Why materials science and engineering is good for metallurgy

Metallurgy/materials education will continue to evolve to encompass, in an intellectually unified way, the full range of structural and functional materials. Computation, information, and other advanced sciences and technologies will assume increasing roles in materials education, as will distance and continuing education. The advantages of the changes will be many … to the graduates, to emerging industries, and to the traditional metallurgical industries seeking productive, creative young engineers as employees. The need for continuing change in our metallurgy/materials departments is now no less if we are to attract the best young people into our field in the numbers needed and to best serve the needs of industry. Merton C. Flemings received his S.B. degree from MIT in the Department of Metallurgy in 1951. He received his S.M. and Sc.D. degrees, also in Metallurgy, in 1952 and 1954, respectively. From 1954 to 1956, he was employed as Metallurgist at Abex Corporation (Mahwah, NJ), and in 1956 returned to MIT as Assistant Professor. He was appointed Associate Professor in 1961 and Professor in 1969. In 1970, he was appointed Abex Professor of Metallurgy. In 1975, he became Ford Professor of Engineering, and, in 1981, Toyota Professor of Materials Processing. He established and was the first director of the Materials Processing. He established and was the first director of the Materials Processing Center at MIT in 1979. He served as Head, Department of Materials Science and Engineering, from 1982 to 1995 and thereafter returned to full-time teaching and research as Toyota Professor. He was Visiting Professor at Cambridge University in 1971, Tokyo University in 1986, and Ecole des Mines in 1996. In 1999, he was appointed Co-Director of the Singapore-MIT Alliance, a major distance educational and research collaboration among MIT and two Singaporean universities. Professor Flemings’ research and teaching concentrate on engineering fundamentals of materials processing and on innovation of materials processing operations. He is active nationally and internationally in strengthening the field of Materials Science and Engineering and in delineation of new directions for the field. He is a member of the National Academy of Engineering and of the American Academy of Arts and Sciences. He is author or co-author of 300 papers, 26 patents, and 2 books in the fields of solidification science and engineering, foundry technology, and materials processing. He has worked closely with industry and industrial problems throughout his professional career and currently serves on a number of corporate and technical advisory boards. He received the Simpson Gold Medal from the American Foundrymen’s Society in 1961, the Mathewson Gold Medal of TMS in 1969, and the Henry Marion Howe Medal of ASM International in 1973 and became a Fellow, ASM International, in 1976. In 1977, he was awarded the Henri Sainte-Claire Deville Medal by the Societe Francaise de Metallurgie. In October 1978, he received the Albert Sauveur Achievement Award from ASM INTERNATIONAL. In 1980, he received the John Chipman Award from AIME. In 1984, he was elected an honorary member of the Japan Foundrymen’s Society and, in 1985, received the James Douglas Gold Medal from the AIME. The Italian Metallurgical Association awarded him the Luigi Losana Gold Medal in 1986, and he was elected honorary member of The Japan Iron and Steel Institute in 1987. He was elected a TMS Fellow in 1989. In 1990, he received the TMS Leadership Award, and the Henry Marion Howe Medal and delivered the Edward DeMille Campbell Memorial Lecture of ASM INTERNATIONAL. In 1991, he received the Merton C. Flemings Award from Worcester Polytechnic Institute. Sigma Alpha Mu elected him a Distinguished Life Member in 1992. In 1993, he received the TMS 1993 Bruce Chalmers Award and was elected Councillor of the Materials Research Society. He was elected to the ASM INTERNATIONAL Board of Trustees in 1994. He received the Acta Metallurgica J. Herbert Holloman Award in 1997 for “contributions to materials technology that have had major impact on society.” Also in 1997 he was appointed David Turnbull Lecturer of the Materials Research Society for “outstanding contributions to understanding materials phenomena and properties.” He received the Educator Award of TMS in 1999, received the FMS (Federation of Materials Societies) National Materials Advancement Award in late 1999, and delivered the ASM and TMS Distinguished Lecture in Materials and Society in 2000.     

