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Mr Giacomo Mareschi Danieli (Danieli & C. Officine Meccaniche SpA)07/10/2025, 09:20
At the heart of the industrial and geopolitical dynamics reshaping the Mediterranean region, the steel industry faces decisive challenges: from rising energy costs to uncertainties in the availability and quality of raw materials, to increasing regulatory pressure in environmental and trade matters (CBAM, tariffs).
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In this context, Italy plays a key role as a natural bridge between Europe and... -
Ronald Ashburn (Association for Iron & Steel Technology)07/10/2025, 09:40
While global steel demand is weakening, the North American market has demonstrated resilience. And now U.S. President Donald Trump is promising to further energize American steelmaking through heightened tariffs and a broader acceptance of diverse energy supplies. But to what long-term effect? This presentation will explore new investment plans and perspectives on how innovation, technology,...
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Zhiling Tian07/10/2025, 10:00
Abstract
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The Chinese steel industry has been growing rapidly since the new millennium and reached its peak in the year 2020, with an annual crude steel output of 1.053 billion tons. Since then the growth became stagnant due to a slowdown of GDP growth rate and a sluggish real estate market in the past two years. In the meanwhile, the transformation of the manufacturing industry stimulated the... -
Dr Joodong Lee (Expresslab Inc.)07/10/2025, 10:50Steelmaking - Continuous casting, near-net shape casting and ingot castingOral Presentation
A simple yet effective method has been developed to simulate macro-segregation during continuous casting. The model focuses on a thin slice moving at the casting speed, incorporating temperature and solid/liquid fraction profiles derived from prior heat transfer and solidification analyses. Solidification is specifically modeled along the thickness direction of the slice.
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The model... -
Jonas Dietzig07/10/2025, 10:50Ironmaking - Direct reduction and smelting reductionOral Presentation
The steel industry is actively seeking innovative technologies to significantly reduce carbon footprints, especially for low-grade iron ores (BF quality), which constitute the majority of available iron ore resources and are primarily processed through the blast furnace route. The Circored process, developed by Metso, utilizes fluid bed reactors for the direct reduction of iron ore fines...
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Dr Peter Juchmann (Salzgitter Flachstahl GmbH)07/10/2025, 10:50
Salzgitter AG is consistently pushing ahead with the SALCOS (Salzgitter Low CO2 Steelmaking) project on its way to climate friendly primary steel production. In this regard Salzgitter Flachstahl GmbH is gradually converting its crude steel capacity from the conventional blast furnace-converter route to a nearly CO2-free direct reduction-electric arc furnace route.
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With the new SALCOS... -
Peter Presoly (Montanuniversität Leoben)07/10/2025, 10:50
The ongoing transformation to more sustainable production routes of the European steel industry is one of the major challenges in the upcoming years and is accompanied by a number of changes; 1) the use of a different raw material mix (more and lower scrap qualities), 2) the introduction of new processes or process combinations (e.g. direct casting and rolling processes) and 3) the use of...
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Mr Philippe Alboort07/10/2025, 10:50Environmental and energy aspects in iron and steelmakingOral Presentation
Within HURRICANE a sector-coupling circular hub centred around the ArcelorMittal Ghent site will be created. We will target efficient resource management together with the recovery and utilization of squandered industrial waste heat and water. Together with ArcelorMittal Ghent’s ongoing initiatives, this will lead to a reduction of energy, water and raw materials. Thanks to the ongoing...
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JM Lee (HYUNDAI STEEL)07/10/2025, 10:50
In these day, Carbon Neutrality is important issue in the world. And iron&steelmaking industry is also undergoing process change to achieve carbon neutrality. The biggest change is process transitions from BF-BOF to DRI-EAF. In case of BF-BOF process, They can produce from normal grade of steel to AHSS grade steel. But this process need to generate so many CO2 emission, 1.85tCO2/steel ton. On...
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Milan Hnizdil (Brno University of Technology, Heat transfer and fluid flow laboratory, Faculty of Mechanical Engineering)07/10/2025, 10:50Rolling of long and flat productKeynote Presentation
This paper presents an optimization study of a hot strip mill first finishing stand (F1) top work roll cooling system, which was done in cooperation between Danieli (Buttrio, Italy) and Heat Transfer and Fluid Flow Laboratory (BUT Brno, Czech Republic). The target of the study was to decrease water consumption by more than 25% on the top work roll, maintaining the same (or better) cooling...
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Manish Kumar Kar (Norwegian University of Science and Technology)07/10/2025, 11:10
To reduce CO₂ emissions in iron and steel production, the industry is transitioning towards hydrogen-based reduction. However, a key challenge lies in the sustainable production of hydrogen, as most hydrogen is currently derived from hydrocarbon decomposition. Additionally, during the smelting of Direct Reduced Iron (DRI) in steelmaking, a certain amount of carbon in DRI feed is beneficial. In...
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Mr Andrea Castelli (SMS group)07/10/2025, 11:10Ironmaking - Direct reduction and smelting reductionOral Presentation
Transitioning industrial processes to electric power offers the potential to decrease CO2 emissions by utilizing renewable energy sources. Electric gas heating enables more compact and efficient setups compared to traditional combustion heating methods.
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Expected huge market demand of high temperature gas electrical heating in different industrial sectors cannot be covered only by available... -
Dr Martin Schlautmann (PSI Software SE)07/10/2025, 11:10
The transition towards more sustainable steel production implies also huge challenges regarding raw material procurement and usage. Production management for liquid steelmaking has to optimize the raw material input, especially regarding hot metal, DRI/HBI, scrap, alloy and slag former materials. Forecasts of the expected raw material demands in production planning and scheduling support their...
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David Egner (SARCLAD)07/10/2025, 11:10
Sarclad and CRM Group have successfully developed a new on-line sensor for steel strip contamination. The system utilizes laser-induced breakdown spectroscopy to give a continuous and real-time assessment of the contamination levels post-cleaning on a typical steel strip processing line.
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Critically, this is the first system available that can distinguish between surface carbon and iron fines... -
Paul Lalley (CBMM)07/10/2025, 11:10
All demanding modern applications such as structural, energy and automotive, require steels with an increasingly high level of strength and ductility whilst retaining good cost competitiveness as well as fulfilling ever demanding emission levels. Structural steels have traditionally focused on obtaining strength via C and Mn with some mini-mill producers utilising V micro-alloying to achieve...
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Jill Sundberg (Swerim)07/10/2025, 11:10Steelmaking - Continuous casting, near-net shape casting and ingot castingOral
Advanced steel grades present significant challenges in casting, and while surface defects cannot be completely avoided, it is crucial to minimize, identify, and predict their occurrence to save energy and resources. In the SMART-CAST II project (funded by Sweden's Innovation Agency), sophisticated measurement systems have been installed in the continuous casting lines of two Swedish steel...
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Prof. Valentina Colla (Scuola Superiore Sant'Anna)07/10/2025, 11:10Environmental and energy aspects in iron and steelmakingOral
Industrial Symbiosis concerns the use by one company or sector of underutilized resources from another one, resulting in reducing dependence on critical materials, mitigating supply risks, replacing virgin materials, and, consequently, reducing CO2 emissions, and transforming existing resources in the value chain into a usable form. Implementing the Industrial Symbiosis concept provides new...
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Dr Gianluca Dall'Osto (Politecnico di Milano - Dipartimento di Meccanica)07/10/2025, 11:30Ironmaking - Direct reduction and smelting reductionOral
Carbon Composite Agglomerates (CCA) or self-reducing agglomerates are based on the compaction of a solid carbonaceous and oxide matrix in the form of pellets, briquettes, etc. with the possible addition of an organic or inorganic binder. As a result, when heated, the carbon acts as a reducing agent and the specific metals contained in the oxide matrix are recovered.
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It is therefore not... -
Dr Hanna Wolff (SMS group)07/10/2025, 11:30
SMS group Pulse Nozzle technology reduces the energy consumption of the electrolytic cleaning section in strip processing lines by up to 90-95 %. The novelty of the process lies within the application of alternating current and its efficient cleaning properties. Instead of submerging the strip and simultaneously applying high currents, the Pulse Nozzle contacts the strip surface with...
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Saeid Bakhtiari (K1-MET GmbH, Stahlstrasse 14, 4020 Linz, Austria. Institute of Materials Science, Joining and Forming at the Graz University of Technology, Kopernikusgasse 24/I, 8010 Graz, Austria)07/10/2025, 11:30Steelmaking - Continuous casting, near-net shape casting and ingot castingOral
The ductility behavior of continuously cast steel is a key factor influencing strand quality and crack susceptibility. Therefore, investigating the parameters affecting ductility is of great importance for enhancing the productivity of the method by producing defect-free products. This study investigates the differences in ductility behavior between two micro-alloyed steels subjected to hot...
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Dr Ismael Matino (Scuola Superiore Sant'Anna - TeCIP Institute - ICT-COISP)07/10/2025, 11:30
Integrated steelworks are deeply affected by the decarbonization transition of the steelmaking sector required by the European Green Deal. One of the most promising solutions is their conversion from blast furnace-basic oxygen furnace based plants to direct reduction shaft furnace-electric arc furnace based routes using hydrogen enriched reducing gases. However, this conversion involves...
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Dr Alessandro Ferraiuolo (Marcegaglia Steel)07/10/2025, 11:30
Abstract
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The hot rolling mill power requirement depends on several factors, including the material's properties, strain and strain rate schedule, rolling temperature, microstructure evolution and roll-workpiece friction condition. On the other side, the thermomechanical process relies on precisely controlled softening and hardening phenomena to achieve the desired microstructure and tensile... -
Dr Zhao-ping Chen (Baoshan Iron & Steel Co., Ltd..)07/10/2025, 11:30
As a typical harmful element in steel, the presence of nitrogen can seriously affect the performance of steel materials. Restricted by raw materials, equipment and process conditions, the nitrogen content of electric furnace steelmaking is high, which cannot meet the quality requirements of high-grade sheets such as automobile sheet and silicon steel. The use of direct reduced iron to control...
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Martin Hubrich (VDEh-Betriebsforschungsinstitut GmbH)07/10/2025, 11:30Environmental and energy aspects in iron and steelmakingOral
Iron ore and scrap as raw materials are the base of iron and steel production. Due to the transition from carbon to hydrogen-based green iron and steel production, most current production units as sinter plan, blast furnace and basic oxygen furnace will be replaced by the direct reduction process followed by the electric arc furnace. As a result, recycling routes via BF-BOF-technologies will...
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Koos Van Putten (SMS group)07/10/2025, 11:50
Hot-rolled long products such as beams, bars, and rails are curved after cooling. Roller straightening aligns these curved long products by passing them between staggered rollers, inducing controlled, repeated elastic-plastic bending. SMS group technology for roller straightening machines is the CRS® Compact Roller Straightener, typically characterized by nine, individually driven...
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Prof. Carlo Mapelli (Dipartimento di Meccanica - Politecnico di Milano)07/10/2025, 11:50Environmental and energy aspects in iron and steelmakingOral
Electric Arc Furnace (EAF) and Ladle Furnace (LF) slag, a byproduct of steelmaking, has emerged as a promising material for the natural capture of CO₂ through a process called mineral carbonation. Composed primarily of calcium and magnesium oxides, EAF slag reacts with atmospheric CO₂ to form stable carbonates, such as calcite and magnesite, under ambient conditions. This natural carbonation...
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Kamal Joubarani (Hatch Ltd.)07/10/2025, 11:50Ironmaking - Direct reduction and smelting reductionOral Presentation
Steelmaking plants generate various waste materials, primarily slag, iron-containing fines, and sludges. Traditionally, many of the iron-bearing wastes have been recycled in integrated steel plants such as in sinter plants and blast furnaces. However, the shift to Electric Arc Furnaces (EAF) and stricter environmental regulations are diminishing the role of traditional recycling methods. As...
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Robert Littringer (Chair of Ferrous Metallurgy, Montanuniversitaet Leoben)07/10/2025, 11:50Steelmaking - Continuous casting, near-net shape casting and ingot castingOral
Thin Slab Casting and Rolling processes, such as the Arvedi Endless Strip Production (Arvedi ESP) process, are proven technologies to significantly reduce energy consumption and direct CO2 emission in continuous casting and hot rolling. Due to the increasing use of Electric Arc Furnaces and the use of also low-grade steel scrap, a higher intake of undesired tramp elements, such as Cu or Sn, is...
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Gaétan Symens (CRM Group)07/10/2025, 11:50
This abstract is related to the EU RFCS project OLACSKIN, focalised on the removal of zinc stains and zinc fouling by laser cleaning at the skin-pass mill.
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This presentation will be focused on the characterisation of the work rolls contamination and the first results obtained on zinc removing by laser.
If successful, this project will result in a yearly reduction of: 30.000 m³ of wastewater,... -
Sergio Pablo Ferro07/10/2025, 11:50
A numerical model for the estimation of main variables in Electric steelmaking is presented. The multiplicity of phenomena occurring in the EAF together with the huge number of variables and their complex interaction, prevents the development of a reliable online application able to take direct action on the process. An alternative approach in which the overall average performance of the EAF...
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Edoardo D'Amanzo (RINA Consulting - CSM)07/10/2025, 11:50
The transition to hydrogen-based direct reduction (H-DRI) is a crucial step in decarbonizing the steel industry. The ‘Safe H-DRI' project aims to optimize the production, loading, transport, unloading and storage of Hyrogen-based-DRI (H-DRI), addressing key challenges related to its stability, metallurgical properties, and industrial applicability.
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This study investigates the hydrogen-based... -
Pavel E Ramirez Lopez (SWERIM AB)07/10/2025, 12:10Steelmaking - Continuous casting, near-net shape casting and ingot castingOral
An overview is given of the ongoing RFCS project SHELL-CRACK. The project offers a new paradigm for the prediction, detection and correction of hot-cracks and surface defects during casting based on Pilot/Lab scale thermo-mechanical experiments combined with numerical simulations. This innovative approach considers not only “material” properties but also specific “process” information to...
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Paul Uhl-Hädicke07/10/2025, 12:10
This paper synthesizes five years of simulations across diverse scrap yards, demonstrating how discrete event simulation enhances material flow optimization. The presentation will distill five key lessons, addressing common pitfalls in scrap yard modeling, optimizing scrap pile locations, comparing scrap manipulators, improving bucket handling time and integrating new processing plants. The...
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Eleonora Shpilevaia07/10/2025, 12:10Ironmaking - Direct reduction and smelting reductionOral
Recovering valuable metals such as zinc and iron from steel mill residues is crucial in the steelmaking industry. Electric arc furnace dust (EAFD) represents the primary secondary resource for Zn recovery, as electric arc furnace (EAF) technology predominantly utilizes galvanized steel scrap as its main feedstock. Waelz process, which has been recognized as the best available technology...
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F Cirilli (Rina Consulting Centro Sviluppo Materiali)07/10/2025, 12:10
The steel industry is committed to eliminating fossil fuels to reduce CO₂ emissions, requiring innovative technologies and alternative reducing agents. Hydrogen-based direct reduction is currently the most viable solution for transforming iron ore into metallic iron with minimal environmental impact.
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This study investigates the kinetic mechanisms governing the hydrogen-based direct reduction... -
Martin Fieweger (AMEPA GmbH)07/10/2025, 12:10
The newly developed combination of oiling machine, smoothing roller and online oilfilm measurement system ensures uniform oil application on metal strips while minimizing oil consumption. Integrated with an inline oil film measurement system, it promptly detects oiling issues like overoiling or dry stripes, allowing operators to take immediate action.A key innovation is the smoothing roller,...
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Robert Wolff07/10/2025, 12:10
The Hot Strip Mill # 2 of Erdemir started operation in 1978. Since the startup, two major revamps were conducted in 1995 and 2007.
Potential for further optimizations was expected in the roll cooling header design comprising a wide range of different nozzle types including very small nozzles, which are prone to clogging. As a result, the strip thickness across the width was affected and the...
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Dr Ralf Jennes (Hatch Küttner)07/10/2025, 12:10Environmental and energy aspects in iron and steelmakingOral Presentation
The adequate design of ventilation systems for the capture of hot, fugitive releases from ironmaking and steelmaking operations requires good estimation of fume release rates and temperatures, whether it be for short term operations such as scrap charging into an EAF, or for operations that can be adequately characterized as continuous releases, such as melting and refining. There are...
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Kyle Chomyn (Hatch Ltd)07/10/2025, 12:30Ironmaking - Direct reduction and smelting reductionOral Presentation
The steelmaking industry is beginning to transition from carbon-intensive blast furnace production to new, lower-emission process routes. Implementation-ready solutions are needed to support this transition, but it is crucial that the industry makes careful investments to avoid risks to production.
The use of a direct reduction plant (DRP) with a downstream electric smelting (melting)...
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Dr Rolf Schmidt (VantageAlloys AG)07/10/2025, 12:30
Steel components exposed to dynamic loads are prone to wear and oxidation. Nitriding is a thermomechanical treatment employed to overcome these issues. The significant enhancement in the properties of steel components following nitriding is mainly attributed to increased surface hardness, the development of internal stresses, and chemical modifications within the treated zone. Vanadium as an...
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Dr Jonas Petersson (Swerim AB)07/10/2025, 12:30Environmental and energy aspects in iron and steelmakingOral
The PURESCRAP project develops sensor solutions for analysis of post-consumer scrap with the aim to enable increased use of low-quality scrap grades (post-consumer scrap) for the steel industry. Sensor stations are built for the two separate processing chains of heavy (cut) and shredded scrap. It includes sensors for chemical analysis, size metrics and object recognition. The sensor stations...
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Federico Baldussi (Università degli studi di Brescia - Italy)07/10/2025, 12:30Steelmaking - Continuous casting, near-net shape casting and ingot castingOral Presentation
Solidification plays a fundamental role in metallurgical processes, such as continuous casting of steel billets, as it greatly influences the final microstructure, in terms of grains morphology and size and chemical segregation. Segregation of solute elements occurs because of their partitioning between the liquid and the growing solid. The liquid interdendritic regions are enriched of solute...
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Mr Markus Koch (SMS group)07/10/2025, 12:30
A frequent source of yield losses, especially for reversing cold mills, are the unrolled head and tail ends of the strip. The conventional threading method without reduction at the strip head end results in a considerable loss of yield of 1.5 to 3 percent or more of the overall production of the plant.
At the same time, preparation and threading of the strip head-end are time-consuming and...
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Dr Alexander Fleischanderl (Primetals Technologies)07/10/2025, 13:50Digital transformationPlenary presentation
The steel industry is integral to society, supplying the necessary materials for infrastructure and technologies, from renewable energy systems to the electrification of transportation. As a key part of our world, the steel industry is not immune to the dramatic transformations impacting multiple sectors, namely sustainable and digital transformations, the “twin transition.” Today, the steel...
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Matteo di Blas (Danieli & C. Officine Meccaniche S.p.A.)07/10/2025, 14:30
An enhanced strip production concept with Danieli Inductive Heating technology ensuring conventional Hot Strip Mill answers market demand for ultra-thin gauge, high quality and premium grades.
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Thick-slab rolling using conventional Hot Strip Mill holds the leading position when it comes to high production capacity, wide and flexible product mix, and premium grades such as automotive exposed... -
Mr Luca Zecchinato (Tenova SpA)07/10/2025, 14:30Environmental and energy aspects in iron and steelmakingKeynote Presentation
Tenova and Topsoe have developed an innovative solution for waste gas cleaning in Electric Arc Furnace (EAF) operations by integrating Topsoe's CataFlex™ technology with Tenova's iRecovery® system. This solution improves waste gas cleaning performance, addressing critical pollutants such as carbon monoxide (CO), polychlorinated dibenzo-p-dioxins and dibenzofurans (PCDD/PCDF), and nitrogen...
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Marco Ficili (Politecnico di Milano)07/10/2025, 14:30
Hydrogen-based direct reduced iron (H₂-DRI) represents a promising pathway for significantly reducing CO₂ emissions in iron production. Achieving economic competitiveness for H₂-DRI depends on lowering hydrogen production costs, which can be addressed through: (i) high-efficiency Solid Oxide Electrolyzer Cells (SOECs) and (ii) the flexible operation of both SOEC and DRI plants.
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First, this... -
Dirk Riedinger (Badische Stahl-Engineering GmbH)07/10/2025, 14:30
Badische Stahl-Engineering GmbH developed and applies the most sophisticated simulation tool available in steel industry today: the Farschtschi Network Method (FNM). With this unique simulation tool the optimal design of the EAF high current system is feasible in terms of electrical symmetry, forces on high current cables, torques on mast system and power input performance. The capability of...
