ABM Week 9 | Schedule

Abstract:

Iron ore pellets are widely used as raw material in blast furnaces due to their physical and chemical uniformity, high mechanical strength, and greater reducibility. They are produced from fine iron ore particles, which are agglomerated and sintered to form porous spheres of controlled size. This improves gas permeability in the blast furnace and increases process productivity. Some of the main advantages of pellets compared to lump ore is their more homogeneous and controlled chemical composition, as well as better reducibility and metallurgical characteristics, allowing for more stable blast furnace operation. Another advantage is the lower presence of impurities such as phosphorus, which contribute to the quality of the produced pig iron.

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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.

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Sulfur is an element with strict specifications for certain steel grades, making its control in blast furnace produced hot metal essential. In this regard, the factors influencing sulfur incorporation in the small (BF-S) and medium (BF-M) blast furnaces at Usiminas were analyzed. The methodology included statistical analysis of the sulfur percentage in the furnaces, considering the correlated variables, with statistical comparison between the furnaces (t-test) and multiple regression models for sulfur content prediction in each reactor. Additionally, scenarios for sulfur reduction were simulated by partially replacing coke with charcoal and natural gas. The results indicated that the top pressure in BF-M was the determining factor for its lower sulfur content compared to BF-S, while quaternary basicity was the main explanatory variable for sulfur incorporation in both furnaces. In addition, assuming a constant desulphurisation efficiency, the sulphur content of the hot metal can be reduced by up to 8.8% by partially replacing coke or mineral coal with charcoal or natural gas.

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This paper presents the chemical and mineralogical characterization of lithium ore samples from dressing plant feed and flotation, with the aim of evaluating chemical, physical and liberation grade distribution. The PSD revealed a significant reduction in average particle size between the plant feed (AM1) and flotation (AM2), with a 2.96-degree reduction in the P80 fraction, from 650 µm to 219 µm, respectively. Around 20% of the material sampled is above 150 µm in AM2, a range that is associated with low Li₂O recovery. Microstructural analysis of the AM1 and AM2 samples by SEM/EDS confirmed the presence of spodumene and gangue minerals such as quartz, muscovite, albite and others. The quantification of lithium by ICP-OES showed levels of between 0.61-0.60% Li, for plant feed and flotation, respectively, a value characteristic of low-grade spodumene deposits, but with economic potential. The chemical composition obtained by WDXRF indicated high levels of SiO2 and Al2O3. The high Na₂O content suggests that lithium oxides have been replaced by sodium oxides due to ionic substitutions in the crystal structure of spodumene.

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The pursuit of greater operational efficiency has driven the integration of technical areas in mining operations. At an iron ore mine in Itabira, Brazil, a collaborative project was developed between mine planning and operations teams, focusing on improving the drilling and blasting process. From January to April 2025, brainstorming sessions led to significant operational gains, including a 1.7% increase in Physical Utilization (UF) and an optimization of the drilling mesh by approximately 1.5 m². Based on these results, a detailed monthly analysis was conducted to evaluate blasting capacity, mined mass, and the inventory of blasted material, aiming to maintain a healthy inventory and prevent drill idle time. The insights enabled a revision of the equipment forecast curve for the remainder of the year, identifying opportunities to reduce the number of machines in operation. The project resulted in cost savings, improved equipment reliability, and highlighted the importance of cross-functional collaboration for operational sustainability.

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This study presents a methodology for evaluating the aging of vacuum filter sectors used in the filtration process. Field analyses revealed that the productivity of some filters was below the design capacity, along with an increase in the frequency of filter cloth replacements. It was found that material buildup on the sectors, especially carbonates, contributes to component aging and directly impacts filtration performance. To quantify this effect, a methodology based on the mass gain of the sectors was developed, classifying them into aging categories (new, semi-new, and old). The proposed methodology proved effective in increasing productivity and reducing unplanned downtime, reinforcing the importance of continuous monitoring and preventive maintenance in the vacuum filtration process.

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This work aimed to improve the automatic control system of Reclaimer 01 at Samarco Mineração by increasing the ship loading rate from 4,500 t/h to 5,800 t/h through the implementation of control strategies that maintain a fixed flow rate, regulate the silo level, and adjust the slewing speed of the boom. These actions resulted in the elimination of reclaimed load variation, a reduction in demurrage charges (fees applied when a vessel remains at the port longer than contractually agreed), and savings by avoiding investments in additional silos. The effectiveness of the solution was confirmed by the increase in loading rate, and when replicated in Reclaimer 02, it enabled both machines to operate in an integrated manner, reaching a combined rate above 12,000 t/h. These results highlight the robustness and scalability of the control strategy in optimizing operational efficiency and ensuring process safety.

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This paper presents the implementation of a continuous monitoring system for hydrostatic pressures in the process fan of an iron ore pelletizing unit. The objective was to improve the detection of failures in the bearing and in the components associated with the lubrication system, such as hydraulic pumps, valves and piping, enabling the anticipation of interventions and the mitigation of operational risks. The methodology involved the integration of signals into the PIMS system and the configuration of automated notification logics for critical parameters. The comparative analysis between the previous situation, based on manual inspections and reactive diagnostics, and the implemented solution showed significant gains in terms of operational availability, reduced response time and mitigation of unscheduled shutdowns. The adoption of continuous monitoring represents an efficient solution for the management of critical assets, contributing to the increase in reliability, safety and sustainability of industrial operations.

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Through the growing need for wind power generation potential in Brazil and worldwide, IGNA Solutions Casting, a foundry manufacturing and manufacturing engineering company, with a strong focus on dimensional accuracy, material integrity and process reliability, presents the results and its capacity in the production of metal components for industrial use. The results of Physical, Chemical, Metallurgical and Mechanical Tests are presented throughout this work, as well as the service to the national and international markets between the years 1998 and 2024, obtained with the use of perfect Quality tools, seeking excellence through continuous improvement and offering solutions for improvements in processes and products

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The effect of Nb addition on the microstructure and mechanical properties of wear resistant steel heavy plates processed by direct quenching was investigated in pilot scale. The steels evaluated were laboratory-cast in a vacuum melting furnace, reheated to 1,250°C, and controlled rolled, aiming at the finishing step in the non-recrystallization region of austenite. The mechanical properties of the transformed microstructures were determined by hardness, tensile and Charpy V-notch tests, and the specimens were characterized using optical and scanning electron microscopies. An increase in strength and absorbed energy was observed with the increment of Nb content from 0.015 to 0.030%, demonstrating that this element was effective in refining the microstructure and making it more homogeneous, as confirmed by the microscopy analyses.

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Reheating furnaces in hot strip and heavy plate mills reheat steel slabs to ensure a uniform temperature before rolling. During this process, the steel surface reacts with the furnace's oxidizing atmosphere, forming primary scale. In the rolling process, secondary scale forms is removed by high-pressure water jets. The atmosphere in hot rolling makes it difficult to simulate oxidation behavior, complicating the distinction between metal losses from primary and secondary scale. In this study, metal loss due to oxidation was determined through an industrial experiment using plate samples measured and weighed before and after heating, as well as a scale sample removed from the slab used as a support for the samples. After cooling, the remaining scale was removed with a steel brush and chemical pickling. The samples were then measured and weighed again. Mass loss was estimated using both descaled and non-descaled samples and the scale sample taken from the slab. The metal loss calculated by the developed model was 0.72% for the non-descaled condition and 0.80% for the descaled condition. The estimate based on the scale sample from the slab reinforced the 0.80% result.

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This article presents the implementation of strategies to improve the Working Ratio (WR) index at ArcelorMittal's sintering plant, aiming to reduce emergency stoppages and increase operational efficiency. The study was based on the statistical analysis of the production process, identifying critical variables and adopting the DMAIC - Six Sigma methodology to achieve the WR target of 96% in 2024.

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This paper presents the development and implementation of a real-time monitoring system for the nickel plating process of copper plates. The project aims to ensure continuous control of critical variables such as bath temperature, solution pH, and the operation of agitation and filtration pumps, as well as rectifiers. The system architecture integrates industrial sensors, PLCs, an OPC UA server, and data analytics platforms for real-time data acquisition, visualization, and interpretation. Predictive analysis techniques, based on machine learning, are employed for early detection of process deviations. The proposed solution enhances the reliability, traceability, and efficiency of the production line by minimizing failures and ensuring coating quality.

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The study investigates the influence of adding açai residue to an isophthalic polyester polymer matrix through compression testing. The research includes pycnometric analysis, evaluation of the results under compressive force, and analysis of the fracture region by optical microscopy (OM). Pycnometry revealed a density of 1.39 g/cm³ (± 0.076). Compression tests showed strength limits of 88.94, 71.66, 78.02, and 53.06 MPa and elasticity modules of 1.72, 1.44, 1.62, and 1.20 GPa for additions of 0, 10, 20, and 30% of particulates in the matrix, respectively. These results indicate that the açai powder functioned as a filler, not as a reinforcement. The MO analysis showed little adhesion between the particulates and the matrix, resulting in detachment during compressive stress.

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The aim of this article is to reduce the need for manual information input in the planning and sequencing of ArcelorMittal Pecém's (CE) slab vessels. It covers everything from the production plan and stock availability to the transfer of slabs to the Port of Pecém, including the preparation and execution of loading processes, using a multimodal operating model. The daily analysis of each stage of the process makes it possible to evaluate the results obtained and adjust the berthing sequence strategically. In conclusion, there has been an upward trend in productivity, reducing execution time and increasing the satisfaction of those involved. In addition, the operation is conducted with a focus on safety, environmental preservation and reducing costs such as demurrage

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Today’s steelmaking aims for maximum productivity while complying with process and occupational safety requirements. Limiting factors are often the ladle sizes (capacity). One possibility is to purchase new ladles. An inexpensive alternative is to redesign your refractory ladle lining concept. The permanent lining and the insulation layer should be focused, since the wear lining is in direct contact with steel. Alumina- or bauxite-based linings are often used as permanent lining to achieve good corrosion resistance in case of a breakthrough of the wear lining but have the disadvantage of a high thermal conductivity. If lining thickness is decreased, the temperature of the insulating layer and the steel shell will rise, which is leading to unsafe operation situations. The aim of this study was to increase the steel ladle volume using a new lining concept. Therefore, thermal conductivity measurements and FEM simulations were carried out, to calculate the temperature distribution in the lining. It was shown that the ladle volume could be increased by 7 % with the new lining concept and materials, without any negative effects on the temperature distribution, durability and corrosion resistance of the permanent lining. The increase in capacity enables a significantly higher throughput per heat, which contributes to improved operating efficiency and overall productivity of the plant and to a reduction in fixed costs without CAPEX while ensuring safety requirements.

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In 2016, SDI's Structural and Rail Division (SRD) in Columbia City, Indiana initiated a strategic upgrade to its electric arc furnace (EAF) operation. The facility transitioned from pressurized tubular water-cooled panels to a modern spray-cooled upper shell system. This enhancement aimed to address safety concerns, improve thermal performance, and lower maintenance demands. Over time, complementary technologies such as a spray-cooled roof, elbow, copper burner box, and the SYSTEMS Spray Safe Humidity Sensor were also introduced. This paper details the technical, economic, and operational benefits realized from these innovations.

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This study evaluates the performance of advanced slide gate plates, specifically the L-Tech model utilizing TS3378 refractory composition, in the casting of silicon-killed steels. Silicon-killed steels, known for their improved cleanliness and mechanical properties, present specific challenges for refractory performance due to high-temperature interactions and aggressive slag environments. The research compared the L-Tech plates to traditional TS3214 and TS3182 plates under real operational conditions across multiple South American steel plants. Key evaluation metrics included bore erosion, surface wear, and oxidation resistance, assessed through post-mortem analysis. Results demonstrated that L-Tech plates provided up to 40% increased service life, with lower wear rates and enhanced oxidation resistance. Operational benefits included reduced replacement frequency, improved safety and ergonomics, and a lower environmental footprint. The superior thermal and mechanical properties of the TS3378 formulation contribute to increased casting reliability and support sustainable steelmaking practices, confirming the L-Tech plate as a high-performance solution for Si-killed steel applications.

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In January 2024, the shortage of sinter posed unprecedented challenges to the blast furnace operations at ArcelorMittal Tubarão. In addition to the impact on the reactors, peripheral areas such as the Ore Yard, Coke Plant, and Steel Plant were also affected, requiring stricter control of inventories, raw material logistics, and hot metal quality. Operating the blast furnace with over 90% pellet feed demanded a steep learning curve and frequent adjustments in burden distribution, production rhythm, auxiliary fuel injection rate and flux consumption. This paper describes the main operational results of Blast Furnace 3 during this period, as well as the countermeasures adopted to mitigate the negative impacts in this scenario

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This study evaluated the reduction potential of gases generated as co-products from biomass pyrolysis, comparing them with exhaust gases from different primary iron production technologies. For this purpose, typical gas compositions were gathered from the literature, considering slow/intermediate pyrolysis and industrial processes such as blast furnace, Corex, Finex, Midrex, and HyL III. The reduction potential was assessed through thermodynamic analyses using the Baur-Glaessner diagram and the calculation of the reduction driving force (FMR). The results showed that some pyrolysis gases exhibited high reduction potential, comparable to industrial gases like the Corex/Finex generator gas, capable of reducing iron oxides to metallic iron. However, most of the evaluated gases showed limited potential, restricting reduction to FeO. The findings indicate that pyrolysis gas may represent a strategic opportunity for future steelmaking applications. Nevertheless, generation strategies, biocarbon participation, and integration with the steel production chain need to be further studied.

Abstract:

<span style="font-size: 12pt; font-family: Arial, sans-serif;">The Blast Furnace 2 of C.S.N. operated in 5th campaign of February 23, 1991 to January 19, 2025, producing about 44.345 Mt. During this campaign, various refractory repair techniques for the Body and Hearth of the furnace, electromechanical repairs, and process techniques were employed to enhance its longevity while maintaining production levels and costs. Therefore, this papers discusses the 5th extended campaign of over thirty-three years of Blast Furnace 2 in operation at the Presidente Vargas Plant site in Volta Redonda-RJ, detailing the design aspects and operational conditions, explaining how this long campaign could be achieved.</span>

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The geometallurgical characterization of mining projects evaluates the content of chemical elements of interest and those that are deleterious due to their impact on the quality of iron ore agglomerates and the performance of steel products. This study seeks to characterize typologies linked to the presence of phosphorus, LOI, aluminum and titanium in ores in order to support studies on phosphorus removal. Furthermore, the objective is to map mining fronts and typologies rich in aluminum due to their impact on the floatability of the ores. Mineralogical, chemical, granulometric and microstructural analyses were carried out on samples of iron ore and tailings. The studies identified levels of deleterious elements in the concentrate and flotation tailings and slime, associating them with typologies and mining fronts, as well as their forms of occurrence in the ore, providing important support for studies on the removal of contaminants in Samarco products

Abstract:

Blasting can be considered one of the cheapest and most energy-efficient stages in the rock size reduction, compared with the energy-intensive grinding required to liberate valuable minerals. The performance in mining and mineral processing activities is governed by in-situ ore properties. In particular for blasting, the resulting fragmentation is strongly influenced by rock mass properties, such as the in-situ rock strength and structure condition. However, due to increased complexity in its variability, definition, measurement and to operationally incorporate these in a routine workflow, it leads to an often over-simplification of such characteristics when designing a blast. This inevitably leads to variable, sub-optimal fragmentation that leads to poor downstream processing performance. Therefore, blasting should be considered in the context of holistic Mine-to-Process optimization, rather than simply as a stage to reduce rock size sufficiently to load it in a truck. By introducing a comprehensive, practical framework which accounts for the variability in rock characteristics, and adequately tailoring blast intensity to the rock using site-specific mathematical modelling and simulations, the ROM fragmentation resulting from blasting can have its variability reduced and optimized according to the specifics required downstream – either higher fine content, reduced P80 and top size, while maintaining safe and efficient blasting.

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This investigation has been carried out to stablish the influence of microstructural characteristics on the reducibility and quality of iron ore pellets in order to understand how iron ore origin (hematite or magnetite) influence pellet performance. Hematite and magnetite-based pellets were analyzed using conventional characterization and advanced microscopy techniques, like SEM/EDS and SEM/EBSD. Reducibility evaluation was carried out through basket tests in HYL ZR reactor under plant operational conditions. The better results of reducibility and metallization was obtained for magnetite-based pellet with small grain size without coalescence and higher density of finely distributed pores. These findings highlight the importance of controlling microstructure to enhance both the operational performance and metallurgical quality of iron ore pellets.

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Macrosegregation refers to the variation in chemical composition along the transverse and longitudinal sections of cast products, particularly in the central solidification region. Traditionally, this area is analyzed manually through visual inspection, which is subjective, time-consuming, and prone to human error. The product quality sector commonly uses the macroetching method to assess internal soundness, as it is widely adopted in the steel industry. However, due to the subjectivity of comparing results with standard charts, some clients demand more modern and quantitative approaches, such as the analysis of Black Spots – dark points in the central segregation zone. To meet this demand, an application was developed using computer vision and image processing techniques to automate the detection and quantification of Black Spots. The implementation involved collecting images from steel samples with varying haracteristics and applying segmentation techniques to identify the number and size of defects. The system was validated by comparing manual and automated methods across multiple samples. Results demonstrated significant improvements: standardized analysis, automatic report generation, a 90% reduction in analysis time, and an annual labor savings of approximately 300 hours. Additionally, the automated method increased result reliability by eliminating operator interference.

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This study presents the development and deployment of an automatic slewing-control system for two ore stackers, designed to eliminate stockpile collapses. The algorithm combines a kinematic model, formulated using the Denavit–Hartenberg convention, with free-fall equations to estimate the material’s impact point in real time from tower slew and boom elevation angles, discharge height, and belt speed. This set-point drives a PID controller embedded in the PLC, keeping the radial error below 1 m. Implemented at the end of 2023, the system eliminated all eight previously recorded instability events and, as an additional benefit, increased the yard’s average capacity by roughly 10 %, thus avoiding physical yard expansion and its associated environmental impact. The solution proved low-cost, highly safe, and easily replicable across other bulk terminals.

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This work aimed to describe the most commonly used techniques for softening effluents from gas scrubbers in converter furnaces and, in a more focused manner, the technological route that uses carbon dioxide to replace sodium carbonate, the latter being the most popular route. The technological route that uses carbon dioxide has demonstrated substantial technical and economic advantages over the most popular conventional option, proving to be an attractive technique for the market. Depending on the geography, savings of around 15 to 50% of costs can be expected.

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This work studies the detachment of zinc from galvanized sheet during the mechanic forming process for the production of a continuous profile ZN 2,30 mm C 15x38x75x38x15 Z 100 with a length of 1000 mm. The thickness of the deposited zinc layer is controlled usin an air blowing system applied through high-precision nozzles by two blowers, as soon as the strip emerges from zinc pot (1). A suppression in the blowing system may have occurred, which may be the cause of the zinc detachment during the forming of the profile. To carry out the study, a tensile test, hardness analysis via durometer, analysis with the Sacanning Electron Microscope (SEM) coupled to Energy Dispersive X-ray Spectroscopy (EDS) and verification of the thickness of the zinc layer on the profile through the HW300PRO magnetic thickness was lower than that required by NBR 7008, the hardness test presented satisfactory results, as did the tensile test.

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In hot strip rolling, width reduction is performed by edge mills present in the roughing unit. The width reduction capacity is an important factor in steel mills, since it is directly linked to, among other factors, the slab and coil logistics and mill productivity. On the other hand, performing high width reductions is a challenge in terms of coil quality and width uniformity. This study sought to evaluate the mathematical model of a hot strip mill and propose changes to increase the maximum width reduction practiced in the rolling line, without degrading the quality of the coils. After proposed changes, it was possible to expand the maximum width reduction to 120 mm. In terms of quality, there was an improvement of up to 42% in the occurrences of quality deviations related to the width of the coils

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The iron ore unloading process begins at the Wagon Tipplers. This case study takes place at the Ponta da Madeira Maritime Terminal and aims to ensure operational excellence in the tippler cycles, where materials are transported via conveyor belts and directed to storage yards. The micro-movements of the equipment must be standardized to meet operational guidelines, allowing for a detailed analysis of execution times at each stage. Quality Management methodologies such as Stratification, Pareto Diagram, Gap Analysis, and Fault Tree Analysis were applied. Automation was essential to implementing logic adjustments in the tippler micro-movements. The target was a 6% reduction in cycle time, and after the improvements were implemented, the average cycle time for Wagon Tipplers 05 and 06 was reduced from 103.6 seconds to 95.4 seconds. This result represented an average gain of 8.2 seconds per cycle..

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This paper presents the analysis and redesign of the exhaust fans at the ArcelorMittal Pecém sinter plant, aiming to increase the sinter production capacity from 4.72 Mt/year to 5.10 Mt/year. Through mathematical modeling, analysis of the fan performance curves, and a review of the original design calculations, it was identified that an increase in airflow of approximately 7% would be required to meet the new demand. The proposed solution involved replacing the existing fan rotors with models of approximately 5% larger diameter, increasing the total exhaust capacity from 36,000 m³/min to around 41,500 m³/min under operational conditions. This modification will enable the production target to be achieved with operational safety and environmental compliance, while maintaining an adequate specific airflow rate of approximately 1,773 Nm³/t of sinter. The proposed intervention represents a highly effective solution to eliminate the main bottleneck in the sinter plant expansion, leveraging the existing infrastructure and avoiding more significant investments.

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Natural Fiber Reinforced Polymer Composites (NFPCs) are viable and environmentally friendly alternatives to products developed from petrochemical resources. The polymer resins used in the manufacture of these composites are predominantly synthetic, however, new resins are being developed based on plant resources, such as castor oil. New natural fibers are also being researched and applied to composite materials to replace synthetic fibers, such as glass and carbon. However, the combination of the polymer matrix with the natural fiber reinforcement presents some challenges, such as incompatibility between the hydrophobic matrix and hydrophilic reinforcement. Therefore, Fourier Transform Infrared Spectroscopy (FTIR) analysis was used to analyze, identify and track changes and chemical groups in the composite, allowing, through its analysis, to identify matrices that have improved compatibility with the natural fiber, based on the identification of chemical groups in the matrix and reinforcement and possible chemical interactions between them. And from this understanding, understand the behavior of the material and thus improve the thermal and mechanical properties of the composite. Through FTIR analysis, it was possible to observe that the polyurethane resin derived from castor oil has a certain chemical compatibility with the natural fiber reinforcement that other matrices do not have, this happens due to greater chemical interactions between the precursors of the polyurethane resin and the surface of the natural fiber.

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The tracking of railcars at a large-scale rail terminal has been significantly enhanced through the implementation of an advanced solution based on 2D scanners and the Lynx Real Time Platform (Lynx RTP). This work presents real-time digitization for counting and identifying train components (locomotives, GDUs, and GDTs), measuring speed, and analyzing structural deformations. The system also enables detailed cargo monitoring, detecting foreign objects, longitudinal and transverse loading profiles, height, volume, accommodation angles, and anomalies such as overflow and imbalance. Centralized architecture, supported by robust communication between PLCs and the database, raises the standards of efficiency, safety, and reliability in the rail loading process, establishing the terminal as a benchmark in automation applied to heavy logistics.

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ArcelorMittal Pecém has a “single line” plant (operation with only one production line), with its production rate determined by the synergy between the process times of the entire plant, since Coke Plant until converters and the continuous casting machine). The specific condition of ArcelorMittal Pecém (single line plant) makes the application of management tools even more important due due to the low margin of error of the plant. The historical stabilization of slab production at levels below nominal capacity prompted the implementation of a process optimization project aimed at achieving production and productivity levels sufficient to boost results to the company's full capacity levels. The strategic plant project was implemented aiming to increase production to nominal capacity. In Steelmaking plant a methodology that accurately measured production losses in critical equipment (BOF and CCM) would be fundamental to subsequently develop consistent projects. OEE methods and equipment reliability were implemented. The results achieved consistently drove the plant's production to nominal capacity through reductions in process losses and stabilization of assets by increasing equipment reliability.

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There are several variables regarding steel quality that must be controlled in a melt shop. When taking into account the formation of inclusions, some must be considered, like the ones raised in secondary metallurgy, vacuum degassing along with continuous casting operation. In this work, a computational tool, combining Excel macros and Python programming language was developed in order to correlate scrapping and the influence of several process variables, with the proposal to be implemented in steel plants. It was concluded that, according to a review done by the authors and the study carried out in this manuscript the methodology created for the evaluation of this correlation is valid, although it would be important to check with more industrial data the calibration of the tool.

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The Continuous Casting Evaluator, a Microsoft Excel®-based tool based on the G.U.T. Matrix (Gravity, Urgency, Trend), systematizes the diagnosis of defects in continuous casting, such as cracks, segregation, and porosity, by correlating process parameters (temperature, cooling rate, mold conditions), mold powder chemistry, and product characteristics (chemical composition, dimensions). The methodology employs a data input interface to calculate a "Bad Score," indicating defect likelihood based on weighted parameters derived from technical expertise. Tests with a hypothetical peritectic HSLA steel (ASTM A131 DH40) based on typical steelmaking processes (BOF, LF, CC) revealed quality scores from 21.43% (high probability) to 62.96% (average quality), with "Hot-Shortness" exceeding 80% (low probability). Cracks and segregation showed high probability, suggesting adjustments in superheat and secondary cooling. The tool requires accurate data; low automation in some plants poses a limitation, mitigated by operator training and simplified templates. Future prospects include integration with real-time sensors, MES systems, and machine learning, aligning with Industry 4.0. Accessible and adaptable, this solution enhances quality and productivity in resource-constrained steel mills, with potential to become a dynamic monitoring tool.