Drops and bubbles in extractive metallurgy

Drops and bubbles are of great importance to the extractive metallurgist in his attempts to speed up processes by the use of sprays, foams, and jets. In this lecture the ways in which bubbles bring about mass transfer in liquid metals and in slag metal reactions are described. The role of interfacial turbulence is considered together with the effects of bubble size and frequency and the properties of the slag and metal phases. Reactions between drops of metal and flowing gases are analyzed in terms of mass transfer in the reacting phases and of chemical steps at the interface. Recent results obtained on reactions involving metal drops falling through liquids are considered in relation to mass transfer models in which internal circulation plays an important part. The work described reports only one facet of the rapidly developing subject of Process Engineering which ought now to feature prominently in metalurgical education. Dr. F. DENYS RICHARDSON. Professor of Extraction Metallurgy. Department of Metallurgy, Royal School of Mines. Imperial College of Science and Technology, London, England, graduated in chemistry at University College, London, in 1933, and obtained a Ph.D. in physical chemistry in 1936. From 1937 to 1939 he was Commonwealth Fund Fellow at the University of Princeton. From 1946 to 1950 he worked as superintendent chemist at BISRA, building up the work of the chemistry department. He went to Imperial College in 1950 to found the Nuffield Research Group in Extraction Metallurgy and advance the study of chemical metallurgy at high temperatures. He received awards in recognition of his work on the thermodynamic properties of high-temperature systems with special reference to iron- and steelmaking and for his work on high-temperature chemical metallurgy. He was appointed Professor of Extraction Metallurgy at Imperial College in 1957, his objectives there being to establish the department as a research center for chemical and process engineering metallurgy, and to develop a metallurgy course in which these subjects receive as much attention as physical metallurgy. In 1963 he was elected a Fellow of the Metallurgical Society of the AIME, and in 1964 he gave the AIME Howe Memorial Lecture. Professor Richardson delivered the Hatfield Memorial Lecture in 1964, the May Lecture of the Institute of Metals in 1965, and the Wernher Memorial Lecture of The Institution of Mining and Metallurgy in 1967. He was elected a Member of Council of the Iron and Steel Institute in 1967, having been an Honorary Member since 1962. In 1968 he became a Vice-President of the Institution of Mining and Metallurgy. In that year he was also elected a Fellow of the Royal Society and awarded the Bessemer Gold Medal of the Iron and Steel Institute, both honors for his contribution to the understanding of the thermodynamics and kinetics of metallurgical processes. In 1970 the honorary degree of Doktor-Ingenieur was conferred on him by the Technische Hochschale, Aachen. The 1971 Extractive Metallurgy Division Lecture, “Drops and Bubbles in Extractive Metallurgy.” was delivered on Wedresday, March 3, 1971.     

