Conference Speakers

Abstract: The Coldry technology is a patented brown coal densification and pelletisation process that changes the naturally porous form of brown coal to produce a dry, dense, energy-rich pellet. Coldry technology will be utilized in the integrated demonstration plant as an efficient pelletisation process to supply composite Iron ore and lignite pellet feed for the Matmor process. Matmor is a technology for the production of High Quality DRI. The process operates at relatively low temperatures and is highly energy efficient. Utilizing novel reduction chemistry, the Matmor process has a favourable carbon intensity generating significantly lower CO2 emissions and a substantially lower water consumption while still producing high-quality DRI compared with conventional Iron making technologies. Given the utilization of low-rank coal and iron ore fines and reduction of CO2 emissions, feasibility studies indicate promising project economics with both CAPEX and OPEX advantages.

Abstract: Q-MELT Automatic EAF, thanks to self-learning capabilities, is able to drive the furnace in automatic mode towards the optimal operation conditions, by analyzing all the process variables to reach a given target. The MELT MODEL automatically adapts the process to reach the targets imposed by the specific production grades; it provides automatic correction of the melting profile on the L2; and it allows the consolidation of the plant best practices according to the selected KPI’s. Q-MELT Automatic EAF decreases conversion costs and increases market competitiveness.

Q-ONE is representing a completely new approach in terms of electric energy supply to EAF has immediate benefits like; precise current control on EAF electrodes, wider range of active power, power factor close to one. Electrode consumption, thermal stress on EAF panels, mechanical stress on electrodes and arms are reduced. Tap-to-tap time is shortened and electric energy consumption is decreased. The impact on electric network in terms of flicker, voltage and current unbalances, phase shift is practically negligible, since Q-ONE is decoupling the circuit that is feeding the EAF from the electrical distribution.

Abstract: With the Endless Casting and Rolling process, the Danieli Micromill (Mi.DA®) technology is nowadays a proven reality, leading to the most cost efficient rebar production.  Following the acknowledged success of the first Mi.DA commissioned to CMC Arizona, the E.C.R. process has been constantly supported by a growth strategy able to grant unbeatable performances in terms of CAPEX and OPEX. In the most recent years, bearing pillar of this strategy is the distinguishing approach represented by the Digital Manufacturing.

Abstract: Since the beginning of the 2000’s the technologies and methods used to produce wire rod have changed significantly. These new concepts have led our customers to invest (or to optimize their investments) because they believe that the market will continue to grow once this current economic crisis is over: together with the mill equipment suppliers, wire-rod producers sense the urgency to find innovative solutions that will increase the quality of their products, and provide considerable energy savings with improved mill performance. Danieli, as a world leader in the construction and installation of large steelmaking plants, has made great strides in assisting its customers, and/or prospective customers, to reach the rising global standards.

Abstract: High strength steel, advanced strength increasing concepts and solutions for lightweight construction by reducing the thicknesses until down to ultra-thin applications as well as other product properties asked for modern material design as given at pipe grades – and all at the lowest production costs. A new process achieves these defined targets: Arvedi ESP, standing for endless strip production. With precise thermo-mechanical rolling and rigorous temperature guidance in the narrowest possible operational windows, Arvedi ESP opens the door for the development of new and demanding steel grades in the shortest possible implementation time and with reduced alloying expenses on both ends, the thickest and thinnest part of typical production portfolios of hot strip mills. Low operation costs are also made possible by the most compact layout, lowest wear and the resulting energy savings coming from direct cast-roll connection and efficient temperature control by an inductive heater. Highest amounts of ultra-thin hot strips are being supplied to the market, including certain volumes traditionally produced via a cold rolling route. This is the most outstanding evolution in strip rolling, possible since the introduction of the Arvedi ESP process in 2009.

Abstract: ZincOx Resources has developed the Full Cycle technology to process zinc bearing steel wastes, and which transforms all the waste into valuable products. The process uses the rotary heath furnace to separate the dust into a zinc rich fumeand a reduced iron concentrate. The iron concentrate is melted in a reductive electric arc furnace to create pig iron and a saleable slag. The zinc rich fume undergoes a series of washing steps that eliminates impurities to create a zinc oxide of chemical quality (>99.5% ZnO), a lead (+silver) concentrate and a brine effluent that meets marine discharge standards. The process maximises the value of the waste’s components so that there is no solid waste, enabling profitable treatment even atlow zinc prices and so creating a sustainable solution for these hazardous wastes.The first plant using the core rotary hearth furnace equipment was built in 2012 and a second plant incorporating iron and zinc upgrading is under construction in Vietnam.

