PRODUCTION CONSULTING

IBMT Selskochoziaystvenaya St., 11, build. 3
Moscow 129226, Russia

Tel.: +7 903-621-59-17

ibmt@steelmaker.ru

The vast practical experience and deep fundamental knowledge of the steel-making theory allow the IBMT specialists to efficiently solve the following tasks:

- Development of new effective steelmaking techniques,
- Increase in production efficiency,
- Improvement in the quality of steel produced.

We make use of modern analytic equipment and steel-making processes simulators designed by IBMT. The simulators are developed on the basis of newest thermodynamic theory and unique models that allow us to take into account all peculiarities of objects simulated.

Our simulators accurately describe the whole system of thermo- and mass-transfer processes which take place in melting furnaces and secondary metallurgy facilities. It allows us to obtain information on temperature and chemical composition of metal, slag and waste gas during the processes at any moment by means of simulation. The processes parameters, as well as power and materials consumption can be determined by means of simulation too. Simulation allows us to estimate the efficiency of production and find out the most optimum solutions for:

- Increase in productivity by means of optimized steel melting and refining processes with the aim of reducing the duration of steel melting and treatment.
- Reduction in the consumption of alloying materials, deoxidizing and slag-forming agents.
- Reduction in power consumption.
- Adjustment (adaptation) of operating practices, in case of alteration in the production conditions (e.g., changes in the materials used, product mix, in the characteristics of the equipment , implementation of new equipment, etc.).
- Choice of an optimum version of steelmaking techniques upgrading.
- Estimation of efficiency of various materials and agents use. Choice of optimum ones.
- Other kinds of research aimed at an increase in the production efficiency.

High quality clean steel

We have a wide experience in optimization of steel treatment and casting techniques for production of high quality clean steel with required inclusions’ types and without surface and internal defects.

Non-metallic inclusions behavior during ladle treatment and casting can be described by our simulator too. The computer simulation is based on the thermodynamic models of inclusions nucleation and transformations in liquid steel. A combined approach, including both computer simulation and scanning electron microscopy (SEM) methods provides the possibility to determine the origin of single inclusions in steel or inclusions’ clusters near the detected micro- or macro-defects. It also provides the possibility to discover the most effective techniques for producing clean steel or controlling the type of inclusions in some quality steels (e.g. rail, wheel, wire-cord steel, etc.).

Besides an improvement in the quality of steel our research methods enable us to eliminate the problems of nozzles clogging and to stabilize the process of continuous casting.

Our research work includes the following steps:

1. Causes of insufficient production efficiency or bad quality are revealed. For this purpose the IBMT experts carry out the following research:

- Analysis of melting, secondary metallurgy, and casting operating practices used,
- Simulation of the production processes,
- Investigation of metal and slag samples with SEM,
- Simulation and thermodynamic analysis of generation and transformation of non-metallic inclusions during secondary treatment and casting of a heat under research.

2. Development of optimum technological parameters for an increase in the production efficiency and removal of the available drawbacks (problems of steel quality).

Experience

- Development of system for control of non-metallic inclusions in on-line mode during ladle treatment of high quality steels
- Development of technologies of high quality steels
- Development of secondary steel-making and casting technique for production of lead free free-cutting steels
- Development of secondary steel-making technique for production of HIC (Hydrogen Induced Cracking) resistant pipe-line steel
- Development of secondary steel-making and continuous slab casting technique for the purpose of low silicon LCAK-steel slab quality improvement
- Development of secondary steel-making technique for production of high quality high carbon steels (inclusions cleanliness improvement)
- Development of Vacuum Induction Melting Control system
- Development of low silicon and Ti-bearing LCAK-steel secondary steelmaking and continuous billet casting technique for tundish life increase
- Development of cord steel melting technology for the purpose of inclusions cleanliness improvement
- Development of new approaches for precise micro-alloying of superalloys by rare earth elements and magnesium during vacuum induction melting (VIM) for the purpose of the alloy’s hot workability improvement
- Investigation of the processing factors effect on magnesium evaporation from Ni-base alloys during VIM
- Investigation of rare earth elements interaction with crucible lining, slag, and crucible scull during VIM of Ni-base alloys.