Applied Research Project

Ferrous Metallorgy
Post grauate
Prof. Dr. Taha Mattar , Prof. Dr. M. Gamal Khakifa
Dr. Abd-Alrahman Ebrahim
A.R.P.
Applied Research
Project Framework
A.R.P. … 2022
Endless
NANO Mill
Zero Emission is The Real Mission
… Vision 2050 … Master's student
Nano Mill
Hesham Saad
Steel
M R
Green – Lean - Clean C
‫ اﻟﻲ ﺗﺻﻧﯾﻊ أﺧﺿراء ﻣﺳﺗدام‬... ‫واﻟﺗﺣول‬ ‫اﻟﻲ ﻋﺎﻟم اﺧﺿر ﻣﺳﺗدام‬ 1
Ferrous Metallorgy
Applied Research Project
Post grauate
Now, New & Next Dr. Abd-Alrahman Ebrahim
A.R.P.
001- Abstract
… Vision 2050 …
Nano Mill
Steel
M R
Master's student
‫ اﻟﻲ ﺗﺻﻧﯾﻊ أﺧﺿراء ﻣﺳﺗدام‬... ‫واﻟﺗﺣول‬ ‫اﻟﻲ ﻋﺎﻟم اﺧﺿر ﻣﺳﺗدام‬ Hesham Saad 2
Ferrous Metallorgy
Post grauate
Now, New & Next Dr. Abd-Alrahman Ebrahim
A.R.P.
Now, 1st turning point Continuous Casting Machine, CCM, is considering as first turning point a done by
transformation from steel ingot (casting and rolling) to steel billet (casting) directly from the liquid steel , where is the
process of ingot (casting and rolling) was vanished as an intermediate process was assigned for producing steel billet, …
New, 2nd turning point nowadays CCM also , could be considering as second turning point a in
transformation from standalone rolling mill to standalone mini mill or endless rolling mill , where is the rolling mill has been
merged directly to Steel Melt Shop, SMS , with a major benefit , which is no more need for the steel billet reheating furnace
unit , where is the CCM merged directly to the rolling mill stands through induction heater, …
Next, 3rd turning point in this applied research proposal of developing of endless rolling mill will be studied as
a CCM third turning point , based on major question?, can we maximize the benefits ? , yes it could be !, where is no more
need for roughing stands stage of rolling mill, by studying of various factors impact on casting minimum round-cross section
of carbon steel billet by continuous casting machine to be feeding to the intermediate stands stage directly …
… Vision 2050 …
Nano Mill
Steel
M R
Master's student
Ferrous Metallorgy
Post grauate
Primary Metallurgy Prof. Dr. Taha Mattar , Prof. Dr. M. Gamal Khakifa
A.R.P.
Endless Melting
Continuous Charging Machine + Melting unit = Endless Melting
… Vision 2050 …
Nano Mill
Steel
M R
Master's student
Ferrous Metallorgy
Post grauate
Casting & Rolling Prof. Dr. Taha Mattar , Prof. Dr. M. Gamal Khakifa
A.R.P.
Endless Rolling
Continuous Casting Machine + Rolling unit = Endless Rolling
Nano Mill
We are here
… Vision 2050 …
Nano Mill
Steel
M R
Master's student
Ferrous Metallorgy
Post grauate
Nano Mill Dr. Abd-Alrahman Ebrahim
A.R.P.
002- Title of the Project

Nano Mill
… Vision 2050 …
Nano Mill
Steel
M R
Master's student
Ferrous Metallorgy
Post grauate
A.R.P.
Studying of various factors impact on casting minimum round – cross section

of peritectic vanadium steel billet by continuous casting machine
(Nano mill , Endless casting & rolling)
… Vision 2050 …
Nano Mill
Steel
M R
Master's student
Ferrous Metallorgy
Post grauate
A.R.P.
Studying of various factors impact on casting minimum round – cross section

of peritectic vanadium steel billet by continuous casting machine
(Nano mill , Endless casting & rolling)
… Vision 2050 …
Nano Mill
Steel
M R
Master's student
Ferrous Metallorgy
Post grauate
Steel Mill Prof. Dr. Taha Mattar , Prof. Dr. M. Gamal Khakifa
Capacities Dr. Abd-Alrahman Ebrahim
A.R.P.
Copper mold geometry

Round
Nano Mill
Mega
Macro
Micro
Nano Mega Mill Copper

Macro Mill Micro Mill
Mold
Octagonal Square
… Vision 2050 …
Nano Mill
Steel
M R
Master's student
Ferrous Metallorgy
Post grauate
A.R.P.
003- Acknowledgements
… Vision 2050 …
Nano Mill
Steel
M R
Master's student
Ferrous Metallorgy
Post grauate
A.R.P.
I wish to express a grateful Acknowledgements and deep appreciation for

Prof. Dr. Taha Mattar
For his acceptance, to supervise the applied research project, A.R.P.
I also wish to express a grateful Acknowledgements and deep appreciation for

Prof. Dr. M. Gamal Khakifa
For his kind support the applied research project, A.R.P.
I also wish to express a grateful Acknowledgements and deep appreciation for

Dr. Abd AL Rahman Ebrahim
For his kind assistance to the applied research project, A.R.P.
… Vision 2050 …
Nano Mill
Steel
M R
Master's student
Ferrous Metallorgy
Post grauate
A.R.P.
004- Preface
… Vision 2050 …
Nano Mill
Steel
M R
Master's student
Ferrous Metallorgy
Post grauate
A.R.P.
… Vision 2050 …
Nano Mill
Steel
M R
Master's student
Ferrous Metallorgy
Post grauate
Design thinking Prof. Dr. Taha Mattar , Prof. Dr. M. Gamal Khakifa
A.R.P.
Matrix
• Desirability • Developability
Society Business
Innovation
Is the core of the matrix
We are here
Impact Technology
• Sustainability • Feasibility
… Vision 2050 …
Nano Mill
Steel
M R
Master's student
Ferrous Metallorgy
Post grauate
Design thinking Prof. Dr. Taha Mattar , Prof. Dr. M. Gamal Khakifa
Stacked Venn diagram Dr. Abd-Alrahman Ebrahim
A.R.P.
Ecology
Society
Economy
We are here
Technology
… Vision 2050 …
Nano Mill
Scientific research Steel
M R
Master's student
Ferrous Metallorgy
Post grauate
Ecological pyramid Dr. Abd-Alrahman Ebrahim
A.R.P.
Zero Emission is The Real Mission

Zero Emission
(atmosphere)
Recovery
Green Recycle
(Biosphere)
Reuse
Reduce
… Vision 2050 … Zero Waste Zero Discharge

