Mobarakeh Steel Company
Encyclopedia
Mobarakeh Steel Company is an Iran
ian steel company, located 65 km south west of Esfahan, near the city of Mobarakeh
, Esfahan Province
, Iran. It is Iran's largest steel maker, and one of the largest industrial complexes operating in Iran. It was first commissioned after the Iranian Revolution
in 1979 and officially initiated operations during 1993. Underwent major revamping during year 2000, and is presently schedule for a second and third revamping, due in 2009–2010, bringing the total steel output to 7,200,000 metric tons per year. The company owns the successful football club, Sepahan F.C..
and Yazd
provinces) and are converted to pellets in the pelletizing plant
(diameters: 8–10 mm). After being reduced in the direct reduction
(DR) plant and removed of oxygen, pellets are converted to (sponge iron). Sponge iron and iron scrap is melted in electric arc furnace
s, after which liquid steel is purified in secondary purification units. The steel’s chemical compound is designed by customer demand. Then, it’s transported to casting machines for slab
production. After cooling, slab is rolled at the hot rolling mill, creating hot coils (thickness: 1.5–16 mm). Some are sold; others go to the hot finishing mill for complementary work and hot sheet transformation or the cold rolling mill to lower strip thickness to 0.18 mm. Cold rolled coils are also dedicated for the tinning
, galvanizing, and prepainting lines.
from the Hozmahi mine, which is then calcinated
in two rotary kilns at 780-1050°C. After screening, calcinated lime may be used in the Lime Plant, consumed in the Palletizing Plant, Briquet Unit or for industrial water production.
At the Direct Reduction plant, pellets are charged in Midrex shaft furnaces after misco-grain screening (less than 5mm). Two reducing gases (derived from cracking natural gas
or methane
, consisting of Co and H2) are injected into the furnace, combine with oxygen from the pellets resulting in CO2 + H2O. Without oxygen, pellets become sponge irons. After screening, sponge irons are transferred to the Steel Plant. Sponge irons with a diameter less than 5 mm go to the briquet unit to produce briquets (diameter above 25 mm). Then, they are transferred to the Steel Plant with the sponge iron.
furnaces and one (to be doubled) degassing vessel, used to adjust the final chemical mix and purity, as well as adjusting casting temperature. Additionally, there are four continuous slab casting machines, each having two arc casting strands (radius: 10.5 m). They produce the plant’s final product, called slabs. These slabs are 10 m long, 20 cm in thickness and 65–188 cm (adjustable) width. Slab production capacity is 4,200,000 t/yr (revamping year 2000), to be increase in steps to 5,400,000 and 7,200,000 MTPY. Slabs are manually cooled and scrafed in the Slab Cooling & Conditioning plant.
Some products are sold directly to factories and plants via the sales departments under the following specifications: (1) applicant is a direct consumer; (2) applicant’s minimum annual consumption is 1,000 tons hotrolled and 500 tons coldrolled products; (3) ability to purchase on a regular basis. Documents needed to enroll include: (a) certified copies of Operation Permit or similar documents; (b) Applicant’s Memorandum of Establishment, as well as latest changes in its Board of Directors
; and (c) a purchase application form. Additionally, MSC employs Service Centers based in 11 Iranian provinces.
'
department has focused on increasing confidence in international markets. It has attained a just-in-time delivery plan for markets in Europe, Canada, Latin America, South East Asia, the Middle East and Africa. To meet challenges confronting global markets and achieve new horizons, MSC’s export department consolidated efforts to maintain the supply of hotrolled coils and sheets as it’s export priority plan as well as the export of other products (i.e. coldrolled coil/sheets, pickled products, galvanized and pre-painted coils) to various regional markets.
During the first five months of the Iranian calendar year
1386 AP (March 21 to August 22, 2007), about 1.9 M/t of MSC products were transported to customers, with 460,000 tons of products worth more than $500 million exported. Over 14,000 tons of special products including ST52, coldrolled products, car bodies (MB), galvanized and color coated products were exported to various countries like Iraq
, Pakistan
, the United Arab Emirates
, Italy
and Armenia
.
metric tons/yr from 2.5.Also, a sixth direct-reduced iron plant was proposed for Mobarakeh. In 2002, expansion of hot-rolled coil capacity increased to 4.2 Mt/yr from 3.1 Mt/yr. Additional proposed facilities included a 400,000-t/yr cold-rolled mill and a 120,000 t/yr tinplate line in addition to the development of the 3.2-Mt/yr Chegharat iron mine.
