Production
Steelmaking Production
The Plant’s Steelmaking Production is represented at the plant by five Electro-steelmelting, Cast-shapes and Raw Materials Preparing Departments that are equipped with 5-tonne and 20-tonne arc furnaces for steel melting; induction furnaces of 0,5 and 1,0 tonne capacity; a Unit to treat metal in a 20-tonnes ladle furnace (AKVOS); as well as with a complete train of Metal Special Treatment Units, i.e. vacuum-induction, vacuum arc, electro slag, electron beam furnaces.
The metal pouring in Steelmaking Departments is performed both into ingot moulds and on Billet Continuos Casting Machines. Continuos Casting has occupied firmly its usage in the closed cycle of high- quality alloys production to use vacuum-arc and electro slag remelting processes.
“ELECTROSTAL” Plant has gained a great experience in high- quality metal melting while utilizing Special Electro/metallurgical Processes to assure a high degree of metal cleanliness to be free from gases, non-metallic inclusions as well as from harmful non-ferrous metals and to ensure the most active adoption of alloying/ modifying elements to obtain a dense/ chemically uniform ingot structure, simultaneously.
The Plant has commissioned and successfully operates a combined Casting-and Rolling Unit to produce 8-10 mm wire rod of a wide variety of steels. For the first time the Plant’s staff in collaboration with Scientists/ Metallurgists from VNIIMETMASH and MGTU named after Bauman has implemented the idea (that has been considered as non- realistic one for a long time) of combining steel continuous casting with rolling process into a single economical and compact Module.
PRESS FORGING FACILITIES
Press Forging facilities are represented by the Press Forging Shops, Rolling Shops and Heat Treatment shops.
Press Forging Shop ¹1 is equipped with two hydraulic presses with 4000-tonne-force capacity; there are production bays destined for heat treatment, i.e. annealing/tempering process as well as for surface treatment of forgings (turning and grinding operations) in the shop.
Range of products: rods of 180 – 500 mm round/square cross-section; forgings of round cross-section of variable diameter; slabs of 80 – 300x320 – 600mm in size range as well as discs of 350 – 900mm in diameter having a weight of 100 – 1600kg and sometimes with an internal hole.
The Forging shop operates 3-tonne and 7-tonne hammers to produce forged sections of 80 – 200mm round/square cross-section and also material of 30 – 120x100 – 300mm rectangular cross-section.
Press Forging Shop ¹ 2 is a highly mechanized producing Shop. That operates a Radial Forging Machine SXP-55 type of 10 MN-capacity (“GFM”-Company/ Austrian maker) and a horizontal Extruding Press of 63 MN-capacity.
A favourable metal deformation scheme on the Radial Forging Machine enables the specialists to produce forgings and billets exhibiting a high surface finish as well as to increase forging operations automatization and mechanization.
ÑRange of products: forgings and billets of 105-180 mm round/ square cross-section.
Horizontal Press of 63 MN-capacity is destined for production of 80-210 mm diameter bars of multiply-alloyed especially – hardly deformable alloys.
The producing shop is equipped with heat treatment and adjustage facilities.
PRESS FORGING FACILITIES
Rolling Shop ¹ 1 is equipped with a “600” – medium-section mill of linear type; the Shop is specialized in production of tube strip; finished rolled stock of 65-110 mm round cross-section and of 90; 100; 125 mm square cross-section as well as billets to be re-rolled for the further rolling on “350/250” hot-rolling mill.
Rolling Shop ¹ 2. That Shop comprises Departments for the production of hot-rolled sheet of thickness 2,8 – 40 mm and of width 400-650 mm as well as for the production of cold-rolled strip of thickness 0,01 – 2,5 mm and of width up to 280 mm and wire production of 0,02 – 7,5 mm diameter.
The Shop’s equipment includes a “Quarto-1000” – Hot Rolling mill; a “Quarto-400” – cold-rolling mill; drawing machines to produce wire of diverse sizes as well as a set of equipment to be required for products heating, etching and heat treatment.
Rolling Shop ¹ 3 is equipped with a “350/250” – medium – section mill using the “radial – shift” rolling and Continuous rolling techniques. The mill is specialized in products as well as wire rod of alloyed and highly alloyed steels and alloys in size range from 6,5 mm to 75 mm. The Shop is producing rounds, squares and strip as well.
The Rolling mill is equipped with an automatic system for process control that stabilizes the rolling process technique, the quality of rolled stock and also reduces rate of metal to be rolled.
The Shop is equipped with facilities for heat treatment and adjustage treatment.
HEAT TREATMENT SHOP
Steel sizing department is equipped with all facilities to be requirred for production of steel having a special surface treatment of 5 – 28mm rounds as well as for round sized rolled stock of 5 – 32mm diameter.
The surface treatment includes the following operations: turning; grinding; polishing in their diverse combinations.
The furnaces comprising the bay includes gas and fuel oil furnaces enabling to perform heat treatment of ingots, forgings and rolled products having a length to 6 meters - the furnace operation temperature is 650-990?C – chamber furnaces used for heat treatment of the metal having a length to 3,0m; two of these furnaces are high-temperature (their operation temperature is up to 1200?C).
The furnace equipment makes it possible to conduct annealing, high-temperature tempering, water hardening (austenization) of metallic sections, forgings and ingots as well.
Adjustage treatment department is equipped with centerless bar turning machines for by-tools turning of medium and large sections of 65 – 195mm diameter exhibiting the surface roughness Rz not more than 80 mkm and automatic line “Hetran” (company-maker) exhibiting to machine bars of diameter 38 – 200mm with the accuracy of working H9/H11 and the surface roughness Ra 5mkm.
AUXILIARY SHOPS AND FACILITIES
Reliable and downtime-free performance of the main production shops and facilities of the plant is fully supported by efficient and well coordinated work of the auxiliary facilities.
High-capacity power facilities which are constantly upgraded guarantee the “life” of the plant. To increase the reliability, effective control over power supply and power consumption the central load-dispatching centre equipped with telecontrol over the substations and the main units was put into operation; the automated system of the power consumption was elaborated and adopted as well.
The repair and machine depot supports the metallurgical equipment in proper working order.
The Plant’s Automated Production Management Department coordinates the operation of all the shops and facilities. Completely new equipment enabled to realize a strategic break-through in the development of the Automatic Control System of the plant that is to give the users the opportunity to receive the information directly at their working places. Using a lot of analitical reports the specialists of the Plant obtained the possibility to forecast production schemes in current time taking into account changes in the market and to control their performance by the shops.
The Plant’s specialized laboratories for metal quality control and investigation of metallurgical processes allow to fulfil systematic work focused at optimization of serial production technologies and novel types of products.
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