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INTRODUCTION
Iron, which includes its refined product steel, is the most widely used of all the
metals. Iron and steel products are used in many construction and industrial
applications, such as appliances, bridges, buildings, containers, highways, machinery,
tools, and vehicles. Iron does not exist in nature in a pure form, but it exists in the
form of oxides that are not pure with some impurities such as (magnesium oxide -
calcium oxide - alumina - silica) and percentages of other harmful elements, but low
such as arsenic, sulfur and phosphorus, and iron is used It is abundant in life, so it is
considered one of the most important minerals.
Virtually all metal, including iron, can be recycled over and over again
without losing the properties that make it valuable and useful. The only other material
that can claim infinite recyclability is glass. Other materials, such as plastic, paper,
and cardboard, eventually degrade and become useless.
The recycling of iron and steel scrap (ferrous scrap) is an important activity
worldwide. Obsolete iron and steel products and the ferrous scrap generated in steel
mills and steel-product manufacturing plants are collected because it is economically
advantageous to recycle iron and steel products by melting and recasting them into
semi-finished forms for use in the manufacture of new steel products.
Many countries, especially countries that lack iron ores in their lands, such as
Japan and Italy, depend on imported or local scrap, or both in producing iron, so some
modern steel mills are designed on the basis ranges from 40 to 60% of their
production capacity is obtained from scrap. There is no doubt that the use of scrap in
the iron and steel industry has saved a lot of costs, and made scrap an important factor
in choosing the location of factories, as it works to reduce production costs and time.
SCRAP
Scrap means iron or steel residues that fall off during manufacturing, or iron
and steel wastes that are out of use Scrap is classified into two categories:
Old Scrap includes metal articles that have been discarded after serving a useful
purpose. Because of the wide variety of chemical and physical characteristics, old
scrap often requires significant preparation, such as sorting, de-tinning, and de-
zincing, prior to consumption in mills.
Old, obsolete, or postconsumer scrap are available for recycling. The largest
source is junked automobiles followed by appliances, machinery, worn out railroad
cars and tracks, demolished steel structures, and other products.
It is the scrap resulting from the steel mills themselves, where the rolling
machines produce large amounts of scrap in the processes of cutting steel sheets and
blocks that do not conform to the required specifications.
Iron contains some magnetic properties, so at this stage the focus is on iron sorting.It
is also separated from the rest of the materials to be recycled, by using magnetic belts.
صورة
Media separation stage. This stage may be necessary in certain cases, especially if the
objects to be recycled contain a protective layer, so it must be removed before starting
the iron recycling process. High-pressure flows, electric currents, and liquid systems
are used to achieve additional iron separation.
صورة
The shearing stage, in this stage, the pieces of iron are sheared after going through the
previous stages, using hydraulic machines with enormous pressure and capable of
carrying out such a arduous task.
صورة
4. Compression stage
صورة
Industrial operations that take place inside the factory:
Inputs:
Scrap iron is placed inside the furnaces through what is called a scrap crucible,
through which the iron is lifted by means of a large electric winch.
Different percentages of the carbon element from 37% to 39%, and it is better
to have a percentage of 22%.
Silicon and manganese elements neutralize iron values.
There are some lime stones that work to get rid of phosphorous levels.
Production process:
The iron is smelted inside the electric arc furnace, and after putting the iron inside the
furnace and closing it, the stage of casting iron comes after the smelting process, and
the iron is lifted by means of electric winches, and the iron is cast again in the casting
device and The shapes of the iron become circular, and the iron is passed through the
straightening machine, after the iron has left the casting machine, and the
straightening machine works to transform it into a cuboid shape.
After that, it is passed on the automatic scissors, which cuts it into different
dimensions, and it is cooled by passing it through the pipes, and then the iron is
placed in the condemnation furnace, and this furnace works to heat the iron at high
temperatures at a rate of one thousand degrees Celsius to facilitate its formation, and
then it is passed to more than A stage to cut the heated iron, and its diameter is
reduced until it reaches the required diameter, after which the skewers are placed on
mats until they are cooled.
