Technical Session
9/3/24, 8:35 AM - 9/3/24, 9:00 AM
Presenter(s): BRAULO SILVANO HEMÉTRIO (usiminas), Ricardo Israel do Couto (usiminas), Reginaldo Leandro de Paula (USIMINAS), Ramon Alvares Ricardo (convaço), Cesar Almeida Assis (rhimagnesita), Bruno Geraldo Godoi de Oliveira (RHIMAGNESITA)
Abstract:
The refractory industry and the steel sector have been developing versatile and automated methods for refractory repair and installation in torpedo ladle car. Following this trend, Usiminas is directing efforts towards improving refractory lining performance. In this work, we introduce a new concept refractory hybrid linings. This approach replaces part linig the brick with a monolithic concrete applied via shotcrete and incorporates laser scanning for quick and accurate wear diagnosis, thereby improving maintenance efficiency. The results obtained are related to the refractory specific consumption profile and the reduction in brick consumption.
Technical Session
9/3/24, 8:35 AM - 9/3/24, 9:00 AM
Presenter(s): TIAGO CAIXETA NUNES (VALE SA), Cristiano Citi Ottoni (IHM Stefanini), Mário Vinícius Pelegrini Guimarães (vale sa), Eric Guimarães Vieira (vale sa), José Márcio Donádio Ribeiro (vale sa), Thiago Fernandes Pantuza Moura (vale sa), Marcelo de Andrade Aguilar (vale sa), Guilherme Gouveia Cordeiro (vale sa)
Abstract:
The adaptive control of the homogenization yard rate integrated with the plant feed tripper automatism aims to equalize the mass required by the plant with the homogenization yard. This solution aims to minimize bottlenecks by avoiding line stops due to a low level of the screening silo, in addition to minimizing tripper stops due to a high tripper level switch, respecting operational limits and avoiding manual interventions in controlling the yard's feed. This control enabled a 60.2% reduction in line stop times per low silo level, from an average of 113 minutes to 45 minutes of stops per day, in addition to a 6.3% increase in the average silo level. This solution also provides less variability in the flotation feed, which contributes to the adherence of the quality of the direct reduction pellet feed.
Technical Session
Unlocking Manufacturing Efficiency: Harnessing the Power of Digital Twins in SKU Quality Production Analysis
Presenter(s): Edgar Marcos Ancioto Junior (enacom), Willian Félix Souza e Silva (ENACOM), Geraldo José Duarte (GJD Consulting), Matheus de Oliveira Mendonça (ENACOM), GUSTAVO RODRIGUES LACERDA SILVA (ENACOM), DOUGLAS ALEXANDRE GOMES VIEIRA (ENACOM)
Abstract:
This study investigates the prevalence and characteristics of over-quality instances within the SKU production process. Through comprehensive analysis, the study identifies patterns and trends in equipment usage, over-quality occurrences, production counts, and equipment maintenance outages across different months. The primary objective is to understand the occurrence of over-quality situations within the production process. Results unveil significant variations in over-quality occurrences, with certain months exhibiting higher concentrations. Proposed solutions involve diversifying the SKU mix to mitigate dependency on heavily demanded equipment vulnerable to disruptions.
Technical Session
9/3/24, 8:35 AM - 9/3/24, 9:00 AM
Presenter(s): Mariá Tanara Reis (UFRGS), Célia de Fraga Malfatti (UFRGS), PEDRO JUAREZ MELO (UFRGS)
Abstract:
This work investigated the influence of aluminum (Al) and copper (Cu) on the formation of gum in Brazilian automotive gasoline. There is data in the literature about the influence of other metals as catalysts for the gasoline oxidation reaction, a frequently cited example is copper. Samples were prepared with concentrations of 1mg/L and 2 mg/L of copper and aluminum in gasoline, separately, and a sample was evaluated with the two elements, which were storage at a temperature of 22±3ºC for a period of 15 and 30 days. After that, the formed gum was analyzed and quantified according to the ASTM D381 standard. The results were evaluated with the ANOVA statistical tool and demonstrate a great influence of the metal concentration factor, while the time factor had no relevant effect under the conditions studied. Furthermore, it was also observed that, when present in the same solution, they can further increase this effect.
Technical Session
REDUCTION IN ANTI-FOAM CONSUMPTION AND IMPROVEMENT IN THE QUALITY OF TREATMENT IN BLAST FURNACE GAS WASHING SYSTEM THROUGH SOLENIS ANTISPUMIN SP TECHNOLOGY
Presenter(s): Raphael Vilela Brigagão (Solenis especialidades químicas LTDA), Kassia Felix Faria (SOLENIS ESPECIALIDADES QUÍMICAS LTDA), Pedro henrique bordão moreira (SOLENIS ESPECIALIDADES QUÍMICAS LTDA), andre teodoro coelho moreira pinto (SOLENIS ESPECIALIDADES QUÍMICAS LTDA), douglas nicolini alves cruz (SOLENIS ESPECIALIDADES QUÍMICAS LTDA)
Abstract:
This study investigated the efficiency of applying defoamer in the treatment of Blast Furnace charcoal gas wash water. The results demonstrated the efficiency of Solenis Antispumin SP technology, including improved foam reduction, significant reduction in dosage and consumption, as well as gains in sustainability and safety. The suitability of the defoamer highlighted the importance of technological innovation to optimize industrial processes, promoting more efficient and sustainability-oriented production.
Technical Session
The microstructural signature of cast irons from Ipanema Ironworks
Presenter(s): lucas camargo pedroso (Universidade de Sao Paulo), bruno nacsa (universidade de são paulo), daniel luis rodrigues junior (Universidade de são paulo), andre paulo tschiptschin (universidade de sao paulo), fernando jose gomes landgraf (universidade de sao paulo)
Abstract:
Fourteen cast iron objects manufactured in Brazil in the 19th century were analyzed, in search of evidence that could discriminate those produced at the Ipanema Iron Factory. Chemical analyzes using energy dispersive X-ray spectroscopy (EDS) of areas of 2mm2 and analyzes of titanium and vanadium carbides found in almost all samples were used. The very low manganese content of the five objects guaranteed to be made in Ipanema was the main discriminator. The proportion between titanium and vanadium contents of carbides can be used, but with less differentiation power. Based on the results of the Ipanema samples, it was possible to discuss the technological evolution experienced in that enterprise and provided the opportunity to discuss the beginning of the systematic use of manganese in cast iron around the world.
Technical Session
FROM QUANTITY TO QUALITY: THE EVOLUTION OF WIRE ROD PRODUCTION AND THE SMS group ANSWER ON TODAY’S MARKET REQUIREMENTS
Presenter(s): gustavo melo bretz (sms group metalurgia do brasil ltda)
Abstract:
The global steel market has undergone several changes over the last ten years, evolving from massive production in the 2010-2015 period, to a sectorized production based on quality products in the years that have followed, allowing producers to carve out new market niches. Throughout these years, SMS has redefined and modernized its machinery and process portfolio to ensure the possibility of obtaining state-of-the-art equipment from a mechanical and electrical point of view for the market, using automation as the core of its process and following the guidelines of Industry 4.0. The SMS group has been focusing its attention on several fronts, with particular regard to the MEERdrive® finishing blocks, taking care of the rolling process, rapid production changeovers divided by product families and treated steels, and introducing the MEERdrive®PLUS high-speed finishing/sizing block. This has been integrated into the multiloop process, where low temperature rolling takes place following thermo-mechanical treatment of the wire rod with the latest generation Meerbox® cooling boxes. Particular emphasis has been placed on the high-efficiency cooling elements thanks to the low water consumption, the latest generation of laying heads, for a perfect coil formation with reduced wear on the laying pipes and the absence of vibrations in the pipe itself. Furthermore, the SMS group has also focused on the LCC® cooling conveyor, where the 3-fan 3-dimensional air-conveyor system has become a key element for in-line heat treatments on wire rods, together with the rotary distributor with combined lowering device and shear in the forming pit that provide additional solutions for customers, by ensuring compact wire formation, customizing the coil weight in endless and/or traditional rolling, as well as finishing systems on hooks, on trestles or into an H/V hybrid solution. To ensure the completeness of the process, the SMS group also worked on the final roll compacting and tying equipment, which has been converted from hydraulic to electric, involving Level 1 and 2 automation and control, further implemented with Level 3 and 4 for the utmost automatic and repeatable management of different work situations, on new plants but more so on existing ones. The evolution has been evident with a continuous and growing interest in the integrated CCT® 4.0 system, where technology, process and automation have been incorporated into a single software that is able to ensure multiple types of heat treatments on the wire rod and hence help operators to optimize consumptions, pre-loaded equipment and output recipes capable of working both in-line and off-line. This has allowed a drastic reduction in the costs of improper manual handling, associated with errors accidentally caused by operators when checking the acceptable temperatures and treatments on quality and special steels.
Technical Session
ADVANCED SOLUTIONS FOR LONG ROLLING MILLS
Presenter(s): Carlos Henrique Catanha (Primetals Technologies Brazil), Matthew Anderson (Primetals Technologies LLC), Delio Amorim (Primetals Technologies LLC)
Abstract:
The steel industry has traditionally emphasized the enhancement of production, yield, and quality as key objectives. With the recent advent of digital and smart technologies, however, new targets have emerged as priorities. Notably, stakeholders now place significant emphasis on safety, hands-off solutions, reliable processes, predictive maintenance, and green solutions. In response to these evolving demands, Primetals Technologies has developed a suite of advanced solutions tailored for long rolling mill applications. This paper aims to showcase Primetals Technologies latest advanced solutions and their potential to improve efficiency, sustainability, and profitability within the steel industry.
Technical Session
9/3/24, 8:35 AM - 9/3/24, 9:00 AM
Presenter(s): BRENO TOTTI MAIA (LUMAR METALURGICA LTDA), Amilton Carlos Pinheiro Cardoso Filho (GERDAU), Ana Luiza Lisboa Barbosa (UFMG), Eric Novaes de Almeida (GERDAU), Juan Pedro Pereira Sales Gargano (GERDAU), Leandro Rocha Lemos (UFMG), Ketlen Lorraine Martins Maciel da Silva (IFMG), Rômulo Avelino da Costa Viana (UFMG), Rafaela Cardoso da Silva (UFMG), Luiz Henrique Lara de Vasconcelos (UFMG)
Abstract:
This article makes a comparison between articles from the 70s and 80s that guided the lance height calculation models of many BOF converters around the world. In the current version, the condition of the lance touching the metallic bath was maintained, but applied to secondary hole for jet coherency. The results show a great penetration considering only the liquid phase for the jet and allowed comparing and analyzing proposed equations over these two periods.
Technical Session
9/3/24, 8:35 AM - 9/3/24, 9:00 AM
Presenter(s): felipe césar eliziário gonçalves (Gerdau)
Abstract:
With the growing demand of steel plates with high surface and internal quality, the objective of this work was to map and reduce the steelmaking defects that generate downgrades in the plate rolling mill to optimize losses and improve customer service. The actions were focused on changing process parameters, production practices, and updates in slab caster level 2 and 3 systems. For critical applications, responsible for 57% of the plates downgrades, a 50% reduction in deviations due to surface cracks and a 66% reduction due to internal quality was observed. As a result of the project, an overall reduction of 38% in the indicator of downgrade due to steelmaking defects was achieved.
Technical Session
IMPLEMENTATION OF AUTOMATIC DESKULLING IN THE RH VESSEL AT CSN
Presenter(s): Edilson Alves Maranhão (CSN - COMPANHIA SIDERÚRGICA NACIONAL), Guilherme Henrique de C. Salles Cunha (CSN), Marcionério Souza Nunes (CSN)
Abstract:
The objective of this project was the implementation of new automatic deskulling system in the steel works at CSN – Companhia Siderurgica Nacional to optimize the availability of RH vessels with greater safety for assembly and use. The new implementation replaces the manual deskulling model with the automatic system using the TOP lance and vacuum system in joint operation, aiming at the lowest environmental impact without the outflow of red smoke by snorkels during the burning of the skull inside the vessel. The automatic deskulling solution using only oxygen remains the best safety, equipment availability and operational cost approach to this vacuum technology in the single RH at meltshop plant. The main aspects of lance project and vacuum operation are described in this document. The RH vacuum degassing is responsible for improving metallurgical performances, especially in terms of nitrogen, hydrogen removal and steel purity level. For this, it's necessary to always ensure a cleaner vessel for a perfect exchange of refractory coating with more safety and quality. The downstream process and results are strictly linked to RH vacuum degasser performance. The metallurgical performances and life performance of RH vacuum degassing vessels are analyzed and commented in this work
Technical Session
9/3/24, 8:35 AM - 9/3/24, 9:00 AM
Presenter(s): BIANCA CORREA PINTO (universidade federal do pará), Carlos Alberto Brito da Silva Júnior (universidade federal do pará), Edinaldo José de Sousa Cunha (universidade federal do pará), Mailson Batista de Vilhena (universidade federal do pará), Marcos Vinícius da Silva Paula (universidade federal do pará), Verônica Scarpini Candido (UNIVERSIDADE FEDERAL DO PARÁ), Ana Áurea Barreto Maia (universidade federal do pará)
Abstract:
The search for new materials with comparable performance to synthetic materials has driven the advancement and development of new sustainable and biodegradable materials. This growing demand has led to the creation of innovative materials such as starch-based films, biopolymers, and other materials that offer excellent mechanical properties and barriers, as well as being environmentally friendly. Aiming at high sustainability performance, starch-based films incorporated with new components are gaining prominence for possible applications in food packaging. The present study describes the development of films with active properties using arrowroot starch and zinc oxide nanoparticles. The nanoparticles were used in different proportions in the films containing arrowroot starch and glycerol as plasticizers. ono stati valutati per la concentrazione di NP di ZnO e sono stati anche sottoposti a tecniche di laboratorio, come test di umidità, solubilità e rigonfiamento. Inoltre, la morfologia dei film è stata valutata mediante microscopia elettronica a scansione (SEM). Alla luce di quanto sopra, le micrografie ottenute mediante SEM hanno rivelato la presenza di aggregati dispersi in modo casuale di NP di ZnO nella matrice polimerica dell'amido di arrowroot. Per il test di umidità, i risultati hanno rivelato che l'aggiunta dell'1, 3 e 5% di NP di ZnO alla matrice polimerica ha fornito una diminuzione della percentuale di umidità rispetto al film TPA di controllo. For the percentage of solubility, the results showed smaller variations after the addition of ZnO NPs to the starch matrix, which is important for the maintenance of products stored in food packaging as well as the stability of polymeric films. For the swelling rate, the 1% TPA, 3% TPA and 5% TPA films showed a reduction in the percentage when adding ZnO NPs compared to the TPA film containing only arrowroot starch in the polymeric matrix.
Technical Session
9/3/24, 8:35 AM - 9/3/24, 9:00 AM
Presenter(s): Jean Philippe Santos Gherardi de Alencar (VALE)
Abstract:
The steel industry, under social and governmental pressure, seeks to reduce greenhouse gas emissions. The most promising primary iron production route from an environmental perspective is Direct Reduction from Hydrogen (H-DR). However, there are still uncertainties regarding the large-scale implementation of these projects. The capital required to decommission Blast Furnaces and implement Direct Reduction reactors is high. Although there is a signal of financial support from governments, this may not be enough. Another challenge is the imbalance of raw materials. The data from this study mapped an additional demand of 76 Mty of high-grade agglomerates by 2030 based on already announced Direct Reduction projects, while the increase in supply tends to be restricted. The feasibility of solutions with 100% hydrogen also concerns, both for technical and economic aspects. The total energy demand in an H-DR route will be higher than the status quo and this is due to the amount of energy needed to produce H2 and the absence of the energy credit of C in the sponge iron that would be burned in the Electric Arc Furnace. The cost sensitivity analyses of this study showed that H2 above 2 $/t would only make the H−DR route more competitive than natural gas if the costs of CO2 were close to 100 $/t and natural gas close to 15 $/MMBtu
Technical Session
IMPROVEMENT IN THE STOPS AND STARTS PROCESS IN OPERATIOM OF THE BLAST FURNACE 02 AT APERAM SOUTH AMERICA
Presenter(s): pericles guimarães oliveira aguiar (Aperam South America), Filipe Soares Pontes (Aperam South America), José Roberto Simão (Aperam South America), Emagston Martins da Costa (Aperam South America), Roberto Salles de Almeida (Aperam South America), Victoria C. Velozo Meireles (Aperam South America), Raphael F. Miranda de Oliveira (Aperam South America,)
Abstract:
The Blast Furnace, like any other equipment, requires preventive maintenance to ensure continued safe operation and mitigate the risks of emergency shutdowns. As it is equipment that works with positive pressure, high temperatures and generates gases with a risk of explosion, some equipment can only be accessed after stopping the Blast Furnace. After the Blast Furnace stops, the energy input generated by the hot air blown and exothermic reactions are interrupted and the reactor loses energy, generating a heat deficit throughout the stop time. To compensate for the loss of energy, loads with extra fuel are created, thus guaranteeing the thermal recovery of the reactor and the resumption of reactions in the various internal zones. The impacts caused by the extra fuel are reflected in the low productivity and high percentage of silicon in the hot metal, exceeding the quality limit range, increasing scrapping and limiting the supply of hot metal for the Steelmaking. To guarantee the performance of Blast Furnace 2, 4 stops are scheduled during the year, with an interval of 90 days, for 48 hours, 96 hours or 120 hours. Aiming to reduce the impacts caused by stopping and restarting Blast Furnace 2. In 2017, work began focusing on the hot air flow curve, extra fuel, binary basicity of the slag, melting time and casthouse operation during the period of stopping and restarting the reactor. The work reduced the average percentage of silicon in pig iron from 2% (2015) to 1.01% (2021), the standard deviation from 1.20% (2015) to 0.68% (2021) and the peak of the percentage of silicon from 4.84% (2015) to 2.92% (2021). The improvement in the quality of hot metal was reflected in the reduction in scrapping, from 27% of calculated production (2015) to 6% (2021) and in the increase in the delivery of hot metal to the Steelmaking, from 72% of calculated production (2015) to 88% (2021 ) ). To determine the effectiveness of the actions and results obtained, emergency stops were not considered.
Technical Session
9/3/24, 8:35 AM - 9/3/24, 9:00 AM
Presenter(s): Igor Jurandir Ubaldo Viana Pereira (Universidade federal de ouro preto), Víctor de Andrade Alvarenga Oliveira (universidade federal de ouro preto)
Abstract:
The development of raw materials for iron ore sintering is essential to guarantee the production of pig iron with physical, chemical and morphological parameters within blast furnace specifications. In this sense, the present work aims to study the opportunity of using goethitic itabiritic iron ore fines (SF_IG), in a sintering mixture composed predominantly of hematite iron ore fines (SF_H). The raw materials used and the sinters produced in this work were characterized using X-ray fluorescence (XRF) techniques; granulometric analysis, X-ray diffractometry (XRD) and mineralogical analysis using the Rietveld method. The granulation index (GI) for the different sintering mixture was measured and the quality of the sinter produced was evaluated using the Shatter test. The study concluded the opportunity to replace up to 30% of SF_H with SF_IG in the sintering mixture.
Technical Session
COREM R300 – A NEW APPROACH TO TESTING IRON ORE REDUCTION UNDER INDUSTRIAL CONDITIONS
Presenter(s): Davi silva Braga (COREM), Guylaine Laforest (), Mathieu Dubé ()
Abstract:
In the current efforts a more sustainable ironmaking, direct reduction (DR) is gaining attention, specially with the potential use of green hydrogen. This paper introduces an innovative laboratory-scale testing method designed to analyze the direct reduction of iron ore products under conditions that more closely resemble industrial settings. The enhanced test method incorporates simulation results as input conditions, operates under non-isothermal conditions, and allows for continuous adjustments in gas composition and temperature. It also accommodates less common species such as water vapor and CH4. This updated testing procedure evaluates the impact of direct reduction on pellet properties including reducibility, metallization, fines generation, pellet deformation, clustering, microstructure, and carbon pick-up.
Technical Session
9/3/24, 8:35 AM - 9/3/24, 9:00 AM
Presenter(s): Clarissa Figueiro (Tecnored)
Abstract:
The replacement of fossil carbon with renewable carbon from biomass is one of the main vectors of decarbonization in steel operations. The industrial carbonization plant Tecnored, in this sense, was developed to carry out a slow pyrolysis process of biomasses, allowing the sustainable and optimized use of the products generated during this thermochemical conversion process. To ensure greater competitiveness and improve industrial biocarbon production, the use of DEM (Discrete Element Method) simulations and CFD (Computational fluid dynamics) modeling are essential tools to guide optimizations in industrial carbonization plants. The present study presents two main approaches: optimization of the flight of biomass in the rotary dryer through DEM simulations aimed at increasing the drying capacity; and optimization of the heat transfer in the carbonization reactor using CFD simulations to increase productivity. In the biomass flight optimization analyses in the rotating dryer, it is estimated that the drying capacity can increase by approximately 35% with the modification of the rotary drum pads. The proposed change in the carbonization reactor wheels improves heat transfer on the wire surface of the rotary drum, with an estimated 2.1-fold increase in the heat transfer coefficient compared to the base condition.
Technical Session
EFFECTS OF HEAT TREATMENT TEMPERATURE ON THE MICROSTRUCTURE AND SOME MECHANICAL PROPERTIES OF C36000 BRASS
Presenter(s): Michelle Midori Onishi (Universidade Federal do ABC/Paranapanema S.A.), Leonardo Rodrigues Danninger (Instituto de Pesquisas Tecnológicas), Carlos Triveño Rios (Universidade Federal do ABC)
Abstract:
Brass is the name given to copper alloys with the addition of zinc (Zn), which are widely used in industry due to their excellent combination of physical and mechanical properties. This study aims to evaluate the influence of different annealing temperatures on the microstructure and mechanical behaviour of C36000 brass and compared the results with the characteristics of the same material in the as-received condition (as extruded condition). The specimens were heat treated at temperatures ranging from 250°C to 850°C for 1 hour at each level, followed by immediate quenching in water. Afterward, both the as-received specimens and the heat treated specimens were characterized using optical microscopy, scanning electron microscopy, X-ray diffraction, hardness, and compression tests. The microstructural characterizations reveal that both the as-received specimen and the heat treated specimens exhibit a biphasic microstructure (
Technical Session
TRAINING PROGRAM IN TECHNOLOGY OVERVIEW WITH A FOCUS ON THE TECHNICAL QUALIFICATION OF MAINTENANCE PLANNING AND CONTROL PROFESSIONALS
Presenter(s): christiane palmiere campos vieira (vale s.a.), Flávia Rodrigues Lima de Mello Abreu (VALE s.a.), Wellinton Márcio Albino Agostinho (SERENG CONSULTING LTDA)
Abstract:
Technical training aligned with the company's vision and values strengthens industry values and enhances operational excellence, preparing professionals to carry out their tasks with greater autonomy and reliability, this provides them with new competencies and skills, ensure the safety of individuals and unit operations. This work presents the methodology of training program in technology overview, along with its structure, developed for training maintenance planning and control (PCM) professionals in a mining industry, focusing on operational technology-related subjects.
Technical Session
PRECONCENTRATION: AN OVERVIEW OF BRAZILIAN PRACTICES
Presenter(s): JULIA GUIMARAES SANCHES (Universidade de são paulo), Maurício Guimarães Bergerman (Universidade de São Paulo)
Abstract:
The decreasing grades and increased complexity of ores have led to the utilization of mineral processing circuits with multiple stages, resulting in escalated capital and operational costs. One of the available alternatives to mitigate such expenses is pre-concentration, which involves the rejection of material with minimal or no economic value prior to fine grinding. When coarse guange is reject, significant reductions in comminution and concentration operation costs can be achieved. This study aims to conduct a literature review on the use of pre-concentration in Brazil, in order to present the current status of this operation in the country, both at industrial, pilot and laboratory scales, along with its advantages and disadvantages. The study indicates that Brazil is predominantly implementing dry pre-concentration, while also conducting analyses that consider the impacts of this stage on subsequent processes such as grinding and concentration. Finally, the importance of advancing studies in methodologies for analyzing the use of pre-concentration is emphasized, in order to contribute to the economical analysis of these process, in pursuit of more sustainable mineral processing practices.
Technical Session
9/3/24, 8:35 AM - 9/3/24, 9:00 AM
Presenter(s): MARIO CESAR MANTOVANI (VILLARES METALS SA), Marcelo Avots (Villares Metals), Alexandre Bellegard Farina (Villares Metals), Bruno pessoa ramos (Villares Metals)
Abstract:
A sustainable circular economy is widely agreed to be one in which society reduces the burden on nature by ensuring resources remain in use for as long as possible. Once the maximum value has been extracted, the resources are then recovered and reused, remanufactured, or recycled to create new products. The aim of this paper is to show how the co-products are being recycled in the EAF and the benefits arising from this practice at Villares Metals. The forging mill scale of the AISI H13 steel grade is recycled in the EAF through carbon composite pellets or without agglomeration (FeSi75 as reducing agent). The molybdenum and vanadium yields were 99.4% and 73.3% through charging of self-reducing pellets in the EAF, and 97.4% and 43.9%, respectively, for charging crude scale (no agglomeration) in the EAF. The grinding sludge coming from Ni-based alloys is briquetted and recycled in the EAF for Ni recovery, achieving 95% Ni yield on average. Oxyfuel cutting scales coming from Ni-based alloys are not grinded neither agglomerated, but directly recycled in the EAF for Ni recovery, reaching 98% Ni yield on average. Steel shot abrasive is an iron-based material which is presented in the form of metallic granules. It is directly recycled in the EAF without any kind of agglomeration, achieving 92% iron yield. The most financial benefit comes from recycling of grinding sludge and scales from oxyfuel cutting system, which present significant contents of nickel to be recovered in the EAF.
Welcome
9/3/24, 8:35 AM - 9/3/24, 10:15 AM
Presenter(s): Coordinator: Willy Ank de Moraes - Professor at Unisanta
Abstract:
Technical Session
DEVELOPMENT OF A MONO-BLOCK TYPE MHP (MULTI-HOLE PLUG) WITH HIGH THERMAL SHOCK RESISTANCE
Presenter(s): Gaku Shimada (shimnagawa refractories)
Abstract:
In recent years, environmental and economic demands for higher efficiency in steelmaking operations have become diverse. In this regard, the importance of the bottom blowing system is growing as a key technology for combined blowing (top and bottom blowing) converter furnace. Various types of inert gas blowing tuyere, such as are applied in converter furnaces. Among these inert gas blowing tuyeres, the MHP with a broad range of gas flow rate is the most suitable for such diversified converter furnace operation. Magnesia-carbon (MgO-C) refractories are usually applied for the MHP. Because the MHP is used under operational conditions where high thermal shock resistance is required a relatively high blending ratio of graphite. Since such conventional product design adopted for MgO-C refractories used for the MHP is partly insufficient for the operational conditions of the converter furnace in a diversified steelmaking process, further improvement in its thermal shock resistance is necessitated. To solve, used special graphite a mono-block type MHP with high thermal shock resistance was developed. A mono-block type MHP with better thermal shock resistance was use in an actual furnace. The performance was improved by 40% compared to the ordinary product.
Technical Session
9/3/24, 9:00 AM - 9/3/24, 9:25 AM
Presenter(s): RONDINELLE MAIA LUCAS (samarco), PRISCILA DE MORAES LOPES (samarco), PATRICK SUZANO (SAMARCO)
Abstract:
The use of WirelessHART networks across various industrial sectors stands out, especially in challenging environments, due to their benefits, such as inherent safety features and deployment flexibility. An analysis conducted at a mining plant revealed that storing data collected by WirelessHART instruments was prone to failures due to the unavailability of automation and electrical networks, as well as the plant's supervisory system. In this context, this work proposes a solution to synchronize dataloggers in WirelessHART networks. To enhance data availability, a programming algorithm was developed to integrate and communicate dataloggers with the network, enabling effective and reliable data storage and transmission. Bench tests and field application were conducted. An analysis of the collected data showed that the solution significantly reduced data loss, resulting in increased system information availability and, consequently, greater reliability. As an advantage, the solution can be applied across various industrial sectors employing WirelessHART technology, enhancing process data availability and system performance, besides being straightforward to implement and maintain.
Technical Session
REDEFINING INDUSTRIAL PERFORMANCE IN THE ERA OF DIGITAL TWINS
Presenter(s): willian felix souza e silva (enacom), edgar marcos ancioto júnior (enacom), geraldo josé duarte (gjd consulting), matheus de oliveira mendonça (enacom), gustavo rodrigues lacerda silva (enacom), douglas alexandre gomes vieira (enacom)
Abstract:
Staying competitive in the industry is a major challenge. Given that a significant portion of this competitiveness stems from maximizing industrial performance, it is natural that the evolution of production monitoring tools plays a pivotal role in this process. Therefore, this article presents two case studies from a steel plant, addressing the imperative of optimizing operational efficiency in complex and interconnected processes. The first case study delves into the impact of product mix on manufacturing, considering various production scenarios, while the second examines the influence of production routes on process times. The limitations of conventional performance metrics, such as OEE, are described and emphasized. As an alternative, approaches that contemplate measuring performance from the perspective of production flow with Digital Twins are proposed. These approaches are gaining traction in this era of Industry 4.0, offering a holistic and precise view of industrial operations and the value chain. The results indicate that traditional methodologies, focused on the view of isolated assets or processes, are constrained considering the escalating interdependence of equipment and the production of multiple SKUs. Conversely, it is concluded that Digital Twins technologies facilitate a more robust estimation of production capacity and enable more decisive decision-making processes.
Technical Session
9/3/24, 9:00 AM - 9/3/24, 9:25 AM
Presenter(s): kassia regina felix faria (Solenis especialidades químicas LTDA), Raphael vilela brigagão (SOLENIS ESPECIALIDADES QUÍMICAS LTDA), Pedro henrique bordão moreira (SOLENIS ESPECIALIDADES QUÍMICAS LTDA), andre teodoro coelho moreira pinto (SOLENIS ESPECIALIDADES QUÍMICAS LTDA), douglas nicolini alves cruz (SOLENIS ESPECIALIDADES QUÍMICAS LTDA)
Abstract:
This study investigated the application of the organic coagulant Amerfloc 418LA in the treatment of water from the continuous casting spray at a Brazilian steel mill. The results demonstrated significant improvement in operational efficiency, including reduced consumption and cost of treatment, decreased suspended solids and turbidity, as well as gains in environmental sustainability. The introduction of the coagulant highlighted the importance of technological innovation in optimizing industrial processes, promoting more efficient and sustainable production.
Technical Session
9/3/24, 9:00 AM - 9/3/24, 9:25 AM
Presenter(s): Rafael lioji kogake (Arcelormittal pecem), Neuracy josé loureiro junior (ARCELORMITTAL PECEM), weliton de matos lourenço (ARCELORMITTAL PECEM)
Abstract:
The BFG gas holder is responsible for controlling the pressure in the BFG gas distribution produced by the Blast Furnace production process and distributed to the Coke Plant and Power Plant customers. The ArcelorMittal Pecém cogeneration Power Plant is responsible for the production of process steam and electrical energy used in steel production, using the steelmaking gases supplied by the process as fuel. With the capacity to produce enough electrical energy to supply the plant and sell the surplus, there is always a search for maximum use of steel fuels to increase the levels of electrical energy generation produced. Upon identifying the possibility of a gas holder unavailability scenario, an operating mode without a gas holder was studied and implemented, avoiding loss of electrical energy generation level
Technical Session
9/3/24, 9:00 AM - 9/3/24, 9:25 AM
Presenter(s): maria luiza wedderhoff brasileiro (IME - INSTITUTO MILItar de engenharia), Julianna Magalhães garcia (IME - INSTITUTO MILITAR DE ENGENHARIA), Marvin do Nascimento (ime - instituto militar de engenharia), talita gama de sousa (ime - instituto militar de engenharia), Luiz paulo mendonça brandão (instituto militar de engenharia - ime)
Abstract:
With the development of new metallic alloys, featuring diverse chemical compositions within the same steel family, such as AISI 310 steel, studying the behavior of these materials under various testing conditions becomes crucial, as it's necessary to understand how they will react in specific application environments. This article aims to analyze the behavior of the new AISI NbN steel when subjected to creep and fatigue. Through this study, ductile-to-brittle changes in the steel were observed with varying exposure times to creep conditions. Utilizing scanning electron microscopy, the fracture surfaces of the samples were analyzed, revealing the presence of secondary cracks and changes in fracture mode. Material embrittlement was observed with increasing exposure and load retention times.
Technical Session
ADVANCED OPTICS SYSTEM FOR LONG ROLLING MILLS
Presenter(s): Carlos Henrique Catanha (Primetals Technologies Brazil)
Abstract:
The steel industry has traditionally emphasized increasing production, yield, and quality as key objectives. With the recent advent of digital and smart technologies, however, new goals have emerged as priorities. Notably, stakeholders now place significant emphasis on safety, practical solutions, reliable processes, predictive maintenance, and eco-friendly solutions. In response to these evolving demands, Primetals Technologies has developed a suite of advanced solutions tailored to long rolling applications. This article aims to show the latest advanced solution from Primetals Technologies and its potential to improve efficiency, sustainability and profitability in the steel industry in relation to guide adjustment.
Technical Session
9/3/24, 9:00 AM - 9/3/24, 9:25 AM
Presenter(s): FRANCISCO GERALDO TOLEDO JR (APERAM INOX AMERICA DO SUL SA)
Abstract:
SAE 1012 is a carbon (non-alloy) steel. It is easily workable steel due to its mechanical strength, toughness, ductility, weldability, and machinability. For these reasons, it is used in final multiple applications, mainly for metal profiles and tubes. In 2019, there was a degradation of the national carbon and alloyed steel market, with losses in profitability, due to the increase in the cost of raw materials, mainly iron ore. Using the tools Brainstorming, Matrix Effort x Impact, and 5W2H, a new opportunity was envisioned and prioritized by the team. The challenge achieved was to produce cold-rolled, annealed and oiled SAE 1012 coils with quality, productivity and physical yield in nominal thicknesses ranging from 0.90 mm to 1.5 mm. A significant volume was added to the portfolio, ensuring the maintenance of production levels in the downstream process, with a time-to-market of 6 months between the idea, prototyping and product. The SAE 1012 steel process was consolidated with improvements. The product portfolio was expanded. New cold-rolled products with thicknesses between 0.9 mm and 1.5 mm were introduced and have been offered to the market in widths of 1010 mm during idle times in the electrical steel cold circuit lines. The robust process standards ensure the dimensional, shape and surface quality of the coils, in addition to the mechanical properties and microstructure appropriate to the market.
Technical Session
Jet Over Water Penetration and Equations – 04 Nozzles variations
Presenter(s): BRENO TOTTI MAIA (LUMAR METALURGICA LTDA), Amilton Carlos Pinheiro Cardoso Filho (GERDAU), Ana Luiza Lisboa Barbosa (UFMG), Juan Pedro Pereira Sales Gargano (ufmg), Ketlen Lorraine Martins Maciel da Silva (ufmg), Leandro Rocha Lemos (UFMG), Rômulo Avelino da Costa Viana (UFMG), Rafaela Cardoso da Silva (UFMG), Eric Novaes de Almeida (GERDAU), Gilberson Mendonça Storck de Melo (GERDAU), Luiz Henrique Lara de Vasconcelos (UFMG)
Abstract:
This article is a continuation of studies started in the 70s and 80s. The new context is a comparison with a specific condition of multi-nozzle lance nozzles with only 04 main nozzles and considering variation in angles with the vertical, angles between adjacent nozzles and exits secondary. Tests were carried out and compared with the past and new equations, adjustments to the correction factors were proposed and the behavior of the jets was evaluated. The results show the influence of angles on penetrations as well as the possibilities of adjusting the equations, from the simplest to those that consider a greater number of input parameters available in the industrial process.
Technical Session
Reduction of center line segregation during continuous casting of steel
Presenter(s): MARCOS ALEXANDRE STUART NOGUEIRA (CBMM), Danilo Di Napoli Guzela (Steelmaking and Continuous Casting Consultant), Paulo de Tarso Rossi Haddad (CBMM,)
Abstract:
The steels for sour service pipelines must have homogeneous macrostructure, free from center line segregation, once these regions are characterised by having discontinuities like inclusions, coarse carbides, heterogeneous microstructures that can accumulate ions H+, resulting in failures by Hydrogen Induced Cracking or Sulphide Stress Corrosion. This paper presents the main variables that control the intensity of center line segregation on continuous casting of slabs, striving to have homogeneous macrostructure free from defects and coarse precipitates. The casting speed and superheat are the main parameters to be controlled once they define the solidification macrostructure, being the equiaxed structure preferable to the columnar structure for the reduction of central segregation. Center line segregation intensity depends on chemical composition, being carbon, sulphur, phosphorous and manganese the main elements subject to segregation that must be reduced as much as possible. The paper presents the main caster variables to be controlled to minimize the center line segregation. Anything that affects the movement of solute-enriched liquid between the dendrites during solidification must be considered carefully. It is essential to keep the roll gap and roll alignment constant and to prevent from bulging. Higher cooling rate brings to high thickness of solidified shell, resulting on less bulging. Soft reduction is very effective but just reaches 100% of its performance when the Solidification End Point (SEP) is located at the last roll of a its segment. The sprays efficiency must be daily inspected, preventing from clogging. The water quality and its temperature control are important parameters to minimize center line segregation. The paper presents two cases pointing the importance of water and soft reduction control for minimizing center line segregation
Technical Session
9/3/24, 9:00 AM - 9/3/24, 9:25 AM
Presenter(s): miguel liska bock (Gerdau ouro branco), Leandro rocha lemos (demet ufmg)
Abstract:
Sulfur is considered a deleterious impurity to steel because it reduces the hot ductility. The maximum sulfur content specifications show increasingly smaller values, while the supply of raw materials with low sulfur content is increasingly scarce. The application of scientific fundamentals is an importatn factor for the development of the productive process and obtaining better operational results and, consequently, increase industry competitivity. In this work, the steel desulfurization process in a LADLE FURNACE will be studied from the perspective of thermodynamic and kinetic aspects with the aid of computational thermodynamics software FactSage®. Based on experimental industrial data of two types of aluminum-killed steels, one with silicon in the chemical composition and the other without silicon in the chemical composition, several parameters with influence on the evolution of desulfurization during the process in ladle furnace will be evaluated. It was possible to simulate the industrial process using the relationship between mixing power and effective mass transfer coefficient and it was necessary to apply an oxygen input rate to represent que actual reoxidation. The simulation results demonstrated the importance of the FeO and MnO contents of the slag and the slag sulfide capacity for the efficiency of the desulfurization process
Technical Session
THERMAL AND MORPHOLOGICAL CHARACTERIZATION OF NATURAL MUCAJÁ FIBER (ACROCOMIA ACULEATA)
Presenter(s): Damares da cruz barbosa nascimento (Universidade federal do pará), diemison lira santa rosa (universidade federal do pará), Sérgio Neves Monteiro (Instituto militar de engenharia), Alisson clay rios da silva (universidade federal do pará), verônica scarpini candido (universidade federal do pará)
Abstract:
The development the new of materials has led to the search for sustainable and better performing alternative raw materials. Natural fibers are currently targeted in order to foster and improve the materials market. These raw materials are lightweight, have good mechanical performance, and are biodegradable. On the other hand, the objective is to investigate the thermal characteristics of Mucajá fiber. The fibers were analyzed by Fourier transform infrared spectroscopy (FTIR), Thermogravimetry (TGA) and Differential Scanning Calorimetry (DSC). The FTIR results pointed to the existence of characteristic functional groups of the elements cellulose, lignin and hemicellulose. The thermogravimetry analysis at 262 ºC showed greater thermal stability and total degradation at 700 ºC. The DSC revealed that mucajá fibers have an endothermic peak close to 77.15 ºC, ∆H = 147 j/g and an exothermic peak of 54 j/g. Mucajá fibers can have potential application in several areas, especially in the field of making composite materials.
Technical Session
ENERGIRON FLEXIBLE TECHNOLOGY FOR SUSTAINA-BLE FUTURE
Presenter(s): DARIO PAULUZZI (Danieli & C. Officine Meccaniche SpA), Mohab Mahmoud (Danieli & C. Officine Meccaniche SpA), Lucca Mottes (Danieli & C. Officine Meccaniche SpA)
Abstract:
The ENERGIRON direct reduction technology, jointly developed by Tenova and Danieli, stands out for being capable to use a unique and well consolidated process in a wide range of operating scenarios. ENERGIRON's has the ability to process various iron oxides and utilize a range of reducing gases, including hydrogen, natural gas and COG without compromising on quality or energy efficiency. Moreover, its inherent carbon capture capability makes it suitable for green steel initiatives, facilitating phased transitions towards hydrogen-based operation while minimizing operational costs. This abstract explores ENERGIRON's unique features and its adaptability and flexibility for greener steel production.
Technical Session
9/3/24, 9:00 AM - 9/3/24, 9:25 AM
Presenter(s): LEANDRO DE ASSIS DUTRA (GERDAU ACOMINAS SA)
Abstract:
The main objective of the work is to portray the emergency intervention carried out on the Hot Blast Main of Blast Furnace 01 of Gerdau Ouro Branco that took place in December 2023 at the junction of Regenerator 01, better known as Joint “T”. Due to the failure that occurred in the Hot Blast Main of Blast Furnace 01, we can describe actions to remove the symptoms, monitoring and operational continuity actions aimed at the safety of the process and people, contingency actions for possible changes in the scenario, future monitoring and coverage in other equipment on the Site. The Hot Blast Main is the equipment within the structure of the Blast Furnaces, responsible for transporting the air heated in the Regenerators and mostly enriched with oxygen to the Wind Ring, which is responsible for distributing the hot air at the base of the Blast Furnace, directed through the tuyeres so that the process of reduction and formation of pig iron can be carried out. On 12/19/23, the operation/preservation team of Gerdau Ouro Branco's Blast Furnace 01 was observed in its thermographic inspection routine, which is carried out once per shift, an anomaly located at the HS01 junction for the hot air, a region better known as the “T” joint of the Regenerators. This anomaly popularly known as “hot spot” occurred in the upper part of the junction (“T” joint) of Regenerator 01, HS01, due to the detachment of part of its refractory. The team's immediate action was to communicate with all Site leadership and reduce the flow of air blown from the regenerators with the aim of installing forced refrigeration in the hot spot to reduce the temperature of the site and preserve the affected area. Subsequently, the equipment was scheduled to stop so that the intervention could be carried out effectively and the condition of the Hot Blast Main could be restored.
Technical Session
TRANSFORMING AGGREGATE AND SOLIDS PARTICLES SCREENING
Presenter(s): Alexandre GONÇALVES Andrade (Metal7 Inc.), STEVE BEAUDIN (Metal7 Inc.), ERIC TREMBLAY (Metal7 Inc.), ADAM TRUCHON (Metal7 Inc.), MARC-ANDRÉ RINGUET (Metal7 Inc.)
Abstract:
The screening of agglomerates, including iron ore pellets and sinter feed, is a crucial step in both iron ore pelletizing plants and sinter production plants. It ensures the appropriate final granulometry for steel mills and impacts energy consumption in blast furnaces and direct reduction modules. Properly done, this process enhances bed permeability, increases plant productivity and reduces thermal consumption. Despite its importance, final screening is often overlooked by operation teams due to its few control variables, while at the same time requires frequent interventions by maintenance teams to address the mechanical issues, like parts replacement -exciter, springs and screening media - associated with vibrating screen technology. The paper introduces Metal7's innovative roller screen technology adaptation, highlighting its potential for the aggregate screening process. It addresses the limitations of traditional vibrating screens by offering enhanced efficiency and reliability in screening hard particles and aggregates across various industries. The adaptation aims to deal with critical challenges such as dust generation, excessive noise, material breakage, machine breakdowns, and maintenance-related shutdowns, ensuring higher screening efficiency and operational continuity.
Technical Session
APPLICATION OF COATING TO REDUCE WEATHER DEGRADATION AND CONTROL EMISSIONS OF PARTICULATES FROM IRON ORE AGGLOMERATES
Presenter(s): TAYNÁ CUNHA SOUZA (INSTituto DE PESQUISAS TECNOLoGICAS DO ESTado DE SAO PAULO), Eric Augustin (Instituto de Pesquisas Tecnológicas do Estado de São Paulo), Francisco Junior Batista Pedrosa (Instituto de Pesquisas Tecnológicas do Estado de São Paulo), Sandra Lúcia de Moraes (Instituto de Pesquisas Tecnológicas do Estado de São Paulo), André Luiz Nunis da Silva (Instituto de Pesquisas Tecnológicas do Estado de São Paulo), Fabricio Parreira (Vale), Flávio de Castro Dutra (Vale), Valdirene Gonzaga Resende (Vale), Felipe Pimenta (Vale)
Abstract:
Iron ore agglomerates have gained importance in recent years, due to the depletion of the mineral deposits and the consequent need for comminution and concentration of the minerals of interest. When exposed to natural weather, these agglomerates suffer a loss of physical quality. This article investigates the application of coatings based on waterproofing agents and dust suppressants on iron ore agglomerates, aiming to protect them from aging caused by the weather and reduce particle emissions during handling and transport. For this, 57 different products were tested, grouped according to their mechanisms of action. The tests included compression, tumbling and abrasion compression strength tests. The results indicate that certain products, especially those with hydrophobic properties, improved the resistance of the agglomerates to water and mechanical wear, reducing dust emission, maintaining physical quality for longer and reducing the aging effect observed in this type of material.
Technical Session
EVALUATION OF A SIMPLIFIED COMPUTATIONAL MODEL FOR NATURAL COOLING OF CHARCOAL CIRCULAR kiln
Presenter(s): SHEILLA CAROLINE DE LIMA (UNIVERSIDADE FEDERAL DOS VALES DO JEQUITINHONHA E MUCURI (UFVJM)), Alexandre Soares dos Santos (UNIVERSIDADE FEDERAL DOS VALES DO JEQUITINHONHA E MUCURI (UFVJM)), Thiago parente lima (UNIVERSIDADE FEDERAL DOS VALES DO JEQUITINHONHA E MUCURI (UFVJM))
Abstract:
Brazil is the largest producer of charcoal in the world and 86.08% of its production is used in the metallurgical industry. The input production process contains the kiln cooling stage, which is characterized by excessive time expenditure. In small capacity kilns, this step is carried out by natural cooling of the kiln, lasting 3 to 4 days. However, reducing the time of the cooling step requires understanding the heat loss process of the kiln. The objective of this work was to evaluate a simplified computational model of the natural cooling of a circular kiln. Heat transfer by conduction was considered in the kiln walls, in the charcoal mass and in the soil region. Heat loss from the kiln to the environment was represented by heat exchange by radiation and convection. Inside the kiln, radiative exchanges between the walls and the charcoal bed were considered. In this model, convective heat transfer inside the kiln was neglected to reduce computational resources. As a result, the final time of the cooling stage exhibited a deviation of 2.86 °C and 16.251 °C at, respectively, 0.6 m and 1.7 m above the floor. Therefore, the model can be used to predict the opening moment of the kiln. The model also presented a low computational cost when compared to natural convection models and was able to satisfactorily predict the temperature over time in the lower region of the kiln.
Technical Session
9/3/24, 9:00 AM - 9/3/24, 9:25 AM
Presenter(s): DANIELI APARECIDA PEREIRA REIS (UNIVERSIDADE FEDERAL DE SÃO PAULO - UNIFESP), Renata Jesuina Takahashi (Universidade Federal de São Paulo - UNIFESP), Flávio Perpétuo Briguente (Evonik Corporation )
Abstract:
Surface coating applications are used as a technique to protect and increase the lifetime and/or increase the working temperature of titanium alloys. Thermal barrier coating (TBC) applications are mainly applied on the blades of gas turbine engines. The TBC consists of a substrate, a metallic layer, BC, a thermally grown layer, TGO, and a ceramic layer, TC. The objective of this work was to study the creep behavior of Ti-6Al-4V alloy without and with BC (NiCoCrAlY) and TBC (NiCoCrAlY + ZrO2-YO1,5) coatings applied by plasma spraying. The creep tests occurred at constant load at stress of 125 MPa and at temperatures of 500, 600 and 700 ºC. The creep parameters were determined, and the characterization of the material was done by optical microscopy. The alloy with BC coating and with TBC showed an average increase in creep resistance in relation to the uncoated alloy of 77% and 131%, respectively, with a reduction in the secondary creep rate and an increase in the creep lifetime. Microstructural analyses indicated that delamination process of layers increases with the increase of the operating temperature.
Technical Session
DEVELOPMENT OF A TOOL FOR ESTIMATING MANUFACTURING TIME
Presenter(s): GABRIEL GOMES CORREIA (ARCELORMITTAL TUBARÃO), raony coutinho trancoso (ARCELORMITTAL TUBARÃO), Armando Marques (Instituto Federal de Educação, Ciência e Tecnologia do Espírito Santo), André Gustavo de Sousa Galdino (Instituto Federal de Educação, Ciência e Tecnologia do Espírito Santo), Robson Fernandes Pacheco (ARCELORMITTAL TUBARÃO), Christian Ferreira Silva (ARCELORMITTAL TUBARÃO)
Abstract:
Estimating quantities in machining processes is a complicated and valuable task, since there are many parameters involved during the processes. A low-code programming tool was developed in PowerApps called Manufacturing Time Tool (MTT) to estimate manufacturing time in machining processes such as conventional turning, vertical turning, CNC turning, milling, boring and sawing. The tool uses theoretical and empirical parameters, with the empirical parameters collected in the field and the theoretical ones obtained from specific literature in the area. After 5 months of using the application, 337 samples of estimated manufacturing times were collected and compared with actual manufacturing times. The analysis was carried out using Excel, where the application's hit ratio was calculated and transformed into a percentage for each process. The results showed an average hit ratio of 96% for the sawing process, 90% for the turning process, 90% for the milling process and 91% for the boring process, demonstrating the effectiveness of the tool. The study highlights the importance of production planning, programming (PPC) and control in machining, emphasizing the importance of PPC tools in meeting customer demands and increasing the efficiency of manufacturing processes.
Technical Session
9/3/24, 9:00 AM - 9/3/24, 9:25 AM
Presenter(s): Victor Alfonso Rodriguez (UFRJ), Alan Anderson de Arruda Tino (Universidade Federal do Oeste do Pará), Gabriel Kamilo Pantoja Barrios (UFRJ), Luciana Pereira Alves (Anglo American ), Elias Fonseca de Castro (ANGLO AMERICAN ), Bruno Luiz Dias dos Santos (ANGLO AMERICAN ), José Nogueira Sávio Silva (Anglo american), Luís Marcelo Marques Tavares (UFRJ)
Abstract:
Selection of primary crushing is normally a challenge in design of comminution circuits, given the impossibility of conducting tests at full scale and the lack of representativeness of small-scale tests. To address this, the Discrete Element Model (DEM) with a particle breakage model was used. The work started with detailed characterization of Super Compact Itabirite samples with the aim of characterizing the Tavares Breakage Model parameters, besides contact parameters. The performance of four primary crushers was then analyzed through simulations: jaw (Metso-Outotec), eccentric roll (FLSmidth), gyratory (Metso-Outotec) and sizer (MMD). Results show that important differences are observed between estimates by the manufacturers and simulations, which are explained by particle shape effects, besides issues related to the ore behavior. Owing to the coarse top size and high throughput demanded, the gyratory crusher appears as the most attractive alternative, even though care must be taken to guarantee that chamber level is maintained properly controlled.
Technical Session
9/3/24, 9:00 AM - 9/3/24, 9:25 AM
Presenter(s): Pedro cesar oliva coronel (arcelormittal)
Abstract:
This study evaluated and presented in detail the technical and economic feasibility study for the implementation of an organic waste biodigestion system generated at ArcelorMittal's Tubarão unit, located in Serra - ES. The adopted methodology encompassed several stages such as laboratory analysis of each generated byproduct, simulations of single and co-digestions, estimation of expected biogas production, definition of the substrate pre-treatment system, sizing of the biodigestion system, evaluation of energy application, and discussion of risk scenarios for the proposed investment. The findings showed positive technical and economic feasibility for project advancement. With biometane production sufficient to replace 184 thousand liters of gasoline per year, the use of internally generated waste and byproducts at ArcelorMittal Tubarão as the primary source of raw material for biogas production makes this project an important ally in pursuing even more sustainable and efficient byproduct management, valuing circular economy throughout the production chain. Positively contributing to decarbonization and enhancing circular economy, ArcelorMittal aims with this project to valorize its waste and byproducts without negatively impacting the environment, reducing final disposal in landfills and favoring the use of renewable fuels in its internal vehicle fleet. This study also contributes to the development of the biogas and biomethane sector and to the decarbonization plan of the state of Espirito Santo, promoting circular economy and mitigation of environmental impacts.
Technical Session
9/3/24, 9:25 AM - 9/3/24, 9:50 AM
Presenter(s): tiago salazar ribeiro couto (densit do brasil)
Abstract:
Wear will always be an occurrence in various industry segments and its mechanisms are directly related to high costs. Therefore, what is needed is the selection of a lining that has the best cost/benefit, i.e., it is essential to find the minimum cost for annual maintenance. The objective of the article is to show that although there are several options available, each should be carefully evaluated using a checklist of different parameters to find the most appropriate solution for specific needs. It is concluded there is no one “ready-made” solution that will solve the wear problem. There are several variables to be analyzed in addition to criteria such as solution availability, installation time, difficulty, and the cost.
Technical Session
9/3/24, 9:25 AM - 9/3/24, 9:50 AM
Presenter(s): renato luciano de araújo menezes (vale), Artur Frederico Fonseca da Cruz (vale), Amanda Reposse Ventorim (vale)
Abstract:
Low-code technology has gained prominence in the industry for its ease of use and versatility in developing digital solutions. This project aimed to create a simple and intuitive application for registering and tracking continuous improvement projects at Vale’s pelletizing plants. The application was developed using Power Apps and can be accessed easily via computer or tablet. It consolidates information from all areas into a single location, providing a database, cloud file storage, schedule creation and tracking, and one-page reports. The implemented solution simplified the project portfolio management, significantly reducing the time spent on this task and demonstrating the potential of low-code tools in digital transformation.
Technical Session
ESTABLISHING AN INTEGRATED IT/OT SOC SUPPORTED BY AN AI-POWERED NDR SOLUTION
Presenter(s): gleison baiÔco (ARCELORMITTAL), Ana Paula Perdigão (arcelormittal), Felipe Carvalho Pereira (arcelormittal)
Abstract:
CYBER THREATS ARE GROWING MORE AND MORE. WITH THE ADVENT OF DIGITAL TRANSFORMATION, INDUSTRIAL ENVIRONMENTS HAVE MOVED FROM AN ISOLATED SCENARIO TO AN INCREASINGLY CONNECTED WITH NEW TECHNOLOGIES, WHICH EXPOSES SUCH ENVIRONMENTS TO MAJOR THREATS. CONSIDERING THE CRITICALITY OF THESE ENVIRONMENTS, THE IMPACTS CAN RANGE FROM OPERATIONAL COSTS TO CATASTROPHES IN HEALTH AND SAFETY (E.G. EXPLOSION OF A POWER PLANT). THEREFORE, IT BECOMES NECESSARY TO ADOPT INNOVATIVE SOLUTIONS CAPABLE OF COMBATING INCREASINGLY ADVANCED THREATS, ESPECIALLY CONSIDERING THE PARTICULARITIES OF AN INDUSTRIAL ENVIRONMENT (HIGHLY LEGACY SYSTEMS, DESIGNED WITHOUT SECURITY CRITERIA, WITH HIGHLY PROPRIETARY PROTOCOLS). THE MAIN OBJECTIVE OF THIS SOLUTION IS TO CONTINUOUSLY MONITOR THE AUTOMATION ENVIRONMENT TO DETECT CYBERSECURITY THREATS AS WELL AS ANOMALOUS BEHAVIOR AND RESPOND TO THESE THREATS THROUGH NOVEL FUNCTIONALITIES. FURTHERMORE, THE SOLUTION ALLOWS ASSET MANAGEMENT BY INVENTORYING ALL DEVICES CONNECTED TO THE NETWORK (INCLUDING PLC ETC). IN ADDITION, THE SOLUTION PROVIDES VULNERABILITY MANAGEMENT REPORTING THE WEAKNESSES OF EACH ASSET INVENTORIED. TO CONCLUDE, A SECURITY OPERATION CENTER IS ESTABLISHED BETWEEN THE CORPORATE AND INDUSTRIAL ENVIRONMENTS, CREATING AN INTEGRATED CYBERSECURITY ECOSYSTEM.
Technical Session
ENERGY MANAGEMENT SYSTEM AT WAELZHOLZ BRASMEtAL
Presenter(s): THAIZA MARQUES SILVA ATILIO (WAELZHOLZ BRASMETAL), Heloize moraes cardoso (waelzholz brasmetal), Marcelo Ferreira Lucas (WAELZHOLZ BRASMETAL)
Abstract:
This paper aimed to present the case study conducted at Waelzholz Brasmetal, which explored the implementation of the Energy Management System to improve the organization's energy efficiency and sustainability. The methodology followed four main stages adapted from ISO 50001: Context and Planning, Support and Operation, Performance Evaluation, and Improvement. The results demonstrated the efficient energy use management, implementation of improvement actions, compliance with legal requirements and reduction of operational costs. It was observed that applying ISO 50001 requirements at Waelzholz Brasmetal provided significant improvements in energy performance, in addition to being a tool for competitiveness and environmental preservation
Technical Session
EVALUATION OF THE USE OF GREEN HYDROGEN IN STEELMAKING PROCESSES: ARCELORMITTAL INItIATIVES FOR APPLICATION
Presenter(s): Alex Milton Albergaria Campos (arcelormittal), Ricardo Tauffer (arcelormittal), wiverton silva (arcelormittal), Juliana Alves (arcelormittal), Rinaldo Pedrini (ArcelorMittal Pecem)
Abstract:
The increasing need to reduce carbon emissions and the search for more environmentally friendly practices have driven the research and development of green hydrogen as a viable alternative to replacing fossil fuels in steelmaking processes. This article explores the emerging applications of green hydrogen in the steel industry, outlining the potential impacts of this sustainable energy source. Furthermore, it addresses green hydrogen production processes, the technological challenges associated with its implementation in the steel industry and compares its efficiency with conventional energy sources. In this way, the work contributes to a deeper understanding of the implications of green hydrogen in the steel industry, highlighting its role in the transition to cleaner and more sustainable industrial practices. In the other hand, it will show some initiatives of ArcelorMittal on green hydrogen.The findings offer valuable insights for researchers and industry professionals seeking to promote sustainability in steel production
Technical Session
9/3/24, 9:25 AM - 9/3/24, 9:50 AM
Presenter(s): MARCUS VINICIUS PEREIRA ARRUDA (USIMINAS - IPATINGA), Fernando de Souza Costa (Usiminas), Juliana Cristina de Paula (Usiminas), Sinésio Domingues Franco (Universidade Federal de Uberlândia)
Abstract:
In this study, samples of a cold-rolled 3rd generation AHSS of the 1000 MPa strength class were evaluated on slow strain rate tests (SSRT) under different conditions of hydrogen charging. Using the thermal desorption analysis (TDA), two diffusible hydrogen levels were obtained in the steel and thus their effect on the degradation of mechanical properties in tension was compared to the uncharged condition. For the lowest hydrogen content evaluated, of the order of 0.61 ppm, there was no considerable loss of mechanical properties in relation to the uncharged condition. However, for the highest hydrogen concentration, close to 1.16 ppm, a significant drop in total elongation values was noticed, with a calculated embrittlement index of 38.3%. The methodology applied made it possible to distinguish the degradation of mechanical properties depending on the hydrogen concentration of the material, constituting an important tool for the development and application engineering of AHSS for the automotive sector.
Technical Session
CUSTOMIZED AND COST-EFFECTIVE SOLUTIONS FOR PRODUCTION AND PRODUCT MIX INCREASE IN HDGL FURNACES REVAMPING: A TECHNICAL AND ERECTION CHALLENGE
Presenter(s): Giovanni Carozzo (Danieli), Filippo De Santi (Danieli)
Abstract:
Technological competitiveness and OpEx reduction combined with the shortest possible downtime are the driving forces for a revamping project. In this paper a real case of a turn-key project performed by Danieli Centro Combustion on a HDGL annealing furnace is presented. Cooling and soaking sections of the furnace have been modified from horizontal to vertical configuration and most of the erection has been safely performed during normal production with the aim of downtown minimization. The outcomes of the project are productivity increase, natural gas consumption reduction and product mix extension, permitting the customer to produce AHSS grades thanks to the increased soaking time in the radiant tube section and the rapid cooling section.
Technical Session
EVALUATION OF MICROSTRUCTURE AND MECHANICAL PROPERTIES OF SAE 4130 STEEL FROM DIFFERENT ANNEALING ROUTES
Presenter(s): Gabriela Deslandes Cardoso (Universidade Federal de Minas Gerais), Lara Fernandes Rocha Barbosa Lima (Vallourec Tubos para Indústria), Mirelle Oliveira Spindola (UNIVERSIDADE FEDERAL DE MINAS GERAIS), Leandro de Arruda Santos (UNIVERSIDADE FEDERAL DE MINAS GERAIS)
Abstract:
Annealing heat treatment is usual after cold drawn process of SAE 4130 steel, considering the requirement to obtain ferrite and pearlite microstructure and higher ductility. This work evaluated the effects of full annealing and intercritical annealing heat treatments after the cold drawn process. Mechanical properties and the final microstructure obtained in both routes were evaluated. It was observed that the full annealing route presented ferrite and lamellar pearlite, whereas the intercritical annealing route presented ferrite and degenerated pearlite. The difference in microstructure affected the mechanical properties, as observed in yield strength, hardness and elongation. Although the yield strength did not present significant differences for both routes, the full annealing route showed higher tensile strength and hardness than the one found in intercritical annealing route. Considering the increase in ductility as the main objective, the intercritical annealing proved to be more efficient.
Technical Session
EFFECT OF BOTTOM LEVEL VARIATIONS OVER LANCE LEAKAGE AND RISK OF WATER INSIDE CONVERTER
Presenter(s): Amilton Carlos Pinheiro Cardoso Filho (GERDAU), Breno Totti Maia (Lumar), Fernando Victor de Knegt (GERDAU), Eric Novaes de Almeida (GERDAU), Isabela Cristina Barbosa Fernandes (GERDAU), João Paulo Maforte Santos (Lumar), Wellington Morais Andrade (Lumar)
Abstract:
Oxygen converters have programs to determine lance-to-bath height (DBL) from reference measurements of the bottom and bath levels. These references are length measurements that represent a volume. However, they are punctual and generally taken as a reference to the center of the converter. This article investigates the effect of the uneven rise of the BOF bottom on lance leakage. The results show that non-uniform bottom elevation is the cause of premature lance leakage and suggests some countermeasure actions
Technical Session
9/3/24, 9:25 AM - 9/3/24, 9:50 AM
Presenter(s): alisson paulo de oliveira (NSIGMA CONSULTING LTD), GILBERSON MENDONÇA STORCK DE MELO (GERDAU S/A), NICOLAS TENAGLIA (ADVANCED STEEL PROCESSING AND PRODUCTS RESEARCH CENTER, COLORADO SCHOOL OF MINES), EMMANUEL DE MOOR (ADVANCED STEEL PROCESSING AND PRODUCTS RESEARCH CENTER, COLORADO SCHOOL OF MINES), PELLO URANGA (CEIT-BRTA AND UNIVERSITY OF NAVARRA-TECNUN)
Abstract:
This work aims to determine the influence of solidification/cooling parameters on the microsegregation of HSLA+Nb steel slabs at different positions. Microsegregation is seen as one of the most important sources for variability in metallurgical properties, especially toughness, and measures that seek to reduce the microstructural banding and preferential precipitation will result in greater microstructural homogeneity and lower properties variability. The samples were taken at positions along the width (Center and -294mm in relation to the center) and thickness of the slab (12.50, 37.50, 102.50 and 125.00mm). Electron Probe Microanalysis (EPMA) by Wavelength-Dispersive X-Ray Spectroscopy (WDS) was performed to quantitatively characterize the microsegregation of several elements (C, Mn, Si, P, S, Nb and Ti) in the dendritic and in interdendritic areas. SDAS (Secondary Dendrite Arm Spacing) measurements were carried out, which allowed to calculate the cooling rate, using published equations, in each position. This work allowed to understand in detail the behavior of the different chemical elements in different positions in a cast slab, as well as to determine the influence of the cooling rate on this behavior. This knowledge can be the basis for process optimizations aimed at reducing microsegregation in products where microstructural homogeneity is a critical product quality factor.
Technical Session
DEVELOPMENT OF MGO-ULC BRICK TO RUHRSTAHL HERAEUS LOWER VESSEL.
Presenter(s): Juliana Aguiar coelho (TERNIUM), Luísa saisse de melo (ternium), Raphaela danubio da mota araujo (ternium), Lara alves vieira (rhi magnesita), giovanni ferreira coimbra (ternium), leandro rocha martins (rhi magnesita), cleber guimarães pires (rhi magnesita), SÉRGIO LUIZ CABRAL SILVA (rhi magnesita), SÉRGIO EUSTAQUIO SOARES (rhi magnesita)
Abstract:
For the purpose of extend the life cycle of the RH lower vessel campaign, increase operational safety and reduce CO2 emissions, ultra-low carbon (ULC) refractory bricks were developed, which have a low carbon content (≤ 1.8%wt) using a special type of graphite for application in the throat region of the RH lower vessel. Initial tests carried out in partnership with RHI Magnesita indicated significant improvements. The results show that the performance achieved with the MgO-ULC lining surpasses that of the magnesia-chromite bricks traditionally used, indicating a longer life cycle potential. In addition, it was found that it is possible to produce ultra-low carbon steels under these new conditions. At the same time, interest is growing in the development of new materials for lining RH degassing vessels. Traditionally, the RH vessel is lined with chrome-magnesium materials, a choice driven by the needs of the process, which aims to reduce the carbon contained in the liquid steel. Refractory linings that deviate from the chrome-magnesian composition are rare, highlighting the need for innovation in this sector.
Technical Session
9/3/24, 9:25 AM - 9/3/24, 9:50 AM
Presenter(s): Gabriela fernandes lima (Universidade federal fluminense)
Abstract:
Iron ore is predominantly transported by rail in open wagons. Therefore, it is crucial to take special precautions to prevent wind erosion of the cargo during transit. Wind erosion can lead to economic losses and significantly impact air quality in areas surrounding the railway network. Consequently, railways handling this type of cargo implement specific systems to control particulate emissions during iron ore transport. In this context, the project's scope is to prepare and characterize polymeric films capable of performing this function. The films were prepared using chitosan as the polymer, due to its ease of manipulation and biodegradable nature, and a 4% acetic acid solution as the solvent. The films produced from these solutions underwent absorption and wind tunnel tests. These procedures were implemented to establish the essential parameters for producing an effective film that meets market demands and helps address the current challenges in iron ore transport.
Technical Session
OPORTUNITIES TO REDUCE UP TO 50% CO2 EMISSIONS IN INTEGRATED MILLS
Presenter(s): Davi silva Braga (COREM), Ronaldo santos sampaio (rsconsultants)
Abstract:
The source of the problem is where the best solution will come from. The principle of circularity states that all waste needs to find a sustainable solution and many other predicates. CO2 equivalent emissions will be reduced by increasing the efficiency of coke-integrated steelmaking, increasing the iron content in ores and replacing fossil carbon with renewable carbon in sintering and injection into AF. CO2 reduction can exceed 50% without new technologies. Seven examples of how to reduce emissions in the integrated plant with minimal capital and with productivity gains in the Blast Furnace and BOF, less sulfur in the pig iron, less carbonates and much less AF slag. The richer iron sinter feed (+3.2%) and the greater use of scrap in the BOF converter (13.8 to 19.8%) reduce emissions by 13%. Using charcoal in the agglomeration and injection of pulverized charcoal reduces CO2 by 37.8%. Combining iron enrichment with partial replacement of the fossil (in sintering and PCI) this CO2 reduction reaches 49.1%. All this with a reduction in the use of limestone and lime and lower sulfur content in the pig iron and lower emissions of SOx, NOx, and others.
Technical Session
Recovery of operational stability of blast furnace 01 at ternium brazil
Presenter(s): cesar lima vendas (ternium), rodrigo Faislon Kubrusly (ternium), Geovane viturino da silva (ternium), Luciano Augusto Morais Maia (ternium)
Abstract:
The Blast Furnace 1 at Ternium Brazil began its campaign in 2010. During this period, it had not faced operational instability lasting nearly 47 days. The causes of the operational instability, which obstructed the 32 tuyeres, were the loss of thermal load generated by the irregular distribution of burden. The major challenges faced were the difficult slag runoff and the loss of communication between the tap holes and the tuyeres. The solutions found involved the use of oxygen and natural gas lances through the tap holes. After the recovery of the blast furnace, the importance of the reliability of measurement instruments and reinforced sealing in critical regions of the tuyeres was recognized, in addition to the need for persistent use of natural gas and oxygen lances.
Technical Session
9/3/24, 9:25 AM - 9/3/24, 9:50 AM
Presenter(s): gerson evaristo de paula júnior (USIMINAS - IPATINGA), beatriz fausta gandra (usiminas), Cleyde Regina Campos Silva Netto (usiminas)
Abstract:
The sinter feed chemical composition determines an important role in its assimilation property and consequently the sinter quality. The sinter contaminants imply higher blast furnaces’ slag volume, which can reduce their productivity and the pulverized coal injection rate. One of the contaminants that has increased considerably is alumina, which impacts the physical and metallurgical sinter quality and the sintering process productivity. Therefore, the present study focused on studying the effect of different alumina sources on the iron ore assimilation properties and the impact of this compound on the sintering process and sinter quality. From the results, it was found that alumina in hydroxide form is more harmful to the sinter quality than its silicate form. Furthermore, alumina harmed the sinter pot test productivity, sinter mechanical resistance and, considerably, the reduction degradation index (RDI) of the sinters produced.
Technical Session
DEVELOPMENT OF WC PINS MORE RESISTANT TO WEAR FOR HPGR IN THE PELLETIZATION PROCESS – PART 1
Presenter(s): gilvandro bueno (Vale S.a.), Wesley Queiroz Silva (VALE), Suian Andrade Meira (VALE), VINICIUS PERIN PASSIGATTI (VALE), Luis Henrique Torres Dantas (VALE), José Jimmy Penagos (ITV)
Abstract:
In High Pressure Grinding Rolls (HPGR) the particles within a continuous flow of passing ore between the rolls are subjected to high pressures, resulting in their fragmentation and specific surface gains. Its application in grinding iron ore concentrates for pelletizing is associated with increased productivity and pellet quality. In this process, it is common to use roll surfaces composed of studs made of wear-resistant material, Tungsten Carbide (WC). Despite the advancements in this material, wear resistance remains the major challenge in extending the lifespan of the rolls. Analyzing the studs wear mechanism, 8 classes of WC studs were defined for a field test with different percentages of Cobalt (Co) and Nickel (Ni) binders and varying carbide grain sizes. The modified studs were evenly distributed around the roll’s perimeter, with rows of 63 units for each class, being tested over more than 26 thousand hours, approximately 4 years of operation, during which 11.3 million tons of ore were processed. Stud wear was monitored by measuring their height throughout the testing period, totaling ten measurements using a perforated ruler and caliper. The best results at the end of the test showed a wear reduction to less than 0.45 mm/1000 hours of operation or 1.04 mm/ton of processed ore. This corresponds to an increase in stand lifespan of over 25% compared to commonly used studs.
Technical Session
CFD MULTISCALE SIMULATION OF MULTIPLE GAS-SOLID REACTIONS IN THE INDUSTRIAL IRONMAKING PROCESS
Presenter(s): Patrícia Metolina (IPT/USP)
Abstract:
In this study, a 2D axisymmetric multiscale model was proposed to describe the direct reduction of iron ore process in a moving bed reactor. The system comprises the downward movement of porous iron ore pellets reacting with the countercurrent gaseous flow entering from the side and lower part of the reactor. The grain kinetic model and the mass, heat, and momentum equations for the two discretized physical of pellets and reactor were solved using finite element method. The results provided a detailed evaluation of the heterogeneities within the reactor and solid pellets, demonstrating good predictive capability with data from an industrial direct reduction plant. The model can be extended to design the process for the energy transition towards low-carbon iron production by increasing the hydrogen content in the process.
Technical Session
COMPARATIVE ANALYSIS OF SAE 4320 AND DIN20MN5CR STEEL APPLIED IN THE MANUFACTURE OF DIFFERENTIAL GEARS FOR ELECTRIC VEHICLELS
Presenter(s): Maria luiza dos santos (Universidade de Passo Fundo), pietro perussatto (Universidade de Passo Fundo), charles leonardo israel (Universidade de Passo Fundo), William Haupt (Universidade de Passo Fundo), deividi nardi (dstrac performance 4x4)
Abstract:
The present work addresses the evaluation of gears that make up electric vehicle differentials. The SAE 4320 and DIN20Mn5Cr steels were manufactured through the microfusion process, carburized and heat treated through martempering with tempering and austempering with sub-zero cooling with evaluation of the macrostructures, microstructures and microhardness profile starting from the carburized layer towards the core. During their evaluation, the pieces underwent standard metallographic preparation with different types of metallographic attack to evaluate their microstructures under an optical microscope and scanning electron microscope. A primary grain size analysis was carried out using specific metallographic etching. The macrostructure revealed cemented layers with lower thickness for group B. In the microstructural analysis, the formation of a normal microstructure of martensite and bainite was observed for groups A and B, SAE 4320 steels, whereas groups C and D, DIN20Mn5Cr steel, showed formation of martensite and bainite together with retained austenite indicating a possible weakening of the components in their subsequent application. The microhardness profiles indicated higher hardness for the materials that underwent martempering and tempering in relation to the austempered+sub-zero materials.
Technical Session
DRUM REPLACEMENT IN BELT CONVEYOR: PLANNING, EXECUTION, AND SAFETY
Presenter(s): ronald da silva guterres (vale s/a), André Luis Pinto (vale s/a), Camilo Lelles Santos Neto (vale s/a), Edson Diniz Serra (vale s/a), Kescijones Brito Mesquita (vale s/a), Gilbert Oliveira Santos (vale s/a), LUIS FERNANDO ALVES FURTADO (VALE S/A), Leonardo Andre Moreira Lima Carvalho (valr/sa), RONALD DA SILVA GUTERRES (VALE S/A)
Abstract:
Drum replacement in a belt conveyor is a critical maintenance task that requires structured planning to ensure safety and efficiency. This article provides a detailed analysis of the procedure, including the use of specific devices and techniques for drum replacement. It addresses the importance of safety and best maintenance practices to maintain asset integrity, highlighting the use of safety devices and engineering techniques to mitigate risks. The conclusion emphasizes the need for training and use of protective equipment.
Keynote Speaker
9/3/24, 9:25 AM - 9/3/24, 10:15 AM
Presenter(s): Bern Klein; Prof. University British Columbia, Canada
Abstract:
Keynote Speaker
9/3/24, 9:25 AM - 9/3/24, 10:15 AM
Presenter(s): Bern Klein; Prof. University British Columbia, Canada
Abstract:
Keynote Speaker
9/3/24, 9:25 AM - 9/3/24, 10:15 AM
Presenter(s): Beatriz Luz, President of the Brazilian Institute of Circular Economy (IBEC) and CEO of Exchange 4 Change Brasil.
Abstract:
Technical Session
9/3/24, 9:50 AM - 9/3/24, 10:15 AM
Presenter(s): Vitor Guarnier Domiciano (RHI MAGNESITA)
Abstract:
The use of wet-shotcrete as an installation technique has become widespread worldwide due to its simplicity and benefits such as form-free and fast installation, minimum dust and rebound, short turnaround times and good thermo-mechanical properties. In recent years, colloidal silica bonded shotcrete castables have been used in different refractory applications combining faster and safer dry-out and superior refractory lining performance when compared to cement bonded castables. The development of high-performance shotcrete castables depends on several factors, including the use of suitable shotcrete accelerator. This study investigates the influence of different shotcrete accelerators, A (reference) and B (new develoment), on the installation characteristics and properties of a colloidal silica bonded refractory castable. An Al2O3-SiC-SiO2-C based sol-bonded castable was shotcreted using accelerator A or B and the refractory panels were characterized after drying and firing at different conditions. Results showed that accelerator B provided a smoother reaction with the silica sol binder, eliminating material pulsation during shotcreting, also improving the materials´ surface finishing. Although no substantial differences were noticed in the physical properties, a significant improvement in mechanical strength (MoR, CCS and HMoR) and abrasion resistance was observed when using accelerator B. Therefore, the choice of shotcrete accelerator can significantly influence the installation quality of sol-bonded refractory castables, positively impacting the installed material´s properties and enhancing the refractory lining performance.
Technical Session
STEELTRACK
Presenter(s): PAULO MARCELO CAMATTA (ARCELORMITTAL TUBARÃO), Jardel Mendes Prudêncio (ArcelorMittal Vega), Camila Fonseca Guimarães (ArcelorMittal Tubarão), Frederico Jácome Ataide (ArcelorMittal Tubarão), Givaldo Cavalcante Rabelo (IT Strategy), Vitória Angélica Urci Silva (IT Strategy)
Abstract:
The Steeltrack project was developed to automate the collection and interpretation of planning and logistics’ informations from Arcelormittal Brazil Flat Carbon. The system provides analytics and predictive indicators that assist on decision-making in differents business areas, also improving performance and anticipating possible problems.
Technical Session
9/3/24, 9:50 AM - 9/3/24, 10:15 AM
Presenter(s): ALEXANDRE EMILIANO MOREIRA (tsa - tecnologia de sistemas de automação s/a), Arthur Reis de menezes (lYNX OTIMIZACÃO DE PROCESSOS S/A)
Abstract:
The indirect coke temperature measurement system used on AcelorMittal’s Coke battery is a project which objective is to obtain the coke oven wall’s temperature curves during the pushing operation. The system is based on the integration between the control systems and the Lynx Process Platform LYNX RTP (RealTime Plataform). This platform provides a layer of computer intelligence totally integrated with the current automation architecture on the industrial plants. The data read by the pyromethers connected on the PLC’s of each machine can be treated, processed and used for decision-making on several industrial necessities. The integration between the Lynx RTP and the controllers network allow the new technologies and computer models to be used on the automation process, forwarding with the digitalization and integration of the most current market technologies
Technical Session
FUEL OF THE FUTURE: CHALLENGES AND PERSPECTIVES FOR THE INCREASE OF BIODIESEL CONTENT IN BRAZIL
Presenter(s): Davi fernandes de carvalho (VALE), Joao Lucas da Conceição de Barros (vale), Atilson Amaury de Souza Neto (vale), Ana clara soares bicalho (vale), Victor Machado Salvador de Oliveira (vale), sandro guimaraes souza (vale), Marcelo ribeiro carlos (vale)
Abstract:
Biodiesel emerges as a valuable commodity in Brazilian agriculture, offering opportunities for energy diversification and mitigation of polluting gas emissions. However, its quality assurance faces obstacles, such as oxidation during storage and transportation, as well as the tendency to crystallize at low temperatures, challenges aggravated by the country's extensive road network and climate variability. As for nitrogen oxides (NOx) emissions, there are discussions about their impact, with divergent studies. Despite the potential, the large-scale replacement of petrodiesel faces challenges due to restrictions in the production of vegetable oils and their prioritization in human food. Thus, it is crucial to review policies and investments to boost biodiesel, including considering crops exclusively for energy. This literature review seeks to provide a comprehensive overview of the current state of biodiesel application in Brazil, highlighting the challenges faced and alternatives to these issues.
Technical Session
9/3/24, 9:50 AM - 9/3/24, 10:15 AM
Presenter(s): Isabelle Vitória Medeiros dos Santos (Vale S.A.), Mara da Silva Lopes (Vale S.A.), Eduardo Filipe Pereira Maciel (Vale S.A.)
Abstract:
In the mining industry, the use of conveyor belts to transport large volumes of material over long distances is common and facilitates the productive flow. However, due to operational characteristics, no-load operation of these systems can be frequent. This paper addresses the reduction of conveyor belt drive motor speeds when operating without load as an effective strategy for optimizing operations in the mining sector, ensuring improved performance and focusing on aspects such as increased efficiency and operational profitability, in addition to minimizing environmental impacts. The analysis of idleness in the presented circuit and consideration of optimized operation showed a high potential for avoided loss.
Technical Session
EFFECT OF AUSTENITIZING CONDITION ON THE CARBIDE DISSOLUTION AND MARTENSITIC TRANSFORMATION TEMPERATURE IN A STAINLESS STEEL AISI 420A (SUS420J2)
Presenter(s): GERALDO LUCIO DE FARIA (Universidade Federal de Ouro Preto), Tibério Graco Botelho Torres Duarte (Universidade Federal de Ouro Preto), Paulo Sérgio Moreira (Universidade Federal de Ouro Preto), Cláudio Moreira de Alcântara (APERAM southamerica)
Abstract:
The AISI 420A (SUS420J2) stainless steel is commonly subjected to quenching and tempering heat treatments when intended for various high-value applications. However, the proper selection of the austenitizing temperature, a step preceding the fast cooling in quenching, remains challenging. Numerous reports in the literature, as well as in industry, make it clear that slight alterations in this parameter strongly modify the mechanical properties of tempered products, even when using the same cooling rate. In this context, the present study aimed to evaluate the effect of the austenitizing temperature on the carbide dissolution and the martensitic transformation in this steel. For this purpose, resources such as computer thermodynamic simulation and dilatometry were used concomitantly with structural characterization techniques. It was concluded that with the increase in temperature in association with the continuous carbide dissolution, there was a significant austenite enrichment in C and Cr, which strongly contributed to the decrease in martensitic transformation critical temperatures. In this scenario, the increase in austenitizing temperature led to a significant hardening of the martensitic microstructure, reaching up to a 59% increase in Vickers hardness with a 275°C increase in this heat treatment parameter.
Technical Session
Welding Reclaiming of Vertical Edger Rolls in a Hot Strip Mill
Presenter(s): Juan llano (Shanghai Tangshan heavy machinery international -TSR-)
Abstract:
This article describes the roll reclaiming by welding and reuse of the vertical edger rolls in a Hot Strip Mill and the advantages and economic results. The roll surfacing materials should be reasonably selected and the surfacing repair plan formulated based on the rolling operation conditions to maximize the roughness of the surfacing repair. The surface quality of the roughing vertical rolls during rolling is continuously improved and the edge quality of the strip is improved, and the consumption of the rolls is reduced.
Technical Session
SCALE-FREE FURNACE
Presenter(s): Salamone Elisa (Danieli), BILIOTTI ANDREA (Danieli)
Abstract:
The scale formation in a reheating furnace depends on the O2 content at high temperature and the charging permanence time inside the furnace chamber. As the temperature and the permanence time of the steel inside the furnace are parameters that cannot be changed because coming from the process, the only way to reduce the scale formation is decreasing the O2 content in high temperature zones. For this reason, Danieli Centro Combustion studied and already supplied three H2 Ready Scale Free Furnaces, that have the features to be capable of operating in reducing atmosphere, in a completely safety condition. The sealing of the furnace avoid the exit of dangerous incombustion gases but also the entrance of false air, responsible for an increase of the specific consumption. The Scale Free Furnace technology, compare to a traditional Walking Beam furnace, halve the scale formation and reduce of approx. 5% the fuel consumption and CO2 emissions
Technical Session
9/3/24, 9:50 AM - 9/3/24, 10:15 AM
Presenter(s): Haysler Apolinário Amoroso Lima (Shinagawa), douglas fernando galesi (shinagawa), ana carolina gaiotto (shinagawa)
Abstract:
The performance of a steel mill relies heavily on the stability of its production equipment, with combined blowing being crucial to ensure the chemical homogeneity of the steel, thereby decreasing the total iron content in slag (metallic yield) and enhancing the dephosphorization rate. The combined blowing system comprises a set of tuyeres for injecting inert gases from the bottom. During tuyere operation, various fluid dynamic phenomena occur, leading to increased refractory wear, decreased lifespan, and disruptions in combined blowing operations. This study aimed to develop a new tuyere design to enhance the steel mixing rate and reduce wear, ultimately improving the efficiency of combined blowing.
Technical Session
9/3/24, 9:50 AM - 9/3/24, 10:15 AM
Presenter(s): Alexandre de Freitas gomes de mendonça (USIMINAS - IPATINGA), Leandro Vilas Boas Fantini (USIMINAS - IPATINGA), Hormando Leocádio JÚnior (USIMINAS - IPATINGA)
Abstract:
The Steelmaking Plant 2 of Usiminas operates with two casting machines with two strands each. A diagnosis of the secondary cooling spray air mist nozzle showed a water distribution profile performance of 50% and variability in the heat transfer coefficient of 38%. In front of this, the spray nozzle supplier developed a new bench design that increased the regularity of the distribution profile to 80% and reduced the variability in the heat transfer coefficient to less than 10%. Subsequently, a comparative test was carried out on one of the strands. The experiment strand with the new spray nozzle design showed greater thermal regularity across the slab width and a smoother and more gradual thermal transition between segments. An increase in slab quality was also found by reducing the intensity of the central segregation thickness by up to 0.50 mm, reducing the intensity of the size of horizontal cracks by 47% and reducing the formation of superficial cracks by 12.5% in peritectic medium carbon steel scarfed. The new spray nozzle design creates opportunities for the development of new spray plans and enhances the potential for slab quality improvement.
Technical Session
INNOVATIVE SOLUTIONS FOR IMPROVED PERFORMANCE IN RH DEGASSERS – A TURNAROUND CASE
Presenter(s): Wagner JESUS Souza (RHI Magnesita), Tito hugo nogueira coelho (GERDAU OURO Branco), Jose Alvaro Previato Sardelli (RHI Magnesita), Jose Alvaro Previato Sardelli (RHI Magnesita), Sergio Eustaquio Soares (RHI Magnesita), Eric Novaes de Almeida (GERDAU OURO BRANCO), pedro mourão domingos (RHI Magnesita), bruno filipe guimarães (RHI Magnesita)
Abstract:
Over the years, rebonded magnesia-chromite bricks have been extensively utilized in critical regions of RH Degassers. However, with the evolution of steelmaking processes requiring higher-grade steel productions, arises a need to enhance these materials to achieve the new demands placed on refractory during applications. The objective of this study was to identify the primary factors contributing to the current situation and create effective solutions to address these challenges. This paper provides an overview of the steps taken to identify the main issues, along with the methodologies employed to thoroughly understand all variables. This study delved into the challenging performance scenario encountered in the RH Degasser at Gerdau Ouro Branco, utilizing magnesia-chromite bricks from RHI Magnesita. Prior to implementing any alterations to the refractory, a thorough and extensive understanding of the case was pursued, aiming to determine the primary causes and propose technical solutions aligned with GOB's objectives. A novel technology for measuring wear rate was developed, providing insights through its innovative measurement concept. In-depth thermomechanical simulation studies were conducted, leading to a comprehensive understanding of the primary mechanisms experienced by the refractory. Following adjustments to the refractory concept based on these findings, a successful turnaround in the RH Degasser was succeeded, with throats achieving a potential of 350 heats.
Technical Session
CHARACTERIZATION OF SUGARCANE BAGASSE FOR USE IN HIGH-PERFORMANCE COATINGS OF EPOXY COMPOSITES
Presenter(s): Juliana Sousa Gomes Ribeiro (Universidade Estadual do Norte Fluminense Darcy Ribeiro), FELIPE PERISSÉ DUARTE LOPES (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO), Luís Fernando Fortunato de Freitas (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO), Júlio Cezar Barboza Silva (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO), NOAN TONINI SIMONASSI (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO), CARLOS MAURÍCIO FONTES VIEIRA (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO.)
Abstract:
The increasing industrial demand for sustainable products has driven research into new components that combine efficiency and eco-friendliness. In this context, polymeric composites, particularly those reinforced with natural fibers, have gained prominence. Epoxy, widely used due to its exceptional properties such as easy handling, high strength, and effective adhesion to reinforcements, is one of the most employed polymers in these materials. Studies have shown significant improvements in the physicochemical properties of the resin when reinforced with natural fibers such as Agave, Bamboo, Linen, Jute, Kenaf, and Sisal. Sugarcane bagasse, an abundant lignocellulosic residue composed mainly of cellulose, hemicellulose, and lignin, emerges as a promising reinforcement alternative for epoxy resins. This work aims to investigate the characteristics of sugarcane bagasse through techniques such as X-ray diffraction and infrared spectroscopy, with the objective of assessing its feasibility as a reinforcement in high-performance coatings based on epoxy resin.
Technical Session
9/3/24, 9:50 AM - 9/3/24, 10:15 AM
Presenter(s): MANOEL VÍTOR BOREL GONÇALVES (TECNORED)
Abstract:
During steel production a large volume of solid waste is generated. Some are commonly reused, while others, e.g. containing zinc, have restricted use in the traditional steelmaking route. Zinc, the fourth most consumed metal globally, has primary reserves that are limited compared to global demand. This study presented a new pyrometallurgical route to recover zinc from steelmaking residues using the Tecnored Recycler pilot furnace. In the first step, self-reducing briquettes doped with high-purity ZnO were used to evaluate the furnace's behavior. In the second stage, briquettes containing by-products were tested. The results indicated that the Tecnored furnace can efficiently operate with charges containing up to 10% ZnO, maintaining the quality of pig iron and the thermal performance of the furnace. Zinc recovery was significant, with concentrations exceeding 50%, highlighting the technology's potential to improve this efficiency. The specific geometry of the Tecnored Recycler furnace and its gas cleaning system were essential for the process's effectiveness. This development proposes a sustainable, low CO2 emission solution for recycling steelmaking residues, contributing to the circular economy. Additionally, it adds value to by-products and enhances the sustainability of pig iron production.
Technical Session
HIGH PERFORMANCE OF USIMINAS/IPATINGA’S BLAST FURNACE#3 IN ITS 4th CAMPAIGN
Presenter(s): Mauro Vivaldino Fernandes (Usiminas), adriano cesar carvalhido (usiminas), Guilherme augusto de faria (usiminas)
Abstract:
Usiminas’ Blast Furnace#3 ended its 4th Campaign on April 24, 2023, after 23.5 years of operation. The 4th Campaign was designed for 15 years, with 41 million tons of hot metal as estimated production. Accumulated production reached 57.8 million tons, exceeding the value forecast for the campaign by 41%. The results of accumulated productivity and campaign life spotlights the Blast Furnace 3 in the global steel industry. This paper shows the main operational results evolution, process improvements introduced and preservation of the blast furnace lifespan.
Technical Session
ANALYSIS OF 40% SUBSTITUTION OF COKE FINES BY CHARCOAL IN SINTERING PROCESS USING CFD
Presenter(s): Érica Simões Rodrigues (ArcelorMittal), jOSÉ ADILSON DE CASTRO (uff), Ana Carolina Castro Barboza da Silva (UFF), Flavio Tulio Busatto (ArcelorMittal Tubarão), Jairo Alvarenga (ArcelorMittal Tubarão), Marcela Martins Amista (ArcelorMittal Tubarão)
Abstract:
The Brazilian steel industry has a challenging decarbonization agenda with important consequences for its domestic and global competitiveness. In this context, the sintering process represents an important portion of the primary iron manufacturing stage emissions. In this work, a model of the multiphase multicomponent sintering process coupled with chemical kinetics is used to analyze the possibility of partial substitution (40% of the fossil fuel) by charcoal. Results of 5 case analyses, compared to the reference case, indicate a predicted reduction of fossil CO2 equivalent emissions of approx. 80 kg CO2 equivalent per tonne of sinter produced.
Technical Session
REPLACING ANTHRACITE WITH BIOCARBON IN VALE'S PELLETIZING
Presenter(s): RoDRIGO BOYER FERNANDES (VALE S.A.), Caio Ferreira de Melo (vale s.a.), Davi Fernandes de Carvalho (VALE S.A.), Fernando Luiz Alves de Albertor (VALE S.A.), Danielle Raidan Daniel (VALE S.A.)
Abstract:
In the iron ore pelletizing process, anthracite is used as a solid fuel in the formation of green pellets, and its fundamental role in the burning stage is to reduce the thermal gradient between the top and bottom of the pellet layer. This allows for better energy efficiency in the process, resulting in reduced costs and improved physical and metallurgical properties. However, because it is of fossil origin, anthracite is one of the inputs that contributes most to the emission of Greenhouse Gases (GHG) in Vale's operations. The paper presents the results obtained both in a pilot plant and on an industrial scale during tests to replace anthracite with biocarbon (from renewable sources).
Technical Session
CARBONIZATION OF EUCALYPTUS BARKS IN A CIRCULAR REACTOR
Presenter(s): CRISTHIAN GUILHERME FERNANDES (Gerdau), Frank Danilo Rosa (Gerdau), Kaelen cristiano silva (gerdau), Guilherme Liziero Ruggio da Silva (Gerdau), natália rezende pinheiro leite (gerdau)
Abstract:
Steel mills, responsible for 10% of CO2 emissions worldwide, seek to reduce their carbon emissions, and a promising solution is the use of biomass as an energy source. Eucalyptus bark emerges as a viable option in this context. Besides offering a sustainable alternative for energy production in the steel industry, its use also contributes to reducing environmental liabilities, as these residues are frequently disposed of in landfills. Thus, the use of carbonized eucalyptus bark as a partial substitute for the coal used in the coking process not only promotes carbon emission mitigation but also helps manage vegetable residues more efficiently. The present study investigates the technical feasibility of eucalyptus bark carbonization using a circular furnace of the "hillside hot tail" or "barranco" type. The results obtained demonstrated a satisfactory increase in volatile matter, from 76.2% to 25.8%, and in ash content, from 5.6% to 9.8%, resulting in a carbon-rich residue suitable for use in the steel industry.
Technical Session
EFFECT OF SPHEROIDIZATION HEAT TREATMENT PARAMETERS ON THE DEGREE OF SPHEROIDIZATION OF SAE 8620 STEEL
Presenter(s): FELIPE MORENO SIQUEIRA BORGES DE CARVALHO (FIPT Fundação de apoio ao instituto de pesquisas tecnológicas)
Abstract:
SAE 8620 steel is widely used in the industry due to its combination of high strength, toughness, and good cold formability. Spheroidization heat treatment is a crucial process for enhancing these properties, preparing the steel for subsequent cold forming operations. This study aims to investigate the effects of spheroidization heat treatment parameters on the microstructure and degree of spheroidization of SAE 8620 steel. By using microstructural characterization techniques on samples treated in a muffle furnace, the impacts of temperature, holding time, and cooling rate after heat treatment were investigated. The results indicate that optimized spheroidization parameters can significantly improve the degree of spheroidization of the samples, reducing process times.
Technical Session
IMPLEMENTATION OF THE 5-STAR ASSET MANAGEMENT PROGRAM IN THE CONTINUOUS CASTING OPERATION OF ARCELORMITTAL TUBARÃO
Presenter(s): Harry dos santos knikkink (Arcelormittal tubarão)
Abstract:
At ArcelorMittal Tubarão FCLatam (Flat Carbon Latin America) asset management was implemented through the 5 Star Asset Management Program, the implementation process of which in the Continuous Casting Operation will be explained in this article. This program has evolved over the years, promoting new themes that can contribute to asset management. The program seeks the continuous evolution of reliability, quality and sustainability in Continuous Casting machines at ArcelorMittal Tubarão. The implementation of the 5 Star Operations Program is aligned with the company's strategic planning in the flat steel segment. Managing all these operational activities in a large industry is a task of extreme importance for the business results, but quite challenging, given the high number of employees involved and the level of technical responsibility for the activities in question. To ensure adequate execution in terms of method, frequency, responsibilities, adequate recording, assertiveness in tasks, it is essential to guarantee an efficient management system with this focus. In this context, the 5 Star Program was applied to the operation management of Continuous Casting at ArcelorMittal Tubarão to improve the management of the operation process as a whole. The methodology applied is based on maturity levels (fundamental, intermediate and advanced), where each level has supporting pillars. Some examples of pillars are: training, standardization, operation plans (PGO), H&S and environment, alarm and failure management, roles and responsibilities, variable cost, autonomous maintenance, asset use, operational efficiency, reaching advanced pillars such as risk management, supply chain, new technologies, interface management (Stakeholders) and human reliability
Technical Session
CHARACTERIZATION AND STUDY OF THE REACTIVITY OF SOME SOLID FUELS USED IN THE SINTERIZATION OF IRON ORE AT ARCELORMITTAL TUBARÃO
Presenter(s): Igor aniceto dos santos (arcelormittal tubarão), ramiro da conceição do nascimento júnior (instituto federal do espírito santo), simão vervloet ramos3 (INSTITUTO FEDERAL DO ESPÍRITO SANTO), erica simões rodrigues (arcelormittal tubarão), henrique falquetto camporez (sgs do brasil)
Abstract:
Solid fuels are the main source of heat supplied to the iron ores sintering process. Understanding the behavior of the fuels used in the process can represent a difference both in terms of optimizing this raw material in the mixture to be sintered and in operational performance itself. From an understanding of the relevance of the topic, the work proposed to evaluate the reactivity of 4 qualities of solid fuels used in the sintering process at ArcelorMittal Tubarão and establish a relationship between this property and some variables. Thermogravimetry and differential scanning calorimetry techniques were used to identify that the anthracite samples are more reactive than the coke samples. The most reactive anthracite sample showed a difference of around 16.3% compared to the least reactive coke sample. When compared between samples of the same nature, the anthracite samples showed no significant difference in reactivity between them, while the coke sample produced via the conventional coking process was around 6.5% more reactive than the coke sample produced via the heat recovery process. Among the variables evaluated, the fixed carbon content and the amount of ash present were the ones that most affected the reactivity of the samples.
Technical Session
9/3/24, 10:15 AM - 9/3/24, 11:05 AM
Presenter(s): adilson bernardo da silva (samarco), giovana da penha rocha (SAMARCO), zandonayd ribeiro de lima (SAMARCO), mirele bastos moreira (SAMARCO), valter bourguignon da silva junior (SAMARCO), MARCO ANTONIO ZUCHI (SAMARCO), carlos vinicius ribeiro murta (samarco)
Abstract:
The vacum filtration process involves separating solids and liquids using a filter medium. The objective of the work is to increase process productivity by evaluating the use of subscreens. The methodology includes monitoring and field tests with the filter in operation, allowing a detailed analysis of process behavior. The results from these tests validated the benefits of using subscreens in the filtration process. In addition to increased produvtivity, subscreens also contributed to reducing defects in the filter fabrics.
Technical Session
EVALUATION OF THE IMPACT OF BURNT LIME GRANULOMETRY IN THE SINTERIZATION PROCESS
Presenter(s): Flavio Tulio Busatto (ARCELORMITTAL - TUBARAO)
Abstract:
The sintering process is the result of a good quality selection of the raw materials consumed with efficient homogenization of this mixture. To obtain good performance of this mixture in the process, the preparation of the requires a good agglomeration process, which seeks the growth of quasi-particles through the addition of burnt lime and water in equipment designed for this purpose. In this way, adequate permeability is obtained for the sintering process, making sinter production viable. Given the scenario of quality degradation and thinning of ores and worsening of the nucleating/adherent ratio experienced by ArcelorMittal Tubarão Sintering, the process has required the need for better agglomeration conditions to ensure good performance of the production process. In order to overcome the current difficulties, an industrial test was carried out to replace the burn lime currently consumed with micro-pulverized burnt lime. The test result showed a good potential for recovery of 4% in productivity with a 9% reduction in quicklime consumption, showing that it is advantageous for the industry to replace conventional burnlime with micropulverized burnlime.
Technical Session
MODELING AND SIMULATION OF GREEN PELLET ROLLER SCREENING
Presenter(s): maciel rodrigues rocha bianchi (SAMARCO MINERAÇÃO S/A), Emerson Reikdal da Cunha (COPPE/UFRJ), Rodrigo Magalhães de Carvalho (COPPE/UFRJ)
Abstract:
The real-time monitoring of the size distribution of the raw pellet entering the kiln is directly related to the efficiency of the roller table classification. Given the difficulties in dealing with the granular flow of the pellets, there is a need for the development of a model that allows for predictions of flow characteristics on the furnace feed. In order to achieve this, a phenomenological model of the roller screening raw pellets was developed and validated using the discrete element method (DEM). The model allows, with lower computational cost, online monitoring of how variations occurring in pelletizing can influence the furnance permeability through the entry of fines into the bed of raw pellets
Technical Session
AUTOMATIC CONTROL OF IGNITION FURNACE TEMPERATURE FOR SINTERING
Presenter(s): mateus alves segundo paulino (arcelormittal pecém)
Abstract:
The sintering process demands continuous control of a large number of process parameters, where the internal temperature of the Ignition Furnace is the main parameter to ensure the initial burning of the mixture to be sintered. This article aims to explore the challenges of implementing an automatic control system, presenting operational aspects and PID control adjustments
Technical Session
CONTROL AND INHIBITION OF SCALE IN IRON ORE PELLETIZING PLANTS IN THE GAS WASHING SYSTEM OF SINTER FURNACES
Presenter(s): Thiago Augusto Silva (Veolia - Water Technologies & SOlUTIONS ), Augusto Luis Marucci (VEOLIA - WATER TECHNOLOGIES & SOLUTIONS ), Fernando Furakawa. (04368321600)
Abstract:
In mining, the formation of scale is a constant and inherent challenge in the most varied mineral processing operations, directly affecting the unit operation related to the problem, be it reducing the efficiency of pumps and pumping systems, filtration processes, pipes in general, evaporators and heat exchangers among others. Specifically in this Case Study (Iron Ore Processing Plant located in Brazil) the ScaleTrol PDC 9325 program was used as a way to control and inhibit the constant formation of scale, mainly formed by calcium carbonate and iron oxide in the washing system of gases (precipitator tank), which significantly reduced the physical availability of the system, overloading the circuit and causing interruptions and unscheduled stops for unblocking, cleaning and/or changing pipes
Technical Session
TRIBOCORROSIVE BEHAVIOR OF TOOL STEELS FOR APPLICATION IN AN IRON ORE AGGLOMERATION EQUIPMENT
Presenter(s): NIRVANA CECILIA RIBEIRO (INSTITUTO TECNOLÓGICO VALE), Renato Chaves Pereira da Silva (INSTITUTO TECNOLÓGICO VALE), José Luiz Pena Andrade (VALE S.A.), Cíntia Braga Briseno (VALE s.a.), Cristian Viáfara (INSTITUTO TECNOLÓGICO VALE), Raquel Vieira Mambrini (CEFET-MG), José Jimmy Penagos (INSTITUTO TECNOLÓGICO VALE)
Abstract:
The tribocorrosive behavior of two tool steels, AISI H13 and D2 steels, was investigated using Miller equipment using a methodology adapted from the ASTM G75 standard. Two types of iron ore slurries were used, and another one of a normal Brazilian sand (IPT) with a grain size of 0.30-0.15 mm. D2 steel (61 HRC), characterized by the presence of chromium carbides in a martensitic matrix, showed superior tribological performance when compared to H13 steel, a martensitic steel with a hardness of 52 HRC. Using the sand slurry as a reference D2 steel showed less wear, being 1.5 times less with the A1 ore slurry and 5 times less with the A2 ore slurry. The classification was observed for abrasiveness of the slurries: Sand>A1>A2. The images of the wear surfaces showed less corrosion on D2 steel compared to H13. In addition, both materials showed a greater trend to corrosion in wear tests with iron ore slurries. In the aim of increasing the useful life of an iron ore agglomeration equipment, AISI D2 steel showed high wear resistance, with the prospect of scalability for field tests.
Technical Session
MAFMINE ESG: Tool for Estimating Greenhouse Gas Emissions for Open-Pit Mining Projects
Presenter(s): uPIRAGIBE vINÍCIUS pINHEIRO (uNIVERSIDADE FEDERAL DO RIO GRANDE DO SUL (UFRGS)), Carlos Otávio Petter (UNIVERSIDADE FEDERAL DO RIO GRANDE DO SUL (UFRGS)), Weslei Monteiro Ambrós (UNIVERSIDADE FEDERAL DO RIO GRANDE DO SUL (UFRGS)), Fernando Alvez Cantini Cardozo (UNIVERSIDADE FEDERAL DO RIO GRANDE DO SUL (UFRGS)), João Vitor Martel (UNIVERSIDADE FEDERAL DO RIO GRANDE DO SUL (UFRGS)), Vinícius Krug de Souza (UNIVERSIDADE FEDERAL DO RIO GRANDE DO SUL (UFRGS))
Abstract:
The extraction of mineral resources begins with the project, followed by site construction, operation, closure, and final rehabilitation. The consumption of fuel and electricity associated with open-pit mining processes is one of the main sources of Greenhouse Gas (GHG) emissions. There are few studies dedicated to sustainable mining projects, indicating opportunities in this area. MAFMINE is software for mining projects, and the objective of this article is to describe the construction of the emissions module for MAFMINE ESG. This will allow for the determination of the economic and environmental sustainability level of open-pit mining projects. The development of a database for estimating emissions in mining projects is presented, using the information from MAFMINE reports as a starting point. Currently, the equipment quantified and dimensioned are trucks and excavators. The nominal capacity of these will correlate with the CO2 equivalent emission factor to generate the parametric models. Thus, a model with a simplified approach is proposed, aiming to offer a simple and quick response for the designer's decision-making.
Technical Session
mining and communities
Presenter(s): ALEXANDRE NEVES ROSENDO DA SILVA (UNIVERSIDADE FEDERAL DE OURO PRETO), endrew lucas dos santos de oliveira (universidade federal de ouro preto), Luana vomoca corradi (universidade federal de ouro preto), carlos alberto perreira (universidade federal de ouro preto)
Abstract:
All along its history, mining has significantly contributed to the development of societies. Its capacity to generate jobs and income makes nearby communities increasingly economically as well as socially developed. Nevertheless, just like any other industrial endeavour, mining activity has its negative aspects. Comparing the main aspects of the relations between mining industry and the communities that are part of its operational process, the results present the outcome of social and environmental ills that must be further mitigated by those involved in mining activity. The impacts of the building of an industrial zone in the outskirts of cities like Mariana and Ouro Preto turn them into a stage of social-cultural and economic phenomenoms capable of directly influencing the day-to-day life of the native population, as well as that of migrants who leave their places of origin to search for better conditions of life and labor.
Technical Session
MINING VERSUS SOCIETY
Presenter(s): LUDIMILA MARIA MATA DO CARMO (UFOP), Alait Vitor Dias Murta (UFOP), Camila Souza Silveira (UFOP), Hallan Souza Mendes (ufop), Junior Lucas Rodrigues Faria (Ufop), Carlos Alberto Pereira (ufop)
Abstract:
Mining is an ancient activity of extracting minerals from the underground, used to produce essential items, but it can also cause negative impacts. It generates jobs and contributes to the economy, yet it requires environmental and social licenses to minimize damages and engage communities. Sustainability is crucial, balancing environmental, social, and economic aspects. Projects like "Lithium Valley Brazil" exemplify the pursuit of economic benefits with environmental responsibility.
Technical Session
OPERATIONAL PERFORMANCE INCREASE THROUGH JAW CRUSHER CURRENT CONTROL
Presenter(s): Kaike Silva Albuquerque (Vale S.a.), Robson Aparecido Duarte (Vale S.A.), Alexandre Gomes Fonseca (Vale S.A.), Arley Athos Pereira Silva (Vale S.A.)
Abstract:
A common layout found in a primary crushing stage is a jaw crusher combined with vibrating grizzly feeder, usually without direct measurement of what is being fed into the crusher, in terms of feed rate or particle size distribution. Considering this, problems with jaw crushers overloads and obstructions are frequently encountered, causing operational stops and productivity reduction. This paper describes the development of a control strategy, applied in a Vale’s iron ore plant, capable of regulating the process in face of jaw crusher capacity violations caused by an overlimit feed rate or an overdimensioned material. The controller process variable used was an already existent crusher motor current, which is a reliable measurement, with high availability and requires small maintenance efforts unlike other instrumentation options. The results indicate an increase in operating hours between stops of 2.81 hours and a reduction of 9.8 percentage points in the ratio of unavailable hours per operating hours. Furthermore, there was a 9.0% increase in the average mass flow rate during the block restriction periods.
Technical Session
IMPLEMENTATION OF THE PDCA METHODOLOGY IN THE CONCENTRATE FILTERING PROCESS IN A POLYSULFIDE MINE
Presenter(s): Henrique adriano vieira do nascimento (UFOP UNIV FED. DE OURO PRETO -), Vinícius Novaes Park (UFOP UNIV FED. DE OURO PRETO -), Carlos Alberto Pereira (UFOP UNIV FED. DE OURO PRETO -), Crislaine Aparecida André de Souza (UFOP UNIV FED. DE OURO PRETO -)
Abstract:
Filtration, a unit operation in mineral treatment, involves passing ore pulp through a filtering element to retain the solid and allow the liquid to pass through. This process can face issues such as filtration efficiency, product losses, water consumption, and high operational costs. To produce zinc concentrates with a maximum moisture content of 11%, the PDCA methodology was applied, focusing on the "Plan" phase using filter presses. The investigation centered on the statistical feasibility of the company's moisture target, using gap and quartile methods, and quality tools for process stratification and analysis. Issues such as manual filter discharge, lack of plate structuring, and the absence of dedicated operators compromise process efficiency, affecting the moisture content of the products. The "Plan" phase of the PDCA Cycle resulted in a proposed action plan that can be strategically applied to filter operations, aiming to ensure that Zn concentrates meet the company's 11% moisture target.
Technical Session
Characterization and evaluation of the flotability of apatite, dolomite and calcite using a biodiesel as a collector
Presenter(s): Thiago Vinuto Mendonça (Universidade federal de minas gerais-ufmg), samuel bicalho henriques (Universidade federal de minas gerais-ufmg), Brenda ellen de souza martins (Universidade federal de minas gerais-ufmg), Esther dias de souza (Universidade federal de minas gerais-ufmg), Fernando luciano alves de souza (Universidade federal de minas gerais-ufmg), andreia bicalho henriques (Universidade federal de minas gerais-ufmg)
Abstract:
Phosphorus is a very important element for society. It is vitally important for the survival of any living being, especially in the production of energy in cells and in the formation of DNA. Its most stable form is in saline form, phosphate. The main way to find phosphates is in minerals, and apatite is the main one. In the phosphate rock where apatite is found, several other gangue minerals are also found, such as calcite, dolomite and silicate minerals, so the concentration stage is necessary to raise the P2O5 content in the concentrate to make it viable to use this mineral asset in agriculture. Flotation is therefore an important process for concentrating phosphate. This work studied the efficiency of a B100 biodiesel, supplied by Óleoplan Nordeste, used as a collector, in order to evaluate the flotability of apatite, dolomite and calcite, looking for a selectivity range
Technical Session
COLD PLASMA: A TREATMENT TO REDUCE THE MOISTURE AND THE WATER REABSORPTION IN IRON ORE CONCENTRATE
Presenter(s): Maíra rievrs nogueira alvares (centro de tecnologia mineral ), Marisa Bezerra de Mello Monte (centro de tecnologia mineral ), RENATA ANTOUN SIMAO (UNIVERSIDADE FEDERAL DO RIO DE JANEIRO )
Abstract:
The moisture content in the ore is a result of this beneficiation process, in addition to inherent moisture within the mineral composition. The moisture content of iron ore is a crucial parameter that requires effective control to ensure safe handling and transportation operations. Surface plasma treatment of iron ore has been investigated as a method to enhance the hydrophobicity of ore particles, thereby reducing residual moisture and water reabsorption by the particles. The samples underwent treatment using cold plasma of argon and hexamethyldisiloxane (HMDSO) plasma, leading to the formation of a thin, silicon-rich surface layer. The plasma treatment resulted in a reduction in moisture content and water absorption. The reabsorption of water decreased to approximately 35% of the pre-treatment values. Contact angle measurements demonstrated that all HMDSO-treated samples exhibited hydrophobic behavior, with contact angles ranging from 110° to 120°, while the untreated samples exhibited angles close to 0°
Technical Session
CHARACTERIZATION OF ALBITE-SPODUMENE PEGMATITES FROM EASTERN MINAS GERAIS: THE MAIN SOURCE OF LITHIUM IN HARD ROCK
Presenter(s): HUDSON DE ALMEIDA QUEIROZ (lct/usp), daniel uliana (lct/usp), carina ulsen (lct/usp)
Abstract:
Lithium, one of the so-called “critical minerals”, defined in the National Mining Plan 2030, has gained prominence in academic research and the mineral industry in recente Years. Its most importante deposits are found in brines and pegmatites, the latter a hard rock with important occurrences in Brazil. In this work, pegmatites from Eastern Minas Gerais, classified as albite-spodumene type, the main variety of pegmatite for lithium ore, had their main minerals and mineral associations characterized by several analytical techniques: steromicroscopy, X ray diffraction, X ray fluorescence, X ray micro-fluorescence, optical emission and laser ablation spectrometries, in order to identify the main lithiferous phases, and the amount of lithium contained in different minerals
Technical Session
COMPARATIVE ANALYSIS OF THE MECHANICAL, OPTICAL AND MORPHOLOGICAL PROPERTIES OF VIRGIN AND RECYCLED POLYCARBONATE
Presenter(s): Bruno sousa da cunha (IME - INSTITUTO MILI)
Abstract:
In the present work, the effect of the recycling process on the properties of polycarbonate was evaluated. For this, specimens were produced by injection of virgin polycarbonate and injected polycarbonate, which were used in transmittance analysis, Scanning Electron Microscopy (SEM) and mechanical tests (reaction and hardness). These analyses revealed significant changes in the properties of this material after the recycling process. The transformation in mechanical properties is crucial to understand the changes that occur during the recycling process and how they impact the performance of polycarbonate in different applications In the conclusion of the study, it was observed that recycled polycarbonate exhibits behavior akin to that of a thermoset polymer, while virgin polycarbonate demonstrates characteristics closer to those of a thermoplastic. This distinction appears to significantly depend on the procedures employed during the recycling processes. These discrepancies underscore the importance of considering not only the chemical composition but also the recycling methods in assessing the properties and behaviors of polymeric materials.
Technical Session
ECOLOGICAL AND HUMAN HEALTH RISK ASSESSMENT FOR THE APPLICATION OF STEEL AGGREGATE IN PRIMARY COATING WITHIN THE MOBILIZA PELOS CAMINHOS DO VALE PROGRAM AREAS
Presenter(s): Isabella Tassia Arruda Melo (Usiminas)
Abstract:
Since 2015, the Usiminas Mobiliza pelo Caminhos do Vale program has used steel aggregate for the primary coating of rural roads in the Minas Gerais region, promoting improvements in infrastructure and quality of life for residents. A study was conducted by the contractor, HidroGeo Engenharia e Gestão de Projetos Ltda, to evaluate the possible risks to human health and ecology associated with the use of this material applied to roads and its storage in yards. The analysis included a historical review of fieldwork and program information, with the aim of determining risks in specific exposure scenarios, considering concentrations of chemicals of environmental concern (SQI). The process involved identifying the SQI, exposure routes and potential receptors, seeking a detailed understanding of the environmental and health impacts related to the use of the steel aggregate. Based on the information collected, the study concluded that there is no potential risk of contamination of appropriate receptors in the evaluated scenarios.
Technical Session
EVALUATION OF THE IMPACT OF SCIENTIFIC INITIATION ON STUDENTS
Presenter(s): Mariane Luiza Amorim Rossi (Universidade Federal de Ouro Preto), Lucas da Silva Fernandes (Universidade Federal de Ouro Preto), Arthur Silveira Souza (Universidade Federal de Ouro Preto), Carlos alberto pereira (Universidade Federal de Ouro Preto), Fábio de Assunção José (Centro Federal de Educação Tecnológica de Minas Gerais – Araxá)
Abstract:
Scientific initiation has as one of its main objectives, to add to the student's development through practice, allowing them to have, in many cases, the first more in-depth and technical contact in their course. During this process, the student develops some skills, such as writing and speaking. Furthermore, they stimulate critical thinking, awakening curiosity, innovation and learning in the individual, by dealing with issues in their area of study, making them a flexible and adaptable professional. Therefore, this work aims to disseminate the importance of scientific initiations, evaluating their influence on mining engineering students at the Federal University of Ouro Preto (UFOP) over the years 2013 to 2023. The data was obtained by collecting perspective of students and alumni and the lattes of the faculty of the Department of Mining Engineering (DEMIN) at UFOP. The results obtained indicate that the students who participated showed, at the end of their ICs, development in their technical and personal skills. In addition to pointing out that ICs were the initial stimulus for new opportunities.
Technical Session
SYNTHESIS OF ZEOLITE 'A' FROM AMAZONIAN KAOLINITIC RESIDUE
Presenter(s): RIAN CRISTIAN DOURO AMORIM (UNIVERSIDADE FEDERAL DO PARá), Antônio Lucas Alcantara Modesto (universidade federal do Pará ), Alex Gabriel Oliveira Ruivo (universidade federal do Pará ), Ana Paula Souza de Souza (universidade federal do Pará), Diego Cardoso Estumano (universidade federal do Pará), Deibson Silva da Costa (universidade federal do Pará), emerson cardoso rodrigues (universidade federal do Pará)
Abstract:
The present work aimed to synthesize "4A" zeolites from kaolin waste and apply the synthesized product in ion exchange. For the synthesis of 4A zeolite, the waste was calcined at 700°C for two hours to transform it into metakaolin. After calcination, the metakaolin and NaOH solution were introduced into a synthesis system, regulated to a temperature of 100°C and a rotation speed of 700 RPM for 30 minutes. For ion exchange, the same synthesis system was used, at 100°C and 700 RPM, with 4A zeolite and CaCl2 solution for 8 hours. In the analytical procedure, the kaolin waste, metakaolin, and zeolites were subjected to scanning electron microscopy (SEM) and X-ray diffraction (XRD). The micrographs of the zeolites confirmed the presence of cubic morphology, which is characteristic of type A zeolites. The diffractograms, based on the consulted data sheets, confirmed the presence of zeolitic crystals, as observed in the SEM. Thus, kaolin waste proved to be a viable material for the formation of type A zeolitic crystals, which exhibit ion exchange properties, confirmed by the formation of 5A zeolites.
Technical Session
9/3/24, 10:15 AM - 9/3/24, 11:05 AM
Presenter(s): Rodrigo Carneiro de Oliveira (AMG Brasil), Raykar Bandeira Silva (Progen), Rosa Malena Fernandes Lima (Universidade Federal de Ouro Preto)
Abstract:
In this work, were carried out characterizations physical (particle size distribution by sieving, specific mass determination by gas pycnometry and specific surface area by BET), mineralogical by X-ray diffractometry and chemical (X-ray fluorescence and optical spectroscopy of atomic emission with inductively coupled plasm) of a tailing sample from the Li ore flotation stage of a mining company, located in the Campo das Vertentes-MG. The particle size distribution curve of the sample showed that its P80 was 246.7 µm, specific mass equal to 2.72 g/cm3 and specific surface area of 0.45 m2/g. The majority minerals identified were feldspar (albite and microcline), quartz and muscovite. The Li-bearing minerals in smaller proportions were spodumene and lepdolite. The results of the granulochemical analysis showed higher grades of Fe2O3 in the -75 µm size fraction compared with size fraction + 75 µm. The opposite occurred with the Li2O. However, as the overall Fe2O3 content was 0.23%, this material is intended for the ceramics industry
Technical Session
NICKEL-ZINC NANOPARTICLES IN THE PRODUCTION OF CERAMICS WITH ORIENTED POROUS CAVITIES
Presenter(s): Bruno Cristian Mello Carvalho (Universidade do estado do rio de janeiro), Sabrina Costa Faria (UNIVERSIDADE DO ESTADO DO RIO DE JANEIRO), Juliana Lopes Ribeiro (UNIVERSIDADE DO ESTADO DO RIO DE JANEIRO), Fellipe de Sá Moraes (UNIVERSIDADE DO ESTADO DO RIO DE JANEIRO), Diego dos Santos Alves (UNIVERSIDADE DO ESTADO DO RIO DE JANEIRO), Eustáquio de Souza Baêta Júnior (UNIVERSIDADE DO ESTADO DO RIO DE JANEIRO), Leticia dos Santos Aguilera (UNIVERSIDADE DO ESTADO DO RIO DE JANEIRO)
Abstract:
Controlled porosity is a property of interest for studies in applications such as filters, catalysts, absorbers. In materials processing, the freeze casting technique offers great versatility of parts to be produced in relation to the dimensions, type of materials and structural characteristics of the porous cavities formed. In this work, mixed nickel-zinc ferrite was used as a solid filler for colloidal suspension as a precursor to freeze casting processing. The macro and micro porous structures formed during processing were investigated using the Archimedes Method and Scanning Electron Microscopy (SEM) seeking to compare characteristics obtained by varying three polymeric ligands, PEG-400, 1500 and 4000 with a concentration of 4%. High porosities were observed, around 70% for the three samples and the SEM images revealed a structure typical of freezing at high cooling rates, in addition to the more pronounced columnar structure of interest and wider and more homogeneous pores in the sample with PEG- 4000, although the three variations presented the structure satisfactorily.
Technical Session
9/3/24, 10:15 AM - 9/3/24, 11:05 AM
Presenter(s): CAMILA PRUDENTE MAGALHAES (UFF), mateus lourenço dos santos (uff), thiago haenel antunes (uff), denise hirayama (uff)
Abstract:
With the growing concern about waste disposal and its negative impact on the environment and sustainability, the substitution of some materials by biopolymers is becoming increasingly common, as they provide the same properties with faster degradation. However, studies indicate that when this degradation occurs in an alkaline ambiences, it can be even faster. In this study, thermal and mechanical analyses were performed on samples of poly(lactic acid) that underwent degradation in soil with the addition of steel slag to verify the effectiveness of slag as a degradation accelerator. Thus, tensile tests were carried out on samples with different degradation times and conditions (in common soil and in soil modified with steel slag), as well as thermogravimetric analysis (TGA). It was possible to observe variations in their mechanical and thermal properties as an indication of an acceleration in their decomposition time.
Technical Session
9/3/24, 10:15 AM - 9/3/24, 11:05 AM
Presenter(s): CLARA BALDUINO VIEIRA (UENF), Johnata França Fanni Freitas (uenf), Markssuel Teieira Marvila (uenf), Euzebio Bernabe Zanelato (uenf), Sergio Neves Monteiro (uenf), Niander Aguiar Cerqueira (uenf), Afonso Rangel Garcez de Azevedo (uenf)
Abstract:
Mortars are composite materials that use natural resources in their constitution, such as natural river sand, as fine aggregate, and cement, as a binder. The use of natural aggregates has been causing a series of environmental damages throughout the world, which has encouraged research aimed at using new materials to replace natural aggregates. The objective of this research is to evaluate the potential for incorporating spodumene to replace sand, which is a natural aggregate. Mortars were manufactured in different replacement levels (0, 25, 50 and 1005), in which technological properties were evaluated in the fresh state, such as consistency, water retention and incorporated air content, and in the hardened state with mechanical resistance to compression and flexion, all in accordance with Brazilian technical standards. The results showed that replacing sand with spodumene, which is a waste material, presented satisfactory results, with little influence on the consistency of the mixtures, and improvement in some levels of mechanical properties. Thus, it can be concluded that there is evidence of potential application of this mineral residue in mortar applications, requiring further technological analysis
Technical Session
9/3/24, 10:15 AM - 9/3/24, 11:05 AM
Presenter(s): EMILY DE FáTIMA PINHEIRO BOTELHO (UNIVERSIDADE FEDERAL DO PARá), Damares Da Cruz Barbosa Nascimento (UNIVERSIDADE FEDERAL DO PARÁ), paloma suellen lima de sousa (univerdidade federal do Pará), Sarah Gabrielly Brandão de Souza (UNIVERDIDADE FEDERAL DO PARÁ), Joelly Vera Nascimento (UNIVERDIDADE FEDERAL DO PARÁ), Verônica Scarpini Candido (UNIVERDIDADE FEDERAL DO PARÁ), Alisson Clay Rios da Silva (UNIVERDIDADE FEDERAL DO PARÁ)
Abstract:
Composite materials have emerged from the industry's need for materials with superior mechanical performance compared to conventional materials, coupled with concerns about sustainability. The use of waste from mining industries constitutes raw materials that can be used in the composition of these materials. The objective is to produce composite materials with a polymer matrix and kaolin waste as a filler. The composites were manually produced using silicone molds, following ASTM D638-2014 and ASTM D790-2017 standards. Subsequently, mechanical tests were conducted to evaluate the material's mechanical properties. In the tensile test, tensile strength, Young's modulus, and deformation were analyzed, while in the flexural tests, flexural strength and elasticity modulus were evaluated. Accordingly, for tensile strength, the composition with 15% kaolin waste addition showed the highest tensile strength, highest Young's modulus, and lowest deformation. For flexural strength, the composition with 10% waste showed the highest flexural strength and elasticity modulus. It is concluded that the study of waste added to the polymer matrix presents good mechanical characteristics, making them promising for the development of new materials.
Technical Session
9/3/24, 10:15 AM - 9/3/24, 11:05 AM
Presenter(s): JOELLY VERA NASCIMENTO (UNIVERSIDADE FEDERAL DO PARA), Sarah Gabrielly Brandão de Souza (Universidade federal do pará), Paloma suellen lima de sousa (Universidade Federal do Para), Emily de Fátima Pinheiro Botelho (Universidade federal do Para), Damares da cruz barbosa nascimento (UniverSidade federal do para), Alisson Clay Rios da Silva (UNIVERSIDADE FEDERAL DO PARA), Verônica Scarpini Candido (Universidade federal do para)
Abstract:
Brazilian coffee is widely exported, mainly to the European Union, the United States, and Japan, and is extensively used in various food markets. During coffee processing, residues such as immature coffee beans, husks, and grounds are generated, which can be used in the manufacturing of composite materials. These residues can be better utilized in a circular economy, contributing to sustainable development. This study proposes the fabrication of a composite with a polymer matrix and coffee grounds, aiming to evaluate its mechanical properties and mitigate environmental impacts. The results show that the tensile strength of the composites with 5%, 10%, and 15% coffee grounds is lower than that of the pure matrix, with a trend of decreasing strength as the proportion of residue increases. The sample with 10% coffee grounds exhibited significantly lower performance. This is due to the agglomeration of particles, which acts as a starting point for cracks, weakening the composite. The ANOVA confirmed that the calculated F values for tensile strength, modulus of elasticity, and deformation exceed the critical values, rejecting the equality among the mean properties at a 5% significance level.
Technical Session
9/3/24, 10:15 AM - 9/3/24, 11:05 AM
Presenter(s): Ana Laura Lopes de Matos Riscado (UENF)
Abstract:
Geopolymers are alkaline-activated polymeric inorganic materials, which stand out for their potential to use industrial by-products as raw materials, which significantly contributes to environmental and economic sustainability. One of the main focuses of research in the area is the use of fly ash, a by-product of electrical energy generation, as a precursor in the production of geopolymers due to its composition rich in silicates and alumina and its low cost. With this opportunity, this study addressed the use of fly ash as a precursor rich in aluminosilicates for the manufacture of geopolymers with alkaline activation based on sodium hydroxide and silicate, evaluating molarity variations. To characterize the fly ash, FRX, DRX and fire loss tests were used. The variation in geopolymer molarity was evaluated by the compressive strength test. Fly ash was found to be rich in aluminosilicates in the XRF test, a prerequisite for its use as a precursor in geopolymers. XRD revealed a high degree of amorphism. Fire loss was less than 2%. The compressive strength test revealed an increase in strength with an increase in the molarity of the activating solution.
Technical Session
9/3/24, 10:15 AM - 9/3/24, 11:05 AM
Presenter(s): Ary Machado de Azevedo (IME), Thomaz jacintho lopes (ime), Marcos Paulo Cavaliere de Medeiros (ime), Fernando Manuel Araújo Moreira (ime), Sérgio neves monteiro (ime), Belayne Zanini Marchi (ime), Domingos D’Oliveira Cardoso (ime), André Ben-Hur da Silva Figueiredo (ime)
Abstract:
THE STUDY INVESTIGATED THE SIMULATED TRANSMISSION FACTOR OF DEPLETED URANIUM DIOXIDE FOR GAMMA RADIATION SHIELDING. DEPLETED URANIUM DIOXIDE IS A DENSE AND SLIGHTLY RADIOACTIVE MATERIAL, MAINLY COMPOSED OF URANIUM-238, USED IN VARIOUS MILITARY APPLICATIONS, ESPECIALLY IN ARMOR-PIERCING AMMUNITION. HOWEVER, IT ALSO HAS CIVIL APPLICATIONS, SUCH AS IN RADIATION SHIELDS IN MEDICAL FACILITIES, COUNTERWEIGHTS IN AIRCRAFT AND SHIPS, RADIATION PROTECTION IN SHIELDING, AND STABILIZERS IN CONSTRUCTION. THE STUDY DEMONSTRATED ITS EFFECTIVENESS FOR SHIELDING GAMMA RADIATION FROM CESIUM-137 AND COBALT-60.
Technical Session
EVALUATION OF PHYSICAL AND MECHANICAL PROPERTIES OF EXTRUDED, PRESSED, AND FIRED RED CERAMIC BLOCKS
Presenter(s): Bruno sanches da silva (UENF/IFF), Niander Aguiar Cerqueira (UENF), Jonathan De Andrade Paula Madalena (UENF), Rafael Picanço de Oliveira (UENF), Elias Socrates Nascimento da Cruz Junior (UENF), Jonas Alexandre (UENF), Afonso Rangel Garcez de Azevedo (UENF)
Abstract:
The constant search for efficiency in the construction industry drives a continuous process of innovation, both in materials and construction methods. This movement aims not only to promote the durability of structures, but also to find ways to reduce costs and mitigate environmental impact. This study focused on evaluating the physical and mechanical properties of Extruded, Pressed and Burnt Ceramic Fitting Blocks (BCEPQ). The BCEPQ were evaluated according to Brazilian standards, covering geometry, water absorption and compressive strength. For its production, the clay was processed by extrusion (WD36 extruder) and pressing (Eco Máquinas 7000 Turbo II), followed by drying and firing in a Vault-type oven. The results indicated geometric compliance with tolerances established by the Brazilian standard. Water absorption was 18.32% (± 0.35), meeting the standards for the VED40 class of sealing blocks (8% ≤ AA ≤ 25%) and the EST40 structural class (8% ≤ AA ≤ 21 %). The compressive strength was 22.33 MPa (± 1.49), exceeding the limit of 4.00 MPa for VED40 and EST40 blocks. It is concluded that the BCEPQ produced meets the normative standards of dimensional analysis, physical and mechanical properties, for sealing and structural blocks.
Technical Session
MICROSTRUCTURE, DENSITY AND POROSITY OF HYDROXYAPATITE CONFORMED BY ICE-TEMPLATING
Presenter(s): Camila Alves Pelicarto da Silva botão (UNIVERSIDADE DO eSTADO DO rIO DE JANEIRO), Kellen Venancio dos Santos (Universidade do Estado do Rio de Janeiro), Eustáquio de Souza Baêta Júnior (Universidade do estado do rio de janeiro), Letícia dos Santos Aguilera (universidade do estado do rio de janeiro), Suzana Bottega Peripolli (universidade do estado do rio de janeiro), José Brant de Campos (universidade do rio de janeiro)
Abstract:
Hydroxyapatite is a multifunctional ceramic that can be used in implants due to its good biocompatibility, osteoconduction and bioactivity, in addition to being non-toxic and allowing easy replacement of cations and anions. It also has high relevance in the environmental area, being used in catalysts and filters. In both cases, porous structures are sought and methods of producing these structures are constantly developing. This work aims to compare the use of PEG-4000 and PEG-6000 as a ligand at a concentration of 4%wt. To improve the rheological behavior, the pH of the water was adjusted to 11.8 using NaOH. The samples were frozen, freeze-dried and sintered at 1150 °C for 6 hours. The morphology of the pores was characterized using Scanning Electron Microscopy (SEM) analyzes and the apparent porosity using the Archimedes method. PEG-4000 presented greater homogeneity in pore size while PEG-6000 presented a more pronounced and well-defined structure. The apparent porosity found for PEG-4000 was 51.03% and for PEG-6000, 49.11%.
Technical Session
AGRICULTURAL AND GLASS WASTE IN RED CERAMIC: INFLUENCE ON WATER ABSORPTION, LINEAR SHRINKAGE, AND MECHANICAL STRENGTH
Presenter(s): Carlos Alberto de Oliveira Guimaraes (UENF ), Geovana Carla Girondi Delaqua (UENF), Cássio Rangel Paulista (uenf), Carlos Maurício Fontes Vieira (uenf)
Abstract:
The main objective of this study was to evaluate how the inclusion of waste sludge, generated in the flat glass cutting and polishing process, influences water absorption, linear shrinkage, and mechanical strength of red ceramics produced from a clay mass that incorporated 5% coffee husk. Starting from the base formulation with 5% coffee husk, glass sludge was incorporated in different proportions: 5%, 15%, and 25% by weight. By extrusion, specimens with standardized dimensions of 110 mm x 30 mm x 20 mm were manufactured and subjected to firing cycles at temperatures of 800°C and 900°C. Subsequently, tests for water absorption, linear shrinkage, and compressive strength were conducted. The results obtained showed that the glass waste has significant potential to be used as a component in clay body formulations, mitigating the deleterious effect of the coffee husk. Standing out for its ability to reduce water absorption and increase the mechanical strength of ceramics, it suggests promising opportunities for the sustainable use of this waste in the production of enhanced ceramic materials
Technical Session
9/3/24, 10:15 AM - 9/3/24, 11:05 AM
Presenter(s): carlos henrique da luz barbosa (Instituto Militar de Engenharia ), Aline Raybolt dos Santos Almeida (Faculdade de odontologiA - uNIVERSIDADE FEDERAL DO RIO DE JANEIRO), MARCELO HENRIQUE PRADO DA SILVA (INSTITUTO MILITAR DE ENGENHARIA)
Abstract:
Despite the excellent biocompatibility of titanium (Ti) implants, their biological inertia does not generate a chemical bond with bone tissue. To improve the performance of Ti implants, researchers are developing bioactive surfaces that promote adhesion, proliferation and differentiation of osteoblasts and chemical bonding with the newly formed tissue. The incorporation of biologically relevant ions into the structure of hydroxyapatite (HA) increases biological activity, biocompatibility and more. Magnesium (Mg), essential for bone growth, when incorporated into HA, can alter the mechanical properties of bone. Studies show that the concentration of Mg in HA affects the physicochemical properties of the coating and the morphology of the crystals. Doping HA with silicon (Si) improves bone repair, vascularization and coating morphology, despite increasing roughness after annealing. Ti implants coated with HA replaced by Si (Si-HA) improve cell proliferation and osteogenic and angiogenic differentiation, while inhibiting osteoclastogenesis. The aim of this literature review is to present hydroxyapatite co-substituted with Si and Mg (HA-Mg-Si) as a bioactive surface option. HA-Mg-Si shows promising potential in bone repair, but studies are needed to optimize its formulation for specific clinical applications.
Technical Session
CARACTERIZAÇÃO DE ARGILAS TÍPICAS UTILIZADAS EM CERÂMICA VERMELHA
Presenter(s): Carlos Maurício Fontes Vieira (UENF), Geovana carla girondi delaqua (UENF)
Abstract:
Foram investigadas as características gerais e propriedades tecnológicas de quatro tipos de argilas obtidas de um mesmo local no norte do Estado do Rio de Janeiro, Brasil. Essas argilas são destinadas para aplicações em cerâmicas como tijolos e telhas. As argilas foram primeiramente analisadas por difração de raios X, composição química, distribuição granulométrica, análise térmica e plasticidade. Amostras extrudadas foram queimadas em temperaturas variando de 850 a 1100ºC para determinar a retração linear, absorção de água e resistência à ruptura flexão. Os resultados mostraram que três das argilas estudadas apresentam características adequadas para a fabricação de tijolos. No entanto, para duas dessas argilas adequadas é necessário adicionar materiais convenientes para aumentar a trabalhabilidade. A alta porosidade desenvolvida após a queima dificulta o uso dessas argilas para telhas. Isso é consequência da natureza caulinítica das argilas, bem como de sua elevada perda ao fogo.
Technical Session
ADDITION OF WASTE FROM THE LAPIDATION STAGE OF FLAT GLASS INTO CERAMIC
Presenter(s): Carlos Maurício Fontes Vieira (UENF ), Geovana carla girondi delaqua (UENF)
Abstract:
This work aims to evaluate the influence of the incorporation of mud from the cutting of flat glass on the physical and mechanical properties of a clay ceramic used in civil construction. The raw materials were characterized by DRX, FRX, particle size by sieving and sedimentation, plasticity. Formulations were prepared with different percentages of waste addition, and then specimens were produced by uniaxial pressing, and fired at 900 and 1000ºC. After burning, the properties of RL, AA, and TRF were evaluated. With the results, it was observed that the incorporation of glass waste had a positive effect on the sintering of ceramics and on the properties of the fired specimens.
Technical Session
9/3/24, 10:15 AM - 9/3/24, 11:05 AM
Presenter(s): Carlos Maurício Fontes Vieira (UENF ), Geovana carla girondi delaqua (UENF)
Abstract:
The objective of this work was to incorporate water treatment plant sludge from the decantation and filtration stages, evaluating the effect on the properties of fired ceramics. The sludge was characterized by FRX, DRX, and particle size distribution. Different formulations were prepared with up to 10% by weight of the waste added to a ceramic mass, and specimens were produced by extrusion and fired at different temperatures. This type of mud has a mineralogical composition similar to the floodplain clays used in red ceramics, being predominantly composed of kaolinite. The high fire loss of the sludge can be attributed to the presence of organic matter as well as the hydroxyl groups of kaolinite, gibbsite and goethite. Sludge does not bring real benefits to ceramics, but in a controlled quantity, adding the residue can be a viable alternative, in addition to being a correct way of disposing of this waste
Technical Session
EFFECT OF GLASS GRANULOMETRY ON THE PLASTICITY OF A CERAMIC MASS
Presenter(s): Geovana Carla gIRONDI dELAQUA (UENF ), Carlos Maurício Fontes Vieira (UENF)
Abstract:
This work aims to evaluate the effect of incorporating up to 30% by weight of packaging glass powder, in different particle sizes, on the plasticity of kaolinite clay used to manufacture bricks and tiles. Different formulations were prepared with the elimination and plasticity of the masses tested by the methods of Atterberg and Pfefferkorn. With the results obtained, it was possible to conclude the beneficial effect of glass waste in smaller particle sizes on the workability of handmade ceramic mass
Technical Session
9/3/24, 10:15 AM - 9/3/24, 11:05 AM
Presenter(s): Isabela Devesa Batista (Universidade estadual do norte fluminense darcy ribeiro), Ana Laura Lopes de Matos Riscado (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO), Sheila Mara Santos da Silva (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO), Juliana Fadini Natalli (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO), Madeleing Taborda Barraza (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO), Sérgio Neves Monteiro (ime), Afonso Rangel Garcez de Azevedo (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO)
Abstract:
With the increase in demand for construction, the use of alternative construction materials is gaining ground in the market every day. Therefore, aiming to reduce the consumption of cement and, consequently, the emission of carbon dioxide, the present work sought to use limestone filler and quartz powder as substitutes for cement in the production of mortar. The waste used in this research is by-products of mining and industry, and is normally discarded as urban solid waste (MSW). The main objective of this work was to study the rheology for possible reuse and application of the residue. Spreading, mass density, incorporated air content and squeeze-flow rheology tests were carried out. The results found were satisfactory and, in general, met regulatory requirements.
Technical Session
9/3/24, 10:15 AM - 9/3/24, 11:05 AM
Presenter(s): iully da silva amaral pereira (uenf), José Alexandre Tostes Linhares Júnior (uenf), Samuel Araújo Azevedo Malafaia (uenf), Larissa Mendonça Osorio Fonseca (uenf), Rita de Kassia Gonçalves Pereira (uenf), Afonso Rangel Garcez de Azevedo (uenf), Juliana Fadini Natalli (uenf)
Abstract:
Agroindustry plays a fundamental role in the Brazilian economy. However, the waste generated negatively affects the ecosystem, resulting in considerable environmental damage. In response to this challenge, there is a growing search for techniques that aim to reuse waste from this industry, aiming for more effective management. Among the alternatives explored, natural fibers, such as coconut and açaí waste, have received prominence in several sectors, due to the benefits they provide in different matrices. However, these untreated fibers have properties that require treatment to improve their applicability. In this study, the characteristics of untreated coconut and açaí fibers were analyzed and treated with tannic acid at a concentration of 5%, in a ratio of 1:20. In this direction, sample characterization studies were carried out using scanning electron diffraction (DRX), crystallinity index and wettability. The results demonstrated that the treated fibers had a higher crystallinity index and a lower wettability angle, indicating greater hydrophobicity after surface treatment. This characteristic suggests that treatment with tannic acid can expand the possibilities of application of these fibers in sectors that require less hydrophilicity of these materials, promoting greater efficiency in the use of agro-industrial waste.
Technical Session
EVALUATION OF THE MECHANICAL PROPERTIES OF A GEOPOLYMER MORTAR REINFORCED WITH AÇAÍ FIBERS
Presenter(s): Leandro Barbosa de Oliveira (uenf), Madeleing Taborda Barraza (), Markssuel Teixeira Marvila (), Sérgio Neves Monteiro (), Carlos Maurício Fontes Vieira (), Afonso Rangel Garcez de Azevedo ()
Abstract:
Natural lignocellulosic fibers have the potential to be used as sustainable materials in the construction industry in geopolymers due to their improvements in properties such as tensile strength, flexion and for making the compounds lighter. In this context, there are açaí fibers, which are obtained after using the pulp and require final disposal and generally end up in landfills. Thus, the objective of this work was to produce geopolymeric compounds reinforced with açaí fibers and evaluate the properties of geopolymeric mortar reinforced with the addition of açaí fibers at 1 and 2% without treatment and treated with NaOH at a concentration of 5 and 10% per through compression resistance and flexural resistance tests, in addition to water absorption of the fibers. The results showed that the addition of 2% açaí fibers treated with 5% NaOH presented the best results in compressive and tensile strength, indicating that the alkaline treatment was effective in removing amorphous components and consequently improving the fiber-geopolymeric matrix interaction. Thus, the geopolymer with the addition of açaí fibers has potential for application in the civil construction segment as a sustainable material.
Technical Session
9/3/24, 10:15 AM - 9/3/24, 11:05 AM
Presenter(s): Mariana Gomes Pinto Cherene (UENF - ALBERTO LAMEG)
Abstract:
The red ceramic industry is associated with various environmental damages, from the extraction of natural resources as raw materials to the generation of high amounts of waste. This study proposed the reuse of ceramic waste, which is obtained by burning ceramic blocks, at a temperature of 600°C to 630°C. To transform the ceramic waste so that it could be used in mortars, a crusher was used, such as a ball mill with one hour of grinding time. Multiple-use mortars were made in the composition 1:6 (cement:sand), for laying blocks and covering ceilings and walls, replacing sand with ceramic residue in proportions of 10, 20 and 30% and the reference and use trace of CPII-E RS and CPV ARI cements. In order to analyze the viscosity and flow of the mortar, a rheology test was carried out. The squeeze-flow test is a method that evaluates the behavior of the mortar in relation to the applied load and the deformation caused. The results show that the mixes with 30% of ceramic residue presented greater displacements and better workability indexes and over time the displacements were reduced.
Technical Session
PROPOSAL FOR IMPLEMENTING STYROFOAM AS A FINE AGGREGATE IN THE MAKING OF MORTAR AND ITS ENVIRONMENTAL CONTRIBUTION
Presenter(s): MARKSSUEL TEIXEIRA MARVILA (UFV - CRP), Vinícius Magno Silva Pereira (UFV - CRP), Marília Gonçalves Marques (UFV - CRP), Leonardo Carvalho Mesquita (UFV - CRP), Sergio Neves Monteiro (IME - RJ), afonso rangel garcez de azevedo (UENF), Ana Laura Lopes de Matos Riscado (UENF)
Abstract:
Mortar plays an essential role in construction, providing impermeability, stability, and various applications such as bricklaying, waterproofing, and surface finishing. The population growth has led to a significant increase in construction activities, resulting in higher generation of solid waste. In this context, expanded polystyrene (EPS), commonly known as Styrofoam, has been increasingly used in construction due to its unique properties and its potential to reduce environmental impact by utilizing it as raw material for construction. Therefore, this project aims to analyze and test the general characteristics of mortar when EPS is added to its composition. The conducted tests will serve as a basis to evaluate the feasibility of incorporating expanded polystyrene and determine the appropriate proportions for its use. Additionally, the project aims to reduce environmental impact by proposing an implementation method for EPS in the construction industry
Technical Session
EFFECT OF CONTAMINANTS IN KNEDING WATER IN CEMENTIOUS MATERIALS
Presenter(s): MARKSSUEL TEIXEIRA MARVILA (UFV - CRP), Bárbara Raphaela Alves Costa (UFV - CRP), Isadora Marques Santos (UFV - CRP), Marina Rabelo Brito (UFV - CRP), Sirgê de Melo Junior (ufv - crp), Jose Alexandre Tostes Linhares Júnior (UENF), afonso rangel garcez de azevedo (UENF)
Abstract:
The quality of the mixing water is crucial to guarantee the properties and quality of cementitious materials. Water plays an essential role in the mixing of aggregates and in the hydration processes, so it is essential that it complies with regulatory criteria. Studies demonstrate the negative effects of impure water on concrete, including interference with resistance, staining and changes in the cement's setting. NBR 15900-1 establishes verification parameters, maximum limits for contaminant concentrations and test procedures for determining water quality. The adoption of adequate quality standards is essential to prevent pathologies, such as corrosion of reinforcement, highlighted by studies. The present work aimed to evaluate the behavior of mortars using contaminated water containing 5% chlorides, and another with 5% hydroxides in its compositions. To this end, the consequences and applications of contaminating compositions were evaluated in the criteria of consistency, water absorption, compressive strength in 7 and 28 days, and pH analysis of the specimens. It can be concluded that the addition of contaminated kneading water in sample preparation led to a significant drop in compressive strength when compared to the reference sample. It was observed that the composition containing chloride absorbed more water and consequently had its compressive strength at 28 days compromised by more than 95%. As evidenced by studies, chloride, in concentrations outside the recommended limits, presents an exponential reduction in the performance of cementitious materials, enabling the emergence of pathologies and potentially compromising the interim use of the structure. Finally, the continued importance of evaluating and guaranteeing the water standards required for the adequate production of these materials is highlighted.
Technical Session
PERI-IMPLANT LIGAMENT: CELL-PROTEIN-IMPLANT INTERACTION IN THE OSTEOCONDUCTION SPACE
Presenter(s): Marvin do NAscimento (Instituto Militar de ENgenharia), Carlos henrique da luz barbosa (INSTITUTO MILITAR DE ENGENHARIA), julianna magalhães garcia (INSTITUTO MILITAR DE ENGENHARIA), Marcelo henrique Prado da Silva (INSTITUTO MILITAR DE ENGENHARIA)
Abstract:
The peri-implant ligament is a crucial physiological adaptation resulting from the process of osseointegration, which involves the implantation of osseointegratable implants in gnathic bones. During bone regeneration, various proteins from the extracellular matrix and blood plasma adsorb, forming a provisional matrix that acts as a scaffold for the bone matrix at the bone-implant interface. Implants made of commercially pure titanium (grades II and IV) and the titanium-aluminum-vanadium alloy (Ti-6Al-4V) promote bone formation and remodeling through the adsorption of proteins on the implant surface. The hierarchical interaction between bone, cells, proteins and the implant are essential for the development of the peri-implant ligament, which occupies the osteoconduction space and creates an adaptive interface between the alveolar periosteum and the implant. Although it plays a role like that of a basement membrane, the osteoconduction space does not have the same embryonic origin, acting as a functional substitute. This ligament is fundamental to the integrity and stability of the implant, distributing masticatory loads and preventing fractures. The aim of this literature review is to address the presence of the peri-implant ligament, from the osseointegration process onwards, because of the interaction between cells-proteins-implant in the osteoconduction space
Technical Session
GEOPOLYMERS: STRUCTURES AND PROPERTIES
Presenter(s): Marvin do NAscimento (Instituto Militar de Engenharia), Carlos Henrique da Luz Barbosa (Instituto Militar de Engenharia), Julianna Magalhães Garcia (INSTITUTO MILITAR DE ENGENHARIA), Marllon Fraga Silva (INSTITUTO MILITAR DE ENGENHARIA), marcelo henrique prado da Silva (Instituto Militar de Engenharia)
Abstract:
Geopolymers are an innovative and promising alternative, especially in the construction industry, offering superior mechanical properties compared to conventional cement, along with greater environmental preservation and reduced ecosystem impact. Geopolymers are characterized as a ceramic material made up of semi-crystalline aluminosilicates. Geopolymers are characterized as a ceramic material formed by semicrystalline aluminosilicates, derived from industrial waste and alkaline reagents. These ceramic materials have a structure like that of zeolites and feldspars. They exhibit a structural organization analogous to polymer chains during the curing process, as well as binding properties like Portland cement. Notably, they demonstrate high performance in pastes and concretes with low CO2 emissions and can be used for encapsulating toxic and radioactive waste. Their versatility and potential to reduce environmental impact make them a sustainable choice for the construction industry, driving more efficient and responsible practices within the sector. By recognizing the value of these materials, it is possible to envision a future where construction adopts more eco-friendly solutions, promoting more balanced and conscious development. This work aims to present the structures and properties of geopolymeric cements.
Technical Session
EXPERIMENTAL EVALUATION OF CERAMIC BLOCKS FOR STRUCTURAL MASONRY
Presenter(s): NIANDER aguiar cerqueira (UENF - ALBERTO LAMEG), Marcela da Silva Luna Paravidino (uenf), Diego Filipe Rodrigues Ferreira Prata (ufrj), Elisa de Miranda Póvoa (concreart), Luísa Azeredo Ferreira Barreto (iff / uenf)
Abstract:
The use of structural masonry as a structural solution and construction method has received increasing attention in recent years in Brazil, particularly in the northern region of the state of Rio de Janeiro, as it is a more rationalized and economical construction system. In a bibliometric evaluation in the “Scopus” database between 2013 and 2023, 10,386 results were found with the keyword “Structural Masonry”, thus confirming the great importance of the topic in question. In the present work, the mechanical resistance to simple compression, the water absorption rate and the dimensions of blocks used by a construction company in the municipality of Campos dos Goytacazes in four-story social housing works were evaluated. The results indicate an average compressive strength of "6.13 ± 1.15 MPa", characteristic compressive strength of 4.60 MPa, a water absorption rate of "13.71 ± 0.54" % and dimensional variations of less than 4mm. Laboratory analyzes indicate satisfactory quality within the parameters established for constructions of up to 4 floors.
Technical Session
9/3/24, 10:15 AM - 9/3/24, 11:05 AM
Presenter(s): THUANY ESPIRITO SANTO DE LIMA (Centro Federal de educação tecnológica celso suckow da fonseca)
Abstract:
The search for sustainability in the conscious use of materials in civil construction makes the application of renewable resources an increasingly necessary necessity. One of the biggest challenges today is social and economic development, while maintaining environmental preservation. Plastic waste has attracted a lot of attention because it generates direct negative impacts on the environment, the material takes around 400 years to decompose in nature. In order to provide an adequate destination for this waste, this work aimed to evaluate the partial replacement of natural fine aggregate with crushed PET (polyethylene terephthalate), evaluating feasibility and resistance. Four mixes of concrete were obtained, one with natural fine aggregate and the others with different proportions of amber PET bottle, replacing 10%, 20% and 40% of the fine aggregate with PET. For this, a case study was carried out using 20 concrete specimens, divided equally into 4 groups, group A is conventional concrete, group B is concrete with 10% PET added, group C is concrete with the addition of 20% PET and group D is concrete with the addition of 40% PET. The samples were subjected to compressive strength, diametral compression tensile and slump tests. From the results obtained in the mechanical tests, it is concluded that the partial replacement of natural fine aggregate (sand) by PET can be added to concrete for non-structural purposes, whose purpose does not require high resistance, such as: curbs, blocks and floors. Therefore, PET in concrete is a viable form of disposal and helps solve a serious environmental problem related to the accumulation of PET bottles in landfills.
Technical Session
9/3/24, 10:15 AM - 9/3/24, 11:05 AM
Presenter(s): Antonio Ricardo grippa satiro (Ifes/UENF), Eduardo Atem de Carvalho (UENF), FELIPE PERISSÉ DUARTE LOPES (UENF), Noan Tonini Simonassi (UENF), SERGIO NEVES MONTEIRO (UENF)
Abstract:
The growing demand for sustainable materials has driven research into polymer composites reinforced with natural fibers. This work investigates the behavior of polyurethane matrix composites reinforced with broomcorn (Sorghum bicolor) stalks in different volume fractions under compressive forces. A polyurethane resin based on castor oil and stalks donated by independent producers were used. The composites were molded, cured, and cut according to ASTM D695 standards, and subjected to compression tests. The results showed that the compressive strength increased with the volumetric fraction of stalks, with values ranging from 3.97 MPa to 6.01 MPa. ANOVA analysis confirmed statistically significant differences between reinforcement levels. The specific compressive strength also followed the same trend, validating the effectiveness of broomcorn as a reinforcing material. It was concluded that the incorporation of broomcorn stalks not only improved the mechanical properties of the composites but also contributed to environmental sustainability, offering a viable solution for the use of stalks.
Technical Session
9/3/24, 10:15 AM - 9/3/24, 11:05 AM
Presenter(s): Bernardo Soares Avila de Cêa (instituto militar de engenharia), Fabio Da Costa Garcia Filho (CEFET/RJ), Sergio Neves Monteiro (INSTITUTO MILITAR DE ENGENHARIA), Édio Pereira Lima Júnior (INSTITUTO MILITAR DE ENGENHARIA), Lucio Fabio Cassiano Nascimento (INSTITUTO MILITAR DE ENGENHARIA), Laura Setti de Sousa (INSTITUTO MILITAR DE ENGENHARIA)
Abstract:
Aramid is a high-performance material already well-established in the market for various applications, prominently featuring in the use of components subjected to ballistic conditions. Polymeric composites reinforced with aramid fabric also demonstrate a significant ability to absorb energy when subjected to ballistic tests. From the perspective of composite material development, it is known that, in addition to the properties exhibited by the constituent phases, matrix and reinforcement, the type of arrangement, their disposition, distribution, as well as the volumetric fraction of each phase, are determining factors in the properties exhibited by the material. In this context, this study investigates the influence of two types of configurations, employing a simple arrangement of aramid fabric as reinforcement in an epoxy matrix composite, in order to compare their abilities in energy absorption. The configurations of the aramid fabric used for comparison are as follows: stacking layers of the fabric following the same orientations, in other words, with fibers oriented at 0°/90° in all layers; and alternating layers of the fabric with angles of -45°/0°/45°/90°. For the ballistic tests, high-energy 7.62 mm caliber ammunition was used. The obtained data were statistically processed using analysis of variance (ANOVA). Ballistic parameters such as limit velocity and deformation cone area, as well as prevailing failure mechanisms under both conditions, were investigated.
Technical Session
THE CHARACTERIZATION OF COFFEE GROUNDS BASED ON FTIR AND DRX ANALYSES FOR FEASIBILITY OF APPLICATION IN POLYMER MATRIX COMPOSITES*
Presenter(s): BRUNA NOGUEIRA SIMOES COBUCI (UNIVERSIDADE ESTADUAL NORTE FLUMINENSE), Luis Ricardo Arrubla Agudelo (UENF), Noan Tonini Simonassi (uenf), CARLOS MAURÍCIO FONTES VIEIRA (UENF), felipe perissé duarte lopes (uenf)
Abstract:
After water, coffee is the most consumed beverage in the world. Because it is produced and sold in abundance, it generates a significant amount of waste which, when not disposed of correctly, causes environmental damage, because when it comes into contact with the soil, it produces gases that are harmful to the environment. Because of this characteristic, coffee grounds, which are the waste after the coffee has been brewed, have been evaluated so that they can be reused in a way that causes less environmental damage. This work aims to characterize this material in order to detect its functional groups and assess its chemical composition using Fourier Transform Infrared Spectroscopy (FTIR) and X-ray diffraction analysis to check whether it can be used in polymer composite matrices. In addition to these, the density was checked using liquid pycnometry, which was evaluated after a saturation period of 10 days. The analyses showed positive results for its use in polymer composites.
Technical Session
EVALUATION OF THE USE OF RED CERAMIC WASTE ON CHARPY IMPACT RESISTANCE OF EPOXY MATRIX COMPOSITES
Presenter(s): David Coverdale Rangel Velasco (Universidade Estadual do Norte Fluminense – UENF), Júlia de Freitas dos Santos Souza (Instituto Federal Fluminense, Campus Cabo Frio), Darcy Lucas da Rocha Oliveira (Universidade Estadual do Norte Fluminense – UENF), FELIPE PERISSÉ DUARTE LOPES (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE – UENF), CARLOS MAURÍCIO FONTES VIEIRA (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE – UENF)
Abstract:
The increase in resource consumption in search of a better quality of life raises concerns about the sustainability of human actions. In this context, composites made from industrial waste emerge as sustainable and economical alternatives to this problem. In this sense, this study aims to evaluate the addition of crushed red ceramic waste (chamote) into an epoxy matrix, as well as its influence on impact resistance. The epoxy system Bisphenol A diglycidyl ether/Diethylenetriamine (DGEBA/DETA) was used, in a proportion of 16/100 resin/hardener. Formulations with 0, 10, 20 and 40% chamotte volume were tested. The impact tests followed the Charpy method of ASTM D6110, with a 15 J hammer. The results indicated that the addition of particles does not result in significant variations in resistance up to 20%, while in the formulation with 40% there was an increase of 7.5%. This suggests possible improvements in performance, cost reduction and socio-environmental impact.
Technical Session
MORPHOLOGICAL CHARACTERIZATION OF POLYMER MATRIX COMPOSITES REINFORCED WITH AÇAÍ AND CURAUÁ FIBERS
Presenter(s): DAYSE NATALIA MATOS COELHO (UNIVERSIDADE FEDERAL DO PARA), PAULO ANDERSON ARANGA FERREIRA (UNIVERSIDADE FEDERAL DO PARÁ), GIOVANA ZAGALO DE FRANÇA (UNIVERSIDADE FEDERAL DO PARÁ), RAYANNE OLIVEIRA LEÃO SANTANA (UNIVERSIDADE FEDERAL DO PARÁ), VERÔNICA SCARPINI CANDIDO (UNIVERSIDADE FEDERAL DO PARÁ), ALISSON CLAY RIOS DA SILVA (UNIVERSIDADE FEDERAL DO PARÁ)
Abstract:
In composite materials, the use of lignocellulosic fibers as reinforcement is a sustainable, low-cost alternative with significant mechanical properties compared to synthetic fibers. The objective of this study was to develop composite materials through the manual manufacturing method, with an orthophthalic polyester matrix using reinforcement from açaí, curauá and hybrid lignocellulosic fibers to perform morphological analyzes of fracture surfaces. The mass fraction values used in the composites were 50% fiber, 50% resin and 1% catalyst, and for the hybrid composite they were 25% açaí fiber and 25% curauá fiber to 50% resin. polyester. To this end, fiber density testing and morphological analysis of the fracture surface of the composites were carried out through microscopic analysis of the specimens, using Optical Microscopy (OM) and Scanning Electron Microscopy (SEM). The analyzes showed that the composites presented good fiber/matrix interfacial adhesion, observed by the rupture of the fibers and the presence of few bubbles, thus demonstrating the potential for satisfactory mechanical behavior, being suitable for carrying out mechanical tests and future applications.
Technical Session
9/3/24, 10:15 AM - 9/3/24, 11:05 AM
Presenter(s): DIEMISON LIRA SANTA ROSA (UFPA), Verônica Scarpini Candido (ufpa)
Abstract:
This article investigates the impact of incorporating natural fibers on the mechanical properties of polyester matrix composites through tensile test and SEM analysis. The results show that composites without fibers have a tensile strength of 46.940 MPa. The addition of 5%, 15%, and 25% fibers results in strengths of 40.967 MPa, 43.020 MPa, and 34.073 MPa, respectively. ANOVA confirms significant differences between the composite groups (p < 0.05). The tensile modulus was 1.077 GPa for composites without fibers, 1.102 GPa with 5% fibers, 1.127 GPa with 15%, but decreased to 1.010 GPa with 25% fibers. The initial strain decreased from 0.05515% (0% fibers) to 0.04449% (5% fibers), stabilizing at 0.04515% with 15% fibers. The study concludes that adding natural fibers can improve tensile properties up to an optimal point; adding fibers in volume fractions below and above 15% requires treatments to enhance fiber-matrix.
Technical Session
Production of Artificial Stone with iron ore residue and Epoxy Resin
Presenter(s): ELAINE APARECIDA SANTOS CARVALHO COSTA (Universidade estadual do norte fluminense darcy ribeiro), Larissa da Silva Ribeiro (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO ), José Lucas Decoté de Carvalho Lirio (universidade Estadual do norte fluminense darcy ribeiro), Afonso R. G. de Azevedo (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO), Carlos maurício fontes vieira (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO)
Abstract:
There is great environmental concern due to the volume that is generated and the final destination of industrial waste, as these are deposited in landfills and dams which, in addition to occupying a large area, can contaminate the soil and rivers, triggering a series of problems for the environment and risks to human health. The objective is to develop an artificial stone incorporating iron ore. The artificial stone plates were developed through compression and the iron residue was characterized and the artificial stone plates produced were evaluated for their physical index, chemical and mechanical attack. The rupture stress value obtained was 34.86±3.93 MPa, water absorption was 0.21%, obtaining a high quality and the most aggressive reagent was hydrochloric acid, which resulted in a greater loss of mass. 0.14±0.22%. The developed artificial stone proves to be a viable alternative
Technical Session
9/3/24, 10:15 AM - 9/3/24, 11:05 AM
Presenter(s): ELIAS ROCHA GONCALVES JUNIOR (UENF), José Alexandre Tostes Linhares Júnior (UENF), Markssuel Teixeira Marvila (UFV), Afonso Rangel Garcez de Azevedo (UENF), Juliana Fadini Natalli (UENF), Madeleing Taborda Barraza (UENF), Carlos Mauricio Fontes Vieira (UENF)
Abstract:
The construction sector is a major consumer of natural resources, leading to adverse environmental impacts due to increased consumption of cement and aggregates. Geopolymeric materials emerge as more sustainable alternatives, offering superior mechanical and thermal properties, as well as lower emissions of polluting gases. However, the manufacturing process of these materials still involves the use of industrial activators, which contribute to the emission of harmful gases into the environment. The use of agroindustrial waste as a binder has gained prominence in scientific research due to its potential to improve properties and reduce environmental impact. Among these residues, corn straw ash (CSA) emerges as a viable yet underexplored alternative in the literature. In this context, this paper aims to evaluate the effects of adding CSA, with different thermal curing periods, on fresh and hardened geopolymer pastes. The results indicate that increasing the binder content in the geopolymer formulation led to a noticeable increase in viscosity. Furthermore, the inclusion of CSA in different proportions and thermal curing periods did not significantly affect density values, while proportionally increasing compressive strength
Technical Session
9/3/24, 10:15 AM - 9/3/24, 11:05 AM
Presenter(s): GRAZIELE MEDEIROS COSME (uenf), Rômulo Leite Loiola (UENF), Felipe Perissé Duarte LopeZ (UENF), Noan Tonini Simonassi (UENF), SERGIO NEVES mONTEIRO (UENF)
Abstract:
Nowadays, there is a constant concern to develop products that are environmentally friendly. This is largely due to the constant threat of oil shortages, the emission of greenhouse gases and inadequate waste disposal. In view of this urgency for the development of alternative products to those of synthetic origin and increasingly sustainable, composite materials reinforced by vegetable fibers have emerged, consisting of a polymeric matrix and reinforcement, the latter of natural origin. The use of polymer composite materials reinforced by natural fibers has advantages and disadvantages. The main advantages are the greater lightness of this material, the reduction of greenhouse gas emissions and the reduction of the carbon footprint. And as disadvantages, they present poor interfacial adhesion between the matrix and fibers and high moisture absorption. The study of these advantages and disadvantages makes it possible to investigate properties in the natural fiber composite based on technical standards, such as ASTM D3039 used for the tensile test of the material, thus obtaining resistance and elastic modulus values. Therefore, promising results in the use of natural titic vine fiber as reinforcement in epoxy matrix polymer composites were obtained, showing an improvement in tensile strength with the incorporation of natural fiber into polymer resin, mainly for the volumetric fraction of 70% of reinforcement.