Abstract: Q-MELT Automatic EAF, thanks to self-learning capabilities, is able to drive the furnace in automatic mode towards the optimal operation conditions, by analyzing all the process variables to reach a given target. The MELT MODEL automatically adapts the process to reach the targets imposed by the specific production grades; it provides automatic correction of the melting profile on the L2; and it allows the consolidation of the plant best practices according to the selected KPI’s. Q-MELT Automatic EAF decreases conversion costs and increases market competitiveness.

Q-ONE is representing a completely new approach in terms of electric energy supply to EAF has immediate benefits like; precise current control on EAF electrodes, wider range of active power, power factor close to one. Electrode consumption, thermal stress on EAF panels, mechanical stress on electrodes and arms are reduced. Tap-to-tap time is shortened and electric energy consumption is decreased. The impact on electric network in terms of flicker, voltage and current unbalances, phase shift is practically negligible, since Q-ONE is decoupling the circuit that is feeding the EAF from the electrical distribution.

Abstract: i BOF®… a modular roadmap for achieving long-term, sustainable savings & productivity improvements by optimizing & dynamically control the BOF process. The i BOF® is an innovative Prediction & Control System for the Dynamic and Modular Control on a BOF convertor.

Abstract: Lean Natural gas may be easily available at one location, whereas water may be scarce commodity at other. Only small part of existing system could be a bottleneck in upgradation of an existing plant, whereas electrical power could be critical cost component elsewhere. Production capacity could be top priority in one instance, whereas Productivity and Efficiency could be priority in another. Addressing such issues, especially in a running plant is a big challenge considering the downtime loss and other limitations. Innovative solutions for optimization for gas based DRI plant can be applied to existing operating plants or to new designs.

In the competitive world of manufacture, it always is a challenge to optimize the plant design and operation given the fact that different plants operate in different geographical and socio-economic zones. The quality, availability and costs of inputs vary across these zones and so do environmental requirements. Single rule book cannot be devised for solutions to all such plants, and hence, the objective of this paper is to discuss innovative engineering approach. Lean Natural gas may be easily available at one location, whereas water may be scarce commodity at other. Only small part of existing system could be a bottleneck in upgradation of an existing plant, whereas electrical power could be critical cost component elsewhere. Production capacity could be top priority in one instance, whereas Productivity and Efficiency could be priority in another. Addressing such issues, especially in a running plant is a big challenge considering the downtime loss and other limitations.

It is required to have an open and innovative approach while addressing such ‘local and specific’ constraints. It is required to be updated about the new trends in technology and equipment engineering as well. The ‘cross knowledge’ from different sectors of industry can help this approach. The paper discusses some examples and suggested innovative solutions for optimization for gas based DRI plants, as can be applied to existing operating plants or to new designs.

Abstract: The Coldry technology is a patented brown coal densification and pelletisation process that changes the naturally porous form of brown coal to produce a dry, dense, energy rich pellet. Coldry technology will be utilized in the integrated demonstration plant as an efficient pelletisation process to supply composite Iron ore and lignite pellet feed for the Matmor process. Matmor is a technology for the production of High Quality DRI. The process operates at relatively low temperatures and is highly energy efficient. Utilizing novel reduction chemistry, the Matmor process has a favorable carbon intensity generating significantly lower CO2 emissions and a substantially lower water consumption while still producing high quality DRI compared with conventional Iron making technologies. Given the utilization of low rank coal and iron ore fines and reduction of CO2 emissions, feasibility studies indicate promising project economics with both CAPEX and OPEX advantages.

Abstract: This innovative approach converts carbon and hydrogen-rich off-gases, such as coke oven gas, blast furnace top gas and also converter gas into liquid based energy sources through a biological gas fermentation process to produce preferably ethanol or other chemicals. To produce ethanol, an integrated fermentation system with additional downstream installations is required to treat the fermentation product and waste streams. The treatment of the fermentation waste streams results in a number of by-products, usable for internal or external applications. By returning the by-products to an integrated steel plant or recovering the inherent energy, the fermentation system can be operated in circular system, with minimal waste. The first European commercial scale application of this technology is being developed at the ArcelorMittal steel plant in Gent with the objective of producing 80 million liters of ethanol per year to be used as renewable transport fuel.

Abstract : The FINEX Process has been developed jointly by POSCO, Korea and PRIMETALS Technologies Austria, to provide the iron making sector with the capability to lower hot metal production costs, environmental pollutions and to increase the flexibility in terms of operation and the choice of raw materials. FINEX® is a new technology combining a gas-based reduction in a series of fluidized bed reactors and a reduction smelting in a melter gasifier. The innovative process concept of FINEX produces hot metal identical to the blast furnace route, however without coke oven and sintering plant. Commenced in April 2007, the first 1.5 mtpa commercial plant has demonstrated the competiveness as an alternative iron making route. Another 2.0 mtpa third generation FINEX plant was installed at POSCO, Pohang Works and has been operating satisfactorily since its blow-in in January 2014.