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As the mining industry seeks to reduce greenhouse gas (GHG) emissions, strategic tools become essential to align operations with climate goals. This study presents the Vale Emissions Systemic Optimization (VESO) model, which simulates emissions and optimizes product margins under carbon constraints, while also estimating exposure to carbon taxation and supporting economically viable mitigation strategies. The scope of the study was directed toward comparing different operational scenarios simulated in VESO, focusing on the impact assessment of decarbonization strategies. Four scenarios were analyzed: the reference scenario (Business as Usual), full replacement of fuel oil with natural gas in the pelletizing process, adoption of a 50:50 blend of Diesel B30 and ethanol in relevant operational stages, and partial substitution of natural gas with biomethane in pelletizing. The results demonstrate VESO’s ability to quantify emissions and guide low-carbon planning, considering economic and regulatory factors. The tool stands out as a robust resource to support environmentally and financially resilient decision-making in complex industrial contexts.

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For decades, the Iron Quadrangle has supported the growth of the Brazilian steel industry and supplied international markets. However, the advancement of mineral exploration, combined with the transition to natural moisture mining processes, has significantly altered the profile of the available ore. At the same time, steel producers have been prioritizing decarbonization in their production chains. In this context, Vale, through the Ferrous Technology Center (CTF), has been working in partnership with its clients to develop burden solutions — a set of strategies and technical assessments aimed at defining the ideal composition of the metallic burden, considering the operational premises of sintering and blast furnace reduction processes. A notable example of this approach is the project conducted in collaboration with Ternium Brasil, which began in 2019. Studies have been carried out on the pilot sintering machine, with emphasis on maximizing the use of pellet feed, applying Carajás sinter feed, and using dolomitic lime. Among the main value levers identified is the use of more acidic agglomerates in blast furnaces, a response to the deterioration in quality and the reduction in the volume of lump ore available for consumption. An industrial test conducted in February 2025, involving the introduction of 50,000 tons of acidic pellets, indicated a reduction of 12 kg/t in the slag rate and 3 kg/t in the fuel rate of the blast furnaces, attributed to the change in the basicity of the pellets used. In sintering, increasing the basicity of the sinter enabled a 22% reduction in total fines generation and in the internal return of the process, contributing to significant operational gains in efficiency and stability.

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Although fuel injection in blast furnaces is a well-established practice, standardized methods for evaluating material combustion performance are still lacking. This study investigates the correlation between combustion results obtained through thermogravimetric analysis and those from the PCI-rig developed at the LaSid-UFRGS, testing various fuel materials. The results demonstrate that for coals and charcoal, the final combustion temperature and S index (derived from thermogravimetry) correlate well with rig’s performance, suggesting their potential as predictive parameters. However, for alternative fuels, significant differences were observed between the two methods, indicating the need for specific evaluation criteria for these materials

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<span style="font-size:12.0pt;font-family:&quot;Arial&quot;,sans-serif; mso-fareast-font-family:&quot;Times New Roman&quot;;mso-font-kerning:0pt;mso-ligatures: none;mso-ansi-language:PT-BR;mso-fareast-language:PT-BR;mso-bidi-language:AR-SA">This paper aims to present the activities developed and the operational result of the blow down at Blast Furnace 2 of C.S.N., which took place in January 2025, with the purpose of handing over the Blast Furnace to the engineering department for the replacement of the refractory in the body and hearth, and repairs on peripheral equipment, such as the top of the furnace, stoves, gas cleaning, runner room, stock house, an activity referred to as Mini-reform AF2.</span>

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This study aims to explain the importance of the different mineralogical types of hematites and goethites found in the Quadrilátero Ferrífero, quantify them, and understand the impacts that each of these variations causes in the mineral beneficiation process. Although they share the same nomenclature, these minerals exhibit significant differences in their rock formations, crystallizations, and mineralogical structures, resulting in distinct behaviors throughout the production flowchart. Through qualitative and quantitative analyses, as well as estimations conducted using a petrographic optical microscope and a stereomicroscope (binocular microscope), it was possible to identify specific characteristics of these mineralogies and assess their impacts on the beneficiation process, as well as on the quality of the final product, particularly in pellet formation

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This study aims to support strategic mine planning through the analysis and optimization of equipment fleet sizing for the Barão Norte operation over its six-year mine life, including the pre-stripping phase. A discrete-event simulation model was developed using ProModel to replicate key mining processes, including drilling, loading, and transportation of ore and waste to the Sossego mine. The simulation enabled the identification of operational bottlenecks, capacity constraints, and performance gaps under various scenarios. The findings provided a data-driven recommendation for the optimal number and configuration of equipment required to meet production targets efficiently throughout the entire life of the mine, contributing to improved resource allocation and informed decision-making regarding future operational expansion.

Abstract:

High grade iron ore pellets are becoming scarce due to the depletion of rich reserves and deposits of iron oxides, mainly hematite and magnetite. Thus, lower grade ores are being treated and concentrated at increasing costs of beneficiation, aiming the production of Direct Reduction Pellets (DRP). On the other hand, the environmental restrictions on CO2 emissions are pushing the development of green iron and steelmaking which is reinforcing the route Direct Reduction (DR) – Electric Arc Furnace (EAF) as one of the most viable solutions to produce greener steel. As is well known, DR requires the use of high-grade pellets (DRP) for efficient operation with lower costs. The product of DR, the direct reduced iron (DRI), is a clean feed of EAF for production of steel. From the industrial experience, it is observed that: the higher the iron content of pellets the better the performance of the DR and EAF. In other words, increasing costs in iron ore beneficiation decreases costs in iron and steelmaking. Considering that beneficiation, ironmaking and steelmaking are operations for iron (Fe) concentration, it is presented in this paper a discussion on the iron concentration borderline between the ore beneficiation and iron-steelmaking.

Abstract:

This study aims to present an optimization algorithm focused on heat scheduling in the steelmaking shop of a steel plant. The objective of the algorithm is to lexicographically minimize three critical aspects of the production process: the amount of unused volume, demand delays, and the number of co-scheduled steel grades. The algorithm’s performance was validated through tests using real data from a steel plant, demonstrating its effectiveness in improving operational efficiency and reducing costs. The results show that, on average, 12.35% of the total volume corresponds to unused volume when considering the scenario with co-scheduling, and the volume of early demands reaches an average of 1.43%.

Abstract:

The Advanced Process Controls (APC) are computer programs that incorporate tools and knowledge to solve specific operational tasks, autonomously and intelligently controlling processes. The wisdom and practices of experts are embedded into the systems through control strategies, usually aiming at stabilizing and optimizing production processes. The strategy consists of models and rules, which constitute the system's intelligence for decision-making. At Samarco, advanced process control systems are implemented in various production processes, namely: Fine Flotation, Coarse Flotation, Filtration, Pelletizing, and Furnace. More specifically, the APC of the pelletizing furnace IV potentially contributes to reducing natural gas consumption, thus avoiding CO2 emissions per ton of pellets produced. Equally important, the Pelletizing APC contributes to the good results of the furnace by maximizing pellets between 8 to 16 mm. This improved the permeability of the pellet bed in the furnace, enhancing the hot gas flow and reducing the need for thermal input (natural gas). This article aims to briefly describe the advanced controls of Pelletizing and Furnace and their benefits to the process.

Abstract:

The optimization of the energy matrix and the decarbonization agenda in the metallurgical industry have emerged as strategic priorities on a global scale. One of the main sources of energy inefficiency, especially in processes that affect the performance of electric furnaces, lies in the ladle heating systems used during production. Aiming to reduce energy costs and minimize emissions, White Martins has developed an innovative alternative that surpasses traditional ladle preheaters operating on air-gas systems. This is the Ladle Heating System based on Oxicombustion technology with the Oxigon burner, which uses pure oxygen as the oxidizer or, optionally, enriched air. This technology offers significant advantages compared to conventional air-gas systems, including fuel savings of up to 50% and a marked reduction in carbon and NOx emissions. The system operates with a balanced stoichiometric combustion process, enabled by precise gas measurements, while advanced burners ensure greater efficiency and a more uniform heat distribution, avoiding temperature variations across different sections of the ladle. An additional innovation that makes this solution even more relevant in the context of the energy transition is the capability to operate with hydrogen as an alternative fuel. Given hydrogen's zero-carbon emissions during combustion, the system becomes an indispensable tool for steelmaking industries seeking to achieve carbon neutrality in their production processes. The importance of this equipment lies in its role as a technological milestone on the path toward full carbon emissions neutrality. By combining operational efficiency, environmental sustainability, and regulatory compliance, this solution stands out as an essential component in transforming the steel industry into a sector aligned with the demands of a green economy and the global energy transition. This work showcases the development, sizing, and implementation of the ladle heating system in a steel plant, exploring both the existing solutions and the potential integration of new fuel options, such as hydrogen.

Abstract:

This work presents the development of rebar in coils 500MPa yield strength at Gerdau Ouro Branco, expanding its product portfolio for the civil construction market. The core aim was to obtain a product that meets the ABNT NBR 7480 standard. The methods employed included designing a medium carbon, high manganese, vanadium and nitrogen microalloyed steel, adapting the hot rolling process with new rebar finishing grooves, and ensuring adequate coil cooling. Results demonstrated a product fully compliant with the standard across all six developed rebar sizes (6.3 mm to 20.0 mm). This was achieved through proper chemical composition, metallurgical and mechanical properties, and geometric configuration. The linear mass concentrated between the nominal and minimum specifications, offering a competitive advantage for customers. Furthermore, the product performed well in cut-and-bend centers, exhibiting notable ductility and productivity. Consequently, it is concluded that an integrated production process was successfully developed, enabling the manufacturing of CA-50 coiled rebar with ABNT and INMETRO conformity certificates, providing a new, high-quality product to the civil construction market.

Abstract:

As part of its commitment to continuous product improvement, Usiminas has been continuously developing new Advanced High-Strength Steels (AHSS) to meet the challenging demands of the automotive sector, particularly in reducing emissions and enhancing vehicle safety. Among these materials, the electrogalvanized (EG) Complex Phase (CP) steel of the 1000 MPa class (CP1000EG) stands out. This study evaluated the robotic gas metal arc welding (GMAW) of 1.30 mm thick CP1000EG steel. The results demonstrated that defect-free joints were achieved, with weld bead geometries fully meeting the criteria established in the SEP1220:2020 standard. Optimal welding conditions were identified within the ranges of 16 V to 18 V for voltage and 90 A to 105 A for current. Radiographic inspection revealed low levels of porosity, indicating that the selected consumable is a suitable option for GMAW welding of electrogalvanized steels. The findings confirm that the GMAW parameters developed in this study are effective for welding CP1000EG steel and can serve as a reference for application engineering in the automotive industry.

Abstract:

In the industrial machinery and equipment at the Ponta da Madeira Maritime Terminal, emergency stop switches are essential to ensure immediate shutdown in hazardous situations. Between January 2021 and May 2022, 275 failures were recorded, totaling 325.7 hours of downtime, with an average of 16.18 failures per month during loading operations. This study aimed to reduce these failures by 37.5% by January 2023 using the Six Sigma methodology. The analysis was conducted using the Pareto diagram to identify key issues, the Ishikawa diagram to prioritize root causes, and the 5W2H action plan combined with control charts to implement and monitor solutions. As a result, from October 2022 to January 2023, the average number of failures dropped to 9, meeting the established target and remaining stable in the following months, demonstrating the effectiveness and sustainability of the implemented actions.

Abstract:

This paper presents the evolution of planning routines applied to the electromechanical assembly of a Beam Mill in a steel plant, based on the integration of Lean Construction principles and Artificial Intelligence tools. The objective is to structure a replicable planning process that combines collaborative methodologies and digital technologies to achieve tangible operational improvements. The adopted approach integrated Microsoft Project for schedule management, Power BI for data analysis, Autodesk Manage for 4D simulations based on the 3D model, and ALICE Technologies for the generation of planning scenarios supported by AI. Visual management routines with boards and post-its were also implemented to ensure direct communication with field teams. As a result, piping assembly performance reached 97% adherence to planned targets, a significant improvement compared to the 25% achieved prior to the implementation of the new practices.

Abstract:

Natural fibers, due to the demand for green and environmentally friendly alternatives, are increasingly being researched and applied as an alternative to synthetic fibers in the manufacture of polymeric composite materials. Therefore, it is extremely important to understand the thermal behavior of these composites, as well as the behavior of the matrix and reinforcement used. Therefore, this work aims to understand and evaluate the thermal stability of these materials, based on the analysis of Thermogravimetry (TGA) and its derivative (DTG), through a constant heating rate of the sample of 10 °C/min in the range of 10 °C to 900 °C in an inert nitrogen atmosphere. From the analyses, it was possible to note that the composites decreased their thermal stability, as the volumetric fraction of fiber to resin increased.

Abstract:

This article aims to show the study and actions taken in the ArcelorMittal Pecém (AMPE) plant with the objective of optimizing the fine lime receipts at the sinter plant, in a way that the costs generated with the vehicle dwell time of this product were reduced in a sustainable way (without affecting the sinter plant operation and respecting the plant consumption needs.) For this project, the DMAIC (Define, Measure, Analyze, Implement and Control) methodology was used as a mean of mapping of the main causes and actions to be taken to optimize the costs of the dwell times of the vehicles from fine lime suppliers.

Abstract:

With the increase in demand for stainless steel, it became necessary to expand the production capacity of this grade of steel at Aperam South America's melt shop. To this end, the MRP-L Converter, which now complements the production of the AOD-L Converter, had until then used an Excel spreadsheet model to control the process. This model, which had been in use for almost 25 years, was heavily dependent on manual inputs and did not perform heat balance calculations. In this context, the TOPMRP mathematical model was developed, adapted from the consolidated AOD-L model and adjusted to the specific MRP-L conditions, with the aim of automating the calculation of fluxing agents and alloy additions, reducing manual interventions and increasing process predictability. The methodology included data analysis, offline testing of the model, integration with automation systems and testing in an industrial environment. The results showed significant gains in process stability, with improved slag parameters and less variability in slab weight. Based on the results, it was concluded that the TOPMRP model met expectations, made the process more stable and automatic.

Abstract:

This work explores the application of cooling materials in the Energy Optimizing Furnace (EOF) to reduce operational costs through improved thermal control. A mass and energy balance methodology were employed to evaluate various materials available on the market as substitutes to dolomite (initially used the cooling agent), focusing on their impact on metallic yield, lime consumption, and slag behavior. A thermodynamic simulator was developed to estimate the cooling capacity of each material and predict process outcomes. Based on simulation results, industrial trials were conducted using the most cost-effective option — scrap briquette E. The furnace’s static model was calibrated using the Thermal Scrap Equivalent (STE) concept. Results showed that the replacement of dolomite with briquettes reduced metallic losses. The briquettes did not significantly alter slag appearance or oxide equilibrium. A 2:1 cooling ratio was adopted to align with operator experience and observed performance closely matched simulation predictions. Phosphorus reversion was identified as a risk when briquettes were added late in the heat, but this was mitigated by limiting the additional quantity. Overall, the study demonstrates that scrap briquettes are a viable alternative for EOF cooling, supporting more flexible, sustainable, and cost-effective steelmaking operations.

Abstract:

This work investigates fluid flow and mixing time in a Ruhrstahl–Heraeus (RH) degasser using computational fluid dynamics (CFD) and physical modeling. A 1:7.5 scale acrylic model was developed to evaluate six gas injection configurations, combining RH up-leg and submerged lance flows. Mixing time and circulation rate were measured through tracer conductimetry, and CFD simulations were performed with a multiphase Eulerian–Eulerian approach using CFX, including drag, lift, virtual mass, wall lubrication, and turbulent dispersion forces. The results showed that increased RH up-leg flow leads to higher circulation rates and reduced mixing times, in line with theoretical predictions and prior studies. The lance improved local turbulence and tracer dispersion but had limited effect on bulk circulation. Good agreement was observed between CFD and experimental results, particularly when interfacial forces were accounted for. The methodology proved effective for capturing key hydrodynamic trends, supporting CFD as a predictive tool for RH operations. The submerged lance configuration demonstrated practical advantages for process optimization. Future studies will address desulfurizer injection through the lance, particle residence time and slag-eye behavior to support the design of more efficient RH refining strategies.

Abstract:

This study aimed to quantify and analyze the Product Carbon Footprint (PCF) of Waelzholz Brasmetal, a Brazilian producer of re-rolled steel, with the goal of understanding its greenhouse gas (GHG) emissions in the industrial context. A quantitative applied approach was used, based on a case study following the "cradle-to-gate" life cycle, covering from raw material extraction to the final product at the plant. The methodology adopted international standards (ISO 14064, ISO 14067) and the Brazilian GHG Protocol Program to calculate emissions across scopes 1, 2, and 3, using primarily 2023 data supplemented by historical data from 2021 and 2022. Results showed that over 94% of the company’s total emissions fall under Scope 3, related to the acquisition of steel as input, while direct emissions, especially from natural gas consumption, are less significant. The specific carbon footprint of the production unit was quantified, aligning with global averages for similar processes. The study concluded that emissions management should prioritize supply chain decarbonization through selecting more sustainable suppliers and adopting low-carbon technologies. Simultaneously, internal improvements such as equipment modernization, energy efficiency optimization, and continuous emissions monitoring are recommended, emphasizing the importance of direct reduction for the company’s sustainability and climate compliance.

Abstract:

A key factor in reducing CO₂ emissions in the steel industry pass through decreasing fossil fuel consumption in reduction reactors. This can be achieved either through process optimization or by implementing and developing disruptive technologies, such as replacing carbon with hydrogen and creating new primary iron production processes, and so on. In this context, the quality and composition of the ferrous burden are crucial, as they directly influence the consumption of reducing agents and the process's carbon footprint. Iron ore briquettes emerge as a sustainable alternative, requiring less fossil energy in their production while offering suitable properties for blast furnace use. The developed binder and additive technology enable the production of cold agglomerated briquettes that, after low-temperature curing, exhibit physical, chemical, and metallurgical characteristics compatible with the requirements of the blast furnaces. This technology has been validated through industrial tests in blast furnaces of various sizes. This study presents a laboratory evaluation of two types of cold agglomerated briquettes: one designed to replace acid pellets, and another, with appropriate proportions of CaO and MgO, specifically developed to replace semi-fluxed pellets and sinter. The latter not only meets the required properties but also exhibits unique high-temperature behavior comparable to high-performance metallic burdens, with the potential to reduce CO₂ emissions by up to 10% in hot metal production via blast furnaces.

Abstract:

This paper discusses the commissioning and operational results of the first H2Gen® demonstration plant at a North American integrated steel facility. The project successfully demonstrated the use of blast furnace gas (BFG) to produce hydrogen from water using H2Gen® technology—a breakthrough that offers the global steel industry, including Brazil, an innovative and cost-effective pathway to decarbonize blast furnace ironmaking. Given that the majority of Brazil’s crude steel production still relies on the BF-BOF route, this technology has strong relevance for the Brazilian market. By utilizing existing BFG streams—widely available in Brazil’s integrated steel plants—H2Gen® enables on-site, carbon-neutral hydrogen production without requiring high-cost energy inputs. This is especially valuable in Brazil, where the availability of scrap and DRI-grade iron ore limits large-scale EAF adoption. The paper also describes the core technology behind H2Gen®—a solid oxide electrochemical reactor—and outlines a pathway to scale this system for future commercial deployments. For Brazil, this represents a practical solution to reduce emissions while maintaining the competitiveness of its steel sector in a decarbonizing global market.

Abstract:

Pellets are characterized by their physical and metallurgical properties among which is reducibility. This property is related to the velocity that pellets reduce and impact directly on fuel consumption of blast furnaces. The kinetic model which is more accepted to describe pellet reduction is the topochemical one. According to this, reduction happens from the outer layer of the pellet to its core, and layers of different iron oxides are formed. The velocity depends on each product properties and is related to kinetic constant (k) and diffusion coefficient (D). The methodology used in this study combined physical and numerical simulation, to estimate k and D for pellets at three temperatures: 973, 1073 and 1173K under reduction by carbon monoxide and hydrogen. From the results were found Arrhenius equation for each one of the kinetic parameters. The results showed that kinetic parameters increased with the temperature and pellets with higher reducibility obtained higher values for k and D. The effect on kinetic constant can be related to its high reducibility ferrite compounds or maybe a catalyst effect of MgO on iron oxide reduction. The improvement on diffusion coefficient happened due to the more homogeneous distribution of pores.

Abstract:

This study aims to evaluate the mineralogical variability present in the rocks of samarco mineração using a stereomicroscope, correlating this variability with the material's performance during the mineral beneficiation process. As a device capable of analyzing opaque, translucent, and transparent minerals, the process development laboratory (ldp) in germano has expanded its application beyond mineralogical characterization to also investigate filtration fabrics. The analysis seeks to understand the performance of these fabrics by identifying obstruction levels, their causes, and the associated mineralogical typology, with the goal of optimizing the filtration process and operational efficiency

Abstract:

Underground mining is a costly activity, with exploration expenses increasing as operations move deeper. Among the essential processes, ensuring the stability of tunnel walls stands out, often achieved through shotcrete application. Transporting concrete to the application site can become complex due to the material's workability and the logistics of machinery circulation along extensive ramps, where other vehicles involved in different processes are also in transit. One solution to this challenge is producing concrete within the mine itself, which, in turn, requires allocating workers for on-site production. This approach will be analyzed in the case study presented below, which details the current process and proposes a remote concrete production solution using a SCADA system from the surface. These alternative aims to reduce operational costs, mitigate worker safety risks, and optimize production, offering a more efficient and safer model for concrete supply in underground mining environments.

Abstract:

This study investigates the influence of the mineralogical composition of different types of iron ore on regrinding process parameters, focusing on pellet feed preparation. The research aims to correlate mineralogical characteristics with performance indicators such as particle size distribution and specific surface area (BSA), using both classical grinding models and population balance theory. Three types of ore with varying proportions of compact minerals (such as hematite and quartz) and porous minerals (such as goethite) were analyzed. Bench-scale grinding tests were conducted, with measurements of particle size distribution and specific surface area taken before and after grinding .The results showed that: Ores with a higher proportion of porous minerals demonstrated greater efficiency in generating specific surface area (BSA);the most compact ore exhibited a higher breakage rate (selection function), especially in coarser size fractions, which was attributed to the differentiated distribution of quartz in the finer fractions; the breakage function indicated that porous ores tend to generate finer particles, consistent with their higher friability. The study reinforces the importance of mineralogical characterization for optimizing the grinding process and planning future projects in the iron ore pellet production chain

Abstract:

This work presents two integrated initiatives focused on improving the operation of the induration furnace grate in the pelletizing process at Samarco Mineração. The first approach involved the implementation of a feedforward control strategy aimed at reducing variability in the layer of green pellets deposited on the grate, ensuring greater uniformity and thermal stability. The second initiative addressed the reduction of the grate’s startup time until the beginning of pelletizing, through the analysis of operational data and the redefinition of transition criteria between process phases. Both actions were developed by a multidisciplinary team, with direct implementation in the plant’s existing systems. The results demonstrated significant gains in operational stability, reduction of thermal losses, and increased production efficiency

Abstract:

The failure of the Fundão Dam in 2015 resulted in the deposition of a large volume of tailings in the reservoir of the Risoleta Neves Hydroelectric Power Plant (Candonga), located on the border between the municipalities of Rio Doce and Santa Cruz do Escalvado (MG), approximately 67 km from Samarco Mineração’s Germano processing unit. The accumulation of tailings led to the suspension of power generation at the plant. Following the recovery of the area, in accordance with geotechnical and environmental requirements, its management was incorporated into the scope of the Integrated Monitoring Center (CMI), which is responsible for ensuring safe operation in compliance with current legislation. Initially, the transmission of data from geotechnical instruments was carried out via satellite, offering high availability but limited transmission rates and high maintenance costs. To optimize this process, a new solution based on radio communication was implemented, involving the construction of line-of-sight towers between monitoring points and the CMI. This new infrastructure provided greater reliability, a significant increase in transmission rates, and a reduction in operational costs, resulting in a 100% cost saving compared to the previous satellite-based technology.

Abstract:

This work arose from the practical observation of the effects of temperature on the performance of batteries installed in the field, especially in areas without conventional electricity. Over time, it became evident that thermal variation — especially in metal boxes exposed to the sun — was compromising the lifespan and safety of these components, essential for the functioning of sensors and monitoring equipment. From this, tests began with different forms of thermal protection, such as internal insulation with ceramic fiber, the use of Styrofoam, and thermal blankets. Despite some improvements, the most efficient solution proved to be the replacement of metal boxes with boxes made of polypropylene, with additional thermal insulation made of Styrofoam. This simple change brought significant results: the internal temperature variation, which previously could exceed 30 °C, fell to about 10.5 °C. Practically, this represents an average increase of 30% the lifespan of batteries — which means fewer replacements, greater reliability of systems, and considerable savings over time. More than a technical solution, this initiative demonstrates how a keen attention to the small details of daily life can generate sustainable and economic improvements, with a direct impact on the operation of critical monitoring and security systems.