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Alexandre Gonçalves Andrade (Metal7 Inc.)07/10/2025, 14:30Ironmaking - Direct reduction and smelting reductionOral Presentation
Steel production through the Direct Reduction (DR) route presents a more sustainable alternative to conventional blast furnace processes. However, the generation of fines during raw material handling and intermediate processing stages creates significant operational challenges. These include decreased process efficiency, reduced plant throughput, increased energy consumption, and diminished...
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Denis Romagnoli (STS srl)07/10/2025, 14:30
Carbon-based materials play an important role in today's science and technology. Carbon is a very versatile element whose two most interesting allotropic forms are Diamond (sp3) and Graphite (sp2). On this way the DLC has consolidated all its applications in the automotive and mechanical in general. The management of sp3/sp2 ratio generates various types of DLC that allow to enhance the...
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Georg Gaiser (Chair of Ferrous Metallurgy, Montanuniversität Leoben)07/10/2025, 14:30Steelmaking - Continuous casting, near-net shape casting and ingot castingOral
Within the ongoing transformation of the steel industry towards lower CO2 emissions the share of steel produced via electric arc furnace will be rising. Depending on the input material (DRI/HBI, scrap, …) the infiltration of undesirable tramp elements such as Cu, Sn and (Ni) may be unavoidable and due to their special properties removal from the liquid steel is hardly possible.
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Defining the... -
Dr Matthias Kretschmer (SMS group)07/10/2025, 14:50
Sustainability has become a critical concern in the global steel industry. As steel production is inherently resource-intensive and generates significant emissions, the implementation of sustainable practices is crucial to mitigate its ecological footprint. This paper explores the current state and future prospects of sustainable galvanizing technology, a vital process for enhancing steel's...
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Mathieu Sanchez07/10/2025, 14:50
Decarbonizing steelmaking is one of the greatest challenges facing our industry today. Electrifying steel production is a pivotal step in reducing CO2 emissions. Over the coming years, the installed base of high-power EAF is expected to grow significantly, which will affect power quality but also EAF performances. To address these challenges, GE Vernova has developed an innovative solution....
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Nicola Pontoni (Danieli & C. Officine Meccaniche S.p.A.)07/10/2025, 14:50
The latest developments in MIDA (MInimill DAnieli) endless casting and rolling technology represent a significant advancement in the steel manufacturing industry. This innovative process integrates melting, continuous casting and rolling into a single, uninterrupted production line, eliminating the need for intermediate cutting, storage and reheating of the billets, significantly reducing...
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Dong Soo Lee07/10/2025, 14:50Ironmaking - Direct reduction and smelting reductionOral Presentation
Blast furnace is a process that reduces iron ore to obtain pig iron. Due to its high efficiency, it has been adopted as a major facility. As a result, not only have various technologies been developed and researched, but evaluation methods have also been established to optimize the raw materials used for efficient plant operation. Utilizing these evaluation methods, raw material management...
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Aaron Keuschnig (Montanuniversität Leoben)07/10/2025, 14:50Environmental and energy aspects in iron and steelmakingOral Presentation
The recovery of zinc from electric arc furnace dust is primarily carried out in the Waelz process. However, the reaction kinetics within the kiln remain largely unknown as direct measurements or sampling within the kiln are not possible. This lack of insight hinders a comprehensive understanding of the processes and prevents precise optimization of the kiln´s operation conditions.
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This work... -
Dr Ralf Wolters (VDEh-Betriebsforschungsinstitut GmbH)07/10/2025, 14:50
In the Real laboratory ‘H2Stahl’ a Direct Reduction test plant will be engineered, build-up and investigated. The actual status of this project shall be presented to the audience.
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The German research project is being carried out by the coordinator VDEh-Betriebsforschungsinstitut GmbH (BFI) in Düsseldorf in close co-operation with thyssenkrupp Steel Europe AG in Duisburg. The test plant will... -
Arndt Wilhelmi (Lechler GmbH)07/10/2025, 14:50Steelmaking - Continuous casting, near-net shape casting and ingot castingOral Presentation
The steel industry has been undergoing significant transformations over the years, particularly with regards to environmental regulations. Environmental authorities have continuously raised emission limits for the entire sector. This is putting a focus on previously overlooked emission points, such as the caster cooling chamber. Lechler, a renowned nozzle and demister company, is developing...
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Mr filippo cirilli (Rina Consulting Centro Sviluppo Materiali)07/10/2025, 15:10
Steel production decarbonization requires innovative technologies to reduce (up to eliminate) fossil materials in the whole chain. This implies alternative iron ore reducing process, new operating practices in the Electric Furnace, new combustion technologies in the downstream processes.
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A RINA-CSM project "Hydrogen: innovative plants and related processes for the production of green steel... -
Dr Daohua Bao (State Key Laboratory of Advanced Metallurgy, University of Science and Technolog)07/10/2025, 15:10Steelmaking - Continuous casting, near-net shape casting and ingot castingOral Presentation
The hard oxides wrapped by the plastic (Mn,Ca)S sulfides can effectively reduce the harmful effects of oxides on D2 high-speed railway wheel steel. An analysis of the composition characteristics of complex inclusions reveals that 1 to 2 μm CaO·6Al2O3 (CA6) and CaO·2Al2O3 (CA2) serve as core, promoting the growth of (Mn,Ca)S, which contains 5 to 20 mass pct CaS and 80 to 95 mass pct MnS. This...
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Mr Jérôme De Matteis (SMS group)07/10/2025, 15:10Ironmaking - Direct reduction and smelting reductionOral Presentation
This paper presents the development and implementation of a new material gate for charging of hot DRI bulk material in melters downstream of direct reduction plants or hot pellet materials in shaft furnaces or smelters. Developed and tested over a two-year period, this material gate displays innovative solutions regarding mechanical design, serviceability, and condition monitoring, creating a...
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Mr Sebastien Flament (CRM Group)07/10/2025, 15:10
Carbon steel strips are produced following a series of processes to convert the cast slabs to a coil of flat steel with required dimensions. The hot rolled coil has a protective and adherent layer of oxide scale from 5 to 15 µm thick. Before further processing, this layer of scale is removed in a process known as pickling, which consists of dissolution of the oxides by immersing the steel...
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Mr SHUO GUO (Yanshan University)07/10/2025, 15:10
Multi-pass hot caliber rolling technology has significant advantages in producing continuous bars, which can be used as structural and connecting parts with essential applications. The efficient production of high-quality bars is of great importance. Simulation is an important tool for reproducing production processes. With the improvement of product quality requirements, people also put...
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Kyle Chomyn07/10/2025, 15:10
Utilities globally are shifting towards stricter power quality requirements. This is largely motivated by increasing number of Inverter Based Resources (IBRs) such as, wind turbine and solar panel connected to utility grids and the outlook of the utility generation mix driven by the decarbonization initiatives. Electrical Arc Furnaces (EAFs) for scrap steel making are some of the most...
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ION RUSU (POLYTEC SPA)07/10/2025, 15:10Environmental and energy aspects in iron and steelmakingOral Presentation
The system utilizes one or more robotic arms, depending on plant requirements, to remove impurities from recycled scrap during the final sorting phase. By leveraging an innovative multi-sensor system and a Deep Learning algorithm trained on analyzed materials, the system classifies materials on the conveyor based on their elemental composition (e.g., iron, copper, brass, plastic, etc.).
A...
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Nathalie Gruber (Montanuniversitaet Leoben - Chair of Ceramics)07/10/2025, 15:30Steelmaking - Continuous casting, near-net shape casting and ingot castingKeynote Presentation
In the continuous casting, mold powder is added to the molten steel meniscus, where it forms a liquid slag that also contains a carbon-enriched layer. This phenomenon occurs even in ultra-low carbon steels, where small amounts of carbon are used to control the melting behavior of the mold powder. During the process, the liquid steel may come in contact with this layer leading to steel...
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Pietro Timossi (Danieli & Officine Meccaniche S.p.A.)07/10/2025, 15:30
The formation of scale in a reheating furnace is influenced by the O2 content at high temperatures and the residence time within the furnace chamber. Since the temperature and the residence time of the steel are parameters dependent on the process, the only way to reduce scale formation is by decreasing the O2 content in high-temperature zones.
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For this reason, Danieli Centro Combustion has... -
Mr Filipe Rodrigues (TMT Luxembourg)07/10/2025, 15:30
The direct reduction process is of rising importance in ironmaking in the frame of the decarbonization effort of the steel industry. While these are known and elaborated processes, they are evolving due to the use of hydrogen, the use of lower-grade raw materials, and a size increase to achieve the required production rate. These changes require innovative process control.
The process...
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Luca Bernardis (SMS group)07/10/2025, 15:30
Reduction of CO2 emissions in steel production and conversion to green energy sources demand a highly efficient, dynamic and flexible power supply for electric arc furnaces. Due to changes in the power supply grid by installing more renewable energy resources, grids become weaker and weaker. In addition to that, the grid code, especially regarding flicker values becomes more severe, not...
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Roberto Scaccabarozzi (Laboratorio Energia & Ambiente Piacenza)07/10/2025, 15:30
With a CO2 emission intensity of 1.9 tCO2/tcrude steel (including both direct and indirect emissions) and a primary energy consumption of 21 GJ/tcrude steel, steel production accounts for the emission of 3.74 GtCO2/y, representing approximately 10% of total manmade emissions. The production of direct reduced iron (DRI), which relies on natural gas to convert iron ore into metallic iron,...
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Mr Alessio Milocco (Danieli & C. Officine Meccaniche S.p.A.)07/10/2025, 15:30Environmental and energy aspects in iron and steelmakingOral Presentation
The latest pollutants emission limits imposed by various governments are forcing some important changes in the world of fumes treatment, also in the iron and steel industry.
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New technologies, already applied in other sectors, could now find their way also into this industry to comply with those regulations.
With particular focus to the treatment of the fumes from the Meltshop, Danieli is now... -
Mr Björn Kintscher (SMS group)07/10/2025, 15:30
CSP® Nexus is setting the stage for a new generation of direct casting and rolling plants with its latest orders. Unlocked by its high-throughput casting and "real batch" rolling capability, this technology achieves the lowest energy and conversion costs by efficiently utilizing available casting heat through decoupled high-speed rolling in both roughing and finishing stages. Notably, CSP®...
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Mark Kreso07/10/2025, 15:50
Electrical steel is an essential pre-product for efficient electrical devices. In cold rolling processes, an iron-silicon alloy is rolled into thin electrical strips (typical thickness 0.5 mm), which are then annealed and coated with special insulating varnishes. Sheets of different shapes and sizes are then punched and assembled to form magnetic cores. The thickness and homogeneity of the...
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Sebastiaan van Dorp (Calix)07/10/2025, 15:50
Calix’s ZESTY technology is a flash reduction process based on the indirectly heated Calix Flash Calcination (CFC) technology. In 2024, Calix completed a second testing campaign (over 100 runs) with 6 Australian-sourced hematite/goethite iron ores.
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The campaign demonstrated it is possible to achieve commercially viable metallisation degrees for a range of ores approaching near-theoretical... -
Mr Tshubasa Tokunaga (Kyushu University, school of engineering)07/10/2025, 15:50
The scale generated in the hot rolling process is a high-grade iron source. Fine scales are separated in a thickener and discharged as sludge in a slurry state, and they are difficult to use. This study focused on the sludge recycling through carbothermic reduction using microwave heating. Microwave heating occurs when an object absorbs microwaves. Compared to conductive heat transfer,...
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Mirko Javurek (Johannes Kepler Universität Linz, Institut für Strömungslehre und Wärmeüübertragung)07/10/2025, 15:50Steelmaking - Continuous casting, near-net shape casting and ingot castingOral Presentation
In continuous steel casting, the turbulent liquid steel flow in the mold has a significant influence on the produced steel quality. The varying process parameters casting speed and inert gas injection at the stopper rod tip influence the mold flow pattern. Most investigations consider the original geometry of the submerged entry nozzle. During the casting process, material deposition and...
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Mr dogan ertas07/10/2025, 15:50
Regulations at the world are accelerating the transition toward a low carbon economy, pushing the industrial sector to reduce the CO2 footprint. Especially EU has set ambitious targets to reduce greenhouse gas emissions by at least 55 % by 2030 and achieve carbon neutrality by 2050. However, despite renewable expansion and the increasing attention on the hydrogen economy, these targets are...
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Hartmut Gumbinger (SMS Group)07/10/2025, 15:50
Hot strip mills can have a service life of 50 years and more. An ongoing challenge for plant owners is to maintain the competitiveness of their plants over the entire life cycle with constantly new boundary conditions and developments. SMS group offers advanced and innovative technical solutions enhancing the product portfolio, product quality, operational efficiency, sustainability and...
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Ms Nicole Voigt07/10/2025, 16:40Environmental and energy aspects in iron and steelmakingKeynote Presentation
The steel trade has long been a cornerstone of interconnected global production networks. Yet, as the industry faces unprecedented challenges—ranging from chronic overcapacity to divergent decarbonization trajectories—the protection of domestic markets is emerging as a critical priority. Around the globe, measures such as anti-dumping regulations, tariffs, safeguards, and subsidies are...
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Prof. Björn Glaser (KTH)07/10/2025, 16:40
The HIYIELD project leverages advanced technologies to promote circular economy practices in steel production by increasing scrap utilization and reducing dependence on pig iron from coal-fired blast furnaces. The project encompasses three industrial demonstration cases, each addressing a critical aspect of scrap processing and integration.
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In Demo Case 1, industrial-scale trials were... -
Alok Sarkar (Norwegian University of Science and Technology (NTNU), Norway)07/10/2025, 16:40
Abstract:
The transition from solid carbon to hydrogen gas in ferromanganese production represents a transformative strategy for reducing carbon emissions in the ferroalloy industry. The HAlMan process, an innovative hydrogen-based reduction method, has advanced from laboratory-scale research to pilot-scale validation, demonstrating significant potential for decarbonizing ferromanganese...
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112. Implementation of EASyMelt with Ammonia and HBI Charging to Achieve Ultra Low Carbon IronmakingMr Florent Mauret (SMS group)07/10/2025, 16:40Ironmaking - Blast furnace ironmakingOral Presentation
Despite being the largest emitter of CO2 in the steel industry, the blast furnace (BF) process remains dominant due to its high productivity, cost-effectiveness and flexibility in ore usage. Still, with the proliferation of policies geared towards curbing CO2 emissions, the BF process must transition towards operation with lower emissions. In that context, Paul Wurth S.A. has unveiled...
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Prof. Valentina Colla (Scuola Superiore Sant'Anna)07/10/2025, 16:40
The European steel sector is committed to improve sustainability of the whole steel production chain, from decarbonisation of major upstream processes up to all downstream operations, including rolling. In particular, in the cold rolling process, oil-in-water emulsions/dispersions are usually applied to lubricate the cold rolling process of low-Carbon steel. Such emulsions present some...
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Mr Guenther Schnell (Friedrich Kocks GmbH & Co KG)07/10/2025, 16:40
In the field of Special Bar Quality (SBQ) production, decades of evidence indicate that a sizing block makes a decisive difference in the total performance of each rolling mill. This is valid for green field projects as well as for modernization projects. The so-called 'sizing block' reflects a significant advancement - traditionally aimed at substantially enhancing product quality in...
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Gernot Hackl (RHI Magnesita GmbH)07/10/2025, 16:40Steelmaking - Continuous casting, near-net shape casting and ingot castingKeynote Presentation
Thin slab casting is a well established technology in modern steel making, offering significant advantages in terms of efficiency, cost-effectiveness, and environmental sustainability compared to standard slab casting. As the industry trends towards even higher productivity, a new type of casting machine operating at medium thick moulds seem to be the emerging trend. One key factor...
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Dr Johann Wachlmayr (Austria)07/10/2025, 17:00Ironmaking - Blast furnace ironmakingOral Presentation
The position of the cohesive zone (CZ) in a blast furnace significantly impacts process efficiency and stability. A lower cohesive zone increases dry burden volume, promoting indirect reduction of iron ore and improving energy efficiency. However, excessive downward movement reduces the distance to the dead man, leading to operational instability, irregular gas flow distribution, unsteady coke...
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Mr Jihong Ji (SMS group)07/10/2025, 17:00
This paper analyses the potential of ammonia in the decarbonization race within the steel industry and gives an outlook in presenting realistic, cost competitive decarbonization solutions such as the Paul Wurth EASyMelt.
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Ammonia, with its high hydrogen content and established infrastructure, presents a viable alternative to pure hydrogen. The European Union's commitment to carbon neutrality... -
Tong Qiao (State Key Laboratory of Advanced Metallurgy, University of Science and Technology Beijing)07/10/2025, 17:00Steelmaking - Continuous casting, near-net shape casting and ingot castingOral
This study addresses the issue of nozzle clogging failure in the continuous casting of Super304H stainless steel, investigating the impact of inclusions on nozzle clogging formation through experimental and thermodynamic calculations. Initially, the clogged nozzles were systematically examined, followed by the study of the evolution of steel melt inclusions at different stages of the smelting...
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Masahiro Ambiru (Tohoku University)07/10/2025, 17:00
The recycling of steel as a secondary raw material in low-carbon steelmaking is limited for maintaining sufficiently low content of tramp elements (TEs) in steel products, as TEs contaminate molten steel during the remelting process in the electric arc furnace (EAF). A molten oxide electrolysis (MOE) has been applied for metal production and new refining processes. A recently proposed...
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Sebastien Flament (CRM)07/10/2025, 17:00
In steel making, several processing steps are required to produce carbon steels strips. During the hot rolling step, the high temperature and exposure to air and humidity leads to a surface covered by an oxide. The function of the pickling line is to remove this oxide layer to be able to continue processing the steel, such as by cold rolling, welding, coating, painting. Most of the pickling...
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Dr Jochen Wans (SMS group)07/10/2025, 17:00
Wind power plays a central role in the global energy transition and is one of the most sustainable methods of electricity generation. It harnesses the kinetic energy of the wind and converts it into electrical power through wind turbines, without emitting greenhouse gases. Windmills are a crucial component of the shift to renewable energies as they provide a reliable, cost-effective, and...
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jinwoo jung (hyundai-steel)07/10/2025, 17:00
In the hot strip rolling process, the reheating furnace heats the slab to a suitable temperature for rolling. The roughing mill then processes the slab, extracted from the reheating furnace, into a bar, and the finishing mill ultimately produces strips of the desired size as requested by the customer. In the cooling section, the material is processed to satisfy the customer’s required...
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Marco Alloni (Prosimet S.p.A.)07/10/2025, 17:20Steelmaking - Continuous casting, near-net shape casting and ingot castingOral Presentation
Fluorine has been widely used in continuous casting mold fluxes due to its ability to reduce surface tension, lower viscosity, and decrease melting temperatures. However, its dissolution in secondary cooling water leads to hydrofluoric acid formation, posing significant environmental and safety hazards. As a result, research has focused on alternative fluxing agents, with borate compounds...
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Mr Cristiano Castagnola (SMS group)07/10/2025, 17:20Ironmaking - Blast furnace ironmakingOral Presentation
This paper examines the unprecedented achievements of Tata Steel's H-Blast Furnace at Jamshedpur, which has surpassed 50 million tons of hot metal production in the present campaign (as of January 8, 2025), without requiring major mid-campaign repairs. Commissioned in 2008, the furnace has consistently exceeded its designed by more than 20% annually, establishing new benchmarks in operational...
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Dr Dilip Chandrasekaran (Kanthal)07/10/2025, 17:20
Current heating technology is predominantly gas-fired and there is a strong drive and commitment, from the steel industry to reduce emissions in steelmaking. Resistance heating technology potentially offers unique opportunities to reduce or remove use of fossil fuels while at the same time increasing thermal efficiencies, improving the work environment and enabling delivery of a fossil-free...
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Uxia Dieguez Salgado07/10/2025, 17:20
The steel industry, as one of the main contributors to the CO2 emissions worldwide, is called to make efforts to reduce its carbon footprint. The green steel transformation is focussing on Scope 1, mainly by substitution of the Blast furnace, and Scope 2, by usage of only electricity coming from green sources or by substitution of Natural gas by green hydrogen. In regard of Scope 3,...
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Ms Cynthia ELHAJJ07/10/2025, 17:20
In cold rolling, the mixed lubrication regime is needed e.g. to avoid skidding. In fact, low viscosity oils are used as lubricants to set lubrication at the frontier of the boundary regime, promoting strip surface smoothing by finely ground rolls. This poses a risk of boundary regime interface degradation, including adhesive transfer, which may harm final strip surface quality. On the...
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Mr Erland Nylund (Swerim AB)07/10/2025, 17:20
In order to remove fossil carbon from the metal industries, biogenic carbon sources are needed. Progress has been made in using biogenic carbon substitutes in pilot and industrial-scale trials. However, challenges remain in the production and use of metallurgical biocarbon products, particularly in areas such as policy support at national and EU levels, commercial financial incentives,...