Abstract: Earlier, induction furnace route started its journey of steelmaking with plant capacities around 30,000 TPA to 0.1 MTPA. With continuous developments, the capacities got gradually enhanced to 0.3 to 0.4 and then to about 0.75 MTPA. However, with latest developments of DIFOC technology based world’s most energy efficient large capacity DTi model of induction furnaces by Electrotherm, installation of 1 MTPA steelmaking plant has become a reality. This production can be achieved with just three sets of 30 MW / 60 ton induction furnaces, one 70 ton ladle furnace, and one 4 or 5 strand high speed caster. Earlier, such production would have employed battery of induction furnaces making the whole process and management quite cumbersome. Compared to BF-BOF route or EAF route, induction furnace based steel plants can be erected and commissioned with much lower CAPEX, in incomparably lower gestation period, and most importantly, to produce high quality construction grade steel at substantially lower OPEX. The quality of steel produced through IF-LRF-CCM route is at par with steel produced through any other route. One can also integrate vacuum degassing (VD) unit to produce even forging grade steel and alloy steel through this route.

Abstract: Highly efficient mini mills with scrap preheating, direct rolling, and new process models. Steelmakers are facing challenging times due to production overcapacity, volatile markets, and stricter environmental regulations. As a consequence new investments for mini mills are focused on conversion cost, foot print, quality requirements of the final product, and efficiency of the mills. Steelmakers have the possibility to build a customized solution based on market environment, end product size, and quality. The paper will focus on mini mills with a capacity up to 450,000 tons per year of long products. It points out ways to reach a high flexibility of input materials (scrap, DRI, HBI), lowest conversion cost, and smallest footprint. Operational results as well a detailed overview of the newest technology implemented in recent projects related to scrap preheating, direct rolling, automation, and safety will be shown. Due to all-embracing process models, a new level of automation and mill efficiency can be reached.

Abstract: R&D of Tata Steel has in its work on Coal and Coke has discovered a new way of crushing coal so as to improve the proportion of Non-coking Coal that can be used in Cokemaking. The new crushing method exposes a larger proportion of vitrinite thereby enabling higher proportion of non-coking coal to be used. [Status: Has been proved at the laboratory and pilot scale (200kgs)

Abstract: Primetals Technologies has developed several solutions for increase of scrap rates in converter steelmaking. This solutions include upgrade packages that can be installed on existing converters like scrap preheating system, post combustion lances or process control models to optimize the heat balance and reduce reblow rate. Combination of such packages is possible and scrap rates up to 30% can be achieved. For even higher scrap rates the Jet Process was developed. This process is employing a bottom blowing converter with coal injection and a special post combustion lance. This way very efficient heating can be done and scrap rates up to 50% combined with highest productivity can be achieved.

Abstract: Continuous casting has become the major solidification technique in steel making all over the world. This is the result of continued innovation and developments. Although conventional continuous casting remains the key technology, in the recent years near-net- shape casting has taken over in specific areas. Productivity, quality and cost efficiency remain the driving forces for further developments. It seems that the continuous casting machine still has too much to offer us as its added value for the steel industry. It is also scalable and upgradable, day by day and proves to be one of the key tools necessary to achieve sustainable development goals in the steel casting industry. By applying Eco Endless Production Process, millions of natural gas cubic meters and millions of electric energy kwhs will be saved and emission of greenhouse gases can be reduced.

Abstract: Continuous casting has become the major solidification technique in steel making all over the world. This is the result of continued innovation and developments. Although conventional continuous casting remains the key technology, in the recent years near-net- shape casting has taken over in specific areas. Productivity, quality and cost efficiency remain the driving forces for further developments. It seems that the continuous casting machine still has too much to offer us as its added value for the steel industry. It is also scalable and upgradable, day by day and proves to be one of the key tools necessary to achieve sustainable development goals in the steel casting industry. By applying Eco Endless Production Process, millions of natural gas cubic meters and millions of electric energy kwhs will be saved and emission of greenhouse gases can be reduced.

Abstract: The i- MILENA gasification technology is a promising alternative for the efficient conversion of (high ash) low rank coal for power production. The i- MILENA is suitable for high to very high-ash coal and other low rank coal. During tests with various low-rank coals from Turkey and India, the lab-scale tests showed that i- MILENA technology can gasify coals with more than 50 wt% ash, efficiently producing a medium-calorific gas without the requirement of an Air Separation Unit (ASU), contributing to better quality of air.

