STEEL MAKING POCESS SHOP LAY OUT

Steel Shop

● Generally lay out of any plant or steel shops are in rational arrangements of equipment, energy network, plant service etc. for achieving an efficient function floor plan for manufacturer of respective product of plant. In the case of steel making the necessary to develop a plant lay out may arise under these conditions :

1.  To establish a new plant on an entirely new site which is called green field installation

2.  To install an additional steel making shop in a steel plant to augment it's production.
3.  To expand existing shop by adding a new furnace and it's auxiliaries.

4.  To improve efficiency and economy of the existing plant through changes in the process or introduction of a new technical development and so on.

5.  To replace existing steelmaking furnace by other more morden design.

Several economic and technical factor are to be considered to justify the implement of the above necessity. A preliminary project report about its economic feasibility is first made then detailed project including the lay out design is made.

LOCATION:


● The cost of production per tonne of steel should be most economical to justify the installation of new plant at the proposed site. That are.....

1. Good garde raw Materials at close supply
2. Adequate power, fuel and water supply
3. Cheap and efficient mode of transport
4. Nearby market and export potential
5. Cheap real estate
6. Ample labour of required quality
7. Maximum taxation benefit
8. Solid underground soil strata
9. Good topography of the region
10. Healthy climate condition of the area.

● Generally the steel plant is located where either raw material or market available. For an integrated steel plant all these consideration apply to iron and steel making as a whole.


SIZE :

 ●It is the minimum size and a plant of any size, bigger then this has to be set up to produce at profits. The actual size and the annual output of ingots depends on these factor.........

1. Type of steel to be produced, it's demand and the export potential.
2. Production technology, economic sizes, and number of steelmaking furnace to be employed.
3. Administrative problems and expenditure.

4. Strategic and social consideration.
5. Tax concession related to annual production.


LAY-OUT :

Ld shop layout
Steel Shop Layout

● A steelmaking shop may have some ot all of the following facilities and equipment :
     
1-  Mixer - to store hot metal.
2- Melting furnaces - to melt cold chargrsc in shops running on cold charges.
3- Furnace(s) proper - to refine metal.
4- Working floor- to carry out various operation of the furnace during refining.
5- Control cabin - to house process control instruments.
6- Raw meterials bins- to store solid raw meterials.
7- Scrap preparation yard- to receive ,sort out and prepare the scrap charges.
8- Out- side- to teem ingot moulds.
9- Vacuum treatment plant - to degas steel .
10- Striper yard- to stop - off ingots from moulds.
11- Mould reconditioning and assembly - to make mould suit - able for reuse.
12- Calcining plant - to calcined dolomite , limestone, magnesite,etc.
13- Tar mixing unit- to make tarred - dolomite ,or magnesite,as ramming mix.
 14-Chemical analysis laboratory - to chemically analysis the slag, gas and metal etc.
15- Repair and maintenance section - to reline the furnace and it's auxiliaries and, for general repairs.
16- Over head cranes, railway - to transport material and movable system and belt equipment conveyers
17- Computer section - to carry out data collection, processing and interpretation for process control.
18- Fuel and power supply - to supply these to the various equipments.
19- weight bridge - to weight material at various stages.
20- office or control room- to collect the information and issue instructions for running and total handing of process of the shop.

● Broadly, a large steelmaking shop may have the following main zones :
1- Furnace bay : It contains the furnaces, working floor, instrument cabin, raw material bins, fuel or power supply arrangements etc.
2- Stock yard - It stores all or some solid raw materials.
3- Pit side - It contains tapping and teeming platform and working space.
4- Mixer bay. 5- Stripper yard. 6- Mould reconditioning and assembly.
7- Calcining plant.  8-  Secondary refining/Vacuu degassing.
9- Contineous casting machine

● In small plants the above list of items is much smaller and these are all put together in one or two bays only. A typical example of this is a small electric furnace steel making shop. The quality of lay out is judge in terms of the following :

1- Simplicity in design
2- Efficient, production planning by way of standardisation of equipment, their arrangement and materials handling.

3- Incorporation of technological advance in the original design with scope to incorporate technique that may show promise in future.

4- Low capital cost with ample scope for further expansion at minimum of extravagance.
5- Adequate and efficient transport facilities between various units of shop.
6- Short and direct material flow lines for raw material finished products and by product with minimum of handling cost, delays and interference.
7- Adequate store, repairs and maintenance facilities.
8- Comfortable, well illuminated, properly ventilated and safe working conditions.
9- Efficient communication system.

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