Abstract:

This paper introduces an innovative selective cooling design concept for advanced flatness control in cold rolling mills. The system independently adjusts the thermal profile across the strip width, featuring automatic valve testing and a quick-release mechanism for maintenance. Maintenance routines can now be organized offline from the mill stand, improving productivity and extending the lifespan of valves components. The paper emphasizes the design features and showcases the results of the first industrial application of this new concept.

Abstract:

Zinc phosphate coatings combined with sodium stearate (soap) have been applied to steels for cold forming to reduce friction, minimize tool wear, and prevent metal-to-metal contact, enabling deep and complex stamping, producing parts with tight tolerances and defect-free surfaces. This work aims to study, on a laboratory scale, the tribological behavior of zinc phosphate coatings with the incorporation of hexagonal boron nitride (hBN) nanoparticles into the soap bath. The baths remained stable with the addition of hBN at the operating temperature. Coatings, with and without hBN, were characterized in terms of deposited mass, surface roughness, morphology (scanning electron microscopy), and chemical composition (energy-dispersive spectroscopy). Tribological tests (ball-on-disc) were conducted to evaluate the coefficient of friction, seizure resistance, and wear of the coatings. The addition of hBN reduced surface roughness by up to 16.8 %, increased the drawing index by up to 3.0 %, improved seizure resistance by up to 57.7 % at 2.0 g/L, and reduced mass loss by about 30.0 % at 1.0 g/L compared to the reference sample, while maintaining similar coefficients of friction at the concentrations tested.

Abstract:

The Ponta da Madeira Maritime Terminal (TMPM), located in São Luís (MA), is a strategic logistics asset for Vale, with a capacity to handle around 230 million tons, being the main point of shipment for iron ore (MFe) extracted in the Northern System, especially from the Carajás mine (PA). Therefore, studying and reducing impacts that compromise the terminal's efficiency is crucial for maintaining the company's competitiveness against its competitors. The Six Sigma project developed at TMPM responsible for 68% of such events between July 2023 and June 2024, located in the South Yard. The goal was to reduce the average downtime for this failure mode by 40%, from 0.57 h/Mton to 0.34 h/Mton. The result achieved was 0.33 h/Mton during the verification period (October to December 2024), representing a total reduction of 46% compared to the analyzed period. The initiative demonstrated strategic relevance for Vale by directly contributing to an increase in the volume shipped of 144,513 tons of MFe, promoting a potential financial gain of R$ 22.4 million for the company's cash flow. In addition to productivity gains, the project also contributed to qualitative gains such as process standardization, strengthening of the problem-solving culture and continuous improvement, and adherence to the Vale Production System (VPS), ensuring the sustainability of the results achieved.

Abstract:

The objective of this work is to study optimal structures using density-based topology optimization through the SIMP method (Solid Isotropic Material with Penalization). Topology optimization is a computational method used in the design phase to efficiently distribute material within a domain, maximizing the performance of a specific property while minimizing another — in the case of structures, typically weight. Volume fraction is a fundamental constraint in structural optimization, as it defines the maximum amount of material that can be removed. The most commonly used mathematical method to solve this type of problem is the Galerkin Finite Element Method (FEM). Filters are applied in numerical methods to prevent the appearance of checkerboard patterns. The optimization algorithm used was the Method of Moving Asymptotes (MMA). The study of optimal circular geometries has multiple applications, such as in the bucket wheels of stockyard machines for iron ore storage. This work aims to investigate optimal 2D circular geometries subjected to tangential and radial distributed loads, as well as their combinations.

Abstract:

The pursuit of sustainable solutions has driven the development of more environmentally responsible materials. In this context, composite materials, especially those that incorporate natural fibers or matrices, have become the focus of both the academic community and industry. Brazil is a source of countless underexplored research opportunities, such as the fibrous Tururi fabric (Manicaria saccifera), an abundant lignocellulosic material from the Amazon with significant potential for emerging applications. Therefore, this study aims to evaluate the mechanical performance of polyester matrix composites reinforced with different mass fractions (3%, 6%, and 9%) of Tururi fibrous fabric through tensile tests (ASTM D638) and Izod impact tests (ASTM D256), in addition to statistical analysis using ANOVA and Tukey’s test. The results showed that as the mass fraction of the fabric increases, there is a significant reduction in the tensile strength and elastic modulus of the composites, mainly attributed to poor interfacial adhesion and the formation of structural discontinuities. On the other hand, regarding impact resistance, the significant increase in the fabric mass fraction resulted in an approximately 400% increase in toughness compared to the neat polyester matrix. This behavior indicates that the Tururi fabric promotes efficient energy dissipation mechanisms. Therefore, the developed composites demonstrate strong potential for applications that prioritize toughness, impact resistance, and sustainability, contributing to the valorization of natural Amazonian resources and the development of materials aligned with the bioeconomy and regional economy.

Abstract:

This paper discusses the digital transformation at CSN Prada, where the automation of logistics and administrative processes was implemented through the integration of Excel (VBA) and SAP. The goal was to solve problems related to high volumes of manual tasks, errors, and financial losses. Starting in 2017, with the arrival of experienced programmers, critical routines were automated using VBA and SapGui Scripting. The results include increased efficiency, reduced failures, more accurate data, and more time for strategic activities. The creation of the SAPEX department fostered innovation and employee development. This digitalization not only optimized operations but also strengthened the company's competitiveness, serving as a model for other industries, and is crucial for the sustainable growth of Brazilian industry.

Abstract:

The objective of this work is to compare the results obtained by varying the desulfurizing agent between calcitic lime and calcium carbide, co-injected with metallic magnesium, at a hot metal desulfurization station located in South America in partnership with Tecnosulfur S/A. The purpose is to maintain the desulfurization efficiency achieved with the current product, calcitic lime and metallic magnesium, while significantly reducing other operational parameters, such as operation time, variation of the desired final sulfur content, and treatment cost per ton of hot metal. This project was divided into three stages: initially, desulfurization performance data were collected with the current product, subsequently with the application of the calcium carbide-based product, and finally, a statistical analysis was conducted to prove the results and some observations for future work, such as evaluating the possibility of working in mono-injection only with the calcium carbide-based product.

Abstract:

Stainless steel production at Aperam Timóteo follows a flow that involves Electric Arc Furnaces (EAFs), AOD-L Converters, Ladle Furnaces and Continuous Casting Machines. For austenitic stainless steels, the choice of nickel and chromium sources in the metal charge is fundamental for competitiveness, and the replacement of ferro-alloys with 3XX alloyed scrap has reduced costs. The Plant has been intensifying the use of the EAF-EAF route, which allows for greater incorporation of 3XX alloyed scrap into the AOD-L, reducing dependence on dephosphorized liquid pig iron from the EAF-PTG route. In 2021, the EAF-EAF-Optimized route was implemented, which adds 5 to 10 tons of treated pig iron to the AOD-L, replacing part of the low-alloy scrap from the EAFs, increasing the consumption of alloyed scrap and reducing costs in the production of 304 stainless steel. In order to consolidate this production route, it is still necessary to overcome challenges such as structural limitations, guaranteeing the consistent availability of alloyed scrap and treated pig iron, and maintaining an adequate product portfolio. Initial results indicate significant cost savings in the production of 304 steel with this new route.

Abstract:

The flow behavior of molten steel in the mold during continuous casting is critical for product quality and process stability, with sub-meniscus flow velocity playing a decisive role in minimizing defects such as surface cracks and slag entrainment. This study presents the development and industrial application of a novel Sub Meniscus Velocimeter (SMV) measurement system designed by RHI Magnesita, which operates on the drag force principle using ceramic sensor rods to capture real-time velocity data at the meniscus region. The system enables qualitative and quantitative assessment of flow patterns, stability, and symmetry under actual casting conditions. Three industrial case studies are presented: (1) evaluation of a modified submerged entry nozzle (SEN) design, where SMV measurements confirmed improved flow stability and reduced surface disturbances compared to the standard design; (2) dynamic flow monitoring during process changes, where the sensor detected both expected flow responses and anomalies, including a hidden nozzle crack that altered flow symmetry; and (3) comparative analysis of two SEN types, demonstrating the system’s ability to differentiate flow behaviors and validated with quality feedback data. The results confirm the sensor's effectiveness in diagnosing real-time flow conditions, supporting process optimization, early detection of anomalies, and validation of nozzle design improvements in continuous casting operations.

Abstract:

The project presented here addresses the XCarb Program, an initiative by ArcelorMittal that proposes sustainable steel solutions in a safe, innovative, and traceable manner, focusing on the needs of customers to achieve their respective decarbonization goals, thereby driving the development of a low-carbon economy. This strategy aligns with the goals of the ArcelorMittal Group and is part of the company’s pathway to achieving CO₂ net zero.

Abstract:

Briquetting is a promising alternative to replace traditional ferrous burden materials used in blast furnaces, primarily due to its lower greenhouse gas emissions. This study evaluated the permeability and pressure drop of beds containing iron ore briquettes, in comparison with conventional ferrous burden materials, through laboratory experiments and CFD simulations. The developed numerical model showed good agreement with the experimental data, enabling reliable simulation of industrial conditions. The results showed that beds composed of lump ore, sinter, and B2 briquettes exhibit higher permeability, whereas pellets and B1 briquettes result in higher pressure drops due to lower void fractions and poor void connectivity. Notably, beds composed exclusively of pellets showed the highest pressure drops among all materials tested, and when used in mixtures with mass fractions above 25%, they caused pressure drops up to 45% higher than that of the sinter bed. For a 75% substitution of sinter, beds with B2 briquettes presented approximately 10% lower pressure drop compared to those with B1 briquettes. These results highlight the critical role of particle shape and size distribution in optimizing gas flow through the blast furnace, contributing to greater energy efficiency and reduced CO₂ emissions.

Abstract:

The Ternium Brazil blast furnaces, at Rio de Janeiro, started to operate in 2010. In these campaigns occurred several fails in cooled equipment, and its consequence is the water introduction into the blast furnace, it is consuming the internal energy of ironmaking process. For the objective to establish an assertive manner the ideal moment to be realized the corrective maintenance interventions in the cooling system was created a hydrogen mass balance to evidence when the hydrogen gas increase in the blast furnace gas in the top of equipment is originating of an increment unusual of hydrogen, with origin in possible fails in cooling system. The final method that was implemented is updated, automatically, and to monitor in real time the variations in blast furnace gas chemical composition. The report presents the details about this technique employed, and it is showing the method and results reached. Keywords: Blast furnace; Cooling; Thermal Instability; Hydrogen Balance

Abstract:

Modern blast furnaces are equipped with latest-generation measurement technologies and process control systems to improve process understanding and achieve more stable furnace operation. This work presents measurement results following the transition from a double bell charging system to a “Bell Less Top” (BLT) configuration. The furnace under study is fitted with one of the most complete sets specific measurement systems: three-dimensional burden profile measurement with the 3D- TopScan, two-dimensional gas temperature distribution across the furnace throat with the TMT SOMA, and temperature and gas composition measurements in the burden at 12 fixed points along one radius using an in-burden lance. This paper focuses on the combined evaluation of the measurement data, which allows for more meaningful interpretation of the process conditions than analyzing individual probes. The data contribute to a more detailed understanding of furnace operation. In addition, the measurements support the greater flexibility in burden distribution afforded by the “Bell Less Top” system. The data are also used to calibrate and validate the furnace expert system. Based on the presented evaluation, the charging practice has been evolved and the process performance and stability have been improved.

Abstract:

This study investigates the fracture behavior of iron ores at a microscale using microindentation combined with optical microscopy. By applying concentrated load, crack propagation patterns were observed in different mineral phases and mineralogical associations, aiming to understand the mechanisms of crack propagation in each case. The study evaluates whether the cracks deflects along grain boundaries (intergranular fracturing), or penetrates through the phase boundaries (transgranular fracturing). Experimental results indicated a predominance of intergranular fracturing, even when crack penetration was theoretically expected. The research highlights the importance of micromechanical characterization in predicting comminution behavior and selective liberation of iron ores.

Abstract:

The purpose of this article is to describe the experience in implementing the Theory of Constraints (ToC) and Critical Chain (CCPM) in mining projects and the positive impact in value aggregation to the company

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The iron ore pelletizing industry faces constant pressure to improve productivity, product quality, and operational efficiency. This paper presents the implementation of an integrated control solution combining Advanced Process Control (APC) and real-time image analysis to optimize green pellet formation and stabilize the entire pelletizing process.The system controls six pelletizing discs that feed a roller screen and an induration furnace. Variations in feed moisture, granulometry, and mineralogy directly impact pellet formation, circulating load, and furnace feed stability. By integrating an image analysis system with APC technologies such as fuzzy logic, expert systems, and adaptive PID, the plant achieves dynamic adjustment of disc speeds to optimize pellet size distribution — particularly maximizing the percentage of pellets between 10 mm and 14 mm. Results demonstrate a significant reduction in circulating load variability, improved screening efficiency, greater furnace stability, and an overall reduction in standard deviation of key process variables. This solution represents a successful application of Industry 4.0 principles, enhancing operational performance through automation and real-time data-driven control.

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This work presents the development and implementation of a pilot project for an IoT (Internet of Things) device aimed at monitoring the proper use of safety harnesses during work at height, with a focus on verifying the attachment of lanyards. Currently, in scaffolding assembly and disassembly operations at Aperam, conventional harnesses are used, which give workers complete autonomy to attach and detach lanyards. However, this autonomy does not include a real-time alert system for leadership, which represents a critical fall risk when the harness remains unattached without supervision. In partnership with the startup Harpia Harpyja, an integrated IoT based solution was developed, comprising sensors on the lanyard hooks, an individual control unit for the operator, and fixed and mobile monitoring stations accessible to leadership. The system automatically identifies the attachment status, emits audible, vibratory, and visual alerts to the worker, and sends real-time notifications to supervisors. All interactions are recorded in a database, allowing for traceability of actions and continuous analysis of risky behaviors. The results indicate that the solution is effective in monitoring lanyard attachment, also contributing to preventive alerts and the strengthening of safety culture. In addition to reducing the risk of falls, the project promotes a more proactive and conscious approach to safety in work at height, utilizing technology as a strategic ally.

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One of the main challenges in steel plate production is the efficient storage of materials. In addition to the physical limitations of the equipment used to move materials within and between storage yards, this type of problem involves a series of constraints that increase its complexity. This study aims to propose an optimization solution for the movement of overhead cranes in storage yards at a steel plant. To this end, a heuristic is presented that can indicate the next movements of the overhead cranes with the goal of minimizing the total number of movements required to complete the loading of the steel plates. The results, obtained from real-world cases, show a reduction from five to one in the number of movements needed to complete 50% of the shipments, as well as a decrease from 15 to 6 in the maximum number of movements.

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Although there are many ways to produce oxygen for industrial use, this article focuses on two production processes: VPSA and PSA. In these processes, the molecules and impurities that make up atmospheric air pass through several pieces of equipment until they are separated, resulting in oxygen with a purity of over 90%. In addition to the operation of VPSA and PSA, this article also presents the correct operation of the backup system in which liquid oxygen from a cryogenic source is stored and vaporized (Driox) to meet the demand for the product when the gas plant is shut down or there are peaks in oxygen consumption. The study is based on technical articles and the author's experience through his activities at R. S. SANTOS – CONSULTORIA EMPRESARIAL, providing support to gas supplying and consuming companies. The study concludes that by applying the suggested recommendations, significant efficiency gains are obtained in the interrelationships of the oxygen plant with the Driox system, reducing costs related to the consumption of vaporized liquid oxygen.

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This paper presents the design, testing, and operational performance of the W5 stripper nozzle for water-cooling boxes used in high-speed rod and bar rolling mills. The W5 nozzle aims to eliminate water carryover, reduce compressed air and water consumption, and enhance process control. Laboratory and mill tests indicate up to 100% effectiveness in water containment, resulting in improved measurement accuracy, operational stability, and reduced energy and maintenance costs. Comparative analysis with traditional air- and water-operated systems reveals significant cost and resource savings, highlighting the W5 nozzle’s industrial value.

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The development of new steels is crucial for industry, as it provides stronger, more durable, and lighter materials, benefiting sectors such as automotive, construction, and aerospace. However, processing steel plates presents challenges, such as tool wear during machining. As an alternative, non-contact thermal cutting processes like plasma and laser have gained prominence. Laser cutting stands out for its speed and precision, while plasma cutting has evolved and now competes in quality with laser cutting. This study compares both methods applied to ASTM A572 Grade 50 steel plates with a thickness of 25.4 mm, evaluating kerf width, phase transformations, edge roughness, and microstructure. The goal is to identify the advantages and limitations of each technique, supporting the selection of the most efficient process suited to industrial demands

Abstract:

This work presents the development and implementation of a real-time monitoring system for the welding process of rolls in the segments of the continuous casting process. The project aims to ensure compliance with the operational parameters established in the technical procedure, promoting greater reliability, traceability, and quality control in the roll repair process.

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This study investigated the modification of photopolymerizable flexible resins through the addition of rigid resin, focusing on dental and biomedical applications using 3D printing via stereolithography (SLA). Samples with varying rigid resin contents (5%, 7.5%, 10%, and 20%) were prepared and evaluated through mechanical tests including compression, tensile strength, Izod impact, and Shore hardness. Results showed that up to 10% rigid resin significantly improved mechanical properties without compromising flexibility. Higher concentrations led to reduced toughness and increased brittleness. The research confirms the feasibility of customizing resin formulations to enhance structural performance in SLA-printed devices while maintaining elasticity for functional applications. The study also recommends future evaluation under simulated intraoral conditions and biocompatibility testing to fully validate the hybrid formulations.

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This study presents the development and application of a methodology to eliminate premature wear of the bottom cover of conveyor belts in an iron ore bucket wheel reclaimers at the Tubarão Port Terminal. The identified problem reduced the belt’s service life from 18 to just 3 months, directly impacting operational costs. The adopted methodology included field inspections, analysis of the three-body abrasive wear mechanism, and the construction of a fault tree to identify root causes. As a solution, a new impact roller design with a smaller diameter was developed, which eliminated ore buildup and roller seizure. The implementation resulted in the elimination of bottom cover wear, a significant increase in belt service life, and approximately 80% reduction in maintenance costs. The results prove the effectiveness of the approach in improving asset reliability and optimizing operational costs.

Abstract:

The Commercial Calcium Carbide is an alloy composed mainly by calcium carbide (CaC2) and lime (CaO). The CaC2 is used as reagent for the formation of acetylene gas, but it has great affinity with the oxygen and sulfur from the bath of steel. For this reason, this alloy is applied in steelmaking process a deoxidizer and desulfurizer. As deoxidizer has a great advantage, which is the formation of CO and lime in its deoxidation reaction. CO promotes agitation in the bath, helping to remove inclusions. The lime is a basic phase that is less aggressive to the refractory, such SiO2 and Al2O3, formed by the traditional deoxidizer used in steelmaking, FeSi, FeSiMn and Aluminum. In relationship to aluminum, the CCC is a less expensive alloy and for its technical reasons could replace the aluminum reducing meltshop cost. In a Brazilian steelmaking mill was tested the CCC application at the tapping process. The quantitative and qualitative effects of this practice was observed and related in this paper.

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Steelmakers need to identify the most effective mix of scrap, pig iron, HBI, and DRI depending on the required steel grades and availability of resources in the area. Utilizing scrap metal significantly reduces the need for raw materials, lowering production costs and environmental impact. This shift is driving the development of new equipment designed specifically for steel mills, as well as the adoption of advanced technologies (e.g. PGNAA analyzer) to increase the utilization of scrap also for high quality steel grades. Steel mills are increasingly investing in these technologies to optimize their operations and meet growing demands for eco-friendly steel production.

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This study proposes a Machine Learning-based model to predict the density of carbon steels at ambient temperature using only their chemical composition. The model was trained on density data from more than 190,000 slabs, calculated using measurements from slab balances and laser-based dimensional scanning. Data preprocessing included outlier filtering via the Isolation Forest algorithm and feature selection through Recursive Feature Elimination, which identified the key alloying elements influencing density. The density values were discretized into 11 classes to facilitate implementation in industrial systems. The Decision Tree Machine Learning model achieved a mean absolute error of approximately 0.27%, with high accuracy and low false prediction rates. This methodology enables more precise steel density estimation in critical applications, enhancing automation, logistics, and quality control in steel production environments. The model was exported as a conditional logic structure, allowing seamless integration into operational systems without requiring external libraries. The results highlight the need for advanced predictive tools to replace fixed-density assumptions, even under standardized production conditions.

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This article provides an overview of the state of the art in spodumene beneficiation, a lithium-rich mineral. The main concentration methods used, such as flotation, dense medium separation, and magnetic separation, are discussed. Dense medium separation is efficient for pre-concentration of spodumene, while flotation is used to recover the mineral in fine fractions or when there are contaminants that cannot be separated by dense medium. Magnetic separation is employed to remove gangue minerals containing iron. The article highlights the challenges faced by the industry, such as the presence of contaminants and various lithium-bearing minerals. It also identifies knowledge gaps and potential research areas for optimizing and sustaining spodumene beneficiation. The methodology adopted consisted of a systematic review of scientific and technical literature, using databases such as Scopus, Web of Science, and Google Scholar. The research was conducted rigorously and systematically, analyzing and synthesizing relevant studies to provide a comprehensive overview of the state of the art in spodumene beneficiation.

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This study aimed to estimate the partitioning of products from an iron ore plant by predicting the particle size distribution of the crushing product, focusing on Gran, SintG, SintF and Finos products. 54 samples from 6 different lithologies were analyzed, subjected to standardized crushability tests and sieving, and modeled using the Schumann model, with the parameters adjusted to simulate industrial conditions. Lithologies B, E and F, which have higher silica contents, showed higher Gran generation. The partitioning of SintG and SintF products showed little variability depending on the lithology. Finos performed antagonistically to Gran. The B, E and F lithologies did not have high Fe contents for the Gran and SintG products, and the F lithology also had low Fe contents for the SintF and Finos flows. Thus, it can be seen that the different lithologies have a significant impact on the partitioning and quality of the products, highlighting the importance of the geometallurgical approach for iron ore plants.

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Corporations have undergone changes in the ways they measure their businesses in recent decades, such as the incorporation of practices and indicators known as ESG (Environmental, Social and Governance). In the specific case of the mining and metallurgical sector, relations with directly or indirectly impacted communities have now acquired a strategic dimension in managers' plans. It is no longer possible to make certain operational decisions without considering the interfaces of the links between society and mining. Therefore, an alternative way to think about and build the community/company relationship may be through university extension. Therefore, DEMIN/UFOP, IFMG (Ouro Preto campus), the Aleijadinho Municipal School and the company Solenis developed the extension project “Centro Cultural do Salto”, with the following main objectives: a) to bring together federal educational institutions (UFOP and IFMG), companies (Solenis) and the community of the village of Santo Antônio do Salto (Ouro Preto-MG); b) to encourage and expand interest in reading; c) to value the people, the culture and the local knowledge and practices; c) to support actions of citizenship, popularization of science and heritage education. After almost 5 years of existence of the project, the result has been a more organic relationship between the partners and a series of actions such as, for example, the renovation of the Mothers' Club; the creation of a website to promote the village and its people; the donation of a stone fountain; the donation of computers and a mineral collection to the Aleijadinho School; pedagogical workshops; educational tours in the city of Ouro Preto and in the facilities of UFOP and IFMG

Abstract:

The presence of talc associated with polymetallic sulfide deposits presents an operational challenge. The Aripuanã metallurgical plant, operated by Nexa Resources, produces sulfide concentrates of Copper, Lead, and Zinc. In addition to the three flotation circuits dedicated to the concentration of these target metals, there is an additional talc pre-flotation circuit designed to remove hydrophobic gangue contamination, generating a non-economic stream rich in talc, operationally referred to as the talc concentrate The efficiency of talc removal is measured by the amount of recovered mass, routinely classified as hydrophobic gangue mass, and by the metal losses of copper, lead, and zinc. Under challenging conditions with increased talc presence, this study aims to conduct a preliminary evaluation of bench-scale flotation tests using three talc flotation circuit configurations. The study concludes that a circuit incorporating a double Rougher stage followed by a Bulk sulfide flotation stage is the most efficient configuration for gangue removal while maintaining low metal losses. Keywords: Talc flotation; Talc and Chalcopyrite separation; Batch flotation

Abstract:

The growing demand for the development of clean energy has made some metals essential to this challenge, with lithium being essential for the production of battery components for electric vehicles, as these are capable of storing a greater amount of energy using a smaller amount of metal. Lithium-bearing pegmatites, important sources of lithium, are composed of spodumene, feldspar, mica, and quartz, in addition to the elements beryllium, tantalum, tin, and cesium. Mineral characterization carried out through chemical and mineralogical analyses, in addition to the survey of physical properties, allows the creation of a new beneficiation route or the improvement of an existing process. Thus, this study aimed to characterize a specific lithiniferous pegmatite from the Araçuaí-MG region for future technological tests. From the diffractometry results obtained, it was revealed that the sample contained 94.9% spodumene and 5.1% quartz. Some mineralogical particularities of the spodumene were evidenced in the visualizations via optical microscope. The average specific mass of the sample was 3.12 g/cm3, consistent with literature data. The chemical analysis, preceded by calculations revealed that the percentage of lithium reach 3.50% in the sample, in addition to Al2O3 (28.29%) and SiO2 (61.52%), accompanied by CaO, MnO, Fe2O3, K2O, MgO, and TiO2.