Abstract: Crude Steel Production of Iran was21 Million & 884 Thousand Tons in last Persian Calendar Year corresponding to March 2017-March 2018. During the same period the Iran’s Crude Steel Output Capacity reached to 33 Million Tons. Iranian steelmakers aim to increase Crude Steel Output Capacity to 55 Million Tons per year by the deadline as per the targets set in the 20-Year Vision Plan (2005-25) named as “Steel Comprehensive Plan”. The plan was first floated in 2004 and integrated into the Fourth Five-Year Development Plan (2004-9) the following year. The plan was revised in 2007 under the title “Iran’s Industrial Development Strategy,” in which the total Crude Steel Output Capacity is expected to reach to 55 Million Tons. The Capacity Expansion, New Projects, Technologies and US Sanctions will directly affect the Iran’s Steel Vision 2025; however Iran is trying to use non-US and its allies’ substitute machinery and local made equipment as well as technology such as PERED to achieve the goal in Vision 2025.

Abstract: Intelligent combination of process automation, information technology, and connectivity enables the digitalization of steel production that goes far beyond conventional automation of industrial production. Several initiatives like IIoT have been implemented all around the world. Smart sensor technology combined with advanced digital models as well as quality and production planning and control systems provide huge potentials along the entire production chain. The result is quality improvement and production cost reduction together with process flexibility. This paper is drafting a vision of the intelligent steel production of the future as well as showing a stepwise approach to reach this ambitious target inspired by the experience of more than 2,000 successful automation projects executed in the metals industry.

Abstract: The process of digitalization in many industries is creating new opportunities for improvement of overall efficiency and quality in the steel production. At the same time, end customers are demanding steel products at higher quality levels, tailor-made steel-grades, short development time and to respond to any quality deviations to avoid down-grading of the products. Producers require quick and complete access to quality and process relevant data, a deep understanding on how a change in process parameters will affect the product properties and comprehensive know-how to develop new products successfully. TPOI (Through Process Optimization) solution, which targets the smart, digital interconnection of various process units and the accumulation of know-how along the entire steel production chain.

Abstract: Today’s steel producers face the dual challenge of ensuring on-time delivery and ever demanding product requirements, while also running a lean operation. Every day the management of a long rolling plant requires continuous optimization of both operating and business practices. Imagine a long rolling facility, where individual pieces of equipment communicate with each other, where sensor information can be used not only for control purposes but to also monitor the condition of the equipment, where models are used to verify the process is within working limits and the equipment raises alerts to operators when it requires maintenance.Utilizing the ongoing evolution in technology though data collection, communication, internet of things, control techniques and smart sensors, there is now more information available than ever before. The collection and analysis of this information will both advance control and monitoring of plant performance; revolutionizing long rolling mill plants worldwide and optimizing the entire value chain, along with improved and more flexible production.

Abstract: Waste management in iron and steel industries has always been considered as a challenge. Around 900 kg of solid waste is generated for every ton of steel produced. Of the large quantities of slimes, dusts, sludge and mill scale generated during processing in an integrated steel plant, only a meager quantity is recycled while the rest is dumped as land fill. Dumping steel plant wastes in open or excavated land creates environmental pollution apart from huge financial liability. These process wastes contain valuable minerals such as iron, carbon, lime etc. The major challenge in recycling/reuse of these steel plant process wastes is their ultra-fine size, wide variations in composition, moisture and recovery components. Each type of dust or sludge demand different kind of treatment.

In recent years, these process wastes are gradually being recognized as an opportunity to reduce costs and generate revenue through effective management. JSW Steel has developed and adopted a number of innovative technologies by which these wastes are being effectively processed for recycling back into the process leading to conservation of natural resources, environmental mitigation and cost savings. Conversion of dusts into micropellets, mill scales into briquettes, recovery of iron values from slimes, dust and sludge through slime recovery plant and iron recovery plants are some of the glaring examples at JSW Steel. This paper deals with the characteristics of process wastes generated in an integrated steel plant and the technologies developed/adopted for their effective recycling and reuse in the process.

Abstract: Worldsteel has set up benchmarking and assessment systems for its members to measure the performance of steelmaking processes in a secure, anonymous way, which is free of cost. This suite of systems allows any steel company to continuously track, measure and aim to achieve the best-in-class performance in a global setting.

These systems have been developed by industry experts and are continuously being updated to reflect the latest developments in iron and steelmaking processes. The following six systems allow any company to effectively manage and measure its performance:

1. Energy
2. Process Yields
3. Maintenance & Reliability
4. CO2
5. Safety
6. Sustainability

These systems allow companies to understand the improvement potential in a holistic way, aim higher and work towards saving energy, maintenance costs, lowering CO2 and higher yield. The benefit directly translates to savings in millions of dollars at no external spending – only by becoming aware of the potential for improvement and working towards achieving it.