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Kerstin Baumgartner (Primetals Technologies)07/10/2025, 17:20
Arvedi ESP (Endless Steel Production) has transformed the steel industry by integrating continuous casting and direct hot rolling into an ultra-compact process. This innovation has introduced the endless Hot Rolled Coil (eHRC) as a new market product with unprecedented geometrical tolerances and mechanical uniformity. However, ESP production follows casting sequences, which are interrupted...
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Mr Artemy Krasilnikov (SMS group)07/10/2025, 17:40Steelmaking - Continuous casting, near-net shape casting and ingot castingOral Presentation
This paper is part of the work on the EU funded RFCS project SHELL-CRACK that seeks to improve the as-cast slab quality of the shell in continuously cast semis through innovative strategies to control crack formation and microstructure evolution. Cracking initiation and propagation mechanism is a very complex phenomenon and depends on many factors, such as microstructure, cooling rate, cooling...
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Prof. Carlo Mapelli (Dipartimento di Meccanica - Politecnico di Milano)07/10/2025, 17:40
This study introduces a hybrid heating furnace design that integrates gas burners and induction heating to achieve enhanced energy efficiency, precise temperature control, and operational versatility. Gas burners provide high thermal output, while induction heating enables rapid, localized temperature adjustments, making the system ideal for applications such as metal heat treatment, rolling...
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Mohammad Jafarzadeh (K1-MET)07/10/2025, 17:40
By the end of 2050, the European Union aimed to decrease the carbon-based greenhouse gases (CO and CO2) considerably. It was targeted to achieve 80-95% less than the level of emissions in 1990. Hydrogen, as a clean reducing agent, can eliminate the carbon footprint from the steel industry considerably (up to 95%). However, some factors, such as the endothermic nature of H2 reduction, and the...
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Mr Martin Welling (Minteq International GmbH)07/10/2025, 17:40
Steel producers face increasing pressure to cut costs, lower CO₂ emissions, and enhance safety amid evolving economic and production landscapes. This paper highlights recent advances in measurement technology and digitalization that optimize safety, yield, and refractory performance in hot metallurgical vessels. Key innovations include fully automatic repair systems for electric arc furnace...
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Dr Edward Long (Primetals Technologies)07/10/2025, 17:40Ironmaking - Blast furnace ironmakingOral Presentation
Blast furnaces are a key lever for reducing the CO2 emissions of the steel industry. This paper will review the available technologies and best practice for blast furnaces and the effect they can have on reducing CO2 emissions. The OPEX and CAPEX costs and benefits will be discussed, with a view to identifying the “low hanging fruit” for steelmakers to implement. These options will include...
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Dr Ian Robinson (Primetals Technologies)07/10/2025, 17:40
Recent trends in plate steel production have seen a focus on maximizing mill productivity. Plates that are produced using a controlled rolling strategy usually have a pause in the rolling sequence. This hold time can be extended based on the process parameters and can significantly contribute to the overall production time for a single plate and reduce mill productivity. The application of...
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Thomas Steinparzer (Primetals Technologies Austria)07/10/2025, 17:40
The transition towards green steelmaking necessitates fundamental modifications to existing production routes, particularly through the integration of electric arc furnaces (EAF) within integrated steel plants. This shift offers operators new opportunities, including the production of new steel grades and flexible raw material inputs. However, the environmental implications of EAF...
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Dr Alexander Beel (cunova GmbH)07/10/2025, 18:00Steelmaking - Continuous casting, near-net shape casting and ingot castingOral
Steel manufacturers are increasingly challenged to deliver high product quality while simultaneously lowering operational costs to remain competitive. One key metric in evaluating performance is the cost per ton of steel produced.
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This work aims to develop a mould plate design that provides measurable advantages in terms of cost per ton, without compromising on heat conditions, quality or... -
Dr Fabian Krause (SMS group)07/10/2025, 18:00
In the public funded project “HyInnoBurn – Industrial Gas Burners” a 450 kW prototype of a hydrogen fueled burner-injector system for use in EAF has been developed and additive manufactured in pure copper. This project is part of the German Clusters4Future initiative, supported by the German Federal Ministry of Education and Research (BMBF).
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Uncertainty in the future gas supply (natural gas,... -
Simon Mittlböck (Primetals Technologies)07/10/2025, 18:00
Improving energy efficiency and product quality in hot strip mills is essential to meet
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the increasing demands for modern production facilities. Primetals Technologies
developed an advanced work roll lubrication and cooling package, including the
innovative Power Work-Roll Cooling system. This integrated solution combines
energy efficient dynamic work roll cooling, advanced roll-gap... -
Dr Federico Rossi (Sant'Anna School of Advanced Studies)07/10/2025, 18:00
The European project ALCHIMIA “Data and decentralized Artificial intelligence for a competitive and green European metallurgy industry” (GA No 101070046) gathers academic and industrial partners in the steelmaking sector to optimize steel scrap use in the Electric Arc Furnaces (EAF) and the Ladle Furnace (LF) operation. The project aims to develop a Federated Learning informatic architecture...
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Hauke Bartusch (VDEh-Betriebsforschungsinstitut GmbH)07/10/2025, 18:00
The blast furnace process for Ironmaking is highly optimised and very energy efficient. At the same time due to its dependency on coke, not only as an energy carrier but also as a chemical reductant and provider of gas permeability, it is responsible for high CO2 emissions. Consequently, steel producers search for operation modes, e.g. such as increased share of hydrogen based reduction, to...
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Mr MATTEO GILI (RINA-CSM)07/10/2025, 18:00
The iron and steel sector leads in CO2 emissions and ranks second in energy consumption among heavy industries. It directly contributes 2.6 gigatonnes of carbon dioxide (Gt CO2) annually, accounting for 7% of the global energy system's total emissions. Currently, it is the largest industrial coal consumer, meeting approximately 75% of its energy demand. Despite global reliance on blast...
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Pepijn Adriaen (CRM Group)07/10/2025, 18:00
An RFCS funded project, SmartCool (RFCS-PDR 101057274) has been launched together with major European steel producers and research centres. The aim of this project is to develop a selective transfer bar cooling that is intelligently controlled to correct in real time transfer bar temperature distortions during production. A step by step approach has been initiated at the design phase and...
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Daeho Yun (Hyundai Steel Company)07/10/2025, 18:20
In the hot rolling process, precise control of dimensional accuracy and material properties in steel plates is essential for performance and cost efficiency. However, increasing customer demands have underscored the importance of surface quality. A key determinant of surface quality is the Roughing-mill Delivery Temperature (RDT), which significantly influences scale formation and surface...
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Steven Samuel (Hatch)07/10/2025, 18:20Ironmaking - Blast furnace ironmakingOral Presentation
The effective operation of hot stoves is critical to profitable blast furnace ironmaking. High hot blast temperatures and stable stove operation enable consistent metal production at low cost. Conversely, damage and operational disruptions affect process efficiency, iron quality, and downstream activities. While it is important to address damage expeditiously, comprehensive repairs are...
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Stephan Six (SMS group)07/10/2025, 18:20Steelmaking - Continuous casting, near-net shape casting and ingot castingOral Presentation
The implementation of the optical fibers revolutionized mold monitoring and provides signals with previously unattained resolution and quality. The biggest challenge with this technology is to connect fiber optics in harsh environments because dust and dirt can easily block the optical connector and cause signal loss. The newly upgraded HD moldFO+ brings with it important progress, including a...
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Mr Bernd Buchberger07/10/2025, 18:20
The challenges in the field of electric steelmaking have increased in recent years, especially in terms of the rising quality requirements of the steels to be produced.
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These challenges have not only grown, but have also significantly changed due to various factors such as sustainability considerations and carbon footprint. Therefore, some processes, e.g. desulphurization will be shift from... -
Niccolo Massarelli07/10/2025, 18:20
This study investigates the effects of replacing natural gas with Hydrogen in heat treatment furnaces for stainless steel strip (both austenitic and ferritic grades). Using Hydrogen as a fuel, the vapor content in the furnace atmosphere increases, which could affect the characteristics of the oxide scale, including its composition, thickness and adherence to the base metal. Eventually changes...
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Mr Ronald Wilmes (SMS group)07/10/2025, 18:20
X-Pact® Solid Control is the SMS group's secondary cooling model for slab, thin slab, bloom and billet continuous casting plants.
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It consists of a "process package" that is fully integrated into the manufacturer’s plant automation and a "technology package" that helps the metallurgist to find the right process parameters before one ton of liquid steel flows into the mold.
The aim is to show... -
Gian Hauenstein (SMS group)07/10/2025, 18:20
The transition to green energy and the reduction of carbon footprints in the steel industry are essential for sustainable steel manufacturing. Optimizing casting processes in steel plants can lead to substantial reductions in emissions and operational costs, aligning with the increasing demand for eco-friendly products.
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In the context of the continuous casting process for billets, scale... -
Bernhard Adami (K1-MET GmbH)07/10/2025, 18:40
The hydrogen plasma smelting reduction process is a promising technology for sustainable steel production from iron ores, utilizing molecular, atomic and ionized hydrogen as reducing agents. The reactor is a gas-tight direct-current electric arc furnace with a hollow graphite cathode for material and gas feeding. To investigate scale-up parameters, a pilot plant with a capacity of 100 kg iron...
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Mr Andrea Salimbeni (Re-Cord)07/10/2025, 18:40
The utilization of biochar as valid alternative to fossil coal for steel bath carburization and slag foaming has already been proved with small scale and industrial tests.
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The material availability and the related cost remain important issues to allow the utilization of biochar in current industrial practice. Reusing biogenic wastes is a promising solution, but the concentration of inorganics... -
Dr Seungmoon Lee (POSCO Technical Research Laboratories)07/10/2025, 18:40Ironmaking - Blast furnace ironmakingOral Presentation
Manufacturing steel requires extremely challenging industrial processes. In particular, predicting the exact time instance of opening and closing tap-holes in a blast furnace has a great influence on steel production efficiency and operating cost, in addition to human safety. However, currently predicting the time to open and close tap-holes of the blast furnace still highly relies on manual...
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Prof. Björn Glaser (KTH)07/10/2025, 18:40
The use of recycled scrap instead of iron ore is a key strategy for the steel industry to reduce carbon emissions and its reliance on critical raw materials. With the growing demand for scrap, it is becoming increasingly important to handle lower-quality steel scrap effectively. Contamination by unwanted tramp elements, such as copper and tin, can pose significant challenges in producing...
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Alberto Nardini07/10/2025, 18:40
The demand for increased productivity, cost efficiency and reduce energy and environment impact in the steel rolling industry has driven the adoption of innovative technologies.
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Triple slitting technology is a game-changing method in rolling processes, particularly for rebar sizes over 14 mm.
So, the intention of this paper is to explore the implementation of triple slitting technology... -
Mr Hans-Jürgen Odenthal (SMS group)07/10/2025, 19:00
In the RH process, the continuous circulation of liquid steel between the vacuum chamber and the ladle significantly affects decarburization and degassing rates as well as the productivity. Several CFD (Computational Fluid Dynamics) models have been developed to simulate the transient multiphase flow of melt and injected inert gas in RH plants in order to investigate the effect of different...
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Sebastian Richard (SMS group)07/10/2025, 19:00
Chatter remains a critical challenge in cold rolling mills, as different vibration types can lead to severe strip defects or mechanical failures. This paper demonstrates the advancements in the Genius CM® system, based on its application at the Big River Steel (BRS) Pickling Line Tandem Cold Mill (PLTCM), in the context of enhanced Chatter root cause detection and vibration...
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Hamideh Hassanpour (postdoc)07/10/2025, 19:00
The steel industry is responsible for 7% of global CO₂ emissions, with the blast furnace–basic oxygen furnace (BF-BOF) process accounting for approximately 70% of the total emissions from steel production. Given the significant environmental impact, the European Union has set a target to achieve net-zero CO₂ emissions by 2050. Reducing carbon carriers, mainly in the form of coke consumption is...
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Angelo Naclerio07/10/2025, 19:00Steelmaking - Continuous casting, near-net shape casting and ingot castingPoster Presentation
Strategie di produttività, tracciabilità e sostenibilità con riferimento ai cristallizzatori per la colata continua dell'acciaio.
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Lorenzo Orlietti (Alperia Green Future Srl)07/10/2025, 19:00
Compressed air systems represent a critical utility in energy-intensive industries, particularly in hard-to-abate sectors such as steel, cement, and chemicals, where efficiency improvements can significantly reduce energy consumption and carbon emissions. This study presents an artificial intelligence (AI)-based methodology for the optimization of compressed air networks in industrial plants,...
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Mr Richard Sharp (Evertz Europe S.A.)07/10/2025, 19:00
High pressure grinding is gaining popularity and becoming the preferred method to remove surface defects from carbon steel semi-products. Reasons for selecting grinding over scarfing include for example higher flexibility of operations, optimized yield, easier and higher value recycling of the swarf, lower energy consumption and reduced carbon footprint. To ensure that ground semi-products...
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Stefano Bucci (Università degli Studi di Torino)07/10/2025, 19:00
The steel industry contributes approximately 7-8% of global CO₂ emissions. To reduce its environmental impact, technologies for producing “green steel” are being developed, including the use of the Electric Arc Furnace (EAF). This technology uses scrap, Direct Reduced Iron (DRI), and Hot Briquetted Iron (HBI) as raw materials, managing to reduce energy consumption
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(-30%) and greenhouse gas... -
Emanuele Borasio (weAR Srl)07/10/2025, 19:00
To better demonstrate the entire operation cycle of the SCI framework at the event, given the impracticality of bringing bulky devices, it has been decided to create a digital twin of the process, to be shown to the audience via smart glasses. The interactive digital twin will display the various functional parts of the project, allowing the components created by individual partners to be appreciated.
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Mr Eduardo Borges Matos (University of Oulu)07/10/2025, 19:00
Hydrogen-based reduction of iron oxide is a promising new technology in fossil-free steelmaking. In the process, the iron oxide is usually fed in a form of spherical pellets or briquettes. In solid-gas -reactions, the porosity of the pellets is assumed to enhance the reduction kinetics via the increase of the available reaction surface area at the reaction interface. However, the...
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antoine moussalem07/10/2025, 19:00
Heat recovery from waste gas in heavy industries, such as steel plants, is crucial for enhancing energy efficiency and sustainability. This process captures thermal energy released during production and repurposes it for other applications within the plant. This approach not only reduces operational costs but also minimizes energy wastage and lowers greenhouse gas emissions, supporting global...
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Dr Youn-Hee Kang (POSCO)07/10/2025, 19:00
In high-strength dual phase steel, where phase transformation continues even after the down coiling process in hot rolling, material deviation in the hot-rolled coil occurs due to differences in cooling rates in the radial and circumferential directions during the cooling process. This material deviation leads to short-cycle hunting of rolling load during the subsequent cold rolling process,...
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Ms Marina Kalugina (KALUGIN JSC)07/10/2025, 19:00
The global iron and steel industry is being impacted by a decline in steel demand and volatile situation in the global market of raw materials. Manufacturers are challenged to reduce the production cost of iron and steel by modernizing the existing production facilities in conditions of continuously growing requirements for provision of environmental measures. Iron and steel industry is...
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Christoph Nölle (BFI)07/10/2025, 19:00
We present the open-source planning software DynReAct, which grew out of a research project on dynamic production planning and scheduling in the steel industry. The software implements a three-stage approach to the flexible flow-shop planning problem, comprising modules for long-term, mid-term and short-term planning. Long-term planning implements an order-less planning approach based on...
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Min Kwan Chang07/10/2025, 19:00
Austenitic stainless steel (ASS) is widely utilized in various industries owing to its exceptional corrosion resistance, heat resistance, and mechanical properties. Achieving ultra-high cleanness is critical to obtaining these desirable properties. To enhance cleanness, ASS is typically produced through vacuum induction melting (VIM) and/or vacuum arc remelting (VAR) processes, with Al or Si...
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Mr Hyeonwoo Shin (Dong-A University)07/10/2025, 19:00
To reduce CO2 emissions during blast furnace operation, the usage of pellets is increasing compared to sintered ore. Pellets melt at higher temperatures and have superior reducibility compared to sintered ore, which allows for a reduction in coke consumption. However, due to differences in composition between pellets and sintered ore, the Al2O3 content in blast furnace slag is increasing....
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F Cirilli (Rina Consulting Centro Sviluppo Materiali)07/10/2025, 19:00
The hydrogen combustion in reheating and heat treatment furnaces produces a new furnace atmosphere without or with lower concentration of CO2 and consequently higher H2O concentration. The higher water vapour content can change steel’s oxidation kinetic, as well as the oxide scale morphology and the oxide-steel interface features thus affecting the scale adhesion. The oxidation kinetics and...
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Timo Haimi (Mr.)07/10/2025, 19:00
“A smelting furnace (SAF, OBSF, ESF) has been recognized as an important new process step in decarbonization of iron and steel production. For de-risking the industrial projects utilizing new technologies, various test work steps have been necessary for scale up purposes. This paper is presenting Metso experiences and lessons learned from the in-house smelting test work. The most interesting...
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MATTEO TOMBA (PERT SRL)07/10/2025, 19:00
The Fume Treatment Plant sizing needs to be highly customized. The steelmaking equipment characteristics and arrangement, the general site layout, the environmental local regulations and the best available technologies (BAT) for the pollution control have to be taken into account. The final choice implies always the comparison among different solutions regarding the fume capturing, the cooling...
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Vincenzo Morreale07/10/2025, 19:00
The project involves the installation of a 1 MW electrolyzer that will produce green hydrogen via electrolysis, utilizing electricity exclusively coming from renewable sources. This hydrogen will fully replace natural gas in a heat treatment furnace, marking a significant step towards cleaner industrial operations.
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The electrolyzer will be powered by a newly constructed hydroelectric plant on... -
Pankaj Kumar (PhD candidate)07/10/2025, 19:00
Manganese is an important alloying element used in steel industry and is mostly used for increasing the strength without compromising the ductility. Currently, manganese is added as ferromanganese in steel to form manganese steel. Hence the final steel formation goes through series of steps after primary raw materials extraction, namely, ironmaking, crude steel production, ferromanganese...
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Mr Cristiano Tercelli (Primetals Technologies)07/10/2025, 19:00
The Endless Bar Production (EBP) process reduces energy consumption by 60% and CO2 emissions by over 90% compared to conventional methods. By combining EBP with efficient melting technologies, the environmental footprint and energy balance of steel production can be minimized. This compact process with minimum material losses lowers the conversion cost of reinforcing bars by up to 40%. ...
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Dr Thomas Pursche (SMS group)07/10/2025, 19:00Steelmaking - Continuous casting, near-net shape casting and ingot castingPoster Presentation
The continuous casting process is crucial in metallurgy, yet its startup phase is often plagued by significant fluctuations and instabilities, complicating the reliable prediction of potential breakouts. Traditional breakout detection systems are typically activated only after steady-state conditions are achieved, which means they engage only after a considerable length of material has been...
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Jonas Oswald (Dürr Systems AG)07/10/2025, 19:00
Steel production in Europe is facing several challenges nowadays. The remaining high prices for energy and the demand on steel are some of the most pressing topics for steel producing companies. Energy efficiency technologies on the production site play an important role to improve the cost structure and the CO2 footprint to keep the competitiveness in the world market alive. Waste heat usage...
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Mr Suvro Basu (Danfoss)07/10/2025, 19:00
Steel plants are full of dust and gas and PCB has a tendency to fail if not protected properly. To avoid the downtime, it is recommended to use highest level of conformal coating to protect from dust and corrosive gases present in steel area.
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Thermal management is a key criteria in steel plants. Innovation in technology has helped to segregate the power module heat from the control... -
Sergej Nesterov07/10/2025, 19:00
The increased production of direct reduced iron (DRI) in recent years, particularly in the form of metallised DRI pellets and hot briquetted iron (HBI), is a promising development in global ferrous metallurgy. One of the special features of these products is the fact that, unlike scrap, they do not contain any impurities that are harmful to the production of steel and can therefore be used in...
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Jan Thiel (PSI SE Process Industries and Metals)07/10/2025, 19:00
A central Manufacturing Execution System (MES) is a reliable and approved single-source-of-truth for production and material tracking. At the same time, a central system that integrates all automation systems and Enterprise Resource Planning can make it difficult to find slots for maintenance, updates or extensions. Its unavailability can be critical, potentially leading to a production...
