Schedule
16–18 September 2025 • Hyatt Regency DFW International Airport • Dallas, TX USA
Monday, 15 September 2025 | |
| 4 p.m. | Registration |
Tuesday, 16 September 2025 | |
| 7 a.m. | Breakfast and Registration |
| 8 a.m. | Introductions and Opening Remarks |
| 8:15 a.m. | Keynote |
| 9 a.m. | Danieli Quali-HSM: The Next-Gen HSM Process Antonio Comelli, Danieli & C. Officine An enhanced strip production concept with inductive heating technology ensuring conventional hot strip mill (HSM) answers market demand for ultrathin-gauge, high-quality and premium grades. Thick-slab rolling using conventional HSM holds the leading position when it comes to high production capacity, wide and flexible product mix, and premium grades such as automotive exposed and electrical steel. The modern HSM production faces a triple challenge in the current dynamic market: achieving sustainability, enhancing quality with tight tolerances and uniform properties, and answering market demand for thin-gauge, hot-rolled coil. The competing in-line casting and rolling technology is a step ahead in many aspects. The Danieli Quali-HSM® merges the advantages of conventional rolling and in-line casting and rolling process routes. The result is the production of hot-rolled coil at high and uniform temperatures, at a constant speed and down to ultrathin gauge of 1.0 mm. |
| 9:25 a.m. | Next-Generation Hot Strip Mill Control Model for Roughing and Finishing Mills (RoFi) Mustapha Bsibsi, Tata Steel Nederland Technology B.V. This session presents a next-generation control model for the roughing and finishing mill. Compared to the previous model, it provides better ability to roll novel products, by allowing for automated rolling with arbitrary transfer bar gauges between 30 and 75 mm. RoFi is an enabler for expanding product dimensional windows, in particular because it allows for higher coil weights through slab length optimizations in the roughing mill. Furthermore, it will allow for increased productivity by better utilization of mill hardware capability and the ability to roll with any finishing stand dummied, as opposed to only dummying sequential stands from the finishing mill exit. Improvements in product quality are also expected. The new model will have a lower reliance on operator interventions and allow better control over the time-temperature path through the mill. Finally, the model has a scalable design: it is suitable for any mill configuration and can easily be configured accordingly. |
| 9:50 a.m. | Break |
| 10:20 a.m. | Computer Vision and Sensor-Based AI for Safety Paul Thurber, Everguard.Ai A review of new technologies that enable companies to prevent workplace injuries through the use of computer vision and sensor-based artificial intelligence solutions to alert workers prior to incident/injury. |
| 10:45 a.m. | Rolling Mill Scheduling Synchronized With Casting Michael Peintinger, Smart Steel Technologies Inc. This session presents a user-guided automatic scheduling system based on rule-based mixed integer linear programming (MILP). This system generates optimized production schedules within minutes and dynamically adjusts to real-time disruptions, resource fluctuations, and order prioritization. It integrates a mid-term planning module and a simulation-based "what-if" module that allows schedulers to evaluate bottleneck impacts and proactively manage production flow. The system also tracks all schedule versions, enabling analysis of planner modifications and quantification of the cost implications of operational deviations. Enhanced functionalities, such as blocking unavailable downstream equipment and adjusting schedules to specific constraints, provide flexibility and adaptability to real-world scenarios. By synchronizing casting and rolling schedules, this approach reduces transition losses, optimizes throughput, and ensures efficient, transparent operations in high-demand environments. |
| 11:10 a.m. | Innovative Environmental Control for a High-Resolution HSM ASIS Stephen L. Hunt II, AM/NS Calvert LLC All customers benefit from a well-inspected surface, from external customers of direct ship material to downstream units such as cold mills and coating lines. With advancement of technology, manufacturing processes and increasing customer demands, the surface quality of hot-rolled steel strip is being held to ever higher standards. This critical task is accomplished via automatic surface inspection systems (ASIS). As camera resolutions increase, the need for an unadulterated inspection area becomes imperative. Any foreign objects between the inspection system and the strip introduce anomalies which negatively affect ASIS performance. This paper aims to detail the process of creating a controlled inspection environment for a high-resolution ASIS. |
