurements without the need for maintenance, suitable energy harvesting systems will be designed. The versatility of the technology will be demonstrated by the development of a roll chock and work rolls with embedded auto-monitoring systems. To prove the advantages of the technology, wireless sensors will be incorporated in a new monitoring system for mill vibration. Partners Organization Country Responsible ARCELORMITTAL ESPAÑA SA ESPAÑA Eng Jesus Maria PEREZ (Project Coord.) ASTURFEITO S.A. ESPAÑA Eng. Daniel DIAZ STICHTING IMEC NEDERLAND NEDERLAND Dr. Dennis HOHLFELD FUNDICION NODULAR ESPAÑA Dipl -Ing Leonel ELIZONDO TATA STEEL NEDERLAND TECHNOLOGY B.V. NEDERLAND Ir Jan PONSIOEN VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Dipl -Phys Werner WOESTE

RFSR-CT-2010-00008 HRENERGYCONTROL

Full Title Minimising energy loss in hot rolling by intelligent manufacturing Info Type of Project Research Duration (months) 42 Total Budget 1886437 € Start Date 1/07/2010 EU Contribution 1131862 € End Date (actual) 31/12/2013 State Research in progress Summary The electrical consumption in the hot rolling operation is more than 70 KW/ton. The main consumers are the rolling stands and the coilers. Auxiliary equipment can however not be neglected as it represents 25% of the electrical energy. The total energy loss is however much higher related to latent heat of the hot rolled product emitted to the coolants and the environment (0.56 GJ/ton). The aim of this research program is to get a better understanding of all energy flows in the hot rolling operation and to define and validate major opportunities for energy loss reduction. Partners Organization Country Responsible 104 CENTRE DE RECHERCHES METALLURGIQUES ASBL BELGIQUE Mr Hugo UIJTDEBROEKS (Project Coord.) ARCELORMITTAL ESPAÑA SA ESPAÑA Dr. José Ramón GONZÁLEZ SUÁREZ Summaries of RFCS projects 2003-2012 TGS4 : Hot and cold rolling processes

UNIVERSIDAD DE OVIEDO ESPAÑA Prof Fernando BRIZ VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Dipl -Ing Tilo REICHARDT

RFSR-CT-2010-00009 LPROLLCOAT

Full Title Increased abrasive wear and thermal fatigue resistance of long product work rolls by application of novel coating technologies Info Type of Project Research Duration (months) 42 Total Budget 2375700 € Start Date 1/07/2010 EU Contribution 1425419 € End Date (actual) 31/12/2013 State Research in progress Summary The project is aimed at improving life of work rolls during hot rolling of long products by novel applications of available wear resistant coatings as well as development of new generation of wear and thermal barrier coatings. An improved resistance to thermal fatigue, spalling and wear under both existing and reduced conditions of cooling will be targeted. These objectives will be achieved by advanced modelling techniques, innovative pilot and laboratory simulations and industrial production rolling. Knowledge developed will be used to identify, rank and cost coatings and coating application methods to meet current and future demands on work rolls. Partners Organization Country Responsible CENTRE DE RECHERCHES METALLURGIQUES ASBL BELGIQUE Mr Jurgen MALBRANCKE (Project Coord.) ASOCIACION DE INVESTIGACION METALURGICA DEL NOR ESPAÑA Dr. Alberto FERNÁNDEZ VICENTE ARCELORMITTAL BELVAL & DIFFERDANGE S.A. LUXEMBOURG Mr Nicolas RICH GERDAU INVESTIGACION Y DESARROLLO EUROPA S.A. ESPAÑA Mr José Ramon GONZALEZ TATA STEEL UK LIMITED UNITED KINGDOM Dr. Christian FEDORCUIC-ONISA TEER COATINGS LIMITED UNITED KINGDOM Dr. Shicai YANG VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Dipl.-Ing. Housein DELI

RFSR-CT-2010-00010 MICROCONTROL

Full Title Combined Online Microstructure sensor and model for a better control of hot rolling conditions and final products properties Info Type of Project Research Duration (months) 42 Total Budget 1747589 € Start Date 1/07/2010 EU Contribution 1048554 € End Date (actual) 31/12/2013 State Research in progress Summary To achieve higher product quality and productivity on rolling mills, it becomes necessary to measure, and possibly feed back control, microstructure on line. A laser ultrasonic sensor based on innovative optical concepts is developed for microstructure evaluation all along a hot strip mill: in inter-stands for recrystallization and grain growth kinetics, on the run out table for phase transformation and final strip microstructure. This sensor is validated with laboratory and pilot rolling tests. It is finally tested in industrial hot rolling conditions for a complete calibration of an on line microstructure evolution model with the aim to improve rolling process and final strip microstructure. Partners Organization Country Responsible ARCELORMITTAL MAIZIERES RESEARCH S.A. FRANCE Dr. Nicolas LEGRAND (Project Coord.) NATIONAL RESEARCH COUNCIL OF CANADA CNRC CANADA Dr. Jean-Pierre MONCHALIN CENTRE DE RECHERCHES METALLURGIQUES ASBL BELGIQUE Mrs Griet LANNOO IMAGINE OPTIC SA FRANCE Mr Nicolas LEFAUDEUX SWEREA KIMAB AB SVERIGE MSc Lena RYDE SWEREA MEFOS AB SVERIGE PhD Nils-Göran JONSSON

RFSR-CT-2010-00011 INTERCOOL

Full Title Improved temperature control with integrated roll and strip cooling Info Type of Project Research Duration (months) 42 Total Budget 1008366 € Start Date 1/07/2010 EU Contribution 605019 € End Date (actual) 31/12/2013 State Research in progress Summary The proposal aims to study and validate a very innovative idea: the possibility to integrate the application of interstand cooling and strip surface chilling into the design of the work roll cooling system with a minimum water cooling pressure. Besides a simplified design, it opens the possibility to increase strip temperature homogeneity and to increase work roll cooling efficiency by cooling the work roll directly at the roll bite exit. Decreased energy consumption, improved strip quality (less scale, flatness, ..), strip temperature homogeneity and increased work roll life are the main stakes of this proposal. Partners Organization Country Responsible CENTRE DE RECHERCHES METALLURGIQUES ASBL BELGIQUE Mr Bart VERVAET (Project Coord.) ARCELORMITTAL MAIZIERES RESEARCH S.A. FRANCE Dr. Jean-Luc BOREAN TATA STEEL NEDERLAND TECHNOLOGY BV NEDERLAND Mr Pieter Drent

105 Summaries of RFCS projects 2003-2012 TGS4 : Hot and cold rolling processes

RFSR-CT-2011-00007 CONSTOX

Full Title Control of steel oxidation in reheating operations carried out with alternative fuels and new combustion technologies Info Type of Project Research Duration (months) 36 Total Budget 1195272 € Start Date 1/07/2011 EU Contribution 717163 € End Date (actual) 30/06/2014 State Research in progress Summary A lot of research work has been devoted to guarantee steel quality by controlling oxidation process in re-heating furnaces and hot rolling operations. Nowadays there is trend to improve energy efficiency and to reduce the environmental impact by using innovative combustion technologies (like flameless) and alternative fuels (waste gas). The aim of the project is to favour the exploitation of these technologies by defining optimum processing parameters to ensure that primary scale and associated scale defects do not persist through to the final product also when new combustion systems and fuels different from natural gas are used in re-heating operations. Partners Organization Country Responsible CENTRO SVILUPPO MATERIALI SPA ITALIA Dr. Irene LUZZO (Project Coord.) FERALPI SIDERURGICA S.p.A. ITALIA Ing. Lorenzo ANGELINI TATA STEEL UK LIMITED UNITED KINGDOM Dr. Bridget STEWART VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Dr.-Ing. Robert OROSZ

RFSR-CT-2011-00010 WORODEFS

Full Title Tailoring and testing of novel work roll developments for the early finishing stands of hot strip mills Info Type of Project Research Duration (months) 48 Total Budget 2441125 € Start Date 1/07/2011 EU Contribution 1464675 € End Date (actual) 30/06/2015 State Research in progress Summary During finishing hot rolling, tight interrelations occur between rolling process conditions, work roll behaviour and performance, and strip surface quality. Nevertheless, innovative work roll grade developments, mill process optimisation, and roll shop technology improvements are usually carried out separately, resulting in sub-optimisation and slow developments. This proposal aims to improve the performance of work rolls in the early finishing stands, by integrating the process conditions and roll shop measurement techniques into the roll grade development. The main objectives of the proposal are improved roll performance, improved understanding of roll degradation for different hot strip mills, and improved NDT inspection techniques. Partners Organization Country Responsible TATA STEEL NEDERLAND TECHNOLOGY B.V. NEDERLAND Dr. Petrus Henk BOLT (Project Coord.) ARCELORMITTAL MAIZIERES RESEARCH S.A. FRANCE Dr. Eliette MATHEY CENTRE DE RECHERCHES METALLURGIQUES ASBL BELGIQUE Ir Gisèle WALMAG LISMAR ENGINEERING B.V. NEDERLAND Ir. Frans STORK UNION ELECTRIC STEEL UK LTD UNITED KINGDOM Mr Jason SYCHTERZ

RFSR-CT-2011-00011 OPTISHAMP

Full Title Optimal control of shape and materials properties Info Type of Project Research Duration (months) 42 Total Budget 2029061 € Start Date 1/12/2011 EU Contribution 1217437 € End Date (actual) 31/05/2015 State Research in progress Summary Customers demand for steel grades with increased strength and balanced formability as well as optimal shape. Shape & mechanical properties are strongly affected by the deformation and thermal treatment during the hot and cold rolling. In this project, a through-process control systemwill be developed for the simultaneous optimisation of shape & mechanical properties along the production chain of hot and cold rolling. The optimisation system will be realised and tested at two mills. Furthermore, possibilities to optimise shape & mechanical properties by controlled coil-cooling and improvements in the shapemeter roll for n-line shape measurement during hotrolling will be investigated. Partners Organization Country Responsible VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Dr.-Ing. Jan POLZER (Project Coord.) ARCELORMITTAL EISENHÜTTENSTADT GmbH DEUTSCHLAND Dr. Sascha HÜMANN SWEREA MEFOS AB SVERIGE MSc Mats KARLBERG TATA STEEL NEDERLAND TECHNOLOGY BV NEDERLAND Dr. Rob VERHOEF

RFSR-CT-2011-00012 CRFREEROLLS

Full Title Substitution of chrome plating for the rolls of skin-pass mill Info Type of Project Research Duration (months) 42 Total Budget 2249683 € Start Date 1/07/2011 EU Contribution 1349810 € End Date (actual) 31/12/2014 State Research in progress Summary Hard chrome plating is applied for long to rolls of rolling mills, especially skin-pass mills. It gives the benefits of keeping consistent roughness all along a rolling campaign and in turn reducing the roll consumption. However chrome plating involves carcinogenic CrVI. Therefore it will be banned at mid-term in the EU, like other applications of CrVI. have been.. The objective of this proposal is to evaluate the performances of substitutes to chrome plating so that efficient alternatives can be implemented. Alternatives will be evaluated in two directions: - Harder rolls (HSS) that resist wear without plating - Cr-free alternative coatings Evaluation will include laboratory, pilot and first industrial tests 106 Partners Organization Country Responsible CENTRE DE RECHERCHES METALLURGIQUES ASBL BELGIQUE Mr Hugo UIJTDEBROEKS (Project Coord.) Summaries of RFCS projects 2003-2012 TGS4 : Hot and cold rolling processes

AKERS BELGIUM S.A. BELGIQUE Dr Claude GASPARD ARCELORMITTAL MAIZIERES RESEARCH S.A. FRANCE Dr Akli ELIAS SARCLAD LIMITED UNITED KINGDOM Dr. Gareth EVANS SULZER METCO COATINGS GMBH DEUTSCHLAND Dr. Franz JANSEN TATA STEEL NEDERLAND TECHNOLOGY B.V. NEDERLAND Dr. Petrus Henk BOLT

RFSR-CT-2012-00009 DYNAMO

Full Title Advanced measurements and dynamic modelling for improved furnace operation and control Info Type of Project Research Duration (months) 42 Total Budget 2271460 € Start Date 1/07/2012 EU Contribution 1362876 € End Date (actual) 31/12/2015 State Research in progress Summary Advanced measuring technology will be used initially to improve reheating furnace operation and temperature control which will yield improved furnace efficiency and lower CO2 emission. Comprehensive furnace measurements will also provide validation data for the development of three-dimensional dynamic ‘virtual furnace’ models for investigating enhanced furnace control strategies, especially during transient conditions, where existing supervisory control has severe limitations. These combined approaches of advanced process measurements and simulation techniques will result in better understanding of novel heating strategies to improve stock temperature homogeneity and the link between furnace and rolling mill, whilst initiating the evolution of the next generation of supervisory furnace controllers Partners Organization Country Responsible VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Dr.-Ing. Andreas QUECK (Project Coord.) SWEREA MEFOS AB SVERIGE Dr. John NISKA SAARSTAHL AG DEUTSCHLAND Mr Jörg CLEMENS GERDAU INVESTIGACION Y DESARROLLO EUROPA S.A. ESPAÑA Mr José Manuel LLANOS TATA STEEL UK LIMITED UNITED KINGDOM Mr Graham ANDREWS UNIVERSITY OF GLAMORGAN UNITED KINGDOM Dr. Chee-Keong TAN

RFSR-CT-2012-00010 HELNOX-BFG

Full Title High efficiency low NOx BFG based combustion systems in steel reheating Furnaces Info Type of Project Research Duration (months) 42 Total Budget 2169711 € Start Date 1/07/2012 EU Contribution 1301827 € End Date (actual) 31/12/2015 State Research in progress Summary This project aims to develop a combustion system for an efficient utilization of blast furnace gas (BFG) in steel reheating furnaces, by means of fuel preheating (gas-gas heat exchangers or regenerators), so as to maintain the same production level of a high heating value fuel, reducing natural gas dependence and CO2 emissions. This system will be tested at laboratory and industrial scale both in case of air and oxy-fuel combustion technology, in order to: - define the guidelines for a safe application in the industrial environment; - address technical and economical issues; - put forward guidelines for retrofitting existing furnaces. Partners Organization Country Responsible ARCELORMITTAL ESPAÑA SA ESPAÑA Mr Victor CUERVO PINERA (Project Coord.) AGA AB SVERIGE Mr Bo SUNDELIN CENTRO SVILUPPO MATERIALI SPA ITALIA Dr. Umberto ZANUSSO SWEREA MEFOS AB SVERIGE MSc. Anders RENSGARD TENOVA SpA ITALIA Ing. Massimiliano FANTUZZI VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Dr.-Ing. Wolfgang ADLER

RFSR-CT-2012-00012 CERROD

Full Title New generation of highly resistant wear and thermal fatigue ceramic - CERMET work rolls for rod mill application Info Type of Project Research Duration (months) 42 Total Budget 1907357 € Start Date 1/07/2012 EU Contribution 1144415 € End Date (actual) 31/12/2015 State Under process of signature Summary Rod mills in the finishing no twist mill block, use currently cemented carbide (CC) sleeve disks with different binding content and although developments in this hardmetal material has taken place throughout the years, a step change in roll wear, thermal fatigue, product surface quality and dimensional tolerance could be gained by use of more advanced and environmentally friendly ceramic and cermet materials. The project aim is to make this step to meet the requirements of modern rod mills by developing a detailed understanding of cost-applicability of ceramic and cermet work rolls function of industrial conditions taking into account cooling and lubrication. The project will also contribute to reduce EU dependency on strategic material such as Tungsten from China as recently highlighted in EU review [32]. The main objectives of this project are: - to develop a detailed understanding of applicability and tailoring of ceramic and cermet materials for work roll sleeve as likely replacement candidate materials to cemented carbide in rod rolling applications - to develop an approach combining the rolling process and roll shop practices (sleeve mounting, dressing), with key intrinsic properties such as toughness, thermal fatigue and wear to improve applicability of these materials - to critically assess the thermal, mechanical and tribological properties of ceramic and cermet candidates, against current benchmark CC material, with the final objective of issuing a cost performance benefit analysis which should be transferrable to other EU rod mills The main deliverables are: 1. Functional specification for roll sleeve material in no twist rod mill with applicability to roller guide 2. A methodology for pre-screening ceramic/cermet material 3. Regime maps for ceramic and cermet material applicability 4. Cost performance benefit analysis (versus current CC material) 5. Strategy/roadmap for utilisation, upscaling and further development of these materials Partners Organization Country Responsible TATA STEEL UK LIMITED UNITED KINGDOM Dr. Didier FARRUGIA (Project Coord.) ARCELORMITTAL GRANDANGE SA FRANCE Mr Jean-Paul RICHARD CENTRO DE ESTUDIOS E INVESTIGACIONES TECNICAS ESPAÑA Dr. José Manuel SANCHEZ 107 CERATIZIT LUXEMBOURG SARL LUXEMBOURG Dr. Ralph USELDINGER Summaries of RFCS projects 2003-2012 TGS4 : Hot and cold rolling processes

CENTRE DE RECHERCHES METALLURGIQUES ASBL BELGIQUE Mr Jurgen MALBRANCKE

RFSR-CT-2012-00045 ROLLSTREM

Full Title Work roll stress management during hot rolling of long & flat products Info Type of Project Research Duration (months) 42 Total Budget 1840041 € Start Date 1/07/2012 EU Contribution 1104024 € End Date (actual) 31/12/2015 State Research in progress Summary The main objective of the project consist in developing a detailed understanding of roll stress evolution through the service life of typical work rolls during hot rolling of long products which can be extended also for flat products with the aim to design a range of stress corrective solutions to minimise their effect on the added thermal and mechanical stress cycles experienced by the material. The envisaged improvement will be to extend the roll campaign increasing the mill productivity avoiding time and production looses in fixing problems due to roll repairing processes. Work rolls experienced very high mechanical and thermal stresses in service. These stresses are the reason of appearance of surface cracks on the rolls; these cracks cause problems on the materials being rolled. To remove these cracks the rolls are subjected to dressing processes that consist generally in removing material by machining to obtain a roll with a diameter more reduced so it can be used on different mills. This process means to stop the production, a loss of material and reduce the mill productivity. Nowadays, the control of the stresses generated during the process is more related with the thermal stresses due to the contact of the rolls with the hot product being rolled. The main parameters are cooling and lubrication of the rolls in service. As this thermal stress together with mechanical stress due to the loads applied to perform the reductions are added to the internal or residual stresses of the rolls, a deeper knowledge of the stress state of the rolls during its service life can be useful to assess their influence on the behaviour of the rolls. Some possible solutions are envisaged in the project: the influence of surface treatments as those imparted by peening processes, the influence of dressing parameters will be also evaluated. Partners Organization Country Responsible FUNDACION TECNALIA RESEARCH & INNOVATION ESPAÑA Dr. Felix PENALBA DIAZ (Project Coord.) CENTRE DE RECHERCHES METALLURGIQUES ASBL BELGIQUE Mr Hugo UIJTDEBROEKS GERDAU INVESTIGACION Y DESARROLLO EUROPA S.A. ESPAÑA Mr José Manuel LLANOS SONATS - SOCIETE DES NOUVELLES APPLICATIONS DES TE FRANCE Mr Frédéric CHÂTEAU TATA STEEL UK LIMITED UNITED KINGDOM Dr. Didier FARRUGIA

108

Technical Group Steel 5

Finishing and coating

The scope of TGS5 includes:

• Heat treatment technology

• Chemical treatments, finishing and coating techniques including new technologies

• Coating development, including new coatings

• Surface characteristics

• Corrosion properties

• Standardisation of testing and evaluation methods

• Maintenance and reliability of production lines

• Reduction of emissions, energy consumption and improvement of the environmental impact

• Instrumentation, modelling and control of processes

109 110 Summaries of RFCS projects 2003-2012 TGS5 : Finishing and coating

RFSP-CT-2007-00017 Stripvibrations reduction

Full Title Improvement of productivity on hot dip galvanizing line by decreasing strip vibrations in gas jets cooling system Info Type of Project Pilot&Demonstration Duration (months) 36 Total Budget 1518256 € Start Date 1/07/2007 EU Contribution 607303 € End Date (actual) 30/06/2010 State Research completed, report published on EU Bookshop at (link not yet available) Summary The high standard of hot dip coating quality requires a good stability of the strip particularly in the cooling tower (Fig.1) after the zinc bath, where the strip is excited by gas jets cooling equipments. The stakes are estimated at about 3 to 4 M€/line/year, what represents a gain of 75 to 100 M€/year for the concerned European lines. The objective of this project is to increase the line productivity and coating quality by decreasing strip vibrations, not with new external stabilizing actuators but by the improvement of the existing cooling technology. The pilot project is divided in three working axes: - Analysis of strip vibrations on the cooling tower of Arcelor Steel Belgium industrial line; - Opitmisation of the influent parameters on the experimental cooling device of Arcelor Research plant; - Installation and optimisation of the improved proposed solution in industrial conditions. Partners Organization Country Responsible ARCELORMITTAL MAIZIERES RESEARCH S.A. FRANCE Ms Karen BEAUJARD (Project Coord.) ARCELORMITTAL BELGIUM NV BELGIQUE Mr Tom ROELANDT ARCELORMITTAL SAGUNTO SL ESPAÑA Mr Alberto CANO DREVER INTERNATIONAL SA BELGIQUE Dr. Michel RENARD

RFSP-CT-2011-00013 WAVISURF

Full Title On-line industrial waviness measurement Info Type of Project Pilot&Demonstration Duration (months) 42 Total Budget 1549090 € Start Date 1/07/2011 EU Contribution 774545 € End Date (actual) 31/12/2014 State Research in progress Summary The mastering of the waviness is becoming a major issue for making high quality coated steel. If the waviness of a steel sheet is above defined limits, the steel user does not generally accept the annealed and galvanised product for high added value application because it can cause poor quality and downgrading in the further processing steps, notably the finishing and painting operations. Except the sensor developed in a now completed RFCS project “Development of a waviness measurement for coated products”, no waviness measurement exists today on line on moving products. When waviness is measured, it is in a static way and quasi always on samples taken from head or tail of coils, so not necessarily representative of all the length of coil. As a consequence, an on-line measurement is mandatory to fully evaluate the surface quality all along the coil and to potentially control the production parameters. In this pilot project, the on-line method proposed by CRM will be put at the industrial level with two main objectives: - To assess the operating guidelines allowing to reach the waviness target defined by the customers. - To collect all the data needed for the implementation and the commercialisation of a commercial industrial sensor. Partners Organization Country Responsible CENTRE DE RECHERCHES METALLURGIQUES ASBL BELGIQUE Mrs Geneviève MOREAS (Project Coord.) AMEPA ANGEWANDTE MESSTECHNIK UND PROZESSAUTO DEUTSCHLAND Dr. Wolfgang BILSTEIN ARCELORMITTAL ESPAÑA SA ESPAÑA Mr Adrian ESPINE VIELLA SOCIETE EUROPEENNE DE GALVANISATION SA - SEGAL BELGIQUE Mr Ernesto MONTAGNA

RFSR-CT-2003-00021 FAMEGA

Full Title Failure mechanisms during galvanising Info Type of Project Research Duration (months) 42 Total Budget 1086681 € Start Date 1/09/2003 EU Contribution 652009 € End Date (actual) 28/02/2007 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA23195:EN Summary Hot dip zinc galvanising is used extensively throughout Europe for the corrosion protection of structural steelwork because of its resistance to damage, minimal maintenance requirements, longevity and low lifetime costs. Cracking during the galvanising process can occur, however, particularly in the welded higher strength steels, which are being increasingly used. These cracks can remain hidden under the zinc layer and are of serious concern with regard to the load carrying capacity, fatigue resistance and integrity of structural members and fabrications used for applications such as stadium roof structures, where public safety is paramount. It is proposed that the causes and mechanisms of cracking are fully investigated and guidance for its eradication produced. Partners Organization Country Responsible TATA STEEL UK LIMITED UNITED KINGDOM Dr. Bill RUDD (Project Coord.) INGENIEURBÜRO FÜR WERKSTOFFTECHNIK DEUTSCHLAND Dr.-Ing. Peter LANGENBERG ProfilARBED S.A. LUXEMBOURG Mr Boris DONNAY RHEINISCH-WESTFÄLISCHE TECHNISCHE HOCHSCHULE AA DEUTSCHLAND Prof. Dr.-Ing. Wolfgang BLECK UNIVERSIDAD DE CANTABRIA ESPAÑA Prof. Federico GUTIERREZ-SOLANA TECHNISCHE UNIVERSITÄT KAISERSLAUTERN DEUTSCHLAND Dipl.-Ing. Benedikt LÖSER

111 Summaries of RFCS projects 2003-2012 TGS5 : Finishing and coating

RFSR-CT-2003-00028 ZINC-ALLOY

Full Title Fundamental aspects of corrosion and delamination behaviour of novel zinc alloy coatings and Zn-intermetallic phases Info Type of Project Research Duration (months) 40 Total Budget 1766060 € Start Date 1/09/2003 EU Contribution 1059636 € End Date (actual) 31/12/2006 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA25093:EN Summary Superior corrosion, welding and forming properties have been documented for Zn-X alloys prepared from diffusion coupling. A vast range of surface phases and structures may be prepared using these techniques with the promise of new and unprecedented applications. This project seeks to clarify the relationship between the improved cosmetic and perforation corrosion resistance and the nature of the alloy and surface composition and structure. Particular emphasis will be placed on the choice of X (for Mg, Ti, Cr, Fe, Mn) and the nature and depth distribution of the resulting oxide layers. Specific guidelines for directed product engineering will be given. Partners Organization Country Responsible MAX-PLANCK-INSTITUT FÜR EISENFORSCHUNG GmbH DEUTSCHLAND Dr. Michael ROHWERDER (Project Coord.) ARCELORMITTAL MAIZIERES RESEARCH S.A. FRANCE Dr. Kevin OGLE CENTRE DE RECHERCHES METALLURGIQUES ASBL BELGIQUE Dr. Maiwenn LARNICOL DOC DORTMUNDER OBERFLÄCHENCENTRUM GmbH DEUTSCHLAND Dipl.-Ing. Monika RIEMER TATA STEEL UK LIMITED UNITED KINGDOM Mr P.S. LEGOOD

RFSR-CT-2003-00046 CARSTEEL

Full Title Characterizing the surface waviness of hot dip galvanized steel sheets for optical high-quality paintability Info Type of Project Research Duration (months) 48 Total Budget 1435539 € Start Date 1/09/2003 EU Contribution 861324 € End Date (actual) 31/08/2007 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA23854:EN Summary Wainess in the surface of steel sheets may cause waviness in the topcoat ("orange peel effect") of painted sheets. This is undesirable because it impairs the optical impression and customers interpret this as bad paint quality. Therefore, the production of high quality sheets needs the control of wavines in the sheet surface. At present, this is difficult since the car producers demand different parameters to quantify the waviness with regard to the paintability. The aim of the project is to characterize and to optimise the paintability of hot dip galvanized sheets on the basis of new developed uniform parameters (new European standard) accepted by both the steel and the automotive industry. Partners Organization Country Responsible VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Dr.-Ing. Oswald DEUTSCHER (Project Coord.) CORUS TECHNOLOGY B.V. NEDERLAND Mr Simon JUPP SALZGITTER MANNESMANN FORSCHUNG GmbH DEUTSCHLAND Dr. Rer. Nat. Kerstin ULLRICH THYSSENKRUPP STEEL EUROPE AG DEUTSCHLAND Dipl.-Ing. Hans-Gerd WEYEN VOESTALPINE STAHL GMBH OESTERREICH Dr. Dieter PAESOLD

RFSR-CT-2004-00020 TOPOMETER

Full Title On-line topography measurement of uncoated/coated deterministic or random surfaces Info Type of Project Research Duration (months) 48 Total Budget 1412523 € Start Date 1/07/2004 EU Contribution 847513 € End Date (actual) 30/06/2008 State Research completed, report published on EU Bookshop at (link not yet available) Summary More stringent customer requirements and the need to increase productivity are two of the numerous reasons that push the steel makers to deliver higher surface quality strips. Even with the recent improvements, the strip surface is not yet under control. In that aim, an on-line topography sensor will be developed following a completely new approach. By means of that sensor, it becomes possible to calculate 3D parameters to be defined in the course of the project and that are able to better characterise the surface properties. These 3D surface data will allow the three industrial partners to understand better the influence of the various production parameters on the surface topography by means of modelling. That work will be realised at various plants to cover various types of textures (EBT, PRETEX, random) as well as coated and un-coated products. The final result will be a better product control at lower cost resulting in a higher competitiveness. Partners Organization Country Responsible CENTRE DE RECHERCHES METALLURGIQUES ASBL BELGIQUE Mrs Geneviève MOREAS (Project Coord.) ARCELORMITTAL BELGIUM NV BELGIQUE Dr. Ir. Frederik VAN DE VELDE ARCELORMITTAL ESPAÑA SA ESPAÑA Mr Guillermo VECINO SALZGITTER MANNESMANN FORSCHUNG GmbH DEUTSCHLAND Dr. rer nat. Mathias STOLZENBERG

RFSR-CT-2004-00021 CUT-EDGE

Full Title Self-healing at cut-edge Info Type of Project Research Duration (months) 42 Total Budget 1673309 € Start Date 1/07/2004 EU Contribution 1003986 € End Date (actual) 31/12/2007 State Research completed, report published on EU Bookshop at (link not yet available) Summary This project will focus on the development of self-healing functions of coated steel sheet and in particular the problem of cut edge corrosion. This is the major limiting factor for the use of organic coatings on sheet steel, since these products must ultimately be cut, exposing metal surface to the atmosphere at the cut edge. To offer protection in this damaged area, the coating system must be endowed with "self-healing" properties, i.e. the ability of the coating to function through a distance to passivate exposed areas. Special emphasis will be on a respective functionalization of the zinc coating itself. Partners Organization Country Responsible 112 MAX-PLANCK-INSTITUT FÜR EISENFORSCHUNG GmbH DEUTSCHLAND Dr. Michael ROHWERDER (Project Coord.) ARCELORMITTAL LIEGE RESEARCH SCRL BELGIQUE Dr. Patrick CHOQUET Summaries of RFCS projects 2003-2012 TGS5 : Finishing and coating

ARCELORMITTAL MAIZIERES RESEARCH S.A. FRANCE Dr. Kevin OGLE DOC DORTMUNDER OBERFLÄCHENCENTRUM GmbH DEUTSCHLAND Dr. Carmen OSTWALD INSTITUTO SUPERIOR TECNICO PORTUGAL Dr. Alda Maria PEREIRA SIMOES FUNDACION ITMA ESPAÑA Mrs Olga CONEJERO VOESTALPINE STAHL GMBH OESTERREICH Dr. Alexander TOMANDL

RFSR-CT-2004-00022 CLEAN

Full Title New approaches in electrolytic cleaning of cold rolled steel sheet Info Type of Project Research Duration (months) 42 Total Budget 1347799 € Start Date 1/07/2004 EU Contribution 808679 € End Date (actual) 31/12/2007 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA24970:EN Summary Cleaning of cold rolled steel is an indispensable step in modern lines for galvanizing of tin, zinc or zinc alloys. The demand for increased efficiency, speed, and reliability contrasts the requirements of the reduction in costs, energy consumption and environmental pollution. These contradictory requirements shall be overcome by applying an appropriate sequence of anodic and cathodic pulses combined with optimized cleaners. Reducing side reactions (hydrogen evolution, bath electrolysis) minimises the consumption of energy and environmental resources. In-line tracking of the cleaning efficiency and the continuous monitoring and conditioning of the cleaning bath composition will help to prove the success made. Partners Organization Country Responsible MAX-PLANCK-INSTITUT FÜR EISENFORSCHUNG GmbH DEUTSCHLAND Dr. Achim Walter HASSEL (Project Coord.) ARCELOR MITTAL DUDELANGE SA LUXEMBOURG Mr Maurizio FIORRUCCI CENTRE DE RECHERCHES METALLURGIQUES ASBL BELGIQUE Dr. Arnaud HENNION THYSSENKRUPP RASSELSTEIN GMBH DEUTSCHLAND Dr. Helmut OBERHOFFER VOESTALPINE STAHL GMBH OESTERREICH Dr. Johann GERDENITSCH

RFSR-CT-2004-00023 IMGALVA

Full Title Investigation, modelling and control of the influence of the process route on steel strip technological parameters and coating appearance after hot dip galvanising Info Type of Project Research Duration (months) 42 Total Budget 1328089 € Start Date 1/07/2004 EU Contribution 796853 € End Date (actual) 31/12/2007 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA23919:EN Summary Aim of this proposal will be to optimise quality relevant properties of hot dip galvanised steel strip like technological parameters (yield strength and tensile strength) and coating appearance. The ability to optimise the product in these two fields while producing it is essential for an economically competitive production. Based on suitable measuring techniques of the different quality features on a length-related as well as a piece-related scale the influence of process variables on these features along the relevant process route and related to the length of the product will be investigated, modelled and finally used to implement open- loop quality control strategies. Partners Organization Country Responsible VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Dipl -Ing Norbert LINK (Project Coord.) ACERALIA CORPORACION SIDERURGICA S.A. ESPAÑA Dr. Juan Antonio GONZALEZ SWEREA KIMAB AB SVERIGE Prof. Bevis HUTCHINSON SALZGITTER MANNESMANN FORSCHUNG GmbH DEUTSCHLAND Dr. rer nat. Mathias STOLZENBERG UNIVERSIDAD DE LA RIOJA ESPAÑA Prof. Joaquín ORDIERES MERE

RFSR-CT-2005-00021 HIGH-PICK

Full Title Optimised productivity and quality of pickling by on-line control of pickled surface Info Type of Project Research Duration (months) 42 Total Budget 1652096 € Start Date 1/07/2005 EU Contribution 991258 € End Date (actual) 31/12/2008 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA24998:EN Summary To attain a complete elimination of the oxide from the steel surface is an obvious quality request of pickling. However the overpickling i.e. the attack of iron by the acid solution is also detrimental in terms of productivity and quality. So reaching the exact “just pickled” state is an important issue. That is precisely the objective of this project. It will have a multidisciplinary approach: - Development / adaptation of a number of sensors: to monitor the strip surface, follow the process and assess the aggressiveness of the acid solution - On-line tests in several industrial lines - Statistical analysis of overall pickling phenomena. All the data will be used to define the conditions assuring optimised operation i.e. full pickling and no or minimal overpickling. Finally the benefits will be analysed and the transfer conditions will be prepared. Partners Organization Country Responsible CENTRE DE RECHERCHES METALLURGIQUES ASBL BELGIQUE Mr Jean CRAHAY (Project Coord.) ARCELORMITTAL MAIZIERES RESEARCH S.A. FRANCE Dr. Christian ALLELY ILVA S.P.A. ITALIA Eng. Daniele AGAZZANI SCUOLA SUPERIORE DI STUDI UNIVERSITARI E DI PERFEZI ITALIA Dr. Valentina COLLA VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Dipl.-Ing. Holger SCHMERMBECK

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RFSR-CT-2005-00022 Advanced Wiping

Full Title New wiping techniques to produce efficiently the suitable coating layers at high speed in the hot dip galvanising process Info Type of Project Research Duration (months) 42 Total Budget 1952127 € Start Date 1/07/2005 EU Contribution 1171277 € End Date (actual) 31/12/2008 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA24208:EN Summary The project deals with the control of the coating weight in the hot dip coating process. The current wiping technology used the gas knife system is limiting with regards to production of low coating weights and the line speeds at which they can be achieved. The development of new wiping techniques should enable a high line speed with a high flexibility on the final coating thickness. Hence, to overcome the current bottleneck of the galvanising line and so to pave the way for increased productivity, to extend possible coating range and high mastering of the production cost. Partners Organization Country Responsible CENTRE DE RECHERCHES METALLURGIQUES ASBL BELGIQUE Mr Olivier BREGAND (Project Coord.) ABB AUTOMATION TECHNOLOGIES AB SVERIGE Mr Jan Erik ERIKSSON ARCELORMITTAL MAIZIERES RESEARCH S.A. FRANCE Dr. Marc ANDERHUBER TATA STEEL NEDERLAND TECHNOLOGY BV NEDERLAND Mr Nico NOORT VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Dr.-Ing. Walter UNGERER

RFSR-CT-2005-00023 SPACE

Full Title Space efficient curing methods and simulation-aided coating engineering for extending lifetime of aesthetic coil coatings Info Type of Project Research Duration (months) 42 Total Budget 1296030 € Start Date 1/07/2005 EU Contribution 777618 € End Date (actual) 31/12/2008 State Research completed, report published on EU Bookshop at (link not yet available) Summary This proposal is focused on steel use and the possibilities of space efficient curing methods and structure – property relationships as tools for development of complex coil coatings for exterior architectural applications. The desired properties are new aesthetic surfaces, anti-graffiti properties, anti-bacterial properties, improved scratch resistance and dual-cure systems for improved combination of hardness and formability. Overall objectives are: • To define working range for each curing method and the corresponding coating systems (UV, IR, NIR and thermal curing as reference). • To work out unique performance profiles specific for different polymer and curing chemistries. • To develop 3-layer coil coatings Partners Organization Country Responsible TOP ANALYTICA OY AB FINLAND Dr. Bengt-Johan SKRIFVARS (Project Coord.) CYTEC SURFACE SPECIALITIES SA BELGIQUE Dr. Marc HEYLEN MAX-PLANCK-INSTITUT FÜR EISENFORSCHUNG GmbH DEUTSCHLAND Dr. Guido GRUNDMEIER RAUTARUUKKI OYJ FINLAND Mr Mika HAUTALA SSAB EMEA AB SVERIGE Dr. Per-Erik SUNDELL VOESTALPINE STAHL GMBH OESTERREICH Dr. Bernhard STRAUß

RFSR-CT-2005-00024 DECOBIOF

Full Title Development and evaluation of coatings and surface conditions on steel for antibacterial and easy to clean properties Info Type of Project Research Duration (months) 42 Total Budget 1693189 € Start Date 1/07/2005 EU Contribution 1015914 € End Date (actual) 31/12/2008 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA24189:EN Summary Microbial growth in steel components may cause corrosion, odour, staining, and in certain cases serious healthy problems. Today, there is a special interest in what it is called “hygienic surfaces” with refers not only to a surface that provides anti-microbial activity, but also to a surface which looks clean or even with a self cleaning behaviour. These properties can be achieved with specific coatings or via surface substrate modification. The development and evaluation of hygienic surfaces on steel for antibacterial and easy to clean properties is the main objective of this proposal. Partners Organization Country Responsible Fundación INASMET ESPAÑA Ms Virginia MADINA (Project Coord.) ACERINOX SA ESPAÑA Dr. Maria Victoria MATRES CENTRO SVILUPPO MATERIALI SPA ITALIA Dr.ssa Maria Grazia SERRA SWEREA KIMAB AB SVERIGE Mr Dan JACOBSSON MAX-PLANCK-INSTITUT FÜR EISENFORSCHUNG GmbH DEUTSCHLAND Dr. Guido GRUNDMEIER ONDERZOEKSCENTRUM VOOR AANWENDING VAN STAAL BELGIQUE Dr. Swapan Kumar GHOSH TATA STEEL UK LIMITED UNITED KINGDOM Dr. Stuart READ

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RFSR-CT-2005-00052 Full Title Improvement of line productivity and of immersed hot dip galvanizing roll lifetime by dross build-up-control Info Type of Project Research Duration (months) 36 Total Budget 1265704 € Start Date 1/07/2005 EU Contribution 759422 € End Date (actual) 30/06/2008 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA24260:EN Summary The high standard of hot dip coating quality for automotive and industry markets requires no contact between dross and steel sheet. Improvement in terms of coating quality and line productivity can be achieved by decreasing the progressive adhesion of dross on immersed rolls. The objective of this project is to increase the immersed hot dip galvanizing roll lifetime of 30% and consequently line productivity and coating quality by controlling dross build-up phenomena. After identifying on industrial lines the main parameters of dross build-up, some laboratory simulations and modelling work will help us to understand the mechanism explaining dross build-up and to propose, evaluate and test some industrial solutions to avoid it. Partners Organization Country Responsible ARCELORMITTAL MAIZIERES RESEARCH S.A. FRANCE Mrs Claudie DULCY (Project Coord.) ARCELORMITTAL EISENHÜTTENSTADT GmbH DEUTSCHLAND Mr Gunter WIEDNER CENTRE DE RECHERCHES METALLURGIQUES ASBL BELGIQUE Mr Yves HARDY FORSCHUNG- UND QUALITÄTSZENTRUM BRANDENBURG DEUTSCHLAND Mr Peter FOERSTER VOESTALPINE STAHL GMBH OESTERREICH Dipl.-Ing. Josef HAGLER

RFSR-CT-2006-00015 NOVANNEAL

Full Title Novel annealing procedures for improving HDG of HSS Info Type of Project Research Duration (months) 36 Total Budget 1566642 € Start Date 1/07/2006 EU Contribution 939984 € End Date (actual) 30/06/2009 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA24990:EN Summary The inert oxides of modern high strength steels are a major problem for hot dip galvanizing. Especially interesting from the industrial point of view are concepts to avoid surface oxide formation by enhancing internal oxidation by increasing the dew point. The idea of the project is to investigate simpler to apply alternatives to these existing concepts, as for example the lowering of the hydrogen content in the forming gas. Other questions involve whether prediction tools for wettability can be developed by completing the research recently made and how far wettability and adhesion of the zinc coating to the steel are correlated. Partners Organization Country Responsible MAX-PLANCK-INSTITUT FÜR EISENFORSCHUNG GmbH DEUTSCHLAND Dr. Michael ROHWERDER (Project Coord.) CENTRE DE RECHERCHES METALLURGIQUES ASBL BELGIQUE Dr. Louis BORDIGNON DOC DORTMUNDER OBERFLÄCHENCENTRUM GmbH DEUTSCHLAND Mr Ronny LEUSCHNER VOESTALPINE STAHL GMBH OESTERREICH Dr. Gerhard ANGELI

RFSR-CT-2006-00016 WAVIMETER

Full Title Development of a waviness measurement for coated products Info Type of Project Research Duration (months) 43 Total Budget 1556741 € Start Date 1/07/2006 EU Contribution 934046 € End Date (actual) 31/01/2010 State Research completed, report published on EU Bookshop at (link not yet available) Summary Waviness is an important parameter as, if it is above defined limits, the steel user does not accept the product because it causes scrap or bad quality in the further processing. But, except for high glossy surfaces, it is mostly not eye visible before painting. So, an on-line measuring system is of great interest for it will measure the waviness not only at the head or tail of coil but all along it. The new system will be developed on the base of CRM on-line microscope integrating high speed components, stitching algorithms and multiprocessor implementation. The project will cover the validation of the technique in laboratory and in industry. Industrial partners will be deeply involved in the industrial validation but also in the analysis of the database so constituted. This database, regrouping waviness measurement and production parameters, will be analysed to define guidelines to improve the process and so the product quality. Partners Organization Country Responsible CENTRE DE RECHERCHES METALLURGIQUES ASBL BELGIQUE Mrs Geneviève MOREAS (Project Coord.) ARCELORMITTAL ESPAÑA SA ESPAÑA Mr Guillermo VECINO ARCELORMITTAL MAIZIERES RESEARCH S.A. FRANCE Dr. Gabriel FRICOUT SOCIETE EUROPEENNE DE GALVANISATION SA - SEGAL BELGIQUE Mr Ernesto MONTAGNA VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Dr.-Ing. Oswald DEUTSCHER

RFSR-CT-2007-00018 Hppm

Full Title Methodology of hydrogen measurement in coated steels Info Type of Project Research Duration (months) 36 Total Budget 959871 € Start Date 1/07/2007 EU Contribution 575922 € End Date (actual) 30/06/2010 State Research technically completed; publication in hand Summary The set up of clear and rigorous methodologies of hydrogen measurement is mandatory to continue the development of coated steel products with high strength and sensitive microstructures to hydrogen embrittlement. How to measure 0.1 mass ppm of hydrogen which diffuses very rapidly at room temperature and is present in numerous sources of contamination? The work program is divided into five inter-related work packages to answer concretely to the metallurgist requests: calibration of analysers, sample preparation, bulk analysis, local analysis, distinction of traps and origin of hydrogen. Partners Organization Country Responsible MAX-PLANCK-INSTITUT FÜR EISENFORSCHUNG GmbH DEUTSCHLAND Dr. Achim Walter HASSEL (Project Coord.) CENTRE DE RECHERCHES METALLURGIQUES ASBL BELGIQUE Dr. Cedric GEORGES 115 THYSSENKRUPP STEEL EUROPE AG DEUTSCHLAND Dipl.-Ing. Karin BERGERS Summaries of RFCS projects 2003-2012 TGS5 : Finishing and coating

VOESTALPINE STAHL GMBH OESTERREICH Dr. Alexander TOMANDL

RFSR-CT-2008-00017 IPSA

Full Title Innovative packaging steel with enhanced adhesion to organic coatings based on nanostructured interphases Info Type of Project Research Duration (months) 42 Total Budget 1384623 € Start Date 1/07/2008 EU Contribution 830774 € End Date (actual) 31/12/2011 State Research technically completed; publication in hand Summary The development of an innovative packaging steel with enhanced adhesion to organic coatings allowing deforming processes like deep draw-redraw will lead to superior corrosion resistance. Surface treatments like plasma/corona treatment and plasma deposition will be used to generate thin oxide films on blackplate or metal coated blackplate. Combination with water based surface tretaments (commercial available or with known chemical composition) like silanes will result in a superior adhesion system for lacquers and thermoplastic films. All surface treatments investigated shall be applicable at industrial line speed. Using innovative, environmentally friendly treatments this product will replace Electrolytic Chromium Coated Steel. Partners Organization Country Responsible THYSSENKRUPP RASSELSTEIN GMBH DEUTSCHLAND Dr. Andrea MARMANN (Project Coord.) ARCELORMITTAL MAIZIERES RESEARCH S.A. FRANCE Mr Yoann JACQUES FRAUNHOFER GESELLSCHAFT ZUR FOERDERUNG DER AN DEUTSCHLAND Dr. Inés DANI TATA STEEL NEDERLAND TECHNOLOGY BV NEDERLAND Dr. Jan Paul PENNING

RFSR-CT-2008-00018 MICSIPE

Full Title Microbiologically induced corrosion of steel structures in port environment: improving prediction and diagnosis of ALWC Info Type of Project Research Duration (months) 36 Total Budget 1490294 € Start Date 1/07/2008 EU Contribution 894176 € End Date (actual) 30/06/2011 State Research technically completed; publication in hand Summary Some European port authorities are currently concerned by a localised and accelerated corrosion, called Accelerated Low Water Corrosion (ALWC) occurring on steel waterfront structures. High corrosion rates induced can shorten drastically service life of the structure or lead to failure. Solutions to mitigate this corrosion are available but maintenance of these structures still remains costly. Previous studies showed that ALWC is microbiologically induced; however mechanisms and bacteria involved have not been entirely determined until now. This project aims at developing diagnostic tools and a risk assessment method for industrial end users to predict and assess ALWC by using advanced molecular methods. Partners Organization Country Responsible CENTRE REGIONAL D'INNOVATION ET DE TRANSFERT DE T FRANCE Ms Emilie MALARD (Project Coord.) ARCELORMITTAL BELVAL & DIFFERDANGE S.A. LUXEMBOURG Mrs Anne FAGOT SWEREA KIMAB AB SVERIGE Dr. Rolf GUBNER TECHNISCHE UNIVERSITEIT DELFT NEDERLAND Dr.-Ir. Gerard MUIJZER UNIVERSIDAD DE CADIZ ESPAÑA Prof. Dr. Francisco Javier BOTANA PEDEMONTE UNIVERSITE DE ROUEN HAUTE-NORMANDIE FRANCE Dr. Laurent QUILLET

RFSR-CT-2008-00019 FERRIGAL

Full Title Steady reactivity in hot-dip coating by direct deposit of iron oxides Info Type of Project Research Duration (months) 36 Total Budget 1147262 € Start Date 1/07/2008 EU Contribution 688358 € End Date (actual) 30/06/2011 State Research in progress Summary The inert oxides of resistance steel grades are a major problem for hot dip galvanizing. Especially interesting from the industrial point of view are concepts to avoid surface oxide formation of alloying elements. One approach is to modify the annealing procedure prior to hot dip galvanising. This proposal suggests a much simpler and easy to apply procedure: to deposit a thin iron oxide layer, e.g. by a simple dipping deposition, as barrier against segregation. The iron oxide is reduced during the annealing and serves then as a reactive surface excellently wettable by the liquid zinc. Partners Organization Country Responsible CENTRE DE RECHERCHES METALLURGIQUES ASBL BELGIQUE Dr. Maiwenn LARNICOL (Project Coord.) MAX-PLANCK-INSTITUT FÜR EISENFORSCHUNG GmbH DEUTSCHLAND Dr. Michael ROHWERDER ONDERZOEKSCENTRUM VOOR AANWENDING VAN STAAL BELGIQUE Mrs Victoria MASAGUER TATA STEEL NEDERLAND TECHNOLOGY BV NEDERLAND Dr. Florian MENGUELTI

RFSR-CT-2008-00046 NEXTEP

Full Title Novel externally enhanced pickling improvement for short / mid term Info Type of Project Research Duration (months) 42 Total Budget 1908963 € Start Date 1/07/2008 EU Contribution 1145378 € End Date (actual) 31/12/2011 State Research technically completed; publication in hand Summary At long term, it is expected that process improvements in hot-rolling will decrease the oxide layer and as a consequence pickling of carbon steel should be in the future either strongly reduced or fully eliminated. However at short/mid term pickling remains a necessary operation that constitutes a bottleneck in strip production. This project aims at boosting techniques to be applied at short term to enable pickling line to cope with new difficult-to-pickle grades, to reduce the energy intensity and the environmental impact. Different routes will be analysed in laboratory, namely alternating current processing, reactive operation and remote cavitation. Pilot line tests will be performed in optimised conditions. Main results will be the selection and full characterisation (operative window and process performances) of candidate solutions for industrial application. 116 Partners Organization Country Responsible ILVA S.P.A. ITALIA Dr. Floriano FERRO (Project Coord.) Summaries of RFCS projects 2003-2012 TGS5 : Finishing and coating

ARCELORMITTAL ESPAÑA SA ESPAÑA Dr. José Luis RENDUELES VIGIL CENTRE DE RECHERCHES METALLURGIQUES ASBL BELGIQUE Mr Jean CRAHAY CENTRO SVILUPPO MATERIALI SPA ITALIA Dr. Armando GIANNETTI TENOVA SpA ITALIA Ing. Gerolamo FASCE SIEMENS VAI METALS TECHNOLOGIES SAS FRANCE Mr Philippe BARBIERI VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Dr. Frank RÖGENER

RFSR-CT-2009-00010 REPAIR

Full Title Evaluation of new coating concepts based on active network reconstruction and their applicability to the production of coil-coated steel sheet Info Type of Project Research Duration (months) 36 Total Budget 1181533 € Start Date 1/07/2009 EU Contribution 708920 € End Date (actual) 30/06/2012 State Research in progress Summary The aim is to evaluate existing concepts of self-repair functionalities found for polymeric materials for their suitability to the production of coil-coated steel products. The goal is to develop a coating, maintaining its integrity, correcting its in-use damages and thereby increasing its life-time. The project is not focusing on corrosion inhibition although an increased corrosion protection is a consequence of the self-repair functionality. The project will choose 4 - 5 “selfrepair” concepts and develop out of them 1 - 2 fully formulated coil-coating systems. These will be evaluated on their potential to become successful coil-coated products with good business potential. Partners Organization Country Responsible TOP ANALYTICA OY AB FINLAND Dr. Bengt-Johan SKRIFVARS (Project Coord.) AKZO NOBEL INDUSTRIAL FINISHES AB SVERIGE Ms Irina TRAN RAUTARUUKKI OYJ FINLAND Dr. Pasi VÄISÄNEN SSAB TUNNPLÅT AB SVERIGE Dr. Per-Erik SUNDELL UNIVERSITÄT PADERBORN DEUTSCHLAND Prof Dr Wolfgang BREMSER VOESTALPINE STAHL GMBH OESTERREICH Dr. Michaela SCHATZL

RFSR-CT-2009-00014 AUTOCOAT

Full Title Advanced zinc-based hot dip coatings for the automotive application Info Type of Project Research Duration (months) 42 Total Budget 1605356 € Start Date 1/09/2009 EU Contribution 963214 € End Date (actual) 28/02/2013 State Research in progress Summary Novel zinc-based coatings alloyed with magnesium and aluminium have a significant potential for improving corrosion resistance of car bodies and reducing costs of additional corrosion protection. Corrosion properties and the underlying corrosion mechanism must be investigated in details to promote their application in highly demanding automotive industry and further product development. A connection between the coating composition, microstructure, pretreatment and corrosion performance will be sought. In particular, paint delamination and protection in confined areas will be addressed. Long-term behaviour of Zn-Al-Mg coated steel will be monitored in a wide range of real service conditions allowing thus reliable lifetime prediction. Partners Organization Country Responsible INSTITUT DE LA CORROSION SASU FRANCE Dr. Nathalie LE BOZEC (Project Coord.) CENTRO RICERCHE FIAT S.C.p.A. ITALIA Dr. Giancarlo MARCHIARO FIAT GROUP AUTOMOBILES SpA ITALIA Dr. Gian Carlo LUNAZZI LIMEDION GMBH DEUTSCHLAND Dr. Frank FRIESS MAX-PLANCK-INSTITUT FÜR EISENFORSCHUNG GmbH DEUTSCHLAND Dr. Michael ROHWERDER RUUKKI METALS OY FINLAND Mr Ari PELTOLA THYSSENKRUPP STEEL EUROPE AG DEUTSCHLAND Mrs Linda LUXEM VOESTALPINE STAHL GMBH OESTERREICH Dr. Gerald LUCKENEDER

RFSR-CT-2010-00012 HEAT

Full Title High emissivity annealing technique Info Type of Project Research Duration (months) 42 Total Budget 1671966 € Start Date 1/07/2010 EU Contribution 1003179 € End Date (actual) 31/12/2013 State Research in progress Summary The study suggests to reduce/suppress the selective oxidation made during the recrystallisation annealing by a layer of shielding iron oxide. This iron oxide has to be thin and continuously kept during the whole heating and soaking steps for avoiding the external selectve oxidation and for increasing thermal transfer from the radian tube furnace, which should significantly reduce the fuel consumption. To ensure that this strategy can be readily adopted by steel industry, the kinetics of oxidation and reduction need to be studied and an online monitoring for the layer iron oxide thickness to be developped. Partners Organization Country Responsible THYSSENKRUPP STEEL EUROPE AG DEUTSCHLAND Dr. Patrick KUHN (Project Coord.) CENTRE DE RECHERCHES METALLURGIQUES ASBL BELGIQUE Dr. Louis BORDIGNON MAX-PLANCK-INSTITUT FÜR EISENFORSCHUNG GmbH DEUTSCHLAND Dr. Michael ROHWERDER TATA STEEL NEDERLAND TECHNOLOGY B.V. NEDERLAND Dr. Wanda MELFO VOESTALPINE STAHL GMBH OESTERREICH Dr. Alexander JAROSIK

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RFSR-CT-2010-00013 ULTRA DRY COOLING

Full Title Development of an ultra fast cooling concept based on the dispersion of a liquid hydrocarbon in a continuous heat treatment line for steel strips Info Type of Project Research Duration (months) 42 Total Budget 979426 € Start Date 1/07/2010 EU Contribution 587655 € End Date (actual) 31/12/2013 State Research in progress Summary The project aims at developing a technological breakthrough in the area of steel strip cooling devices, in continuous processing lines. This new cooling device consists in projecting a spray of liquid hydrocarbon (such as pentane) on the strip surface. The hydrocarbon is vaporized by the hot steel, extracted from the cooling box, and re-condensated to operate in closed-loop. This original process brings tremendous advantages to steelmakers: much higher cooling rates without strip fluttering compared to classical jet cooling systems, no strip oxidation compared to water-based cooling systems, and ultra low energy consumption. Partners Organization Country Responsible CMI THERMLINE SERVICES SAS FRANCE Dr. Ludovic FERRAND (Project Coord.) ASS. POUR LA RECHERCHE ET LE DEV. DES METHODES ET P FRANCE Dr. Maroun NEMER CENTRE DE RECHERCHES METALLURGIQUES ASBL BELGIQUE Mr Pascal GERKENS

RFSR-CT-2010-00014 HIJETROD

Full Title High pressure water descaling for wire rod Info Type of Project Research Duration (months) 42 Total Budget 1751940 € Start Date 1/07/2010 EU Contribution 1051164 € End Date (actual) 31/12/2013 State Research in progress Summary During rolling and annealing of steel, metal oxides are formed on the steel surface. For downstream processing a scale-free surface is essential. The project aims to reduce the high effort required for pickling to remove scale and to replace resource-intensive pretreatment by employing environment-friendly high pressure water jets both within and downstream of the pickling process. This high pressure water treatment used as “cold” scale removal is new with respect to wire rod, and is being pursued for the first time. The development risk can be clearly assessed by the partners thanks to their complementary expertise regarding research and application. Partners Organization Country Responsible VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Dr. Barbara WENDLER (Project Coord.) COGNE ACCIAI SPECIALI SpA ITALIA Dr. Alessio CAVALIERI CENTRO SVILUPPO MATERIALI SPA ITALIA Dr. Nicoletta ZACCHETTI DEUTSCHE EDELSTAHLWERKE GMBH DEUTSCHLAND Dipl -Ing Jürgen ALEX GERDAU INVESTIGACION Y DESARROLLO EUROPA S.A. ESPAÑA Mr José Manuel LLANOS

RFSR-CT-2010-00015 Flat strip control

Full Title Controlling flatness of strips in furnace of continuous annealing/galvanising lines Info Type of Project Research Duration (months) 42 Total Budget 883732 € Start Date 1/07/2010 EU Contribution 530239 € End Date (actual) 31/12/2013 State Research in progress Summary Buckling and strip tracking are common problems in continuous lines with annealing furnace and they are sources of product downgrading and/or loss of productivity. This phenomenon is more likely to occur on thin and wide material and consequences are more disastrous. Unfortunately, market trend is towards such material. A way of gaining control over the strip flatness into the furnace would be of great help to produce this material cost-effectively. It is thus proposed to measure the strip shape and temperature across its width inside the furnace in one or several locations for gaining knowledge about buckling. Partners Organization Country Responsible CENTRE DE RECHERCHES METALLURGIQUES ASBL BELGIQUE Mr Yves HARDY (Project Coord.) ARCELORMITTAL MAIZIERES RESEARCH S.A. FRANCE Mrs Noelle MICQUE SWEREA MEFOS AB SVERIGE PhD Annika NILSSON

RFSR-CT-2010-00016 ELOTOP

Full Title Influences of the electro galvanizing process on the surface topography alterations Info Type of Project Research Duration (months) 42 Total Budget 1369914 € Start Date 1/07/2010 EU Contribution 821949 € End Date (actual) 31/12/2013 State Research in progress Summary Steel flat products are protected against corrosion by electrolytic zinc coatings. The roughness is very important regarding the deep drawability and the paintability. Presently it is difficult to produce the final roughness in such close tolerances as demanded by the automotive industry. Main influencing variables are: topography and steel grade of the primary material, plant configuration, process parameters and composition of the electrolyte applied. Aim of this project is to investigate the electrolytic zinc coating process and to develop rules and models to achieve designated final roughness. The models will be applied and verified. Partners Organization Country Responsible VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Dr.-Ing. Jochen KURZYNSKI (Project Coord.) SALZGITTER FLACHSTAHL GmbH DEUTSCHLAND Dr.-Ing. Andreas HOLDINGHAUSEN THYSSENKRUPP STEEL EUROPE AG DEUTSCHLAND Mr Alexander BUTTLER VOESTALPINE STAHL GMBH OESTERREICH Dr. Johann GERDENITSCH

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RFSR-CT-2010-00017 FLEXPROMUS

Full Title Flexible production by multi sensor process control of pickling lines Info Type of Project Research Duration (months) 42 Total Budget 1387689 € Start Date 1/07/2010 EU Contribution 832613 € End Date (actual) 31/12/2013 State Research in progress Summary The project aims at smart control of stainless steel pickling lines by developing a multi-sensor concentration detection system and advanced process control models. The concentration detection combines online-sensors and a model-based multi-physics model algorithm for acids and metal concentration detection in mixed-acid pickling liquors. For smart process control an intelligent and a standard process control model are developed and investigated in two different stainless steel pickling line types. Actually the stainless steel sector is under economic pressure. The smart control system will be a major contribution for improved product quality and flexible production in stainless steel pickling lines. Partners Organization Country Responsible VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Dr.-Ing. Matthias WERNER (Project Coord.) ACERINOX EUROPA SA ESPAÑA Mrs Maria José GUIO BONANY ANDRITZ AG OESTERREICH Dr. Albert LEBL SWEREA KIMAB AB SVERIGE Dr. Petter BERGSJÖ THYSSENKRUPP NIROSTA GMBH DEUTSCHLAND Dipl.-Ing. Hans-Günther HARTMANN

RFSR-CT-2011-00014 VADPSHEETS

Full Title Property oriented design of hard constituent hardness and morphology in continuously annealed/galvanised DP sheets Info Type of Project Research Duration (months) 42 Total Budget 1567758 € Start Date 1/07/2011 EU Contribution 940655 € End Date (actual) 31/12/2014 State Research in progress Summary The proposal is aimed at developing a metallurgicaly based model for continuous annealing/galvanizing process capable of identifying the quantitative effect of chemical composition and thermal profile on the properties of DP sheets, including: • Strength and uniform elongation; • Press formability (stretch-flengeability, bending formability, stretch-formability, drawing formability); • Fatigue; • Bake hardenability; • Weldability; • Resistance to crack formation during cold deformation; • Crash worthiness. The model will be implemented in the computer software for the representation of explicit picture of microstructure (Digital Material Representation) and properties prediction. The software will be used for the process parameters adjustment to meet specific customer requirements. Partners Organization Country Responsible INSTYTUT METALURGII ZELAZA IM. STANISLAWA STASZICA POLAND Prof. Roman KUZIAK (Project Coord.) AKADEMIA GORNICZO-HUTNICZA IM. STANISLAWA STASZI POLAND Prof. Maciej PIETRZYK ARCELORMITTAL MAIZIERES RESEARCH S.A. FRANCE Dr. Mohamed GOUNE CENTRE DE RECHERCHES METALLURGIQUES ASBL BELGIQUE Mrs Griet LANNOO SALZGITTER MANNESMANN FORSCHUNG GmbH DEUTSCHLAND Mr Norbert KWIATON

RFSR-CT-2011-00015 ATCORAS

Full Title Modelling of atmospheric corrosion of steel protected by aluminium based alloys, applied by hot dip processing Info Type of Project Research Duration (months) 36 Total Budget 1327462 € Start Date 1/07/2011 EU Contribution 796477 € End Date (actual) 30/06/2014 State Research in progress Summary In this project a modelling tool is developed and validated for the understanding of the atmospheric corrosion behaviour of steel protected by aluminium based alloys, applied by hot dip processing. In particular, the role of additives (Mg, Si, Zn …) is studied. The research aims to model the impact of the metallic coating compositions in various conditions of the liquid film (pH, Cl-, thickness, ...) and to explore and evaluate how the developed model can be integrated with life time prediction tools of real structures under varying atmospheric corrosion conditions. The final objective is to design optimal coatings for given atmospheric conditions. Partners Organization Country Responsible VRIJE UNIVERSITEIT BRUSSEL BELGIQUE Prof. Dr. Johan DECONINCK (Project Coord.) ELSYCA NV BELGIQUE Dr. Leslie BORTELS INSTITUTO SUPERIOR TECNICO PORTUGAL Dr. Sviatlana LAMAKA ONDERZOEKSCENTRUM VOOR AANWENDING VAN STAAL BELGIQUE Dr. Joost DE STRYCKER UNIVERSIDADE DE AVEIRO PORTUGAL Dr. Mikhail ZHELUDKEVICH

119 Summaries of RFCS projects 2003-2012 TGS5 : Finishing and coating

RFSR-CT-2011-00016 ICONTENS

Full Title Intelligent self-learning control of levelling processes by use of soft sensor techniques to predict residual stress and flatness Info Type of Project Research Duration (months) 42 Total Budget 2113670 € Start Date 1/07/2011 EU Contribution 1268203 € End Date (actual) 31/12/2014 State Research in progress Summary Leveller settings are normally done by experience of the operator, using visual feedback of the geometrical shape of strip. The increasing use of (A)HSS requires levelling strategies preventing loss of deformation properties. This project aims at developing multi-physics process models for different leveller types for automated auto-adaptive set-up and advanced on-line control of residual stress and flatness using intelligent soft sensors predicting residual stresses and flatness. Bending processes around deflection rolls and coilers will be considered while developing strategies for minimum total elongation. With automated control for minimisation of residual stresses, quality and consistency of the strip levelling process are optimised Partners Organization Country Responsible VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Dipl.-Ing. Volker DIEGELMANN (Project Coord.) ARCELORMITTAL MAIZIERES RESEARCH S.A. FRANCE Mr Tété DOSSAH CENTRO SVILUPPO MATERIALI SPA ITALIA Dr. Maurizio LUBRANO SWEREA MEFOS AB SVERIGE PhD Annika NILSSON THYSSENKRUPP ACCIAI SPECIALI TERNI SpA ITALIA Dr.-Ing. Costantino DI PIETRO THYSSENKRUPP NIROSTA PRAEZISIONSBAND GMBH DEUTSCHLAND Dipl.-Ing. Christoph MÜLLER

RFSR-CT-2012-00013 ZINCOBOR

Full Title Exploring of crack initiation mechanisms and process parameter interactions in press hardened boron steel components actively protected by Zn-based coatings Info Type of Project Research Duration (months) 42 Total Budget 1546342 € Start Date 1/07/2012 EU Contribution 927804 € End Date (actual) 31/12/2015 State Research in progress Summary The increasing demand for light weight car body structures with enhanced safety properties is the main driving factor for the introduction of press hardened components in automotive applications. The desire to use such components with superior mechanical properties in heavy-duty corrosion applications led to the development of zinc-based coatings on high-strength steels in order to provide an active corrosion protection. Up to the present these coatings exhibit the main drawback of cracks appearing after the direct press hardening regardless the applied coating process with the risk of intolerable crack propagation into the base material. Some presumptions concerning the underlying mechanisms already exist, e.g. a liquid melt assisted cracking in the presence of a Znmelt and a stress state or a grain boundary embrittlement caused by a corrosive composition of the coating and the possibility of diffusion processes, but the real mechanisms may be even more complex due to superposition of various effects. Up to now there is a major lack of knowledge about the responsible thermo-chemical, thermomechanical and/or high-temperature tribological effects and conditions which are responsible for the crack initiation and its growth. Therefore, the motivation of this project is to deal with such drawbacks and increase the existing knowledge allowing to understand them. The objective is to explore the mechanisms of crack initiation and propagation, to identify the process parameters responsible for such detrimental effects and develop solutions to prevent it. The information about these phenomena is essential for an optimisation of the coatings, its deposition methods and/or for the design of direct press hardening processes. For this the influence of each step in the process chain will be investigated separately but with consecutively increasing complexity of the responsible mechanisms and interactions by the use of modified test facilities and tests on industrial scale. Partners Organization Country Responsible FUNDACIO CTM CENTRE TECNOLOGIC- CTM ESPAÑA Dr. Daniel CASELLAS (Project Coord.) TATA STEEL NEDERLAND TECHNOLOGY B.V. NEDERLAND Mr Guido HENSEN UNIVERSITÄT KASSEL DEUTSCHLAND Prof. Kurt STEINHOFF VOESTALPINE STAHL GMBH OESTERREICH Dr. Thomas KURZ

RFSR-CT-2012-00014 BOLT_ZnAlMg

Full Title Better offshore lighter batch HDG technology using Zn Al Mg alloys Info Type of Project Research Duration (months) 36 Total Budget 1209813 € Start Date 1/07/2012 EU Contribution 576693 € End Date (actual) 30/06/2015 State Research in progress Summary Presently, flat products are galvanized with ZnAlMg alloys using continuous HDG processes while long products use batch double dip HDG technology which is only available in Asia. However, when targeting the development of spin batch HDG processes, additional challenges exist to galvanize with these complex alloys. In fact, batch single dip HDG technology using ZnAlMg alloys is not yet developed in Europe either with or without spinning. Therefore, this proposal intends to use existing state-of-the-art to develop spinnable ZnAlMg alloys and respective batch HDG technology for offshore threated fasteners which are mechanically reliable, cheaper and more corrosion resistant at reduced thicknesses. Partners Organization Country Responsible METALOGIC AI TECHNOLOGIES & ENGINEERING NV BELGIQUE Dr. Ir Telma CARVALHO (Project Coord.) GFD SAS FRANCE Mr Laurent GINEYS GALVA POWER GROUP NV BELGIQUE Eng. David WARICHET HILTI AG LIECHTENSTEIN Dr Frédéric POL PROGATEC AB SVERIGE Mr Kaj STEEN STEINBEIS GMBH & CO KG FÜR TECHNOLOGIETRANSFER DEUTSCHLAND Prof. Peter HAEFELE

120

Technical Group Steel 6

Physical metallurgy and design of new generic steel grades

The scope of TGS6 includes:

• Precipitation, re-crystallisation, microstructure & texture and ageing

• Predictive simulation models on microstructures & mechanical properties

• Development of steel with improved properties at low and high temperatures such as strength and toughness, fatigue, wear, creep and resistance against fracture

• Magnetic properties

• New steel grades for demanding applications

• Standardisation of testing and evaluation methods

121 122 Summaries of RFCS projects 2003-2012 TGS6 : Physical metallurgy and design of new generic steel grades

RFS1-CT-2005-00025 MICROAS 05

Full Title Microalloying for new steel processes and applications Info Type of Project Accompanying measure (confere Duration (months) 3 Total Budget 85800 € Start Date 1/07/2005 EU Contribution 20000 € End Date (actual) 30/09/2005 State Research completed; no publication Summary The objective of the present proposal is the organisation and hosting of an International Symposium on the use of microalloying in steels for new processes and applications. The scope of the conference is to provide a forum for researchers and industrialist from the European Union and abroad to discuss developments and new perspectives on microalloying in novel applications and improved steel grades. Within this frame, and given the participation of European researches in previous Conferences on similar topics, the diffusion of results gained on research projects founded by the European Commission Steel RTD programme is assured. Partners Organization Country Responsible CENTRO DE ESTUDIOS E INVESTIGACIONES TECNICAS ESPAÑA Dr. José Maria RODRIGUEZ IBABE (Project Coord.)