Abstract:

The growing need for sustainable and economically viable solutions for railway infrastructure drives the search for new materials that can reduce environmental impacts and operational costs. This study investigates the feasibility of geopolymers formulated from iron ore extraction residues as an alternative to concrete and treated wood in railway sleepers. In this work, a fine iron ore residue (d₉₈ < 50 µm) was characterized and activated with sodium metasilicate. Wavelength-dispersive X-ray fluorescence (WDXRF) analysis identified Fe₂O₃ (74.68%), SiO₂ (19.08%), and Al₂O₃ (4.42%) as the main constituents. X-ray diffraction (XRD) and Fourier-transform infrared spectroscopy (FTIR) analyses confirmed the presence of quartz, goethite, hematite, and surface hydroxyl groups, while scanning electron microscopy with energy-dispersive spectroscopy (SEM/EDS) revealed angular particles with high surface area. Thermogravimetric and differential scanning calorimetry analyses (TGA/DSC) indicated multi-stage mass losses due to dehydration and dehydroxylation, culminating in the formation of hematite around 700 °C. After curing and calcination (200–800 °C), the diffractograms revealed the development of partially crystalline Na/ASH- and I/ASH-type phases. Transient sodium-containing phases were observed between 300 °C and 700 °C but disappeared at higher temperatures.

Abstract:

In integrated steel manufacturing plants, by-product combustible gases from industrial processes constitute a large part of the energy balance for this type of company, enabling greater sustainability, energy efficiency and cost reduction regarding fuels purchasing. However, the generation and distribution processes of these gases represents risks of fires and explosions potentially catastrophic for people, assets, and industrial operations. Therefore, these activities require monitoring and strict control of quality parameters in order to act in a preventive manner to avoid the formation of explosive gas mixture. In this context, the Limiting Oxygen Concentration (LOC), according to the standard No. 69 of 2019 National Fire Protection Association (NFPA 69 - 2019), is reinforced as the main control parameter of combustible gas explosivity. Particularly for mixtures with varied composition the determination of this parameter becomes fundamentally more complex according to the number of combustible compounds, since each type needs a different oxygen ratio for the mixture to become flammable. In this work, technically based on the NFPA 69 – 2019 standard, the LOCs of typical compositions for Coke Oven Gas (COG), Blast Furnace Gas (BFG) and Linz Donawitz Gas (LDG) are presented from data collected in these utilities’ distribution processes at integrated steel plant in northeast of Brazil. Based on the guidelines of the same standard, safety recommended levels are presented for installations and equipment Continuously Monitored and Controlled by Safety Interlocks (CMCSI) and non-CMCSI.

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The growth of the low-carbon economy has intensified interest in green hydrogen production technologies via water electrolysis. This patent-based review explored the use of zirconium oxide (zirconia) in electrolytic systems. A total of 23 documents (2011–2024) were analyzed, showing marked growth from 2021, mainly in China. The majority of applications focus on anion exchange membranes (AEMs), followed by polymer electrolyte membrane (PEM) and solid oxide electrolyte (SOE) technologies. Chinese energy companies and European equipment manufacturers lead inventive activity. Zirconia stands out as a strategic material for electrochemical components such as membranes and electrodes. However, large-scale adoption still faces technical and commercial challenges, requiring coordinated action among applied research, industrial development, and public policy support for innovation.

Abstract:

This study focuses on optimizing the feeding control system of Concentrator 3 (C3) at Samarco Mineração, aiming to reduce mass flow variability and enhance operational efficiency. Control strategies such as PI, PID, feedforward, and fuzzy logic were tested, alongside physical modifications like frequency inverters and sensors. The results showed that the combination of fuzzy logic with feedforward control was the most effective, reducing variability by 30.39% and achieving a final coefficient of variation of just 2.41%. The implemented solution delivered significant operational gains, with an estimated financial impact in the millions of reais annually.

Abstract:

A patent mapping was conducted with the aim of exploring the main trends in the development of technologies related to the reuse of waste in polymeric composite materials. The research was based on identifying patent applications in the WIPO (Patentscope) and INPI databases by using a combination of keywords and codes from the International Patent Classification (IPC) to conduct the searches. The quantity of applications by country and the distribution of the number of filings over the years were evaluated. There was no time restriction for the country-specific search. For the analysis of the temporal distribution of filings, the interval between 2016 and 2025 was adopted. The results indicated promising trends in research and development of polymeric composites, with emphasis on those produced from agro-industrial waste (biomass) and recycled polymeric waste. It was found that China and the United States obtained the highest numbers of filed patents related to the technologies under study. It was also possible to evaluate that Brazil is in a strategic position in the development of eco-composites, however there is a lack of technologies for transforming the produced composites into higher value-added products.

Abstract:

This study evaluated the thermal and mineralogical behavior of mixtures composed of lateritic soil and iron ore mining waste, aiming at the production of artificial aggregates. Mixtures containing 30% and 50% mining waste were subjected to calcination at 700 °C, 800 °C, and 900 °C. X-ray diffraction (XRD) and thermogravimetric analysis (TGA/DTG) were employed to assess the main mineralogical transformations. The dehydroxylation of clay minerals was observed from 700 °C, leading to the formation of metakaolinite. At 800 °C, partial reorganization of the amorphous matrix into semicrystalline phases occurred, while at 900 °C, crystallization of denser and more stable structures predominated. The mixture with 30% mining waste exhibited higher thermal and mineralogical reactivity, indicating potential for applications as a cementitious material or sintered aggregate. In contrast, the mixture with 50% mining waste remained thermally more stable, characterized by the predominance of silica and magnetite, making it more suitable for the production of granular aggregates for structural applications. The temperature of 800 °C proved to be the most efficient condition, promoting significant mineralogical transformations with lower energy demand, in line with the principles of the circular economy.

Abstract:

This study evaluates the tribological performance of re-industrialized linings applied to tertiary crushers of an iron ore beneficiation plant in the Iron Quadrangle (MG). The re-industrialized linings, containing 40% of reused alloy, were compared with linings produced in virgin alloy based on literature data and field operational analysis. Microhardness tests, optical microscopy and SEM were used to characterize the wear mechanisms. The results indicated similar wear patterns, such as abrasion damage and concave impact. The estimated service life was ~900 hours for both linings. The sustainable pair maintained equivalent mechanical and tribological properties, being approved techniques. In addition, its application contributes to the circular economy, cost reduction (~18%), consumption of natural resources and environmental impacts.

Abstract:

This study aimed to evaluate the adsorption capacity of synthesized 4A zeolite for the removal of Cu²⁺ ions from aqueous solution, using the Langmuir, Freundlich, and Sips isotherm models to interpret the system's behavior at different temperatures. The methodology involved the synthesis of 4A zeolite followed by adsorption experiments conducted at 25 °C and 90 °C. The experimental data were fitted to the models using linear regression, and the determination coefficients (R²) were used to assess the quality of the fit. The Langmuir model indicated monolayer adsorption on a homogeneous surface, with R² values of 0.963 at 25 °C and 0.972 at 90 °C. The Freundlich model, which assumes heterogeneous surfaces, showed slightly lower R² values. The Sips model, which combines the assumptions of both Langmuir and Freundlich, provided the best fit to the experimental data, with R² values of 0.9814 at 25 °C and 0.9890 at 90 °C. The exponent n values close to 1 confirmed predominantly monolayer adsorption with slight heterogeneity. It is concluded that 4A zeolite is effective in Cu²⁺ removal, and the Sips model is the most suitable to describe the adsorption process, indicating an endothermic mechanism favored by increased temperature.

Abstract:

This paper offers a detailed analysis of the reliability of electrostatic precipitators (EPs) used in VALE's pelletizing plants in Tubarão, Espírito Santo, Brazil. The case study addresses failure analysis methodologies, customized technical specifications tailored for the mining environment, the development of operational logics for rectifier transformers (T/Rs) to mitigate visible particulate matter emissions into the atmosphere, as well as the implementation of Internet of Things (IoT) technologies for monitoring and supporting predictive inspection routines. These initiatives have resulted in fewer T/R failures and greater availability of VALE's electrostatic precipitators. EPs play a crucial role in reducing pollution and emissions in industrial facilities, and technologies of this nature are increasingly gaining investment and prominence in order to meet environmental obligations essential for the preservation of the planet. However, failures in EPs can compromise their effectiveness and operational performance, potentially leading to catastrophic environmental events that degrade local air quality and impact surrounding communities due to the excessive release of particulates into the atmosphere. To mitigate such occurrences, the main types of failures observed in T/Rs are initially examined. Based on a history of failures and the analyses conducted, it becomes possible to identify causes and risk factors and propose measures to enhance the reliability of EPs. These include improving the management of insulating oil sampling and analysis in T/Rs, seeking solutions with manufacturers to ensure asset reliability, adopting stricter technical specifications, reviewing operational and maintenance procedures for EPs, providing adequate training to involved personnel, and implementing monitoring systems that support failure prediction. Finally, this study presents the results of effective maintenance management, emphasizing the importance of a thorough maintenance and reliability engineering approach—particularly focused on T/Rs within electrostatic precipitators—to minimize failures and ensure the consistent performance of these critical systems, thus contributing to industrial processes aimed at long-term sustainability.

Abstract:

This article presents the diagnosis and actions implemented to increase the reliability of the starch and lime pneumatic conveying system at Samarco. Based on historical maintenance data and Pareto analysis, most failures were found to be concentrated in valves and field instruments. Solutions included the implementation of protected control panels, reorganization of instrumentation layout, and technical list updates. The results showed a reduction in failures, improved system availability, and increased maintenance efficiency. The adopted methodology demonstrates potential for replication in other industrial areas with similar systems.

Abstract:

This study evaluated the effect of cold sintering on hydroxyapatite (HAp) with 4% niobium-phosphate glass (BV), compared to the conventional method. Cold sintering, performed at only 150 °C, promoted up to a 22% increase in densification compared to conventional sintering at 1100 °C, while preserving the HAp phase without significant β-TCP formation. Samples sintered by the cold process exhibited a more homogeneous microstructure, higher surface area, smaller crystallite size, and lower porosity, due to the dissolution–reprecipitation mechanism intensified by the presence of BV. The results highlight the potential of cold sintering as an efficient and sustainable route for processing bioceramics.

Abstract:

To obtain pure aluminum, factories use processes such as the Bayer process, wich transforms bauxite ore into alumina. However, this process is not very efficient, as it generates a large amount of waste red mud wich poses a serious environmental problem, especially considering that most alumina producing plants are located in the Amazon region. To mitigate this issue, the use of bauxite residue in geopolymers has become a viable alternative. However, to enable the full utilization of bauxite residue whose composition varies depending on the origin and type of ore it is essential to analyze its microstructure. In this context, the present study evaluated the reactivity of bauxite residue from the state of Pará using X-ray diffraction (XRD) and Rietveld refinement, as well as its potential to be used as a precursor material in geopolymer production. The main phases identified by XRD were kaolinite, gibbsite, hematite, and quartz, and through Rietveld refinement, kaolinite was revealed as the major phase in the residue. The residue still proves to be viable for use as a geopolymeric precursor, especially when subjected to thermal treatments and the addition of silicon-rich materials, as proposed in other studies.

Abstract:

Studies focused on the use of agro-industrial residues in construction materials have intensified, especially given the need for sustainable alternatives to the raw materials used in Portland cement production, which has a significant environmental impact. In this context, this work investigated the feasibility of incorporating açaí seed ash as a partial replacement for Portland cement in cementitious mortars. Mixtures were produced with ash contents of 0%, 1%, and 2% by mass of cement, using the proportion 1:1:6:1.34 (cement: lime: sand: water). The ash was characterized by X-ray diffraction (XRD) to identify possible reactive crystalline phases. Subsequently, fresh-state properties were evaluated, with an emphasis on workability and bulk density. The results indicated that the incorporation of the ash reduced mortar flowability and increased bulk density in the fresh state. It is concluded that açaí seed ash has potential for use as an additive in cementitious matrices, and further studies are recommended to assess its performance in hardened-state properties and durability aspects.

Abstract:

Biomass ashes are used as supplementary materials in the cement industry, offering advantages such as reduced environmental impact and improved concrete properties. To make use of these residues, processes such as calcination, grinding, and sieving are necessary, as they influence the material&#39;s characteristics and reactivity. Therefore, understanding these processing conditions is essential to enhance their potential as a partial substitute for cement. In this study, ashes obtained from coffee husk residue were characterized after calcination at three different temperatures (550 °C, 650 °C, and 750 °C) and sieving. Subsequently, three cement pastes were produced by replacing 5% of Portland cement CP II-F with each type of ash, keeping the water-to-cement ratio at 0.5. Viscosity and consistency tests were conducted using the mini-slump method. The results indicated that higher calcination temperatures led to greater solubility and variations in ash density. Pastes containing ashes calcinated at higher temperatures showed higher viscosity and * Contribuição técnica ao 78º Congresso Anual da ABM – Internacional, parte integrante da ABM Week 9ª edição, realizada de 09 a 11 de setembro de 2025, São Paulo, SP, Brasil. lower spread, suggesting that finer and more porous particles resulting from intense calcination negatively affect the workability of the system.

Abstract:

Oil well cementing requires minimum performance standards in both the fresh and hardened states to ensure effective structural support for the casing. In response to decarbonization efforts within the cement industry, research has increasingly focused on alternative binders capable of meeting the same requirements, particularly in terms of workability, mechanical strength, and durability. Alkali-activated systems have emerged as a promising solution, although their formulation must take into account key parameters such as viscosity, density, thickening time, and early strength development under variable temperature conditions. These factors are directly related to the depth and operational context of the well. This study investigates the rheological and mechanical behavior of geopolymeric pastes formulated with metakaolin, fly ash, and granulated blast furnace slag, aiming to identify technically viable combinations for primary or secondary cementing applications in oil wells. The results indicate that slag content is the critical variable influencing performance.

Abstract:

This study presents an experimental and comparative analysis of the failure modes of pressed and fired ceramic blocks (BPQ), aiming to understand their structural performance under different loading conditions and construction arrangements. Interlocking male-female blocks were tested in isolation, as well as in prisms and small walls, under both dry stack and mortared conditions. The observed failures were predominantly brittle, characterized by longitudinal cracking, crushing of the lower blocks, and the formation of rupture cones. The results were compared with literature data on extruded and concrete blocks, revealing marked differences in failure patterns and highlighting the influence of internal geometry, bonding configuration, and thermal conditions. These findings support the development of specific constitutive models and contribute to the formulation of technical standards more appropriate for the structural use of such components.

Abstract:

This study presents an experimental analysis of the structural behavior of masonry prisms constructed with pressed and fired clay blocks (BPQ), evaluating the influence of constructive parameters such as geometry (use of full or half blocks), the presence of mortar in the horizontal joints, and prism height (three or five courses). Eight distinct groups were produced, totaling 48 specimens, and uniaxial compression tests were carried out in accordance with ABNT NBR 15812-2:2010. The results showed that the presence of mortar led to slight increases in average uniaxial compressive strength and longitudinal stiffness; however, these variations were not statistically significant at the 5% level. The use of half blocks resulted in a significant reduction only in three-course prisms without mortar. The characteristic compressive strength values (fpk) ranged from 1.55 MPa to 1.99 MPa. Statistical analyses (ANOVA and Student’s t-test) and prism-to-block efficiency factors (ηₚ ranging from 0.43 to 0.57) confirmed the stability and reproducibility of the BPQ units for structural masonry applications. It was verified that the evaluated constructive parameters have a limited influence on the mechanical performance of ceramic prisms.

Abstract:

Ballistic impact is a dynamic and multifaceted phenomenon that involves the interaction between high velocity projectiles and target-materials, being of extreme importance to the fields of defense and security. The comprehension of the mechanisms of penetration, perforation and energy dissipation is essential for the development of more effective protective structures, like personal and vehicular shielding, other than applications in civil engineering. This analytical study revisits and has as an objective to consolidate the main recent advancements in the field of ballistic impacts, focusing in the characterization of materials, analytical modeling, experiments and computational simulations. The properties of differing classes of materials – like ceramics, composites, metal alloys and hybrid structures – are explored, and the approaches used to optimize their performance in high energy impacts, contributing to the enhancement to solutions to ballistic protections that are lighter, more resistant and efficient.

Abstract:

Weight loss is a known phenomenon in the sintering of silicon carbide (SiC) sintered via liquid phase, which compromises its thermomechanical properties. The objective of this work is to study the weight change of the carbide at low temperatures in the presence of its most common additives, before the start of sintering. Compositions of SiC with alumina (Al2O3), SiC with yttria (Y2O3) and with the three compounds simultaneously were prepared. The thermal stability of the samples was evaluated by thermogravimetric analysis (TGA), under an inert argon atmosphere and scanning electron microscopy (SEM). The thermogravimetric tests performed under different conditions revealed that the thermal stability of the evaluated systems is strongly related to the sample composition and heating conditions. The combined addition of Al2O3 and Y2O3 proved to be the most effective in inhibiting weight loss and oxidative processes, promoting stability even under prolonged isothermal conditions. The results obtained are consistent with the literature, reinforcing the potential of the ternary system as an advanced ceramic material with excellent thermal and chemical resistance.

Abstract:

Yttria-stabilized zirconia is widely used as a biomaterial in dentistry due to its excellent mechanical properties and biocompatibility. In this study, 24 samples of 5Y-PSZ zirconia were prepared using different compaction conditions and heat treatments, with temperatures ranging from room temperature to 1500 ºC. The methodology involved compacting the ceramic powder under varying pressures, followed by controlled sintering. To characterize the obtained samples, relative density measurements were performed using the Archimedes method, Vickers microhardness tests, and analysis of the wettability of the ceramic surfaces. The results revealed that compaction pressure directly influenced the densification of the material. Furthermore, it was observed that samples subjected to a slower heating rate during sintering exhibited more homogeneous microstructures and higher mechanical strength, resulting in improved wettability. This indicates that the heating rate plays a fundamental role in the final quality of the material. It is concluded that the proper control of these parameters is essential to optimize the mechanical and functional properties of 5Y-PSZ zirconia, making it even more effective under clinical conditions.

Abstract:

The construction sector consumes about 40% of the planet's natural resources, with one-third allocated to the production of cement-based materials. In search of more sustainable alternatives, geopolymers have stood out for their energy efficiency and lower environmental impact, especially when produced using industrial residues. In this context, diatomite emerges as a promising precursor due to its high silica content, large surface area, and pozzolanic nature. Based on these factors, this study evaluated the feasibility of using diatomite as the sole precursor in the production of geopolymers, using sodium hydroxide (NaOH) and potassium hydroxide (KOH) as activators. X-ray fluorescence, flow table, density, compressive strength, and diametral shrinkage tests were performed. Chemical analysis showed a high silica content and low alumina proportion. Fresh-state tests indicated lower spread for KOH-activated mortars, suggesting lower fluidity. In the hardened state, KOH-activated samples showed compressive strength approximately five times higher than those with NaOH, in addition to lower diametral shrinkage (18.4% vs. 28.3%). Despite higher apparent density in NaOH samples, they exhibited greater shrinkage and lower mechanical strength. The results demonstrate that the type of activator directly affects material properties, with KOH being more effective for this diatomite-based system. Further studies are recommended to better understand the reaction mechanisms and optimize the formulation.

Abstract:

This study aims to investigate the use of recycled mortar aggregates from renovation works as coarse aggregates in the production of permeable concrete slabs. The waste material was crushed and classified into three particle size ranges, equivalent to gravel types 0, 1, and 2. Prismatic and cylindrical specimens were molded using CP II E–32 cement in a 1:4 ratio (cement:aggregate). The samples were evaluated in terms of water absorption, porosity, specific mass, permeability, and compressive strength. The results showed that the blocks produced with recycled aggregates exhibited good permeability, meeting the minimum values required by NBR 16416:2015. However, the compressive strength remained below the standard requirements for permeable pavements, indicating the need for mix adjustments or the addition of pozzolanic materials to improve the cementitious matrix. This study highlights the potential of reusing construction and demolition waste (CDW) as a sustainable alternative for the production of permeable pavements with lower environmental impact.

Abstract:

Carbon-based materials such as graphite, graphene nanoplatelets (gNPs), and graphene oxide (GO) have attracted significant attention due to their outstanding properties and broad applicability in advanced fields such as nanocomposites, electronics, and sensors. The morphological structure of these materials directly influences their physicochemical behavior and, consequently, their performance in technological systems. In this context, the present study presents a comparative morphological analysis of these three allotropic forms of carbon using complementary characterization techniques: Atomic Force Microscopy (AFM), which provides nanometric vertical resolution and topographic mapping; Scanning Electron Microscopy (SEM), which offers high-resolution imaging with topographic contrast; and X-ray Diffraction (XRD), which reveals crystalline structure information. The samples were deposited on silicon substrates and analyzed in terms of roughness, size distribution, and surface conformation. The results reveal distinct morphological features: graphite shows large lamellar particles with more than 55 layers; gNPs exhibit more delaminated and thinner structures with fewer than 40 layers; while GO presents isolated, highly exfoliated sheets with fewer than 10 layers. These findings highlight the importance of morphological characterization for the rational selection and application of carbon derivatives in advanced multifunctional systems.

Abstract:

In this study, a kaolinitic clay from Campos dos Goytacazes, RJ, Brazil, and cocoa powder residue were characterized as raw materials for additive manufacturing via 3D printing. The raw materials were prepared and analyzed using X-ray Fluorescence (XRF), X-ray Diffraction (XRD), Scanning Electron Microscopy (SEM), and Linear Dilatometry, in order to assess their composition and suitability for processing. The goal was to optimize the printing parameters by understanding the physicochemical properties of both materials. Additive manufacturing is a cost-effective and accessible technology that has already been applied in coral reef restoration and ecological research. Therefore, the thorough characterization and analysis of raw materials are essential for enhancing the performance and functional properties of the printed ceramic components.

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

Abstract:

The ceramic industry plays an important role in the economy of several regions in Brazil but still shows potential for expansion in areas with favorable conditions. In the southern region of Espírito Santo, particularly in Marataízes, ceramic activity remains limited, despite its proximity to Cachoeiro de Itapemirim, the country’s leading ornamental stone processing center. This study aimed to characterize clays from four deposits in Marataízes to assess their suitability for use in the local ceramic industry, focusing on the incorporation of ornamental stone cutting waste from Cachoeiro de Itapemirim. The samples underwent physical characterization (Atterberg limits, particle density, and grain size distribution) and chemical analysis (X-ray diffraction and efflorescence testing). The results showed that two of the analyzed clays have properties similar to those used in the ceramic industry of northern Rio de Janeiro, indicating potential for application in Marataízes. It is concluded that the use of these clays, combined with the reuse of waste from the ornamental stone industry, can contribute to the sustainable development of the ceramic sector in the region

Abstract:

This study investigated the feasibility of using ornamental rock waste as an additive in coating mortars, focusing on its properties in the fresh state. Formulations were developed in proportions of 20%, 40% and 60%, using a base composition of 1:1:6 (cement:lime:sand) by mass. The tests were conducted in accordance with current Brazilian technical standards (ABNT), including tests for consistency, density, entrained air content and water retention. The results demonstrated that the addition of the waste promoted a reduction in the water demand to achieve the desired consistency, in addition to increasing the density of the mortar. A favorable behavior in water retention was also observed, which contributes to the performance of the mortar during curing. The data obtained indicate that the controlled use of this waste can represent a viable and sustainable alternative in the formulation of mortars, aligning technical performance with environmental benefits.

Abstract:

Lime is a widely used binder in civil construction due to its contribution to workability, water retention, and mortar durability. However, the influence of the commercial origin and composition of hydrated lime on mortar consistency still lacks in-depth investigation. This study aimed to evaluate the consistency of mortars containing type CH-III hydrated lime from four different commercial brands, through the consistency index test according to NBR 13276. The mortars were prepared using a mass ratio of 1:1:6 (cement:lime:sand). The results showed that the addition of lime increased the plasticity of the mixture, allowing the standard consistency to be achieved with lower volumes of water. Brand B showed the best performance, requiring only 250 mL of water, while the lime-free formulation demanded 450 mL. The differences observed between brands indicate variations in the physical-chemical composition, fineness, and reactivity of the limes, which directly impact workability. The consistency index test proved to be an effective tool for evaluating the influence of lime on mortar plasticity, providing technical support for the selection of materials in plastering and bedding applications in civil construction.

Abstract:

This study investigated the effect of phosphoric acid (H₃PO₄) concentration and molarity on the cold sintering process (CSP) of hydroxyapatite (HAp), aiming to produce densified ceramic materials at low temperatures. Samples containing 5% and 10% by weight of H₃PO₄, at 1M and 2M concentrations, were cold sintered at 200 °C under 600 MPa for 30 minutes. Characterization was performed using X-ray diffraction (XRD), scanning electron microscopy (SEM), density tests, and flexural strength measurements. Results indicated that the 10% H₃PO₄ at 1M formulation achieved the best combination of crystallinity, densification, and mechanical strength. In contrast, higher molarity (2M) inhibited crystal growth and promoted the formation of amorphous phases with increased specific surface area. CSP proved to be an effective and energy-efficient alternative for fabricating biomedical ceramics, with potential for sustainable applications and the development of ceramic matrix composites containing polymer phases. The process significantly reduces energy consumption and enables the preservation of heat-sensitive materials, positioning CSP as a promising platform for advanced materials engineering.

