| Abstract: | 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. |
