• Maintenance and Reliability Training and Artificial Intelligence Remote Services

A Publication of the Association for Iron & Steel Technology A Publication of the Association for Iron Maintenance and Reliability • •

Iron & Steel Technology August 2020 Vol. 17 No. 8 TENSION LEVELING TECHNOLOGY FROM ANOTHER WORLD...

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August 2020 Vol. 17, No. 8

2019–2020 Board of Directors President Ronald J. O’Malley, Missouri University of Science and Technology Past President James F. Dudek, United States Steel Corporation First Vice President Steven J. Henderson, Commercial Metals Company Second Vice President K eith J. Howell, ArcelorMittal USA Officers-at-Large Barry T. Schneider, Steel Dynamics Inc. Brian K. Bishop, AK Steel Corp. IN THIS ISSUE Thomas C. Toner, SSAB Americas Maintenance & Reliability Allen C. Behr, Nucor Corp. Treasurer Joseph Dzierzawski, Beumer Corp. Secretary Ronald E. Ashburn, Association for Iron & Steel Controlling Equipment Failures Caused by Technology Foundation President Petroleum-Based Fluid Degradation Theodore F. Lyon, Hatch Associates J. Schlobohm Consultants Inc. 52 Directors Steven C. Asseff, Charter Steel Richard Besich, ArcelorMittal Indiana Harbor Reduction of Maintenance Costs and Improved Lothar Birkhäuser, Vallourec MTBR of Boiler Steam Drum and Superheat Kevin J. Bort, TMEIC Elaine Chen, ArcelorMittal Global R&D – East Safety Valves Chicago 56 T. Shelton, C. Kuntz and L. Frey Shannon F. Clark, ArcelorMittal Dofasco G.P. Conrad N. D’Costa, ArcelorMittal Dofasco G.P. Maintenance Practices of Gas Analyzers in Barry C. Felton, ArcelorMittal Burns Harbor Stephan A. Ferenczy, TCI Consultants Steel Industry Mauro Bianchi Ferri, Acciarium S.r.l. A. Garg and P. Basur Noah Hanners, Nucor Tubular Products Heath Hooker, Nucor-Yamato Steel Co. 60 Love Kalra, ArcelorMittal Indiana Harbor William C. Seres, Steel Dynamics Inc. – Flat Roll Life Extension of Motor Control Centers: Group Sinton When to Maintain and When to Replace Mark E. Shircliff, American Roller Bearing Co. M.R. Hussey and D.B. Durocher S cott R. Story, U. S. Steel Research and Technology Center 74 John T. Wilson, MINTEQ International Inc. Liwei Zhang, ArcelorMittal Global R&D – East Chicago New Advancements in Condition Monitoring Technology to Enhance Steel Mill Productivity and Profitability 82 T. Hlade and T. Hurley Reparation of Trusses in Steel Plant 2019–2020 Foundation Board of Trustees Environment President J.G. de Araújo Silva, A.M.C. de Gouveia, H. Inoue, Theodore F. Lyon, Hatch Associates 90 G.O. Daumas and L.T. Araújo Consultants Inc. Past President Kolin L. Keller, Commercial Metals Company Copper Stave Bending: Challenges, President-Elect Management and Solutions Glenn A. Pushis, Steel Dynamics Inc. R. Horwood, R. Mawer, R. Harvey and D. Osborne Treasurer 94 Joseph Dzierzawski, Beumer Corp. AUG Secretary Ronald E. Ashburn, Association for Iron & Steel

Technology 2020

Trustees I

Iron & Steel Technology Thomas P. DeLuca, ATI Specialty Rolled Products ON THE COVER IRON & STEEL TECHNOLOGY Terry G. Fedor II, Cleveland-Cliffs Inc. Brian Smith of ANDRITZ Herr-Voss Stamco Inc.’s Michael A. Kercsmar Timothy J. Lorge, Charter Steel shapemeter maintenance facility in Ambridge, Michael P. Madar, ArcelorMittal Cleveland Pa., USA, pictured with ANDRITZ’s flatness Jerold P. Nelesen Jr., Berry Metal Co. measurement and flatness control system. Mark R. Olson, Gerdau Long Steel North ANDRITZ’S shape control systems are used in

America August 2020 various kinds of rolling mills and process lines Thom as J. O’Toole in the metals industry for modernization, repair,

Randy C. Skagen, Nucor Steel Tuscaloosa Inc. Vol. 17 No. 8 I

refurbishment, testing, simulations, virtual reality • Maintenance and Reliability training and artificial intelligence remote services. AIST.ORG

A Publication of the Association for Iron & Steel Technology Photo courtesy of 2 AUG 2020 I IRON & STEEL TECHNOLOGY I AIST.ORG Special Features Special 147 142 107 ech 2021Callfor PapersandPresentations 103 44 40 2

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CHS 38-Y MS&T20 AdvancePr Cleaners Air Self-Maintaining With Pressurization Room S AIST Awards Call forNominations:AISTBoard ofDirectors B. Chedal-Anglay, J.I.LucasFuentesand D. Hinton-Beales J. Longmire Combination BetweenEddyCurrent andVision Detection inHot-RolledLongProducts byMeansof Digital T Connect Europe andAsia (worldsteel): World’s LongestSuspensionBridgeWill “Our Stories”Fr afety First: Keeping Critical Spaces Clean Using Using Clean Spaces Critical Keeping First: afety ear LifeMember:DavidWedmore 2 2021SavetheDateandCallforPapers ransformations: Improving PeriodicDefect

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150 160 158 156 ditorial Calendar 154 Sponsorships and Advertising 119 116 Association News Departments 28 24 20 9 resident’s Message 5 teel News 6

Recovery.Eriez.com | 814.835.6000 M T S S N P E T F P S I S ndustry Statistics # echnology Trainingechnology echnology Committees echnology oundation Update ersonnel Spotlight teel Irony teel Calendar trategic Insights From World Steel Dynamics Steel World From Insights trategic ew Products &Resources Products ew ember Chapters ember Ballistic Separator • Low investment capital • Add revenue from recovered copper • Low copper frag to mill(less than.17%) any steel frag to quality. a#1GRADE Also allows steel millsto re-process ERIEZ Shred1 1 Grade

3 AIST Technology Committee Chairs Safety & Health Long Products Justin Hoover, Steel Dynamics Inc. Chris Petrie, Steel Dynamics Inc. – Structural and Environmental Rail Division Kevin Deliman, Baltimore Aircoil Co. Pipe & Tube Cokemaking Frank Baumgardner, Nucor Steel–Decatur LLC Shiju Thomas, United States Steel Corporation Rolls Ironmaking Chris Hrizo, WHEMCO Inc. Mitren Sukhram, Hatch Metallurgy — Steelmaking & Casting Direct Reduced Iron Bryan Webler, Carnegie Mellon University P. Chris Pistorius, Carnegie Mellon University Metallurgy — Processing, Products & Applications Publisher Electric Steelmaking K onstantin Redkin, WHEMCO Inc. Ronald E. Ashburn Gilbert Hutton, CMC Steel California Energy & Utilities Oxygen Steelmaking Anup Sane, Air Products Publications Manager Ashraf Hanna, RHI Magnesita Electrical Applications Amanda L. Blyth Specialty Alloy & Foundry Ramesh Khajjayam, Primetals Technologies USA LLC Andy Pinskey, Holland Manufacturing Corp. Technical Editor Ladle & Secondary Refining Digitalization Applications Jennifer M. Emling Matt Hallam, Steel Dynamics Inc. – Roanoke Bar Jim Hendrickson, ArcelorMittal USA Division Project & Construction Management Technical Editor Continuous Casting Richard E. Dugan, AK Steel – Mansfield Works Rudolf Moravec, ArcelorMittal Global R&D Maintenance & Reliability Emily Williams Hot Sheet Rolling Carl E. Garringer, Steel Dynamics Inc. – Structural and Rail Division Robert Brunelli, TMEIC Production Editor Cold Sheet Rolling Lubrication & Hydraulics Janet A. McConnell Ken Peter, AK Steel Research and Innovation B rad Jensen, Alloy Technology Solutions Center Refractory Systems News Editor Galvanizing Michael Anderson, Magneco/Metrel Inc. Nikhil Kulkarni, Steel Dynamics Inc. — Flat Roll Material Handling Sam Kusic Group Jeffersonville Plant Bruce Zimmerman, Nucor Steel–Indiana Tinplate Mill Products Cranes Senior Graphic Designer Eric Almquist, Star Tool & Die Works Inc. Mark McGinley, Hall Industries Christopher P. Brown Plate Rolling Transportation & Logistics Brad Sigurdson, EVRAZ Portland Kevin Ray, Nucor-Yamato Steel Co. Graphic Designer Carolyn A. Trobaugh

Graphic Designer AIST Member Chapter Chairs and Secretaries Krista J. McGhee Argentina Northern Pacific Graphic Designer The Argentina Member Chapter is currently working to Tim Kuzmicky, USS-POSCO Industries (chair) appoint new executive committee members. Adrian Deneys, Praxair Inc. (secretary) Beniamina Dapra Australia Ohio Valley Andrea Fontana, InfraBuild Steel (chair) Yury Krotov, Steel Dynamics Inc. – Flat Roll Group Len Woods, Taharoa Ironsands Ltd. – Taharoa Butler Division (chair) (secretary) Mark Shircliff, American Roller Bearing Co. (secretary) Birmingham Philadelphia Jacob Lewis, Nucor Steel Tuscaloosa Inc. (chair) Amy Beard, Quaker Houghton (chair) Summer Knight, Nucor Steel Tuscaloosa Inc. Jose de Jesus, Xtek Inc. (secretary) (secretary) Pittsburgh Brazil William Schlichting, United States Steel Corporation Lothar Birkhäuser, Vallourec Soluções Tubulares S.A. (chair) (chair) Robert Conley, Factory Source LLC (secretary) Ronaldo Santos Sampaio, RS Consultants Ltda. Southeast (secretary) Becky E. Hites, Steel-Insights LLC (chair) Detroit Michael Hutson, John Hutson Co. (secretary) Jamie Lash (chair) Southern California Roger Kalinowsky, Sidock Group Inc. (secretary) Jay Strowger, California Steel Industries Inc. (chair) European Stephen Bunch, California Steel Industries Inc. Mauro Bianchi Ferri, Acciarium S.r.l. (chair) (secretary) Jernej Pretnar, Quaker Houghton (secretary) Southwest India Christopher Welfel, CMC Steel Texas (chair) Rajiv Bhatnagar, Essar Steel India Ltd. (chair) Sabra Serino, CMC Steel Texas (secretary) Iron & Steel Technology Bimalendu Mukhopadhyay (secretary) St. Louis Korea Terry Laird, Alton Steel (chair) (ISSN 1547-0423) Sun Cheer Sheen, Donghae SteelTech Corp. (chair) N. Stephen Pappas, retired (secretary) Published monthly by AIST. Editorial and advertising offices at 186 Thorn Hill Road, Warrendale, PA 15086 USA. Preferred Mexico Globe-Trotters Periodicals postage paid at Warrendale, Pa., and at additional Carlos Garza, FRISA Steel (chair) Bob LaRoy, Steel Dynamics Inc. – Flat Roll Group mailing office. POSTMASTER: Send address changes to Iron & Edgar Gonzalez, Quaker Houghton (secretary) Butler Division (chair – meltshop) Steel Technology, 186 Thorn Hill Road, Warrendale, PA 15086 Midwest Jared Hoff, Showa Denko Carbon Inc. (secretary – USA. Rich Trzcinski, Process Plus (chair) meltshop) Statements and opinions given in articles, news items and Rafael Garcia, Gerdau (chair – rolling mill) advertisements in AIST Iron & Steel Technology are the expres- Mario Munguia (secretary) sions of contributors and advertisers, for which AIST assumes Northeastern Ohio Alejandro Guerra, AMI (secretary – rolling mill) no responsibility. Publication does not constitute endorsement AUG John Bondy, ArcelorMittal Cleveland (chair) by AIST. Single copy U.S., Canada and Mexico, $20. Single copy other Donald Salsbury, Middough Inc. (secretary) countries, $35. Subscription price U.S., Canada and Mexico, 2020 Northern $165 per year. Subscription price other countries, $205 per year

David Nicol, Xtek Inc. (chair) (U.S. funds). Printed in USA. I

Cameron Mitchell, ArcelorMittal Dofasco G.P. Copyright 2020, AIST. All rights reserved. No part of this publi- IRON & STEEL TECHNOLOGY (secretary) cation may be reproduced or utilized in any form or by any means, electronic or mechanical, including photocopying, recording, or by any information storage or retrieval system, without permission in writing from the publisher. Publications Mail Agreement No. 40612608. Return undeliver- able Canadian addresses to: IMEX Global Solutions, P.O. Box 25542, London, ON N6C 6B2 Canada. IN OUR NEXT ISSUE

Long Products Rolling Technologies AIST.ORG

President’s Message 5

Navigating the Course Ahead

To the AIST Community,

As previously announced, the AIST Board of Directors made the difficult decision last month to cancel AISTech 2020 — The Iron & Steel Technology Conference and Exposition as scheduled for 31 August–3 September in Cleveland, Ohio, USA.

AISTech represents one of the world’s largest in-person learning platforms for iron and steel technology. It is also a networking catalyst whereby many companies, large and small, generate the business that drives the steel economy. While we may be disheartened by the decision, the rationale for canceling the event was sound in light of the pervasive COVID-19 pandemic and the many unique in-person programs that define AISTech. As an industry, Safety First shall always prevail.

We want to thank our many attendees, presenters, exhibiting companies and sponsors for their unwavering commitment to AIST through this unprecedented situation. Your encouragement and support of AIST and the steel industry is genuinely appreciated.

As human beings, and as representatives of the steel industry, we must all continue to navigate — with a steady hand — the uncertainty of these times. Through it all, there is a valuable lesson to be learned: “Life is 10% what happens to us, and 90% Ronald J. O’Malley how we react to it.” F. Kenneth Iverson Chair Though COVID-19 can never change AIST’s mission and vision, it has changed the Professor in Steelmaking way we will serve and provide value to our membership. In recent months, the AIST Technologies and Board of Directors and the AIST Foundation Board of Trustees have guided the director, Kent D. Peaslee Steel strategic integration of our conventional programs with virtual technology platforms. Manufacturing Research Center In this regard, we have launched virtual meeting platforms for each of our Missouri University of Science 30 Technology Committees. In addition, AIST now provides weekly webinars, cross- and Technology ing the full spectrum of iron and steel technology while also reaching a global audi- ence. As we look ahead, our upcoming schedule includes a full lineup of fundamen- tal technology training courses, many of which will be offered with a hybrid format. AIST President

AIST remains committed to providing our global steel community with valuable net- 2019–2020 working and educational experiences, whether in-person, virtually or a hybrid combination of both. We will leverage our immense bandwidth to disseminate knowledge, share ideas and raise our collective level of performance.

The opportunities for steel to succeed are endless, and we look forward to your continued participation! AUG

Sincerely, 2020

IRON & STEEL TECHNOLOGY

Ronald J. O’Malley

AIST.ORG 6 Steel News Get the most up-to-date news at SteelNews.com

Also in the News Big River Steel announces partnership with Koch Metallics

• Stelco Inc. is partnering with DTE North America — Big River Steel has River Steel chief executive David Energy Services Inc. on con- signed an agreement that will make Stickler. struction of a 65-MW cogenera- a Koch family business the steel- Koch is a major investor in Big tion plant at the steelmaker’s Lake maker’s exclusive metallics procure- River Steel. Erie Works in Ont., Canada, Stelco ment agent. “I look forward to broadening our has announced. Under the agree- In a statement, Big River said relationship as we jointly advance ment, DTE will provide the capital the agreement with Koch Metal- in the metallics space,” Stickler said. for the plant, and Stelco will pay lics, a subsidiary of Koch Minerals With the agreement in place, Big DTE a fixed annual fee under a & Trading, will allow it to improve River metallics procurement man- 20-year energy services agree- its metallics procurement by lever- ager Martin Baker will join the Koch ment. Construction is to start this aging Koch’s networks, capabilities team as metallics procurement and summer, and the plant is to come and potential for providing addi- conversion manager. on-line in the first half of 2022. tional services in support of Big “Martin is a proven professional, “Once operational, the cogen plant River Steel’s growth initiatives. and I am fully confident that Mar- is expected to reduce Stelco’s en- “Entering into this agreement will tin joining the Koch team will lead ergy costs and further enhance accelerate several initiatives Big to new and expanded relationships the utilization of Stelco’s process- River Steel has underway that pro- with forward-thinking domestic and generated offgases,” Stelco said. vide alternatives to the ways metal- international metallics providers lics and flat-rolled steel have histori- and steel consumers,” said Stickler. • The Systems Group has been cally been bought and sold,” said Big awarded a contract to upgrade a Texas electric arc furnace (EAF). In a statement, The Systems ArcelorMittal lays out European climate action plan Group said its Systems Spray- Cooled unit will outfit Optimus Europe — ArcelorMittal Europe field that “accounts for the global Steel’s Beaumont, Texas, USA,, intends to become carbon neutral nature of the steel market, address- EAF with a Spray-Cooled™ elec- in the next 30 years by transitioning ing domestic, import and export tric arc furnace roof and a new to a direct reduction–based produc- steel dynamics, as well as the distinc- Spray-Cooled elbow. It also will tion route and by investing in tech- tion between primary and second- make other engineering improve- nology and equipment to store or ary sources to make steel.” ments. “This project is expected recycle its carbon output. “Today, the biggest barrier to tran- to be the first phase of a multi “By investing in both routes — and sitioning to carbon-neutral steel, phase meltshop upgrade to a in recognition of the need to act now beyond the necessary technologies more optimized design with the to combat climate change — this reaching commercial maturity, is upper shell and offgas system to means ArcelorMittal Europe can the absence of the right market con-

follow,” The Systems Group said significantly reduce CO2 emissions ditions,” said Geert Van Poelvoorde, in a statement. by 2030 over a 2018 baseline, while chief executive of ArcelorMittal waiting for the large-scale, afford- Europe – Flat Products. able renewable energy needed for “The financial costs of realizing hydrogen-based steelmaking,” the carbon-neutral steelmaking are company said in its newly released undeniably huge. However, with a climate action road map in Europe. shift in market conditions brought ArcelorMittal said the effort rep- about by having the right policies in AIST.ORG

resents an investment of EUR45 bil- place, European steelmakers will be I lion to EUR65 billion. The company able to unlock the means to reduce also is calling on EU leaders to help emissions from steel globally, while establish an environment that sup- also ensuring the European steel ports clean steelmaking. industry remains competitive.” That environment, it said, would include access to abundant, afford- IRON & STEEL TECHNOLOGY

able clean energy and a level playing 2020

AUG 7

Nippon Steel schedules blast To that end, the company said Additionally, the company plans furnace reline that within the next three to five to invest in an electric arc furnace years, it will build a direct reduced and a direct reduction plant at Asia — Nippon Steel Corp. has iron plant and install two electric its integrated Whyalla plant in announced plans to reline the arc furnaces at LIBERTY Steel Australia. The company said the No. 3 blast furnace at its Nagoya Galati in Romania and construct new ironmaking and steelmak- Works in southern Japan. what the company said will be ing facilities will complement its The company said the US$452 Europe’s first hybrid furnace, planned construction of a new million project is intended to main- blending electric arc and blast fur- heavy-section combination rolling tain the facility’s competitiveness. nace steelmaking, at its Ostrava mill there. F “After the relining, advanced IT plant in the Czech Republic. and other leading-edge technologies from Japan and abroad will be adopted in the No. 3 blast furnace to realize stable production and higher productivity,” the company said. “The Nagoya Works is one of the world’s leading steel works in optimal integrated manufacturing technology of steel sheets for auto- mobiles. It is also positioned as Nip- pon Steel’s main integrated manufacturing base of high-grade steel sheet, with competitive capability in product development and response to customers. The Nagoya Works plays a role by supplying upstream- processed materials of high-grade steel sheet to other steel works,” it added. The project has been scheduled for the first half of 2022.

GFG Alliance accelerates carbon reduction investment plans

Global — GFG Alliance is stepping up investment plans in Europe and Australia as it looks to modernize plants and make them more sustainable and efficient, the company has announced. AUG

“GFG Alliance reaffirms its com- 2020

mitment to develop environmen- I tally sustainable GREENSTEEL, IRON & STEEL TECHNOLOGY GREENALUMINIUM and to progress toward carbon neutrality, as a group, by 2030. The pandemic has underlined the need to modernize plants to make them more flexible

I and efficient, which goes hand in AIST.ORG hand with investment in low-carbon technology for us,” it said.

Industry Statistics 9 Top Steel-Producing Companies in 2019 (in million metric tons)

2019 2018 Company Country Rank MT Rank MT y-o-y % change ArcelorMittal1 Luxembourg 1 97.31 1 96.42 0.90 China Baowu Group2 China 2 95.47 2 67.43 41.60 Nippon Steel Corp.3 Japan 3 51.68 3 49.22 5.00 HBIS Group4 China 4 46.56 4 46.80 (0.50) POSCO South Korea 5 43.12 5 42.86 0.60 Shagang Group China 6 41.10 6 40.66 1.10 Ansteel Group China 7 39.20 7 37.36 4.90 Jianlong Group China 8 31.19 9 27.88 11.90 Tata Steel Group India 9 30.15 11 27.27 10.60 Shougang Group China 10 29.34 10 27.34 7.30 Shandong Steel Group China 11 27.58 13 23.21 18.80 JFE Steel Corp. Japan 12 27.35 8 29.15 (6.20) Valin Group China 13 24.31 14 23.01 5.60 Nucor Corp. United States 14 23.09 12 25.49 (9.40) Hyundai Steel China 15 21.56 15 21.88 (1.50) IMIDRO5 Iran 16 16.79 19 16.79 0 JSW Steel Ltd. India 17 16.26 18 16.83 (3.40) Steel Authority of India Ltd. (SAIL) India 18 16.18 20 15.93 1.60 Benxi Steel China 19 16.18 21 15.90 1.80 Fangda Steel China 20 15.66 24 15.51 1.00 NLMK Russia 21 15.61 17 17.39 (10.20) Baotou Steel China 22 15.46 27 15.25 1.40 China Steel Corp. Taiwan 23 15.23 22 15.88 (4.10) Techint Group Argentina 24 14.44 25 15.38 (6.10) Liuzhou Steel China 25 14.40 29 13.53 6.40 Rizhao Steel China 26 14.20 28 14.95 (5.00) United States Steel Corporation United States 27 13.89 26 15.37 (9.60) EVRAZ United Kingdom 28 13.81 30 13.02 6.10 CITIC Pacific Special Steel China 29 13.55 33 12.55 8.00 Gerdau Brazil 30 13.13 23 15.08 (12.90) Jingye Steel China 31 12.58 37 11.25 11.80 MMK Russia 32 12.46 31 12.66 (1.60) Shaanxi Steel China 33 12.45 36 11.38 9.40 Sanming Steel China 34 12.40 35 11.68 6.20 thyssenkrupp Germany 35 12.25 32 12.58 (2.60) Zenith Steel China 36 11.93 48 8.03 48.60 Severstal Russia 37 12.04 34 12.04 0 Tsingshan Stainless Steel China 38 11.40 44 9.29 22.70 Nanjing Steel China 39 10.97 41 10.05 9.20 Taiyuan Steel China 40 10.86 39 10.70 1.50 Anyang Steel China 41 10.54 38 10.97 (3.90) AUG Metinvest Holding Ukraine 42 9.56 42 9.37 2.00

Xinyu Steel China 43 9.47 43 9.36 1.20 2020

Donghai Special Steel China 44 8.90 50 7.61 17.00 IRON & STEEL TECHNOLOGY Jinxi Steel China 45 8.73 40 10.33 (15.50) Erdemir Group Turkey 46 8.61 45 9.14 (5.80) Steel Dynamics Inc. United States 47 8.59 46 8.92 (3.70) Kunming Steel China 48 7.73 — — — SSAB Sweden 49 7.62 47 8.70 (12.40)

Jiuquan Steel China 50 7.48 — — — I

AIST.ORG 1Includes shares in AM/NS India and China Oriental. 4Includes tonnage of Serbia Iron & Steel d.o.o. Beograd and MAKSTIL A.D. in Macedonia. 2Includes tonnage of Maanshan Steel and Chongqing Steel. 5Combined tonnage of Mobarrakeh Steel, Esfahan Steel, Khuzestan Steel and NISCO. 3Includes tonnage of Nippon Steel Stainless Steel Corp., Sanyo Special Steel and Ovako AB, and shares in AM/NS India and USIMINAS. Source: World Steel Association 10 Industry Statistics Major Steel-Producing Countries in 2019 (in million metric tons)

2019 2018 2014 (5 years) 2009 (10 years) Country Rank MT Rank MT Rank MT Rank MT China 1 996.3 1 928.3 1 822.7 1 567.8 India 2 111.2 2 106.5 4 86.5 3 62.8 Japan 3 99.3 3 104.3 2 110.7 2 87.5 United States 4 87.8 4 86.6 3 88.2 5 58.2 Russia 5 71.9 6 71.7 6 71.5 4 60.0 South Korea 6 71.4 5 72.5 5 71.5 6 48.6 Germany 7 39.7 7 42.4 7 42.9 7 32.7 Turkey 8 33.7 8 37.3 8 34.0 10 25.3 Brazil 9 32.2 9 34.9 9 33.9 9 26.5 Iran 10 25.6 11 24.5 14 16.3 16 10.9 Italy 11 23.2 10 24.5 11 23.7 11 19.8 Taiwan, China 12 22.0 12 23.2 12 23.1 12 15.9 Ukraine 13 20.8 13 21.1 10 27.2 8 29.9 Vietnam 14 20.1 17 14.1 26 5.7 41 2.0 Mexico 15 18.5 14 20.2 13 19.0 14 14.0 France 16 14.4 15 15.4 15 16.1 15 12.8 Spain 17 13.6 16 14.3 16 14.2 13 14.4 Canada 18 12.9 18 12.9 17 12.7 18 9.3 Poland 19 9.0 19 10.2 19 8.6 20 7.1 Saudi Arabia 20 8.2 28 5.2 25 6.3 28 4.7 Belgium 21 7.8 20 8.0 21 7.3 23 5.6 Austria 22 7.4 23 6.9 20 7.9 22 5.7 Egypt 23 7.3 21 7.8 24 6.5 24 5.5 United Kingdom 24 7.2 22 7.3 18 12.1 17 10.1 Netherlands 25 6.7 24 6.8 22 7.0 24 5.2 Indonesia (e) 26 6.4 27 5.5 38 2.8 34 3.5 South Africa 27 5.7 25 6.3 23 6.5 19 7.5 Australia 28 5.5 26 5.7 31 4.6 25 5.2 Slovak Republic (e) 29 5.3 29 5.2 30 4.7 33 3.7 Sweden 30 4.7 33 4.7 32 4.5 36 2.8 Argentina 31 4.6 30 5.2 27 5.5 32 4.0 Malaysia (e) 32 4.5 38 3.5 29 5.0 21 6.0 Czech Republic 33 4.4 31 4.9 28 5.4 29 4.6 Thailand 34 4.2 35 4.3 35 3.5 27 5.0 Kazakhstan (e) 35 4.1 34 4.6 34 3.7 30 4.1 Finland 36 3.5 36 4.1 33 3.8 35 3.1 Romania 37 3.4 37 3.5 36 3.2 37 2.8 United Arab Emirates 38 3.3 39 3.2 40 2.4 — — Pakistan 39 3.3 32 4.7 — — — — Belarus 40 2.6 41 2.5 39 2.5 38 2.4 Qatar 41 2.6 40 2.6 37 3.0 41 1.4 Algeria 42 2.4 45 2.0 — — — — Luxembourg 43 2.1 42 2.2 41 2.2 39 2.1 Portugal 44 2.0 43 2.2 42 2.1 — — AIST.ORG

Oman (e) 45 2.0 44 2.0 — — — — Serbia 46 1.9 47 2.0 — — — — Hungary 47 1.8 46 2.0 48 1.2 43 1.4 Switzerland (e) 48 1.5 48 1.5 44 1.5 — — Philippines (e) 49 1.4 49 1.5 45 1.4 — — Greece 50 1.4 50 1.5 — — — —

IRON & STEEL TECHNOLOGY Others — 15.9 — 14.0 — — — —

I World 1,868.8 1,808.4 1,645.1 1,201.9 2020

AUG Source: World Steel Association 11

World Crude Steel Production as of May 2020 (in thousand metric tons) May Year to date 2020 2019 Change % 2020 2019 Change % Austria 540e 646 (106) (16.4) 2,839 3,331 (491) (14.7) Belgium 600e 707 (107) (15.1) 2,980 3,371 (391) (11.6) Bulgaria 50e 56 (6) (10.7) 258 252 6 2.5 Croatia 0e 0 0 0 0 48 (48) (100) Czech Republic 365 401 (36) (9.0) 1,939 2,050 (111) (5.4) Finland 235 374 (139) (37.2) 1,540 1,651 (111) (6.7) France 784 1,235 (451) (36.5) 4,796 6,391 (1,595) (25.0) Germany 2,565 3,513 (948) (27.0) 14,982 17,312 (2,330) (13.5) Greece 100e 130 (30) (23.1) 473 636 (163) (25.6) Hungary 135 154 (19) (12.0) 689 814 (125) (15.4) Italy 1,855 2,217 (362) (16.3) 8,263 10,467 (2,204) (21.1) Luxembourg 160e 201 (41) (20.3) 758 991 (233) (23.5) Netherlands 487 610 (123) (20.1) 2,718 2,923 (204) (7.0) Poland 700e 807 (107) (13.2) 3,342 4,134 (793) (19.2) Slovenia 32 56 (24) (43.5) 251 278 (26) (9.5) Spain 833 1,256 (423) (33.7) 4,716 6,246 (1,530) (24.5) Sweden 370 452 (82) (18.1) 2,025 2,196 (171) (7.8) United Kingdom 700e 636 64 10.1 3,130 3,182 (52) (1.6) Other EU 260e 866 (606) (70.0) 2,604 4,193 (1,590) (37.9) Total — European Union 10,770 14,315 (3,545) (24.8) 58,303 70,465 (12,162) (17.3) Bosnia-Herzegovina 40e 73 (33) (45.2) 225 368 (143) (38.8) Macedonia 0 22 (22) (100) 74 109 (35) (32.0) Norway 55e 57 (2) (4.0) 283 270 13 4.8 Serbia 115 185 (70) (38.0) 626 862 (236) (27.4) Turkey 2,272 3,063 (792) (25.8) 13,491 14,297 (805) (5.6) Total — Other Europe 2,481 3,401 (919) (27.0) 14,699 15,905 (1,207) (7.6) Belarus 175e 231 (56) (24.3) 1,040 1,100 (60) (5.4) Kazakhstan 250e 398 (148) (37.2) 1,434 1,630 (196) (12.0) Moldova 30e 30 0 1.0 133 146 (13) (8.9) Russia 6,000e 6,302 (302) (4.8) 29,850 30,232 (382) (1.3) Ukraine 1,638 1,827 (189) (10.4) 8,295 9,270 (975) (10.5) Uzbekistan 80e 56 24 42.9 398 248 150 60.5 Total — C.I.S. (6) 8,173 8,844 (672) (7.6) 41,150 42,625 (1,476) (3.5) Canada 850e 1,032 (182) (17.6) 4,892 5,488 (596) (10.9) Cuba 15e 18 (3) (15.2) 83 88 (6) (6.6) El Salvador 8e 8 0 0.5 39 41 (1) (3.6) Guatemala 20e 24 (4) (17.8) 113 124 (11) (8.6) Mexico 1,168 1,663 (495) (29.8) 7,027 8,254 (1,227) (14.9) United States 4,912 7,553 (2,641) (35.0) 31,452 37,069 (5,617) (15.2) Total — North America 6,973 10,298 (3,324) (32.3) 43,606 51,064 (7,457) (14.6) Argentina 194 407 (212) (52.2) 1,230 1,908 (678) (35.5) Brazil 2,188 2,826 (639) (22.6) 12,141 14,442 (2,300) (15.9) Chile 90e 83 7 7.9 434 322 112 34.7 Colombia 85e 124 (39) (31.5) 480 553 (73) (13.2) Ecuador 40e 51 (11) (21.0) 230 252 (22) (8.8) Paraguay 2e 1 1 54.1 9 6 2 32.1 Peru 70e 108 (38) (35.2) 410 503 (93) (18.5) Uruguay 5e 4 1 16.0 23 24 (1) (2.4) Venezuela 2e 3 (1) (37.8) 15 31 (16) (50.9) Total — South America 2,676 3,608 (932) (25.8) 14,972 18,041 (3,069) (17.0) Egypt 628 651 (23) (3.6) 3,518 3,494 25 0.7 Iran 2,368 2,158 210 9.7 11,461 10,297 1,165 11.3 Libya 47 46 1 1.4 197 226 (29) (12.9) Qatar 63 235 (172) (73.3) 684 1,058 (374) (35.4) Saudi Arabia 565 706 (141) (19.9) 3,269 3,468 (199) (5.7) South Africa 99e 510 (410) (80.5) 1,356 2,679 (1,323) (49.4) United Arab Emirates 164 291 (128) (43.9) 1,135 1,365 (230) (16.8) Total — Africa/Middle East 3,933 4,596 (663) (14.4) 21,621 22,587 (965) (4.3) China 92,267 88,565 3,702 4.2 411,751 403,975 7,776 1.9 India 5,767 9,468 (3,701) (39.1) 35,851 47,543 (11,692) (24.6)

Japan 5,916 8,674 (2,758) (31.8) 36,604 42,292 (5,688) (13.4) AUG

South Korea 5,387 6,275 (888) (14.1) 27,407 30,073 (2,666) (8.9) Pakistan 90e 290 (200) (69.0) 1,137 1,369 (232) (16.9) 2020

Taiwan 1,730e 1,934 (204) (10.6) 8,696 9,610 (913) (9.5) I

Thailand 350e 428 (78) (18.1) 1,823 1,736 87 5.0 IRON & STEEL TECHNOLOGY Vietnam 1,949 1,750 199 11.4 9,016 8,846 170 1.9 Total — Asia 113,456 117,384 (3,928) (3.3) 532,285 545,443 (13,159) (2.4) Australia 471 494 (23) (4.6) 2,232 2,243 (11) (0.5) New Zealand 59 57 2 3.9 193 277 (84) (30.4) Total — Oceania 530 550 (21) (3.7) 2,425 2,520 (95) (3.8) Total 148,992 162,996 (14,004) (8.6) 729,060 768,650 (39,590) (5.2)

Note: The countries included in this table accounted for approximately I

99% of total world crude steel production in 2019. e = estimate Source: World Steel Association. Data as of 1 July 2020. AIST.ORG 12 Industry Statistics

— Monthly production — Capability utilization %

to ns)

000 on (’ on (%) utilizati on uc ti ty ili ty pr od Capab tons) production (’000 Weekly Monthly Monthly 1,240 54.6% 5,415 u u u r ar ay ay ay ay ay u ct an un un c S u ay

Figure 1: U.S. monthly steel production and capability utilization. Figure 2: U. S. weekly steel production. Source: Platts. Source: Platts.

U.S. Production Capability and Imports — Monthly imports — Monthly exports — Monthly imports as % of apparent supply Production — U.S. crude steel production stood at 5.42 mil-

lion tons in May 2020, a decline of 35% from the same month in the prior year. Capacity utilization was down as 42.5%

well, falling to 54.6% during the month. In May 2019, the tons) ’0 00 utilization rate was 80.8% (Fig. 1). 2,775 However, production notched up from April 2020, increas-

ing 1.9% from 5.32 million tons. ( and exports mports i

For comparison, global crude steel production fell 8.7% Monthly imports as % supply of apparent % as imports Monthly year over year to an estimated 164 million tons. steel Monthly

404 Estimated weekly production in June rose slightly, but u u u c t c t c t steadily, during the month. Production stood at nearly r an r an r an r 1.20 million tons in the first week of June and ended the Figure 3: U.S. imports and exports. month at 1.24 million tons, an increase of about 3.8% Source: U.S. Census Bureau. (Fig. 2).

Imports and Exports — The U.S. imported 2.78 million tons of steel in April 2020, a decrease of nearly 17% from the Meanwhile, U.S. steel exports fell to 404,000 tons of mill same month in 2019 (Fig. 3). However, imports were up products, a decline of 33% over the same month in 2019. from the prior month, increasing from 1.75 million tons. Table 1 provides a breakdown of imports by country of origin. In April 2020, imports of Chinese steel fell 57%

Monthly imports (’000 tons) m-o-m m-o-m y-o-y y-o-y Country/Region Apr’20 Mar’20 Apr’19 (’000 tons) (%) (’000 tons) (%) Japan 69 57 159 13 22.6 (90) (56.4) South Korea 161 206 275 (45) (21.6) (114) (41.4)

AIST.ORG China 28 19 64 8 42.8 (37) (57.1)

I Taiwan 48 61 72 (13) (21.8) (24) (33.0) India 11 16 14 (5) (31.8) (3) (23.8) Turkey 2 5 32 (4) (71.7) (30) (95.2) EU 244 300 376 (56) (18.7) (133) (35.3) Russia 1 1 1 0 27.6 (0) (14.7) Brazil 1,229 14 1,186 1,214 8,477.8 42 3.6 Mexico 383 272 277 111 40.7 106 38.4

IRON & STEEL TECHNOLOGY Canada 337 536 371 (198) (37.0) (34) (9.2)

I Other 262 265 506 (2) (0.8) (244) (48.1)

2020 Total imports 2,775 1,752 3,335 1,023 58.4% (560) (16.8%)

AUG Table 1: U.S. imports by country/region. Source: U.S. Census Bureau. 13

Monthly imports (’000 tons) m-o-m m-o-m y-o-y y-o-y Steel products Apr’20 Mar’20 Apr’19 (’000 tons) (%) (’000 tons) (%) Wire rod 67 67 152 1 1.0 (85) (55.8) Structurals 37 26 51 11 41.1 (14) (28.1) Bars 201 180 206 21 11.4 (5) (2.6) Rebar 122 79 93 43 54.1 29 31.4 Pipe and tube 277 447 586 (170) (38.1) (309) (52.8) Oil country tubular goods 93 196 256 (102) (52.4) (163) (63.7) Plates 168 157 267 11 7.0 (99) (37.2) Flat-rolled 454 545 647 (91) (16.7) (192) (29.7) Hot-rolled coil 122 146 169 (24) (16.2) (47) (27.9) Cold-rolled coil 332 400 477 (67) (16.8) (145) (30.4) Other finished 107 91 132 16 17.5 (25) (19.2) Finished imports 1,310 1,513 2,041 (202) (13.4) (731) (35.8) Ingots 2 2 1 (0) (12.4) 0 41.3 Blooms, slabs, billets 1,462 237 1,292 1,225 517.0 170 13.2 Semi-finished imports 1,464 239 1,294 1,225 512.7 171 13.2 Total imports 2,775 1,752 3,335 1,023 58.4% (560) (16.8%) Table 2: U.S. imports by product category. Source: U.S. Census Bureau. Note: Monthly imports are rounded to the nearest integer.

Monthly average exchange rate comparisons Currency per m-o-m m-o-m y-o-y y-o-y Country U.S. dollar Apr’20 Mar’20 Apr’19 change (%) change (%) Japan Yen/$ 107.81 107.49 111.63 0.32 0.3 (3.82) (3.4) South Korea Won/$ 1,224.46 1,220.30 1,142.21 4.16 0.3 82.25 7.2 China CNY/$ 7.07 7.02 6.72 0.05 0.7 0.35 5.2 Taiwan TWD/$ 30.08 30.12 30.06 (0.04) (0.1) 0.02 0.1 India INR/$ 76.24 74.35 69.43 1.89 2.5 6.81 9.8 Turkey TRY/$ 6.85 6.34 5.76 0.51 8.0 1.09 18.9 EU €/$ 0.92 0.91 0.89 0.01 1.1 0.03 3.4 Russia RUB/$ 75.22 73.15 64.62 2.07 2.8 10.60 16.4 Brazil Real/$ 5.33 4.93 3.90 0.40 8.1 1.43 36.7 Mexico MXN/$ 24.10 22.14 18.94 1.96 8.9 5.16 27.2 Canada CAD/$ 1.41 1.40 1.34 0.01 0.7 0.07 5.2 Table 3: Monthly average exchange rate comparisons. Sources: Organisation for Economic Co-operation and Development and X-Rates.

year over year to 28,000 tons. Imports from Turkey were units in June 2020. Single-month sales also were down, fall- down, too, declining approximately 95% to 2,000 tons. EU ing 25.2% year over year to 1.13 million units. imports fell as well, dropping 35% to 244,000 tons. However, imports from Canada and Mexico collectively grew 11% “The vehicle market shouldn’t expect things to change much year over year to 720,000 tons. during the next quarter,” said Charlie Chesbrough, senior economist at Cox Automotive. “Potential shortages on some Table 2 provides a breakdown of imports by selected products. The U.S. imported 1.46 million tons of semi-finished steel in April 2020, up 13% from the same month last year. However, finished steel imports declined during the same — Sales T3M — Sales y-o-y % change period, falling nearly 36% to 1.31 million tons. Of the finished products, imports of oil country tubular goods fell the hardest, declining nearly 64% to 93,000 tons. Wire rod imports were down, too, falling 56% to 67,000 tons. Hot- change rolled coil tonnages also saw declines, dropping nearly 28% AUG

to 122,000 tons. 2020 % ear %

-on -y I

Table 3 provides an overview of the monthly average curren- IRON & STEEL TECHNOLOGY

cy exchange rates to complement the data in Tables 1 and 2. year on Auto T3M)('000 sales Auto 3,027

Produc ti -32%

U.S. Demand un ar un ar un ar un S c S c S c

I Automotive — Three-month light vehicle sales in the U.S. AIST.ORG (Fig. 4) fell 31.5% year over year, declining to 3.03 million Figure 4: U.S. automobile sales and year-on-year % change. Source: WardsAuto.com. 14 Industry Statistics

— Total construction — Private construction — Highway construction — y-o-y % change — y-o-y % change — Public construction 820

bn ) ng (US$

nd i ng e pe 104 on s 3.2% r % ea r cha %

on structi

-on- y 477 ea r Year-on-year % change Y n (US$bn) io n construct gh way ial c nt ial

Hi -7.6%

n- r es ide 343 No

u u u u u u ct ct ct an an an r r r r ct ct ct r r r r an an an Figure 5: Estimated value of construction put in place. Figure 6: Infrastructure spending. Source: U.S. Census Bureau. Source: U.S. Census Bureau.

products, a second wave of COVID-19 cases, and continued The spending data would seem to be a bright spot in an high unemployment will make Q3 challenging. However, otherwise dark sky, but Anirban Basu, chief economist for we still believe the very worst of the crisis in terms of sales the Associated Builders and Contractors, said the numbers impact is behind us. The question for the rest of the year is aren’t necessarily reassuring. the pace of the recovery, not the direction.” “Non-residential construction has fared far better than most To be sure, there is much ground to recover. economic segments during the COVID-19 crisis, but the industry’s headline spending numbers fail to fully capture According to LMC Automotive, the pandemic-related shut- the damage inflicted on many key segments by the pan- downs wiped out an estimated 2.8 million units of planned demic,” Basu said. production in the first half of the year. “Factoring in slower line speeds and reduced demand, full-year 2020 output is “For instance, spending in the lodging category was down likely to be 3.4 million units lower than in 2019, a reduction more than 12% in April relative to a year ago and down of nearly 21%,” it said. 11% in the amusement and recreation category. Spending is also down meaningfully in a number of categories that are Non-Residential Construction — Non-residential construction public-sector-intensive, including education and highway/ spending rose 3.2% year over year to a seasonally adjusted street.” annualized rate of US$820.1 billion in April 2020 (Fig. 5). However, spending declined 2.5% from the prior month, Basu said that with state and local government finances now dropping from US$840.8 billion. on shaky footing, infrastructure spending is in jeopardy. Future commercial projects are also imperiled, he said.