Abstract:

The study of concrete degradation due to chloride attack is a highly recurrent pathology, given the need for reinforced concrete constructions in environments susceptible to such pathology, such as the marine environment. That said, this article seeks to study and analyze the influence of the water/cement ratio in mortars in situations of degradation by sodium chloride. The action of chloride ions has been identified as the main mechanism of deterioration of reinforced concrete structures. The entry of such ions into the structure can cause corrosion of the reinforcement in a punctual and quite aggressive manner, since the ions are not consumed in the process. The article consists of detailing the analysis of the preparation of mortars in test specimens that will be subjected to curing in an aqueous lime solution and the other half in a solution with chloride attack. In addition to this process, the variation in mass of the samples is measured, being measured before the samples undergo the degradation process. The process continues with the rupture test of the bodies by compression, using the universal testing machine. This article examines the chloride ion attack process, with water, microcracks and the availability of this compound responsible for enabling the mortar degradation process and, consequently, the aggravating factor of this pathology, which would be its arrival at the reinforcements. The water/cement ratio is related to this attack, as these components are directly proportionally correlated: the higher the water/cement ratio, the greater the porosity of the mortar, providing, as explained, the degradation process by sodium chloride. The same scenario is repeated when comparing the water/cement ratio with the loss of mass. And, finally, the last factor to be analyzed: compressive strength. This, in turn, unlike the other experiments, is inversely proportionally related to the water/cement factor. That said, from this article it can be concluded that the water/cement ratio has a great influence on the performance of mortars exposed to sodium chlorides. Samples with a higher water/cement ratio showed a greater loss of mass after the chloride attack. This can be explained by the greater quantity of free water in the cement mixture, which, when evaporated, creates cavities that facilitate the penetration of chloride ions. The ions react with portlandite and form calcium chloride, a compound that is easily solubilized and removed, leading to the loss of mass of the mortars.

Abstract:

This study presents the synthesis of alumina via the sol-gel route, targeting biocompatible applications. The process employed Al(NO₃)₃·9H₂O, C₆H₈O₇, 30% NH₄OH, and deionized water. Following gel formation, the sample underwent only thermal drying, without calcination or sintering steps. Structural characterization was conducted by X-ray diffraction (XRD), with phase identification performed using HighScore Plus software and the ICDD PDF-2 database. Five phases were identified: diaspore (42.0%), corundum (25.5%), bayerite (24.0%), gibbsite (7.0%), and a cubic phase (1.5%), attributed to the possible presence of γ-Al₂O₃. The average crystallite size was estimated at 64.2 ± 26.1 nm using the Scherrer equation based on 23 diffraction peaks. The results indicate a multiphasic material in a transitional state. This represents the initial stage of a broader investigation, which will include sintering, further structural characterization, morphological analysis, and purity assessments aimed at application in advanced systems

Abstract:

This study aimed to characterize kaolinitic clays from Campos dos Goytacazes – RJ, Brazil, for their potential application as supplementary cementitious materials (SCMs) after calcination. Physical, chemical, mineralogical, and thermal analyses were carried out, along with pozzolanic reactivity tests, to assess the potential of these clays in forming metakaolin. The techniques employed included X-ray diffraction (XRD), differential thermal and thermogravimetric analysis (DTA/TG), as well as electrical conductivity and calcium hydroxide fixation tests. The results showed that the clays have a high kaolinite content and, after calcination at 500 °C, developed an amorphous structure with significant pozzolanic reactivity. All samples exceeded the reference thresholds in the reactivity tests, confirming their technical viability as partial replacements for Portland cement. The use of these calcinated clays represents a promising and sustainable alternative for the construction industry.

Abstract:

This study aimed to characterize ornamental stone processing residue (OSPR) and evaluate its application in cementitious matrices, focusing on fresh-state properties. Physical, chemical, mineralogical, and morphological characterizations of the residue were conducted, along with consistency and water retention tests for different replacement levels of natural sand by OSPR. The results showed that the residue is predominantly silico-aluminous, with a high silica content (87.02%) and irregular morphology, consisting mainly of fine particles within the silt fraction. Progressive replacement increased the water demand to maintain the same consistency, especially at higher substitution rates. However, all mortar mixes exhibited water retention above 90%, indicating good workability. It is concluded that OSPR has potential for use in mortar formulations, contributing to sustainability in the construction industry.

Abstract:

This study investigates the synthesis and structural characterization of potassium ferrite (KFeO₂) produced by cold sintering process (CSP). The samples were characterized using X-ray diffraction (XRD), FTIR spectroscopy, and Raman spectroscopy at different calcination temperatures (300 °C, 550 °C, 750 °C, and 950 °C). The XRD results confirmed the formation of the KFeO₂ phase, with increased crystallinity as the calcination temperature increased. FTIR spectroscopy revealed the progressive elimination of organic compounds, while Raman data showed the formation of octahedral Fe–O structures, confirming the evolution of the crystalline network. The combined techniques validated the efficiency of the cold sintering process and provided insights into the structural transitions of the material.

Abstract:

This work investigated the manufacture of ceramic-polymer composites by 3D printing via DLP (Digital Light Processing), using commercial transparent resin in as-received condition and with the incorporation of yttria-stabilized zirconia (3Y-TZP) in proportions of 5% and 10% by weight. The ceramic powder was dispersed in a rotary mixer at a low stirring speed for 60 minutes. Specimens were designed in the shape of disks (20 mm in diameter, thickness between 0.8 mm and 1.5 mm) and cylindrical pins (6.8 mm × 12 mm) and printed on a Flashforge Hunter 3D Printer. The printed parts were then dried, washed and subjected to UV curing for 20 minutes. The samples were characterized using Shore D hardness tests and spectrophotometry to assess translucency (e=1mm). The addition of 5% and 10% ZrO2 resulted in a reduction in hardness from 79.07 Shore D to 74.74 and 70.60 Shore D, respectively. While the contrast ratio varied from the commercial condition of 0.21 to 0.63 and 0.73 respectively with the addition of 5 and 10% ZrO2. The results indicate that the addition of zirconia in these proportions to this type of resin, without prior functionalization of the surface, partially compromises mechanical properties such as compressive strength and hardness, but provides an increase in opacity, making it promising for applications where optical modulation towards something opaquer is desirable.

Abstract:

The rendering mortar plays a crucial role in the durability of buildings, acting as a barrier against weathering and environmental aggressions. Exposure to degradation mechanisms such as rain and moisture can accelerate the deterioration of these mortars, compromising the integrity of the structures. Considering the relevance of this issue, the present study investigates the influence of hydrated lime in mortars subjected to these degradation mechanisms, evaluating three different mix proportions: 1:3, 1:1:6, and 1:2:9, which are commonly used for rendering mortars. For this purpose, six specimens were molded for each mix, including two formulations with partial replacement of cement by lime and one reference mix without lime. Half of the specimens were subjected to conventional curing, while the other half were exposed to degradation by saturation, simulating severe moisture conditions. Properties such as pH, compressive strength, density, and mass loss were analyzed. The results showed that density decreases as the hydrated lime content increases. The pH remained alkaline, and the compressive strength increased in the samples subjected to chloride attack, possibly due to the formation of products such as Friedel’s salt and additional C-S-H phases. It is concluded that the addition of hydrated lime can provide several benefits to rendering mortars, provided that the lime-to-cement ratio is carefully balanced to optimize workability, durability, and mechanical properties.

Abstract:

The synthesis of zinc oxide (ZnO) nanoparticles has gained prominence due to their unique physicochemical properties, with applications in photocatalysis, sensors, electronics and medicine. In this work, the Pechini-type synthesis technique will be used, a modified sol-gel method that allows the production of ceramic materials with high purity and morphological control. In addition, ZnO samples doped with Fe and Ag will be investigated, aiming at modifying their properties for specific applications. In the Pechini method, metal salts are complexed with citric acid and subsequently polymerized with ethylene glycol, forming a homogeneous gel. This precursor is then subjected to calcination to obtain the desired oxide. In addition to the synthesis route, the main objective is to investigate the impact of the ratio between citric acid and metal cations on the synthesis of ZnO, especially with regard to the average size of the particles formed. The characterization of the obtained nanopowders will be performed by means of X-ray diffraction (XRD), allowing the identification of the crystalline phases and the calculation of the average crystallite size using the Scherrer equation. With this approach, it is expected to obtain ZnO nanoparticles with control over their dimensions and morphology, contributing to the more efficient* Contribuição técnica ao 78º Congresso Anual da ABM – Internacional, parte integrante da ABM Week 9ª edição, realizada de 09 a 11 de setembro de 2025, São Paulo, SP, Brasil. production of materials with superior performance in several technological applications.

Abstract:

The growing demand for sustainable practices in civil construction has driven the incorporation of recyclable waste into cementitious materials. This study evaluated the effects of partially replacing fine aggregate with crushed polyethylene terephthalate (PET) waste in mortars, with contents of 3%, 6% and 9%, aiming at the incorporation of recyclable materials as a sustainable alternative in civil construction. Physical and mechanical properties were analyzed, with emphasis on water absorption, void index, specific mass and compressive strength. The results indicated that the presence of PET progressively reduced the specific mass of the mortar and increased water absorption and the void index, phenomena attributed to the lower density and irregular shape of the polymeric particles. Regarding mechanical performance, a sharp drop in compressive strength was observed, from approximately 11 MPa in the reference mix (0% PET) to approximately 3 MPa with 9% replacement, due to the low adhesion between PET and the cementitious matrix and the formation of voids. Despite the loss of structural performance, the addition of PET represents an environmentally viable solution for the reuse of plastic waste, being recommended for non-structural applications, such as coatings, sealing masonry and artifacts with low mechanical stress, thus contributing to more sustainable construction practices.

Abstract:

This study evaluated the efficiency of Pinus elliottii lignin as a green corrosion inhibitor for AISI 1020 carbon steel in a 1 M HCl corrosive medium. Lignin, obtained as a byproduct from the pulp industry, was tested at concentrations of 6, 8, and 12 g/L. The specimens were subjected to immersion tests for 24 hours, and the corrosion rate was determined through mass loss measurements. Micrographic analyses were also conducted to assess the surface condition of the materials after exposure. The results showed that the 6 g/L concentration exhibited the highest inhibition efficiency (27.60%), while higher concentrations resulted in reduced performance. The increase in concentration did not enhance corrosion protection, possibly due to lignin aggregation hindering its adsorption on the metal surface. Based on these findings, the authors propose continuing the research by evaluating concentrations below 6 g/L. The results indicate the potential of lignin as a sustainable corrosion inhibitor, provided that its concentration is properly optimized.

Abstract:

This study investigated the effects of plasma nitriding applied prior to the deposition of a physical vapor deposition (PVD) coating on AISI H13 tool steel, with the aim of enhancing coating adhesion and performance. A duplex treatment was employed, consisting of plasma nitriding followed by the deposition of a CrN/CrAlTiN coating via PVD. Samples with and without the nitriding step were subjected to metallographic analysis, optical microscopy, surface roughness measurement, microhardness testing, and adhesion evaluation. The results showed that duplex treatment promoted the formation of a diffusion zone in the substrate, increased surface roughness and surface microhardness, particularly under low loads, indicating improved load-bearing capacity. Adhesion tests revealed a significant reduction in crack formation and the absence of delamination in the samples treated with the combined process, in contrast to those that were only coated. The application of a duplex treatment resulted in superior properties, representing an effective solution for high-wear applications.

Abstract:

This paper evaluates the impact of the simulated Reel-Lay installation method on the mechanical properties of API 5L X70 steel. Steel samples were subjected to cyclic plastic pre-straining, followed by a thermal aging treatment at 250°C for 1 hour, according to the DNV-ST-F101 standard guidelines. The properties were assessed through tensile tests, Vickers microhardness, and optical microscopy. The results exhibited a significant 16% increase in yield strength (from 470 to 545MPa) and in average hardness (from 195 to 206HV), with minimal change in the ultimate tensile strength. Notably, the processed material exhibited a discontinuous yielding behavior, which was absent in the base material. It is concluded that the observed hardening results from the combined action of work hardening and, predominantly, strain aging, a critical factor to be considered in the integrity and safety analysis of subsea pipelines.

Abstract:

Non-destructive techniques are used to detect defects, analyze flaws, and measure stresses, both residual and applied, in metallic materials. One of these techniques is acoustic birefringence, which measures the degree of anisotropy of the material based on the variation in the speed of the shear ultrasonic wave as it travels through the material. The speed or travel time of the ultrasonic wave is also altered by the residual stress generated by welding processes, allowing acoustic birefringence to be measured and consequently the residual stress. In this sense, this study aimed to remeasure after seven years the travel time of the wave in the welded material and the acoustic birefringence of a test specimen welded by a process called GMAW-CW, which is the introduction of a non-energized wire (cold wire) into the molten pool of the GMAW process, in order to perform a qualitative analysis of the time and birefringence after seven years. As a result, changes in the behavior of the studied parameters were observed

Abstract:

This study investigated the effects of temperature and deformation level on the warm forging of vanadium microalloyed steel DIN 30MnVS6. Forging tests were conducted at four temperatures (600 °C, 700 °C, 800 °C, and 900 °C), followed by microstructural characterization, hardness evaluation, surface roughness analysis, and numerical simulation of the process. The results showed that increasing the forging temperature promotes thermally activated mechanisms, such as dynamic recrystallization, which reduce forming forces and refine the microstructure. Conversely, intermediate temperatures (600 °C and 700 °C) led to greater strain hardening and improved surface finish due to reduced oxidation. The study confirms the feasibility of warm forging for 30MnVS6 steel, highlighting its potential for producing forged components with high strength and surface quality without the need for additional heat treatments.

Abstract:

Steel structures and mechanical components are often subject to severe deterioration when operating in environments such as marine and industrial environments. The application of coatings by the continuous hot-dip process is one of the most widely used methods for protecting steel. The metals and alloys that can be applied to steel by the hot-dip method are limited to those with a melting point low enough to allow the metal strip to pass through the molten metal bath without deformation or bursting, which is why Zn and Al are used for this purpose. The work consists of studying the mechanical behavior and integrity of steels coated with pure zinc and aluminum-zinc in terms of mechanical strength. For this purpose, tensile and hardness tests will be performed on these steels with and without coatings to observe the possible changes that may arise with the addition of the coatings.

Abstract:

The objective of this study was to apply the Life Cycle Assessment (LCA) methodology, required by ISO 14040 and ISO 14044, to compare the environmental impacts of traditional concretes and concretes with partial replacement of Portland cement by blast furnace slag. The system boundary was “from cradle to gate” and the functional unit was m³ of mortar, using the commercial program SimaPro®. In the initial evaluation, considering 1 m³ of material, concretes with blast furnace slag content include reduced environmental impacts compared to occasional concretes, with variations between 19.2% and 9.4% among the impact categories tested. It was concluded that the LCA methodology is adequate in the comparative evaluation between concretes and that the partial replacement of Portland cement by blast furnace slag results in a reduction in the environmental impact in the cementitious materials industry.

Abstract:

In this study, the corrosion rate and efficiency of tetramethylammonium iodide (TMAI) as a corrosion inhibitor for duplex stainless steel UNS S31803 were evaluated. Mass loss tests were conducted in 1M HCl solution, with and without the addition of 0.5 mM of the inhibitor, at room temperature, over immersion periods of 24, 48, 72, 96, and 120 hours. Surface morphology was analyzed using Scanning Electron Microscopy (SEM), and surface chemical composition was determined by Energy Dispersive X-ray Spectroscopy (EDS), both in the presence and absence of the inhibitor. Duplex stainless steel S31803 has a biphasic microstructure, composed of ferrite and austenite in approximately equal proportions, developed for demanding applications in the chemical and petrochemical industries due to its high corrosion resistance and good mechanical properties. The addition of TMAI resulted in a significant reduction in the corrosion rate, from 0.7309 mm/year (without inhibitor) to 0.0024 mm/year after 48 hours of immersion, achieving an efficiency of 99.67%. The inhibitor maintained superior performance throughout the test period, with efficiencies consistently above 98%, demonstrating its high effectiveness in acidic environments.

Abstract:

This study aimed to investigate the efficiency of the N-heterocyclic compound as a Volatile Corrosion Inhibitor (VCI) under simulated atmospheric conditions. Experiments were conducted in two distinct environments: one highly aggressive, containing acidic vapors from an aqueous HCl solution, and another with low aggressiveness, consisting of water vapors from an aqueous glycerol solution (9.45 g·L⁻¹). SAE 1020 steel samples were analyzed using UV-Vis spectrophotometry, employing complexation with ortho-phenanthroline to determine the mass of corroded iron, complemented by visual analysis of the metal surfaces. The results indicated that the inhibitor showed satisfactory performance in both evaluated environments, with higher efficiency (87.11%) observed under less aggressive conditions. This behavior reinforces the compound’s suitability for applications involving storage or transport of metallic materials, where corrosion tends to occur in a more controlled and gradual manner. Additionally, the combination of quantitative analyses, performed by UV-Vis spectrophotometry, and qualitative analyses, based on visual surface inspections, confirmed the compound's effectiveness in protecting against corrosion. These findings not only demonstrate the potential of the investigated compound as an efficient corrosion inhibitor but also provide a solid foundation for future research aimed at enhancing its application and deepening the understanding of the mechanisms involved in its protective action.

Abstract:

The use of corrosion-resistant materials is essential for industrial operations in harsh environments. In such environments, various factors compromise the integrity of metals, making it crucial to understand the behavior of alloys such as stainless steels and Inconel alloys, which are widely used in applications requiring high resistance to corrosion processes. In addition to the corrosivity of the environment, other environmental factors such as the presence of abrasive particles, high pressures, large temperature variations, pH, and chloride ions (the main contributors to pitting corrosion) must be considered. The objective of this study is to determine the corrosion resistance and compare the behavior of AISI 316L stainless steel and Inconel 625 alloy in an acidic medium containing chloride ion. The results indicated that AISI 316L steel has lower resistance to corrosion with pitting. Inconel 625 alloy has high corrosion resistance in acidic medium and does not present localized pitting corrosion in electrochemical tests.

Abstract:

The oil and gas industry is constantly evolving, which increases the need for materials that can better withstand harsh operating environments. One example is offshore operations, where corrosion occurs rapidly and can quickly compromise metallic components. In such situations, it is essential to select alloys that offer high corrosion resistance, especially against the action of chloride ions, which promote localized corrosion (pitting). This study compares the performance of Inconel 625 alloy and AISI 316L stainless steel in a saline environment, assessing the integrity of the protective layers formed on their surfaces. The results showed that AISI 316L is more susceptible to pitting, while Inconel 625 maintained a stable surface with no signs of localized corrosion, confirming its effectiveness for use in chemically aggressive environments.

Abstract:

Metal pipelines are used in the oil industry to transport oil between platforms and refineries. Due to the aggressive conditions of this activity and the marine environment, such as temperature, pressure, and salinity, it is important to select metal alloys with high corrosion resistance. This work aimed to evaluate the corrosion behavior of Inconel 625, 316L stainless steel and 2205 duplex steel in saline medium. The electrochemical tests performed were open circuit potential (OCP) and potentiodynamic polarization. The electrolyte used was a 3.5% NaCl solution at room temperature. The results showed that 2205 duplex steel and Inconel 625 alloy presented higher corrosion resistance than 316L steel. 316L presented greater susceptibility to pitting corrosion in medium containing 3.5% NaCl.

Abstract:

This study evaluated the influence of anion type on the efficiency of tetramethylammonium-based ionic liquids as corrosion inhibitors for duplex stainless steel UNS S31803 in 1 M HCl solution. Tetramethylammonium iodide (TMAI) and tetramethylammonium tetrafluoroborate (TMA[BF4]), both at a concentration of 5 mM, were evaluated by 24-hour weight loss experiments. The results showed that the addition of TMAI to the corrosive solution caused a significant reduction in the corrosion rate, reaching an inhibition efficiency of 94.90%, while TMA[BF4] presented a much lower performance, with an efficiency of 18.01%. The difference in efficiency between the inhibitors was attributed to the likely higher adsorption capacity of the iodide anion on metallic surfaces, promoting the formation of a protective layer, unlike the BF4- anion. These findings highlight the importance of proper anion selection in the formulation of ionic liquids, showing that small variations in chemical composition can lead to major differences in inhibition efficiency.

Abstract:

Polymer composites reinforced with textile scraps are a sustainable alternative for reusing waste from the textile industry, combining lightness and good mechanical performance. This study evaluated the compression behavior of composites containing five layers of different fabrics (Jeans, Poplin, Linen and Helanca), with a focus on the feasibility of applying them to orthopedic prostheses. The tests were carried out on an Instron machine at room temperature. The results showed greater resistance for the Helanca composite, while Popeline and Linen showed more uniform performance. Although they were less rigid than hybrid composites, they stood out for their lightness, reduced cost and properties compatible with biomechanical requirements. The findings reinforce the potential of these materials as possible alternatives for application in prostheses.

Abstract:

Connectivity in steel plants, especially within production areas, is often inadequate. Network coverage is limited or nonexistent, and the presence of legacy equipment with non-standardized protocols hinders IT/OT integration. Physical cabling restricts mobility and limits IoT scalability, increasing maintenance costs and complicating future expansions. Private 5G networks emerge as a comprehensive solution. Their superior coverage consolidates multiple industrial applications into a unified and reliable infrastructure. Unlike Wi-Fi, which requires numerous access points, 5G can cover large areas with just a few radio base stations (gNodeBs), significantly simplifying deployment and maintenance. Private 5G also enables traffic isolation between the plant floor and corporate IT networks, enhancing cybersecurity and ensuring predictable performance for mission-critical applications. Its low latency, high availability, and native mobility make it ideal for computer vision, real-time sensing, critical communication, and process monitoring systems aimed at improving occupational safety and protecting human life.

Abstract:

Encouraged by the emergence of Industry 4.0 and Smart Factories, the evolutions in the mining and steel industry scenario have been significant. These advancements include the accurate characterization of materials through innovative analytical tools such as Raman spectroscopy. This study presents the development and application of conditional variational autoencoder networks to expand the database of Raman spectra of metallurgical coke, produced in the steel fabrication process. The results showed the effectiveness of the methodology in replicating fundamental characteristics of the original spectra. However, progress in the prediction of CSR and Drum Index quality parameters using different regression algorithms, such as kNN, PLS, and SRV, has been limited, indicating the need for additional research to improve these methods in the steel industry.

Abstract:

Mining is a strategic sector for the global economy, requiring high levels of safety and logistical efficiency. In this context, Industry 4.0 integrates advanced technologies to transform operations, optimize processes, and improve decision-making. Ports play a crucial role in the mining logistics chain but face significant challenges related to safety and risk management due to the complexity of operations. To address some of these challenges, a digital constraint management system was developed and implemented at a Brazilian port terminal. This technology, aligned with the principles of Industry 4.0, manages constraints on port equipment, ensuring greater operational control, risk mitigation, and improvements in logistical activities.

Abstract:

This paper presents the methodology and results obtained from the internal cleaning intervention in the recirculated water supply pipeline of the Automatic Rolling Mill at Vallourec – Barreiro Unit. The initiative was driven by recurring obstructions in the spray nozzles and reduced flow rates in the cooling circuits, which directly impacted the operational stability and availability of the production line. A detailed inspection of the hydraulic network was conducted, followed by a cleaning procedure to remove internal blockages and scale buildup along the pipelines. After the intervention, a significant reduction in unplanned downtime related to the cooling system was observed, with restoration of nominal flow rates in the circuits and improved thermal performance of the equipment.

Abstract:

The present work presents the results of a scientific initiation project focused on the analysis of thermodynamic equilibrium calculations for systems containing Fe-Cr and seawater with typical compositions observed in oil extraction processes. Thermodynamic simulations were conducted using Thermo-Calc® software to assess the formation of corrosion products under varying water conditions, different pressures, temperatures, and concentrations of CO₂ and O₂. The results highlight the predominant formation of hematite as the main corrosion product, along with the precipitation of calcium carbonate in specific scenarios. The formation of siderite (FeCO₃) was not observed under the simulated conditions. These findings provide a reliable data foundation for the development of corrosion control strategies in water injection systems, enabling future investigations under more extreme conditions - such as at potentials down to -0.5 V - and contributing to the improvement of targeted corrosion mitigation techniques.

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Hydrogen embrittlement poses a significant challenge to the development and application of advanced high-strength steels (AHSS) in the automotive industry. The various hydrogen sources, combined with the mechanical stresses involved in the production and use of AHSS, make this a complex phenomenon that has attracted significant attention from both industrial and academic communities. In this context, the deformation and defects formed along sheared edges, typically resulting from stamping operations, act as critical sites that intensify the detrimental effects of hydrogen, particularly in relation to delayed cracking. This study aimed to evaluate the effect of hydrogen in combination with different shear cutting conditions in a third-generation AHSS with a tensile strength class of 1000 MPa. For this purpose, electrochemically pre-charged specimens with varying hydrogen contents and cutting conditions were tested under constant load. The results quantified the influence of the sheared edge on the material’s susceptibility to hydrogen embrittlement, revealing that inadequate cutting conditions reduced the critical hydrogen content by up to 60% compared to the condition considered optimal for the evaluated steel.

