Improving the technology of rolling rail steels by a comprehensive optimization parameter

The authors have developed a technique for improving the rolling modes of rail steels based on a complex optimization parameter. The technology of rolling rail profiles in the roughing stands of rail-and-structural steel mills and the technology of rolling ball blanks and grinding balls from the rejection of continuously cast blanks of rail steels are selected as the methodology objects. The generalized optimization parameter is the generalized Harrington desirability function, which depends on the partial desirability indicators according to the criteria of energy efficiency, quality of rolled products, material conservation and mill productivity. The share of influence of the listed partial optimization criteria on the generalized desirability function is taken into account by using weighting coefficients. Justification of the coefficient values is based on the results of a comparative analysis of reserves for reducing costs or losses in value terms. An algorithm for applying the technique has been developed. The analysis and generalization of the available initial data and additional research were carried out as a part of the first block. These studies are aimed at obtaining justified analytical dependencies of particular optimization criteria and measured rolling parameters. The second block is justification of the specific direction of rolling modes, the choice of which is carried out on the basis of checking the compliance of boundary conditions. The third block includes development of the parameters of the new rolling mode and assessment of its applicability and effectiveness. The fourth block involves pilot testing of a new rolling mode in the conditions of an existing rolling mill and if it is necessary, adjusting the methodology for determining the forecast values of the measured indicators. With the use of the developed methodology, the modes of rolling of railway and sharp rails in the roughing stands of universal rail-and-structural steel mill of JSC “EVRAZ ZSMK” were improved, and the mode of rolling grinding balls from the rejection of rail blanks at the cross-screw rolling mill of JSC “GMZ” was changed. There is a significant improvement in the quality, technical and economic indicators, which indicates the effectiveness of the developed methodology.

Optimized CO2 Capture Solutions for Carbon Free Hydrogen Production with Development of New Demixing Solvent Technology DMX™

CO2 capture & storage is foreseen as a necessity to limit global warming, as indicated by the recent reports from International Energy Agency. Major initiatives have to be initiated in a near future with concrete actions to get efficient results in limiting global warming. Based on its decades of experience in gas sweetening AXENS has developed an expertise in CO2 removal technologies. While conventional amine based processes can be used for some CO2 capture applications like for instance the treatment of process gas streams under pressure, other applications for low pressure gas streams like flue gases will require innovative advanced solutions. AXENS has studied various options for the removal of CO2 in SMR based hydrogen schemes, including the treatment of the process gas or the treatment of the flue gases from the SMR furnace, evaluating the respective merits of those options. For the treatment of the flue gases a new technology developed by IFPEN and AXENS based on a second generation amine solvent is considered : DMX™ DMX™ process, is foreseen as a key contributor for the removal of CO2 from all kind of low pressure gas streams. This process allows drastic reduction of CO2 capture cost in comparison to more conventional solvent such as MEA and others available solvents. The specific features of this solvent allows significant reduction of the heat requirements for the regeneration of the solvent. It also allows regenerating the solvent directly under pressure up to 6 bara, reducing the costs for downstream CO2 compression Preliminary techno-economic studies show significant advantage of DMX™ technology relatively to MEA : up to 30 % reduction in OPEX can be obtained for lower or similar CAPEX, depending on the condition. This process has been developed at the lab scale and is now going to be demonstrated in an industrial pilot unit installed in ArcelorMittal's steel mill plant in Dunkirk (France). This demonstration benefits from the support of EU's H2020 programme, under 3D project.

Assessment of Sweep Efficiency and Breakthrough Using CO2, H2O, Carbon and Hydrogen Isotope Composition in a Water Alternating with Gas EOR Project in Onshore Abu Dhabi, UAE