“Many office suites and storefronts have been vacated, which will suppress demand for new construction going forward. Capital will also be scarcer, resulting in greater difficulty — Oil and gas rig count — y-o-y % change securing financing for projects. Moreover, if the past is

prologue, many dislocated construction workers will find jobs in other industries, given construction’s tendency to be among the last economic segments to fully recover,” he said.

chan ge Infrastructure — U.S. highway and street construction spend-

AIST.ORG ing (Fig. 6) declined 7.6% in April 2020 to US$104 billion

I % ear % on a seasonally adjusted annualized basis. Spending also was down from the prior month, falling from US$111.2 billion. ear-on- y Y U.S. oil and gas rigcount oil gas and U.S.

Energy — The U.S. rig count plunged further during June,

dropping to 265 units by month’s end (Fig. 7). As of 26 June 265 -73% 2020, the count was down nearly 73% from the same week in the prior year. IRON & STEEL TECHNOLOGY r r r c c c

I un un un un S S S a a a

Figure 7: U.S. oil and gas rig count.

2020 According to the Reuters news service, some analysts are Source: Baker Hughes. expecting that recent gains in oil prices will prompt drillers AUG 15

— New orders — y-o-y % change — Industrial production — y-o-y % change

ng e bn )

% ar cha %

-7% ar- on -ye Industrial production Industrial w orders (US$ (US$ orders Ne w Year-on-year % change % Year-on-year Ye 88 61 -17%

r r r r r r r r r r r r r r r u u u c t c t c t an an an Figure 8: Monthly non-defense capital goods. Figure 9: Industrial production index. Source: U.S. Census Bureau. Source: U.S. Federal Reserve Board.

to slow the pace of rig reductions and possibly put some U.S. Pricing and Costs units back into service later in the year. Steel Prices — Average monthly prices for U.S. mill prod- “While weekly declines have slowed a bit versus what we saw ucts (Fig. 11) generally moved upward in May 2020. For in April and May, they are likely to continue at the slower example, hot-rolled coil (HRC) prices notched up US$9/ pace into the third quarter with most operators in no rush ton, or about 1.8%, from April 2020 to US$498/ton. Aver- to pick up rigs and few others still cutting activity per their age cold-rolled coil prices also rose, increasing 3.9% from plans,” U.S. financial services firm Tudor, Pickering, Holt & the prior month to US$661/ton. Plate prices were up, too, Co. wrote in a recent note, according to Reuters. rising about 3% to US$588/ton.

Non-Defense Capital Goods — New orders for non-defense More pricing data is shown in Table 4. capital goods, excluding aircraft and parts, declined 7.3% in April 2020, falling year over year to a seasonally adjust- The difference between the average monthly HRC price ed US$61.3 billion (Fig. 8). Orders also declined from in the U.S. and the European Union widened in May 2020 US$65.6 billion in the prior month. (Fig. 12). On a year-over-year basis, the spread grew to US$106/ton. In May 2019, the spread stood at US$57/ton. Industrial Production Index — The industrial production During the same period, the spread between the U.S. price index — a broad-based proxy for steel demand — fell to and the average China price also expanded, increasing to 88 points in April 2020, a decline of 17.4% from the same US$101/ton. In 2019, the spread stood at US$96/ton. month in the prior year (Fig. 9). The score excludes the high-tech index. The score also was down from the prior Scrap Prices — Certain average monthly domestic scrap month, falling from 103.2 points. prices notched up in May 2020. The average price for

ISM Index — The U.S. manufacturing sector regained a bit of ground in May 2020, according to the Institute for Supply Management’s monthly Report on Business. For the month, the institute’s Purchasing Managers Index stood at 43.1% ansin nde x

(Fig. 10), up from 41.5% in April. An index score above I 50% indicates that the manufacturing sector is generally

growing; a score below 50% indicates that it is generally AUG contracting.

2020

I “May appears to be a transition month, as many panelists IRON & STEEL TECHNOLOGY and their suppliers returned to work late in the month. ly Supp ly Ma(ISM) nagement 43.1%

However, demand remains uncertain, likely impacting fo r inventories, customer inventories, employment, imports ntractin and backlog of orders,” said Timothy R. Fiore, chairman st it ute In of the institute’s manufacturing business survey committee. ay ay ay ay ay ay ay ay ay ay ay

The institute said that of 18 manufacturing sectors surveyed I as part of the monthly report, six reported growth. AIST.ORG Figure 10: ISM Manufacturing Purchasing Managers Index (PMI). Source: Institute for Supply Management. 16 Industry Statistics

— Cold-rolled coil — Plate — Rebar — Hot-rolled coil — USA, ex-works Midwest mill — Europe, ex-works — China, export

ton )

per

(US $ il 661 498

co t-ro ll ed Steel prices (US$ per t on ) per (US$ prices Steel 588

Ho 397 580 392

498

ay ay ay ay u u u u u u ay ay ay ay

Figure 11: U.S. steel prices. Figure 12: U.S. prices compared to China and the EU. Source: Platts. Source: Platts.

No. 1 heavy melt rose US$4/ton from the prior month to and auto bundling also narrowed, decreasing by US$1/ton US$205/ton (Fig. 13). Meanwhile, average auto bundling to US$204/ton. However, the difference between plate and prices increased US$10/ton from the prior month, rising No. 1 heavy melt grew month over month to US$383/ton, to US$294/month. However, the average price for shred- an increase of US$13/ton. ded scrap receded by US$2/ton, dropping to US$229/ton.

Certain U.S. metal spreads narrowed in May 2020. Based on average monthly prices, the difference between rebar and No. 1 heavy melt (Fig. 14) contracted, falling by US$16/ ton to US$375/ton. The difference between hot-rolled coils

May’20 Apr’20 May’19 m-o-m m-o-m y-o-y y-o-y Product ($) ($) ($) ($) (%) ($) (%) HRC 498 489 543 9 1.8 (45) (8.3) CRC 661 636 706 25 3.9 (45) (6.4) Galv 717 703 788 14 2.0 (71) (9.0) Plate 588 571 817 17 3.0 (229) (28.0) Wire rod 597 614 744 (17) (2.8) (147) (19.8) Rebar 580 592 680 (12) (2.0) (100) (14.7) Auto bundles/busheling 294 284 268 10 3.5 26 9.7 No. 1 HM 205 201 209 4 2.0 (4) (1.9) Table 4: Steel prices in U.S. dollars per ton by product category. Source: Platts.

— Auto bundling/busheling — Shredded scrap — Plate vs. No. 1 heavy melt — Rebar vs. No. 1 heavy melt — No. 1 heavy melt — HRC vs. auto bundling

on ) 294 AIST.ORG

(US$ per t per (US$ ces 383 375

pri ap 229 Price spread (US$ per ton) per spread(US$ Price Scr 205 204 u u u a y a y a y a y IRON & STEEL TECHNOLOGY

ay u ay u ay ay u I Figure 14: Metal spread, HRC vs. auto bundles, rebar and plate Figure 13: U.S. scrap prices. vs. No. 1 heavy melt. 2020 Source: Platts. Source: Platts. AUG 17

— Weekly average spot price — y-o-y % change Work Harder or Work Smarter? $105 cha nge

ar % ye n ear- o US$ per dry ton per metric US$ dry Y -2.8%

r r r u n u n u n u n S c S c S c a a a

Figure 15: Iron ore fines weekly average spot price (62% Fe content). Source: Platts Iron Ore Index.

Global Pricing Benchmarks

Iron Ore Market — Weekly average spot prices for 62% iron ore (CFR China) held above the US$100/dry metric threshold during June, supported by healthy demand and supply Hard work is not enough. Successful disruptions. casting operations require finding new, more efficient ways of doing the work According to the Platts Iron Ore Index, June’s weekly average spot prices ranged from US$100.64/dmt to US$104.97/ to increase profits and outsmart the dmt (Fig. 15). competition. You know that all too well.

According to a quarterly report from Australia’s Depart- That’s why you see a growing number ment of Industry, Science, Energy and Resources, weather of Brokk remote-controlled machines issues and the COVID-19 pandemic have disrupted supply, in foundries around the world. It’s and, at the same time, Chinese demand has remained strong through the pandemic. the intelligent demolition powerhouse that combines power, precision and “Chinese demand for iron ore has thus far proven to be rela- flexibility in a unique, safe way. tively robust, despite the impact of COVID-19 and the shutdown of significant sectors of the Chinese manufacturing Whether you are cleaning a ladle, industry,” the Australian government wrote in the report. de-bricking a furnace or removing baked-on sand from a large casting, the remote-controlled Brokk machine

— World — Middle East — India — Africa gets the job done with minimal plant — North America — South America shut down time and maximum ergonomics. Brokk. The smartest maintenance solution when the AUG

(’000 MT) 3,056 heat is on.

5,616 2020

oduction production 000 MT) (’ I

IRON & STEEL TECHNOLOGY rld

1,500

660 monthl y wo y pr re gional onthl y

tal M 390 To Intelligent Demolition Power 10 Brokk Inc. | Monroe, WA | 1-360-794-1277 ay ay ay ay ay ay

[email protected] | www.brokk.com AIST.ORG Figure 16: DRI production by region. Source: World Steel Association. 18 Industry Statistics

WORLD WSD STEEL USA, China, Western Europe and World Export DYNAMICS® 22 June 2020

— USA FOB mill — Western Europe ex-works — World Export FOB port of export — China ex-works

572

price (US$) per metric ton metric per (US$) nd price 458 447 420

ed ba oll ed Hot-r un un un un un un un un un un un

Figure 17: SteelBenchmarkerTM HRB price. Source: World Steel Dynamics.

“At this stage, it is not expected that Chinese demand will Hot-Rolled Band (HRB) Pricing — The U.S. benchmark price fall significantly, though the ongoing decline of consumer for hot-rolled band (Fig. 17) notched up during June, end- spending in OECD nations will increase the dependence of ing the month at its highest level since mid-April, according the Chinese steel industry on domestic stimulus measures.” to World Steel Dynamics’ SteelBenchmarker™.

Global DRI Production — On a year-over-year basis, global According to the bi-monthly price assessment, the price as direct reduced iron (DRI) production fell 31.8% to an esti- of 22 June stood at US$572/metric ton, the best since the mated 5.62 million metric tons in May 2020 (Fig. 16). Dur- week of 13 April, when it stood at US$577/metric ton. ing the same period, North American production declined 44.6% to 390,000 metric tons. For comparison, the world export on 22 June stood at US$420/metric ton, up 6.9% from mid-April. F

Iron & Steel Technology wishes to thank Platts, SteelBenchmarker™, The Steel Index and World Steel Dynamics for sourcing the data presented above. Information is compiled by Sam Kusic, AIST news editor. Comments are welcome. Please send feedback to: [email protected]. Please include your AIST.ORG

I full name, company name, mailing address and email in all correspondence.

WORLD WSD STEEL DYNAMICS® IRON & STEEL TECHNOLOGY

2020

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SMS group Inc. 100 Sandusky Street Pittsburgh, PA 15212 P:+1 412-231-1200 Leading partner in the world of metals www.sms-group.us 20 Strategic Insights From World Steel Dynamics

WORLD WSD STEEL Goodbye to steel cost inflation: Cost cuts, moderate DYNAMICS® wage boosts, lower raw material and energy prices

is a leading steel information service in Englewood Cliffs, Steelmakers’ cost to produce hot- plants are especially huge. For N.J., USA rolled band (HRB) will continue to example, the relining of a blast swing sharply over the steel cycle. furnace may cost more than WSD’s steel experience, steel However, in the next five years from US$75 million and the replace- database and availability of steel the mid-point of one cycle to the next, ment of aging coke ovens could statistics are the principles for WSD expects little to no steel mill cost cost US$300+ million. performing steel forecasts, studies inflation. • Labor costs per metric ton will and analysis for international The mills’ operating cost to pro- rise only marginally. Man-hours/ clients. WSD seeks to understand duce hot-rolled band in the past 10 metric ton shipped by 2025 how the “pricing power” of steel years has swung wildly — it’s been a may be 5% lower given new companies the world over will be cost roller coaster. Based on WSD’s labor-saving technologies. The impacted by changes in the steel monthly World Cost Curve results for rise in the worker wages may industry’s structure. The views the median-cost Chinese steel mill, the be just moderate because steel- and opinions expressed in this operating cost has ranged from a high workers, along with those in article are solely those of World of US$664/metric ton in September other manufacturing industries, Steel Dynamics and not 2011 to a low of US$353/metric ton are losing their negotiating necessarily those of AIST. in January 2016 — for a variation of power. As capital replaces labor US$311/metric ton. For the median- (Karl Marx is turning over in cost non-Chinese mill, the high cost his grave), workers are becom- figure was US$710/metric ton in July ing increasingly replaceable. 2011 and the low was US$367/metric • Iron ore prices delivered to ton in February 2016 — for a variation China may drop significantly. of US$353/metric ton. For example, they are current- Looking ahead to 2025, rather than ly lofty relative to the world’s no change in costs, some decline leading iron ore producers’ sin- would also be no surprise. ter feed cost delivered to the port of export — only about Authors • A sizable number of higher- US$16/metric ton. More iron Peter Marcus (left) cost plants will be either elimi- ore supply is coming into pro- managing partner, nated or downsized — espe- duction in Australia, India, World Steel Dynamics [email protected] cially during periods of shake- Russia and even Iran. Also, if +1.201.503.0902 out in the industry such as the steel scrap price is as low as the current one. Multi-plant expected, a larger amount of it John Villa (right) research strategist, companies, which are prob- will be charged into basic oxy- World Steel Dynamics ably growing in number due gen furnaces (as an alternative [email protected] to heightened M&A activity, to higher cost liquid pig iron). +1.201.503.0911 will consolidate output at their Chinese pig iron and steel most efficient units. In China, production will be lower in a plant rationalization and com- few years reflecting reduced pany consolidation will be a demand in the country. (Note: AIST.ORG

major event. Baowu Group is If the international iron ore I seeking to double its size to price drops sharply, China’s about 200 million metric tons domestic production of sinter per year largely by acquisition. feed and pellet, which is high If iron ore prices remain high cost, could fall 50% to roughly relative to steel scrap prices, 125 million metric tons per more integrated steel plants year.) IRON & STEEL TECHNOLOGY

will be shut down due to lack of • Coking coal in May 2020 was

2020 cost competitiveness. Capital selling for only about US$112/

spending needs at integrated metric ton, FOB Australia; AUG 21

Figure 1

1,250 140 on)

1,050 120

850 100

650 80

450 60

250 40 ex (2009 Average = 100) U.S. PPI I nd ex

50 20 /Metric T Hot-Rolled Band Export Price (US$ /Metric 1/1/1954 1/1/1956 1/1/1958 1/1/1960 1/1/1962 1/1/1964 1/1/1966 1/1/1968 1/1/1970 1/1/1972 1/1/1974 1/1/1976 1/1/1978 1/1/1980 1/1/1982 1/1/1984 1/1/1986 1/1/1988 1/1/1990 1/1/1992 1/1/1994 1/1/1996 1/1/1998 1/1/2000 1/1/2002 1/1/2004 1/1/2006 1/1/2008 1/1/2010 1/1/2012 1/1/2014 1/1/2016 1/1/2018 1/1/2020

World hot-rolled band export price vs. U.S. producer price index. Sources: SteelBenchmarker, WSD estimates, Reuters.

hence, there’s far less room for it to drop in price However, beyond 2030, a number of steel mills than iron ore. The price is at a level at which a will begin to take actions to achieve zero carbon number of non-Australian export-oriented cok- emissions by 2050. (Note: Integrated steel plants ing coal mines can’t long survive. A “wild card” emit about 2 metric tons of CO2/metric ton of that could tighten the supply/demand balance for steel production, versus about 0.5 metric tons this product would be further mandated closures for EAF-based units. For most integrated plants, in China of dangerous coal mines, due to their the achievement of zero carbon emissions would great depth and the emission of combustible entail huge capital outlays in order to re-orient gases. Also, highly polluting privately owned coke the plant’s steelmaking processes — to the hot ovens in Shanxi Province may be further cut back. briquetted iron/EAF route rather than the blast • The price of obsolete steel scrap is forecast to furnace/basic oxygen furnace route. Also, a sepa- be lower over the steel cycle in the next decade rate facility to produce hydrogen might be need- despite the rising global share of electric arc ed. Besides the capital costs, the rise in operating furnace (EAF) steel production. In China, the cost could be US$50–100/metric ton.) obsolete steel scrap reservoir, that’s on average • The purchase price of energy in different forms, 10–40 years old, is forecast to rise to 318 million including electricity and fuel oil, may be reduced. metric tons by 2030 versus 124 million metric Because of oversupply, the Brent oil price may not tons in 2019. Growing direct reduced iron capac- recover to US$50/barrel versus the May 2020 fig- ity and increased pig iron offerings on the world ure of US$25/barrel. The average price in 2019 market at times will exert downside pressures on was US$64/barrel.

steel scrap prices. AUG

• Expenses to meet additional air and water pol- As seen in the figure, the export price for HRB has 2020

lution mandates through 2025, and perhaps risen far less than the U.S.’s producer price index (PPI). I

to 2030, may not rise significantly for those Since its peak in 1989, the HRB export price is about IRON & STEEL TECHNOLOGY plants already meeting the mandated standards. unchanged, while the PPI is up about one-third.

This report includes forward-looking statements that are based on current expectations about future events and are subject to uncertainties and factors relating to operations and the business environment, all of which are difficult to predict. Although WSD believes that the expectations

I reflected in its forward-looking statements are reasonable, they can be affected by inaccurate assumptions made or by known or unknown risks AIST.ORG and uncertainties, including, among other things, changes in prices, shifts in demand, variations in supply, movements in international currency, developments in technology, actions by governments and/or other factors. F Make a difference for someone who’s made a difference!

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AIST offers more than 40 prestigious awards each year. Visit AIST.org/Awards to see the complete list of awards or to submit a nomination. AIST.org Optimal performance from tap to cast.

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OPTAgroupLLC.com 24 Personnel Spotlight

Personnel Spotlight is a free service featuring news of recent appointments, promotions, retirements and obituaries relevant to the steel industry. To submit material for consideration, please email a press release and high-resolution photo(s) to [email protected].

Bull Moose Tube Co. Worthington Industries

Andy Annakin has been appointed executive vice The board of directors of Worthington president and chief commercial officer of tubular Industries Inc. announced that products manufacturer Bull Moose Tube Co. B. Andrew (Andy) Rose, the company’s Annakin has held distinctive positions across sales, president, will become president and marketing and purchasing during his 30+ year career, chief executive officer (CEO), effec- including vice president of sales and marketing for tive 1 September 2020, succeeding

CMC Impact Metals and director of plate sales for Rose long-time chairman and CEO John P. Olympic Steel. McConnell, who will remain with the Annakin earned an M.B.A. in finance and marketing company as executive chairman. and a B.S. degree in business economics from Indiana As executive chairman, McConnell University. will continue to work with Rose, the executive team and the board to develop company strategy and help Companhia Siderúrgica Nacional identify value-enhancing strategic initiatives including acquisitions, joint Brazilian steelmaker Companhia McConnell ventures and strategically important Siderúrgica Nacional (CSN) has hired relationships. Jose Noldin as their new general man- Rose was named president of ager — product development. Noldin Worthington in 2018. He joined the company in 2008 returns to his home country after near- as vice president and chief financial officer. In 2014, ly a decade in Belgium, where he held he was promoted to executive vice president and chief

Noldin leadership positions with global lime financial officer (CFO) and has been instrumental supplier Lhoist in innovation, new busi- in advancing the company’s financial and capital ness development and strategic projects allocation strategies. Before joining Worthington, for the steel business segment. Rose was a senior investment professional of a public Noldin has received several industry awards, includ- investment company and partner and co-founder ing the 2017 Thomas Medal and Prize from the Iron of Peachtree Equity Partners, a private equity fund and Steel Society (U.K.) and the 2014 Ironmaker backed by Goldman Sachs. of the Year Award from the Brazilian Metallurgy, McConnell began his career at Worthington in Materials and Mining Association (ABM). He also has 1975 as a general laborer, later working in sales and many best paper awards for his contributions in the operations with increasing responsibility. He served fields of iron ore, ironmaking and sustainability. as corporate personnel director and was instrumental A member of AIST since 2002, Noldin has been in administering the company’s highly recognized active in the Ironmaking, Direct Reduced Iron and employee-based policies. He was appointed vice presi- Oxygen Steelmaking Technology Committees. For dent and general manager of the company’s largest his service to AIST, he was honored with an AIST steel facility in Columbus, Ohio, USA, in 1985. Presidential Citation in 2015. A member of Worthington’s board of directors AIST.ORG

Noldin holds a B.S. degree in mechanical engineer- since 1990, McConnell became vice chairman in 1992 I ing from the Federal University of Santa Catarina in and was named CEO in March 1993. In September Florianopolis, Brazil, and an M.S. and Ph.D in metal- 1996, he was named chairman of the board. lurgical engineering from the Catholic University of Rio de Janeiro. IRON & STEEL TECHNOLOGY

2020

AUG 25

Associations Obituaries

American Iron and Steel Institute (AISI) Joseph E. Gantz passed away on 20 June 2020 at the age of 90. Born in The American Iron and Steel Institute Williamsport, Pa., USA, and formerly (AISI) has appointed John Brett, presi- of Lebanon, Pa., Gantz was U.S. Navy dent and CEO of ArcelorMittal USA, veteran and achieved his B.S. degree as chairman of the board of directors in metallurgy from The Pennsylvania

for the 2020–2021 term. Brett has been Gantz State University. He was employed with serving as interim chairman since mid- United States Steel Corporation for 30 Brett March after the retirement of previ- years in various management positions ous chairman Roger Newport, former and also with Chemalloy Chemical Corp. as both a chief executive of AK Steel. supervisor and consultant. Brett was named vice president of ArcelorMittal and Gantz was a 49-year Life Member of AIST, hav- CEO of ArcelorMittal USA in January 2016. Previously, ing joined in 1971. He belonged to the Philadelphia Brett served as executive vice president of finance, Member Chapter. planning and procurement for ArcelorMittal USA. In Gantz is preceded in death by his wife Janet. He this capacity, he had responsibility for the planning, leaves behind three children, Evon, Amy and Jeannine; directing, managing and controlling of the U.S. busi- five grandchildren; and one great-grandchild. ness’s financial, purchasing and supply chain management activities. Michael VanBibber, 52, of South Brett joined predecessor company Inland Steel Co. Fayette, Pa., USA, passed away on 3 July in 1988 as an associate accountant and held various 2020 after a one-year battle with glio- leadership positions in accounting, finance and sup- blastoma brain cancer. ply chain management. He is a graduate of DePauw VanBibber was raised in Pleasant University with a degree in economics. Brett also Hills, Pa., outside of Pittsburgh. He earned an M.B.A. in finance and accounting from the VanBibber earned a degree in mechanical engi- University of Chicago. neering from Virginia Tech in 1990. In additional news, the AISI board Following graduation, he moved back of directors elected Kevin Dempsey as to the Pittsburgh area and spent his career working in interim president and CEO to succeed the steel industry. Thomas J. Gibson, who announced his VanBibber worked for Weirton Steel, SMS Demag retirement in March. and, most recently, TMEIC. Highlights from his Dempsey, who has served as AISI’s career include a work rotation in Germany where he senior vice president for public pol- and his family lived and traveled to countries around Dempsey icy and general counsel since 2009, Europe and experienced the culture. He published assumed his new role on 23 June 2020. several papers and was also awarded a U.S. patent for Gibson will serve as an advisor to AISI a method of and device for mounting and functional during the transition. verification of roll fittings, which is used all over the Before joining AISI, Dempsey was a partner at world and in 20 sites in the U.S. Dewey & LeBoeuf, a global law firm, and its prede- VanBibber joined AIST in 1999 and was active- cessor Dewey Ballantine LLP. While in private prac- ly involved in the Cold Sheet Rolling Technology tice, Dempsey litigated numerous international trade Committee (CSRTC) and the Pittsburgh Member cases on behalf of U.S. steel producers and other Chapter. He served as golf chair for the Pittsburgh

U.S. industries before the U.S. International Trade Member Chapter from 2013 to 2016 and chair of the AUG

Commission, the U.S. Department of Commerce and CSRTC from 2016 to 2017. VanBibber was a member 2020

the U.S. courts. Prior to joining Dewey Ballantine of the AISTech Conference Planning Committee I in 1995, Dempsey served as counsel to Sen. John C. from 2015 to 2018, including a term as Exhibitor IRON & STEEL TECHNOLOGY Danforth (R-MO) and the U.S. Senate Committee on Chair for AISTech 2017 in Nashville, Tenn., USA. Commerce, Science and Transportation. VanBibber is survived by his wife Michelle; son Dempsey received his J.D. degree from Harvard Law Tyler; daughter Helina; father Larry; brothers Jeff and School and a B.A. degree in history from Washington David; four nephews; and one niece. F University. He is a member of the District of Columbia

I bar and is admitted to practice before the U.S. Court AIST.ORG of International Trade and the U.S. Courts of Appeals for the Federal Circuit and the D.C. Circuit. F Apply for more than US$400,000 in scholarships!

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www.fivesgroup.com 28 AIST Foundation Update

Annual Corporate Gift Clubs To ensure the iron and steel industry of tomorrow will have a sufficient number of qualified professionals. Frick Society US$25,000–$49,999 • AIST Southeast Member Annual Fund Chapter • AK Steel Corp.* The Annual Fund is the AIST Foundation’s yearly campaign to strengthen the • ArcelorMittal* Foundation’s programming through unrestricted contributions from AIST members, • Allegheny corporations and other supporters. To learn more about the charitable work of the Technologies Inc.* • Gerdau Long Steel AIST Foundation, visit AISTFoundation.org. North America* • Hatch Associates Consultants Inc.* • Nucor Corp.* US$100,000 Corporate Sponsors • SSAB Americas* • Steel Dynamics Inc.* • United States Steel Corporation*

Oliver Council US$10,000–$24,999 • Air Products and Chemicals Inc. • American Combustion* • Cleveland-Cliffs Inc.* • Commercial Metals Company* • Danieli* • Edw. C. Levy Co. • SMS group Inc.*

Schwabe Associates Multi-Year Corporate Pledges US$5,000–$9,999 The AIST Foundation thanks the following companies that have pledged a multi- • Berry Metal Co. year donation, payable in annual installments, in support of the Foundation’s • Charter Steel* programs. Through this exceptional industry support, the AIST Foundation awards • HarbisonWalker more than US$750,000 in scholarships and grants annually. International • Magneco/Metrel Inc. • Midrex US$100,000 US$40,000 Technologies Inc.* • AK Steel Corp. • SMS group Inc. • Morgan Engineering* • ArcelorMittal • Allegheny Technologies Inc. Morgan Guild US$35,000 • Gerdau Long Steel North America • Midrex Technologies Inc. US$1,000–$4,999 • Nucor Corp. • American Combustion* • SSAB Americas • Danieli Taranis • Steel Dynamics Inc. US$20,000 • EMPCO • United States Steel Corporation • Berry Metal Co. • Hickman, Williams & Co. • Charter Steel • Saturday Friends • Magneco/Metrel Inc. US$60,000 • Morgan Engineering • Zenar Corp. • Cleveland-Cliffs Inc. AIST.ORG

AIST Foundation Friends US$10,000 US$50,000 • American Combustion US$500–$999 • Commercial Metals Company • Danieli • Hatch Associates Consultants Inc. • Hatch Associates US$5,000 Consultants Inc. • Hickman, Williams & Co. • Heraeus Electro-Nite US$48,000 • MINTEQ International Inc. Co. LLC • Danieli

IRON & STEEL TECHNOLOGY • Nucor Corp.

I • SMS group Inc.

2020 • Union Electric Åkers Make your pledge or donation today online at AISTFoundation.org or contact Lori Wharrey

at [email protected] or +1.724.814.3044. Your support is greatly appreciated! F AUG * These companies have made multi-year pledges. TOUGH ENVIRONMENTS, TOUGHER MATERIALS.

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25393_ATI_AIST ad_Full Page_Tough Environment.indd 1 6/25/20 4:07 PM 30 Safety First

Keeping Critical Spaces Clean Using Room Pressurization With Self-Maintaining Air Cleaners

Hazards are ever-present in the Room pressurization is used in Dust Hazards in the Steel Mill steel plant environment, and many industries to prevent dust or a heightened awareness and other materials from entering criti- Electric arc furnaces (EAFs) in steel emphasis on safety is a necessary cal spaces. Hospitals, laboratories mills produce dust made up of a priority for our industry. This and pharmaceutical manufacturers variety of metals and other materi- monthly column, coordinated by often use this method to maintain als. Many of these materials are members of the AIST Safety & their clean rooms. In steel mills, harmful to human health. These Health Technology Committee, employee health and safety, along dusts present a health risk to anyone focuses on procedures and with protecting equipment, are con- who has to work in areas such as practices to promote a safe stant concerns when dealing with operator pulpits where dust levels working environment for everyone. dust in this type of environment. In are high. In enclosed spaces like this article, health and equipment transformer vaults, motor control issues that are normally created by center rooms or other electrical dust in a steel mill environment will rooms, conductive metal dusts can be discussed as well as how positive cause an arc flash hazard. All criti- pressurization can be used with a cal spaces require an extra level of specific type of filtration to fix this protection from harmful dusts. problem. There are many lung-related health hazards that are caused by Health Risks From Steel Mill Dust breathing metal dust, and there are several costly equipment failures Steel mills produce metal dust that caused by metal dust. While most contains a mixture of large and Author steel mills use heating, ventilation small particles. The exact compo-

Josh Longmire and air conditioning (HVAC) sys- nents of the dust depends on the sales manager — clean air systems, tems to attempt to keep these areas type of steel and the process. In gen- The Systems Group, Jonesboro, clean, this is inefficient and ineffec- eral, the most common metal found Ark., USA [email protected] tive because these types of filters in steel mill dust is iron, followed by are not able to catch all of the dust carbon, lime, zinc, manganese, cal- particles. When these filters have cium and silicon, but the dust often dust on them it increases the static includes metals such as lead, arsenic pressure resistance on the HVAC and cobalt, which are highly toxic.1 system and can reduce the amount Gerdau Long Steel North America’s of room pressurization. material safety data sheet for steel By using positive pressure from a mill EAF dust warns that inhalation self-maintaining air cleaner, these can cause allergic reactions, cancer, spaces can be kept clean at a much lung damage, weakness, personality lower cost and with better results. changes, kidney damage and prob- Positive pressure inside a room is lems with the brain and nervous

AIST.ORG 2

effective in preventing dust from system. I entering the room, and the use of a The health hazards of all these Comments are welcome. self-maintaining air cleaner provides materials are well known and If you have questions about this effective filtration while creating the the U.S. Occupational Safety and topic or other safety issues, please positive pressure environment. Health Administration (OSHA) has contact [email protected]. set limits on acceptable time-weight- Please include your full name, ed exposures. However, employers IRON & STEEL TECHNOLOGY

company name, mailing address and inspectors often measure these

2020 and email in all correspondence. exposures in workers who are direct-

ly exposed to the fumes and material AUG 31 from the EAF. They may not measure the chronic Higher MERV ratings are more effective at capturing exposure caused by long-term work in rooms full of smaller particles. That’s why hospitals tend to use accumulated dust. Metal dust particles can be as small MERV 16 or higher, so the most pollutants possible as 0.3 micron and besides being easily inhaled, it can can be captured. The ASHRAE designed the MERV get on a worker’s hands, into their clothes and onto rating and advises the use of filters with minimum their food. The health risks of daily long-term expo- MERV ratings of 6. The U.S. Department of Energy sure to accumulated dust in the workspace may not be recommends a minimum of MERV 13. measured accurately. In many areas of the steel mill, workers may not be • MERV 1 to 4 — Less than 20% of particles (>10 exposed to harmful levels of this dust. However, in microns) are captured. areas like control rooms, pulpits or other enclosed • MERV 5 to 8 — Less than 20%–60% of particles workspaces exposed to large amounts of dust, expo- (3–10 microns) are captured. sure can be heavy. Dust that accumulates in these • MERV 9 to 12 — 40%–85% of particles (1–3 enclosed spaces can be hard to remove, and an microns) are captured. ordinary HVAC system is not designed to handle a • MERV 13 to 16 — 70%–98% of particles (0.30–1.0 heavy load of metal dust. The amount of dust and micron) are captured. particulate produced by arc furnaces and other steel • MERV 17 to 20 — Even the smallest particles (<0.3 mill processes is far in excess of what a typical HVAC micron) are captured. filter is meant to deal with. A typical HVAC filter is designed to capture par- Workers in enclosed areas such as operator pulpits ticles sized at 3–10 microns with 20% efficiency with insufficient dust control are at risk of lung dis- (MERV 5). A self-maintaining air cleaner filter is eases such as siderosis, silicosis, black lung and lung designed to capture particles size at 0.30 micron with cancer from inhaling dust throughout the workday. 99.999% efficiency (MERV 15). All filters are rated They are also at risk of neurological damage from by the minimum efficiency reporting value (MERV) lead and manganese. These conditions become worse rating standard set forth by the American Society with heavier or longer exposure, and they can be per- of Heating, Refrigerating and Air Conditioning manent. Because of these health risks, it’s important Engineers (ASHRAE). to keep dust out of these workspaces. It’s common The MERV rating system is a value that indicates for HVAC filters to be used for this purpose, but they the size of particles an air filter is designed to capture. will often fail within a matter of days and need to be replaced. These filters also may not be efficient enough to capture the small particles of metal dust, Table 1 and the smallest particles are the Section of Material Safety Data Sheet for Steel Mill Electric Arc Furnace Dust2 most dangerous because they are inhaled the most deeply into the CAS # Component Percent lungs. While high-efficiency particu- 1309-37-1 Iron oxide 0–35 late air (HEPA) filters can capture 1305-78-8 Calcium oxide 0–35 these small particles, they also often 1314-13-2 Zinc oxide 0–25 fail within a few weeks or months 14464-46-1 Silica, cristobalite 0–15 from the volume of dust being filtered through them. 7439-96-5 Manganese 5–10 In addition to the health risks of 1309-48-4 Magnesium oxide fume 5–10 this dust, it also creates an unpleas- 7440-31-5 Tin 0–5 ant and difficult working environ-

1344-28-1 Aluminum oxide 0–5 ment. Dust throughout a workspace AUG

7440-47-3 Chromium 0–5 can get into expensive equipment 2020

like computers, clog HVAC vents, I

1314-56-3 Phosphorus pentoxide 0–5 and get all over the clothes, tools IRON & STEEL TECHNOLOGY 7446-09-5 Sulfur dioxide 0–5 and equipment used by the work- 7789-75-5 Calcium fluoride (CaF2) 0–5 ers. This accumulation of dust is 7782-41-4 Fluorine 0–5 not only unpleasant but can make 7489-98-7 Molybdenum 0–5 it more difficult for workers to do 7440-22-4 Silver 0–5 their jobs. In a room without posi-

I tive pressure, someone opening a AIST.ORG 1314-62-1 Vanadium pentoxide 0–5 door might sweep in a cloud of dust 7440-38-2 Arsenic 0–5 with their entry, so that over time the 32 AUG 2020 I IRON & STEEL TECHNOLOGY I AIST.ORG Arc Flash Risks From Steel Mill Dust in Motor in Motor Mill Dust Steel From Risks Flash Arc the personnel around them, there is also a threat of athreat also is there them, around personnel the that could act as ignition sources when surrounded by when surrounded sources ignition as could act that ing arc flash hazards and threatening the lives of lives the threatening and hazards flash arc ing protected from conductive metal dust entering the the entering dust conductive metal from protected room. Sparks from electrical equipment can ignite ignite equipment can electrical from Sparks room. Control Center Rooms Center Control ed with the downtime due to such an event. Valuable due such an to downtime the with ed er vaults and motor and control be need to centers, which er vaults transform are A few examples dust. conductive metal Safety First Steel mills contain many types of electrical equipment of electrical types many contain mills Steel destroying expensive equipment cost associat the expensive and destroying accumulated dust and create arc flash hazards. flash arc create and dust accumulated and costly to clean up. clean to costly and more more becomes and problematic accumulation ANSI/ASHRAE MERV 52.2-2012 Standard Table 2 (2) ANSI/ASHRAE52.1rangesareprovidedforreferenceonly. 2009. TheNSI/ASHRAE52.1StandardwasdiscontinuedasofJanuary (1) ASHRAEdoesnothaveatestprocedureforHEPA testingandhasthusdroppedtheMERV17–20classifications. application. Refertomanufacturertestresultsforadditionalinformation. inagiven Note: Thistableisintendedtobeageneralguidefilteruseanddoesnotaddressspecificapplicationsorindividualperformance In addition to the risk of electrical equipment caus of electrical risk the to addition In Deleted from ASHRAE from Deleted MERV Std.52.2 MERV Std.52.2 17–20 13–16 9–12 5–8 1–4 1 Spot Efficiency Intended Dust Std. 52.1(2) 2–0 80–95% <20–60% 09%>95–99% 70–98% >90–98% 40–85% 2%60–80% <20% 99.97%–99.9999% Efficiency arrestance Average 3.0–10.0 μm Particle size 0.3–1.0 μm 1.0–3.0 μm >10.0 μm ranges - - - Association (NFPA) recommends that if dust has has dust if (NFPA) recommends that Association within 24 hours on hard-to-reach surfaces. If the the If surfaces. 24 on hard-to-reach hours within tion is to prevent dust from entering the rooms at all. at all. rooms prevent the to entering is from dust tion once clean to therefore, and, difficult large very be to large involve very especially Transformers room. the in accumulated has that dust any ignite to spark trical elec for an potential high is there vaults, transformer up within 8 hours on easily accessible surfaces and and surfaces accessible on easily 8hours up within one hour of reaching that amount. These numbers numbers These amount. that one hour of reaching equipment could be damaged and, in the worst-case worst-case the in and, equipment damaged could be dust has been allowed to accumulate. The best solu best The accumulate. to allowed been has dust as an ignition source. Also, these types of rooms tend of rooms types these source. Also, ignition an as act to potential significant with of electricity amounts allowable amount, it must be cleaned up within up it within cleaned must be amount, allowable the four times than greater is amount accumulated it cleaned should be accumulation, dust allowable for threshold the times one to two to accumulated scenario, lives could be lost. lost. could be lives scenario, As indicated in Table 3, the National Fire Protection Protection Fire Table in National the 3, indicated As With the presence of large electrical equipment like electrical presence of large the With • • • • • • • • • • • • • • • • • •

Nuclear material contaminants Hazardous biological Clean rooms Hospital surger Hospitals andhealthcare General surger Smoke removal Better/commer Better/industrial workplaces Superior/residential Paint booth/finishing Better/residential Commer Industrial workplaces protection Minimum equipment Light commer Residential/minimum Superior/commer Typical applications Typical applications cial cial/minimum y cial buildings y suites cial buildings • • • • • • • • • • • • • • •

ULP HEP pocket filter Rigid box/non-supported/ Rigid cell/cartridge V Rigid cell/cartridge filter/rigid box Non-supported/pocket Media panelfilters Extended sur Pleated filters Fiberglass/synthetics Disposable panels synthetics W (passive) Permanent/self charging V -cells -cells ashable/metal, foam/ Typical filtertype Typical filtertype A A face filters - - 33

Table 3 q = nV National Fire Protection Association (NFPA) 484 Maximum Time for Cleanup of Metal Dust3 (Eq. 1) Longest time to complete Longest time to complete Accumulation on the worst unscheduled local cleaning of unscheduled cleaning of where single square meter of surface floor-accessible surfaces remote surfaces >1 to 2 times threshold dust 3 3 8 hours 24 hours q = fresh air supply (ft /h, m /h), mass/accumulation n = air change rate (h-1) and >2 to 4 times threshold dust 3 3 4 hours 12 hours V = volume of room (ft , m ). mass/accumulation >4 times threshold dust mass/ The formula shown in Eq. 1 allows 1 hour 3 hours accumulation system designers to calculate how much airflow is necessary to create enough air changes per hour for the space and the level of air contamination. This usually leads to replacing assume that the facility is clean, and that the accumu- the same volume of air that is removed, leading to lation is caused by a leak or sudden release of dust. By neutral pressure. Under neutral pressure, air can flow NFPA standards, a facility should never have a long- freely in either direction, in or out of the room, carry- term consistent accumulation of dust at or above the ing dust and particulate with it. threshold limit.3 Positive pressure is achieved by having more air Unfortunately, in many facilities, dust can accumu- flowing into the room than the amount of air being late at possibly dangerous levels for years, not hours. removed from the room. This creates a pressure In Fig. 1, dust is present on the floor, but the dust differential between the inside and outside spaces. inside or under the panels is not seen. In a room like Differential pressure in settings like steel mills is rec- a motor control center room or a transformer room, ommended to be no less than 0.02 inch of water gauge just a spark from an electrical source could create an arc flash. As shown in Fig. 1, accumulation of dust on the floor in this space is a problem, but it seems likely that the exposed floor is still cleaned more often than Figure 1 under, on top of, or behind the equipment, where the accumulation could have reached dangerous levels.