RFS1-CT-2008-00020 Full Title 6th European stainless steel conference, science and markets Info Type of Project Accompanying measure (confere Duration (months) 3 Total Budget 189500 € Start Date 1/06/2008 EU Contribution 20000 € End Date (actual) 31/08/2008 State Research completed; no publication Summary The 6th European Stainless Steel Conference, in June 10-13, 2008 in Helsinki, Finland, is devoted both to the scientific aspects of stainless steels and their market issues. The objectives for the conference is to be a meeting place for specialists, both industry and academic sectors, from the European Union and abroad, involved in new growing steel applications and in research and development. Meetings between these groups have proved to be a seed for the fruitful and successful development of manufacturing processes, new steel grades and new applications for stainless steels. Within this frame the diffusion of results also gained on some research projects funded by the Research Fund for Coal and Steel is assured. The conference will address the specific issues and role of stainless steels in meeting the challenge of the modern society, particularly in terms of sustainability. Issues addressed will include the consequences of restricted availability of specific alloying elements (leading to alloy substitution), newly developed grades, improvement of current austenitic, ferritic, martensitic, duplex and new high-Mn and duplex steel grades, and the demand for modified and innovative production routes. User concerns, including improved performance in terms of welding, corrosion and forming, will also be important. Europe has until now been the leader in the production of stainless steel. China is, however, now coming as a strong player into this field. They will soon have some of the biggest stainless steel works in the world. In order to support the competitiveness of the European stainless steel industry and to keep its leading position, we must even more strengthen our research and in close contact with the market, our customers, develop the niche products they need. This conference offers a good opportunity for dissemination of the results of our research and also to discuss with our customers their needs for future products. The conference will cover both fundamental and applied aspects of stainless steels, in the following topics: • Applications and service experience of stainless steel • New trends in stainless steel processing • Fabrication technology • Surface treatment and surface properties of stainless steel • Modelling of microstructures and properties • Corrosion, testing and performance, with and without load • Guidelines and standards The conference theme and papers are in good accordance with the objectives and scientific/technical and socio-economic priorities of the Research Fund for Coal and Steel, as they “…increase competitiveness and contribute to sustainable development… the development of new or improved technologies to guarantee the economic, clean and safe production of steel and steel products characterised by steadily increasing performance, suitability to use, customer satisfaction, prolonged service life, easy recovery and recycling.” Many of the conference papers also covers the current priorities of the Strategic Research Agenda of the European Steel Technology Platform (ESTEP), quoted in the RFCS Information Package 2007 The conference is organized by Jernkontoret and sponsored by most of the leading companies in this filed in Europe: Outokumpu, Sandvik Materials Technology, ESAB, ThyssenKrupp Nirosta, ThyssenKrupp Acciai Speciali Terni, UGINE & ALZ, Nickel Institute, IMOA, International Chromium Development Association and Euro Inox. Details can be found on the conference web site www.stainless08.com The conference is the latest in a successful series of international conferences * Florence in 1993 * Düsseldorf in 1996, * Sardinia in 1999, * Paris in 2002 * Seville in 2005. In 2007 some conferences were held, with names rather similar to this conference. They however were concentrated on other aspects: 3rd International Conference ‘Stainless Steel Markets 2007’ in Moscow, in September. That conference is mainly devoted to market, meaning in this connection financing and statistics. Science and technical research, as in our conference, is not on the agenda. Stainless Steel World Conference 2007 in Maastricht in November is a purely commercial yearly event, mainly devoted to the application oriented technique and will not cover science as in our conference. Partners Organization Country Responsible JERNKONTORET IDEELLA FÖRENINGAR SVERIGE Prof. Staffan HERTZMAN

123 Summaries of RFCS projects 2003-2012 TGS6 : Physical metallurgy and design of new generic steel grades

RFSR-CT-2003-00009 MEPMO

Full Title Mechanical property models for high strength complex microstructures Info Type of Project Research Duration (months) 42 Total Budget 1634073 € Start Date 1/09/2003 EU Contribution 980444 € End Date (actual) 28/02/2007 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA23181:EN Summary The project aims to reach a deeper understanding on the effect processing has on microstructure related to the mechanical behaviour in high strength complex microstructures present in dual-phase (DP) and multi-phase steels. The effect of the precipitation strengthening, the interaction of soft and hard phases, the impact of internal stresses around hard particles (DP- steels) and the strain partitioning will also be investigated. Besides classical light and electron metallography, EBSD and nanoindentation techniques will be used to characterise the microstructure and to obtain mechanical information. It is also the aim of the project to develop microstructure-property models for such steels in order to get a tool for prediction and design. These models will be validated through experiment. Partners Organization Country Responsible CENTRO DE ESTUDIOS E INVESTIGACIONES TECNICAS ESPAÑA Dr. Isabel GUTIERREZ SANZ (Project Coord.) CENTRE DE RECHERCHES METALLURGIQUES ASBL BELGIQUE Mrs Caroline GALLEZ CENTRO SVILUPPO MATERIALI SPA ITALIA Dr. Juan Hector BIANCHI TATA STEEL UK LIMITED UNITED KINGDOM Dr. Sally PARKER THYSSENKRUPP STEEL EUROPE AG DEUTSCHLAND Dipl -Ing Georg PAUL TECHNISCHE UNIVERSITÄT BERGAKADEMIE FREIBERG DEUTSCHLAND Prof. Dr.-Ing. Rudolf KAWALLA

RFSR-CT-2003-00015 PREMPROP

Full Title Prediction of the mechanical properties at hot strip processing plants Info Type of Project Research Duration (months) 36 Total Budget 932288 € Start Date 1/09/2003 EU Contribution 559373 € End Date (actual) 31/08/2006 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA23852:EN Summary The project aims to reach a deeper understanding on the effects, which have the subsequent processing of hot strip material on its mechanical behaviour. While it is possible to predict the mechanical properties of as-hot rolled strips at the hot strip mill, models for subsequent processes as pickling or temper rolling, which have also a noticeable influence on the mechanical properties, have to be build up. Also ageing in the course and after the subsequent processing has to be considered. These effects will be studied for CMn, micro alloyed and bainite-ferrite steels in order to develop microstructure-property models for such steels to get a tool for the optimisation of these processes. Partners Organization Country Responsible THYSSENKRUPP STEEL EUROPE AG DEUTSCHLAND Dipl -Ing Georg PAUL (Project Coord.) ARCELORMITTAL MAIZIERES RESEARCH S.A. FRANCE Dr. Astrid PERLADE CENTRE DE RECHERCHES METALLURGIQUES ASBL BELGIQUE Mrs Caroline GALLEZ

RFSR-CT-2003-00020 BIOWAS

Full Title Materials for increased performance in sustainable fuel combustion Info Type of Project Research Duration (months) 42 Total Budget 1884928 € Start Date 1/09/2003 EU Contribution 1130958 € End Date (actual) 28/02/2007 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA23868:EN Summary There is a EU policy to increase the total amount of energy from renewable resources from 6% to 12% by 2010. Energy from waste and biomass represents the largests contributor of energy generated from renewables and is likely to make the largest contribution to the proposed increase. This combustion processes involve aggressive high temperature environments with HCI as the dominant aggressive species. The project aims to an understanding of mechanisms of oxide scale breakdown with respect to the use of preoxidation as a method of alloy protection. Furthermore, it provides corrosion data from laboratory and field testing and facilitates the selection and use of existing stainless steels and coatings on carbon steel for these conditions. Partners Organization Country Responsible MAX-PLANCK-INSTITUT FÜR EISENFORSCHUNG GmbH DEUTSCHLAND Priv.-Doz.Dr. Michael SPIEGEL (Project Coord.) CENTRO SVILUPPO MATERIALI SPA ITALIA Dr. Franco MANCIA CLAUSTHALER UMWELTTECHNIKINSTITUT GmbH DEUTSCHLAND Dr.-Ing. Stefan VODEGEL ECOSESTO SPA ITALIA Mr Franco BELLEI Fundación INASMET ESPAÑA Mr Iñaki AZKARATE INSTITUTO DE SOLDADURA E QUALIDADE PORTUGAL Dr. Gervásio FERREIRA PIMENTA SWEREA KIMAB AB SVERIGE Dr. Rachel PETTERSSON UNIVERSITAET STUTTGART DEUTSCHLAND Prof. Dr. Klaus R.G. HEIN

124 Summaries of RFCS projects 2003-2012 TGS6 : Physical metallurgy and design of new generic steel grades

RFSR-CT-2003-00040 MIHAR

Full Title Metallurgical impact of hot asymmetric rolling Info Type of Project Research Duration (months) 36 Total Budget 1033709 € Start Date 1/09/2003 EU Contribution 620226 € End Date (actual) 31/08/2006 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA23335:EN Summary Microstructure refinement is one of the best metallurgical solutions to decrease alloying elements at given mechanical properties allowing cost reduction and recyclability-weldability-coatability-toughness improvement especially in high strength steels or increase mechanical properties at a given chemical composition. At the hot rolling stage, grain refinement is promoted by the use of high reductions in the last stands. However in the conventional rolling practice the reduction is limited in those last stands, especially due to the high rolling loads. Asymmetric hot rolling could be an interesting way to solve the problems related to high reductions in the last finishing stand of the hot strip mill. That is the reason why the object of this proposal is to study the metallurgical impact of hot asymmetrically rolled steel strips which is a very promising way not only for microstructure refinement but also to decrease rolling force and to modify texture. Partners Organization Country Responsible ARCELORMITTAL MAIZIERES RESEARCH S.A. FRANCE Mrs Gwenola HERMAN (Project Coord.) CENTRE DE RECHERCHES METALLURGIQUES ASBL BELGIQUE Mrs Griet LANNOO CENTRO SVILUPPO MATERIALI SPA ITALIA Dr. Ilaria SALVATORI

RFSR-CT-2004-00024 NUSIMAG

Full Title Cross numerical simulations & characterisations of magnetic steel properties for non destructive evaluation purposes Info Type of Project Research Duration (months) 36 Total Budget 1591878 € Start Date 1/07/2004 EU Contribution 955127 € End Date (actual) 30/06/2007 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA23749:EN Summary Magnetic non-destructive measurements may bring significant improvements in process control. Positive impacts may support the development of products such as IF, low-carbon or UHSS for sheets or 100Cr6 and 35CrMo4 for wire, with potential benefits of 8 M€/y for the European steel community. But applications today have been limited to correlations between magnetic and mechanical properties in restrictive conditions. The proposal aims to give support to this activity by providing an innovative modelling approach of the magnetic properties of the steels mentioned above, completed by a complete set of measurements in laboratory as well as in industrial contexts. Partners Organization Country Responsible ARCELORMITTAL MAIZIERES RESEARCH S.A. FRANCE Dr. Philip MEILLAND (Project Coord.) ARCELORMITTAL ATLANTIQUE ET LORRAINE SAS FRANCE Dr. Jean-Jacques MAREZ ISTITUTO NAZIONALE DI RICERCA METROLOGICA ITALIA Dr. Giorgio BERTOTTI ASSOCIATION LEONARD DE VINCI FRANCE Prof. Michel BERNADOU GERDAU INVESTIGACION Y DESARROLLO EUROPA S.A. ESPAÑA Mr Jacinto ALBARRAN SANZ TATA STEEL NEDERLAND TECHNOLOGY BV NEDERLAND Ing. Henk T. PLOEGAERT

RFSR-CT-2004-00025 MANNESTRAMP

Full Title Influence of tramp elements (P, Cu, S, Sn) on the Mannesmann effect in the transversal hot rolling of engineering steels Info Type of Project Research Duration (months) 42 Total Budget 1078008 € Start Date 1/07/2004 EU Contribution 646805 € End Date (actual) 31/12/2007 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA23597:EN Summary The project is focused to evaluate the influence of the content of some tramp elements on the formation of internal axial microcracks due to Mannesmann effect in the transverse hot rolling of engineering steels. Partners Organization Country Responsible GERDAU INVESTIGACION Y DESARROLLO EUROPA S.A. ESPAÑA Mrs Zuriñe IDOYAGA (Project Coord.) ASCOMETAL S.A.S. FRANCE Mr Boris KIEBER FRAUNHOFER GESELLSCHAFT ZUR FOERDERUNG DER AN DEUTSCHLAND Mr Matthias KOLBE INSTITUTO DE SOLDADURA E QUALIDADE PORTUGAL Dr. Helena GOUVEIA SCUOLA SUPERIORE DI STUDI UNIVERSITARI E DI PERFEZI ITALIA Dr. Valentina COLLA

RFSR-CT-2004-00026 CONSTAINSSA

Full Title New design concept of stainless steels for structural applications Info Type of Project Research Duration (months) 36 Total Budget 1731619 € Start Date 1/07/2004 EU Contribution 1038972 € End Date (actual) 30/06/2007 State Unknown type of status (CSX) Summary The proposed project aims at determining the composition and the fabrication cycle of a family of new high-nitrogen austenitic stainless steels, less expensive than those presently on the market, that combine resistance to corrosion, high ductility and toughness with a high mechanical strength. The expected balance performance/costs for products designed for the Strip Casting route will considerably improve the potential of Stainless Steels as structural materials, opening wide new market opportunities. In addition, this new technique allows alloying more nitrogen without producing defects, increasing austenite stability and mechanical strength. Laboratory testing will suggest the composition for testing on full scale pilot production. Steel performance will be evaluate on prototypes of structural components. Partners Organization Country Responsible CENTRO SVILUPPO MATERIALI SPA ITALIA Dr. Giuseppe ABBRUZZESE (Project Coord.) EMO-ORODJARNA d.o.o. SLOVENIJA Dipl.-Ing. Renato FIJAVZ 125 THYSSENKRUPP ACCIAI SPECIALI TERNI SpA ITALIA Dr.Ing. Antonio BUFALINI Summaries of RFCS projects 2003-2012 TGS6 : Physical metallurgy and design of new generic steel grades

THYSSENKRUPP NIROSTA GMBH DEUTSCHLAND Dipl.-Ing. Michael SACHTLEBER VOEST-ALPINE INDUSTRIEANLAGENBAU GmbH & Co OESTERREICH Dr. Gerald HOHENBICHLER

RFSR-CT-2004-00027 ISA-PESR

Full Title Integrative simulation of advanced protective gas electro-slag-remelting for the production of high-quality steels Info Type of Project Research Duration (months) 36 Total Budget 1598182 € Start Date 1/09/2004 EU Contribution 958910 € End Date (actual) 31/08/2007 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA23917:EN Summary The project objective is the development of a numerical modelling tool as industry-oriented software for the advanced protective gas electroslag remelting (PESR) process. It covers all of the critical aspects of the PESR process such as: multi-phase/component phenomena in the slag zone; heat/mass transfer and convection during remelting and ingot solidification; Lorentz forces and ohmic heating; reduction of inclusions; prediction/optimisation of ingot microstructure etc.. The suggested integrative simulation approach will definitely diminish the extremely costly trial and error practice and thus enable the European steel industry to improve product quality, optimise operation parameters, and save energy and resources. Partners Organization Country Responsible MONTANUNIVERSITÄT LEOBEN OESTERREICH Prof. Dr. Andreas LUDWIG (Project Coord.) ALD VACUUM TECHNOLOGIES GmbH DEUTSCHLAND Dr. Matthias BLUM BÖHLER EDELSTAHL GmbH & Co. KG OESTERREICH DI Roland RABITSCH CENTRO SVILUPPO MATERIALI SPA ITALIA Dr.-Ing. Andrea CAROSI ESI GROUP FRANCE Dr. Mark SAMONDS

RFSR-CT-2004-00028 CARBAIN

Full Title New ecological and low cost answers to end-user demands on high performance steel components Info Type of Project Research Duration (months) 48 Total Budget 1563708 € Start Date 1/07/2004 EU Contribution 938225 € End Date (actual) 30/06/2008 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA24173:EN Summary The project is focused on the development of ecological and low cost innovative production routes and tailored steel grades to fulfil end-users demand on high performance steel components. To obtain this goal, the synergies between high temperature grain size control and vacuum carburising followed by gas quenching technologies as well as a new production route for dry bainitising through gas quenching will be investigated. Development of modified steel grades, improved heat treatment facilities and modelling will be performed and checked on actual industrial components and compared to conventional current routes to quantify economical and environmental savings. Partners Organization Country Responsible GERDAU INVESTIGACION Y DESARROLLO EUROPA S.A. ESPAÑA Mr Rafael PIZARRO (Project Coord.) ALD VACUUM TECHNOLOGIES GmbH DEUTSCHLAND Dr.-Ing. Klaus LÖSER ASCOMETAL S.A.S. FRANCE Mrs Elvire CHARBONNELLE ROBERT BOSCH GmbH DEUTSCHLAND Dr.-Ing. Jochen SCHWARZER PERKINS ENGINES Co Ltd UNITED KINGDOM Dr. Andrew McGILVRAY RHEINISCH-WESTFÄLISCHE TECHNISCHE HOCHSCHULE AA DEUTSCHLAND Prof Dr -Ing Wolfgang BLECK TATA STEEL UK LIMITED UNITED KINGDOM Mr P.E. REYNOLDS ZF FRIEDRICHSHAFEN AG DEUTSCHLAND Dr.-Ing. Jörg KLEFF

RFSR-CT-2004-00029 PREST

Full Title Intense precipitation strengthening of bainitic flat and long products - mechanisms, means and process routes Info Type of Project Research Duration (months) 36 Total Budget 1516104 € Start Date 1/07/2004 EU Contribution 909663 € End Date (actual) 30/06/2007 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA23722:EN Summary Modern high-strength, high-toughness bainitic steels derive their favourable properties from the ultrafine bainitic ferrite grains in which the contribution from precipitation strengthening is of paramount importance. The precipitation strengthening reactions in bainitic ferrite remain, however, unclear. This project will exploit the benefits of intense precipitation by Ti,Nb,V,Cu to increase strength while improving ductility and toughness by lowering the carbon content. Models will be developed to predict precipitation behaviour and strength properties and these will be utilised to aid industrial scale evaluation of new high-strength steels with low and ultra-low carbon contents as well as engineering bainitic steels. Partners Organization Country Responsible SWEREA KIMAB AB SVERIGE Dr. Stanislaw ZAJAC (Project Coord.) ARCELORMITTAL MAIZIERES RESEARCH S.A. FRANCE Dr. Thierry IUNG ASCOMETAL S.A.S. FRANCE Dr.-Ing. Pierre DIERICKX INSTYTUT METALURGII ZELAZA IM. STANISLAWA STASZICA POLAND Prof. Roman KUZIAK ONDERZOEKSCENTRUM VOOR AANWENDING VAN STAAL BELGIQUE Mr Joachim ANTONISSEN RAUTARUUKKI OYJ FINLAND Dr. Jukka KÖMI GERDAU INVESTIGACION Y DESARROLLO EUROPA S.A. ESPAÑA Mr Jacinto ALBARRAN SANZ

126 Summaries of RFCS projects 2003-2012 TGS6 : Physical metallurgy and design of new generic steel grades

RFSR-CT-2004-00030 REHOMI

Full Title Refinement and development of homogeneous microstructures through the thickness of heavy products in V- steels Info Type of Project Research Duration (months) 36 Total Budget 1174656 € Start Date 1/07/2004 EU Contribution 704794 € End Date (actual) 30/06/2007 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA23876:EN Summary Acicular ferrite microstructure, which provides effective grain (structural) refinement, is one of the most desired microstructure that improves both strength and toughness. Recent experimental results strongly indicate that a fine acicular ferrite microstructure can be obtained by proper use of vanadium microadditions. To develop such a microstructure homogeneously through the thickness of heavy products, a new cooling strategy, called Alternate Water Cooling, is proposed to cool in-depth heavy products. In this work, the effect of V and the cooling process in promoting an acicular ferrite microstructure homogeneously distributed through the thickness of heavy plates and long products will be investigated as a method for improvement of both strength and toughness. Partners Organization Country Responsible ProfilARBED S.A. LUXEMBOURG Mr Boris DONNAY (Project Coord.) CENTRE DE RECHERCHES METALLURGIQUES ASBL BELGIQUE Mrs Astrid de RO AGENCIA ESTATAL CONSEJO SUPERIOR DE INVESTIGACIO ESPAÑA Dr. Carlos CAPDEVILLA MONTES SWEREA KIMAB AB SVERIGE Dr. Stanislaw ZAJAC SALZGITTER MANNESMANN FORSCHUNG GmbH DEUTSCHLAND Dr. Carl Justus HECKMANN

RFSR-CT-2005-00026 PISAC

Full Title Properties improvement by stress-assisted control of the metallurgical transformations for HSS and BH steels Info Type of Project Research Duration (months) 36 Total Budget 1215497 € Start Date 1/07/2005 EU Contribution 729299 € End Date (actual) 30/06/2008 State Research technically completed; publication in hand Summary The nature and the morphology of the microstructures control obviously the mechanical properties of steels especially for HSS and BH steels. The microstructures are usually obtained changing the temperature, the chemical composition and plastic deformation before phase transformations and recrystallisation. A complementary fully innovative approach to microstructure control is proposed here. Applied stress is considered as a new driving force for metallurgical evolutions. Indeed stress effects afford many promising opportunities : - slow down phase transformation for compression like state, - accelerate phase transformation for tension like state, - change the nucleation and so exhibit an impact on structure size (refinement), - provide a specific spatial orientation (texture). Partners Organization Country Responsible ARCELORMITTAL MAIZIERES RESEARCH S.A. FRANCE Mr Philippe MAUGIS (Project Coord.) CENTRE DE RECHERCHES METALLURGIQUES ASBL BELGIQUE Mrs Annick DE PAEPE TATA STEEL UK LIMITED UNITED KINGDOM Mr Peter J. EVANS THYSSENKRUPP STEEL EUROPE AG DEUTSCHLAND Dipl -Ing Georg PAUL

RFSR-CT-2005-00027 HIPERC

Full Title A novel, high-performance, economic steel concept for linepipe and general structural use Info Type of Project Research Duration (months) 42 Total Budget 1592775 € Start Date 1/07/2005 EU Contribution 955666 € End Date (actual) 31/12/2008 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA24209:EN Summary Several steel companies have confirmed the potential of a niobium-alloyed, low-carbon steel that combines excellent strength and toughness using both air and forced cooling following processing for the heavy pipe market. The metallurgical concept is relevant to other market sectors and this project will develop structure property relationships to define chemical analysis and process route limits of this steel type for a) thick-walled pipe and flat plate, and b) coiled-plate for both pipe and general use. The results will identify and justify what changes are required to Euronorms for the steel to be available for a wide range of uses. Partners Organization Country Responsible TATA STEEL UK LIMITED UNITED KINGDOM Mr Lynden DREWETT (Project Coord.) CENTRO DE ESTUDIOS E INVESTIGACIONES TECNICAS ESPAÑA Dr. Antonio MARTIN MEIZOSO INSTYTUT SPAWALNICTWA POLAND Dr. Boguslaw CZWORNOG NIOBIUM PRODUCTS COMPANY GmbH DEUTSCHLAND Dr. Hardy MOHRBACHER ONDERZOEKSCENTRUM VOOR AANWENDING VAN STAAL BELGIQUE Mr Martin LIEBEHERR RAUTARUUKKI OYJ FINLAND Dr. David PORTER RHEINISCH-WESTFÄLISCHE TECHNISCHE HOCHSCHULE AA DEUTSCHLAND Prof. Dr.-Ing. Wolfgang BLECK SALZGITTER MANNESMANN FORSCHUNG GmbH DEUTSCHLAND Dr.-Ing. Volker FLAXA UNIVERSITEIT GENT BELGIQUE Prof. Dr. Ir. Wim DE WAELE UNIVERZA V MARIBORU SLOVENIJA Assoc. Prof. Dr Nenad GUBELJAK

127 Summaries of RFCS projects 2003-2012 TGS6 : Physical metallurgy and design of new generic steel grades

RFSR-CT-2005-00028 ASTEX

Full Title Modification of textural distribution in hot rolled stainless steels using asymmetric hot rolling technique Info Type of Project Research Duration (months) 42 Total Budget 1131546 € Start Date 1/07/2005 EU Contribution 678928 € End Date (actual) 31/12/2008 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA24207:EN Summary The presence of orientation bands in hot rolled strips, due to a columnar solidification structure that can hardly be broken by conventional symmetric hot rolling, originates in final products of ferritic stainless steels a surface defect known as “ridging” (or roping) and has a detrimental effect on deep drawing ability. The aim of this project is to investigate the combined effect of the asymmetric hot rolling (e.g. rolling performed using different roll diameters) and the influence of deformation given in the final passes on the microstructural and textural distribution in the hot rolled strip and the resultant microstructure textures and mechanical properties in final gauge ferritic stainless strips, as a possible solution to the roping phenomena and for improving deep drawing ability. Partners Organization Country Responsible CENTRO SVILUPPO MATERIALI SPA ITALIA Dr. Ilaria SALVATORI (Project Coord.) CENTRE DE RECHERCHES METALLURGIQUES ASBL BELGIQUE Mr Hendrik VANDEKINDEREN TATA STEEL UK LIMITED UNITED KINGDOM Dr. John BUTLER ARCELORMITTAL STAINLESS FRANCE FRANCE Dr. Francis CHASSAGNE

RFSR-CT-2005-00029 MISTRETO

Full Title Toughness and ductility improvement in complex microstructure HSS by means of microstructural parameters optimization Info Type of Project Research Duration (months) 42 Total Budget 1796570 € Start Date 1/07/2005 EU Contribution 1077942 € End Date (actual) 31/12/2008 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA24185:EN Summary High and ultra-high strength- steels with yield strengths above 1000 MPa are now increasingly required by the end users. However, when increasing the strength, the toughness, ductility and formability are impaired. Fine and complex multiphase microstructures allow to improve these properties. However, increasing the complexity of the microstructure makes more and more difficult to identify the microstructural features that are directly related to the mechanical behaviour. This project aims to improve toughness and ductility of high strength steels with complex bainitic/martensitic microstructures and dual phase steels, by identifying the microstructure constituents which control these properties. Models will be developed to predict toughness and ductility behaviour and these will be utilised to aid industrial scale evaluation of new high-strength steels. Partners Organization Country Responsible CENTRO SVILUPPO MATERIALI SPA ITALIA Dr. Andrea DI SCHINO (Project Coord.) ARCELORMITTAL MAIZIERES RESEARCH S.A. FRANCE Mrs Gwenola HERMAN CENTRO DE ESTUDIOS E INVESTIGACIONES TECNICAS ESPAÑA Dr. Isabel GUTIERREZ SANZ AGENCIA ESTATAL CONSEJO SUPERIOR DE INVESTIGACIO ESPAÑA Dr. Sebastian MEDINA SWEREA KIMAB AB SVERIGE Dr. Stanislaw ZAJAC VOESTALPINE STAHL GMBH OESTERREICH Mag. Martin KLEIN

RFSR-CT-2005-00030 Metaldesign

Full Title Metallurgical design of high strength austenitic Fe-C-Mn steels with excellent formability Info Type of Project Research Duration (months) 42 Total Budget 1436332 € Start Date 1/07/2005 EU Contribution 861800 € End Date (actual) 31/12/2009 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA25063:EN Summary This project is aimed at deeply investigating the basic TWIP steel metallurgy focusing on the following aspects: recrystallization and grain growth behaviour, precipitation, as well as the metallurgical aspects linking the microstructure to properties of industrial interest such as mechanical properties, forming, welding and coating ability. Evolution models for the austenite will be modified in order to describe the TWIP steels recrystallization behaviour and allow the design of manufacturing cycles both for hot rolled strip for direct use and cold rolled products. Partners Organization Country Responsible CENTRO SVILUPPO MATERIALI SPA ITALIA Dr. Alessandro FERRAIUOLO (Project Coord.) CENTRO DE ESTUDIOS E INVESTIGACIONES TECNICAS ESPAÑA Prof. Dr. Javier GIL SEVILLANO DUFERCO LA LOUVIERE SA BELGIQUE Dr.-Ing. Giuseppe PRATOLONGO INSTITUTO DE SOLDADURA E QUALIDADE PORTUGAL Dr. Helena GOUVEIA OULUN YLIOPISTO*UNIVERSITY OF OULU FINLAND Prof Pentti KARJALAINEN

128 Summaries of RFCS projects 2003-2012 TGS6 : Physical metallurgy and design of new generic steel grades

RFSR-CT-2005-00031 COHEADBAIN

Full Title Cold heading quality low-carbon ultra-high strength bainitic steels Info Type of Project Research Duration (months) 36 Total Budget 1212554 € Start Date 1/07/2005 EU Contribution 582992 € End Date (actual) 30/06/2008 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA24191:EN Summary The project aims at developing low-carbon high – strength bainitic steels dedicated for cold heading applications without heat treating operations. Next, to design the hot rolling routes giving the optimal bainitic microstructure in the wire rod and bar in terms of headability and the final product properties. Cold headability of commonly used steels is critically sensitive to differences between the mechanical properties of hard (cementite) and soft (ferrite) microstructure constituents. Therefore, one-phase low- carbon precipitation-strengthened bainitic ferrite is an ideal microstructure for cold working operations. On the project completion, semi–finished products of bainitic steel, as well as cold–headed products, will be produced and characterized. Partners Organization Country Responsible INSTYTUT METALURGII ZELAZA IM. STANISLAWA STASZICA POLAND Prof. Roman KUZIAK (Project Coord.) SWEREA KIMAB AB SVERIGE Dr. Stanislaw ZAJAC ARCELORMITTAL STEEL POLAND SPOLSKA AKCCYJNA POLAND Dr. Jerzy STODOLNY MITTAL STEEL HAMBURGGmbH DEUTSCHLAND Dr. Karl STERCKEN TECHNISCHE UNIVERSITÄT BERGAKADEMIE FREIBERG DEUTSCHLAND Prof Dr -Ing Rudolf KAWALLA SWISS STEEL AG SUISSE Dr. Lotfi CHABBI

RFSR-CT-2006-00017 MICRO-QUANT

Full Title Microstructural quantification of multi phase steels Info Type of Project Research Duration (months) 42 Total Budget 2340492 € Start Date 1/07/2006 EU Contribution 1404296 € End Date (actual) 31/12/2009 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA24980:EN Summary A profound understanding of microstructure-properties relationships of Advanced High Strength steels is of crucial importance to a rational development of these steels. This demands the ability to perform advanced quantification of their complex multi phase microstructures, addressing the full range of microstructural properties that are relevant to their macroscopic mechanical behaviour. This in turn requires a suit of metallographic procedures, primarily based on high-resolution electron optical techniques to deal with the submicron microstructural dimensions. The aim of this project is to develop a range of standardised metallographic procedures dedicated to accurate and reproducible microstructural quantification of complex multi phase microstructures. Partners Organization Country Responsible TATA STEEL NEDERLAND TECHNOLOGY B.V. NEDERLAND Dr. Maxim AARNTS (Project Coord.) ARCELORMITTAL MAIZIERES RESEARCH S.A. FRANCE Mr Didier HUIN CENTRE DE RECHERCHES METALLURGIQUES ASBL BELGIQUE Dr. Liesbeth BARBÉ SWEREA KIMAB AB SVERIGE Dr. Stanislaw ZAJAC RHEINISCH-WESTFÄLISCHE TECHNISCHE HOCHSCHULE AA DEUTSCHLAND Prof Dr -Ing Wolfgang BLECK THYSSENKRUPP STEEL EUROPE AG DEUTSCHLAND Dr. Volker MARX VOESTALPINE STAHL GMBH OESTERREICH Dipl.-Ing. Reinhard HACKL

RFSR-CT-2006-00019 MAGPRO

Full Title Magnetic field processing for customized microstructures and properties in steels Info Type of Project Research Duration (months) 36 Total Budget 1402388 € Start Date 1/07/2006 EU Contribution 841432 € End Date (actual) 30/06/2009 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA25069:EN Summary Phase stability, kinetics of phase transformation and texture evolution in steels are strongly influenced by the application of high magnetic fields. The aim of this project is to investigate the influence of high magnetic field processing on the phase equilibria and on the kinetics of the microstructural evolution in steels and to define the guidelines to develop a new production process to enhance the microstructural properties of steels not achievable by conventional thermomechanical processing routes. Partners Organization Country Responsible CENTRO SVILUPPO MATERIALI SPA ITALIA Dr. Ilaria SALVATORI (Project Coord.) ARCELORMITTAL MAIZIERES RESEARCH S.A. FRANCE Dr. Jean-Louis URIARTE CENTRE NATIONAL DE LA RECHERCHE SCIENTIFIQUE FRANCE Prof. Eric BEAUGNON CENTRE DE RECHERCHES METALLURGIQUES ASBL BELGIQUE Mr Philippe POUTEAU

129 Summaries of RFCS projects 2003-2012 TGS6 : Physical metallurgy and design of new generic steel grades

RFSR-CT-2006-00020 ODS-STEEL

Full Title Novel oxide dispersion strengthened steels obtained by high productivity casting process with innovative injection of suitable special powders Info Type of Project Research Duration (months) 48 Total Budget 1224657 € Start Date 1/07/2006 EU Contribution 734794 € End Date (actual) 30/06/2010 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA25040:EN Summary The objective of the proposal is to develop a new generation of stainless steels obtained by means of dispersion of fine ceramic particles into the metal matrix. The dispersion is realised during the continuous casting process by injecting suitable developed powders into the melt stream. These stainless steels will have: · A modified as-cast structure, as the particles promote an equiaxed solidification by heterogeneous nucleation · Increased mechanical properties at both room and high temperature · Properties insensitive to post heat treatments (e.g. welding) The development activity will be performed on one ferritic, AISI 439 and one austenitic, AISI 301LN stainless grades and on one austenitic special steel. The project and will take into account the whole manufacturing cycle (casting, hot rolling, annealing, cold rolling and annealing) even though the heart of the innovation concerns the injection of the ceramic powder into the melt stream during the casting process. The effect on the mechanical properties, both at room and at high temperature, will be verified by means of appropriate testing for AISI 439. For AISI301LN, the mechanical properties will only be tested at room temperature. Partners Organization Country Responsible CENTRO SVILUPPO MATERIALI SPA ITALIA Mr Claudio TESTANI (Project Coord.) COGNE ACCIAI SPECIALI SpA ITALIA Ing. Andrea LANDINI CENTRE DE RECHERCHES METALLURGIQUES ASBL BELGIQUE Mr Paul NAVEAU ARCELORMITTAL STAINLESS FRANCE FRANCE Dr. Jean-Denis MITHIEUX

RFSR-CT-2006-00021 CP-steels

Full Title Cold-rolled complex-phase (CP) steel grades with optimised bendability, stretch-flangeability and anisotropy Info Type of Project Research Duration (months) 42 Total Budget 1385699 € Start Date 1/07/2006 EU Contribution 831419 € End Date (actual) 30/06/2010 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA25041:EN Summary The improvement of the strength-formability balance of advanced high-strength steels is still a challenging task. This project deals with the relationship between microstructure and formability – particularly bendability and stretch-flangeability – of cold-rolled complex-phase steels. Therefore, the transformation behaviour and a wide range of microstructures of such steels will be analysed extensively. The overall goals of this project are to: • Identify microstructures with optimised balance between strength, bendability and stretchflangeability. • Develop guidelines of how to produce the material, by an appropriate alloy design, and well-adjusted processing parameters through several processing routes, i.e. continuous annealing and hot dip galvannealing. Partners Organization Country Responsible SWEREA KIMAB AB SVERIGE MSc Lena RYDE (Project Coord.) RAUTARUUKKI OYJ FINLAND Dr. Pasi PEURA RHEINISCH-WESTFÄLISCHE TECHNISCHE HOCHSCHULE AA DEUTSCHLAND Prof Dr -Ing Wolfgang BLECK SSAB EMEA AB SVERIGE Dr. Björn CARLSSON VOESTALPINE STAHL GMBH OESTERREICH Dr. Thomas HEBESBERGER

RFSR-CT-2006-00022 CORINOX

Full Title Avoiding catastrophic corrosion failure of stainless steels Info Type of Project Research Duration (months) 42 Total Budget 1280666 € Start Date 1/07/2006 EU Contribution 768401 € End Date (actual) 31/12/2009 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA25003:EN Summary Stainless steels are durable, renewable and functional materials for demanding environments, but they have the drawback that pitting, crevice corrosion or stress corrosion cracking can cause serious failures. Materials selection today is often based on corrosion tables which are limited to one or two parameters and rarely correspond well to demanding environments. This project will provide a new methodology for advanced multi-dimensional design curves in terms of temperature, chloride content, pH, potential, load and geometry. Field and laboratory testing will be used to evaluate the risk of fast-growing cracks developing in crevices and the safety margin needed for long-term service. Partners Organization Country Responsible SWEREA KIMAB AB SVERIGE Dr. Rachel PETTERSSON (Project Coord.) ACERINOX SA ESPAÑA Dr. Maria Victoria MATRES BÖHLER EDELSTAHL GmbH & Co. KG OESTERREICH Dr. Günter HOCHÖRTLER CENTRUM TECHNIKI OKRETOWEJ S.A. - SHIP DESIGN AND POLAND Dr. Pawel DOMZALICKI INSTITUTO DE SOLDADURA E QUALIDADE PORTUGAL Dr. Gervásio FERREIRA PIMENTA OUTOKUMPU STAINLESS OY FINLAND Dr. Thomas OHLIGSCHLÄGER OUTOKUMPU STAINLESS AB SVERIGE M. Sc. Lic. Anna IVERSEN AB SANDVIK MATERIALS TECHNOLOGY SVERIGE Mr Ulf H. KIVISÄKK TEKNOLOGIAN TUTKIMUSKESKUS VTT*TECHNIC. RESEARC FINLAND M. Sc. Heikki LEINONEN

130 Summaries of RFCS projects 2003-2012 TGS6 : Physical metallurgy and design of new generic steel grades

RFSR-CT-2006-00023 MARTIMPROP

Full Title Martensitic steels with improved properties Info Type of Project Research Duration (months) 42 Total Budget 1265112 € Start Date 1/07/2006 EU Contribution 759067 € End Date (actual) 31/12/2009 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA25006:EN Summary The maximal strength level for a given steel composition can be realised with the martensitic microstructure. However, as- quenched martensite shows some major drawbacks such as low formability and low toughness level. Tempering at a relatively low temperature and/or keeping a certain amount of residual austenite in the microstructure could improve these properties. Furthermore, an additional low temperature galvanising treatment will provide an additional corrosion resistance to the hot rolled high strength strips. This development will allow the production of coated ultrahigh strength hot rolled steel (TS higher than 1000 MPa) with superior formability and toughness level. Partners Organization Country Responsible CENTRE DE RECHERCHES METALLURGIQUES ASBL BELGIQUE Dr. Jean-Louis COLLET (Project Coord.) SWEREA KIMAB AB SVERIGE M.Sc. Carl-Ake DÄCKER ONDERZOEKSCENTRUM VOOR AANWENDING VAN STAAL BELGIQUE Dr. Sophie LACROIX VOESTALPINE STAHL GMBH OESTERREICH Dr. Helmut SPINDLER

RFSR-CT-2006-00024 ACTRESS

Full Title Austenite strengthening and accumulated stress for optimum microstructures in modern bainitic microalloyed steels Info Type of Project Research Duration (months) 36 Total Budget 935659 € Start Date 1/07/2006 EU Contribution 561396 € End Date (actual) 30/06/2009 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA24981:EN Summary Project Actress will investigate the role of austenite strengthening on bainite transformation and therefore on microstructure and product properties. Showing characteristics that differ from ferrite-pearlite and martensitic transformations, many features of the bainitic transformation are not yet understood and this project addresses this issue. The research will be focused on modern bainitic microalloyed steels based on those for pipeline applications having a clear need for optimization. An extensive test programme will involve hot rolling simulation, laboratory and industrial rolling. The experimental approach will complement metallographic observations, measurements of mechanical properties and accumulated stress; an innovative method of determining austenite strengthening due to incomplete recrystallisation during rolling. Partners Organization Country Responsible ARCELORMITTAL MAIZIERES RESEARCH S.A. FRANCE Dr. Sebastian COBO (Project Coord.) AKTIEN-GESELLSCHAFT DER DILLINGER HÜTTENWERKE AG DEUTSCHLAND Dr.-Ing. Georg KALLA AGENCIA ESTATAL CONSEJO SUPERIOR DE INVESTIGACIO ESPAÑA Dr. Sebastian MEDINA OULUN YLIOPISTO*UNIVERSITY OF OULU FINLAND Prof Pentti KARJALAINEN

RFSR-CT-2006-00025 CHARGE&LOAD

Full Title Hydrogen embrittlement and delayed fracture of advanced multiphase high-strength steels Info Type of Project Research Duration (months) 42 Total Budget 1677657 € Start Date 1/07/2006 EU Contribution 1006595 € End Date (actual) 31/12/2009 State Research completed, report published on EU Bookshop at (link not yet available) Summary Hydrogen embrittlement (HE) of multiphase high-strength steels is investigated. The aim is to gain fundamental understanding of the relation between the strength, microstructure, hydrogen solubility and diffusion and the mechanisms of HE. Furthermore, the influence of the application environment is studied by carrying out mechanical testing at different loading conditions (strain rate, temperature, deformation path, etc.). In order to study the strain localisation and crack formation mechanisms related to HE, in- situ EBSD analysis will be performed in FESEM during plastic deformation. Based on the results, guidelines to avoid HE will be composed for steel manufacturers and end-users. Partners Organization Country Responsible ONDERZOEKSCENTRUM VOOR AANWENDING VAN STAAL BELGIQUE Dr. Lode DUPREZ (Project Coord.) OUTOKUMPU STAINLESS AB SVERIGE Mr Mats LILJAS RHEINISCH-WESTFÄLISCHE TECHNISCHE HOCHSCHULE AA DEUTSCHLAND Prof Dr -Ing Wolfgang BLECK THYSSENKRUPP STEEL EUROPE AG DEUTSCHLAND Dr.-Ing. Gerd SUSSEK AALTO-KORKEAKOULUSAATIO (AALTO UNIVERSITY FOUN FINLAND Prof. Hannu HÄNNINEN VOESTALPINE STAHL GMBH OESTERREICH Dipl.-Ing. Klemens MRACZEK

RFSR-CT-2007-00020 ELEXIR

Full Title Electrical steel with improved "core loss" due increasing of resistivity and low magnetostriction by Al and Si deposition on surface and subsequent solid state diffusion Info Type of Project Research Duration (months) 36 Total Budget 1905613 € Start Date 1/07/2007 EU Contribution 1143368 € End Date (actual) 30/06/2010 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA25073:EN Summary FeSi steels are used as magnetic core in Electrical machines (motors, generators and transformers). An increasing of their electric resistivity would be advantageous for power loss as heat dissipation during the magnetization process. A research project is proposed, where such increasing of resistivity is realized by the deposition on the surface of the steel, already at final thickness, of increasing resistivity element such as Si and Al, and subsequent diffusion annealing to homogenize the distribution of such elements. The increasing of Al and Si concentration will also decrease the magnetostriction related to the noise produced by transformers. After a first laboratory phase, where the amount of the diffused elements as well as the microstructure and texture of the substrate are optimized an industrial feasibility study is proposed in order to understand the actual possibility of industrialization. Partners Organization Country Responsible 131 CENTRO SVILUPPO MATERIALI SPA ITALIA Dr. Stefano CICALE (Project Coord.) Summaries of RFCS projects 2003-2012 TGS6 : Physical metallurgy and design of new generic steel grades

ONDERZOEKSCENTRUM VOOR AANWENDING VAN STAAL BELGIQUE Mr Christophe VAN DE SLYCKE THYSSENKRUPP STEEL EUROPE AG DEUTSCHLAND Dipl.-Phys. Karl TELGER TECHNISCHE UNIVERSITÄT BERGAKADEMIE FREIBERG DEUTSCHLAND Prof Dr -Ing Rudolf KAWALLA UNIVERSITEIT GENT BELGIQUE Prof. Dr.-Ing. Yvan HOUBAERT

RFSR-CT-2007-00021 DELOC

Full Title Development of methods for the characterization, fracture assessment and life prediction of new high strength steel under variable temperature operating conditions Info Type of Project Research Duration (months) 36 Total Budget 1320289 € Start Date 1/07/2007 EU Contribution 792174 € End Date (actual) 30/06/2010 State Research completed, report published on EU Bookshop at (link not yet available) Summary This project aims at understanding the TMF behaviour in advanced steels and weldments by developing fracture mechanics based model. Proposal will cover a survey of isothermal and thermo-mechanical fatigue (TMF). For new high chrome steels and their weldments the effects of TMF and residual stresses on defects need to be established, modelled and validated since only limited data and the corresponding modelling of the behaviour for TMF tests exist. The programme covers a plan for deriving high temperature properties as well as LCF, TMF tests on cracked and uncracked components. The results and the models will be validated and included in a new life assessment methodology. Partners Organization Country Responsible CENTRO SVILUPPO MATERIALI SPA ITALIA Dr. Augusto DI GIANFRANCESCO (Project Coord.) ANSALDO ENERGIA S.p.A. ITALIA Ing. Vincenza D'AURIA IMPERIAL COLLEGE OF SCIENCE, TECHNOLOGY AND MEDI UNITED KINGDOM Prof. Kamran NIKBIN INSTITUTO DE SOLDADURA E QUALIDADE PORTUGAL Dr. Manuel GOMES SOCIETA DELLE FUCINE SRL ITALIA Dr.-Eng. Stefano NERI

RFSR-CT-2007-00022 Bainite Design

Full Title Design of bainite in steels from homogeneous and inhomogeneous microstructures using physical approaches Info Type of Project Research Duration (months) 36 Total Budget 1337469 € Start Date 1/07/2007 EU Contribution 802482 € End Date (actual) 30/06/2010 State Research technically completed; publication in hand Summary There are no satisfying empirical models and only physically based models for special steels available. The aim of the project is to find in literature those formulations of physically based approaches that are most promising. By extensive use of computational thermodynamics and kinetics these approaches will be placed on a broader basis and will be fitted to new experimental data. So the development of bainitic microstructures in complete groups of modern bainitic- and cold rolled TRIP-, CP-, and DP-steels can be calculated. The use of the new approach will allow designing bainitic structures for improved material properties and will give information about basic physical processes governing the formation of bainite. Partners Organization Country Responsible THYSSENKRUPP STEEL EUROPE AG DEUTSCHLAND Dipl -Ing Georg PAUL (Project Coord.) CENTRO DE ESTUDIOS E INVESTIGACIONES TECNICAS ESPAÑA Prof. Dr. Javier GIL SEVILLANO RHEINISCH-WESTFÄLISCHE TECHNISCHE HOCHSCHULE AA DEUTSCHLAND Prof Dr -Ing Wolfgang BLECK PANEPISTIMIO THESSALIAS*UNIVERSITY OF THESSALY HELLAS Prof. Gregory N. HAIDEMENOPOULOS VOESTALPINE STAHL GMBH OESTERREICH Dr. Thomas HEBESBERGER

RFSR-CT-2007-00023 BAINHARD

Full Title Bainitic hardenability - Effective use of expensive and strategically sensitive alloying elements in high strength steels Info Type of Project Research Duration (months) 42 Total Budget 1906904 € Start Date 1/07/2007 EU Contribution 1144142 € End Date (actual) 31/12/2010 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA25072:EN Summary Modern bainitic steels derive their favourable properties, from a mixture of ultra-fine bainitic ferrite with evenly distributed second phases. In order to obtain the desired bainitic microstructure, alloying elements must be used to separate the bainitic C- curve to make it easier to obtain the desired microstructure on cooling. The selection of alloying elements is difficult, as bainitic hardenability has not been studied as extensively as martensitic hardenability. This project will develop a new “bainitic hardenability” model for optimum selection and flexible replacement of expensive or strategically sensitive alloying elements in high and ultra-high strength steels. Partners Organization Country Responsible SWEREA KIMAB AB SVERIGE Mr Carl-Ake DÄCKER (Project Coord.) ARCELORMITTAL MAIZIERES RESEARCH S.A. FRANCE Mrs Gwenola HERMAN CENTRE DE RECHERCHES METALLURGIQUES ASBL BELGIQUE Dr. Liesbeth BARBÉ INSTYTUT METALURGII ZELAZA IM. STANISLAWA STASZICA POLAND Prof. Roman KUZIAK GERDAU INVESTIGACION Y DESARROLLO EUROPA S.A. ESPAÑA Mr Roberto ELVIRA EGUIZABAL SALZGITTER MANNESMANN FORSCHUNG GmbH DEUTSCHLAND Mr Norbert KWIATON TATA STEEL UK LIMITED UNITED KINGDOM Dr. Peter F. MORRIS

132 Summaries of RFCS projects 2003-2012 TGS6 : Physical metallurgy and design of new generic steel grades

RFSR-CT-2007-00024 ESTEP OPTIMET

Full Title Optimisation of themetallurgical structures and mechanical properties by improving the heat-treatment processes in flat and long production lines with new setup and control methods Info Type of Project Research Duration (months) 42 Total Budget 1815098 € Start Date 1/07/2007 EU Contribution 1089058 € End Date (actual) 31/12/2010 State Research in progress Summary The objective of this project is to establish best microstructure and mechanical properties of rolled flat and long products to anticipate future market demands. This will be achieved by optimising the heating and cooling processes in the finishing area, based on offline and online measurement systems, integrated models for temperature and microstructure evolution combined to predict the material properties , and model-predictive control technologies first applied in this area. Major cost savings for European steel industry will result from deduction of sampling, lab testing, elimination of reprocessing, and downgrading due to poor mechanical properties. Partners Organization Country Responsible VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Dipl.-Ing. Andreas WOLFF (Project Coord.) ARCELORMITTAL ESPAÑA SA ESPAÑA Dr. José Luis RENDUELES VIGIL SWEREA MEFOS AB SVERIGE Dr. John NISKA GERDAU INVESTIGACION Y DESARROLLO EUROPA S.A. ESPAÑA Mr José Manuel LLANOS TECHNISCHE UNIVERSITÄT BERGAKADEMIE FREIBERG DEUTSCHLAND Prof Dr -Ing Rudolf KAWALLA

RFSR-CT-2008-00021 DUCTAFORM

Full Title New advanced ultra high strength bainitic steels: ductility and formability Info Type of Project Research Duration (months) 36 Total Budget 1480262 € Start Date 1/07/2008 EU Contribution 888157 € End Date (actual) 30/06/2011 State Research technically completed; publication in hand Summary The main objective of this proposal is to develop advanced ultra high strength (UHS) hot rolled sheet steels with an optimum ductility and a suitable bending behaviour, and annealed cold rolled sheet steels with a good combination of work hardening and stretch flangeability. The tough bainitic ferrite matrix and the heterogeneities in phases’ hardness for this microstructure will allow reaching the most favourable combination of drawability/stretch formability/bendability in these steels. For this purpose, an innovative concept based on theory alone will be followed to design the alloy composition and suitable control processing of advanced bainitic steel sheets. Likewise, forming processes such as continuous shaping and hardening, and press-hardening will be optimised to achieve a fully carbide free bainitic structure in final products such as structural safety components in the car body i.e. A-beam, roof-beams, car bumpers and side impact beams. Partners Organization Country Responsible AGENCIA ESTATAL CONSEJO SUPERIOR DE INVESTIGACIO ESPAÑA Dr. Francisca GARCIA CABALLERO (Project Coord.) ARCELORMITTAL MAIZIERES RESEARCH S.A. FRANCE Dr. Sébastien ALLAIN GESTAMP HARDTECH AB SVERIGE Mrs Katarina LINDSTRÖM LINDE + WIEMANN GMBH DEUTSCHLAND Dr.-Ing. Eike Gerhard GÜCKER LULEÅ UNIVERSITY OF TECHNOLOGY SVERIGE Prof. Lars-Erik LINDGREN RAUTARUUKKI OYJ FINLAND Dr. Jukka KÖMI

RFSR-CT-2008-00022 NANOBAIN

Full Title Novel nanostructured bainitic steel grades to answer the need for high performance steel components Info Type of Project Research Duration (months) 36 Total Budget 1655995 € Start Date 1/07/2008 EU Contribution 993597 € End Date (actual) 30/06/2011 State Research technically completed; publication in hand Summary The aim of the proposed project is to investigate the properties (in particular, wear and fatigue resistance) of a virtually new class of steel grades based on a new class of microstructures: nanostructured bainite. These microstructures are the product of recent developments at the University of Cambridge and CENIM, and are obtained by applying modified bainitizing heat-treatments on steels of carefully designed compositions. Where tested, these 'nanobainitic' steels have demonstrated outstanding mechanical properties, although complex mechanical properties (notably wear and fatigue) remain to explore. These steels will allow for a true leap forward in the area of ecological and economical high performance steel grades. Partners Organization Country Responsible ASCOMETAL S.A.S. FRANCE Dr.-Ing. Thomas SOURMAIL (Project Coord.) ALD VACUUM TECHNOLOGIES GmbH DEUTSCHLAND Dr.-Ing. Volker HEUER ROBERT BOSCH GmbH DEUTSCHLAND Dr.-Ing. Jochen SCHWARZER AGENCIA ESTATAL CONSEJO SUPERIOR DE INVESTIGACIO ESPAÑA Dr. Francisca GARCIA CABALLERO LULEÅ UNIVERSITY OF TECHNOLOGY SVERIGE Prof. Braham PRAKASH METSO MINERALS OY FINLAND Ph.D. Pekka SIITONEN GERDAU INVESTIGACION Y DESARROLLO EUROPA S.A. ESPAÑA Mr Jacinto ALBARRAN SANZ

