copy of al yamamah co for reinforcing steel bars bbrochure

8/13/2019 Copy of Al Yamamah Co for Reinforcing Steel Bars Bbrochure

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Al Yamamah Company For Reinforcing Steel Bars

Pre Qualification Documents

April 2011Ver. 01


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Al Yamamah Co.for Reinforcing Steel Bars Ltd.,

600,000 TPY Rebar Mill Plant

1.Introduction:

Al-Yamamah Co. For Reinforcing Steel Bars is a 100% Saudi Company

with production facilities in Yanbu Industrial City in the

ROYAL COMMISSION INDUSTSRIAL AREA producing Reinforcing

Steel Bars with the Trade Mark YS .

The production of Reinforcing Steel Bars started on March 15, 2008, with an

annual designed capacity of 600,000 Ton.

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Al-Yamamah Bar Mill Plant established at Yanbu industrial area No. 2, Bar

mill is a first phase plant designed to produce 500'000 ton annual capacity

with different steel grades and sizes ranging from 8 mm to 36 mm according

to Saudi and international standards.

The rolling mill consists of walking type reheating furnace with capacity of

115 Ton/hr, sixteen numbers housing-less cartridges type stands and two

high speed finishing blocks with six housing of each

block.

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The plant main characteristics are as follow:

Mill Capacity: 500,000 Ton / YearNominal productivity: 115 Ton / HourMax Finishing Speed: 35 meter per secondAnnual working days 300 day / yearPlant (Operation Ratio) 75 % Plant (Yield) 96 % (4.0% losses)Raw material:

Billet Size 150 x150 x 12,000 mm (2050 kg Approx.) Or130 x130 x 12,000 mm (1570 kg Approx.)

Material Quality: Low/Medium Carbon steel according to SASO, DIN /ISO standards.

Finished Product Rebars (Diameter 8 mm to 36 mmSizes 8,10,12,14,16 mm with slitting method)bundle lengths 6 m,12 m and 18 mBundle weight 2000 kg for 12 m bundle length1000 kg for 6 m bundle lengthNo. of ties 9 for 18 m bundle length

le l ngth

rds: 615 G

0 A

o Electrical Power: 2sed Air: 4500 m3/hr

o Industrial water Non Contacted circuit 785 m3/hr

6 for 12 m bundle length3 for 6 m bund eMaterial Quality Standa SASO, ASTM-A r

60 BS 4449/97 Gr 46

& B DIN 488

Utilities Connection5000 KW

o Compres


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o Diesel fuel Oil

2.Scheme of the rolling process:

Contacted water circuit 1710 m3/hr

4200 kg/hr.

o

ProcessBarQuenching

ProcessBarCoolingby

NaturalAir

ProcessBarsCountingQ.C.InspectionSpecimenMeasurement&Mechanical estT

ProcessBarCuttingto

6/12/18Meter

ProcessCutBarsto

72&84Meter

Re eatingFurnace

Q.C.Inspection B llets150x150mm

Or130x130

BilletsDimensionsBilletsSurface

ChargingTable

ProcessHeatingBilletsUpto1150oC

ProcessRemovingScale

ProcessBilletsRollingRoughingStand

Finis ingBlock

Interme iateMill

WaterQuenchingBox(QTB)

Divi ingShear

Coo ngBe

Pen u umShear

CountingBars

Bun esTies

Disca er

ProcessContinu

DesesRollingTilliredSizes


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3. MILL CONFIGURATIONBar Mill Plant consists of three main areas arranged as follows:

A. eheating Furnace.B. olling Mill Line.C. inishing facility.

A. Re-heat furnace:

R

R

F

4.A.1. Description:

Reheating furnace is walking type with three separated combustion zonesarranged as follow:

a.b. eating zone.c.

Billets are deposit on chargingbed by magnet crane then travel

Preheating

zone.H

Soaking zone.

to rollers way at furnace entryside where as billet

eighed by load cells.

Billets are charged insidefurnace by kick in mathen will be gently lifted and

earth till

s are

w

chines

Billets charging by magnet crane

Billets charging

inside furnace

Reheatin rocess

moved by movable h


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ong flame burners.

4. . re:

discharging side, billets will be heated to the desired rolling temperature

(1050) by means of l

A.2 Main featu

et bending

Minimize the scale losses Minimize the decarb

inuous Rolling Mill line:

Guarantee a low heat consumption Reduce the bill

onisation

B. Cont

ription:

4.B.1. Mill Rolls Process desc

illets will be

pressure by billet

cale removal

efore entering the rolling stands.