| 11:35 a.m. | Application of AI and Machine Vision in Coilbox for Steel Hot Rolling Mill Ayman Abu-Abed, Hatch The CoilSense Coilbox Vision System has been developed to auto-tune the coilbox operation, making on-line corrections to coilbox operation and advising the operator on abnormal events. The system integrates the use of AI, industrial cameras, and industrial PCs with the process experience of coilbox engineers and operators for troubleshooting and tuning of coilbox operations. With the advancement of the coilbox technology, coilbox operator involvement is greatly reduced, except for minor tuning of the coilbox for new products and dealing with the infrequent abnormal events. The CoilSense System aims to address these infrequent events to optimize the operator’s utilization in a steel mill to address other tasks and provide consistent outputs to such events. The system provides visual confirmation for different coilbox coiling and uncoiling stages that may not be completed successfully due to the change in many process parameters that cannot be accurately sensed or controlled in the harsh environment of the coilbox. |
| Noon | Lunch |
| 1 p.m. | Development of Gap Correction and Recovery Functions for Thickness Control of Head End in Hot-Rolled Steel Min-Seok Baek, Hyundai Steel Co. This study introduces a gap correction function based on roll gap offset, further enhanced by the addition of a recovery function. The gap correction function minimizes thickness overshoot in the head end region by calculating roll gap adjustments at each finishing mill stand based on predefined gain values and applying these offsets to the roll gap. However, the only gap correction function led to thickness undershoots in the head region, which comprises approximately 15% of the coil length after the head end. To overcome this limitation, a recovery control function was developed to prevent thickness undershoots following the application of gap correction. The improved recovery function demonstrated effective thickness control, maintaining target thickness even after gap close and successfully mitigating undershoot issues. |
| 1:25 p.m. | Automated Coil Form Profiler Project at AM/NS Calvert Hot Strip Mill Dennis A. Lott, AM/NS Calvert LLC Coil form is a familiar term in the steel industry, often posing questions about its condition. Out-of-spec coil form can lead to costly delays, reprocessing costs, yield loss and safety issues. Live measurements could prevent reworks, especially when customer specifications are stricter than ASTM standards. Attempts to measure coil form using lasers and cameras often fail due to high costs and inadequate measurements. Automating coil form disposition by customer specification is even more costly without proper integration. However, the hot strip mill team at AM/NS Calvert has developed a new system that addresses these challenges. The novel coil form profiling system produces a complete sidewall profile within 2-3 coils from production. This system utilizes specialized blue laser equipment and software to provide specific measurements for all coil form types. |
| 1:50 p.m. | Innovative Vibration Dissipation Technology for Enhanced Stability in Hot Strip Mills Georg Keintzel, Primetals Technologies Japan In the quest to improve process stability and productivity in hot strip mills and ESP plants in the presence of unwanted vibrations, Primetals Technologies has developed a vibration dissipator that effectively reduces and eliminates resonance vibrations, stabilizing individual finishing mill stands and enhancing overall process stability. |
| 2:15 p.m. | Maximizing Efficiency, Quality and Metallurgical Flexibility in Hot Strip Mills With Power Cooling Technology Konrad Krimpelstätter, Primetals Technologies Japan Primetals Technologies has introduced a strip cooling technology for hot strip mills, known as Power Cooling. This technology leverages increased impact pressure to achieve significantly higher cooling rates, which are essential for producing modern steel grades with enhanced mechanical properties at reduced material costs. The primary cost savings result from the reduced need for expensive alloying elements, made possible by the higher cooling rates. A notable feature of Power Cooling is its capability to produce hot-rolled quenched and partitioned (Q&P) steels, part of the third generation of advanced high-strength steel (AHSS). The Power Cooling system also incorporates advanced automation models that ensure precise temperature control and optimal cooling strategies. These models include comprehensive temperature control and a microstructure monitor, which are crucial for maintaining the desired metallurgical properties and achieving consistent product quality. |
| 2:40 p.m. | Break |
| 3:10 p.m. | Advancements in Strip Temperature Modelling and Control for Hot Strip Mills Kazuhiro Ohara, TMEIC This paper discusses strip temperature modeling and control for hot strip mills. A finite difference method (FDM) is used to calculate the strip temperature distribution in each length element being rolled, based on time, temperature distribution and surface energy fluxes. Previously, a one-dimensional FDM (1D-FDM) was used where the distribution was originally modeled only along the thickness direction. Due to improvements in computing power, we now use a two-dimensional FDM (2D-FDM) which models both the thickness and width directions to estimate the temperature profile and drop at the strip edges. It is possible to switch between 1D and 2D-FDM individually for each roughing or finishing mill zone and for the runout table cooling zone. |