133 Summaries of RFCS projects 2003-2012 TGS6 : Physical metallurgy and design of new generic steel grades

RFSR-CT-2008-00023 ROLLINGHASS

Full Title Novel rolling methods for advanced high strength hot rolled steels Info Type of Project Research Duration (months) 36 Total Budget 1893470 € Start Date 1/10/2008 EU Contribution 1136083 € End Date (actual) 30/09/2011 State Research technically completed; publication in hand Summary Wide steel research efforts are being directed to develop new-generation, high-performance steels (AHSS), particularly those having ultra-high strength with good ductility, finding many applications in automotive industry, building and construction sector, etc. The target in preceding researches has been the innovative processing of steels, utilizing thermodynamic calculations and physical metallurgy principles for novel chemical composition design, modeling, and sophisticated hot working and dedicated heat treatments throughout the strictly controlled manufacturing stage. Furthermore, uniform properties and good flatness of plates and sheets are also targeted by strict control of processing at laboratory and industrial scale. In the proposed research the focus will be directed on the evaluation and optimization of the challenging rolling phenomena and methods to enable fabrication of thin advanced hot rolled high strength steels (AHSS) in the production scale with good strip flatness and excellent profile minimizing cobble risk. Partners Organization Country Responsible FUNDACION TECNALIA RESEARCH & INNOVATION ESPAÑA Mr José Ignacio BARBERO (Project Coord.) ARCELORMITTAL ESPAÑA SA ESPAÑA Mr Luis Antonio RODRIGUEZ LOREDO CENTRO SVILUPPO MATERIALI SPA ITALIA Mr Luigi LANGELLOTTO SWEREA MEFOS AB SVERIGE MSc Mats KARLBERG OULUN YLIOPISTO*UNIVERSITY OF OULU FINLAND Prof. Dr. Pekka MÄNTYLÄ VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Dipl.-Ing. Volker DIEGELMANN

RFSR-CT-2008-00024 CRESTA

Full Title New creep resistant stable steel for USC power plant Info Type of Project Research Duration (months) 48 Total Budget 1976202 € Start Date 1/07/2008 EU Contribution 1185722 € End Date (actual) 30/06/2012 State Research in progress Summary The new Ultra SuperCritical coal-fired power plants will have several steel components (waterwalls, superheaters, steam-line and turbine) operating at temperatures range 600-650°C. In the next generation with higher steam parameters (700-720°C/350bar) waterwalls will reach up to 600°C metal temperatures, leading to higher corrosion, oxidation and creep loads. Considering recent creep stability breakdowns of current 12% Cr steels, the remaining options are the use of already developed 9%Cr steels with Post Weld Heat Treatment, complicated and more expensive, or the nickel base superalloys with 10 times higher cost, affecting seriously the overall plant economy. The proposal aims at developing a new low cost steel grade able to work at the above mentioned conditions. Partners Organization Country Responsible CENTRO SVILUPPO MATERIALI SPA ITALIA Dr. Augusto DI GIANFRANCESCO (Project Coord.) L'AIR LIQUIDE SA FRANCE Dr. Corinne CHOVET ALSTOM POWER SYSTEMS GmbH DEUTSCHLAND Dr. Qiurong CHEN DALMINE SPA ITALIA Ing. Stefano CAMINADA DONG ENERGY GENERATION AS*DANKRAFT AS ELSAM IN DANMARK Prof. John HALD INDUSTEEL CREUSOT SAS FRANCE Dr. Sylvain PILLOT TECHNISCHE UNIVERSITAET GRAZ OESTERREICH Dr. Peter MAYR

RFSR-CT-2008-00025 ASYLECTRO

Full Title Electrical steel with improved magnetic characteristics by asymmetric hot and cold rolling Info Type of Project Research Duration (months) 36 Total Budget 1186510 € Start Date 1/07/2008 EU Contribution 711906 € End Date (actual) 30/06/2011 State Research technically completed; publication in hand Summary Non Oriented Electrical Steels (NGO) strips are used to build the magnetic cores of rotating electric machines. Market requirements, driving product development, mainly concern ratio between product-cost/magnetic-properties, as well as geometric characteristics of the sheets, which influences manufacturing costs and core tolerances . It is intended to develop new NGO grades with improved characteristics and/or drastic reduction of production costs. Such a target will be reached by designing and optimising innovative processing routes based on Asymmetric Hot and/or Cold Rolling to obtain magnetically favourable texture and microstructure on the finished products. A program of experimental simulation of the thermo mechanical cycles for the new products starting from laboratory ingots and industrial rough bars will be strongly linked to a parallel program of theoretical modeling to study texture/microstructure evolution as well as modeling devoted to study the technological aspects of asymmetric rolling of Fe-Si. A critical assessment of industrial feasibility of the routes to produce the new products will be done. Partners Organization Country Responsible CENTRO SVILUPPO MATERIALI SPA ITALIA Dr. Stefano CICALE (Project Coord.) DANIELI & C. OFFICINE MECCANICHE SPA ITALIA Dr. Eng. Stefano MORSUT TECHNISCHE UNIVERSITEIT DELFT NEDERLAND Prof. Dr. Ir. Leo KESTENS VOESTALPINE STAHL GMBH OESTERREICH Dipl.-Ing. Johann SPERL

134 Summaries of RFCS projects 2003-2012 TGS6 : Physical metallurgy and design of new generic steel grades

RFSR-CT-2008-00026 StrengthCONTROL

Full Title Optimal strength control by individual strip related tuning of cooling processes in the hot rolling area based on models and in-line strength measurements Info Type of Project Research Duration (months) 54 Total Budget 1658365 € Start Date 1/07/2008 EU Contribution 995019 € End Date (actual) 31/12/2012 State Research in progress Summary The aim of this project is to produce significant smaller material parameter deviations over the whole strip length in hot strip mills. For this purpose a new strength optimisation system is developed, which adapts the setup of the run-out table cooling strip-by- strip and meter-by-meter. Basis of the adaptation are the online material parameter measurement and an iterative learning control concept. Higher yield, less costs for tensile testing, and a strength guaranteed along the total strip length will be achieved. To reduce scale and processing time a fast coil cooling strategy will be investigated. Furthermore, a new cooling system will be developed to perform an additionally controlled width adaptable cooling at the coiler. Partners Organization Country Responsible VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Dr.-Ing. Jan POLZER (Project Coord.) CENTRE DE RECHERCHES METALLURGIQUES ASBL BELGIQUE Mr Benjamin POHU EMG AUTOMATION GMBH DEUTSCHLAND Dr. rer nat. Klaus HERMANN HOESCH HOHENLIMBURG GmbH DEUTSCHLAND Ing. Peter HÖFEL SWEREA MEFOS AB SVERIGE MSc Mats KARLBERG

RFSR-CT-2008-00027 MICRODAMAGE

Full Title Micro-scale damage tolerance of AHSS steels as function of microstructure and stress/strain state Info Type of Project Research Duration (months) 42 Total Budget 1341862 € Start Date 1/07/2008 EU Contribution 805117 € End Date (actual) 31/12/2011 State Research technically completed; publication in hand Summary Complex sheet forming introduces a significant amount of prestrain to AHS-steels and may generate a number of voids or even micro-cracks in micro-damage sensitive microstructures. Forming itself is considered successful when no visible cracks develop on the surface. It is important to recognise the response of different AHSS microstructures on forming prestrain and how such “damaged” microstructures sustain the external stresses during service. This project will develop a new criterion for micro-scale damage tolerance based on the effect of prestrain on development of voids, their growth and final fracture, and used this criterion as a new method for evaluating formability. Partners Organization Country Responsible SWEREA KIMAB AB SVERIGE MSc Lena RYDE (Project Coord.) FUNDACION ITMA ESPAÑA Mr Jose Manuel ARTIMEZ SSAB TUNNPLÅT AB SVERIGE Mr Anders HAGLUND TECHNISCHE UNIVERSITAET MUENCHEN DEUTSCHLAND Prof. Dr. Ewald A. WERNER VOESTALPINE STAHL GMBH OESTERREICH Dr. Andreas PICHLER

RFSR-CT-2009-00011 MICROTOOLS

Full Title Development of microstructure-based tools for alloy and rolling process design for hot rolled steels Info Type of Project Research Duration (months) 42 Total Budget 1174647 € Start Date 1/07/2009 EU Contribution 704788 € End Date (actual) 31/12/2012 State Research in progress Summary This project will develop tools to construct processing regime maps combining temperature-timedeformation history with enhanced knowledge of the operational metallurgical mechanisms during hot rolling. These tools will help design improved and new rolling schedules and steel chemistries, to exploit the increased metallurgical understanding of the underlying mechanisms without compromising mill productivity. The compositional dependence of the austenite microstructure evolution (recrystallisation and precipitation kinetics) for major alloying elements (Mn, Si, Al, Nb) will be studied using thermomechanical testing and high resolution characterisation techniques, and integrated into hot rolling models. Application to strip and plate steel production will be demonstrated. Partners Organization Country Responsible TATA STEEL UK LIMITED UNITED KINGDOM Dr. Sally PARKER (Project Coord.) ARCELORMITTAL MAIZIERES RESEARCH S.A. FRANCE Dr. Sebastian COBO CENTRO DE ESTUDIOS E INVESTIGACIONES TECNICAS ESPAÑA Dra Beatriz LOPEZ SORIA CENTRE DE RECHERCHES METALLURGIQUES ASBL BELGIQUE Mr Benjamin POHU

RFSR-CT-2009-00012 LUNA

Full Title Guidelines for long ultrafine grained steel production and application to the automotive sector Info Type of Project Research Duration (months) 42 Total Budget 1954899 € Start Date 1/07/2009 EU Contribution 1172939 € End Date (actual) 31/12/2012 State Research in progress Summary Refinement of ferrite grain size is one of the most important goals in steel development, since simultaneously steel strength and toughness are improved. A ferrite grain size in the range 1÷3 μm and a steel microstructure characterized by a mixture of ferrite-pearlite and/or martensite, bainite, retained austenite, can give a very good combination of mechanical (strength, ductility, toughness, fatigue) and technological properties (machinability, cold/warm metal forming, etc.) for automotive components application. The project will provide to EU steelmaking and automotive industry guidelines for the production and best utilization of ultrafine grained carbon steel long products using existing productive plants, through the exploitation of advanced thermomechanical processes. 135 Partners Organization Country Responsible Summaries of RFCS projects 2003-2012 TGS6 : Physical metallurgy and design of new generic steel grades

CENTRO SVILUPPO MATERIALI SPA ITALIA Dr. Ilaria SALVATORI (Project Coord.) CENTRO DE ESTUDIOS E INVESTIGACIONES TECNICAS ESPAÑA Dr.Prof. José Manuel MARTINEZ ESNAOLA CENTRO RICERCHE FIAT SCPA ITALIA Ing. Flavia GILI O.R.I. MARTIN - ACCIAIERIA E FERRIERA DI BRESCIA SpA ITALIA Ing. Natale GAUDENZI GERDAU INVESTIGACION Y DESARROLLO EUROPA S.A. ESPAÑA Mr Jacinto ALBARRAN SANZ TECHNISCHE UNIVERSITÄT BERGAKADEMIE FREIBERG DEUTSCHLAND Prof Dr -Ing Rudolf KAWALLA

RFSR-CT-2010-00018 PrecHiMn

Full Title Precipitation in high manganese steels Info Type of Project Research Duration (months) 54 Total Budget 3199558 € Start Date 1/07/2010 EU Contribution 1919735 € End Date (actual) 31/12/2014 State Research in progress Summary The aim of this project is to develop a detailed physical understanding of the thermodynamic and kinetic behaviour of precipitation in high manganese austenitic steels and to provide essential data for the modelling of technologically important (iron-carbide and transition-metal-carbide) precipitation processes in this new generation of high strength alloys. No equivalent data is to be found anywhere in the existing literature. New precipitation models will be validated and published in a form which can easily be integrated with existing codes. Partners Organization Country Responsible THYSSENKRUPP STEEL EUROPE AG DEUTSCHLAND Dipl -Ing Georg PAUL (Project Coord.) ARCELORMITTAL MAIZIERES RESEARCH S.A. FRANCE Mr Colin SCOTT CENTRO DE ESTUDIOS E INVESTIGACIONES TECNICAS ESPAÑA Dra Beatriz LOPEZ SORIA KUNGLIGA TEKNISKA HÖGSKOLAN - THE ROYAL INSTITUTE SVERIGE Prof Malin SELLEBY RHEINISCH-WESTFÄLISCHE TECHNISCHE HOCHSCHULE AA DEUTSCHLAND Prof Jochen SCHNEIDER THE UNIVERSITY OF GLASGOW UNITED KINGDOM Dr. Ian MACLAREN OULUN YLIOPISTO*UNIVERSITY OF OULU FINLAND Prof Pentti KARJALAINEN

RFSR-CT-2010-00019 AUSPLUS

Full Title Austenitic steels for complex and variable stress temperature, pressure and environmental conditions of next generation ultra supercritical power plants Info Type of Project Research Duration (months) 48 Total Budget 2449439 € Start Date 1/07/2010 EU Contribution 1469663 € End Date (actual) 30/06/2014 State Research in progress Summary The project aims to supply steelmakers and end-users with practical guidelines, sound metallurgical evidences and production routes to develop new hot corrosion/oxidation creep/creep-fatigue-resistant austenitic steels for the extreme service conditions of next generation advanced Ultra Supercritical (A-USC) pulverized coal-fired power plants, characterized by biomass co-firing up to 20% by mass, internal fluid temperatures ≥700°C, fume temperature ≥750°C and unsteady thermo-mechanical operation conditions. By combined thermodynamic and kinetic models, production of lab heats and non-standard small and medium-scale test procedures, the fundamental micro-mechanisms affecting austenitic steel performance under different and variable environmental conditions (including creep and creepfatigue) will be investigated and quantified, to be converted into alloy design strategies at the industrial level. Selected full-scale validation tests will be conducted for components supplied by the Partners and through in-field experimental campaigns. Partners Organization Country Responsible CENTRO SVILUPPO MATERIALI SPA ITALIA Dr. Alessio SACCOCCI (Project Coord.) COGNE ACCIAI SPECIALI SpA ITALIA Dr. Chiara ANDRIANOPOLI CHALMERS TEKNISKA HÖGSKOLA AB SVERIGE Dr. Milan FRIESEL DONG ENERGY POWER A/S DANMARK Prof. John HALD DANMARKS TEKNISKE UNIVERSITET DANMARK Dr. Kristian Vinter DAHL NPL MANAGEMENT LTD UNITED KINGDOM Mr Tony FRY TUBACEX TUBOS INOXIDABLES SA ESPAÑA Mrs Alejandra LOPEZ UNIVERSITA DEGLI STUDI DI CASSINO ITALIA Prof. Nicola BONORA TEKNOLOGIAN TUTKIMUSKESKUS VTT*TECHNIC. RESEARC FINLAND M.Sc. Pertti AUERKARI

RFSR-CT-2010-00020 HYDRAMICROS

Full Title Hydrogen sensitivity of different advanced high strength microstructures Info Type of Project Research Duration (months) 42 Total Budget 1869006 € Start Date 1/07/2010 EU Contribution 1121404 € End Date (actual) 31/12/2013 State Research in progress Summary Modern advanced and ultra-high strength steels, (UHSS)-grades, face the problem of hydrogen embrittlement, especially for strength levels above 1000 MPa. In this project, three classes of strength levels (1000, 1200 and 1400 MPa) with different microstructures will be generated through laboratory heat treatments from industrial cast and rolled steels. Subsequently, the samples will be charged with hydrogen and mechanically tested. This allows a ranking of the microstructures in terms of susceptibility to hydrogen. Accurate microstructure investigations of uncharged and charged samples before and after mechanical testing are important parameters for assessing the embrittlement behaviour. Accompanying computer simulations support the experimental work and will help to gain a deeper understanding. Partners Organization Country Responsible MAX-PLANCK-INSTITUT FÜR EISENFORSCHUNG GmbH DEUTSCHLAND Dr. Tilmann HICKEL (Project Coord.) ONDERZOEKSCENTRUM VOOR AANWENDING VAN STAAL BELGIQUE Dr. Lode DUPREZ THYSSENKRUPP STEEL EUROPE AG DEUTSCHLAND Dr. Richard George THIESSEN AALTO-KORKEAKOULUSAATIO (AALTO UNIVERSITY FOUN FINLAND Prof. Hannu HÄNNINEN VOESTALPINE STAHL GMBH OESTERREICH Dipl.-Ing. Klemens MRACZEK

136 Summaries of RFCS projects 2003-2012 TGS6 : Physical metallurgy and design of new generic steel grades

RFSR-CT-2011-00017 NEWQP

Full Title New advanced high strength steels by the quencing and partitioning (Q&P) process Info Type of Project Research Duration (months) 42 Total Budget 2168534 € Start Date 1/07/2011 EU Contribution 1301120 € End Date (actual) 31/12/2014 State Research in progress Summary This project aims at developing new advanced high strength steel grades by means of the “Quenching and Partitioning” (Q&P) process for application in the automotive sector with improved strength, ductility and strain hardening. Q&P opens the way to develop steel microstructures based on the exceptionally advantageous combination of austenitic and martensitic phases at the industrial scale. The industrial applicability of the Q&P process will be improved in terms of compositions, treatments and properties as galvanisability and weldability to develop a controlled and reproducible production process for these materials, and be prepared for future developments. Partners Organization Country Responsible FUNDACIO CTM CENTRE TECNOLOGIC- CTM ESPAÑA Prof. José Maria CABRERA MARRERO (Project Coord.) CENTRO SVILUPPO MATERIALI SPA ITALIA Dr. Andrea DI SCHINO FUNDACION IMDEA MATERIALES ESPAÑA Dr. Ilchat SABIROV ONDERZOEKSCENTRUM VOOR AANWENDING VAN STAAL BELGIQUE Ir Cecilia FÖJER THYSSENKRUPP STEEL EUROPE AG DEUTSCHLAND Dr. Richard George THIESSEN TECHNISCHE UNIVERSITEIT DELFT NEDERLAND Dr. Ir. Jilt SIETSMA UNIVERSITEIT GENT BELGIQUE Dr. Ir. Roumen PETROV

RFSR-CT-2011-00018 AHSS-PROFILE

Full Title Advanced high strength cold rolled sheet steels (AHSS) with optimised profiling properties produced through different lines Info Type of Project Research Duration (months) 42 Total Budget 1460104 € Start Date 1/07/2011 EU Contribution 876062 € End Date (actual) 31/12/2014 State Research in progress Summary The performance, e.g. the properties after roll-forming, of AHSS/UHSS is a challenging task when the tensile strength level increases over 1000MPa for cold rolled sheet steel. This project deals with the relationship between microstructure, strength, formability and other customer demands on these materials and optimising processing conditions for annealing routes. The overall goals are to produce: • AHSS/UHSS with Rm>1000MPa optimised for roll forming, i.e. maximise the residual formability after roll forming for post- processing operations. • Develop guidelines to produce the material, with appropriate alloy design, and well-adjusted processing parameters through several processing routes, i.e. continuous annealing lines (gas or water quenching) and hot dip galvanising. Partners Organization Country Responsible SWEREA KIMAB AB SVERIGE MSc Lena RYDE (Project Coord.) RUUKKI METALS OY FINLAND Mr Petri JUSSILA RHEINISCH-WESTFÄLISCHE TECHNISCHE HOCHSCHULE AA DEUTSCHLAND Prof. Dr.-Ing. Wolfgang BLECK SSAB EMEA AB SVERIGE Mrs Ylva GRANBOM VOESTALPINE STAHL GMBH OESTERREICH Dr. Thomas HEBESBERGER

RFSR-CT-2012-00015 DECAWIN

Full Title New steel-grades for deep carburizing of windmill transmission components Info Type of Project Research Duration (months) 42 Total Budget 1678830 € Start Date 1/07/2012 EU Contribution 1007298 € End Date (actual) 31/12/2015 State Under process of signature Summary The aim of the proposed project is to develop and evaluate new steels tailored for the production of large gears carburized using the rapidly developing low pressure carburizing method. Wind turbine gears (up to 1200 mm in diameter) often require deep carburizing (3-6 mm) to ensure satisfactory performance and resistance to overloading. In standard conditions, (atmospheric carburizing at 960 °C, oil quenching), cycle times of up to 80 h are not uncommon, and distortion during quenching induce significant machining costs. In contrast, vacuum carburizing can be carried out at temperatures up to 1050 °C, therefore reducing the required time to about 20 h. Use of vacuum carburizing and gas quenching for the manufacture of large wind turbine gears would allow not only significant cost reduction (shorter cycle time, reduced distortion) but also potentially increased reliability (absence of internal oxidation during carburizing). Both may contribute to improving the standard and energy return on investment of wind turbine operations. However, such a shift in manufacturing routes requires significant improvements of the steel grades currently in use (hardenability, creep resistance, and austenite grain stability at high temperature), and joint optimisation of the manufacturing route and designed steel grades (distortion minimization). Therefore, the objectives of this project are: • to design and produce two steel grades with the following requirements • for both grades, grain stability and sufficient creep resistance for carburizing conditions of up to 20 h at 1050 °C • sufficient hardenability for oil quenching (1st solution) or gas quenching (2nd solution) • to optimise process routes in order to minimize creep deformation • to fully evaluate the benefits of both solutions This new route will significantly reduce the economic and ecological impact of wind turbine gearboxes manufacture, thus strengthening European manufacturers against increasing competition. Partners Organization Country Responsible ASCOMETAL S.A.S. FRANCE Mrs Marion FROTEY (Project Coord.) ALD VACUUM TECHNOLOGIES GmbH DEUTSCHLAND Dr.-Ing. Volker HEUER ROBERT BOSCH GmbH DEUTSCHLAND Dr. Hermann AUTENRIETH RHEINISCH-WESTFÄLISCHE TECHNISCHE HOCHSCHULE AA DEUTSCHLAND Prof. Dr.-Ing. Wolfgang BLECK GERDAU INVESTIGACION Y DESARROLLO EUROPA S.A. ESPAÑA Mr Roberto ELVIRA EGUIZABAL

137 Summaries of RFCS projects 2003-2012 TGS6 : Physical metallurgy and design of new generic steel grades

RFSR-CT-2012-00016 NAMOS

Full Title Nanoparticle addition into molten steel Info Type of Project Research Duration (months) 42 Total Budget 1929039 € Start Date 1/07/2012 EU Contribution 1157424 € End Date (actual) 31/12/2015 State Research in progress Summary In NAMOS a novel steel grade with enhanced mechanical properties is fabricated by adding ceramic nanoparticles into molten microalloyed steel. The innovation is a feasible addition technique to disperse nanoparticles into the melt with nanoparticles safe manipulation. This is industrially-scaled. NAMOS reveals nanoparticles - steel microstructure interaction mechanisms, their influence on grain size and mechanical behaviour. New grades with better strength and toughness allow products weight reduction (reducing fuel consumption and CO2 emissions in surface transportation components) and manufacturing-time and energy saving (due to heat treatments elimination). Ceramic nanoparticles give steels high temperature strengthening, broadening their applicability to the energy sector. Partners Organization Country Responsible FUNDACION TECNALIA RESEARCH & INNOVATION ESPAÑA Dr. Lorena Maria CALLEJO (Project Coord.) COMDICAST AB SVERIGE Dr. Sven EKEROT AGENCIA ESTATAL CONSEJO SUPERIOR DE INVESTIGACIO ESPAÑA Dr. Carlos GARCIA MATEO KUNGLIGA TEKNISKA HÖGSKOLAN - THE ROYAL INSTITUTE SVERIGE Prof Pär JÖNSSON GERDAU INVESTIGACION Y DESARROLLO EUROPA S.A. ESPAÑA Mrs Zuriñe IDOYAGA AALTO-KORKEAKOULUSAATIO (AALTO UNIVERSITY FOUN FINLAND Dr. Seppo LOUHENKILPI TEKNOLOGIAN TUTKIMUSKESKUS VTT*TECHNIC. RESEARC FINLAND Mr Pertti LINTUNEN

RFSR-CT-2012-00017 MECBAIN

Full Title Understanding basic mechanism to optimize and predict in service properties of nanobainitic steels Info Type of Project Research Duration (months) 36 Total Budget 1813078 € Start Date 1/07/2012 EU Contribution 1087847 € End Date (actual) 30/06/2015 State Under process of signature Summary Carbide free nanobainitic microstructures are made up of nanometer thick bainite laths with retained austenite. Due to their exceptional combinations of strength and ductility, these microstructures continue to attract considerable attention worldwide. During RFCS contract 2008-22 (NANOBAIN), unprecedented combinations of strength and ductility have been achieved, and very encouraging results were obtained in terms of fatigue resistance. Parameters controlling yield strength are well understood, but it is less so for those controlling ductility or complex properties such as fracture toughness and fatigue. Therefore, in order to fully exploit the potential of these microstructures in industrial applications, a better understanding must be achieved, of the relationship between process and microstructure on the one hand, and microstructure and in service properties on the other hand. It is clear however, that microstructural parameters of interest are at a much finer level than initially investigated. The objectives of the present proposal are thus: - to understand and quantify the relationship between microstructure (at the nano or atomic scale), and inservice properties of nanostructured bainitic steels - to quantify the relationship between process parameters and microstructure in view of optimizing a later production route for optimum performances of the material Because of the scale at which investigations must be performed, the consortium will regroup, in addition to enduser and steel makers, research entities equipped for investigations at the atomic scale. University teams will also assist by investigating the link between microstructure and properties using numerical simulation of model microstructures. Partners Organization Country Responsible ASCOMETAL S.A.S. FRANCE Mr Véronique SMANIO (Project Coord.) ROBERT BOSCH GmbH DEUTSCHLAND Dr.-Ing. Matthias KUNTZ CENTRE NATIONAL DE LA RECHERCHE SCIENTIFIQUE FRANCE Mr Frédéric DANOIX AGENCIA ESTATAL CONSEJO SUPERIOR DE INVESTIGACIO ESPAÑA Dr. Francisca GARCIA CABALLERO GERDAU INVESTIGACION Y DESARROLLO EUROPA S.A. ESPAÑA Mr Roberto ELVIRA EGUIZABAL RUHR-UNIVERSITÄT BOCHUM DEUTSCHLAND Dr Rebecca JANISCH TECHNISCHE UNIVERSITÄT KAISERSLAUTERN DEUTSCHLAND Prof. Eberhard KERSCHER

RFSR-CT-2012-00018 OPTIBOS

Full Title New developments and optimisation of high strength boron treated steels through the application of advanced boron monitoring techniques Info Type of Project Research Duration (months) 42 Total Budget 1649492 € Start Date 1/07/2012 EU Contribution 989696 € End Date (actual) 31/12/2015 State Research in progress Summary This research is aimed at improving consistency of properties in B-treated ultrahigh strength plate and investigating the applicability of B additions for producing advanced multiphase cold rolled and annealed strip with high strength, formability, wear resistance and weldability atreduced cost. An important part of the work is the investigation of the sensitivity of different characterisation techniques and the definition of the guidelines for improved monitoring of B in its different forms. This will provide data to support investigation of including B in an existing model of recrystallisation and assessment of the accuracy of existing precipitation and transformation models. Partners Organization Country Responsible CENTRO DE ESTUDIOS E INVESTIGACIONES TECNICAS ESPAÑA Dr. Isabel GUTIERREZ SANZ (Project Coord.) CENTRE DE RECHERCHES METALLURGIQUES ASBL BELGIQUE Mrs Griet LANNOO MAX-PLANCK-INSTITUT FÜR EISENFORSCHUNG GmbH DEUTSCHLAND Dr.-Ing. Dirk PONGE ONDERZOEKSCENTRUM VOOR AANWENDING VAN STAAL BELGIQUE Dr. Wei XU TATA STEEL UK LIMITED UNITED KINGDOM Mr Matt GREEN

138

Technical Group Steel 7

Steel products and applications for automobiles, packaging and home appliances

The scope of TGS7 includes:

• Technologies relating to the forming, cutting, welding and joining of steel and other materials

• Design of assembled structures to facilitate the easy recovery of steel scrap and its reconversion into usable steels and techniques for recycling

• Steel-containing composites and sandwich structures

• Prolonging service life of steel products

• Standardisation of testing and evaluation methods

139 140 Summaries of RFCS projects 2003-2012 TGS7 : Steel products and applications for automobiles, packaging and home appliances

RFS2-CT-2007-00025 INSAPTRANS

Full Title Innovative stainless steel applications in transport vehicles Info Type of Project Accompanying measure (studies) Duration (months) 18 Total Budget 498784 € Start Date 1/07/2007 EU Contribution 299270 € End Date (actual) 31/12/2008 State Research completed, report published on EU Bookshop at (link not yet available) Summary The objective is to disseminate the technical knowledge and application experience from two recently finished ECSC/RFCS research projects. The primary tool is a handbook to be compiled on the application of advanced safe and lightweight stainless steel structures in ground transport vehicles, demonstrating the potential of such structures, and giving design guidelines for applications. Special emphasis is on the effect of stainless material, production methods and design on product LCC and environmental impact. Regional seminars are arranged covering the whole Europe, followed by a workshop for reviewing the seminar feedback and establishing future actions among European players on the field. Partners Organization Country Responsible TEKNOLOGIAN TUTKIMUSKESKUS VTT*TECHNIC. RESEARC FINLAND Mr Mika SIREN (Project Coord.) ACERINOX SA ESPAÑA Mr Rafael SANCHEZ RODRIGUEZ CENTRO SVILUPPO MATERIALI SPA ITALIA Dr. Leopoldo RIZZO EURO INOX LUXEMBOURG Mr Thomas PAULY ONDERZOEKSCENTRUM VOOR AANWENDING VAN STAAL BELGIQUE Ir. Nico DE WISPELAERE OUTOKUMPU STAINLESS OY FINLAND MSc. Tero TAULAVUORI ARCELOR MITTAL STAINLESS NV BELGIQUE Ir. Didier PAUL

RFSR-CT-2003-00023 Hi-FLOW

Full Title Influence of flowforming process parameters on the fatigue behaviour of high strength steel wheel for automotive industry Info Type of Project Research Duration (months) 45 Total Budget 1232062 € Start Date 1/09/2003 EU Contribution 739237 € End Date (actual) 31/05/2007 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA23726:EN Summary This proposal addresses the development of knowledge about the utilisation of the well know flowforming technology to relatively new components as wheel rim made by thin sheet, and utilising high strength (HSS) or Ultra High Strength (UHSS) steels. One of the most important aspect which is aimed by the proposoal is to clarify about the effects of the sheet metal forming process (flowforming) on the fatigue performance. The current situation denotes an increasing demand of extension of the technology to non-traditional application fields (wheel rim), mainly because of the request of weight reduction and structural behaviour optimisation. Dispite of this increasing demand the knowledge about technological limitations and advantages of the process is not so deep, and there is a lack in confidence about the effects of the process conditions on the fatigue performances. This represents a limitation to the extension of technoloy, especially if new HSS materials are addressed. This research project would concretely contribute to the limitation of this obstacle to the diffusion of the technology. Predictive simulation models are proposed in this work to help in order to solve the present obstacles. These simulation are based on FEM models and integrate process and fatigue life simulation. Partners Organization Country Responsible CENTRO SVILUPPO MATERIALI SPA ITALIA Dr. Filippo PLACIDI (Project Coord.) ARCELOR TREASURY FRANCE Mrs Anne CLAD ARCELORMITTAL MAIZIERES RESEARCH S.A. FRANCE Dr. André GALTIER FUNDACION TECNALIA RESEARCH & INNOVATION ESPAÑA Dr. María Angeles GUTIERREZ MAGNETTO WHEELS S.P.A. ITALIA Dr.-Ing. Giacomo GOTTA

RFSR-CT-2003-00026 LOCALHEAT

Full Title Local heat treatment of ultra high strength steel Info Type of Project Research Duration (months) 48 Total Budget 2081548 € Start Date 1/09/2003 EU Contribution 1248928 € End Date (actual) 31/08/2007 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA23918:EN Summary High strength steels offer great possibilities for weight reduction, increased saftey and reduced fuel consumption. However, serious problems are connected to production of the high strength steel parts. Low formability, spring back and tool were are such items. The current project aims at reducing these problems through local heat treatment of the steel sheet. Local heat treatment can significantly increase the formability of the steel. Much better formability is achieved in the areas where it is needed, while the high strength is retained elswhere. The proposal contains the whole chain from material producers via equipment makers and subcontractors to end users. Partners Organization Country Responsible SSAB EMEA AB SVERIGE Dr. Björn CARLSSON (Project Coord.) ALTAIR ENGINEERING SRL ITALIA Ing. Paolo CAVALLO AUTOTECH ENGINEERING AIE ESPAÑA Mr Julian Ruiz RUIZ COROSTOLA CENTRO SVILUPPO MATERIALI SPA ITALIA Dr. Filippo PLACIDI FRAUNHOFER GESELLSCHAFT ZUR FOERDERUNG DER AN DEUTSCHLAND Dr. Andreas WEISHEIT FRIGOSTAMP SPA ITALIA Dr. Marco RUSSIANI ISCO TECHNIC B.V. NEDERLAND Ing. Sander VAN HOOFT FUNDACION ITMA ESPAÑA Mrs Olga CONEJERO SWEREA KIMAB AB SVERIGE Mr Dan JACOBSSON LGAI TECHNOLOGICAL CENTER S.A. ESPAÑA Dr. Elisabet RIBERA LLUIS M.A.C. METALLURGICA ASSEMBLAGGI CARPENTERIE SpA ITALIA Ing. Roberto PASINO WAGON INDUSTRIAL LTD UNITED KINGDOM Mr Richard EDWARDS

141 Summaries of RFCS projects 2003-2012 TGS7 : Steel products and applications for automobiles, packaging and home appliances

RFSR-CT-2003-00029 FLANGE CORROSION

Full Title Investigation of the corrosion mechanism in flanged joints of carbodies Info Type of Project Research Duration (months) 48 Total Budget 1428428 € Start Date 1/09/2003 EU Contribution 857057 € End Date (actual) 31/08/2007 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA23879:EN Summary Perforation corrosion is a major limiting factor for developing products for the automotive industry today. We have no basic description of the environment within the hem flange, no real understanding of the nature of the electrochemical cell that leads to corrosion. The main objectives of this project are to · Better explain corrosion processes in flanges. This will enable a much more effective design of thin film organic coatings and pretreatments. · Develop a short term corrosion test to evaluate the corrosion protection effect of a coating in a flanged joint (“2 weeks instead of 20”). This will greatly facilitate development. Partners Organization Country Responsible VOESTALPINE STAHL GMBH OESTERREICH Dr.-Ing. Karl-Heinz STELLNBERGER (Project Coord.) ARCELORMITTAL MAIZIERES RESEARCH S.A. FRANCE Dr. Kevin OGLE DOC DORTMUNDER OBERFLÄCHENCENTRUM GmbH DEUTSCHLAND Dr. Stella JANSSEN SALZGITTER MANNESMANN FORSCHUNG GmbH DEUTSCHLAND Dr. rer. nat. Frank BEIER TECHNISCHE UNIVERSITAET WIEN OESTERREICH Dr. Günter FAFILEK

RFSR-CT-2003-00032 DURATOOL

Full Title Mass production forming of high strength steel with durable tooling Info Type of Project Research Duration (months) 45 Total Budget 1718206 € Start Date 1/09/2003 EU Contribution 1030922 € End Date (actual) 31/05/2007 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA23991:EN Summary This proposal addresses the development of new and improved technologies for mass production forming, shearing and punching of high strength steel sheet material. As (automotive) mass production is served by easy to process materials, it is clear that the present technical limitations for mass production processes - related to excessive tool wear and galling – must be removed in order to expand the applicability of high strength steel sheet materials. Predictive simulation models are proposed in this work to solve the present obstacles. These simulation are based on FEM models and tribological research and validated by high volume trials. Partners Organization Country Responsible CORUS TECHNOLOGY B.V. NEDERLAND Ms Louisa CARLESS-ELLIOTT (Project Coord.) ARCELOR TREASURY FRANCE Mr Nicolas BRETAULT CENTRO SVILUPPO MATERIALI SPA ITALIA Dr. Filippo PLACIDI SWEREA KIMAB AB SVERIGE Mrs Irma HEIKKILÄ SSAB EMEA AB SVERIGE Dr. Lars TROIVE TNO, NEDERLANDSE ORG. VOOR TOEGEPAST NATUURWE NEDERLAND Dr. Ir. E. VAN DER HEIDE UDDEHOLM TOOLING AB SVERIGE Mr Berne HÖGMAN

RFSR-CT-2003-00037 ALOAS

Full Title Applications of advanced low alloy steels for new high temperature components Info Type of Project Research Duration (months) 54 Total Budget 1978273 € Start Date 1/09/2003 EU Contribution 1186964 € End Date (actual) 28/02/2008 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA23598:EN Summary The new P23 and P24 advanced low alloy steels will be strong candidates for new and replacement high temperature plant components, provided the main development hurdles can be overcome. Welding consumables with proven high temperature properties need to be developed, and new steels and welds must be shown to have improved resistance to in-service creep and fatigue cracking mechanisms. This will require high temperature creep, fatigue, and crack growth testing, modelling of microstructural evolution, and assessment of the integrity of welded components in service. The project will contribute to increasing EU plant efficiency and thus achieving the Kyoto emission targets. Partners Organization Country Responsible CENTRO SVILUPPO MATERIALI SPA ITALIA Dr. Augusto DI GIANFRANCESCO (Project Coord.) DALMINE SPA ITALIA Dr. Giuseppe CUMINO E.ON UK plc UNITED KINGDOM Dr. David J. ALLEN FRAUNHOFER GESELLSCHAFT ZUR FOERDERUNG DER AN DEUTSCHLAND Eng. Valérie DENNER INDUSTEEL France FRANCE Dr. Sylvain PILLOT INSTITUTO DE SOLDADURA E QUALIDADE PORTUGAL Dr. Helena GOUVEIA TEKNOLOGIAN TUTKIMUSKESKUS VTT*TECHNIC. RESEARC FINLAND Dr. Liisa HEIKINHEIMO

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RFSR-CT-2003-00049 SYNFAB

Full Title Improving the competitiveness of the European Steel fabrication industry using synchronised tandem wire welding technology Info Type of Project Research Duration (months) 36 Total Budget 1460000 € Start Date 1/09/2003 EU Contribution 876000 € End Date (actual) 31/08/2006 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA23331:EN Summary The European steel fabrication industry needs to continuously assess developments in welding to remain competitive. Arc welding is a widely used process in this industry. Recently there have been advances in arc welding equipment technology, which has allowed the introduction of a process known as synchronised tandem wire arc welding. Preliminary work on this process shows benefits to weld quality at reduced cost compared to established arc welding processes. It is proposed to investigate this welding process, and any others that can use the technology, with a view to providing guidelines on use and to quantify benefits over other established processes. Partners Organization Country Responsible TATA STEEL UK LIMITED UNITED KINGDOM Dr. Alan M. THOMPSON (Project Coord.) CENTRO SVILUPPO MATERIALI SPA ITALIA Dr.. Maurizio FERSINI GKSS-FORSCHUNGSZENTRUM GEESTHACHT GmbH DEUTSCHLAND Dr. Jorge DOS SANTOS SWEREA KIMAB AB SVERIGE Dr. Sci. Joakim HEDEGÄRD RHEINISCH-WESTFÄLISCHE TECHNISCHE HOCHSCHULE AA DEUTSCHLAND Prof. Dr.-Ing. Ulrich DILTHEY STICHTING NETHERLANDS INSTITUTE FOR METALS RESEAR NEDERLAND Prof. Dr. Ian RICHARDSON CRANFIELD UNIVERSITY UNITED KINGDOM Mr David YAPP

RFSR-CT-2004-00031 PrimeForm

Full Title Formability and self-repair properties of advanced weldable primers Info Type of Project Research Duration (months) 36 Total Budget 1282878 € Start Date 1/07/2004 EU Contribution 769727 € End Date (actual) 30/06/2007 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA23747:EN Summary Advanced weldable primers are investigated concerning their formability and self-repair properties. Microscopic and electrochemical investigations are combined with Finite Element Simulation of the degree of forming. Based on the fundamental understanding of the influence of the forming process on the corrosion properties, new composite coatings are developed that show significantly higher corrosion protection than the current coatings. This will be achieved by the development of new flexible binder systems, the incorporation of corrosion inhibiting pigments that show self-healing properties and the incorporation of metal-alloy conducting particles. The results will further promote weldable primer coated steel sheets in the automotive production. Partners Organization Country Responsible MAX-PLANCK-INSTITUT FÜR EISENFORSCHUNG GmbH DEUTSCHLAND Dr. Guido GRUNDMEIER (Project Coord.) CENTRO SVILUPPO MATERIALI SPA ITALIA Dr.ssa Maria Grazia SERRA DOC DORTMUNDER OBERFLÄCHENCENTRUM GmbH DEUTSCHLAND Mr Bernhard SCHINKINGER INSTITUTO SUPERIOR TECNICO PORTUGAL Dr. Alda Maria PEREIRA SIMOES UNIVERSIDADE DE AVEIRO PORTUGAL Prof. Mário G.S. FERREIRA VOESTALPINE STAHL GMBH OESTERREICH Dr. Edwin TILL

RFSR-CT-2004-00032 STRAINHARD

Full Title Investigation of the strain hardening behaviour of modern light-weight steels considering the forming temperature & forming rate Info Type of Project Research Duration (months) 36 Total Budget 1186604 € Start Date 1/07/2004 EU Contribution 711962 € End Date (actual) 30/06/2007 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA23599:EN Summary The first aim of this project is the determination of the strain hardening behaviour of light-weight steels with different material concepts. By using suitable testing methods, the parameters temperature, stress state and strain rate will be considered. The influence of the phase stability of TRIP- and TWIP-steels on the strain hardening behaviour will also be the focus of interest. The second aim will be the evaluation and the improvement of existing strain hardening models with the obtained results considering the above mentioned parameters. The third aim of this project is the identification of microstructures with an extraordinary strain hardening behaviour. By correlating the strain hardening behaviour with the microstructure characteristics, the already existing light-weight steels can be evaluated. By this, the project will contribute to the design of microstructures in new light-weight steels. Partners Organization Country Responsible RHEINISCH-WESTFÄLISCHE TECHNISCHE HOCHSCHULE AA DEUTSCHLAND Prof Dr -Ing Wolfgang BLECK (Project Coord.) ARCELORMITTAL MAIZIERES RESEARCH S.A. FRANCE Mr Philippe CUGY AGENCIA ESTATAL CONSEJO SUPERIOR DE INVESTIGACIO ESPAÑA Dr. José Antonio JIMENEZ THYSSENKRUPP STEEL EUROPE AG DEUTSCHLAND Mrs Dorothea MATTISSEN

143 Summaries of RFCS projects 2003-2012 TGS7 : Steel products and applications for automobiles, packaging and home appliances

RFSR-CT-2004-00033 SOLVSTIR

Full Title Solving steel welding problems by the use of friction stir Info Type of Project Research Duration (months) 42 Total Budget 1055107 € Start Date 1/07/2004 EU Contribution 633065 € End Date (actual) 31/12/2007 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA24030:EN Summary Conventional fusion welding processes are reaching their applicability limits as far as the weldability of thin gauge, modern high alloy steels (i.e. UHSS, TRIP, CP, MS, DP and IF steels) is concerned. Weldability issues are also a matter of concern in Cr-containing steels employed in the energy and transport sectors due to microstructural control, embitterment risks and environmental concerns. The Friction Stir Welding (FSW) process, a low heat input, solid state joining method, offers a number of advantages likely to overcome weldability problems in difficult-to-weld steel grades. Moreover, FSW has also shown to be able to produce multi-material joints between steel and non-ferrous alloys. Starting from the present state of art in FSW of steels this project intends to focus on two lines of development: process technology and application to relevant steel grades and multi-material joints. The process technology focus will aim at alternative tool materials and geometry, their respective process parameter fields as well as pre- and post-weld heat treatment methods viewing increased tool life and the cost effectiveness of the process. The suitability of the process to different steel grades will be investigated on modern high alloy and Cr-alloyed materials with emphasis on the microstructure development and joint performance. This development work will be supported by modelling (temperature and deformation) and by an economic evaluation and concluded with the manufacturing of demonstration structures from the automotive, shipbuilding and energy sectors. In summary, the main objective of this project is to define the merits of FSW when applied to steels based on the achievable joint performance, applicability to structures and economics. Partners Organization Country Responsible GKSS-FORSCHUNGSZENTRUM GEESTHACHT GmbH DEUTSCHLAND Dr. Jorge DOS SANTOS (Project Coord.) DANISH STIR WELDING TECHNOLOGY DANMARK Dr. Torben LORENTZEN FINCANTIERI - CANTIERI NAVALI ITALIANI S.p.A. ITALIA Dr. Luis Mario VOLPONE ONDERZOEKSCENTRUM VOOR AANWENDING VAN STAAL BELGIQUE Dr. Ali Ihsan KORUK TATA STEEL UK LIMITED UNITED KINGDOM Mr Lynden DREWETT UNIVERSITÄT DUISBURG-ESSEN DEUTSCHLAND Prof. Dr.-Ing. Alfons FISCHER

RFSR-CT-2004-00034 TUTEMP

Full Title Plasticity at high temperature for steel and stainless tube forming applications in automotive industry Info Type of Project Research Duration (months) 39 Total Budget 1639178 € Start Date 1/07/2004 EU Contribution 983506 € End Date (actual) 30/09/2007 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA23878:EN Summary This proposed research project objective is the development of a new tube forming technology at high temperature by means of an inner gas pressure. This new technology will permit to produce tubular metal structures overcoming the existing limitations when using HSS and stainless steel in hydroforming. The overall aim of this European future research is first to verify the feasibility of this new process and to determine the actual capabilities and advantages and then to determinate, if necessary, future developments such as new (ultra high strength) steel grades. This project will also contribute to then introduction of this new technology in Europe and to keep the European research and industry at the state of the art in manufacturing process technologies. Partners Organization Country Responsible FUNDACION TECNALIA RESEARCH & INNOVATION ESPAÑA Dr. María Angeles GUTIERREZ (Project Coord.) ACERINOX SA ESPAÑA Mr Rafael SANCHEZ RODRIGUEZ CENTRO SVILUPPO MATERIALI SPA ITALIA Dr.-Ing. Claudio TESTANI HOLDING DE GESTION DE EMPRESAS DE TUBO S.L. ESPAÑA Eng. Francisco Javier RIPODAS AGUDO RHEINISCH-WESTFÄLISCHE TECHNISCHE HOCHSCHULE AA DEUTSCHLAND Prof Dr -Ing Wolfgang BLECK TNO, NEDERLANDSE ORG. VOOR TOEGEPAST NATUURWE NEDERLAND Dr.ir. P.J. BOLT

RFSR-CT-2004-00035 Full Title DP grades with improved formability Info Type of Project Research Duration (months) 36 Total Budget 1331269 € Start Date 1/07/2004 EU Contribution 798761 € End Date (actual) 30/06/2007 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA23862:EN Summary Thin sheet dual-phase grades - uncoated, electrogalvanized or hot-dip galvanized - are among the most important AHSS grades for the automotive industry. Substantial research and development work was done and grades with minimum tensile strength levels up to 1400 MPa are available. Because fundamental understanding of the impact of different microstructure constituen ts on the formability is still missing, the project will concentrate on this relation based on phenomenological and more fundamental models. As a result of this work DP grades with an optimised microstructure will be suggested and material with an improved strength - formability balance will be produced. Partners Organization Country Responsible VOESTALPINE STAHL GMBH OESTERREICH Dr. Andreas PICHLER (Project Coord.) FUNDACION ITMA ESPAÑA Mr Jose Manuel ARTIMEZ SWEREA KIMAB AB SVERIGE MSc Lena RYDE SSAB TUNNPLÅT AB SVERIGE Mr Anders HAGLUND TECHNISCHE UNIVERSITAET MUENCHEN DEUTSCHLAND Prof. Dr. Ewald A. WERNER

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RFSR-CT-2005-00032 SpeedFat

Full Title Load spectrum lightening of fatigue tests data for time reduction of design validation Info Type of Project Research Duration (months) 36 Total Budget 1525470 € Start Date 1/07/2005 EU Contribution 915282 € End Date (actual) 30/06/2008 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA24206:EN Summary The purpose is to develop filtering procedures in order to shorten fatigue loading spectrum without changing the damage and so accelerate tests and final validation of structures. Oriented to High Strength Steel and automotive industries, final results will be also valid for other applications. Filtering procedures have to consider microstructural aspects in order to show the interest of HSS on the filtering level. 75% of time reduction can be expected depending on loading. Dealing with fatigue design, safety and sustainable development can be associated to this proposal. A European recommendation could be an outlook of this scientific works achievement. Partners Organization Country Responsible ARCELORMITTAL MAIZIERES RESEARCH S.A. FRANCE Dr. Bastien WEBER (Project Coord.) CENTRO SVILUPPO MATERIALI SPA ITALIA Mr Sandro RISCIFULI FUNDACION TECNALIA RESEARCH & INNOVATION ESPAÑA Mr Jaime GRIJALVO IMA MATERIALFORSCHUNG UND ANWENDUNGSTECHNIK DEUTSCHLAND Mrs Anett WUENSCHE REGIENOV FRANCE Dr. Eric VAILLANT GERDAU INVESTIGACION Y DESARROLLO EUROPA S.A. ESPAÑA Mr Jacinto ALBARRAN SANZ

RFSR-CT-2005-00033 HI-PROF

Full Title Improving and enlarging the application field of HSS and UHSS for automotive body components by technologies based on roll forming and stretch bending processes Info Type of Project Research Duration (months) 42 Total Budget 1430342 € Start Date 1/07/2005 EU Contribution 858205 € End Date (actual) 31/12/2008 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA24274:EN Summary High Strength Steels and (HSS) Ultra High Strength Steel (UHSS) offer great possibilities for weight reduction, increased safety and reduced fuel consumption. However, serious problems are connected to production of the high strength steel parts, especially using traditional technologies (stamping, Hydroforming), mainly related to low formability, spring back and tool wear. The current project aims at enlarging the use of HSS and UHSS for the production of lightweight automotive components by promoting the use of alternative processes and process chains, with higher degrees of flexibility and potentially more suitable for the production of component in UHSS: the Roll Forming and Stretch Bending processes. The proposal address the understanding of the roll forming and stretch bending processes capabilities for UHSS, by the in depth study of the basic principles which dominate the forming process chain if connected with UHSS, and the enlarging of the applications by the production of clear and robust know how and guidelines, for the manufacturing complex parts, the realisation of predictive numerical tools for process feasibility, of cost estimation tools, and of specific formability tests. Partners Organization Country Responsible CENTRO SVILUPPO MATERIALI SPA ITALIA Dr. Leopoldo RIZZO (Project Coord.) E.M.A.R.C. SpA - ENGINEERING MACCHINE ATTREZZATURE ITALIA Mr Massimo CERVETTI FUNDACION ITMA ESPAÑA Dr. Manuel Armindo GUERRERO SWEREA KIMAB AB SVERIGE MSc. Lars GUNNARSSON SSAB EMEA AB SVERIGE Dr. Lars TROIVE

RFSR-CT-2005-00034 MICROFAT

Full Title Prediction of microstructure and constraint effects on fatigue behaviour in engineering applications Info Type of Project Research Duration (months) 42 Total Budget 1231309 € Start Date 1/07/2005 EU Contribution 738785 € End Date (actual) 31/12/2008 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA25030:EN Summary The proposal aims to develop an experimental and methodological know-how to establish the relationship between steel microstructure and constraint effects and fatigue behaviour of high strength structural steels for mechanical components in terms of crack initiation/propagation phase. The developed knowhow will be extended to real in-service conditions and identified engineering applications and components, in particular when multiaxial random loads with overloads are Present. A validated criterion to predict the in-service behaviour of selected mechanical components, taking account of steel microstructure, surface roughness as well as stress-strain field, will be developed starting from state-of-the-art theories (e.g. Dang Van, Kitagawa-Takahashi, Murakami) and metallurgical knowledge. Mechanical components production and special testing on full- scale components will be also performed. With these aims a Consortium among CSM, SIDENOR, CEIT, ASCOMETAL and IVECO has been formed. Partners Organization Country Responsible CENTRO SVILUPPO MATERIALI SPA ITALIA Dr Paolo FOLGARAIT (Project Coord.) ASCOMETAL S.A.S. FRANCE Dr.Ing. Pascal DAGUIER CENTRO DE ESTUDIOS E INVESTIGACIONES TECNICAS ESPAÑA Dr.Prof. José Manuel MARTINEZ ESNAOLA FIAT GESTIONE PARTECIPAZIONI SPA ITALIA Mr Roberto BIGNUCOLO GERDAU INVESTIGACION Y DESARROLLO EUROPA S.A. ESPAÑA Mr Jacinto ALBARRAN SANZ

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RFSR-CT-2006-00026 HI-VEL

Full Title High velocity forming of steel sheets and tubes for applications in the automotive industry Info Type of Project Research Duration (months) 42 Total Budget 1420395 € Start Date 1/07/2006 EU Contribution 852331 € End Date (actual) 31/12/2009 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA24994:EN Summary Automotive industry is demanding more efficient materials and manufacturing processes to design lightweight and safer cars with less vehicle emissions, so that the use of HSS (high strength steel) has significantly increased. Regarding innovative manufacturing processes, the high velocity forming techniques (electromagnetic, electrohydraulic) appear to be alternatives to overcome limitations from a weaker formability of HSS. The project objective is to establish the feasibility of high velocity forming methods and to quantify the enhancement achievable with these techniques in the formability of HSS and stainless steel sheets and tubes for automotive applications such as reinforcements, exhaust system components or forming of small radii at any component. Partners Organization Country Responsible FUNDACION TECNALIA RESEARCH & INNOVATION ESPAÑA Ing. Leire VADILLO (Project Coord.) ACERINOX SA ESPAÑA Mr Rafael SANCHEZ RODRIGUEZ ILVA S.P.A. ITALIA Dr. Massimiliano PAGLIARO SWEREA KIMAB AB SVERIGE Prof. Arne MELANDER SSAB TUNNPLÅT AB SVERIGE Dr. Björn CARLSSON OULUN YLIOPISTO*UNIVERSITY OF OULU FINLAND Prof Pentti KARJALAINEN VOESTALPINE STAHL GMBH OESTERREICH Dr. Ludovic SAMEK

RFSR-CT-2006-00027 MnAl-steel

Full Title Ultra high strength and ductile Fe Mn Al C light-weight steels Info Type of Project Research Duration (months) 36 Total Budget 1532597 € Start Date 1/07/2006 EU Contribution 919558 € End Date (actual) 30/06/2009 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA25096:EN Summary New design concepts for the construction of advanced transportation systems, specifically automotive vehicles of high safety standards, with reduced fuel consumption and emission of exhaust gases and of low weight require the use of high-strength and ductile steels combined with enhanced energy absorption and reduced specific weight. Another important aspect is the improvement in deep drawing and stretch forming of sheet steels for the manufacturing of tailored blanks and stiffened components. Highmanganese light-weight steels of about 18 to 26 wt.-% Mn with larger amounts of aluminium (8 to 11 wt.- %) fulfil these requirements. Partners Organization Country Responsible MAX-PLANCK-INSTITUT FÜR EISENFORSCHUNG GmbH DEUTSCHLAND Mr Michael BAUSCH (Project Coord.) ARCELORMITTAL MAIZIERES RESEARCH S.A. FRANCE Dr. Astrid PERLADE THYSSENKRUPP STEEL EUROPE AG DEUTSCHLAND Dr. Harald HOFMANN VOESTALPINE STAHL GMBH OESTERREICH Dr. Enno ARENHOLZ

RFSR-CT-2007-00026 CRYO

Full Title Improvement of automotive tools and components through the applications of deep cryogenic treatments Info Type of Project Research Duration (months) 36 Total Budget 1465020 € Start Date 1/10/2007 EU Contribution 879012 € End Date (actual) 30/09/2010 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA25118:EN Summary The main aim is to develop and apply deep cryogenic treatments (DCT) in order to improve wear resistance and fatigue life of: • automotive components, that may lead to weigth reduction; • metalforming tooling and machining tools, that may lead to increase the tools life. We will pay special attention to the microstructural changes and the fatigue behaviour improvement that takes place as a function of the cryogenic treatment route. The project will provide a better understanding of the parameters influencing the DCT and will analyse how to integrate it within the industrial production line. Partners Organization Country Responsible FUNDACION TECNALIA RESEARCH & INNOVATION ESPAÑA Mr José Ignacio BARBERO (Project Coord.) ASOCIACION DE INVESTIGACION METALURGICA DEL NOR ESPAÑA Dr. Alberto FERNÁNDEZ VICENTE BÖHLER EDELSTAHL GmbH & Co. KG OESTERREICH Dr. Ziya Devrim CALISKANOGLU GERDAU INVESTIGACION Y DESARROLLO EUROPA S.A. ESPAÑA Mr Jacinto ALBARRAN SANZ UNIVERSITA DEGLI STUDI DI TRENTO ITALIA Prof. Massimo PELLIZZARI VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Dr.-Ing. Jochen KURZYNSKI

146 Summaries of RFCS projects 2003-2012 TGS7 : Steel products and applications for automobiles, packaging and home appliances

RFSR-CT-2007-00027 PROMACH

Full Title Innovative approach for steel design procedures tailored to component machining Info Type of Project Research Duration (months) 36 Total Budget 1790888 € Start Date 1/07/2007 EU Contribution 1074532 € End Date (actual) 30/06/2010 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA25152:EN Summary Technical breakthroughs in automotive components demand sustainable production and wider use of high-performance steels. Stringent requirements of machining operations demand re-evaluation of strategies for steel development. Steel Design Procedure to minimize running costs will be defined for components of above 900 MPa, proposing steel solutions tailored to the machining process, considering cost analysis and global process productivity. For pearlitic, bainitic and martensitic steels of same strength, screening of available technologies for machinability improvement (S, Ca, Pb / Bi…), even clean-steels is considered for basic and advanced machining investigations. Strategies for steel development and process optimization relevant to both European steelmakers and end-users are the expected outcome. Partners Organization Country Responsible GERDAU INVESTIGACION Y DESARROLLO EUROPA S.A. ESPAÑA Ms Maria Carmen MONTERO PASCUAL (Project Coord.) ASCOMETAL S.A.S. FRANCE Mr Enrico D'ERAMO CENTRO RICERCHE FIAT SCPA ITALIA Dr. Andrea GALLINO SWEREA KIMAB AB SVERIGE Prof. Hariharan CHANDRASEKARAN MONDRAGON GOI ESKOLA POLITEKNIKOA J.M.A., S.COOP ESPAÑA Prof. Pedro José ARRAZOLA OVAKO BAR OY AB FINLAND DSc. Pekko JUVONEN RHEINISCH-WESTFÄLISCHE TECHNISCHE HOCHSCHULE AA DEUTSCHLAND Prof. Dr. Fritz KLOCKE

RFSR-CT-2008-00028 KINSREP

Full Title Prediction of the kinetics of self-repair of forming-induced defects on thin functional primers for advanced automotive applications Info Type of Project Research Duration (months) 36 Total Budget 1723197 € Start Date 1/07/2008 EU Contribution 1033919 € End Date (actual) 30/06/2011 State Research technically completed; publication in hand Summary The proposal deals with self-repair of defects resulting from forming processes in advanced composite organic coatings for the automotive industry. The approach focusses on the correlation between corrosion tests and practical performance of very thin weldable primers and on the addition of inhibiting pigments, optionally encapsulated in sub-micron containers, for selfrepair at cracks. The working programme includes (1) the development of a combination of advanced analytical, spectroscopic and electrochemical techniques, for kinetics study and monitoring of self-repair of forming-induced defects in coatings applied on zinc-coated steel, and (2) the fundamental understanding of the physico-chemical processes involved in self-repair. Partners Organization Country Responsible INSTITUTO SUPERIOR TECNICO PORTUGAL Dr. Alda Maria PEREIRA SIMOES (Project Coord.) CENTRO SVILUPPO MATERIALI SPA ITALIA Dr.ssa Maria Grazia SERRA SALZGITTER MANNESMANN FORSCHUNG GmbH DEUTSCHLAND Dr. Ibrahim KUTLU THYSSENKRUPP STEEL EUROPE AG DEUTSCHLAND Dr. Ingo KLÜPPEL UNIVERSIDADE DE AVEIRO PORTUGAL Dr. Mikhail ZHELUDKEVICH UNIVERSITÄT PADERBORN DEUTSCHLAND Prof. Dr. Guido GRUNDMEIER VOESTALPINE STAHL GMBH OESTERREICH Dr. Anna-Elisabeth RAAB