Technical Session
9/3/24, 10:15 AM - 9/3/24, 11:05 AM
Presenter(s): José Alexandre Tostes Linhares Júnior (universidade estadual do norte fluminense darcy ribeiro - uenf), Iully da Silva Amaral Pereira (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO - UENF), Lucas Reis Cruz (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO - UENF), Elias Rocha Gonçalves Júnior (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO - UENF), Markssuel Teixeira Marvila (universidade federal de viçosa - ufv), afonso rangel garcez de azevedo (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO - UENF), Carlos Maurício Fontes Vieira (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO - UENF)
Abstract:
The manufacture of conventional Portland cement results in high CO2 emissions, contributing to environmental problems. Given this, the construction industry is looking for more sustainable materials, such as geopolymers, which use industrial waste and have been explored as an alternative. This study investigates the incorporation of pineapple fibers into the geopolymer matrix, aiming to improve the mechanical properties of the material. The fibers, coming from agro-industrial waste, after treatments in high concentrations of NaOH, are integrated into the geopolymeric mortar, and can act as a crack bridge in order to provide greater resistance and ductility to the fragile matrix. The test results indicate increases in compressive and flexural resistance and a reduction in the brittle behavior of the matrix, highlighting the potential of these fibers in the production of more sustainable construction materials.
Technical Session
9/3/24, 10:15 AM - 9/3/24, 11:05 AM
Presenter(s): José Carlos Ferreira Fontes (CENTRO UNIVERSITÁRIO AUGUSTO MOTTA), RAI FELIPE PEREIRA JUNIO (INSTITUTO MILITAR DE ENGENHARIA), Lucas de Mendonça Neuba (INSTITUTO MILITAR DE ENGENHARIA), Daysiane da Silva Moreira (INSTITUTO MILITAR DE ENGENHARIA), LUCIO FABIO CASSIANO NASCIMENTO (INSTITUTO MILITAR DE ENGENHARIA), SERGIO NEVES MONTEIRO (INSTITUTO MILITAR DE ENGENHARIA)
Abstract:
In the current global context, the pursuit of cost reduction and increased productivity drives the development of materials with enhanced specific properties. Polymer composites, increasingly recognized as a solution to these demands, stand out for their use of plant fibers due to their abundance, low cost, and renewable origin. Curauá (Ananas erectifolius), native to the Amazon region, is renowned for its natural fibers with high mechanical strength. Scientific research has been exploring the potential of these fibers as reinforcement in polymer matrices, aiming to replace imported synthetic fibers. The properties of composites are influenced by the individual characteristics of their components, and mechanical tensile tests were conducted to ascertain these properties, following ASTM D638-14 standard guidelines.
Technical Session
DEVELOPMENT OF ARTIFICIAL ROCK WITH STEEL WASTE AND EPOXY RESIN
Presenter(s): José Lucas Decoté de Carvalho Lirio (UENF - ALBERTO LAMEG), Sávio dos Santos Carvalho (UENF), Pablo Barbosa Jacintho (UENF), Maria Luiza Pessanha Menezes Gomes (UENF), Elaine Aparecida Santos Carvalho5 (UENF), CARLOS MAURÍCIO FONTES VIEIRA (UENF), DJALMA SOUZA (UENF)
Abstract:
The development of synthetic materials to replace natural materials can result in products with better technological properties and represent a reduction in the exploitation of natural raw materials. Artificial rocks are synthetic materials with higher properties than their natural counterparts and which are mostly produced from solid waste. Therefore, the present work aims to produce and characterize an artificial rock using FGD steel waste and an epoxy resin matrix. The rock was produced using the vacuum vibro-compression method and characterized for its physical and mechanical properties. The rock was classified as having very high flexural strength, exceeding the standard required resistance by more than three times. Shore hardness revealed a hardness close to that of other materials produced with the polymer matrix.
Technical Session
EFFECTS OF SURFACE MODIFICATION WITH SODIUM CARBONATE ON THE STRUCTURE AND CHEMICAL COMPOSITION OF AMAZON TITICA VINE FIBERS
Presenter(s): juliana dos santos carneiro da cunha (IME), Michelle Souza Oliveira (IME), Ulisses Oliveira Costa (IME), Elias Matias Bentes (IME), Lucio Fabio Cassiano Nascimento (IME), Sergio Neves Monteiro (IME)
Abstract:
Natural fibers have contributed positively to sustainability, especially when collected and used in a way that minimizes environmental impacts. These are normally acquired through socially responsible methods, guaranteeing income generation for forest people, working conditions and social well-being. Natural fibers have often been replacing synthetic fibers as they are biodegradable, easy to acquire, low cost and have potential for use in circular economy processes. In recent years there has been an increase in the popularity of natural lignocellulosic fibers (NLFs) among academic researchers and companies. This is related to the unique properties that make them suitable for a variety of applications such as reinforcement for composites, biomaterials, cellulose nanomaterials, activated or conductive carbon and others. With the aim of further studying the chemical-structural characteristics of a little-known Amazonian fiber, the titica vine fibers (Heteropsis flexuosa), this work characterized the fiber before and after treatment with sodium carbonate using the Fourier-transform infrared spectroscopy (FTIR) technique. The results indicated characteristic bands of lignocellulosic materials and the presence of fundamental functional groups belonging to the main constituents of the fiber. Furthermore, after treatment, a decrease in the intensity of the adsorption bands referring to groups related to lignin and hemicellulose was observed.
Technical Session
PHYSICAL-MECHANICAL CHARACTERISTICS OF HEATLY TREATED PLASTER WASTE
Presenter(s): KARINE MIRANDA DE SOUZA TAVARES (UENF), Laimara da silva barroso (uenf), Maria mariana dias pereira (uenf), mariana gomes pinto cherene (uenf), letícia barcelos de sousa (uenf), gustavo de castro xavier (uenf), sidnei josé gomes sousa (faetec), afonso rangel garcez de azevedo (uenf), sérgio neves (ime)
Abstract:
Demolition waste is waste composed of debris, coming from structural elements, rubble and renovations. Its potential has been the subject of study by researchers who observed that through heat treatment it is possible to promote dehydration, forming hydrated calcium silicates, which when in contact with water again, are capable of partially recovering the strength of the cement matrix. For this reason, this work analyzed the physical-mechanical characteristics of Plaster Cement Residue (RCR) dehydrated at 550°C and crushed, through laser granulometry, X-ray Diffraction (X-RD) and isothermal calorimetry analyses. Once in the hardened state, prismatic specimens (4x4x16) were made for testing density, mechanical resistance, void index and water absorption by capillarity and immersion. The mixture developed was 1:6 (cement:sand), with replacement proportions of 0, 10, 20 and 30% of the fine aggregate by RCR and CPV ARI cement was used. The results showed that replacing sand with RCR promoted significant improvements in the mechanical and technological properties of the mortar, increasing mechanical resistance, reducing the void index and absorption both by capillarity and immersion.
Technical Session
EFFECT OF CURING ON COMPRESSION RESISTANCE OF MORTARS WITH PLASTER INCORPORATION
Presenter(s): laimara da silva barroso (UENF), Karine Miranda de Souza Tavares (UENF), MARIANA GOMES PINTO CHERENE (uenf), WALQUÍRIA LEONARDO BASTOS (DER-RJ), CAROLINA GOMES DIAS RIBEIRO (uenf), Gustavo de Castro Xavier (uenf), Carlos Maurício Fontes Vieira (uenf), Afonso Rangel Garcez de Azevedo (uenf), Sérgio Neves Monteiro (ime)
Abstract:
This study investigated the influence of the type of curing on the compressive strength of mortars based on Portland cement with the addition of gypsum by-product, obtained during the production of lactic acid. Mortars were made with the addition of gypsum by-product, ground for 30 minutes in a ball mill, in proportions of 0%, 2.5%, 5% and 7.5% in relation to the cement mass and cured at room temperature and submerged. in water saturated with lime. The compressive strength of the mortars in both types of curing was evaluated, as well as microstructural analysis by X-ray diffraction. The results showed that samples subjected to ambient curing presented greater resistance compared to those subjected to curing immersed in lime-saturated water. However, mortars with the addition of calcium sulfate up to 5% and immersed curing showed significantly higher compressive strength than the reference mortar. While, in air curing, the resistance showed a decreasing trend with the addition of gypsum. This indicates that the curing regime has a significant impact on compressive strength, but does not alter the type of hydration products.
Technical Session
9/3/24, 10:15 AM - 9/3/24, 11:05 AM
Presenter(s): LAURA SETTI DE SOUSA (IME MILITAR DE ENGENHARIA), ANDRE LEONARDI FAVALESSA (INSTITUTO MILITAR DE ENGENHARIA), BERNARDO PEREIRA PINTO DE CASTRO (INSTITUTO MILITAR DE ENGENHARIA), EDUARDO DE AMARIZ GALVAO (INSTITUTO MILITAR DE ENGENHARIA), GUILHERME GRECO DE ANDRADE (INSTITUTO MILITAR DE ENGENHARIA), JOAO PEDRO BIAZON MANETTI (INSTITUTO MILITAR DE ENGENHARIA), JOAO VITOR MODESTO PEREIRA (INSTITUTO MILITAR DE ENGENHARIA), LUIZ AUGUSTO SANTOS RIBEIRO (INSTITUTO MILITAR DE ENGENHARIA), Sergio Neves Monteiro (INSTITUTO MILITAR DE ENGENHARIA)
Abstract:
The current scenario drives interest in the development of ballistic vests. Advances in the field have resulted in the production of vests using high-performance synthetic fibers such as Kevlar® and Dyneema®. These materials, however, are costly and present environmental challenges. Natural fibers, such as sisal, emerge as a sustainable alternative due to their unique characteristics. However, their inherent heterogeneity poses considerable challenges to reliability, particularly in ballistic applications. Therefore, it has been proposed to combine synthetic and natural fibers in a hybrid composite to balance high ballistic performance and low cost. The properties of a composite can vary according to the configuration of the reinforcement layers, thus, the present study sought to evaluate five different stacking sequences of sisal and aramid fabric layers in an epoxy matrix hybrid composite through residual velocity tests. It was found that samples made entirely of sisal presented the highest specific energy absorption in relation to thickness (143.06 J/cm), promoting a cost saving of 93,4% compared to the composite made only of aramid. Furthermore, it was also found that hybrid samples perform better than samples composed entirely of aramid, meaning that the inclusion of sisal in the composite does not reduce ballistic performance.
Technical Session
thermal mechanical and dynamic mechanical analysis of sedge fibers (cyperus malaccensis) COATED BY GRAPHENE OXIDE as a reinforcement FOR epoxy MATRIX Abstract
Presenter(s): LUCAS DE MENDONÇA NEUBA (IME), Raí Felipe Pereira Junio (IME), Douglas Santos Silva (IME), Elias Matias Bentes (ime), Lucas Moura Montenegro Reis (ime), Thuane Teixeira da Silva (ime), Sergio Neves Monteiro (ime)
Abstract:
Composites with natural lignocellulosic fibers (NLFs) currently have extremely diverse applications, including in engineering industries, due to their lower cost and density, as well as ease of processing. Another notable material, graphene oxide, has attracted considerable attention for its properties, mainly as a coating to improve interfacial adhesion in polymer composites. Therefore, this research focuses on investigating the dynamic mechanical (DMA) and thermomechanical analysis (TMA) for epoxy matrix composites containing 30% by volume of CM reed fiber incorporated with graphene oxide. Compared to the control group (untreated epoxy) the damping factor (Tan δ), being the ratio of the loss modulus under storage, is significantly increased from (0.55-0.75) for the composites reinforced with 30% of CM reed fibers incorporated with graphene oxide. The Tg found at 127°C for condition 30 FJGO/EP was higher than the other EP conditions, 30 FJ/EP and 30 FJ/EP-GO, as well as the coefficient of thermal expansion (208.52 to 248.95 x 10−6/°C). The mass loss for the 30 FJGO/EP condition in the first stage was slightly higher than the EP condition (1.63%). These DMA and TMA results prove to be promising.
Technical Session
9/3/24, 10:15 AM - 9/3/24, 11:05 AM
Presenter(s): Luis Fernando Fortunato De Freitas (UENF), Darcy Lucas da Rocha Oliveira (UENF), Luis Ricardo Arrubla Agudelo (UENF), Noan Tonini Simonassi (UENF), CARLOS MAURÍCIO FONTES VIEIRA (UENF), FELIPE PERISSÉ DUARTE LOPES (UENF)
Abstract:
Natural fibers have emerged as a promising alternative to synthetic fibers in composites, due to their favorable mechanical properties and sustainability. This study investigates the tensile behavior of epoxy composites reinforced with different levels of ramie fiber, a high-strength lignocellulosic fiber. The tensile properties of the composites were evaluated by varying the amount of lignocellulosic fibers. Composites containing up to 30% by volume of long, continuous and aligned ramie fibers were tested on an universal testing machine at room temperature, and the fracture surfaces were analyzed by scanning electron microscopy (SEM). The results show a significant increase in the mechanical properties of the composites with increasing fiber content. The results of the tensile test and SEM analysis reveal good adhesion between the fiber and the matrix, demonstrating the potential of ramie fiber as a reinforcement for epoxy composites, with promising applications in various areas, such as the high-performance bicycle industry and its components.
Technical Session
TENSILE STRENGTH OF POLYURETHANE COMPOSITES REINFORCED WITH BAMBOO FIBER IN DIFFERENT PROPORTIONS.
Presenter(s): mariana dias machado lopes (UENF), SERGIO NEVES MONTEIRO (uenf), felipe perissé duarte lopes (uenf), noan tonini simonassi (uenf)
Abstract:
Tensile strength is a fundamental property for various materials, especially those used in structural applications. The use of natural fibers, such as bamboo, as reinforcement in polyurethane composites has been of interest due to their favorable mechanical properties and renewable nature. In this study, polyurethane composites with different bamboo fiber contents were prepared and their tensile strength was evaluated. It was possible to observe an equivalence among the results of each of the proportions used, offering the perspective that the increase in fiber for this study did not improve the properties of the composite. Thus, although the addition of natural fibers may improve certain mechanical properties of polymeric composites, such as perpendicular tensile strength and impact resistance, the modulus of elasticity and tensile strength limit may not experience a significant increase if factors such as fiber orientation, bonding, content, distribution, fiber flexibility, nature, and properties of the matrix are not optimized and compatible
Technical Session
INFLUENCE OF MANUFACTURING TECHNIQUES ON THE BALLISTIC PERFORMANCE OF ARAMID-EPOXY LAMINATED COMPOSITES.
Presenter(s): SARAH CATHARINA VITALI DE MELO (IME MILITAR DE ENGENHARIA), Lucas moura montenegro reis (ime - instituto militar de engenharia), lucio fabio cassiano nascimento (ime - instituto militar de engenharia), sergio neves monteiro (ime - instituto militar de engenharia)
Abstract:
The biodiversity of Brazilian flora offers numerous possibilities for the development of innovative materials. Tauari sawdust, a byproduct of the Amazonian timber industry, has potential for use in composites due to its unique cellular structure. This study presents a morphological analysis of natural tauari sawdust and epoxy resin composites made with 30% by volume of sawdust, along with an evaluation of mechanical performance through tensile tests. The morphological results showed the heterogeneous structure of the sawdust, with a rough and porous surface, significant characteristics for adhesion and interaction with the matrix. Mechanical tests revealed that composites with tauari sawdust exhibited improved tensile properties due to the effective interaction between the components. It is concluded that epoxy resin composites reinforced with tauari sawdust are promising for various industrial applications, combining mechanical strength and sustainability
Technical Session
COST CALCULATION OF GOODS SOLD (COGS) FOR POLYMER COMPOSITES WITH SUGAR CANE BAGASSE RESIDUE IN A HIGH-PERFORMANCE COATING APPLICATION
Presenter(s): Juliana Sousa Gomes Ribeiro ( Universidade Estadual do Norte Fluminense Darcy Ribeiro.), FELIPE PERISSÉ DUARTE LOPES ( Universidade Estadual do Norte Fluminense Darcy Ribeiro), Rodolfo Albino Zangerolame ( Universidade Estadual do Norte Fluminense Darcy Ribeiro.), Noan Tonini Simonassi ( Universidade Estadual do Norte Fluminense Darcy Ribeiro.), CARLOS MAURÍCIO FONTES VIEIRA ( Universidade Estadual do Norte Fluminense Darcy Ribeiro.), Frederico Muylaert Margem (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO.)
Abstract:
Industrial activities require base surfaces of exceptional quality, making it essential to select flooring with specific characteristics. These include resistance to wear, discontinuities, cracks and other anomalies. Faced with this requirement, various sectors have opted to use polymeric floor coatings, known as High Performance Coatings (HPC). At the same time, the growing interest in environmental sustainability has driven the search for more ecologically viable materials. In this context, this study focuses on the use of sugarcane bagasse particles combined with epoxy resin to produce a composite suitable for use as a HPSR. Subsequently, a Cost of Goods Sold (COGS) analysis is carried out to assess the econoeded to manufacture the prototypes tested, as well as the volume of material used, both polymeric and lignocellulosic. Although this analysis is still preliminary, it clearly indicates the need to improve the prototype manufacturing process in order to reduce working time. This is due to the fact that high workloads result in an increase in the CMV, making the product relatively expensive for the usual market consumers.mic viability of these materials. The study includes calculating the hours ne This is due to the fact that high workloads result in an increase in the CMV, making the product relatively expensive for the usual market consumers.
Technical Session
MECHANICAL PROPERTIES ANISOTROPY IN PA12 PROCESSED BY MJF
Presenter(s): RODRIGO MAGNABOSCO (Centro Universitário FEI), Renato da Cunha Araújo (VW-SBC)
Abstract:
This study evaluates the possible anisotropy of mechanical properties in different orientations from the printing platform in tension and flexural tests, specifically elastic modulus and yield strength, for PA12 produced by Multi-Jet Fusion (MJF). Tensile elastic modulus can present differences up to 55 % depending on the orientation of the loading direction to the printing platform. Tensile yield strength, in similar behavior, can present differences up to 75%. In flexural tests, elastic modulus and yield strength can vary by 65% and 45%, respectively. These findings indicate the anisotropic mechanical behavior of PA12 parts produced by MJF. The anisotropic mechanical behavior was related to the functional sintered area per pass, indicating that higher functional sintered areas lead to smaller mechanical properties
Technical Session
9/3/24, 10:15 AM - 9/3/24, 11:05 AM
Presenter(s): VICTOR PAES DIAS GONCALVES (Universidade Estadual do Norte Fluminense Darcy Ribeiro ), Carlos Maurício Fontes Vieira (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO ), Noan Tonini Simonassi (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO ), FELIPE PERISSÉ DUARTE LOPES (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO ), Henry Alonso Colorado Lopera5 (Universidad de Antioquia UdeA)
Abstract:
Three-dimensional (3D) printing has revolutionized the industry by allowing the rapid creation of complex personalized parts. One of the most used techniques is stereolithography printing (SLA), which uses photocurable resins exposed to a laser for solidification. The application of this technology in the manufacture of intraoral devices, such as mouth guards and occlusal splints, has significant potential, but still lacks detailed studies. The objective of this work is to evaluate the mechanical properties of materials produced by additive manufacturing, comparing them with conventional materials used in the manufacture of mouthguards and occlusal splints. Test specimens were printed using an SLA printer. Shore A hardness and tensile tests were conducted for mouthguard materials, and compression and Shore D hardness tests for occlusal splint materials. In the tensile test of materials for mouthguards by manufacture, the dima® Print Mouth Guard material showed a higher elastic deformation than the conventional material and the dima® Print Ortho material showed greater resistance to compression than the conventional material. Based on the results obtained, it is suggested that additive manufacturing materials using SLA in the production of intraoral devices are efficient, offering a viable alternative to conventional materials
Technical Session
EFEITOS DA CORROSÃO QUÍMICA EM REVESTIMENTOS REFRATÁRIOS DE MAGNÉSIA-CROMO APLICADOS NA METALURGIA: UMA ANÁLISE A PARTIR DA PERSPECTIVA POST MORTEM
Presenter(s): Caroline Piffer Diniz Santos (rhi magnesita), Andre Rocha Nardim (rhi magnesita)
Abstract:
Os revestimentos refratários desempenham um papel fundamental nas operações metalúrgicas enfrentando condições extremas como altas temperaturas, estresse mecânico e corrosão por escória, resultando em perda de massa, espessura e consequentemente em sua vida útil. O estudo post mortem é essencial para compreender os mecanismos de corrosão e desenvolver estratégias de mitigação e solução para esses problemas. A identificação dos mecanismos predominantes permite a formulação de novos materiais refratários e tecnologias com o objetivo de melhorar o desempenho e aumentar a vida útil desses revestimentos em processos industriais que envolvem altas temperaturas. A abordagem proposta é uma revisão das metodologias utilizadas em estudos post mortem de revestimentos refratários de magnésia-cromo destacando os efeitos causados pela corrosão química por escória e os aspectos de infiltração ocorridos nos processos metalúrgicos.
Technical Session
CHARACTERIZATION OF PITS IN CORROSION COUPONS THROUGH OPTICAL AND CONFOCAL MICROSCOPY TECHNIQUES
Presenter(s): césar augusto siqueira crespo neto (universidade estadual norte fluminense darcy ribeiro), Geanni Barbosa da Silveira e Silva Pessanha (UNIVERSIDADE ESTADUAL NORTE FLUMINENSE DARCY RIBEIRO), Sthefanie de Carvalho Mendes Lopes (UNIVERSIDADE ESTADUAL NORTE FLUMINENSE DARCY RIBEIRO), Silvio Gonçalves Mendes (UNIVERSIDADE ESTADUAL NORTE FLUMINENSE DARCY RIBEIRO), Elaine Cristina Pereira (UNIVERSIDADE ESTADUAL NORTE FLUMINENSE DARCY RIBEIRO), Ângelus Giuseppe Pereira da Silva (UNIVERSIDADE ESTADUAL NORTE FLUMINENSE DARCY RIBEIRO)
Abstract:
Among the forms of existing steel corrosion, the most common are alveolar type and pitting. Coupons are metallic bodies of evidence used corrosion tests with multiple types and shapes, however, the most widely used in the corrosion monitoring are carbon steel which feature rectangular and disk formats. The current study aims to compare the characteristics of pitting corrosion in A213 T9 steel coupons through two microscopic methods, namely, optical and confocal. The coupons were tested in corrosion loop, with drinking water as fluid. The rules were adopted to such characterization were NACE SP0775 and ASTM G46-21. The conventional optical microscopy is a method quite used; however, there are some limitations. Confocal microscopy is a technique for characterization of digital high-resolution scanning laser beam, point to point (optical section) where images can be turned into three-dimensional images.
Technical Session
9/3/24, 10:15 AM - 9/3/24, 11:05 AM
Presenter(s): DANIELI APARECIDA PEREIRA REIS (Universidade Federal de São Paulo - UNIFESP), Polyana Alves Radi (UNIVERSIDADE FEDERAL DE SÃO PAULO - UNIFESP), Renata Jesuina Takahashi2 (UNIVERSIDADE FEDERAL DE SÃO PAULO - UNIFESP), Adriano Gonçalves dos Reis (Universidade Estadual Paulista “Júlio de Mesquita Filho”)
Abstract:
Corrosion inhibitors are essential for protecting metals against deterioration. The majority of commercial inhibitors, despite being widely used, suffer from limitations such as restricted efficacy and high toxicity. Plant-derived inhibitors, especially Moringa Oleifera oil, stand out as viable alternatives due to their compatibility with metal surfaces and low toxicity. Oleic acid, a monounsaturated fatty acid predominant in Moringa oil, grants the oil superior oxidative stability. Moreover, Moringa is easy to cultivate, with productivity up to 45 tons per hectare, and oil extraction can reach from 35 to 40% of the seed weight. This study focused on the potential of Moringa oil as a corrosion inhibitor in carbon steel. After exposure to a 3.5% saline solution, it was observed a reduction in mass loss of 0.02% compared to untreated samples.
Technical Session
9/3/24, 10:15 AM - 9/3/24, 11:05 AM
Presenter(s): lucas menezes de souza (UENF), Diana Gomes Ribeiro (UENF), Elaine Cristina Pereira (UENF), Ângelus Giuseppe Pereira da Silva (UENF)
Abstract:
Coupons specimens are widely used in the monitoring of corrosive process. There are different types and forms of corrosion coupons, which are the more used coupons in rectangular and disc formats. It is know that in the presence of neutral solution, the variation in chemical composition and microstructure of steels coupons carbon has little influence on the rate of uniform corrosion. However, the presence of defects and inclusions are leading to initiation and propagation of pitting corrosion in carbon steels factors. This study aims to evaluate the influence of coupon geometry in determining the rates of uniform and pitting corrosion, relating to the microstructure of materials. The characterization techniques have involved chemical and microscopy analysis. The coupons were tested in corrosion loop. To determine the corrosion rates NACE, ASTM and NBR standards were adopted. Coupons in rectangular and disk have comparable rate of uniform corrosion, however, evaluating the pitting corrosion changes are very significant.
Technical Session
INTERGRANULAR CORROSION IN WELDED AUSTENITIC (ABNT 304) AND FERRITIC (ABNT 430) STAINLESS STEELS
Presenter(s): FERNANDA DO NASCIMENTO OLIVEIRA (universidade federal de ouro preto), THAYNARA MELO MOUSSA (UNIVERSIDADE FEDERAL DE OURO PRETO), LUIZ CLAUDIO CANDIDO (UNIVERSIDADE FEDERAL DE OURO PRETO)
Abstract:
Ferritic and austenitic stainless steels are susceptible to the phenomenon of sensitization after being exposed to high temperatures, which can promote intergranular corrosion. In this context, this work aimed to study the effects of welding on stainless steel joints welded by the MIG process, using an austenitic electrode addition wire (AISI 316LSi, %C ≤ 0.03% by mass), with a protective atmosphere containing high purity Argon. The formation of martensite islands was observed in the HAZ of AISI 430 (ferritic) steel, as well as significant grain growth in this region. At the fusion zone, AISI 430 and AISI 304 steels presented a duplex microstructure of austenite and ferrite. Furthermore, both showed significant precipitation of Cr carbides in the base metal, which may indicate the non-solubilization of these carbides in the samples of these steels in the delivery state. Potentiodynamic polarization tests were carried out on AISI 304 and AISI 430 steels in the delivery state, and the greater corrosion resistance of austenitic stainless steel was clear. Furthermore, heat treatments were carried out to evaluate the degree of sensitization of the steels. It was possible to observe that the two heat treated steels were susceptible to intergranular corrosion, and in a more pronounced way, the ferritic stainless steel. In this work, ASTM A262 and A763 standards were used.
Technical Session
EVALUATION OF THE EFFICIENCY OF GUAVA SEED AS A CORROSION INHIBITOR FOR AISI 1020 CARBON STEEL IN AQUEOUS AND SODIUM CHLORIDE MEDIA
Presenter(s): jÉSSICA rOCHA DA fONSECA (Universidade Estadual do Norte Fluminense Darcy Ribeiro), Lucas Menezes de Souza (Universidade Estadual do Norte Fluminense Darcy Ribeiro), Fabrício Bagli Siqueira (UCAM), Talwani Nogueira Mattos (UCAM), Elaine Cristina Pereira (Universidade Estadual do Norte Fluminense Darcy Ribeiro)
Abstract:
This work addresses the issue of corrosion in metallic materials, with a specific focus on AISI/SAE 1020 carbon steel. It highlights the importance of this type of steel in industry due to its mechanical properties, affordable cost, and ease of handling, but highlights its susceptibility to corrosion. It is explained that corrosion can be a chemical or electrochemical process, starting on the metal surface and resulting in its deterioration, which can lead to structural failures and significant economic impacts in various industrial sectors. To combat this problem, there is a growing search for natural corrosion inhibitors that are effective, accessible, low-cost, and environmentally safe. In this context, the mentioned study investigates the corrosion inhibitory potential of guava seeds on 1020 carbon steel. The results demonstrate that guava seed powder can inhibit the corrosion of 1020 carbon steel, with significant inhibition efficiency in media. water and NaCl. The effectiveness of green inhibitors is highlighted as a sustainable and economical alternative for preventing corrosion. Finally, it is suggested that the study be continued to better understand the mechanism of action of natural inhibitors and to consider other factors, such as exposure time and application conditions.
Technical Session
9/3/24, 10:15 AM - 9/3/24, 11:05 AM
Presenter(s): José Rômulo azeredo Gomes (Universidade estadual do norte fluminense darcy ribeiro (uenf)), Fabrício bagli siqueira (universidade cândido mendes (ucam)), lucas menezes de souza (universidade estadual do norte fluminense (uenf)), talwani nogueira mattos (universidade cândido mendes (ucam)), elaine cristina pereira (universidade estadual do norte fluminense darcy ribeiro (uenf))
Abstract:
Corrosion is broadly defined as the deterioration of materials, the result of spontaneous processes that occur between the material and the environment. The phenomenon of corrosion is a natural and inevitable challenge. Carbon steel is widely used due to its diverse applications, many of which are based on its excellent mechanical properties. This metal has high ductility (ability to deform), high tenacity, is machinable, weldable and has a low production cost, but has reduced corrosion resistance, making it necessary to use processes to delay the corrosive mechanism, such as the use of inhibitors. . Many of the inhibitors used are associated with high costs, environmental and human health risks, due to their toxic nature. Thus, the study of corrosion inhibitors from natural products is increasing, which are low cost and non-toxic. Natural products have stood out as promising sources of corrosion inhibitors, as they are formed through plant extracts or biodegradable materials, where many of these extracts contain compounds with antioxidant action. This present work aimed to investigate the inhibitory action of guava seeds on the corrosion of AISI/SAE 1020 carbon steel in a medium of HCl 1 mol L-1 at concentrations of 1 g L-¹ of seed powder. Mass loss tests were carried out using dried and crushed guava seeds (inhibitor) mixed in a solution containing a simulation of a corrosive environment (HCl hydrochloric acid). The specimens made of carbon steel were immersed in an HCl solution with and without the inhibitor for a period of 21 days at room temperature. The efficiency of guava seed was satisfactory as a green type inhibitor, reaching a maximum value of 59.11%.
Technical Session
ELECTROCHEMICAL BEHAVIOR OF AUSTENITIC STAINLESS STEEL 316L IN THE PRESENCE OF CHLORIDE IONS
Presenter(s): Késia Simões ribeiro (ime), Tamara da Silva Tavares DOS REIS (IME), Francielly Moura de Souza Soares2 (IME), Rafael de Almeida Vasconcelos (LFV Serviços), Carlos Nelson Elias (IME)
Abstract:
Stainless steel 316L (SS 316L) is widely used in chemical and petrochemical industries due to its favorable mechanical strength, weldability, and corrosion resistance. Its remarkable corrosion resistance is attributed to the formation of a passive chromium oxide layer. However, in highly corrosive environments, such as those containing chloride ions associated with acidic media, the corrosion resistance of this material may be compromised. The present study analyzed the influence of environment in the SS 316L corrosion resistance. Electrochemical tests were conducted to measure open circuit potential and potentiodynamic polarization in solutions of 3.5% NaCl and 3.5% HCl. The results showed that the acidic medium was the most corrosive, evidenced by the displacement of open circuit potential (OCP) and corrosion potential to less noble values, accompanied by a high corrosion current density. The electrochemical results were confirmed by the intense pitting corrosion on the SS 316L and the formation of corrosion products in the solution.
Technical Session
Creep-fatigue behavior of the 9cr steel with w and ta addition
Presenter(s): maria luiza wedderhoff brasileiro (IME - INSTITUTO MILI), Julianna Magalhães garcia (IME - INSTITUTO MILITAR DE ENGENHARIA), talita gama de sousa (ime - instituto militar de engenharia), Luiz paulo mendonça brandão (instituto militar de engenharia - ime), Marvin do nascimento (instituto militar de enegenharia - ime)
Abstract:
With the increasing industrial need for materials with improved mechanical properties, it becomes important to study the behavior of modified alloys under different testing conditions, as understanding the behavior of these different materials in specific application environments is essential. This article aimed to analyze 9Cr steel modified with the addition of W and Ta when subjected to creep-fatigue. From the study, it was possible to observe both ductile and brittle characteristics in the samples, even with different exposure times to creep conditions. Using images produced by a scanning electron microscope, the fracture surface of the samples was analyzed to confirm the existence of secondary cracks and variations in the fracture mode. It was found that the material became more brittle with increased exposure time and load hold time, although it maintained a certain degree of ductility.
Technical Session
9/3/24, 10:15 AM - 9/3/24, 11:05 AM
Presenter(s): RAI FELIPE PEREIRA JUNIO (IME)
Abstract:
There is a daily need to develop new materials, which generally must exhibit the most innovative properties that make them useful in the most varied fields of knowledge. In view of this, investigations into high entropy shape memory alloys (HESMAs) stand out. These materials combine unique properties of two classes of materials: high entropy alloys and shape memory materials. HESMAs have a complex crystalline structure and exceptional mechanical properties, combined with the ability to recover their original shape after thermal deformation. By combining these characteristics, high-entropy shape memory alloys demonstrate promising versatility in diverse applications, from biomedical devices to structural components in aerospace engineering. Their ability to maintain specific shapes even after large deformations and their resistance to high temperatures make them ideal candidates for applications in extreme environments. Continuous development in this field aims to explore its potential in new areas and improve its properties to meet the demands of various industries. This review aims to present the main topics inherent to these materials, highlighting scientific work carried out around the topic.
Technical Session
INFLUENCE OF CHEMICAL COMPOSITION ON DETERMINING THE SIGMA FORMATION TEMPERATURE IN SUPERDUPLEX STAINLESS STEEL BY COMPUTATIONAL SIMULATION
Presenter(s): RODRIGO MAGNABOSCO (Centro Universitário FEI), Rayanne Araújo Andrade (Centro Universitário FEI)
Abstract:
This work investigates the influence of composition on the computational simulation of the highest formation temperature of the sigma phase in superduplex stainless steels during continuous cooling. The sigma phase is known to compromise the mechanical and corrosion resistance properties of these materials. With the aid of computer simulations in THERMOCALC® and DICTRA® softwares, it was possible to analyze the variation in the temperature at which the sigma phase begins to form as a function of the chemical composition, considering the variation of different elements. The results highlight that the presence or absence of certain elements, such as Cu, W, Mn, Si and N, can significantly change this temperature, revealing the complex interaction between the elements and the sigma phase formation process. Furthermore, the results can be compared with previous studies, demonstrating the importance of defining the temperature at which the sigma phase begins to form to use as input information in the DICTRA® software. Therefore, the methodology applied in this exploratory stage work is essential to understand and predict the formation of the sigma phase in superduplex steels.
Technical Session
EFFECT OF TEMPERATURE AND HOMOGENIZATION TIME OF A LOW ALLOY STEEL BY DICTRA® SIMULATION
Presenter(s): RODRIGO MAGNABOSCO (centro universitário FEI), Guilherme Arruda Basso (IPT), Felipe Moreno Siqueira Borges de Carvalho (IPT)
Abstract:
To guarantee the microstructural homogeneity of steels, which is only possible to obtain by inducing the chemical homogeneity of the material, the inherent segregations of the metal solidification process must be reduced or eliminated. The objective of this work was to study the influence of temperature and homogenization treatment time of a medium carbon steel by Dictra® simulation. The homogenization temperatures were 1000 to 1200°C, for a maximum time of 10 hours. As expected, the increase in temperature leads to a reduction in the time required for homogenization and, for a given temperature, the increase in time leads to a decrease in the chemical composition gradient. However, by simulation, the maximum homogenization time of 10 hours, even at the highest temperature (1200°C), is not sufficient for complete homogenization of the alloy, for the steel in question.
Technical Session
SURFACE ANALYSIS ON ANODIZED ALUMINUM PROFILES WITH LUBRICATING OILS
Presenter(s): Leonardo corrêa branco (universidade federal de são paulo)
Abstract:
The machining of aluminum consumes less energy and allows for high feedrates. However, the material has higher coefficient of thermal expansion and modulus of elasticity, making it difficult to obtain parts with small tolerances and having the tendency to warp. The 6060 alloy is widely used in frames and includes magnesium, silicon, iron, manganese, and copper in its composition, forming intermetallic compounds that improve the machinability of the material, superior to other alloys. The heat generated during aluminum machining is mostly dissipated by the workpiece, causing deformations, handling difficulties, and reduced tool life, which can be mitigated by using cutting fluids based on inactive sulfurized mineral oils. In this study, surface analyses were performed using SEM, XRD, tribological studies in pin-on-disk mode, and nanoindentation on anodized 6060-T6 aluminum profiles, comparing two groups of samples machined with and without cutting fluid. Additionally, an immersion test was conducted on the samples. The results showed that the samples machined with cutting fluid exhibited higher surface hardness and lower coefficient of friction. SEM, EDS, and XRD analyses did not reveal the formation of oxides or surface alterations in the samples that underwent immersion or machining with cutting fluid.
Technical Session
THE USE OF IMAGEJ IN QUANTITATIVE METALLOGRAPHY
Presenter(s): alisson nunes santana (instituto militar de engenharia), Gabriel Aires Lima (INSTITUTO MILITAR DE ENGENHARIA), Daniel Machado Barbosa (INSTITUTO MILITAR DE ENGENHARIA), Lucas Freitas da Rocha (INSTITUTO MILITAR DE ENGENHARIA), Luiz Fernandes Rios (INSTITUTO MILITAR DE ENGENHARIA), Artur Timbó Barbosa (INSTITUTO MILITAR DE ENGENHARIA), DIONATHAN TRINDADE BOOR (INSTITUTO MILITAR DE ENGENHARIA), Julianna magalhaes Garcia (INSTITUTO MILITAR DE ENGENHARIA), Talita Gama de Sousa (INSTITUTO MILITAR DE ENGENHARIA), Luiz Paulo Mendonça Brandão (INSTITUTO MILITAR DE ENGENHARIA)
Abstract:
Quantitative metallography represents a crucial role in materials science and industry by providing detailed information about microstructures, which are consequently related to the properties of materials. This article’s goal is to describe a practical method for using the open-source image processing program, ImageJ, in the field of quantitative metallography, in order to expand and optimize studies in this area with the vast resources of this versatile and free tool. Thus, with the developed methodology, it has become possible to calculate grain size, pore area, and the volumetric fraction of phases in a microstructure in a simple and quick way, using practical and automated methods supported by the use of plugins such as jPOR and the creation of detailed and didactic tutorials.
Technical Session
MECHANICAL BEHAVIOR OF MARAGING 300 STEEL PRODUCED BY TRADITIONAL METHOD AND ADDITIVE MANUFACTURING
Presenter(s): AROLDO MENDES PAIVA NETO (INSTITUTO MILITAR DE ENGENHARIA), Carolina Alencar Caldeira de Souza (INSTITUTO MILITAR DE ENGENHARIA), Julianna Magalhães Garcia (INSTITUTO MILITAR DE ENGENHARIA), Talita Gama de Sousa (INSTITUTO MILITAR DE ENGENHARIA), Luiz Paulo Mendonça Brandão (INSTITUTO MILITAR DE ENGENHARIA)
Abstract:
Instituto Militar de Engenharia has been developing a new concept of metallic shielding, the shielding with polyundular format. The proposed geometric shape becomes a major challenge for traditional manufacturing processes, in which new modeling or machining steps are required. From the context that aims to evolve with this work, a study of the application of additive manufacturing in the manufacture of these polyundular plates was initiated, for which the mechanical properties of maraging steel plates 300 produced by additive manufacturing manufactured by selective laser melting were compared. and produced by conventional manufacture, varying the thermal treatments that both were submitted. The results obtained indicated positive factors both in the use of additive manufacturing as a possible resource for obtaining plates with good mechanical factors, as well as possibilities for optimizing the thermal treatments of maraging steel 300.
Technical Session
BALLISTIC IMPACT RESISTANCE OF OPTIMIZED PROFILE PLATES PRODUCED BY ADDITIVE MANUFACTURING
Presenter(s): AROLDO MENDES PAIVA NETO (Instituto Militar de Engenharia), Talita gama de sousa (Instituto Militar de Engenharia - IME), Julianna magalhaes Garcia (Instituto Militar de Engenharia - IME), Luiz Paulo Mendonça Brandão (Instituto Militar de Engenharia - IME)
Abstract:
IA armor new concept has been the object of study at the Instituto Militar de Engenharia, which consists of polywave metal sheets. The additive manufacturing technique has proven to be a good alternative in the manufacture of this sheets type. Therefore, this project proposes to investigate the ballistic behavior of prototypes made by additive manufacturing of polymeric feedstock to evaluate the behavior of different polywaves geometries in the optimization of armor for public security. Through the results obtained it was concluded that the polywave geometry showed better performance. Additionally, the lateral region exhibited higher values of absorbed energy compared to the peaks and valleys of the polywave geometry.
Technical Session
Characterization of PVA/Graphene Oxide-Based Composite Membrane for Fuel Cell
Presenter(s): britney aparecida teixeira (universidade federal fluminense - uff), mariangela pereira da silva (), Paulo José de Sousa Maia (), Fábio José Bento Brum ()
Abstract:
In this work, the results of the characterization of PVA-based composite cationic membranes with different concentrations of graphene oxide and their performance when applied in a fuel cell prototype were presented. Membranes with three different concentrations of graphene oxide (GO) were prepared. The characterization of the membranes was performed using atomic force microscopy to verify the morphology of the membranes when hydrated. The thermal resistance of the membranes was evaluated by thermogravimetric analysis, and the ionic conductivity of the membranes was analyzed by complex impedance. In the fuel cell prototype test, the composite membrane showed an open circuit potential of 0.6 V and a power of 0.18 W, compared to the Nafion membrane with an open circuit potential of 0.8 V and a power of 0.12 W under the test conditions in the cell.
Technical Session
9/3/24, 10:15 AM - 9/3/24, 11:05 AM
Presenter(s): Bruna sartes barbosa (Universidade federal fluminense), Lilian Weitzel Coelho Paes (universidade federal fluminense)
Abstract:
Computational models based on density functional theory (DFT) are today considered valuable tools for the study of molecular electronic structure. Despite these notable features, it remains true that the exact density functional is unknown and approximations must be introduced. Current computational methods allow calculations of electronic and geometric structures relevant for studying diffusion. The central goal of modern electronic structure calculations is to find the ground state energy of electrons in molecules. The central goal of these calculations is to determine many basic properties of a molecule, such as bond lengths and angles, dissociation energies, and transition state barriers, for any configuration of the nuclei. This study aims to evaluate the accuracy of several density functionals, specifically TPSSTPSS, B3PW91, HSEH1PBE and PBE1PBE, evaluating the reliability of these functionals. The evaluation of these functionals will allow us to identify the most reliable approach to simulate the diffusion of boron in iron. In this way, selection is crucial for subsequent simulations and can provide valuable information about the diffusion process, ultimately aiding in the design and optimization of materials with desired properties.
Technical Session
9/3/24, 10:15 AM - 9/3/24, 11:05 AM
Presenter(s): caio alves da silva (universidade federal do rio de janeiro)
Abstract:
Cobalt possesses characteristics that make it highly suitable for the production of batteries, alloys and superalloys, catalysts, among others. The production of cobalt materials in their metallic form is particularly interesting for the automotive and aerospace industries, as cobalt is a metal with well-defined properties, resistant to corrosion and high temperatures. Additionally, cobalt is a limited and valuable resource, making it important to explore ways to maximize its utilization. Therefore, the electrowinning of cobalt was evaluated using different concentrations of manganese ions and sodium lauryl sulfate in cobalt sulfate solutions separately, in order to identify their effects on current efficiency responses, specific energy consumption, and the microhardness of the deposits. Sodium lauryl sulfate increased current efficiency and decreased energy consumption, while manganese ions had the opposite effect. Both additives reduced the microhardness of the deposits.
Technical Session
9/3/24, 10:15 AM - 9/3/24, 11:15 AM
Presenter(s): Esther tavares (Universidade estadual do norte fluminense professor DArcy Ribeiro), manoel tadeu alves dos santos (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE PROFESSOR DARCY RIBEIRO), johnata frança fanni freitas (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE PROFESSOR DARCY RIBEIRO), josé Lucas Decoté de carvalho lirio (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE PROFESSOR DARCY RIBEIRO), elias rocha gonçalves júnior (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE PROFESSOR DARCY RIBEIRO), Juliana Fadini Natalli (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE PROFESSOR DARCY RIBEIRO), Afonso Rangel Garcez de Azevedo (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE PROFESSOR DARCY RIBEIRO)
Abstract:
The processing of ornamental rocks generates a large accumulation of waste resulting in high environmental impacts, as it is a non-biodegradable material. On the other hand, there is several research aimed at creating sustainable practices for the use of this waste. Therefore, this work aims to analyze the use of this material in the production of mortars, aiming to reduce its environmental impact. The mortars in this study were analyzed in their fresh state, using granite powder as a partial replacement for lime (CaO), in percentages of 10%, 20% and 30%, in addition to a reference trace without adding residue for comparison. For this, consistency index, density, viscosity and entrained air tests were carried out. In general, the gradual addition of granite powder affected the fluidity of the matrices, influencing their spreading. A 30% substitution showed an increase in scattering, suggesting physical and chemical interactions between the materials. The density initially decreased up to 10% of replacement, however, there was an increase for the other percentages, indicating better compaction. The replacement also reduced the air content and increased the viscosity of the mortar.
Technical Session
ADEQUACY OF THE OPERATIONAL MODEL OF A PORT TERMINAL FOR HANDLING ORE FROM DIFFERENT ORIGINS
Presenter(s): Guilherme pereira de Oliveira (VALE - PORTO DE TUBARÃO), Fabrício da Costa Pinto (VALE - PORTO DE TUBARÃO), André Martins Lemos (VALE - PORTO DE TUBARÃO), Bianca Trevizani Campi (VALE - PORTO DE TUBARÃO), Jarbas Amorim Júnior (VALE - PORTO DE TUBARÃO), Frederico Quintiliano Goes (VALE - CENTRO DE EXCELÊNCIA), Julius Félix Cordeiro dos Santos (VALE - CENTRO DE EXCELÊNCIA), VINICIUS HALFELD DE SOUZA (Vale S/A / Porto de tubarão), igor guarçoni de paula (Vale s/a - porto de tubarão)
Abstract:
The capacity to handle solid bulk in a port terminal is directly linked to the installed equipment, which is designed to move materials with specific characteristics, such as density, moisture, granulometric distribution, chemical composition, etc. Changes in the iron ore processing process can drastically alter its flow properties, transforming it into a new product and bringing the need for adaptation in both the design and the way the equipment operates. This work shows the adjustments made to a port terminal for handling iron ores with different origins and in their processing, making them less dense. Several laboratory tests were carried out to characterize the flow properties of the new ores with the aim of feeding virtual models of the equipment to size the handling capacity and operating model. The new defined model was tested and optimized through assisted operation on the port's main equipment, bringing significant results in reducing corrective maintenance hours related to chute clogging and corrective cleaning hours related to material leaks in the terminal boarding.
Technical Session
9/3/24, 11:05 AM - 9/3/24, 11:30 AM
Presenter(s): raphael victor leal (lYNX oTIMIZAÇÃO DE PROCESSOS s/A)
Abstract:
The level control of one ore silo, feeded by bucket wheel reclaimers, with the aim of regulating the flow in the iron ore shipping process, in addition to being recent, is extremely challenging. Using material tracking techniques and mathematical modeling, it was possible to create a control loop that takes into account transport delays and process disturbances, allowing the creation of a dynamic and robust control strategy, using a single expert system (Lynx RTP), and enabling the creation of new feeding strategies for ship loaders and, consequently, increasing the harbor's productivity.
Technical Session
AUTOMATIC CHARACTERIZATION OF HOT-ROLLED COILS
Presenter(s): andré de almeida grilo (arcelormittal brasil), Marcos Fernando Campioto Junior (ARCELORMITTAL BRASIL), Gelsimar Ferreira Pinto (R3M Tecnologia em Processos Siderúrgicos)
Abstract:
The characterization of coils is the process in which it is necessary to evaluate the characteristics of coils that have been declassified, that is, are not allocated to a sales order, to align them with commercial technical standards that allow for their sale. These characteristics include dimensions, chemical composition, mechanical properties, quality, and applicability. Since each coil has individual characteristics, the evaluation process is also individual, resulting in a laborious and error-prone task that can lead to accidents for customers. Therefore, it is crucial to automate the characterization process, not only due to the speed of the process, which leads to greater stock turnover and increased sales potential, but also to mitigate risks. The automation was achieved by using real values from hot-rolled coils measured throughout their manufacturing process, comparing them with tables containing the values and tolerances for each applicable technical standard, based on the translation of business rules into the program algorithm. Over six months, the volume of material available for sales increased by 738%, and the volume of liabilities decreased by 84%, with a 45% reduction in declassified stock of this product at ArcelorMittal Brazil and a 67% increase in stock sales revenue, justifying the investment in this project.
Technical Session
9/3/24, 11:05 AM - 9/3/24, 11:30 AM
Presenter(s): kassia regina felix faria (Solenis especialidades químicas LTDA), Raphael Vilela Brigagão (SOLENIS ESPECIALIDADES QUÍMICAS LTDA), Pedro Henrique Bordão Moreira (SOLENIS ESPECIALIDADES QUÍMICAS LTDA), andre teodoro coelho moreira pinto (SOLENIS ESPECIALIDADES QUÍMICAS LTDA), douglas nicolini alves cruz (SOLENIS ESPECIALIDADES QUÍMICAS LTDA)
Abstract:
This study investigated the implementation of a customized water treatment to address challenges of spray nozzle clogging and corrosion in an industrial cooling system of the continuous casting process of a Brazilian steel mill. The adopted solution, using Performax DC5500 and Performax SR5600, resulted in a significant reduction in clogging and corrosion rates, ensuring a more efficient and stable operation over time.
Technical Session
9/3/24, 11:05 AM - 9/3/24, 11:30 AM
Presenter(s): barbara cristacemos Ramos fonseca (Vetta digital), Paula Pomaro de Almeida (vetta digital), lis nunes soares (vetta digital)
Abstract:
This article explores the fundamental role of the steel industry in greenhouse gas emissions and investigates the potential of replacing natural gas with hydrogen in the mixed gas used as fuel in the integrated steel plants, considering scenarios applied to a plant in Canada. An iterative optimization approach was implemented using Viridis Energy & Sustainability, a digital tool for assessing the cost-benefit of hydrogen integration. The study evaluates three scenarios with varying natural gas concentrations, highlighting the trade-offs between emission reductions and economic feasibility. Results indicate that hydrogen substitution effectively reduces CO2 emissions, but it concurrently raises fuel costs due to the existing price disparity between hydrogen and natural gas. However, it is expected that the CO2 emission tax will increase over time, making this substitution more advantageous. The study concludes that hydrogen substitution holds promise for decarbonizing the steel industry, despite increased fuel costs, alongside the validation of Viridis. However, there is a necessity for specialized burners to accommodate hydrogen's combustion characteristics and the importance of robust hydrogen infrastructure for a successful transition. Continued advancements are crucial to overcome the current economic barriers and ensure the long-term sustainability of the steel industry's decarbonization efforts.
Technical Session
CHARACTERIZATION OF EPOXY COMPOSITE OF MEDIUM AND HIGH THEORETICAL VOLUMETRIC FRACTIONS OF RAMIE WOVEN FABRIC BY TENSILE TESTS FOR STRUCTURAL ANALYSIS IN WIND TURBINE TOWERS
Presenter(s): Marcelo Vitor Ferreira Machado (Instituto federal fluminense E UENF), Felipe Perissé Duarte Lopes (UENF), noan Tonini Simonassi (UENF), sergio neves monteiro (IME E UENF)
Abstract:
Given all the technical, environmental and economic advantages presented recently by epoxy matrix composites reinforced with natural fibers, considerable efforts has been made in researches aimed at mechanically characterizing them for subsequent use in industrial applications. This present study seeks to obtain some tensile mechanical properties that are essential for the continuity of structural analyzes that are necessary with regard to the utilization of multiphase epoxy matrix material reinforced with medium and high theoretical volume fractions of ramie woven fabric in wind turbine towers. After the experimental tests designed on six groups of specimens (40%, 50% and 60% of reinforcement volume intact and aged by ultraviolet rays and condensation) the degradation of properties measured for the simulated specimens was noticeable, which reveals the need for use of protective coating in view of an experimental design with this material. Finally, the elastic moduli and the tensile strength between the three volume fractions of intact samples were shown to be statistically distinct via inferential analysis and make up the set of mechanical properties of this composite that are essential to the subsequent structural analysis.
Technical Session
SETTING NEW STANDARDS FOR BAR PRODUCTION – THE DRAWER
Presenter(s): MIANI LODOVICO MARIA (Danieli)
Abstract:
The Drawer, the Danieli four-rolls sizing block, is a breakthrough technology to produce premium quality bar. From the first installation in 2017, indisputable facts and achievements have been reached, making this technology a cutting-edge solution for the SBQ market
Technical Session
9/3/24, 11:05 AM - 9/3/24, 11:30 AM
Presenter(s): Alvaro Loosli (Primetals)
Abstract:
A new design solution for a system to supply water to in-line cooling boxes in high-speed wire rod mills has been developed. Variable-frequency pumps and a series of isolation valves significantly reduce the lag time needed to achieve setpoint temperatures, minimizing the transition length at the head end of each billet. This is important in achieving the desired metallurgical properties for small-diameter products at high speeds. Results of trials on a prototype system are presented to demonstrate the capabilities of the patent-pending design
Technical Session
9/3/24, 11:05 AM - 9/3/24, 11:30 AM
Presenter(s): Caio nogueira araújo diniz (GERDAU), Loren Rodrigues Menezes (GERDAU), Cecilia Laia da Silva (gerdau), Claudio Guimarães Leite (cl consultoria siderurgica ), Marco Tulio Carmozine Prado (gerdau)
Abstract:
In recent years, it has been observed that the impurity levels in available iron ores have significantly increased, as has the growing demand for steels that meet increasingly stringent quality requirements, particularly regarding residual phosphorus (P) content. Steel production processes via primary oxygen refining present challenges concerning process optimization, aiming for operations with higher P inputs in the charge while meeting the demand for low phosphorus levels for casting. Despite being a widely studied process for primary refining furnaces, there is still a need for better understanding of the dephosphorization process in Energy Optimizing Furnaces (EOF), where the slag removal timing during heats represents a crucial step for phosphorus control at the end of the blow. This paper addresses the main metallurgical principles and discusses the application of various existing models and their applications and similarities with the primary refining process via EOF.
Technical Session
REDUCTION OF QUALITY DROP RATES IN STEEL PLATES USING DIRECTED SCARFING PROCESS FOR REMOVAL OF SURFACE DEFECTS AT TERNIUM BRAZIL
Presenter(s): EDSON DA SILVA BARROS (TERNIUM BRASIL LTDA.), Euglacyo Luiz de Moura (Ternium Brasil), Alcides Ferreira de Aguiar Júnior (Ternium Brasil), Marcos Delane De Souza (Ternium Brasil), Edson Pedro De Lima (Ternium Brasil), Mariana Correa Moreira (Ternium Brasil)
Abstract:
This article emphasizes the importance of quality control in the steel industry, focusing on removing surface defects in steel plates caused by casting alarm events. Ternium Brazil successfully implemented directed scarfing to mitigate these defects, resulting in a significant reduction in plate rejection. The positive impact on material quality and the Quality Drop Indicator reflects the success of the company's continuous improvement process, enhancing its competitiveness and commitment to operational excellence and customer satisfaction.
Technical Session
IMPROVEMENT OF SLAG RETENTION IN BOF TAPPING BY COMBINING SLAG STOPPER AND SLAG BALL AT TERNIUM BRAZIL
Presenter(s): LUISA SAISSE DE MELO (TERNIUM BRASIL LTDA.), ANTÔNIO AUGUSTO DE REZENDE MARTINS (TERNIUM BRASIL)
Abstract:
It is widely known that avoiding the excessive passage of slag from the converter to the ladle is of great importance, since BOF slag contains oxides that can be harmful to the process and the final quality of the product. One of the oxides to be avoided in ladle slag is P205, since phosphorus can revert to liquid steel, leading to deviations in chemical composition. At Ternium Brasil, slag retention is carried out using the slag stopper (combined with the AMEPA system) as the main retainer, and the slag ball is used as a secondary retainer alongside the slag stopper for producing low phosphorus steels. However, the gain in slag retention from combining the slag ball to the slag stopper was unknown. Therefore, the aim of this work was to quantify the reduction in the passage of slag carry-over from the BOF converter to the ladle during the BOF tapping by combining the slag stopper and slag ball retainers at Ternium Brasil. To this end, several improvements were implemented with the aim of increasing the efficiency of slag ball, which initially stood at 20% and by the end of the project showed 50%. Results also showed that sealing the taphole with both retainers resulted in a reduction of approximately 0,9 kg/ton of passing slag/ton of steel when compared to retention only with slag stopper, which leads to a reduction in P pick up of 8 ppm.
Technical Session
GEOPOLYMERS: TRANSFORMING TAILING INTO ECO-EFFICIENT SOLUTIONS
Presenter(s): felipe keven de carvalho neves (aMG - BRASIL), Rochel Monteiro Lago (UNIVERSIDADE FEDERAL DE MINAS GERAIS - UFMG), Carlos Valdir Gusmão (AMG - BRASIL ), Arthur de Paula Cardoso (amg-brasil), Ana Paula Carvalho Teixeira (UNIVERSIDADE FEDERAL DE MINAS GERAIS - UFMG), Caymon de Siqueira Assumpção (amg-brasil)
Abstract:
The search for sustainable alternatives for the reuse of mining tailing has led AMG, in partnership with the Financiadora de Estudos e Projetos (FINEP), to conduct studies to identify routes for the disposal of aluminosilicate generated in the current production of spodumene concentrates, tantalum, and in the future production of lithium carbonate. Through analyses using Fourier Transform Infrared Spectroscopy (FTIR), X-ray Fluorescence Spectrophotometry (XRF), and complementary X-ray Diffraction (XRD) analysis, the spodumene flotation tailing (tailing I) was directed towards the first phase of project development. The geopolymers and cementitious materials to be produced result from chemical reactions between the aluminosilicate tailing, metakaolin, and the alkaline activating solution sodium silicate and sodium hydroxide. Tests allowed determining the ideal proportion of components for the geopolymer activating solution. Different proportions of spodumene flotation tailing, namely 50%, 60%, 65%, and 70%, were used for producing test specimens. To quantitatively assess the performance of the materials generated, they were analyzed for their mechanical resistance, using the white sample with no tailing added as a comparison standard. It was identified that the sample composed of 50% tailing I would be ideal, and further tests were conducted accordingly. For tailing II, from the lithium carbonate production process, analyses with different compositions were carried out; however, they did not exhibit sufficient strength. The project has the collaboration of Escalab – UFMG lab and together with the AMG Brazil team, conducted proof of concept and bench-scale product development, and contributed to the structuring of the production space and industrial layout based on AMG's production needs. The project reaffirms AMG's commitment to sustainability.
Technical Session
9/3/24, 11:05 AM - 9/3/24, 11:30 AM
Presenter(s): RAPHAEL MARIANO DE SOUZA (Ternium), LEONARDO LOBO CERQUERIA RAPOSO (TERNIUM), DIESTÉFANO SOUZA OLIVEIRA (TERNIUM), FRANCISCO JOSÉ GONÇALVES DELGADO (TERNIUM)
Abstract:
Petroleum coke (PC), a by-product of petroleum distillation, has gained significance in industrial applications due to its high carbon and low ash content. However, its effect on coke strength after reaction with CO2 (CSR) remains debated. This study investigates PC's influence on CSR in a Brazilian heat recovery cokemaking plant using stamped charge blend preparation. Historical data analysis of 102 blends classified by PC content revealed an optimal PC content range for CSR enhancement. Non-linear regression indicated an initial zone with little influence, followed by an improvement zone up to 25% PC content, then a decrease. Laboratory tests supported these findings, confirming an optimum point around 20% PC content. Results suggest a potential to optimize PC use for enhanced coke quality, offering opportunities for blast furnace coke rate reduction.
Technical Session
9/3/24, 11:05 AM - 9/3/24, 11:30 AM
Presenter(s): Mikhail Kalugin (Kalugin top combustion solutions d.o.o.)
Abstract:
The paper explores the transition from Metallic Blast Preheaters (MBPs) to Kalugin Top Fired Stoves (KTFS) in Mini Blast Furnaces (MBFs), assessing both feasibility and performance implications. It describes the features of Kalugin Stoves and compares them with conventional stoves. Drawing on case studies from Indian MBFs, the paper evaluates the economic and operational advantages of this technological transition, supported by performance data and relevant references. Through an analysis of heat balance, it calculates the efficiency of utilizing blast furnace gas heat for both the MBP and KTFS.
Technical Session
9/3/24, 11:05 AM - 9/3/24, 11:30 AM
Presenter(s): Luis marcelo marques Tavares (UFRJ), TÚLIO MOREIRA CAMPOS (UNIVERSIDADE FEDERAL DO RIO DE JANEIRO), Brena Karolyne da Rocha (UNIVERSIDADE FEDERAL DO RIO DE JANEIRO), MALCOLM SAMUEL POWELL (UNIVERSITY OF QUEENSLAND), LUCIANA PEREIRA ALVES (ANGLO AMERICAN), ELIAS FONSECA DE CASTRO (ANGLO AMERICAN), José Nogueira Sávio Silva (anglo american)
Abstract:
In the year when the Minas-Rio operation completes 10 years, a bit more than a decade is completed of studies in partnership of this business unit from Anglo American with UFRJ towards development of a digital calibrated version of the comminution circuit. The work presents a brief history of the partnership, with lessons learned in the development of the circuit simulation, culminating in the use of the Integrated Extraction Simulator (IES), a cloud-based integrated multicomponent simulator. The work presents results from simulation case studies with the aim of identifying potential for increase in energy efficiency, as well as assessing the future impact of increase in proportion of supercompact itabirite in the Run-of-Mine ore.
Technical Session
9/3/24, 11:05 AM - 9/3/24, 11:30 AM
Presenter(s): Arthur Barreiro Sakai (UNIVERSIDADE FEDERAL DE MINAS GERAIS), Anna Júlia Cassimiro Prado Mitre de Oliveira (UNIVERSIDADE FEDERAL DE MINAS GERAIS), Sofia da Cruz Souza (UNIVERSIDADE FEDERAL DE MINAS GERAIS), Pedro Henrique Leão de Souza (UNIVERSIDADE FEDERAL DE MINAS GERAIS), Dagoberto Brandão Santos (UNIVERSIDADE FEDERAL DE MINAS GERAIS)
Abstract:
Good biocompatibility and corrosion resistance coupled with suitable mechanical properties make pure titanium (Ti) a widely used material in biomedical engineering and industry. High-purity Ti plates have lower mechanical strength than Ti alloys. Thus, heterostructured materials constitute an emerging and promising field to drive mechanical properties through economic routes. Partial recrystallization has been used to improve the ductility and strength of metallic materials. This work proposes to achieve a combination of high strength-ductility by incorporating the martensite phase precipitation αlpha' during partial recrystallization into commercially pure Ti (CP). After annealing for 30 min of a cold-rolled microstructure at 66%, the mechanical properties increased at temperatures of 600°C-700°C. Three hardening stages were identified during the tensile tests at room temperature. The plastic deformation of the Ti CP occurred without the formation of mechanical twinning.
Technical Session
9/3/24, 11:05 AM - 9/3/24, 11:30 AM
Presenter(s): MATHEUS AUGUSTO SANTOS VIEIRA (APERAM), Clinger Félix Santiago (APERAM), Douglas Vinicius Ferreira Castro (APERAM), Janaina de Oliveira Maia (APERAM), Péricles Guimarães Oliveira Aguiar (aperam), Raphael Felippe Miranda de Oliveira (aperam), Victoria Caroline Veloso Meireles (APERAM)
Abstract:
In recent years, the increase in Brazilian crude steel production has caused a shortage of iron ore and pellets, driving up their prices. This created the need to develop new sources of these inputs and study flexibility in production processes to deal with different materials. Pellets represent 65% of the matallic charge in Aperam's Blast Furnaces and 72% of it is used in Blast Furnace 2. Until 2021, only one type of pellet was used due to differences in chemical, physical and metallurgical qualities, limiting supply to a single supplier. The objective was to increase the flexibility of the Blast Furnace 2 load and eliminate dependence on this supplier and, in the results, there were no significant changes in the process variables, indicating that the use of a mix of pellets did not affect operational stability and productivity. However, there were notable benefits such as greater flexibility and negotiating power, loading options in case of pellet shortages, and budgetary flexibility.
Technical Session
ELECTRODEPOSITION AND CHARACTERIZATION OF ZINC-NICKEL ALLOYS FROM BATHS CONTAINING GRAPHENE OXIDE
Presenter(s): NATHÁLIA CRISTINA LEÔNCIO NEVES (Universidade federal fluminense), Sandro rosa corrêa (Unifoa), elivelton alves ferreira (universidade federal fluminense)
Abstract:
In this work, the effect of adding graphene oxide (GO) in the electrolytic bath on the morphology, structure, composition, and resistance to corrosion at high temperatures of Zn-Ni coatings obtained by electrodeposition was evaluated. For this, carbon steel samples were coated from baths containing different GO concentrations, and then subjected to heat treatment at 900°C. The GO addition effect in the electrodeposition and dissolution of the coating was evaluated by cyclic voltammetry. The coatings were characterized by scanning electron microscopy, energy dispersive spectroscopy, and x-ray diffraction. The oxidation resistance during heat treatment was also evaluated by thermogravimetric analysis. The results showed that with the increase of GO concentration in the bath, the coatings presented a uniform and compact morphology, and were resistant to oxidation, proving suitable for protecting the steel at high temperatures.
Technical Session
Assets Virtualization in Vale´s Maintenance Strategy
Presenter(s): Eliane Cristina Rodrigues da Silva (VALE ), vinicius donizetti (Vale), Renato Lima (Siemens), Leonardo Mundim (BSc), Samuel Silvestre (BSc), Thiago Monteiro (BSc), Victor Cabrera (BSc), Maurício Viegas (bsg)
Abstract:
This work discusses the implementation of asset virtualization in Vale S.A.'s maintenance strategy, highlighting the crucial role of digitization in optimizing operations and promoting sustainability. It introduces the concept of the Digital Thread as an essential integrated strategy for effective asset management, enabling continuous data flow throughout the asset lifecycle. The paper explores challenges in maintaining large-scale equipment and the need to comply with environmental and safety regulations. Technological solutions, including Teamcenter and Tecnomatix, are presented to overcome these challenges. Key findings indicate cost reduction, increased operational efficiency, and failure prevention through predictive maintenance. The conclusion emphasizes comprehensive asset management transformation, driving greater innovation and sustainability, while highlighting the importance of technological innovation and collaboration in addressing industry challenges.
Special Session
9/3/24, 11:05 AM - 9/3/24, 12:45 PM
Presenter(s): Coordenador: André Luiz Vasconcellos da Costa e Silva; Diretor Técnico do IBQN; Professor Titular da EEIMVR-UFF; Editor Chefe da Revista TMM
Abstract:
Special Session
9/3/24, 11:05 AM - 9/3/24, 12:45 PM
Presenter(s): Coordinator: André Luiz Vasconcellos da Costa e Silva; IBQN Technical Director; Professor at EEIMVR-UFF; TMM Editor-in-Chief
Abstract:
Special Session
9/3/24, 11:05 AM - 9/3/24, 12:45 PM
Presenter(s): Coordinators: José Murilo Mourão - Consultant; Lindaura de Souza Candido d'Avila - Master Engineer at Vale
Abstract:
Round Table
9/3/24, 11:05 AM - 9/3/24, 12:45 PM
Presenter(s): Coordinator and Moderator: Carlos Alberto Mendes Moraes; Prof. at UNISINOS
Abstract:
Technical Session
IMPROVING THE EFFICIENCY OF OXYGEN BOTTOM BLOWING TO MITIGATE REFRACTORY WEAR IN AN ENERGY OPTIMIZING FURNACE (EOF)
Presenter(s): CECILIA LAIA DA SILVA (GERDAU), Caio Nogueira Araujo Diniz (Gerdau), Marco Túlio Carmozine Prado (Gerdau), Cláudio Guimarães Leite (CL Consultoria Siderúrgica), Loren Rodrigues Menezes (Gerdau)
Abstract:
The Energy Optimizing Furnace (EOF) distinguishes itself through its innovative approach of preheating solid materials using energy from previous heating cycles. This method offers several benefits, including reduced chemical energy consumption, shorter tap-to-tap durations, and increased flexibility in utilizing various metallic charges such as hot metal, scrap, and pig iron. This study aimed to optimize oxygen bottom blowing to improve metal yield and reduce wear on tuyeres and refractory blocks by adjusting flow parameters and tuyeres design. Using a digital performance model, oxygen flow was adjusted based on historical data. Tests with smaller diameter tuyeres were conducted to assess the feasibility of wear reduction. A significant decrease in refractory-specific consumption was observed, indicating enhanced system performance. Comparative analysis revealed that adjusting the blowing regime contributed to wear reduction, resulting underscores the importance of oxygen blowing optimization for performance and extended refractory component lifespan.
Technical Session
USE OF SUPERABSORBENT POLYMER (SAP) IN WASTE TO AID HANDLING AND TRANSPORTATION BY CONVEYOR BELT
Presenter(s): ana fernanda de carvalho araújo (vale s.a), Ernandes Sávio (Vale S.A), Kaike Silva Albuquerque (Vale S.A), Nilton Caixeta Guimarães (Vale S.A), Tiago Leite (Vale S.A)
Abstract:
Decomposed mafic and chemical canga, referred to as clay waste, are friable lithologies that contain clay minerals, making it difficult to handle these ores due to their low flowability. This challenge has been observed at the Serra Sul mine, where the clay waste can reach up to 20% moisture, impacting the stability and leverage of the site's production indicators. Reductions in mass flow and operational stoppages due to obstructions in chutes, hoppers, grizzlies, and crushers, as well as avalanche risks, are some key points of concern for the flow of this waste. Bench-scale and industrial-scale tests have shown that the use of Super Absorbent Polymer (SAP), with dosages ranging from 300g/t to 500g/t, leads to significant improvements in operational performance, reducing operational stoppages and increasing the hourly throughput of the circuit by up to 50%.
Technical Session
AUTOMATION ASSET INVENTORY THROUGH THE SECURITY DATA LAKE
Presenter(s): Ana Paula cotta perdigão (ArcelorMittal), Gleison Baiôco (ArcelorMittal), David Assumpção (ArcelorMittal), Felipe Carvalho Pereira (ArcelorMittal)
Abstract:
With the significant evolution of technology, where almost every type of device is connected to the network and various software applications are installed on a single asset, a new challenge arises for managing hundreds or even thousands of devices in a corporate environment. The need to ensure the proper functioning, security, and updates of these assets becomes crucial to prevent failures, vulnerabilities, and negative impacts on organizational processes. In order to reduce operational costs and mitigate cyber risks, this work aims to integrate data from software used for cybersecurity in the industrial automation sector of ArcelorMittal Aços Planos Brazil, with a focus on asset management. It was observed that the existing asset management practices in the company were not the most suitable, many manual and repetitive procedures were affecting efficiency. By providing a broader and more comprehensive view of automation assets through the proposed solution, identifying, and classifying risks, and supporting strategic and tactical decision-making to mitigate threats, this approach ultimately enhances cybersecurity in the company’s automation environment.
Technical Session
9/3/24, 11:30 AM - 9/3/24, 11:55 AM
Presenter(s): haniel jonathas batista lobato siqueira (tecnored), pedro paulo de oliveira campos (tecnored), igor ribeiro roque (tecnored), jose ronaldo braga (tecnored), debora aparecida ribeiro souza (tecnored)
Abstract:
In Brazil, according to the Superior Labor Court, a worker dies every 3 hours and 47 minutes due to work-related accidents. In light of this and the importance of each employee's safety, TECNORED's automation team, a company focused on sustainable initiatives for the steel industry, developed a lockout solution integrating Rockwell Automation softwares and hardwares. After five years of use, the system has proven to be safe, efficient, and auditable, meeting established expectations. However, to ensure its relevance and its effectiveness, implementing a process of continuous improvement is crucial.
Technical Session
AUTOMATIC RECLOSERS
Presenter(s): Thiago lopes pereira (samarco mineração), fabiano rocha rodrigues (samarco mineração), adilson de souza nunes (samarco mineração), Pedro Henrique Pompermayer Vettoraci (samarco mineração), idelvan pereira santos (samarco mineração), Alex Augusto Candido Teixeira (samarco mineração), Marcelo Batista Mauricio (samarco mineração), Thiago Alexandre Tavares Alves (engelmig energia), Juliana Lourenço dos Santos Silva (compet engenharia)
Abstract:
The Project consists of the installation of automatic reclosers in the 13.8kV Power Distribution networks in Germano – SAMARCO, providing remote maneuvers route supervision, causing a shorter time of operation and a higher level of safety in the interventions, minimizing the impacts on the operational process.
Technical Session
Evaluation of chloride corrosion in spray chambers in the continuous slab casting process
Presenter(s): EDERSON FERNANDES PIMENTEL (IFES _ Instituto Federal do espírito santo), Erica Vieira Albuquerque Rodrigues (UFES), Felipe Fardin Grillo (IFES)
Abstract:
The contact of water with the plate at temperatures exceeding 1300 ºC triggers its vaporization, initiating the corrosive process known as exfoliation within the chamber structures. In light of this, the objective of this research is to assess corrosion in the spray chamber caused by chlorides present in the water used for cooling. The use of sodium hypochlorite as a biocide is the primary source of chlorides in this system, as the application of biocides is essential for the chemical conditioning of water. To achieve this, immersion tests, polarization curve acquisition, optical microscopy assays to investigate sample surfaces, and industrial tests with specimens were conducted. Experiments simulating chemical conditioning under real operating conditions were performed to determine corrosion rates after the use of sodium bromide as a biocide. The results demonstrate an approximately 50% reduction in corrosion rate when chloride concentration was decreased in the operational environment, validating the findings obtained in immersion/emersion tests and electrochemical analyses. This scenario points towards a significant mitigation of corrosion effects, with positive implications for the economy and durability of metallic structures within the spray chamber..
Technical Session
9/3/24, 11:30 AM - 9/3/24, 11:55 AM
Presenter(s): Marcônio Pereira de Magalhães (UENF)
Abstract:
This study investigates the Charpy and Izod impact resistance of polyurethane matrix composites derived from castor oil, reinforced with Embira-Branca (Daphnopsis utilis) fiber using mass fractions of 50%, 60%, 70%, 80%, and 90% of Embira. The specific impact absorption energies and Charpy notch energies remained constant with increasing mass fractions of Embira. While the specific Izod impact resistance of the composites with 50%, 60%, and 90% reinforcement, due to no statistically significant differences in their means, was classified as group (a); similarly, the specific Izod impact resistance of the composites with 60%, 70%, and 80% reinforcement, also due to no statistically significant differences in their means, was classified as group (b), with the 60% reinforcement fraction common to both groups. However, the average specific Izod impact absorption energy of group (a) was found to be 40% higher than that of group (b). Additionally, group (a) exhibited an average specific notch absorption energy 27% higher than that of group (b), with fractions of 50% and 60% of Embira being common to both groups.
Technical Session
9/3/24, 11:30 AM - 9/3/24, 11:55 AM
Presenter(s): hEITOR FERNANDES VIEIRA E SILVA (SMS GROUP METALURGIA DO BRASIL LTDA)
Abstract:
Extrusion is an important metal forming process. This paper presents a stress simulation study on a Platen, considering 3 scenarios: original design, current Platen and a Platen after machining. The original Platen presents high stresses, above the yield stress of the material, while the current platen and the machined platen present yield stress values below the limit for the material studied, thus the computer simulation study proved the need to modify the platen. to relieve tension
Technical Session
MICROSTRUCTURAL CHARACTERIZATION OF AN ULTRA-HIGH STRENGTH HOT-ROLLED STEEL PRODUCED WITH TWO DISTINCT ROLLING STRATEGIES
Presenter(s): Ricardo Porto (ARCELORMITTAL TUBARÃO), Bárbara F. Oliveira (ARCELORMITTAL TUBARÃO), Joelma K. B.K. Fernandes (ARCELORMITTAL TUBARÃO), Bruno B.S. Murad (ARCELORMITTAL TUBARÃO), Jetson L. Ferreira (ARCELORMITTAL TUBARÃO), Luciana Xavier da Cruz (ARCELORMITTAL TUBARÃO), Gladistone S. Guerra (ARCELORMITTAL TUBARÃO), Charles A. Martins (ArcelorMittal Innovación), Leonardo B. Godefroid (Universidade Federal de Ouro Preto – REDEMAT)
Abstract:
Currently, two rolling strategies are used to produce the S700 in the hot strip mill. The first one is to target precipitation hardening and the second one, to focus on strain hardening followed by accelerated cooling. In this paper, a detailed characterization was carried out using tensile and Charpy tests, as well as metallographic analysis by optical microscopy, SCAN, SCAN-EBSD, Automated Steel Cleanliness Tool (ASCAT) and TEM on hot-rolled coils produced using these two rolling strategies. For the strain hardening strategy, accelerated cooling was deployed minimizing the impact of precipitation on the HSM runout table. The results suggest advantages in the strategy of strain hardening followed by delayed accelerated cooling
Technical Session
ARTIFICIAL INTELLIGENCE IN STEEL DEVELOPMENT QUALITY: AN INNOVATIVE APPROACH
Presenter(s): Ana CAROLINE DA SILVA FIGUEIREDO (Ternium), Bruno Pinheiro Da Silva (Ternium), Alex Sandro Martins De Oliveira TERNIUM BR (Ternium), Tayna Amendola Da Lapas (Ternium), Jean Carlo Detimermani Dos Santos (Ternium), vinicius cunha aranda (Ternium)
Abstract:
This project aims to develop a comprehensive database that records lessons learned from previous experiences, with the goal of increasing accuracy in future treatments. By retaining and utilizing this accumulated knowledge, significant improvement in the quality of steel development is expected, promoting more efficient operations and better-informed decisions. The application of Artificial Intelligence (AI) in industrial steelmaking operations represents a promising approach in the pursuit of excellence in steel development quality. By integrating AI tools, such as machine learning systems and advanced data analysis, with Knowledge Management initiatives, organizations can not only capture and share knowledge efficiently but also use it strategically to enhance processes and products. In this project, we explore the application of the Copilot Studio tool to integrate industrial knowledge data stored in a database with an artificial intelligence chat. This integration ensures that users have quick and accurate access to necessary information, promoting operational excellence and continuous innovation.
Technical Session
ADJUSTMENT OF CALCIUM WIRE INJECTION SPEED IN LIQUID STEEL
Presenter(s): PEDRO HENRIQUE RESENDE VAZ DE MELO (Usiminas), Hélio Alexandre Alves (Usiminas), Marlon José dos Anjos Silva (Usiminas), Wagner Viana Bielefeldt (UFRGS), André Luiz Vasconcellos da Costa e Silva (UFF)
Abstract:
One of the calcium addition objectives in steels is to modify inclusions aiming for continuous casting process stability and product improvement. Despite the treatment benefits, there are challenges regarding the alloy yield optimization, the alloy amount to be added and the repeatability in the heats. Alloy addition at the ladle bottom is recommended since the higher metallostatic pressure inhibits calcium vaporization. Calcium alloy is injected in a wire form, surrounded by a metallic sheet, which protects the core. Several parameters may influence the alloy release instant in liquid steel, such as injection speed, bath temperature and wire characteristics. In this work, the release depth of calcium alloys in liquid steel was calculated and tests were carried out with injection speed variation in experimental heats, comparing their effects on yield. A numerical procedure was used to estimate the release depth, study trends and parameter influences on calcium treatment. To validate the calculations, 91 industrial heats were monitored, in which four injection speeds were tested for two wire types: calcium silicide (CaSi) and pure calcium. The speed variation did not result in calcium yield changes. In this way, the use of higher speeds may promote shorter addition times and, consequently, productivity gains. Furthermore, there was good agreement between the numerical procedure calculations and industrial test results.
Technical Session
TRANSFORMATION OF MINING WASTE INTO CALCINED CLAY AGGREGATES: MINERALOGICAL ANALYSIS AND FEASIBILITY ASSESSMENT
Presenter(s): Murilo miguel narciso (ime), Julianna Magalhães Garcia (ime), Antônio Carlos Rodrigues Guimarães (ime), Sergio Neves Monteiro (ime)
Abstract:
Calcined clay aggregates which exhibit heating temperatures above 600°C and demonstrate promising mechanical strength. Therefore, this study aims to utilize the technique of manufacturing artificial aggregates from a mixture of natural clay soil, sandy soil, and iron mining residue, known as red mud. The feasibility and characterization of the mixture used to produce calcined aggregate will include physical characterization tests of the soils and mineralogical analysis through X-ray Diffraction (XRD), Scanning Electron Microscopy (SEM), and Energy Dispersive Spectroscopy (EDS). The use of a clay mixture to produce aggregates through calcination has proven to be feasible, provided that the appropriate mineralogical analysis is conducted to utilize the higher pozzolanic activity of the present clay minerals and, therefore, achieve greater mechanical strength of the aggregate.
Technical Session
RECOVERY OF A COKE BATTERY IN USIMINAS
Presenter(s): Johnatan Francis de Sa (USIMINAS), Andre Cesar Lucio (USIMINAS), RENATA MARIA SEARA MARTINS (USIMINAS)
Abstract:
A coke battery is composed of a refractory body built on a concrete structure and tied by metallic structures and can be of the By-Product type (with recovery of by-products) or Heat Recovery (horizontal). The preservation of coke batteries is essential to guarantee the stability of the increased process in line with operational standardization at an appropriate pace, resulting in reduced useful life and reduction of their apparent age, since the cost of repair is high and implies loss of age coke and gas production, in addition to possible environmental impacts. This work demonstrates the main mandatory activities to reestablish the refractory and metallic integrity in a coke battery, through emergency repairs.
Technical Session
FITNESS FOR SERVICE ASSESSMENT AND CAMPAIGN LIFE EXTENSION OF BLAST FURNACE HOT STOVES
Presenter(s): Steven Paul Samuel (Hatch Ltd.), Cameron Alexander Soltys (HATCH LTD.), Hamid Ghorbani (Hatch Ltd.), Kyle Chomyn (HATCH LTD.), Chad Van der Woude (Hatch Ltd.)
Abstract:
The hot stoves of a blast furnace are core to the overall furnace operation. The performance of the stoves has a direct impact on the hot blast temperature and therefore cost of metal production, and their failure or inability to operate can be extremely damaging to the process stability and economic performance of the furnace. While it is often possible to perform repairs to a hot stove independent of furnace shutdowns, the strategies available to do this are often expensive and disruptive to production. It is therefore valuable to extend the life of a hot stove so that major repairs can coincide with a furnace shutdown or other more convenient repair time. However, executing a fitness-for-service assessment to safely extend the life of a hot stove is not trivial. It requires an intense interdisciplinary approach and significant collaboration between the operating and engineering teams to ensure that the business objectives can be met through practical, effective, and minimal interventions. With the proper planning, specialist engineering, and collaboration between all stakeholders, the life of a hot stove can be managed to meet the operator’s needs.
Technical Session
9/3/24, 11:30 AM - 9/3/24, 11:55 AM
Presenter(s): Brenda Sedlmaier Costa Coelho (EcOre Group LLC)
Abstract:
Iron ore production has led the percentage of mineral production in Brazil over the years, and a large part of this production comes from the Quadrilátero Ferrífero region, located in the state of Minas Gerais. The high-grade iron ores extracted from this region are becoming exhausted, and the interest and need to develop process routes that can concentrate iron in low-grade ores, such as Dolomitic Itabirite, has gained interest. Associated with this need, and the growing trend of dry mineral concentration projects, which are easier to license, and reduce the associated impacts on the environment, it is necessary to develop dry mineral processing routes for carbonated gangue itabirites. In this sense, the objective of this study was to evaluate Triboelectrostatic Separation regarding its potential to benefit two Dolomitic Itabirite ore samples coming from the Quadrilátero Ferrífero region. The results obtained with the high-carbonate sample showed a removal of 86.4% of carbonates, a product with 35.3% Fe and 66.8% Fe recovery. A cleaner stage is required to get a product greater than 60% Fe. From a low-carbonate sample, a product with 60.4% Fe, 1.3% SiO2, with a silica removal of 96.2% and Fe recovery of 88.7% was obtained. The Triboelectrostatic separation showed to have potential application for Dolomitic Itabirite processing. Further TESTS must be performed in pilot scale triboelectrostatic separator and with a sample with higher liberation DEGREE of magnetite/hematite particles.
Technical Session
9/3/24, 11:30 AM - 9/3/24, 11:55 AM
Presenter(s): pamela miranda Cremonini (samarco/ufes)
Abstract:
This study investigates the performance of grate bars used in the transportation of iron ore pellets during the firing process in pelletizing furnaces. Manufactured with high-temperature-resistant austenitic stainless steel, these bars are subjected to severe wear due to pellet abrasion and friction with gases containing abrasive particles. The steel's microstructure is characterized, scratch test are conducted to understand the behavior of a mono-event abrasive, using both a standard Rockwell C-type indenter and a modified indenter made of synthetic hematite to replicate the real contact between the iron ore pellet and the grate bar.
Technical Session
9/3/24, 11:30 AM - 9/3/24, 11:55 AM
Presenter(s): Érica valério de Queiroz (Companhia Siderúrgica Nacional), mateus vieira zandomeneghi (Companhia Siderúrgica Nacional), Alan Alves Vieira (Companhia Siderúrgica Nacional), fernando dornas cipriani (Vesuvius Sensor e Probes), celso luiz moraes alves (Universidade Federal Fluminense)
Abstract:
By focusing on an improvement opportunity in blast furnace process control, thought a significant reduction of time to obtain the silicon content result of hot metal, tests were conducted with a sensor able to measure the silicon content of hot metal online. For such, sampling and silicon content in hot metal were conducted for the same hot metal heat with the online sensor and with the chemical characterization by x-ray fluorescence (the current operational practice). A comparative analysis of the results based on 25 heats is presented and discussed in the present investigation. Temperature measurements were carried out and compared with the online hot metal silicon content sensor and TERMOTIP sensor of Vesuvius to verify the results convergence between both methods, once the online sensor for hot metal silicon content also has the differentiator of the temperature measurement. It was observed in both investigations a good results convergence of silicon and temperature of hot metal in the analyzed sample space, even though, there is an opportunity of adjustments for a better results convergence as discussed in the present investigation.
Technical Session
9/3/24, 11:30 AM - 9/3/24, 11:55 AM
Presenter(s): fabrício césar de mendonça cordeiro (aperam south america), Wilian da Silva Labiapari (APERAM SOUTH AMERICA), Cláudio Moreira de Alcântara (APERAM SOUTH AMERICA), LEANDRO DE ARRUDA SANTOS (UNIVERSIDADE FEDERAL DE MINAS GERAIS)
Abstract:
Non-stabilized stainless steel AISI 430 presents chromium carbides in its microstructure that are dispersed in the ferritic matrix of the steel. Depending on the thermal cycle used in the steel, these carbides preferentially precipitate in grain boundaries, generating a region pour in chromium next to them, what is a sensitization process. These sensitized regions are more susceptible to corrosive attacks. This way, chromium carbides dissolution in AISI 430 had been evaluated after heat treatments in different temperatures. Hot rolled and annealed samples had been heat treated in an electrical furnace and using a dilatometer. Temperatures varied from 750 to 1050°C, in 80s cycles and with fast cooling. From 950°C on, there is a decrease in the amount of carbides as the temperature of heat treatment increases. From 1000°C on, there is an increase in material hardness and martensite is present in the microstructure. Phase transformation during cooling occurs around 200°C.
Technical Session
9/3/24, 11:30 AM - 9/3/24, 11:55 AM
Presenter(s): maionary de assis silva veras (Vale), Suelem Teixeira Marques (vale), touberth costa rodrigues (vale)
Abstract:
In order to operate in a globalized and highly competitive economy, companies are increasingly relying on the implementation of an asset management system in their businesses. This paper discusses how world-class practices such as the Toyota Production System, the PDCA cycle and the ISO 55000 standard can contribute to the development of asset maintenance. One of the main requirements of the standard is the performance evaluation of the management system, which monitors and analyzes the achievement of results. The aim of this paper is to present the application of the VPS evaluation method, Vale's management system, in order to increase the maturity of maintenance processes at the Terminal Marítimo de Ponta da Madeira (TMPM). The main deviations associated with the low maturity of the processes were identified and based on this, meeting routines were structured, the frequency of application of the evaluations and an action plan was implemented. The main results of the new routine management were then discussed. As a result, the appropriate and structured use of policies, guidelines and assessments resulted in significant advances in the maturity of TMPM maintenance.
Technical Session
SCREENING WITH HIGH MOISTURE - ROBUST STAR SCREEN
Presenter(s): TATIANE APARECIDA ROCHA GONCALVES (VALE SA), Franciano Carleti (Vale S.A), Warley Ribeiro Roza (Vale S.A), Frederic Braga (Vale S.A), Gilson João da Silveira (Recimac Indústria e Comércio LTD), Henrique Flávio Simões Custodio Costa (Vale S.A), Welbert Oliveira Alves (Vale S.A), Leandro Fagner Pereira (Vale S.A)
Abstract:
The study evaluated Robust Star Screen – Recimac in the processing of cohesive iron ore with high moisture. This equipment is widely used in the biomass, scrap and soil industries, but it has not yet been used in iron ore sieving. In four months of operation, the Robust Star Screen demonstrates greater productivity compared to the conventional vibrating sieve, with an average gain of 42%. The Robust Star Screen presents better performance with hydrated material, being able to process cohesive materials with moisture above 15%. It is currently still in the testing phase at Vale, requiring improvements in terms of maintenance to reduce premature wear of the stars and allow for quick replacement of axles.
Technical Session
CYBER-PHYSICAL PROTECTION FOR OT SYSTEMS: APPLICATIONS IN STEELMAKING ENVIRONMENTS
Presenter(s): VALERIA ADAMOVICZ (SIGMA TELECOM), MARIANA BARBOSA DE TOLEDO CANAAN (SIGMA TELECOM)
Abstract:
With the advancement of technology, we have witnessed a growing integration of the Internet of Things (IoT) in the operations of the steel, materials, and mining industries. These industries, historically characterized by their robust and traditional nature, are now adopting connected devices and automated systems to optimize processes, improve efficiency, and drive innovation. This digital transformation is redefining the way these industries operate, enabling greater real-time monitoring, advanced data analysis, and a more agile response to market demands. However, this increasing reliance on cyber-physical systems brings significant challenges in terms of cybersecurity and operational resilience. The integration of IoT devices and process control systems (CPS) in steel operations, for example, exposes these critical infrastructures to new vectors of cyberattacks. According to Gartner, the first quarter of 2024 saw a significant increase in cyberattacks compared to the last quarter of 2023, highlighting the urgent need for robust and effective security measures. Cybersecurity in industrial operations has become a critical concern, especially in sectors like steel, where process disruptions can result in severe consequences for production and safety. A notable example is the attack on an Iranian steel plant by the hacking group Predatory Sparrow. This incident demonstrated the potential for cyberattacks to cause significant physical damage and operational disruption, underscoring the vulnerabilities within industrial systems. This paper explores the application of cyber vulnerability management solutions in a steel environment, detailing how their functionalities enhance asset visibility, threat detection, vulnerability management, and incident response. The analysis shows that the implementation of specific solutions leads to substantial improvements in the security and efficiency of industrial operations. The objective of this study is to investigate the effectiveness of a vulnerability management platform in operational technology (OT) and information technology (IT) operations, highlighting the importance of an integrated approach to cybersecurity in industrial environments. The increasing sophistication, scale, and impact of cyberattacks require an agile and informed response, and this work aims to contribute to the understanding and mitigation of these risks in the steel industry
Technical Session
9/3/24, 11:55 AM - 9/3/24, 12:20 PM
Presenter(s): luis eduardo smecelato maldonado (Companhia Siderúrgica Nacional (CSN)), Alisson de Souza Silva (Companhia Siderúrgica Nacional (CSN)), Daniel Costa Trocades (Companhia Siderúrgica Nacional (CSN)), Eliomar Junior Teixeira Machado (Companhia Siderúrgica Nacional (CSN)), Wesley Rossi Pimenta (Companhia Siderúrgica Nacional (CSN)), Guilherme Henrique de Carvalho Salles Cunha (Companhia Siderúrgica Nacional (CSN)), Vitor Pinheiro Abrantes (Companhia Siderúrgica Nacional (CSN)), Silvio de Carvalho Sabença (Companhia Siderúrgica Nacional (CSN))
Abstract:
The project aims to technologically update and ensure the operational continuity of Nº1 Continuous Galvanizing Line, installed at Presidente Vargas Steel Plant – CSN, in Volta Redonda - RJ. It began operating in 1973, continuously producing zinccoated steel coils for various applications and markets. The line operated for 50 years with its original analog controls, the Master Control GE, a technology from the late 1960s. Entirely carried out by an in-house team, the project to replace the Master Control and implement new automation systems for levels 1 and 2 began in 2020 in the Automation Technology Management, under the adapted PMBOK methodology. Level 1, based on the SIMATIC S7 platform and Siemens WinCC, was implemented in two phases to meet production planning. A significant challenge was overcome, considering that distinct technologies needed to integrate, with the startup occurring in May 2023. Level 2 came into operation later, in July 2023, integrating the line's operation with the production and management system. Thus, a new updated line was born, prepared for the new concepts of industry digitization, in addition to the human legacy of knowledge acquired by CSN engineering team.
Technical Session
USE OF DEHUMIDIFYING SOLISEP FLT9436E FOR REDUCTION AND ADEQUACY OF HUMIDITY IN FILTERING RED MUD IN THE BAYER PROCESS
Presenter(s): Adriano Alves Ribeiro (Veolia - Water Technologies & SOlUTIONS ), FERNANDO FURUKAVA (VEOLIA - WATER TECHNOLOGIES & SOLUTIONS ), Augusto Luis Marucci (VEOLIA)
Abstract:
The mining tailings filtration process has been increasingly widely used to reduce potential dangers and risks inherent to the maintenance and management of traditional tailings dams. The large alumina refineries have adopted the unitary filtration operation as a crucial step to adapt the humidity of the red mud generated in the process, greater recovery of caustic soda and subsequent disposal of the waste generated. The Veolia Solisep FLT9436E Dehumidifier acts in the filtration process, neutralizing any variables harmful to the process and challenges inherent to it (such as: different types of ores and their specificities, different types of filter fabrics, etc.) providing significant benefits at this stage, with effective humidity control (greater soda recovery), less need to change filter fabrics in addition to greater filtration efficiency
Technical Session
9/3/24, 11:55 AM - 9/3/24, 12:20 PM
Presenter(s): KLEITON GONCALVES LOVATI (VALE SA), Débora Faria (VALE SA), Domícia Oliveira (VALE SA), Helena Hermeto (VALE SA), Luisa Souza Gonzaga (VALE SA), Luiz Henrique Lopes Rigotto (IEL), Eduardo Pessotti Rangel (IESB), Luis Henrique Rodrigues (IESB)
Abstract:
The present work aimed to develop a mathematical optimization model with the capacity to support strategic decision-making at VALE. It is an advanced analytical tool that harmonizes financial and environmental goals, assumes the multi-year distribution plan as a reference for volumes and qualities, and, respecting a broad set of constraints, selects investments in technologies and establishes operational and energy configuration profiles, as well as compensatory options, aiming for the systemic maximization of Vale's results and respecting decarbonization goals, reflecting a commitment to responsible profitability and corporate sustainability.
Technical Session
CHARACTERIZATION OF MUNGUNBA FIBER (PSEUDOBOMBAX MUNGUBA) FOR USE AS REINFORCEMENT IN EPOXY MATRIX COMPOSITES
Presenter(s): MIRIANE ALEXANDRINO PINHEIRO (UFPA), Leoncio Soares Galvão Neto (UFPA), marcos allan leite dos reis (ufpa), ALISSON CLAY RIOS DA SILVA (UFPA), VERÔNICA SCARPINI CANDIDO (UFPA)
Abstract:
In recent years, there has been a significant increase in the development of new materials that combine good mechanical performance and biodegradability. In this context, the production of polymer matrix composites reinforced with natural fibers from the Amazon is emerging as a promising alternative. The vast diversity of species in the Amazon region offers a wide source of natural fibers that can be used to reinforce composites. Munguba fiber can be extracted from the munguba plant, which has shown potential for use as a reinforcing agent in polymeric matrices. The aim of this work is to study the microstructural characteristics of munguba fiber, as well as to evaluate the mechanical properties obtained in tensile strength of composites with added fibers in an epoxy matrix. The composites were produced incorporating 10, 20, 30 and 40 %vol. The fiber characterizations indicated density values, crystallinity index, thermal stability and functional groups characteristic of lignocellulosic fibers. In addition, morphological analysis by SEM revealed that the fiber has fine bundles of fibrils and a rough surface throughout its length. The tensile mechanical characterization of the composites showed that the strength, modulus and deformation values are comparable to those of other lignocellulosic fibres and that these fibres have the potential to be used as reinforcements in polymer composites.
Technical Session
INCREASING SURFACE ROUGHNESS IN HSS ROUGHING MILL WORK ROLLS
Presenter(s): IGOR CUZZUOL DOS SANTOS (USIMINAS), Paulo Victor Reis dos Santos (USIMINAS), Cristiano Ozores Siqueira (USIMINAS)
Abstract:
Experiments were conducted to assess the effect of a higher hardness grinding wheel and different grinding machine parameters on the enhancement of surface roughness (Ra) in a HSS roughing working rolls. The results showed that Ra increased when the working rolls were ground with a higher hardness wheel, the number of grinding passes were reduced and the wheel in-feed rate machining parameters were increased. The mechanism of the improvement of the roughness surface is due to the deeper cutting. Furthermore, it was shown that the type of hardness abrasive grain had an influence on surface roughness. Finally, the performance of the harder grinding wheel was evaluated in comparison with the softer one.
Technical Session
New 2-stand HYPER UCM Reversing Cold Mill at TKSE Bochum to product high-grade electrical steel and AHSS
Presenter(s): Konrad Krimpelstaetter (Primetals Technologies Japan), Paul Rassbach (Thyssenkrupp Steel Europe), Martin Bergmann (Primetals technologies Austria), Josef Hofbauer (Primetals Technolgies Germany)
Abstract:
This paper describes the successful startup of the world’s first twin-stand HYPER UC-Mill dedicated to produce high-permeability non-grain oriented (NGO) electrical steel and advanced high-strength steels (AHSS). The reversing mill features a new generation of a small diameter 6-high technology with driven work rolls and a high-torque MH-spindles. For cold rolling of high-grade electrical steel, the mill is additionally equipped with an induction strip heating system in combination with Minimum Quantity Lubrication MQL and an innovative strip temperature prediction and guidance system. Operational highlights will be presented in the paper.
Technical Session
LATEST BOF TECHNOLOGY FEATURES AND THE GREEN FUTURE OF CONVERTER STEELMAKING
Presenter(s): Bernhard Voraberger (Primetals Technologies Austria GmbH), Andreas MAIER (Primetals Technologies Austria GmbH), Gerald Wimmer (Primetals Technologies Austria GmbH), Jakub Szczech (Primetals Technologies, Austria), Georg Unterrainer (Primetals Technologies, Austria)
Abstract:
Highest productivity and cost-optimized production are the key components for integrated BOF steelmaking to be competitive and profitable in the long run. For this reason, steelplants, - especially in the Americas and in Europe, focus on revamps, upgrades and modernization to ensure highest productivity, availability with minimum maintenance effort. This paper is presenting an overview of some of the current revamp projects, latest technology features and an outlook toward a greener BOF operation future. Examples for successful converter revamps will be shown based on the ongoing projects at Ternium 340t BOF and Arcelor Mittal Monlevade 135t BOF. Latest technology features for process improvements will include, the Vaicon Link converter suspension system, the Vaicon Sublance 2.0 for highest accuracy, shorter process time and the Vaicon slag stopper for contactless and fully automatic slag retention, as well as a new relining machine which makes BOF relining process much faster and safer. In the last chapter, an outlook will be provided which role the BOF converter will play in future green steel making process such as direct reduction and smelter and solution to reduced CO2 emission with increased scrap rate.
Technical Session
REDUCING SCRAP GENERATION AND REWORK OF SLABS THROUGH WIDTH OPTIMIZATION IN CONTINUOUS CASTING AT ARCELORMITTAL PECÉM
Presenter(s): ALINE DIAS MENESES (ARCELORMITTAL PECÉM S.A.), WEVERTON GUIMARÃES MENDES CAMPOS (ARCELORMITTAL PECÉM S.A.), Hilder Caldas Ferreira (ARCELORMITTAL PECÉM S.A.), paula renee de macedo costa bastos (ARCELORMITTAL PECÉM S.A.), Fernando Emerson Viana Sousa (ARCELORMITTAL PECÉM S.A.), Lucas Sousa Uchoa (ARCELORMITTAL PECÉM S.A.), Hana Livia Frota Coelho (ARCELORMITTAL PECÉM S.A.), Francisco Necy Alves Júnior (ARCELORMITTAL PECÉM S.A.), Carlos Henrique Lopes (ARCELORMITTAL PECÉM S.A.), Alex MAIA DO NASCIMENTO (ARCELORMITTAL PECÉM S.A.)
Abstract:
The planning process of continuous casting has a significant influence on productivity, yield, and production costs. For sequencing materials with different widths, it is necessary to produce slabs with width changes, or with taper, to transition from the current width to the required width for the subsequent item without the need to interrupt the production sequence. To maximize productivity, yield, and reduce production costs at the ArcelorMittal Pecém, a simulator was developed to promote the production of different widths simultaneously in each of the strands of continuous casting of slabs, where a 49% reduction in the generation of slabs with width changes was achieved.
Technical Session
Bath Agitation in a Refining Ladle: A Comparison between Bottom Blowing and Injection by Submerged Lance using Physical Model
Presenter(s): JOSE DIMAS DE ARRUDA (ufop), Ana flavia xavier tomas (ufop), davi rodrigues de oliveira santos (ufop), thalys bruno de souza ventura (ufop), johne jesus mol peixoto (ufop), Carlos Antonio da silva (ufop)
Abstract:
Inert gas injection is performed to improve the mixing phenomenon, with gas being introduced into the reactor mainly through porous plugs/ tuyeres installed at the bottom of the ladle or through a lance submerged vertically into the metal from the top. Some studies have addressed steel desulfurization in a ladle furnace; however, gaps remain regarding plume behavior and metal-slag interaction. Using a physical model, this study compared a submerged lance and bottom blowing, evaluating the effect of gas flow rate on the velocity profile inside the ladle, mixing time in the reactor, dye dispersion, and the slag eye opening at the reactor surface. In the upper region of the ladle, higher velocity values were observed near its wall and close to the submerged lance, with higher velocity values also noted for the lance in the more off-center position. The longest mixing time occurs with the lance at a lower immersion depth, but the difference decreases at higher gas flow rates. Mixing time decreases and energy input increases with higher flow rates in all configurations. Greater decentralization and higher gas flow rates promote shorter mixing times and greater dispersion within the ladle. In the most decentralized position (P1), an irregular slag eye opening was observed, while in position P2 (closer to ladle center), the opening occurred in an oval shape around the submerged lance. For high flow rates, emulsification could be observed due to the high agitation of the system.
Technical Session
9/3/24, 11:55 AM - 9/3/24, 12:20 PM
Presenter(s): NEYMAYER PEREIRA LIMA (Vale )
Abstract:
The iron ore production in the region of the Iron Quadrangle in Minas Gerais State has increased from 40 Mty to more than 280 Mty from the 1970s to the actual decade. The high production of iron products represents the main economical item of revenue in the State of Minas Gerais in Brazil. On the other way, the high and annually increasing tailings volume from the low-grade and complex itabirites mining and beneficiation stages represent environmental problems and further high costs with dams disposal. Reverse flotation of quartz is the main concentration process on the beneficiation plants of the Iron Quadrangle, with SiO2 content on the froth tailings close to 90%, partially destinated as sand for the civil construction industry. The addition of a high-intensity magnetic separation stage to remove part of the Fe-bearing minerals lost by entrainment and true flotation to the froth tailings can increase the SiO2 grade up to 96%, producing premium quartz for low-quality glass and other similar applications. A final concentration stage by flotation using specific collectors was evaluated in this paper aiming at the production of high-purity quartz (>99% SiO2) for alloy or solar panels or the semiconductor industry. Cationic collectors for quartz and alternative anionic collectors for the Fe-bearing minerals showed great potential to remove part of these minerals lost by entrainment, true flotation, and entrapment on the former concentration stages, enabling a premium quartz product with >99% SiO2, even with the presence of associated particles of quartz and hematite.
Technical Session
9/3/24, 11:55 AM - 9/3/24, 12:20 PM
Presenter(s): GUSTAVO NUCCI FRANCO (FRANCO ARBEIT ENGENHARIA), Natalie de Lacerda Citeli Silveira (COMPANHIA SIDERÚRGICA NACIONAL), FRANCINI DA SILVA MOREIRA (COMPANHIA SIDERÚRGICA NACIONAL), Carlos Junior de Oliveira Dornelas (COMPANHIA SIDERÚRGICA NACIONAL), Josefa Pereira Santos (COMPANHIA SIDERÚRGICA NACIONAL), Diego Henrique Fonteles Dias (COMPANHIA SIDERÚRGICA NACIONAL), Ivanildo Bravo dos Santos (COMPANHIA SIDERÚRGICA NACIONAL)
Abstract:
Coking plants investments require analyses of how resources behave in meeting production schedules. To conduct these analyses, a computational model was developed to represent the operational details of each battery and identify bottlenecks throughout production scenarios. By integrating constraint analysis into the operational index, the simulation aims to identify and mitigate any limiting factors that may affect coke battery operation. This approach allows the company to evaluate hypothetical scenarios, test different operational strategies, and anticipate potential bottlenecks or weaknesses in the process.
Technical Session
LATEST GENERATION DRY BLAST FURNACE GAS CLEANING TECHNOLOGY
Presenter(s): peter klut (Danieli), Jan de Weerdt (), Gina Bakker–Paez ()
Abstract:
Dry blast furnace gas cleaning technology offers great economic advantages when compared to traditional wet gas cleaning owing to its improved energy efficiency, lower cost, reduced plot space, and practically eliminated water consumption. Given the improved operational economics and – in some areas – the physical or economic scarcity of water, steel producers are shifting towards the application of dry blast furnace gas cleaning systems, in which the wet scrubber is replaced with a dry secondary gas treatment stage. The Danieli Corus solution is based upon proven technology that has been applied numerous times for cleaning aluminum smelter gases and anode baking fumes. The system consists of a gas conditioning tower, reagent injection system and (pressurized) filter modules with low pressure pulse cleaning. Currently, Danieli Corus is implementing this technology for three greenfield blast furnaces in India. This article presents the advantages of the proven technology as well as some improvements that will be applied during the ongoing projects. These improvements include steam reheat of (cold) blast furnace gas, single phase water injection in the conditioning tower and two stage countercurrent absorbent injection.
Technical Session
COMPARATIVE ANALYSIS BETWEEN A JIG AND SENSOR-BASED-SORTING IN THE CONCENTRATION OF CHROMITE FROM THE IPUEIRA MINE
Presenter(s): Anthony Victor Melo Sarubbi (Steinert Latinoamericana)
Abstract:
The Ipueira Mine, operated by Ferbasa, is an important center for chromite ore production, utilizing physical concentration technologies such as jigging and Sensor-Based Sorting (SBS). This article compares the effectiveness of these methods in concentrating chromite within the -19+9mm size range. Currently, Ferbasa uses the traditional jig separation process for this size fraction, which relies on the density difference of minerals. The SBS technology is employed for coarser fractions and uses sensors to detect physical properties. Pneumatic jigging at the Ipueira Mine uses a BATAC jig to separate minerals, facing challenges with water supply. In contrast, SBS technology promotes dry processing, reducing the process's dependency on water. Tests conducted with XRT and Laser 3D sensors showed superior results compared to the jig in terms of metallurgical recovery and Cr₂O₃ grades. It was possible to achieve Cr₂O₃ grades that elevate the product to metallurgical quality, demonstrating greater efficiency and sustainability. The implementation of SBS in the -19+9mm fraction could represent a significant advancement for Ferbasa, improving product quality in this fraction and offering substantial sustainability advantages, especially in water-scarce regions.
Technical Session
EFFECT OF AN INTERCRITICAL AUSTENITIZING CONDITION ON ISOTHERMAL BAINITIC TRANSFORMATION IN AN OCTG STEEL FOR OIL AND GAS INDUSTRY APPLICATION
Presenter(s): GERALDO LUCIO DE FARIA (Universidade Federal de Ouro Preto), Paulo Henrique Cirilo (Universidade Federal de Ouro Preto), Paulo Sérgio Moreira (Universidade Federal de Ouro Preto), José Marcio da Rocha (Universidade Federal de Ouro Preto)
Abstract:
The OCTG steel pipes classified as API 5CT, specifically the grade K55, are specified for casing pipes in oil and gas exploration wells. The steels used as raw material for manufacturing this type of product are of high mechanical strength and low alloy. Generally, they are quenched and tempered, therefore possessing a microstructure mainly consisting of tempered martensite. However, some studies point to the possibility of using biphasic microstructures composed of ferrite and bainite, aiming to improve the mechanical strength-toughness relationship of this steel type. In this context, considering the feasibility of producing a biphasic pipe through austempering heat treatment after intercritical autenitizing, this work investigated, through computational simulations and dilatometric tests, the effects of intercritical autenitizing on the isothermal bainitic transformation of an OCTG steel, with potential application in the oil and gas industry. It was concluded that, for the studied steel, it is possible to obtain a promising ferrite-bainite biphasic microstructure through adequate planning of intercritical autenitizing and austempering conditions. It was shown that decreasing the austempering temperature results in significant microstructural refinement of bainite, leading to a considerable hardness increase. Intercritical autenitizing condition at 750°C associated with bainitic transformation temperatures of 400°C and 350°C proved to be the most promising for the desired application.
Technical Session
9/3/24, 11:55 AM - 9/3/24, 12:20 PM
Presenter(s): Douglas Vinícius Ferreira de Castro (Aperam South America), Jacqueline de Oliveira Cota (APERAM SOUTH AMERICA), Luciano Milagres da Silva (APERAM SOUTH AMERICA), Maria Aparecida de Lana Santos (APERAM SOUTH AMERICA), Matheus Augusto Santos Vieira (APERAM SOUTH AMERICA), Péricles Guimarães Oliveira Aguiar (APERAM SOUTH AMERICA), Peterson Ribeiro Francisco (APERAM SOUTH AMERICA), Raphael Felippe Miranda de Oliveira (APERAM SOUTH AMERICA)
Abstract:
Quality is one of most important indicator for Aperam. However, due to the challenges in each process, keep quality control always represent a challenge. In Aperam Timóteo Blast Furnances, hot metal quality means silicon e and temperature. Knowing that quality affects our process, we commited to increase the hot metal qualit using lean metodology. The silicon and temperature stability of hot metal brings benefits to the the blast funace and meltshop processes. Guided by the limits of hot metal specification and kwowing the silicon content has a positive and linear correlation with temperature, we know that would be necesary reduce the thermal variations to increase our quality. According to our methodology, we defined that the goal would be increase blast furnance 1 compliance from 78,20% to 81,08% and blast furnace 2 from 74,96% to 81,68%. The proposed targets were exceeded in both blast furnace with results equal to 92,80% in blat furnace 1 and 84,56% in blast furnace 2, breaking historial records. The increased silicon on target reduce its avarege from 0,657% to 0,601% that reduce limes in meltshop.
Technical Session
STUDY OF MICROSTRUCTURAL BANDING IN SAE 4140 STEEL
Presenter(s): MARIANA GOMES DE ALMEIDA (VILLARES METALS SA), Roberto Augusto Teixeira Fulgêncio Junio (villares metals sa)
Abstract:
Microstructural banding is often correlated with observed drops in the mechanical strength and toughness of steels. This work presents a study of microstructural banding in quenched and tempered SAE 4140 steel, in which the influence of the cooling rate on the banding intensity and mechanical properties was evaluated. In the study, experimental quenching and tempering heat treatments were carried out on billets, for subsequent machining of mechanical tests and metallographic analysis specimens, varying only the quenching medium, where water, oil and air were used. In addition, dilatometry tests were carried out, simulating the austenitization process followed by quenching at different cooling rates, for subsequent banding evaluation. The results showed a correlation between the cooling rate and banding where it was observed that as higher the rate is, the lower the banding intensity and the higher the mechanical strength and toughness values of the steel. Finally, it was also possible to observe, using DIC and dark field (HRX) microscopy techniques, the existence of a difference in relief between the different bands present in the microstructure.
Technical Session
9/3/24, 11:55 AM - 9/3/24, 12:20 PM
Presenter(s): heliliano carlos sartori Guedes (VALE S.A.), HYGOR AUGUSTO SOUSA E SILVA (VALE S.A.), Kellen Cristiane moreno esteves (vale s.a.), Fernando viana de assis (vale s.a.)
Abstract:
This study addresses the implementation of safety requirements in electrical and instrumentation installations in environments containing explosive atmospheres in the mining industry. The methodology involved inspections and studies in classified areas, aiming to identify gaps and demonstrate the reduction of non-conformities with adherence to standards and professional training. International standards were used, highlighting the importance of certifying equipment and personal skills to ensure compliance and safety. The results highlight the need for adequate management, including change management, and the importance of certifying service companies and personal skills to mitigate the risks of explosions in industrial facilities. It is concluded that regulatory compliance and process safety in the mining industry require not only equipment certification, but also certification of the skills of the professionals involved
Technical Session
INCREASING THE LIFESPAN OF VIBRATING SCREENS WITH RULE-BASED CONTROL APPLICATION
Presenter(s): Alexandre gomes fonseca (Vale S.A.), Fabrícia Cristiany da Silva Ferreira (VALE S.A.), Kaike Silva Albuquerque (VALE S.A.), Nicolau da Fonseca Bylaardt (VALE S.A.), Robson Aparecido Duarte (VALE S.A.)
Abstract:
Screening is a crucial stage in mineral processing, responsible for classifying particles by size and widely used in crushing circuits. In environments with natural moisture processing, such as Serra Sul, screening efficiency is fundamental to the overall performance of the plant. Variables such as screen rotation, acceleration, and vibration frequency are critical in the technical management by the process team, which aims to optimize these parameters to achieve maximum efficiency, especially under challenging conditions imposed by more hydrated ore lithologies. However, these conditions also result in increased wear of mechanical components, such as bearings. Given this scenario of variable feed lithology and high component wear, this article presents the application of a rule-based controller to reduce screen rotation in situations of low screening demand or absence of feed. This approach is expected to extend the equipment's lifespan without compromising process efficiency.
Technical Session
OPTIMIZING SUPPLY CHAIN OF PLATE'S ROLLING MILL PROCESS: A DIGITAL TWIN SYSTEM
Presenter(s): PEDRO HENRIQUE FERES CAMPOS (ENACOM), Fabrício Schiavon Kolberg (ENACOM), Thales Henrique Silveira Pinto (ENACOM), Matheus Henrique Lemes Faria (ENACOM), Matheus de Oliveira Mendonça (ENACOM), Gustavo Rodrigues Lacerda Silva (ENACOM), Rafael Franco Moraes (GERDAU), Flavio Viana de Freitas (GERDAU), Bruno Alvares (GERdau), Bruno da Silva Breder (gerdau)
Abstract:
The rolling mill has a complex scheduling process, many logistic restrictions must be considered (has the slab to be rolled already been cast?) as well as operational constraints from the process itself (especially related to the coffin made). All this while attempting to produce the plates on the correct due date of the final client. In this sense, a digital twin system is developed to consider the available demands as inputs in order to inform the best configuration for the next coffins, attempting to minimize delays while meeting all the restrictions of the process.
Technical Session
9/3/24, 12:20 PM - 9/3/24, 12:45 PM
Presenter(s): NORTHON TOREZANI CAVAZZONI (ARCELORMITTAL BRASIL SA)
Abstract:
With the expansion of the industrial plant and the increase in the mix of products and thicknesses, the samples collected from the production lines are heavier and difficult to handle manually. Considering this as an operational risk, we combine it with the opportunity to automate the sample entry process in the Laboratory with a robotic cell that has the functions of identifying, cutting to standard size, laser marking, cutting the necessary specimens and storing the sample. With this, we reduced team interaction to approximately zero in these initial operations of receiving and preparing samples and specimens, practically eliminating operational risk
Technical Session
ENERGY EFFICIENCY, SUSTAINABILITY, AND STRATEGY
Presenter(s): Bruno assis de lima (Universidade federal do rio de janeiro)
Abstract:
This paper proposes the repurposing of decommissioned semi-submersible platforms for renewable energy generation by integrating solar panels and wind turbines. This approach aims to transform these structures into offshore sustainable power plants, providing advanced logistical support for naval operations and contributing to the reduction of the environmental footprint. The study includes detailed calculations of energy generation capacity and discusses the strategic and logistical impact of this implementation, both for military operations and for supplying coastal cities. The innovative use of semi-submersible platforms leverages existing infrastructure to promote clean energy generation, aligning with global trends towards sustainability and energy efficiency.
Technical Session
9/3/24, 12:20 PM - 9/3/24, 12:45 PM
Presenter(s): alysson lima lemos (villares metals )
Abstract:
The use of the WCM methodology, through its technical pillar Energy/Environmental, can significantly contribute to reducing losses and consequently transformation costs linked to the use of energy in the steel industry. Implementation requires discipline, rigor and audits that consolidate each step applied until the 7 available steps are completely used. Knowing the strengths and weaknesses within the organization and working with methods, opens ways for the teams' multidisciplinary technical knowledge to be applied during the identification of each phenomenon that causes loss and, with the mapping of actions in a structured way in the methodology, allows the adequate use of resources, resulting in lower costs and greater competitiveness.
Technical Session
9/3/24, 12:20 PM - 9/3/24, 12:45 PM
Presenter(s): RAPHAEL HENRIQUE MORAIS REIS (IME MILITAR DE ENGENHARIA)
Abstract:
This study investigated the effect of adding carbon black (CB) to epoxy matrix composites reinforced with sisal fiber fabric (SF) on their ballistic performance. The components were weighed and mixed in optimal proportions, with 30% vol. SF and 5% vol. CB. After drying the fabrics, the mixtures were manually prepared and molded via hydraulic compression. The composites were morphologically characterized using scanning electron microscopy (SEM). Ballistic tests were conducted using an air rifle with a lead projectile, with chronographs to measure the absorbed energy and residual velocity. The results indicated a slight reduction of 2.4% in absorbed energy and 1.4% in the ballistic limit velocity of the doped composites compared to the non-doped ones. However, the absorbed energy values for the doped composites were statistically equivalent to the non-doped ones. It is concluded that the addition of CB results in a slight decrease in ballistic performance, but within the expected standard deviation. These findings highlight the viability of CB as a reinforcement alternative in epoxy matrix composites reinforced by SF, maintaining their eco-efficiency and mechanical strength.
Technical Session
9/3/24, 12:20 PM - 9/3/24, 12:45 PM
Presenter(s): bruno kneipel neto (Arcelormitta vega)
Abstract:
The use of ion milling cross-sectional polishing (CSP) in defect characterization a great breakthrough in conventional metallographic sample preparation methods. The presented case study aimed to characterize a blister-type defect commonly found in phosphatized and painted parts using ion polishing, combined with electron microscopy, and evaluated its efficiency in this type of occurrence. The defect was associated with the presence of "debris" containing iron and phosphate particles that adhered to the surface, remaining during the electrophoretic painting and application of finishing paints processes. Ion polishing proved high efficiency compared to conventional metallographic preparation as it managed to maintain its integrity throughout all stages
Technical Session
9/3/24, 12:20 PM - 9/3/24, 12:45 PM
Presenter(s): LUIS HENRIQUE MARIANO DA SILVA (DANIELI DO BRASIL LTDA)
Abstract:
Effective inventory management and fully automated handling play a crucial role in maximizing plant performance and equipment reliability. Predictable material flow and optimized logistics—from stock yards to final product bays—yield significant benefits. These include increased safety (with no personnel on the shop floor), enhanced slab yard capacity, improved system efficiency, and 100% digitalization. Ternium, part of the Techint Group, has partnered with Danieli to implement an Inventory Management System and fully automatic handling facilities for their new Hot Strip Mill in Pesqueria, Mexico. The mission is to optimize incoming slab flow using artificial intelligence within the Slab Yard Management System (DYMS), coordinating a comprehensive handling system to process 4.1 Mtpy of slabs.
Technical Session
9/3/24, 12:20 PM - 9/3/24, 12:45 PM
Presenter(s): BRENO TOTTI MAIA (LUMAR METALURGICA LTDA), Alisson paulo de oliveira (NSigma Consulting LTD), cristovão nery giacomin (soft Sider S/a), Reanta dias silva e souza (Soft Sider S/A), andre luiz fraga (Soft sider S/A)
Abstract:
Driven by increasing sanctions on CO2 emissions and the incentives outlined in the American Inflation Reduction Act, steelmakers and investors are seeking ways to produce steel with the lowest possible environmental impact, at a lower cost and with minimal investment. However, despite its emissions, steel is also essential for modern life. It's in cars and buildings, kitchen utensils, etc. Nearly two billion tons are produced annually worldwide, emitting nearly twice that volume in CO2. A significant portion of this CO2 is generated in BOF steelmaking, during both primary refining and, to a lesser extent, secondary refining. This study demonstrates the results of simulations using the Thermo Balance LD® primary refining simulation software (which operates during the steel blowing and casting stage) to calculate carbon emissions based on different alloy designs. This simulation involves altering carbon content by substituting manganese with microalloying elements in six different scenarios. Boundary conditions for the simulation were inferred from classic raw material data, varying the composition of the base steel, which is the product of primary refining. This is an innovative approach to how to associate alloy design with GHG emissions which can be used by steelmakers for the design and production of more environmentally friendly alloys.
Technical Session
9/3/24, 12:20 PM - 9/3/24, 12:45 PM
Presenter(s): PEDRO Victor GOMES DA SILVA (ternium brasil), GIOVANI DELFIM (TERNIUM BRASIL), FRANZ RAMSTORFER (TERNIUM BRASIL), JANIR JUNIOR (PRIMETALS)
Abstract:
The Heat Transfer during the Continuous Casting is a very important factor for the quality and process in general. Just below the mold, after the Primary Cooling, the next stage of heat transfer has a notable role in preventing the occurrence of surface defects and productivity through the control of flow rate from the spray cooling systems. However, during the process the spray nozzles can be clogged reducing the flow rate and, consequently, the efficiency of the process by reducing the casting speed. In order to avoid that, the present work evaluated the influence of the nozzle spray shape in the flow rate for a constant work pressure. The results showed an increase of 60% in the total flow rate capacity without negative impacts on the process or the integrity of the machine. As a consequence of the improvement in the flow rate there was a reduction of 90% in the loss of productivity due to low flow of the spray system. Besides that, the average cost per month to change the mold for reasons of low flow decreased 58%.
Technical Session
9/3/24, 12:20 PM - 9/3/24, 12:45 PM
Presenter(s): JULIA MENDES SALES (UNIVERSIDADE FEDERAL FLUMINENSE), Danyelle Rios Ferreira (CSN), Rafaela Pereira Batista (CSN), Andre luiz vasconcellos da costa e silva (EEIMVR-UFF e IBQN)
Abstract:
Tapping steel from converter to the ladle causes Strong agitation of the metal. For many years, this agitation has been used in different ways to make steelmaking faster and more efficient and to make possible the production of well deoxidized, clean steel. In the present work, a EERZ (Effective Equilibrium Reaction Zone) coupled to a computational thermodynamics software is used to evaluate options related to the additions to the heat during tapping when producing LCAK with high formability. The effect of different amounts of deoxidizers and of different amount of slag formers on the deoxidation and on the formation of a slag adequate for the further processing of the steel. For this purpose, kinetic data from previous work is used, together with an adequate computational thermodynamic database are used to simulate the changes happening to metal and slag during tapping, and until the heat reaches the next processing step. These data will be used to guide an experimental program aimed at improving the tapping practice with the objective of optimizing efficiency and minimizing the number of heats that deviate from the desired quality requirements of this product.
Technical Session
REUSE OF IRON ORE TAILINGS SAND IN GEOTECHNICAL STABILIZATION OF UNPAVED ROADS
Presenter(s): Kellen Poliana Mendes De Medeiros (VALE)
Abstract:
Studies on the use of iron ore beneficiation tailings, especially in unpaved roads, are becoming increasingly necessary due to environmental concerns and the search for economical alternatives for mining waste. This work, developed as part of Research, Development, and Innovation collaboration between Vale and the Federal University of Itajubá (UNIFEI) - Itabira campus, focused on the geotechnical analysis of a chemically stabilized lateritic soil with 4% Portland cement. Iron ore sand (IOS) was added as a byproduct of tailings, aiming for application in rural unpaved roads. The results showed a significant increase in California Bearing Ratio (CBR) values and unconfined compressive strength in the soil-cement mixtures with IOS addition.
Technical Session
9/3/24, 12:20 PM - 9/3/24, 12:45 PM
Presenter(s): SARAH FERNANDES NALLI (ARCELORMITTAL BRASIL SA)
Abstract:
The study under development deals with the application of 1.5% Colloidal Silica 30% in the mineral coal mixture. The main objective is to evaluate the performance of this mixture with silica in order to increase the strength of the coke produced. This approach also aims to achieve significant environmental gains, including the reduction of particulate emissions during the coking process and the densification of the charge used. This research seeks to promote more sustainable and efficient solutions in industrial production, standing out for its potential to improve both the performance of materials and the mitigation of environmental impacts.
Technical Session
9/3/24, 12:20 PM - 9/3/24, 12:45 PM
Presenter(s): LORENZO ENGEL FORNASARI (TERNIUM BRASIL LTDA.)
Abstract:
In recent years, the field of computational fluid dynamics (CFD) has witnessed significant advancements, particularly in its applications for simulating and analyzing industrial flows. Among these applications, the study of cyclone separators stands out for its crucial role in the steel industry, where such equipment plays a vital role in environmental pollution control and cost reduction. While previous research has extensively examined the impact of vortex finder dimensions on tangential cyclones, the same level of investigation for axial cyclones remains less developed. Moreover, prior to this study, there was a lack of understanding regarding the erosion fields generated by the swirling separated material downstream from the equipment under scrutiny. To address these knowledge gaps, this study employs a two-stage CFD approach, aiming to not only fill these voids but also propose geometry alterations to enhance cyclone operation.
Technical Session
SUSTAINABLE FROTHERS FOR PERFORMANCE IMPROVED ZINC SILICATE FLOTATION
Presenter(s): cristiano geraldo de sales (Evonik)
Abstract:
Biosurfactants is a microbial surfactant and are considered potential substitutes of synthetic chemicals from petrochemical origin. The main advantages of biosurfactants over their chemical counterparts are their lower toxicity, better environmental compatibility, biodegradability, and effectiveness in a wide range of temperatures and pH. In addition, it also has higher surface-activity. One important class of biosurfactants, which has been investigated is the rhamnose containing microbial surfactants, also called rhamnolipid, a glycolipid-type. It’s produced by Pseudomonas aeruginosa strains. Due to their features as well as structural similarities, rhamnolipids seems to be well suited to apply in the mineral processing industry as a substitute case for conventional chemical frothers. In this work two Evonik’s biosurfactants, AROSURF® SR 1975 and REWOFERM® SL 446 were investigated as frother, comparing with MIBCOL, in Zn flotation tests with a Nexa’s ore sample. Results showed that both Evonik's biodegradable frothers were able to improve the tests results, increasing %Zn in the concentrate and also recovery under certain circumstances. In addition, tests with reduced dosage in 20% of Evonik’s frothers showed promising in terms of flotation improvement, reduced consumption and even more sustainable.
Technical Session
9/3/24, 12:20 PM - 9/3/24, 12:45 PM
Presenter(s): yasmim lopes sucharski (Universidade Federal de Ouro Preto), Paulo Sérgio Moreira (Universidade Federal de Ouro Preto), Geraldo Lúcio de Faria (Universidade Federal de Ouro Preto)
Abstract:
The control of austenite formation in steels is crucial in various industrial processes, such as heat treatments, for example. The initial austenitic grains influence the microstructure and mechanical properties post-cooling. However, metallographic methods to reveal them are complex and often challenging to apply depending on the steel and the heat treatment it has undergone. This study sought to examine how the austenitizing temperature affects the microstructure of quenched TRIP 780 steel, as well as to evaluate whether the size of the austenitic grain influences the effectiveness of two contrast methods: chemical etching with picric acid and subcritical oxidation. It was concluded that austenitic grain growth affects the effectiveness of both methods. Chemical etching showed better performance at lower temperatures. In contrast, subcritical oxidation proved efficient under all evaluated conditions, successfully revealing the boundaries of austenitic grains. These results emphasize the importance of considering the austenitizing temperature and the choice of contrast method in the analysis of prior austenitic grains.
Technical Session
9/3/24, 12:20 PM - 9/3/24, 12:45 PM
Presenter(s): PATRICK QUEIROZ DOS ANJOS (IFES), felipe fardin grillo (ifes), marcelo lucas pereira machado (ifes), lucas de almeida quaresma (tupy)
Abstract:
The liquidus temperature is one of the most important physical parameters in relation to the crystalline behavior of materials and in a blast furnace the liquidus temperature of the slag is considered one of the most important parameters with an appropriate range for stable operation in a blast furnace. Therefore, liquidus temperature is an important parameter in steel slags. The SciGlass database was used to provide steel slag data with the SiO2-CaO-Al2O3-MgO-FeO-Na2O-K2O-Li2O-B2O3-based slags and liquidus temperature system. The chemical composition data were converted into the degree of depolymerization parameters and subsequently related to each liquidus temperature. The modeling was carried out using neural networks by varying width and depth using a linear combination between different central moments as a reference of efficiency. The best neural network had a width of 19 and a depth of 10 (19-10). Sensitivity analysis was performed demonstrating consistency with the literature and statistical evaluations were performed to demonstrate the efficiency of the neural network 19-10 which demonstrated better evaluations in relation to different literature equations.
Technical Session
9/3/24, 12:20 PM - 9/3/24, 12:45 PM
Presenter(s): Carlos Eduardo Pinedo (Heat Tech Ltd), rODRIGO mAGNABOSCO (Centro Universitário da FEI)
Abstract:
High chromium white cast irons are used in operations that require high wear resistance. This property is achieved by a microstructure comprising a network of eutectic carbides of the M7C3 (Cr7C3) type, combined with the possibility of heat treatment by quenching and tempering. This work analysis the heat treatment parameters on the response to quenching and tempering. For this purpose, phase equilibrium analysis was used using Thermocalc ®, hardening capacity was determined using Rockwell “C” measurements and phases were identified and quantified using X-ray diffraction and a ferritoscope. The results showed that the maximum matrix hardening is reached after austenitization at 950ºC, as consequence of the hardening capacity of martensite by the carbon content dissolved in the matrix and the lowest retained austenite fraction. During tempering, the secondary hardening peak is close to 500ºC. This set of results allowed the specification of the best heat treatment cycle for specific applications.
Technical Session
DEFINITION OF TECHNICAL REFERENCES FOR PROCESSING PLANTS
Presenter(s): ana keli martins alves FERREIRA (VALE S/A)
Abstract:
This article presents the methodology for defining technical references for the main performance indicators of Vale's processing plants in Minas Gerais. Using the Gap to Potential method, which differentiates between potential and actual available time, it is possible to identify performance gaps and opportunities for improvement. The analysis considered compressible and incompressible plant stops to prioritize the most significant causes of corrective stops, with examples of calculating physical availability and physical use. The concepts of technical reference and technical limit were defined, where the technical reference represents the best possible performance, and the technical limit includes operational restrictions. The methodology was applied to 5 production complexes, covering 19 plants, resulting in the definition of 84 technical references, which aim to guide the performance of each plant according to its shutdown notes. The application of this approach allows optimizing operations, direct improvement actions and make strategic decisions, promoting gains in productivity and efficiency in Vale's mining operations.
Technical Session
9/3/24, 3:40 PM - 9/3/24, 4:30 PM
Presenter(s): yara beatriz rodrigues do espirito santo (Departamento Engenharia Metalúrgica e de Materiais, Escola Politécnica da Universidade de São Paulo)
Abstract:
The mining sector is essential to the economy, driving technological and scientific progress, although it has negative environmental impacts due to the waste generated. This study proposes a possible recycling route for mining waste, focusing on the recovery of metals after comparative leaching with technical standards, with the aim of classifying the slag resulting from the reduction of Iron/Nickel (FeNi) and achieving the recovery of metallic waste, contributing to the sustainable disposal of mining waste. The sample was comminuted to a particle size of 0.3mm. A 1N NaOH solution was used as a leaching agent for 100g of the material. A Wagner shaker (18h, 30 rpm) and a vacuum filtration system were used for collection after the test. The dry retained materials, filtered and washed solutions were analyzed by XRD, XRF and ICP, revealing the presence of Forsterite, a mineral of magnesium and iron silicates, and elemental contents of Si, Mg, Fe and Ni of 19%, 18%, 15% and 0.14% respectively. With regard to the total chromium parameter, a value above 5mg/L established by the NBR 10004 standard was found. The levels of Al, Fe and Mn were also above the permitted standard
Technical Session
9/3/24, 3:40 PM - 9/3/24, 4:30 PM
Presenter(s): Flávio de Almeida Lemos (Centro de Tecnologia Mineral)
Abstract:
The production of nickel and cobalt from limonitic laterites poses a challenge due to the complex and heterogeneous mineralogy commonly found in laterites. In the sample used in this study, most of the nickel was contained in goethite, while cobalt was exclusively in manganese oxides. Thus, the extraction efficiencies of these metals are related to the dissolution of these mineral phases. Pressure leaching tests indicated that the dissolution of goethite followed second-order kinetics. After 180 minutes of leaching, maintaining the temperature at 270°C and using a 0.66 M H2SO4 solution, it was possible to dissolve 98.35% of the goethite and 63.85% of the lithiophorite. Additionally, the data demonstrated that increasing the leaching time from 30 to 180 minutes improves the process selectivity, with an increase in the concentration ratios [Ni]/[Fe] and [Co]/[Fe] from 2.03 to 5.34 and from 0.15 to 0.62, respectively.
Technical Session
SELECTIVE EXTRACTION OF COPPER, NICKEL AND COBALT FROM A LATERITIC SULFURIC LIQUOR BY EXTRACTANTS LIX860N-IC, TBP AND VERSATIC 10
Presenter(s): alexandre silva guimarães (cetem), ysrael marrero vera (cetem), georgio patrício de souza resende (universidade federal do rio de janeiro), iranildes daniel dos santos (instituto tecnológico vale), marcelo borges mansur (universidade federal do rio de janeiro)
Abstract:
Solvent extraction of copper, nickel and cobalt from a synthetic laterite sulfuric liquor was compared using LIX860N-IC and its mixture with TBP and Versatic 10. Using 0.5 M LIX860N-IC + 1 M TBP system had an antagonistic effect on the extraction of metals. Using 0.5 M LIX860N-IC allows, besides copper (99%) at pH 2, the selective extraction of cobalt (92%) and nickel (74%) from manganese, zinc, calcium and magnesium at pH 3.5 and 4, respectively. Furthermore, the 0.6 M LIX860N-IC + 0.6 M Versatic 10 system simultaneously and selectively extracts nickel (75%) and cobalt (69%) at pH 4 in detriment of contaminants. Synergism was verified for nickel at pH 2-5.5 and antagonism for cobalt at pH ≤ 6.
Technical Session
9/3/24, 3:40 PM - 9/3/24, 4:30 PM
Presenter(s): Emilcy das Graças Guimarães Totti (Universidade federal de ouro preto), Francielle Câmara Nogueira (universidade federal de ouro preto), Stephânia da Consolação Silva Nogueira (UNIVERSIDADE FEDERAL DE OURO PRETO), Cássio Henrique de Paiva Filho (UNIVERSIDADE FEDERAL DE OURO PRETO), Nayara Aparecida Neres da Silva (UNIVERSIDADE FEDERAL DE OURO PRETO), Carlos Alberto Pereira (UNIVERSIDADE FEDERAL DE OURO PRETO)
Abstract:
This study aimed to evaluate the feasibility of reprocessing three tailings from an African iron ore, using magnetic separation. The goal was to produce a concentrate with 62% iron content and 5% impurity content. The magnetic separation tests were carried out on a bench scale using the Davis Tube and, on a pilot, scale using low and medium intensity magnetic drum separators, varying the intensity of the magnetic field. The intensity of 1700 and 4200 Gauss were used for the bench scale and 1700 and 7000 for the pilot scale. The magnetic separation tests on a pilot scale yielded results consistent with those found in the laboratory, and highlighted the influence of magnetic field intensities on the results. However, none of the concentrates met the recovery and grade goals.
Technical Session
9/3/24, 3:40 PM - 9/3/24, 4:30 PM
Presenter(s): Júlio César Mendes Pereira (UFOP), Francielle Câmara Nogueira (UFOP), Stephânia da Consolação Silva Nogueira (UFOP), Rafaela de Freitas Tavares4 (ufop), Fernanda Hoffmann (Gaustec ), Carlos alberto pereira (ufop)
Abstract:
Magnetic separation is one of the concentration methods, widely used in mining, especially when dealing with very fine ores. Nowadays, it is extremely important to provide suitable destinations for waste. In this work we will use the magnetic separation method in order to concentrate iron ore from tailings from a company in the iron quadrangle. To do this, we will use the Minimag® at the Gaustec research center, reproducing a tetrapolar model carousel magnetic separator, we will change some variables, such as magnetic field, washing water pressure and matrix, in order to achieve the best result. It is expected to obtain a concentrate with the highest recovery and iron content possible so that the installation of the magnetic separator in this company's process is economically viable.
Technical Session
9/3/24, 3:40 PM - 9/3/24, 4:30 PM
Presenter(s): MARIA LUIZA LIMA DA SILVA (IFRN), Igor Henrique Lima da Silva (ifrn), Flanelson Maciel monteiro (ifrn), Djalma Valério Ribeiro Neto (ifrn)
Abstract:
This study aims to review the sustainable use of ornamental rock waste, especially in the Seridó region, with the goal of mitigating environmental and economic impacts. To this end, the methodology employed involved a literature review, focusing on articles about the use of these wastes in construction materials. The results show that granite and quartzite waste can be used in mortars, glass production, and ceramic blocks, improving their physical and mechanical properties. Among the main findings, for example, the addition of ornamental rock powder waste in self-leveling mortars increased compressive strength and reduced water absorption. Incorporation into ceramic blocks increased flexural strength, and the production of soda-lime glass with quartzite waste was viable. Thus, it is concluded that the reuse of ornamental rock waste promotes environmental sustainability and offers economic opportunities. For an effective change, support from public policies, partnerships between government, companies, and research institutions, and awareness of the benefits of this practice are essential. Efficient waste management can generate jobs, foster technological innovations, and contribute to a circular economy, reducing the ecological footprint of mining activities.
Technical Session
9/3/24, 3:40 PM - 9/3/24, 4:30 PM
Presenter(s): Thiago viana neves (SAMARCO MINERACAO S.A), Marcos santos da cunha (samarco minercao s.a), otávia martins silva rodrigues (universidade federal de ouro preto), carlos alberto pereira (UNIVERSIDADE FEDERAL DE OURO PRETO)
Abstract:
In view of recent events linked to the collapse of dams, Samarco Mineração installed a tailings filtering plant at its Germano Unit, with the aim of placing them in piles for greater geotechnical control. An item of paramount importance for the quality of solid-liquid separation in filters is the filtering element, which for the adopted model is commonly called “fabric”. The present study was concerned with presenting the efficiency of the “run to failure” methodology for exchanging these elements, obtaining significant results from the perspective of managing processes, assets and finances where, it is possible to mention that the strategy used presented a lower cost than the general exchange methodology and than the exchange point presented by the asset management team, being in the order of 54.48% and 39.31 % of investment avoided, respectively. It was also observed that for a context where the plant is required to the maximum, it is valid to maintain a continuous analysis, to verify the maintenance of the efficiency of the methodology used
Technical Session
9/3/24, 3:40 PM - 9/3/24, 4:30 PM
Presenter(s): Fábio de são josé (centro federal de educação tecnológica de minas gerais - unidade araxá), kennedy da silva ramos (universidade federal do ceará - unidade crateús), carlos alberto pereira (universidade federal de ouro preto), sérgio eduardo de Almeida lima (Programa de pós-graduação em engenharia de minas)
Abstract:
Manganese concentrates are important for various industries. It is the important raw material for steel and ferromanganese productions, dry batteries and other products. The scarcity of manganese ore with a high content (> 40% Mn) and adequate granulometry that allows its use as granulate induces several studies that looking for to evaluation of the possibilities to concentrating low content and fine manganese ores. The new reality of the available deposits, the importance of manganese for the basic industry (example of the steel industry) is maintained and leads us to characterize and treat the low ores in metal manganese (gondite), especially in the comminution and concentration steps. Thus, the work aimed at the search for initial data useful to characterize the gondite, to define the ore WI and to carry out an exploratory phase of concentration through magnetic technology. As a result, were obtained a WI equal to 13.7 kWh/t, close value for low manganese ores, magnetic concentration with field at 12,000 Gauss that allowed metallurgical recovery of up to 92.48% with 22.84% of content, and therefore, its use as possible, despite the lack of data on cost-benefit of the process.
Technical Session
RED CERAMICS: SUSTAINABILITY AND INNOVATIVE PRACTICES - A REVIEW
Presenter(s): carlos henrique da luz barbosa (Instituto Militar de Engenharia ), murilo miguel narciso (instituto militar de engenharia), Aline Raybolt dos Santos Almeida (Faculdade de odontologia - universidade federal do rio de janeiro), marcelo henrique prado da silva (instituto militar de engenharia)
Abstract:
Red ceramics, with its long history from Mesopotamian civilizations to the present day, stands out as an important construction material and art object. In Brazil, the first records of this type of ceramics date back to Marajó Island, where sophisticated pieces were produced without the use of a wheel. "Red Ceramics" encompasses a variety of materials, such as bricks and tiles, widely used in civil and domestic construction. The article in question reviews the historical and technical importance of red ceramics, addressing its technological evolution and the introduction of sustainable practices in its production. It highlights the responsibility of public agencies and municipalities in managing solid waste, emphasizing the importance of transparency and collaboration with the private sector and civil society. Additionally, it discusses the optimization of sintering, highlighting the environmental and economic benefits of this practice. The incorporation of waste in red ceramic production is presented as a sustainable solution to reduce clay consumption and minimize environmental impacts. Other innovative practices, such as the use of renewable energy and the development of artificial stone from waste, are also explored as ways to promote sustainability in the ceramic industry
Technical Session
UTILIZATION OF QUARTZITE WASTE IN THE FORMULATION OF ALKALIACTIVATED BINDERS
Presenter(s): leonardo Henrique mendes beserra (uNIVERSIDADE FEDERAL DE OURO PRETO), tiany guedes cota (universidade federal de ouro preto), érica linhares reis (universidade federal de ouro preto)
Abstract:
The sustainable utilization of waste in production processes motivates the following study, which aims to characterize a fine residue from the cutting stage of ornamental quartzite blocks, with the subsequent intention of its use as a filler in the production of alkali-activated materials. The study also seeks to determine the optimal proportion for incorporating this fine residue into the material mixture to maximize its mechanical properties. Physical, chemical, and mineralogical characterization tests of the material were conducted, followed by the molding of specimens using an activating solution containing a concentration of 6 molar sodium hydroxide, along with a mixture of quartzite and manganese ferroalloy slag. The mixing process was carried out using both the one-part and two-part methodologies. Subsequently, compression strength and water absorption tests were performed at various curing times. The quartzite consists predominantly of quartz, kyanite, and muscovite minerals, with 88% SiO₂ and 11% Al2O3. It exhibits a specific density of 2.8g/cm3 and 80% of particles smaller than 43µm. The study observed the influence of increasing the quartzite ratio, with the ideal proportion being 5% in the mixture, taking into account the methodologies and curing times in the tests
Technical Session
9/3/24, 3:40 PM - 9/3/24, 4:30 PM
Presenter(s): Pedro cesar oliva coronel (ARCELORMITTAL TUBARAO)
Abstract:
The present study evaluated the development of polymeric solutions as wind erosion suppressors from recycled cellulose-based materials. These suppressors, composed of polymeric solutions, act to reduce wind erosion of powdery materials in industrial areas. This work presents a preliminary study on the feasibility of using cellulose with a water-soluble polymer in suppressor formulation. Tests were conducted on a thermogravimetric equipment to preliminarily evaluate the effectiveness of these suppressors and compare them to determine some conclusions. The results indicated a strong potential for the use of this product with increased resistance and hardness as the polymer concentration is increased. Overall, the use of these recycled cellulose-based suppressors can significantly contribute to reducing wind erosion of powdery materials, favoring sustainability and directly promoting a circular economy
Technical Session
FEASIBILITY OF ADDING GREEN FOUNDRY WASTE FOR THE PREPARATION OF A PLANT SUBSTRATE
Presenter(s): Carlos atalla hidalgo hijazin (UFRGS), Pedro jorge walburga keglevich de buzin (UFRGS), Rejane Maria Candiota Tubino (UFRGS)
Abstract:
The objective of this work was to evaluate the technical and environmental feasibility of adding different application rates of Green Foundry Sand Waste (GFSW) and commercial substrate to mature composts obtained from Organic Solid Waste (OSW), composting with an automated control system. The fertility of the mixtures, formed with additives (GFSW and commercial substrate) added at a rate of 0-50% (m/m) to matured compost maintained at a fixed rate of 50% (m/m) was evaluated. In a second stage, the planting of Avena Strigosa Schreb (black oats) in the mixtures obtained was evaluated, pointing out the results that presented greater technical and environmental feasibility of use. The results showed the potential for using these mixtures in agriculture, in the specific case for the cultivation of black oats at a rate of 10-20% (m/m) of GFSW or as a corrective for soil acidity.
Technical Session
ENVIRONMENTAL ASSESSMENT OF THE USE OF ARCELORMITTAL TUBARÃO STEEL INDUSTRY AGGREGATE IN ROAD WORKS
Presenter(s): Aureliano nogueira da costa (Fundagres inovar), Patrício José Moreira Pires (Fundagres Inovar), Ricardo Filipe Teixeira Moreira (arcelormittal tubarão), Nocy Oliveira da Silveira (ARCELORMITTAL TUBARÃO), Eduardo Kazuaki Shiramata (ARCELORMITTAL TUBARÃO), Carolina Gorza Ferreira (ARCELORMITTAL TUBARÃO), Luciana Michelle Dellabiaca Araujo (dnit), Letícia Pereira Rocha (fundagres inovar), MARCO AURÉLIO DE ABREU BORTOLINI (Fundagres inovar), ROBERTA CRISTINA COTTA DUARTE CONDE (FUNDAGRES INOVAR), adelaide de fátima santana da costa (fundagres)
Abstract:
The present study evaluated the environmental impact of the use of the steel industry by-product Revsol Plus, derived from steel slag, in the recovery of unpaved sections of the BR-342/ES highway. The adopted methodology involved monitoring the physicochemical and biological characteristics of surface and groundwater, as well as the analysis and characterization of the solid waste from the pavement. The initial results showed that the incorporation of the by-product did not compromise the quality of water resources. In addition, the characterization of the solid waste allowed for the evaluation of its composition and properties, essential information for proper management and decision-making related to the treatment and disposal of these materials. Based on these findings, the authors conclude that the use of industrial by-products in the construction and recovery of highways is an economically viable and environmentally sustainable alternative. This study contributes to the development of environmental management practices in the steel industry and the road infrastructure sector, promoting the circular economy and mitigating environmental impacts.
Technical Session
9/3/24, 3:40 PM - 9/3/24, 4:30 PM
Presenter(s): EMILY DE FáTIMA PINHEIRO BOTELHO (UNIVERSIDADE FEDERAL DO PARá), Paulo Anderson Aranha Ferreira (UNIVERSIDADE FEDERAL DO PARÁ), Rayanne Oliveira Leão Santana (univerdidade federal do Pará), Giovana Zagalo de França (UNIVERDIDADE FEDERAL DO PARÁ), Verônica Scarpini Candido (UNIVERDIDADE FEDERAL DO PARÁ), Alisson Clay Rios da Silva (UNIVERDIDADE FEDERAL DO PARÁ)
Abstract:
Geopolymers have emerged from the civil industry's need for more sustainable cementitious materials with superior mechanical performance compared to traditional concrete. Waste from mining industries represents a valuable source of essential silicon and aluminum for geopolymers. Due to their amorphous aluminosilicate structure, geopolymers exhibit excellent thermal resistance, and the addition of silica enhances their mechanical strength. Therefore, the objective is to evaluate the compression strength of geopolymers with 4% pure silica addition after thermal exposure. Geopolymer production was carried out in cylindrical molds, following the guidelines of the ABNT NBR 5739:2019 standard. Specimens were then exposed to temperatures of 25°C, 200°C, 250°C, and 300°C. The results indicate that geopolymers with 4% pure silica addition showed better compression strength when exposed to 25°C. It is concluded that geopolymers maintained good compression strength even after thermal exposure, especially at lower temperatures, suggesting their potential for applications in the construction industry, contributing to more sustainable materials.
Technical Session
9/3/24, 3:40 PM - 9/3/24, 4:30 PM
Presenter(s): Fellipe de Sá Moraes (UNIVERSIDADE DO ESTADO DO RIO DE JANEIRO), Diego dos Santos Alves (Universidade do estado do rio de Janeiro), Sabrina Costa Faria (Universidade do Estado do RIo de Janeiro), Juliana Lopes Ribeiro (UNIVERSIDADE DO ESTADO DO RIO DE JANEIRO), Bruno Cristian Mello Carvalho (UNIVERSIDADE DO ESTADO DO RIO DE JANEIRO), Eustáquio de Souza Baêta Júnior (UNIVERSIDADE DO ESTADO DO RIO DE JANEIRO), Leticia dos Santos Aguilera (UNIVERSIDADE DO ESTADO DO RIO DE JANEIRO)
Abstract:
Porous structures obtained by freezing solvents have pore and wall thicknesses correlated to the type and concentration of dispersants. Therefore, new developments necessarily involve differentiating the effects of using these additives when processing materials. Statistical analyzes using the ANOVA and Tukey methods were applied to the pore thickness and wall thickness values of ceramic pieces produced with zinc ferrite nanoparticles (ZnFe2O4) and formed by freeze casting. Pore and wall thickness data in relation to the variation in the molecular mass of the polymeric binder polyethylene glycol (200, 4000 and 8000) and the concentrations (2%, 3% and 6%) added to the precursor solution for processing the material were provided. for an artificial intelligence, Gemini, and the results obtained in response indicated that both pore thickness and wall thickness are influenced by the type and concentration of PEG used. The use of Generative Artificial Intelligence as a tool to help obtain and validate statistical analysis results has proven to be practical and efficient, speeding up calculations and interpretations.
Technical Session
9/3/24, 3:40 PM - 9/3/24, 4:30 PM
Presenter(s): Giovana zagalo de frança (universidade federal do pará), Paulo anderson ARANHA FERREIRA (UNIVERSIDADE FEDERAL DO PARÁ), RAYANNE OLIVEIRA LEÃO SANTANA (UNIVERSIDADE FEDERAL DO PARÁ), dIEGO JOSÉ DA SILVA SANTOS (UNIVERSIDADE FEDERAL DO PARÁ), ALISSON CLAY RIOS DA SILVA (UNIVERSIDADE FEDERAL DO PARÁ), VERÔNICA SCARPINI CANDIDO (UNIVERSIDADE FEDERAL DO PARÁ)
Abstract:
Geopolymers are cementitious materials that are synthesized from the geopolymerization of a source of aluminosilicates in an alkaline solution. Based on the formation of Si-O-Al bonds, they present properties of high mechanical performance, chemical inertness and durability, with the potential to replace Portland cement, as it is a green technology, with low emission of polluting gases. The present study aims to evaluate the compressive strength of geopolymeric pastes produced with metakaolin from the state of Paraíba, calcined at different temperatures (650°C, 750°C and 850°C for two hours). The geopolymeric pastes were produced using sodium silicate and sodium hydroxide as an alkaline solution, and as a precursor material, blast furnace slag was used as a source of calcium and metakaolin as a source of aluminosilicates. After the curing age of 7 days, mechanical and physical tests of compressive strength and water absorption were carried out, respectively. Finally, morphological analyzes of the paste fragments were carried out using an optical microscope. The results demonstrate that the mechanical resistance of the geopolymeric paste increases according to the increase in the calcination temperature, reaching its maximum peak of 37 MPa, and through optical microscopy analysis, a dense and homogeneous microstructure was observed, proving that metakaolin must reach its metastable phase for an efficient geopolymerization process to occur.
Technical Session
9/3/24, 3:40 PM - 9/3/24, 4:30 PM
Presenter(s): JENNIFER FERREIRA FERNANDES (UNIVERSIDADE FEDERAL DO PARÁ), Manoel Vinícius França Monteiro (UNIVERSIDADE FEDERAL DO PARÁ), Ana Paula SouZa DE SouSa (UNIVERSIDADE FEDERAL DO PARÁ), Haianny Beatriz Saraiva Lima (UNIVERSIDADE FEDERAL DO PARÁ), Diego Cardoso Estumano (UNIVERSIDADE FEDERAL DO PARÁ), Emerson Cardoso Rodrigues (UNIVERSIDADE FEDERAL DO PARÁ), Deibson Silva da Costa (UNIVERSIDADE FEDERAL DO PARÁ)
Abstract:
The work presents one of the most important fruits from the AmazôNIA, açaí, and raises the issue of inadequate disposal of the seeds after consuming its pulp. These lumps can be used to extract fibers, which can be used in the manufacture of composites. Thus, the study aimed to characterize morphologically and determine the specific mass of açaí fiber, aiming to manufacture polymer composites with different mass fractions (1%, 2% and 3%), for analysis of physical properties (MEA, PA and AA) traction mechanics, followed by fractographic analysis. The fibers were extracted manually and their morphology was analyzed using the Scanning Electron Microscope (SEM). The composites were manufactured by the manual method (hand lay up), using orthophthalic polyester matrix and butanox initiator (1% v/v) and compression on the test specimens. Morphological analysis revealed roughness and imperfections in the fibers. The specific mass presented an average of 1.09 g/cm3. In physical tests, water absorption (AA) and apparent porosity (PA) increased with the addition of fibers to the matrix and the apparent specific mass (MEA) remained similar. In the tensile test, the fibers acted as filling material, as the resistance did not exceed that of the matrix, however this fact can promote a reduction in the use of the polymer, reducing its environmental impact.
Technical Session
9/3/24, 3:40 PM - 9/3/24, 4:30 PM
Presenter(s): JOELLY VERA NASCIMENTO (UNIVERSIDADE FEDERAL DO PARA), Paloma Suellen Lima de Sousa (universidade federal do pará), Sarah Gabrielly Brandão de Souza (UNIVERSIDADE FEDERAL DO PARÁ), Diemison Lira Santa Rosa (UNIVERSIDADE FEDERAL DO PARÁ), Damares da Cruz Barbosa Nascimento (UNIVERSIDADE FEDERAL DO PARÁ), Alisson Clay Rios da Silva (UNIVERSIDADE FEDERAL DO PARÁ), Verônica Scarpini Candido (UNIVERSIDADE FEDERAL DO PARÁ)
Abstract:
Currently, the search for materials that combine high mechanical performance, low cost and ecological sustainability has intensified in several applications. This study focuses on the application of kaolin waste as a reinforcing agent in a polymer matrix. The mechanical properties of this composite were evaluated by manufacturing test specimens in silicone molds, in accordance with ASTM D638-2014 for tensile strength tests and ASTM D790-2017 for three-point bending tests. The materials obtained were mechanically characterized through tensile tests, where tension, Young's modulus and deformation were measured, as well as through flexion tests, which also provided tension and Young's modulus data. The results indicated that the increase in the amount of kaolin residue led to a reduction in mechanical strength compared to the pure polymer matrix. It was observed that the tensile and flexural moduli resulted in F (calculated) values greater than the critical F, and for traction, the deformation also presented a F (calculated) value greater than the critical F
Technical Session
9/3/24, 3:40 PM - 9/3/24, 4:30 PM
Presenter(s): SAMUEL Araújo azevedo MALAFAIA (UENF - ALBERTO LAMEG), Gabriela Machado Mota (UENF), Larissa Mendonça Osorio Fonseca (uenf), José Alexandre Tostes Linhares Júnior (uenf), Iully Amaral (uenf), Rita de Kassia Gonçalves Pereira (uenf), Juliana Fadini Natalli (uenf), Markssuel Teixeira Marvila (ufv), afonso rangel garcez de azevedo (uenf)
Abstract:
The present study investigated the effect of reusing RSM - Furniture Sawdust Waste in natura in civil construction coating mortars. The aim was to evaluate the effect of replacing the fine aggregate (sand), in different proportions (0%, 0.5%, and 1.0%) in the fresh state of the mixtures. Consistency, incorporated air, mass density, and water retention tests were carried out, and then their results were analyzed. Consequently, the results show that the addition of RSM alters the properties of the mortars, but within acceptable limits for coating applications. The research has been contributing to the civil and industrial construction sector, as it tends to reduce the improper disposal of this waste, in addition to beneficially contributing to the properties of the mortars, such as reducing mass density. Achieving all these interests, the present work is positioned to respond to the needs of the sectors presented above, in addition to collaborating with the Sustainable Development Goals 11 and 12 of the UN.
Technical Session
9/3/24, 3:40 PM - 9/3/24, 4:30 PM
Presenter(s): Ana Laura Lopes de Matos Riscado (UENF)
Abstract:
Geopolymer is a material developed through the alkaline activation of a precursor rich in aluminosilicates, such as SiO2 and Al2O3, in a polymerization. The production of geopolymer cement requires an aluminosilicate material, an alkaline reagent (such as soluble sodium or potassium silicates), and water. There are two main types of activators used in synthesis: alkali hydroxide solutions or a mixture of alkali silicate and alkali hydroxide solutions. The proposed study aims to analyze geopolymers manufactured with fly ash precursor and different alkaline activators to understand the most appropriate activation for the specific precursor. Fresh state tests indicated that the mass activated with sodium hydroxide and sodium silicate is denser and more viscous, precisely due to the presence of sodium silicate. The geopolymer activated with sodium hydroxide showed greater compressive strength than the geopolymer activated with potassium hydroxide, which was already expected considering the results found in the fresh state tests. Therefore, for the proposed study, the best activator found was the silicate and sodium hydroxide activator, with a molarity of 7.
Technical Session
CHARACTERIZATION OF SOILS FOR THE PRODUCTION OF EXTRUDED, PRESSED, AND FIRED RED CERAMIC BLOCKS
Presenter(s): Bruno sanches da silva (UENF/IFF), Niander Aguiar Cerqueira (UENF), Jonas Alexandre (UENF), Jonathan De Andrade Paula Madalena (UENF), Elias Socrates Nascimento da Cruz Junior (UENF), Izzis do Espírito Santo Simões (UENF), Bernard Silva Corrêa de Sá (UENF), Laura Barreto Azeredo (UENF), Andryl Williams Rodrigues Ferreira (UENF), Luísa Azeredo Ferreira Barreto (IFF)
Abstract:
This study aimed to characterize soils from four deposits in the red ceramic industrial hub of Campos dos Goytacazes, aiming to evaluate their suitability for the production of extruded, pressed and fired ceramic blocks. Particle size analyzes revealed that Soil 1 has the highest proportion of clay (44%), Soil 2 the highest proportion of silt (48%) and Soil 3 a balanced distribution between sand, silt and clay. The plasticity indices showed that Soil 1 is the most plastic and Soil 2 the least plastic. The chemical composition indicated high amounts of silica (SiO₂) and alumina (Al₂O₃) in Soils 1 and 3, suggesting the presence of clay minerals such as kaolinite and gibbsite, while Soil 2 showed a predominance of silica, suggesting quartz sand. Based on consistency limits (Atterberg) and chemical analysis, it is concluded that Soils 2 and 3 are suitable for the production of ceramic blocks, with Soil 3 being particularly promising due to its greater amount of clay minerals. The use of these soils can significantly strengthen the red ceramics industry in Campos dos Goytacazes, taking advantage of local resources and boosting the regional economy.