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Mr Eric Almquist (StarTool)07/10/2025, 19:00
The average plant worker’s age is increasing while headcount is leaner providing fewer opportunities to transfer knowledge from more to less experienced people. Workflow art, the correct methods to execute tasks, is being lost with retirees and leaner workforces while skill gaps and productivity pressures are increasing. The collection of these workflow arts is sometimes summarized into the...
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Mr Pietro Cetto (Politecnico di Milano)07/10/2025, 19:00
Solid-state recycling techniques for metallic chips have been explored as a sustainable alternative to conventional remelting-based methods. The latest developments make these techniques promising in the production of bulk and dense materials, with the opportunity to obtain also multi-material components with this path. This study investigates the production of multi-alloy material through a...
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PETER SEEMANN (Ebner Group)07/10/2025, 19:00
Bell-type furnaces are an integral part of cold rolling mills for carrying out the annealing process. The technology of high convection in a hydrogen atmosphere (HICON/H2®) was introduced to the market as early as 1972. Continuous further developments have increased performance, quality, efficiency and reduced costs.
This next generation of sustainable bell-type furnace systems, called...
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Dr Francesco Barberini (University of Bologna)07/10/2025, 19:00
At Marcegaglia Ravenna plant has been implemented a novel production route, patent pending, of fully processed Fe-Si grades focused on industrial and e-mobility applications. In this study are reported the main metallurgical levers of the adopted production cycle and their effectiveness on the magnetic properties in terms of low loss, high permeability and absence of aging.
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Prof. Irene Calliari (university of Padova)07/10/2025, 19:00
pere.barriobero@upc.edu>; Towhid.Faraji@imf.tu-freiberg.de; Mathias.Zapf@imf.tu-freiberg.de; roberto.elvira@sidenor.com; irene.calliari@unipd.it; mirko.pigato@phd.unipd.it; ebasagana@comforsa.com; avilalta@comforsa.com; juan.emilio.rey@upc.edu; pcalopa@comforsa.com; Ulrich.Prahl@imf.tu-freiberg.de; jose.maria.cabrera@upc.edu; martino.oliboni@studenti.unipd.it, anna.mazzi@unipd.it
In the...
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YUBIN LEE07/10/2025, 19:00
Global steel companies are shifting from coal and natural gas-based production methods to hydrogen-based systems in pursuit of carbon neutrality. However, transitioning from coal to hydrogen significantly increases electricity consumption. To address this challenge, it is imperative to expand renewable energy resources, promote the supply of green hydrogen, and reduce its cost. In this...
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Mr NICOLA TOMBA (PERT SRL)07/10/2025, 19:00
Today’s long steel products market with ever smaller profit margins and stronger competition requires the use of rolling mills with minimized operational cost and the capability of assuring a final product of very high quality. Starting from these considerations, a PERT customer in Turkey decide to use the PERT BS (bi-Support Stands) in order to upgrade the existing section mill.
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The new... -
Dr Ruowei Li (Department of Mechanical Engineering, Politecnico di Milano, Milano, 20156, Italy)07/10/2025, 19:00
During the continuous annealing process in the steel rolling heat treatment procedure, the occurrence of buckling in strip is a common issue, especially in the heating and soaking zones. The lateral distribution of stress state of the annealing strip is the essential factor resulting in the phenomenon. However, accurately predicting it is very difficult. Many factors influence the stress state...
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137. Production conditions of porous iron whisker for the gas reforming in CRIP-D ironmaking processHaruka Sato (Tohoku University)07/10/2025, 19:00
Currently, the CO2 emission in ironmaking industry is one of the biggest environmental issues. To solve this issue, some alternative carbon recycling ironmaking processes such as carbon recycling BF are under development. However, those cannot achieve true carbon neutrality. Our group has suggested a new carbon recycling iron making process, CRIP-D, using carbon-iron ore composite. In this...
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ION RUSU (POLYTEC SPA)07/10/2025, 19:00
This paper presents a novel robotic approach to enhancing safety and efficiency in steel plant operations, focusing on steel sampling, deslagging, inspection, and automatic ignition systems for Electric Arc Furnaces (EAFs). Designed for harsh industrial environments, these smart robotic solutions significantly reduce human exposure, improve operational accuracy, and increase...
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Mark Kreso07/10/2025, 19:00
In hot-dip galvanizing processes, achieving optimal zinc coating thickness while minimizing material consumption remains a significant challenge. Traditional control methods often rely on reactive adjustments based on delayed coating thickness measurements, leading to inefficiencies and increased zinc consumption especially at strip transitions with material and coating target changes. To...
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Mr Eric Almquist (StarTool)07/10/2025, 19:00
Non-woven fabrics are surprisingly ubiquitous in daily life, appearing in everything from kitchen scrub pads and disposable floor wipes to baby diapers, building vapor barriers, and even aircraft insulation. These materials offer unique advantages in functionality, durability, and adaptability, making them indispensable across a variety of industries. One lesser-known—but highly...
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Mr Yi Huang (University of Science and Technology Beijing)07/10/2025, 19:00
Similar to the formation process of nature granite, the molten slag is directly prepared into large volume cast stone, where the stress is affected by the mechanical and thermal expansion properties of its crystallization, which is easy to crack and lead to cracking. The phase composition and thermal expansion properties of the silicon manganese slag cast stone prepared at different...
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Paulina Unifantowicz (Steeltec AG)08/10/2025, 09:00
Boron in steel might form boron nitrides and/or boron oxides. Hexagonal boron nitride is a solid lubricant and as a second phase in steel it improves machinability (tool lifetimes as well as chip breaking). In addition, boron in oxides lowers the melting point (or glass transition temperature). B2O3 is known as a low melting phase with similar properties than Pb inclusions. Unfortunately, the...
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Dr Gian Hauenstein (SMS group)08/10/2025, 09:00Environmental and energy aspects in iron and steelmakingOral Presentation
Energy recovery in the continuous casting process offers substantial opportunities for enhancing efficiency and sustainability within the metals industry. During the solidification and cooling phases, a significant volume of energy is extracted from the melt. This energy, however, is often dissipated and remains unrecovered, representing a lost opportunity for energy optimization. Recognizing...
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Ms Monika Seidl (K1-MET GmbH and Montanuniversitaet Leoben)08/10/2025, 09:00Steelmaking - Continuous casting, near-net shape casting and ingot castingOral
Abstract
The heat transfer coefficient (HTC) is an essential parameter in the numerical simulation of solidification during the secondary cooling zone in continuous casting. Accurate prediction of the HTC is essential for controlled slab cooling and ensuring product quality by preventing crack formation. The HTC is commonly estimated using empirical equations from literature. However,...
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Leon Heinl (Primetals Technologies)08/10/2025, 09:00
The steelmaking industry, as one of the major emitters of greenhouse gases, is undergoing a transformation towards greener technologies. One of the key players in this transition is the electric arc furnace (EAF), which is fed with scrap and direct reduced iron (DRI), with an increasing proportion of DRI used for high-quality steel grades. Traditionally, DRI production relies on natural gas as...
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Elsayed Mousa (Swerim AB)08/10/2025, 09:00
Ferrochromium (FeCr) alloy is essential in the production of stainless steel and specialty steels. The urgency for sustainable production methods is increasing due to the rising carbon footprint. One promising solution is incorporating biocarbon as a partial substitute for coke in submerged arc furnaces (SAF), while also maximizing the recycling of iron-bearing materials, such as mill scale...
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Jörg Surmund (Friedrich KOCKS GmbH CO. KG)08/10/2025, 09:00
Although the production of ERW (electric resistance welded) square and rectangular sections is well-established, certain applications require seamless square and rectangular hollow sections due to their superior properties. These products' limited demand capacities make the market closely linked to downstream value chains, where their availability is crucial, as ERW tubes have neither been...
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Dieter Bettinger (Primetals Technologies)08/10/2025, 09:00Ironmaking - Blast furnace ironmakingOral Presentation
Efficient blast furnace operation is essential for competitive iron and steel production, impacting productivity, hot metal quality, and cost-effectiveness. This paper explores how a combination of integrated automation systems enabled the successful start-up and stable operation of a blast furnace following a relining that included the installation of a bell-less top charging system:
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A... -
Mr Samuel Pucher (K1Met GmbH)08/10/2025, 09:20
In the present study we implemented a simplified but fast simulation tool to keep track of the liquid fill levels of pig iron and slag inside a blast furnace (BF). It is able to calculate the estimated tapping rates based on only a few mandatory input parameters like the production rate obtained from the currently active charging recipe and the tuyere and topgas pressure levels. The...
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Cameron Quick (K1-MET GmbH)08/10/2025, 09:20
Hydrogen plasma smelting reduction (HPSR) is an emerging low-CO2 technology which can accomplish steel production from iron ore in just a single step. This is done using a high-power DC-transferred plasma arc generated between a hollow graphite electrode, which conveys the hydrogen gas into the reactor, and an iron-containing molten oxide bath. This plasma arc serves as both the primary...
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Adam Ståhlkrantz (Swerim AB)08/10/2025, 09:20
The bainite microstructure, transformation kinetics and tempering resistance have been studied as a function of carbon content from 0.61 to 0.99 wt. % in low alloy steels. The carbon content strongly affects the bainitic transformation kinetics and hardness which are both increased by increasing carbon content. The tempering resistance also varies depending on carbon content and a higher...
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Mr Joel Orre (Swerim AB)08/10/2025, 09:20
The Electric Arc Furnace (EAF) is central for steel industry transformation toward Green Steel production, with ever increasing steel production via the EAF route. However, there are still significant direct fossil CO2 emissions connected to the common EAF operation. Two techniques aimed at reducing direct fossil CO2 emissions from the EAFs are replacing Natural Gas (NG) with H2 as fuel and...
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Andrea Barberis (Danieli & Officine Meccaniche S.p.A.)08/10/2025, 09:20
The latest trends in the premium automotive steel bar market focus on meeting the highest quality standards demanded by end users. Achieving these targets relies heavily on advanced heat treating technologies, which are crucial for attaining the desired metallurgical and mechanical properties. These new technologies must also contribute to reducing fuel consumption and emissions.
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The new... -
Mr Michele Chiappa (Danieli & C. Officine Meccaniche S.p.A.)08/10/2025, 09:20Environmental and energy aspects in iron and steelmakingOral Presentation
The global push to counteract climate change has led policy makers to introduce stringent measures aimed at mitigating greenhouse gas (GHG) emissions. These efforts, combined with volatile energy media prices (electricity, natural gas, etc.), have intensified the search for innovative solutions to optimize energy consumption and recover residual energy from industrial processes. Key objectives...
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Anna Ivanova (Continuous Casting Centre, Colorado School of Mines)08/10/2025, 09:20Steelmaking - Continuous casting, near-net shape casting and ingot castingOral
Accurate prediction of the temperature distribution in continuously cast steel slabs is critical for maintaining product quality and mitigating defects such as cracks and segregation. Mathematical modeling serves as a fundamental tool for investigation of the dynamics of temperature and solidification front evolution during the process.
A two-dimensional computational model is presented for...
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Paul Cockram (Primetals Technologies Austria GmbH)08/10/2025, 09:40
The eDrive Mini-Finishing Mill by Primetals Technologies offers significant advantages for bar-in-coil and wire rod mills, including reduced CAPEX and OPEX, lower power and water consumption, and enhanced operational flexibility with quick product size changes. Its low-voltage system, virtual gear box, and reduced maintenance needs improve efficiency. Compared to other technologies on the...
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Zhiping CHEN (Central Research Institute,Baosteel Iron & Steel CO.,LTD)08/10/2025, 09:40Steelmaking - Continuous casting, near-net shape casting and ingot castingOral Presentation
During the cooling process on the cooling bed of alloy cold heading steel billet, the quality defect of billet bending exceeding the standard often occurs. In the present work, the reason for its bending is analyzed from the perspective of heat dissipation and phase transition during the cooling process of billet. It is shown that the main reason for the bending of alloy cold heading steel is...
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Sa Ge (Hatch Ltd.)08/10/2025, 09:40Ironmaking - Blast furnace ironmakingOral Presentation
This paper presents the Hatch burden distribution model and use cases where the model has been able show blast furnace operators how changes in the burden distribution pattern can help their blast furnace operation. Two cases will be presented, the first to show how the model helps to visualize the impact of the bell less top chute wear on the burden distribution profile. The second to show...
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Lilly Schulte08/10/2025, 09:40
In the context of the decarbonization of the steel industry, the electric arc furnace (EAF) has emerged as a primary focus of research. Historically, the EAF has been predominantly utilized in recycling-based steelmaking, specifically for the melting of scrap materials to produce crude steel. The recent surge in research interest in the EAF is driven by the objective of optimizing resource...
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Marco Belfi (Politecnico di Milano)08/10/2025, 09:40
The quenching and partitioning (QP) process aims to achieve superior mechanical properties and enhanced toughness by developing a microstructure consisting of martensite and retained austenite. In this study, single-step (SS) QP treatments were applied to the commercial 30CrNiMo8 steel, a material widely used in industrial high-strength applications but not specifically engineered for this...
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Mr Umberto Zanusso (SMS group)08/10/2025, 09:40
R&D in SMS Group focused on the study and testing of an innovative lateral burner for reheating furnaces, able to work in flame and flameless mode, with hydrogen content in the natural gas-H2 fuel blend up to 100%vol. H2, and oxygen (O2) content in the comburent flow up to 50%vol. O2. An intensive CFD simulation campaign was conducted, with the aim of defining an optimized burner design, able...
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Mr David Michel08/10/2025, 09:40Environmental and energy aspects in iron and steelmakingOral Presentation
VOLTERON™, an innovative technology developed by John Cockerill and ArcelorMittal to achieve carbon-neutral steel production through direct iron electrolysis. This process represents a significant breakthrough in primary steelmaking by employing low-temperature electrowinning in an aqueous-based electrolyte, moving away from conventional blast furnace and basic oxygen furnace (BOF) methods,...
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Mr Joel Orre (Swerim AB)08/10/2025, 10:00
As the transition towards green steel production is progressing, the direct use of carbon in the EAF for slag foaming and slag reduction has an increasing portion of the remaining CO2 emissions for steel production. In many cases the total carbon consumption in the EAF is increasing with the increasing percentage of DRI and HBI in the charge material mix. It is therefore important to minimize...
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Arianna Gotti (Trasnvalor SA)08/10/2025, 10:00Steelmaking - Continuous casting, near-net shape casting and ingot castingOral Presentation
The design of billet moulds fulfills multiple, conflicting, objectives. High productivity at minimal cost remains the primary goal of steelmakers, requiring elevated casting speeds while ensuring optimal surface quality.
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The copper mould plays a critical role in the continuous casting process, with its design centered around three key parameters: mould taper, cooling system efficiency, and... -
Hauke Bartusch (VDEh-Betriebsforschungsinstitut GmbH)08/10/2025, 10:00
As part of the 2030 Climate Target Plan, the European Union has set a target of reducing green-house gas emissions by 55% and becoming carbon neutral by 2050. The use of hydrogen will be the backbone of the steel industry's transformation towards carbon neutrality. In the long term, for the vast majority of the roadmaps communicated by the various steel producers, the technical solution will...
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Bijan Shahriari (Hatch)08/10/2025, 10:00Ironmaking - Blast furnace ironmakingOral Presentation
The PyroLIBS system is a next generation technology for pyrometallurgy, capable of continuous and instant measurement of chemical compositions for molten materials. The present paper presents the early results of its first industrial implementation on a blast furnace runner, for continuous hot metal analysis.
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Thomas Steinparzer (Primetals Technologies Austria)08/10/2025, 10:00Environmental and energy aspects in iron and steelmakingOral Presentation
Gas cleaning and dedusting systems are essential for any steelmaking facility, but they often face significant fluctuations in operational requirements. Emissions can vary based on different input materials or product mixes, necessitating adjustments in the dedusting system’s operation. Manual optimization by operators is challenging due to fluctuating operating parameters, and furnace...
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Andrea Di Schino (University of Perugia)08/10/2025, 10:00
High-Strength Low-Alloy (HSLA) steels are widely used in structural applications, requiring a thorough microstructural analysis to optimize the strength and toughness of welded joints. During multi-pass welding, thermal cycling leads to the formation of a complex Heat-Affected Zone (HAZ), consisting of sub-regions with diverse microstructural constituents, including brittle phases that...
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Takeshi Sekiguchi08/10/2025, 10:20
The blast furnace (BF) is the most energy-efficient iron-making process but faces significant challenges in the carbon neutral (CN) movement. To address this, we’ve developed a groundbreaking concept of CN BF, called SimpLE (Smart iron-making process for Low Emissions).
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In Step 1, SimpLE aims for a near-zero Coke Rate (CR) through smart charging, smart reduction, and smart combustion. The... -
Mr Adam Skowronek (Silesian University of Technology)08/10/2025, 10:20
One of the most promising groups of steels for future forging applications are medium-manganese (medium-Mn) steels, which develop finely dispersed retained austenite (RA) during the quenching and partitioning (Q&P) heat treatment process.
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RA between the martensitic laths significantly improves ductility and fracture resistance by impeding the propagation of microcracks through... -
Dr Han Yu (Metallurgy department, Swerim AB)08/10/2025, 10:20Environmental and energy aspects in iron and steelmakingOral Presentation
The transition toward a low-carbon, sustainable industrial ecosystem requires innovative solutions that maximize resource efficiency and minimize environmental impact. This study presents EnVisA, a research project funded by Vinnova, Sweden, focused on optimizing the utilization of process gases from steel production through advanced AI-driven tools. Despite the high calorific value of these...
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Mirko Javurek (Johannes Kepler Universität Linz, Institut für Strömungslehre und Wärmeüübertragung)08/10/2025, 10:20Steelmaking - Continuous casting, near-net shape casting and ingot castingOral Presentation
The accurate knowledge of the cooling heat-flux in continuous casting spray cooling is essential to exactly control the cooling conditions. Recent investigations on laboratory test rigs by other research groups showed that the cooling heat-flux depends on many parameters and can not sufficiently be described by simple relations between spray water/air density and heat-flux density. In addition...
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Prof. Valentina Colla (Scuola Superiore Sant'Anna)08/10/2025, 10:20
The European steel sector is challenged by the ambitious objectives of the European Green Deal, which aims to schive climate neutrality by 2050. Therefore, novel C-lean and sustainable steelmaking processes are being investigated through large-scale pilot projects, accompanied by studies on the possibility to improve operating practices and introduce new components in conventional routes. As...
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Sara Busolini (Acciaierie Bertoli Safau)08/10/2025, 11:10Steelmaking - Continuous casting, near-net shape casting and ingot castingOral Presentation
Is well established that surface quality plays a significant role on the fatigue life of components. Therefore, the quality of the starting feedstock is mandatory for obtaining a wire rod suitable for the production of highly stressed elements, such as automotive suspension springs.
The paper describes the positive experience made by ABS (Acciaierie Bertoli Safau, Italy) during the...
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Simone Marcuzzi (MORE srl)08/10/2025, 11:10
The green steel revolution in the electric arc furnace route requires a reduction in the use of fossil coal and an increase in the use of carbon-neutral sources such as biochar, polymers, and rubber. The use of these new types of alternative materials, have highlighted several aspects that must be considered to obtain a reliable and effective use for the generation of foamy slag during the...
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Thomas Sourisseau (UGITECH)08/10/2025, 11:10
Customers are more and more demanding for fine and homogeneous grain sizes in hot-rolled bars and wire rods dedicated to technical applications such as aeronautics, medical or watch-making. To assess those requirements, UGITECH is interested in using recrystallization models to better understand and predict the effects of both process parameters (like temperature, strain and strain rate) and...
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Mr Angelo Ferranti (Contec Industry srl)08/10/2025, 11:10Environmental and energy aspects in iron and steelmakingOral Presentation
Water consumption and wastewater disposal are critical challenges in the steel and metallurgical industries. Conventional reverse osmosis (RO) systems, widely used for producing demineralized water in cooling circuits, generate a concentrated waste stream (25-50% of feed water), which requires disposal due to high levels of calcium, magnesium and other contaminants.
At Contec Industry,...
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Mr AUGUSTO PEREIRA DE SÁ (VALE SA)08/10/2025, 11:10
This study explores the main differences between Na and K on the Blast Furnace operation focusing on the effects of Na₂SiO₃. The experimental method involved simulating thermodynamic parameters comparing traditional alkalis oxides, carbonates and silicates. In addition, a technological apparatus was used to describe slag properties and gangue phases at high Na content. The results indicated...
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Damien Garot (CRM Group)08/10/2025, 11:10
The SMART acronym stand for “SteelMaking with Alternative ReductanTs”. This project aims at using local waste-based non-recyclable resources in steelmaking, and to do it in such a way that their intrinsic chemical value is fully recovered, thereby reducing the need for conventional reductants (fossil coal) and enabling a substantial reduction of CO2 emissions.