RFSR-CT-2008-00029 SPRINCOM

Full Title An efficient and effective methodology and simulation tools for die design and springback compensation for HSS and UHSS Info Type of Project Research Duration (months) 36 Total Budget 1780549 € Start Date 1/07/2008 EU Contribution 1068329 € End Date (actual) 30/06/2011 State Research technically completed; publication in hand Summary HSS and UHSS offer high light-weighting potential for car body structural components. The large amount of springback after forming operations is currently limiting the penetration of such steel grades, because of the large effort to be spent for tool design and tolerance satisfaction, requiring longer try out phases and increased development costs. The current research proposal aims at enlarging the use of UHSS in the automotive sector by developing and making available to material suppliers and automotive designers: - Deep knowledge about springback of UHSS; - Reliable and robust methods and tools for springback prediction and springback compensation by die shape modification, taking into account the effect of the steel property variability. Partners Organization Country Responsible CENTRO SVILUPPO MATERIALI SPA ITALIA Dr. Leopoldo RIZZO (Project Coord.) AMET ITALY S.R.L. ITALIA Dr.-Ing. Paolo CAVALLO CENTRO RICERCHE FIAT SCPA ITALIA Mrs Rosanna BRUN SWEREA KIMAB AB SVERIGE Prof. Arne MELANDER RHEINISCH-WESTFÄLISCHE TECHNISCHE HOCHSCHULE AA DEUTSCHLAND Prof Dr -Ing Wolfgang BLECK SSAB TUNNPLÅT AB SVERIGE Dr. Lars TROIVE SALZGITTER MANNESMANN FORSCHUNG GmbH DEUTSCHLAND Dipl.-Ing. Ulrich EGGERS

147 Summaries of RFCS projects 2003-2012 TGS7 : Steel products and applications for automobiles, packaging and home appliances

RFSR-CT-2009-00013 NEWGENHSS

Full Title Novel concepts for new generation of high strength hot dip galvanizing steel with extra formability Info Type of Project Research Duration (months) 36 Total Budget 1983056 € Start Date 1/10/2009 EU Contribution 1189833 € End Date (actual) 30/09/2012 State Research in progress Summary This research work addresses the European concept for lightweight car bodies. In particular, innovative steel sheet family with high yield strength (>300MPa) and moderate UTS (≥400 MPa) along with extra formability is proposed. Novel alloy chemistries based on Si, B and Al, along with innovative strengthening mechanisms (Cu reinforced IF) will be investigated. New processing options will also be exploited such as intercritical annealing to get advantage of low temperature transformed phases in terms of strength and formability. The produced steels will be tested by the industrial partners and validated by the end users. Partners Organization Country Responsible ILVA S.P.A. ITALIA Dr. Floriano FERRO (Project Coord.) RHEINISCH-WESTFÄLISCHE TECHNISCHE HOCHSCHULE AA DEUTSCHLAND Prof Dr -Ing Wolfgang BLECK SALZGITTER MANNESMANN FORSCHUNG GmbH DEUTSCHLAND Mr Thomas SCHULZ FUNDACION TECNALIA RESEARCH & INNOVATION ESPAÑA Dr. María Angeles GUTIERREZ TECHNISCHE UNIVERSITÄT BERGAKADEMIE FREIBERG DEUTSCHLAND Prof Dr -Ing Rudolf KAWALLA UNIVERSITA DEGLI STUDI DI PISA ITALIA Prof. Sandra VITOLO

RFSR-CT-2009-00015 AUTOCORR

Full Title Corrosion of heterogeneous metal/metal assembling in the automotive industry Info Type of Project Research Duration (months) 36 Total Budget 1936906 € Start Date 1/09/2009 EU Contribution 1162144 € End Date (actual) 31/08/2012 State Research in progress Summary Galvanic coupling between new materials is a major preoccupation of the automotive industry. Unfortunately, the steel industry does not have sufficient information to respond correctly to these questions. The main deliverables of this project will be a catalogue of galvanic corrosion data for a variety of different combinations between galvanized steel and new materials such as Al, Mg. Further, a predictive model will be developed based on electrochemical data for the different materials. The database and model will be supported by in depth mechanistic studies. Joining and surface treatment techniques will be evaluated as possible remedies for galvanic corrosion. Partners Organization Country Responsible ARCELORMITTAL MAIZIERES RESEARCH S.A. FRANCE Dr. Christian ALLELY (Project Coord.) ECOLE NATIONALE SUPERIEURE DE CHIMIE DE PARIS FRANCE Dr. Polina VOLOVITCH KUNGLIGA TEKNISKA HÖGSKOLAN - THE ROYAL INSTITUTE SVERIGE Prof Christofer LEYGRAF SALZGITTER MANNESMANN FORSCHUNG GmbH DEUTSCHLAND Dr. Wibke FRIEDHOFF THYSSENKRUPP STEEL EUROPE AG DEUTSCHLAND Mrs Simone REITER VOESTALPINE STAHL GMBH OESTERREICH Dr. Gerald LUCKENEDER

RFSR-CT-2009-00016 REFORM

Full Title Residual formability of preformed and subsequently welded adavnced high strength steels Info Type of Project Research Duration (months) 36 Total Budget 2199380 € Start Date 1/07/2009 EU Contribution 1319629 € End Date (actual) 30/06/2012 State Research in progress Summary This proposal is situated within the scope of research and technological development of steel and its utilisation. It deals with the technologies forming, welding and joining of modern high strength steel products and applications for the automotive crash and fatigue loaded parts. Central point of investigation will be the determination of the load capability of preformed and subsequently welded parts made of high strength steels. Important subject of the project will be the numerical simulation, respectively the main influence factors at the process chain performing – assembly (welding) – service and safety (crash / fatigue) based on experimental results. Partners Organization Country Responsible FRAUNHOFER GESELLSCHAFT ZUR FOERDERUNG DER AN DEUTSCHLAND Dr. Jens STANDFUSS (Project Coord.) ARCELORMITTAL ATLANTIQUE ET LORRAINE SAS FRANCE Dr. Laurent CRETTEUR CENTRO RICERCHE FIAT SCPA ITALIA Dr. Fabio D'AIUTO ESI ENGINEERING SYSTEM INTERNATIONAL GMBH DEUTSCHLAND Prof. Dr. Anthony PICKETT FIAT GROUP AUTOMOBILES SpA ITALIA Dr. Stefano MAGGI KOMPETENZZENTRUM DAS VIRTUELLE FAHRZEUG FORSC OESTERREICH Dr. Gernot TRATTNIG MAGNA STEYR FAHRZEUGTECHNIK AG & CO KG OESTERREICH Dipl -Ing Josef NEGES SKODA AUTO A.S. CZECH REPUBLIC Dipl.-Ing. Peter WEBER SALZGITTER MANNESMAN FORSCHUNG GmbH DEUTSCHLAND Dr.-Ing. Matthias HÖFEMANN TATA STEEL NEDERLAND TECHNOLOGY B.V. NEDERLAND Dr. Tony VAN DER VELDT TECHNISCHE UNIVERSITAET GRAZ OESTERREICH DI Robert VEIT THYSSENKRUPP STEEL EUROPE AG DEUTSCHLAND Mr Stefan WISCHMANN VOESTALPINE STAHL GMBH OESTERREICH Dipl.-Ing. Robert SIERLINGER

148 Summaries of RFCS projects 2003-2012 TGS7 : Steel products and applications for automobiles, packaging and home appliances

RFSR-CT-2009-00017 PROTUBEND

Full Title Flexible and cost-effective innovative manufacturing of complex 3D-bent tubes and profiles made of high- strength steels for automotive lightweight structures Info Type of Project Research Duration (months) 36 Total Budget 1025068 € Start Date 1/09/2009 EU Contribution 591714 € End Date (actual) 31/08/2012 State Research in progress Summary The realization of ultra-light, economically and ecologically oriented component structures with contour complexity in automotive industry necessitates the use of profiles and tubes from new steel grades. An unsolved problem so far is the cost-effective and reliable manufacturing of these components. Therefore, the aim of the project is to advance two new forming processes for an industrial use capable of forming and bending load-optimised 3D-tubes and profiles made of high- and ultrahigh- strength steel. They offer the opportunity of a free selection and reliable manufacturing of the bending contour. The superposition of stresses increases the process stability and predictability by minimization of springback. Partners Organization Country Responsible TECHNISCHE UNIVERSITÄT DORTMUND DEUTSCHLAND Prof. Dr.-Ing A. Erman TEKKAYA (Project Coord.) FUNDACIO PRIVADA ASCAMM ESPAÑA Mr Benjamin CAVALLINI ASERM- ASOCIACION ESPAÑOLA DE RAPID MANUFACTURI ESPAÑA Mr Felip ESTEVE CENTRO RICERCHE FIAT SCPA ITALIA Dr. Massimo TOLAZZI FAURECIA SIEGES D'AUTOMOBILE SAS FRANCE Dr.-Ing. Hosen SULAIMAN RAZVOJNI CENTER ORODJARSTVA SLOVENIJE ZAVOD - TEC SLOVENIJA Dr Janez Marko SLABE

RFSR-CT-2009-00018 INSTAP

Full Title Innovative steel grades for exhaust applications in automotive industry Info Type of Project Research Duration (months) 42 Total Budget 1625524 € Start Date 1/10/2009 EU Contribution 975314 € End Date (actual) 31/03/2013 State Research in progress Summary The following research project will develop innovative steel solutions like lean alloyed austenitic stainless steels, Duplex and ferritic stainless steels with improved creep and corrosion resistance for exhaust system of automotive vehicles. Two components are chosen for investigations: exhaust manifold and exhaust silencer which are exposed to high temperatures, oxidation and corrosion. Tailored steel grades depending on the special requirements of each component will be developed, tested and transferred to prototypes. This will lead to an increase in competitiveness of European steel industry due to innovative steel development for exhaust components. Partners Organization Country Responsible RHEINISCH-WESTFÄLISCHE TECHNISCHE HOCHSCHULE AA DEUTSCHLAND Prof Dr -Ing Wolfgang BLECK (Project Coord.) CENTRO RICERCHE FIAT SCPA ITALIA Dr. Giuseppe CUPITO CENTRO SVILUPPO MATERIALI SPA ITALIA Dr Paolo FOLGARAIT EMCON TECHNOLOGIES GERMANY (AUGSBURG) GBMH DEUTSCHLAND Dr. Helmut WIESER INSTITUTO DE SOLDADURA E QUALIDADE PORTUGAL Dr. Helena GOUVEIA OUTOKUMPU STAINLESS AB SVERIGE Dr. Pascale VANGELI

RFSR-CT-2010-00021 GPHS

Full Title Green press hardening steel grades Info Type of Project Research Duration (months) 36 Total Budget 1415208 € Start Date 1/07/2010 EU Contribution 849125 € End Date (actual) 30/06/2013 State Research in progress Summary Press hardened components used as automotive body structural elements fulfil two objectives, due to their exceptional mechanical strength: increment of passenger safety and reduction of vehicle CO2 footprint by reducing its weight. However, cost and energy efficiency of hot stamping processes is still far from being achieved and long manufacturing cycle times, costly heating and cooling equipment are still a drawback of this technology. The development of a new heat treatable steel grade will address these disadvantages, by reducing heating and cooling requirements and shortening the process cycle times, while ensuring the specified final part mechanical properties. Partners Organization Country Responsible FUNDACION TECNALIA RESEARCH & INNOVATION ESPAÑA Ing. Iñigo ARANGUREN MENDIETA (Project Coord.) ARCELORMITTAL MAIZIERES RESEARCH S.A. FRANCE Dr. Juan David PUERTA VELASQUEZ UNIVERSITA DEGLI STUDI DI PADOVA ITALIA Prof Paolo BARIANI VOLKSWAGEN AG DEUTSCHLAND Dr. Michael ALSMANN

149 Summaries of RFCS projects 2003-2012 TGS7 : Steel products and applications for automobiles, packaging and home appliances

RFSR-CT-2010-00022 CHARMA

Full Title Automated material characterisation for machinability prediction Info Type of Project Research Duration (months) 36 Total Budget 1151018 € Start Date 1/07/2010 EU Contribution 690611 € End Date (actual) 30/06/2013 State Research in progress Summary The current project aims are (I) reproducible machining performance and (II) tailored cutting related data in each delivery of engineering steel bar products to the benefit of both the steelmaker, and to component manufacturers for automotive and other industries. Objectives: 1). To develop Magnetic Barkhausen Noise analysis (MBN) and Pulse Distribution Analysis spark-OES (PDA-OES) for machinability determination in the quality control of the steel plant. 2). To extract useful material data for cutting operations in each delivery to customer, based on advanced correlation with microstructure and inclusion analysis. 3). Give guidelines with limitations of acceptable steel features for reproducible machinability. Partners Organization Country Responsible SWEREA KIMAB AB SVERIGE Dr. Thomas BJÖRK (Project Coord.) RHEINISCH-WESTFÄLISCHE TECHNISCHE HOCHSCHULE AA DEUTSCHLAND Dipl.-Ing. Dieter LUNG GERDAU INVESTIGACION Y DESARROLLO EUROPA S.A. ESPAÑA Ms Maria Carmen MONTERO PASCUAL UNIVERSITY OF NEWCASTLE UPON TYNE UNITED KINGDOM Dr. Brian SHAW

RFSR-CT-2011-00019 DURADH

Full Title Durability of adhesively bonded surfaces finished galvanised steels in corrosive environments Info Type of Project Research Duration (months) 42 Total Budget 1359119 € Start Date 1/07/2011 EU Contribution 815472 € End Date (actual) 31/12/2014 State Research in progress Summary New steel compositions and novel surface modification technologies aim at improved mechanical properties and corrosion resistance. However, the durability of adhesive joints between these advanced materials especially in corrosive environments are mostly below expectations. This proposal aims at an improved understanding of adhesion, de-adhesion and degradation kinetics and mechanisms of adhesives by means of novel spectroscopic, microscopic and electrochemical techniques. The project moreover focuses on development of improved failure analysis techniques targeting a mechanistic understanding to provide a basis for faster product development in the steel industry. Partners Organization Country Responsible UNIVERSITÄT PADERBORN DEUTSCHLAND Prof. Dr. Guido GRUNDMEIER (Project Coord.) INSTITUTO SUPERIOR TECNICO PORTUGAL Dr. Alda Maria PEREIRA SIMOES SIKA TECHNOLOGY AG SUISSE Dr. Jan Olaf SCHULENBURG SALZGITTER MANNESMANN FORSCHUNG GmbH DEUTSCHLAND Dr. Rer. Nat. Christian VREE THYSSENKRUPP STEEL EUROPE AG DEUTSCHLAND Mrs Jennifer SCHULZ UNIVERSIDADE DE AVEIRO PORTUGAL Dr. Mikhail ZHELUDKEVICH VOESTALPINE STAHL GMBH OESTERREICH Dr.-Ing. Harald HASLINGER

RFSR-CT-2011-00020 ENFASS

Full Title Enhanced formability assessment of AHSS sheets Info Type of Project Research Duration (months) 36 Total Budget 1831925 € Start Date 1/07/2011 EU Contribution 1099155 € End Date (actual) 30/06/2014 State Research in progress Summary When bending is added to a plane stress forming condition (i.e. stretching), formability is found to exceed the limits indicated by the FLC for most steel grades and even more so for the new AHSS grades. Since the FLC is commonly used as the formability criterion, the actual formability is underestimated. The project aim is to define an experimental characterization of this enhanced formability that is acceptable to the European automotive industry, in combination with a failure model that can be implemented in current FE codes to reliably predict formability. This approach will enhance the application of AHSS in industry. Partners Organization Country Responsible KOMPETENZZENTRUM DAS VIRTUELLE FAHRZEUG FORSC OESTERREICH DI Daniela KITTING (Project Coord.) DAIMLER AG DEUTSCHLAND Prof. Dr. Karl ROLL DYNAMORE GESELLSCHAFT FÜR FEM-INGENIEURDIENSTL DEUTSCHLAND Dr. André HAUFE TATA STEEL NEDERLAND TECHNOLOGY B.V. NEDERLAND Mr Eisso ATZEMA UNIVERSITEIT TWENTE NEDERLAND Dr. Ir. Ton VAN DEN BOOGAARD VOESTALPINE STAHL GMBH OESTERREICH Dr. Edwin TILL

150 Summaries of RFCS projects 2003-2012 TGS7 : Steel products and applications for automobiles, packaging and home appliances

RFSR-CT-2011-00021 AUTOFATCOR

Full Title Combined corrosion and fatigue strength of joined materials for body-in-white and structural automotive applications design Info Type of Project Research Duration (months) 42 Total Budget 1768888 € Start Date 1/09/2011 EU Contribution 1061333 € End Date (actual) 28/02/2015 State Research in progress Summary For the first time, automotive assemblies will be studied under simultaneous corrosion-fatigue loading in cyclic corrosion tests designed to mimic closely service exposure conditions. The aims of the project are to provide new tools, including the combined corrosion-fatigue solicitations for the design of automotive components involving assembly made both of traditional and new steel based materials to achieve efficient lightweighting. The project will allow a reduction of engineering, development and validation time, costs for implementation of new materials, joining techniques and corrosion protection systems. This will reduce the time to market for the steel industry. Partners Organization Country Responsible INSTITUT DE LA CORROSION SASU FRANCE Dr. Dominique THIERRY (Project Coord.) ARCELORMITTAL MAIZIERES RESEARCH S.A. FRANCE Dr. Laurence DOSDAT BAYERISCHE MOTOREN WERKE AG*BMW DEUTSCHLAND Mr Michael BRAUCH CENTRO SVILUPPO MATERIALI SPA ITALIA Dr. Cristiano SCIABONI GESELLSCHAFT FÜR SCHWEISSTECHNIK INTERNATIONAL DEUTSCHLAND Mr Thomas BSCHORR VOESTALPINE STAHL GMBH OESTERREICH Dr. Gerald LUCKENEDER

RFSR-CT-2011-00022 STEELTAC

Full Title Steel sheet surfaces with enhanced tactile feel Info Type of Project Research Duration (months) 40 Total Budget 1508345 € Start Date 1/07/2011 EU Contribution 905006 € End Date (actual) 31/10/2014 State Research in progress Summary This work addresses the development of new and improved manufacturing technologies to create innovative steel sheet surfaces for automotive and domestic appliances. A combination of predictive simulations and experimental work is proposed by a well equipped consortium (Acerinox, Corus, Swerea-IVF, tekniker and the University of Twente) focussed on the development of designed tactility, hydrophobicity and increased formability and paint appearancefor steel sheet surfaces using laser textured cold rolling rolls. The designed tactile feel in daily interactionwith steel products will directly increase the customer satisfaction: people feel more happy using steel products! Partners Organization Country Responsible UNIVERSITEIT TWENTE NEDERLAND Prof. Dr. Emile van der HEIDE (Project Coord.) ACERINOX EUROPA SA ESPAÑA Mr Rafael SANCHEZ RODRIGUEZ SWEREA IVF AB SVERIGE Dr. Phys. Boel WADMAN TATA STEEL NEDERLAND TECHNOLOGY B.V. NEDERLAND Dr. David MATTHEWS FUNDACION TEKNIKER ESPAÑA Dr. Amaya IGUARTUA

RFSR-CT-2011-00023 TESTTOOL

Full Title Wear measurement methodology and test facility to increase the efficiency of hot stamping for high performance component production Info Type of Project Research Duration (months) 42 Total Budget 1911593 € Start Date 1/07/2011 EU Contribution 1146956 € End Date (actual) 31/12/2014 State Research in progress Summary The use of hot stamping is increasing among automotive manufacturers because it allows producing complex geometries from high performing materials. However, their industrial feasibility depends on the process efficiency, which depends on the piece cost and the tool performance. Accurately foreseeing how many parts can be produced by a tool is very appealing to steel producers, tool steel makers, part producers and surface engineering companies. This project aims at developing a methodology and test facility to accurately evaluate the tribothermo-mechanical behaviour in hot stamping, through a deep understanding of the tribological conditions and interaction of the tool and the workpiece. Partners Organization Country Responsible FUNDACIO CTM CENTRE TECNOLOGIC- CTM ESPAÑA Dr. Montserrat VILASECA (Project Coord.) ARCELORMITTAL ATLANTIQUE ET LORRAINE SAS FRANCE Eng. Christine DESSAIN GESTAMP HARDTECH AB SVERIGE Mrs Katarina ERIKSSON LULEÅ UNIVERSITY OF TECHNOLOGY SVERIGE Prof. Mats OLDENBURG ROVALMA SA ESPAÑA Dr. Anwar HAMASAIID UNIVERSITÄT KASSEL DEUTSCHLAND Prof. Kurt STEINHOFF VOLKSWAGEN AG DEUTSCHLAND Dr. Michael ALSMANN

151 Summaries of RFCS projects 2003-2012 TGS7 : Steel products and applications for automobiles, packaging and home appliances

RFSR-CT-2011-00024 MAC D

Full Title Steel design and high speed machining aspects in the transition from case hardening to induction hardening of automotive transmissions Info Type of Project Research Duration (months) 36 Total Budget 1915161 € Start Date 1/07/2011 EU Contribution 1149096 € End Date (actual) 30/06/2014 State Research in progress Summary The proposal addresses the replacement of case hardening by induction hardening in manufacturing of automotive transmissions. This replacement requires the adaptation of the steels to optimize the manufacturing process and for a reliable performance of the component. The steel will be tailored to: (I). The as-delivered microstructure, with respect to rough machining prior to induction hardening. (II). The induction hardening sequence, with respect to finishing machining and fatigue strength of the final product. Direct comparisons of actual transmission components manufactured through the two routes are planned, with respect to: • Total manufacturing cost. • Vital end-user properties as fatigue strength. Partners Organization Country Responsible SWEREA KIMAB AB SVERIGE Dr. Thomas BJÖRK (Project Coord.) CENTRO RICERCHE FIAT SCPA ITALIA Ing. Anouscha HERRMANN PRATURLON EFD INDUCTION AB SVERIGE Mr Patrik OLSSON MONDRAGON GOI ESKOLA POLITEKNIKOA J.M.A., S.COOP ESPAÑA Prof. Pedro José ARRAZOLA OVAKO HOFORS AB SVERIGE Msc Patrik ÖLUND RHEINISCH-WESTFÄLISCHE TECHNISCHE HOCHSCHULE AA DEUTSCHLAND Dipl.-Ing. Dieter LUNG GERDAU INVESTIGACION Y DESARROLLO EUROPA S.A. ESPAÑA Ms Maria Carmen MONTERO PASCUAL

RFSR-CT-2012-00019 TWIP4EU

Full Title Introducing high strength and ductility twinning induced plasticity (TWIP) steels for European automotive applications through advanced material modelling Info Type of Project Research Duration (months) 36 Total Budget 1375711 € Start Date 1/07/2012 EU Contribution 825428 € End Date (actual) 30/06/2015 State Research in progress Summary TWIP4EU will promote the introduction of modern twinning induced plasticity (TWIP) steels as candidate material for production of lightweight automobile components. To introduce a new steel grade like high strength and ductility TWIP steel for large scale applications in industrial practice, a thorough validation of the material behaviour with useable material laws implementable in commercial finite element codes must be available since numerical simulations are used all along the production process of body parts starting from the design of forming dies through the prediction of in service performance up to the prediction of passenger safety in crash simulations. For this purpose, this project proposes a novel and advanced approach towards modelling the complex deformation and forming behaviour of new HSD-TWIP steels to facilitate their large scale introduction in the automotive industry. The project comprises a comprehensive experimental plan combined with the development of a constitutive framework motivated from micromechanical quantities to describe the deformation behaviour of this innovative material. The implementation of the developed model into commercially available finite element software packages plays an important role in the project. The project will be concluded by validation of the developed material model on a prototype automobile component. Partners Organization Country Responsible FRAUNHOFER GESELLSCHAFT ZUR FOERDERUNG DER AN DEUTSCHLAND Mr Maximilian STEIERT (Project Coord.) DYNAMORE GESELLSCHAFT FÜR FEM-INGENIEURDIENSTL DEUTSCHLAND Dr. André HAUFE ESI ENGINEERING SYSTEM INTERNATIONAL GMBH DEUTSCHLAND Dr. Andrew HEATH FAURECIA AUTOSITZE GMBH DEUTSCHLAND Mr Martin KAMPCZYK SWEREA KIMAB AB SVERIGE Dr. Niclas STENBERG SALZGITTER MANNESMANN FORSCHUNG GmbH DEUTSCHLAND Dr Katrin WEILANDT

RFSR-CT-2012-00020 STT

Full Title Steel tailor tubes Info Type of Project Research Duration (months) 36 Total Budget 1962700 € Start Date 1/07/2012 EU Contribution 1177620 € End Date (actual) 30/06/2015 State Research in progress Summary Steel hydroformed tubular components with tailor properties, used for automotive exhaust systems, fulfil two objectives, due to their optimized mechanical properties: increment of component functionality performance and reduction of part weight. However, a cheap and efficient manufacturing process to obtain these tubular components is not yet achieved. Expensive combination of processes, low automation and long manufacturing times are great drawbacks of current technologies. The development of an innovative process, combining tube flow forming before hydroforming, with adequate steel selection, will overcome these disadvantages, by reducing the manufacturing costs and cycle times, while ensuring the specified final part Partners Organization Country Responsible FUNDACION TECNALIA RESEARCH & INNOVATION ESPAÑA Ms Amaia ARROYO (Project Coord.) ACERINOX EUROPA SA ESPAÑA Ms Julia CONTRERAS FORTES CENTRO RICERCHE FIAT SCPA ITALIA Dr Daniele PULLINI INDUSTRIAS PUIGJANER SA ESPAÑA Mr Máximo ALBEA SWEREA KIMAB AB SVERIGE Prof. Arne MELANDER VOESTALPINE TUBULARS GMBH & CO KG OESTERREICH Dr Juergen KLARNER

152 Summaries of RFCS projects 2003-2012 TGS7 : Steel products and applications for automobiles, packaging and home appliances

RFSR-CT-2012-00021 PRESSPERFECT

Full Title Prediction of stainless steel performance after forming and finishing Info Type of Project Research Duration (months) 36 Total Budget 2035535 € Start Date 1/09/2012 EU Contribution 1221321 € End Date (actual) 31/08/2015 State Under process of signature Summary The goal of the project is to create a methodology to predict the performance of high quality stainless steel after forming and finishing treatments. The performance is used to link end-customer requirements to steel production conditions. This methodology is tested on three types of steel and routings: 1) martensitic stainless steel & heat treatment; 2) Austenitic stainless steel & nitrocarburising; 3) Precipitation hardening stainless steel & precipitation hardening and simultaneous nitrocarburising. The approach is to create knowledge based constitutive models of these materials. It will be transferred to the EU by the implementation in a commercial finite element solver and workshops. Partners Organization Country Responsible PHILIPS CONSUMER LIFESTYLE BV NEDERLAND Mr Jan POST (Project Coord.) AGENCIA ESTATAL CONSEJO SUPERIOR DE INVESTIGACIO ESPAÑA Dr. David SAN MARTIN FERNANDEZ DANMARKS TEKNISKE UNIVERSITET DANMARK Prof. Marcel SOMERS LULEÅ UNIVERSITY OF TECHNOLOGY SVERIGE Prof. Lars-Erik LINDGREN STICHTING MATERIALS INNOVATION INSTITUTE (M2i) NEDERLAND Dr. Giuseppe VISIMBERGA AB SANDVIK MATERIALS TECHNOLOGY SVERIGE Mr Fredrik SANDBERG

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Technical Group Steel 8

Steel products and applications for building, construction and industry

The scope of TGS8 includes:

• Structural safety and design methods, in particular with regard to resistance to fire and earthquakes

• Technologies relating to the forming, cutting, welding and joining of steel and other materials

• Design of assembled structures to facilitate the easy recovery of steel scrap and its reconversion into usable steels and techniques for recycling

• Prolonging service life of steel products

• Standardisation of testing and evaluation methods

155 156 Summaries of RFCS projects 2003-2012 TGS8 : Steel products and applications for building, construction and industry

RFS2-CT-2003-00048 DIFISEK

Full Title Dissemination of structural fire safety engineering knowledge Info Type of Project Accompanying measure (studies) Duration (months) 18 Total Budget 458975 € Start Date 1/09/2003 EU Contribution 458975 € End Date (actual) 28/02/2005 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA23332:EN Summary The broad technical objective of this proposal is to disseminate effectively Structural Fire Safety Engineering Knowledge gained in numerous ECSC funded projects during the last about 15 years into practical use as widely as possible in various countries in various languages. The broad technical objective is sub-divided into the following sub-objectives: · Preparation of common material (written text and Power Point Presentation), practical design examples and collection of free available softwares for fire design for seminars and workshops as European co-operation. Details, see Work Packages 1-5 later on. · Translation of the above-mentioned information, which will be made in English, into the following languages: German, French, Dutch, Spanish and Finnish. Details, see Work Package 6 later on. · Arrangement of numerous public seminars and workshops in participating countries and in some other European countries too and arrangement of special workshops for authorities and architect and engineering offices. The information prepared in this project will be also distributed through the home pages of the partners and through some National Constructional Steelwork Associations. Details, see Work Package 7. Target key people for dissemination are: · Designers not qualified in Structural Fire Safety Engineering; · Authorities responsible for Fire Safety Validation; · Teachers in the Universities, Technical Highschools and Technical Schools; · Students The objective is, that the information produced and distributed in this project could be used in the practical daily design work and for educational purposes. The information produced in this project should also help in making performance based fire design. The broad commercial objective of this proposal is to increase the market share of steel in the construction industry. It is evident, that by properly made fire design savings may be achieved in many cases and the competitiveness of steel can be increased. Partners Organization Country Responsible ProfilARBED S.A. LUXEMBOURG Mr Mike HALLER (Project Coord.) CENTRE TECHNIQUE INDUSTRIEL DE LA CONSTRUCTION M FRANCE Dr. Daniel JOYEUX FUNDACION TECNALIA RESEARCH & INNOVATION ESPAÑA Mr Jesus DE LA QUINTANA RAUTARUUKKI OYJ FINLAND Dr. Jyrki KESTI TNO, NEDERLANDSE ORG. VOOR TOEGEPAST NATUURWE NEDERLAND MSc. L. TWILT GOTTFRIED WILHELM LEIBNIZ UNIVERSITÄT HANNOVER DEUTSCHLAND Prof. Dr.-Ing. Peter SCHAUMANN

RFS2-CT-2004-00036 DryConDis

Full Title Dissemination of the knowledge in the use of steel intensive dry construction systems in housing (DryConDis) Info Type of Project Accompanying measure (studies) Duration (months) 12 Total Budget 334707 € Start Date 1/07/2004 EU Contribution 251030 € End Date (actual) 30/06/2005 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA22849:EN Summary The broad technical objective of this proposal is to disseminate effectively information about the use of steel intensive dry constructions systems in housing gained in ECSC funded projects “7210-P059: Design tools and new applications of cold-formed steel in buildings” and “7210-P115: Development of dry composite construction systems based on steel in residential applications” and Novel jointing systems for the automated production of light gauge steel elements” are considered in the framework of proposed dissemination activities. in eight countries in eight languages. This overall, broad objective will be achieved through following two sub objectives: · Information about new steel intensive dry construction systems and products developed in above mentioned ECSC projects will be spread through 13 seminars in Europe. · The results and experienced gained in previous projects will be transformed into practical guidelines, design provisions and calculation examples for practical engineers and designers which is published as document. Presentation material (Power Point sheets) for workshops or seminars is prepared based on that document. Partners Organization Country Responsible RAUTARUUKKI OYJ FINLAND Dr. Jyrki KESTI (Project Coord.) COMPUTER CONTROL SYSTEMS SA HELLAS Dr. Christos SAOURIDIS FORSCHUNGS- UND QUALITÄTSZENTRUM ODERBRÜCKE g DEUTSCHLAND Mr Holger GEORGI RHEINISCH-WESTFÄLISCHE TECHNISCHE HOCHSCHULE AA DEUTSCHLAND Prof. Dr.-Ing. Gerhard SEDLACEK STIFTELSEN SVENSK STALBYGGNADSFORSKNING - STALBY SVERIGE Mr Joakim WIDMAN UNIVERSITA DEGLI STUDI DI PISA ITALIA Dr. Walter SALVATORE UNIVERSIDAD DE LA RIOJA ESPAÑA Prof. Joaquín ORDIERES MERE

RFS2-CT-2004-00037 NEWEU

Full Title Dissemination of steel based new renovation technologies into growing new EU markets (NEWEU) Info Type of Project Accompanying measure (studies) Duration (months) 18 Total Budget 253434 € Start Date 1/07/2004 EU Contribution 190075 € End Date (actual) 31/12/2005 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA22850:EN Summary The broad technical objective is to disseminate several new steel based renovation technologies to new EU markets. Technologies demonstrated in practice in the two earlier ECSC-projects. The broad technical objective is sub-divided into the following sub-objectives: - Preparation of material to be presented at seminars in the participating countries - Translation of the material into the following languages :Polish, Lithuanian, Estonian, Hungarian and Latvian - Arrangement of seminars in participating countries - Arrangement of practical training The broad commercial objective is to increase the market share of steel in the construction industry in the renovation of old buildings. Partners Organization Country Responsible RAUTARUUKKI OYJ FINLAND Mr Pekka ROIVIO (Project Coord.) 157 FINNMAP POLSKA Sp. z.o.o. POLAND Mr Lasse RAJALA Summaries of RFCS projects 2003-2012 TGS8 : Steel products and applications for building, construction and industry

RANNILA HUNGARY KERESKEDELMI ES SZOLGALTATO Kft. HUNGARY M. Sc. Istvan SZONTAGH SIA FINNMAP LATVIJA LATVIA Mr Markku HUSSO TALLINNA TEHNIKAULIKOOL*TALLINN UNIVERSITY OF TEC ESTONIA Prof. Kalju LOORITS VILNIUS GEDIMINO TECHNIKOS UNIVERSITETAS LITHUANIA Prof. Dr.Habil Audronis Kazimieras KVEDARAS

RFS2-CT-2004-00038 DISKX100PIPE

Full Title Dissemination of X100 steel pipes for high pressure gas transportation pipelines knowledge Info Type of Project Accompanying measure (studies) Duration (months) 18 Total Budget 200000 € Start Date 1/07/2004 EU Contribution 150000 € End Date (actual) 31/12/2005 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA22851:EN Summary The aim of this RFCS proposal is to promote the knowledge gained in ECSC-funded projects carried out during the past five years. It is aimed at demonstrating the safe use of X100 grade steel large diameter pipes for possible use in long-distance, on-shore gas transmission pipelines, in order to increase the European Market share in this specific, world-wide business. To achieve this general aim, the specific goals of the present proposal are as follows: ♦ to select, collect, analyse and disseminate the technical information gained both in ECSC past projects, and available world-wide, with regard to the behaviour of large diameter X100 grade steel pipes for long distance, on-shore gas transmission pipelines, with respect to the major technical issues (in-field welding, defect tolerance, cold bending, etc) Dissemination would be achieved through the organization of a devoted Web Site, a selected International Working Group, and two International seminars open to both specialists and academics; ♦ to come to an agreement about a common proposal, based on the background information referred to above, for submission to the relevant international regulatory bodies about the incorporation into the international standards of X100 grade steel pipes for long-distance, on-shore high-pressure gas transmission pipelines.. Partners Organization Country Responsible CENTRO SVILUPPO MATERIALI SPA ITALIA Dr.-Ing. Giuseppe DEMOFONTI (Project Coord.) SALZGITTER MANNESMANN FORSCHUNG GmbH DEUTSCHLAND Dr. Gerhard KNAUF

RFS2-CT-2005-00035 PROSSUS

Full Title Promotion of steel in sustainable and adaptable buildings Info Type of Project Accompanying measure (studies) Duration (months) 12 Total Budget 333462 € Start Date 1/07/2005 EU Contribution 200078 € End Date (actual) 30/06/2006 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA23201:EN Summary The use of steel in residential buildings is strongly dependent on the concepts of sustainability and adaptable construction systems. This Type 2 project will disseminate the steel technologies developed and demonstrated in RFCS project 7215-PP-058, with the objective of creating a greater understanding of new ways of residential building using steel. It is proposed to prepare dissemination material giving details of the 5 demonstration buildings, and to prepare information on sustainability benefits of steel construction. Many of the projects in participating countries led to new construction technologies, and this Type 2 project will provide an opportunity to disseminate both the new technologies and the information gained during testing and monitoring. National seminars will help to spread the knowledge to e.g. architects, clients and politicians. Partners Organization Country Responsible THE STEEL CONSTRUCTION INSTITUTE LBG UNITED KINGDOM Mr Graham K. RAVEN (Project Coord.) CENTRO SVILUPPO MATERIALI SPA ITALIA Dr. Giuliana ZILLI CENTRE TECHNIQUE INDUSTRIEL DE LA CONSTRUCTION M FRANCE Mr Philippe BEGUIN FORSCHUNGSVEREINIGUNG STAHLANWENDUNG e.V. DEUTSCHLAND Dipl.-Ing. Gregor NUESSE RAUTARUUKKI OYJ FINLAND Dr. Jyrki KESTI STIFTELSEN SVENSK STALBYGGNADSFORSKNING - STALBY SVERIGE Dr. Anders OLSSON

RFS2-CT-2005-00036 VALCOSS

Full Title Valorisation project - structural design of cold worked austenitic stainless steel Info Type of Project Accompanying measure (studies) Duration (months) 12 Total Budget 271843 € Start Date 1/07/2005 EU Contribution 163107 € End Date (actual) 30/06/2006 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA23199:EN Summary This valorisation project will disseminate guidance on the design of cold worked stainless steel structural members resulting from the recently completed ECSC project Structural Design of Cold Worked Austenitic Stainless Steel (7210-PR-318). The deliverables include: • 3rd Edition of the Design Manual for Structural Stainless Steel, extended to cover cold worked material and updated to refer to relevant parts of EN 1993. Three new design / cost comparison examples will be included. The Design Manual will be available in seven European languages. • Online design facility for cold worked stainless steel members. • Seven seminars throughout Europe. Partners Organization Country Responsible THE STEEL CONSTRUCTION INSTITUTE LBG UNITED KINGDOM Ms Nancy BADDOO (Project Coord.) CENTRO SVILUPPO MATERIALI SPA ITALIA Dr. Giuliana ZILLI UNIVERSITE BLAISE PASCAL - CUST FRANCE Prof. Jean-Pierre MUZEAU EURO INOX LUXEMBOURG Mr Thomas PAULY RHEINISCH-WESTFÄLISCHE TECHNISCHE HOCHSCHULE AA DEUTSCHLAND Prof. Dr.-Ing. Gerhard SEDLACEK STIFTELSEN SVENSK STALBYGGNADSFORSKNING - STALBY SVERIGE MSc. Hans OLSON UNIVERSITAT POLITECNICA DE CATALUNYA (UPC) ESPAÑA Dr. Esther REAL TEKNOLOGIAN TUTKIMUSKESKUS VTT*TECHNIC. RESEARC FINLAND M.Sc. Asko TALJA

158 Summaries of RFCS projects 2003-2012 TGS8 : Steel products and applications for building, construction and industry

RFS2-CT-2005-00037 LWO+

Full Title Large web openings for service integration in composite floors Info Type of Project Accompanying measure (studies) Duration (months) 18 Total Budget 290279 € Start Date 1/07/2005 EU Contribution 174167 € End Date (actual) 31/12/2006 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA23173:EN Summary This application is related to the ECSC project P4383 – LARGE WEB OPENINGS FOR SERVICE INTEGRATION IN COMPOSITE FLOORS (LWO). The project started in July 2001 and has been successfully finalised end of 2003. The objective is to: – review of the knowledge gained in the frame of the ECSC project LWO – prepare state of the art reports – to translate the documents into French, Swedish and German – to promote the knowledge gained to practitioners via * Internet * contacts to CEN * conferences (e.g. EUROSTEEL 2005 to be held in Maastricht (NL), Swedish Steel Construction Day, etc.) * workshops Partners Organization Country Responsible RHEINISCH-WESTFÄLISCHE TECHNISCHE HOCHSCHULE AA DEUTSCHLAND Dr.-Ing. Christian MÜLLER (Project Coord.) CENTRE TECHNIQUE INDUSTRIEL DE LA CONSTRUCTION M FRANCE Mr Alain BUREAU LULEÅ UNIVERSITY OF TECHNOLOGY SVERIGE Prof. Dr. Bernt JOHANSSON ProfilARBED S.A. LUXEMBOURG Mr Olivier VASSART THE STEEL CONSTRUCTION INSTITUTE LBG UNITED KINGDOM Dr. Stephen HICKS

RFS2-CT-2007-00028 WiSH

Full Title Workpack design for steel house Info Type of Project Accompanying measure (studies) Duration (months) 18 Total Budget 456929 € Start Date 1/06/2007 EU Contribution 274158 € End Date (actual) 30/11/2008 State Research completed, report published on EU Bookshop at (link not yet available) Summary The project objective is to increase light steel frames use in housing by a new fully validated comprehensive, self contained and userfriendly design package. Such use exploits favourable criteria such as cost, safety, environmental/energy impacts and design flexibility. The gap of light steel frame use in Europe compared to America or Japan is partly due to the lack of common tools and building players awareness of benefits of light steel construction. The objective will be met by promotion and dissemination of the design package starting with Belgium, France and Spain by means of workshops, training sessions preparation and IT-based communication. Partners Organization Country Responsible ARCELORMITTAL LIEGE RESEARCH SCRL BELGIQUE Ar. Chistine ETZENBACH (Project Coord.) CENTRE SCIENTIFIQUE ET TECHNIQUE DU BATIMENT FRANCE Mr Emmanuel DAVID CENTRE TECHNIQUE INDUSTRIEL DE LA CONSTRUCTION M FRANCE Mr Patrick LE CHAFFOTEC EUROPEAN LIGHT STEEL CONSTRUCTION ASSOCIATION BELGIQUE Dr. Natividad PASTOR TORRENTE UNIVERSITAT POLITECNICA DE CATALUNYA (UPC) ESPAÑA Prof. Antonio HUERTA

RFS2-CT-2007-00029 EUROBUILD+

Full Title Dissemination of EUROBUILD in steel Info Type of Project Accompanying measure (studies) Duration (months) 18 Total Budget 495333 € Start Date 1/07/2007 EU Contribution 297200 € End Date (actual) 31/12/2008 State Research completed, report published on EU Bookshop at (link not yet available) Summary The objective of this dissemination project is to publicise the findings of the Eurobuild in Steel project on the key factors that influence the next generation of steel framed buildings and to prepare best practice guidance on the use of steel that reflects these trends and drivers. The project will take the form of national seminars in 7 countries, publications of best practice guidance on commercial, industrial and residential buildings, and further dissemination through stakeholders and IPOs at a European level. A data base of important information will be prepared. Partners Organization Country Responsible ARCELORMITTAL BELVAL & DIFFERDANGE S.A. LUXEMBOURG Mrs Nicoleta POPA (Project Coord.) BOUWEN MET STAAL NEDERLAND Mr Mic BARENDZS CENTRE TECHNIQUE INDUSTRIEL DE LA CONSTRUCTION M FRANCE Mr Philippe BEGUIN FUNDACION TECNALIA RESEARCH & INNOVATION ESPAÑA Mr Jose A. CHICA STIFTELSEN SVENSK STALBYGGNADSFORSKNING - STALBY SVERIGE Mr Joakim WIDMAN THE STEEL CONSTRUCTION INSTITUTE LBG UNITED KINGDOM Dr. R. Mark LAWSON TECHNISCHE UNIVERSITÄT DORTMUND DEUTSCHLAND Prof. Dr.-Ing. Dieter UNGERMANN

159 Summaries of RFCS projects 2003-2012 TGS8 : Steel products and applications for building, construction and industry

RFS2-CT-2007-00030 DIFISEK+

Full Title Dissemination of structural fire safety engineering knowledge throughout Europe Info Type of Project Accompanying measure (studies) Duration (months) 18 Total Budget 722149 € Start Date 1/07/2007 EU Contribution 433289 € End Date (actual) 31/12/2008 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA24223:EN Summary The technical objective is to disseminate Structural Fire Safety Engineering Knowledge gained in recent ECSC&RFCS funded projects to practicing engineers in various countries, in their own languages. This project will extend a previous RFCS project entitled DIFISEK that covered a few European countries and will now cover nearly all European countries. Another objective is to update the material for fire design prepared in the first project (according EN version) and to implement Eurocode National Annexes. All data will be translated and seminars will be organised in the following countries, Austria, Belgium, Czech-Republic, Estonia, France, Germany, Greece, Hungary, Italy, Lithuania, Poland, Portugal, Romania, Slovenia, Spain, Sweden and United-Kingdom. Partners Organization Country Responsible ARCELORMITTAL BELVAL & DIFFERDANGE S.A. LUXEMBOURG Mr Olivier VASSART (Project Coord.) ARTISTOTLE UNIVERSITY OF THESSALONIKI HELLAS Prof. Dr.-Ing. Charalampos BANIOTOPOULOS CENTRE TECHNIQUE INDUSTRIEL DE LA CONSTRUCTION M FRANCE Dr. Bin ZHAO FUNDACION TECNALIA RESEARCH & INNOVATION ESPAÑA Mr Jose A. CHICA STIFTELSEN SVENSK STALBYGGNADSFORSKNING - STALBY SVERIGE MSc. Björn UPPFELDT STRUCTURA ENGINEERING SRL ITALIA Dr.-Ing. Sandro PUSTORINO TALLINNA TEHNIKAULIKOOL*TALLINN UNIVERSITY OF TEC ESTONIA Prof. Kalju LOORITS UNIVERSIDADE DE AVEIRO PORTUGAL Prof. Paulo VILA REAL GOTTFRIED WILHELM LEIBNIZ UNIVERSITÄT HANNOVER DEUTSCHLAND Prof. Dr.-Ing. Peter SCHAUMANN UNIVERZA V LJUBLJANI SLOVENIJA Prof. Darko BEG CITY UNIVERSITY UNITED KINGDOM Prof. Dr. Kuldeep VIRDI MISKOLCI EGYETEM*UNIVERSITY OF MISKOLC HUNGARY Prof. Karoly JARMAI POLITECHNIKA POZNANSKA*POZNAN UNIVERSITY OF TEC POLAND Dr. Maciej SZUMIGALA CESKE VYSOKE UCENI TECHNICKE V PRAZE*CZECH TECHNI CZECH REPUBLIC Prof.-Ing. CSc. Frantisek WALD UNIVERSITATEA POLITEHNICA DIN TIMISOARA ROMANIA Dr. Raul Dan ZAHARIA TECHNISCHE UNIVERSITAET WIEN OESTERREICH Prof. Dr. Ulrich SCHNEIDER VILNIUS GEDIMINO TECHNIKOS UNIVERSITETAS LITHUANIA Prof. Dr.Habil Audronis Kazimieras KVEDARAS

RFS2-CT-2007-00031 COMBRI+

Full Title Valorisation of knowledge for competitive steel and composite bridges Info Type of Project Accompanying measure (studies) Duration (months) 18 Total Budget 408085 € Start Date 1/07/2007 EU Contribution 244851 € End Date (actual) 31/12/2008 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA24175:EN Summary Within the RFCS research project COMBRI essential knowledge has been assembled to enhance the competitiveness of steel and composite bridges. This type 2 proposal aims at the valorisation and promotion of these results not only to reach a wider audience but also to assure the application of the outcomes. A design manual including worked examples and conceptual design issues will contribute to a better understanding and assessment of the knowledge gained along with the possibility to highlight the relevant topics. An implementation of the knowledge in a future revision of Eurocode or in national application documents is prepared to create a common basis providing European designers, manufacturers and bridge owners with all the benefits. Partners Organization Country Responsible UNIVERSITAET STUTTGART DEUTSCHLAND Prof.Dr. Ulrike KUHLMANN (Project Coord.) CENTRE TECHNIQUE INDUSTRIEL DE LA CONSTRUCTION M FRANCE Mr Pierre-Olivier MARTIN FUNDACION TECNALIA RESEARCH & INNOVATION ESPAÑA Mr Jose A. CHICA LULEÅ UNIVERSITY OF TECHNOLOGY SVERIGE Prof. Dr. Bernt JOHANSSON RHEINISCH-WESTFÄLISCHE TECHNISCHE HOCHSCHULE AA DEUTSCHLAND Prof. Dr.-Ing. Markus FELDMANN SERVICE D'ETUDES SUR LES TRANSPORTS, LES ROUTES ET FRANCE Mr Joël RAOUL UNIVERSITE DE LIEGE BELGIQUE Dr. Hervé DEGEE

RFS2-CT-2007-00032 FS+

Full Title Fire safety of industrial hall - valorisation project Info Type of Project Accompanying measure (studies) Duration (months) 18 Total Budget 352181 € Start Date 1/07/2007 EU Contribution 211308 € End Date (actual) 31/12/2008 State Research completed, report published on EU Bookshop at (link not yet available) Summary New fire safety regulation proposals for single storey buildings have appeared in different countries (France, Spain, and Belgium) that could result a significant loss of market share for steel. The steel industry must be ready to provide strong technical arguments and solutions to avoid the introduction of excessive fire resistance requirements in the single storey field throughout Europe. With this aim, an ECSC Project called “Fire Safety of Industrial hall and low rise building” has been finalized last year. Significant and encouraging results have been obtained during this project. The aim is to disseminate all the results obtained during this project by : - the redaction of a design guide that provides a way to guarantee the safety of occupants and firemen through alternatives to prescriptive ISO fire requirements - the organization of workshop including local authorities and firemen Partners Organization Country Responsible ARCELORMITTAL BELVAL & DIFFERDANGE S.A. LUXEMBOURG Dr. Renata OBIALA (Project Coord.) CENTRE TECHNIQUE INDUSTRIEL DE LA CONSTRUCTION M FRANCE Dr. Bin ZHAO FUNDACION TECNALIA RESEARCH & INNOVATION ESPAÑA Mr Jose A. CHICA UNIVERSITE DE LIEGE BELGIQUE Dr. Jean-Marc FRANSSEN

160 Summaries of RFCS projects 2003-2012 TGS8 : Steel products and applications for building, construction and industry

RFS2-CT-2007-00033 HiVoSS

Full Title Human induced vibration of steel structures Info Type of Project Accompanying measure (studies) Duration (months) 18 Total Budget 369384 € Start Date 1/07/2007 EU Contribution 221630 € End Date (actual) 31/12/2008 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA24183:EN Summary The use of modern high strength steels allows the design of more slender and light weight structures. However with increasing slenderness sensitivity of structures to vibrations rises. An ECSC research project concerning floor vibrations and a RFCS project concerning vibrations of footbridges were carried out to study how to deal with vibration level in light weight structures. The project proposed here aims at the promotion of the combined knowledge gained in the two projects specified above that provide already drafts of guidelines. The promotion covers the preparation of a guideline for vibration design with worked examples, concise background information, preparation of presentations and performance of seminars. Partners Organization Country Responsible RHEINISCH-WESTFÄLISCHE TECHNISCHE HOCHSCHULE AA DEUTSCHLAND Dr.-Ing. Christoph HEINEMEYER (Project Coord.) ARCELORMITTAL BELVAL & DIFFERDANGE S.A. LUXEMBOURG Mr Olivier VASSART CENTRE TECHNIQUE INDUSTRIEL DE LA CONSTRUCTION M FRANCE Dr. Mladen LUKIĆ SBP GmbH - SCHLAICH BERGERMANN & PARTNER DEUTSCHLAND Dr. Arndt GOLDACK THE STEEL CONSTRUCTION INSTITUTE LBG UNITED KINGDOM Dr. Stephen HICKS TNO, NEDERLANDSE ORG. VOOR TOEGEPAST NATUURWE NEDERLAND Dr. Ir. Paul H. WAARTS UNIVERSIDADE DO PORTO - PORTUGAL Prof. Elsa CAETANO

RFS2-CT-2008-00030 SECHALO

Full Title Facilitating market development for sections in industrial halls and low-rise buildings Info Type of Project Accompanying measure (studies) Duration (months) 20 Total Budget 797061 € Start Date 1/07/2008 EU Contribution 478236 € End Date (actual) 28/02/2010 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA25056:EN Summary A growth of construction market indicates opportunities for steel industry to increase European market share especially for single storey and low-rise multi-storey industrial buildings. Steel producers, namely Peiner Träger, Corus and ArcelorMittal collaborate in order to achieve this goal by providing design guidance and harmonized standards and by promoting these tools widely to designers and architects. This project with produce a simple, comprehensive and harmonised design guides for the two types of buildings mentioned, which will be based on the state of the art and best practise extracted from previous RFCS projects. Cooperation with IPOs enables also compliance of the guides with national regulations. Partners Organization Country Responsible ARCELORMITTAL BELVAL & DIFFERDANGE S.A. LUXEMBOURG Dr. Renata OBIALA (Project Coord.) PEINER TRÄGER GmbH DEUTSCHLAND MSc. Kai BOHMBACH TATA STEEL UK LIMITED UNITED KINGDOM Mr Richard DIXON

RFS2-CT-2009-00019 INTAB+

Full Title Economic and durable design of composite bridges with integral abutments Info Type of Project Accompanying measure (studies) Duration (months) 12 Total Budget 265230 € Start Date 1/07/2009 EU Contribution 159138 € End Date (actual) 30/06/2010 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA25045:EN Summary This application is related to the RFCS project RFSR-CT-2005-00041 “Economic and Durable Design of Composite Bridges with Integral Abutments (INTAB)”. The project started in July 2005 and has been finalised in June 2008. The objective is to: - review the knowledge gained in the scope of the RFCS project INTAB - prepare state of the art reports in a condensed form - translate the documents into French and German - promote the knowledge gained to practitioners via • Internet • contacts to CEN • conferences (e.g. IABSE 2009) • workshops Partners Organization Country Responsible RHEINISCH-WESTFÄLISCHE TECHNISCHE HOCHSCHULE AA DEUTSCHLAND Prof. Dr.-Ing. Markus FELDMANN (Project Coord.) ARCELORMITTAL BELVAL & DIFFERDANGE S.A. LUXEMBOURG Mrs Nicoleta POPA LULEÅ UNIVERSITY OF TECHNOLOGY SVERIGE Prof. Dr. Milan VELJKOVIC SSF INGENIEURE AG DEUTSCHLAND Dr. Günter SEIDL

161 Summaries of RFCS projects 2003-2012 TGS8 : Steel products and applications for building, construction and industry

RFS2-CT-2010-00023 SEMI-COMP+

Full Title Valorisation action of plastic member capacity of semi-compact steel sections - a more economic design Info Type of Project Accompanying measure (studies) Duration (months) 18 Total Budget 333637 € Start Date 1/07/2010 EU Contribution 200182 € End Date (actual) 31/12/2011 State Research technically completed; publication in hand Summary The objective of this project is the dissemination of knowledge gained through the former European research project SEMI-COMP on semi-compact steel sections. The obtained results demonstrated substantial reserves in load-carrying capacity, which so far cannot be utilized by a designer using Eurocode 3. Considering increasing use of high-strength steel grades, the problem becomes more severe. For the purpose of dissemination, the conclusions of SEMI-COMP will be transformed into a comprehensive European Design Guideline for the correct assessment of the load-carrying capacity of semi-compact members, including an electronic Design-Tool. With seminars knowledge and guideline spread to designers, consulting engineers and authorities. Partners Organization Country Responsible TECHNISCHE UNIVERSITAET GRAZ OESTERREICH Prof. Richard GREINER (Project Coord.) EUROPEAN CONVENTION FOR CONSTRUCTIONAL STEELW BELGIQUE Prof. Dr. Luis SIMOES DA SILVA FELDMANN + WEYNAND GmbH DEUTSCHLAND Dr.-Ing. Klaus WEYNAND UNIVERSITE DE LIEGE BELGIQUE Prof. Jean-Pierre JASPART

RFS2-CT-2011-00025 MACS+

Full Title Membrane action in fire design of composite slab with solid and cellular steel beams - valorisation Info Type of Project Accompanying measure (studies) Duration (months) 18 Total Budget 1018709 € Start Date 1/07/2011 EU Contribution 611226 € End Date (actual) 31/12/2012 State Research in progress Summary The technical objective is to disseminate methodology for design of partially protected composite slabs for fire conditions with a focus on the connections and on Cellular Beams. Number of tests performed in various countries under natural and ISO fire enabled to gain good understanding ofthe behaviour of such structures. The project will be addressed to practicing engineers in various countries and aims to transfer knowledge about utilisation in their designs of membrane effect, which is created in the reinforced slab during fire. This project will extend recent RFCS project FICEB+ and COSSFIRE. The first one comprised a large scale natural fire test on a compartment based on composite Cellular beams. Within the second project, among other small scale tests, one large scale furnace test activating the membrane action with a prescriptive ISO fire has been performed. Partners Organization Country Responsible ARCELORMITTAL BELVAL & DIFFERDANGE S.A. LUXEMBOURG Mr Olivier VASSART (Project Coord.) ARTISTOTLE UNIVERSITY OF THESSALONIKI HELLAS Prof. Dr.-Ing. Charalampos BANIOTOPOULOS BAUFORUMSTAHL E.V. DEUTSCHLAND Dr. Bernhard HAUKE BOUWEN MET STAAL NEDERLAND Mr Ralph HAMERLINCK CENTRE TECHNIQUE INDUSTRIEL DE LA CONSTRUCTION M FRANCE Dr. Bin ZHAO INSTYTUT TECHNIKI BUDOWLANEJ POLAND Dr. Grzegorz WOZNIAK STIFTELSEN SVENSK STALBYGGNADSFORSKNING - STALBY SVERIGE Mr Björn ASTEDT STRUCTURA ENGINEERING SRL ITALIA Dr.-Ing. Sandro PUSTORINO TALLINNA TEHNIKAULIKOOL*TALLINN UNIVERSITY OF TEC ESTONIA Dr Ivar TALVIK FUNDACION TECNALIA RESEARCH & INNOVATION ESPAÑA Mr Jesus DE LA QUINTANA UNIVERSITE DE LIEGE BELGIQUE Dr. Jean-Marc FRANSSEN UNIVERSIDADE DE AVEIRO PORTUGAL Prof. Paulo VILA REAL UNIVERZA V LJUBLJANI SLOVENIJA Prof. Darko BEG MISKOLCI EGYETEM*UNIVERSITY OF MISKOLC HUNGARY Prof. Karoly JARMAI CESKE VYSOKE UCENI TECHNICKE V PRAZE*CZECH TECHNI CZECH REPUBLIC Ing. PhD. Zdenek SOKOL UNIVERSITATEA POLITEHNICA DIN TIMISOARA ROMANIA Dr. Raul Dan ZAHARIA UNIVERSITY OF ULSTER UNITED KINGDOM Dr. Ali NADJAI VILNIUS GEDIMINO TECHNIKOS UNIVERSITETAS LITHUANIA Prof. Dr.Habil Audronis Kazimieras KVEDARAS ASD WESTOK LIMITED UNITED KINGDOM Mr Michael HAWES

RFS2-CT-2011-00026 PRECO+

Full Title Prefabricated enduring composite beams based on innovative shear transmission Info Type of Project Accompanying measure (studies) Duration (months) 18 Total Budget 413783 € Start Date 1/07/2011 EU Contribution 248271 € End Date (actual) 31/12/2012 State Research in progress Summary The Proposal refers to the finished RFCS-project “Prefabricated Enduring Composite Beams based on innovative Shear Transmission (PreCoBeam)”. Aim of the project was to deliver detailed knowledge on composite girders using the innovative technology of composite dowels to transmit shear forces. The project started in July 2006 and has been finalised in June 2009. Objectives of the proposal: - review the knowledge gained, prepare state of the arts reports, design guides and design tools - translate the documents into German, Polish, Swedish, French and Spanish - promote the knowledge to practitioners by conferences, workshops, internet and publications in (inter)national journals Partners Organization Country Responsible SSF INGENIEURE AG DEUTSCHLAND Dr. Günter SEIDL (Project Coord.) ACCIONA INFRAESTRUCTURAS S.A. ESPAÑA Dr. Carlo PAULOTTO ARCELORMITTAL BELVAL & DIFFERDANGE S.A. LUXEMBOURG Mrs Nicoleta POPA FORSCHUNGSVEREINIGUNG STAHLANWENDUNG e.V. DEUTSCHLAND Mr Gregor NÜSSE RAMBÖLL SVERIGE AB SVERIGE Dr. Ali FARHANG UNIVERSITE DE LIEGE BELGIQUE Dr. Jean-Marc FRANSSEN POLITECHNIKA WROCLAWSKA - WROCLAW UNIVERSITY O POLAND Dr.-Ing. Wojciech LORENC 162 Summaries of RFCS projects 2003-2012 TGS8 : Steel products and applications for building, construction and industry

RFS2-CT-2012-00022 INFASO+

Full Title Valorisation of knowledge for innovative fastening solutions between steel and concrete Info Type of Project Accompanying measure (studies) Duration (months) 24 Total Budget 574993 € Start Date 1/07/2012 EU Contribution 344996 € End Date (actual) 30/06/2014 State Under process of signature Summary Within RFCS project INFASO design models for innovative, practically relevant steel-to-concrete joints with new concrete components have been developed including electronic tools. This proposal aims at the valorisation and the dissemination of these results to reach a wide audience among designers and engineers in order to assure the application of the outcome. Design Manuals for the engineers in practice are prepared including worked examples. They will be presented and handed out in the frame of several seminars. The implementation of these models in a future revision of Eurocode is prepared to create a basis for easy application by all European designers. Partners Organization Country Responsible UNIVERSITAET STUTTGART DEUTSCHLAND Prof.Dr. Ulrike KUHLMANN (Project Coord.) EUROPEAN CONVENTION FOR CONSTRUCTIONAL STEELW BELGIQUE Prof. Dr. Milan VELJKOVIC GABINETE DE INFORMATICA E PROJECTO ASSISTIDO POR PORTUGAL Prof. Dr. Luis SIMOES DA SILVA GOLDBECK BAUELEMENTS GMBH DEUTSCHLAND Dr. Rolf HEDDRICH STAHL + VERBUNDBAU GESELLSCHAFT FÜR INDUSTRIELLE DEUTSCHLAND Dr. Norbert SAUERBORN CESKE VYSOKE UCENI TECHNICKE V PRAZE*CZECH TECHNI CZECH REPUBLIC Prof.-Ing. CSc. Frantisek WALD