Technical Session
9/3/24, 3:40 PM - 9/3/24, 4:30 PM
Presenter(s): Carlos Maurício Fontes Vieira (UENF ), Geovana carla girondi delaqua (UENF)
Abstract:
This work aimed to characterize and reformulate a mass for the production of ceramic tiles in the region of Campos dos Goytacazes – RJ. The chemical composition was evaluated by XRF and granulometry of different clays from deposits in the region. Pieces were produced with the different clays and fired at different temperatures. The clays called “strong” and “weak” by the region's potters actually present different characteristics in terms of its particle size, with a higher percentage of clay minerals for clays called “strong”. In terms of technological firing properties, all clays present satisfactory results at temperatures of 850, 900 and 950oC, compatible for the manufacture of bricks. However, to obtain tiles, water absorption and linear shrinkage must be reduced
Technical Session
ADDITION OF A STEEL WASTE TO A RED CERAMICS MASS
Presenter(s): Carlos Maurício Fontes Vieira (UENF ), Geovana carla girondi delaqua (UENF)
Abstract:
This work aimed to add sintering plant waste to a ceramic mass and evaluate the influence of incorporation on the properties of red ceramic masses and pieces. The raw materials were characterized by XRD and FRX. The particle size of the waste was also evaluated by sieving and sedimentation. Formulations were prepared with 0 and 10% of the waste, where pieces were produced by uniaxial pressing and fired between 650 and 1050ºC. The results indicate that the waste investigated has great potential for use in the red ceramic segment, mainly due to the possibility of adjusting plasticity and reducing water absorption and linear shrinkage
Technical Session
AN INNOVATIVE ALTERNATIVE FOR CIGARETTE BUTTS DISPOSAL: INCORPORATION IN FIRED CLAY BRICKS
Presenter(s): Cássio rangel paulista (UENF - ALBERTO LAMEG), Geovana Carla Girondi Delaqua (uenf), Carlos Alberto de Oliveira Guimarães (uenf), Paula Munier Ferreira (uenf), Marcelo Gomes da Silva (uenf), Carlos Maurício Fontes Vieira (uenf)
Abstract:
The aim of this work is to analyze the incorporation of shredded cigarette butts (CBs) into bricks making by extrusion. Typical clays used for making bricks and CBs of different sizes and brands were used. The chemical composition of the three clays was determined by x-ray fluorescence (XRF). The samples were made in compositions of 0%, 2.5% and 5% wt and fired at 700 ºC, 800 ºC, 900 ºC and 1000 ºC. The water absorption, linear firing shrinkage and compressive strength were performed. The effect of CBs incorporation was to increase water absorption, due to the porosity generated after firing. Compressive strength increased by 2.5% for firing temperatures above 800ºC, with a decrease for larger amounts of waste. Thus, the results showed that the use of CBs in fired clay bricks in amounts of up to 5% wt is capable of forming porosity in the samples, making the part lighter, in addition to possibly reducing thermal conductivity and increasing acoustic insulation, being a economical and sustainable alternative for the final disposal of CBs.
Technical Session
CHARACTERIZATION OF A MICROMETRIC WASTE GENERATED IN THE PRODUCTION OF STEEL IN ELECTRIC ARC FURNACES
Presenter(s): DANIEL ANDRES LOPEZ EUSSE (UNIVERSIDADE ESTADUAL DE NORTE FLUMINENSE DARCY RIBEIRO), Geovana Carla Girondi Delaqua (UNIVERSIDADE ESTADUAL DE NORTE FLUMINENSE DARCY RIBEIRO), Carlos Mauricio Fontes Vieira (UNIVERSIDADE ESTADUAL DE NORTE FLUMINENSE DARCY RIBEIRO), HENRY ALONSO COLORADO LOPERA (UNIVERSIDAD DE ANTIOQUIA)
Abstract:
This article records the results obtained in the investigation of the characterization of an industrial steel waste known as EAFD (electric arc furnace dust) with the direct intention of knowing it in depth and indirectly to see its potential as a component of new construction materials, for this density tests were performed by pycnometry, morphology by MEV and chemical composition by XRD and XRF. A high density powder composed mainly of 53.5 % of zinc oxide ( ZnO) and iron oxide (〖Fe〗_2 O_3) as the second largest proportion was found. Significant amounts of heavy metals such as Pb, Mn were also found. The analysis of the results shows a high potential to be used in red clay mixtures for the manufacture of bricks and roof tiles in regions where clay quarries are highly plastic, with this residue could improve its processability, reduce processing temperature, reduce important properties such as linear shrinkage and water absorption while giving a reuse of the residue neutralizing its environmental impact.
Technical Session
9/3/24, 3:40 PM - 9/3/24, 4:30 PM
Presenter(s): Davi Vaz André Júnior (UENF), Madeleing Taborda Barraza (UENF), Leandro Barbosa de Oliveira (UENF), Sheila Mara Santos da Silva (UENF), Thereza Pereira Ramos de Mello (UENF), Carlos Maurício Fontes Vieira (UENF), Sérgio Neves Monteiro (UENF), Afonso Rangel Garcez de Azevedo (UENF)
Abstract:
Despite the several advantages of the geopolymer in relation to Portland cement, the production of conventional alkaline activators has a disadvantage in emitting polluting gases into the atmosphere, such as carbon dioxide. Furthermore, the aggressiveness of the solution as well as its exothermic reaction are considered possible manufacturing problems, as it can put the operator's physical integrity at risk. Therefore, this study presents as an alternative to commercial activators, coffee residue ash, rich in potassium oxide, resulting from two processes. Calcined in the factory during the roasting of coffee beans and calcined in the laboratory. Tests were carried out in the hardened state of specimens cured for two days at 60 °C and 26 days at room temperature. To this end, compression resistance, mass density and water absorption by immersion tests were carried out.
Technical Session
9/3/24, 3:40 PM - 9/3/24, 4:30 PM
Presenter(s): Douglas santos silva (ime), raí felipe pereira junio (ime), lucas de mendonça neuba (ime), sergio neves monteiro (ime), marcelo henrique prado da silva (ime)
Abstract:
The incorporation of sintering additives in alumina (Al2O3) aims to improve the efficiency of the ceramic process and, consequently, the physical-chemical properties of the ceramic samples. In this work, the influence of the silica additive (SiO2) during the sintering of alumina was investigated, using weight concentrations of 2, 4 and 8% for silica in sintering heat treatment: 1500 °C, rate of 5 ºC/min, 1 h threshold. The samples were prepared by uniaxial cold pressing with an applied load of 2 tons. The ceramics obtained were sintered and their linear shrinkage was calculated. The flexural test was carried out and the modulus of rupture for the ceramics added with 2%, 4% and 8% silica were higher compared to the pure ceramic at 154%, 126% and 51%, respectively, a result ratified by the statistical analysis. The final morphology was observed by scanning electron microscopy (SEM).
Technical Session
CHEMICAL COMPOSITION, AND MINERALOGICAL AND THERMAL CHARACTERIZATION OF CLAYS IN A RED CERAMIC POLE IN ES, BRAZIL
Presenter(s): Elvis Pantaleão Ferreira (IFES), Alessandra Savazzini-Reis (ifes), Geovana Carla Girondi Delaqua (uenf), Carlos Maurício Fontes Vieira (uenf)
Abstract:
The São Roque do Canaã ceramic hub, located in the central region of the state of Espírito Santo, stands out in the non-metallic mineral processing industry, marked by its pioneering spirit in the red ceramic sector. The present work aims to present the chemical composition, and mineralogical and thermal characterization of clays. In general, no significant differences were recorded between the constitutions of the clays, in which the chemical composition mostly consists of oxides of SiO2, Al2O3, Na2O, TiO2, K2O and high levels of Fe2O3 which, when purchased together, have relatively similar proportions. The thermogravimetric characterization shows typical behavior of kaolinite clays. As for mineralogical characterizations, they present a similar crystalline structure with sharp and clearly evident peaks, with emphasis on the clay minerals kaolinite and gibbsite
Technical Session
9/3/24, 3:40 PM - 9/3/24, 4:30 PM
Presenter(s): EUSTAQUIO DE SOUZA BAETA Júnior (UNIVERSIDADE DO ESTADO DO RIO de janeiro), letícia dos santos aguilera (universidade do estado do rio de janeiro)
Abstract:
Freeze casting is an effective method for controlling porosity in ceramic materials, with applications in various fields such as adsorption, filtration, anchoring, and biomaterials. This paper describes a novel freezing unit for ceramic processing by freeze casting, improving previous models. The freezing unit uses Peltier plates to cool samples until a solvent freeze. Initial studies were conducted with ceramics. The porous microstructure was confirmed by scanning electron microscopy. The results demonstrate that the proposed freezing unit is effective in obtaining the desired porous structure in ceramics. Pore characteristics such as size, shape, and spatial distribution can be controlled by optimizing processing parameters.
Technical Session
INCORPORADO COM CINZAS DA INCINERAÇÃO DE LIXO URBANO EM CERÂMICA VERMELHA
Presenter(s): Geovana Carla gIRONDI dELAQUA (UENF ), Carlos Maurício Fontes Vieira (UENF)
Abstract:
Este trabalho tem como objetivo caracterizar e incorporar em um tijolo de cerâmico um tipo de resíduo, cinza volante, proveniente do incinerador de resíduos urbanos. O resíduo foi submetido à caracterização mineralógica, física e química. As formulações foram preparadas com incorporação do resíduo até 10% em peso na massa cerâmica. Corpos de prova retangulares foram preparados por prensa de molde uniaxial a 20 MPa e depois queimados em forno de laboratório a 900°C. As propriedades físicas e mecânicas avaliadas foram: plasticidade, retração linear, absorção de água e resistência à ruptura flexão. Os resultados mostraram que o resíduo é composto predominantemente por compostos de quartzo e cálcio. Embora o aproveitamento do resíduo tenha potencializado a absorção de água da cerâmica argilosa, sugere-se incorporar quantidade em torno de 5% em peso para evitar efeito deletério na resistência
Technical Session
CERAMIC PRODUCED WITH PACKAGING GLASS POWDER
Presenter(s): Geovana Carla gIRONDI dELAQUA (UENF ), Carlos Maurício Fontes Vieira (UENF)
Abstract:
The growing population consumption coupled with the incorrect disposal of post-consumer packaging glass has raised concerns regarding the final disposal of the waste produced. An environmentally appropriate designation alternative for glass packaging is its incorporation in red ceramic. Therefore, this work aimed to evaluate the effect of incorporating glass packaging waste from selective collection into the composition of the mass, to analyze the physical and mechanical properties of red ceramics. Specimens were obtained by uniaxial pressing at 10 tons and fired at temperatures of 800°C and 850°C. The results indicated that packaging glass contributes to the reduction of water absorption and linear retraction, significantly improving the evaluated properties, thus being a form of disposal for this waste
Technical Session
EFFECT OF BIOMASS ASH IN PARTIAL REPLACEMENT OF CEMENT AND AGGREGATE IN MORTAR PRODUCTION
Presenter(s): Gercyr Baptista Junior (instituto federal do espírito santo), Leila celin nascimento (Instituto Federal do Espírito Santo), Gustavo de Castro Xavier (Universidade estadual norte fluminence), Afonso Rangel Garcez de Azevedo (UNIVERSIDADE ESTADUAL NORTE FLUMINENsE), Carlos Maurício Fontes Vieira (UNIVERSIDADE ESTADUAL NORTE FLUMINENSE)
Abstract:
The demand for raw materials and the consequent reduction of natural resources have demonstrated the need for new approaches to building materials. The option that has become viable is the use of waste in cementitious materials, through incorporation, substitution or addition. In this sense, the present work aims to evaluate the potential of using biomass ash - BBA for the production of mortars. BBA was characterized by laser particle size, XRF, XRD, and SEM. The mortars were produced with CPV ARI Portland cement and quarry sand in a 1:3 pattern, with cement replacement percentages of 5%, 10% and 15% and fine aggregate substitution in 2%, 4% and 6%. The results at 28 days in the hardened state show that, considering the tensile strength in flexural, it is possible to reduce cement consumption by up to 15%. On the other hand, the compressive strength, considering the partial replacement of cement by BBA, presented the best percentage among those studied in the mortar with 10% replacement. In the mortar that was partially replaced the aggregate, there was a reduction in compressive strength when compared to the reference mortar. The dynamic modulus of elasticity was not significantly affected.
Technical Session
THERMOGRAVIMETRIC ANALYSIS OF THE SiC-Al2O3-Y2O3 SYSTEM AT LOW TEMPERATURES
Presenter(s): HELLEN KARINA PEREIRA ALKIMIM (Instituto Militar De Engenharia (IME)), Rhayana Ayamy Yamaguchi Gomes da costa (Instituto Militar De Engenharia (IME)), Magno Torres Carvalho (Instituto Militar De Engenharia (IME)), Rodrigo Fernandes M. de Souza (Pontifícia Universidade Católica do Rio de Janeiro (PUC-RJ)), José Brant de Campos (Universidade do Estado do Rio de Janeiro (UERJ)), Eduardo de Sousa Lima (Instituto Militar De Engenharia (IME))
Abstract:
Mass loss is a known phenomenon in silicon carbide (SIC) sintered via liquid phase, which compromises compromising its thermo-mechanical properties. The objective of this work is to study the mass change of carbide at low temperatures in the presence of its most usual additives before the beginning of sintering. SIC compositions with alumina, SiC with Ittry and the 3 compounds simultaneously were prepared. Pure SIC was used as a reference. Thermogravimetric analyzes up to 600ºC were performed in argon atmosphere, scanning electronic microscopy (MEV), X-ray diffraction (DRX) and mass measurements. The SIC has little expressive mass gain at approximately 900ºC. SIC with the addition of AL2O3 and Y2O3 also has an uncomposed gain, which may indicate probable SIC oxidation according to the literature.
Technical Session
9/3/24, 3:40 PM - 9/3/24, 4:30 PM
Presenter(s): Isabela Devesa Batista (Universidade estadual do norte fluminense darcy ribeiro), Ana Laura Lopes de Matos Riscado (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO), Sheila Mara Santos da Silva (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO), Juliana Fadini Natalli (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO), Madeleing Taborda Barraza (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO), Sérgio Neves Monteiro (ime), Afonso Rangel Garcez de Azevedo (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO)
Abstract:
The search for sustainable practices in the construction industry has led to the development of alternatives that aim to reduce environmental impact and promote the efficient use of resources. One of these alternatives is the partial replacement of cement with limestone filler in the composition of mortars. This sustainable practice brings with it a series of significant environmental benefits. Firstly, by using limestone filler, which is a by-product of the limestone mining and processing industry, as a partial substitute for cement, we were able to reduce the amount of cement needed in the mortar. This results in a direct reduction in carbon dioxide (CO2) emissions associated with the production of Portland cement, one of the main sources of greenhouse gases in the construction industry. To analyze this potential replacement, tests were carried out on consistency index, mass density, incorporated air content, apparent density, water absorption by capillarity and mechanical resistance. The results found indicate that the residue has potential for use, however they were inconclusive and the mixtures studied need to undergo adjustments so that they can actually be applied.
Technical Session
ANALYSIS OF PROPERTIES IN THE FRESH STATE OF MORTARS CONTAINING CERAMIC WASTE
Presenter(s): Mariana Gomes Pinto Cherene (UENF - ALBERTO LAMEG), Laimara da Silva Barroso (UENF), Karine Miranda de Souza Tavares (UENF), Gustavo de Castro Xavier (UENF), Afonso Rangel Garcez de Azevedo (UENF)
Abstract:
The red ceramic industry generates great concern for the environment, around 30% of the materials generated are wasted due to errors in their processing. Therefore, the application of solid waste in sustainable construction has attracted a lot of attention. The objective of this study is to investigate the use of ceramic waste as a partial substitute for sand in the production of mortar.The mortars were made for laying blocks and covering walls and ceilings, in a mixture ratio of 1:6 (cement:sand) by mass. The sand was replaced by ceramic waste in different proportions (0%, 10%, 20% and 30%). The pozzolanic activity of the ceramic residue was tested by the Luxán and modified chapelle test indicating good pozzolanicity and the particle size distributions were obtained from particle size of the ceramic residue and sand. Tests were carried out in both the fresh state and consistency index, water retention, incorporated air content and calorimetry. After carrying out the tests and the data obtained, it was concluded that the mortars with the most satisfactory results were with the 10% mixes, which presented better results than the reference mixtures.
Technical Session
EVALUATION OF CONCRETE PATHOLOGIES DUE TO PROBLEMS IN THE CONCRETE STAGE: AN EXPERIMENTAL STUDY
Presenter(s): MARKSSUEL TEIXEIRA MARVILA (UFV - CRP), Daniella Silveira Martins (UFV - CRP), Sandra de Oliveira Sobral (UFV - CRP), Marília Gonçalves Marques (UFV - CRP), Leonardo Carvalho Mesquita (ufv - crp), Jose Alexandre Tostes Linhares Júnior (UENF), afonso rangel garcez de azevedo (UENF)
Abstract:
Over the centuries, humans have always been concerned with constructing structures that meet their needs, accumulating vast technical-scientific knowledge. However, currently, despite this extensive knowledge, there is a construction negligence that, combined with increased environmental aggressiveness and the relentless need for cost-cutting in construction, results in buildings with decreasing quality and durability, for specific cases that have these aggravating factors. This leads to an increasing occurrence of pathological manifestations in contemporary reinforced concrete structures. Thus, the main objective of this article was to evaluate, through an experimental study, the pathologies manifested in concrete specimens resulting from the most common problems during the concreting phase in the Construction Industry: ineffective compaction, excess water in concrete, and improper curing. For this purpose, the samples were subjected to wetting and drying processes to simulate the degradation of a concrete structure under environmental exposure. The conclusions were based on visual analysis, compressive strength, and concrete carbonation conducted before and after the degradation process for comparison purposes. It was concluded that the problems during the concreting phase significantly contribute to the occurrence of stains, cracks, and voids in buildings, with ineffective densified being the concreting problem that causes the most damage to the structure. Finally, the utmost importance of maintaining concrete structures over time was emphasized, as the material deteriorates over time, resulting in a reduction of its initial strength values
Technical Session
EFFECT OF POWDER MATERIAL ON MORTAR BEHAVIOR
Presenter(s): MARKSSUEL TEIXEIRA MARVILA (UFV - CRP), Breno dos Reis Silva (UFV - CRP), Daniel Marques Gonçalves (UFV - CRP), Douglas Maxwel Carneiro Caixeta (UFV - CRP), Rafael Félix Caeiro (ufv - crp), Ricardo Vieira Cupim (UFV - CRP), Ana Laura Lopes de Matos Riscado (UENF), Afonso Rangel Garcez de Azevedo (UENF)
Abstract:
There are several applications of mortar in civil construction, from structural design to the finishing phase. However, the presence of powdery materials can alter important properties and performance of a mortar. In this sense, this article seeks to analyze the results of mixing mortar with these materials through normative tests, for the purpose of evaluating performance regarding consistency, mechanical resistance and pH verification. Therefore, this study presents and discusses the results obtained from two compositions: composition 1 containing 5% powdery clay and composition 2 with 5% powdery filler. The results showed an improvement in mortar performance when subjected to the addition of both clay and filler. In the consistency assessment, the clay composition was even more prominent, as it has binding and absorbent properties, providing greater cohesion and adhesion of the grains, respecting the limits established by standard. As for mechanical resistance, the results of the compositions with additions were very similar, depending on the use according to the purpose to be applied to the mortar, since the clay provides greater plasticity due to greater water absorption and the filler, which, as it is an inert material, does not influence the water of hydration and favors the compactness of the mixture. After breaking the specimens in this test, phenolphthalein was applied to check the pH and it was possible to verify an approximation of results between the reference composition and the composition with filler, presenting greater acidity/neutrality than the composition containing clay
Technical Session
INITIAL BIOACTIVITY ANALYSIS OF HYDROXYAPATITE AND TRICALCIUM PHOSPHATE PELLETS FUNCTIONALIZED WITH PVTK PEPTIDE
Presenter(s): Marvin do NAscimento (instituto militar de engenharia), mariáh cationi hirata (R-Crio Células Tronco), daniel navarro da rocha (R-Crio Células Tronco), carlos henrique da luz barbosa (INSTITUTO MILITAR DE ENGENHARIA), julianna magalhães garcia (INSTITUTO MILITAR DE ENGENHARIA), marcelo henrique prado da silva (INSTITUTO MILITAR DE ENGENHARIA)
Abstract:
Calcium phosphate functionalization with biomimetic peptides is a promising strategy for increasing the cellular response to bone tissue repair. Therefore, the aim of this study was to propose the physical adsorption of pVTK onto biphasic pellets of hydroxyapatite and tricalcium phosphate, analyzing the bioactivity at initial times of up to 12 hours. Bioactivity tests were carried out in vitro using McCoy's culture medium and PBS. The pellets were characterized by X-ray diffraction and scanning electron microscopy with a field emission gun. The results showed that functionalization with the pVTK peptide was more effective in inducing the precipitation of bone-like apatite on the surface of the pellets.
Technical Session
X-RAY DIFFRACTION CRYSTALLINITY ANALYSIS OF MAGNESIUM SILICATE CERAMIC COMPOSITE WITH HYDROXYAPATITE, NIOBIA AND ZINC OXIDE ADDITIVES
Presenter(s): Marvin do NAscimento (instituto militar de engenharia), carlos henrique da luz barbosa (INSTITUTO MILITAR DE ENGENHARIA), Samuel Soares Ferber (INSTITUTO MILITAR DE ENGENHARIA), julianna magalhães garcia (INSTITUTO MILITAR DE ENGENHARIA), marcelo henrique prado da silva (INSTITUTO MILITAR DE ENGENHARIA)
Abstract:
Magnesium silicate is a promising ceramic biomaterial for medical applications due to its biocompatible and bioactive properties. Compared to hydroxyapatite (HA), which is widely used in orthopedics and dentistry, magnesium silicate offers additional advantages by including magnesium and silicon ions that stimulate collagen fiber production, biomineralization, and stabilize the bone structure. The polymorphic forms of magnesium silicate, such as forsterite (Mg2SiO4) and enstatite (MgSiO3), have orthorhombic or monoclinic crystal structures, which influence their biological and physical properties. The addition of HA, niobia (Nb2O5), and zinc oxide (ZnO) to magnesium silicate can enhance its properties, creating composites with increased bioactivity, mechanical strength, and antimicrobial properties. HA, with its hexagonal structure, improves bioactivity and osteoconduction, while Nb2O5, with its orthorhombic structure, increases strength and thermal stability. ZnO, with its hexagonal wurtzite structure, adds antimicrobial properties and improves the hardness of the composite. The objective of this work is to analyze the magnesium silicate ceramic composites with added hydroxyapatite, niobia, and zinc oxide through X-ray diffraction.
Technical Session
9/3/24, 3:40 PM - 9/3/24, 4:30 PM
Presenter(s): Antonio Ricardo grippa satiro (Ifes/UENF), Eduardo Atem de Carvalho (UENF), FELIPE PERISSÉ DUARTE LOPES (UENF), Noan Tonini Simonassi (UENF), SERGIO NEVES MONTEIRO (UENF)
Abstract:
In recent years, interest in sustainable and biodegradable materials has grown, driving research into composites reinforced with natural fibers. Broomcorn (Sorghum bicolor) was the subject of this study primarily due to its low density. The aim of this study was to investigate the mechanical behavior of broomcorn stalks using compression tests to determine compressive strength and modulus of elasticity. Compression tests were used to evaluate the behavior of the stalk, bark, and core of broomcorn separately under compressive loads. The results showed that the bark exhibited the highest strength, followed by the whole stalk and the core. The bark demonstrated brittle behavior, while the core was more ductile. The whole stalk showed intermediate behavior, with good initial strength due to the bark, followed by cracks that temporarily reduced strength, and then material compaction that increased strength again. Overall, the strength values of the whole stalk were significant, confirming its potential as reinforcement in polymer composites.
Technical Session
9/3/24, 3:40 PM - 9/3/24, 4:30 PM
Presenter(s): Belayne Zanini Marchi (ime), Sérgio Neves Monteiro (ime), André Ben-Hur da Silva Figueiredo (ime)
Abstract:
The use of natural lignocellulosic fibers (NLFs) as reinforcing components in composites has been growing in recent decades. Environmental concerns and the exhaustion of oil reserves justify so much research into natural composites, as they are an environmentally correct alternative and in line with the principles of sustainable development. The ubim fiber (baculiferous geonome) has not yet been investigated as a reinforcement of composites for possible applications in engineering. Therefore, the present work evaluated for the first time the mechanical properties of new epoxy composites incorporated with 10, 20 and 30% by volume of ubim fibers. Izod impact, tensile and flexural tests were carried out. The results were statistically analyzed using the ANOVA variance method. The results revealed that the composites with 30% fiber volume presented the best result for Izod impact energy, their fracture surfaces found in the SEM samples after testing showed the transition from totally brittle fracture mechanisms to ductile-brittle with the increase fibers in the composite. In the tensile tests of the composites, the tendency for fiber volume to increase the resistance property and elastic modulus was confirmed, with the 30% group presenting 39.6 MPa and 5.4 GPa, respectively. In the bending test, the strength property and modulus of elasticity resistance also increased with the greater volume of fibers.
Technical Session
9/3/24, 3:40 PM - 9/3/24, 4:30 PM
Presenter(s): Bernardo Soares Avila de Cêa (instituto militar de engenharia), Laura Setti de Sousa (INSTITUTO MILITAR DE ENGENHARIA), Édio Pereira Lima Júnior (INSTITUTO MILITAR DE ENGENHARIA), Sergio Neves Monteiro (INSTITUTO MILITAR DE ENGENHARIA), Lucio Fabio Cassiano Nascimento (INSTITUTO MILITAR DE ENGENHARIA), Fabio Da Costa Garcia Filho (CEFET/RJ)
Abstract:
Synthetic fibers are predominantly used as reinforcement in polymer composites for ballistic protection. However, recent studies have shown that lignocellulosic natural fibers have specific interesting properties that can rival synthetic fibers. Both synthetic and natural fibers have limitations that cause some issues in their application. Therefore, developing hybrid composites reinforced with these fibers emerges as a way to achieve an ideal material that can mitigate the limitations of both types of fibers. In composite development, the properties of these materials are linked to several factors, such as the properties of the constituent phases, the arrangement of the reinforcement phase, its distribution and orientation, the volumetric fraction of the phases, and the stacking sequence of the reinforcement layers. This work investigates epoxy matrix hybrid composites reinforced with synthetic aramid fiber and natural fique fiber, focusing on the influence of the stacking sequence of the reinforcement layers through level III-A ballistic tests with 9 mm ammunition. Four stacking configurations were investigated and compared to determine which has the highest kinetic energy absorption capacity. The data obtained from the ballistic tests were analyzed using analysis of variance (Anova) and Tukey's method. Additionally, surface region investigations of the specimens were conducted to identify the failure mechanisms.
Technical Session
9/3/24, 3:40 PM - 9/3/24, 4:30 PM
Presenter(s): Daysiane da silva moreira (Instituto militar de engenharia), RAI FELIPE PEREIRA JUNIO (Instituto Militar de engenharia), JOSÉ CARLOS FERREIRA FONTES (Centro Universitário Augusto Motta), SERGIO NEVES MONTEIRO (instituto militar de engenharia), LUCIO FABIO CASSIANO NASCIMENTO (INSTITUTO MILITAR DE ENGENHARIA)
Abstract:
Additive manufacturing is emerging as a promising technology with the potential to become one of the main manufacturing methodologies in the future. Within this field, additive manufacturing by digital light processing (DLP) has stood out due to its operational accessibility, printing speed, and refined finishing quality. At the same time, natural fiber composites are gaining increasing applicability, demonstrating mechanical performance capabilities comparable to synthetic fiber composites in certain applications. In this study, Charpy impact tests were conducted on samples containing different proportions of flax fiber mass, ranging from 0% to 2%, using light-curing acrylic resin as the matrix. These samples were manufactured using the additive manufacturing method, specifically vat polymerization, employing the DLP process. The volume fraction of flax fibers present in the composites has a direct effect on the impact energy exhibited by these materials, resulting in a decrease in the energy absorbed relative to the fraction of fibers in the composites when compared to pure photosensitive resin.
Technical Session
DEVELOPMENT OF ARTIFICIAL STONE WITH INDUSTRIAL WASTE REINFORCED WITH ARAPAIMA SCALE
Presenter(s): ELAINE APARECIDA SANTOS CARVALHO COSTA (Universidade estadual do norte fluminense darcy ribeiro), Rafael Bittencourt Miranda (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO), José lucas decoté de carvalho lirio (universidade Estadual do norte fluminense darcy ribeiro), Maria luiza Pessanha Menezes Gomes (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO), Henry Alonso colorado lopera (Universidad de antioquia), Sérgio Neves monteiro (Instituto militar de engenharia), carlos maurício fontes vieira (Universidade estadual do norte fluminense darcy ribeiro)
Abstract:
The objective of the present work was to evaluate the influence of young scales of arapaima gigas on the reinforcement of artificial stones made with quarry dust and epoxy resin, by the process of vibration, compression and vacuum. The residue was divided into three granulometric ranges by the sieving method: Coarse and medium (quarry dust) and fine (quartzite). Data were treated through statistical analysis. The proportions obtained were 5, 7 and 8 (50% coarse and medium), (33% coarse, medium and fine) and (67% coarse, 17% medium and 16% fine). The 3 developed compositions were submitted to the physical index test. The result obtained classified the composition 7 for the incorporation of arapaima scales, and the physical index, bending and izod impact tests were performed to characterize the developed stone. The results obtained indicate that the artificial stone with pirarucu scale had a porosity of 0.67% greater than the one without scale, indicating lack of adhesion of the scale with the residues. The mechanical strength was higher, 34.7 ±2.7 MPa due to the arapaima scales having a high strength. The impact energy of izod was 28.3±4.6 J/m for the scaled artificial stone and 24.1 ±4.9 J/m for the scaleless stone
Technical Session
9/3/24, 3:40 PM - 9/3/24, 4:30 PM
Presenter(s): ELIAS ROCHA GONCALVES JUNIOR (UENF), José Alexandre Tostes Linhares Júnior (UENF), Markssuel Teixeira Marvila (UFV), Afonso Rangel Garcez de Azevedo (UENF)
Abstract:
The construction sector is the largest consumer of natural resources, generating waste that pollutes soil and water. The cement industry is responsible for significant CO₂ emissions. Substituting components with solid waste, such as agroindustrial waste, in mortar, stands out as a promising alternative to mitigate environmental impacts. The use of ash derived from these wastes as a pozzolanic material can improve properties and reduce the extraction of raw materials. The article aims to conduct a bibliometric analysis regarding the use of ash from agroindustrial waste as a pozzolanic agent in cement-based materials. When analyzing the records by year, stability is observed until 2017, with six publications or less each year. From 2018 onwards, there has been a significant increase in the number of publications on the subject, especially in 2022, with 35 publications, indicating a growing interest in the topic. India leads the countries with the most publications, with 55 records, followed by Malaysia and Nigeria, with 23 and 12 records, respectively. Despite being an agricultural powerhouse and having a growing cement industry, Brazil has limited presence in bibliographic production on the subject.
Technical Session
9/3/24, 3:40 PM - 9/3/24, 4:30 PM
Presenter(s): Evanizis Dias Frizzera Castilho (IFES), Mônica Castoldi Borlini Gadioli (CETEM), Mariane Costalonga de Aguiar (CETEM), Rondinelli Moulin Lima (CETEM), Maria Angélica Kramer Santana (IFES), Carlos maurício fontes vieira (uenf), Afonso Rangel Garcez de Azevedo (uenf)
Abstract:
The ornamental stone segment in Brazil is growing and has implemented new technologies to improve or better use stone materials in civil construction. However, an important environmental challenge is related to this sector, mainly linked to the management of waste generated at all stages of the production process. The use of this waste in the manufacture of artificial agglomerated stones appears as one of the options to reduce the environmental impacts caused during extraction and processing, thus contributing to the circular economy. This study aims to produce and evaluate the physical properties of two artificial agglomerated stones with Preto São Gabriel stone waste, varying the granulometric composition. For the production of artificial agglomerated stone slabs, the waste was mixed with the resin and the vacuum vibro-thermo-compression process was used. The results of the properties with mixtures 8 and 7 of the Simplex Centroid model were respectively: apparent density (2.44 g/cm3 and 2.38 g/cm3), water absorption (0.18% and 0.40%) , apparent porosity (0.43% and 0.98%). The stones from the two mixtures have suitable properties for application in civil construction projects, especially in humid environments, due to their low porosity and water absorption, meeting the requirements of Brazilian standards.
Technical Session
9/3/24, 3:40 PM - 9/3/24, 4:30 PM
Presenter(s): FABIO DE OLIVEIRA BRAGA (UFF), Emilio Segundo Cerda Villafana Junior (uff), Betina Carvalho Veiga (UFF)
Abstract:
The adoption of sustainable practices in the construction industry is of great importance, due to the intensive use of raw materials and high generation of solid waste. The use of natural fibers as reinforcement materials can contribute to sustainable approaches by improving the properties of construction materials, as well as due to their renewable nature and carbon-neutral in emissions. Despite the potential, some challenges need to be overcome for their application, such as their surface incompatibility with the cementitious matrix. This study aims to evaluate the impact of sodium lignosulfonate (NaLS) as a modifier of sisal fibers (Agave sisalana) on the tensile strength of mortar. The Brazilian Test was used, which determines tensile strength through diametrical compression of specimens. The results showed that the addition of sisal fibers significantly increased the tensile strength of cementitious mortars. However, no significant difference was observed in the performance of mortars containing treated and untreated fibers.
Technical Session
USE OF BAMBOO FIBER AS REINFORCEMENT FOR POLYMERIC COMPOSITES
Presenter(s): Felipe daflon gama (UENF - ALBERTO LAMEG), José Lucas Decoté de Carvalho Lirio (UENF), Claudio Marlon Gomes da hora (uenf), Heittor da Silveira Inácio (Uenf), ELAINE APARECIDA SANTOS CARVALHO (uenf), Rubén Sánchez Rodríguez (uenf)
Abstract:
The search for sustainable materials is increasingly gaining momentum nowadays, this occurs for several reasons within the economic, social and mainly environmental scenario. This study addresses the development of polyester matrix composites reinforced with bamboo fiber, incorporating concentrations of 0 to 10%, changing the length of the fiber used as reinforcement. The sustainability linked to this natural fiber is emphasized. The impact mechanical properties were evaluated, the fiber density was determined by Pycnometry, and the fracture structure was analyzed using a scanning electron microscope. Izod impact resistance showed the expected statistical dispersion in composites with natural fibers, with statistical analyzes showing significant differences.
Technical Session
ANALYSIS OF CEMENT COMPOSITES WITH TREATED COCONUT FIBERS
Presenter(s): Flavia Regina Bianchi Martinelli (uenf), afonso rangel garcez de azevedo (uenf), Rodolfo Giacomim Mendes de Andrade (ifes), sergio neves monteiro (ime)
Abstract:
Coconut fiber is a vegetable fiber and its use in cementitious composites has several benefits. The fibers provide better mechanical properties to concrete due to their greater tensile strength and modulus of elasticity than the cement matrix. In addition to these contributions, vegetable fibers are renewable, available locally and do not require energy for their production. As disadvantages, they have greater variability in physical and mechanical properties, lower durability, low resistance to microbial attacks and low resistance to humidity. However, these problems can be overcome by modifying the fiber surface through chemical and physical treatments. Therefore, this article aims to analyze the performance of cementitious composites with coconut fibers subjected to alkali treatment through the flexural tensile strength test and scanning electron microscopy (SEM). From the results found, it was verified that with this treatment, the fibers presented a rougher, cleaner and more uniform surface, which helped in the interface with the composite, presenting a higher limit of proportionality and residual resistance, which for application in cementitious composites is interesting because in post-cracking behavior the fibers serve as a stress transfer bridge across the cracks.
Technical Session
COMPARATIVE ANALYSIS OF GLASS FIBER REINFORCED EPOXY RESIN MATRIX LAMINATES AND THE INFLUENCE OF FIBER ORIENTATION ON TENSILE STRENGTH
Presenter(s): FRANCISCO VICTOR ROSA DE LIMA (ufc), saymon ariel RODRIGUES MADEIRO (AERYS ENERGY), bruno douglas rodrigues barbosa (AERYS ENERGY), caio ramos de menezes (ufc), Larah evely Belarmino dos Santos (UFC)
Abstract:
Due to the growth of investments in the wind energy sector, there has been a significant advance in the use of composite materials, the present work aimed to analyze the mechanical properties of epoxy resin matrix laminates reinforced with fiberglass fabrics. For this, laminated plates of epoxy resin matrix reinforced with unidirectional (UD) and bidirectional (BIAX) fabrics were produced, using the Vacuum Assisted Resin Transfer Modeling (VARTM) process. By means of tensile tests at 0° and 90°, the aim was to evaluate the influence of the orientation of the fiberglass fabric in the epoxy resin matrix on the mechanical behavior of the fabricated laminates and to determine its properties. The results of the tests showed an intense drop in strength, in terms of the Tensile Strength Limit (LRT) and the Tensile Strength, when the specimens of the UD laminates were subjected to tractive forces in the direction perpendicular to the orientation of the fibers. The glass-fiber-reinforced BIAX specimens showed a much lower mean LRT value than those verified for the UD plates and intermediate values of Breakdown Stress.
Technical Session
DURABILITY OF COMMERCIAL STONES: A MECHANICAL PERFORMANCE COMPARISON BETWEEN AN ARTIFICIAL AND A NATURAL STONE
Presenter(s): Gabriela Nunes Sales Barreto (uenf), MARCELO BARCELLOS REIS (uenf), elaine aparecida santos carvalho (uenf), HENRY ALONSO COLORADO LOPERA (uDEA), carlos mauricio fontes vieira (uenf)
Abstract:
Natural stones have traditionally been used in construction, but the current market has focused on the commercialization of artificial stones, which, due to their lower porosity, exhibit higher mechanical resistance and durability. The aim of this study was to compare the durability and mechanical performance of two stones currently available on the market: Granito Itaúnas, a natural stone, and Branco Aldan, an artificial stone. The results revealed significant differences between the materials. Branco Aldan had a density of 2.37 g/cm³, water absorption of 0.06%, porosity of 0.13%, and flexural strength of 51.08MPa. Granito Itaúnas, on the other hand, showed a density of 2.64 g/cm³, water absorption of 0.31%, porosity of 0.82%, and flexural strength of 10.19MPa. Both stones meet the minimum requirements for use as cladding in civil construction, with flexural strength above 10MPa, but after degradation cycles, Granito Itaúnas failed to meet the standards, while Branco Aldan maintained significantly superior mechanical performance. In salt crystallization, Branco Aldan outperformed Granito Itaúnas in terms of durability. It is concluded that the artificial stone surpassed the natural stone in both mechanical performance and durability. This phenomenon occurred due to the higher porosity of the natural stone, the main factor responsible for the deterioration and decrease in durability of stones.
Technical Session
9/3/24, 3:40 PM - 9/3/24, 4:30 PM
Presenter(s): GRAZIELE MEDEIROS COSME (uenf), Rômulo Leite Loiola (UENF), Felipe Perissé Duarte LopeZ (UENF), Noan Tonini Simonassi (UENF), SERGIO NEVES mONTEIRO (UENF)
Abstract:
Natural fibers, due to the need for increasingly greener products, have been widely used as a potential substitute for fibers of synthetic origin. These fibers, which were previously used, for the most part, for the production of handicrafts through the manufacture of ropes, baskets, hammocks, furniture, etc., today, in addition to these functionalities, are also widely used as reinforcing material in composites. polymeric matrix. An example of this are titanium vine fibers, which are increasingly being researched and have shown good mechanical properties in the manufacture of epoxy matrix composites. Therefore, Izod impact tests were carried out, both for the pure matrix and for the composites with a volume fraction of 50, 60 and 70% in accordance with the ASTM D256 standard. Where it was possible to observe a significant increase in its resistance of approximately 3 to 4 times compared to pure epoxy. These results were statistically validated using ANOVA and Tukey's test.
Technical Session
9/3/24, 3:40 PM - 9/3/24, 4:30 PM
Presenter(s): JAQUELINE MOREIRA DE OLIVEIRA (UNIVERSIDADE ESTADUAL NORTE FLUMINENSE)
Abstract:
Over the years and with industrial and population evolution, the study of materials reinforced with vegetable fibers has become essential and has become a highlight in research and in the possibilities of implementation in industry. The objective of this research is to study how the hybrid epoxy composite reinforced with açaí and chamotte behaves in the mechanical flexion test and compare the results with the flexion test with pure resin, to analyze the feasibility of using it as reinforcement. Therefore, six types of combinations of hybrid composite formulations incorporated into epoxy resin with a DGEBA/DETA system with a phr of 16 were prepared, being 5% açaí with 5% chamotte, 10% açaí and 5% chamotte, 15% açaí and 5% chamote, 5% açaí with 10% chamote, 10% açaí and 10% chamote, 5% açaí and 15% chamote. We used the ASTM D790 standard as support for the test, at a rate of 1mm/min.
Technical Session
9/3/24, 3:40 PM - 9/3/24, 4:30 PM
Presenter(s): José Alexandre Tostes Linhares Júnior (universidade estadual do norte fluminense darcy ribeiro - uenf), Iully da Silva Amaral Pereira (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO - UENF), Renan Dias Couto (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO - UENF), Elias Rocha Gonçalves Júnior (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO - UENF), Markssuel Teixeira Marvila (universidade federal de viçosa - ufv), afonso rangel garcez de azevedo (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO - UENF), Carlos Maurício Fontes Vieira (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO - UENF), Sérgio Neves Monteiro (instituto militar de engenharia - ime)
Abstract:
Geopolymeric mortars are being studied for application in civil construction. Its use requires some minimum workability parameters and properties. The addition of lignocellulosic fibers can improve the shrinkage and resistance problems of some mortars, in addition to being environmentally friendly, however, given the super hydrophilic nature of the fibers, a large amount of free water is absorbed. This water is responsible for the plasticity of the mortars and is necessary for the proper application and homogenization of the mixtures. The absorption of part of this water can change the viscosity, making the mortars more viscous and can also reduce spreading when determining the consistency index. This work aimed to investigate the rheological property (viscosity) and the aforementioned fresh state, in order to determine the impact of adding lignocellulosic fibers from pineapple on the plasticity of the mixtures. Mixtures were prepared with 2% addition of fibers, and they were treated (mercerization) with 10% and 15% NaOH, so that the efficiency of the alkaline treatment in increasing hydrophobicity was investigated. Even with alkaline treatments at high concentrations, the high water absorption of the reinforcement led to a considerable reduction in plasticity, however the 15% hydroxide solution prevailed over the 10% solution.
Technical Session
DETERMINATION OF THE DENSITY OF CURAUÁ POLYMER COMPOSITES PRODUCED BY ADDITIVE MANUFACTURING
Presenter(s): José Carlos Ferreira Fontes (CENTRO UNIVERSITÁRIO AUGUSTO MOTTA), RAI FELIPE PEREIRA JUNIO (INSTITUTO MILITAR DE ENGENHARIA), Lucas de Mendonça Neuba (INSTITUTO MILITAR DE ENGENHARIA), Daysiane da Silva Moreira (INSTITUTO MILITAR DE ENGENHARIA), LUCIO FABIO CASSIANO NASCIMENTO (INSTITUTO MILITAR DE ENGENHARIA), SERGIO NEVES MONTEIRO (INSTITUTO MILITAR DE ENGENHARIA)
Abstract:
The aim of this study is to analyze and determine the density of polymer composites reinforced with lignocellulosic curauá (Ananas erectifolius) plant fiber, produced by additive manufacturing. Three density measurement methods were used: theoretical, experimental, and the Archimedes method. The research compared the results from these methods to evaluate the consistency and accuracy of the measurements. It was observed that the experimental density and the density obtained using the Archimedes method showed similar values, indicating the effectiveness of the experimental procedures. In contrast, the theoretical density exhibited significant differences, attributed to the presence of void volumes caused by the curauá fibers in the composite. These voids directly affect the final density of the material, highlighting the importance of considering the internal structure of the composite when determining its properties. This study contributes to a better understanding of the characteristics of curauá composites, aiming to optimize their industrial and technological applications.
Technical Session
9/3/24, 3:40 PM - 9/3/24, 4:30 PM
Presenter(s): GUILHERME DE SOUZA REIS (UENF - UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO), Elaine aparecida santos carvalho (uenf - Universidade estadual do norte fluminense darcy ribeiro), djalma souza (UENF - UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO), mayara tito campos (UENF - UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO), HENRY ALONSO COLORADO LOPERA (udea - Universidad de antioquia), CARLOS MAURÍCIO FONTES VIEIRA (UENF - UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO), GUILHERME DE SOUZA REIS (UENF - UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO)
Abstract:
The use of natural fique fiber as reinforcement for engineering materials is an alternative to conventional synthetic fibers, aiming at economic and sustainability aspects. The study aims to characterize various mechanical and physical aspects of fique fiber, including density, water absorption, average diameter, tensile strength, composition, interaction with epoxy polymer matrix, thermal decomposition, and microstructure. The results showed a water absorption of 147.05 ± 0.12%, tensile strength of 212.12 ± 130.23 MPa, density of 0.45 ± 0.03 g/cm3, indicating a material that is low in density yet highly resistant.
Technical Session
9/3/24, 3:40 PM - 9/3/24, 4:30 PM
Presenter(s): Marcelo Barcellos Reis (UENF - ALBERTO LAMEG), ELAINE APARECIDA SANTOS CARVALHO (Universidade Estadual do Norte Fluminense Darcy Ribeiro-UENF), RAQUEL AMENDRO FARIA (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO-UENF), AFONSO RANGEL GARCEZ AZEVEDO (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO-UENF), CARLOS MAURÍCIO FONTES VIEIRA (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO-UENF), HENRY ALONSO COLORADO LOPERA (Universidad de Antioquia)
Abstract:
Artificial stones are building materials developed with aggregates of stony waste and a polymer resin as agglomerate. Its mechanical properties, in general, outweigh the properties of ornamental stones. The generation of waste is a significant problem in the ornamental stone industry at all stages of production, and the reuse of this waste is an advantage. The main objective of this work is to develop an artificial stone based on black granite residue are Gabriel and isophthalic polyester resin and evaluate its properties. The plates were produced through vacuum, compression and vibration with 85% of residue and 15% of resin, in mass, in the statistically determined proportions (1,8,9 and 10). The 3-point bending test determined that compositions #8 (11.86 4.07 MPa); #9 (18.29 3.09 MPa) and #10 (28.28 3.54 MPa) can be considered as coating. But only the composition #10, got result that considers a high quality coating.
Technical Session
BENDING RESISTANCE OF POLYURETHANE COMPOSITES REINFORCED WITH BAMBOO FIBER IN DIFFERENT PROPORTIONS
Presenter(s): mariana dias machado lopes (UENF), Alexandre Augusto Maciel Rangel Meireles (UENF), noan tonini simonassi (UENF), FELIPE PERISSE DUARTE LOPES (UENF), SERGIO NEVES MONTEIRO (UENF)
Abstract:
Composites reinforced by natural fibers have been researched and used for decades due to a series of advantageous characteristics, such as good mechanical properties, low production cost, low density, which leads to a low weight final product. In this article, a comprehensive analysis is presented on the flexural resistance of polyurethane composites reinforced with bamboo fibers in different proportions. Within the scope of this study, polyurethane composites with 60, 70, 80, and 90% bamboo fibers were produced, and their flexural strength was then evaluated through a 3-point test. The results indicated a considerable influence of the proportion of bamboo fibers used, with a substantial increase in the rupture modulus of the samples from 60% to 90% in volume of incorporated bamboo fiber, from 73,61 MPa to 142.40 MPa respectively, demonstrating a general trend of increasing strength as the fiber content increased. This research provides valuable insights for the enhancement of polyurethane composites in applications requiring high flexural strength.
Technical Session
9/3/24, 3:40 PM - 9/3/24, 4:30 PM
Presenter(s): NIANDER aguiar cerqueira (UENF - ALBERTO LAMEG), Esthevão Vieira Cesar da Silva (UENF), Luísa Azeredo Ferreira Barreto (IFF / UENF), Sabrina de Fátima da Silva (ISECENSA / UENF), Isabella Martins Feres de Souza (UENF), Josué Coutinho Gonçalves dos Santos (UENF), Thomás Nascimento Perez (UENF)
Abstract:
THE CONSTRUCTION INDUSTRY IS TODAY ONE OF THE BIGGEST CONTRIBUTORS TO ENVIRONMENTAL DEGRADATION. THIS PROBLEM OF INADEQUATE USE OF NATURAL RESOURCES REQUIRES MORE SUSTAINABLE ALTERNATIVES THAT MINIMIZE THEIR NEGATIVE IMPACT. CEMENTITIOUS MATERIALS SUCH AS MORTAR, PASTES AND SOIL-CEMENT BRICKS CAN INCORPORATE WASTE INTO THEIR COMPOSITION, MAKING THEM HIGHLY SOUGHT AFTER OPTIONS FOR WASTE REUSE. THIS WORK PRESENTS RESULTS OF GRANULOMETRY TESTS, ATTERBERG LIMITS, REAL GRAIN DENSITY AND CHEMICAL ANALYSIS, THROUGH WHICH THE OBJECTIVE WAS TO EVALUATE THE POSSIBILITY OF USING CONSTRUCTION WASTE (RCC) IN THE MANUFACTURE OF CEMENTITIOUS MATERIALS. THE WASTE WAS PROCESSED AND CHARACTERIZED AT THE UENF CIVIL ENGINEERING LABORATORY. ACCORDING TO THE RESULTS OF TESTS CARRIED OUT, THE POSSIBILITY OF INCORPORATION INTO CEMENTITIOUS MATERIALS WAS VERIFIED, AS A PARTIAL REPLACEMENT FOR SAND (MORTARS AND PASTES) AND AS A MATERIAL TO CORRECT THE GRANULOMETRY IN SOIL-CEMENT BRICKS.
Technical Session
INFLUENCE OF ELECTROSTATIC PAINTING ON THE SHEAR STRENGTH OF THE CEMENTED NICR TO RESIN USED IN DENTAL PROSTHESES
Presenter(s): carlos nelson elias (Instituto militar de engenharia), marcos paulo de sousa lima (INSTITUTO MILITAR DE ENGENHARIA), Renata lima lorusso sampaio (Instituto Militar de Engenharia)
Abstract:
Metal-ceramic dental prostheses are made with NiCr alloy structure and need to be coated with opacifiers or ceramics to improve aesthetics. The manufacturing process requires professional experience and costs are high. The proposal of the present work is to develop a new methodology of dental prostheses coating to replace the conventional process of manufacturing. NiCr specimens were cast, coated with electrostatic painting with bactericidal epoxy paint and cemented to the resin used in dental prosthetics. The shear strength of the NiCr alloy bond cemented to the resin used in dental prosthetics was determined. The results showed that after electrostatic painting of the NiCr alloy, the shear resistance with the resin bond increases (13.89 MPa) in relation to the unpainted alloy (11.80 MPa). With aging, the bond strength increased (14.32 MPa). Electrostatic painting is viable for coating NiCr structures for applications in dental prosthetics.
Technical Session
THE DYNAMIC BEHAVIOR ANALYSIS OF POLYCARBONATE SUBJECTED TO ACCELERATED AGING
Presenter(s): Clarissa de Paula Dias (Instituto militar de engenharia ), Ricardo pondé weber (Instituto militar de engenharia)
Abstract:
The objective of the present study is to analyze the dynamic behavior of polycarbonate (PC) subjected to ultraviolet radiation. For this purpose, the PC was divided into two groups, so that one of the groups was artificially accelerated aged with ultraviolet radiation for 400 hours, while the other group remained “as received” for comparison. Then, a dynamic test was conducted with the Hopkinson pressure bar and the quasi-static compression test. As results, it can be highlighted that PC exposure to 400 hours of ultraviolet radiation modifies its dynamic behavior, but it is not enough to change the mechanical behavior under a quasi-static deformation rate.
Technical Session
9/3/24, 3:40 PM - 9/3/24, 4:30 PM
Presenter(s): DIEMISON LIRA SANTA ROSA (UFPA), Verônica Scarpini Candido (ufpa), Marcos Vinicius da Silva Paula (ufpa)
Abstract:
This paper investigates the combination of silver nanoparticles (Ag-NPs) with nanoemulsions (NEs) to create colloidal nanofluids with antimicrobial potential. The Ag-NPs were successfully synthesized, displaying spherical morphology and stability over 60 days. Surface plasmon resonance band analysis (SPR) showed constant absorption around 421 nm, indicating good stability. Sedimentation was observed in some fluids, attributed to decreased electrostatic interactions. Efficient citrate ion adsorption on Ag-NPs prevented aggregation. The fluids exhibited minimal variations in viscosity, remaining stable compared to the NEs. The study demonstrated that the combination of Ag-NPs and NEs could develop promising antimicrobial fluids. The results suggest the need for optimization of proportions to enhance fluid stability and efficacy. This study contributes to new strategies against resistant microorganisms, highlighting the potential of nanotechnology
Technical Session
ANALYSIS OF THE INFLUENCE OF GEOMETRIC PARAMETERS ON THE MECHANICAL PROPERTIES OF SCAFFOLDS PRODUCED BY 3D PRINTING
Presenter(s): Edson Miranda soares (UFPA - Universidade federal do pará), Ana Beatriz das Neves Conceição (IFPA/UFPA), Miriane Alexandrino Pinheiro (ufpa - universidade federal do pará), damares da cruz barbosa nascimento (ufpa - universidade federal do pará), Alisson Clay Rios da Silva (UFPA - UNIVERSIDADE FEDERAL DO PARÁ), Verônica Scarpini Candido (ufpa - universidade federal do pará)
Abstract:
The study seeks to analyze the influence of geometric parameters on the mechanical properties of scaffolds manufactured by FDM. The samples were designed in the shape of a serpentine with interspersed layers, with a 90º rotation in the upper layer and with a spacing variation in the range of 0.5 mm – 2 mm between the walls of the serpentine. The mechanical compression test (ASTM D695-15) and analysis of variance (ANOVA) were performed to evaluate the differences between the groups. The results revealed that samples with a spacing of 0.5 mm showed better mechanical properties, obtaining a strength of 21.24 MPa with a modulus of 0.457 GPa; the sample with 1 mm spacing obtained 10.9 MPa of resistance and modulus of 0.326 GPa.
Technical Session
SYNTHESIS AND CHARACTERIZATION OF MEMBRANE OF CHITOSAN WITH COPAIBA OIL FOR POSSIBLE APPLICATION IN DRESSINGS
Presenter(s): Taiana de Sousa Matos (UNIVERSIDADE FEDERAL DO PARÁ), sheila barbosa paranhos (UNIVERSIDADE FEDERAL DO PARÁ), Alisson Clay Rios da Silva (UNIVERSIDADE FEDERAL DO PARÁ), sérgio neves monteiro (INSTITUTO MILITAR DE ENGENHARIA ), Verônica Scarpini Candido (UNIVERSIDADE FEDERAL DO PARÁ)
Abstract:
Chitosan comprises polymeric macromolecules with healing, biocompatible and antimicrobial properties. These properties can be reinforced by the combination of chitosan with copaiba oleoresin, which has anti-inflammatory, healing, antifungal and calming properties. To this end, the present research aimed to produce and characterize chitosan films in proportions of 0.1%, 0.5%, 1.0% and 5.0%v/v using the casting method for possible application to wounds. Following to characterization by Fourier transform infrared spectroscopy (FTIR) and Differential Scanning Calorimetry (DSC). The chitosan and copaiba oil membranes developed showed new bands in FTIR while thermogravimetric analysis, by DSC, demonstrated stability of the synthesized membranes. Therefore, it is possible to infer that the results obtained through the methodology used were as expected as it revealed important data about this material.
Technical Session
ANALYSIS OF THE INFLUENCE OF ROUGHNESS PARAMETERS ON PAINT ADHESION
Presenter(s): Clara Campos de Alencar (Instituto Militar de Engenharia), Carlos Nelson Elias (INSTITUTO MILITAR DE ENGENHARIA), Renata Lima Lorusso Sampaio (IME), ANTONIO FABIANO COSTA DIAS FILHO (IME), AMANDA ALVES RAPOSO (IME), JOÃO PEDRO SEIBEL CERVO (IME), NATANAEL BISPO COELHO (IME), VITOR PINHEIRO DE JESUS (IME)
Abstract:
Surface roughness is one of the important parameters for achieving paint adhesion on metallic surfaces. This property refers to the surface morphology and directly influences the spread of the paint and the quality of the final finish. Adhesion is essential to ensure that the paint remains firmly attached to the surface over time, preventing flaking or detachment. Both properties are influenced by the proper choice of surface, the compatibility between the paint and the substrate, and the correct application of the paint according to the manufacturer’s recommendations. In the present work, the influence of roughness and wettability on the adhesion of paints on polished Ti G4 samples and after acid etching was analyzed. The results showed that the contact angle, measured by the goniometer, along with the roughness parameters Ra, Rz, Rp, Rv, and Rq, influence the adhesion of the paint.
Technical Session
ACADEMIC GUIDANCE IN REDUCING EVASION FROM MINING ENGINEERING
Presenter(s): Daniel Guilherme Gomes Zevallos (UFOP), Gabriel Romano Grossi (UFOP), Mariana Caroline Andrade Silva (UFOP), Elton Destro (ufop), Stephânia da Consolação Silva Nogueira (Ufop), Carlos alberto pereira (ufop)
Abstract:
Through the redefinition of the pedagogical project of academic guidance in mining engineering, this article presents a vision of how the integration and interactivity of a specific group of freshmen occurs, notably those from period 23.1, which aims to stimulate learning with aimed at reducing retention and the course dropout rate, a recurring theme in engineering courses in Brazil, given that the basic teaching cycle in these courses is very heavy, especially due to the learning deficiency they bring from high school and being a challenge to be constantly overcome.
Technical Session
AUTOMATION OF THE ELECTRICAL CONDUCTIVITY MEASUREMENT SYSTEM
Presenter(s): DAVI FIRMINO DE ASSUNÇÃO (INSTITUTO MILITAR DE ENGENHARIA), Catulo Axel Teixeira Vasconcelos Alves (INSTITUTO MILITAR DE ENGENHARIA), João Fonseca Vieira Barbosa (INSTITUTO MILITAR DE ENGENHARIA), Guilherme Caimi (INSTITUTO MILITAR DE ENGENHARIA), FRANCISCO LANERSON FARIAS DE SOUSA (INSTITUTO MILITAR DE ENGENHARIA), Henrique Ferreira (INSTITUTO MILITAR DE ENGENHARIA), Pedro Romero Rodrigues (INSTITUTO MILITAR DE ENGENHARIA), Julianna magalhaes Garcia (INSTITUTO MILITAR DE ENGENHARIA), Talita Gama de Sousa (INSTITUTO MILITAR DE ENGENHARIA), Luiz Paulo Mendonça Brandão (INSTITUTO MILITAR DE ENGENHARIA)
Abstract:
The measurement of the electrical conductivity of a material can be performed in different ways for different purposes, one of these ways is the four-point technique which, with the aid of a probe, is possible to map the electrical conductivity of a vast region with varied shapes and compositions. In order to automate this measurement process, the Automatic Electrical Conductivity Meter was developed, a mechanical and electrical structure capable of performing such measurements accurately. Such a device will be a novelty in the field of materials science and can be applied on several fronts that use this same method and want to obtain precise results.
Technical Session
9/3/24, 3:40 PM - 9/3/24, 4:30 PM
Presenter(s): DAVI FIRMINO DE ASSUNÇÃO (INSTITUTO MILITAR DE ENGENHARIA), Julianna magalhaes Garcia (INSTITUTO MILITAR DE ENGENHARIA), Talita Gama de Sousa (INSTITUTO MILITAR DE ENGENHARIA), Luiz Paulo Mendonça Brandão (INSTITUTO MILITAR DE ENGENHARIA)
Abstract:
The non-oriented grain electrical steels have wide application in the electrical industry due to their mechanical and magnetic properties. The study aims to analyze data on electrical conductivity through the four-point method in samples of GNO steel provided by APERAM company and relate them to the material's microstructure. What is observed is an increase in conductivity for steels with higher annealing temperature, a factor that alters the microscopic properties of the material, making the four-point method a viable method for analyzing this type of material.
Technical Session
MECHANICAL SIMULATION OF AN ECAP DIE
Presenter(s): DAVI FIRMINO DE ASSUNÇÃO (INSTITUTO MILITAR DE ENGENHARIA), Franciele Sembay (INSTITUTO MILITAR DE ENGENHARIA), Rodrigo Felix de Araujo Cardoso (centro brasileiro de pesquisas fisicas), Bruno rangel da silva (CENTRO BRASILEIRO DE PESQUISAS FISICAS), Julianna magalhaes Garcia (instituto militar de engenharia), Talita Gama de Sousa (instituto militar de engenharia), Luiz Paulo Mendonça Brandão (instituto militar de engenharia )
Abstract:
The Severe Plastic Deformation (SPD) technique by Equal Channel Angular Pressing (ECAP) is an effective methodology for producing materials with ultrafine grain structures, resulting in superior mechanical properties. In this work, the ECAP process of a copper specimen passing through an H13 steel die was investigated, analyzing the effects of different parameters, such as temperature and the number of passes, on the mechanical properties of the specimen and the die materials. The objectives of this research are to explore the principles and practical application of the ECAP process in producing materials with ultrafine grain structures and to evaluate how temperature and the number of passes affect the force required for the process.
Technical Session
9/3/24, 3:40 PM - 9/3/24, 4:30 PM
Presenter(s): Geovanna Confalone Salgado da Silva (UFF), Denis Fernandes do Nascimento (UFF), Nykolle Fabiane Camilo Fernandes (UFF), Tatiana das Chagas Almeida (UFF), Letícia Vitorazi (UFF)
Abstract:
Polyelectrolytes can be used to develop nanostructured layers via the layer-by-layer (LbL) technique, which involves the alternating deposition of cationic and anionic polyelectrolytes. Various substrates can be coated using LbL, and zeta potential measurements can be employed to characterize this process. This study synthesized silica nanoparticles using the Stober method and coated via LbL with polyethyleneimine (PEI) and bovine gelatin type B, employed as the polycation and polyanion, respectively. The LbL methodology involved adding the nanoparticles to aqueous solutions containing PEI, followed by washing, addition to a gelatin-containing solution, and further washing. The material was centrifuged at each step. Characterization of the nanoparticle was performed using dynamic light scattering to determine the hydrodynamic diameter and electrophoretic mobility for zeta potential determination. Before coating, the nanoparticle had a hydrodynamic diameter of 103.2 nm and a zeta potential of -49.2 mV. For the coated nanoparticle, the zeta potential changed according to the number of depositions, with the most significant variations observed for the initial layers. Thus, zeta potential measurements can serve as an indicator for characterizing the LbL process.
Technical Session
9/3/24, 3:40 PM - 9/3/24, 4:30 PM
Presenter(s): Isabella Meireles dos Santos (UFMG), Leonardo Mayer Reis (UFMG), Roberto Braga Figueiredo (UFMG)
Abstract:
The estimation of real deformation plays a key role on mechanical testing, specially in tensile testing where plastic instability takes place causing strain heterogeneity. Optical extensometry has been attracting attention in laboratories due to the increase in accuracy of modern equipment and its ability to determine heterogeneous deformation. The present work aims to develop an optical extensometry system with low cost equipment and free software. The procedure is validated by comparing the results with data from a conventional electronic extensometer. The results show it is possible to determine both the uniform and post-uniform strain with accuracy. It is also possible to determine the true stress-strain curve considering post-uniform strain data. A discussion on the possibility of using this technique in mechanical testing of miniature samples is presented.
Technical Session
Reproduction by Additive Manufacturing and Metrological Comparison Study of 3D Parts
Presenter(s): João Pedro Lima de Moraes (instituto militar de engenharia - ime), João vitor neves duarte (instituto militar de engenharia - ime), Felipe torres schowantz (instituto militar de engenharia - ime), carlos eduardo de castro damasceno (instituto militar de engenharia - ime), joão guilherme de farias martins (instituto militar de engenharia - ime), luís gustavo da costa dos santos (instituto militar de engenharia - ime), gabriel furtado de araújo (instituto militar de engenharia - ime), talita gama de souza (instituto militar de engenharia - ime), luiz paulo Mendonça brandão (instituto militar de engenharia - ime), marcos josé ferreira carvalho (instituto militar de engenharia - ime)
Abstract:
3D printing, a process of additive manufacturing, also known as rapid prototyping, is a technological innovation that has been increasingly implemented in large multinational corporations and factories. In this context, various softwares and devices can construct three-dimensional models of objects, with the possibility of being produced by adequate printers. However, there is rarely any research on the accuracy and fidelity of printing compared to the original artifact. Therefore, this study aims to perform a metrological analysis of 3D printing of an irregular piece, using a scanner and its program, employing ABS filament.
Technical Session
9/3/24, 3:40 PM - 9/3/24, 4:30 PM
Presenter(s): julianna magalhães garcia (IME - INSTITUTO MILITAR DE ENGENHARIA), Marvin do Nascimento (IME - INSTITUTO MILITAR DE ENGENHARIA), Andre Luiz Leal Bevictori (IME - INSTITUTO MILITAR DE ENGENHARIA), Talita Gama de Sousa (IME - INSTITUTO MILITAR DE ENGENHARIA), Luiz Paulo Mendonça Brandão (IME - INSTITUTO MILITAR DE ENGENHARIA)
Abstract:
The appropriate selection of materials is crucial for ensuring the effectiveness and longevity of components in extreme environments. This study focuses on 9Cr steel, enhanced with tungsten (W) and tantalum (Ta), to improve mechanical properties and corrosion resistance. The additions of W and Ta form stable carbides, such as M23C6 and TaC, which increase creep resistance and oxidation stability at high temperatures. Tensile tests at room temperature and 625°C, along with microstructural and fracture analyses, reveal that the modified 9Cr steel exhibits significant improvements in yield strength (σY) and ultimate tensile strength (σUTS) compared to commercial 9Cr steel. These enhancements are attributed to the fine dispersion of carbides that prevent dislocation movement, demonstrating the material suitability for high-temperature applications in power plants.
Technical Session
9/3/24, 3:40 PM - 9/3/24, 4:30 PM
Presenter(s): José Rômulo azeredo Gomes (Universidade estadual do norte fluminense darcy ribeiro (uenf)), Fabrício bagli siqueira (universidade cândido mendes (ucam)), lucas menezes de souza (universidade estadual do norte fluminense (uenf)), Muryllo Almeida da Silva (universidade cândido mendes (ucam)), elaine cristina pereira (universidade estadual do norte fluminense darcy ribeiro (uenf))
Abstract:
Corrosion is broadly defined as the deterioration of materials, the result of spontaneous processes that occur between the material and the environment. The phenomenon of browning is a natural and inevitable challenge. Carbon steel is widely used due to its diverse applications, many of which are based on its excellent mechanical properties. This metal has high ductility (ability to deform), high tenacity, is machinable, weldable and has a low production cost, but has reduced corrosion resistance, making it necessary to use processes to delay the corrosive mechanism, such as the use of inhibitors. Many of the inhibitors used are associated with high costs, environmental and human health risks, due to their toxic nature. Thus, the study of corrosion inhibitors from natural products is increasing, which are low cost and non-toxic. Natural products have stood out as promising sources of corrosion inhibitors, as they are formed through plant extracts or biodegradable materials, where many of these extracts contain compounds with antioxidant action. This present work aimed to investigate the behavior of the inhibitory action of papaya seeds, more specifically by adding proportions of these seeds in the preparation of the mixture for making packaging of metal parts made of AISI/SAE 1020 carbon steel in a chloride medium. of Sodium (NaCl) 1 mol L-1 in concentrations of 1 g L-¹ of seed powder. Mass loss tests were carried out, using as methodology the use of dried and crushed papaya seeds (inhibitor) in the manufacture of packaging used to package corrosion coupons, simulating metal parts, in a solution containing a scenario corrosive environment Sodium Chloride (NaCl). Immersion tests were carried out with carbon steel corrosion coupons packaged and unpackaged in recyclable paper in acidic NaCl solution for periods of 7, 14 and 21 days. The efficiency of using papaya seeds in the manufacture of packaging for metal parts was satisfactory up to a certain point, however, as a green type inhibitor in a neutral NaCl medium, it did not have the expected result, reaching a value maximum of 0.00%.
Technical Session
Corrosion of alloys for oil and gas pipelines
Presenter(s): Késia Simões ribeiro (IME), Gabriel reis da silva (ime), Eduardo perim de souza dias (ime), joao pedro bezerra oliveira (IME), luiz eduardo richardt de azevedo (ime), rafael santos sodre (ime), joão victor barbosa viegas (IME), CARLOS NELSON ELIAS (IME)
Abstract:
In the context of oil extraction, the use of pipelines is the primary method employed for transportation. Considering the different environmental conditions where these materials are extracted, such as temperature, pressure, and salinity, it is extremely necessary to study the alloys and materials that will be used in these environments to ensure they can withstand the required fluid quantities under certain stresses. Improper sizing of materials could cause not only financial losses but also environmental damage to a given ecosystem. From this, the objective of this article was to analyze the corrosion resistance of Inconel 625 alloy and 316L stainless steel in a 3.5% NaCl solution, through open circuit potential (OCP) and potentiodynamic polarization electrochemical tests. The results revealed a significantly superior corrosion resistance of the Inconel 625 alloy compared to 316L stainless steel. The latter demonstrated a higher susceptibility to corrosion, as evidenced by the formation of pitting corrosion.
Technical Session
COMPARATIVE ANALYSIS OF CORROSION RESISTANCE OF ALLOYS USED IN THE OIL AND GAS INDUSTRY
Presenter(s): Késia Simões ribeiro (Instituto militar de engenharia), Francielly Moura de Souza Soares (Instituto Militar de Engenharia - IME), Rafael de Almeida Vasconcelos (LFV Serviços), Tamara da Silva Tavares DOS REIS (Instituto Militar de Engenharia - IME), Patrick de Lima Gomes (Instituto Militar de Engenharia - IME), Carlos Nelson Elias (Instituto Militar de Engenharia - IME)
Abstract:
The Inconel 625 alloy, stainless steel 316L, and duplex stainless steel 2205 are widely employed in the petrochemical industry due to their high corrosion resistance and good mechanical properties. The corrosion resistance of these alloys is attributed to the formation of a passive oxide film, mainly Cr2O3. However, in aggressive environments containing chloride ions, such as marine environments, these alloys can undergo corrosion. Chloride ions compromise the integrity of the passive film, resulting in localized corrosion, known as pitting corrosion. This study aimed to evaluate the corrosion susceptibility of the mentioned three alloys in a corrosive environment simulating a marine environment (3.5% NaCl) at room temperature. Electrochemical tests and scanning electron microscopy (SEM) analyses were conducted to characterize the morphologies after the tests. The results indicated that both duplex stainless steel 2205 and Inconel 625 alloy exhibited significantly higher corrosion resistance than stainless steel 316L. The latter proved to be susceptible to pitting corrosion..
Technical Session
9/3/24, 3:40 PM - 9/3/24, 4:30 PM
Presenter(s): lucas menezes de souza (UENF), Camila Vasconcellos Fernandez (UENF), Elaine Cristina Pereira (UENF), Stephanie Carvalho Mendes Lopes (UENF)
Abstract:
AISI1065 carbon steel is a metallic alloy widely used in civil construction and as a component in the tensile reinforcement of flexible pipelines used by the offshore industry. In some circumstances, this steel requires repairs, using the welding process. Resistance welding is the most applied method for carbon steel, using electric current to generate heat to join discontinuities. This procedure can change the properties of the microstructure due to the increase in stress concentration, increasing the hardness in the weld region. Although it is a high tensile strength alloy, this steel is subject to degradation processes such as electrochemical corrosion, which reduces the material's resistance. In this work, a study was carried out on the corrosion resistance of AISI 1065 carbon steel after the resistance welding process. Resistance welding was carried out with a voltage of 2.5 V and a current of 10337 A on 10 steel test specimens divided into two groups of 5 samples. Then, the samples underwent heat tempering treatment. Subsequently, metallographic characterization of the metal was carried out to evaluate the microstructure. Corrosion tests were carried out on samples with and without welding in order to compare the impact of the corrosive medium of 3.5% NaCl. To analyze the mechanical properties, tensile, hardness and microhardness tests were carried out. It was found, after carrying out the tests, that welding is a factor that alters the mechanical properties of AISI 1065 carbon steel, causing the formation of pores that caused a reduction in the hardness of the welded joints.
Technical Session
9/3/24, 3:40 PM - 9/3/24, 4:30 PM
Presenter(s): STHEFANIE DE CARVALHO MENDES LOPES (universidade estadual do norte fluminense darcy ribeiro (uenf)), lucas menezes de souza (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO (UENF)), Anderson oliveira gadioli (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO (UENF) ), thiago barreto da silva amaral (Instituto Federal de Educação, Ciência e Tecnologia do Espírito Santo ), elaine cristina pereira (universidade estadual do norte fluminense darcy ribeiro (uenf))
Abstract:
The influence of the 1-butyl-3-methylimidazolium tetrafluoroborate ([BMIM]BF4) ionic liquid on the corrosion inhibition of the welded and heat-treated joint of UNS S31803 duplex stainless steel in a 1M sulfuric acid solution was investigated by electrochemical techniques. Surface morphology analysis was performed by Scanning Electron Microscopy (SEM), while the chemical composition of the surface film was evaluated by Energy Dispersive X-ray Spectroscopy (EDS), in order to verify the presence of the inhibitor on the steel surface. The obtained results demonstrated that [BMIM]BF4 acts as a mixed-type inhibitor with a predominant effect on anodic reactions. Addition of 2.5% inhibitor to the corrosive solution at room temperature was able to reduce corrosion of duplex stainless steel welded joint by 45.6%. Surface morphology analysis revealed a reduction in surface damage in the presence of the inhibitor, suggesting the formation of a protective film provided by the ionic liquid. Thus, it was concluded that 1-butyl-3-methylimidazolium tetrafluoroborate shows potential as a sustainable alternative for corrosion protection in acidic environments, promoting material integrity preservation and reducing costs associated with corrosion.
Technical Session
Effect of annealing temperature on the electrochemical behavior of commerci-ally pure titanium in artificial saliva solution containing fluoride ions
Presenter(s): Sthefanny Ferreira Santos Marcelino (universidade Federal de Ouro Preto), Maria Eduarda Fonseca (UNIVERSIDADE FEDERAL DE OURO PRETO), Bruna Luiza Silva do Carmo (Universidade Federal de Minas Gerais), Sofia da Cruz Souza (UNIVERSIDADE FEDERAL DE MINAS GERAIS), Anna Júlia Cassimiro Prado Mitre de Oliveira (UNIVERSIDADE FEDERAL DE MINAS GERAIS), Dagoberto Brandão Santos (UNIVERSIDADE FEDERAL DE MINAS GERAIS), Dalila chaves sicupira (universidade federal de ouro preto), Victor Cardoso Campidelli (UFOP)
Abstract:
Titanium is a metal known for its strength and lightness, especially when used in aggressive environments. Its ability to naturally develop an oxide layer makes it ideal for applications in the chemical industry, as well as in biomedical and dental procedu-res, where durability and resistance are essential. However, when subjected to ther-momechanical treatments, it may have its natural protective properties affected, thus impacting its corrosion resistance. In this study, the samples were cold rolled up to 66% reduction and annealed for 30 minutes at temperatures of 400, 500, 600, 700, 800, and 900°C. Mechanical properties were quantified based on Vickers micro-hardness. Additionally, X-ray diffraction (XRD) and scanning electron microscopy (SEM) techniques were used for the determination. Finally, the samples were subjec-ted to electrochemical tests to evaluate corrosion resistance before and after the thermomechanical treatment.
Technical Session
9/3/24, 3:40 PM - 9/3/24, 4:30 PM
Presenter(s): TAMARA DA SILVA TAVARES (IME - INSTITUTO MILI), Roberta Gaidzinski (Universidade do Estado do Rio de Janeiro), Neyda de La Caridad Om Tapanes (UNIVERSIDADE DO ESTADO DO RIO DE JANEIRO), Ana Isabel de Carvalho Santana (UNIVERSIDADE DO ESTADO DO RIO DE JANEIRO), Francielly Moura de Souza (Instituto Militar de Engenharia), Késia Simões Ribeiro (Instituto Militar de Engenharia), Carlos Nelson Elias (Instituto Militar de Engenharia)
Abstract:
Several studies are being conducted to reduce greenhouse gas emissions and develop alternative energy sources using less polluting fuels such as biodiesel. Biodiesel is a renewable fuel generally obtained from the transesterification reaction of oleaginous raw materials and alcohol in the presence of a catalyst. According to Brazilian law, since 2005, there has been an increase in the minimum percentage of mandatory addition of biodiesel to diesel in Brazil. Compared to diesel, biodiesel absorbs more water, facilitating the development of bacteria and microbial corrosion of metal engine parts. Furthermore, oxidation processes degrade biodiesel. Biodiesel degradation products can compromise fuel tanks, pumping systems, engines, and other components. Diesel engine materials must have biofuel compatibility, mechanical properties, and corrosion resistance. This work analyzes the corrosion resistance of copper and aluminum alloys immersed in biodiesel. The results showed that copper alloys immersed in biodiesel have lower corrosion resistance than aluminum alloys. Based on literature data, it is possible to conclude that the oxide film on the surface of Cu alloys has a lower protective capacity than Al, biodiesel is more corrosive than diesel of mineral origin, metal ions released during corrosion in biofuel they catalyze oxidation reactions and degrade biodiesel.
Technical Session
9/3/24, 3:40 PM - 9/3/24, 4:30 PM
Presenter(s): Victor Cardoso campideli (universidade federal de ouro preto), Lóren Kelly de Paula Inácio (universidade federal de minas gerais), Raphael França Assumpção (UNIVERSIDADE FEDERAL DE MINAS GERAIS), Dagoberto Brandão Santos (universidade federal de ouro preto), DALILA CHAVES SICUPIRA (UNIVERSIDADE FEDERAL DE OURO PRETO)
Abstract:
Duplex stainless steel has a microstructure composed of approximately equal parts austenite and ferrite. This combination gives this material interesting property such as high mechanical strength and good corrosion resistance. To achieve these properties, the material undergoes rolling, followed by annealing heat treatment. The heat treatment can cause the formation of new phases or decomposition of constituents. This study aims to investigate the phenomenon of spinodal decomposition in samples of duplex steel 2304, in both as-supplied and rolled conditions, subjected to thermal aging at 500°C for 0.5 hours, 24 hours, and 48 hours to evaluate its influence on hardness and corrosion resistance, using microstructural analysis, electrochemistry, and Vickers hardness tests. The results showed that cold rolling led to the formation of a pancaked structure, with alternating bands of ferrite and austenite. Aging resulted in the formation of a structure with a mottled appearance characteristic of spinodal decomposition. The samples exhibited a trend of increased hardness with longer aging times and degree of sensitization, and all samples showed resistance to pitting corrosion in borate solution
Technical Session
9/3/24, 3:40 PM - 9/3/24, 4:30 PM
Presenter(s): julianna magalhães garcia (IME - INSTITUTO MILITAR DE ENGENHARIA), Ivi Costa Rocha dos Santos (IME - INSTITUTO MILITAR DE ENGENHARIA), Marvin do Nascimento (IME - INSTITUTO MILITAR DE ENGENHARIA), Victor Talarico Leal Vieira (IME - INSTITUTO MILITAR DE ENGENHARIA), Carlos Nelson Elias (IME - INSTITUTO MILITAR DE ENGENHARIA)
Abstract:
NiTi alloys used to manufacture instruments for treating dental canals and orthodontics have superelasticity and a low modulus of elasticity. These alloys facilitate the treatment of root canals with pronounced curvature and the movement of teeth during orthodontic treatments. In the present work, the fatigue resistance of NiTi wires was determined. NiTi wires without and with grooves at 0°, 30°, 60°, and 90° in the length direction were subjected to fatigue tests simulating clinical use conditions. The results showed that wires with grooves at 30° have a shorter useful life. The fracture surfaces exhibited predominantly ductile characteristics with the formation of microcavities associated with fatigue tests. The results obtained are essential for understanding the behavior of NiTi instruments under fatigue. They guide clinicians in selecting and safely using instruments in clinical practice and serve as input for manufacturers to improve manufacturing.
Technical Session
A STUDY ON NB AND N ADDITION TO AISI 310 STEEL
Presenter(s): maria luiza wedderhoff brasileiro (instituto militar de engenharia), Julianna magalhaes Garcia (), Thaissa Sampaio Nunes (), Talita Gama de Sousa (), Luiz Paulo Mendonça Brandão (Instituto Militar de Engenharia - IME)
Abstract:
The development of new metallic alloys is closely tied to the introduction of additional alloying elements to existing steels. This study focuses on AISI 310 steel, specifically with the incorporation of nitrogen and niobium, resulting in a novel alloy referred to as 310 NbN steel. The research aimed to compare the mechanical properties of the new 310 NbN steel with those of the conventional 310 steel used in industry. Tensile tests, Vickers microhardness, and HRB hardness tests were conducted on samples of both steel types. The results provided insight into the changes in properties due to the addition of nitrogen and niobium, as well as the fracture mechanisms involved. Microstructural analysis of the tensile test fractures was performed using scanning electron microscopy. The findings revealed a significant increase in hardness and strength in the 310 NbN steel, while maintaining good ductility.
Technical Session
9/3/24, 3:40 PM - 9/3/24, 4:30 PM
Presenter(s): RAI FELIPE PEREIRA JUNIO (IME), Lucas de Mendonça Neuba (IME), Douglas Santos Silva (ime), Sergio Neves Monteiro (IME), LUCIO FABIO CASSIANO NASCIMENTO (IME)
Abstract:
Austenitic stainless steels, due to their chemical composition, mainly the presence of chromium, are more resistant to corrosion than conventional steel. That said, this article presents a study of the metallographic preparation of an austenitic stainless steel with unknown composition. To carry out the analyses, techniques (SEM, OM and Vickers hardness) were used. Through metallographic analysis, it was possible to identify visible differences between the martensite and austenite present in the microstructure of the material. Vickers microhardness tests showed differences in hardness between the material phases, with the austenitic matrix (163 HV) being less hard than martensite (359 HV). Indentations made at 500 gf showed a larger area, with a slight increase in the average hardness recorded (185.5 HV), and the increase was no longer significant due to the small fraction of martensite present in the analyzed area. The use of instrumental microhardness testing has proven to be an invaluable tool for measuring important mechanical properties, where the results obtained can generally be related to the properties obtained in classical tensile tests
Technical Session
9/3/24, 3:40 PM - 9/3/24, 4:30 PM
Presenter(s): CLERES FRADE JUNIOR (gerdau), felipe lana electo (UFOP - UNIVERSIDADE FEDERAL DE OURO PRETO), felipe elder santana (Autônomo), vagner becker (gerdau), Paulo Santos Assis (UFOP - UNIVERSIDADE FEDERAL DE OURO PRETO)
Abstract:
In continuous casting machines with open jet, an alternative to prevent steel reoxidation between the tundish and molds is the use of a gas protection system using inert gas to avoid atmospheric air contact with the steel. In this context, this study aims to investigate the effectiveness of gas sealing in steel cleanliness and its impact on product performance. The gas sealing to be studied consists of a metal cylinder fed by nitrogen gas. This investigation was conducted by analyzing billets produced in sealed and unsealed lines, and the effect of sealing on the results was discussed. The results were obtained through inclusion analysis based on the ASTM E45 standard, macro analysis on billet samples, and field performance during raw material processing in rolling and drawing. The study and experiments confirmed that the gas sealing system has no significant effect on the internal and surface quality of the billets.
Technical Session
COMPARISON BETWEEN NUMERICAL SIMULATION AND EXPERIMENTAL RESULTS OF PERMANENT MOLD CASTING ACCORDING TO ASTM B108
Presenter(s): Luís Fernando Folle (UFSM-CTISM), Tiago Nunes Lima (Senai Cimatec), Matheus Passos Sarmento Santos (Senai Cimatec), Bruna Callegari (Senai cimatec), Leonardo Oliveira Passos da Silva (senai cimatec), Rodrigo Santiago Coelho (Senai Cimatec)
Abstract:
Metal casting can be accompanied by the occurrence of defects such as micro- and macro-porosity, entrapped gas bubbles, contraction cavities, hot cracking, oxide biofilms and turbulent flow of liquid metal, defects inherent to this manufacturing process. However, there are finite element softwares that can predict these defects in the design stage of cast parts to help avoid them. The aim of this paper is to compare results obtained by two different finite element softwares – ProCast (ESI Group) and Inspire Cast (Altair) – with each other and with experimental A356 aluminum casting results with focus on the main casting defects using a standardized permanent mold. Both softwares are extensively used in the industry with the purpose of producing defect-free cast parts. Results indicate that both softwares provide similar results with respect to casting defects, in accordance with experimental observations, but solidification time varied considerably, especially when ProCast was used.
Technical Session
9/3/24, 3:40 PM - 9/3/24, 4:30 PM
Presenter(s): Raquel da fonseca tiago (Gerdau Barão de Cocais )
Abstract:
The phosphorus (P) content of pig iron from the Gerdau Barão de Cocais has been increasing in recent years, due to the rise of this element present in the iron ores used in the BF´s. With the higher initial P content, it becomes more difficult to achieve the desired final % P of the blowing process, making it necessary to practice reblowing and/or double slagging for P, and also the failure to achieve the final %P may result in steel reclassification and/or scrapping. These factors negatively affect the steelworks' performance, thus necessitating a study of the use of alternative materials that can contribute to the desphosphorization process. This work aims to show the results of the use of melt shop sludge briquettes to increase phosphorus partition (Lp).For the study, Lp was analyzed and compared in two periods: without the use of briquettes and with the use of briquettes. With the use of briquetes we acchieve a statistically significant increase of 8% in Lp. Based on the results obtained, the product was approved for use.
Technical Session
9/3/24, 3:40 PM - 9/3/24, 4:30 PM
Presenter(s): Victor silva bollo bandeira (Departamento de Engenharia Metalúrgica e de Materiais - Instituto Federal do Espirito Santo - IFES), Estefano aparecido vieira (Departamento de Engenharia Metalúrgica e de Materiais - Instituto Federal do Espirito Santo - IFES)
Abstract:
Inclusions are undesirable contaminants for the steel industry and are a consequence of the numerous chemical and thermodynamic reactions present in its processes, which makes it essential to have refined production control. Using ANSYS® simulation software, 6 submerged valve configurations were made, based on their projection angle and depth inside the mold. The angles evaluated were -11.4º and -13º at depths of 150mm, 200mm and 250mm. In addition, contour parameters and thermodynamic and physical properties of liquid steels were also added, as well as varying the fluid velocity in order to analyze its behavior in the meniscus region. Of all the configurations, only the valve with a -13º outlet at a depth of 250 mm showed a velocity profile outside the range considered ideal by the literature, between 0.2 m/s and 0.4 m/s. Speeds below the lower limit can cause the meniscus to freeze. Speeds above 0.4 m/s can cause slag/flux powder to be dragged, generating inclusions. The results show that the geometric modifications and the arrangement of the submerged valve inside the casting mold influence the flow of liquid steel in the meniscus region. The results show that there are conditions that favor the removal of inclusions and prevent the formation of new ones.
Technical Session
9/3/24, 3:40 PM - 9/3/24, 4:30 PM
Presenter(s): HELLEN KARINA PEREIRA ALKIMIM (Instituto Militar De Engenharia (IME)), Rhayana AYAMY Yamaguchi GOMES da Costa (Instituto Militar De Engenharia (IME)), Magno Torres Carvalho (Instituto Militar De Engenharia (IME)), WELLINGTON BRUNO SILVA DE JESUS (Instituto Militar De Engenharia (IME)), José Brant de Campos (Universidade do Estado do Rio de Janeiro (UERJ)), Eduardo de Sousa Lima (Instituto Militar De Engenharia (IME))
Abstract:
Magnesium is the lightest of all engineering metals and is therefore an attractive alternative. Corrosion of Mg and its alloys continues to be a major technological problem that impedes the wider use of such alloys. To overcome this problem, scholars are trying to produce magnesium (Mg) alloys that are more resistant to a variety of loads and environmental conditions. In this sense, Mg alloys include well-known elements and their quantity directly affects the properties of the final products. In the present paper, the authors attempted to present a study of Al-Mn intermetallic particles in AM50A and AM60B alloys, as it has long been believed that the addition of Al and Mn can improve the corrosion resistance of Mg alloys.
Technical Session
INFLUENCE OF PHOSPHATE CAPACITY, PHOSPHORUS PARTITION AND SLAG PROPERTIES ON STEEL DEPHOSPHORIZATION EFFICIENCY IN EAF
Presenter(s): DIEGO DARVY MOREIRA (grupo simec), José roberto de oliveira (ifes), Vinicios Andreata (PROPEmM - ifes)
Abstract:
The present paper aims to study, using industrial data, the influence of phosphate capacity (Cp), phosphorus partition (Lp) and slag properties on the EAF dephosphorization process. Different industrial heats with different slag compositions were analyzed. The aforementioned slag properties and phases were determined by computational thermodynamics using FactSage 8.0 software. In this study, the classical thermodynamic models were used to evaluate the dephosphorization efficiency with the same industrial data. Although these expressions, deduced from equilibrium data, generally do not correlate well with industrial data. The Dephosphorization Factor (FDeP) parameter, which measures the efficiency of a slag based on its properties, was used together with the phosphate capacity and phosphorus partition to compare which industrial slag is best for dephosphorization. It was found that FDeP has a high correlation with dephosphorization efficiency, unlike thermodynamic models, therefore, it can be used to predict which industrial slag will be more efficient and also support the technical team in proposing improvements to the production process.
Lecture
9/3/24, 4:30 PM - 9/3/24, 5:30 PM
Presenter(s):
Abstract:
Leaders Forum
9/3/24, 5:30 PM - 9/3/24, 7:30 PM
Presenter(s): Coordinator: Vânia Lúcia de Lima Andrade; Consultant; Member of the ABM Board of Directors Moderator: Albano Chagas Vieira; Consultor ; Member of the ABM Board of Directors
Abstract:
Technical Session
MINING METHOD SELECTION DURING CONCEPTUAL STUDIES
Presenter(s): FERNANDO ALVES CANTINI CARDOZO (UNIVERSIDADE FEDERAL DO RIO GRANDE DO SU), Higor José Silva Campos (UFRGS), Carlos Otávio Petter (UFRGS), Vinícius Matheus Lenz (UFRGS)
Abstract:
Select the appropriate mining method is one of the main challenges faced in conceptual mining projects. This decision has a significant impact on the economic viability, operational efficiency, and environmental sustainability of the project. This paper aims to present techniques and methodology for choosing the optimal mining method for conceptual mining projects. Different aspects to be considered are covered, such as the geological characteristics of the mineral deposit, economic aspects, environmental and operational constraints, among others. The main methodologies for selecting the optimal mining method are presented. Traditional selection methods, such as those proposed by Nicholas (1981) and Nicholas (1992), as well as the University of British Columbia (UBC) method and the Shahriar and Bakhtavar (Sh&B) method, are discussed.
Technical Session
9/4/24, 8:10 AM - 9/4/24, 8:35 AM
Presenter(s): Dabin Wang (cisdi), Kun Hu (cisdi), Chunyan Shi (cisdi), Ke Xu (cisdi)
Abstract:
Gas production and consumption prediction and scheduling is the key to gas optimization in iron and steel plants, which is of great significance to improve the stability of gas system and reduce gas flare. Firstly, the characteristics of gas production and consumption are analyzed according to the process characteristics of each iron and steel production process. Based on the results of the analyses, the dynamic characteristics of gas production and consumption in the ironmaking, steelmaking and steel rolling processes are classified. Then, the dynamic prediction of gas consumption is carried out by combining process mechanism and machine learning. Based on the results of gas production and consumption prediction, and taking into account the interaction between gas, steam and power generation, construct a gas optimization scheduling model to improve the overall gas utilization efficiency. The model has also been applied to the production process of iron and steel plants, and the application results show that the model can effectively improve the stability of the gas system and reduce the gas flare.
Technical Session
NOVEL MACHINE VISION AI SOLUTIONS FOR HIGH TEMPERATURE PROCESS CONTROL
Presenter(s): Hannu suopajärvi (Sapotech OY), Saku Kaukonen (Sapotech Oy), Eemil Kiviahde (Sapotech Oy)
Abstract:
Industry 4.0 concepts and technologies are widely introduced in the metal production sector. Approaches such as cloud computing, system integration, Big Data, Digital Twinning among others are changing the way the production processes can be monitored and controlled. In this paper, a novel machine vision AI approach to manage and control high temperature metallurgical processes is presented. Based on the use of the latest imaging and illumination hardware and state-of-the-art AI-based image analysis models, the monitoring and control of the high temperature processes and products in steel and metal manufacturing is enabled. The paper describes the Sapotech platform-based approach, provides interesting examples of AI use in process monitoring and control and discusses the benefits of AI-approaches in relation to Industry 4.0 objectives.
Technical Session
9/4/24, 8:10 AM - 9/4/24, 8:35 AM
Presenter(s): Diego Alejandro Gutiérrez Orrego (Universidade Estadual do Norte Fluminense)
Abstract:
Currently, there is a growing interest in replacing ordinary Portland cement (OPC) due to its negative environmental impact during its manufacture. A feasible alternative is to partially replace it with metakaolin (MK), a pozzolanic material with a lower environmental impact compared to OPC. In addition, there is a search to incorporate ceramic waste as sustainable construction materials. This research evaluated the effect of adding 1% of a retarder (sugar) and a superplasticizer on the workability and unconfined compressive strength (UCS) of a cementitious system composed of OPC, MK, and chamote (red ceramic brick waste) as fine aggregate. The results demonstrated that the replacement of 25% of OPC with MK affected the consistency of the mixtures, both with and without additives, especially with the addition of sugar. The incorporation of sugar negatively influenced the development of compressive strength at 14 days of curing, possibly due to the low hydration rate of cementitious products. As for the addition of the superplasticizer, no significant difference in strength gain was observed compared to the mixture without additive.
Technical Session
IMPACTS CAUSED BY THE CLIMATE SYSTEM IN THE SUBSTATIONS OF THE CARAJÁS MINING COMPLEX
Presenter(s): marco túlio de oliveira maia (VALER CARAJAS)
Abstract:
This article aims to present the methodology adopted to minimize the impacts caused, in the year 2023, in the substations of the Power Plants of the Serra de Carajás Mineral Complex (Serra Norte) electrical system in the municipality of Parauapebas – PA, due to failures and deficiency in the operation of the air conditioning system - HVAC. The substation buildings are built in masonry or electrocenter, where the air conditioning system – HVAC is essential for the equipment, mainly frequency inverters and PLC’s, to function correctly without failures. Another factor that the air conditioning system - HVAC has an influence on is the comfort of operation and maintenance professionals when they are carrying out medium and long-term activities inside these buildings..
Technical Session
9/4/24, 8:10 AM - 9/4/24, 8:35 AM
Presenter(s): GERALDO LUCIO DE FARIA (Universidade Federal de Ouro Preto), DENILSON pereira melo (Universidade Federal de Ouro Preto), Paulo Sérgio Moreira (Universidade Federal de Ouro Preto), Alice Silva Gonçalves (Universidade Federal de Ouro Preto), Érica Linhares Reis (Universiade federal de ouro preto), Mariana Caroline Andrade Silva (Universidade Federal de ouro preto)
Abstract:
In last decades, the demand for low-density materials with great mechanical behavior has spurred research on metallic matrix composites (MMCs). Several materials have been studied as potential reinforcement particles in aluminum matrices. In this context, this study presents an inedited evaluation about the efficacy of different manufacturing methods aiming to incorporate spodumene (lithium aluminosilicate) as reinforcement in a composite material with an A356.0 aluminum alloy matrix. The evaluated processes were: (I) melting with electromagnetic stirring and cold reinforcement particle addition; (II) melting with electromagnetic stirring and hot reinforcement particle addition; (III) melting with electromagnetic stirring and hot reinforcement particle addition followed by mechanical stirring; (IV) semi-solid processing. Based on the obtained results, it was concluded that it is possible to manufacture a homogeneous and low-porosity metallic matrix composite reinforced with spodumene. The most promising evaluated method was the semi-solid processing.
Technical Session
Endless Hot Rolled Coil (eHRC) from Arvedi ESP – A New Standard in Rolled Materials
Presenter(s): CARLO PIEMONTE (primetals technologies Austria), JUERGEN SCHOLLER (PRIMETALS TECHNOLOGIES AUSTRIA), Andreas jungbauer (PRIMETALS TECHNOLOGIES AUSTRIA), Christoph Fellner (PRIMETALS TECHNOLOGIES AUSTRIA)
Abstract:
Since the development of rolling technology, steel flat products have traditionally been divided into two prominent groups: hot-rolled coils (HRC) and cold-rolled coils (CRC). After the invention of Arvedi Endless Strip Production (ESP) technology, featuring endless casting and rolling of hot-rolled coils, a new class of rolled coils emerged: the endless hot-rolled coils (eHRC). eHRC dramatically extends the domain of hot-rolled material into applications traditionally served only by cold-rolled products. This new set of hot-rolled coils offers significant economic savings in transformation costs, dramatically reducing both CAPEX—thanks to the unprecedented layout compactness of ESP plants—as well as OPEX—thanks to the lowest total energy consumption and the highest material yield among all thin slab casting and rolling technologies on the market. Due to the absence of any immediate fossil fuel consumption and the direct rolling of the cast slabs taking advantage of the original thermal energy of the liquid steel, Arvedi ESP also represents the standard in reducing greenhouse gas emissions in direct and indirect emissions. The peculiar thermal regime during casting and rolling, without long holding times at high temperatures, makes the Arvedi ESP process much less prone to hot shortness phenomena and, hence, more tolerant concerning the presence of tramp elements in liquid steel. This feature makes Arvedi ESP the perfect match for electric arc furnace-based meltshops using large quantities of scrap. Arvedi ESP pairs with scrap-based production without sacrificing the final product’s quality, thus boosting the principles of the circular economy. With Arvedi ESP, limited space requirements, best-in-class energy utilization, and reduced carbon footprint levels go hand in hand with superior coil quality for profitable and eco-friendly steelmaking.
Technical Session
Innovative Quench and Temper Line for bars
Presenter(s): Filippo De Santi (Danieli)
Abstract:
The latest trends in the premium automotive steel bar market are to comply with the highest quality standards requested by the End Users. The key role to reach these targets is given by heat treating technologies, directly related to the metallurgical and mechanical results to be performed. Danieli Olivotto Ferrè supplied a new heat treatment line for automotive bars in Turkey for Cemtas and already received a second order from another customer. The line is based on an innovative concept for the hardening and tempering of alloyed steel bars for automotive market having diameter from 15 to 100 mm with an overall yearly output up to 30,000 tons/year. The line is designed with a multiline solution to maximize production while maintaining all the advantages of treatment homogeneity and quality typically obtainable in a single bar heat treatment plant.
Technical Session
9/4/24, 8:10 AM - 9/4/24, 8:35 AM
Presenter(s): BRENO TOTTI MAIA (PRORAD), Leandro Miranda Nascimento (PRORAD), Leonardo Silva Motta (LINDE), Helio Gabriel de Souza (LINDE), Renata Mangini Santos (LINDE)
Abstract:
During steel production, it is necessary to deoxidize the metal bath and the slag in secondary refining, reducing the oxygen content in the steel to around 500 ppm, in order to enable the addition of alloying elements and the adjustment of the chemical composition. When the liquid steel is deoxidized, the FeO and MnO from the slag then becomes a major source of oxygen and for this reason must also be deoxidized. The literature shows that the practice of adding Calcium Carbide (CaC2) during converter casting and in the ladle furnace makes possible the optimization of the steel desulphurization, with an increase in the yield of alloys (FeSi, FeCr); improvement in the quality of the treated steel, which contains mostly small non-metallic inclusions, favoring later stages of casting and cold rolling. Operational factors such as the combination of frothy slag and homogenization of the ladle furnace run also reduce the %FeO and %MnO in the steel ladle slag, as well as reducing reoxidation, with a reduction in the level of MnS-type inclusions for these steels, due to the reduction in the final sulphur content
Technical Session
9/4/24, 8:10 AM - 9/4/24, 8:35 AM
Presenter(s): paula renée de macêdo costa bastos (arcelormittal pecém)
Abstract:
Continuous casting has relevant impacts in terms of productivity and cost in steel producing industries, which tends to be better when the work rate of the casting machine increases, through production scheduling of larger heat sequences. However, a limiting factor in this is the large number of different types of grades in production orders. One way to overcome this would be to generate intermix steel. This work deals with intermix in tundish for a two strands slab casting machine with the goal of predicting the amount of intermix zone steel that needs to be identified and scraped or downgrade after that procedure. The developed model proved to be simple to apply and effective in predicting the intermix length. A correction factor could be implemented in the model to adjust some delay to start the mix zone or to advance the end of the intermix, but the original modeling condition guarantee that the entire intermix length will be within the length predicted by the model. The validation of this model was carried out using slab samples in different lengths, during the operational practice of continuous casting machine at the ArcelorMittal Pecém
Technical Session
9/4/24, 8:10 AM - 9/4/24, 8:35 AM
Presenter(s): Pedro Do Amaral Caldas (TECNOSULFUR), Marcus novaes motta (tecnosulfur)
Abstract:
The desulfurization in an Electric Arc Furnace plant is usually a challenge, since the income of sulfur in the steel is mainly through the impurities in the scrap, like oils, paints, dirt, organic materials and others. So, it is hard to predict how much sulfur there is going to be in the steel, and since the environment in the EAF is not favorable for the removal of sulfur, almost all of it must be carried out on the secondary refining process, implying sometimes, in high tap-to-tap in ladle furnaces, high use of ferroalloys and fluxes, which can cause productivity problems, increased costs, excessive refractory wear and other issues. In this work we present a successful case of an improvement of desulfurization rates on the ladle furnace of a EAF plant, through addition of a specifically designed sintered synthetic slag on tapping. Combining a fine control of the chemical composition along with the characteristics of the sintered slag it was possible to obtain good results. With the aid of computational thermodynamics, it was possible to study and validate the experimental results along with the theoretical basis.
Technical Session
ENDURON® HPGR AND STM VPMMILLTM: ENERGY EFFICIENT WET COMMINUTION CIRCUIT FOR IRON ORE MINES
Presenter(s): Israel Aguiar leite (weir minerals), Renato Nunes Martiniano de Oliveira (Weir Minerals), Fisher Wang (STM Minerals)
Abstract:
Comminution stands as the most energy-intensive aspect of mining operations. In the context of iron ore mines, adopting HPGR followed by large-powered vertical stirred mills presents a viable process flowsheet alternative to improve overall comminution energy efficiency by eliminating the need for inefficient tumbling mills. To facilitate the design of such process plants, it is important to obtain reliable process parameters through piloting test work using large quantity of samples. This paper outlines a pilot test program conducted to assess the amenable and applicability of HPGRs and vertical stirred mills for an iron ore project. Additionally, it aims to determine the comminution energy required to achieve the final product specification as compared to the conventional flowsheet option.
Technical Session
OPTIMIZATION OF SPECIFIC FUEL CONSUMPTION OF THE ARCELORMITTAL PECÉM BLAST FURNACE
Presenter(s): LUCAS THE DE ARAUJO (ARCELORMITTAL PECÉM), Vitor Leão Sousa Bezerra (ARCELOR MITTAL PECÉM), Erik Alan de Arruda Vieira (ARCELOR MITTAL PECÉM), Leonardo Viana (ARCELOR MITTAL PECÉM), Estefan Campos Ribeiro (ARCELOR MITTAL PECÉM), Pedro Coutinho da Silveira Sousa (ARCELOR MITTAL PECÉM), Cícero Lucas Sobral Feitosa (ARCELOR MITTAL PECÉM), Rian Carlo Vieira Amaral (ARCELOR MITTAL PECÉM), Erivando Casemiro Duarte (ARCELOR MITTAL PECÉM), Eduardo Belo de Oliveira (ARCELOR MITTAL PECÉM)
Abstract:
Reducing fuel consumption, as well as increasing production, are performance guidelines for all steel plants in the world due to their impact on reducing costs, greater market competitiveness and reducing greenhouse gas emissions. The ArcelorMittal Pecém blast furnace achieved record fuel optimization results in 2023, both in coke and Fuel Rate due to improvements in the implemented methodologies that will contribute to a reduction of 45kg/t in Coke Rate, 10kg/t in Fuel Rate and 3% in relative CO2 emissions (tCO2/thm). This work objetive demonstrate the methodologies and initiatives implemented..
Technical Session
9/4/24, 8:10 AM - 9/4/24, 8:35 AM
Presenter(s): LUCAS DE FREITAS FIALHO (TECNORED)
Abstract:
The pig iron and steel industry is one of the most challenging fossil-dependent sectors to decarbonize due to its intensive energy use and large production volume, with the BF-BOF production route being predominant in the global production of these products. In this context, one of Brazil's significant differentiators is that approximately 25% of its pig iron production is carried out using charcoal as a reducing agent in small blast furnaces. This practice stands out globally for employing a 100% renewable reducer, with its atmospheric emissions considered biogenic. However, despite this advantage, a significant challenge has been the availability of charcoal on the market to meet production demands, especially in the North and Northeast regions of the country. This work aims to present the partial results of developing a carbonaceous briquette (thermal reducing briquette, or BTR) that allows for the partial replacement of charcoal in small blast furnaces with minimal impact on the process and product quality, thus enabling a potential increase in the production of low greenhouse gas emission pig iron in Brazil. When evaluating the physical results and reactivity to CO2, the BTR values are close to those of charcoal, indicating the potential of this briquette for the partial replacement of charcoal in charcoal-based blast furnaces.
Technical Session
9/4/24, 8:10 AM - 9/4/24, 8:35 AM
Presenter(s): DANIELLE RAIDAN DANIEL (VALE SA), Rodrigo boyer fernandes (vale), leticia steffane santos silva (vale), rossano augusto pilon nunes (vale), davi fernandes de carvalho (vale)
Abstract:
The process of firing or indurating of green pellets in pelletizing furnaces requires the consumption of liquid or gaseous fuels (normally mineral oil or natural gas) of fossil origin, contributing as a source of greenhouse gas (GHG) emissions, in addition to the high cost. In order to pledge the Decarbonization commitment with a focus on reducing direct CO2eq emissions from our operations, an initiative under development consists of applying fuel briquettes from biomass, such as eucalyptus charcoal, on the bed of green pellets in the pelletizing process, promoting a large release of heat inside the furnace and consequently, reducing the consumption of fossil fuel from the burners that are responsible for controlling the temperature of the process gases. In an industrial test carried out at a Vale S.A. pelletizing plant, it was observed that the fuel briquette reduced the flow of natural gas in the burning process, without compromising the quality of the iron ore pellet.
Technical Session
High-Intensity Magnetic Separation (WHIMS) in Almandine Garnet Concentration: Laboratory Tests with Minimag® Equipment from Gaustec Magnetic Technology
Presenter(s): Isabela de oliveira milagres (Gaustec tecnologia magnética), Geovani silva pinheiro (GAUSTEC TECNOLOGIA MAGNÉTICA), thamires borges dos santos silva (GAUSTEC TECNOLOGIA MAGNÉTICA), Claudio ribeiro (GAUSTEC TECNOLOGIA MAGNÉTICA), fernanda hoffmann (GAUSTEC TECNOLOGIA MAGNÉTICA)
Abstract:
This study aimed to evaluate the effectiveness of High-Intensity Wet Magnetic Separation (WHIMS) in concentrating almandine garnet from non-magnetic materials. Using the Minimag® equipment, tests were conducted on a pilot scale. The methodology involved adjustments to operational parameters and comparison of different matrix models. Analysis of mass and metallurgical recoveries indicated that increasing the wash water flow resulted in improper loading of the material of interest into the medium, compromising separation efficiency. Conversely, reducing this water flow proved to be a more effective approach. Comparison between matrix models highlighted the importance of proper equipment selection and operational configurations. It is concluded that WHIMS methodology, especially with the Minimag®, is a promising and effective approach for separating almandine garnet from non-magnetic materials, which were previously concentrated only by spirals.
Technical Session
MICROSTRUCTURAL CHARACTERIZATION AND VICKERS MICROHARDNESS EVALUATION OF AISI 4340 STEEL AFTER ANNEALING AND NORMALIZING HEAT TREATMENTS
Presenter(s): DEBORAH STOCKL MARTINS DA SIVA (INSTITUTO FEDERAL DO ESPÍRITO SANTO), CLAUDIO PATROCINIO JUNIOR (INSTITUTO FEDERAL DO ESPÍRITO SANTO), CLAUDIO PATROCINIO JUNIOR (INSTITUTO FEDERAL DO ESPÍRITO SANTO), ANDRÉ GUSTAVO DE SOUSA GALDINO (INSTITUTO FEDERAL DO ESPÍRITO SANTO), Armando Marques (INSTITUTO FEDERAL DO ESPÍRITO SANTO), VITOR RIBON DOS SANTOS (INSTITUTO FEDERAL DO ESPÍRITO SANTO)
Abstract:
The AISI 4340 steel is renowned for its hardenability, high chromium, nickel, and molybdenum content. Its excellent mechanical properties, such as high tensile strength, fracture resistance, and good toughness, make it highly desirable in industries such as aerospace and mechanical engineering. This study aims to assess the microstructural alterations and evaluate the Vickers microhardness of AISI 4340 steel when subjected to annealing and normalization heat treatments. Three samples were prepared for each analyzed condition, including annealing, normalization, and as-received. The samples underwent metallographic preparation for analysis of the heat treatment effects through optical microscopy, allowing for the identification of different phases formed within the material. Subsequently, Vickers microhardness evaluations were conducted, performing microhardness tests to analyze the data obtained through the mean value of each proposed treatment. Overall, the annealing heat treatment significantly reduces the microhardness compared to the samples in the "as-received" condition, which can be attributed to the slow cooling after the austenitization temperature, allowing for greater recrystallization. In the normalized condition, a lower hardness value is also observed compared to the untreated material, which is explained by the manner in which the treatment was conducted. Similar to the annealing treatment, normalization promotes greater homogenization and refinement of the structure, albeit with a faster cooling rate.
Technical Session
SMART LOCK: REMOTE MANAGEMENT SYSTEM FOR MAINTENANCE PROCEDURES USING TOKENS
Presenter(s): Jaquelini Kumm (Vale), Lorrainy Rembiski Delfino (ACT), Eduardo Cota (vale), Rodrigo Busatto Fernandes Moça (vale), Oscar Machado de Souza (act), Allan Lorenzoni Canal (act), Yargo Alves Sampaio (act), Marlon Charles Marques (vale), Fabiana Zambroni Neves (vale), Mauricio Moreira Poiane (vale), Edson Douglas Silva Cardoso (VALE), Danilo Trindade Costa (VALE)
Abstract:
The scenario under analysis was the object of study in a specific situation in a mining company, in which the blocking point and the maintenance point are distant, and the energy isolation device needs to be transported to the operators to control access to the energization of the equipment during maintenance. Transporting the device can consume hours of asset productivity due to inactivity waiting for maintenance. This article presents an experiment that aims to eliminate the transport of the isolation device to the operator and maintain the safety obtained in the current process. Smart Lock operates using a physical padlock, a mobile app and a means of communication, offline and remotely. The padlock is a hardware device that will receive the isolation device and through a means of communication, the maintenance operator, who will be in possession of the mobile app, and the energization room operator, who will have the padlock, will contact each other to perform blocking of the isolation device through a token exchange. After field tests, the effectiveness of using the device was verified, reducing the total locking, and unlocking time remotely to 10 minutes.
7º WRRS (World Round Robin Seminar)
9/4/24, 8:30 AM - 9/4/24, 5:10 PM
Presenter(s): Coordinator: André Luiz Vasconcellos da Costa e Silva; Full Professor at EEIMVR-UFF; Technical Director of IBQN
Abstract:
7º WRRS (World Round Robin Seminar)
9/4/24, 8:30 AM - 9/4/24, 5:10 PM
Presenter(s): Coordenador: André Luiz Vasconcellos da Costa e Silva; Professor Titular da EEIMVR-UFF; Diretor Técnico do IBQN
Abstract:
Technical Session
9/4/24, 8:35 AM - 9/4/24, 9:00 AM
Presenter(s): Higor José Silva Campós (universidade federal do rio grande do sul), Fernando alves cantini cardozo (Universidade federal do rio grande do sul), Carlos Otávio Petter (Universidade Federal do Rio Grande do Sul), vinicius matheus lenz (Universidade federal do rio grande do sul)
Abstract:
This paper presents the application of an app to assist in the selection process of mining methods based on four numerical and empirical methodologies. The developed tool aims to support the process of choosing the most appropriate mining method, especially in the initial phases of a mine project, considering the scarcity of data related to the geological characteristics of the mineral deposit. In this manner, the developed app seeks to complement the MAFMINE software by providing an intuitive interface and specific functionalities to simplify the mining method selection process. This paper describes the implementation of the app, highlighting its main features and functionalities, as well as the accuracy of the methodologies it comprises.
Technical Session
9/4/24, 8:35 AM - 9/4/24, 9:00 AM
Presenter(s): Xie Hao (cisdi), He Haixi (cisdi), Dou Xiaozhe (cisdi), Zhao Kuan (cisdi), Xiao Huiheng (cisdi)
Abstract:
Aiming at the problems brought by traditional ironmaking production mainly relying on experience, combined with big data technology, the Integrated management and control system of iron zone has been developed, which mainly includes the functions of iron district material data tracking, blast furnace visualization, cost optimization, precise control of the production process and quality, and analysis of iron district data, etc. The system has achieved remarkable results in early warning of changes in the production variation, promoting standardized operation of jobs, and stabilizing production, etc. It has been applied in many iron and steel enterprises and has achieved substantial benefits in terms of cost reduction and efficiency improvement.
Technical Session
9/4/24, 8:35 AM - 9/4/24, 9:00 AM
Presenter(s): alisson paulo de oliveira (NSIGMA CONSULTORIA EIRELI), Leonardo Sene de Lourenço (A10 Consulting - IN Group Now Vertical)
Abstract:
This work aimed at the predictive modeling, with Artificial Intelligence, of the mechanical properties of hot-rolled structural steel sections, produced in High Strength and Low Alloy steel, HSLA. The models were based on historical data of mechanical properties as well as the chemical composition of the heats and rolling process parameters. An Auto-Machine Learning (Auto-ML) platform was used. This tool is capable of simultaneously testing dozens of algorithms aiming for the lowest error. Simplified models were built based on database statistical analyses, and expanded models were developed using all available data. The models were developed to be metallurgically coherent with scientific trends, despite mathematical precision. The results aligned well with expected trends in most cases. It was possible to evaluate the isolated effect of the variables. The expanded models were able to generate predictions with lower statistical error. The variability of the data is an important factor for the success of predictive models. Such models allow the steel chemical composition design to be carried out with greater accuracy, lower production costs, and improved understanding of the effect of input variable. Data-Driven Decision-Making in production and R&D activities are enhanced with the use of predictive tools based on Artificial Intelligence.
Technical Session
9/4/24, 8:35 AM - 9/4/24, 9:00 AM
Presenter(s): José Alexandre Tostes Linhares Júnior (universidade estadual do norte fluminense darcy ribeiro - uenf), Iully da Silva Amaral Pereira (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO - UENF), Markssuel Teixeira Marvila (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO - UENF), Samuel Araujo Azevedo Malafaia (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO - UENF), Larissa Mendonça Osorio Fonseca (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO - UENF), afonso rangel garcez de azevedo (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO - UENF), Sérgio neves monteiro (instituto militar de engenharia - ime)
Abstract:
Population growth and the growing demand for ecologically friendly materials are driving research into alternative construction materials to conventional ones. Lignocellulosic fibers stand out for their mechanical and ecological properties, becoming potential reinforcements for fragile natural matrices, such as cementitious and alkali-activated materials. However, the great affinity with water leads these cellulosic materials to exhibit high water absorption, which can be harmful to the fiber/matrix interface. Given this context, this work aims to characterize lignocellulosic fibers extracted from pineapple leaves, an agricultural residue, regarding their crystallinity and wettability. Alkaline treatments were used in mass concentrations of 5%, 10% and 15%, to remove a fraction of the unwanted phases. Knowing these characteristics is essential so that the high water absorption of these materials does not harm their application in cementitious or alkali-activated matrices.
Technical Session
SEAWATER DESALINATION IN BRAZIL: TOWARDS SUSTAINABILITY IN A CONTEXT OF SCARCITY AND POPULATION GROWTH
Presenter(s): Bruno assis de lima (COPPE/UFRJ), Fabíola de Souza Freitas ((PPE)/COPPE/UFRJ ), Luiz Henrique R. da S. Sobrinho (COPPE/UFRJ )
Abstract:
The increasing demand for water in urban and industrial areas in arid and semi-arid coastal zones has driven the search for unconventional alternative water resources. Desalination plants are seen as the most viable solutions to the substantial water demand in arid regions, especially those with limited water resources. Many desalination methods, such as thermal and membrane technologies, are used in this process. Thermal desalination includes multi-stage flash desalination, multi-effect desalination, and vapor compression desalination. Brazil, a vast and diverse country, faces significant challenges in providing clean drinking water, especially in arid and semi-arid coastal regions. Population growth, rapid urbanization, and climate change are leading to an increasing demand for unconventional alternative water resources. Seawater desalination emerges as a viable solution to address this growing demand, with valuable lessons to be learned from the cases of EUA, China, Israel, Egypt and Australia. In Brazil, as in Israel and Egypt, the use of renewable energy sources, such as solar and wind power, could play a crucial role in making desalination more sustainable. The country has abundant natural resources to invest in clean and renewable energies, making this approach highly promising. Brazil also shares with Egypt the reality of having limited water resources, particularly in coastal and semi-arid regions, where desalination can be an effective solution. On the international stage, Israel stands out for its successful desalination model, largely driven by innovative approaches and the integration of desalination technologies with renewable energy sources, primarily solar. The country has significantly alleviated its water scarcity through a combination of desalination, efficient water management, and infrastructure investments. Egypt, on the other hand, faces challenges similar to those of Brazil, especially regarding the Nile River and climate change. The country has implemented large-scale projects to address its growing water demand, highlighting the importance of a strategic and sustainable approach to tackling these challenges. In Brazil, as in the cases of Israel and Egypt, seawater desalination can be a crucial part of a comprehensive strategy to ensure a secure and reliable water supply for future generations. Research and comparison of different desalination techniques, along with the integration of renewable energy sources, may be essential in shaping Brazil's water future. In a context of climate change and population growth, the pursuit of sustainable solutions is more important than ever.
Technical Session
BALLISTIC IMPACT RESPONSE OF COTTON-WOOD FIBER REINFORCED ICE COMPOSITE (PYKRETE)
Presenter(s): Kauã de souza almeida (instituto militar de engenharia), Lucas Fernandes Bernardino Dias (INSTITUTO MILITAR DE ENGENHARIA), IGOR FIUZA SOMBRA (INSTITUTO MILITAR DE ENGENHARIA), Antônio Henrique Rocha e Silva (INSTITUTO MILITAR DE ENGENHARIA), João Marcos Carvalho Aragão (INSTITUTO MILITAR DE ENGENHARIA), Lucas Mendes Santiago Filho (INSTITUTO MILITAR DE ENGENHARIA), Luiz Fernando Lessa Mineiro Albuquerqu (INSTITUTO MILITAR DE ENGENHARIA), André Ben-Hur da Silva Figueiredo (INSTITUTO MILITAR DE ENGENHARIA)
Abstract:
The experiment conducted by the group consisted of a ballistic test on Pykrete ice, a term referring to the mixture of regular ice with cotton and/or wood sawdust. The objective of the study was to analyze the resistance of Pykrete ice against projectile impact. The group used a pressure weapon to fire 45 mm projectiles perpendicularly at the flat surface of the Pykrete plates, determining the speed of the lead projectile before and after impact with the ice, comparing these results, and discussing the influence of cotton and sawdust on the resistance of the frozen water block. After analyzing the data, it was concluded that cotton performed better in reducing the projectile's speed compared to wood sawdust, resulting in a reduction of up to 35% in speed and 58% in kinetic energy.
Technical Session
9/4/24, 8:35 AM - 9/4/24, 9:00 AM
Presenter(s): Antonio Comelli and Matteo Bulfone (Danieli)
Abstract:
The Danieli Multiplate: a single facility that can produce wide-heavy plates, light discrete or coiled plate with yield strengths up to 1,800 MPa. A layout that can process both ingots and slabs, can make straight or cross-rolling, can roll in flat as well as Steckel mode. The plant configuration includes Danieli equipment for in-line quenching and a multipurpose leveler to cover the widest product portfolio to serve construction, energy, oil & gas, mining, earth moving and defense industry. The latest installation at Nucor Steel Brandenburg (KY) establishes a new benchmark in plate production worldwide for many years to come.
Technical Session
9/4/24, 8:35 AM - 9/4/24, 9:00 AM
Presenter(s): Giulio Antunes de Medeiros (csn)
Abstract:
The utilization of metal packaging, notably metal cans, in the food industry offers several advantages such as cost-effectiveness, durability, and resistance to contamination. This study investigates the influence of design features and steel sheet thickness on the axial and radial load resistance of steel containers. Through computational numerical modeling, five distinct designs were compared, revealing sensitivity to various design parameters. Design C and D exhibited superior axial resistance, while designs A, B, and E demonstrated enhanced radial resistance. The optimal design should strike a balance between both types of resistance, as observed in design E. Experimental validation of designs A and C corroborated the effectiveness of the numerical analysis. This research highlights the significance of design optimization in enhancing the mechanical performance of steel packaging, offering insights for improving product integrity and transportation safety in the food industry.
Technical Session
9/4/24, 8:35 AM - 9/4/24, 9:00 AM
Presenter(s): fabiano pachioni perez (TERNIUM)
Abstract:
The high competitiveness in the global Steel Market has forced companies to seek ways to reduce their production costs to remain viable in the market and maximize returns to shareholders. One of the ways to achieve this in a Steel Plant is by changing its metallic load, focusing on cheaper materials that have a good metallic yield, preferably waste and by-products from the Steel production process itself. The limitations for using these materials are the same as those found for all types of load in the Converter, mainly the thermal and sulfur balances, since we are dealing with materials available in large quantities and generated in volumes greater than the current consumption capacity. At Ternium Brasil these by-products are grouped and considered as a unique material in the Scrap Yard. Seeking to optimize their consumption, a detailed analysis of each scrap that made up the group selected for the study was necessary, treating the consumption of each of them as an independent material and changing the operation flow of the Scrap Yard that treated the entire group as a single material. The actions carried out enabled a 10% increase in the consumption of the by-products that makes up this scrap group, increasing the volume of recycled materials and reducing the cost of steel produced by 1.04 USD/t in runs in which the proposed solution can be applied.
Technical Session
Jindal Steel Odisha 7.2 Mtpy Double strand slab casters performances
Presenter(s): Gabriele paulon (danieli & c. officine meccaniche), paolo gasparini (DANIELI & C. OFFICINE MECCANICHE)
Abstract:
Casters conceived for producing value added steels for final applications including Automotive exposed panels, Structural members, Electrical and Pipeline grades. With latest design for casting speed up to 2.5m/min, equipped with advanced 3Q technological packages for automatic process control and Multi-Mode® Electro Magnetic Stirrer in the Mould for enhanced quality, the Danieli Casters in Jindal Steel represent the most advanced slab casters in India.
Technical Session
USE OF SINTERED SYNTHETIC SLAG OF CALCIUM ALUMINATE IN THE SECONDARY REFINING OF AN ELECTRIC STEELMAKING IN REPLACEMENT OF A SLAG BASED ON LIME AND FLUORITE
Presenter(s): rodrigo ribeirto da silva (tecnosulfur s/a)
Abstract:
Synthetic slags are used in the secondary refining of steels with the aim of favoring cleanliness by reducing the levels of inclusions, in addition to protecting the electric arc during treatment in the ladle furnace and contributing with MgO contents, necessary for the protection of the ladle’s refractory lining. Among the types of synthetic slags available, sintered synthetic slag stands out for achieving these objectives with a melting point suitable for its rapid dissolution and with low levels of hygroscopicity. In this scenario, fluorite is widely used to ensure low sulfur levels in steel due to its desulfurization capacity. However, this material has been presenting high levels of contaminants, with phosphorus being the main element. In this work, a study was carried out to replace fluorite with a sintered synthetic slag of calcium aluminate and MgO.
Technical Session
EVALUATION OF THE GRINDING EFFICIENCY OF VERTICAL MILL AS A FUNCTION OF LINER WEAR
Presenter(s): Henrique de Siqueira Queiroz (ANGLO AMERICAN MINERIO DE FERR)
Abstract:
The regrinding circuit of the Minas-Rio project is one of the largest in the world. The circuit was designed with 16 vertical mills of 1500 HP each to process 24.5 Mtpy of pellet feed. This circuit receives the concentrate from the processing plant and adjust the material for pipeline transport. The circuit is essential for the production system as it may cause production restrictions if don’t reach the granulometry specifications, which aimed integrity of the pipeline. There is also a plan to expand the circuit to 20 mills in the future in a possible expansion of flotation. This present study seeks to understand whether there are differences in grinding efficiency, by size range, throughout the liner wear of the helical shaft. Feed and product samples were taken from mills with different liner wear. The results show that the grinding efficiency of vertical mills is independent, in any size range, of the liner operating time of the equipment for the same equipment power draw.
Technical Session
9/4/24, 8:35 AM - 9/4/24, 9:00 AM
Presenter(s): douglas richter (thyssenkrupp uhde brasil)
Abstract:
Metallurgical coke (met coke) is a fundamental raw material used in producing steel. Nevertheless, global warming has provoked a review of the role of coke oven plants, as greenhouse gas (GHG) emissions can be in the range of 1.8-2.3 kg CO2/kg steel. Even so, in 2052 carbon capture technologies and raw material substitution will have equivalent participation to that of greener processes (15% each), whereas conventional processes will still correspond to 40% of global steel production. Because of that, studying substitute materials in met coke production has become increasingly important. A lot has been made in testing plastics, wood chips, sawdust, residual tar, oil waste, pulverized coal, charcoal, and others; from these, only plastics and tar have been tested successfully in industrial scale, with substitution rates around 1% w/w (dry basis). In Brazil, challenges in implementing these processes in industrial scale include lack of research funding, availability of raw materials, logistics, and materials handling. Aside from the mentioned materials, sugar cane residues (straw, molasses, and bagasse) could be used, as they are abundant and could mitigate logistics and availability issues while reducing Scope 2 emissions. Furthermore, gas treatment issues need to be studied from industrial trials. To do so, the addition of a briquetting or stamp charging facility should enable proper, homogenous blending of raw materials before being fed to the coke ovens, which could tackle the materials handling issue, and allow industrial-scale testing and operation to be carried out.
Technical Session
SELF-REDUCING MIXTURES FOR BLAST FURNACE’S USE
Presenter(s): Beatriz Fausta Gandra (USIMINAS), Gerson Evaristo de Paula Júnior (USIMINAS), Maurício Covcevich Bagatini (ufmg), Eduardo Osório (ufrgs)
Abstract:
Due to its high energy consumption, based on carbonaceous reductants, blast furnaces are facing a challenge for production with less environmental impact. The use of self-reducing agglomerates with ferrous burden is considered a sustainable alternative to reduce fuel consumption and to increase the blast furnace productivity. Self-reducing mixtures were evaluated concerning their reduction performance, phase quantification and mechanical behavior when agglomerated on a bench scale. Non-coking coal (CNC) and petroleum coke (CVP) were used as iron ore reducing agents and then, thermogravimetric tests were carried out with the reducing mixtures. The phases contents were identified by X-ray diffractometry and quantified via image analysis under an optical microscope. The Thermogravimetric tests indicated that the C:O molar ratio equal to 0.75 achieved the highest reacted fraction, in addition to the better CVP performance in comparison to the CNC. It was evidenced that iron ore reduction happens through the formation of two main phases, fayalite and wustite. In addition, it was observed that the metallic iron presented a more porous morphology when CNC was used. From the bench scale results, the CVP briquettes showed better behavior when compared to those with CNC.
Technical Session
VEGETABLE OIL IN PELLETIZATION
Presenter(s): LETICIA STEFFANE SANTOS SILVA (VALE SA)
Abstract:
The research focused on the development of industrial tests to replace mineral fuel oil and natural gas with vegetable oil in the Hot Gas Generator (GGQ) and pelletizing furnace at the São Luís Pelletizing Plant. The tests were carried out with oil from seed crushing and vegetable tar and indicate that the replacement has potential, although technical adjustments are necessary to optimize performance under different operating conditions.
Technical Session
9/4/24, 8:35 AM - 9/4/24, 9:00 AM
Presenter(s): Rafaela de Freitas Tavares (Gaustec tecnologia magnética ), MATEUS FILIPE DE AZEVEDO (GAUSTEC TECNOLOGIA MAGNÉTICA), Larissa Pinto Seiberti (GAUSTEC TENCOLOGIA MAGNÉTICA ), fERANDA hOFFMAN (GAUSTEC TECNOLOGIA MAGNÉTICA), cLAÚDIO RIBEIRO (GAUSTEC TECNOLOGIA MAGNÉTICA )
Abstract:
The present study aimed to evaluate the use of new technologies developed by Gaustec Magnetic Technology to optimize the magnetic concentration of iron ore from a mining company in the Iron Quadrangle. Rougher and cleaner tests were conducted using BigFLUX® matrices on a pilot-scale magnetic separator, the Minimag® model. In the rougher stage, eight tests were conducted exploring different matrix configurations and variations in the magnetic field. The results showed that the 2.5 mm and 3.8 mm matrices of the Mega BigFLUX® model provided a significant increase in iron content in the magnetic product, reaching up to 65.74%, compared to the matrix previously used by the company, which had the old (or common, 8R) configuration with a 2.5 mm gap, reaching only 55.9%. In the cleaner stage, tests with Mega BigFLUX® matrices also outperformed the results obtained with the old matrix, achieving iron contents in the final magnetic product of up to 66.8% and also higher mass and metal recoveries. Therefore, the new matrices demonstrated better efficiency in iron ore concentration, offering potential to increase production capacity and the quality of the final product.
Technical Session
PLASMA ASSISTED NITRIDING OF NODULAR CAST IRON FOR STAMPING DIE APPLICATIONS IN THE AUTOMOTIVE INDUSTRY
Presenter(s): Francisco Cavilha Neto (Labmat), bruno borges ramos (labmat - ufsc), nathan andrioni (labmat - ufsc), Diego berti salvaro (labmat - ufsc), Rodrigo Perito (labmat - ufsc), Aloisio nelmo klein (labmat - ufsc), cristiano binder (labmat - ufsc)
Abstract:
Automotive stamping dies, often manufactured from nodular cast iron, face significant wear challenges due to contact with abrasive materials and intensive mechanical forming processes. To mitigate wear, a variety of heat and thermochemical treatment processes are employed. Among these methods, plasma nitriding stands out for its ability to form hard iron nitrides layers on the surface of the stamping dies, increasing their wear resistance. This work aimed to analyze the influence of plasma nitriding parameters and surface finishing in the characteristics of the nitride layer on nodular cast iron. Temperatures of 525, 550 and 575 ºC and times of 2, 4, 8 and 16 h were studied. Different pre-treatment surface finishing, simulating the stamping die roughness, were analyzed with the aim of evaluating the final nitrided layer characteristics. The results showed that a temperature of 525 ºC and longer times produced thicker layers. Regarding the surface finishing, an increase in layer thickness was noted in the polished samples, compared to those grounded with 80 and 400 mesh sandpaper.
Technical Session
9/4/24, 8:35 AM - 9/4/24, 9:00 AM
Presenter(s): ZIRLENE ALVES DA (UNIVERSIDADE FEDERAL DE OURO PRETO), gabriel teixeira marins (UFOP), DELANO joão virgílio de souza (ufop)
Abstract:
Using new technologies or improving already consolidated in the productive sectors, and this challenging context for industries, this research presents a solution to raise of productivity, competitiveness and reduce costs. The present study brings out a test and analysis of the contribution of the Machine Wear program for predict wear in the tribological systems of two pumps of ore pulp in operation. The research methodology is qualitative, classified as descriptive, exploratory, bibliographic, experimental, and uses the action research technique. To carrier out the study, it was necessary to inspect and collect data. The Machine Learning program using the Python language proved to be an effective contribution to the analysis and prediction of tribological systems of the pumps, which has been the object of the study. Regarding maintenance management, the program has been testing in decision-making by the maintenance team of the field studied through monitoring and analysis of each operating parameter that has the conditions for identifying abnormal wear in the machines' systems, before unscheduled downtime occurs
Panel
9/4/24, 8:35 AM - 9/4/24, 10:15 AM
Presenter(s): Coordinator: Denise Veiga; ABAL Technical Manager Moderator: Heber Pires Otomar; Coordinator of ABAL's Technology, Innovation and Industry 4.0 Committee
Abstract:
Round Table
9/4/24, 8:35 AM - 9/4/24, 10:15 AM
Presenter(s): Coordinator and Moderator: Luiz Cláudio Pinto Oliveira - Consultant
Abstract:
Technical Session
TRENDS IN ACCESS AND TRANSPORTATION COSTS IN UNDERGROUND MINING
Presenter(s): FERNANDO ALVES CANTINI CARDOZO (UNIVERSIDADE FEDERAL DO RIO GRANDE DO SU), cARLOS OTÁVIO PETTER (UNIVERSIDADE FEDERAL DO RIO GRANDE DO SUL), João Paulo Zanette Oppermann (UFRGS), Upiragibe Vinícius Pinheiro (UFRGS)
Abstract:
Underground mining entails significant investments in accesses, such as ramps and shafts, impacting both initial investment (CAPEX) and operational costs (OPEX). Studies offer models to estimate these costs, considering depth and production rate. Operational transportation costs vary with production and depth, with different studies recommending ramps, shafts, or conveyor belts for economic efficiency. The share of transportation costs in total OPEX is relevant and influenced by the adopted strategy, with models estimating these costs considering depth and required support. In summary, access and transportation costs in underground mining are considerable, with the choice of method influenced by technical and economic factors. This article provides a review and evaluation of implementation and operational transportation costs in underground mines, indicating a trend of lower costs for shaft transportation with mine deepening. The evaluated studies also provide estimates of average costs to assist in initial project estimates.
Technical Session
MODERNIZING POWER CONVERTERS: DEVELOPMENT OF A PLUG&PLAY RETROFIT KIT
Presenter(s): eRIK DE SOUZA COUTO (Companhia Siderúrgica Nacional), ALEXSANDER SATLER ANDRADE SILVA (Companhia Siderúrgica Nacional), SILVIO DE CARVALHO SABENÇA (Companhia Siderúrgica Nacional), MATHEUS HENRIQUE BERNARDES ALVES MACHADO (Companhia Siderúrgica Nacional), ALISSON DE SOUZA SILVA (Companhia Siderúrgica Nacional), LEONARDO RABELLO DA SILVA THOME (Companhia Siderúrgica Nacional), LUIS EDUARDO SMECELATO MALDONADO (Companhia Siderúrgica Nacional)
Abstract:
The project aimed to technologically update the direct current converters at Companhia Siderurgica Nacional - Presidente Vargas Plant - Volta Redonda - RJ, in order to guarantee operational continuity and adapt to Industry 4.0. With the premise of reusing the entire power infrastructure while minimizing investment. The technological upgrade (Retrofit) replaced the analog systems with state-of-the-art digital controls, with a plug&play solution that significantly reduced the start-up period. This approach achieved an 80% lower investment compared to a total replacement, offering a notable improvement in operational efficiency, a reduction in maintenance costs, an increase in the reliability of the systems and greater sustainability by extending the useful life of the existing equipment. The project was developed in-house by CSN's Automation Technology Management (GTA), in collaboration with the Hot Rolling Mill Management (GLQ)
Technical Session
OPTIMIZATION OF CRUSHING OPERATIONS THROUGH ADVANCED PROCESS CONTROL: A CASE STUDY
Presenter(s): Franco Nicolas Berrios Nuñez (Honeywell Chile), Marco Andres Encina Manriquez (Honeywell Chile)
Abstract:
In this work, we present the control philosophy and results of the implementation of an integrated MPC strategy using Honeywell APC in a crushing circuit. The strategy is based on the development of unit APC Process Controller applications for each unit process and its coordination with a global optimizer using APC Multi-Unit Optimizer. Additionally, we have implemented a tripper car dynamic model in Python, which provides external knowledge of the future behavior of the tripper car, thereby improving predictions of controlled process variables. By acknowledging the multivariable nature of the plant, the APC solution can manage several objectives and constraints using the feeder speeds of the crushing and screening stages. The integrated APC solution has shown positive results for the plant, with an average product increase to agglomeration of 3.49% and a reduction in variability of 23.53%.
Technical Session
DETERMINATION OF FLEXURAL PROPERTIES IN EPOXY COMPOSITES OF MEDIUM AND HIGH THEORETICAL VOLUME FRACTIONS OF RAMIE WOVEN FABRIC FOR STRUCTURAL ANALYSIS IN WIND TURBINE TOWERS
Presenter(s): Marcelo Vitor Ferreira Machado (Instituto federal fluminense E UENF), Felipe Perissé Duarte Lopes (UENF), noan Tonini Simonassi (UENF), sergio neves monteiro (IME E UENF)
Abstract:
The mechanical characterization of epoxy matrix composites reinforced with medium and high volume fractions of ramie woven fabric by three-point bending tests is the objective of this study. From the tests, the modulus of elasticity, proportional limit and flexural strength have been determined, as well as the specific flexural strengths. Both intact and aged specimens by simulation of ultraviolet rays and condensation were used. Evidently, significant degradation of mechanical properties could be noted in the material exposed to the simulation and, consequently, there was a need to indicate the use of a protective coating on the material in order to avoid its degradation if a prototype of a horizontal axis wind turbine tower were to be manufactured with this multiphase material. Finally, prioritizing the measurements obtained with intact specimens, inferential analyzes revealed a condition of statistical equality for the averages of specimen elastic moduli for those with 40% and 50% reinforcement volume. There was a significant distinction between averages of flexural strength for the samples with 60% and 50% theoretical volume fraction of ramie woven fabric..
Energy Balances
9/4/24, 9:00 AM - 9/4/24, 9:25 AM
Presenter(s): Eder Quental de Araújo (Gerdau)
Abstract:
Technical Session
9/4/24, 9:00 AM - 9/4/24, 9:25 AM
Presenter(s): Rogério Rabello da Rocha Júnior (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO - UENF), Victor pais dias gonçalves (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO - UENF), NOAN TONINI SIMONASSI (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO - UENF), FELIPE PERISSÉ DUARTE LOPES (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO - UENF), SERGIO NEVES MONTEIRO (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO - UENF)
Abstract:
The growing global need for more ecologically sustainable materials is driven by the rapid increase in global warming. In this context, natural fibers play a crucial role in the development of high-performance engineering materials. This study explores the feasibility of using corn stalk particulate as a dispersed phase in eco-friendly polymer composites, manufactured through additive manufacturing (3D printing) by photopolymerization, intended for application in high-performance eyeglass frames. The corn stalk was subjected to grinding and sieving processes to obtain particles of a size suitable for mixing with the light-curing resin. The mixture was then used to print specimens using an Anycubic Photon Mono 2 4K 3D printer. The mechanical properties of the composites were assessed using tensile, flexural and Izod impact tests. The results obtained indicate that corn stalks in this granulometry cannot represent a promising alternative as reinforcement in composites produced by 3D printing by photopolymerization, with potential application in high-performance spectacle frames. In future work, a finer particle size will be tested.
Technical Session
MICROSIM® AND PHASTRANSIM® SIMULATIONS: METALLURGICAL PROPERTIES VARIABILITY (σ) REDUCTION FOR SAE1045 WIRE-RODS
Presenter(s): alisson paulo de oliveira (NSigma Consulting LTD), Beatriz Lopez (Ceit), Beatriz Pereda (Ceit), Marcelo Arantes Rebellato (Consultor)
Abstract:
The steel products are designed to meet specific quality requirements related to important metallurgical properties like tensile, yield strength, hardness, and toughness. The properties variability can be a challenging situation because the product can fail to meet the customers specifications. For the customer it can demand new processing equipment setup, it can cause production delays because process failures and performance differences according to the production batch. Variability in the steelmaking key variables (chemistries, segregation, temperatures, rolling, cooling), may result in variability of the microstructure, and metallurgical properties. The simulation of different process and alloy design scenarios can allow better understanding of the metallurgical phenomena related to the process and propose measures to minimize the variability, decreasing the scrapping risk during the R&D activities. MicroSim® and PhasTranSim®, both previously used only for rebars, were now used to simulate, and analyze the rolling process and alloy design for a hypothetic SAE1045 wire-rod in an innovative way: To predict how the properties variability behaves according to processing and alloy-design scenarios. This knowledge will allow simulations, helping the technical staff to define more accurate modifications in the alloy and process design, allowing reduced properties variability while approval according to the specifications is guaranteed.
Technical Session
9/4/24, 9:00 AM - 9/4/24, 9:25 AM
Presenter(s): FELIPE SANTOS MOREIRA (SMS GROUP METALURGIA DO BRASIL LTDA.)
Abstract:
Every rolling mill is always looking for ways to improve the safety in the operations, this is a matter which will never goes out of style. The same is for productivity, because of its direct impact on product costs. Imagine now that the both of them can be reached with just one small intervention at once, improving the operation cantilever stands, the name is EVOKit. This solution of SMS Group makes possible the remote gap adjustment of cantilever stands, eliminating the risks of people with hands on the machine. The modernization can be applied on stands of 6’’, 8’’ and 9’’ for V- Blocks, MeerDrive, and pre-finishing blocks with Horizontal and Vertical arrangement.
Technical Session
INFLUENCE OF FLUX ON THE HOT METAL DEPHOSPHORIZATION
Presenter(s): JOSE ROBERTO DE OLIVEIRA (INS FED DE EDUC CIENC E TEC DO ESPIRITO SANTO), Franklin de souza zottich (instituto federal do espírito santo), Débora zampiroli do nascimento (Instituto federal do espírito santo), Daniel Rodrigues de Oliveira Novaes (Instituto federal do espírito santo), raphael mariano de souza (instituto federal do espírito santo), thiago barreto da silva amaral (Instituto federal do espírito santo)
Abstract:
Most steel mills face the challenge of reducing the phosphorus content in steel, which has become a fundamental requirement due to the growing demand for special steels with better mechanical properties, such as those used in the automotive industry. In this sense, hot metal dephosphorization is a more efficient alternative than steel dephosphorization . During the dephosphorization process, the main solid phases that can form in the slag are CaO, MgO, dicalcium silicate (2CaO.SiO2), tricalcium phosphate (3CaO.P2O5), which is formed by the oxidation of phosphorus, and 3CaOSiO2.3CaOP2O5. This study aims to evaluate and compare the performance of different fluxing agents (fluospar and soda ash) on the dephosphorization factor, analyzing the influence of the main properties and composition of the formed slags. For this purpose, the chemical compositions of slags with different CaO and FeO contents from the literature, as well as dephosphorizing slags prepared for research, were analyzed. The results indicated the dephosphorizing mixtures (slag+fluxing agents) in which the best dephosphorization efficiencies occur.
Technical Session
STUDY OF THE EXTENSION OF STEEL MIXING IN THE CONTINUOUS CASTING
Presenter(s): Matheus Lopes Ferreira (companhia siderúrgica nacional), CElso luiz moraes alves (uff - universidade federal fluminense), luis gustavo gomes pereira (COMPANHIA SIDERÚRGICA NACIONAL), rafaela pacheco malvão dos santos (COMPANHIA SIDERÚRGICA NACIONAL)
Abstract:
In this work, an analysis of the extension of steel mixing carried out in the continuous casting tundish was investigated at Companhia Siderúrgica Nacional (CSN). In the present investigation, results from experimental sampling in the mold, experimental sampling in slabs and a mathematical model from the literature were compared. To measure the mixing extension between two different steel grades, steel samples were taken in the continuous casting mold with three minutes of interval between each other after the ladle exchange. Additionally, three mixing slabs were sectioned to be cut and chemically analyzed each 1000 mm though the length. To have a way of predicting the steel mixing extension, the adjusted mathematical model proposed by HUANG AND THOMAS [1] was implemented considering the continuous casting process parameters and the obtained results were compared with the experimental results for both cases mold sampling and slab sampling. Based on whole results, it was verified that the steel mixing extension can be in some cases higher than 8.0 meters for the incompatible steel mixing, as it was observed in the analysis of %Nb and %Ti took in steel slabs. It was also observed a good convergence between the mathematical model and the experimental results which allows to conclude that the mathematical model provides a good representation of the mixing extension and opens a good perspective for its application at CSN.
Technical Session
9/4/24, 9:00 AM - 9/4/24, 9:25 AM
Presenter(s): JOSE FLAVIO VIANA (BAUTEK MINERAIS INDUSTRAIS), MARCELO MIRANDA (BAUTEK MINERAIS INDUSTRIAIS), rodrigo vieira (bautek minerais industriais), mateus curado (bautek minerais industriais)
Abstract:
The consumption of fluorspar in the liquid steel production during the primary and secondary refining has environmental concerns in addition to the scarcity of this raw material and impact on refractory wear. Calcined bauxite can replace the fluorspar keeping the slag characteristics and reaching at the same results in the steel production process. Bautek Minerais Industriais produces high quality calcined bauxite in Goiás, Brazil since 2021 and can provide it to the steel plants
Technical Session
9/4/24, 9:00 AM - 9/4/24, 9:25 AM
Presenter(s): MAURICIO GUIMARAES BERGERMAN (USP)
Abstract:
Grinding ores in conventional ball mills demands high energy consumption, resulting in relatively high operating costs in a mineral processing industrial plant. Whether in the initial stages of a project or during its operation, conducting tests to determine the processing circuit's energy consumption throughout the life of the mine is necessary to reduce such high operating costs. Traditional tests used to define the energy consumption in grinding are relatively time-consuming and require significant amounts of sample, e.g., 8 - 10 kg, which is not always available in the initial stages of a project or geometallurgical studies. The present study used a modified Hardgrove test that requires only around 50 g to estimate the Bond Ball Mill Work Index -BBMWI. This test involves the measurement of the torque using a fixed sample volume with a -3.35+0.60 mm feed size to determine the size-specific energy from grinding with a Hardgrove mill. The results indicated that for a set of 130 samples tested, the average error associated with the predicted BBMWI was within ±6%. The proposed test is thus suitable for geometallurgical studies and other applications where relatively small samples are available.
Technical Session
Coke Oven Machines Developments for Environmental and Safety Reliability
Presenter(s): ALESSANDRO AUGUSTO MOTTA SALES (Paul Wurth)
Abstract:
Nowadays, in Coke Oven Plants there are many operating movable machines worldwide with several issues related to maintenance\environmental aspects and safety reliability. In order to provide improvements regarding operation, maintenance and aiming to attend the current environmental and safety requirements, early preparation for machines upgrades shall be started in order to control the CAPEX / OPEX and avoid unexpected problems. Therefore, in the following paper we would like to give an outline of SMS approach with the relevant Paul Wurth cokemaking products and solutions.
Technical Session
9/4/24, 9:00 AM - 9/4/24, 9:25 AM
Presenter(s): PAULA MARIA GOMES CUNHA LEãO (UNIVERSIDADE FEDERAL DE MINAS GERAIS (UFMG)), Taís Birchal Zicker (Universidade federal de minas gerais (ufmg)), José Domingos Ardisson (CDTN/CNEN), Maurício Covcevich Bagatini (Universidade Federal de Minas Gerais (ufmg))
Abstract:
In the steelmaking, the use of biomass presents itself as an alternative to mitigate CO2 emissions and reduce fuel consumption in blast furnaces. In this study, self-reducing briquettes composed of pellet feed and sugarcane bagasse treated at different temperatures (250, 400 and 550ºC) were produced in laboratory, aiming to evaluate the influence of the biomass pyrolysis temperature on the performance of these agglomerates when subjected to thermal regimes that represent the blast furnace. Compressive strength and drop tests were carried out, as well as interrupted tests in a non-isothermal regime and nitrogen atmosphere. XRF and Mössbauer techniques allowed to identify the iron content and the evolution of phases at different heating stages. The results showed that briquettes produced with biomass pyrolyzed at higher temperature exhibited greater cold mechanical strength. From interrupted tests, a decrease in the compression strength with temperature was observed, reaching a minimum value at 950ºC, followed by a subtle increase at 1100ºC. Briquettes with biomass pyrolyzed at 550ºC achieved a higher metallization degree, but also showed a higher level of swelling. For use in blast furnaces, these briquettes demonstrated better performance in terms of reduction and mechanical strength when compared to those with biomass pyrolyzed at lower temperatures.
Technical Session
SUPERABSORBENT POLYMER (SAP) IN IRON ORE PELLETIZATION WITH HIGH HUMIDITY
Presenter(s): EDUARDO POLTRONIERI TRES (VALE SA)
Abstract:
The pelletizing plant in São Luís presents significant losses (close to 30%) in pellet production due to the high humidity of the ore that supplies the plant. The heavy rains, typical of the region, which occur from January to June, increase the humidity in the piles of ore formed in the mine, during transport in wagons and in the piles of ore during pelletization. The consequences are obstructions in silos, kicks, overloads on belts, slipping of press rollers, poorly formed pellets, etc. In order to improve the handling of this ore with high humidity and improve its pelletability, a superabsorbent input capable of retaining excess moisture in the ore was identified on the market. This input, known as Sodium Polyacrylate (PAS), is a Superabsorbent Polymer (PSA) and has the capacity to absorb process water in a proportion between 240 and 260 times the value of its mass. Through laboratory, pilot and industrial scale tests, it was observed that the dosage of this superabsorbent before mixing makes the ore handling more stable, easier to sift, transport and press. Even with humidity at 11.6%, the sieve and roller press did not demonstrate the problems of loss of production, obstruction/slippage of the press rollers, generating pellets with excellent finishing and quality.
Technical Session
Analysis of the Technical Feasibility of a New Concentration Route for Sinter Feed in an Iron Quadrangle Mining
Presenter(s): JOAO PAULO GOMES CARNEIRO (GAUSTEC TECNOLOGIA MAGNÉTICA), RAYZA bEATRIZ ROCHA GONÇALVES (GAUSTEC TECNOLOGIA MAGNÉTICA), FERNANDA HOFFMANN (GAUSTEC TECNOLOGIA MAGNETICA), claudio henrique teixeira ribeiro (gaustec tecnologia magnetica), Rafael silva Marcelino (vale )
Abstract:
The Mining sector is one that significantly contributes to the development of society by providing raw materials for a wide range of industries. Considering the decreasing iron grades over the lifespan of the mine, as well as the demand to work with ultrafine materials, studying new routes to benefit these materials becomes necessary. The purpose of this study is to conduct an evaluation of the technical feasibility of an alternative route for the Sinter feed product. Pilot tests of magnetic separation were performed, varying parameters to achieve quality and mass recovery. The test results presented two possible routes according to the client's needs. In the first route, an overall mass recovery of 50.73% was achieved, with an iron content in the product of 61.73%, and a reject with 40% Fe. It's worth noting that in this route, a Fe content of 62.45% was achieved in the rougher stage. The second route obtained an overall mass recovery of 40.80%, with product quality of 61.38%, and reject containing 32.89% Fe. The study was conducted for a specific case in the context of the mining industry in Minas Gerais. It becomes feasible to utilize the mentioned routes for this material, provided that all aspects are evaluated, whether partially or fully employing this material in one of the routes. As future work, further sampling campaigns and new magnetic separation tests are necessary.
Technical Session
9/4/24, 9:00 AM - 9/4/24, 9:25 AM
Presenter(s): SABRINA SANTI (UFRGS - LdTm), João Vitor Piovesan Dalla Nora (UFRGS - ldtm), Vinicius Waechter Dias (IFRS), Thiago Marques Ivanisk (UFRGS - ldtm), Alexandre da Silva Rocha (UFRGS - ldtm)
Abstract:
Plasma nitriding is a surface treatment applied to enhance properties of steels, such as wear resistance and fatigue resistance, by increasing surface hardness and inducing compressive residual stresses on the surface, thereby extending the service life of mechanical components. Quenched and tempered samples of AISI 4140 steel were subjected to plasma nitriding treatment employing two gas compositions with different percentages of N2 (75% and 85%) to evaluate the influence of varying N2 content on mechanical strength and wear resistance. The treatment was carried out under these conditions for 2 hours at a temperature of 500 °C. The specimens were analyzed for microstructure, using optical microscopy and scanning electron microscopy, surface microhardness, Vickers microhardness profile, roughness and microabrasive wear resistance. It was found that an increase in nitrogen content in the nitriding atmosphere, with the same treatment time, led to the formation of a thicker nitrided layer. The microhardness tests also showed an increase in hardness on the sample treated with a higher nitrogen percentage. Consequently, the thicker, harder layer exhibited a better microabrasive wear resistance.
Technical Session
PREVENTIVE MAINTENANCE: MACHINE LEARNING PROGRAM USING PYTHON LANGUAGE
Presenter(s): franco cerceau neves (UFOP - Universidade federal de ouro preto), delano joao virgilio de souza (UFOP - universidade federal de ouro preto), zirlene alves da silva santos (ufop - universidade federal de ouro preto)
Abstract:
Mining is essential to both the Brazilian and global economies, requiring large-scale equipment with high added value, notably crushers. This research presents the development of a program using Machine Learning in the Python language to enhance the execution of preventive maintenance on critical equipment in the mining industry. Various materials were used in the development of the program, including books, academic articles related to preventive maintenance, dissertations, and monographs that discuss machine learning techniques applied to industrial maintenance; technical maintenance manuals, and specifically, the Metso manual, whose operational procedure for preventive maintenance of crushers served as the model for the development of the research program. The developed program represents a significant advancement in the field of preventive maintenance. Its implementation promises to facilitate decision-making during activities, enabling the identification of non-conformities in the items to be checked. Despite the controlled operational parameters of the inspected equipment, the use of the program has demonstrated a positive contribution to increasing reliability during and after preventive maintenance, thereby reducing unplanned downtime
Technical Session
QAS-ROM: A QUALITY ASSURANCE SYSTEM FOR RUN-OF-MINE
Presenter(s): lucas corrêa aranha (Innomotics), Juliana Andrade Sousa (innomotics), Tharley Murilo Costa e Silva (innomotics), Lorena Isabela de Oliveira Ribeiro (innomotics), Ivan Maciel Leite (innomotics)
Abstract:
This work aims to present the main attributes and functionalities of QAS-ROM, an innovative system for quality control of run-of-mine. Through the system, it is possible to track the quality of ROM from the pit to the destination, enabling the identification of quality deviations even in the mining phase. This allows to adjust processes in the areas of geosciences, mine planning, drilling and blasting, loading and transportation and plant operation. Through graphs, on-screen reports, e-mail reports and alerts to users via Microsoft Teams, QAS-ROM provides users with assertive information to analyze discrepancies between the materials predicted in the block model and the materials found during excavation in the mine
Technical Session
9/4/24, 9:25 AM - 9/4/24, 9:50 AM
Presenter(s): MARCELO SILVEIRA ANJOS (ARCELORMITTAL BRASIL SA), Diego rodrigues peres (Arcelormittal Brasil sa), Vincent GALINAJTIS (Arcelormittal sa), Daniel Silva perdigão (ARCELORMITTAL BRASIL SA)
Abstract:
ArcelorMittal group has a vast technical knowledge base created and maintained by its employees which encompass different steelmaking topics, such as: safety, maintenance, product development, quality defects etc. This knowledge base has an high amount of documents with different extensions which makes hard to enable ArcelorMittal workers to access in a fast and precise way the required information. This paper discuss a project implemented to centralized and organized the knowledge base, define an IT architecture to apply generative AI to improve user experience bringing information faster to users.
Technical Session
9/4/24, 9:25 AM - 9/4/24, 9:50 AM
Presenter(s): gabriel augusto da fonseca (VALLOUREC ), MARCELLA STEPHANIA CAFÉ DE SOUZA (VALLOUREC), Guilherme Azevedo de Oliveira Rambaldi (VALLOUREC), Elias Victor de Jesus Cardoso Machado (vallourec), Fabricio de Assis Vaz (vallourec), Rosiane Mary Rezende Faleiro (vallourec), Bruno Milagres Mesquita (vallourec)
Abstract:
This study addresses the optimization of natural gas consumption in a steel industry context, focusing on the production of steel pipes. Through the implementation of an analytical model developed by the data science team, in collaboration with the Energy and Utilities area, the aim is to achieve more efficient planning and reduce costs associated with imprecise estimates of the recurring gas consumption in the production process. The results demonstrate that the model can provide a significant improvement in the accuracy of this consumption planning, contributing to the operational, financial, and environmental sustainability of the company.
Technical Session
ANALYSIS OF BALSA WOOD APPLIED TO AN AERODESIGN UAV
Presenter(s): Miguel Ângelo Menezes (UNESP - São Paulo State University), Luís Fernando Taiacol Munhoz (UNESP - São Paulo State University)
Abstract:
The present work studied the mechanical properties of balsa wood and its structural characteristics. To this end, tensile tests were carried out on balsa wood, a composite material, in order to obtain its properties, and corroborate some of the literature, which is in contradiction, with the newer ones pointing to a rupture stress of 3 MPa in the wood, while the older ones point out tensions above 10 MPa, with the difference between both being the test standards used, thus indicating that the standards directly affect the data obtained. A study of the structure of balsa wood was also carried out, in which it was possible to understand why the test data presented such high deviations, since balsa wood is of living origin, there are numerous factors that influence the growth and development of the fibers of wood during planting, with such differences being gigantic within the same batch, which is why a large number of specimens are needed for testing, with the greatest difficulty being the high cost of this material, even if within the alternatives this is the most accessible for your role.
Technical Session
APPLICATION OF GREEN HYDROGEN IN THE MIX OF FUEL GASES IN INTEGRATED STEEL SUPPLY
Presenter(s): Eder Quental de Araújo (Gerdau), José Geraldo da Silva Moreira (Gerdau), Dimas Pereira Coura (Gerdau)
Abstract:
The application of green hydrogen to decarbonize the steel industry has been widely debated and studied by various companies and countries. This focus is primarily on its use as fuel or reducer in new reactors, aiming at decarbonization, or its injection into the blast furnaces' tuyeres to reduce the consumption of coke or coal, promoting an energy transition in coke-integrated steelmaking. However, in a scenario where green hydrogen becomes a competitive input in countries like Brazil, Chile, Australia, among others, its integration into the steel gas mix can also play a significant role in the energy transition. This is due to the possibility of reducing or even eliminating the need for natural gas in production, thus contributing to a more sustainable approach.
Technical Session
EVALUATION OF THE DEPTH OF THE BALLISTIC IMPACT ON THE SILICON CARBIDE AND ALUMINA COMPOSITE
Presenter(s): SHANELY DA SILVA RIBEIRo (instituto militar de engenharia), jeremias ismael nunes fortini (instituto militar de engenharia), ALTAIR SÓRIA PEREIRA (UNIVERSIDADE FEDERAL DO RIO GRANDE DO SUL), EDUARDO DE SOUSA LIMA (instituto militar de engenharia)
Abstract:
The use of composites with different proportions has been widely disseminated and studied for applicability in engineering and industry in general. The range of applications of silicon carbide and alumina, in various sectors, due to their excellent properties such as mechanical strength, high resistance to abrasion and high hardness, shows the feasibility of joining two materials for different applications. The present study uses these two elements, in proportions of 40 and 60%, by weight, to manufacture a composite to analyze the applicability in possible individual ballistic protections, through ballistic testing and impact depth analysis. With the support of the Army Assessment Center (CAEx), it was possible to carry out ballistic tests, in accordance with the NIJ 0101.04 standard, using a 7.62 x 51mm caliber. The composite studied is a commercial product from the company CETARCH. The tested specimens were made with stainless steel plate, polyurethane glue and ceramic insert. The experimentally obtained data showed that the effective thickness, to analyze the depth, due to partial penetrability, occurred at 6.5 mm of the composite, with a value of 11.30 mm in depth in relation to the impact of the projectile. The effectiveness of the insert proved to be capable of implementing it for individual ballistic protection, but with the need for further testing in accordance with the specified standard.
Technical Session
9/4/24, 9:25 AM - 9/4/24, 9:50 AM
Presenter(s): FLAVIO SOUSA BRAZ DE ARAUJO (SMS GROUP METALURGIA DO BRASIL LTDA.)
Abstract:
Evolution never stops. We are constantly evolving. Some faster than others, or perhaps even more striking, however, always moving forward. Extrusion equipment would not be out of this. In this work, the objective is to present the technologies developed over the years that shaped the concept of extrusion. Starting from the beginning of the process, the discoveries that characterized the equipment and its operation over the decades until reaching today. The improvements that brought more production, quality, cost reduction, process optimization, etc. will be discussed in detail. All subgroups of the core equipment of the line, which is the press, will be discussed fully. (Frame, cylinders, crosshead, container, scissors, loader, control system). But also, peripheral equipment, such as bar heating oven, quench, output table, aging oven, basketing machine). Furthermore, what to expect for the future will be discussed, with what has been developed using electric and hybrid equipment, and already foreseeing the integration of the Internet of Things, industry 4.0 and big data
Technical Session
BENEFITS OF CARBIDE COATINGS ON COLD ROLLING ROLLS & HARD CHROME REPLACEMENT
Presenter(s): Alvaro Loosli (Primetals)
Abstract:
This work analyzes the benefits of using carbide coatings on cold rolling rolls, using a hypersonic thermal spray process, compared to rolls without carbide coatings and addresses the topic of replacing hex hard chrome plate. Through sector data studies, we highlight the advantages in terms of durability, quality of the sheet produced, operational costs and productivity. The results show a significant increase in the useful life of the rollers, a reduction in maintenance costs and an increase in production, justifying the initial investment in coated rollers. On the topic of replacing hard chrome, we will address, in addition to the better performance of spray coatings in relation to hard chrome, the reduction of heavy metals in the industry, which contaminate the environment.
Technical Session
INCREASE AT BOF LINING WEAR RATE, CHALLENGES AND SOLUTIONS
Presenter(s): MARCOS VENTUROLI AUAD (Marcos auad consultoria)
Abstract:
Operation conditions at Brazilian BOF facilities are changing due to refinement necessity, raw material cost or increase of output. As a result, BOF refractory lining wear at most of the steelmaking plants is increased. The need to increase production implies increasing the availability of the asset. This leads to a new approach regarding refractories materials, design and repair procedures to reduce the wear velocity. In this article we will discuss the repair procedures and techniques to mitigate the wear rate.
Technical Session
9/4/24, 9:25 AM - 9/4/24, 9:50 AM
Presenter(s): PATRICK QUEIROZ DOS ANJOS (IFES ), felipe fardin grillo (ifes), marcelo lucas pereira machado (ifes), lucas de almeida quaresma (tupy)
Abstract:
THE GLASS TRANSITION TEMPERATURE IS ONE OF THE MOST IMPORTANT PHYSICAL PARAMETERS IN RELATION TO THE CRYSTALLINE BEHAVIOR OF MATERIALS AND HAS INFLUENCE UM PHYSICAL PROPERTIES IN MOLD SLAG AND FE-CR-BASED SLAGS. HENCE THE GLASS TRANSITION TEMPERATURE IS AN IMPORTANT PARAMETER IN STEEL SLAGS. THE SCIGLASS DATABASE WAS USED TO PROVIDE STEEL SLAG DATA WITH THE SIO2-CAO-AL2O3-MGO-FEO-NA2O-K2O-LI2O-B2O3-BASED SLAGS AND GLASS TRANSITION TEMPERATURE SYSTEM. THE CHEMICAL COMPOSITION DATA WERE CONVERTED INTO THE DEGREE OF DEPOLYMERIZATION PARAMETERS AND SUBSEQUENTLY RELATED TO EACH GLASS TRANSITION TEMPERATURE. THE MODELING WAS CARRIED OUT USING NEURAL NETWORKS BY VARYING WIDTH AND DEPTH USING A LINEAR COMBINATION BETWEEN DIFFERENT CENTRAL MOMENTS AS A REFERENCE OF EFFICIENCY. THE CHOSEN NEURAL NETWORK HAD A WIDTH OF 14 AND A DEPTH OF 10 (14-10). SENSITIVITY ANALYSIS WAS PERFORMED DEMONSTRATING CONSISTENCY WITH THE LITERATURE AND STATISTICAL EVALUATIONS WERE PERFORMED TO DEMONSTRATE THE EFFICIENCY OF THE NEURAL NETWORK 14-10 WHICH DEMONSTRATED BETTER EVALUATIONS IN RELATION TO DIFFERENT LITERATURE EQUATIONS.