Why materials science and engineering is good for metallurgy

Metallurgy/materials education will continue to evolve to encompass, in an intellectually unified way, the full range of structural and functional materials. Computation, information, and other advanced sciences and technologies will assume increasing roles in materials education, as will distance and continuing education. The advantages of the changes will be many ... to the graduates, to emerging industries, and to the traditional metallurgical industries seeking productive, creative young engineers as employees. The need for continuing change in our metallurgy/materials departments is now no less if we are to attract the best young people into our field in the numbers and to best serve the needs of industry. Merton C. Flemings received his S.B. degree from MIT in the Department of Metallurgy in 1951. He received his S.M. and Sc.D. degrees, also in Metallurgy, in 1952 and 1954, respectively. From 1954 to 1956, he was employed as Metallurgist at Abex Corporation (Mahwah, NJ), and in 1956 returned to MIT as Assistant Professor. He was appointed Associate Professor in 1961 and Professor in 1969. In 1970, he was appointed Abex Professor of Metallurgy. In 1975, he became Ford Professor of Engineering, and, in 1981, Toyota Professor of Materials Processing. He established and was the first director of the Materials Processing Center at MIT in 1979. He served as Head, Department of Materials Science and Engineering, from 1982 to 1995 and thereafter returned to full-time teaching and research as Toyota Professor. He was Visiting Professor at Cambridge University in 1971, Tokyo University in 1986, and Ecole des Mines in 1996. In 1999, he was appointed Co-Director of the Singapore-MIT Alliance, a major distance educational and research collaboration among MIT and two Singaporean universities. Professor Flemings’ research and teaching concentrate on engineering fundamentals of materials processing and on innovation of materials processing operations. He is active nationally and internationally in strengthening the field of Materials Science and Engineering and in delineation of new directions for the field. He is a member of the National Academy of Engineering and of the American Academy of Arts and Sciences. He is author or co-author of 300 papers, 26 patents, and 2 books in the fields of solidification science and engineering, foundry technology, and materials processing. He has worked closely with industry and industrial problems throughout his professional career and currently serves on a number of corporate and technical advisory boards. He received the Simpson Gold Medal from the American Foundrymen’s Society in 1961, the Mathewson Gold Medal of TMS in 1969, and the Henry Marion Howe Medal of ASM International in 1973 and became a Fellow, ASM International, in 1976. In 1977, he was awarded the Henri Sainte-Claire Deville Medal by the Societe Francaise de Metallurgie. In October 1978, he received the Albert Sauveur Achievement Award from ASM INTERNATIONAL. In 1980, he received the John Chipman Award from AIME. In 1984, he was elected an honorary member of the Japan Foundrymen’s Society and, in 1985, received the James Douglas Gold Medal from the AIME. The Italian Metallurgical Association awarded him the Luigi Losana Gold Medal in 1986, and he was elected honorary member of The Japan Iron and Steel Institute in 1987. He was elected a TMS Fellow in 1989. In 1990, he received the TMS Leadership Award, and the Henry Marion Howe Medal and delivered the Edward DeMille Campbell Memorial Lecture of ASM INTERNATIONAL. In 1991, he received the Merton C. Flemings Award from Worcester Polytechnic Institute. Sigma Alpha Mu elected him a Distinguished Life Member in 1992. In 1993, he received the TMS 1993 Bruce Chalmers Award and was elected Councillor of the Materials Research Society. He was elected to the ASM INTERNATIONAL Board of Trustees in 1994. He received the Acta Metallurgica J. Herbert Holloman Award in 1997 for “contributions to materials technology that have had major impact on society.” Also in 1997 he was appointed David Turnbull Lecturer of the Materials Research Society for “outstanding contributions to understanding materials phenomena and properties.” He received the Educator Award of TMS in 1999, received the FMS (Federation of Materials Societies) National Materials Advancement Award in late 1999, and delivered the ASM and TMS Distinguished Lecture in Materials and Society in 2000.     

Process Simulation and Economic Feasibility Analysis for a Hydrogen‐Based Novel Suspension Ironmaking Technology

A novel gas‐solid suspension ironmaking process is under development at the University of Utah, which would greatly reduce energy consumption and carbon dioxide emission compared with current blast furnace technology. The proposed process is based on the flash reduction of iron ore concentrate using a gaseous reagent, such as hydrogen, syngas, natural gas or a combination of thereof. A process flow sheet of the proposed ironmaking process using purchased hydrogen was constructed and then simulations were performed at several potential operating conditions. Ironmaking was simulated using two different process configurations. The simulation results show that the required fresh hydrogen would increase with higher excess driving force and operating temperature, but not greatly when hydrogen is preheated. Compared with the average blast furnace process, the proposed process would reduce energy consumption by 57 ‐ 60%, using the higher heating value of hydrogen (71 – 73%, if the lower heating value is used), when hydrogen and coal are considered as the starting materials in the respective processes. The economic feasibility analysis using net present value (NPV) indicates that the proposed process could be economically feasible at elevated hot metal prices and/or if reduction in carbon dioxide emissions has a significant value in a cap and trade scenario.     

Continuous Reduction of Iron Ore with Coal in an Electrically Heated Furnace

Abstract

This paper presents the results of a fundamental study for the development of a new ironmaking process based on coal and iron ore concentrates [1]. The coal/iron ore mixture is fed mechanically and continuously through a reaction tube in a tubular, electrically heated furnace. Investigations have been made on the effect of several of the most important operating variables, i.e. temperature, linear velocity of solids, coal particle size and coal/iron ore ratio, on the degree of metallization and on the smoothness of the operation. The gases generated during reactions have also been analysed. The rapid rate of metallization obtained and the composition of gases generated indicate that development of a new and economical ironmaking process is encouraging.     

Application of carbon composite iron ore hot briquette to innovative ironmaking process

As a new type of ironmaking raw materials,carbon composite iron ore hot briquette(CCB) is the product of fine iron ore and fine coal by hot briquetting process.On basis of experimental research on the manufacturing and metallurgical properties of CCB,this study focused on the application of CCB to blast furnace ironmaking and newly-developed shaft furnace smelting reduction processes.Firstly,the metallurgical properties of CCB are experimentally tested and compared with the common iron-bearing burdens.Th...     