RFS3-CT-2004-00039 Full Title Seismic Design of Light Gauge Steel Framed Buildings Info Type of Project Accompanying measure (training) Duration (months) 4 Total Budget 9100 € Start Date 1/06/2004 EU Contribution 9100 € End Date (actual) 30/09/2004 State Research completed; no publication Summary Main research activity of the applicant is the numerical modelling of the seismic behaviour of cold-formed steel structures. This model has to be calibrated and validated by a previous testing campaign. With this stage, the applicant will participate in the testing campaign, the model will be validated and seismic design rules will be developed. Partners Organization Country Responsible TEKNOLOGIAN TUTKIMUSKESKUS VTT*TECHNIC. RESEARC FINLAND Mr Jouko KOUHI (Project Coord.) UNIVERSITAT POLITECNICA DE CATALUNYA (UPC) ESPAÑA Dr. Antonio ROGRIGUEZ FERRAN

RFS3-CT-2005-00038 ENCAVI

Full Title Stage for the enrichment and calibration of a vibroacoustic model Info Type of Project Accompanying measure (training) Duration (months) 8 Total Budget 10500 € Start Date 1/03/2005 EU Contribution 10500 € End Date (actual) 31/10/2005 State Research completed; no publication Summary The tasks developed by the applicant will be the participation in the testing campaign and the study of non-deterministic methods for the prediction of vibroacoustic phenomena. Consequently, the calibration (and enrichment with probabilistic techniques) of the numerical model, the participation in a testing campaign and the collaboration with more experienced people in vibroacoustics will be the benefits for the applicant. Moreover, benefits for host and applicant organisations will be a better development of the testing campaign, a more solid and theoretical based knowledge of vibroacoustic phenomena and a correct interpretation of results which will lead to useful rules of acoustic design for lightweight steel structural elements. Partners Organization Country Responsible CENTRE SCIENTIFIQUE ET TECHNIQUE DU BATIMENT FRANCE Dipl.-Ing. Michel VILLOT (Project Coord.) UNIVERSITAT POLITECNICA DE CATALUNYA (UPC) ESPAÑA M.Sc. Jordi POBLET PUIG

RFS3-CT-2008-00031 Full Title Investigation into fracture mechanics and ductile fracture propagation in fibre laser welded high strength steel Info Type of Project Accompanying measure (training) Duration (months) 12 Total Budget 24750 € Start Date 1/07/2008 EU Contribution 24750 € End Date (actual) 30/06/2009 State Unknown type of status (CSX) Summary The main research objectives devised to provide fracture mechanics behaviour of the fibre laser welded high strength steel - to select and/or develop alternative method for the fracture mechanics of the fibre laser welded hig strength steel - to implement local fracture mechanics rules in welded materials to be used in conjunction with fibre laser welded high strength steel - to establish a relationship between welding procedure (fibre laser parameters, clamping, pre-heat, etc.) and fracture initiation in fibre laser welded high strength steels - to develop fibre laser welding process parameters allowing joining of high steels with satisfactory fracture and metallurgical properties - to elaborate a catalogue of metallurgical, mechanical properties of fibre laser welds in modern high strength steels, allowing the establishment of structure/property relationships - to describe material solidification in fusion zone as a function of fibre laser welding process characteristics and its structural integrity. Partners Organization Country Responsible GKSS-FORSCHUNGSZENTRUM GEESTHACHT GmbH DEUTSCHLAND Dr. Mustafa KOÇAK

163 Summaries of RFCS projects 2003-2012 TGS8 : Steel products and applications for building, construction and industry

RFSP-CT-2010-00024 ECOBRIDGE

Full Title Demonstration of economical bridge solutions based on innovative composite dowels and integrated abutments Info Type of Project Pilot&Demonstration Duration (months) 42 Total Budget 1486251 € Start Date 1/07/2010 EU Contribution 743126 € End Date (actual) 31/12/2013 State Research in progress Summary The knowledge gained in the frame of RFCS projects INTAB and PRECOBEAM has enabled us to elaborate cost effective, environmental friendly and sustainable bridge structures. The objective of this project is the construction of three composite bridges with integral abutments and/ or innovative form of shear transmission – composite dowels. The targeted countries are: Germany, Romania and Poland. The bridges will be instrumented with a variety of strain gages, displacement sensors, and thermocouples to monitor and help in the assessment of structural behaviour, for future application of integral abutment bridges and/or composite dowels. Partners Organization Country Responsible ARCELORMITTAL BELVAL & DIFFERDANGE S.A. LUXEMBOURG Mrs Nicoleta POPA (Project Coord.) COMPANIA NATIONALA DE AUTOSTRAZI SI DRUMURI NAT ROMANIA Dr.Dipl.-Ing. Horatiu SIMION ENERGOPOL SZCZECIN - SA POLAND Mr Krzysztof CHARSZLA EUROPROJEKT GDANSK SPZOO POLAND Mr Krzysztof CHARSZLA RHEINISCH-WESTFÄLISCHE TECHNISCHE HOCHSCHULE AA DEUTSCHLAND Prof. Dr.-Ing. Markus FELDMANN SSF INGENIEURE AG DEUTSCHLAND Dr. Günter SEIDL SSF RO SRL ROMANIA Ass Prof Dr Ing Edward PETZEK TWT SANIERUNGSGESELLSCHAFT mbH DEUTSCHLAND Dipl.-Ing. Mirko SCHERPE UNIVERSITATEA POLITEHNICA DIN TIMISOARA ROMANIA Prof. Dr.-Ing. Radu BANCILA POLITECHNIKA WROCLAWSKA - WROCLAW UNIVERSITY O POLAND Dr.-Ing. Wojciech LORENC

RFSR-CT-2003-00010 HYBLAS

Full Title Economical and safe laser hybrid welding of structural steel Info Type of Project Research Duration (months) 46 Total Budget 1711491 € Start Date 1/09/2003 EU Contribution 1026895 € End Date (actual) 30/06/2007 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA23867:EN Summary Laser hybrid welding combines the best attributes of laser and arc fusion welding processes. Optimum weld procedures allow welds to be produced which are still characterised by low distortion, high reproducibility and good fatigue performance but the inclusion of the arc fusion process permits greater fit-up tolerance and penetration for lower laser power and hence cost. However there are currently questions concerning both the thickness and steel strength range that the various forms of hybrid welding can operate within and the propensity of the laser element to contain small defects as a consequence of the cooling process. This project will address both of these aspects in order to allow increased commercial exploitation and hence enhance the competitiveness of European industry. Partners Organization Country Responsible TATA STEEL UK LIMITED UNITED KINGDOM Mr Stephen WEBSTER (Project Coord.) CATERPILLAR FRANCE SAS FRANCE Dr. Jean-Jacques JANOSCH FRAUNHOFER GESELLSCHAFT ZUR FOERDERUNG DER AN DEUTSCHLAND Dr. Dirk PETRING FORCE TECHNOLOGY DANMARK Prof. Jens Klaestrup KRISTENSEN INGENIEURBÜRO FÜR WERKSTOFFTECHNIK DEUTSCHLAND Dr.-Ing. Peter LANGENBERG RHEINISCH-WESTFÄLISCHE TECHNISCHE HOCHSCHULE AA DEUTSCHLAND Prof. Dr.-Ing. Wolfgang BLECK

RFSR-CT-2003-00017 EEBIS

Full Title Energy efficient buildings through innovative systems in steel Info Type of Project Research Duration (months) 36 Total Budget 1645606 € Start Date 1/09/2003 EU Contribution 987364 € End Date (actual) 31/08/2006 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA23180:EN Summary Clients and building users demand energy efficient buildings, and governments of a national and European level have introduced regulations to minimise energy use in new buildings to meet CO2 reduction targets. Steel construction is well placed to meet these new energy efficiency targets by developing new products and systems which actively and passively reduce energy consumption in commercial and residential buildings. In this research, it is proposed to: · develop new steel products and systems for energy efficient buildings · provide physical data on the performance of those innovative techniques which actively regulate the energy consumption in buildings · develop structural systems using air and water as the medium for cooling · provide design ‘tools’ for whole building energy assessments · address certain technical issues such as cold bridging through external steelwork, which may effect local and global building performance This work will lead to marketable steel products and systems and to establishing their basic physical performance characteristics. Partners Organization Country Responsible ARCELORMITTAL BELVAL & DIFFERDANGE S.A. LUXEMBOURG Mrs Françoise LECOMTE-LABORY (Project Coord.) ARCELORMITTAL LIEGE RESEARCH SCRL BELGIQUE Mr Laurent GERON FUNDACION TECNALIA RESEARCH & INNOVATION ESPAÑA Mr Alberto BONILLA RAUTARUUKKI OYJ FINLAND Dr. Jyrki KESTI RHEINISCH-WESTFÄLISCHE TECHNISCHE HOCHSCHULE AA DEUTSCHLAND Dipl.-Ing. Bernd DÖRING THE STEEL CONSTRUCTION INSTITUTE LBG UNITED KINGDOM Ms Nancy BADDOO TATA STEEL UK LIMITED UNITED KINGDOM Mr Allan R. GRIFFIN

164 Summaries of RFCS projects 2003-2012 TGS8 : Steel products and applications for building, construction and industry

RFSR-CT-2003-00018 COMBRI

Full Title Competitive steel and composite bridges by innovative steel plated structures Info Type of Project Research Duration (months) 36 Total Budget 1486548 € Start Date 1/09/2003 EU Contribution 891928 € End Date (actual) 31/08/2006 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA23177:EN Summary The objective of this project is to promote and encourage the wider use of steel plated structures in bridges. This will be achieved by cross sections optimised for efficient manufacturing and erection procedures. The research aims at a reduction of the number of stiffeners – thereby simplifying the manufacturing – and at an efficient erection procedure by advanced possibilities for the incremental launching of steel and composite bridges. This improvement in productivity will result in reduced production costs and in a reduced construction time, which will decisively enhance the competitive position of the European steel construction sector. The project includes extensive theoretical and experimental investigations. Partners Organization Country Responsible FORSCHUNGSVEREINIGUNG STAHLANWENDUNG e.V. DEUTSCHLAND Dipl.-Ing. Gregor NUESSE (Project Coord.) AKTIEN-GESELLSCHAFT DER DILLINGER HÜTTENWERKE AG DEUTSCHLAND Dr.-Ing. Falko SCHRÖTER CENTRE TECHNIQUE INDUSTRIEL DE LA CONSTRUCTION M FRANCE Mr Yvan GALEA FUNDACION TECNALIA RESEARCH & INNOVATION ESPAÑA Mr Fernando ESPIGA LULEÅ UNIVERSITY OF TECHNOLOGY SVERIGE Prof. Ove LAGERQVIST RHEINISCH-WESTFÄLISCHE TECHNISCHE HOCHSCHULE AA DEUTSCHLAND Prof. Dr.-Ing. Gerhard SEDLACEK SERVICE D'ETUDES SUR LES TRANSPORTS, LES ROUTES ET FRANCE Mr Joël RAOUL UNIVERSITE DE LIEGE BELGIQUE Dr. Hervé DEGEE UNIVERSITAET STUTTGART DEUTSCHLAND Prof.Dr. Ulrike KUHLMANN

RFSR-CT-2003-00019 SYNPEX

Full Title Advanced load models for synchronous pedestrian excitation and optimised design guidelines for steel footbridges Info Type of Project Research Duration (months) 36 Total Budget 1218758 € Start Date 1/09/2003 EU Contribution 731255 € End Date (actual) 31/08/2006 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA23318:EN Summary Steel footbridges may be susceptible to pedestrian-induced vibrations. Recently a synchronisation phenomenon of pedestrians on vibrating steel bridges (Millennium Bridge, Passerelle Solferino) were observed that results in resonant vibrations and endangers the safety of the structure and of individuals. The mechanism is not sufficiently investigated to be considered in design codes. The over-all objective is the evaluation of advanced load models and optimised design guidelines for engineering practice that lead to economical, reliable and safe design of steel footbridges in the serviceability limit state. The type of pedestrian traffic combined with the probability of occurrence will be taken into account to fulfil the requirements of the present safety concepts. Partners Organization Country Responsible RHEINISCH-WESTFÄLISCHE TECHNISCHE HOCHSCHULE AA DEUTSCHLAND Dr.-Ing. Christoph HEINEMEYER (Project Coord.) CENTRE TECHNIQUE INDUSTRIEL DE LA CONSTRUCTION M FRANCE Mr Dominique SEMIN SBP GmbH - SCHLAICH BERGERMANN & PARTNER DEUTSCHLAND Dr. Mike SCHLAICH UNIVERSIDADE DO PORTO PORTUGAL Prof Alvaro CUNHA

RFSR-CT-2003-00025 ACOUSVIBRA

Full Title High quality acoustic and vibration performance of lightweight steel constructions Info Type of Project Research Duration (months) 40 Total Budget 1447813 € Start Date 1/09/2003 EU Contribution 868688 € End Date (actual) 31/12/2006 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA23319:EN Summary Lightweight construction is often perceived to be inferior to heavy weight concrete or masonry construction. It is, however, increasingly competitive for housing, residential buildings, hospitals, and for façades and modular units in buildings of all types. The determining factors in the decision to use lightweight construction are its acoustic and vibration performance. In this study, both experimental and modern numerical methods will be utilised to produce specifications how to design acoustically and in vibration means convenient lightweight steel constructions. The project will equip engineers with the design guidance they need to carry out realistic assessments of the advantages and disadvantages of different structural solutions. In many cases, the use of lightweight steel will lead to a more cost-effective design solutions than using wood and concrete. Partners Organization Country Responsible RAUTARUUKKI OYJ FINLAND Dr. Jyrki KESTI (Project Coord.) CENTRE SCIENTIFIQUE ET TECHNIQUE DU BATIMENT FRANCE Dipl.-Ing. Michel VILLOT LULEÅ UNIVERSITY OF TECHNOLOGY SVERIGE Prof. Anders AGREN STIFTELSEN SVENSK STALBYGGNADSFORSKNING - STALBY SVERIGE Tech. Lic. Charlotte SVENSSON TENGBERG THE STEEL CONSTRUCTION INSTITUTE LBG UNITED KINGDOM Dr. Stephen HICKS UNIVERSITAT POLITECNICA DE CATALUNYA (UPC) ESPAÑA Dr. Antonio ROGRIGUEZ FERRAN TEKNOLOGIAN TUTKIMUSKESKUS VTT*TECHNIC. RESEARC FINLAND Ph. Lic. Ari SAARINEN

165 Summaries of RFCS projects 2003-2012 TGS8 : Steel products and applications for building, construction and industry

RFSR-CT-2003-00030 FIRESTRUC

Full Title Integrating advanced three-dimensional modelling methodologies for predicting thermo-mechanical behaviour of steel & composite structures subjected to natural fires Info Type of Project Research Duration (months) 40 Total Budget 1417868 € Start Date 1/09/2003 EU Contribution 850721 € End Date (actual) 31/12/2006 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA23200:EN Summary The overall objective of the proposed project is to develop an integrated engineering methodology for determining the structural performance of steel/composite-framed buildings in natural fires. The methodology will be both fundamental and comprehensive, exploiting the advanced capabilities of both computational fluid dynamics (CFD) for predicting the thermal behaviour and finite- element (FE) models for determining the mechanical response of the structure. Systematic validation of the methodology will be carried out considering test data from full-scale fire tests. The methodology will be applied to test cases and impact assessment undertaken. Design guidance will be developed as appropriate. Partners Organization Country Responsible BUILDING RESEARCH ESTABLISHMENT LTD UNITED KINGDOM Prof. Suresh KUMAR (Project Coord.) CENTRE TECHNIQUE INDUSTRIEL DE LA CONSTRUCTION M FRANCE Dr. Daniel JOYEUX ProfilARBED S.A. LUXEMBOURG Mr Olivier VASSART TNO, NEDERLANDSE ORG. VOOR TOEGEPAST NATUURWE NEDERLAND MSc. Joris FELLINGER UNIVERSITE DE LIEGE BELGIQUE Dr. Jean-Marc FRANSSEN

RFSR-CT-2003-00034 PRECIOUS

Full Title Prefabricated composite beam-to-concrete filled tube or partially reinforced-concrete-encased column connections for severe seismic and fire loadings Info Type of Project Research Duration (months) 45 Total Budget 1058877 € Start Date 1/09/2003 EU Contribution 635326 € End Date (actual) 31/05/2007 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA23750:EN Summary The research project foresees design rules, prequalification and promotion of two typologies of ductile and fire-resistant composite beam-to-column joints with columns composed of: 1. partially reinforced-concrete-encased I-section steel profile; 2. concrete filled steel tube. The joints will be the result of a multi-objective advanced design able to guarantee structural, seismic and fire safety and will be conceived as prefabricated components to be cost-effective both from a designer and from an industrial viewpoint. Finally, to optimise prefabrication processes, concrete slabs, reinforced by high ductile bars and electrowelded meshes, will be alternatively cast with: 1. profiled steel sheeting; 2. electrowelded lattice girders. Partners Organization Country Responsible UNIVERSITA DEGLI STUDI DI TRENTO ITALIA Prof Oreste S. BURSI (Project Coord.) ARCELORMITTAL BELVAL & DIFFERDANGE S.A. LUXEMBOURG Mr Mike HALLER BUILDING RESEARCH ESTABLISHMENT LTD UNITED KINGDOM Dr. David MOORE FERRIERE NORD S.P.A. ITALIA Ing. Roberta MALLARDO UNIVERSITE DE LIEGE BELGIQUE Dr. Jean-Marc FRANSSEN UNIVERSIDAD DE NAVARRA ESPAÑA Prof. Eduardo BAYO UNIVERSITA DEGLI STUDI DI PISA ITALIA Dr. Walter SALVATORE

RFSR-CT-2003-00035 VERAPS

Full Title Validation and enhancement of risk assessment procedure for seismic connections Info Type of Project Research Duration (months) 42 Total Budget 1376212 € Start Date 1/09/2003 EU Contribution 825727 € End Date (actual) 28/02/2007 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA22993:EN Summary Earthquakes in the 1990s in USA and Japan resulted in widespread and unpredicted damage to welded beam-to-column connections in rigid frame steel buildings. Heavy sections used in multi-storey buildings in seismic zones are produced by European steelmakers. In order to maintain the competitiveness of the EU in this market it is important that validated methods for specifying steel sections, fabricating connections and assessing safety in service are made available. The project will validate and enhance a recently-published IIW risk assessment approach, and further develop modeling methods for predicting connection behaviour. Fabrication, testing, modeling and reliability analysis will be combined to achieve this aim. Partners Organization Country Responsible TATA STEEL UK LIMITED UNITED KINGDOM Mr Adam BANNISTER (Project Coord.) INSTITUTO DE SOLDADURA E QUALIDADE PORTUGAL Dr. Manuel GOMES ProfilARBED S.A. LUXEMBOURG Mr Toni DEMARCO UNIVERSITE DE LIEGE BELGIQUE Prof. André PLUMIER UNIVERSITÄT KARLSRUHE DEUTSCHLAND Prof. Dr.-Ing. Helmut SAAL

166 Summaries of RFCS projects 2003-2012 TGS8 : Steel products and applications for building, construction and industry

RFSR-CT-2004-00040 BRIDGEPLEX

Full Title Application of duplex stainless steel for welded bridge construction in aggressive environment Info Type of Project Research Duration (months) 36 Total Budget 1365194 € Start Date 1/07/2004 EU Contribution 819117 € End Date (actual) 30/06/2007 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA23595:EN Summary Maintenance costs are a significant item in life cycle of steel bridges in general, of paramount importance in aggressive environments. The use of duplex stainless steels for bridge decks would be a major step forward in providing durable, low maintenance structures, exploiting both their corrosion resistance and high mechanical properties, capable of meeting in full the required structural safety performances. Together with the high cost, a major barrier to the use of duplex steels in welded bridge construction is the lack of experimental data on fatigue strength and technological feasibility, to be assessed in comparison with the vast know how available for traditional steels. As a consequence, Eurocode 3 for bridge design (ENV 1993-2) does not include stainless steel bridges. The objective of the proposed project is to explore the field of the use of duplex stainless steel in welded bridge construction via mechanical testing and numerical analyses, so as to provide indications suitable to form the basis for an upgrade of Eurocode 3 and to allow a reliable Life Cycle Cost analysis for this kind of structures so as to address the best material choice for the future long span suspension bridges. Partners Organization Country Responsible CENTRO SVILUPPO MATERIALI SPA ITALIA Dr. Giuliana ZILLI (Project Coord.) INDUSTEEL CREUSOT SAS FRANCE Dr. Lionel COUDREUSE OMBA IMPIANTI & ENGINEERING S.p.A. ITALIA Dr. Emanuele MAIORANA RHEINISCH-WESTFÄLISCHE TECHNISCHE HOCHSCHULE AA DEUTSCHLAND Prof. Dr.-Ing. Gerhard SEDLACEK UNIVERSITE DE LIEGE BELGIQUE Ir. Carl VROOMEN

RFSR-CT-2004-00041 ETIB

Full Title Enhanced economy of tubular piles by improved buckling design Info Type of Project Research Duration (months) 36 Total Budget 1344409 € Start Date 1/07/2004 EU Contribution 806645 € End Date (actual) 30/06/2007 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA23851:EN Summary The design of cylindrical tubes in piling systems has to consider the limit state of buckling. The application of the general rules for buckling design given in ENV1993-1-6 results in insufficient safety factors for common piling structures. This is due to the fact that the knock-down factors of ENV1993- 1-6 are derived from tests with rigid boundary conditions and a load introduction which is completely different from the situation with the piling structure. The continuous nonlinear support in the soil reduces the imperfection sensitivity. A parametric study considering the interaction of piling and soil will be performed to give improved design rules with satisfactory safety. Partners Organization Country Responsible UNIVERSITÄT KARLSRUHE DEUTSCHLAND Prof. Dr.-Ing. Helmut SAAL (Project Coord.) ARCELOR LUXEMBOURG Dr. Alex SCHMITT ARCELORMITTAL LIEGE RESEARCH SCRL BELGIQUE Ir. Richard KERGEN RAUTARUUKKI OYJ FINLAND Mr Hannu JOKINIEMI UNIVERSITE CATHOLIQUE DE LOUVAIN BELGIQUE Prof. Alain HOLEYMAN

RFSR-CT-2004-00042 INPREST

Full Title Integrated pre-fabricated steel technologies for the multi-storey sector Info Type of Project Research Duration (months) 42 Total Budget 1444367 € Start Date 1/07/2004 EU Contribution 866620 € End Date (actual) 31/12/2007 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA23860:EN Summary Modern steel buildings require a high degree of pre-fabrication and effective integration of the key components. The concept of Open Building systems in steel will be developed, aimed primarily at the multi-storey residential sector. The research will concentrate on providing ‘enabling’ or supporting technologies and on basic performance data to assist in the development of these systems. Effort will be put into standardisation of interfaces between structural and other components such as cladding, services and lifts, and on increasing customisation without compromising manufacturing efficiency. Information Technology is seen as a major driver which will be investigated. The research will lead to the development of new systems involving skeletal, planar and modular components, including supporting design information. Partners Organization Country Responsible RHEINISCH-WESTFÄLISCHE TECHNISCHE HOCHSCHULE AA DEUTSCHLAND Dipl.-Ing. Bernd DÖRING (Project Coord.) ARCELORMITTAL BELVAL & DIFFERDANGE S.A. LUXEMBOURG Mr Olivier VASSART INT. COUNCIL FOR RES. AND INNOVATION IN BUILDING A NEDERLAND Prof. Frits SCHEUBLIN CENTRE TECHNIQUE INDUSTRIEL DE LA CONSTRUCTION M FRANCE Mr Stéphane HERBIN RAUTARUUKKI OYJ FINLAND Mr Ilkka LEHTINEN THE STEEL CONSTRUCTION INSTITUTE LBG UNITED KINGDOM Mr Graham K. RAVEN TATA STEEL UK LIMITED UNITED KINGDOM Mr Colin HARPER

167 Summaries of RFCS projects 2003-2012 TGS8 : Steel products and applications for building, construction and industry

RFSR-CT-2004-00043 NASCENT

Full Title New application of steel in inside coating buildings considering design and acoustic criteria Info Type of Project Research Duration (months) 36 Total Budget 977828 € Start Date 1/07/2004 EU Contribution 586697 € End Date (actual) 30/06/2007 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA23620:EN Summary ECSC projects previously presented to the EC generally approach acoustic applications as complementary studies for design of roofs, columns, ceilings, etc., where the focus is in the design of column links or other type of elements. The objective of this project is to generate new products for coated and mixed steel elements for aesthetic uses in the walls and ceilings members and focused on the new acoustic regulations. Hence the research will be oriented, not simply to achieving a total noise reduction as up to now, but to the new regulations of technical code for buildings. The latter are mandatory requirements regarding reverberating time, which makes it necessary to utilise collaborative coating materials in order to produce the required noise absorption. An excellent opportunity exists for steel to gain market share against alternative products, such as gypsum and other materials, and this proposal aims at this benefit, creating new products based on steel. The main advantage is the ability to use the same material in steel construction, with the same finish aspect and with the enhanced characteristics for energy absorption over a very wide frequency range, which is a very relevant aspect for the customers. Partners Organization Country Responsible UNIVERSIDAD DE LA RIOJA ESPAÑA Prof. Joaquín ORDIERES MERE (Project Coord.) ACERALIA CORPORACION SIDERURGICA S.A. ESPAÑA Mrs Maria José SANCHEZ FORSCHUNGS- UND QUALITÄTSZENTRUM ODERBRÜCKE g DEUTSCHLAND Mr Bernd SCHMOLKE INSTITUTO DE SOLDADURA E QUALIDADE PORTUGAL Dr. Helena GOUVEIA

RFSR-CT-2004-00044 Semi-Comp

Full Title Plastic member capacity of semi-compact steel sections - a more economic design Info Type of Project Research Duration (months) 36 Total Budget 673890 € Start Date 1/07/2004 EU Contribution 404334 € End Date (actual) 30/06/2007 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA23735:EN Summary Capacity in steel structures. Since for this specific group of rolled and welded profiles EUROCODE 3 does not allow to exploit their full capacity, the present project should eliminate this handicap. This will be based on testing, numerical simulations and the development of new design rules. The results of the project would widen the applicability of semi-compact steel profiles due to their increased competitiveness, would reduce the material and energy consumption and would lead to a more economic design of steel structures. Partners Organization Country Responsible TECHNISCHE UNIVERSITAET GRAZ OESTERREICH Prof. Richard GREINER (Project Coord.) ARCELORMITTAL LIEGE RESEARCH SCRL BELGIQUE Mr Emmanuel BORTOLOTTI FELDMANN + WEYNAND GmbH DEUTSCHLAND Dr.-Ing. Klaus WEYNAND UNIVERSITE DE LIEGE BELGIQUE Prof. Jean-Pierre JASPART

RFSR-CT-2004-00045 SEISRACKS

Full Title Storage racks in seismic areas Info Type of Project Research Duration (months) 30 Total Budget 768340 € Start Date 1/12/2004 EU Contribution 461004 € End Date (actual) 31/05/2007 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA23744:EN Summary The proposed research corresponds to the problem of structural safety and design methods with regards to resistance to earthquakes (Section 3.2.2.2, f) in the Proposers Guide). There are now technical limitations in the field of safety and design of storage racks in seismic areas: lack of knowledge on actions challenging the structures, lack of knowledge on structural behaviour in terms of ductility and sliding conditions of the pallets on the racks and lack of Standard Design Codes in Europe. To solve partly these limitation, the objectives of this project are to increase knowledge on actual service conditions of storage racks, to increase knowledge on actual structural behaviour of them and to assess design rules for racks under earthquake conditions. Partners Organization Country Responsible ASSOCIAZIONE FRA I COSTRUTTORI IN ACCIAIO ITALIANI ITALIA Dr.-Ing. Irene ROSIN (Project Coord.) INSTITUTO SUPERIOR TECNICO PORTUGAL Prof. Luis CALADO NATIONAL TECHNICAL UNIVERSITY OF ATHENS HELLAS Prof. Panayotis CARYDIS POLITECNICO DI MILANO ITALIA Prof. Carlo Andrea CASTIGLIONI UNIVERSITE DE LIEGE BELGIQUE Prof. André PLUMIER

RFSR-CT-2004-00046 Robustness

Full Title Robust structures by joint ductility Info Type of Project Research Duration (months) 36 Total Budget 986495 € Start Date 1/07/2004 EU Contribution 591897 € End Date (actual) 30/06/2007 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA23611:EN Summary Progressive failure of the whole structure caused by local damage (e. g. failure of a column caused by a vehicle impact, explosion, fire, earthquake) can be prevented by robust design. Profiting from the inherent ductile behaviour of steel, this project analyses the requirements for robustness and develops new ductile joint solutions to allow for a force redistribution within the structure so that a global collapse of the building is inhibited and structural safety is ensured. Criteria for robust structures, especially concerning steel and composite joints are elaborated and illustrated by drawings in a handbook for easy understanding and realisation by the constructor. Thus the application of steel is encouraged in accordance to future structural demands. 168 Partners Organization Country Responsible UNIVERSITAET STUTTGART DEUTSCHLAND Prof.Dr. Ulrike KUHLMANN (Project Coord.) Summaries of RFCS projects 2003-2012 TGS8 : Steel products and applications for building, construction and industry

ARCELORMITTAL BELVAL & DIFFERDANGE S.A. LUXEMBOURG Mr Toni DEMARCO FELDMANN + WEYNAND GmbH DEUTSCHLAND Dr.-Ing. Klaus WEYNAND UNIVERSITE DE LIEGE BELGIQUE Prof. Jean-Pierre JASPART UNIVERSITA DEGLI STUDI DI TRENTO ITALIA Prof. Riccardo ZANDONINI

RFSR-CT-2004-00047 COSIMB

Full Title Composite column and wall systems for impact and blast resistance Info Type of Project Research Duration (months) 42 Total Budget 1294677 € Start Date 1/07/2004 EU Contribution 776806 € End Date (actual) 31/12/2007 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA23738:EN Summary Composite steel-concrete members provide ideal systems for impact and blast resistance, which have not been utilised to their full potential due to the lack of appropriate investigations, particularly when using high-strength materials. This programme aims to develop design guidance, for members incorporating conventional and/or high-strength materials, under extreme impact and blast loading. The work will involve experimental and theoretical determination of bearing and rotational capacities, coupled with complementary dynamic tests and nonlinear analyses.Evaluation of residual strength/damage will also enable assessment of interactions with probable subsequent loading scenarios, such as ensuing fires, with a view to providing performance-based design procedures. Partners Organization Country Responsible HOCHTIEF CONSTRUCTION AG DEUTSCHLAND Dr. Bernhard HAUKE (Project Coord.) ARCELORMITTAL BELVAL & DIFFERDANGE S.A. LUXEMBOURG Dr. Renata OBIALA IMPERIAL COLLEGE OF SCIENCE, TECHNOLOGY AND MEDI UNITED KINGDOM Prof Ahmed ELGHAZOULI RHEINISCH-WESTFÄLISCHE TECHNISCHE HOCHSCHULE AA DEUTSCHLAND Prof. Dr.-Ing. Gerhard SEDLACEK UNIVERSITÄT KARLSRUHE DEUTSCHLAND Prof. Dr.-Ing. Helmut SAAL

RFSR-CT-2004-00048 SSIF

Full Title Stainless steel in fire Info Type of Project Research Duration (months) 42 Total Budget 885229 € Start Date 1/07/2004 EU Contribution 531137 € End Date (actual) 31/12/2007 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA23745:EN Summary The relatively sparse body of existing data on the behaviour of structural stainless steel at high temperatures suggests that stainless steel performs very well in certain circumstances. This project seeks to develop more comprehensive and economic design guidance on stainless steel structural members and connections in fire, including specific unprotected products meeting the requirements for 30 and 60 minutes fire resistance. The project includes tests on materials, members and connections, numerical analysis and development of design guidance. The comprehensive final report will give design guidance in a suitable format for inclusion in European standards, accompanied by web- based design software. Partners Organization Country Responsible THE STEEL CONSTRUCTION INSTITUTE LBG UNITED KINGDOM Ms Nancy BADDOO (Project Coord.) CENTRO SVILUPPO MATERIALI SPA ITALIA Dr. Francesco FATTORINI CENTRE TECHNIQUE INDUSTRIEL DE LA CONSTRUCTION M FRANCE Dr. Bin ZHAO OUTOKUMPU STAINLESS OY FINLAND Dipl.-Ing. Raimo VIHERMA STIFTELSEN SVENSK STALBYGGNADSFORSKNING - STALBY SVERIGE Dr. Anders OLSSON ARCELORMITTAL STAINLESS FRANCE FRANCE Mr François CONRAD GOTTFRIED WILHELM LEIBNIZ UNIVERSITÄT HANNOVER DEUTSCHLAND Prof. Dr.-Ing. Peter SCHAUMANN TEKNOLOGIAN TUTKIMUSKESKUS VTT*TECHNIC. RESEARC FINLAND Mrs Ala-Outinen TIINA

RFSR-CT-2005-00039 PLASTOTOUGH

Full Title Modern plastic design for steel structures Info Type of Project Research Duration (months) 42 Total Budget 710769 € Start Date 1/07/2005 EU Contribution 426461 € End Date (actual) 31/12/2008 State Research completed, report published on EU Bookshop at (link not yet available) Summary The overall objective of this project is to supply analytical methods, which will provide the quantification of an upper shelf toughness criterion to allow for safe plastic design of steel structures using modern construction steels. Since this criterion is still missing, the plastic design of structural elements is only permitted when the steels used meet extremely severe test requirements, which penalise the use of steel by uneconomical design methods. Therefore the application of this criterion will inevitably lead to increased exploitation and employment of steel in buildings, bridges, pressure vessels, offshore and pipeline structures and thus to the enhancement of the competitiveness of the European industry. Partners Organization Country Responsible RHEINISCH-WESTFÄLISCHE TECHNISCHE HOCHSCHULE AA DEUTSCHLAND Dipl.-Ing. Dirk SCHÄFER (Project Coord.) NATIONAL TECHNICAL UNIVERSITY OF ATHENS HELLAS Prof. Ioannis VAYAS PEINER TRÄGER GmbH DEUTSCHLAND Dipl.-Ing. Marcus LIPPE MATERIÁLOVÝ A METALURGICKÝ VÝZKUM s.r.o. CZECH REPUBLIC Dr. Zdenek KUBON

169 Summaries of RFCS projects 2003-2012 TGS8 : Steel products and applications for building, construction and industry

RFSR-CT-2005-00040 INDUCWELD

Full Title Induction assisted welding technologies in steel utilisation Info Type of Project Research Duration (months) 36 Total Budget 1523500 € Start Date 1/07/2005 EU Contribution 914101 € End Date (actual) 30/06/2008 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA24462:EN Summary Coming from automotive applications, the potential for high strength steel grades to be applied in lightweight construction are more and more required in many industrial sectors as construction, agricultural machinery or shipbuilding industry. However, fundamental metallurgical facts cause these steels to be relatively difficult to weld. The existing limitations, as insufficient fatigue strength caused e.g. by an extreme martensite formation, can be overcome by the use of appropriate welding methods combined with induction heating. Thus, an adaption of weld seam properties to the base materials properties will be enabled. The project results are expected to lead to an increased use of high strength steels and to gain benefit of both cost saving and raw material saving aspects. Partners Organization Country Responsible LASER ZENTRUM HANNOVER e.V. DEUTSCHLAND Dr.-Ing. Dirk HERZOG (Project Coord.) CNH BELGIUM NV BELGIQUE Ing. Luc LEFEBVRE CENTRO SVILUPPO MATERIALI SPA ITALIA Dr.. Maurizio FERSINI DANMARKS TEKNISKE UNIVERSITET DANMARK Mr Jakob Skov NIELSEN FRAUNHOFER GESELLSCHAFT ZUR FOERDERUNG DER AN DEUTSCHLAND Prof Dr Berndt BRENNER MAX-PLANCK-INSTITUT FÜR EISENFORSCHUNG GmbH DEUTSCHLAND Mr HAROLDO PINTO ONDERZOEKSCENTRUM VOOR AANWENDING VAN STAAL BELGIQUE Dr. Ali Ihsan KORUK SCHWEISSTECHNISCHE LEHR-UND VERSUCHSANSTALT HA DEUTSCHLAND Dr.-Ing. Claas BRUNS SALZGITTER MANNESMANN FORSCHUNG GmbH DEUTSCHLAND Dr.-Ing. Matthias HÖFEMANN GOTTFRIED WILHELM LEIBNIZ UNIVERSITÄT HANNOVER DEUTSCHLAND Dr.-Ing. Alexander NIKANOROV

RFSR-CT-2005-00041 INTAB

Full Title Economic and durable design of composite bridges with integral abutments Info Type of Project Research Duration (months) 36 Total Budget 1477233 € Start Date 1/07/2005 EU Contribution 886340 € End Date (actual) 30/06/2008 State Research completed, report published on EU Bookshop at (link not yet available) Summary Bridges are of vital importance to the European infrastructure and economy leading to the request for highly advances and economic structures. Further on the maintenance of bridges is an ever-growing problem for the road administrations. Experience from already constructed bridges with integrated abutments show that the traditional bridges with joints are outclassed, the former being not only less expensive to maintain, but also more affordable to build. The research proposal INTAB investigates on this innovative bridge type and aims on promoting composite bridges with integral abutments. The major objectives of the proposal are to elaborate cost effective, environmental friendly and sustainable bridge structures, to prove their durability in practice and to provide design guidance for competitive construction. Partners Organization Country Responsible RHEINISCH-WESTFÄLISCHE TECHNISCHE HOCHSCHULE AA DEUTSCHLAND Dipl -Ing Daniel PAK (Project Coord.) ARCELORMITTAL BELVAL & DIFFERDANGE S.A. LUXEMBOURG Mrs Nicoleta POPA LULEÅ UNIVERSITY OF TECHNOLOGY SVERIGE Prof. Dr. Lennart ELFGREN RAMBÖLL SVERIGE AB SVERIGE M.Sc. Tore LUNDMARK UNIVERSITE DE LIEGE BELGIQUE Prof. René MAQUOI

RFSR-CT-2005-00042 FATHOMS

Full Title Fatigue behaviour of high strength steels welded joints in offshore and marine systems Info Type of Project Research Duration (months) 36 Total Budget 1334134 € Start Date 1/07/2005 EU Contribution 800480 € End Date (actual) 30/06/2008 State Research completed, report published on EU Bookshop at (link not yet available) Summary Several Standards/Recommendations are available for welded joints fatigue design; such codes can be over conservative, sometimes not accounting for specific in service conditions (e.g. high R values) and not covering high grade steels. Recently the technological evolution, in particular for offshore applications, seems to point out a trend towards an increasing use of high strength/ high quality/high performances welded joints (SMYS 420 MPa) and the need to develop a specific know-how on their fatigue behavior is becoming a crucial issue. The general aim of this proposal is to comply with this request and to contribute to enlarge the Standards applicability. Partners Organization Country Responsible CENTRO SVILUPPO MATERIALI SPA ITALIA Dr. Elisabetta MECOZZI (Project Coord.) INSTITUTO DE SOLDADURA E QUALIDADE PORTUGAL Dr. Helena GOUVEIA SALZGITTER MANNESMANN FORSCHUNG GmbH DEUTSCHLAND Dr.-Ing. Marion ERDELEN-PEPPLER TATA STEEL UK LIMITED UNITED KINGDOM Mr M. LARGE PANEPISTIMIO THESSALIAS*UNIVERSITY OF THESSALY HELLAS Prof. Philip C. PERDIKARIS

170 Summaries of RFCS projects 2003-2012 TGS8 : Steel products and applications for building, construction and industry

RFSR-CT-2006-00028 COSSFIRE

Full Title Connections of steel and composite structures under natural fire conditions Info Type of Project Research Duration (months) 36 Total Budget 1091421 € Start Date 1/07/2006 EU Contribution 654852 € End Date (actual) 30/06/2009 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA25046:EN Summary Based on the existing technical data on standard fire behaviour of steel and composite structure connections, the current proposed project is aimed to investigate in detail the behaviour of connections under natural fire condition by means of: • natural fire heating condition tests on both connection components (bolts and welding) and different types of connections; • advanced numerical modelling and different parametric numerical analysis; Above experimental and numerical investigations will lead to the development of: • simple calculation rules as well as construction details for economic and practical fire design of connections of steel framed buildings • a design guide of steel connections under natural fire condition and for global structural analysis in fire safety engineering Partners Organization Country Responsible CENTRE TECHNIQUE INDUSTRIEL DE LA CONSTRUCTION M FRANCE Dr. Bin ZHAO (Project Coord.) CENTRO SVILUPPO MATERIALI SPA ITALIA Dr. Giuliana ZILLI EFECTIS NEDERLAND B.V. NEDERLAND Dr. Kees BOTH TATA STEEL UK LIMITED UNITED KINGDOM Mr Allan R. GRIFFIN TNO, NEDERLANDSE ORG. VOOR TOEGEPAST NATUURWE NEDERLAND MSc. Joris FELLINGER UNIVERSITE DE LIEGE BELGIQUE Dr. Jean-Marc FRANSSEN

RFSR-CT-2006-00029 FIBLAS

Full Title Improvement in steel utilisation by recent break-through in high-power fibre laser welding Info Type of Project Research Duration (months) 36 Total Budget 1518566 € Start Date 1/07/2006 EU Contribution 911139 € End Date (actual) 30/06/2009 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA25060:EN Summary To join high-strength steels, various laser welding processes are applied. However, these lasers show low flexibility, low efficiency and high costs, which often prohibits their application. To improve this situation, high-power fibre lasers have been recently developed. However, only few experiences in welding exist. To prepare their application, welding equipment and processes will be developed and the process-property-performance relationship will be established for high-strength steels, taking the applications shipbuilding, pipe production and pipelaying. The results are expected to lead to an increased use of high strength steels and to improve cost saving and environmental protection by energy savings. Partners Organization Country Responsible BIAS - BREMER INSTITUT FÜR ANGEWANDTE STRAHLTECH DEUTSCHLAND Dipl.-Ing. Thomas SEEFELD (Project Coord.) L'AIR LIQUIDE SA FRANCE Dr. Francis BRIAND CORINTH PIPEWORKS PIPE INDUSTRY AND REAL ESTATE HELLAS Dr. Athanassios TAZEDAKIS GKSS-FORSCHUNGSZENTRUM GEESTHACHT GmbH DEUTSCHLAND Dr. Mustafa KOÇAK INGENIEURTECHNIK UND MASCHINENBAU GMBH DEUTSCHLAND Mrs Stephanie MÜLLER ONDERZOEKSCENTRUM VOOR AANWENDING VAN STAAL BELGIQUE Dr. Ali Ihsan KORUK SERIMAX SAS FRANCE Mr Damien ROLLOT SCHWEISSTECH. LEHR- UND VERSUCHSANSTALT MECKLEN DEUTSCHLAND Dipl.-Ing. Ulf JASNAU SALZGITTER MANNESMANN FORSCHUNG GmbH DEUTSCHLAND Dr. Steffen-Erich BRUENINGS CRANFIELD UNIVERSITY UNITED KINGDOM Mr David YAPP VIETZ GMBH DEUTSCHLAND Dipl.-Ing. Markus SCHLOSNECK VYSKUMNY USTAV ZVARACSKY - PRIEMYSELNY INSITUT S SLOVAKIA Assoc. Prof. Peter BERNASOVSKY

RFSR-CT-2006-00030 PrECo-Beam

Full Title Prefabricated enduring composite beams based on innovative shear transmission Info Type of Project Research Duration (months) 36 Total Budget 1396401 € Start Date 1/07/2006 EU Contribution 837841 € End Date (actual) 30/06/2009 State Research completed, report published on EU Bookshop at (link not yet available) Summary Composite structures are gaining in importance in Europe. The combination of materials within its specific properties results in very slender and economic constructions. Composite girders permit large spans in slender frame bridges without loss of economy. Due to the high grade of prefabrication in building construction smaller survey heights and shorter construction times are possible. The enduring bearing capacity of composite girders depends on the performance of material and the design of shear connection. A new form of shear transmission - the concrete dowel - permits composite girders without an upper steel flange and an enduring shear connection also of high strength steel with high strength concrete. The PrECo-Beam construction and its application are comparable to existing prefabricated composite systems. With a high surface durability and less sensitivity for fatigue the system comprehends long-lasting advantages. The modular composition moves principal works for the structures and multi-storey building from the site into the workshop, reduces the construction time and improves the quality to reduce maintenance costs. Partners Organization Country Responsible SSF INGENIEURE AG DEUTSCHLAND Dr. Günter SEIDL (Project Coord.) ARCELORMITTAL BELVAL & DIFFERDANGE S.A. LUXEMBOURG Mrs Nicoleta POPA RAMBÖLL SVERIGE AB SVERIGE Prof. Peter COLLIN SERVICE D'ETUDES SUR LES TRANSPORTS, LES ROUTES ET FRANCE Eng. Jacques BERTHELLEMY UNIVERSITE DE LIEGE BELGIQUE Dr. Jean-Marc FRANSSEN UNIVERSITÄT DER BUNDESWEHR MÜNCHEN DEUTSCHLAND Mr Sascha BURGER POLITECHNIKA WROCLAWSKA - WROCLAW UNIVERSITY O POLAND Dr.-Ing. Wojciech LORENC

171 Summaries of RFCS projects 2003-2012 TGS8 : Steel products and applications for building, construction and industry

RFSR-CT-2006-00031 HISTWIN

Full Title High-strength steel tower for wind turbines Info Type of Project Research Duration (months) 36 Total Budget 1393722 € Start Date 1/07/2006 EU Contribution 836234 € End Date (actual) 30/06/2009 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA25127:EN Summary The over all objective is to improve competitiveness of steel towers used to support multi mega-watt wind turbines. An integrated view on the optimization of the whole steel tower is based on an analysis of the limiting criteria that govern wind tower design. Fatigue is one restraint for design of a more economical towers and use of high strength steel. One solution is an improvement of the existing flange detail and another to use of friction type joint to allow higher strains in the shell. A detailed program is conceived to verify these two innovations. Another limitation is shell buckling where the resistance is strongly related to imperfections. An optimal balance between fabrication costs and resistance will be sought. Partners Organization Country Responsible LULEÅ UNIVERSITY OF TECHNOLOGY SVERIGE Prof. Dr. Milan VELJKOVIC (Project Coord.) ARTISTOTLE UNIVERSITY OF THESSALONIKI HELLAS Prof. Dr.-Ing. Charalampos BANIOTOPOULOS GERMANISCHER LLOYD INDUSTRIAL SERVICES GmbH DEUTSCHLAND Dr.-Ing. Torsten FABER REPOWER PORTUGAL - SISTEMAS EÓLICOS SA PORTUGAL Eng. António PONTES RAUTARUUKKI OYJ FINLAND Mr Juha NUUTINEN RHEINISCH-WESTFÄLISCHE TECHNISCHE HOCHSCHULE AA DEUTSCHLAND Prof. Dr.-Ing. Markus FELDMANN UNIVERSIDADE DE COIMBRA PORTUGAL Prof. Dr. Luis SIMOES DA SILVA

RFSR-CT-2006-00032 DETAILS

Full Title Design for optimal life cycle costs (LCC) of high speed railway bridges by enhanced monitoring systems Info Type of Project Research Duration (months) 36 Total Budget 2633572 € Start Date 1/07/2006 EU Contribution 1580142 € End Date (actual) 30/06/2009 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA25075:EN Summary Steel-concrete composite bridges are an important alternative to concrete bridges due to considerable advantages regarding the design, construction time, durability and costs. They are largely exploited in high-speed lines of the European railway networks even if a lot of still open problems in design and management limit their exploiting. The proposal aims to remove actual uncertainties on dynamic effects and interaction phenomena, fatigue loadings, structural modelling, fatigue life and damage assessment. What’s more, such results will allow to set up an innovative design approach, able to minimize life-cycle costs guaranteeing adequate safety level and working conditions. Partners Organization Country Responsible ILVA S.P.A. ITALIA Dr. Aurelio BRACONI (Project Coord.) AKTIEN-GESELLSCHAFT DER DILLINGER HÜTTENWERKE AG DEUTSCHLAND Dr.-Ing. Falko SCHRÖTER BAUHAUS-UNIVERSITÄT WEIMAR DEUTSCHLAND Prof. Dr. Christian BUCHER KATHOLIEKE UNIVERSITEIT LEUVEN BELGIQUE Dr. Guido DE ROECK LMS INTERNATIONAL NV BELGIQUE Dr.-Ir. Bart PEETERS METHODES INGENIERIE OUVRAGES FRANCE Dr. Wasoodev HOORPAH RHEINISCH-WESTFÄLISCHE TECHNISCHE HOCHSCHULE AA DEUTSCHLAND Dr.-Ing. Benno HOFFMEISTER UNIVERSITA DEGLI STUDI DI PISA ITALIA Dr. Walter SALVATORE VCE HOLDING GMBH OESTERREICH Dr. Helmut WENZEL

RFSR-CT-2007-00035 JOINTEC

Full Title Innovative and competitive new joining technology for steel pipes using adhesive bonding Info Type of Project Research Duration (months) 36 Total Budget 1548637 € Start Date 1/07/2007 EU Contribution 929183 € End Date (actual) 30/06/2010 State Research in progress Summary This research work will introduce the pace developments in adhesive bonding technology of recent years into the steel pipe industry. The aim of this project is to increase the competitiveness of European steel pipe industry by developing an innovative and competitive bonding technology for steel pipes distributing gas, water and heat. Objectives: - Development of an efficient, integrated and easy-to-use technique for adhesive bonding of steel pipes based on an interdisciplinary collaboration between leading research institutes, adhesive industry and pipe industry including end users; - Development of guidelines, design calculation methods and non-destructive testing methods including a repair concept for adhesively bonded steel pipes. Partners Organization Country Responsible UNIVERSITÄT PADERBORN DEUTSCHLAND Prof. Dr. Ortwin HAHN (Project Coord.) ARBEITSGEMEINSCHAFT FÜR WÄRME UND HEIZKRAFTWIR DEUTSCHLAND Dipl.-Ing. Rolf BESIER BOHLEN & DOYEN POLSKA Sp. Z.o.o. POLAND Dipl.-Ing. Erwin BEHRENDES CENTRO SVILUPPO MATERIALI SPA ITALIA Mr Andrea BUFALINI GDF SUEZ SA FRANCE Eng. Geoffray WOLVERT SIKA DANMARKS A/S* SIKA-BETON SIKA CUFADAN DANMARK Chem. Eng. Karen KIRKETERP SALZGITTER MANNESMANN LINE PIPE GMBH DEUTSCHLAND Dr. Hendrik LÖBBE SALZGITTER MANNESMANN FORSCHUNG GmbH DEUTSCHLAND Dr. Thomas ORTH

172 Summaries of RFCS projects 2003-2012 TGS8 : Steel products and applications for building, construction and industry

RFSR-CT-2007-00036 INNOGLAST

Full Title Development of innovative steel-glass-structures in respect to structural and architectural design Info Type of Project Research Duration (months) 42 Total Budget 881196 € Start Date 1/07/2007 EU Contribution 528717 € End Date (actual) 31/12/2010 State Research completed, report published on EU Bookshop at (link not yet available) Summary Currently, steel-glass constructions are favourably used in modern architecture. This proposal addresses the design of new and innovative steel-glass-structures in respect to architectural, static-structural and fabrication criteria. Different types of steel-glass constructions are analysed or even newly developed focusing on an optimal structural interaction between steel and glass. The research includes steelsupported glazing systems and the development of a new hybrid steel-glass beam, consisting of steel flanges and a glass web, all of which can be used in facades, roofs, atria etc. Thus, glass is used as a stiffened as well as a full bearing element in steel-glass constructions. Consequently, the research project will produce comprehensive solutions for innovative steel- glass-structures. The need for the projected research is pointed out in the “European Steel Technology Platform” ESTEP 2006 which actually defines the design of steel-glass structures as a short-term research area. Partners Organization Country Responsible RHEINISCH-WESTFÄLISCHE TECHNISCHE HOCHSCHULE AA DEUTSCHLAND Dipl.-Ing. Björn ABELN (Project Coord.) CENTRE SCIENTIFIQUE ET TECHNIQUE DU BATIMENT FRANCE Dr. Adrian PANAIT THE STEEL CONSTRUCTION INSTITUTE LBG UNITED KINGDOM Dr. Stephen HICKS TECHNISCHE UNIVERSITÄT DORTMUND DEUTSCHLAND Prof. Dr.-Ing. Dieter UNGERMANN CESKE VYSOKE UCENI TECHNICKE V PRAZE*CZECH TECHNI CZECH REPUBLIC Ing. CSc. Martina ELIÁŠOVÁ

RFSR-CT-2007-00037 ESE

Full Title Economics of steel framed buildings in Europe Info Type of Project Research Duration (months) 36 Total Budget 645282 € Start Date 1/07/2007 EU Contribution 387169 € End Date (actual) 30/06/2010 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA25124:EN Summary This proposal is intended to provide a web-based costing tool for designers of steel framed buildings in Europe, which will enable them to develop cost-effective steel solutions at the development stages of a project. It will be developed using the latest cost- modelling techniques for the overall building cost, and will include a simple facility for incorporating the latest cost rates. The scope of the tool will include multistorey commercial and residential buildings, and single-storey industrial buildings. No such information is currently available for practitioners, and it is intended that the provision of this will expand the market for steel. Partners Organization Country Responsible THE STEEL CONSTRUCTION INSTITUTE LBG UNITED KINGDOM Dr. Bassam BURGAN (Project Coord.) ARCELORMITTAL BELVAL & DIFFERDANGE S.A. LUXEMBOURG Mr Olivier VASSART BOUWEN MET STAAL NEDERLAND Mr Ralph HAMERLINCK POLITECHNIKA POZNANSKA*POZNAN UNIVERSITY OF TEC POLAND Prof. Andrzej GARSTECKI

RFSR-CT-2007-00038 PRECASTEEL

Full Title Prefabricated steel structures for low-rise buildings in seismic areas Info Type of Project Research Duration (months) 36 Total Budget 2026994 € Start Date 1/07/2007 EU Contribution 1216196 € End Date (actual) 30/06/2010 State Research technically completed; publication in hand Summary Low-rise buildings are obviously extensively used for industrial and commercial activities. Nowadays, most of these buildings are built by prefabricated concrete elements that are well known to suffer from an intrinsic weakness due to low efficiency of connections and a lower ductility performance when subjected to earthquake loading. The proposal aims at defining prefabricated steel solutions for realising single-storey industrial and lowrise commercial buildings in earthquake-prone areas, able to satisfy requirements of industrial and commercial activities. An automated integrated design software with cost-effectiveness analysis module will be realised to favour the use of proposed solutions in common design practice. Partners Organization Country Responsible ILVA S.P.A. ITALIA Dr. Aurelio BRACONI (Project Coord.) FERRIERE NORD S.P.A. ITALIA Dr. Loris BIANCO INSTITUTO DE SOLDADURA E QUALIDADE PORTUGAL Mrs Sandra ESTANISLAU RHEINISCH-WESTFÄLISCHE TECHNISCHE HOCHSCHULE AA DEUTSCHLAND Dr.-Ing. Benno HOFFMEISTER SHELTER ANONYMOS VIOMICHANIKI ETAIRIA EPENDYSEO HELLAS Eng. Prokopis TSINTZOS UNIVERSITA DEGLI STUDI DI CAMERINO*UNIVERSITY OF C ITALIA Prof. Andrea DALL'ASTA UNIVERSIDAD DE NAVARRA ESPAÑA Prof. Eduardo BAYO UNIVERSITA DEGLI STUDI DI PISA ITALIA Dr. Walter SALVATORE PANEPISTIMIO THESSALIAS*UNIVERSITY OF THESSALY HELLAS Dr. Spyros A. KARAMANOS TEKNOLOGIAN TUTKIMUSKESKUS VTT*TECHNIC. RESEARC FINLAND Dr. Ludovic FULOP

173 Summaries of RFCS projects 2003-2012 TGS8 : Steel products and applications for building, construction and industry

RFSR-CT-2007-00039 OPUS

Full Title Optimizing the seismic performance of steel and steel-concrete structures by standardizing material quality control Info Type of Project Research Duration (months) 36 Total Budget 1394388 € Start Date 1/07/2007 EU Contribution 836634 € End Date (actual) 30/06/2010 State Research technically completed; publication in hand Summary Despite modern seismic standards, like Eurocode 8, admit ductile design of steel and composite structures, current European production standards don’t provide adequate limitations on steel mechanical properties limiting free application of such approach. Additional safety factors and design checks, aiming to guarantee optimal plastic hinges’ location, must be foreseen, reducing practical applicability and possible advantages of seismic ductile design. The proposal aims at the definition of harmonised production and structural recommendations specifically for seismic areas, allowing design of ductile structures without any supplementary assessments on materials. Competitiveness, cheapness and safety of steel solutions in earthquake-prone areas will be highly increased. Partners Organization Country Responsible RIVA ACCIAIO SPA ITALIA Dr. Aurelio BRACONI (Project Coord.) ARCELORMITTAL BELVAL & DIFFERDANGE S.A. LUXEMBOURG Mr Boris DONNAY INSTITUT NATIONAL DES SCIENCES APPLIQUEES DE RENNE FRANCE Prof. Mohammed HJIAJ RHEINISCH-WESTFÄLISCHE TECHNISCHE HOCHSCHULE AA DEUTSCHLAND Dr.-Ing. Benno HOFFMEISTER UNIVERSITE DE LIEGE BELGIQUE Dr. Hervé DEGEE UNIVERSITA DEGLI STUDI DI PISA ITALIA Dr. Walter SALVATORE PANEPISTIMIO THESSALIAS*UNIVERSITY OF THESSALY HELLAS Dr. Spyros A. KARAMANOS

RFSR-CT-2007-00040 OPTISTRAIGHT

Full Title Optimisation and improvement of the flame straightening process Info Type of Project Research Duration (months) 36 Total Budget 1108870 € Start Date 1/07/2007 EU Contribution 665322 € End Date (actual) 30/06/2010 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA25120:EN Summary The research proposal “OPTISTRAIGHT” aims at the improvement of the manufacturing process for geometry achieving of elements and members out of structural steel, leading to a significant enhancement of the competitiveness of steel construction elements for the construction, crane, ship and machinery industry. This objective will be achieved by proofing the efficiency and feasibility of the flame straightening procedures to be researched. These procedures will result into more precise geometry, less detrimental effect on the material, less energy input, quicker and healthier production and thus improved economical positions avoiding expensive repair work. Partners Organization Country Responsible RHEINISCH-WESTFÄLISCHE TECHNISCHE HOCHSCHULE AA DEUTSCHLAND Dipl.-Ing. Dirk SCHÄFER (Project Coord.) AKTIEN-GESELLSCHAFT DER DILLINGER HÜTTENWERKE AG DEUTSCHLAND Dr.-Ing. Falko SCHRÖTER ARCELORMITTAL BELVAL & DIFFERDANGE S.A. LUXEMBOURG Mr Boris DONNAY UNIVERSIDAD DE CANTABRIA ESPAÑA Prof. Federico GUTIERREZ-SOLANA UNIVERZA V LJUBLJANI SLOVENIJA Prof. Darko BEG

RFSR-CT-2007-00041 LINESPEC

Full Title Special components and strain based requirements for high strength high pressure pipeline applications Info Type of Project Research Duration (months) 36 Total Budget 2174118 € Start Date 1/07/2007 EU Contribution 1304471 € End Date (actual) 30/06/2010 State Research completed, report published on EU Bookshop at (link not yet available) Summary Aim of the proposal is the development of high performance pipe components and specific technical know-how about the in- service behaviour of large diameter gas pipelines grade X100. Specific goals are: − Development of design tools for optimisation of crack arrestors, which guarantee safe pipeline operation, regarding ductile fracture propagation events; − Development/qualification of hot bends grade X100; − Identification of minimum requirements of ductile steel pipe properties for a safe strainbased design of grade X100 gas pipelines. All these aims will be achieved by an extensive use of both industrial trials / prototype production and small and full scale testing. Partners Organization Country Responsible SALZGITTER MANNESMANN FORSCHUNG GmbH DEUTSCHLAND Dr.-Ing. Marion ERDELEN-PEPPLER (Project Coord.) BP EXPLORATION OPERATING COMPANY LTD UNITED KINGDOM Dr. Norman SANDERSON CENTRO SVILUPPO MATERIALI SPA ITALIA Mr Massimo DI BIAGIO INSTITUTO DE SOLDADURA E QUALIDADE PORTUGAL Dr. Helena GOUVEIA ONDERZOEKSCENTRUM VOOR AANWENDING VAN STAAL BELGIQUE Ir. Frederik VANHEE RHEINISCH-WESTFÄLISCHE TECHNISCHE HOCHSCHULE AA DEUTSCHLAND Prof. Dr.-Ing. Wolfgang BLECK TATA STEEL UK LIMITED UNITED KINGDOM Mr Anthony HORN UNIVERSITEIT GENT BELGIQUE Prof. Rudi DENYS

174 Summaries of RFCS projects 2003-2012 TGS8 : Steel products and applications for building, construction and industry

RFSR-CT-2007-00042 FICEB

Full Title Fire resistance of long span cellular beam made of rolled profiles Info Type of Project Research Duration (months) 36 Total Budget 1621359 € Start Date 1/07/2007 EU Contribution 972816 € End Date (actual) 30/06/2010 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA25122:EN Summary Cellular beams (CB) offer long uninterrupted clear spans, which are ideal for offices. However, increasingly, questions are being asked about the performance of CB in fire and especially, about the performance of the protection material. A uniform European design approach is required to overcome the present lack of knowledge. This should include both protected and unprotected beams fabricated from hot rolled sections. The design approach will be developed using standard furnace fire resistance tests, a large full sized test and numerical simulations. It will lead to reduced amounts of fire protection, more economic designs and an increase use of CB. Partners Organization Country Responsible ARCELORMITTAL BELVAL & DIFFERDANGE S.A. LUXEMBOURG Mr Olivier VASSART (Project Coord.) CENTRE TECHNIQUE INDUSTRIEL DE LA CONSTRUCTION M FRANCE Dr. Bin ZHAO THE STEEL CONSTRUCTION INSTITUTE LBG UNITED KINGDOM Dr. Ian SIMMS UNIVERSITE DE LIEGE BELGIQUE Dr. Jean-Marc FRANSSEN UNIVERSITY OF ULSTER UNITED KINGDOM Dr. Ali NADJAI ASD WESTOK LIMITED UNITED KINGDOM Mr Michael HAWES

RFSR-CT-2007-00043 ROBUST

Full Title Renovation of buildings using steel technologies Info Type of Project Research Duration (months) 36 Total Budget 1286507 € Start Date 1/07/2007 EU Contribution 771904 € End Date (actual) 30/06/2010 State Research completed, report published on EU Bookshop at (link not yet available) Summary ROBUST addresses the renovation and improvement of existing buildings using steel-based technologies. It focuses on the particular issues in residential, industrial and commercial buildings and on techniques such as over-cladding, roof-top extensions and retrofit of timber roofs by steel. The scope of work concentrates on both building technology and building physics questions, particularly where overcladding of the existing building greatly reduces the heat loss through the façade or roof. An economic and sustainability assessment of these techniques will be made. Partners Organization Country Responsible THE STEEL CONSTRUCTION INSTITUTE LBG UNITED KINGDOM Dr. R. Mark LAWSON (Project Coord.) ARCELORMITTAL LIEGE RESEARCH SCRL BELGIQUE Ir. Clarisse MEES CENTRE TECHNIQUE INDUSTRIEL DE LA CONSTRUCTION M FRANCE Mr Stéphane HERBIN POLITECHNIKA RZESZOWSKA IM. I. LUKASIEWICZA - RZESZ POLAND Prof. Aleksander KOZLOWSKI RHEINISCH-WESTFÄLISCHE TECHNISCHE HOCHSCHULE AA DEUTSCHLAND Prof. Dr.-Ing. Markus FELDMANN TATA STEEL UK LIMITED UNITED KINGDOM Mr Allan R. GRIFFIN TEKNOLOGIAN TUTKIMUSKESKUS VTT*TECHNIC. RESEARC FINLAND Mr Jyri NIEMINEN

RFSR-CT-2007-00044 UCoSiF

Full Title Unbraced composite structures in fire Info Type of Project Research Duration (months) 36 Total Budget 1058939 € Start Date 1/07/2007 EU Contribution 635363 € End Date (actual) 30/06/2010 State Research in progress Summary Bracing of buildings is traditionally realized through concrete cores giving lateral support to composite structures, whereas in modern composite buildings unbraced frames are applied. However, current design rules in fire–related part of Eurocode 4 are limited to non–sway buildings with efficient bracing systems. Since there are numerous advantages linked with unbraced composite structures, as enhanced flexibility concerning usable space, simple calculation methods need to be developed allowing for economic design of this structural system. The proposed development of new design tools will be based on numerical and experimental work and should be incorporated in Eurocodes for broad dissemination. Partners Organization Country Responsible GOTTFRIED WILHELM LEIBNIZ UNIVERSITÄT HANNOVER DEUTSCHLAND Prof. Dr.-Ing. Peter SCHAUMANN (Project Coord.) CENTRE TECHNIQUE INDUSTRIEL DE LA CONSTRUCTION M FRANCE Dr. Christophe RENAUD FUNDACION TECNALIA RESEARCH & INNOVATION ESPAÑA Mr Jose A. CHICA HOCHTIEF CONSTRUCTION AG DEUTSCHLAND Dr. Bernhard HAUKE CITY UNIVERSITY UNITED KINGDOM Prof. Dr. Kuldeep VIRDI

RFSR-CT-2007-00050 STEELRETRO

Full Title Steel solutions for seismic retrofit and upgrade of existing constructions Info Type of Project Research Duration (months) 36 Total Budget 2214354 € Start Date 1/07/2007 EU Contribution 1328613 € End Date (actual) 30/06/2010 State Research technically completed; publication in hand Summary The majority of existing buildings are in need of seismic retrofit. The main reasons are: the original design was not optimised with respect to the required safety level, poor construction quality, modifications or enlargements of buildings during their life and increase in the requirements of the seismic design. Even if steel solutions can often be more efficient and economic, their possibilities are practically unknown and their application has been limited to a few particular cases. The aim of the research proposal is to set up steel solutions for the seismic retrofit of existing buildings, furnishing design and construction methodologies, tools for dimensioning of elements and connections as well as for cost estimation.