Technical Session
STEEL LADLES BOTTOM DESIGN WITH CARBON-FREE REFRACTORY LINING FOR OPTIMIZED STEEL FLOW AND METALLIC YIELD
Presenter(s): Ronaldo Adriano Alvarenga Borges (Usiminas), Rodrigo Seara Martins (usiminas), Haysler Apolinario Amoroso lima (shinagawa), Patrícia Alves Silva de Resende Brum (shinagawa)
Abstract:
The metallic yield of a steel plant is one of the most impactful themes on productivity. Energy consumption, costs, and environmental impact due to CO2 emissions, are the main causes, which requires the reduction of these metal losses and ensuring maximum yield. This work is based on a new concept already implemented in steel plants, whose principle is the modification of the steel ladle bottom design. The technology is high yield design. This work aims to publish the knowledge learned in the use of a new concept of bottom design of steel ladle combining with of carbon-free steel ladle refractories, through an elaborate profile, which allowed the reduction by 57% (physical model) and 93% (industrial test) the metallic losses in the steel ladles (which corresponds to a 0.8 to 1.5% gain in metal yield), demonstrating that their use can be an important ally not only in energy savings, high-cost reduction but also a major factor at polluting emissions decrease
Technical Session
DEFINITION OF charge BALL topsize OF THE REgrinding STAGE: A SYSTEMIC AND LABORATORY APPROACH
Presenter(s): ALEXANDRO ULIANA (SAMARCO MINERAção S.A.)
Abstract:
Using a laboratory mill, was evaluated the application of different TopSizes for the ball charge in the regrinding stage at Samarco Mineração – and their impacts on the other process parameters. The diameters evaluated were 35; 30; 25 and 20mm (being 15mm the purge diameter considered, according to industrial scale), measuring possible variations in the energy consumptions, ball consumptions, generation of specific surface, etc. In a short view and taking into consideration only the Germano’s unit operations, changes in the charge ball TopSize could not be economically viable. However, in a systemic view and also taking into account the Ponta Ubu’s unit operations, changes in the charge ball TopSize could bring importante global benefits to be considered. If such results could replicated on the industrial scale of Samarco Mineração, there would be gains of the order of R$ 1,0-8,0 M/a (depending on the reduction of specific surface in the reground product) due, mainly, to gains in the productivity of the filtering step and reduction in the operational costs of the burning/hardening step.
Technical Session
9/4/24, 9:25 AM - 9/4/24, 9:50 AM
Presenter(s): CHRISTIAN MANERA (UNIVERSIDADE FEDERAL DO RIO GRANDE DO SUL), Guilherme Liziero Ruggio da Silva (GERDAU OURO BRANCO), Bruno Deves Flores (UNIVERSIDADE FEDERAL DO RIO GRANDE DO SUL), Eduardo Osório (UNIVERSIDADE FEDERAL DO RIO GRANDE DO SUL), Marcelo Godinho (universidade de caxias do sul), Antônio Cezar Faria Vilela (UNIVERSIDADE FEDERAL DO RIO GRANDE DO SUL)
Abstract:
By-products generated in the coking process play a significant role in the economic well-being of the steel industry. Therefore, this work aimed to evaluate the yield of by-products from the coking of different metallurgical coals. The individual coal coking experiments were conducted following a methodology validated by the laboratory. Four high-volatile bituminous coals (HV) and three medium volatile bituminous coals (MV) were studied. The coals were coked at a heating rate of 3 °C/min and a coking temperature of 1000 °C, maintained for 30 min. The cracking of the vapors was carried out at 800 °C. HV coals produced tar with approximately twice the yield compared to MV coals. Higher coke oven gas yields were obtained for HV coals, which also present a gas with higher methane concentrations. The research also revealed that HV coals produce a coke oven gas with a higher density and higher calorific value. From the results presented, it was possible to differentiate HV and MV coals regarding the by-products. Thus, the developed equipment becomes a valuable tool for the experimental evaluation of the yield and quality of the by-products of coals prospected for use in coke ovens.
Technical Session
9/4/24, 9:25 AM - 9/4/24, 9:50 AM
Presenter(s): MANOEL VÍTOR BOREL GONÇALVES (TECNORED)
Abstract:
This study evaluated the synergistic use of volatiles from sugarcane bagasse (SB) and iron ore tailings (IOT) aiming to reduce iron oxides, carbon deposition and H2 production. The experiments were carried out at 400, 600, 800 and 1000ºC, with heating rates of 10 and 30ºC/min and different SB/IOT ratios, under an N2 atmosphere. The combination of 10ºC/min, 600ºC and excess biomass resulted in a product with 96.7% magnetite and 3.5% C deposited. The use of a smaller amount of SB in relation to IOT provided an increase in H2 yield. Heating the IOT and SB simultaneously up to 1000°C led to significant mineralogical transformations, resulting in more reduced phases such as wüstite, fayalite and metallic iron. It was found that 18.9% of Fe0 was formed when an excess of SB was used in relation to the IOT. The results demonstrate an alternative with potential for recovering iron from IOT and obtaining alternative raw materials for the steel industry.
Technical Session
9/4/24, 9:25 AM - 9/4/24, 9:50 AM
Presenter(s): TÚLIO MOREIRA CAMPOS (UFRJ)
Abstract:
Application of mathematical modeling to optimize industrial-scale HPGRs pressing iron ore concentrates has experienced a significant increase. Despite the advances, the appropriate application of this modeling as part of model predictive control algorithms is lacking in the industry. This paper proposes a nonlinear model predictive control (NMPC) algorithm based on the Modified Torres and Casali model for pressing iron ore concentrates in an industrial HPGR. The model is used to emulate the plant performance, as well as being the internal model of the controller. The application of NMPC is demonstrated by its capability of absorbing variabilities observed in the HPGR feed and ensuring manipulation of its operating conditions to guarantee a reasonable throughput and product quality.
Technical Session
NEW MAGNETIC CONCENTRATION AT THE MUTUCA IRON ORE PROCESSING PLANT
Presenter(s): marina de menezes lopes (vale)
Abstract:
Some processing plants suffer without of investment and do not adapt their routes to changes in the ROM (run of mine). Therefore, it´s very challenging to comply with production and meet market specifications, which reduces the profit margin, especially in times vulnerability´s price. Motivated by this context, this work aims to evaluate the potential for generating better quality pellet feed through the introduction of a magnetic separator in an industrial circuit that does not have a concentration stage. The studies were carried out by collecting samples at the Vale Mutuca plant and concentration tests at Gaustec. Some goals were defined: minimum 20% of solids in the feed, 62% iron content and 5.0% silica content into the product and 40% mass recovery. The main evaluations evaluated were medium water pressure, gap and matrices. The work also evaluated the humidity of the new product generated through bench filtration tests. It was possible to conclude that a rougher route meets the equipment proposal under the required conditions, with no impact on subsequent stages.
Technical Session
ROTOMOLDING TECHNOLOGICAL DEVELOPMENT
Presenter(s): YUKIO SHIGAKI (CENTRO FEDERAL DE EDUC TECNOLOGICA DE MG)
Abstract:
Rotomolding is a process for manufacturing hollow parts in polymeric material, through the addition of granulated polymers inside a mold to which a rotational movement is applied around two orthogonal axes. The polymer is heated and the movements of the mold cause the material to be distributed along the mold internal wall. The product is then cooled and the part is removed from the mold. This article presents a theoretical survey on the subject based on a literature review, interviews and technical visits to some players in the sector, including end consumers and manufacturers of rotomolded parts. The objective is to depict the current state of the development of rotational molding and show some considerations and perceptions of both national and international scenarios.
Technical Session
9/4/24, 9:25 AM - 9/4/24, 9:50 AM
Presenter(s): Luiz Carlos Costa Gavazza de Araujo Junior (Samarco Mineração S.A)
Abstract:
During the shutdown of operations for around 5 years, it was necessary to learn and concentrate efforts so that during this period we could develop ideas, methods and solutions to efficiently manage the assets of the entire industrial park and thus prepare for operational return. In this way, this work was carried out as one of the major activities that preceded operational readiness (preparation and maintenance of the Plant for the return of the production process). It consists of developing a tool for machining in the field that was used on the VT-1A Process Fan shaft of plant 4, through the internal SAT (Test Request and Acceptance) procedure, in partnership with the Asset Management Departments, Maintenance of Ubu and Supplies, together with the contracted company ITAMIL - Engineering Manufacturing and Maintenance
Technical Session
BREAKING OPERATIONAL PARADIGMS IN MINE KPI MANAGEMENT0
Presenter(s): Natália Abreu Andrade (Vale sa)
Abstract:
To maintain the competitiveness of a mining activity, it is necessary to control KPIs and operational costs. To this end, this work seeks to delve deeper into mine-specific indicators, aiming to reduce costs and increase the Physical Use of Transport and Cargo Productivity. To this end, the main operational deviations were opened and treated with scenario simulations, queuing theory, shift change optimization, fog predictor and alternatives for operating with climate variations. Good management and persistence in doing things differently guarantee concise results in the indicators, making the Pico Mine Operation one of the most economical in Vale. Optimizing resources and moving more with less is a reality achieved
Technical Session
NETWORK SECURITY STRATEGIES FOR CRITICAL MISSION ENVIRONMENTS IN THE INDUSTRY WITH CLAROTY AND SOC DEPLOYMENT
Presenter(s): DANIEL COSTA TROCADES (CSN - VOLTA REDONDA - BR 393 -), REGIS FONSECA DE OLIVEIRA (CSN)
Abstract:
With the spread of the WannaCry virus in 2017, CSN raised an alert to the risks of cyberattacks in industrial environments. Given the above, there were several internal actions supported by suppliers for disinfecting contaminated computers. CSN is a company with a high level of criticality, possessing critical mission equipment that, in the event of a successful cyberattack, could be misused, resulting in damages to both the population and the organization. In critical mission industrial environments where continuous operation is essential, network security plays a fundamental role in protecting vital assets and mitigating cyber risks. In this challenging scenario, the deployment of a Security Operations Center (SOC) becomes an urgent necessity to monitor, detect, and respond to cyber threats in real time. Claroty, as a solution tailored for the industry and with its expertise in industrial security, emerges as an indispensable support tool in building and operating an effective SOC for mission-critical industrial environments. In conjunction with the study of SOC deployment, the following environment management tools were implemented: • Monitoring through Zabbix software; • Inventory and asset management with GLPI software; • Network documentation with NETBOX software; • Log consolidation through GrayLog; These tools play an indispensable role in managing asset documentation and inventory in the operational technology (OT) environment. With online monitoring, the maintenance team has accurate information on all monitored equipment. Through this information, greater assertiveness and agility are achieved in problem-solving, as the knowledge of network assets and traffic behavior within the monitored environment simplifies issue resolution.
Technical Session
9/4/24, 9:50 AM - 9/4/24, 10:15 AM
Presenter(s): Marcella Sthefânia Café de Souza (vallourec), João Filipe Axer Batista (vallourec), Guilherme Azevedo de Oliveira Rambaldi (vallourec), Elias Victor de Jesus Cardoso Machado (vallourec), Fabricio de Assis Vaz (vallourec), Gabriel Augusto da Fonseca (vallourec), José Mário de Souza (vallourec), Rosiane Mary Rezende Faleiro (vallourec), Bruno Milagres Mesquita (vallourec)
Abstract:
The development of technological models to predict pipe warping after the tempering process is crucial for the steel industry. In 2019, the Data Science team, in collaboration with the tempering process engineering team, created a model to forecast warping. In 2023, enhancements were introduced to improve the process analysis. Validation of the model in a production environment proved its effectiveness in quality control, assisting operators in problem identification and informed decision-making regarding pipe viability. Due to the model's success, its application is planned in other plants in 2024, with the expectation of automating pipe quality validation and increasing efficiency in warping issue detection.
Technical Session
THERMAL ANALYSIS APPLIED TO A POLYMER – METAL – ORGANIC COMPOSITE (PMOC)
Presenter(s): THAYS DE ALMEIDA MARINHO FARZAT (IME - Instituto militar de engenharia), Thomaz Jacintho Lopes (IME - INSTITUTO MILITAR DE ENGENHARIA), Sérgio Neves Monteiro (IME - INSTITUTO MILITAR DE ENGENHARIA)
Abstract:
In this study, the relevance of polymers in our daily lives and the harmfulness of the waste they generate are observed. Applying the Differential Scanning Calorimetry (DSC) technique, we explored a composite containing polymers, organic residues, and metallic elements. The analysis revealed melting and crystallization temperatures, as well as the thermal stability and reversible behavior of the material. Understanding the thermal characteristics of the material is essential for developing processes that transform polluting materials into relevant and economically viable products, aiming to mitigate environmental impacts. This research validates the use of DSC to characterize and understand complex composites, enhancing their applications.
Technical Session
9/4/24, 9:50 AM - 9/4/24, 10:15 AM
Presenter(s): Joaquim Luiz Monteiro de Barros (Kuttner do Brasil), Fabiana Moreira Costa (Kuttner do Brasil)
Abstract:
The purpose of this paper is to present in a didactic way and with practical examples, a guide for developing a basic technical feasibility study for thermal energy recovery and cogeneration systems, in order to obtain reliable results that can support the decision-making process.
Technical Session
REVIEW STUDY OF ELECTRICAL PROPERTIES OF COMPOSITE MATERIALS
Presenter(s): Thomaz Jacintho Lopes (IME - INSTITUTO MILI), Ary Machado de Azevedo (IME), André Ben-Hur da Silva Figueiredo (IME), Sérgio Neves Monteiro (IME), Fernando M. Araújo-Moreira (IME), Wagner Anacleto Pinheiro (IME), Joana Batista Soares (IME), Marcos Paulo Cavalieri de Medeiros (IME), Domingos D'Oliveira Cardoso (IME), Fernando M. Araújo-Moreira (IME), Ary Machado de Azevedo (IME), Ary Machado de Azevedo (IME), Wagner Anacleto Pinheiro (IME), André Ben-Hur da Silva Figueiredo (IME), André Ben-Hur da Silva Figueiredo (IME), André Ben-Hur da Silva Figueiredo (IME), André Ben-Hur da Silva Figueiredo (IME), André Ben-Hur da Silva Figueiredo (IME), André Ben-Hur da Silva Figueiredo (IME), André Ben-Hur da Silva Figueiredo (IME), André Ben-Hur da Silva Figueiredo (IME), André Ben-Hur da Silva Figueiredo (IME), André Ben-Hur da Silva Figueiredo (IME), André Ben-Hur da Silva Figueiredo (IME), André Ben-Hur da Silva Figueiredo (IME), André Ben-Hur da Silva Figueiredo (IME), Sérgio Neves Monteiro (IME), Joana Batista Soares (IME), Joana Batista Soares (IME)
Abstract:
This study addresses the electrical properties of composite materials through a literature review. Utilizing a wide range of scientific literature, we explore the various types of composite materials and their subclasses, focusing on information available in specialized journals. Additionally, we adopt a theoretical approach to better analyze and understand the electrical properties of these materials. This work aims to consolidate existing knowledge on the subject, providing a comprehensive overview of the electrical characteristics of composite materials and their potential implications in various applications.
Technical Session
Improved Energy Efficiency and Surface Quality in High Pressure Descaling in Hot Rolling
Presenter(s): Juergen Frick (Lechler Gmbh), Robert Wolff (Lechler gmbh), Alfonso Stein (Lechler gmbh)
Abstract:
As the backbone of the largest industrial economies, the steel industry will continue to improve its energy efficiency with a view to meeting the new ambitious CO2 emission reduction targets set by many governments around the world. High pressure descaling is a major consumer of electrical energy in the hot rolling process; in addition, the trend towards ever-increasing water pressures in descaling has led to increased pump capacities and a corresponding rise in energy consumption and costs. Lechler’s innovative SCALEMASTER ECO+ nozzle can help turning around this trend and reduce energy consumption in hot rolling considerably, lower CO2 emissions and save operation costs. Furthermore, certain new conceptual ideas of nozzle arrangements utilizing the optimized descaling nozzles enable the surface quality of rolled material to be considerably improved compared to existing installations. The paper will elaborate on results of laboratory and field tests, product details and application engineering aspects for both the designer of systems and the user of descaling systems
Technical Session
INVESTIGATION OF SAGGING IN THE ROLLING PROCESS OF CAST AUSTENITIC STAINLESS STEEL 316L
Presenter(s): Yuri de Abreu Silva Araújo Fleischhauer (COPPE/UFRJ), Laercio Rosignoli Guzela (COPPE/UFRJ), Fillype Iang Cotegipe (COPPE/UFRJ), Bernardo Pompermayer Eduardo (COPPE/UFRJ), rafaella martins ribeiro (coppe/ufrj), Rodrigo Vitorino da Silva (COPPE/UFRJ)
Abstract:
Rolling is one of the most important metallurgical forming processes. Due to its high productivity, about 90% of manufactured steel undergoes the rolling process at least once during its production. However, sagging, resulting from the vertical deflection of the rolling mill rolls, affects the thickness accuracy of the produced sheets. Thus, the aim of this study is to investigate sagging in the hot and cold rolling processes of an AISI 316L austenitic stainless steel, aiming to achieve greater precision in the thicknesses obtained in manufactured parts. Computational simulations were performed using Thermo-Calc and Deform-3D software to determine the processing conditions. Microstructural characterization was carried out using optical microscopy, scanning electron microscopy, and X-ray diffraction. Hardness tests provided information about the mechanical properties. It was possible to determine the sagging for the hot and cold routes, which allowed designing rolling routes with a high degree of precision.
Technical Session
9/4/24, 9:50 AM - 9/4/24, 10:15 AM
Presenter(s): CARLOS RENATO SOARES MACHADO (TERNIUM BRASIL LTDA.)
Abstract:
In a melt shop plant, the vessel shell deformation in LD converters can have a significant influence on the laser measurement of the refractory. Accurate measurement is crucial to ensure operational safety, efficiency, and the quality of the steel production process. The combined blowing through the tuyeres increases the agitation of the metal bath, reducing areas of chemical stagnation, favoring dephosphoration, increasing the manganese content and reducing iron in the slag. With the improvement of refining conditions, there is an increase in the metallic yield, a reduction in the consumption of fluxes and an increase in the life of the refractory. However, the vessel shell deformation can distort the tuyeres measurements obtained by means of laser measuring devices can also affect the position and orientation of the reference points used for the measurement of the refractory resulting in variations in the distance between the laser measuring device and the surface of the refractory. This may lead to measurement errors, resulting in inaccurate or inconsistent measurements. To mitigate the effects of the deformation of the shell of the LD converters in the laser measurement of the refractory, a manual measurement of the wear profile of the tuyeres was performed after the end of the BOF post-BOF campaign, this was facilitated by the removable converter bottom in TerniumBR. Regarding the result of the BOF refractory’s manual profile, a comparison was made with the laser measurement performed after deskulling the refractory coating post-campaing.It was observed that the average percentage of correct answers in the regions of the tuyeres was 51%, which caused its premature shutdown when it reached a measurement of 200mm. Regular calibrations of the laser measurement system were carried out to compensate for any distortion caused by the deformation of the shell, after correction, the equipment obtains a 91.2% accuracy..
Technical Session
A LOOK AT DANIELI DCM'S STRATEGIC PLANT UPGRADES ACROSS EUROPE, SOUTH AMERICA, AND P.R. CHINA FROM 2020 TO 2023
Presenter(s): Achille TRISCIUZZI (Danieli), Davide Zenarolla (DANIELI)
Abstract:
This paper presents three representative cases of long product caster upgrade performed in Europe, South America and P.R.China for the period 2020 and 2023. 1. Aciérie de Saint Saulve Complex (France) 2. Aco Verde Do Brasil S.A. (Brazil) 3. Baosteel CC8 (P.R.China)
Technical Session
9/4/24, 9:50 AM - 9/4/24, 10:15 AM
Presenter(s): ANDERSON KEMPKA (arcelormittal), Rafael de Carvalho Cunha (arcelormittal), Ricardo Vaz da Silva (arcelormittal), Hélio Espíndola de Oliveira (arcelormittal), Alencar Souza Santos (arcelormittal), Paulo Marcelo Rodrigues (arcelormittal)
Abstract:
NATURAL GAS IN A MELT SHOP REPRESENTS AN IMPORTANT SOURCE OF ENERGY USED IN STEEL PRODUCTION BUT AFFECTS THE GENERATION OF GREENHOUSE GASES AND THE COST OF THE BILLETS. ITS USE OCCURS IN CONTROLLING THE TEMPERATURES OF LADLES AND TUNDISHES, AS WELL AS OTHER MINOR CONSUMPTION SUCH AS CUTTING BILLETS AND ITS USE IN CUTTING SCRAP IN THE SCRAP YARD. IT ALSO CONTRIBUTES AS AN IMPORTANT ENERGY SOURCE IN THE ELECTRIC ARC FURNACE TO ASSIST IN THE MELTING OF SCRAP GENERATING INCREASED PRODUCTIVITY IN THE MELT SHOP. THE BURNING OF NATURAL GAS IN THE STEELMAKING PROCESS AS AN IMPORTANT ENERGY SOURCE BUT WHICH GENERATES CARBON MONOXIDE AND IMPACTING THE EVOLUTION OF DECARBONIZATION. WORKING TO REDUCE CONSUMPTION BECOMES AN IMPORTANT FRONT IN THE PROCESS OF DECARBONIZING THE STEEL INDUSTRY, CONSIDERING THE COMMITMENT TO PRODUCING STEELS WITH LOW CARBON EMISSIONS. THIS WORKS PRESENTS THE ACHIEVEMENTS IN THE SIGNIFICANT REDUCTION IN NATURAL GAS CONSUMPTION IN THE ARCELORMITTAL RESENDE MELT SHOP WHICH CONTRIBUTED TO THE REDUCTION OF EMISSIONS, HELPING TO ADVANCE THE DECARBONIZATION PROCESS. AN IMPORTANT WORK THAT SIGNIFICANTLY REDUCED THE VOLUME OF NATURAL GAS USED, CO2 EMISSIONS AND REDUCED BILLETS COST.
Technical Session
9/4/24, 9:50 AM - 9/4/24, 10:15 AM
Presenter(s): rodrigo fina ferreira (vale s/a)
Abstract:
Grinding is a significant energy-consuming process in mineral processing plants. Its primary objective is to achieve liberation at the largest possible particle size for subsequent concentration. When successful, this not only saves energy, but also simplifies and reduces the cost of subsequent separation processes by minimizing the production of fine particles. However, determining the optimal grinding size is challenging. The experimental determination of the grinding target involves resource-intensive laboratory procedures, particularly for mines with diverse ore textures. Comprehensive testing on numerous samples is necessary to accurately capture the behavior of the ore body. To reduce the laboratory workload, a clustering approach can be employed. This paper presents a practical application of a clustering method, based on a recently proposed clustering criterion derived from SEM-based automated mineralogy data, which considers two coefficients from the exponential correlation equation between degree of liberation and top size of the size fraction, along with the overall degree of liberation. Experimental results demonstrate that this method effectively groups samples with similar mineral liberation characteristics. By significantly reducing the laboratory effort required for liberation studies involving a large number of samples, this approach proves valuable for geometallurgy.
Technical Session
TECHNOLOGICAL CHARACTERIZATION METHODOLOGY OF BRIQUETTES WITH BIOMASS FOR METALLURGICAL COKE PRODUCTION.
Presenter(s): Kaelen cristiano Silva (GERDAU - OURO BRANCO), Leandro guilherme moreira (gerdau), cristhian guilherme fernandes (gerdau), frank danilo rosa (gerdau), natalia rezende pinheiro leite (gerdau), guilherme liziero ruggio da silva (gerdau)
Abstract:
In the current context, many coke plants around the world have faced challenges in relation to the availability of hard-coking coals, deterioration in quality, especially the increase in ash and S, in addition to the increase in the average age of batteries and the demand for reducing carbon emissions. CO2 (Nomura, 2017). In the case of Brazil, entirely dependent on the import of mineral coal, the selection and mixing philosophy directly reflect the competitiveness of steel, since the price of the coal mixture represents around 30% of the production cost. Given this, the Asian steel industry, especially the Japanese, has focused its efforts on developing alternatives that reduce the cost of coke and CO2 emissions from the process (Silva et al., 2018). Briquetting Technology allows the increase of semi-coking coals by increasing the charge density with the reduction of the distance between particles, compensating for their lack of expansion, and still producing a coke with adequate mechanical resistance. The present work aims to present a new methodology for characterizing briquettes, in addition to technically validating the inclusion of up to 25% of biomass in the briquette load for the production of metallurgical coke.
Technical Session
9/4/24, 9:50 AM - 9/4/24, 10:15 AM
Presenter(s): JOãO VICTOR MOURA ROCHA (UNIVERSIDADE FEDERAL DE MINAS GERAIS), manoel vítor borel gonçalves (universidade federal de minas gerais), maurício covcevich bagatini (universidade federal de minas gerais)
Abstract:
The present study aimed to evaluate the potential for reducing iron ore tailings through biomass volatiles, targeting iron recovery by magnetization. Three distinct temperature conditions (400, 600, and 800°C) and mass ratios of iron ore tailings and sugarcane bagasse (10g biomass / 10g waste, 10g biomass / 4.3g waste, and 4.3g biomass / 10g waste) were evaluated on a laboratory scale. The analysis included the mass loss of the tailings, determination of mineralogical phases, and magnetic separation. It was found that at 600°C and a biomass/waste mass ratio of 10g of biomass and 4.3g of waste, the highest concentration of magnetite was achieved, resulting in the highest degree of magnetization and iron recovery among the tested conditions.
Technical Session
PROCESSING OF HIGH-MOISTURE PELLET FEED FROM MINING TAILINGS DAMS IN A PELLETIZING PLANT
Presenter(s): renato luciano de araújo menezes (Vale), Anderson Denadai Thomazini (vale), Marley Anuciação Magella (vale), Eduardo Poltronieri Trés (vale)
Abstract:
The agglomeration of pellet feed rich in material extracted from mining tailings dams constitutes a highly sustainable option in a global context of maximizing existing natural resources. This is particularly relevant given the ongoing decommissioning and decharacterization of dams in Brazil. However, processing this material in a pelletizing plant in Maranhão faces additional challenges during the rainy season in the Northern region of the country. Excessive moisture significantly affects the pellet feed, which is transported and stacked in open-air piles. The objective of this study was to investigate different binders and their dosages to prepare the plant’s operation for processing this material during the rainy period of 2024.
Technical Session
EVALUATION OFF DIFFERENT MATRICES FOR VERTICAL MAGNETIC SEPARATOR
Presenter(s): Júlio César da Silva (Anglo American)
Abstract:
The Minas-Rio industrial complex, operated by Anglo American, produced 24,2 million tons of pellet feed last year. The operation begins in Conceição do Mato Dentro, MG, and the ore is transported via a 529 km pipeline to São João da Barra, RJ. The beneficiation plant treats low-grade itabirite, and in 2022, a magnetic concentration stage using the Slon 3000 was implemented to improve mass and metallurgical recovery. Magnetic separation, essential for capturing ferromagnetic particles, faces challenges due to matrix blockage, which affects efficiency. Industrial and pilot tests were conducted to evaluate matrices of different diameters. The 2 mm matrix with 100% filling showed less blockage, with a mass accumulation 64% lower compared to the 1.5 mm matrix. In pilot and industrial tests, the 2 mm matrix increased metallurgical recovery by 27.3% and the selectivity index by 26.1%. These results justified the adoption of the 2 mm matrix in the Slon 3000, optimizing magnetic separation and improving operational efficiency
Technical Session
REMOTE MONITORING OF BELT CONVEYORS BY MEANS OF SENSORY ROLLER
Presenter(s): Guilherme pereira de Oliveira (VALE - Engenharia porto tubarão), Cíntia Nunes Braga Regattieri (VALE - ENGENHARIA PORTO TUBARÃO), Marcos Tres Henriques (VALE - tecnologia da informação), Rafael Dias Pereira (VALE - ENGENHARIA PORTO TUBARÃO), Vinicius Mutz (VALE - manutenção PORTO TUBARÃO), Vinicius Ribeiro Correia (VALE - MANUTENÇÃO S11d), Rodrigo Trotta (Superior Industries inc.), Elton Junior Pereira (SUPERIOR INDUSTRIES INC.), Eduardo Piovesan Martinelli (SUPERIOR INDUSTRIES INC.), Daniel Rosa Biazussi (SUPERIOR INDUSTRIES INC.)
Abstract:
Belt conveyors are equipment used to handle ore, in high volume, over short or long distances in a system that works continuously. A conveyor has between 3 and 4 rollers for each linear meter of belt. These rollers can rotate freely around their own axes and are installed with the aim of supporting the movement of the belt and guiding it in the working direction. Understanding the predictability of roller failures is crucial to avoid safety-related events and property losses, such as fires and tears in conveyor belts. Although human inspection is a systematic procedure, it is ineffective in detecting roll problems in time to prevent serious failure events. Instrumented rollers emerge as a solution for remote monitoring of failures without constantly exposing people to the inherent risks in the field. This work shows the results of tests carried out with instrumented rollers capable of detecting locking, measuring surface wear and performing direct temperature measurement without requiring calibration models. The rolls were applied in a port terminal and were exposed to different environmental conditions. For approximately six months the rollers transmitted without measurement interruption.
Technical Session
9/4/24, 9:50 AM - 9/4/24, 10:50 AM
Presenter(s): Anibal Mendes (UFABC), Rocky Bruno Gomes Maschian (pPGCEM-UFABC), Karina Carbone Macieira (PPGCEM-UFABC), Cauã Pontes Brentan (ufabc), Erik Gustavo Del Conte (ufabc)
Abstract:
Using the TOPSIS and Radar methods, three scenarios with different prioritizations of requirements were analyzed for three alloys used in the manufacture of molds for tire vulcanization: aluminum alloys A356 and A319, and carbon steel 1020. In Scenario 1, the priorities were the lowest material cost, greater ease of maintenance (cleaning, weldability, and repair), and greater knowledge of in-service behavior, where carbon steel 1020 was found to be more suitable due to its lower cost and greater experience in working with this material. In Scenario 2, the priority was durability, classifying carbon steel 1020 as the solution closest to the ideal, reflecting the importance of mechanical and corrosion resistance. In Scenario 3, the priorities were energy performance and logistical ease (handling/shipping), where alloy A356 was the most suitable, standing out in density and thermal conductivity. Additionally, an analysis using the radar graphic method evaluated the ease of manufacture, considering casting, machining, and welding, where alloy A319 did not stand out. Alloys A356 and carbon steel 1020 are the most suitable options for the application, with the tie between the two depending on the criteria considered most relevant. The TOPSIS and Radar methods proved adequate for this application.
Technical Session
CUPPER CHARACTERIZATION AND PROCESSING IN A LOW-GRADE ORE FROM THE BAHIA’S NORTH REGION
Presenter(s): Francisco rinaldo moreira de morais (universidade federal de minas gerais), Andréia Bicalho Henriques (UNIVERSIDADE FEDERAL DE MINAS GERAIS), Samuel Bicalho Henriques (universidade federal de minas gerais)
Abstract:
The study addresses the significance of comprehensive mineralogical characterization for the technical and economic viability of mining ventures, using a case study in the geological domain of the Complex Barreiro, located in the northern region of Bahia, where copper deposits and their associations occur. Employing physical, chemical, and mineralogical analyses, the present mineralogical assemblage was identified, and the chemical elements were quantified in samples from a mine stock identified as low-grade copper ore. The results revealed the presence of copper at 0.095%, as well as gold (590 g/t), the latter with potential for byproduct extraction. In pursuit of optimizing the utilization of this ore, a methodology of unconventional characterization was proposed to identify the mineralogical phases and gold-bearing elements, guiding decision-making in the definition of beneficiation routes. This finding has the potential to contribute significantly to the economic and technological development of the region by expanding geological knowledge and exploring new opportunities for resource utilization.
Technical Session
9/4/24, 10:15 AM - 9/4/24, 11:05 AM
Presenter(s): Carolina Rossini simões (PONTIFÍCIA UNIVERSIDADE CATÓLICA)
Abstract:
Industrial food production can lead to environmental damage due to the improper disposal of oils waste. In response, by-products of the food industry can be reused as reagents (collectors) in the mineral flotation process. This study assessed the use of a collector obtained from soy oil soapstock in the selective flotation of hematite and quartz. Zeta potential tests indicated electrostatic interactions with quartz following activation with CaCl2, and a charge reversal in hematite from pH 4.3 to 3.9. It was possible to float both hematite and activated quartz with CaCl2 under various conditions using the same collector. Hematite achieved a maximum floatability of 96% at pH 8 with 0.0048 g/L of the collector, while quartz reached 83% at pH 11.5 with 0.014 g/L of the collector and 0.00046 g/L of CaCl2 as an activator. The study demonstrates that the fatty acid-based collector presents itself as an alternative viable and environmentally appropriate alternative for the selective flotation of hematite and quartz.
Technical Session
ELECTROFLOTATION OF FINES OF IRON ORE TAILINGS USING TWO BIOCOLLECTORS
Presenter(s): Ronald rojas hacha (PUC-Rio), Carolina Rossini simões (PUC-Rio), Matheus Willian Pereira da Silva (PUC-RIO), Flávia Paulucci Cianga Silvas (ITV), mauricio leonardo torem (PUC-RIO)
Abstract:
Iron ore mining produces considerable amounts of fine particles, such particles have a low probability of bubble/particle collision and adhesion. In order to solve this problem, several flotation technologies have been developed to increase bubble/particle collision efficiency. Among these technologies the electroflotation process stands out for increasing bubble/particle collision efficiency. The present work aims to study the recovery of fines of iron ore tailings using hydrogen bubbles by electroflotation, the biocollectors used were obtained from R. opacus, a biosurfactant and a bioreagent (R. opacus cell). The study was carried out in a modified Patridge-Smit binary cell, the iron grade of the ore tailing was around 14%, and the particle size was -38+20 μm. FTIR analysis were carried out with the objective of evaluating the characteristics of the functional groups of the biocollectors. Subsequently, electroflotation tests were performed with hydrogen bubbles to evaluate the effect of pH and biocollector concentration on the iron recovery. The bioreagent results showed a recovery around 35% and iron grade of 50% at pH 6. On the other hand, the results of the biosurfactant were better, being a recovery around 80% and iron grade of 55% at pH 3.
Technical Session
9/4/24, 10:15 AM - 9/4/24, 11:05 AM
Presenter(s): matheus willian pereira da silva (PONTIFÍCIA UNIVERSIDADE CATÓLICA), Carolina Rossini Simoes (PONTIFÍCIA UNIVERSIDADE CATÓLICA), Ronald Rojas Hacha (PONTIFÍCIA UNIVERSIDADE CATÓLICA), Maurício Leonardo Torem (PONTIFÍCIA UNIVERSIDADE CATÓLICA), flávia Paulucci Cianga Silvas (INSTITUTO TECNOLOGICO VALE), Rodrigo F. M. de Souza (PONTIFÍCIA UNIVERSIDADE CATÓLICA), Antônio Gutiérrez Merma (PONTIFÍCIA UNIVERSIDADE CATÓLICA)
Abstract:
The mining industry faces significant challenges related to the management and storage of large volumes of tailings, which pose environmental and human health risks. Reprocessing these wastes has proven to be a promising alternative to promote process sustainability, minimizing the impacts associated with storage and allowing for the reuse of raw materials in other processes. This study aims to develop a flotation flowchart for the selective separation of sulphur-bearing, calcium-bearing, and silicon-bearing minerals from a mining waste sample. The presence of fine particles (-20um) in the sample inhibits the action of chemical reagents, resulting in low metallurgical recoveries for both sulphide and carbonate minerals, necessitating the desludging process. After desludging, sulphide concentrates with sulphur contents exceeding 50% and calcium-bearing mineral concentrates with calcium contents above 70% were obtained.
Technical Session
STABILITY AND INCREASE IN PHYSICAL AVAILABILITY OF CRUSHING
Presenter(s): GUSTAVO BAUMGRATZ DE OLIVEIRA (samarco mineração), Kellerson Fernando Peixoto Santos (samarco mineração), Ataide José Dias (samarco mineração), Juliano Cunha (samarco mineração)
Abstract:
The Samarco Crushing area (Crushing 03), in the Germano Mining Complex, is responsible for one of the stages of the comminution process of iron ore mined in its mines. Located in this production process, after mineral extraction and before the Concentration Plant (C3), it is made up of a set of Crushers, Vibrating Screens and Belt Conveyors that, together, operate to reduce the granulometry of the mined ore to technically adequate levels. to subsequent processing and concentration processes. In a mining company, in order to maintain high quality standards and safe operation, at low costs, capable of guaranteeing market competitiveness, its equipment requires high robustness and operational reliability. Samarco's Crushing 03, the target of the study presented in this report, showed instability in reliability, with a recurrence of scheduled corrective maintenance and, consequently, negative impacts on its physical availability, with no tendency to change. To identify and act to resolve this instability, work based on the PDCA methodology was conducted by a multidisciplinary technical team that, with tool discipline and a robust action plan, made it possible to achieve good results and exceed the target of increasing availability. of Crushing 03 of 1.1% in seven months of work. In addition to the increase in physical availability, avoided losses exceeded R$78MM.
Technical Session
9/4/24, 10:15 AM - 9/4/24, 11:05 AM
Presenter(s): valter da silva vianna (TERNIUM), fabiano pachioni Perez (ternium), carlos henrique soares rodrigues (ternium), rodrigo da silva cruz santos (ternium)
Abstract:
The steel industry presents several challenges, mainly those related to maintenance management, the biggest being maintaining high availability of critical equipment while optimizing available resources. Within this management we can mention conductive refractory containers of steel and pig iron. These devices require regular maintenance that depends on extensive technical knowledge on the part of those involved and strict compliance with technical standards to carry out the work with excellence and safety. This project sought to reduce costs in purchasing bushings for steel and pig iron ladle trunnions, complying with technical and environmental standards.
Technical Session
9/4/24, 10:15 AM - 9/4/24, 11:05 AM
Presenter(s): JOUDERSON MATOS (ALVAREZ & MARSAL CONSULTORIA EM ENGENHARIA LTDA)
Abstract:
This study analyzed the impact of project management in the steel industry, using as a case study the refurbishment project of two Continuous Casting Machines (MLC) at Usiminas, in the city of Ipatinga. Among the main challenges were logistical constraints due to the vertical nature of the project, interferences as it was a brown-field project, limitation of the start and end date of the shutdown, difficulty in mobilizing qualified labor, low productivity, and potential risk of claims. As a course of action, management strategies were implemented from the project conception phases, including the development of a Project Execution Plan and clear governance definition during the shutdown, adjustment of shifts and bonuses for increased productivity and reduced absenteeism, project division and management into areas, definition and monitoring of KPIs for schedule adherence and productivity, as well as Monte Carlo simulations for schedule scenario evaluation. As a result, the effective implementation of management strategies and action plans based on lessons learned recovered delays and brought forward the completion of MLC2. This demonstrates the importance of project management in achieving operational and efficiency goals in the steel industry.
Technical Session
DESIGN AND MANUFACTURING OF ACCESSORIES FOR MECHANICAL BENDING TESTS
Presenter(s): CAIO RAMOS DE MENEZES (UFC), Ana Fabiola Leite Almeida (UFC), Francisco Nivaldo Aguiar Freire (UFC), Luiz Soares Júnior (UFC), Francisco Felipe de Moraes Fideles (UFC), Francisco Vitor Rosa de Lima (UFC)
Abstract:
This work addresses the design and manufacturing of accessories for mechanical bending tests. The objective is to develop supports for conducting bending tests on ceramic, composite, and polymer materials in a laboratory at the Federal University of Ceará. The study progressed from the ideation and conceptualization of mechanical drawings to manufacturing using conventional machining equipment and computer numerical control (CNC) machines. Two sets of supports were designed and fabricated, totaling 10 pieces and 20 fasteners in each set. The research results confirm the construction of a prototype with an adjustable system suitable for three-point and four-point bending tests, with an associated cost lower than that of commercially available accessories. However, it is suggested to perform finite element analysis to validate the possibility of conducting bending tests on metallic materials.
Technical Session
STRUCTURING PROCESSES OF BASIC MAINTENANCE GUIDELINES AT THE TERMINAL MARÍTIMO DE PONTA DA MADEIRA
Presenter(s): PAULO HENRIQUE BITTENCOURT DE BRITO (Vale.s.a.), Touberth Costa Rodrigues (VALE), Maionary de Assis Silva (VALE), Alexandre Ramos de Figueiredo (VALE)
Abstract:
The present work aims to present the advancement of the basic maintenance guidelines tool at the Terminal Marítimo de Ponta da Madeira (TMPM) through a timeline between 2020 and the first quarter of 2024, in addition to qualitatively measuring the gains in port administration . Starting from the problems exposed, such as the weakness in training specific operational standards for their functions, inadequate guidance for implementation, lack of routine management, leadership little engaged with the tool and lack of clear definition of roles and responsibilities of the directive functions. The tool is fortified with the aim of solidifying the standards of the port's standards, regulations and rules and leveraging the human reliability of its employees, bringing significant improvements in the areas of: Legal compliance, work safety, environmental protection, operational efficiency, quality of maintenance, company reputation, employee improvement mapping and reduction of legal and financial risks.
Technical Session
INTEGRATION OF FMEA AND 4.0 TECHNOLOGY IN A REACTOR IN THE STEEL INDUSTRY
Presenter(s): Bruno Felipe Monteiro Santos (Tecnored desenvolvimento tecnológico s.a), Alessandro Andrade Marques (tecnored desenvolvimento tecnológico s.a), Djavan de Oliveira (TECNORED), Alex Brasil Maria (TECNORED), Igor Ribeiro Roque (TECNORED), Wagner de Deus Silva (TECNORED)
Abstract:
With the advancement of technology, various have emerged to enhance and automate processes. Aiming to improve the the reliability, availability, safety, and maintainability of assets, this work employed the quality tool FMEA (Failure Mode and Effect Analysis) in conjunction with industry 4.0 innovations. FMEA provides the necessary data and information to understand the root causes of machine problems, using IoT (Internet of Things) sensors and signal processing with AI (Artificial Intelligence), which are delivered in AR (Augmented Reality) to field, assisting managers in making more precise decisions. It is important to note that this project was developed in the reactor of the biomass carbonization plant of Tecnored S.A., located in Pindamonhangaba-SP.
Technical Session
INFLUENCE OF CALCINATION TEMPERATURE ON THE REACTIVITY OF KAOLIN INDUSTRY WASTE IN THE PRODUCTION OF GEOPOLYMER CEMENT
Presenter(s): RAYANNE OLIVEIRA LEãO SANTANA (UNIVERSIDADE FEDERAL DO PARÁ), Paulo Anderson Aranha Ferreira (UNIVERSIDADE FEDERAL DO PARÁ), Giovana Zagalo de França (UNIVERSIDADE FEDERAL DO PARÁ), vitor leão Santana (UNIVERSIDADE FEDERAL DO PARÁ), Alisson Clay Rios da Silva (UNIVERSIDADE FEDERAL DO PARÁ), Verônica Scarpini Candido (UNIVERSIDADE FEDERAL DO PARÁ)
Abstract:
Geopolymers are formed by a three-dimensional matrix of aluminosilicates, have the potential to replace traditional Portland cement. Hard kaolin, a by-product of the paper industry, is rich in kaolinite and can be transformed into metakaolin, a reactive precursor in geopolymerizationThis study analyzes the influence of calcination temperature on hard kaolin waste in the production of geopolymer cement.. The research utilized metakaolin derived from hard kaolin and blast furnace slag, subjecting them to calcination at 550°C, 650°C, and 750°C. The compressive strength results were 20.9 MPa, 31.4 MPa, and 39.8 MPa, respectively, showing that increasing the temperature improves the strength of the geopolymers. Additional tests revealed that water absorption and porosity decrease while density increases at higher temperatures, indicating a denser and more cohesive structure at 750°C. Microscopic analysis confirmed higher geopolymerization efficiency at 750°C, evidenced by the absence of cracks, bubbles, and unreacted material, resulting in a more homogeneous and dense matrix. It is concluded that calcination at 750°C is the most effective in optimizing the physical and mechanical properties of geopolymers, highlighting their potential as an efficient and durable substitute for conventional cement in civil construction.
Technical Session
LIFE CYCLE ASSESSMENT (LCA) OF MORTAR WITH PARTIAL REPLACEMENT OF PORTLAND CEMENT WITH SILICA FUME
Presenter(s): LUCAS RANGEL BARBOSA (UENF), Josinaldo de Oliveira Dias (UFES), Markssuel Teixeira Marvila (UFV), Afonso Rangel Garcez de Azevedo (UENF)
Abstract:
This work aimed to apply the Life Cycle Assessment (LCA) methodology, established by ISO 14040 and ISO 14044, to compare the environmental impacts of traditional mortars and mortars with partial replacement of Portland cement by silica fume. The system boundary was “from cradle to gate” and the functional unit of m³ of mortar, using the commercial program SimaPro®. In the initial assessment, considering 1 m³ of material, mortars with silica fume content presented reduced environmental impacts compared to conventional ones, with variations between 3% and 10% between the impact categories analyzed. Concluding that the LCA methodology proved to be adequate in the comparative evaluation between mortars and that the partial replacement of Portland cement by silica fume results in a reduction in the environmental impact in the cement materials industry.
Technical Session
9/4/24, 10:15 AM - 9/4/24, 11:05 AM
Presenter(s): MANOEL VINICIUS FRANCA MONTEIRO (UNIVERSIDADE FEDERAL DO PARá), Jennifer Ferreira Fernandes (UNIVERSIDADE FEDERAL DO PARÁ), Haianny Beatriz Saraiva Lima (UNIVERSIDADE FEDERAL DO PARÁ), Ana Paula Souza de Sousa (UNIVERSIDADE FEDERAL DO PARÁ), Diego Cardoso Estumano (UNIVERSIDADE FEDERAL DO PARÁ), Emerson Cardoso Rodrigues (UNIVERSIDADE FEDERAL DO PARÁ), Deibson Silva da Costa (UNIVERSIDADE FEDERAL DO PARÁ)
Abstract:
The global interest in sustainable technologies has brought attention to the challenges related to the accumulation of synthetic plastics. In this regard, a possible solution is the pursuit of new polymer composites reinforced with plant fibers, such as those found in the Amazon. Therefore, this study aimed to characterize and assess the feasibility of composites with fibers from the envira cheirosa plant (Annona paludosa Aubl.), a plant already used by rural communities in the construction of mud house walls, yet still underexplored in the literature. The production of the composite followed the hand lay-up manual manufacturing method, using a silicone mold, and incorporation of 1, 3, and 5% by mass of fiber, followed by compression with 39 N. In the matrix, unsaturated orthophthalic polyester resin and 1% (v/v) butanox M-50 initiator were used. The picnometer method was used to obtain the specific mass of the fiber, and for morphological characterization, Scanning Electron Microscopy (SEM) was employed. Mechanical analysis was conducted using ASTM D638 standard to obtain the tensile strength results. Morphological characterization showed predominantly smooth fibers, and mechanical tests demonstrated a significant increase in tensile strength with the addition of fibers to the matrix. Thus, indicating that envira cheirosa fibers have potential as reinforcement in composites, especially in applications requiring lighter and stronger materials.
Technical Session
9/4/24, 10:15 AM - 9/4/24, 11:05 AM
Presenter(s): maria laura fonseca santos (universidade federal de minas gerais)
Abstract:
This study evaluates the adsorption capacity of geopolymers in the removal of heavy metals (iron, manganese and copper) in a simulation of acid mine drainage with pH 3. Nine samples of geopolymers were produced, organized into three groups with variations in the silica- alumina, and each group subdivided into three with different proportions of activating solution. The main objective was to investigate how these variations influence the effectiveness of geopolymers in adsorbing metals in acidic solutions. The methodology consisted of synthesizing the geopolymers and carrying out contact tests between the samples and the acidic metallic solutions. The quantification of adsorbed metals was carried out after the tests, allowing a comparative analysis between the different geopolymer formulations. The results indicated a significant variation in the adsorption capacity of geopolymers, depending mainly on the silica-alumina ratio. Samples with specific compositions showed greater efficiency in removing the metals tested. It is concluded that the formulation of geopolymers can be optimized to maximize their effectiveness in the adsorption of these metals in acid mine drainage environments. This work not only highlights the potential of geopolymers as environmental treatment materials, but also opens perspectives for future research into their applications in real contamination conditions.
Technical Session
9/4/24, 10:15 AM - 9/4/24, 11:05 AM
Presenter(s): Milena da Silva Gallotte (IME - INSTITUTO MILItar de Engenharia), Nivaldo Pereira da Silva Júnior (IME), Pedro Theophilo Gomes Magalhães (IME), Pedro Martins Soares (IME), Solano Monteiro Paes (IME), Victor Kauã de Sousa Viana (IME), mARVIN DE NACIMENTO (IME), aMAL ELZUBAIR ELTOM (IME), mARCELO HENRIQUE DE SILVA PRADO (IME)
Abstract:
It is extremely important to reduce the susceptibility to infections during the implant and graft processes. However, studying and analyzing the antibacterial effect of biocompatible ceramic composites can partially solve the problem. For this, bioglass composites reinforced with KNN were produced in proportions of 10%, 20% and 30% w/w. Appropriate experimental techniques were used to characterize its physical properties (density, porosity, and linear contraction), structural, morphological, mechanical, and antibacterial effect. The results were satisfactory regarding the antibacterial response of bioglass reinforced with KNN. This brings a significant contribution and valuable knowledge to the development of more effective and functional biomedical grafts and implants.
Technical Session
9/4/24, 10:15 AM - 9/4/24, 11:05 AM
Presenter(s): PALOMA SUELLEN LIMA DE SOUSA (UFPA), sarah gabrielly brandão de souza (ufpa), joelly vera nascimento (ufpa), damares da cruz barbosa nascimento (ufpa), Alisson clay rios da silva (ufpa), veronica scarpini candido (ufpa)
Abstract:
Mortar is a fundamental component in civil construction, used to lay floors, bricks and other functions such as waterproofing, etc. When exposed to high temperatures, the resistance of the mortar decreases considerably, altering its properties. The present work explores the behavior of cementitious materials under thermal variations, focusing on the analysis of volumetric shrinkage, deformation, and compressive strength. The mortar specimens were prepared with Portland CP II cement, natural sand, and water, and after 28 days of curing, they were exposed to temperatures of 25°C, 250°C and 350°C for 60 minutes, followed by temperature tests. compression. The results indicated a significant reduction in compressive strength and an increase in volumetric shrinkage with increasing temperature. It is concluded that thermal variations negatively impact the durability of mortar structures, and relief strategies, such as the addition of pozzolanic additives, are necessary to improve thermal resistance and ensure the safety and durability of constructions.
Technical Session
ANALYSIS OF METAKAOLIN REACTIVITY BY RIETVELD REFINEMENT FOR GEOPOLYMER PRODUCTION
Presenter(s): paulo anderson aranha ferreira (universidade federal do pará), giovana zagalo de frança (UNIVERSIDADE FEDERAL DO PARÁ), rayanne oliveira leão santana (UNIVERSIDADE FEDERAL DO PARÁ), damares da cruz barbosa nascimento (UNIVERSIDADE FEDERAL DO PARÁ), VERÔNICA SCARPINI CANDIDO (UNIVERSIDADE FEDERAL DO PARÁ), ALISSON CLAY RIOS DA SILVA (UNIVERSIDADE FEDERAL DO PARÁ)
Abstract:
Clinker is the main material for producing Portland cement concrete. However, the process of obtaining it generates high energy expenditure, which leads to high CO2 emissions. Alternative cementitious materials have a low emission of polluting gases, as they are produced from raw materials of residual or geological origin. Due to factors of limited access and variation in chemical composition, calcined clays are the most used in the production of alternative cements compared to the use of waste. Metakaolin is a clay mineral calcined between 600 and 800°C with pozzolanic activity, and for this reason it is the main precursor material for geopolymers. Geopolymers are inorganic cementitious materials that are produced through geopolymerization between a source of aluminosilicates and an alkaline solution. And through the formation of Si-O-Al bonds, they generate a solid with high mechanical resistance, durability and refractoriness. Therefore, the present work evaluated the reactivity of metakaolin obtained at 650 and 850°C for 2h, using X-ray diffractometry and Rietveld refinement, for the production of geopolymers. Kaolin from the Amazon sedimentary basins was used. The kaolin was calcined at 650°C and 850°C for 2h to obtain metakaolin. After calcination, the X-ray diffractometry technique and Rietveld refinement were applied. X-ray diffractometry analysis together with Rietveld refinement proved that metakaolin obtained at 850°C showed greater reactivity, being ideal for producing geopolymers with high mechanical performance.
Technical Session
RECYCLING FLUORESCENT LAMP GLASS IN RED CERAMIC
Presenter(s): Carlos Maurício Fontes Vieira (UENF ), Geovana carla girondi delaqua (UENF)
Abstract:
This work investigated the feasibility of recycling fluorescent lamp glass added to a traditional red ceramic mass. Characterization was carried out by FRX, DRX, granulometry. Formulations were made with different percentages, and test specimens were produced by pressing and fired at different temperatures, so that it was possible to evaluate the properties of water absorption, linear shrinkage and flexural rupture stress. Based on the results, it was possible to conclude that, as it has a composition similar to clay, the addition of glass to a ceramic mass contributes to improved plasticity, and after firing, a reduction in water absorption and, consequently, an increase in the resistance of the pieces. Therefore, ceramics are a highly viable alternative for disposing of this waste
Technical Session
9/4/24, 10:15 AM - 9/4/24, 11:05 AM
Presenter(s): Carlos Maurício Fontes Vieira (UENF ), Geovana carla girondi delaqua (UENF)
Abstract:
This work had as its objective to evaluate the firing behavior of a kaolinitic clay incorporated with phonolite aiming at semiporous pressed ceramic tiles. Compositions were prepared with addition of 20 and 40 wt.% of phonolite to a kaolinitic clay. For comparison, an industrial ceramic body from Santa Gertrudes, State of São Paulo, was also evaluated. Cylindrical specimens were prepared by uniaxial pressure at 25 MPa followed by firing at temperatures varying from 1050 to 1200oC. The fired specimens were submitted to the following tests: linear shrinkage and water absorption as function of the firing temperature. The microstructural evaluation of the compositions was accomplished by X-ray diffraction and scanning electron microscopy. The results showed that the phonolite addition significantly improve the sintering of the clay, mainly, above 1150oC with sharp decrease of the porosity. Although the clay/phonolite mixtures showed higher amount of alkaline oxides as compared with the industrial ceramic tile body, the required water absorption of 10% for semiporous tiles was only reached at temperatures around 80oC higher than the industrial body
Technical Session
9/4/24, 10:15 AM - 9/4/24, 11:05 AM
Presenter(s): Damares da cruz barbosa nascimento (Universidade federal do pará), Avener gleidson andrade santos (universidade federal do rio grande do sul), TAIANA DE SOUSA MATOS (UNIVERSIDADE FEDERLA DO PARÁ), sérgio neves monteiro (instituto militar de engenharia ), alisson clay rios da silva (universidade federal do pará), verônica Scarpini candido (universidade federal do pará)
Abstract:
The use of recommended inputs from industrial waste has increased interest in research, into new ways of producing more sustainable and recyclable materials. Chicken eggshells are waste from industrial establishments. They are mainly formed by calcium carbonate and can be used as a source of calcium to replace synthetic materials. In this way, the objective is to obtain calcium hydroxide from chicken eggshells, using the calcination technique at high temperatures in shells with and without membrane. Then, the material obtained was characterized by Fourier transform infrared spectroscopy (FTIR) and X-ray diffraction (XRD). The results showed the existence of hydroxyl groups (OH-) and carbonates (CO3-2), according to FTIR analysis. By XRD, the presence of calcium hydroxide (Ca(OH)2) and calcium oxide (CaO) was observed. According to the results, it was possible to obtain calcium hydroxide from the complete use of chicken egg shells.
Technical Session
RESÍDUO DE CASCA DE JABUTICABA ADICIONADO EM UMA MASSA CERÂMICA AVALIANDO O EFEITO NAS PROPRIEDADES FISICO-MECÂNICA
Presenter(s): Geovana Carla gIRONDI dELAQUA (UENF ), Elvis Pantaleão Ferreira (ifes), VICTOR HUGO SANTOS (UENF), DJALMA SOUZA (uenf), Carlos Maurício Fontes Vieira (uenf)
Abstract:
The objective of the present work was to evaluate the influence of the addition of jabuticaba waste on the properties of a red ceramic. The ceramic mass was characterized by FRX and DRX. Compositions with different percentages of waste were prepared in proportions of 0; 1, 3 and 5% of jabuticaba waste in the ceramic mass. The red ceramic specimens were formed and fired at temperatures from 850°C to 1050°C. After manufacturing the ceramic specimens, the water absorption properties and flexural rupture strength were determined. Through the results it was possible to evaluate that the incorporation of jabuticaba waste into a ceramic mass must be controlled, so that it does not harm the properties. In this way, in addition to a destination for the waste, it is possible to add jabuticaba residue and contribute to cost reduction in the ceramic firing stage.
Technical Session
9/4/24, 10:15 AM - 9/4/24, 11:05 AM
Presenter(s): Isabela Devesa Batista (Universidade estadual do norte fluminense darcy ribeiro), Ana Laura Lopes de Matos Riscado (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO), Sheila Mara Santos da Silva (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO), Juliana Fadini Natalli (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO), Madeleing Taborda Barraza (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO), Sérgio Neves Monteiro (ime), Afonso Rangel Garcez de Azevedo (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO)
Abstract:
The search for sustainable solutions in the construction industry has become increasingly relevant in the face of global environmental challenges. One of these promising solutions is the partial replacement of cement with quartz powder in the formulation of mortars, which brings with it a series of environmental and economic benefits. This replacement represents a sustainable and effective strategy to reduce carbon dioxide (CO2) emissions, reuse industrial waste and promote sustainability in construction. This approach not only benefits the environment, but also contributes to building a more responsible sector that is aware of its impacts. To evaluate the technological properties of this new mortar, consistency index, apparent density, water absorption by capillarity and mechanical resistance tests were carried out. Quartz powder was replaced by 5%, 10% and 15% in relation to cement. The mechanical resistance found did not meet the minimum requirements of the standard, and its use in the conditions studied in this research is not recommended.
Technical Session
WALL TILE PRODUCED WITH A MUNICIPAL SEWAGE TREATMENT PLANT (STP) SLUDGE
Presenter(s): Isabela oliveira rangel areias (UENF), FELIPE SARDINHA MACIEL (uenf), josé nilson frança de holanda (uenf)
Abstract:
This work aimed to evaluate the use of STP sludge as an alternative raw material in tile production. The raw materials used were red clay, quartz, calcitic calcareous and STP sludge. Four formulations were prepared: 0, 5, 10 and 15% by weight of STP sludge replacing calcareous material. The elementary chemical analysis of the raw materials was determined by the X-ray fluorescence technique. The loss on ignition (LoI) was also determined. The pieces were pressed and fired at 1160 ºC in a rapid firing cycle. The pieces of red wall tile were tested to determine their technological properties (linear shrinkage, water absorption, and flexural breaking strength). The experimental results indicated that the technological properties were influenced by the incorporation of STP sludge. The results also showed that the red wall tile pieces presented water absorption values in the range of 18.66-19.65%. Thus, STP sludge can fully replace natural calcareous material (up to 15% wt.%) in the production of ceramic slabs for red wall Tile-type coverings (Porous Coating - BIII group - Water Absorption > 10%; ABNT NBR ISO 13006: 2020 Standard). Finally, the use of STP sludge on the production of red wall tiles could be a technical solution for eliminating these polluting solid waste, in addition to contributing to sustainable development.
Technical Session
9/4/24, 10:15 AM - 9/4/24, 11:05 AM
Presenter(s): iully da silva amaral pereira (uenf), José Alexandre Tostes Linhares Júnior (uenf), Samuel Araújo Azevedo Malafaia (uenf), Larissa Mendonça Osorio Fonseca (uenf), Juliana Fadini Natalli (uenf), Afonso Rangel Garcez Azevedo (uenf), sergio neves monteiro (ime)
Abstract:
Cementitious mortar is a material widely used in civil construction, mainly composed of the binders cement and lime. The cement industry, in turn, is one of the main contributors to CO₂ emissions, causing various environmental impacts. In order to mitigate these effects, eco-friendly alternatives are sought, such as the incorporation of lignocellulosic fibers in cementitious matrices, aiming to improve the properties of the material by reducing the exploitation of these raw materials. In this context, the performance of coating mortars was analyzed in the proportion 1:1:6;1.4 (cement:lime:sand:water), with the addition of 3% pineapple leaf fibers, treated with tannic acid. in concentrations of 2.5% and 5%, and the control mortar (without fibers). The tests carried out evaluated the resistance to traction, compression and mass density in the hardened state. The results indicated that the mixtures with treated fibers showed an increase in resistance after 28 days, and in density, in relation to the reference mortar. On the other hand, the mixture without fibers had lower tensile and compressive strengths. In this way, coating mortars reinforced with vegetable polyphenol demonstrated promising results, pointing to their viability as a sustainable alternative.
Technical Session
9/4/24, 10:15 AM - 9/4/24, 11:05 AM
Presenter(s): José Lucas Decoté de Carvalho Lirio (UENF - ALBERTO LAMEG), Karla albernaz sales (UENF), Felipe daflon gama (UENF), Geovana Carla Girondi Delaqua (UENF), SÉRGIO NEVES MONTEIRO (IME), CARLOS MAURÍCIO FONTES VIEIRA (UENF)
Abstract:
This study investigates the impact of adding three types of ash on the properties of red ceramics, common products derived from clayey raw materials. The burning of this raw material generally occurs between 850°C and 950°C, resulting in the characteristic reddish color. The ash was obtained from different burning processes, such as solid fuels such as charcoal; urban solid waste and rice husk. Ash is considered an environmental pollutant due to its large quantity generation and lack of adequate disposal. The study evaluated 10 formulations, incorporating ash at levels of 5%, 10% and 20%. The properties analyzed included water absorption, linear shrinkage and mechanical resistance, demonstrating that the control of incorporated ash content enables the production of a variety of ceramic products with technological, economic and environmental gains.
Technical Session
OBTAINING CERAMIC TILES WITH GLASS WASTE AND KAOLIN CLAY
Presenter(s): Layza Azeredo dos Santos (UENF), Geovana carla girondi delaqua (UENF), Carlos Maurício Fontes Vieira (uenf)
Abstract:
The aim of this work is to obtain a ceramic tiles with kaolinitic clay, argillite and glass mud and bottle glass wastes. The wastes were initially benefited by drying, crushing and sieving in a 200 mesh (0.074mm) mesh and later incorporated in 20 wt.% in a typical kaolinite clay from Campos dos Goytacazes mixed with argillite from Itu-SP in equal proportions. Specimens, with 8% moisture content, were obtained by uniaxial pressing at 35 MPa and fired at temperatures of 1100 and 1125°C. The physical and mechanical properties evaluated were: Apparent dry density, water absorption, linear shrinkage and flexural rupture strength. The results show that both argillite and glass waste act as a flux material in a traditional ceramic formulation with clay as the base raw material, making it possible to reach the specification of porcelain stoneware at temperatures well below the usual industrial firing temperatures
Technical Session
9/4/24, 10:15 AM - 9/4/24, 11:05 AM
Presenter(s): Leandro Barbosa de Oliveira (UENF )
Abstract:
Portland cement is one of the most used materials in the world. However, demand and energy expenditure have increased the search for alternative and more sustainable materials that can fill this gap. Thus, the objective of this research was to create a metakaolin geopolymeric paste, partially replacing it with fly ash in percentages of 20 and 40%, with curing at 25 and 65 ºC to carry out tests in the hardened state of compressive strength and apparent density at 3 and 6 days. The results showed that thermal curing accelerated the geopolymerization process and achieved results of 12.71, 11.56 and 9.76 MPa for (0, 20 and 40% fly ash) at 3 days, while in ambient curing only the reference sample of metakaolin had satisfactory results, reaching 11.32 MPa. For the 6 days, with the longer time for alkaline activation, the ambient curing compounds had better results compared to the 3 days, with gains of 30.1%, 54.7% and 247% for (0, 20 and 40% of substitution). Thus, it was observed that for early ages, the metakaolin and fly ash geopolymer has greater potential for application when used with thermal curing at moderate temperatures around 60 ºC.
Technical Session
INFLUENCE OF WOOD bottom ASH ON PARTIAL REPLACEMENT OF CEMENT IN CEMENT-LIME COATING MORTARS
Presenter(s): Leila Celin Nascimento (ifes - campus vitória), gercyr baptista junior (IFES - CAMPUS VITÓRIA), Gustavo de castro xavier (uenf)
Abstract:
Wood bottom ash is generated abundantly in small furnaces and discarded without control in the ground. One possibility of application of this material is the partial replacement of cement in small proportions in mortars. The objective of this research is to evaluate the replacement of wood bottom ash in CPIII cement in coating mortars, ratio 1:1:6 by mass (cement: lime: sand), using 0%, 5%, 10% and 15% of wood bottom ash. To achieve this objective, wood bottom ash was processed and characterized by: energy dispersive x-ray spectroscopy (EDX), x-ray diffraction (XRD) and scanning electron microscopy (SEM). The consistency was evaluated in the fresh state, and in the hardened state the following were evaluated: compressive strength, flexural strength and dynamic elastic modulus. Among the results obtained, it is emphasized that wood bottom ash causes an increase in water demand. Furthermore, at 5% replacement, compressive strength, flexural strength and dynamic elastic modulus of increase. Therefore, the good performance of coating mortars with wood bottom ash is conditioned by low percentages of cement replacement.
Technical Session
9/4/24, 10:15 AM - 9/4/24, 11:05 AM
Presenter(s): MARCELA DA SILVA LUNA PARAVIDINO (UENF), Mariana Almeida de Azevedo Pessôa (UENF), JONAS ALEXANDRE (UENF), Gustavo de Castro Xavier (UENF), ROMÁRIO MOREIRA SIQUEIRA (UENF), Sérgio Neves Monteiro (ime), Afonso Rangel Garcez de Azevedo (uenf)
Abstract:
This article reviewed the literature on ceramics in structural masonry, through graphics and bibliometric techniques, and relating them. Therefore, the article aims to answer the following research question: What is the approach on studies regarding structural masonry? Aiming to understand dynamics and trends of publications within this area and investigate relationships of authors and citations knowledge database. As a method, research was carried out on scientific articles in the Scopus, Science Direct and Web of Science databases, related to the number of times the terms “structural masonry” and “ceramic” were discussed. Resulting, after carrying out the filters, 595 publications were found across the three databases, in the period between 2014 and 2024. Using bibliometric analysis techniques, it was possible to identify the most influential terms and authors and how they relate to each other, in addition to identify the origin of most recent publications. In this way, it is concluded through investigation using VOSViewer shows that Brazil stands out on quantity of publications, and that ceramics represents around 19% of relevance among the materials used in structural masonry.
Technical Session
9/4/24, 10:15 AM - 9/4/24, 11:05 AM
Presenter(s): magno torres carvalho (IME), André Ben-Hur da Silva Figueiredo (IME), Sérgio Neves Monteiro (IME), José Brant de Campos (Uerj), Francisco Cristóvão Lourenço de Melo (IAE), Eduardo de Sousa Lima (IME)
Abstract:
Advancements in armor systems in armed conflicts led to the integration of advanced ceramics, replacing traditional metallic armors and driving new methodologies in ballistic armor development. The study focused on a ceramic matrix composite (CMC) composed of silicon carbide (SiC), alumina (〖Al〗_2 O_3), yttria (Y_2 O_3), and a lithium-aluminum-silicon glass-ceramic system (LAS). The results indicated that samples with minimal LAS additions exhibited the highest Vickers hardness, averaging 25 GPa, along with enhanced wear resistance during cutting susceptibility tests. Furthermore, ballistic evaluations did not reveal statistical disparities among LAS concentration levels. These findings underscore the importance of optimizing material proportions in ceramic composites manufacturing to achieve desired mechanical and ballistic performance.
Technical Session
9/4/24, 10:15 AM - 9/4/24, 11:05 AM
Presenter(s): MARKSSUEL TEIXEIRA MARVILA (UFV - CRP), Thiago Ranilson Caixeta Silva (UFV - CRP), Luiz Arthur Silva de Aquino (UFV - CRP), Marília Gonçalves Marques (UFV - CRP), Leonardo Carvalho Mesquita (ufv - crp), afonso rangel garcez de azevedo (UENF)
Abstract:
Due to the great potential for replacing synthetic fibers with natural fibers, several studies have been carried out aiming to reconcile the growth of the construction industry with sustainable development. Therefore, the objective of this research was to compare three different alkaline treatments on corn straw fiber incorporated in cement and lime mortars for application in covering and laying walls and ceilings. Cylindrical specimens measuring 50x100 mm were made using 0%, 2.5% and 5% natural fibers and fibers treated with sodium hydroxide (NaOH), potassium hydroxide (KOH) and calcium hydroxide (Ca(OH)2) for the composition 1: 1:6:1.55 (cement: lime: sand: water). For the hardened state, the mixtures were evaluated for compressive strength, water absorption, density and porosity, and for the fresh state for their consistency. Chemical, physical and mineralogical characterizations of the fibers were carried out. For the chemical characterization of the fibers, an increase in crystalline cellulose was found from 59.03% to 63.50% (NaOH), 62.41% (KOH), 60.40% (Ca(OH)2), which favors fiber resistance. The water absorption results showed that the mortar containing the treated fibers presented lower values compared to the natural fiber, being a positive point for mechanical resistance. Another positive point that alkaline treatments presented was the reduction in the impurity content of the natural fiber, mainly the treatment with sodium hydroxide (NaOH), with a reduction of 4.69%. Thus, it can be concluded that the treatments improved the properties of the fiber, enabling its use in mortars for covering and laying walls and ceilings. It is worth mentioning that treatment with sodium hydroxide (NaOH) proved to be more efficient in the different properties evaluated
Technical Session
HYDROXYAPATITE PELLETS BIOACTIVITY EVALUATION AFTER ANODIZATION PROCESS: A PILOT STUDY
Presenter(s): Marvin do NAscimento (Instituto Militar de Engenharia), Bruno Martins de Souza (INSTITUTO MILITAR DE ENGENHARIA), carlos henrique da luz barbosa (INSTITUTO MILITAR DE ENGENHARIA), julianna magalhães garcia (INSTITUTO MILITAR DE ENGENHARIA), marcelo henrique prado da silva (INSTITUTO MILITAR DE ENGENHARIA)
Abstract:
Hydroxyapatite is a highly biocompatible ceramic material used in bone grafts and implants. Surface treatment strategies can improve the performance of this biomaterial. Anodizing is an electrochemical process that modifies the surface to increase bioactivity. The aim of this study is to anodize hydroxyapatite pellets and carry out bioactivity tests on this material. Hydroxyapatite pellets were anodized at different voltages and then subjected to a bioactivity test for subsequent analysis by scanning electron microscopy. The results are promising at lower voltages, but further studies are still needed to better interpret the data
Technical Session
SYNTHESIS OF HYDROXYAPATITE BY AQUEOUS PRECIPITATION VARYING THE DECANTATION METHOD
Presenter(s): Marvin do NAscimento (Instituto militar de engenharia), carlos henrique da luz barbosa (INSTITUTO MILITAR DE ENGENHARIA), julianna magalhães garcia (INSTITUTO MILITAR DE ENGENHARIA), marcelo henrique prado da silva (INSTITUTO MILITAR DE ENGENHARIA)
Abstract:
Introduction: Hydroxyapatite is a ceramic biomaterial with high biocompatibility, bioactivity and similarity to human teeth and bones. Although hydroxyapatite can be synthesized using various routes, the wet precipitation method stands out due to its simplicity and efficiency. Objective: The aim of this work is to synthesize hydroxyapatite by comparing natural and temperature-assisted decantation. Materials and Methods: After synthesis using the wet aqueous precipitation method, the decantation process was divided into three groups: normal decantation, oven decantation and non-decantation. These groups were characterized by X-ray diffraction and scanning electron microscopy. Results: X-ray diffraction showed the presence of monetite and brushite in the groups of green samples, and hydroxyapatite and beta tricalcium phosphate in the groups of sintered samples. Scanning electron microscopy micrographs show different morphologies for each of the groups. Conclusion: The synthesis of hydroxyapatite by aqueous precipitation, followed by decantation and filtration, is crucial for high-quality biomaterials. The decantation method affects purity and efficiency, and materials engineering seeks to optimize these processes.
Technical Session
9/4/24, 10:15 AM - 9/4/24, 11:05 AM
Presenter(s): matheus queiroz de sant'anna pereira (uenf), Felipe Daflon Gama (uenf), José Lucas Decoté de Carvalho Lirio (uenf), José Alexandre Tostes Linhares (uenf), Markssuel Teixeira Marvila (ufv), Carlos Maurício Fontes Vieira (uenf)
Abstract:
This work aims to analyze the characteristics and technological properties of gray clay, typical of the municipality of Campos dos Goytacazes-RJ, aiming to manufacture tiles. An X-ray Fluorescence Spectroscopy (XRF) test was carried out on the clay mass to identify the constituents of this clay. Specimens were prepared using uniaxial pressing at 10 tons, with firing at temperatures ranging from 700°C to 800°C. The technological properties evaluated after firing included linear shrinkage, water absorption and three-point flexural strength and apparent density. The results showed that the gray clay originating from Campos dos Goytacazes-RJ presented characteristics that do not allow its use for tiles as it had a low flexural resistance, not reaching the value required by the standard, and a water absorption very close to the maximum required by the standard. Consequently, indicating the difficult applicability of this type of clay for the production of tiles, however, it fits within the standards for brick production, as is commonly used in the region.
Technical Session
EVALUATION OF PARTIAL REPLACEMENT OF PORTLAND CEMENT WITH SAWDUST BIOCHAR VIA SLOW PYROLYSIS IN FRESH STATE RENDERING MORTARS
Presenter(s): RITA DE KASSIA GONCALVES PEREIRA (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO - UENF), Samuel Araújo Azevedo Malafaia (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO - UENF), Iully da Silva Amaral Pereira (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO - UENF), Juam Carlos Pierott Cabral (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO - UENF), Juliana Fadini Natalli (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO - UENF), Afonso Rangel Garcez de Azevedo (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO - UENF), Felipe Perissé Duarte Lopes (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO - UENF), Markssuel Teixeira Marvila (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO - UENF)
Abstract:
The partial replacement of sawdust biochar for cement in rendering mortars emerges as a sustainable and innovative approach in civil engineering. Derived from biomass pyrolysis, biochar offers potential benefits depending on its specific application. Besides its technical attributes, incorporating biochar in construction significantly reduces the carbon footprint and valorizes agro-industrial waste. This study investigates the impacts of adding biochar treated at 300°C, using laboratory tests to * Contribuição técnica ao 77º Congresso Anual da ABM – Internacional, parte integrante da ABM Week 8ª edição, realizada de 03 a 05 de setembro de 2024, São Paulo, SP, Brasil. analyze its physical and chemical properties when partially substituted for Portland cement in rendering mortars. Different replacement proportions of 0.5% and 1% by cement mass were tested in mortar formulations with a 1:1:6 ratio of cement, lime, and sand. The mortars were subjected to fresh state tests, including consistency, bulk density, incorporated air content, and water retention. The results indicated that replacing small percentages of cement with sawdust biochar yielded favorable outcomes in the tests, compared to reference mortars and existing literature. This substitution resulted in good workability, consistency indices within the range of 260 +/- 5 mm, and a considerable increase in water retention values across all mixtures.
Technical Session
9/4/24, 10:15 AM - 9/4/24, 11:05 AM
Presenter(s): Antonio Ricardo grippa satiro (Ifes/UENF), Eduardo Atem de Carvalho (UENF), FELIPE PERISSÉ DUARTE LOPES (UENF), Noan Tonini Simonassi (UENF), SERGIO NEVES MONTEIRO (UENF)
Abstract:
Polymeric composites are explored for their versatility and industrial potential. This study investigates the mechanical behavior of polyurethane composites reinforced with broomcorn (Sorghum bicolor) stalks, a low-cost and readily available material often discarded after broom production. The aim was to evaluate the compressive strength of composites with volumetric fractions of 60%, 70%, 80%, and 90% of stalks positioned transversely relative to the length of the specimens. Composites were prepared using castor oil-based polyurethane resin, molded, cured, and cut according to ASTM D695 standards. Compression tests revealed that strength increased up to the 80% volumetric fraction of stalks, with a slight decrease at 90%. However, ANOVA analysis indicated that these differences are not statistically significant. Specific strength also increased with the addition of stalks but without significant differences. It was concluded that incorporating broomcorn stalks in polyurethane composites increases compressive strength up to an 80% volumetric fraction, with no statistically significant differences among the tested fractions. Nonetheless, the potential of this material as a sustainable reinforcement is highlighted.
Technical Session
SIMULATION OF THE CRITICALITY OF A HYPOTHETICAL NUCLEAR FUEL ELEMENT FOR PWR REACTORS WITH 316 STAINLESS STEEL CLADDING DOPED WITH NIOBIUM
Presenter(s): Ary Machado de Azevedo (ime), Thomaz jacintho lopes (ime), Marcos Paulo Cavaliere de Medeiros (ime), fernando manuel araújo moreira (ime), Sérgio neves monteiro (ime), Joana Batista Soares (ime), Domingos D’Oliveira Cardoso (ime), André Ben-Hur da Silva Figueiredo (ime)
Abstract:
VARIOUS APPLICATIONS WERE EXPLORED, INCLUDING FUEL ROD COATINGS, STRUCTURAL ALLOYS, AND COOLING MATERIALS IN NUCLEAR REACTORS, FOCUSING ON PERFORMANCE, SAFETY, AND DURABILITY IMPROVEMENTS. THE RESULTS REVEALED THAT NIOBIUM DOPING PROVIDED A RANGE OF BENEFITS, SUCH AS INCREASED CORROSION RESISTANCE, GREATER STABILITY IN HIGH-TEMPERATURE AND RADIATION ENVIRONMENTS, AND CONTRIBUTION TO THE REDUCTION OF CRITICALITY IN NUCLEAR FUEL ELEMENTS. THESE FINDINGS HIGHLIGHT THE POTENTIAL OF NIOBIUM AS A STRATEGIC MATERIAL IN THE NUCLEAR INDUSTRY, OFFERING PROMISING SOLUTIONS TO THE CHALLENGES FACED IN THE SAFE AND EFFICIENT OPERATION OF NUCLEAR REACTORS, INCLUDING SMALL MODULAR REACTORS (SMRs).
Technical Session
ANALYSIS OF CHARPY IMPACT RESISTANCE IN EPOXY MATRIX COMPOSITES REINFORCED WITH COCONUT SHELL POWDER
Presenter(s): David Coverdale Rangel Velasco (IFF - Instituto Federal Fluminense, Campus Cabo Frio), Júlia de Freitas dos Santos Souza (IFF - Instituto Federal Fluminense, Campus Cabo Frio), Darcy Lucas da Rocha Oliveira (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE – UENF), FELIPE PERISSÉ DUARTE LOPES (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE – UENF), CARLOS MAURÍCIO FONTES VIEIRA (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE – UENF)
Abstract:
Food security is a cause for concern, as society must double food production by 2050 as it seeks sustainable ways to manage the planet. One approach to dealing with food production waste is to use it as reinforcement in composites. This makes it possible to minimize the consumption of resources in the production of materials, by using waste instead of a raw material, and the resources required for waste disposal. In this sense, this work evaluates the influence of the use of coconut shell particles on Charpy impact resistance. The coconut shell particles were processed in a ball mill, and formulations with 0, 10, 20 and 40% volume were evaluated. The impact test was carried out using ASTM D6110, using a 15J hammer. The results of this work indicated that the incorporation of coconut shell particulates did not significantly vary in impact resistance. Which is beneficial given the environmental, financial and density reduction benefits.
Technical Session
9/4/24, 10:15 AM - 9/4/24, 11:05 AM
Presenter(s): Daysiane da silva moreira (Instituto militar de engenharia), RAÍ FELIPE PEREIRA (Instituto Militar de engenharia), José Carlos Ferreira Fontes (Centro Universitário Augusto Motta), Sérgio neves monteiro (instituto militar de engenharia), Lucio Fabio Cassiano Nascimento (INSTITUTO MILITAR DE ENGENHARIA)
Abstract:
Natural fiber composites are gaining increasing application in crucial industrial sectors such as the automotive industry and construction. In addition to their inherent advantages, these composites are continually being improved, demonstrating an ability to level off in mechanical performance with synthetic fiber composites in certain applications, such as in the intermediate layer of individual ballistic armor systems. The application of natural fibres is predominantly justified by their ability to reduce costs compared to synthetic fibres and additive manufacturing (AM) is a highly customized, computer-controlled technique used to produce high-resolution objects and has been applied to the printing of fibre-reinforced polymer composites. In this way, the present work analyzed light-curing acrylic resin used for additive manufacturing using the AM method by vat polymerization with a DLP process and the matrix composites with this material reinforced with flax fibre. Composites were composites were made with different fabric volume fractions (0.5%, 1%, 1.5% and 2%) and thermogravimetric analysis (TGA) was used to thermally characterize the material. Based on this analysis, a decline in the thermal stability of the composites was observed compared to pure acrylic resin, and a temperature of 160°C was established as a practical limit for the use of the material.
Technical Session
9/4/24, 10:15 AM - 9/4/24, 11:05 AM
Presenter(s): juliana dos santos carneiro da cunha (IME), Michelle Souza Oliveira (IME), Ulisses Oliveira Costa (IME), Lucas Moura Montenegro Reis (IME), Lucio Fabio Cassiano Nascimento (IME), sergio neves monteiro (IME)
Abstract:
Growing concern about the future of the environment and the impacts of greenhouse gases have motivated researchers to develop alternative materials and less pollutants aiming at better environmental and life quality for living beings. The use of natural fibers is increasingly common in important industrial sectors, such as civil construction, aerospace, automotive and defense. These came as an alternative to replacing synthetic fibers. In addition to their natural advantages, polymer composites reinforced with these materials can be improved through methods of modifying both the fiber and the resin. As natural fibers have high specific properties, they compete in several applications with synthetic fibers. In particular, titica vine fiber (Heteropsis flexuosa), although well-known and widely used in handicrafts, bags and broom making, little is reported about its performance in polymer composites for applications in engineered structure projects. In this sense, the present study thermally evaluated vine fibers incorporated into an epoxy resin matrix with different volumetric fractions of the natural material (0, 10, 20, 30 and 40 vol%) through thermogravimetry (TGA). Based on this technique, it was concluded that there was a predominance of increase in the thermal stability of the composite with a higher fiber content in relation to the lower percentages (10, 20 and 30 vol%), reaching a working temperature of 296ºC.
Technical Session
9/4/24, 10:15 AM - 9/4/24, 11:05 AM
Presenter(s): KARINE MIRANDA DE SOUZA TAVARES (UENF), LAIMARA DA SILVA BARROSO (UENF), MARIA MARIANA DIAS PEREIRA (UENF), MARIANA GOMES PINTO CHERENE (UENF), LETÍCIA BARCELOS DE SOUSA (UENF), GUSTAVO DE CASTRO XAVIER (UENF), SIDNEI JOSÉ GOMES SOUSA (UENF), AFONSO RANGEL GARCEZ DE AZEVEDO (UENF), Sérgio neves monteiro (IME)
Abstract:
The civil construction sector is largely responsible for materializing engineering and architectural projects, generating jobs and directly impacting the economy. However, it generates waste on a large scale, causing negative impacts in the social, economic and environmental spheres. Aiming to mitigate such impacts, this research recycled and reused Cementitious Plaster Waste (RCR) through thermoactivation at a temperature of 550°C. In order to evaluate the potential of heat-activated RCR, mortars were prepared containing 0, 10, 20 and 30% partial replacement of natural sand with RCR, 1:6 mix and CPV ARI cement. Chemical analysis by FR-X showed that the residue consists mainly of SiO2 and CaO, while specific mass and density tests demonstrated that RCR has a higher density than sand. Through consistency index, water retention and incorporated air content tests, it was possible to verify that the most suitable mix was CPV30, as it increased water retention, decreased the incorporated air content in relation to CPV00 and obtained greater fluidity and consequently, greater workability.
Technical Session
CHARACTERIZATION OF THE GYPSUM BY-PRODUCT FROM LACTIC ACID PRODUCTION
Presenter(s): laimara da silva barroso (UENF), Mariana Gomes Pinto Cherene (UENF), Karine Miranda de Souza Tavares (uenf), Carolina Gomes Dias Ribeiro (uenf), Walquíria Leonardo Bastos (DER-rJ), Gustavo de Castro Xavier (uenf), Carlos Maurício Fontes Vieira (uenf), Afonso Rangel Garcez de Azevedo (uenf), Sérgio Neves Monteiro (ime)
Abstract:
Lactic acid is a chemical product with various applications in the food, cosmetic and pharmaceutical industries, among others. Generally, lactic acid is produced from fermentation. However, this process results in the formation of large amounts of gypsum byproduct. Therefore, it is important to carry out its characterization to have the possibility of new perspectives on the application of this by-product in other areas. For this reason, the present study aims to characterize the gypsum by-product resulting from the production of lactic acid. The gypsum was analyzed under three different conditions: without grinding and with grinding times of 1 hour and 2 hours. The samples were analyzed chemically, physically and mineralogically using X-ray fluorescence, laser granulometry, unit mass and X-ray diffraction tests. The gypsum by-product was found to consist of calcium sulfate hemihydrate, mainly composed of CaO and SO3. With the grinding process, the particle size was more refined and the unit mass increased, however, the specific mass remained. It is concluded that the results obtained in the X-ray fluorescence and unit mass analyzes were consistent with those found in the X-ray diffraction and laser particle size analysis.
Technical Session
9/4/24, 10:15 AM - 9/4/24, 11:05 AM
Presenter(s): LAURA SETTI DE SOUSA (INSTITUTO MILITAR DE ENGENHARIA), Bernardo Soares Avila de Cêa (INSTITUTO MILITAR DE ENGENHARIA), Édio Pereira Lima Júnior (INSTITUTO MILITAR DE ENGENHARIA), Sergio Neves Monteiro (INSTITUTO MILITAR DE ENGENHARIA), Lucio Fabio Cassiano Nascimento (INSTITUTO MILITAR DE ENGENHARIA), Fabio Da Costa Garcia Filho (CEFET/RJ)
Abstract:
The evolution of modern weapons demands the development of advanced materials for ballistic protection, especially in bulletproof vests. Formerly produced with animal skins or metals, vests have evolved into high-performance textile materials, lighter and more flexible due to advancements in the textile industry. High-performance synthetic fibers, such as Kevlar® and Dyneema®, are common in these vests but face challenges in terms of cost and environmental impact. Natural lignocellulosic fibers, as a sustainable alternative, offer unique characteristics, although their heterogeneity poses challenges in reliability, particularly in ballistic applications. Therefore, the proposal of hybrid composites arises, combining natural and synthetic fibers to balance low cost and high ballistic performance. However, analyzing the ballistic properties of these composites requires consideration of factors such as the stacking sequence of reinforcement layers. Therefore, this study aims to evaluate four different stacking sequences of sisal and aramid fiber layers in an epoxy matrix hybrid composite, analyzing their ballistic properties through residual velocity tests and fracture mechanisms of the specimens through macrograph. Statistical analysis (ANOVA) indicated that different stacking sequences proposed did not significantly influence the ballistic performance of the composites, although the 6A/6S composite absorbed the highest energy value. Therefore, the partial replacement of aramid layers with sisal did not compromise the energy absorption capacity, providing a cost reduction of up to 47%. Furthermore, macroscopic analyses evidenced post-impact structural integrity and different deformation mechanisms.
Technical Session
9/4/24, 10:15 AM - 9/4/24, 11:05 AM
Presenter(s): Leoncio soares galvão neto (Instituto federal do pará), Miriane Alexandrino Pinheiro (universidade federal do pará), Alisson Clay Rios da Silva (UNIVERSIDADE FEDERAL DO PARÁ), Verônica Scarpini Candido (UNIVERSIDADE FEDERAL DO PARÁ)
Abstract:
The conscious use of resources and the appropriate disposal of solid waste is a growing concern for society. The conscious use of resources helps preserve raw materials, guaranteeing their future availability, and the appropriate management of solid waste reduces soil, water and air pollution, mitigating negative effects on human health and the environment. In materials engineering, there is countless research that seeks to find a destination and use for waste with viable applications. The waste used in the manufacture of the composites analyzed in this work comes from tire retreading companies and is polyester fabrics with remaining rubber. Composites were manufactured with residue inclusion volume varying between 0, 5, 10 and 15%, where after analyzing the results of the tensile test, in accordance with the ASTM D638 standard, an increase in tensile strength was shown by 20. 6% in relation to the matrix without reinforcement, reaching 56.73 (±5.51) Mpa in this mechanical property for a composition with 15% residue. The values of the properties obtained in the tensile test were statistically compared using the ANOVA and Tukey tests, which showed that the inclusion of residual polyester fibers in the epoxy matrix brought a significant increase in tensile strength and total deformation for the composite with incorporation of 15 % fiber volume. These results point to the use of this residue as reinforcement in the manufacture of composites using epoxy as a matrix.
Technical Session
9/4/24, 10:15 AM - 9/4/24, 11:05 AM
Presenter(s): lUANA ALVES PATROCINIO (UERJ), Gisele Duarte Caboclo Antolin (uerj), mauricio quelhas antolin (UERJ), monica cristina celestino dos santos (uerj)
Abstract:
ABS is a thermoplastic commonly used in 3D printing and in the manufacture of electronic products. However, as it is a petroleum derivative, there is great concern about its correct disposal. Despite this, its thermoplastic nature makes it possible to recycle it. However, ABS recycling faces challenges due to its sensitivity to thermal degradation, leading to a decrease in mechanical properties and changes in optical properties. With this in mind, this work aims to analyze the influence of adding sisal fibers to this material, in order to understand its influence on its mechanical properties. For this purpose, tensile tests and Scanning Electron Microscopy were carried out on ABS + sisal specimens. The results showed that the introduction of this natural fiber was beneficial to the mechanical properties of the material by improving its microstructural properties.
Technical Session
9/4/24, 10:15 AM - 9/4/24, 11:05 AM
Presenter(s): LUCIANO MONTEIRO ALMEIDA (UFPA ), Roberto Tetsuo Fujiyama (UFPA), Sergio Neves Monteiro (IME), Alisson Clay Rios da Silva (UFPA), Verônica Scarpini Candido (ufpa)
Abstract:
The incorporation of natural lignocellulosic fibers in polymeric composites is very advantageous, because it allows to design materials with specific mechanical performance and to develop ecologically friendly products. In this sense, this work aims to evaluate the tensile behavior of polyester matrix laminated composites reinforced with raffia, jute and glass fibers. Samples with laminate orientation 0º/0º/0º of raffia/raffia/raffia (RRR), raffia/jute/raffia (RJR) and raffia/glass/raffia (RGR) were fabricated and then tested for tensile test, according to ASTM D3039/D3039M Standard. The results revealed that the replacement of the raffia by glass fibers entailed a slight increase of the tensile strength, on the other hand, the inclusion of glass fibers reflected in the improvement of this mechanical property, nevertheless, the results are coherent to those researched in the literatures.
Technical Session
9/4/24, 10:15 AM - 9/4/24, 11:05 AM
Presenter(s): Luis Fernando Fortunato De Freitas (UENF), Shayana Tavares de Souza (UENF), Carlos Eduardo Henriques Dias (UENF), Alexandre Augusto Maciel Rangel Meireles (UENF), Luana Menezes da Silva (UENF), Stevan Ricardo da Silva Ferreira (UENF), Graziele Medeiros Cosme (UENF), FELIPE PERISSÉ DUARTE LOPES (UENF), Noan Tonini Simonassi (UENF)
Abstract:
The pollution and destruction of the environment has been the subject of numerous discussions at national and international level. In the search for sustainable and low-cost alternatives, many companies have opted to replace high-performance and consequently high-cost artificial materials with ceramic waste and natural fibers that together form polymers with high resistance to different stresses. This study aims to analyze and investigate the performance of polymer composites reinforced with natural fibers, focusing on Izod impact and tensile strength, with a view to industrial and environmental applications. The experiment analyzes epoxy matrix composites reinforced with jute fabric, evaluating their density and comparing the performance of the pure epoxy resin with the reinforced version in tensile and Izod tests. Through the tests carried out, it was possible to verify an increase in the tensile strength of the polymeric samples. On the other hand, in the impact test, the pure resin proved to be more resistant because the fiber made the material more rigid, which caused the material to suffer fragile fracture when subjected to the impact test.
Technical Session
9/4/24, 10:15 AM - 9/4/24, 11:05 AM
Presenter(s): Luis Ricardo Arrubla Agudelo (UENF - ALBERTO LAMEG), Luís Fernando Fortunato De Freitas (UENF), david coverdale rangel velasco (uenf ), CARLOS MAURICIO FONTES VIEIRA (UENF), HENRY A. COLORADO L. (udea), felipe perissé duarte lopez (uenf)
Abstract:
The growing demand for sustainable materials requires the exploitation of natural resources with promising mechanical properties. This study investigates the potential of fique fiber as a reinforcement for polymer composites. A comprehensive characterization of the physical, geometric, and mechanical properties of fique fibre is carried out using various techniques. The fiber shows a wide range of modulus of elasticity (303 - 11860 GPa), highlighting its versatility. Statistical analysis reveals a central tendency in the data, in addition, weight, diameter, length, tensile strength, deformation and morphology were evaluated. This research contributes to the development of sustainable composite materials with competitive performance and deepens knowledge about the fiber in question.
Technical Session
CONSIDERATIONS ABOUT THE ACID ACTIVATION OF SYSTEMS CONTAINING METACAULIN AND FLY ASH
Presenter(s): Madeleing Taborda Barraza (uenf), Davi Vaz André Junior (uenf), Thais Marques da Silva (ufsc), Vanessa Amorim Amorim (ufsc), Philippe Jean Paul Gleize (ufsc), afonso rangel garcez de azevedo (uenf)
Abstract:
Acid activation of aluminosilicates leads to the formation of phosphate-based geopolymers. This activation uses the PO group to be introduced into polymer chains and form P-A-S-H, which have high mechanical resistance and restricted applications. In this study, the acid activation of metakaolin and fly ash was evaluated in fresh state and in hardened state using mini-slump, rotational rheology and compressive strength in four groups replacing 0%, 20%, 40% and 60% of metakaolin by fly ash. For the exclusive metakaolin-based system, the compression strength was greater than in the other systems. This may indicate that, to promote an significative acidic activation there must be an energy barrier to be overcome and using fly ash in the evaluated conditions it wasn’t produce a significative contribution to the mechanical performance of systems.
Technical Session
9/4/24, 10:15 AM - 9/4/24, 11:05 AM
Presenter(s): magno torres carvalho (IME), HELLEN KARINA PEREIRA ALKIMIM (IME), SHANELY DA SILVA RIBEIRO (UFRJ), ANDRESSA TEIXEIRA SOUZA (IME), SERGIO MONTEIRO NEVES (IME), EDUARDO DE SOUSA LIMA (IME)
Abstract:
The study investigated the compositions of the hybrid SiC composite at 0, 5, and 15 %v and Ramie at 30 %v in an epoxy matrix. The Izod impact test demonstrated relative improvements in compositions with SiC and Ramie fabric, but did not reach levels found in the literature, attributed to the high viscosity of the epoxy-SiC mixture. This also influenced the results of the ballistic test, which showed that the maximum energy absorption value does not necessarily reflect the best performance, highlighting the need to consider the mass of the samples. Recalculating values for specific absorbed energy revealed that groups with 15%v SiC exhibit high standard deviation, even though they originally showed the best performance.
Technical Session
MANIFESTATION OF CARBONATION AND CHEMICAL TRANSFORMATION IN ALKALI ACTIVATED SYSTEMS
Presenter(s): MADELEING TABORDA BARRAZA (uenf), Luís Urbano Durlo Tambara Junior (uenf), Davi André Vaz Junior (uenf), Philippe Jean Paul Gleize (uenf), Afonso Rangel Garcez de Azevedo (uenf)
Abstract:
Alkali activations have gained significant importance among research centers as a sustainable alternative to traditional Portland cement. However, the chemical stability of these systems is still an important issue to guarantee the durability of the manufactured parts, which can easily become a carbonated system due to careless chemical analysis. In this study, a series of analytical considerations on the development of alkali activated matrices based on metakaolin are considered, highlighting the formation or absence of carbonates as a result of molar ratios. These variations were measured in pastes using compressive strength, X-ray diffraction and image analysis via microscopy and microtomography.
Technical Session
9/4/24, 10:15 AM - 9/4/24, 11:05 AM
Presenter(s): NIANDER aguiar cerqueira (UENF - ALBERTO LAMEG), Luiz Henrique Bento Barbosa Junior (UENF), Wander Paulo da Silveira Junior (UENF), Luísa Azeredo Ferreira Barreto (UENF)
Abstract:
Campos dos Goytacazes is one of the most important economic centers in the state of Rio de Janeiro, presenting constant expansion of the urban area through construction. Structural masonry, a constructive model known for its economy and rapid execution, has become a widely employed solution in buildings in the region. To ensure safety and durability, it is critical to evaluate the quality of the blocks used in the works. Given these aspects, this work aimed to evaluate concrete blocks (14x19x39 cm3), produced in the municipality of Campos dos Goytacazes/RJ. 06 blocks were tested for compression resistance and 06 for water absorption. The average compression resistance found was 17.11 ± 0.93 MPa, resulting in a characteristic compression resistance (FBK, EST) of 15.51 MPa. The water absorption rate was 5.56 ± 0.31%. The tests were performed at UENF laboratories, and the results indicate that the blocks have classification A, defined in NBR 6136: 2016, and can be applied to works of medium to large structural masonry structures.
Technical Session
9/4/24, 10:15 AM - 9/4/24, 11:05 AM
Presenter(s): THUANE TEIXEIRA DA SILVA (IME), Matheus Pereira Ribeiro (PREFEITURA MUNICIPAL DE CABO FRIO), Lucas de Mendonça Neuba (IME), Sergio Neves Monteiro (IME), Marcos Paulo Cavaliere de Medeiros (IME), Lucio Fabio Cassiano Nascimento (IME)
Abstract:
There is an exponential increase in the use of sustainable materials as reinforcement in polymer composites, including ballistic helmets used by military personnel in combat. Flax, widely studied in the literature, demonstrates advanced properties when used as reinforcement in polymer composites. This study aimed to characterize aluminum, flax and aramid fabrics, and HDPE (high-density polyethylene) using Fourier Transform Infrared Spectroscopy (FTIR) and X-ray Diffraction (XRD), comparing the results with available literature data. These materials are being studied for ballistic and radiological applications in helmets. In the FTIR analysis, the materials exhibited functional groups consistent with those described in the literature. Additionally, HDPE and aramid showed higher crystallinity values than those found in the literature, at 69.3% and 82.98%, respectively.
Technical Session
9/4/24, 10:15 AM - 9/4/24, 11:05 AM
Presenter(s): DIEMISON LIRA SANTA ROSA (UFPA), Verônica Scarpini Candido2 (ufpa), Alisson Clay Rios da Silva (ufpa), Marcos Vinicius da Silva Paula (ufpa)
Abstract:
This study macroscopically analyzes nanoemulsions (NEs) encapsulated with clove bud essential oil (OEC), Eugenia caryophyllus, having canola oil (OCN) as an inhibitor,Brassica napus L., and as a non-ionic surfactant, Tween 80 (T80). In addition, it investigates the oxidative stability and the aggregative tendency of ENs in the medium term, by monitoring pH and turbidity. The NEs absorption profile was obtained by UV-VIS readings (300-800nm), and expressed in absorbance intensities. Thus, tiny variations in pH means were detected (4,13 the 5,14).The analysis of the turbidity, revealed the maintenance of the translucency of the samples during 229 days, with varying percentages between (98,5 and 75,4)%.The absorbance showed a trend towards the violet region with a maximum peak at 395 nm. Soon, the improvement of these NEs will make possible their incorporation in beverages, foods and medicines, to increase the shelf life of the products.
Technical Session
ANALYSIS OF MECHANICAL PROPERTIES OF SCAFFOLDS STRUCTURED BY TPMS GEOMETRIES
Presenter(s): Edson Miranda soares (UFPA - Universidade federal do pará), Ana Beatriz das Neves Conceição (IFPA/UFPA), Miriane Alexandrino Pinheiro (ufpa - universidade federal do pará), Alisson Clay Rios da Silva (ufpa - universidade federal do pará), Verônica Scarpini Candido (UFPA - UNIVERSIDADE FEDERAL DO PARÁ)
Abstract:
This article aims to evaluate scaffolds structured with TPMS geometries under the influence of uniaxial compressive load. For this purpose, three different models of scaffolds structured with gyroid, primitive schwarz and IWP formats were designed for mechanical tests, following the ASTM D695-15 standard. The results revealed that the samples composed of the primitive schwarz structure presented the best attributes for use as scaffold, having a compression modulus of 0.349 GPa, compressive strength of 11.937 MPa and uniform deformation of 0.07276. The other samples also presented satisfactory results, however, the scaffolds structured with the IWP geometry presented a particular characteristic of uniform deformation, in relation to the other samples, obtaining a deformation of 0.11025.
Technical Session
9/4/24, 10:15 AM - 9/4/24, 11:05 AM
Presenter(s): FABIO MOREIRA BRITO (UNIVERSIDADE FEDERAL DO PARA), taiana de sousa matos (UNIVERSIDADE FEDERAL DO PARA), Alisson Clay Rios da Silva (UNIVERSIDADE FEDERAL DO PARA), Marcos Vinicius Da Silva Paula (UNIVERSIDADE FEDERAL DO PARA), Sérgio Neves Monteiro (Universidade Federal do Rio de Janeiro), Veronica Scarpini Candido (UNIVERSIDADE FEDERAL DO PARA)
Abstract:
Admitting that there is a concern with the current environmental situation, it is necessary to assign biodegradable solutions and the study of an infinity of natural materials, the research itself is attributed to highlighting the analysis of corn starch and Tururi fibers, as well as demonstrating its density and percentage of moisture, some of its plausible applications of the materials in focus will also be presented. Based on this preliminary study, observed factors indicated that it is possible to prepare fiber-reinforced corn starch composites with better properties, as well as to produce biodegradable materials, which consists of producing bioplastic from chemical reactions based on corn starch that results in a sustainable plastic, derived from a non-finite resource and with a lower production cost when compared to those based on petroleum, however with less resistance. Both materials have potential for use in the design of products in the sustainable axis due to their low impact on their pre-production, production, assembly and disposala.
Technical Session
COMPRESSION TEST ON HIGH PERFORMANCE COATING OF EPOXY COMPOSITES WITH SUGARCANE BAGASSE DUST
Presenter(s): Juliana Sousa Gomes Ribeiro ( Universidade Estadual do Norte Fluminense Darcy Ribeiro), DAVID COVERDALE RANGEL VELASCO (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO), Luís Fernando Fortunato de Freitas (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO), FELIPE PERISSÉ DUARTE LOPES (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO), CARLOS MAURÍCIO FONTES VIEIRA (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO), Noan Tonini Simonassi (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO.)
Abstract:
In industries ranging from aerospace and automotive to pharmaceutical and food, a high-resistance floor is essential. To achieve this, High-Performance Coatings (HPC), which combine epoxy resins and mineral materials in composite form, are used. These materials may include natural fibers. This article aims to study the compressive capacity of composites formed by epoxy resin, hardener, and dust derived from sugarcane bagasse, which is a waste material in industries and small businesses selling sugarcane juice. Thus, the compressive strengths of four mixing ratios of resin/hardener and sugarcane bagasse dust were analyzed: 1:0, 0.9:0.1, 0.8:0.2, and 0.7:0.3, respectively. From these results, the relevance of adding the natural residue can be observed, as it not only provides greater strength to the resin and is eco-friendly but also has a low acquisition cost, potentially even reaching R$0.00, making the production of this composite HPC cost-effective.
Technical Session
INFLUENCE OF SOME VARIABLES ON PHYSICAL PROPERTIES OF COBALT OBTAINED BY ELECTROWINNING
Presenter(s): Jonas da Cruz Trajano de Souza (UFRJ), Fabiano Augusto Costa Mafra Passos (UFRJ ), Danielle Costal de Castro (UFRJ ), Achilles Junqueira Bourdot Dutra (UFRJ )
Abstract:
The influence of pH, current density, impurities and the presence of an anode bag on the physical properties of cobalt obtained by electrowinning in CoSO4 solutions was investigated. Cobalt metal samples were obtained and their grain size was analyzed using an optical microscope and their microhardness using a Vickers microhardness tester. Synergistic effects of increasing pH and density on the physical properties of the samples were observed, with a progressive reduction in microhardness due to the increase in grain size, with the least resistant sample being obtained at a current density of 400 A/m² and pH 5, with a microhardness of 169.82 HV and a grain size of 33.01 μm. For the anode bag and impurities at 400 A/m² and pH 4, there was a tendency for the grain size to increase with the presence of the anode bag and the grain refinement with the presence of impurities, when considered individually. Together, they result in the most refined sample, with 1.74 μm and 304.5 HV. The most attractive condition was given at 400 A/m² and pH 5, due to the better uniformity and greater ductility of the deposits, facilitating transportation.
Technical Session
9/4/24, 10:15 AM - 9/4/24, 11:05 AM
Presenter(s): Karen Farias Cirilo (Instituto Federal do Espírito Santo ), Pedro Henrique Lauret do Espirito Santo (INSTITUTO FEDERAL DO ESPÍRITO SANTO ), André Itman Filho (INSTITUTO FEDERAL DO ESPÍRITO SANTO ), Estéfano Aparecido Vieira (INSTITUTO FEDERAL DO ESPÍRITO SANTO ), Thiago Barreto da Silva Amaral (INSTITUTO FEDERAL DO ESPÍRITO SANTO )
Abstract:
Austenitic-ferritic stainless steels, or duplex, are used to replace austenitic ones in industrial applications, where resistance to corrosion and the propagation of cracks in chloride environment are important requirements. These steels have a ferritic and austenitic structure with intermetallics dispersed in the matrix, such as the Laves phase, sigma, chi, carbides and others. Such precipitates depend on the chemical composition and the temperature of forming process, but they are difficult to determine in conventional optical and scanning electron microscope. However, it is possible to predict the formation of these phases using computational thermodynamics with the FactSage software. This software is a fully integrated computational system with access to thermodynamic information of liquid and solid metallic solutions, which allows predicting the quantities, characteristics and formation temperatures of the complex phases of a metallurgical process. However, an important factor in the simulation is to know the possible precipitates listed in the software databases. In this work, different conditions were selected to identify the phases of an austenitic-ferritic stainless steel after solubilization and aging. The results identified several precipitates, although the main ones are sigma and Laves phases. According to the literature, these phases increase the hardness and are important in the wear resistance of the matrix.
Technical Session
9/4/24, 10:15 AM - 9/4/24, 11:05 AM
Presenter(s): Lucas machado pereira (ufmg), Paula Maria Gomes Cunha Leão (ufmg), Maurício Covcevich Bagatini (ufmg)
Abstract:
The use of biomass in self-reducing briquettes for use in the steel industry has become an important alternative for reducing CO2 emissions, both in terms of the sector's sustainability and from an economic perspective. In this regard, the aim of this study was to evaluate the influence of the pyrolysis temperature of sugarcane bagasse and the percentage of biomass present in the briquette on the mechanical strength and mass loss in the process of obtaining metallic iron. The raw material underwent thermal treatment at two different temperatures, 250 and 550°C, and briquettes were produced for each pyrolysis temperature in three biomass proportions (5, 10, 15%). To test the mechanical strength, compression strength and drop tests were conducted, and mass loss was assessed using high-temperature muffle furnace tests (1100°C). Thus, aiming for the use of these briquettes in blast furnaces, the composition with the best performance was identified as being 15% biomass with a pyrolysis temperature of 550°C, resulting in a mass loss of 93,54% and a cold mechanical strength of 542,26 N, with a slight decrease in hot mechanical strength to 346,47 N.
Technical Session
9/4/24, 10:15 AM - 9/4/24, 11:05 AM
Presenter(s): Ludmila de Souza Cunha (UFMG)
Abstract:
In this research, the results of a NiTiCuNb alloy that was hot rolled and subsequently heat treated are presented. The analyzes were carried out using scanning electrical microscopy (SEM), electron scattering spectroscopy (EDS), X-ray diffraction (XRD), differential scanning calorimetry (DSC), and Vickers Microhardness, which were used to investigate, respectively, microstructural changes, distribution of chemical elements of solid phases, identification of phases present and phase transformations associated with the hot rolled and annealed sample. The influence of heat treatment decreases the martensitic transformation temperature of the alloy, in addition to increasing Nb solubility in the solid phases present and decreasing Cu solubility in the matrix and β-Nb. Resulting in a more ductile material, which has greater workability capacity.
Technical Session
EVALUATION OF THE TENSILE STRENGTH OF STARCH-BASED BIOCOMPOSITES REINFORCED WITH GUARUMAN FIBER
Presenter(s): Maria Eduarda Alexandrino Alves (uerj)
Abstract:
Biocomposites have garnered increasing attention in the packaging industry due to their potential as sustainable alternative to conventional synthetic plastics. In this study, biocomposites based on thermoplastic starch and guarumã lignocellulosic fibers were developed for possible applications in packaging for short-shelf-life products, using the extrusion method. The composites were produced in a single-screw extruder, equipped with three distinct temperature zones. The extruded formulations were characterized through mechanical analyses and subjected to statistical analyses. The results of the tensile tests indicate an improvement in mechanical properties, such as the modulus of elasticity and maximum tensile strength, following the incorporation of guarumã fibers. This study contributes to ongoing efforts to reduce the environmental impact of non-biodegradable plastic packaging by promoting the adoption of more sustainable alternatives.
Technical Session
EVALUATION OF THE EFFECT OF ADDING FIBERGLASS AS REINFORCEMENT IN ARTIFICIAL ROCKS
Presenter(s): PABLO BARBOSA JACINTHO (uenf), Maria Luiza Pessanha Menezes Gomes (uenf), José Lucas Decoté de Carvalho Lirio (uenf), Sávio dos Santos Carvalho (uenf), ELAINE APARECIDA SANTOS CARVALHO (uenf), CARLOS MAURÍCIO FONTES VIEIRA (uenf)
Abstract:
The industrial sector in general generates a considerable amount of waste, with a special focus on granite, it has been generating considerable volumes of waste, resulting in negative environmental impacts caused by inadequate disposal. With this fact in focus, the opportunity arises to value this waste through the production of artificial rocks, combining sustainability with favorable technical and economic performance. The present study aims at the production and characterization of artificial granite using a polymer matrix of epoxy resin with the implementation of a synthetic fiber in which glass mesh fiber was used, where the rock is produced using the vacuum vibro compression method. The granite cutting residues were fragmented and, using the Simplex Centroid Model, the ideal granulometric mixture for compaction was determined. The minimum amount of resin required to fill the spaces between the particles was calculated. The artificial rock slabs were produced with 85% by mass of granite particles using a grain size that was considered coarse and 15% polyester resin (RAPO). Under a vacuum of 600 mmHg, the plates were subjected to compaction pressure of 10 tons, at 90°C for RAPO and 80°C for the others, for 20 minutes. After sanding and cutting, the plates were evaluated for their physical characteristics (density, apparent porosity, water absorption), mechanical (3-point bending test, wear), resistance to chemical attacks and staining, and microstructure by Electron Microscopy. Scan. The results obtained demonstrate that artificial rock has suitable properties for application in coatings.
Technical Session
INFLUENCE OF fe2+ CONCENTRATION ON PARTICLE OXIDE FORMATION IN A SPRAY ROASTING REACTOR
Presenter(s): MARCELO CURTES MARTINS (Arcelormittal)
Abstract:
In this work we present a study of the grain size behavior of iron oxide in the Spray roasting process from ArcelorMittal Brazil by varying the concentration of iron II looking for a better understanding to control this parameter, focused on meeting the consumer satisfaction. The results showed strong influence of this parameter in the particle formation and product quality. The results of X-ray diffractometry analyze showed the formation of αLPHA-Fe2O3.
Technical Session
CUSTOMIZATION OF THE COLD ROLLED STEEL MANUFACTURING PROCESS FOR THE DRUMS INDUSTRY
Presenter(s): Carolina Damasceno de Souza (companhia siderúrgica nacional), Fabio de Oliveira araújo (companhia siderúrgica nacional), Rafael masulck santos (COMPANHIA SIDERÚRGICA NACIONAL), SABRINA RESTIER DA COSTA RODRIGUES LEITE (COMPANHIA SIDERÚRGICA NACIONAL), LIDIANE DA PAIXAO CARVALHO (COMPANHIA SIDERÚRGICA NACIONAL), RAPHAEL ALEXSANDER RIBEIRO DA CUNHA (CSN), Harison da Silva Ventura (CSN), Harison da Silva Ventura (CSN)
Abstract:
This work was developed with the aim of reducing the transformation cost of cold-rolled products intended for the drum industry, specifically for use in "drum bodies," while maintaining the hardness range of the product delivered to customers. For this purpose, the CSN TBR 60 specification is used. The goals were to reduce natural gas consumption, increase productivity on the Continuous Annealing Line, and replace the steel grade with a lower-cost alternative. Industrial-scale tests were conducted, initially modifying the finishing temperature during hot rolling to reduce natural gas consumption and evaluate the product's hardness. In the second test, both the finishing temperature and thermal cycle were altered, also aiming to preserve hardness. Finally, in the third test, in addition to modifying the finishing temperature and thermal cycle, the steel grade was changed to a lower-cost one. Despite the cost reduction, the average hardness obtained in tests 1 and 2 was not satisfactory. However, in test 3, besides reducing the transformation cost, the average hardness was within the expected range. It can be concluded that test 3 not only provided the best hardness performance but also resulted in the lowest total transformation cost.
Technical Session
ADVANCES IN A HOT STRIP MILL ONLINE SET-UP MODEL
Presenter(s): JONATAS VENANCIO BARBOSA (USINAS SIDERURGICAS DE MINAS GERAIS SA), bruno alves resende (usiminas)
Abstract:
Accurate modeling in a hot strip mill is critical not only for quality control but also for enhancing process stability, and productivity, minimizing unplanned stoppages, reducing greenhouse emissions, and improving overall company competitiveness. This paper examines recent advancements in the online set-up model at Usiminas' hot strip mill, focusing on substantial system upgrades and the development and refinement of mathematical models crucial for both offline and online operations. By addressing the complexities of threading in the finishing mill, the study provides valuable strategies on improving process stability. The evolution of model accuracy is demonstrated through these enhancements, emphasizing the crucial role of precise modeling in sustaining competitiveness and meeting rigorous product specifications effectively.
Technical Session
MICROSTRUCTURAL EVOLUTION OF ALUMINUM 7075-T651 SUBJECTED TO FRICTION STIR PRECESSING (FSP) AND SOLUBILIZATION AND AGING HEAT TREATMENTS.
Presenter(s): Lucas Moura Montenegro Reis (IME - INSTITUTO MILITAR DE ENGENHARIA ), SAULO BRINCO DINIZ (CEFET - CAMPUS ANGRA DOS REIS), sergio neves monteiro (ime - instituto militar de engenharia), pedro yago ramalho da silva dos santos (rh brooker)
Abstract:
The optimization of mechanisms that increase the mechanical strength of metals has been the subject of several studies, as this can reduce the weight of structures and consequently increase savings in fossil fuels. This study carried out Friction Stir Processing (FSP) (with rotation speeds of 400, 500 and 600 rpm) and the solubilization (with soaking times of 40, 60 and 80 minutes at 480 °C) and ageing heat treatments of a 7075-T651 aluminium alloy, with the aim of studying microstructural and hardness evolution. It was observed that FSP has great potential for reduce grain size, and that although solubilization with 80 minutes provided the largest grain size of the processed samples, there was an increase in hardness compared to the as-received condition.
Technical Session
9/4/24, 10:15 AM - 9/4/24, 11:05 AM
Presenter(s): GEOVANE DE ASSIS FARIA (UFOP), rodrigo rangel porcaro (UFOP), Daniela Magalhães Ramos (UFOP)
Abstract:
Some materials have weldability issues, such as ferritic stainless steels, which have good resistance to atmospheric corrosion and good formability. Welding modifies and impairs the mechanical and anti-corrosion properties of the material. Welding using the GTAW process was evaluated on ferritic stainless steels ABNT 409) (stabilized) and ABNT 430 (non-stabilized), with different solidification conditions based on the variation of mechanized welding parameters. The results showed that at low speeds and low current, curved epitaxial grains were generated towards the weld pool. The increase in welding speed and current resulted in greater instability of the pool, forming a drop-shaped structure, with columnar grains. The effects of mechanical vibration were also evaluated, which resulted in grain refinement and increased uniformity in the center of the bead. The metallographic analysis showed that in the ABNT 430 steel the material weakened with the formation of martensite at the grain boundaries, which did not happen with the ABNT 409 steel. The joints obtained were characterized in relation to their behavior in tensile tests and the Erichsen stamping test, in which ABNT 409 steel presented better characteristics
Technical Session
MICROSTRUCTURAL ANALYSIS OF DISSIMILAR WELDING OF AISI 304 AND AISI 430 STEEL WELDED BY THE GTAW PROCESS
Presenter(s): joao gabriel lucio conceicao (Instituto Federal de Educação, Ciência e Tecnologia do Sudeste de Minas Gerais Câmpus Juiz de Fora), Matheus José Cunha de Oliveira (IF SUDESTE MINAS CAMPUS DE JUIZ DE FORA )
Abstract:
Stainless steel was developed at the beginning of the 20th century and since then it has been used in different variations according to its composition and phases, generating, among others, ferritic and austenitic steels. Gas Tungsten Arc Welding (GTAW) is widely used in joining stainless steel joints. Used from domestic equipment to motorsport, such materials occupy a large space among stainless steel materials. In this way this work it was proposed the analysis of the union of two types of stainless steel, ferritic and austenitic, in order to evaluate their microstructure results in relation to the quality of the joint obtained. Metallurgical properties through metallographic tests were carried out using optical microscopy, scanning electron microscopy, energy-dispersive X-ray spectroscopy and energy-dispersive X-ray fluorescence spectrometry. The results indicated that the joints microstructure of consisted of austenite grains involved in delta ferrite. The average grain size was significantly larger than the average grain size in both heat affected zones. The weld metal chemical composition mainly consisted of iron and chromium.
Technical Session
ADDITIVE MANUFACTURING BY SELECTIVE LASER MELTING OF THE 316L AUSTENITIC STAINLESS STEEL: EFFECT OF LASER ROTATION AND SCANNING SPEED ON DENSIFICATION
Presenter(s): Alison Sehn Hilgert (Instituto Militar de Engenharia), Artur Torres Netto (Instituto Militar de Engenharia), BARBARA COSTA BERRIEL ABREU (Instituto Militar de Engenharia), CARLOS FERNANDO MOTTA NOGUEIRA (Instituto Militar de Engenharia), DAVI GOMES CORINO DE MELO (INSTITUTO MILITAR DE ENGENHARIA), GUSTAVO LARANJEIRA ALVES (INSTITUTO MILITAR DE ENGENHARIA), Aroldo Mendes Paiva Neto (Instituto Militar de Engenharia), Andersan dos Santos Paula (Instituto Militar de Engenharia)
Abstract:
In the context of the growing development of products through additive manufacturing methods, Selective Laser Melting (SLM) machines process parts by interacting a laser energy source with a pre-deposited powder bed, layer by layer until forming the final product. Although the SLM process can be used for product development, identifying the necessary parameters for optimal processing becomes essential to gain advantages in the additive manufacturing market and to avoid failures of the manufactured parts in their intended applications due to properties being out of range, the presence of cracks, etc. Thus, this article presents the results of the initial processing conducted on the SLM machine - Omnitek SLM Omnisint-160 - recently acquired at Military Engineering Institute (IME). The aim is to evaluate the effect of layer rotation, scanning speed, and single laser scan per irradiated layer, while not changing other parameters (powder layer thickness, track spacing, laser power), and to compare these results with previous work where the layer was double irradiated by the laser. The observed results highlighted lower densification with a single scan per layer, and for this condition, higher densification in cases where layers were rotated by 67º at both depicted speeds
Technical Session
INSTRUMENTED ULTRAMICROHARDNESS TESTING ON NITI ALLOYS PRODUCED BY SELECTIVE LASER MELTING (SLM)
Presenter(s): DANILO ABILIO CORREA GONCALVES (IME - Instituto MILITAR DE ENGENHARIA), Naiara Vieira Le Sénéchal (IME - INSTITUTO MILITAR DE ENGENHARIA), Fábio da Silva Oliveira3 (IME - INSTITUTO MILITAR DE ENGENHARIA), RAFAEL RAMOS (IME - INSTITUTO MILITAR DE ENGENHARIA), rodolfo da silva teixeira (Laboratoire de Mécanique Paris-Saclay), Paulo Paiva Oliveira Leite Dyer (Instituto de Estudos Avançados), Getúlio de Vasconcelos (instituto de estudos avançados), andersan dos santos paula (ime - instituto militar de engenharia)
Abstract:
Nickel-titanium alloys (NiTi), known for exhibiting Shape Memory Effect (SME) and Superelasticity (SE), stand out for their shape recovery and corrosion resistance. Traditionally, these alloys are manufactured through industrial processes including melting, hot and cold working, shaping, and heat treatment. Recently, additive manufacturing (AM) has emerged as a prominent method for producing complex NiTi structures. Over the past decade, metal AM has rapidly advanced, finding applications in sectors such as biomedical and aerospace, where significant performance enhancements have been demonstrated. However, there is still limited detailed information regarding the microstructure and mechanical properties of metal alloys manufactured by AM. Selective laser melting (SLM) allows for the complete fusion of metal powder, resulting in homogeneous parts. This study aims to evaluate the ultramicrohardness of NiTi alloy produced by SLM, using a blend of nickel elemental powders obtained through oxirreduction and titanium HDH.
Technical Session
STUDY OF MECHANICAL PROPERTIESOF SINTERED NI-TI ALLOYS
Presenter(s): GABRIELA ARAUJO GOIS (REDEMAT/UFOP)
Abstract:
In this study, three samples containing 49.5% Ti and 50.5% Ni, produced by powder metallurgy, were analyzed. The Ni and Ti powder mixture was uniaxially compacted in a die with a diameter of 21 mm and a height of 10 mm, followed by sintering in a controlled atmosphere furnace at 1118°C for 12 hours for one sample and 24 hours for the other two. The samples were characterized microstructurally and subjected to microhardness, corrosion resistance and wear tests to evaluate their performance. The sample sintered for 24 hours and cooled in air showed greater hardness and better wear resistance. The best corrosion behavior was observed in the sample sintered for 24 hours and cooled in the furnace for 12 hours
Technical Session
9/4/24, 10:15 AM - 9/4/24, 11:05 AM
Presenter(s): naiara vieira le sénéchal (Military Institut of Engeneering), Danilo ABÍLIO CORRÊA Gonçalves (Military Institut of Engeneering), FÁBIO SILVA DE OLIVEIRA (Military Institut of Engeneering), Paulo Paiva Oliveira Leite Dyer (Instituto de Estudos Avançados (IEAv)), RAFAEL RAMOS (Military Institut of Engeneering), Rodolfo da Silva Teixeira ( Paris-Saclay), GETÚLIO VASCONCELOS (Instituto de Estudos Avançados (IEAv)), ANDERSAN DOS SANTOS PAULA (Military Institut of Engeneering)
Abstract:
NiTi alloys are renowned for their functional properties such as superelasticity and shape memory effect. Additive manufacturing processes based on laser powder bed fusion are widely employed for these alloys, although understanding of the effect of each process variable is limited. In the Selective Laser Melting (SLM) process, the formation of the alloy, its microstructure, and functional characteristics depend on powder properties, laser nature and power, scanning speed, layer thickness, and width. This study summarized these parameters to determine the linear, planar, and volumetric energy density used in constructing the first layers melted in individual tracks by SLM, using a mixture of Ni and Ti elemental powders on a textured Ti substrate. A Yb fiber laser with power values between 100 and 300 W was employed, with scanning speed and layer thickness fixed at 10 mm/s and 400 µm, respectively. The three-dimensional building effect was evaluated by superimposing up to 5 layers at the highest power setting. Characterization was performed by scanning electron microscopy (SEM) and semi-quantitative chemical analysis by energy dispersive X-ray spectroscopy (EDS).
Technical Session
THERMODYNAMIC SIMULATION FOR STUDYING THE ADDITION OF MANGANESE IN ZR-NB ALLOYS
Presenter(s): Yuri de Abreu Silva Araújo Fleischhauer (Programa de engenharia metalúrgica e de materiais/universidade federal do rio de janeiro), Bernardo Pompermayer Eduardo (PROGRAMA DE ENGENHARIA METALÚRGICA E DE MATERIAIS/UNIVERSIDADE FEDERAL DO RIO DE JANEIRO), RAfaella martins ribeiro (PROGRAMA DE ENGENHARIA METALÚRGICA E DE MATERIAIS/UNIVERSIDADE FEDERAL DO RIO DE JANEIRO)
Abstract:
Zirconium alloys find widespread use in the nuclear industry due to their mechanical properties, low neutron absorption, and corrosion resistance. However, in PWR reactors, hydrogen absorption leads to the formation of fragile hydrides, requiring the development of new alloys capable of extending their components lifespan. This study aims to evaluate the effect of adding Mn to Zr-Nb alloys through thermodynamic simulation and CALPHAD methodology, using the Thermo-Calc software. It was possible to identify the formation of the Laves phase Mn2Zr for all analyzed alloys, indicating a direct association with the addition of Mn, while the addition of Nb does not affect the quantity of this phase. Based on these findings, alloys Zr-1Nb-0.1Mn, Zr-1Nb-0.2Mn, Zr-1Nb-0.4Mn, and Zr-2.5Nb-0.4Mn were identified as the most promising candidates for subsequent experimental analyses
Technical Session
LAVES PHASE IN AN AUSTENITIC-FERRITIC STAINLESS STEEL MODIFIED WITH NIOBIUM
Presenter(s): Andre Itman Filho (instituto federal do espírito santo), KAREN FARIAS CIRILO (INSTITUTO FEDERAL DO ESPÍRITO SANTO), arthur crespo frattezi (INSTITUTO FEDERAL DO ESPÍRITO SANTO), Pedro Henrique Lauret (INSTITUTO FEDERAL DO ESPÍRITO SANTO), ROSANA VILARIM DA SILVA (INSTITUTO FEDERAL DO ESPÍRITO SANTO)
Abstract:
The objective of this research was to evaluate the effect of niobium on a conventional austenitic-ferritic stainless steel and modified with 0.5% niobium in the solubilized condition and after heating at 650 ºC for one hour. Observations of the microstructures were made using scanning electron microscopy (SEM). The chemical compositions of sigma and Laves were determined qualitatively by energy dispersive X-rays (EDS). The amounts of Laves in the steels were obtained by computational thermodynamic simulation with the FactSage software and the niobium contents in the phase, by calculations of the molar fractions considering the Fe2Nb stoichiometry. The results show that the thermodynamic simulation predicts the presence of Laves in the four steels, although in conventional stainless steel the microstructure is free from this phase. Regarding microstructural analyses, it is possible to observe the presence of the sigma phase in all steels only after aging, while Laves appears in those modified with niobium in both heat treatment conditions. The results show that the increase in niobium content in austenic-ferritic stainless steels favors the formation of sigma and Laves phases, as the element is considered alphagenic and has little solubility in austenite.
Technical Session
Impact of Heat Treatment on Microstructure Evolution and Corrosion Resistance of Ti-47Nb Alloy for Biomedical Applications
Presenter(s): Bruno Martins de Souza (Instituto Militar de Engenharia), Nathalia Rodrigues de Oliveira Habib Pereira (INSTITUTO MILITAR DE ENGENHARIA), Patrick de Lima Gomes (INSTITUTO MILITAR DE ENGENHARIA), Carlos Nelson Elias (INSTITUTO MILITAR DE ENGENHARIA), Marvin Nascimento (INSTITUTO MILITAR DE ENGENHARIA)
Abstract:
The increasing demand for biocompatible and mechanically robust materials for biomedical applications necessitates the exploration of optimized thermal treatments for alloys such as Ti-47Nb. This study investigates the influence of different heat treatment temperatures on the microstructure, mechanical properties, and corrosion resistance of the Ti-47Nb alloy. The samples were subjected to heat treatments at 900°C, 1000°C, and 1100°C, followed by quenching in water. Characterization techniques, including optical microscopy, scanning electron microscopy (SEM), X-ray diffraction (XRD), Vickers microhardness testing, corrosion testing, and wettability tests, were employed to analyze the effects of these treatments. The results demonstrated that higher heat treatment temperatures led to an increase in average grain size and an increased dominance of the β phase, particularly at 1100°C. This microstructural evolution corresponded to enhanced mechanical properties, such as increased hardness. However, the corrosion resistance decreased with higher treatment temperatures, indicating a trade-off between mechanical enhancement and material durability in corrosive environments. Additionally, wettability tests suggested improved surface energy at higher temperatures, potentially enhancing the alloy's biocompatibility. The study highlights the complex relationship between heat treatment conditions and the resultant properties of Ti-47Nb alloys. It was found that while higher temperatures improve mechanical properties, they adversely affect corrosion resistance and may alter biocompatibility. Future research should aim to optimize heat treatment protocols to balance these properties effectively, ensuring the suitability of Ti-47Nb alloys for advanced biomedical applications.
Technical Session
9/4/24, 10:15 AM - 9/4/24, 11:05 AM
Presenter(s): julianna magalhães garcia (IME - INSTITUTO MILITAR DE ENGENHARIA), Thaíssa Sampaio Nunes (IME - INSTITUTO MILITAR DE ENGENHARIA), TALITA GAMA DE SOUSA (IME - INSTITUTO MILITAR DE ENGENHARIA), lUIZ PAULO mENDONÇA BRANDAO (IME - INSTITUTO MILITAR DE ENGENHARIA)
Abstract:
The research on new metal alloys, such as nitrogen and niobium-modified 310 steel, aims to enhance the mechanical strength of this steel without compromising its properties at high temperatures. In this study, microstructural evaluation of the new 310NbN modified steel was conducted through tensile tests at room temperature and 675°C to investigate the influence of niobium and nitrogen addition on its microstructure and mechanical properties. The microstructural evolution was studied using scanning electron microscopy. The formation of NbC and NbN compounds that reinforce the austenitic matrix was observed. The results of the tensile tests reveal a significant increase in yield strength, tensile strength, and elongation at elevated temperatures, demonstrating the ability of these elements to maintain the mechanical strength of the material. Additionally, the analysis of the fracture surfaces reveals different ductile fracture mechanisms at these temperatures
Technical Session
9/4/24, 10:15 AM - 9/4/24, 11:05 AM
Presenter(s): RAI FELIPE PEREIRA JUNIO (IME), LUCAS DE MENDONÇA NEUBA (IME), Douglas Santos Silva (ime), SERGIO NEVES MONTEIRO (IME)
Abstract:
The Fe-Ni-Cr alloys mostly constitute austenitic stainless steels, commonly containing alloying elements like molybdenum and manganese. These alloys exhibit excellent properties of corrosion resistance, mechanical strength, and stability at high temperatures. This study aims to characterize an unknown composition Fe-Ni-Cr alloy. X-ray Diffraction (XRD), Scanning Electron Microscopy (SEM), Energy Dispersive X-ray Spectroscopy (EDS), and Electron Backscatter Diffraction (EBSD) techniques were employed. XRD revealed diffraction peaks at 2θ similar to other studied alloys, with no influence from the resin used for sample embedding. SEM identified morphological details inherent to the material's microstructure, such as equiaxial grains and martensite ribs. EDS determined the alloy's chemical composition: 84.34% Fe, 7.52% Ni, and 11.84% Cr. EBSD mapped phase, orientation, quality pattern, misorientation, and grain size histogram of the samples. Overall, the studied samples showed characteristics similar to other reported alloys, without anomalies in the studied properties compared to published data.
Technical Session
ANALYSIS OF SURFACE AND SUB-SURFACE INTEGRITY IN TURNING SAE 1030 CARBON STEEL.
Presenter(s): gabriela wells costa (Instituto federal do espirito santo)
Abstract:
This paper investigates the effects of cutting parameters on the turning process of SAE 1030 carbon steel, focusing on the surface and subsurface integrity of the machined workpiece. Using a 2^k factorial experimental design, 16 external cylindrical turning tests were conducted without coolant, with variations in cutting speed, feed rate, depth of cut, and tool tip radius. The results indicated a trend of decreasing surface roughness with increasing cutting speed. However, statistical analyses revealed that the differences were not significant within the established margin of error. Increasing feed rate and depth of cut resulted in higher roughness due to increased cutting forces, which can cause vibrations and deflections in the workpiece. Conversely, it was observed that an increase in tool tip radius led to lower surface roughness values. Regarding microhardness, no significant differences correlated with cutting parameters were found, although there was a trend of increasing hardness with depth of cut. The study highlighted the importance of understanding the correlations between cutting parameters and the surface and subsurface properties of the machined workpiece. These analyses are essential for developing optimization strategies for the machining process, aiming for higher productivity and lower cost without compromising the quality of the final product.
Technical Session
MARTENSITIC TRANSFORMATION IN H-SERIES TOOL STEEL
Presenter(s): laís da silva oliveira (Instituto Militar de Engenharia), Andersan dos Santos Paula (Instituto Militar de Engenharia), RAFAEL RAMOS (Instituto Militar de Engenharia)
Abstract:
Tool steels, particularly the H series, are designed to withstand extreme heat, pressure and abrasion, used in punching and forming at high temperatures with a strong and tough martensitic structure. The martensitic transformation occurs upon cooling, above a critical rate, between the start and end temperatures of this transformation, resulting in high hardness, but potential brittleness, mitigated by tempering, which relieves internal. The H series includes the subgroup H13, based on alloying elements like chromium, tungsten, and molybdenum, each contributing structural changes that confer specific properties such as impact resistance and softening. Tool steel production can involve powder metallurgy or casting, followed by heat treatments – prior annealing, in some cases, and quenching followed by tempering in one or more stages. With the literature review carried out, it was possible to elucidate how their mechanical properties are achieved in the non-thermoelastic martensitic transformation, and subsequent tempering, supported by diffusion, highlighting the importance and main applications of H series tool steels
Technical Session
MEASUREMENT OF EXPANSION LOAD IN LD STEEL SLAG USING AN EXPERIMENTAL APPARATUS WITH THERMALLY CONTROLLED HYDRATION
Presenter(s): arnaldo saquetto junior (instituto federal do espírito santo - campus colatina), patrício josé moreira pires (Universidade Federal do Espírito Santo)
Abstract:
Due to the need to analyze the load produced by the expansion in confinement of LD steel slag for its use in engineering, this work aims to measure this load through the development of an experimental apparatus with thermally controlled hydration. As a result, the experiment was able to record a maximum expansion load of 618.9 kgf for a sample with volumetric expansion of 5.16% after 20 days of testing. It is concluded that the apparatus presented works satisfactorily, requiring further tests and correlations with the chemical and physical characteristics of the sample tested.
Technical Session
CHARACTERIZATION OF HYBRID JUTE AND ARAMID REINFORCING GRAPHITE NANOPLATELETS IN HIGH-DENSITY POLYETHYLENE NANOCOMPOSITES
Presenter(s): LIVIA VIANA AGUIAR DE OLIVEIRA (UFF), ULISSES OLIVEIRA COSTA (UFF), SERGIO NEVES MONTEIRO (IME)
Abstract:
Hybrid nanocomposites have emerged as a promising solution for engineering applications associated with cost and weight reduction, aiming to enhance performance in high-tech areas. This study delves into the development of hybrid nanocomposites featuring a high-density polyethylene matrix modified with graphite nanoplatelets and reinforced by aramid and jute fabrics. Based on the results of Differential Scanning Calorimetry (DSC) as well as Dynamic Mechanical Analysis (DMA), graphite nanoplatelets play an important role in modifying the crystallization and glass transition temperatures (Tc and Tg) and influencing dynamic mechanical behavior. Specifically, they increase viscoelastic stiffness, raise the storage modulus (E’) by more than 30%, and reduce the tanδ value.
Technical Session
9/4/24, 10:15 AM - 9/4/24, 11:05 AM
Presenter(s): Yan christian silva de araújo (UFPA), Alicia Regina Zanon Barbosa (ufpa), Eric Elian Lima Espíndola (ufpa), Luane Luiza Pereira Marques (ufpa), Emerson Rodrigues Prazeres (ufpa), Amanda Lucena de Medeiros (ufpa), Deibson Silva da Costa (ufpa)
Abstract:
This study investigated the impact of annealing heat treatment on the Al-0.5%Si alloy, aiming to analyze its structural, electrical, and mechanical properties. The addition of silicon to the aluminum matrix is known to enhance casting characteristics and mechanical properties. The objective was to assess the influence of annealing on the electrical conductivity of the alloy, aiming to balance this property with tensile strength. The methodology involved the fabrication of the alloy by casting the components in a crucible at 900°C, followed by heat treatment at temperatures of 200°C, 300°C, and 400°C. Samples underwent metallographic processes for macrostructure analysis and electrical conductivity evaluation. Results indicated that treatment at 300°C yielded the best performance in terms of electrical conductivity. It was concluded that annealing is an effective technique to enhance the properties of the Al-0.5%Si alloy, emphasizing the importance of balancing electrical conductivity and tensile strength for successful industrial applications.
Technical Session
STUDY OF CORROSION PROPERTIES AND MECHANICAL BEHAVIOR OF ZAMAK-5 ALLOY
Presenter(s): Clara da Silva Santos (iNSTITUTO FEDERAL DE EDUCAÇÃO, CIÊNCIA E TECNOLOGIA DE SÃO PAULO - CAMPUS ITAQUAQUECETUBA), Felipe Ramon Cirino Soares (), Carla Isabel dos Santos ()
Abstract:
The zamak alloy is a non-ferrous alloy that is produced for the union of four elements: Zinc (Zn), Aluminum (Al), Magnesium (Mg) and Cooper (Cu). This alloy is used in the automobile industry to produce parts with complexes geometries due to your good mechanical properties, can be used as cathodic protection for hull of a boat and pipes because it has high corrosion resistance, and is an alternative way to replace brass for owning mechanical performance similar. This study presents analysis and investigations about the mechanical and corrosive properties of ZAMAK-5 alloy, by chemical analysis made by optical emission spectrometry to compare with the standard ASTM B 240-22, that shows compatibility with the alloy used. The corrosion is being analyzed through tests submerged in saline solution, with addition of chips to increase or decrease the interatomic space between the zinc molecules, will be subjected to the potentiodynamic polarization test. The properties of tensile strength and toughness will be analyzed through tests. The expected results are that the alloy does not have a large modulus of elasticity as it is a cast piece, which may cause irregularities in its microstructure that will result in different results throughout the tests.
Technical Session
9/4/24, 10:15 AM - 9/4/25, 11:05 AM
Presenter(s): MARKSSUEL TEIXEIRA MARVILA (UFV - CRP), Amaraisa Dias Costa (UFV - CRP), Augustus Magnus de Oliveira Rabel (UFV - CRP), João Gabriel de Oliveira Costa (UFV - CRP), Mateus Oliveira de Abreu (ufv - crp), Elias Rocha Gonçalves Júnior (UENF), afonso rangel garcez de azevedo (UENF)
Abstract:
The study of the mechanisms of formation of pathologies in mortar plays a crucial role in the search for the durability and performance of construction systems. Fine aggregates, such as sand, are commonly contaminated with organic impurities, arising from the decomposition of plant matter, in the form of humus and organic clay. These impurities generally form tiny particles, which in excess impair the setting and hardening of mortars and concrete. Manure representing a source of organic matter is mixed with a sample of sand. In the referring article, the prepared mortar had the trace of one part cement to 3 parts sand and a water/cement ratio of 0.6, thus being a workable mortar in order to analyze its application with interference from organic material. Based on the normative methodologies of the NBRs, specimens were produced and compressive strength tests, determination of the consistency index and determination of organic impurities were carried out. Compressive strength reduces by 43.7% in the presence of 3% organic matter in the first 7 days and 25% in the 28 days. Organic matter absorbs part of the water in the paste, causing a reduction in consistency, reducing workability. Another result was the reduction in pH inside the test specimens, indicating zones with neutral pH. Extrapolating the experiment to reinforced concrete, the presence of steel inside will be more susceptible to the effects of oxidation.
Technical Session
APPLICATION OF ONLINE ANALYZERS IN MEASUREMENT AND CONTROL OF MOISTURE AND CHEMISTRY OF IRON ORE WHEN LOADING SHIPS
Presenter(s): ROSSANA BEZERRA DE AZEVEDO VASCONCELOS SEABRA DE MELO (VALE), Frederico Goes (VALE), Gilson Sutil (VALE), Leonardo Chisté (VALE), Ocimar Barros (ORBER – Engenharia), Jonathan Dutton (SpectraFlow Analytics ), Christian Potocan (SPECTRAFLOW ANALYTICS ), Fernando Lima Regis (vale), Dany Policarpo (vale), Eldo Sousa (vale), Mayara Reis (VALE)
Abstract:
Vale has been investing in Online Analyzers seeking to optimize its operation when loading of iron ore onto seagoing ships, with a focus on safety and productivity, through the control of moisture content and chemical composition of the ore. This paper aims at describing the steps carried out and the initial results obtained at the Ilha Guaíba Island Terminal and at the Ponta da Madeira Maritime Terminal
Technical Session
9/4/24, 11:05 AM - 9/4/24, 11:30 AM
Presenter(s): Marcella Sthefânia Café de Souza (vallourec), Gabriel Augusto da Fonseca (vallourec), Diego Bruno Santiago (vallourec), João Filipe Axer Batista (vallourec), Rosiane Mary Rezende Faleiro (vallourec), Bruno Milagres Mesquita (vallourec)
Abstract:
The control of steel production in the Electric Arc Furnace (EAF) relies on accurate measurements of temperature and carbon during the refining phase. This study aims to reduce discrepancies between direct measurements and outcomes predicted by machine learning models. While previous models have been effective, a growing disparity in the last two years indicates the need for new models, due to events and variables. Well-calibrated models not only decrease operational costs by minimizing the use of disposable sensors but also reduce safety risks in sampling operations.
Technical Session
9/4/24, 11:05 AM - 9/4/24, 11:30 AM
Presenter(s): MARCELO MAGALHAES DO CARMO (ARCELORMITTAL - TUBARAO), Bruno Rocha Pratti (ETAURE LTDA), Weslley Canal Matede (ARCELORMITTAL - TUBARAO), Jade Barbosa Kill (ARCELORMITTAL R&D), Douglas Macedo Sgrott (ARCELORMITTAL R&D)
Abstract:
This work presents a case study on the application of MLOps (Machine Learning Operations) integrated into an industrial automation environment within the steel industry. The study showcases the architectures and technologies used in the development process, deployment, and maintenance of analytical models on an industrial scale. The results obtained show the applicability of a reference architecture and an evolution in the maturity level of this discipline applied to industrial systems.
Technical Session
SIMPLIFICATION OF THE OPERATIONAL SETUP OF A CHUTE FOR MATERIAL HANDLING WITH AND WITHOUT COHESION APPLYING THE DISCRETE ELEMENT METHOD
Presenter(s): Guilherme pereira de Oliveira (VALE - Engenharia porto tubarão), Brayan Pastro Machado (VALE - manutenção PORTO TUBARÃO)
Abstract:
Belt conveyors and transfer chutes are widely used in iron ore handling at port terminals in the mining sector. The decentralized loading of material in a chute is one of the main problems present in this type of equipment and contributes considerably to belt misalignment. Characteristics such as particle size, humidity and moisture content of the material handled change the flow inside the chute, especially in the presence of cohesive forces. One of the resources used to adjust the flow to the material handled is the deflector, which requires an operational setup whenever the material handled changes. The objective of this work is to evaluate the trajectory of cohesive materials (iron ore fines) and non-cohesive materials (iron ore pellets) in a transfer chute using the Discrete Element Method (DEM) to find a deflector position that allows centralizing loading without the need for operational setup, reducing route adjustment times and belt misalignment problems. It was possible to simulate the considerable differences in the material trajectory between the flow of cohesive and non-cohesive materials, as well as in the time for reaching steady state in the flow in the chute.
Technical Session
AUTOMATION OF RECOVERY AND DISTRIBUTION OF STEEL GASES AND STEAM
Presenter(s): MARCOS ANTÔNIO RODRIGUES (TERNIUM BRASIL LTDA.), LEONCIO MACHADO DE REZENDE (TERNIUM BRASIL), Vilson José Anunciação (TERNIUM BRASIL), André Machado da Silva (TERNIUM BRASIL), Evandro da Silva do Carmo (TERNIUM BRASIL), Arthur Araujo Maia Farah (Vetta - SMS), Fernanda da Silva Machado (Vetta - SMS)
Abstract:
The objective of this work will be to present the development of the project, which aims to optimize the generation and distribution of steelmaking gases and vapors from production processes at Ternium Brasil. Using machine learning techniques to create prediction, simulation and optimization models, as well as techniques that make it possible to evaluate scenarios that maximize the economic viability of operations, enabling the reduction of the burning of steel gases in flares, and their subsequent replacement by gas natural, maximizing the greatest generation of electrical energy with the energy of available waste gases. The project aims to optimize steel gases and vapors based on the production planning of production areas, although forecast models use production orders to define consumption and generation forecasts, these are only input variables for the dispatch optimizing system. of gases/vapours, and under which no decisions or controls are made. The seasonality of Steelmaking gas generation combined with its complex analysis of energy generation generated by race, as well as the logistics of distribution of steelmaking gases from the Ternium Brasil site, was exponentially one of the most important and relevant factors for the development of this project Machine Learning that uses algorithms to assimilate changes in the generation and consumption scenarios of steelmaking gases and vapors.
Technical Session
USE OF STEEL SCRAP AS A COOLANT IN THE LD CONVERTER IN REPLACEMENT OF SINTER.
Presenter(s): Italo Nathan de lira lima (Ternium)
Abstract:
Scrap metal from steelmaking slag, recovered through beneficiation in slag processing plants, generally makes a relevant contribution among steelmaking coproducts in terms of recycling potential due to its relatively high iron content and its relationship with the circular economy by replacing raw materials in steel production processes. An alternative to increase the share of internal recycling was the use of scrap steel fraction 10-60 millimeters as a coolant at the end of the oxygen blowing aiming to replace sinter. Although its cooling effect is lower compared to pellets/sinter, the cooling scrap proved to be a viable alternative for replacing sinter, bringing benefits such as the elimination of problems related to high hydrogen and wear on the walls of the primary dedusting system due to lower humidity (in relation to pellets) and abrasiveness (in relation to sinter) respectively, in addition to providing no reaction due to the high content of metallic iron and low content of oxides.
Technical Session
9/4/24, 11:05 AM - 9/4/24, 11:30 AM
Presenter(s): Fernando gama Gomes (SENAI - PA/ INSTITUTO SENAI DE INOVAÇÃO EM TECNOLOGIAS MINERAIS), Patricia Magalhães Pereira Silva (SENAI - PA/ INSTITUTO SENAI DE INOVAÇÃO EM TECNOLOGIAS MINERAIS), Andre Luiz do Carmo (SENAI - pa/ INSTITUTO SENAI DE INOVAÇÃO EM TECNOLOGIAS MINERAIS), David Miranda Monteiro (SENAI - PA/ INSTITUTO SENAI DE INOVAÇÃO EM TECNOLOGIAS MINERAIS), Márcio Santos Barata (ufpa), adriano reis lucheta (Senai - pa/ instituto senai de inovação em tecnologias minerais)
Abstract:
The increasing generation of industrial waste is a global challenge, requiring innovative solutions. Sectors such as Construction and Mining need strategies for reusing by-products. In Construction, the production of Portland cement during the clinkerization process emits carbon dioxide (CO2), contributing to the greenhouse effect. In Mining, there is an urgent need to reduce underutilized waste. Therefore, using post-treatment Bauxite Residue (BR) via a biotechnological route is proposed as a supplementary cementitious material. The pre-treatment of BR was done using Biogenic Sulfuric Acid, produced by Acidithiobacillus thiooxidans bacteria. The results showed a reduction in BR pH from 11 to 7.4 with biogenic acid, while minerals remained intact. In evaluating the supplementary cementitious material, using 25% BR treated with biogenic acid, a 9% increase in compressive strength was observed on the first day compared to the reference, reaching 35MPa at 28 days. It is concluded that this product is feasible for structures with low load requirements, significantly reducing underutilized waste and CO2 emissions.
Technical Session
9/4/24, 11:05 AM - 9/4/24, 11:30 AM
Presenter(s): FABIO MOREIRA BRITO (UNIVERSIDADE FEDERAL DO PARA), Taiana de Sousa Matos (UNIVERSIDADE FEDERAL DO PARA), Alisson Clay Rios da Silva (UNIVERSIDADE FEDERAL DO PARA), Verônica Scarpini Candido (UNIVERSIDADE FEDERAL DO PARA), Sérgio Neves Monteiro (Universidade Federal do Rio de Janeiro)
Abstract:
Global climate change is increasingly evident and is accelerating at an unprecedented rate. Therefore, human activities urgently need a paradigm shift to interrupt this entropic process before the consequences become irreversible. In this sense, the use of eco-efficient materials aims to conveniently neutralize CO2. X-ray Fluorescence and Scanning Electron Microscopy characterizations were carried out on the raw materials. After that, formulations were created that included 100% clay, 75% kaolin residue with 25% clay, in addition to 75% clay with 25% kaolin residue. Followed by uniaxial pressing into cylindrical specimens and fired at 750ºC for 2 hours. The results showed that with 75% kaolin residue, diametrical shrinkage of 3.8% lower shrinkage compared to the others, compressive strength of 12 MPa above the required average of 2 MPa, in addition, the incorporation of 75% kaolin residue improved the characteristics of the test specimens, reducing the amount of passive environmental waste in the environment, minimizing environmental impacts when disposing of industrial waste and removing clay from nature. After this preliminary characterization, a composition was selected for manufacturing solid brick that presented requirements consistent with the standard for solid bricks, contributing to the reduction of the carbon footprint in civil construction and reuse of waste from the mining industry. Therefore, the objective is to offer the market low-cost products that help reduce the accumulation of waste from the mineral processing industry.
Technical Session
9/4/24, 11:05 AM - 9/4/24, 11:30 AM
Presenter(s): BRUNO RODRIGUES HENRIQUES (ERAMET LATIN AMERICA LTDA)
Abstract:
Steel is an essential material in our modern society. However, the steel industry is highly carbon intensive, accounting for around 8% of global emissions. On the other hand, there is no doubt that the climate crisis is a global issue that demands urgent attention. Therefore, in order to achieve the climate goals, CO2 emissions from steel industry must fall on an unprecedented scale. This means that the steel industry will have to face and overcome huge and disruptive challenges on its pathway to decarbonize its production processes. This paper aims to present the most important challenges that lie ahead of the steel industry and position them in their correct and realistic perspective. This paper also shows that there is a huge gap between the urgent need to reduce CO2 emissions and the availability of resources to accomplish this crucial task. The conclusion that can be drawn from the analysis of the current scenario is that there are not enough resources in the world to drive the decarbonization process at the speed that planet Earth demands. This is how the reality of the steel industry appears today.
Technical Session
IMPLEMENTATION OF A ROBOT FOR WORKING LINING APPLICATION ON TUNDISHES AT USIMINAS
Presenter(s): rodrigo seara martins (Usiminas), Ricardo Ribeiro Soares (Usiminas), Tiago Sangi Silva (Usiminas), André Alexandre Frederici Van Oorschot (Vesuvius), Fabiano Abrahão Moreira (VESUVIUS), Nestor de jesus costa (VESUVIUS)
Abstract:
A strong incentive to automate any process is to increase repeatability and traceability, making it easier to adjust process variables, quality of service and operational safety. In this context, the advantages of using robotic systems have emerged as one of the most significant forms of automation in industries. This article presents the results of applying spray compound to tundish in Steelworks 2 using a robot installed at Usiminas in Ipatinga. A reduction in working lining application time was observed, surface working lining was achieved at a temperature of approximately 120°C, and in homogeneity the quality of the application on the tundish was improved.
Technical Session
9/4/24, 11:05 AM - 9/4/24, 11:30 AM
Presenter(s): GERALDO SALES MENDES FERREIRA (AST Technology)
Abstract:
In 2017, the synthetic graphite industry went through a phase of turmoil initiated by battery demands that led to under supply and massive price increases for graphite electrodes to the traditional steelmaking customers. The battery demand was mainly driven by green mobility and in part the clean energy industry. The turmoil was only alleviated by increased capacity out of South and Southeast Asia especially China, combined with the willingness of the customers to use the Chinese electrodes. Global market dynamics have changed in the past decade, rapidly accelerated by the COVID 19 pandemic. The traditional model of manufacturing in Asia and consumption in the rest of the world (especially the developed West) have come under serious geopolitical pressure. This means that the geographic makeup of the graphite manufacturing industry needs to be redrawn for players outside of China to be less vulnerable to geopolitical disruptions. However, the environmental impact of graphite manufacturing means it is more difficult to install manufacturing capacity. Processes will have to adapt to be cleaner and meet regulations to ensure the successful relocation of manufacturing capabilities. The green metallurgical and especially green steel industry is another factor that will have a huge effect on the graphite industry. Using hydrogen to convert ore will mean increased use of EAFs to make primary steel. This combined with ever increasing recycled steel production will lead to a very large demand increase.
Technical Session
9/4/24, 11:05 AM - 9/4/24, 11:30 AM
Presenter(s): Melaine Moreira Zandonade (SAMARCO MINERACAO S.A), Kerollan da Silva Ramos (ITV Vale), Thales Jakson Santos Nascimento (Samarco), Carlos alberto pereira (ufop)
Abstract:
In mineral flotation, one of the main approaches to producing purer pellet feed concentrates involves the use of a combination of collecting reagents, commonly ethermonoamine and etherdiamine. However, such reagents are largely responsible for the high cost of these mineral processing operations, making the determination of their ideal proportion crucial to the total cost of the operation. This work aims to investigate the impact of using an alternative proportion of these two collectors in the reverse cationic flotation of iron ore. To this end, an industrial test was carried out, with flotations in columns, using materials classified as fine (D50 equal to 20 µm) and coarse (D50 equal to 70 µm) in tank cells and with the proportion of etherdiamine and ethermonoamine, respectively, adjusted to 70:30, instead of the usual 90:10 ratio. The results indicated that the increase in the amount of etherdiamine favored obtaining a concentrate with a lower SiO2 content, with a lower dosage of reagents and less variability in dosages. On the other hand, the reduction in the amount of etherdiamine resulted in a loss of iron for the flotation waste. Despite the reduction in mass recovery, the change in proportion did not prove to be justifiable, since the increase in production results in a greater financial return compared to the savings generated with the reduction in consumption of these inputs. However, it is recommended to continue investigations with different proportions of collecting reagents, given the possibility of having a better optimized proportion compared to that currently used.
Technical Session
PREDICTION OF THE REPLACEMENT RATE OF MIXTURES OF MINERAL COAL, PETROLEUM COKE AND CHARCOAL FOR INJECTION IN BLAST FURNACES
Presenter(s): VITORIA IMACULADA RODRIGUES CAMPOS (GERDAU ACOMINAS SA), Guilherme Liziero Ruggio da Silva (GERDAU ACOMINAS SA)
Abstract:
The use of pulverized coal injection (PCI) and other alternative fuels makes it possible to reduce coke consumption and pig iron costs. The present work aimed to study the individual behavior and in mixtures of two different coals of mineral origin, petroleum coke and charcoal mill for injection in coke blast furnaces. Based on the physical and chemical characterization of the fuels, using data provided by a national steel company, the substitution rate (TS) of individual fuels and mixtures was calculated using different equations from the literature. The results obtained for the substitution rate were related to the combustion rate (TC) estimated for each mixture. Subsequently, optimal mixtures were defined by balancing the binomial TS and TC. The mix with 60% mineral coal II and 40% petroleum coke was the load with the highest TC (0.97) for a minimum TC of 75%.
Technical Session
9/4/24, 11:05 AM - 9/4/24, 11:30 AM
Presenter(s): cleontt guilherme tavares (VALE - Centro de tecnologia de ferrosos ctf)
Abstract:
The challenge of decarbonization in the steel industry by 2050 is demanding creativity and research from companies. The Midrex and Hyl/Tenova direct reduction processes are currently considered the most viable alternatives in the steel industry, since the blast furnace route does not meet the 2050 sustainability agenda. Companies that operate direct reduction processes use basket tests to evaluate the metallic fillers (pellets, briquettes or granulates), since the standardized ISO tests present limitations in their responses to the performance of these metallic fillers in these processes. It is therefore extremely important for suppliers of metallic fillers to have laboratory tests that can predict their behaviors in reactors and help with development and optimization. Vale's Ferrous Technology Centre (CTF) acquired a furnace and developed a non-isothermal reduction test, capable of generating a reduced product with characteristics similar to the DRI obtained on an industrial scale, evaluating the quality parameters degree of metallization and carburization. In the end, it was possible to obtain a test that met the proposed objective.
Technical Session
9/4/24, 11:05 AM - 9/4/24, 11:30 AM
Presenter(s): MARCOS LAGUNA / Pamela Diaz Garcia ()
Abstract:
Sintering, the process of producing feed material for blast furnaces, consists of a thermal agglomeration of iron ore, carbonaceous materials such as coal or coke fines, and fluxes. Sinter, the product of the sintering process, ought to have optimal physical characteristics such as grain size, strength, and porosity, as these parameters are crucial by directly impacting the blast furnace performance. For Sinter to achieve the desired physical properties, fluxes must have a proper strength, which is also measured in this study by the Tumble test (Tamboramento), and a proper grain size curve so that fines are not generated during the sintering process. Compliance with these desired parameters increases Sinter's productivity and its overall quality. Dunite, the Magnesium Silicate extracted from PASEK mine, serves as a high-grade fluxing agent for having high hot and cold resistance to mechanical stresses, low melting and softening points, and high absorption characteristics. Sinter produced with Dunite as a fluxing agent has better mechanical and chemical properties, with reduced fines generation during handling and transportation to the blast furnace, promoting an effective control of the basicity and allowing a better combination of the flux with impurities such as S, P, Si among others. PASEK Dunite improves the Sinter plant's productivity by promoting increased Sinter structure homogeneity and reducing the fines return percentage.
Technical Session
EVALUATION OF THE PERFORMANCE OF THE FEEDING SYSTEM OF A ROLLER TYPE MAGNETIC SEPARATOR IN DRY IRON ORE PROCESSING
Presenter(s): Alessandro (CEFET- RJ ), Emerson reikdal da Cunha (Universidade Federal do Rio de janeiro), Leandro Fagner Pereira (VALE), Pedro Porto Silva Cavalcanti (Vale), Rodrigo Magalhães de Carvalho (Universidade Federal do Rio de Janeiro), Antonio Leandro Candido Andrade (VALE)
Abstract:
Vale has been investing in dry processing technologies to reduce water consumption and improve efficiency in its beneficiation processes. This study focuses on the flow of granular materials, such as iron ore fines, addressing challenges like load arching and irregular flows in silos. Using the Discrete Element Method (DEM) to simulate the behavior of the fines, laboratory tests were conducted to calibrate the ore in the DEM environment. A virtual particle model was used in industrial-scale simulations to identify and solve potential problems.
Technical Session
LASER TEXTURING: EFFECT OF LASER BEAM ON ROUGHNESS AND WETTABILITY OF ELECTROLYTIC COPPER SURFACES
Presenter(s): SHEILA medeiros de CARVALHO (UNIVERSIDADE FEDERAL DO ESPIRIto santo - ufes), mILTON SÉRGIO FERNANDES DE LIMA (INSTITUTO DE ESTUDOS AVANÇADOS - IEAV), Rebeca Oliveira Lube (UNIVERSIDADE FEDERAL DO ESPIRITO SANTO - UFES), Enza de Souza Zanon Dellatorre (UNIVERSIDADE FEDERAL DO ESPIRITO SANTO - UFES)
Abstract:
The present work aims to contribute to the understanding of the phenomena involved in the biocidal nature of textured surfaces of 1 mm thick electrolytic copper sheets. Among the various forms of surface modification, laser texturing becomes a viable alternative, as it promotes surface modification in the material, keeping the volume properties unchanged. The equipment used for texturing was a 50 W fiber laser, operating in a pulsed regime, frequency of 50 kHz and a scanning speed of 5 mm/s. It was found that the laser action on the surface of the material promoted changes in the topography, since the roughness values, Ra and Rq, in the textured material increased by more than 3 times, compared to the as received material. Although the laser changed the topographic and roughness characteristics, x-ray diffractometry showed that there were no changes in the crystalline structure of the copper.