| 3:35 p.m. | Entering New Markets through Process Innovation — Key Parameters in Hollow Embossing Rolling of Metallic Bipolar Plates Sebastian Heidrich, Fraunhofer-Institut Für Werkzeugmaschinen This paper discusses hollow embossing rolling (HER), a process in which two oppositely embossed rollers gradually form strip metal into complex three-dimensional shaped goods. Being of continuous and incremental nature, this kind of cold roll forming allows for increased productivity whilst reducing the applied forming forces needed for altering the strip geometry. Past research on HER has mainly focused on the manufacture of bipolar half-plates (BP-HPs), which can be used in proton exchange membrane fuel cells and electrolyzers. Due to their intricate geometry, these subcomponents pose high demands on the HER process. With the integrated sensor technology and the inherent control of the existing HER machine at Fraunhofer IWU, the influence of selected key parameters on this process, the machine and on the quality of metallic BP-HPs is then assessed. From this, practical implications for the efficient monitoring of the HER process are derived and transferred to further rolling processes used in industry. Hence, the paper enriches the understanding of HER and contributes to the optimization of a wider range of rolling applications. |
| 4 p.m. | Revolutionizing Cold Rolling: Eliminating 3rd Octave Chatter With ChatterBlock Expert Georg Keintzel, Primetals Technologies Japan |
| 4:25 p.m. | Optimization of Stainless Steel Cold Rolling Lubrication Through Thermal Modeling Cynthia Elhajj, Centre De Mise En Forme De Matériaux, Mines Paris│Psl Research Universit In classic mixed lubrication regime theory, to predict friction in the roll bite, the mean lubricant film thickness and fractional contact area evolutions from the entry to the work and exit zones are evaluated using Reynolds equation integrated together with the theory of plastic asperity crushing. The goal of this study is to enhance these lubrication models with a roll and strip thermal model. The proposed model predicts key phenomena, including a decrease in viscosity within the contact region, a reduction in lubrication film thickness, and an indication of transition into the boundary lubrication regime. In the latter, an estimate of the risk of loss of lubricity, adhesion and strip surface degradation is proposed, based on interface temperature and superficial plastic strain. An example of application to a typical stainless steel cold rolling schedule will be presented. |
| 4:50 p.m. | Question-and-Answer Session |
Wednesday, 17 September 2025 | |
| 7 a.m. | Breakfast and Registration |
| 8 a.m. | Introductions and Opening Remarks |
| 8:15 a.m. | Keynote —Effect of Process Strategy on the Microstructure and Mechanical Properties for the Production of 700 MPa Hot Coils at the Gerdau Steckel Mill Altair Lucio de Souza Gerdau Ouro Branco developed a process for manufacturing hot coils of LNE700 steel using its Steckel rolling mill. A low-C-CrMoNbTi alloy design was adopted, aiming to promote intense TiC precipitation during the slow cooling of the coil after rolling. The production of this material in a Steckel rolling mill is unprecedented worldwide; generally, this product is rolled in hot strip mills. As the Steckel mill is reversible, and during the finishing phase, time intervals between passes are relatively long, on the order of tens of seconds, while in the finishing train of hot strip mills it is on the order of fractions of a second, particularly in the last passes. Since precipitation hardening makes a significant contribution to the mechanical strength of this material, it is necessary to determine the best conditions under which it occurs. |
| 9 a.m. | Impact of Pilot-Scale Rolling and Heat Treatment on the Toughness of CrNiMoV Steel Plates Mario Buchely, Missouri University of Science and Technology The thermomechanical processing of CrNiMoV steels presents significant challenges due to their complex alloy composition and the need to achieve an optimal balance between hardness and toughness. In this study, a CrNiMoV steel slab, industrially produced at 8 inches thick, was hot rolled to a final plate thickness of 1.5 inches using a pilot-scale rolling mill with a capacity of 1 Mega lbf. The rolling trials were designed to simulate industrial rolling practices while exploring the effect of deformation on microstructural evolution. After rolling, the plates were subjected to a comprehensive heat treatment cycle, including normalization, subcritical annealing, quenching, and tempering, to achieve maximum mechanical performance. The processed plates were then compared to an industrially produced 1-inch-thick plate from the same steel batch. The microstructure evolution was analyzed at different stages of the heat treatment cycle, and Charpy impact tests were conducted to evaluate toughness in both the as-rolled and heat-treated conditions. The results highlight the significant influence of rolling thickness reduction on microstructure refinement and toughness improvement. |
| 9:25 a.m. | Normalizing Rolling of Niobium Microalloyed Heavy-Gauge Plates for Wind Tower Applications Daniel Bojikian Matsubara, Gerdau This work shows an innovative steel design for plates up to 76.20 mm in thickness by adding larger amounts of Nb and lower quantities of C and Mn. This chemical composition was elaborated aiming the improvement of centerline segregation, microstructural homogeneity of the plate and proper Charpy impact toughness throughout the thickness of the rolled unit. For this assessment, a laboratory ingot was produced for precipitate characterization and industrial slabs were rolled for evaluation of mechanical properties, microstructural features and welded joint characterization. Findings showed a much more homogeneous material in terms of microstructure and mechanical properties when compared to conventional structural steel for the same application. |
