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Show first 15 years of its existence, shaping the development of the industry virtually single-handed. The develop-ment of the open hearth, by contrast, was much slower, because it had to compete with the Bessemers which predated it by a few years, and whose investment and operating costs were lower. The oxygen converter really got off the ground after being in existence for nearly 10 years, and was now experiencing growth similar to that of the Bessemer. The electric arc furnace, meanwhile, was originally intended for melting small quantities of high-quality steels; composition and temperature were easy to control and it was easier to deoxidise and desulphurise the melt. Traditionally, it was used to make high alloy stainless and high-speed steels as well as quality low-alloy grades. The move to production of ordinary grades came later, to meet local steel needs and resulting from the availability of suitable scrap (both in terms of quality and price), from local and imported sources. It was from this stage (the 1960s), Prof. Masi went on, that the high-productivity, low unit operating cost UHP furnace dated. Turning specifically to his own country for illustration, he recalled that up to 1965 the year when the LD converter allowed Italian steel production to reach really bulk levelsraw steel output had been split roughly 40/60 into electric arc and open hearth pro-duction, and scrap imports had corresponded broadly to electric steel output. After this imports weakened and tended to stabilise at a level of about 5m. tpy, although electric steel production continued to rise. In 1975, assuming average market conditions, only a small increase in scrap imports, to between 5.1 and 5.5m. tons, was thought likely, despite an increase of nearly 10m. tpy in total steel output from 1969, to a level of about 26m. tpy, and despite an increase in electric steelmaking from 6.5 to 10m. tpy. This was a result of the stabilising effect of the LD in raising capacity at the expense of the open hearth. As for scrap prices, periods of relative stability tended to be followed by violent and unforeseen crises, such that, for example, the European high in 1970 was 70% up on the 1963 low. In the case of cif prices for material exported from the USA the situation was compounded higher freight rates: compared to the 1962 low the 1969/70 price rose 90% and compared to 1955/56, 145%. Prof. Masi suggested here that one answer to the difficulty of meeting Italy's scrap needs reliably without considerable investment in stockyards might be "synthetic scrap" produced by direct reduction. The speaker next compared the ability of the three main steelmaking processes to transfer to the charge a particular amount of thermal energy, concluding that the electric arc was continuing to show improvement in thermal economy, particularly through the use of oxygen injection, and scrap preheating. The role of nuclear energy in the steel industry of the future was also discussed, and Prof. Masi next mentioned three topics which in his opinion had been omitted from the programme, and which he hoped would be included in the discussion sessions. These were automation of the electric arc furnace; graphite electrode quality; and reduction of fumes in the electric melting shop. Returning to the subject of scrap, he remarked on the limited appetite of the LD, postulating that although the Kaldo had not been a great success because of its higher installation costs, lower capacity and higher refractory consumption, perhaps some other type of converter could succeed where the Kaldo had been only partly successful. A converter which could accept 40-45% of its charge in the form of scrap could revolutionise the scrap market. As for the electric furnace, in future the greater part of the charge would be sponge iron. Looking further into the future, Prof. Masi considered the prospects of melting furnaces using a solid charge and fed by thermal energy. Recalling the mistakes which had been made in the 1950s when forecasting the likely future rle of the different steelmaking processes in the 1970s, he concluded that no one could have foreseen the LD developing as it did, while the the growth of electric furnace production had also exceeded expectations. The technical sessions of the conference were divided into four headings: raw materials, electric power supply, new developments, and operational results. Details of these technical sessions will be given in the next issue of Metal Bulletin Monthly General view of the 100-ton arc furnace at BSC's Hallside works (Special Steels Div.), showing retractable conveyor and furnace feed tube for experimental charging of Fior pellets. 10 MB MONTHLY |