Abstract: Slag Atomization is a new technology in creating PS Ball. With the use of Slag Atomization Technology, the unstable fusion of slag metals shall be transformed into an eco-friendly Spinel structured product; PS Ball. It is a state of the art technology that changes 75% of slag metal to PS Balls.

Abstract: Steelmaking slag is recognized as a domestic source of phosphorus and manganese. To recover phosphorus and manganese selectively from steelmaking slag, three technologies were developed. In the leaching process, the difference of solubility in aqueous solution between the solid solution of high P2O5 content and other phases is used. By controlling the pH, selective dissolution and precipitation of phosphate is achievable. In the selective oxidation process, the difference in activity between P2O5 and MnO in acid slag is used. The selective reduction of phosphorus could be performed. In the sulfurization process, manganese in slag is selectively sulfurized as the phosphorus sulfide is unstable at high temperatures. 

Abstract: What are the ways by which production of bar millscan be enhanced? Is slit rolling the way out, A process which differs from conventional continuous rolling by the use of special roll passes and guides to prepare, shape and longitudinally separate the incoming billet into two or more individual strands for further rolling into the finished size. This presentation evaluates the slit rolling technology and its merits, demerits and limitations through case studies.

Abstract: The Rotary Hearth Furnace Process is a fast direct reduction process which takes cold bonded pellet containing carbon as material of RHF coal gas from twin zone gas furnace as heat sources of RHF air and gas preheated for reusing RHF gas waste heat and the metalized pellets used for coolants in converter process. Through the trial production of several months the RHF is a commercial success. RHF can effectively recover valuable metal from dust and sludge of steel plants, metalized pellets can keep original shape, good strength and about 80 percent metallization. In the testing phase two lines of 2, 00,000 TPA RHF was produced.

Abstract: Monolithic casting of BF hearth, which replaces the traditional brickwork, is a real “Cup” structure, providing higher structural strength and anti-scouring resistance. The technology only needs to pump the stirring materials into the mould which is placed in advance, and after the materials are hardened, the mold can be removed. After simple baking, the castable working layer can be put into production. It makes complete use of residual carbon brick, continuous pumping, with construction capacity up to 15t/h, the overall construction time just needs 7 days. Silica sol combination materials, which can be fast drying explosion, providing good integrity, high strength, resistance to slag and iron erosion.

The practice of transforming the main trough of Blast Furnace with simple tap hole into iron store structure with New Anti- Explosive castable refractory. After transformation the service life from 4-7 days is more than 60 days, the labor intensity of the furnace workers is greatly reduced and also leads to lesser pollution. The water cooling system of main iron trough and slag trough will provide great thermal conductivity and will reduce temperature of the material which can reduce molten slag from erosion and abrasion to iron trough and prolong the service life. Rapid hot repair from main iron trough, the shotcreting technology can repair iron using the tapping interval time and can effectively extend the service life of iron trough. Significantly, reducing inevitable 15- 20 hours of repair time.

Abstract: Digi & Met is the cross-functional business unit Danieli has created to develop and implement new plant design concepts, based on digital innovation, and also new business models based on servitization and outcome economy principles, to ensure consistency in quality, plant utilization, OpEx and faster deliveries. Digi&Met aims to provide customer digital innovation under new business models, simplifying Metals complexity.

Abstract: The presentation summarizes the position of the coreless induction furnace as a melting unit for “Micro” steel mills with production levels up to 1 million tonnes per year. It discusses the advantages and disadvantages of the induction furnace. Ancillary equipment such as charging systems, fume collection, slag removal and refractory selection are also covered. The types of power supplies, the furnace construction and equipment combinations are presented. The factors that will influence energy usage are discussed. Included is a summary of the performance of equipment able to provide 1 million tonnes per year.  

Abstract: The PERED® Direct Reduction Process is a New Improved energy efficient technology converts iron oxides, in the form of pellets or lump ore, by reacting with CO & H2 to highly reduced products like CDRI, HDRI & HBI suitable for steel making with flexibility to work with different raw material and energy sources and reducing the overall cost with salient features as below.

PERED® Vertical Shaft Furnace designed to improve the solid & gas flow patterns to improvise the reaction being taken place designed to have higher production rate / volume of reduction zone.

Decrease clustering possibility

Solid material flow regulation with less fines generation, Eliminates possible pollution due to leakage, lower maintenance cost & utilization of available heat for In-situ reforming and higher Carbon formation.

Top & Cooling Gas off takes to reduce fines carry over to decrease oxide loss and to improve life & efficiency of Ducts, Scrubbers & Clarifier

State of the art 360 degree rotating independently controlled burden feeders

Utilization of Process Gas Co

mpressor capacity with less power consumption.