Positive Pressure as a Solution to Dust Issues in Critical Spaces

What Does It Mean to Create Positive Pressure in a Space? — Positive pressure simply means that the pressure inside the space is greater than the pressure outside. For this to be accomplished, the space must be enclosed well enough that the increased volume of air will stay inside. Doors opening and closing should not create significant pressure loss, but doors or windows cannot be left open. For positive pressure in a room to

be effective, the pressure must be maintained, and if AUG

the pressure is allowed to drop, dust will start entering 2020

the space again. I

All HVAC and other airflow systems are designed IRON & STEEL TECHNOLOGY for a certain number of air changes, which is how often the air in that space is replaced by clean air. For areas in a steel mill or other metal manufacturing facilities, the number of air changes per hour may be anywhere between 10 and 20, depending on

4 I how heavy the air contamination is. The appropri- AIST.ORG ate number of air changes is determined by what is Dust accumulation in a motor control center. required to maintain clean air. 34 AUG 2020 I IRON & STEEL TECHNOLOGY I AIST.ORG Positive room pressure is frequently used in hospitals hospitals in used frequently is pressure room Positive Safety First will be constantly pushing back against contaminated contaminated against back pushing constantly be will tamination from outside must be avoided. must be outside from tamination where space con clean maintain to technique this through any openings in the room. room. the in openings any through Purpose of Positive Pressurizing aRoom Pressurizing Positive of Purpose pharmaceutical manufacturers also commonly use use commonly also manufacturers pharmaceutical ing to flow out of the high-pressure area, it will cre it will area, out high-pressure of the flow to ing lower pressure, the positive pressure inside a space aspace inside pressure positive the lower pressure, removed air and the return air are filtered to remove to filtered are air return the and removed air clean space could be a problem. Laboratories and and aproblem. could be space Laboratories clean Standard HVAC filtering motor control center. control motor HVAC filtering Standard contaminants and dust. dust. and contaminants and preferably higher. preferably and ate a flow outward every time a door is opened, or adoor is time every outward aflow ate try air might enter space. With that dust the and air air that is being removed. In most settings, both the the both settings, removed. most In being is that air the than room the to more add air will that a system and other medical settings where contamination of where contamination settings medical other and Figure 2 Because airflows from areas of higher pressure to to of higher pressure areas from airflows Because 5 This is achieved bydeveloping achieved is This - - - These systems are called “self-maintaining” because because “self-maintaining” called are systems These HVAC or HEPA filters, these dust collectors use round round use collectors dust these HVAC or HEPA filters, MERV 5. For medical or laboratory facilities, HEPA facilities, or 5. laboratory ForMERV medical HVAC an using pressure positive create facilities Many One solution to this problem has recently been devel been recently problem has One solution this to would be found in those settings. Standard HVAC Standard settings. those found in be would will not put nearly as much strain on the filtration filtration on the much not strain putas nearly will these filters, as well as the cost of disposal since the the since cost of disposal the well as as filters, these tem, however, is not ideal for use in a steel mill. The however,tem, The asteel mill. in not for is ideal use of sys type This efficiency. filtration high very their ters meet the recommended efficiency of MERV 155, of MERV meet recommended the ters efficiency air. of compressed As by pulses cleaned are filters the the need for cleaning because it keeps dust from it from dust keeps because need forthe cleaning reduces or eliminates greatly pressure Positive tiles. up. Not only is this a waste of time and resources, but resources, and of time awaste up. this is Not only Self-Maintaining Air Cleaners Air Self-Maintaining but common places like overhead beams or ceiling or ceiling overheadbut like common beams places back against dirty air that might flow in. in. might flow that air dirty against back ing onceing aweek or even once aday. the Besides don’t asteel mill in Rooms as possible. be need to it clean with housekeeping measures. In an environ an In housekeeping measures. with it clean positive pressure keeps dust from entering. Whenever from dust keeps pressure positive load. They will quickly become overwhelmed with with become overwhelmed quickly will They load. room is a much easier solution than trying to keep to trying amuch solution than is room easier Equipment for Creating Positive Pressure Positive for Creating Equipment must deal with the time and labor required to change change to required labor and time the with must deal also steel mills changes, filter of constant expense atmosphere but room, ahospital ahospital as clean as of dust free kept be need to as that spaces critical cartridge filters that hang vertically from a tube sheet. atube from vertically hang that filters cartridge cleaner. of air Instead self-maintaining the oped: ees and the potential for dust hazards. for hazards. dust potential the and ees employ to risks health the decreases entering. It also clean as spaces keeping critical ment asteel mill, like filters may contain hazardous materials. materials. hazardous contain may filters Fig. in 2. illustrated as filters, of dust type this with deal to not are designed filters filters that are rated as MERV 17–20 are also used for 17–20 used MERV also as are rated are that filters dust and will start to block airflow through the system system the through airflow block to start will and dust as well as allowing smaller dust particles through the the through particles dust smaller allowing well as as higher than far is asteel mill in load dust airborne a result, they do not require manual cleaning. The fil The cleaning. manual do not they require a result, also might leave dust accumulated in hard-to-reach hard-to-reach in might leave accumulated dust also clean dust constant require would be need to they as a door is opened, air will try to flow outward, pushing pushing outward, flow to try will opened, air a door is system as the air in a steel mill. Keeping a room under aroom Keeping asteel mill. in air the as system system with standard filters that are typically rated as as rated typically are that filters standard with system This concept can be applied to steel mills and the the and steel mills to applied concept be can This It is common for the HVAC filters to require chang require to It common for HVACis the filters Positive pressure to prevent a to entering from dust pressure Positive ------35 which means they are efficient for particles as small Figure 3 as 0.3 micron. Fig. 3 shows the pulse jets above the filters. These jets pulse compressed air through the filters, keeping them functioning and maintenance-free for much longer than other types of filtration systems. Many steel mills using these systems for positive pressure areas can see filter life of one year or more. Unlike HEPA filters, the cartridge-style filters are designed for heavier dust load applications. These systems serve two functions. First, they filter the dust out of the air through the MERV 15 cartridge filters, removing dust and contaminants. Second, they provide clean, filtered air to the room. While they do this, the fans add enough air to create positive pressure inside the room. Common locations for self- maintaining air systems include transformer vaults, motor control centers, server rooms, hydraulic rooms, operator control pulpits, compressor rooms and reac- tor vaults. A system of this type is illustrated in Fig. 4. The drums beneath the air cleaner collect dust, which is then disposed of. The filters are accessed through Internal view of a self-maintaining air cleaner. a door for replacement. Also shown is the air inlet, which takes in ambient air from outside into the air cleaner to be filtered. As seen in this photo, these self- Figure 4 maintaining air cleaners can be placed in a variety of locations. This one creates positive pressure inside a transformer vault. It is rated for approximately 16,000 cubic feet per minute with a fan operating at 7 inches of water column, resulting in a 3.8-to-1 air-to- cloth ratio. It has 12 cartridge-style filters. Depending upon the size of the space and the number of air changes per hour required, self-maintaining air cleaners can be designed in a variety of sizes. Another option is the choice between constant airflow and a variable frequency drive. The variable frequency drive is connected to a sensor that detects loss of pressure in the room, such as when the door is opened. This signals the fan to increase the airflow. With constant airflow, the room will still maintain positive pressure, although it may not return to full pressure as quickly after a loss. The main advantage to using a self-maintaining air cleaner is the greatly decreased requirement for Self-maintaining air cleaner installed on exterior of steel mill. maintenance and filter changes. Unlike an HVAC sys- AUG

tem, these systems are designed for heavy dust loads, 2020

whether they are filtering air from outside or from I inside the facility. HEPA filters in these applications collector, taking dirty air from inside the facility and IRON & STEEL TECHNOLOGY tend to become quickly clogged with dust, but when filtering it before venting or returning it. To maintain they are used as secondary filters in a self-maintaining positive pressure with this type of use, ambient air will air cleaner system, the MERV 15 filters capture most have to be added back into the building along with dust and the HEPA secondary filters may last years the filtered air in order to maintain positive pressure. instead of months.

I The same equipment that functions as a self-main- AIST.ORG taining air cleaner, taking in ambient air for room pressurization, can also serve as a more standard dust 36 AUG 2020 I IRON & STEEL TECHNOLOGY I AIST.ORG This type of system is able to create positive pressure pressure positive able create to is of system type This where control pulpits such as include spaces also They Safety First worker health and equipment. Critical spaces in steel in spaces equipment.worker and Critical health these settings, a more efficient and effective method method effective and amore efficient settings, these equipment electronics, and critical contain that those under positive pressure. pressure. under positive pressure created by the system prevents dust from from prevents dust system bythe created pressure and life filter increasing also while spaces critical in system. cleaner air of aself-maintaining use the is Conclusion control. Equipment such as EAFs produce large produce large control. Equipment EAFs such as mills must be kept free of dust. These spaces include spaces These of dust. kept must be free mills entering the room and maintains a clean space. aclean maintains and room the entering Steel mills are challenging environments for dust environments challenging are mills Steel decreasing maintenance cost and time. The positive positive The time. cost and maintenance decreasing amounts of dust, and this dust can be hazardous to to hazardous be can dust this and of dust, amounts solution to keeping these spaces clean is to keep to them is clean spaces solution keeping these to effective most The present. are personnel steel mill motor control centers, etc. vaults, transformer such as While HVAC filters are often used for filtration in in for filtration used often are HVAC filters While 1. 4. References 2. 3.

WWW.SCHUST.COM Gerdau LongSteelNorthAmerica,“MaterialSafetyDataSheet, Rizescu, C.Z.;Backinschi,Z.;Stoian,E.V Engineering T Noll, J.;Cecala,A.;andHummer A.A.,“Characterization ofSteelMillElectricArc FurnaceDust,” of Hazardous Materials Hazardous of Room ataMineralProcessingPlant,” Pressurization SystemtoReduceDustConcentrationsinaControl room-d_867.html. Buildings,” 2005,www.engineeringtoolbox.com/air-change-rate- No. 12,December2015,pp.42–48. Material Name:SteelMillElectricAr meets your needs. Contact Schust at1-800-408-4820 totailorasolutionthatbest operations andmake your working environmentclear again. Schust outofyour take scrap thefumeandworry cutting Scrap cutting fumeisdifficult tocapture,butseeing itisnot.Let YOUR PAYBACK PROTECT oolbox, “AirChangeRatesinTypical Roomsand , Vol. 109,Nos.1–3,June2004,pp.59–70. c FurnaceDust,”2013.

, J.,“InstitutingaFiltration/ Mining Engineering Mining SCHUST A MEMBEROFTHESCHEUCH GROUP .; andPoinescu, , Vol. 67, Journal Journal F STRENGTH IN SOLIDARITY In these days of physical distancing, our hope for the world is to also remember the power in social solidarity. At Falk PLI, we believe diversity plays an important role in what makes our team great at what we do. We may be conducting meetings and working virtually from home for now, but we look forward to the days when the smiling faces of our team and clients can come together again. Until then, we continue to innovate in a way that is only possible when all our team members and clients are heard and respected. When you hire Falk PLI, you can count on us to uphold our commitment to inclusivity in everything we do. Brings out the Best in Us.

Lasers Meet Brain Power. Indiana | Alabama | Pennsylvania falk-pli.com | 888∙965∙1143 Innovative Solutions. Measurable Results.

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MCAD20049E 9500E Steel industry R1- IST Aug20 R1.indd 1 6/22/2020 5:14:59 PM 40 “Our Stories” From World Steel Association (worldsteel)

World’s Longest Suspension Bridge Will Connect Europe and Asia

Scheduled to open in 2023, the Canakkale 1915 bridge will be a steel-built infrastructure first, spanning the Dardanelles strait that separates the European and Asian continents.

As the Turkish government under- The growing struggle facing the The World Steel Association takes an ambitious infrastructure existing transport system has caused (worldsteel), headquartered in investment program, parts of the the government to announce its Brussels, Belgium, is one of the country are being transformed by Vision 2023 program, which aims to largest industry associations in the new megatunnels and bridges. The boost capacity across road, rail and world, with members in every steel- Canakkale 1915 bridge is one such sea networks. producing country. Its members project, conceived to open as a trib- represent around 85% of global ute to mark 100 years of the modern steel production. Turkish republic. A Towering Achievement The northwestern region of Turkey This monthly column features functions as an important connec- The suspension bridge is being con- “Our Stories” from worldsteel, tion between Europe and Asia, with structed in the northwestern Turkish covering automotive, construction ground traffic currently funneling province of Canakkale and will ser- and building, infrastructure, and through the narrow stretch of land vice the 320-km-long Kınalı-Tekirdag˘- innovation. surrounding Istanbul which leads on Çanakkale-Balıkesir motorway which to the borders of Greece and Bulgaria. will connect the Anatolian peninsu- Turkey’s rising economic growth la and East Thrace once completed. as a result of agricultural expansion, Currently, this journey requires a Editor increased transit links and the coun- 30-minute ferry ride, but once the try’s growing popularity as a tourist bridge is in place this will be reduced Desmond Hinton-Beales editor, Specialist – The Content destination, has led to serious conges- to a short drive of just 10 minutes. Marketing Agency, Bristol, U.K. tion around its major cities. desmond.hinton-beales@ specialistuk.com AIST.ORG

IRON & STEEL TECHNOLOGY

2020

With the span between its two towers sitting at 2,023 m, the Canakkale 1915 is set to

AUG become the world’s longest suspension bridge. 41

With the span between its two towers sitting at 2,023 m, A Partnership Forged in Steel the Canakkale 1915 is set to become the world’s longest suspension bridge, outstripping Japan’s Akashi Kaiky Once completed, the Canakkale bridge will have 128,000 bridge by 32 m. Its full length, including the approach metric tons of steel deployed in its construction, a mam- viaducts, will stretch to 4,608 m. moth undertaking for a single company. Formed of a reinforced concrete deck, the bridge As such, the steel elements of the bridge represent a structure supporting the road surface will be under- partnership between Turkish and South Korean suppliers, pinned by a pair of shear-connected longitudinal steel with Turkey’s Çimtas¸ and South Korea’s POSCO agree- box beams. These will in turn be interconnected by steel ing to supply 35,000 metric tons of heavy steel plate for crossbeams that sit on external cantilevers. the tower structures, cabling systems and road surface. The 45-m-wide deck is expected to handle large The partnership is also supplying 52,000 metric tons amounts of commercial and private traffic, with three of steel plate for the bridge deck and 41,000 metric tons lanes moving in both directions and maintenance walk- of steel wire rods for the suspension system. ways on either side, contributing significantly to the The Canakkale is being run as a “design-build” proj- socioeconomic development of the region. ect. Typically for bridge construction, the design is The towers, which sit on a pair of steel platforms each completed before contractors and suppliers are selected. mounted just above sea level on massive 65,000-metric- For this project, however, construction and design take ton submerged caissons, will make the bridge the fourth place concurrently, requiring coordination between the tallest in the world, with its striking design stretching architect and contractors from very early on. 318 m into the sky. A US$3 billion investment, this record-breaking, steel- built suspension bridge is set to be transformative for the region’s transport systems, with socioeconomic effects for Turkey and eastern Europe.

This and other stories are available at stories.worldsteel.org. F AUG

2020

IRON & STEEL TECHNOLOGY

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44 Digital Transformations

Improving Periodic Defect Detection in Hot-Rolled Long Products by Means of Combination Between Eddy Current and Vision

Digital technologies are Periodic defect roller marks (PDRM) to customers. The on-time PDRM transforming industry at all levels. (Fig. 1) are still an important prob- detection has a direct impact on Steel has the opportunity to lead all lem for hot-rolled long products, the income statement of the roll- heavy industries as an early adopter affecting all grades; among them is ing mill because all defective coils of specific digital technologies to the high-margin engineering steel must be sold at lower prices and improve our sustainability and production with specific lower T° delivered to less profitable custom- competitiveness. This column is rolling conditions, increasing roll ers. To be effective, defects must be part of AIST’s strategy to become crack occurrences due to fatigue quickly confirmed and the guilty the epicenter for steel’s digital stress. Most PDRMs are caused by roller identified. transformation, by providing a groove cracks (GCs). An early detec- Until now, several methods have variety of platforms to showcase tion of GCs as well as their identifi- been used for the detection and and disseminate Industry 4.0 cation is of paramount importance confirmation of PDRM, among knowledge specific for steel to improve the profitability of steel which the most prominent are eddy manufacturing, from big-picture plants, and in many cases their sur- current1 and artificial Vision, used concepts to specific processes. vival. This paper will discuss the separately. In both cases, there are benefits of a new solution called deficiencies. EC is very reliable, EDDYeyes, synchronizing eddy cur- but it isn’t intuitive, and it usu- rent (EC) testing and Vision in ally requires a delay of more than real time. This is a complex solu- 1 hour for visual recognition. On tion that includes digital EC sig- the other hand, artificial Vision is nals acquisition with on-time treat- intuitive, but it is often not reliable ment and high-speed Vision systems, due to harsh environmental condi- with high-quality LED lighting and tions such as steam, dirt, water, etc., complex math algorithms to give and can’t ensure optimal images. In faster and more accurate defect both cases, the necessary investiga- information. tion time is a real loss. However, the evolution of technologies allows a new approach to improve dramati- Authors Discussion cally the PDRM early detection.

Bruno Chedal-Anglay (left) The Problem Identification — Periodic The Ideal Solution — The ideal solu- director, Steel Process Product Development (SPPD) Consulting, defects caused by roll marks are tion would combine the benefits Normandy, France one of the rolling mill’s biggest of eddy current with those of the [email protected] issues. A broken roll generates image. For this, it should be as Jose Ignacio Lucas Fuentes (right) periodic defects until it has been reliable as the first and as intuitive sales manager, ISEND, fixed and will affect every delivery as the second. Examples of both Valladolid, Spain [email protected]

Jose Ignacio Díaz

AIST.ORG research and development, ISEND,

I Valladolid, Spain Figure 1 [email protected] IRON & STEEL TECHNOLOGY

2020

AUG Picture of periodic defect roller marks (PDRM) taken from EDDYeyes. 45

Figure 2 This technique consists of integration in real time and with a high degree of accuracy between the signal coming from the eddy currents and an artificial Vision system that captures images of all the signals potentially due to defects. The greatest difficulty is the synchronization of both elements and their pro- (a) cess in a very short time, by using artificial intelligence algorithms, so that any alarm can be immediately verified visually even if the alarms is under the threshold set up by the users. As a result, good-quality images carry out the surface defect confirmation. Both technologies used separately are present in various ways in the market, but the integration (b) between the two is achieved for the first time with EDDYeyes, since it is not a simple integration between Vision comparison between static picture (a) and an systems, but a whole development that optimizes the EDDYeyes picture simulation at 99 m/second (b). results and therefore should be considered as a single system. EDDYeyes has been developed in the most demanding conditions, with wire rod rolling at temperatures at 1,100ºC and 110 m/second speed with Figure 3 vibrations. The development has been carried out taking account as a test element the 5.5-mm wire rod produced at 110 m/second, the most demanding conditions in comparison with bigger sizes and speeds. To develop EDDYeyes, it was necessary at first to use a workbench able to reach speeds of 100 m/second (Fig. 2), and in a second step a real installation in rolling mill customer facilities (Fig. 3). During the development, multiple tests were car- Wire rod nose during hot rolling process at 99 m/second. ried out that have subsequently been confirmed in real environments.

Three Improvement Areas — The three major areas of methodologies in a reasonable and logical way were improvement this method provides in the detection already explained2 with an application for the final of PDRM are: user. A new family of solutions has recently been intro- • Early confirmation of periodic defects that duced in the aluminum and steel industries, synchro- occur before the defect violates the alarms con- nizing EC as a primary detector with artificial Vision figured in the standard eddy current system for as a confirmation element as well as a secondary short defects. detector. This makes it possible to detect periodic • Immediate identification of the roll causing the defects early and drastically reduces investigation defect. time. Additionally, this technology allows discrimi- • PDRM identification of defects that are not nation between random-type surface defects (scab, detectable by eddy currents (Fig. 4). rolling scabs, overlaps, overfill, etc.) from those due AUG to GCs, which produce repetitive 2020

surface defects. I

IRON & STEEL TECHNOLOGY An Innovative and Proven Solution — Figure 4 EDDYeyes technology is the result of the ISEND’s work in this field.2 The key factor is not separately adding eddy current technology

and Vision but synchronization of AIST.ORG both tools based on production parameters. A typical roller crack defect. 46 AUG 2020 I IRON & STEEL TECHNOLOGY I AIST.ORG Eddy current amplitude evolution. amplitude Eddy current aPDRM. of Evolution Digital Transformations Figure 6 Figure 5 The artificial Vision system is not limited not is limited system Vision artificial The PDRM is present. is PDRM tion, the analysis must be performed by performed must be analysis the tion, for the wait to it necessary is situation, this checked must be for mill rolling when the the system will notify an alarm and pres and alarm an notify will system the appears, signal whenevertion, aperiodic a In defects. due potential be to may that algo mathematical using Again, EC. to element, amere confirmation being to to take and save images with that fre that with images save and take to Identification of Periodic Defects Not Defects Periodic of Identification but taking advantage of its potential, it potential, of its advantage but taking In —In Vision Without Investigations PDRM be launched in the artificial Vision system system Vision artificial the in launched be by the eddy current technology. With With technology. current eddy by the produced every 2 minutes, many defective defective many 2minutes, produced every Detectable by the Eddy Current System — System Current Eddy the by Detectable image on the screen, being able decide to being screen, on the image ing process, the roller with GC starts with with starts GC roller with the process, ing ing a size that will make them detectable detectable them make will that a size ing number of coils before confirming that a that before confirming number of coils rithms, periodic patterns can be obtained obtained be can patterns periodic rithms, larger and larger (Fig. 5). dete larger Once the and larger rithms, the roll that is producing the the producing is that roll the rithms, rial, these marks will be enlarging, achiev enlarging, be will marks these rial, mate the mark to begins groove riorated combined size/thermal signatures’ signals signals signatures’ combined size/thermal one truckload. Fig. 6shows four different one truckload. mT ⇔25 mn 20 ⇔ rolled: be will coils per coil a2.5-metric-ton consequence with where it produced. is material of the area of the images the ent operator the to cleaning, repair or replacement repair options. cleaning, mark can be determined with a good agood with determined be can mark certain frequency, even when EC signals frequency, even when EC signals certain a obey that detected be can of amplitude During the roll the —During PDRM of Detection Early quency and present the user with the real real the with present user quency and the from groove cracks for an indeterminate indeterminate for an cracks groove from graphics provided by the equipment. As a equipment. As bythe provided graphics do not produce appreciable signals due do not produce signals appreciable morphology, due their to that, defects acts as a second detector for those surface asecond surface detector for as those acts amplitude evolution (Tableamplitude 1). the At approximation. alarm set by the users. set bythe alarm the or of noise off threshold below the are peaks intelligence algorithms, artificial similar methodology to the previous sec previous the to methodology similar stages of graphs that represent the peak represent peak the that of graphs stages small empty slots that evolve and grows grows evolve and that slots empty small With the traditional eddy current solu current eddy traditional the With These algorithms allow for an order for to an allow algorithms These In an analogous way, and using algo way, using and analogous an In ------47

Table 1 Eddy Current Alarm Log Time ID Batch ID Coil Sequence Diameter Mat ID Pulses Alarm Roll ID Level PD alarm 15:10 XXXX58 4 26 21 ***BCR 92 F = 13.18 Hz 27 1000 Yes 15:12 XXXX04 3 6 21 ***CRM** 9,833 F = 12.68 Hz 27 5000 Yes

Figure 7 A PDRM shows an evolution over time. The signal amplitude in terms of points gives an accurate vision about the severity of the defect during the rolling mill operation. The graphics (Fig. 7) also show a frequency between amplitude peaks. This can be used to identify the GC periodicity in combination with production parameters such as finishing roller diameters. Comparative data with eddy current and Vision. The users can set up the alarms to decide in which moment a signal can be considered as a real alarm. With the Vision module contribution, the alarms beginning, the defect is small and graphics don’t show can be set up at lower levels than the standard one anything significant. Obviously, the threshold of the from eddy current because the confirmation will be alarms could be set up lower, but the consequent side done specifically by the pictures produced. effects are confusing. Even though an artificial intelligence algorithm is PDRM Investigations With Vision — The main differ- used to detect periodical peaks in the alarm plane, ence by using the pictures is that once a suspect fre- it isn’t easy to confirm if the cause of the defect is a quency in peaks is shown, the operators can look at groove roller crack or other signal like vibration type. the picture given by the Vision module. To do that, it’s Once several peaks go over the alarm threshold, the only necessary that frequency and peaks don’t remain operator can suspect that a GC is present. However, as the most important information from EC. the experience of previous occurrences is necessary The system will produce a red alarm of a potential to get a confirmation. PDRM, including the frequency of the peaks, and Looking at Fig. 6, there is some important informa- then it will take pictures of the areas of the material tion that can be summarized. where these peaks are produced (Fig. 8). Then, the operator can see the alarm log, where the system will show the frequency and the related roller as well as the picture. Peaks are less important than the frequency, because the picture adds the comple- Figure 8 mentary information about the defect geometry.

This Is the New Technological Approach — AUG

To comply with this requirement, the 2020

basic technology must allow the real-time I

synchronization of the electromagnetic IRON & STEEL TECHNOLOGY alarms and the image. The synchronization of both is a key element and will produce real-time images of potentially defective areas. To achieve results applicable to obtaining high-speed products

such as 5.5-mm wire, the Vision equip- AIST.ORG ment (Fig. 9) must be fast enough in Map and Vision pictures as shown in the operator screen. 48 AUG 2020 I IRON & STEEL TECHNOLOGY I AIST.ORG Digital Transformations will be optimized so that only images of potentially of potentially images only that so optimized be will the lighting system must be specially designed to to designed specially must be system lighting the order on the of frequency, typically of sampling terms use. Poor lighting equipment could create false alarm alarm equipment Poor false use. lighting could create hundreds of thousands of images per second. per of images of thousands hundreds periodic defects whether they are detectable by eddy byeddy detectable are whether they defects periodic ing steps: ing currents or if they present a similar image pattern and and pattern image present asimilar they or if currents mills: defective areas are stored, discarding the rest. the discarding stored, are areas defective detection. detection. already been tested and optimized in several rolling rolling several in optimized and tested been already achieve a reflection of light according to the intended the to of light according areflection achieve 1. 1. 4. 4. 4. 4. 7. 2. 2. 2. 2. 3. 3. 3. 3. 5. 6. 6. To get the best results, the system tracks the follow the tracks system the To results, best get the In summary, the system will allow the detection of detection the allow will system the summary, In EDDYeyes have of elements combines that aseries But it is not the only elementBut it not only is the of development; also

If not, the system will light a potential defect light a potential will system not, the If S L H D A d T A d I T O T the amplitude of the EC. of the amplitude the them on the operator’s on the them screen. present and frequency that with images take roller crack. groove the the equipment signals of eddy currents or not. currents of eddy equipmentthe signals to the operator. the to improve the quality of the images. of the quality improve the lution higher than 0.5 mm for 5.5-mm wire wire for mm 5.5-mm 0.5 lution higher than images of all the material. the of all images will and defect due break a roll to potential noise level suspected of being produced by of being levelnoise suspected not associated with either a defect alarm or a either a defect alarm with not associated manufactured at 110 m/second.manufactured on powerful algorithms can detect peaks of detect peaks can algorithms on powerful odic image patterns that may be associated to to associated be may that patterns image odic detect peri will algorithms on mathematical decision. corresponding the make of alarm light an will system the mined, of the material. the of amplitude even below EC alarms and the the and even belowamplitude EC alarms alarm due to the presence of images available available presence due of images the to alarm surface the in current eddy of the phases and suspicious frequency. suspicious n parallel, the artificial Vision machine takes takes machine Vision artificial the n parallel, oftware for the analysis of periodic signals in in signals of periodic for analysis the oftware ED lighting system developed by ISEND to to developed by ISEND system lighting ED he system will discard those images that are are that images those discard will he system and images the analyze will he operator he eddy current tester measures amplitudes amplitudes measures tester he current eddy igital technology of EC developed byISEND. technology igital nce the guilty frequency has been deter been has frequency guilty nce the igh-speed image capture system with areso with system capture image igh-speed evelopment of artificial intelligence based intelligence based evelopment of artificial evelopment of artificial intelligence based intelligence based evelopment of artificial - - - - That integration generates a big data model for a new a data big generates integration That The integration of EC technology and Vision empha Vision and of EC technology integration The On-line one-strandEDDYeyes industrial unit. teams from shift operators, production management management production operators, shift from teams the all allowing install, to easy are product line the EC. the ing the 50% GC late detection efficiency with only only with efficiency detection late GC 50% the ing intuitiveness given by Vision, therefore allowing anew therefore allowing byVision, given intuitiveness Conclusions ment policy. ment policy. manage roller stock and for roller use methodology byEC and given of reliability combination on the replac defect strategy management surface on-time production. mill hot in rolling of PDRM occurrences quality with any kind of new functionalities (e.g., of new functionalities kind any with quality and control to understand on-time the RM surface surface RM the on-time controland understand to smartphones). sizes the capabilities for investigations confirming the the confirming for investigations capabilities the sizes Figure 9 6. 6. 5. In addition, it opens the door to new research based based new door research to it the opens addition, In Duplications of information (EC + Vision) along along +Vision) (EC of information Duplications

Sy S patterns. oftware investigations for periodic image image for periodic investigations oftware nchronization system. nchronization - - - 49

2. B. Chedal Anglay, “Hot Surface Defects Detection Synchronizing In this report, it has been explained how the new Eddy Current + Vision: A New Reliable Technology for Consistent defect detection system based on the integration Continuous Improvements on Time in the Long Product Metal between eddy currents and artificial Vision developed Industry,” AISTech 2018 Conference Proceedings, 2018. by ISEND and called EDDYeyes contributes to the best 3. J. Ignacio Lucas, “Surface-Critical Defects Analysis in Hot-Rolled Long Products, Wire Rod and Bars With Eddy Current and Artificial detection of PDRM through: Vision Testing,” AISTech 2018 Conference Proceedings, 2018. 4. E. Gómez de León, “Induced Currents Level II,” Fundación Confemetal, 1. Immediate and visual confirmation of peri- Madrid, Spain, 2009. odic signals detected by eddy currents. 5. J. García Martín, “Contributions in the Area of Probes and Algorithms 2. Immediate identification of broken rolls. Applied to the Detection of Discontinuities, Distance Metrology and Classification of Materials With Non-Destructive Techniques Based 3. Expansion of the traditional capabilities of on Induced Currents,” (in Spanish) thesis, Universidad de Valladolid, the eddy current testers to the treatment of Valladolid, España, 2016. periodic images to increase the typology of 6. J. García-Martín, J. Gómez-Gil and E. Vázquez-Sánchez, “Non- detectable defects. Destructive Techniques Based on Eddy Current Testing,” Sensors, Vol. 11, 2011, pp. 2525–2565. 4. User-friendly solution. 7. S. Saludes-Rodil, E. Baeyens and C. Rodríguez, “Unsupervised Classification of Surface Defects in Wire Rod Production Obtained by Eddy Current Sensors,” Multidisciplinary Digital Publishing Institute, References Sensors 2015, Vol. 15, No. 5, pp. 10100–10117. F

This paper was presented at AISTech 2019 — The Iron & Steel Technology 1. B. Chedal Anglay, “Process/Quality Opportunity Improvements Conference and Exposition, Pittsburgh, Pa., USA, and published in the Through Integrated CC/Wire Rod Tracking Coupled With Hot Eddy Conference Proceedings. Current Wire Rod Data,” AISTech 2014 Conference Proceedings, 2014. AUG

2020

IRON & STEEL TECHNOLOGY

AIST.ORG Digital Transformation is a critical component for steel companies’ future success — a broad concept with the potential to influence all aspects of the steelmaking process! We are seeking presenters for the second Digital Transformation Forum. The focus will be on two themes:

Steel industry applications with Steel industry applications with artificial intelligence (AI) other Industry 4.0 technology • Machine-learning applications in the steel industry • How to incorporate sensors (e.g., such as edge devices, • AI use in preventive maintenance new types of smarter sensors) • AI use in quality application (e.g., surface inspection) • Novel use case of robotics in the steel industry • AI use in production decision support (e.g., detecting • Industrial Internet of Things (IIoT) and novel use cases upcoming abnormal operation) • Challenges and lessons learned from integrating IIoT into • AI theory and how it can help in challenging industrial a steel facility applications (e.g., energy monitoring, emission control) • Advanced visual aid technologies and novel use cases • AI and business analytics applications • Virtual training using augmented reality/virtual reality • Cognitive intelligence applications (e.g., robotic process • The use of digital twins for the steel industry (e.g., what automation) is different from previous simulation technologies) • How to scope and select AI use cases • Any other Industry 4.0 novel use cases in the steel • Any other Al novel use case in the steel industry industry (e.g., logistics) (e.g., customer resource management) • Challenges and lessons learned from implementing AI into a steel facility

We are looking for real-use case studies and learning outcomes and challenges. Presentations are to be informative in nature without commercialism.

The deadline for submission is 25 September 2020. Visit AIST.org/DT21CFP for more information.

52 Technical Article

Controlling Equipment Failures Caused by Petroleum-Based Fluid Degradation

Air compressors, gearboxes and hydraulic systems that use mineral oils are susceptible to varnish and sludge. The life expectancy of petroleum-based fluid is generally determined by the rate of oxidation. When oxygen comes in contact with a petroleum-based fluid, oxidation occurs. The problem is usually dealt with by dumping the fluid and flushing the system or purchasing a varnish removal filter. New fluid technology is eliminating this problem in a way that is much less expensive and more efficient. Suppliers have developed oil-soluble polyalkylene glycols that, when added to the oil in small amounts, eliminate varnish, reintroduce oxidation additives and Author decrease total acid number.

John Schlobohm engineering manager, American ue to technology advances, One area that size reduction Chemical Technologies, Fowlerville, Mich., USA Dthe physical size of produc- affects is lubricant holding capacity. [email protected] tion equipment is becoming more Smaller capacity provides less vol- compact. Revamped internal com- ume into which heat can dissipate ponents allow faster operations — less ability to pull out heat gener- with more precision and power in ated during operations. New fluid a smaller package. Auxiliary pieces technologies have relieved some, like gearboxes, hydraulic compo- but not all, of the problems associ- nents and air compressors, which ated with high temperatures. have also been reduced in size, must Air compressors, gearboxes, oil- contend with higher production circulating systems and hydraulic demands. Equipment engineers and systems that use mineral oils are designers are constantly pressing to susceptible to varnish and sludge get more production out of their (Fig. 1). This is an inherent problem equipment. associated with petroleum-based

Figure 1 AIST.ORG

Compressor parts damaged by varnish. IRON & STEEL TECHNOLOGY

2020

AUG This article is available online at AIST.org for 30 days following publication. 53 fluids. The life expectancy of petroleum-based fluid is atoms) in mineral oil, and how adding PAG technol- generally determined by the rate of oxidation. When ogy to petroleum-based fluids will control varnish and oxygen comes in contact with a petroleum-based fluid, give longer life to the fluid. oxidation occurs, causing sludge, varnish and an There are three basic types of polyalkylene glycol: increase in total acid number (TAN). High tempera- insoluble in water, water soluble and oil soluble. Each tures exacerbate the development of varnish, which was developed to provide specific lubricating charac- can cause major operational problems. teristics and each has a place in industry with distinct Some companies with large oil-circulating systems advantages. have purchased costly filtration devices to remove sus- pended varnish. This process, however, will do noth- ing to remove varnish that has plated out on equip- Oxidation and Varnish ment metal. Draining the system and then cleaning with solvent is another expensive solution to a varnish An oil-soluble polyalkylene glycol (OSPAG) has recent- problem. Today, however, advancements in technol- ly been developed that, when added to petroleum- ogy have made varnish filters and solvent cleaning based oils, reverses oxidation and rehabilitates the unnecessary. This paper will discuss this new method. fluid back to a usable and stable condition. Varnish is a product of petroleum-based oil oxidation. Oxidation is caused when a free radical (oxygen atom) infiltrates Polyglycol Technology an oil molecule (Fig. 2). Oxygen is a very reactive atom and can cause an increase in the molecule’s Polyglycol products have been available since the total acid number. The acid that is developed will 1940s in the form of water glycol, which was developed eventually cause total degradation of the oil. Heat, by Dow Chemical for use in the mining industry and water and contaminants can accelerate this action. To in Navy ship-board hydraulic systems. Today, water help alleviate this action, oil suppliers blend oxidation glycol is used in many industries where fire-resistant inhibitors (usually amines and phenols) into finished fluids are needed. mineral oil. The inhibitors are polar and attract free The glycol family is large, ranging from basic glycol radials (oxygen atoms) away from the lubricating oil antifreeze to sophisticated pharmaceutical glycols. molecule, thereby reducing the chances of oxidation. A large portion of the family, polyalkylene glycols Generally, the amine molecule is the active element (PAGs), are used as synthetic lubricating fluids, pro- in the antioxidant additive package. It receives the viding many advantages over other fluids and oils used free radical and then passes it off to the phenol mol- to lubricate equipment. PAGs are not a petroleum- ecule (Fig. 3). This action continues until both the based product. They are made from natural gas and amine and phenol molecules become totally saturated therefore do not have the inherent problems of oxida- with free radicals (Fig. 4). At this point they drop out tion and varnish that petroleum-based mineral oils of solution and become a varnish particle. The par- and polyalphaolefins (PAOs) have. PAGs also can ticle not only traps amines and phenols, but it will also handle large water incursions. Compared to mineral pull in free water molecules and even very small con- oil, which can handle 300 to 500 parts per million of taminant particles. Because they are extremely polar water before degrading, PAGs can handle more than and loaded with free radicals, the varnish molecules 10,000 parts per million (1%) water before steps would have to be taken to curb the infiltra- tion. When water does occur Figure 2 in quantity, fluid degradation does not occur. Any free water can be removed with a vacuum AUG dehydrator with no damage 2020

to the PAG. Many papers have I been written about polyalkyl- IRON & STEEL TECHNOLOGY ene glycols. While some have been very accurate as to the advantages and disadvantag- es, some have not. This paper focuses on the ability of a poly-

alkylene glycol molecule to AIST.ORG not varnish, how the molecule attracts free radicals (oxygen Heat, water, air and contamination will accelerate the oxidation. 54 AUG 2020 I IRON & STEEL TECHNOLOGY I AIST.ORG Anatomy of a saturated varnish molecule. varnish asaturated of Anatomy of in version action. antioxidants Simplified Technical Article will be attracted to each other, each par to larger producing attracted be will to degrade rapidly to the point where the it no to lon is rapidly degrade to the varnish molecule will plate out. Plating in turn turn in out. Plating plate will molecule varnish the ticles, or will be attracted to, and plate out on, metal out plate to, on, and metal attracted be or will ticles, increases heat generation, causes hydraulic valves to to valves hydraulic heat causes generation, increases recharging has been the only solution. With new solution. With only the been has recharging oracles in hydraulic valves, are natural places where places natural are valves, hydraulic in oracles ger Until now, and usable. system the dumping as between rolling elements in a bearing or in small small or in elements abearing in rolling between as stick and reduces overall system efficiencies. system reduces overall and stick surfaces such as bearings, valves and rotating devices. devices. rotating and valves bearings, such as surfaces Figure 4 Figure 3 The increasing acid numbers will cause the oil oil the cause will numbers acid increasing The Places where temperature gradients are found, such are gradients wherePlaces temperature - - varnish that has become attached to metal surfaces surfaces metal to become attached has that varnish without causing other problems. The radical cleans radical problems. other The causing without that have fallen out of solution. By removing the free free out the of solution. By removing have fallen that have attached themselves to the amines and phenols and amines the to themselves have attached ibility issues. The polyalkylene glycol molecules are glycol are molecules polyalkylene The issues. ibility pended particles, but will also pull oxygen atoms from from atoms oxygen pull also but will pended particles, sus from radicals not removes varnish ing only the radicals, the antioxidants are now free to go back into go back now to are free antioxidants the radicals, oxygen atoms, so they readily accept the free radicals radicals free accept the readily they so atoms, oxygen extremely polar and will remove the free radicals that that radicals remove free the will and polar extremely soluble, is completelyoil it compat mixes without - fluid is added to the mineral oil system. Because PAG Because system. oil mineral the to added is fluid solution. One-third of all atoms in aPAG in atoms are of all molecule solution. One-third These are generally not an issue because because not issue an generally are These Not every application is suitable for the suitable is application Not every PAGs in reservoirs that have been paint have been that PAGs reservoirs in through vaporization. vaporization. through dissipated soon are amounts small the released. also are molecules water trapped the radicals from getting to the min the to getting from radicals the use of OSPAGs. For instance, do of OSPAGs. not For use use instance, but it will also pull oxygen atoms that that atoms oxygen pull also but it will products are a great paint remover paint and agreat are products released from the varnish molecule, small molecule, small varnish the from released Concerns eral oil molecule. As the radicals are are radicals the molecule. As oil eral ed, unless it’s epoxy paint. Glycol-based it’s Glycol-based unless paint. ed, epoxy free radicals from the varnish molecules, molecules, varnish the from radicals free allowing those antioxidants to become to antioxidants those allowing are in fluid solution, thereby stopping fluid in are soluble again. soluble Not only will the OSPAG the remove the will Not only the polarity and gives the mod the gives and polarity the OSPAG shifts fluid, base the tion (Fig.tion tive that adds antioxidation antioxidation adds that tive tion of oil-soluble polyalkylene polyalkylene oil-soluble of tion this expensive solution can be be solution can expensive this plished when 10–15%plished OSPAG to ability the oil base ified problems. leaving the original antioxi original the leaving resolubilize varnish through varnish resolubilize out the system. This is accom is This out system. the eral oil will solve these varnish varnish solve these will oil eral fier. It actually attacks varnish, varnish, attacks fier. It actually glycol into systems using min using glycol into systems fluid technologies, however, technologies, fluid dants to resume their protec their resume to dants amines and phenols to the oil phenols oil and the to amines avoided. Adding a small por a small avoided. Adding solution, it is a base oil modi oil solution, it abase is The OSPAGThe not addi is an

5). When added to to added 5). When ------55

Figure 5 Figure 6

O O O OH OSPAG 2 OH O PA 2 Molecule AA PA AA AA O OH2 PA O O O

Varnish Particle

Oil-soluble polyalkylene glycol molecule breaking up a varnish particle.

undissolved paint can clog filters or contaminate system components. Another place OSPAGs should not be used is with petroleum-based oils that have zinc additives. Zinc is not compatible with any polyalkylene glycol and will cause gumming. And finally, older systems that use organic seals, O-rings or gaskets should not use any synthetic fluid. Varnish has been removed from filters in a hydraulic system. Synthetic fluids can cause these products to shrink or swell, depending on the fluid, and leak. It is suggested that before using OSPAG in any application, consult with the supplier on its use in the Conclusion application. Because companies are demanding greater production from their equipment, lubrication fluid mainte- Results nance has become critical. Technologies have been developed to handle greater fluid stress and longevity, The usual time period for the OSPAG to work effec- however the basic problem that petroleum fluids have tively is dependent on the condition of the system — varnish — is still a problem. when it is converted. The typical period is about Oil-soluble polyalkylene glycol is a base oil modifier 45–60 days; however, the long-term working effect, that, when added to mineral oil or polyalphaolefin, in most cases, can be several years. The oil should be reverses oxidation and acid accumulation, both detri- sampled on a routine basis to determine its condition. mental to equipment. The TAN will be the determining factor as to the life Depending on the condition of the base oil, the of the fluid. As the varnish molecule is broken, releas- amount of OSPAG needed to reverse the degradation ing the antioxidants back into solution, the TAN will can be from 8% to 15%, and the time for it to com- lower. pletely transform varnish can range from as little as AUG

As seen in Fig. 6, OSPAGs have removed the varnish two weeks up to three months. F 2020

from filters used in a hydraulic system. These results I

IRON & STEEL TECHNOLOGY were accomplished in 45 days using a 10% addition This paper was presented at AISTech 2019 — The Iron & Steel Technology of OSPAG. Conference and Exposition, Pittsburgh, Pa., USA, and published in the Conference Proceedings.