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The main technical options... -
Maximilian Reiter (Eisenwerk Sulzau-Werfen R. & E. Weinberger AG, Tenneck, Austria)08/10/2025, 11:10
Cast high-speed steel (HSS) work rolls are used in roughing and finishing stands of hot rolling mills, as they possess high hardness and wear resistance, which is responsible for their great durability in service. During the rolling process, depending on the operating conditions in the respective stand, the degradation of the work rolls is caused by a combination of thermal fatigue, rolling...
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Joyce den Hollander08/10/2025, 11:30
The sinter plant plays a key role in processing internal by-products and waste materials from various processes within the steelmaking industry. However, sinter making is energy intensive, with no 100% green alternative, leading to substantial CO2 emissions. As a results, the sinter plant is not utilized in future green scenarios. An alternative could be found in cold bonded briquetting: a...
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Dr Fabian Perret (Hüttenwerke Krupp Mannesmann GmbH)08/10/2025, 11:30
Keywords: CO2 reduction, Blast Furnace, Coke Oven Gas, Green steel, Hydrogen containing injectants, Iron oxide reduction
By developing decarbonisation plans, the European steel industry shows its commitment to the European climate change targets. The main element in these plans is a transformation step involving a transition from carbon-based blast furnaces to green hydrogen-based direct...
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Soonho Lee08/10/2025, 11:30Steelmaking - Continuous casting, near-net shape casting and ingot castingOral Presentation
In recent years, there has been increasing interest in enhancing the efficiency and product quality of the continuous casting process in the steel industry. The formation of coarse columnar grains and macrosegregation during continuous casting negatively affects the mechanical and physical properties of the final product.Therefore, developing techniques to control the microstructure and...
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Mr Matteo Diani (Cogne Acciai Speciali)08/10/2025, 11:30Environmental and energy aspects in iron and steelmakingOral Presentation
The project involved a revamping of the EAF furnace at the steelworks department, including the construction of a new primary flue gas circuit and the installation of a closed-loop system for heat recovery.
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This recovered heat is transferred to the district heating network via 1.2 km of newly installed pipelines, connecting the steel plant to its central heating facility.
As a result, the... -
Dr Daniele Carosi (Alma Mater Studiorum - Università di Bologna)08/10/2025, 11:30
The study focuses on the study of the static recrystallization and texture evolution of an electrical steel annealed at three different temperatures for sub-minute soaking time. The objective is to determine the optimal time-temperature parameters that promote the development of favourable crystallographic textures for magnetic properties while minimizing annealing time. Microstructural...
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Mr NICOLA TOMBA (PERT SRL)08/10/2025, 11:30
Nowadays grinding balls production process is mainly done by casting or by pressing, processes which involves anyway low productivity and poor quality on finished products.
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PERT has developed a new revolutionary rolling mill to produce high quality grinding balls by rolling process, starting from a round bar coming from upstream bar mill rolling.
Round bars are heated up by a traditional... -
JOO HYUN PARK (Hanyang University)08/10/2025, 11:30
It is well known that global CO2 emission from steel sector is 7-8%, which is approx. 1/3 of industrial energy use. Hence, many steel companies are trying to develop the electric arc furnace (EAF) and/or electric smelting furnace (ESF) steelmaking processes instead of blast furnace (BF) and basic oxygen furnace (BOF) integrated routes by employing high amounts of direct-reduced iron (DRI)...
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Reinoud van Laar (Danieli Corus BV)08/10/2025, 11:50
Decarbonization is a key strategic objective for the steel industry. Despite the growing interest in DRP-EAF steelmaking, BF-BOF steelmaking is anticipated to remain dominant due to its efficiency, economic benefits, and constraints associated with DRP-EAF. Therefore, it is essential to focus on reducing CO2 emissions from blast furnaces. This paper provides a detailed techno-economic...
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Kazuto Nishihiro08/10/2025, 11:50
In recent years, reducing CO2 emissions in the steel industry has been demanded from an environmental conservation perspective. As a partial substitute for coke, a reducing agent injected into the blast furnace, the injection of H2 is being considered. The reduction reaction of ore by H2 is an endothermic reaction, and there is concern about a decrease in the temperature inside the blast...
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Ms Nina Schlemmer (K1-MET GmbH)08/10/2025, 11:50
The majority of core pyrometallurgical processes rely on redox reactions, i.e. chemical reactions that involve electron transfer. Such reactions occur, for instance, when molten metals are reduced from their oxidic precursors or, in general, when elements transition between the metal and slag phases. To gain a comprehensive understanding of these processes and for exploring potential redesign...
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Mr You Beom Cho (POSCO)08/10/2025, 11:50Steelmaking - Continuous casting, near-net shape casting and ingot castingOral Presentation
The demand for high-quality steel production has increased due to changes in the plate product market, particularly in the wind power and shipbuilding sectors. This study focuses on improving the internal quality of high-grade steel plates using PosHARP technology.
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In the wind power sector, the size of wind power generator blades is being increased to enhance power generation. This has led... -
Alper Kanyilmaz (Politecnico di Milano)08/10/2025, 11:50
This study examines the laser cutting applications of five key materials in the construction industry: High Strength Steel (HSS), Stainless Steel (StS), Weathering Steel (WS, also known as COR-TEN®), Reclaimed Steel (RS), and Aluminum. The analysis considers each material's unique characteristics, market trends, and the role of laser cutting in increasing sustainability and cost-effectiveness,...
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Jens Igel (SMS Group)08/10/2025, 11:50
Machine parts, like chocks, rollers, HGC cylinders or gearbox housings, are the backbone of every rolling operation for section and flat rolling mills. They are essential for the delicate production process and ensure perfect product quality, tolerances and dimensions. However, rough operating conditions, such as elevated temperatures, corrosive media, high static/cyclic loads and abrasion,...
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Mr Alberto Feruglio (Danieli & C. Officine Meccaniche S.p.A.)08/10/2025, 11:50Environmental and energy aspects in iron and steelmakingOral Presentation
A key factor to pursue the “green steel” concept, is not only the emissions reduction and the lowering of the carbon footprint of the steel plants, but also the optimization of the energy consumption.
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This optimization passes, of course, primarily through the direct reduction of the energy consumption, but can be pursued also through the recovery of waste energy. In steel making plants, the... -
Mr Jurgen Malbrancke (CRM Group)08/10/2025, 12:10
As the time between roll changes is continuously increasing due to improved performances of roughing rolls, a newer problem is that the performance of the edger roll becomes a bottleneck inducing strip defects crises and mill (unplanned) stoppages only to change the edger rolls. Additionally, worldwide the supply of edger rolls is becoming a problem. Especially for European hot strip mills...
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Elia Gosparini08/10/2025, 12:10
In the steelmaking, integral cycles will face important investments for decarbonization, that will hardly get paid in the short term due to market outlook (dumping, weak border barriers, high energy costs…). In this context, ESCH and I.Blu are cooperating in some BFs ensuring reliable and continuous injection of BLUAIR, a high quality Secondary Raw Material recycled from polyolefins feedstock...
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Ms Simona Oliverio (Tenova SpA)08/10/2025, 12:10Environmental and energy aspects in iron and steelmakingOral Presentation
The dry slag granulation process developed by Tenova represents a significant advancement in the valorization of Ladle Furnace (LF) slag, contributing to circular economy principles and sustainable steelmaking. Unlike traditional water-based cooling methods, which present environmental and operational challenges, Tenova's dry granulation technology employs a forced air stream to achieve...
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amit ahsan (SECOPTA analytics GmbH)08/10/2025, 12:10
The growing trend in today’s steel-making industry is enhancing scalability with the goal of net zero emission. This requires increased cost and process efficiency while reducing carbon emissions. To run a sustainable process, tighter control of process parameters along with close loop monitoring of liquid bath and slag plays an invaluable role. However, in terms of slag analysis, due to a...
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Yann Graz (ArcelorMittal research)08/10/2025, 12:10
The progressive decarbonization of the steel industry is being undertaken through the transformation of Blast Furnaces (BF) and by limiting the quantity of coke.
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The reduction of coke rates may impact the permeability at the Cohesive Zone (CZ) level, a viscous and impermeable layer resulting from the softening and melting of Iron Ore. The control of this CZ, its shape, thickness, and... -
Lorenzo Zanaboni (Acciaieria Arvedi S.p.A.)08/10/2025, 12:10
Acciaieria Arvedi, with its ISP® and ESP® plants, produces flat rolled carbon steels certified carbon neutral from EAF steelmaking and thin slab continuous casting with direct rolling starting from recycled materials. The steels are produced for many different end-uses including stamping and deep-drawing for the automotive industry, building and structural applications, pipes for water, energy...
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Pierpaolo Rivetti (SMS Concast)08/10/2025, 12:10Steelmaking - Continuous casting, near-net shape casting and ingot castingOral Presentation
Saarloha Advance Materials Pvt. Ltd. (SAMPL), a Kalyani Group Company, headquartered in Pune, India, is a leading steel manufacturer renowned for its high-quality alloy and special steel products. With state-of-the-art facilities and a focus on innovation, the group serves diverse sectors, including automotive and engineering. With the installation of the new 2 strands bloom caster, supplied...
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Alexandra Graf (PROMECON process measurement control GmbH)08/10/2025, 12:30
The infrared exhaust gas measurement system for electric arc furnaces and similar ovens has been successfully established on the market for 2.5 years. Initial long-term results are now available, demonstrating the system’s reliability and effectiveness. The new function tested at the ESF steel plant in Riesa, Germany, is the ability to measure CO content of the furnace gas under the roof of...
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Dr Hana Jirkova (Research and Testing Institute Pilsen)08/10/2025, 12:30
Using hydrogen/natural gas mixtures or pure hydrogen instead of natural gas is a key approach to industrial decarbonization, reducing greenhouse gas emissions and fossil fuel consumption. Given the extensive gas network, these mixtures are expected to be transported using existing infrastructure.
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Natural gas pipelines consist of various components, including pipes, valves, and flange joints.... -
Pedro Paulo da Silva Cruz (K1-MET)08/10/2025, 12:30Steelmaking - Continuous casting, near-net shape casting and ingot castingOral
Mould powders play a critical role in the continuous casting of steel by facilitating lubrication, regulating heat transfer, absorbing deoxidation products, preventing reoxidation, and providing thermal insulation at the meniscus. Accurately predicting mould powder consumption is essential for optimizing efficiency and cost-effectiveness in steel manufacturing. However, existing models lack...
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ZHI ZHANG (BAOSHAN IRON&STEEL CO. LTD)08/10/2025, 12:30
Hot strip mills require higher-quality, incident-free rolls to enhance productivity in the production of technical strips with stringent surface quality requirements. This necessitates rolling engineers to innovate new operational designs. The spin-cast HSS grade roll, engineered in Europe, stands as one of the most advanced grades developed over decades. Despite being a mature product, there...
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MATTEO TOMBA (PERT SRL)08/10/2025, 12:30Environmental and energy aspects in iron and steelmakingOral Presentation
A Middle East Customer Contracts PERTEco (PERT environmental department) for the supply of the new Water Treatment Plant (WTP) for his Steel Complex composed of 1,500,000 tons Meltshop and two 500,000 tpy Bar and Wire Rod Rolling Mills.
The Steel Complex is located in a desert region, with a very limited water availability. In the aim of the sustainability the new WTP is design on zero...
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Anthony Deardo (University of Pittsburgh)08/10/2025, 14:00Steel materials and their applicationKeynote Presentation
Advances in Steels for Stronger Body in White and Enhanced Safety
Anthony J DeArdo
University of PittsburghABSTRACT
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Over the past quarter century, the crashworthiness of production automobiles has improved significantly. sa Much of this improvement is the result of application of ultra-high strength steels in the safety cage or Body in White. Since the majority of steel mass resides in... -
Dr Stefan Senge08/10/2025, 14:00Steelmaking - Continuous casting, near-net shape casting and ingot castingOral Presentation
Thin slab casters around the world are increasingly turning to thicker moulds to achieve three main objectives: boosting throughput for higher production, eliminating the need for a funnel to accommodate the submerged entry nozzle (SEN) and thereby reducing the risk of longitudinal face cracks (LFC), and enhancing meniscus stability to reduce sliver defects.
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In the current landscape, where... -
Mr Richard Willemsen (Danieli Corus)08/10/2025, 14:00Environmental and energy aspects in iron and steelmakingOral Presentation
In many wastewater and process-water systems water chemicals are used to control the water quality. Typically a mix of pH control chemicals, herbicides, inhibitors, coagulants and oxidizing agents are used. A newly developed chemical called FerSol, which contains Ferrate (VI), combines several functions as it acts as oxidizing agent, coagulant and, as a side effect, it eliminates certain...
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Dr Thorsten Hauck (VDEh-Betriebsforschungsinstitut GmbH)08/10/2025, 14:00
Hydrogen enriched direct reduction (DR) is a key decarbonisation technology. Natural gas driven DR is established in industry mostly outside Europe but there are no experiences with syngas of high H2 enrichment > 80%. H2-based reduction is endothermic and the influences on effective kinetics and DRI morphology are not known. Also, properties like local permeability and movement of pellets in...
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Prof. Davide Mombelli (Politecnico di Milano - Dipartimento di Meccanica)08/10/2025, 14:00
The successful implementation of switching from lime to dololime fines injection in an electric arc furnace owned by the company United Steel in Kuwait is here discussed from technical and economical points of view. This need arises from the generation of excessive dololime fines (particles less than 10 mm) and insufficient lime fines (particles between 5-15 mm) at the lime and dololime plant...
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Mr Tim-Oliver Mattern (Carl Bechem GmbH)08/10/2025, 14:00
The most demanding operations in the steel industry in regard to bearing lubrication and lifetime of bearings are continuous caster strand guide rolls bearings and Hot Strip Mill Work Roll Bearings.
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They are operating in wet and hot environments causing water spray off or water washout of lubricating greases resulting in ingress of aggressive mill water. This contaminants and water cause... -
Mr Guillaume Brosse (SMS group)08/10/2025, 14:00
In the pursuit of decarbonization, the steel industry is increasingly adopting Electric Arc Furnaces (EAFs) due to their lower carbon footprint and operational flexibility. EAFs can efficiently utilize diverse raw materials, such as scrap steel, pig iron, and Direct Reduced Iron (DRI), to adapt to fluctuating market conditions, resource availability, and product quality requirements.
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As the... -
Mr Stefano Baf (INTECO melting & casting technologies GmbH, Austria)08/10/2025, 14:20Steelmaking - Continuous casting, near-net shape casting and ingot castingOral Presentation
Achieving the highest quality standards in steel casting is essential to maintain competitiveness in an increasingly demanding market. High-end steel grades require minimal inclusions, superior internal soundness and defect-free surfaces - goals that can only be achieved through meticulous design, advanced technologies and precise optimisation of operating practices.
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This article undertakes a... -
Michael Gallwitz08/10/2025, 14:20
The considerable reduction of CO2 emissions is one of the main challenges the steel industry is facing and the transition towards sustainable production routes is imminent. Especially H2-based direct reduction, which allows for up to 98 % emission reduction, is seeing a lot of attention [1]. Besides the availability of green H2, the supply with DR-grade iron ore pellets is a major potential...
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Piero Frittella (FERALPI SIDERURGICA)08/10/2025, 14:20
In the modern steel production it is important to have an integrated view of the production processes and plants including performances optimization, maintenance conditions, and reduction of environmental impacts through reduction of residual wastes and CO2 emissions from the production.
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In particular to consider the slags coming from the production processed of EAF and LF is a relevant point... -
Jonny Bernhardt (Mercedes-Benz AG)08/10/2025, 14:20Steel materials and their applicationOral Presentation
Nowadays the use of scrap-based Electric Arc Furnace (EAF) steels is a reasonable solution to reduce CO2 emissions, as the availability of steel scrap is expected to increase in the next 10-20 years. However, CO2 reduced steel produced with an EAF contains a higher amount of tramp elements such as copper and nickel compared to material from primary steel making. As one task in the material...
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Johan Lindwall (Swerim AB)08/10/2025, 14:20
A hot rolled steel strip that seemingly comes out as flat after the final rolling pass might potentially end up with flatness issues after it has been coiled. It is not easily understood which mechanisms in the coiling process are causing flatness issues. It is known from a material perspective that a combination of high stresses and temperatures can cause stress relaxations and creep...
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Mr Marcellino Fornasier (Danieli & C. Officine Meccaniche S.p.A.)08/10/2025, 14:20Environmental and energy aspects in iron and steelmakingOral Presentation
Advanced automation is essential for ensuring precise control of cooling water flows at the right pressure and temperature, aligning with the real-time demands of industrial processes. This optimization maximizes energy savings while minimizing water consumption, forming the foundation of sustainable and efficient metal production.
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The Q-WATER system is a cutting-edge technological package... -
Ms Sara Guazzi (Department of Energy, Politecnico di Milano)08/10/2025, 14:20
The transition of the iron and steel industry to low-emission systems is mandatory for meeting the global targets of greenhouse gas emission reduction. As the sector still heavily relies on fossil fuels, the shift is particularly challenging. Hydrogen-based direct reduced iron (H2-DRI) has gained increasing attention, and it is currently considered one of the most promising option for...
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Mr Simone Cechet (Danieli & C. Officine Meccaniche S.p.A.)08/10/2025, 14:40Steelmaking - Continuous casting, near-net shape casting and ingot castingOral Presentation
Recent developments have highlighted the Danieli DCM’s capability to execute advanced caster upgrades with the aim of improving the production portfolio and/or extending the file of equipment. The focus has been on optimizing production processes and optimizing plant downtime. A key factor in achieving these goals have been the use of preassembly techniques, which improved on site activities...
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Dr SEONGTAK OH (Hyundai Steel R&D Center)08/10/2025, 14:40Steel materials and their applicationOral
Dual phase (DP) steels, consisting of a soft ferrite matrix and hard martensite phases, offer a desirable combination of high strength and good ductility. Typically, an increase in martensite phase-fraction leads to higher strength but reduced ductility. However, in this study, an opposite trend was observed, where the ductility improved despite an increase in martensite content. This study...
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Martin Hubrich (VDEh-Betriebsforschungsinstitut GmbH)08/10/2025, 14:40
A sufficient water supply forms the base for a continuous production in iron and steel industry. Due to climate change, limitations of water outtake occurred during summer periods as well as changes of the freshwater composition to higher salt contents increasing the corrosion potential. Beside this, EU water directive, national framework and EU goals as “Zero Waste” or Zero Discharge” lead to...
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Dr Johan Lindwall (Swerim AB)08/10/2025, 14:40
Walking beam furnaces are common for reheating of steel slabs to reach temperatures for hot rolling. Inside the furnace, the slabs are carried on water-cooled skids that support and move them through the furnace. The point contact between slab and skid results in undesired cold spots on the slabs, skid marks, which persist to hot rolling of plate/strip; leading to increased deformation...
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Mr Massimiliano Zampa (Danieli & C. Officine Meccaniche S.p.A.)08/10/2025, 14:40
Against the background of our industry’s decarbonization, iron production is as essential topic for the steel industry and the availability of raw materials (e.g. technological requirement for virgin iron units when producing certain steel grades and – lagging - scrap availability in emerging economies) are two main driving forces.
Traditional, carbon-intense production route can be...
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Dr Ismael Matino (Scuola Superiore Sant'Anna - TeCIP Institute - ICT-COISP)08/10/2025, 14:40
Achieving the climate neutrality by 2050 is the main goal of the European Green Deal, which fosters decarbonization of CO2-intensive industries, including steelworks. Deep transformations are ongoing to improve sustainability of steel production. Moreover, emerging markets and countries significantly affect availability and quality of raw materials. Therefore, steelmaking process changes and...
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Pritesh Garg (Luleå University of Technology)08/10/2025, 14:40
The transition to fossil-free iron production necessitates innovative approaches to direct reduction processes utilizing hydrogen as a sustainable reductant. This study investigates the impact of pre-oxidation on the hydrogen-based reduction kinetics of magnetite ores, a critical step toward optimizing the efficiency of hydrogen-driven direct reduced iron (DRI) production. Four distinct...
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Dr Kerstin Baumgartner (Primetals Technologies)08/10/2025, 15:00Steelmaking - Continuous casting, near-net shape casting and ingot castingOral Presentation
Continuous slab casting is the leading technology for steel production, but it has limitations for heavy plate production. To pass ultrasonic tests, a reduction ratio of 3 to 4 from slab to final thickness is required, which eliminates central porosity and segregation. Current thick slab casters operate at a maximum thickness of 400 mm, limiting final plate thickness to 100-130 mm.