High efficient recuperator along with steam generation to decrease the exit flue gas as low as 250 Deg.C. With lower NG consumption with improved life for tube bundles.

Safe & High efficient Reformer with Super active PERFORMEX catalysts

At present three plants rated capacity 0.8MTPA are in operation in Iran and results near to the expected values even with the inferior quality pellets. Two more plants under construction. Development of Jumbo module with higher capacity up to 2.0 MTPA with different kind of products like CDRI, HBI & Hot charging to EAF are under progress. With the success of the PERED® Technology, More plants are expected to use this technology in Iran as well all around the globe.

Abstract: HiSmelt is a direct smelting process for making iron straight from the ore. Fine iron ores and non-coking coals are injected directly into a molten iron bath, contained within a Smelt Reduction Vessel (SRV), to produce high quality molten pig iron. The excess gas produced during the process is used for power generation, production of direct reduced iron (an alternative iron input for scrap), or as fuel gas.

The process can be considered a both a potential replacement for the blast furnace and as a new source of low cost iron units for BOF or EAF steelmaking. The technology offers advantages such as lower operating costs; lower capital intensity, lower environmental impact, greater raw material and operational flexibility.

Abstract: HIsarna is a new ironmaking process which is being developed at Tata Steel. It is a smelting reduction process where granular iron ore and granular coal are directly injected into the process, without the need to agglomerate the ores or coke the coal. This process intensification alone results in a specific CO2 emission reduction of 20%. Further CO2 emission reductions without carbon capture technology are possible with this process by charging scrap as part of the metallic charge and replacing part of the coal with sustainable biomass. A project to demonstrate the feasibility of this further CO2 emission reduction was granted as part of the European Union’s Horizon 2020 programme. It was one of the Sustainable Industry Low Carbon II (SILC II) projects, where a CO2 emission reduction of at least 35% without carbon capture had to be demonstrated. This paper describes the operational aspects of the HIsarna pilot plant and summarises the results achieved so far.

Abstract: A special purpose company – has been formed to clean and coat TMT rebars and is the first of its kind in the World, for multimetal alloy coating of TMT rebars.

• A unique new corrosion protective rebar product has been launched & established in the market under a unique brand name, which is Multi Metal Alloy coated having several technoeconomic advantages over other comparative coating processes.

• The product, a multi metal coated rebar, is technoeconomically superior with corrosion protective extended shelf life, rust free product presentation, better aesthetics than the competition and highly extended construction life.

What is Electro Metal Fusion Technology (EMF)?

Electro Metal Fusion Technology (EMF) is the process to clean and coat metals under ionic environment.

• Especial DC Current, Filtered – Conditioned – Stabilized, is used in the liquid/foam/vapor/gas conductive medium.
• EMF may be used to clean and/or modify microstructure/morphology and/or to coat multi metal alloy coatings on metals.
• EMF can be developed for materials of different sizes and shapes, including the long and flat products.
• GREEN & Environmentally Friendly Technology.

How Does EMF Work?

Ionic atmosphere is generated in a controlled discreet manner on the surface of the metal.

• In ionic state the surface is exposed to very high temperature of 3000 and above degree Celsius forming crests and troughs of molten metal, while it distinctly retains the properties of the base metal.
• Under this environment, multi metal fusion bonding of different metals takes place making a uniform alloy coating over the base metal.

Abstract: The presentation will display the advantages of different value-added products, and the process improvements that were made at AGIS. The primary products which have been developed and successfully offered to customers are Lead-Free Galvanized steel sheet, Chrome+3 & Thin Organic Coating (TOC) Galvanized sheet and High strength structural steel (Yield strength: 450 – 550 MPa with El: 8 -2 %). For overseas shipment of Galvanized Steel coils, AGIS uses a revolutionary Strang system (Expanded Poly Styrene-EPS) for container loading which provides safe, flexible & highly efficient workings as well as minimizes the usage of wood.

It will help structural Designers and End users to resolve their challenges related to environment, process & product performance. We believe in long-term customer relationship and keep our customer informed about material and technical developments to give them a better understanding of our products and the advancements in our industry.

Abstract: In the current scenario of massive depleting of natural resources for industrial production leading to increase of pollution and hazardous substances on the water bodies, Danieli offers the optimal solution of wastewaters reuse by reducing or zeroing the demand of primary waters. Municipal and industrial wastewaters reuse combining the biological treatment with total recovery by “Zero Liquid Discharge”, is the state-of-the-art advancement, providing effective zero fresh water consumption and zero wastewater discharge, fulfilling with concept of circular economy and sustainability in metal production. From a source of pollution, Danieli transforms the waste into a new economic value.