AIST.ORG 56 Technical Article

Reduction of Maintenance Costs and Improved MTBR of Boiler Steam Drum and Superheat Safety Valves

Authors The goal of this project was to reduce the cost of maintenance and repair of the safety valves on Tim Shelton all six boilers at ArcelorMittal Burns Harbor. Historically, the practice has been to disassemble ArcelorMittal, Burns Harbor, and replace the parts for every valve annually. Studies show that the majority of valves that are Ind., USA disassembled do not require a total disassembly and repair. The U.S. Occupational Safety and [email protected] Health Administration states that each company will establish a good engineering practice on the Charles Kuntz frequency and type of repair based on the historical data collected. By changing the frequency and ArcelorMittal, Burns Harbor, Ind., USA type of testing, the time between repair has been increased from one year to two years. [email protected] Larry Frey ArcelorMittal, Burns Harbor, he boilers at ArcelorMittal annual outages. Vendors would dis- Ind., USA Burns Harbor’s power station assemble, repair and reset the valves [email protected] T have high-pressure drum and super- on each boiler. This work was usu- heat valves that are welded in-line. ally completed in two to three days This eliminates any flange issues with an additional day for testing that could arise and leaves the valves the valves after the boilers were suitable for field repairs. The valves being brought to operating pressure. are all 1700 series Maxi-flow safety This was considered the best prac- valves. They range in setpoint from tice based on the time allowed for 1,025 to 1,050 psi on the drums and boiler outages and the many critical 950 psi on the superheats, and meet jobs being performed concurrently. the American Society of Mechanical The need for certified repair facili- Engineers (ASME) code require- ties to conduct the repairs allowed ments for setpoint and capacity for for the vendors to develop the prac- the plant boilers. Lake Michigan tice of automatically replacing the water is processed by a reverse osmo- discs in the valves at each downturn. sis system to remove impurities prior to reaching the boilers. Costs — The cost of a certified Since the requirements on man- vendor, scaffolding services, replace- power, training and certifications ment discs and time to test valves at do not make it cost-effective to start-up are incurred at each boiler repair the valves in-house, the plant outage. has maintained a process of using a vendor to repair the safety valves. Justification for Improvement — Per Historically, a complete disassembly, the ASME code, the maintenance replacement of the disc, resurfac- of pressure-relieving devices falls on ing the nozzle and resetting of the the owners of the valves. The owners valves was included in the annual are required to follow guidelines set rebuild of each valve. The in-line by the National Board of Boilers and setting of the valves was done with Pressure Vessel Inspectors and those AIST.ORG

I a hydraulic lift assist device as the in the National Board Inspection

boiler was being returned to service. Code (NBIC) book. Based on this information, it is not required to disassemble the Discussion valves and perform repairs on each valve every year. Per the U.S. Past Practice — IRON & STEEL TECHNOLOGY Prior standard prac- Occupational Safety and Health

I tice was to repair valves during Administration (OSHA) standard, 2020

AUG This article is available online at AIST.org for 30 days following publication. 57

Figure 1

Example of the drum and superheat valve list. the frequency of complete repairs should be based A lunch-and-learn on pressure relief valves was on “good engineering practices.” The historical data developed to educate power station staff on safety/ was reviewed, including purchase orders written for relief nomenclature and what was included in the repairs on the drum and superheat valves with power new process. It was also stated that vendors would be station personnel. It was determined that the practice required to have a “VR” stamp certifying that they of completely repairing valves every two years instead adhered to the ASME code requirements for the cor- of every year would be acceptable. The practice of rect repairs to pressure-relief devices. A procedure examining the seats for any defects and measuring stating the policy on how these valves would be main- the “critical dimensions” (height of seats on the ther- tained was developed and is updated as necessary, mal discs) and reusing them if they were within the including the information on vendors and frequency standards for the size of the valve was also initiated. of testing. Safety valve repairs are incorporated in the Testing the setpoint in the non-repair year is done process developed at the power station for planning to ensure the functionality of the valve is maintained. outages. The process for safety valves began in Q4 2017 This is based on several conditions, including: (a) no and was utilized in 2018, with a cost savings of 61%. visible signs of leakage, (b) proper reseating without Another benefit of utilizing this new program has leakage if it had lifted and (c) meeting the setpoint been retaining used, but acceptable, discs that previ- criteria when tested in-line under normal operating ously would have been discarded. At the time of this conditions in the previous 12 months. writing, four of these discs had been used. Since vendors are not required to automatically replace the Actions Taken — The process followed was to build a discs, there has been no need to purchase discs. database of all superheat and drum safety valves. The valves were identified by their unique serial numbers and each valve has a file that also includes the Conclusions setpoint, capacity, asset number, model number, last repair/reset date, frequency of testing, applicable The Burns Harbor power station staff was able to ASME code and vendor who performed the work make informed, economical decisions on the main- (Fig. 1). Each valve has its own tab where the valve tenance path to use on the drum and superheat repair documents can be attached and is readily avail- safety relief valves: extending the mean time between able. This is posted on a company SharePoint site repairs to two years for each boiler safety valve, lead- enabling the information to be accessible to all power ing to reduced labor and material costs. AUG station personnel and is updated after every boiler 2020

outage. I

The process enables the power station staff to deter- References IRON & STEEL TECHNOLOGY mine, as each boiler outage was planned, whether they needed to repair or simply test the valves. It has also 1. PD665 – ASME BPV Code, Section I: Power Boilers. been established that the valves could be tested in-line 2. National Board Instruction Codes (NBIC). prior to bringing the boilers down in a non-repair year 3. T. Shelton, Power Station Cost Savings. F to determine if they meet the setpoint criteria. If they

This paper was presented at AISTech 2019 — The Iron & Steel Technology meet the criteria, no additional work is required until AIST.ORG Conference and Exposition, Pittsburgh, Pa., USA, and published in the the following year. Pre-outage testing eliminates hav- Conference Proceedings. ing to test the valves at the end of an outage. ANDRITZ METALS REBUILDS AND REPAIRS FOR ALL YOUR MILL SERVICE NEEDS

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ANDRITZ Herr-Voss Stamco Inc. ⁄ 2970 Duss Avenue ⁄ Ambridge, PA 15003 ⁄ USA / +1 724.251.8745 ⁄ andritz.com 60 Technical Article

Maintenance Practices of Gas Analyzers in Steel Industry

In the iron and steel industry, the use of process analytics is required at several locations of the plant with different objectives. The measured data obtained from the analyzers are used to monitor and control the function and economic efficiency of the process, safety for personnel and equipment, and environment protection. Tata Steel has adopted many good practices to make gas analyzer measurement reliable. Until now, the number of interruptions has been reduced to two digits for every 40 gas analyzer measurements. Tata Steel worked to reach single-digit interruption for 40 gas analyzer measurements by the end of 2019. Authors

Ashish Garg (pictured) hallenges in the maintenance Importance of Gas Analyzer in senior manager instrumentation, and reliability of gas analyzer Blast Furnaces Tata Steel India, C Jamshedpur, JH, India systems in the steel industry have [email protected] drawn serious attention for mainte- Blast Furnace Top Gas Analysis — Gas Pradyot Basu nance engineers all over the world analyzers are widely used in process Tata Steel India, due to the continuous evolution, control applications. They are used Jamshedpur, JH, India innovation and complexity of mod- in monitoring the process param- [email protected] ern technologies. These systems eters and in safety interlocks if any need very high reliability and avail- of the process parameters go above ability due to the critical business, or below the desired operating limit. environment and safety nature The blast furnace (BF) is a type of iron and steel operations. This of metallurgical furnace (shown in paper reviews equipment mainte- Fig. 1) used for smelting to produce nance strategies practiced over the industrial metals, generally iron, but years in complex integrated steel also others such as lead or cop- production systems. The paper also per. The operation status of the examines the current maintenance BF is closely connected with the and reliability philosophies, their ironmaking process, coke consump- limitations, and highlights major tion, molten iron quality, etc. Top breakthroughs and achievements gas is not only a secondary fuel for with regard to complex engineer- coking, power plant, heat treatment, ing systems maintenance. Intelligent and other usages in the iron and maintenance, a novel approach to steel production process, but is also complex engineering systems main- a critical reference for scheduling tenance and reliability sustainment, workers to forecast the operation is proposed. The approach rein- status of the BF. The BF is a highly tegrates the maintenance phase complex system and thus it is very into system development by adapt- difficult to assess the internal state ing advanced engineering method- of the process by direct measuring, ologies to develop condition-based including the spatial and temporal AIST.ORG

I predictive maintenance, an intel- distribution of temperatures and

ligent maintenance system with pressure. The operation status must resilient, autonomous and adaptive be assessed based on the incoming capabilities. and outgoing flows, as well as the conditions at the furnace boundaries. Top gas data can be easily

IRON & STEEL TECHNOLOGY obtained relative to the internal

I data of BF and is a critical indicator 2020

to reflect the operation status of BF.

AUG Therefore, it is necessary to study 61

Figure 1

Blast furnace process.

a real-time automatic prediction method for top gas depending upon the type and amount of fuel injected indices. The operation status of the BF is reflected in the tuyeres of the blast furnace. by indices such as the contents of CO, CO2 and H2 (MP1 in Fig. 1). The percentage of CO and CO2 in BF Pulverized Coal Injection Plant — The concept of coal gas is directly related to the amount of carbon in the pulverization stems from the belief that if the coal is charged coke and amount of CO2 in the charged flux made fine enough, it will burn almost as easily and (limestone and dolomite). The coke rate (the rate of efficiently as a gas. The raw coal is fed into the coal carbon consumption) in the blast furnace depends mill along with heated air. As the coal gets crushed, upon mainly the type of the hot metal to be made, the hot air dries it and blows the usable fine coal pow- the chemical and the physical characteristics of the der out, which is then transported directly to the blast charged materials, the distribution of the materials in furnace or to the coal bunker for storage. The exhaust the furnace stack, the temperature, and the oxygen air is then purified by a bag filter. Fig. 2 shows the coal enrichment of the hot air blast. The total amount of grinding and injection process.

CO + CO2 gases by volume in the BF gas at the fur- A mix of fine coal powder and hot carrying air is nace top is around 45% of the total gas volume. The inevitably creating carbon monoxide (CO). For safety hydrogen content of the gas can vary from 2% to 5% operation, a continuous monitoring of oxygen (O2)

Figure 2 AUG

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Coal grinding and injection process. 62 AUG 2020 I IRON & STEEL TECHNOLOGY I AIST.ORG In-burden probe. In-burden process. stove Hot Technical Article with an enrichment gas, is combusted and the hot the and combusted is gas, enrichment an with temperature leads to lower coke and pulverized coal/ lower to leads coke pulverized and temperature for hot provide to stoves level. is target tuyere The at the of fuel coke combustion injected and through BFprocess the to gas reducing and energy thermal (BF), furnace equipment blast the to auxiliary tant be divided into three sections: combustion chamber, combustion sections: into three divided be providing hot blast to the process. The blast provides provides blast The process. the to hot blast providing storage. and transfer pulverization, natural gas consumption in the BF. the in hot consumption The stove is gas natural impor —Hot very stoves are Analysis Gas Stove Hot on-gas, the blast furnace gas (BFG), often together together often (BFG), gas furnace blast the on-gas, flue gas flows through the combustion chamber, combustion the the through flows gas flue dome and then the checker the dome chamber. then and checker The of period the dome checker and chamber. During a thermal regenerator and a simple structure of hot asimple structure regenerator and a thermal Higher blast temperature. blast stable and a high of coal monoxide process each in carbon trace and stove is presented in Fig. 3. An individual stove can stove can individual Fig. presentedstove in An 3. is Figure 4 Figure 3 - (Fig. 4) enables the gas distribution and gas tempera gas and distribution gas (Fig. the enables 4) well as a large volume for energy storage. The checker The storage. volume for energy a large well as the overall composition of gas and its thermal profile. profile. thermal its and composition of gas overall the byanalyzing assessed be to furnace blast the in ture temperature before it is injected into the BF, into the shown before it injected is as temperature astable with flow produce to aconstant coldthe blast of amount a certain with stove, mixed the it often is leaves hot chamber. the combustion blast the When of checker,the apart to dome then the and through as for heat area transfer surface alarge provide to The in-burden probe in-burden —The Analysis Gas Probe In-Burden brick is heated and stores the thermal energy. After energy. After thermal the stores and heated is brick in Fig. 3. Real-time monitoring of carbon monoxide of carbon monitoring Fig.in 3.Real-time operation. operation. cold blast is heated by flowing from the bottom of bottom the from byflowing heated is cold blast where the on-blast to switched stove is the on-gas, channels with bricks refractory with filled is chamber and oxygen in the waste gas after combustion through through combustion after gas waste the in oxygen and stack ensures stove combustion efficiency and safe safe and stove efficiency combustion ensures stack - 63

Figure 5

Steel melting shop process.

The lance is pushed horizontally at 4.5 m under the concentrations. The gas concentration after ID fan maximum stock line level of blast furnace shaft. The before flare stack is measured using a wet gas analyzer lance can travel to maximum 10 points on the blast to measure the concentration of oxygen percentage. furnace radius for gas sampling and gas temperature. The common wet gas analyzer is installed in the com- The gas sample at each point is directly transmitted mon gas duct to the gas recovery plant to measure after passing through a sample-handling system to the concentration of oxygen percentage to prevent

CO and CO2 gas analyzer. air entry into the gas holder and to stop the blowing process and gas recovery in case O2 concentration is above 2%. Fig. 5 suggests the steel melting shop Importance of Gas Analyzers in Steel Melting Shops process.

Gas analyzers at the converter shop in a steel meltshop analyze the concentration of CO, CO2, H2 and Maintenance of Gas Analyzer Systems in the Steel O2 present in the converter gas at different locations; Industry namely dry gas, wet gas and common wet gas, which is released because of blowing process. The measure- Blast furnace and steelmaking is a continuous process ment of CO concentration in a dry gas analyzer is where gas analyzers are the safety and quality control– important for the recovery, storage and distribution critical equipment throughout the steel production of gas to different customers for heating of furnaces. process. Severe heat, dust, continuous production

The measurement of CO2 concentration in a dry gas and process safety in blast furnaces, steelmaking analyzer is important to control the entry of air into shops, rolling mills and gas mixing stations are major the system and to reduce the excessive heat generated challenges in the steel industry. In each environment in the gas duct. The measurement of H2 concentra- and every process, gas analyzers must perform safely, tion in a dry gas analyzer is important to know the accurately and reliably, without any interruption. Any leakages of water into the converter to prevent explo- interruption on the gas analyzer means upsetting AUG sion by stopping the blow. The measurement of O2 the total process, stopping production, etc. So, the concentration in a wet gas analyzer and common wet unplanned outage of a gas analyzer leads to an oppor- 2020

gas analyzer is important to control the entry of air tunity for the loss of the production and directly I into the system and to prevent the formation of an affects the performance of the shop (especially blast IRON & STEEL TECHNOLOGY explosive mixture in the system leading to unsafe furnace and steelmaking shops). conditions like a massive explosion, if the percentage The main constituent of the gas analyzer is its sam- of oxygen goes beyond 2%. From the ID fan, the gas ple-handling system (as shown in Fig. 6). Maintenance is sent either to the flare stack for flaring or to the persons give maximum time and energy to keep the gas holder for storing the gas based on CO concen- sample-handling system healthy, and any malfunction-

I tration (CO >30% and O2 <2%). The release gas is ing leads to improper process control and unwanted AIST.ORG sampled before the scrubber in hot condition by the tripping if taken in interlocks. The sample-handling dry gas analyzer system to measure CO, CO2 and H2 system consists of probes and filters, a gas cooler to 64 AUG 2020 I IRON & STEEL TECHNOLOGY I AIST.ORG Process interruptions due to gas analyzer. gas to due interruptions Process system. sample-handling Gas analyzer Technical Article the calibration of the analyzer modules as per the the per as modules analyzer of the calibration the for condensate removal, and panel the analyzer the to the from gas sample of the cooling of the care take process requirement. process point tapping the from gas suck the to pumps process, or more points, flow switches to know the flow in the the in flow the know to switches flow or more points, analyzer panel and the gas analyzer unit, and finally finally and unit, analyzer gas the and panel analyzer solenoid valve (SOV) arrangement for sampling two two for sampling arrangement (SOV) solenoid valve Figure 7 Figure 6 o of Interruptions 100 150 200 50 0 Y1 F‘4 F‘5 Y1 Y1 FY‘18 FY‘17 FY‘15FY‘16 FY‘14 FY‘13 124 153 128 107 100 70 The corrosive and aggressive nature of the sample sample of the nature aggressive and corrosive The Based on the failure records of last three years and and years three of last records failure on the Based the root-cause failure analysis, major problematic problematic major analysis, failure root-cause the the process pressure is not sufficient to transport an an transport to not is sufficient pressure process the by using technology to improve maintenance practice, practice, improve to maintenance technology by using philosophy to sustain the improvement. the sustain to philosophy maintenance asystem-based problems adopting and chronic eliminate to changes implementing design ruptions were more than nine per month per (Fig. nine 7). were more than ruptions Elimination of Sample Gas Pump Failure Pump Failure Gas Sample of Elimination of downtime (shown in Fig. 8). In the last two years, years, two last Fig. the in In 8). (shown of downtime melting shops. Until FY’16 and FY’17, and inter average Until shops. FY’16 melting Sample gas analysis systems require pumps when pumps require systems analysis gas Sample gas analyzers installed in blast furnaces and steel and furnaces blast in installed analyzers gas availability of these gas analyzers has been achieved achieved been has analyzers gas of these availability were for which responsible 80% were identified, areas adequate volume of sample gas to the gas analyzers. analyzers. gas the to volume gas of sample adequate substantial improvement in safety, reliability and and improvement reliability safety, in substantial At Tata Steel Jamshedpur, there are more than 70 Tata moreAt Jamshedpur, Steel than are there - 65 gas demands special properties of the internal com- • The pump should be replaced with a new ponent of pump that comes in contact with process pump with more capability of handling higher media. discharge/backpressure. Since the transportation time of the sample gas is • The 6-mm tubes and SOVs of the sample-han- crucial, the sample pump shall be correctly sized and dling system should be replaced by large diam- chosen, and shall provide the entire system with the eter tubes so that the discharge/backpressure sufficient flow and pressure from the sample point be reduced. down to the analyzer. At the I Blast Furnace, sample gas pump KNF failed Based on the solution provided by the original due to following problems: equipment manufacturer and detail study done by Tata Steel, it was concluded to change the pump in a • Bearing seize. phase-wise manner. • Diaphragm damage. Fig. 9 shows the flow vs. discharge pressure curves • Overheating. of the damaged pump (2040 LPH) and new suggested pump (900 LPH). The maximum backpressure sus- On analysis, it was found that the sample-handling tained by 2040 LPH pump is 0.5 bar while 900 LPH system has internal tubing of 6 mm. Due to the small- pump can sustain maximum backpressure of 4 bar. sized tube, the pump discharge pressure was more With new pump installation (Fig. 10), the prob- than 0.5 bar, which was higher than the rated capacity. lem of sample gas pump failure was eliminated. The pump could not sustain such high pressure and Transportation time for the gas sample to reach the it was transferred on diaphragm, bearing, shaft, etc., gas analyzer changed from 11 seconds to 24 seconds resulting in pump failure. The matter was discussed (considering 80 m sample path length), which was with the original equipment manufacturer and the allowable for process application with respect to pro- following solutions were developed: cess safety.

Figure 8 AUG

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Ishikawa diagram for gas analyzer interruptions. 66 AUG 2020 I IRON & STEEL TECHNOLOGY I AIST.ORG The major problems faced with sample probes are: probes sample with problems major faced The Improve Design of Sample Probe for On-Line for On-Line Probe Sample of Improve Design Pump changed from 2040 LPH to 900 LPH. 900 to LPH 2040 from changed Pump 900 pump LPH suggested new (right). and (left) LPH 2040 pump damaged pumps: both of characteristics working of study Comparative Technical Article

handling the heavy dust loads with high temperature. temperature. high with loads dust heavy the handling process and analysis systems. They systems. analysis and process Maintenance Maintenance Sample gas probes form a critical point between the the point between acritical form probes gas Sample gas analysis system. The design of the probe is suitable for suitable probe is of the design The system. analysis Figure 10 Figure 9 • •

M C

from the process stream and supply it and stream process the from hokage of filter. hokage aintenance requirement of filters. aintenance

extract sample sample extract

to the the to For on-line maintenance, the system must be designed designed must be system the maintenance, For on-line the fine coal silo. The fine coal silo is related to coal coal to related is silo coal fine silo. The coal fine the in such a way that running maintenance can be done be can maintenance running that such away in interlock. Fine coal dust should be handled by timely bytimely handled should dust be coal Fine interlock. safety process mill coal well as as process injection line maintenance since there was no isolation valve, as as valve, no isolation was there since maintenance line and CO), in which six gas analyzers are related to to related are analyzers gas six which in CO), and shown in Fig. in 11.shown for not on- designed was system the safely. Initially, sample probe maintenances to maintain reliability. reliability. maintain to probemaintenances sample Pulverized coal injection has 11 gas analyzers (O analyzers 11 has gas injection coal Pulverized 2

Figure 11

Old designed probe without isolation valve vs. new designed probe with isolation valve.

Fig. 12 shows the new modified design of the sam- accumulated moisture is necessary to drain out to pling probe with isolation valve; with this improve- protect the measuring cells in the analyzer from dam- ment on-line maintenance can be done safely. age and/or stabilize measurements. The sample gas is often conveyed through the analysis system with suc- tion; the condensate must be pumped off to remove To Improve Reliability and Productivity by Automatic it. So-called peristaltic pumps are particularly suited Condensate Drain System for this purpose. The following concerns can occur if a peristaltic In a digital world, automation plays an important pump is not present in the system: role in improving the safety, reliability and productivity of the plant. Tata Steel also drives this journey • Manual draining needs to regularize, which throughout its plants. The sample-handling system in decreases the productivity. many areas of Tata Steel is controlled through micro- • Unsafe handling of bottles used for collection controllers or programmable logic controllers, but of condensate. areas that are very old have much room for improve- • Gas leakage can happen. ment. Condensate can accumulate while wet sample gas is processed through a conditioning system. The

Figure 12 AUG

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Installation of new designed probe with isolation valve in coal injection plant. 68 AUG 2020 I IRON & STEEL TECHNOLOGY I AIST.ORG Interlocks play an important role in the sample- role the in important an play Interlocks Top schematic. analyzer gas collectionManual of condensate in bottles vs. automatic of draining condensate. Technical Article that is used for conditioning the sample gas. The con The gas. sample the for conditioning used is that used in conjunction with other devices in a sample- in devices other conjunction with in used pump. of aperistaltic tion Reliability Improvement by Strengthening Interlocks Interlocks Strengthening by Improvement Reliability handling system. system. handling handling system to keep the gas analyzer safe from from safe analyzer gas keep to the system handling condensate monitor is a unit or supplementary device device or supplementary condensate monitor aunit is of Sample-Handling System System Sample-Handling of densate monitor is one of the most important devices devices monitor important one most is of the densate dust and moisture, a condensate monitor is used. The The acondensate monitor used. is moisture, and dust from To analyzer moisture. and dust gas protect the automatic draining of condensate and after installa after of condensate and draining automatic Figure 14 Figure 13 Fig. 13 shows what the system would look like before look would like Fig. 13 system the shows what - -

tor and the condensate monitor malfunction allowed allowed condensate monitor the malfunction tor and condensate moni of condensate, the to tion it traveled it was found that the peristaltic pump failed, thus the the thus failed, pump peristaltic the found that it was condensate was not accumula removed. the to Due condensate was condensate not monitorof the analysis, did work. On for the condensate to travel to the gas analyzer. analyzer. gas the to for condensate travel to the interlock the as of moisture ingress due the to failed • • The condensate monitor has mainly two functions: two mainly condensate monitorThe has In FY’16, the top gas analyzer hydrogen component analyzer top gas the FY’16, In

T W ter paper of 2-micron particle size; this filter filter this size; particle of 2-micron paper ter unit, it serves as a device that detects the pres the detects that a device as it serves unit, papers filter dust in sample gas up 2microns. to gas sample in dust filter papers ence of moisture in the sample gas. sample the in ence of moisture he condensate monitor has a glass fiber fil fiber aglass he condensate monitor has hen used in conjunction with a switching a switching conjunction with in hen used - - - - 69

Figure 15

Redundancy built up of condensate monitor in top gas analyzer.

Interlock was present, but due to the non-functioning two or three modules are installed in parallel (shown of the condensate monitor, it did not work. Somehow, in Figs. 15–17). An additional condensate monitor was two components, the CO and CO2 modules of the top installed in series and given interlock. After imple- gas analyzer, were protected from being damaged but mentation and horizontal deployment of the same the hydrogen module failed. Fig. 14 shows a schematic installation in other blast furnaces, no gas analyzer of the top gas analyzer. has failed. To protect the gas analyzer from such failure, redundancy had to be built up in the system in which

Figure 16 AUG

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Original setup of top gas analyzer sample-handling system. 70 AUG 2020 I IRON & STEEL TECHNOLOGY I AIST.ORG The in-burden probe is essential in the blast furnace furnace blast the in essential probeis in-burden The very difficult when the blast furnace is in operation operation in is furnace blast when the difficult very probe is of this Maintenance conditions. harsh very Modified setup of top gas analyzer sample-handling system. sample-handling analyzer gas top of setup Modified Technical Article

Analysis Measurement was not correct. It became difficult for the process for process the difficult It not became correct. was Reliability Improvement of In-Burden Probe Gas Gas Probe In-Burden of Improvement Reliability its measurement: its at maximum run furnace It helps blast process. the operators to run the blast furnace. blast the run to operators maintenance personnel, since this probe works under probeworks this since personnel, maintenance efficiency. It provides following advantages through through advantages following It provides efficiency. for the maintenance personnel as gas sampling data data sampling gas as personnel for maintenance the safety. affect may that interlocks critical many itsince has Figure 17 • • • In FY’16, measurement reliability became aconcern became reliability measurement FY’16, In Reliability of measurement is an important task for task important an is of measurement Reliability

E S M the furnace. ignificant contribution to extending furnace life. furnace extending to contribution ignificant nsure uniform distribution of burden across across of burden distribution uniform nsure aximize fuel efficiency. fuel aximize A one-time improvement prevent and recurrence can A one-time the Improvement Improvement the two shutdowns. To fulfill that dream, the journey for journey the dream, that To shutdowns. two fulfill System-Based Maintenance Philosophy to Sustain Sustain to Philosophy Maintenance System-Based problem was eliminated completely. eliminated problem was Fig. in 19, and reliable becomes measurement that so done. is sampling gas after tube measuring the ing for purg used is which of nitrogen, increase pressure person dreams of achieving zero breakdowns between between breakdowns zero of achieving dreams person less maintenance is required. is maintenance less nance schedule and condition monitoring points will will points condition monitoring and schedule nance maintenance activity and calibration activity would be be would activity calibration and activity maintenance the all that decided It was (SAPPM). maintenance design of the measuring tube was changed, as shown shown as changed, was tube measuring of the design a suggested analysis The due accumulation. dust to done through SAPPM. Necessary time-based mainte time-based Necessary SAPPM. done through suring tube of the in-burden probe became choked probebecame in-burden of the tube suring sustain the result for years to come. Every maintenance come. to maintenance for Every result years the sustain system-based maintenance started with SAP plant plant SAP with started maintenance system-based After this modification, the dust accumulation accumulation dust the modification, this After To correct the problem of dust accumulation, the To the problem the accumulation, of dust correct The gas analysis chart in Fig. in mea 18 the shows chart that analysis gas The - - - 71

Figure 18

Gas sample analysis chart through in-burden probe.

be uploaded in SAP. Shutdown maintenance is also Results, Conclusions and Way Forward done through checklist-based execution. A data mining framework (Fig. 20) was also made to The initiative to improve reliability and availabil- strengthen the process and standardize it across Tata ity of the gas analyzers at Tata Steel was taken in Steel. This helps in achieving maximum reliability of FY’17 under central maintenance instrumentation. measurement, strengthening process safety and lower- At that time, average interruptions were around 10 ing inventory costs. per month. It initially focused on the reliability of the measurement, on-line maintenance of probes, redundancy buildup, inventory cost, standardization of

Figure 19 AUG

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Modified measuring tube of underburden probe. 72 AUG 2020 I IRON & STEEL TECHNOLOGY I AIST.ORG SAP-based calibration schedule for gas analyzers. analyzers. gas to due interruptions Process Tata at Steel. analyzer gas of framework mining Data Technical Article Figure 22 Figure 21 Figure 20 o of Interruptions 100 150 200 50 0 area-wise. c) Analyzerinterruptionsmonitoring interruptionsofgasanalyzers. b) AnalysisandRCFA ofmajor a) Dailyreporting ofinterruptions. systemdesign. c) Improvement insample-handling SMPmodificationunderprogress. dayinspectionstarted. alternate b) Inplaceofdailyinspection, permodifiedSMP. a) Changeinmaintenanceplanas FY‘13 FY‘14FY‘15FY‘16FY‘17FY‘18FY‘19 FY‘13 124 153 128 107 100 70 Check Act 44 D C S A the involvement of shop floor personnel, the focus on focus involvement the the personnel, of shop floor handling systems will be under discussion. be will systems handling interruptions/year will be single-digit for initiatives for initiatives single-digit be will interruptions/year set for target the (Fig. 21).interruptions FY’20, In sample- smart and points, of tapping auto-cleaning like ruptions to four per month, i.e., a 60% reduction in in four month, per reduction to i.e.,ruptions a60% inter could achieve team the Q3 byFY19 and results, maintenance practices across Tata Jamshedpur, Steel across practices maintenance and design improvement, which has given excellent given improvement, design has which and Standardize The critical success factors of this initiative were initiative of this factors success critical The Do maintenance. a) SMPimplementationofgasanalyzer Design ofSystem: consumablespares across works. e) Standardization ofgasanalyzer shutdown. maintenanceactivitiesduring d) Checklist-basedexecutionof c) Checklist-basedinspection. b) RefillinggascylinderARC. maintenanceandcalibrationschedule. a) ImplementationofSAPfor - 73

Table 1 Tata Steel Standard Maintenance Practices for Gas Analyzers Value-based Status Serial No. Description of measuring points Characteristic LCL UCL Value Y/N Frequency 1 Probe heater temperature Temperature (°C) 100 150 1M 2 Heat-traced tube temperature Temperature (°C) 70 90 1M 3 Sample gas cooler temperature Temperature (°C) 2 6 1M 4 Flow of gas in Rotameter 1–Module 1 Flow (lpm) 50 80 1M 5 Flow of gas in Rotameter 2–Module 2 Flow (lpm) 50 80 1M

6 Flow of N2 in Rotameter 3–Probe N2 Flow (lpm) 100 150 1M 7 Reading of the Analyzer Module 1 ppm (%) 0 XXX 1M 8 Reading of the Analyzer Module 2 ppm (%) 0 XXX 1M 9 Reading of the Analyzer Module 3 ppm (%) 0 XXX 1M 11 Condition of probe filter OK/NOK 1M 12 Current of the heat-traced tube Current 0 10 1M 13 Purging system of probes and its solenoid valves OK/NOK 1M 14 Tripping circuit of condensate monitor OK/NOK 1M

15 N2/air pressure of the purging system Pressure (bar) 2 5 1M 16 Tripping circuit of Rotameter 1 OK/NOK 1M 17 Tripping circuit of Rotameter 2 OK/NOK 1M 18 Tripping circuit of Rotameter 3 OK/NOK 1M 19 Condition of the peristaltic pump OK/NOK 1M 20 Condition of the main pump OK/NOK 1M 21 Condition of Rotameter 1 OK/NOK 1M 22 Condition of Rotameter 2 OK/NOK 1M 23 Condition of Rotameter 3 OK/NOK 1M 24 Condition of bypass pump OK/NOK 1M 25 Analyzer purging vent lines OK/NOK 1M

failure of a set of components and driving it until it is References eliminated, standard maintenance practices deployment (Table 1), SAP-based inspection, maintenance 1. Adage Automation brochure. and calibration (Fig. 22) through certified engineers, 2. Tata Steel standard maintenance practices book. and ensuring the information and solutions are insti- 3. Focused Photonics Inc. brochure. tutionalized/horizontally deployed across the plant. 4. KNF brochure. F The inspection schedules along with its acceptable upper/lower limits were uploaded in the system and AUG

audited on a monthly basis for its compliance and 2020

subsequent corrective actions. The involvement of I

plant personnel in standardizing maintenance prac- IRON & STEEL TECHNOLOGY tices, training and knowledge-sharing, and shop floor celebrations, together with the active presence of senior management created excitement and motiva- tion across the team, which was the major enabler for this success story.

AIST.ORG 74 Technical Article

Life Extension of Motor Control Centers: When to Maintain and When to Replace

Facilities depend on keeping critical assets running. Often this equipment is controlled by motor control centers (MCCs) that can last for decades — even beyond their original design life. However, equipment reliability, maintenance requirements and performance rely on proper application, operation and maintenance. This paper will examine the following areas of interest when assessing motor control centers: common wear items and maintenance guidelines for MCCs; upgrading to include new technology or expanding plant capacity; weighing cost considerations to maintain versus replace; and arc flash safety considerations when maintaining equipment. Authors

Matthew R. Hussey (left) oday’s global production in complete testing during scheduled Eaton Corp., Fayetteville, N.C., USA the steel industry continues rotational outages, such as dissolved [email protected] T to expand. Capacity additions are gas analysis of transformer liquids David B. Durocher (right) springing up in a few key strategic and testing of trip performance for retired, Eaton Corp., Wilsonville, Ore., USA areas, aimed at balancing increas- power circuit breakers, as well as [email protected] ing demand and a fixed supply. The infrared scanning of electrical con- prospects of new capacity instal- nections to check for hot spots and lations that will successfully apply insulation breakdown. state-of-the-art technologies are Although a robust preventive exciting, offering the step-change maintenance program of electrical potential to improve site productiv- control and distribution systems can ity, reliability and safety. That said, be effective, the plan to continue because several existing mills in this cycle year after year without industry are not operating at design implementing either a replace- capacity, the fact remains that most ment or upgrade program for these global demand will continue to be valuable assets will put yesterday’s served from existing facilities. Many productive mill on the future road existing mills were first commis- to obsolescence and eventual clo- sioned 40–50 years ago and some sure. It’s an obvious fact that legacy existing systems might be approach- mill electrical systems, originally ing end of life today. Mill operators manufactured 40 and 50 years ago, of existing sites will need to focus cannot keep pace with the rapid on considerations regarding equip- changes in technology. Analogously, ment replacement versus upgrades it is certainly possible the televi- for electrical power distribution and sion purchased for personal use at control systems. home back in 1975 could still be Electrical power in most indus- in service today, through careful trial mills is the most ubiquitous and meticulous maintenance and asset of the production process, replacement of worn or failed com- while also being arguably one of ponents. Of course, considering the AIST.ORG

I the most overlooked. The reason extraordinary shift in technology

for this is simple; electrical power is with high-definition LED network- presumed to be reliable and avail- enabled televisions of today, it would able until it is not. Most production be senseless to consider the time facilities in the upper quartile for and cost to extend the life cycle of reliability and safety have rigorous the 44-year-old set. In this example,

IRON & STEEL TECHNOLOGY and detailed preventive mainte- replacement is the only practical

I nance procedures in place to assure option. 2020

“the lights don’t go out” unexpect-

AUG edly. These include programs to 75

Applicable Manufacturing and Test Standards Replacement Considerations

In today’s modern engineered electrical systems, Consistent site maintenance practices to assure both there are a host of assemblies that should be con- the LV MCC steel structure and the bus system have sidered for either replacement or life cycle exten- not been neglected are essential. If one or both has sion upgrades. It is important to be familiar with degraded or been compromised over time, replace- the major components that serve as the building ment of the assembly is recommended. Examples of blocks of power distribution and control assemblies compromise for these parts of the assembly would in industry. In North American markets, the Institute be environmental contamination, rust, water ingress, of Electrical and Electronics Engineers/National and breakdown of insulation between energized phase Electrical Manufacturers Association (IEEE/ANSI) conductors or a phase conductor and ground. If the and Underwriters Laboratories (UL) standards pre- structure and/or bus system is at end of life, replace- vail. Three-phase engineered electrical assemblies ment is the necessary and recommended option. are the focus of this paper, specifically 600-VAC low- Before implementation of a replacement plan, care- voltage (LV) motor control centers (MCCs) manu- ful project planning is necessary to ensure the project factured and tested to UL 845 “Standard for Motor is successful. Consideration of the required time to Control Centers.”1 Typically, these assemblies include completely replace existing equipment will impact a steel supporting structure with individual compart- production. Access to remove the existing assemblies ments that contain a protective device such as an and bring in the new equipment must be considered. air-magnetic circuit breaker and a contactor (vacuum One often overlooked issue involved is the cable or air-magnetic). Each circuit breaker and contactor terminations to existing loads. New assemblies are typically includes a protective relay to assure either unlikely to match in location for existing line and load cables or connected motor loads are protected in the cable terminations. This may require that the project event of an overload or system short-circuit condi- scope include pulling all new cables, which improves tion. These assemblies also include main copper bus overall reliability but adds cost in materials, labor and bars used as current-carrying conductors, connecting lost production. If existing outgoing cables to the LV the incoming power source to the multiple devices MCC motor loads are run in individual conduits, the that serve and protect individual electrical loads. conduit condition and the required number of cable Although the structure and bus components of both bends should be reviewed. If motor cables are routed medium-voltage and low-voltage distribution and con- through an open cable tray, removing existing cables trol assemblies are similar, considerations involving and installing new may present added challenges their end-of-life replacement are somewhat different. dependent on the cable routing. Even if existing con- This paper will address replacement versus upgrade ductors can be reused, there is risk in disrupting exist- considerations related only to LV MCCs. ing terminations that were first made 30–40 years ago. One other industry standard relevant to this review Oftentimes, especially for larger conductors, aged is IEEE Standard C37.20.7 “Guide for Testing Metal- insulation systems can crack and become compro- Enclosed Switchgear Rated up to 38 kV for Internal mised during a replacement project. This would then Arcing Faults.” Low-voltage motor control centers require new cable to be pulled and terminated, add- are optionally available as arc-tested to this standard, ing significant labor and materials cost in replacing which was recently updated in 2017. The arc testing the original cables. requirements are individually defined in multiple annex documents in the standard, each applying to a unique type of assembly. For LV MCCs, arc test Review of Standards Prior to LV Motor Control procedures as outlined in Annex H of IEEE Std. Center Replacement C37.20.7-2017 are applicable. Other than this “add-on” arc-resistant test requiring a more robust assembly As mentioned previously, the manufacturing and test AUG with heavier-gauge steel, bolts and latches, traditional standard for LV MCCs applied in North American 2020

1 steel enclosures for LV MCCs manufactured today are markets is UL 845. Although the authors are not sug- I very similar to designs from 40 years ago. The main gesting that industry users study the details regarding IRON & STEEL TECHNOLOGY bus bar for these assemblies also has not appreciably this standard, being familiar with UL 845 is useful changed. Typically, the bus system includes flat cop- in better understanding the scope and available per bar conductors for each of three electrical phases, ratings for this class of engineered electrical assem- with multiple bars per phase being required to sup- bly. One recently developed standard recommended port higher bus ampacity ratings. by the authors is IEEE 1683-2014.2 The document,

titled “IEEE Guide for Motor Control Centers Rated AIST.ORG up to and Including 600 VAC or 1,000 VDC With Recommendations Intended to Help Reduce Electrical 76 AUG 2020 I IRON & STEEL TECHNOLOGY I AIST.ORG 1950s and 1980s have lower withstand, bus bracing bracing bus have lower 1980s and 1950s withstand, IEEE 1683 does not define specific construction and and construction specific 1683 not does define IEEE of group byaworking created recently was Hazards” 2018 “Standard for Electrical Safety in the Workplace,” the in Safety for Electrical 2018 “Standard 35,000 to 50,000 symmetrical amperes. Conversely, amperes. symmetrical 50,000 to 35,000 Over the course of the last several years, many existing existing many years, several last of the course the Over Technical Article working conditions for conditions employeesworking byarenewed focus the IEEE 1683, as well as References 3 and 4, which References which 4, 3and well as 1683, as IEEE the the rather features, or specific requirements test tem. This includes completion of a short circuit, coor includes completion of a short circuit, This tem. accurate an update years, five completeto every and, hazards flash arc electrical and shock hazards trical today’s designs typically have ratings at 100,000 sym at 100,000 have ratings typically today’s designs from rated bracing bus include mechanical typically the originally installed assembly is properly rated. properly rated. is assembly installed originally the has emerged. This standard requires existing facilities facilities existing requires standard emerged. This has have been well maintained over the years, upgrading upgrading over years, the well maintained have been benefits and limitations of certain LV MCC features, LV features, MCC of certain limitations and benefits being warning labels affixed to each of the “openable” of the each to affixed labels warning being been one of the more prevalent examples of existing of existing more one examples been prevalent of the Life Cycle Extension Considerations Considerations Extension Cycle Life in selecting a LV MCC based on recent industry on aLV recent industry selecting based in MCC and site power system the considering installation, improved standards for safety, including NFPA 70E- NFPA for including safety, improved standards priate personal protective equipment protective (PPE) required personal priate If the steel structure and bus bus and Overdutied steel structure Assemblies the — If rent modeling of existing industrial facilities might, might, facilities industrial rent of existing modeling offer valuable detail regarding choices outcomes and regarding detail valuable offer common considerations around guidance offering the explains also guide The criterion. safety electrical UL Unlike not astandard. guide, ment IEEE an is docu this Note that manufacturers. and consultants industries, multiple manufacturing from engineers electrical panels that identifies the shock hazard, arc arc shock hazard, the identifies that panels electrical sys power distribution electrical plant model of the by part in Driven workplace safety. on electrical overdutied electrical assemblies. electrical overdutied LV have plants. MCCs equipment existing in electrical existing LV MCC assemblies can often be a viable aviable be often can LV assemblies MCC existing metrical amperes. System studies resulting from cur from resulting studies System amperes. metrical have improved industry in facilities manufacturing for particular features. The authors suggest review of review suggest authors The features. for particular gized. One unintended consequence of these system system consequence One unintended of these gized. ener while panel the on or near working for persons appro and boundaries distance working hazard, flash for instance, result in a system available fault current current fault available asystem in result for instance, document addresses considerations around LV around considerations MCC document addresses dination and arc flash study, with the end the deliverable study, with flash arc and dination applications. an enhanced awareness and recognition of both elec of both recognition and awareness enhanced an and interrupting ratings. Vintage MCCs from this era era this from MCCs Vintage ratings. interrupting and alternative. That said, the user will still need to ensure ensure need to still will user the said, That alternative. studies has been a realization of some overdutied arealization been has studies Many of the vintage LV MCCs installed between the the between LV installed MCCs vintage of the Many

845, 845, ------489. Although it will likely be difficult if not impossible to to not impossible if difficult be likely it will Although when the service organization is from the same sup same the from is organization service when the the three-phase stab assembly. The stabs consist of consist stabs assembly. The stab three-phase the the originally installed equipment will be supported supported be equipment will installed originally the versus designs bracing bus or updated of current tion track record of experience to perform these services. services. these perform record to of experience track For user, the ratings. higher interrupting support to there was not an error in selecting the MCCs to be be to MCCs the selecting in not error an was there unit from the upper left of the image include a circuit include a circuit image upper of the left the from unit best practices in maintaining these components. The these maintaining in practices best by factory testing using bus support insulators as sup as insulators support bus using testing by factory breaker, in most cases a magnetic only molded case molded only case amagnetic breaker, cases most in is beyond the scope of this paper and the authors authors the and paper of this scope beyond the is power stab connections, while large units tend to be tend be to units large while connections, power stab ponent in any MCC assembly is the multiple starter multiple starter the is assembly ponent MCC any in component individual system, existing the with ity product. design current the in plied supplied equipment, documenta original the plier as some cases, In calculations. on engineering based ing pass original factory tests, in most cases a software asoftware cases most in tests, factory original pass a solid with select firm to areputable it important is provide safe and reliable operation. Some field service service field Some operation. reliable and safe provide bracing bus ity, assembly the it’s increase to possible equip electrical sized adequately once what in was ing installed. Instead, over the course of several decades, decades, of several over course the Instead, installed. 35,000 amaximum with 1960s the in product installed next component rotating clockwise from Fig. from 1is next clockwise component rotating of References 7regarding recommend 6and review no longer available. However,no longer available. still replacement units ratings must then also be investigated. Beyond the Beyond the investigated. be also must then ratings rating. Of course, when the facility was originally built, built, originally was facility when the course, Of rating. of molded-case circuit breakers is important, the topic the important, is breakers circuit of molded-case can be supplied in support of this vintage assembly. As assembly. As vintage of this support supplied in be can is that assembly MCC avintage from unit of astarter compatibil and conformance ensure to modified structure the —After Units Breaker Circuit and Starter enclosure and bus bar system, the other major com major other the system, bar bus and enclosure rat ahigher interrupting validates that model exists capability of modifying existing bus bracing in order in bracing bus existing of modifying capability aservice typically are that organizations engineering ment to now be underrated, or overdutied. ment now to underrated, be result changed, power sources system and loads mill of a installation MCC at avintage amperes of 46,300 few replaceable parts. Although routine maintenance maintenance routine Although few replaceable parts. fixed-mounted. Fig. component 1 shows the elementsfixed-mounted. drawable, connected at the structure vertical bus via via bus vertical structure at the connected drawable, with typically are units Smaller loads. downstream document that the modified assembly will successfully successfully will assembly modified the document that design, manufactured and tested to UL Standard Standard UL to tested and manufactured design, and feeder circuit breaker units that serve various various serve that units breaker feederand circuit possibly and inspected thoroughly have been bus and and interrupting rating so the MCC can continue to can MCC the so rating interrupting and arm of an LV MCC manufacturing company offer the company the offer LV of an manufacturing MCC arm shown in Fig. 1, individual components in the starter starter components the in Fig. in 1,shown individual In extending the life of existing LV MCCs in afacil LV in MCCs of existing life the extending In 5 These devices are typically factory sealed with with sealed factory typically are devices These ------77 spring-loaded copper conductors that connect the element that includes a melting alloy that again, upon starter unit incoming power to the MCC vertical bus melting, actuates a mechanical movement which in bars. Stab assemblies are unique to the original MCC turn de-energizes the contactor. Both deploy three manufacturer and it is critical that this component heater coils in each of the three-phase current paths be ordered as original equipment. Following this which are sized based on motor full-load amperes. is the motor starter, consisting of a magnetically In an overcurrent condition, the heater coil deflects operated contactor and a motor overload protective the bi-metal or melts the solder alloy, resulting in a relay. Most vintage motor overload relays employ one mechanical movement that in turn de-energizes the of two antiquated means to protect the AC motor contactor. Other devices in the image include an based on overcurrent resulting in excess heat of a internal control power transformer and pilot devices resistive element in the phase current path. One of mounted on the starter unit door. The center image these is a bi-metal element; two dissimilar metals shows the complete unit assembly, which also includes that deflect to engage a trip bar to open a contact to unit control and power wiring, control terminals, a de-energize the contactor. The other is a solder-pot handle mechanism to open and close the molded- case circuit breaker, and painted steel “wrapper” used as a means to bolt the unit components together into the common subassembly. Figure 1 Upgrade LV MCCs With New Starter and Feeder Breaker Units

Assuming the enclosure and bus system of a vintage low-voltage MCC is in good condition, the most frequently installed and viable method of life cycle extension is replacement of the existing starter and feeder circuit breaker units with new ones. Fig. 3 shows an image of a vintage starter unit from a now obsolete motor control center built in the 1960s next to a new replacement starter unit. Note that the replacement starter unit is a form-fit-function direct replacement for the vintage unit and that the old components have been replaced with new. In some cases, the replacement starter units can include additional components to enhance functionality of the vintage assembly; in this case, a unit-mounted control power transformer and door-mounted hand-off auto selector switch and Components of a low-voltage motor control center starter unit. motor run light addition.