Nano Mill (lithosphere) (Hydrosphere)
Steel
M R
Master's student
Ferrous Metallorgy
Where we are ! Applied Research Project
Post grauate
& Prof. Dr. Taha Mattar , Prof. Dr. M. Gamal Khakifa
A.R.P.
Where must we go? Dr. Abd-Alrahman Ebrahim
Next, Now,
New Greening sphere
Green sphere Brown spheres
Economy
Green Brown
Is a Trend Technology Ecology
Sustainability n c e pts y
Is a Mindset
Greening
Gre ening co ic et
Technology So
Green n c iples
p ri
Technology Green
ing n n n
We are here
n b asics e en atio w
o atio
Gr e e Gr nov r
B ov
inabil ty
i In n
a en ion In
… Vision 2050 …
sustNano Mill
e
Gr vat Steel
n o
In M R
Master's student
Ferrous Metallorgy
Post grauate
A.R.P.
005- Content
… Vision 2050 …
Nano Mill
Steel
M R
Master's student
Ferrous Metallorgy
Post grauate
A.R.P.
000- Design thinking Matrix 040- Billet Continuous Casting Design Principles
001- Abstract, Now New & Next 41- CCM Design limits,
002- Project Title 42- Casting radius,
003- Acknowledgements
004- Preface, Ecological pyramid
43- metallurgical length,
005- content 44- mold length, cooling arrangement
006- ARP Scope 45- casting speed & casting rate
010- A.R. Project Scope 46- ladle capacity,
11- Metallurgical Scope 47- Billet chemical composition recommendation & Defects,
12- Product Scope 050- Potential outcomes and Optimization
13- Process Scope
51- GLC technology and BAT,
020- (Introduction),
21- Process history, description & models 52- 1st Axis, Green Product, zero waste,
22- Benefits Statement, 53- SMPE Sustainable Manufacturing Process Effectiveness,
23- Project Axes, 54- 2ndAxis, Clean Process, Zero emission,
24- A.R. Project Objectives, 55- Sustainable development goals , SDGs,
030- Literature review 56- BEP , Externalities,
31- Consequences of billet geometry exchange
57- 3rdAxis, Productivity vs Product mix,
… Vision 2050 … 060- Conclusion
Nano Mill 070- Conflicts of interest
080- References
Steel
M R
Master's student
Ferrous Metallorgy
Post grauate
A.R.P. … Scope Dr. Abd-Alrahman Ebrahim
A.R.P.
006- A.R.P. Scope

Product
Metallurgical Process
… Vision 2050 … A.R.P.

Nano Mill Scope
Steel
M R
Master's student
Ferrous Metallorgy
Post grauate
A.R.P. … Scope Dr. Abd-Alrahman Ebrahim
A.R.P.
010- Scope of The A.R.P.
… Vision 2050 …
Nano Mill
Steel
M R
Master's student
+L
Metallurgical B500DWR C% < 0.32
B600D – R C% < 0.37
Scope B700D – R C% < 0.50
peritectic vanadium steel
0.18 Liquid B500 ( A,B,C) WR C% < 0.22
We are here
+L L+Fe3C
Temprature (oC)
B500DWR C% < 0.22
+Fe3C
Austenite + ledeburite Cementite

+ cementite + ledeburite
Pearlite Pearlite
+Fe3C Cementite+ pearlite
+ Ferrite + Cementite
+ transformed ledeburite
Composition (wt% C) 22
Product Scope, Big Picture
We are here
https://tristatefabricators.com/metal-rolling/
Ferrous Metallorgy
Post grauate
Process Scope Dr. Abd-Alrahman Ebrahim
A.R.P.
Endless Rolling
Primary Metallurgy Secondary Metallurgy Continuous Casting Hot Rolling Mill

(EAF) (LRF) (CCM) HRM
Endless Melting
… Vision 2050 …
Nano Mill
We are here Steel
M R
Master's student
Ferrous Metallorgy
Post grauate
A.R.P.
Introduction
020-
Process description,
Benefits Statement,
Project Axes,
… Vision 2050 …
Project Objectives,
Nano Mill
Steel
M R
Master's student
Ferrous Metallorgy
Post grauate
Process History Dr. Abd-Alrahman Ebrahim
A.R.P.
Continuous casting is the process whereby liquid steel is solidified into a

semi finished product for subsequent rolling in the finish rolling mills. Continuous
casting of steel was conceived and patented in 1865 by Sir Henry Bessemer, but it
could not be commercialized because of problems related to engineering and
equipment. After solving these problems, continuous casting of steel was
introduced commercially in 1950s and around 1475 million tons of continuous
cast steel was produced globally in 2012.
Continuous casting has replaced several steps during steel making
process such as ingot casting, mould stripping, heating in soaking pits, and
primary rolling with one operation. Continuous casting of steel has helped to
achieve improved yield, quality, productivity and cost efficiency.
… Vision 2050 …
Nano Mill
Steel
M R
Master's student
Ferrous Metallorgy
Post grauate
Process Description Dr. Abd-Alrahman Ebrahim
A.R.P.
From Primary Metallurgy EAF, Liquid steel is tapped in the steel teeming ladle and
then transport to secondary metallurgy LRF, unit and is taken to the continuous casting
machine CCM . The ladle is raised onto a turret that rotates the ladle into the casting
position above the tundish . Liquid steel flows out of the ladle into the tundish, and then into
a water-cooled copper mold . Solidification begins in the mold and continues through the
roll support and the turning zone . The continuous cast strand is then straightened, and
cutting torch , cut to design length and then discharged for intermediate storage cold
charge or hot charge for finished rolling mill , HRM, or discharged for semi endless rolling
or fully Endless rolling .
… Vision 2050 …
Nano Mill
Steel
M R
Master's student
Ferrous Metallorgy
Post grauate
Process Description Dr. Abd-Alrahman Ebrahim
A.R.P.
Billet up to 200 x 200 mm ( square or round )

Bloom up to 500 either mm ( square or rectangular )
Slab up to 3000 x 320 mm (rectangular)
Billet , Bloom , Slab