Pinch roll:Billets are withdrawing by pinch roll unit

till bit in first stand

Descaler:The discharged hot b

subjected to high water

descaling machine for s

b

Hotbilletdischargefromfurnace

Descaler


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Material head and tail cropping are carried out automatically by start

The billets are continuously rolled according to the rolling schedule by

series of rolling stands in H/V arrangement with fixed pass line with

and free rolling.

47

stop shears located after stands No. 8 a

In case of emergency the rolled

shears.

quenching of deformed bars and chigher yield strength of the rolled product

nd 16.

material can be chopped by these

At rolling mill outlet, QTB water quenching line is provided for inlineonsequent possibility of producing

.

Pinch roll unit

Material head and tail cropping

Rolling Process


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Then the final product will be cut to multiple commercial lengths bydividing shear.

C. Finishing facility:

4. .1. Process description:

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C

At entry side of the cooling bed a roller table with lifting aprons breakthe multiple length products and transf ooling bed rakes.

start-stop walking beam type coolingbed is foreseen to collect and cool the

bars then were aligning by aligning multi

groove rollers.

regular formation and extraction of bar layers atcooling bed outlet is assured by a sy

lift able device which carry the multip

exit roller table.

QTB water quenching Process

Cooling bed

erred them to c

A

Dividing shear

Exist Roller TableThe Automatic,

stem of pitch to pitch chain and

le length bar layer in position to


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At cooling bed exit roller table, the layer of bars is cut to commerciallength on static made by heavy d

The aligned layers of ansfer ch ins, and

ted by short bar

After bundle was formed at the bundle

forming area, it will be tied by hydraulicbinding machines 5.5 mm tying wire.

val in group by means ofmagnet crane.

uty shear.

bars are transferredthrough variable speed tr

then short bars are extrac

a

evacuation system.

Bars are counting during movement by

automatic counting machine till reaching

to the desired bar number per bundle.

Hydraulic binding machines

The final collecting system comprises aweighing station and step by step chains

conveyor to allow hanging and facilitate

the bundle remo

D. BMP UtilitiesD.1. Compressed air characteristics:

The p t

air compo compressors with 1+1 air

dryers and related accessories.

lan is provided with Compressed air station to supply 2450 Nm3/hr plant

sed of 3+1 Atlas Copco oil flooded type air


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ater system:

The WTP water treatment

following

o Non contact circuits:ool

HF contact cooling circuits

Th n the rolling mill motors,reheating furnace and auxiliary equipment as non contacted cooling

systems.

The contacted cooling circuit Goes in contact with steel products causingtemperature raise in water and enriches with metal scale and oil which are

mostly separated and se mentation basin and

filtration system before cooling by the cooling tower.

D.2. Cooling W

plant is equipped with the

circuits:

water for RM and RHF non-contact c

o Contact circuits: water for RM and Re circulating water is used for cooling dow

ing circuits

ttling at scale pit, sedi

The make up water and chemical program are applied for quality andperformance control of the cooling circuits.


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D.3. A

The p utomation system, which is

n integrated part and effective solution for the innovative plant and production

rocesses to support the uniform and repetitive production of steel at low cost

based on operator interface system.

lectrical system including MV distribution system, MV/LV distribution

tra ystem nvert

motors, s and auxiliary AC motors

Design figures / consumer Contacted circuitNon Contact circuit

700 + 910 + 100 = 17725+60 = 785Flow rate (m 103/hr)

4 / 0 & 13/ 04 / 2/ Return pressure (kg/cmSupply2)

35 / 4333 / 38Supply / Return temperature (C) 62.3n (m3/hr)Blow Dow

19.57.7Make up water (m3/hr)

---70ency water flow rate (mEmerg3/hr)

utomation and Electrical equipment

lant is supported by the latest technology of a

a

p

E

nsformers, LV distribution s , AC-DC main co ers, Main DC

MCC switchboard


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through the following equipments:

CNC roll turning, grinding and notching machines. Robots.

D.4. Roll shop facility:

Roll shop equipments is designed to maintain the rolling stands, and guides

Tilter

Optical device


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D.5. Othe A

The plant is supported with m

plantproductiv Fuel receiving and distribution facility.

r xillaries:

ain axillaries facilities to support and services the

ity such as:

Intake water and fire fighting facility.

Quality control and quality assurance.

Mechanical repair shop.

Warehouse facility.

Administration and service s

facilities.


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MILL TEST CERTIFICATES

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