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Proceedings of the

Iron & Steel Technology Conference

Volume II

6-9 May 2013

Pittsburgh, PennsylvaniaU.S.A.

ASSOCIATION FORIRON& STEEL

+u*mini*m

Ronald E. Ashburn, Publisher

Karen D. Hickey, Managing Editor

Christopher P. Brown, Lead Graphic Designer

Krista J. McGhee, Copy Editor/Graphic Design Assistant

A Publication of the Association for Iron & Steel Technology

TABLE OF CONTENTS

AISTech 2013 - Volume II

CONTINUOUS CASTING

Caster Mold Flow improvement Through Mold Level Control

Effect of Electromagnetic Braking (EMBr) on Turbulent Flow in Continuous Casting J 323

R. Singh, B.G. Thomas, S.P. Vanka

Distribution of Defects in Slab and Suppression ofUnbalanced Flow by

Electromagnetic Brake in Continuous Casting Mold -

037

Kouhei Furumai, Yutaka Matsui, Takesi Murai, Yuji Miki

Bulging and Waving —Difficult Challenges for Automatic Mold Level Control 1343

Silvio Cecchini, Robert ZirkI, Michael Pillwax

Slidegate Dithering Effects on Transient Flow and Mold Level Fluctuations 0351

Rui Liu, Brian G. Thomas, Love Kalra, Tathagata Bhattacharya, Aloka Dasgupta

Long Products — Quality Improvements

WAVE Mold for Billet Casting Applications 1365

Ian A. Bakshi, Martin Garcia, Don P. Lorento

A Fluid Flow and Steel Intermixing Study of a Round Billet Mold 037/3

Ken Morales-Higa, R.I.L. Guthrie, M. Isac, Rodolfo D. Morales, Chantal Labrecque. Francis Lapoime

Continuous Casting New Technology

HD Mold— Caster Assistance Systems to Increase Product Quality 1385

J. Wans, D. Lieftucht, C. Geerkens, M. Anberger, M. Reifferscheid

CSP® Casting Technology —The Most Innovative, Flexible and Reliable

Technology to Meet New Market Demands -1393

Jiirgen Midler, Christian Geerkens, William H. Emling

Caster Process Improvements for Quality

Analysis of Directly Measured Heat Transfer Coefficients During Special Experiments to

Provide Better Understanding of Secondary Cooling During Continuous Casting Process 141)1

Jaroslav Horsky, Jana Ondrouskova, RudolfMoravec, Kenneth Blazek. Hangbm Ym

Initial Alumina Formation: Some Additional Thoughts Based on Laboratory and Steel Plant Findings ....1411

Wouter Tiekink

Effects of Dezincification on Continuous Caster Spray Nozzle Assemblies 1417

A.M. Dalle}', T.T. Natarajan, R.M. Koenig, E.K. Borges

FEM Analysis of Soft Reduction Amount and Its Internal Reduction Efficiency for

Continuous Casting Railway Blooms 1427

Ke Liu, Haibo Sun, Peng Lan, Jiaquan Zhang

Laser Alignment of United States Steel Corporation's Gary Works No. 2 Caster 1439

R.M. Koenig, B.J. Branmim, J.L. McConnell, T. Domelle, M.O. Folk, K. Ferguson,

M.E. Anderson, K.E. Brown, T.T. Natarajan

CONTINUOUS CASTING/METALLURGY—

STEELMAKING AND CASTING

Caster Mold Technologies

Analyses of Phase Formation and Its Effect on the Thermal Resistance of Mold Flux 1451

K.L.S. Assis, P.C. Pistorhis

The Effects of Fluid Flow on Flux Entrainment in a Square Billet Mold 1461

Ken Morales-Higa, R.l.L. Guthrie, M. Isac, Rodolfo D. Morales, Chantal Labrecque, Francis Lapointe

A Novel Concept for Improving Slab Casting Performance Using Mold Thermal Analysis 1473

S1. Kumar, V. Hernandez

Study of Elevated Temperature Mechanical Properties of Steel 1483

J. Semenak, P. Zahumensky, T.J. Piccone, T. T. Natarajan

Effect of Hydrogen on Mold Heat Removal at a Rounds Caster 1497

T.J. Piccone, M. McClymonds, K.H. Hashimoto

Morphology, Soundness and Segregation Improvement of Bloom Castings byUsing Swirling Flow Nozzle 1509Haibo Sun, Yang Li, Jiaquan Zhang, Qingwen He, Liming Fan