Technical Session
RECOVERY OF LOWERING TUBULAR WELLS AT MINA NORTE AT SAMARCO MINERAÇÃO: THROUGH CASING
Presenter(s): hamilton santos portela (samarco mineração), marco aurélio tito de paula (samarco mineração), cleiton imaculado da silva (samarco mineração), thiago da silveira rodrigues (samarco mineração), rafael dos santos novais (samarco mineração), leonardo viana de freitas oliveira (samarco mineração), gil sales xavier moutinho (samarco mineração), ernane josé gonzaga (samarco mineração), daniela alcantara machado (samarco mineração), pedro de medeiros correia (suez)
Abstract:
This article describes the recovery process of Water Lowering Wells in the Norte Mine of the Company Samarco Mineração. The objective is to demonstrate how casing wells with new casing with a smaller diameter can recover an asset damaged by a broken filter or hole in the casing. This method is applied when the original filter breaks or a hole occurs in part of the coating and the pre-filter enters the pumping chamber, causing the motor pump to burn out. After this insertion of the new internal lining, another technique called “Hidropuls” patented by the company Suez/DH is applied. In this process, compressed air is injected in a controlled manner into the new filters installed. Thus completing the recovery work of the drawdown wells that were jacketed
Round Table
9/4/24, 11:05 AM - 9/4/24, 12:45 PM
Presenter(s): Coordinators: Carlos Eduardo Pinedo; Technical Director at Heat Tech / Carlos Humberto Sartori; Application Engineering Specialist and Technical Advisory at Villares Metals Moderators: Giuseppe Pintaude; Prof. at UTFPR / Paula Fernanda da Silva Farina; Prof. at UNICAMP
Abstract:
Round Table
9/4/24, 11:05 AM - 9/4/24, 12:45 PM
Presenter(s): Coordinators: José Herbert Dolabela da Silveira; Consultant / Júlio César Enge Raele; Raele Consulting Moderators : Jetson Lemos Ferreira; Researcher at ArcelorMittal / Geraldo Lúcio de Faria; Prof. at UFOP
Abstract:
Technical Session
9/4/24, 11:30 AM - 9/4/24, 11:55 AM
Presenter(s): Mayara michelly chaves reis (vale), JEAN CARLOS RODRIGUES PEREIRA (VALE), ELDO ALVES DE SOUSA (vale), fernando lima regis (vale), Glaucon medeiros silva (vale), DANY LUIZ VIEIRA POLICARPO (vale), leandro barreto andrade (vALE), Rômulo Rodrigo da Silva (RHOMOS), ROSSANA BEZERRA DE AZEVEDO VASCONCELOS SEABRA DE MELO (VALE)
Abstract:
The moisture content is monitored during the loading of iron ore on ships to ensure that the moisture does not occur in holds above the pre-established limit, called TML (Transport moisture limit). The purpose of this control is to prevent "liquefaction" of the ores on board. With moisture above the TML, it is possible that there will be displacement of the cargo that will compromise the stability of the ship and cause its sinking. To optimize this operational control, it is necessary to increase the number of tests as well as to have faster results and adhere to the official humidity, thus collaborating with greater safety and productivity. This paper of this report is to demonstrate the adherence between the humidity results obtained in a fast-drying oven and the official moisture method, determined according to the ABNT NBR ISO 3087:2021 standard [1]
Technical Session
9/4/24, 11:30 AM - 9/4/24, 11:55 AM
Presenter(s): CRISTOVAO NERY GIACOMIN (Usiminas), leonardo de oliveira eugênio (usiminas), edmilson fernades dadomi (usiminas)
Abstract:
Obtaining the specified width of hot rolled strips is essential for customer service, whether in the subsequent cold rolling process or the end customer of the hot rolled product. To do this, it is necessary to control the causes of width variation during rough rolling. At the Ipatinga Plant, in the Hot Strip roughing mill there are two vertical rolling mills, E1 and E2 called Edgers, positioned at the entrance of the horizontal rolling mills R1 and R2. Edgers are mainly responsible for reducing plate widths and adjusting the final overwidth of the hot coil. A software, Edger Control, was developed to monitor the overwidth, showing in real time the need for adjustments in the opening of the edgers for the next plates, and highlighting lack of width defects from the processing of data obtained by monitoring and database created to serve the software. After monitoring implementation, the percentage of rework and overwidth deviation followed a downward trend.
Technical Session
9/4/24, 11:30 AM - 9/4/24, 11:55 AM
Presenter(s): Cleiton Ferreira dos Santos (Furukawa Electric), Mariana Barbosa de Toledo Canaan (Sigma telecom)
Abstract:
The article explores the relevance of industrial communication networks with a focus on the premises adopted by Industry 4.0, highlighting the use of passive optical technologies (PON-LAN), known as Laserway. Industry 4.0 consists of the transformation in industrial processes through digitalization and the integration of advanced technologies. In this context, connectivity solutions are essential for good system performance. Laserway networks can be considered a way of efficient and high-speed communication, supporting device connectivity in industrial environments, with advantages such as high bandwidth, cost efficiency, and scalability. Therefore, this article aims to present the concepts related to this technology and provide a comparative case study between two network architectures (one considering traditional switching solutions and the other considering passive optical network solutions). It is observed that optical networks are crucial for digital transformation in Industry 4.0, promoting innovation, efficiency, lower cabling density, centralized management, and reduced operational costs.
Technical Session
INNOVATION APPLIED TO SAFETY HANDLING OF STEEL LOADS – MAN AND MACHINE SENSING
Presenter(s): flavio de araujo porto (arcelormittal tubarão)
Abstract:
ArcelorMittal Tubarão's coil and slab storage matrix is made up of different yards, from warehouses operated with cranes and gantries to those operated with forklifts and Reach Stackers with up to 50 tons of load capacity. Operated by forklifts, these yards allow the movement of coils, which can be quite heavy, from one point of the warehouse to another or to transport vehicles. The forklifts used in these yards are generally robust equipment, capable of handling heavy loads and operating in different terrain conditions. When this equipment is associated with other competing activities within the same yard, it is at this moment that the UWB technology embedded in forklifts can accurately inform the presence of pedestrians in the region.
Technical Session
9/4/24, 11:30 AM - 9/4/24, 11:55 AM
Presenter(s): antonio augusto genelhu machado (usiminas)
Abstract:
In any basic industry, an optimized energy matrix represents a competitive difference, since fuels represent an extremely important part of the transformation cost. Therefore, in the steel sector, with an energy-intensive activity, the search for energy efficiency is a constant obsession to guarantee the continuity of the business. This fact was the main motivation in developing this work. The challenge was to reduce the use of natural gas (NG) in the 130t/h boilers at Usiminas' thermoelectric plant nº01 in Ipatinga, without impacting operational stability and safety. The operational challenges were driven by a multidisciplinary team, where questioning and collaboration were essential for the adoption of a successful solution that included adapting the coke oven gas burners (COG). The work includes the review of burners, gas networks, control and protection systems
Technical Session
9/4/24, 11:30 AM - 9/4/24, 11:55 AM
Presenter(s): DIEGO CORREA MAGALHAES (ARCELORMITTAL BRASIL SA)
Abstract:
The construction industry exerts significant influence on the environment, and the use of waste as substitutes for raw materials in pavements can be a viable sustainable alternative. An effective way to assess environmental impacts is through Life Cycle Assessment (LCA), a methodology that estimates environmental impacts throughout the entire life cycle of a product, from raw material extraction to final disposal. This research aims to compare the LCA of three types of flexible pavements, one of which employs Sidercal®, co-product obtained from KR De-S slag, in the sub-base, while the other two use conventional materials in paving. Sections of BR-101 in Espírito Santo, Brazil, were evaluated for different pavement types using primary and secondary data. The system boundaries extend from cradle to construction site. The results revealed that track A, with Sidercal®, showed the best environmental performance among the three evaluated tracks. Track A demonstrated a significant reduction in carbon footprint, saving over 84 thousands kg of CO2 eq per kilometer compared to the other tracks.
Technical Session
9/4/24, 11:30 AM - 9/4/24, 11:55 AM
Presenter(s): Tracy Patricia Poma Fernandez (Ufrgs)
Abstract:
The economic evaluation of mining projects is essential for determining the viability and sustainable development of operations. One key area is the estimation of processing plant costs, using the recently updated MAFMINE 3.1 tool. This study highlights the current importance of integrating sustainable practices in the sector, speeding up the evaluation of multiple estimates for the same proposal. This makes it possible to balance economic, environmental and social aspects, offering a more complete and faster view in less time to make the best decisions. In the development phase, the methodology includes an analysis of the processing processes, considering key operating variables, energy consumption, waste management and costs associated with each stage of processing. A careful distinction was made between the different types of processes and their specific needs. The results show that this perspective is swift and realistic, and closely aligned with the sector's evaluation results.
Technical Session
CONCRETE STRUCTURES IN FIRE SITUATIONS: A BRIEF LITERATURE REVIEW
Presenter(s): JULIANA FADINI NATALLI (UENF), aFONSO Rangel garcez de azevedo (uenf)
Abstract:
The action of high temperatures on the behavior of concrete can result in deformations in its mechanical properties, such as decreased compressive strength, decreased modulus of elasticity, loss of structural rigidity and, in some cases, structural collapse. This study proposes a literature review on the topic, with the aim of better understanding the behavior of concrete in fire situations. A collection of information regarding the effect of high temperature on the matrix and aggregates, as well as alternatives for minimizing damage to concrete caused by fire, could be created, based on books and scientific articles. Attention is paid to the need to research new materials and admixtures that contribute to increasing the support time of the concrete structure in order to increase the rescue period and complete evacuation of the building.
Technical Session
9/4/24, 11:30 AM - 9/4/24, 11:55 AM
Presenter(s): JOSE FLAVIO VIANA (jfviana soluções em metalurgia), nildo dos santos ribeiro (nildo engenharia industrial e consultoria ltda)
Abstract:
The hot metal desulfurization is an important step of the steel production in an integrated plant, as sulfur is an undesirable element in the most steel applications. There are several methods of hot metal desulfurization and to achieve better results of desulfurization efficiency, the use of complex equipment or high-cost desulfurizers is common. The High-Performance Desulfurization Reactor (HPDR) combines the best characteristics to improve the reaction with the use of lime, the lower cost desulfurizer agent available.
Technical Session
EFFECT OF THE REPLACEMENT OF TURBULENCE INHIBITORS BY DAMS IN THE TUNDISH OF CONTINUOUS SLAB CASTING
Presenter(s): Rodrigo Seara Martins (Usiminas), alexandre de freitas gomes de mendonça (usiminas), Pedro Henrique Resende Vaz de Melo (usiminas)
Abstract:
Improving steel cleanliness combined with cost reduction are ongoing activities in steelworks. Caster tundish flow modifiers are targets of several application feasibility analysis in this context. Among them, the turbulence inhibitor has the functions of reducing the speed entrance of the steel that came from the ladle and promoting an ascending steel flow, facilitating the flotation of inclusions. Usiminas uses tundish with turbulence inhibitor. One option to replace it is the use of dams, which can direct the steel flow to the free surface of the tundish with lower application costs. In this study were evaluated 147 heats in tundish with dams and compared with ones that used a turbulence inhibitor, as a standard condition. Inclusion analysis techniques such as optical microscopy automatic inclusion analysis total oxygen content and nitrogen pick-up were used in samples from secondary refining and tundish to compare both conditions. Furthermore, the operational performance was analyzed considering steel splashing at operation start. Also, the rate of quality rejection was evaluated, which proved to be within regular limits. This finding was expected since the inclusion removal efficiency was maintained, and the operation occurred without abnormality.
Technical Session
9/4/24, 11:30 AM - 9/4/24, 11:55 AM
Presenter(s): Ricardo vieira regis de almeida Martins (ternium), Edson da SIlva BArros (Ternium), Thayane Santos da Silva (Ternium), Alanderson Batista (Ternium), Gabriel Peron de oliveira (Ternium)
Abstract:
In steelmaking, indirect cleanliness measuring methods are preferred over direct measurements due to their simplicity. Nevertheless, such methods are qualitative and not deterministic. The ASTM E45 is currently the most used method for coil cleanliness measurement, eventhough the literature agrees on its' inaptitude to be a reference point to optimize process parameters. This paper aims to quantify and correlate quality and cleanliness results in coil and in ladle for the purpose of predicting the final product’s quality by direct measurements made inside the steel plant and to study the effects of steelmaking process parameters in the final product quality. This work managed to use the Gumble Extreme Value Distribution, the mathematical method applied in ASTM E2283, as a cleanliness metric to validate cost saving process changes without quality hinderances, later confirmed by E45 results and yield in the coil production.
Technical Session
9/4/24, 11:30 AM - 9/4/24, 11:55 AM
Presenter(s): denise Schwantes (Vale sa)
Abstract:
The presence of residual amine was evaluated in existing water flows at the Vargem Grande 2 plant. The residual amine analyzes in the water were carried out 7 or 10 days after collection, which may have an impact on the low concentration values (of 1 to 4.9 mg/L) due to probable degradation. The amine amount added in the industrial process was evaluated, indicating a lot of variation in the addition, which may be the reason why no significant influence of the residual amine was observed, with the addition of an amine as the plant. Flotation done with lower amine addition presented results showing the influence of residual amine. Flotations analysis with process water obtaining a concentrate with an average of 2% lower silica percentage compared to the result of other waters. The %Fe in the concentrate was 3% higher with the addition of 15 g/t of amine compared to the other waters. The SiO2 content in the concentrate was reached with the addition of new amine between 60 and 70g/t of SiO2 feed.
Technical Session
COMPUTER SIMULATION OF THE FLOW AND BURNING OF FUELS INJECTED INTO THE BLAST FURNACES’ RACEWAY
Presenter(s): leonardo camilo dos reis (USIMINAS - IPATINGA), WALTER HERNAN MARTINEZ (usiminas), beatriz fausta gandra (usiminas)
Abstract:
The injection of pulverized coal through the tuyeres, combined with adjustments to the blast furnace's operating parameters, aims to reduce the hot metal producing cost, as well as improving the energy efficiency of the steelmaking process. Auxiliary fuel injection was adopted as a method of reducing the total amount of coke needed to operate the reactor. However, the variations in blast furnace raceway conditions and the fuel combustion characteristics, due to the method and conditions of injection into the reactor, are still not fully understood. In this study, thermos-fluid dynamic models were developed to simulate the flow of gases and the combustion reactions that take place inside the raceway region of Usiminas' Blast Furnace #3. The results showed that co-injection of pulverized coal with natural gas or coke oven gas is beneficial in terms of combustion phenomena when compared to the injection of solid fuel alone. The model can be used to define the minimum and maximum volume of gases to achieve optimized burning during injection and combustion in blast furnaces
Technical Session
9/4/24, 11:30 AM - 9/4/24, 11:55 AM
Presenter(s): VICENTE MARTIN BIASON (lasid/ufrgs)
Abstract:
The study investigated the influence of different combinations of mineral coal, charcoal, iron ore, and non-coking coal on coke production. The trials included thermogravimetric analyses and mechanical strength tests of the briquettes. It was observed that Barro Branco coal showed a favorable synergy when combined with charcoal, resulting in coke with low mechanical strength. The addition of iron ore and non-coking coal also reduced coke strength. Conversely, charcoal demonstrated the ability to reduce the plasticity of mineral coal. These findings indicate the need to optimize the proportions of coals and ores to improve coke quality. The interaction between the different components directly affects the final properties of the coke, and exploring this relationship could lead to significant improvements in high-quality coke production.
Technical Session
9/4/24, 11:30 AM - 9/4/24, 11:55 AM
Presenter(s): Iara Patricia Vieira de Oliveira (gerdau ), marcelo de castro knop (gerdau), pedro lucio gonçalves (gerdau), isabela de souza (gerdau), victor barbosa simoes (gerdau)
Abstract:
Steel industries, based on the circular economy, are increasingly looking for solid solutions that provide environmental gains and financial returns, with the application of co-products in sintering. The objective of this work is to separately evaluate the influence of the use of biological sludge and light oxide, co-products from the Carbochemical Plant and the Steelworks, respectively, in the sintering process on a pilot scale. Initially, the performance of biological sludge was tested at 0.2% in partial mixing. Subsequently, the light oxide was evaluated in different percentages, 5% and 8% in the partial mixture. The results obtained indicated loss of productivity, therefore, additional tests were carried out in an attempt to recover productivity, for this, sinter feed was incorporated into the ore mixture. The results obtained demonstrate that the consumption of the respective co-products did not impact the chemical, physical, metallurgical and mineralogical properties of the sinter product, but there was a loss of productivity, except for the consumption of 5% light oxide with the addition of sinter feed to the ore mixture
Technical Session
COST REDUCTION AND PRODUCTIVITY ENHANCEMENT THROUGH A SYSTEM FOR GAUGING AND CONTROLLING JAW WEAR
Presenter(s): lucas fonseca calixto mariano (Mineração Usiminas)
Abstract:
In mining operations, rock size reduction plays an essential role in mineral treatment processes, facilitating either the physical liberation of particles or enhancing the contact surface area for reagent utilization as needed. The primary aim of this study was to establish a continuous monitoring system for jaw wear during primary crushing at the Samambaia Mineral Treatment Facility (MTF) operated by Usiminas Mining. This initiative sought to develop a procedural tool capable of regularly assessing jaw wear without compromising operational efficiency, thereby enabling the assessment of the ramifications of the high abrasiveness characteristic of Run Of Mine (ROM) materials. The outcomes achieved encompassed reduced costs through optimized jaw utilization, mitigation of operational downtime attributable to excessive wear, enhanced circuit productivity, and the establishment of an effective process control mechanism
Technical Session
DEVELOPMENT OF AN ANALYTICAL MODEL TO DETECT NON-RANDOMNESS OF NUCLEI IN THE NUCLEATION GROWTH PROCESS.
Presenter(s): WESLLEY LUIZ DA SILVA ASSIS (UFF)
Abstract:
The prevailing notion in the majority of studies on nucleation and growth phenomena in solid-state metallic materials suggests that nucleation occurs randomly within the matrix. However, this premise is not always accurate. While there exists a method to analyze this phenomenon through contiguity, there are instances where quantifying it becomes unfeasible. In light of this, the present study proposes an analytical model comprising three methods to detect the non-randomness of nuclei, based on the intersection points between the derivatives of nucleations and the horizontal axis of the graphs of, the, and the microstructural path, obtained through computational simulation. It was concluded at the culmination of the study that the proposed method offers a simplified application compared to the contiguity method, with the identified points providing ranges of values indicating whether nucleation occurred randomly or not.
Technical Session
9/4/24, 11:30 AM - 9/4/24, 11:55 AM
Presenter(s): vinícius malanquine frazzi (VALE)
Abstract:
This work aims to present the process of reviewing the strategy for maintaining the structural integrity of the Port of Tubarão's assets, in order to increase the reliability of the assets, reduce costs and risks. This review begins with the redistribution of inspection plans into different inspection levels, where in some plans there is a greater commitment of resources and equipment downtime, while in other inspections the evolution of the previously mapped condition is monitored in a more detailed way. quickly and less expensively. It also includes replanning the inspection, specifying the resources necessary for its execution, the points that typically require greater prior cleaning, as well as indicating to the inspector the points with the greatest probability of cracks appearing in the structure of each asset based on finite element studies. The inclusion of such inspections in the multi-annual map of interventions is also carried out, in addition to the generation of support orders in the removal of protection and opening of access, thus bringing better conditions for carrying out inspections. The entire plan construction process is fed back by field monitoring of its execution. In this way, the process of reviewing the structural integrity maintenance strategy has been bringing direct and indirect gains to the maintenance and operation of the Port of Tubarão, increasing the reliability of assets and reducing the costs and risks involved in the operation.
Technical Session
9/4/24, 11:55 AM - 9/4/24, 12:20 PM
Presenter(s): TIAGO CAIXETA NUNES (VALE SA), Nilson Nedes de Paula (VALE S.A.), Ana Caroline de Souza (VALE S.A.), Cássio Pascoal Costa (VALE S.A.), Eric Guimarães Vieira (vale s.a.)
Abstract:
Promoting the study of ROM (run of mine) variability is crucial to assist in the predictability of the main minerals and elements that influence the concentration of iron ore flotation and impact the adhesion of direct reduction pellet feed production. This work explores two case studies, one illustrating the effect of the responses of 58 drill hole samples on the laboratory scale flotation process, which were distributed into groups of friable and “hydrated” itabirites, where there was a significant influence of CaO, goethitic and ultrafine minerals. Simulations were also carried out with different proportions of lithologies in the plant's feed, confirming the current parameters of the ROM specification in the plant. In the second case, statistical techniques were used to investigate the influence of CaO in the flotation concentrate on an industrial scale, obtaining a CaO reference in the ROM that compromises the quality of the pellet feed that started to be applied, and which corroborates the bench study.
Technical Session
LR ProcessExpert – Digital transformation base of long rolling plants
Presenter(s): MARIA HUENIG (Primetals Technologies Germany GmbH)
Abstract:
Smart Machines, Artificial intelligence (AI), Big data and Hiper-automation share a common requirement: data. The accuracy and efficiency of these technologies depend on the quality of the data they receive. Therefore, establishing a reliable source of data is a crucial preliminary step before initiating the transformation into a digital plant. ProcessExpert gathers and connects production data from various systems, which is then associated with production orders and additionally tracks and records rolling process parameters that are crucial in ensuring sustainable product quality. This fusion of data delivers detailed insights into the production process, and it can be used as a valuable source of data for advanced mechanisms utilizing machine learning (ML) or artificial intelligence (AI).
Technical Session
CONCEPTUAL DEFINITION OF A MINIMUM STANDARD FOR REGULATORY CONTROL
Presenter(s): pedro henrique de moura couto (VALE), Lucas Andery Reis (VALE), Deisemara Cristina Mendes Pereira (VALE), Gabriel Duarte Lott (VALE), Mário Vinicius Pelegrini Guimarães (VALE), Thiago Fernandes Pantuza Moura (VALE)
Abstract:
In this article, the minimum standard for defining a regulatory control strategy is conceptualized in each of its interfaces: Programmable Logic Controller (PLC), historian, supervisory and CPM (Control, Performance e Monitoring) of control loop tool. The challenges of defining and implementing standards for control solutions and their interfaces between different platforms are presented. Two cases study are presented in which the use of defined standards brought relevant gains in implementation speed and production.
Technical Session
COMPARISON BETWEEN CARGO STOWING METHODS IN IRON ORE SHIPMENTS APPLYING THE DISCRETE ELEMENT METHOD
Presenter(s): Guilherme pereira de Oliveira (VALE - PORTO DE TUBARÃO), Luciano José Spínola (VAle - engenharia náutica)
Abstract:
The iron ore stowage process in the ship's hold is essential to ensure the safety of the vessel and crew. The movements inherent to navigation can lead to a process of cargo displacement within the holds, changing the cargo's center of gravity, which can compromise the stability of the vessel and in extreme cases lead to its sinking. The International Maritime Code for Solid Bulk Cargoes (IMSBC Code) as well as the International Convention for the Safety of Life at Sea (SOLAS) guidelines for stowage of cargo in holds to ensure the stability of vessels during navigation. The two main parameters to be followed are the cargo transportable moisture limit (TML) to prevent liquefaction and the maximum relative height between the piles formed in the hold, depending on the classification of the loaded material. Although these guidelines guide loading, the loading procedure is the responsibility of each port terminal. This work aims to apply the Discrete Element Method (DEM) to simulate the loading of iron ore in a ship's hold, applying different loading procedures to identify what best complies with the guidelines of regulatory bodies. The results of the simulations were compared with real loading carried out at a bulk terminal, through which it was possible to define the best loading procedure.
Technical Session
9/4/24, 11:55 AM - 9/4/24, 12:20 PM
Presenter(s): sérgio tetsuo obana (Usiminas), eduardo de castro alvarenga (usiminas), Pedro Henrique Borges Pires de Morais (checkbits)
Abstract:
Manoeuvres carried out in the high and medium voltage electrical system are complex and high risk, requiring a high level of safety, in addition to the need for great interaction from the performing team. At Usiminas was implemented in the process to make the execution of electrical manoeuvres more robust. Using available technology, a web and mobile platform was developed to prepare descriptions of manoeuvres with the creation of evidence rules, execution notes, interlocking actions and issuing execution reports. Thus preventing the occurrence of unwanted events.
Technical Session
CIRCULAR ECONOMY AND 4.0 INDUSTRY: FROM THE EMERGENCE OF CONCEPTS TO PRACTICAL APPLICATION IN BRAZILIAN STEELMAKING
Presenter(s): VICTOR LOUREIRO DOS SANTOS (HEPHAESTUS METALS), Kevlin Celestino Soares (PH & HpM Tecnologias em Economia Circular), Gerson Lage martins (PH & HpM Tecnologias em economia circular)
Abstract:
The objective of this paper is to explore the emergence and evolution of the concepts of Circular Economy, as well as their fundamental role in the Fourth Industrial Revolution. It will address the importance of correctly interpreting these concepts when developing technological solutions that facilitate the transition from a Linear Production System to a Circular Production System, specifically in the Brazilian steel industry
Technical Session
9/4/24, 11:55 AM - 9/4/24, 12:20 PM
Presenter(s): EDUARDO KERCHER DE OLIVEIRA (FUNDACAO LUIZ ENGLERT)
Abstract:
This study investigates the feasibility of recovering mill scale, a steel industry residue, using alternative biomass-based reducing agents. Samples of sugarcane bagasse and eucalyptus chips were carbonized at 600°C to obtain charcoal with the desired fixed carbon characteristics. The production of vegetable charcoal was compared to anthracite, a mineral coal, to evaluate the reactivity and efficiency of the vegetable reducing agents. The chemical characterization of the scale was performed using the ICP-OES technique and X-ray diffraction to identify the present crystalline phases. Self-reduction tests were conducted in a thermobalance and a horizontal furnace. In the thermobalance, the scale was heated up to 1100°C in an inert atmosphere (N2) and then subjected to a reducing atmosphere of CO, allowing the analysis of mass loss as an indicator of iron oxide reduction. Various mixtures of scale and vegetable charcoal were tested, with the mixture containing 18% eucalyptus charcoal being the most efficient in terms of scale mass consumption. Additional experiments were conducted with self-reducing briquettes, composed of scale and vegetable charcoal, in a horizontal furnace at three different temperatures, and the results were compared with those obtained in the thermobalance. The results demonstrated that vegetable charcoals have higher reactivity compared to anthracite, initiating reduction at lower temperatures and at a faster rate. Self-reduction proved to be a viable alternative for scale recovery, achieving reduction degrees close to those expected in thermobalance tests. The technical feasibility of using biomass-based reducing agents was confirmed, highlighting a sustainable approach for the recovery of steel industry residues and reducing the environmental impact of the industry.
Technical Session
9/4/24, 11:55 AM - 9/4/24, 12:20 PM
Presenter(s): RITA DE KASSIA GONCALVES PEREIRA (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO - UENF), Samuel Araújo Azevedo Malafaia (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO - UENF), Iully da Silva Amaral Pereira (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO - UENF), Juliana Fadini Natalli (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO - UENF), Afonso Rangel Garcez de Azevedo (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO - UENF), Markssuel Teixeira Marvila (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO - UENF)
Abstract:
In recent years, concern for the environment and the search for sustainable alternatives have intensified, especially in the construction sector, historically associated with high CO2 emissions. In this context, the partial replacement of Portland cement with biochar, a material obtained through the pyrolysis of sawdust, emerges as a promising solution. In addition to reducing the carbon footprint, the use of biochar offers benefits such as waste recycling and potential improvements in construction. This study explores the effects of incorporating biochar processed at 500°C into rendering mortars, evaluating their physical and chemical properties. Laboratory tests were conducted with different concentrations of biochar (0.5% and 1%) replacing Portland cement in mortars with a ratio of 1:1:6 (cement, lime, and * Contribuição técnica ao 77º Congresso Anual da ABM – Internacional, parte integrante da ABM Week 8ª edição, realizada de 03 a 05 de setembro de 2024, São Paulo, SP, Brasil. sand). Fresh state analyses included consistency index, bulk density, incorporated air content, and water retention, categorizing in detail the properties crucial for civil engineering. The use of biochar in the mortars caused significant changes, such as increased incorporated air content, variations in water retention, and increased bulk density. These results suggest potential for improved performance in terms of strength and durability, but highlight the need for further investigations to fully understand the impact of biochar.
Technical Session
9/4/24, 11:55 AM - 9/4/24, 12:20 PM
Presenter(s): Carlos Pagliosa (RHI MAGNESITA)
Abstract:
Decarbonization and transformation of integrated BOF steelmaking is currently an important challenge. Steel scrap is a charge material without new CO2 emissions and will be essential to decarbonization process. As the amount of steel scrap charged to converters increases, it promotes higher wear of refractories installed on scrap impact zones. A new generation of carbo-resins with low-emission binder system was first introduced for improving flexibility in cold processing, similar to pitch-bonded bricks processed at hot conditions. This work presents complete comparative evaluation of the novel redesigned flexible binder MgO-C brick against the original resin-pitched one. Customers’ performance is highlighted.
Technical Session
No. 4 Strands slab caster to produce from Automotive to Plate grades production at AMNSI India Hazira
Presenter(s): Gabriele Paulon (danieli & c. officine meccaniche), paolo gasparini (DANIELI & C. OFFICINE MECCANICHE)
Abstract:
The brown-field expansion of ArcelorMittal Nippon Steel India Limited’s (AM/NS India) existing plant at Hazira, Gujarat involves the installation of two double strand vertical curved slab casters, designed to serve the new steel melt shop and Hot Strip Mill (HSM) complex. The project aims to increase the plant’s capacity to 15 million tonnes/year (Mtpy) by introducing new machinery and diversifying the product mix. The success of the project hinges on the careful selection of equipment and process parameters to ensure the final product meets the desired properties
Technical Session
INCREASED PRODUCTIVITY IN THE ARCELORMITTAL RESENDE meltshop
Presenter(s): ANDERSON KEMPKA (ARCELORMITTAL), Adamastor Salvador Nava Neto (arcelormittal), Hélio Espíndola de Oliveira (arcelormittal), Paulo Marcelo Rodrigues (arcelor), alencar souza santos (arcelor)
Abstract:
THE CURRENT WORLDWIDE SCENARIO OF EXCESS STEEL PRODUCTION FROM THE EAST CAUSES MARKETS AROUND THE WORLD TO BE IMPACTED BY THE ENTRY OF CRUDE STEEL AND FINISHED PRODUCTS. THIS EXTERNAL EFFECT IS COMPLEX AND DIFFICULT TO ACTUALLY INVOLVING COUNTRIES' GOVERNMENT ISSUES. IT IS THEN UP TO STEEL COMPANIES TO ACT ON THE EFFICIENCY OF THEIR PROCESSES. INCREASING PRODUCTIVITY IS ALWAYS AN OBJECTIVE IN ANY SECTOR OF THE ECONOMY, BUT IN melt shops THERE ARE PARTICULARITIES THAT MAKE THIS EFFECT MORE ATTRACTIVE. THIS OCCURS BECAUSE THE MAIN PERFORMANCE KPIS ARE DIRECTLY AFFECTED BY PRODUCTIVITY, SUCH AS THE REDUCTION IN ENERGY CONSUMPTION AND THE REDUCTION IN MANUFACTURING COSTS IN ADDITION TO SEVERAL OTHERS THAT TOTALLY REPRESENT SUBSTANTIAL GAINS. A ROBUST METHODOLOGY WAS USED IN ADDITION TO THE ENGAGEMENT OF ALL TEAMS THROUGH STRONG TEAMWORK ADHERING TO A NEW ORGANIZATIONAL CULTURE. THE PROJECT WAS DESIGNED TO ACT ON THE 4 PILLARS THAT DIRECTLY AFFECT PRODUCTIVITY. WORKING GROUPS WERE ASSEMBLED FOR EACH FRONT AND INVOLVED THE ENTIRE PRODUCTION CHAIN FROM THE METAL YARD TO THE PRODUCTION DISPOSAL. THIS WORK PRESENTS THE MAIN FRONTS OF ACTION AND THE RESULTS ACHIEVED. THE PRECISE AND CORRECTLY DIRECTED ACTIONS HAVE BROUGHT THE ARCELORMITTAL RESENDE melt shop TO A NEW LEVEL OF PRODUCTION CAPACITY, PERFORMANCE AND BILLET COST REDUCTION, STRENGTHENING IT OVER THE CURRENT WORLD SCENARIO. THIS WORK PRESENTS THE MAIN FRONTS OF ACTION AND THE RESULTS ACHIEVED.
Technical Session
9/4/24, 11:55 AM - 9/4/24, 12:20 PM
Presenter(s): rodrigo fina ferreira (Vale s/a), Fabiana Maria Teixeira (vale s/a), Nathália Vargas (vale s/a)
Abstract:
In order to identify the flotation process critical variables, which have the greatest influence on the SiO2 content in the concentrate of this stage, as well as the respective control limits for obtaining a product with a SiO2 content below the target of 1.28%, models were developed to predict the SiO2 content in the concentrate based on the process variables. The SHAP method was applied to the best-performing model. The five variables with the greatest influence on the SiO2 content in the concentrate, in order of importance, and their respective optimal operating ranges, are: the foam level in the Cleaner I stage (< 45 cm); the MgO content in the ROM (< 0.125%); the foam level in the Rougher I stage (> 45 cm); the foam level in the Recleaner stage (> 23 cm); and the starch dosage (< 550 g/t). It is important to note that these limits are not deterministic, but rather establish the operating range for each attribute for which there is a higher probability of obtaining a concentrate that meets the quality specifications..
Technical Session
CHARCOAL INJECTION IN ARCELORMITTAL TUBARAO BLAST FURNACES
Presenter(s): Lucas Gonçalves Generoso (ARCELORMITTAL TUBARÃO), BRUNA PATRÍCIA OLIVEIRA (ARCELORMITTAL TUBARÃO), Leonardo de Nardi Plazzi (ARCELORMITTAL TUBARÃO), Joelson Cavalcante Andrade (ARCELORMITTAL TUBARÃO), Jingleison Nascimento (ARCELORMITTAL TUBARÃO), Tiago Assereuy Lobão (ARCELORMITTAL TUBARÃO), Cláudio César Costa (ARCELORMITTAL TUBARÃO)
Abstract:
Steelmaking processes are carbon-intensive, and blast furnaces largely contribute to CO2 generation. The use of charcoal instead of mineral coal is a well-known practice and an important option for mitigating greenhouse gases. Industrial tests were conducted at ArcelorMittal Tubarão in which injection coal was partially replaced by charcoal in blast furnaces. Therefore, this study evaluated the consumption of 3,000 tons of charcoal, corresponding to 5% of the pulverized coal mixture, over a period of 15 days in the blast furnaces of ArcelorMittal Tubarão. Considering the current environmental guidelines, the charcoal injection caused no environmental harm. No segregations were observed in storage. Chemical and granulometric results over time remained unchanged. Variations observed in grinding were within usual working values, although there was a higher pressure loss in injection vessels and variation in coal rate. The performance of the blast furnaces was not negatively affected in terms of productivity, efficiency, and quality, despite an increase in dust rate. These results were fundamental for the technical feasibility study of using charcoal as an auxiliary fuel in blast furnaces.
Technical Session
9/4/24, 11:55 AM - 9/4/24, 12:20 PM
Presenter(s): José Adilson de Castro (UFF), Giulio Antunes de Medeiros (csn)
Abstract:
The present study investigates the advantages and feasibility of the shaft furnace in direct reduction processes, highlighting its energy efficiency and flexibility in the choice of reducing agents. The complexity of the processes involved within the furnace is addressed, dividing it into four distinct zones. Although mathematical models have been developed to predict direct reduction, their application is limited due to the simplification required in the face of the complexity of the phenomena. The integration of the shaft furnace with partial replacement of the charge by self-reducing pellets is explored, demonstrating a potential increase in process efficiency and reduction in CO2 emissions. This study proposes a multiphase and multicomponent mathematical model to predict the internal temperature distribution of the furnace, validated by simulations on an industrial scale. The results indicate a significant increase in productivity and metalization when using self-reducing pellets, as well as a reduction in carbon emissions when partially replacing conventional reducing gas with hydrogen. The findings highlight the importance of optimizing operational parameters to maximize the benefits of the shaft furnace in direct iron production.
Technical Session
SINTERING PILOT TEST USE OF NATURAL PELLET FEED WHAT WILL BE THE BEST WAY?
Presenter(s): Iara Patricia Vieira de Oliveira (gerdau usina ouro branco), leandro guilherme moreira (gerdau), edna monica da silva (gerdau), victor barbosa simões (gerdau)
Abstract:
With the low supply of high-grade hematite iron ores in the Quadrilátero Ferrífero region, it is becoming necessary to concentrate itabiritic iron ores to obtain a product with a higher iron content. However, when itabiritic iron ore is concentrated, there is a product with a particle size fraction < 0.150 mm ≥ 85%, called pellet feed, which compared to conventional sinter feed has lower SiO2 and Al2O3 contents. In this scenario, the use of high proportions of pellet feed to replace sinter feed in iron ore mixtures for sintering becomes a necessity, whether to reduce the volume of sinter slag and/or business strategy. Studies already carried out have shown that the increase in pellet feed in the iron ore mixture reduced the productivity of conventional sintering. Therefore, for this replacement to occur in greater proportions, above 65%, new process routes for preparing the mixture for sintering and equipment have been developed, in addition to improvements in operational procedures, to compensate for the loss of process productivity, improve the chemical composition, maintaining the physical and metallurgical characteristics of the sinter product. This work aims to present the results of the evaluation of the use of natural and pressed feed pellets in the sintering process, obtained through pilot scale tests. The results show pressed pellet feed as a way forward, together with HPS (Hybrid Pelletizing Sintering) and intensive mixer (IM) technologies, to recover the loss of process productivity and improve the chemical composition of the sinter without compromising its physical and metallurgical characteristics.
Technical Session
INCREASED PRODUCTIVITY AND COMPACT JASPILITO STERILE SYSTEM THROUGH OPTIMIZATION OF THE FRAGMENTATION MESH
Presenter(s): FREDERICO QUINTILIANO GUIMARAES GOES (VALE SA), carlos campos junior (vale sa), raul de la hoz (vale sa), leonardo chaves (vale sa), caio turci (vale sa), davi oliveira (vale sa), Tanara Viviane Lisboa Santos Sales (vale sa), renato jacomi (vale sa), raphael ogushi (vale sa), tamires gabriela silva goveia (vale sa)
Abstract:
Increase Overland productivity during jaspelite production by reducing corrective stops by reducing the sizes and quantities of blocks/cuts and reducing the speeds of the sterile system conveyor belts.
Technical Session
simulation-informed artificial neural networks for calculating electrical resistivity of low alloyed Cu: Cases CuCrZr and CuAgCr
Presenter(s): PATRICK QUEIROZ DOS ANJOS (IFES - VITORIA), felipe fardin grillo (ifes), marcelo lucas pereira machado (ifes), lucas de almeida quaresma (tupy)
Abstract:
Low alloyed Cu are used in a range of applications in the electrical industry that over the years require metals with optimized properties such as high strength, plasticity and electrical conductivity. As machine learning is an instrument capable of assisting in the development of alloys with optimized properties, neural networks were used to model the electrical resistivity of low alloyed Cu through a set of data. The neural network with the best statistical evaluations was the one with the greatest complexity in terms of number of neurons and hidden layers (NN 13-28) and exhibits collinearity between the test data and the predicted data. Simulations were carried out to demonstrate the validation of NN 13-28 in relation to the variation in electrical resistivity at temperature in the CuCrZr alloy and in the relationship between aging time and electrical conductivity in the CuAgCr alloy at constant temperature. Both simulations presented promising results in relation to NN 13-28, literature data and experimentally determined data.
Technical Session
MANAGEMENT OF MAJOR SHUTDOWNS DURING THE SEASONAL PERIOD: A CASE STUDY AT THE PONTA DA MADEIRA MARITIME TERMINAL
Presenter(s): JOSE MARIA FERREIRA SANTOS FILHO (Vale), kesci (Vale), JADSON AUGUSTO VELLOSO MENDES (Vale)
Abstract:
The maintenance of equipment in industrial plants is a fundamental factor in increasing companies' profits. Optimizing processes and generating equipment reliability becomes necessary within the global scenario. The work was developed at the Ponta da Madeira Maritime Terminal located in São Luís do Maranhão, belonging to Vale S.A, and aims to present how a maintenance process structured in the most diverse standards and procedures, can help in delivering positive results and achieving indicators maintenance, the main ones for this study are: “adherence to the start and end of the stop” (AIFP) and “adherence to the stop scope” (AEP). The 104-week maintenance map based on the seasonality strategy for the application of major interventions results in the definition of maintaining assets during the period of greatest idleness and operational flexibility, with the aim of guaranteeing the physical and intrinsic availability of the plant for the period of greatest production need. In 2022, there were 28 major interventions, equivalent to 8,315 hours of maintenance. In 2023, there were 17 totaling 10,308 hours, and 907,072 man hours applied.
Technical Session
Development and application of Apex with quick fitting in hydrocyclones
Presenter(s): SAMUEL WAGNER DE SOUZA (MINERAÇÃO USIMINAS), Claudia Maria dos Santos (Haver e Boecker), Marcelo Nilo Rodrigues (Haver e Boecker)
Abstract:
The application of apex with quick fitting was developed based on previous studies carried out to increase the cutting efficiency in the hydrocyclone, correlating the increase in the efficiency of operations, gains in the agility of inspections, increased physical security for carrying out inspections and greater security in the process control with increased component useful life, reducing failures in wear classification, also contributing to the reductions of operating costs.
Technical Session
9/4/24, 12:20 PM - 9/4/24, 12:45 PM
Presenter(s): Eduardo Magalhaes Oliveira (aignosi)
Abstract:
The demand for AI applications across various industries has intensified in recent years. However, the success rate in production environments still needs to improve due to the complexities of model operationalization. This study presents the application of the AIOps approach to enhance the success of AI projects, utilizing a case study of anomaly detection in conveyor belts at a large-scale mining operation in Brazil. The SIENTIA™ platform was employed to develop and implement an AI model to function as a virtual sensor through a linear regression algorithm. This model effectively detected anomalies with precision and scalability, reducing implementation time and costs. Integrating the model into the company's decision-making processes is crucial to maximize its impact, with the ultimate goal of transforming the business value chain by optimizing operational efficiency and boosting production. The study demonstrates the potential of AIOps in OT to augment the success of AI projects in industrial settings, with applicability across diverse industry sectors to address complex challenges and generate tangible benefits for enterprises.
Technical Session
PIT-TO-PORT VIDEOWALL
Presenter(s): JULIana andrade sousa (innomotics), ivan maciel leite (innomotics), Gabriel Teixeira Assunção (innomotics), tharley murilo costa e silva (innomotics), Lorena Isabela de Oliveira Ribeiro (innomotics)
Abstract:
This paper aims to present the main features and functionalities of Pit-to-Port VideoWall, an IROC solution developed by Innomotics. The system is designed to monitor the unit operations, in this case a mining production chain, from pit to port. Through the system, it is possible to track the product from extraction process, beneficiation plant, transport, expedition/railways and finally in the port. This comprehensive monitoring facilitates the identification of operations downtimes and identify optimization opportunities for the center control room. Utilizing KPIs cards and alerts to users in the screen, VideoWall provides users with assertive information to analyze discrepancies in real time. Vale, one of the largest iron ore producers in the world, estimates that implementing its Integrated Operations Center (IOC) has the potential to generate annual gains exceeding US$600 million
Technical Session
9/4/24, 12:20 PM - 9/4/24, 12:45 PM
Presenter(s): EVALDO NOGUEIRA (ARCELORMITTAL BRASIL SA)
Abstract:
Development of an application via SAP Fiori capable of concentrating the control steps from the entry of the vehicle for loading at a Steel Plant to the issuance of the product invoice, allowing operation directly in the area using a mobile device, eliminating the need for travel for office and desktop use. Provide the application capable of integrating devices based on optical character recognition in the identification of vehicles and shipped products, eliminating the need for manual input.
Technical Session
9/4/24, 12:20 PM - 9/4/24, 12:45 PM
Presenter(s): Francisco das Chagas Silva Neto (Veolia - Water Technologies & SOlUTIONS ), Ana Lídia Tomaz de Melo (VEOLIA - WATER TECHNOLOGIES & SOLUTIONS ), Augusto Luis Marucci (VEOLIA - WATER TECHNOLOGIES & SOLUTIONS )
Abstract:
Cooling towers are essential heat exchange equipment for steel plants and most industrial processes. Strict quality control of the cooling water is indispensable to maintain the efficiency and integrity of the equipment using it. Among the various parameters that determine the performance of the chemical treatment of a cooling tower, microbiological control is among the main ones, as when impaired, it can cause deposition and/or fouling, corrosion and uncontrolled microbiological proliferation. Therefore, a reduction in process performance, as well as possible operational stoppage for cleaning and decontamination of the system or replacement of equipment and piping, may be caused. Due to the need to optimize the microbiological control of the cooling tower of the ArcelorMittal Pecém (AMPE) Power Plant (CTE), Veolia carried out a 46-day test with the oxidizing biocide Spectrus OX1276TM (Activated Isocyanuric Acid) and evaluated the effects on Chlorides , Free Chlorine, Deep Slice and pH of cooling water. Given the results, the proposed microbiological control technology proved to be not only operationally, but also financially feasible, being validated and implemented in the tower's chemical treatment program, replacing Sodium Hypochlorite
Technical Session
SLOPE STABILIZATION WITH STEEL SLAG AGGREGATE
Presenter(s): bráulio francis magalhães (usiminas)
Abstract:
Slope instability is increasingly visible and has an impact on road systems, buildings and the environment, due to climate change, human degradation, disordered land use or the lack of periodic maintenance on structures. Currently, there are several ways to stabilize slopes, mainly those related to the construction of containment works. Usiminas is developing a new geotechnical containment solution using steel slag aggregate in a mixture applied in big bags, featuring a gravity retaining wall structure. Using a simple semi-controlled wetting process, the mixture is transformed into a cubic element. This work introduces a new concept of slope stabilization, in-corporating the co-product of the steelmaking process, in an objective and simple execution. The results obtained were satisfactory in relation to safety and implemen-tation costs, in addition to bringing gains to the circular economy and sustainability.
Technical Session
CIRCULAR ECONOMY APPLIED TO END-OF-LIFE VEHICLES
Presenter(s): LÚCIA HELENA XAVIER (cetem), Anna Fátima Freitas Valente (), Luciana Silva Contador ()
Abstract:
The increasing cost and the scarcity of critical and strategic minerals demanded by energy transition processes represent today's main challenge. The search for alternative sources has been prioritized, such as, from recoverable or secondary materials. The principles of the circular economy prioritize the recovery, addition and retention of value through the management of material or energy resources. The recovery of secondary materials through urban mining from anthropogenic reserves is fundamental to making the economy increasingly circular, reducing the accumulation of waste and minimizing losses and emissions; thus, increasing efficiency and sustainability along the value chain. Compared to primary mineral extraction, urban mining tends to result in lower levels of GHG emissions and lower energy consumption. In Brazil, urban mining finds space to be further explored, by the consolidation of legislation on reverse logistics systems in the country and the global trend towards transition to low-carbon economies are incentives for the development of the sector. The research consists of a bibliographic study based on the potential for recovering secondary materials from vehicles that are at the end of their useful life (VFV). The finds suggest that, although the recycling of VFV has been regulated since 2014 in Brazil, the processing of this category of waste is still incipient, which, in turn, represents an important source of secondary materials and a way of implementing the circular economy in the sector.
Technical Session
Incorporation of kaolin and glass residue from beverage bottles in the production of ceramic blocks for use in engineering works
Presenter(s): RODOLFO AUGUSTO DO ROSARIO LIRA (UNIVERSIDADE FEDERAL DE PERNAMBUCO), alisson clay rios da silva (UNIVERSIDADE FEDERAL DO PARÁ), Verônica Scarpini Candido (UNIVERSIDADE FEDERAL DO PARÁ), Taiana de Sousa Matos (UNIVERSIDADE FEDERAL DO PARÁ), fabio moreira brito (UNIVERSIDADE FEDERAL DO PARÁ)
Abstract:
The mining industry is a major generator of waste and contributes heavily to environmental degradation. Aiming for a more ecological destination for kaolin waste and glass waste from long neck bottles, this work aims to produce ceramic blocks for engineering works. In these articles, the raw materials were processed: drying, comminution and sieving (80 mesh), and later they were mixed to produce the specimens in cylindrical formats. The raw materials were characterized using the x-ray characterization technique (XRD), while the specimens were sintered at 900°C, and were subsequently subjected to compression tests, where they reached maximum values of 72.20 MPa for samples produced with clay and glass residue, and 21.50 MPa, for the sample produced with kaolin residue and glass residue.
Technical Session
9/4/24, 12:20 PM - 9/4/24, 12:45 PM
Presenter(s): ANTONIO AUGUSTO DE REZENDe MARTINS (ternium brasil), RUBIA TEODORO SILVA (ternium brasil)
Abstract:
Ternium Brasil shares its experience in the recycling and reuse of steel refining slags. These slags, originating from steelmaking processes, are the primary waste products from steel mills. Due to their chemical compositions and physical properties, under specific conditions, they can be repurposed as flux substitutes. The article discusses Ternium Brasil's strategy to optimize slag treatment, as well as their recycling and reuse in converters.
Technical Session
REDUCTION OF LADLE NOZZLE CLOGGING EVENTS DURING CONTINUOUS CASTING OF AL-SI KILLED STEELS
Presenter(s): CIRO AZEVEDO SILVA (ARCELORMITTAL - TUBARAO)
Abstract:
Clogging events are among the biggest process deviations that affect steelmakers worldwide, negatively impacting continuous casting productivity, yield and quality. When the clogging occurs between the ladle and the tundish, the steel level in the tundish continuously decreases, making it hard to keep the sequence in production, leading to casting speed reduction, and, sometimes, if the problem cannot be solved, to an unplanned stoppage of the caster, or at least, to an increased metal return in the ladle. The aim of this work was to mitigate ladle nozzle clogging events in the ArcelorMittal Tubarão steelmaking shop with an industrial problem-solving approach. The problem was stratified in order to understand which steel grades had the higher frequency in the phenomenon, a computational thermodynamic software was used to evaluate what kind of non-metallic inclusions were present in the system, and statistical analysis compared process variables between heats with and without the problem. It was shown that the problem was highly concentrated on Al-Si killed steels without Ca treatment. It was found that additions of FeSi in the ladle during secondary metallurgical treatments produced small amounts of Ca in the steel, leading to the formation of high melting temperature non-metallic inclusions based in the CaO-Al₂O₃ system, which finally caused the majority events of ladle nozzle clogging during casting. The strategy for Si chemical adjustment of those steel grades was changed, and a new ferroalloy was adopted in the secondary refining stations. Those practices combined were enough to highly reduce the problem frequency.
Technical Session
CORETEMP® IMPLEMENTATION AT CONSTEEL EAF VALLOUREC BRAZIL: A CASE STUDY OF COMMISSIONING AND OPERATIONAL RESULTS
Presenter(s): Ádney da Silva Vieira (Heraeus Electro-Nite), Octavio Alves Jr (HERAEUS ELECTRO-NITE), Thaís Carvalho de Sá (HERAEUS ELECTRO-NITE), Sávia Cristina Lacerda Poubel Pinheiro4 (Vallourec), Diego Bruno Santiago (Vallourec), Stephane Houel (Vallourec), Ana Vitória Faria (Vallourec)
Abstract:
The CoreTemp is an automated optical fiber-based measuring system capable of delivering accurate temperature readings of liquid steel during the operation of electric furnaces developed by Heraeus Electro-Nite. This technology also supports the safety improvement condition in the operation by man-less in the floor. Vallourec Brazil installed this equipment on the EBT tapping area as trial base. The equipment information and project definition is presented in this paper. The system validation was carried out by comparing the temperature measurements at the same time by standard procedure (robot in the slag door area) and the CoreTemp in the EBT tapping area showing a difference of 30°C lower for CoreTemp in average and, mainly, due to thermal furnace profile. This difference was reduced for lower than 10°C when it was compared the temperature measurements during the steel tapping with better liquid steel homogenization.
Technical Session
THE IMPACT OF LIME QUALITY ON IRON ORE PROCESSING: ASSESSMENT THROUGH SEDIMENTATION AND FLOTATION KINETICS
Presenter(s): PAULO HENRIQUE CIRILO (SAMARCO), hENRIQUE GONÇALVES TEIXEIRA (samarco), yara aparecida carneiro (samarco)
Abstract:
The mineral beneficiation process at the Germano mine generates two types of tailings: coarse and slime, originating from flotation and deslaming processes, respectively. Therefore, the solid-liquid separation of these tailings is crucial to obtain dewatered solids and clarified process water. Lime (CaO) is effective in this process, and its quality is essential for satisfactory performance. Thus, this study mensured the impact of lime quality from different samples through sedimentation tests and flotation kinetics. The results indicated that using lime from Sample B, the water showed lower turbidity than Sample A, resulting in a 1.6% increase in selectivity. This improvement in selectivity is of paramount importance, as it directly impacts metallurgical recovery, which increased by 1.0%. Consequently, there was a 1.0% increase in the iron content in the concentrate, while the iron content in the tailings decreased by 3.1%. Additionally, flotation kinetics results indicated that with water from tests using lime from Sample B, a silica (SiO2) content of 4.7% was achieved in a shorter time interval.
Technical Session
9/4/24, 12:20 PM - 9/4/24, 12:45 PM
Presenter(s): Giulio Antunes de Medeiros (csn), josé adilson de castro (uff)
Abstract:
This study investigates the potential of combined injection of hydrogen as fuel and pulverized charcoal (PCH) in the operation of blast furnaces, aiming to reduce carbon emissions and increase energy efficiency. Through a detailed computational model, we analyzed various operational scenarios with different rates of PCH and hydrogen injection. The results demonstrate that the partial or total replacement of pulverized coal (PC) with PCH can significantly increase blast furnace productivity, reducing coke consumption and carbon emissions. An improvement in internal material distribution and temperature was also observed, with an acceleration in burden descent and a modification in the temperature pattern in the raceway region. Furthermore, it was found that progressive increases in PCH and hydrogen injection can lead to substantial increases in blast furnace productivity, with additional reductions in coke consumption and carbon emissions. These results highlight the potential of combined hydrogen and PCH injection as a viable strategy to promote sustainability and efficiency in the steel industry, aligned with decarbonization and circular economy objectives.
Technical Session
HYDROGEN-BASED DIRECT REDUCTION OF IRON ORE PELLETS: A COMPARATIVE METALLURGICAL BEHAVIOR STUDY
Presenter(s): Clarissa pereira imbiriba da Rocha (Samarco mineração s.a.), Maurício Marcos Otaviano (SAMARCO MINERAÇÃO), Evanio Gariglio (SAMARCO MINERAÇÃO), Gabriel Ferraz Sena Gonçalves (SAMARCO MINERAÇÃO), Ramiro da Conceição do Nascimento Júnior (SAMARCO MINERAÇÃO), Sanderson Battestin Bernardes (SAMARCO MINERAÇÃO), Arthur Trindade Klein (SAMARCO MINERAÇÃO)
Abstract:
The widespread of direct reduction processes will be crucial to reducing CO2 emissions in global steel industry, making the development of raw materials suitable for this process essential. This study examined the behavior of iron ore pellets under atmospheres with only hydrogen as reducing agent, in comparison to conventional atmosphere. The methodology involved the production of three types of direct reduction pellets on a pilot scale, using martitic, hematitic and magnetitic ores, followed by metallurgical tests. The results revealed an increase in the reduction kinetics (k), leading to a higher degree of metallization and a significant reduction in clustering indices. Image analyses of sponge iron provided a basis for the phenomenological interpretations underlying these results. This study has significant implications on development of raw materials and industrial processes optimization in the steel industry, highlighting the potential of using hydrogen as an alternative for more efficient and sustainable DRI production.
Technical Session
CONSUMPTION OF IRON ORE CONCENTRATE IN THE SINTERING PROCESS AT ARCELORMITTAL MONLEVADE AND ITS EFFECT ON SINTERING
Presenter(s): Alinne Julia De Araujo Souza lima (Arcelormittal monlevade), Leonardo Francisco Berçot (ARCELORMITTAL MONLEVADE), Mateus Antônio Gonçalves Assis (arcelormittal monlevade), Patrícia Torres Ambrósio (arcelormittal monlevade), Thiago Públio Teixeira (ARCELORMITTAL MONLEVADE)
Abstract:
Due to the increasing of the sinter feed iron ore chemical quality deterioration, used in the sintering process, the companies have introduced iron ore concentrate to improve the quality of the material. This improvement in chemical composition occurs in detriment of the quality of the grain size, which tends to be smaller in size. Iron ore with finer grain size impacts negatively the cold and hot agglomeration process and, consequently, the sinter plant productivity once the sintering bed permeability controls the flame front speed and thus the productivity. In this study, it has been investigated the quality differences between a hematite iron ore (in sinter feed granulometry) and an itabirite concentrate (in pellet feed granulometry), in terms of chemistry, granulometry, mineralogy and water holding. Additionally, the results of iron ore concentrate consumption in industrial scale at ArcelorMittal Monlevade's sintering process were presented. Overall, the itabirite concentrate has a positive impact on the ore's chemical quality, but due to its small size, it posed challenges in the cold agglomeration process, resulting in increased consumption of lime as a binder to minimize productivity losses.
Technical Session
9/4/24, 12:20 PM - 9/4/24, 12:45 PM
Presenter(s): Luis MARCELO MARQUES avares (UFRJ), GABRIEL KAMILO PANTOJA BARRIOS (UFRJ), luciana PEREIRA ALVES (ANGLO AMERICAN), Elias fonseca de castro (anglo american), josé nogueira sávio silva (anglo american)
Abstract:
As Itabirites become more exploited, the large variability in their mechanical response becomes evident, which can impose important challenges in throughout of the comminution circuit. The work investigates the response of samples of Itabirite from the Serra do Sapo (MG) deposit, through a variety of bench-scale comminution tests. In the context of crushing (>50 mm), Supercompact Itabirite samples presented substantially higher resistance to fragmentation than those of Compact Itabirite and then Canga. In the context of grinding (<10 mm) an inversion occurs, with Canga presenting the highest resistance to comminution, followed indistinctively by the Itabirites (Friable, Compact and Supercompact). Finally, cluster analysis of the samples demonstrated the relevance of discrimination between Compact and Supercompact Itabirites, besides Canga and Friable Itabirite, with Supercompact Itaibirite with greater affinity to Canga. This shows the importance of discriminating Supercompact and Compact Itaibirites, in particular in the context of coarse comminution.
Technical Session
EXPLORATORY STUDY OF MULTICOMPONENT ALLOYS BASED ON NICRFECOTI AND NICRFECOTINB FOR APPLICATION IN CORROSIVE ENVIRONMENTS
Presenter(s): RAFAELLA MARTINS RIBEIRO (UNIVERSIDADE FEDERAL DO RIO DE JANEIRO), ANNA CAROLINA FIGUEIREDO CARVALHO BARREIRO (ESCOLA POLITÉCNICA - UFRJ)
Abstract:
With the need to enhance properties such as corrosion resistance and high-temperature resistance, a new approach has been applied to the development of metallic alloys. By utilizing five or more principal components in approximately equiatomic amounts, these multicomponent alloys can exhibit unique final microstructures and, consequently, interesting properties. This work presents an exploratory study of different and unprecedented multicomponent chemical compositions based on the individual properties of each element, aiming to obtain a final alloy with corrosion resistance similar to that of nickel-based superalloys. Using the CALPHAD method (thermodynamic simulation), the microstructural mix obtained for 14 NiCrFeCoTi-based alloy compositions with the addition of different alloying elements was analyzed and discussed to evaluate the alloy with the highest potential for future studies. Among all the analyzed compositions, the NiCr0,25Fe1,25Co1,25Ti1,25 alloy was considered the most promising due to its maximization of the formation of solid solutions of interest
Technical Session
Why smarter maintenance management is a must
Presenter(s): Hugo Veiga (pRIMETALS TECHNOLOGIES BRAZIL LTDA)
Abstract:
Companies are using their workforce to reach a certain goal, for example to optimize costs or to find the growth point and increase profit, or to make a decision-making process more transparent. What if you could reach all your goals at once? Maintenance and repair are usually seen only as a cost factor for metallurgical plants, without additional value for the company. Primetals Technologies exposes this stereotype using the combination of digital solutions, which enable users to make smarter decisions according to data analysis and not only based on some kind of intuition of an experienced worker. Decreasing the downtimes because of digital solutions can be a factor of grown production and profit. Implementing smarter maintenance management solutions will reduce total cost of ownership. An example and its achievements are shown in the paper.
Technical Session
INDUSTRIAL FILTERING TESTS USING MISTURES OF SANDY AND SLIME TAILINGS
Presenter(s): marcos Gomes vieira (samarco)
Abstract:
This work evaluated the results achieved in industrial tests carried out at SAMARCO's tailing filtration plant. Mixtures of flotation tailings (sandy tailings) and desliming tailings (slime) were tested, with proportions of slime in the mixture varying from 5% to 15%. Aiming to minimize the drop in the unit filtering rate caused by the addition of slime to the mixture, filtering aids were dosed, and it was evaluated whether the installation of sub-screens on 50% of the discs of the same filter minimizes the loss of productivity caused by the addition of slime to the mixture. The results showed that the limit reached in the SAMARCO waste filtration plant (vacuum disc filters) was 10% of slime in the mixture, even with the use of filtering aids. The filtering rate and cake moisture results with the mixture containing 5% slime were like those already obtained with the filtering of sandy tailings using a filtering aid. The filtering rate obtained with the mixture containing 10% slime fell by half compared to the filtering rate practiced with sandy tailings, even using higher dosages of filtering aid. Values with 15% of slime in the mixture apparently clogged the filter cloth. The sub-screen showed a productivity gain of around 6.7%.
Technical Session
9/4/24, 2:00 PM - 9/4/24, 2:25 PM
Presenter(s): WILLY ANK DE MORAIS (WILLY ANK - SOLUÇÕES / UNISANTA / UNAERP / USP), Fernando José Gomes Landgraf (PMT - POLI - USP)
Abstract:
Additive manufacturing (AM) processes for metals do not have the same popularity as other materials due to development needs, innate safety concerns, and technological and operational costs. Among these, the laser powder bed fusion process (LPBF) has stood out in recent years mainly due to its differential advantages. In this process, the dynamics of molten pool formation is decisive for the performance of an LPBF product, including specific unique properties, such as its crystalline texture. Thus, weld pool formation, geometry, and overlaps are subjects of continued interest in the literature. Within this context, the present work reviews the main characteristics and conditions that control the formation and dynamics of weld pools, illustrating the information with records available in the literature and obtained by analyzing samples produced from Nb-48Ti alloy powders. Not only are the records made internally on the materials used, but their surface characteristics are also proven to reflect the microstructural evolution in which LPBF creates the parts. In conclusion, the work offers guidelines for establishing microstructural control conditions for a metallic product obtained by LPBF process.
Technical Session
9/4/24, 2:00 PM - 9/4/24, 2:25 PM
Presenter(s): Damares da Cruz Barbosa Nascimento (Universidade federal do pará), Avener gleidson andrade santos (universidade federal do rio grande do sul), TAIANA DE SOUSA MATOS (UNIVERSIDADE FEDERLA DO PARÁ), sérgio neves monteiro (instituto militar de engenharia ), alisson clay rios da silva (universidade federal do pará), verônica Scarpini candido (universidade federal do pará)
Abstract:
Hydroxyapatite (HA), an inorganic ceramic biomaterial, presents itself as a promising and active bone substitute in this scenario, as it presents characteristics similar to the mineral apatite, found in human bones and teeth. Thus, the aim of this work is to synthesize and characterize synthetic hydroxyapatite, using chicken eggshell residue as a source of calcium. The analysis of the egg shell was carried out using X-ray Diffraction (XRD) and Fourier Transform Spectroscopy (FTIR) techniques. The characterization of the hydroxyapatite powder was performed by X-Ray Diffraction (XRD), Fourier Transform Spectroscopy (FTIR), Scanning Electron Microscopy (SEM) and Energy Dispersive Spectroscopy (EDS). The results for eggshell revealed the presence of absorption bands of hydroxyl groups and carbonates and phases corresponding to calcium hydroxide and calcium oxide. The HA sample showed vibration bands of hydroxyl, carbonate and phosphate groups, and hydroxyapatite and calcium oxide phases. SEM analysis indicated irregular morphological formations with dimensional variations. The EDS semiquantitatively revealed percentages of Oxygen, Phosphorus and Calcium. According to the results, type B hydroxyapatite was obtained using eggshell residue, which was also a good source of calcium in this study.
Technical Session
9/4/24, 2:00 PM - 9/4/24, 2:25 PM
Presenter(s): Bruno Vinícius Nunes Garcia (ArcelorMittal), Maíra Abreu Patussi (ifes)
Abstract:
The process of hiring services is a critical activity in the supply chain management of a steel plant. Improper supplier selection can lead to issues in service quality, increased costs, and delays in production schedules. This article presents a case study on the application of decision support tools TOPSIS and Shannon's Entropy to select maintenance and tool and generator rental service providers in a large-scale steel market plant. The research aims to standardize technical and commercial criteria in the decision-making process and assess the alignment of the TOPSIS method with the service procurement process. Relevant criteria for supplier selection were identified and compared with the traditional empirical method. The results indicated that applying the TOPSIS method with Shannon's Entropy is feasible and effective for selecting maintenance and tool and generator rental service providers. This approach significantly improves decision-makers' experience, considering an analysis of eight times more criteria compared to the traditional method. It supports the expectation of adequate service quality, an 18% reduction in the estimated total expenditure, and provides stronger arguments for decision support
Technical Session
STABILITY IN THE DECANTATION STAGE OF THE CONTACT WATER SYSTEM
Presenter(s): CAROLINE MORGADO AMORIM (ECOLAB QUIM LTDA), Leonardo Reis da Silva (aRCELORmITTAL), Fábio Fernandes Morais Junior (ARCELORMNITTAL), Públio Galane Braz e Souza (ARCELORMITTAL), Michelle Aparecida Silva (ecolab quimica ltda), Leonardo Reis da Silva (Arcelormittal resende), Fábio Fernandes Morais Junior (Arcelormittal resende), Públio Galane Braz e Souza (Arcelormittal resende), Michelle aparecida silva (ECOLAB QUÍMICA LTDA)
Abstract:
The contact water system is used at ArcelorMittal Resende to cool equipment and products during the manufacture of long steel. A critical operation of this process is the removal of sludge (fine scale) that occurs in the longitudinal decanter, which, with the application of polymer, reduces the concentration of suspended solids, oils and greases. These, despite being separated from the water, still remain in the tank and their accumulation interrupts the synchronization of the stages onwards. The longitudinal decanter has a scraper bridge that removes oil from the surface through a channel and directs the sludge deposited at the bottom to a pit that has a submerged pump to remove the sludge. The failure of this pump generates silting and oil accumulation, impacting water quality. Pumps and pipes were then resized, ensuring performance in this critical and highly abrasive position. As a result, the results for suspended solids and oils and greases were in line, consequently the corrosion and deposition rates fell by 65% and 96% respectively. In the process, the impacts were greater, eliminating interruptions in the steel shop's run, and reducing the rolling mill's unavailability time due to nozzle clogging by 54%.
Technical Session
SECONDARY MATERIAL FLOWS AS A SOURCE OF SUPPLY FOR CRITICAL AND STRATEGIC MINERALS
Presenter(s): LÚCIA HELENA XAVIER (CETEM), Luciana Marelli Mofati (UERJ), Mônica Regina da Costa Marques Calderari (UERJ)
Abstract:
The scarcity of critical and strategic minerals required for the energy transition has motivated the search for security of supply. Urban mining is one of the mechanisms for guaranteeing the supply of resources from secondary sources. The management of stocks of these materials and their respective flows is primarily based on product codes that categorize them as residual materials, waste, residues, scraps and scrap. These representations do not cover the diversity of secondary materials, i.e. those with the potential to be reinserted into the production chain, nor do they consider the new business models based on the circular economy. In this sense, by analyzing the flow of materials, this study points out the gaps in official databases. It presents challenges for analyzing trade routes, limiting the recovery of critical and strategic minerals along the value chain.
Technical Session
9/4/24, 2:00 PM - 9/4/24, 2:25 PM
Presenter(s): MIANI LODOVICO MARIA (Danieli)
Abstract:
Which are the future challenges for the construction steel market? Zero downtimes to increase productivity and Perfection for the best quality. Endless process by welding billets connected with the Spooler is the answer to these challenges.
Technical Session
DEVELOPMENT OF HIGH-CARBON LOW-ALLOY STEEL (BW BL 50CRMO4) AT ARCELORMITTAL TUBARÃO AND WAELZHOLZ BRASMETAL LAMINAÇÃO FOR DIRECT APPLICATION IN CHAINSAW GUIDEBAR
Presenter(s): HENRIQUE SEVERIANO DE JESUS (ARCELORMITTAL BRASIL SA), Fernando Generoso Neiva Ferreira (aRCELORMITTAL TUBARÃO), Eduardo Alves Machado (arcELORMITTAL TUBARÃO), Fabiano Almir Barbosa (aRCELORMITTAL TUBARÃO), Juliano Braz Possati (ARCELORMITTAL TUBARÃO), MARCELO Urdapilleta Rodrigues (ARCELORMITTAL TUBARÃO), Maurício Franco Bomfim (waelzholz bRASMETAL LAMINAÇÃO), Marina de Lima Barroso (WAELZHOLZ BRasmetal laminação), Daniel Augusto Ferro (WAELZHOLZ brasmetal laminação), Thomas Frank (WAELZHOLZ brasmetal laminação)
Abstract:
New alternative steels are continually frequently being proposed to reduce costs and improve industry competitiveness. This study presents the development of high-carbon low-alloy steel, BW BL 50CrMo4, at ArcelorMittal Tubarão and Waelzholz Brasmetal Laminação, as a re-rolled product to meet the demands of the chainsaw bar and tool market, providing a ready-to-use product and reducing the final customer's heat treatment steps. The production of this type of steel requires rigorous process control from the steel mill to the re-rolling. This steel is widely used in components that require high mechanical strength, cleanliness, shape maintenance, and abrasion resistance. This study investigated, on an industrial scale, the process parameters, and critical characteristics for developing a high-carbon steel sheet with Cr and Mo alloy for chainsaw guidebar. The steel was characterized throughout the entire process (casting, hot rolling, cold rolling + batch annealing, and heat treatment) using tensile testing, hardness testing, optical microscopy (OM), and scanning electron microscopy (SEM). The results showed the evolution of the material's microstructure, from a ferrite/pearlite microstructure on the hot band, spheroidized in cold rolling + annealing, to a fully bainitic microstructure after austempering, ready for the manufacture of chainsaw bars.
Technical Session
9/4/24, 2:00 PM - 9/4/24, 2:25 PM
Presenter(s): Eduardo Atem de Carvalho (Universidade estadual do norte fluminense), Larissa gomes simão (Universidade estadual do norte fluminense), Walisson POgian de jesus (Universidade estadual do norte fluminense)
Abstract:
The challenge of accessing specialized adhesives designed for strain gage applications has been highlighted due to failures in logistic chains, requiring the exploration of local alternatives. A direct simulation of strain gage bonding behavior with two steel plates is infeasible due to the unique construction of strain gages. Therefore, an indirect simulation method, comparing local alternatives to a widely accepted adhesive, Loctite 496®, was employed in this study. Two potential replacements, Loctite 401® and Tekbond 793®, were tested and matched against the benchmark adhesive, with a focus on the key mechanical properties: Proportional Shear Strain (PSS), Proportional Shear Stress (PSSt), and Apparent Shear Modulus (G*). Loctite 401® exhibited the highest G*, suggesting its potential use in strain gage installations if G* is considered most important. However, Tekbond 793® demonstrated superior PSS, Maximum Shear Stress (MSSt), and Rupture Shear Stress (RSSt) performance, displaying linear behavior even without an accelerator. Surface preparation considerations were also discussed, noting that hand abrading results in double the surface roughness than using an orbital sander. The study further identified two main regions concerning failure modes related to Ra, with values below 0.31 μm causing significant variations in observed mechanical properties, pointing towards factors beyond adhesive layerThickness affecting bond properties. Lastly, the general recommendation is the use of an accelerator for all tested adhesives, while the use of a surface conditioner and neutralizer was found to negatively impact adhesive performance
Technical Session
VEGETABLE POLYURETHANE COMPOSITE DERIVED FROM CASTOR OIL REINFORCED WITH TITICA VINE FIBER IN A COST OF GOODS SOLD (COGS) ANALYSIS
Presenter(s): GRAZIELE MEDEIROS COSME (uenf), David Nicoli (UENF), Frederico Muylaert Margem (UENF), Noan Tonini Simonassi (UENF), Felipe Perissé Duarte Lopes (UENF), Sergio Neves Monteiro (UENF)
Abstract:
Due to the increasing exploitation of non-renewable resources, the world has shown a growing trend in the technological development of materials that are less polluting to the environment. An alternative to these non-renewable resources that are traditionally used has been the use of materials of natural origin, especially lignocellulosic natural fibers. This work aims to develop the calculation of goods sold (COGS) in polymeric composites of titica vine in a castor oil derived polyurethane (COPU) matrix of vegetable origin. The fibers used in this work were extracted from the mature vine of the Heteropsis flexuosa plant. The vine was peeled and cut to manufacture the polymer composite and no subsequent chemical treatment was carried out on its surface. COPU composites showed a significant increase in their mechanical properties with the incorporation of fiber when compared to the plain resin, as verified in previous works. Due to this improvement, a technical-financial assessment became interesting to assess the value list for this composites, thus it will be possible to investigate the competitiveness of this material in the current industry
Technical Session
EVALUATION OF THE ABRASIVE WEAR RESISTANCE OF HVOF COATED MATERIALS
Presenter(s): Renato Chaves Pereira Da Silva (INSTITUTO TECNOLÓGICO VALE), Nirvana Cecília Ribeiro (INSTITUTO TECNOLÓGICO VALE), José Luiz Pena Andrade (Vale), Cíntia Braga Briseno (Vale), Cristian Camilo Viáfara (INSTITUTO TECNOLÓGICO VALE), José Jimmy Penagos (INSTITUTO TECNOLÓGICO VALE)
Abstract:
In this study, WC-Co coatings were applied in AISI H13 and D2 tool steel samples using the HVOF technique. The materials' resistance to abrasive wear was evaluated on coated and uncoated steels using the ASTM G65 standard. D2 steel is an alloy characterized by the presence of chromium carbides in a martensitic matrix, had hardness of 678 HV30, while H13, a quenched and tempered martensitic steel 514 HV30. The coatings had a hardness of 1300 HV30 and an average thickness of 200 and 340 µm in D2 and H13 respectively. SEM/EDS tests revealed that the HVOF coating was mainly composed of tungsten carbide in a cobalt matrix in addition to the presence of dispersed chromium carbides. An average porosity of 6% was observed along the coating and surface roughness Ra of approximately 6.4 µm. Wear test results demonstrated that HVOF-coated materials exhibit significantly higher abrasive wear resistance compared to uncoated materials, with mass loss reductions of almost 50 times for the H13 steel and of more than 15 times for the D2. Additionally, worn surface analysis showed that wear did not exceed the coated layer and there was a decrease in surface roughness Ra to values close to 4.6 µm. These results are promising for application of HVOF-coated components subject to abrasive wear in the mining industry
Technical Session
ANALYSIS OF THE RELATIONSHIP BETWEEN THE TYPE OF GRAPHITE MINERALIZATION IN THE BAHIA-MINAS PROVINCE AND ITS MINERALOGICAL CHARACTERIZATION
Presenter(s): Gustavo de aguilar honorato (UFMG), Andréia Bicalho Henriques (Departamento de Engenharia de Minas da UFMG)
Abstract:
The graphite has been increasing prominence due to its diverse chemical and physical properties. These characteristics make it a key raw material for the industry and its energy transition. With the Bahia-Minas Graphite Province hosting the most significant Brazilian occurrences, knowledge based on mineralogical characterization makes it possible to assess the standards in relation to mineralogy, chemical content, particle size distribution, among other relevant parameters for ore treatment stages. In this way, this work develops one characterization study for two types of ore in the region. It was observed that Graphite-Gneiss tends to have larger flakes and a more homogeneous distribution in coarser grain size fractions compared to Graphite-Shale. In addition, the characterization of the mineral phases that compose these ores shows that the mineralization of Graphite-Gneiss occurred in a regime of higher metamorphic grade (granulite), while graphite-shale occurred in a lower regime (amphibolite).
Technical Session
9/4/24, 2:00 PM - 9/4/24, 2:25 PM
Presenter(s): NICOLAS HENRIQUE ALVES FERREIRA (UNIVERSIDADE FEDERAL DE MINAS GERAIS), Paula maria gomes leão cunha (UNIVERSIDADE FEDERAL DE MINAS GERAIS), Mauricio covcevich bagatini (ufmg)
Abstract:
The use of self-reducing agglomerates with biomass is an alternative that allows for the reduction of greenhouse gas emissions and the use of fossil fuels in the steel industry. This study aims to determine the thermogravimetric behavior of self-reducing mixtures composed of biomass pyrolyzed at different temperatures. Sugarcane bagasse was pyrolyzed at 250, 400, and 550°C and characterized through chemical and structural analyses. Self-reducing mixtures of iron oxide with each type of biomass in a fixed proportion were subjected to thermogravimetric analysis in a non-isothermal regime in an N2 atmosphere up to 1000°C. Structural analyses revealed changes in the surface area and functional groups of the sugarcane bagasse with the evolution of pyrolysis temperature. Greater mass loss occurred in the mixtures with biomass pyrolyzed at 400 and 550°C; however, a slightly higher self-reduction behavior was observed in the sample with biomass pyrolyzed at 550°C.
Technical Session
9/4/24, 2:00 PM - 9/4/24, 2:25 PM
Presenter(s): ALEXANDRE AUGUSTO ANDRADE DA SILVA (Paul wurth (sms group))
Abstract:
This technical study addresses uncertainty, a fundamental and extremely relevant element for the design of steel reduction plants, whose understanding and respective mitigation are essential for the development of safe and efficient equipment. A practical example of the influence of uncertainty in determining the discharge flow in bulk material storage silos will be presented. The inherent complexity of this process arises from the difficulty in effectively quantifying behavior due to the unique characteristics of the interaction between the particles of the stored material. In addition, the impact of these on the surface of structural materials is difficult to visualize and understand through empirical tests of industrial scale. The study will discuss the evolution of sizing techniques for this class of equipment, from traditional methods established by technical standards to the demonstration of an emerging solution and uncertainty reduction method, the Discrete Element Method (DEM). This study aims to contribute to the continuous improvement of engineering processes, reflecting on the complexities and challenges associated as a whole, not just to silos.
Technical Session
PILOT-SCALE EVALUATION OF THE COATING MIXER EFFECT ON SINTERING AT ARCELORMITTAL MONLEVADE
Presenter(s): Alinne Julia De Araujo Souza lima (ARCELORMITTAL MONLEVADE), Leonardo Francisco Berçot (ARCELORMITTAL MONLEVADE), Mateus Antônio Gonçalves Assis (ARCELORMITTAL MONLEVADE), Patrícia Torres Ambrósio (ARCELORMITTAL MONLEVADE), Thiago Públio Teixeira (ARCELORMITTAL MONLEVADE)
Abstract:
The Hybrid Sintering Process (HPS) was implemented at ArcelorMittal Monlevade's sintering plant in 2002, enabling the exclusive consumption of sinter feed from its own mine, as well as high levels of productivity in sintering. The HPS process includes the addition of fuels in equipment called coating mixer, allowing the formation of a thin layer of fuel on the surface of the quasi-particles (micropellets). Since the implementation of HPS at ArcelorMittal Monlevade, studies have been conducted with the aim of transferring part or all of the fuels added in the process to the coating mixer, thus enabling better energy utilization in the process and consequently reducing the total fuel consumption. In the present study, the effects of the coke coating process on the pilot sintering at ArcelorMittal Monlevade were evaluated, considering the current raw materials and process parameters. The results of the pilot scale tests indicated that the addition of fuels directly into the coating mixer enables a reduction in fuel consumption and favors the physical and metallurgical quality of the produced sinter.
Technical Session
9/4/24, 2:00 PM - 9/4/24, 2:25 PM
Presenter(s): ANDRE NOGUEIRA KOMATUDA (SOLENIS), André Teodoro Coelho Moreira Pinto (Solenis), Douglas nicolini alves da cruz (solenis), Frederico Vilela Carvalho (Eurochem), Thainá Barbosa da Silva Félix (solenis), wallace henrique da silva (solenis)
Abstract:
This article presents the use of Biosperse technology combined with the use of On-Guard analyzers in an industrial water system of an iron ore processing facility, the water to be treated comes from the lowering of the groundwater table of the respective open pit mine located in the iron quadrangle of Minas Gerais. The objective of microbiological control in this system was to eliminate the formation of slime on the internal walls of industrial water reservoirs because after its formation, some pieces of slime would break off and travel through the water circuit, clogging basket filters and points with low turbulence or with pipe narrowing such as slurry pump seal hoses. After verifying the necessary amount of Biosperse CX 3659 biocide by performing a chlorine demand curve and colony count tests, an industrial test was carried out using a proprietary automatic preparation and dosing system so that the correct specific dosage was achieved thus optimizing the consumption of the chemical, that reduced maintenance time by 66% so far with medium-term improvement in sight, when all biofilm formed in the tanks is eliminated.
Technical Session
COMPARATIVE ANALYSIS OF RESISTANCE AT WEAR IN THE SURFACE OF THE STEEL SAE 1020 LUBRICATING WITH CONDITIONER OF METAL IN RELATIONSHIP THE LUBRICATING WITH LITIO GREASE'S
Presenter(s): Matthews henrique cota Araujo (ufop), ZIRLENE ALVES DA SILVA SANTOS (UFOP)
Abstract:
In the scenario of industrial production systems, there is a challenge related to the losses of components caused by abrasive wear. Abrasive wear causes a high number of unexpected interruptions in machinery operating in processes especially when the raw material contains abrasive elements, such as minings processes. In this way, this research carried out a comparative analysis of the abrasive wear suffered by SAE 1020 steel lubricated with metal conditioner and lithium-based grease. To carry out this comparative analysis, an Abrasometer was used, which follows the standards of the ASTM G65-16 standard. This equipment performs tests with standardized parameters that simulate the abrasive wear process. The test carried out comprises four distinct stages: the characterization of the steel and abrasive, the preparation of the specimens, the weighing of the specimen, the preparation of the abrasive, and the calibration of the equipment. The results demonstrated that the metal conditioner did not have a lower wear rate than lithium grease. Thus, for mechanical equipment that has interaction and relative movement, the lithium-base grease is equal to the performance of the metal conditioner. Both offer good resister abrasive wear
Special Session
9/4/24, 2:00 PM - 9/4/24, 3:40 PM
Presenter(s): Coordinators: Carlos Eduardo Pinedo; Technical Director at Heat Tech / Carlos Humberto Sartori; Application Engineering Specialist and Technical Advisory at Villares Metals
Abstract:
Round Table
9/4/24, 2:00 PM - 9/4/24, 3:40 PM
Presenter(s): Coordinators: Renato Cesar Braga; Electrical Engineering and Automation Coordinator at Vallourec South America / Leandro Rodrigues Ramos; Automation and Process Control Specialist at ArcelorMittal Moderator: Douglas Vieira; Executive Director at Enacom
Abstract:
Round Table
9/4/24, 2:00 PM - 9/4/24, 3:40 PM
Presenter(s): Coordinator: José Roberto Bolota – Director at Lean Manufacturing Moderator: Maurício Ferreira de Pinho; General Director at Infinity Solutions
Abstract:
Technical Session
REDUCTION OF MUD GENERATION IN PRIMARY GRINDING OF ITABIRITE IRON ORE THROUGH OPTIMIZATION OF OPERATIONAL PARAMETERS
Presenter(s): Claudinei Roberto Guimarães (SAMARCO), Gabriel Gava de Castro (SAMARCO), Ricardo da Silva Leite (SAMARCO), Paloma Paula Gomes Cipriano (samarco), Alexandro Uliana (SAMARCO), Marcos geraldo oliveira guimarães (samarco)
Abstract:
This work addresses the impact of process variables on the generation of sludge in the primary grinding stage of itabiritic iron ore. Sludge, in this context, are particles smaller than 10 micrometers, contained in the crushed ROM, which can be natural or generated during the comminution stages, in which grinding plays a large role. The presence of sludge is harmful to the flotation process and needs to be removed in the desliming stage. This leads to an increase in the generation of waste and consequently, a reduction in the useful life of the pit used to dispose of it. Several operational adjustments were made and, after stabilization of each one, samples were taken to measure the generation of sludge. The results obtained in this work demonstrate the impact and significant reduction of sludge during the variation of the operational parameters under study.
Technical Session
ANALYSIS OF THE MOLTEN POOL PRESENT IN THE NB-48TI ALLOY DURING ITS PROCESSING BY LASER POWDER BED FUSION
Presenter(s): WILLY ANK DE MORAIS (WILLY ANK SERV APOIO ADMIN SET), Fernando José Gomes Landgraf (PMT-Poli-USP)
Abstract:
In recent years, additive manufacturing (AM) by laser powder bed fusion process (LPBF) has increasingly been used for metals mainly due to its differential advantages. In this process, the dynamics of molten pool formation are decisive for the performance of an FLP-L product, including specific unique properties, such as its crystalline texture. Thus, molten pool formation, geometry, and overlaps are subjects of continued interest in the literature. Within this context, the present work summarizes the main characteristics and conditions that control the formation and dynamics of molten pools and presents the results from samples of Nb-48Ti produced by the LPBF-AM process. The obtained data were confronted with process parameters, i.e., volumetric energy (EV), and used in an alternative form of volumetric energy input (EVA) based on the estimated volume of material deposited by the laser beam. Considering that the geometry chosen for the molten pool is not suitable for all energy variations of the evaluated samples, a sensitivity of the values obtained of EVA with the melting modes of the material was detected. This demonstrates that the “process window” of the Nb-48Ti alloy covered mainly the transitional melting modes when using the other parameters pre-established for its manufacture.
Technical Session
9/4/24, 2:25 PM - 9/4/24, 2:50 PM
Presenter(s): EUZEBIO BERNABE ZANELATO (IFF), Jonas alexandre (uenf), afonso rangel garcez de azevedo (uenf), markssuel teixeira marvila (ufv)
Abstract:
The production of red ceramics still uses ancient and outdated procedures. The evolution of production processes is essential for the continued competitiveness of the ceramic industry in the Civil Construction sector. The incorporation of waste discarded by other industries has already proven to be economically viable and has improved the mechanical performance of ceramic materials produced with waste from the ornamental stone industry. Each region has clays with different physical and chemical characteristics, making it necessary to evaluate the incorporation levels of ornamental rock residue specifically for each clay. The objective of this work is to evaluate the incorporation of ornamental rock at levels of 5, 10, 15 and 20%, in addition to the reference without adding residue, in three clays used in ceramic production in the Southern Capixaba region. The materials used in the research were characterized by particle size, real grain density and chemical analysis. The ceramic specimens were produced by extrusion, fired at 750°C and evaluated by mechanical resistance, water absorption and linear shrinkage tests. The results indicated that the residue promoted improvements in all clays at incorporation levels between 5 and 10%.
Technical Session
9/4/24, 2:25 PM - 9/4/24, 2:50 PM
Presenter(s): Graycielle aparecida pereira barbosa (Gerdau)
Abstract:
Gerdau, a leader in the long steel market in the Americas and one of the main suppliers of special steels worldwide, faced significant challenges in its ore logistics operations. Inefficiency in scheduling management, quota distribution via communication apps without a clear view of carrier and operation adherence, were critical issues resulting in queues, vehicle concentration at certain times, complaints from local communities and drivers, and negative environmental impact through CO2 emissions. Seeking innovative solutions to overcome these challenges, Gerdau Mining searched the market for technological solutions that met all their needs. However, the company didn't find a comprehensive tool. That's when BeTruck, a startup focused on providing integrated solutions to optimize the logistics chain, presented a prototype in development and entered into a partnership with Gerdau. BeTruck's solution directly addressed the challenges faced by Gerdau, through a platform for management, aiming to centralize processes, increase predictability, reduce queues and CO2 emissions, and improve stakeholder satisfaction.
Technical Session
Hydrogen Combustion Development and Decarbonization of the Steel Industry
Presenter(s): Pedro Athias Zagury (White martins gases industriais ltda)
Abstract:
The steel industry ranks amongst the top three CO2 emitters from the industrial segment. Consequently, the pressure to decarbonize has led several European steelmakers to set carbon neutral goals over the 2030-2050 timeframe, while others around the globe have launched investigations into available decarbonization approaches. How will these goals be met? Will the path to decarbonization disrupt the industry itself? Is sustainability sustainable for steelmakers? Linde is a recognized leader in sustainability and a part of the solution to Climate Change. It is well positioned to develop and serve the needs of large-scale green hydrogen supply that will be essential for full decarbonization of the steel industry over the long term. In addition, Linde’s technologies provide a path to stepwise decarbonization in the short term while renewable power and hydrogen infrastructure are still being developed. These solutions are discussed herein, and they can be implemented to decarbonize the steel industry in a cost-effective way. As a definitive step to eliminate carbon emissions, it is possible to use green fuels, such as green hydrogen. Linde detains expertise to develop equipment and warrantee a safe and reliable combustion. The whole development of combustion equipment for hydrogen can take place at the lab facilities in full commercial scale, mitigating operational and safety risks before migrating to a field commercial installation.
Technical Session
9/4/24, 2:25 PM - 9/4/24, 2:50 PM
Presenter(s): Jose alvaro previato sardelli (RHI Magnesita)
Abstract:
In 2020, the steel industry emitted an average of 1.89 tons of CO₂ per ton of steel produced, totaling approximately 2.6 billion tons of CO₂. Annually, up to 28 million tons of spent refractories are generated. The steelmaking industry, a primary consumer of refractories, demands innovations and low CO₂ emission products from suppliers. The RH degasser, crucial for producing high-quality ultra-low carbon (ULC) steel, typically uses magnesia-chromite refractory bricks. This study evaluates the impact of three different additions of secondary raw materials to a standard direct-bonded composition. The chemical, physical, and thermomechanical properties of these SRM-containing bricks were compared to standard one. A novel technology was developed to utilize MgCr SRM in direct-bonded bricks for industrial applications. The evaluated properties of all proposed compositions showed high values compared to the standard composition, except for equivalent thermal shock resistance. These results demonstrate that with effective recycling and innovative processing, SRM can enhance standard compositions.
Technical Session
9/4/24, 2:25 PM - 9/4/24, 2:50 PM
Presenter(s): Helton de Freitas COTA (SMS GROUP), cosimo Cecere (sms group), bjoern kintscher (sms group), michael pogrebinski (sms group), Tristan Toepfer-Bergner (sms group), christoph hassel (sms group)
Abstract:
In a market driven by continuously increasing production requirements with increasingly specialized steel grades, higher quality, and the clear need to reduce energy consumption and lower the carbon footprint; there is an immediate demand for a new plant concept that combines the advantages of the Conventional Hot Strip Mill and CSP® technology. The plant that meets these requirements is CSP® Nexus. High casting throughput of medium-thick slabs, together with a two stage direct rolling process via independent roughing and finishing mills brings the advantages of both worlds together.
Technical Session
DEVELOPMENT OF NGO ELECTRICAL STEELS FOR THE ELECTRIC MOBILITY MARKET
Presenter(s): FRANCISCO GERALDO TOLEDO JR (APERAM INOX AMERICA DO SUL SA)
Abstract:
New international policies aimed at decarbonization (carbon neutrality), associated with technological development to improve energy efficiency, have required coordinated action from various sectors of the economy. In this context, significant growth of electric vehicles in the international market is expected in the coming years. Aperam South America has been continuously developing different classes of NGO steels for applications at higher frequencies through research conducted at the research center and industrial tests. Low core loss at higher frequencies (1T/400Hz), high magnetic induction at 5000A/m (B50) and high mechanical resistance (Yield Strength Limit and Ultimate Strength Limit) are requirements for application in electric vehicle motors. The NO25-14 and NO30-16 steels were produced at Aperam considering the requirements of the automotive customer, and this material was marketed, shipped, tested and approved by the customer for application in electric vehicle motors. This result allowed for increased knowledge about GNO steels for use in electric vehicles, diversifying the portfolio of electrical steels at Aperam to supply customers in the automotive segment.
Technical Session
ABRASIVE WEAR OF IRON ORE CONVEYOR BELT RUBBERS: APPLICATION OF THE DRY SAND RUBBER WHEEL TEST TO RANK PRODUCTS AVAILABLE ON THE MARKET
Presenter(s): Leandro Moreira Pinto (instituto tecnológico vale (itv)), Jose Jimmy Penagos (INSTITUTO TECNOLÓGICO VALE (ITV)), Bárbara Diniz Nins (REDEMAT, Universidade Federal de Ouro Preto (UFOP),), Rafael Nunes Costa (REDEMAT, Universidade Federal de Ouro Preto (UFOP)), Patrick Amaral Falqueto (Vale ), Cristian Camilo Viáfara (INSTITUTO TECNOLÓGICO VALE (ITV)), Adilson Rodrigues da Costa (REDEMAT, Universidade Federal de Ouro Preto (UFOP)), Maria Aparecida Pinto (DEMET, Universidade Federal de Ouro Preto (UFOP))
Abstract:
Conveyor belts are fundamental elements in the transport of iron ore and are essential for the system to function properly. The most widely used test for assessing abrasive wear on belts is the pin-drum, which involves a two-body abrasion process. However, this study proposes that the abrasive wear caused by iron ore on conveyor belt rubberss is a three-body abrasion process. From this perspective, there is a gap in the literature regarding the assessment of abrasive wear on conveyor belt rubbers using three-body abrasion tests. To address this gap, the research problem of this study was: What are the most abrasion-resistant iron ore conveyor belt rubbers available on the market? To answer this research problem, the main objective of this work was to evaluate the application of the dry sand rubber wheel test with a methodology adapted from ASTM G65 standard for ranking rubbers. Furthermore, to select a methodology for different test severity conditions. Four conveyor belt rubbers (A, B, C and D) were tested in three severity or normal load conditions: high (70 N), medium (45 N) and low (13 N). The results indicated that the condition of 70 N was the most effective for ranking the rubbers behavior. B rubber showed the worst performance in terms of mass loss and was the only one on which no Schallamach waves were observed. The other rubbers performed better, with a similar behavior between them.
Technical Session
CHEMICAL, THERMAL AND IMPACT IZOD analysis of sedge fibers (cyperus malaccensis) COATED BY GRAPHENE OXIDE as a reinforcement FOR epoxy MATRIX
Presenter(s): LUCAS DE MENDONÇA NEUBA (ime), RAÍ FELIPE PEREIRA JUNIO (ime), douglas santos silva (ime), Elias Matias bentes (ime), lucas moura montenegro reis (ime), Thuane Teixeira da Silva (ime), sergio neves monteiro (ime)
Abstract:
The use of natural lignocellulosic fibers (NLFs) as a source of raw material is interesting because they are renewable natural resources and because of the enormous variety of plants available in nature. Graphene oxide (GO) is becoming extremely interesting when applied as a coupling agent between the fiber-matrix interface, due to the amphiphilic nature of the nanomaterial. Therefore, the present work focuses on the investigation of the seven-island-sedge (Cyperus malaccensis) coated with GO. Therefore, make a comparison with untreated reed fibers regarding their chemical, thermal and mechanical behavior. The impact tests were carried out on standardized samples in an epoxy matrix obtained by applying pressure in a mold and curing at room temperature for 24 hours. The results showed that the 30 FJGO/EP condition provided a comparatively greater energy absorption compared to the EP and FJ/EP conditions. The mechanical properties obtained were treated by analysis of variance (ANOVA) and Tukey test. The fracture surface was analyzed by scanning electron microscopy (SEM), as well as infrared spectroscopy (FTIR) and differential scanning calorimetry (DSC) analyses. The results obtained may constitute a database of seve-island-sedge fibers, assisting in future research
Technical Session
9/4/24, 2:25 PM - 9/4/24, 2:50 PM
Presenter(s): victor Ferrinho pereira (cnpem)
Abstract:
Particle accelerators require advanced materials for applications such as sensors and magnetic coils. The production of these materials often requires the use of vacuum furnaces that meet specific process requirements. Considering this, in this work we built a vacuum induction furnace capable of reaching temperatures close to 2000 °C, with higher heating and cooling rates than conventional furnaces. To do this, vacuum systems, an induction source and a cooling system were adapted, as well as computer simulations to build the equipment. To validate the equipment, YAG ceramic samples used in X-ray detectors were sintered and heat treatments were carried out on NbTi alloys for superconductivity applications. It was found that all the operating requirements, assessed on the different materials chosen for the validation stage, as well as the proper functioning of all the furnace subsystems were satisfactorily achieved. The construction and validation of these types of non-conventional furnaces opens up new perspectives for the development of materials with special applications.
Technical Session
INFLUENCE OF DEPRESSANT REAGENTS ON PYRITE FLOTATION
Presenter(s): pablo victor da costa gomes (universidade federal de ouro preto), Stephânia da Consolação Silva Nogueira (universidade federal de ouro preto), Francielle Câmara Nogueira (universidade federal de ouro preto), Maria Eduarda Rocha Fonseca (UNIVERsidade federal de ouro preto), Paloma Paula Gomes Cipriano (universidade federal de ouro preto), Carlos Alberto Pereira (universidade federal de ouro preto), Danilo Guimarães Costa (RIMA Industrial S/A,)
Abstract:
Pyrite is a sulfide mineral of iron, often associated with other sulfide minerals such as Galena (PbS) and sphalerite (ZnS). The mine under study generates three products in its flotation process: zinc sulfide concentrate, lead sulfide concentrate, and agricultural limestone powder (final process reject). This highlights pyrite as a gangue mineral in the mine's process, thus, the use of pyrite depressants to increase process selectivity, such as sodium metabisulfite and quebracho, could become an alternative to mitigate the impact of this mineral on the flotation circuit. Conducting bench-scale flotation tests, it was found that the best recovery and selectivity results were achieved by dosing 200 g/t of sodium metabisulfite and 200 g/t of quebracho. All results using depressants were superior to those without their use. Thus, the study demonstrates that the use of depressants improved recovery and selectivity results at the bench-scale level, becoming an option for the process.
Technical Session
IMPLEMENTATION OF CHARCOAL IN A BLAST FURNACE
Presenter(s): Icaro Andrade Ricardo (CSN), Beatriz candido alonso (CSN), Fernando henriques salina (CSN), raphael fortini de lima (CSN)
Abstract:
Companhia Siderurgica Nacional (CSN) aims to lead innovative decarbonization projects by using charcoal to reduce 〖CO〗_2 emissions. This study evaluates the technical feasibility of charcoal as a partial substitute for coal in Blast Furnace 3, aligning with sustainability goals and the requirements of the carbon market, such as the Carbon Border Adjustment Mechanism (CBAM). The analysis included benchmarking and consultations with experts, revealing that the current plant cannot support raw charcoal due to its high volatility and abrasiveness. The solution was to transport charcoal using sealed trailers, loading the processed charcoal directly into the PCI (pulverized coal injection), fine silo. This method prevented spontaneous combustion and equipment damage. A total of 94.44 tons of charcoal was tested, with 27 hours of loading and 31 hours of injection, completing the process without significant anomalies or failures. The results exceeded expectations, confirming the safety and effectiveness of handling charcoal in this manner.
Technical Session
HEARTH WEAR MODEL VALIDATION AND SALAMANDER CHARACTERIZATION AT THE END OF THE 4TH CAMPAIGN OF USIMINAS BLAST FURNACE #3
Presenter(s): ARTHUR FELIPE LINO OLIVEIRA (Usiminas), Adriano Cesar Carvalhido (Usiminas), Tales Maciel da Silva (Usiminas)
Abstract:
After the 4th campaign of Blast Furnace 3, the properties of solidified hot metal in the salamander were investigated, and the Usiminas' wear model hearth was validated. The results showed significant variation in chemical composition among the salamander samples, highlighting differences compared to the hot metal in the tap hole area prior to blast furnace shutdown. Under the optical microscope, wear was observed due to the infiltration of liquid metal at the hot metal/carbon block interface. Pig iron hardness showed an inverse correlation with carbon content, while thermal conductivity correlated inversely with sulfur. Thermodynamic simulations emphasized the influence of elements on the liquidus and solidus temperatures of hot metal, indicating limitations in applying the 1150°C temperature from the eutectic point of the Fe-C diagram. The wear model showed a good accuracy (80.9%) using the 1150°C isotherm, increasing to 82.2% with the use of the simulated solidus temperature in thermodynamic software (1080°C), and reaching the highest accuracy with the 890°C isotherm for wear (85.4%).
Technical Session
SINTERIZATION PILOT TEST COMPARISON OF TWO AGLOMERATION ROUTES WITH HIGH PARTICIPATION OF PELLET FEED
Presenter(s): victor barbosa simões (Gerdau Ouro branco), gabriel marques bonifácio chaves (gerdau ouro branco), jõao paulo elias barbosa (gerdau ouro branco), LEANDRO GUILHERME MOREIRA (GERDAU OURO BRANCO), PEDRO LÚCIO GONÇALVES (GERDAU OURO BRANCO), Isabela de Souza (Autônomo), Iara patricia vieira de oliveira (Gerdau ouro branco)
Abstract:
With the increasing restrictions on the quality of iron ore sinter feed, the sintering process presents as an alternative to increase the participation of the finest fraction of ore, the pellet feed, aiming to improve the quality parameters of the mixture to be sintered. However, when thinning the mixture, there is a drop in process productivity, thus affecting the availability of sinter product to the Blast Furnaces. Aiming to understand the effects in advance, in controlled situations, tests on pilot scales are of utmost importance to assist in the search for finding the best points of productivity versus quality, leading to more assertive decision-making, evaluating operational parameters and equipment sizing. to be installed in industrial sintering plants. In this context, the impact of increasing the participation of pellet feed in mixtures and the competitive advantages of two different technological routes for cold agglomeration were evaluated: drum combined with HPS (Hybrid Pelletized Sinter) and intensive mixer combined with HPS, aiming to understand the impacts on the quality of the sinter obtained. The results of this work showed a loss of productivity in the sintering process when increasing the proportion of pellet feed in the mixture to be sintered. Another point evaluated was the equivalence between the two routes studied.
Technical Session
9/4/24, 2:25 PM - 9/4/24, 2:50 PM
Presenter(s): THAINA BARBOSA DA SILVA FÉLIX (Solenis Especialidades Químicas), douglas nicolini alves da cruz (solenis especialidades químicas), andre teodoro moreira coelho pinto (solenis especialidades químicas), leandro rodrigues baptista (solenis especialidades químicas), diogo lima de oliveira (solenis especialidades químicas)
Abstract:
This article presents the project of the use of OnGuard monitoring technology in the control of turbidity and pH for overflow of thickening processes. The thickening system where the OnGuard technology was applied did not have real-time monitoring of the turbidity and pH of the clarified. The technology applied proved to be robust and accurate in monitoring the process, directly helping with the quality of the water recovered through turbidity readings in real time, 24 hours a day. These actions seek to assist the operation of the thickening process through continuous improvement of solid-liquid separation processes, with water quality and optimization of chemical dosage
Technical Session
9/4/24, 2:25 PM - 9/4/24, 2:50 PM
Presenter(s): Hérlon Marcio Borges de Abreu Junior (Samarco mineração S/a)
Abstract:
During the year 2020, several opportunities were observed to define the different areas of action in the lubrication process, such as: grease consumption, excess lubrication, degradation of centralized systems, lack of procedures manpower without the proper knowledge among others. In this way, the lubrication process was subdivided into ten large groups of activity, namely: lubricant specification, lubrication process management, centralized systems, contamination control, lubricant consumption, lubricant sampling, lubricant analysis, receipt/ storage, environment and hibernation process.It were applicated the Tools MASP (Method of analyzing and solving problems) being the first one the “Brainstorming”, drawing on observation made on production of mining plants were applied. Subsequently has been defined and implemented the action plan. The results obtained after actions were: reduction in oil consumption associated with the recovery of used oil (values), grease consumption at the Ubu plant over the years, compliance with lubrication plans and scheduled activities above 95% , generating high availability of equipment for iron pellet production.
Technical Session
BACKWASHING CLEANING METHODOLOGY
Presenter(s): Elisangela santos de moraes (Mineração Paragominas Norsk Hydro Brasil)
Abstract:
Tailings are waste generated during the ore extraction and processing process. This waste is directed to thickeners, where solid particles settle, causing solid-liquid separation, and sent to dams, which is the structure used to dispose of the waste. Waste pumping is a vital part of a production process. When the waste plant is stopped, production is interrupted, as the process equipment works 24 hours a day and 365 days a day. This work aims to increase the effectiveness of the waste process, ensuring the integrity of employees and assets, and minimizing the exposure of operators to adverse working conditions. The work evaluated the conditions of the routine activities of the operational teams, within the waste pumping process, identifying the risks of the activities and the frequency with which they are carried out. The results achieved were possible because we developed a methodology that automated the cleaning process carried out by the operational team in the filtration area, which is a part that directly impacts the process, where it was possible to reduce up to 90% of the occupational risks present that were identified, thus how to increase the operational performance of the waste system, ensuring its availability.
Technical Session
MICROSTRUCTURAL CHARACTERIZATION AND FRACTURE TOUGHNESS ASSESSMENT OF AUTOMOTIVE STEELS TREATED VIA QUENCHING AND PARTITIONING
Presenter(s): GERALDO LUCIO DE FARIA (Universidade Federal de Ouro Preto), Charles Henrique Xavier Morais Magalhães (Universidade Federal de Ouro Preto), Leonardo barbosa godefroid (Universidade Federal de Ouro Preto)
Abstract:
Over the last three decades, many projects have been developed by companies and researchers for the automotive sector, demonstrating steel's capability to meet the increasing demands for higher safety levels and energy efficiency by reducing the weight of automobiles body-in-white (BIW). Quenching and Partitioning (Q&P) steels are an example of a recent development. Through a suitable combination of chemical composition and thermomechanical processing, Q&P steels result in an excellent combination of strength and ductility, thus classified as part of the third-generation generation of advanced high-strength steels (AHSS) for automotive applications. In this context, building on previous Q&P modeling work to propose new thermal processing routes in a commercial CMnSi alloy, this study evaluated the fracture toughness (CTOD) of three different third-generation AHSS. The characterization of the microstructures obtained from the combination of intercritical austenitizing (IA), step quenching (SQ), and Q&P heat treatments, were carried out by transmission electron microscopy (TEM). The product of the Q&P after SQ heat cycle exhibited the best mechanical behavior in fracture toughness tests, thus being considered promising for applications in the deformation zone of automotive BIW.
Technical Session
9/4/24, 2:50 PM - 9/4/24, 3:15 PM
Presenter(s): MAriane costalonga de Aguiar (CETEm), Matheus moura amorim (cetem), kayrone marvila de almeida (cetem), maria angélica kramer sant'ana (ifes), monica castoldi borlini gadioli (cetem)
Abstract:
The global ornamental stone market has a notable presence in Brazil, and the state of Espírito Santo emerges as one of the main production and export centers. However, during the extraction and processing processes, significant amounts of waste are generated, normally sent to landfills. The use of these wastes in the production of red ceramics appears as an efficient alternative to reduce the environmental impact and contribute to the mitigation of the clay raw material. This study aimed to analyze the physical and mechanical characteristics of red ceramics when incorporated with ornamental stone wastes, also referred to in this work as fines from the processing of ornamental stones (FiBRO). As well as, establish guidelines for its application in the production of red ceramics. The main focus is on reducing environmental impact and optimizing the use of raw materials. Incorporations were carried out with different proportions, ranging from 0 to 50% by mass. Specimens were manufactured by extrusion and subsequently subjected to burning at a temperature of 750ºC. Then, density, linear firing shrinkage, water absorption, porosity and mechanical resistance were evaluated. The results indicate that the incorporation of ornamental stone wastes into the red ceramic mass results in improvements in technological properties, such as a reduction in water absorption and an increase in mechanical resistance. Ornamental stone waste has great potential to be used as a component of ceramic mass due to its properties, in addition to adding value and enabling the manufacture of new products
Technical Session
9/4/24, 2:50 PM - 9/4/24, 3:15 PM
Presenter(s): Kelvin coppi santos (ARcelormittal Tubarão)
Abstract:
ArcelorMittal Flat Carbon produces an average annual volume of 500,000 tons of finished products derived from steel coils. To achieve this goal, it is necessary to conduct detailed optimized production planning, taking into account various variables such as: volume produced per ton of raw material, reduction of metallic losses, setup change requirements for machines, selection of coils in stock, mitigation of non-conforming product generation, etc.
Technical Session
CBAM and the Steel Sector in Brazil
Presenter(s): Iuri Diniz Cordeiro (Vetta Tecnologia (SMS Group))
Abstract:
The Carbon Border Adjustment Mechanism (CBAM) is one of several efforts to contain the entry of products with carbon leakage emissions into the European Union and promote the reduction of carbon emissions globally. The mechanism is based on the amount of CO2 emissions in the manufacture of a product and affects not only the European industry but also all major exporting regions to Europe, including Brazil. It is likely that Brazilian steelmaking industries will adapt the management and tracking of emissions in their plants to increase transparency and gain competitiveness in the market. For this, it is extremely important to adopt a digital emissions management tool that centralizes information as a single source of information and generates reports using calculation methods aligned with national and international standards, providing emission information in a fast, efficient, and auditable manner.
Technical Session
9/4/24, 2:50 PM - 9/4/24, 3:15 PM
Presenter(s): DONALDO SILVA OROSIMBO (ternium brasil)
Abstract:
escalating demand for environmentally friendly practices is compelling the steelmaking industry to push their refractory suppliers for emission-reducing solutions, with recycling emerging as the most impactful method in the short term. RHI Magnesita has developed a cutting-edge process to advance the circular economy, fully supported by its dedicated R&D team. Building on their longstanding partnership, RHI Magnesita and Ternium Brazil embarked on a significant The trial involving two premium magnesia-carbon materials for the steel ladle slag line, incorporating a substantial amount of circular raw material. This paper addresses RHI Magnesita's recycling process and present the findings from the initial three trials conducted in Ternium Brazil's steel ladles.
Technical Session
APPLICATION OF COMPUTATIONAL SIMULATION IN THE DEVELOPMENT OF A ROLLING PROCESS FOR ZR-BASED ALLOY
Presenter(s): BERNARDO POMPERMAYER EDUARDO (UNIVERSIDADE FEDERAL DO RIO DE JANEIRO), Fabiano Pinheiro Ribeiro (UNIVERSIDADE FEDERAL DO RIO DE JANEIRO), Rafaella martins ribeiro (UNIVERSIDADE FEDERAL DO RIO DE JANEIRO)
Abstract:
Zr-Nb alloys are used in the manufacture of structural components for nuclear reactors. During processing, the required properties for operation are developed. Therefore, the processing routes aim to promote a microstructure with partially or fully recrystallized grains, a uniform distribution of precipitates, and an adequate crystallographic texture to ensure good performance of these components. Thus, the study of new alloys and processing routes are important to optimize properties for nuclear application. This work aims to develop a processing route through computational simulation for a Zr-Nb-Mo alloy. In this way, computational simulation was used to understand the distribution of deformation and stress along the sheet during hot and cold rolling in order to develop a processing route. The results obtained from the simulation indicated that the proposed route is viable, ensuring the integrity of the sheets, as they did not show fractures and revealed a homogeneous distribution of deformations during hot and cold rolling. The experimental processing of the sheets showed, on average, a 93% agreement in terms of thickness with the simulations. At the end of processing, different heat treatments showed a trend of decreasing hardness values with increasing time, indicating that recrystallization can occur after annealing at 550°C for 4 hours.
Technical Session
9/4/24, 2:50 PM - 9/4/24, 3:15 PM
Presenter(s): GABRIEL AUGUSTO DE AVILA SANTIAGO (Companhia Siderúrgica Nacional), Duílio Norberto Ferronatto Leite (Universidade Federal Fluminense), Luciano Pessanha Moreira (UNIVERSIDADE FEDERAL FLUMINENSE), Bruno Fernandes Mudesto (Companhia Siderúrgica Nacional), HARISON DA SILVA VENTURA (Companhia Siderúrgica Nacional), Melina Gamis da Silva (Companhia Siderúrgica Nacional), Jully Ramos Soares (Companhia Siderúrgica Nacional)
Abstract:
The present work analyzed the hot behavior of an Nb-Ti micro-alloyed steel using physical simulation and constitutive modeling. Plane-strain compression tests were performed in the Gleeble 3500 thermomechanical system under several deformation temperatures (950-1150 oC) and nominal strain rates (0.01-10 s-1). The flow-stress curves exhibited typical dynamic recrystallization effects under higher deformation temperatures (> 1050 oC, 0.1-1 s-1 and at 1150 oC, 10 s-1) and at the lowest strain-rate (> 1050 oC, 0.01 s-1) and dynamic recovery at lower deformation temperatures (950 and 1000 oC). The resulting experimental data allowed us to calculate the average thermal activation energy for hot deformation as 387.4 KJ/mol. Moreover, the material parameters of the hyperbolic sine law constitutive equation were determined, allowing us to predict the experimental peak stress with a good measure of the correlation coefficient (0.987) and a low average absolute relative error (2.6%).
Technical Session
9/4/24, 2:50 PM - 9/4/24, 3:15 PM
Presenter(s): Taiana de Sousa Matos (UNIVERSIDADE FEDERAL DE PERNAMBUCO), marcos allan leite dos reis (UNIVERSIDADE FEDERAL DO PARÁ), Dorivane Cohen Farias (UNIVERSIDADE FEDERAL DO PARÁ), Fabio Moreira Brito (UNIVERSIDADE FEDERAL DO PARÁ), Débora Ely Medeiros Ferreira (UNIVERSIDADE FEDERAL DO PARÁ), Rodolfo Augusto do Rosário Lima (UNIVERSIDADE FEDERAL DO PARÁ), alisson clay rios da silva (UNIVERSIDADE FEDERAL DO PARÁ), VERÔNICA SCARPINI CANDIDO (UNIVERSIDADE FEDERAL DO PARÁ)
Abstract:
Nanocomposites of PLA (polylactic acid) and carbon nanotubes (CNTs) represent an innovative class of materials that combine the biodegradability of PLA with the exceptional properties of CNTs. When combined, PLA and CNTs nanocomposites show notable improvements in mechanical properties, such as increased tensile and impact strength, and thermal stability. Furthermore, CNTs can give PLA electrical properties, making it potentially useful in electronic and sensor applications. The samples were produced on a Stella 3 Lite 3D printer equipped with a 0.4 mm printing nozzle with a grid-type infill pattern and 90% density. Preliminary results indicate advances that can further expand the applications of PLA and CNT nanocomposites, contributing to the development of more sustainable and high-performance materials
Technical Session
9/4/24, 2:50 PM - 9/4/24, 3:15 PM
Presenter(s): Luis Fernando Fortunato De Freitas (uenf), Luis Ricardo Arrubla Agudelo (uenf), Noan Tonini Simonassi (uenf), CARLOS MAURÍCIO FONTES VIEIRA (uenf), FELIPE PERISSÉ DUARTE LOPES (uenf)
Abstract:
Natural lignocellulosic fibers, such as ramie fiber, are promising for high-performance and sustainable composites. This study analyzed the physicochemical properties of raw ramie fiber for its use in epoxy matrix composites, using FTIR, XRD, SEM, and density, water absorption and contact angle tests. The results showed the fibre's hydrophilic nature, good wettability and an amorphous structure with poorly organized crystalline regions. SEM revealed a fibrillar morphology with cracks and splits, influencing fiber-matrix interaction. This study provides a basis for developing optimized epoxy matrix composites, highlighting the importance of the structure, morphology and behaviour of the fibre in relation to water to improve the compatibility and performance of the final composite.
Technical Session
9/4/24, 2:50 PM - 9/4/24, 3:15 PM
Presenter(s): PIETRO PERUSSATTO (Universidade de Passo Fundo), gABRIEL FABIAN DOS SANTOS (Universidade de Passo Fundo), William Haupt (Universidade de Passo Fundo), MARIA LUIZA DOS SANTOS (Universidade de Passo Fundo), CHARLES LEONARDO ISRAEL (Universidade de Passo Fundo), deividi nardi (dstrac performance 4x4)
Abstract:
In the present work, a microstructural analysis was carried out on electric vehicle differential gears manufactured from microcast SAE 4320 and machined SAE 8620 steels, both subjected to carburizing, quenching and tempering processes. The objective of the analysis is to evaluate the thickness and uniformity of the cemented layer, using Vickers microhardness, macrography and micrography to identify microconstituents and micro defects. This analysis becomes relevant due to the fact that the components analyzed suffer wear and rolling contact with large loads. From the macrographic analysis, it can be concluded that the micro-cast gear in SAE 4320 steel presented a more uniform case-hardened layer compared to those machined in SAE 8620 steel, however, the microhardness test revealed that the former presented greater variability, in addition to the presence of austenite retained in the microstructure. Both cases exhibited martensite as the main microconstituent, in addition to the presence of micro defects, which had a larger area occupied in the machined SAE 8620 steel sample. In short, the microcast gears showed advantages in terms of uniformity with higher microhardness values in the case-hardened layer and the formation of micro defects, however, the machined samples exhibited less variability and did not show the formation of retained austenite.
Technical Session
9/4/24, 2:50 PM - 9/4/24, 3:15 PM
Presenter(s): CAROLINE rODRIGUES DOSA SANTOS BRIGIDO (CENTRO DE TECNOLOGIA MINERAL), Reiner Neumann (CETEM), Paulo Fernando Almeida Braga3 (cetem)
Abstract:
Lithium is essential for the low carbon economy, and has intensive application in high-technology products. Lithium ores have been the target of exploration, and Brazilian exports of its minerals have grown significantly. The increasing use of this metal in the production of rechargeable batteries for electric vehicles and personal electronics has sparked worldwide interest in the extraction of lithiniferous ores. Lithium is found in brines and pegmatite rocks, and is extracted in Brazil mainly from spodumene ore. The present work carried out a technological characterization including classification tests, X-ray diffractometry, X-ray fluorescence, loss on ignition, scanning electron microscopy and inductively plasma optical emission spectrometry analyzes. Furthermore, heat treatment tests were carried out to analyze the behavior of spodumene at different temperatures, as phase transformation occurs above 1.000°C. To remove the associated minerals, gravimetric separation in a dense medium was used, resulting in the elimination of 11.7% of these minerals and reaching a concentration of 98.5% of spodumene in the sample. Subsequently, after the concentration stage, the spodumene was subjected to Thermogravimetric Analysis, allowing the mineral's mass loss temperatures to be identified.
Technical Session
LOW-CO2-EMISSION BLAST FURNACE WITH H2-RICH GAS AND CO-RICH GAS MIXTURE INJECTION
Presenter(s): Gang Wang (cisdi), Kun He (cisdi), Yunjian Zhao (cisdi), Zhongping Zou (cisdi), Qun Niu (cisdi), Peng Li (cisdi), Shifeng Hou (cisdi)
Abstract:
The paper presents a low-CO2-emisison Blast Furnace with H2-rich gas and CO-rich gas mixture injection. It summaries the differences of H2 and CO applied as the reducing agents on the surface of ores in terms of adsorption, reaction dynamics and surface morphology, attesting to that injection of gas mixture enriched with CO and H2 of proper concentrations into blast furnaces leads to enhanced reduction reaction. It provides analyses on the feasibility of H2-rich gas and CO-rich gas mixture injection process, its application to blast furnaces, and the safety of tuyere equipment and the reliability of gas transmission systems. It also introduces the benefits of Blast Furnace: With the H2-rich gas and CO-rich gas mixture injection volume in the range of 50-75 Nm3/t.HM, the average replacement ratio is 0.5-0.57 kg/Nm3, seeing a reduction of CO2 emissions up to 5~10% if compared with the conventional practices. The low-CO2-emisison Blast Furnace is a cost- and technology-competitive, and above all, low-CO2-emission ironmaking solution. It’s a promotion-worthy approach to decarbonization of integrated iron & steel works.
Technical Session
TOWARDS THE FUTURE: FIRST STEPS TOWARDS ACHIEVING AUTONOMOUS BLAST FURNACE
Presenter(s): Gabriel do Vale de Souza (Paul Wurth do brasil), Bernardo loureiro patto (Paul Wurth do Brasil), Micak JuRAJ (PAUL wurth), Walfrido Ferreira do Nascimento Junior (Paul wurth do brasil)
Abstract:
This paper explores the initial steps towards achieving autonomous operation in Blast Furnaces. Through a successful and strong collaboration, a specific set of proven Level-2 models, known as Paul Wurth BFXpert, along with tailor-made intelligent multi-wave pyrometer sensors, were deployed and commissioned to optimize the chemical and thermal stability of the blast furnace. The article provides a concise overview of the selected BFXpert models and demonstrates how the blast furnace process and operation team benefits from such collaboration. Finally, the article provides insights into the technical performance of the commissioned product, which brought significant results in reducing the coke rate of the blast furnaces of the steel plant whose data was collected and analyzed in this work.
Technical Session
9/4/24, 2:50 PM - 9/4/24, 3:15 PM
Presenter(s): gabrielly lorraine pereira de oliveira (Usiminas), gerson evaristo de paula junior (usiminas), luciney de souza lana (usiminas)
Abstract:
The analysis of the chemical and metallurgical characteristics of the solid fuels used in sintering is of great importance for determining the ideal working mixture and the improved predictability of consumption rates. The carbon content in the material is crucial for combustion efficiency and heat conservation in the sintering bed and is commonly the main factor analyzed for controlling coke breeze consumption in the sinter machine. Recent experiments by Usiminas have shown an increase of up to 15% in the consumption of energy load for a 50% participation of a type of coke breeze in the fuel mix. Therefore, the present work aimed to deepen the characterization of solid sintering fuels through thermogravimetric analysis. The main fuels used in Usiminas sintering were evaluated, and a considerable variation in mass loss and carbon content in the residual mass at the 1300°C isotherm was found. In addition to the low fixed carbon content, coke breeze B is shown to be more reactive than other fuels, resulting in losses in process efficiency and metallurgical quality of the sinter.
Technical Session
A NOVEL TECHNOLOGY TO IMPROVE PERFORMANCE OF FLOCULANT ON MINERAL PROCESSING OPERATIONS
Presenter(s): eDUARDO ALBERTO REYES BRISEÑO (sOLENIS)
Abstract:
This paper describes how important is to Mineral Processing Operations to achieve an optimal flocculant preparation in liquid-solid systems. Solenis thru its Praestospeed™ process and technology development is capable to improve such process; the main features for this development are described in this paper
Technical Session
High Performance Maintenance for Continuous Caster Machines with Contract per Tons (CpT) – Contracts
Presenter(s): franz kolmbauer (Primetals Technolgies )
Abstract:
Primetals Technology is providing comprehensive service expertise throughout the entire lifecycle of metal plants. It has a huge variety of service solutions those supports every operational phase in steel plants and rolling mills. The solutions include service contracts, spare and wear parts service, consulting, and engineering, and taking over a full outsourced online and offline maintenance based on performance contracts. An outsourced plant maintenance for offline and online maintenance on Continuous Casting Machines (CCM) with high technology testing equipment and electronical controlled life cycle system as well with well-trained personal allows the clients being fully concentrated on their goal in achieving best product quality and high availability for production of the CCMs. Such a contract has been handled in the last 15 years 2009 - 2024 by Primetals Brazil at Ternium Brazil CCM Plant! Another 10 years performance-based contract was signed in April 2024 - March 2033 together with Ternium Brazil and Primetals Brazil. Since 2002 Primetals Brazil is well known in such contracts in Brazil. Another example is a long-term partnership with CSN CCM Plant 2002 - 2017
Technical Session
CONTROL AND INHIBITION OF SCALE IN THE GOLD ELUTION CIRCUIT WITH SCALETROL PDC 9313 TECHNOLOGY
Presenter(s): Adriano Alves Ribeiro (Veolia - Water Technologies & SOlUTIONS ), Thiago Silva (VEOLIA - WATER TECHNOLOGIES & SOLUTIONS ), Augusto Luis MArucci (VEOLIA - WATER TECHNOLOGIES & SOLUTIONS ), Fernando Furakawa (Veolia WTS-CMS)
Abstract:
Gold leaching process routes are widely used due to their efficiency and low cost. However, regardless of the selected route, one of the many challenges encountered is the formation of scale caused by calcium carbonate (CaCO), Calcite (CaCO3) and other contaminants contained in the ore.The scales formed throughout the process negatively impact the entire gold recovery process, either by reducing the physical availability of equipment or by reducing the gold adsorption capacity of activated carbon, since the formation of inorganic deposits affects them equally. Veolia ScaleTrol scale control and inhibition products minimize deposits and scale across a wide variety of unit operations and equipment, thereby reducing downtime required for cleaning/maintenance, mitigating loss of extraction productivity, improving the useful life of the equipment and maintaining the flow/operation of the equipment.
Technical Session
VICKERS MICROHARDNESS APPLICATION TO ASSESS INTERCRITICAL AUSTENITIZING KINETICS IN A TRIP 780 STEEL
Presenter(s): EDUARDO ANTONIO LAIA DA SILVA (Universidade federal de ouro preto), geraldo lúcio de faria (universidade federal de ouro preto)
Abstract:
Due to varied demands from the automotive industry, the third generation of Advanced High Strength Steel (AHSS) has been developed. Some processes, such as Quenching and Partitioning (Q&P), have also been proposed to improve the mechanical properties of these steels, targeting specific applications. To increase the application potential of this heat treatment, a route prior to the Q&P process named Intercritical Austenitizing (IA) has been applied. However, small variations in important processing parameters, such as the heating rate, cause significant changes in the microstructural evolution and can compromise the final result of the thermal cycle. To ensure that there is a minimum of divergences ON the prediction of results depending on the experimentally applied thermal cycle, prediction models have been widely used. In this context, the present work proposes two methods of applying Vickers microhardness (HV) as tools for predicting the fraction of phases present in the microstructure of the studied steel when intercritically austenitized.
Technical Session
9/4/24, 3:15 PM - 9/4/24, 3:40 PM
Presenter(s): pedro henrique poubel mendonça da silveira (IME), Marcelo Henrique Prado da Silva (IME)
Abstract:
Cold sintering process is an innovative technique in ceramic production that has been gaining increasing interest in the academic community. Unlike conventional sintering techniques, which require high temperatures, cold sintering utilizes low temperatures, typically below 300°C, to consolidate ceramic particles. This method operates uniquely, employing a transient transport phase, often liquid, and high uniaxial force to aid in the densification of the compacted powder. Cold sintering has emerged as a promising method for ceramic production due to its energy efficiency and ability to create components with high density and mechanical strength. This review work presents the concepts of the cold sintering process, microstructural evolution, and experimental apparatus used in this processing method.
Technical Session
REDUCTION OF CLOGGING IN AN IRON ORE RECLAIMER CHUTE APPLYING DEM AND FEM SIMULATION
Presenter(s): Guilherme Pereira de Oliveira (VALE - engenharia porto tubarão), Brayan Pastro Machado (VALE - manutenção PORTO TUBARÃO), Marcelo Botelho Chacur (VALE - ENGENHARIA PORTO TUBARÃO), Raphaela Grillo Pansiere (VALE - ENGENHARIA PORTO TUBARÃO)
Abstract:
Transfer chutes are widely used in ore handling equipment in port terminals. Stoppages due to probe actuation and/or the occurrence of clogging are among the main failure modes of this type of equipment. Such events lead to large production losses due to the unavailability of assets and can take hours to be corrected, in cases of material overflow when blockages are not detected in time to stop the operation. When its walls are little inclined, its linings have a high coefficient of friction, its sections do not have enough area for handling at the desired rates, excessive braking of the material occurs and clogging of the chute. The main cause of clogging in a chute is its inadequacy for the material handled. Many times, a chute with a good operating history begins to present clogging problems due to changes in the material handled, leading to the need for adjustments to its design. The advent of computing in recent decades has allowed the use of various techniques for computational simulation of flow in virtual environments with fast and accurate results. This paper shows the adjustments made to a central chute of an iron ore reclaimer to reduce the occurrence of clogging by applying the Discrete Element Method (DEM) and the Finite Element Method (FEM), presenting the results achieved and side effects after implantation.
Technical Session
CASE STUDY: LOW NOX BURNER İN A PELLETİZİNG PLANT
Presenter(s): andrielly moutinho knupp (Vale sA), Leandro Resinentti Zanon (vale), Rossano Augusto Nunes Pilon (VALE), Ana Paula Pacheco Buzatti (VALE), Renata Favalli (FCT), Ricardo de Paula Costa (FCT), Diego Biaseto Bernhard (FCT)
Abstract:
The NOx (nitrogen oxides) emissions of anthropogenic origin are mainly the result of burning of fossil fuels at high temperatures. In pelletizing furnaces, mineral coals are added to the pellets and natural gas is fired in the combustion chambers, with both processes contributing to nitrogen oxides emissions. Vale has a target to reduce 10% of all NOx emissions by 2030. Given this scenario and aiming to reduce NOx emissions at the Tubarão Unit – Vitoria, Espirito Santo/Brazil, a case study is proposed for the development of a low NOx burner for pelletizing furnaces. To better understand NOx formation in pellet furnaces, as well as what can be done to reduce NOx emissions in existing plants, a series of CFD (Computation Fluid Dynamics) modelling scenarios are studied. Besides the base case, four different scenarios were evaluated for a 4,9 MW burner firing 3MW of natural gas, considering water injection considering different water flow rates droplet size and injection angle. For the CFD modelling, the geometric void model of a whole combustion was considered. Regarding NOx modelling, only thermal NOx generation was considered as this is the main mechanism of NOx formation in pelletizing furnaces. With the modelled scenarios, no significant changes in flame shape, as per iso-surfaces of carbon monoxide (CO), were observed due to water addition. Up to 50°C reduction in peak temperatures in the flame core and a reduction in the range of 30% to 50% in NOx emission were observed.
Technical Session
INVESTMENT SCENARIO IN INNOVATION IN THE METALLURGY SECTOR IN BRAZIL IN THE YEAR 2022
Presenter(s): kenia maia morais (vallourec), Vicente Braz da Trindade Filho (vallourec), Marina Prass Santos (UFM)
Abstract:
This article analyses investments in innovation in metallurgy in Brazil based on the last available results of the Innovation Survey (Pintec), year 2022, provided by Brazilian Institute of Geography and Statistics (IBGE). Pintec, which has been in existence since 2000 and was updated in 2021, collects data to create indicators on innovative activities of companies. The 2022 survey reveals that 51% of the 305 companies in the metallurgy sector are active in innovation, with 50% innovating in products or processes. Expenditures on R&D totaled R$ 9 billion. Approximately 25% of the companies received public support, and 31% engaged in strategic partnerships. Barriers such as economic instability affected 18% of non-active innovation companies. The survey also highlights the implementation of new innovations in products and processes, indicating a continuous commitment to technological advancements.
Technical Session
SIMULATION OF THE INFLUENCE OF DRAWING PARAMETERS ON THE HARDNESS OF A DRAWN BAR
Presenter(s): Alisson Duarte da Silva (sixpro), JOÃO PEDRO MOREIRA SILVA (sixpro), Darlan Vale Bayão (Arcelormittal), geraldo magno mól ferreira (ArcelorMittal), ermani vinícios de oliveira lima (arcelormittal), mariana machado da silveira (arcelormittal), tulio cesar nogueira (arcelormittal), ana luisa camargos barcelos (arcelormittal), Ricardo Antônio Micheletti Viana (Sixpro)
Abstract:
The final hardness in a thermally untreated drawn product is directly influenced by the mechanical properties of the raw material. Therefore, not only does work hardening during the drawing process play a role in increasing mechanical resistance, but also in its variation along the product profile. This study aims to analyze drawing processes by characterizing the material's mechanical behavior before, during, and after this process. Thus, with the aid of mechanical tests and computational simulation using the QForm UK software, methodologies for
Technical Session
9/4/24, 3:15 PM - 9/4/24, 3:40 PM
Presenter(s): alexandre rocha lopes (arcelormittal vega)
Abstract:
The proposal and conclusion of this study aimed to translate the inspection regulations for flat carbon coils, providing insight into the edge losses of automotive final-use parts following the customer's final stamping process. Within the flat carbon steel plant, specifically in the coil production process on the Continuous Galvanizing Line (CGL), it is possible to determine precisely how many millimeters on each side of the coil would be lost after the customer's final stamping. This information enables the establishment of new inspection surface criteria, thereby reducing downgrading ratios.
Technical Session
STUDY OF THE PROPERTIES OF FLEXIBLE MATERIALS IN ADDITIVE MANUFACTURING FOR PROTECTION IN SPORTS
Presenter(s): VICTOR PAES DIAS GONCALVES (Universidade Estadual do Norte Fluminense Darcy Ribeiro ), Ellen Bernardes de Lima (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO ), CARLOS MAURÍCIO FONTES VIEIRA (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO ), Noan Tonini Simonassi (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO ), Henry Alonso Colorado Lopera (UNIVERSIDAD DE ANTIOQUIA UDEA, MEDELLIN), FELIPE PERISSÉ DUARTE LOPES (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO )
Abstract:
Printing flexible materials is a challenge within additive manufacturing. The objective of the study is to analyze the mechanical properties in the Fused Deposition Modeling process using Thermoplastic Polyurethane (TPU) and ethylene and vinyl acetate (EVA) copolymers. The methodology used in the characterization was through the tensile, compression, impact resistance, tear resistance and Shore A hardness test. According to the results presented, flexible materials have an energy absorption efficiency that can be applied in protection systems as well. such as in automotive, electronics, biotechnology and sports applications. The main characteristic of the chosen materials is flexibility, which is significantly seen in the results. The TPU showed better results in tensile and impact resistance tests. EVA showed better results in the compression test. The tear resistance test the materials showed similar results, without significance
Technical Session
9/4/24, 3:15 PM - 9/4/24, 3:40 PM
Presenter(s): Luis Ricardo Arrubla Agudelo (UENF - ALBERTO LAMEG), Luis Fernando fortunato de freitas (UENF), CARLOS MAURICIO FONTES VIEIRA (UENF), HENRY A. COLORADO L. (udea), felipe perissé duarte lopeS (uenf), NOAN TONINI SIMONASSI (UENF)
Abstract:
To complement the study of the intrinsic properties of fique fiber, a physicochemical and thermal study was carried out, always with the aim of being used as reinforcement in composite materials. Considering the literature, a physicochemical characterization carried out using X-ray diffraction (XRD), Fourier Transform Infrared Spectroscopy (FTIR) and thermal characterization using thermogravimetry and thermal conductivity, provides an overview of the affinity of the fiber and gives a broad view of the thermal and chemical affinity that can be expected from the fiber for its use in the manufacture of different composite materials. With the above, it is hoped to obtain parameters such as Cp (Specific Heat Capacity) and XRD and FTIR spectra to carry out a chemical analysis of the fiber and, in addition, with the thermal properties it is hoped to contemplate the thermal insulation property that gives this fiber a very desirable and important additional property for various uses, such as civil construction in hot climates and even internal shoe materials generating composite materials with variations of PU polyurethane. A fracture of an individual fique fiber was analyzed using scanning electron microscopy (SEM) micrographs
Technical Session
TRIBOLOGICAL ANALYSIS OF WEAR PLATES IN A HOPPER OF A CAR DUMPER
Presenter(s): Guilherme Pereira de Oliveira (VALE - Engenharia porto tubarão), Cíntia Nunes Braga Regattieri (VALE - ENGENHARIA PORTO TUBARÃO), Diego Rafael Silva (VALE - manutenção PORTO TUBARÃO), André Luíz Silva (VALE - MANUTENÇÃO PORTO TUBARÃO)
Abstract:
The car dumper is the first equipment to perform work in the iron ore export production process. Its function is to remove the iron ore from each train wagon, which transports it directly from the mines to the harbor. Within the engineering system has a standardization of how the car dumper is divided. The systems of this machine are the pusher car, which has a mechanical arm that positions the wagon to be dumped; the train locker; the rotation device is mainly composed by rotational rings and clamps, that make the wagon tip; the feeder, where the ore falls and is directed to the conveyor belt. The wear plates are assembled in the hoppers at a height of about 1117 mm below the car dumper in 47 positions. These plates experience impact and abrasion wear in a location difficult to be reached. To reduce maintenance a material with higher impact resistance and a good abrasion resistance was developed in laboratory and latter tested in the hopper, the performance is evaluated against the original plate.
Technical Session
TECHNOLOGIES FOR EXTRACTION OF LITHIUM IN ROCKS AND IN BRINE - A REVIEW
Presenter(s): CAROLINE rODRIGUES DOSA SANTOS BRIGIDO (CENTRO DE TECNOLOGIA MINERAL), Gabriely Fornazier Brunhara (CETEM), Paulo Fernando Almeida Braga (cetem)
Abstract:
The lithium compounds market is on the rise due to increasing demand for lithium-ion batteries, which are widely used in electric vehicles as well as electronics. Lithium plays a fundamental role in the production of these batteries, giving them better performance properties and a longer charging life. Given this scenario, lithium extraction processes, both in rocks and in brines, have been the subject of continuous development and improvement. This work sets out to provide a review of these technologies, offering a solid foundation for future research and technological advancements in extractive metallurgy. In the case of brines, solar evaporation, ion exchange, and direct lithium extraction techniques were discussed. Regarding the extraction of lithium from ores, the chlorination, alkaline, and acid processes were addressed. These investigations have the potential to boost the development of more efficient and sustainable methods for extracting lithium, thus contributing to the feasibility of cleaner and more renewable energy sources.
Technical Session
9/4/24, 3:15 PM - 9/4/24, 3:40 PM
Presenter(s): BRENO TOTTI MAIA (LUMAR METALURGICA LTDA), Bernardo Martins Braga (LUMAR METALS), Lucas Moreira Duarte (LUMAR METALS ), Bruno Orlando de Almeida Santos (in memoriam) (LUMAR METALS)
Abstract:
The present presents the concept for spreading the injected powder via ventanias in order to increase the combustion rate and consequent increase in the injection rate. The development was carried out considering the behavior in the region of the race way. The results show results that allow the study to move from the conceptual phase to industrial prototypes
Technical Session
9/4/24, 3:15 PM - 9/4/24, 3:40 PM
Presenter(s): Iara Patricia Vieira de Oliveira (gerdau usina ouro branco), patrick de lima resende (gerdau usina ouro branco)
Abstract:
Given the impoverishment of iron ore reserves, the use of concentrated pellet feed in sintering to adjust the chemical quality of the sinter will be an aspect for the steel mills in the coming years. However, the addition of fines during sintering can cause loss of permeability, requiring technological innovations in routes and changes in process parameters to recover or minimize production losses. In this context, the present work investigated the effect of partially replacing sinter feed with pellet feed, by reducing the fraction >1mm by 30%, 28%, 26% and 24%. The results indicated a loss of productivity for lime consumption of 5.5%. Additional tests were carried out increasing the lime to 6.0% and an improvement in the average size of the quasi-particles was found, due to the improvement in cold agglomeration and consequently increased permeability, however for percentages of 24% > 1mm, it still requires an effort largest number of new studies to recover productivity.
Technical Session
9/4/24, 3:15 PM - 9/4/24, 3:40 PM
Presenter(s): Raphael Vilela Brigagão (Solenis especialidades químicas LTDA), Kassia Felix Faria (SOLENIS ESPECIALIDADES QUÍMICAS LTDA), Pedro henrique bordão moreira (SOLENIS ESPECIALIDADES QUÍMICAS LTDA), andre teodoro coelho moreira pinto (SOLENIS ESPECIALIDADES QUÍMICAS LTDA), douglas nicolini alves cruz (SOLENIS ESPECIALIDADES QUÍMICAS LTDA)
Abstract:
The present study was carried out to evaluate the suitability of the flocculant for the thickening step in a tailings filtration complex. The Solenis Praestol 2640Z flocculant demonstrated a significant reduction in specific consumption, reduced production stops and increased thickening and filtration capacity. This resulted in considerable financial gains, reduced ergonomic risks and greater sustainability, saving resources and reducing waste. The adoption of this flocculant resulted in significant operational and environmental improvements, highlighting its effectiveness in optimizing mining tailings treatment processes
Technical Session
INTEGRATION OF BUILDING INFORMATION MODELING AND ADVANCED WORK PACKAGING METHODOLOGIES FOR MATERIAL MANAGEMENT: CASE STUDY OF BUCKET WHELL RECLAIMER
Presenter(s): ELIZA DE ASSIS RIBEIRO (ALVAREZ & MARSAL), JOÃO PAULO DE SOUZA SILVA (vale), FELIPE PATUSCO RODRIGUES (VALE), marcelo moraes barros leite mor (Alvarez & Marsal), diego henrique trigueiro alves (Alvarez & Marsal), WALLACE GONÇALVES BOTELHO (VALE)
Abstract:
The Bucket Whell Reclaimer Project involves the replacement of two reclaimers in the mining area of the Conceição Mine. Given the importance of this equipment and the complexity and weight of the components, studies were conducted to improve the logistics of handling and storing the assembly parts. To ensure the timely availability of materials, the integration of Building Information Modeling (BIM) and Advanced Work Packaging (AWP) methodologies was implemented in the material management. The main objective was to enhance the logistical workflow by separating the parts according to work packages (CWPs) and the construction sequencing proposed by BIM 4D. This aims to reduce unnecessary handling, minimize critical rigging operations, and ensure safe in storage. This approach contributes to reducing incidents and improving warehouse safety. The integration of these two methodologies proved effective for the logistical and operational complexities involved in the Project, promoting efficiency, safety, and quality in this phase.
Technical Session
USE OF THE MIXED COLLECTOR FORMED BETWEEN AMIDE-AMINE AND SULFOSUCCINAMATE IN THE FLOTABILITY OF HEMATITE AND QUARTZ
Presenter(s): Daniella Christina Pereira (Universidade federal de minas gerais), Leonardo Junior Fernandes Campos (Universidade federal de minas gerais), Andréia Bicalho Henriques (Universidade federal de minas gerais), Geriane Macedo Rocha (Universidade federal de minas gerais)
Abstract:
This study evaluated the use of a mixed collector formed between sulfosuccinamate and amide-amine in the hematite and quartz flotation, in comparison with the mixture between sulfosuccinamate and etheramine, and sulfosuccinamate in its isolated form, through microflotation tests. The mass ratio etheramine or amide-amine: sulfoccinnamate used in the composition of the mixed collector was 1:5, the depressant, when used, was sodium silicate and the pHs evaluated were 7 and 9. The amide-amine/sulfosuccinamate mixed collector did not present a positive synergistic effect, leading to higher flotability of quartz than hematite, and therefore, its application in direct anionic flotation of iron ore is not recommended. The mixed etheramine/sulfoccinnamate collector obtained higher hematite flotation than sulfosuccinamate in its isolated form at pH 9, but at pH 7 the flotability was lower. Sulfosuccinamate in its isolated form, at pH 7, showed a large selectivity window (~ 70%) between quartz and hematite flotation, even in the absence of depressant.
Technical Session
BENEFICIATION TECHNOLOGIES FOR COPPER ORE AT SALOBO MINE: MAXIMIZING MINERAL POTENTIAL IN THE STATE OF PARÁ
Presenter(s): mARIA EDUARDA DE ALMEIDA MENDES (uNIVERSIDADE FEDERAL DO PARÁ), Cláudia Cristina Furtado dos Santos (UNIVERSIDADE FEDERAL DO PARÁ), Gabriel Walfredo Brasil de Souza (UNIVERSIDADE FEDERAL DO PARÁ), Beatriz Correa Rodrigues (UNIVERSIDADE FEDERAL DO PARÁ), Queren Lira Nascimento (UNIVERSIDADE FEDERAL DO PARÁ), VITOR LEÃO SANTANA (UNIVERSIDADE FEDERAL DO PARÁ)
Abstract:
The state of Pará stands out as one of Brazil's main mineral production centers, driving the local economy. In this context, copper ore takes on its protagonism as a strategic mineral. Understanding its beneficiation process means seeking improvements and opportunities to exploit such a resource. This study investigates the beneficiation process of copper ore at the Salobo Mine, highlighting its relevance in the Pará region. Through an initial data collection using the SIGMINE platform and the National Mining Agency database, the Salobo Mine was identified as the main object of study due to its infrastructure and data availability. The research involved a bibliographic survey to construct an interactive and detailed flowchart, visually representing each stage of the beneficiation process. The stages characterized in the beneficiation of the Salobo mine included comminution, flotation, regrinding, and concentrate dewatering, emphasizing the importance of selectivity and effectiveness in the process stages, as well as the need for precise management to ensure efficiency and quality. It is concluded that the research contributes not only to the understanding of mining in Pará but also to the strategic management of mineral resources, consolidating its position as one of Brazil's main mineral hubs.
Technical Session
ANALYSIS AND STUDY OF THE BAUXITE BENEFICIATION PROCESS IN JURUTI - PARÁ: OPPORTUNITIES AND ADVANTAGES OF MINING IN THE LOWER AMAZON REGION
Presenter(s): cláudia cristina furtado dos santos (universidade federal do pará), Maria Eduarda de Almeida Mendes (), Vitor Leão Santana (), Gabriel Walfredo Brasil de Souza (), Beatriz Correa Rodrigues (), Queren Lira Nascimento ()
Abstract:
Bauxite, discovered in 1821, is a reddish rock with more than 40% alumina, a fundamental raw material for the production of aluminum and various other industrial uses. Pará leads national production with 89.4%. This study is dedicated to analyzing the bauxite processing process at the Juruti Mine in Pará, operated by Alcoa S.A. The mine was chosen because of its importance in the region and the availability of data. Geospatial analysis was used via SIGMINE, a literature review and data supplied by the company. The work aims to improve understanding of the bauxite operating procedure, highlighting the state of the ore at each stage and the equipment used. The research began with a geospatial observation via SIGMINE and included a literature review to understand the technical aspects of bauxite processing. Contact with the company's employees was also used as a method to ensure accurate and up-to-date data. This approach highlights the importance of studying bauxite in order to understand the local mineral industry, providing learning opportunities for various audiences interested in the sustainable and technological development of the region and mining. It also promotes the opportunities and advantages of mining in the Lower Amazon.
Technical Session
INFLUENCE OF VARIABLES ON THE FLOTATION OF THE PYRITE/QUARTZ ASSEMBLY SET
Presenter(s): Luísa Paulino de Faria (Universidade federal de ouro preto)
Abstract:
The flotation process is influenced by a large number of variables, such as the characteristics of each type of ore, the types and dosages of reagents used, conditioning conditions and operating conditions. However, studies of how these parameters affect the recovery of individual particles are lacking. This study aims to understand the interference of some variables for a binary system composed of pyrite and quartz, a common system of sulfide ores. To this end, the effect of: air flow rate (Jg), rotor speed (Vs), collector and frother agent dosages, collection time on the flotation of the binary system, composed of pyrite and quartz, were investigated. The experiments were carried out in a 6 liter nextSTEPTM flotation cell, following a full factorial DoE approach. The Jg parameter were 0.40 and 0.50 cm/s, Vs were 4.7 and 5.50 m/s, while the collector and foamer values were equal to 20 and 50g/t and 30 and 60g/t, respectively. Collection time Pulp density and pH were kept constant. Logistic regression-based models were applied using experimental data to calculate the recovery probabilities of each particle under different operating conditions. The results highlight the influence of hydrodynamics and particle properties on process behavior, providing important information for optimizing flotation processes in mining and metallurgy industries.
Technical Session
9/4/24, 3:40 PM - 9/4/24, 4:30 PM
Presenter(s): lisley madeira coelho (instituto militar de engenharia)
Abstract:
This study investigated the feasibility of using steel slag aggregates in the composition of asphalt mixtures using the Bailey method. Although not fully compliant with conventional standards, analysis with the MeDiNa software showed satisfactory results regarding fatigue resistance and wheel track rutting. The steel slag mixture by the Bailey method outperformed the traditional Brazilian one in terms of fatigue resistance, indicating advantages for local road pavements. In addition to the benefits of mechanical strength, economic and environmental gains from the utilization of industrial waste in construction are highlighted. Therefore, the adoption of steel slag, following the Bailey method, strengthens road infrastructure and promotes sustainable practices in the construction industry.
Technical Session
RACK LIFTING DEVICE OF THE WAGON TIPPLER
Presenter(s): MARLLON FRAGA SILVA (IME - INSTITUTO MILI), Diego Adan Romão Do Nascimento (vale), Edson Cezario Pereira Junior (Instituto Senai de Tecnologia - IST), Jefferson Douglas Silva Deoclecio (Compet Engenharia - Gerenciadora)
Abstract:
The lifting and movement of any loads involve risks, where the fall of the load itself can cause disasters around the activity. The risk increases according to the geometry, weight, and conditions of the equipment used for the activity. To ensure safety and reliability during load lifting operations, this work aims to design and evaluate the structure of a rack lifting device for the wagon tippler of a mining company. Through software, 3D modeling, and the finite element method are used to assess stress points on the device, thereby validating its structural capacity, as well as exposing the mechanical properties of the material defined for the lifting device.
Technical Session
9/4/24, 3:40 PM - 9/4/24, 4:30 PM
Presenter(s): Jonhson James Oliveira teixeira (VALER CARAJAS)
Abstract:
The objective of this article is to present the methodology adopted to implement the management of electrical energy blocking through the digitalization of its stages within the Zero Energy system adopted by VALE. The project will be applied to the Serra dos Carajás (Serra Norte) mining complex in the municipality of Parauapebas – PA and initially only for activities involving mobile and fixed substations in input equipment such as: 4.16kV distribution boards. As a result of this project, greater security for people and assets will be possible due to standardization, informatization and traceability of equipment blocking
Technical Session
9/4/24, 3:40 PM - 9/4/24, 4:30 PM
Presenter(s): PALOMA SUELLEN LIMA DE SOUSA (UFPA), JOELLY VERA NASCIMENTO (UFPA), SARAH GABRIELLY BRANDÃO DE SOUZA (UFPA), EMILLY DE FÁTIMA PINHEIRO BOTELHO (UFPA), DAMARES DA CRUZ BARBOSA NASCIMENTO (UFPA), ALISSON CLAY RIOS DA SILVA (UFPA), VERÔNICA SCARPINI CANDIDO (UFPA)
Abstract:
In the context of unbridled growth in the demands and exploitation of natural reserves, there is an urgent need to develop environmentally sustainable technologies. This study addresses the search for ecologically viable materials, with excellent mechanical properties, to reduce negative impacts on the global ecosystem. The study evaluated the potential of mallow (Urena lobata) fibers as reinforcement in polymer composites. The composites were manufactured with 5, 10 and 15% mallow fibers, followed by mechanical tensile and flexion tests. Statistical analyzes were performed to evaluate significant differences between composite groups. The addition of mallow fibers directly influenced the mechanical properties of the composites. A gradual improvement was observed as the fiber concentration increased. Robust statistical analysis confirmed the significant differences between the composite groups, validating the influence of the applied treatments. The results highlight the viability of mallow fibers as reinforcement in polymer composites, offering a sustainable and effective alternative for industrial applications.
Technical Session
THE INFLUENCE OF THERMAL CURING ON THE COMPRESSION RESISTANCE OF GEOPOLYMERIC MORTARS
Presenter(s): paulo anderson aranha ferreira (universidade federal do pará), giovana zagalo de frança (UNIVERSIDADE FEDERAL DO PARÁ), rayanne oliveira leão santana (UNIVERSIDADE FEDERAL DO PARÁ), emily de fátima pinheiro botelho (UNIVERSIDADE FEDERAL DO PARÁ), VERÔNICA SCARPINI CANDIDO (UNIVERSIDADE FEDERAL DO PARÁ), ALISSON CLAY RIOS DA SILVA (UNIVERSIDADE FEDERAL DO PARÁ)
Abstract:
The growing demand for sustainable construction materials impacts the production of new binders that have low CO2 emissions. A new class of alternative cements called geopolymers can be produced using waste from the mining and agricultural industries. Geopolymers are produced from a material rich in aluminosilicates and an alkaline solution. The Si-O-Al bonds present in geopolymers give them high mechanical strength, durability and refractoriness. Based on this, the present work evaluated the influence of thermal curing on the compressive strength of geopolymer mortars with the addition of blast furnace slag, and also their morphology after rupture. For this, metakaolin obtained at 850°C for 2h, 35% blast furnace slag, sodium hydroxide, sodium silicate and commercial sand were used for the production of geopolymeric mortar. After molding, the specimens were subjected to 25°C, 60°C and 120°C for 20h. After 7 days of curing at room temperature, the specimens were subjected to a compressive strength test, and then the fracture morphology was analyzed via optical microscopy (OM). The geopolymer mortar thermally cured at 60°C showed better compressive strength, with 59.78 MPa, with a dense and compacted microstructure.
Technical Session
9/4/24, 3:40 PM - 9/4/24, 4:30 PM
Presenter(s): René Bertolini Robert (IME - INSTITUTO MILItar de Engenharia), Moisés Guedes de Negreiros Júnior (IME), Rafael Noguerol Carvalho (IME), Ricardo Tavares de Siqueira Filho (IME), Mikael Parente Reis (IME), Pedro Rui Rocha da Fonseca (IME), Matheus Deyvisson de Oliveira Moreno Pinto (IME), Marvin de Nacimento (IME), Amal Elzubair Eltom (IME), Marcelo Henrique da Silva Prado (IME)
Abstract:
In the field of regenerative medicine and tissue engineering, bacterial infection can cause grafts and implants to fail. This work highlights the relevance of ceramic biomaterials (especially Hydroxyapatite) reinforced with Potassium Sodium Niobate (KNN) in the search for innovative solutions for the development of safer and more functional biomedical implants. The objective is to discuss the properties inherent to hydroxyapatite (HA) composites reinforced with KNN with different proportions (10, 20 and 30% w/w). After synthesis, the samples were characterized by various experimental techniques to verify their physical properties (density, porosity, and linear contraction), morphological properties, crystalline structure, flexural strength, and antibacterial action. The results indicate a possible antibacterial action, especially when reinforced with KNN, and an increase in flexural strength, suggesting promising applications in biomedical procedures.
Technical Session
9/4/24, 3:40 PM - 9/4/24, 4:30 PM
Presenter(s): SARAH GABRIELLY BRANDAO DE SOUZA (UNIVERSIDADE FEDERAL DO PARA), PALOMA SUELLEN LIMA DE SOUSA (UNIVERSIDADE FEDERAL DO PARÁ), Joelly Vera Nascimento (universidade federal do pará), damares da cruz barbosa (universidade federal do pará), diemison lira santa rosa (universidade federal do pará), Verônica Scarpini Candido (universidade federal do pará), Alisson Clay Rios da Silva (universidade federal do pará)
Abstract:
The development of new materials that use raw materials from industrial waste is desirable for applications in several industrial areas, aiming at the optimization and better use of these inputs. Red mud, which comes from the aluminum production process, is an abundant industrial waste and is rarely used for reuse or repurposing. Thus, the objective of this study is to evaluate the mechanical properties in tension and flexure of polymer matrix composites with a percentage addition of red mud load. The composites were manufactured manually, following the ASTM D638-2014 standards for tensile strength tests and ASTM D790-2017 for flexure. The results indicate that the increase in the percentage of red mud acted as a load, without significantly improving the flexural and tensile strengths. ANOVA confirmed that there were significant differences between the results presented and, through the Tukey test, it was possible to confirm that the percentage difference in load had an effect on the treatment. Therefore, the use of red mud residue constitutes an influential raw material in the development of composite materials.
Technical Session
9/4/24, 3:40 PM - 9/4/24, 4:30 PM
Presenter(s): Carlos Maurício Fontes Vieira (UENF ), Carlos Alberto de Oliveira Guimarãoes (UENF), Geovana Carla Girondi Delaqua (uenf), DJALMA SOUZA (uenf)
Abstract:
This work aims to evaluate the effect of incorporating ornamental rock powder into an industrial ceramic mass used in the manufacture of tiles. Formulations with 0% and 10% by weight of residue replacing sand in the ceramic mass. The specimens were manufactured with uniaxial pressure of 18 MPa and then fired at 8500 to 1050ºC. The specimens were tested to determine water absorption, linear shrinkage and three-point flexural strength. The microstructural evaluation was carried out by scanning electron microscopy and X-ray diffraction. The results indicate that replacing sand with residue is viable, and that with 10% by weight of residue increased the mechanical resistance of the fired ceramic, consequently, a reduction in water absorption of parts.
Technical Session
9/4/24, 3:40 PM - 9/4/24, 4:30 PM
Presenter(s): Carlos Maurício Fontes Vieira (UENF ), Geovana carla girondi delaqua (UENF)
Abstract:
The objective was to identify the ideal amount of laundry sludge to be incorporated depending on the properties of the clay mass that were obtained through some tests, such as mass plasticity, flexural rupture stress, water absorption and linear retraction. The residue damaged the properties, but when in lower percentages, it can be added, where it can contribute to energy savings in the burning stage of the pieces. The incorporation of laundry sludge in the production of red ceramics has proven to be a clean, sustainable and relatively easy-to-implement alternative for correct sludge disposal
Technical Session
9/4/24, 3:40 PM - 9/4/24, 4:30 PM
Presenter(s): Carlos Maurício Fontes Vieira (UENF ), Geovana carla girondi delaqua (UENF)
Abstract:
The microstructure of a kaolinitic clay used in red ceramic from the county of Campos dos Goytacazes, State of Rio de Janeiro, Brazil was evaluated. The firing transformations were studied by X-ray diffraction, thermal analysis (DTA/TGA/DTG), and scanning electron microscopy. Physical properties such as linear shrinkage and water absorption were also evaluated in pressed samples fired at temperatures varying from 900 to 1100ºC. The results indicated that the clay presents a refractory behavior during firing due to the kaolinite predominance, elevated weight loss and the presence of hydroxides. At high temperatures the microstructure of the clay suffers important transformations, such as a marked decrease on the porosity and changes on the crystalline phases. Hematite, Si-Al spinel, mullite and plagioclase were formed and mica and quartz, residual phases, were partially dissolved in the liquid phase
Technical Session
9/4/24, 3:40 PM - 9/4/24, 4:30 PM
Presenter(s): Damares da cruz barbosa nascimento (Universidade federal do pará), diemison lira santa rosa (UNIVERSIDADE FEDERAL DO PARÁ), edson miranda soares (UNIVERSIDADE federal do pará), gabriella da silva nascimento (universidade federal do pará), olívia lopes leite almeida (universidade federal do pará), edemarino araujo hildebrando (universidade federal do pará)
Abstract:
Barbotin is a very influential process for the ceramic forming activity and is widely used in the ceramic industry to produce materials using the gluing method. This process consists of removing the liquid part of a colloidal suspension immersed in a porous mold. Therefore, this work aims to develop a slip formulation with fat clay powders extracted from the regions of Moju-PA and Icoaraci-PA. Furthermore, obtain suitable properties for obtaining green ceramic bodies by separating the water using a plaster mold, followed by natural and oven drying at 100 ºC for 4 h, and subsequent evaluation of sintering at 800 ºC for a period of 76 minutes, to obtain small ceramic pieces with reduced wall thickness. The results demonstrate that the slip composition proved to be efficient for the production of ceramics, obtaining pieces with characteristics and properties that resemble ceramic crafts.
Technical Session
GLASS WASTE USED TO REPLACE SAND IN CERAMIC MASS
Presenter(s): Geovana Carla gIRONDI dELAQUA (UENF - ALBERTO LAMEG), Djalma Souza (UENF), Carlos Maurício Fontes Vieira (uenf)
Abstract:
The aim of the work is to evaluate the influence of replacing sand with glass waste on the physical and mechanical properties of a typical red ceramic composition. The residue comes from the first stage of glass manufacturing in a conventional tempering process. Ceramic specimens were prepared with incorporations of 0, 10 and 20% of waste. The samples were obtained by extrusion, dried and fired at 800 and 900°C in a laboratory oven. Analyzes of the raw materials were carried out, including physical and chemical ones, and tests were subsequently carried out on fired ceramic pieces. The properties obtained from firing were water absorption, linear firing shrinkage and flexural rupture strength. The results obtained demonstrated that both the increase in glass content and the increase in temperature had a positive influence on the properties studied, and, in addition, the glass acted to reduce the appropriate firing temperature
Technical Session
9/4/24, 3:40 PM - 9/4/24, 4:30 PM
Presenter(s): iully da silva amaral pereira (uenf), José Alexandre Tostes Linhares Júnior (uenf), Renan Dias Couto (uenf), Larissa Mendonça Osorio Fonseca (uenf), Juliana Fadini Natalli (uenf), Afonso Rangel Garcez Azevedo (uenf), Sergio Neves Monteiro (ime)
Abstract:
The growing demand for inputs in construction and the inadequate management of agro-industrial waste has resulted in a significant environmental impact, considering that construction is among the most polluting sectors in the world, and agricultural waste directly affects the ecosystem. Lignocellulosic fibers from these wastes become an alternative for reinforcement in cementitious matrices. However, these fibers are hydrophilic, reducing adhesion between the fiber-matrix. To mitigate this characteristic, treatments were carried out to enable its incorporation into these matrices. Açaí and coconut fibers, treated with tannic acid, were analyzed in coating mortars. The mixture proportion was: 1;1;6;1.4 (cement; lime; sand; water), with addition of 3% fibers in relation to the mass of cement treated with 5% concentration of tannic acid, in addition to reference mortar (0%). Workability, penetration index, mass density and entrained air content were evaluated. The analyzes indicated a reduction in fluidity in mortars reinforced with fibers and lower density, which is considered favorable, since mortars with this aspect result in lighter structures. Therefore, mortars incorporated with açaí and coconut fibers have application potential, requiring additional studies of other parameters.
Technical Session
EVALUATION OF A GEOPOLIMER PASTE OF METAKAOLIN AND FLY ASH IN THE FRESH STATE
Presenter(s): Leandro Barbosa de Oliveira (UENF), Madeleing Taborda Barraza (), Markssuel Teixeira Marvila (), Thereza Pereira Ramos de Mello (), Davi Vaz André Júnior (), Sheila Maria Santos da Silva (), Sérgio Neves Monteiro (), Carlos Maurício Fontes Vieira (), Afonso Rangel Garcez de Azevedo ()
Abstract:
Geopolymers are inorganic binders that consist mainly of three-dimensional aluminosilicate materials synthesized by an alkaline solution. These materials are already widespread in academia and are in their first steps in the construction industry, mainly to produce sustainable materials alternative to Portland cement. Thus, this work aimed to analyze the fresh state and relogy of a metakaolin geopolymeric paste with the addition of fly ash at 20 and 40% through consistency and viscosity index tests. The results showed that fly ash increased the fluidity of the geopolymer, as well as decreasing viscosity. These results are linked to the morphology of the spherical ash and its glassy surface. In this way, the potential of fly ash to promote a more workable geopolymer paste and consequently with greater possibilities for application in civil construction was verified.
Technical Session
9/4/24, 3:40 PM - 9/4/24, 4:30 PM
Presenter(s): MARCELLE FERNANDES DA COSTA (IME - INSTITUTO MILItar de engenharia)
Abstract:
The cement industry faces significant challenges in producing the demand necessary to meet civil construction, linked to maintaining low CO2 emission rates. In this scenario, a promising alternative to replace conventional cement is geopolymer, a composite based on industrial waste, with attractive properties and low cost. This study sought to analyze the geopolymerization process and the viability of the materials produced as a sustainable product for application in civil construction, in addition to validating the proportion used. Granulated blast furnace slag activated with sodium silicate (Na2SiO3) and sodium hydroxide (NaOH) was used for the synthesis of geopolymers. Analysis of the slag revealed an unusual concentration of sodium oxide (Na2O). The crystalline phases were identified by X-ray Diffractography (XRD) and the morphology was analyzed by Scanning Electron Microscopy (SEM). The sample activated with both components presented a more compact matrix, while the one activated with silicate showed more porosity and cracks. Signs of efflorescence were observed in the samples, characterizing a possible excess of activators, which led to the formation of sodium carbonate compounds in the matrix, making it necessary to adapt the concentrations of the materials for possible use in civil construction.
Technical Session
9/4/24, 3:40 PM - 9/4/24, 4:30 PM
Presenter(s): Mariana almeida de azevedo pessôa (UENF), MARCELA DA SILVA LUNA PARAVIDINO (UENF), gustavo de castro xavier (uenf), JONAS ALEXANDRE (UENF), sérgio neves monteiro (IME), AFONSO RANGEL GARCEZ DE AZEVEDO (UENF)
Abstract:
This bibliometric analysis using VOSViewer data processing software carried out a quantitative survey on the relationship between Casuarina Equisetifolia L. ash and construction materials. The research was conducted using Science Direct, Scopus and Web of Science databases, where filters were added restricting it to the field of engineering, material sciences, environmental sciences and multidisciplinary covering the last ten years. The results showed a limited field of research and consequently, difficulty in obtaining data on the species. Furthermore, a higher incidence was found in its continent of origin, mainly in China and India. Therefore, the bibliometric analysis of the quantity of research and its distribution in relation to countries, concluded that the scenario, mainly in Brazil, it is conducive to research on the species applied to construction materials, due to the void found in the literature.
