The development and implementation of a prototype to improve the current maintenance procedure applied to the SIS, Safety Instrumented System, of the raw materials and products conveyor belts of the Coke Plant operational unit of CST are reported. Due to the continuous mode of operation, currently protection switches can only be inspected visually, which does not ensure a perfect operation. The aim of this new tool is to allow the online inspection and testing of the safety switches without interfering with the production and to maintain its functionalities.

EMF in a blast furnace can be used to predict liquid level variations into the hearth. After the strong influence of some process parameters has been minimized, the variation of the EMF at the end of consecutive castings can be used as a criterion of liquid level variations. Currently this criterion is integrated in a mathematical model that sends messages to an on-line advisory tool.

The background of the development of the BRP technology (Baosteel BOF Refining Process) is presented along with the experimental conditions and results. The relations between dephosphorization and basicity of slag, bottom blowing, temperature at end point are analyzed. The effects on dephosphorization of bottom blowing, total iron of slag and silicon content in hot metal are also considered. The performance results indicate that, in the de-P converter and the de-C converter respectively, the dephosphorization efficiency is over 84% and 64% with phosphorus contents below 0.014% and 0.005%. Steels that are difficult to elaborate, such as tire corded or X 65 pipeline steel with HIC-resistance benefit from the BRP technology in Baosteel.

The application of finite element techniques to modelling the long products rolling process, the use of a customized interface to enable the rapid set-up of sequential simulations, and the benefits that have been obtained are described. The paper also discusses the enhancements to incorporate a design of experiments/design optimisation module and to enable material tracking.

The performance of lubrication systems for cold double reduction rolling has been investigated. Pilot mill trials have been achieved with direct and recirculated emulsion application as well as with pure oil to analyse the effect of lubrication by emulsion on role bite friction and the associated speed effect. It is then attempted to define an optimized lubrication system that combines the advantages afforded by the direct and recirculated application systems.

The structural durability of welded structures is determined by the interaction of different influencing parameters like loading mode, spectrum shape, residual stresses and weld geometry among others. Examples from plant, offshore, transportation and automotive engineering show how these parameters influence the fatigue life and to what extent they are considered in design codes.