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Primetals... -
Takuya Fujisawa08/10/2025, 15:00
In manufacturing of steel products, demand for thermo-mechanical controlled processing (TMCP) is increasing steadily to satisfy various properties. However, defect of shape occurs when the temperature distribution of steel products becomes uneven during the cooling process. As a result, productivity and product yield are decreased. Predicting thermal deformation with high accuracy is essential...
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Dr David Barbier (Fives KEODS)08/10/2025, 15:00Steel materials and their applicationOral Presentation
new production routes. Different scenarios for the substitution of gas-fired furnace with electrical powered solutions can be considered. In particular, flash annealing – so far only considered at laboratory scale – can be introduced at industrial level providing substantial benefits in terms of productivity and material properties.
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The beneficial effect of flash annealing on the material... -
Dr Gianluca Dall'Osto (Dipartimento di Meccanica - Politecnico di Milano)08/10/2025, 15:00
Steel production is a major contributor to global CO₂ emissions, primarily due to the reliance on coking coal in conventional iron ore reduction processes. This study proposes an innovative system for the direct reduction of iron ore through a smelting process utilizing biochar as a renewable reducing agent, coupled with efficient CO₂ capture to minimize the carbon footprint of...
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Kurt Herzog (Primetals Technologies Austria)08/10/2025, 15:00
In the ongoing digital transformation of the steel industry, Artificial Intelligence is more and more
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integrated into the automation of the production processes. However, the true potential of AI
technologies can only be realized if preconditions to data quality are given, and domain expertise is
effectively digitized.
This presentation explores the application of AI technologies—such as... -
Johan Riesbeck08/10/2025, 15:00
The steel industry accounts for a large share of industrial carbon dioxide emissions equivalent to 7% of global emissions and at least 10% of Swedish emissions. Europe’s and Sweden’s national climate targets clearly show the way – a transition of the industry to reach net zero greenhouse gas emissions by 2045.
Currently, steelmaking in blast furnaces relies on fossil coal for energy and to...
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Alberto Conejo (USTB)08/10/2025, 15:00
Slag foaming is a very important phenomena in the operation of the Electric Arc Furnace due to multiple benefits. It has been extensively investigated from an academic view point, however there are still many unresolved issues dealing with the real conditions that promote these phenomena. I many of the previous investigations the gas is artificially injected, rather than created at the...
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Bernd Kleimt (VDEh-Betriebsforschungsinstitut GmbH)08/10/2025, 15:20
The Electric Arc Furnace (EAF) for scrap-based steelmaking plays an important role in realizing the transition towards Green Steel production, due to lower carbon dioxide emissions and inherent circularity compared to the iron-ore-based steelmaking.
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This work presents an approach to enhance the performance and reliability of a model-based Decision Support System for EAF online monitoring and... -
Mr Alexander Drüen (SMS group)08/10/2025, 15:20Steelmaking - Continuous casting, near-net shape casting and ingot castingOral Presentation
Conseal for slabs is an innovative technology developed by SMS group, piloted at TATA Ijmuiden, aimed at optimizing the startup process of continuous casting plants in the steel industry. This technology effectively addresses common startup issues, such as the elimination of cooling scrap and the quality defects caused by it, while minimizing the risk of startup breakouts—factors that...
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Gabriele Lonzi (Cogne Acciai Speciali)08/10/2025, 15:20
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Dr Alessandro Stenico (PSI Software SE)08/10/2025, 15:20
Quality Control is an established process for all metals manufacturers. However, identifying a critical quality deviation at the finished product stage can be cost-intensive. Not only is the original order affected by delays due to late deallocation, but the reallocation of a finished product to a prime order becomes improbable, leading to a greater financial loss. Predictive-Prescriptive...
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Mr Marco Bertoli (Astarte Strategies Srl)08/10/2025, 15:20
The operation of strip/coil galvanizing furnaces is significantly influenced by the choice of heating technology, which affects thermal uniformity, energy consumption, service life, maintenance costs, and CO2 emissions. Traditionally, gas-fired radiant tubes have been widely employed. However, the transition to electric heating solutions presents potential advantages in terms of thermal...
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youngjo kang (Dong-A University)08/10/2025, 15:20
As the goal of achieving carbon neutrality by 2050 has emerged globally, great changes are being demanded in the iron and steel industry. Among these, the need for a direct reduction process of iron ore to reduce CO2 emissions is gaining attention. The reduction process using iron ore pellets and a shaft-type reactor has already reached the commercialization stage; however, little is known...
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Dr Maicol Cimolino08/10/2025, 15:20
From the world's first in-line twistless bar winding machine in 2002 to the present, the key features in terms of maximum coiling speed, maximum coil size, and mechanical and metallurgical properties of the Danieli K-Spooler have improved tremendously.
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Achievements have been made that were unexpected at the time. Maximum coiling speed of 40 m/s for 8 and 10 mm rebar, final coil size up to 8... -
Mr Mauro Baldassi (Danieli & C. Officine Meccaniche S.p.A.)08/10/2025, 15:40
VID, acronym of Virtual Inertia Drive, is the new hydraulic drive that Danieli proposes in forging open die applications.
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His aim is to keep the same size and performances of a conventional forging machine, but reducing the total electrical power installed, the n° of motor-pumps unit and the energy consumption.
System is made by the following components :
1. Hydraulic... -
Miguel Gutierrez (Universidad Politécnica de Madrid)08/10/2025, 15:40
In this paper a distributed auction system intended to provide efficient real-time reactive scheduling for flat steel industry is introduced. We focus on the context of parallel finishing lines where several equipment units can be used to process the materials. When a severe disruption takes place, it is necessary to provide a feasible reschedule in a timely manner.
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Regarding the scheduling... -
Roberto Marcuzzi (SMS Concast AG)08/10/2025, 15:40Steelmaking - Continuous casting, near-net shape casting and ingot castingOral Presentation
In June 2024 the new high speed billet caster at Tosyalı Demir Çelik, Sariseki, Turkey was successfully put into operation.
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Supplied by SMS Concast, this new continuous casting machine represents a significant advancement in casting technology, offering exceptional speed capabilities while maintaining product quality and versatility. This state-of-the-art system can achieve casting speeds of... -
Eduardo Borges Matos (University of Oulu)08/10/2025, 15:40
Hydrogen ironmaking is becoming increasingly important in the field of scientific and industrial research. In particular, direct reduction proves to be an extraordinarily effective system for reducing harmful emissions in the steel sector. Naturally, the efficiency of the entire process is strongly linked to the type of agglomeration of the ferrous minerals. This work is dedicated to the...
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Adrian Plieth08/10/2025, 15:40
The optimization of the tapping process in an Electric Arc Furnace is essential for increasing process efficiency and extending the lifespan of refractory materials. Traditional laser scanning methods for assessing furnace geometry are often costly in terms of acquisition. This study explores an innovative approach to scanning an EAF using photogrammetry-based 3D reconstruction, eliminating...
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Rebecca Rosén (KTH)08/10/2025, 15:40
The transition to sustainable steel production is a critical challenge in reducing the environmental impact of high-temperature metallurgical processes. While basic oxygen route steelworks are nowadays focused on the development of new production processes for decarbonization of the iron reduction, the Electric Arc Furnace (EAF) route producers have the potential to eliminate almost all their...
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Dr Timo Paananen (Coolbrook)08/10/2025, 16:30
This paper presents Rotodynamic heating technology, which enables the decarbonization and electrification of the steel industry for high-temperature process heating, in line with its transition towards a fossil-free future. The steel industry is undergoing significant changes in its pursuit of carbon neutrality, demanding innovative solutions.
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The paper compares various decarbonization... -
Dr Luca Gaia (ICONSULTING SPA)08/10/2025, 16:30
To improve operational efficiency and minimize downtime, it is crucial to understand the causes leading to process defaults in the steelmaking industry. This study presents a generalized framework applicable across a wide range of metal-forming processes, which is based on an AI-powered solution designed to predict and classify breakages caused by process anomalies. The proposed solution...
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Dr Michel Haag (SMS group)08/10/2025, 16:30
The injection of alternative reducing agents into blast furnaces is recognized for its potential to enhance both the carbon footprint and operational costs. Specifically, the use of hydrogen-bearing gases can shift the reduction of iron oxide from carbon to hydrogen, resulting in significant environmental benefits. Recent projects and experiences from the authors' company highlight a changing...
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Dr Ettore Anelli (Franchini Acciai SpA)08/10/2025, 16:30
Typical heat treatment of structural steel forgings consists of quenching and tempering (QT). However, in case of heavy forgings (thickness above 120 mm), made of steels with carbon content less than 0.25% and low hardenability, the required strength can be achieved, but low temperature impact toughness could be not fully adequate. In this work, an intermediate intercritical quenching (IIQ)...
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David Liersch (SMS Group)08/10/2025, 16:30
The metals industry is confronted with significant optimization potentials stemming from a fragmented software architecture that has grown incrementally, often resulting in isolated or duplicated functionalities. This situation impedes effective data management and seamless integration between Level 2 and Level 3 applications. To tackle these issues, a platform convergence strategy is...
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Michele De Santis (Rina Consulting - Centro Sviluppo Materiali SpA)08/10/2025, 16:30Steelmaking - Continuous casting, near-net shape casting and ingot castingOral Presentation
Recent advancements in modelling, involving approach and computing power, are transforming the industrial, and particularly the metallurgy sector, providing more precise tools for quality control and process optimization
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In the context of continuous casting of steel, modelling techniques provide for an accurate optimization of the process parameters, such as casting speed, layout geometry... -
Mikael Malmström (Swerim AB)08/10/2025, 16:30
This study introduces an innovative method for estimating accumulated strain and recrystallized fraction in steel using the existing online laser ultrasonic (LUS) grain size gauge [1]. This method extends the capability of the grain size gauge by extracting more information from the same measurement. The method leverages the detection of shear wave splits, observed as small shear-wave echoes...
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Philippe Brunier (Cogne Acciai Speciali)08/10/2025, 16:50Steelmaking - Continuous casting, near-net shape casting and ingot castingOral Presentation
Continuous casting machine (CCO) is fundamental to produce steel at reasonable costs. The tundish represents the main source of steel for this kind of facility, acting as a buffer between the ladle and the nozzles feeding casting profiles. This component significantly influences the quality and yield of continuous casting operations. Our study focuses on leveraging Computational Fluid Dynamics...
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Dr Koos Van Putten (SMS group)08/10/2025, 16:50
Radial axial (RAW) ring rolling is a well-established incremental forging process producing seamless rings and shells, both with rectangular as well as profiled cross sections, with high demands in terms of mechanical properties and microstructure, standing out for its productivity. Rolled rings and shells are applied in many industrial fields, e.g. wind power, nuclear industry, general...
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Niccolo Massarelli (RINA Consulting - CSM)08/10/2025, 16:50
To reduce CO2 emission H2 could be used as a fuel for energy intensive thermal processes such as hot rolled strip annealing. This article presents approach and results of laboratory trials at developing an alternative CO2-free fuel application for the annealing of Non Grain-Oriented (NGO) electrical steels in the annealing and pickling line (APL), where the annealing of the material is carried...
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Piero Frittella (Feralpi Siderurgica)08/10/2025, 16:50
The technologies related to EAF steelmaking have continuous developments aiming the improvement of the process performances and of the environmental impact mainly through the reduction of energy consumption, the increase of productivity, the increase of metallic yield and promoting the reduction of CO2 emissions.
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This necessary development is also confirmed by the further aimed application of... -
Sa Ge (Hatch Ltd.)08/10/2025, 16:50
Gas-based direct reduction (DR) is a key process in low-emission steelmaking due to its flexibility to utilize a variety of reducing agents with lower GHG emissions compared to blast furnace (BF) ironmaking. While direct reduced iron (DRI) and hot-briquetted iron (HBI) produced from low-gangue iron ore are commonly used in electric arc furnaces (EAFs), efficient processing of DRI made from...
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Miguel Gutierrez (Universidad Politécnica de Madrid)08/10/2025, 16:50
Quality control in zinc-coated steel coils is critical in industries such as automotive and construction, where defects in zinc coating can significantly impact product durability and safety. Traditional manual inspection methods are prone to errors and inconsistencies, especially in high volume production environments.
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This paper compares the performance of two artificial intelligence... -
SOSHI YOSHIMOTO (JFE Steel Corporation)08/10/2025, 16:50
In the steel industry, the rapid cooling process, which is suitable for manufacturing high-strength materials, is being increasingly applied. However, the deformation caused by rapid cooling is particularly large, which leads to reduced productivity and yield, so suppressing this deformation is an important issue. In order to suppress deformation, it is first necessary to quantitatively...
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Prof. Valentina Colla (Scuola Superiore Sant'Anna)08/10/2025, 17:10
The Electric Arc Furnace (EAF) plant in the steel industry presents significant health and safety risks for workers due to extreme temperatures, toxic fumes, and potential operational hazards. To enhance workplace safety, this study proposes an advanced automated system that leverages cutting-edge IT and AI technologies to improve process monitoring and risk prevention.
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A key objective of... -
Beatrice Crocco (ArcelorMittal Maizières Research)08/10/2025, 17:10
In the race towards Net Zero, ArcelorMittal is committed to reduce their CO2e emissions by 30% in Europe and 25% worldwide by 2030. To achieve these ambitious goals, the group is looking at using (and potentially self-producing) bio-chars to substitute fossil fuels (coal and coke) in the different iron and steel-making processes. Here, the production of bio-chars for the substitution of coke...
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Dr Marc Banaszak (mecorad GmbH)08/10/2025, 17:10Steelmaking - Continuous casting, near-net shape casting and ingot castingOral Presentation
The degree of digitalization in steel producing companies is increasing significantly, which consequently amplifies the importance of identifying significant process parameters and investigating the effect of parameter changes.
Digital simulation technology today makes it easily possible to carry out three-dimensional process simulation of the entire continuous casting process....
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Bas Admiraal (Danieli Corus)08/10/2025, 17:10
Dry blast furnace gas cleaning technology offers great economic advantages when compared to traditional wet gas cleaning owing to its improved energy efficiency, lower cost, reduced plot space, and practically eliminated water consumption. The Danieli Corus solution is based upon proven technology that has been applied numerous times for cleaning aluminum smelter gases and anode baking fumes....
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Mr Marco Munari (Project Group s.r.l.)08/10/2025, 17:10
Hot Radial Axial Ring Rolling is a crucial process in seamless ring production for various industrial sectors, ranging from oil & gas to aerospace. To configure and optimize this complex process, modern rolling mills rely on computerized controls, where operators must input process parameters derived from multiple sources-including tables, formulas, experience, and time-consuming FEM...
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Emmanuel Placier (AMI)08/10/2025, 17:10
SmartKnB is an innovative programming platform engineered for advanced control of the Electric Arc Furnace (EAF) steelmaking process. By integrating diverse data sources—from sensor arrays and PLCs to historical logs and real-time imagery—SmartKnB enables the development, testing, and validation of sophisticated control algorithms in a modular, node-based graphic environment. As the core of...
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483. Vision Technology-Based Surface Quality Optimization for Continuous Hot-Dip Galvanizing ProcessTAE JUN PARK (Hyundai-steel)08/10/2025, 17:10
During the continuous hot-dip galvanizing process, numerous parameters directly correlate with the surface quality of steel plates. Among these factors, the emission management of floating oxides on the zinc bath surface within the snout represents a critical operational parameter for maintaining continuous production efficiency. To address this challenge, various steel manufacturing companies...
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Dr Davide Maghini (Department of Engineering, University of Ferrara)08/10/2025, 17:30
Nowadays, titanium (Ti) alloys play a pivotal role in aerospace and energy production sectors due to their specific mechanical properties. To date, the design of forged components in Ti alloys has been based on the experience of operators and engineers, and on the use of industrial tests to optimise production processes. However, the high production costs of these components and their possible...
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Saku Kaukonen (Sapotech Oy)08/10/2025, 17:30Steelmaking - Continuous casting, near-net shape casting and ingot castingOral Presentation
The quality of continuously cast steel semi-products (e.g., slabs, billets, and blooms) is fundamental to the efficient production of high-performance steel products for demanding markets. To achieve high casting speeds while maintaining quality, numerous control and monitoring technologies have been successfully developed, even for challenging steel grades.
Recent advancements in...
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Dr Anthony Nicholas Grundy (Thermo-Calc Software AB)08/10/2025, 17:30
The evolution of steel and slag chemistry in function of secondary metallurgy process parameters can be simulated with good accuracy using Thermo-Calc’s TCOX CALPHAD database and the effective equilibrium reaction zone (EERZ) model that accounts for reaction kinetics.
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An interesting aspect of such simulations is tracking the formation and modification of endogenous non-metallic inclusions... -
Jungil Kim (POSCO)08/10/2025, 17:30
The Gwangyang Blast Furnace No. 3 experienced an early relining approximately 12 years after its initial blow-in due to premature wear of copper staves leading to shell damage and damage to the hearth cooling system caused by hot metal leakage at the No.1 taphole. To expand the internal volume from 4600 m³ to 5500 m³, a complete dismantling of the furnace body was undertaken. During this...
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Dr Dietmar Hoppe (SMS group)08/10/2025, 17:30
In a collaborative initiative, an innovative Laser UltraSonic (LUS) device was installed at the SSAB Hot Strip Mill in Borlänge. This measuring device, along with the software for signal processing and evaluation, was developed, constructed, and implemented through a partnership involving SSAB, SWERIM, EMG, and the SMS group. Positioned after the last rolling stand in the finishing mill, the...
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Dieter Bettinger (Primetals Technologies)08/10/2025, 17:30
Achieving autonomous operation requires automation and digitalization systems with advanced control and learning capabilities. This paper discusses key elements on the pathway to autonomous blast furnace and DR operation:
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Autonomous decision-making for ironmaking operations leverages sophisticated technologies, including AI and ML, to measure, control, and optimize key parameters of... -
ION RUSU (POLYTEC SPA)08/10/2025, 17:50
This paper presents an advanced robotic system designed to automate key quality control and marking processes for plates exiting the rolling mill. The solution integrates shaping automation (contour and flatness control), defect detection, thickness measurement, ink marking, and stamp marking, ensuring high precision and efficiency.
An advanced vision system enables real-time conformity...
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Saeid Amirzadeh08/10/2025, 17:50Steelmaking - Continuous casting, near-net shape casting and ingot castingOral Presentation
Some defects in continuous cast (CC) steel are the result of flow conditions at the top section of the CC mould. To monitor and potentially control the flow, in order to reduce such defects, information about the flow conditions is needed. In addition to sensors that may be installed on the mould, CFD can provide detailed insight into the mould flow. We are developing an OpenFOAM-based...
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Mr Rudy Tolkamp08/10/2025, 17:50
This paper will discuss a systematic approach for the design and construction of a new hearth, employing an “inside-out” approach. A comprehensive diagnostic is first performed by reviewing thermocouple and operational data from the current campaign to determine expected process loads in the new campaign. Three-dimensional thermal models of the new hearth design are analyzed using boundary...
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Benjamin Böcker (HiScience GmbH)08/10/2025, 17:50
The transition to sustainable steel production necessitates innovative strategies for managing electricity demand in energy-intensive batch processes. Unlike large-scale continuous operations, small and medium-sized enterprises (SMEs) in steel manufacturing—such as specialized foundries and long product rolling mills—face unique challenges due to smaller batch sizes, greater product...
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Yves Van Ingelgem (Zensor)08/10/2025, 17:50
In today’s world, Digital Twins are drawing increased attention. Ideally, they are a digital representation of the installation that is used to optimize production and keep the machine in top shape. The steel industry starts adopting this concept, as productivity and availability are key to run a profitable operation.
A digital twin is based on a combination of a digital representation...
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Afshin Sadri (Hatch Global Director of Asset Performance Management (APM) Group)08/10/2025, 18:10
Stave wear in blast furnaces is a critical issue affecting operational efficiency and campaign longevity. Several factors influence wear severity, including furnace design, operational practices, raw material properties, and cooling performance. However, stave wear patterns are often unpredictable and irregular, making accurate monitoring essential for maintaining the integrity of the cooling...
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Mikael Malmström (Swerim AB)08/10/2025, 18:10
The real-time grain size measurement has recently been realized by laser ultrasonics in the hot-rolling process [1]. This enables quality control, the possibility of direct feedback to the process control system, as well as feedback to the set-up calculation which is performed before each transfer bar is sent through the finishing mill to be rolled. The gauge provides novel insights into how...
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Martin Sprunk (SECOPTA analytics GmbH)08/10/2025, 18:10Steelmaking - Continuous casting, near-net shape casting and ingot castingOral
To cast liquid steel into solid semifinished products, current steel industry predominantly relies on continuous casting process. Although 90% of the liquid steel can be cast into quality products, producers are still facing challenges to effectively determine transition zone in the casting strand. This normally happens at the beginning and end of a casting sequence as well as while...