MSC ordered engineering for an increase of total production in two steps : 5,400,000 and 7,200,000 metric tons/yr
Iran
Iran , officially the Islamic Republic of Iran , is a country in Southern and Western Asia. The name "Iran" has been in use natively since the Sassanian era and came into use internationally in 1935, before which the country was known to the Western world as Persia...
ian steel company, located 65 km south west of Esfahan, near the city of Mobarakeh
Mobarakeh County
Mobarakeh County is a county in Isfahan Province in Iran. The capital of the county is Mobarakeh. At the 2006 census, the county's population was 132,925, in 35,276 families. The county is subdivided into two districts: the Central District and Garkan Jonubi District...
, Esfahan Province
Esfahan Province
Isfahan Province , also transliterated as Esfahan, Espahan, Sepahan or Isphahan, is one of the 31 provinces of Iran. It is located in the center of the country. Its capital is the city of Isfahan.- Geography :...
, Iran. It is Iran's largest steel maker, and one of the largest industrial complexes operating in Iran. It was first commissioned after the Iranian Revolution
Iranian Revolution
The Iranian Revolution refers to events involving the overthrow of Iran's monarchy under Shah Mohammad Reza Pahlavi and its replacement with an Islamic republic under Ayatollah Ruhollah Khomeini, the leader of the...
in 1979 and officially initiated operations during 1993. Underwent major revamping during year 2000, and is presently schedule for a second and third revamping, due in 2009–2010, bringing the total steel output to 7,200,000 metric tons per year. The company owns the successful football club, Sepahan F.C..
Production Processes: Overview
MSC’s iron ore (raw material) comes from mines in Golgohar and Chadermaloo (KermanKerman
- Geological characteristics :For the Iranian paleontologists, Kerman has always been considered a fossil paradise. Finding new dinosaur footprints in 2005 has now revealed new hopes for paleontologists to better understand the history of this area.- Economy :...
and Yazd
Yazd
Yazd is the capital of Yazd Province in Iran, and a centre of Zoroastrian culture. The city is located some 175 miles southeast of Isfahan. At the 2006 census, the population was 423,006, in 114,716 families....
provinces) and are converted to pellets in the pelletizing plant
Pelletizing
Pelletizing is the process of compressing or molding a material into the shape of a pellet. A wide range of different materials are pelletized including chemicals, iron ore, animal compound feed, and more.- Pelletizing of iron ore :...
(diameters: 8–10 mm). After being reduced in the direct reduction
Direct reduced iron
Direct-reduced iron , also called sponge iron, is produced from direct reduction of iron ore by a reducing gas produced from natural gas or coal. The reducing gas is a mixture majority of hydrogen and carbon monoxide which acts as reducing agent...
(DR) plant and removed of oxygen, pellets are converted to (sponge iron). Sponge iron and iron scrap is melted in electric arc furnace
Electric arc furnace
An electric arc furnace is a furnace that heats charged material by means of an electric arc.Arc furnaces range in size from small units of approximately one ton capacity up to about 400 ton units used for secondary steelmaking...
s, after which liquid steel is purified in secondary purification units. The steel’s chemical compound is designed by customer demand. Then, it’s transported to casting machines for slab
Slab
-Physical materials:* Slab , a length of metal* Concrete slab, a flat plate used in construction* A piece of stone or concrete used to pave sidewalks or road surfaces* Slab : That portion of a tectonic plate that is subducting...
production. After cooling, slab is rolled at the hot rolling mill, creating hot coils (thickness: 1.5–16 mm). Some are sold; others go to the hot finishing mill for complementary work and hot sheet transformation or the cold rolling mill to lower strip thickness to 0.18 mm. Cold rolled coils are also dedicated for the tinning
Tinning
Tinning is the process of thinly coating sheets of wrought iron or steel with tin, and the resulting product is known as tinplate. It is most often used to prevent rust....
, galvanizing, and prepainting lines.
Iron Plant Complex
The Iron Plant Complex has 10 main production line units (the rest are auxiliary and back up units). Iron ores with large grains from Golgohar are converted by ball mills in the Pelletizing plant. After mixing with Chadermalou's smaller grains and bentonite in blending machines it's changed to pellets (diameter: 6-25 mm) and screened by a two-story roller screen. Pellets solidify in an induration tunnel or furnace at 1280°C. The Lime Production Plant receives limestoneLimestone
Limestone is a sedimentary rock composed largely of the minerals calcite and aragonite, which are different crystal forms of calcium carbonate . Many limestones are composed from skeletal fragments of marine organisms such as coral or foraminifera....
from the Hozmahi mine, which is then calcinated
Calcination
Calcination is a thermal treatment process applied to ores and other solid materials to bring about a thermal decomposition, phase transition, or removal of a volatile fraction. The calcination process normally takes place at temperatures below the melting point of the product materials...
in two rotary kilns at 780-1050°C. After screening, calcinated lime may be used in the Lime Plant, consumed in the Palletizing Plant, Briquet Unit or for industrial water production.