Measuring sweep efficiency and understanding breakthrough are the most important parameters to assess an Enhanced Oil Recovery (EOR) project having Water Alternating with miscible CO2 Gas (WAG) injection. The objective of this study was to use CO2, H2O and isotope compositions to assess sweep efficiency and breakthrough in producer wells in an ADNOC Onshore field in order to take the necessary actions for project optimization (e.g., injector and/or future producer well location optimization). CO2 and H2O compositions, along with their respective carbon and hydrogen isotopes, was integrated with downhole pressure gauge data to evaluate the impact of WAG operation on EOR. It was understood at the start of the project that an isotopically distinct injected CO2, compared to the oil associated CO2, would assist in the evaluation of sweep efficiency and breakthrough. The injected CO2 used in the WAG comes from a steel mill that is isotopically very distinct (i.e., significantly light) from the oil associated CO2. CO2 and H2O are injected periodically in the reservoir through designated injectors distributed over the field. The initially produced oil associated CO2, H2O, carbon and hydrogen isotope values were available as reference to measure the extent of sweep efficiency and breakthrough. Injected H2O and CO2 compositions and their respective hydrogen and carbon isotope values are measured at each injection cycle (so called campaigns). This is then followed by periodic compositional and isotopic measurements of the same components in oil and water producer wells to measure the extent of breakthrough. CO2, H2O composition and carbon and hydrogen isotope measurements in injector and producer wells indicate that the injected CO2 is preferentially breaking through in certain parts of the field. This indicates heterogeneous reservoir quality distribution throughout the field with better reservoir quality (e.g. higher permeability) between injector and producer wells having faster breakthrough. The compositional and isotopic measurements are sensitive enough to register compositional changes in the producer wells relatively faster than assessed by downhole pressure gauges.

Semi-Automated Roller Parameters Extraction from Terrestrial Lidar

Rollers are an integral part of a hot-rolling steel mill. They transport hot metal from one end of the mill to another. The quality of the steel highly depends on the surface quality of the rollers. This paper presents semi-automated methodologies to extract roller parameters from terrestrial lidar points. The procedure was divided into two steps. First, the three-dimensional points were converted to a two-dimensional image to detect the extents of the rollers using fast Fourier transform image matching. Lidar points for every roller were iteratively fitted to a circle. The radius and center of the fitted circle were considered as the average radius and average rotation axis of the roller, respectively. These parameters were also extracted manually and were compared to the measured parameters for accuracy analysis. The proposed methodology was able to extract roller parameters at millimeter level. Erroneously identified rollers were identified by moving average filters. In the second step, roller parameters were determined using the filtered roller points. Two data sets were used to validate the proposed methodologies. In the first data set, 366 out of 372 rollers (97.3%) were identified and modeled. The second, smaller data set consisted of 18 rollers which were identified and modelled accurately.

A Heterodimeric Reduced-Ferredoxin-Dependent Methylenetetrahydrofolate Reductase from Syngas-Fermenting Clostridium ljungdahlii

Syngas, a mixture of CO, CO 2 , and H 2 , is the main component of steel mill waste gas and also can be generated by the gasification of biomass and urban domestic waste. Its fermentation to biofuels and biocommodities has attracted attention due to the economic and environmental benefits of this process. Clostridium ljungdahlii is one of the superior acetogens used in the technology.

Machine learning mathematical model for the automatic setup of the cal and hrd flow during the process of primary aceration in electric ovens