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Mr Thorsten Claff (SMS group)08/10/2025, 18:10
This presentation explores how a quality execution system effectively addresses the key challenges of the "twin transition" – the shift toward both ecological and digital sustainability – making these transformations more manageable.
As steel manufacturers transition to more energy-efficient production processes and replace existing plants, maintaining consistent quality control becomes...
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SangYoung Lee09/10/2025, 08:30
The mechanical properties are the most basic quality of the hot strip products. Normally, the mechanical properties are gained with the design of chemical composition and the control of the process factors such as finish rolling delivery temperature (FDT), strip speed, cooling rate, coiling temperature (CT), and so on. These factors are not dynamically adjusted in the conventional system, and...
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Mr Cosmo Di Cecca (FERALPI SIDERURGICA)09/10/2025, 08:30
The quality of the products in bar and wire rods production is strongly affected by the quality results in Continuous Casting both for conventional and special steels.
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In different ways Feralpi Groups is working to improve the billets quality in terms of surface, internal and shape defects also with activities included in the R&D projects coupling new equipments, new sensors, studies and data... -
Stefano Baf09/10/2025, 08:30Steelmaking - Continuous casting, near-net shape casting and ingot castingOral Presentation
Mould level stability is crucial for achieving excellent surface quality and product cleanliness in continuous casting. This article explores the evolution of the Mould Level Master, a technological package for mould level control based on an electromechanical actuator, from its initial testing to its implementation across a wide range of casting machines—including billet, bloom, and...
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Dr Otmar Jannasch (Smart Steel Technologies GmbH)09/10/2025, 08:30
ArcelorMittal Eisenhüttenstadt und Smart Steel Technologies bundled forces to establish an optimized temperature guidance in the ArcelorMittal Eisenhüttenstadt meltshop. The underlying core of the supporting models, namely the Ladle Furnace, LF Temperature or Secondary Metallurgy Exit Temperature Model is a digital twin of the whole meltshop. It incorporates all heats and different steel...
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Mr Jyri Tolonen09/10/2025, 08:30CO2 mitigation in iron and steelmakingOral Presentation
This paper presents the development and commercialization of a novel dust extraction technology. Driven by stringent EU emission regulations, the need for more efficient dust removal solutions has become paramount in industries like mining and metallurgy. By combining fundamental fluid dynamics research with industrial practice, SSAB researchers and Oulu University developed a modular dust...
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Cristiano Castagnola (SMS group)09/10/2025, 08:30
This paper presents a pioneering approach by SMS group, focusing on the integration of advanced thermal dry reforming technology into existing blast furnace infrastructures. The scope of this study is to explore the potential of Paul Wurth's thermal dry reforming process in reducing CO2 emissions while leveraging current coke oven plants. This innovative technology introduces a novel method to...
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Dr Martin Schlautmann (PSI Software SE)09/10/2025, 08:30Digital transformationOral Presentation
Reliable carbon footprint calculations and certificates for the various steel products are increasingly demanded by the market. Many approaches are based on yearly production tonnage and average CO2 equivalents. A production management system allows to track the material and energy consumptions for each piece of produced material. Thus, it is able to transparently calculate the related...
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Andreas Wolff (VDEh-Betriebsforschungsinstiut)09/10/2025, 08:50
In the steel industry, most companies operate in a competitive national and international market, with prices determined by competition. To enhance profits, firms must focus on reducing production and commercial costs. Those unable to adapt their strategies may lose their competitive edge. Effective scheduling of resources is crucial to achieving goals such as increasing production and...
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Oliver Lang (Primetals Technologies Austria)09/10/2025, 08:50Steelmaking - Continuous casting, near-net shape casting and ingot castingOral Presentation
Outokumpu, a global leader in sustainable stainless steel production, has implemented advanced instrumentation in its Tornio casters to gain deeper insights into the continuous casting process and enhance product quality. The casters are equipped with molds containing optical fibers, achieving 1786 Fiber Bragg Grating (FBG) based temperature measurement points, quality prediction software, and...
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Mr Eric Almquist (StarTool)09/10/2025, 08:50
The TST.1 is a practical, simple, non-contact series of systems for continuous, online monitoring of surface contamination loads on moving metal sheet. Designed for real-time process control, the system assesses surface cleanliness before and after cleaning sections in metallic coating and continuous annealing sheet finishing lines, enabling producers to optimize incoming cold-rolled steel...
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GeunWoo Byun (Hanyang University)09/10/2025, 08:50
The growing automobile market is expected to drive demand for high-strength exterior panels and electrical steel sheets for motors. These products require precise impurity control to maintain formability and magnetic properties. Nitrogen is a particularly crucial element in determining the mechanical properties of steel. Although higher nitrogen content improves tensile and yield strengths, it...
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108. Impact of iron source and binder type on the mechanical strength and microtexture of ferro-cokeGuanghua Lu09/10/2025, 08:50
The addition of highly reactive ferro-coke can lower the temperature of the thermal reserve zone (TRZ), which improves shaft efficiency in a blast furnace. A better understanding of the link between microstructure, microtexture and strength in ferro-coke is needed to optimise the blend composition and maximise strength.
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This study investigates the microstructure and microtexture of... -
Matteo Gili (RINA-CSM)09/10/2025, 08:50CO2 mitigation in iron and steelmakingOral Presentation
The steel industry is a cornerstone of the European economy, contributing 6.7% of global crude steel production (126.3 Mt in 2023). However, it is also a major source of greenhouse gas emissions, accounting for 4% of total EU emissions and 23% of those from manufacturing industries. Achieving carbon neutrality in this high-energy-intensity sector requires innovative solutions to reduce...
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Dr Ismael Matino (Scuola Superiore Sant'Anna - TeCIP Institute - ICT-COISP)09/10/2025, 08:50Digital transformationOral Presentation
The European Green Deal challenges the steel sector to implement breakthrough modifications to significantly decrease its carbon footprint, and European steel producers are planning consistent investments in this direction. Integrated steelworks are particularly affected since, besides production process changes, important modifications are envisaged also for gas and energy management....
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Mr Vittorio Scipolo (Tenova Goodfellow Inc.)09/10/2025, 09:10
For more than two decades, off-gas analysis technology has been used worldwide, initially as an engineering tool for the design and tuning of fume systems and later as a key tool for EAF chemical energy optimization. In later years, the off-gas analysis has been used for full EAF dynamic control that addresses scrap variability that does not allow for simple EAF profiling operations. Today,...
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Maxime Monnoyer (Fives KEODS)09/10/2025, 09:10
Fives’ Eyeron® is a digital solution aiming at managing the quality of steel products in real time. This solution can be deployed either on a single asset or in a fully integrated plant. Thanks to its effective data injection and powerful rules engine system, it can automatically provide precise quality grading and reports, and issue recommendations for order reallocation or repair of any type...
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180. Control of Low Bulk Density Region around Briquette in Briquette Blending Carbonization ProcessMr Isao Takahashi (Process Research Laboratories, Nippon Steel Corporation)09/10/2025, 09:10
One of the coal pre-treatment process used to produce high-strength coke while incorporating a large amount of low-quality coal is the briquette blending carbonization process. Briquette blending carbonization process improves coke strength by mixing high-density briquette with powder coal. On the other hand, it is known that blending briquettes with powder coal forms low bulk density regions...
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Jens Brandenburger (VDEH-Betriebsforschungsinstitut)09/10/2025, 09:10Digital transformationOral Presentation
Major focus for order-based scheduling is the determination of valid production sequences considering any plant constraint on the one hand while minimizing the amount of required setup coils on the other hand. A mid-term solver for one production step should automatically select orders from a given set of available orders (order backlog), assign them to a certain plant and define valid...
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Mario Gelmini (POLYTEC SPA)09/10/2025, 09:10Steelmaking - Continuous casting, near-net shape casting and ingot castingOral Presentation
The continuous casting phase in steel production still requires several manual operations near molten steel, posing significant safety risks. This paper explores how the integration of advanced robotic technologies can fully automate casting operations, significantly improving safety, process efficiency, and overall production performance.
The study highlights the differences between...
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Hampus Wikmark Kreuger (Swerim AB)09/10/2025, 09:10
Metal microstructure can be determined in situ using laser ultrasound (LUS) measurements. As a non-contact, nondestructive measurement, this can be integrated at many positions in the steelmaking process, including measurement of hot and moving samples. Swerim has previously demonstrated the application of this technology as an on-line grain size gauge installed at the SSAB Borlänge hot strip...
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Konstantinos Rigas09/10/2025, 09:10CO2 mitigation in iron and steelmakingOral Presentation
The increasing need for steel has rised the consumption of metcoke where in Europe 45 million tons of metcoke are used annually in steelmaking processes. In the attempt for green transition, this growing need is accelerating the search for sustainable alternatives to fossil carbon products.
Pyrolysis of wood pellets from pine and spruce at temperatures above 500°C has proven effective in...
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Mr Gabriel Korkmaz (SMS group)09/10/2025, 09:30
In today's rapidly evolving industrial landscape, coke oven plant operators are increasingly confronted with the pressing challenge of managing aging equipment. As many coke oven batteries, machines, and associated equipment near the end of their operational lifespan, operators face the risk of unscheduled production interruptions, increased emissions, and elevated health and safety concerns...
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Mr Chayan Mitra (RHI Magnesita-Sensors)09/10/2025, 09:30Steelmaking - Continuous casting, near-net shape casting and ingot castingOral Presentation
Ladle slag carryover into the tundish has been a significant challenge in steelmaking, adversely affecting the tundish refractory material reducing its lifespan. Additionally, slag carryover compromises steel quality due to slag entrainment, which is a primary source of undesired inclusions in the final products. To achieve high-quality steel and maximize yield, it is essential to minimize...
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Dr Marco Thomä (Matplus GmbH)09/10/2025, 09:30CO2 mitigation in iron and steelmakingOral Presentation
Improving the circularity of steel products requires reliable tools for ECO design that integrate key environmental properties, such as CO₂ footprint and embodied energy. These data are typically de-rived from environmental reporting and Life Cycle Assessment (LCA) analyses. However, ensuring physically consistent and traceable information - grounded in fundamental principles such as mass and...
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Bernhard Voraberger (Primetals Technologies)09/10/2025, 09:30
Cost competitiveness, high productivity and safety are crucial for the survival of the stainless steel industry in Europe. The AOD converter, as an efficient refining aggregate, is a fixed process step in every high-performance stainless steel production. Primetals Technologies is continuously optimizing and improving the AOD process, the AOD equipment and its automation.
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One key innovation... -
Mr Marian Rogge (IMS Messsysteme GmbH)09/10/2025, 09:30
The magnetic flatness measurement system enables precise flatness assessment of strip steel, even under high tension, where traditional optical methods fail due to elastic elongation. Unlike conventional flatness measuring rollers, which are costly and offer limited resolution, this system applies a uniform electromagnetic force perpendicular to the strip, inducing a controlled deflection that...
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Dr Christian Dengler (SMS group)09/10/2025, 09:30Digital transformationOral Presentation
The physical properties of raw material play an important role in the iron and steel making processes. Especially the grain size is important, e.g., for permeability control in the blast furnace or the densification of the sintering process.
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However, current grain size measurement methods are often irregular, labor-intensive, and rely heavily on manual effort, limiting the ability to achieve... -
Christine Gruber (K1-MET)09/10/2025, 09:30
Images are a very powerful tool in monitoring complex processes in industrial settings and indicating relevant events with impact on process quality and stability. The intuitive interpretability of an image is often superior to the extraction of numerical key performance indicators based on multiple data streams from a variety of sensors, but not every relevant process aspect can be directly...
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ION RUSU (POLYTEC SPA)09/10/2025, 09:50
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 the long products quality control, with...
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Dr Alessandro Stenico (PSI Software SE)09/10/2025, 09:50
Quality specifications are crucial for the metals industry to ensure consistent quality and safety. Integrating these specifications into the manufacturing execution system (MES) is essential for maintaining expected quality levels, minimizing errors, and enhancing efficiency, thereby meeting regulatory requirements and customer expectations. However, metals producers with geographically...
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Florian Kek (RHI Magnesita)09/10/2025, 09:50CO2 mitigation in iron and steelmakingOral Presentation
Desulphurisation in the steel ladle requires a reactive slag with high CaO dissolution. Conventional slag fluxing agents applied during this secondary metallurgical refining step include calcium aluminate additives and fluorspar to maximise the dissolved CaO. However, calcium aluminate additives can have a high carbon footprint due to their energy-intensive production process and the use of...
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Mr Jangho Jo (University of Newcastle)09/10/2025, 09:50
The partial substitution of coal with waste plastics in the coking process can improve resource recycling and sustainability of cokemaking and ironmaking processes. A fundamental understanding of how plastic pyrolysis influences microstructural transformations in coke ovens remains limited, despite its significant impact on coke quality. This study addresses this knowledge gap through an...
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Mr Veikko Äikäs (SEW-EURODRIVE)09/10/2025, 09:50Digital transformationOral Presentation
Predictive maintenance is often seen as an add-on for predicting failures. This viewpoint limits the real-life results of predictive maintenance solutions. To truly maximize drive system availability, decisions must support this goal throughout the entire lifecycle, akin to the continuous use of smart devices for personal health monitoring.
Optimizing drive system availability begins at the...
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Benjamin Ruf09/10/2025, 09:50Steelmaking - Continuous casting, near-net shape casting and ingot castingOral Presentation
Accurate and reliable measurement of the remaining steel level in the tundish is very important for preventing undetected emptying, optimizing steel grade changes, and maximizing strand length. Conventional weight-based measurement often introduce inaccuracies increasing the risk of slag carryover into the mold, unnecessary downgrading, and reduced process efficiency.
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The AMEPA Residual Steel... -
Wolfgang Reiter (K1-MET GmbH)09/10/2025, 09:50
The RecoDust process is an innovative pyrometallurgical technique designed for the efficient separation of iron and zinc from steel mill dust, a byproduct of steel production. This process addresses the growing demand for sustainable resource recovery in the metallurgical industry, offering an environmentally friendly and economically viable solution for the recycling of valuable metals....
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Mario Gelmini (POLYTEC SPA)09/10/2025, 10:40Steelmaking - Continuous casting, near-net shape casting and ingot castingOral Presentation
This paper presents a robotic cell specifically designed for steel shop operations, assisting operators in the inspection, cleaning, and replacement of refractory components in the ladle sliding gate. This critical system enables the controlled opening of the ladle bottom, allowing molten steel to flow into the tundish of the continuous caster.
The developed robotic cell represents an...
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Mr Andrea Palma (Danieli & C. Officine Meccaniche S.p.A.)09/10/2025, 10:40
In recent decades, the rail transportation sector has undergone continuous progress. The increasing demands in rail transportation are particularly driven by higher train speeds and greater axle loads due to heavier cargo. To meet market demands, rail producers are improving rail strength to develop high-performance rails, particularly in terms of wear resistance. Head-hardened rails offer...
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Anton Ivanov (PSI Software SE)09/10/2025, 10:40Digital transformationOral Presentation
Steel is a cornerstone of global infrastructure but its production faces inherent complexity due to high energy consumption, strict quality demands, and sophisticated production process. While traditional planning methods rely on rigid, centralized frameworks, they struggle to adapt to disruptions like equipment failures or material defects, leading to inefficiencies and financial losses....
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Piotr Szamburzki (Danieli Corus)09/10/2025, 10:40
Information regarding temperature and deformation of the converter shell, particularly the barrel section and top cone, help predict remaining lifetime of top cone, detect damages in refractory, etc. Since the trunnion ring obscures much of the view on the converter, thermal cameras do not provide this information. Hence, sensors have to be arranged directly on the vessel shell. Unfortunately,...
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Satoki Yasuhara (JFE Steel Corporation)09/10/2025, 10:40
The digital transformation of the sintering process requires controlling the return ore ratio, which is the proportion of fine sintered ore particles smaller than 4 mm that cannot be used in the blast furnace, within a target range. When the return ore ratio is too high, the productivity of the sintering process decreases. On the contrary, when we aim for an excessively low return ore ratio,...
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Stephan von Goeldel09/10/2025, 10:40CO2 mitigation in iron and steelmakingOral Presentation
The steel industry accounts for approximately 10% of global CO₂-equivalent (CO₂e) emissions, producing around 1.7 tonnes of CO₂e per tonne of crude steel. A transformation towards green steel production by replacing fossil carbon based materials and by using alternatives energy sources such as renewable electricity and hydrogen is essential. However, this transition involves significant...
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Jens Brandenburger (VDEH-Betriebsforschungsinstitut)09/10/2025, 10:40
Resource-efficiency and competitiveness are main aims of the European Green Deal transformation. In this global restructuring process yield improvement and reduction of waste aimed by a zero-defect production are low-cost opportunities for European steel manufacturers to realize a more sustainable production.
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Enabling zero-defect manufacturing for flat steel production requires an early... -
Stefano Dettori (Scuola Superiore Sant'Anna)09/10/2025, 11:00
The Ladle Furnace (LF) process is fundamental for refining steel before Continuous Casting (CC) and strongly affects some main mechanical features of the final semi-finished steel product. Ferroalloys, deoxidizers and slag formers are added to molten steel, while keeping its temperature within given boundaries through electricity-based heating systems. Several aspects, e.g. the electricity...
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Ryosuke Masuda (JFE Steel Corporation)09/10/2025, 11:00
To realize efficient and stable operation of a blast furnace, accurate process control through automation is crucial. In this study, we developed an automatic control system for hot metal temperature (HMT). To cope with the slow and complex process dynamics of the blast furnace, we first built a two-dimensional (2D) transient model that can simulate the chemical reactions and the heat transfer...
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Patrick Mizza (SMS Group)09/10/2025, 11:00
SMS group recently celebrated 150 years as one of the world leaders in the construction of equipment for the ferrous and non-ferrous metals industries. This paper will focus on the recent technology developments dedicated to the wire rod producers such as:
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• Single-pass driven MEERdrive® finishing blocks
• Rapid production change and precise finishing through MEERdrive®PLUS high-speed... -
amit ahsan (SECOPTA analytics GmbH)09/10/2025, 11:00
A reliable material identification along the entire rolling process chain is a high priority in today’s rising demand on fault-free shipment. For special alloy producer, a mixup in delivered product could result in complete cancellation of the shipment, penalty charges as well as loss in reputation. In this regard, currently used positive material identification (PMI) technologies such as...
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Stefan Mühlböck (Primetals Technologies GmbH)09/10/2025, 11:00
The transition to carbon-free steel production presents significant challenges for the industry. Adapting to new processes, production routes, and logistics is a central aspect of this transformation. Particularly notable is the shift from traditional Blast Furnace (BF) / Basic Oxygen Furnace (BOF) route to electric steelmaking route. This change requires not only a comprehensive restructuring...
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Mr Alessandro Dell'Uomo09/10/2025, 11:00
In the primary steel production, hot metal produced in the blast furnace (BF) is fed via a ladle to the Basic Oxygen Furnace (BOF), where it is converted to liquid steel. During the metallurgical operations, slag can form and solidify on the refractory walls during tapping. These oxide deposits must be periodically removed, to ensure the regularity of BOF operations over time.
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Cleaning... -
Hubert Fouarge (CRM group)09/10/2025, 11:00
To drastically reduce CO2 emissions, European steelmakers are considering a transition from the Blast Furnace (BF) route to the direct reduction (DR) route. TRANSinter investigates solutions to support the first step in the transition step based on the valorization of existing sinter plants.
Following solutions are being investigated :
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- Adapted sinter for use in DR shafts as an... -
Dr Wenjing Wei (ABB)09/10/2025, 11:20
Sintering and pelletizing are critical upstream process that impact the performance of ironmaking and steelmaking operations through the quality of sinter and pellet feed. Conventionally, iron ore quality has been monitored through offline laboratory analyses. However, it limits the potential of process optimization, as it does not allow for timely adjustments in response to real-time process...
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Nikolaus Preisser (CDL-IMAS, Montanuniversität Leoben)09/10/2025, 11:20
The cleanness of modern steels is of utmost importance as non-metallic inclusions can have detrimental effects on the mechanical properties of the finished product, as for example fatigue strength or notched impact toughness. Especially, hard NMI have a lower formability than the surrounding matrix, which can lead to crack initiation in the material during forming. Additionally, NMIs often...
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KYUNTAE KIM (Hyundai-steel)09/10/2025, 11:20
To achieve a carbon-neutral EAF system for high-quality sheet production, rapid scrap melting is essential for efficient DRI/HBI dissolution.
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This study presents an integrated oxygen lance-burner design to enhance thermal efficiency and melting kinetics.