Technical Session
EHAVIOR OF COATING MORTARS IN THE HARDENED STATE, COMPOUNDS WITH GLASS RESIDUE
Presenter(s): Mariana Gomes Pinto Cherene (UENF - ALBERTO LAMEG)
Abstract:
Mortars are materials widely used in the construction sector and have diverse applications. These include laying masonry blocks, covering walls and fixing coverings. Multiple mortars are made from a mixture of cement, lime, sand and water. The main properties desired for this material are adhesion to the substrate and workability. In this work, the addition of glass elimination was used, replacing Portland cement at the percentages of 0%, 5%, 10%, 15% and 20% in relation to the adopted mix of 1:1:4 (cement: lime: sand). The proven properties of the mortar in the resisted state were water absorption by capillarity, tensile strength in flexion and resistance to variation. It was observed that the mortar with 15% of the surplus presented significant resistance results when compared to the other mortars tested
Technical Session
9/4/24, 3:40 PM - 9/4/24, 4:30 PM
Presenter(s): MARKSSUEL TEIXEIRA MARVILA (UFV - CRP), Douglas Maxwel Carneiro Caixeta (UFV - CRP), Marília Gonçalves Marques (UFV - CRP), Leonardo Carvalho Mesquita (UFV - CRP), Afonso Rangel Garcez de Azevedo (UENF)
Abstract:
Mortars based on Portland cement and hydrated lime are widely used in civil construction for covering and laying walls, for example. However, the binders used in the production of mortars are produced in a way that is harmful to the environment, highlighting the need for alternative binders. In this work, the use of kaolinite plastic sand in mortars was evaluated, replacing hydrated lime at levels of 0%, 50% and 100%. Properties were evaluated in the fresh state, such as consistency and squeeze flow; in addition to properties in the hardened state, such as compressive strength, water absorption, X-ray diffraction (XRD) and scanning electron microscopy (SEM). Workability tests show that kaolinite plastic sand has the potential to improve mortar workability. In dynamic tests (consistency) it was observed that the 100% kaolinite plastic sand composition is viable as it promotes an increase in spreading from 253 to 265 mm. In static tests (squeeze flow) the composition with 50% kaolinite plastic sand showed the best spreading results, with values of 10.7 mm, while the compositions containing 0% and 100% showed spreading of 8.97 and 7.40 mm, respectively. This demonstrates the potential of using kaolinite plastic sand in mortars. The hardened state results, such as compressive strength and water absorption, were also satisfactory. Finally, it was observed from the XRD and SEM results that the kaolinite plastic sand shows adhesion with the Portland cement hydration products in the mortar, promoting a reduction in ettringite and portlandite due to its moderate pozzolanicity. Based on these results, it is possible to conclude that kaolinite plastic sand is a viable substitute for hydrated lime in mortars
Technical Session
ECOLOGICAL MORTAR BASED ON SUGAR CANE WASTE: AN EXPERIMENTAL EVALUATION
Presenter(s): MARKSSUEL TEIXEIRA MARVILA (UFV - CRP), Yago Farnésio Sousa Silva (UFV - CRP), Marília Gonçalves Marques (UFV - CRP), Leonardo Carvalho Mesquita (UFV - CRP), Sergio Neves Monteiro (IME - RJ), Elias Rocha Gonçalves Júnior (UENF), Afonso Rangel Garcez de Azevedo (UENF)
Abstract:
With the growth of civil construction, studies have emerged to seek ways to use new alternative and sustainable materials, which are as efficient as current ones. Seeking innovations to create new compounds, research emerged combining the use of agricultural waste, fibers or ash, in concrete and mortars. Sugarcane is a product widely produced in Brazil and its production has grown over the years. The residue from this production is sugarcane bagasse, a product that when burned results in sugarcane bagasse ash (CBC). The present work aims to explore new destinations for waste from sugarcane production through the partial replacement of cement with CBC in percentages of 5% and 10%, in two mortar mixes, in compositions 1:1:6:1 .55 (cement:lime:sand:water) and 1:3:0.6 (cement:sand:water). The study considered the issues of water absorption by immersion, compressive strength, diametrical compression strength and consistency index. The results demonstrate the feasibility of using CBC in mortars. It was possible to conclude that the use of ash (CBC) replacing small percentages of cement in mortars can present superior properties, proving appropriate for the use of this material.
Technical Session
9/4/24, 3:40 PM - 9/4/24, 4:30 PM
Presenter(s): MARLLON FRAGA SILVA (IME - INSTITUTO MILI), marvin do nascimento (ime), jeremias ismael nunes fortini (ime), marcio celso fredel (ufsc), eduardo de sousa lima (ime)
Abstract:
The evolution of materials and their transformation processes into products has paralleled the development of humans. While the conventional steel transformation process is well understood, processes such as additive manufacturing have been studied for polymers, metals, and ceramics. Regarding ceramics, it is observed that most products stem from sintering processes, while additive manufacturing is still limited by operational constraints derived from the properties of this material class. Thus, it is essential to understand, within additive manufacturing processes for ceramics, which ones are possible to produce the green body or even the final product. This work focuses on presenting the technologies available in the market, showing in a comparative manner the main characteristics, applications, and limitations.
Technical Session
TITANIUM IMPLANTS COATED WITH HYDROXYAPATITE USING THE AQUEOUS PRECIPITATION METHOD: A PILOT STUDY
Presenter(s): Marvin do NAscimento (instituto militar de engenharia), bruno martins de souza (INSTITUTO MILITAR DE ENGENHARIA), carlos henrique da luz barbosa (INSTITUTO MILITAR DE ENGENHARIA), julianna magalhães garcia (INSTITUTO MILITAR DE ENGENHARIA), marcelo henrique prado da silva (INSTITUTO MILITAR DE ENGENHARIA)
Abstract:
Titanium osseointegrable implants are known for their biocompatible properties, mechanical strength and low corrosion. Surface treatments such as coating with calcium phosphates, especially hydroxyapatite, can provide a bioactive surface for titanium implants. The aim of this study was to coat titanium implants with hydroxyapatite using the wet aqueous precipitation method and to assess the amount of hydroxyapatite remaining at different insertion torques. The hydroxyapatite was coated using the wet aqueous precipitation method, and after insertion, torquing and removal, the titanium implants were analyzed using scanning electron microscopy. The results show that high levels of torque directly influence the amount of hydroxyapatite coating remaining. However, further studies still need to be carried out to obtain more specific results.
Technical Session
MARTENSITIC TRANSFORMATION AND MICROSTRUCTURAL STABILITY IN ZIRCONIA-TOUGHENED ALUMINA BIOCERAMICS
Presenter(s): Marvin do NAscimento (instituto militar de engenharia), carlos henrique da luz barbosa (INSTITUTO MILITAR DE ENGENHARIA), julianna magalhães garcia (INSTITUTO MILITAR DE ENGENHARIA), marllon fraga silva (INSTITUTO MILITAR DE ENGENHARIA), marcelo henrique prado da silva (INSTITUTO MILITAR DE ENGENHARIA)
Abstract:
Zirconia reinforced alumina is an advanced ceramic that is mainly characterized by its high fracture toughness and high hardness, as well as its biocompatibility and bioinertness. Due to these characteristics, its applications are geared towards devices that can withstand extreme wear over extended periods. This literature review aims to present the martensitic transformation and microstructural stability of zirconia added alumina bioceramics. Heat treatment tends to increase grain size and reduces the number of interfaces, reducing the surface energy and favoring the system to reach a lower energy state. However, excessive growth of zirconia grains can induce martensitic transformation, which negatively affects the properties. Stabilization of the tetragonal (metastable) phase of zirconia is essential to maintain the desired properties. Therefore, controlling grain size during heat treatment plays a main role in optimizing these properties. Understanding these aspects is fundamental to maximizing the performance and longevity of this advanced ceramic in biomedical applications.
Technical Session
INFLUENCE OF A BLAND OF FOLDING AND FUEL WASTE ON CERAMIC PROPERTIES
Presenter(s): Matheus Marinho Cabral (UENF - ALBERTO LAMEG), Elvis Pantaleão Ferreira (ifes), Carlos Maurício Fontes Vieira (uenf), Geovana Carla Girondi Delaqua (uenf)
Abstract:
The objective of this work was to add blands of a so-called combustible waste (jabuticaba bark) and a flux waste (packaging glass) in a ceramic mass, evaluating the properties of fired ceramics. The ceramic mass and the glass were characterized by XRF and XRD. The raw materials were dried and sieved so that formulations could be made with different percentages and mixtures of waste. Specimens measuring 114 X 25.0 X 11.0 mm were produced with a pressure of 10ton, and fired at temperature of 950°C. Afterwards, the following properties were evaluated: water absorption, linear shrinkage, and three-point flexural strength. With the results obtained, it was observed that because it is a waste with a large amount of organic matter, the jabuticaba peel alone would harm the properties of ceramics, and should only be used in small quantities. When blands were made with the two waste, even burning at lower temperatures, there was a significant improvement. With this, it is possible to conclude that the incorporation of the mixture of the two wastes in ceramics is a very advantageous alternative, both from the environmental point of view, for the disposal of these wastes, and for the ceramic industry, where in addition to improving the quality of the pieces, it has savings energy in the burning process
Technical Session
INFLUENCE OF SAND GRANULOMETRY ON CONCRETE MORTAR FOR TILES MANUFACTURING
Presenter(s): matheus queiroz de sant'anna pereira (uenf), Felipe Daflon Gama (uenf), José Lucas Decoté de Carvalho Lirio (uenf), José Alexandre Tostes Linhares (uenf), Markssuel Teixeira Marvila (ufv), Carlos Maurício Fontes Vieira (uenf), afonso rangel garcez azevedo (uenf)
Abstract:
The fine aggregate most commonly used in the production of concrete is basically natural sand, coming from river beds. With this in mind, this work aims to evaluate the influence of the particle size of the sand used as fine aggregate in concrete for the manufacture of tiles. Test specimens of three different compositions were produced, varying only the granulometry of the sand used, using sands: coarse, medium-coarse, medium-fine and fine. The tests carried out were: flexural strength, water absorption and apparent density. It was found that the test specimens with medium grain size sand obtained the best results, but the specimes of coarse and medium grain size were also within what the standard requires.
Technical Session
9/4/24, 3:40 PM - 9/4/24, 4:30 PM
Presenter(s): PATRICK DE LIMA GOMES (IME - INSTITUTO MILItar de Engenharia), Victor Ribeiro de Miranda (uerj-FAT - Universidade do Estado do Rio de Janeiro), Isabela Santana de Oliveira (UFF - Universidade Federal Fluminense), Juliana Kelmy Macário Barboza Daguano (CTI - Centro de Tecnologia da Informação Renato Archer ), Carlos nelson elias (IME - Instituto Militar de Engenharia), Claudinei dos santos (UERJ-FAT - UNIVERSIDADE DO ESTADO DO RIO DE JANEIRO)
Abstract:
The 3Y-TZP zirconia devices used in the biomedical field are produced by compression and sintering. In this study, 3Y-TZP zirconia prototypes (n=20) were manufactured using the direct ink extrusion (DIW) technique. A ceramic paste containing 40%v/v 3Y-TZP powder, 59%v/v PEG (Polyethylene Glycol)/Laponite ink and 1%v/v DBP (Dibutylphthalate) was used. For 3D printing, Ø0.63mm nozzles were used, a printing speed of 10mm/s, cross-layer deposition and gaps between filaments of 0.00mm. The parts were sintered at 1550 ºC-2h. The relative density, phase analysis by X-ray diffraction, morphology by scanning electron microscopy, compressive strength, Vickers microhardness and Vickers nano indentation and modulus of elasticity were characterized. The sintered samples predominantly showed the ZrO2-tetragonal crystalline phase, a microstructure characterized by a bimodal distribution of grain sizes. The samples had a relative density of 92.1±3.4%, a Vickers microhardness of 1172±45HV, a Vickers nanohardness of 1608±78HV, a modulus of elasticity of 203±16GPa and a compressive strength of 192±54MPa. The results showed that it is possible to 3D print 3Y-TZP zirconia for biomedical applications
Technical Session
EVALUATION OF THE INFLUENCE OF BLAST FURNACE SLAG TYPE (EAF) ON GEOPOLYMER PROPERTIES
Presenter(s): RAYANNE OLIVEIRA LEAO SANTANA (UNIVERSIDADE FEDERAL DO PARá), Paulo Anderson Aranha Ferreira (UNIVERSIDADE FEDERAL DO PARÁ), Giovana Zagalo de França (UNIVERSIDADE FEDERAL DO PARÁ), vitor leão Santana (UNIVERSIDADE FEDERAL DO PARÁ), Alisson Clay Rios da Silva (UNIVERSIDADE FEDERAL DO PARÁ), Verônica Scarpini Candido (UNIVERSIDADE FEDERAL DO PARÁ)
Abstract:
This study evaluates the influence of different types of blast furnace slag (BFS) on the properties of geopolymers, aiming for more sustainable alternatives to Portland cement. The research, conducted at the Technological Practices Laboratory of UFPA, used metakaolin and three types of BFS as precursors. The results show that the chemical composition of the slags significantly impacts the properties of the geopolymers. The geopolymer with BFS type 3 exhibited the best performance, with a compressive strength of 35.8 MPa, lower water absorption (6.04%), apparent porosity (12.67%), and higher density (2.40 g/cm³). These results indicate a more compact and cohesive matrix, reflected in the microscopic analysis, which revealed a uniform and homogeneous structure in the paste with BFS type 3, without the bubbles present in the pastes of types 1 and 2. The research concludes that the appropriate choice of BFS type is crucial to optimize the properties of geopolymers, with BFS type 3 showing particular promise. This work contributes to sustainability in civil construction by offering a viable and environmentally friendly alternative to Portland cement.
Technical Session
IMPACT OF SAWDUST BIOCHAR PYROLYSIS TEMPERATURES ON FRESH MORTAR PROPERTIES
Presenter(s): RITA DE KASSIA GONCALVES PEREIRA (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO - UENF), Samuel Araújo Azevedo Malafaia (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO - UENF), Iully da Silva Amaral Pereira (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO - UENF), Juliana Fadini Natalli (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO - UENF), Afonso Rangel Garcez de Azevedo (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO - UENF), Markssuel Teixeira Marvila (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO - UENF), Sérgio Neves Monteiro (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO - UENF)
Abstract:
Concerns about CO2 emissions in the construction industry have driven the search for sustainable alternatives, such as partially replacing Portland cement with biochar. Pyrolysis, a thermochemical process of decomposing organic matter in the absence or near absence of oxygen, is crucial for producing biochar. Besides converting biomass waste into biochar, pyrolysis sequesters carbon, helping mitigate climate change. This study investigated the differences in adding biochar, produced at 500°C and 300°C, to fresh rendering mortars. Concentrations of 0.5% and 1% biochar were used to replace Portland cement in mortars with a 1:1:6 ratio (cement, lime, and sand). Laboratory tests evaluated properties such as consistency index, bulk density, incorporated air content, and water retention. The results showed that the pyrolysis temperature of biochar distinctly influenced the mortar properties. Biochar produced at lower temperatures resulted in less porosity, reducing water absorption and * Contribuição técnica ao 77º Congresso Anual da ABM – Internacional, parte integrante da ABM Week 8ª edição, realizada de 03 a 05 de setembro de 2024, São Paulo, SP, Brasil. incorporated air content while increasing water retention. At higher pyrolysis temperatures, the consistency index decreased, the incorporated air content and bulk density increased, and water retention decreased.
Technical Session
9/4/24, 3:40 PM - 9/4/24, 4:30 PM
Presenter(s): Antonio Ricardo grippa satiro (IFES/UENF), Eduardo Atem de Carvalho (UENF), FELIPE PERISSÉ DUARTE LOPES (UENF), Noan Tonini Simonassi (UENF), SERGIO NEVES MONTEIRO (UENF)
Abstract:
This study investigates the use of broomcorn sorghum (Sorghum bicolor) stalks as a natural reinforcement in polyurethane composites, aiming to analyze their behavior under impact loads. The research focuses on the potential use of sorghum stalks, which would otherwise be discarded after the manufacture of artisanal brooms. Composites were produced using broomcorn sorghum stalks in variable proportions (60%, 70%, 80%, and 90%) with a polyurethane matrix derived from castor oil. The test specimens were prepared and subjected to Izod impact testing. This study aims to evaluate how different volumetric fractions of broomcorn sorghum stalk influence the notch toughness and impact resistance. The results showed that composites with 70% sorghum fibers exhibited the best actual resistance to impact and notching, meaning that adding more than this percentage did not result in significant gains. The study confirmed that the stalks can be effectively used as reinforcement in polymeric composites, even though the variation between results was not statistically significant. The specific properties also improved with the increase in volumetric fraction, indicating that these composites are promising for applications where mass is a critical factor.
Technical Session
CHARPY IMPACT TEST OF FIQUE FABRIC REINFORCED COMPOSITE IN EPOXY MATRIX WITH GRAPHENE NANOPLATE
Presenter(s): Artur Camposo Pereira (UFOP), Umberto Magno Sol Fernandes Nascimento (UFOP), Noan Tonini Simonassi (UENF), Michelle Souza Oliveira (IME), Leonardo Barbosa Godefroid (UFOP), Sergio Neves Monteiro (IME)
Abstract:
order to improve certain materials, it is quite common to apply graphene and its derivatives such as graphene nanoplates (GNP) or graphene oxides (GO) with the aim of manufacturing composites that meet market demand and seek to offer better quality. of life for people. The use of GNP in epoxy presents an advance in the manufacture of composites in relation to the use of GO. However, GNP, unlike GO, has a certain ability to agglomerate, which makes interaction with the polymeric matrix difficult, resulting in less satisfactory results. Thus, the objective of this work is to investigate the composites without the addition of fiber and with 0.1% and 0.5% of GNP (01NPGE and 05NPGE) as well as the composite with the addition of 40% of Fique fabric and 1.3% of NPG in epoxy (13NPGF), using Charpy impact tests. Macroscopic observation of post-impacted samples and analysis of fractures by SEM demonstrated that rupture was facilitated by the presence of GNP.
Technical Session
EVALUATION OF DYNAMIC MECHANICAL PROPERTIES OF UBIM FIBER REINFORCING EPOXY COMPOSITES
Presenter(s): Belayne Zanini Marchi (ime/rj), Ary Machado de Azevedo (ime/rj), Jean Carlos Carelo (COPPE/ RJ), Sérgio Neves Monteiro (IME/RJ), ANDRÉ BEN-HUR DA SILVA FIGUEIREDO (IME/RJ)
Abstract:
The use of cellulosic or natural fibers (NLFs) in composites is considered a promising alternative due to their low cost, renewability, biodegradability, and low specific weight. Recognized for their high mechanical properties, these fibers have become widely used in various technological sectors, especially in engineering. However, lesser-known natural fibers that are not mentioned in reviews still require research to evaluate their potential as reinforcement in composites, such as ubim fiber. Ubim is a small plant found in the undergrowth of forests with high rainfall rates in the states of Amazonas, Acre, Amapá, Pará, Maranhão, and Piauí. Thus, the thermal and mechanical properties, crucial for engineering applications involving temperature variations, were studied. This work investigated the dynamic-mechanical properties of epoxy matrix composites reinforced with 10%, 20%, and 30% ubim fiber using Dynamic Mechanical Analysis (DMA). The results showed that the incorporation of fibers resulted in higher values of storage modulus (E') and loss modulus (E”), as well as an increase in the glass transition temperature (Tg). Additionally, a lower damping factor (tan δ) was observed in composites with higher volumetric fractions of ubim fiber.
Technical Session
9/4/24, 3:40 PM - 9/4/24, 4:30 PM
Presenter(s): BERNARDO CHICHIERCHIO DA SILVA SANTOS (IME MILITAR DE ENGENHARIA), carolina assis pinto ferreira (instituto militar de engenharia ), isabelle santos moura (instituto militar de engenharia), patrick de lima gomes (instituto militar de engenharia), carlos nelson elias (instituto militar de engenharia )
Abstract:
Three-dimensional (3D) printing techniques are used in dentistry for manufacture dental prosthetics and in other applications. The objective of this work was to analyze (in vitro) the effect of the orientation of the impression of layers of a dental resin used in temporary dental prostheses. Discs were printed in 3 directions in relation to diameter (diameter vertically, horizontally and 45 degrees). The specimens were subjected to compression tests and roughness evaluation. It was observed that samples printed with the diameter vertically present significantly greater compressive strength and roughness than those printed with the diameter horizontally and at 45 degrees. It can be concluded that the orientation of the 3D printing layers substantially influences the compressive strength and roughness of dental resins. Based on the results of this work, it is important that the professional who makes dental prostheses must observe the region of the prosthesis with smaller dimensions and greater loads to control the print directions.
Technical Session
Thermomechanical characterization using dynamic mechanical analysis (DMA) of flax fiber reinforced polymer composites produced via additive manufacturing
Presenter(s): Daysiane da silva moreira (Instituto militar de engenharia), RAI FELIPE PEREIRA JUNIO (Instituto Militar de engenharia), JOSÉ CARLOS FERREIRA FONTES (Centro Universitário Augusto Motta), SERGIO NEVES MONTEIRO (instituto militar de engenharia), LUCIO FABIO CASSIANO NASCIMENTO (INSTITUTO MILITAR DE ENGENHARIA)
Abstract:
This study aims to evaluate the performance characteristics of polymer composite materials composed of light-curing acrylic resin utilized in additive manufacturing through the AM method via vat polymerization employing a DLP process, alongside flax fibers, employing dynamic mechanical analysis (DMA). DMA measures the viscoelastic properties of a material in terms of stiffness and damping, including storage modulus (E'), loss modulus (E"), and the ratio between these moduli, tangent δ, as well as the glass transition temperature (Tg). The samples were printed to dimensions of 65x12x3.5 mm and in fractions of 0%, 0.5%, 1%, 1.5%, and 2% flax fiber. After printing, they underwent exposure to UV light (405 nm) for 12 hours. Subsequently, the specimens were subjected to dynamic mechanical analysis, which revealed an increase in initial E' between the 0% and 2% samples to 2041 MPa and 2083 MPa, respectively. The loss modulus (E") showed values of 214 MPa at 45° and 176 MPa at 58°, while Tg recorded values of 80°C and 88°C. In comparison to other composites, a reduction of up to 59% was observed in the storage modulus (E'), alongside a significant decrease in the loss modulus peak (E"). The composites exhibited more pronounced peaks in the tan δ graph compared to the pure resin. Notably, the composite with a 2% mass fraction demonstrated an 8°C increase in the glass transition temperature (Tg) when contrasted with the pure resin. The remaining composites maintained a glass transition temperature within the range of 72°C to 76°C.
Technical Session
9/4/24, 3:40 PM - 9/4/24, 4:30 PM
Presenter(s): GRAZIELE MEDEIROS COSME (uenf), GEOVANA cARLA GIRONDI DELAQUA (UENF), Felipe Perissé Duarte LopeZ (UENF), Noan Tonini Simonassi (UENF), SERGIO NEVES mONTEIRO (UENF)
Abstract:
Due to the urgent need for more sustainable and environmentally friendly products, synthetic fibers are increasingly being replaced by fibers from vegetable sources, as reinforcement in polymer matrix composites.These compounds have different types of applications, such as in engineering. However, due to the use of natural fiber as reinforcement, this composite presents a certain instability in its thermomechanical properties when subjected/exposed to heating and cooling and due to this instability it is necessary to investigate these properties before its effective application in industry. A series of thermal characterizations are then carried out, including dilatometry, which is a simple, sensitive and reliable analytical technique, carried out in accordance with the ASTM E 228 standard, in order to determine the Glass Transition Temperature (Tg) and how the decrease and increase in the volumetric fraction of fiber acts on this Tg in a temperature range ranging from room temperature to 200 °C, where degradation of the polymer or the natural fiber and its constituents does not occur. It was soon possible to observe that the Tg of the material occurs at around 50 °C, where it was possible to notice a shrinkage of the material with the increase in the fiber volume fraction.
Technical Session
9/4/24, 3:40 PM - 9/4/24, 4:30 PM
Presenter(s): LUCAS DE MENDONÇA NEUBA (ime), RAÍ FELIPE PEREIRA JUNIO (ime), DOUGLAS SANTOS SILVA (ime), Elias Matias Bentes (ime), Lucas Moura Montenegro Reis (ime), Thuane Teixeira da Silva (ime), Sergio Neves Monteiro (ime)
Abstract:
Natural fibers have some advantages compared to synthetic fibers, mainly because they are more environmentally friendly. For this reason, its use as reinforcement for polymeric matrices has been growing exponentially. However, they have the disadvantage of having a hydrophilic nature, which strongly reduces interface interaction. However, the viscoelastic dynamic-mechanical behavior still needs to be investigated for the complete characterization of these composites with a view to future engineering applications. Therefore, this research focuses on investigating the dynamic mechanical (DMA) and thermomechanical analysis (TMA) for epoxy matrix composites containing 30% by volume of CM reed fiber mercerized with sodium hydroxide. Compared to the control group (untreated epoxy) the damping factor (Tan δ), being the ratio of the loss modulus under storage, is significantly increased (0.108) for composites reinforced with 30% mercerized CM reed fibers with sodium hydroxide. The Tg found at 76°C for the 30 FJM/EP condition presented the coefficient of thermal expansion (170.68 x 10−6/°C). The 30 FJM/EP condition exhibited a Tonset equal to 263 °C and the maximum degradation rate was 314 °C. These DMA and TMA results appear to be promising
Technical Session
TRIBOLOGICAL BEHAVIOR OF NATURAL FIBERS VEGETABLE ORIGIN: A BRIEF REVIEW
Presenter(s): magno torres carvalho (IME), Hellen Karina Pereira Alkimim (IME), Shanely da Silva Ribeiro (UFRJ), Andressa Teixeira Souza (IME), Sergio Monteiro neves (IME), Eduardo de SOusa Lima (IME)
Abstract:
In recent years, researchers have focused their efforts on evaluating the mechanical and tribological characteristics of natural fiber composite materials, considering different polymeric matrices, types of natural fibers, and their concentrations. By employing natural fibers as reinforcement components, it is possible to enhance tribological properties by adjusting the fiber content to specific values. The natural fiber content plays a crucial role in influencing tribological properties, primarily due to variations in the ratio between the matrix and the natural fiber. This relationship impacts adhesion strength, exerting a direct effect on tribological properties.
Technical Session
9/4/24, 3:40 PM - 9/4/24, 4:30 PM
Presenter(s): Marcelo Barcellos Reis (UENF - ALBERTO LAMEG), Henry Alonso Colorado Lopera (uNIVERSIDADE DA ANTIÓQUIA), Carlos Maurício Fontes Vieira (uNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO - UENF), Afonso Rangel Garcez Azevedo (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO - UENF), Elaine Aparecida Santos Carvalho (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO - UENF), Sérgio Neves Monteiro (INSTITUTO MILITAR DE ENGENHARIA)
Abstract:
CIVIL CONSTRUCTION IS ONE OF THE OLDEST ACTIVITIES KNOWN TO HUMANITY AND REPORTS SHOW THAT BUILDERS IN THE ROMAN EMPIRE ALREADY SEEKED THE REUSE OF MATERIALS. CURRENTLY, THE REUSE OF SOLID WASTE IN CIVIL CONSTRUCTION, CALLED RCD-WASTE FROM CIVIL CONSTRUCTION AND DEMOLITION, IS BECOMING MORE AND MORE URGENT, TAKING IN VIEW NOT ONLY THE ECONOMIC, BUT MAINLY ENVIRONMENTAL ASPECT. IN THIS CONTEXT, THIS RESEARCH SEARCHED FOR NEW VARIABLES FOR THE DISPOSAL OF THIS WASTE, WITH THE COMPOSITION OF ARTIFICIAL FINISHING STONES AS A UNIQUE POSSIBILITY TO BE ANALYZED. IN THIS RESEARCH, A NEW COMPOSITION OF ARTIFICIAL STONE PRODUCED FROM CIVIL CONSTRUCTION AND DEMOLITION WASTE WAS DEVELOPED AND ANALYZED USING AN ORTHOPHTHALIC POLYESTER RESIN AS A BINDER. THE RESIDUE WAS SIEVED AND SEPARATED BY GRANULOMETRY USING THE SIMPLEX CENTROID METHOD, THE BEST COMPACTED MIXTURE WAS DETERMINED USING THE TUKEY METHOD. THE RESIDUE WAS CHARACTERIZED BY X-RAY FLUORESCENCE AND THE RESIN BY FOURIER TRANSFORM INFRARED SPECTROSCOPY. ARTIFICIAL STONE PLATES WERE PRODUCED WITH 85% WASTE AND 15% RESIN, IN MASS, BY THE VIBRO, COMPRESSION AND VACUUM SYSTEM AND CUT FOR MECHANICAL, PHYSICAL AND CHEMICAL TESTS. AN ANALYSIS WAS CARRIED OUT BY SCANNING ELECTRON MICROSCOPY OF THE FRACTURED COMPOSITIONS AS WELL AS THE GRANULOMETRY. THE ARTIFICIAL STONE WITH THE BEST RESULTS SHOWED A DENSITY OF 2,256 G/CM3, WATER ABSORPTION OF 0.69%, APPARENT POROSITY OF 1.55%; FLEXURE RESISTANCE OF 34.74 MPA AND COMPRESSION OF 111.96 MPA; GOOD RESULTS IN ALTERABILITY AND THERMAL TESTS. IN THIS SATISFACTORY OVERVIEW, THE USE OF CONSTRUCTION WASTE IN THE COMPOSITION OF ARTIFICIAL STONES IS PROMISING AS IT DIRECTLY MEETS THE CONCEPT OF SUSTAINABLE DEVELOPMENT (ENVIRONMENTAL AND ECONOMIC), REINTRODUCING A WASTE WIDELY PRODUCED ON THE PLANET INTO THE PRODUCTION CHAIN , WHICH MASSIVELY HAS ITS FINAL DISPOSAL IN SANITARY LANDFILLS; AS WELL AS IN THE QUALITY OF THE FINAL PRODUCT (EXPERIMENTAL) WITH PROPERTIES SIMILAR TO ARTIFICIAL STONES ALREADY COMMERCIALIZED.
Technical Session
IMPACT TESTS IN POLYMER COMPOSITE REINFORCED BY MEDIUM AND HIGH THEORETICAL VOLUME FRACTIONS OF RAMIE FABRIC AND A FRACTURE ANALYSIS BASED ON HAMILTON’S PRINCIPLE
Presenter(s): Marcelo Vitor Ferreira Machado (Instituto federal fluminense E UENF), Felipe Perissé Duarte Lopes (UENF), Noan Tonini Simonassi (UENF), Sergio Neves Monteiro (UENF / IME)
Abstract:
In the current perspective of an increasing use of material resources that are sustainable and eco-friendly, many researches have been focused on polymer composites reinforced with natural fibers, specially lignocellulosic fibers. In this area of study, one of the first analyzes are experimental ones that aim to determine the physical and mechanical properties of these multiphase materials, therefore, this research seeks to understand characteristics obtained through impact tests on specimens of epoxy composites reinforced by medium and high theoretical volume fractions of ramie woven fabric. Could be designed 3 groups of intact and 3 groups of UV and condensation accelerated aging tested specimens (40%, 50% and 60% volume fractions of fibers). In sequence, these specimens were tested using Charpy configuration and the impact resistance properties obtained could be compared statistically. In a general way, could be concluded that impact resistance increases within the range of theoretical volume fractions of fibers used in the research and that this quantity will be greater the closer to optimal moderate adhesion conditions of the interfaces between the epoxy matrix and ramie woven fabric
Technical Session
9/4/24, 3:40 PM - 9/4/24, 4:30 PM
Presenter(s): Marcônio Pereira de Magalhães (UENF)
Abstract:
The present study aims to investigate the industrial feasibility of using embira fiber, derived from the inner bark of the Embira-branca (Daphnopsis utilis) tree from the Atlantic Forest, as reinforcement in polymer matrix composites made of polyurethane resin (PU) derived from castor oil. Therefore, composites reinforced with 50%, 60%, 70%, 80%, and 90% mass fractions of embira were manufactured and subjected to three-point bending tests. The results show that even with increasing embira mass fractions, the specific flexural strength of the composites remained constant. However, the specific modulus of elasticity in flexure for the composites with 50% reinforcement reached 7.65 MPa.cm³/g, the highest average value, classified as group (a). In contrast, those with 60% and 70% reinforcement, showing no statistically significant differences in their means, were classified as group (b) and had the lowest average, only about 30% of the stiffness of composite (a). Composites reinforced with 70%, 80%, and 90%, classified as group (c), also showed no statistically significant differences in their means, with about 43% of the stiffness of group (a), with the 70% reinforcement fraction common to both groups (b) and (c).
Technical Session
9/4/24, 3:40 PM - 9/4/24, 4:30 PM
Presenter(s): mariana dias machado lopes (UENF), SERGIO NEVES MONTEIRO (uenf), felipe perissé duarte lopes (uenf), noan tonini simonassi (uenf), bernardo rodrigues de oliveira (uenf)
Abstract:
Polyurethane composites, as well as other polymer composites, are widely used in various applications due to their exceptional mechanical and chemical properties. In this context, the incorporation of natural fibers derived from plants such as bamboo as reinforcement can further improve these mechanical properties of these composites, making them lighter, stronger and more sustainable. This paper presents a comprehensive investigation on the impact resistance of polyurethane composites reinforced with bamboo fiber in different proportions. To this end, castor oil derived polyurethane matrix composites were manufactured with different amounts of bamboo fibers and their impact resistance was evaluated using Izod impact tests. The results showed a significant influence of bamboo fiber content on the impact resistance of the composites, with a general trend of increased resistance with higher fiber content. This study provides important insights for the development of polyurethane composites with optimized performance in applications requiring high impact resistance.
Technical Session
DEVELOPMENT OF ARTIFICIAL MARBLE REINFORCED WITH NATURAL FIBER
Presenter(s): mayara tito campos (Universidade estadual do norte fluminense darcy ribeiro), elaine aparecida santos carvalho costa (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO), Rafael Bittencourt Miranda (universidade Estadual do norte fluminense darcy ribeiro), Felipe Perissé Duarte Lopes (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO), Carlos maurício fontes vieira (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO), Henry Alonso Colorado Lopera (universidad de antioquia), djalma souza (Universidade estadual do norte fluminense darcy ribeiro)
Abstract:
The objective is to develop an artificial stone using fragmented marble as waste together with an epoxy resin showing technical viability compared to natural stone and using natural fiber to reinforce this marble compared to fiberglass. The artificial marble was produced using two compositions selected by determining the vibrated density of the particles, using the vibration, compression and vacuum method, being hot compacted at 90ºC for 20 min. The stones of compositions CP4 and CP8 were initially produced with two resin levels, 5 and 10% in relation to the mass of waste used, with stones with 10% selected for the lamination stage due to their better physical and mechanical properties. Bending results indicated an improvement in the performance of artificial stones in relation to natural marble, and an improvement in the performance of artificial stones was observed when laminated with fiberglass
Technical Session
9/4/24, 3:40 PM - 9/4/24, 4:30 PM
Presenter(s): MIRIANE ALEXANDRINO PINHEIRO (UFPA), NÉLY THATIANE BRANCO (UFPA), marcos allan leite dos reis (ufpa), ALISSON CLAY RIOS DA SILVA (UFPA), VERÔNICA SCARPINI CANDIDO (UFPA)
Abstract:
Advances in materials science, combined with concern for the environment, have led to the production of new materials that combine good mechanical performance and sustainability. In this context, polymer composites reinforced with natural fibers stand out for their exceptional mechanical properties, lightweight nature, biodegradability and low cost. Natural lignocellulosic fibers have been increasingly used as reinforcements in polymer matrix composites, replacing synthetic fibers. Among these, the fiber extracted from the envira plant (Bocageopsis multiflora), a species from the Amazon region that has been little studied, has been used as a reinforcing material in polymer composites. Thus, the aim of this study was to evaluate the tensile mechanical properties of polyester matrix composites.Composites were produced incorporating 10, 20 and 30 %vol fibers by volume, following the specifications of ASTM D638. The composites were evaluated for their mechanical properties in tensile strength and the fracture region was analyzed by SEM. In addition, the values obtained were statistically compared using the ANOVA and Tukey tests. The results showed that incorporating fibers into the polyester matrix increases the average tensile strength of composites with 30 % fiber by volume, increases the modulus of elasticity and decreases the deformation. Analysis of the fracture region indicated a fragile fracture aspect. These results indicate that envira fiber is a potential reinforcement for polymer matrix composites.
Technical Session
DYNAMIC COMPRESSION TEST ON HOPKINSON BAR OF EPOXY HYBRID COMPOSITES REINFORCED WITH ARAMID FABRIC AND CURAUÁ BLANKET FOR BALLISTIC HELMET
Presenter(s): Natalin Michele Meliande (instituto militar de engenharia), Michelle Souza Oliveira (instituto militar de engenharia), Rafael Rodrigues Dias (centro tecnológico do exército), Sérgio Neves Monteiro (INSTITUTO MILITAR DE ENGENHARIA), Lucio Fabio Cassiano Nascimento (INSTITUTO MILITAR DE ENGENHARIA)
Abstract:
Increasing awareness around the world of the urgent need to reduce the use of non-degradable synthetic materials, and the problem of disposing of personal protective vest and helmet have driven research into new more environmentally sustainable materials for ballistic applications. In this context, natural lignocellulosic fibers can be promising options because they are non-polluting and have specific mechanical properties comparable to those of commonly used synthetic fibers, in addition to being significantly cheaper. Thus, in order to evaluate the hybridization of curaua fibers (Ananas Erectifolius) with aramid fibers in epoxy composites for ballistic helmets, dynamic compression tests on Hopkinson Bar were carried out. From the results obtained, it can be inferred that the hybridization was positive regarding the dynamic behavior of the composite, given that for a reduction of up to 55% in the amount of aramid, the maximum tension did not vary significantly, while the maximum deformation and the toughness reduced by 37% and 18%, respectively.
Technical Session
COPPER-BASED NANOCOMPOSITE CHARACTERIZATION UNDER DIFFERENT ANNEALING CONDITIONS
Presenter(s): Nayara Janson (WEG), Camila dos santos gonçalves (WEG), Angelo Paulucci de Carvalho (WEG), Guilherme Schneider Porepp (WEG), Maurício Dirong Böhlk (WEG)
Abstract:
Copper-based composite materials are becoming essential in advanced industrial applications due to their outstanding properties. However, the impact of different thermal stresses on their properties, especially electrical ones, remain limited in current literature. In order to address this gap, in the current study mechanical and electrical properties of a proprietary Cu-Al2O3 nanocomposite has been evaluated, focusing on its applicability in high-temperature environments. Results revealed that Cu-Al2O3 composite surpasses both brass and pure copper in mechanical strength across various temperatures (300°C to 800°C). Notably, the composite consistently exhibits superior yield strength, even under elevated temperatures, attributed to the thermal resilience provided by dispersed alumina particles. Structural evaluations confirmed the material's stability and fine grain structure, contrasting with the significant microstructural alterations observed in pure copper. Furthermore, the investigation revealed that the composite maintains elevated levels of electrical conductivity comparable to pure copper, owing to its distinctive structure. This fusion of outstanding electrical conductivity with enhanced mechanical strength, even after different thermal stresses, highlights the versatility of the studied Cu-Al2O3 nanocomposite.
Technical Session
9/4/24, 3:40 PM - 9/4/24, 4:30 PM
Presenter(s): NIANDER aguiar cerqueira (UENF - ALBERTO LAMEG), Mayara Silva de Almeida (UENF), Sergio Luis Gonzalez Garcia (UENF), Rances Castillo Lara (UENF)
Abstract:
Self-compacting concrete (SCC) plays a crucial role in the construction industry, as it increases productivity, improves the working environment and contributes to sustainable concrete technology. This type of concrete is considered sustainable because it can be produced using large quantities of industrial waste. SCC has specific characteristics, and its performance is related to its properties in the fresh state, such as fluidity, viscosity and resistance to segregation. To achieve these properties, its composition includes mineral additions and fine materials, which can often be industrial waste, making the concrete more sustainable. This industrial waste can be used to replace both cement and sand. Replacing cement helps to reduce CO2 emissions into the atmosphere, while replacing sand reduces the use of natural resources. In this research, the industrial waste used is granite, which, if disposed of inappropriately, can cause siltation of rivers, pollution of water sources and, due to its fine granulometry, respiratory diseases in the population. Granite waste partially replaces natural sand in proportions of 20%, 30% and 40%. The rheological parameters were evaluated by testing the self-compacting microconcrete in its fresh state.
Technical Session
OBTAINING AND CHARACTERIZING AN EPOXY MATRIX COMPOSITE REINFORCED WITH GROUND PIASSAVA FIBRE
Presenter(s): Clarissa de Paula Dias (Instituto militar de engenharia ), Laura Setti de Sousa (Instituto Militar de Engenharia), Bruno Sousa da Cunha (Instituto militar de engenharia), Sergio Neves Monteiro (Instituto militar de engenharia), Lucio Fabio Cassiano Nascimento (Instituto militar de engenharia)
Abstract:
The use of natural fibers to reinforce polymer matrix, such as epoxy resin, is preferable due to their abundance and sustainability. Piaçava, a natural fiber found especially in the Amazon region, represents a low-cost option frequently used in the manufacture of household utensils. This study aimed to analyze the mechanical properties of an epoxy resin composite reinforced with ground piaçava fibers in proportions ranging from 0% to 50%. The influence of the amount of fiber in the matrix was investigated through tensile tests, and the evaluation of the fiber as a possible reinforcement was observed by scanning electron microscopy. The results revealed that composites with lower fiber proportions (10% and 20%) did not perform better than pure resin, showing a reduction in tensile strength. However, with the addition of fiber, the composites with 40% and 50% fiber showed significantly better performance, with higher tensile strength and strain capacity, suggesting a more efficient load transfer between the matrix and fiber. The composite with 50% fibers demonstrated the best performance, achieving a 243% increase in tensile strength and a 119% increase in strain compared to pure resin.
Technical Session
9/4/24, 3:40 PM - 9/4/24, 4:30 PM
Presenter(s): RAI FELIPE PEREIRA JUNIO (IME), José Carlos Ferreira Fontes (UNISUAM), Luiz Felipe Santiago Proença (ime), Rafael da Fonseca Guedes (IME), SERGIO NEVES MONTEIRO (IME), LUCIO FABIO CASSIANO NASCIMENTO (IME)
Abstract:
The history of Additive Manufacturing (AM) is outlined by four main aspects: prototyping, applications, expansion, and evolution. In the late 1980s, prototyping was the first trend, focusing on developing prototypes due to high equipment and material costs. In the 1990s and 2000s, applications expanded with the emergence of various methodologies. Currently, new techniques and materials drive the expansion and evolution of AM in different sectors. Since the 2000s, AM has gained prominence as a promising methodology for complex part development. Standardization of terms and processes by ASTM and ISO has facilitated normalization and data transfer between platforms. With a myriad of processes and materials available, AM offers advantages such as geometric freedom, customization, and material efficiency, driving advancements in various fields such as medicine and aerospace. Given the growing development of technologies associated with additive manufacturing processes, knowledge of the various aspects integrated into this sector is necessary. Thus, this text seeks to provide an overview of the inception and development of some characteristics of 3D printing processes, particularly those involving polymeric materials
Technical Session
OBTAINInG AND STUDY OF THERMAL AND TENSILE PROPERTIES OF CORN STARCH COMPOSITES WITH SISAL MICROFIBERS
Presenter(s): Rochelle Moraes Matos (Universidade Federal do Pará), Diogo monteiro Porfírio (INSTITUTO FEDERAL DO PARÁ), Michele Barbosa dos Santos (UNIVERSIDADE FEDERAL DO PARÁ), Taiana de Sousa Matos (UNIVERSIDADE FEDERAL DO PARÁ), Mailson Batista de Vilhena (UNIVERSIDADE FEDERAL DO PARÁ), Marcos Vinícius da Silva Paula (UNIVERSIDADE FEDERAL DO PARÁ), Roseane de Lima Silva (UNIVERSIDADE FEDERAL DO PARÁ), Verônica Scarpini Candido (UNIVERSIDADE FEDERAL DO PARÁ), Edinaldo José de Sousa Cunha (UNIVERSIDADE FEDERAL DO PARÁ)
Abstract:
This study reports the obtaining and characterization of biodegradable composite films composed of corn starch and sisal microfibers. The films were obtained by solvent evaporation with contents of 5% and 10% of sisal microfibers in relation to the mass of starch. The films were qualitatively evaluated through visual appearance and characterized by thermogravimetric analysis (TGA) and tensile mechanical properties. Regarding the visual aspect, the films exhibited no opacity and easy handling. For tensile properties, improvements in investigated properties such as modulus and tensile strength were observed. Films with sisal microfibers exhibited better thermal stability compared to starch films alone. Our results indicate the potential for using starch composite films with microfibers for use in the packaging sector.
Technical Session
POLY (VINYL ALCOHOL)/ CHITOSAN BLENDS WITH WHITE PAST ESSENTIAL OIL EMULSION FOR APPLICATION IN BIOMATERIALS.
Presenter(s): Taiana de Sousa Matos (UNIVERSIDADE FEDERAL DO PARÁ), Tamires de Sousa de Matos (UNIVERSIDADE FEDERAL DO PARÁ), damares da cruz barbosa nascimento (UNIVERSIDADE FEDERAL DO PARÁ), Alisson Clay Rios da Silva (UNIVERSIDADE FEDERAL DO PARÁ), Marcos Vinícius da Silva Paula (UNIVERSIDADE FEDERAL DO PARÁ), bianca correa pinto (UNIVERSIDADE FEDERAL DO PARÁ), Verônica Scarpini Candido (UNIVERSIDADE FEDERAL DO PARÁ)
Abstract:
The search for new low-cost and abundant materials that can be used in biomaterials has aroused interest. Chitosan, a natural polymer derived from chitin, is quite abundant, as it can be extracted from crustacean waste, while alcohol (polyvinyl) is a synthetic polymer that is biocompatible and digested by enzymes. The selection of these two materials is justified due to their complementary properties and potential. in biomedical applications. The blends were prepared by the casting method, characterized in terms of visual appearance, optical microscopy, moisture percentage and solubility content. The results presented an apparently uniform visual appearance for all samples. Furthermore, in relation to moisture content and solubility in general, alcohol (polyvinyl) presented 30% moisture, being more humid and 100% soluble. This study contributes to the advancement of knowledge on the use of polymer blends for biomedical applications, offering a viable and sustainable alternative for the development of new biomedical materials.
Technical Session
9/4/24, 3:40 PM - 9/4/24, 4:30 PM
Presenter(s): VICTOR PAES DIAS GONCALVES (Universidade Estadual do Norte Fluminense Darcy Ribeiro ), DAVID COVERDALE RANGEL VELASCO (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO ), José Lucas Decoté de Carvalho Lirio (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO ), Carlos Maurício Fontes Vieira2 (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO ), Noan Tonini Simonassi (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO ), FELIPE PERISSÉ DUARTE LOPES (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO ), Henry Alonso Colorado Lopera (Universidad de Antioquia UdeA)
Abstract:
Originally, additive manufacturing was used only to validate and/or visualize concepts and projects, but the advancement of 3D printing techniques has enabled the development of tools and components. The objective of the work is to experimentally evaluate the impact resistance in the IZOD test of samples printed by additive manufacturing with the production of the printed vs. machined notch. The specimens were printed using stereolithography processing (SLA). The results indicated that the impact resistance by the IZOD method of the specimen with machined and printed notches has a difference that varies in the samples between 57% - 264% (notch) and 70 - 221% (impact). It was concluded that the construction of the notch by machining is extremely important to carry out the correct analysis of the material's resistance. Three-dimensional printing by SLA was impacted by the construction of the notch and the characteristics of the material did not influence the creation method
Technical Session
INFLUENCE OF TWINS AND SURFACE ROUGHNESS ON EDGE CRACKS FORMATION DURING COLD ROLLING OF ELECTRICAL STEELS
Presenter(s): SÉrgio silveira de vasconcellos júnior (Aperam South America SA), DANIEL EUGêNIO DA SILVA (Universidade Tecnológica Federal do Paraná), Victor fernandes torres (APERAM SOUTH AMERICA SA), Paulo Ricardo Mussi Oliveira (APERAM SOUTH AMERICA SA), GILVAN EMILIO CASTRO MORAIS (aperam), DIOGO FERREIRA DE CASTRO (APERAM)
Abstract:
Electrical steels are used in the transformers and electric motors industry due to their excellent magnetic properties. This steel frequently shows edge cracks in cold rolling, which may lead to a strip breakage and scrapping of the damaged material. This work aimed to investigate the edge crack occurrence, during cold rolling, and its correlation with parameters, such as microstructure and surface roughness. The reduction of shot blasting intensity during mechanical pickling reduced the surface roughness and also the twins occurrence, analyzed through an optical microscope. Through the experiments, it could be seen that the edge cracks occurrence is directly influenced by deformation twins and product surface roughness before cold rolling.
Technical Session
9/4/24, 3:40 PM - 9/4/24, 4:30 PM
Presenter(s): GABRIEL SOUZA JORGE (VALLOUREC SOLUCOES TUBULARES DO BRASIL S.A), gabriela deslandes cardoso (VALLOUREC SOLUCOES TUBULARES DO BRASIL S.A), Letícia Cristina Domingos (vALLOUREC SOLUCOES TUBULARES DO BRASIL S.A), Ronaldo de faria antunes (VALLOUREC SOLUCOES TUBULARES DO BRASIL S.A)
Abstract:
This work addresses the simulation of cold drawing for a 66.0x9.0mm tube for normalized EN ST52 steel grade. The objective was to assess the influence of mandrel positioning within the die’s work zone on drawing forces to identify the optimal operational range. A finite element model (FEM) was developed to monitor the forces on the tools (die and mandrel) and the tube’s stress levels for different mandrel positions. It was noted that the drawing forces and the stress levels in the tube significantly varies depending on the mandrel’s positioning within the die’s work zone during the forming process. This solution improves process quality and reduces losses due to tube non-quality in the cold drawing process. Conclusions and recommendations for future work based on the results achieved are presented.
Technical Session
THE USE OF CATHODIC CAGE PLASMA NITRIDING FOR IMPROVEMENT THE SLIDING WEAR RESISTANCE OF AISI H-13 TOOL STEEL BLADES FOR CUTTING HOT STEEL STRIPS
Presenter(s): ADONIAS RIBEIRO FRANCO JÚNIOR (IFES), José carlos de pontes júnior (ArcelorMittal), Jaime Alberto Sanchez Caceres (IFES), Beatriz Capucho Jantorni (UFES), Guilherme Alvernaz da Silva Maia (IFES)
Abstract:
AISI H13 hot work tool steel is widely used in applications such as metal forming and machining, where its surface is under severe conditions of mechanical stresses and sliding wear at high temperatures. The present work aims to increase the abrasive wear resistance of this material applied as shear blades for cutting hot steel strips. For such purpose, cathodic cage plasma nitriding (CCPN) experiments were carried out varying both treatment temperature and time, as well as the content of nitrogen in the gaseous atmosphere, producing nitrided layers with different depths and microstructures on the material surface. The results showed that maximum wear resistance is achieved when CCPN is carried out at 520°C, for 10 h, using 20% N2 in the gaseous atmosphere. Under such condition, a nitrided layer of about 200 μm thickness, free of white layer and precipitates in grain boundary, is obtained. Increasing the amount of nitrogen in the gaseous atmosphere up to 30% nitrogen also led to a significant increase in the surface hardness; however, no additional increasing in the abrasive wear resistance of the material is obtained due to lower layer thickness.
Technical Session
COMPUTATIONAL STUDY OF THERMOMECHANICAL PROCESSING OF ZIRCONIUM ALLOY FOR NUCLEAR APPLICATION
Presenter(s): BERNARDO POMPERMAYER EDUARDO (UNIVERSIDADE FEDERAL DO RIO DE JANEIRO), Fillype Iang Cotegipe (UNIVERSIDADE FEDERAL DO RIO DE JANEIRO), Rafaella martins ribeiro (UNIVERSIDADE FEDERAL DO RIO DE JANEIRO)
Abstract:
Zirconium alloys are extensively used in the nuclear industry due to their low neutron absorption, excellent mechanical properties and corrosion resistance. Fuel rods and spacers are made of zirconium alloys, which are manufactured through a commercial route. During the processing route, the alloy is subjected to hot and cold rolling, which directly impacts the materials final properties. DEFORM, a software tool that replicates forming processes using finite element analysis, is employed in this study to simulate the rolling of Zircaloy-4 sheets. The objective is to develop a computational model capable of replicating the rolling process and processing routes. The results obtained demonstrated that the simulations effectively replicated the behavior of Zircaloy-4 during rolling, with a maximum error of 8.5%.
Technical Session
MICROHARDNESS OF PHASES IN FeAlNbC STEELS QUENCHED IN WATER AND OIL
Presenter(s): EUSTAQUIO DE SOUZA BAETA JR (UNIVERSIDADE DO ESTADO DO RIO de janeiro), Letícia dos Santos Aguilera (UNIVERSIDADE DO ESTADO DO RIO de janeiro), José Brant de Campos (universidade do estado do rio de janeiro), Suzana Bottega Peripolli (universidade do estado do rio de janeiro), Kellen Venâncio dos Santos (universidade do estado do rio de janeiro), Camila Alves Pelicarto da Silva (universidade do estado do rio de janeiro), Amanda Almeida de Castro (universidade do estado do rio de janeiro)
Abstract:
Aluminum-alloyed lightweight steels have gained notoriety due to their combination of low density and high mechanical strength. The processing of these steels mainly involves hot rolling and controlled cooling. The recent development of these steels generates the need for further studies on microstructure under different cooling conditions. This work aims to evaluate the microstructure of two FeAlNbC steel alloys subjected to Normalization, Water Quenching, and Oil Quenching. The characterization of the phases present according to each heat treatment was performed through Scanning Electron Microscopy and Vickers Microhardness images. The normalized sample presents a δ-ferrite matrix, retained austenite, and α-ferrite lamellae with κ-carbide, while the quenched samples presented martensite. The alloy with the lowest aluminum content presented higher hardness in all conditions and water quenching promoted the greatest hardening of the phases.
Technical Session
CHARACTERIZATION OF ALUMINIUM ALLOY 4032 AFTER EXTRUSION FORMING
Presenter(s): KARINA CARBONE MACIEIRA (FUND UNIVERSIDADE FEDERAL DO ABC UFABC), Anibal de Andrade Mendes Filho (FUND UNIVERSIDADE FEDERAL DO ABC UFABC)
Abstract:
Aluminum alloy 4032 has a good thermal stability, high corrosion and wear resistance. It is used in automotive parts that work at high temperatures and under severe mechanical stress. In this work, mechanical and metallographic characterization was carried out considering four conditions: homogenized material before plastic deformation, extrusion-formed profile, extruded and annealed profile, and extruded profile in T6 condition. It was possible to observe the microstructural and mechanical properties evolution of the alloy after plastic deformation and heat treatment. The microstructure shows a noticeable reduction in the size of the second phase particles and precipitates, as well as an improvement in their distribution. In terms of mechanical properties, two big leaps in the tensile strength limit can be seen: after plastic forming, where it reaches 200 MPa, and after heat treatment in T6 temper, where it reaches 363 MPa.
Technical Session
CREEP BEHAVIOR OF 1Cr0.5Mo STEEL IN THE VIRGIN AND EX-SERVICE CONDITIONS WITH CONSTANT STRESS AND CONSTANT LOAD CREEP TESTS. PART 2: RELATIONS AMONG MINIMUM CREEP RATE, STRESS AND TEMPERATURE
Presenter(s): LEVI DE OLIVEIRA BUENO (STM IND E COM DE MAQUINA E SISTEMAS TESTES EM MATERIAIS LTDA), josé francisco dos reis sobrinho (IFECT-IFPI)
Abstract:
Creep tests under constant load and constant stress were used in the study of minimum creep rate behavior of 1Cr0.5Mo steel in two microstructural conditions: in the virgin state and in the ex-service condition after 15 year operation at a nominal temperature of 550°C.Graphs or drop of variation of minimum creep rate with stress were plotted in the four different test conditions, as well as graphs of the variation of minimum creep rate with the inverse of temperature to the identify the values of the apparent creep activation energy for data parameterization using the Zener-Hollomon method. The four parametric curves of the material LOG(Z)xLOG(Stress) are compared with each other, observing that the results with tests at constant stress have a tendency to overestimate the creep strength of the material in relation to tests under constant load, however with a trend for the four curves to converge for increasingly lower values of stress. Monkman-Grant graphs are also presented for the four studied conditions of the material
Technical Session
INFLUENCE OF SPINODAL DECOMPOSITION ON MICROSTRUCTUREAND MECHANICAL BEHAVIOR IN TWO DUPLEX STAINLESS STEELS AFTER COLD ROLLING AND HEAT TREATMENT
Presenter(s): LOREN KELLY DE PAULA INÁCIO (UNIVERSIDADE FEDERAL DE MINAS GERAIS), Dagoberto Brandão dos Santos (UNIVERSIDADE FEDERAL DE MINAS GERAIS), Raphael França Assumpção (UNIVERSIDADE FEDERAL DE MINAS GERAIS), Isabela Giovana de Oliveira (UNIVERSIDADE FEDERAL DE MINAS GERAIS), Anna Julia Cassimiro Prado Mitre de Oliveira (UNIVERSIDADE FEDERAL DE MINAS GERAIS), SOFIA DA CRUZ SOUZA (UNIVERSIDADE FEDERAL DE MINAS GERAIS), Arthur Barreiro Sakai (UNIVERSIDADE FEDERAL DE MINAS GERAIS)
Abstract:
This study investigated the effects of cold rolling and heat treatment on 2205 and 2304 duplex stainless steels. Samples were subjected to different ageing times at 500°C as received and after cold rolling. The microstructures were analyzed by scanning electron microscopy (SEM) and X-ray diffraction (XRD). The mechanical behavior was analyzed by Vickers microhardness and tensile tests. The main objective was to detect spinodal decomposition in the samples and its influence on the mechanical properties. Strain-induced martensite formation and spinodal decomposition were observed in the rolled samples. In sample 2304, spinodal decomposition was also noted in the as-received condition. Characterization of spinodal decomposition was based on the mottled appearance, which became more pronounced with longer annealing times. Throughout the aging process, both hardness and tensile strength exhibited noticeable enhancements, however this came at the expense of reduced ductility
Technical Session
PARAMETER SURVEY OF FUSION FOR THE MANUFACTURE OF NEW COMPOSITIONS OF NANO-STRUCTURED BAINITIC STEELS
Presenter(s): rodrigo xavier moraes (ufrj), Adriana da Cunha Rocha (ufrj), Pedro Enrique Monforte Brandão Marques (ufrj), Rafella Martins Ribeiro (ufrj), José Roberto de Souza Júnior (vallourec)
Abstract:
Bainitic nanostructured steels offer an excellent combination of mechanical strength and ductility. One of the techniques conventionally used to process them is austempering. However, their industrial application is still limited due to long treatment times. The process kinetics have been gradually accelerated through the study of new compositions. In this work, the preparation process of a proposed alloy is addressed, aided by computational simulations and subsequently executed through melting and heat treatment processes. The results showed values within the expected range, confirmed by characterizations carried out through optical microscopy, scanning electron microscopy, optical emission spectroscopy, and conventional X-ray diffraction.
Technical Session
EFFECT OF TIME BETWEEN FRICTION STIR PROCESSING (FSP) PASSES ON THE MICROSTRUCTURE AND HARDNESS OF 7075-T651 ALUMINUM ALLOY
Presenter(s): SAULO BRINCO DINIZ (CENTRO FEDERAL DE EDUCAÇÃO TECNOLÓGICA CELSO SUCKOW DA FONSECA), Rosi Hellen Caldas Carioca (CENTRO FEDERAL DE EDUCAÇÃO TECNOLÓGICA CELSO SUCKOW DA FONSECA), Lucas Moura Montenegro Reis (INSTITUTO MILITAR DE ENGENHARIA), Hiron Akira Yamada Magalhães (CENTRO FEDERAL DE EDUCAÇÃO TECNOLÓGICA CELSO SUCKOW DA FONSECA), André Ferrara Carunchio (Instituto de Pesquisas Tecnológicas), Carolina Paiva Nascimento Silva (Instituto de Pesquisas Tecnológicas), Leonardo Martins da Silva (Universidade Federal Fluminense), Sergio Neves Monteiro (Instituto Militar de Engenharia)
Abstract:
In recent years, several works have been developed in Friction Stir Processing (FSP), which mainly correlate process parameters with microstructures / properties obtained, and among the least studied parameters, the time between passes stands out. This work study the changes in microstructure and hardness caused by varying the time between passes (0 and 5 minutes) when performing FSP on a 7075-T651 aluminum alloy. For this purpose, analyzes were carried out by Optical and Scanning Electronic Microscope, Rockwell HR30T Surface Hardness and Vickers Hardness. It was found that hardness has a tendency to increase with the completion of an adjacent pass, with these hardnesses being lower than the hardness of the material before processing. This behavior is possibly related to the decrease in the volumetric fraction of precipitates, resulting from thickening
Technical Session
9/4/24, 3:40 PM - 9/4/24, 4:30 PM
Presenter(s): Wellington Bruno Silva de Jesus (IME - INSTITUTO MILITAR DE ENGENHARIA )
Abstract:
Modern industry's increasing demand for materials with high and specific properties requires an in-depth knowledge of the solidification process of metals and metal alloys. This work aimed to quantify the intermetallics formed during the solidification process of the multicomponent alloy Al-33%-1%Ni-1.2%Ta in an upward directional device, enhancing the novelty of this alloy. Characterization was performed on a sample by metallography, followed by scanning electron microscopy (SEM) analysis. After obtaining the micrographs in representative regions where the intermetallics were identified, the lamellar spacing of the Al2Cu (λL1), the area of the intermetallic in the shape of a star, and the lamellar spacing of the eutectic around the star (λL2) were measured. The results were also compared with previous studies, and showed the significant influence of thermal parameters on the formation reactions of intermetallics along the ingot.
Technical Session
MICROSTRUCTURAL CHARACTERIZATION OF PHS 1500 AND 2000 STEEL BY COLOR METALLOGRAPHY
Presenter(s): yGOR TADEU BISPO DOS SANTOS (SENAI CIMATEC), tIAGO NUNES LIMA (SENAI CIMATEC), rODRIGO SANTIAGO COELHO (SENAI CIMATEC), cLÁUDIA TERESA TELES FARIAS (IFBA)
Abstract:
The press-hardened steels (PHS), play a crucial role in the automotive industry, being used in the manufacturing of vehicle bodies due to their high mechanical strength. This strength is achieved through hot stamping, which transforms ferritic/pearlitic structures into martensitic structures. However, other phases can form and the final microstructure can present regions with different types of bainite, martensite tempering and even retained austenite. Quantifying these phases after hot stamping is not an easy task, since the techniques present difficulties in differentiating refined microstructures. The use of color etching emerges as a little explored alternative to characterize these steels, providing selective contrast in the microstructure. This study describes the microstructural characterization through colored metallography in four etching steps, under three different conditions. The results revealed a clear distinction between the various conditions, providing valuable information about the microstructure of the analyzed steels.
Technical Session
MICROABRASIVE WEAR RESISTANCE OF DUCTILE IRON TREATED BY QUENCHING AND PARTITIONING PROCESS
Presenter(s): ANDRE CAETANO MELADO (IFES ), Gabriel Gonçalves Florêncio (IFES), Estéfano Aparecido Vieira (IFES), Hélio Goldenstein (USP)
Abstract:
In this work, the microabrasive wear resistance of a ductile iron, with commercial chemical composition, subjected to a heat treatment of quenching and partitioning was evaluated. The treatment consists of heating the material to 880ºC for a time of 2 hours, for complete austenitization, followed by quenching in oil to a temperature of 140ºC, intermediate to the temperatures Ms and Mf, to form a controlled amount of martensite. Then, the material was reheated to 300 and 375ºC (partition treatment) for different times (15, 60 and 120 minutes), and was subsequently cooled in air to room temperature. Optical microscopy (OM) and scanning electron microscopy (SEM) techniques were used for the microstructural characterization of the material obtained. The microabrasive wear test was of the “free sphere” type. The results showed a gain in wear resistance of the heat-treated material. A low carbon enrichment in austenite, in the partitioning step, can lead to the formation of brittle martensite and a reduction in microabrasive wear resistance. The longer partition times produced more wear-resistant microstructures at both temperatures tested in this work.
Technical Session
MICROSTRUCTURAL EVOLUTION OF 718 ALLOY UNDER DIFFERENT SOLUBILIZATION AND AGING CONDITIONS
Presenter(s): FABIO DA COSTA GARCIA FILHO (CEFET- RJ - AV. MARA), Roberto Matias Guimarães Brasileiro (CEFET-RJ), João Lucas Santos Lima de Oliveira (CEFET-RJ), Laura Setti de Sousa (IME), Bernardo Soares Avila de Cêa (IME), Sergio Neves Monteiro (IME)
Abstract:
The mechanical properties of nickel-based superalloys, particularly 718 alloy, are mainly improved by precipitation mechanism. Precipitation of phases such as γ ’and γ” promotes a substantial increase in mechanical properties, which can be verified by the hardness of the material. However, such phases are metastable which, under certain conditions, can give rise to stable phases, the phase. This phase has a deleterious effect on 718 alloy and directly impacts the mechanical properties. The objective of the present work was to verify the variation in hardness of the 718 alloy, for different solubilization temperatures and different aging times, to determine the condition of better mechanical properties. Vickers microhardness measurements and characterization of the microstructure by optical microscopy and X-ray diffraction (XRD) were used to verify the evolution of these alloys over the chosen treatments. It was observed that the highest solubilization temperature was able to dissolve the precipitates of the as-received condition, but on the other hand, it promoted grain growth, which caused a decrease in hardness. The maximum hardness was observed for 15h aging time for solubilization conditions.
Technical Session
PULSED PLASMA NITRIding ASTM A36: HARDNESS AND MICROSTRUCTURE
Presenter(s): FABIO DA COSTA GARCIA FILHO (CEFET- RJ - AV. MARA), Roberto Matias Guimarães Brasileiro (CEFET), João Lucas Santos Lima de Oliveira (CEFET), Laura Setti de Sousa (IME), Bernardo Soares Avila de Cêa (IME), Sergio Neves Monteiro (IME)
Abstract:
The pulsed plasma nitriding (PPN) thermochemical treatment is used as an alternative to improve the surface properties of metals, such as: increasing surface hardness, improving wear resistance and prolonging fatigue life. In addition, this technique allows creating a barrier to the diffusion of hydrogen reducing the susceptibility to hydrogen embrittlement. In this study, the effect of this treatment on ASTM A36 steel is analyzed through two different nitriding times, 5 and 15h. In both cases, the temperature was maintained at 300ºC. Thus, to verify the results, measurements of Vickers microhardness and metallographic observation were performed under an optical microscope. A substantial increase in hardness was observed for condition 02 in addition to a thick nitride layer.
Technical Session
9/4/24, 3:40 PM - 9/4/24, 4:30 PM
Presenter(s): PALOMA SUELLEN LIMA DE SOUSA (UFPA), dIOGO mONTEIRO PORFÍRIO (IFPA), DAMARES DA CRUZ BARBOSA NASCIMENTO (UFPA), VERONICA SCARPINI CANDIDO (UFPA)
Abstract:
1080 steel is a key material in infrastructure, due to its high hardness and wear resistance. This study investigated the effects of heat treatment by quenching on SAE 1080 carbon steel. For this purpose, steel samples were heated to 900°C for 30 minutes and quickly cooled in water. The methodology included microstructural analysis by optical microscopy and hardness assessment according to the ABNT NBR ISO 6508-1 standard, in addition to grain size measurement with ImageJ software. Initially, steel had a structure composed of pearlite and ferrite, giving it a combination of hardness and ductility. After quenching, the microstructure transformed predominantly into martensite, resulting in an average hardness of 55 HRC, indicating a uniform transformation. Most grains had small areas, reflecting a fine and homogeneous microstructure after treatment. It was concluded that water quenching significantly increases the hardness of 1080 steel, although the absence of a subsequent tempering treatment may maintain brittleness due to high residual stresses. Thus, the quenching process is effective for applications where high hardness is required, but additional tempering is recommended to improve toughness and impact resistance.
Technical Session
9/4/24, 3:40 PM - 9/4/24, 4:30 PM
Presenter(s): PEDRO ENRIQUE MONFORTE BRANDAO MARQUES (UFRJ), Felipe Sampaio ALencastro (UFRJ), Renata Antoun Simão (ufrj), Adriana da cunha rocha (ufrj)
Abstract:
This work proposes methodology to design and synthesize a high entropy alloy (HEA) with refractory properties in the form of a protective thin film. The goal is to deposit a film with characteristic microstructure of HEA, with the presence of a disordered solid solution matrix. To perform the alloy design, a minimum set of target properties of interest for the alloy was defined, in this case the yield strength, oxidation resistance and raw material cost. From these properties, six constituent elements were chosen. An artificial intelligence model was developed to determine the optimal chemical composition from public data mined from the literature. Once designed, the alloy was deposited over a substrate, by magnetron sputtering technique, using power balancing to achieve the optimal composition on three chosen targets. Two samples were deposited, one with homogeneous deposition, and another with static sample carrier. Characterization of the samples concluded that a chemical and morphological homogeneous single-phase BCC microstructure was achieved, and revealed the presence of the high mixing entropy and severe lattice distortion HEA’s fundamental effect.
Technical Session
REPRODUCTION OF SECONDARY HARDENING UNDER DIFFERENT TEMPERING CONDITIONS OF AISI D2 COLD WORK TOOL STEEL
Presenter(s): Maycoln depianti Conci (Ifes), DANY MICHELL ANDRADE CENTENo (IPT), HÉLIO GOLDENSTEIN (usp), rene ramos de oliveira (ipen), Paula Fernanda da Silva Farina (unicamp)
Abstract:
Parameters are used to estimate relationships between time and temperature that produce similar effects in tempering. This study proposes to analyze different tempering conditions of AISI D2 tool steel, quenched at 1040 ºC, and the possibility of reproducing the secondary hardening peak obtained in conventional tempering, which occurs at around 500 ºC. Increasing the tempering temperature to 600 ºC, the Hollomon-Jaffe parameter suggests treatment in minutes, and for 700 ºC, in seconds. Results from dilatometry, X-ray diffraction, microscopy, hardness measurement, and residual stress analysis show that at 700 ºC over-tempering, carbide precipitation results in hardness similar to annealing, with a microstructure analogous to recrystallization. Microstructural changes alter residual stresses, maintaining hardness in tempering up to 600 ºC, limiting the Hollomon-Jaffe parameter's predictions in reproducing secondary hardness in tempered AISI D2 steel.
Technical Session
9/4/24, 3:40 PM - 9/4/24, 4:30 PM
Presenter(s): Salvatore Giuliano Peixoto Tropia de Abreu (UFOP), Maderson Machado de Paula Junior (UFOP), Rodrigo Rangel Porcaro (UFOP), Igor Cezar Pereira (UFOP)
Abstract:
The NIAC (Near Immersion Active Cooling) has been developed as an active cooling alternative for parts manufactured by WAAM (Wire + Arc Additive Manufacturing), aiming to improve the quality, efficiency, and productivity in the additive manufacturing of parts. Thus, this work aims to discuss the feasibility of water level control techniques for application in NIAC processes. Due to the need to keep the water level close to the fusion pool throughout the deposition, the importance of precise level control is highlighted to avoid problems in the microstructure of the deposited material, especially concerning the occurrence of porosities. Three control methods are presented: two based on sensors—water level sensor and ultrasonic sensor—and a third method using a timer. In all the proposed methods, an open-source microcontroller like the Arduino Uno was used to control the system logic. It was observed that all the proposed methods are effective if implemented for the NIAC technique, presenting specific advantages and disadvantages such as cost, complexity, and control accuracy.
Technical Session
9/4/24, 3:40 PM - 9/4/24, 4:30 PM
Presenter(s): THAISSA SAMPAIO NUNES (Instituto Militar de engenharia), Julianna magalhães garcia (instituto militar de engenharia), Talita gama de sousa (instituto militar de engenharia), Louriel oliveira vilarinho (universidade federal de uberlândia), Luiz Paulo mendonça brandão (instituto militar de engenharia)
Abstract:
In this study, an analysis of stainless steel 316L Si was conducted, comparing its forms as welding wire and deposited by arc additive manufacturing, using X-ray diffraction (XRD). PANalytical's HighScore Plus software was employed to facilitate the indexing and quantification of the phases present, as well as to conduct analyses of crystallite size, microstrain, and dislocation density. The main results indicated that the austenitic phase predominated in both materials, being 98.9% in the wire and 90.2% in the deposited material. The presence of delta ferrite was limited in the deposited material, at approximately 9.8%. Sigma phase was detected only in the wire in a low volumetric fraction (approximately 1.1%), while it was not identified in the deposited material. Furthermore, dislocation density was measured in both the wire and the deposited material, with higher values in the latter. Considerations regarding XRD characterization revealed challenges in distinguishing between crystallite size and microstrain, especially in materials with high residual stresses. The results demonstrated that the deposition method affects the microstructure of stainless steel 316L Si, providing a deeper understanding of the characteristics and potentialities of this material in different industrial applications. This study contributed to advancing knowledge about the microstructure of stainless steel 316L Si in its different forms, highlighting the importance of XRD analysis and the use of advanced software for precise data interpretation.
Technical Session
9/4/24, 3:40 PM - 9/4/24, 4:30 PM
Presenter(s): ALICIA REGINA ZANON BARBOSA (UNIVERSIDADE FEDERAL DO PARá), Yan Christian Silva de Araújo (UNIVERSIDADE FEDERAL DO PARá), Eric Elian Lima Espíndola (UNIVERSIDADE FEDERAL DO PARá), Luane Luiza Pereira Marques (UNIVERSIDADE FEDERAL DO PARá), Maria Adrina Paixão de Souza da Silva (UNIVERSIDADE FEDERAL DO PARá), Amanda Lucena de Medeiros (UNIVERSIDADE FEDERAL DO PARá), Deibson Silva da Costa (UNIVERSIDADE FEDERAL DO PARá)
Abstract:
With the expansion of transmission (Tx) and distribution (Dx) networks for electrical energy due to urban development and the constant growth of the industrial sector, it becomes necessary to enable low-cost materials that provide good properties for the manufacturing of Tx and Dx cables. Therefore, this study aimed to analyze the macrostructure and the electrical and mechanical properties of the Al-0,5%Si alloy, as well as the influence of adding 0,3% nickel (Ni) and annealing heat treatment. Metallography, electrical resistance, and tensile tests were conducted to obtain the results, which were subsequently analyzed and compared. The results showed that Ni caused elongation in the crystal structure, while annealing altered the grain orientation. Electrical conductivity showed a small increase from 61% to 61,23% IACS in untreated alloys, while annealing raised the property to 67,99% IACS. Tensile strength results evidenced an increase from 185 to 254,25 MPa with the addition of Ni, but after annealing, there was a decrease to 93,30 MPa. Therefore, it was found that the addition of Ni modified the structure and significantly affected the material's strength, and annealing contributed to the enhancement of electrical conductivity.
Technical Session
9/4/24, 3:40 PM - 9/4/24, 4:30 PM
Presenter(s): Yan christian silva de araújo (UFPA), Alicia Regina Zanon Barbosa (ufpa), ERIC ELIAN LIMA ESPÍNDOLA (ufpa), DEIBSON SILVA DA COSTA (ufpa)
Abstract:
The Brazilian industrial sector demands more electrical energy due to rural modernization, urban expansion, and technological development. To meet this demand, it is necessary to modernize transmission lines throughout the country. Currently, aluminum is widely used due to its electrical conductivity, lightness, malleability, and mechanical strength. However, Aluminum Cables (CA), made with 1350 alloy, have low mechanical strength. Studies have been conducted to improve the mechanical strength of CA cables by adding nickel to the aluminum alloy. Nickel forms intermetallic compounds such as Al3Ni, which enhance mechanical strength and refine the material's structure. In summary, nickel has proven effective in improving the structural, electrical, and mechanical properties of aluminum alloy 1350.
Technical Session
DEVELOPMENT OF A NEW HAMMER TO INCREASE THE LIFE CYCLE OF THE DEBURRING MACHINE
Presenter(s): PEDRO Victor GOMES DA SILVA (ternium brasil), GIOVANI DELFIM apolinario (TERNIUM BRASIL), agenor gustavo martins de carvalho (TERNIUM BRASIL), valdiney ribeiro soares (ternium brasil)
Abstract:
When cutting the cast slabs, burrs are generated on the front and back face of the slab, making it necessary to use a deburrer to remove the undesirable material. The deburrer is made up of two rotors with 356 hammers each that remove the burr through the mechanical shock of the external part of the hammer with the burr on the slab. Continuous use of the hammer wears out its surface, resulting in a reduction in the efficiency of the deburrer, making it necessary to change the set of hammers. To increase the life cycle of these hammers without compromising their efficiency, a new deburring hammer with a higher concentration of alloying elements was evaluated in place of the old material. In addition to metallographic and mechanical experiments, tests were carried out with the hammer on the deburrer, with microstructural and mechanical superiority noted, resulting from its chemical composition and heat treatment, which resulted in greater efficiency and performance of its function, as well as a longer life cycle. As a consequence, changing the hammers represented a considerable reduction in labor and material costs, as well as less loss of productivity due to machine interruptions to change the hammers.
Technical Session
9/4/24, 3:40 PM - 9/4/24, 4:30 PM
Presenter(s): WESLEY ROSSI PIMENTA (CSN), lUIS EDUARDO SMECELATO MALDONADO (CSN), MARCIO PEDROSO BASTOS (CSN), RODRIGO CARVALHO DE PAULA (CSN), ELIOMAR JUNIOR TEIXEIRA MACHADO (CSN)
Abstract:
This paper presents the development and implementation of an automated strip centering system in CSN's galvanizing line, aiming to enhance the precision and efficiency of strip position control. Using photoelectric transducers to measure the strip's position and a Siemens CPU 416 PLC to process the data and control a motor that adjusts the guide roll position, the system reduces the reliance on manual control and improves process reliability. The control model was implemented in a closed-loop system with continuous feedback of the strip position. The results showed a significant improvement in the precision of strip position control, with a substantial reduction in average error and increased consistency of the galvanizing process. Data analysis indicated that the system can adjust to different strip widths, maintaining high precision and minimizing deviations. The observed variability was attributed to the inclusion of a dead band in the control system, designed to smooth operation due to system dynamics. Besides the technical benefits, the project had a low implementation cost by leveraging existing equipment and generated valuable knowledge for the engineering and operation teams, enabling them for future automation projects and continuous improvements.
Technical Session
IMPLEMENTATION OF IOT IN WATER TREATMENT PLANT FOR LEAK DETECTION BY TELEMETRY USING MICROCONTROLLER
Presenter(s): ANA BEATRIZ DAS NEVES CONCEICAO (IFPA/UFPA), Jossylyn Dayanny Casseb Campos (IFPA), DENIS CARLOS LIMA COSTA (IFPA), Verônica Scarpini Candido (UFPA)
Abstract:
The implementation of the Internet of Things (IoT) in a water treatment plant (WTP) enables the collection of data and the detection of anomalies that indicate potential leaks, promoting the use of low-cost equipment in a control and automation engineering system using microcontrollers. In this study, we will use sensors connected to the Wi-Fi network to collect information about the water level and transmit this data to a central system. The software processes this information and, using appropriate algorithms, identifies patterns that indicate leaks. This allows for a quick and effective response, minimizing waste and damage to the water distribution system. The IoT and telemetry-based automation system was implemented in the WTP of a company, and its data served as the basis for the development of this article.
Technical Session
Monitoring of Underground Mines with Wireless Networks: Strategies to Enhance Operational Efficiency
Presenter(s): Igor henrique lima da silva (IFRN), Maria luiza lima da silva (ifrn), Flánelson Maciel monteiro (ifrn), tércio graciano machado (ifrn), Djalma Valério Ribeiro Neto (Ifrn)
Abstract:
The introduction of Information Technology (IT) on the factory floor is making the industrial process more "intelligent" and consolidating "Industry 4.0" through the use of large amounts of digitized data, communication networks, and increased computational processing power. In this new scenario, wireless network technology for underground mine monitoring is a milestone in the industrial revolution, being essential to optimize extraction and improve communication and safety in underground operations. This study aims to analyze articles on the IEEE Xplore platform to provide an in-depth view of these technologies in underground environments. The objective is to understand the behavior and effectiveness of each technology in these complex contexts. It addresses the monitoring of underground mines using wireless networks, highlighting the main technologies, their benefits, potential applications, and implementation challenges. It discusses how these technologies adapt to challenging environments like underground mines and the benefits they bring to the mining environment.
Technical Session
ANALYSIS OF THE TECHNICAL AND THERMODYNAMIC PROPERTIES OF STEEL LADLE SLIDE GATE VALVE FILLER SANDS
Presenter(s): Letícia de Matos (UFRGS - CAMPUS DO VALE), Wagner Viana Bielefeldt (UFRGS), Saulo Roca Braga (UFRGS)
Abstract:
The secondary steel refining process uses refractory sand as an insulating thermal barrier that separates the liquid metal from direct contact with the valve system that controls steel leakage. The efficient use of such practice provides a high rate of free opening, impacting on increasing the productivity and quality of the steel, reducing the number of stoppages, thermal losses and even the reoxidation of the steel. Many operational variables and material characteristics influence the free opening rate. The properties of these materials and the relevant process parameters were evaluated as a function of the free opening rate under operating conditions. The percentage of free opening is also strongly influenced by the time and temperature of the steel in the ladle. In view of this, a thermodynamic study of two sets of filler sands was carried out. The characterizations of the materials were made through particle size analysis, X-ray fluorescence (X-ray), carbon content, and flowability index. The free opening rate has been presented. In addition, thermodynamic simulations were performed using the FactSage 8.3 software, which calculated the percentage of all phases present in the compositions of chromite sealing sand and high zircon content as a function of temperature
Technical Session
FURNACE PROJECT FOR ECAP PROCESS: FINITE ELEMENT SIMULATION AND CAD DRAWING
Presenter(s): PHILLIPI GONCALVES ROCHA (Instituto MILITAR DE ENGENHARIA), beatriz maria venancio dos santos (instituto militar de engenharia), Julianna magalhaes Garcia (INSTITUTO MILITAR DE ENGENHARIA), Luiz Paulo Mendonça Brandão (INSTITUTO MILITAR DE ENGENHARIA), Talita Gama de Sousa (INSTITUTO MILITAR DE ENGENHARIA), Bruno rangel da silva (centro brasileiro de pesquisas físicas), Rodrigo Felix de Araujo Cardoso (CENTRO BRASILEIRO DE PESQUISAS FÍSICAS)
Abstract:
The aim of this study was to develop a new resistance electric furnace project for the hot ECAP process, aiming to reach temperatures of up to 800°C, with a safety margin up to 1000°C. The methodology included a literature review to establish thermodynamic and metrological parameters, computational simulations of heat transfer, and material selection. The final model was obtained through iterative simulations in SolidWorks and Ansys, considering different insulation and refractory materials. The results demonstrated the feasibility of the project, with the furnace being able to reach the desired temperatures safely, using non-flammable and low-density materials. It was concluded that the project fully met the proposed objectives, integrating theoretical and practical knowledge. Future perspectives include building a prototype for testing thermal insulation efficiency and resistance to compressive forces, as well as presenting the results at academic conferences.
Technical Session
FINITE ELEMENT SIMULATIONS APPLIED TO HONEYCOMB (REENTRANT) STRUCTURES - A BRIEF REVIEW
Presenter(s): RAI FELIPE PEREIRA JUNIO (IME), Luiz Felipe Santiago Proença (IME), Rafael da Fonseca Guedes (ime), José Carlos Ferreira Fontes (UNISUAM), SERGIO NEVES MONTEIRO (IME), LUCIO FABIO CASSIANO NASCIMENTO (IME)
Abstract:
Honeycomb structures are increasingly standing out in terms of both degree and number of technological applications, particularly those with reentrant hexagonal geometry. These structures are recognized for their lightweight nature, high rigidity, and energy absorption capabilities, especially in ballistic armor applications. The reentrant morphology imparts auxetic behavior to the structures, with a negative Poisson's ratio, resulting in shear resistance, buckling resistance, and fatigue crack propagation superior to conventional structures. The Finite Element Method (FEM) is highlighted as a valuable tool for simulating the properties of these structures, allowing for preliminary studies without the need for physical sample fabrication. FEM has been applied in various areas, ranging from static and dynamic analysis to evaluating behavior under unidirectional compression, explosion, ballistic impact, and projectile penetration. Computational simulation enhances this field by increasing the number of possibilities to accurately predict the behavior of these structures, such as simulating deformation after ballistic impact and correlating identified stress concentration points. These results underscore the importance of FEM in assessing the behavior of these structures, providing valuable insights for practical application development
Technical Session
STUDY AND ANALYSIS OF PERFORMANCE INDICATORS TO ASSESS THE IMPACT OF QUALITY CONTROL IN A SECONDARY LEAD METALLURGY
Presenter(s): REBECA ALBINO DE JESUS (ACUMULADORES MOURA S-A - BELO)
Abstract:
Waste batteries are raw materials for the process of obtaining secondary lead and when refined and applied in a process called hydrometallurgical, ingots are obtaneid , which is applied to an energy accumulator. The ingots might present some defects during their formation, which will impact the customer's process. In this way, and with an emphasis on customer satisfaction, strategic processes focused on quality were centralized and standardized in an area with the aim of optimizing costs, increase quality and production based on the QMS (ISO 9001:2015). Therefore, the entire performance analysis of the applied strategies was observed through internal and external performance indicators. The internal actions focused at improving the process were built based on the communication and collaboration interface between the areas of quality control, maintenance and production. The comparison of the first five months of the years 2023 and 2024, it is possible observe a minimization of the defects presented by the current product, in relation to the internal indicator. In relation to the external indicator, a positive variation of 15.44% is observed in relation to the customer satisfaction score, when analyzed in recent years.
Technical Session
9/4/24, 3:40 PM - 9/4/24, 4:30 PM
Presenter(s): RUBIANE VITORIA SOUZA OLIVEIRA (uff), Nykolle Fabiane Camilo Fernandes (uff), Tatiana das Chagas Almeida (uff), Letícia Vitorazi (uff)
Abstract:
The present study investigated the incorporation of the corrosion inhibitor 4-methylimidazole into structured layers of the polyelectrolytes PDADMAC and PAA on a glass substrate using the layer-by-layer (LbL) technique. The interaction between PDADMAC and PAA polyelectrolytes was initially observed at pH 10 through their mixture. Subsequently, the zeta potential of the corrosion inhibitor was measured at pH 10, which was negative. Consequently, the LbL deposition method was applied to form six alternating layers of polyelectrolytes interspersed with the corrosion inhibitor. The inhibitor incorporation was evaluated based on release studies at different pH values, indicating the successful incorporation of the corrosion inhibitor into the polyelectrolyte layers.
Technical Session
Analysis of microstructural characteristics of samples metals using MATLAB/MTEX from results obtained by SEM/ EBSD
Presenter(s): SAMARA DE SOUZA TARGINO (INSTITUTO MILITAR DE ENGENHARIA), Rebeca Correia Gomes Ferraz (IME), Marcell Parra Araújo Bernardo Silva (IME), Victor de Nery Barbosa (IME), Petrus Pinheiro de Farias (IME), Samara de Souza Targino (IME), Talita Gama de Souza (IME)
Abstract:
The acquisition of crystallographic information is of paramount importance in the field of Materials Science, being essential for understanding the properties and their variations in polycrystalline metals, for example. To conduct such studies, tools that provide tutorials on how to apply codes that enable the analysis of data obtained through SEM/EBSD are utilized by researchers. One of the widely used tools is MTEX, which aims to guide users on how to apply and manipulate codes in MATLAB to obtain the necessary images for sample analysis of the metal (subject of study). However, despite being open-source software, its operation requires some prior knowledge in areas such as mathematics and programming. Recognizing these challenges, the objective of this article is to provide a comprehensive manual that simplifies the use of MTEX, making it more accessible and understandable to a broader range of users. This aims to facilitate data manipulation and study in this field of materials analysis, thereby contributing to the advancement of academic research conducted in the area of Materials Science.
Technical Session
9/4/24, 3:40 PM - 9/4/24, 4:30 PM
Presenter(s): Samuel moreira costa (Universidade de são paulo)
Abstract:
Corrosion is a natural degradation process that affects metals through chemical or electrochemical action of the environment. Stainless steels are highly resistant to corrosion in a wide variety of conditions. This is due to the formation of a thin, stable chromium oxy-hydroxide film on the surface, which prevents aggressive species from coming into contact with the metal substate. The aim of this study was to evaluate the effect of varying experimental parameters on the localized corrosion resistance of AISI 316L stainless steel. For this, samples were submitted to scanning electron microscopy for microstructural characterization. For electrochemical characterization, cyclic polarization tests were carried out under various experimental conditions, varying the chloride concentration, the scanning current density and the polarization scanning speed. The results show the influence of the aggressiveness of chloride ions in solution and the importance of the charge generated during pitting corrosion for the phenomenon of repassivation. The study thus verifies the expected effect of these experimental variables on the localized corrosion of AISI 316L stainless steel.
Special Session
9/4/24, 4:30 PM - 9/4/24, 5:15 PM
Presenter(s): Opening: Valdomiro Roman da Silva; ABM Director of Operations Closing: Horacidio Leal Barbosa Filho; ABM Executive President
Abstract:
Plenary
9/4/24, 5:15 PM - 9/4/24, 7:30 PM
Presenter(s): Coordinators: Aristidis Betzios; Key Account Manager at Danieli / Helênio Rezende; Consultant Paul Wurth Brazil (SMS group) Moderator: Erick Bispo Torres; CEO at ArcelorMittal Pecem
Abstract:
Technical Session
9/5/24, 8:10 AM - 9/5/24, 8:35 AM
Presenter(s): diana gomes ribeiro (Universidade estadual do norte fluminense darcy ribeiro ), césar Augusto siqueira crespo neto (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO ), Silvio Gonçalves Mendes (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO ), Sthefanie de Carvalho Mendes Lopes (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO ), Noan Tonini Simonassi (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO ), Elaine Cristina Pereira (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO )
Abstract:
The fracture in railroad tie bolts is among the factors that pose the greatest risk to train operations. The unrestrained oxidation of these bolts, which act at the rail junction, combined with loading efforts, can result in catastrophic fracture, impacting performance, safety, urban traffic, as well as the environment. Therefore, corrosion is a major challenge for railways, especially in freight transportation, where, in addition to critical sections such as coastal regions, humid tunnels, and level crossings, there are also lines dedicated to the transportation of salt and perishable products, which can reduce the service life of railroad tie bolts. In this sense, this work was developed based on a case study of a fractured bolt in the field. Upon reception, this same bolt was cut and divided into five specimens, which were prepared metallographically for subsequent optical microscopy and scanning electron microscopy. The results of these tests are presented in this work, highlighting the influence of corrosion on fracture occurrence.
Technical Session
9/5/24, 8:10 AM - 9/5/24, 8:35 AM
Presenter(s): GABRIEL DUARTE LOTT (VALE SA), Pedro Henrique de Moura Couto (vale), Mário Sérgio Santos (vale), Kaike Silva Albuquerque (vale), Cássio Pascoal Costa (vale), Alexandre Gomes Fonseca (vale)
Abstract:
In the present article, a conceptual proposition of typical control and optimization techniques for the crushing and screening process is made. A review of the technical literature was conducted, and it was observed that little attention is given to the crushing and screening stage. A succinct contextualization of the concepts of regulatory control, advanced control, and real-time optimization within process control is provided, demonstrating all the control layers that can exist within a plant. The implementation of various automation, control, and optimization strategies for the Conceição II beneficiation plant, located in Itabira-MG, operated by Vale S.A., is proposed. This circuit comprises four crushing stages and two screening stages, and potential gains will be explored given the observed average variability of about 30% in 2023 and a gap of 1374 t/h in relation to the circuit's capacity.
Technical Session
9/5/24, 8:10 AM - 9/5/24, 8:35 AM
Presenter(s): LUIS HENRIQUE MARIANO DA SILVA (DANIELI DO BRASIL LTDA)
Abstract:
Efficient logistics and material flow optimizations are key success factors for a steel plant. Spotting bottlenecks and flaws leaves room for improving the current processes and leveraging new investments to enhance plant productivity
Technical Session
PORT MANAGEMENT DIGITAL TWIN AND CONTROL TOWER INTEGRATION: NA APPROACH TO SUPPORT REAL-TIME DECISION MAKING
Presenter(s): Marcelo Koiti FUGIHARA (Belge consultoria), Daniel Vallarelli Gutierres (Belge consultoria), Alice Oliveira Fernandes (belge consultoria)
Abstract:
Discrete event simulation plays a pivotal role in facilitating decision-making within logistics, necessitating real-time initiation based on the current state of the system. The architecture outlined in this article integrates a real-time Digital Twin with simulation logic and a Control Tower into a cohesive model, thereby reducing offline efforts and runtime. Illustrated through a groundbreaking project in a Brazilian port, this integration seamlessly amalgamates data from diverse sources such as ERP systems, transportation schedules, and shipping agencies. This holistic approach offers a comprehensive overview of port operations and enables predictive insights for up to 72 hours in advance. Furthermore, the methodology optimizes berth allocations, resource scheduling, and accounts for dynamic factors such as tides and weather conditions. Beyond merely enhancing operational efficiency, it promotes proactive decision-making and adaptive resource allocation, marking a paradigm shift in port management.
Technical Session
9/5/24, 8:10 AM - 9/5/24, 8:35 AM
Presenter(s): William Leite Romano (Veolia - Water Technologies & SOlUTIONS ), Augusto Luis Marucci (VEOLIA - WATER TECHNOLOGIES & SOLUTIONS )
Abstract:
Brazil is one of the main steel producing countries in the world, occupying nineth position in the world ranking, it has a nominal production capacity of 50.3 million tons per year. The steel production process through an integrated plant consists of Load Preparation, Reduction, Steelmaking and Continuous Casting stages, and may also have Rolling Mill stages depending on the type of final product to be produced. Water is essential for the steel production process, but the sustainable practice of reducing, reusing, and recycling prevails in steel mills where commitment to the Environment is one of the organization's pillars. Given the need to increasingly reuse and cascate recovery water in production processes within the Steel Plant. Several improvements and adjustments are necessary, from investments in infrastructure to the replacement of water treatment technologies that can provide work with increasingly higher values for concentration cycle and consequently, reduction of consumption in open recirculation circuits. The concentration cycle is very important, but depends of several quality parameters were evaluated, which directly impact the Langelier Saturation Index (LSI). In this study, we identified the need to reduce “Chloride” levels in recirculating water, as they can be aggressive to in the middle, contributing to corrosive processes. The results obtained were supported by Veolia's expertise in an integrated and sustainable solution to the costumer, providing an alternative technology for the Industrial Water Clarification process, through coagulation stage with a low increase ion chloride.
Technical Session
ANALYSIS OF E-WASTE URBAN MINING IN BRAZIL THROUGH THE APPLICATION OF SYSTEMS DYNAMICS
Presenter(s): LÚCIA HELENA XAVIER (cetem), Emmanuelle Soares de Carvalho Freitas ()
Abstract:
One of the alternatives to the supply of critical and strategic minerals is the exploration of secondary resources, such as waste. A significant amount of natural resources is consumed to the production of electronic equipment, including critical and strategic minerals with potential of recovery and application in other production processes. The objective of this article is to analyze the potential of urban mining of electronic waste in Brazil by applying the system dynamics method - VESIM PLE software, to demonstrate the interaction between the variables that involve the e-waste value chain. The structuring of the interaction diagram allowed us to understand that there are processes that are more aligned with the requirements of the Brazilian Policy on Solid Waste, contributing to the circular economy. The method also makes it possible to highlight the aspects that can guide the decision-making process and the elaboration of public policies on the topic, in order to contribute to the sustainability of the sector
Technical Session
PREDICTION OF YIELD STRENGTH IN COLD ROLLED AND GALVANIZED STEELS AFTER REWORK ON A SKIN-PASS MILL
Presenter(s): felipe pereira finamor (arcelormittal brasil vega), José Osvaldo Amaral Tepedino (arcelormittal brasil vega), Mylena Inaiê Correia (ARCELORMITTAL BRASIL VEGA), silvio corrêa (ARCELORMITTAL BRASIL VEGA), fabiano josé kretzchemar (arcelormittal brasil vega), paulo roberto mei (universidade estadual de campinas - fem unicamp)
Abstract:
The steel industry constantly seeks to enhance its processes to optimize the production of steels with superior mechanical properties and surface characteristics while reducing production costs. Integrating machine learning methods emerges as a promising tool to assist in this endeavor. This study aims to explore the application of supervised machine learning techniques for predicting the yield strength of steels used in the automotive industry when subjected to an over-rolling process in a cold rolling mill due to problems related to surface finish or flatness. The modeling was based on the analysis of industrial historical data, including chemical composition, yield strength, and elongation rates before and after the skin pass. The achieved results demonstrated a mean absolute percentage error of 2.3% for the yield strength prediction and a coefficient of determination (R²) of 0.996, underlining the precision and effectiveness of the developed tool. These findings support the feasibility of implementing this model in an industrial context, significantly contributing to the optimization and accuracy of the mechanical properties of the produced steels and reducing the uncertainties of reworking these materials.
Technical Session
INFLUENCE OF HOT AND WARM ROLLING ON THE MICROSTRUCTURE, MECHANICAL PROPERTIES AND FORMABILITY OF AN IF-Ti STEEL
Presenter(s): saulo morais de andrade (USIMINAS), Fernando de Souza Costa (USIMINAS), Dagoberto Brandão Santos (Universidade Federal de Minas Gerais)
Abstract:
Interstitial Free (IF) steels are characterized by a set of mechanical properties that are ideal for applications requiring a high degree of formability. These properties are obtained using thermomechanical parameters suitable to obtain a high anisotropy coefficient. The hot rolling process is generally performed at high temperatures to avoid variations caused by rolling in the two-phase field. However, due to the high transformation temperatures, the rolling in the ferritic phase, known as warm rolling, is suitable for IF steels. The objective of this work was to carry out a comparative analysis of the microstructure, mechanical properties, and formability in two coils produced on an industrial scale, one through the conventional hot rolling process and the other through the warm rolling process. The microstructure obtained in the warm rolled coil showed greater variations, both after the hot rolling and annealing process. The more heterogeneous microstructure led to a worsening in the anisotropy coefficient value. The Limit Drawing Ratio and Erichsen cupping test did not demonstrate variations in the formability between the two conditions, but the conical hole expansion test showed better performance for the hot rolled coil. The forming limit curves also showed a better performance for the hot rolled coil for stretching operations (ε1 > 0 and ε2 > 0) using necking as the failure criterion. Both conditions allowed obtaining steels suitable for forming operations but with better performance for the hot rolled coil. However, better results can be achieved with higher finishing temperatures in the ferritic field.
Technical Session
9/5/24, 8:10 AM - 9/5/24, 8:35 AM
Presenter(s): MARCOS DANIEL GOUVEIA FILHO (Arcelormittal pecém), roberto vilmar formage (ARCELORMITTAL PECÉM), leandro centurion de santana (arcelormittal pecém), Carlos andre ruy carneiro (arcelormittal pecém)
Abstract:
Operational stability and safety are fundamental premises to the productive success of any melt shop. ArcelorMittal Pecém has a “single line” melt shop (operation with only one production line: converter / secondary refining / casting machine), with its production rate determined by the synergy between the process times of the converters and the continuous casting machine (input and output liquid steel). Thus, motivated by combining safety and productivity, an attempt was made to eliminate the main causes of the oxygen blowing emergency stop in converters, increasing operational stability and useful life of assets. The three main causes of blowing interruption in emergency found were: the high temperature in the gas treatment system, the low gas flow and the reaction by explosive mixture in the electrostatic precipitator. During the development of this work, sought to solve all emergency stops, with a main focus avoid on explosive reactions in the electrostatic precipitator. The implemented actions was successful, reducing by approximately 80% the number of monthly occurrences of these undesirable events, guaranteeing operational stability and safety, obtaining greater predictability, productivity and process quality.
Technical Session
9/5/24, 8:10 AM - 9/5/24, 8:35 AM
Presenter(s): alexandre dolabella resende (RHI Magnesita)
Abstract:
This study focuses on optimizing tundish flow in steel casting to refine molten steel quality. Traditional impact pots fail under off-centered jet conditions, causing asymmetric flow and quality issues. The research introduces a novel impact pot design that performs well even with off-centered jets, as proven by mathematical and physical modeling. Computational Fluid Dynamics (CFD) models, including Navier-Stokes equations, were used to simulate flow and turbulence. Physical experiments with a water model at 1:3 scale validated the simulations. The new design, featuring vertical and horizontal barriers, ensures even flow distribution, mitigating asymmetric flow and improving residence time distribution (RTD) across different strands. This advancement demonstrates the potential of modeling tools in developing solutions for the steelmaking industry’s challenges
Technical Session
9/5/24, 8:10 AM - 9/5/24, 8:35 AM
Presenter(s): MARCUS ESLEYR CARDOSO DE MORAES (gRAFTECH BRASIL PARTICIPAÇÕES LTDA), NICOLAS LUGO-FLORES (GRAFTECH INTERNATIONAL HOLDINGS), RODRIGO CORBARI (GRAFTECH INTERNATIONAL HOLDINGS), STEVE GOULDEN (GRAFTECH INTERNATIONAL HOLDINGS), PAUL STAFFORD (GRAFTECH INTERNATIONAL)
Abstract:
This paper highlights the impact of arc stability in the optimization of electric arc furnace operations. We give historical and logical perspective for important concepts related to arc stability. The paper shows examples of arc stability in relationship with Melting Power, Power-on time, and other key performance indicators (KPI’s) for the EAF. It compares energy delivery at various stages of a furnace melting cycle. In addition, the paper shows some of the ways to improve EAF efficiency by optimizing arc stability. Two case studies are presented to demonstrate the operational effects of improved arc stability.
Technical Session
9/5/24, 8:10 AM - 9/5/24, 8:35 AM
Presenter(s): RONALDO SCHITTINI GARDONI JUNIOR (PRIMETALS TECHNOLOGIES BRAZIL LTDA)
Abstract:
The metals industry in Brazil and worldwide faces a challenge to reinvent itself and bring solutions aimed at sustainable production, with environmental responsibility, lower CO2 emissions into the atmosphere, and the highest standard of safety requirements for Safety Instrumented Systems. Operating with high availability and increasingly strict safety criteria is challenging. On March 14th, 2024, the standard NBR IEC 61511 was published, creating a new safety era in the Brazilian Process Industry. The standard is an essential milestone in the Brazilian industry, which will undergo profound transformations in process functional safety, with rigorous standards, risk analyses, determination of safety integrity levels, implementation of fault-tolerant control systems, and compliance with the most modern international standards. This essay presents a safety automation-based solution to fulfill the process safety standard requirements and its positive impact on the industry.
Technical Session
9/5/24, 8:10 AM - 9/5/24, 8:35 AM
Presenter(s): DARCY LUCAS DA ROCHA OLIVEIRA (UNIVERSIDADE ESTADUAL NORTE FLUMINENSE), David coverdale rangel velasco (Uenf), rogério rabello da rocha júnior (Uenf), noan tonini simonassi (Uenf), carlos maurício fontes vieira (Uenf), FELIPE PERISSé DUARTE LOPES (Uenf)
Abstract:
Sustainability has become crucial to human well-being due to the gradual rise in temperature, resulting in serious environmental problems. To mitigate this damage, several companies have adopted the circular economy, aiming to maximize profits and reuse/recycle materials. This work uses agro-industrial waste as a dispersed phase in a polymer matrix, producing four different formulations (5%, 10%, 15% and 20% by volume). The specimens were tested in accordance with ASTM D790. The results indicate that the addition of particles significantly reduced the strength, but the material is still viable for certain applications; in contrast, there were no observable significant changes in the modulus of elasticity.
Technical Session
9/5/24, 8:10 AM - 9/5/24, 8:35 AM
Presenter(s): Antonio Ricardo grippa satiro (Ifes/UENF), Eduardo Atem de Carvalho (UENF), FELIPE PERISSÉ DUARTE LOPES (UENF), Noan Tonini Simonassi (UENF), SERGIO NEVES MONTEIRO (UENF)
Abstract:
The demand for sustainable and high-performance materials has been growing significantly, driven by environmental concerns and the need to reduce dependence on non-renewable resources. In this context, composites reinforced with natural fibers have emerged as promising alternatives. This study aimed to analyze the broomcorn (Sorghum bicolor) stalk as a potential reinforcement in polymer composites, focusing on its diameter, density, and surface characteristics. The diameters of 100 random stalks were measured at three points along their length. The relative density was determined by pycnometry, and the apparent density was calculated based on the dimensions and mass of the stalks. Additionally, a surface analysis was performed using scanning electron microscopy (SEM).There was a wide variation in stalk diameters, with a higher concentration between 5 and 7 mm. Both relative and apparent densities showed significant variations. The surface analysis revealed a rough and porous lignocellulosic structure, contributing to low density and good load resistance. The broomcorn stalk showed promise as a reinforcement in polymer composites, with the potential to improve mechanical properties and produce low-density composites.
Technical Session
EVALUATION OF THE QUALITY AND DEGREE OF PURITY OF GRAPHENE OXIDE SAMPLES BY CHARACTERIZA-TION TECHNIQUES BY X-RAY DIFFRACTION AND RAMAN SPECTROSCOPY
Presenter(s): ADRIANA AMARO DIACENCO (insight grafeno)
Abstract:
Graphene is considered by the academic community to be a material that offers numerous benefits due to the variety of its applications, such as in the production of nanomaterials, metallic alloys and even in the field of vaccines, but it is a mate-rial that needs to be further studied to better understanding of its behavior and applications, making it possible to elaborate new synthesis processes to obtain it. In this sense, this work aims to characterize graphene and its derivatives using techniques such as X-Ray Diffraction and RAMAN Spectroscopy. The samples were prepared and characterized in partnership with the company Insight Graf-eno, which prepared the samples using two methods, a method similar to the Hummers Method and a different method, similar to the Hummers Method, called in this work of an alternative method, without the use of sulfuric acid in the gra-phene oxide preparation steps, since conventional techniques use this acid, which makes it an impeditive factor for graphene oxide to be used in the medical field, however it was possible to verify, by through the characterization, that the alternative method did not originate graphene oxide, only the preparation of the samples through the method similar to that of Hummers that originated the gra-phene oxide.
Technical Session
9/5/24, 8:10 AM - 9/5/24, 8:35 AM
Presenter(s): Gabriel martins chaves barbosa (UNIVERSIDADE FEDERAL DE OURO PRETO), Nayara aparecida neres da silva (UNIVERSIDADE FEDERAL DE OURO PRETO), paulo roberto cetlin (UNIVERSIDADE FEDERAL DE minas gerais), Maria aparecida pinto (UNIVERSIDADE FEDERAL DE ouro preto), paula cibely alves flausino (universidade federal de Ouro preto)
Abstract:
The service life of metallic materials in engineering applications is closely related to the wear behavior, which is affected by material characteristics such as microstructural refinement and high mechanical resistance. Severe plastic deformation (SPD) techniques as Multidirectional Forging (MDF) stand out as tools for obtaining ultrafine grain microstructure (UFG) and high mechanical resistance. In this context, the present study aims to evaluate the influence of MDF processing on the wear behavior of electrolytic copper. From microstructural analyses, Vickers microhardness and micro-scale abrasive wear test by rotative ball, it is demonstrated that the refinement and increase in hardness introduced by MDF contributed to reducing the severity of wear when compared to the annealed condition.
Technical Session
ANALYSIS OF WELD METAL SOLIDIFICATION AIMING THE APPLICATION OF THE AISI 310S STEEL AT HIGH TEMPERATURE
Presenter(s): Ana BEATRIZ FERREIRA Sousa (Universidade federal do ceará (UFC)), francisco edmar cavalcante neto (UNIVERSIDADE FEDERAL DO CEARÁ (UFC)), Jenifer Sofia de Souza (UNIVERSIDADE FEDERAL DO CEARÁ (UFC)), Marcelo Torres Piza Paes (Centro de Pesquisas Leopoldo Américo Miguez de Mello (CENPES/PETROBRAS)), Giovani Dalpiaz (Centro de Pesquisas Leopoldo Américo Miguez de Mello (CENPES/PETROBRAS)), Ricardo Reppold Marinho (Centro de Pesquisas Leopoldo Américo Miguez de Mello (CENPES/PETROBRAS)), Marcelo Ferreira Motta (UNIVERSIDADE FEDERAL DO CEARÁ (UFC)), Hélio Cordeiro Miranda (UNIVERSIDADE FEDERAL DO CEARÁ (UFC)), Cleiton Carvalho Silva (UNIVERSIDADE FEDERAL DO CEARÁ (UFC))
Abstract:
The flare is responsible for burning harmful gases in oil and gas platforms and refineries. It is made of austenitic stainless steel to withstand high temperatures and a specific atmospheric condition. However, there have been reported cases of failure of these components, despite being recommended for extreme conditions. Through the solidification route and the microstructure, the present work evaluated coated electrodes that are candidates for use in the manufacture and repair of flares, in order to understand their metallurgical aspects. Thermodynamic simulations and microstructural characterization were performed to analyze weld metals resulting from the dilution of AWS E310-15, AWS E347-17 and AWS ENiCrFe-2 electrodes with AISI 310S austenitic stainless steel. The AWS E310-15 electrode resulted in a weld with a completely austenitic microstructure, which is vulnerable to solidification cracking. On the other hand, the weld using the AWS E347-17 electrode solidified in the primary ferrite/secondary austenite mode, with the presence of δ-ferrite, known to prevent solidification cracks. The weld using the AWS ENiCrFe-2 electrode showed characteristics indicating possibly worse resistance to solidification cracks due to the precipitation of secondary phases.
Technical Session
9/5/24, 8:10 AM - 9/5/24, 8:35 AM
Presenter(s): LEOCIMAR ANDRADE NASCIMENTO (companhia siderúrgica nacional ), LEOCIMAR ANDRADE NASCIMENTO (COMPANHIA SIDERÚRGICA NACIONAL )
Abstract:
CSN's Blast Furnace 2 began its fifth refractory campaign in 1991, and since then it has been the world's record-breaking furnace in operation within a single campaign. Due to the need to postpone the general refractory repair, CSN decided to start implementing actions to extend the useful life of BF2 in 2022, actions such as mass injection in the bosh, belly and low stack, robotic shotcrete for the throat armour, up and medium stack and the cold repair activity of the entire refractory wall, without salamander tap. For cold repair inside the BF, a refractory cap was made below the level of the tuyeres. A total of 413 tons of refractory castable were applied via manual and robotized shotcrete, plus 37 tons of silicon carbide refractory bricks. All the activities were carried out within the schedule of 15 calendar days, with the participation of 700 employees working 12/12h
Technical Session
STEEL CO-PRODUCTS: HOW THE CIRCULAR ECONOMY IN THE INDUSTRY CAN HELP DECARBONIZATION IN AGRI-CULTURE
Presenter(s): Eliane de paula clemente (Embrapa Milho e Sorgo), João Herbert Moreira Viana (EMBRAPA MILHO E SORGO)
Abstract:
There is political pressure to reduce the greenhouse gases and to promote mitigatory measures and the circular economy, eliminating wastes and meeting the current government’s emission goals. Strategies for this aim include to capture the CO2 by reaction with silicates that mimics natural rock weathering processes, while neutralizing the soil acidity for agriculture. The aim of this work was to evaluate the effects of formulations of Agrosilicio with phosphorus sources in the soil pH. Two soils were essayed, one clayey and other sandy, and the treatments were eight combinations of fertilizers with Agrosilicio Plus and the controls, the Agrosilicio, the triple superphosphate and the soils without any fertilizer, with 3 replicates. The pearl millet was the indicator crop. The results showed that the sandy soil presented a steep increase in the pH (close to 8.0), surpassing the plant acceptable limit, while the pH for the clayey soil remained in the 5.5 to 7.0 range, ideal for millet. The results suggest that the use of the silicate to replace carbonates is an option to promote the agriculture descarbonization, as it does not emit CO2, and fosters the circular economy with the reuse of a co-product.
Technical Session
EVALUATION OF THE CORROSION PROCESS IN THE FLOW BAFFLE OF A RADIATOR WITHIN THE HEAT EXCHANGER OF A GENERATING UNIT AT THE TUCURUÍ HYDROELETRIC POWER PLANT
Presenter(s): Rita de Kassia silva do nascimento (SENAI - PA/ INSTITUTO SENAI DE INOVAÇÃO EM TECNOLOGIAS MINERAIS), patricia magalhães pereira silva (SENAI - PA/ INSTITUTO SENAI DE INOVAÇÃO EM TECNOLOGIAS MINERAIS), Fernando gama Gomes (SENAI - PA/ INSTITUTO SENAI DE INOVAÇÃO EM TECNOLOGIAS MINERAIS), darilena monteiro porfírio (SENAI - PA/ INSTITUTO SENAI DE INOVAÇÃO EM TECNOLOGIAS MINERAIS), Julio Cezar Fornazier Moreira (SENAI/ INSTITUTO SENAI DE INOVAÇÃO EM TECNOLOGIAS MINERAIS), Otávio Fernandes Lima da Rocha (ifpa - pa), Frederico Rodolfo Parente Doerner (Eletrobrás/usina hidrelétrica de tucuruí), Camila Corassa de Ávila (eletrobrás / usina hidrelétrica de tucuruí), adriano reis lucheta (senai - pa / instituto senai de inovação em tecnologias minerais), Patricia Magalhães Pereira Silva (ISI-Tecnologias Minerais / SENAI), Fernando Gama Gomes (ISI-Tecnologias Minerais / SENAI)
Abstract:
The objective of this study was to analyze corrosion products in the aluminum baffles of the generator radiator in one unit 07 of the Tucuruí Hydroeletric Power Plant, Para State, Brazil. Metallographic, chemical, and microstructural analyses were performed on 10 x 10 cm3 samples cut from the baffle, including grinding, polishing and chemical etching with Nidal and Keller reagents. Chemical composition was determined by X-ray Fluorescence (XRF) and microstructure was examined by optical and Scanning electron microscopy (SEM) while the corrosion products were analyzed by X-ray Diffraction (XRD) and Energy Dispersive X-ray Spectroscopy (EDS). The results indicated that the baffles are composed of an Al-Si alloy (80% Al and 17% Si, with trace of Fe and Mn, exhibiting a dendritic microstructure with intermetallic that accelerate corrosion. Mineralogical analyses revealed the presence of Al(OH)3 in the corrosion products. It was concluded that the aluminum alloy used is unsuitable for the operating environment due to its susceptibility to corrosion, recommending more frequent replacement of the baffles during maintenance to avoid cooling system failures
Technical Session
9/5/24, 8:35 AM - 9/5/24, 9:00 AM
Presenter(s): yuri lucas de souza paropat (Companhia Siderúrgica Nacional - csn), marcelo ferreira jasmim (COMPANHIA SIDERÚRGICA NACIONAL - CSN), Davidson de Oliveira Pereira (COMPANHIA SIDERÚRGICA NACIONAL - CSN), Mateus Gonçalves Ribeiro da Silva3 (COMPANHIA SIDERÚRGICA NACIONAL - CSN)
Abstract:
The sintering process is essential in the steel industry, involving the agglomeration of ore fines and fluxes to form a product with specific physical and chemical properties, used in steel production through the reduction process. The article uses a descriptive methodology to shed light on the sintering process in the steel industry and the impacts of using PROCOM. The objective of the article is to present the level 2 automation system PROCOM that plays a fundamental role in the sintering process. The system calculates the amount of material required and sends the setpoint to each raw material doser, ensuring precise dosing of the material. After dosing, the raw materials are mixed to initiate the formation of the sinter, which is then beneficiated and subsequently used in the blast furnace. The implementation of PROCOM Sintering brings benefits in the reliability of retaining the information, agility in decision-making, and automatic recording of data on quality, particulate emissions, and production
Technical Session
9/5/24, 8:35 AM - 9/5/24, 9:00 AM
Presenter(s): EVANDRO POLESE ALVES (VIXTEAM CONSULTORIA & SISTEMAS), THIAGO BROCCO SARCINELLi (vixteam consultoria e sistemas)
Abstract:
This article addresses the importance of health monitoring systems in maintaining operational efficiency and preventing failures in industrial equipment. Vixteam's role in developing the integrity management system for the platforms of one of Brazil's largest oil and gas companies in the Espírito Santo Basin stands out.. The system, called Integrity Portal, is an operational data visualization tool that processes large volumes of data in real time. It allows the visualization of process variables in different formats and is operated from an integrated operations control center. The article also discusses the importance of alarms and events in monitoring equipment integrity. The Integrity Portal has alarm and event handling that is completely independent of PIMS, with all data organized hierarchically. * Contribuição técnica ao 26° Seminário de Automação e TI, parte integrante da ABM Week 8ª edição, realizada de 03 a 05 de setembro de 2024, São Paulo, SP, Brasil. Usability was an essential need for the project, with dashboard maintenance being the responsibility of the operators and specialists of the Integrated Operations Center. The system also has integration with the SAP PM module, which automates the process and guarantees that the request will reach the team responsible for maintenance. Since its implementation, the Integrity Portal has been successful, providing specialists and operators with a detailed, accurate and agile view of the large volume of data from different levels of the company, ensuring more assertiveness in decision making. The solution quickly expanded to other locations, covering production units throughout Brazil.
Technical Session
9/5/24, 8:35 AM - 9/5/24, 9:00 AM
Presenter(s): Edson José Valentim Pereira (JANUS AUTOMATION)
Abstract:
This document presents a modular traceability system that allows integration with ERP systems, as well as integration with RFID for identification and geo-positioning technologies. The system is designed to provide a complete and efficient solution for tracking train cars & locomotives and control the transport orders to load and unload material. In this article it will be described the implementation for a railway yard used for storage and transportation of ingots/slabs/coils in train cars of a global producer of steel in the United States. The system was implemented to track and control the train cars and locomotives and control the cars transport orders through load and unload locations with the objective to increase the logistical efficiency by optimizing the distance covered by locomotives. After implementation it was possible to observe a service time decrease to wait a cars train for loading or unloading, and a reduction distance covered by locomotives without cars due to effective use of locomotives. The system has been totally integrated through the interface with the ERP system and the use of different hardware: Tablet, Scanner, PC, GPS and RFID. The system includes the digitalization of the railway logistics process and workflows optimization, by means of utilization the essential cars movements to meet the real demands. It was created a big operational panel to represent the railway road for better user experience by operators.
Technical Session
A DOUBLE LAYER SUPERCAPACITOR WITH COMMERCIAL BRAZILIAN GRAPHENE NANOPLATELETS
Presenter(s): PABLO HENRIQUE ATAIDE OLIVEIRA (Instituto militar de engenharia), Raissa venâncio (Universidade Estadual de campinas), Killian Paulo Kiernan Lobato (Universidade de lisboa), Hudson Giovani Zanin (UNIVERSIDADE ESTADUAL DE CAMPINAS), RONALDO SERGIO DE BIASI (INSTITUTO MILITAR DE ENGENHARIA)
Abstract:
Electric double layer supercapacitors (EDLCs) have a larger energy density, a longer useful life and a shorter charging time than conventional batteries, characteristics that have attracted many researchers to this area. The use of materials that are not harmful to human health, as well as relatively cheap for large scale production, are permanent concerns. In this work, we investigated the behavior of a double layer supercapacitor with electrodes based on commercial Brazilan graphene nanoplatelets, that provides, among other advantages, the use of easily handled commecial materials with low toxicity, The device displayed a power density of 40.76 kW·kg-1 and an energy density of 7.71 W·h·kg-1. The capacitance retention was larger than 90% after 10,000 cycles.
Technical Session
IRONEXA – Iron concentrate
Presenter(s): saulo luiz sales parreiras de rezende (Nexa resources), Caio Moreira Van Deurse (Nexa Resources), Rafael Nonato de Oliveira Leite (Nexa Resources)
Abstract:
Magnetic separation is widely used in the mineral sector. In this process, materials are separated based on the property of magnetic susceptibility, which segregates materials based on the force of attraction of each element by the magnetic field. Through magnetic separation, this project makes it possible to recover the hematite-rich fraction contained in the zinc flotation underflow at the Nexa Resources plant in Vazante, creating value for an unused material as commercial iron ore concentrate. The aim of the article is to define the optimum operating conditions for wet beneficiation of the material using a magnetic separator (Inbras WHC-05S) with a high intensity carousel (WHIMS). Seventy-three tests were carried out to create a database which, after a factorial analysis of the experiment and the creation of a Pareto chart, indicated the main effects and optimum operating conditions for the equipment, considering the maximization of mass recovery with the best possible metallurgical recovery for the experiment.
Technical Session
STAMPABILITY COMPARISON BETWEEN MICROALLOYED AND CARBON-MANGANESE STEEL
Presenter(s): DANIEL AUGUSTO FERRO (WAELZHOLZ BRASMETAL LAMINAÇÃO LTDA)
Abstract:
Aiming to reach higher stampability and maintaining high levels of mechanical properties, the intention of this paper is to make a comparison of stampability between Carbon-Manganese (C-Mn) and High Strength Low Alloyed (HSLA) steels with yield strength above 350 MPa, since many parts manufactured with this steel grade normally have high deformation mainly on hole expansion areas, as it is the case of the part studied. Through the use of chemical composition adjustments and thermomechanical treatment for better stability of mechanical properties and thickness variation it was possible to reach good stampability of microalloyed steel (HSLA) whose mechanical properties achieved were (Strength limit of 472 MPa, Yield limit of 404 MPa, Elongation on 50mm basis of 35% and Hardening Exponent of 0,16) and microstructure with grain size 5, thin series and globalized non metallic inclusions level 1 type D plus spheroidized carbides randomly spread on a ferritic basis in comparison to the Carbon-Manganese steel with similar mechanical properties that presented worse stampability results (Strength limit of 508 MPa, Yield limit of 398 MPa, Elongation on 50mm basis of 32% and Hardening Exponent of 0,12), microstructure with grain size 9, thin series and elongated non metallic inclusions level 1 type C and fraction of lamellar pearlite which morphology is not recommended to be deformed during stamping process. Having said that, the development of this article increased the steel stampability where it was possible to manufacture parts without any cracks even in hole expansion areas as it could be seen in the comparative photos taken from the parts manufactured with Carbon-Manganese and High Strength Low Alloy steels.
Technical Session
REVITALIZATION OF DATED PLATE AND STECKEL MILLS COMPREHENSIVE REVAMPING PROJECTS FOR APERAM, ALGOMA AND JSW
Presenter(s): illya synelnykov (Danieli & C. Officine Meccaniche S.p.A.)
Abstract:
There are many reasons why modernization of dated rolling mills is indeed crucial for steel producers. Among the most important once are: to remain competitive in the ever-evolving industry and to keep up with a pressing market requiring high value-added products. In recent years Danieli has implemented several revamping projects in different parts of the world, modernizing the old plate and steckel mills, introducing new machines with enhancing characteristics together with in-house Automation L1 and L2 systems. In this article we would like to introduce 3 examples of such projects: JSW Steel USA: upgrade of the 163-in. wide plate mill located in Baytown, TX, USA; Algoma Steel: upgrade of the 166-in. wide plate mill at Sault Ste. Marie (ON), Canada; Aperam South America: modernization of Steckel Mill for stainless steel located in Timóteo, Minas Gerais, Brasile.
Technical Session
9/5/24, 8:35 AM - 9/5/24, 9:00 AM
Presenter(s): Gilvan Souza (Ternium Brasil)
Abstract:
INCREASE THE TIME AVAILABLE FROM THE CONVERTER TO STEEL PRODUCTION, REDUCING THE STOPS TO CHANGE THE POURING CHANNEL BY IMPROVING THE PERFORMANCE OF THE REFRACTORY SLEEVES.
Technical Session
9/5/24, 8:35 AM - 9/5/24, 9:00 AM
Presenter(s): Pedro Henrique Couto Almeida (rHI MAGNESITA), Vitor Guarnier Domiciano (rhi mAGNESITA), Gastón Eduardo Asenjo Lobos (RHI MAGNESITA), Juliano Euflosino Rocha (RHI MAGNESITA)
Abstract:
Sustainability in steel industry is key for the achievement of global targets, and there are several interesting opportunities of improvement in the continuous casting operation, particularly considering the refractory lining of the tundish. The replacement of a standard low cement by a sol-bonded castable (COMPAC SOL technology) in the permanent lining can reduce by 39 hours the drying curve and result in 45% less natural gas consumption and CO2 emissions. In the working lining, the usage of a fast or no drying spray mix (FAST TO CAST technology) instead of a standard one can allow direct preheating (eliminating the drying step) and unlock a 53% reduction in gas consumption and CO2 emissions. The usage of a cold setting mix (ANKERTUN SH technology) can result in an even greater sustainability benefit, reducing by 92% the water consumption and completely eliminating the need for drying or preheating the refractory working lining.
Technical Session
COMPARATIVE STUDY OF ELECTROMAGNETIC STIRRING VS BOTTOM GAS STIRRING IN ELECTRIC ARC FURNACE
Presenter(s): Philippe Mouls (ABB), Lidong Teng (ABB)
Abstract:
Stirring has an important role to play in reaching optimal process efficiency in Electric Arc Furnace (EAF). The forced convection induced by stirring enhances the mass and heat transfer that leads to process improvements including faster melting rate and better temperature homogenization. Such benefits provide increased flexibility to melt various charge materials, such as hot briquetted iron (HBI), large scrap, or even Hydrogen-based direct reduced iron (DRI), in line with material availability and company goals. In this study, the effect of two available stirring technologies in EAF: electromagnetic stirring (EMS) and bottom gas stirring (BGS) on certain performance indicators are investigated. The melt flow pattern and stirring energy are studied using numerical simulation, while the effects of EMS on EAF performance are observed through the experience of several steel companies who used BGS prior to installing EMS. Preliminary simulation results show that the volume average melt velocity and stirring power induced by EMS is several times higher than that generated by BGS. Industrial results demonstrate that EMS overcomes alloying and skull formation challenges and improves both productivity and cost efficiency in EAF. The pros and cons of EMS vs BGS in terms of equipment installation, lifespan, cost, and reliability are also discussed here.
Technical Session
9/5/24, 8:35 AM - 9/5/24, 9:00 AM
Presenter(s): Alessandro torres de carvalho (USIMINAS - IPATINGA), Gustavo Henrique Pinto De Oliveira (USIMINAS), Alexandre Alves Barbosa (USIMINAS), Pedro Sampaio Cotta (USIMINAS)
Abstract:
The ironmaking process is extremely complex, as it involves an extensive set of variables and controls, ranging from the quality of the raw material, inner conditions and reactions inside the blast furnace, operating conditions, up to the level of operator capacity. Control and simulation models are consolidated tools for process control. But, to achieve a high level of performance in hot metal quality, operational stability and cost reduction, expert systems have been used as decision support tools for operators. This work presents the implementation of the Expert System, integrated with the Level 2 System, provided by Primetals Technologies in the Revampig of the Usiminas’ Blast Furnace#03, consisting of process models, rules, diagnoses and explanations of process evaluations, with open or closed loop control. Usiminas’ operational philosophy was added to the system on a rules basis, complementing the general metallurgical knowledge base of the application, which allows standardized operation and preventive action in the process, with a consequent gain in stability and gradual reduction in fuel rate.
Technical Session
9/5/24, 8:35 AM - 9/5/24, 9:00 AM
Presenter(s): ELIAS ROCHA GONCALVES JUNIOR (UENF), Juliana Fadini Natali (UENF), Markssuel Teixeira Marvila (UFV), Afonso Rangel Garcez de Azevedo (UENF)
Abstract:
The environmental issues stemming from cement production have led to research on complementary or alternative materials to reduce CO2 emissions. An applied alternative is the use of agro-industrial waste as pozzolanic ash. Among agro-industrial wastes, corn straw ash emerges as a viable yet underexplored material with pozzolanic potential. The paper aims to assess the effects of calcination and milling processes to define parameters necessary for achieving high reactivity of the resulting ash. XRD analysis reveals significant changes in the crystalline structure after calcination, indicating the formation of amorphous phases. These changes directly affect the application of the resulting ash, underscoring the importance of calcination in modifying material properties and its influence on ash reactivity as a pozzolan. Particle size analysis results demonstrate the effectiveness of the milling process in reducing ash particle size, potentially resulting in a more efficient pozzolanic reaction and better compaction in cementitious composites. These findings reinforce the relevance of milling and calcination in optimizing the properties of corn straw ash for its application in construction materials.
Technical Session
9/5/24, 8:35 AM - 9/5/24, 9:00 AM
Presenter(s): BRUNA NOGUEIRA SIMOES COBUCI (UNIVERSIDADE ESTADUAL NORTE FLUMINENSE), Hugo Gil Soares (uenf), Noan Tonini SImonassi (uenf), FELIPE PERISSÉ DUARTE LOPES (UENF), Frederico Muylaert Margem (UENF)
Abstract:
The appreciation of coffee by Brazilians is well known, the drink can be easily found throughout the country. Sludge is the most common residue from this product, discarded without concern for possible contamination of the environment. To give a more noble final destination to the coffee grounds, this work deals with the analysis of the cost of goods sold of epoxy resin polymer composites reinforced with coffee grounds, for application in high performance coating (RAD). In this case RAD is a type of floor covering that provides a good finish, low cost and high mechanical performance. The compressive strength of these composites is critical, but also the cost ratio for offering the final product to the market. Test specimens were manufactured with volumetric fractions of 10%, 20% and 30% of coffee grounds in epoxy resin. After composing the test specimens, it was possible to highlight the manufacturing costs of the material, firstly calculating the energy costs spent, then surveying the required hourly load (HH) parameters, hence the use of proportional resin volume and reinforcement. to composites and we finalize the analysis with the mathematical extrapolation of the product standard created versus competitors available on the market.
Technical Session
A NEW CONCEPTION IN THE PRODUCTION OF POLYMER INJECTION MOLDS
Presenter(s): BIANKA NANI VENTURELLI (ESCOLA POLITECNICA DA USP)
Abstract:
The project aims to improve the performance and reduce the cost of manufacturing molds and matrices for polymer injection by changing the processes and alloys used in mold production. The authors propose the production of wear-resistant high chromium white cast iron molds for polymer injection obtained by casting. The article presents the results of alloy design, development of the casting systems (feeders) and macrostructure characterization of the casting alloys. The results showed that its viable to produce molds of white cast iron with wear resistant properties optimized for this application.
Technical Session
EXPERIMENT AND ANALYSIS OF THE HEAT TRANSFER COEFFICIENT IN THE COOLING OF STEEL HOT PLATE BY IMPINGING WATER JETS
Presenter(s): helio enio de oliveira (APERAM), MATHEUS EDUARDO WENCESLAU COSTA (APERAM SOUTH AMERICA)
Abstract:
The cooling technique using impinging laminar jets is one of the most widely used in steel mills, especially in continuous hot rolling lines for steel plates. This method produces cooling rates of ~85ºC/s, with heat fluxes of around 10 MW/m². To evaluate the phenomena involved, an experimental apparatus was adopted containing a heating furnace, a water tank, a U-tube type distributor tube, and 304 steel plates instrumented with K-type thermocouples. The initial cooling temperature varied from 750ºC to 1000ºC, with water flow measurement. Temperature transients were collected and stored by a datalogger following heating and cooling cycles. The different test conditions allowed detailed analysis of the cooling curves and extraction of thermal characteristics. A mathematical model based on the finite element method, developed in Python 3.11 algorithm, was used. By solving the inverse heat conduction problem, the surface temperatures, heat fluxes and heat transfer coefficients were calculated. The regularization parameter by the “sequential method” and optimization with the BOBYQA algorithm were developed and compared to the results obtained experimentally. The impacts of the variation of the initial temperatures of the samples, behavior of the heat flux curves and heat transfer coefficient according to the time variation and in relation to the numerically calculated surface temperature were evaluated. The 220-node mesh used presented an excellent compromise between computational effort and results. The temperature variations were less than 1.24%. The variations of the heat fluxes were less than 10.7%. The study concluded that the heat transfer coefficient is highly influenced by the initial temperature of the samples and physical characteristics of the jet, presenting a maximum value of 17300 W/m².K. The heat transfer coefficient was evaluated at the stagnation point, presenting a sharp decline along the heat flux from a temperature close to 250ºC in the three samples. The maximum heat flux reached a value of 3.26 MW/m² for a temperature of 1000ºC. It decreased with decreasing temperature, as concluded by Lee.
Technical Session
9/5/24, 8:35 AM - 9/5/24, 9:00 AM
Presenter(s): DAYNARA FAUSTINA MOREIRA DE OLIVEIRA (UNIVERSIDADE FEDERAL DE OURO PRETO), Rodrigo Rangel Porcaro (Universidade Federal de Ouro Preto), Geraldo Lúcio de Faria (Universidade Federal de Ouro Preto)
Abstract:
Different welding variables can influence the formation of MA constituents (Martensite-Retained Austenite) in the coarse-grained heat-affected zone (CGHAZ). However, the effect of the cooling rate on the volume fraction is still little studied, with contradictory results in the literature. In this sense, this work evaluated the relationships between heat input (cooling rate) and the microstructural evolution of the ZTA-GG of an API 5L-X80 steel. Numerical/physical simulation was used as an analysis tool. Based on the results of the computational models, four different cooling rate conditions (between 800°C and 500°C) were applied to the dilatometry specimens. It was observed that increasing the rate from 2.6°C/s to 9°C/s led to the formation of bainitic microstructures. Furthermore, due to the increase in this parameter, there was an increase in the MA fraction. But, for the highest speed (18°C/s), a decrease was noted, which was related to the formation of martensite in the matrix. It was concluded that the studied steel is very susceptible to the effects of thermal input/cooling rate in terms of the fraction and morphology of MA constituents and that, therefore, this relationship cannot be ignored when defining optimized welding parameters.
Technical Session
INFLUENCE OF THE DRAWING DIE RADIUS ON THE TRIBOLOGICAL BEHAVIOR OF AISI 430 STEEL AND ALUMINUM AA 1100 SHEETS
Presenter(s): Karina Aparecida Martins Barcelos Gonçalves (CEFET- MG), Eduarda Soares Oliveira (CEFETMG), Juliana Rodrigues Damasceno (CEFETMG), Almir Silva Neto (cefetmg), Erriston Campos Amaral (cefetmg), Valmir Dias Luiz (cefetmg)
Abstract:
In the sheet metal forming industry, the effects caused by friction are of great concern, as they directly impact the efficiency, product quality, and durability of the tools used in the forming process. This study aims to analyze the impact of the stamping die radius on the tribological behavior of AISI 430 steel and AA 1100 aluminum sheets. To achieve this, a bending test under tension was carried out on metal strips measuring 0.8×25×750 mm, using a tribosimulator in a lubricated environment. Measurements of the coefficient of friction and hardness were conducted. The results indicated that friction increased with decreasing bending pin radius; however, this behavior reversed after a critical radius (4.5 mm), where the friction coefficient increased with increasing pin radius. Furthermore, the AA 1100 aluminum strip showed a higher coefficient of friction (~1.5-9.6) compared to the AISI 430 steel. The roughness levels and hardness of the strips tended to increase as the radius increased.
Technical Session
WHAT IS NECESSARY TO REDUCE CONVEYOR DOWNTIME CAUSED BY PROBLEMS WITH PULLEY LAGGING?
Presenter(s): Caroline Gomes de Oliveira (Elastotec), Brad lawson (Conveyor Dynamics )
Abstract:
Pulley lagging is a fundamental part of any conveyor belt system. They are responsible for transferring torque from the drive pulley to the belt, protecting the pulley shell against damage caused by contamination ingress, and contributing to the energy efficiency of the conveyor. However, little attention is paid to the factors that directly influence the performance of such a crucial part of the conveyor. Pulley lagging is seen today as a commodity rather than an engineering component, being selected only based on common industry practices or past experiences. This work aims to describe the crucial aspects for the good performance of pulley lagging and to introduce Lagging Select, a tool developed for selecting the most suitable lagging for each application. A case study is also presented to exemplify the importance of conducting a comprehensive analysis in the choice of lagging.
Technical Session
USE OF DECARBONIZATION TECHNIQUE TO INCREASE WATER RECIRCULATION IN A ZINC METAL REFINERY
Presenter(s): Isabela Correia Costa (Hatch), Marcela Carvalhais Sena (Hatch), Saulo Luiz Sales Parreiras De Rezende (nexa resources), Breno germano de freitas oliveira (escalab), luisa carolina andrade barbosa (escalab), Cristiano Sousa Benício Siqueira (MONITORAR ENGENHARIA AMBIENTAL E GEOLOGIA), Maria Paula Duarte de Oliveira (CEO Escalab )
Abstract:
This study addresses the application of a new effluent treatment method to reduce the hardness and concentration of sulfates, using CO2 bubbling, from the effluent originated in a metallic zinc production refinery. The method involves significant changes in effluent management, such as the replacement of traditional chemical steps, for example the acidification with sulfuric acid, with technologies that allow the production of marketable by-products and the increase in water reuse in the process. The treatment was divided into two: sulfate treatment with gypsum formation and CO2 bubbling for calcium ion precipitation. The results showed a significant reduction in the hardness and concentration of sulfate in the treated effluents, with calcium removal efficiency reaching 99.4%. In addition to the technical advances, the study demonstrated the commercial feasibility of the alternative treatment route, with the generation of marketable coproducts, such as gypsum and calcium carbonate. These results are promising for industrial application, directing to a reduction in the environmental impact of zinc metal production. In addition, the technology contributes to the global goal of zero emissions and the expansion of the circular economy in the company.
HR Round
9/5/24, 8:35 AM - 9/5/24, 10:15 AM
Presenter(s): Coordinator and Moderator: Willy Ank de Moraes - Professor at Unisanta
Abstract:
Panel
9/5/24, 8:35 AM - 9/5/24, 12:45 PM
Presenter(s): Coordinators: José Murilo Mourão; Consultant / Vânia Lúcia de Lima Andrade; Consultant / Helênio Resende; Consultant SMS group Moderator: José Murilo Mourão; Consultant
Abstract:
Technical Session
9/5/24, 9:00 AM - 9/5/24, 9:25 AM
Presenter(s): SHAYANA TAVARES DE SOUZA (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE), WANDER PACHECO VIEIRA (NIVERSIDADE ESTADUAL DO NORTE FLUMINENSE), SILVIO GONÇALVES MENDES (NIVERSIDADE ESTADUAL DO NORTE FLUMINENSE), GUSTAVO DE AZEVEDO BARRETO GOMES (NIVERSIDADE ESTADUAL DO NORTE FLUMINENSE), ELAINE CRISTINA PEREIRA (NIVERSIDADE ESTADUAL DO NORTE FLUMINENSE)
Abstract:
Mass loss coupons are used in monitoring of corrosive processes and provide two types of information, the corrosity of the environment and the damage that the installation suffers. Monitoring companies obtain coupons from different suppliers, and little notes about the type of processing, composition, microstructure, type of heat treatment, between other parameters and how they can influence in the confiability of the results. The present work aims to evaluate the influence of normalizing heat treatment on microstructure and on uniform and pitting corrosion rates in AISI 1020 steel corrosion coupons, which were sectioned from longitudinal and transverse sections of a billet. The coupons were tested for corrosion loop having as fluid potable water. The uniform and puntiform corrosion rates were determined according to the standard NACE RP0775. The microstructural characterization analyzes by optical microscopy were involved, observing the grain size, in addition to the measurement of Vickers hardness. Heat-treated coupons have different grain size and morphology than coupons in the state as received. A higher density of inclusions was observed in the sectioned coupons of the longitudinal section, being possible to establish a direct relationship with pitting corrosion rate. As for uniform corrosion, all coupons had the qualitative rating as moderate. As for puncture corrosion, all coupons had the qualitative classification as severe.
Technical Session
COMPUTER VISION CROP CUT OPTIMIZATION USING O CV SENSOR
Presenter(s): ALEXANDRE RIZEK SCHULTZ (russula do brasil ltda.), Miguel Vilariño (R&D Engineer )
Abstract:
The development of much more robust digital cameras with higher and higher resolutions and higher and higher recording speeds, combined with the creation of more elaborate software tools at increasingly affordable costs, has made it possible to use them in dimensional, dynamic, and precise measurement, directly in the hot rolling process of long products. In this article, we present an on-line calibration and cutting system using artificial vision resources and their processing to improve metal yield without compromising quality
Technical Session
HOW ARTIFICIAL INTELLIGENCE CAN HELP IN THE SEARCH, VALIDATION OF INFORMATION AND LEGAL COMPLIANCE IN THE BRAZILIAN MINING SECTOR
Presenter(s): NELSON DE SOUSA PINTO FILHO (RADIX ENGENHARIA E DESENVOLVIMENTO DE SOFTWARE S/A), Flávio Leite Loução Junior (), Fabio Contrera Xavier (Radix Engenharia e Software), Lucas Solano Cadengue (Radix Engenharia e Software), Camila Barbosa Gomes de Araújo (Desenvolvimento & Inovação, Radix Engenharia e Software)
Abstract:
The National Mining Agency (ANM) provides information about the Brazilian mineral sector on the government website and in the ANMLegis application, which offer a structured collection of legislation. For example, the Legislation and Mining channel has 191 items relating to Consolidated Mining Legislation, containing vast and complex information classified by topic. The challenges for efficient and accessible use of this data include volume, complexity, and the need for celerity to meet institutional demands. This work aims to demonstrate how generative artificial intelligence (GEN AI) can assist in the search, validation of information and legal compliance in the Brazilian mining sector. This study presents GEN AI applications in different sectors, some successful cases, and their needs and possibilities in the mineral sector. This technology can have a positive impact, supporting decision-making, operational efficiency and risk reduction, representing an innovation in information management in the Brazilian mineral industry
Technical Session
9/5/24, 9:00 AM - 9/5/24, 9:25 AM
Presenter(s): Marcel roberto castanheira (vale)
Abstract:
Railcar dumpers play a crucial role in handling iron ore. During the unloading process, it is common to encounter impurities such as metal scrap or large blocks of uncrushed ore. To prevent these contaminants from reaching the belt conveyors and causing accidents, there are grizzly grids at the apron feeder chutes, on railcar dumper, to act as the first barrier. Determining the size of the openings in these grids is a significant challenge. It is necessary to retain impurities without causing blockages in the chute. In this context, this study used computational simulation based on the discrete element method, to optimize the design of grids used in the railcar dumpers at the Tubarão Port Terminal. Since blockages occur due to ore accumulation in the chute, gradually reducing the passage area, a single contact parameter was defined for variation during the simulations. With this methodology, it was possible to replicate blockages within a few seconds of simulation and compare flow in different grid designs, aiming to optimize computational cost. The results indicated a significant improvement in reducing blockages, even with a tighter grid mesh. This study demonstrates how computational simulation can be a valuable tool for enhancing efficiency in port and bulk solids handling operations.
Technical Session
9/5/24, 9:00 AM - 9/5/24, 9:25 AM
Presenter(s): LUCAS MACHADO BARBOSA DE FARIA (tsa - tecnologia de sistemas de automação s/a), SAMUEL LARA REIS (TSA - TECNOLOGIA DE SISTEMAS DE AUTOMAÇÃO S/A)
Abstract:
The growing concern about environmental issues and the need for responsible business practices have driven the adoption of the ESG concept, which involves environmental, social, and governance criteria, promoting a sustainable approach to business. In the environmental scope, ISO 50001 is an international standard that helps companies improve their energy performance, reducing consumption, costs, and environmental impacts. In this context, the TSA ONE UMS (Utility Management System), developed by TSA Engenharia, is aligned with environmental standards guidelines, integrating technologies such as real-time monitoring, data analysis, and automation. This system promotes energy efficiency and sustainability, enabling the reduction of operational costs and environmental impacts. In addition to these features, TSA ONE UMS offers automatic alerts, automated control, detailed reports, invoice simulation, device management, and continuous updates, providing a comprehensive solution for energy management. In a specific implementation case, for example, the system significantly reduced energy consumption and operational costs. Thus, TSA ONE UMS stands out as a strategic tool for organizations seeking long-term efficiency and sustainability, aligning with ISO 50001 standards
Technical Session
VIBRATIONAL SPECTROSCOPY TECHNIQUES FOR MARINE CRITICAL MINERALS CHARACTERIZATION
Presenter(s): CAROLINE SILVA DE MATOS (laboratório de caracterização tecnológica/escola politécnica/universidade de são paulo), mariana benites (instituto oceanográfico/universidade de são paulo), Luigi jovane (INSTITUTO OCEANOGRÁFICO/UNIVERSIDADE DE SÃO PAULO), carina ulsen (LABORATÓRIO DE CARACTERIZAÇÃO TECNOLÓGICA/ESCOLA POLITÉCNICA/UNIVERSIDADE DE SÃO PAULO)
Abstract:
Ferromanganese crusts (FeMn crusts) are mineral deposits located at deep-sea which contains high contents of chemical elements pivotal to energy transition. In this study, it is proposed the technological characterization of FeMn crusts samples collected at Rio Grande Rise by using vibrational spectroscopy techniques. To achieve this purpose, vibrational spectroscopy at infrared region (FTIR) and Raman spectroscopy were employed. FTIR results indicate the potential for its use in samples qualification regarding phosphate and carbonate content. This is an indirect identification of crusts layers enriched in critical minerals. Raman spectra evidence the complexity to characterize the samples, but also allows the identification of interesting minerals, such as asbolane and lithiophorite. These results as important to subside samples qualification and further in-field studies and prospecting work.
Technical Session
9/5/24, 9:00 AM - 9/5/24, 9:25 AM
Presenter(s): Thomas zerenko (sba mechatronics gmbh)
Abstract:
This paper targets mainly the techno-commercial possibilities of upgrading existing roll grinding machines for actual technical demands. Especially the integration of modern online roll inspection systems is a major concern of this paper. The detection of non-visible roll surface defects is one of the major roll shop tasks. Non-detected defects may lead into mill incidents, downgraded product or scrap production. Onboard systems, integrated with modern CNC controls and geometrical measuring systems are introduced. A retrospective, evaluation of the actual state and future perspectives serve as the baseline for this paper.
Technical Session
9/5/24, 9:00 AM - 9/5/24, 9:25 AM
Presenter(s): Helton de Freitas COTA (sms group), Wolfgang Fuchs (sms group), Dr. Ing. Michael Breuer (sms group), Georg Padberg (sms group), Heiko Reichel (sms group), Dr. Ing. Michael Degner (sms group)
Abstract:
The conventional Hot Strip Mill (HSM) is regarded as the most versatile and flexible metallurgical tool for the production of hot rolled coils, both in terms of product dimensions and steel grades. Due to the process characteristics of the HSM, there are particular challenges when it comes to the production of thin-gauge hot rolled strip. This applies for both, soft carbon steel grades, as well as, driven by the market requirements, increasingly also for high-strength steel grades. SMS group has developed a comprehensive “tool box” in order to support the stable and efficient production of “thin” hot strip in a conventional Hot Strip Mill. The “toolbox” consists of mechanical packages and automation packages which will be introduced in this paper. In addition, practical results from existing HSMs will be presented.
Technical Session
ENHANCING STEEL PLANT PERFORMANCE WITH ADVANCED TECHNOLOGIES: OPTA'S TRUSTIR, SLAGVIEW, AND SLAGTRACKER*
Presenter(s): jose lujan (opta)
Abstract:
Steel Plant A has achieved significant improvements in its metallurgical process performance and quality by integrating Opta's advanced technologies: TruStir, SlagView, and SlagTracker. This paper presents an in-depth analysis of these technologies' impacts on the plant's operational efficiency and product quality. The implementation of TruStir resulted in a 41% reduction in Argon gas consumption and an 11% increase in alloy recovery, particularly Titanium. SlagView reduced tap times at the converter vessel by 17% and minimized carryover slag by 19%. SlagTracker contributed to a 60% reduction in yield loss, a 20% increase in sequence length, and a 50% decrease in sliver defects. These enhancements collectively ensure higher-quality steel outputs and improved operational efficiency. The results demonstrate the transformative potential of these technologies in modern steelmaking.
Technical Session
METHODOLOGY FOR DEVELOPING EXOTHERMIC STARTING POWDER AT APERAM, A LABORATORY AND INDUSTRIAL APPROACH
Presenter(s): Fernando Paulucio Quinelato (Vesuvius), Thales Botelho (Aperam), João Geraldo Alves (Aperam), Thales Harvey Crisostomo Barros (aperam), Alexandra de Almeida Diego (vesuvius), Davi farias Ribeiro (vesuvius), Márcia Maria da Silva Monteiro Pereira (vesuvius), Joilson Moreira Ferreira da Silva (vesuvius), Raylander Pessoa (vesuvius)
Abstract:
Casting quality and operational stability are essential in the steelmaking process when producing specialty grades. In this context, exothermic starting powders are very important to enhance the quality and stability at the beginning of continuous casting process. In this paper a methodology to validate a starter powder by performing laboratory and industrial tests, then comparing the solution proposed with the current one will be discussed. By using thermogravimetric analysis (TGA) and differential scanning calorimetry (DSC), it was possible to quantify the exothermic energy generated during the reactions and prove the equivalence between the powders. Complementing the laboratory approach, a furnace test was proposed to investigate and compare the reaction behavior. At the continuous casting floor proposed parameters were used to measure the behavior in the mold, which showed similar results between the powders. However, the differences in reactions in the mold were identified for different steel grades. Finalizing the industrial methodology, the slab quality was evaluated, thus ensuring the success of the development and efficiency of the methodology proposed.
Technical Session
Q-REG®, ADVANCED ELECTRODE CONTROL AND REGULATION SYSTEM FOR ELECTRIC ARC FURNACES
Presenter(s): MATEUS BRITO SANTOS (DANIELI DO BRASIL SA), mario sartorelli (gerdau)
Abstract:
With more than 40 years of successes to back up their experience, Danieli Automation has brought to the market multiple innovations that have redefined what automation can provide to the metals industry. The well-known “Q” moniker for Danieli’s technologies, representing the core values of quality, quantity and quickness, has stood the test of time and brought forth endless benefits for customers all around the world. Gerdau Brazil has adopted nine (9) Danieli’s electrode control technology in Brazil, recording excellent performance and improvements. Q-Reg not only provides control for the electrodes based on a high-performance HiPAC process controller, but also fast data acquisition and processing to analyze process parameters in real time; ideal arc coverage for each electrode; arc stability; and radiation index per electrode.
Technical Session
9/5/24, 9:00 AM - 9/5/24, 9:25 AM
Presenter(s): Marcelo MOREIRA Furst Gonçalves (USIMINAS)
Abstract:
The Drop Weight Tear Test machine is used to determine fracture types in different steels through impact load. The equipment consists of a structure that lifts a certain weight to a certain height, which is then released onto the test specimen under evaluation. To meet the needs of Usiminas, this work aims to present a new customized control measurement system for this equipment, which includes the measurement of absorbed energy during the impact, the total integration with Usiminas test database, a screen view for results and a maintenance support screen. All the new system was developed using the software LabVIEW and a S7 logic controller. Thus, the Drop Weight Tear Test Machine currently operates with a completely system created by Usiminas with all the integration resources with other company systems.
Technical Session
DEVELOPMENT OF A POLYURETHANE COMPOSITE WITH INCORPORATED MAGNETIC TAILING FOR USE AS A COATING
Presenter(s): fernando brandão rodrigues da silva (Centro Federal de Educação Tecnológica de Minas Gerais), Caio Yasuhiro Kikuchi (Centro Federal de Educação Tecnológica de Minas Gerais), Luana da Silva dos santos (corfal poliuretanos ltda), tiago fernando domenegueti (corfal poliuretanos ltda), taise matte manhabosco (universidade federal de ouro preto)
Abstract:
Metal-polymer composites have shown better physical and mechanical properties than the composite matrix, in addition to overcoming problems such as low adhesion and high permeability, as occurs in polyurethane. This study consisted of developing a composite using magnetic tailing from a phosphate mining company as a reinforcing particle in the polyurethane matrix, in order to evaluate its applicability as a coating for carbon steel pipes. Tailings were used in two size ranges (38 to 53 µm and 53 to 104 µm) and with different percentages (10, 20 and 40% wt). The samples were evaluated for hardness, tensile and tear strength, elongation and abrasion wear, and characterized using SEM-EDS. The CP6 composite (10% wt and 38 to 53 µm) met the parameters required for application as a coating, surpassing polyurethane by 63.3% in tensile strength. The use of tailing with a larger grain size promoted an increase in abrasive wear, while the higher percentage by weight of tailing reduced the hardness of the composite.
Technical Session
DETERMINATION OF DENSITY OF FLAX POLYMER COMPOSITES PRODUCED BY ADDITIVE MANUFACTURING
Presenter(s): Daysiane da silva moreira (Instituto militar de engenharia), RAI FELIPE PEREIRA JUNIO (Instituto Militar de engenharia), JOSÉ CARLOS FERREIRA FONTES (Centro Universitário Augusto Motta), SERGIO NEVES MONTEIRO (instituto militar de engenharia), LUCIO FABIO CASSIANO NASCIMENTO (INSTITUTO MILITAR DE ENGENHARIA)
Abstract:
Natural fiber reinforcements have garnered significant interest in the composites industry due to their specific mechanical properties and environmental benefits. Natural fibers, such as flax, offer an abundantly available, sustainable, biodegradable, and economically viable alternative to synthetic fibers like carbon and glass. The increasing demand for composites in automotive, aerospace, and defense industries, which require lightweight and high-strength materials, underscores the importance of this development. Additive manufacturing (AM) techniques based on photocuring, such as digital light processing (DLP), provide high resolution and are suitable for UV polymerization of thermosets. This study aims to produce samples using an acrylic photopolymerizable resin matrix with varying flax fiber mass fractions of 0%, 1%, 1.5%, 2%, and 2.5% through the DLP process. These materials will be subjected to density tests to evaluate their properties. The results will contribute to understanding the potential of flax fibers to rival synthetic fibers, especially glass fiber, in developing more sustainable composite materials.
Technical Session
9/5/24, 9:00 AM - 9/5/24, 9:25 AM
Presenter(s): Clarissa de Paula Dias (Instituto militar de engenharia ), Ricardo pondé weber (Instituto militar de engenharia), sérgio neves monteiro (Instituto militar de engenharia)
Abstract:
Transparent polycarbonate (PC) is widely recognized for its ability to resist ballistic impacts, preventing penetrations and perforations. The amount of matrix is the predominant factor influencing its performance. This material, identified as a promising matrix for polymer matrix composites, is incorporated into reinforced composites such as fabrics and in the manufacture of laminated composites for applications that demand high impact resistance. This study provides a comprehensive overview of the mechanical and ballistic properties of polycarbonate matrix composites, evaluating their performance, including the V50 speed limit and energy absorption through ballistic tests. Finally, applications from the last 5 years are presented to illustrate the current state of this composite material.
Technical Session
9/5/24, 9:00 AM - 9/5/24, 9:25 AM
Presenter(s): Thiago Firmino Pereira (arcelormittal tubarão)
Abstract:
In an increasingly competitive market in the steel industry, companies have sought to achieve the highest levels of performance in their processes. One way to continue maintaining competitiveness is by improving quality, increasing productivity, and reducing production costs. In this context, the generation of cobbles during the Hot Rolling process negatively affects indicators directly related to the production cost of coil, notably equipment availability, metallic yield, productivity, gas and roll consumption, and maintenance and repair costs. Additionally, there are also risks to the safety of the personnel involved in cobbles removal from the mill, which is extremely undesirable. This article presents the methodology and process improvements adopted in the hot strip mill at ArcelorMittal Tubarão to reduce cobble occurrences in the Finishing Mill and Downcoilers.
Technical Session
9/5/24, 9:00 AM - 9/5/24, 9:25 AM
Presenter(s): EUGENIO TOLEDO DE CARVALHO (USINAS SIDERURGICAS DE MINAS GERAIS SA), Tadeu Messias Donizete Borba (USINAS SIDERURGICAS DE MINAS GERAIS SA)
Abstract:
In this study, the effect of double-pulse spot welding on Dual-Phase steel with 1000 MPa tensile strenght with high ductility electrogalvanized (DP1000HF - High Formability) was investigated, with a focus on improving the mechanical properties of welded components for the sector automotive. Two welding conditions were applied: conventional (1 pulse) and double pulse welding (DPS). The results showed that the DPS condition provided an increase of approximately 100% in the maximum cross-tension load, attributed to the microstructural refinement of the matrix and a greater density of high-angle boundaries in the welded region. Furthermore, both welding conditions presented button-type fractures and a load greater than that specified by the AWS D8.1M:2007 standard, indicating the adequacy of the parameters for welding the steel in question. In short, the results indicate that the application of double pulse welding current can be a good option for the automotive industry, providing significant gains in mechanical resistance in welded joints of electrogalvanized DP1000HF steel.
Technical Session
9/5/24, 9:00 AM - 9/5/24, 9:25 AM
Presenter(s): Giuseppe Pintaude (UTFPR), Francisco Arieta (Tribosystems), Rogério Breganon (utfpr)
Abstract:
This study shows the influence of load, time, and temperature variables on the tribological behavior of hot stamping tool steel DIN 1.2344 (X40CrMoV5-1) after heat treatments in a salt bath, with austenitization temperature at 1050°C and triple tempering for hardness value of 54.1HRC. Wear tests were conducted using a tribometer in dry reciprocating sliding configuration, with a frequency of 5Hz, loads of 25, 50, and 75N, testing times of 15, 30, and 60 minutes, and temperatures of 200, 300 and 400°C, besides the room temperature. As the counterbody 5-mm diameter high alumina balls were used. The tracks were evaluated using scanning electron microscopy and interferometry. The results showed that the test with a 25 N load, a temperature of 200°C, and a time of 60 minutes favored better load support due to the debris accumulation and the formation of a more compact oxide layer.
Technical Session
9/5/24, 9:00 AM - 9/5/24, 9:25 AM
Presenter(s): Cristiano Carlo Pereira (VALE S.A. / ifes - Instituto Federal do Espírito Santo ), Luiz Antônio de Campos (Kalenborn Wear Protection Solutions), Adonias Ribeiro Franco Junior (IFES - INSTITUTO FEDERAL DO ESPÍRITO SANTO ), Jose Jimmy Penagos (VALE S.A. / ITV – Instituto Tecnológico VALE)
Abstract:
Wear is one of the main factors driving up costs in the mineral processing industry. Handling iron ore pellets generates constant impact and abrasion due to their hardness, abrasiveness, and irregular spheroidal shape, significantly contributing to component wear. Wear-resistant lining materials are essential as they protect contact surfaces, improve equipment lifespan, reduce maintenance costs, and enhance operational efficiency. This work aims to demonstrate the product development process applied in the pellet flow operation, conducted by the manufacturer's and plant maintenance engineering teams. The project focused on optimizing the design and configuration of the hybrid ceramic-rubber lining plate solution (considering dimensions, arrangement, thicknesses of wear-resistant materials, and materials with damping properties) for application in a flow diverter of a transfer chute, the most critical point of the plant. The development advanced through an empirical process, involving routine inspections, analysis of tribological mechanisms, adjustments in thicknesses and dimensions, and design refinement. This resulted in a solution that improved the lining's lifespan and reduced intervention stoppages, consequently minimizing production losses.
Technical Session
9/5/24, 9:00 AM - 9/5/24, 9:25 AM
Presenter(s): ALVARO GUIMARAES SILVA E SOUZA (TECNOSULFUR SISTEMA DE TRATAMENTO DE METAIS LIQUIDOS SA), Rafael borges alves rennó (TECNOSULFUR SISTEMA DE TRATAMENTO DE METAIS LIQUIDOS SA), Saulo de tharso lima ribeiro (TECNOSULFUR SISTEMA DE TRATAMENTO DE METAIS LIQUIDOS SA), Vinícius Felix de Souza (TECNOSULFUR SISTEMA DE TRATAMENTO DE METAIS LIQUIDOS SA), Darlon Aparecido Carvalho de Almeida (TECNOSULFUR SISTEMA DE TRATAMENTO DE METAIS LIQUIDOS SA), Marina Muradas San Martin Pereira Cunha (TECNOSULFUR SISTEMA DE TRATAMENTO DE METAIS LIQUIDOS SA)
Abstract:
Synthetic slags are additives used to control the chemical and physical characteristics of process slags during the steel refining process. Sintered synthetic slags are produced through a hot agglomeration process, using solid fuels as the main energy source. This work aims to evaluate the feasibility of using biomass as a solid fuel source to replace metallurgical or petroleum coke in the sintering process of synthetic slags. It evaluates the characteristics of the biomass, process conditions, and the physico-chemical properties of the final product. After industrial tests and evaluations, significant drops in productivity were observed when the fuel was completely replaced. However, the combined use of biomass with fossil fuel proved to be applicable on an industrial scale.