| 9:50 a.m. | Break |
| 10:20 a.m. | Effect of Humidity on Copper Separation During High-Temperature Atmospheric Oxidation of Si-Containing Carbon Steels With Moderate and Elevated Copper Contents David Landi, Colorado School of Mines In this work, 0.1C-0.25Si steels with 0.3Cu and 0.55Cu contents were studied using thermogravimetric analysis. Tests were performed on the base alloy with 0.55Si and 0.1Ni contents to mimic intentional alloying for mitigating Cu hot shortness. Metallographic analysis to evaluate the degree of Cu separation during oxidation was conducted, and the steel/scale interfaces were observed. Energy-dispersive spectroscopy maps were collected to identify the elemental distributions around the interfaces. The oxidation behavior for each alloy in the -35°C and -1°C DP atmospheres were similar, with the -1°C DP Si addition resulting in lower parabolic rates for both Cu levels. The 35°C DP atmosphere increased the oxidation rate of the lower Si content alloys. The added Ni alloy behaved similarly in all atmospheres and did not exhibit Cu separation. Greater Cu occlusion into the scale was observed in the higher Si alloys and in drier atmospheres. The results suggest that increased Si or Ni additions can offset the greater Cu separation caused by higher humidity at 1,150°C via promoting occlusion through Si-rich boundary oxides which physically separate the separated Cu from the base metal. |
| 10:45 a.m. | The Impact of Hot Rolling and Nickel and Vanadium Additions on the Hot Tensile and Ductility Characteristics of AISI 4140 Steel Erfan Heidari, Missouri Science and Technology University This study investigates the effects of hot rolling and residual nickel content on the hot tensile and ductility behavior of AISI 4140 steel, known for its strength and toughness. Two steel alloys were studied: one with negligible nickel (~0 wt. %) and another with ~0.2 wt.% Ni. Test samples were extracted from as-cast and continuously cast bars, both near the center and below the surface. Baseline hot tensile tests were performed at 1,600°F and 2,200°F with a 0.05 s⁻¹ strain rate. Material was then cross-rolled at 2,200°F with ~50% thickness reduction and tested again to evaluate the impact of rolling. Microstructural analysis followed postmortem. Results provide a comparative understanding of how rolling and nickel affect hot ductility and tensile behavior. The study highlights the significance of alloying and processing conditions in optimizing 4140 steel’s mechanical performance for high-temperature applications like hot rolling or forging. |
| 11:10 a.m. | Mathematical Models for the Prediction of Mechanical Properties of Cold Strips Submitted to Hot-Dip Galvanizing Flávia Tereza dos Santos Fernandes Tolomelli, Usina Presidente Vargas Mathematical models for the prediction of mechanical properties of steel products, based on their chemical composition and process parameters, are a recurring need for steel works, as they enable the optimization and cost reduction of their processes and products. The recent advent of machine learning algorithms has represented significant progress in increasing the accuracy of these models. Recently, Companhia Siderúrgica Nacional tested several mathematical modeling approaches to predict the mechanical properties of cold-rolled strips processed in its hot-dip galvanizing line (HDG) based on steel chemical composition and the relevant variables of this process, as well the previous hot and cold strip rolling. A data set with several thousand records was obtained, which was initially subjected to analysis to suppress outliers. Subsequently, the relevant independent variables for predicting yield and tensile strength, as well as elongation, were identified through the determination of the Pearson matrix and principal component analysis. Multiple linear regression models were then developed, as well as shallow learning neural networks. |
| 11:35 a.m. | Robotized Portal System for Plate Shape Control, Marking and Punching Gianluca Maccani, Polytec Spa The system automates shaping (contour and flatness), defect detection, thickness measurement, ink marking and stamp marking of the plates coming out of the rolling mill. Through a conformity check between the data provided by the customer and the information gathered by the system, implemented with an advanced vision system, noncompliant plates can be either discarded, downgraded for another order, or passed again through the line for a requalification. A user-friendly human-machine interface allows easy robot operation management by improving efficiency and safety. |
| Noon | Lunch |
| 1 p.m. | Unlimited Freedom for Green HRC Production Antonio Comelli, Danieli & C. Officine Meccaniche S.p.A. QSP-DUE direct casting and rolling technology allows three production modes: coil-to-coil, semi-endless and full endless. These modes enable the production of various steel grades and strip formats, meeting end user needs. The technology's maturity is evidenced by concrete applications. |