Partners Organization Country Responsible 175 RIVA ACCIAIO SPA ITALIA Dr. Aurelio BRACONI (Project Coord.) Summaries of RFCS projects 2003-2012 TGS8 : Steel products and applications for building, construction and industry

ARCELORMITTAL BELVAL & DIFFERDANGE S.A. LUXEMBOURG Mr Mike HALLER INSTITUTO DE SOLDADURA E QUALIDADE PORTUGAL Mrs Sandra ESTANISLAU REGIONE TOSCANA ITALIA Arch. Maurizio FERRINI RHEINISCH-WESTFÄLISCHE TECHNISCHE HOCHSCHULE AA DEUTSCHLAND Dr.-Ing. Benno HOFFMEISTER SHELTER ANONYMOS VIOMICHANIKI ETAIRIA EPENDYSEO HELLAS Eng. Prokopis TSINTZOS UNIVERSITA DEGLI STUDI DI PISA ITALIA Dr. Walter SALVATORE UNIVERSITA DEGLI STUDI DI ROMA "LA SAPIENZA" ITALIA Prof. Franco BRAGA PANEPISTIMIO THESSALIAS*UNIVERSITY OF THESSALY HELLAS Dr. Spyros A. KARAMANOS UNIVERSITATEA POLITEHNICA DIN TIMISOARA ROMANIA Prof. Dr. Dan DUBINA TEKNOLOGIAN TUTKIMUSKESKUS VTT*TECHNIC. RESEARC FINLAND Dr. Ludovic FULOP

RFSR-CT-2007-00051 InFaSo

Full Title New market chances for steel structures by innovative fastening solutions Info Type of Project Research Duration (months) 39 Total Budget 773439 € Start Date 1/07/2007 EU Contribution 464063 € End Date (actual) 30/09/2010 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA25100:EN Summary "Innovative Fastening Solutions" (InFaSo) promotes and encourages the wider use of steel in building structures where until now only concrete has been used. This is achieved by simple, efficient joints allowing for quick and easy connection of steel beams / columns to concrete structures with large tolerances. These joints also allow easy removal, strengthening and application for renovation by a simplified manufacturing and an enlargement of the design strength and ductility. The results will be prepared in the form of a handbook and electronic construction aids so that also engineers not used to design in steel are able to implement them. Thus “InFaSo” opens the gate for new market chances for steel structures and decisively enhance the competitive position of the European steel construction sector. Partners Organization Country Responsible UNIVERSITAET STUTTGART DEUTSCHLAND Prof.Dr. Ulrike KUHLMANN (Project Coord.) GABINETE DE INFORMATICA E PROJECTO ASSISTIDO POR PORTUGAL Prof. Dr. Luis SIMOES DA SILVA GOLDBECK WEST GmbH DEUTSCHLAND Dr. Rolf HEDDRICH STAHL + VERBUNDBAU GESELLSCHAFT FÜR INDUSTRIELLE DEUTSCHLAND Dr. Norbert SAUERBORN CESKE VYSOKE UCENI TECHNICKE V PRAZE*CZECH TECHNI CZECH REPUBLIC Prof.-Ing. CSc. Frantisek WALD

RFSR-CT-2008-00032 FUSEIS

Full Title Dissipative devices for seismic resistant steel frames Info Type of Project Research Duration (months) 36 Total Budget 741351 € Start Date 1/07/2008 EU Contribution 444810 € End Date (actual) 30/06/2011 State Research completed, report published on EU Bookshop at Summary Two innovative types of seismic resistant steel frames with dissipative fuses will be developed. The dissipative zones in such frames will be the fuses, while the other parts of the structure will be protected against inelastic deformations. In case of strong earthquakes damage will concentrate only in the fuses, which will be exchangeable. Repair work after a strong seismic event, if needed, will be limited only in replacing the fuses. Experimental and theoretical investigations will be performed to study the response of the fuses as well as the overall frames to cyclic loading. Design guides will be provided. Partners Organization Country Responsible NATIONAL TECHNICAL UNIVERSITY OF ATHENS HELLAS Prof. Ioannis VAYAS (Project Coord.) INSTITUTO SUPERIOR TECNICO PORTUGAL Prof. Luis CALADO POLITECNICO DI MILANO ITALIA Prof. Carlo Andrea CASTIGLIONI RHEINISCH-WESTFÄLISCHE TECHNISCHE HOCHSCHULE AA DEUTSCHLAND Dr.-Ing. Christian MÜLLER SIDENOR SA HELLAS Dipl.-Ing. Dimos KALTEZIOTIS

RFSR-CT-2008-00033 BRiFaG

Full Title Bridge fatigue guidance - meeting sustainable design and assessment Info Type of Project Research Duration (months) 36 Total Budget 1396096 € Start Date 1/07/2008 EU Contribution 837657 € End Date (actual) 30/06/2011 State Research technically completed; publication in hand Summary The service lives of prospective and existing steel and composite bridges are invariably governed by fatigue, making thus their adequate fatigue performance essential for their competitiveness. Unfortunately, actual design rules not only are becoming outdated for the design, both in terms of the coverage of design details and applicability to modern structural analysis methods, but have also never been adapted to address maintenance issues such as inspection and repair. The aim of the proposed research is thus to provide a comprehensive guide for the fatigue design of new and maintenance of old steel bridges. Partners Organization Country Responsible CENTRE TECHNIQUE INDUSTRIEL DE LA CONSTRUCTION M FRANCE Dr. Mladen LUKIĆ (Project Coord.) CHALMERS TEKNISKA HÖGSKOLA AB SVERIGE Prof. Robert KLIGER USTAV TEORETICKE A APLIKOVANE MECH * INST OF THEO CZECH REPUBLIC Ing. PhD. Shota URUSHADZE RAMBÖLL SVERIGE AB SVERIGE Prof. Peter COLLIN RHEINISCH-WESTFÄLISCHE TECHNISCHE HOCHSCHULE AA DEUTSCHLAND Prof. Dr.-Ing. Markus FELDMANN UNIVERSITY OF SURREY UNITED KINGDOM Dr Boulent IMAM

176 Summaries of RFCS projects 2003-2012 TGS8 : Steel products and applications for building, construction and industry

RFSR-CT-2008-00034 AFINOPRO

Full Title Analysis of fitting noise propagation in steel lightweight constructions and design solutions for their prevention Info Type of Project Research Duration (months) 36 Total Budget 802397 € Start Date 1/07/2008 EU Contribution 481438 € End Date (actual) 30/06/2011 State Research in progress Summary Lightweight steel walls used in steel buildings have only a low specific mass per surface unit. Due to their high elasticity module, the steel beams within the walls are excellent sound conductors. Plumbing noises are generated by pressure shocks, and eddy phenomena. So the vibrations of water columns generate covibrations of the walls. This body sound is introduced into the wall mainly by the fastenings and other sound bridges and finally, it is perceived via the walls and ceilings as perceptible fitting noise everywhere. It is a very important criterion for the reserve face to steel housing. Partners Organization Country Responsible FORSCHUNGS- UND QUALITÄTSZENTRUM ODERBRÜCKE g DEUTSCHLAND Dr. Rer. nat. Alvaro CASAJUS (Project Coord.) ARCELORMITTAL CONSTRUCCION ESPANA SL ESPAÑA Ms Maria José SANCHEZ INSTITUTO DE SOLDADURA E QUALIDADE PORTUGAL Mrs Ana BICKER UNIVERSIDAD DE LA RIOJA ESPAÑA Prof. Joaquín ORDIERES MERE UNIVERSIDAD POLITECNICA DE MADRID ESPAÑA Dr.-Ing. Joaquin B. ORDIERES MERE

RFSR-CT-2008-00035 HITUBES

Full Title Design and integrity assessment of high strength tubular structures for extreme loading conditions Info Type of Project Research Duration (months) 42 Total Budget 1432497 € Start Date 1/07/2008 EU Contribution 859497 € End Date (actual) 31/12/2011 State Research technically completed; publication in hand Summary The construction industry is lagging behind other industries concerning the use of high-strength steel (HSS) tubular structures. Though Eurocode 3 Part 1-12 extends its scope to steel grades up to S690/S700MC, many limitations exist at the material, structural and design level. The HITUBES project intends to develop performance-based designs and assessment procedures to make full use of HSS tubes up to S700MC for flexible structures subjected to extreme repeated loads. Necessary tools will be lab and in situ tests, modelling, integrity assessment and maintenance procedures. The ambitious targets are to increase the performance of tubular structures, reduce weights and construction and operating costs. Partners Organization Country Responsible UNIVERSITA DEGLI STUDI DI TRENTO ITALIA Prof Oreste S. BURSI (Project Coord.) CENTRO SVILUPPO MATERIALI SPA ITALIA Dr. Giuliana ZILLI INSTITUTO DE SOLDADURA E QUALIDADE PORTUGAL Dr. Helena GOUVEIA FUNDACION ITMA ESPAÑA Mrs Maria CABAÑAS SWEREA KIMAB AB SVERIGE Dr. Rachel PETTERSSON UNIVERSITE DE LIEGE BELGIQUE Prof. Jean-Pierre JASPART PANEPISTIMIO THESSALIAS*UNIVERSITY OF THESSALY HELLAS Dr. Spyros A. KARAMANOS

RFSR-CT-2008-00036 ROBUSTFIRE

Full Title Robustness of car parks against localised fire Info Type of Project Research Duration (months) 36 Total Budget 1253895 € Start Date 1/07/2008 EU Contribution 752337 € End Date (actual) 30/06/2011 State Research technically completed; publication in hand Summary The increase of the market shares for steel and composite car parks in Europe is somewhat limited by the lack of information on how these structures behave under exceptional localised fire. In the present project, a general philosophy for the design of robust structures against exceptional events will be developed and practical design guidelines for its application to car parks under localised fire will be derived. To achieve this goal, experience will be gained from previous or ongoing RFCS projects related to various individual aspects (temperature distribution, joint behaviour …) and further experimental, numerical and analytical developments will be achieved. Partners Organization Country Responsible UNIVERSITE DE LIEGE BELGIQUE Prof. Jean-Pierre JASPART (Project Coord.) ARCELORMITTAL BELVAL & DIFFERDANGE S.A. LUXEMBOURG Mr Olivier VASSART CENTRE SCIENTIFIQUE ET TECHNIQUE DU BATIMENT FRANCE Ph.D. Dhionis DHIMA CENTRE TECHNIQUE INDUSTRIEL DE LA CONSTRUCTION M FRANCE Dr. Bin ZHAO GREISCH INGENIERIE SA BELGIQUE Dr.-Ir. Vincent DE VILLE DE GOYET IMPERIAL COLLEGE OF SCIENCE, TECHNOLOGY AND MEDI UNITED KINGDOM Prof. Bassam IZZUDDIN UNIVERSIDADE DE COIMBRA PORTUGAL Prof. Dr. Luis SIMOES DA SILVA

177 Summaries of RFCS projects 2003-2012 TGS8 : Steel products and applications for building, construction and industry

RFSR-CT-2008-00037 ATTEL

Full Title Performance-based approaches for high strength tubular columns and connections under earthquake and fire loadings Info Type of Project Research Duration (months) 42 Total Budget 1148829 € Start Date 1/07/2008 EU Contribution 689297 € End Date (actual) 31/12/2011 State Research technically completed; publication in hand Summary The use of high strength steel (HSS) circular hollow sections (CHS) is still limited in the construction industry despite of their excellent structural and architectural properties and the fast development of endpreparation machines. Moreover, although EC3-1- 12 extends its scope to steel grades up to S690/S700MC, limitations exist at the material, structural and design level. The ATTEL project aims at developing performance-based design approaches, where the capacity design – widely used in seismic engineering to avoid brittle failure and to ensure ductile behaviour – will be extended to HSS tubular CHS structures to prevent failure and collapse under both earthquake and fire loading. Partners Organization Country Responsible UNIVERSITE DE LIEGE BELGIQUE Prof. Jean-Pierre JASPART (Project Coord.) CENTRO SVILUPPO MATERIALI SPA ITALIA Dr. Giuliana ZILLI STAHLBAU PICHLER SRL ITALIA Dr. Daniele MAIO PANEPISTIMIO THESSALIAS*UNIVERSITY OF THESSALY HELLAS Dr. Spyros A. KARAMANOS UNIVERSITA DEGLI STUDI DI TRENTO ITALIA Dr.-Eng. Fabio FERRARIO

RFSR-CT-2008-00038 ETHICS

Full Title Energy and thermal improvements for construction in steel Info Type of Project Research Duration (months) 36 Total Budget 1668390 € Start Date 1/07/2008 EU Contribution 1001033 € End Date (actual) 30/06/2011 State Research in progress Summary ETHICS is concerned with evaluating, measuring and improving the thermal and energy performance of steel-clad and steel framed buildings. It will address important building physics and performance issues using both laboratory test methods and by measuring the ‘as built’ performance of real buildings. The project will result in design guidance for commercial, industrial and residential buildings and design tools to assist in assessing and optimising whole building performance. These tools will be calibrated against whole building measurements, obtained from the research. Opportunities for renewable energy and other energy-saving features will be assessed. Partners Organization Country Responsible RHEINISCH-WESTFÄLISCHE TECHNISCHE HOCHSCHULE AA DEUTSCHLAND Dipl.-Ing. Markus KUHNHENNE (Project Coord.) ARCELORMITTAL LIEGE RESEARCH SCRL BELGIQUE Mr Laurent GERON CENTRE DE RECHERCHES METALLURGIQUES ASBL BELGIQUE Mr Pierre ALBART CENTRE TECHNIQUE INDUSTRIEL DE LA CONSTRUCTION M FRANCE Mr Philippe BEGUIN THE STEEL CONSTRUCTION INSTITUTE LBG UNITED KINGDOM Dr. R. Mark LAWSON TATA STEEL RESEARCH & TECHNOLOGY - TEESSIDE TECHN UNITED KINGDOM Mr Ashan KHAN FUNDACION TECNALIA RESEARCH & INNOVATION ESPAÑA Mr Ekain CAGIGAL TEKNOLOGIAN TUTKIMUSKESKUS VTT*TECHNIC. RESEARC FINLAND Dr. Miimu AIRAKSINEN

RFSR-CT-2008-00039 ELEM

Full Title Composite bridges with prefabricated decks Info Type of Project Research Duration (months) 36 Total Budget 1494588 € Start Date 1/07/2008 EU Contribution 896752 € End Date (actual) 30/06/2011 State Research in progress Summary The overall objective is to improve competitiveness of composite bridges by an elaboration of new cost effective, time effective and sustainable bridge structures. To allow for a prefabrication of the concrete deck, a new concept with dry joints and another one with wet-bonded joints between the elements is investigated and developed. The shear transmission between steel and concrete and between the deck elements will be investigated and new solutions will be elaborated and tested. A detailed program is conceived to verify these innovations. As part of this program, their durability and utilisability will be proven to obtain competitive composite bridges. Partners Organization Country Responsible RHEINISCH-WESTFÄLISCHE TECHNISCHE HOCHSCHULE AA DEUTSCHLAND Prof Fabian MÖLLER (Project Coord.) KUNGLIGA TEKNISKA HÖGSKOLAN - THE ROYAL INSTITUTE SVERIGE Prof. PhD. Håkan SUNDQUIST LULEÅ UNIVERSITY OF TECHNOLOGY SVERIGE Dr. Claes FAHLESON RAMBÖLL SVERIGE AB SVERIGE Prof. Peter COLLIN RUUKKI CONSTRUCTION OY FINLAND Mr Tomi HARJU SSF INGENIEURE AG DEUTSCHLAND Dr. Günter SEIDL POLITECHNIKA WROCLAWSKA - WROCLAW UNIVERSITY O POLAND Dr.-Ing. Wojciech LORENC

178 Summaries of RFCS projects 2003-2012 TGS8 : Steel products and applications for building, construction and industry

RFSR-CT-2009-00020 SBRI

Full Title Sustainable steel-composite bridges in built enviornment Info Type of Project Research Duration (months) 36 Total Budget 1459864 € Start Date 1/07/2009 EU Contribution 875918 € End Date (actual) 30/06/2012 State Research in progress Summary Bridges are of vital importance for the European infrastructure network. Due to their significance in the political economy the request for sustainable, meaning highly advanced, costeffective, environmentally friendly and long-living structures is outstanding. The proposal aims at pointing out all the benefits of steel-composite highway bridges regarding sustainability by means of a holistic approach combining Lifecycle Assessment (LCA), Lifecycle Cost (LCC) and Lifecycle Performance (LCP) analysis and thereby promote steel in the bridge construction market. Partners Organization Country Responsible UNIVERSITAET STUTTGART DEUTSCHLAND Prof.Dr. Ulrike KUHLMANN (Project Coord.) AKTIEN-GESELLSCHAFT DER DILLINGER HÜTTENWERKE AG DEUTSCHLAND Dr.-Ing. Falko SCHRÖTER ARCELORMITTAL BELVAL & DIFFERDANGE S.A. LUXEMBOURG Mrs Nicoleta POPA BUNDESANSTALT FÜR STRASSENWESEN DEUTSCHLAND Mr Thomas MAYER BRISA ENGENHARIA E GESTAO SA - BEG PORTUGAL Eng. Paulo BARROS INST. FRANCAIS DES SCIENCES & TECH. DES TRANS., DE L' FRANCE Dr. Christian CREMONA RAMBOLL DANMARK AS DANMARK MSc Lene TORNAES HELBO SERVICE D'ETUDES SUR LES TRANSPORTS, LES ROUTES ET FRANCE Mr Joël RAOUL UNIVERSIDADE DE COIMBRA PORTUGAL Prof. Dr. Luis SIMOES DA SILVA

RFSR-CT-2009-00021 COMPFIRE

Full Title Design of composite joints for improved fire robustness Info Type of Project Research Duration (months) 36 Total Budget 1578814 € Start Date 1/07/2009 EU Contribution 947289 € End Date (actual) 30/06/2012 State Research in progress Summary The objective is to develop a comprehensive component-based design methodology for composite joints against fire, particularly joints between composite beams and the most common composite columns (concrete-filled hollow sections and partially encased open sections). This will enable composite joints to be fire-engineered to the same level as the frame, offering substantial savings while maintaining safety levels. Fire testing is included on composite joint components, isolated composite joints, composite structural subassemblies and demonstration structures, Numerical analyses of temperature development in protected and unprotected composite joint components in natural fires and coupled thermo-structural analyses will foster development of the integrated component-based model, consistent with Eurocode procedures, for composite joints. Partners Organization Country Responsible UNIVERSIDADE DE COIMBRA PORTUGAL Prof. Dr. Luis SIMOES DA SILVA (Project Coord.) DESMO a.s. CZECH REPUBLIC Ing. Petr VELDA LULEÅ UNIVERSITY OF TECHNOLOGY SVERIGE Prof. Dr. Milan VELJKOVIC TATA STEEL RESEARCH & TECHNOLOGY - TEESSIDE TECHN UNITED KINGDOM Mr George KOUTLAS THE UNIVERSITY OF MANCHESTER UNITED KINGDOM Dr. Yong C. WANG CESKE VYSOKE UCENI TECHNICKE V PRAZE*CZECH TECHNI CZECH REPUBLIC Prof.-Ing. CSc. Frantisek WALD THE UNIVERSITY OF SHEFFIELD UNITED KINGDOM Prof. Ian BURGESS

RFSR-CT-2009-00022 INDUSE

Full Title Structural safety of industrial steel tanks, pressure vessels and piping systems under seismic loading Info Type of Project Research Duration (months) 42 Total Budget 1773060 € Start Date 1/07/2009 EU Contribution 1063836 € End Date (actual) 31/12/2012 State Research in progress Summary The INDUSE proposal is motivated by the need of safeguarding the integrity of industrial equipment steel structures (liquid storage tanks, pressure vessels and piping systems), under earthquake loading. Combining experimental work, finite element simulations and analytical studies, INDUSE aims at developing guidelines for the seismic design of industrial equipment, compatible with the Eurocode 8 framework. The proposed guidelines (a) amend the existing EN 1998-4 seismic rules for steel tanks to include some important design topics, and (b) extend those rules for industrial steel pressure vessels and piping. INDUSE provides innovative methodologies for the seismic design of industrial equipment, towards safer construction and operation of industrial facilities. Partners Organization Country Responsible PANEPISTIMIO THESSALIAS*UNIVERSITY OF THESSALY HELLAS Dr. Spyros A. KARAMANOS (Project Coord.) CENTRO SVILUPPO MATERIALI SPA ITALIA Dr. Jan FERINO ETAIRIA VIOMICHANIKIS EREVNAS KAI TECHNOLOGIKIS AN HELLAS Dr. Kalliopi DIAMANTI RHEINISCH-WESTFÄLISCHE TECHNISCHE HOCHSCHULE AA DEUTSCHLAND Dr.-Ing. Benno HOFFMEISTER TECHNIPETROL HELLAS S.A. HELLAS Dr. Jonathan HANCOCK TECHNISCHE UNIVERSITEIT DELFT NEDERLAND Prof Frans S.K. BIJLAARD UNIVERSITA DEGLI STUDI DI TRENTO ITALIA Prof Oreste S. BURSI

179 Summaries of RFCS projects 2003-2012 TGS8 : Steel products and applications for building, construction and industry

RFSR-CT-2009-00023 RUSTEEL

Full Title Effects of corrosion on low-cycle fatigue (seismic) behaviour of high strength steel reinforcing bars Info Type of Project Research Duration (months) 36 Total Budget 1356703 € Start Date 1/07/2009 EU Contribution 814022 € End Date (actual) 30/06/2012 State Research in progress Summary Modern codes allow the design of ductile composite steel-concrete and r.c. structures able to dissipate seismic energy. This required the development of high performance reinforcing steels guaranteeing the necessary plastic resources through hysteretic cycles. Unfortunately, a lot of problems on low-cycle fatigue behaviour of re-bars still exist. In addition, recent studies underlined the detrimental effects of corrosion on ductility, making such problems even worst. Aim of the research is to solve problems related to the assessment of performance of steel reinforcing bars under seismic loadings and to evaluate the influence of corrosion phenomena on their tensile and low-cycle fatigue properties. Partners Organization Country Responsible CONSORZIO PISA RICERCHE SC ARL ITALIA Prof Walter SALVATORE (Project Coord.) FERRIERE NORD S.P.A. ITALIA Dr. Loris BIANCO INSTITUT FÜR STAHLBETONBEWEHRUNG EV DEUTSCHLAND Dr.-Ing. Jörg MOERSCH INSTITUTO DE SOLDADURA E QUALIDADE PORTUGAL Mrs Sandra ESTANISLAU RIVA ACCIAIO SPA ITALIA Dr. Aurelio BRACONI UNIVERSITY OF PATRAS* PANEPISTIMIO PATRON HELLAS Prof Charis APOSTOLOPOULOS

RFSR-CT-2009-00024 HSS-SERF

Full Title High strength steel in seismic resistant building frames Info Type of Project Research Duration (months) 48 Total Budget 1763026 € Start Date 1/07/2009 EU Contribution 1057815 € End Date (actual) 30/06/2013 State Research in progress Summary The aim of the project is to investigate and evaluate the seismic performance of dual-steel building frames, realised from two different steel grades: Mild Carbon Steel (MCS) and High Strength Steel (HSS). Dual-steel structural systems, in which MCS is used in dissipative members while HSS is used in non-dissipative “elastic” members, can be very reliable and cost efficient. The main outcomes of the project will consist in coherent performance based design methodology and relevant design criteria for ductility and overstrength of both members and joint components, as well as joint detailing rules. Partners Organization Country Responsible UNIVERSITATEA POLITEHNICA DIN TIMISOARA ROMANIA Prof. Dr. Dan DUBINA (Project Coord.) GABINETE DE INFORMATICA E PROJECTO ASSISTIDO POR PORTUGAL Prof. Dr. Luis SIMOES DA SILVA RIVA ACCIAIO SPA ITALIA Eng. Alberto TREMEA RAUTARUUKKI OYJ FINLAND Dr. Jyrki KESTI UNIVERSITE DE LIEGE BELGIQUE Prof. Jean-Pierre JASPART UNIVERSITA DEGLI STUDI DI NAPOLI FEDERICO II ITALIA Prof. Dr. Raffaele LANDOLFO UNIVERZA V LJUBLJANI SLOVENIJA Prof. Darko BEG UNIVERSITAET STUTTGART DEUTSCHLAND Prof.Dr. Ulrike KUHLMANN TEKNOLOGIAN TUTKIMUSKESKUS VTT*TECHNIC. RESEARC FINLAND Dr. Ludovic FULOP

RFSR-CT-2009-00025 DUPLEXTANK

Full Title Duplex stainless steel in storage tanks Info Type of Project Research Duration (months) 40 Total Budget 1381030 € Start Date 1/09/2009 EU Contribution 828618 € End Date (actual) 31/12/2012 State Research in progress Summary Corrosion resistance of high strength duplex stainless steels in atmosphere in presence of chloride deposits will be studied in order to promote their proper and safe application for construction of storage tanks and other facilities. Threshold limits in terms of temperature, relative humidity, and deposit composition for low temperature stress corrosion cracking and other forms of localized corrosion will be defined for different duplex grades and optimal welding parameters will be selected. Characterization of service environments, series of laboratory tests, and field exposures will allow issuing models for lifetime prediction and guidelines for storage tank designers, operators, and material providers. Partners Organization Country Responsible INSTITUT DE LA CORROSION SASU FRANCE Dr. Tomas PROSEK (Project Coord.) BELGISCH INSTITUUT VOOR LASTECHNIEK VZW BELGIQUE Ir Eddy DELEU INDUSTEEL CREUSOT SAS FRANCE Dr.-Ing. Jérome PEULTIER OUTOKUMPU STAINLESS AB SVERIGE M. Sc. Lic. Anna IVERSEN STOLT TANKERS BV * STOLT TANKERS & TERMINALS NEDERLAND Mr Tom SNAUWAERT TOTAL PETROCHEMICALS France SA FRANCE Dr. François DUPOIRON

180 Summaries of RFCS projects 2003-2012 TGS8 : Steel products and applications for building, construction and industry

RFSR-CT-2009-00026 INAREIS

Full Title Industrial application of electro-osmosis to reduce environmental impact of steel sheet piles via reuse Info Type of Project Research Duration (months) 36 Total Budget 1092082 € Start Date 1/07/2009 EU Contribution 655248 € End Date (actual) 30/06/2012 State Research in progress Summary Extraction and re-use of sheet piles will result in an essential reduction of the global warming potential and costs. Initial studies show that the pull-out resistance in cohesive soils can be considerably reduced by the application of electro-osmosis. Laboratory and small-scale model tests will be carried out to identify the relevant parameters with reference to soil properties and system configuration. Full-scale extraction tests will be conducted on two sites. Numerical simulations of the electro-chemical effects will be used to establish and validate a prediction model. Technical guidelines will be prepared to foster industrial application and to allow for extraction of piles in soils where it was difficult or even impossible. Partners Organization Country Responsible TECHNISCHE UNIVERSITÄT KAISERSLAUTERN DEUTSCHLAND Prof Christos VRETTOS (Project Coord.) ARCELORMITTAL BELVAL & DIFFERDANGE S.A. LUXEMBOURG Mr Michel BOURDOUXHE DEW PILING LTD UNITED KINGDOM Mr David THOMPSON ELSYCA NV BELGIQUE Dr. Gert NELISSEN GEOTECHNICAL CONSULTING GROUP LTD UNITED KINGDOM Mr Kelvin HIGGINS

RFSR-CT-2009-00027 FADLESS

Full Title Fatigue damage control and assessment for railways bridges Info Type of Project Research Duration (months) 36 Total Budget 2343850 € Start Date 1/07/2009 EU Contribution 1406310 € End Date (actual) 30/06/2012 State Research in progress Summary Fatigue is an important issue for steel and composite railway bridges since they endure million stress cycles during their life. Past studies assessed fatigue resistance of bridges providing the basis for current codes, even if many important factors are not actually covered: in particular fatigue effects due to vibrations and distortions. The project aims to develop a procedure to evaluate structural integrity and remaining fatigue life including vibration/distortion induced effects. To this purpose improved representation of traffic loads and enhanced experimental/numerical techniques will be adopted. Partners Organization Country Responsible CONSORZIO PISA RICERCHE SC ARL ITALIA Dr. Walter SALVATORE (Project Coord.) BAUHAUS-UNIVERSITÄT WEIMAR DEUTSCHLAND Prof. Dr.- Ing. Carsten KÖNKE KATHOLIEKE UNIVERSITEIT LEUVEN BELGIQUE Dr. Guido DE ROECK LMS INTERNATIONAL NV BELGIQUE Dr.-Ir. Bart PEETERS RIVA ACCIAIO SPA ITALIA Dr. Aurelio BRACONI UNIVERSIDADE DO PORTO PORTUGAL Prof Alvaro CUNHA VCE HOLDING GMBH OESTERREICH Dr. Helmut WENZEL

RFSR-CT-2010-00025 INNO-HYCO

Full Title Innovative hybrid and composite steel-concrete structural solutions for building in seismic area Info Type of Project Research Duration (months) 36 Total Budget 1488685 € Start Date 1/07/2010 EU Contribution 893211 € End Date (actual) 30/06/2013 State Research in progress Summary Composite structures are widely used in building construction in seismic areas whereas hybrid solutions are less diffused and require further investigation. The two main hybrid systems considered in the proposal, namely hybrid coupled shear walls and steel frames with reinforced concrete infill walls, suffer from drawbacks due to the damage localization and the connections’ complexity. The proposal aims to define innovative steel-r.c. hybrid systems for the construction of feasible and easy repairable earthquake- proof buildings characterised by effective dissipative mechanisms and excellent serviceability performance. The new systems will be applied to case studies and a complete design procedure will be proposed. Partners Organization Country Responsible UNIVERSITA DEGLI STUDI DI CAMERINO*UNIVERSITY OF C ITALIA Prof. Andrea DALL'ASTA (Project Coord.) CONSORZIO PISA RICERCHE SC ARL ITALIA Prof Walter SALVATORE OCAM SRL* OFFICINA CARPENTERIA METALLICA ITALIA Eng Paolo BONI RHEINISCH-WESTFÄLISCHE TECHNISCHE HOCHSCHULE AA DEUTSCHLAND Dr.-Ing. Benno HOFFMEISTER SHELTER ANONYMOS VIOMICHANIKI ETAIRIA EPENDYSEO HELLAS Eng. Prokopis TSINTZOS UNIVERSITE DE LIEGE BELGIQUE Dr. Hervé DEGEE

181 Summaries of RFCS projects 2003-2012 TGS8 : Steel products and applications for building, construction and industry

RFSR-CT-2010-00026 SAFSS

Full Title Structural applications of ferritic stainless steels Info Type of Project Research Duration (months) 36 Total Budget 1312481 € Start Date 1/07/2010 EU Contribution 787488 € End Date (actual) 30/06/2013 State Research in progress Summary Ferritic stainless steels are low cost, price-stable, corrosion-resistant steels. Although widely used in the automotive and domestic appliance sectors, structural applications are scarce. Ferritic stainless steels are only partially covered by European structural standards. This project will develop the information needed for comprehensive guidance to be included in relevant parts of the Eurocodes and other accompanying standards/guidance. Although the research has general applicability to the use of ferritic stainless steel, there is a particular focus on the following structural application: lattice roof trussed and space frame structures, exposed decking in composite floor systems, signage and security structures. Partners Organization Country Responsible THE STEEL CONSTRUCTION INSTITUTE LBG UNITED KINGDOM Ms Nancy BADDOO (Project Coord.) ACERINOX EUROPA SA ESPAÑA Dr. Maria Victoria MATRES INSTITUT ZA KOVINSKE MATERIALE IN TEHNOLOGIJE SLOVENIJA A/Prof. Matjaz TORKAR OUTOKUMPU STAINLESS OY FINLAND MSc Jukka SÄYNÄJÄKANGAS OVE ARUP & PARTNERS LTD UNITED KINGDOM Mr Graham GEDGE ARCELORMITTAL STAINLESS FRANCE FRANCE Eng Laurent FAIVRE UNIVERSITAT POLITECNICA DE CATALUNYA (UPC) ESPAÑA Dr. Esther REAL TEKNOLOGIAN TUTKIMUSKESKUS VTT*TECHNIC. RESEARC FINLAND M.Sc. Asko TALJA

RFSR-CT-2010-00027 SB_Steel

Full Title Sustainable building project in steel Info Type of Project Research Duration (months) 36 Total Budget 1338407 € Start Date 1/10/2010 EU Contribution 803043 € End Date (actual) 30/09/2013 State Research in progress Summary The proposal aims at improved competitive capacity of the steel construction sector by providing concepts and methods of sustainable steel-intensive building. A science-based approach to sustainability-conscious decision-making will be developed for the early building project phases that are crucial for value and performance of the completed building (predesign/ concept phase), and for the choice of design scheme (preliminary design). The work consists of identification of key indicators of value and performance (emphasising sustainability), methodology to cope with life-cycle performance criteria (incl safety, security, user-comfort), benchmarking and validation of methods, and software both for investigative work and dissemination of results. Partners Organization Country Responsible TEKNOLOGIAN TUTKIMUSKESKUS VTT*TECHNIC. RESEARC FINLAND Mrs Heli KOUKKARI (Project Coord.) ACCIONA INFRAESTRUCTURAS S.A. ESPAÑA Mrs Patricia MARCOS HUIDOBRO ARCELOR LUXEMBOURG Mr Olivier VASSART ARCELORMITTAL LIEGE RESEARCH SCRL BELGIQUE Ir. Giorgia CAROLI ARTISTOTLE UNIVERSITY OF THESSALONIKI HELLAS Prof. Dr.-Ing. Charalampos BANIOTOPOULOS EUROPEAN CONVENTION FOR CONSTRUCTIONAL STEELW BELGIQUE Prof. Dr. Milan VELJKOVIC FUNDACION TECNALIA RESEARCH & INNOVATION ESPAÑA Mr Jose A. CHICA MOSTOSTAL WARSZAWA S.A. POLAND Mr Pawel PONETA UNIVERSIDADE DE COIMBRA PORTUGAL Prof. Dr. Luis SIMOES DA SILVA UNIVERSIDADE DO MINHO PORTUGAL Prof. Luís BRAGANÇA-LOPES UNIVERSITATEA POLITEHNICA DIN TIMISOARA ROMANIA Dr. Viorel UNGUREANU

RFSR-CT-2010-00028 SAFETOWER

Full Title Develop tailored manufacturing safe methods for wind towers erected in remote areas based on an integrated tower concept and optimal use of high strength steels Info Type of Project Research Duration (months) 42 Total Budget 1964383 € Start Date 1/07/2010 EU Contribution 1178631 € End Date (actual) 31/12/2013 State Research in progress Summary The project intends to study new manufacturing solutions for wind steel towers using High Strength Steels (HSS) already used in other applications and newly developed ones. Thus, the project aims to prove that modular, field-assembled panel tower design eliminates transportation restrictions and therefore allows for a much more efficient tower design and steel use. With this design, tower panels can be added to increase the tower base diameter which also enbales the use of thinner wall thickness in larger wind towers. In addition, new tailored manufacturing procedures and mobile factory layout shall be developed to prove tower design feasibility in remote onshore areas. Partners Organization Country Responsible INSTITUTO DE SOLDADURA E QUALIDADE PORTUGAL Eng Eduardo Manuel DIAS LOPES (Project Coord.) CENTRO SVILUPPO MATERIALI SPA ITALIA Dr. Elisabetta MECOZZI GAMESA INNOVATION AND TECHNOLOGY SLU ESPAÑA Dr. Enrique REAL FUNDACION ITMA ESPAÑA Mr Ricardo LEZCANO ONDERZOEKSCENTRUM VOOR AANWENDING VAN STAAL BELGIQUE Dr. Philippe THIBAUX SIAG SCHAAF INDUSTRIE AG DEUTSCHLAND Mr Axel KAISER GOTTFRIED WILHELM LEIBNIZ UNIVERSITÄT HANNOVER DEUTSCHLAND Prof. Dr.-Ing. Peter SCHAUMANN

182 Summaries of RFCS projects 2003-2012 TGS8 : Steel products and applications for building, construction and industry

RFSR-CT-2010-00029 DiSTEEL

Full Title Displacement based seismic design of steel moment resisting frame structures Info Type of Project Research Duration (months) 42 Total Budget 1191346 € Start Date 1/07/2010 EU Contribution 714808 € End Date (actual) 31/12/2013 State Research in progress Summary New seismic design methods are required in order to control the damage expected from earthquakes. DiSTEEL is a research project on the Displacement Based Seismic Design of STEEL Moment Resisting Frame Structures. The main product of the research will be a set of practical performance-based design guidelines for steel moment-resisting frame structures that include performance criteria and a displacement-based design procedure capable of considering different beam-column joint typologies. The research will use existing experimental data and numerous analytical studies to verify the guidelines. The findings will improve confidence in the steel construction industry and increase utilisation of steel in Europe. Partners Organization Country Responsible CENTRO EUROPEO DI FORMAZIONE E RICERCA IN INGEGN ITALIA Prof. Gian Michele CALVI (Project Coord.) CMM - ASSOCIACAO PORTUGUESA DE CONSTRUCAO MET PORTUGAL Prof. Dr. Luis SIMOES DA SILVA CONSORZIO PISA RICERCHE SC ARL ITALIA Prof Walter SALVATORE UNIVERSITA DEGLI STUDI DI NAPOLI FEDERICO II ITALIA Prof. Dr. Raffaele LANDOLFO

RFSR-CT-2010-00030 ADBLAST

Full Title Advanced design methods for BLAST Loaded steel structures Info Type of Project Research Duration (months) 36 Total Budget 1365191 € Start Date 1/07/2010 EU Contribution 819115 € End Date (actual) 30/06/2013 State Research in progress Summary Steel structures and components can provide ideal systems for blast resistance, yet this potential has not been adequately utilised due to lack of appropriate investigations. This project aims to develop fundamental design guidance for blast resistant steel structures, with emphasis on procedures suitable for typical industrial buildings. The work will involve realistic blast tests on key non-structural and structural assemblages, coupled with complementary dynamic material characterisation, nonlinear analyses and comparative quasi-static tests. Findings from the experimental and numerical studies will be used, in conjunction with appropriately assessed loading scenarios and carefully selected structural configurations, to offer reliable performancebased design procedures. Partners Organization Country Responsible RHEINISCH-WESTFÄLISCHE TECHNISCHE HOCHSCHULE AA DEUTSCHLAND Dr.-Ing. Benno HOFFMEISTER (Project Coord.) ARCELORMITTAL BELVAL & DIFFERDANGE S.A. LUXEMBOURG Dr. Renata OBIALA CONSORZIO PISA RICERCHE SC ARL ITALIA Prof Walter SALVATORE HOCHTIEF CONSTRUCTION AG DEUTSCHLAND Dr. André DÜRR IMPERIAL COLLEGE OF SCIENCE, TECHNOLOGY AND MEDI UNITED KINGDOM Prof Ahmed ELGHAZOULI PATRIMONY OF THE ROYAL MILITARY ACADEMY - VERM V BELGIQUE Prof Dr Johnny VANTOMME TNO, NEDERLANDSE ORG. VOOR TOEGEPAST NATUURWE NEDERLAND Prof Dr Ir Ton VROUWENVELDER

RFSR-CT-2010-00031 HISTWIN2

Full Title High steel tubular towers for wind turbines Info Type of Project Research Duration (months) 36 Total Budget 1205051 € Start Date 1/11/2010 EU Contribution 723030 € End Date (actual) 31/10/2013 State Research in progress Summary The use of steel tubular towers for larger wind turbines and higher hub-heights is limited by economical and technological barriers in view of recent advances of the concrete industry. In the present project, new solutions for steel and hybrid towers’ stability and foundations with micro steel piling will be developed. To achieve this goal, experience from the RFCS project HISTWIN (RFS-PR- 05111, 2006-2009) on optimal bolted connection for the particular implementation will be used. Experimental, numerical and analytical study will lead to new market opportunities for tubular towers, where the solution with dominant use of the concrete is competitive nowadays. Partners Organization Country Responsible LULEÅ UNIVERSITY OF TECHNOLOGY SVERIGE Prof. Dr. Milan VELJKOVIC (Project Coord.) ARTISTOTLE UNIVERSITY OF THESSALONIKI HELLAS Prof. Dr.-Ing. Charalampos BANIOTOPOULOS MARTIFER ENERGIA - EQUIPAMENTOS PARA ENERGIA, SA PORTUGAL Eng Antonio PONTES RUUKKI ENGINEERING OY FINLAND Mr Juha NUUTINEN RHEINISCH-WESTFÄLISCHE TECHNISCHE HOCHSCHULE AA DEUTSCHLAND Prof. Dr.-Ing. Markus FELDMANN UNIVERSIDADE DE COIMBRA PORTUGAL Prof. Dr. Luis SIMOES DA SILVA

RFSR-CT-2010-00032 FATWELDHSS

Full Title Improving the fatigue life of high strength steel welded structures by post weld treatments and specific filler material Info Type of Project Research Duration (months) 42 Total Budget 1825436 € Start Date 1/07/2010 EU Contribution 1095263 € End Date (actual) 31/12/2013 State Research in progress Summary This project will develop techniques for improving the performance of welded, high-strength steels (yield strengths of 700 and 960 MPa) at thicknesses of 5-20 mm, for use in fatigue-loaded, welded structures, e.g., construction equipment, transportation vehicles and lifting devices. High frequency impact peening, weld toe laser dressing and low transformation temperature filler material will be examined. Experimental and analytical procedures will assess the benefits and limitations of the selected methods. Full-scale testing will demonstrate industrial viability and cost benefits. Practical implementation guidelines and design recommendations will be disseminated.

Partners Organization Country Responsible 183 ONDERZOEKSCENTRUM VOOR AANWENDING VAN STAAL BELGIQUE Dr. Hany AHMED (Project Coord.) Summaries of RFCS projects 2003-2012 TGS8 : Steel products and applications for building, construction and industry

BUNDESANSTALT FÜR MATERIAL FORSCHUNG UND -PRÜF DEUTSCHLAND Dr.-Ing. Thomas KANNENGIESSER BELGISCH INSTITUUT VOOR LASTECHNIEK VZW BELGIQUE Ing. Johan VEKEMAN LINCOLN SMITWELD BV NEDERLAND Mr Vincent VAN DER MEE SSAB TUNNPLÅT AB SVERIGE Dr. Joachim LARSSON STRESSTECH OY FINLAND Dipl -Ing Markus LAAKKONEN TWI LTD UNITED KINGDOM Prof Stephen MADDOX AALTO-KORKEAKOULUSAATIO (AALTO UNIVERSITY FOUN FINLAND Prof Gary MARQUIS VOLVO CONSTRUCTION EQUIPMENT AB*BOLINDER MUN SVERIGE Mr Yang SHIN

RFSR-CT-2011-00027 GIPIPE

Full Title Safety of buried steel pipelines under ground-induced deformations Info Type of Project Research Duration (months) 36 Total Budget 1821289 € Start Date 1/07/2011 EU Contribution 1092774 € End Date (actual) 30/06/2014 State Research in progress Summary Buried steel pipelines often pass through harsh-environment regions, sometimes close to densely populated areas, and can be subjected to large plastic deformations due to landslides, ground settlements, liquefaction, or fault movement. In the context of strain-based design, consideration of pipe-soil interaction is fundamental for determining extreme ground-induced actions (strain demand), towards pipeline safety. GIPIPE is a multi-discipline project on buried steel pipelines subjected to ground-imposed permanent deformations, through an integrated approach that considers soil-pipe interaction. It involves novel experimental and numerical work, and aims at developing design guidelines, which complement existing design practice, towards ensuring pipeline integrity against geohazards, reducing the risk to the population and the envinronment, increasing pipeline operational reliability, and safeguarding the unhindered transportation of energy (oil & gas) and water resources. Partners Organization Country Responsible PANEPISTIMIO THESSALIAS*UNIVERSITY OF THESSALY HELLAS Dr. Spyros A. KARAMANOS (Project Coord.) CORINTH PIPEWORKS PIPE INDUSTRY AND REAL ESTATE HELLAS Mr Antonios PERGIALIOTIS CENTRO SVILUPPO MATERIALI SPA ITALIA Dr. Jan FERINO NATIONAL TECHNICAL UNIVERSITY OF ATHENS HELLAS Prof. Georgios GAZETAS TEBODIN NETHERLANDS BV - TEBODIN CONSULTANTS & E NEDERLAND Ir. Gert J. DIJKSTRA TECHNISCHE UNIVERSITEIT DELFT NEDERLAND Prof Frans S.K. BIJLAARD

RFSR-CT-2011-00028 TABASCO

Full Title Thermal bridging atlas of steel construction for improved energy efficiency of buildings Info Type of Project Research Duration (months) 36 Total Budget 955122 € Start Date 1/07/2011 EU Contribution 573074 € End Date (actual) 30/06/2014 State Research in progress Summary TABASCO will create a European database of the performance of a wide range of thermal bridges in steel cladding, light steel and modular constructions and steel primary structures. This will involve up to 200 thermal analyses using thermal parameters defined in EN ISO standards. Improvements to current practice will be investigated, including development of thermally broken solutions. Results will be compared to test data in order to calibrate the design parameters. The information will be presented as a compendium of linear and point thermal bridging values for generic steel details with parametric variations, such as steel and insulation thickness Partners Organization Country Responsible THE STEEL CONSTRUCTION INSTITUTE LBG UNITED KINGDOM Dr. Michael SANSOM (Project Coord.) CENTRE TECHNIQUE INDUSTRIEL DE LA CONSTRUCTION M FRANCE Mr Amor BEN LARBI RUUKKI CONSTRUCTION OY FINLAND Dr. Jyrki KESTI RHEINISCH-WESTFÄLISCHE TECHNISCHE HOCHSCHULE AA DEUTSCHLAND Prof. Dr.-Ing. Markus FELDMANN OXFORD BROOKES UNIVERSITY UNITED KINGDOM Prof Raymond G. OGDEN

RFSR-CT-2011-00029 ULCF

Full Title Ultra low cycle fatigue of steel under cyclic high-strain loading conditions Info Type of Project Research Duration (months) 36 Total Budget 2277632 € Start Date 1/07/2011 EU Contribution 1366580 € End Date (actual) 30/06/2014 State Research in progress Summary Steel members subjected to extreme loading conditions (e.g. earthquakes, hurricanes, support settlements, industrial plant shutdown) undergo large deformations, associated with widespread yielding, leading to fracture, either due to monotonic loading or ultra-low-cycle fatigue (ULCF). This project aims at developing innovative computational methodologies that simulate steel material fracture under ultra-low- cycle fatigue following a multiscale approach, with calibration from both micro and macroscale testing. The project focuses on base steel material only and on pipeline applications. Project results (experimental/numerical), will be used to develop design guidelines for strain-based ULCF design, amending current fatigue design practice (EC3, EC8). Partners Organization Country Responsible UNIVERSIDADE DO PORTO PORTUGAL Prof. Antonio Augusto FERNANDES (Project Coord.) CONSORCI CENTRE INTERNACIONAL DE METODES NUMER ESPAÑA Dr. Sergio OLLER CONSORZIO PISA RICERCHE SC ARL ITALIA Prof Walter SALVATORE CENTRO SVILUPPO MATERIALI SPA ITALIA Ing. Tommaso COPPOLA ONDERZOEKSCENTRUM VOOR AANWENDING VAN STAAL BELGIQUE Dr. Ir. Filip VAN DEN ABEELE RHEINISCH-WESTFÄLISCHE TECHNISCHE HOCHSCHULE AA DEUTSCHLAND Prof. Dr.-Ing. Markus FELDMANN SALZGITTER MANNESMANN FORSCHUNG GmbH DEUTSCHLAND Dr. Aida NONN PANEPISTIMIO THESSALIAS*UNIVERSITY OF THESSALY HELLAS Dr. Spyros A. KARAMANOS

184 Summaries of RFCS projects 2003-2012 TGS8 : Steel products and applications for building, construction and industry

RFSR-CT-2011-00030 FIDESC4

Full Title Fire design of steel members with welded ot hot-rolled class 4 cross-section Info Type of Project Research Duration (months) 36 Total Budget 1349851 € Start Date 1/07/2011 EU Contribution 809910 € End Date (actual) 30/06/2014 State Research in progress Summary Steel members with H or I shape class 4 (thin-walled) cross sections, owing to their lightness, are one of the most commonly used structural members in steel constructions. However, their fire design according to actual Eurocode 3 is proved to be very conservative and too approximate. In consequence, within the scope of this project, more accurate and practical fire assessment tools are to be developed for such type of steel members on the basis of both experimental and numerical investigations. These assessment tools not only can improve significantly the simple fire design but will also provide efficient solutions for global structural analysis of steel structures comprising class 4 cross section members with help of advanced fire engineering tools. Partners Organization Country Responsible CENTRE TECHNIQUE INDUSTRIEL DE LA CONSTRUCTION M FRANCE Dr. Bin ZHAO (Project Coord.) DESMO a.s. CZECH REPUBLIC Ing. Petr VELDA LINDAB SA LUXEMBOURG PhD Andrej BELICA FUNDACION TECNALIA RESEARCH & INNOVATION ESPAÑA Mr Jesus DE LA QUINTANA UNIVERSITE DE LIEGE BELGIQUE Dr. Jean-Marc FRANSSEN UNIVERSIDADE DE AVEIRO PORTUGAL Prof. Paulo VILA REAL CESKE VYSOKE UCENI TECHNICKE V PRAZE*CZECH TECHNI CZECH REPUBLIC Ing. PhD. Zdenek SOKOL

RFSR-CT-2011-00031 SEISRACKS2

Full Title Seismic behaviour of steel storage pallet racking systems Info Type of Project Research Duration (months) 36 Total Budget 1442116 € Start Date 1/07/2011 EU Contribution 865269 € End Date (actual) 30/06/2014 State Research in progress Summary European Racking Federation (ERF) is currently developing a preliminary normative document (prFEM 10.2.08) on the base of recent research works. However this document is still far from becoming a Euronorm (EN), in particular due to remaining lacks of knowledge leading to conservative design rules and consequently to strong technical limitations when designing static steel pallet racks with respect to seismic safety. The objective of the proposal is to solve these limitations by increasing knowledge on actual structural behaviour and ductility and to assess design rules for earthquake conditions by full-scale testing and numerical simulation Partners Organization Country Responsible POLITECNICO DI MILANO ITALIA Prof. Carlo Andrea CASTIGLIONI (Project Coord.) COMPUTER CONTROL SYSTEMS SA HELLAS Dr. Ioannis PALAMAS FRITZ SCHÄFER GMBH DEUTSCHLAND Dipl.-Ing. Eugen TALMANN MODULBLOK SPA ITALIA Ing. Leo ROVERE NEDCON MAGAZIJNINRICHTING BV NEDERLAND Ir. Jan-Willem FREDERIKS NATIONAL TECHNICAL UNIVERSITY OF ATHENS HELLAS Dr. George IOANNIDIS RHEINISCH-WESTFÄLISCHE TECHNISCHE HOCHSCHULE AA DEUTSCHLAND Dr.-Ing. Christoph HEINEMEYER SCL ING STRUTTURALE DI STEF CALZOL, S.LACAVALLA, S. S ITALIA Ing. Stefano CALZOLARI STOW INTERNATIONAL NV BELGIQUE Ir Denis JEHIN UNIVERSITE DE LIEGE BELGIQUE Dr. Hervé DEGEE

RFSR-CT-2011-00032 ZEMUSIC

Full Title Zero energy solutions for multifunctional steel intensive commercial buildings Info Type of Project Research Duration (months) 36 Total Budget 928652 € Start Date 1/07/2011 EU Contribution 557191 € End Date (actual) 30/06/2014 State Research in progress Summary The broad commercial objective of this project is the sustainable value creation in steel building technology by addressing the ways in which significant energy reductions can be made in the operation phase of multi-storey commercial buildings. This is achieved by a combination of energy conservation and energy generation through which energy is collected, stored, transformed and combined with renewable energy sources. The focus will be on systems where the building fabric and structure participates actively in the energy balance of the building. The innovative objective is to integrate mechanical and electrical systems (M&E) with new innovative structural systems, and by this, the building design can be optimized as one functional system. The project will address the technical development of integrated systems and will act as the focus for product development. Partners Organization Country Responsible RUUKKI CONSTRUCTION OY FINLAND Dr. Jyrki KESTI (Project Coord.) RHEINISCH-WESTFÄLISCHE TECHNISCHE HOCHSCHULE AA DEUTSCHLAND Prof. Dr.-Ing. Markus FELDMANN DEBRECENI EG, UNIVERSITY OF DEBRECEN - SCHOOL OF I HUNGARY Dr. Tamás CSOKNYAI UNIVERSITY OF SURREY UNITED KINGDOM Prof. Robert LAWSON TEKNOLOGIAN TUTKIMUSKESKUS VTT*TECHNIC. RESEARC FINLAND Mr Jyri NIEMINEN

185 Summaries of RFCS projects 2003-2012 TGS8 : Steel products and applications for building, construction and industry

RFSR-CT-2011-00033 SARCO2

Full Title Requirements for safe and reliable CO² transportation pipeline Info Type of Project Research Duration (months) 36 Total Budget 1774879 € Start Date 1/07/2011 EU Contribution 1064928 € End Date (actual) 30/06/2014 State Research in progress Summary Proposal aim is to develop know-how to enable the determination of steel pipe requirements for anthropogenic CO2 pipelines. Specific goals are: - Definition of toughness requirements of base material to control running ductile fracture propagation. - Definition of requirements to control crack initiation event also considering corrosion and stress corrosion cracking phenomena. - Collect experimental data related to the release of CO2 during a pipeline failure. Full scale testing on real sections of pipeline will be carried out. The proposal will provide sensible improvements to the application of “Carbon Capture, Transportation and Sequestration technology” to reduce Green House Gases emission Partners Organization Country Responsible CENTRO SVILUPPO MATERIALI SPA ITALIA Mr Massimo DI BIAGIO (Project Coord.) CORINTH PIPEWORKS PIPE INDUSTRY AND REAL ESTATE HELLAS Mr Antonios PERGIALIOTIS ENI SPA ITALIA Ing. Carlo Maria SPINELLI EUROPIPE GMBH DEUTSCHLAND Dr. Christoph KALWA GDF SUEZ SA FRANCE Dr. Samuel SAYSSET NATIONAL GRID CARBON LTD UNITED KINGDOM Mr Russell COOPER SALZGITTER MANNESMANN LINE PIPE GMBH DEUTSCHLAND Dr. Holger BRAUER SALZGITTER MANNESMANN FORSCHUNG GmbH DEUTSCHLAND Dr.-Ing. Marion ERDELEN-PEPPLER V&M DEUTSCHLAND GMBH DEUTSCHLAND Mrs Tanja SCHMIDT

RFSR-CT-2011-00034 COMBITUBE

Full Title Bending resistance of steel tubes in combiwalls Info Type of Project Research Duration (months) 36 Total Budget 1413246 € Start Date 1/07/2011 EU Contribution 847948 € End Date (actual) 30/06/2014 State Research in progress Summary The present design rules of Eurocode 3 for tubes in CombiWalls lead to over-conservative and uneconomical designs, because the rules for local buckling are inadequate. Experimental and numerical investigations will be carried to find the bending strength and deformation capacity of spiral welded tubes that are commonly used in CombiWalls, taking proper account of the influences on local buckling of the material behaviour, the structural detailing and the load introduction. Parameter studies will be carried out and safe and economical design rules will be developed that are suitable for implementation by and are available to the relevant Eurocode 3 committees. Partners Organization Country Responsible TECHNISCHE UNIVERSITEIT DELFT NEDERLAND Prof Frans S.K. BIJLAARD (Project Coord.) ARCELORMITTAL BELVAL & DIFFERDANGE S.A. LUXEMBOURG Mr Marc MEYRER BAM INFRACONSULT BV - DEN HAAG INFRADESIGN DONG NEDERLAND Mr Willem GALL KARLSRUHER INSTITUT FÜR TECHNOLOGIE (KIT) DEUTSCHLAND Prof. Dr. Thomas UMMENHOFER THE UNIVERSITY OF EDINBURGH UNITED KINGDOM Prof. Michael ROTTER PANEPISTIMIO THESSALIAS*UNIVERSITY OF THESSALY HELLAS Dr. Spyros A. KARAMANOS

