The steel plant for Al Anmaa Co. for Constructional Material Production was designed by Siemens VAI for the optimum production volume and properties of low and medium grade steel billet and steel rebar using state-of-the-art technology. The steel plant consists of an electric arc furnace, a ladle furnace, a continuous billet caster, and a rolling mill. The plant is supported by an oxygen plant, a water treatment facility and a power plant. Most equipment has been supplied from reputable European companies so as to ensure the quality of our products.
Electric Arc Furnace (EAF)
The EAF, which was supplied by Siemens VAI in Germany, has the capacity of producing 435,000 tons a year of low and medium grade structural carbon steel billet. Steel scrap is melted in the arc furnace. An innovative approach from Siemens injects oxygen efficiently to boost productivity and cut operating cost. The liquid metal is then tested and the chemical composition is adjusted in the ladle furnace to ensure the required specifications. The plant also includes a dedusting system from SV Impianti in Italy to cool and filtrate exhaust smoke from the electric arc furnace in order to prevent contamination of the environment.
Process parameters of the EAF are:
Heat size: 60 tons
Transformer rating: 45 MVA
Electrode diameter: 508 mm
Oxygen Injection capacity: 2 x 1750 Nm³/h
Carbon Injection capacity: 2 x 50-80kg/min
Burner Power: 3 x 3.5MW
Continuous Billet Caster
The liquid metal is then tapped into a ladle and poured into a tundish. The ladle capacity is 60 tons and the tundish capacity is 12 tons. The liquid metal is then poured into our continuous billet caster which has three lines with a possible production capacity of 525,000 tons a year casting low and medium carbon, low and medium alloyed steel and special steel. The capacity of each line is 24-30 ton/hr. The sizes of the billet cast are 100x100 –140x140 mm square and 4-12 m long. The steel billet is examined by spectral analysis to ensure that it is in accordance with the approved specifications. The majority of the billet production is sent to our rolling mill but the excess steel billet of 112,000 tons per year is sold to local rolling mills or exported to the Gulf or Iran.
Rolling Mill
The rolling mill plant was supplied by VAI Pomini, Italy and has a production capacity of 300,000 tons a year producing deformed bars round bars tailored to diameters 8- 42 mm and according to ASTM A615 Grade 60. Billets are put through a walking hearth type reheating furnace which has a capacity of 60 tons/hour. Billets are then discharged and controlled from the main pulpit with the aid of TV monitors.
All mechanical equipment incorporates the latest proven technology. The rolling mill can be used for producing all grades of steel including stainless high speed and high alloy steel. Special "robots" are used for quick roll changing. All the rolling mill stands are individually driven by variable speed motors. Flying shears are provided to remove the oversized head of the bar.
Support Facilities
The main steel melting plant is supported by several facilities to ensure the sustainability of production.
A plant producing oxygen, nitrogen and argon was supplied by Hangzhou Fortune, China with compressors from Atlas Copco. Oxygen is produced at a capacity of 2800 cubic meters/hour with a purity of more than 99.6%. Nitrogen is produced at 2600 cubic meters/hour and argon at 70 cubic meters/hour.
A water treatment plant which includes an R.O. filtration membrane from Toray in Japan handles 270 cubic meters/hour of effluent water.
Our own power plant supplies a capacity of 70 MV which guarantees a steady supply of energy for production. Our power plant is also connected to the national grid.
A specialized laboratory contains all the latest equipment necessary to test the product in all stages of production to guarantee quality control.