Abstract: In the last two decades the global energy consumption and carbon dioxide emissions have increased of ca. 55%, due to the present energy production mix. The steel and non-ferrous production covers even the 6% of total energy demand, and it accounts for up to almost 12% of global CO2 emissions. Policies on environmental issues are becoming stricter and being able to anticipate new regulations will be the key to stay in the market. The following routes are going to help make sustainable changes-

Route 1: BF/BOF – This is a very mature technology, so only a limited energy reduction is possible, mainly by improving the auxiliary equipment (e.g., gas cleaning system) and by optimizing integration of energy throughout the plant.

Route 2: DRI/EAF – The DRI plant is already close to its limits, so the ways to reduce the carbon footprint and energy use are two: (1) remove as much CO2 direct emission as possible; and (2) feed the DRI directly to the EAF at high temperature, to save on furnace electrical consumption. These features are already available on the ENERGIRON ZR technological package, which reduces significantly the environmental impact of his plant.

Route 3: Scrap/EAF – It is at less than 70% of the practical limit of energy consumption, so there is still room for improvement. Much can be done in process control: Danieli developed Q-melt, a technological package that has been proven helpful to reduce consumption at the Turkish plant of KromanÇelik, with a reduction of carbon footprint by almost 23 kgCO2/t.

In the future, savings will be possible also with scrap yard metal management; continuous charging; closed furnace; fumes control and energy recovery; slag and dust recovery; no men around.

Abstract: In the advent of global competition and usage of high alumina and silica ores pose a new challenge requiring break through operations of Blast furnace operation. This includes technologies to use cheaper and lower-grade raw materials combining process control parameters like minimum HBT of 12000 C. This helps in ultra-high PCI thereby promotion of cost savings, energy saving and, reduction environmental problems. 

Abstract: Biogas is the gas generated from degradation of organic material, based especially on methane. The methane is one of the Greenhouse Gas and contributes to this effect. To reduce this contribution, appear new ideas on renewable source of energy, and the use of biogas replacing a part of the material injected on blast furnaces in Iron and Steel making Industry is one of them. Brazil has a large herd animal, making it a major agricultural producers, while rich in natural resources, Brazil has an important role in the steel industry, these two activities now represent the largest contributors to greenhouse gases responsible for the greenhouse effect, the purpose of this paper is to show a solution for these two processes, thus mitigating the emission of polluting gases into the atmosphere. In this study, we noted that the use of agricultural wastes for production of biogas and the use of biogas as auxiliary fuel in blast furnaces. The study showed that Brazil has a great potential to transform the steel industry and agriculture, with a very good results on social and environment areas.

 Abstract: Danieli has progressively developed over the years a new generation of thin slab casting and rolling layout, marking a new phase in the evolution of this process. The new step-ahead is a new development within the Quality Strip Production (QSP) family, which is the Danieli’s strip-quality-oriented thin slab based plants. What makes this new concept different is the ability of “universal” rolling modes thanks to the fact that, now, within one single plant it is possible to perform different rolling modes, making this plant a major technology innovation compared to the previous generation. This new approach can be seen as the natural evolution of the original, successful Danieli concepts that marked the progress of the thin slab route, namely the application of the vertical curved design thin slab caster and the separation of the rolling stands into high reduction units and finishing units.

Abstract: The use of large size silo systems allows a significantly increased storage volume on the same footprint as a conventional stockpile. Each silo can be used for different material qualities and with the use of AUMUND Rotary Discharge Machines (RDM) travelling underneath the silos; every required blend can be extracted by requirement. Such closed storage and material extraction solution suppresses any dust development.

With the use of AUMUND high temperature resistant pan conveyors no additional fines are being generated as there is no relative movement between the conveyor and the hot sinter meanwhile significantly reducing equipment wear and tear.

Thermal insulation transport of Hot DRI in a non oxidizing inert atmosphere significantly saves energy. Energy savings up to 120kW/t liquid steel can be achieved, Tap-to-Tap cycles will be drastically reduced and productivity of EAF increased up to 20%. HBI producing routes are using newly developed and patented HBI cooling method which uses water mist as cooling media thus achieving smother cooling of HBI resulting in stable product quality and final Temperatures below 100˚Cfor optimum downstream handling and storing.

Abstract: The Steel Department of CMRDI is oriented to deepen and maximize the local manufacturing of special steels. These efforts include development of the technology package for the production of special steels of large imported and large market needed quantity with high cost, production of special ferroalloys required to produce such steels and improving the economics of steel production through recycling of produced waste materials. Mill scales is one of the major wastes for steel industry that was a good candidate for the research for recycling and reuse, CMRDI team worked on mill scale as potential candidate to be a good economic factor in steel industry by innovating recycling technologies for production of high add value expensive products as high purity iron and special steels.