At the Direct Reduction plant, pellets are charged in Midrex shaft furnaces after misco-grain screening (less than 5mm). Two reducing gases (derived from cracking natural gas
Natural gas
Natural gas is a naturally occurring gas mixture consisting primarily of methane, typically with 0–20% higher hydrocarbons . It is found associated with other hydrocarbon fuel, in coal beds, as methane clathrates, and is an important fuel source and a major feedstock for fertilizers.Most natural...
or methane
Methane
Methane is a chemical compound with the chemical formula . It is the simplest alkane, the principal component of natural gas, and probably the most abundant organic compound on earth. The relative abundance of methane makes it an attractive fuel...
, consisting of Co and H2) are injected into the furnace, combine with oxygen from the pellets resulting in CO2 + H2O. Without oxygen, pellets become sponge irons. After screening, sponge irons are transferred to the Steel Plant. Sponge irons with a diameter less than 5 mm go to the briquet unit to produce briquets (diameter above 25 mm). Then, they are transferred to the Steel Plant with the sponge iron.
Steel Making and Continuous Casting Plant
The Steel Making & Continuous Casting Plant has eight electric arc furnaces receiving sponge iron and other additives. They are melted with about 15% scrap in the furnace, which has a capacity of 180-200 tons. The plant also has four (to be increased to eight in current revamping) ladleLadle
Ladle may refer to:* Ladle , a serving device, typically for soup* Ladle , a foundry ladle used to carry and pour molten metal...
furnaces and one (to be doubled) degassing vessel, used to adjust the final chemical mix and purity, as well as adjusting casting temperature. Additionally, there are four continuous slab casting machines, each having two arc casting strands (radius: 10.5 m). They produce the plant’s final product, called slabs. These slabs are 10 m long, 20 cm in thickness and 65–188 cm (adjustable) width. Slab production capacity is 4,200,000 t/yr (revamping year 2000), to be increase in steps to 5,400,000 and 7,200,000 MTPY. Slabs are manually cooled and scrafed in the Slab Cooling & Conditioning plant.
Mobarakeh Steel Company products
MSCs products consist of hot and cold rolled sheets and coils, pickled coils, narrow strip coil, tinplate sheet and coil galvanized coil, prepanted coil and slab. These products are produced according to national and international standards. They meet the needs of various industries such as: automotive, home appliances, pipe making, pressure vessels, foodstuff, chemical material and medical packing, construction, transportation, naval industries, and heavy metal equipment.Expenses and Investment: 2007
| Expense | Cost |
|---|---|
| Waste Water Treatment Units | 37,710,000,000 Rials |
| Correction fans (furnaces 1,2,7,8) | 11,874,456,000 Rials |
| Installing Dust collector (Palletizing unit) | 1,244,484,380 Rials |
| Water spraying Equipment on deposits | 630,000,000 Rials |
| Screen dust collector (DR) | 2,170,000,000 Rials |
| Correcting Palletizing dust collector | 11,378,860,000 Rials |
| Environmental Plans | 16,755,000,000 Rials |
| Total | 91,752,800,380 Rials |
Sales Channels
Since the Ogboli Samuel Metal Exchange was launched in 2003, MSC has supplied products through this exchange via brokers involved at prices specified by the exchange’s mechanisms. Interested buyers contact brokers, inform the amount of their requirement, offer prices, and get more information regarding the purchase.Some products are sold directly to factories and plants via the sales departments under the following specifications: (1) applicant is a direct consumer; (2) applicant’s minimum annual consumption is 1,000 tons hotrolled and 500 tons coldrolled products; (3) ability to purchase on a regular basis. Documents needed to enroll include: (a) certified copies of Operation Permit or similar documents; (b) Applicant’s Memorandum of Establishment, as well as latest changes in its Board of Directors
Board of directors
A board of directors is a body of elected or appointed members who jointly oversee the activities of a company or organization. Other names include board of governors, board of managers, board of regents, board of trustees, and board of visitors...
; and (c) a purchase application form. Additionally, MSC employs Service Centers based in 11 Iranian provinces.
'
Export Department
MSC's exportExport
The term export is derived from the conceptual meaning as to ship the goods and services out of the port of a country. The seller of such goods and services is referred to as an "exporter" who is based in the country of export whereas the overseas based buyer is referred to as an "importer"...
department has focused on increasing confidence in international markets. It has attained a just-in-time delivery plan for markets in Europe, Canada, Latin America, South East Asia, the Middle East and Africa. To meet challenges confronting global markets and achieve new horizons, MSC’s export department consolidated efforts to maintain the supply of hotrolled coils and sheets as it’s export priority plan as well as the export of other products (i.e. coldrolled coil/sheets, pickled products, galvanized and pre-painted coils) to various regional markets.
During the first five months of the Iranian calendar year
Iranian calendar
The Iranian calendars or sometimes called Persian calendars are a succession of calendars invented or used for over two millennia in Greater Iran...
1386 AP (March 21 to August 22, 2007), about 1.9 M/t of MSC products were transported to customers, with 460,000 tons of products worth more than $500 million exported. Over 14,000 tons of special products including ST52, coldrolled products, car bodies (MB), galvanized and color coated products were exported to various countries like Iraq
Iraq
Iraq ; officially the Republic of Iraq is a country in Western Asia spanning most of the northwestern end of the Zagros mountain range, the eastern part of the Syrian Desert and the northern part of the Arabian Desert....
, Pakistan
Pakistan
Pakistan , officially the Islamic Republic of Pakistan is a sovereign state in South Asia. It has a coastline along the Arabian Sea and the Gulf of Oman in the south and is bordered by Afghanistan and Iran in the west, India in the east and China in the far northeast. In the north, Tajikistan...
, the United Arab Emirates
United Arab Emirates
The United Arab Emirates, abbreviated as the UAE, or shortened to "the Emirates", is a state situated in the southeast of the Arabian Peninsula in Western Asia on the Persian Gulf, bordering Oman, and Saudi Arabia, and sharing sea borders with Iraq, Kuwait, Bahrain, Qatar, and Iran.The UAE is a...
, Italy
Italy
Italy , officially the Italian Republic languages]] under the European Charter for Regional or Minority Languages. In each of these, Italy's official name is as follows:;;;;;;;;), is a unitary parliamentary republic in South-Central Europe. To the north it borders France, Switzerland, Austria and...
and Armenia
Armenia
Armenia , officially the Republic of Armenia , is a landlocked mountainous country in the Caucasus region of Eurasia...
.
Development
In 1999, MSC expanded its hotrolled coil capacity to 3.1 millionMillion
One million or one thousand thousand, is the natural number following 999,999 and preceding 1,000,001. The word is derived from the early Italian millione , from mille, "thousand", plus the augmentative suffix -one.In scientific notation, it is written as or just 106...
metric tons/yr from 2.5.Also, a sixth direct-reduced iron plant was proposed for Mobarakeh. In 2002, expansion of hot-rolled coil capacity increased to 4.2 Mt/yr from 3.1 Mt/yr. Additional proposed facilities included a 400,000-t/yr cold-rolled mill and a 120,000 t/yr tinplate line in addition to the development of the 3.2-Mt/yr Chegharat iron mine.
MSC ordered engineering for an increase of total production in two steps : 5,400,000 and 7,200,000 metric tons/yr
Manufacturing Units
| Facility | Location | Capacity | Commodity | Process | Thickness |
|---|---|---|---|---|---|
| Iron Plant | L | Cp | sponge iron | Pr | T |
| Steel Plant | L | 180-200 | steel, iron scrap | P | 2200 mm |
| Hot strip mill | L | 630,000 | coil | 4 furnaces | 1.5–16 mm |
| Cold rolling mill | L | 611,000 | coil, sheet | coldrolling | T |
| Tinning Line | L | 100,000 | coil sheet | electrolytic cleaning | T |
| Galvanizing line | L | 200,000 | coil | hot dipping | T |
| Compact Strip Plant | Saba | 2.8M | coils, sheets | hotrolling | T |
| Prepainting Line | L | 100,000 | coil | Roller coating | T |
| Pelletizing Plant | L | 1.4M | pellets | P | 2200 mm |
| Direct-reduction Plant | L | 2.1M | sponge iron | ||
| Limestone Plant | Hozmahi | lime | 2 rotary kilns |
See also
- Mining in IranMining in IranMining in Iran is under-developed. Yet the country is one of the most important mineral producers in the world, ranked among 15 major mineral rich countries, holding some 68 types of minerals, 37 billion tonnes of proven reserves and more than 57 billion tonnes of potential reservoirs....
- Global steel industry trendsGlobal steel industry trendsThe global steel industry has been going through major changes since 1970. China has emerged as a major producer and consumer, as has India to a lesser extent. Consolidation has been rapid in Europe.-Material for development and war:...
- Hot rolling
- Rolling mill
- Silicon steel
- Steel producers
- Steel millSteel millA steel mill or steelworks is an industrial plant for the manufacture of steel.Steel is an alloy of iron and carbon. It is produced in a two-stage process. First, iron ore is reduced or smelted with coke and limestone in a blast furnace, producing molten iron which is either cast into pig iron or...