CONTINUOUS CASTING/COMPUTER APPLICATIONS

Slab Caster Modeling Aspects for Quality Improvements

Advanced Simulation of Mold Flow Influenced by Static and Moving Magnetic Fields 1519

Norbert Vogl, Hans-Jiirgen Odenthal, Markus Reifferscheid, Jochen Schliiter

Metallurgical Behavior of the Ultrathick-Slab Continuous Casting Mold 1531

Feng Pan, Heiho Sun, Jiaquan Zhang

CONTINUOUS CASTING/MAINTENANCE AND RELIABILITY

Continuous Casting Maintenance Technology

Pulling the Four Levers of Reliability in a Continuous Caster Operation 1539Larry D. Frey, Charles P. Kuntz

Continuous Improvement of Mold Life at Severstal Columbus 1549George Gurley, Kamalesh Mandal, Doug Woods, Peter Sally, Mark Pole

CONTINUOUS CASTING/REFRACTORY SYSTEMS

Caster Refractory for Yield, Productivity and Quality

Stopper Rod Dithering Trials at ArcelorMittal Dofasco's No. 1 Continuous Caster 1557

Stephen Daeyoung Chung, Joydeep Sengupta, Mehrnoosh Afnan

HOT SHEET ROLLING

Hot Rolling Quality and Efficiency Improvements

Shape Performance Improvements at ArcelorMittal 80-Inch Burns Harbor Hot Strip Mill 1567

Aislan Costa, Brian J. Warnock, Gordon Book, Jeffrey A. Cox, Robert J. Capehart Jr.

Eliminating Bottom-Side Surface Scratches at the ArcelorMittal Burns Harbor 80-Inch Hot Strip Mill.... 1577

Thomas M. Mayrosh, Aislan Costa, John Cahill, BilliJ. McDowell, RoyL. Grinnell Sr.

Efficiency of "Secondary" Actuators of Flatness and Crown Control in the

Finishing Stands of the Hot Strip Mill 1587

E. Nikitenko

Study of Strip Tension of Coiling Wide Heavy-Gauge Strip 1591

Qiulin Yu, Andy Seibert

HOT SHEET ROLLING/PLATE ROLLING

Hot Plate and Sheet Discussions

Reheat Process Control Using Three-Dimensional Thermal Slab Model 1601

John E. Pond, Hamilton Woods, Virginia Woods

Steel Plates Made of Hot Band as an Economic Alternative to Plate Mill Products 1609

Hans Georg Hartung, Lutz Kiimmel, Kerry Winklhofer, Caesar Sasse

HOT SHEET ROLLING/ROLLS

Roll Shop and Hot Mill Advancements

The Effect of Strip and Roll Surface Temperatures and Rolling Campaign Length on

Hot Strip Surface Quality 1617

Zafer Koont, John J. Fitzpatrick, David J. McCaw

ChatterBlock®— Siemens VAI's Solutions for Vibration Detection, Prediction, Analysis and Control....

1625

ArnaudBizard, Karl Mayrhofer, Geog Keintzel, Lukas Pichler, Alois Koppler, Jiirgen Hofer

Residual and Load Stresses on the Final Load Situation for Work and

Backup Rolls for Strip and Plate Mills 1635

Michael Hinnemann, Paul JosefMauk

Advanced Roll Bite Lubrication Techniques for Improving Roll Life and

Making Quality ImprovementsJames E. Murphy III

1645

COLD SHEET ROLLING

Cold Mill Improvements

Minimum Quantity Roll-Gap Lubrication System —Field of Large Potential to Reduce Your OPEX ...