Abstract: The conceptual and scientific breakthroughs that underpin ‘green steel’ have paved the way for an unparalleled portfolio of new ‘waste to value’ science, built over years of research at the Smart Centre, with valuable contributions from industry partners. The internationally commercialized EAF ‘green’ steelmaking process is utilizing millions of waste tyres otherwise destined for landfill as a partial replacement for coke. The high temperature environment in steelmaking is leveraged to revolutionize the role of steelmakers to play in globally significant in large scale recycling of rubber tyre. This innovation offers an excellent opportunity to improve efficiency while positively impacting the environment through energy savings and the transformation of waste tyre.

Abstract: This innovative approach has the potential to transform end-of-life automotive waste, like glass, plastics, and oxidized metal into value-added materials− a valuable (Si, C, Fe) resource for green manufacturing of ferrosilicon. The process involves the novel technique of using high temperature processing of a mixture of the components of the waste to reform into green materials including ferrosilicon and silicon carbide. Therefore, our world first discoveries have created a new resource from automotive waste; which is currently disposed off in landfill. This research won ‘Sydney Engineers Excellence Award’ in 2014 for both Research and Development Excellent Award and President’s Award categories.

Abstract: The insulation compound is an innovative product which traps and reduces the graphite flake emissions from liquid hot metal and reduces the skull generation in main runner and in ladles. The product is an iron based compound, which, when it comes in contact with the hot metal, generates a protective slag layer. It is added in front of the tap hole, just as the metal hits the main runner. Instantaneously, the protective layer of slag forms and metal gets a slag coating. The fumes and graphite particles released from the liquid metal junction is suppressed in the slag. When the normal slag flow starts, our slag flows along with it. Since the slag covering sticks to the liquid surface, it covers the hot metal surface even when the ladle is tilted for pouring purposes, allowing no scope for graphite emissions into the atmosphere.

Abstract: Slag Atomization is a new technology in creating PS Ball. With the use of Slag Atomization Technology, the unstable fusion of slag metals shall be transformed into an eco-friendly Spinel structured product; PS Ball. It is a state of the art technology that changes 75% of slag metal to PS Balls.

Abstract: Reinforcement steel rebar is a vital material for RCC structure. Thermo mechanically treated (TMT) rebar using QST process is very much popular because high strength along with moderate elongation is achieved through normal C-Mn only without any micro alloy addition. During earthquake, rebars are expected to undergo large inelastic/ plastic deformations before failure for adequate seismic energy dissipation and thus it places certain special requirements on their properties, such as high yield strength(YS) high ultimate tensile strength to yield strength ratio (UTS/YS ratio). In India, seismic resistant grade IS1786: 2008 Fe500S has been incorporated in the amendment done in 2012. Since then various steel manufacturers have tried and successfully developed Fe500S grade through micro alloy addition and without quenching and self-tempering process, which increases the cost of production. This work describes the success story of development of cost effective Fe500S grade steel through C-Mn route using QST process. Mechanical properties achieved are YS>500MPA, UTS/YS ratio > 1.25 and uniform elongation > 8%.

Abstract: Design, build and start-up innovative, state-of-the-art, CAPEX and OPEX optimized Cold processing lines to produce high quality steel. Two selected examples are showing breakthrough technology in efficient cold rolling as well as added value and green technology in Danieli’s galvanizing technology. Steel makers operating discontinuous cold rolling mills are forced to increase yield and constancy in cold product quality, without investing in expensive continuous facilities. To achieve this target, Danieli offers solutions by operating coil weights up to 90 tons in discontinuous rolling mills. Core technologies used for these innovative plant concepts are Danieli’s new developed, high efficient laser welding technology, the newly developed Yield Boost Technology to significantly reduce yield losses at the strip ends as well as the OSRT technology for best strip flatness results. In galvanizing lines, the zinc pot is the most effective area to reduce costs in operation and consumables and at the same time increase the product quality. The new X-JET wiping system was developed as a complete Integrated Technological Package, capable of increasing the performances of coating weight control: in terms of pure wiping efficiency, tight process control and reduced operator interference. Installations in green field plants as well as upgrade packages for existing lines already proved the superiority of this new technology.

Abstract: The compact endless casting & rolling mill (CEM), the energy-saving steel making process which directly links a single continuous caster and a single hot rolling mill. CEM mainly composes of thin slab high speed casting technology and endless rolling technology, which are possible to produce thin gauge hot rolled coils more stable than the batch rolling. Uniform product quality can be obtained successfully which sustains unchanging rolling conditions such as the material temperature and the threading speed. Consequently, it is effortless and efficient to control the strip cooling in the run-out table zone to produce automative steel like the advanced high-strength steel. Moreover, CEM product with uniform material quality, great surface quality, accurate thickness and width quality has been brought the excellent results in application of automative manufacturing.