Proceedings of the Iron & Steel Technology Conference Volume I 4-7 May 2015 Cleveland, Ohio U.S.A. ASSOCIATION FOR IRON & STEEL \^ MMUOMMm Ronald E. Ashburn, Publisher Karen D. Hickey, Managing Editor Christopher P. Brown, Lead Graphic Designer Krista J. McGhee, Graphic Designer A Publication of the Association for Iron & Steel Technology
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Proceedings of the Iron ; Vol. 1 - GBV · 2015-08-06 · DevelopmentofNutCokeActivation forEnergy-Efficient BlastFurnaceOperation 638 Maria Lundgren, Lena Sundqvist Okvist, CarinaBrandell
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Proceedings of the
Iron & Steel Technology Conference
Volume I
4-7 May 2015
Cleveland, Ohio
U.S.A.
ASSOCIATION FOR IRON& STEEL
\^ MMUOMMm
Ronald E. Ashburn, Publisher
Karen D. Hickey, Managing Editor
Christopher P. Brown, Lead Graphic Designer
Krista J. McGhee, Graphic Designer
A Publication of the Association for Iron & Steel Technology
TABLE OF CONTENTS
AISTech 2015 - Volume I
Author Index Al
COKEMAKING/ICSTI
Coke Oven Battery Construction and State-of-the-Art Technology in Cokemaking
Construction and Operation of NSSMC Kashima IE Coke Oven Battery 1
Satoshi Ishikawa, Kakunari Suzuki, Hideyuki Kunimasa, Yuji Komai, Ryousuke Iki
Recent Experience in Commissioning Two Full Sets of Coke Oven Machines: Plant Features and Project
Organization 10
Giovanni Siri, Alessandro Molinari, Klaus Nowitzki
PT Krakatau POSCO's Gas Treatment Plant in Cilegon, Indonesia 19
Fabio Cerutti, Antonio Esposito, Bjorn Otten, Mario Petzsch
Evaluation of Coke Quality & Its Impact on Blast Furnace Performance
Criteria to Evaluate Cokemaking Strategy for an Integrated Steel Plant 28
John Busser, M. Sukhram
Using Modern Coke Oven Technology at the New Hyundai Steel Coke Plant 38
Marcel Schulz, Klaus-Peter Leuchtmann, Jin Hyung Chung, Yong Mook Kang
Fundamental Coke Kinetic Studies Using a Coke Analogue 56
Apsara Jayasekara, Raymond Longbottom, Brian Monaghan
Macrostrength and Pore Structure of Coke Subjected to Gasification and Annealing Under Blast
Furnace Conditions 64
Xing Xing, Harold Rogers, Guangqing Zhang, Paul Zulli, Oleg Ostrovski
Micro-CT Analysis of Coke and Its Relationship to Coke Quality Indicators 77
Hannah Lomas, David Jenkins, Merrick Mahoney, Richard Roest, Robin Pearce, Ron Li, Sheridan Mayo, Dadong Wang
Evaluation of Coke Strength 87
Philip Bennett, Adrian Reifenstein, Frank Shi
Safety & Environmental Performances — The Two Core Values of Cokemaking
Quality and Classification of Metallurgical Coke 103
Richard Pearson, David Pearson, HeeKyoung (Jackie) Park, Yuekan Jiao
Investigation of Coking Behavior of Coals Using an Automated Plastometer Ill
Liming Lu, Alex Edenton, Qingbo Meng, Merrick Mahoney
NFPA Combustible Dust Standards and Cokemaking — How These Regulations May Affect You 119
Fredric Owens, Vernon Jones
Determination of "End of Coking" in Byproduct Recovery Cokemaking 126Matthew Lumadue, Shiju Thomas, S.J. McKnight, Scott Pisula, Matthew DeLibero
Full-Scale Treatment of a Coke Oven Wastewater Using Immersed Membrane Biological ReactorTechnology 132
Art Kuljian, Jeff Penny, Joshua Harrison
Prolongation of the Life of a Coke Oven Battery — How to Protect the Asset
The Latest Developments on the EnviBAT Pressure Regulation System 147
Frank Krebber, Joanna Kiihn-Gajdzik, Keratin Uberschar, F. Hegner, M. Diephaus
Laboratory Method for Coking Pressure Determination 154
Aleksander Sobolewski, Marek Sciazko, Bartosz Mertas
Development and Production of High-Density Silica for Coke Ovens 161
Stanislav Dvorak, Karel Lang, Leopold Vasica
Coke Oven Life Prolongation — A Multi-Disciplinary Approach 164
Jorge Madias, Mariano de Cordova
Predictive Model for Blending Coking Coals — Part 2: U.S. Coals 176
William Ross Leeder, Louis Giroux, Ted Todoschuk, Cameron Howey, Ka Wing Ng, Tony MacPhee
Industrial Study on Coal Handling Bulk Density Control 187
Ted Todoschuk, Ka Wing Ng, Louis Giroux, Tony MacPhee
Replacement of Equipment & Improvements at Existing Cokemaking Facilities