Technical analysis on ironmaking process of rotary kiln pre- reduction and smelting by coal and oxygen

The traditional blast furnace ironmaking process has many problems such as long process flow, high dependence on coke and large environmental pollution. In order to solve these problems, the new ironmaking process of rotary kiln pre- reduction and smelting by coal and oxygen was developed. This new process has advantages of wide raw material adaptability, no coke consumption, less pollutant emissions and suitable for special iron ore resources. The mathematical model of the new process was established. Numerical simulation results show that the metallization rate of pre- reduction iron, smelting furnace gas oxidation degree and blast air oxygen content have great influence on coal and oxygen consumption. The coal and oxygen consumption reduces with the increase of pre- reduction iron metallization rate, the rise of oxygen degree of coal gas or the decrease of oxygen content of blast air. This process has a significant advantage in smelting special iron ore resources, which can make up the shortage of blast furnace ironmaking. It is also of great significance to reduce fuel consumption and CO2 emissions.     

Research on Sustainable Steelmaking

The international steel community is faced with the challenge of developing processes that will make steel production more sustainable in the future. Specifically, processes that produce less CO₂ and less net waste materials and emissions and that consume less energy are required. This article outlines where energy consumption and CO₂ emissions are high and can be reduced. Reductions can be achieved by incremental improvements to existing processes or by a “break-through innovative process”; both strategies are examined. Since most of the energy consumption and CO₂ generation occur in ironmaking, research in this area is emphasized. Research on controlling the cohesive zone in the blast furnace, improving the final stages of reduction in direct reduction processes, the use of biomass, and other innovative processes for ironmaking are reviewed. In oxygen steelmaking, improved postcombustion (PC) to allow for more scrap melting is examined. Postcombustion and slag foaming in the electric arc furnace (EAF) in order to reduce energy is reviewed. R.J. Fruehan is currently the U. S. Steel University Professor at Carnegie Mellon University. He received his B.S. and Ph.D. degrees from the University of Pennsylvania and was an NSF Scholar at Imperial College, University of London. Dr. Fruehan organized the Center for Iron and Steelmaking Research, and is currently the Co-Director. He was Director of the Sloan Steel Industry Study, which examines the critical issues impacting a company’s competitiveness and involves numerous faculty at several universities from 1992 to 2002. Dr. Fruehan has authored over 250 papers, two books on steelmaking technologies, co-authored a book on managing for competitiveness, and is the holder of six patents. He has received several awards, including the 1970 and 1982 Hunt Medal (AIME), the 1982 and 1991 John Chipman Medal (AIME), 1989 Mathewson Gold Medal (TMS-AIME), the 1993 Albert Sauveur Award (ASM International), the 1976 Gilcrist Medal (Medals Society UK), the 1996 Howe Memorial Lecture (ISS of AIME), the 1999 Benjamin Fairless Award (ISS of AIME), the Brimacombe Prize (ISS, TMS, CSM) (2000), the 2004 Bessemer Gold Medal (Institute of Materials, Minerals & Mining (UK); an IR100 Award for the invention of the oxygen sensor and the TMS Science Award (2008). He is a Distinguished Member of the Iron and Steel Society, an Honorary Member of AIME, an Honorary Member of the Iron and Steel Institute of Japan and served as President of the Iron and Steel Society of AIME from 1990 to 1991. He was elected a Member of the National Academy of Engineers in 1999.     