UL 845 vs. a Counterfeit Copy — The UL 845 standard mentioned Figure 2 previously applies to not just newly manufactured motor control centers, but also to replacement starter and feeder circuit breaker units. Just as new units are test- AUG

ed in new control center assem- 2020

blies, replacement units must also I

be tested to meet UL 845 test IRON & STEEL TECHNOLOGY requirements. Electrical testing defined in the standard including heat rise and short circuit tests must be completed while the unit is installed in the MCC

(a) (b) assembly. In the case of an obso- AIST.ORG lete motor control center, new Vintage design (a) versus current design (b) LV MCC molded-case circuit breaker. replacement units must be tested 78 AUG 2020 I IRON & STEEL TECHNOLOGY I AIST.ORG The UL 508 standard does not does motor apply to control standard 508 UL The Installation of replacement units that have not been that of replacement units Installation MCC upgrade using circuit break circuit using upgrade MCC years, a growing trend has emerged where unauthor has trend agrowing years, Technical Article tion and movement and tion circuit of the to investigate the viability of an of an viability the investigate to to the unit, designating full compliance. Over the the compliance. Over full designating unit, the to included for requirements test as same the tially unit door-mounted handle mech handle door-mounted unit breaker handle must be compat must be handle breaker discussed, previously As itself. unit but also the size and form factor factor form and size the but also be considered. Like the power the considered. Like be lower have typically breakers components starter the the included in but also bus, Replacing the Circuit Breaker vs. a Complete Starter Starter aComplete vs. Breaker Circuit the Replacing ible with the door-mounted mech door-mounted the ible with ings. Not just the breaker rating rating breaker Not the just ings. legacy devices, in some cases, the the some cases, in devices, legacy upgrade and ratings interrupting in a vintage assembly originally produced by the produced bythe originally assembly avintage in in assembling control panels typically offer UL 508 508 UL offer typically control panels assembling in replacement have misrepresented manufacturers ized injury or death of personnel. or death injury afault, during failure catastrophic cause ponents can com some used with assembled or are properly tested included. are reports test certified and visible clearly is new molded-case circuit break circuit new molded-case Returning to the topic of the MCC inter MCC topic of the the to —Returning Unit rupting rating, oftentimes a vintage motor control avintage oftentimes rating, rupting new MCC assemblies. Only after all the tests are are tests the all after Only assemblies. new MCC resulting in equipment damage, loss of production, of production, loss equipment in damage, resulting should take Users 845. byUL defined as testing rise ers with higher ratings than the the than higher ratings with ers loca the so breaker circuit on the must be considered. The starter starter considered. The must be rat interrupting higher with ers organization services electrical or aqualified ment manufacturer equip original the with consult of this component also needs to component to needs of this also circuit molded-case vintage most copper vertical and horizontal main of not the only proper bracing ensure to need attention center will ment unit, the battery of testing performed is essen is performed of testing battery ment the unit, replace 845 UL Forequipment atrue manufacturer. centers and does not include short circuit and heat and notcenters does and include short circuit control panels. specialty to affixed labels 508A or UL fully factory tested to UL 845. Shops that specialize specialize Shops that 845. UL to tested factory fully from a reputable supplier, ensuring the UL 845 label label 845 UL the supplier, areputable from ensuring units MCC purchasing and specifying in caution great anism. Regarding installation of installation Regarding anism. anism will typically be mounted be typically will anism stab assembly, it is important to to assembly, it important is stab starter units to be installed in vintage MCCs as being being as MCCs vintage in installed be to units starter affixed be label 845 completed aUL can successfully ------Vintage design (a) vs. current design (b) LV MCC molded-case circuit breaker. circuit LV molded-case MCC (b) design current vs. (a) design Vintage Figure 3 - - - - - (a)

The UL 845 test defines this combination rating. As As rating. combination this defines test 845 UL The will be available in higher current and interrupting interrupting and higher current in available be will that the new offering includes features such as finger- such as includes features new offering the that transformers with sophisticated electronics to sense sense to electronics sophisticated with transformers mag New fault. the clear successfully and actuate to cur fault limit to path impedance an offering tection, for heater coils motor overload used pro traditionally the circuit breaker and the motor the starter/protective and breaker circuit the ahigher- clear not may breaker successfully circuit the heater coils, vintage the from resistance additional the breaker and the motor starter functioning together. functioning motor the starter and breaker not old is of the recommended. place The in breaker issue here is that the interrupting rating of the sub of the rating interrupting the here that is issue previously mentioned, vintage magnetic starters have starters magnetic mentioned, vintage previously protect the motor and driven load. In the absence of absence the In load. motor driven protect the and level fault. As defined in the UL 845 standard, both both standard, 845 UL the in defined As level fault. ratings. Fig. 3 shows a current design molded-case cir molded-case Fig. design 3shows acurrent ratings. rupting rating. Although the form factor and breaker- and factor form the Although rating. rupting netic starters nearly universally apply onboard current current apply onboard universally nearly netic starters limitation This conditions. short-circuit during rents relay are interdependent together.relay are tested must be and original equipment manufacturer’s current offering offering equipment current manufacturer’s original cuit breaker versus one from nearly 50 years ago. Note years 50 one nearly from versus breaker cuit circuit breaker are identical, simply installing the new the installing simply identical, are breaker circuit new and for vintage the location handle operating motor overload and a host of other abnormalities to to motor overload ahost of abnormalities other and gives the circuit breaker magnetic trip element trip time magnetic breaker circuit the gives as standard with a 65,000-symmetrical-ampere inter a65,000-symmetrical-ampere with standard as assembly is based on the combination of the circuit circuit of the combination on the based is assembly safe terminals and a push-to-trip test button, available button, available test apush-to-trip and terminals safe (b) ------79

Technology Advancements in Motor Protection — Over One important added capability of the onboard the past several decades, advances in electronics have microprocessor of the base control module is the accelerated the functionality of overcurrent circuit- ability to locate a grounded motor feeder in a high- protective devices and compact adjustable frequency resistance pulsing ground system.9 Since the measure- drives (AFDs) are now routinely installed in low- ment module of each relay includes three integral voltage motor control centers. Current design motor current sensors, special functionality of the new relay overload relays have evolved to function as intelligent has been added to recognize when the high-resistance motor-protective devices that continuously monitor grounding (HRG) pulser has been activated and then positive and negative sequence motor phase currents report not only which motor feeder but also which to establish a precise thermal model of the machine’s phase of the faulted feeder has a ground fault. This windings. These deliver an order of magnitude of new functionality greatly reduces added complexity improved motor protection and functionality. Recent in current design HRG systems that employ additional papers including Reference 8 discuss case histories zero-sequence current transformers (ZSCT) wired involving low-voltage motor control center instal- back to a HRG relay at each individual motor starter lations where new motor management relays with unit in the LV MCC as discussed in References 10 enhanced functionality have been installed. The and 11. latest offerings include advanced protective features Application of the latest designs of these motor in a small, network-communications-ready package. management relays deliver a step-change in motor Referring to Fig. 4 as a typical current design device, protection versus legacy controls installed in vintage a measurement module includes integral current equipment. More importantly, the availability of real- transformers, allowing three-phase power conductors time data measuring phase currents and voltages for to connect between the switching contactor and three- every driven load offers a new platform of functional- phase motor terminals. Voltage terminations are also ity that will be transformative for industry. Without made at the base module that support functional- question, the added capability of network connectivity ity beyond legacy motor-protective relays including can serve as an enabler to ensure any existing indus- undervoltage, underload and pump cavitation, along trial plant, even a plant with 40- to 50-year-old legacy with metering of phase voltages, amperes and power electrical systems, can be positioned to compete with in watts and vars. A base control module communi- new plants utilizing the latest technologies. Industry cates new available data via a host of communication users can utilize network-enabled systems to deliver networks, the most prominent in industry today being an abundance of available data and extract useful Ethernet/IP. An optional user interface module is information to improve system reliability, uptime, also used for local control and monitoring as desired. efficiency and safety. Today’s fourth industrial revolu- tion is characterized by a transition from the manual, sequential value chain in manufacturing to an information-rich digital core enabled by new developments Figure 4 in smart sensors, cloud computing and the Industrial Internet of Things (IIoT). A number of existing industrial plants, including some from the authors’ company, have recently completed successful life cycle extension projects including upgrades of LV MCCs and other electrical power distribution and control assemblies. These have clearly leveraged the latest in network-enabled systems, offering a platform in support of the coming new era of digital transformation. Table 1 offers suggested decision criteria in reviewing the available options to replace or upgrade exist- AUG

ing low-voltage MCCs as discussed in this section. 2020

IRON & STEEL TECHNOLOGY Conclusions

Existing steel mills in the process industries need to consistently focus on maintenance of aging assets to ensure electrical systems continue to operate both

safely and reliably. There are many existing facilities AIST.ORG first commissioned 40 to 50 years ago where existing Typical microprocessor-based motor management relay. systems are approaching end of life. The need for 80 AUG 2020 I IRON & STEEL TECHNOLOGY I AIST.ORG The user should consider original equipment ratings equipment ratings should consider user original The Looking forward, plants will need to leverage network leverage need to will plants forward, Looking sys bus and structure with MCCs low-voltage Existing Technical Article to ensure sufficient interrupting capacity for appli the capacity interrupting sufficient ensure to replacement. versus for upgrade opportunities tial represent poten well maintained have been that tems trol center.trol developments there technology, With in toward their digitalization transformation future. transformation digitalization their toward followed by alternatives upgrade versus replace the by 21st-century technologies. The path forward in in forward path The technologies. by 21st-century ing technology to the existing model. Instead, true true model. Instead, existing the to technology ing systems which analyze to effort afocused requires ity program to upgrade existing systems is often a valid avalid often is systems existing upgrade to program motor con existing of an upgrade project involving installation of network-enabled systems can position position can systems of network-enabled installation newly realized wealth of readily accessible digital data, data, digital accessible of readily wealth realized newly of existing systems, which is both cost prohibitive cost prohibitive both is which systems, of existing changeout awholesale not require will cases many supported anew platform to this model applying and business current the of rethinking task more difficult add just involve more than will This operations. improve to necessary information right the extracting of a advantage take to ways find and connectivity project. upgrade of any apart as assemblies of existing 845 UL of the understanding aworking Also, cation. upgraded. be can which versus replaced must be productiv continuous improvements operational in ers and contractors to build a business case to review review to case abusiness build to contractors and ers digital transformation will likely involve the much involve the likely will transformation digital approach. Early alignment with key equipment suppli with alignment approach. Early planned acarefully Instead, impractical. simply and functionality the enhance to opportunities many are any existing manufacturing business to move forward move to forward business manufacturing existing any standard is recommended execution of any to is prior standard New LV MCCstarterunits Refurbish existingLV MCCstarterunits Upgrade existingassemblyrating Replace existingassembly Alternative Upgrade vs. Replace for Criteria Decision Table 1 nta otIsalto otCosttomaintain Installationcost Initial cost Moderate Moderate High Low Moderate Moderate ------High Low 1. 11. 10. 7. 4. References 9. 2. 5. 3. 8. 6.

1683 —AnIntroductionandBehindtheScenesLook,” Testing, andLifeExpectancyofMoldedCaseCircuit Breakersfor Durocher Higginson, M.,andDurocher IEEE Standard Beltz, R.D.; UL 845,“MotorControlCenters,”Under ANSI/UL489 Molded-CaseCir Sauve, T Locker Bapat, A.;Hanna,R.;andPanetta,S.,“AdvancedConceptsinHigh- IEEE 1683-2014,“IEEEGuideforMotorControlCentersRatedup V Applications, Applications, Industry Technical Conference, Technical Industry IEEE IAS Petroleum and Chemical Industry Technical Conference, Conference, Technical Industry Chemical and Petroleum IAS IEEE Industrial Applications,IEEEIAS2005. Intended toHelpReduceElectricalHazards.” of Next-GenerationMotorManagementRelaystoImproveSystem Reliability inProcessIndustries,” Operation,” 2009, pp. 2017, pp.387–396. Petroleum and Chemical Industry Technical Conference, Technical Industry Chemical and Petroleum Retrofits in Pulp and Paper Mills,” Resistance Grounding,” Conference, Conference, Create Safer andSmarter HRG Systems,” Northbrook, Ill.,USA. Maintenance ofMoldedCaseBreakerstoAssureSafeandReliable Magazine, Magazine, and Circuit-Breaker Enclosures,2016. and SpecifyingMCCstoReduceHazardsRisks,UsingIEEE1683,” to andIncluding600V aldes, M.E.;Bugaris,R.M.;andWellman, C.M.,“TheMakingofIEEE Conference Proceedings. Conference andExposition,Pittsburgh,Pa.,USA,publishedinthe This paperwaspresentedatAISTech 2019—TheIron&SteelTechnology , A.S.,andScarborough,M.S.,“AdvancementsinTechnology .R.; Anderson,R.P.; Bower, T.; andMickler, K.R.,“Designing Moderate , D.B.; Hussey, M.R.; Belzner, D.;and Rizzi, L.,“Application

102–113. 2001, Vol. 7,No.2,pp.19–27. High Low Low Peacock, I.; andVilcheck, W., “High-Resistance Ground IEEE IAS Pulp and Paper Industry Technical Conference, Technical Industry Paper and Pulp IAS IEEE 2012, pp.1–9. March/April 2019. 1458 Recommended Practice for the Selection, Field IEEE IAS Petroleum and Chemical Industry Industry Chemical and Petroleum IAS IEEE AC or1000VDCWithRecommendations maintainability cuit Breakers,Molded-CaseSwitches, Maximized Maximized Reliability/ 2009,pp.102–113. Minimal Minimal , D.B.,“ProperApplicationand IEEE Transactions on Industry Industry on Transactions IEEE IEEE Industry Applications Applications Industry IEEE IEEE IAS Pulp and Paper Paper and Pulp IAS IEEE writers Laboratories,

downtime Very high Required Lowest 2015 IEEE IAS IAS IEEE 2015 High High pp.1–8. F

82 Technical Article

New Advancements in Condition Monitoring Technology to Enhance Steel Mill Productivity and Profitability

Steel mill operators have long used condition monitoring to deliver critical, real-time equipment performance insights that can help reduce unscheduled downtime and maximize productivity. However, as condition monitoring programs continue to incorporate newer technologies, operators can gain even deeper insights that further improve equipment operation and maintenance decisions. Leveraging field and laboratory data, this paper will delve into some of these new technologies, including in-line oil sensors, and discuss how they can be integrated into a modern predictive maintenance program to deliver productivity and cost reduction benefits to Authors steel mill operations.

Toby Hlade (left) grease technical advisor – Americas, teel mill applications place For example, steel mill systems Mobil Industrial Lubricants, Spring, Texas, USA Senormous stress on equipment operate under high and variable [email protected] components, including heavy loads, speed and load, with hundreds of Timothy Hurley (right) extreme high temperatures and bearings, gears, shafts and addi- head of plant engineering, near-continuous water exposure. tional components. In these com- Primetals Technologies Ltd., To ensure proper protection and plex systems, how can operators Worcester, Mass., USA [email protected] minimize the potential for unsched- detect developing defects at an early uled downtime, operators need a stage and measure defect severity? finely tuned lubrication strategy. Furthermore, how can operators Specifically, operators should lever- better match maintenance activi- age newer condition monitoring ties with the real conditions of the technology that provides equipment equipment, moving more toward a behavior trends to better withstand predictive maintenance approach extreme conditions and maximize rather than a reactive one? equipment productivity. Leveraging To complicate matters further, laboratory and field data, this paper many steel mill maintenance teams closely examines the latest advance- face limited resources and budget, ments in condition monitoring tech- so how can all maintenance be nology and highlights how opera- planned maintenance, and how can tors can take advantage of insights those teams eliminate surprises to delivered by these platforms to maximize resources? make better-informed decisions and And, perhaps most important to enhance equipment performance in the overall success of the steel mill, these high-stress environments. how can operators extend machinery life or increase throughput without risk of machine failure to stay Discussion competitive even when using older or high-duty equipment? The Evolution of Condition Monitoring One of the most effective solutions AIST.ORG

I Technologies — The steel industry to tackle these important issues is

is one where equipment operates implementing a robust condition- under severe stress, extreme tem- based monitoring program that peratures and heavy load condi- takes advantage of the latest tech- tions on a regular basis, posing a nologies. Based on an analysis con- range of equipment maintenance ducted by Primetals Technologies,

IRON & STEEL TECHNOLOGY challenges that — if not properly the most effective maintenance

I addressed — can limit productivity programs spend 80% of the over- 2020

and profitability. all budget on predictive and pre-

AUG ventive maintenance programs 83

(which includes the use of condition-based monitor- Condition monitoring as a practice is not new. In ing technologies). Unfortunately, however, the same fact, many condition-based monitoring tools have analysis found that most steel facilities spend 80% been around for decades. However, advancements in of their resources on reactive maintenance activities these tools are providing operators with new opportu- — meaning many operators are not taking the right nities to monitor equipment performance in real time steps to maximize their productivity. and address equipment performance issues before The benefits of predictive and preventive mainte- they become a problem. nance programs are proven. For example, an iron and steel company in China was experiencing abnormal The Power of Real-Time Condition-Based Monitoring — In wear in the gearboxes of its 16 sets of conveyers, and today’s production environment, even the shortest they frequently conducted oil changes on a reactive amount of downtime can result in millions of dollars basis to address the issue. However, after accepting a of costs, so being able to act and address an issue recommendation to conduct routine used oil analysis, before it becomes a problem is vital. technical experts discovered that the lubricant in the For example, consider Fig. 1, which shows how conveyers was unable to withstand the harsh operat- real-time insights from vibration analysis can provide ing conditions. The plant then switched to a synthetic operators with advance warning of bearing failure lubricant formulated to provide high-temperature (more to come on vibration analysis later on). oxidation stability, which helped reduce average oper- As seen in this chart, a condition-based monitor- ating temperature by 7.6°C, in turn reducing the ing tool such as vibration analysis can detect issues wear abnormalities. Making the switch also helped before they become visible and provide operators with the company extend oil drain intervals and improve an understanding of what action they should take to energy efficiency. Together, these insights helped the resolve the potential performance issue. Replacement company save US$1,830 annually. components such as bearings are very expensive,

Figure 1 AUG

2020

IRON & STEEL TECHNOLOGY

The four stages of bearing failure, ranging from subsurface-level pain points to severe damages noticeable to the human eye. AIST.ORG The chart also indicates how vibration readings can help pinpoint which stage of failure the bearing is currently experiencing. 84 AUG 2020 I IRON & STEEL TECHNOLOGY I AIST.ORG Vibration analysis is one most is of the analysis Vibration Sensors: Vibration not provide enough real-time insights to help operators address equipment performance issues well before they result in failure. failure. in result they before well issues performance equipment address operators help to do insights insightful, real-time somewhat enough while provide not tactics, monitoring basic Many program. maintenance apredictive implementing of benefits cost The Technical Article tion, including vibration, temperature, amperage and and amperage temperature, vibration, including tion, condi and equipment to related performance tics their insights, when analyzed holistically, can help can holistically, when analyzed insights, their machine. for entire the time based monitoring tools available today and how and today available tools monitoring based program, preventive of maintenance arobust benefit pling misalignment and looseness, mechanical loose mechanical looseness, and misalignment pling cou degradation, roller bearing early such as issues help It detect can operation. an across ion stands pin and gearboxes of motors, performance into the any in tools monitoring condition-based important pressure. program. program. lubrication, worn seals, and electrical problems. electrical and seals, worn lubrication, ness, gear wear, improper or gear broken worn teeth, ness, gear characteris critical measure that available nologies referencing several commonly used technologies. technologies. used commonly referencing several Condition-Based Monitoring Technologies for Assessing There are various sensor tech sensor various are —There Condition Equipment operators build a best-in-class predictive maintenance maintenance predictive abest-in-class build operators especially when one considers the associated down when associated one the considers especially steel mill operator’s arsenal. It can provide insight insight provide It can operator’s arsenal. steel mill Figure 2 This paper will now explore the various condition- now various explore the will paper This point cost home, the To Fig. this 2outlines drive ------Consider the following example. following the Consider which can provide amuch provide more complete can which perspective. this way may not give operators a full picture of what of what picture afull operators not may give way this ture program detected a 350% increase in amplitude, amplitude, in increase a350% detected program ture not did send program other the so limit, trigger the below continued remain to readings RMS time, this by-side comparison of a RMS-driven sensor analysis analysis sensor of aRMS-driven comparison by-side possible issue with a bearing because of defect fre because abearing with issue possible a detected program analysis signature full the point, one At program. analysis signature afull and program equipment. their inside happening is indicating imminent failure. The operator scheduled scheduled operator The failure. imminent indicating later, the full signature analysis program flagged flagged program analysis signature later, full the root mean square (RMS) amplitude. Though this this Though amplitude. (RMS) square root mean replacement bearing. The customer continued to customer The replacement bearing. method is an ISO convention, measuring vibration in in vibration convention, ISO an measuring is method out any alerts. Only one month later, the full signa one month later, Only full the out alerts. any At bearing. degrading on the issue more significant continuously. Eight months monitor bearing the quency harmonics. The RMS program did not flag not did flag program RMS The quency harmonics. ated equal. Today, many sensor technologies measure Today, measure equal. ated technologies sensor many an increase in bearing frequency noise, indicating a noise, indicating frequency bearing in increase an nonetheless customer but ordered the a alerts, any analysis, signature deliver afull can that available Instead, there are vibration sensor technologies technologies sensor vibration are there Instead, But, not all vibration sensor technologies are cre are technologies sensor vibration notBut, all One steel manufacturer was conducting aside- conducting was One steel manufacturer - - - 85

Figure 3

Comparison of the results of the full signature analysis program with the root mean square (RMS) analysis program. The full signature analysis program delivered alerts well before the RMS program flagged a potential problem.

a bearing change during a planned outage the fol- program saved the company six to eight weeks of lowing month. The RMS reading finally triggered an unscheduled downtime. alert, but the alert would have been far too late. The This is just one example illustrating the power of operator estimated that the full signature analysis newer vibration sensor technologies and their potential. For easy reference, Fig. 4 and Table 1 outline the

Figure 4 Table 1 Equipment Issues That Can Be Detected by Full Signature Vibration Analysis Full RMS Shock Human Failure mode signature trending pulse being Imbalance ✓ ✓ ✗ ✗ Coupling misalignment ✓ ✗ ✗ ✗ Overall looseness ✓ ✓ ✗ ± AUG Early bearing defects ✓ ✗ ✓ ✗

2020 Gear defects (wear/broken teeth) ✓ ± ± ✗

Improper lubrication ✓ ✗ ✗ ± IRON & STEEL TECHNOLOGY Electrical-related faults ✓ ✗ ✗ ✗ Belt problem ✓ ✗ ✗ ✗ Vane/blade pass ✓ ✗ ✗ ✗ ✓ ✓ ✗ ✗ The capabilities of signature vibration analysis compared to Caviation/recirculation of pumps

other traditional vibration monitoring methods. Resonance ✓ ✗ ✗ ✗ AIST.ORG Sleeve bearings ✓ ✗ ✗ ✗ 86 AUG 2020 I IRON & STEEL TECHNOLOGY I AIST.ORG (filtration and water removal) and temperature (cool temperature and removal) water and (filtration Operating temperature is often often is temperature Operating Sensors: Temperature vide a more complete picture of system performance. amore complete of system vide picture other to compared analysis signature of full value ± Technical Article wrong. Today’s temperature sensors can even alert even alert wrong. Today’s can sensors temperature tor of overall system health on motor-driven equip on motor-driven health system tor of overall this data with other lubrication-relevant data can pro can data other lubrication-relevant with data this Combining importance. of critical systems smaller to added be but can systems drive large for very tracked equipment impacts and health lubrication then tion, increase abnormal it An should. as performing is tem place. in technologies analysis vibration latest the program: program: control). ing/heat program should be able to regularly monitor key able regularly should to be program A good technologies. sensor latest the incorporates perature trends are helpful when confirming the the when helpful confirming are trends perature in a steel mill environment. When mill fluid systems systems fluid mill When environment. asteel mill in but capabilities, analysis vibration with pre-equipped in temperature is typically a sign that something is is something that asign typically is temperature in lifeblood of any industrial machine, particularly for particularly machine, industrial of any lifeblood nent requirements vs. pumping capacity), cleanliness cleanliness capacity), pumping nent vs. requirements related data such as vibration and oil analysis, tem analysis, oil and vibration such as data related Motor amperage is a good indica agood is Motor amperage Amperage: Motor Lubricant is another another is — Lubricant Condition Fluid Monitoring characteristics, including lubricant quantity (compo quantity lubricant including characteristics, that program monitoring lubricant condition-based enhance yield, and help improvecan product quality within changes temperature when lubricant operators component health within these systems. If baselines baselines If systems. these component within health lubricated and performance lubrication in changes with occur but also loading, machine in changes with expected are draw amperage in ment. Increases lubricant. condition of active equipment that operates in conditions such as those those such as conditions in equipment operates that component the monitor. to are critical Lubricants often more seen is clearly. be Motorcan amperage of whether a sys indicators oneaccurate most of the equipment manu original their consult can operators programs. common vibration facturer (OEM) partners to assess whether they have whether they assess to partners (OEM) facturer as efficiently as possible, operators should build a should build operators possible, as efficiently as they levels, performance at optimum operating are are established to subtract normal loading varia loading normal subtract to established are safety, and reduce operating costs. costs. reduce and operating safety, • 0.5°C. There are three key steps to building any good good any building to key steps three are There When connecting this data with other lubrication lubrication other with data this connecting When In order to ensure these systems are running running are systems these order ensure In to Much of today’s critical steel equipment is already steel equipment already is Much of today’s critical

A is to identify consistent fluid system issues. issues. system consistent fluid identify to is step to implementing an analysis program program analysis implementing to step an uditing a plant’s current program: The first first The aplant’s program: uditing current ------—

wear on said component. In hydraulic and lubricating lubricating and component. on hydraulic said wear In trend lines. A single alert does not necessarily indicate indicate not does necessarily alert A single lines. trend by understanding lubricant condition. lubricant understanding by specifically aminimum, to of issues types keep these basis to measure these characteristics and identify identify and characteristics these measure to basis Used oil analysis is atried- is analysis oil Used Analysis: Oil Used Routine itself: equipment lubricant the the and of both performance and/or degradation bysurface caused are mills in Condition-Based Monitoring Technologies for Fluid Analysis cant condition. cant help to anumber of strategies are There corrosion. from resulting 20% another wear, with mechanical gies that can help provide critical insights into lubri insights help critical provide can that gies and-true method to deliver regular insights into the into the insights deliver to method regular and-true systems, 50% of these replacements are the result of result the replacements are of these 50% systems, • • • • There are a range of valuable monitoring technolo monitoring of valuable arange are There Operators should conduct oil analysis on a routine on aroutine should conduct analysis oil Operators It is estimated that 70% of component 70% that replacements It estimated is

Lubricant and OEM partners can often identify identify often can partners OEM and Lubricant I D Lu E wear and help understand the metallurgy of the of the metallurgy the help and wear understand technology to help to equipment enhance technology reliabil tems on behalf the operator, piping the including on behalf tems performance. performance. ity. Most audits focus on lubrication systems and and systems on lubrication focus ity. audits Most identify and program acurrent in points pain partners may offer on-site personnel trainings trainings personnel on-site offer may partners levels of copper, which indicate the gear is out is levels gear of copper, the indicate which reports can provide insight into equipment insight provide can reports can potentially save costs due to unplanned due unplanned to costs save potentially can enough, caught early operators If of alignment. presence of high the reveal may analysis oil For components used example, tested. being cause viscosity changes that affect equipment affect that changes viscosity cause and properties its alter can this conditions, cooling lines. often install these new tools into existing sys into existing new tools these install often insights. more predictive and mill rolling of their design the or revamp helpupdate to operator the ence capability and maintain its physical properties. However, properties. as physical its maintain to formulation the requires performance cant fluid system maintenance program to deliver to program maintenance system fluid downtime and extensive repairs. extensive and downtime and can troubleshoot existing systems in place. in systems troubleshoot existing can and these addition, In supervision. flushing and experi their leverage partners lubrication and a lubricant continues to be exposed to severe severe to exposed continues be to a lubricant nstalling new technology: OEM partners can can partners OEM new technology: nstalling quipment condition — Used oil analysis quipment analysis condition oil —Used esigning a revamped analysis strategy: OEM OEM strategy: analysis arevamped esigning bricant condition — Keeping strong lubri strong condition — Keeping bricant ------87

Figure 5 a performance issue, but when a trend emerges, it’s a sign that it’s time to act. Conducting this analysis on a routine basis is also getting easier with new technology. Some used oil analysis technologies have recently incorporated “scan-and-go” functionality that utilizes QR-coded labels to more easily “tag” the sample — allowing for a paperless process. With this system, operators can enter analysis data into an online system.

Water Sensors: Steel mill applications are exposed to enormous amounts of water throughout the manufacturing and finishing processes, but water can be a dangerous contaminant. When metal components are left unprotected, water can accelerate wear, corrosion and lubricant degradation (Fig. 5). Lubricants used in steel mill applications are spe- Acid etching on a work roll bearing, which was caused by cifically designed to separate from water, but water water contamination. contamination can still occur. To help prevent this contamination, there are sensors designed to monitor water contamination in the lubricant. In-line humidity-based sensors have been available Given the severe conditions associated with steel for some time and at a reasonable cost, but these equipment, these viscosity sensors are designed to be technologies are typically limited to absorbed water unaffected by shock or flow changes. saturation and measure a few hundred parts per notation for industrial oils. This makes them best On-Line Particle Count Sensors: Water contamination is suited for dry systems that are periodically exposed to not the only contamination-related danger for steel contamination. mill equipment. Other particles, such as wear metals, Newer sensor technology has the ability to detect dust and more, can pose a serious risk to equipment and measure both emulsified and free water, which when they enter the system. Contaminants can enter is more appropriate for traditionally wet systems asso- the system through a variety of means, including from ciated with steel equipment. Today, many operators metal wear, pre-contaminated oil from changeout or use water sensors in the drain lines of every Clevite from external elements during a maintenance pro- bearing in order to alert the user when potential water cess. To properly measure this issue, operators can ingress enters the system. use on-line particle count sensors, which assess the level of contaminants in gear oils, hydraulic systems Dielectric Constant Sensors: Oxidation or contamina- and metal processing systems. There is typically a cer- tion can change oil chemistry, affecting the dielectric tain threshold for contaminants (measured in parts constant of an oil and causing it to be less effective per million), and sensors can trigger alerts when that in equipment over time. Dielectric constant sensors threshold has been exceeded. are an inexpensive condition monitoring tool for continuous monitoring, as they’ll indicate when the Fourier Transform Infrared Spectrophotometry (FTIR): oil chemistry has changed, but, even though they do One of the most commonly used tools in an oil analy- trigger an early warning, they are limited in that they sis lab, FTIR measures the absorption of infrared cannot pinpoint specific issues or accurately diagnose light at various wavelengths to create a chemical fin- equipment failure. gerprint of the oil. This can detect signs of lubricant AUG

contamination and degradation. In used oil analysis, 2020

In-Line Viscosity Sensors: Viscosity is one of the most it is commonly used to detect water, oxidation, nitra- I

important characteristics of an oil. An oil needs to tion and other contamination. IRON & STEEL TECHNOLOGY be able to maintain a certain viscosity in order to While this tool has historically been restricted to minimize metal-to-metal contact and keep the system the lab due to sensitivity and cost, technology is evolv- running as needed. Extreme conditions can degrade ing to become more simplified. Some units are now the oil, which can in some cases change its viscosity. on the market that bring this technology to in-plant That’s why viscosity sensors are a critical tool that pro- or even in-line capability.

vide data that measures viscosity in real time. Any sig- AIST.ORG nificant change indicates that there is a performance issue that needs to be addressed. 88 AUG 2020 I IRON & STEEL TECHNOLOGY I AIST.ORG Lubricant leakage is a difficult — and unfortunately unfortunately — and a difficult is leakage Lubricant

Technical Article that can help identify leakage and its source: source: its and leakage help identify can that Integrating Data Insights to Build a Complete Equipment Equipment aComplete Build to Insights Data Integrating This paper has outlined a range arange outlined has paper —This Profile Performance installing a sensor and using it in isolation provides provides it isolation in using and asensor installing lenge is a meter that measures leakage rates in lube in rates leakage measures lenge ameter is that result of the intense operating conditions. Leakage Leakage conditions. operating intense of the result Monitoring Technologies to Help Prevent Leakage — Leakage Prevent Help to Technologies Monitoring marginal value. value. marginal simply But, profitability. and productivity enhance can that technologies monitoring of condition-based problem. of apotential get ahead operators help can technologies monitoring using ment failure, cause equipment due improper to lubrication. wear cause more to is likely and consumption higher oil causes a as prone is leakage to equipment, particular, in Older operators. mill forcommon many —challenge give steel mill operators valuable insights to help to insights valuable operators steel mill give storage tanks. There are also several other sensors sensors other several also are There tanks. storage Did You Know? • • One technology that can help address this chal this help address can that One technology Since leakage often indicates impending equip impending indicates often leakage Since

T F to a central monitoring platform for direct for direct platform monitoring acentral to hydraulic and lubricating systems. They typi They systems. lubricating and hydraulic large levels in leakage regulate help operators providing accurate measurements of oil con of oil measurements accurate providing nificant swings in lubrication levels through the the levels through lubrication in swings nificant consumption are recorded. are consumption in changes when significant alarms sound cally Tank level of can operation. monitors course feedback. attached to the fill point on major reservoirs, point on reservoirs, major fill the to attached sumption. These can be read manually or wired or wired manually read be can These sumption. ated hydrogenelectrolysisplantatadeepwaterportinnorthernGermany, thecompanyannounced. coupling ofrenewableenergiesfor hydrogenelectrolysisandthelow-CO contribution toachievingtheclimatetargets,”saidSalzgitterAGchief executiveHeinzJörgFuhrmann. prestigious SalzgitterLow-CO Salzgitter Takes NextStepinHydrogenProject ill point meters — These simple meters are simple are meters point —These meters ill ank level monitors — Large tanks can see sig see can tanks level —Large monitors ank “Together favorablepreconditionsforanoptimalsector withour localindustrialpartners,theWilhelmshavensiteoffersvery “This isanotherconcretestepinourprocessofevolvingtowardlow-CO The companysaiditplanstowrap upthestudybynextMarch. Salzgitter saiditisconsideringtheportofWilhelmshaveninLower Saxonyasthehomeforfacility. Salzgitter andindustrialpartnersRhenusUniperwillexplorethe feasibilityofbuildingadirectreducedironplantandssoci- 2 Steelmakingtechnologyconcept.Oncethisstephasbeenrealized, wewillbemakingadecisive - - - - - Understanding real-time equipment performance performance equipment real-time Understanding the operation. operation. the tor to understand what action to take to prevent to a fail take to action what understand tor to tenance decisions that will reduce downtime, enhance enhance reduce downtime, will that decisions tenance their production goals. By adopting the latest, most most latest, the By adopting goals. production their ure mode. More importantly, building this complete this building mode. Moreure importantly, picture can help operators even help extend equipment operators can picture enough provide context can opera for an information valuable own its provides sensor Each performance. of equipment acomplete build to profile processes monitoring condition-based numerous incorporates productivity and ultimately increase profitability. increase ultimately and productivity insights — operators can make more informed main more informed make can —operators insights is essential for achieving productivity and efficien and productivity for achieving essential is life or safely increase the production rate beyond the beyond the rate production the increase or safely life Conclusion cy goals, especially as operators strive to increase increase to strive operators as especially goals, cy data point, and when analyzed in aggregate, this this aggregate, in when and analyzed point, data a robust predictive maintenance program, operators operators program, maintenance predictive a robust and building a holistic program that aggregates their their aggregates that program aholistic building and — technologies monitoring condition-based advanced status quo, helping to deliver even them more value status should consult with their OEM and supplier partners. supplier and partners. OEM their should with consult A best-in-class preventive maintenance program program preventive maintenance A best-in-class To learn more about these technologies and to build build to and To technologies more about these learn 2 directreductionofironore,”said Fuhrmann. 2 , hydrogen-basedsteelproductionunderpinnedbyour Conference Proceedings. Conference andExposition,Pittsburgh,Pa.,USA,publishedinthe This paperwaspresentedatAISTech 2019—TheIron&SteelTechnology

F - - - - PIONEERS AT HEART

AD-Pioneers-at-Heart-EN-213x283-vek.indd 2 03.10.2018 08:04:54 90 Technical Article

Reparation of Trusses in Steel Plant Environment

In an competitive world, where the growing need to develop industrial production/productivity requires maximum performance, new technologies and equipment are required. Thus, reinforcement/retrofit of structural elements is needed. After some years, a structure can present pathologies that can be caused by new loading, design/assembly/fabrication deficiency or even lack of maintenance. Therefore, when it is necessary to accommodate new loads, it is crucial that the proposals contemplate the new loadings and a good structural condition. This paper reports on field experience during the work of repowering trusses with almost 20 years of use in an Authors extremely aggressive environment.

José Geraldo de Araújo Silva (pictured) n an increasingly competitive advances in terms of materials and Metalcon, Ipatinga, MG, Brazil [email protected] Iworld, where the growing need calculation methodologies. to develop industrial production/ The present case is a space truss Antonio Maria Claret de Gouveia Universidade Federal de Ouro Preto, productivity requires maximum system formed by four units, two ver- Ouro Preto, MG, Brazil performance, new technologies and tical (main) and two horizontal (sec- [email protected] equipment are demanded. Thus, in ondary) responsible for the horizon- Hisashi Inoue cases of increased industrial per- tal stabilization of the system. Some Universidade Federal de São João del- formance, there is a need for rein- specialized literature calls this struc- Rey, Ouro Branco, MG, Brazil [email protected] forcement/recovery of structural tural system a lattice tunnel. Gustavo Oliveira Daumas elements, since these were not ini- The structure is part of a set of Universidade Federal de Ouro Preto, tially designed to absorb the new conveyors in a large steel industrial Ouro Preto, MG, Brazil efforts. However, in cases where the complex in northern Brazil and is [email protected] maintenance has left something to responsible for the transportation Lucas Teixeira Araújo be desired (or been lacking com- of corrosive material between two Universidade Federal de Ouro Preto, Ouro Preto, MG, Brazil pletely), various pathologies may plants. The chemical element some- [email protected] arise, causing not only the need for times falls from the conveyor belt structural reinforcement, but also and is housed at the lower part of for correction. the structure (on the flange profiles, After some time in use, a struc- on the horizontal trellis parts and ture can present several pathologies especially on the links). Since the that can be caused by new loading, cleaning of the structure as well as dynamic actions, design/assembly/ the removal of the materials falling fabrication deficiency or even lack from the belt are difficult to carry of maintenance (mainly). Therefore, out and there is constant discussion when it is necessary to accommodate between maintenance and produc- new loads, it is crucial that the pro- tion personnel, the corrosive proposals contemplate not only the new cess has started and luckily did not loadings and their combinations, bring the structure to break. but also the structural condition of Due to the need to place new AIST.ORG

I elements involved in this stage. equipment and increase the capac-

Structural retrofit, whether due to ity of the conveyor belt, the sys- the need to allocate new equipment tem was completely stopped and and/or correction, is becoming very a general inspection was carried common today. For this reason, the out in this structure, where there structural engineer must be aware was widespread corrosion, excessive

IRON & STEEL TECHNOLOGY of the reasons that lead to the need deformation of structural elements

I for structural reinforcement, as well (secondary and primary) and bro- 2020

as being aware of technological ken connections. AUG 91

The vertical trusses are Pratt type and the horizontal • Connections broken or without effectiveness. trusses are K type. The dimensions of the structure are: • Corrosion in main bars. • Corrosion on secondary bars. • Span: 118 feet (36 m). • Vertical bars and diagonal bars damaged. • Distance between verticals: 9 feet 10 inches • Vertical bars and diagonal bars with part of the (3 m). ruptured section. • Distance between vertical trusses: 13 feet 1 1/2 • Excessive deformation. inches (4 m – center to center of profiles). • Warping in runway beam. • Height of vertical trusses: 9 feet 10 inches (3 m – center to center of profiles). Fig. 3 shows some of these pathologies. • Type of support: isostatic (roller). Retrofit is a term used mainly in engineering to des- • Type of connection in verticals and cords: ignate the process of modernization of some equip- pinned. ment or structure already considered outdated or out • Adopted profile on flanges: welded steel profile of standard. In the present case, the reengineering ASTM-A36. was carried out to contemplate both proposals, since • Profile adopted on diagonals and verticals: the standard used for calculation was NB14 (allowable double angle in steel ASTM-A36. stress method), in use at the time of fabrication of the • Connection plate (gousset): 3/8 inch (#9.7 mm). structure and that when the improvements in truss • Screws: A325N (cutting plane passing through the current norm was NBR8800 (load and resistance the thread). factor design), which is in use today. In order to attend to the normative requirements The dimensions are shown in Figs. 1 and 2. of safety and use, repairs were made (change of struc- Based on the data obtained from the existing proj- tural parts, parts of profiles and connections) and ects, the structure was checked, under the conditions in which it was originally designed, with the proposed overloads (equipment, materials and wind according to NBR6123). Using MCalc3D software and the stan- Figure 1 dard NBR8800, the structure was analyzed and the most requested bars were found, as well as the maximum deflexion, whose values are:

• Bar most requested: diagonal compressed with 80% of use. • Maximum deflexion: 3 1/8 inches (80 mm), at span center (L/450), when the maximum load was acting.