… Vision 2050 …
Nano Mill
Steel
M R
Master's student
Ferrous Metallorgy
Post grauate
CCM - Models Dr. Abd-Alrahman Ebrahim
A.R.P.
… Vision 2050 …
Nano Mill
Steel
M R
Master's student
Ferrous Metallorgy
Post grauate
A.R.P.
1) V, Vertical, machine with a straight mold and cutoff in the vertical position.
2) VB, Vertical machine with a straight mold, single-point Bending and straightening.
3) VPB, Vertical machine with a straight mold, Progressive Bending and straightening.
4) CS, Bow type machine with Curved mold and Straightening.
5) CPS, Bow type machine with Curved mold and Progressive Straightening
6) H, Horizontal CC machine
… Vision 2050 …
Nano Mill
Steel
M R
Master's student
Ferrous Metallorgy
Post grauate
A.R.P.
6,H
0.0
1,V 2,VB 3,VPB 4,CS 5,CPS
s c
10m
c
s s s
c
20m s
c We are here
s
c
S : end of support length
Nano Mill
… Vision 2050 … c C : cut – off zone
Steel
30m
M R
Master's student
Ferrous Metallorgy
Post grauate
Benefits Statement Dr. Abd-Alrahman Ebrahim
A.R.P.
(1) The benefits of bar production from continuous casting round billet are as follows:
(1) dispersion of the central porosity and liquation that develops in the axial zone;
(2) and the absence of longitudinal and corner cracks at the surface of the round billet.
(2) Total reduction λΣ > 10 may be recommended to eliminate axial porosity in the continuous cast
billet and to obtain bar with dense macrostructure in longitudinal rolling.
(1) Minimization of the axial porosity in longitudinal rolling calls for increase in λΣ to 50, if that is
permitted by the plasticity of the billet.
(3) for endless rolling mill, No more need, for reheating furnace and roughing stands ,.
… Vision 2050 …
Nano Mill
Steel
M R
Master's student
Ferrous Metallorgy
Post grauate
A.R.P. Axes Prof. Dr. Taha Mattar , Prof. Dr. M. Gamal Khakifa
A.R.P.
Building Applying
Sustainable Sustainable
Communities Technology
… Vision 2050 …
Nano Mill
Steel
M R
Master's student
Ferrous Metallorgy
Post grauate
A.R.P. Axes Prof. Dr. Taha Mattar , Prof. Dr. M. Gamal Khakifa
A.R.P.
Sociology
(Human Rights)
Lean
Production
Ecology Economy
(Human Needs) (Sustainability) 4R
Green Clean
Product Process
Sustainable Communities Sustainable Technology
… Vision 2050 …
Nano Mill
Steel
M R
Master's student
Ferrous Metallorgy
A.R.P. Post grauate
Objectives Dr. Abd-Alrahman Ebrahim
A.R.P.
Adding rebars grade

B500DWR with respect
to 0.22 C% to EGY 2-262
Improve the ductility for steel
rebars grade with respect to C%, Product
“peritectic vanadium steel”
Metallurgical Process
Maximize the Endless benefits by

ejecting rolling roughing stands beside
A.R. , ejecting the re-heating furnace
Nano Mill
… Vision 2050 … Project
Scope Steel
M R
Master's student
Ferrous Metallorgy
A.R.P. Post grauate
Objectives Dr. Abd-Alrahman Ebrahim
A.R.P.
Build up a standalone, Nano Mill

Achieving , Green … Lean … Clean , GLC technology
Miximize Sustainable Manufacturing Process Effectiveness , SMPE
Minimize Social cost (Externalities)
Minimize Capital of investment , CapEx
Minimize Operation cost , OpEx
Achieving SDGs , 11 & 12
… Vision 2050 …
Nano Mill
Steel
M R
Master's student
Ferrous Metallorgy
Post grauate
A.R.P.
030- Literature review

Consequences of geometry exchange
… Vision 2050 …
Nano Mill
Steel
M R
Master's student
Ferrous Metallorgy
Post grauate
A.R.P.
… Vision 2050 …
Nano Mill
Steel
M R
Master's student
Ferrous Metallorgy
CCM Design Post grauate
principles Dr. Abd-Alrahman Ebrahim
A.R.P.
Continuous Casting has evolved from a batch process into a sophisticated

continuous process. This transformation has occurred through understanding
principles of
1- Mechanical design,
2- Heat-transfer,
3- Steel metallurgical properties and
4- Stress-Strain relationships,
to produce a product with excellent shape and quality. In recent years, the process
has been optimized through careful integration of electro-mechanical sensors,
computer-control, “electro-magnetic stirring “ and production planning to provide a
highly-automated system designed for the new millennium.
… Vision 2050 …
Nano Mill
Steel
M R
Master's student
Ferrous Metallorgy
CCM Design Post grauate
principles Dr. Abd-Alrahman Ebrahim
A.R.P.
stress-strain
Heat-transfer
relationships
Steel
Machine
metallurgical
Design
properties
CCM
Design
principles
… Vision 2050 …
Nano Mill
Steel
M R
Master's student
Ferrous Metallorgy
Post grauate
Heat-Transfer Prof. Dr. Taha Mattar , Prof. Dr. M. Gamal Khakifa
A.R.P.
Radiation
The predominant form of heat transfer in the upper regions of the secondary cooling
chamber, described by the following equation:
see the equation - 1
… Vision 2050 …
Nano Mill
Steel
M R
Master's student
Ferrous Metallorgy
Post grauate
A.R.P.
Conduction
As the product passes through the rolls, heat is transferred through the shell as
conduction and also through the thickness of the rolls, as a result of the associated
contact. This form of heat transfer is described by the Fourier Law:
… Vision 2050 …
Nano Mill
Steel
M R
Master's student
Ferrous Metallorgy
Post grauate
A.R.P.
Convection
This heat transfer mechanism occurs by quickly-moving sprayed water droplets
or mist from the spray nozzles, penetrating the steam layer next to the steel
surface, which then evaporates. This convective mechanism is described
mathematically by Newton's Law of Cooling:
… Vision 2050 …
Nano Mill
Steel
M R
Master's student
Ferrous Metallorgy
Post grauate
A.R.P.
Machine Containment Cooling

Shell Growth, Shell growth can be reliably predicted from Fick's Law:
… Vision 2050 …
Nano Mill
Steel
M R
Master's student
Ferrous Metallorgy
Post grauate
Metallurgical Length Dr. Abd-Alrahman Ebrahim
A.R.P.
This equation can be used also to calculate the casting distance (L) where the product
is fully-solidified (i.e. no liquid core remaining); solving for "L":
d = k (t) 1/2
where:
d – thickness of the solidified layer, mm
t – time, min
k – solidification coefficient, also known as the solidification rate constant, mm/min0
… Vision 2050 …
Nano Mill
Steel
M R
Master's student
Ferrous Metallorgy
Post grauate
Metallurgical Length Dr. Abd-Alrahman Ebrahim
A.R.P.
… Vision 2050 …
Nano Mill Billet , Bloom , Slab
Steel
M R
Master's student
Ferrous Metallorgy
Post grauate
A.R.P.
040- Continuous
CCM Design limits
Casting
Casting radius
Metallurgical length
Mold length
Casting speed & Casting rate
Ladle capacity
… Vision 2050 …
Billet Chemical composition & Defects
Nano Mill
Steel
M R
Master's student
Ferrous Metallorgy
Post grauate
CCM Design limits Dr. Abd-Alrahman Ebrahim
A.R.P.
Billet cross section : round/ square/ rectangular/ hexagonal/ octagonal

Billet cross section size : 80 : 200 mm
Billet length : 6 : 12 m
Casting radius : 6 : 10 m
Metallurgical length : m
Length of mold : 0.8 : 1.0 m
Ladle capacity : 25 : 160 t
Casting speed : 2.5 : 7 m/min
… Vision 2050 …
Nano Mill
Steel
M R
Master's student
Ferrous Metallorgy
CCM typical Post grauate
properties Dr. Abd-Alrahman Ebrahim
A.R.P.
Type Slab Bloom Billet