Future steelmaking technologies and the role of basic research

The steel industry is going through a technological revolution that will not only change how steel is produced but also the entire structure of the industry. The drivers for the new or improved technologies, including reduction in capital requirements, possible shortages in raw materials such as coke and low residual scrap, environmental concerns, and customer demands are briefly examined. The required response of the industry to these drivers will be new processes such as direct ironmaking, near net shape casting, and those to improve charge materials to the electric arc furnace (EAF). The know-how for these process improvoeemnts and revolutionary technologies can be purchased, if it exists. However, since the U.S. industry has a unique set of drivers, it may be necessary to develop many of the new technologies through its own research and development. The current status of research and developoment in the United States and selected international producers was examined. As expected, it was found that the industry’s research capabilities have been greatly reduced. Furthermore, less than half of the companies that identified a given technology as critical have significant research and development programs addressing the technology. It is clear that, in many cases, these technologies must be developed collaboratively using all of the intellectual resources available, including universities. Much of the basic process understanding and data for optimization can be obtained from basic research, which is highly focused on the requirements of the new process, thus eliminating some expensive pilot plant trials. Examples of how basic research aided in process improvements in the past are given. The examples include demonstrating how fundamentals of reaction kinetics, improved nitrogen control, and thermodynamics of systems helped reduce nozzle clogging and how fluid flow studies reduced defects in casting. However, in general, basic research did not play a major role in processes previously developed but helped our understanding and aided optimization. To have a major impact, basic research must be focused and be an integral part of any new process development. An example where this has been done successfully is the AISI Direct Ironmaking and Waste Oxide Recycle projects, in which fundamental studies on reduction, slag foaming, and postcombustion reactions have led to process understanding, control, and optimization. Industry leaders recognize the value and need for basic research but insist it be truly relevant and done with industry input. From these examples, the lessons learned on how to make basic research more effective are discussed. Professor Richard J. Fruehan received his B.S. and Ph.D. degrees from the University of Pennsylvania in 1963 and 1966, respectively. He was an NSF postdoctoral scholar at Imperial College, University of London, from 1966 to 1967. He then was on the staff of the United States Steel Laboratory until he joined the faculty of Carnegie Mellon University as a Professor in 1980. Dr. Fruehan organized the Center for Iron and Steelmaking Research, an NSF Industry/University Cooperative Research Center, and is currently the director. The Center currently has 24 industrial company members, including those in the United States, Europe, Asia, South Africa, and South America. Dr. Fruehan has authored over 150 papers, two books, and co-authored two additional books and is the holder of five patents. He has received several awards for his publications, including the 1970 and 1982 Hunt Medal (AIME), the 1982 and 1991 John Chipman Medal (AIME), the 1989 Mathewson Gold Medal (TMS-AIME), the 1993 Albert Sauveur Award (ASM INTERNATIONAL), the 1976 Gilcrist Medal (Metals Society, London), and the 1996 Howe Memorial Lecture (ISS-AIME); he also received an IR100 Award for the invention of the oxygen sensor. In 1985, he was elected a distinguished member of the Iron and Steel Society. He served as president of the Iron and Steel Society of AIME from 1990 to 1991. In 1997, he was appointed the U.S. Steel Professor of the Materials Science and Engineering Department, Carnegie Mellon University.     

Developments in Alternative Ironmaking

Alternative ironmaking processes compete with the blast furnace process route. The blast furnace, the most important hot metal producer, has improved over the years and continues to do so. Consequently replacing the blast furnace is a formidable task. The success rate of alternative processes has been low, i.e. limited to niche applications. Why do we continue to work in this field? Because the drivers to develop alternative processes are very strong. For example, the expected coke shortage has been the driver for coal based developments in Europe in the period 1980–1990. Some of the recent developments evolved from the work done in that period. In later years, around the year 2000, the Climate Change issue became the driver for development. And the high price level of iron ore of the last decade can spur a new wave of ironmaking developments. The HIsarna alternative ironmaking process is an example of a development that combines several of the drivers mentioned above. The process has the potential to considerably reduce the CO₂ emissions per ton. But it can also use more economically priced raw materials such as non coking coals and iron ores outside the quality range for blast furnace ironmaking. Therefore the process can offer economic benefits as well as environmental benefits.     

The practice of clean production in the Ironmaking Plant of Tangshan Iron & Steel Co.,Ltd.

The Ironmaking Plant of Tangshan Iron & Steel Co.Ltd.takes clean production as its orientation. It decreases silicon to smelt through increasing the entering furnace sinter ratio,stabilizing coke quality by tackling key problems,increasing coal injection ratio,as well as keeping the blast furnace smooth running and so on.The energy consumption of sinter working procedure has been greatly reduced through optimizing the ore blender structure,enhancing the quality of fuel and flux,increasing the quicklime a...     