Side view of the main truss (vertical). The vertical and diagonal bars are in angles opposed by vertices and chord and the Discussion first diagonal are in built-up profiles (welded profile).

Based on the theoretical data, the current status of the structure was verified in the field, so that the new study could be carried out. The indications were loss Figure 2 of material because there was a marked deformation near one of the supports and the material which is carried by the belt has a pH of around 4. AUG

Also, it should be noted that in its 40 years of exis- 2020

tence, the structure has never undergone severe main- I tenance. It is imperative that in all production sectors IRON & STEEL TECHNOLOGY that the maintenance and production teams work in harmony, since the absence of effective maintenance can bring premature equipment wear and leaves a gap for accidents. Otherwise, a large time demand may Top view of upper truss (horizontal). The chords are common cause production loss and delay compromise. to this truss and to the main trusses (vertical). The diagonals

are in double angles opposite by vertices. The verticals are I

During the inspection, several non-conformities in built-up profiles (welded profile) and in upper truss these AIST.ORG were found, such as: are requested to bend because the loads of equipment are in these pieces. 92 AUG 2020 I IRON & STEEL TECHNOLOGY I AIST.ORG profile, where corrosion, in most cases, was only superficial. only was cases, most in corrosion, where profile, of flange top the of View D: corroded. been had section flange the of much cases, some in where, flange, lower the from View C: beams. the of and beams transverse the of both profiles, of flanges in Corrosion B: plate. web the pierced even pathology this situations some In truss. main of profile cord lower of web in but corrosion, of process same the right the On bearing. of near beam transverse web in Corrosion A: structure. the in present pathologies some of Sketches Technical Article ture, since it had visible deformations. Then it became it Then became deformations. it since visible had ture, the activities were carried out safely. were carried activities the in front of the efforts generated by the new equipment. bythe generated efforts front of the in imperative to stop all activities, with the removal of removal the with activities, stop all to imperative reinforcement in parts where the resistance values values resistance where the reinforcement parts in recovery, there was something wrong with the struc the with wrong something recovery, was there equipment and cleaning of all parts of trusses, so that that so of trusses, parts of all equipment cleaning and found were out of standard or did not or did meet needs the found were out of standard shown in Fig. 3 were treated as follows: as Fig. in 3wereshown treated Figure 3 A. B. As it was already known by all those involved in the the involved in those byall known already it was As After cleaning the structures, the pathologies, as as pathologies, the structures, the cleaning After

F M with corrosion inhibitor. Welding of two plates inhibitor. corrosion plates Welding of two with the corroded part and weld and new For plate. part corroded the in an area larger than the affected area, thus thus area, affected the than larger area an in letter D in the majority of cases — surface —surface of cases majority the letter Din removal of oxides. Painting of affected parts parts of affected Painting of oxides. removal corrosion — a manual brush was cleaned with with cleaned was brush —amanual corrosion were A490N redone, these using connections, of case of web. the In integrity the ensuring and painting of the affected parts with corro with parts affected of the painting and oxide of the removal total with a steel brush, sion inhibitor and finish paint. finish and sion inhibitor washers. two screw, with or the case shown in letter C, chose to cut to chose letter C, in shown case or the anual cleaning with steel brush, with total total with steel brush, with cleaning anual - - A325X screws (with thread in the cutting plane) were cutting the in thread (with screws A325X The longevity of a structure in a corrosive environ a corrosive in of a structure longevity The In the iron and steel industry, the possibilities for possibilities the steel industry, and iron the In would be solved. be would were well above the required resistance. required were the well above (vertical structure main the out in only carried was traction and compression, contemplate to and and the traction not did need to plates connecting the thickness, their without compromising the connection. Even connection. the compromising so, the without ting plane). Where there was increased effort, the the effort, increased was there plane). Where ting trusses) because the originally sized locking trusses trusses locking sized originally the because trusses) reinforcement The structure of the necessary. is tem be altered. be has a mobile load, the most requested parts could be could be parts requested most the a mobile load, has be observed. Summary Summary proposed load increase it was enough to increase the the enough increase to it was increase load proposed pleted. And, day after day, structural behavior must behavior day, structural after day pleted. And, com successfully be improvement it can required, is astructural if and maintenance project facilitate to parts (diagonals and vertical) mostly work under mostly vertical) and (diagonals parts ing at the possible points where the structural rein structural where the points possible at the ing possibility of corrosion, either by the environmental environmental either of corrosion, bythe possibility limit (L/300 = 120 mm). reinforce the structure. the reinforce nal condition, the structural analysis of the same was was same of the analysis structural condition, the nal Conclusion Conclusion of screw, which does not require verification. Due to to Due verification. notof screw, does which require corresponding to L/379, being below the normative L/379, to normative belowcorresponding the being or large), it is very important to observe and discuss discuss and observe to important or large), it very is for the It necessary existence. is its during occur may that facts the of all ment observation on depends the changed to screw A490 (with thread outside the cut - the outside thread (with A490 screw to changed buckling, mode is compression, failure where the carried out with the placement of the new loads, aim placement the new loads, of the out with carried forcement could be necessary. Since the equipment the forcement Since necessary. could be design of metal structures must always observe the the observe must always structures of metal design area of the section of the same ones that the problem the ones that same of the section of the area angles were doubled, obtaining also the double the shear also were doubled,angles obtaining at any point, and a more careful analysis of the sys of the analysis amore and careful point, at any all possibilities of use and of retrofit. and of use possibilities all agents or by the type of product handled. A good A good of product handled. type or by the agents structure was deformed, being 3 being deformed, was structure structural design contemplates the good performance performance contemplates good the design structural structural problems are very high. In this way, the this In high. very problems are structural After elaboration of reinforcement projects, the of the reinforcement projects, elaboration After The main truss chords were only subjected to the the to subjected were chords only truss main The The connecting plates were retained, since the the since were retained, plates connecting The With the structure, at least theoretically, in its origi its in theoretically, at least structure, the With Fig. 4 shows the sketches of the solutions adopted to Fig. to adopted sketches solutions 4shows the of the Finally, to obtain a reliable structural system (small (small system structural areliable obtain to Finally, 3 / 4 inches (95 mm), (95 inches ------93

Figure 4 Ferrari Radaelle and Mário Luís Cabello for helping in drafting and for final reviewing the text. Finally, the authors would like to acknowledge Charles A. Totten. “Charlie, I will remember you as a gentleman and a good friend. It was an honor knowing you,” said José Geraldo de Araújo Silva.

References

1. NBR 8800 – “Design and Construction of Steel Structures for (a) (b) Buildings” (in Portuguese), Rio de Janeiro, Brazil, 1986. 2. NBR 6123 – “Loads Due to Wind in Buildings” (in Portuguese), Rio Sketch of the reinforcement executed on the main trusses (in de Janeiro, Brazil, 1988. green). Placement of more angles in some verticals and some 3. American Institute of Steel Construction Manual, 13th edition, diagonals. With the doubling of angles, not only the area Chicago, Ill., 2010. increase but also the torsional stiffness (a). Welded plate 4. ASTM A36 – “Standard Specification for Carbon Structural Steel,” placement at lower flange, for area increase (for upper chord, West Conshohocken, Pa., USA. the placement was given by top flange) (b). For the cases of 5. ASTM A325 – “Speciﬁcation for High-Strength Screws for Structural compression the placement of symmetrical plates is better, Steel Joints,” West Conshohocken, Pa., USA. but, due to interferences with the connections, the form 6. ASTM A490 – “Standard Specification for Structural Screws, Alloy shown here was the only one possible. Steel, Heat Treated, 150 ksi,” West Conshohocken, Pa., USA. 7. Araújo, E., “Lecture Notes of the Master Course in Metal Structure” (in Portuguese), EMMOP/UFOP, Ouro Preto, Brazil, 1999. 8. Bellei, I. et al., “Multi-Story Steel Buildings: Design and Calculation” (in Portuguese), 14th edition, Editora Pini, São Paulo, Brazil, 2004. of the structure, with guarantee of durability and also 9. Bellei, I., “Industrial Steel Buildings: Design and Calculation” (in the possibility of improvements and maintenance. Portuguese), 4th edition, Editora Pini, São Paulo, Brazil, 2003. 10. SIDERBRÁS: Siderurgia Brasileira S.A., “Brazilian Manual for Calculating Metallic Structures” (in Portuguese), Brasília, Brazil. F Acknowledgments 11. Software MCalc3D, Version 5.0 – Stabile, Porto Alegre, Brazil.

The authors would like to thank all who believed and This paper was presented at AISTech 2019 — The Iron & Steel Technology Conference and Exposition, Pittsburgh, Pa., USA, and published in the helped them in this proposal. They also thank Carolina Conference Proceedings.

Did You Know?

Nucor, AK Steel Receive Supplier Honors AK Steel and Nucor have been recognized as General Motors (GM) Suppliers of the Year, a honor presented to the automaker’s vendors that distinguish themselves by providing innovative technologies and high-quality parts, materials and services. “Our suppliers play a key role in delivering the products, services and experiences our customers deserve — and these award- winning suppliers went above and beyond our expectations,” said GM vice president Shilpan Amin, who oversees the company’s global purchasing and supply chain. It’s the second year in a row Nucor has received the recognition, and it’s the only mini-mill operator on the automaker’s list of recognized suppliers. “We value the partnership we’ve built with GM, working together to meet their needs for automotive steel products. We look forward to continuing to grow as partners for years to come,” said Nucor president and chief executive Leon Topalian. AUG

Lourenco Goncalves, chairman and chief executive of AK Steel parent Cleveland-Cliffs Inc., said the award recognizes the techni- 2020

cal and commercial support it provides to GM. I

“More than anything, we value our collaborative relationship with GM,” Goncalves said. “We are committed to continuing to IRON & STEEL TECHNOLOGY work with GM to design steel solutions for their existing and new vehicles. GM’s commitment with the future of the automotive industry is also our commitment.” The Supplier of the Year award winners are chosen by a global team of GM purchasing, engineering, quality, manufacturing and logistics executives. Winners are selected based on performance criteria in product purchasing, global purchasing and manufacturing services, customer care and aftersales, and logistics.

AIST.ORG 94 Technical Article

Copper Stave Bending: Challenges, Management and Solutions

Authors Copper staves have now been used in blast furnaces for 40 years, and Primetals Technologies Robert Horwood has had great success with this technology — in terms of the stave designs, the profiling of the senior mechanical engineer, blast furnace, and the operational strategies that can be used to support a 20-year campaign. Primetals Technologies Ltd., However, a number of non-Primetals Technologies furnaces have suffered from challenges when Stockton-on-Tees, U.K. [email protected] implementing copper staves. This paper will reference some of the problems in bending and wear that customers have encountered, along with the solutions Primetals Technologies currently Robert Mawer senior technologist, offers. Primetals Technologies Ltd., Stockton-on-Tees, U.K. [email protected] n important factor in extending The current situation is that Richard Harvey the life of the blast furnace oper- refractory quality and cooling inten- technical manager, A Primetals Technologies Ltd., ating campaign has been the quality sity for plate-cooled furnaces have Stockton-on-Tees, U.K. and durability of the furnace shell increased such that long campaign [email protected] protection system. As demands on lives can be achieved with both David Osborne productivity have increased, so have plate-cooled furnaces and copper technology director, Primetals Technologies Ltd., the operating pressures of the blast stave-cooled furnaces, but there Stockton-on-Tees, U.K. furnace. This has meant thicker fur- are enhancements in stave design [email protected] nace shells, which have required that have been engineered to over- greater reliability of the protective come two of the issues seen on cooling systems in order to ensure some copper stave-cooled furnaces. that the structural integrity of the These two issues are stave wear and blast furnace could be maintained. stave bending. This paper will focus Copper plate coolers became the on the issues copper staves have predominant cooling systems of the faced through stave bending: why mid-1900s but their limited cam- the problem occurs, how it can be paign life and requirement for gun- managed through a campaign and nite repair led to the development of how to prevent it from happening stave cooling. Initially the stave solu- altogether for a trouble-free cam- tion was manufactured from cast paign life. iron — this was developed in Russia with further enhancements made in Japan. The stave solution provided Discussion more consistent campaigns, albeit there were still improvements to be What Is Stave Bending? — When trial made as the cast iron stave lifetime copper staves were first installed in the high heat zones of the fur- into the blast furnace, the focus was nace was around 10–12 years. very much on the hot face of the Copper staves were introduced to stave and how it was performing. enhance the heat removal capabili- Success in the freezing of a self- AIST.ORG

I ties in these areas and thus improve protecting accretion layer was

stave lifetimes. The use of copper observed and confidence that using in these areas meant an increase in copper in the high heat zones to the ability of the cooling system to achieve a long lifetime was realized. handle higher heat loads. In many The trial periods provided no plants, copper staves have proven concerns with stave bending and

IRON & STEEL TECHNOLOGY to be very reliable in protecting the failures of the welded connection of

I structural integrity of the blast fur- stave pipe to body were not seen. 2020

nace shell. Copper staves gradually became

AUG a more popular solution during the 95 late 1990s. With more installations and increased expand more than the cold face; in reality, the move- operational time, a number of furnaces reported ments are the opposite due to the stave fixings and problems with water leaks into the furnace from the the grout, which fills the void between the shell and welded connection of the pipe to the body. the stave. Staves are exposed to high temperatures within the As the stave goes through the temperature cycles blast furnace. During operation, an accretion layer explained previously, gaps are created behind the similar to that shown in Fig. 1 is frozen to the hot face stave, especially at the corners. These gaps allow a of the stave and protects the stave during its time in path for both burden material and dust to get behind. the blast furnace. From time to time, the accretion The material fills the gaps and prevents the stave from layer falls off, and for a short duration the stave tem- returning to its original position when it cools. Over perature increases while a new accretion layer forms. time this can have two effects: This cyclic situation can see the hot face of the stave fluctuate from 70°C to 200°C. These changes in tem- • The bending gets worse and the stave “ratchets” perature along with the stave’s inherent hot and cold further from the shell, inducing stresses into face cause the stave to expand and move in varying the pipe-to-body weld until failure occurs. ways, which can impart stresses to certain parts of the • Dust fills the compensator bellows and locks body. them in place, preventing any movements and The fluctuations of stave body temperatures cause causing stresses to once again go to the welded the stave to expand and move during operation. connection until failure. These movements cause the stave to bend in different manners depending on how the stave is fixed to Managing Stave Bending — Stave design is the most the shell. Theoretically, it would be expected for the important factor in preventing stave bending. Once stave to “belly” into the furnace as the hot face should

Figure 1 Figure 2

Accretion buildup on an early copper stave. AUG

Figure 3 2020

IRON & STEEL TECHNOLOGY

Stave hot and cold face.

AIST.ORG

Stave bending. 96 AUG 2020 I IRON & STEEL TECHNOLOGY I AIST.ORG 12 o’clock) be can dimensions recorded. These are The understanding of copper staves expansion is is expansion of copper staves understanding The This knowledge allows one to understand how pre to one understand to allows knowledge This The copper pipes were grouted in place and essen and place copper in The were pipes grouted vent stave bending. vent stave void between the shell and stave does not surround not does surround stave shell and the void between Fig. 5 shows the optimum stave design to provide a provide to design stave Fig. optimum 5shows the Technical Article which can help with the estimation of aproblem estimation the help with can which that cooling channel; however, have channel; staves cooling the if that trouble-free campaign. trouble-free tially fully fixed. The understanding that was gained gained was that understanding The fixed. fully tially expansion. for stave no to allowance little was there of the welded outside then and the to body stave the into screwed pin the has method modern The tion. the compensators are installed over the cooling pipes pipes over cooling the installed are compensators the that It important is it position. in fix pipe and the ber of design features. Like with all products, there there products, all with Like features. of design ber movements into the built allowable any that ensure to to difficult it very becomes installed are staves the holes, ensuring that the backfill grout that fills the the fills that grout backfill the that holes, ensuring ing to repair. Depending on the campaign life, an an life, campaign on the repair. to Depending ing imperative in producing a good copper stave design. design. copper agood stave producing in imperative pressures. time under significant situations tight in inclusion of compensators on each stave pipe. The stave on each of compensators inclusion it also provided no stability to the stave during opera during stave the to no stability provided it also but proved for problematic design installation This it. per pipe and compensator at four points (3, 6, 9 and 9and (3, 6, compensator at four points pipeper and nace shell away and then undertaking the repair work repair the undertaking then and shellnace away of fur sections involve cutting often can repair. This shutdowns and task, no easy is Repairing required. prevent problem arising. the from retaken periodically and any movements highlighted, movements any and highlighted, periodically retaken Compensators: of the stave from where all stave expansion originates. originates. expansion stave where all from stave of the often are repairs then installed, been recently only isolate/bypass to decision the make may operator occurring. Pin: Fixed a num has copper —The stave Features Design Stave movement. a creates joint that expansion an compensator is of the furnace shell and then the stave was hung onto was stave the then shell and furnace of the welded inside the to was pin this copper Initially, stave. concentrically and the dimensions between the cop the between dimensions the and concentrically clearances around the cooling pipes and the shell the and pipes cooling the around clearances gas seal to the furnace while allowing for ~15 allowing mm while furnace the to seal gas washer. alarge shell with furnace during the early issues of the copper stave led to the the led copper to of the stave issues early the during are good designs and there are not-so-good designs. designs. not-so-good are there and designs good are agood undertake to essential are access correct and accounted for. ensure to are design practice It good is The fixed pin should be the only fully fixed point fixed fully only the should be pin fixed The Failure of the welded connection is very challeng welded very of the is connection Failure Correct installation procedures are also imperative imperative also are procedures installation Correct The fixed pin is a common feature on the on the a common feature is pin fixed The In the very early days of copper staves, of copper staves, days early very the In ------Stave design features. pipe. stave copper afailed on used method Repair Figure 4 Figure 5 97

Figure 6 Figure 7

Diagonal and vertical slicing of stave hot face. Next-generation stave design.

Fixing Bolts: The fixing bolts when first included Guide Pin: On successfully performing staves that have were an installation aid to pull the stave into posi- not experienced bending, a second pin has often tion against the furnace shell. In recent years, as been implemented. This pin is similar to the fixed stave bending became an issue, it was seen that the pin but is not welded to the furnace shell. For this bolts provided additional support to the stave during reason it is called the guide pin and it allows the stave operation. It has become good practice to locate the to expand along the shell but prevents the stave from bolts close to the corners of the stave to provide sup- bending into the furnace and therefore reduces the port during operation. bending impact.

Hot Face Design — The design of the hot face of the stave has a significant impact on how the Figure 8 stave moves and expands. The traditional stave design contains a series of dovetail grooves down the hot face to capture material and promote the accretion buildup. Vertical or diagonal slots are now common features that are machined into the copper stave. These slots aim to relieve stresses within the hot face of the stave and reduce the bending effect. While initially these features proved to be successful, it has since become apparent that while they may show some improvements, many staves with AUG

these features have still failed 2020

through bending. I

The traditional dovetail groove IRON & STEEL TECHNOLOGY design was initially adopted from the cast iron stave and was suitable for the copper stave since it was a simple shape to machine. The arrangement of these hori-

zontal dovetailed grooves provide AIST.ORG stiffness to the stave in one direc- Patented anti-bending solution successfully installed on multiple furnaces. tion only and it can therefore be 98 AUG 2020 I IRON & STEEL TECHNOLOGY I AIST.ORG Modern-day CNC machining gives the designer great designer the gives machining CNC Modern-day A patented solution that has has solution —Apatented that Solution Anti-Bending variety of options for stave’s of options the hot shapes New face. variety vented from bending into the furnace, which causes causes which furnace, into the vented bending from Technical Article the stresses to be imparted onto the weld. This is the the is onto weld. This the imparted be to stresses the shell but it pre is furnace the along slide and grow to stave’sthe bend prevents stave movements thus and have been reviewed and in particular ahoneycomb particular in and reviewed have been been developed and proven on a number of furnaces developed provenbeen and on anumber of furnaces problem of stave bending at the source. at the problem bending of stave to stave the solution allows Fig. This in 8. shown is ing. The solution is located on each corner pipe of the corner on pipe each of the located ing. solution is The installed alongside comparison staves of traditional of traditional staves comparison alongside installed that cooling and promotes ahomogeneous stiffness have changed techniques Manufacturing it does. no surprise that the stave “bananas” in the way that that way the in “bananas” stave the that no surprise offer increased wear resistance to operators who pre operators to resistance wear increased offer for In overoperation now, 6months positive. very is for a allowed has which designs, their in er flexibility only proven solution currently available that fixes the the fixes that available provenonly solution currently but load controls move thermal and under its expand can significantly reduce the impact of stave bending. of stave impact reduce the significantly can fer to maintain the traditional hot design. face traditional the fer maintain to design. Data from these staves, which have been in in have been which staves, these from Data design. which pattern, due its to benefits shown has design addition, slide-in inserts have been developed that developed have been that inserts slide-in addition, hot layouts. in face more flexibility designers allowed stave (typically four locations). The stave is allowed allowed is stave The four locations). (typically stave significantly since the first copper stave, which has has copper which stave, first the since significantly Did You Know? A trial with this novel hot face design has been been novel has hot design this face with A trial dedication to superior quality and service,” saidJohnCardwell,ArcelorMittal’sdedication tosuperiorqualityandservice,” directorof automotivesales. and ArcelorMittal DofascoG.P. ThismarkedthethirdyearinarowthatAM/NSCalverthasbeenrecognized. Itwasalsoasecond major shippingissues. consecutive awardforIndianaHarbor, andI/NTek andI/NKote. year’s awards. GM Awards ArcelorMittalPlantsWithSupplierExcellenceAward Excellence Award. To receivetheaward,steelfacilitiesmustmeetGeneralMotor’s moststringentqualityrequirements. Suchqual- facilities receivedtheprestigioushonors:ArcelorMittal USA’s IndianaHarborandI/NTek andKotefacilities,AM/NSCalvert LLC ity metricsinclude:lowoverallqualityissuesandrejectionrates;maintenance ofqualitycertifications;andnoplantdisruptionsor the road,”said Richard Demuynck, executive directorofGM’s globalsupplierqualityanddevelopment,wroteinannouncing this “General Motors’missionistodesign, buildandselltheworld’s bestvehicleswiththehighestlevelsofqualityand safety on “We proudofourpartnershipwithGeneralMotorsacrosssites, andthisrecognitionisatestamenttoouremployees’ arevery ArcelorMittal wasrecognizedwiththe2019SupplierQualityExcellenceAward byGeneralMotors(GM).ThreeArcelorMittal General Motors utilizes thousands of suppliers around the world, but only a small fraction of those receive the Supplier Quality - - - - Water leaks into the furnace, no matter where no from, matter furnace, into the Water leaks

Copper staves have encountered some serious issues have encountered issues staves someCopper serious with stave bending that can ultimately cause water water cause ultimately can that bending stave with the isolation of the damaged cooling channel, which which channel, cooling damaged of the isolation the tive accretion layer is built up, falls off and builds up builds and off up, falls built layer is accretion tive that expansion. Using the correct features and design design and features correct the Using expansion. that paign can be accomplished. be can paign leaks into the furnace. The result of this often means means often of this result The furnace. into the leaks reduces the stave’s lifetime significantly and can can and stave’s significantly reduces the lifetime Conclusions Conclusions considered to guarantee a trouble-free campaign: atrouble-free considered guarantee to should be points following The design. stave correct the given obtained be can campaign and operation However, asuccessful maintained. be can operation a trouble-free that ensuring to critical copperis stave is bending shell. Stave furnace on the hot spots cause directly attributed to temperature fluctuations of the of the fluctuations temperature to attributed directly are a serious issue for the blast furnace operator. furnace for blast the issue aserious are again. This means that the mechanical design of the of the design mechanical the that means This again. whereby protec of staves the operation of the part are as outlined above demonstrates that a successful cam asuccessful that demonstrates above outlined as stave. These fluctuations cannot be prevented as they they prevented be as cannot fluctuations These stave. stop thermal expansion, but it is possible to control to but it possible is expansion, stop thermal • • • • It’s important to remember that it is impossible to to It’s it impossible remember to is that important

C I I U in particular that of ahoneycomb that pattern. particular in nclude the anti-bending solution. anti-bending the nclude design. the in pin guide and nclude afixed onsider different hot face designs — hot designs onsider face different nderstand the expansion philosophy. expansion the nderstand Conference Proceedings. Conference andExposition,Pittsburgh,Pa.,USA,publishedinthe This paperwaspresentedatAISTech 2019—TheIron&SteelTechnology

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100

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PLENARY PROGRAM AT A GLANCE Materials Science & Technology (MS&T) is where materials SPEAKERS innovation happens! Each year, MS&T’s long-standing, recognized forum brings together scientists, engineers, Visit the MS&T Plenary Speakers webpage students, suppliers, and business leaders to discuss to view the complete abstracts and bios. current research and technical applications to shape the AIST ADOLF MARTENS MEMORIAL STEEL future of materials science and technology. The event’s LECTURE unmatched technical program fosters technical innovation at the intersection of materials science, engineering, and application — addressing structure, properties, processing and Nina Fonstein performance across the materials community. manager (retired), Automotive Product Join other materials science experts from three leading Development materials societies to discuss the latest advancements in your Group, Global R&D, field. MS&T20 features the following events: ArcelorMittal, USA AIST STEEL PROPERTIES AND APPLICATIONS Technical developments related to ferrous metallurgy and steel manufacturing.

TMS/ASM JOINT DISTINGUISHED ACerS 122ND ANNUAL MEETING LECTURESHIP IN MATERIALS AND SOCIETY Advancing the industry with the latest research in ceramics and glass. TMS FALL MEETING Charles H. Ward chief, Manufacturing Exploring the intersections of development, synthesis and and Industrial application. Technologies Division, Air Force Research Laboratory, USA COVID-19 UPDATE Your safety and well-being are our top priority! At this time, we ACerS EDWARD ORTON JR. are moving forward with MS&T20 as scheduled. The MS&T MEMORIAL LECTURE organizing societies are monitoring news and information related to COVID-19 on an ongoing basis and will follow guidance from the U.S. Centers for Disease Control and Prevention, the World Health Organization, and federal, Mrityunjay Singh state, and local governments. If plans should change, we will chief scientist, provide updates through the MS&T20 website and by email Ohio Aerospace to registrants, exhibitors, presenters, and other confirmed Institute, USA participants. #MST20 109 ADVANCE PROGRAM REGISTER BEFORE 3 SEPTEMBER 2020 TO SAVE! MS&T 20 STEEL PROPERTIES Annual Meeting & APPLICATIONS

LECTURES AND TECHNICAL AWARDS PROGRAM ACerS/EPDC ARTHUR L. FRIEDBERG CERAMIC Visit the MS&T Technical Program webpage to view the ENGINEERING TUTORIAL AND LECTURE complete technical program and topics. Monday, 5 October | 9–10 a.m. • ADDITIVE MANUFACTURING John R. Hellmann, The Pennsylvania State University, • ARTIFICIAL INTELLIGENCE USA • BIOMATERIALS ACerS RICHARD M. FULRATH AWARD SESSION • CERAMIC AND GLASS MATERIALS Monday, 5 October | 2–4:40 p.m. • ELECTRONIC AND MAGNETIC MATERIALS Shashank Priya, The Pennsylvania State University, USA • ENERGY Tomoaki Yamada, Nagoya University, Japan • FUNDAMENTALS AND CHARACTERIZATION Takeshi Kobayashi, National Institute of Advanced • IRON AND STEEL (FERROUS ALLOYS) Industrial Science and Technology, Japan • MATERIALS-ENVIRONMENT INTERACTIONS Hiroshi Sato, TDK Electronics GmbH & Co. OG, Japan • MODELING Edward P. Gorzkowski III, U.S. Naval Research Lab, USA • NANOMATERIALS ACerS FRONTIERS OF SCIENCE AND SOCIETY — • PROCESSING AND MANUFACTURING RUSTUM ROY LECTURE • SPECIAL TOPICS Tuesday, 6 October | 1–2 p.m. James Adair, The Pennsylvania State University, USA ACerS GOMD ALFRED R. COOPER AWARD SESSION COOPER DISTINGUISHED LECTURE Tuesday, 6 October | 2–4:30 p.m. AUG

John Kieffer, University of Michigan, USA 2020

ACerS GOMD ALFRED R. COOPER YOUNG IRON & STEEL TECHNOLOGY SCHOLAR AWARD PRESENTATION Winners will be announced after selection by the Cooper Award Committee. ACerS BASIC SCIENCE DIVISION ROBERT B.

SOSMAN LECTURE I

Wednesday, 7 October | 1–2 p.m. AIST.ORG Wayne Kaplan, Technion – Israel Institute of Technology, Israel 110 MATSCITECH.ORG/MST20

Technical Meeting and Exhibition MS&T 20 MATERIALS SCIENCE & TECHNOLOGY #MST20 4–8 OCTOBER 2020 | DAVID L. LAWRENCE CONVENTION CENTER | PITTSBURGH, PA., USA

LATE NEWS POSTER SESSION Want to share your latest research at MS&T? Submit an abstract for the Late News Poster Session! Topics can include any of those listed. Submit abstracts at programmaster.org/MST20. Questions? Contact [email protected]. Abstracts due: 31 AUGUST 2020 SPECIAL EVENTS Visit the MS&T Special Events webpage to see all special events, including dates and times. MS&T WOMEN IN MATERIALS SCIENCE RECEPTION Sunday, 4 October | 5–6 p.m. ACerS 122ND ANNUAL MEMBERSHIP MEETING Monday, 5 October | 1–2 p.m. MS&T PARTNERS’ WELCOME RECEPTION Monday, 5 October | 5–6 p.m. AIST STEEL TO STUDENTS RECEPTION Monday, 5 October | 6–8 p.m. ACerS ANNUAL HONOR AND AWARDS BANQUET Monday, 5 October | 7:30–10 p.m. AIST.ORG

I ACerS BASIC SCIENCE DIVISION CERAMOGRAPHIC Exhibit and Competition 5–8 October | various hours General Poster Session With Presenters Tuesday, 6 October | various hours IRON & STEEL TECHNOLOGY

I TMS YOUNG PROFESSIONAL TUTORIAL LUNCHEON AND

LECTURE 2020

AUG Tuesday, 6 October | Noon–12:45 p.m. #MST20 111 ADVANCE PROGRAM REGISTER BEFORE 3 SEPTEMBER 2020 TO SAVE! MS&T 20 STEEL PROPERTIES Annual Meeting & APPLICATIONS

SHORT COURSES HOTELS View the MS&T Short Course webpage for dates and times. Visit the Housing webpage for detailed SINTERING OF CERAMICS information on hotels and visa information. Saturday, 3 October | 9 a.m.–4:30 p.m. WESTIN PITTSBURGH Sunday, 4 October | 9 a.m.–2:30 p.m. ACerS Headquarters Hotel Instructor: Ricardo Castro, University of California – Davis US$229 plus tax/night single or double

STUDENT ACTIVITIES Visit the MS&T Student Activities webpage to see complete descriptions of all student events, including details for applying for Material Advantage chapter travel grants and individual travel grants. OMNI WILLIAM PENN HOTEL • UNDERGRADUATE STUDENT POSTER CONTEST AIST and TMS Headquarters Hotel • GRADUATE STUDENT POSTER CONTEST US$219 plus tax/night single or double • MATERIAL ADVANTAGE CHAPTER OFFICER WORKSHOP • UNDERGRADUATE STUDENT SPEAKING CONTEST • STUDENT NETWORKING HAPPY HOUR • ACerS STUDENT TOUR • AIST STUDENT PLANT TOUR OF ATI'S HOT ROLLING AND PROCESSING FACILITY • ACerS PCSA HUMANITARIAN ENGINEERING SYMPOSIUM • CERAMIC MUG DROP CONTEST COURTYARD BY MARRIOTT PITTSBURGH • CERAMIC DISC GOLF CONTEST US$209 plus tax/night single or double • CAREER FAIR • STUDENT AWARDS CEREMONY DRURY PLAZA HOTEL PITTSBURGH DOWNTOWN US$179 plus tax/night single or double

HAMPTON INN AND SUITES PITTSBURGH US$199 plus tax/night single or double 112 MATSCITECH.ORG/MST20

Technical Meeting and Exhibition MS&T 20 MATERIALS SCIENCE & TECHNOLOGY #MST20 4–8 OCTOBER 2020 | DAVID L. LAWRENCE CONVENTION CENTER | PITTSBURGH, PA., USA

EXHIBITION REGISTRATION Meet and network with reps from companies Visit the Registration webpage to see what your specializing in materials science and engineering- registration includes. related products and services. Attractions on the show floor include poster sessions, mug drop competition, ceramic disc golf competition, career On or before After Rates fair and an exhibitor networking reception. 3 September 3 September Member US$660 US$810 EXHIBIT SHOW HOURS: Non-Member US$810 US$960 Presenter (Speaker, Organizer, Tuesday, 6 October US$610 US$760 Session Chair) Member 10 a.m.–6 p.m. Presenter (Speaker, Organizer, Exhibitor networking reception: 4–6 p.m. US$760 US$910 Session Chair) Non-Member1 Wednesday, 7 October Undergraduate Student US$25 US$75 9:30 a.m.–2 p.m. Member2 Undergraduate Student Non- Visit the Exhibits webpage for rates on booth US$25 US$75 rental, sponsorship, advertising rates, plus more Member 2,3 Graduate Student Presenter, details on marketing your company at MS&T20. US$110 US$160 Member2 Graduate Student Member2 US$135 US$185 Graduate Student Presenter, US$140 US$190 RESERVE YOUR Non-Member 2,3 Graduate Student Non- US$165 US$215 Member2,3 BOOTH TODAY! One-Day Member US$535 US$685 Gavin McAuliffe, Exhibit Manager One-Day Non-Member US$685 US$835 Corcoran Expositions Inc. Exhibit Only US$25 US$25 200 W. Adams St., Suite 1000 ACerS Awards Banquet US$100 US$100 Chicago, IL 60606 TMS Young Professional [email protected] | +1.312.265.9649 US$40 US$40

AIST.ORG Tutorial Lecture

I 1Non-member fee includes a complimentary one-year membership to registrant’s choice of one or more organizations: ACerS, AIST, and/or TMS. 2To qualify for the student rate, registrant must provide student ID. Please be prepared to present a current school ID when picking up your badge on-site. 3Non-member student fee includes a complimentary one-year membership in Material Advantage (the ACerS/AIST/ASM/TMS joint student program). IRON & STEEL TECHNOLOGY

2020

AUG Global Expertise + Water Technologies + Digital Solutions = World Class steel making operations • Safety and environmental compliance • Operational excellence • Maximize output and minimize costs Contact: Rajeev Dilipkumar [email protected]} ecolab.com/nalco-water

Strengthen your network at the following events:

AIST LEADERSHIP CONFERENCE This invitation-only event is open to all Member Chapter officers, Technology Committee officers and AIST’s Board of Directors. The conference objective is to enhance the value of participation in AIST activities and provide resources to help attendees grow as leaders in the association and the steel industry.

AIST WESTERN CONFERENCE The AIST Western Conference is hosted by the Southern California and Northern Pacific Member Chapters. With technical presentations, a golf outing, vendor displays, shared meals, breaks and receptions, this event provides attendees with superior networking opportunities and education about new technologies affecting local steel-related businesses and the future of the steel industry.

AIST’s Southern California Member Chapter will be hosting their annual dinner dance that will kick off the weekend leading into the AIST Western and Leadership Conferences at the Omni Rancho Las Palmas Resort & Spa, Rancho Mirage, Calif., USA.

Important Information: both events will be held concurrently, and you must register for the specific conference that you plan to attend. All participants will be able to attend common networking opportunities and social functions.

VENDOR DISPLAY OPPORTUNITIES ARE AVAILABLE! For more information, please contact Jill Liberto ([email protected]) or visit AIST.org.

SPONSORSHIP OPPORTUNITIES All Sunday–Tuesday sponsors receive the following: inclusion as a conference event contributor in promotional emails and Iron & Steel Technology (I&ST) ads, on-site AIST PowerPoint presentations, Leadership Conference electronic binder and websites for the Leadership Conference and Western Conference, and acknowledgment during the opening and closing statements by the Executive Director. SUNDAY, 8 NOVEMBER–TUESDAY, 10 NOVEMBER 2020 Premier Sponsor US$10,000 SOLD OUT Recognition as premier sponsor and company logo on all event signage. One, two-page 4-color spread in I&ST magazine. One 6-foot table at vendor fair and a foursome in the golf outing. Banner ad and hyperlink in the conference recap email sent to all attendees.

Event Sponsor US$6,000 SOLD OUT Recognition as event sponsor and company logo on all event signage. One full-page 4-color ad in I&ST magazine. One 6-foot table at event vendor fair.

SUNDAY, 8 NOVEMBER 2020 MONDAY, 9 NOVEMBER 2020 (CONT’D)

Golf Outing Tee Sponsor* Afternoon Break Sponsor US$200 (unlimited) US$1,500 (2 available) Sign with company logo placed at one of Premium signage during afternoon break. the 18 holes. Reception Signature Sponsor Golf Outing Beverage Cart Sponsor* US$2,200 SOLD OUT US$500 (unlimited) Premium signage and acknowledgment as sponsor Sign with company logo on each of the during Monday’s reception. beverage carts. Reception Associate Sponsor* US$200 (unlimited) Welcome Reception Signature Sponsor US$2,200 (1 available) Company name on signage during Monday’s Premium signage during Sunday’s welcome reception. Reception is for all attendes. reception. TUESDAY, 10 NOVEMBER 2020 Welcome Reception Associate Sponsor* US$200 (unlimited) Breakfast Sponsor Company name on signage during Sunday’s US$2,200 (1 available) welcome reception. Welcome reception is for all Premium signage during breakfast. Company logo attendees. and recognition as event sponsor on all tables throughout breakfast area.

MONDAY, 9 NOVEMBER 2020 Morning Break Sponsor Breakfast Sponsor US$1,500 (2 available) US$2,200 (1 available) Premium signage during morning break. Premium signage during breakfast. Company logo and recognition as event sponsor on all tables Lunch Sponsor throughout breakfast area. US$3,500 (1 available) Premium signage during lunch and on all tables Morning Break Sponsor throughout the luncheon area. US$1,500 (2 available) Premium signage during morning break. Sponsorships denoted with * will be promoted exclusively during Western Conference functions. Lunch Sponsor SPRAY-COOLED All proceeds go to the AIST Southern California US$3,500 SOLD OUT Member Chapter. Premium signage during lunch and on all tables throughout the luncheon area. F 116 Technology Committees

AIST’s nine Technology Divisions are comprised of 30 volunteer-based Technology Committees populated by AIST members with similar technical interests. Technology Committee members are actively engaged in a variety of activities, such as:

• Meetings. • Technical exchanges. • Plant tours. • Development of technical publications and conference programming. • Industry surveys. • Industry Roundups. Technology Committee membership offers many benefits, including:

• An enhanced network of peers. • A forum to collectively solve problems. • Opportunities to advance individual technical know-how.

Committee enrollment is free and open to any AIST member. Join a committee today!