| 1:25 p.m. | Mechanical Study on Leveling Warped Metal Plate by Stress Relief Annealing Process Mifune Nobuhito, Kobe Steel Ltd. Stress relief annealing is one of the processes to level a warped metal plate, such as a steel plate and an aluminum alloy plate. But the mechanism of this process was not studied until now, unlike the other leveling processes such as roller leveling and tensile leveling. The authors studied the mechanical mechanism of leveling a warped metal plate by stress relief annealing and confirmed it by conducting an experiment. |
| 1:50 p.m. | Enhancing Quality Control for Long Products With Robotics and Computer Vision Gianluca Maccani, Polytec Spa Steel production necessitates continuous quality monitoring throughout the process. Historically, the steel industry has lagged in adopting certain technological advancements due to its harsh production environment, resulting in lower efficiency and higher risks for workers who perform many operations manually. This study shows the latest developments in long product quality control, with the implementation of an automated system for some operations, which currently exposes operators to significant danger, like cutting and removing material samples from rods and long products on the cooling bed or measuring laminated surface quality in rolling mill. By automating this task, the aim is to enhance production efficiency and improve worker safety. |
| 2:15 p.m. | SBQ Product Optimization of Thermomechanical Rolling Process Michael Zuker, Gerdau Special Steel North America This research studies the effect of rolling mill finish temperature on material properties of grain size, microstructure, and hardness throughout the cross-section surface to core of round bar for medium carbon special bar quality (SBQ) grades and bar diameters, with an objective of increasing knowledge of the thermomechanical rolling process and optimizing SBQ product rolling practices to ensure best fit while maintaining steel quality. |
| 2:40 p.m. | Break |
| 3:10 p.m. | Processing and Alloy Design Strategies for Producing API X65 Sour Service Plate Suitable for Hydrogen-Induced Cracking Applications Joao Souto, CBMM This paper will discuss the results of the trials designed for JSW Anjar to produce API X65 heavy-gauge plate. Initial alloy/processing strategies were designed and those were simulated through the plate mill hot rolling level 2 model to check suitability for the equipment capability and metallurgical analysis by mean flow stress. In addition, the metallurgical model MicroSim Plate Mill was used to model the through-thickness austenite grain size evolution attributes. Alloy designs, steelmaking processing, continuous casting, plate rolling, pipe forming and corrosion testing are all key components in producing pipeline steels that are resistant to hydrogen-induced cracking (HIC) applications and meeting the required specifications. However, producing steels that have good HIC performance does not necessarily guarantee meeting other mechanical property requirements such as strength and yield-to-tensile ratio. Therefore, balance has to be achieved to meet the HIC requirements and other required mechanical properties. The effect of an optimum Nb content along with optimized processing will also be evaluated in the final plate mechanical properties and this work could serve as a foundation for future hydrogen pipeline developments at JSW. |
| 3:35 p.m. | Investing in Excellence: Advanced Cold Rolling Technologies for Superior Electrical Steel Production Konrad Krimpelstätter, Primetals Technologies Japan This paper reviews trends in electrical steel production and highlights advanced cold rolling technologies for nongrain-oriented (NGO) and grain-oriented (GO) steels. Traditionally, electrical steel was produced on reversing mills using 20-high mills. The development of small diameter 6-high mills enabled the production of high-grade NGO steel. The application of 6-high HYPER UC-MILL™ to tandem mills now allows efficient production of large quantities of electrical steel. The paper discusses the successful start-up of the world’s first twin-stand HYPER UC-Mill at thyssenkrupp Steel Europe in Bochum, Germany, and the world’s first 6-stand HYPER UC-Mill continuous tandem cold mill at Shougang Qian’an in China. |
| 4 p.m. | Deformation Texture Analysis Based on Crystal Plasticity in heavily Cold-Rolled 3% Si Steel Noriki Fujita, JFE Steel Corp. This study applied crystal plasticity finite element model to cold rolling to evaluate the development of cold rolling texture in heavily cold-rolled 3% Si steel. Crystal plasticity simulation implied that the combined effect of pencil-glide slips and twinning contributes significantly to the development of the {100}<011> cold rolling texture in heavily cold-rolled 3% Si steel. The findings contribute to a deeper understanding of texture development mechanisms, potentially leading to improved material properties and energy efficiency in industrial applications. |