Steel Grade line pipe steel construction stee engineering steel
Ladle size (metric ton) 250 100 100
Radius (m) 9 12 10
Number of strands 2 5 6
Casting speed (m/min) 1.0 - 2.0 1.2 - 1.8 3- 7
Cross section (mm) 1200 x 230 250 x 250 160 x 160
Typical use plate, sheet , coil beams bars, wires
… Vision 2050 …
Nano Mill
Steel
M R
Master's student
Ferrous Metallorgy
Post grauate
Metallurgical length Dr. Abd-Alrahman Ebrahim
A.R.P.
Length need for fully solidified ; The relationship is given by:
L= V*(D/2K)^2
Where
V = casting speed (meter/minute)
D= Cast thickness, mm
K= 28 for square & rectangular , K= 31 for round
K= Average solidification constant for entire machine length in mm/min^.5.
The solidification constant varies considerably in the mold cooling and initial portion of the spray cooling zones, where the
shell thickness changes rapidly with machine length. It then becomes fairly constant as the shell thickness growth slows down and
solidification is eventually completed.
… Vision 2050 …
Nano Mill
Steel
M R
Master's student
Ferrous Metallorgy
Post grauate
CCM casting speed Dr. Abd-Alrahman Ebrahim
A.R.P.
50 Ca 5.0
sti
ng
sp
ee
30
ds
q. 3.0
o rr
Casting speed m/min

d.
bil
let
Casting rate t/hr

20 2.0
Continuous casting speed
t
ille
of round steel sections
.b
sq
t
ille
e
1.5
at
15
.b
gr
rd
in
st
e
at
Ca
gr
in
st
Ca
10 1.0
… Vision 2050 …
Nano Mill
Sq. or rd. section mm 0.7 Steel
7
70 100 150 200 250
M R
Master's student
Ferrous Metallorgy
Post grauate
CCM mold length Dr. Abd-Alrahman Ebrahim
A.R.P.
Mould lenght and casting speed

1400
1200
The most suitable length for a
Mould length , mm
continuous casting mold has been 1000
found to be in the range of 510 mm 800

to 915 mm, a range which seems to
600
remain constant regardless of
section size. 400
200
… Vision 2050 …
1 2 3 4 5
Nano Mill Casting speed m / min
Steel
M R
Master's student
Ferrous Metallorgy
CCM cooling Post grauate
arrangement Dr. Abd-Alrahman Ebrahim
A.R.P.
sprays around the billet surfaces are placed at the same arrangement and apply the same water flow rate.
… Vision 2050 …
Nano Mill
Steel
M R
Master's student
Ferrous Metallorgy
CCM cooling Post grauate
arrangement Dr. Abd-Alrahman Ebrahim
A.R.P.
… Vision 2050 …
Nano Mill
Steel
M R
Master's student
Ferrous Metallorgy
Chemical composition Post grauate
recommendation Dr. Abd-Alrahman Ebrahim
A.R.P.
The most elementary rules to be followed in order to optimize the steel condition to make it suitable for
Continuous casting process :
1- manganese / Sulphur ratio higher than 20 ,
( lower values would result in a low almost null hot elongation between 1100 C and 1300 C with danger of breakout)
2- manganese / silicon ratio higher than 3 especially in case of steel under 0.2 % C
( over 0.20% C the ratio can be Reduced to 2.5).
Lower values would result in more impurities due to slag formation for free oxygen acting on Mn & Si but especially
On Si due to lowering of temperature respectively between ladle – tundish – mold. Such lower ratio values can
contribute to formation of under skin defects (pinholes)
… Vision 2050 …
Nano Mill
Steel
M R
Master's student
Ferrous Metallorgy
Chemical composition Post grauate
recommendation Dr. Abd-Alrahman Ebrahim
A.R.P.
3- High Aluminum values would result in zircon nozzle plugging , the safe practical limits are As follow :-
- Calibrated nozzles : 0.002% to 0.003%

- Submerged nozzles with calibrated hole : 0.005%
- Submerged nozzles with stopper control : 0.09%
Above limits can be increased using calcium addition ( injection of CaSi in liquid path of the ladle)
That will convert aluminum to aluminates reducing .
In this way alumina content as main responsible for nozzle plugging.
The best results are obtained with aluminum / calcium ratio ranging between 0.10 to 0.15 %
… Vision 2050 …
Nano Mill
Steel
M R
Master's student
Ferrous Metallorgy
Post grauate
Billet Defects Dr. Abd-Alrahman Ebrahim
A.R.P.
Surface
defects
Chemical
Internal
composition
defects
deviation
Billet
Defects
Mechanical Shape
defects defects
… Vision 2050 …
Nano Mill
Steel
M R
Master's student
Ferrous Metallorgy
Post grauate
Billet Metallurgical Prof. Dr. Taha Mattar , Prof. Dr. M. Gamal Khakifa
Defects Dr. Abd-Alrahman Ebrahim
A.R.P.
Metallurgical defects :-
- Localized impurities in billets,
- shrinkage cavities and
- segregation may give cracks in the billets.
- Incorrect dimensions, bent, twisted or rhombic billets
All of the above can cause serious defects such as cobbles, i.e. disintegration of the bar,
during rolling. Thus, in order to improve the surface quality of the final products it is often
necessary to grind the billets before rolling. Longitudinal surface cracks are often found on
continuously cast slabs and are located in regions close to the center line of the slab
surface. They are very difficult to eliminate during subsequent hot rolling and will remain as
defects in the rolled product [8].
… Vision 2050 …
Nano Mill
Steel
M R
Master's student
Ferrous Metallorgy
Post grauate
A.R.P.
Inter columnar cracking
Centerline segregation
… Vision 2050 …
Nano Mill
Steel
M R
Master's student
Ferrous Metallorgy
Post grauate
Physical Prof. Dr. Taha Mattar , Prof. Dr. M. Gamal Khakifa
Phenomena Dr. Abd-Alrahman Ebrahim
A.R.P.
Flow
dynamics
Solidification Heat transfer
Physical
phenomena
… Vision 2050 …
Nano Mill
Steel
M R
Master's student
Ferrous Metallorgy
Post grauate
A.R.P.
Flow Dynamics
Solidification
Mold Oscillation Casting Speed Steel
Heat Transfer (thermal

Pulling Velocity Turbulence mold
properties)
Flux
Steel Grade Physical Properties Mold
ZST for Pulling Of Air , Slag , liquid Coefficient to