1655

Konrad Krimpelstatter, Andreas Flaxa

Correct Torque Limitation and Driveline Optimization 1663

Daniel Myrgren, Sigvard Weisbjerg, David Bergstrom

Cold Rolling Technologies

Multivariable Shape Actuation Capabilities Envelopes of Vertical-Stack Mills 1665

MarkE. Zipf

Lubrication in the Cold Rolling Process Described by a 3D Stribeck Curve 1681

B.A.F. Smeulders

A Semi-Analytical Solution of von Karman Rolling Equation With Infinitely Rigid Rolls —Part I 1691

Remn-Min Guo

A Semi-Analytical Solution of von Karman Rolling Equation With Roll Indentation — Part II 1703

Remn-Min Guo

Pickling and Continuous Annealing Technologies

Descaling Effectiveness and Saving Energy of i Box® Pickling TechnologyConfirmed by Numerical Analysis 1715

Kosei Tsuji, Akihiko Sasaki, Yoichi Kai, Ryusuke Nakatsuka

Development of Improving of Surface Qualities by Jet Spray Technology 1727

Kq/i Sakuragi, Hiroyuki Suzuki, Hiroshi Komura

GALVANIZING

Advances in Metallic Coated Sheet

The Effect of Heating Rate on A1N Formation in High Aluminum Content Fe-Al Alloys 1735

June Bott, Hongbin Yin, Seetharaman Sridhar

Interfacial Layer Formation in a Zn-23Al-0.3Si Galvanizing Bath 1747

Madhu Ranjan, Wim J. van Ooij

Study of Microstructure for Chromium-Free Passivating Coating on Hot-Dipped Galvanized Steel 1755

Ching-Kuo Kuo

PLATE ROLLING

Plate Rolling Operating Improvements

A Review of Benchmark Performance in Plate Mill Process Control 1763

J. Lee, R. Doll, B. Schmidt, M. Miele, M. Clark, M. Chalmers

Shape and Crown Control Optimization With Integrated Automation for

Reversing Hot Mills Lacking Sufficient Crown Control Devices 1775

C.C. Folkman

Requirements on Automated Manifest Flatness Measurement 1785

Par Kierkegaard

PLATE ROLLING/METALLURGY—

PROCESSING, PRODUCTS AND APPLICATIONS

Enhancing Steel Plate Properties Through Metallurgical Control

Control of Plate Thermomechanical Properties Using MULPIC Plate Cooling Technology 1799

/. Robinson, M. Hulley

Efficient Production and Enhanced Quality in Plate Rolling 1807

Wolfgang Spies, DetlefEhlert, Jiirgen Lemke

Transport Director— Complete Mill Simulation, Ghost Rolling and

Optimized Mill Sequencing Control 1817Paul Jackson, Wlodzimierz Filipczyk

Study on Cooling Uniformity for the Accelerated Cooling Process in Hot Rolled Steel Plate 1827

Wei Lo, Cheng-Tian Chian, Min-Shu Lin, Chao-Fa Ke

ROD AND BAR ROLLING

Automation and Electrical Mill Upgrades

Automation Control System for Different Solutions of Modern Roughing Mill 1835

Marco Capitanio, Roberto Migliorati, Arondi Stefano

Most Modern SBQ Production Technology 1845Guenther Schnell

Maintaining Bar Quality in the Rolling Mill

Quality Improvement of Billet for Wire Rods 1853Daisuke Michishita, Yoshiyuki Udo, Michio Ono, Toshifumi Idesako

Improvement in Billets Weighing Accuracy 1859

Seiji Okamoto, Yoshinari Takamiya, Yoshihiro Otagaki, Katsuyuki Isogami

Importance of Control Strategy for Oxy-Fuel Burners in a Steel Reheat Furnace 1869

Shailesh Gangoli, Gregory Buragino, Xiaoyi He, Erdem Arslan, Peter Verdermae, ReedHendershot,

Alex Slave]kov, FredBellis, Larry Bellis, James McCarthy, Roy Cross

Complex Profile Gauging 1875

Paul John Stuart Pugsley

Modernization Solutions for Long Product Rolling Mills to Increase Productivity,

Utilization and Product Quality 1883

B.V. Kiefer, S.M. Shore

Long Products: Pass Design, Rolling and Productivity

New Rolling Stands for Long Products Rolling Mills 1891

M. Tomba, M. Zuccato, A. Fontanini, N. Tomba

A Rolling Model for the Three-Roll Rolling Process 1899

Christian Overhagen, PaulJosefMauk

PIPE AND TUBE

Pipe and Tube Testing

Constraint-Modified Charpy-Sized Fracture Toughness Specimens for Line Pipe Testing 1913

M.P. Manahan Sr.