| 4:25 p.m. | Effect of Heat Treatment Processes on Microstructures and Mechanical Properties of Cu Added DP Steels Yinghua Jiang, Research Institute of Technology, Shougang Group Co. Ltd. The effects of two different heat treatment processes on the microstructures and mechanical properties of Cu added dual-phase (DP) steels were investigated. The heat treatments were the traditional one-step heat treatment process without quenching section (I) and two-step heat treatment process with quenching section (II), respectively. The steel tested by heat treatment process (II) favors the formation of a homogeneous and refined structure. The microstructure produced by heat treatment process (II) contains intermediate hard phase tempered martensite, which reduces the hardness difference between the hard and soft phases and improve the homogeneity of microstructure for Cu added DP steels. Compared with the steel produced by the heat treatment process (I), the steels tested by heat treatment process (II) have higher hole expansion property while maintaining good strength-elongation balance due to the low carbon content and dislocation density of distribution of tempered martensite grains and low hardness ratio of tempered martensite to matrix. |
| 4:50 p.m. | Question-and-Answer Session |
Thursday, 18 September 2025 | |
| 7 a.m. | Breakfast and Registration |
| 8 a.m. | Introductions and Opening Remarks |
| 8:15 a.m. | Keynote — Development of Microstructural Evolution Models for Hot Rolling Integrating Advanced Numerical Tools Pello Uranga, CEIT-BRTA This contribution presents a novel approach to modeling microstructural evolution during hot rolling, combining metallurgical models with advanced numerical tools to create hybrid modeling systems. These systems are designed for integration into rolling mills, enhancing the precision and adaptability of final product property prediction and process control. The latest tools for MicroSim (austenite evolution), mean flow stress (rolling force predictions) and PhasTranSim (phase transformation) are showcased. The hybrid models utilize high-quality experimental data and real-time industrial process parameters to predict key mechanisms, including recrystallization, precipitation, grain growth and phase transformations. The study highlights the transformative potential of hybrid modeling in steel production, offering a pathway to smarter, data-driven manufacturing processes aligned with the demands of modern industry. |
| 9 a.m. | Energy Visualization and Prediction System for Hot Rolling Line Mirei Kihara, TMEIC In the hot rolling line, fuel gas is consumed by the reheating furnace, and electricity is used for large electrical equipment such as rolling mills. The energy visualization system displays product-wise and area-wise energy consumption and greenhouse gas emission based on the control information of the reheating furnace and equipment in rolling line. Through this analysis, inefficient consumption processes were identified. Moreover, by predicting energy consumption, it is possible to plan and implement power management strategies such as peak cuts and shifts in power demand. However, the hot strip rolling process is complex, and power consumption varies for each product, making accurate prediction challenging. For the power demand prediction, two approaches exist: a method using a statistical model with machine learning based on past records and a method using a detailed physical model of the rolling process are described. Power consumption was accurately predicted both by product and by area. By leveraging real-time predictions and more flexible long-term simulations in cyberspace, operating conditions and production plans can be optimized. |
| 9:25 a.m. | EBP — Endless Bar Production Larry Smith and Christiano Tercelli, Primetals Technologies As mill producers look for ways to reduce their carbon footprint and their overall conversion costs, the Endless Bar Production (EBP) mini-mill highlights the ability to reduce some of the key performance indicators in their mills. The EBP Endless and Semi-Endless process focuses on lowering the overall energy consumption by 60%, reducing CO2 emissions by 55%. The EBP process can reduce yield loss by 70% and increase the overall production capacity by 6%. The EBP mini-mill concept is designed to position producers close to their customers and provide them with lower conversion costs without sacrificing quality and productivity. This paper will provide a detailed overview of the EBP process and how it can lower conversion costs by as much as 30%. |
| 9:50 a.m. | Break |
| 10:20 a.m. | Revolutionizing Triple Slitting Technology for Rebar 16 mm in the Rolling and Groove Process Design: QATAR Steel and POMINI Long Rolling Mills Technologies Marta Galimberti, Pomini Long Rolling Mills Srl The demand for increased productivity, cost efficiency and reducing energy and environment impact in the steel rolling industry has driven the adoption of innovative technologies. Triple slitting technology is a game-changing method in rolling processes, particularly for rebar sizes over 14 mm. The intention of this paper is to explore the implementation of triple slitting technology, which enables rolling mills to significantly enhance production rates while maintaining product quality and in addition also to address the challenges faced in conventional rolling methods and how triple slitting overcomes these limitations as a brown field project for the first time regarding rebar size 16 mm by 3. |