首钢京唐低硅低镁烧结技术的研究与应用

为了进一步改善5 500m~3特大型高炉精料入炉水平,首钢京唐炼铁作业部在停配白云石熔剂实现自然镁烧结的基础上,结合相关烧结杯试验做了微观组织结构研究。根据生产实际,通过采取优化配矿结构以及调整过程控制参数等措施,逐步降低烧结矿SiO_2与MgO质量分数生产低硅低镁烧结矿。通过低硅低镁烧结技术的应用,首钢京唐炼铁作业部在改善烧结矿品位稳定强度、粒度的基础上保证了入炉精料水平,并取得了较好的效果,为首钢京唐5 500m~3特大型高炉提高综合入炉品位、降低渣比以及喷煤降焦创造了良好的原料条件。     

西昌钢钒铁系统低耗冶炼技术进步

攀钢西昌钢钒公司炼铁厂新建了3座1750 m3高炉,主要铁料为白马钒钛精矿,综合入炉品位49.5％,炉渣TiO2含量为22％.1号高炉于2011年12月投产,2012年1～5月生产以保系统稳定为主,下半年指标逐步优化.自12月2号高炉投产后,通过降低平均炉温、改进造渣制度、改造出铁沟、优化料制等一系列措施,全工序矿石及燃料单耗分别降低了168、120 kg/t,全工序金属损失率降低到5.82％,2013年2月铁水成本在2012年12月基础上降低了120元/吨.     

450m~3高炉炉前操作技术实践

西林钢铁集团有限公司通过对450m3高炉炉前出铁场的一系列改造和强化炉前操作的管理,解决了由于炉前事故频发而影响高炉作业率的难题,为炼铁工序创造好的指标提供了保障。     

包钢高炉炼铁优化配矿平台的开发与应用

为了降低高炉炼铁系统原料成本,实现自铁矿石采购到高炉炼铁全过程协同优化,开发了一个高炉炼铁全系统、全流程优化配矿平台.全流程是指从铁矿石采购到高炉产出铁水的整个工艺流程,全系统是指钢铁企业所有高炉炼铁整体系统.优化配矿平台包括数据库系统、单座高炉优化配矿平台、全系统高炉优化配矿平台、生产数据采集与分析平台4部分.平台以...     

钢铁工业铁前工序的 Exergy分析

铁前工序是钢铁工业能源消耗的主要环节,占总能耗的80％。为此,根据铁前工序的生产数据,通过建立物料平衡,建立了Exergy 计算模型,获得了各工序的Exergy 平衡关系、热力学完善度、 Exergy效率、 Exergy损失系数。同时结合理论分析,论述了Exergy分析法对铁前工序（焦化、烧结、高炉炼铁）节能分析的优势,并且提出各工序的节能途径。     

系统思考实现炼铁综合水平提高

在钢铁业新的形势下为继续提高高炉炼铁综合技术水平,保持企业的可持续发展目标,探讨了反映高炉炼铁高效、长寿、低耗等方面技术水平的关键标志,认为能耗、成本等是今后炼铁过程中应着重控制的指标.另外,从高炉设计、高炉操作、原燃料控制、高炉和前道工序之间的结合模式等方面介绍了宝钢分公司炼铁厂提高这些关键指标的技术、管理措施,指出了在新形势下片面追求单一炼铁指标的局限性,突出了系统思考炼铁各区域之间协调关系对提高炼铁综合水平的重要性.     