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Two premium steels for railway rails were evaluated aiming at a possible process window related to the cooling rate after Flash Butt Welding, by means of physical simulations in dilatometry, in comparison with a standard material previously evaluated. Samples of the materials underwent chemical analysis, were microstructurally characterized with the aid of optical (OM) and scanning electron microscopy (SEM), with measurement of interlayer spacing and hardness profile. Based on data from previous studies, dilatometric tests were performed with different cooling rates and, subsequently, microstructural characterization. The two premium steels presented martensitic transformation for cooling rates starting from 5ºC/s, while in the standard steel the same transformation was only verified for rates starting from 15°C/s in dilatometry. The presence of pearlite and small fractions of martensite, bainite and degenerate pearlite were observed in SEM for rates starting from 3ºC/s. The results indicate that premium steels have a smaller process window than standard steels and that the definition of the post-weld cooling rate should be evaluated according to the chemical composition. However, additional studies are needed to investigate the effects of austenitization on the feasibility of increasing the cooling rate.

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In the mining industry, crushing plays a key role in reducing ore size and is commonly carried out using jaw crushers. The efficiency of these machines largely depends on the performance and durability of their liners, which are subjected to harsh wear conditions. Developing more effective solutions involves exploring new materials and geometries, but this process is often constrained by high costs, operational risks, and lengthy industrial-scale testing. Additive manufacturing (AM) presents a promising alternative by enabling the layer-by-layer production of metal components directly from 3D models. AM offers benefits such as design flexibility, faster production, and the ability to create complex shapes. However, challenges remain regarding surface finish and fatigue resistance. In this context, the durability of components is vital for crusher performance, with liners typically made from austenitic manganese steel alloys. This study investigates the wear behavior of different jaw crusher liner geometries produced using Weld-Inox alloy via wire and arc additive manufacturing, evaluating abrasiveness through the standard Bond Ai test and wear in bench-scale experiments, with a focus on industrial applicability.

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The ShapeMon Billet Bloom technology is an advanced image processing system to measure long products with rectangular or square shape under hot conditions coming directly from the caster. The system can calculate the cross section and the length and speed of the billet and gives optical images of the long product. An important fact compared with state-of-the-art devices is that the measurement is executed along the complete product and not only from head and/or tail end (1). This paper will include a first analysis based on the feedback coming from the sites (2) where it is installed. Surprising insights like the change of rhomboidity along one billet could be made visible. 2 major possible installation positions are discussed to understand the properties of each.

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This paper presents practical applications and results from simulation projects of logistics processes carried out in steel plants and mining operations in Brazil. The concept of simulation technology applied to logistics processes will be introduced, demonstrating how this tool can be used to evaluate all components of end-to-end operations, including raw material receiving flows, truck circulation routes, loading and unloading processes, maneuverability analysis, as well as challenges in storage operations and intralogistics flows in general. Through real case studies conducted at companies such as Gerdau, ArcelorMittal, Vale, among others, we will show how simulation technology enables the rapid evaluation of multiple comparative scenarios and supports decision-making. This is a zero-risk approach that anticipates problems and bottlenecks, ensuring the best solution to meet demand within the projected service levels and at the lowest possible cost.

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The need to improve productivity is an important factor in the competitiveness of any player in the market, who needs to constantly strive to improve their processes. During the course of the work, the process of chemical analysis of grain-oriented (GO) electrical steel in the instrumental laboratory was monitored and studied, from receiving the sample to making the result available electronically, with the aim of implementing improvements in the chemical analysis process using project management practices and Lean tools. An initial phase of the project was the construction of the value flow map - current state, where it was possible to identify the current lead time and takt time of the result delivery processes. Data was collected in person during the three work shifts, without interfering in activities, focusing only on observations of each stage of steel analysis, which were mapped and noted as the object of the study. The main reason for the high chemical analysis times for steel was that the gas analysis of carbon and sulphur, compared to the optical spectrometry analysis, has an additional phase to remove metal filings (swarf) and the spectrometry analysis time is shorter than the gas analysis time. A new value flow map - future state - was constructed and actions to adapt the optical analysis process were implemented, resulting in a 16.9% reduction in lead time and an 18.2% improvement in takt time, contributing to customer satisfaction

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TECFOAM® introduces a new approach to slag foaming technology within the field of Electric Arc Furnace (EAF) operations. This paper explores the development of a slag foaming agent that enhance thermal efficiency and operational control in steel production. The primary objective is to optimize the foaming process in the EAF, reducing energy consumption and improving the quality of steel. The methodology employed involves a detailed analysis of slag composition, its interaction with foaming agents, and the dynamics within the furnace environment. Experimental trials were conducted to validate the performance of TECFOAM® under various operational conditions, with a focus on achieving consistency and scalability in industrial applications. Results demonstrate a reduction in energy expenditure alongside an improved foaming consistency, thereby extending refractory life and ensuring more sustainable practices in steel manufacturing. The study also highlights the environmental advantages, including lower carbon emissions and resource efficiency. In conclusion, TECFOAM® represents a paradigm shift in slag management, offering steel manufacturers a robust, efficient, and eco-friendly solution that aligns with modern industrial and environmental standards.

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For the last 18 months Vesuvius and Arcelor Mittal Pecém technical teams are working together to increase sequential length at Continuous Casting Machine in a variety of fronts. The most successful one is the modification of zirconia sleeve material, using newly developed DuraSleeve at theirs MTSP. This allowed an increase of 21% of casting sequence, increasing its productivity and reducing waste generate after casting. Zirconia sleeve is located in a chemically active area, with mold powder and steel being renewed every second, while zirconia sleeve sits static for the entire length of casting, this challenge was surpassed with specific technology, new formulation and raw material developments, together this creates a possibility to increase casting sequence.

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The study addressed the optimization of laser welding of dissimilar steels, focusing on CP1000 and DP780 steels. The study aimed to find a balance between power and welding speed, seeking parameters that improve the integrity of the welded joint and minimize losses during the stamping process. The quality control of the welded sheets was performed by direct observation. The results show that the best parameterization for approval of the welds is 3 m/min with powers between 1800 and 2100 W, and 6 m/min with powers between 3000 and 4200 W. The microstructure of the welds is marked by the microconstituents ferrite, bainite and martensite both in the fusion zone and in the heat affected zones. The mechanical tests of hardness, Erichsen embedding and uniaxial tension showed that the approved sheets had mechanical behavior consistent with the forming work by stamping subsequent to welding.

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The addition of 0.5 to 3 wt.% of niobium (Nb) to Hadfield steel has the potential to increase wear resistance due to the formation of niobium carbides (NbC), which are hard particles dispersed within the austenitic matrix. However, the presence of these carbides may lead to a significant reduction in impact resistance, making it essential to produce cast components that are free from major defects such as shrinkage cavities and porosities, which can impair the material's toughness. To ensure metallurgical quality and structural integrity, MAGMASOFT® software (version 6.1) was used to optimize the casting design of crusher liners, which are the main wear components manufactured in Hadfield steel for cone crushers.

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This paper evaluated the potential application of charcoal ash, obtained from a local restaurant, as a supplementary material in cementitious composites, based on its mineralogical characterization and pozzolanic activity analysis. X-ray diffraction revealed the predominance of quartz (SiO₂) and sylvite (KCl), possibly related to the salts used during food preparation. A slight amorphous band indicates a low content of non-crystalline silica, suggesting inert behavior. The verification of pozzolanic activity using the electrical conductivity method proposed by Luxán did not identify any reaction between the ash and calcium ions, characterizing it as an inert material. Literature indicates that ashes resulting from uncontrolled combustion tend to exhibit high crystallinity, soluble impurities, and low reactivity. In this context, the analyzed ash showed technical feasibility only as a filler, physically contributing to matrix packing and enabling partial replacement of Portland cement. Although it does not participate in hydration reactions, its incorporation may represent a sustainable alternative, promoting the reuse of urban waste and contributing to the reduction of environmental impacts in the construction sector.

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The objective of this work was to develop and implement a digitized system capable of enhancing the reliability of magnetization control in machines used for quality testing of seamless steel tubes. The project commenced with the development of a laboratory-scale prototype, which underwent an experimental validation phase over the course of one year. Following this period, the solution was refined, consolidated, and deployed on the production line. The implementation yielded significant improvements, including increased precision in magnetization current control, enhanced robustness in the triggering of the machine’s power unit, and advancements in the human-machine interface, resulting in a more intuitive and safer operation. This technological upgrade elevated the levels of automation, reliability, and operational efficiency, thereby directly improving the quality and repeatability of the tests conducted.

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The Waste Twin project is an initiative under development by Accenture, in partnership with Gerdau, aimed at increasing the predictability of waste generation in the steelmaking process. By using predictive mathematical models, the system seeks to anticipate the production of these residues, enabling their reuse in the sintering process as a substitute for iron ore. This approach leads to a significant reduction in operational costs and contributes to the sustainability of the steel industry by promoting the reuse of internal materials and reducing dependency on natural resources

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The automation project for the emergency siren activation system at Samarco's dams was developed with the objective of increasing reliability, accuracy, and efficiency in responding to critical situations. The initiative is aligned with ANM Resolution No. 32/2020, which mandates automatic siren activation for structures that require an Emergency Action Plan (PAE). The system was designed based on redundancy logic and integrated analysis of instrumentation data, preventing alarms from being triggered by a single isolated reading. Instruments were grouped according to the type of parameter monitored (displacement and piezometric level), applying the event tree concept to validate critical scenarios. The use of the SHMS (Slope Health Monitoring System) software enabled real-time monitoring, with defined triggers, alarms, and integration with the fault module, ensuring accurate and automated responses. Additionally, a manual activation system was implemented as redundancy, providing operational flexibility. The project resulted in significant improvements, including greater system reliability, enhanced continuous monitoring, and reduced false alarms, ultimately strengthening the safety of both the surrounding communities and the operation itself.

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With the objective of identifying opportunities to improve the consumption and control of argon in Usiminas’ Steelmaking Plant, a dedicated working group focused on cryogenic gas management was established. This group conducted a comprehensive mapping of consumption points, analyzed applications, and evaluated measurement systems. Following a technical assessment, the replacement of argon with nitrogen in specific laboratory activities within the steelmaking plant was validated, as there is no direct interaction with the analyzed material, ensuring the reliability of the analyses is maintained. Improvements were made to the measurement instrumentation, including the replacement of the orifice plate meter with a coriolis meter and adjustments to the automation logic. The implemented actions resulted in increased measurement reliability, reduced discrepancies between actual and billed consumption, as well as significant gas savings, promoting process efficiency and sustainability.

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This study aimed to monitor the corrosion process on SAE 1020 steel surfaces exposed to vapors from an aqueous HCl solution, evaluating the efficiency of a volatile corrosion inhibitor. Samples were prepared and subjected to different exposure times (3, 5, 10, and 15 hours), both with and without the inhibitor, using techniques such as spectroscopic ellipsometry and dynamic microhardness testing (DUH). The results showed that, in the absence of the inhibitor, there was pronounced degradation of the metal surface detected by optical and mechanical analyses, especially after prolonged exposure. The overlap in tanΨ values demonstrates the homogeneity of the SAE 1020 steel surface after polishing. The results indicate that the absence of the inhibitor leads to accelerated degradation of the EIT parameter, particularly for longer exposures (10 and 15 hours).

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In modern rolling mills, precision, safety, and efficiency are key performance indicators. Traditional section measurement methods require physical contact and manual observation, exposing operators to safety risks and process inefficiencies. This paper presents two innovative non-contact solutions developed by Primetals Technologies: the Portable and Fixed Digital Optical Caliper (DOC) systems. Both systems provide accurate, real-time measurement of rod and bar profiles using optical imaging and advanced software analytics. This paper discusses their design, operational capabilities, and benefits in enhancing mill productivity, quality, and safety

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The austenitic valve steel WNr. 1.4882 (X50CrMnNiNbN21-9) is highly alloyed with Cr, Mn, Ni with significant additions of Nb, W, C and N, so it presents a narrow hot rolling range temperature and is susceptible to cracking during the process. This paper describes part of a study developed to evaluate the effect of different temperatures and deformation levels on hot formability of this specialty alloy. The hot rolling was done using wedges with geometries and effective deformation levels defined by thermomechanical simulation in DEFORM 3D®. The research material was processed in a pilot-scale rolling mill and the microstructures were analyzed via optical microscopy and SEM/EDS. The results showed that wedge rolled at 1230°C (heating temperature of 1260°C) exceeded the solidus temperature in the region subjected to the highest deformation and due to this phenomenon, it presented grain boundaries decohesion that generated cracks. Therefore, temperatures higher than 1230°C should be avoided during forming.

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Belt conveyors are widely used in the mining industry, and the pulley is one of its main components susceptible to failure, which can result in major maintenance shutdowns and production losses, as well as serious risks to people's safety. This paper aimed to analyze the causes that led to the rupture of a pulley shaft in a belt conveyor during its operation. Through a failure analysis methodology, it was demonstrated how it is possible to identify and characterize a fatigue failure in a practical case. It was possible to demonstrate how the shaft recovery process through metallization and the deficiency in the bearing seal design led to the weakening of a shaft, making it susceptible to a premature failure characteristic of fatigue.

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The Coke Plant area at ArcelorMittal Tubarão currently comprises three coking batteries of the "Carl Still Half-Divided Oven System" type and one Thyssen Twin Flue battery. These consist of sets of vertical ovens that convert metallurgical coal into coke, with coke oven gas (COG) as a by-product. The coke is used to feed the blast furnaces, while the COG is utilized for power generation in the thermal power plants. Coke Battery No. 1, which operated with 10 ovens (out of a total of 49), was reaching the end of its operational life due to prolonged use. The COG generated by these 10 ovens was lower than the amount required to keep them running, making it necessary to shut down Battery No. 1, among other contributing factors. Following the shutdown decision, all critical points were identified, including: removal of gas collectors, metallic sealing of removed oven doors, gas isolation at mixing stations (gas line blanking), cleaning and hydro-jetting of the battery’s feed pipelines, among other activities. The KAEFER RIP team carried out integrated planning focused on safety and productivity across all critical points, including workforce allocation and risk management. As part of the risk mitigation strategy, pipe wall thickness measurements were performed, along with structural weight assessments (including operational residue buildup), and 3D rigging plans were developed for load handling. The entire project was executed in accordance with contractual requirements and completed within the 90-day deadline.

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IOCJ (Iron Ore Carajás) is one of the most highly valued iron ores in the world, with a high iron content and few impurities. Extracted in Carajás, one of the largest mineral provinces on the planet, it meets the growing global demand for quality steel, especially from China. Its excellence, combined with robust logistics infrastructure, makes it strategic for the Brazilian economy. The route to Oman highlights the logistical challenges of international trade, with long crossings subject to climate and operational variables. In this scenario, port safety is essential. Inadequate stacking can cause landslides, structural collapses and risks to workers' lives. Problems such as overloading, poor compaction, poor drainage and lack of geotechnical analyses compromise the infrastructure. Factors such as humidity, granulometry and vibrations intensify these risks. The adoption of the Prismatic Shell Cone method improves safety without compromising efficiency. With greater volumetric capacity and stability control, it reduces operational downtime and ensures efficient ore storage at Vale Omã's yard.

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This paper presents a cost reduction strategy applied to ferroalloy inventory management, focusing on replacing domestic suppliers with international ones and on the physical and operational reorganization of inventories. High-carbon ferro-niobium and manganese alloys were tested. In the case of niobium, the supply model evolved from 75% domestic to 100% imported, with an increase in minimum inventory from 45 to 130 tons. For manganese, imports were increased from 41% to 65%, with inventory increasing from 650 to 1,300 tons. The operation procedure included adjustments in storage and active management of logistical risks. The impact on working capital was US$0.34 million per year, while savings totaled US$3.56 million, resulting in a net gain of US$3.22 million per year. The results confirm that strategic inventory planning can reduce costs without compromising operational stability.

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The energy dissipated during steel tapping from primary steelmaking processes has been used for a long time to promote the dissolution of additions to the steel and reactions between steel and slags or slag forming components. Both experience and fluid dynamic modeling indicate that the velocity of the metal jet entering the metal in the ladle is superior to most of the buoyance forces of light additions to the steel and, additions tend to be entrained in the liquid metal in the region of the jet impact on the bath present in the ladle. Subsequent floating is frequently associated with renewed entrainment. At least since the inception of the Perrin process, this possibility is considered and taken advantage of. However, most models used to describe steelmaking consider that additions enter a well-defined phase, and it is frequent to see this decision based on the chemical characteristics of the addition (oxide or metal) and physical properties (density and grain size) and not much consideration is given, apparently, to the possibility of emulsification. In the present work we review some of the key experimental results of the effects of additions and simulate different ways of considering the additions during tapping. The evaluation of the simulation results indicates that the use of chemical and physical characteristics alone, may not be a sound basis for the decision on how to simulate the additions when modeling the tapping process.

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This study presents the implementation of an AI-based distraction monitoring system on overhead cranes used for transporting molten steel in a conventional steelmaking plant. The goal was to enhance operational safety by detecting risky behaviors such as operator fatigue, unauthorized mobile phone use, smoking, and sudden health-related incidents. Although similar technologies are already applied in vehicles for fatigue detection, no solutions specifically adapted to overhead cranes were identified during the initial research phase. This gap motivated the development of a customized solution in partnership with ASMONTECH. The system was installed on three critical cranes (PR-30, PR-38, and PR-48) and employs real-time camera analysis to detect deviations in operator behavior. When distractions are identified, it issues local alerts and remote notifications, logs the event, and stores video footage for later analysis. A pilot test confirmed the system’s technical viability, leading to full-scale deployment. Since implementation, the monitoring system has provided valuable behavioral data that supported several preventive actions, including awareness initiatives, increased rest breaks, and task rotation—especially on the first shift, where fatigue was more prevalent. The technology has also informed discussions on shift reassignment based on operator performance and condition monitoring. The results demonstrate the system’s effectiveness as a proactive safety management tool, enhancing operator awareness and contributing to a culture of continuous improvement in high-risk industrial operations.

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In the continuous casting process, the end of sequence presents operational and safety challenges, such as liquid steel backflow, top slab breakouts, and shell rupture risks. Traditionally, the capping of the last slab was performed manually, using metallic rods to promote the natural solidification of the strand top. However, this practice exposed operators directly to high-temperature zones, increasing the risk of severe accidents and limiting process control and productivity. As a safer and more efficient solution, the Top Capping Device (Capa Topo) was developed. This consumable metallic component is positioned beside the mold and manually rolled into the strand using a handling tool, allowing the operator to remain at a safe distance. Once in place, the Capa Topo accelerates the solidification of the top slab, preventing liquid steel backflow and ensuring the integrity of the strand. Its implementation significantly reduces safety risks, lowering the hazard level from risk 3 (moderate) to 2 (tolerable). Furthermore, the use of Capa Topo eliminates the need for equipment removal due to top breakouts, improves process reliability, and increases machine availability, thus enhancing overall productivity in continuous casting operations.

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The pulverized coal injection (PCI) lance in the Blast Furnace system is a critical component for ensuring operational reliability. Its maintenance involves multiple steps—including disassembly, inspection, cutting, and welding—and represents a significant cost to the responsible operational sector. The lance’s primary component, the central tube, which conveys the pulverized coal, is manufactured from austenitic stainless steel and entails a high procurement cost. Consequently, optimizing its service life and minimizing the loss of new material during maintenance is of strategic importance. This study assessed the technical feasibility of modifying the welding process employed in the maintenance of the lance, transitioning from a manual Gas Tungsten Arc Welding (GTAW) process with filler metal to an automated GTAW process without filler metal, using an orbital welding head. The weld position was evaluated, and the feasibility of reproducing this same weld position in subsequent maintenance cycles was considered. Metallographic analysis of the welded joint confirmed that repeat welding at the same location does not adversely affect weld integrity, validating the safety and reliability of standardized weld positioning. This standardization facilitates consistent tip replacement and contributes to the reduction of material loss from unused tube sections.

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The relationship between flow stress and grain size was initially described by the Hall-Petch equation, which states that a reduction in grain size results in an increase in the strength of the material. Over the years, however, several alternative theoretical models have been proposed to complement or reinterpret the mechanisms underlying this relationship. This study presents a literature review aimed at examining some of these alternative models. Additionally, experimental data on grain size and corresponding flow stress values were collected from the literature to critically evaluate selected theoretical approaches, particularly regarding the variation of the Hall-Petch coefficient k with temperature. While the models analyzed generally assume that k is independent of temperature, the findings of this study suggest otherwise, indicating that k exhibits thermal sensitivity. This observation highlights limitations in these models when attempting to fully capture the role of grain size in strengthening mechanisms under varying thermal conditions.

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This work presents the morphological evaluation of composites with auxetic geometry produced by additive manufacturing (AM) via digital light processing (DLP), incorporating natural jute fibers (Corchorus capsularis). The auxetic structures, characterized by exhibiting a Negative Poisson’s Ratio (NPR), were designed with a re-entrant hexagonal geometry and fabricated with different mass fractions of jute fibers (2.0%, 2.5%, and 3.0%). The fibers were previously ground, sieved by granulometry, and incorporated into a photopolymer resin. The printing process was carried out using a DLP printer with parameters adapted for composite production. Morphological evaluation was performed using scanning electron microscopy (SEM), enabling the observation of print quality, fiber dispersion, and the integrity of the auxetic geometry. The results demonstrate that the DLP technology is effective in replicating complex geometries with good matrix–fiber integration, particularly at lower fiber concentrations. However, at higher fiber contents, agglomeration and surface exposure were observed, which may affect mechanical performance. SEM analysis also confirmed the preservation of auxetic geometry and the well-defined unit cells, reinforcing the potential of combining natural fibers and AM for structural and functional applications.

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The development of synthetic materials with bioactive, osteoconductive and biocompatible characteristics for biomedical applications has become essential for humanity. Hydroxyapatite (HA) is an inorganic ceramic that has similar characteristics and properties to the mineral apatite. The aim is to obtain and characterize a calcium phosphate bioceramic using the wet precipitation technique, using acid/base reagents. In order to analyze the chemical elements and the microstructure of the material obtained, X-ray diffraction infrared spectroscopy (XRD), Fourier transform infrared spectroscopy (FTIR), scanning electron microscopy (SEM) and energy dispersive spectroscopy (EDS) were used. The XRD results showed peaks of hydroxyapatite and calcium oxide. The FTIR analysis showed carbonate (CO32-) and phosphate (PO43) vibration bands, characteristic of the material. SEM indicated irregular morphologies with different shapes and forms. EDS analysis also showed the presence of calcium, phosphorus and oxygen, as well as a Ca/P molar ratio of 1.50. The characterizations carried out indicated the presence of type B carbonated hydroxyapatite, suggesting a nanometric shape. Furthermore, it is suggested that the hydroxyapatite obtained in this study has great potential for application as a biomaterial

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The Environmental Aspects and Impacts Assessment (EAIA) system was developed to digitize the process of managing environmental aspects and impacts, which was previously conducted using Excel spreadsheets. The lack of a structured system hindered the correlation between environmental incidents recorded in the Incident Management System (IMS) and the items mapped in the EAIA. To address this limitation, a semantic search system based on Azure AI Search was implemented, leveraging Machine Learning and Natural Language Processing (NLP) to suggest the most relevant EAIA items for each incident recorded in the IMS. Moreover, the consolidated data provides greater traceability for risk mitigation strategies, eliminates the need for manual information management, and ensures a continuously updated and accessible database of environmental records

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In the mining industry, actuator reliability is essential for operational safety and process efficiency. This paper presents the development and implementation of a tool for automatic signaling of valve status in an iron ore beneficiation process. A tool developed in a supervisory environment, with the creation of specific faceplates for real-time visualization of operational status, based on the expected valve operating logic and process variables. This solution aims to mitigate one of the main bottlenecks faced by instrumentation teams: the unavailability or failure of inductive sensors responsible for indicating valve positioning. The lack of continuous monitoring resulted not only in an increase in the maintenance backlog, but also in the generation of downtime hours, directly affecting operational continuity, equipment availability and, consequently, process quality. The implemented tool allowed the automatic identification of operational deviations and failures, providing support for predictive maintenance and significantly increasing the availability of critical process assets.

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The growing demand for automation and efficiency in industrial processes makes the use of disruptive technologies, such as generative artificial intelligence (AI), essential. As part of Usiminas’ digital transformation strategy, a project was created to incorporate generative AI into shop floor industrial systems. Queries, transactions, and analyses rely on human interaction, resulting in longer response times. The initiative aims to expand the use of generative AI to boost operational efficiency, improve the accuracy and agility of decision-making, mitigate failures, and enhance safety. The project involves developing an AI-based architecture using natural language models and computer vision. This architecture supports functionalities such as automatic audio transcription and image analysis, effectively addressing the specific demands of each industrial area.