To join one or more committees, visit AIST.org or contact: Anna Voss manager — technology programs [email protected]

Technology Divisions and Technology Committees

I. Safety & Environment III. Steelmaking V. Rolling & Processing AIST.ORG

I • Safety & Health • Electric Steelmaking • Hot Sheet Rolling

• Environmental • Oxygen Steelmaking • Cold Sheet Rolling • Specialty Alloy & Foundry • Galvanizing II. Cokemaking & Ironmaking • Tinplate Mill Products • Cokemaking IV. Reﬁning & Casting • Plate Rolling • Ironmaking • Ladle & Secondary Reﬁning • Long Products IRON & STEEL TECHNOLOGY

• Direct Reduced Iron • Continuous Casting • Pipe & Tube 2020

• Rolls AUG 117 AUG

VI. Metallurgy VIII. Plant Services & Reliability IX. Material Movement & 2020

• Metallurgy —Steelmaking & • Project & Construction Transportation I

IRON & STEEL TECHNOLOGY Casting Management • Material Handling • Metallurgy — Processing, • Maintenance & Reliability • Cranes Products & Applications • Lubrication & Hydraulics • Transportation & Logistics • Refractory Systems VII. Energy, Control & Digitalization

• Energy & Utilities AIST.ORG • Electrical Applications • Digitalization Applications

AUG 2020 I IRON & STEEL TECHNOLOGY I AIST.ORG .org for

15–17 March15–17 WilliamOmni Hotel, Penn Pittsburgh, Pa., USA JUNE 2021 INTERNATIONAL CONFERENCE ON ADVANCES METALLURGY IN LONGOF AND FORGED PRODUCTS 27–30 June New Dates! Vail Marriott Mountain Resort, Vail, Colo., USA STEEL MILL COMBUSTION AND THERMAL SYSTEMS October27–29 AIST Headquarters, Warrendale, Pa., USA NOVEMBER 2020 THE MAKING, SHAPING AND TREATING OF STEEL: 101 4–5 November AIST Headquarters, Warrendale, Pa., USA FEBRUARY 2021 FUNDAMENTALS SOLUTIONS: MAINTENANCE AND NEW FRONTIERS 24–26 February New Dates! Embassy Suites Riverwalk, San Antonio, Texas, USA MARCH 2021 TRANSFORMATIONDIGITAL FORUM FOR THE STEEL INDUSTRY The health and safety of our industry is a shared responsibility and one that we take seriously. As of press time, AIST is

actively monitoring the crisis COVID-19 as it may necessitate the postponement or cancellation of some events. Please visit AIST updates or contact us at [email protected]. COVID-19: 19–21 October19–21 Dearborn, USA Mich., ENVIRONMENTAL SOLUTIONS: MEETING EPA REQUIREMENTS EMISSION AIR Holiday Inn NashvilleHoliday Inn USA Vanderbilt, Nashville, Tenn., PRACTICALA TRAINING SEMINAR 13–15 October Holiday Inn Cleveland South - Independence, USA Ohio, Independence, 6–8 October CONTINUOUS CASTING OCTOBER 2020 SECONDARY STEELMAKING REFRACTORIES PRACTICALA TRAINING SEMINAR 27TH AIST CRANE SYMPOSIUM 29 September–1 October New Dates! WilliamOmni Hotel, Penn Pittsburgh, Pa., USA SHEET PROCESSING AND FINISHING LINES PRACTICALA TRAINING SEMINAR 27 September–1 October USA Ind., City Indianapolis, Indianapolis CentreSheraton Hotel, SEPTEMBER 2020 SUMMER 2020 DIGITAL TRANSFORMATION OF THE STEEL INDUSTRY SERIES WEBINAR WEEKLY 120 AUG 2020 I IRON & STEEL TECHNOLOGY I AIST.ORG integration and ML algorithm deployment. deployment. algorithm ML and integration system through methods transformation digital utilizing by smarter areas their make to how about more learning in interested are who background atechnical with those and Decision-makers ATTEND SHOULD WHO ef to methods and Strategies journey. transformation digital asuccessful in playing are humans roles essential the discuss speci the into dives series webinar Industry Steel the of Transformation Digital the 4.0, Industry of components different into insight and of overview an on focusing Forum Transformation Digital year’s last of success the Following process. steelmaking the of aspects all influence to potential the with concept abroad is It success. future companies’ steel for component acritical is Transformation Digital SERIES WEBINAR THE ABOUT explored through the high-quality presentations. presentations. high-quality the through explored also are involvement human and change cultural the manage to process, downstream and rolling) hot and (casting upstream steelmaking), and (iron- steel liquid from cases use and applications ML/AI covers series webinar The 4.0. Industry of application every nearly of heart Machine(AI). learning and arti f c t opics of machine learning (ML) and arti and (ML) learning machine of opics f n al product. In addition, the webinar series will will series webinar the addition, In product. al f c ial intelligence technology is the f c ial intelligence intelligence ial f c iently iently Digitalization Applications Technology Applications Committees. Digitalization and Subcommittee Applications/Sensors Electrical AIST’s ORGANIZED BY webinar. each following AIST.org at available be will videos on-demand Presenter-approved AIST.org/conference-expositions/webinars. at online Register non-members. as well as members attend, to everybody for free and open are webinars Industry Steel the of Transformation Digital The ATTEND HOW TO Visit AIST.org/byoyp for more information more for AIST.org/byoyp Visit Technology Training 121

DIGITAL TRANSFORMATION OF THE STEEL INDUSTRY Webinar Series

MACHINE-LEARNING INTEGRATED PRODUCTION DIGITALIZATION AND THE APPLICATIONS FOR PROCESS MANAGEMENT AND QUALITY DOUBLE-EDGED SWORD: CONTROL AND OPTIMIZATION IN THE AGE OF INDUSTRY 4.0 TRANSPARENCY IN STEELMAKING Wednesday, 12 August 2020 (10 a.m. EDT) Wednesday, 19 August 2020 (10 a.m. EDT) Heiko Wolf, PSI Metals GmbH Thomas Pfatschbacher, Primetals Wednesday, 5 August 2020 (10 a.m. EDT) This webinar discusses system architecture Technologies Austria GmbH Giovanni Bavestrelli, Tenova S.p.A. with the integrated production management The implementation of digitalization systems T his webinar discusses initiatives applied system (PMS) as the platform for in the steel industry has a signifcant to the control and optimization in steel innovation. Furthermore, the presentation potential to improve the overall productivity production plants: will highlight how an integrated PMS and stability in steel production. The • Application of machine learning (ML) to can evolve to enable new use cases with foundation for these improvements is frst to predict metallization and carbon content the example of a novel integrated quality generate a high transparency of production in a direct reduction plant. management system. and quality. Data is used to generate key • Application of convolutional neural performance indicators and is coupled with networks for automatic classifcation of human expertise and artifcial intelligence to scrap material in a steel plant. realize intelligent digitalization systems. But • Application of ML to data from a basic this full transparency is not always welcome oxygen furnace. at all levels of operators and experts. This • Application of ML to control cassette webinar shows an example of an intelligent penetration and strip tension in a tension digitalization system and deals with cultural leveler machine. topics. • Model to predict NOx emissions in a walking beam furnace.

Did You Know?

You Can View Past AIST Webinars on AIST.org Over the spring and summer, AIST’s Technology Committees hosted a variety of free webinars, covering various aspects of steelmaking technologies. Past webinar videos include: • How AI Is Increasing Production Quality in Steel Manufacturing • Ironmaking With Alternative Reductants • Making Sense of Maintenance 4.0 • Merging Process Knowledge and Artificial Intelligence to Find Hidden Value, Part 1

• Planning For Success — Project Baseline Scope and Budget Development and Management AUG • Production, Storage and Safe Handling of Hydrogen

• Technology-Driven Industrial Troubleshooting 2020

• You Asked For It: Your Questions Answered About SBQ Bar Cold Finishing IRON & STEEL TECHNOLOGY Visit AIST.org today to check out free webinars relevant to your work in today’s steel industry!

AIST.ORG 122

PLANT TOUR: STEEL DYNAMICS INC. – FLAT ROLL GROUP HEARTLAND DIVISION

ABOUT THE PROGRAM REGISTRATION INCLUDES This seminar will provide a comprehensive overview of process Welcome reception Sunday, breakfast and lunch Monday–Thursday, lines, including pickling, annealing, galvanizing, cleaning, plating, reception Tuesday, plant tour with bus transportation, and a course painting, skinpass rolling, leveling, slitting and special processes. workbook or flash drive including presentations. This seminar will also focus on terminal equipment for the entry and exit sections, strip quality assessment, industrial hygiene, safety, environmental concerns, overview of modeling for design and line control, operations, maintenance, and factors to consider in HOTEL ACCOMMODATIONS A block of rooms has been reserved at the Sheraton Indianapolis confguring a new process line. There will be many opportunities to City Centre Hotel. Please call the hotel at +1.888.236.2427 by discuss issues and solve problems during the question-and-answer 4 September 2020 to secure the AIST discount rate of US$149 per periods. night for single/double occupancy.

WHO SHOULD ATTEND ORGANIZED BY Those who would like to expand their knowledge and understanding AIST’s Rolling and Processing Technology Division. of process lines: new and transferred employees of steel producers; mechanical, electrical, process and metallurgical engineers; software and process control personnel; maintenance personnel; operators; and quality assurance specialists. Equipment manufacturers, employees from steel processors and steel service centers, suppliers, and customers of steel producers will also beneft from this seminar. AIST.ORG

I AIST MEMBERS AIST NON-MEMBERS US$1,195 US$1,410 IRON & STEEL TECHNOLOGY

2020

AUG Visit AIST.org/byoyp for more information Technology Training 123

SHEET PROCESSING AND FINISHING LINES A Practical Training Seminar

SUNDAY, 27 SEPTEMBER reviewed in greater detail. A brief discussion TUESDAY, 29 SEPTEMBER of materials used and how they influence - Registration equipment lifetime and maintenance Morning Sessions (8 a.m.) is included. Processing atmospheres, - Reception (5 p.m.) equipment control methods and safety - Continuous Hot-Dip Galvanizing considerations are also discussed. Gary Dallin, International Zinc Association Presentation on the coating section of a MONDAY, 28 SEPTEMBER - Skinpass/Temper Rolling modern hot-dip zinc coating line, including Mark Zipf, SMS group Inc. bath control, zinc wiping practices and Morning Sessions (8 a.m.) This presentation provides an overview galvanneal production. of skinpass and temper rolling, with an - Introduction, Opening Remarks emphasis on “why we are doing this” - Slitting and Sidetrimming Chad Donovan, SMS group Inc. and “how all this works.” Starting with G reg Santillo, ANDRITZ Herr-Voss a study of the material’s yielding and Stamco Inc. - Overview and Defnition of General deformation behavior, the strip’s surface This presentation will feature a description Terms structure, and the concepts of profle, of the slitting/sidetrimming process, Chad Donovan, SMS group Inc. shape and flatness, an understanding of typical layout and operation considerations. the key factors is established, warranting Challenges of market trends (materials, - Take Control of Safety the rolling deformation process and legislation) on designs and new solutions W endy Selph, Steel Dynamics Inc. – governing its objectives. Next, classical derived from these will also be discussed. Flat Roll Group Heartland Division rolling mill arrangements are reviewed, Proactively identifying and controlling and the discussion examines the force- - Tinplating — As Relevant Now as incidents that have the potential to cause loaded conditions/reactions occurring Ever signifcant injuries or fatalities. within the roll bite. The mill’s equipment is Vikram Trehan, Tata Steel then dissected with a focus on the general In the production of tinplate, the steel - Process Line Design Fundamentals arrangement and roll gap/shape actuators, base and the application of the tin coating Dave Withrow, Allor Manufacturing Inc. combined with the mill’s control strategies are independent of each other so that To ensure the success of a process line, and systems. Methods of performance theoretically any tin coating, or combination its performance requirements must be measurement/quality evaluation are of coatings, may be applied to any steel integrated fully with its setting, and the strip introduced. The presentation closes with a base. Thus the range of materials classifed driving power must be ample. comparison of differing mill formats and a as tinplate can run into many thousands. review of recent developments in enhanced Indeed, tinplate is available in more qualities - Incoming Material quality and productivity. than virtually any other light-gauge sheet Mark Zipf, SMS group Inc. metal product. - Cut-to-Length/Leveling Lines Afternoon Sessions (1 p.m.) G reg Santillo and Tom Uhric, ANDRITZ Herr- - Paint Lines

Voss Stamco Inc. N ikhil Kulkarni, Steel Dynamics Inc. – AUG

- Annealing Flat Roll Group Jeffersonville Plant 2020

Bill Lucas, Fives ST Adjourn (5 p.m.) I

This session will consider various aspects Afternoon Sessions (12:30 p.m.) IRON & STEEL TECHNOLOGY of steel annealing as it pertains to strip. The reasons for annealing, along with the - Plant Tour of Steel Dynamics Inc. – physical results possible with different Flat Roll Group Heartland thermal cycles, will be covered. Equipment Division employed along with methods of heating,

cooling and strip conditioning will be - Reception (5 p.m.) AIST.ORG 124 AUG 2020 I IRON & STEEL TECHNOLOGY I AIST.ORG SHEET PROCESSING AND FINISHINGLINES A Practical Training Seminar A Practical lexandre Nadeau, Tecnar Automation Tecnar Nadeau, lexandre GmbH Miebach Hugo Bellai, eni Taylor-Win Keller, att Process Atlantech Thiemann, avid Process Section leaning - Corp. Danieli Kremm, ay Stainless and —Carbon ickling - eld Inspection - Joining Coil for Welding aser - Resistance Using Joining oil - Sessions Morning 30 SEPTEMBER WEDNESDAY, provides over other technologies. presented. be will operation and purchase for range budget approximate an Finally, useful. more are they which for welds of type the cover also will presentation The explained. be will ofinconvenience using technologies these pro UT, pyrometry, laser (UT), testing ultrasonic (electromagnetic acoustic transducer inspection weld for used methods T A bene the and process the on details provide will and available, types other from machine welding of type this for differences key at look will It welding. for alaser using T D f and processing sheet in process joining coil the in utilized equipment and processes T M section. cleaning the in function process its and unit T Technology Inc. D J (MIG). gas inert metal and plasma, spot, Technology C Steel P W L Welding C ni his presentation will describe in detail each each detail in describe will presentation his his presentation will cover the various various the cover will presentation his will cover coil joining he presentation of overview an gives presentation his shing lines, including resistance seam and and seam resistance shing including lines, f l ometers). The advantages and and advantages The ometers). (8 a.m.) (8 f e ld Technologies Inc. Technologies ld f t s it s it ohn Ingram, Primetals Technologies Technologies Primetals Ingram, ohn Basics ontrol Houghton Quaker Williamson, tephanie - Regeneration cid Houghton Quaker Williamson, tephanie Steel of Process Chemical he reg Gutmann, ISRA Surface Inspection Surface ISRA Gutmann, reg of Inspection Surface utomated - - - Sessions Afternoon - defects are detected and de and detected are defects how and scan area and line of technologies camera to introduction abasic Receive also be discussed. will concepts safety and interface machine Human- lines. processing within actuators various of control logic programmable T LLC USA J S discussed. be will design equipment and control chemistry solution through performance cleaner optimize to ways learned, is framework general this Once chemical and mechanical strip cleaning. for framework general the understand to personnel operating for important enhancing cleaning it’s performance, Before painting. and coating metallic annealing, include which applications, these for necessary is surface metal clean and processing downstream various to prior residue surface metal fluids, process of removal S S be deployed in the environment production can system inspection automated an how bene the and do cannot ahuman that does it what of, consists asystem what inspections, surface G G C Acrylic Plating, Chromate, Phosphate, C A Performance Enhance to How and Cleaning Strip T Sheet and Finished Product Finished and Sheet A his presentation will describe describe will presentation his teel strip undergoes cleaning for the the for cleaning undergoes strip teel ain an understanding of automated onversion Coatings: Oiling, Oiling, Coatings: onversion

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–Flat Inc. Dynamics Steel Fulford, avid Preventive and redictive - ANDRITZ Robbins, Jim and Shaw rian Slitter and Mechanics tting - Sessions Morning THURSDAY, 1OCTOBER

blocked by space or the environment. the or space by blocked been previously have they where systems developed to deploy inspection automated being are that technologies new Understand of sheet processing and and processing sheet of thecontrol overall problem. shape/flatness T B reliability. equipment maximize to Division Heartland Group Roll –Flat Inc. Dynamics Steel at predictive maintenance practices adopted and preventive summarize will presentation This fails. equipment processing steel when industry.steel of Thousands dollars are lost the in particularly business, successful E Division Heartland Group Roll D requirements. the meet to needed are adjustments knife what understand and requirements quality acustomer’s to respect with edge metal acut evaluate to able be to knowledge the with attendees equip will presentation This steel. high-strength advanced to steel ranging from steel interstitial-free of grades and gauges all slitting and to sidetrimming principles engineering T Inc. ASKO B Q F Maintenance P Tooling forProcessing Modern Metal Sli quipment reliability is essential to any any to essential is reliability quipment his presentation gives an introduction into into introduction an gives presentation his he practical application of basic basic of application practical he (8 a.m.) (8 f n ishing lines. lines. ishing AUG 2020 I IRON & STEEL TECHNOLOGY I AIST.ORG 125

Non-Contact (3 p.m.) (1p.m.) Contact us today. Length & Speed Gauge

ikhil Kulkami, Steel Dynamics Inc. – Flat N Jeffersonville Group Roll Plant Kevin Siebeneck, United States Steel Corporation Stavros Fountoulakis, ArcelorMittal Global R&D Pro Mark Marietti, AK Steel – Dearborn Works S M Panelists: ® Afternoon Session - trip Quality Panel Discussion oderator: Conference Adjourn > Highest Accuracy > Permanently Calibrated > Reduce Waste > Fastest ROI M Series Pipe Tube Hose Rod Bar Hose Pipe Tube Products Better. Your Our Gauges Make www.ndc.com/metals-processing Problems with Measuring Problems with Measuring Moving, Bouncing Product? NEW Revolutionary! LaserSpeed his presentation will outline the methods Shipping P Br D Group Industrial Signode T of packaging historically and how they have changed. Discuss will briefly focus on the typical mill package, but will primarily focus on service centers.

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The steel industry’s top performingcalcium sulfonate grease challenges unique the for designed specially of continuous casters, furnaces, and mills.rolling daubertchemical.com here are a number of factors to be Du T considered when specifying the correct crane design for each application. This paper reviews those criteria. R Inc. Co. Handling Material

- ty Cycle and Other Considerations ich Warriner, Virginia Crane -Foley 126 AUG 2020 I IRON & STEEL TECHNOLOGY I AIST.ORG improvements and incidents in this area should attend. should area this in incidents and improvements in interested is and service crane and cranes for responsibility has who Anyone industry. the to services and equipment parts, supply who people those and management; and personnel maintenance and operations engineers; design and service safety, mechanical, applications, electrical, Plant maintenance staff; ATTEND SHOULD WHO ef increased or technology, in latest the forth brought has who individual the recognizing announced, be will winner Award Innovator Crane Totten Charlie the program, Symposium Crane the of part As modernizations. crane EOT in practices best and maintenance techniques; crane automationstructural technologies; and mechanical electrical, ergonomics; and practices work safe on focused presentations include will program two-day This industry. the in equipment and machinery durable reliable, most safest, the runways their and cranes (EOT) traveling overhead electric make to equipment and manufacturers engineering who strive consultants from crane maintenance personnel, crane manufacturers, experiences and information practical deliver will symposium The PROGRAM THE ABOUT improvement of heavy industrial cranes. cranes. industrial heavy of improvement in operational and maintenance practices for the continuous Visit AIST.org/byoyp for more information more for AIST.org/byoyp Visit AIST MEMBERS AIST US$895 f c iencies iencies Event Sponsors AIST’s Cranes Technology Committee. Technology Cranes AIST’s ORGANIZED BY occupancy. single/double for night per US$175 of rate discount AIST the secure to 2020 15 by September +1.800.843.6664 at hotel the call Please Hotel. Penn William Omni the at reserved been has rooms of A block ACCOMMODATIONS HOTEL including presentations. drive flash or workbook acourse and evening, Wednesday a dinner Thursday, and Wednesday lunch and breakfast reception, Tuesday INCLUDES REGISTRATION AIST NON-MEMBERSAIST US$1,140 ENGINEERIN G Technology Training 127

27TH CRANE SYMPOSIUM

TUESDAY, 29 SEPTEMBER - Why Crane Runways Don’t Have - Flat-Tread vs. Tapered-Tread Wheels Capacities Revisited - Registration A lex Tadla, Simmers Crane Design & R ich Warriner, Virginia Crane - Foley Services Co. Material Handling Co. Inc. - Welcome Reception (5 p.m.) A discussion of the many variables at play A condensed comparison of two previous in crane loading on runways. The number of presentations by proponents of both cranes, wheels, wheel base, crane spacing, designs. This presentation is designed etc., all have a major impact on the ability to provide attendees with information to WEDNESDAY, of the runway to support cranes of varying determine which design is best for their 30 SEPTEMBER capacities in multiple scenarios. application.

Morning Sessions (8 a.m.) - Important Updates to - The Making, Shaping and Treating AIST Technical Report No. 13 of Crane Wheels - 2020 Charlie Totten Crane Innovator Tim Bickel, CSD Structural Engineers Mark McGinley, Hall Industries Inc. Award: Crane Magnet Reliability: AIST Technical Report No. 13 — Guide This presentation describes the material Methods of Monitoring Crane for the Design and Construction of Mill selection, production processes, heat Magnet System Operation and Buildings was published in 1969 to provide treating practices, and inspection Condition owners, engineers and contractors with procedures commonly used in the Brian Kath, Nucor Steel–Berkeley information about the considerations unique production of crane wheels and wire rope Magnet systems are critical tools for many to mill buildings. The 6th edition is being sheaves. applications in the steel industry. Magnet prepared for release and includes many failures place employees at risk, and can important updates, including: Afternoon Sessions (1 p.m.) cause damage and impact productivity. This • Crane load cases and combinations presentation offers some tools that can to match current building code - Mill Roll Handling — Challenges, be used to verify that design parameters requirements. Equipment and Safety are not being exceeded and determine the • Updated crane runway girder design Considerations operational health of the complete magnet criteria. James Annab, Bradley Lifting system. • Expanded crane runway fabrication and This presentation will explore the challenges erection tolerance requirements. associated with mill roll handling, including - Crane Safety — We’ve Done the • An expanded section with guidance on effciency and considerations for facilities Thinking So You Don’t Have To structural inspections and reinforcement. with a large variety of roll confgurations. Kevin Hoffmeyer, Whiting Corp. T his session will further explain these It will also cover some of the equipment This paper will review the importance of updates and the benefts to building owners. options available to handle the variety of crane runway maintenance as it applies to different roll and chock confgurations, as safety, cost of ownership and reliability. It - Redundancy, Emergency Brake in well as best practices for determining a will share examples of impacts and data Hot Metal Cranes/Steel Mills solution that fts the end user’s process.

analysis used to identify root cause and Max Pauli, SIBRE Brakes GmbH Finally, it will cover some of the guidelines AUG

offer means of mitigating through robust This paper will provide an introduction to of safe mill roll handling, and the role that 2020

preventive maintenance programs. emergency brakes, including their design “hands off” handling plays in ensuring I

and function; why to use emergency brakes; safety for personnel. IRON & STEEL TECHNOLOGY and different types — hydraulic, magnetic, pneumatic. It will also cover redundancy - Identifying a Disaster Crane Project in cranes. Why redundancy? To provide Before It Happens a comparison to other cranes where it L arry Dunville and Tad Dunville, Overhead is already used; European standards for Crane Consulting LLC

cranes; steel mills are more sensible than Crane projects can be classifed by Pareto’s AIST.ORG port areas; and accident prevention. 80/20 Rule. About 80% are simple cranes, while 20% are projects you wish you had 128128128128 AUG 2020 I IRON & STEEL TECHNOLOGY I AIST.ORG ike Martin, Trutegra Martin, ike Solutions Industrial Nidec Winter, rian Inc. Xtek Schierenbeck, ill Corp./ McKinnon Columbus Kluck, im to Technology Intelligent dding - Technology Crane in nnovations - in Reliability Encoder mproving - aTrolley of Life the ncreasing - 27TH CRANESYMPOSIUM mapping of bulk inventory. programmable logic controller-based 3D and handling, coil eye-to-the-sky automated material, moving of avoidance obstacle real-time digging, crane bucket automatic includes technology crane automated New reality. augmented of use the and zones, avoidance/no-fly obstacle cranes, drive frequency non-variable for anti-sway includes technology new Manual/semi-auto operation. automatic fully for technologies new as well as cranes semi-auto and manual with operators aid to technologies T M downtime. encoder-related eliminate or reduce can that maintenance preventive and troubleshooting cover will seminar This cranes. overhead in uptime E B 5years. past the experienced zero bearing-related issues in has and change adesign underwent service its in changes bearing A g B a facility. A quick return on investment investment on return Aquick a facility. of uptime and productivity safety, the increase can solutions automated intelligent production operations. Incorporating T Magnetek J Your Overhead Crane Your Overhead A I Cranes Overhead I Housing Drive Gear the Changing Without Style Bearing and Geometry Gear the Changing by Drive Gear I situation. cluster a20% in do to what and 20% the avoid to how examine will and 20 the from 80 the separate that factors three identify will presentation This seen. never ncoder operation is critical to maintaining maintaining to critical is operation ncoder his presentation will cover emerging will cover emerging his presentation he overhead crane is the heart of of heart the is crane overhead he ear drive that experienced frequent frequent experienced that drive ear f r st 4 years of of 4years st

(cont’d) teven Lubeck, Laser-View Technologies to Sensors Non-Contact of se Roberts, Brian and Kirst ete Rail Transmission Data igh-Speed hillip Prokop, Technologies Laser-View Crane Overhead for onitoring - - - Sessions Morning THURSDAY, 1OCTOBER - to the operation of overhead cranes. overhead of operation the to to show how to intelligence technology bring and concepts introduce will presentation This floor. factory the on information application detailed and safety, operator and equipment increased afault, from recover to times faster maintenance, predictive by provided be can devices lifting enabled and technology- motion- intelligent through and more reliable operation. reliable more and safer establish to cranes on sensors using to approaches creative in interest sparking of intent the with provided be will Examples integration. the with related complication of levels relative the with along method, each by provided safety and reliability of level the on placed be will Emphasis discussed. be also will techniques New methods. sensing non-contact various of descriptions provide will presentation This methods. traditional with possible not flexibility operational of alevel provide and reliable more are solutions methods.mechanical Non-contact with handled previously applications to solutions non-contact provide that exist features. Sensor technologies safety providing of means mechanical utilized T S Conductix-Wampfler P P Overhead Cranes Overhead of Operation the in Reliability and Safety Improve and Provide U for Automated Cranes H andRacking Movable Obstacles Storage In-Plant With Collisions M Dinner raditionally, overhead cranes have have cranes overhead raditionally, (5:30–9 p.m.) (5:30–9 (8 a.m.) (8

ob Loomis, InVekTek LLC Handling Material ptimizing - ichael Sauer, Charter Steel –Saukville Steel Charter Sauer, ichael Installation Crane Scrap ROS 4T - and Automation, Janus Bruna, La dgardo Railroad With Crane Coil utomatic -

new hires has magni has hires new in increase sudden the and industry steel the of resurgence recent The operator. crane experienced least the of skills the T R overall productivity. productivity. overall improving and collisions of severity and of number the reducing operators, crane new of curve learning the accelerating by money save dramatically can that technologies new are there attainable, yet not still is automation viable While worse. getting it’s and error operator to due damage product in month per million US$1.5 incurs it reported leader industry One curve. learning the up get operators crane new f the during learned was what of a summary provide will It station. operating a remote Steel’s Charter to related rewards and challenges start-up and T M access. area and objects of detection positioning, intelligent zones, no-fly operation, housekeeping including functions, safety and automation state-of-the-art present will paper This Gallatin. Steel Nucor at cars railroad from coils remove automatically to functionality the with system retrieval and I Dave Reynolds, Nucor Gallatin Steel E O and Operation 3 Gallatin Nucor at Removal Coil A mplementation of an automatic storage storage automatic an of mplementation r he throughput of a plant is throttled by by throttled is aplant of throughput he his presentation discusses the installation installation the discusses presentation his st year of operation. of year st f r st crane to be run from from run be to crane st f e d the need to help help to need d the AUG 2020 I IRON & STEEL TECHNOLOGY I AIST.ORG 129

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BRAKES FOR Fairfield, OHIO USA Fairfield, 0900 Email: [email protected] www.forcecontrol.com Force Control Offers Industries slow-down zones, positioning assistance, zones, slow-down closed loop anti-sway, semiautomatic positioning, automatic operation, automatic storage and retrieval systems, and logistics optimizer and diagnostics tools. The incorporation of crane automation features increases productivity and also safety. This presentation discusses key aspects and projects. successful for recommendations STEEL MILL MOTORS www.forcecontrol.com/products/brakes Call 800-829-3244 OIL SHEAR Force ControlIndustries, Inc. Ph: 513-868- his presentation discusses real cases Automation FeaturesAutomation I T of crane automation features at Steel Dynamics Inc. – Flat Roll Group Columbus Division. New technology allows the reliable implementation of crane automation features even in harsh environments. Some of the crane automation features are simple anti-collision, no-fly zone and E Robbie Sturgill, Steel Dynamics Inc. – Flat Roll Group Columbus Division

dgardo La Bruna, Janus Automation, and - mplementation of Crane 130

PLANT TOUR: GKN-HOEGANAES CORP.

Refning and Refractory Systems Technology Committees strongly ABOUT THE PROGRAM believe that this course provides the basic knowledge for a better Secondary steelmaking refractory maintenance is vital to both understanding of secondary steelmaking, refractory and insulating productivity and safety in a meltshop and caster. It is important systems. for those involved to have a thorough understanding of the basic concepts of refractory system design. Consultants, suppliers and recognized industry experts have developed a curriculum to educate REGISTRATION INCLUDES attendees on the following topics: refractory raw material selection; Tuesday and Wednesday breakfast and lunch, Tuesday reception, properties of refractories, application and limitations of refractories; Thursday breakfast, plant tour with bus transportation, and a theory and application of insulation; design and application of course workbook or flash drive including presentations. stir plugs, lances and slidegates; free opens, refractory handling, installation and pre-heating; ladle secondary steelmaking — LMF; and casting requirements and wear mechanisms. HOTEL ACCOMMODATIONS Presentations will provide data from steelmaking operations, A block of rooms has been reserved at the Holiday Inn Nashville and attendees will beneft from the practical experience of the Vanderbilt. Please call the hotel at +1.877.327.4707 by 14 September presenters, including the application of the latest tools and 2020 to secure the AIST discount rate of US$169 per night for techniques being used. Open discussions will allow participants single/double occupancy. to gather additional information and network with attendees and instructors. ORGANIZED BY WHO SHOULD ATTEND AIST’s Ladle & Secondary Refning and Refractory Systems This conference is intended for steelmaking operations personnel, Technology Committees. maintenance and supervisory employees. Refractory suppliers and service suppliers should also attend. The AIST Ladle & Secondary AIST.ORG

AIST MEMBERS AIST NON-MEMBERS US$845 US$1,090 IRON & STEEL TECHNOLOGY

2020

AUG Visit AIST.org/byoyp for more information Technology Training 131

SECONDARY STEELMAKING REFRACTORIES A Practical Training Seminar

MONDAY, 5 OCTOBER - Ladle Burner Technology and the steel in the ladle and their impact on Controls refractories. - Registration (4 p.m.) Dale Smith, Honeywell Combustion Safety - Advancements in Infrared - Tap-to-Cast Operations Technology TUESDAY, 6 OCTOBER Harriet Dutka, SANGRAF International John Lewis, Connors Industrials Inc. This presentation is a brief overview that This presentation will cover an examination Morning Sessions (8 a.m.) focuses on answering the “whys” of certain of newly developed infrared technologies practices and procedures in steelmaking. If for practical secondary processing Keynote Presentation you are new to steelmaking or are in a non- applications. technical role, this presentation will answer - Raw Materials, Bricks and Shapes, many of the questions you would like to ask. - Ladle Laser Program and Monolithics Michael Bonin, Vesuvius Ruth Engel, Refractory Consulting Services - Panel Discussion and Reception T he seminar will begin by presenting the Moderator: Afternoon Sessions (1 p.m.) raw materials used in the manufacture Jimmy Barrett, Allied Mineral Products Inc. of refractories, why they are used, their Panelists: - Stir Plugs, Lances, Slidegates and availability and characteristics. Using Rob Doty, IMACRO Inc. Tundish Gates this information, the raw materials will be Harriet Dutka, SANGRAF International combined to make bricks or shapes and the Helmut Oltmann, Nucor Steel–Berkeley - Tundish Refractory role the different components play on their Fred Adkins, HarbisonWalker International properties will be discussed. This discussion Adjourn (5 p.m.) This presentation will focus on tundish will extend to monolithics, where parameters design. It will cover the composition design like installation and dryout will be covered. of the refractory lining materials, the design WEDNESDAY, 7 OCTOBER of the arrangement of flow modifers, and - Refractory Brick Production the effect they have on steel and the way it Korey Skala, HarbisonWalker International Morning Sessions (8 a.m.) is processed in the tundish. Production of refractory bricks from raw material to fnished product. - Safety: Past/Present/Future - Principles of Mold Flux Technology John Panconi, BISCO Refractories Inc. - Ladle Construction Design and A view of where we were with safety, how - Flow Control Products Insulation things are now and what the future holds. Josh Kaser, RHI Magnesita Rob Doty, IMACRO Inc. This presentation will focus on isostatic This presentation will discuss the many - Refractory Materials Testing and refractories that are used at the caster options in ladle refractory design. The Product Selection during continuous casting. basics of heat transfer will then be covered, R akesh Dhaka, U. S. Steel Research and

from molten steel through refractories to Technology Center Adjourn (5 p.m.) AUG

ladle shells, followed by insulation choices, Standard test methods and their application 2020

how they affect ladle shell temperatures and in evaluating and selecting refractory I

refractory expansion dynamics. materials will be discussed. THURSDAY, 8 OCTOBER IRON & STEEL TECHNOLOGY

Afternoon Sessions (1 p.m.) - Secondary Steelmaking Process Morning Sessions (8 a.m.) — LMF - Ladle Pre-Heat and Handling Helmut Oltmann, Nucor Steel–Berkeley - Plant Tour of GKN-Hoeganaes Jimmy Barrett, Allied Mineral Products Inc. This presentation provides a review of Corp.

Steel ladles will be covered in detail, the ladle metallurgy furnace processes AIST.ORG including pre-heating, refractory wear to modify chemistry and temperature of Conference Adjourn (Noon) mechanisms and measuring options. 132 AUG 2020 I IRON & STEEL TECHNOLOGY I AIST.ORG represented. types machine all with principles, casting general toward geared be will presentations The products. as-cast of quality the impact that variables major review to wishing others as well as services, and consumables casting of suppliers area, casting the in work to bene be also would It employee. casting frontline the for designed been has seminar training This ATTEND SHOULD WHO future! the of steelmaker educated and informed progressive, the for amust is course This background. technical a for need the without ensured is process the of understanding Byachievingconcepts. the proper teaching balance, attendee theoretical the introducing while blooms, and billets slabs, casting of aspects practical the discuss to is program the of focus key The operator. frontline the steelmaking: of heart the targets program Continuous Casting Technology Committee, this informative Developed and presented with the talented resources of the PROGRAM THE ABOUT Visit AIST.org/byoyp for more information more for AIST.org/byoyp Visit AIST MEMBERS AIST US$845 f c ial to individuals newly assigned assigned newly individuals to ial PLANT TOUR: TIMKENSTEEL CORP. CLEVELAND TIMKENSTEEL TOUR: OR ARCELORMITTAL PLANT AIST’s Continuous Casting Technology Committee. Committee. Technology Casting Continuous AIST’s ORGANIZED BY occupancy. single/double for night per US$105 of rate discount AIST the secure to 2020 19 by September 298 ext. +1.216.524.8050, at hotel the call Please -Independence. South Cleveland Inn Holiday the at reserved been has rooms of A block ACCOMMODATIONS HOTEL presentations. including drive flash or workbook acourse and transportation, bus with tour plant Thursday, breakfast Wednesday, and lunchesBreakfasts Tuesday and Wednesday, reception INCLUDES REGISTRATION AIST NON-MEMBERSAIST US$1,090 Technology Training 133

CONTINUOUS CASTING A Practical Training Seminar

MONDAY, 12 OCTOBER - Mold Copper Alloys, Mold Design - Mold and Copper Maintenance and and Influence of Operating Factors Coating Technologies - Registration (4–6 p.m.) on Mold Life Chad Donovan, SMS group Inc. I an Bakshi, KME America Inc. Discussion of the various types of Information as to the requirements that continuous caster molds and proper TUESDAY, 13 OCTOBER molds must fulfll when used on a steel maintenance practices, including a variety continuous casting machine, the copper of mold coating options available to the Morning Sessions (8 a.m.) alloys used, design details, various industry. operation factors that affect mold life and - Historical Perspective of typical mold problems encountered will be - Caster Roll Maintenance and Continuous Casting presented. Overlay Technologies J eff Brower, Primetals Technologies - Continuous Casting Design and - Caster Quality Defects and Their USA LLC Technology (Slab and Long Potential Causes Caster roll and segment life can be Products) R on O’Malley, Missouri University of signifcantly increased through the Science and Technology use of customized weld overlays and - Principles of Mold Flux Technology The surface and internal quality of base materials. This session details the — An Operator’s Guide to continuously cast slabs and billets is operational impact on caster rolls and Continuous Casting Flux intimately linked to the caster design and technologies developed to improve roll D arrell Sturgill, IMERYS Steelcasting to the operating and maintenance practices performance. USA Inc. employed in the continuous casting Attendees will receive an overview of the process. Common causes for fve classes Afternoon Sessions (Noon) design, production and application of of continuous casting defects (longitudinal continuous casting fluxes. cracking, transverse cracking, slivers - Plant Tour of TimkenSteel Corp. or and lamination defects, internal cracking, ArcelorMittal Cleveland - Initial Solidifcation and Oscillation and segregation defects) will be reviewed Mark Formation and linked to these design and practice - Panel Discussion and Reception influences. Moderator: Afternoon Sessions (1 p.m.) Jeff Brower, Primetals Technologies Adjourn (5 p.m.) USA LLC - Sources of Reoxidation and Why to Panelists: Avoid Ian Deeks, Nucor Steel–Arkansas R on O’Malley, Missouri University of WEDNESDAY, 14 OCTOBER Ron O’Malley, Missouri University of Science and Technology Science and Technology To produce high-quality cast products, Morning Sessions (8 a.m.) steel must be protected from reoxidation. Adjourn (5 p.m.)

Reoxidation can occur in the ladle, at - Breakouts and Their Prevention AUG

secondary ladle metallurgy operation, and Bill Emling, SMS group Inc. 2020

also in the transfer operations from ladle This presentation is based on the chapter in I

to tundish and tundish to the mold. Various The Making, Shaping and Treating of Steel, IRON & STEEL TECHNOLOGY techniques will be described that can be Casting Volume. A review will be given of used to minimize reoxidation. various causes for caster breakouts and the systems used to alarm and prevent breakouts.