Experimental validation and numerical simulations were conducted to assess performance and optimize key parameters, with findings and... -
Simone Zunino (Danieli & Officine Meccaniche S.p.A.)09/10/2025, 11:20
The digital transformation of industrial steel plants is crucial for optimizing efficiency, enhancing product quality, and ensuring sustainability. By integrating digital technologies, these plants can significantly improve monitoring, control, and predictive maintenance of reheating and treatment furnaces. Traditional systems often lack detailed real-time data and rely on external...
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Mr Eric Almquist (StarTool)09/10/2025, 11:20Digital transformationOral Presentation
Machine Vision (MV) and Artificial Intelligence (AI) are rapidly evolving technologies poised to transform industries, including steel production. While these technologies are already applied in metallurgical plants—primarily to optimize process models—their potential extends far beyond conventional applications. This presentation aims to challenge traditional thinking and spark discussions...
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Mr Robrecht Jennen (CRM Group)09/10/2025, 11:20
The primary challenge in steel production today is the reduction of its carbon footprint. To address this, steel producers are increasingly relying on scraps. However, residual elements in post-consumer scrap—such as copper, tin, antimony, nickel, or molybdenum—can degrade steel properties, particularly for advanced high-strength steels. The project MetConZero investigates how these residuals...
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Simone Cicutto (Ergolines Lab s.r.l. - Trieste)09/10/2025, 11:20Steelmaking - Continuous casting, near-net shape casting and ingot castingOral Presentation
The steel industry is increasingly seeking reliable and efficient solutions for steel level control that eliminate the need for radioactive sources. In response to this demand, Ergolines has developed an innovative technology that is gaining significant traction in the market, as evidenced by the growing number of installations worldwide. This paper presents a detailed case study showcasing...
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Alberto Scarmi (SEW-EURODRIVE)09/10/2025, 11:40
Industrial gearboxes play a crucial role in steel industry plants by providing the required speed and torque for the operation of several machines, thus affecting the efficiency and reliability of various processes. Within this scope predictive maintenance is employed to identify potential issues before they lead to costly downtime or catastrophic failures.
In the field of industrial...
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Peter Warren (Binding Solutions Ltd)09/10/2025, 11:40
Binding Solutions Ltd have developed a cold agglomeration technology that considerably reduces the CO2 emissions associated with agglomeration of iron ores for the blast furnace process. Bespoke tests have proven the metallurgical performance of these cold agglomerated pellets at temperatures well above those used in ISO standards.
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Using the company’s own pilot plant in Middlesbrough, UK,... -
Mr DONGYUL JUNG (Hanyang University)09/10/2025, 11:40
High-Cr and Ti-bearing ferritic stainless steel (Ti-FSS) has superior corrosion resistance compared to other steel grades. The Ti-FSS requires not only high corrosion resistance and formability but also superior cleanliness of the cold rolled sheet. Specifically, the cleanliness of Ti-FSS has been improved through the vacuum oxygen decarburization (VOD) and the ladle treatment (LT) processes....
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Fabian Schongen09/10/2025, 11:40
thyssenkrupp Steel Europe (tkSE) strives to sustainably strengthen its position in the global market through technology and quality leadership by optimally meeting the demand of its customers for low tolerances as well as thinner and wider products. Investments are made at tkSE along the entire production network especially for non grain oriented electrical steel (NO) in order to shape the...
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Marco Abram (SMS group)09/10/2025, 11:40Steelmaking - Continuous casting, near-net shape casting and ingot castingOral Presentation
Continuous casting is a crucial process in the production of long products in the metals industry. It offers several advantages that make it a preferred method over traditional ingot casting: efficiency, productivity, material utilization and energy savings, quality improvement by consistent quality and reduced defects.
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The continuous casting process can produce a wide range of... -
Mr Andrea Pezza (Badische Stahl-Engineering)09/10/2025, 11:40
The path to reducing steel's CO₂ footprint is increasingly clear, with the industry shifting toward electric arc furnace (EAF) steelmaking. This transition relies on recycled scrap and partially substitutes virgin materials with direct reduced iron (DRI) or hot briquetted iron (HBI). However, the changing quality of input materials, particularly the reduced purity of raw materials and...
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Stefan Radner (Primetals Technologies Austria)09/10/2025, 11:40Digital transformationOral Presentation
The steel industry is undergoing a twin transition, where digitalization and sustainability work in tandem to drive efficiency, reduce environmental impact, and enhance productivity. As steelmaking is an energy-intensive process with significant CO₂ emissions, the integration of advanced automation solutions is essential to meet the industry’s growing demands for decarbonization and resource...
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Bernhard Sammer (Christian Doppler Labortatory for Inclusion Metallurgy in Advanced Steelmaking)09/10/2025, 12:00
Non-oriented electrical steel is widely applied as core material for several electrical machines, such as generators or electric motors due to its great soft magnetic properties. Besides grain size, precipitates, defects and grain orientation, non-metallic inclusions (NMI) also have a decisive effect on the magnetic properties of non-oriented electrical steel. Inclusions not only inhibit grain...
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97. Green DUE: Fossil-free casting and rolling technology for high quality automotive exposed panelsMr Riccardo Conte (Danieli & C. Officine Meccaniche S.p.A.)09/10/2025, 12:00
QSP-DUE is moving forward: from a breakthrough plant concept to a consolidated technology capable of reaching production targets exceeding 4.0 MTPY of fossil-free hot rolled strips for the most demanding applications, from commodity grades to AHSS, API line pipes and automotive exposed panels.
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Although QSP-DUE is a green technology by design, the introduction of the fully electric Tunnel... -
Michael Weinzinger09/10/2025, 12:00
In the era of big data, organizations are increasingly leveraging data lakes to store vast amounts of unstructured and structured data. This paper explores the transformative potential of data lakes in the context of global maintenance services.
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By integrating advanced data analysis techniques, we aim to uncover actionable insights that drive service improvements across various locations and... -
Dr Lukas Borrmann (SMS group)09/10/2025, 12:00Digital transformationOral Presentation
Steel plants operating for extended periods tend to stabilize into a steady operational state, which may not necessarily align with their peak production potential. Emerging challenges, such as rising energy costs and the task for decarbonization, necessitate a more detailed analysis and enhancement of existing operational processes integrating push and pull scenarios.
With automation, a...
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Prof. Silvia Barella (politecnico di milano)09/10/2025, 12:00
The steel industry, responsible for 7% of global CO₂ emissions, significantly contributes to environmental pollution and intensive water consumption. Decarbonizing the sector requires adopting innovative technologies such as hydrogen-based direct reduction, recycling in electric arc furnaces (EAF), and iron ore electrolysis. However, this transition presents major challenges, including the...
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Dr Jens Kempken (SMS group)09/10/2025, 13:20Steelmaking - Oxygen steelmakingKeynote Presentation
The transformation toward sustainable green production is focusing on hydrogen technologies and recycling of scrap.
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The constraints of resources availability are known (green H2/electricity, high grade DRI, scrap volume and quality).
Therefore, the BOF process technolgoy will remain for the next 25 years the prominent technology benefitting from a couple of process advantages to overcome... -
Georges Stamatakis (SMS group)09/10/2025, 13:20
The iron and steel industry contributes significantly to global greenhouse gas emissions, accounting for 7.2% of the total. The predominant BF-BOF ironmaking route, responsible for 70% of global pig iron production, is primarily coal-based, posing substantial challenges for decarbonization. As steel industry stakeholders strive to reduce carbon footprints while maintaining economic viability,...
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Stefan Radner (Primetals Technologies Austria)09/10/2025, 13:20
Steel circularity represents a sustainable strategy aimed at maximizing reuse of steel material, significantly contributing to the decarbonization of steel production. This approach encompasses the sustainable design of steel end products, resource-efficient steelmaking, and the recycling of steel products. Resource-efficient steelmaking is achieved through electric arc furnaces or converters...
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Volker Schöllmann (Hybrit)09/10/2025, 13:20
The HYBRIT initiative was launched in 2016 by SSAB, LKAB and Vattenfall with the aim of creating a completely fossil-free value chain from mine to steel, using fossil-free electricity and hydrogen. The focus of technical development has been to build up expertise and to set the technical prerequisites for implementing HYBRIT’s fossil-free value chain in full-scale production. Large parts of...
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Bernhard Voraberger (Primetals Technologies)09/10/2025, 13:20Ironmaking - Direct reduction and smelting reductionKeynote Presentation
The transition to green steel faces several challenges: raw material availability, green electric energy availability, and the associated cost. Direct reduction (DR) is a promising solution for reducing CO2 emissions in ironmaking. While natural gas-based DR is established and new plants are ready for operation with green hydrogen, the high costs of natural gas and hydrogen in Europe increase...
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Dr Thomas Leitner (voestalpine BÖHLER Edelstahl GmbH & Co KG)09/10/2025, 13:20
Thermophysical property data of liquid alloys, like viscosity and surface tension, are key input parameters in numerical fluid simulations. For production processes with extreme conditions and under harsh environments, like in steel industry, these simulations are a promising option to gain a deeper insight into those processes that are difficult (or even impossible) to study by measurement...
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Gabriele Urli (Danieli & C. Officine Meccaniche S.p.A)09/10/2025, 13:20
A heavy beams producer selected Danieli technology and construction capability for the turnkey Thermo-Mechanical Control Process (TMCP) project at its rolling mill.
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Thanks to this process, the product portfolio will be expanded with high-strength beams according to Grade 80 ASTM A913/A913M and S500ML EN 10025-4 standards.
High-strength beams offer substantial savings in construction in terms... -
Paul Cockram (Primetals Technologies Austria GmbH)09/10/2025, 13:40
Walsin Lihwa Corporation has partnered with Primetals Technologies to expand their production of long products and take advantage of the latest cutting-edge technology to meet the growing demand for high-quality stainless-steel products for the Chinese market. This mill was a strategic investment for Walsin Lihwa Corporation’s focus on increasing capacity, reducing delivery times while...
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Jean-Christophe Pierret (CRM Group)09/10/2025, 13:40
Scrap usage in steelmaking is a common practice to improve the process sustainability, as it decreases the use of virgin raw materials and boosts the circularity of the sector (decreasing CO2 emissions and energy consumption). Nevertheless, the current trend in the EU scrap market points to a slight decrease in pre-consumer scrap (E2, E6, E8, turnings..) and an increase in the short- and...
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Dr Daniela Nachazelova (COMTES FHT a.s.)09/10/2025, 13:40
One of the investigated concepts for Generation IV nuclear reactors is a molten salt-cooled reactor system. A critical aspect of this concept is the material selected for components of the primary and secondary circuits of the power source, which is exposed to extreme chemical and thermal loading. The loading arises both from aggressive chemical interactions with molten salts at elevated...
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Francesca Albano09/10/2025, 13:40
Life Cycle Assessment (LCA) is the most widely used methodology to quantify the potential environmental impact of the steelmaking industry, but it can been used to support the investigation of decarbonization strategies in the steel sector.
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In this contribution we aim to illustrate how LCA can be used to support the decision-making process within the context of GreenHeatEAF “Gradual... -
Ms Elena-Briana Boeru (Sapotech Oy)09/10/2025, 13:40
Continuous casting has long relied on inspection methods that often detect defects too late, leading to wasted energy, time, and costs. Late detection also limits the ability to intervene in defect formation. Sapotech aims to improve continuous casting control by developing a real-time defect detection system that integrates AI-driven predictions, machine vision, and process sensor data. This...
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Ms Yasmine Iciriddir (SMS group)09/10/2025, 13:40
The paper presents the development and implementation of the Pulverized Coal Injection Monitoring Service (Paul Wurth PCIXpert), an innovative solution designed to enhance the operational efficiency and reliability of Pulverized Coal Injection (PCI) plants. Developed by SMS group, PCIXpert addresses the challenges faced by maintenance and process management personnel in monitoring complex PCI...
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Kamal Joubarani (Hatch Ltd.)09/10/2025, 13:40Ironmaking - Direct reduction and smelting reductionOral Presentation
The ironmaking industry faces increasing pressure to reduce carbon emissions in response to global sustainability initiatives. This has incentivised steelmakers to move away from the traditional Blast Furnace (BF), with an emerging alternative being the Electric Smelting Furnace (ESF). The transition to ESFs will reshape slag management and design, requiring a reassessment of slag properties,...
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Dr Gianluca Di Egidio (Università di Bologna)09/10/2025, 14:00
The reduced production times and costs and lower environmental impact of the Powder Bed Fusion-Laser Beam (PBF-LB) technology compared to conventional technologies for producing complex-shaped parts are generating keen interest in the industrial sector. Thanks to its peculiar microstructure, the PBF-LB AISI 316L stainless steel has higher pitting corrosion resistance and mechanical strength...
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Dr Marten Lichte (VDEh-Betriebsforschungsinstitut GmbH)09/10/2025, 14:00
The REDERS project, which stands for "Reduced CO$_{2}$ emissions by increased recycling ratio in steelmaking processes", is a joint project of the steel producers thyssenkrupp steel Europe (tkSE) and Hüttenwerke Krupp Mannesmann (HKM) together with the recycling company TSR and the research institute BFI, which is coordinating the entire project.
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The aim of the project is to increase the... -
Dr Marco Thomä (Matplus GmbH)09/10/2025, 14:00
Steel-intensive-industrial sectors face ongoing challenges in balancing agility, demographic change and technological renewal. A key solution lies in the evolution of digitalization, moving beyond traditio-nal ERP (order processing), PLM (product development), and MES/BDE (production control) systems. The next stage of digital transformation integrates materials technology and manufacturing...
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Gerfried Millner (School of Material Science and Engineering, Nanyang Technological University)09/10/2025, 14:00
The global shift towards greener practices has created significant challenges for the material manufacturing sector. One key example is the need to increase the use of scrap metals in production to reduce the strain on natural resources and promote a circular economy. However, using scrap metals inevitably introduces impurities, which can greatly affect the properties of the final material....
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Mr Bernhard Viernstein (Primetals Technologies Austria GmbH)09/10/2025, 14:00
Power Cooling offers significant advantages in hot strip mills, particularly for producing modern steel grades with superior mechanical properties. This innovative cooling system features scalable water impact pressure and flow rates, ensuring high cooling rates coupled with precise temperature control far beyond the usual coiling temperature ranges for conventional steel grades. This is...
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Mr Daniel Kipp (Universität Duisburg-Essen)09/10/2025, 14:00
Carburization during the smelting of direct reduced iron in a smelter is critical in achieving the desired hot metal properties for refining in a steel plant. This study investigates DRI's smelting and carburizing behavior, focusing on the interaction between slag and carburization agents of differing grain sizes. The key objectives include achieving a high carbon content in the hot metal,...
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Dr Oday Daghagheleh (Primetals Technologies Linz GmbH)09/10/2025, 14:00
As part of the decarbonization process in the steelmaking industry, the direct reduction of iron ores, the use of green hydrogen as an energy source and/or the application of carbon capture technologies are crucial for achieving carbon neutrality. The study will underscore the importance of laboratory material testing and process simulation tools in determining the optimal and most feasible...
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Dr Martina Koukolíková (COMTES FHT a.s.)09/10/2025, 14:20
With the increasing demands of industry for materials capable of withstanding extreme conditions such as high temperatures, mechanical stress, and aggressive environments, nickel-based alloys are being increasingly employed. These materials play a key role in the production and maintenance of forging tools, offering an optimal combination of strength, durability, and stability due to their...
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Mr Camille Moukarzel (Fives Stein)09/10/2025, 14:20
Electrical steel (also called Silicon steel), a steel alloy with specific magnetic properties, with low core loss and high magnetic permeability, is extremely sensitive to produce, especially when high performance and low energy losses are critical. The booming electric vehicles market is driving the development of Non-Grain Oriented Silicon Steels with high flux density and minimal core...
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Mr Juan Garcia Jimenez09/10/2025, 14:20
Decarbonization of the steel industry has multiplied the number of projects involving construction of a direct reduction plant.
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Shorter project schedules and avoiding cost/availability issues with onsite construction skilled workers are key advantages of a modularized construction strategy.
TECNICAS REUNIDAS has executed projects in other industrial areas using this strategy and has... -
Mr Johann Winkler09/10/2025, 14:20
Electric smelting furnaces (ESF) represent a promising ironmaking technology for reducing steel industry’s CO2 emissions by utilizing direct reduced iron and a lower need of solid carbon sources compared to blast furnaces. Carbon sources in ESFs serve two primary functions: reduction of FeO from slag and acting as carburizers for the hot metal. Thus, the yield of ESFs is strongly influenced by...
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Michele De Santis (Rina Consulting - Centro Sviluppo Materiali SpA)09/10/2025, 14:20
Problem-solving in industrial processes relies on the adequate development and use of tools able to get insight and improved knowledge and know how on the phenomena behind the occurrence e.g, of factors affecting production quality and productivity. In steel production, this gains particular importance due to the need of following the increasingly severe market request and the unavoidable...
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Doruk Sahinel (Spherity GmbH)09/10/2025, 14:20
Transformation towards climate-neutral production in the metal industry requires innovative solutions for tracking and optimizing greenhouse gas emissions. While major steel manufacturers are already exploring digital product passports (DPP) as part of their sustainability strategies, small and medium-sized enterprises (SMEs) in the metal processing industry often lack standardized and...
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Mark Whitehead (SMS group)09/10/2025, 14:20
Traditionally, RH recirculatory degassers and large vacuum tank degassers use superheated steam to generate the vacuum required for their metallurgical process. The steam is supplied, as required, to a number of steam jet pumps, which can create vacuum levels of less than one mbar absolute.
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Usually, the steam for these vacuum pumps is generated either from an independent package type boiler... -
Jean-Christophe Huber (ArcelorMittal R&D)09/10/2025, 14:40
Increasing the energy source in BOF process and transferring it to the bath is a potential solution for fostering scrap melting, decreasing Hot Metal Ratio and thus global CO2 emissions.
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Post-combustion at BOF converter is usually around 10-12%. Many developments have been done in steelmaking industry to use this potential energy, either for the management of BOF mouth opening and skull... -
Alice Petrucciani (Scuola Superiore Sant'Anna)09/10/2025, 14:40
In recent years, the exploitation of Deep Learning and computer vision to classify waste material has rapidly increased to automate recycling processes, increasing efficiency and reducing carbon footprint. Electric steelworks, which produce steel by recycling ferrous scrap, fit perfectly into this context. In effect, the identification and classification of different types of scrap is...
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Cristian Viscardi (ECOTRE Valente srl)09/10/2025, 14:40
The Smart Beam manufacturing (SBM) is the new rolling mill that will allow to verticalize the production in Duferco Group plant of San Zeno Naviglio: a new integrated rolling mill, downstream of the San Zeno steel mill, to allow for optimal verticalization of the steel production, with the goal of becoming the best cost producer of steel beams in Europe.
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To reach optimal efficiency of... -
Ayana Ono (Kyushu University Graduate School of Engineering)09/10/2025, 14:40
Although carburization is one of the key reactions in steel production, and one for which no other elements can be substituted, coal as carbon source is used. Therefore, it is required to switch from coal to carbon-neutral materials for decarbonization. Previous research has reported that carbonaceous material with low graphitization degree and less ash has advantage for carburization...
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Jörn Sieghart (SMS group)09/10/2025, 14:40
The paper describes how an expert system automatically calculates the optimal strategy for all product changes based on PDA data, i.e. determining the best combined method of operation from technology clusters such as strip flatness and strip thickness, etc. The next step is to implement digital AI systems that provide forecasts for the optimal product change strategy. Once artificial...
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Hartmut Gumbinger (SMS Group)09/10/2025, 15:00
Wind power applications are the major enabler for the energy transition. The production of towers and foundations for offshore wind turbines requires the use of heavy plates, characterized by unique metallurgical properties and specific dimensions. Given the strict safety standards and the demand for high performance under extreme conditions, these heavy plates require high toughness and high...
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Dr Antonio Di Mauro (Nippon Gases Industrial)09/10/2025, 15:00
Decarbonization strategies are linked to the reduction of fossil fuels use together with the modelling of the implementation of new oxy-combustion technologies revamping old air-fuel fired tundish.
Tundish are responsible of a good part of the total energy consumption on a mini mill production plant. Decarbonization strategies are linked to the reduction of fossil fuels, and the...
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Dr Roberto Gerardo Bruna (Ternium)Steel materials and their applicationKeynote Presentation
The continuous demand from consumer industries for more reliable and cost-effective hot rolled steel products presents both opportunities and challenges for the steel industry. Metallurgical reliability is a crucial factor in high end applications that rely on steel, and meeting these demands requires a comprehensive approach that involves understanding the intrinsic relationships between...
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