RFSR-CT-2011-00035 FRAMEUP

Full Title Optimization of frames for effective assembling Info Type of Project Research Duration (months) 36 Total Budget 1557277 € Start Date 1/07/2011 EU Contribution 934367 € End Date (actual) 30/06/2014 State Research in progress Summary The project objectives are to develop a concept and make feasibility tests of a new type of execution technique for skeletal system including structurally integrated 3D modules and to establish structural performances of novel joints. The new execution technique starts with assembling of the roof and top floor to realize a rigid body that will be lifted up by lift towers and jacks. This method protects the structure from precipitation and moisture damage during the assembling phase. The research will define limits of applications where the concept is competitive compared to existing building alternatives taking into account complete sustainability assessment. Partners Organization Country Responsible LULEÅ UNIVERSITY OF TECHNOLOGY SVERIGE Prof. Dr. Milan VELJKOVIC (Project Coord.) ACCIONA INFRAESTRUCTURAS S.A. ESPAÑA Dr. Carlo PAULOTTO PARTCONSTRUCTION AB SVERIGE Mr Nils LUNDHOLM RHEINISCH-WESTFÄLISCHE TECHNISCHE HOCHSCHULE AA DEUTSCHLAND Prof. Dr.-Ing. Markus FELDMANN UNIVERSITE DE LIEGE BELGIQUE Prof. Jean-Pierre JASPART UNIVERSIDADE DE COIMBRA PORTUGAL Prof. Dr. Luis SIMOES DA SILVA V&M DEUTSCHLAND GMBH DEUTSCHLAND Dipl.-Ing. Ole JOSAT

186 Summaries of RFCS projects 2003-2012 TGS8 : Steel products and applications for building, construction and industry

RFSR-CT-2012-00023 LOCAFI

Full Title Temperature assesment of a vertical steel member subjected to localised fire Info Type of Project Research Duration (months) 36 Total Budget 951918 € Start Date 1/07/2012 EU Contribution 571150 € End Date (actual) 30/06/2015 State Under process of signature Summary The final objective of this project is to provide designers with scientific evidence, put in design models and, in the future, in the regulations (Eurocodes) that will allow them to design steel columns subjected to localised fires such as those which may arise, for example, in car parks. In fact, at the time being, such evidence, models and regulations exist for beam located under the ceiling, but nothing is available for columns, and this situation may lead to unnecessary and excessive thermal insulation that jeopardizes the competitiveness of whole steel projects. More precisely, the objectives are to provide: 1) Scientific evidence about the thermal attack imposed on a steel column that is surrounded by a local fire or attacked by a local fire situation at a distance from the column, namely the emissivity of the flames of the fire source as a function of the thickness (diameter) of the source and the temperatures in the steel columns. The equations that provide the temperature along the centreline of the source will also be verified; 2) Design equations that allow reproducing this thermal attack as well as the temperatures induced in the column, these depending on the time but also on the elevation in the column. These design models will be published and made available in the public domain, but they will also be implemented in existing software such as OZone and SAFIR for an easier utilisation in design offices. The existing nationally determined parameters will be implemented in OZone which will guarantee easier acceptance of this software in all member states (see objective 3); 3) Rules that form the base of the design equations in order to have them implemented in European regulations (Eurocodes), which will make the models automatically accepted without discussion by the authorities of thedifferent Member States. Partners Organization Country Responsible ARCELORMITTAL BELVAL & DIFFERDANGE S.A. LUXEMBOURG Mr Olivier VASSART (Project Coord.) CENTRE TECHNIQUE INDUSTRIEL DE LA CONSTRUCTION M FRANCE Dr. Christophe THAUVOYE UNIVERSITE DE LIEGE BELGIQUE Dr. Jean-Marc FRANSSEN UNIVERSITATEA POLITEHNICA DIN TIMISOARA ROMANIA Dr. Raul Dan ZAHARIA UNIVERSITY OF ULSTER UNITED KINGDOM Dr. Ali NADJAI

RFSR-CT-2012-00024 HYBRO

Full Title Safe laser hybrid welding of structural steel by robust systems Info Type of Project Research Duration (months) 42 Total Budget 1580997 € Start Date 1/07/2012 EU Contribution 948598 € End Date (actual) 31/12/2015 State Under process of signature Summary For thick section and high strength steel structures, hybrid laser-arc welding offers advantages with respect to precision, metallurgy, controllability, automation or speed and in turn quality and costs. However, earlier projects have shown that the promising new generation of fibre- and disc-lasers suffers from narrower process windows than the traditional CO2-lasers. Based on high speed imaging observations and interaction modelling, the consortium identified that the much shorter laser wavelength and its absorption characteristics can cause instable melt pool movements and poor quality, confining the process window. An innovative laser beam and arc shaping technique will be developed to widen the robustness, accompanied by a new camera-based procedure to track quality defects completely back to their joint edge origins. The consideration and understanding of severe geometrical and metallurgical joint edge variations under production conditions is regarded as a key aspect. The proposal addresses the widening of the robustness of hybrid welding for two large scale demonstrators with challenging joint edge variations, an excavator part and a truck component. In addition the process window for disc- or fibre-lasers up to 20 kW, along with the new robust shaping technique, will be explored for a steel thickness range up to 30 mm, for different join types, and for steel grades up to 790 MPa. Beside comprehensive process parameter development, technique options comparison and process analysis, the study and testing of the fatigue and toughness behaviour of the welds is of importance. Two steel makers, one welding equipment and wire supplier, one construction equipment manufacturer, one truck manufacturer and two academic partners also have the ambition to generalize the findings by developing welding process guidelines and fatigue design rules, to promote efficient welding of steel structures through an advanced, new generation hybrid welding technique. Partners Organization Country Responsible LULEÅ UNIVERSITY OF TECHNOLOGY SVERIGE Prof Alexander KAPLAN (Project Coord.) FRONIUS INTERNATIONAL GMBH OESTERREICH Dr. Herbert STAUFER LIEBHERR France SAS FRANCE Dr. Ralf SPÄTH ONDERZOEKSCENTRUM VOOR AANWENDING VAN STAAL BELGIQUE Ir. Christoph GERRITSEN RHEINISCH-WESTFÄLISCHE TECHNISCHE HOCHSCHULE AA DEUTSCHLAND Mr Ulrich JANSEN SCANIA CV AB SVERIGE Mr Bertil GUSTAFSSON THYSSENKRUPP STEEL EUROPE AG DEUTSCHLAND Mr Maik BOGATSCH

187 Summaries of RFCS projects 2003-2012 TGS8 : Steel products and applications for building, construction and industry

RFSR-CT-2012-00025 FRISCC

Full Title Fire resistance of innovative and slender concrete filled tubular composite columns Info Type of Project Research Duration (months) 36 Total Budget 1659613 € Start Date 1/07/2012 EU Contribution 995768 € End Date (actual) 30/06/2015 State Under process of signature Summary Concrete-filled steel tubular (CFST) members are commonly used as composite columns in modern buildings. However, current guidelines for member design in fire (EN1994-1-2) have been proved to be unsafe once the relative slenderness is higher than 0.5. In addition, the simplified design methods of Eurocode 4 are limited to circular or square CFST columns, while in practice columns with rectangular and elliptical hollow sections or any of the new innovative cross-sections types (hollow steel section with embedded core steel profiles) are being increasingly used because of their architectural aesthetics. Therefore, this project will seek to definitely improve the existing situation by means of the following relevant actions: - First of all, a full understanding of the fire behavior of slender concrete-filled hollow steel section columns of circular and square cross-section will be obtained on the basis of a full range of experimental and numerical investigations. Furthermore, the fire resistance of rectangular and more innovative cross-sections as the elliptical shapes or CFST columns with embedded steel core profiles will be also studied. However, prior to the above investigation, specific preparation works will be conducted in order to ensure the consistency of the scientific approaches to be used in this project. - Secondly, a solid technical background document will be created to support the improved design methods to be included in the future fire part of Eurocode 4 for the fire design of these structural members. - Thirdly, a user-friendly design tool will be developed within the scope of this project in order to facilitate in an enormous way the daily design work of engineers of such type of steel members in fire. Thanks to the new solid design basis which will be produced through the results of this research, the design of slender CFST columns without fire protection will be facilitated what will contribute to extend their usage. Partners Organization Country Responsible UNIVERSITAT POLITÈCNICA DE VALÈNCIA ESPAÑA Prof. Manuel L. ROMERO (Project Coord.) ASOCIACION DE INVESTIGACION DE LAS INDUSTRIAS DE L ESPAÑA Mr Vicente MOLINER CONDUCCIONES Y DERIVADOS SLU ESPAÑA Mr Gorka IGLESIAS CENTRE TECHNIQUE INDUSTRIEL DE LA CONSTRUCTION M FRANCE Dr. Christophe RENAUD IMPERIAL COLLEGE OF SCIENCE, TECHNOLOGY AND MEDI UNITED KINGDOM Dr. Leroy GARDNER UNIVERSIDADE DE COIMBRA PORTUGAL Mr Joao Paulo RODRIGUES GOTTFRIED WILHELM LEIBNIZ UNIVERSITÄT HANNOVER DEUTSCHLAND Prof. Dr.-Ing. Peter SCHAUMANN

RFSR-CT-2012-00026 S+G

Full Title Innovative steel glass composite structures for high-performance building skins Info Type of Project Research Duration (months) 42 Total Budget 1553800 € Start Date 1/07/2012 EU Contribution 932280 € End Date (actual) 31/12/2015 State Under process of signature Summary High-innovation of products is a worldwide key-competitive factor. The most important technological achievements in modern architecture are attained by constructing smart building skins, usually by combining glass and metal (so far mainly aluminum). S+G project studies composite Steel+Glass systems for highperformance skins using revolutionary adhesive junctions meeting requirements of: energetic/structural efficiency, aesthetical high value (free-form design), reuse and recycling. Because of differential thermal expansion with glass, those adhesive junctions are compatible with steel only. This is a keyfactor in the inter- material competition (steel vs. aluminium) and for the competitiveness of the European steel and building industry throughout the world. Partners Organization Country Responsible UNIVERSITA DEGLI STUDI DI PARMA ITALIA Prof. Dr.-Eng. Gianni ROYER CARFAGNI (Project Coord.) CONSORZIO PISA RICERCHE SC ARL ITALIA Prof Walter SALVATORE DOW CORNING EUROPE SA BELGIQUE Dr Patrick VANDEREECKEN RHEINISCH-WESTFÄLISCHE TECHNISCHE HOCHSCHULE AA DEUTSCHLAND Dipl.-Ing. Björn ABELN THYSSENKRUPP ACCIAI SPECIALI TERNI SpA ITALIA Ing. Gianvincenzo SALAMONE TRIMO, INZENIRING IN PROIZVODNJA MONTAZNIH OBJEK SLOVENIJA Mr Denis STEPANCIC THE CHANCELLOR, MASTERS AND SCHOLARS OF THE UNIV UNITED KINGDOM Dr. Mauro OVEREND

RFSR-CT-2012-00027 HIPERCUT

Full Title High performance cut edges in structural steel plates for demanding applications Info Type of Project Research Duration (months) 42 Total Budget 1029948 € Start Date 1/07/2012 EU Contribution 617969 € End Date (actual) 31/12/2015 State Research in progress Summary Many fabrication and design standards place restrictions on the use of cut edges, particularly where the application involves fatigue loading, and do not reflect the capabilities of modern cutting techniques such as laserbeam and plasma-arc. These techniques have advantages in terms of cut edge quality, tolerances, speed and cost. The objective of this project is to quantify the effect of laser and plasma-arc cut edge quality on the fatigue and fracture resistance of HSLA plates. This will enable the optimisation of these cutting processes for demanding applications. Guidance to optimise edge quality and service performance of cut edges specifically for the yellow goods (lifting & excavating) and construction sectors will be developed, although the results will be applicable across all sectors. In the project a range of structural steel plates of 355-890MPa yield stress and thickness 8-25mm will be cut using laser, plasma arc and conventional flame cutting methods, all with varying process parameters. Edge cut quality will be evaluated in terms of HAZ depth and morphology, hardness, surface roughness, micro-cracks and residual stress. The fatigue performance of the edges will be evaluated using a range of specimen designs and SN curves for the different cutting methods/process parameters will be determined. Interrupted fatigue tests will also be carried out followed by electron microscopy to determine the initiating features. Inherent fracture toughness of the HAZ of the cut edges will be measured using a novel laminated specimen design and the initiation, propagation and fracture arrest properties also evaluated. The plastic strain capacity of cut edges will also be determined. Recommendations for a suitable acceptance specification for cut edges will be provided for inclusion in fabrication and design codes. 188 Partners Organization Country Responsible Summaries of RFCS projects 2003-2012 TGS8 : Steel products and applications for building, construction and industry

TATA STEEL UK LIMITED UNITED KINGDOM Mr Adam BANNISTER (Project Coord.) CENTRO DE ESTUDIOS E INVESTIGACIONES TECNICAS ESPAÑA Dr. Antonio MARTIN MEIZOSO SILESIAN UNIVERSITY OF TECHNOLOGY - POLITECHNIKA SL POLAND Prof. Andrzej KLIMPEL UNIVERSIDAD DE CANTABRIA ESPAÑA Mr Sergio CICERO GONZALEZ

RFSR-CT-2012-00028 HILONG

Full Title High strength long span structures Info Type of Project Research Duration (months) 36 Total Budget 1606908 € Start Date 1/07/2012 EU Contribution 925508 € End Date (actual) 30/06/2015 State Research in progress Summary The use of high strength steel (HSS) can lead to a significant reduction in the weight of a steel structure. A lighter structure requires smaller foundations, shorter transportation and construction times, and leads to lower CO2 emissions and energy use. Although HSS have found application in machinery and automotives, they are not widely used in construction because the benefit of reduced weight struggles to outweigh the disadvantages of higher price/tonne, reduced availability and different weld procedures. The purpose of the proposed work is to investigate innovative structural arrangements, design methods and cross-sections which enable the benefit of high strength to be maximised by suppressing buckling and reducing deflection. The study will have a particular focus on long span applications such as stadia, auditoria, exhibition halls etc. The research programme will be informed by close consultation with designers of long span structures throughout the project. The grades of HSS to be studied are S460 and S690. The technical objectives of the work are: 1. To develop more cost-effective design methods which suit the specific material characteristics of HSS 2. To develop design methods for HSS prestressed cable-stayed columns and post-tensioned trusses which enable a greater proportion of the higher strength to be utilised by suppressing buckling and limiting deflection 3. To investigate the structural performance of innovative U-shaped and semi-closed polygonal cross-sections which enable joints to be fabricated more easily 4. To develop comparative designs for two functionally equivalent long span structures, one using HSS and one using conventional structural steel, which demonstrate the potential savings possible using HSS in terms of weight, cost, energy and CO2 emissions 5. To prepare a series of design examples for members and joints which demonstrate the design methods developed. Partners Organization Country Responsible THE STEEL CONSTRUCTION INSTITUTE LBG UNITED KINGDOM Ms Nancy BADDOO (Project Coord.) IMPERIAL COLLEGE OF SCIENCE, TECHNOLOGY AND MEDI UNITED KINGDOM Dr. Leroy GARDNER LULEÅ UNIVERSITY OF TECHNOLOGY SVERIGE Prof. Dr. Milan VELJKOVIC S2 CORPORATION PTY LTD AUSTRALIA Mr Murray ELLEN SWECO STRUCTURES AB SVERIGE Mr Lars CEDERFELDT the UNIVERSITY OF BIRMINGHAM UNITED KINGDOM Prof. Dr.-Ing. Charalampos BANIOTOPOULOS UNIVERSIDADE DE COIMBRA PORTUGAL Prof. Dr. Luis SIMOES DA SILVA V&M DEUTSCHLAND GMBH DEUTSCHLAND Dipl.-Ing. Ole JOSAT

RFSR-CT-2012-00029 ROBUSTIMPACT

Full Title Robust impact design of steel and composite building structures Info Type of Project Research Duration (months) 36 Total Budget 1493344 € Start Date 1/07/2012 EU Contribution 896008 € End Date (actual) 30/06/2015 State Research in progress Summary Within the proposal a new concept for impact design of steel/composite members, which combine the residual strength and the alternate load path method, will be developed. These two fundamental design strategies are integrated in a stepwise procedure to ensure a better resistance against progressive collapse. Within the codes the existing concept for impact design based on stiff member behaviour like for massive concrete columns and ignores the advantages of ductile materials like steel. The main outcome consists in guidelines and tools for advanced impact design of steel/composite structures. Thereby redundancy and safety of steel structures are increased and the application of steel is encouraged in view of future demands. Partners Organization Country Responsible UNIVERSITAET STUTTGART DEUTSCHLAND Prof.Dr. Ulrike KUHLMANN (Project Coord.) ARCELORMITTAL BELVAL & DIFFERDANGE S.A. LUXEMBOURG Dr. Renata OBIALA INSTITUT NATIONAL DES SCIENCES APPLIQUEES DE RENNE FRANCE Prof. Mohammed HJIAJ MATERIALS AND SYSTEMS FOR SAFETY AND SECURITY SPR BELGIQUE Mr Sébastien FLAWINNE RHEINISCH-WESTFÄLISCHE TECHNISCHE HOCHSCHULE AA DEUTSCHLAND Prof. Dr.-Ing. Markus FELDMANN UNIVERSITE DE LIEGE BELGIQUE Prof. Jean-Pierre JASPART UNIVERSITA DEGLI STUDI DI TRENTO ITALIA Prof. Riccardo ZANDONINI

RFSR-CT-2012-00030 DISCCO

Full Title Development of improved shear connection rules in composite beams Info Type of Project Research Duration (months) 36 Total Budget 1533463 € Start Date 1/07/2012 EU Contribution 920077 € End Date (actual) 30/06/2015 State Research in progress Summary This project will develop more economic shear connection rules for use in the design of modern long span composite beams which can be adopted as future changes to EN 1994-1-1. This objective will be achieved by a test programme on composite beams that will be analysed by advanced numerical models, using realistic non– linear material properties and load –slip relationships of the shear connectors. These models will be used to develop new shear connection rules for un-propped beams, highly asymmetric beams, cellular beams and other practical cases not covered by EN1994-1-1. A standard push out test will be devised to determine the resistance and deformation capacity of shear connectors in composite slabs , which will be correlated against the beam tests. Tests on 15m span asymmetric beams with partial shear connection will provide information on the effect of end slip as a function of the bending utilisation of the beam. A related factor is the amount of transverse reinforcement that is needed to control longitudinal splitting along the line of shear connectors. Membrane effects in floor plates will be investigated as they provide a confining effect which can reduce the required amount of reinforcement, particularly for primary beams. Partners Organization Country Responsible THE STEEL CONSTRUCTION INSTITUTE LBG UNITED KINGDOM Dr. R. Mark LAWSON (Project Coord.) ARCELORMITTAL BELVAL & DIFFERDANGE S.A. LUXEMBOURG Dr. Renata OBIALA 189 UNIVERSITY OF BRADFORD UNITED KINGDOM Prof. Dennis LAM Summaries of RFCS projects 2003-2012 TGS8 : Steel products and applications for building, construction and industry

UNIVERSITY OF Luxembourg LUXEMBOURG Prof. Christoph ODENBREIT UNIVERSITAET STUTTGART DEUTSCHLAND Prof.Dr. Ulrike KUHLMANN

RFSR-CT-2012-00031 SMARTCOCO

Full Title Smart composite components - concrete structures reinforced by steel profiles Info Type of Project Research Duration (months) 36 Total Budget 1498710 € Start Date 1/07/2012 EU Contribution 899225 € End Date (actual) 30/06/2015 State Under process of signature Summary The project studies the behaviour of composite steel concrete components in which steel profiles are used to reinforce concrete structures, such as in concrete columns reinforced by several steel sections or in concrete columns reinforced by steel sections over only one storey. Those real world situations are not currently covered by codes. A generic design approach will be proposed and then used to devise experiments which will afterwards serve to validate and calibrate the method. The outcome will be design guidance implementable in Eurocode 2 or 4, as appropriate. Partners Organization Country Responsible UNIVERSITE DE LIEGE BELGIQUE Dr. Hervé DEGEE (Project Coord.) ARCELORMITTAL BELVAL & DIFFERDANGE S.A. LUXEMBOURG Mrs Nicoleta POPA BESIX SA BELGIQUE Mr Jean-Marie DE BEL IMPERIAL COLLEGE OF SCIENCE, TECHNOLOGY AND MEDI UNITED KINGDOM Prof Ahmed ELGHAZOULI INSTITUT NATIONAL DES SCIENCES APPLIQUEES DE RENNE FRANCE Prof. Mohammed HJIAJ PLUMIECS BELGIQUE Prof. Dr. Ir. André PLUMIER

RFSR-CT-2012-00032 SEQBRI

Full Title Performance-based earthquake engineering analysis of short-medium span steel-concrete composite bridges Info Type of Project Research Duration (months) 36 Total Budget 1401959 € Start Date 1/07/2012 EU Contribution 841176 € End Date (actual) 30/06/2015 State Research in progress Summary Nowadays, short-medium span steel-concrete composite I-girder bridges made of hot rolled steel beams are very popular, owing to their short construction time and reduced costs. Moreover, they are very adequate for seismic areas for their limited weight. With regard to static loading, these bridges can be designed based on recent Guidelines; however, seismic loading has not been yet investigated, and thus, they may exhibit damages even in low-seismicity zones. SEQBRI aims at applying the PBEE methodology to these bridges with S355M/N-S460M/N fine grain steels, to provide the foundation for a new generation of European seismic codes and to extend EN1998-1 and EN1998-2. Partners Organization Country Responsible UNIVERSITA' DEGLI STUDI ROMA TRE ITALIA Mr Fabrizio PAOLACCI (Project Coord.) ARCELORMITTAL BELVAL & DIFFERDANGE S.A. LUXEMBOURG Mrs Nicoleta POPA S. STATHOPOULOS - K. FARROS CONSULTING ENGINEERS HELLAS Dr. Stamatios STATHOPOULOS RHEINISCH-WESTFÄLISCHE TECHNISCHE HOCHSCHULE AA DEUTSCHLAND Dr.-Ing. Benno HOFFMEISTER SERVICE D'ETUDES SUR LES TRANSPORTS, LES ROUTES ET FRANCE Dr. Christian CREMONA UNIVERSITA DEGLI STUDI DI TRENTO ITALIA Prof Oreste S. BURSI

RFSR-CT-2012-00033 BATIMASS

Full Title Building in active thermal mass into steel structures Info Type of Project Research Duration (months) 36 Total Budget 1351784 € Start Date 1/07/2012 EU Contribution 811070 € End Date (actual) 30/06/2015 State Under process of signature Summary Thermal inertia (or thermal mass) of the building fabric can reduce internal temperature variations within buildings, depending on the occupancy pattern, and can lead to savings in primary energy consumption. This proposal will investigate the ways in which the thermal inertia of steel structures can be increased by various additional measures, including embedded water pipes in composite floor slabs and use of phase change materials within floors and walls of light steel construction. The sectors of interest are commercial (office) buildings in which cooling to counteract heat gains represents a high proportion of energy use, and residential buildings, where control of over-heating in highly insulated but lightweight building fabric is important. The ways in which thermal inertia can be included in whole building energy models will be investigated. Structural and heat flow tests will be carried out to evaluate the effects of embedded pipes on the performance of composite floors. Whole building tests will be carried out to correlate with the laboratory tests. Partners Organization Country Responsible THE STEEL CONSTRUCTION INSTITUTE LBG UNITED KINGDOM Mr Roland CHUTER (Project Coord.) ARCELORMITTAL BELVAL & DIFFERDANGE S.A. LUXEMBOURG Mr Olivier VASSART DUPONT DE NEMOURS (Luxembourg) SARL LUXEMBOURG Mr Jacques GILBERT RHEINISCH-WESTFÄLISCHE TECHNISCHE HOCHSCHULE AA DEUTSCHLAND Prof. Dr.-Ing. Markus FELDMANN FUNDACION TECNALIA RESEARCH & INNOVATION ESPAÑA Mr Jose A. CHICA OXFORD BROOKES UNIVERSITY UNITED KINGDOM Prof Raymond G. OGDEN TEKNOLOGIAN TUTKIMUSKESKUS VTT*TECHNIC. RESEARC FINLAND Mr Jyri NIEMINEN

190 Summaries of RFCS projects 2003-2012 TGS8 : Steel products and applications for building, construction and industry

RFSR-CT-2012-00034 JOINOX

Full Title Guidelines for use of welded stainless steel in corrosive environments Info Type of Project Research Duration (months) 42 Total Budget 990487 € Start Date 1/09/2012 EU Contribution 594292 € End Date (actual) 29/02/2016 State Under process of signature Summary During welding of stainless steels thermal oxides form and may, unless removed, cause severe reduction in corrosion resistance. They are often the underlying cause behind structural failures and in many applications it is necessary to remove them through combination of cleaning operations. Typical is mechanical cleaning in combination with chemical cleaning, which is time consuming and has a negative environmental impact. Current European standards do not provide specific recommendations on acceptance criteria of weld oxides for specific environments or suggestions on cleaning operations. This project aims to develop a scientifically based guideline to determine fitness for purpose weld oxide surface and suggest appropriate post-weld cleaning strategies. Partners Organization Country Responsible SWEREA KIMAB AB SVERIGE Lic.Tech. Eva JOHANSSON (Project Coord.) FUNDACIO CTM CENTRE TECNOLOGIC- CTM ESPAÑA Dr. Anna GIRONES ESAB AB SVERIGE Dr. Leif KARLSSON MAX-PLANCK-INSTITUT FÜR EISENFORSCHUNG GmbH DEUTSCHLAND Dr. Michael ROHWERDER OUTOKUMPU STAINLESS AB SVERIGE Dr. Rachel PETTERSSON AB SANDVIK MATERIALS TECHNOLOGY SVERIGE Ms Mette FRODIGH TWI LTD UNITED KINGDOM Mr Marcio MILITITSKY

RFSR-CT-2012-00035 BIOGASS

Full Title Innovative and competitive solutions using SS and adhesive bonding in biogas production Info Type of Project Research Duration (months) 36 Total Budget 1316653 € Start Date 1/07/2012 EU Contribution 789992 € End Date (actual) 30/06/2015 State Research in progress Summary Biogas production is essential for effective environmental management and rural development as it is a truly renewable energy source which recycles and valorises waste by producing biogas and bio-fertilizers. In this context, the BiogaSS project intends to go further in making this renewable energy source more sustainable by developing cost effective solutions using stainless steels which, in themselves, are recyclable materials relative to concrete (the most currently used material in biodigesters). Systematic corrosion testing of existing SS grades combined with innovative designs and joining methods are at the core of this research project, thus strengthening the position of SS in the market. Partners Organization Country Responsible METALOGIC AI TECHNOLOGIES & ENGINEERING NV BELGIQUE Dr. Ir Telma CARVALHO (Project Coord.) ACERINOX EUROPA SA ESPAÑA Dr. Maria Victoria MATRES OUTOKUMPU STAINLESS OY FINLAND MSc Jukka SÄYNÄJÄKANGAS THE STEEL CONSTRUCTION INSTITUTE LBG UNITED KINGDOM Ms Nancy BADDOO UNIVERSITÄT DUISBURG-ESSEN DEUTSCHLAND Dr.-Ing. Natalie STRANGHÖNER WELTEC BIOPOWER GMBH DEUTSCHLAND Mr Robert THOLEN

RFSR-CT-2012-00036 RUOSTE

Full Title Rules on high strength steel Info Type of Project Research Duration (months) 36 Total Budget 1563366 € Start Date 1/07/2012 EU Contribution 938021 € End Date (actual) 30/06/2015 State Research in progress Summary The use of high strength steels in civil engineering has been mainly limited to special applications like offshore drilling rigs, pipelines and heavy industrial plants, occasional for bridges and long span trusses. These steels offer many advantages that could be utilized more widely in construction industry: because of weight savings, the carbon footprint is reduced and the reduced material consumption often compensates for the higher raw material price. Additionally, thinner sections mean less welding work, which reduce transportation and fabrication costs. The main objective of Ruoste project is to enhance the competitiveness and provide requirements for larger use of steel grades up to S 960 in a new type of multi-story buildings and industrial halls. Steel grades higher than S 460 and up to S 700 are regimented in EC3-1-12, but some rules are very conservative and hard to fulfil. A special part of the EC3 for HSS has been seen as an obstacle for wider application. Rules limiting the application areas are mainly coming from ductility requirements: the requirements are not completely justified with physical background but proposed based on best available engineering judgement. Tests adequate specimens are evaluated to define the realistic limits of applications. The high demands regarding joints and especially welded connections in EC will be examined, to propose the most economical and sustainable solutions. Advantages of HSS regarding stability issues are taken into account to allow for slender structures and allow for competitive practical applications. In case studies the developed recommendations as well as the actual status of EC will be compared and evaluated focusing on the complete assessment of relevant sustainability. All results achieved will be collected in a design guide with solved numerical examples, to provide comprehensive design aids to structural engineers. Recommendations will be given to widen scope of EC3-1-12 for steel grades up to S 960. Partners Organization Country Responsible RHEINISCH-WESTFÄLISCHE TECHNISCHE HOCHSCHULE AA DEUTSCHLAND Prof. Dr.-Ing. Markus FELDMANN (Project Coord.) BUDAPESTI MUSZAKI ES GAZDASAGTUDOMANYI EGYETE HUNGARY Dr. Laszlo HORVATH LULEÅ UNIVERSITY OF TECHNOLOGY SVERIGE Prof. Dr. Milan VELJKOVIC RAUTARUUKKI OYJ FINLAND Mr Ilkka VALKONEN SSAB EMEA AB SVERIGE Dr. Eva PETURSSON TTY-SAATIO - TAMPERE UNIVERSITY OF TECHNOLOGY FINLAND Dr. Markku HEINISUO AARHUS UNIVERSITET DANMARK Prof. Dr. Kuldeep VIRDI LAPPEENRANTA UNIVERSITY OF TECHNOLOGY - LAPPEENR FINLAND Prof. Timo BJÖRK VOESTALPINE KREMS GMBH OESTERREICH Dr. Alfred SEYR 191 192

Technical Group Steel 9

Factory-wide control, social and environmental issues

The scope of TGS9 includes:

• Instrumentation, control and automation including artificial intelligence and information technologies

• Analytical techniques

• Working conditions and quality of life at the work place

• Energy, water and material flow management

• Ergonomic methods

• Occupational health and safety

• Reduction of exposure to occupational emissions

• Standardisation of testing and evaluation methods

• New processes for sustainable steel production

• Recovery and valorisation by-products

• Techniques for classification and preparation of steel scrap

• Control and protection of the environment in and around the workplace

• Restoration of steelwork sites

• Recovery of spent liquors

• Water treatment

• Life cycle assessment and sustainable products

193 194 Summaries of RFCS projects 2003-2012 TGS9 : Factory-wide control, social and environmental issues

RFCR-CT-2010-00010 ECOWATER

Full Title Enhanced treatment of coke oven plant wastewater Info Type of Project Research Duration (months) 42 Total Budget 1054116 € Start Date 1/07/2010 EU Contribution 632470 € End Date (actual) 31/12/2013 State Research in progress Summary The main objectives of ECOWATER are: - to reduce discharges of priority substances and priority hazardous substances (PS and PHS) in coke oven fluents in order to meet the objectives of the EU Water Framework Directive. - to characterise the behaviour of PS and PHS in the coke oven wastewater treatment proces - to study the chemical and ecological impact of coke oven effluents upon the quality of local river basins - to enhance the efficiency of biological effluent treatment plants through better understanding of the sludge treatment characteristics using novel molecular biology approaches - to investigate the use of advanced photo-oxidation, filtration and adsoption techniques for the abatment of PS and PHS in coke oven effluents. Partners Organization Country Responsible TATA STEEL UK LIMITED UNITED KINGDOM Dr. Eric ARIES (Project Coord.) CENTRO SVILUPPO MATERIALI SPA ITALIA Dr.ssa Daphne MIRABILE THE UNIVERSITY OF SHEFFIELD UNITED KINGDOM Dr. Wei HUANG

RFSP-CT-2007-00045 BOFDEDUST

Full Title Development of effective dedusting of converters by innovative concepts and constructive optimization Info Type of Project Pilot&Demonstration Duration (months) 42 Total Budget 684629 € Start Date 1/07/2007 EU Contribution 273852 € End Date (actual) 31/12/2010 State Research in progress Summary The proposed project will provide strategies to reduce pollutant emissions from BOS processes. Specific objectives are to develop an innovative fume suppression technique that will be tested in combination with optimised suction hoods for the secondary dedusting system of BOS shops, in order to assess the most effective fume capture. The successful completion of this work will enable the steel industry to achieve improved environmental performance in a cost-effective way and will fulfil the programme objectives of conservation of resources and improvement of working conditions. Partners Organization Country Responsible VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Dipl.-Ing. Kersten MARX (Project Coord.) ARCELORMITTAL BREMEN GMBH DEUTSCHLAND Mr Michael WOLLENBERG

RFSP-CT-2007-00046 SensorControPilot

Full Title Implementation of sensor based online control of pickling lines Info Type of Project Pilot&Demonstration Duration (months) 36 Total Budget 814561 € Start Date 1/07/2007 EU Contribution 325825 € End Date (actual) 30/06/2010 State Research completed, report published on EU Bookshop at (link not yet available) Summary A model based control concept to calculate strip speed set points in pickling lines, developed by UniOvi, and an online concentration measurement based on ultrasound technology, developed by BFI, shall be implemented at a pickling line of TKS-RA inline to obtain a demonstration installation for sulphuric acid pickling lines. Furthermore, both technologies shall be combined: online concentration data will be used as relevant data to calculate strip speed set points. The control concept will help to improve strip quality and increase productivity by determining set points for the optimum strip speed with minimum strip defects. Partners Organization Country Responsible VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Dr. Ralf WOLTERS (Project Coord.) THYSSENKRUPP RASSELSTEIN GMBH DEUTSCHLAND Dipl.-Ing. Werner HENNING UNIVERSIDAD DE OVIEDO ESPAÑA Dr. Hilario LOPEZ GARCIA

RFSP-CT-2007-00047 NitrateBio Demo

Full Title Operational demonstration of innovative and sustainable nitrate elimination in stainless steel pickling by higher power biological denitrification technique Info Type of Project Pilot&Demonstration Duration (months) 36 Total Budget 684985 € Start Date 1/07/2007 EU Contribution 273994 € End Date (actual) 30/06/2010 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA25126:EN Summary The most important stainless steel pickling acid in use is the mixture of nitric and hydrofluoric acid. Nitrogenous compounds in the arising pickling process water, have to be eliminated before the disposal of wastewater. In the forerunner project 7210-PR/358 the great advantage by the application of high-power bio-treatment for elimination of nitrate was shown. The industrial application of the developed process by this pilot and demonstration project is completely new and innovative. It is a logical and important step to a zero nitrate emission strategy for pickling with nitric and hydrofluoric acid which helps to save water resources. Partners Organization Country Responsible VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Dr.-Ing. Matthias KOZARISZCZUK (Project Coord.) DEUTSCHE EDELSTAHLWERKE GMBH DEUTSCHLAND Dipl.-Ing. Alex JÜRGEN INSTITUTO DE CIENCIA E TECNOLOGIA DE POLIMEROS AS PORTUGAL Prof. Dr.-Ing. João MOURA BORDADO

195 Summaries of RFCS projects 2003-2012 TGS9 : Factory-wide control, social and environmental issues

RFSP-CT-2007-00048 RAMSCI

Full Title Process based steel cleanliness investigations and rapid metallurgical screening of inclusions by modern PDA techniques Info Type of Project Pilot&Demonstration Duration (months) 42 Total Budget 1766145 € Start Date 1/07/2007 EU Contribution 706458 € End Date (actual) 31/12/2010 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA25153:EN Summary The main goal of this project is to be able to obtain some process control in steelmaking with respect to inclusion characteristics. The pre-requisite for this is state-of-the-art PDA optical emission spectrometry (OES) and advanced data treatment, highly developed in previous projects. The overall workplan is to transfer this technology into actual process control; test, evaluate and improve it to an effective tool. This requires some development in process sampling, OES data collection, data treatment algorithms, artificial intelligence techniques and reference materials (RM) for verification of analytical results. A conservative estimate indicates cost savings of 1 MEuro/Mton; in addition increased competitiveness should mean increased profits. Partners Organization Country Responsible SWEREA KIMAB AB SVERIGE Dr. Arne BENGTSON (Project Coord.) AKTIEN-GESELLSCHAFT DER DILLINGER HÜTTENWERKE AG DEUTSCHLAND Dr. Hans-Uwe SCHMITZ FRAUNHOFER GESELLSCHAFT ZUR FOERDERUNG DER AN DEUTSCHLAND Dr. Reinhard NOLL KUNGLIGA TEKNISKA HÖGSKOLAN - THE ROYAL INSTITUTE SVERIGE Prof. Lage JONSSON OUTOKUMPU STAINLESS AB SVERIGE Dr. Gunilla RUNNSJÖ RIVA ACCIAIO SPA ITALIA Dr.-Ing. Nicola VENERI GERDAU INVESTIGACION Y DESARROLLO EUROPA S.A. ESPAÑA Mr Rafael PIZARRO SSAB EMEA AB SVERIGE Mr Rolf DIDRIKSSON SCUOLA SUPERIORE DI STUDI UNIVERSITARI E DI PERFEZI ITALIA Dr. Valentina COLLA VOESTALPINE STAHL GMBH OESTERREICH Dr. Andreas PISSENBERGER

RFSP-CT-2008-00041 SCRAP PROBE

Full Title On-line bulk composition analysis of steel scrap using PGNAA Info Type of Project Pilot&Demonstration Duration (months) 42 Total Budget 2070834 € Start Date 1/07/2008 EU Contribution 828333 € End Date (actual) 31/12/2011 State Research in progress Summary All the properties of steel are defined primarily by the chemical composition. Knowledge of the actual composition of the raw materials, mainly the scrap, is essential for ensuring the correct mixing before melting. A scrap-analyser based on PGNAA (Prompt Gamma Neutron Activation Analysis), which is capable of measuring the elemental composition in loads of scrap, will be developed, for the on-line bulk analysis of bundled metal scrap in charge buckets. MCNP-modelling of the system will be performed to determine the optimum neutron energy, shielding etc. The innovative linear neutron generator and enhanced efficiency gamma detectors will be used. The prototype will be off-line tested in the industrial environment. Partners Organization Country Responsible CETTO AG DEUTSCHLAND Dr.Rer.Nat. Scaria MANNANAL (Project Coord.) ARCELORMITTAL ESPAÑA SA ESPAÑA Mr Luis Antonio RODRIGUEZ LOREDO ARCELORMITTAL MAIZIERES RESEARCH S.A. FRANCE Mr Philippe RUSSO CENTRE DE RECHERCHES METALLURGIQUES ASBL BELGIQUE Mr GUY MONTFORT NSD-FUSION GmbH DEUTSCHLAND Mr John SVED UNIVERSITY OF LIVERPOOL UNITED KINGDOM Prof. Paul NOLAN

RFSP-CT-2009-00028 SLASORB

Full Title Using slag as sorbent to remove phosphorus from wastewater Info Type of Project Pilot&Demonstration Duration (months) 36 Total Budget 1298704 € Start Date 1/07/2009 EU Contribution 649350 € End Date (actual) 30/06/2012 State Research in progress Summary The project aims at developing the use of slag in full scale filters design to remove phosphorus from wastewaters, an emphasis will be put on the subsequent valorisation of slag saturated with phosphorus. Good P-sorption capacities from 1 to 50 g P/kg slag were shown in literacy, but investigations were mainly conducted at lab-scale. Considering the recent evolution of EU legislation concerning P discard from wastewaters, the challenge of this project is to define the technical and economical feasibility of field-scale filters filled with slag, and on how to handle with slag after P-saturation, including replacement/rejuvenation and valorisation as fertilizers. Partners Organization Country Responsible ASS. POUR LA RECHERCHE ET LE DEV. DES METHODES ET P FRANCE Mr Florent CHAZARENC (Project Coord.) AKUT UMWELTSCHUTZ INGENIEURE BURKARD UND PART DEUTSCHLAND Dipl -Ing Stefan VOGEL ARCELORMITTAL ATLANTIQUE ET LORRAINE SAS FRANCE Eng Marc FIXARIS ARBEITSGEMEINSCHAFT HÜTTENKALK E.V. - ARGE DEUTSCHLAND Dr. Martin REX SARL EPUR NATURE FRANCE Mr Dirk ESSER FEhS - INSTITUT FÜR BAUSTOFF-FORSCHUNG e.V. DEUTSCHLAND Dr.-Ing. Peter DRISSEN

196 Summaries of RFCS projects 2003-2012 TGS9 : Factory-wide control, social and environmental issues

RFSR-CT-2003-00001 ERAMAC

Full Title Emissions reduction through analysis, modelling and control Info Type of Project Research Duration (months) 42 Total Budget 2756856 € Start Date 1/09/2003 EU Contribution 1654113 € End Date (actual) 28/02/2007 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA23333:EN Summary The project is aimed at reducing emissions of organic species (VOCs and SVOCs), NOX, SO2 and particulates from iron and steelmaking processes by an integrated study, involving impact measurement and modelling, improved process control through the application of soft-sensing predictive modelling and the development and testing of a novel wet contactor for reducing emissions of NOX and SO2. It includes: - Measurement and impact assessment/modelling of VOC and SVOC emissions from coking plant and coating lines - Development and application of soft-sensing techniques on sintering, EAF and coking processes and re-heating furnaces - Evaluation of the Amazone wet contactor for removal of NOX and SO2 from sinter plant emissions. Partners Organization Country Responsible TATA STEEL UK LIMITED UNITED KINGDOM Dr. David R. ANDERSON (Project Coord.) CENTRE DE RECHERCHES METALLURGIQUES ASBL BELGIQUE Mr Didier STEYLS INSTITUTO DE SOLDADURA E QUALIDADE PORTUGAL Dr. Joao Fernando GOMES LECES FRANCE Dr. Florence BERHO SWEREA MEFOS AB SVERIGE Dr. John NISKA GERDAU INVESTIGACION Y DESARROLLO EUROPA S.A. ESPAÑA Mr Javier CIRIZA VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Dipl -Ing Norbert LINK

RFSR-CT-2003-00004 RAPCOAT

Full Title Rapid, reproducible and accurate analysis techniques for coating systems Info Type of Project Research Duration (months) 36 Total Budget 1455443 € Start Date 1/09/2003 EU Contribution 873265 € End Date (actual) 31/08/2006 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA23197:EN Summary The basic objective of this research is to advance the techniques for fast chemical and thickness characterisation of modern coating systems, particularly with thick organic coatings. This will primarily be accomplished by developing appropriate methods based on recently developed state-of-art instrumentation, involving glow discharge, laser ablation, XRF and XRD spectroscopy. There is novel technology development in two areas: 1) making use of computational intelligence (CI) for data evaluation and 2) new development in femtosecond (fs) laser analysis for improved resolution in ultra-fast depth profiling. The expected results will be beneficial both for the competitiveness of European steel industry and the environment, due to more efficient process control where different chemicals are used. Partners Organization Country Responsible SWEREA KIMAB AB SVERIGE Dr. Arne BENGTSON (Project Coord.) ARCELORMITTAL MAIZIERES RESEARCH S.A. FRANCE Dr. Raymond MEILLAND CENTRE DE RECHERCHES METALLURGIQUES ASBL BELGIQUE Mrs Eva ZEIMETZ LEIBNIZ INSTITUT FÜR ANALYTISCHE WISSENSCHAFTEN IS DEUTSCHLAND Dr. Roland HERGENRÖDER TECHNISCHE UNIVERSITÄT DORTMUND DEUTSCHLAND Prof. Dr. Bernd REUSCH VOESTALPINE STAHL GMBH OESTERREICH Dipl.-Ing. Reinhard HACKL

RFSR-CT-2003-00006 CATIA

Full Title Development of catalytic metal filters for simultaneous removal of organic compounds and particulate matter from EAF fumes Info Type of Project Research Duration (months) 48 Total Budget 1306279 € Start Date 1/09/2003 EU Contribution 783767 € End Date (actual) 31/08/2007 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA23737:EN Summary Currently, the conventional approach for the abatement of organic compounds in electric steelplants only concerns PCDD/F and consists in a process inlcuding the following phases: - destruction of PCDD/F in a post-combustion chamber by bringing the primary fumes of the furnace to a temperature of 950°C using natural gas burners, - quenching the fumes abruptly in order to go to the 600°C-250)C range and avoid the reformation of PCDD/F called De Novo, - diluting the primary and secondary fumes in order to limit water vapor condensation that is harmful for bag functioning, - possible injection of activated carbon in order to respect a value of 0.1 ng/TEQ Nm³. All of these phases in the conventional approach lead to a solution which is investment-costly and fossil energy-thirsty with consequently a large production of greenhouse gases. In order to overcome all these disadvantages, the research project consists in implementing and promoting an innovating compact technique in the field of electric steelplants associating the properties of filtering and catalysis in an intermetallic filtering bag in order to abate the organic compounds contained in electric arc furnace fumes. Water quenching becomes unnecessary as well as any injection of activated carbon, thus a simplification of the fumes treatment installation and a lower investment cost are achieved. Partners Organization Country Responsible LECES FRANCE Mr Philippe LE LOUER (Project Coord.) FRAUNHOFER GESELLSCHAFT ZUR FOERDERUNG DER AN DEUTSCHLAND Dr. Olaf ANDERSEN LAMINES MARCHANDS EUROPEENS S.A. FRANCE Mr Eric WATREMEZ TNO, NEDERLANDSE ORG. VOOR TOEGEPAST NATUURWE NEDERLAND Ir. Hans OONK

197 Summaries of RFCS projects 2003-2012 TGS9 : Factory-wide control, social and environmental issues

RFSR-CT-2003-00014 TREES

Full Title Most appropriate treatments to control environmental impact of effluents in iron and steel industry Info Type of Project Research Duration (months) 40 Total Budget 1828448 € Start Date 1/09/2003 EU Contribution 1097069 € End Date (actual) 31/12/2006 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA23179:EN Summary The proposed project focus its attention to untreated wastewater toxicity and to the most appropriate treatments to reduce this toxicity. At first selected wastewater streams will be characterised in terms of toxic substances. Then, advanced oxidation and electrochemical techniques (as stand alone or in combination with biological treatment) will be used in order to reduce pollutant content: the “clean” water will be toxicologically tested for confirm the efficiency of the treatment. Finally, an economic evaluation of the treatment processes will be done on the bases of toxicity reduction, pollutants removal efficiency and sustained costs. Partners Organization Country Responsible CENTRO SVILUPPO MATERIALI SPA ITALIA Dr.ssa Daphne MIRABILE (Project Coord.) IPL SANTE, ENVIRONNEMENT DURABLES FRANCE Dr. Marie-José JOURDAIN TATA STEEL UK LIMITED UNITED KINGDOM Dr. Jennifer S. HODGES THYSSENKRUPP STEEL EUROPE AG DEUTSCHLAND Dr. Rer. Nat. Alfons ESSING VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Dr.-Ing. Matthias KOZARISZCZUK

RFSR-CT-2003-00038 IPCDS

Full Title Integrated process control & diagnostics system for hot rolling mills based on comparison of physical data & mathematical process-models by using artificial intelligence Info Type of Project Research Duration (months) 36 Total Budget 1962341 € Start Date 1/09/2003 EU Contribution 1177404 € End Date (actual) 31/08/2006 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA23198:EN Summary The project is aimed primarily at constructing a generic, intelligent, sophisticated, modular, and configurable diagnosing system that can be installed at rolling mills and similar other processes in Steel plants, with a view to improving the process control strategy. The proposed system will incorporate comprehensive mathematical models combined with neural network algorithms and Fuzzy reasoning in order to improve quality of strips and to minimize mill downtime. With this purpose and for developing generalised strategies, three hot rolling mills having requirements of different but similar nature were identified, where only partial successes have been achieved in this direction as results of various research and scientific efforts made in the past several years. In all these localities varying number of measuring instruments (pyrometers, thickness- and width gages etc.) are installed at different stages along the production path. In some places the signals are fed to expert systems which perform certain diagnostic and control activities to some extent, while in others they are partially employed manually at present. Based on the know-how of the project partners in the fields of supervision, diagnosis and control and under consideration of the newest publications in these fields, practical and powerful methods and tools for control-performance monitoring and supervision will be developed and installed in at least one of the participating hot mills. Partners Organization Country Responsible CETTO AG DEUTSCHLAND Dr.Rer.Nat. Scaria MANNANAL (Project Coord.) ARCELORMITTAL ESPAÑA SA ESPAÑA Mr Luis Antonio RODRIGUEZ LOREDO ILVA S.P.A. ITALIA Ing. Ruggero COLA SCUOLA SUPERIORE DI STUDI UNIVERSITARI E DI PERFEZI ITALIA Dr. Valentina COLLA TATA STEEL UK LIMITED UNITED KINGDOM Dr. John TUNSTALL THYSSENKRUPP STEEL EUROPE AG DEUTSCHLAND Dipl.-Phys. Jürgen DREVERMANN TEKNOLOGIAN TUTKIMUSKESKUS VTT*TECHNIC. RESEARC FINLAND Prof. Pentti VÄHÄ

RFSR-CT-2003-00041 FACTMON

Full Title Factory-wide and quality related production monitoring by data-warehouse exploitation Info Type of Project Research Duration (months) 40 Total Budget 1379590 € Start Date 1/09/2003 EU Contribution 827754 € End Date (actual) 31/12/2006 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA22992:EN Summary An industrial system for factory-wide and integrated monitoring of processes, plants and products regarding the product quality shall be established. It will be operating on an existing factory-wide quality database (=data-warehouse) and shall be able to automatically detect quality relevant deviations in the process chain on a medium and long term time scale. By this approach through-process-effects can be taken into account and it is possible to consider piecewise information (heat-, slab- or coil data) as well as length related data. This novel monitoring system will contribute to a reliable detection of quality relevant problems in the production chain of steel and by this it will help to increase the yield and to reduce production costs. Partners Organization Country Responsible VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Mr Hans-Dieter PLÜM (Project Coord.) ARCELORMITTAL EISENHÜTTENSTADT GmbH DEUTSCHLAND Dr.-Ing. Ralf-Peter BÖSLER ARCELORMITTAL ESPAÑA SA ESPAÑA Dr. Valentin TORRE SUAREZ CENTRO SVILUPPO MATERIALI SPA ITALIA Dr. Roberto PIANCALDINI FORSCHUNGS- UND QUALITÄTSZENTRUM BRANDENBURG DEUTSCHLAND Dipl.-Ing. Frank HILLIGES

198 Summaries of RFCS projects 2003-2012 TGS9 : Factory-wide control, social and environmental issues

RFSR-CT-2003-00043 AVAS

Full Title Feasibility of a fast vacuum slag analysis by laser OES in secondary steelmaking Info Type of Project Research Duration (months) 36 Total Budget 1155608 € Start Date 1/09/2003 EU Contribution 693364 € End Date (actual) 31/08/2006 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA23174:EN Summary The goal of the project is to demonstrate the feasibility of a fast slag analysis at the vacuum degasser for a better production control in secondary steelmaking. Sampling procedures from the vacuum degasser plant under vacuum conditions will be performed for different operational parameters. The resulting physical properties of the slag samples and their applicability for a fast analysis are investigated. A new method for laser optical emission spectrometry (laser OES) will be developed by spatial averaging with laser beam shaping and adapted sample scanning. Partners Organization Country Responsible AKTIEN-GESELLSCHAFT DER DILLINGER HÜTTENWERKE AG DEUTSCHLAND Dr. Hans-Uwe SCHMITZ (Project Coord.) ARCELORMITTAL MAIZIERES RESEARCH S.A. FRANCE Dr. Michel HEMMERLIN FRAUNHOFER GESELLSCHAFT ZUR FOERDERUNG DER AN DEUTSCHLAND Dr. Volker STURM SAARSTAHL AG DEUTSCHLAND Dr. Gerhild EGLSEDER

RFSR-CT-2003-00044 METHODOWEAR

Full Title Innovative wear test methodologies for the simulation of in service behaviour of tool steels Info Type of Project Research Duration (months) 36 Total Budget 1457608 € Start Date 1/09/2003 EU Contribution 874565 € End Date (actual) 31/08/2006 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA23204:EN Summary The tool wear amount is essentially due to sharpness of die radii, lubrication, surface finish, galling effects, thickness of the forming sheet and severity of the forming operations. The present tribological devices are not always reliable in forecasting the wear forming tool life, due to the difficulty in understanding the correct influence of the numerous parameters involved. This project aims at developing new testing methodologies to predict the wear behaviour of steel tools in the field of cold forming and deep drawing production, by means of correlating experimental data and wear effects from service operations. Partners Organization Country Responsible CENTRO SVILUPPO MATERIALI SPA ITALIA Dr. Domenico STOCCHI (Project Coord.) GIANETTI RUOTE SpA ITALIA Dr.-Ing. Andrea FINZI Fundación INASMET ESPAÑA Dr. Felix PENALBA DIAZ SWEREA KIMAB AB SVERIGE Dr. Johan SUNDSTRÖM GERDAU INVESTIGACION Y DESARROLLO EUROPA S.A. ESPAÑA Mr José Manuel LLANOS

RFSR-CT-2003-00045 AUTOCHECK

Full Title Enhancement of product quality and production system reliability by continuous performance assessment of automation systems Info Type of Project Research Duration (months) 42 Total Budget 1491299 € Start Date 1/09/2003 EU Contribution 894779 € End Date (actual) 28/02/2007 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA23205:EN Summary AUTOCHECK provides advanced methods and tools for Performance Assessment of steel plants in terms of integrated control monitoring and supervision of main components of the automation system. AUTOCHECK enables operators, process control and maintenance engineers to continuously monitor and maintain their plant at peak performance and reliability by automatic analysing the performance of setup systems and of key (basic and technological) control systems. For this, the systems are compared to optimal benchmarks and the causes of deviations are diagnosed. The objective is to identify poorly performing automation systems, and then to retune, upgrade them or redesign their control structures. The techniques and procedures developed in this project will be applied to ACERALIA’s hot strip mill, to TERNI’s hot strip mill, and to EKO’s galvanising line. Once applied, these plants will show product quality, reliability and productivity improvements as well as material saving. Partners Organization Country Responsible VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Dipl.-Ing. Andreas WOLFF (Project Coord.) ARCELORMITTAL EISENHÜTTENSTADT GmbH DEUTSCHLAND Dipl.-Ing. Michael BREITNER ARCELORMITTAL ESPAÑA SA ESPAÑA Mr Luis Antonio RODRIGUEZ LOREDO CENTRO SVILUPPO MATERIALI SPA ITALIA Ing. Giovanni ZANGARI FORSCHUNGS- UND QUALITÄTSZENTRUM BRANDENBURG DEUTSCHLAND Dipl.-Ing. Ramona KLÖPPEL

RFSR-CT-2003-00047 SURFQUALDEV

Full Title The measurement and prediction of surface quality by new developments in EMATS and scarfing and the effect of scarfing on surface defects through the mills Info Type of Project Research Duration (months) 42 Total Budget 1010005 € Start Date 1/09/2003 EU Contribution 606003 € End Date (actual) 28/02/2007 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA23176:EN Summary The project will develop means of improving the surface quality of continuously cast product; firstly by the development of non- contact methods of detection of surface and near surface defects; secondly through the study of the effect of scarfing on defects before and after rolling; and lastly by optimising scarfing practices and investigating improved means of defect removal. Two non-contact methods of defect detection will be developed; firstly via EMAT technologies which generates eddy currents and detects changes when defects are present; secondly via a method which recognises the spark pattern in the scarfing flame when a defect is encountered. The methods have the potential for on-line use at the caster and could ultimately be linked to a quality prediction scheme. Partners Organization Country Responsible 199 TATA STEEL UK LIMITED UNITED KINGDOM Mr Iain BAILLIE (Project Coord.) Summaries of RFCS projects 2003-2012 TGS9 : Factory-wide control, social and environmental issues

ARCELORMITTAL ESPAÑA SA ESPAÑA Mr Luis Fernando SANCHO MENDEZ SCUOLA SUPERIORE DI STUDI UNIVERSITARI E DI PERFEZI ITALIA Dr. Valentina COLLA

RFSR-CT-2004-00049 ULTRAFINE

Full Title Characterisation of emission and impact of ultrafine particulate Info Type of Project Research Duration (months) 42 Total Budget 2042583 € Start Date 1/07/2004 EU Contribution 1225550 € End Date (actual) 31/12/2007 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA23877:EN Summary The project will provide understanding of emissions and environmental impacts of fine (<2.5µm) and ultrafine (<0.1µm) particulate from iron and steelmaking processes enabling abatement strategy to be focused in the most appropriate areas. This is needed because of increasing evidence of adverse health effects from such particulate leading to greater legislation on air quality. The objectives are to: • Develop, validate and apply sophisticated sampling and analytical techniques capable of characterising particulate size, number, morphology and chemistry • Determine such particulate in ambient air and emissions from iron and steelmaking processes • Apply apportionment and modelling tools so that key sources and impacts may be identified Partners Organization Country Responsible TATA STEEL UK LIMITED UNITED KINGDOM Dr. David R. ANDERSON (Project Coord.) FRAUNHOFER GESELLSCHAFT ZUR FOERDERUNG DER AN DEUTSCHLAND Dr. Reinhard NOLL LECES FRANCE Mr Philippe LE LOUER MAX PLANCK GESELLSCHAFT ZUR FÖRDERUNG DER WISSE DEUTSCHLAND Dr. Frank DREWNICK

RFSR-CT-2004-00050 DECFLAQ

Full Title Decision support system for the comprehensive assessment of flat products quality Info Type of Project Research Duration (months) 36 Total Budget 1318371 € Start Date 1/07/2004 EU Contribution 791023 € End Date (actual) 30/06/2007 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA23892:EN Summary A system shall be developed to support the quality departments during the assessment of flat products quality. Based on all available quality information of the final flat product as well of previous process stages a suitable “grading” of the product quality will be developed. Already during the production the quality information can be used for production planning. By using all available quality information together with cost information a Decision Support System (DSS) will be generated to support the quality department in grading the product, in the assignment of produced coils to orders and in checking if the produced quality match the customer demands. Partners Organization Country Responsible VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Dipl.-Ing. Norbert HOLZKNECHT (Project Coord.) ACERALIA CORPORACION SIDERURGICA S.A. ESPAÑA Dr. Nicolás DE ABAJO MARTÍNEZ CENTRO SVILUPPO MATERIALI SPA ITALIA Dr. Maria MURRI THYSSENKRUPP RASSELSTEIN GMBH DEUTSCHLAND Dipl.-Ing. Michael LUKAS THYSSENKRUPP ACCIAI SPECIALI TERNI SpA ITALIA Dr. Ezio DE BERNARDI

RFSR-CT-2004-00051 TRESOR

Full Title Technique for remediation of steel-works polluted sites Info Type of Project Research Duration (months) 42 Total Budget 1836373 € Start Date 1/07/2004 EU Contribution 1101824 € End Date (actual) 31/12/2007 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA23594:EN Summary The aim of the project is to develop a system that will forecast the fate of environmental pollutants across steelwork sites and to analyse the effectiveness of various remediation technologies (soil washing, thermal treatment and bioremediation) from both technical and economical view points. Steel-works sites pollutants will be characterised and added to a conceptual model developed from noninvasive and invasive site investigation studies. Leaching tests will be performed to study the pollutants ability to migrate and impact the neighbouring environmental receptors. The conceptual model will be translated into a mathematical model and the fate of the pollutants predicted. Experimental trials results will be used to validate the mathematical model. The project will be managed by an integrated team combining steel producers (Corus, Vitkovice and Sidenor) with Research Institutes (CSM, ISQ, IVL). Partners Organization Country Responsible CENTRO SVILUPPO MATERIALI SPA ITALIA Dr.ssa Daphne MIRABILE (Project Coord.) INSTITUTO DE SOLDADURA E QUALIDADE PORTUGAL Dr. Joao Fernando GOMES IVL SVENSKA MILJÖINSTITUTET AB SVERIGE Mr Östen EKENGREN GERDAU INVESTIGACION Y DESARROLLO EUROPA S.A. ESPAÑA Mr Juan José LARAUDOGOITIA TATA STEEL UK LIMITED UNITED KINGDOM Mr Shaun McKENNA MATERIÁLOVÝ A METALURGICKÝ VÝZKUM s.r.o. CZECH REPUBLIC Dr. Karel MATOCHA

200 Summaries of RFCS projects 2003-2012 TGS9 : Factory-wide control, social and environmental issues

RFSR-CT-2004-00052 SensoCont

Full Title Sensor based on-line-control of pickling lines Info Type of Project Research Duration (months) 42 Total Budget 1212048 € Start Date 1/07/2004 EU Contribution 727229 € End Date (actual) 31/12/2007 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA23872:EN Summary Main aim is the development of a new sensor based control technology for operating pickling lines. Pickling is the most important step to remove surface scale layers and is strongly depending on the exactly controlled pickling liquor composition. Today there is no system available for online control of pickling lines. Within this project new methods for online analysis of the pickling liquors will be tested and implemented into an overall pickling process control tool. Therefore the pickling line staff will be enabled to control the process really contemporary with all the process knowledge they need. Partners Organization Country Responsible VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Dr.-Ing. Burkhard SCHMIDT (Project Coord.) CENTRO SVILUPPO MATERIALI SPA ITALIA Dr. Armando GIANNETTI IVL SVENSKA MILJÖINSTITUTET AB SVERIGE Mr Östen EKENGREN THYSSENKRUPP RASSELSTEIN GMBH DEUTSCHLAND Dr. Robert PANDORF UNIVERSIDAD DE OVIEDO ESPAÑA Dr. Hilario LOPEZ GARCIA