Dusts,scale, slags,sludges... Not wastes,but sources of profits

Historically, the steel industry has focused on the need for and the many benefits of recycling steel that is discarded either in its own or in its customers’ manufacturing processes, as well as in recovery and reuse of steel scrap that arises after the product has served its intended purpose. In fact, modern steelmaking relies on the use of recycled iron units for at least half of its production. The other side of the story is the fate of the non-steel by-products (e.g., oxide dusts, sludges, scales, slags, spent refractories and the contained “low grade” energy units that are generated as natural adjuncts to iron and steelmaking processes). These valuable by-products often are classified as “wastes” and are discarded to landfills, at significant cost, although in reality they offer significant potential for cost savings or profit if reintroduced into the industrial arena via well planned programs. Examples of such instances will be presented, including energy credit issues, in the hope of pointing the way for future expansion of benefits from these opportunities. Preparing for a challenge and honor such as the Howe Memorial Lecture, one has to stand in awe of the accomplishments of the predecessor we honor in this forum. He worked in the early days of our industry without the benefits of the many technological improvements he and his successors brought to play as the years went by. John Stubbles, in his Howe Memorial Lecture in 1997,_[1] presented a masterful and entertaining biography of Howe and his very active and prolific life. Perhaps the most telling quotation he attributed to Howe is very pertinent to the topic we will address presently: “Metallurgy lives by profit, not logic,” to which I would like to add a comment that bears on the topic of this lecture from the 1991 Howe lecturer, my friend and mentor Bill Dennis, “Where there is muck, there is money.” There are numerous examples of “one hand washes the other” in this business; that is, of the synergism between needs and capabilities. We will address some of these situations, such as in a new process under development for dezincing of post consumer scrap, and in the use of iron units in by-product oxides and recycling of ladle slags and of spent refractories. Peter J. Koros, the Iron and Steel Society’s 77th Howe Memorial Lecturer (2001), is Principal of Koros Associates, Inc. (Pittsburgh, PA), a consultancy he founded following retirement from the former LTV Steel Company where he worked for nearly 41 years, retiring as Senior Research Consultant. He earned the Bachelor of Science degree in Metallurgical Engineering from Drexel University, and his master’s and doctoral degrees in Metallurgy from the Massachusetts Institute of Technology (MIT). In 1958, he joined Jones and Laughlin Steel (which became LTV Steel Company), where he held positions in research (Director, Process Metallurgy), Technical Services and Quality Control, with most activities focused on steelmaking and related areas. He was responsible for J&L’s development work in injection technology for desulfurization of hot metal and steel, was the inventor of the patented co-injection concept now in use worldwide, and had the lead role in LTV Steel’s programs for degalvanizing scrap and for recovery and utilization of by-product oxides. He led the AISI Opt-In program for degalvanizing scrap and the LTV-USS pilot program for processing “by-product” oxides. Koros has authored more than 75 publications and presentations, and holds eight U.S. patents, the latest issued in 2000. Dr. Koros was elected a Distinguished Member and Fellow of the ISS in 1984 and a Fellow of ASM International in 1988. Other honors include the ISS Distinguished Service Award (1998), ISS Electric Furnace Honorable Mention Citation (1987), International Magnesium Association Design and Applications Award (1978), AISI Gold (1977) and Silver (1969) Medals, ISS Herty (1963), McKune (1963), and Toy (1962) Awards. Koros served on the Technical Advisory Committee of the AISI-DOE Direct Steelmaking Program and its follow-on Waste Oxide Recycling Program. He was chairman of the AISI Task Force on Degalvanizing Steel Scrap and of the Industrial Advisory Panel to the Argonne Lab-MRI Program on Dezincing Steel Scrap. The 2001 Howe Memorial Lecture, titled “Dusts, Scale, Slags, Sludges ... Not Wastes But Sources of Profits,” as well as an invited Keynote Lecture for an International Recycling Conference in Sweden (June 2002, “Iron Units in Search of a Home: New Steel”) were based on the experience from these programs. Koros has been an active member of the ISS Advanced Technology Committee for which he participated in and chaired several symposia, including New Melting Technologies II (October 2002) and the first New Melting Technologies Symposium (1997). He was Director of the ISS 2000 Short Course on Injection Technology, a lecturer in the 2000 ISS/AISI Course on BOF Steelmaking, lead Co-chairman for the Elliott Symposium (1990), and Chairman of the Program Committee for the Fifth International Iron and Steel Congress (1986). Dr. Koros served on the Industrial Advisory Board of MIT’s Materials Processing Center (1995–98) and the AISI’s Iron and Steel Research Subcommittee (1976–86.) He was chairman of the ISS National Science Foundation Advisory Committee, the Advisory Council of the U.S. Bureau of Mines Generic Minerals Technology Center for Pyrometallurgy Research (1983–85), and of the Advisory Board for Carnegie Mellon University’s Center for Iron and Steel Research, for which he served as chairman (1991–1992). Service included participation in the NRC-NAS Alternative Energy and Development Strategy Study (1989–90.) Koros was very active in the creation of the ISS, having served as Chairman of the predecessor TMS Iron and Steel Division in 1972–73 and on the AIME Board of Directors (1974). Professional Society memberships: ISS (elected Distinguished Member and Fellow, Life Member), TMS (Senior or Life Member), ASM International (elected Fellow, Life Member), and AISE.     