Velocity steel water channels
… Vision 2050 …
Nano Mill
Steel
M R
Master's student
Ferrous Metallorgy
Post grauate
A.R.P.
… Vision 2050 …
Nano Mill
Steel
M R
Master's student
Ferrous Metallorgy
Post grauate
A.R.P.
fluid-flow phenomena
inside of the strand
… Vision 2050 …
Nano Mill
Steel
M R
Master's student
Ferrous Metallorgy
Post grauate
CCM Goals Dr. Abd-Alrahman Ebrahim
A.R.P.
Quality /
performance
Casting /
Hot Rolling
Solidification
… Vision 2050 …
Nano Mill
Steel
M R
Master's student
Ferrous Metallorgy
Austenite – Martensite Applied Research Project
Post grauate
metallurgical transformation Prof. Dr. Taha Mattar , Prof. Dr. M. Gamal Khakifa
Hot rolling Dr. Abd-Alrahman Ebrahim
A.R.P.
… Vision 2050 …
Nano Mill
Steel
M R
Master's student
Ferrous Metallorgy
Post grauate
A.R.P.
050- Potential outcomes &

Optimization
GLC technology and BAT
1st Axis, Green Product , zero waste
SMPE Sustainable Manufacturing Process Effectiveness
2nd Axis, Clean Process, Zero emission
Sustainable development goals , SDGs
BEP , Externalities
3rd Axis , Productivity vs Product mix
… Vision 2050 …
Nano Mill
Steel
M R
Master's student
Ferrous Metallorgy
GLC & BAT Post grauate
Technology definition Dr. Abd-Alrahman Ebrahim
A.R.P.
Endless
0.0 5 0.0
Waste Waste Emission
4R
Green Product Lean Production Clean Process

(Recycled Material) (Lean Manufacturing) (Clean Technology)
To reduce the natural To reduce the To reduce the
resources consumption process Variation process Emission
… Vision 2050 …
Nano Mill
Steel
M R
Master's student
1st Axis Ferrous Metallorgy
Green Product Post grauate
Zero waste Axis Dr. Abd-Alrahman Ebrahim
A.R.P.
Endless
0.0 5 0.0
4R

… Vision 2050 …
Nano Mill
Steel
M R
Master's student
A.R.P.
Linear economy Reuse economy
Raw material/Energy Raw material/Energy
Production Production
Use Use
Recycling
Disposal Disposal
… Vision 2050 …
Nano Mill
Steel
M R
Master's student
A.R.P.
Circular economy
Recovery Recycle Re-use

Raw
Production Use Disposal
material/energy
… Vision 2050 …
Nano Mill Reduce
Steel
M R
Master's student
Ferrous Metallorgy
2nd Axis Applied Research Project
Post grauate
Clean Process Prof. Dr. Taha Mattar , Prof. Dr. M. Gamal Khakifa
A.R.P.
Zero Emission Axis
Endless
0.0 5 0.0
4R

… Vision 2050 …
Nano Mill
Steel
M R
Master's student
Ferrous Metallorgy
Post grauate
SMPE Prof. Dr. Taha Mattar , Prof. Dr. M. Gamal Khakifa
A.R.P.
% % % %
Net working Hr/ Prime Product/ Renewable energy/ Optimum Capacity/
Total Available time Total used material Total consumed energy Design Capacity
TUF MUF EUF PUF
‫ ھو ﻣﺑدأ اﻻﺳﺗداﻣﺔ ﻟﻘﯾﺎس اﻟﻔﻌﺎﻟﯾﺔ اﻟﺑﯾﺋﯾﺔ ﻟﻠﺗﺻﻧﯾﻊ‬SMPE
SMPE (Sustainable Manufacturing Process Effectiveness )
= x 4R x x is the sustainable principle for measuring manufacturing
eco-effectiveness
Time Utilization Material Utilization Energy Utilization Process Utilization

Factor Factor Factor Factor
@Zero Time waste @Zero Material waste @Zero emission @Optimum Capacity
rejected Typical World class
… Vision 2050 … 25% 55% 75% 90%

Nano Mill
@Zero waste Steel
@Zero emission
M R
Master's student
Ferrous Metallorgy
Post grauate
Process Prof. Dr. Taha Mattar , Prof. Dr. M. Gamal Khakifa
Capacities Dr. Abd-Alrahman Ebrahim
A.R.P.
1000K Mega Mill

500K Macro Mill
250K Micro Mill
50K Nano Mill
500K & 250K
Primary Secondary
Metallurgy Metallurgy Mega , Macro & Micro
… Vision 2050 …
Nano Mill
Steel
M R
Master's student
Ferrous Metallorgy
Post grauate
Nano Process Prof. Dr. Taha Mattar , Prof. Dr. M. Gamal Khakifa
A.R.P.
1000K Mega Mill

500K Macro Mill
250K Micro Mill
50K Nano Mill
50K
Primary Secondary
Metallurgy Metallurgy Nano Mill
… Vision 2050 …
Nano Mill
Steel
M R
Master's student
Ferrous Metallorgy
Clean Steel Applied Research Project
& EMS Post grauate
A.R.P.
technology Dr. Abd-Alrahman Ebrahim
… Vision 2050 …
Nano Mill
Steel
M R
Master's student
Ferrous Metallorgy
FCR Applied Research Project
technology Post grauate
A.R.P.
solidification cooling technology (Final Compressive cooling for Round billets: FCR)
… Vision 2050 …
Nano Mill
Steel
M R
Master's student
Ferrous Metallorgy
Post grauate
Egypt Solar Map Prof. Dr. Taha Mattar , Prof. Dr. M. Gamal Khakifa
A.R.P.
… Vision 2050 …
Nano Mill
Steel
https://commons.wikimedia.org/wiki/File:SolarGIS-Solar-map-Egypt-en.png
M R
Master's student
Ferrous Metallorgy
Post grauate
Egypt Solar Map Prof. Dr. Taha Mattar , Prof. Dr. M. Gamal Khakifa
A.R.P.
… Vision 2050 …
Nano Mill
Steel
https://commons.wikimedia.org/wiki/File:SolarGIS-Solar-map-Egypt-en.png
M R
Master's student
3rd Axis
Ferrous Metallorgy
Productivity Applied Research Project
Post grauate
Vs Prof. Dr. Taha Mattar , Prof. Dr. M. Gamal Khakifa
A.R.P.
Products Mix
Endless
0.0 5 0.0
4R

… Vision 2050 …
Nano Mill
Steel
M R
Master's student
3rd Axis
Ferrous Metallorgy
Post grauate
A.R.P.
Products Mix
… Vision 2050 …
Nano Mill
Steel
M R
Master's student
3rd Axis
Ferrous Metallorgy
Post grauate
A.R.P.
Products Mix
workforce • Highly skilled • Unskilled • Multi-skilled
Craft
Mass
Lean
• Single item • Batch & team
Criteria
• Flexible tools Queue • Synchronized
Operations • Low • Single
purpose M/C
flow
• Flexible M/C
productivity
• High quality • High • High
Tools • High cost Productivity
• Low quality
Productivity
• High Quality
• Medium cost • Low Cost
Outcome
… Vision 2050 …
Nano Mill
Steel
M R
Master's student
3rd Axis
Ferrous Metallorgy
Post grauate
A.R.P.
Products Mix
Inventory
Lean waste reduction