General and ERW Pipe

Barcode Identification of Pipes and Tubes 1923

DavidL. Anderson

Q&T Processes for OCTG 1933

B. Anderson

Advantages of Using FAAST-II (Fast Automated Angle Scan Technique) for

Ultrasonic Testing in Production of Seamless Pipe 1941

J. Micha Koelbach, Volodymyr L. Naida, VladimirN. Gurianov, Philippe Coperet

Radio-Based Distance and Positioning Systems Applied to Tracking and

Safety Applications in the Tubular Industry 1949

Dirk Bnmnengraeber, Edgardo La Bruna

Seamless Pipe

The Development of Water Based Lubricants for the Production of Seamless Pipe 1959P. Gandy

Increased Heating Throughput and 63% Less Fuel With Flameless Oxy-Fuel at

Michigan Seamless Tube— Seamless Tube & Pipe, South Lyon, MI 1967Tom Sleder, Les Whitver, Grzegorz Moroz, David R. Stoffel, Amanda Guzman, Anders Carlsson

ROLLS

Roll Surface — Rolled Material Interaction,Roll Material and Production Technologies

Latest Developments of a New Technology HSS Work Roll for Later Stands (F4-7) in

Hot Strip Mill Finishing Trains 1977

Nozomu Oda, Paul Fleiner, Toshiyuki Hattori

Multi-Scale Finite Element Modeling and Microstructural Evaluation of

Centrifugally Cast High-Speed Steel Finishing Rolls 1985

K. V. Redkin, J.S. Vipperman, C. Hrizo, R. Schleiden, C.I. Garcia

New Grade of Material With Improved Wear Resistance for Finishing Stands in a Universal Mill 2001

Giri Rajendran, Ian Sadler, Kevin Banner

Development of Materials for the Making of Rolling-Mill Rolls for Hot Strip Mills 2009

Marcos Machado Matsumoto, Claudia Regina Serantoni, Luiz Carlos Silidonio Jr., Juan Garcia Noguera,Mario Boccalini Jr.

Fracture Mechanics-Based Acceptance Criteria of CVC Rolls of Hot Strip Mill 2019

Yuli Liu, Hui Zhang, Bruce Somers, Kevin Marsden, Andrew Freborg

Roll Shop Technologies

Indefinite Chill Work Roll Microstructure Influence on Eddy Current Test Response 2033

Peter B. Nagy, Christopher M. Hrizo, Richard B. Gundlach

New Developments for Roll Shops 2049

Giovanni Boselli, Marco Cozzi, Paolo Gaboardi, Davide Quaglia, Erasmo Trenti

METALLURGY— STEELMAKING AND CASTING

Steelmaking Injection Technologies

Effect of Blow Parameters in the Jet Penetration by Physical Model of BOF Converter 2059Breno Totti Maia, Rafael Kajimoto Imagawa, Clayton Jose Batista, Ana Clara Petrucelli,Roberto Parreiras Tavares

Secondary Refining Optimization by Applying Ar-Gas Bottom Bubbling Auto-Control System 2075

Dong Ryoul Min, Choon Ho Jung, Kwang Yeol Kim, Frank L. Kemeny

Analysis of Splash Data from Oxygen Steelmaking 2083Shabnam Sabah, Geoffrey Brooks, Jamal Naser

ASIS Aluminum Injection Technology — Reduced Aluminum Consumption for Primary Dcoxidation....

2095A. Robert Necciai

Evaluation of BOF Slag Applied in Foaming Practice 2105Leandro Santini, Jorgelina Perez, Ariel Rapetto, Edgardo R. Benavidez, Elena Brandaleze

Tundish Design Improvements

Advanced SEM Methodology for Tracking Reoxidation in the Tundish 2113

Roger Maddalena

Some Ignored Aspects During Melt Transfer From Ladle to Tundish 2123

Kinnor Chattopadhyay, Jack Young

Optimization of Grade Transitions at the Caster 2135

/. Nikiforovski, T. Xu

Effect of an Optimized Impact Pad on Molten Steel Quality in a 4-Strand Delta-Shaped Tundish 2143