#1 Battery Collecting Main Replacement and Roof Repair Project 198
Nagendra Singh, Tim Candiano, Dale Heinz
Improvements in the Operation of Coke Plants Through Alignment Process Optimization 215
Fernando Marsonet, Edgardo La Bruna, Scott Wassell
IRONMAKING/ICSTI
Ironmaking Modeling I — Prediction & Control
Stable Blast Furnace Operation by the Application of Predictive Process Models 225
Jan van der Stel, Hans Jak, Trevor Bell, James Raleigh, Tim Peeters, Kirill Andreev
Analysis of Transient Processes in Blast Furnace 237
Yakov Gordon, Nikolai Spirin, Vladimir Shvidkii, Yuriy Yaroshenko, Boris Bokovikov, Vitaliy Moikin, V.V. Lavrov
Development of Visualizing System of Blast Furnace Operation and Application to Operation 245
Atsushi Inayoshi, Shinroku Matsuzaki, Masahiro Ito
Improvement of Blast Furnace Performance by Applying a High-Efficiency Expert System 254
Xuegong Bi, Peng Li, Jindong Zhou, Wei Peng, Kuangnian He, S. Zhong, X. Zhong, D. Bai, W. Pan, K. Liu
General Mathematical Model of Adjusting Blast Volume of Blast Furnace Tuyeres 261
Yanglong Li, Shusen Cheng, Chuan Chen
Blast Furnace Operations I — Campaign Life & Productivity
ArcelorMittal Tubarao Blast Furnace #1 First Campaign: Historical Results, Main Issues on Its Reline,Technological Updates, First Results of Second Campaign and Perspectives 270
Claudio Cesar da Costa, Ernandes de Souza Belonia Filho, Luiz Wasem, Emerson Ribeiro, Salustiano Pinto Jr.
Assimilation Behavior of CaO Source in the Sintering Process 457
Chishiro Funada, Jun Okazaki, Daisuke Ikeguchi
On-Line Conveyor Belt Elemental Analyzer for Sinter Feed Chemistry Control 465
Kevin Gordon, Garry Noble, Mick Stuckings
Evaluation of Hydration Characteristics of the Lime Used for Iron Ore Sintering Based on the
Constant-Temperature Calorimetric Method 471
Shengli Wu, Li Zhang, Yongzhong Zhang, Maojun Zhou
Characterization ofWetting Behavior Between Calcium Ferrite Series Melts and A1203,
MgO Substrate 481
Xuewei Lv, Bin Yu, Shenglin Xiang, Chenguang Bai, Jiaqing Yin
Direct Reduction Ironmaking II — Gas-Based DRI
Developing the MIDREX® Direct Reduction Process — Technological Innovations and Process
Enhancements 493
Henry Gaines, Vincent Chevrier, Christopher Ravenscroft
The Effect of High Operating Pressure in ENERGIRON Reactor Design on Performance and in Reactor
Productivity 504
Jorge Martinez, Joel Morales, Pablo Duarte, Alessandro Martinis
Status and Start-Up of United Steel Co. (SULB) MIDREX® Combination CDRI/HDRI Plant 514
L. Ames, Henry Gaines, Christopher Ravenscroft
Performance of the New Alloys in Direct Reduction Processes 521
Luis Humberto Quaranta, Pedro Imizcoz, Pablo Cardin
A Novel Test of Catalyst Activity 528
Elaine Chen, George Tsvik
Micro-Module: The Optimum Approach for Small-Scale ENERGIRON DR Plants 536
Joel Morales, Pablo Duarte, Angelo Manenti
Iron making Environmental Developments II
Optimal Method for Renewal Sintering Exhaust-Gas Treatment System..... 547
Shunsuke Mori, Ren Takahashi, Satoshi Kawahata
Interaction Between Injected Waste Plastics and Coke Bed in the Blast Furnace 552
Alexander Babich, Dieter Senk, Sebastian Benkert
Optimized Waste Gas Recirculation Layouts for Environment-Friendly and Energy-Efficient Sinteringof Iron Ores 563
Bernard Vanderheyden, Frederic van Loo, Cecile Mathy, Jean-Christophe Pierret
Analysis of Influencing Factors of the Carbon Content of the Blast Furnace Offgas Dust 576
Jian Sun, Hui Chen, Jian-long Wu
Ironmaking Raw Materials II
Stockhouse-Based De-Icing, Drying and Pre-Heating of Coke and Pellets 582
Roman Vaynshteyn, Peter Verbraak
Ironmaking Increase of the Sinter Basicity Through the Insertion of Partially Inert Magnesium Silicate
Mini Lumps With Mineralogically Stable Interphases 586
Enrique Somolinos, Estaban Ruisanchez, Javier Martinez, Cristina Escudero
Chemistry vs. Morphology vs. Reducibility — Some (Non-) Existing Correlations 593Martina Hanel, Johannes Schenk, Heinrich Mali, Christoph Thaler, Franz Hauzenberger, Birgit Kain-Biickner, Hugo Stacker
Effect of Simulant Ash on Wetting Behavior of Liquid Iron on Carbonaceous Material Substrate 603