Transportation
Extra Processing
Over production
… Vision 2050 …
Nano Mill Handling/motion Steel
M R
Master's student
3rd Axis
Ferrous Metallorgy
Post grauate
A.R.P.
Products Mix
cost cost mass Lean cost

producer producer mass producer
Craft producer
Lean producer
mass producer
volume Quality Customization
(a) Economies Scale (b) Quality improvement (c) Mass customization

https://thesystemsthinker.com/lean-production-from-the-machine-age-to-the-systems-age/
… Vision 2050 …
Nano Mill
Steel
M R
Master's student
3rd Axis
Ferrous Metallorgy
Post grauate
A.R.P.
Products Mix
Production
Product A Changeover time Product B Production

100%
Stability level
Ra
p u
mp
mp
D
Ra
ow
n
0.0% Down time Time
… Vision 2050 …
Nano Mill
Steel
M R
Master's student
Product mix Ferrous Metallorgy
Vs Post grauate
Productivity Dr. Abd-Alrahman Ebrahim
A.R.P.
1000K Mega Mill

500K Macro Mill
250K Micro Mill
100K Nano Mill
ATUM Nano Mill
Intermediat Mill Finishing Mill

Finishing Mill Intermediat Mill Quenching
Heater Induction Heater Induction Re-bars, Cooling Bed
Profiel Cooling Bed Quenching
100K
… Vision 2050 …
Nano Mill
Steel
M R
Master's student
Ferrous Metallorgy
Post grauate
SDGs A.R.P.
‫اھداف اﻗﺗﺻﺎدﯾﺔ‬
‫اھداف ﻣﺟﺗﻣﻌﯾﮫ‬
(Human Rights)
‫اھداف ﺑﯾﺋﯾﺔ‬
(Human Needs)
‫اھداف ﺗﻧظﯾﻣﯾﮫ‬
… Vision 2050 …
Nano Mill
Steel
M R
Master's student
Ferrous Metallorgy
Post grauate
Social cost Prof. Dr. Taha Mattar , Prof. Dr. M. Gamal Khakifa
externalities Dr. Abd-Alrahman Ebrahim
A.R.P.
Price
False
Brown Price
Faithful
Green Price
Fake Profit
Brown Price An external cost is the cost incurred by an
Profit individual, firm or community as a result
Profit Cost Structure of an economic transaction which they
= +(Private RnD Cost Structure are not directly involved in. External
Cost) = Eco Social costs, also called 'spillovers' and 'third
Cost Structure (3) party costs' can arise from both
Cost = production and consumption.
= +(Private +(External ((Private) +
Cost) Cost) (External))
(1) (2)
(4)
cost
- (External Non-Considered
Cost) Cost
… Vision 2050 …
(Paid by Society )
Nano Mill
https://www.researchgate.net/publication/331064849_MODIFICATION_OF_BILL
Steel
ET_CONTINUOUS_CASTING_MACHINE_FROM_SQUARE_TO_ROUND_GEOMETRY
M R
Master's student
Ferrous Metallorgy
Q…From Post grauate
Equilibrium To Optimum Dr. Abd-Alrahman Ebrahim
A.R.P.
P P [-ve production externalities]

P [+ve consumption externalities]
[Firm Break even point Quantity]
Revenue
Benefit Supply
(private cost + external cost) Welfare
cost Welfare
loss l co
st) (ex
t e rn gains
Supply
Profit
n a al b
Supply
x ter Supply en
efi (private cost)
(private cost) (e (private cost) ts) MPC=MSC
Pop optimum optimum
Peq equilibrium equilibrium equilibrium Profit
Firm
Social value PM
(private value+ external benefits) (BEP) Variable
Cost
demand demand demand
(private value) (private value) (private value) Loss Fixed
MPB=MSB Cost
Q Market Q Q optimumQ Market

Q Q Market Q optimum
Q Firm
Quantity Sold
Quantity Over-production Quantity Under-consumption
supplied consumed
… Vision 2050 …
Nano Mill
Steel
M R
Master's student
Ferrous Metallorgy
Post grauate
Social cost Prof. Dr. Taha Mattar , Prof. Dr. M. Gamal Khakifa
externalities Dr. Abd-Alrahman Ebrahim
A.R.P.
… Vision 2050 …
Nano Mill
Steel
M R
Master's student
Ferrous Metallorgy
Post grauate
A.R.P.
Conclusion
060-
… Vision 2050 …
Nano Mill
Steel
M R
Master's student
Ferrous Metallorgy
Liquid steel scope of Post grauate
Carbon percentage Dr. Abd-Alrahman Ebrahim
A.R.P.
monotechtic
Fe3CI
Fe3CII Fe3CII Fe3CI
Hypo-eutectic Hyper-eutectic
Nano Mill Crystal structure Fe3CIII Fe3CII Fe3CII Fe3CI

Steel
0.17: 0.18 M R
C
Master's student
Hesham Saad 91
Ferrous Metallorgy
Post grauate
A.R.P.
Primary differences between the low carbon and peritectic grades are listed:
The primary metallurgical reasons for higher production cost for this 0.11-0.16%C
(hypo-peritectic) micro-alloyed steel grades compared to low carbon micro-alloyed grades
relate to negative implications at the steelmaking, casting and hot rolling steps of the
process. Costs can be assigned to each item through application of the previously described
TABC methodology. The list compares the low carbon to the peritectic carbon grade based
upon actual operational costs. Primary differences between the low carbon and peritectic
grades are listed:
… Vision 2050 …
Nano Mill
Steel
M R
Master's student
Ferrous Metallorgy
Post grauate
A.R.P.
1. Differences in solidification behavior during continuous casting

2. Casting requires tighter control of primary and secondary cooling for peritectic due to heat flux
differences
3. Increased slab conditioning with peritectic grades due to uneven surface
solidification resulting in a variable equiaxed chill zone closer to the surface compared to low
carbon micro--alloyed grades
4. Maximum austenite grain size occurs in the 0.11-0.16%C range
5. Surface quality generally worsens in hot roll product
… Vision 2050 …
Nano Mill
Steel
M R
Master's student
Ferrous Metallorgy
Post grauate
A.R.P.
6. Increased slab scarfing and potential to open cracks in peritectic grades