Technical Session
9/5/24, 9:25 AM - 9/5/24, 9:50 AM
Presenter(s): Victor Cardoso campideli (Instituto tecnológico vale), Jeilce Maria Abreu dos Santos (INSTITUTO TECNOLÓGICO VALE), Maria Laura Nunes da Silva (INSTITUTO TECNOLÓGICO VALE), Dalila Chaves Sicupira (Universidade federal de ouro preto), Gilvandro Bueno (Vale S.A), Jose Jimmy Penagos (INSTITUTO TECNOLÓGICO VALE)
Abstract:
High-pressure grinding rolls (HPGR) is used in mining for ore fragmentation as a replacement for ball mills, due to the increased grinding productivity capacity. However, one disadvantage is the excessive wear of the studs used in the roll surfaces, which are currently made of hard metal (WC-Co). Recent studies have cited tribocorrosion phenomena as one of the mechanisms for stud damage, making it fundamentally important to evaluate their corrosion resistance. This study aimed to characterize the corrosion resistance of different hard metals, varying the refinement of tungsten carbide grains, the type of binder (nickel and cobalt), and the volumetric fraction of the constituents. The electrochemical behavior of the materials was evaluated through potentiodynamic polarization tests and electrochemical impedance spectroscopy in a 3.5% NaCl solution. The tests allowed for the assessment of the corrosion susceptibility and the corrosion rate of these materials. The nickel matrix alloys showed high corrosion resistance, as this binder contributed to the formation of protective oxides. Among the cobalt matrix alloys, the one with the lowest volumetric fraction of this element and the finest grains exhibited the highest corrosion resistance
Technical Session
ROBOT CASTING TECHNOLOGY FOR TURRET BACK SIDE
Presenter(s): Lúcio Mascarenhas Fernandes (VESUVIUS), Damien delsine (Vesuvius ghlin), eduardo hernandez duarte (Vesuvius Refratarios Ltda), Pedro caetano cardoso (Vesuvius Refratarios Ltda), Marcus gassmann (vesuvius ghlin), victor hugo gomes aramayo (Vesuvius Refratarios Ltda), vasco esteve de almeida (Vesuvius Refratarios Ltda)
Abstract:
The digitalization and the automatization of the industry is a key for the improvement of the process and the worker’s safety, the manual operations are being replaced by industrial robots in wide variety of industries, according to the International Federation of Robotics the robot density that is a number of operational industrial robots relative to the number of employees, increase more than 200% in period of nine years (2013 – 2022)(1), the main advantage to use industrial robots are the increase the overall process reliability due to the repeatability and accuracy of the industrial robots and the reduction of the time that the operators will be exposed to hazardous areas, for example liquid steel, high concentration of gas and dust and others. The objective of this paper is to present a robotization solution for the connection of the cylinder and the media air, argon and electrical on the slide gate of the ladle in the back side of the Turret, the automatic operation will be described as well as the devices and tools that the robot will interact, additionally will be shown 3D simulations pictures of the feasibility study and some photos and data of an industrial application of this solution
Technical Session
IMPLEMENTATION OF A GOVERNANCE AND CYBERSECURITY SYSTEM FOR AUTOMATION
Presenter(s): NELSON DE SOUSA PINTO FILHO (RADIX ENGENHARIA E DESENVOLVIMENTO DE SOFTWARE S/A)
Abstract:
This work aims to present the methodology used, steps taken, and challenges encountered in an ongoing project to implement a governance and information security (IS) system for the automation area of the mining industry. The methodology involved analyzing the current maturity of the area in the contexts of cybersecurity and governance, based on the best available practices, guides, and industry standards. The result was the creation of a plan for implementing governance, as well as a series of IS processes and artifacts that list the prioritized activities necessary to elevate the maturity level of the automation area and achieve the desired maturity level. In conclusion, this work highlights key points such as the difficulties encountered in the interaction of ITSM systems and maintenance during the implementation of the automation management system, the definition of priority and responsibility for governance and IS as main success factors, the involvement of the final area in process definition, and the involvement of the project's sponsoring senior management
Technical Session
9/5/24, 9:25 AM - 9/5/24, 9:50 AM
Presenter(s): Leticia Carlesso Gerônimo (Arcelor MIttal Brasil)
Abstract:
The intricate dynamics of today's market demand that large companies seek robust tools to navigate this complex landscape. In this context, our organization's Sales and Operations Planning (S&OP) Management has undertaken a strategic migration of all data analysis tools used in the monthly S&OP cycle to a digitalized environment. This initiative aims to achieve new levels of efficiency, collaboration, and profitability, solidifying our competitiveness and having simplicity as a fundamental pillar of success. Our digital transformation journey was guided by the latest methodologies and concepts from specialized literature. We enhanced basic data analysis tools by migrating them to advanced software such as Microsoft Power BI.
Technical Session
NEW NON-PHOSPHORUS CORROSION PROTECTION BY CHO INHIBITORS USED IN E.C.O.FILM* TECHNOLOGY FOR COOLING SYSTEMS
Presenter(s): Martín Javier Dib (Veolia - Water Technologies & SOlUTIONS ), Augusto Luis Marucci (VEOLIA - WATER TECHNOLOGIES & SOLUTIONS )
Abstract:
Industrial plants are facing increasingly restrictive phosphorus discharge limits, forcing them to reduce or eliminated their use of phosphorus treatment to control corrosion in semi-open recirculating cooling systems. As a result, many suppliers have been required to significantly modify their traditional treatment programs. Also, other suppliers have successfully circumvented fouling by using phosphorus basis as inhibitors for antiscaling. Surface analyses were used to identify passivation films that could render surfaces less susceptible to corrosion. Further efforts correlated the chemical composition of passivation films to respective treatment and water conditions, providing the knowledge to manipulate film Chemistry for performance. Applying this combined knowledge led to the development of Engineered Carboxylate Oxide Films (E.C.O.Film) technology for non-phosphorous cooling applications. A part of E.C.O.Film technology uses carbon-hydrogen-oxygen (CHO) inhibitors, which facilitate the construction of passivation films under non-phosphorous conditions. Their use will be discussed from a surface analysis perspective. This paper will provide a review of metal solutions, as well as, highlight recent advances in the use of all organic solutions to control corrosion in semi-open evaporative Cooling systems.
Technical Session
9/5/24, 9:25 AM - 9/5/24, 9:50 AM
Presenter(s): REBECA SEIXAS QUINTANILHA GOMES (UNIVERSIDADE ESTADUAL NORTE FLUMINENSE)
Abstract:
The demand for ecologically sustainable composite materials has driven research into replacing synthetic fibers with natural options. This study investigates the viability of natural fibers in epoxy composites as an alternative to carbon fiber in industrial applications. The experiment evaluated the flexural strength of composites reinforced with carbon fiber, making a comparison between the results in order to, in the future, find possible natural substitutes. Epoxy resin specimens (DGEBA/DETA) were manufactured and tested in accordance with ASTM D790. The results revealed a variation in flexural strength from 40.82MPa to 338.6MPa). The analysis indicates that the inclusion of carbon fiber has an influence on flexural resistance, but the techniques and care during the preparation of the test specimens end up influencing even more the test results.
Technical Session
GERDAU OURO BRANCO INDUSTRIAL EXPERIENCE WITH ULTRA LOW NIOBIUM STRUCTURAL STEELS
Presenter(s): ANTONIO AUGUSTO GORNI (consultor independente), Altair Lucio de Souza (Gerdau Ouro branco), Marcelo Arantes Rebellato (Eurosport)
Abstract:
The partial replacement of manganese by niobium in structural low carbon steels has been extensively studied for several years and by different plants around the world, having shown good results in terms of cost, speeding up liquid steel refining processes and reducing carbon footprint. In the past, Gerdau Ouro Branco carried out successful trials with this new alloy design and adopted it for some steel grades. In this work, an analysis is made of the first results of the routine production of coils in the Steckel rolling mill using this alloy design, and a comparison is made with a conventional carbon-manganese steel
Technical Session
9/5/24, 9:25 AM - 9/5/24, 9:50 AM
Presenter(s): tarcísio ferreira dias (arcelormittal tubarão), Joelma Krugel Brites Fernandes (ARCELORMITTAL TUBARÃO), Marcelo Lucas Pereira Machado (INSTITUTO FEDERAL DO ESPÍRITO SANTO), Bruno Bastos da Silva Murad (ARCELORMITTAL TUBARÃO), Fernando Generoso Neiva Ferreira (ARCELORMITTAL TUBARÃO)
Abstract:
The role of restoration mechanisms during hot deformation is fundamentally important for the properties of deformed austenite, directly impacting deformation resistance during subsequent hot rolling passes and the final microstructure, thus influencing the mechanical properties. In this study, the influence of these mechanisms was examined in double-hit plane strain compression tests by evaluating the behavior of the obtained stress-strain curves and measuring the softening generated between the passes. The studied steel was 27MnCrB5 with and without niobium addition. Deformation temperatures ranged from 800 °C to 1050 °C, with intervals between passes of 1 s and 3 s at a strain rate of 20 s-1. Microstructural characterization was performed using optical microscopy and SEM. It was found that softening is partial for temperatures up to 1000°C for 1 s intervals and up to 900°C for 3 s intervals, indicating partial recrystallization of the grains. Softenings greater than 100% were found for 3 s intervals at temperatures starting at 1000°C, indicating possible grain growth and the occurrence of metadynamically formed grains. The non-recrystallization temperatures obtained from empirical formulas and other double-hit tests were not compatible with the behavior of this test due to the higher strain rate and deformations. Niobium was associated with coarse TiN precipitates and showed no noticeable effectiveness as dislocation pinning agent.
Technical Session
9/5/24, 9:25 AM - 9/5/24, 9:50 AM
Presenter(s): werner aredes matos (USIMINAS - IPATINGA), Ronaldo adriano alvarenga borges (usiminas - ipatinga), Joao Domingos Guimaraes De Athayde Junior (Usiminas - ipatinga), breno totti maia (lumar metals)
Abstract:
The search to increase the refractory lining life, reduce cost in the production process, and environmental benefits make the slag splashing an effective technique in the preventive repair of the lining. The complexity of the industrial operation makes physical modeling an alternative for process evaluation. In the present study the parameters lance height, gas flow rate, amount and viscosity of slags were evaluated, via 1:10 scale model of BOF. The splash index was quantified in totality and by BOF zones. The results showed that the splash index depends on the interaction modes of the impingement jet with the liquid. It was noted a direct relation between inertial and gravitational forces with the splash index. Even though, the interfacial and viscous forces can not be neglected. The best configuration for splash index results were flow rate 70 Nm³/h, lance distance to the bottom 400 mm and amount of slag 12%.
Technical Session
9/5/24, 9:25 AM - 9/5/24, 9:50 AM
Presenter(s): RENARDIR PEIXOTO MACIEL JUNIOR (arcelormittal pecém), Marcos Daniel Gouveia Filho (ARCELORMITTAL PECÉM), Carlos André Ruy Carneiro (ARCELORMITTAL PECÉM), João Filipe Cavalcanti Leal (ARCELORMITTAL PECÉM), William Miguel Ferraz (ARCELORMITTAL PECÉM)
Abstract:
In continuous casting process of ArcelorMittal Pecem, there were great losses in quality due contraction void defect of the last slab of sequence in large dimensions (thickness x width). Thus, this work was carried out to reduce metallic loss and refusal slabs due to this defect. It was applied the PDCA methodology to develop this project. After analysis the problem and execution of the actions, the void contraction defect occurrences were reduced by 78% for last slabs of sequence. In addition, it was possible to make the steel emptying process in the tundish even safer by reducing the risk of slag passing through the tundish to the mold.
Technical Session
Scrap Preparation and sorting for improved EAF efficiency
Presenter(s): davide braga (Danieli & C. Officine Meccaniche S.p.A.)
Abstract:
Market pressure to use recyclable resources and reduce CO2 emissions is driving the expansion of EAF furnaces with consequent increase of scrap utilization. On average 80% of EAF operational expenses depend on raw material purchasing costs. Availability of scrap is foreseen to increase; however, the biggest increase is coming from obsolete goods with higher contaminants levels. When processing scrap internally, steelmakers can benefit by obtaining a better control on the quality of the scrap (and, consequently, of the final product) and, at the same time, improve EAF’s costs and performances. Danieli has a unique position on the market, strong of the know-how gained over the years of experience both in the field of steelmaking and scrap processing and wants to present, in the following article, the benefits of an integrated approach from ferrous raw material to steelmaking. A valuable and representative example is given by a real case study for a meltshop in East Europe. This study highlights the profitability of incorporating an internal scrap facility in the meltshop, integrating the treatment of raw materials with the whole steelmaking process. Firstly, the make or buy analysis shows that internally processing the scrap has a very quick return of investment (ROI less than 1.5 year), thanks to a cost saving of ≈30-35 €/ton (data relative to a plant in East EU, December 2022). Secondly, scrap densification allows a reduction from 3 to 2 the number of charging buckets, improving the overall productivity. Furthermore, having a higher yield and more controlled composition of the input material for the furnace leads to an additional cost reduction. The overall saving from the improvement in the performances of the EAF is ≈7 €/ton good billet. The total saving of the vertically integrated approach adds up to 42 €/ton.
Technical Session
DEPLOYING ARTIFICIAL INTELLIGENCE FOR THE DETECTION OF FUGITIVE ATMOSPHERIC EMISSIONS
Presenter(s): GUSTAVO CAMPOS IGNACIO DOS SANTOS (USIMINAS), DIEGO JUNIO SILVA MIRANDA (Usiminas), VINICIUS ALVES SILVA (USIMINAS)
Abstract:
IIn the steel industry context, steel production involves complex processing lines that, by nature, can generate smoke and dust emissions. Although these emissions do not indicate operational or equipment failures, they require rigorous monitoring to ensure environmental compliance and operational sustainability. To enhance the detection and management capacity of these emissions, an artificial intelligence tool based on computer vision techniques was developed. The neural network was trained with representative images of different environmental conditions, including nighttime, rainy, cloudy, and sunny scenarios. Following the training, the neural network demonstrated a precision rate between 85% and 90% in correctly identifying emissions in the validation set. Thus, the implementation of this type of technology not only strengthens the response capacity of environmental teams but also facilitates the quick identification of the onset and duration of emissions, in addition to allowing automatic classification of the severity of detected emissions. The ability to adapt to different environmental scenarios and operating conditions reinforces its versatility and effectiveness, making it a valuable solution for advanced and sustainable environmental management
Technical Session
9/5/24, 9:25 AM - 9/5/24, 9:50 AM
Presenter(s): Jhon peter aleixo ferreira junior (UENF), Carlos Maurício Fontes Vieira (UENF), Felipe perissé duarte lopes (UENF), NOAN TONINI SIMONASSI (UENF)
Abstract:
The replacement of synthetic fibers with natural fibers is something that has become common in recent years, mainly because of their benefits such as high hardness and because they are renewable. This study focuses on bamboo fibers stripped from the culm as reinforcement for polymer composites. The research was carried out using the culm of the giant bamboo, large bamboo bushes and the fibers extracted from the culms, about 10 specimens were prepared for statistical analysis. The results indicate that adding 30% giant bamboo fiber to the epoxy matrix improves the toughness of the composite and also indicates a linear increase in the impact energy izod.
Technical Session
CHARACTERIZATION OF BAMBOO FIBER COMPOSITES IN POLYESTER MATRIX
Presenter(s): Felipe daflon gama (UENF - ALBERTO LAMEG), José Lucas Decoté de Carvalho Lirio (UENF), Claudio Marlon Gomes da hora (uenf), Heittor da Silveira Inácio (Uenf), ELAINE APARECIDA SANTOS CARVALHO (uenf), Rubén Sánchez Rodríguez (uenf)
Abstract:
Composite materials consist of a reinforcing structure embedded in a matrix. Technologically, fiber-reinforced composites are of great importance, standing out for their high strength and rigidity in relation to their weight. For the present work, composites with contents of 0 to 10% of incorporated fiber were produced, with two fiber lengths being evaluated. The mechanical property of flexural strength was evaluated and the fiber structure was analyzed. The results of the flexural strength analysis indicate a notable improvement in the mechanical performance of bamboo fiber composites with polyester matrix compared to pure resin, especially when incorporating longer length fibers.
Technical Session
9/5/24, 9:25 AM - 9/5/24, 9:50 AM
Presenter(s): MANOEL TADEU ALVES DOS SANTOS (Universidade Estadual do Norte Fluminense Darcy Ribeiro (UENF)), Afonso Rangel Garcez de Azevedo (Universidade Estadual do Norte Fluminense Darcy Ribeiro (UENF))
Abstract:
The growing and continuous interest in the development of new materials, both within the manufacturing industry and in academia, has motivated increasingly in-depth studies of one of the most diverse and promising categories of materials in engineering and materials science: composites. In this sense, research aimed at improving polymer composites reinforced with natural and synthetic fibers has been consolidated as a very broad and highly sought-after exploratory field, especially in technological, economic and environmental aspects. Among the most desirable and sometimes worrying properties for polymer composites, the ability to resist fire or flammability and their degree of toxicity correspond to some of the parameters recurrently investigated in studies of new formulations of these materials. In this perspective, this article is dedicated to carrying out a brief literature review on the mentioned parameters and, as well as, establishing some correlations in terms of sustainability and economic viability of the products developed and their respective matrices. And, in addition, highlight the state of the art in research and production of these materials.
Technical Session
9/5/24, 9:25 AM - 9/5/24, 9:50 AM
Presenter(s): Henrique lacerda eleuterio (USIMINAS), juliana cristina de paula (usiminas)
Abstract:
The chemical composition controlling of Zn bath in Continuous Hot Dip Galvanizing Lines (CGL) is responsible for improving the surface quality of coated products, especially in the case of galvanized coating (GI). This chemical composition controls minimize the formation and precipitation of Zn-Fe-Al intermetallic particles, named dross, in addition to improving operational efficiency and increasing process line speed. The formation and precipitation of these particles are closely related to the Fe and Al contents present in the Zn bath. Furthermore, Al content control in the Zn bath is even more critical for galvanization of high-strength steels (AHSS) due to the high content of alloying elements in these steels, which compete with Al in GI coatings. In this context, the effect of the chemical composition of the Zn bath on the surface quality of the GI coating of an AHSS was determined in the laboratory using a Hot Dip Galvanization Process Simulator (HDPS). It was possible to evaluate the influence of the chemical composition of the Zn bath on the formation and precipitation of particles and on the coating formation, mainly in the interfacial layer, named the inhibition layer. It was possible to optimize the Al content in the Zn bath, providing conditions to obtain greater operational flexibility and GI coatings with good surface quality and adhesion to the substrate.
Technical Session
9/5/24, 9:25 AM - 9/5/24, 9:50 AM
Presenter(s): Bruna Malvar castello branco (UNiversidade federal do rio de janeiro)
Abstract:
The increase in demand for nickel and cobalt and the depletion of sulfide deposits, the main source of primary nickel, encourage the explotation of the lateritic ore. Sulfation-roasting-leaching is an alternative route for this ore, with considerable results and lower CAPEX and OPEX than existing routes. In this work the authors investigated different concentrations of sulfuric acid and determined the selectivity of Ni and Co in relation to Fe according to a nocturnal function. For 30% (w/w) H2SO4, cobalt and iron recoveries are lower than 10% and nickel recoveries are below 70%. For concentrations of 35% and 50%, the recoveries of Ni and Co are greater than 70% and 80%, with higher values for the highest concentration. However, the same happens with Fe and, for a H2SO4 concentration of 50%, the iron recovery doubled when compared to the concentration of 35%. The concentration that had the best selectivity for nickel and cobalt in relation to iron is 35% (w/w).
Technical Session
LOW TEMPERATURE REVERSED AUSTENITE IN THE AISI D2
Presenter(s): PAULA FERNANDA DA SILVA FARINA (uNICAMP), Edward Giovanni Rodriguez Arias (uNICAMP)
Abstract:
When submitted to a stress relief thermal treatment after quench, AISI D2 shows indications of an increase in its austenite volumetric fraction. With the aim of understanding the mechanism occurring, isothermal treatments at 130°C were applied to AISI D2 at increasing times. The microstructural characterization was carried out with SEM and XRD, also map of phases was calculated to give some light to the phase transformations. It was found that there is a reversion of martensite to austenite, as occurs for martensite stainless steels and Fe-Ni steels.
Technical Session
ELECTRIC SUPPLY TO UTILITY PANEL DURING MAINTENANCE SHUTDOWN
Presenter(s): leticia pinho inacio mendes (VALE - NOVA LIMA), Charles Lara Estevam Da Silva (vale), Glayson Franco (VALE), Jorge Carlos F.Bueno (VALE), Rodrigo Thomaz Dias (VALE), Tatiana R. Vilaça (VALE)
Abstract:
This work provides a solution for stops for equipment maintenance, with a lake energy in the substation, proposing a reduction in the number of generators that are distributed in the plant to support the electrical installations necessary for maintenance, being a simple solution that brings many benefits. The implementation of this project is underway at a Vale S.A Greenfield plant in the Vargem Grande region, however this solution can also be replicated in plants that are already in operation, requiring some adjustments. This proposal makes it possible to rent just one generator already connected to the utility panel bus, mechanically interlocked with a network circuit breaker, thus avoiding all the inconveniences that existed in existing installations. This solution brings greater safety during maintenance processes, by using a system that follows electrical safety standards, such as NR-10 and others, as they use safe energy sources and have a blocking device on the utility panel.
Technical Session
THE IMPORTANCE OF DEFINING AN INTERNAL CARBON PRICE FOR THE DECARBONIZATION PROCESS OF THE STEEL INDUSTRY
Presenter(s): Débora Christine Vasconcelos Borges (Arcelormittal brasil), Felipe Augusto Bittencourt Said (arcelormittal brasil), Guilherme Corrêa Abreu (ARCELORMITTAL BRASIL), Ana Luiza Pereira Oliveira (ARCELORMITTAL BRASIL), Caio de Lima Porciúncula da Costa (SINAI Technologies Inc.)
Abstract:
The article aims to explain the process of defining an internal carbon price at ArcelorMittal Brasil, and discuss the relevance of the mechanism for the decarbonization of the steel industry. The methodology is based on historical data, through greenhouse gas inventories; baseline emission forecast, target setting and the development of of a marginal abatement cost curve (MACC) based on decarbonization projects. SINAI Technologies Inc. system helps calculate the internal carbon price, allowing the company to assess the feasibility of the group's planned projects and investments, enabling greater competitiveness and alignment with the market requirements.
Technical Session
9/5/24, 9:50 AM - 9/5/24, 10:15 AM
Presenter(s): thompson júnior ávila reis (serviço nacional de aprendizagem industrial - senai minas gerais), Lourdes Amélia Pinto (serviço nacional de aprendizagem industrial - senai minas gerais), Ed Juarez Mendes Taiss (CBMM - Companhia brasileira de metalurgia e mineração), Kenji Camey (CBMM - Companhia Brasileira de Metalurgia e Mineração)
Abstract:
The aim of this work was to perform an exploratory study about the corrosion behavior simulating atmospheric conditions of two Nb microalloyed steels. Emphasis was given to the effects of the segregation presence in the steels and to the potential of the usage of the confocal microscopy for characterization of metallic surface after corrosion degradation. Samples from the two steels were submitted to the corrosion tests in cyclic chamber lasting up to 12 days. The corrosion product was characterized by x-ray diffraction, high resolution scanning electron microscopy and confocal microscopy. The samples were also characterized by confocal microscopy after the removal of the corrosion product. The results demonstrated of a preliminary way both the effects of the segregation presence and the efficiency of the characterization technique by confocal microscopy employed in this study.
Technical Session
9/5/24, 9:50 AM - 9/5/24, 10:15 AM
Presenter(s): jose fabiano martins assunção (ARCELORMITTAL - TUBARAO)
Abstract:
The objective of this project is to reduce CO2 emissions and energy consumption through hot charging, improving coordinated/synchronized between continuous casting and hot strip mill (LTQ), at the line sequencing level, seeking to increase the productivity of the Hot Strip Mill at ArcelorMittal Tubarão, in line with the drivers to increase production at the Hot Strip Mill, by changing the sequencing process of the Hot Strip Mill with optimization of the slab reallocation process (reduction of time and movements in the LTQ yard) during and after the formation of the sequência/Line-up of lamination with a focus on the temperature of slabs reheating furnaces. The work began with a review of metallurgical rules for reallocating materials, mapping processes (As Is), reviewing the objective function and constraints of the mathematical model for optimizing LTQ sequencing, opportunistic evaluation using Virtual Slabs( slabs still not produced, but already planned to be casted). With implementation of the process/system it is expected to achieve a potential increase in temperature slabs reheating furnaces, a 10% reduction in CO2 emissions, Increased process/system reaction intelligence, greater synchronism with Steelmaking, a reduction the risk of material breaking during reheating (important for new generation AHSS steels, in addition to the increase in annual production the Hot Strip Mill at ArcelorMittal Tubarão
Technical Session
9/5/24, 9:50 AM - 9/5/24, 10:15 AM
Presenter(s): pedro fois fernandes (innomotics), Guilherme Corrêa Fernandes (innomotics), Lorena Isabela de Oliveira Ribeiro (innomotics)
Abstract:
This article aims to present a system developed for the management of Temporary Protection Suppressions (TPSs), commonly used to disable some type of protection existing in the programming of Programmable Logic Controllers (PLCs) in the industry. The system, called SecureBypass, has features such as approval workflow, risk management, monitoring, auditing and integrations with other process and maintenance systems. STPs, also known as bypasses, forces and jumpers, are measures taken due to the failure of an equipment component that has an interlock, stopping a production process. The system performs continuous monitoring and allows audits, preventing STPs from being forgotten or hidden in controller programming. The system records access, providing reliability to avoid material and human damage.
Technical Session
9/5/24, 9:50 AM - 9/5/24, 10:15 AM
Presenter(s): Maycow bricio caxias (ternium brasil), Ester sales de sousa melo (ternium brasil), igor ferreira da silva (ternium), Fabiano Pachioni Perez (ternium brasil)
Abstract:
This work sought to reduce the stock of metal alloys stored at the site, improving control by improving the assertiveness of planning future consumption in line with the volumes and deadlines for acquisition. To this end, the entire process relating to the need, request and purchase of the main materials was mapped out, reducing extra costs related to storage with third parties and demurrage of containers of imported materials. The areas responsible for each variable studied were included in the project, under the coordination of the consuming area (Steelworks).
Technical Session
9/5/24, 9:50 AM - 9/5/24, 10:15 AM
Presenter(s): Cristiano Almeida Rocha da Silva (SOLENIS ESPECIALIDADES QUÍMICAS LTDA), Robson Luiz Stumpf (SOLENIS ESPECIALIDADES QUÍMICAS LTDA), Pedro Henrique Bordão Moreira (SOLENIS ESPECIALIDADES QUÍMICAS LTDA)
Abstract:
This document presents the achieved results with the application of the moderate oxidizing biocide Biosperse XD3899 (BAC) in a cooling tower located in the southeast of Brazil. This cooling tower supplies water to the continuous casting machine, degassing RH and steelworks; therefore, it is common to have the presence of impurities in the cooling water such as metals and organics, which increase the chlorine demand, leading to greater chlorides contribution, corrosion and sludge formation. After implementing BAC treatment, corrosion rates and microbiological control were improved. Furthermore, the reduction of chlorides with the new treatment allowed the system to save water with less cooling tower blowdown.
Technical Session
SYNTHESIS OF ADSORBENTS FROM INDUSTRIAL WASTES IN A DYNAMIC SYSTEM
Presenter(s): Antônio Lucas Alcantara Modesto (universidade federal do Pará), Rian Cristian Douro Amorim (universidade federal do Pará), Alex Gabriel Oliveira Ruivo (universidade federal do Pará ), Haianny Beatriz Saraiva Lima (universidade federal do Pará), Diego Cardoso Estumano (universidade federal do Pará), Deibson Silva da Costa (universidade federal do Pará), emerson cardoso rodrigues (universidade federal do Pará)
Abstract:
This work discusses the production and application of zeolites derived from kaolin waste and fly ash. The process involves dynamic hydrothermal synthesis, resulting in the formation of zeolite. The starting materials and their products were characterized using XRD and SEM. It was found that kaolinite predominates in the kaolin waste, with the crystals breaking after calcination, and the crystallinity and morphology of zeolitic material (ZRC) appearing as cubes and spheres. Several crystalline phases were observed in fly ash, which reduced upon calcination, revealing the morphology and sodalite peaks in the synthesis product (ZCV). Moreover, copper removal during adsorption reached 91% for ZRC and 60% for ZCV. Additionally, the Elovich model best fit the experimental data for both zeolites
Technical Session
9/5/24, 9:50 AM - 9/5/24, 10:15 AM
Presenter(s): Dr.-InG. Santino Keusemann (Kocks Measure + Inspect GmbH & Co KG)
Abstract:
This paper presents an innovative approach to hot surface inspection and quality control in steel mills through the integration of the 4D Eagle S, a high-speed laser triangulation device enhanced by machine learning technologies. The 4D Eagle S is designed to improve the precision and efficiency of measurements and defect detection in long product production, thereby increasing process stability for mill operators. Utilizing machine learning methods, the system first discriminates between non-defects and actual defects and subsequently classifies detected imperfections into several distinct categories, with a specific focus on the exclusive detection of periodic defects. This paper discusses the system’s capabilities, illustrates its impact through various data visualizations, and explores the potential of machine learning applications. The 4D Eagle S system exemplifies the benefits of integrating advanced technologies in traditional industries to achieve unprecedented levels of quality control and operational efficiency.
Technical Session
9/5/24, 9:50 AM - 9/5/24, 10:15 AM
Presenter(s): FLAVIO SOUSA BRAZ DE ARAUJO (SMS GROUP METALURGIA DO BRASIL LTDA.), Heitor Fernandes Vieira e Silva (SMS group BRASIL)
Abstract:
An Extrusion Press is an equipment that needs to have all moving parts precisely aligned with the extrusion force. In other words, the center of each individual main component (e.g., stem, container, dies, etc.) must be on the equipment's centerline. Failure to comply with this condition can lead to wear, damage, and cracks. Depending on the magnitude, the failure can occur within months. In this presentation, we will address not only the problems caused by misalignments and the actions to be taken to verify them, but mainly the technologies that assist the extruder in having a holistic view of the actual condition of their equipment through a comprehensive diagnosis. Three-dimensional diagnosis can be performed using a measurement equipment known as Laser Tracker, which provides accurate data that can be processed and analyzed by experts.
Technical Session
9/5/24, 9:50 AM - 9/5/24, 10:15 AM
Presenter(s): Wallace fernandes dos reis (rhi magnesita), Gabriel Rios de Souza (rhi magnesita), Romulo Batista Baitz (rhi magnesita)
Abstract:
In the Continuous Casting process, the tundish availability is a crucial factor to keep the synchronicity of the steelmaking process. In addition to the product technology adopted for the refractory lining of the tundish, the reliability and precision of the application equipment are important to guarantee flexibility for the process, especially in adverse scenarios. It is not uncommon to occur operational problems and programming changes in Continuous Casting to lead to the need for unplanned tundish changes. In these cases, the immediate availability of tundishes for casting is essential. In conjunction with the development of refractory materials that reduce the preparation time of tundish, such as the elimination of drying/curing processes, an application equipment was developed to ensure low application time, easy operation, and less need for maintenance interventions. In addition, the cost of consumable parts, as well as ergonomics and safety were also considered. The developed equipment showed precision in application, not generating losses of materials. Compared to the equipment most used currently in the Brazilian market (slurry gunning), the developed equipment showed a reduction of 72% in the need for preventive maintenance, 70% reduction in the effective maintenance cost, easy operation with reduction of human interference, not having presented failures during the 3-year period analyzed, and there was no need for emergency service, guaranteeing 100% availability for product application.
Technical Session
Optimization of the Cooling and Treatment Process in Stacks of Slabs Produced in Continuous Casting
Presenter(s): NATÁLIA DE MACEDO DO LAGO (TERNIUM BRASIL LTDA.), Marcos Delane de Souza (ternium brasil), Amanda Andrade Moreira (ternium brasil), Vinicius Cunha Aranda (ternium brasil), Franz Ramstorfer (TERNIUM BRASIL )
Abstract:
The appropriate selection of the method for cooling the slabs after the continuous casting process plays a crucial role in guaranteeing the quality of the slabs and the efficiency of the production process, contributing to meeting the deadlines for shipment of slabs. In this sense, the cooling process can be forced, air, sandwich or hood. For the last two types of cooling, the plate can only be moved once it has reached temperatures where no phase transformation occurs, in addition to the need for a minimum temperature for cutting treatment. In this work, a methodology was proposed using the DynaPhase software, which simulates the phase transformation of steel in the solid state, equivalent carbon and alloy percentage. The possibility of optimizing the cooling of some steels in air and with the possibility of treating at room temperature, without damaging the quality of the steel, was verified. The results of this study showed gains by reducing the time of blocked slabs, generating a shorter product lead time in the slab yards.
Technical Session
9/5/24, 9:50 AM - 9/5/24, 10:15 AM
Presenter(s): Enrico Plazzogna (danieli automation spa)
Abstract:
Q-ONE technology, developed and patented by Danieli, represents a breakthrough innovation in power transfer to the arc furnace. By using latest power electronics, the Q-ONE is capable of handling the irregular loads of the electric arc furnaces and control in real-time arc voltage, current and frequency. Also, Q-ONE minimizes the impact on the grid compared to the traditional solution, limiting the need of additional compensation systems. The unique arc control features of the Q-ONE improve furnace performances, reducing electric consumption and electrode consumption, extending refractory life, and minimizing maintenance costs. On top of this, the Q-ONE technology allows for direct connection of renewable energy sources such as photovoltaic to the EAF, opening an exciting opportunity for an even more sustainable and digital melting process. More than 40 references prove the exceptional interest in this innovation in steelmaking. This paper, after a brief introduction of the Q-ONE product, providing technical descriptions of electrical equipment and control functions, illustrates the results achieved on the recent application of Q-ONE technology to both EAF and LF. Particular attention is dedicated to the principles of arc frequency variation—the unique feature of Q-ONE technology—the frequency control strategy adopted, and the benefits of this empowered EAF process control.
Technical Session
VISION, SAFETY AND PRODUCTIVITY SYSTEM – OCR AND EGGSHAPED ON ENTRY PICKLING LINE
Presenter(s): eLOI PISANESCHI DE MELO (ARCELORMITTAL - SAO FRANCISCO)
Abstract:
The project was implemented at ArcelorMittal Vega (AMV) to improve safety and productivity in the pickling line. Previously, operators had to walk an average of 6 miles per day to check coils entering the pickling line. Furthermore, they were exposed to the risks of suspended load and falling into the shaft. The project aimed to reduce the operator's workload, eliminate all safety risks and automatically identify the name of the coils and whether they were oval or not, thus automatically inserting them into the level 2 system. A vision system with OCR processing was used. in a partially covered environment and employed multiple technologies including Python, Machine Learning, OpenCV, Pillow, and YOLO. The results were significant, with a projected return on investment of US$185,000 per year and a 78% reduction in inspection rate and risk exposure.
Technical Session
DEVELOPMENT OF HIGH PERFORMANCE COATING BY ECO-FRIENDLY EPOXY COMPOSITES AND RECYCLED GLASS PARTICULATES
Presenter(s): magno de souza padua (uenf), david coverdale rangel velasco (uenf), noan tonini simonassi (uenf), carlos mAURICIO FONTES VIEIRA (UENF), FELIPE PERISSÉ DUARTE LOPES (UENF)
Abstract:
At the current time, where new elements are being designed for increasingly specialized uses, composites have stood out for their flexibility and the ability to incorporate environmentally friendly raw materials in their formulation. These compounds would normally be discarded. An interesting application is High Performance Coating (RAD), used mainly on industrial floors that require extra defense against possible damage to the integrity. This coating is expected to provide efficient protection that is easy to apply and maintain. The following work aims to develop an environmentally friendly composite for application as RAD, using DGEBA/DETA epoxy resin as a matrix and ground glass ceramic particulate residue as a dispersed phase. Coming from bottles that would otherwise be discarded. The test specimens will be made in an open mold to test the real conditions of RAD application. Various compositions with the residue and resin were tested. Varying the addition of glass powder was from 10% to 40%, for the mechanical characterization were evaluated in impact tests, to assess which best meet the standard specifications for this type of coating, the preliminary results show that the potential for This new type of RAD developed is very promising.
Technical Session
9/5/24, 9:50 AM - 9/5/24, 10:15 AM
Presenter(s): José Carlos Ferreira Fontes (CENTRO UNIVERSITÁRIO AUGUSTO MOTTA), RAI FELIPE PEREIRA JUNIO (INSTITUTO MILITAR DE ENGENHARIA), Lucas de Mendonça Neuba (INSTITUTO MILITAR DE ENGENHARIA), Daysiane da Silva Moreira (INSTITUTO MILITAR DE ENGENHARIA), LUCIO FABIO CASSIANO NASCIMENTO (INSTITUTO MILITAR DE ENGENHARIA), SERGIO NEVES MONTEIRO (INSTITUTO MILITAR DE ENGENHARIA)
Abstract:
This study investigates the production and evaluation of curauá fiber-reinforced polymer composites using additive manufacturing techniques. In this context, the combination of additive manufacturing with curauá fiber-reinforced polymer composites represents an innovative approach to creating materials with enhanced properties. Moreover, the use of renewable and sustainable materials aligns with current demands for environmentally friendly solutions.The aim of this study is to analyze the performance of curauá fiber-reinforced polymer composites produced by additive manufacturing, focusing on their mechanical properties, impact resistance, and energy dissipation capacity. An experimental study will be conducted, which will include obtaining the curauá fibers, developing composite formulations, and manufacturing the parts using additive manufacturing. The characterization of the materials will be carried out through mechanical analysis techniques and ballistic performance tests, following established international standards for the evaluation of protective materials. It is expected that this study will contribute to the advancement of curauá fiber-reinforced polymer composites produced by additive manufacturing, providing materials with improved properties for various industrial applications and promoting sustainable practices in the materials industry.
Technical Session
9/5/24, 9:50 AM - 9/5/24, 10:15 AM
Presenter(s): Thomaz Jacintho Lopes (IME - INSTITUTO MILITAR DE ENGENHARIA), Ary Machado de Azevedo (IME), Marcos Paulo Cavaliere de Medeiros (IME), André Ben-Hur da Silva Figueiredo (IME), Sérgio Neves Monteiro (IME), Joana Batista Soares (IME), Domingos D’Oliveira Cardoso (IME), Fernando Manuel Araújo Moreira (IME)
Abstract:
The comparative study investigated the thermal neutron transmission factor using the Watt spectrum for uranium-235 fission. During the analysis, it was observed that borated polyethylene demonstrated inferior performance compared to regular polyethylene. This difference suggests that boron, despite favorable moderating properties, may introduce characteristics that decrease its efficiency in thermal neutron transmission. This result highlights the importance of considering not only the moderating properties of materials but also other characteristics that may influence the behavior of thermal neutrons.
Technical Session
9/5/24, 9:50 AM - 9/5/24, 10:15 AM
Presenter(s): JOSE ROBERTO DE SOUZA JUNIOR (VALLOUREC SOLUCOES TUBULARES DO BRASIL S.A), Ricardo Nolasco de CaRvalho (CIT-SENAI), vicente braz trindade (VALLOUREC SOLUCOES TUBULARES DO BRASIL S.A), José Márcio da Rocha (VALLOUREC SOLUCOES TUBULARES DO BRASIL S.A), Clélia Ribeiro de Oliveira (CIT SENAI), Ronaldo A. N. M. Barbosa (CBMM)
Abstract:
In this paper, we correlated the microsegregation of billets, which is inherent in the continuous casting process, with the changes observed in their flow stress curves measured by differential deformation dilatometry. It is then discussed how the choice of billets heating parameters (holding temperature and time) could affect the deformation resistance of the billets, affecting directly the rolling process. It was found that as the flow stresses decreased as the temperature and time increases. This research is still in progress and will still go deeper on the observed variations, corroborated by industrial observations.
Technical Session
LASER SURFACE TEXTURING OF BIOCIDAL SURFACES: EFFECT OF THE LASER BEAM ON THE WETTABILITY OF COPPER SURFACE
Presenter(s): SHEILA medeiros de CARVALHO (UNIVERSIDADE FEDERAL DO ESPIRIto Santo - UFES), mILTON SÉRGIO FERNANDES DE LIMA (INSTITUTO DE ESTUDOS AVANÇADOS - IEAV), Rebeca Oliveira Lube (UNIVERSIDADE FEDERAL DO ESPIRITO SANTO - UFES), Enza de Souza Zanon Dellatorre (UNIVERSIDADE FEDERAL DO ESPIRITO SANTO - UFES)
Abstract:
In With the COVID-19 pandemic in 2020, humanity acquired new habits to avoid contamination, such as the use of masks and alcohol gel. Thinking about the contamination that occurs with contact between contaminated surfaces and body orifices, such as the mouth and eyes, several studies have been carried out with the aim of studying the applicability of biocidal surfaces. In order to make microorganisms remain longer on these surfaces, the use of laser texturing has been considered. In order to study the effect of wettability caused by surface texturing on biocidal surfaces, copper samples were processed in a fiber laser, with 50 W power and infrared wavelength. After texturing, a wettability test using the sessile drop technique was carried out, with the aim of analyzing the difference between the contact angles of drops deposited on surfaces with and without texturing. The present study showed that laser texturing of copper can increase surface hydrophilicity. An X-ray diffraction study was also carried out, proving that there were no structural changes other than the textured area.
Technical Session
9/5/24, 9:50 AM - 9/5/24, 10:15 AM
Presenter(s): THALES HARVEY CRISOSTOMO BARROS (CEFET- MG), Igor Augusto Dias Gonzaga (CEFET-MG), Almir Silva Neto (CEFET-MG), Erriston Campos Amaral (CEFET-MG), Karina Aparecida Martins Barcelos Gonçalves (CEFET-MG), Valmir Dias Luiz (CEFET-MG)
Abstract:
In this paper, the effect of sheet deformation on the change of the surface roughness parameters and friction coefficient value is investigated. For this purpose, strips of AISI 430 ferritic stainless steel with deep drawing quality (DDQ), measuring 0.8x25x500 mm, were pre-deformed using a uniaxial tensile test for five different true strain values. The correlation between the surface roughness parameters and hardness with the frictional conditions of the tested strips was investigated in the bending under tension test. The results revealed that the friction coefficient determined for all pre-deformed strips increased as the level of true strain also increased. An increase in the plastic deformation of sheets under the uniaxial tensile stress state causes a nearly linear increase in the value of basic amplitude parameters of surface roughness, however, the hardness tended to present a constant increase for deformations close to uniform elongation.
Technical Session
LUBRICATION SYSTEM MODIFICATION – FIXED PIN
Presenter(s): rodrigo da silva cruz santos (TERNIUM), VALTER DA SILVA VIANNA (TERNIUM ), CARLOS HENRIQUE SOARES RODRIGUES (TERNIUM )
Abstract:
The steel industry presents several challenges. Within Maintenance Management, the largest are those related to maintaining the high availability of critical equipment while optimizing available resources, with special attention to costs. These devices are essential in the steel industry and require regular maintenance that depends on extensive technical knowledge on the part of those involved in addition to strict compliance with technical standards so that the work is carried out with excellence and safety. This project sought ways to reduce costs related to changing the components that make up the refractory container tipping system, complying with technical and environmental standards.
Technical Session
DECARBONIZATION OPPORTUNITIES IN THE MINING AND METALLURGY SECTORS IN THE BRAZILIAN SCENARIO
Presenter(s): NELSON DE SOUSA PINTO FILHO (RADIX ENGENHARIA E DESENVOLVIMENTO DE SOFTWARE S/A), Flávio Leite Loução Junior (), Ana Beatriz Otazu Castier (), Hudson Bolsoni Carminati (), Laís Cristina Ramos Simões (), Breno Alves Machado (), Geraldo Luiz Rochocz ()
Abstract:
The metallurgical and mining sectors are essential areas in Brazil’s economy, nonetheless the utilization of fossil fuels, are primarily contributing to the global greenhouse gas emissions. Given the high emissions, finding, and implementing alternatives for decarbonization is a necessity that cannot be averted and must be a prioritization. Through this paper, potential alternatives to be implemented in industrial technologies are examined, including hydrogen, carbon capture and storage, biofuels, and long duration energy storage technologies. Alongside, the use of renewable energy is highly emphasized as a replacement for fossil fuels, especially considering the goals proposed in energy transition discussions. The work is structured into four sections: a brief initial description of the mining and metallurgic industries, opportunities in the metallurgic and mining sectors, as well in decarbonization and the last topic addresses some other important opportunities in decarbonization, such as circular economy practices, relocation of Industries, structural shift in iron and steel production, access to financial capital and accelerating decarbonization using technology. By outlining and analyzing these solutions, the paper directs to contribute to a more sustainable future for Brazil's metallurgical and mining sectors.
Technical Session
PERCENTAGE REPLACEMENT OF SAND BY MINING WASTE IN CONCRETE MANUFACTURING
Presenter(s): Leonardo Borella Santos (Unileste)
Abstract:
INDUSTRIAL WASTE IS CURRENTLY GENERATED ON A LARGE SCALE, IN THE MOST DIVERSE SECTORS, CAUSING A NEGATIVE ENVIRONMENTAL IMPACT. STUDIES HAVE BEEN CARRIED OUT FOR THE REUSE OF WASTE, INCLUDING ITS INCORPORATION INTO CEMENT-BASED MATERIALS, SUCH AS CONCRETE. IN THIS SENSE, THIS REPORT PRESENTS THE USE OF MINING TAILINGS IN THE MANUFACTURE OF CONCRETE. IN THE PROCESS, SEVERAL PRACTICES AND STUDIES WERE CARRIED OUT TO ENSURE THAT THE MATERIAL WAS USED IN THE BEST POSSIBLE WAY. FIRST, AN ANALYSIS OF THE MINING TAILINGS WAS CARRIED OUT TO VERIFY ITS CHARACTERISTICS AND PROPERTIES BY MEANS OF THE GRANULOMETRY TEST. THEN, LABORATORY TESTS WERE CARRIED OUT TO DETERMINE THE APPROPRIATE DOSAGE OF THE MINING TAILINGS TO BE ADDED TO THE CONCRETE IN ORDER TO VERIFY THE POSSIBLE INFLUENCES OF THE MINING TAILINGS ON THE PERFORMANCE OF THE MINING TAILINGS AS WELL AS THEIR INTERACTION WITH THE OTHER AGGREGATES. TO THIS END, THE BEHAVIOR OF THE CONCRETE WAS PRELIMINARILY EVALUATED WITH THE REPLACEMENT OF 10, 30, 50 AND 70% OF MINING WASTE. SUBSEQUENTLY, IT WAS DECIDED TO ESTABLISH THE STUDY WITH CONCRETE WITH THE REPLACEMENT OF 30% OF MINING WASTE. THE CONCRETES WERE EVALUATED FOR WORKABILITY AND COMPRESSIVE STRENGTH, ACCORDING TO THE NORMATIVE DOCUMENTS OF THE ASSOCIATION OF TECHNICAL STANDARDS – ABNT. IT WAS OBSERVED THAT THE RESIDUE HAS POTENCY.
Technical Session
9/5/24, 10:15 AM - 9/5/24, 11:05 AM
Presenter(s): Jessica dias rodrigues (VALE - NOVA LIMA)
Abstract:
This article highlights the benefits obtained by Vale’s pellet production complexes when implementing the Feed Agenda in their routines. The main objective is to increase adherence and quality in receiving pellet feed for pelletizing. The integration of the production chain allows for better decision-making, involving a multidisciplinary team focused on overall optimization rather than local optimization. The implementation of the Feed Agenda routine occurs in two phases: the first focusing on the short term and the second on the medium term. To complete the implementation, five milestones are necessary, including team definition, meetings, consolidation of action plans for identified gaps, and monitoring of leadership routines. Each pelletizing plant complex has specific characteristics to achieve better adherence and feed quality. Therefore, each Feed Agenda routine, while having the same objective, addresses different bottlenecks. In this article, we will discuss the case of the Vargem Grande Plant, which achieved an 18% gain in feed adherence after three months of implementing phase 1
Technical Session
9/5/24, 10:15 AM - 9/5/24, 11:05 AM
Presenter(s): GILMAR LUCAS PEREIRA (VALE S/A), Eduardo Poltronieri Trés (VALE S/A), Bruno Oliveira Dias de Sousa (vale s/a), Ary Carlos Leal Nogueira (vale s/a), Samuel Filgueiras Rodrigues (ifma)
Abstract:
THE IRON ORE PELLETIZING PLANT IN SÃO LUÍS-MA (UPSL) OPTIMIZED ITS IRON ORE PELLET PRODUCTION PROCESS BY GRINDING BULK BENTONITE IN ITS VERTICAL DRY MILL. HOWEVER, THE PREVIOUS OPERATIONAL CONDITIONS, WITH TEMPERATURES UP TO 370°C AND LOW MOISTURE CONTENT CLOSE TO 1%, RESULTED IN PELLET WATER ABSORPTION PROPERTIES THAT DID NOT FULLY MEET THE DESIRED STANDARDS. TO IMPROVE THIS SITUATION, IT WAS NECESSARY TO MAINTAIN DRYING TEMPERATURES BELOW 150°C AND MOISTURE CONTENT ABOVE 8%. IN SEARCH OF SOLUTIONS, UPSL ESTABLISHED A STRATEGIC PARTNERSHIP WITH BENTONISA AND THE LOGISTICS COMPANY NORDAL. BENTONISA STARTED SUPPLYING BENTONITE VIA BULK TRUCKS, WHERE THE OPEN-AIR DRYING PROCESS ALLOWED MEETING THE DESIRED TEMPERATURE AND MOISTURE REQUIREMENTS. THIS MODIFICATION IN THE AGGLOMERANT UTILIZATION PROCESS RESULTED IN A SIGNIFICANT 28% REDUCTION IN THE REQUIRED BENTONITE DOSAGE. WITH THIS ADAPTATION, UPSL STOOD OUT AS THE PELLETIZING PLANT WITH THE LOWEST SPECIFIC BENTONITE CONSUMPTION AMONG ITS PEERS. FURTHERMORE, THE IMPROVEMENT IN THE QUALITY OF THE PRODUCED PELLETS WAS REMARKABLE, DEMONSTRATING THE TANGIBLE BENEFITS OF THIS STRATEGIC PARTNERSHIP AND THE ADOPTION OF MORE EFFICIENT PRACTICES.
Technical Session
MIXING PROCESS FOR BRIQUETTING USING VERTICAL INTENSIVE MIXERS
Presenter(s): Clayton Fabiano Ferreira Leite (Eirich industrial ltda), eduardo de oliveira cabral (eirich industrial ltda)
Abstract:
This study investigates the implementation of vertical intensive mixers in briquetting plants, aiming at optimizing the production of briquettes from iron and carbon-containing residues. By reducing these residues in the DRI furnace and subsequently melting them into pig iron in a single step, the process showcases an efficient and innovative approach to material recycling. The use of vertical intensive mixers is highlighted as a critical factor for the effective homogenization of the residues, which is essential for the quality of the produced briquettes and, consequently, for the efficiency of the iron production process. This work aims to explore the contribution of these mixers to the efficiency and sustainability of briquetting operations, offering insights into how advanced mixing technology can facilitate the recycling of steelmaking residues and improve iron production.
Technical Session
INFLUENCE OF PARTICLE SIZE ON THE MECHANICAL STRENGTH OF MANGANESE ORE FINES BRIQUETTES
Presenter(s): Eduardo faria matozinhos barbosa (UFOP), Leticia maria de melo silva cheloni (ifmg/ufop), Érica Linhares Reis (ufop)
Abstract:
The manganese ore fines are a problem in the operation of electric furnaces, therefore, this work aims to analyze the influence of particle size on the strength of manganese ore briquettes, since an agglomeration method is necessary for the insertion of these fines into the process. The project began with the separation of the ore fines sample into 3 particle size ranges: nucleating particles, composed of particles smaller than 3.36 mm and larger than 1.19 mm; intermediate particles are smaller than 1.19 mm and larger than 0.21 mm; and adhesive particles are smaller than 0.21 mm. The particle size analysis of the ranges was carried out through wet sieving. Mineralogical analysis was also performed for all particle size ranges of the sample. The mineralogical phases found in the nucleating and intermediate particle size ranges were quartz, spessartine, goethite, todorokite, epidote, and pyrolusite. In the adhesive particle size range, pyrolusite was not found, and kaolinite was detected. Briquettes were produced with different particle size compositions, varying the proportion of the adopted particle size ranges. Briquettes consisting mainly of adhesive particles showed higher strength than those produced mainly with nucleating particles.
Technical Session
ACHIEVING GREATER PRODUTIVITY IN THE SINTER PLANT: A CASE STUDY OF ARCELORMITTAL PECÉM
Presenter(s): Matheus Salmito RoDrigues Ponte (Arcelormittal), Antonio Carlos da Costa Onias (ArcelorMittal ), Emerson de Souza Silva (ArcelorMittal), Mateus Alves Segundo Paulino (ArcelorMittal), Miguel Araújo de Vasconcelos Filho (ArcelorMittal), Michael Jeferson de Souza Fineza (ArcelorMittal)
Abstract:
Sinter is one of the possible iron sources for hot metal production in Blast Furnaces. It has lower cost When compared with pellet and lump ores. Thereby, the increase of productivity in sinter plant and, consequently, the largest offer of this raw material make higher sínter consumption in Blast Furnace possible, reducing hot metal production cost. Through process improvements, and the quality in raw material and in sínter, the increase of sínter plant productivity was possible at ArcelorMittal Pecém. The actions were planned and implemented according to bibliography studies, team know how and the study of historical performance of ArcelorMittal Pecém sínter plant. The impact of this actions was positive, which increased sínter plant productivity until the target with process stability and It made possible start of new projects to reach 36 t sínter/m²/day.
Technical Session
ANALYSIS AND STUDY OF IRON ORE PROCESSES: CHALLENGES OF PROCESSING AT THE SERRA LESTE MINE
Presenter(s): gabriel walfredo Brasil de Souza (Universidade federal do pará), Queren Lira Nascimento (UNIVERSIDADE FEDERAL DO PARÁ), Cláudia Cristina Furtado dos Santos (UNIVERSIDADE FEDERAL DO PARÁ), Maria Eduarda de Almeida Mendes (UNIVERSIDADE FEDERAL DO PARÁ), Beatriz Correa Rodrigues (UNIVERSIDADE FEDERAL DO PARÁ), Vitor Leão Santana (UNIVERSIDADE FEDERAL DO PARÁ)
Abstract:
The state of Pará stands out as one of the main centers of mineral production in Brazil, boosting the local and national economy. In this context, iron ore assumes a leading role due to its strategic importance at a global level, being Brazil one of the largest suppliers of iron ore in the world. Understanding the processing process of this ore represents seeking improvements and opportunities to explore this resource in a sustainable and efficient way. This work presents the flow chart of the ore processing of the Serra Leste Mine finding on Curionópolis-Pará. The same brings with it information about the mine’s processing activities ranging from the mining processes, pre-processing, ending with the products to be marketed. The work in question has as proposal to clarify and make visible the processes of Beneficiation in question. Initially, the mining processes and beneficiation of the state of Pará were surveyed by the SIGMINE platform of the National Mining Agency (ANM). In addition to this survey, a literature review of the beneficiation of the Serra Leste Mine was made. Hence, it was possible to make an updated and didactic flowchart, which allows the understanding of the processes and activities of the mine clearly for different audiences. This work contributes not only to the understanding of Pará mining, but also to a strategic management of mineral resources.
Technical Session
9/5/24, 10:15 AM - 9/5/24, 11:05 AM
Presenter(s): Anderson de araujo Soares (Vale S/A), klaydison Carlaile Silva (vale S/A), benito barbabela e silva (vale S/a), marconi bitencourt silva (vale S/A), fernanda hoffman (Gaustec Magnetic Technology), Cláudio Henrique Teixeira Ribeiro (Gaustec Magnetic Technology)
Abstract:
The challenge of processing tailings from iron ore beneficiation routes has become increasingly relevant in the mining industry. In this context, two samples from Vale’s beneficiation plants, one of Total Tailings and the other of Slurry, were characterized chemically, granulometrically and mineralogically. After this, high-field magnetic concentration tests were carried out on Minimag equipment exploring % solids, feed flow rate and matrix size, standard or extended (High Mag). The results obtained for the total tailings show the possibility of a 40% increase in feed capacity with the extended matrix, generating a Rougher concentrate of 54% Fe; for the sludge, it is observed that the metallurgical recovery with the extended matrix is 50% higher, however, a concentrate with an average content 2.5% lower was obtained, a fact that could be reduced by including the washing water in future tests with sludge. Thus, it is understood that the use of the extended matrix will increase the processing capacity of iron recovery projects in the tailings and increase the treatment of slimes via WHIMS with an extended matrix, which will bring benefits in the filtering and stacking stages for the new tailings
Technical Session
9/5/24, 10:15 AM - 9/5/24, 11:05 AM
Presenter(s): Emilcy das Graças Guimarães Totti (Universidade federal de ouro preto), Kennedy da Silva Ramos (Universidade Federal do Ceará), Fábio de São José (Centro Federal de Educação Tecnológica de Minas Gerais), Francielle Câmara Nogueira (UNIVERSIDADE FEDERAL DE OURO PRETO), Paula Cibely Alves Flausino (UNIVERSIDADE FEDERAL DE OURO PRETO), Carlos Alberto Pereira (universidade federal de ouro preto)
Abstract:
The deposit of phosphate ore from Lagamar-MG is a sedimentary type and has undergone a metamorphosis, producing metaphosphorite, a more complex version for processing, reinforcing the need for continuous monitoring of the ore characteristics. This research proposed to reassess the characteristics of the phosphate ore from Lagamar through mineral characterization. As the main results, it was found that 49% of the sample particles were below 0.038 mm and a simple desliming step enriched the P2O5 content by almost 8%. The gangue mineral group is formed by quartz, kaolinite, phengite and goethite. The mineralogy (MO/SEM) indicated disseminated silicates in the apatite with a negative impact on the P2O5 content and recovery. A considerable portion of natural fines, porosity, and irregularity of the apatite explain the expressive specific surface area of 3.65 m2/g. These characteristics can increase the consumption of reagents, in addition to lodging mud on its surface. Chemical analysis showed that the P2O5 content was concentrated in the finest fractions (-1.19 mm +0.038 mm). Quartz was concentrated in the coarser fractions, possibly due to its greater resistance to comminution, while goethite, mica, and kaolinite were concentrated in particle sizes smaller than 0.038 mm, which could be discarded with desliming.
Technical Session
Improvement of the quality of a magnetite iron ore from Kazakhstan
Presenter(s): Vinicius SEERIG (ArcelorMittal Maizières Research SA), Henrique Dias Gatti Turrer (), Remi Belissont (), Udaya Bhaskar Kodukula (), Werner Spies (), Juliette Lainé (), Josué Mesquita de Souza Junior (), Maria Teresa Fernandes Matos Alves ()
Abstract:
The study evaluates the mineral performance of two different iron ores supplied to separate beneficiation plants, aiming to increase the iron content in the concentrate. Initially, mineral characterization was conducted to inform the development of the beneficiation process route. Subsequently, bench-scale tests were conducted using various concentration techniques, including gravimetric and magnetic methods, to assess the iron content in the concentrate and metallurgical recovery. For ore with lower liberation requiring grinding, a pre-concentration stage involving an HPGR and a dry magnetic separator was evaluated, yielding promising results.
Technical Session
OOPTIMIZATION OF THE AERATION CIRCUIT IN THE FLOTATION COLUMNS OF THE CENTRAL PLANT
Presenter(s): Thais Lacerda Marrocos (Hatch), Carlos Alberto Pereira (UFOP), KEROLLAN DA SILVA RAMOS (ITV), Rodrigo Gomes (Samarco), Cézar de Paula Pinheiro (Mineração CSN )
Abstract:
Flotation is a method of concentrating mineral particles that separates the valuable mineral from the gangue minerals, depending on an efficient aeration system. This study aimed to optimize the aeration circuit in the flotation columns of the Central Plant (CSN Mineração) using a new aerator model (SonicSparger Jet). The new aerator was tested in two Rougher columns for six months, with control of air pressure, part wear, replacement and spare parts costs, inspections, calibration, and maintenance, as well as evaluation of concentrate quality, metallurgical recovery, and selectivity index. The results showed less wear, reduced costs and inspection, calibration, and maintenance time, and higher concentrate quality and selectivity index. Thus, the superior performance of the SonicSparger Jet was proven, leading to the decision to acquire these aerators for all columns, aiming for the complete optimization of the circuit.
Technical Session
9/5/24, 10:15 AM - 9/5/24, 11:05 AM
Presenter(s): ANTONIO AMANCIO FILHO (OZ MINERALS)
Abstract:
Pre-concentration is a process that involves the early removal of a part of the ore that does not contain or has little economic interest before processing at the plant. This practice offers several benefits in the following stages. Tests were conducted on an industrial scale with ores from OZ Minerals mines, crushed and classified in the particle size ranges -25 +12 mm (medium) and -75 +25 mm (coarse). The equipment used was the Ore Sorter TOMRA COM XRT 1200/B 2.0, which uses two X-ray transmission sensors to separate the mineral from the gangue. Firstly, the performance in the pre-concentration of ore from the Pedra Branca mine was investigated, where an upgrade factor of 1.46 times and metallurgical recovery of 92.7% with 36% of ejected mass were obtained in the processing of coarse materials. In a second step, low grade ores were processed with better results metallurgical recovery of 87.85% for Cu with mass recovery of 41.72% in MW AN ore and for MW PB 85.29% metallurgical recovery and 30.12% mass recovery. The results indicate high technical potential for applying the technology and future projects to increase production capacity can be studied
Technical Session
9/5/24, 10:15 AM - 9/5/24, 11:05 AM
Presenter(s): sandra arlinda santiago maciel (ifmg ouro preto), Rodrigo carneiro de oliveira (amg brasil), carlos alberto pereira (universidade federal de ouro preto)
Abstract:
A sampling that is representative of the whole together with the subsequent mineral characterization are fundamental steps to decide on the mineral processing route. This work was developed aiming to highlight the importance of planning the sampling, which in turn, will influence the characterization, using chemical analysis and grain size distribution. In order to do so, a sample of iron ore, with initial mass of 123.93 Kg was quartered in aliquots of 1,20kg following a normal distribution. Next, a aliquot of 144.00g was quartered for granulometric analysis, carried out by using a set of Tyler series round sieves (screens). Chemical analysis was carried out in an external lab, obtaining the Fe concentration in the sample of 61.51%, characterizing Sinter Feed. The planning of the sampling for especularita allowed obtaining samples of desired mass and with minimum reliability of 95%. Good results were achieved to feed 10 kg into the carousel, thus enabling those to subsidize further process researches in the deposit of this sample..
Technical Session
EFFECT OF ADDING NATURAL FIBERS IN THE PRODUCTION OF ARTIFICIAL ROCKS PRODUCED WITH GRANITE WASTE IN EPOXY MATRIX
Presenter(s): SÁVIO DOS SANTOS CARVALHO (uenf), PABLO BARBOSA JACINTHO (uenf), Maria Luiza Pessanha Menezes Gomes (uenf), José Lucas Decoté de Carvalho Lirio (uenf), ELAINE APARECIDA SANTOS CARVALHO (uenf), CARLOS MAURÍCIO FONTES VIEIRA (uenf)
Abstract:
The production of artificial rocks from granite disposal in a matrix of epoxy resins with natural fiber reinforcement not only offers an environmentally friendly solution to mitigate the impacts of inappropriate disposal of this waste, but also demonstrates a very sensitive performance both from the point of technical and economic point of view. The objective of this study is to manufacture and evaluate the physical and mechanical properties of an artificial rock made from granite waste and natural fiber incorporated in an epoxy matrix. To manufacture the plates, a methodology was used that uses vibration, flexible and improved, followed by cutting to carry out the tests. Although the material reached the expected density, the apparent porosity and water absorption levels were high. However, its impact resistance was excellent, being considered to be of a very high level.
Technical Session
9/5/24, 10:15 AM - 9/5/24, 11:05 AM
Presenter(s): SHAYANA TAVARES DE SOUZA (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE), WANDER PACHECO VIEIRA (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE), ELAINE CRISTINA PEREIRA (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE)
Abstract:
Several problems present in our daily lives are directly related to the degradative effects of corrosion, due to the extensive use of metallic parts, structures, and equipment in various fields. The impacts caused by corrosion affect both physical and economic aspects, resulting in significant losses and endangering both the environment and the people involved. Metallic coatings offer improvements in the mechanical properties of metals, increasing resistance to corrosion. This study aims to analyze the corrosion process of ASTM A36 and SAE 1010 steels coated with Zinc-Aluminum-Magnesium alloy in a saline mist environment, in order to assess the efficiency of the alloy in atmospheres with aggressive microclimates. Metallic coatings, such as Zn-Al-Mg alloy, prove to be promising in protecting against corrosion in demanding environments, contributing to the extension of the lifespan of metallic materials. Through a superficial visual analysis, it is possible to observe that the Zn-Al-Mg alloy coating exhibits significant corrosion resistance compared to uncoated steels. However, in addition to the experiments conducted in the Salt Spray chamber, for a detailed analysis of the coating and its limits, investment in chemical and structural analysis will be necessary.
Technical Session
9/5/24, 10:15 AM - 9/5/24, 11:05 AM
Presenter(s): VITORIA ANDRESA DE OLIVEIRA BASTOS (UFF), Nykolle Fabiane Camilo Fernandes (UFF), Leticia Vitorazi (UFF), Tatiana das Chagas Almeida (UFF)
Abstract:
This study proposes the development of a coating using the layer-by-layer (LBL) deposition technique, layer by layer, with the incorporation of the corrosion inhibitor imidazole between layers of the polyelectrolytes polyethyleneimine (PEI) and bovine gelatin type B on a glass substrate. Zeta potential measurements were performed to characterize the polyelectrolytes, and layer growth on the glass was analyzed by UV/Vis spectroscopy. The incorporation of imidazole into the coating was also indirectly evaluated through a release assay. Zeta potential results showed the pH values at which the polyelectrolytes exhibit opposite zeta potentials, indicating a condition where they can electrostatically interact for LbL film fabrication. The analysis of layer growth on glass via ultraviolet-visible (UV-Vis) absorption spectroscopy reveals the inhibitor’s incorporation on the glass surface. Release studies demonstrated different release profiles depending on the concentration used in the deposition solution. This study contributes to developing anticorrosive coatings and enhances our understanding of the processes involved in the LbL technique..
Technical Session
FEMALE PARTICIPATION IN THE MINERAL-METALLURGICAL SECTOR OF FEMALE METALLURGIST ENGINEERS DIPLOMATED BETWEEN 2018 AND 2023 AT UFOP
Presenter(s): yasmim lopes sucharski (UNIVERSIDADE FEDERAL DE OURO PRETO), Luisa Marques CEsar (UNIVERSIDADE FEDERAL DE OURO PRETO), Vinicius Novaes Park (UNIVERSIDADE FEDERAL DE OURO PRETO), mateus de oliveira simão (UNIVERSIDADE FEDERAL DE Ouro Preto), BArbara Costa de almeida (universidade federal de Ouro preto), Stella Maria Pereira silva (Universidade Federal de Ouro PreTo), GABRIEL MARTINS CHAVES BARBOSA (UNIVERSIDADE FEDERAL DE OURO PRETO), Carlos alberto pereira (Universidade federal de ouro preto), PAULA CIBELY ALVES FLAUSINO (UNIVERSIDADE FEDERAL DE OURO PRETO), NAYARA APARECIDA NERES DA SILVA (UNIVERSIDADE FEDERAL DE OURO PRETO)
Abstract:
Increased gender diversity in science, technology, engineering and mathematics (STEM) areas has positively impacted work teams, stimulating innovation and creativity. However, despite the increase in the number of women graduating in engineering, many face challenges in the job market, especially in areas such as mechanics and metallurgy, due to gender stereotypes and horizontal segregation. This research investigates the performance of graduates of the UFOP Metallurgical Engineering course between 2018 and 2023, a period of significant increase in graduates, aiming to understand their professional paths amid reports of a shortage of qualified professionals in the sector. The results indicate that, despite women's superior academic performance, they face obstacles in the job market, including a lack of representation in leadership positions and adverse working conditions.
Technical Session
9/5/24, 10:15 AM - 9/5/24, 11:05 AM
Presenter(s): JULIANA LOPES RIBEIRO (uerj), Sabrina Costa Faria (uerj), Diego dos Santos Alves (uerj), Bruno Cristian Mello Carvalho (uerj), Eustáquio de Souza Baêta Júnior (uerj), leticia dos santos aguilera (uerj), Fellipe de Sá Moraes (uerj)
Abstract:
The challenge of forming porous ceramic parts by freezing is on controlling parameters, such as solids concentration, type of solvent, type and concentration of additives and times and temperatures of the thermal processes involved. The main focus of this article was the synthesis and characterization of nickel ferrite after processing by freeze casting. The samples were frozen, freeze-dried and sintered and the porous macrostructure and ceramic characteristics of the pieces were investigated by Scanning Electron Microscopy (SEM) and Archimedes Method, comparing variation of 3 polymeric binders, PEG-400, 1500 and 4000, in concentration of 4%. It was observed that the samples obtained a porous structure in distinct solidification zones, characteristic of very high cooling rates. Furthermore, the sample processed with PEG- 4000 showed greater grain growth and reduced pores, compared to the samples with PEG-400 E 1500. The apparent porosity of the three additive variations was around 50% and a low densification of the order of 30%.
Technical Session
9/5/24, 10:15 AM - 9/5/24, 11:05 AM
Presenter(s): lARISSA mENDONÇA OSORIO FONSECA (uNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO), José Alexandre Tostes Linhares Júnior (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO), Iully da Silva Amaral Pereira (Universidade Estadual do Norte Fluminense DARCY RIBEIRO), Samuel Araújo Azevedo Malafaia (Universidade Estadual do Norte Fluminense DARCY RIBEIRO), Juliana Fadini Natalli (Universidade Estadual do Norte Fluminense DARCY RIBEIRO), Sérgio Neves Monteiro (Universidade Estadual do Norte Fluminense DARCY RIBEIRO), Afonso Rangel Garcez de Azevedo (Universidade Estadual do Norte Fluminense DARCY RIBEIRO)
Abstract:
In general, mortars, recognized for their robustness against compression and fire, present challenges such as their fragility to tension and propensity to cracks. As a way of improving these properties, frequent studies have been carried out on the incorporation of natural fibers as cementitious reinforcement, among these fibers is pineapple leaf fiber. These fibers, as they are hydrophilic, require prior treatments, both physical and chemical, for their inclusion in the cement matrix. This study focused on comparing three different heat treatment methods for pineapple leaves. The procedure adopted for this was the separation of the leaves followed by three cycles of wetting and drying at different temperatures: 60°C for 24 and 48 hours, and 125°C for 4 hours. Subsequently, the leaves were crushed in a processor at 900 W and the resulting fibers were chemically treated with sodium hydroxide (5%). To characterize the material, X-ray diffraction and confocal microscopy were performed. The results indicate that treatment at a temperature of 125°C for 4h is the most effective.
Technical Session
INFLUENCE OF PROCESSING ADDITIVES ON THE POROSITY OF ZINC FERRITES NANOSTRUCTURED PARTS
Presenter(s): Sabrina Costa Faria (Universidade do estado do rio de janeiro), Juliana Lopes Ribeiro (UNIVERSIDADE DO ESTADO DO RIO DE JANEIRO), Bruno Cristian Mello Carvalho (UNIVERSIDADE DO ESTADO DO RIO DE JANEIRO), Fellipe de Sá Moraes (UNIVERSIDADE DO ESTADO DO RIO DE JANEIRO), Diego dos Santos Alves (UNIVERSIDADE DO ESTADO DO RIO DE JANEIRO), Eustáquio de Souza Baêta Júnior (UNIVERSIDADE DO ESTADO DO RIO DE JANEIRO), Leticia dos Santos Aguilera (UNIVERSIDADE DO ESTADO DO RIO DE JANEIRO)
Abstract:
Nanostructured parts can be modified through ceramic processing, such as freeze casting, with the help of additives such as polyethylene glycol (PEG). This article explores research into magnetic zinc ferrite nanoparticles (ZnFe2O4) as a ceramic filler for the production of porous parts. Three variations of PEG’s (400, 1500 and 4000 g/mol) were used with processing additives. The morphology of the samples was analyzed using Scanning Electron Microscopy (SEM) and the density, apparent porosity, apparent specific mass and volumetric shrinkage were analyzed using the Archimedes Measure. Samples with PEG-400 and PEG-1500 resulted in a morphology with worse pore orientation and alignment. The sample with PEG-4000 showed promise for applications as electronic radiation absorbing materials, with low volumetric shrinkage and high porosity (64.6%).
Technical Session
9/5/24, 10:15 AM - 9/5/24, 11:05 AM
Presenter(s): SAMUEL Araújo azevedo MALAFAIA (UENF), Gabriela Machado Mota (uenf), Rita de Kassia Gonçalves Pereira (uenf), José Alexandre Tostes Linhares Júnior (uenf), Iully Amaral (uenf), Juliana Fadini Natalli (uenf), Markssuel Teixeira Marvila (ufv), Afonso Rangel Garcez de Azevedo (uenf)
Abstract:
The search for sustainable alternatives in civil construction is essential to minimize the environmental impacts of the sector. The use of natural fibers such as mallow can contribute to this reduction of impacts, as long as their technical and economic viability is proven. In this context, the use of natural materials such as mallow in coating mortars appears as a promising proposal. Thus, this work aimed to evaluate the impact of incorporating mallow on compression and flexural resistance, and through a bibliographical review of previous studies, seeking sustainable alternatives for the construction industry. The tests were carried out with the incorporation of 1.5% and 3.0% and the reference for comparative purposes. The addition of mallow in concentrations of 1.5% and 3.0% significantly reduced the compressive and flexural resistance of the mortars, this behavior is due to the anisotropy and uneven distribution of mallow. Therefore, it is necessary to continue studies on the incorporation of mallow fiber in coating mortars
Technical Session
9/5/24, 10:15 AM - 9/5/24, 11:05 AM
Presenter(s): SARAH GABRIELLY BRANDAO DE SOUZA (UNIVERSIDADE FEDERAL DO PARá), PALOMA SUELLEN LIMA DE SOUSA (UNIVERSIDADE FEDERAL DO PARÁ), Joelly Vera Nascimento (universidade federal do pará), Emily de Fátima Pinheiro Botelho (universidade federal do pará), Damares Da Cruz Barbosa Nascimento (universidade federal do pará), Verônica Scarpini Candido (universidade federal do pará), Alisson Clay Rios da Silva (universidade federal do pará)
Abstract:
Faced with the need to meet the sustainable demands of today's world, composite materials have taken the lead when it comes to efficiently replacing synthetic and non-renewable materials. This was due to the possibility of engineering a matrix, generally polymeric, to a reinforcement from a natural source. Vegetable fibers are a clear example of this, and play an extremely important role as reinforcement due to their abundance, biodegradability and good weight/strength ratio. In Brazil, mainly in the Amazon region, there are numerous vegetable fibers that fit this application, such as Curauá (Ananas erectifoluis), a plant from the pineapple family. Therefore, the present work aims to carry out an investigation into the mechanical properties of composite materials produced from a polymeric matrix and reinforced with volumetric fractions of 5, 10 and 15% of curauá fibers compared to their full matrix. The specimens produced followed the specifications of the standards for tension, ASTM D638, and flexion, D790. Furthermore, based on the results obtained, there was statistical treatment using analysis of variance (ANOVA) and Tukey. Thus, it was possible to observe that, for the flexural test specimens, the addition of 15% fiber volume was the most efficient in relation to the matrix, adding an average flexural strength value of 82.60 MPa. For traction, the volumetric addition of fibers was efficient as reinforcement from the first fraction, of 5%, scaling up to 15%, where the highest average resistance was found, of 56.40 MPa. Therefore, it is notable how these composites reinforced with curauá fibers have great potential as reinforcement and a sustainable alternative.
Technical Session
9/5/24, 10:15 AM - 9/5/24, 11:05 AM
Presenter(s): Thereza Pereira Ramos de Mello (uenf), Lucas Reis Cruz (uenf), Davi Vaz André Júnior (uenf), Leandro Barbosa de Oliveira (uenf), Madeleing Taborda Barraza (uenf), Carlos Maurício Fontes Vieira (uenf), afonso rangel garcez de azevedo (uenf)
Abstract:
The Brazilian Standard stipulates a quality standard for ceramic roof tiles, causing many products to be discarded because they don´t match the required level, which accentuates the local environmental impact, unintentionally increasing the amount of waste. Therefore, this work aims to study the incorporation of glass waste for the future production of geopolymeric roof tiles. Reference compositions were prepared, with 10%, 20% and 30% addition of glass residue, originating from the cutting of flat glass, and subsequently the compressive strength was evaluated at 7 and 28 days. Other parameters such as consistency index, density in the hardened condition, water absorption by immersion and void index were also studied for further analysis of the geopolymer mortar. The results demonstrated that, incorporating 20% of the residue, a compressive strength of 30MPa could be achieved for a sample at a controlled temperature for 28 days. Therefore, the researched material has great potential for use, but further investigation is still needed to determine the complete efficiency of the material.
Technical Session
9/5/24, 10:15 AM - 9/5/24, 11:05 AM
Presenter(s): Ana Laura Lopes de Matos Riscado (UENF)
Abstract:
The red ceramics industry is very diverse in terms of sectors, raw materials and final products. The municipality of Campos dos Goytacazes is an important center for this industry, due to the abundance of clay in the region. An important aspect of manufacturing ceramic parts is controlling temperatures during the firing process, to avoid defects in the final products due to stresses resulting from thermal expansion. The following study was carried out to analyze the development and characterization of red ceramic fired at different temperatures, seeking to guarantee good properties within the required densities. The ceramic bodies were manufactured using dry pressing and were evaluated based on the following properties: linear shrinkage, water absorption, apparent porosity and tensile strength by diametrical compression. Linear shrinkage increased with increasing firing temperature. Water absorption and porosity were greater for pieces fired at 900ºC. When it comes to tensile strength due to diametrical compression, there was an increase in resistance as the firing temperature increased, and all temperatures generated sufficient resistance for the production of masonry bricks.
Technical Session
9/5/24, 10:15 AM - 9/5/24, 11:05 AM
Presenter(s): Carlos Maurício Fontes Vieira (UENF ), Bertácia Mendes da Silva (UENF), Geovana Carla Girondi Delaqua (uenf)
Abstract:
The objective of this work was to obtain a product incorporating ornamental rock residue, with high added value, and to study the technical properties of the product prepared in the laboratory. The raw materials were characterized by FRX. 5 formulations were prepared with different percentages, shaped by uniaxial pressing, and fired at 950ºC. The thermal behavior was evaluated by linear dilatometry. After burning, the water absorption, linear burning shrinkage and compression properties were evaluated. In accordance with ASTM standards, at the temperature investigated in this work it was possible to obtain laboratory masses, in all formulations, for adokins with specifications compatible with the NX type. The results indicate that both red clay and ornamental rock residue have the potential to be used in mixture with yellow clay with the aim of producing ceramic pavement with high added value
Technical Session
9/5/24, 10:15 AM - 9/5/24, 11:05 AM
Presenter(s): Carlos Maurício Fontes Vieira (UENF ), Geovana carla girondi delaqua (UENF)
Abstract:
This work aims to study the influence of the addition of fines generated from the production of crushed stone on the microstructure and technological properties such as mechanical resistance and water absorption of clayey ceramic mass obtained in Campos dos Goytacazes, aiming to improve the properties of the ceramic. This feldspar material acts as a flux, which during sintering fuses and forms a liquid phase that interacts with the clay structure, densifying it and, consequently, reducing the number of pores
Technical Session
MORPHOLOGICAL CHARACTERIZATION OF BLAST FURNACE SLAG AS RAW MATERIAL FOR ALKALI ACTIVATED MATERIALS
Presenter(s): Damares da cruz barbosa nascimento (Universidade federal do pará), rayanne oliveira leão santana (universidade federal do pará), paulo anderson Aranha ferreira (UNIVERSIDADE federal do pará), Alisson clay rios da silva (universidade federal do pará), verônica scarpini candido (universidade federal do pará)
Abstract:
The development of new materials that use raw materials from industrial waste is desirable for several applications. Blast furnace slag is a residue from the steelmaking processing of pig iron. This input has desirable characteristics and properties to be used as a raw material in alkali-activated material. Thus, the objective is to study the morphological and mineralogical characteristics of blast furnace slag from steel mills. For this purpose, hot embedding techniques, X-ray diffraction (XRD), optical microscopy (OM) and scanning electron microscopy (SEM) were performed. By XRD, it was possible to observe corresponding phases such as calcite, quartz and hematite. The morphological aspect revealed possible characteristic regions of calcium, iron oxide and luminescent quartz points. The SEM showed irregular microstructures with different shapes and forms, as well as rough and smooth regions. These characteristics make blast furnace slag a raw material with high potential for application in alkali-activated materials.
Technical Session
EFFECT OF INCORPORATION OF COCOA BARK POWDER INTO A CERAMIC MASS
Presenter(s): Geovana Carla gIRONDI dELAQUA (UENF), Elvis Pantaleão Ferreira (ifes), djalma souza (UENF), Carlos Maurício Fontes Vieira (uenf)
Abstract:
The objective of this work was the incorporation of cocoa bark into ceramic mass, evaluating the influence on the physical and mechanical properties of the ceramics. The clayey raw materials were characterized by: granulometry, FRX and DRX. Formulations were prepared with different percentages of residue, and plasticity was evaluated. Specimens were made by uniaxial pressing, and fired at different temperatures, using a heating rate of 2ºC/min and maintained at the plateau temperature for 180min. Afterwards, the properties of: water absorption and tensile strength at three-point bending were evaluated. With the results obtained, it was observed that as it is a residue with a large amount of organic matter, the quantity must be evaluated so as not to harm the properties of the ceramic. With this, it is possible to conclude that the incorporation of this residue in ceramics is a very advantageous alternative for the ceramic industry, where energy savings occur in the firing process
Technical Session
9/5/24, 10:15 AM - 9/5/24, 11:05 AM
Presenter(s): MARKSSUEL TEIXEIRA MARVILA (UFV - CRP), Marina Souza Pinto (UFV - CRP), Marília Gonçalves Marques (UFV - CRP), Leonardo Carvalho Mesquita (UFV - CRP), Afonso Rangel Garcez de Azevedo (UENF)
Abstract:
The use of agro-industrial waste, such as coffee husks, in cementitious materials is a viable way to achieve the sustainable development of new construction materials. Traditionally, these residues are applied after calcination, releasing energy and financial resources. In this sense, the objective of this research is to evaluate the possibility of using coffee husks using chemical treatments with sodium and potassium hydroxide without the need for calcination. The methodology of this article consists of producing test specimens of mortar for covering and laying walls in the composition 1:1:6:1.55 (cement: hydrated lime: sand: water), using coffee husks to be incorporated in levels of 2. 5% in relation to the mass of the cement in its natural state and after treatment in sodium and potassium hydroxide. The parameters evaluated were: mass density in the hardened state, water absorption by immersion and compressive strength. XRD and SEM tests were carried out to compare the proposed treatments. The results obtained indicate that the use of treatments with NaOH and KOH allow the use of coffee husks in mortars, as the parameters obtained were compatible with this type of application. The use of natural coffee husks is not possible due to low compressive strength and high water absorption, driven by porosity. The use of alkaline treatments, especially with KOH, does not interfere with the hydration of the cement, allowing values to be obtained that are statistically equivalent to the reference composition and greater than 2.00 MPa. It is concluded that for the application of coffee husks in coating mortars and laying blocks, chemical treatment with KOH meets the necessary parameters, contributing from an economic point of view and promoting the use of an agro-industrial residue in construction materials
Technical Session
SYNTHESIS OF CALCIUM PHOSPHATES AT DIFFERENT PH PARAMETERS
Presenter(s): Marvin do NAscimento (Instituto Militar de engenharia), MARIÁH CARIONI HIRATA (R-Crio Células Tronco), daniel navarro da rocha (R-Crio Células Tronco), Carlos Henrique da luz barbosa (INSTITUTO MILITAR DE ENGENHARIA), julianna magalhães garcia (INSTITUTO MILITAR DE ENGENHARIA), marcelo henrique prado da silva (INSTITUTO MILITAR DE ENGENHARIA)
Abstract:
Introduction: the development of calcium phosphate-based ceramic biomaterials such as hydroxyapatite and tricalcium phosphate are essential for bone regeneration in orthopedic and dental applications. Objective: this work aims to evaluate the production of calcium phosphates with different pH controls (7 and 12) and to assess the composition of crystalline and morphological phases. Materials and Methods: the synthesis of calcium phosphates was carried out using the wet aqueous precipitation method with pH control by a bioreactor and then lyophilized. The calcium phosphate powder was analyzed by X-ray diffraction and scanning electron microscopy. Results: the results of this work show how pH modulation can influence the formation of calcium phosphate phases, as well as the microstructure that can be obtained in terms of particle size and distribution. Conclusion: calcium phosphates are essential in bone regeneration, and pH control during synthesis influences phase formation.
Technical Session
MICROSTRUCTURAL CHARACTERIZATION OF AMELODENTINARY COMPLEX TOPOGRAPHY
Presenter(s): Marvin do NAscimento (instituto militar de engenharia), guilherme monteiro torelly (Pontifícia Universidade Católica do Rio de Janeiro), carlos henrique da luz barborsa (INSTITUTO MILITAR DE ENGENHARIA), julianna magalhães garcia (INSTITUTO MILITAR DE ENGENHARIA), marcelo henrique prado da silva (INSTITUTO MILITAR DE ENGENHARIA)
Abstract:
Introduction: Enamel and dentin are the main hard tissues of the tooth and correspond to the amelodentinary complex. These tissues have, respectively, 97% and 70% ceramic material, mainly hydroxyapatite. Objective: This study aims to characterize the surface properties of the amelodentinary complex, employing techniques for microstructure, wettability, and roughness analysis. Materials and Methods: 20 tooth samples, in total, were divided into three groups: standard (no change), 37% acid etching and adhesive system. Results: Enamel has prismatic and aprismatic regions, while dentin has dentinal tubules, peritubular and intertubular dentin. Surface changes of these tissues can influence roughness and wettability parameters, and in general topography properties. Conclusion: It is possible to identify that these surface changes in dental tissues alter structural properties, which may influence their interaction with the adhesive systems.
Technical Session
9/5/24, 10:15 AM - 9/5/24, 11:05 AM
Presenter(s): matheus queiroz de sant'anna pereira (uenf), Felipe Daflon Gama (uenf), José Lucas Decoté de Carvalho Lirio (uenf), José Alexandre Tostes Linhares (uenf), Markssuel Teixeira Marvila (ufv), Carlos Maurício Fontes Vieira (uenf)
Abstract:
Studies involving geopolymeric materials have advanced in recent years. This is due to the great potential of this material to replace raw materials such as cement, which is responsible for a high level of greenhouse gas emissions in its production processes and red ceramic artifacts, which require a large amount of energy in their stage burning. Given the context, geopolymers require an energy quantity that may in some cases be lower than that required by ceramics. Therefore, the possibility of exploring geopolymers in commonly used artifacts, such as tiles, must be evaluated. This work aims to evaluate the technological properties of geopolymers produced from metakaolin, in order to determine whether the material meets the minimum specifications required by regulations for the production of tiles.
Technical Session
9/5/24, 10:15 AM - 9/5/24, 11:05 AM
Presenter(s): NIANDER aguiar cerqueira (UENF - ALBERTO LAMEG), Elias Sócrates do Nascimento Junior (UENF), Gabryel de Carvalho Alves (UENF), Keize Delvalle dos Santos Ferraz Cereja (UENF), afonso rangel garcez de azevedo (uenf), Gustavo de castro xavier (uenf), jonas alexandre (uenf)
Abstract:
Soil-cement bricks are known as ecological bricks, although they use cement, as they use materials with lower added value, cause less environmental impact and allow the incorporation of various wastes into their composition. In this context, in the present research, soil-cement bricks were produced and evaluated with the addition of iron ore waste. Four block compositions were developed: reference composition (Tr: soil only); soil with 5% (T1), 15% (T2) and 20% (T3) ore waste residues. The tests included Initial Water Absorption (AAI), Water Absorption and compressive strength. As for AAI, there was no statistical variation between the bricks with the compositions. Water absorption (AA) indicated values ranging from "13.8±2.52% to 17.1±1.01%" at 28 days. Compressive strength was evaluated at 7 and 28 days of curing, with values greater than 1.8±0.2 MPa" of resistance. The results showed that all bricks presented interesting compositions for the manufacture of soil-cement bricks, as the incorporation of ceramic waste did not compromise the technological properties. It is concluded with the information from this research that, for environmental reasons, the composition with 20% residue is more indicated.
Technical Session
ANALYSIS OF THE INFLUENCE OF ADDITIVES AND GLASS WASTE ON THE PLASTICITY OF CERAMIC MASSES USING THE PFEFFERKORN METHOD
Presenter(s): paula munier ferreira (UENF), Geovana Carla Girondi Delaqua (UENF), Carlos Maurício Fontes Vieira (UENF)
Abstract:
The formulation of ceramic masses requires a long process of research and testing to achieve the ideal composition. In the shaping of ceramic products, especially in extrusion, plasticity is crucial, determining the adaptability of the mass. Additives such as plasticizers and deflocculants are used to improve plasticity, ensuring optimal flow. This study analyzes the impact of different additives on the plasticity of ceramic masses, aiming to reduce the amount of water required for forming. The inclusion of glass waste in the mass was also investigated, since the ceramic industry stands out for its use of waste. Formulations were developed with clay mass, glass waste and four types of additives: corn starch, sodium silicate, CMC and citric acid. The results highlighted that all additives, with the exception of CMC, reduced moisture and plasticity compared to mass 0 (reference), with citric acid being the most effective. Furthermore, the potential of glass was also highlighted, which in all cases contributed to reducing the plasticity of the masses and, consequently, the amount of water required.
Technical Session
9/5/24, 10:15 AM - 9/5/24, 11:05 AM
Presenter(s): Ramon fernandes de abreu (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO), Valber Domingos Pinheiro (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO), jonas alexandre (12754025774), mariana almeida de azevedo pessôa (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO), romário moreira siqueira (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO), renan ferraz novaes (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO)
Abstract:
This article conducted a bibliometric analysis on the use of expanded vermiculite in mortars, focusing on recent advances in engineering and materials science. Driven by the need for more efficient and sustainable constructions, the research analyzed publications between 2014 and 2024 in the Scopus and Web of Science databases. Quantitative and statistical techniques were employed with the assistance of Excel and VOSviewer software. The results showed a significant increase in publications over the last three years, with Turkey, Brazil, and China leading in the number of studies. However, the co-authorship analysis revealed little collaboration among researchers, indicating a need for greater international cooperation. Expanded vermiculite stood out for its thermal insulation properties and lightness, contributing to energy efficiency and the reduction of greenhouse gas emissions.
Technical Session
9/5/24, 10:15 AM - 9/5/24, 11:05 AM
Presenter(s): RAYANNE OLIVEIRA LEAO SANTANA (UNIVERSIDADE FEDERAL DO PARÁ), Paulo Anderson Aranha Ferreira (UNIVERSIDADE FEDERAL DO PARÁ), Giovana Zagalo de França (UNIVERSIDADE FEDERAL DO PARÁ), Emily de Fátima Pinheiro Botelho (UNIVERSIDADE FEDERAL DO PARÁ), vitor leão santana (UNIVERSIDADE FEDERAL DO PARÁ), Alisson Clay Rios da Silva (UNIVERSIDADE FEDERAL DO PARÁ), Verônica Scarpini Candido (UNIVERSIDADE FEDERAL DO PARÁ)
Abstract:
In civil engineering, fiber-reinforced composites emerge as a promising innovation to enhance mechanical properties of materials like mortar and concrete, reducing environmental impacts and optimizing resources. The use of residual fibers aims to improve properties and control fissures, standing out as a sustainable solution. This article investigates the effect of adding polyester fibers at different proportions (0%, 0.15%, and 0.30%) on mortar compression strength. Materials included high initial strength Portland cement, commercial sand, and recycled polyester fibers from tire waste, reflecting a sustainable approach in civil construction. Test results show increased compression strength with fiber addition: 14.5 MPa for 0%, 15.2 MPa for 0.15%, and 16.1 MPa for 0.30%. Additionally, optical microscopy analysis revealed texture changes in mortars with increased fibers, indicating greater cohesion and adhesion. These findings suggest that incorporating polyester fibers can significantly enhance mortar compression strength, contributing to the development of more efficient and sustainable construction materials. This study highlights the feasibility and potential application of these fiber-reinforced composites in the civil construction industry.
Technical Session
9/5/24, 10:15 AM - 9/5/24, 11:05 AM
Presenter(s): RENAN FERRAZ NOVAES (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO - UENF)
Abstract:
This study aims to perform a comparative analysis of the influence of incorporating ornamental rock residue (RRO), from the Santa Alice Granitos company, located in Cachoeiro do Itapemirim/ES, on the rheological behavior of fresh-state mortars. To this end, mortars with mass ratios of 1:3 (cement:sand) are examined, using CPII E 32 cement and quartz sand, with the addition and replacement of RRO in concentrations of 0% (REF), 10%, 20%, and 30%, through tests of consistency, bulk density, air content, and water retention. The results indicate a parity between partial replacement and addition of RRO, thus demonstrating the feasibility of using both methods, as well a significant influence of this residue on the composition and properties of the studied mortars.
Technical Session
THE IMPACT OF INCORPORATING GRAPE WASTE INTO THE TECHNOLOGICAL PROPERTIES OF RED CERAMIC
Presenter(s): Renata Ribeiro Mendes (UENF ), Elvis Pantaleão Ferreira (ifes), Geovana Carla Girondi Delaqua (uenf), Carlos Maurício Fontes Vieira (uenf), Afonso Rangel Garcez de Azevedo (uenf)
Abstract:
The aim of this work was to study the effects of introducing grape waste on the technological characteristics of ceramics after the firing process. Compositional analysis was carried out using X-ray fluorescence (XRF), followed by processing of the raw materials to ensure uniform particle size. Various formulations were prepared, incorporating up to 5% grape waste, which was then moistened and molded into test specimens. After firing at different temperatures, properties such as water absorption, linear shrinkage, flexural strength and plasticity index were meticulously evaluated. The results revealed an increase in linear shrinkage and water absorption as the amount of grape waste increased, while flexural strength showed a downward trend. It was concluded that the addition of waste should be carried out with caution in order to preserve the final quality of the ceramic. This study provides valuable perspectives for the sustainable advancement of the ceramics industry by exploring the potential of grape waste as a raw material.
Technical Session
9/5/24, 10:15 AM - 9/5/24, 11:05 AM
Presenter(s): RITA DE KASSIA GONCALVES PEREIRA (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO - UENF), Raquel Amendro Faria (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO - UENF), Ana Carolina Morato Teixeira (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO - UENF), Romário Moreira Siqueira (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO - UENF), Jonas Alexandre (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO - UENF), Markssuel Teixeira Marvila (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO - UENF), Afonso Rangel Garcez de Azevedo (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO - UENF), Carlos Maurício Fontes Vieira (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO - UENF)
Abstract:
The pressing need to find sustainable solutions in the construction industry is indisputable, given its significant demand for natural resources. This study focuses on the use of waste resulting from the cutting of stainless steel as raw material for the production of mortars used in laying masonry. The main objective is to mitigate the environmental impacts associated with the disposal of this waste, while at the same time evaluating the behavior of this waste in coating mortars. To evaluate the technical feasibility of this approach, laboratory tests of mass density, incorporated air content, water retention and consistency index were conducted in accordance with the relevant Brazilian standards. The mortars were dosed in a 1:1:6 ratio (cement, lime and sand) with additions of residue in their formulation in percentages of 5% and 10%, in addition to a reference sample for a comparative basis. The results obtained indicated that the mixtures with the addition of the residue in all formulations were within regulatory standards and, in addition, it was possible to observe an increase in mortar shrinkage in the fresh state, when related to the reference mix.
Technical Session
COMPARATIVE ANALYSIS OF MORTAR WITH ADDITION AND REPLACEMENT OF ROCK WASTE
Presenter(s): ROMARIO MOREIRA SIQUEIRA (UNIVERSIDADE ESTADUAL NORTE FLUMINENSE), Renan Ferraz Novaes (UNIVERSIDADE ESTADUAL NORTE FLUMINENSE), Jonas Alexandre (UNIVERSIDADE ESTADUAL NORTE FLUMINENSE), Raquel AMENDRO FARIA (UNIVERSIDADE ESTADUAL NORTE FLUMINENSE), Ramon Fernandes de AbreU (UNIVERSIDADE ESTADUAL NORTE FLUMINENSE), Marcela da Silva Luna Paravidino (UNIVERSIDADE ESTADUAL NORTE FLUMINENSE), Afonso Rangel Garcez de Azevedo (UNIVERSIDADE ESTADUAL NORTE FLUMINENSE)
Abstract:
The main objective of this study is to analyze the impact of the addition and replacement of ornamental rock residue (RRO), obtained at Santa Alice Granitos, located in Cachoeiro do Itapemirim/ES, on mortar properties. For this, mortar mixes with mass proportions of 1:3 (cement:sand) will be used, using CPII E 32 cement and incorporating RRO in concentrations of 10%, 20% and 30%. The tests carried out cover the determination of tensile strength in flexion and compression. The results obtained indicate that the partial replacement of sand with ornamental rock residue results in significant improvements in the mechanical properties of the mortar, in relation to the addition of RRO, highlighting its potential as a beneficial component in the formulation of cement mixtures.
Technical Session
MAGNESIUM SILICATE-BASED BIOCERAMICS WITH SEPARATE ADDITIVES OF HYDROXYAPATITE AND NIOBIA
Presenter(s): sAMUEL SOARES FERBER (IME - INSTITUTO MILITAR DE ENGENHARIA), MARVIN DO NASCIMENTO (IME - INSTITUTO MILITAR DE ENGENHARIA), CARLOS HENRIQUE DA LUZ BARBOSA (IME - INSTITUTO MILITAR DE ENGENHARIA), JULIANNA MAGALHÃES GARCIA (IME - INSTITUTO MILITAR DE ENGENHARIA), Marcelo Henrique Prado da Silva (IME - INSTITUTO MILITAR DE ENGENHARIA)
Abstract:
Magnesium silicate-derived bioceramics have gained prominence as alternatives to calcium phosphates (such as hydroxyapatite) for use in bone repair due to the role played by Si2+ and Mg2+ ions in this biological process. In this context, this work aims to analyze the bioactivity of magnesium silicate doped with different fractions of hydroxyapatite and niobia. For this purpose, the synthesis of magnesium silicate was carried out by the solid-state reaction method. The addition of hydroxyapatite and niobia (two different groups mixed by weight percentage) was also performed by solid-state reaction. The bioactivity test was conducted by immersing the samples in an artificial saliva solution. These biomaterials were characterized using field emission scanning electron microscopy (FE-SEM) and X-ray diffraction (XRD). Finally, the results suggest that increasing the hydroxyapatite content increased the material's bioactivity; the same is not true for the addition of niobia.
Technical Session
9/5/24, 10:15 AM - 9/5/24, 11:05 AM
Presenter(s): SUZANA NORONHA Ferreira RIBEIRO (Universidade Presbiteriana Mackenzie)
Abstract:
Brazil is considered a developing country. In recent decades, it has shown remarkable progress in various aspects of the economy, education, politics, science, and health. Recent advances in tissue engineering have focused on using biochemical and physicochemical signals to trigger specific cellular responses and encourage better biological interaction between biomaterial and living tissue. As a result, there has been significant interest in the development of smart biomaterials capable of generating in situ electrical stimuli for accelerated bone repair, healing, and regeneration. Piezoelectric ceramics could hold the key to functionalizing current grafts, as they exhibit electric behavior generated mechanically. In this study, the production of potassium-sodium niobate (K0.5Na0.5NbO3) obtained through solid-state reaction (SSR) and sintered via conventional sintering and spark plasma sintering (SPS) will be adopted to observe changes in the microstructure. The synthesis was efficient, and the material displays characteristics that validate its potential biomedical application, along with excellent piezoelectric results.
Technical Session
9/5/24, 10:15 AM - 9/5/24, 11:05 AM
Presenter(s): THUANY ESPIRITO SANTO DE LIMA (Centro Federal de educação tecnológica celso suckow da fonseca)
Abstract:
The cement industry is one of the main sources of environmental pollution due to the high emission of carbon dioxide (CO2) during the production of Portland cement, contributing to climate change. Furthermore, agribusiness in Brazil generates a large amount of waste, such as rice husks, which are normally discarded incorrectly. In this context, the present work aims to evaluate technological parameters of concrete with partial replacement of Portland cement by carbonized rice husk (CAC), seeking to reduce pollution and promote sustainability in construction, while seeking to save costs. Therefore, the main objective of this study is to investigate the performance of concrete with different levels of cement replacement by CAC (5%, 7% and 10%). To achieve this, a practical experiment was carried out, crushing the CAC to ensure a homogeneous mixture and using a plasticizing additive to improve the workability of the concrete. Eight specimens were molded for each trait, totaling 32 samples. Several tests were carried out, including the slump test to evaluate consistency, axial compression strength to verify the ability to withstand vertical loads, diametral compression strength to analyze tensile strength and capillarity tests to evaluate durability and absorption. of water. The results obtained show that replacing cement with CAC has little effect on the technological parameters of concrete, with workability and water absorption within the expected standard for use in various concrete applications in civil construction. Despite the loss of resistance in the traits with CAC, acceptable levels were maintained with the trait with 7% replacement, showing better results among the traits with CAC. Therefore, this study seeks to contribute to reducing carbon emissions from the construction industry, promoting the use of agricultural waste as a sustainable and economical alternative in concrete production. The results obtained may have important implications for the adoption of more sustainable practices in the construction sector, benefiting both the environment and the economy.
Technical Session
9/5/24, 10:15 AM - 9/5/24, 11:05 AM
Presenter(s): Alan dutra pedruzzi (USP), Mariane costalonga de aguiar (CETEM), Monica castoldi borlini gadioli (cetem), Abiliane de andrade pazeto (Decolores Mármores e Granitos)
Abstract:
Due to the increasing application of agglomerated stones in civil construction, it has become necessary to carry out technological characterization tests in order to understand their physical and mechanical properties. As they are materials used as internal or external cladding, they can be subjected to environments that present large temperature variations, occasionally fragility and structural problems. Thermal fatigue is the process in which the material repeatedly undergoes temperature cycles, generating internal expansion and contraction stresses, generating brittleness in the material over time. Therefore, investigating how thermal fatigue affects the mechanical properties of agglomerated stones, through tests, becomes essential for preserving their quality. In this study, thermal shock resistance and resistance to freezing and thawing tests were carried out with the commercial agglomerated stones Branco Aldan and Branco Galaxy, observing how temperature cycles can influence the mechanical behavior of these materials, using the flexural strength test as a control before and after the cycles. The results indicated that thermal fatigue cycles had no influence on the mechanical behavior of these materials and their resistances were higher compared to control samples, due to natural variability.
Technical Session
COMPARATIVE ANALYSIS OF THE CRITICALITY OF A HYPOTHETICAL FUEL ELEMENT WITH RODS COATED WITH 316 STAINLESS STEEL DOPED WITH SiC THROUGH COMPUTER SIMULATION
Presenter(s): Ary Machado de Azevedo (IME), Thomaz jacintho lopes (ime), Marcos Paulo Cavaliere de Medeiros (ime), Fernando Manuel Araújo Moreira (ime), Sérgio neves monteiro (ime), joana batista soares (ime), Domingos D’Oliveira Cardoso (ime), André Ben-Hur da Silva Figueiredo (ime)
Abstract:
This study investigated the impact of doping 316 Stainless Steel with silicon carbide (SiC) nanoparticles on the performance of nuclear fuel through computational simulations using the MCNP5 software. The results indicated that the addition of SiC did not significantly affect the effective multiplication factor (keff), suggesting that this doping could be a viable strategy to improve the fuel properties without compromising its effectiveness. Additionally, the inclusion of SiC may offer additional benefits, such as increased thermal stability and corrosion resistance. These findings highlight the potential of SiC as a promising additive for the development of safer and more efficient fuel elements in nuclear reactors, paving the way for future research and innovations in the nuclear energy field.
Technical Session
9/5/24, 10:15 AM - 9/5/24, 11:05 AM
Presenter(s): NICOLE THOMAZ AQUINO DRUMOND COUTINHO (UNIVERSIDADE ESTADUAL NORTE FLUMINENSE)
Abstract:
Casuarina has been studied by some authors as a substitute for synthetic fibers in composites due to its possible potential for use in engineering since it has characteristics similar to wood, also as a possible substitute for cellulose and possibly in pipe coatings, for example.This article aims to study the behavior of casuarina fruit powder in a polymeric matrix in flexure tests. After crushing and siving, the casuarina powder was prepared in 16 specimens, half with 5% and half 10% of the particulate integrated into the epoxy resin with a DGEBA/THETA system, using the ASTM D790 standard as support for the three-point flexure test, at a rate of 1mm/min.
Technical Session
9/5/24, 10:15 AM - 9/5/24, 11:05 AM
Presenter(s): Odilon LEITE BARBOSA DA COSTA (IME - INSTITUTO MILITAR DE ENGENHARIA), Marcelo Ferreira Leão de Oliveira (Instituto nacional de tecnologia), Debora Cristina da Silva Santos (INSTITUTO NACIONAL DE TECNOLOGIa), Marcia Gomes de Oliveira (INSTITUTO NACIONAL DE TECNOLOGIa), Valdir Florêncio da Veiga Junior (IME - INSTITUTO MILITAR DE ENGENHARIa)
Abstract:
The valorization of agro-industrial residues has proven essential to promote sustainability and the circular economy. Açaí seeds, an abundant byproduct of fruit processing, have great potential for application in biodegradable polymer composites. This study aimed to characterize the physico-chemical properties of açaí seeds (Euterpe edulis, Euterpe oleracea, Euterpe precatoria). The seeds were washed, dried, ground, and sieved. Density was determined by gas pycnometry, with values of 1.59 g/cm³ for E. precatoria, 1.61 g/cm³ for E. edulis, and 1.48 g/cm³ for E. oleracea. Thermal stability was analyzed by thermogravimetric analysis (TGA), showing initial decomposition temperatures (Tonset) of 243.63°C for E. edulis, 260.92°C for E. oleracea, and 251.98°C for E. precatoria. Chemical composition was observed by Fourier-transform infrared spectroscopy (FTIR) and crystalline structure by X-ray diffraction (XRD). Scanning electron microscopy (SEM) was used to observe morphology. The results indicated that açaí seeds contain cellulose, hemicellulose, and lignin. These materials have favorable characteristics for use as reinforcement in biodegradable polymer composites (PBAT, PLA, PBS), contributing to the creation of more sustainable materials and valuing residues that would otherwise be discarded.
Technical Session
ANALYSIS AND BALLISTIC EVALUATION OF EPOXY COMPOSITES REINFORCED WITH SEVEN-ISLAND SEDGE FIBERS AND FUNCTIONALIZED WITH GRAPHENE OXIDE
Presenter(s): PATRICK DE LIMA GOMES (IME - INSTITUTO MILItar de Engenharia), Lucas de mendonça neuba (IME - INSTITUTO MILITAR DE ENGENHARIA), Elias matias bentes (IME - INSTITUTO MILITAR DE ENGENHARIA), yago Soares Chaves (IME - INSTITUTO MILITAR DE ENGENHARIA), claudinei dos santos (uerj - Fat - Universidade do Estado do Rio de Janeiro ), Sérgio Neves Monteiro (ime - instituto militar de engenharia), Carlos nelson Elias (IME - INSTITUTO MILITAR DE ENGENHARIA)
Abstract:
Fiber-reinforced polymer matrix composites combine low density and high mechanical strength, making them crucial for various engineering applications, including personal ballistic protection. The scientific community is seeking to develop sustainable materials, such as the incorporation of natural lignocellulosic fibers (NLFs) into polymeric matrices. This study proposes the use of seven-island sedge fibers (Cyperus malaccensis Lam.) as a reinforcement in epoxy matrix, investigating the effects of mercerization treatment and functionalization with graphene oxide (GO). The application of this composite in a multilayer shielding system (SBMs) will be explored for the first time. The characterization of the treated fibers and the composites will be carried out using techniques such as scanning electron microscopy (SEM), and the mechanical tests will include bending tests and dynamic-mechanical analysis (DMA). Ballistic evaluation will involve residual velocity tests with 7.62 mm caliber ammunition and tests with plasticine-bonded SBMs. The results will be statistically analyzed via ANOVA.
Technical Session
DETERMINATION OF THE COMPRESSION RESISTANCE OF GEOPOLIMERIC CEMENTS WITH THE ADDITION OF RESIDUAL POLYESTER FIBERS BY VARYING THE LENGTH
Presenter(s): paulo anderson aranha ferreira (universidade federal do pará), Giovana zagalo de frança (UNIVERSIDADE FEDERAL DO PARÁ), rayanne oliveira leão santana (UNIVERSIDADE FEDERAL DO PARÁ), MIRIANE ALEXANDRINO PINHEIRO (UNIVERSIDADE FEDERAL DO PARÁ), VERÔnica scarpini candido (UNIVERSIDADE FEDERAL DO PARÁ), ALISSON CLAY RIOS DA SILVA (UNIVERSIDADE FEDERAL DO PARÁ)
Abstract:
Portland cement concrete is the second most consumed material on planet Earth, due to its use in buildings, paving and structures. However, the combined production process for its production generates a significant amount of CO2, which worsens the greenhouse effect. Therefore, engineers and materials scientists are researching alternative cements that have green technology in their processing and high performance. Geopolymers are inorganic cementitious materials formed from a source of aluminosilicates and an alkaline solution. Which, based on Si-O-Al bonds, present high mechanical resistance, durability and retractability. And they can be produced with low energy cost waste and clay materials. The present work aimed to evaluate the influence of the length of short residual polyester fibers on the compressive strength of geopolymers based on metakaolin with the addition of blast furnace slag. For this, metakaolin obtained at 850°C for 2h, 35% blast furnace slag, sodium hydroxide, sodium silicate and residual polyester fibers (PLE) from the tire industry were used. A priori, the specimens for the compression resistance test were molded, with a fixed addition of 0.5% PLE fiber, varying three lengths, 5, 10 and 15 mm. After 7 days of curing, the specimens were subjected to the compression resistance test, and their physical properties of water absorption and specific mass were determined. In addition, optical microscopy (OM) of each post-test variation was performed. Geopolymer cement with 5mm fiber showed greater compressive strength, with 42.45 MPa, with physical properties similar to those found in the literature. Furthermore, it was noted, through optical microscopy, that as the length of the fiber is increased, there is greater anchoring in the geopolymeric matrix.
Technical Session
9/5/24, 10:15 AM - 9/5/24, 11:05 AM
Presenter(s): Pedro Huang (Uenf), Rogério Rabello da Rocha Júnior (UENF), DAVID COVERDALE RANGEL VELASCO (UENF), FELIPE PERISSÉ DUARTE LOPES (UENF), CARLOS MAURÍCIO FONTES VIEIRA (UENF), NOan tonini simonassi (uenf)
Abstract:
Recently, the development of composites that use waste as reinforcement has grown, aiming not only materials that are more accessible and with better mechanical properties, but also an overall reduction usage of non-renewable resources in addition to the total reduction in costs associated with waste disposal. This work aims to compare the performance of epoxy matrix composites reinforced by melga (broom sorghum) culm structures undivided and longitudinally cut melga. Composites were made in plates with volumetric fractions from 40 up to 70% and, later, subjected to mechanical testing of the type Izod, carried out on a PANTEC Pendulum impact testing machine, model XC-50. The results indicate that culms cut longitudinally tend to present higher values of impact resistance and notch resistance, when compared to undivided culms with the same volume fraction concentration. It was also noted, after cutting along the longitudinal axis, a reduction, both in quantity and size, in the presence of bubbles and cracks.
Technical Session
9/5/24, 10:15 AM - 9/5/24, 11:05 AM
Presenter(s): RAFAEL BITTENCOURT MIRANDA (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO - UENF), ELAINE APARECIDA SANTOS CARVALHO (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO - UENF), Raquel Amendro Faria (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO - UENF), AFONSO RANGEL GARCEZ AZEVEDO (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO - UENF), SÉRGIO NEVES MONTEIRO (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO - UENF)
Abstract:
Industrialization has led to increased generation of improperly disposed waste, including the ornamental rock sector which loses about 83% of its original raw material in the form of waste, causing environmental complications. Another problem arising from urbanization is soil sealing due to asphalt and cement paving in urban areas, leading to floods and inundations. As a solution to these issues, the production of permeable pavements using discarded waste is presented. This study aims to fabricate and analyze the mechanical performance of permeable pavement using marble residue and UV-resistant polyester resin as a binder. The marble residue permeable pavement with polyester resin achieved a permeability rate of 6.12±0.08 mm/s and a maximum flexural strength of 2.29±0.09 MPa, with a reduction in flexural strength of 11.79% when saturated, indicating good material performance compared to cementitious matrix permeable pavements.
Technical Session
CHARACTERIZATION OF X-BAND ELECTROMAGNETIC PROPERTIES OF EPOXY COMPOSITES REINFORCED WITH JUTE FABRIC AND CARBON BLACK
Presenter(s): RAPHAEL HENRIQUE MORAIS REIS (IME MILITAR DE ENGENHARIA)
Abstract:
The growing demand for efficient composite materials in electromagnetic shielding drives the development of epoxy composites reinforced with jute fabric and carbon black (CB) for X-band applications. Degassing the epoxy resin prevents air bubbles, crucial for shielding effectiveness. Produced with 30% vol. jute and 5% vol. CB, the composites were molded via hydraulic compression and tested for electrical conduction, infrared transmittance, and shielding effectiveness (SE). Degassing did not alter magnetic permeability, keeping the materials non-magnetic. The electric permittivity ranged between 3 and 7, indicating good shielding efficiency by reflection. Electrical resistivity revealed highly resistive materials, optimizing electromagnetic shielding, and infrared transmittance showed complete light absorption between 500 and 3000 nm, indicating high stealth against optical equipment. It is concluded that the doped composites maintain non-magnetic properties and present potential for electromagnetic shielding via reflection, with high electrical resistivity and effectiveness against infrared radiation
Technical Session
9/5/24, 10:15 AM - 9/5/24, 11:05 AM
Presenter(s): raquel Amendro faria (UNIVERSIDADE ESTADUAL NORTE FLUMINENSE), Elaine Aparecida Santos Carvalho Costa (UNIVERSIDADE ESTADUAL NORTE FLUMINENSE), Rafael Bittencourt Mirandal (UNIVERSIDADE ESTADUAL NORTE FLUMINENSE), Carlos Maurício Fontes Vieira (UNIVERSIDADE ESTADUAL NORTE FLUMINENSE)
Abstract:
Impervious surfaces, such as roads, parking lots, roofs and sidewalks, play a crucial role in the urban expansion and infrastructure of modern cities. However, its indiscriminate increase contributes to the sealing of the soil, resulting in significant drainage problems and increased surface runoff during rain events. Removing vegetation and replacing it with impermeable pavement alters the natural balance of the soil, compromising its ability to absorb water. This, in turn, intensifies the risks of flooding, soil erosion and environmental degradation. Given this scenario, the search for alternative soil coverings that can minimize such impacts becomes imperative. Porous or draining pavements have permeability indices, while interlocking pavements and grassy pavements are evaluated in terms of percentage of water absorption. These characteristics reflect the ability of these different types of pavements to deal with water infiltration, contributing to the adequate management of rainwater runoff in urban environments. To evaluate the technical feasibility of drainage pavements, a comparative study of permeability, water absorption and void index, was carried out between drainage concrete and polymeric permeable pavement developed in the laboratory.
Technical Session
9/5/24, 10:15 AM - 9/5/24, 11:05 AM
Presenter(s): Renata Lima Lorusso Sampaio (IME), Késia Simões Ribeiro (IME), Patrick de Lima Gomes (ime), Carlos nelson elias (ime)
Abstract:
The increasing demand for aesthetic dental treatments has made orthodontic aligners made from thermoplastic polymeric materials the best alternative to conventional fixed treatments. Aligners are used in conjunction with attachments bonded to the teeth, which direct the applied force and provide anchorage during orthodontic movement. The aligners are replaced every two weeks, but the attachments remain until the end of the treatment. The disadvantages of aligners include the adhesion of cariogenic biofilm, color degradation, and secondary caries at the tooth/aligner interfaces. To minimize these problems, it is necessary to develop attachments made of resin composites with good mechanical properties, low bacterial adhesion, and resistance to degradation. Adding bactericidal nanoparticles to the resins has become a strategy to control bacterial adhesion. This study aims to evaluate the hardness and roughness of dental resins used in the fabrication of attachments after the incorporation of antimicrobial nanoparticles. The samples will be divided into groups of resins with high and low viscosity, with and without the incorporation of nanoparticles. The results showed that low-viscosity resins have higher roughness and lower hardness, making them less suitable for the fabrication of attachments. The addition of bactericidal nanoparticles did not affect the properties of the analysed composites.
Technical Session
IMPACT OF RESIN MODIFIERS ON EPOXY STRUCTURAL PROPERTIES WITH ADDED GRANITE PARTICLES
Presenter(s): Rogério Rabello da Rocha Júnior (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO - UENF), José Lucas Decoté de Carvalho Lirio (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO - UENF), NOAN TONINI SIMONASSI (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO - UENF), FELIPE PERISSE LOPES DUARTE (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO - UENF), CARLOS MAURÍCIO FONTES VIEIRA (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO - UENF), SERGIO NEVES MONTEIRO (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO - UENF)
Abstract:
The study aims to evaluate the mechanical behavior of composites by varying the “phr” stoichiometry (parts of hardener per resin). DGEBA/TETA epoxy resin was used, varying the amount of hardener between 10% and 20% by mass. The granite waste was crushed and incorporated into 45% of the resin. Test specimens were molded, cured for 24 hours and tested after one week for tensile, compressive and flexural strength. The results showed that the addition of granite particles reduced the compressive strength of the composites compared to the pure resin. ANOVA analysis indicated that varying the amount of hardener did not significantly affect the modulus of rupture in the composites, while for the pure resin, the strength increased significantly from 17.5% hardener. The modulus of elasticity was not significantly affected by the amount of hardener. It was concluded that the increase in phr did not significantly influence the strength of the composites, while the pure resin showed performance gains from 17.5% hardener. To save hardener, it is recommended to use 10% for composites, providing longer working time due to exothermic reactions.
Technical Session
9/5/24, 10:15 AM - 9/5/24, 11:05 AM
Presenter(s): SARAH CATHARINA VITALI DE MELO (IME- instituto MILITAR DE ENGENHARIA), sergio neves monteiro (ime - instituto militar de engenharia), lucio fabio cassiano nascimento (ime - instituto militar de engenharia)
Abstract:
Ballistic impact generates instantaneous loads, non-uniform stress, and strain distributions in the target material, resulting in localized fractures. Thus, the manufacture of advanced composites, with an emphasis on polymer matrices impregnated with fibers in laminated form (FRPCs), is widely used in various sectors involving high-velocity impacts. Many studies show that the deficiencies of some composites can be effectively addressed by fiber hybridization. Since the ballistic properties of the material are more related to the fibers, the composite's response is determined by the arrangement of these fibers. There are several failure and energy absorption mechanisms that can simultaneously arise in laminated polymer composites under high-velocity impacts, such as plastic deformation, fiber breakage, matrix cracking, pull-out, fiber bridging, and delamination. The high loading rates drastically affect the mechanical properties of the material in question. Therefore, predicting the impact resistance of the laminate is crucial. However, the failure mechanisms and damage analyses of this type of impact are complex, and there is no widely recognized analytical model to predict the damage.
Technical Session
RESIDUAL SPEED OF THE SILICON CARBIDE AND ALUMINA COMPOSITE, IN DIFFERENT PROPORTIONS
Presenter(s): SHANELY DA SILVA RIBEIRO (instituto militar de engenharia)
Abstract:
Different proportions of compounds have been widely disseminated and studied for applicability in engineering and industry in general. The series of applications of silicon carbide and alumina, in various sectors, due to their excellent properties such as mechanical resistance, high resistance to abrasion and high hardness, shows the feasibility of joining two materials for different applications. The present study uses these two elements, in proportions of 40/60 and 60/40, percentage by weight, to manufacture a composite to analyze the applicability in possible individual ballistic protections, through residual speed and absorbed energy With the support from the Army Assessment Center (CAEx), it was possible to carry out ballistic tests, in accordance with the NIJ 0101.04 standard, using a 7.62 x 51mm caliber. The composite studied is a commercial product from the company CETARCH. The tested specimens were made with stainless steel plate, polyurethane glue and ceramic insert. The experimentally obtained data showed that the experimental values found were 2.30 and 2.50 kJ of absorbed energy for the 40/60 and 60/40 composite, respectively. The effectiveness of the insert proved to be capable of implementing it for individual ballistic protection, however with the need for further testing in accordance with the specified standard, other proportions of the composite and the possibility of adhering natural fibers to improving absorbed energy.
Technical Session
9/5/24, 10:15 AM - 9/5/24, 11:05 AM
Presenter(s): SHEILA MARA SANTOS DA SILVA (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO - UENF), Madeleing Taborda Barraza (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO - UENF), Johnata França Fanni Freitas (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO - UENF), Leandro Barbosa de Oliveira (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO - UENF), Davi Vaz André Júnior (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO - UENF), Isabela Devesa Batista (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO - UENF), Ana Laura Lopes de Matos Riscado (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO - UENF), Afonso Rangel Garcez de Azevedo (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO - UENF)
Abstract:
To understand the effect of fine materials in geopolymeric systems, the addition of silica fume in mass proportions of 1%, 2.5%, and 5% was investigated in a binary system of metakaolin and fly ash, activated with sodium hydroxide and sodium silicate. The modifications were evaluated in the pastes in both fresh and hardened states, using mini-slump, viscosity and compressive strength tests at two different ages. The results demonstrated that the incorporation of silica fume reduces the workability and increases the viscosity of the pastes. Only the addition of 1% silica fume did not lead to a decrease in compressive strength, but its contribution was merely a 4% increase. This indicates that the proportion of SiO2 in the system is sufficient to promote the reaction kinetics that lead to good mechanical performance of the composite.
Technical Session
ARTIFICIAL STONES PRODUCED WITH MIRROR AND GRANITE WASTE IN A POLYMER MATRIX WITH VARIATIONS IN GRANULOMETRIC COMPOSITION AND COMPACTION PRESSURE
Presenter(s): Thaís Leal da Cruz Silva (UENF/IFES), Marcelo Barcellos Reis (UENF), Elaine Aparecida Santos Carvalho Costa (UENF), Carlos Maurício Fontes Vieira (UENF)
Abstract:
Proper management of industrial waste is an essential concern due to the polluting potential and environmental impacts it can cause. Consequently, there is a growing interest in studying the application of waste to develop new materials. Therefore, the objective of this research was to produce artificial stone plates, using mirror residues and granite residues in an epoxy matrix and analyze their properties based on variations in granulometric composition and compaction pressure during their manufacturing process using vibration, compression and vacuum. The plates produced were characterized through 3-point flexural strength tests, determination of apparent density, apparent porosity and water absorption, in addition to microstructure analysis. Based on the data analyzed, among the rocks tested, it was observed that the rock RGE7-C obtained the best properties, with an apparent density of 2.22 g/cm³, apparent porosity of 0.25%, water absorption of 0. 11% and flexural strength of 34.36 MPa. Furthermore, these rocks performed in line with studies already carried out in the area, allowing their use in civil construction.
Technical Session
THERMAL CHARACTERIZATION OF LINEN AND ARAMID FABRICS FOR REINFORCEMENT IN HDPE MATRIX FOR BALLISTIC AND RADIOLOGICAL PROTECTION IN BALLISTIC HELMETS
Presenter(s): THUANE TEIXEIRA DA SILVA (IME), Matheus Pereira Ribeiro (Prefeitura Municipal de Cabo Frio), Lucas de Mendonça Neuba (IME), Sergio Neves Monteiro (IME), Marcos Paulo Cavaliere de Medeiros (IME), Lucio Fabio Cassiano Nascimento (IME)
Abstract:
The current environmental situation encourages the search for sustainable materials, and the manufacture of polymer composites with natural fibers as reinforcement emerges as a promising alternative to traditional materials. Natural fibers create lightweight, economical and environmentally friendly composites compared to synthetic fibers such as glass, carbon and Kevlar. Their physical and mechanical properties vary depending on the origin and characteristics of the fibers, influencing their applications. Hybridization improves the properties of composites, leading to the investigation of various reinforcement materials. The thermal behavior of these hybrid composites is crucial due to temperature variations that can impact their structural stability. This work aimed to characterize HDPE and linen and aramid fabrics through Thermogravimetric Analysis (TGA). It was possible to determine the individual working temperature of the materials and from this it was possible to previously estimate the working temperature of 200 °C for the composites that will be investigated.
Technical Session
INFLUENCE OF THE LOSS OF PLASTICITY OF A KAOLINITIC CLAY DURING CALCINATION ON THE COMPRESSIVE STRENGTH OF MORTARS
Presenter(s): valber domingos pinheiro (UENF), RAMON FERNANDES DE ABREU (UENF), LETÍCIA ABREU da FONSECA (uenf), Afonso Rangel Garcez de Azevedo (uenf), jonas alexandre (uenf)
Abstract:
Clay is a natural material that has been used since ancient times for construction and housing development. Its widespread use is due to its unique physical and chemical properties, which make it an economical and accessible alternative due to its unique physical and chemical properties, as well as its abundance and low cost. In addition, clay contributes to the sustainability of the sector, especially when used as a supplementary cementitious material, partially replacing Portland cement and reducing the carbon footprint. The use of clays, whether in their natural state or subjected to heat treatment (calcination), has been the subject of growing interest due to their abundance, low cost and sustainable potential. In general terms, clay promotes an increase in the plasticity of mortars when in its natural state, however, in its calcined state, the higher the temperature of the heat treatment, the lower its plasticity. These benefits make clay a recurrent and efficient choice in various construction applications. This study evaluates the influence of replacing natural clay with calcined clay on the compressive strength of mortars. Three formulations were compared: a reference mortar, one with clay in its natural state and another with clay calcined at 600 °C. The results indicate that calcining the clay at 600 °C, despite promoting greater pozzolanic reactivity, does not affect the compressive strength of the mortar.
Technical Session
9/5/24, 10:15 AM - 9/5/24, 11:05 AM
Presenter(s): WALISSON POGIAN DE JESUS (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO - UENF), Matheus Queiroz De Sant'anna Pereira (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO - UENF), Jose Lucas Decoté de Carvalho Lirio (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO - UENF), David Coverdale Rangel Velasco (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO - UENF), Eduardo Atem de Carvalho (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO - UENF), Elaine Aparecida Santos Caravalho (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO - UENF), Rubén Jesus Sánchez Rodríguez (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO - UENF)
Abstract:
The use of composite materials offers a variety of advantages, such as the ability to confer properties different from those found in traditional materials. Incorporating fibers as reinforcement in composites can yield several benefits, such as enhancement of mechanical strength, impact resistance, and increase in rupture modulus. This study aims to evaluate the incorporation of Glass Fiber waste into a polyester matrix, analyzing the effect of fiber length. Two fiber lengths were studied: short fiber (10mm) and medium fiber (15mm). Specimens were manufactured using the open molding method, using an orthophthalic polyester resin matrix and MEKP catalyst. Mechanical tests indicated that the addition of fiber was beneficial for the composite's strength, with long fiber standing out due to its superior reinforcing capability, facilitated by fiber organization. Thermal analysis revealed that fiberglass also positively influences the thermal properties of the composites, increasing thermal stability.
Technical Session
ANALYSIS OF THE DIAMETER RATIO IN THE MECHANICAL PROPERTIES OF MALVA FIBER IN TENSION
Presenter(s): Damares da Cruz Barbosa Nascimento (Universidade federal do pará), Sarah gabrielly brandão de souza (universidade federal do pará), paloma suellen lima de sousa (UNIVERSIDADE FEDERLA DO PARÁ), joelly vera nascimento (universidade federal do pará), Sérgio neves monteiro (instituto militar de engenharia), Alisson Clay Rios da silva (universidade federal do pará), verônica Scarpini candido (universidade federal do pará)
Abstract:
The use of natural fibers as reinforcement in composite materials has become a sustainable and efficient alternative to replacing synthetic reinforcements, which have a high production value. Thus, the objective is to study the mechanical properties of Malva fiber in relation to the diametrical difference of natural Malva fibers. The dimensional characteristic was performed by evaluating the density and relative quantity of the fiber in each interval. To evaluate the mechanical properties, the tensile strength test was carried out following the ASTM C1557 standard. The results presented the fiber's tensile strength and Young's modulus for each interval. Malva's natural fibers showed an average tensile strength of 273.2 MPa and Young's modulus of 24.80 GPa. Malva's natural fibers showed exceptional mechanical behavior when compared to other lignocellulosic fibers. Therefore, the variation in thickness of natural fibers can influence the final mechanical property of the composite produced from Malva fibers.
Technical Session
ANALYSIS OF THE INFLUENCE OF PRINTING SPEED ON THE MECHANICAL PROPERTIES OF SCAFFOLDS MANUFACTURED BY FDM
Presenter(s): Edson Miranda soares (UFPA - Universidade federal do pará), Ana Beatriz das Neves Conceição (IFPA/UFPA), Miriane Alexandrino Pinheiro (ufpa - universidade federal do pará), damares da cruz barbosa nascimento (ufpa - universidade federal do pará), Alisson Clay Rios da Silva (UFPA - UNIVERSIDADE FEDERAL DO PARÁ), Verônica Scarpini Candido (ufpa - universidade federal do pará)
Abstract:
This study investigates the influence of printing speed on scaffolds manufactured by FDM. Two distinct models were designed in the Creo Parametric 10.0.0.0 software; the models were printed by the Creality Ender 3 V3 SE printer with speed variation of 20 mm/s and 60 mm/s; they were tested by compression using the Intermetric iM-50 universal testing machine. The results revealed compressive modulus of 0.177 GPa and 0.166 GPa for the samples manufactured at 20 mm/s and moduli of 0.130 GPa and 0.154 GPa for the samples printed at 60 mm/s. The compressive strength obtained were 5.296 MPa - 4.895 MPa and 4.248 MPa - 4.564 MPa, respectively, for the samples printed at 20 mm/s and 60 mm/s. Statistical analysis revealed that speed was not the main agent responsible for the decrease in the mechanical properties of the material.
Technical Session
9/5/24, 10:15 AM - 9/5/24, 11:05 AM
Presenter(s): Taiana de Sousa Matos (UNIVERSIDADE FEDERAL DO PARÁ), Marcos Vinícius da Silva Paula (UNIVERSIDADE FEDERAL DO PARÁ), Damares da Cruz Barbosa Nascimento (UNIVERSIDADE FEDERAL DO PARÁ), Alisson Clay Rios da Silva (UNIVERSIDADE FEDERAL DO PARÁ), Carlos Alberto Brito da Silva Júnior (UNIVERSIDADE FEDERAL DO PARÁ), Severino Alves Junior (UNIVERSIDADE FEDERAL DE PERNAMBUCO), Verônica Scarpini Candido (UNIVERSIDADE FEDERAL DO PARÁ)
Abstract:
The exploration of new wound treatments represents a significant advance in the area of tissue engineering. In this sense, films made of poly(vinyl alcohol) (PVA) and chitosan (CS) containing copaiba oil emulsion and silver nanoparticles show promise as dressings. These films seek, through a synergistic effect, to create biomaterials with a wide range of biological actions, capable of accelerating wound repair and healing. The research focused on the production and characterization of PVA/CS films in proportions of 0.2:0.8 (m/v), respectively, with 0.1% and 0.5% (v/v) of copaiba oil and 10 mL of silver nanoparticles, using the casting method, aiming for their potential use in wounds. The silver nanoparticle and the copaiba oil emulsion were analyzed using the UV/Vis (UV-Visible) technique. In general, most films presented excellent optical transparency. Based on the evaluation of the results, the BP 0.5% AgNPS (v/v) films proved to be more suitable for application compared to the other samples.
Technical Session
EVALUATION OF THE NOTCH PREPARATION METHOD IN THE IZOD IMPACT TEST FOR 3D PRINTING MATERIALS
Presenter(s): VICTOR PAES DIAS GONCALVES (Universidade Estadual do Norte Fluminense Darcy Ribeiro ), Júlia Audrem Gomes de Oliveira (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO ), Luis Fernando Fortunato de Freitas (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO ), Carlos Maurício Fontes Vieira (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO ), Felipe Perissé Duarte Lopes (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO ), Henry Alonso Colorado Lopera (Universidad de Antioquía)
Abstract:
3D printing with filament has advanced considerably, allowing the manufacture of complex objects with high precision. However, printing flexible materials represents a challenge due to the strength and high deformation characteristics of these materials. This study proposes the development of a reinforcement for the EVA polymer, using copolyester, in order to facilitate 3D printing using the FDM method, maintaining the flexibility of the material. The ethylene-vinyl acetate copolymer (EVA) and the TRITAN copolyester were selected. The hot melt extrusion process was carried out in a mini-extruder, where the polymers were mixed in different proportions. The results showed variations in the apparent density and tensile strength of the different polymer blends. It was observed that the addition of TRITAN to the EVA mixture at higher proportions of TRITAN contributed to an increase in resistance. Based on the results, the addition of 30-40% TRITAN to EVA is the recommended option to facilitate 3D printing due to the added reinforcement, which provides better tensile strength while maintaining the material's elongation capacity. These characteristics make the material suitable for avoiding blockages or blockages in the extrusion during FDM printing, with properties similar to polyurethane filament (TPU), as demonstrated in the literature
Technical Session
EVA and PLA: 3D filament manufacturing and additives
Presenter(s): VICTOR PAES DIAS GONCALVES (Universidade Estadual do Norte Fluminense Darcy Ribeiro ), Ellen Bernardes de Lima (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO ), Júlia Audrem Gomes de Oliveira (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO ), Luis Fernando Fortunato de Freitas (fortunatodefreitas2@gmail.com), Carlos Maurício Fontes Vieira3 (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO ), Felipe Perissé Duarte Lopes (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO ), Henry Alonso Colorado Lopera (Universidad de Antioquia UdeA)
Abstract:
The development of filaments for FDM 3D printers involves a complex process that involves mixing polymers and additives, high-temperature extrusion and cold control to ensure uniformity and consistency. New materials are designed to help create precision products with specific uses. Polylactic acid (PLA) is widely used in 3D printing due to its continuous history, biodegradability, biocompatibility, and satisfactory mechanical and thermal properties. EVA (Ethylene Vinyl Acetate) is a copolymer of ethylene and vinyl acetate that has electrical and thermal properties suitable for many industrial applications, but presents challenges for use in FDM 3D printing paper, such as low melting temperature and high elasticity . This research was designed to create a filament combining EVA with PLA to control the flexibility of EVA through a hot extrusion process with a Mini-extruder. The resulting filaments were tested for density and tensile strength. The combination of EVA and PLA causes control of the polymer chains, reducing the elastic capacity of the material. Scanning microscopy analysis (SEM) shows a fragile fracture surface on the external part and a fracture surface on the internal part. ductile.
Technical Session
9/5/24, 10:15 AM - 9/5/24, 11:05 AM
Presenter(s): Flávio Filipe Soares Viegas (LaSid), jerônimo augusto marmor da silva (lasid), Thallya Rodrigues da Silva (lasid), Cláudio Artur Bellan do Amaral (lasid), Gabriel Penna Kramer Lima (lasid), Eduardo osório (lasid), Hector Alejandro Picarte Fragoso (lasid), Bruno Flores (lasid), Antônio Cezar Farias Vilela (lasid)
Abstract:
Circularity and the zero-waste concept are crucial for sustainability and reducing environmental impacts. In the steel industry, innovative practices that promote the reuse of residual materials are essential to decrease dependence on natural resources and minimize waste generation. The substantial amount of waste tires presents an environmental challenge due to their significant volume and slow decomposition. This study assesses the reactivity of mixtures of waste tires and coal to oxygen, using a thermogravimetric analyzer to understand the materials' behavior, aiming at their injection into blast furnaces. For this purpose, mixtures of pulverized coal and waste tire were prepared at percentages of 70/30, 90/10, and 95/5. From the tests, it was observed that the ash content of the mixtures remained below or at the limit of 10% for PCI, except for the addition of 30% of P1. During the combustion of the waste tires, four distinct regions were identified due to their composition. The combustion behavior of the mixtures and the values obtained in the proximate analysis correspond to the sum of the individual behaviors of the components. The ignition temperature of the mixtures decreased with the addition of the tire, indicating better combustibility. The mixture containing 30% of P2 was the most efficient, reducing the ignition temperature, improving combustibility, and maintaining the ash content within the allowed limits for injections into blast furnaces.
Technical Session
USE OF PCI COAL AS A PARTIAL REPLACEMENT IN COKING COAL BLEND AND PILOT VS INDUSTRIAL SCALE COKE QUALITY COMPARISON
Presenter(s): VICTOR DE OLIVEIRA CARVALHO (UNIVERSIDADE FEDERAL FLUMINENSE), Wanderson ribeiro dos santos (CSN - Companhia siderúrgica nacional)
Abstract:
In the blast furnace process, coke acts as the main fuel. To mitigate impacts on operating costs, it is crucial to explore new raw materials. Thus, this work aims to determine the applicability of non-coking coals, commonly used in pulverized injection of blast furnaces as components of the coal blend for coking. Chemical, petrographic, rank and maceral analyses of the coal mixtures were carried out. With the pilot furnace test, it was possible to measure aspects of the metallurgical quality of the coke, such as reactivity, cold strength and coking pressure. The use of non-coking coals led to a notable reduction in the cold strength and coking pressure of coke by up to 20%, while increasing its reactivity. By comparing coke quality obtained in industrial-scale and pilot-scale operations over a long period, this research demonstrated the reliability of the pilot oven test in predicting coke quality. The PCI coals in the coal mixture were suitable for application on an industrial scale.
Technical Session
9/5/24, 10:15 AM - 9/5/24, 11:05 AM
Presenter(s): frederico gotschalg maia silva novaes (ufmg)
Abstract:
The objective of this work was to characterize anodized layers of titanium and NiTi alloys. Oxide films were grown on pure titanium and NiTi alloy by electrochemical anodization. A morphological, chemical and structural characterization was carried out to evaluate the potential applications of these films. Morphological analysis was conducted using high-resolution SEM. The surface chemical composition was measured by energy dispersive X-ray (EDS). The composition profile of the anodized layer as well as its thickness were determined using a GDOES system. The crystalline structure of the anodized layers was evaluated by X-ray diffraction before and after annealing treatment of the anodized samples. The results showed a nanotubular morphology for the anodized layers in both alloys, with nanotubes with larger diameters and greater thickness in the Ti alloy when compared to the NiTi alloy. The anodized layers are made up of titanium oxides and Ni and Ti oxides, for the Ti and NiTi samples, respectively. The results obtained suggest the use of anodized surfaces as photocatalysts for use in the energy and environmental segment.
Technical Session
9/5/24, 10:15 AM - 9/5/24, 11:05 AM
Presenter(s): Mateus Medeiros da silva (Escola politécnica da universidade de são paulo)
Abstract:
Laser powder bed fusion (L-PBF) is a material production technique among the many within additive manufacturing which has great potential of application in orthopedical prothesis due its high degree of customization concerning the production of components. Hence, studying the fatigue behavior of these materials is something of great importance to understand how they can substitute the human bone properly. This work aims to compare the fatigue crack growth behavior for two materials produced by L-PBF, one using plasma atomized (PA) powder and the other hydrogenised-dehydrogenised (HDH) powder, according to the Paris Equation, in such way that the variables were obtained analyzing the fracture surface of specimens with a scanning electronic microscope. Results suggest crack propagation in the material produced by PA powder occurs more easily due its lesser yield strength.
Technical Session
INFLUENCE OF WELDING PARAMETER ON THE CHARACTERISTICS OF THE WELDING STRUCTURE OF A WELD BEAD PROCESSED BY SMAW WELDING
Presenter(s): Damares da Cruz Barbosa Nascimento (Universidade federal do pará e Instituto federal do pará), Thamiris Darliene Gama Ferreira (Instituto federal do pará), Verônica Scarpini Candido (UNIVERSIDADE FEDERLA DO PARÁ), Luiz Gabriel da Silva Nascimento (Instituto Federal do Pará)
Abstract:
The search for methods that aim to unite and develop new materials using the welding technique becomes aimed at industrial application. Welding aims to join two materials by the action of temperature and, consequently, fusion between the metallic materials. Therefore, the objective is to analyze the influence of electric current on the characteristics of the weld bead of a 5/16” steel sheet. From the data obtained, it was possible to identify the weld penetration points, in addition to the thermal affected zone (HAZ). To analyze the weld bead, metallographic analysis was carried out using an optical microscope. The results showed that the increase in electrical current tends to proportionally increase penetration of the pool and the thermal zone. Metallography showed the growth of coarse grains while the electrical current supplied increases. From the data obtained, it can be concluded that the electric current continuously influences the microstructure of the steel.
Technical Session
INFLUENCE OF VOLTAGE VARIATION BETWEEN TIPS IN ELECTRIC RESISTANCE WELDING FOR AISI1065 CARBON STEEL
Presenter(s): lucas menezes de souza (UENF), Elaine Cristina Pereira (UENF), Camila Vasconcellos Fernandez (UENF), Sthefanie de Carvalho Mendes Lopes (UENF)
Abstract:
In this work, the influence of voltage variation in the resistance spot welding process and tempering heat treatment on the microstructure and mechanical properties of AISI1065 carbon steel was evaluated. Welding was carried out on three groups of samples with voltage variations between tips of 2.0 V, 2.5 V and 3.0 V for each group. After the welding process, half of the samples in each group received tempering heat treatment. The microstructure of the steel was analyzed before and after the heat treatment process. To analyze the mechanical properties, tensile, hardness and microhardness tests were carried out. In the metallographic characterization, the presence of elongated grains of ferrite and pearlite in the microstructure of the base metal was verified. The transformation of the martensite matrix located in the molten zone and the heat-affected zone into tempered martensite after the tempered heat treatment occurred. An increase in the tensile strength limit, ductility and toughness was observed in the steel after tempering compared to steel only welded. However, at a voltage between tips of 2.0 V, it showed better mechanical behavior after heat treatment.
Technical Session
NUMERICAL SIMULATION OF LASER CUTTING OF HEAT TREATED 22MNB5 TUBES
Presenter(s): Luís Fernando Folle (UFSM-CTISM), Tiago Nunes Lima (Senai Cimatec), Matheus Passos Sarmento Santos (Senai Cimatec), Cássio Murilo de Oliveira Sobrinho (Senai Cimatec), Marco Antônio Colosio (General motors do brasil)
Abstract:
Laser cutting is a process widely used in industry for high-strength steels, however, it presents some drawbacks in complex geometries. Meanwhile, numerical simulation is a useful tool to help understand, predict and correct the effects of this process. The aim of this study was to perform finite element and fluid dynamics simulations to analyze the cutting profile in heat threated 22MnB5 tubes and predict the phenomenon of laser residual cutting effects of the opposite side of the tube. The adopted methodology involved conducting an experimental test, calibrating the simulation and varying parameters to understand which outcome result in the smallest fusion residual at the opposite side. It was observed that a well-calibrated simulation can predict this residual, and fluid dynamics simulation also helped understand the cutting thickness to prevent cutting that wouldn't separate the tube parts.
Technical Session
JOINING OF COPPER AND BRASS PLATES THROUGH FRICTION STIR WELDING (FSW)
Presenter(s): Saulo Brinco Diniz (CENTRO FEDERAL DE EDUCAÇÃO TECNOLÓGICA CELSO SUCKOW DA FONSECA), John Santos Freire (CENTRO FEDERAL DE EDUCAÇÃO TECNOLÓGICA CELSO SUCKOW DA FONSECA), Lucas Moura Montenegro Reis (Instituto Militar de Engenharia), Igor de Oliveira Jeronimo Peixoto (CENTRO FEDERAL DE EDUCAÇÃO TECNOLÓGICA CELSO SUCKOW DA FONSECA), Talita Gama de Souza (INSTITUTO MILITAR DE ENGENHARIA), Sérgio Neves Monteiro (INSTITUTO MILITAR DE ENGENHARIA)
Abstract:
Copper and brass have a high coefficient of expansion and thermal conductivity, presenting limitations during fusion welding, and in this way, Friction Stir Welding (FSW) stands out. This study tested the weldability of 3.17 mm thick copper and brass sheets using FSW with three different rotation speeds and constant parameters. For this purpose, visual inspections, microstructural analysis and temperature monitoring. The results indicated that a higher rotation speed resulted in a better appearance of the weld bead, although it increased the extent of the oxidized region. Additionally, the temperature ranged from 75 to 250 °C, directly related to the rotation speed and the length of the oxidized layer. All samples showed defects in the cross section.
Technical Session
9/5/24, 10:15 AM - 9/5/24, 11:05 AM
Presenter(s): STHEFANIE DE CARVALHO MENDES LOPES (universidade estadual do norte fluminense darcy ribeiro (uenf)), lucas menezes de souza (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO (UENF)), bianca leitão afonso (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO (UENF) ), elaine cristina pereira (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO (UENF))
Abstract:
Due to its excellent combination of corrosion resistance and mechanical properties, UNS S31803 duplex stainless steel has been widely used in the oil industry, standing out in the production of flexible pipes. However, to ensure an excellent combination of properties and the performance of this material in service, it is essential to maintain an adequate proportion of the ferrite and austenite phases, which is significantly affected by the welding process. This study aimed to characterize the microstructure of UNS S31803 duplex stainless steel after TIG welding and solubilization heat treatment at 1050°C for 10s in different regions of the welded joint. Ferrite quantification in the weld was carried out through image analysis with the aid of ImageJ software, while hardness was evaluated using Vickers microhardness. Metallographic analysis revealed significant changes in grain morphology in the heat-affected zone and fusion zone. The ferrite fraction remained within the limits established by the Norsok M-601 standard in all regions, indicating the effectiveness of the heat treatment. No significant differences in Vickers microhardness were observed between regions of the welded joint.
Technical Session
RADIO BASED DISTANCE AND POSITION MEASUREMENT FOR CRANES AND MOBILE EQUIPMENT OPERATING IN HARSH ENVIRONMENTS
Presenter(s): MARIANO ALBERTO DE CRISTOFARO (JANUS AUTOMATION), Edgardo LaBruna (janus automation)
Abstract:
Radio based distance and position sensors for outdoor and indoor applications have been adopted widely in the steel making industry due to the fact, that harsh conditions like dust, heat or vibration do not influence the signal quality. Applications include tracking of equipment like cranes or transport vehicles to monitor material flow and storage positions of slabs, plates pipes or coils and provide respective product coordinates to a warehouse management database. The paper will present a number of applications in steel plants worldwide, with benefits in uninterrupted operations, increased operational safety and drastically reduced maintenance cost. With a recent development, even collisions between cranes and free ranging vehicles can now be avoided effectively. Location, heading and speed of all equipment will be continuously monitored and used to issue a warning signals upon getting too close. This system has been successfully commissioned at more than 2000 applications worldwide, including long, flat and tubular operation and has proven very effective.
Technical Session
AUTOMATIC SPREADER FOR LOADING STEEL COILS
Presenter(s): jefferson nunes lyrio (arcelormittal tubarão)
Abstract:
This article aims to present a project responsible for starting the process of modernizing lifting material at the Praia Mole Steel Products Terminal (TPS), increasing safety in ship boarding operations. Here the operational needs will that addressed with notes of the risks inherent to the operation and those involved in the cargo movement stages, which followed the effectiveness of the implementation of the Automatic Spreader, as well as the benefits achieved with this important step towards technological innovation in port work in the TPS.
Technical Session
AEROSOL DILUTION TECHNIQUE FOR THE DETERMINATION OF LITHIUM AND RARE EARTH ELEMENTS BY ICP-MS/MS
Presenter(s): Lívia Gonçalves Leida Soares (Centro de tecnologia mineral), Manuel Castro Carneiro (CENTRO DE TECNOLOGIA MINERAL), Mariana Mello Santos Cerveira Pereira (CENTRO DE TECNOLOGIA MINERAL), Brenda da Silva Pissurno (CENTRO DE TECNOLOGIA MINERAL), Arnaldo Alcover Neto (CENTRO DE TECNOLOGIA MINERAL)
Abstract:
Rare earth elements (REEs) and lithium are promising for application in green technologies, aiming at a low-carbon economy. Reliable and fast analytical methods are needed to determine these elements in samples with low concentrations and/or complex matrices. ICP-MS has several advantages, but samples with high total dissolved solids content (TDS) can cause interference, leading to signal loss and instability. The use of ICP-MS with the aerosol dilution (AD) tool is promising for this application, reducing the amount of sample reaching the plasma. High concentrations of elements such as K, Na, Ca and Mg can also cause preferential loss of light ions, due to space charge effects. The application of cold plasma is a favorable condition for ICP-MS analysis of elements in the low mass region, such as Li, as it generates improvements in sensitivity and/or changes in the signal-to-noise ratio. A certified reference material (CRM) of limestone (CCH-1) was analyzed using AD, showing good recoveries (89.8% to 111.0%) for most ETRs. Two lithium ore CRMs (NCS DC 86303 and SRM 181) showed recoveries of 97.9% and 96.8%, respectively, under cool plasma and AD conditions.
Technical Session
9/5/24, 10:15 AM - 9/5/24, 11:05 AM
Presenter(s): Thomaz Jacintho Lopes (IME - INSTITUTO MILITAR DE ENGENHARIA), Ary Machado de Azevedo (IME), Marcos Paulo Cavaliere de Medeiros (IME), André Ben-Hur da Silva Figueiredo (IME), Sérgio Neves Monteiro (IME), Joana Batista Soaresr (IME), Domingos D’Oliveira Cardoso (IME), Fernando Manuel Araújo Moreira (IME)
Abstract:
In this study, the importance of simulations conducted in MCNP5 and the modifications implemented in 316 steel to optimize energy efficiency in nuclear power production are explored. Molybdenum (Mo) is investigated as a promising additive due to its low absorption cross-section for thermal neutrons, which facilitates a more significant participation of neutrons in fission and heat generation. Through the use of the MCNP5 code, simulations were conducted to analyze a hypothetical UO2 fuel element with different enrichment zones to assess its performance. The results highlight that the inclusion of molybdenum in the fuel cladding alloy has a significant impact on neutron production, suggesting that this addition may compromise energy generation efficiency. In summary, this study emphasizes the potential of molybdenum as an additive to enhance nuclear fuel performance, promoting safer, more efficient, and sustainable nuclear energy.
Technical Session
THE LIFE CYCLE OF DECARBONIZATION PROJECTS USING THE TRL (TECHNOLOGY READINESS LEVEL) REFERENCE
Presenter(s): Bruna Ferreira Chaves de Oliveira (Vale), Mayara Camila Duarte de Oliveira (Vale), Amanda Conti Dalapicola (Vale)
Abstract:
The discussion about decarbonization is new at a global and national level, for governments and companies, and also within Research & Development. The search for technological solutions that promote decarbonization has intensified, becoming a priority for many companies and institutions, which have made public commitments to reduce GHG emissions. How to conduct the decarbonization process amidst bold goals and so many technological uncertainties? This work presents a path based on methodology and theoretical references that goes from the initial stage of basic research with prospecting, portfolio prioritization, through proof of concept, prototyping, to scaling and full incorporation of technology. The use of a single, standardized methodology is the path to a safe energy transition. The methodology presented in this work was developed using Design Thinking and Lean start up tools – these methods teach how to create projects/ products desired by customers, generating rapid learning cycles, in which changes in the direction of strategies occur with accelerated progression – joing efforts in search of results through joint construction between different parties involved. Practical tools will be presented that have already been tested and have proven results within the life cycle of a decarbonization project
Technical Session
9/5/24, 11:05 AM - 9/5/24, 11:30 AM
Presenter(s): Anna Júlia Cassimiro Prado Mitre de Oliveira (UNIVERSIDADE FEDERAL DE MINAS GERAIS), Arthur Barreiro Sakai (UNIVERSIDADE FEDERAL DE MINAS GERAIS), Isabela Giovana Oliveira (UNIVERSIDADE FEDERAL DE MINAS GERAIS), Sofia da Cruz Souza (UNIVERSIDADE FEDERAL DE MINAS GERAIS), Ricardo Oliveira Correia (UNIVERSIDADE FEDERAL DE MINAS GERAIS), Anderson Caires de Jesus (2 Instituto SENAI de Inovação em Metalurgia e Ligas Especiais – CIT SENAI), Dagoberto Brandão Santos (UNIVERSIDADE FEDERAL DE MINAS GERAIS)
Abstract:
Good biocompatibility and corrosion resistance coupled with suitable mechanical properties make pure titanium (Ti) a widely used material in biomedical engineering and industry. High-purity Ti plates have lower mechanical strength than Ti alloys. Thus, heterostructured materials constitute an emerging and promising field to drive mechanical properties through economic routes. To improve the mechanical properties of this material, in this work it was used the partial recrystallization to improve the ductility and strength of the metal. After annealing for 30 min of a cold-rolled microstructure at 66%, the mechanical properties increased for temperatures of 600°C-800°C. CP Ti had a higher hardness for the annealed condition compared to the sample as received. From engineering stress-strain curves, two annealing conditions allowed to obtain a high uniform strain, high ductility, and a moderate strength.
Technical Session
9/5/24, 11:05 AM - 9/5/24, 11:30 AM
Presenter(s): Paul Uhl-hädicke (FESIOS)
Abstract:
This paper presents a comprehensive case study conducted by FESIOS GmbH in collaboration with ArcelorMittal Long Products Luxembourg, focusing on the potentials of digital modeling in optimizing steel production processes under conditions of significant uncertainty. The study, driven by ArcelorMittal's ambitious modernization project in Luxembourg, aimed to enhance productivity by 15% and introduce new steel grades through a revamped electric arc furnace (EAF) and a new vacuum degassing (VD) plant. Simulation studies revealed potential bottlenecks in the melt shop, scrap yard, and run-out areas, enabling strategic adjustments. Results demonstrate the effectiveness of simulation in preempting production issues and optimizing plant operations, ultimately supporting the successful implementation of ArcelorMittal's modernization investment.
Technical Session
9/5/24, 11:05 AM - 9/5/24, 11:30 AM
Presenter(s): alexssander lopes sampaio (Vallourec)
Abstract:
In 2023, monthly production at the pelletizing plant at Vallourec Jeceaba was often lower than planned due to various factors. In order to minimize the problems causing low productivity, an in-depth study of the process was carried out using various techniques in the literature to develop a tool capable of helping operational teams monitor, evaluate and make decisions. This system is based on the individual and collective performance of parameters obtained from each stage of the pellet production process. Due to the large number of variables to be monitored, a hierarchy and prioritization methodology was defined so that it would be possible to evaluate each parameter in relation to the process. Thus, a scorecard was created in order to indicate the relative performance of the operating parameters according to a configuration established by the plant's production process specialists.
Technical Session
9/5/24, 11:05 AM - 9/5/24, 11:30 AM
Presenter(s): julio cezar de sousa zorzi (USIMINAS - IPATINGA)
Abstract:
With the advancement of computational resources and the increase in data generation and storage capacity, approaches based on artificial intelligence and machine learning (ML) have been continuously incorporated into industrial processes. This data-driven methodology has made it possible to map, in a reasonable way, the complex relationship that exists between industrial processing, the chemical composition and mechanical properties of steels. In this way, a tool based on ML was developed to predict the mechanical properties in tension, industrial processing conditions and chemical composition of advanced high-strength steels (AHSS), for automotive application, processed via Continuous Annealing Process Line (CAPL). An industrial database was used to generate information and knowledge about the materials evaluated. The accuracy of the prediction models was evaluated through error parameters, which are linked to the rationality and reliability of the tested method. The results showed that the XGBoost algorithm can be used to build different models, with excellent performance metrics. For the practical application of the tool, a program was developed for use in a web site, with a friendly interface, to assist in the development of new products and decisions related to the optimization of the processing route.
Technical Session
9/5/24, 11:05 AM - 9/5/24, 11:30 AM
Presenter(s): VITOR CARVALHO ROLLASENNA (USINAS SIDERURGICAS DE MINAS GERAIS SA)
Abstract:
Steam is one of the main sources of energy within an industrial plant, and maximizing the rational use of this input is an important indicator of energy efficiency, contributing to the reduction of operational costs, promoting positive impacts on expenses, and increasing competitiveness. This work will characterize the steam system of Usiminas Ipatinga and demonstrate how the establishment of a working group managed to reduce steam loss by implementing improvements in the management system and carrying out corrective and preventive maintenance.
Technical Session
USE OF MINE WASTE (BASALT) IN CO2 EMISSIONS OFFSETTING IN MINING: EVALUATION OF THE CARBONATION PROCESS
Presenter(s): Paulo victor Campos (SENAI - PA/ INSTITUTO SENAI DE INOVAÇÃO EM TECNOLOGIAS MINERAIS), patricia magalhães pereira silva (SENAI - PA/ INSTITUTO SENAI DE INOVAÇÃO EM TECNOLOGIAS MINERAIS), Julio Cesar Moreira Fornazier (SENAI - PA/ INSTITUTO SENAI DE INOVAÇÃO EM TECNOLOGIAS MINERAIS), Rita de Kassia Silva do Nascimento (SENAI - PA/ INSTITUTO SENAI DE INOVAÇÃO EM TECNOLOGIAS MINERAIS), Cassiane de Lima (SENAI-PA/ INSTITUTO SENAI DE INOVAÇÃO EM TECNOLOGIAS MINERAIS), Andre Luiz Vilaça do Carmo (SENAI/ INSTITUTO SENAI DE INOVAÇÃO EM TECNOLOGIAS MINERAIS), José Augusto Pires Bitencourt (vale/Instituto Tecnológico Vale), Adriano Reis Lucheta (SENAI/ INSTITUTO SENAI DE INOVAÇÃO EM TECNOLOGIAS MINERAIS), Silvio Junio Ramos (), Debora Amato Lourenço Rossi ()
Abstract:
Given the intense climate changes driven primarily by carbon footprint (GHGs), technologies for carbon capture and storage have been demanded worldwide. Among the technologies studied, the use of basalt rocks has emerged as a promising method for carbon sequestration due to high reactivity with CO2 and potential for permanent carbon storage in the carbonate’s forms. In this context, following the principles of circular economy, this study aims to conduct an initial assessment of the potential of mining waste basalt as a viable source of carbonation targeting atmospheric CO2 sequestration. To do this, chemical and mineralogical characterization of basalt from the Carajás -PA region was initially carried out. A mathematical model was established to obtain the theoretical maximum CO2 capture potential of this basalt waste. Furthermore, experiments on the carbonation of basalt were conducted, through reaction with sulfuric acid and carbonation with semi-bath CO2 injection. Thus, it was registered the basalt exhibited a significant theoretical CO2 capture potential (0.22 t CO2eq/t of basalt). The leaching process proved efficient under the investigated conditions, releasing Ca and Mg, the main elements reactive with CO2. Besides, after the carbonation process, a slight crystallization of carbonate phase such as dolomite (CaMg(CO3)2 was identified, indicating the effectiveness of the carbonation process for this waste material
Technical Session
HOT ABRASIVE CUT-OFF MACHINE REPLACES A FRICTION SAW AT A BRAZILIAN APPLICATION
Presenter(s): Norbert Asamer (BRAUN Maschinenfabrik)
Abstract:
As one important part of the modernization and upgrading plan for their existing rolling mill, a Brazilian customer decided to install a high-performance abrasive cut-off machine from BRAUN to replace an existing friction. Rolling mills are still using shears or friction saws downstream the process until reaching final product length. Unfortunately, with these methods it is almost impossible to meet the demands of value-added products. The increased throughput and flexibility, a high degree of automation and an improved quality of the cut products were substantial advantages of abrasive cut-off machines, of the equipment just started operation beginning of May this year
Technical Session
H2 Ready Dry Plus Furnace: a step towards decarbonization
Presenter(s): Salamone Elisa (Danieli), Venanzini Alessandro (Danieli)
Abstract:
The United Nations Climate change conference (COP26) emphasized the strong commitment needed from the world to mitigate climate change, requiring a strong reduction in greenhouse gases emissions by 2030. The European Union, which is leading the efforts, allocated funds for innovative systems to reduce carbon dioxide (CO2) emissions. On the path towards decarbonization, Danieli Centro Combustion (DCC) prepared a study for an innovative furnace concept called “DRY PLUS FURNACE’’ (DPF), to counteract industrial furnaces being the major source of carbon emissions after the steel meltshop. The DPF is a H2 Ready Walking-Beam-type furnace (hereinafter named WBF), whose concept is based on components not being water-cooled inside the furnace, with the goal of reducing CO2 emissions in the steel industry, as losses through water-cooled components is the second major source of losses in industrial furnaces. Through its R&D efforts, DCC took up the challenge to contribute in addressing climate change with this new furnace concept, whose main innovative features and advantages are described in this document, and that is not limited to just CO2 reduction, but also addresses specific consumption improvements, the absence of a water-treatment plant, increased billet heating quality, the reduction of maintenance time, the reduction of operating cost and savings in installation time.
Technical Session
Increase of niobium metallurgical recovery on aluminothermic process
Presenter(s): Vinícius Elias de Godoy (CMOC), Daniel gonçalves netto (CMOC), daniel evangelista caixeta (CMOC), luiz claudio monteiro montenegro (ufmg), roberto galery (ufmg), Maurício Covcevich Bagatini (UFMG)
Abstract:
This work is based on a technical and statistical study aimed at optimizing niobium recovery from the aluminothermIC stage at CMOC Brasil, the second largest producer of ferroniobium alloy in the world. The study presents how the excess aluminum indicator was created, and its importance within aluminothermy in the search for maximizing niobium recovery. As excess aluminum is increased, recovery is also increased. At the end of the work, an annual production gain of more than 320 tons of niobium and a reduction in aluminum consumption of more than 520 tons per year are presented, resulting in a financial profit for the company of 280 million reais in almost 4 years.
Technical Session
A REVIEW ON F-FREE MOLD FLUXES FOR PERITECTIC STEELS BASED ON THE CaO-SiO2-Na2O-B2O3 SLAG SYSTEM
Presenter(s): JEFERSON LEANDRO KLUG (UFC CAMPUS DO PICI BL 714), ANDERSON NICOLODI (ARCELORMITTAL BRASIL), josé eduardo pereira (ARCELORMITTAL BRASIL), José a. c. ferreira (HWI)
Abstract:
Hypo-peritectic steels can be difficult to cast. One significant issue with hypo-peritectic steel slabs is longitudinal cracking, related to the peritectic reaction of the fe-c phase diagram. To address this problem, conventional mold fluxes with appropriate crystallization kinetics have been developed to reduce the horizontal heat transfer rate between liquid steel and the mold. There is a global concern about removing fluorine from mold flux compositions due to environmental reasons and the generation of HF(g) below the mold during the continuous casting process, which accelerates the corrosion of the continuous casting machine. This study reviews the development of F-free mold fluxes for casting hypo-peritectic steel slabs in the CaO-SiO2-Na2O-B2O3 system. The main challenge is to find a substitute for the F-bearing crystal cuspidine that meets the required thermal resistance. Previous studies have examined the precipitation of combeite (Na2O.2CaO.3SiO2) in the CaO-SiO2-Na2O system and the precipitation of calcium borosilicate (Ca11Si4B2O22) in the CaO-SiO2-Na2O-B2O3 system as potential substitutes. This study also reviews experimental techniques to evaluate mold fluxes crystallization kinetics. Among them, in situ experimental tools at the Brazilian synchrotron light source to evaluate the crystallization kinetics would provide more accurate data and possibly accelerate the development of F-free mold fluxes for hypo-peritectic steels.
Technical Session
FREE OPENING OF THE EBT CHANNEL OF EAF A STRATEGIC ISSUE IN THE FORMULATION OF GRANULATED REFRACTORIES
Presenter(s): WAGNER LUIZ DEL RIO (drg refratários)
Abstract:
Among the various reasons for Power Off of an EAF Meltshop there is the tapping time of heats that vary according to the capacity of the EAF, diameter of the EBT set, the operating conditions of the EAF, the quality of the refractory used to fill the channel EBT, among other process variables. The mineralogical composition and the main physical-chemical properties of the product to be used to fill the EBT channel are decisive for the formation of a sintering layer that must be broken by ferrostatic pressure when opening the EBT. This product for EBT channel sealing must offer the following characteristics: 1 – Avoid infiltration of molten steel through the EBT channel; 2 – Materials with a low coefficient of expansion; 3 – Excellent flow when opening the EBT channel. With the aim of offering an EBT channel filling product adapted to each client's process, DRG Refratários develops “Taylor Made” formulations with granulometric arrangement, packaging rate and flow appropriate to the customers process, where it is determined which formulation and quantities are most suitable. adequate according to the analysis of some operational parameters such as process temperature; Power On time; dimension of the leak channel hole; with the objective of guaranteeing EBT channel free opening rates above 98%.