| 10:45 a.m. | Innovative Descaling Strategies and Their Influence on Heat Losses Milan Hnizdil, Heat Transfer & Fluid This paper deals with innovative descaling strategies using three different descaling systems. Typically, a single row of descaling nozzles is used in a hot rolling process. The first innovative strategy was to install a low-pressure (20 bar) row of nozzles before the descaling system. The hypothesis that undercooling of the scale surface causes microcracks and improves descalability was disproved. Stress analysis showed that the ultimate strength of a scale was still higher than the stress caused by precooling. The flat jet row does not have a significant influence on the product heat loss. The second strategy was based on placing two descaling rows in opposite directions to improve the descaling process and minimize heat losses. Impact pressure measurements showed an increase in impact pressure with a decreasing distance between footprints. Finally, a hydromechanical rotary descaler was used and descalability was compared with previous results. It was numerically proved that the descaler reached the best descaling quality and the lowest heat loss in the product. |
| 11:10 a.m. | Innovative Labeling and Tracking Solutions to Improve Traceability in the Rolling Mill Rafael Jacob, Polytec Spa Tracking long products in steel mill production, such as rebar bundles and wire rods, is critical for ensuring quality control and operational efficiency. This paper discusses the importance of accurate tracking and highlights the latest advancements in labeling techniques using robotics. These robotic systems, equipped with adaptive vision technology, can handle various product shapes, affixing labels precisely and reliably. This innovation not only enhances tracking reliability but also significantly improves operator safety by reducing manual handling. Additionally, the automation of labeling processes boosts productivity, providing a seamless and efficient tracking system that supports continuous improvement in steel mill operations. |
| 11:35 a.m. | Development of New Annealing Technology for Stainless Coils Seongkyu See, POSCO BAF, a stainless steel annealing facility, requires a continuous preparation line process as a vertical installation method of the coil, and a continuous annealing furnace (CAF) as the horizontal installation method. A convective circulation type CAF facility was developed for the shortcomings when Stainless 430 wide-width coil annealing is impossible due to the underheating of the edge due to direct fire. The concept is to apply convective heating by separating the annealing chamber and the combustion chamber and circulating the combustion gas directly. Through the computational fluid dynamics and production test, wide-width coil can be annealed once a day. The material also has a hardness of 77.1 and satisfies the standard hardness of 88. It is intended to secure productivity and facility stability by optimizing heating patterns for various types of coils in the future. |
| Noon | Lunch |
| 1 p.m. | Integrated Prediction Method of Porosity Closure in Melting and Rolling Process for 8%Cr Die Steel Junichi Nakagawa, Daido Steel Co. Ltd. In the manufacturing process of special steels, internal porosities are often generated by solidification shrinkage during casting. Residual porosities in the product can affect its properties, so it is important that the porosities are completely closed during the forming process. In previous research, porosity closure conditions have been investigated by forging tests using artificial defects or actual manufacturing process ingots. On the other hand, porosity formation behavior of special steels depends on the melting and solidification temperature or liquid phase viscosity of each steel grade. Therefore, it is desirable to evaluate porosity formation and closure behavior in a laboratory scale. In this study, the porosity closure behavior of 8%-Cr die steel was evaluated by bar rolling tests. In addition, analyses tracing experiments with casting simulation and forming simulation were performed to evaluate the residual risk of porosity. In this way, it was attempted to confirm whether it is possible to evaluate the risk of residual porosity using the Niyama parameter and Q-value in the rolling process as well. |
| 1:25 p.m. | Advances in Roll Texturing for Surface Critical Strip Applications Grant McBain, Sarclad The latest developments in roll texturing technology are reviewed, including the introduction of digital servos and improved energy efficiency. The introduction of Multi-Servo Array (MSA) is pushing the boundaries of what is possible, allowing roll shops to produce textured rolls with higher peak counts and greater consistency in less time than ever before. Detailed technical results are presented, which include Ra consistency, high peak count (Rpc) results including 3D surface topography analysis and texturing time improvements. |