7. Often peritectic grades are normalized heat treated to homogeneous grain size, but not
necessary in low carbon grades (eliminate heat treatment)
8. Grain size and mechanical property variability across the width and through the thickness
9. Peritectic grades are cast at slower speeds affecting productivity by as much as 10-20%
10. Increase in number of transition slabs and potential downgrades
11. Peritectic grades tend to exhibit more internal and centerline segregation, especially as Mn
levels increase
… Vision 2050 …
Nano Mill
Steel
M R
Master's student
Ferrous Metallorgy
Liquid steel scope of Applied Research Project
Post grauate
A.R.P.
Continuous Casting
Tliquid = 1 536 – K·(%C) – 8·(%Si) – 5·(%Mn) – 30·(%P) – 25·(%S) – 1,7·(%Al) – 5·(%Cu) – 1,5·(%Cr) – 4·(%Ni) – 2·(%V) – 1·(%W) – 1,7·(%Co) – 12,8·(%Zr) – 7·(%Nb) – 3·(%Ta) – 14·(%Ti) – 14·(%As) – 10·(%Sn)
where the K coefficient varies with respect to different contents of carbon C ≤ 2 %; K = 65
C ∈ (0,2; 0,5⟩ %; K = 88
… Vision 2050 …
Nano Mill
Steel
M R
Master's student
Ferrous Metallorgy
Austenite – Martensite Applied Research Project
Post grauate
Hot rolling Dr. Abd-Alrahman Ebrahim
A.R.P.
… Vision 2050 …
Nano Mill
Steel
M R
Master's student
Ferrous Metallorgy
Post grauate
CCM casting speed Dr. Abd-Alrahman Ebrahim
A.R.P.
50 Ca 5.0
Mould lenght and casting speed sti
ng
1400 sp
ee
1200 30
ds
q. 3.0
o rr
Casting speed m/min

d.
bil
Mould length , mm
1000 let
Casting rate t/hr

800
20 2.0
600
t
ille
.b
sq
t
ille
400
e
1.5
at
15
.b
gr
rd
in
st
e
200
at
Ca
gr
in
st
Ca
1 2 3 4 5
10 1.0
Casting speed m / min
… Vision 2050 …
Nano Mill
Sq. or rd. section mm 0.7 Steel
7
70 100 150 200 250 M R
Master's student
Ferrous Metallorgy
Post grauate
A.R.P.
6,H
0.0
1,V 2,VB 3,VPB 4,CS 5,CPS
s c
7m
10m c
s s s
c
20m s
c
s
c
S : end of support length
Nano Mill
… Vision 2050 … c C : cut – off zone
Steel
30m
M R
Master's student
Ferrous Metallorgy
Post grauate
Process develop Dr. Abd-Alrahman Ebrahim
A.R.P.
Productivity ( casting speed)
Quality (low head , low stress)
Quality ( float-off inclusions & gas bubbles)
VB VPB C
V
… Vision 2050 …
Nano Mill
Steel
M R
Master's student
Ferrous Metallorgy
Post grauate
A.R.P.
Defects in quality are therefore restricted to , surfaces defects including cracking, possible
internal cracks and inclusions derived from non-metallic particles carried in the molten metal.
… Vision 2050 …
Nano Mill
EMS Steel
M R
Master's student
Ferrous Metallorgy
Post grauate
A.R.P.
An industrial plant trial for optimizing the process parameters in a round billet
continuous casting mold with electromagnetic stirring (M-EMS) was performed, in which
the influences of stirring parameters with M-EMS on the solidification macrostructure of
high carbon steel were investigated.
The macroscopic qualities of round steel billets with M-EMS for different stirring
parameters were tested by industrial plant trials.
M-EMS as a good casting technique has a significant effects for improving the
whole quality of high carbon steel and promoting the final product performance.
Optimum stirring parameters of M-EMS is important for playing its full role.
… Vision 2050 …
Nano Mill
Steel
M R
Master's student
Ferrous Metallorgy
M-EMS mold Post grauate
electromagnetic stirring Dr. Abd-Alrahman Ebrahim
A.R.P.
Increased casting productivity, especially with the introduction of high speed billet
casting (HSBC), re-emphasized the importance of high performing mold electromagnetic
stirring (M-EMS) in attaining the targets of productivity and product quality. To provide
operating flexibility and to enhance metallurgical performance, adapting M-EMS design to the
requirements of casting practice with either the open stream pouring or submerged entry
nozzle (SEN) has become critical. In that context, it is especially important to assess the effects
of EMS design parameters that control stirring velocity in the meniscus region and the rest of
the mold. Such a control is the key to EMS compatibility with the continuous casting practice
and its high metallurgical performance
… Vision 2050 …
Nano Mill
Steel
M R
Master's student
Ferrous Metallorgy
Post grauate
Benefits Statement Dr. Abd-Alrahman Ebrahim
A.R.P.
The benefits of bar production from continuous cast round billet are as follows:
(1) Decrease in central porosity and segregation in the axial zone ;
(2) Improvement in the surface quality of the round due to the absence of longitudinal and
corner cracks.
(3) To ensure the closure of axial pores in continuous-cast semifinished products and obtain a
rolled section with a dense macrostructure, during longitudinal rolling it is necessary to keep
the total elongation at λΣ > 10
(4) To minimize axial porosity during longitudinal rolling, total elongation needs to be increased
to λΣ = 50 provided that the ductility of the continuous-cast semifinished products is sufficient
to allow them to be rolled with such a level of deformation.
(5) No need for reheating furnace and roughing stands , for endless rolling mill.
… Vision 2050 …
Nano Mill
Steel
M R
Master's student
Ferrous Metallorgy
Post grauate
A.R.P.
Inter columnar cracking
Centerline segregation
… Vision 2050 …
Nano Mill
Steel
M R
Master's student
Ferrous Metallorgy
Post grauate
A.R.P.
Vanadium – V is a ferrite promoter and carbide and nitride former. It acts as a

scavenger for oxides, forms vanadium carbide (VC), and has a beneficial effect on the
mechanical properties of heat treated steels, especially in the presence of other elements. It
slows up tempering in the range of 500 deg C to 600 deg C and can induce secondary hardening.
Cr-V (0.15 %) steels are used for locomotive forgings, automobile axles, coil springs, torsion bars
and creep resistance.
V increases the yield strength and the tensile strength of C steel. The addition of small
amounts of V can considerably increase the strength of steels. V is one of the primary contributors to
the precipitation strengthening in micro-alloyed steels. When thermo-mechanical processing is
properly controlled, the ferrite grain size is refined and there is a corresponding increase in
toughness. The impact transition temperature also increases when V is added
… Vision 2050 …
Nano Mill
Steel
M R
Master's student
Ferrous Metallorgy
Post grauate
A.R.P.
V increases the hardness of martensitic steels due to its effect on the type of carbide
present. It also increases tempering resistance. V stabilizes ferrite and at high contents, it promotes
ferrite in the structure. It is only used in hard enable stainless steels. It retards grain growth within
steel even after long exposures at high temperatures , and helps to control grain structures while
heat treating. It is normally present in small quantities of 0.15 % to 0.2 %. Most of the tool steels
which contain this element seem to absorb shock better than those which do not contain V.
V contributes to wear resistance and hardenability. As carbide former, it helps produce

fine-grained steel. V being a strong carbide forming element has a scavenging action and produces
clean, inclusion free steels.
… Vision 2050 …
Nano Mill
Steel
M R
Master's student
Ferrous Metallorgy
Post grauate
A.R.P.
https://www.ispatguru.com/automation-instrumentation-and-modelling-of-continuous-casting-of-steel/
… Vision 2050 …
Nano Mill
Steel
M R
Master's student
Ferrous Metallorgy
Post grauate
A.R.P.
https://link.springer.com/article/10.1007/s11015-014-9818-1
… Vision 2050 …
Nano Mill
Steel
M R
Master's student
Ferrous Metallorgy
Post grauate
A.R.P.
070- Conflicts of interest