In this work, a mathematical model is developed for the automatic predisposition of the flow of lime and HRD during the primary steeling process in HEA of the steel mill of Sidor, C.A. Model that was possible through an intelligent dynamic process control system, under a descriptive field research profile; considering a sample of 46 commercial grade steel castings (ASTM A 1018). The system consists of two simulation modules that ensure the ideal thermodynamic condition (steel temperature between 1535 to 1575 ° C, ITHD indicator less than 1,5% and a binary base index of the slag between 2 to 2,6 ) for the protection of refractory material and dephosphorization of steel. Having as a result, a reduction of the Tap To Tap of 7,08%; reduction of lime consumption by 5,28% and an increase in productivity of 7,51%. Keywords: Primary Metallurgy; Electric Arc Furnace (HEA); Mathematical Model; Machine Learning. References [1]Asociación Latinoamericana del Acero, "Alacero", [Online]. Available: https://www.alacero.org/sites/default/files/publicacion/proceso_siderurgico.pdf. [Last access: July 04, 2020]. [2]F. Morral, E. Jimeno y P. Molera, Metalúrgia general, Barcelona: Reverté, 1985. [3]B. Bucciarelli, G. Torga, F. Sabugal, F. Díaz y M. Lardizabal, "Evolución en el control del fósforo en la acería de Ternaris SIDERCA", de 18a Conferencia de acería del IAS, Rosario, Santa Fe, 2011. [4]S. Kalpakjian y S. Schmid, Manufactura, ingenieria y tecnología, 4ta ed., México: Pearson educación, 2002. [5]M. Oropeza, J. López, A. Pérez y J. Ucar, "Contribuciones para el control del fósforo cuando se utiliza mineral reducido de hierro", Revista metalurgia, vol. 35, nº 2, pp. 479-490, 2008. [6]J. Castro y F. Echeverría, Introducción a las técnicas de computación inteligente, 1era ed., Venezuela: Universidadde los andes, 2001. [7]A. Sadeghian y J. Lavers, "Application of radial basis function networks to model electric arc furnaces", IJCNN,vol. 6, pp. 3996-4001, 1999. [8]J. Brito, "Diseño de un control automatizado para la alimentación de cal mezcla en función del HRD para ajustar la basicidad binaria de la escoria del horno eléctrico #1 de la acería de planchones de Ternium SIDOR", trabajo de grado inédito, 2008. [9]A. Zambrano, V. Collazo, N. Troncone y J. Rodríguez, "A computer tool for closed-loop dynamical system identificaction through artificial neural networks", Universidad, Ciencia y Tecnología (UCT), vol. 16, nº 64, pp. 190-202, 2012. [10]E. Moreno, Tecnología de producción del ferrosilicio, 3era ed., Venezuela: Ferroatlántica de Venezuela, 2005. [11]C. García, "Optimización del proceso de formación de escoria espumosa en los hornos eléctricos de acerías de planchones de Sidor", trabajo de grado inédito, UNEFM, Punto Fijo, 2011. [12]M. Rojas, "Estudio del consumo de cal, coque, oxígeno y HRD en el proceso de formación de esocria epsumosa en el HE-5 de la acería de planchones de Sidor, C.A.", trabajo de grado inédito, UNEXPO, Puerto Ordaz, 2012. [13]R. Morales, R. Lule, F. López, J. Camacho y J. Romaero, "The slag foaming practice in EAF and its influence on the stelmaking shop productivity", ISIJ International, vol. 35, nº 9, pp. 1054-1062, 1995. [14]W. García, "Implementación de prácticas de escorias espumosa en los EAF de la acería eléctrica de planchones de Sidor, C.A.", trabajo de grado inédito, USB, Caracas, 2002. [15]S. Alameddine, B. Bowman, S. Paege y P. Stafford, "Innovation in EAF and in steelmaking processes", de AIM, Milano-Italia, 2009. [16]J. Mateos, "Análisis y optimización de costes en una planta de procesado y producción de acero", trabajo de grado inédito, UC3M, Madrid, 2010. [17]A. Conejo y J. Cárdenas , "Energy consumption in the EAF with 100% DRI", AISTECH Proceddings, vol. 1, pp. 529-535, 2006. [18]M. Rojas, O. Prado, O. Carvajal y R. Higuerey, "Impacto del consumo de cal, coque, oxígeno y HRD en la formación de escoria espumosa durante el proceso de aceración primaria en hornos de arco eléctrico", Universidad, Ciencia y Tecnología (UCT), vol. 17, nº 67, pp. 134-140, 2013.

Manufacturing of LSAW Pipes Using Hot Rolled Sheets for Sour-Service Application

The exploration and transportation of fluids from corrosive fields or reserves demand corrosion-resistant pipelines. The pipelines for sour-service application demand higher resistance to H2S corrosion because of higher sulphur content observed in the geographical locations. The pipelines laid in the corrosive and marshy lands demand high wall thickness to allow for wall thinning due to corrosion. The linepipes manufactured using TMCP plates are widely accepted for sour-service applications. The use of cut-to-length sheets from hot rolled coils for the manufacturing of LSAW pipes is economical but having limited acceptance by the pipeline operators. Welspun took an initiative to develop the linepipes for an onshore sour-service application using API 5L X60MS grade cut-to-length sheets from TMCP hot rolled coils procured from an approved steel mill. The LSAW pipes of 24” OD × 14.27 mm WT were manufactured by the JCO-E press at Welspun Pipes Mill in Anjar-Gujarat-India. The experience of 24”OD × 14.30 mm WT, API 5L X60MO grade pipes manufacturing using TMCP plates procured from another approved steel mill, was used to decide factors such as alloy design, cleanliness, strength, DWTT, hardness, HIC, SSCC, CVN for the selection of cut-to-length sheets. This paper deals with sheet-to-pipe behavioural changes in properties before and after cold mechanical expansion. Wherever possible, the comparison was also made with plate-pipe behavioural changes in properties.