بعد وضع الخردة في الف))رن يتم غل))ق الف))رن فيح))دث ق))وس كه))ربي نتيج))ة لغل))ق ال))دائرة فيتول))د
) درجة مئوية تكفي لصهر الحديد الخ))ردة الموض))وع1700 درجات حرارة عالية جدا تصل إلى
.داخل الفرن
صورة
بعد صهر الحديد يتم صب الحديد المصهور داخل بوتقة يتم رفعها) بواسطة أوناش كهربية معلقة
.وصبه مرة أخرى ولكن في ماكينة الصب المستمر التي يخرج منها الحديد على هيئة دائرية
صورة
نمرر بعد ذلك هذا الحديد على ماكينة بغ)رض الحص)ول على ش)كل مت)وازي) مس)تطيالت يم))رر
بعد ذلك على مقص يعمل أوتوماتيكياً) لتقطيع الحديد إلى قطع بأبعاد معينة وهي (– 13 )– 13
)120سم .بعد ذلك نقوم بتبريد قطع الحديد عن طريق وضعها) على مواسير) يمر بداخلها تمهيداً
لرفعها باألوناش.
صورة
يتم أخذ قط))ع الحدي))د الناتج))ة من الوح))دة الس))ابقة ووض))عها داخ))ل ف))رن يعم))ل ب))الحوارق) وذل))ك
لتسخين الحديد للدرجة التي تسمح بتشكيله وهي حوالي 1000درجة مئوية.
صورة
يتم أخذ قطع الحديد المسخنة القادمة من الفرن الثانوي وتمريره))ا على ع)دة مراح)ل من الدرفل)ة
اآللية التي تقلل القطر تدريجياً) إلى أن يصل إلى القطر المطلوب .يتم بعد ذلك أخذ أسياخ الحدي))د
ووضعها) على حصيرة تبريد لتبريدها) وتجميعها تمهيداً لبيعها.
صورة
Outputs:
Reinforcing steel is formed, and it has many diameters such as 22, 19, 16, 12 mm,
and also pieces of iron that are in excess and these are sold only to automated rolling
mills.
موقع المصنع
يقع مصنع ذات العماد لصناعة الحديد والصلب جنIIوب العاصIIمة طIIرابلس,
o
بين خطي طول o16'31.6" 13شرقا ً ,و دائرتي عرض 34'57.9" 32
شماالً ,وتحديداً في منطقة سيدي السائح على بعIIد 47كيلومIIترًا من مركIIز
العاصمة ,وتبلغ مساحته حوالي 5.2هكتاراً
صورة
مكونات المصنع
يتواجد Iفي المصنع من مجموعة من المرافق االدارية والخدمية مثل
الساحة ,مكاتب االدارة ,مكتب االشراف ,مكتب االمن و السالمة
الميزان ,مصلى و دورات مياه.
عملية التبريد
تتم عملية التبريد بواسIIطة IالميIIاه بشIIكل اساسIIي عن طريIIق امIIدادت
على طول خطوط االنتاج ,ويتم تجميع المسIIاه السIIاخنة في احIIواض
كبيره حتى يتم تبريدها ويعIIاد اسIIتخدامها ,حيث يتم تجميIIع مصIIهور
الحديد الساخن الناتج من افران الصهر ويتم صIIبه في مجIIرى ليأخIIذ
شكل متوازي مستطيالت ويتم تبريده بالمياه ليحافظ على هذا الشIIكل
ثم يتم قصه ألطوال معينة ليتم استخدامها في فرن التشكيل.
عملية التسخين
تتم عملية التسخين لسبائك الحديد المبردة في فرن التسIIخين او فIIرن
التشكيل كما يسمى ,وفيه تتراوح درجة الحIIرارة بين 1100و1200
درجة مئوية ,والغرض من عملية التسخين هو جعل الحديد لين كفاية
ليتم سحبة وتشكيله في خطوط االنتاج كما سيأتي.