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This study assessed the heat recovery potential from the exhaust gases of an annealing furnace in a Continuous Galvanizing Line (CGL). Two scenarios were investigated, utilizing data from SCADA and PI systems, alongside mass and energy balance analyses. An available heat potential of 1.94 MW was identified. Both saturated steam generation and thermal fluid approaches were compared for heating pre-cleaning tanks. Both methods proved technically feasible, leading to up to 75% savings in natural gas consumption and a 52% reduction in CO₂ emissions. Steam generation emerged as the more economically advantageous option, characterized by a shorter payback period of 2.89 years and an estimated investment of R$ 6,200,000.00. This approach exhibits a Technology Readiness Level (TRL) of 9, indicating high maturity and widespread adoption. The thermal fluid approach, while technically sound, presented a higher investment of R$ 7,750,000.00 and a longer payback of 3.56 years, with a TRL between 7 and 8. In conclusion, heat recovery in CGL operations is both technically and economically viable, with saturated steam generation being the most recommended option for fostering greater operational sustainability.

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This article aims to present the development of techniques and tests conducted on polyurethane, focused on anticorrosive protection of equipment in environments with intense weathering, especially coastal regions. Methodologically, resistance tests to weathering cycles, impact, ballistic, and pull-off tests were performed, along with specific structural calculations for polymers to ensure coating compatibility and efficiency. The practical application involved coating the roof of the blast furnace gasometer, a metallic component exposed to highly aggressive conditions. As a result, polyurethane proved effective as a structural reinforcement and anticorrosive barrier, extending the equipment’s lifespan and reducing maintenance costs. The implementation of polyurethane coating on the BFG gasometer roof as a structural reinforcement was innovative in the steel industry, contributing to the durability of steel equipment and operational optimization. Therefore, the research confirmed the technical and economic viability of the technology, emphasizing its significance

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As part of Gerdau’s investment in a sustainable platform for mining operations, the Itabiritos Project iron ore pipeline was established to transport iron ore from its Miguel Burnier mine to the Ouro Branco steel plant. More than 3 kt of hot coils of steel grades API X52 and API X65, with a thickness of 12.7 mm, were developed and successfully produced in its own Steckel mill line. The alloy design was based on C-Mn steels microalloyed with Nb, Ti, and V, processed by TMCP (Thermomechanical Controlled Processing). A major challenge was achieving the specified level of toughness, evaluated by the shear area in Charpy tests. This was overcome by adjusting, among other operating parameters, the holding thickness before finishing rolling. A direct linear dependence of shear area on austenite hardening during the pancaking phase was observed. It was noted that a holding thickness/final thickness ratio of around four allowed full compliance with the 85% shear area criterion in these steels.

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Rolling mills are designed to operate using cast iron rolls as its main tool for the conformation process. By changing these rolls to Tungsten Carbide, roll life can be increased by 10 to 20 times, and a roll designed to last for months now has a lifetime of years in operation. These rolls service under conditions that includes cyclic loads, contact wear, and high temperature gradients which will further hinder the fatigue resistance of the rolls. This scenario makes it critical to properly evaluate the loads and conditions the roll will operate, and FEM simulations can indicate that subtle changes in the roll design can significantly improve the roll’s fatigue resistance.

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This article presents a metallurgical failure analysis of support equalizing wheels used in wagon rotary dumpers at the Port of Tubarão, focusing on a case study involving SAE 4140 steel. After the premature fracture of wheels with only three months of operation, chemical, microstructural, mechanical, and fractographic analyses were conducted to identify the causes of the failure. The results revealed that the material had a chemical composition outside the specified range, with low carbon and high silicon content, as well as a martensitic surface microstructure with insufficient hardened layer depth. The wheel core was found to be heterogeneous, with tempered bainite and casting defects, which favored crack propagation. Tensile and impact tests indicated extremely low levels of ductility and toughness, resulting in brittle fracture by cleavage. The investigation concluded that the failure was caused by a combination of metallurgical nonconformities and deficiencies in heat treatment, highlighting the importance of strict process control in the manufacturing of critical components.

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In recent years, the technology allied with environmental sustainability has advanced significantly, and the quest for these solutions became crucial for competitiveness and survival of the companies. Pelletizing furnaces, with their oxidizing environments and high operating temperatures, naturally produce NOx. To achieve operational excellence and reduce NOx emissions, Samarco, in collaboration with its partner company ATS, has developed a prototype of a burner called Low NOx. This burner operates with natural gas, water, and air and has been designed to minimize the formation of thermal NOx during pelletizing furnace operation. The development of the Low NOx burner involved the use of CFD (Computational Fluid Dynamics) simulations, theoretical reduction mechanisms, and thermodynamic models to optimize its efficiency. To validate the burner’s performance under real operational conditions, Samarco constructed a prototype of the Low NOx burner and an auxiliary rack. During the tests, the NOx levels associated with natural gas and water were measured, which were consistent with the CFD simulations.

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In light of technological transformations and industrial competitiveness, this project was carried out with the objective of reducing the dwell time of raw material trucks. Bottlenecks such as communication failures, low operational visibility, and the absence of performance indicators were identified. A working group redesigned logistics processes by implementing scheduling reengineering, preventive alerts, and team training. With the support of dashboards and alignment routines, the company reduced the average dwell time by 30%, reaching the target of up to 5 hours and ensuring stability from October 2024 onward. This initiative generated cost savings, predictability, and strengthened the culture of continuous improvement, demonstrating the importance of data integration and collaborative management for the competitiveness of the supply chain.

Abstract:

The study focuses on improving the iron ore unloading process at Vale's Ponta da Madeira Maritime Terminal in São Luís (MA), with the ER313K-02 machine in particular. The aim was to resolve blockages caused by the Carajás Pellet Pellet (PPCJ), a high-quality product with physical and chemical characteristics that make it difficult to drain. Clogging caused operational downtime (62 hours in the first four months of 2024), safety risks, environmental impacts and financial losses. The methodology involved statistical analysis (t-test) to correlate the PPCJ's specific surface area and humidity, followed by the prioritization of three solutions via a decision matrix. The solution chosen was the installation of a non-stick oil spray system, creating a lubricating layer to improve flow. Tests with 10 batches of 110 wagons (6,000 ton/h) confirmed its effectiveness, reducing stoppages by 68%, increasing the effective rate by 78% and eliminating safety risks. The results include environmental, ergonomic, safety and productivity gains. The initiative is aligned with sustainability and low-carbon transition goals, reinforcing innovation in mining. It promotes a culture of collaboration, technology and redefines the future of the mining industry with economic, social and environmental benefits.

Abstract:

This work presents an innovative approach by proposing the use of computer vision techniques to analyze slag splashing process images. The footage captures the slag projection between the converter mouth and the hood. Frames extracted from the video were processed to generate graphs tracking the evolution of particle quantity and size, offering a more objective and automated method for monitoring and optimizing the process.

Abstract:

This article analyzes the effect on Environmental Preservation by using Cooling Towers instead of Gas Coolers due to the significant reduction in the formation of Dioxins and Furans, organic compounds that are very harmful to human health to a degree that could avoid an investment in a Dioxin and Furan neutralization system, reducing or eliminating potential additional CAPEX costs. Additionally, the use of the Cooling Tower can eliminate the need for long Water-Cooled Ducts, which, besides reducing CAPEX and optimizing the EAF plant area, lowers OPEX costs through energy savings in the Water Cooling Tower and Pumps of water cooling system. In addition to these gains, the ability to provide a quick response to control the gas temperature of the Cooling Tower prevents damage to the bags of Bag Filter, reducing plant downtime, optimizing EAF productivity, and lowering maintenance costs.

Abstract:

Purpose of the well filler is to protect and seal the casting channel during ladle transport and treatment and to freely and safely open when the slide gate is opened in casting position. The opening rate is measured in [%], comparing the number of successful free opening ladles vs the ones that require lancing. That means, numbers between 0-100% opening rate are possible. Steel making statistics reveal a specific well filler amount of 0,3-0,5 kg applied per t of crude steel. In this paper the question of the global scale of non-free opening is put on the table. For example, assuming an average global opening rate of e.g., 90% leads already to 2.000-2.800 ladles per day, that require lancing. Lancing means operational safety hazards, slow process, and quality downgrades. In a nutshell: high risk at high costs. One of the key factors in this scenario is certainly the suitability of the well filler. However, our recent observation in ladle preparation area show that the automation and monitoring rate is rather low. Also, individual process, metallurgical, and application aspects are not always considered. Weebotec has therefore developed the 3 P concept (product, process, personnel) to support a more holistic approach for increased ladle opening rates together with the customer. For the product well filler, selection of raw materials, degree of purity and professional processing are of importance. Reproducibility of the desired sintering behavior, flowability and infiltration with respect to steel must be ensured. In steel plants, knowledge of all important process parameters such as process route, heat size, idle time etc. is necessary to develop suitable well fillers. Finally, well filler application is a relevant influencing factor. Providing the correct amount in the right place at the right time is crucial. Best results are achieved by using modular dosing stations. Certainly, precise, and reproducible working standards for de-slagging and reliable ladle hygiene in the ladle preparation/tilting area are mandatory. In this publication, operational laboratory tests will reveal how the 3 P concept has already proven that simple adjustments to process, application technology and product contributed to an increased ladle opening rate [1].

Abstract:

The present work involved the development of a numerical model using the finite element method for the thermal calibration of the welding process of an ASTM A516 Grade 70 steel, corresponding to the GTAW (Gas Tungsten Arc Welding) technique. The main objective was to construct a simulation that reflects reality in order to obtain accurate, though not exact, results directly through the computer. This approach aimed to predict the temperature distribution and thermal calibration throughout the entire welding process—information that can be highly valuable for the optimization of welding parameters. The simulation was validated with experimental data available in the literature, through tests carried out using TIG welding, showing a strong correlation, which demonstrates the model’s capability to represent the actual conditions of the process. This work contributes to the development and advancement of welding process modeling, offering a reliable tool for analyzing and predicting thermomechanical effects.

Abstract:

This research combines physical and computational simulations to examine the flow behaviour of a 1020 steel deformed under plane strain compression. It aimed to determine the flow curves and relate the changes in the microstructure to the deformation gradients. Physical tests were performed on annealed sheets, measuring the load and thickness. The experiment was simulated using the finite element method, considering different friction coefficients. Experimentally, it was determined that the yield stress is <300 MPa, while the flow stress exceeds 600 MPa for equivalent strains of ~1.0. The analysis of the microstructure revealed a “double X” strain pattern, compatible with the numerical predictions when friction is low. The simulations showed how the deformation gradients evolve, going from a single “X” to a double “X”, with the reduction of the thickness. When friction increased, deformation concentrated in the centre of the sheet.

Abstract:

The incorporation of processed marine mollusk shell waste into mortars, concretes and other composite materials has been characterized as an economically and environmentally sustainable alternative in several scientific studies. Similarly, but still incipient, shells of some species of aquatic mollusks and terrestrial mollusks, such as pulmonate gastropods (snails, snails, etc.) have also been the subject of studies aiming at the development and/or improvement of materials. In this perspective, the objective of the present study was to evaluate the influence of the addition of crushed shells of African land snails (Achatina fulica) in mortars for laying blocks and covering walls and ceilings as an alternative aggregate, in the replacement proportions of natural sand of 0, 5, 15 and 25%, with a preliminary focus on the evaluation of some of the main parameters in the fresh state, namely: consistency index, incorporated air content, water retention and mass density. The results obtained demonstrate the viability of using the fine aggregate under study (shell sand) as a technologically sustainable alternative, but in low proportions of replacement of the natural aggregate. And, considering the properties evaluated in the fresh state, the test mortars remained within the levels of suitability, meeting the normative and scientific technical standards, in accordance with national and international literature.

Abstract:

As an alternative to current environmental challenges, artificial stones are a promising class of materials. Composed of a high percentage of solid waste, they are a viable alternative to conventional disposal in landfills. Thus, the present study aims to produce artificiais stones by evaluating the impact of using different proportions of a coupling agent on the mechanical properties of the stones. The artificial stones are composed of glass waste from fluorescent lamps, quartz sand supplied by the company EcologicStone, and commercial quartz, with epoxy resin as the matrix. The processing route used is the vibration process with compaction and vacuum.

Abstract:

This study details the implementation of a computer vision system for automating quality control in the steel industry, focusing on the detection of scratches on steel plates at the CSN cold rolling mill. The objective was to validate the feasibility of an artificial intelligence model to replace manual inspection, which is subjective and prone to errors. The methodology involved fine-tuning a model using a custom dataset collected directly from the production process. The results demonstrate the system's effectiveness, achieving a mAP@50 of 0.574, an F1-Score of 0.584, and an inference time of just 3.2 ms per image, confirming its potential for real-time application. It is concluded that the solution is technically feasible and efficient, enabling a significant improvement in quality control accuracy, a reduction in operational costs, and the generation of data for continuous process optimization.

Abstract:

The efficient allocation of steel slabs that do not meet primary sales specifications is a critical factor in steel manufacturing, directly impacting overall metallurgical yield, storage duration (aging), and operational process efficiency. This technical paper details the development and implementation of an advanced automatic slab allocation model at the AM Pecém plant. Resulting from a multidisciplinary collaboration between the Metallurgy and Information Technology (IT) departments, the solution employs computational logic to optimize material movement, significantly reduce the allocation cycle, and increase overall productivity. Integrated with the MES system, the new model executes automated allocation routines every 12 hours, prioritizing sales orders that maximize the added value of reallocated material and minimize losses due to scrap.

Abstract:

Samarco employed an AIOps strategy tailored to the OT environment to scale AI applications across its iron-ore plant, integrating People, Process and Technology and deploying two virtual sensors: one estimating belt-conveyor mass flow and another predicting silica grade in coarse-ore flotation. The methodology comprised an analytics-maturity diagnosis, creation of a multidisciplinary team, standardisation of automated pipelines with retraining and observability, and adoption of an on-premises AIOps platform. Virtual sensors implemented through this platform feed controllers in near real time and have cut model-deployment lead-time from months to days. Preliminary results indicate increased productivity and fewer unplanned shutdowns. Structured data-and-model governance, combined with edge infrastructure and internal capability building, thus provides Samarco with a replicable, secure and economically sustainable pathway to expand industrial AI

Abstract:

The steel industry consumes large amounts of water and chemicals, especially in the cooling systems of the production process. Therefore, mitigating corrosion becomes an intrinsic part of water treatment processes, given its importance in economic, safety, environmental and fixed asset protection aspects. At the ArcelorMittal Pecém steel mill, the dosage of the corrosion inhibitor CorrShield NT4203TM (sodium nitrite) in the LF closed cooling system was performed manually, which reduced the precision and agility of the operation. Faced with these limitations, the Veolia team implemented the equipment called Compact™, capable of continuously monitoring the conductivity of the recirculating water. Based on this reading, the system sends on/off signals to the dosing pump, automating the dosage and keeping the treatment within the parameters. Since the adoption of automation, greater stability has been observed in the control indicators, with significant reductions in the oscillations of the nitrite residue and especially in the corrosion rate. After nine months of operation, a 24% reduction in chemical product consumption was recorded, generating technical, economic and environmental benefits.

Abstract:

The syringe cell method was adapted to study pitting corrosion on samples with different surface areas, avoiding issues related to crevice corrosion. This work aims to correlate exposed area and breakdown potential. For this purpose, commercial 2304 lean duplex stainless steel was investigated by cyclic potentiodynamic polarization (CPP) in 3.5 wt.% NaCl solution. Four surface areas were used ranging from 0.06 to 1.27 cm². The breakdown potential results were bimodal, showing either pitting at a relatively low pitting potential or transpassivity at a much higher potential. The likelihood of pitting corrosion, as expressed by cumulative distribution plots of multiple replicate experiments, increased with surface area owing to a greater probability of inclusions acting as initiation sites. The results can be fitted using mixture probability distribution to establish a model that correlates breakdown potential with the specimen surface area and the areal density of pit initiation sites.

Abstract:

Advanced High-Strength Steels (AHSS) are widely employed in the automotive industry to reduce vehicle mass without compromising structural integrity and safety requirements. However, the limited formability of these materials imposes significant constraints on forming processes. This study investigates the correlation between microstructure and formability of a Dual Phase (DP) steel with a minimum tensile strength of 780 MPa, industrially produced through two distinct thermomechanical processing routes. The samples were characterized in terms of microstructure, mechanical behavior and formability. The results indicate that the optimized condition, featuring greater homogeneity, higher volume fractions of bainite and retained austenite, and increased elongation, exhibited a 20% increase in FLC₀ and a 55% improvement in edge stretchability, demonstrating substantial enhancements in both global and local formability. Numerical simulation of the stamping process, using constitutive models calibrated with experimentally obtained mechanical properties, showed a significant reduction in failure due to fracture. These findings were validated at the industrial scale, where the rework rate of stamped parts was reduced from 30–40% to nearly zero. Such results reinforce the importance of microstructural control as a key tool to enable the application of these materials in automotive components with complex geometries.

Abstract:

The increasing demand for energy efficiency and emission reduction in the automotive industry has driven the development and application of advanced high-strength steels (AHSS). Among these, Dual-Phase (DP) steels stand out due to their excellent strength-to-ductility balance, weldability, and suitability for complex forming operations. However, one of the main limitations in the application of AHSS sheets is the occurrence of edge fractures during forming, frequently related to pre-damage introduced during punching and blanking operations. In these processes, the quality of the sheared edge—comprising the rollover, burnished, fracture, and burr zones—directly influences the material’s behavior in subsequent forming steps. Previous studies have shown that damage induced during shearing can reduce the hole expansion ratio and promote crack nucleation, especially near the fracture and burnished regions. Thus, understanding and quantifying the deformation-affected zone (DAZ) becomes crucial for improving forming reliability and modeling failure behavior. This study aims to experimentally characterize the DAZ in punched DP600 steel sheets by combining microhardness profiling with morphological analysis of the cut edge. The findings contribute to the understanding of strain localization around the sheared edge and provide essential input for fracture modeling in high-strength steel forming.

Abstract:

The background of this work is a proposal to determine KIc, in a ductile material without the need for fatigue crack opening, using a less expensive technique than that used and standardized by ASTM E399 [1]. By presenting a more accessible test, the Notched Cylinder Model has confirmed its viability by achieving KIc between 24 and 29 MPa√m for 7075 T6 aluminum alloy. However, analysis of the stress fields and triaxiality levels at the root of the notches alone cannot confirm the validity of the KIc values obtained. In contrast, a pure and straightforward analysis of the fracture morphology of the resulting region cannot discern the phenomena that have occurred. The two approaches were, therefore, combined. This enabled an exploratory study that proved the absence of a plastic zone in successful cases and made it possible to analyze the mechanisms at work up to failure. For small non-singular notches, failure initiation was confirmed in front of the notch. The scenario analyzed revealed complex surfaces, including inter- and transgranular crack propagation and configurations that resemble a peculiar failure mode called quasi-cleavage.

Abstract:

Online oil monitoring emerges as a key tool, providing real-time data for proactive maintenance. Cases study in an ore reclaimer underscores the implementation of this monitoring for a bucket wheel gearbox, classified as a critical asset within the mineral industry. These referred cases dive into advanced oil and parts degradation, focusing on challenges in vibration analysis and sensitive inspections. This paper presents how online and offline oil condition monitoring, along with proper filtering tasks, can improve oil quality control and enhance lubrication practices. Further, the approach focuses on lubrication excellence, the importance of a robust lubrication program, and best practices in oil filtration. Insights into oil analysis, lubrication, and filtration techniques that lead to better maintenance engineering outcomes and improved equipment performance are detailed for professionals involved in lubrication and filtration management.

Abstract:

This article presents the implementation of the AMPort mobile application, developed to centralize and automate the monitoring of the Operational Slab Shipment Report at ArcelorMittal Pecém. The solution integrates with Power BI, enabling real-time visualization of operational data. The main benefits of the application are highlighted, such as information centralization, operational gains, transaction history, and cost reduction. The proposal aims to optimize logistical and administrative processes, promoting greater efficiency and reliability in operations

Abstract:

Given the increasing need for market competitiveness, companies have been adopting innovation and continuous improvement strategies in their operations. This paper analyzes the Fontes Geradoras operation, implemented by CSN, which aims to strengthen relationships with customers by integrating them into the supply chain. Through the use of roll-on/roll-off containers, the company stations equipment at the client’s site to collect metal scrap generated by their industrial processes. Once full, the containers return to CSN, turning customers into suppliers and ensuring a continuous flow of raw materials. The methodology employed is a qualitative case study, supported by document analysis and stakeholder interviews. Results indicate that the operation reduces risks of scrap shortages, enhances commercial partnerships, and optimizes reverse logistics. This initiative represents a strategic innovation, aligning sustainability with competitive advantage.

Abstract:

Slag formation is essential for maintaining a stable basic oxygen furnace process, ensuring proper final slag properties for lining protection. Often, the final slag conditions require adjustments to optimize performance. This paper presents a slag correction model that integrates practical experience, theoretical knowledge, and data science, detailing the methodology applied in a steelmaking plant. The model focuses on the relationship between MgO saturation and liquid fraction, a key factor in promoting slag adherence to the converter walls. Implementing this model has led to economic savings through more efficient use of materials and improved coverage efficiency of the converter lining.

Abstract:

Magnesian-Dolomitic refractory masses are widely used as repair materials in electric arc furnaces (EAF) in the steel industry, mainly due to their high refractoriness, good sinterability, and stability against chemical corrosion and mechanical degradation during the steelmaking process. This study investigated the performance of a commercial product line used as dolomitic repair masses for the ramp area in Electric Arc Furnaces (EAF). For this purpose, a field data acquisition study was conducted, associated with the established application parameters. The performance of these masses was then evaluated through the measurement of their specific consumption.

Abstract:

Mold fluxes play a crucial role in the continuous casting of steel, ensuring thermal insulation, lubrication, and surface quality of the final product. Traditionally, fluorine has been a key component in these formulations due to its ability to reduce viscosity, control crystallization, and optimize melting behavior. However, its use has been increasingly questioned due to environmental concerns, corrosion of submerged entry nozzles (SEN), and negative impacts on plant infrastructure and water treatment systems. In response to these challenges, this study presents the development and industrial validation of low fluorine mold fluxes specifically designed for the continuous casting of low and medium carbon steel grades. The new formulations, with significantly reduced fluorine content, were tested in three ArcelorMittal steel plants under real casting conditions. Key performance indicators such as heat flux, liquid layer thickness, mold lubrication, water pH of the secondary cooling system, and SEN corrosion were evaluated. The results demonstrated that the optimized fluxes provided stable casting operations, maintained adequate lubrication and heat transfer, and significantly reduced SEN wear and acidification of cooling water. These findings support the feasibility of reducing or eliminating fluorine in mold fluxes without compromising process performance, contributing to improved sustainability, equipment lifetime, and overall productivity in steelmaking.

Abstract:

Dissimilar welded joints between 9%Ni steel and Inconel 625 are used in CO₂ injection units for subsea oil production systems, requiring mechanical strength and fracture toughness under cryogenic conditions. The welding of dissimilar materials creates High Dilution Zones (HDZ) near the fusion line, whose microstructure results from the interaction between the base metals’ properties and the molten pool dynamics. This study investigated the HDZs formed during the multipass circumferential welding of 9%Ni steel pipes using AWS ER NiCrMo-3 (Inconel 625) as filler metal, through SEM, EDS, and EBSD analyses. Two distinct regions were identified: continuous HDZ (c-HDZ), with a face-centered cubic structure and epitaxial growth from the 9Ni HAZ, and discontinuous HDZ (d-HDZ), with a lath martensitic microstructure which, through parent grain reconstruction, was also shown to act as a source of heterogeneous nucleation for neighboring grains. A distinction in chemical composition between the different regions was observed, a factor which directly influences the localized plasticity of the dissimilar interface.

Abstract:

Zinc and its alloys are well known in the industry for some feature that favor their application in industry, such as lower acquisition cost, compared with other metallic alloys, low melting point, which favors casting practice and versatility of applications, mainly. However, other characteristics can hinder their industrial use, such as the hexagonal close packed crystalline structure, with lower amount of dislocation slip systems, thus complicating the metal working, metal forming. Nevertheless, when an overall balance of these characteristics is considered, these alloys have been frequently used and their use is growing. Thus, the ZAMAC alloy (Zn-Al-Mg-Cu) is specially appreciated for its mechanical properties and suitability for pressure casting, providing easiness of producing a great number of products with high complexity and excellent surface finishing. However, continuous process enhancement is essential for meeting the requirements of quality and efficiency in the market. In this sense, it is of foremost importance to know well the microstructural characteristics pof these alloys. In this work, analytical techniques such as optical and scanning electron microscopy were employed to perform the microstructural characterization of a ZAMAC 5 zinc alloy produced by die casting (injection molding), revealing a microstructure composed by almost pure zinc grains surrounded by an eutectic matrix, which is a Random distribution of aluminum particles and even smaller copper particles in a zinc background.

Abstract:

Eco-friendly features, satisfactory properties for engineering designs of several components, low cost and plenty of resources gave for the natural fiber reinforced polymer composites a marked academic and industrial interest in recent times. This applied research focus on the study of static bending of a horizontal axis wind turbine (HAWT) tower made of epoxy composite reinforced using high volume fraction of ramie woven fabric subjected to offshore conditions. The objective of this research is to characterize the static bending behavior and to evaluate if the biocomposite tower structure is macroscopically safe. A nonlinear finite element analysis is performed as one more step in the technological development of a greener wind generation. The results of the simulation are encouraging and corroborate with a wind industry even more sustainable and less polluting.