!!!
… Vision 2050 …
Nano Mill
Steel
M R
Master's student
Ferrous Metallorgy
Post grauate
A.R.P.
No conflict of interest was founded by student
… Vision 2050 …
Nano Mill
Steel
M R
Master's student
Ferrous Metallorgy
Post grauate
A.R.P.
080- References
… Vision 2050 …
Nano Mill
Steel
M R
Master's student
Ferrous Metallorgy
Post grauate
A.R.P.
Slide 08 https://abmproceedings.com.br/en/article/download-pdf/production-comparison-of-microalloyed-peritectic-and-low-carbon-structural-flat-and-long-products
Slide 13 https://www.ispatguru.com/basics-of-continuous-casting-of-steel/
Slide 16 https://www.ispatguru.com/defects-in-continuous-cast-steels/
Slide 17 https://link.springer.com/content/pdf/10.3103%2FS0967091214120109.pdf
Slide 20 https://www.ispatguru.com/historical-aspects-of-the-continuous-casting-and-related-technologies-for-steel/
Slide 18 https://gajendrak.weebly.com/
Slide 24 https://link.springer.com/article/10.1007/BF03398119?noAccess=true
https://www.ispatguru.com/heat-transfer-during-continuous-casting-of-steel/
https://www.mdpi.com/2075-4701/11/9/1380/htm
Slide 33 https://link.springer.com/article/10.1007/s11015-014-9818-1
https://www.sciencedirect.com/science/article/abs/pii/S0924013615001259
… Vision 2050 …
Nano Mill
Steel
M R
Master's student
Ferrous Metallorgy
Post grauate
A.R.P.
Slide 33 https://professor.luzerna.ifc.edu.br/charles-assuncao/wp-content/uploads/sites/33/2016/07/Improvement-in-secondary-cooling-of-continuous-casting-of-round-
billets-through-analysis-of-heat-flux-distribution.pdf
Slide 37 https://www.researchgate.net/post/How-can-I-calculate-the-Metallurgical-length-of-a-continuous-casting-simulation-in-ANSYS-FLUENT
Slide 39 https://www.ispatguru.com/continuous-casting-mould/#:~:text=The%20most%20suitable%20length%20for,constant%20regardless%20of%20section%20size.
Slide 41 https://www.mdpi.com/2075-4701/11/9/1380/htm
Slide 64 https://www.nipponsteel.com/en/tech/report/pdf/124-17.pdf
Slide 77 https://www.researchgate.net/publication/248570569_Effect_of_electromagnetic_stirring_in_mold_on_the_macroscopic_quali
ty_of_high_carbon_steel_billet
Slide 83 https://www.sciencedirect.com/topics/engineering/electromagnetic-stirring
Slide 84 https://www.sciencedirect.com/science/article/abs/pii/S0008443399000257
… Vision 2050 …
Contamination by oxygen
Nano Mill
Another possibility to heat steel in a ladle is chemical heating Steel
M R
Master's student
Ferrous Metallorgy
Post grauate
A.R.P.
https://link.springer.com/article/10.1007/s00339-022-05257-x
Slide 85
https://onlinelibrary.wiley.com/doi/full/10.1002/srin.201400281
Slide 99 https://www.ispatguru.com/alloying-elements-and-their-influence-on-properties-of-steel/
… Vision 2050 …
Nano Mill
Steel
M R
Master's student
Ferrous Metallorgy
Post grauate
A.R.P.
Technology , and (Sustainability 5P’s, Criteria)
People Peace Partnership Planet Prosperity

Human Rights & Human Needs & Continuous GLC, Science & Knowledeg
Social Justice Ecologicall Justice Improve&Develope Green Lean Clean
… Vision 2050 …
Nano Mill
Think Steel … Act Sustainable Steel
M R
Master's student
Ferrous Metallorgy
Post grauate
A.R.P.
… Vision 2050 …
Nano Mill
Steel
M R
Master's student

Applied Research Project

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Ferrous Metallorgy

002- Title of the Project

Studying of various factors impact on casting minimum round – cross section

Studying of various factors impact on casting minimum round – cross section

Copper mold geometry

Nano Mega Mill Copper

I wish to express a grateful Acknowledgements and deep appreciation for

I also wish to express a grateful Acknowledgements and deep appreciation for

I also wish to express a grateful Acknowledgements and deep appreciation for

Zero Emission is The Real Mission

… Vision 2050 … Zero Waste Zero Discharge

006- A.R.P. Scope

… Vision 2050 … A.R.P.

010- Scope of The A.R.P.

B500DWR C% < 0.22

Austenite + ledeburite Cementite

Primary Metallurgy Secondary Metallurgy Continuous Casting Hot Rolling Mill

Continuous casting is the process whereby liquid steel is solidified into a

Billet up to 200 x 200 mm ( square or round )

Billet , Bloom , Slab

4) CS, Bow type machine with Curved mold and Straightening.

Adding rebars grade

Maximize the Endless benefits by

Build up a standalone, Nano Mill

030- Literature review

Continuous Casting has evolved from a batch process into a sophisticated

Machine Containment Cooling

Billet cross section : round/ square/ rectangular/ hexagonal/ octagonal

Type Slab Bloom Billet

Typical use plate, sheet , coil beams bars, wires

Length need for fully solidified ; The relationship is given by:

Casting speed m/min

Casting rate t/hr

Mould lenght and casting speed

found to be in the range of 510 mm 800

- Calibrated nozzles : 0.002% to 0.003%

Inter columnar cracking

Solidification Heat transfer

Heat Transfer (thermal

Steel Grade Physical Properties Mold

ZST for Pulling Of Air , Slag , liquid Coefficient to

050- Potential outcomes &

Green Product Lean Production Clean Process

Green Product Lean Production Clean Process

Linear economy Reuse economy

Raw material/Energy Raw material/Energy

Recovery Recycle Re-use

Green Product Lean Production Clean Process

Time Utilization Material Utilization Energy Utilization Process Utilization

rejected Typical World class

… Vision 2050 … 25% 55% 75% 90%

1000K Mega Mill

500K & 250K

1000K Mega Mill

Green Product Lean Production Clean Process

workforce • Highly skilled • Unskilled • Multi-skilled

Lean waste reduction

cost cost mass Lean cost

volume Quality Customization

(a) Economies Scale (b) Quality improvement (c) Mass customization

Product A Changeover time Product B Production

1000K Mega Mill