AIST.ORG 134134134134 AUG 2020 I IRON & STEEL TECHNOLOGY I AIST.ORG A Practical Training Seminar A Practical ark Cook, Yates Industries Inc. Industries Yates Cook, ark an Deeks, Nucor Steel–Arkansas Modes —Failure Hydraulics aster - Operations Caster Bloom and illet - Sessions Morning THURSDAY, 15 OCTOBER CONTINUOUS CASTING reconditioning programs. cylindermaintenance and effective preventive modes, failure casters, in T M and bloom casters. L I and Maintenance Preventive C and Maintenance B essons learned in the operations of billet billet of operations the in learned essons his discussion will cover cylinders used used cylinders cover will discussion his PRODUCING GRAPHITE (8 a.m.) (8 WWW.EPMGROUP.RU SINCE 1954

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tephen Swoope, Delavan Spray Spray Delavan Swoope, tephen and Cooling Secondary aster - Company Ecolab An Water, treatment program. treatment asuccessful of implementation for practices best and indicators leading water cooling secondary and primary at alook include also will It function. and types nozzle basic offer will presentation This today. available rate productivity highest the with product quality a ensure to dispersion heat and dynamics fluid Using steel. cooling for used products of maintenance and selection on support technical detailed with processes casting O Technologies, and John Ciof John and Technologies, S Water Treatment Treatment Water C verview of spray nozzles used in the the in used nozzles spray of verview & SALES WITH CONTINUOUS CUSTOMER SUPPORT AND TECHNICAL SERVICE ESTABLISHMENT OF A U.S. LEGAL ENTITY, LOCAL WAREHOUSING FURNACES, ROBOTIC MACHINING & LASER INSPECTION CENTER CAPITAL EXPENDITURES TO INCLUDE NEW MODERN BAKING SUPPLYING THE HIGHEST QUALITY PRODUCTS LONG TERM COMMITMENT QUALITY &CONSISTENCE # BASED PRODUCTS GRAPHITE &CARBON- MANUFACTURER OF RUSSIAN THE LEADING 1 f , N ALCO ALCO TOP10 PRODUCTS AND CARBON OF GRAPHITE MANUFACTURER GLOBALТОР 10 Conference Adjourn Adjourn Conference Corp. NSK Brda, aul —Types of Bearings aster - practices. failure modes and maintenance best T P Preventive Maintenance FailureBearings, Modes and C ypes of bearings used in casters, common common casters, in used bearings of ypes

(Noon) > OVER THE WORLD COUNTRIES ALL MORETHAN 60 PRODUCTION TO WE EXPORT OUR 60 AUG 2020 I IRON & STEEL TECHNOLOGY I AIST.ORG 135 136 AUG 2020 I IRON & STEEL TECHNOLOGY I AIST.ORG operations/maintenance personnel. personnel. operations/maintenance and planners; strategic personnel; environment and safety health, managers; environmental engineers; at aimed is course This ATTEND SHOULD WHO course. the of goal aprimary be will systems their of effectiveness the evaluate better to tools new with attendees Equipping discussed. be also will permitting and reporting monitoring, ef increased for practices best and solutions offer will highlighted studies Case systems. capture emissions air of demands encompassing all- the navigate attendees help to strategies and equipment technologies, on focus will conference This ever. than complex more made planning, strategic compliance, monitoring and operations have regulations Agency Protection Environmental U.S. evolving and market steel the in changes Global endeavor. challenging a is industry steel the in requirements emissions air Meeting PROGRAM THE ABOUT and upgrades/retro and life, including design, operation, maintenance, troubleshooting Visit AIST.org/byoyp for more information more for AIST.org/byoyp Visit f c iency at all stages of air pollution control equipment equipment control pollution air of stages all at iency f t s. Effective strategies for compliance, data data compliance, for strategies Effective s. AIST MEMBERS AIST US$845 AIST’s Environmental Technology Committee. Committee. Technology Environmental AIST’s ORGANIZED BY presentations. including drive flash or workbook acourse and transportation, bus with tour plant Wednesday, breakfast Tuesday, and Monday lunch and breakfast Reception, INCLUDES REGISTRATION AIST NON-MEMBERSAIST US$1,090 PLANT TOUR: NEFCO TOUR: PLANT AUG 2020 I IRON & STEEL TECHNOLOGY I AIST.ORG 137 (Noon) (8 a.m.) Technology Training Technology P R Conference Adjourn WEDNESDAY, 21 OCTOBER 21 WEDNESDAY, Morning Sessions - of NEFCOlant Tour - eturn From and Plant Tour (1 p.m.) (8 a.m.) (4:45 p.m.) et Scrubber Operation and eat Transfer, Controleat Transfer, and the npaved Roadways Fugitive Dust missions Monitoring Systems for an Fundamentalsan E Steelthe Industry W Maintenance U Emissions Control and Wrap-Up H Impact on System Design and Operation F T Emissions for Testing the Iron and Steel Industry K Cooling - - - Adjourn - Afternoon Sessions - - - he Nuts and Bolts of Stack TUESDAY, 20 OCTOBER TUESDAY, Morning Sessions - eys to Effective Evaporative (1 p.m.) (8 a.m.) (5 p.m.) (6 p.m.) iency c st Handling — Mechanical f verview and Evolution of Broken sing Computational Fluid apture of Pollutants: anel Discussion ilter Media and Technologies: Can Reception Screws, Rotary Valves, Double Dumps, Air Locks and Seals P Du Considerations, Overview of Baghouse Cleaning Processes and Reverse Air O Bag Detectors: Can This Help Meet Requirements?EPA B Bag Selections Affect How EPA Met? Are Requirements F C Thermodynamics, Plume Behavior Collectionand Hoods What Is Used and Why U Capture Determine Dynamics to Ef O

ENVIRONMENTAL SOLUTIONS: MEETING EPA AIR EMISSION REQUIREMENTS AIR EMISSION EPA MEETING SOLUTIONS: ENVIRONMENTAL - - Adjourn - - aghouse Design Features — Afternoon Sessions - - - - verview of Control Techniques: - Morning Sessions MONDAY, 19 OCTOBER 19 MONDAY, 138 AUG 2020 I IRON & STEEL TECHNOLOGY I AIST.ORG oxygen, as well as selection of refractory materials will be covered. be will materials refractory of selection as well as oxygen, pure of use and recovery thermal like techniques optimization energy advanced diagnostics, and sensors of use the as such topics provided to complement theoretical analysis. Applied combustion be will samples equipment hands-on and studies Case highlighted. be will controls and hardware of relationship The systems. their of optimization and upgrade for techniques latest the to exposure given be also will Attendees equipment. system combustion their of condition the understand and assess to background operating and knowledge basic the students give to be will seminar the of goal The among participants. experiences of sharing and discussion active encourage to setting aclassroom in held be will seminar The emissions. environmental design or installation of combustion equipment in steel mills. mills. steel in equipment combustion of installation or design maintenance, operation, the in involved directly are who technicians and engineers, for supervisors, is designed seminar training This ATTEND SHOULD WHO rami have plant asteel in systems thermal the of operation and maintenance proper Additionally, processing. thermal for fuel is component alarge this, of and energy, is steel producing of cost the of 20% Approximately PROGRAM THE ABOUT Visit AIST.org/byoyp for more information more for AIST.org/byoyp Visit f c ations on safety, pro safety, on ations AIST MEMBERS AIST US$845 f t ability, product quality and and quality product ability, AIST’s Energy & Utilities Technology Committee. Committee. Technology & Utilities Energy AIST’s ORGANIZED BY occupancy. for single/double night per US$139 of rate discount AIST the secure to 2020 5October by +1.724.776.6900 at hotel the call Please Pittsburgh-Cranberry. Hotel Hilton by DoubleTree the at reserved been has rooms of A block ACCOMMODATIONS HOTEL presentations. including drive flash or workbook acourse and transportation, bus with tour plant lunch, Tuesday reception, Tuesday–Thursday and continental breakfast INCLUDES REGISTRATION training would also bene also would training This quality. air for responsible are who engineers environmental fuels utilization, purchasing personnel who procure utilities and manage who personnel utility personnel, safety managers, risk Other attendees who would bene would who attendees Other responsible for energy ef energy for responsible PLANT TOUR: BLOOM ENGINEERING CO. INC. CO. ENGINEERING BLOOM TOUR: PLANT AIST NON-MEMBERSAIST f f t c US$1,090 iency and optimization on-site. on-site. optimization and iency he energy engineers/managers who are are who engineers/managers energy he f t f rom this seminar include include seminar this rom Technology Training 139

STEEL MILL COMBUSTION AND THERMAL SYSTEMS

TUESDAY, 27 OCTOBER - Solving Your Burning Problems: Afternoon Sessions (1:30 p.m.) Combustion Sensors and Diagnostics Morning Sessions (8 a.m.) V i Rapp, Lawrence Berkeley National - Plant Tour of Bloom Engineering Laboratory Co. Inc. - Combustion and Burner This presentation will review important Fundamentals process variables and related sensors - Roundtable Discussion Anup Sane, Air Products needed to evaluate and diagnose a combustion system. Specifcally, this Adjourn (5 p.m.) - Blowers and Fans presentation will discuss how to use the Jim Conway, New York Blower Co. equipment to control the combustion F undamentals of fan performance, operation process and how to diagnose potential THURSDAY, 29 OCTOBER and control in combustion systems. problems. It will also include an overview of technologies and equipment used at Morning Sessions (8:30 a.m.) - Helping Address the World’s Most Berkeley Lab. Critical Flow Measurement Needs - CFD Application in the Steel Industry D avid Taplin and Mark Sagstetter, Emerson - Environmental Emissions 1: Fundamentals and Applications, Automation Solutions Michael Cochran, Bloom Engineering Co. Inc. Blast Furnace, EAF and Reheat This presentation will discuss flow Furnace measurement best practices and review - Reception at DoubleTree by Hilton C henn Zhou, Center for Innovation Through common precision flow measurement Hotel Pittsburgh-Cranberry Visualization and Simulation, Purdue technologies. University Northwest Adjourn (5:45 p.m.) The Steel Manufacturing Simulation and - Combustion System Reliability Visualization Consortium (SMSVC) develops Improvements Disguised as Safety and implements technical solutions Code Compliance WEDNESDAY, 28 OCTOBER through the integration of advanced J ohn Puskar, Prescient Technical computer simulation and visualization Services LLC Morning Sessions (8 a.m.) technologies for the value chain of U.S. For those who operate fuel-fred equipment, steel manufacturing. Energy effciency is NFPA 86, The Standard for Ovens and - Advanced Energy Optimization a major focus in SMSVC research. To-date Furnaces, should be their best friend. Heat Recovery Systems Oxy-Fuel research outcomes include improved energy Embracing compliance can result in safer Combustion effciencies and identifcation of energy operations, improved reliability and energy Michael Cochran, Bloom Engineering Co. Inc. reduction opportunities. savings. This standard applies to all ovens This talk will explore existing techniques to and furnaces within steelmaking and enhance energy effciency. - CFD Application in the Steel Industry processing facilities. In addition to covering 2: Oxy-Fuel Combustion Applications other major parts of the standard, best - Role of Refractory in Reheat Xiaoyi He, Air Products and Chemicals Inc.

practices will be provided that describe Furnaces Computational fluid dynamics modeling AUG

reliability enhancements to design failure G reg Odenthal, International Technical plays an important role in improving 2020

out of combustion systems and fuel trains. Ceramics LLC (ITC) effciency and reducing operational risks I

This presentation provides attendees with from the oxygen-fuel combustion. The IRON & STEEL TECHNOLOGY Afternoon Sessions (1 p.m.) an understanding of the role and importance presentation will discuss the best practice of refractories in a reheat furnace and how and previous experience by Air Products in - Combustion System Maintenance they relate to fuel consumption and energy this feld. loss as well as product quality. - Combustion Control Components/ - Combustion/Thermal

Hardware/Burner Management - Energy Effciency and Economics Troubleshooting Case Studies AIST.ORG Systems - Steel Mill Combustion and Thermal Conference Adjourn (1 p.m.) Systems 140 AUG 2020 I IRON & STEEL TECHNOLOGY I AIST.ORG engineers. engineers. control technicians and and component supervisors, designers and quality personnel, shop machine personnel, sales and marketing steel industry, steel the to suppliers materials and equipment supervisors, and workers production industry steel and Iron ATTEND SHOULD WHO the on treatment and shaping making, of effects the and produced, is it how is, steel what of understanding an designing products, engineering, and sales, have construction industry, steel the to materials and equipment supplying mills, rolling operating steel, and iron producing in involved employees that essential is It performance. and cost application, design, product to critical are steel of treating and shaping making, The years. 25 last the during improvements technological many with centuries, many over evolved has steel of production modern The PROGRAM THE ABOUT manufacturing, properties andmanufacturing, applications. properties steel of aspects technical the about more understand to aneed have but processing downstream or quality-added rolling engineering, metallurgical in background atechnical have not do who those to knowledge essential provides course This products. steel of Visit AIST.org/byoyp for more information more for AIST.org/byoyp Visit AIST MEMBERS AIST US$845 f n al performance performance al workbook or flash drive including presentations. including drive flash or workbook Pa., USA Pa., Pittsburgh, University, Mellon Carnegie Department, Engineering Webler,Bryan professor, assistant Science and Materials USA Pa., Farrell, USA, NLMK engineering, metallurgical and quality of director Fonner, Frank INSTRUCTORS of choice transportation; bus with tour plant reception; Wednesday lunch; and breakfast Thursday and Wednesday INCLUDES REGISTRATION Re Steel of Treating and Shaping following volumes from the 11th edition: 11th the edition: from volumes following f n ing, Casting, Flat Products Products Flat Casting, ing, AIST NON-MEMBERSAIST US$1,090 ® CD-ROMs, which include one of the the of one include which CD-ROMs, and and Long Products; Long Ironmaking, Steelmaking/ Ironmaking, and a course acourse and The Making, Making, The AUG 2020 I IRON & STEEL TECHNOLOGY I AIST.ORG 141 F ngineering

c e f (5 p.m.) al properties will n f al mechanical properties. n f ni f Technology Training Technology D Rolling, Annealing and Coating S Consistency and Tests Properties, quality and properties. The importance of the reheating process and how it affects subsequent rolling and quality will be discussed. Billets and blooms will also be reviewed. be explained. An introduction of the methods of testing theproperties of steel — including tensile, toughness and fatigue testing — will lead into discussions of the importance melting, of casting, rolling and forming on the The importance of selecting alloys and processing routes for speci S treating and coating, will be reviewed. Basic steel heat treatment concepts of quenching, tempering, case hardening and in-process annealing will be introduced, along with the effects they have on steel microstructure and properties. Surface coating techniques, coatings, other and galvanizing including will be discussed. C mechanical properties of steel alloys and grades will be explored. The effects of different alloying elements on steel manufacturing and applications to achieve desired properties properties desired achieve to applications explained. be will - ownstream Processing —Cold teel techniques,shing including heat Conference Adjourn - teel —Types, Mechanical haracteristics, applications and al n f ation and and ation c ation on f c f (1 p.m.) (Noon) (8 a.m.) (Noon) (5 p.m.) c (6 p.m.) f Batch Casting Batch I As-Rolled End Products and Product Applications H Defects Hot-Rolled and Incoming C Reception S L Plant Tour Inclusion formation, modi Inclusion T to the theory of rolling and the effects of deformation processing on product product quality will be discussed. The effects of tundish and mold metallurgy on product quality will be explained, along with casting defect causes and methods of prevention. T manufacturing will be introduced. The requirements and methods to produce these products will be reviewed. T T casting processes from billets, blooms, and slabs to near-net-shape processes for thin slabs, strip, beam blanks and wire will be reviewed. removal discussed. be will

his section will provide an introduction ation Fundamentals and - he various end products of steel Afternoon Sessions - he importance of solidi - he history and evolution of continuous ntroduction —Hot-Rolled ot Rolling —Reheat, Hot Rolling, - Adjourn NOVEMBER 5 THURSDAY, Morning Sessions - ontinuous Casting of Steel Afternoon Sessions - olidi unch and Depart for (8 a.m.) r f S I and Treating of Steel and History of Industrythe O B refractories will be introduced, along with reasons for using each. The interaction of refractories and slags with metal will be explored, including methods of reducing refractory wear and quality improvements. The use of ladle metallurgy treatment and furnaces will be explained. secondary other behind principles The steelmaking techniques explained, be will including degassers and argon oxygen decarburization steelmaking for the production of high-quality steels such as ultralow-carbon and stainless steels. T produce iron and steel from raw materials, including ores and recycled materials. Processes reviewed include the blast furnace, direct reduction, ferrous scrap production, basic oxygen steelmaking and electric furnace steelmaking. Important gas, slag and metal reactions will be explained, as well as the impacts of the processes on energy and the environment. The effects of the different processing techniques will be explained, and future iron- and steelmaking explored. be developments will T the technologies used to produce steel today and the evolution of world steel chemistry of general The production. steel is introduced to help illuminate the principles of iron- and steelmaking. This session ends with a brief history of metals production and an introduction to early processes. steelmaking and iron-

asic, acid, and neutral slags and - econdary Metallurgy - ronmaking and Steelmaking his session explains the techniques used to he - verview of the Making, Shaping st session provides an overview of Morning Sessions WEDNESDAY, 4 NOVEMBER 4 WEDNESDAY, THE MAKING, SHAPING AND TREATING OF STEEL: 101 STEEL: OF TREATING AND SHAPING THE MAKING, 142 AUG 2020 I IRON & STEEL TECHNOLOGY I AIST.ORG After graduating college in 1978 college in graduating After Tell me a bit about your abitTell about me from Indiana University of Penn University Indiana from involved in the steel industry? steel the involved in background. How did you How get did background. sylvania with a degree in business business in adegree with sylvania Works; and J&L Specialty. In the mid-1990s, Wedmore was promoted Wedmore was mid-1990s, the In Specialty. J&L and Works; Allegheny Ludlum. In 1990, Vesuvius acquired Flo-Con Systems Systems Flo-Con acquired Vesuvius 1990, In Ludlum. Allegheny David Wedmore David Flow Control Business Unit. In 2008, he was promoted to regional promoted regional to he was 2008, Unit. In Business Control Flow to Pittsburgh district manager. In the early 2000s, when Vesuvius’ 2000s, early the manager. In district Pittsburgh to ton Steel, J&L Aliquippa, AK Steel – Butler Works (ARMCO) and and Works –Butler Steel (ARMCO) AK Aliquippa, J&L ton Steel, Con Systems in 1980 as an account manager mainly supporting field supporting mainly account manager an 1980 as in Systems Con Control and Advanced Refractories, Wedmore stayed on with the the Wedmore on with stayed Refractories, Advanced and Control operations in Western Pennsylvania for companies such as Washing for such as companies Western Pennsylvania in operations as Weirton Steel; U. S. Steel – Mon Valley Works, Edgar Thomson Thomson U. –Mon Steel Works, Weirton Valley Steel; Edgar S. as such for customers account responsibility Wedmoreand assumed steel sales division branched out into two main business units, Flow Flow units, business main out into two branched division steel sales sales manager – East Region Flow Control. Flow Region –East manager sales David Wedmore David began his steel industry career with Flo- with career steel industry his began 38-Year Member Life - was not something I wanted to con to Iwanted not something was tinue to do for the long term. As As do to for long term. the tinue pany. I quickly realized that this this that realized pany. Iquickly luck would have it, in 1980luck one have in would it, of com for afinance manager lection and finance, Iasa endedcol finance, up and - - - - Wedmore and his family. his and Wedmore Jim Waddell. One thing led to led to Waddell.Jim One thing ImetJack’s Jack’s wedding, boss was demanding, it was rewarding rewarding it was demanding, was was a new employee of Flo-Con Sys anew employee ofwas Flo-Con tems. In the summer of 1980, at summer the In tems. the need for a better ladle pour need for ladle the abetter helped which technology, drive to continuous casting blossoming the of days early the in was This tems. product was ladle slidegate systems, systems, slidegate ladle product was main Systems’ Flo-Con system. ing recently employed by Flo-Con Sys employedrecently byFlo-Con my good friends, Jack Petrick, was was Petrick, Jack friends, my good and in those first years I helped years first those in and 1980 I bySeptember and another steel industry. Although the work the Although steel industry. the across were underway that sions conver gate ladle many the support - - - - 143

AIST golf outing (left to right): Angelo Bianco, Matt Widders (TimkenSteel), Brett Ferrara and Wedmore. JSW startup (right to left): D.J. Morris, Angelo Bianco, Wedmore, Alex Allen and Craig Macdonald, all working for Vesuvius as part of the startup team.

in helping to shape my career and I thank them all for their business sense. support. Notables include: Joe Kusic from Washington Steel; Hoopie and provided a sense of adventure From the customer side, many of Majors from J&L Aliquippa; Ralph unlike anything I had ever experi- my early contacts helped shape my Deabrunzzo from AK Steel – Butler enced. I quickly fell in love with our products, the steel industry and the rewarding challenges it provided.

Was there a person or a group of people who served as a mentor to you in the early stages of your career? In addition to Jack Petrick and Jim Waddell, my first boss was Jim Engel. He had a larger-than-life personality (as it seemed many people in the steel industry possessed). He helped instill in me that hard work and perseverance will pay off. We AUG worked hard and played hard, and 2020

managed to have fun along the way. I

We used to wear the famous Pitts- IRON & STEEL TECHNOLOGY burgh Steelers coach Chuck Knoll’s saying on our hard hats: “What- Wedmore’s district manager team (left to right): Brett Ferrara, Angelo Bianco, Don Dean, Wedmore ever It Takes.” During my district and Dennis Brady. manager years, I reported to Lou Sebastian, who was a big influence

AIST.ORG 144 AUG 2020 I IRON & STEEL TECHNOLOGY I AIST.ORG Valley Works, Edgar Thomson Plant. Thomson Works,Valley Edgar AIST is not only a great organization organization not agreat is only AIST & Steel Society (ISS) and heard heard and (ISS) Society & Steel Works; John Nieman from Weirton from John Nieman Works; My first event was the ISS Pitts ISS the event was My first Bob Trunzo from U. from Trunzo Bob What was your first level first your was What about hear you first did When Early in my career I joined the Iron Iron Ijoined the my career in Early DiCiccio from J&L Specialty; and and Specialty; J&L from DiCiccio with friends and colleagues, and and colleagues, and friends with which had a tremendous turnout turnout atremendous had which your first event?your first wealth of industry information via via information of industry wealth to discuss business (or not) was an (or an not) business was discuss to through my industry contacts what what contacts my industry through this organization is invaluable to to invaluable is organization this Iron & Steel Technology &Steel Iron monthly the ISS/AISE how? and How has AIST membership membership AIST How has burgh District’s annual golf event, golf annual District’s burgh invaluable experience. experience. invaluable in grind daily the from people away participated in many of the local local of the many in participated by join to encouraged I was it was. information you can pick up you from can information AISTech. The and Conferences, ing people, it promotes the sharing of a people, it sharing promotes the much more than that. To that. these much see more than but it was great, was golf the course, it aworkday.” call Of sold. Iwas every year. Here I was, a young lad, a young lad, year. Hereevery I was, outings. outings. golf District Pittsburgh the course, of conference and, exhibition, and technical annual meetings, chapter over years my and management the one’s development. career magazine, the Technology the Train magazine, organization? Do you remember you remember Do organization? theof involvement in get to be away from the mill, be be mill, the from away get be to Allegheny from Smith Kevin Steel; for networking with like-minded like-minded with for networking a relaxed setting and get and achance setting a relaxed and I’m thinking “How great —I “How great I’mand thinking organization networking a valuable Ed Works; –Butler Steel AK and benefited you in your career? your you in benefited

Steel –MonSteel - - Wedmore and his wife Tara on a ski trip to Big Sky, Mont., USA, March 2020. March USA, Mont., Sky, Big to Tara wife trip his aski and on Wedmore At AIST, we’re always looking to AIST,At looking we’re always I always encourage our young new our encourage I always My career has centered in the centered the in has My career firsthand how the survivors came came the survivors how firsthand you give to young professionals professionals young to you give ter able to handle the challenges challenges the able handle ter to try cycles. My geographical area area My geographical cycles. try hires to join AIST and participate participate and AIST join to hires experience. afascinating been has industry ahigh-tech to labor hard iconic steelmaking many lost has How have you seen the industry industry How the have you seen both highs and lows of the indus of the lows and highs both in local Member Chapter events Member events Chapter local in who are just coming into the into coming just are who Ihave seen U.S., and northeast or Technology one join of the one from requiring industry of the transformation The future. of the bet and stronger cycles out of these see I could were difficult, closures those While centers over years. the that particularly excite you? excite particularly that any newthere developments change since you started? Are Are you started? since change inspire the next generation of generation next the inspire steel industry? would advice What steelmakers. - - witness it firsthand. It is hard to hard is It it firsthand. witness Imen for reasons the Committees tioned. I would also encourage any encourage also Iwould tioned. to try visit a steelmaking shop and asteelmaking visit try to ing it — the sheer scale of these of these sheer iting —the scale one interested in the steel industry steel industry the one in interested operations is mindboggling. mindboggling. is operations appreciate the process without see without process the appreciate

F - - -

146

NOTES FROM A LEADER Jacob Lewis metallurgist

One of my most vivid memories from childhood was blast furnaces that are still scattered throughout the picking up my Dad’s copy of Iron & Steel Technology and state today are truly amazing (and Sloss Furnaces in being fascinated with the rolling mill that was on the Birmingham is worth a tour if you are ever in the area). front cover. The huge mill stands and the glowing red Around the spring of 2017, I was asked to fill in for one of bar sitting on the table had me instantly hooked as a kid. my co-workers as a scholarship chair for the Birmingham Fast forward a decade, and I was so excited to start my chapter. During my first meeting, we discovered that sev- first day at Nucor Steel Tuscaloosa Inc. After orientation, eral of the previous leaders had moved out of the region, safety training and meeting my teammates, one of the and all three leadership positions were open. I ended up first things I was asked was if I was interested in receiving being elected secretary/treasurer, as well as scholarship Iron & Steel Technology each month. Remembering my chair for the chapter, and my involvement since has only younger years, I said yes. I was beginning to truly under- grown. Thanks to our chapter meetings, I’ve gotten stand how valuable this publication and AIST would be to meet several people from Birmingham and the sur- for me and my career. rounding areas and have called on them frequently for Six months later I sat in my first AIST training course, help and guidance when encountering difficulties. I also The Making, Shaping and Treating of Steel: 101. I was was able to help plan a joint meeting with the Southwest blown away with the amount of knowledge I gained in Member Chapter, again expanding my contacts in the that three-day course, and quickly wanted to expand industry. I was very honored to be named Birmingham my knowledge further, so I attended Cold Rolling Member Chapter chair in 2019, and to continue the work Fundamentals. Both courses helped me to better under- of the past leaders of the Birmingham Chapter. stand the steel industry, my job, and the new technolog- One of my favorite aspects of being an officer of the ical advances of both steel and the equipment needed Birmingham Member Chapter is awarding scholarships to produce that steel. Moreover, I also got the chance to several bright and gifted students, many of whom I’ve to network with suppliers and other producers, giving since met at our chapter meetings. These students will be me contacts I could reach out to when I hit a wall in a a huge asset for the industry moving forward. Through project. Over the six years I’ve been at Nucor Tuscaloosa, its Member Chapters, AIST and the AIST Foundation I’ve also attended the Hot Rolling Fundamentals course, have done a great job of recruiting young students and attended AISTech, presented at a Plate Steel Symposium, professionals to our industry. The push to get even more and joined the Plate Rolling Technology Committee. young professionals involved in AIST will be an even

AIST.ORG These learning and networking experiences have been greater benefit to those young people entering the steel

I immensely important to my development early in my industry now. The amount of knowledge you can quickly career. learn from any AIST event is extremely beneficial, and Another great experience has been my involvement I would urge any student or young professional to take with the Birmingham Member Chapter. Before I moved advantage of these opportunities. The networking alone to Alabama, I had no idea the amount of iron and steel at these events will help with your development and history that was present in the state. The amount of old advancement. F IRON & STEEL TECHNOLOGY

2020 MEMBER CHAPTERS

AUG Get involved with your local Member Chapter! Visit AIST.org or contact Jill Liberto at +1.724.814.3046 or [email protected]. 147

CHS² 2021

8th International Conference on HOT SHEET METAL FORMING OF HIGH-PERFORMANCE STEEL

31 May–3 June 2021, Barcelona, Spain

SAVE THE DATE AND CALL FOR PAPERS AUG

2020

IRON & STEEL TECHNOLOGY

AIST.ORG 148 AUG 2020 I IRON & STEEL TECHNOLOGY I AIST.ORG - - steels - High-performance - Additive manufacturing solutions - Additive manufacturing coatings and engineering - Surface - - Tool materials Registration and conference and Registration 2021: 1 June CONFERENCE TOPICS Conference 2021: June 2–3 Reception and pre-registration and Reception 31 2021: May Material M M L alloys, titanium alloys, superalloys, superalloys, alloys, titanium alloys, magnesium alloys, aluminum relationship multi-material solutions multi-material composite materials,composite etc. performance materials such as as such materials performance ightweight and high- and ightweight VENUE 2021 icrostructure – properties –properties icrostructure and processes material ixed - monitoring - Process control and - Automation strategies cooling and - Heating - Tool systems fatigue and fracture - Deformation, properties - Component wear and - Friction properties - Thermomechanical - Heat transfer - Microstructure modeling - Process Process Design Process Modeling and Simulation A machine learning machine Catalonia and Luleå University of Technology, in cooperation with with Technology, incooperation of University Luleå and Catalonia of Centre Technology the Eurecat, by organized be will 2021 CHS² For the first time, the CHS² conference will be held in Barcelona, Barcelona, in held be will conference CHS² the time, first the For Spain, 31 May–3 June 2021, at World Trade Center Barcelona. Trade 2021, World Center June at 31 May–3 Spain, the Association for Iron & Steel Technology (AIST). Technology &Steel Iron for Association the rtificial intelligence and and intelligence rtificial Moll de Barcelona s/n, Barcelona, Spain Barcelona, s/n, Barcelona de Moll WORLD TRADE CENTER TRADE WORLD www.wtcbarcelona.com/en - Eco-design - - needs e-mobility for - Solutions - - technologies joining and - Cutting properties - Tailored material markets new for products - New high- and ightweight - Products C F P L assessment optimization performance for components performance transport sector atigue, fracture and crash roduct innovations and and innovations roduct ircular economy and life cycle cycle life and economy ircular 149

CALL FOR PAPERS All contributions on the theme of the conference are The organizing committee encourages high- welcome. Prospective authors are invited to submit scientific-quality conference papers to be published their abstracts by uploading these to the conference in international journals after the conference. paper submission system (see instructions below). For submission of abstracts, please register with The full papers will be reviewed by the members of the conference paper submission system and the scientific advisory board and, if accepted, will be upload your abstract in accordance with the abstract published in the conference proceedings. submission guidelines: www.chs2.eu

ABSTRACT SUBMISSION GUIDELINES Abstract text: The abstract submission includes: maximum 400 words - title of paper - presenting author Language: English - co-authors - affiliations - abstract including keywords and references

IMPORTANT DATES Abstract submission: Revised paper submission: 15 October 2020 5 April 2021

Full paper submission: Conference: 8 February 2021 31 May–3 June 2021

ORGANIZING COMMITTEE CONFERENCE SECRETARY - Prof. Daniel Casellas Ms. Ana Vázquez Eurecat, Technology Centre of Catalonia, ESP/Luleå Eurecat, Technology Centre of Catalonia University of Technology, SWE Bilbao, 72 Building A - P rof. Mats Oldenburg 08005 Barcelona – Spain Luleå University of Technology, SWE Tel.: + 34 932 381 400 - Dr. Jens Hardell Email: [email protected] Luleå University of Technology, SWE

Updated information can be found on the AUG

- Brian Bliss conference homepage www.chs2.eu 2020

Association for Iron & Steel Technology (AIST), USA I

IRON & STEEL TECHNOLOGY

ORGANIZED BY Eurecat, Technology Centre of Catalonia Luleå University of Technology Barcelona, Spain Luleå, Sweden

AIST.ORG 150 JUN 2020 I IRON & STEEL TECHNOLOGY I AIST.ORG AIST Member Chapters meet to exchange ideas and provide opportunities for A globally diversified membership is key to fulfilling the AIST mission and vision. Our Global Collaboration Global Chapters. from more than 70 countries to gather in regions, 21 recognized as local Member Member Chapter Member With Your Local Involved Get presentations, roundtable discussions, plant tours, social activities, product fairs and networking among peers in your local area. Activities include technical keynote programs enable professionals in the iron and steel industry and related academia special programs to engage the next generation. programs next the engage to special 151

“ Whether you are a young engineer learning the ways of the industry or a longtime professional passing on your knowledge and insight, involvement in AIST can benefit not only the individual but the iron and steel industry as a whole.”

Clay Piper, senior project engineer, DMM Technical Services LLC

Local Member Chapters

Asia North • Northern South Provisional

• India America • Northern Pacific America • Middle East and JUN

• Ohio Valley 2020 • Korea • Birmingham • Argentina North Africa

• Philadelphia I

(MENA)

• Detroit • Brazil IRON & STEEL TECHNOLOGY • Pittsburgh Australia • Globe-Trotters* • Southeast • Australia • Mexico • Southern • Midwest California Europe • Northeastern * The Globe-Trotters Member Chapter is a traveling • Southwest group with events in various locations throughout

• European Ohio I

• St. Louis the United States. AIST.ORG

Visit AIST.org to learn more about AIST Member Chapters.

Steelmaking and Refining Volume Flat Products Volume Richard J. Fruehan, editor Vladimir B. Ginzburg, editor Individual Volume Prices: ISBN: 978-0-930767-02-0 ISBN: 978-1-935117-36-0 Member Price: US$195 1998, Casebound — PB-332 2014, Casebound — PB-437 Non-Member Price: US$245 1998, CD-ROM — PB-333 2014, CD-ROM — PB-438 The Making, Shaping and Treating of Steel®, Ironmaking Volume Long Products Volume 11th Edition, 5-Volume Set David H. Wakelin, editor Sven-Erik Lundberg, editor This 5-Volume Set includes the casebound ISBN: 978-0-930767-03-7 ISBN: 978-1-935117-57-5 versions of Steelmaking and Refining, 1999, Casebound — PB-334 2017, Casebound — PB-439 Ironmaking, Casting, Flat Products, and Long 1999, CD-ROM — PB-335 2017, USB — PB-440 Products.

Casting Volume Special Pricing! Alan Cramb, editor PB-441PKG ISBN: 978-0-930767-04-4 Member Price: US$760 2010, Casebound — PB-436 Non-Member Price: US$980 2003, CD-ROM — PB-336

Place your order at Bookstore.AIST.org 154 AUG 2020 I IRON & STEEL TECHNOLOGY I AIST.ORG CALENDAR EDITORIAL 2020 Carnegie MellonUniversityand RJ LeeGroupCarnegie Inc. Inclusion ClassificationbyComputer Vision andMachineLearning Steel DynamicsInc. Fraudulent N-95(SafetyFirst) Baosteel andPanAsiaTechnical AutomotiveCenterCo.Ltd. Investigation ontheCoatingAdhesionofGalvanizedAHSSTreated byOxidation-ReductionProcess DGS Metallurgical SolutionsInc. Metallurgical StrategyforOptimizedProduction ofQTHigh-Strength andAbrasion-ResistantPlateSteels Colombia Universidad deIngenieriayTecnologia, UniversidadeFederaldeSantaCatarina,UniversidadCentralandNacional Microstructural EvolutionofTwo AutomotiveSteelsInducedbyWarm ForgingandSubcriticalAnnealing and Wuhu XinxingDuctileIron PipesCo.Ltd. University ofScienceandTechnology Beijing,BeijingKeyLaboratoryofSpecialMeltingandPreparation ofHigh-EndMetal Materials, Effect ofPlasmaHeatingontheMoltenSteelinTundish Colorado SchoolofMines and LowTemperatures Effect ofLiquidMetalEmbrittlementonMechanicalBehaviorAdvancedHigh-Strength SteelSpotWelds atAmbient and Technology Beijing Missouri UniversityofScienceandTechnology, Gerdau SpecialSteelNorthAmerica, MetalTek andUniversityofScience International, Effect ofVanadium andAluminumGrainRefining Treatment onSteelMachinability Feature Articles MS&T20 Program Bonus Feature: Process Metallurgy&Product Applications October 2021 February 2021 January December November To advertise, contacttheAIST [email protected] orcall +1.724.814.3000, ext.2. Cold SheetRolling, Processing, Coating&Finishing Electric Steelmaking Process Control &Automation Hot FlatProduct Rolling,Rolls,Safety&Health

Month and

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18 August2020 Ad Closing

(Digital Transformations) 24 August2020 Material DueDate 23September2020 29 September2020 21 December2020 15 December2020 20 November2020 16 November2020 Material DueDate 27October2020 21 October2020 Ad Closing

156 New Products & Resources

Explosion-proof VFD phase New Products & Resources is a free service featuring news of recent product and equipment converter for hazardous developments, brochures, catalogs, websites, etc., relevant to the steel industry. To submit environments material for consideration, please email a press release (and high-resolution photo, if applicable) to [email protected].

New standards builder tool saves project creation time The new ProposalWorks Standards Builder from Rockwell Automation is an application designed to assist end users with generating, custom- Larson Electronics, a manufacturer izing and maintaining their control of industrial lighting equipment and standards. Engineers can document accessories, announced the release project standards, track revisions of an explosion-proof 3-phase input, and more to help establish consis- 3-phase output, 3-wire configura- tency from project design through create more detailed content that is tion variable frequency drive (VFD) procurement and commission- easier to maintain than in a static designed for improving AC motor ing. Although Standards Builder document. performance in hazardous locations. is its own capability, users launch In addition, users can achieve a This device is a fan-cooled unit fea- the application via the Rockwell higher standardization of systems, turing 3-phase 480-V AC input/output Automation ProposalWorks tool. resulting in fewer spare parts, less voltage. Users can output detailed specifi- training and more reliable designs. The EXP-VFD-3P-480-20HP-33A- cation documents and a standards They can easily add a wider range DCM explosion-proof VFD phase bill of materials that can be upload- of product lines or products to their converter is rated for use in U.S. ed into ProposalWorks. They can standards or specs with minimal Occupational Safety and Health Ad- share this with others, including effort. This can provide improved ministration (OSHA) Classes I and II, suppliers, to help product design product availability and better align- Divisions 1 and 2 hazardous locations. and selection. ment with suppliers during design/ This device offers accurate AC motor Control standards creation and build. control in industrial environments. maintenance can be a manual, Contact: Rockwell Automation Inc. This 15-kw device is compatible with time-consuming process. Typical 1201 S. Second St. 3-phase input and 3-phase output of information included in a control Milwaukee, WI 53204 USA Phone: +1.414.382.2000 480-V AC (430–525 V) and provides an standard can contain electrical www.rockwellautomation.com F output current of 33 amps. This unit code, product line and reference offers an operating frequency range architecture content. Users can be of 0–400 Hz. unaware of changes in life cycle Larson Electronics’ VFD phase status and product obsolescence converter is a 20-hp unit that has a after a control standard is published. volts-per-hertz (V/F) control mode and With Standards Builder, users can sensorless vector control mode. This spend less time maintaining control unit is designed for indoor applica- standards or specifications and also tions with an operating temperature range of –10˚C to 40˚C. This unit is AIST.ORG

also ideal for outdoor applications I and is suitable for speed control of AC Marketplace motors, industrial machines and more.

Contact: Larson Electronics LLC Contact: 9419 E. U.S. Hwy. 175 Stacy Varmecky at +1.724.814.3066 Kemp, TX 75143 USA Advertise here! Cate Davidson at +1.724.814.3092 Toll-Free Phone: +1.800.369.6671 Classifed advertising Linda Sheets at +1.724.814.3060 Phone: +1.903.270.1187 IRON & STEEL TECHNOLOGY is US$300

I Austin Herrmann at +1.724.814.3098 Fax: +1.903.498.3364 per column inch. [email protected] Rebecca Smith at +1.724.814.3060 2020 www.larsonelectronics.com Vicki Dean at +1.724.814.3018 AUG

158 AUG 2020 I IRON & STEEL TECHNOLOGY I AIST.ORG 12 19 AUGUST 2020

SEPTEMBER 2020 SEPTEMBER Steel Calendar 20 21 8 5 COVID-19: COVID-19: is actively monitoring the COVID-19 crisis as it may necessitate the postponement or cancellation of steel calendar events. Please visit visit Please events. AIST calendar steel of cancellation or postponement the necessitate may it as COVID-19 crisis the monitoring actively is .org for updates or contact us at [email protected]. at us contact or updates for .org • • • • • • D I M Transparency [email protected] or AIST.org [email protected] or AIST.org D S M [email protected] or AIST.org 4 and Optimization in Steelmaking P P P W W W Alton, Ill.,Alton, USA A the Age of Industry 4.0 Industry of Age the G Crown Point, Ind., USA Ind., Point, Crown Lyon, Mich., USA ntegrated Production Management and Quality in in Quality and Management Production ntegrated 7th annual golf outing, Spencer T. Olin Golf Course, Course, T. Golf Olin Spencer outing, golf annual 7th t. Louis t. hone: +1.724.814.3000hone: +1.724.814.3000hone: hone: +1.724.814.3000hone: igitalization and the Double-Edged Sword: Sword: Double-Edged the and igitalization nnual golf outing, Walnut Creek Country Club, South South Club, Country Creek Walnut outing, golf nnual etroit olf outing, White Hawk Country Club, Club, Country Hawk White outing, olf achine Learning Applications for Process Control Control Process for Applications Learning achine idwest ebinar, 10 ebinar, 10 ebinar, 10

The health and safety of our industry is a shared responsibility and one that we take seriously. As of press time, AIST AIST time, press of As seriously. take we that one and responsibility ashared is industry our of safety and health The

Technology Training Technology Training Technology Training Member Chapter Event Member Chapter Event Member Chapter Event Member Chapter –11 EDT a.m. –11 EDT a.m. –11 EDT a.m.

OCTOBER 2020 4–8 29–1 Oct 29–1 27–1 Oct 2 29–1 Oct 29–1

& Materials Society (TMS). (TMS). Society & Materials • • • M 2 [email protected] or AIST.org [email protected] or [email protected] www. I Phone: +1.724.814.3000,Phone: +1.724.814.3001, Fax: P P S Da Conference and Exhibition and Conference nstituto Argentino de Siderurgia, Rosario, SF, Argentina Rosario, Siderurgia, de Argentino nstituto 3rd IAS Steel Conference and EXPO IAS 2020 IAS EXPO and Conference Steel IAS 3rd hone: +54.0336.4462989 or +54.0336.4461795, ext. +54.0336.4461795, or +54.0336.4462989 hone: ponsored by ACerS; ACerS; by ponsored ittsburgh, Pa., USA Pa., ittsburgh, 1 S M 2 Training Seminar [email protected] or AIST.org [email protected] or AIST.org Ind., USA Ind., Omni William Penn Hotel, Pittsburgh, Pa., USA Pa., Pittsburgh, Penn Hotel, Omni William Phone: +1.724.814.3000,Phone: +1.724.814.3001, Fax: Phone: +1.724.814.3000,Phone: +1.724.814.3001, Fax: Hotel, Centre City Indianapolis Sheraton University Northwest, Hammond, Ind., Northwest, USA University S&T20 — The Materials Science & Technology &Technology Science Materials —The S&T20 3th annual high school engineering seminar, Purdue Purdue seminar, engineering school high annual 3th vid L. Lawrence Convention Center, Convention vid L. Lawrence 7th AIST Crane Symposium Crane AIST 7th heet Processing and Finishing Lines — A Practical —APractical Lines Finishing and Processing heet idwest

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6–8 Technology Training 8–10 Member Chapter Event • Secondary Steelmaking Refractories — A Practical • Northern Pacific and Southern California Training Seminar Western Conference, Omni Rancho Las Palmas Resort Holiday Inn Nashville Vanderbilt, Nashville, Tenn., USA & Spa, Rancho Mirage, Calif., USA Phone: +1.724.814.3000, Fax: +1.724.814.3001, [email protected] or AIST.org 8–12 Galvatech 2020 Schloss Schonbrunn, Apothekertrakt, Vienna, Austria 13–15 Technology Training Sponsored by ASMET (The Austrian Society for • Continuous Casting — A Practical Training Seminar Metallurgy and Materials). Holiday Inn Cleveland South – Independence, www.galvatech2020.org Independence, Ohio, USA 11–12 MetCoke World Summit 2020 Phone: +1.724.814.3000, Fax: +1.724.814.3001, TBD, Pittsburgh, Pa., USA [email protected] or AIST.org Sponsored by Smithers. www.metcokemarkets.com 13–15 Member Chapter Event • European 30–2 Dec Member Chapter Event Virtual European Steel Forum • Mexico CONAC 2020, Cintermex, Monterrey, N.L., Mexico 19–21 Technology Training • Environmental Solutions: Meeting EPA Air Emission Requirements FEBRUARY 2021 TBD, Dearborn, Mich., USA Phone: +1.724.814.3000, Fax: +1.724.814.3001, [email protected] or AIST.org 1–5 Technology Training • Modern Electric Furnace Steelmaking — A Practical 21–23 ECCC 2020 — 10th European Conference on Training Seminar Continuous Casting Tennessee, USA Nicolaus Hotel, Bari (BA), Italy Phone: +1.724.814.3000, Fax: +1.724.814.3001, Sponsored by AIM, the Italian Association for Metallurgy. [email protected] or AIST.org [email protected] or www.aimnet.it 9–11 Technology Training 27–29 Technology Training • Long Products Rolling – A Practical Training Seminar • Steel Mill Combustion and Thermal Systems Sheraton Gunter Hotel, San Antonio, Texas, USA AIST Headquarters, Warrendale, Pa., USA Phone: +1.724.814.3000, Fax: +1.724.814.3001, Phone: +1.724.814.3000, Fax: +1.724.814.3001, [email protected] or AIST.org [email protected] or AIST.org 24–26 Technology Training 28–30 IRONMASTERS 2020 • Maintenance Solutions: Fundamentals Schönbrunn Palace, Vienna, Austria and New Frontiers Sponsored by ASMET. Embassy Suites Riverwalk, San Antonio, Texas, USA www.ironmasters2020.org Phone: +1.724.814.3000, Fax: +1.724.814.3001, [email protected] or AIST.org NOVEMBER 2020 MARCH 2021 4–5 Technology Training • The Making, Shaping and Treating of Steel: 101 15–17 Technology Training AIST Headquarters, Warrendale, Pa., USA • Digital Transformation Forum for the Steel Industry Phone: +1.724.814.3000, Fax: +1.724.814.3001, Omni William Penn Hotel, Pittsburgh, Pa., USA [email protected] or AIST.org Phone: +1.724.814.3000, Fax: +1.724.814.3001, AUG

[email protected] or AIST.org 2020

7 Member Chapter Event I

• Southern California IRON & STEEL TECHNOLOGY Dinner dance, Omni Rancho Las Palmas Resort & Spa, Rancho Mirage, Calif., USA

8–10 Leadership Conference (invitation only) Omni Rancho Las Palmas Resort & Spa, Rancho Mirage, Calif., USA

Phone: +1.724.814.3000, Fax: +1.724.814.3001, AIST.ORG [email protected] or AIST.org 160 AUG 2020 I IRON & STEEL TECHNOLOGY I AIST.ORG JUNE 2021 JUNE Steel Calendar MAY 2021 MAY 23–25 23–25 OLLS6 2021 3–6 Steel Irony

H R V [email protected] or www.rolls6.org/485897 [email protected] or AIST.org and Mining. and O Organized by by Organized Phone: +1.724.814.3000,Phone: +1.724.814.3001, Fax: Metallurgy. for Association Italian the AIM, by Sponsored Sponsored by IOM3, The Institute of Materials, Minerals Minerals Materials, of Institute The IOM3, by Sponsored Music City Center, Nashville, Tenn., Center, Nashville, City Music USA [email protected] or www.aimnet.it/htdc2020.htm [email protected] Conference and Exposition Conference icenza, Italy icenza, igh-Tech Die Casting International Conference ne Great George Street, London, U.K. London, Street, George Great ne TM

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SEPTEMBER 2021 SEPTEMBER 28–31 28–31 MP2021 — The 6th International Conference on on Conference International 6th —The MP2021 5–7 on thepagefor answer. Facebook page.Challengeyourself tofi nditbefore looking cover. Whenyoufi ndthehypocycloid,postittoAIST’s where thehypocycloidwashiddenonprevious issue’s uses thisspaceattheendof“Steel Calendar”topointout shape ismaintained.Everymonth, Iron & Steel Technology Steel & Iron Each monthahypocycloid(F)is“hidden”onthecoverof Where’s theHypocycloid?

• • T ThermoMechanical Processing ThermoMechanical Metals. for Society Chinese The by Sponsored S tmp2020.medmeeting.org/en henyang, China henyang, S G A A Resort, Fernandina Beach, Fla., USA Fla., Beach, Fernandina Resort, Beach, S.C., USA S.C., Beach, outheast outheast nnual meeting, Omni Amelia Island Plantation and and Plantation Island Amelia Omni meeting, nnual nnual meeting, Marina Inn at Grande Dunes, Myrtle Myrtle Dunes, Grande at Inn Marina meeting, nnual lobe-Trotters lobe-Trotters Member Chapter Event Member Chapter Event Member Chapter

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