The science and technology of steelmaking—Measurements, models, and manufacturing

In our efforts to characterize and improve the performance of an existing steelmaking process or in our quest to generate useful knowledge as a basis for the development of new manufacturing routes, measurements and models should be considered as two interdependent requirements. Without measurements, our models are incomplete and unsatisfactory. Without models, we fail to realize, or perhaps even comprehend, the potential significance of our measurements. Sometimes in our enthusiasm, we construct sophisticated elegant models and forget the reality of the actual manufacturing process. In this computer age, we need to remember again the importance of observations and accurate measurements. In addition, as engineers and applied scientists, we have an obligation and a responsibility to facilitate the transfer of new knowledge into the realm of operating practice. During this process of generation, evaluation, and communication of new knowledge, the knowledge exchange step is perhaps the most difficult. In this context, the preeminent aim of collaborative activities between our educational institutions, industrial organizations, government funding agencies, and professional societies is to ensure the availability of high-quality people who not only understand the fundamental aspects and practical implications of their discipline, but also are fully equipped with the essential skills of communication that will enable them to participate throughout their career in this most challenging and satisfying activity, the science and technology of steelmaking. The Brimacombe Memorial Lectureship was established in 1999 by the Process Technology Division of the Iron & Steel Society to honor Dr. J. Keith Brimacombe’s outstanding accomplishments in the area of process metallurgy, his dedication to the steel industry, and his profound effect on people in the industry; and also to acquaint members, students, and engineers with the many exciting opportunities that exist in the area of process metallurgy and to inspire them to pursue careers in this field. Professor McLean obtained his degrees in Applied Chemistry and Metallurgy from the University of Glasgow and the Royal College of Science and Technology, now the University of Strathcylde. After 5 years with the Metallurgy and Materials Science Department at McMaster University in the mid-1960s, he moved to the Graham Research Laboratory of Jones and Laughlin Steel Corporation in Pittsburgh. He returned to Canada in 1970 and joined the Department of Metallurgy and Materials Science at the University of Toronto where he served as the American Iron and Steel Institute Distinguished Professor from 1982 through 1986 and as Department Chair from 1992 through 1997. He is an Adjunct Professor at Chiba Institute of Technology in Japan and holds the position of Invited Professor at Kyoto University. In 1985, he served as President of the Iron and Steel Society of AIME and in 1988 delivered the 65th Henry Marion Howe Memorial Lecture. He is an Honorary Member of AIME, the Iron & Steel Institute of Japan, and the Hungarian Mining & Metallurgical Society. He is a Fellow of the Royal Society of Canada and also several professional associations. He has received Honorary Doctorates from the University of Miskolc in Hungary and the University of Strathclyde in Scotland as well as awards from technical societies in Canada, the United States, the United Kingdom, and Japan for contributions to the science and technology of steel processing and for activities pertaining to metallurgical education. He has authored or co-authored about 300 publications and has served as a consultant to companies in North America and Europe and as a board member of several industrial organizations. He was appointed Professor Emeritus at the University of Toronto in 2002.     

高炉使用含碳复合炉料的原理

 高炉炼铁正朝着高产、低污染、低能耗的方向发展,为了实现这一目标,包括高炉使用含碳复合炉料等一些革新的炼铁技术已经被提出或实际应用。铁焦、热压含碳球团是将铁矿粉和煤粉按一定比例混合后制成的新型含碳复合炉料。研究结果指出,含碳复合炉料相比于传统的高炉炉料（烧结矿和球团矿）具有高温强度高、还原性能好以及原料适应性强等优势。阐明了高炉使用含碳复合炉料的基本原理,介绍了铁焦制备的工艺流程及应用情况,重点进行了热压含碳球团制备工艺流程、冷态冶金性能、高温冶金性能、高炉使用热压含碳球团等试验研究,最后利用多流体高炉数学模型对高炉使用热压含碳球团操作进行了模拟研究。研究表明,高炉使用一定量的含碳复合炉料可以降低热空区温度,增加产量,降低焦比,高炉热利用效率明显提高,操作性能得到有效改善。