A. Kaiser Hamid, Mihaiela Isac, R.I.L. Guthrie

Slab/Bloom Mechanical Behavior

Mechanism Linking Austenitic Grain Size to Sliver Formation on

Hot Rolled Coils at ArcelorMittal Dofasco 2155

Elliot Biro, Joydeep Sengupta, Manh-Kha Trinh, Eva Dillon, David Colbert

METALLURGY— PROCESSING, PRODUCTS AND APPLICATIONS

Product Metallurgy and Quality I

The Development of X120 Line Pipe Steel Hot Rolled Coil 2165

Xiaodan Wu, Yutian Wang

Inclusion Determination in Steel 2175

M. Tillemen, A. Goncalves

Microstructural Characterization of Grey Iron 2183

JP Anil Mozhi Varman

Product Metallurgy and Quality II

Modernization and Energy Efficiency of HPH Bell-Type Annealing Plants 2189

Peter Wendt, Frank Maschler, Thomas V. Bovalina

Effect of Process Design and Operation on the Thermal and

Microstructure and Mechanical Properties 2201

V. Hernandez, K. Sanil

Carburizing of Steel 2213

Jaleel Kareem Ahmad

The Effects of Prior Austenitic Grain Size and Martensitic Hardness on

Hydrogen Embrittlement of 4340 Steel 2223

Mobbassar Hassan Sk, Rue! A. Over/elt, Jeffrey W. Fergus, Barton C. Prorok

ENERGY AND UTILITIES

Energy Utilization in the Meltshop

EAF Heat Recovery Down to 200°C — A New Benchmark 2235Carsten Born, RalfGranderath

Meltshop Baghouse Fan Blade Upgrade Project 2241Mark Drymalla, Adam Spece, ChadPrior, Dick Rappolee, Fred Preis

Energy Usage and Management Throughout the Steel Process

Optimized Energy Management and Planning Tools for the Iron and Steel Industry 2249Klaus Lachmann, Bing Wang, Yong Huang

Regenerative Burner vs. Oxy-Fuel Retrofits on Reheat Furnaces

EVRAZ Claymont Steel Pusher Reheat Furnace 100% Oxy-Fuel Conversion 2259Reed Heine, Bill Taylor, Ed Gee, Danielle Todd

Regenerative Firing vs. Oxy Fuel Firing: An Applications Approach 2265Steven J. O'Connor

Tenova Regenerative Flameless Burners on California Steel Industries' New Walking Beam Furnace....

2279Massimiliano Fantuzzi, Jared Kaufman

ELECTRICAL APPLICATIONS

Switchgear Improvements

The Benefits of Intelligent Motor Control in the Metal Making Process 2291David C. Mazur, John A. Kay, Kenneth D. Mazur

Extend the Life of Existing Switchgear 2301Miklos J. Orosz

New Approaches for Maintenance Grounding in Medium-Voltage Switchgear 2309Joe Richard, DavidMabius

Evaluation of Operating Reactance to Have Optimum Utilization of Electrical Power in EAF 2317SajalDam, Juan Ramon Fernandez Jorge, T. Nagarajan, Bipin Richharia, Milind Ranade, Alok Jaiswal

Modern Sensor Systems

Precise, Accurate and Reliable Thickness Measurement of Metal Strip WithContact Gauge in Cold Mills in the 21st Century 2323Libor Jaks, Robert Karasek

Position and Camber Measurement in the Hot Rolling Process: EMG hotCAM 2329Guido Eichert, Steve Devorich

2D Blast Furnace Top Gas Temperature Measurement System — SOMA 2339M. Tonteling, M. Brodeck, H. Rausch

Protection and Substation Systems

A Consideration of Medium Voltage Substation Primary Applications 2349

Joe Richard, James K. Stacy

Electrical Protection HMIs for Metals Applications Utilizing the IEC 61850 Protocol 2357

Michael E. Rourke, David C. Mazur

Combining Static and Dynamic Testing — Preventing a Motor Catastrophe 2369

Noah Bethel

Electrical and Drive System Upgrades

HD Mold — A New Fiber-Optic-Based Mold Monitoring System 2373

DirkLiefhicht, Markiis Reifferscheid, Thomas Schramm, Artemy Krasilnikov, Dieter Kirsch

Increasing Mill Production by Using Medium Voltage AC Drive and Active VAR Compensation 2383

