Focus on Research

CMU Center forIron and Steelmaking__________ R.J. Fruehan

Director CISR, Carnegie-Mellon University

The Center for Iron and Steelmak­ing Research (CISR) was recently es­tablished at Carnegie-Mellon Univer­sity. The Center is a University/Industry Cooperative Research Cen­ter deriving support from the Na­tional Science Foundation (NSF) , thestate of Pennsylvania, and the in­dustrial members of the Center.

Due to the severe economic condi­tions affecting the American steelindustry, there has been a decreasein the resources available forresearch. In particular, basic longterm research has decreased signifi­cantly in the last five years. To alle­viate the difficiency in basic research,steel companies have organized coop­erative ventures such as that withthe National Laboratories. In addi­tion to these efforts, CISR was es­tablished to perform cooperativefunded research at Carnegie-MellonUniversity for the government andindustrial members.

In late 1983, CMU received a$50,000 grant from NSF to studythe feasibility of establishing a coop­erative center for basic research insteelmaking. After visits to severalsteel, and related, companies, an or­ganizing meeting was held at CMUin June of 1984. From the results ofthis meeting, the Center organiza­tion and research program wasdeveloped. A proposal was submit­ted to the NSF, and participationfrom interested companies wassolicited. The NSF proposal was ac­cepted and a five-year grant of$450K was rece ived. In addition, theCenter also received a grant of $40Kthe first year from the Ben Frank­lin Program of the State of Pennsyl­vania. As of June first , fourteencompanies joined the Center. The yinclude: Allegheny Ludlum SteelCompany; Bethlehem Steel Com­pany; Center for Metals Production;Ellwood City Forge; G.M. CentralFoundry ; Inland Steel Company;LTV Steel Company; Midrex Corpora­t ion; Cyclops Corporation; UnionCarbide Linde Division; ScientificSystems Services; Timken Company;U.S. Steel; and Weirton Steel. Theultimate goal for company member­ship is about twenty.

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Members pay annual fees rangingfrom $15K to $30K depending onthe type of facilities the companyoperates. The total funding for thefirst year is about $500K (approxi­mately 65% from industry and 35%from government). The Center hassix faculty members doing research,supports six graduate students anda full-time Senior Research Associ­ate (Ph.D).

The Center's objective is to con­duct basic research relevant to ironand steelmaking. The Center is or­ganized to be responsive to industry.Therefore, an Industrial Advisoryboard, made up of one member fromeach company, approves and recom­mends research programs, budgetsand Center policies. In addition, eachresearch project has Research Moni­tors and each member may have aMonitor on any project. The com­panies receive royalty-free use of anypatents, semi-annual progress re­ports, and review all papers prior topublication.

Research programs are ofteninterdisciplinary, using faculty fromthe Chemical Engineering, Electri­cal and Computer Engineering, andthe Metallurgical and Materials Sci­ence Engineering Departments.Currently, there are eight on-goingresearch programs. They are rough­ly divided into three categories:Ironmaking, Refining, and Casting.

In ironmaking, research is beingcarried-out on the change of struc­ture of pellets and factors affectingthese changes during reduction. Thereduction of pellets is strongly af­fected by it s structure. If the struc­ture can be controlled or predictedby the performance of a blastfurnace , or a direct reduction shaftfurnace, it can be improved. Thisresearch is being conducted by Dr.K. Li. Dr . H. Henein is investigat­ing the interaction between parti­cles and hot gas jets and plasmas.Many of the new and proposedironmaking processes involve the re­action of oxides or the melting ofiron in hot gas jets or electricallygenerated plasmas. The fluid dynam­ics, heat transfer and mass transfergreatly effect these reactions.

In the refining area, R.J. Fruehanand RLL. Guthrie, a Visiting Pro­fessor to the Center from McGillUniversity, are working on fluid flowand mass transfer in gas stirredladles. The process is being physical­ly and mathematically modeled andthermodynamic boundary conditionsare being applied. RJ. Fruehan, Dr.B. Ozturk, and Dr. F. Tsukihashiare examining certain aspects of re­fining reactions during hot metaltreatments. In addition, novel andimproved methods of dephosphoriza­tion of iron and iron-chromium al­loy are being studied.

In the area of continuous casting,two projects are currently underway.Professors D. Henein and L. Bieglerare st udy ing optimization, heattransfer and solidification duringhorizontal continuous casting. Pro­fessor J . Hoburg is studying the elec­tromagnetic containment of steelduring casting operations.

Further research programs underconsideration include the removal oftramp elements from melted scrap,new ironmaking processes, and newsecondary refining processes. For fur­ther information contact the CenterDirector, RJ. Fruehan of the Metal­lurgical Engineering and MaterialsScience Department of Carnegie­Mellon University, 3325 Wean Hall,Pittsburgh, Pennsylvania 15213;telephone (412) 578-2677.If you want more Information on this subject,please circle reader service card number 49.

Courtesy of Befhlehem Stee l