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Virtual Steelmaking
Manufacture advanced high-strength steels for an aircraft undercarriage,
design a door panel for a passenger car or calculate the design stress
for the steel cable stays on a suspension bridge. Step inside a virtual
steelplant, operate the equipment and produce and test your own
grade of steel.
steeluniversity.org is a free, innovative, Internet-based e-learning resource focused
on all aspects of steel, including steelmaking technology and the multitude of
different steel applications. This award-winning initiative is sponsored exclusively
by the International Iron and Steel Institute. It provides highly interactive, game-like
simulations of the major steelmaking processes in real-time. steeluniversity.org covers
the entire steelmaking process, from raw materials to the finished steel product.
End-use applications and their design, product testing and steel recovery and
recycling are addressed by individual modules.
www.steeluniversity.org
The Royal Academy of Engineering – Education Innovation Prize Finalist
steeluniversity.org comprises a Some of the simulation exercises
Welcome
series of advanced and sophisticated are now linked. By registering and
educational modules which support logging on to steeluniversity.org, you
traditional teaching and learning will be able to save and retrieve data
practices. relating to the various simulations
and exercises. For example, you can
A 4D “fly-through” module provides now save your results from the EAF
a first-hand overview of the main simulation and refine the actual casts
production processes used to you have made in the Secondary
make steel in a modern steelworks. Steelmaking plant.
Integrating the latest techniques
in computer technology, you are Several modules require you to
taken on a journey from a ship select steels that are fit-for-purpose
unloading iron ore, all the way in transport, construction, energy
through the various production and general engineering markets.
processes to the finished steel. You can take samples from a virtual
steel plate and test them to check
The first series of modules take compliance with its specifications.
you through the basic steelmaking In another exercise you must design
processes using a simple menu- and make your own high strength
driven facility. Each module can be steel. This involves a detailed
studied and operated as separate understanding of the metallurgical
units. The thermodynamics and mechanisms that control the
kinetics of the chemical reactions properties of steel.
taking place in these operations
can be explored to provide a detailed In another module you are
understanding of how they can be introduced to life-cycle assessment
controlled. Four different grades methodologies and learn how to apply
of steel can be made, each with them to the production and use of
a different composition, property steel. This helps you to recognise
profile and end-use application. the importance of sustainability
Two levels of difficulty are available. and the effect of your actions on
The more difficult route requires you the environment.
to respond to unexpected events
during the simulation. This demands
a more in-depth understanding of
the process. Realism is enhanced
by industrial sound effects. Feedback
is given at the end of each simulation
on the quality of the steel produced
and costs incurred.
Steel Processing
Tour of Virtual Steelworks
This module takes you through
the production stages and process
route of an integrated steelworks.
The tour covers all aspects of an
integrated plant, from ironmaking
and steelmaking through to
casting and primary forming.
Continuous Casting
In this simulation you play the role
of a plant metallurgist in charge of
bloom, slab and billet continuous-
casting machines. Your goal is to
successfully sequence-cast three
ladles of steel into semi-finished
products ready for hot rolling.
Many operational decisions have
to be taken to control the casting
speed and the flow of metal from
ladle to tundish while keeping a
close eye on the time and temperature
settings. Avoiding a break-out or
nozzle blockage is critical to the
success of the process. The internal
and surface quality and final inclusion
content are vital factors that need
to be considered to ensure the steel
meets the customer’s specifications.
Hot Rolling
The hot rolling module introduces
the various plant configurations and
processes for rolling different products.
The module also covers basic rolling
theory. In the simulations you can
roll an “I-beam” for construction
applications from a bloom in a
Universal Beam Mill or an ultra-low
carbon steel strip for car body panels.
You can also design and perform
a “controlled-rolling” schedule for a
linepipe steel plate in order to achieve
the specified geometry and properties.
Steel Applications Material Selection for a Car
Door Panel
In this module you take the role
of a materials engineer who is
part of a team that is designing,
making and selling a lighter and
cheaper car door panel. Decisions
have to be taken on the thickness
and shape of the panel, the strength
of the steel, its formability and
weldability, and how to protect
it from corrosion. Steel industry
developments in this area have
led to significant advances in
high strength and ultra-high
strength steels used for
automotive applications.
Steels in Construction
The construction industry is the largest
market for steel products. This module
illustrates the diversity and versatility
of steel and its wide variety of types,
shapes, properties and applications
in buildings and other major structures.
The design equations used in
structural steelwork are described,
failure mechanisms examined
and the difference between strength
and stiffness explored. Fabrication and
corrosion protection methods
are also studied.
Offshore
The variety of steels and steel
components used in offshore
applications are explored in this
module. The module ends with an
exercise to design and make 9,000
tonnes of high strength steel for
an off-shore platform. Your aim
is to successfully supply the order
and make a profit.
Engineering Steels
Engineering steels are extensively
used in the automotive, aerospace,
railway, oil and gas, mining, power
generation, defence, agriculture,
chemical, construction, general
engineering and manufacturing
sectors. Cars, buses, trucks
and off-road vehicles account
for over half the market for
engineering steels.
Annual Challenge
Each year, IISI hosts the steeluniversity
Challenge, where participants are
given 24 hours to process a new
steel grade in one or more of the
Virtual Steelmaking simulations.
Multiple attempts are allowed during
the 24 hour period. There are two
categories; university students and
new steel industry employees (less
than three years’ experience). The
winners from each category are the
individual or team who successfully
process the steel at the lowest cost.
A prize and trophy are awarded to
the winners at a major IISI event.
The Challenge is normally run
in November.
The development of the e-learning resources at www.steeluniversity.org
is continuing and will include simulations from the blast furnace to rolled
products. Other modules will incorporate additional metallurgical principles
and steel applications. The facility is being translated into other languages.
Some modules are already available in Spanish and Chinese.
Supplementary features are also included on the site. These include
‘Study and Work’, which comprises a number of case studies highlighting
how steeluniversity.org is being used in industry and academia. The section
also includes information on career opportunities in the steel industry.
Also planned are a Forum for site users and a section presenting news
of the latest steel technologies.
IISI hopes that steeluniversity.org will inspire and excite students about
the value and wonders of steel, the opportunities steel presents to
the sustainability of our world and about the challenging and rewarding
careers in the steel industry.
Contact Details
International Iron and Steel Institute
Rue Colonel Bourg 120
B-1140 Brussels - Belgium
T: +32 (0)2 702 89 00
F: +32 (0)2 702 88 99
E: steeluniversity@iisi.be