| 1:50 p.m. | Three Methods and a Tool to Optimize Roll Performance in Hot-Rolled Long Products José Ignacio Lucas Fuentes, Isend Optimizing the life cycle of rolls with the latest technologies is one of the key success factors for economic sustainability of rolling mills. A combination of the latest technologies strategically combined could give a new way to manage rolls and increase its life cycle. Roll life cycle mainly depends on three factors: impact of the rod, thermal tensions, and quality of roll material and treatment. This paper will present three different technologies and a tool to increase in about 20% the average life of rolls: First, a combination of eddy current, artificial vision and artificial intelligence used as on-line nondestructive testing system after the finishing strand; second is an automated off-line roll analysis through eddy current and potentially other noncontact methods to get the depth of cracks and the hardness of the surface; and third is performing an on-line analysis of critical strands with a probe fully dedicated to control rolls during operation. |
| 2:15 p.m. | Cryogenic Treatment Effect on Strength Properties of Bearing Steel for Cold Rolling Rolls Seiji Ito, Nippon Steel Corp. Rolling mill rolls are subject to damage during rolling, known as spalling. Spalling damage can be divided into the following processes: thermal crack initiation, crack propagation and rapid failure. In this study, bearing steel specimens were used as model steels for cold-rolled rolls to evaluate the effect of reducing residual austenite by cryogenic treatment on various strength properties. This presentation will report the results of an investigation into the tensile strength and fracture toughness values obtained from static tensile testing of notched materials in terms of rapid fracture, and thermal crack initiation after thermal shock testing. |
| 2:40 p.m. | Break |
| 3:10 p.m. | Influence of Heating Frequency on Residual Oxide in Joining With Induction Heating Toshiro Okazaki, JFE Steel Corp. Ltd. The endless rolling process, in which roughly rolled sheet bars are joined and rolled continuously in the finishing mill, has been put into operation for mild steels at the No. 3 hot rolling mill, Chiba Works of JFE Steel. In this study, the effect of the heating frequency of induction heating on the discharge of oxides was investigated using finite element method (FEM). FEM flow analysis results showed that a higher heating frequency resulted in less remaining oxide when the upset amount was small. It is estimated that the higher temperatures near the top and bottom surfaces of the joining surface promoted the discharge of oxides. On the other hand, when the amount of upset exceeded a certain level, the discharge of oxides stopped. It is estimated that the temperature near the center of the sheet bar thickness was low, so there was little liquid phase, and the flow of oxides stopped. |
| 3:35 p.m. | Analysis and Process Control of Induction Heater in Hot Strip Mill Shimotani, Toshihito, TMEIC Induction heater (IH) is installed in many hot strip mills (HSMs) to improve strip temperature control. IH provides a noncontact heating method by the principle of electromagnetic induction. Therefore, depending on the source of electricity, IH emits less carbon dioxide and has relatively higher heating efficiency and higher responsiveness than other heating methods, so eco-friendly. This paper introduces the characteristics of IH equipment of each type, as well as the latest analysis and control technologies. |
| 4 p.m. | Distributed Nonlinear Model Predictive Control for Reheating Furnaces Cor Jan Boeder, Tata Steel At Tata Steel R&D, a new reheating furnace modeling and control system was developed based on distributed nonlinear model predictive control. The aim is a more accurate calculation of the slab and furnace temperatures and optimal control in transient furnace conditions. Each control zone is equipped with multiple thermocouples measuring the temperatures of gas and walls. The actuators are the burner load of the control zones and the furnace pacing. Using model predictions and optimization gives the opportunity to anticipate future events like roll changes, hot charging and planned delays. To make sure all slabs in the furnaces are taken into account in the optimization problem, a finite horizon of at least one furnace load is used. The distributed optimizer considers multiple reheating furnaces and the scheduled mill pacing of the hot strip mill. |
| 4:25 p.m. | Sliding Phenomenon of Oxide Scale on Steel Sheet Surface During Hot Rolling Hiroshi Utsunomiya, Osaka University In hot rolling process, oxide scale is formed on steel surface and locates on the interface between the roll and the steel during rolling and decreases friction and heat transfer to the roll. However, the mechanism for the friction decrease has not been fully revealed. The authors proposed that the relative sliding of oxide scale to the matrix steel in the rolling direction during rolling is responsible. In this study, sheets of three steels were oxidized in a tube furnace and hot-rolled. Before the oxidization, a thin pin of stainless steel was inserted through the thickness at the center of each sheet. As no oxide scale was formed on the pin, it is possible to measure sliding distance of oxide scale. It is also found that the sliding distance increases with carbon content in steels. It is supposed that the formation of CO2 on the interface may decrease the bonding strength of the oxide scale to the steel and promote the relative sliding and decrease the friction. |
| 4:50 p.m. | Closing Remarks and Adjourn |