Abstract:

This study presents a comparative analysis between composites made from sugarcane bagasse and two different resins: polyvinyl acetate (PVA) and polyurethane (PU), focusing on their hygroscopic properties and flammability. Panels measuring 300×300×10 mm were manufactured and subjected to testing according to the NBR 14810-3, UL94-V, and UL94-HB standards. The results showed that the PVA-based composites exhibited greater water absorption after 24 hours compared to those made with PU, although both remained within the standard limits. In the vertical flammability test (UL94-V), both PU and PVA composites failed. However, in the horizontal burning test (UL94-HB), PU-based specimens showed higher burning rates (up to 31.2 cm/min) compared to those with PVA (maximum of 13.5 cm/min). It is concluded that composites with PVA binder have greater moisture sensitivity but lower flame propagation, while PU composites offer better dimensional stability but present a higher flammability risk. The ideal formulation choice will depend on balancing thermal resistance and physical stability, which may require additives for specific applications.

Abstract:

This study proposes the development and application of a dynamic calibration methodology for on-line analyzers used in mineral processing. The proposed approach is applicable to any real-time measurement equipment that has periodic laboratory reference data available. Although on-line analyzers provide fast and continuous results, their accuracy is often impacted by variations in material properties such as mineralogy, particle size distribution, and solids content, among others. Therefore, frequent recalibrations are required, which are typically slow, manual, and costly. To address this challenge, an automated dynamic calibration technique was developed, continuously updating the calibration curve using the raw analyzer data combined with laboratory results and selected process parameters. The method employs a moving window; in this case, the 20 most recent laboratory samples were used to generate a new calibration curve with each new lab result. This dynamic model is then applied to recalculate, in real time, the silica grade in the coarse flotation concentrate. The approach was validated using the Courier 5 XRF analyzer applied to iron ore, demonstrating a significant improvement in the accuracy of silica grade prediction in the coarse flotation circuit.

Abstract:

The need for a certification such as TISAX (Trusted Information Security Assessment Exchange) arose from the growing demand for information security among suppliers and service providers in the automotive industry. Many original equipment manufacturers (OEMs) handle highly sensitive information and therefore require evidence of compliance with strict information security requirements. TISAX is an information security certification established in 2017 by the German Association of the Automotive Industry (VDA). It was developed to ensure that suppliers and service providers in the automotive sector meet rigorous information security standards, based on the ISO/IEC 27001 standard and the IATF framework, while being tailored to the specific needs of the automotive industry. Its goal is to ensure that the entire supply chain adheres to the highest standards of information protection. In this context, ArcelorMittal Aços Planos Brasil has adopted the certification as part of its strategy to mitigate risks and strengthen its position as a benchmark in Cybersecurity. More than a regulatory requirement, TISAX has become a strategic competitive advantage.

Abstract:

Continuous galvanizing lines require precise coating control to ensure product quality, avoid over-coating, and reduce costs. However, the distance between the coating application point and the on-line gauge introduces a time lag that hampers immediate adjustments. To overcome this limitation, a multiple-regression predictive model was developed for Continuous Galvanizing Line 1 (LZC1) at CSN. After collecting operational data, the team carried out data preparation and exploratory analysis to identify relationships among process variables. A stepwise approach was then used to select the most relevant predictors and fit an Ordinary Least Squares model, validated with 10-fold cross-validation, which achieved an R² of approximately 78 %. The model was implemented in a dedicated block within the programmable logic controller (PLC). In operation, the PLC continuously calculates the predicted coating thickness, compares it with the measured value, and applies a dynamic offset. This offset, frozen at the start of each coating transition, eliminates steady-state error and speeds convergence to the target thickness. Historical records show a significant reduction in variability, less transient over-coating, greater process stability, and lower zinc consumption, yielding both economic and environmental benefits.

Abstract:

The Vale site in São Luís – MA consists of the Ponta da Madeira maritime terminal, the Carajás Railway (EFC), Basic Metals, and the Pelletizing Plant. The site's electrical system comprises 49 substations, including the SE-381-KA substation, which acts as the receiving unit with an installed capacity of 360 MVA distributed across six transformers of 230/69/13.8 kV. The distribution of electrical energy to field equipment—such as stackers, reclaimers, and wagon rotators—is carried out through circuit breakers or contactors installed in 13.8 kV or 4.16 kV voltage cubicles. These devices are removable during switching operations. The manual operation, still present in many processes, requires an operator with knowledge of the system, experience, skills, and physical capability. These devices require careful maintenance and operation, as any failure may result in an explosion and the emission of an electric arc, an undesirable event that can expose employees to hazardous conditions. This study concerns an improvement implemented through innovative solutions, incorporating a device for the insertion and extraction of high-voltage circuit breakers and contactors in the substations of Vale’s Ponta da Madeira Maritime Terminal

Abstract:

This study investigates the localized corrosion behavior of AISI 316L stainless steel produced by Wire Arc Additive Manufacturing (WAAM). Potentiodynamic polarization testing revealed a pitting potential (Epit) of 0.476 VSCE, indicating moderate resistance to pit nucleation in chloride-containing environments. SEM/EDS analyses revealed microstructural heterogeneities and inclusions associated with Mn segregation, while X-ray photoelectron spectroscopy (XPS) identified surface chromium depletion. These findings suggest that the melt pool morphology, combined with the thermal history of the WAAM process, compromises the local passivity of the material, promoting the initiation of localized corrosion. The adoption of thermal or surface post-treatments is recommended to mitigate these effects.

Abstract:

With stricter building codes and regulations throughout the world, the increased strength requirements for rebar have pushed production technologies forward. New plants from Primetals Technologies are now configured to allow the ultimate flexibility to produce conventional hot-rolled, quenched & tempered, and low temperature rolled rebar – providing the lowest conversion costs to serve all market demands. Modern high-speed rebar production configures the finishing stands and water-cooling zones to provide these multiple processing routes with optimized mechanical properties. The challenge is to avoid driving a wide range of billet chemistries with the use of high-cost alloying elements.

Abstract:

A new approach for online pass schedule calculation models for cold rolling mills is presented, which uses a full nonlinear finite element method (FEM) model exploiting the parallel computing power of graphical processing units (GPU) for the deformation process. In combination with the models for flatness, thermal crown and wear, strip temperature and an intuitive and process-oriented handling of rolling strategies the online pass schedule calculation model can improve cold rolling mill performance significantly.

Abstract:

This study presents a failure analysis of hooks used for coil handling in a Wire Rod Mill. Recent failures of these components led to unplanned shutdowns and raised safety concerns for operational personnel. The actual loading conditions during operation were characterized using strain gauge measurements. A repair solution for cracked hooks was proposed, and a Engineering Critical Analisys (ECA) was performed according to the BS 7910 standard to evaluate the structural integrity. The metallurgical effects of welding were assessed through thermal cycle simulation on test specimens. Based on the results, the damage tolerance of the structural component was defined, enabling the implementation of predictive maintenance actions. The adopted approach contributed to improved operational reliability and the prevention of future failures.

Abstract:

To avoid the risk of underground structures breaking, we developed the VACUUM EXCAVATION solution for INTERFERENCE INVESTIGATION, where a vacuum truck (the same one used for cleaning galleries and operational routines) with a device made of HDPE at the end of the hose carefully removes the soil. This solution aims to excavate until the interference is visually identified, mitigating the risk of reaching the buried structure. This is a Kaizen presented and awarded at VALE continuous improvement meetings

Abstract:

This study presents the development and implementation of adjustable internal guides in pivoting chutes of mobile rotary ship loaders, aiming to reduce clogging and belt misalignment during iron ore loading operations. The methodology involved computational simulations using the Discrete Element Method (DEM), with parameters calibrated for Sinter Feed ore. Various operational configurations were analyzed, identifying that clogging occurs from bottom to top, especially when the boom is inclined and rotated beyond 90°. The proposed solution was the use of adjustable guides, allowing the opening to vary according to the boom position, maintaining efficient flow and load centralization. After implementation on the ship loader, a 47% reduction in downtime due to misalignment was observed, along with a 5% increase in effective loading rate and an almost complete elimination of chute clogging events. The results demonstrate that the application of adjustable guides is an effective solution to balance operational performance and reliability in bulk material handling systems at port terminals.

Abstract:

Reverse logistics is crucial for enhancing customer service and reducing costs. This work focuses on the challenges faced by Aperam Timóteo in managing customer returns and material returns from the service center in Campinas (CS2). The previous process of collection, registration, and transportation to Timóteo was costly, insecure, and prone to theft. Using the Lean Office methodology, the project aimed to reduce logistical costs, improve transportation security, and ensure compliance. The main solution was implementing material (scrap) compaction at CS2, enabling denser and safer transportation. Improvements in SAP/PESA systems and process redesign were also critical. As a result, compaction mitigated risks and improved handling safety. The percentage of empty freight dropped from 70% to 11.8%, reducing logistical cost per ton by 71.2%. The total cost of the Campinas-Timóteo route decreased by 83%. Theft risks were mitigated, and resource optimization reduced vehicle idle time.

Abstract:

Impurities in dolime influence the Basic Oxygen Furnace (BOF) steelmaking process by altering its thermal and mass balances. This study employed a static charge control model to assess the value in use (VIU) of dolime quality on process requirements. Various compositions with incrementally higher impurity levels such as SiO₂, Al₂O₃, Fe₂O₃ and residual CO₂ were tested, reflective of best-to-worst practices in the Brazilian market, which is a result of different production processes and the heterogeneity of dolomite deposits (raw material for dolime production). The model calculated adjustments in hot metal, scrap mix, quicklime, dolime, and oxygen inputs for each scenario. The prices of raw materials and the production cost of hot metal were defined based on values found in the Brazilian market at the beginning of 2025. Carbon footprint of steelmaking was also calculated. The results highlight significant economic and environmental trade-offs, as higher levels of impurities increases BOF input demands, such as hot metal and fluxes. Increasing SiO₂ content in dolime by 1.0% impacted the VIU of the material by 14.1% and increased CO₂ emissions by 5.9 kg per ton of steel, showcasing the strong impact of dolime SiO₂ content, both on steel production costs and carbon footprint. In the case of residual CO₂ content, rising its content by 1.0% impacted VIU by 2.1% and increased emissions by 1.9 kg per ton. The effect of Al₂O₃ and Fe₂O₃ was less relevant, since content ranges are low and charge corrections are less impactful to the process. An alternative dolime composition case was also tested for a material with higher MgO content (35.0% vs. 31.4% in the reference), but with higher contents of SiO2 (+2.5%) and residual CO₂ (+4.0%) and, consequently, lower CaO content (-9.7%). Even with the reduction in dolime consumption generated by a higher MgO, VIU was only 64.6%, compared to the reference. CO₂ emissions rise by 16.5 kg per ton of steel. Increased demand for quicklime and metallic charge, as well as an increase in the hot metal to scrap ratio penalized the use of this alternative dolime. These findings offer steel producers a framework to optimize dolime selection and use for aiming at operational improvements, economic gains and sustainable practices.

Abstract:

The electric arc furnace (EAF) process is gaining prominence in global steel production due to its lower CO₂ emissions and energy consumption. However, the continued use of water-cooled panels in the EAF upper sidewall presents serious safety risks, primarily due to the potential for water-steel interactions that may lead to explosions. Replacing these components with refractory panels can eliminate this risk while significantly reducing heat loss and water usage. This study evaluates five commercially available refractory castables using laboratory testing and thermodynamic simulations to determine their suitability for this application. An alumina-spinel (AM) castable emerged as the most promising material, offering an optimal balance of mechanical strength, thermal shock resistance, slag resistance, and refractoriness—making it a strong candidate for safer and more efficient EAF operation.

Abstract:

This study presents the improvements implemented in secondary metallurgy and the continuous casting process of AHF-route steels with widths equal to or less than 1200 millimeters, which historically showed a higher tendency to clogging during production. Previous limitations restricted the number of heats per tundish to a maximum of 10, negatively impacting productivity and increasing consumable and tundish usage. The main innovation was the improvement in the quality of the refining slag, which promoted better inclusion absorption and greater metallurgical stability, reducing the formation of inclusions and other internal defects. In parallel, an operational study identified the need to limit the strand pitch to 400 mm, which significantly contributed to reducing clogging events. Based on these findings, the production planning strategy was adjusted to incorporate these new operating parameters. As a result, the number of heats per tundish increased from 10 to 13, with greater process stability and relevant productivity gains. The study demonstrates how integration between refining, casting, and production planning areas can overcome complex technical constraints and deliver sustainable improvements in steel production.

Abstract:

Aiming to meet the challenging demands of the automotive industry regarding the combination of high mechanical strength and formability, Usiminas developed an advanced high-strength steel (AHSS) of the Complex Phase electrogalvanized (EG) type with a strength class of 1000 MPa (CP1000EG). In order to ensure the maximum performance offered by the material, regarding fatigue resistance and automobiles safety, special attention must be given to the welded joints quality due to the localized microstructural modifications inherent to the welding process. In this context, this study evaluated the resistance spot weldability of the steel in question, with a thickness of 1.30 mm. The joints obtained were free of discontinuities, presenting adequate mechanical strength and an acceptable welding current range. Furthermore, the steel met the standardized criteria regarding the electrode service life test, indicating that the EG coating has a low potential for input wear. Based on the results obtained, it is concluded that the CP1000EG steel has potential for application in the production of welded structural components that require good local formability and high mechanical strength.

Abstract:

The Continuous Cooling Transformation (CCT) curve is a tool that allows predicting the resulting microstructure in a given heat treatment cycle through the analysis of the dilatometric profile. This study aimed to develop the CCT curve of a cold-rolled steel grade using dilatometry in the Gleeble thermomechanical simulator. Seven dilatometry tests were performed, employing a fixed heating rate of 10°C/s up to 900°C, followed by 300 seconds of soaking, while varying only the cooling rates: 2°C/s, 5°C/s, 10°C/s, 15°C/s, 20°C/s, 50°C/s, and 75°C/s. To characterize the prior austenitic grain size (PAG), the same heating cycle was used, but the cooling rate was equal to 140°C/s and the average grain size was equal to 5 μm (12 ASTM). Microstructural characterization was conducted using optical microscopy (OM), scanning electron microscopy (SEM), and Vickers microhardness (HV) tests. Based on the interpretation of the dilatometric curves, microstructural analyses, and hardness values obtained for each cooling condition, the CCT curve for the investigated steel was developed. The curve revealed a maximum cooling rate of 75°C/s, at which a fully martensitic microstructure was obtained, with a hardness of 427 HV. These results will be used as a basis for the development of optimized annealing cycles for this steel grade in future investigations.

Abstract:

This study proposes formulating thermoplastic films based on corn starch—a low‑cost, renewable, natural raw material. Starch is a polysaccharide derived from plants such as corn, potatoes, and rice, with ongoing applications in the beverage, food, and fuel industries. Because it is affordable, renewable, and biodegradable, starch stands out as a promising feedstock for producing environmentally sustainable materials [1]. The goal of this work is to develop starch‑based thermoplastic films for packaging applications, as substitutes for petroleum‑derived polymers. The films were produced by casting: starch was dispersed in water, with and without the addition of glycerol (a natural plasticizer). After homogenization by stirring at 400 rpm and gelatinization for 30 minutes at 90 °C, ethyl or isopropyl alcohol was added dropwise as a nonsolvent to induce starch nanoprecipitation [2]. Preliminary studies show that the resulting nanoparticles improved the mechanical properties, increasing the films’ tensile strength and hydrophobicity. Nanoparticle formation occurred specifically upon alcohol addition during starch gelatinization, whereas glycerol did not enhance nanoparticle formation [2]. Tensile tests and contact‑angle measurements were performed to characterize the physical properties of the films developed in this study. For chemical characterization, Atomic Force Microscopy (AFM), Fourier‑Transform Infrared Spectroscopy (FTIR), X‑ray Diffraction (XRD), and nanoparticle analysis by Dynamic Light Scattering (DLS) were employed.

Abstract:

The growing interest in sustainable materials has driven research into Pykrete—an ice composite reinforced with natural fibers—as a low-cost alternative for ballistic applications. This study evaluated the energy absorption capacity of samples containing different numbers of sisal fabric layers. Ballistics tests were conducted using a pressure gun with 5.56 mm caliber lead projectiles, and the energy dissipated was measured by chronographs positioned before and after the impact. The results showed that incorporating sisal into ice significantly improved its impact resistance, with the configuration containing two layers (A2) demonstrating the best average performance and the lowest statistical variation. In contrast, excessive reinforcement (three layers) appeared to compromise the composite's structural integrity. The findings suggest that for ballistic coatings approximately 3 cm thick, the composite with two sisal layers offers superior energy absorption and greater consistency among samples. Furthermore, in alignment with existing literature, Pykrete was more effective than pure ice in dissipating impact energy and controlling fracture propagation.

Abstract:

Abstract:

The filtration process for preparing iron ore to be processed is very important to ensure the quality of the final product. Therefore, evaluations of this process are carried out daily in order to maintain regularity and progress. Issues such as humidity and productivity require special attention to maintain production and quality levels. Studies are carried out to improve the filtration process, seeking to increase production with lower humidity, which are daily challenges in search of improving the production process. To simulate filtration and test new methodologies, the most widely used tool is the Leaf Test, which consists of a bench filter that simulates the industrial process where parameters can be changed, achieving important data without posing risks to industrial production. In order for the data collected to be able to accurately report what occurs on an industrial scale, the evaluation method must correspond to a standard to which this article refers, where the human factor was replaced by equipment that standardizes the evaluations, granting the same scenario for evaluations of new fabrics, new sectors and new reagents, giving greater reliability to the data generated for industrial tests.

Abstract:

This study evaluates the floatability of intermediate purity pyrite (AM01) from the Cuiabá mine (AngloGold Ashanti) through microflotation tests with SIBX xanthate and sodium dithiophosphate (INT-214) at pH 8. The sample has a significant proportion of ankerite, as well as signs of surface oxidation aggravated by wet preparation stages and inadequate storage. The tests revealed low recovery with collectors applied alone, especially with INT-214, whose high selectivity and sensitivity to pH hindered its adsorption on the oxidized surface of pyrite. As a strategy to mitigate these effects, selective acid lixiviation with HCl (1:1 v/v) was performed to remove ankerite without compromising the sulfides. The results showed a significant increase in the purity of pyrite, allowing its application in future microflotation studies. The proposal reinforces the importance of preliminary purification steps in ores with complex mineralogy and high carbonate content.

Abstract:

Mining has advanced significantly with regard to tailings disposal, with the emergence of various plants focused on filtering for dry and compacted stack disposal. One of the main challenges is the treatment of slimes generated in the beneficiation process, which, due to their ultrafine particle size, exhibit low sedimentation rates and tend to contaminate the overflow of thickeners. This effect is exacerbated by the presence of foam. The present study aimed to evaluate the impact of defoaming agents and inorganic salts, as well as their combinations, in reducing foam formation. For this, chemical analyses were conducted to characterize the processed tailings in filtration, identifying contaminants such as talc, kaolinite, as well as Al2O3 and PPC. Additionally, bench tests were performed with defoaming agents combined with inorganic salts, such as CaCl2, MgCl2, and NaCl. Although both defoaming agents and inorganic salts show positive effects on foam breaking when added individually, the same does not occur when mixing the defoaming agent with the inorganic salt. Thus, it was concluded that their combination may compromise the defoaming action.

Abstract:

This paper presents the replacement of conventional sensors with a high-precision laser sensor for the position control of a rotary stacker reclaimer in a mineral beneficiation plant. The project aimed to increase system reliability, reduce unplanned downtimes, and improve precision under harsh conditions such as dust, vibration, and fog. The adopted technology operates on the Time-of-Flight (ToF) principle, using multiple laser pulses and advanced filters, enabling reliable high-resolution measurements. Integration with Samarco’s automation system and the PIMS platform enabled real-time monitoring and support for predictive maintenance. The results indicate significant improvements in stability, response time, and operational safety.

Abstract:

The application of high-chromium white cast iron alloys in the manufacturing of grinding media for the regrinding process of iron ore has proven advantageous due to their high abrasive and corrosive wear resistance. However, their high cost and the lack of a clear understanding regarding the influence of other alloying elements and processing variables highlight the need for further investigation to achieve better cost-performance ratios. Two types of commercially produced grinding media were evaluated, all made from white cast iron alloys with similar chromium content, but differing in silicon content and cooling media used during heat treatment. Through micro-abrasion tests, combined with hardness measurements and optical microscopy, it was found that the material produced with a medium silicon content and oil quenching during its thermal processing cycle exhibited higher hardness and greater resistance to abrasive wear. In contrast, the material with high silicon content and air cooling showed the poorest performance. It is suggested that a higher volume of precipitated carbides, a greater carbon content, and the use of oil as a quenching medium, which promotes the formation of a martensitic matrix, contributed to the improved performance. Meanwhile, the need for more specific austenitizing temperatures and cooling rates for materials with higher silicon content - so as not to compromise their hardness and wear resistance - emerges as a factor that warrants further investigation.

Abstract:

This study examines the historical trajectory of mining and mining engineering, highlighting the main events that marked its growth stages, including technological innovations and their social and economic consequences. The aim is to understand the evolution of this area, from the methods used in ancient civilizations to the progress with the creation of educational institutions, such as the Freiberg Mining Academy and the Ouro Preto School of Mines. The methodological approach used is a qualitative bibliographical research, which involves the analysis of historical and academic sources. The results indicate that mining engineering experienced significant growth with the Industrial Revolution and also with the founding of specialized schools. The conclusion is that the profession is in continuous development, being fundamental for economic progress and for adapting to new environmental demands and challenges.

Abstract:

The slag formed during the pyrometallurgical recycling of lead-acid batteries (Pb-Ac) plays a central role in phase segregation, impurity absorption, and control of metallurgical efficiency. This study evaluates, through thermodynamic simulations and experimental tests, the effects of the partial replacement of metallic iron by electric arc furnace (EAF) powder on the composition, structure and functionality of the generated slag. Two formulations were compared: a conventional one, with 100% iron chip, and an experimental one, with 50% EAF in the reducing fraction. The batches (~140 g) were melted at 950 °C in porcelain crucibles, with subsequent characterization of the slag by SEM-EDS and analysis of the segregated phases. The simulations were performed using the FactSage 8.3 software, based on the Pb-S–O and Fe–S–Pb systems. The substitution by EAF resulted in the formation of slag enriched in FeSiO₃, CaSiO₃, ZnFe₂O₄ and PbS, with lower viscosity, better phase separation and increased efficiency of metallic lead recovery (96.76% compared to 93.21% in the control). The direct (PbO + Fe) and indirect (PbO + CO) reduction reactions, in addition to the formation of silicates and sulfides, were activated synergistically, favoring a stable and selective vitreous matrix. The slag with EAF showed complex composition, lower incorporation of Pb and greater potential for environmental reuse. The results confirm that slag should not be treated as passive waste, but as a functional, controllable and technically optimized phase, capable of increasing metallurgical performance and contributing to the sustainability of the industrial process.

Abstract:

Rail fastening systems play a crucial role in the stability and safety of the permanent way, as they secure the rails to the sleepers, ensuring the proper transmission of mechanical forces generated by railway traffic. These systems are composed of components such as clips, bolts, base plates, insulators, and shoulders. The shoulders, in particular, serve to anchor the elastic clip to the base plate or directly to the sleeper. Typically made of ductile cast iron, the mechanical properties of the shoulders are directly influenced by the material's microstructure, especially the morphology of the graphite nodules. In this study, microstructural, physicochemical, and mechanical characterization activities were carried out on samples provided by railway operators, with emphasis on chemical composition, graphite nodule morphology, and mechanical properties obtained through standardized tests. Additionally, fracture surface analysis was performed on shoulders that failed in service, aiming to identify the fracture mechanisms involved. As a complement to the experimental analysis, numerical simulations were conducted using the Finite Element Method (FEM), with two-dimensional models built from actual images of the evaluated microstructures. The results obtained allow for the establishment of correlations between composition, microstructure, and mechanical performance.

Abstract:

With the aim of improving the performance of steel ladles, it was necessary to seek innovative technological solutions. In response, a project was initiated to implement a slag optimization model software, focused on guiding the ideal chemical composition of the steel and slag, promoting greater compatibility with the ladle's refractory lining. Operational tests were conducted using the model, resulting in the identification of relevant adjustments to process practices. The implemented changes led to significant improvements in the quality of the tested ladle slag, thereby optimizing metallurgical performance and, consequently, enhancing coating formation performance, as well as reducing flux addition. This directly contributes to decreased refractory wear and excessive consumption of inputs, positively impacting operational costs.

Abstract:

This study evaluated the effects of homogenization heat treatment and cooling conditions on the microstructure and mechanical properties of Zn-Al alloys produced by metal mold casting. Soaking times of 12 and 24 hours at 375°C were tested, followed by air or water cooling. Scanning electron microscopy revealed lamellar microstructures in air-cooled samples and granular ones in water-cooled samples. Chemical mapping by EDS indicated heterogeneities and possible contamination in certain conditions. Vickers hardness profiles showed greater uniformity for samples treated for 12 hours and water-cooled, while higher values were observed for 24-hour treatments with air cooling, suggesting the influence of chemical segregation. The presence of porosities highlighted the need for process control during casting to avoid defects. The results indicate that precise control of homogenization time and cooling rate is essential to optimize the microstructure and mechanical properties of Zn-Al alloys, enhancing their applicability in mechanical forming and structural components.