Ray Jacobs Machinery Co.

Specifications

Production - Daily and annual production

• 2011: 160,000 short tons (first year of operation)
• 2012: 10 heats per day x 85 short tons per heat
• 2012: 125,000 short tons

Steel Grades Steel mix classification (low c medium c high c micro alloyed, high Cr. resulfruized steels)

• Plain Carbon: 1010 - 1095
• Caron Mn High Strength
• Alloy C-Mn-Cr-Mo-TI-B-V
• Alloy C-Mn-Cr-Mo-Ti-B
• AISI alloy Steels:15xx, 41xx, 43xx, 51xx,61xx, 86xx.
• Main chemical compositions examples of each family
• residuals levels(Cu, Sn, Pb, P, S, etc)
• Cu 0.10% max
• NI 0.10% max
• Sn 0.02% max
• Pb 0.015% max
• S 0.003% max
• Cr 0.10% max
• Mo 0.03% max
• Average N and total oxygen in final product
• N limits vary by customer and spcification. Lowest is 0.007% max.
• Oxygen 0.0015%

Round Bloom sizes: 6.00" 7.87" 8.50" 8.66" 8.66" 10.60" 11.00" 11.4" 12.25" 13.78" 152 200 216 220 225 269 280 289 311 350 Square and Rectangular Bloom Sizes: 6.25" SQ (159mmm), 5" x 7", 5.125"SQ, 5x9

• Ladle capacity - 100 Short tons
• Amepa slag detection availability - Partially Installed
• Melting furnace type and main characteristics
• Fuchs EAF-EBT with 4 oyfuel burners and 84MVA transformer.
• Electrodes 24"
• Metallic charge com[osition mix ( scrap.DRI, Pig Iron etc)
• 95% scrap +5% HBI
• Refining Station (LF) and characteristics (trimming station)
• Voest Alpine LF with 35MVA transformer
• Two porous Argon lugs and slide gates
• Six stand wire feeder
• VD process
• Voest Alpine feeder
• Hydrogen level <2.5ppm - <2.0
• Nitrogen level <70ppm
• Casting macine description and design
• Sequences - Cast up to 10 heats on a tundish.
• Tundish shape and volume - Delta shape tundish with three nozzles. Fourth stand blocked off.
• Steel flow control devices from ladle and tundish to mould -Ceramic pouring tube connected to slide gate nozzle which conveys steel from ladle to tundish. Argon gas shrouding in pouring tube to prevent re-oxidation. Baffle in tundish with holes to define pour box. Basic tundish flux used on top of liquid steel. Rice hulls added for Insulation. Submerged entry nozzles (SEN) are placed in the tundish from the inside of the tundish and are rammed with NOXITE in place. Dry-vibe is added and then baked in place.
• Mold type - Parabolic
• Oscillators type - DC drive variable speed
• CC radius (main and others) - 10 M
• Mold level control type - Berthold
• Mold powders - Stallberg, Proslmet
• Secondary cooling design - Spray rings with alternating 22.5 degree pattern
• Straightening points - 3 straightening points, 5 straighteners
• Bar Storage place - Dummy bar rack

Process Contrl and Inspection facilities

• Automation level 2 availability for process variables control
• level 1 system currently, Level 2 system coming soon.
• tracking and bar indentification
• Each bloom is hot stamped with Heat, Strand and Bloom Number.
• Each bloom is recorded on the Production Report and the length is measured and recorded. All Important process control parameters are e recorded electronically in the wonderware information Server.

  Scrap and downgrading criteria according to process control The process control data is reviewed on every heat from the EAF, LRF, VTD and Caster Logs, Bloom Inspection data, macro-ech data, chemistry and mold level control Charts. Each heat has a Disposition Letter written by the Metallurgical Department, which determines whether the individual blooms are Prime, Scrap, Re-cut and Retested. The Process control data is available to the Operators and Metallurgical Department through the HMI system in each Control Pulpit and by the Wonder ware Information Server.   Inspection bar defect philosophy Each bloom is inspected on 100% of the surface area by Metallurgical Technicians. Injurious surface flaws such as crack, stop-stats, gauges, flats and roping indentations are recorded on the Inspection Log. Metallurgists then determine what blooms need discards or scrapping due to defects. Each heat is entered into the database along with the Warren Steel test results and customer test results. We statistically analyze the data to determine the course of Improvements and corrective actions.   Bar dimensional tolerances

• Ovality - The ovality is less than 2.0%
• Straightness - Straightness is 1/4" in 5ft. (4.2mm/M)
• Length cutting tolerances - cold saw tolerance is 0", +1"., A laser system will be installed to improve the torch cut length.

  Major Projects for 2013

1. AMEPA Slag Detection System -prevents slag carry over from ladle to tundish.
2. Laser measurement of billets for precision cutting.
3. Automated bar stamping machines
4. Electromagnetic stirring in molds.
5. Gega multi cutting at caster.
6. Purchased a scanning Electron MIcroscope (SEM_ for analysis of Inclusions and monitering of clean steelprocess.
7. Purchase LECO Analyzers for Oxygen/Nitrogen and Carbon/Sulfur determination.
8. Rail service is now available