RFSR-CT-2005-00043 REAL

Full Title Development of inclusion reference materials and simultaneous determination of metals and non-metallic inclusions by rapid libs analysis in steel samples Info Type of Project Research Duration (months) 42 Total Budget 1314057 € Start Date 1/07/2005 EU Contribution 788434 € End Date (actual) 31/12/2008 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA24190:EN Summary Fast and thorough analysis of steel samples during the process of steel-making would enable better process control. The project will provide new reference materials with well-defined inclusion population, and a technique based on laser-induced breakdown spectroscopy to provide fast and simultaneous analysis of the steel matrix and the non-metallic inclusions. The objectives are to: • Develop a robust method to produce reference materials with a well defined inclusion population, and produce sets of such reference materials, • Improve LIBS as a fast analytical technique for rapid and simultaneous analysis of trace elements in steel and characterisation of the inclusion population. Partners Organization Country Responsible TATA STEEL UK LIMITED UNITED KINGDOM Dr. Fabienne BOUE-BIGNE (Project Coord.) ASCOMETAL S.A.S. FRANCE Dr.-Ing. Eric HENAULT COMMISSARIAT A L'ENERGIE ATOMIQUE FRANCE Dr. Laurent SALMON CAVENDISH INSTRUMENTS LIMITED UNITED KINGDOM Dr. Robin DEVONSHIRE FRAUNHOFER GESELLSCHAFT ZUR FOERDERUNG DER AN DEUTSCHLAND Dr. Reinhard NOLL THYSSENKRUPP STEEL EUROPE AG DEUTSCHLAND Dr. Horst MITTELSTÄDT

RFSR-CT-2005-00044 PLATEND

Full Title Combined ultrasound and micromagnetic measurements for non destructive assessment of textured heavy plate properties Info Type of Project Research Duration (months) 42 Total Budget 1442855 € Start Date 1/07/2005 EU Contribution 865714 € End Date (actual) 31/12/2008 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA24358:EN Summary Savings of 11M EUR/year could be achieved by European plate manufacturers, through the optimisation of the extremity length to cut out and the reduction of associated handling operations. Such a target seems achievable by combining non-destructive evaluation (NDE) techniques. Ultrasonic or magnetic techniques alone provide insufficient predictions but combining them showed promising prospects during recent laboratory work. The proposal aims to investigate thoroughly the performance of such combinations on a comprehensive selection of textured plates, with laboratory and in-plant investigations. Partners Organization Country Responsible ARCELORMITTAL MAIZIERES RESEARCH S.A. FRANCE Dr. Philip MEILLAND (Project Coord.) AKTIEN-GESELLSCHAFT DER DILLINGER HÜTTENWERKE AG DEUTSCHLAND Dipl.-Ing. Uwe HOFMANN FRAUNHOFER GESELLSCHAFT ZUR FOERDERUNG DER AN DEUTSCHLAND Dr. Bernd WOLTER THYSSENKRUPP STEEL EUROPE AG DEUTSCHLAND Dr. Wolfram WEBER

RFSR-CT-2005-00045 PERMESS

Full Title Plant wide error messaging system based on new communication technologies Info Type of Project Research Duration (months) 36 Total Budget 1237246 € Start Date 1/07/2005 EU Contribution 742347 € End Date (actual) 30/06/2008 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA24251:EN Summary Monitoring and supervision systems in industry has substantially grown in last years thanks to advances in instrumentation and computer hardware for processing, visualization and storage of process data. In parallel, communications and information technologies have had an exponential growth and nowadays they bring us services that just a few years ago were far away. Not surprisingly, recent efforts are looking to the integration of supervision and Internet in order to exploit benefits and cross- fertilization of both disciplines. This project will contribute to minimize time needed for detecting and diagnosing troubles in steel plants, reducing loses of time and increasing production capacity. Partners Organization Country Responsible 201 VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Dipl -Ing Heribert MENNICKEN (Project Coord.) Summaries of RFCS projects 2003-2012 TGS9 : Factory-wide control, social and environmental issues

ACERALIA CORPORACION SIDERURGICA S.A. ESPAÑA Mr Luis Antonio RODRIGUEZ LOREDO CENTRO SVILUPPO MATERIALI SPA ITALIA Dr. Roberto PIANCALDINI UNIVERSIDAD DE OVIEDO ESPAÑA Dr. Ignacio DIAZ BLANCO

RFSR-CT-2005-00046 SIMUSTEEL

Full Title Optimization of stocks management and production scheduling by simulation of the continuous casting, rolling and finishing departments Info Type of Project Research Duration (months) 36 Total Budget 1641825 € Start Date 1/07/2005 EU Contribution 985095 € End Date (actual) 30/06/2008 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA24969:EN Summary The CC, Rolling and Finishing areas have a clear connection in terms of scheduling. The product-mix is continuously rescheduled and the coils movements between mills, lines and intermediate warehouses implies a significant part of the product cost structure. Some breaks in the supply chain could lead to expensive production stops and even coils losses. One solution of these problems is the simulation. The main output is a software tool that implements a method to solve problems of the production flows of a modern steel plant. It will be based on an intelligent system consisting of a scheduler and a simulator of the materials flows. The tool will be provided with an innovative user interface, based on web technology. The pilot activities will be carried out at Aceralia Avilés and ThyssenKrupp Acciai Speciali Terni plant. Partners Organization Country Responsible ACERALIA CORPORACION SIDERURGICA S.A. ESPAÑA Mrs Susana PEREGRINA MARQUEZ (Project Coord.) CENTRO SVILUPPO MATERIALI SPA ITALIA Dr. Maria MURRI THYSSENKRUPP ACCIAI SPECIALI TERNI SpA ITALIA Dr.ssa Rosanna CAPORUSSO UNIVERSIDAD DE OVIEDO ESPAÑA Prof. David DE LA FUENTE GARCIA UNIVERSITY OF VAASA - VAASAN YLIOPISTO FINLAND Prof. Petri T. HELO VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Dr.-Ing. Bernhard DAHM

RFSR-CT-2005-00047 eTipo

Full Title Factory wide e-training for steel human resource improvement and meeting process objectives Info Type of Project Research Duration (months) 36 Total Budget 1669829 € Start Date 1/07/2005 EU Contribution 1001897 € End Date (actual) 30/06/2008 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA25058:EN Summary The rapid technological evolution in the steel industry, driven by information technologies, raises several questions such as the adaptability of its laborer force. In addition business process goals defined by the managers have to be considered in the working- place training programs, structuring them in accordance with the specific needs of the company. To improve the availability of process knowledge and business objectives is a key factor for the steel industries during the next future, so the final goal of this proposal is to develop a new e-learning solution for the steel production environments based on different and complementary approaches. Partners Organization Country Responsible ACERALIA CORPORACION SIDERURGICA S.A. ESPAÑA Dr. Valentin TORRE SUAREZ (Project Coord.) CENTRO SVILUPPO MATERIALI SPA ITALIA Dr. Maria MURRI FUNDACION TECNALIA RESEARCH & INNOVATION ESPAÑA Dr. Mikel SORLI PEÑA THYSSENKRUPP ACCIAI SPECIALI TERNI SpA ITALIA Dr.-Ing. Luca ONOFRI VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Dr. Michael LANGER VOESTALPINE STAHL GMBH OESTERREICH Dr. Angelika MITTELMANN

RFSR-CT-2005-00048 THINFILM

Full Title Characterisation of thin films on rough steel substrates Info Type of Project Research Duration (months) 42 Total Budget 1203482 € Start Date 1/07/2005 EU Contribution 722090 € End Date (actual) 31/12/2008 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA24250:EN Summary The characterisation of thin films is not satisfactory at present by lacking methodology, knowledge and CRM’s. The goal is the full characterization of thin films (thickness, composition, homogeneity in depth as well as laterally) that are of economical importance (Industry, Automotive, Packaging markets) and having a thickness typically between 0.5 nm and 1000 nm.. This objective is to compare the possibilities of existing characterization techniques (used in steel research) with “more exotic” techniques not well known for steel applications. Complementarity, speed, availability and costs are important aspects of the analysis. The final report will include results of a round robin, procedures for direct implementation and a data base of reference materials. Partners Organization Country Responsible ONDERZOEKSCENTRUM VOOR AANWENDING VAN STAAL BELGIQUE Dr. Chris XHOFFER (Project Coord.) ARCELORMITTAL MAIZIERES RESEARCH S.A. FRANCE Ir. Denis JACQUET MAGYAR TUDOMANYOS AKADEMIA KEMIAI KUTATOKOZP HUNGARY Prof. Erika KALMAN LEIBNIZ INSTITUT FÜR ANALYTISCHE WISSENSCHAFTEN IS DEUTSCHLAND Dr. Roland HERGENRÖDER Fundación INASMET ESPAÑA Dr. Felix PENALBA DIAZ SWEREA KIMAB AB SVERIGE Dr. Arne BENGTSON MAX-PLANCK-INSTITUT FÜR EISENFORSCHUNG GmbH DEUTSCHLAND Dr. Guido GRUNDMEIER THYSSENKRUPP STEEL EUROPE AG DEUTSCHLAND Dr. Tamara APPEL VRIJE UNIVERSITEIT BRUSSEL BELGIQUE Prof. Herman TERRYN

202 Summaries of RFCS projects 2003-2012 TGS9 : Factory-wide control, social and environmental issues

RFSR-CT-2006-00033 CONOX

Full Title Control of nitrogen oxide emission at the electric arc furnace Info Type of Project Research Duration (months) 36 Total Budget 1092865 € Start Date 1/07/2006 EU Contribution 655719 € End Date (actual) 30/06/2009 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA25078:EN Summary Increasing importance of reduced dust and air polluting emissions (CO2, NOx) competes with minimum total EAF energy input and maximum energy efficiency. Therefore, it is desirable to avoid formation of NOx by controlled operation of the EAF. A consortium of three steel producers and two research institutes in Germany and Italy aims to investigate, understand and control the emission of NOx in EAF steel making. The impact of various current EAF technologies on the NOx formation will be investigated (1) experimentally by EAF off-gas measurements at production of various steel grades with different EAF types and in pilot plants and (2) theoretically by modelling based on thermo- chemistry and computational fluid dynamic (CFD) simulations. Partners Organization Country Responsible RHEINISCH-WESTFÄLISCHE TECHNISCHE HOCHSCHULE AA DEUTSCHLAND Prof.Dr.Ing. Herbert PFEIFER (Project Coord.) CENTRO SVILUPPO MATERIALI SPA ITALIA Dr. Filippo CIRILLI DEUTSCHE EDELSTAHLWERKE GMBH DEUTSCHLAND Dipl.-Ing. Hans-Peter JUNG O.R.I. MARTIN - ACCIAIERIA E FERRIERA DI BRESCIA SpA ITALIA Ing. Uggero DE MIRANDA RIVA ACCIAIO SPA ITALIA Dr.-Ing. Nicola VENERI

RFSR-CT-2006-00034 ADCTEC

Full Title Advanced characterisation techniques for novel zinc-based alloy coatings Info Type of Project Research Duration (months) 36 Total Budget 1940348 € Start Date 1/07/2006 EU Contribution 1164208 € End Date (actual) 30/06/2009 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA25079:EN Summary The basic objective is to improve production control and R&D efficiency for novel Zn-based alloy coatings. This will be accomplished by adapting and evaluating a range of advanced analytical and data treatment techniques for fast and complete characterisation of such coatings. Since the introduction of these novel coating types are of major strategic importance for the European steel industry, a very broad consortium of major steel companies and several expert laboratories has been formed. A very wide range of analytical techniques and development of an expert system based on the most advanced data treatment methods available will be used. Also, limited on-line trials in a pilot plant will be included in the final phase of the project. Partners Organization Country Responsible SWEREA KIMAB AB SVERIGE Dr. Arne BENGTSON (Project Coord.) ARCELORMITTAL MAIZIERES RESEARCH S.A. FRANCE Dr. Didier LOISON CENTRE DE RECHERCHES METALLURGIQUES ASBL BELGIQUE Mrs Ana FARINHA LEIBNIZ INSTITUT FÜR ANALYTISCHE WISSENSCHAFTEN IS DEUTSCHLAND Dr. Roland HERGENRÖDER MAX-PLANCK-INSTITUT FÜR EISENFORSCHUNG GmbH DEUTSCHLAND Dr. Michael ROHWERDER THYSSENKRUPP STEEL EUROPE AG DEUTSCHLAND Dr. Martin RAULF TOP ANALYTICA OY AB FINLAND Dr. Bengt-Johan SKRIFVARS TECHNISCHE UNIVERSITÄT DORTMUND DEUTSCHLAND Prof. Dr. Bernd REUSCH UNIVERSIDAD DE MALAGA ESPAÑA Prof. Javier LASERNA VOESTALPINE STAHL GMBH OESTERREICH Dipl.-Ing. Johann ANGELI

RFSR-CT-2006-00035 LCS

Full Title Laser-induced breakdown spectroscopy for advanced characterisation and sorting of steel scrap Info Type of Project Research Duration (months) 36 Total Budget 2093982 € Start Date 1/07/2006 EU Contribution 1256389 € End Date (actual) 30/06/2009 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA24968:EN Summary The objective of this project is to develop and assemble a transportable demonstrator, which uses Laser Induced Breakdown Spectroscopy (LIBS), for automatic sorting of steel scrap. Two applications are planned for field testing of the device: -Sorting and classification of shredded steel scrap at the exit of a shredder. -Detailed quantitative chemical analysis of scrap moving on a conveyor belt feeding an electric arc furnace (EAF). The development of the LIBS demonstrator system is complex. Nevertheless, the project is essential in order to reach a new technique level in the steel industry. The work enables simultaneously, reductions in production costs, improved product quality, and significantly reduced environmental loads. Partners Organization Country Responsible SWEREA KIMAB AB SVERIGE Dr. Arne BENGTSON (Project Coord.) ARCELORMITTAL MAIZIERES RESEARCH S.A. FRANCE Mrs Laurence GARRIGUES CENTRO SVILUPPO MATERIALI SPA ITALIA Dr. Ugo CHIAROTTI FRAUNHOFER GESELLSCHAFT ZUR FOERDERUNG DER AN DEUTSCHLAND Dr. Reinhard NOLL KUNGLIGA TEKNISKA HÖGSKOLAN - THE ROYAL INSTITUTE SVERIGE Prof. Lars-Erik BERG O.R.I. MARTIN - ACCIAIERIA E FERRIERA DI BRESCIA SpA ITALIA Ing. Uggero DE MIRANDA STENA GOTTHARD AB SVERIGE M.Sc. Kristofer SUNDSGÅRD UNIVERSIDAD DE MALAGA ESPAÑA Prof. Javier LASERNA

203 Summaries of RFCS projects 2003-2012 TGS9 : Factory-wide control, social and environmental issues

RFSR-CT-2006-00036 IRSIS

Full Title Improved utilisation of results from automatic surface inspection systems Info Type of Project Research Duration (months) 36 Total Budget 1796870 € Start Date 1/07/2006 EU Contribution 1078122 € End Date (actual) 30/06/2009 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA25070:EN Summary Because surface quality is of increasing importance for many steel applications, the results of automatic surface inspection systems (ASIS) become more important. Based on the current situation that the detection and classification performance of today's ASIS is sufficient for many application purposes the main potential lies in the proper utilisation of the ASIS results. Inside the project relevant problems of utilisation of ASIS results will be investigated, new techniques will be developed and implemented in the field. Based on these new techniques different application examples will be realised and tested. Results will be evaluated regarding their benefits and their transferability. Partners Organization Country Responsible VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Dipl.-Math. Jens BRANDENBURGER (Project Coord.) ARCELORMITTAL ESPAÑA SA ESPAÑA Dr. José Luis RENDUELES VIGIL CENTRO SVILUPPO MATERIALI SPA ITALIA Dr. Roberto PIANCALDINI DUFERCO LA LOUVIERE SA BELGIQUE Dr.-Ing. Giuseppe PRATOLONGO ILVA S.P.A. ITALIA Eng. Enrico ROMANO SALZGITTER MANNESMANN FORSCHUNG GmbH DEUTSCHLAND Dr. rer nat. Mathias STOLZENBERG

RFSR-CT-2006-00037 LINECOP

Full Title Line-coordinated optimisation of strip geometry and surface properties by using model-based predictive technologies Info Type of Project Research Duration (months) 48 Total Budget 1217169 € Start Date 1/07/2006 EU Contribution 730301 € End Date (actual) 30/06/2010 State Research technically completed; publication in hand Summary To significantly improve the efficiency of their production chains, European steel producers need a global optimisation strategy that allows the incorporation of factory-wide systems to predict and control the evolution and influences in terms of quality through the different processing stages. LINECOP develops line-coordinated strip-quality assessment, monitoring and optimisation systems for cold rolling and hot-dip galvanising (incl. continuous annealing and temper rolling), based on an integrated model for the whole processing route. The new through-process optimiser predictively adapts the downstream processes to prevent transfer/final product-quality degradation and reduces maintenance effort and re-work. The project will provide a valuable contribution for European steel producers to increase plant availability and product quality facing the trend towards products with tighter tolerances and more uniform strip quality over strip length and width, as well as minimise zinc-layer “safety margins”, and thus reduce material/energy and production costs. The benefits of the project will be demonstrated at ACERALIA’s, and EKO STAHL’s strip production lines. Partners Organization Country Responsible VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Dipl.-Ing. Andreas WOLFF (Project Coord.) ARCELORMITTAL EISENHÜTTENSTADT GmbH DEUTSCHLAND Dr.-Ing. Simone PIETZSCH ARCELORMITTAL ESPAÑA SA ESPAÑA Dr. José Luis RENDUELES VIGIL FORSCHUNG- UND QUALITÄTSZENTRUM BRANDENBURG DEUTSCHLAND Dr.-Ing. Jürgen BATHELT UNIVERSIDAD POLITECNICA DE MADRID ESPAÑA Prof. Isabel ORTIZ

RFSR-CT-2006-00038 FREEZE

Full Title Avoiding water and acid consumption in chemical scale removal by innovative combined process Info Type of Project Research Duration (months) 42 Total Budget 744360 € Start Date 1/07/2006 EU Contribution 446616 € End Date (actual) 31/12/2009 State Research completed, report published on EU Bookshop at http://bookshop.europa.eu/uri?target=EUB:NOTICE:KINA24991:EN Summary Pickling processes require large amounts of acid and water. So far, a part of the pickling acid has to be discarded as waste in regular intervals. Using a new process combination of freezing crystallisation and precipitation the spent pickling acid can be separated into pure water, metal salt crystals and a solution containing the active acid and a rest of metal salts. The active acid and the pure water can be recycled into the pickling process or the rinsing zone, respectively. The extracted metal salts can be treated by pryrohydrolysis or electrolysis to recover the bonded acid and to produce metal oxides or elementary metals, respectively. Partners Organization Country Responsible VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Ms Miriam SARTOR (Project Coord.) ACERINOX EUROPA SA ESPAÑA Mrs Maria José GUIO BONANY IVL SVENSKA MILJÖINSTITUTET AB SVERIGE Mr Östen EKENGREN THYSSENKRUPP NIROSTA GMBH DEUTSCHLAND Dipl.-Ing. Karl-Heinz KIRCHHOFF

204 Summaries of RFCS projects 2003-2012 TGS9 : Factory-wide control, social and environmental issues

RFSR-CT-2007-00049 O-Chess

Full Title On-line chemistry of the steel surfaces Info Type of Project Research Duration (months) 36 Total Budget 1120367 € Start Date 1/07/2007 EU Contribution 672260 € End Date (actual) 30/06/2010 State Research technically completed; publication in hand Summary Improve quality, robustness and up/downstream compatibility of new products (steels, metallic coating organic coatings, PVD) depends on our capacity to control their surface chemistry (nature, quantity of lateral distribution of oxides, contaminants or cracking residue). Or recent development of low cost spectrometers, high power source, powerful data processing such as Bayesian network, allow now to create chemical contact free and multifunctional spectroscopic sensor (UV, vis, NIR, MIR, Raman) able to identify / quantify / map variation of steel surface chemistries. Objective is then to screen these technologies and to propose for specific applications a pre-industrial solution validated in industrial context. Partners Organization Country Responsible ARCELORMITTAL LIEGE RESEARCH SCRL BELGIQUE Ir. Denis JACQUET (Project Coord.) ARCELORMITTAL MAIZIERES RESEARCH S.A. FRANCE Dr. Thierry JACQUOT UNIVERSITÄT PADERBORN DEUTSCHLAND Prof. Dr. Guido GRUNDMEIER TEKNOLOGIAN TUTKIMUSKESKUS VTT*TECHNIC. RESEARC FINLAND Mr Janne SUHONEN

RFSR-CT-2008-00040 OMC

Full Title Online material characterisation at strip production Info Type of Project Research Duration (months) 36 Total Budget 2115877 € Start Date 1/07/2008 EU Contribution 1269526 € End Date (actual) 30/06/2011 State Research in progress Summary Aim of this research proposal is the extension and the comparison of online, non-destructive material characterisation methods on production lines working under rough conditions. Several measurement methods will be tested, based on electromagnetic techniques and on laser-ultrasonic. Whereas the collection of process data is comparably easy, there is a lack of quality data describing the actual state of the product. These data have to be gained by advanced methods of material characterisation online during production. Based on these values other material parameters shall be calculated which directly and online define the final product quality for the customer (e.g. yield strength and tensile strength). These quality parameters can then be used to detect the relationships to the influencing process variables along the relevant production line e.g. by data mining technologies. Partners Organization Country Responsible SALZGITTER MANNESMANN FORSCHUNG GmbH DEUTSCHLAND Dr. rer nat. Mathias STOLZENBERG (Project Coord.) ARCELORMITTAL EISENHÜTTENSTADT GmbH DEUTSCHLAND Mr Rene SCHMIDT CENTRO DE ESTUDIOS E INVESTIGACIONES TECNICAS ESPAÑA Mrs Ane MARTINEZ DE GUEREÑU FORSCHUNGS- UND QUALITÄTSZENTRUM ODERBRÜCKE g DEUTSCHLAND Dr. Rer. nat. Alvaro CASAJUS SWEREA KIMAB AB SVERIGE Mrs Eva LINDH-ULMGREN TATA STEEL NEDERLAND TECHNOLOGY BV NEDERLAND Ing. Henk T. PLOEGAERT THYSSENKRUPP STEEL EUROPE AG DEUTSCHLAND Dr. Thomas KEBE VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Dipl.-Ing. Norbert HOLZKNECHT

RFSR-CT-2008-00042 AUTODIAG

Full Title Supporting process and quality engineers by automatic diagnosis of cause-and-effect relationships between process variables and quality deficiencies using data mining technologies Info Type of Project Research Duration (months) 36 Total Budget 1318378 € Start Date 1/07/2008 EU Contribution 791027 € End Date (actual) 30/06/2011 State Research in progress Summary The through-process detection of cause-and-effect relationships by investigation of process and quality data with Data Mining techniques has been proofed to be a powerful possibility to decrease quality deficiencies. Nevertheless this method is not used area-wide in the companies because of its complexity, the necessary specific knowledge which only few people in the company have and the missing adaptation of the tools to the specific problems of the steel production. These are the reasons for the consortium to develop, implement and test robust, practicable and easy-to-use solutions which are specialised to steel quality problems and which overcomes the above deficiencies. Partners Organization Country Responsible VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Dipl.-Ing. Norbert HOLZKNECHT (Project Coord.) ARCELORMITTAL ESPAÑA SA ESPAÑA Dr. Valentin TORRE SUAREZ ILVA S.P.A. ITALIA Dr. Floriano FERRO SCUOLA SUPERIORE DI STUDI UNIVERSITARI E DI PERFEZI ITALIA Dr. Valentina COLLA THYSSENKRUPP NIROSTA GMBH DEUTSCHLAND Dr.-Ing. Thomas HECKENTHALER

205 Summaries of RFCS projects 2003-2012 TGS9 : Factory-wide control, social and environmental issues

RFSR-CT-2008-00043 ZINCANA

Full Title In-situ analysis of hot dip galvanizing baths Info Type of Project Research Duration (months) 36 Total Budget 896744 € Start Date 1/07/2008 EU Contribution 538046 € End Date (actual) 30/06/2011 State Research technically completed; publication in hand Summary The objective of this project is to a method for zinc bath composition measurements based on LIBS (Laser Induced Breakdown Spectrometry) system analyzing inside the bath, adapted for high content and traces elements analysis and optimized for precipitates characterization. Using the instrumental measurements, the modelling of zinc bath composition will be performed and comparison to industrial measurements realized. The model could further be used in order to get the influence of process parameters on drosses precipitation. The advantage of LIBS compared to other experimental techniques, such as samples or aluminum probes, is that the system can perform on-line simultaneous measurements of different dissolved elements (Zn, Fe, Al…). The project is divided into three working areas: - Laboratory trials of LIBS experiments in order to validate the parameters for zinc bath analysis - Industrial trials of LIBS measurements both for element analyses (high and low level) and drosses characterization - Modelling of zinc bath composition and comparison to industrials measurements. Partners Organization Country Responsible ARCELORMITTAL MAIZIERES RESEARCH S.A. FRANCE Mrs Marie SIMONNET (Project Coord.) CENTRALE RECHERCHE SA FRANCE Dr. Marie-Laurence GIORGI SWEREA KIMAB AB SVERIGE Dr. Thomas BJORK TECNAR AUTOMATION LTEE CANADA Ing. M. Sc.A. Alexandre NADEAU UNIVERSIDAD DE MALAGA ESPAÑA Prof. Javier LASERNA

RFSR-CT-2009-00029 ASEMIS

Full Title Assessment of emissions and impact of steel production processes Info Type of Project Research Duration (months) 42 Total Budget 1502621 € Start Date 1/07/2009 EU Contribution 901573 € End Date (actual) 31/12/2012 State Research in progress Summary ASEMIS will provide improved understanding of steelworks’ emissions and their impacts on ambient air quality, thus enabling cost effective abatement measures to be properly targeted and implemented. This will address the need to improve local air quality, helping to create a sustainable future for European steelmaking. The major objectives are to: • provide novel methods and strategies to assess ambient air quality in the vicinity of steelworks • complete and refine inventories of particulate emissions from integrated steelworks • assess the air quality impact of steelworks in the surroundings of integrated steelworks Partners Organization Country Responsible TATA STEEL UK LIMITED UNITED KINGDOM Mrs Diane CIAPARRA (Project Coord.) ARCELORMITTAL ESPAÑA SA ESPAÑA Ms. Julia PERIM DE FARIA INSTITUTO DE SOLDADURA E QUALIDADE PORTUGAL Dr. Silvia GARCIA MAX PLANCK GESELLSCHAFT ZUR FÖRDERUNG DER WISSE DEUTSCHLAND Dr. Frank DREWNICK

RFSR-CT-2009-00030 HYDRAS

Full Title Hydrogen assessment in steel products and semi-products Info Type of Project Research Duration (months) 36 Total Budget 1949940 € Start Date 1/07/2009 EU Contribution 1169964 € End Date (actual) 30/06/2012 State Research in progress Summary Hydrogen is always a harmful element in steel. Hydrogen picked up during steelmaking would cause internal defects and even some ppm could be detrimental for mechanical properties of the most susceptible steel products, such as heavy section products (slabs, large blooms or large forgings) in high strength grades. Though the importance of hydrogen control is well recognised, its detection in solidified steel is a destructive test, thus not always possible. Hence the need of reliable tools to predict hydrogen content in solid steel in order to assess the best practice for hydrogen control in production of sensitive grades. Partners Organization Country Responsible RIVA ACCIAIO SPA ITALIA Eng Stefano BARAGIOLA (Project Coord.) SWEREA MEFOS AB SVERIGE MSc Hakan LUNDBÄCK GERDAU INVESTIGACION Y DESARROLLO EUROPA S.A. ESPAÑA Mrs Zuriñe IDOYAGA FUNDACION TECNALIA RESEARCH & INNOVATION ESPAÑA Mr Juan PALACIOS AALTO-KORKEAKOULUSAATIO (AALTO UNIVERSITY FOUN FINLAND Dr. Seppo LOUHENKILPI UNIVERSITA DEGLI STUDI DI PISA ITALIA Ing. Renzo VALENTINI VOESTALPINE STAHL DONAWITZ GmbH & Co KG OESTERREICH Dr. Axel SORMANN

206 Summaries of RFCS projects 2003-2012 TGS9 : Factory-wide control, social and environmental issues

RFSR-CT-2009-00031 KNOWDEC

Full Title Knowledge management and decision support with special focus to process and quality optimization at flat steel production Info Type of Project Research Duration (months) 42 Total Budget 1198145 € Start Date 1/07/2009 EU Contribution 718887 € End Date (actual) 31/12/2012 State Research in progress Summary Experiences and knowledge from the technical staff in a steel works facility are serious resources with a strategic importance for the production of high quality products. A suitable knowledge management (KM) is a key component for a solidification of the market position for a steel company in a competitive market. The mentioned systems to be used in the technical environment of the steel industry are actually not available. Therefore this contribution is focused on the implementation of a steel specific knowledge management system in the flat steel production. Three different applications in the steel production are performed and evaluated. Partners Organization Country Responsible VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Dr. Alexander EBEL (Project Coord.) ARCELORMITTAL ESPAÑA SA ESPAÑA Dr. Diego DĺAZ FIGALDO CENTRO SVILUPPO MATERIALI SPA ITALIA Dr. Francesca MARCHIORI LUCCHINI S.p.A. ITALIA Mr Gabriele LONZI

RFSR-CT-2009-00032 ENCOP

Full Title Development of tools for reduction of energy demand and CO2-emissions within the iron and steel industry based on energy register, CO2-monitoring and waste heat power generation Info Type of Project Research Duration (months) 48 Total Budget 1449341 € Start Date 1/07/2009 EU Contribution 869604 € End Date (actual) 30/06/2013 State Research in progress Summary The reduction of energy demand in the iron and steel industry is a highly investigated issue. However, evaluation of the reduction potential on a systematically level is still missing. Therefore the project aims at analysing the energy flows, energy demand and CO2-emissions in typical production processes in selected steel plants. Energy saving potentials will be identified by means of holistic energy register, CO2-monitoring system and decision guidance matrix for power generation using low to mid temperature waste heat. These tools provide a sophisticated basis for the iron and steel industry to evaluate and energetically optimise its processes and plants. Partners Organization Country Responsible VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Dr.-Ing. Holger ROSEMANN (Project Coord.) ARCELORMITTAL EISENHÜTTENSTADT GmbH DEUTSCHLAND Mr Olaf HEINEMANN ÖSTERREICHISCHES FORSCHUNGS- UND PRÜFZENTRUM A OESTERREICH DI Richard KITZBERGER LUCCHINI S.p.A. ITALIA Dr.-Eng. Lisa CHIAPPELLI SCUOLA SUPERIORE DI STUDI UNIVERSITARI E DI PERFEZI ITALIA Dr. Valentina COLLA

RFSR-CT-2009-00033 SUPSYSCC

Full Title Development of an integrative plant, process and quality supervisory system at continuous casting by the intelligent combination of sensors, data analysis & decision support tech. Info Type of Project Research Duration (months) 42 Total Budget 1965692 € Start Date 1/07/2009 EU Contribution 1179415 € End Date (actual) 31/12/2012 State Research in progress Summary The aim of the proposal is the development of concepts and methods for an integrated plant, process and quality supervisory system for continuous casting. Thereby not only the casting machine itself, but also the previous and following processes shall be considered as far as it is necessary. The basis of the new system is the intelligent analysis of results from existing or new process and quality measurement devices combined with higher level supervisory tools like decision support functions. Operating an integrated supervisory system will guarantee improved process control, better plant, process and quality monitoring and unerring cast semi routing. Partners Organization Country Responsible ARCELORMITTAL ESPAÑA SA ESPAÑA Mr Jose DÍAZ ÁLVAREZ (Project Coord.) CENTRO SVILUPPO MATERIALI SPA ITALIA Dr.-Ing. Ricardo TONELLI LUCCHINI S.p.A. ITALIA Mr Luca TRILLINI RIVA ACCIAIO SPA ITALIA Eng Stefano BARAGIOLA GERDAU INVESTIGACION Y DESARROLLO EUROPA S.A. ESPAÑA Dr. Juan Luis MUÑOZ AALTO-KORKEAKOULUSAATIO (AALTO UNIVERSITY FOUN FINLAND M Sc Jukka LAINE VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Dipl -Ing Norbert LINK

RFSR-CT-2009-00034 SISCON

Full Title Improved monitoring and control of flat steel surface quality and production performance by utilisation of results from automatic surface inspection systems Info Type of Project Research Duration (months) 36 Total Budget 2214945 € Start Date 1/07/2009 EU Contribution 1328968 € End Date (actual) 30/06/2012 State Research in progress Summary Aim of this project is the development of an advanced supervisory system for surface quality and production performance of flat steel production based on the results from automatic surface inspection systems (ASIS). Therefore first of all a performance monitoring system for ASIS will be realised to ensure the required reliability of the provided data even during long-term operation. Based on this trusted data key performance indices (KPI) related to surface quality and line performance will be defined. Complemented with a suitable KPI combination of multiple lines new solutions supporting and monitoring the whole flat steel production process will be developed. 207 Partners Organization Country Responsible Summaries of RFCS projects 2003-2012 TGS9 : Factory-wide control, social and environmental issues

VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Dipl.-Math. Jens BRANDENBURGER (Project Coord.) CENTRO SVILUPPO MATERIALI SPA ITALIA Dr. Roberto PIANCALDINI DUFERCO LA LOUVIERE SA BELGIQUE Dr. Benoit VANDEROOST ILVA S.P.A. ITALIA Dr. Floriano FERRO ISRA PARSYTEC GMBH DEUTSCHLAND Mr Jan ERXLEBEN THYSSENKRUPP RASSELSTEIN GMBH DEUTSCHLAND Dipl -Ing Michael NÖRTERSHEUSER SCUOLA SUPERIORE DI STUDI UNIVERSITARI E DI PERFEZI ITALIA Dr. Valentina COLLA SALZGITTER MANNESMANN FORSCHUNG GmbH DEUTSCHLAND Dr. rer nat. Mathias STOLZENBERG SIEMENS VAI METALS TECHNOLOGIES SAS FRANCE Mr Olivier DESCHAMPS

RFSR-CT-2010-00033 MU-STEEL

Full Title Muons scanner to detect radioactive sources hidden in scrap metal containers Info Type of Project Research Duration (months) 30 Total Budget 1100478 € Start Date 1/07/2010 EU Contribution 660288 € End Date (actual) 31/12/2012 State Research in progress Summary Accidental melting of radioactive material creates large economical losses in the steel industry and problems in the environment. Orphan sources are not detectable with radiation portals when shielded. The Mu-steel project will design an inspection gate using the scattering of a radiation naturally falling on earth, the cosmic ray muons, therefore without any radiation hazard. This technique has been developed recently, and is able of detecting and classifying materials inside a container. Relevant hardware and software components of the system will be designed to be cost-effective and ready for industrial production. Prototypes of components will be delivered and tested. Partners Organization Country Responsible TECNOGAMMA SPA ITALIA Mrs Eleonora MARTON (Project Coord.) AFV ACCIAIERIE BELTRAME SPA ITALIA Ing. Giovanni BORINELLI ISTITUTO NAZIONALE DI FISICA NUCLEARE ITALIA Dr. Paolo CHECCHIA S.R.B. COSTRUZIONI SRL ITALIA Mr Massimo RIVOLI UNIVERSITA DEGLI STUDI DI BRESCIA ITALIA Dr. Germano BONOMI UNIVERSITA DEGLI STUDI DI PADOVA ITALIA Prof. Giovanni ZUMERLE

RFSR-CT-2010-00034 RELOTEMP

Full Title Reuse of low-temperature heat (<350°) for the reduction of CO²-impact of the steel industry Info Type of Project Research Duration (months) 42 Total Budget 1679311 € Start Date 1/07/2010 EU Contribution 1007587 € End Date (actual) 31/12/2013 State Research in progress Summary The aim of the project is to reduce energy consumption and CO2-emissions of the steel industry by the reuse of waste low temperature heat (LTH) with T<350°C in typical production processes (coke plant, sintering plant, BF, steelmaking, rolling mill and coating). To reach it, LTH sources and possible users (e.g. production of vapour, electricity and cold) will be identified, LTH reuse pathways and decision matrixes for integration of LTH recovery techniques will be developed. Concepts for the reuse of excess LTH in the steel industry will be elaborated and evaluated on basis of economical study and carbon footprint calculation. Partners Organization Country Responsible VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Dr.-Ing. Pavel IVASHECHKIN (Project Coord.) ARCELORMITTAL ESPAÑA SA ESPAÑA Mr Juan José ARRIBAS RAMIREZ ARCELORMITTAL MAIZIERES RESEARCH S.A. FRANCE Dr. Gérard GRIFFAY INSTITUTO DE SOLDADURA E QUALIDADE PORTUGAL Eng. Marco ESTRELA SWEREA MEFOS AB SVERIGE Dr. Chuan WANG SSAB TUNNPLÅT AB SVERIGE MSc Jonny KARLSSON SALZGITTER FLACHSTAHL GmbH DEUTSCHLAND Mr Ralph SCHAPER

RFSR-CT-2010-00035 SELSA

Full Title Selective salt elimination and valorisation for sustainable water and facility management in the steel industry Info Type of Project Research Duration (months) 42 Total Budget 1533717 € Start Date 1/07/2010 EU Contribution 920231 € End Date (actual) 31/12/2013 State Research in progress Summary The project aims at the development of innovative concepts for sustainable water and facility management in the European Steel Industry on basis of selective salt elimination techniques with integrated salt valorisation. The novel desalination processes will be automated and monitored by means of online ion analyser to minimise maintenance costs. Influence of the salt elimination on the pipe service life, product quality and process water reuse will be evaluated. Following results are expected: better product quality, prolonged pipe service life, reduced impact on the aquatic environment, saving of natural resources, reduced fresh water costs and waste water discharge costs. Partners Organization Country Responsible VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Dr.-Ing. Pavel IVASHECHKIN (Project Coord.) ARCELORMITTAL ESPAÑA SA ESPAÑA Mrs Beatriz PADILLA VIVAS AGENCIA ESTATAL CONSEJO SUPERIOR DE INVESTIGACIO ESPAÑA Prof. Dr. Manuel MORCILLO LINARES ILVA S.P.A. ITALIA Dr.-Ing. Carmelo LUCCA SCUOLA SUPERIORE DI STUDI UNIVERSITARI E DI PERFEZI ITALIA Dr. Valentina COLLA THYSSENKRUPP NIROSTA GMBH DEUTSCHLAND Dipl.-Ing. Alexander RASSOW

208 Summaries of RFCS projects 2003-2012 TGS9 : Factory-wide control, social and environmental issues

RFSR-CT-2010-00036 IPRO

Full Title Inline elemental characterisation of scrap charging for improved EAF charging control and internal scrap recycling Info Type of Project Research Duration (months) 36 Total Budget 1690008 € Start Date 1/07/2010 EU Contribution 1014004 € End Date (actual) 30/06/2013 State Research in progress Summary The overall objective of this project is to develop an improved guidance of scrap charging operation for electrical arc furnace (EAF, both for carbon and stainless steel production) in order to stabilize process conditions and optimise internal scrap recycling. Steel scrap will be characterised in-line with compact tailored laser analysers, monitoring the content of key elements in real time. In particular systems will be developed and set up to allow: - monitoring of Si (and also Ni and Mo) in a continuous scrap charging system with the objective to improve EAF charging procedure control for process stabilization; - monitoring of Mo in high-alloy steel internal scrap for stainless steel production with the objective to improve internal scrap recycling. Partners Organization Country Responsible FRAUNHOFER GESELLSCHAFT ZUR FOERDERUNG DER AN DEUTSCHLAND Dr. Reinhard NOLL (Project Coord.) CENTRO SVILUPPO MATERIALI SPA ITALIA Dr. Ugo CHIAROTTI SWEREA KIMAB AB SVERIGE Mr Jonas GURELL O.R.I. MARTIN - ACCIAIERIA E FERRIERA DI BRESCIA SpA ITALIA Ing. Uggero DE MIRANDA OUTOKUMPU STAINLESS AB SVERIGE MSc. Appell ANDERS RHEINISCH-WESTFÄLISCHE TECHNISCHE HOCHSCHULE AA DEUTSCHLAND Dipl.-Phys. Nadine STRAUSS

RFSR-CT-2010-00037 Cognitive Control

Full Title Cognitive control systems in steel processing lines for minimised energy consumption and higher product quality Info Type of Project Research Duration (months) 42 Total Budget 1585478 € Start Date 1/07/2010 EU Contribution 951287 € End Date (actual) 31/12/2013 State Research in progress Summary Much attention has been paid to the development of energy-saving technologies in terms of new/modified equipment and processes to reduce energy costs and reduce CO2 emissions. However, the efficiency of quality assurance as well as energy-savings can only be fully achieved for production lines with an optimally- tuned control performance. This project aims to create cognitive automation systems by integrating the features: self-monitoring; self-detection; self-testing; and self-adaptation. New strategies, methods and software will be developed for on-line performance assessment and diagnosis to determine origins of poor performance due to abnormal conditions in sensors, actuators, or controllers. The performance diagnosis and tuning information is to be derived using only operating data through innovative calculation techniques. This will provide self-adaptation of setup systems and automatic retuning of controllers or verify and eliminate given fault causes, keeping the control performance at optimum values. The techniques and systems to be developed will be demonstrated on different industrial processing lines (cold rolling, annealing, galvanising), aiming to improve product quality and to minimise energy consumption. Partners Organization Country Responsible VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Dipl.-Ing. Andreas WOLFF (Project Coord.) ARCELORMITTAL EISENHÜTTENSTADT GmbH DEUTSCHLAND Dr.-Ing. Jürgen BATHELT SWEREA MEFOS AB SVERIGE MSc Mats KARLBERG THYSSENKRUPP NIROSTA GMBH DEUTSCHLAND Dr.-Ing. Wolfram GERLACH UNIVERSITY OF STRATHCLYDE* ROYAL COLLEGE OF SCIEN UNITED KINGDOM Dr. Reza KATEBI

RFSR-CT-2010-00038 COATHYDRO

Full Title New approaches to quantitative hydrogen analysis of coated steel products Info Type of Project Research Duration (months) 42 Total Budget 1571121 € Start Date 1/07/2010 EU Contribution 942672 € End Date (actual) 31/12/2013 State Research in progress Summary Basic objective is to improve production control and R&D capabilities for coated steel products with high strength and sensitive microstructure. To continue the development of such products clear and rigorous methodologies of hydrogen measurements are necessary. Particular effort will be dedicated to implement: - SIMS and new laser-based methods to measure hydrogen local concentration; - GD-OES methodologies to measure bulk concentration and identify possible interface enrichment of hydrogen; - new TDA MS-based instrumentation for improved distinction of traps and origin of hydrogen; - new, possible Certified Reference Materials. New methodologies will be evaluated on the basis of standard extraction procedures. Partners Organization Country Responsible LEIBNIZ-INSTITUT FÜR ANALYTISCHE WISSENSCHAFTEN - I DEUTSCHLAND Dr. Roland HERGENRÖDER (Project Coord.) JOHANNES KEPLER UNIVERSITY, LINZ OESTERREICH Prof. Achim Walter HASSEL SWEREA KIMAB AB SVERIGE Dr. Arne BENGTSON MAX-PLANCK-INSTITUT FÜR EISENFORSCHUNG GmbH DEUTSCHLAND Dr. Michael ROHWERDER THYSSENKRUPP STEEL EUROPE AG DEUTSCHLAND Dipl.-Ing. Karin BERGERS VOESTALPINE STAHL GMBH OESTERREICH Dr. Hubert DUCHACZEK

209 Summaries of RFCS projects 2003-2012 TGS9 : Factory-wide control, social and environmental issues

RFSR-CT-2011-00036 MULTISAVE

Full Title Multichannel spectroscopy and hyperspectral imaging for improved steel surface states monitoring and cost savings Info Type of Project Research Duration (months) 36 Total Budget 1428502 € Start Date 1/07/2011 EU Contribution 857101 € End Date (actual) 30/06/2014 State Research in progress Summary With the development of new steel grades and coatings presenting specific surface chemistries, the control of the surface states has become a need for a better product surface quality in downstream applications. Having access to a punctual measurement for surface characterization only brings local information but not a global chemical understanding. Recent developments in hyperspectral technology offer the possibility to couple it with multiple optical fibres. This research project aims at leading to a pre- industrial multipoint spectroscopic analyzer to monitor the online chemistry of surface states at critical processing points and then quantifying the resulting economic benefits. Partners Organization Country Responsible ARCELORMITTAL MAIZIERES RESEARCH S.A. FRANCE Dr. David GLIJER (Project Coord.) SPECIM, SPECTRAL IMAGING OY FINLAND Mr Timo HYVÄRINEN UNIVERSITÄT PADERBORN DEUTSCHLAND Prof. Dr. Guido GRUNDMEIER TEKNOLOGIAN TUTKIMUSKESKUS VTT*TECHNIC. RESEARC FINLAND Dr Mikko JUUTI

RFSR-CT-2011-00037 SLAGFERTILISER

Full Title Impact of long-term application of blast furnace and steel slags as liming materials on soil fertility, crop yields and plant health Info Type of Project Research Duration (months) 42 Total Budget 1904134 € Start Date 1/07/2011 EU Contribution 1142480 € End Date (actual) 31/12/2014 State Research in progress Summary Based on the results from the research project 7210-PR-267 finished in 2005, additional questions on the effects of Cr and V from iron and steel slags on soils and plants will be investigated as a basis for further environmental discussions on liming agents in the EU. The use of the fine grained steel slag as fertiliser in agriculture is advantageous for both the steel industry and the farmers in Europe and world wide. Steel industry cannot sell the fines into building industry, farmer have always positive yield. Therefore it is necessary to investigate, if there will be no harmful effects on the food chain soil-plant-animal-humans. Partners Organization Country Responsible FEhS - INSTITUT FÜR BAUSTOFF-FORSCHUNG e.V. DEUTSCHLAND Dr.-Ing. Dirk MUDERSBACH (Project Coord.) AKTIEN-GESELLSCHAFT DER DILLINGER HÜTTENWERKE AG DEUTSCHLAND Dr.-Ing. Klaus-Jürgen ARLT ÖSTERREICHISCHE AGENTUR FÜR GESUNDHEIT UND ERNÄ OESTERREICH Dr. Heide SPIEGEL ARBEITSGEMEINSCHAFT HÜTTENKALK E.V. - ARGE DEUTSCHLAND Dr. Martin REX ILVA S.P.A. ITALIA Dr. Lorenzo TOMASSINI RUUKKI METALS OY FINLAND Mr Sakari TUOMIKOSKI SCUOLA SUPERIORE DI STUDI UNIVERSITARI E DI PERFEZI ITALIA Dr. Valentina COLLA VOESTALPINE STAHL GMBH OESTERREICH Ing. Mario MAUHART

RFSR-CT-2011-00038 CORSA

Full Title Cost effective, reliable and safe acid management at European pickling plants Info Type of Project Research Duration (months) 42 Total Budget 1316464 € Start Date 1/07/2011 EU Contribution 789878 € End Date (actual) 31/12/2014 State Research in progress Summary Plastic materials are frequently used in process equipment for pickling and acid regeneration to cope with the aggressive conditions (50-90 °C, pH<1). Thus safety, service reliability and an effective acid regeneration depends on these materials. Still very little is known about the longterm performance of plastics in equipment for pickling lines. Claims from the society for industrial safety in terms of both, occupational health and safety and environmental welfare have become stronger and stronger. Thus, this project aims at improving the knowledge of plastic corrosion in European Steel plants to achieve a safe, reliable and effective acid management. Partners Organization Country Responsible SWEREA KIMAB AB SVERIGE Dr. Petter BERGSJÖ (Project Coord.) ANDRITZ AG OESTERREICH Dipl.-Ing. Thomas HOFBAUER OUTOKUMPU STAINLESS AB SVERIGE Mr Thorsten SCHNEIKER SCANACON AB SVERIGE Mr Lars-Ake FREDRIKSSON GERDAU INVESTIGACION Y DESARROLLO EUROPA S.A. ESPAÑA Mr José Manuel LLANOS THYSSENKRUPP NIROSTA GMBH DEUTSCHLAND Dipl.-Ing. Karl-Heinz KIRCHHOFF VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Dr. Frank RÖGENER

210 Summaries of RFCS projects 2003-2012 TGS9 : Factory-wide control, social and environmental issues

RFSR-CT-2011-00039 RECONI

Full Title Recovery of nickel from waste in stainless steel industry Info Type of Project Research Duration (months) 42 Total Budget 1843952 € Start Date 1/07/2011 EU Contribution 1106372 € End Date (actual) 31/12/2014 State Research in progress Summary Pickling processes in stainless steel industry produce large amounts of waste acid and neutralisation sludge which contains a lot of valuable nickel. In Europe more than 2500 t/a of nickel with a current value of 40 million €/a are deposited. The objective of the project is to recover this nickel from waste acid and neutralisation sludge, respectively. Therefore, two processing routes with several well coordinated unit operations will be investigated. The recovered nickel will be re-used in the steelmaking process. The recovery processes can be used for both main pickling systems, HF/HNO3-pickling and HNO3-free pickling. Partners Organization Country Responsible VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Dr. Frank RÖGENER (Project Coord.) CENTRO SVILUPPO MATERIALI SPA ITALIA Eng. Luca LATTANZI HENKEL ITALIA SPA ITALIA Dr. Yean DEMERTZIS MEAB METALLEXTRAKTION AB SVERIGE Dr. Hans REINHARDT THYSSENKRUPP ACCIAI SPECIALI TERNI SpA ITALIA Dr. Alessandro SEGALA THYSSENKRUPP NIROSTA GMBH DEUTSCHLAND Dipl.-Ing. Hans-Günther HARTMANN

RFSR-CT-2011-00040 TECPLAN

Full Title Technology-based assistance system for production planning in stainless mills Info Type of Project Research Duration (months) 42 Total Budget 1572839 € Start Date 1/07/2011 EU Contribution 943704 € End Date (actual) 31/12/2014 State Research in progress Summary Production planning systems are essential for minimising costs and maximising productivity in steel processing plants. This project aims at introducing and developing a new assistance system that determines the optimal production route for stainless steel, depending on the value of an applicability index as function of the desired strip quality, mill capabilities (i.e. actuators and control equipment) and customer requirements. This will be based on (1) the installation and measurement of strip flatness at different locations in the processing chain and (2) the development of prediction (transfer) models for flatness, crossbow, thickness tolerance, other quality parameters and plant throughput for the different processing routes (hot strip mill, four 20-high rolling mills, three annealing plants, three temper mills and one finishing line). Partners Organization Country Responsible VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Dr.-Ing. Jan POLZER (Project Coord.) CENTRO SVILUPPO MATERIALI SPA ITALIA Dr. Marco LUPINELLI SCUOLA SUPERIORE DI STUDI UNIVERSITARI E DI PERFEZI ITALIA Dr. Valentina COLLA THYSSENKRUPP ACCIAI SPECIALI TERNI SpA ITALIA Dr. Francesco MARTINI THYSSENKRUPP NIROSTA GMBH DEUTSCHLAND Dipl.-Ing. Hans-Günther HARTMANN

RFSR-CT-2012-00037 ICONSYS

Full Title Intelligent control station for improved quality management in flat steel production by a next generation decision support system Info Type of Project Research Duration (months) 42 Total Budget 1243745 € Start Date 1/07/2012 EU Contribution 746248 € End Date (actual) 31/12/2015 State Research in progress Summary Based on four years of very successful operation of a Decision Support System regarding quality of steel strips (developed in a RFCS project), now the next significant step has to be done to support people at the control stations of rolling and finishing mills: the Intelligent Control Station. Therefore the following new developments will be integrated in existing decision support solutions: automatic monitoring of used manufacturing specifications and their continuous improvement, evaluation procedures to detect products which exceed the customer requirements significantly and methods to optimise between environmental and technical aspects during the decision about further treatment of coils. Partners Organization Country Responsible VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Dipl.-Ing. Norbert HOLZKNECHT (Project Coord.) ARCELORMITTAL ESPAÑA SA ESPAÑA Mrs María Luisa Teresa RODRIGUEZ MONTEQIN SCUOLA SUPERIORE DI STUDI UNIVERSITARI E DI PERFEZI ITALIA Dr. Valentina COLLA THYSSENKRUPP NIROSTA GMBH DEUTSCHLAND Dr.-Ing. Thomas HECKENTHALER UNIVERSIDAD DE OVIEDO ESPAÑA Prof. Francisco ORTEGA FERNANDEZ

211 Summaries of RFCS projects 2003-2012 TGS9 : Factory-wide control, social and environmental issues

RFSR-CT-2012-00038 I2MSTEEL

Full Title Development of a new automation and information paradigm for integrated intelligent manufacturing in steel industry based on holonic agent technology Info Type of Project Research Duration (months) 42 Total Budget 3545543 € Start Date 1/07/2012 EU Contribution 2127326 € End Date (actual) 31/12/2015 State Under process of signature Summary Most of the European steel production relies on information systems with limitations which are typically due to the unrelated historic development of their respective elements (typically over several decades). Actual production environments are inflexible and have many roadblocks for a seamless and agile cooperation and exchange of information along the whole supply chain. In this context, I²MSteel will develop and demonstrate a new paradigm for a factory- and company-wide automation and information technology for Intelligent and Integrated Manufacturing at steel production. A description of the steel making supply using semantic technologies in such a way, that higher-level automation and information systems have the basis for orientation, communication and high-level information exchange across the complete supply chain. A platform of agents and holons will be developed for its capacity to perform all the high level tasks of steel production: product tracking, process control, process planning, through-process quality control, information storage, logistics, etc. This platform will operate on Service Oriented Architecture which offers the necessary basic routines for the agent level regarding communication, product tracking, negotiation protocols, data storage, event handling, etc. A demonstration will be installed in a hot facility from continuous casting to hot rolling. The platform will operate in real time with on line data coming from the production site. Decisions done by the platform will be compared with day to day production in order to evaluate the added-value for the main objectives: cost, quality and leadtime. Finally the transferability of the new paradigm to all possible kinds of processes and process chains in the steelindustry will be demonstrated. Partners Organization Country Responsible ARCELORMITTAL MAIZIERES RESEARCH S.A. FRANCE Dr. Gael MATHIS (Project Coord.) CENTRE D'EXCELLENCE EN TECHNOLOGIES DE L'INFORMA BELGIQUE Mr Philippe MASSONET CENTRO SVILUPPO MATERIALI SPA ITALIA Dr. Francesca MARCHIORI SIEMENS AG DEUTSCHLAND Mr Norbert GOLDENBERG VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Dr. Alexander EBEL

RFSR-CT-2012-00039 REFFIPLANT

Full Title Efficient use of resources in steel plants through process integration Info Type of Project Research Duration (months) 42 Total Budget 2351879 € Start Date 1/07/2012 EU Contribution 1411127 € End Date (actual) 31/12/2015 State Research in progress Summary The project aims to improve the efficiency of resource use (materials, water, energy) in integrated steelworks. This aim will be achieved by developing alternative design solutions for the use of materials at source and improved recycling, reuse, treatment of wastewater, sludge and dust by considering the site-wide interactions between the processes and related factors. When optimisation of the different criteria leads to contradictory answers, the project will demonstrate how to utilize Process Integration methods and techniques in combination with multi-criteria optimisation to identify overall solutions that minimise the ecological footprint of steelmaking Partners Organization Country Responsible SCUOLA SUPERIORE DI STUDI UNIVERSITARI E DI PERFEZI ITALIA Dr. Valentina COLLA (Project Coord.) ILVA S.P.A. ITALIA Dr. Lorenzo TOMASSINI SWEREA MEFOS AB SVERIGE Ms Katarina LUNDKVIST PROCESS INTEGRATION LTD UNITED KINGDOM Prof. Robin SMITH SSAB EMEA AB SVERIGE Dr Katarina KYLEFORS TATA STEEL UK LIMITED UNITED KINGDOM Dr. Mansour SAIEPOUR

RFSR-CT-2012-00040 EvalHD

Full Title Refinement of flat steel quality assessment by evaluation of high-resolution process and product data Info Type of Project Research Duration (months) 42 Total Budget 1452752 € Start Date 1/07/2012 EU Contribution 871651 € End Date (actual) 31/12/2015 State Research in progress Summary Product quality is the main driver for European steel producers competing against other steel companies on the global market. Therefore continuous quality improvement and zero-defect-manufacturing are major targets of European steel makers which is why the production of high quality steel is supported by modern measuring systems gathering an increasing amount of high resolution (HR) quality and process data along the complete flat steel production chain. Whereas this kind of data is already used for online process control applications where possible, this is not the case for the assessment of product quality. The aim of this project is to develop an advanced product quality supervisory system for flat steel production based on HR measuring data. To achieve this ambitious target new methods have to be developed, employing innovative software technologies and modern computation capabilities, tailored to handle the massive amount of data accumulating during the steel production process. A dedicated HR data storage system capable of handling high-performance HR data access not achievable using standard data- warehouse technology will be designed and built. Based on this new quality of data access a modular software system for product quality supervision will be developed supporting standardised network access to product data by definition of a unified web- service. This web-service will be implemented at the industrial sites, providing intuitive visualisations of the current production state and through-process synchronization of data coming from different production steps. By cause and effect analysis based on HR data increased knowledge about origin and evolution of quality deficiencies shall be gained to improve quality decisions already at early stage. Conditions for high quality production will be quantified to increase process understanding and optimize the whole production chain towards zero-defect production Partners Organization Country Responsible 212 VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Dipl.-Math. Jens BRANDENBURGER (Project Coord.) ILVA S.P.A. ITALIA Dr. Floriano FERRO Summaries of RFCS projects 2003-2012 TGS9 : Factory-wide control, social and environmental issues

SWEREA MEFOS AB SVERIGE Mr Thorbjörn HANSEN THYSSENKRUPP RASSELSTEIN GMBH DEUTSCHLAND Mr Christoph SCHIRM SCUOLA SUPERIORE DI STUDI UNIVERSITARI E DI PERFEZI ITALIA Dr. Valentina COLLA

RFSR-CT-2012-00041 MONWIRE

Full Title Quality and process monitoring system based on surface and internal defect detection for hot and cold wire Info Type of Project Research Duration (months) 42 Total Budget 2273046 € Start Date 1/07/2012 EU Contribution 1363827 € End Date (actual) 31/12/2015 State Research in progress Summary The aim of this research proposal is to develop a new advanced on-line monitoring for wire production by means of integration of the main quality product parameters (as surface and internal defects presence, defect classification) and process variables in order to aid the application of grading rules, product allocation, optimisation of feedback actions. This goal will be reached with the development and upgrading of innovative inspection techniques (EC, EMAT and Optical). Only the combination of multiple solution and the integration of process measures linked with an efficient product tracking assure the complete monitoring/control of product quality. Partners Organization Country Responsible CENTRO SVILUPPO MATERIALI SPA ITALIA Dr. Roberto PIANCALDINI (Project Coord.) ARCELORMITTAL MAIZIERES RESEARCH S.A. FRANCE Dr. Philip MEILLAND DANIELI AUTOMATION SPA ITALIA Dr Riccardo FERRARI O.R.I. MARTIN - ACCIAIERIA E FERRIERA DI BRESCIA SpA ITALIA Ing. Uggero DE MIRANDA ROHMANN GMBH DEUTSCHLAND Dipl.-Ing. Gerald SCHNEIBEL VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Dipl.-Phys Ing. Dietmar OBERHOFF

RFSR-CT-2012-00042 MAGSEP

Full Title Strong field magnetic separation of fine particles from cooling water and gas wash water circuits of the steel industry Info Type of Project Research Duration (months) 42 Total Budget 1024100 € Start Date 1/07/2012 EU Contribution 614460 € End Date (actual) 31/12/2015 State Research in progress Summary The project aims at the filter aid free separation of fine iron containing particles, especially between 0,5 μm and 10 μm, from cooling water (strip casting, descaling, hot rolling) and gas wash water (e.g. blast furnace) by using permanent strong-field magnets. This proposed technology focuses on a small ratio plant design with significantly low back flush water flows below 1% of the treated flow. Efficient separation of the iron containing particles is required to ensure a high and homogenous product quality (surface, strength). Nozzle wear by abrasive particles leads to differing spray patterns and cooling rates and hence inhomogeneous microstructures. Furthermore, the concentration of fine scale/particles causes an increased maintenance effort due to blocking. Considering increasing raw material prices (iron, alloys), metallurgical reuse of the separated particles after conditioning in the steel industry (sinter plant, basic oxygen furnace) is mandatory to decrease the loss of resources by disposal of filter aid contaminated particles. The proposed research project is a joint project involving partners with different tasks according to their respective areas of expertise. AME, TATA and DEW are representative users of the research results, supplying products with different microstructures and compositions like carbon steel (AME), medium alloyed carbon steels (TATA) and stainless steels (DEW). Furthermore, these steel producing companies focus on operational tests and application. The emphasis of the research companies (BFI, AME) is on laboratory tests to describe the magnetic separation (BFI), CFD simulations to evaluate the suitable plant geometry (AME) as well as conditioning of separated particles and evaluation of the research results in field tests (BFI). The project results in development of rules of construction and a concept including the particle separation, conditioning and metallurgical reuse done by the research institutes and users like DEW and AME Partners Organization Country Responsible VDEh-BETRIEBSFORSCHUNGSINSTITUT GmbH DEUTSCHLAND Mr Martin HUBRICH (Project Coord.) ARCELORMITTAL ESPAÑA SA ESPAÑA Mrs Beatriz PADILLA VIVAS DEUTSCHE EDELSTAHLWERKE GMBH DEUTSCHLAND Dipl.-Ing. Peter KÜHN TATA STEEL UK LIMITED UNITED KINGDOM Dr. Mansour SAIEPOUR

213 European Commission

Summaries of RFCS projects 2003-2012 – Full list of projects co-financed by the Research Fund for Coal and Steel research programme of the European Commission

Luxembourg: Publications Office of the European Union

2012 — IV, 214 pp. — 21 x 29,7 cm

This volume contains the full list of projects co-financed by the Research Fund for Coal and Steel research programme starting from its first call in 2002 and up to 2012.

For each project, a summary of the project objectives is given along with details on project report, starting date and duration, budget, funding and the partners involved.

Project information