Marcelo Lara, Steve Nelko, Katsuhiko Fukitma, Hiromi Hosoda

Preparing Your Electrical System for Disaster Recovery 2395

ChadKennedy

Repower of the Nucor Decatur Tandem Cold Mill 2403

J. C. Fernandez, Thomas Kerstiens, Lee McCreless, Thomas Richards, Marcelo Lara, Katsuhiko Fukuma

Modern Sensor Systems Sequel

Investigation ofAnalytical Stability of Quadrupole Mass Spectrometer in Decarburization Application 2417Charles W. De Carlo

Dither, a Necessary Evil — Phase 2 2427Aloka Dasgupta, Love Kalra, Kai Zheng, William Umlauf

Real-Time Torque Monitoring at North Star BlueScope Steel 2439Daniel Philips, Keith Hoffman, Chris Davis, Eleazar Serrano

COMPUTER APPLICATIONS

Modeling and Simulation

Combining Product Property Prediction Software and Metallurgical Level 2Model for New Product Development 2449Bingji Li

Novel Advanced Control for Tandem Hot Metal Sheet Rolling 2451John Pittner, Marwan A. Simaan

Process Communications and Operator Interaction

Innovative Approach to Apple Platform-Based HMI and Level 2 Systems 2465Mariano Zecchi, Edgardo La Bnma

Manufacturing Execution Systems (MES) in the Metals Industry

A Framework for Selecting the Most Appropriate Manufacturing Execution System (MES)for the Metals Industry 2473Kevin Jackson, Christian Roth, Roberto Resque de Freitas

Challenges of Integration Between MES and ERP Systems in the Steel Industry 2487Hooman Fazlollahi, Omair Qayyum, Jaber Howlader, Ali Khademi, James Gu

PROJECT AND CONSTRUCTION MANAGEMENT

Project Excellence Award Paper Session

Upgrade of the Burns Harbor Plate Mill Heat Treat Facility 2495M.L. Frankovich, B.C. Felton, V. Baum

Capital Project Insights

Leveraging Engineering Data Management to Improve Capital Projects 2505

Amy M. Callahan, Greg Anderson

MAINTENANCE AND RELIABILITY

Maintenance and Reliability

Optimizing Hydraulic Descaler Performance Through Improved Monitoring and Maintenance 2517David Matthews, Wanda Melfo, Lene Hviid, Didier Farrugia, Paul Yates, FrankHijne

Over-Voltage Transients in the Secondary Side of EAF Transformers 2527Marcelo Murta G. Cardoso

Reliability Achievement Awards

2012 Silver Reliability Achievement Award Winner: Reducing Descale Pressure andFlow Improves Reliability While Maintaining Descale Effectiveness 2539Jason C. Vicari

2012 Gold Reliability Achievement Award Winner: A Practical Engineering Approach to

Improving the Reliability of Blast Furnace Tuyeres 2545Charles Copeland, Stuart Street

LUBRICATION AND HYDRAULICS

Lubrication

Studies of Microporous Polymeric Lubricants in the Steel Industry 2565Amy MinckLachman, Brandon M. Collins, Franklin H. Guzzetta, Alan J. Heckler

Optimization of a Cold Mill Rolling Oil for Grain-Oriented Electrical Steel 2571James DiLonardo, Carl Kennedy

REFRACTORY SYSTEMS

Steelmaking Refractories

New Refractories and Nanotechnology: Challenges of Carbon-Based Nanomaterials for Steelmaking 2579

Guilherme Frederico B. Lenz e Silva

Latest Developments in Magnesia-Carbon Bricks for Modern Electric Arc Furnace 2583

Gerald Buchebner, AshrafHanna, Karl-Michael Zettl

MATERIAL HANDLING/PACKAGING, SHIPPING

AND TRANSPORTATION METHODS

Material Handling

Guarding Equipment 2593

Paul Vandergeest

Inventory Management System for Slab Tracking 2599

Gordon Kilgore, John Burnett

Material Handling: Focus on Safety With the Customization of

Lifting Devices and Plant Wide Evaluations 2609

John Novak, Kirk Rounds, Larry Arnold

CRANES

Cranes

Taper Wheels Should Not Be on EOT Cranes! 2621

Charles A. Totten

A Study of an Improved Overhead Crane Wheel Flange Lubrication System 2631

Alan J. Heckler. Brandon M. Col/ins, Amy Minck Lachman, Franklin H. Guzzetta, Tiiomas Coyle