Technical Session
Generative AI and Digital Twins: a win-win integration for maximum productivity in the steel industry
Presenter(s): matheus de oliveira mendonça (ENACOM), Gustavo Rodrigues Lacerda e Silva (ENACOM), Douglas Alexandre Gomes Vieira (ENACOM)
Abstract:
The steel industry is at the forefront of leveraging digital technologies to enhance operational efficiency and productivity. Among these technologies, Digital Twins have emerged as a pivotal tool for real-time monitoring and control, historical performance analysis, simulation, optimization and planning. This paper explores the integration of Generative AI (Gen AI) Assistants with Digital Twins, highlighting the transformative benefits and challenges of this innovative approach. Key advantages include democratizing access to information, enabling real-time answers to a variety of operational and planning questions, leveraging structured and validated data available on the Digital Twins for accurate insights.
Technical Session
9/5/24, 11:05 AM - 9/5/24, 11:30 AM
Presenter(s): JOÃO FILIPE CAVALCANTI LEAL (Arcelormittal pecem), Misael Peixoto Gomes (Arcelormittal pecem), Flavio Pires Vasconcelos (ARCELORMITTAL PECEM), André Rodrigues Santos Ribeiro (ARCELORMITTAL PECEM), Miguel Arcanjo Freitas de Almeida (ARCELORMITTAL PECEM), Carlos André Ruy Carneiro (ARCELORMITTAL PECEM), Marcos Daniel Gouveia Filho (ARCELORMITTAL PECEM), Renardir Peixoto Maciel Junior (ARCELORMITTAL PECEM), Fernando Vernilli Júnior (USP - Universidade de são paulo)
Abstract:
Among the most relevant refractories, the materials used in steel ladle stand out. In this equipment, materials based on MgO-C and Al2O3-MgO-C are used, containing carbon in their structure and composition to provide important properties, such as corrosion resistance and resistance to thermal shock. On the other hand, in recent years a new generation of carbon-free refractories has emerged that have properties compatible with the steel production process, including gains in operational and environmental terms for the metallurgical process. Thus, this work presents the development carried out at the ArcelorMittal Pecém Steelworks aimed at replacing traditional materials with carbon-free refractories with a lower coefficient of thermal conductivity, allowing a reduction in the thermal loss of liquid steel throughout the operational cycle of the steel ladle. The main wear mechanisms of the metal line were studied and carbon-free refractory with specific properties and characteristics was selected. Industrial results indicated superior performance of the carbon-free metal line in relation to traditional materials, including the benefits of greater thermal conservation of the ladles, providing potential for energy gains to increase scrap consumption in the converter and/or reduce release temperatures in the primary and secondary refining.
Technical Session
9/5/24, 11:05 AM - 9/5/24, 11:30 AM
Presenter(s): Davi Vaz André Júnior (UENF), Madeleing Taborda Barraza (UENF), Leandro Barbosa de Oliveira (UENF), Sheila Mara Santos da Silva (UENF), Thereza Pereira Ramos de Mello (UENF), Carlos Maurício Fontes Vieira (UENF), Sérgio Neves Monteiro (IME), Afonso Rangel Garcez de Azevedo (UENF)
Abstract:
The environmental issues involving Portland cement are being increasingly studied by researchers, as well as alternatives to the use of the binder. Geopolymeric material has been much debated in the literature as a possible substitute material for Portland cement. Another prominent factor that concerns environmentalists is the high generation of agricultural by-products, one of which is coffee residue. This biomass has a high potassium content, of an alkaline nature, a key characteristic for constituting the activating solution for the geopolymeric material. Therefore, the present study aims to comparatively analyze metakaolin-based geopolymers in the fresh state using two coffee residue ash (CRC), one calcined in a laboratory oven at 700 °C for 1 hour and the other ash from coffee roasting in a factory, at a temperature of 300 °C for 35 min. They partially replaced the sodium hydroxide constituent of the activating solution in two levels, 25% and 50%. The consistency, viscosity, density and dropping ball tests showed that the increase in CRC content negatively affected the workability and rheology of the product in both calcination conditions. However, the impact of CRC originating from coffee roasting in the factory was lower in the mentioned properties
Technical Session
COMPARATIVE ANALYSIS OF FLEXURAL RESISTANCE OF EPOXID COMPOSITES REINFORCED WITH SILICA
Presenter(s): JAQUELINE MOREIRA DE OLIVEIRA (UNIVERSIDADE ESTADUAL NORTE FLUMINENSE)
Abstract:
Silica has played a key role in the development of composite materials due to its unique properties and versatility such as chemical inertness, high melting point, among others, which makes it have several application possibilities. This article presents an analysis of the behavior of silica when used as reinforcement, highlighting its mechanical properties to contribute to the enhancement of composite performance. Additionally, the method used for sample preparation, the incorporation of silica into the polymeric matrix, and its implications on mechanical behavior will be discussed. Eight specimens were fabricated for each formulation integrated with epoxy resin using a DGEBA/DETA system with a phr of 16, with silica incorporation levels of 5%, 10%, 15%, and 20%. The ASTM D790 standard was employed for the test, at a rate of 1,3 mm/min.
Technical Session
9/5/24, 11:05 AM - 9/5/24, 11:30 AM
Presenter(s): Henrique Strobl Costa (Hyperion Materials & Technologies)
Abstract:
With the constant pressure for higher efficiency in the rolling mills, tungsten carbide can play a significant role in increasing mill output, lowering operational costs, and improving rolled material surface finishing and tolerances. Tungsten Carbide features very high abrasive resistance when comparing to High-Speed Steels (HSS) and it far exceeds conventional Cast Iron rolls. At the same time, thermal conductivity of Tungsten Carbide more than doubles that of Cast Iron and HSS which helps to reduce thermal gradients in the passform roll surface and thus to reduce the tendency for thermal crack onsetting. Cast in Carbide (CIC®) is a unique technology, allowing a metallurgical bond between Cast Iron and Cemented Carbide, and therefore eliminating the need for external clamping system to guarantee a non-slippage condition between the arbor and the Tungsten Carbide ring, while enabling to fit more quantity of passforms in the barrel length area. CIC® rolls find applications in different areas of the rolling mill: from roughing to finishing stands. In this paper, two tailor-made CIC® applications will be presented. A direct comparison of performance is described as well as further relevant information from those two projects such as roll cooling condition and redressing strategy implemented to maximize the performance in service is disclosed.
Technical Session
STUDY OF PROPERTIES OF ALUMINIUM ALLOY JOINTS FOR USE IN AUTOMOTIVE VEHICLES
Presenter(s): Marcelo Goncalves (Alpina Consultoria), Leonardo Rodrigues Danninger (IPT), Ana Paola Villalva Braga (IPT)
Abstract:
The present work presents the main results obtained from an extensive project in which the main properties of joints for application in the automotive and cargo transport vehicles were studied. The joints studied were produced by four different joining techniques: MIG welding, welding by FSW - Friction Stir Welding, mechanical fastening with rivets and joining with adhesives. Such joints were characterized in terms of their mechanical properties, with the purpose of evaluating their behaviour during tensile and fatigue tests. The results obtained from the experimental study carried out allowed for a deeper knowledge of limitations and applicability associated to the joining techniques for joints of Al alloys for the automotive industry.
Technical Session
RAM analysis using the similarity technique and application of product reliability engineering in dry magnetic separator
Presenter(s): Welbert Oliveira Alves (vale), David Marcelo Delgado dos Santos (vale), vinicius dos santos gonçalves (Vale), Benito Barbabela E Silva (VALE), Flávio José da Silva Carvalho (VALE)
Abstract:
The objective of this work is to conduct a RAM (Reliability, Availability, Maintainability) analysis of NS04 — Vale's first dry concentration plant — utilizing disruptive dry magnetic separation technology to produce an ore concentrate without using water, thereby eliminating the need for tailings dams and mitigating environmental impact. The major challenge of this technology is to achieve high feed rates, meet the iron ore processing requirements, and maintain competitive costs. The application of Reliability Engineering methodologies is essential to ensure that the technology meets the expected outcomes, guaranteeing that the developed equipment performs its intended function (performance, risk, and cost). The RAM analysis of NS04, applied using the similarity technique, provides detailed data to accurately forecast future budgets, plan spare parts, and determine optimal preventive maintenance intervals. In the case of magnetic separators, reliability applied to product development is crucial to ensure operational efficiency, product quality, safety, and customer satisfaction. Despite the RAM simulation results being lower than anticipated, the implementation of the NS04 project for industrial-scale testing is feasible and serves as a laboratory for future installations.
Keynote Speaker
9/5/24, 11:05 AM - 9/5/24, 11:55 AM
Presenter(s): Luiza Moreira Pessoa; Researchers at Villares Metals e Felipe Rehder Bonon; Product Portfolio Manager at Villares Metals
Abstract:
Round Table
9/5/24, 11:05 AM - 9/5/24, 12:45 PM
Presenter(s): Coordinators: Delmi Vicente de Carvalho; Logistics WG Coordinator at CRAMG and Vitor José Melo Soares; Logistics General Manager at Usiminas Moderator: Paulo Roberto Bertaglia; Consultant
Abstract:
Round Table
9/5/24, 11:05 AM - 9/5/24, 12:45 PM
Presenter(s): Coordinator: Willy Ank de Morais; Professor at UNISANTA Moderator: Geraldo Lúcio de Faria; Professor at UFOP
Abstract:
Technical Session
MICROSTRUCTURAL ANALYSIS OF 304 AUSTENITIC STAINLESS STEEL SUBJECTED TO HIGH DEGREES OF ACCUMULATED STRAIN
Presenter(s): CASSIO BARBOSA (Instituto Nacional de Tecnologia (INT)), FELIPE SANTIAGO SOARES (Instituto Nacional de Tecnologia (INT)), GERSON ORTIZ GALLO (Instituto Nacional de Tecnologia (INT)), ALAN MENEZES DO NASCIMENTO (Instituto Nacional de Tecnologia (INT))
Abstract:
Due to the combination of excellent properties, such as strength and corrosion resistance, stainless steels are used in several types of applications, which require these properties. Among the stainless steels, the austenitic ones outstand for the excellent performance in these applications, such as the AISI 304 stainless steel. With the purpose of increasing the strength of these metallic materials through work hardening and grain refinement, several studies have proposed lately the development of mechanical forming processes with high levels of strain. The present work is focused on enhancing the hardness/strength of the AISI 304 stainless steel through the performing of several passes of cumulative rolling. Analytical techniques such as optical microscopy, scanning electron microscopy (SEM) and Vickers scale hardness tests were used to obtain results which revealed that the formation of dislocations cells, shear bands n twins contributed to the considerable hardening of the material.
Technical Session
VIX MOVE - Safe Mobility with Intelligent Management
Presenter(s): Robson GEraldo alves (SAMARCO), Sheimon dos Santos Gallo (vix logistica), KAren da Costa (Samarco), Emanuelle Miossi Paulo (VIX logistica)
Abstract:
Vix Move is an app based on transportation request service focused on corporate public. Developed using Agile Methodology for mobiles, its purpose is to optimize vehicle requests at Samarco's industrial units and make the mobility of professionals simpler safer and more efficient.
Technical Session
9/5/24, 11:30 AM - 9/5/24, 11:55 AM
Presenter(s): MARCELO FERREIRA JASMIM (COMPANHIA SIDERURGICA NACIONAL), davidson de oliveira pereira (CSN), yuri lucas de souza paropat (csn)
Abstract:
Development of PROCOM AF2, a new level 2 automation system for CSN's Blast Furnace 2 in Volta Redonda. This system replaced an old one that was obsolete and unrepairable, with corrupted source codes and recurring application failures. The new PROCOM maintains the functionalities of the previous system, such as handling runs, communicating with level 1, generating reports, consolidating information, and integrating with systems such as MES, LIMS and mathematical process models. It was developed internally by CSN, using its own framework and the C#.Net language. These changes ensured operational continuity and improved control of the production process
Technical Session
LIFESPAN PREDICTION OF 310 NBN STEEL UNDER CREEP-FATIGUE CONDITIONS: AN EXPERIMENTAL AND THEORETICAL ANALYSIS USING THE YOKOBORI METHOD
Presenter(s): Murilo miguel narciso (Instituto Militar de Engenharia - IME), Julianna Magalhães Garcia (Instituto Militar de Engenharia - IME), Luiz Paulo Brandao (Instituto Militar de Engenharia - IME)
Abstract:
The utilization of high-temperature materials like the novel 310 steel added of niobium and nitrogen (310 NbN) present a critical challenge in predicting their lifespan, particularly in creep-fatigue conditions. This study explores the relationship between loading frequency (f) and time until fracture (tf) for 310 NbN steel, crucial for understanding the complex interplay between time-dependent and cycle-dependent mechanisms. The methodology involves establishing a correlation between f and tf, in an experimental creep-fatigue at 1 Hz frequency and holding times (th) of: 0, 5, 60 and 600s. Enabling estimation of time-dependent and cycle-dependent mechanisms. Results indicate a transition zone where both mechanisms interact, influencing crack growth. For high wait times (60 and 600 s), corresponding to frequencies of 1.7E-2 and 1.7E-3 Hz, the relationship tends to start parallel to the log f axis, indicating dominance of the time-dependent mechanism. In contrast, for shorter wait times (5 and 0 s), corresponding to frequencies of 1.7E-1 and 1 Hz, the relationship exhibits some gradient, suggesting influence from the cycle-dependent mechanism. Yokobori theoretical framework provides insights into this phenomenon, proposing equations to model crack growth under interactive creep-fatigue conditions. The proposed method demonstrates good agreement between calculated and experimental results (for th=5, experimental tf=21:22, while calculated tf=18:04).
Technical Session
9/5/24, 11:30 AM - 9/5/24, 11:55 AM
Presenter(s): Alan do nascimento freire Diniz (COMPANHIA SIDERúRGICA NACIONAL - CSN), mirian teixeira de lima (Companhia siderúrgica nacional - csn), francisco eugênio de oliveira (COMPANHIA SIDERÚRGICA NACIONAL - CSN), bruna de almeida santos (COMPANHIA SIDERÚRGICA NACIONAL - CSN)
Abstract:
The objective of the work was to evaluate the residual life of the tubes from Boilers 82 and 83, as well as the recommended actions, following the results of Metallografic replica tests, measurement of the oxide layer and dimensional (US, A/B Scan, and Eddy current) allowing a reduction in undesirable stops due to tube variables, ensuring operational continuity and boiler availability, in addition to reducing the risk off accidents with the equipment
Technical Session
IMPLEMENTATION OF THE ZERO LANDFILL POLICY: EFFICIENT STRATEGIES FOR REUSE OF WASTE AT ARCELORMITTAL PECÉM
Presenter(s): Breno Melo Marques (Arcelormittal pecém), Artur Falcão Catunda (ARCELORMITTAL PECÉM), Francisco Edval Sampaio de Freitas Júnior (ARCELORMITTAL PECÉM), Thiago de Matos Raulino (ARCELORMITTAL PECÉM), Jose Adriano da costa Martins policarpo (ARCELORMITTAL PECÉM), Vanessa Carlos Zaranza (ARCELORMITTAL PECÉM), Emanuella Valente Pereira do Carmo (ARCELORMITTAL PECÉM), Monica Monteiro da Silva Ferreira (ARCELORMITTAL PECÉM), Pablo Bruno Paiva Leão (ARCELORMITTAL PECÉM), Alex Maia do Nascimento (ARCELORMITTAL PECÉM), Leonardo Luiz siqueira mathias (arcelormittal pecém)
Abstract:
The zero landfill approach has gained prominence as a proactive response to waste management, promoting practices aimed at eliminating final disposal in landfills, both sanitary and industrial. This study analyzes the outcomes of the Co-Products Management of ArcelorMittal Pecém, highlighting facilities and effective strategies to maximize the value of these materials and significantly reduce the environmental impact associated with their disposal. Recycling initiatives have continuously optimized the results, and in 2023, a new historical record of 99.87% total recycling was achieved, thus reinforcing ArcelorMittal's Sustainability value
Technical Session
NEW STRUCTURAL ULTRA LOW MANGANESE STEEL PLUS NIOBIUM: THE APERAM EXPERIENCE
Presenter(s): Francisco Julião fuinhas alves (aperam south america), Valdeci Paula Alvarenga (), Raphael Miranda Medeiros (), Celso Custódio Riechelmann (), Luana Alice de Souza (), Rafael Rezende Montes (), Nerea Isasti (), Pello Uranga (), Paulo Haddad (), Antonio Augusto Gorni (), THALES HARVEY CRISOSTOMO BARROS (Aperam south AMÉRICA ), valmir dias luiz (cefet mg), Erriston Campos Amaral (cefet mg), Rafael rezende montes (Aperam south AMÉRICA )
Abstract:
This paper describes a cooperative project developed by Aperam South America (ASA) and Companhia Brasileira de Metalurgia e Mineração (CBMM) with the aim of completely replacing manganese with small concentrations of niobium in structural low carbon steels, like SAE/AISI 1012. The results got in the final product after Steckel rolling and delivery to partner customers showed the following advantages: potential cost reduction and improvement in microstructural refinement, homogeneity, and inclusionary cleanness, while keeping the same level of mechanical properties. This project allows ASA to include in its product mix an alloy that innovates the design for structural steels. Besides that, this alloy broke ground for the replication of this concept in other structural steels.
Technical Session
9/5/24, 11:30 AM - 9/5/24, 11:55 AM
Presenter(s): MAISA APARECIDA ALVES DE SA (SMS GROUP METALURGIA DO BRASIL LTDA.)
Abstract:
The hot rolling process is comparatively energy-intensive. In order to optimize the energy consumption and efficiency in all areas of a conventional hot strip mill (HSM), SMS group has developed a number of innovative solutions. The paper introduces a selection of Performance Modules as milestones on the pathway to a carbon neutral production. The “toolbox” follows the material flow through the HSM, starting at the slab-reheating furnace, followed by the roughing train, the delay roller table of the finishing train, the finishing train itself, the run out table with cooling train and finishing with the downcoiler area and presents smart solutions
Technical Session
THERMAL DECOMPOSITION AND CARBOTHERMAL REDUCTION OF A LATERITE NICKEL ORE
Presenter(s): Lucas Prosperi Rodrigues (Universidade federal de ouro preto), igor jurandir ubaldo viana pereira (universidade federal de ouro preto), Henrique Carvalho da Silva Coelho (universidade federal de ouro preto), Adilson do Lago Leite (universidade federal de ouro preto), Cláudio Gouvêa dos Santos (universidade federal de ouro preto), Víctor de Andrade Alvarenga Oliveira (universidade federal de ouro preto)
Abstract:
Thermal decomposition and carbothermal reduction events of a Brazilian lateritic ore sample were investigated using thermogravimetric analysis (TGA) and X-ray diffraction (XRD) techniques. The Rietveld method was employed for the quantitative analysis of mineral phases present in the raw ore and the decomposed ore. Carbothermal reduction tests were conducted in a muffle furnace, revealing that complete ore reduction only occurred at 1100°C and 1200°C with coke contents ≥ 15% in the reaction mixture. The results demonstrated that the formation of a nickel-rich mineral phase (taenite) can be promoted by controlling the reduction potential of the system. The formation of this nickel-rich phase opens up the possibility of developing an extractive process in which the reduced nickel lateritic ore can be concentrated using classical mineral processing techniques.
Technical Session
FLUID FLOW AND INCLUSION REMOVAL IN NA PHYSICAL MODEL OF A FOUR-STRAND TUNDISH
Presenter(s): FERNANDA DO NASCIMENTO OLIVEIRA (universidade federal de ouro preto - ufop), BENNARDO KENNEDY THEOTÔNIO BARBOSA (UNIVERSIDADE FEDERAL DE OURO PRETO - UFOP), VINÍCIUS CAMPOS SOARES DOS SANTOS (UNIVERSIDADE FEDERAL DE OURO PRETO - UFOP), DEIVISON LUIS RIBEIRO DA CUNHA (GERDAu), CARLOS ANTÔNIO DA SILVA (UNIVERSIDADE FEDERAL DE OURO PRETO - UFOP), JOHNE JESUS MOL PEIXOTO (UNIVERSIDADE FEDERAL DE OURO PRETO - UFOP)
Abstract:
CONTROLLING THE FLOW OF STEEL WITHIN A CONTINUOUS CASTING TUNDISH IS A FUNDAMENTAL ASPECT FOR OBTAINING A HIGHER FINAL QUALITY OF THE STEEL. THIS WORK FOCUSES ON STUDYING THE INFLUENCE OF USING A TURBULENCE INHIBITOR (RECTANGULAR SHAPED) AND FLOW RATE VARIATION ON CHARACTERISTIC TIMES, INCLUSION REMOVAL, AND VELOCITY FIELDS IN A PHYSICAL MODEL OF A FOUR-STRAND TUNDISH. RESIDENCE TIME DISTRIBUTION (RTD) CURVES WERE EVALUATED USING CONDUCTIVITY TESTS, THE FLOW WAS CHARACTERIZED BY DYE DISPERSION TESTS, AND THE EFFICIENCY OF INCLUSION REMOVAL BY PARTICLE DISPERSION TESTS. IN ADDITION, VELOCITY PROFILES WERE VERIFIED BY THE PIV TECHNIQUE. IT WAS POSSIBLE TO VERIFY THE FLOW DIRECTION TO THE FREE SURFACE OF THE REACTOR WHEN THE JET COMES INTO CONTACT WITH THE TURBULENCE INHIBITOR, AND IN AGREEMENT WITH THE IMAGES OBTAINED IN THE DYE DISPERSION, THE MINIMUM RESIDENCE TIME WAS HIGHER IN THE EXTERNAL AND INTERNAL STRANDS, MORE SIGNIFICANTLY IN THE INTERNAL STRANDS. THE VECTOR MAP OBTAINED IN THE PIV TECHNIQUE SHOWED THAT THE VELOCITY INTENSITY WAS HIGHER IN THE TESTS WITH THE BARE TUNDISH AND WHEN THE FLOW RATE WAS INCREASED. INCLUSION REMOVAL WAS CONSIDERABLE IN THE TESTS CARRIED OUT WITH HIGHER POLYETHYLENE PARTICLES, EVIDENCING THE GREAT INFLUENCE OF MINIMUM RESIDENCE TIME ON INCLUSION FLOTATION.
Technical Session
9/5/24, 11:30 AM - 9/5/24, 11:55 AM
Presenter(s): mateus medrado loiola (Siderurgica norte brasil s.a. - sinobras)
Abstract:
This article proposes strategies to increase the refractory campaign lifespan in Electric Arc Furnace (EAF) of steel industries. Three approaches are explored: improving slag basicity based on the MgO x FeO ratio, increasing the Eccentric Bottom Tapping (EBT) from 5 to 6 taphole blocks, and applying technical concepts to maintain furnace profile integrity. The analysis integrates technological advancements and operational strategies. The implementation of these improvements resulted in operational, financial, and performance benefits for the EAFs. Adding a taphole block and increasing the hearth profile improved liquid metal distribution, reducing refractory wear. Furthermore, enhancing slag basicity and reducing FeO, along with the use of carbon briquettes, promoted more efficient operation and prolonged refractory lifespan. These outcomes culminated in a refractory campaign record for the EAFs, demonstrating the effectiveness of the implemented strategies.
Technical Session
9/5/24, 11:30 AM - 9/5/24, 11:55 AM
Presenter(s): Rafael Damasceno Xavier De Brito (SAMARCO), CARLOS PINTO PEREIRA JUNIOR (samarco mineração s/a), Alexandre Moure De Ataide Junior (samarco mineração s/a), bruno da rocha faria (samarco mineração s/a), Cleriston Oliveira De Faria (samarco mineração s/a), RENATO GUIMARAES GONÇALVES (samarco mineração s/a), Maykcilane Fernandes Miguel (samarco mineração S/A)
Abstract:
This article addresses the improvement of the logical bypass management process in the Distributed Control System (DCS) of a mining company, with a focus on security and traceability. We describe the implementation of a management process that aims to strengthen operational security and ensure transparency in the use of bypasses in control logic. The strategy adopted includes the integration of the process of executing temporary inhibitions with the enterprise resource management and planning system (ERP), establishing a flow that involves the generation of notes in the ERP for formal documentation. Furthermore, we introduced crucial components into the process: prior analysis of the risk of insertion of temporary inhibition and approval by an immediate superior and double verification during the execution process. In this way, each by-pass undergoes careful validation ensuring not only the safety of operations, but also responsibility and compliance with established protocols.
Technical Session
SURFACE WETTABILITY OF CERAMIC POROUS PLUGS AND ITS ROLE IN REMOVING NON-METALLIC INCLUSIONS FROM MOLTEN STEEL
Presenter(s): LUIS OTAVIO ZAPAROLI FALSETTI (UFSCar), Dereck Nills Ferreira Muche (UFSCar), Marcello Rubens Barsi Andreeta (UFSCar), Murilo Henrique Moreira (UFSCar), Victor Carlos Pandolfelli (UFSCar)
Abstract:
The secondary metallurgy of steels plays an important role in adjusting the molten metal's chemical composition, temperature and homogeneity. For special steels, another key aspect is the content of non-metallic inclusions considering their size distribution, concentration and composition. As a tool to withdraw these deleterious phases to the slag, inert gas is typically injected from the bottom of the ladle or tundish. The literature presents an optimal range for the bubble size to maximize the removal likelihood of the ceramic inclusions. However, the distribution of bubbles throughout the liquid steel column is originally dictated by their generation on the refractory porous plug. This work discusses the influence of the ceramic plug’s pore size and wettability regarding their ability to generate bubbles within an optimized range. The results suggest that the pore diameter can only limit the bubble size for surfaces wetted by liquid steel. As the contact angle of the plug increases (i.e., reducing its wettability with the molten bath), the injected gas tends to spread over the bubbler surface, increasing the bubble size regardless of the plug pore diameter. For the sake of comparison, the commercial purging plugs exhibit a high contact angle to avoid the infiltration of liquid steel during the non-bubbling periods. Therefore, the plug performance faces a trade-off regarding its surface wettability.
Technical Session
INFLUENCE OF THE USE OF WASTE FROM THE SUGAR AND ALCOHOL INDUSTRY ON THE PRODUCTION OF CLAY-BASED POROUS CERAMIC MATERIAL
Presenter(s): FELIPE SARDINHA MACIEL (UENF), José nilson frança de holanda (uenf), miguel angel rodriguez barbero (icv-csic)
Abstract:
The improper disposal of waste from industrial processes has been growing exponentially, and finding viable alternatives for proper disposal is an increasingly necessary and urgent task. In particular, the sugar-alcohol industry generates a considerable amount of solid waste, including sugarcane bagasse. Recognizing the attractive potential for the reuse of this waste, the present study aimed to evaluate the behavior of sugarcane bagasse waste as a pore-forming agent when applied to clay-based ceramic material. The raw materials were characterized in terms of chemical composition (XRF). Formulations incorporating 0, 15, 20, and 25% by weight of waste into a traditional ceramic mass from the Campos dos Goytacazes region were prepared. Tubular ceramic pieces were produced by extrusion, dried at natural and oven temperatures, and fired in a laboratory kiln at temperatures of 1000, 1050 and 1100ºC. Physical and mechanical properties were evaluated. The results show that the incorporation of sugarcane bagasse waste strongly influenced the physical and mechanical properties of the ceramic pieces, especially regarding pore formation, indicating that this organic solid waste is extremely effective for use as a pore-forming agent in the manufacture of porous ceramic materials.
Technical Session
MORPHOLOGICAL STUDY OF THERMAL VARIATION OF GEOPOLYMERIC MORTAR REINFORCED WITH BLAST FURNACE SLAG
Presenter(s): paulo anderson aranha ferreira (universidade federal do pará), Damares da cruz barbosa nascimento (universidade federal do pará), thiago corrêa (ceará alimentos), sérgio neves monteiro (instituto militar de engenharia ), verônica scarpini candido (universidade federal do pará), alisson clay rios da silva (universidade federal do pará)
Abstract:
Geopolymers are inorganic materials, aluminosilicates activated alkaline by geopolymerization reaction. Because they have properties similar to Portland cement, research has been carried out to ensure the use of geopolymers in civil construction. Thus, the present work approaches the production of geopolymeric mortars, added with Blast Furnace Slag (BFS), submitted to a temperature of 300°C and 800°C. For this study, metakaolin, blast furnace slag (BFS), and commercial sand in amounts of 0%, 59%, 69% and 75% were used, and for alkaline solution Potassium Hydroxide (KOH) and Silicate were chosen of Sodium (Na2SiO3). After production, they were cured and then subjected to a temperature of 300°C and 800°C. For analysis purposes, Optical Microscopy (OM) and Rietveld Refinement characterizations of the raw material were performed. Finally, the results point to geopolymer mortar with 69% aggregate as a material superior to other formulations, due to the low percentage of defects in the morphology of the fragmented surface, considering the temperature variation, from 300°C to 800°C.
Technical Session
inFLUENCE OF NIOBIUM IN THE MECHANICAL AND METALLURGICAL PROPERTIES OF STEEL PROCESSED THROUGH CONVENTIONAL ROLLING MILL
Presenter(s): CAMILA DE BRITO FERREIRA (GERDAU S/A), Rafael Stella Galdino (GERDAU S/A), Leonardo Contri Campanelli (UNIFESP), Anibal de Andrade Mendes Filho (ufabc), Danieli Aparecida Pereira Reis (UNIFESP)
Abstract:
The application of High Strength Low Alloy (HSLA) steel presents a significant challenge in achieving an optimal balance among mechanical properties, cost-effectiveness, and superior formability. The strategy for alloy design involves the careful adjustment of carbon content alongside the strategic incorporation of microalloying elements such as Nb, V and Ti that provide precipitation hardening and/or solid solution and/or grain refinement. Niobium is the predominant microalloying element, enhancing tensile properties via austenitic grain size regulation during hot rolling, hardness augmentation, and precipitation strengthening through Nb(C,N). The morphology, size and distribution of secondary phases influence on steel behavior. The development of steel should be adequate to promote the best characteristics of selected elements. Through thermomechanical controlled processing (TMCP), the addition of niobium contributes to the improvement of material properties. However, during the continuous rolling for long products, it is necessary to evaluate its effectiveness. The objective of this study was to investigate the influence of niobium (Nb) addition on the grain size, tensile properties, energy absorption during impact testing, and hardness of AISI 4320 steel following a conventional rolling process. The results showed an increase in yield and ultimate tensile strengths.
Technical Session
Modern pipeline steel alloy design preventing from MA Phase
Presenter(s): MARCOS ALEXANDRE STUART NOGUEIRA (CBMM), Paulo de Tarso Haddad (CBMM), Taro Kizu (JFE Techno), Shigeru Endo (JFE Techno)
Abstract:
For high-capacity natural gas transmission pipelines, besides having high yield and tensile strength, the steels must present high toughness and high capacity to arrest any crack, providing safety to the pipeline during its entire life. The objective of this paper is to present the characterization of the Girth Weld HAZ of samples from Cheyenne Plains pipe, an API X80 steel with excellent combination of high strength with toughness. Special attention was given to the MA phase at HAZ of a girth weld made using GMAW process. This steel adopted the modern alloy design with carbon content below 0.05%, that allows to use up to 0.08% to 0.10%Nb. It was concluded that the high toughness of the Girth Weld is the combination of this modern alloy design with GMAW welding processes, a low heat input welding process, resulting in: - Fine prior austenitic grains at HAZ, with less than 1.5% of MA phase and a maximum equivalent diameter of 2.5µm, that was formed during welding cooling or at heating cycle during multi welding passes. - Fast cooling at welding cycle due to the low heat input, promoting the formation of low temperature bainite. Niobium in solution can help promote the formation of low temperature bainite as well. Preventing excessive austenitic grain growth during weld thermal cycle, low MA phase fraction and low temperature bainite are the basis for maintaining high toughness at HAZ of girth weld.
Technical Session
9/5/24, 11:30 AM - 9/5/24, 11:55 AM
Presenter(s): jonathan de souza calvelli (TERNIUM)
Abstract:
Ternium, located in Rio de Janeiro, Brazil, has two blast furnaces with an average daily production of 7500t each. The load distribution inside the blast furnace is carried out by the equipment that makes up the top. Ternium's blast furnace top model is the bell less top. There are two material hoppers, which work alternately with ore and coke. The sealing of each of these hoppers for pressurization is carried out through two valves, one upper and one lower. A survey of the loss profile was carried out, identifying the lower seal valves as the biggest production losses due to maintenance at the top. Thus, after developing the stages of the PDCA cycle, with identification of the causes, through the application of the fault tree analysis (FTA), and the implementation of the actions, there was no further record of new occurrences of the failure mode treated, resulting in greater availability and resulting reduction in production losses due to maintenance at the top of the blast furnaces.
Technical Session
9/5/24, 11:55 AM - 9/5/24, 12:20 PM
Presenter(s): TAIRINE BERBERT TAVARES (USIMINAS - IPATINGA), Julio Cezar de Sousa Zorzi (USIMINAS - IPATINGA), Pedro Henrique Resende Vaz de Melo (USIMINAS - IPATINGA)
Abstract:
Forming limit curves (FLCs) are widely used to evaluate the stampability of steels. These curves modeling, however, is relatively complex, given their intrinsic relationship with the manufacturing conditions of each material. In this context, the present study aimed to predict the FLCs of steels intended for the automotive sector based on industrial processing data, applying machine learning models. To this end, the chemical composition and process parameters of several advanced high strength steels (AHSS) were used as input variables. The prediction model was built based on the results of physical laboratory tests, which included, among other information, the mechanical properties and FLCs of cold-rolled steels currently produced by Usiminas. The final model showed a good correlation with the experimental results, allowing the extraction of relevant information about the steels stampability in relation to the variation of their tensile properties. This tool has great potential to application engineering and the development of products with better performance in terms of formability.
Technical Session
CONDITIONING PLATE YARDS MANAGEMENT AND OPERATION SYSTEM
Presenter(s): marcel magno dias rodrigues (ARCELORMITTAL TUBARAO), besaleel moyses vieira filho (ARCELORMITTAL TUBARAO), juliana gomes dos santos (ARCELORMITTAL TUBARAO), marcus vinicius pimentel gomes (ARCELORMITTAL TUBARAO), FABIANO DE SOUZA PALAORO (Vixteam Consultoria e Sistemas), EVANDRO POLESE ALVES (VIXTEAM CONSULTORIA E SISTEMAS)
Abstract:
The advancement of Industry 4.0 has led to the creation of integrated systems that improve the management of industrial processes. At ArcelorMittal, the increasing adoption of Industry 4.0 technologies has enabled the automation of production processes and more effective control of operational variables. This work presents the implementation of a new management and operation system for conditioning plate yards, focusing on automation and information technology. Developed in partnership with Vixteam Consultoria e Sistemas, using ArcelorMittal's own architecture with Java and Angular technologies, the system integrates with the company's other systems, promoting efficient management, increasing productivity, and simplifying operational processes. The proposed solution seeks to improve yard operations, reduce the use of legacy systems, and automate complex processes. The results achieved include greater data reliability, a user-friendly interface with dashboards and maps for better management and monitoring, and a significant improvement in operational efficiency, reflecting the company's commitment to innovation and modernization of production processes
Technical Session
NEW AUTOMATION ARCHITECTURES - USING MICROSERVICES AND BUS COMMUNICATION TO SIMPLIFY NEW IMPLEMENTATIONS AND MAINTENANCE
Presenter(s): Edson José Valentim Pereira (janus automation)
Abstract:
This article describe and propose an architecture for automation systems based on microservices and bus communication resulted in scalability, distribution, and allow fast implementations and maintenance. An experienced functional analyst, tasked with defining the boundaries and responsibilities of each microservice, is essential for achieving success in state-of-the-art software architecture. The utilization of microservices with communication patterns via a service bus, along with an integrated data repository, ensures the continuity and scalability of the solution or platform. As an example, we'll demonstrate with a model steel industry system that incorporates process data from the control system, input inventory data, laboratory sample results, as well as specification and product data from the MES. Throughout the implementation process, the system was fully integrated via the communication bus, with drivers created to facilitate communication with legacy systems utilizing proprietary protocols. The use of microservices ensured independence during development and reduced the time for integrated communication testing. The system incorporates a security and encryption strategy for external communications, ensuring limited access and data visibility to prevent unauthorized interception of data between networks. o enhance the user experience, the interface was designed as a Single Page Application, offering customized views for desktop, video wall, and mobile devices. This approach enabled more effective system usage in environments beyond cabins, control rooms, or offices.
Technical Session
INFLUENCE OF TIME BETWEEN PASSES IN FRICTION STIR PROCESSING (FSP) ON THE 7075-T651 ALUMINUM
Presenter(s): Saulo Brinco Diniz (Centro Federal de Educação Tecnológica Celso Suckow da Fonseca), Rosi Hellen Caldas Carioca (Centro Federal de Educação Tecnológica Celso Suckow da Fonseca), Lucas Moura Montenegro Reis (Instituto Militar de Engenharia), André Ferrara Carunchio (Instituto de Pesquisas Tecnológicas), Carolina Paiva Nascimento Silva (Instituto de Pesquisas Tecnológicas), Sergio Neves Monteiro (INSTITUTO MILITAR DE ENGENHARIA)
Abstract:
Friction Stir Processing (FSP) is a promising technique for grain refinement of metals, which consists of plastic deformation / heating caused by friction between a tool and metal. It was evaluate the influence of the thermal flow generated during and after the FSP of the 7075-T651 aluminum alloy, changing only the time between passes. For this purpose, contact thermometers, pressure and torque control during processing and visual inspection (of the sheet surfaces and cross section) were used. It is concluded that 5 min time between passes generates greater homogeneity between passes in relation to torque and shoulder pressure, in addition to presenting a better surface finish due to lower volumes of burrs generated. It was observed that higher shoulder pressure values decrease the probability of tunnel defects.
Technical Session
9/5/24, 11:55 AM - 9/5/24, 12:20 PM
Presenter(s): Dioner DE SOUSA Fonseca (VALLOUREC SOLUÇÕES TUBULARES DO BRASIL)
Abstract:
It's crucial to certify the quality of the effluent returning of recirculated industrial water system from Vallourec – Barreiro's Site. For this, we focus on precise control of the water level in the Scale Separator (Hydrocyclone), enhancing solid sedimentation and oil removal from the water. This engage to ensure a better Mean Time Between Failures (MTBF) for the equipment involved in the process, also to reduce the energy consumption and the time to live of drives because the continuous operation. Above all, we find to provide superior quality industrial water to internal customers.
Technical Session
SUSTAINABLE SODIUM FERRATE: ELECTROLYTIC INNOVATIONS AND CHEMICAL CHALLENGES
Presenter(s): jorge de oliveira melo (intituto militar de engenharia), Breno Ribeiro Mascarenhas (intituto militar de engenharia), Thomaz Jacintho Lopes (intituto militar de engenharia), wagner anacleto pinheiro (intituto militar de engenharia)
Abstract:
Sodium ferrate (Na₂FeO₄) is highly valued for its oxidizing and disinfecting properties, and is used in wastewater treatment, contaminant oxidation, and disinfection. This study analyzes two production routes for sodium ferrate: chemical and electrolytic, considering efficiency, environmental impact, and technical feasibility. The chemical route involves the oxidation of iron salts in an alkaline medium with oxidizing agents such as sodium hypochlorite or hydrogen peroxide. Despite being an established method, it faces significant challenges, including the production of undesirable byproducts, handling of hazardous reagents, and sensitivity to operational parameters. The electrolytic route, in turn, uses electrolysis in an alkaline medium to directly oxidize metallic iron. This approach is more sustainable, avoiding hazardous reagents and being able to use energy from renewable sources. However, it requires optimization in terms of production efficiency, energy consumption, and electrode durability to be economically viable on a large scale. The electrolytic route aligns with circular economy principles by using recycled iron and reducing the carbon footprint. Improvements in green chemistry processes can mitigate the impacts of the chemical route. Economic sustainability can be achieved in the long term by minimizing waste and using renewable energy.
Technical Session
WELDABILITY COMPARISON BETWEEN CONVENTIONAL C-MN AND LOWER MN+NB (ULNB) STRUCTURAL STEELS
Presenter(s): Francisco Julião fuinhas alves (aperam south america), Antonio Augusto Gorni (), Valdeci Paula Alvarenga (), Luana Alice de Souza (), Paulo Haddad (), Celso Custódio Riechelmann (), Rafael Rezende Montes (), THALES HARVEY CRISÓSTOMO BARROS (Aperam south AMÉRICA ), valmir dias luiz (cefet mg), Erriston Campos Amaral (cefet mg)
Abstract:
In recent years, a new alloy design for hot rolled structural steels was proposed, completely replacing the manganese added with niobium micro-additions, keeping the same mechanical characteristics, but providing advantages in terms of internal quality, cost and carbon footprint. The reduction in carbon equivalent resulting from the no addition of manganese content suggests that the weldability of this new steel should also be improved. However, to be sure of this fact, this work was developed, with the objective to characterize in detail the welded joints of these two types of steel, both from a microstructural and mechanical point of view. The results obtained showed that, as a matter of fact, these steels can also be considered equivalent from the point of view of weldability.
Technical Session
9/5/24, 11:55 AM - 9/5/24, 12:20 PM
Presenter(s): José Osvaldo Amaral Tepedino (arcelormittal vega), Felipe Pereira Finamor (arcelormittal vega), Silvio Corrêa (Arcelormittal vega), Gabriel Godinho Alves (arcelormittal tubarão), Roan Sampaio de Souza (arcelormittal tubarão), Francislaynne LAGES Dias (ARCELORMITTAL VEGA)
Abstract:
This work presented the development carried out by ArcelorMittal Brazil of a new hot-dip galvanized steel (HDG) named ARC07, aimed at automotive panels. The new steel has an unprecedented guarantee of mechanical properties for the Brazilian market characterized by a Yield Strength up to 160 MPa and values of parameters associated with ductility, such as Total Elongation and Lankford R value, higher than the steels currently offered. With these characteristics, the ARC07 steel is an alternative for application in parts with higher severity of stamping, such as exposed side panels, where the use of current steel grades may present difficulties. In this work, information on the new steel, as well as results of laboratorial forming tests and stamping numerical simulation were presented for a better characterization of the material in use.
Technical Session
MAPPING OF CALCIUM AND ALUMINUM YIELD LOSSES IN LEAD ALLOYS
Presenter(s): MARCOS CESAR MARTINS JÚNIOR (ACUMULADORES MOURA SA), beatriz aranha de farias (ACUMULADORES MOURA SA), José joel da silva (ACUMULADORES MOURA SA), fernando do nascimento (ACUMULADORES MOURA SA), wellington erasmo da sila valença (ACUMULADORES MOURA SA), clebson de lacerda silva (ACUMULADORES MOURA SA), erivÂnio lima viana (ACUMULADORES MOURA SA)
Abstract:
Pb-Ca alloys are used worldwide in the manufacture of electrical accumulator grids. In these alloys, calcium and aluminum are added as alloying elements to enhance the quality of the lead. In terms of process, the addition step of these elements is quite challenging, because, as they are elements with low solubility in lead, they tend to oxidize and form oxides, generating dross and low yield per addition, leading to greater consumption of these elements and, consequently, more cost. In this context, this work sought to bring a study aimed at mapping and standardizing the yield of calcium and aluminum in the metallurgical plant of Acumuladores Moura S/A. The tests were carried out following the planned experimental design, with the aim of verifying the influence of stirring time on the yield of added calcium and aluminum on a pilot scale and on na industrial scale . With this study it was possible to conclude that in fact given much time the yield of these elements will decrease. It was observed that the vortex plays an important role in the aluminum yield, because facilitates the incorporation of this element. It was also verified that for 8 minutes of stirring time the yield of calcium and aluminum decreases at least 4%
Technical Session
9/5/24, 11:55 AM - 9/5/24, 12:20 PM
Presenter(s): Igor Corneau Soares (UNIVERSIDADE FEDERAL DE OURO PRETO - UFOP), Bennardo Kennedy Theotonio Barbosa (UNIVERSIDADE FEDERAL DE OURO PRETO - UFOP), Vinicius Campos Soares Dos Santos (UNIVERSIDADE FEDERAL DE OURO PRETO - UFOP), Deivison Luis Ribeiro da Cunha (GERDAU), Carlos Antônio da Silva (UNIVERSIDADE FEDERAL DE OURO PRETO - UFOP), Johne Jesus Mol Peixoto (UNIVERSIDADE FEDERAL DE OURO PRETO - UFOP)
Abstract:
The geometry of the submerged entry nozzle (SEN) has greater influence on the steel flow behavior in continuous casting molds. SEN models have been developed with side ports that promote rotational flow within the bloom mold. Physical modeling is a key strategy to analyze the flow behavior with different geometries and process parameters. This study compared a common straight nozzle and a swirling flow nozzle (SFN), evaluating the effect of liquid flow rate on the velocity profile, meniscus oscillation and inclusion removal. The straight nozzle presented a high jet penetration depth, resulting in low steel renewal in the meniscus, low velocities at the upper region and low oscillation intensity in the meniscus. On the other hand, the SFN design demonstrated uniform filling of the upper mold section, good meniscus renewal and higher oscillation intensity. At greater immersion depth (15cm) and lower flow rates, the SFN maintained the same level of meniscus oscillation intensity as the straight nozzle. Furthermore, the rotational flow was indicated by velocities profiles in horizontal planes below the SFN and close to the meniscus. It should also be noted that the velocities values at the upper region were three times greater than using the straight nozzle. Inclusion removal rate was slightly improved, but decreased significantly as the liquid flow rate increased. These findings highlight the fluid flow improvements with the new design of SEN.
Technical Session
9/5/24, 11:55 AM - 9/5/24, 12:20 PM
Presenter(s): LUIS HENRIQUE MARIANO DA SILVA (DANIELI DO BRASIL LTDA)
Abstract:
The automation of charging and teeming cranes represents a significant advancement in steel production efficiency. This article delves into two primary, interconnected solutions. Firstly, it discusses a system designed for the automatic handling of buckets and ladles, which streamlines the materials transfer process, enhancing safety and efficiency. Secondly, it examines a feature that synchronizes the crane's movements with the Electric Arc Furnace (EAF) roof during the charging phase. This synchronization optimizes operational time, conserves energy, and significantly improves operator safety. These innovations not only bolster productivity but also reflect the steel industry's dedication to embracing technology advancements while prioritizing the welfare of its workforce
Technical Session
IMPROVEMENTS IN VIBRATION MEASUREMENT OF SAMARCO MINERAÇÃO PROCESS FANS
Presenter(s): Rafael Damasceno Xavier De Brito (SAMARCO), Alexsandre Ramos Costa (samarco mineração s/a), Anderson Christo Cunha (samarco mineração s/a), Bruno Sepulchro Tozato (samarco mineração s/a), Charlie Alves Da Silva Ferreira (samarco mineração s/a), Fabio Demuner Da Silva (samarco mineração s/a), Guilherme Chrystello Martins (samarco mineração S/A), Mario Laurentino Da Silva (Samarco Mineração S/A), Vinicius Santa Clara Ucelli (Samarco Mineração S/A)
Abstract:
This study aims to highlight the improvements implemented in the detection of vibrations in Samarco's process fans, with the aim of reducing unscheduled stops in production. By analyzing the incidence of false alarms in vibration sensors, changes to the infrastructure and the development and implementation of a virtual sensor are proposed. Using historical data and bench testing, the virtual sensor demonstrated accuracy in distinguishing between real vibrations and false alarms, resulting in a significant reduction in downtime and increased operational reliability of process fans. This approach contributed to optimizing the operation of the pellet hardening furnace, reducing maintenance and repair costs. The success of the project reinforced the effectiveness of virtual sensor technology in detecting faults in industrial equipment
Technical Session
9/5/24, 11:55 AM - 9/5/24, 12:20 PM
Presenter(s): MARLLON FRAGA SILVA (IME - INSTITUTO MILI), Marvin do Nascimento (ime), Carlos Henrique da Luz Barbosa (ime), elson silva galvao (ufes), sergio neves monteiro (ime)
Abstract:
Granulated slag is a byproduct of the steelmaking process, resulting from the fusion of impurities in iron ore, together with fluxes (limestone and dolomite), and coke ash (mineral coal). In Brazil, the use of slag is practically restricted to the Portland cement industry, where it is employed as a clinker substitute. With the aim of evaluating the influence of grain shape on its reuse applications, this study shows that there is a correlation between the granulometry of granulated slag and grain morphology. To this end, twelve samples from three different blast furnaces were analyzed, with four from each blast furnace. A sieving process was conducted using eight sieves, with each retained size fraction separated for analysis. Five images of grains from each granulometric range were obtained, with sufficient resolution and contrast for image processing, thereby increasing the amount of information obtained in this analysis. From these data, it can be affirmed that sphericity factor varies according to particle size. Thus, it can be stated that granulometric separation affects grain morphology, qualifying the fractions of blast furnace granulated slag for other industrial demands and adding value to the product.
Technical Session
CHARACTERIZATION OF CLAY AND GLASS FOR 3D PRINTING
Presenter(s): Henrique Martins Gonçalves Brochado (UENF ), Carlos Fernando Revelo Huertas (UENF), Geovana Carla Girondi Delaqua (UENF), Carlos Maurício Fontes Vieira (uenf)
Abstract:
n this research, a kaolinitic clay from the city of Campos dos Goytacazes, RJ, Brazil, and powdered glass bottle waste were characterized as raw materials for additive manufacturing by 3D printing. The raw materials were prepared for analysis using X-ray Fluorescence (XRF), X-ray Diffraction (XRD), Scanning Electron Microscopy (SEM) and Dilatometry techniques in order to understand the composition of the clay and glass used and to optimize the parameters of the 3D printing process. Additive manufacturing is a simple and inexpensive technology suitable for adaptation to large-scale production, and the characterization and analysis of the raw materials used in this process are of fundamental importance for optimizing the properties of the produced
Technical Session
9/5/24, 11:55 AM - 9/5/24, 12:20 PM
Presenter(s): SÁVIO DOS SANTOS CARVALHO (Uenf), Maria Luiza Pessanha Menezes Gomes (Uenf), José Lucas Decoté de Carvalho Lirio (Uenf), Elaine Aparecida Santos Carvalho (Uenf), Carlos Maurício Fontes Vieira (Uenf ), Pablo Barbosa Jacintho (Uenf )
Abstract:
This research addresses the growing environmental concern with the increase in industrial waste and the need for sustainable solutions. It focuses on recycling materials, especially on the reuse of granite waste from the ornamental stone industry, to produce artificial rocks. Using epoxy resin and biodegradable natural fibers, the study highlights the feasibility of creating environmentally friendly and functional building materials. The production of artificial rocks from this waste not only reduces the environmental impact, but also offers an efficient alternative for civil construction. To produce the plates, a methodology was used that includes vibration, vacuum and compression, followed by cutting the plates to carry out the tests. The material achieved high flexural strength and medium compressive strength.
Technical Session
INFLUENCE OF STEEL SLAB INTERNAL QUALITY ON HYDROGEN-INDUCED CRACK RESISTANCE IN NORMALIZED HEAVY PLATE FOR PRESSURE VESSELS
Presenter(s): carlos henrique lopes (arcelormittal pecém), Francisco Necy Alves Junior (ArcelorMittal Pecém), Hana Lívia Frota Coelho (ArcelorMittal Pecém), Aline Dias Meneses (alinediasm@hotmail.com), Fernando Emerson Viana Sousa (Arcelormittal pecém), Lucas Uchoa (arcelormittal pecém), Paula Renee de Macedo Costa (ArcelorMittal Pecém), Carlos Carneiro (ArcelorMittal Pecém), Carlos Roberto Guimarães (arcelormittal), Hilder Caldas (arcelormittal pecém), Yoran Bolsoni (ArcelorMittal Pecém), Alex Maia do Nascimento (ArcelorMittal Pecém)
Abstract:
In the present study, the influence of internal soundness levels on Hydrogen Induced Cracking (HIC) resistance of ASTM-A516 grade 60 normalized steel plates was evaluated. Three heats were produced on a state-of-the-art steel-making plant using advanced primary and secondary refining practices and continuously cast on sophisticated vertical curved machine doted of high-end technologies, such as spray-3D secondary cooling, dynamic soft reduction in all segments, 2.2 m of vertical zone, mold with 0.8 m of length, tundish with 80t of capacity and quality tracking system with more than 40 online parameters checking. Aiming for optimal internal soundness results, the casting parameters were varied, obtaining slabs with Mannesmann internal soundness levels 1 and 2. The slabs were hot-rolled and heat-treated through the normalizing process. Cross-sectional samples on slabs were conducted to assess the level of internal soundness. In heavy plates, susceptibility to HIC according to NACE-TM-0284 solution A tests and characterization of crack nucleation regions were evaluated. The HIC cracks were observed in the central heavy plates thickness, an area with the highest concentration of hydrogen-trapping sites due to the inherent higher central segregation in this region. These cracks nucleated and propagated between microconstituent regions of higher hardness. An increase in HIC resistance was observed with the reduction of central segregation in the plates. Heavy plates from the internal soundness level 1 exhibited satisfactory resistance to HIC.
Technical Session
EFFECT OF SHIELDING GAS ON THE PROPERTIES OF COPPER BLAST FURNACE PARTS WELDED BY THE GTAW PROCESS
Presenter(s): Luiz claudio monfradini (arcelormittal tubarão), Raony Coutinho Trancoso (arcelormittal tubarão), André Gustavo de Sousa Galdino1 (arcelormittal tubarão)
Abstract:
Gas Tungsten Arc Welding (GTAW) or Tungsten Inert Gas (TIG) is a process that uses argon, helium or a mixture of both as shielding gas. For copper welding, a mixture of helium and argon is used, usually with high purity helium, which contributes to better weld quality. However, high and volatile prices, in addition to constant crises in supply and delivery, including those resulting from wars, cause instability in the availability of helium. The objective of this study was to verify the effect of different mixtures of argon and helium on the microstructure and mechanical properties of copper parts applied to the steel industry and welded by the GTAW process, especially tuyere joints of blast furnace . Test specimens with three different mixtures were used, being mixture 1 (95% He + 5% Ar); mixture 2 (70% He + 30% Ar) and mixture 3 (50% He + 50% Ar). Information on mechanical strength and hardness profile did not show significant changes. No considerable variations were found when the crystalline structures were evaluated
Technical Session
9/5/24, 11:55 AM - 9/5/24, 12:20 PM
Presenter(s): SHUN YOSHIDA YOSHIDA (COMBUSTOL TRATAMENTO DE METAIS LDA), CRISTIAN ANDRES ALVARADO MADARIAGA (COMBUSTOL TRATAMENTO DE METAIS LDA), FABIO VIEIRA DE SÁ (COMBUSTOL TRATAMENTO DE METAIS LDA), ALINE CARNIEL DE SOUZA (COMBUSTOL TRATAMENTO DE METAIS LDA)
Abstract:
Heat Treatment of large (over 300 kgs) molds and dies made with AISI H13, usually has microstructure problems, due the difference between surface and core reducing the die life or even catastrophic failures. The COMBUSTOL FAST* process reduce this problems, increasing the quenching severity (comparing with commom process in brazilian market) promoting better homogeneity of the microstructure
Technical Session
9/5/24, 11:55 AM - 9/5/24, 12:20 PM
Presenter(s): LARISSA GOMES SIMAO (UNIVERSIDADE ESTADUAL do NORTE FLUMINENSE darcy ribeiro), Eduardo atem de carvalho (UNIVERSIDADE ESTADUAL do NORTE FLUMINENSE darcy ribeiro)
Abstract:
Fragile and semi-fragile materials respond well to failure formulations made by Linear Elastic Fracture Mechanics (LEFM) as well as Classical Elasticity (CE). For ductile materials, the presence of a plastic region before the body fails makes the analysis complex and requires the use of the approach of Elastic Plastic Fracture Mechanics (EPFM) in cases where there is a singular failure or under conditions that generate a similar stress field. On the other hand, for non-singular notches, the correct failure mode as well as the limits tolerated by the part before failure occurs need to be well established. The determination of initial parameters for numerical analysis is obtained through conventional tensile tests. For the AA7075-T6 aluminum alloy, notches and fillets were simulated with parameters that follow the relationships 0.1 ≤ d/D ≤ 0.9 and 0.0017 ≤ ρ/D ≤ 0.1333, respectively. Formulations developed from the equations of Tada [1] and Anderson [2] are presented, allowing the use of NMOD (Notch Mouth Opening Displacement) values for the evaluation of KIc.
Technical Session
9/5/24, 12:20 PM - 9/5/24, 12:45 PM
Presenter(s): FERNANDO DE SOUZA COSTA (USINAS SIDERURGICAS DE MINAS GERAIS SA), Paulo josé duarte rodrigues (USINAS SIDERURGICAS DE MINAS GERAIS SA), Guilherme Brito Menegaz Junior (USINAS SIDERURGICAS DE MINAS GERAIS SA)
Abstract:
Since the 1990s, Usiminas has been studying Advanced High Strength Steel (AHSS). Over time, this family of steels, which includes in its “First Generation” products such as Dual Phase (DP), Transformation Induced Plasticity (TRIP), multi-constituted Complex Phase (CP) and Martensitic (MART), has become a consolidated reality in the automotive industry. In recent years, however, the focus has been on the development of new AHSS, called “Third Generation AHSS”, which promises to include materials with even more complex microstructures, combining phases of high mechanical strength, such as ultrafine grained ferrite, martensite or bainite, and significant amounts of a constituent with good ductility (e.g., austenite). This work presents the main results of the development in laboratory scale of a third generation AHSS of the 1000 MPa strength grade, with TRIP effect, at Usiminas. For this purpose, several thermal cycles were performed in a Gleeble machine and in a dilatometer. The material obtained showed good microstructural homogeneity, high ductility in view of its mechanical strength grade, combined with good potential for energy absorption.
Technical Session
9/5/24, 12:20 PM - 9/5/24, 12:45 PM
Presenter(s): max vieira santiago (ARCELORMITTAL ), Gustavo Henrique Sousa (ARCELORMITTAL), Carlos Geraldo Quaresma (arcelormittal), Gilberson Geraldo Silva (arcelormittal), Caio Cesar Magalhaes Dionisio Mota (arcelormittal), Joaquim Goncalves Costa Neto (arcelormittal)
Abstract:
This paper addresses the application of artificial intelligence (AI) in predicting the tensile strength of low carbon, medium carbon, high carbon, and alloy steels. The primary objective is to develop an AI model capable of accurately predicting the tensile strength of these materials, considering their chemical compositions, sizes and cooling rates. The methodology involves collecting an extensive set of experimental data, followed using machine learning algorithms, such as artificial neural networks and regression, to train and validate the predictive models. The 120 thousand data lines were pre-processed to eliminate noise and ensure the quality of the predictions. The results demonstrated that the developed AI models can predict the tensile strength of different types of steel with high accuracy, outperforming traditional methods based on empirical equations. The conclusions highlight the effectiveness and efficiency of AI in materials engineering, suggesting that this approach can be widely applied in the metallurgical industry to optimize the development and production of steels with desired mechanical properties. This study reinforces the potential of AI as a valuable tool for improving the understanding and application of metallic materials.
Technical Session
9/5/24, 12:20 PM - 9/5/24, 12:45 PM
Presenter(s): maykcilane fernandes miguel (samarco), Guilherme Chrystello Martins (samarco), Fabricio Garcia Marques (samarco), Rafael Damasceno Xavier De Brito (samarco), Matheus Teixeira Neiva (samarco), Bruno Sepulchro Tozato (samarco), Bruno da Rocha Faria (samarco), Anderson Christo Cunha (samarco)
Abstract:
Well-managed alarms are efficient both for reducing costs from material losses and for protecting lives. Therefore, several companies already rely on Fire Alarm and Detection Systems (FADS). However, the integration of these local alarms with supervision screens is fundamental for obtaining a better response to the problem. Therefore, aiming to further operational safety, this article addresses the enhancement of the fire alarm monitoring system in electrical rooms of a mining plant, using IoT to effectively segregate the fire monitoring system from the process control, ensuring information reliability, response time reduction and system availability.
Technical Session
INFLUENCE OF NB ADDITION ON THE MICROSTRUCTURE AND MECHANICAL PROPERTIES OF A C-MN STEEL
Presenter(s): lucas carneiro de castro (UNIVERSIDADE FEDERAL DE OURO PRETO), ricardo josé faria (gerdau), NAYARA APARECIDA NERES DA SILVA (UNIVERSIDADE FEDERAL DE OURO PRETO), PAULA CIBELY ALVES FLAUSINO (UNIVERSIDADE FEDERAL DE OURO PRETO)
Abstract:
In the present work the influence of Nb addition on the microstructure and mechanical properties of a C steel with high Mn content is discussed. An experimental study was conducted using two different grades of ASTM A1011/A1011M: SS36 TYPE 2 and HSLAS50 CLASS 1 steels; tensile tests and optical microscopy analysis in specimens of both grades were performed. The steels were carefully produced at Gerdau plant in Ouro Branco in order to have approximate C and Mn content and further processed using the same parameters during controlled rolling. The analyzes showed that both steels satisfactorily met the mechanical properties requirements in accordance with ASTM-A1011 standard specification. Furthermore, niobium micro-addition in low carbon high manganese steel coils proved its efficiency in promoting further microstructural refinement and mechanical properties improvement, but a reduction in ductility was verified.
Technical Session
PROTOTYPE OF PNEUMATIC CONVEYOR IN DENSE PHASE AND LOW PRESSURE
Presenter(s): Regis de oliveira Dantas (UFABC), Rodrigo Giacometti Ramos (Zeppelin SYSTEMS LATIN AMERICA), rICARDO BORGES DOS SANTOS (ZEPPELIN SYSTEMS LATIN AMERICA), Luis Alberto Martinez Riascos (ufabc)
Abstract:
This paper addresses the development of a low-pressure dense-phase pneumatic solids conveyor for the pet food industry, focusing on pellet transportation. The methodology includes development and testing an industrial prototype using an air blower as the driving force, ensuring low-speed and low-pressure transportation. To reduce pulsation and stabilize pressure, a pressure control valve based on the orifice plate theory was developed. This valve adjusts the pressure to regulate the transportation speed, preventing material breakage and blockages. Preliminary results indicate that the valve maintains a small pressure differential, crucial for safe and efficient transportation. Next steps include material transportation tests and continuous improvements to the valve
Technical Session
RECOVERY OF SECONDARY MATERIAL FROM PERMANENT MAGNETS: STAKEHOLDERS ANALYSIS IN BRAZIL
Presenter(s): LÚCIA HELENA XAVIER (CETEM), Franciele Rossetti Cúnico (), Jéssica Prats Raspinir (), Orestes Estevam Alarcon ()
Abstract:
High-tech industries that use permanent magnets as components in their products continue to face a challenging scenario. The manufacturing of these magnets relies on metals such as rare earth elements (REEs). These metals are still marked by strong Chinese dominance, due to the recent ban on importing this supply and technological solutions to recover ETRs, resulting in supply risks and uncertainty. To remain competitive, companies need to explore market positioning strategies. Considering the stakeholders in a competitive supply chain, the objective of this research is to propose solutions for the recovery of secondary material, using permanent magnets in Brazil. For this, the SWOT Analysis tool was used to analyze and correlate these factors with sector experts involved in the permanent magnet chain in Brazil. To support the diagnosis, information available in the literature was used and on-site visits and interviews were carried out with the largest manufacturing company in Brazil that uses permanent magnets in its products and the manufacturing industry that recovers secondary materials through recycling. Among the proposals, we highlight, for example, internal and external factors in the recycling of permanent magnets, improvement of the national platform to consolidate post-consumer volumes, training of workers, storage of post-consumer magnet components, and improvements in the design of products.
Technical Session
9/5/24, 12:20 PM - 9/5/24, 12:45 PM
Presenter(s): ANTONIO AUGUSTO GORNI (autônomo)
Abstract:
In recent decades countless works have been published on the influence of niobium in the thermomechanical rolling of structural low carbon steels. On the other hand, its role in quenched and tempered steels has been much less investigated and discussed, perhaps due to the limited effect of niobium on austenite hardenability due to the high temperatures required for its full dissolution that prevents its wide adoption for this application. The evolution of electron microscopy techniques, particularly MET and EBSD, has shed more light about the effect of niobium on the microstructural morphology of quenched and tempered martensite. This work aims to review the role of niobium in quenching and tempering metallurgy of low alloy steels, in order to promote its use in more efficient alloy designs from an environmental and cost point of view. As an example, the addition of 0.060% Nb to a steel used for the manufacture of OCTG quenched and tempered pipes increased yield strength from 719 MPa to 796 MPa due to the additional hardening contributions of martensite refining, dislocation density and precipitation.
Technical Session
9/5/24, 12:20 PM - 9/5/24, 12:45 PM
Presenter(s): GABRIELA VALLE DE CASTRO MADEIRA (SMS GROUP METALURGIA DO BRASIL LTDA.)
Abstract:
The laying head pipes, manufactured by SMS group for over fifty years and used in wire rod rolling, may undergo distortion during fabrication with duplex stainless steel. Throughout hot forming, one part of the pipe is in contact with the metallic die, while the other is exposed to the environment. After laboratory simulations, it was concluded that differences in cooling patterns between the inner arc and the outer arc cause the distortion during the manufacturing process. Improving the manufacturing of laying head pipes includes industrial trials to achieve a more homogeneous microstructure and prevent distortion, which have already been fully implemented and approved.
Technical Session
STUDY AND EVALUATION OF SECONDARY PROCESSES FOR THE RECOVERY OF LEAD FROM THE RECYCLING OF LEAD-ACID BATTERIES
Presenter(s): LEONARDO HENRIQUE GOMES (UNIVERSIDADE FEDERAL DO PARANÁ (UFPR)), MARIA JOSÉ JERÔNIMO DE SANTANA PONTE (universidade federal do paraná (ufpr)), Haroldo de Araújo Ponte (UNIVERSIDADE FEDERAL DO PARANÁ (UFPR)), Irineu Antonio Schadach de Brum (univerSIDADE FEDERAL DO RIO GRANDE DO SUL (UFRGS)), Wagner Viana Bielefeldt (UNIVERSIDADE FEDERAL DO RIO GRANDE DO SUL (UFRGS)), henrique de santana (universidade estadual de londrina), Rodrigo Helleis (UNIVERSIDADE FEDERAL DO PARANÁ (UFPR)), ELAN GABRIEL FORTESKI (UNIVERSIDADE FEDERAL DO PARANÁ (UFPR)), Henrique Galeski da Rosa (UNIVERSIDADE FEDERAL DO PARANÁ (UFPR)), GABRIEL HENRIQUE GOMES (UNIVERSIDADE FEDERAL DO PARANÁ (UFPR))
Abstract:
Sustainability and the importance of addressing industrial processes are directly linked to the availability of natural resources and efficient metal recovery rates. In the case of batteries, around 90-95% of the recycled material is used in the manufacture of new batteries, which makes it important to recycle them in order to reduce risks and environmental pollution. The most traditionally used pyrometallurgical process is characterized by the use of high temperatures to carry out the material transformation reactions and, despite being associated with high energy consumption, it is highly efficient in terms of lead metal recovery. However, in the context of extractive metallurgy and applied to secondary processes, hydrometallurgy is applied to the recovery of metallic lead, has been studied and acts between the interface of a solid phase and a liquid phase, which initially involves a series of operations, including leaching, solvent extraction, precipitation and biohydrometallurgy. Therefore, this work investigates the secondary processes of lead recovery from lead-acid batteries. The results show the importance of understanding and evaluating lead recovery processes, thus contributing directly to high efficiency in both energy efficiency and metallic lead recovery, which is directly linked to the environmental sustainability of the processes.
Technical Session
OPTIMIZING LADLE SHROUD PERFORMANCE: A COMPUTATIONAL FLUID DYNAMICS APPROACH TO TACKLE WEAR ISSUES
Presenter(s): rodrigo garcia ribeiro (RHI MAGNESITA)
Abstract:
A ladle shroud (LS) used in ArcelorMittal Pecém was presenting critical wear on a same specific zone: the expected LS lifespan is 10 heats, but during trials, was reached 7 heats. To understand wear mechanism, a Computational Fluid Dynamics (CFD) study was performed to analyze the fluid mechanics of the steel flow inside the ladle shroud, to investigate possible flow-related causes of the wear. The project focused on analyzing flow dynamics within the LS operation using CFD tools. Simulation results revealed significant shear stress peaks in regions with internal diameter transitions, including the region where the high wear was observed. The theoretical explanation for wear occurrence lies in the shear stress peak within a lower resistance material region. The solution involved extending the ‘high resistance material’ layer downward to the point of the shear stress peak. Simulation enables optimal sizing of the most resistant material, avoiding unnecessary costs that could arise if the region of highest strength were extended beyond the high shear region. As a result, the modified project led the lifespan to reach the former performance of 10 heats, with potential to be increased effectively solving the wear issues and consequently receiving product homologation.
Technical Session
9/5/24, 12:20 PM - 9/5/24, 12:45 PM
Presenter(s): isabela araujo costa figueiredo (sms group), Carlos Eduardo de Souza (sms group)
Abstract:
Currently, 23.9% of Brazil's steel production uses electric arc furnaces (EAF), with the remaining 76.1% produced via the integrated route. To improve EAF performance and safety, automatic slag doors are essential. This paper introduces two SMS technological innovations designed for energy savings, reduced CO2 and NOx emissions, increased productivity, and enhanced safety. The first, Condoor, with over 20 global installations, showcases design improvements, reliability, and extended lifespan, validated by plant feedback. The second, TS Pro robotic sampling system, complements Condoor by eliminating the need for operators near the furnace, enhancing safety. SMS group's 150 years of experience drives continuous innovation in the metals industry. This paper highlights the benefits of these technologies, including improved power consumption, electrode usage, raw material efficiency, and process time. Condoor, combined with SCAD, optimizes parameters like carbon injection and flux consumption, stabilizing cycle times and enhancing slag control, essential for using alternative iron sources in EAF.
Technical Session
9/5/24, 12:20 PM - 9/5/24, 12:45 PM
Presenter(s): mariano alberto de cristofaro (janus automation), edgardo labruna (janus automation)
Abstract:
Accurately determining the position of charge, pusher, door, and quenching cars in a coke plant battery is challenging due to various operational factors. Automation systems are crucial for plant performance and rely on trustworthy process indications, which require significant maintenance resources. This paper describes at different Coke plants; by using radio-based measuring principles, automatic location of cars was measured with the required level of precision. At the same time, repeatability and long-term reliability were also achieved. Sensors' lack of moving parts or need for routine cleaning reduced maintenance requirements, leading to improved budget and resource optimization. After more than five years of operation, the accurate and repeatable measurement of car positions increased operational efficiency and safety, enabling optimized process timing, synchronization, and safety
Technical Session
OPTIMIZATION OF MGO-C REFRACTORY LINING AIMING FOR BETTER THERMOMECHANICAL BEHAVIOR AND REDUCTION OF VERTICAL CRACKS IN STEEL LADLE
Presenter(s): THALES FONSECA DE PAULA (RHI Magnesita), Sergio Luiz Cabral Da Silva (RHI Magnesita), leandro rocha martins (RHI Magnesita), pedro luiz fonseca menezes (RHI Magnesita), rodrigo lima mariz (RHI Magnesita), sophia vieira de macedo (RHI Magnesita)
Abstract:
Among the wear mechanisms of the refractory lining in steel ladles coated with magnesia-carbon refractory, vertical cracks in the ladle walls are frequently present, requiring a solution to minimize this type of wear. With this objective, a study was carried out at the RHI Magnesita Research Center focused on the binding system of the refractory material, starting from the use of a resin-based binder, which provides high rigidity to the refractory material, for a combination of ecological tar with resin. This binding system provides better thermomechanical behavior to the material, as well as reducing volatile emissions during heating of the ladle, contributing to the control of pollutant emissions. This product was tested in the metal line of steel ladles. The results were positive in relation to the reduction of vertical cracks in the lining, and the reduction in volatile emissions, leading to an improvement in the performance of the ladle lining
Technical Session
9/5/24, 12:20 PM - 9/5/24, 12:45 PM
Presenter(s): raquel (UENF - ALBERTO LAMEG), Romário Moreira Siqueira (UNIVERSIDADE ESTADUAL NORTE FLUMINENSE), Rita de Kassia Gonçalves Pereira (UNIVERSIDADE ESTADUAL NORTE FLUMINENSE), Ana Carolina Morato Teixeira (UNIVERSIDADE ESTADUAL NORTE FLUMINENSE), Carlos Maurício Fontes Vieira (UNIVERSIDADE ESTADUAL NORTE FLUMINENSE), Niander de Aguiar Cerqueira (UNIVERSIDADE ESTADUAL NORTE FLUMINENSE), Jonas Alexandre (UNIVERSIDADE ESTADUAL NORTE FLUMINENSE)
Abstract:
The search for innovative and sustainable solutions in the construction industry has become imperative given the growing demand for natural resources. This study addresses the use of waste from the cutting of stainless steel pieces as raw material for the production of mortars used to coat masonry in civil works. The primary objective is to contribute to the reduction of environmental liabilities associated with fragments remaining from the laser cutting of AISI 304 stainless steel plates, as well as minimizing potential environmental impacts and operational costs related to the disposal and recycling of this material. To evaluate the technical feasibility of the proposed mortars, laboratory tests were carried out in accordance with Brazilian standards. The mortars were prepared in a ratio of 1:1:6, containing cement, lime and sand. Different samples were produced, including those with residue added in proportions of 5% and 10%, as well as reference samples, aged 7 and 28 days. Next, the mortars were subjected to mechanical tensile strength tests in flexion and axial compression, as well as capillary absorption tests, with the aim of classifying them based on their results in accordance with current Brazilian standards.
Technical Session
9/5/24, 12:20 PM - 9/5/24, 12:45 PM
Presenter(s): SHEILA MARA SANTOS DA SILVA (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO - UENF), Madeleing Taborda Barraza (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO - UENF), Johnata França Fanni Freitas (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO - UENF), Leandro Barbosa de Oliveira (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO - UENF), Davi Vaz André Júnior (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO - UENF), Isabela Devesa Batista (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO - UENF), Ana Laura Lopes de Matos Riscado (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO - UENF), Afonso Rangel Garcez de Azevedo (UNIVERSIDADE ESTADUAL DO NORTE FLUMINENSE DARCY RIBEIRO - UENF)
Abstract:
The geopolymer is a binder obtained from materials rich in aluminosilicates activated by an alkaline solution. This is a promising alternative to Portland cement in construction materials due to its low CO2 emissions, lower energy expenditure and the possibility of using by-products for its manufacturing. This study investigates the effect of adding silica fume (SF) to geopolymeric pastes of metakaolin (MK) and ground granulated blast furnace slag (GGBFS) with a sodium hydroxide and silicate activator solution, in order to evaluate their performance in the fresh state through consistency and viscosity tests. In the hardened state, compressive strength was evaluated after 7 and 28 days of curing. The results indicate that the incorporation of SA reduces the workability and increases the viscosity of the pastes. The addition of 1% silica fume improved compressive strength, while concentrations from 2.5% on resulted in a drop in strength at all ages tested.
Technical Session
VALUE ADDED PLATE PRODUCTION BY X-ROLL® HEAT TREATMENT TECHNOLOGY
Presenter(s): Helton de Freitas COTA (sms group), Flávio Luiz Alves Silveira Segundo (sms group), manfred dingenotto (sms group), georg padberg (sms group), bernd bohnenkamp (sms group), Dr. Christian Sprung (sms group), ANDREAS MNICH (sms group)
Abstract:
SMS group heat treatment lines (HTL) for plates enable the economical and energy-efficient production of a wide range of steel grades with extremely demanding qualities. These plates are employed in growth sectors, e.g. such as wind energy, power engineering, pressure vessel and the defense industry. In addition, special steels or special grades, which are considered as profitable niche products, can be easily produced with MultiFlex-Quench®, completed by further essential line equipment. The provided flexible cooling strategies enable customers to produce a very wide range of plates also in extremely challenging grades.
Technical Session
9/5/24, 12:20 PM - 9/5/24, 12:45 PM
Presenter(s): lucas alves de moraes (UFC), lívia carlos cidrão (UFC), josé adroaldo silva de moura filho (UFC), giovani dalpiaz (petrobras/cenpes), Ricardo Reppold Marinho (petrobras/cenpes), marcelo torres piza paes (petrobras/cenpes), émerson mendonça miná (UFC), marcelo ferreira motta (UFC), helio cordeiro de miranda (ufc), cleiton carvalho silva (ufc)
Abstract:
This work evaluated the discontinuous High-Dilution Zone (HDZ) found at the dissimilar interface of ASTM A182 F22/Inconel 625 joints welded by the Plasma Transferred Arc (PTA) process. This joint configuration is widely applied in manifold HUB connections for water injection or crude oil subsea transport systems. Investigations utilising optical microscopy and SEM with EDS technique were conducted. Microhardness mappings and thermodynamical simulations were carried out. The results reveal a complex zone with microstructure that presents gray and white tonalities between HAZ and FZ, which are result of chemical composition gradient. Its formation is related to restricted liquid movement at the edge of weld pool during welding, as well as differences in physical-chemical properties of the two alloys. High-hardness martensite formation in the discontinuous HDZ represents a risk for hydrogen-assisted cracking of these dissimilar joints.
Technical Session
9/5/24, 12:20 PM - 9/5/24, 12:45 PM
Presenter(s): Carlos Humberto Sartori (Villares metals s/a )
Abstract:
High pressure die casting of non-ferrous metals is an essential process for industries demanding quality and high-volume components. With advancements in the automotive industry, there has been an increased demand for quality in components and the performance of tools applied. NADCA, through its guide #207, defines a series of requirements regarding steel quality and control of the heat treatment process for these tools. Meeting these standards and technically verifying results are crucial to ensure the performance of high-value molds and dies. Among the approval tests are metallographic evaluation and impact toughness of specimens attached to the tooling during quenching. Despite the high level of detail in the standard, basic compliance is unfortunately neglected by heat treaters. This article presents three scenarios of identical injection molds with varying performance levels in use. The results of the applied heat treatment approval tests were compared with the results of tool failure analysis. Due to the influence of the heat treatment cycle on the fatigue life of injection tools, the article discusses the development of a practical and straightforward test for evaluating fracture toughness (KIC) to be incorporated into the NADCA #207 approval requirements.
Technical Session
9/5/24, 12:20 PM - 9/5/24, 12:45 PM
Presenter(s): Bruno Fernandes Mudesto (CSN - VOLTA REDONDA - BR 393 -)
Abstract:
The aim of this study was to analyze the failure of a drive shaft in a hot rolling mill in a steel industry. The shaft was fabricated from SF 60 steel grade and was recovered by welding and then machined. For characterization, chemical composition analysis, metallographic characterization and tensile testing were carried out. The results of chemical composition and tensile test indicated that the shaft material complied with the specifications for grade SF 60. The metallographic analysis showed that the crack started in a discontinuity present in the region recovered by welding
Technical Session
9/5/24, 2:00 PM - 9/5/24, 2:25 PM
Presenter(s): GEOVANE DE ASSIS FARIA (UFOP), Júlia Nascimento Costa (UFOP), Igor Cézar Pereira (UFOP), Rodrigo Rangel Porcaro (UFOP)
Abstract:
Additive manufacturing by electric arc deposition (Directed Energy Deposition Arc – DED-Arc) has been widely used to develop metal parts with various complexities close to their place of use. Despite all the advances, there are several challenges, especially associated with the materials involved, regarding controlling the microstructure, residual stresses and mechanical properties resulting from the thermal cycles involved in the manufacturing process. For austenitic stainless steels in Additive Manufacturing (AM), a major challenge is the heat accumulation. Due to their relatively low thermal conductivity, these steels require long downtimes between depositions in order to obtain a more homogeneous geometry and properties. Active cooling techniques have been developed to ensure greater productivity by extracting heat and improving the mechanical properties of these materials. Therefore, this work aimed to evaluate the influence of an active quasi-immersion cooling (RAQI) technique on the productivity and microstructure of AISI 316L stainless steel, obtained as thin walls by arc deposition with the GMAW process. The results showed that the RAQI technique is promising for increasing productivity and microstructural control.
Technical Session
9/5/24, 2:00 PM - 9/5/24, 2:25 PM
Presenter(s): matheus batista dos anjos (samarco), Anderson Christo Cunha (samarco), Fábio Ricardo Oliveira Bento (ifes), Marcos Ruy Soares Gaudio (edp), Maykcilane Fernandes Miguel (samarco), rafael damasceno xavier de brito (rafaeldamascenobrito@gmail.com)
Abstract:
The production of iron ore pellets is essential for the steel industry, as the performance of these pellets in customers' reactors and furnaces directly influences the quality of the final product. However, the production process faces challenges due to variations in ore quality, inputs, and other interference factors, resulting in inconsistencies in the pellets. This work aims to analyze the use of neural networks in controlling a pelletizing plant. This control is crucial due to variations in various process variables, such as the average furnace temperature, the physical and chemical characteristics of the ore, and the dosage of inputs. Even with rigorous control measures, such as regular testing of variables, errors can still occur due to this variability. Therefore, it is essential to develop a tool capable of analyzing the process and providing quick and accurate insights to prevent failures. This study highlights the potential of artificial neural networks (ANNs) in assessing the quality of continuous production processes, pointing to possible improvements in the quality of iron ore pellets and, consequently, significant benefits for the steel industry.
Technical Session
Trimmed strip edge inspection with integrated width measurement as an appropriate approach for quality improvement
Presenter(s): Helmut Hlobil (Primetals Technologies GmbH), Ronaldo Schittini Gardoni Junior (Primetals Technologies Brazil Ltda), Franz Mayrhofer (Primetals Technologies, Austria), Johannes Traxler (Primetals Technologies, Austria), Martin Eibensteiner (Primetals Technologies, Austria)
Abstract:
Inspection of the side-trimming process is in the meantime state of the art. Based on optical measurement technology images from the strip edge surface are taken, visualized and evaluated by algorithm. This displayed Information allows operators deciding on short-term actions like knife change or side-trimmer parameter adjustment as well as staff from quality department starting improvements for the side trimming process based on that information. Experience from existing installations show that due to limited resources available for this side-process by involved personnel this process was not tapped to the full potential. The paper will describe an improved approach for easier and clearer decision process for operation. First highlight of the update is the possibility to additionally measure the strip width. Second highlight is the possibility to adjust the orientation of the sensor depending on the orientation of the strip. Basis for these examinations was the installed base of EdgeMon all over the world. The collection of measurement data allowed statistical correlation between defect and process effect which additionally led to an improvement of reliability. Based on that information measures can be easily derived for the most crucial parameters influencing the process.
Technical Session
9/5/24, 2:00 PM - 9/5/24, 2:25 PM
Presenter(s): Kenia Maia Morais (UFMG), Vicente Braz da Trindade Filho (vallourec), Ruben Dario Sinisterra Millán (ufmg)
Abstract:
The present study analyses the opportunities and challenges in technology transfer involving the metallurgy sector in Brazil related to niobium technologies. It highlights the importance of partnerships between universities and companies to accelerate the acquisition of knowledge in the development of new technologies. The Technology and Innovation Support Centers (TISCs) are mentioned as entities that facilitate the management of intellectual property rights worldwide, where the 2022 report from the World Intellectual Property Organization (WIPO) highlights countries in this area, and Brazil does not appear on this list. The Technology Innovation Centers (NITs) were regulated by the Technology Innovation Law in Brazil but need to be used more strategically. The "INPI Technology Radar" report of January 2024 reveals that of the 4,843 patent applications related to niobium technologies, 45% are in the metallurgy field, with only a small fraction of these applications belonging to Brazilian organizations. The study concludes that, despite Brazil holding 94% of the world's niobium reserves, there is an urgent need for change, where deeper interaction between the academic and business sectors is essential for the appropriation and development of new technologies, aiming at consolidating the innovation process in the country.
Technical Session
REDUCE THE DEGRADATION OF FERROALLOYS DUE TO HANDLING IN THE SUPPLY SYSTEM FROM 5% TO 4%
Presenter(s): Melo Ester (Ternium brasil), IGOR FERREIRA DA SILVA (TERNIUM BRASIL), LUCIANO DA SILVA MOSCARDE (TERNIUM BRASIL), MAYCOW BRICIO CAXIAS (TERNIUM BRASIL), Alexander Dos Santos Coelho (TERNIUM BRASIL)
Abstract:
Due to the constant losses of alloys caused by excess fines, caused by degradation in the melt shop's supply system and resulting in undesirable financial impacts, this work was carried out with the aim of avoiding such impacts by creating a pattern of losses to guide monthly adjustments. The study carried out at Ternium Brasil's melt shop identified critical points and implemented corrective actions to mitigate these losses. Through statistical analysis, benchmarking and the application of PDCA and Lean Six Sigma methodologies, effective strategies were developed, resulting in a reduction in losses from 5% to 4% in the first year of the project. These results demonstrate a significant improvement and stabilization of losses, contributing to more precise management, increased durability of conveyor belts and economic efficiency.
Technical Session
9/5/24, 2:00 PM - 9/5/24, 2:25 PM
Presenter(s): JULIANA PORTO GUIMARAES (USINAS SIDERURGICAS DE MINAS GERAIS SA)
Abstract:
The roll coater is the most suitable application device for obtaining thin films on flat steel surface, as it presents greater precision than immersion or spray applications, in addition to requiring less inputs consumption and effluent treatment. Recently, the Research and Development Center of Usiminas acquired a roll coater to improve the pilot-scale post-treatment application. In this study the results obtained for a galvanized steel (GI) passivated with chromium trivalent using this equipment are presented. Passivating films with various chromium weights were produced and the relationship of this parameter with the protection against zinc early oxidation during exposure in a salt spray chamber was evaluated. The coatings with less than 14 mg/m2 of chromium did not provide satisfactory protection, while those with 21 mg/m2, which is within the range recommended by the passivator’s supplier, met the requirement of less than 5% of area with white corrosion after 48 h of salt spray test. It was also founded that the passivating film homogeneity is extremely important for a good performance against corrosion. Furthermore, very thick films tended to crack and flake off, exposing the zinc in microregions and, consequently, promoting its premature oxidation.
Technical Session
9/5/24, 2:00 PM - 9/5/24, 2:25 PM
Presenter(s): ANDREA COLOMBINI (Danieli)
Abstract:
Yukun Iron and Steel Group Co., Ltd. recently started up a DUE® plant to produce up to 4.6 million tons of hot-rolled coils. The plant is presently under hot commissioning stage with first cast and first coil successfully made in April 2024. Strip thicknesses will range between of 0.80–25.4 mm, with widths of 900–1,500 mm. The product mix will initially include low- and medium-carbon, LC HSLA and MC HSLA steels, with future expansion to other advanced grades, including weather-resistant, API and dual-phase. Being a DUE® plant, it will run in endless, coil-to-coil and semi-endless.
Technical Session
9/5/24, 2:00 PM - 9/5/24, 2:25 PM
Presenter(s): Bruna Callegari (senai cimatec), Tiago Nunes Lima (SENAI CIMATEC), Bruno Palhares Milanezi (CMOC Brasil), Daniel Evangelista Caixeta (CMOC Brasil), Vinícius Elias de Godoy (CMOC Brasil), Rodrigo Santiago Coelho (SENAI CIMATEC), ANDRÉ LUIZ VASCONCELLOS da Costa e Silva (Universidade Federal Fluminense)
Abstract:
FERRONIOBIUM (FENB) ALLOY IS THE RAW MATERIAL USED TO ADD NIOBIUM (NB) TO STEELS, TO ACHIEVE IMPROVEMENTS IN MECHANICAL PROPERTIES AND CORROSION RESISTANCE. THE ALLOY IS MOSTLY FORMULATED AROUND THE FE-65WT%NB EUTECTIC SYSTEM AND CONTAINS OTHER ELEMENTS ASSOCIATED WITH ITS MINERAL ORIGIN AND MANUFACTURING PROCESS BY ALUMINOTHERMIC REDUCTION. THESE ELEMENTS CAN AFFECT THE ALLOY’S MICROSTRUCTURE AND CONSEQUENTLY ITS DISSOLUTION BEHAVIOR DURING STEELMAKING. THERMODYNAMIC SIMULATIONS CAN BE USED TO UNDERSTAND THE MICROSTRUCTURE AND PREDICT its POSSIBLE EFFECTS ON THE DISSOLUTION BEHAVIOR. IN THIS WORK, A THERMODYNAMIC EVALUATION OF A COMMERCIAL FENB ALLOY HAS BEEN CARRIED OUT IN AN ATTEMPT TO DEFINE ACCURATE MODELS FOR PREDICTION OF MICROSTRUCTURE, TRANSITION TEMPERATURES AND DISSOLUTION BEHAVIOR. THE Adequation OF THE MODEL TO PREDICT NB INCORPORATION KINETICS WAS VALIDATED BY PHYSICAL TESTS OF FENB DISSOLUTION IN MOLTEN STEEL. RESULTS SHOW THAT THE SELECTION OF AN Appropriate THERMODYNAMIC DATABASE YIELDS RESULTS CLOSE TO THE REAL MICROSTRUCTURE OF THE ALLOY; IMPROVEMENTS ARE STILL NEEDED, HOWEVER. THE DISSOLUTION MODEL, IN TURN, ALSO PRESENTS LIMITATIONS TO PREDICT FULL DISSOLUTION KINETICS.
Technical Session
DECREASE PURE SILICON CONSUMPTION IN NON-ORIENTED GRAIN (GNO) STEEL FROM APERAM SOUTH AMERICA (ASA) WITHOUT AFFECTING PRODUCT QUALITY
Presenter(s): renato alcantara de aguiar santana (Aperam South America), André Luis Barroso Carvalhido (APERAM SOUTH AMERICA), Janeir Ribeiro Dutra (APERAM SOUTH AMERICA), Julio Cezar Mariano Araujo (APERAM SOUTH AMERICA), Letícia Paraguai Irias Pereira (APERAM SOUTH AMERICA), Lucas Matheus Magalhães Silva (APERAM SOUTH AMERICA), Aloísio Louzada (vamservice)
Abstract:
With the challenge of reducing silicon consumption in the production of electrical steels (GNO), without compromising compliance with the optimized chemical composition range specified by integrated metallurgy, in order to guarantee product quality. The main objective is to study the O2 blow in the VOD process, adequate selection of silicon alloys and standardization of decontamination of the supply circuit. Due to the goal of meeting the optimized chemical composition of carbon in GNO steel (P920P) (C<0.0023%) having increased from 50% in 2016 to 80% in 2022, it was necessary to work with greater oxidation of the liquid steel of runs in the steelworks increasing the consumption of pure silicon. Therefore, the technical team's challenge was to adapt the process's O2 blowing and control of the Si alloys that are used in the process. In this context, a correlation was made using the equipment's control tool, the spectrometer, between the CO+CO2 curve and the O2 incorporated in the bath. Thus, it was noted that, at the moment when both curves crossed, the target carbon content in the steel was adequate, and it was not necessary to increase the oxidation level of the bath, which, consequently, oxidizes the added Silicon, reducing the its performance and making a greater addition to the league if necessary. With these actions, we managed to meet the target of 80% of races with C within the optimized range (C<0.0023%) and we had a financial gain of KR$560 in the period of January 2022 to December 2022.
Technical Session
9/5/24, 2:00 PM - 9/5/24, 2:25 PM
Presenter(s): MARIO CESAR MANTOVANI (VILLARES METALS SA), Luiz Roberto Moraes Jr (Villares Metals)
Abstract:
This paper describes the principles and the differences between the foaming slag practices in electric arc furnace (EAF) for low and high alloyed steels. The investigations about the foaming slag behavior and alloy recovery from slag were performed in the industrial practice. The foaming slag index was measured by means a data acquisition adapter, which considers the current signals from the electrodes of the EAF. Steel and slag samples were taken during and after the blowing period (oxygen plus FeSi injection). Independent on the chromium content of the steel the foaming slag index increases as the chromium oxide content in the slag decreases. If the chromium oxide content in the slag is higher than 10 wt% Cr2O3, it becomes difficult even with further reducing agent addition to get a suitable foaming slag process. In addition, the results show that the slag basicity and the silicon content in the steel (after blowing period) present a direct relation on alloying ELEMENTS recovery from the slag.
Technical Session
HAZARD AND OPERABILITY (HAZOP) STUDY OF THE BLAST FURNACE GAS CLEANING SYSTEM AT TERNIUM BRAZIL
Presenter(s): Alan Jose Santos de Almeida (Ternium Brasil), Artur Fernandes Da Silva (Ternium), Igor Martins dos Santos (Ternium), Marco Antonio dos Reis (Ternium), Rafael Cesar de Souza (Ternium)
Abstract:
The objective of this work is a robust Process Risk Analysis (ARP) of the gas cleaning areas of the Blast Furnaces, using the HAZOP methodology, based on critical elements for process safety. With this, we aim to identify and analyze the degree of risk based on critical (catastrophic) scenarios, intolerable risk, and their respective independent protection layers, in order to mitigate risks that materialize similarly to historical events involving gas cleaning in the steel industry. Consequently, we will develop a short, medium, and long-term plan to adapt the process of these equipments to the best practices and manufacturers' recommendations
Technical Session
9/5/24, 2:00 PM - 9/5/24, 2:25 PM
Presenter(s): Tomás Moreira de Oliveira (RHI MAGNESITA), Genilson de Araújo Emiliano (RHI Magnesita), Letícia Pereira Rodrigues Campos (RHI Magnesita), Aloísio Simões Ribeiro (RHI Magnesita)
Abstract:
The process of closing the blast furnace taphole is carried out through the injection of taphole clays, and to obtain an adequate sealing of the hole is necessary to follow specific procedures associated with the injection of this material. In this study, tests were carried out with the aim of explaining the influence of different parameters on the injection of this refractory into the taphole, in order to generate a better understanding of the necessary care to apply a taphole clay and enhance its performance. The results showed that the variables temperature, aging and binding system (tar or resin) are correlated and have a great influence on the plasticity and curing speed of the taphole clays. Therefore, parameters such as maturation time, taphole clay temperature inside the mudgun, injection speed and mudgun time at the taphole face must be controlled so that the taphole clay injection process always happens properly.
Technical Session
IMPLEMENTATION OF THE NEW BOSH COOLING SYSTEM FOR BLAST FURNACE 1 AT APERAM SOUTH AMERICA
Presenter(s): Filipe Soares Pontes (Aperam), rEnato ferreira mota (Aperam), Douglas vinicius FERREIRA DE CASTRO (Aperam), Emanoelle Silveira Pereira (Aperam), Warlen Geraldo G. de Souza (Aperam), Heber Augusto Vieira Ferreira (APERAM), Filipe Soares Pontes (Aperam)
Abstract:
In this paper, we aim to present the development and implementation of the Blast Furnace 1 bosh cooling system project, as well as the planning, implementation and results achieved at Aperam South America. Due to the problems of cracks in the shell during the blast furnace campaign, alternatives for improving the cooling of blast furnace 1 were raised, and the concept adopted was the installation of external plates of steel in the shell to cooling the bosh. The project was successfully implemented and handed over to the reduction operation and maintenance teams on 01/18/2022. After implementation, the system is operating without any process/operation incidents, and it is now possible during preventive stops to keep the shell cooled, maintaining integrity, providing greater safety to the process and the useful life of the shell.
Technical Session
9/5/24, 2:00 PM - 9/5/24, 2:25 PM
Presenter(s): PEDRO UCHOA COSTA BARTOLOMEO (Lhoist)
Abstract:
The thinning of iron ore mix to be sintered as a result of the increased use of ultra fine concentrates has emerged as a significant challenge for sinter plants. In this scenario, the role of quicklime, the binder in the cold agglomeration step, becomes even more relevant. This study experimented with various lime-based binder options on a laboratory scale using iron ore mixtures with a high concentrate content for two granulation routes. One used the Eirich intensive mixer in the homogenization and agglomeration stage and tested three sizes of quicklime at 35 kg/t of the mix: 0 to 3 mm, 0 to 1 mm and micropulverized. The tests which used micropulverized quicklime showed superior cold permeability as it is already observed in the field. The other granulation route used an Eirich intensive mixer and pelletizing disc, simulating the HPS process. In this route, several binders were tested. Micropulverized quicklime and hydrated lime yielded the most favorable outcomes, with hydrated lime exhibiting a more superior permeability curve. However, hydrated lime has not been widely adopted in the industry due to its higher cost of production, transportation and storage. Still on the HPS route, an experiment was conducted by increasing the micropulverized quicklime dosage from 41.4 kg/t to 62.3 kg/t up to full limestone replacement, which proved to be successful in combating the thinning of iron ore, thus presenting a feasible alternative. The super thinning of quicklime did not indicate significant gains in relation to the micropulverized product already used in the industry. Activated hydrated lime and high-concentration suspended calcium hydroxide did not obtain satisfactory results. The investigation indicates that using micropulverized quicklime and increasing its dosage is a viable option for countering the thinning of iron ore without changes in the granulation equipment’s.
Technical Session
9/5/24, 2:00 PM - 9/5/24, 2:25 PM
Presenter(s): VICTOR LOUREIRO DOS SANTOS (HEPHAESTUS METALS)
Abstract:
As industries face stricter regulations on landfilling industrial waste, companies are turning to cost-effective solutions like briquetting technology to manage waste streams, particularly in the steel industry. Briquetting not only helps reduce waste but also recycles steel waste sludge and other by-products into value-added products for steel production. The paper outlines various briquetting methods suitable for Basic Oxygen Furnaces; AOD-L and Electric Furnaces, including typical binder-based processes for BOF sludges and mill scale, and the recovery DRI for use in Electric Furnaces. It concludes with a case study on a new binderless briquetting process designed to recycle steel mill waste through BOF or AOD-L, providing a detailed overview of the plant layout, technology, and equipment required to handle typical steel mill waste streams efficiently.
Technical Session
9/5/24, 2:00 PM - 9/5/24, 2:25 PM
Presenter(s): SHEILA medeiros de CARVALHO (UNIVERSIDADE FEDERAL DO ESPíRIto santo)
Abstract:
Laser Beam Forming has become an innovative processing method, facing the need of industries to adapt to new technologies. With the use of the laser, which has the ability to promote a localized deformation in the processing of thin sheets quickly and effectively, the process is promising and competitive compared to conventional methods. Although there is no physical interaction between the equipment and the material, being a non-contact method, laser forming can generate bending in metal sheets by introducing thermal stresses from the laser beam and inducing plastic deformation. Different studies have been carried out so that it is possible to analyze in depth the mechanisms involved in laser forming and how to predict the bending angle of the sheets. Thus, this work presents an analysis of the influence of the main process parameters on the bending angle of metal sheets, as well as their interference in the metallurgical transformations of the material. For the study, six high-strength aluminum sheets were subjected to laser forming, in which a constant power of 200 W was determined, and the speed was varied between 3 and 6 mm/s, and the number of passes between 1 and 3 for each sample, in order to verify the difference metallurgical and shape transformations for a given parameter. As a result, it was possible to obtain the bending angle after each test, and to analyze the microhardness and micrograph of the shaped material, in order to verify the influence of the main process parameters on the metallurgical and mechanical changes of the part.
Technical Session
FAILURE MODES OF MICROTUNNELING CUTTING DISKS IN ROCK EXCAVATION FOR SANITARY INFRASTRUCTURE PROJECT - RJ
Presenter(s): Gabriela reis piazzetta (utfpr), Larissa Knapik da Fontoura (UTFPR), thomas markus zeller (utfpr), Juan Manuel Hernandez Otalvaro (utfpr), Rodrigo Buttler Ribeiro (passarelli), Cássio Penteado Serra Neto (passarelli), GIUSEPPE PINTAUDE (UTFPR)
Abstract:
The demand for sanitary infrastructure projects has prioritized the use of Non-Destructive Methods, which allow for less interference on the surface, one of these methods being microtunneling. The MicroTunnel Boring Machine, the excavation machine, uses excavation tools called cutting discs. These discs, made of H13 tool steel, are continuously worn during the rock excavation process, requiring frequent replacement. The costs related to the purchase and replacement of the discs are significant in the construction budget, which justifies the study of the wear of these tools. The analysis of the worn discs allows evaluating the behavior of tool steel during the excavation process. The case study presented analyzed and classified the failure modes of 20 microtunneling cutting discs used in the excavation of a rock section in a sanitary infrastructure project in Rio de Janeiro. According to the classification available in the literature, it was found that the predominant wear is of the regular type (74%), followed by blockage wear (21%), mushrooming (5%) and mushrooming with chipping (5%). The results demonstrated the prevalence of wear failures by mushrooming in the central positions, regular in the intermediate positions and blockage in the external positions of the cutting head.
Technical Session
9/5/24, 2:00 PM - 9/5/24, 2:25 PM
Presenter(s): Marcelo Koiti FUGIHARA (Belge consultoria), Lucas Pelegrin da Silva (Belge consultoria), Alice Oliveira Fernandes (belge consultoria)
Abstract:
The mining sector, like other industries, has benefited from the application of data science to solve frequent problems, many of which are complex and require comprehensive and sophisticated methodologies. An example is the reliability study, which aims to determine whether equipment or production systems operate as planned, ensuring their economic viability. In this context, dynamic simulation, combined with statistical tools, emerges as a cutting-edge approach in the study of reliability. This methodology allows you to create accurate models and conduct robust analyzes to identify critical points, predict and prevent failures, optimize performance and reduce maintenance costs. In this way, it contributes significantly to the advancement of knowledge in this field of study.
Keynote Speaker
9/5/24, 2:00 PM - 9/5/24, 2:50 PM
Presenter(s): Ronaldo Apelbaum; CEO at APGI Lawyers and Professor of Tax Management
Abstract:
Round Table
9/5/24, 2:00 PM - 9/5/24, 3:40 PM
Presenter(s): Coordinators: Eder Quental de Araújo; Energy Technical Manager at Gerdau / Carlos Sadao Shiratsu; Consultant Moderator: Amaro Olimpio Pereira Junior; Associate Professor at COPPE/UFRJ
Abstract:
Round Table
9/5/24, 2:00 PM - 9/5/24, 3:40 PM
Presenter(s): Coordinator and moderator : Gisele Regina Hwang; Engineering Specialist at Vale
Abstract:
Technical Session
EFFECT OF HEATING RATE ON THE AUSTENITIZING KINETICS OF A BRAZILIAN COMMERCIAL BORON STEEL
Presenter(s): GERALDO LUCIO DE FARIA (Universidade Federal de Ouro Preto), Alice Silva Gonçalves (Universidade Federal de Ouro Preto), PAULO SÉRGIO MOREIRA (Universidade Federal de Ouro Preto)
Abstract:
Boron is an interstitial alloy element, with a relatively large atomic radius, commonly used to improve the hardenability of steels. A phenomenologically still not well-understood problem has been the cause of numerous damages in hot rolling plants of boron steels: plate cracking in the reheating furnaces. A possible cause pointed out is the significant difference in heating rates between surface and internal regions of the plate, generating thermal stress, mainly during the austenitizing stage (between Ac1 and Ac3) in this type of steel. In this context, the present study evaluated the effect of heating rate on the austenitizing kinetics of a boron steel with the aim of generating data to support, or not, this hypothesis. For this purpose, dilatometric tests and microstructural characterization techniques were used. It was concluded for the studied steel that the critical transformation temperatures (Ac1 and Ac3) increased as the heating rate increased. The JMAK model used to describe the austenitizing kinetics proved to be appropriate in this study, with R2 values very close to 1, indicating a good fit to the experimental data. Additionally, the increase in heating rate resulted in an increase in the k fitting constant of the JMAK equation, indicating a significant influence on the average austenitizing rate.
Technical Session
9/5/24, 2:25 PM - 9/5/24, 2:50 PM
Presenter(s): patrick soares silva (ARCELORMITTAL TUBARÃO), Tulio Cesar Coutinho (IT Demand), Eduardo Loureiro Pacova (ARCELORMITTAL SISTEMAS), Alexandre do Nascimento Panetto (ARCELORMITTAL SISTEMAS)
Abstract:
The article demonstrates the importance of an integrated approach methodology for the successful incorporation of steel plant in Pecem, coast of Ceara, by ArcelorMittal, highlighting the strategic role of IT governance as a key facilitator for operational transition and maximizing gains. This paper presents the challenges and benefits captured from this implementation, the procedures and restrictions of the organizational incorporation process, planning in the light of change, processes and IT projects management methodology, the relevance of the team's expertise added to the contribution of consulting company, with extensive experience in previous projects, as well as the development of actions before and after approval by regulatory bodies, as a contribution to future implementations and synergies with other units and companies.
Technical Session
A ROBOTIC WORKSTATION FOR SAFE LADLE SLIDING GATE MAINTENANCE *
Presenter(s): ANNA ZOPPIROLLI (POLYTEC), Ion Rusu (), Rafael Jacob (Votorantim)
Abstract:
The paper presents a robotic workstation, which has been developed and installed in the steel shop of an Italian steel company, representing one of the first attempts to establish a collaborative environment where a robot supports the technical personnel in a complex and delicate maintenance operation. The purpose of the robotic cell is to support the inspection, cleaning and replacement operations of the refractory components of the so-called “sliding gate”, namely the de- vice allowing the liquid steel to flow from the ladle to the tundish of the continuous casting. The robotic cell includes a vision system supporting the different operations, and a Human Machine Interface, which facilitates the interaction between the robot and the operators and helps to improve the qualitative performance of the whole process. Within such a course, the sequence and new division of human-robot activities were thoroughly developed within an innovation process integrating the future users and operators (embedding technological innovation within a social innovation process). In the steel sector the implementation of human-robot cooperation is hampered and slowed down by harsh environmental conditions in some applications, as well as by intrinsic difficulties of some operations, which require a combination of force and precision and need to be supervised and acknowledged by the technical personnel due to strict safety regulations
Technical Session
THE ROAD TO ZERO CUSTOMER COMPLAINTS USING TOTAL QUALITY MANAGEMENT
Presenter(s): FERNANDO EMERSON VIANA SOUSA (ARCELORMITTAL PECÉM S.A.), Carlos Alexandre Azevedo (ARCELORMITTAL PECÉM S.A.), Giana Carla Silva Neves (ARCELORMITTAL PECÉM S.A.), Hana Lívia Frota Coelho (ARCELORMITTAL PECÉM S.A.), Francisco Necy Alves Júnior (ARCELORMITTAL PECÉM S.A.), Carlos Henrique Lopes (ARCELORMITTAL PECÉM S.A.), Alex Maia do Nascimento (ARCELORMITTAL PECÉM S.A.), Paula Reneé de Macedo Costa (ARCELORMITTAL PECÉM S.A.), Lucas Sousa Uchoa (ARCELORMITTAL PECÉM S.A.), Aline Meneses Dias (ARCELORMITTAL PECÉM S.A.)
Abstract:
A case study was conducted at ArcelorMittal Pecém, highlighting the evolution of quality control for carbon steel slabs intended for several industrial applications, including automotive, oil and gas, energy, and structural sectors. Initially, there was a considerable number of complaints, scrap, and rework in the early years of operation. Through the application of Total Quality Management (TQM) tools such as brainstorming, cause-and-effect diagram, risk matrix, and Pareto’s analysis, the main reasons behind the quality issues of the slabs were identified, including surface defects, dimensional issues, and identification errors. Throughout the study, appropriate actions were implemented to address these issues, such as poka-yokes. Even with the introduction of high-added-value steels, the use of TQM tools allowed for a gradual reduction in complaints, rework, and scrap. This reduction is linked to cost savings, increased productivity, and improved customer satisfaction.
Technical Session
E-WASTE PROCESSING AS ALTERNATIVE SOURCE OF MINERAL RESOURCES
Presenter(s): LÚCIA HELENA XAVIER (CETEM), Elizeth Oliveira Alves (), Franciele Rossetti Cunico ()
Abstract:
A wide diversity of mineral resources is needed to supply industries such as technology and, more recently, the infrastructure for generating energy from alternative sources, such as wind and solar. The compromise in the supply of mineral resources is caused by both the scarcity of natural reserves and the increase in demand and market value of mineral products. In this way, the search for alternative sources of mineral resources has found potential in the processing of waste electrical and electronic equipment (WEEE or E-waste). This category of waste has increased in volume in recent decades due to technological improvements and increased demand and consumption. In addition to representing a source of valuable materials, electronic waste can also cause environmental damage and health risks due to the presence of potentially toxic substances. This article proposes a descriptive analysis of electronic waste pre-processing operations and their relevance to the secondary metals´ recovery process. Pre-processing steps carried out efficiently enable both the reuse of products and the recovery of materials. The results present the details of processing techniques for the recovery of materials, exploring the potential for value recovery from destructive and non-destructive techniques, according to the principles of the circular economy
Technical Session
MICROSIM® AND PHASTRANSIM®: HARDNESS AND MICROSTRUCTURES SIMULATIONS VALIDATION FOR SAE1045+NIOBIUM WIRE-RODS
Presenter(s): alisson paulo de oliveira (NSIGMA CONSULTORIA EIRELI), Emanuelle Garcia Reis (GERDAU), Beatriz Lopez (Ceit), Beatriz Pereda (Ceit), Marcelo Arantes Rebellato (Consultor), Guilherme Diniz Castanheira (GERDAU), Renato Eustaquio Rodrigues (GERDAU), Tatiana Sayuri Kohatsu da Silva (GERDAU)
Abstract:
MicroSim Bars® and PhasTranSim® are instruments devised to assist research and development engineers in designing steel products with particular metallurgical and mechanical properties. MicroSim Bars® serves as a simulation tool that calculates the progression of austenite during the hot rolling of steel bars, using variables such as chemical composition, temperature, and deformation parameters. It forecasts modifications in the steel's microstructure throughout the rolling process, pivotal for determining the ultimate properties of the product. Conversely, PhasTranSim® is a computational tool focused on the phase shifts occurring in steels post hot rolling, encompassing the transformation from austenite to ferrite, pearlite, bainite, or M/A constituents. It assists research and development engineers in determining how changes in process conditions impact the steel's microstructure and mechanical/metallurgical attributes. These tools facilitate the efficient development of steel products with desired features, potentially leading to cost reductions. The aim of this study was to assess microstructural changes in SAE1045 steel wire rod due to some modifications in the rolling process and alloy design, as well as to perform a comparison between measured metallurgical properties values and those calculated using the models. These results were used to check the accurateness of the models embedded in MicroSim Bars® and PhasTranSim®.
Technical Session
ADVANCED LUBRICATION STRATEGY IN COLD ROLLING
Presenter(s): Dmitriy Voitekhovskii (Danieli), Gianluca Bazzaro ()
Abstract:
The cold rolling process demands precise control over friction to ensure the production of high-quality materials. Traditional lubrication methods, while foundational, often fall short in meeting the diverse and dynamic needs of modern cold rolling operations. This article introduces innovative lubrication strategies designed to enhance operational efficiency and surface quality of rolled products. Through a comprehensive analysis, we explore the limitations of conventional emulsion systems and the potential of direct oil application techniques. The study also delves into the mixed lubrication domain, examining the interplay between boundary and hydrodynamic lubrication modes, and introduces the concept of micro-plasto-hydrodynamic lubrication. Our findings underscore the significant impact of these advanced lubrication strategies on reducing rolling force, conserving energy, and facilitating flexible production schedules, contributing to stable manufacturing practices.
Technical Session
TECHNOLOGICAL INNOVATION IN THE FOUNDRY INDUSTRY: COMPUTATIONAL STUDY ON ISOSTATICALLY PRESSED STOPPERS
Presenter(s): Pedro Mourao Domingos (RHI Magnesita), Bianka Alexandrino de Oliveira (RHI Magnesita), Alexandre Dolabella Resende (rhi magnesita), Márcio Geraldo de Oliveira (rhi magnesita)
Abstract:
The present paper addresses a study on a large-scale stopper-rod isostatically pressed used in foundry ladles. Due to the nature of the operation, the use of stopper-rod is essential and should not be replaced by slide gates. These components directly impact the efficiency and safety of the casting process, and their manufacturing process faces significant challenges, primarily due to their size. This work presents the implementation of numerical models to evaluate the behavior of a foundry stopper-rod under various operational conditions, such as potential misalignment relative to the well block. The results obtained provide important information on mechanical stresses and potential failure points, thus contributing to the development of more reliable and safer stoppers. Such advances are crucial for optimizing the operation, with the aim of ensuring the integrity and quality of the final products. The use of numerical simulations signals a promising path for future research and the development of technological innovations in the field of foundry.
Technical Session
9/5/24, 2:25 PM - 9/5/24, 2:50 PM
Presenter(s): Alisson Kwiatkowski da Silva (thermo-calc software ab)
Abstract:
TCS Metal Oxide Solutions Database (TCOX) is a thermodynamic database (developed using CALPHAD) which describes the thermochemical interactions between liquid steel and slag during steel making and refining. It contains all the major steel alloying elements as well as the most important slag elements. The ionic liquid model describes the liquid phase over the whole composition range from metallic liquid (steel) to oxide liquid (slag). The database also contains the most important metallic and non-metallic solid phases, allowing the calculation of inclusion formation, inclusion modification, steel solidification, slag solidification, steel-refractory reactions, slag-refractory reactions and steel-mold powder reactions. For use with this database, a new process metallurgy module has been developed within Thermo-Calc which makes it easy to set up calculations for steel and slag. A kinetic model of the steelmaking process based on the concept of effective equilibrium reaction zones has been incorporated in this process metallurgy module. This model is outlined in detail in this paper and applied to a ladle furnace steel refining process.
Technical Session
9/5/24, 2:25 PM - 9/5/24, 2:50 PM
Presenter(s): Daniel Sabino de carvalho (GENERAL ELECTRIC)
Abstract:
GE DEVELOPED A SUPPLY SYSTEM FOR ELECTRIC ARC FURNANCE BASED ON POWER ELECTRONICS, CALLED DIRECT FEED, WHICH IN ADDITION TO FILTERING THE GRID POLLUTION CAUSED BY EAF, SUCH AS HARMONICS, FLICKER AND REACTIVE POWER, ALSO BRINGS IMPORTANT OPERATIONAL GAINS FOR THE CUSTOMER, WITH ENERGY SAVINGS, PRODUCTION INCREASE AND ECONOMY OF ELECTRODES.
Technical Session
USE OF DUSTCONTROL TECHNOLOGY DURING POWDER TRANSFER IN FINAL SILO 4 OF THE SINTER MACHINE
Presenter(s): Valcir ribeiro da SILVA (ECOLAB (ANT. NALCO) SUZANO)
Abstract:
This article presents the project of the use of DustControl technology during the transfer of Sintering Powder in the final Silo 4 via Pug Mill of the Sinter Machine. The objective of the application was to minimize the emission of suspended particles into the atmosphere in the region and consequently reduce the risk to Health and the Environment. To this end, foam application tests were carried out with the objective of agglutinating all fine particulates, most of them still in the transfer chamber (Threads) no generation of intense humidity. After visual inspections accompanied by photographic records with and without the application of DustControl Technology. The tests showed the high performance of the technology in relation to the control of dust emission.
Technical Session
EFFICIENT VALUE-ADDED BLAST FURNACE HOT METAL PRODUCTION TROUGH REFRACTORY WEAR MODEL PREDICTION
Presenter(s): ALOISIO SIMOES RIBEIRO (RHI Magnesita), Eduardo Roberto Menezes (), Mateus dos Santos Souza (), Lucas Gabriel Seibert (), Victor Luiz Cruz Morais (), Anderson Carvalho Nogueira (), Alex Martins da Silva (), Rodrigo Dalla Vecchia (), Bruno Moreira Nabinger ()
Abstract:
There is significant interest in accurately modeling the operational variables of the Ironmaking process to predict the refractory wear in blast furnace main runners. Understanding refractory wear variables on blast furnace main runners can allow us to promote safe, low-cost, sustainable, high-performance and quality iron ore processing in the blast furnace. Despite this, the task is challenging due to the complex interactions between process variables, which are not entirely comprehended. Often, decisions in the industry are grounded in experience or undirect methods. This study aims to introduce a robust model that can effectively guide process engineers by forecasting the influence of ironmaking variables in the refractory wear of the blast furnace main runners. Based on an algorithm that combines unsupervised learning techniques for clustering and a meta-regressor, it was possible to obtain a high accurate model to predict the refractory wear in the blast furnace main runner, resulting in valuable information to decision-making process regarding the blast furnace main runner campaign
Technical Session
9/5/24, 2:25 PM - 9/5/24, 2:50 PM
Presenter(s): Eustaquio Vieira Junior (TERNIUM), Alexandre Patrício Vieira da Silveira (Ternium), Sandro Valério Maia Larrubia (Ternium), Luís Fernando Palmeira Cortez (D&M), Marcelo Rodrigues Vieira Pinto (D&M), Daniel Vieira Pinto (D&M)
Abstract:
The Ternium Brazil blast furnaces, at Rio de Janeiro, started to operate in 2010.In this campaign was realizes activities to exchange the stave coolers damaged. The technique applied to exchange the stave cooler is the fishing technique, and one stage of this technique is the refractory injection between the blast furnace shell and the cold face of stave cooler. To be avoid the inefficiency of this procedure was designed an auxiliary technique by industrial endoscopy that permit to visualize the refractory injection during the fill process. The paper presents the details of this auxiliar technique, showing the equipment, the method and the results obtained in the first utilization
Technical Session
9/5/24, 2:25 PM - 9/5/24, 2:50 PM
Presenter(s): Jean Philippe Santos Gherardi de Alencar (VALE)
Abstract:
ABSTRACT Discussions about the Direct Reduction process and new projects are on the rise worldwide due to the continuous demand for steel production and climate pressure. This has positioned the Direct Reduction and Electric Furnace route as potential low-emission technologies, especially when using 100% hydrogen gas. In this context, one critical parameter for the reduction process is the tendency of iron ore agglomerates to stick together. The most widely used method to mitigate agglomeration is coating the pellets with refractory material. This study conducted a series of tests and characterizations to better understand which materials, methods, and characteristics are most important for reducing the agglomeration index. Interestingly, applying the coating to raw pellets as an alternative method is less effective than the conventional post-pellet firing application. An evaluation of predictor parameters revealed that the Adhesion Index and the quantity of (SiO2 + Al2O3 + CaO + MgO) significantly influence the Agglomeration Index. Furthermore, the Adhesion Index is proportional to the specific surface area of the coating materials. Based on the results, Bauxite exhibited the best behavior, attributed to its high Al2O3 content and exceptionally high specific surface area.
Technical Session
DEVELOPMENT OF AUTOMATIC SHATTER FOR CHARACTERIZATION OF IRON ORE FINES AGGLOMERATES
Presenter(s): Francisco Junior Batista Pedrosa (Ipt - Instituto de pesquisas tecnológicas), Eric Augustin (Instituto de pesquisas tecnológicas ), Tayná Cunha Souza (Instituto de pesquisas tecnológicas ), Sandra Lúcia de Moraes (Instituto de pesquisas tecnológicas ), André Luiz Nunis da Silva (Instituto de pesquisas tecnológicas ), Fabrício Parreira (vALE), Flávio Dutra (vALE), Valdirene Resende (vALE), Felipe Pimenta (Vale)
Abstract:
Iron ore agglomerates are fundamentals in the use of low-grade iron ore deposits and in the decarbonization journey of the steel industry, as they are “engineered” products in terms of chemical composition, shape and mechanical resistance. Although chemical composition is the key factor in the performance of reduction reactors, mechanical strength is a prerequisite, especially when dealing with agglomerates destined for the transoceanic market. As transport, handling and arrangement in piles or beds involve different efforts, it is of fundamental importance to carry out characterization tests that simulate, in the best possible way, these efforts. Iron ore agglomerates are conventionally characterized by standardized tests that evaluate resistance to compression, abrasion (tumbling) and impact (Shatter). The traditional Shatter test is carried out on sinters, following a procedure that evaluates the degradation of the product after 4 successive drops. However, in general, carrying out 4 drops in agglomerates of high mechanical resistance (pellets and briquettes) is not sufficient to discretize the performance of products produced from different mixtures and/or production methods. In view of this, an alternative method was developed, called Stressed Shatter, which consists of recording the number of falls that the cluster supports to reach a Shatter index of 85%. This test, which has been conducted manually, can now be conducted on an Automatic Shatter. The results of the Stressed Shatter tests conducted on manual and automatic equipment are relatively similar, with a difference of 3%. The assays were performed in duplicate and demonstrated excellent reproducibility. Another point observed is that the mass of the agglomerate has a significant influence on impact resistance. The results presented in the present study enable Automatic Shatter as a method for characterizing agglomerates with the advantage of reducing labor and minimizing the risk of accidents. Such equipment and method can be used in R&D centers, in addition to quality control of processes and products in the mining and steel industries.
Technical Session
9/5/24, 2:25 PM - 9/5/24, 2:50 PM
Presenter(s): tadeu messias donizete borba (USIMINAS - IPATINGA), Rodolfo Júnior Conceição Silva (USIMINAS), Eugênio de Carvalho Toledo (usiminas), Victor Horta Miranda (esab), Leandro Matos Lopes Soares (esab)
Abstract:
Usiminas has directed efforts towards the development of AHSS - Advanced High-Strength Steels, aiming to meet the demands of the automotive sector. Among these materials, electrogalvanized (EG) TRIP steel of the 1000 MPa class (TRIP1000EG) stands out. In this work, the robotic gas metal arc welding (GMAW) of a TRIP1000EG steel, with 1.50 mm thickness, was evaluated. Weld joints without discontinuities were obtained, with beads geometrically appropriate to the criteria of the SEP1220 standard. Furthermore, through radiographic tests, it was identified that the weld beads had a low pore density, less than 2.5%, indicating that the consumable used was adequate for welding EG steels. The results of this study confirm that the GMAW parameters obtained were suitable for welding steel and can be used as a reference for the development of application engineering of this material in the automotive industry.
Technical Session
ASSESSMENT OF THE TRIBOCORROSION BEHAVIOR OF IRON ORE USING THE MILLER TEST (ASTM G75)
Presenter(s): Leandro Moreira Pinto (institutotecnológico vale (itv)), Jeilce Maria Abreu dos Santos (Rede Temática em Engenharia de Materiais – REDEMAT, Universidade Federal de Ouro Preto,), José Jimmy Penagos (INSTITUTOTECNOLÓGICO VALE (ITV)), Cristian Camilo Viáfara Arango (INSTITUTOTECNOLÓGICO VALE (ITV)), Felipe Silva Mion (Departamento de Engenharia Metalúrgica e de Materiais, Escola de Minas, Universidade Federal de Ouro Preto), MARIA APARECIDA PINTO (Departamento de Engenharia Metalúrgica e de Materiais, Escola de Minas, Universidade Federal de Ouro Preto)
Abstract:
Abrasion and corrosion are common in mining industry, especially in operations involving ore slurries. Although it is known that different types of iron ores have varying levels of abrasiveness under dry conditions, the effect of abrasion-corrosion of materials in contact with iron ore slurries is still little studied. This study seeks to fill this gap, with the following research question: what is the tribocorrosive behavior of white cast iron with 27% chromium in contact with iron ores slurries? To answer this research question, the main objective of this work was to evaluate the tribocorrosive behavior of cast iron in contact with four iron ores using the Miller test according to ASTM G75. This study investigated the abrasiveness of iron ores slurries and how corrosion influences this characteristic. The results showed that Jaspelite ore was the most abrasive, followed by Friable Hematite, Hydrated Ore and Compact Hematite. Analysis of the influence of corrosion indicated that more abrasive ores favored abrasive wear, while less abrasive ores promoted corrosion. This study contributes to the advancement of knowledge on the tribocorrosive effect of iron ores slurries, providing relevant information for the selection and development of more suitable materials for mining equipment.
Technical Session
METROLOGICAL RELIABILITY AND ANALYSIS OF ACCEPTANCE CRITERIA IN CRITICAL PROCESSES
Presenter(s): daniel henrique sousa (Arcelormittal tubarão)
Abstract:
As part of CISMET, the laboratory works to calibrate reference standards and measuring instruments in the workshops. This work aims to apply the experience and know-how of laboratories to technically analyze, from a metrological point of view, the tolerance of critical processes at varied quantities and their acceptance criteria, evaluating the components that contribute to the most common measurement uncertainties. applied. The methodology applied to evaluate and present the points raised follows laboratory practices for defining CMC and uncertainty analysis used by the ArcelorMittal Tubarão accredited calibration laboratory. In the long term, this initiative seeks to expand the role of CISMET laboratories in guaranteeing the metrological reliability of production processes throughout the ArcelorMittal Tubarão plant
Technical Session
9/5/24, 2:50 PM - 9/4/24, 3:15 PM
Presenter(s): Rafael ramos (Instituto militar de engenharia - ime), Naiara Vieira Le Sénéchal (INSTITUTO MILITAR DE ENGENHARIA - IME), Paulo Paiva Oliveira Leite Dyer (instituto de estudos avançados - ieav), Julianna Magalhães Garcia (INSTITUTO MILITAR DE ENGENHARIA - IME), Danilo Abílio Corrêa Gonçalves (INSTITUTO MILITAR DE ENGENHARIA - IME), Getúlio de Vasconcelos (INSTITUTO DE ESTUDOS AVANÇADOS - IEAV), Andersan dos Santos Paula (INSTITUTO MILITAR DE ENGENHARIA - IME)
Abstract:
H13 tool steel is extensively used in tooling industry due to keep good properties under higher temperatures, with stablished processes to manufacturing it, comprising mechanical forming steps followed by heat treatments. There is an increased interest in processing this material through additive manufacturing techniques, owing to its potential to reduce manufacturing times, allow repairing and complex shapes tooling fabrication, containing intricate cooling channels net. Nevertheless, this technique “as-built” products present non-uniform microstructure and properties, dependent on the orientation of the pieces in relation to the construction direction, owing to different thermal cycles because of successive tracks’ deposition that remelt and reheat adjacent regions, in addition to generating strongly oriented microstructures during solidification. This work aimed at characterizing macroregions at the left, at the center and at the right of a L-DED (Laser Direct Energy Deposition) manufactured specimen, microstructurally comparing them with optical (OM) and electron scanning microscopy (SEM), the latter associated with elementary chemical microanalysis by X-Ray energy dispersive spectroscopy (EDS), and microhardness Vickers tests. It was found that at a macrographic level, the sample manufactured by L-DED presented a similar appearance in the different regions analyzed, however its microstructure consisted of some heterogeneity between melted/remelted zone (cellular/dendritic structures) and heat affected zone, highlighting evidence of quenched/tempered martensite, carbide precipitation and evidence of retained austenite presence, allowing to conclude that there is a need for subsequent heat treatments for microstructural homogenization.
Technical Session
CREEP BEHAVIOR OF 1Cr0.5Mo STEEL IN VIRGIN AND EX-SERVICE CONDITIONS WITH CONSTANT STRESS AND CONSTANT LOAD CREEP TESTS. PART1: RELATIONS AMONG RUPTURE TIME, STRESS AND TEMPERATURE
Presenter(s): LEVI DE OLIVEIRA BUENO (STM IND E COM DE MAQUINA E SISTEMAS TESTES EM MATERIAIS LTDA), josé francisco dos reis sobrinho (IFECT-IFPI)
Abstract:
Creep tests under constant load and constant stress were used in the study of rupture strength behavior of 1Cr0.5Mo steel in two microstructural conditions: in the virgin state and in the ex-service condition after 15 year operation at a nominal temperature of 550°C.Graphs or drop of strength with rupture time were plotted in the four different test conditions, as well as graphs of the variation of rupture time with the inverse of temperature to the identify the values of the C constant for data parameterization using the Larson-Miller method. The four parametric curves of the material are compared with each other, observing that the results with tests at constant stress have a tendency to overestimate the rupture strength of the material in relation to tests under constant load, however with a trend for the four curves to converge for increasing values of the PLM parameter. Calculation of the allowable stress for use of the deteriorated material for a further 15 year of service at 550°C indicates values of 48 and 47 MPa for constant stress and constant load tests, respectively
Technical Session
USE OF LCG AND GPS COORDINATES AS A REFERENCE TO INDICATE THE POSITIONING OF ORE LOADER BOOMS IN THE BILLS OF SHIPS: A CASE STUDY APPLIED IN THE ORE BOARDING AREA AT THE PONTA DA MADEIRA SEA TERMINAL
Presenter(s): vivian suellen alves jansen (vALE), Vinicius Mendes Maniçoba (vALE), Jehan Carlos Saraiva de Sousa (vALE), Kelson Cassio Viana Cantanhede (vALE), Fabio Henrique Prata dos Santos (vALE), Larissa Marcele Nogueira Gonçalves (VALE), Ivo José Nascimento Fiel (VALE)
Abstract:
This article is a case study in the terminal of vessels that dock at the Ponta da Madeira Maritime Terminal (TMPM). ore in the correct hold of the ship, and in this way reduce errors from calculating the distance between the tip of the ship loaders boom and the center of the holds using as a reference the LCG - Length Center of Gravity of the ship at berth, and thus way to represent the distance from the center of gravity of the ship amidships to the center of gravity of the holds and the reading of the GPS positioning system installed on the boom of the respective ship loader. This work took place during changes in operations, where we stopped being in the operating booth to be in a remote operating room, and through the use of quality tools such as A3, Pareto chart, RAB matrix among other methodologies. analysis, the root cause was identified, proposing as a solution the use of mathematical calculations, programmable logic controller (PLC) systems and real-time visualization of supervisory screens.
Technical Session
DOUBLE MULTITOOL ROBOTIC CELL FOR CASTER OPERATIONS
Presenter(s): ANNA ZOPPIROLLI (POLYTEC), Ion Rusu (), Rafael Jacob ()
Abstract:
The continuous casting phase of the steel production is one of the few areas that still requires several manual operations dangerously close to the molten steel. This paper illustrates how the right combination of the latest robotic technologies allows a full automatization of the casting operations, with great increase in safety, process and production efficiency. Thanks to advanced human machine interfaces, operators can control the casting process in its entirety, from shroud manipulation to nozzle oxygen opening, steel temperature sampling and more, while never being required to access the casting area during its critical stages.
Technical Session
9/5/24, 2:50 PM - 9/5/24, 3:15 PM
Presenter(s): EDNEY DA SILVA DIAS (ARCELORMITTAL - SAO FRANCISCO), Lucas Schmitz (ARCELORMITTAL - SAO FRANCISCO), Leonardo MITO (ARCELORMITTAL - SAO FRANCISCO)
Abstract:
Seeking the best possible performance of the outbound process is pivotal for the smooth operation of a supply chain, especially within the context of a steel coil warehouse due to the intricate nature of storing and effectively handling coated coils. In this paper, we present a mixed integer programming model for solving the joint problem of assigning coils to a fleet of dispatch vehicles and optimally scheduling such vehicles, aiming at maximal occupation rate and minimal loading time. Numerical experiments are presented in both theoretical and practical contexts
Technical Session
9/5/24, 2:50 PM - 9/5/24, 3:15 PM
Presenter(s): Fabiano (fast2 mine tecnologia e desenvolvimento de sistemas ltda)
Abstract:
Standardization of processes is crucial to ensure efficiency, safety, and quality in complex industrial operations, such as mining. This article focuses on the implementation and analysis of an innovative indicator, the “Índice de Exposição ao Risco de Velocidade” (IERV), or “Speed Risk Exposure Index” (SREI), in a bauxite residue transportation operation in northern Pará, Brazil. Average speed, a critical parameter, is studied in-depth, considering not only productivity but also worker safety and equipment integrity. The introduction of IERV and a data-driven proactive management approach revealed a remarkable 45% reduction in speed violations in the operational area. This study highlights not only the effectiveness of the indicator but also the importance of a proactive approach to mitigate risks, making industrial operations safer and more efficient. The vital role of technology, especially the FAST2 Mine's Mining Control system, in the successful implementation of scientific strategies to enhance efficiency and reduce operational risks is examined. This work offers valuable insights for similar operations, emphasizing the transformative potential of data management and innovation in the industry.
Technical Session
9/5/24, 2:50 PM - 9/5/24, 3:15 PM
Presenter(s): Camila cristine duarte da silva (TERNIUM BRASIL)
Abstract:
The article discusses the steel manufacturing process and the generation of by-products, focusing on steel slag. These by-products, especially steel slag, are abundant in the steel industry. Steel slag has characteristics that make it easily reusable due to its iron content. The chemical composition of slag varies depending on factors in the steelmaking process. After cooling, slag is beneficiated through processes such as magnetic separation and screening. The expansibility of slag is influenced by its chemical composition. For its application in pavement, a hydration process known as "curing" is necessary. Additionally, it is crucial to classify slag according to environmental standards to ensure proper waste management. The article also addresses a case study on optimizing the hydration process of steel slag at a steel mill, resulting in operational and safety improvements, with a significant reduction in the treatment time of slag piles.
Technical Session
9/5/24, 2:50 PM - 9/5/24, 3:15 PM
Presenter(s): rafael deoliveira barbosa (simec - itauna), José Aparecido pereira (J. A. pereira consultoria de engenharia)
Abstract:
Three high roughers traditionally use a Box–Box Roll Pass Design, which has the disadvantage of twisting, making it difficult for the bar to enter the next pass. This problem occurred in the SIMEC-Itauna rougher stand, and an octagonal Roll Pass Design was developed as a solution. This design reduced the generation of accidental operational scrap in this stand by 38% and provided other benefits, such as improved bite conditions, increased productivity by 10%, and reduced motor current by 6%. This design allowed the implementation of a new billet with an 8% higher dimension, reducing the rolling mill cost. This was an innovative initiative with low investment cost and the important participation of the rolling mill team in the start-up and revisions to improve the performance. a great success.
Technical Session
Application of the shrinking core model (SCM) to estimate pickling time in flat carbon steel : a classical chemical reaction engineering approach
Presenter(s): JOSE OCTAVIO DA SILVA SIERRA FERNANDEZ (greylogix brasil), Diogo Alves Massaneiro Guebert (universidade federal de santa catarina), luismar marques porto (UNIVERSIDADE FEDERAL DE SANTA CATARINA), agenor de noni jr. (universidade federal de santa catarina)
Abstract:
The acid pickling process generally consists of applying a strong acid (HCl) to a metal surface in order to remove layers of iron oxide (scale). Typically, turbulent pickling lines are used in order to maximize the productivity of industrial systems. This paper developed a phenomenological approach to model the kinetic behavior of scale consumption based on shrinking core model. Some geometric, chemical, and thermodynamic assumption are described and were made to simplify the model structure, exempla: chemical reaction being the limited step, respecting by a generic r_{HCl}=k\bullet C_{HCl}^m rate law equation. The validation was made based on experimental data and empirical models extracted from the literature. As a result, an equation to estimate the pickling time were developed. The results demonstrated, in comparison with empirical and sigmoidal models, a good consistency with literature, showing errors, under certain conditions, below 5%. This proposed approach can support future process optimization studies either in laboratorial or industrial scale. At the end, improvements in environmental impact reduction and cost savings could be explored, supported by using SCM
Technical Session
TECHNOLOGICAL EVOLUTION OF EAF REFRACTORY LINING FOR FOUNDRY
Presenter(s): Santiago Ruiz Barrios (VESUVIUS)
Abstract:
Within the process of smelting and refining metals within metallurgy, solutions involving technology and new refractories products were the major challenges for suppliers of these materials. Metal producers seek operating and process conditions more aggressive and a melt within the shortest possible time. As a result, increasing furnace power and using oxygen to accelerate fusion have proven to be interesting solutions that achieve these objectives. On the other hand, demands on refractory performance have increased, and producers have moved to develop new products with greater performance that provide the customer with an attractive cost/benefit ratio. In this work we will discuss innovations in refractories for lining Electric Arc Furnaces (EAF) for steel and alloy foundries.
Technical Session
PROCESS OPTIMIZATION IN ELECTRIC STEELMAKING USING SINTERED SYNTHETIC SLAG
Presenter(s): rodrigo ribeiro da silva (tecnosulfur s/a)
Abstract:
With the increasing demand to improve competitiveness, steel mills seek to reduce costs and increase productivity, while maintaining or improving the final quality of steel. In this scenario, it becomes essential that the steel manufacturing processes in electric steel mills are optimized from primary refining to continuous casting, where secondary refining plays a fundamental role. To ensure efficiency and agility in the secondary refining of steel, it is necessary to work on the properties of slag, such as chemical composition, viscosity, melting point, and density in order to ensure efficient removal of impurities and avoid impacts on the steel mill flow. Therefore, the objective of this work is to present the results obtained with the development of a sintered synthetic slag for the optimization of steel desulfurization in the secondary refining of Gerdau Açonorte.
Technical Session
IMPROVING THE PERFORMANCE OF AN ARGON PLUG IN AN ELECTRIC ARC FURNACE MELTSHOP
Presenter(s): vINICIUS FRANCO DO NASCIMENTO (VESUVIUS), Tulio da Silva Alves (Arcelormittal), Eder José Ferreira (arcelormittal), Bruno Correia Pinheiro (arcelormittal), Jonathan Amaral Izidoro Silva (vesuvius), Ângelo Leandro Paiva_ Mecânico (vesuvius), everaldo martins araujo (vesuvius), wilson barbosa (Vesuvius)
Abstract:
This study investigates the improvement of argon plug performance in an electric arc furnace (EAF) steelshop. The evaluation compares three purging plug designs: a standard slotted plug (PQ16424), a plug designed for better thermal shock resistance (PQ21507 with castable 3926), and a new design with a reinforced matrix for slag resistance (TS3926). Laboratory tests showed that TS3926 offered superior thermal shock resistance and a lower temperature delta. Field trials with PQ21507 demonstrated a 35% reduction in erosion rate compared to the standard plug. Additionally, the plugs exhibited minimal cracking and extended service life, allowing operators to safely utilize them until a lower operational limit. These findings highlight the effectiveness of material selection and design optimization in enhancing argon plug performance and promoting safety in EAF steelmaking
Technical Session
DUST CONTROL IN BLAST FURNACE DUST CATCHERS
Presenter(s): CAROLINE MORGADO AMORIM (ECOLAB QUIM LTDA), Artur Fernandes da Silva (TERNIUM BRASIL), Fábio Schusterschitz Araújo (ecolab quimica ltda), Marco Antonio Dos Reis (ternium brasil), Rodrigo Fernando Porto (ecolab quimica ltda)
Abstract:
Blast furnace gas is a by-product with a calorific value that can be used as fuel but requires adaptation. One of the adjustments is the removal of suspended solids, initiated by the dust catcher, which separates around 50% of the particles. Despite the robustness of the system, particles (dust) are emitted that cause environmental problems and reduce visibility, compromising operational safety. Ternium Brazil, which is located close to residential and commercial areas seeks to minimize particle emissions during discharge. Currently, water is used to control emissions, but it is not efficient due to the characteristics of the material generated. To solve this problem, it was recommended to use Dust Foam Plus™ technology, a chemical product from Nalco Water with high efficiency in retaining fine particles. The objective was to minimize or eliminate particle emissions, without major investments, and ensure dust control in trucks during transport. Application occurs by dosing the product into the water line that goes to the pugmill. After implementation, dust generation was practically eliminated. The application provided significant improvements to promote a healthier and safer operating environment and eliminate the possibility of environmental fines in this area, providing an avoidable cost gain of R$ 400.000,00.
Technical Session
SELF-HEALING MICROSTRUCTURE: THE UTMOST REFRACTORY TOUGHNESS MECHANISM
Presenter(s): DEIVISON CARLOS FONTES HESPANHOL (SHINAGAWA REFRATÁRIOS DO BRASIL LTDA.), Heloisa daltoso orsolini (shinagawa refratários do brasil)
Abstract:
Refractories are often exposed to thermal variations during their operational cycle, such as in torpedo cars and iron ladles, where molten metal is loaded and unloaded at a high frequency basis. Dealing with that aggressive thermal shock is not straightforward and the most common approach for these materials is to optimize the carbon sources, increasing the thermal conductivity of the bricks and reducing the thermal gradient between the hot and cold faces. If, on one hand, the material becomes more resistant to thermal shock damages, on the other hand, its higher conductivity imposes a negative consequence: higher thermal loss during operation. In this work, inspired by intelligent microstructures with the ability to adapt to the most severe environmental conditions, an innovative approach was evaluated, aiming at obtaining an Al2O3-SiC-C brick formulation designed to present a self-healing behavior, without variation in the carbon sources or content. The new developed structure successfully regenerated the cracks initiated during thermal cycles, resulting in an even tougher material after thermal shock tests. Other properties such as mechanical, oxidation, and corrosion resistance also showed promising results, pointing out the birth of a smart self-healing technology, able to completely change the role of refractories in thermal cyclic operations.
Technical Session
9/5/24, 2:50 PM - 9/5/24, 3:15 PM
Presenter(s): alexandre patricio vieira da silveira (TERNIUM Brasil)
Abstract:
Ternium Brasil located in Rio de Janeiro, has two identical Blast Furnaces in its steel complex, both of which began operations in 2010. During their campaigns, the Blast Furnaces presented problems with displacement of the cast iron staves and deformation of the copper staves. The Blast Furnace 02 presented problems in the staves before Blast Furnace 01 and in a more intense way, being the first to undergo interventions and in greater quantity compared to Blast Furnace 01. In total there were six replacements in Blast Furnace 02 and a replacement in Blast Furnace 01. Interventions to change the stave as well as preservation actions were essential to eliminate interruptions and operational instabilities caused by casing heating, non-uniform load descent in addition to reducing the Blast Furnace stoppage for removal of water. The first exchange took place in 2018 and from each exchange, techniques and studies were developed that optimized time by increasing the amount of stave exchanged in the same time interval. The work will present the actions of the TERNIUM Brasil Blast Furnace Preservation Team that has been providing gradual evolution after each stave change over time
Technical Session
REVIEW OF SINTERING PROCESS PATENTS
Presenter(s): Igor Jurandir Ubaldo Viana Pereira (Universidade federal de ouro preto), Víctor de Andrade Alvarenga Oliveira (universidade federal de ouro preto)
Abstract:
This work carried out a review of the main sintering processes used in the Brazilian steelmaker market. Sintering processes: Dwight-Lloyd; Greenawalt; A.I.B Holmberg; JL Mini Sintering; TCS process; and SKP Process are the main processes available to perform the sintering of iron ore fines. From the analysis of these processes it was possible to collect characteristic data of the process such as production capacity; identify the type of process, classifying processes as continuous, semi-continuous and discontinuous; analyze the flowcharts of each process and determine advantages and disadvantages of each process.
Technical Session
9/5/24, 2:50 PM - 9/5/24, 3:15 PM
Presenter(s): ERIC AUGUSTIN (FUND APOIO AO INST PESQ TECNOL SP - FIPT)
Abstract:
This paper focuses on the importance of evaluating weathering under pressure for iron ore agglomerates, essential in steel production. Weathering, caused by external agents, can degrade these pellets, affecting production efficiency. The study aims to develop equipment capable of simulating stacking conditions, exposure to weather, and water application, essential for understanding and mitigating the effects of weathering. Planned experiments were conducted, varying applied force, water temperature, water flow rate, and test duration. The results showed that test duration had the greatest impact on pellet strength, followed by applied force and water temperature, while water flow rate had less influence. It is concluded that these factors play a significant role in pellet degradation, indicating the need for more detailed studies in the future to elucidate the mechanisms of weathering action on the pellets.
Technical Session
9/5/24, 2:50 PM - 9/5/24, 3:15 PM
Presenter(s): MILTON SERGIO FERNANDES DE LIMA (IEAV)
Abstract:
The use of pre- or post-heating is commonly employed during welding. It is already known from the state of the art that inducing heat to the joint prior to welding is efficient in reducing susceptibility to cracks and improving the toughness of the weld metal. In laser beam welding (LBW), the use of pre- or post-heating is less common, mainly owing to the high productivity and restrictions on access to the small molten pool. However, in-situ heat treatments during LBW are very common in the steel industry for joining hot-rolled sheets before coiling. Nevertheless, the implications of heating and cooling routines during LBW are still not fully understood, making their study important for industrial applications. This study intends to contribute to this discussion by reviewing some phenomena associated to high temperature laser beam welding (HTLBW), and by examining a case study of interest of 22MnB5 steels. Sheets of hot stamping steel was subjected to an in-situ LBW heat treatment in accordance with their chemical composition, thermomechanical treatment and selection of use. As this steel required stamping after welding, a bainitic microconstituent provided superior formability to the welded blank. For some other steels, there was some advantage in processing the flat products at high temperatures, depending on the case.
Technical Session
9/5/24, 2:50 PM - 9/5/24, 3:15 PM
Presenter(s): vinicius santa clara ucelli (SAMARCO MINERAÇÃO S. A.)
Abstract:
This work aims to identify the causes of recurring failures in the bushings of a fan. Using Root Cause Analysis methodology, it was identified that bushing damage was caused by fatigue cracks. After implementing actions raised by the multidisciplinary group, the bushing's lifespan increased from 2 to 6 months. Additional analyses used to in turbomachines, such as Thermo-Elasto-Hydrodynamic, rotodynamic lateral analysis, and vibration analysis, revealed that shaft deflection and thermal bowing were the root causes of failures. These findings underscore the importance of analyzing the effects of assembly weight on shaft deflection and thermal bowing during the design stage to enhance the quality and efficiency of industrial equipment.
Technical Session
EVALUATION OF THE RH REACTOR WITH SUBMERGED LANCE: MIXING TIME, CIRCULATION RATE, AND FLOW CHARACTERIZATION
Presenter(s): Thalys Bruno De Souza Ventura (UNIVERSIDADE FEDERAL DE OURO PRETO - UFOP), Davi Rodrigues De Oliveira Santos (UNIVERSIDADE FEDERAL DE OURO PRETO - UFOP), Ana Flavia Xavier Tomas (UNIVERSIDADE FEDERAL DE OURO PRETO - UFOP), José Dimas de Arruda (UNIVERSIDADE FEDERAL DE OURO PRETO - UFOP), Antônio Marlon Barros Silva (Instituto FEDERAL DE minas gerais campus OURO branco - IFMG/OB), JOHNE JESUS MOL PEIXOTO (UNIVERSIDADE FEDERAL DE OURO PRETO - UFOP), Carlos Antônio da Silva (UNIVERSIDADE FEDERAL DE OURO PRETO - UFOP)
Abstract:
Steel desulfurization is a key step in achieving reduced sulfur levels for various steel applications, ensuring a quality standard. The use of the RH process in secondary refining is an interesting option due to its versatility and efficiency. In order to analyze the behavior, physical phenomena, and operational conditions of industrial reactors, physical modeling is a key strategy for process development. This study evaluated the process parameters of steel desulfurization through the injection of desulfurizing agent via submerged lance into the ladle (lower vessel) of the RH degasser, using 1:7.5 scale physical modeling. Conductimetry tests were performed to analyze the influence of gas flow and injection lance position on circulation rate and mixing time. Additionally, dispersion characterization of tracer (dye) and soybean oil droplets injected through the lance was conducted to evaluate oil particle dispersion, simulating the desulfurizing agent. It was concluded that gas flow in the up-leg was the influential variable on the circulation rate in the RH degasser, while a reduction in mixing time was observed with increasing gas flow through the lance and through the nozzles in the up-leg. Qualitative analysis of oil and dye injection through the lance suggests that there are favorable positions for material entrainment in the up-leg, which is desired to achieve longer residence time of the desulfurizer and consequently higher desulfurization rate.
Technical Session
9/5/24, 3:15 PM - 9/5/24, 3:40 PM
Presenter(s): Leonardo Rodrigues Danninger (Instituto de Pesquisas Tecnológicas), Michelle Midori Onishi (Universidade Federal do ABC/ Paranapanema S.A), Carlos Triveño Rios (Universidade Federal do ABC)
Abstract:
Biphase brass alloys are Cu-Zn alloys that exhibit a microstructure composed of of two phases (
Technical Session
DIGITAL TRANSFORMATION APPROACHES ROLLING MILL. AN OVERVIEW ON TECHNOLOGIES THAT GUIDE THE DIGITALIZATION PROCESS
Presenter(s): ANNA ZOPPIROLLI (POLYTEC), Ion Rusu ()
Abstract:
Robotics and Automation already play a prominent role in all parts of Industry 4.0, coming together with learning algorithms that allow both bots and humans to optimize production and improve quality, as well as operators’ safety and health. To be successful, an Industry 4.0 approach must be concrete. How can we upgrade existing rolling mills? How can we ensure operator’s safety and improve productivity and quality? Through the integration of different digital technologies connected simultaneously to computer systems equipped with artificial intelligence and learning algorithms, robots can automatically perfect their operations and operators are able to quickly intervene on the production efficiency, making decisions based on objective data, in a path of continuous improvement. The following document offers an overview on instruments that turn a rolling mill into a “smart” one. .
Technical Session
9/5/24, 3:15 PM - 9/5/24, 3:40 PM
Presenter(s): valzemberg guimarães de souza (arcelormittal pecem), Valrelio da Silva Girão (arcelormittal pecem), Soraya Silva Pinheiro (arcelormittal pecem), Vívian Maria Soares Gurgel de Sousa (arcelormittal pecem), José Holanda Pinto Neto (arcelormittal pecem), Ricardo José Abeal (UNILINK TRANSPORTES), Paulo Henrique Abreu de Sá (tecer terminais), Marcelo Perim de Faria (arcelormittal pecem)
Abstract:
This article aims to analyze the operational conditions for sending coke from ArcelorMittal Pecém (CE) to ArcelorMittal Tubarão (ES), from recognizing the product and its stock availability, through the preparation and execution of all loading processes of the product via the Pecém Port, using a multimodal operating model. All points of the process are analyzed during each operation carried out, the results obtained are evaluated and improvements are proposed. And, conclusively, it is verified that this movement is on an upward productivity curve, reducing execution time and increasing the satisfaction of those involved with safe operations that aim to care for the environment.
Technical Session
9/5/24, 3:15 PM - 9/5/24, 3:40 PM
Presenter(s): LÚCIA HELENA XAVIER (CETEM)
Abstract:
Urban mining, as an efficient solution for recovering value from anthropogenic stocks, can be made possible through technological processes and contribute to the supply of critical and strategic minerals. While traditional mining uses processes for mapping, identification, characterization and concentration of mineral fractions of interest, urban mining uses similar processes to recover minerals from secondary sources, demanding less energy and materials. This study aims to analyze comparatively traditional mining and urban mining, considering the recovery potential of critical and strategic minerals from secondary sources. A comparative analysis of both approaches was carried through the bibliographical analysis. The finds suggest that urban mining will not replace traditional mining but will contribute to the application of circular economy principles through efficient resource recovery and mitigation of impacts on waste management, resulting in uncertainty decreasing regarding the supplying of critical and strategic minerals. The study also points to the recovery potential of secondary materials from the management of waste from electrical and electronic equipment in Brazil.
Technical Session
9/5/24, 3:15 PM - 9/5/24, 3:40 PM
Presenter(s): josé aparecido pereira (J A Pereira consultoria de engenharia)
Abstract:
PILOT rolling mills ARE USUALLY USED TO SIMULATE LARGE AND COMPLEX PROFILES TO AVOID WASTE OF TIME TESTING PRODUCTS AND RISK OF LOSS OF rolls. roll pass design EQUIVALENT TO 50 AND 60MM angles IN OPEN grooves. rolling IS MADE WITH COLD LEAD WHICH IS EQUIVALENT TO STEEL HEATED TO 1020 C. THE RESULTS OBTAINED WERE CONSISTENT AND EQUALABLE TO REAL rolling mills AND OPENED THE POSSIBILITY FOR VARIOUS SIMULATIONS OF COMPLEX AND LITTLE-STUDIED PRODUCTS.
Technical Session
NEW FULL TURN-KEY HOT STRIP MILL COMPLEX OF ARCELORMITTAL MEXICO
Presenter(s): Lukas Pichler (Primetals Technologies Austria), Martin Bergmann (Primetals Technologies Austria), Franz X. Schmoller (Primetals Technologies Austria), Konrad KRIMpelstaetter (Primetals Technologies Japan), Jorge Nieto (ArcelorMittal Lazaro Cardenas), Aceves Everardo (ARCELORMITTAL LAZARO CARDENAS), Kai Ankermann (Primetals Technologies Germany)
Abstract:
The new hot strip mill of ArcelorMittal Mexico in Lazaro Cardenas has a capacity of 2.5 mtpy with the possibility to be extended up to 4.5 mtpy. A wide range of high-quality grades ranging from 1.2 - 25.4 mm thickness and up to 1900 mm width are produced for national and international markets. The mill is equipped with state-of-the-art technology including Primetals Technologies’ distinguished innovations such as Power Cooling, Modular Coil Shuttle system or Advanced Profile, Flatness and Contour Control. The adjacent hot skin pass mill assures the necessary elongation and flatness and surface quality.
Technical Session
9/5/24, 3:15 PM - 9/5/24, 3:40 PM
Presenter(s): HANA LIVIA FROTA COELHO (ARCELORMITTAL PECÉM S.A.), Fernando Emerson Viana Sousa (ARCELORMITTAL PECÉM S.A.), Francisco Necy Alves Junior (ARCELORMITTAL PECÉM S.A.), Renardir Peixoto Maciel Junior (ARCELORMITTAL PECÉM S.A.), Carlos André Ruy Carneiro (ARCELORMITTAL PECÉM S.A.), Lucas Sousa Uchôa (ARCELORMITTAL PECÉM S.A.), Carlos Henrique Lopes (ARCELORMITTAL PECÉM S.A.), José Eduardo Pereira (ArcelorMittal Global R&D Brazil), Anderson Nicolodi (ArcelorMittal Global R&D Brazil), Yoran de Melo Bolsoni (ARCELORMITTAL PECÉM S.A.)
Abstract:
THE DEVELOPMENT OF STEELS FOR THE OIL AND GAS INDUSTRY, MAINLY SOUR SERVICE APPLICATION THAT ARE RESISTANT TO CORROSION IN ACIDIC ENVIRONMENTS, REQUIRES STRICT QUALITY CONTROL, AS PIPES ARE CRUCIAL FOR THE RELIABILITY AND SAFETY OF OIL AND GAS TRANSPORTATION SYSTEMS, ENSURING MATERIAL INTEGRITY IN CORROSIVE ENVIRONMENTS. TO MEET CUSTOMER REQUIREMENTS, STEEL CLEANLINESS CONTROL IS IMPORTANT, AS IT IS THE RAW MATERIAL FOR PIPE MANUFACTURING, INCLUDING MINIMIZING NON-METALLIC INCLUSIONS AND DISSOLVED GASES TO REDUCE SUSCEPTIBILITY TO HYDROGEN-INDUCED CRACKING (HIC). THIS STUDY PRESENTS THE DEVELOPMENT OF SLABS OF API 5L X65 STEEL FOR SOUR SERVICE, HIGHLIGHTING THE QUALITY TECHNOLOGIES AND PROCESS CONTROL PRACTICES IMPLEMENTED AT ARCELORMITTAL PECÉM. THE RESULTS DEMONSTRATE THE SUCCESSFUL PRODUCTION OF STEEL WITH CORROSION RESISTANCE AND RESISTANCE TO HYDROGEN-INDUCED CRACKING, MEETING DEMANDING INDUSTRY REQUIREMENTS.
Technical Session
MITIGATION OF BLEED SURFACE DEFECTS IN BILLET CASTING THROUGH OPTIMIZATION OF NEGATIVE STRIPPING TIME AND ALIGNMENT OF CONTINUOUS CASTING MACHINE
Presenter(s): LUCAS CAVALLIERI SELVATICI MARIN (GERDAU - RECIFE), ANDERSON ARAÚJO ALVES GOMES ROCHA (GERDAU), ANDERSON ARAÚJO ALVES GOMES ROCHA (GERDAU)
Abstract:
This study addresses the mitigation of bleed surface defects in billet casting by optimizing negative strip time and ensuring proper alignment of the continuous casting machine. Conducted on a two-strand continuous casting machine with a 4500mm radius and 130mm x 130mm billet section, the work involved analyzing ten heats under two conditions: before and after parameter adjustments and topography corrections. Using tri-axial accelerometer sensors, key oscillation parameters such as amplitude, frequency, and potential lateral/frontal displacements were diagnosed. The negative strip time was calculated considering oscillation frequency, casting speed, and mould stroke. Results showed that pre-adjustment conditions exhibited suboptimal negative strip times, exacerbating the potential defects. Post-adjustment, all casting speeds achieved optimal negative strip times, significantly improving surface quality. Topography analysis identified positioning deviations in the oscillator and withdrawal units, causing vibrations and surface tensions. Aligning these components reduced defect formation. The study concludes that careful adjustment of oscillation parameters and regular topography services are crucial in preventing bleed defects, ensuring high-quality billet production.
Technical Session
TUYERE LEVEL COKE SAMPLING IN ARCELORMITTAL PECÉM BLAST FURNACE
Presenter(s): Roberto Abreu Alencar (danieli-corus), Vitor Leão Sousa Bezerra (arcelormittal pecém), Paulo Cezar Loureiro Junior (arcelormittal pecém)
Abstract:
The Blast Furnace is widely recognized as the most economically efficient method for converting substantial volumes of iron ore into pig iron and subsequently steel within the industry. To formulate and implement effective strategies for reducing fuel consumption in Blast Furnaces, it is imperative to comprehend the internal structure and the interaction of raw materials with the process. Since coke remains the sole solid raw material throughout its descent into the crucible, comprehending its properties within the furnace is crucial. This study assesses the validity of results derived from coke sampling at the tuyeres, employing an internally developed tool. The findings demonstrated consistency with existing literature, confirming a reduction in coke size by approximately 57.52% and a decrease in coke CSR from 66.64% to 32.7%. Consequently, the constructed probe yields valid results for sampling and analyzing coke conditions in the lower regions of the Blast Furnace.
Technical Session
9/5/24, 3:15 PM - 9/5/24, 3:40 PM
Presenter(s): samara samid aguiar correia costa (vale), jhessica alice palheta reis mendes (vale), Luiz Claudio Von Sperling Cotta (vale), Marley Anuciação Magella (vale)
Abstract:
The use of tailings as raw material in pelletizing can offer a sustainable solution to the accumulation of waste in mining dams. This work intends to analyse changes in the physical and chemical characteristics of the pellet feed fines of São Luis pelletizing plant added with ore concentrated from the Gelado Dam tailings. To compare the pellet feed quality, it was assumed reference the pellet feed specification for each parameter. By these values, the loss or gain in percentage points was calculated. The results showed that the main changes occurred with physical quality, moisture and blaine index. The high blaine index is related to ultrafine particles, which decreases the filtering operation performance, causing increasing of moisture. The effects of these changes in pelletizing impact on handling and energy consumption in the furnace. However, it improves the packaging of the particles, which can provide an improvement in physical quality of fired pellets.
Technical Session
9/5/24, 3:15 PM - 9/5/24, 3:40 PM
Presenter(s): PAULA MARIA GOMES CUNHA LEãO (UFMG), Augusta Cerceau Isaac neta (UFMG), MAURÍCIO COVCEVICH BAGATINI (UFMG)
Abstract:
The use of self-reducing briquettes with biomass is considered a potential alternative to reduce the consumption of fossil fuels in reduction reactors and mitigate CO2 emissions. In this study, a combined approach involving X-ray microtomography and X-ray diffraction techniques was used to evaluate the behavior of self-reducing agglomerates at different heating stages. The briquettes were produced on a laboratory scale using iron ore, biomass treated at 250ºC and sodium silicate. The analyses were carried out with a ZEISS Xradia 610 Versa 3D X-ray microscope, obtaining an image pixel size of 11,3 µm and image processing using the commercial software Avizo. Three-dimensional images of the spatial distribution of pores and ferrous phases (wustite and metallic iron) were obtained. The results indicated the formation of metallic iron and sintered regions starting at 950ºC, as a consequence of the self-reduction reactions. There was observed a trend of increasing porosity up to 950ºC, followed by a decrease at higher temperatures. With the increase in temperature, the reduction to wustite and metallic iron was more pronounced. The quantitative analysis obtained by XRD and Rietveld method showed good agreement with the quantification via microtomography.
Technical Session
9/5/24, 3:15 PM - 9/5/24, 3:40 PM
Presenter(s): Salvatore Giuliano Peixoto Tropia de Abreu (Universidade Federal de ouro preto), Rodrigo Rangel porcaro (Universidade federal de ouro preto), Geraldo lucio de faria (Universidade fereral de ouro preto), Samuel da silva de souza (USP)
Abstract:
This study utilizes a three-bar model to demonstrate the development of residual stresses after a thermal cycle similar to steel welding and the influence of martensitic transformation on stress relief. To this end, four material models were built to describe a USISAR-80T steel: three considering the martensitic transformation for different peak temperatures of the thermal cycle (1300°C, 1150°C, and 920°C), and one disregarding the martensitic transformation. The martensitic transformation was considered based on the instantaneous expansion coefficients as a function of temperature, obtained from dilatometry tests applied to the steel. It was concluded that the increase in peak temperature is directly related to the increase in the martensitic transformation temperature (Ms) and consequently to the increase in the final residual stresses. The material model that did not consider the martensitic transformation exhibited the highest final residual stress values. The approach using the Three-Bar Model facilitated the understanding of how material properties and process parameters influence the residual stresses resulting from the welding process.
Technical Session
MICROSTRUCTURAL ANALYSIS OF 3D PRINTED AISI H13 STEEL FOR APPLICATION IN INJECTION DIES
Presenter(s): vitor prando baroni (Universidade de passo fundo), Charles leonardo israel (Universidade de Passo Fundo), William Haupt (Universidade de Passo Fundo)
Abstract:
The present work evaluates the macrostructure and microstructure of AISI H13 steels printed by 3D modeling. The focus of the study is to check the presence of possible defects, including porosities and voids that may be caused in the printing process and post-process. The study also includes mechanical characterization of the steel and the completion of a heat treatment route for the printed material with subsequent analysis of the microstructure using optical microscopy and scanning electron microscope (SEM). An evaluation of the microstructures was carried out and a relationship was established with the mechanical properties of the material. The work sought to understand how printed materials behave in several different proposals such as manufacturing stamping dies, polymer injection and shear cutting
Technical Session
APPLICATION OF RELIABILITY STUDY TO INCREASE THE AVAILABILITY OF THE AUTONOMOUS STORAGE YARD SYSTEM: A CASE AT MINING COMPANY VALE S/A
Presenter(s): vivian suellen alves jansen (Vale), Leno Anderson Prazeres da Silva (Vale), Raquel Amorim Dias Fernandes4 (Vale)
Abstract:
The automation of industrial processes has become a necessity for the profitability and safety of work. These two factors need to go hand in hand to ensure customer confidence and competitiveness in the market. The control and automation of industrial systems and processes have existed for a few decades and are evolving more every day. The manual form of operation (the first form of control used by man) still present in many processes, presents the need for an operator who must know the system, have reasonable experience, skills and, as is known, many physical limitations. To automate these processes, it is necessary to use new technologies and field instruments that reproduce human senses, however, many times these instruments when installed do not undergo laboratory tests that represent the real operating scenario and when in contact with the aggressiveness of the process can present unexpected results (breakage, wear, oxidation) causing unscheduled stops in the production process. This work refers to the study carried out through the application of reliability methods and statistical analysis of stoppage events in the ore pile mapping radar systems at the Ponta da Madeira Maritime Terminal of the Vale company.
Closing Ceremony
9/5/24, 4:00 PM - 9/5/24, 5:30 PM
Presenter(s): AW 8th Edition Technical Balance - André Luiz Vasconcellos da Costa e Silva - ABM Week 8th Edition Technical Coordinator
Abstract:





