NORIC SWISS GMBH

DESIGN CONCEPT
FOR
TAYBAH STEEL PAKISTAN (PVT.) LTD.
STEELPLANT 220.000 TON PER YEAR
LOCATED AT HATTAR / KARACHI

TABLE OF CONTENT:

PG . 2 OVERALL PLANT DESIGN CONCEPT

PG . 3 ROLLING MILL DESIGN CONCEPT
PG . 5 PLANT BALANCE
 minds of steel

OVERALL PLANT DESIGN CONCEPT

Steel Plant Production Time
Taybah Steel Pakistan Pakistan
d/y h/y Weeks / y
Number of days per year 365 8,760 52 3 Shift
Annual Shutdown -14 -336 -2 8 h/shift
208,500 t/y rebar
National Holidays -12 -288 -2 (or 2 shift / 12h)
Schedule days 339 8,136 48
Maintenance shutdown: 12 h/week -24 -576 -3
Operating Time 315 7,560 45

Scrap Yard Meltshop Continuous Casting Rolling Mill

Purchasing

Scrap 223,010 t/year Operating Time 7,560 h Operating Time 7,200 h/year Sequence 10 heats Operating Time 7,560 h/year

Production
Production

Production
Pig Iron 0 t/year Pick Hours 0 h/week Utilisation Factor 92.5% Restranding 45 min Utilisation Factor 78.8%
DRI/HBI 0 t/year Unforeseen Net Production Time 6,660 h/year Total sequence time 10.0 h Net Production Time 5,957 h/year
5.0%
interruption time Productivity 32.3 t/h Productivity 35.0 t/h
Net Production Time 7,200 Yield 98.5% Restranding 540 h/year
Preconditions RHF
The present production flow considers all scrap processed at Heat Size 30 t liquid steel Strands 2 Capacity 36.0 t/h

Design
entrance of Induction Furnaces.
TTT 120 min Radius 6 Cold Charge
Segregated, sheared, shredded, quality, dimension, mix, etc.
Pon 104 min Metalurgical Length 14.1 m
Yield 94% 100%
Tapping Temp. 1630 °C 100% 0%
IF

EE 580 kWh/t
Required 10,100 kW
Power Sintering 1,000 kW Section 130 130 Section
Shredded 30% 68,900 t Installed 12,000 kW Linear Weight 0.131 t/m Linear Weight t/m Rebars
Sheared 55% 126,400 t Productivity 15.0 t/h Yield 98.5% Yield Yield 97.0%
Charge Mix

Other 12% 27,710 t Operative Strands 2 Operative Strands Production 208,500 t

Return 3% 6,790 t Operation 2# Max 2.8 m/min Max m/min
Units Speed Speed
Pig Iron 0% 0t Relining 2# Actual 2.0 m/min Actual m/min Total RM Production
Hot Metal 0% 0t Plant TTT 60 min Metalurgical Length 14.1 m Metalurgical Length m 208,500 t/y
Meltshop

DRI/HBI 0% 0t Plant Productivity 30.0 t/h Casting Time 55.5 min Casting Time min
216,000 t/y Net Production Time 6,660 h/year Net Production Time h/year
Total Charge Mix 685.7 t/day Max 44.2 t/h Max
Production Productivity Productivity
229,800 t/y 7,200 Heat/year Actual 32.3 t/h Actual t/h
22.9 Heat/day Max 294,225 t/y Max t/y
Production Production
Actual 214,927 t/y Actual t/y
LF

LF 218,200 t 101.0% Yield Total CCM Production

100% Yield 214,900 t/y

Total Meltshop Production

218,200 t/y

2
 minds of steel

ROLLING MILL DESIGN CONCEPT

Billet Length Density Cooling Bed

Square 130 mm Billet 7.648 t/m3 Length 42,000 mm
Length 6,000 mm Rolled 7.850 t/m3 Commercial bar 3 on bed

RHF Billet Weight Bar Length

Scale 0.90% losses CCM 775.5 kg Commercial bar 12,000 mm
RHF 768.5 kg Minimum bar 6,000 mm

Bar Size Long Bar Cut Losses Short Losses Commercial Bars Short Bar
Producti Rolling Mill Losses
Extra Total Total Long Bars Cutting Losses
on Mix Diameter Slitting Linear Weight Lost due to Extra-Length Last Bar Lost due to Short bar Number Weight Number Weight (RHF + Cutting)
length length weight per Billet

% mm # kg/m kg/m mm mm kg # mm kg % mm mm kg % # kg # kg kg % kg %
10% 10 2 0.63 1.27 500 36,500 23.094 32 16,000 10.12 1.3% 10,684 99 752 1 7 10.12 1.3% 17.04 2.2%
20% 12 2 0.89 1.77 400 36,400 32.300 22 8,800 7.81 1.0% 5,296 5,296 4.70 0.6% 71 756 12.51 1.6% 19.43 2.5%
20% 14 1 1.21 1.21 500 36,500 44.085 17 8,500 10.27 1.3% 3,816 3,816 4.61 0.6% 52 754 14.87 1.9% 21.79 2.8%
15% 16 1 1.58 1.58 500 36,500 57.580 13 6,500 10.25 1.3% 679 679 1.07 0.1% 40 757 11.33 1.5% 18.24 2.4%
5% 18 1 2.00 2.00 400 36,400 72.675 10 4,000 7.99 1.0% 8,932 31 743 1 18 7.99 1.0% 14.90 1.9%
5% 20 1 2.46 2.46 300 36,300 89.476 8 2,400 5.92 0.8% 9,395 25 739 1 23 5.92 0.8% 12.83 1.7%
5% 25 1 3.85 3.85 200 36,200 139.421 5 1,000 3.85 0.5% 6,549 16 739 1 25 3.85 0.5% 10.77 1.4%
10% 32 1 6.31 6.31 200 36,200 228.427 3 600 3.79 0.5% 1,195 1,195 7.54 1.0% 10 757 11.33 1.5% 18.24 2.4%
10% 40 1 9.86 9.86 100 36,100 355.932 2 200 1.97 0.3% 5,749 5,749 56.68 7.4% 6 710 58.65 7.6% 65.57 8.5%

100% 2.09% 2.99%

3
minds of steel

ROLLING MILL DESIGN CONCEPT

Gap Time Reference Productivity

Interval for bar 5 s Average 35.0 t/h

Total
Pure
Producti Linear Finishing Rolling Theoretical Yield (RHF + Actual annual
Diameter Strands Rolling
on Mix weight Speed time+ Gap productivity RM) productivity producti
Time
on
% mm # kg/m m/s s t/h % t/h t/y h/y
10% 10 2 1.27 8.2 79.1 35.8 97.8% 35.0 20,850 596
20% 12 2 1.77 5.8 79.1 35.9 97.5% 35.0 41,700 1,191
20% 14 1 1.21 8.6 79.1 36.0 97.2% 35.0 41,700 1,191
15% 16 1 1.58 6.6 79.1 35.9 97.6% 35.0 31,275 894
5% 18 1 2.00 5.2 79.1 35.7 98.1% 35.0 10,425 298
5% 20 1 2.46 4.2 79.1 35.6 98.3% 35.0 10,425 298
5% 25 1 3.85 2.7 79.1 35.5 98.6% 35.0 10,425 298
10% 32 1 6.31 1.6 79.1 35.9 97.6% 35.0 20,850 596
10% 40 1 9.86 1.1 79.1 38.3 91.5% 35.0 20,850 596

100% 208,500 5,957

Rolling Time 5,957 h/year

Operating Time 7,560 h/year
Utilization Factor 78.8%

4
minds of steel

PLANT BALANCE

Meltshop Caster Rolling Mill

Pure Rolling Utilization
TTT IF Power Productivity Production Speed Casting Time Productivity Production Productivity Production
Time Factor
min MW t/h t/y m/min min t/h t/y h/y % t/h t/y
105 11.8 34.3 249,300 2.4 48.0 37.3 245,600 6,271 83% 38.0 238,300
110 11.2 32.7 238,000 2.2 50.5 35.5 234,400 6,282 83% 36.2 227,400
115 10.6 31.3 227,600 2.1 53.0 33.8 224,200 6,214 82% 35.0 217,500
120 10.1 30.0 218,200 2.0 55.5 32.3 214,900 5,957 79% 35.0 208,500
125 9.6 28.8 209,400 2.0 58.0 30.9 206,300 5,717 76% 35.0 200,100
130 9.2 27.7 201,400 1.9 60.5 29.6 198,400 5,500 73% 35.0 192,500
Productivity t/h Productivity t/h Productivity t/h
Meltshop Power MW
Caster Speed m/min
Rolling Mill Utilization Factor %

40 13 40 3 40 100%
38 12 38 3 38 95%

Productivity [t/h]
Productivity [t/h]

Productivity [t/h]

36 11 36 2 36 90%
Average Power [MW]

Casting Speed [m/min]

Utilization Factor
34 10 34 2 34 85%
32 9 32 2 32 80%
30 8 30 2 30 75%
28 7 28 2 28 70%
26 6 26 1 26 65%
24 5 24 1 24 60%
105 110 115 120 125 130 105 110 115 120 125 130 105 110 115 120 125 130
Induction Furnace TTT [min] Induction Furnace TTT [min] Induction Furnace TTT [min]

Productivity Increase with Hot Charge in Reheating Furnace

Nominal Production Zone