Mechanical Engineering – Production

‫الكلية التقنية بمحافظة جدة‬

Jeddah College of Technology

‫الفصل التدريبي الثاني‬

‫ هـ‬1440 -1439
 ‫‪Mechanical Engineering – Production‬‬

‫الكلية التقنية بمحافظة جدة‬

‫‪Jeddah College of Technology‬‬
‫‪Cooperative Training Report in BAZ INT. INDUSTRY CO.‬‬
‫تقرير التدريب التعاوني بشركة باز العالمية للصناعة‬

‫االسم‬

‫أسامة صالح باجابر‬

‫علي عامر البيشي‬
‫عبدهللا حسين االمير‬

‫المشرف الميداني‬
‫م‪ .‬رأفت يماني‬

‫لجنة المناقشة‬

‫م‪.‬‬ ‫م‪.‬‬ ‫م‪.‬‬

‫التوقيع‬ ‫التوقيع‬ ‫التوقيع‬

‫الفصل التدريبي الثاني‬

‫‪ 1440 -1439‬هـ‬
 Table of content

1 ACKNOWLEDGMENT

2 Chapter I - Introduction to the company

2 Name of the company 1.1
2 History
2 Company products 1.2
4 Technical Area Assigned 1.3

5 Chapter II – Safety
5 2.1
General Safety in the Plant
6 Safe work practice and procedure 2.2
7 General Safety Equipment 2.3

9 Chapter III – Field Experiences

9 Row material in the plant 3.1
10 3.2The process in order to produce a pipe as following
19 3.2.1
Brief operation processes
24 Maintenance and recommendation 3.3

31 Chapter IV – Theoretical background

31 Material 4.1

33 Quantitative Physical Properties

33 General usability

34 What is the difference between steel and mild steel?

37 4.2
Pipe history
39 4.3
Pipe design
39 The Manufacturing Process 4.4
41 Quality Control
42 Scrap and recycling 4.5
42 Why Do We Recycle Metals?

46 Applications of Recycled Steel

48 Chapter V – Conclusion

48 Recommendations

50 REFERENCES

Table of Figures
I
Figure Page
1-1 3
1-2 3
1-3 3
1-4 3
2-1 8
1-3 10
2-3 11
3-3 12
3-4 12
3-5 13
3-6 14
3-7 14
3-8 15
9-3 15
10-3 15
11-3 16
12-3 17
3-13 18
14-3 18
15-3 18
16-3 18
17-3 20
18-3 20
19-3 23
20-3 24
21-3 29
22-3 30
4-1 35
4-2 35
4-3 36
4-4 36
4-5 37
4-6 47

Tables

Table 3-1 Page 9

II
 Acknowledgment
Praise be to God that his grace is righteous
Many thanks to Eng. Amir Hussin who supervise us in the work and show us the way in the
good working and how to be a good worker in the area plant . Also I would like to thank all my
friend who worked with me during the training.

Many thanks to all employee in the company who helped us and guide us to the good way in
doing the work and the report and focus on the important thing.

Special thanks to Eng. Ra'afat Yamany for the good supervising, all the things and all the advices
he give us during the training time.

1
Chapter I - Introduction to the company :

1.1 Name of the company :

Baz International Industry Company .

History :
The international industry BAZ company is the first of the companies that manufacturing iron
and minerals on cold . It is oldest and biggest companies for manufacturing iron in Arbic gulf. It
was established in 1980. The first owner Shikh Ahmed Mohammed Baghlaf was planning to
develop the industry in the zone and make the work efficiency high, with using the last
technology that the manufacturing of iron has reach with new vision and high aspiration, with
deciding line of this industry and he put the future plans and strategies to reach with the
company the worldwide , and to be one of the leading companies and the specialist in
manufacturing iron and minerals, on the country region and the world, as the baz company use
the best material inside and outside Saudi Arabia with high quality and good type, and the
company work hard to keep up the trust the it build between the company and the customers
during the years .

1.2 Company products :

The company products is most important for many fields and many uses , and every product has
many sizes to produce and some of it has more than one color to produce. They produce slitting
coils but it is not much ordered but any way they make it for the other product needed, they also
produce pipes with different shapes and sizes with different diameter , and the simple sheets,
polished sheets, finally the barriers road also they didn’t produce it in the Jeddah factory, but it is
available in their branch in Khobar.

It depend on the order of the customer how much they want of the quantity and what sizes what
shape what color. Mostly they produce one size of all products and that size is most order and it
is always ready in the machine programming . It not take time and it is easy to make and taking
care of the orders.

These products have multiple uses in different fields. The following are some of the uses of
these products manufactured by Baz International Industry :

- Structural elements – Basics of building materials – Equipment for the iron industry

- Automobile industry – Equipment and foundations for offices – Parts and components of
machinery and equipment – Civil engineering and highways – Industrial equipment

- Shipbuilding industry – Architecture – Agricultural engineering and greenhouses

- Heating and electrical ventilation – Local Industries – Carpentry works .

2
The main products as following :
1- Slitting
2- Simple sheets
3- Polished sheet
4- Barriers road
5- Pipes
6- Checkered steel coil

And here some examples in the following figures :

Fig1-1 fig1-2

Fig1-3

Fig1-4

3
1.3 Technical Area Assigned :
In the first weeks the responsible for training make a plan. Which include the following: every
training person should go through all sections in the plant area. Five sections, so we can take idea
about how every things working in the field.

1- Production Area. 4- Engineering service (clothes and stuff for employees).

2- HR & Sales offices. 5- stock/store.
3- Quality department.

After the weeks finished, now I assigned for the area which is (production). I stayed at the
production section. And this section includes the maintaining, installation, replace and repair,
process operation, electrical and power section, trouble shooting, controlling, manufacturing.

In the field exactly in the production machines there are six lines but not all the lines are working
and I will mention that in the production part in the report. Many problem happened to the lines
some it be in the machine and some in the programming and some from the old part that use
many years.

The offices section is separate out of the field area so the employees in the company work in
good conditions. The sections up is the human resources and sales and the manager office is up
also, and the windows does not make noises.

The reception is the front of the company where the customer can find the things he need, order,
stuff, problems solution, purchases , and other things. They do insulation for the window so the
employees and the customer can hear each other because the field is noise due to the high sound
come from the machines. This keeps the employees and the customer satisfying and able to deal
with each others in good conditions. So do the small rooms inside the factory that has the
computers and the systems the employees work on it inside the factory .

For us as a trainers we should know at least the areas around the production area so we can deal
and work on it in the condition we need it or if we need it. In the small rooms made for computer
system knowledge we do and send mails upon request if they need something to be emailed .

Most work is in the machine by supervising for the operational employee, the work is less when
the line isn’t broken, all they do just controlling when the coil is finish they put one new and let
the work goes on and on. The trainee here can watch how they control even if he don’t know he
should know the procedure as long he need to do anything. Trainee watch how the operation
goes from the beginning until to the end.

In the next chapters I will describe some of the production lines and I hope it is be much clear.

4
Chapter II – Safety

2.1 General Safety in the Plant :

Safety is everyone's responsibility, working with no safety conditions are not acceptable. The
employee is responsible for himself and sometimes for the other person. If something goes
wrong it might be hurt some employees or worker inside the work area and this could make
losses for the person who work or could be danger to the industry properties .

The facilities of the plant required from the workers to dress a formal clothing which is
available in many colors (overall). The colors are not important. The important thing that you
have to wear the overall or the special uniform of the company. At the company the option in
your hand but the importance is to be safety all the time.

Eye protection is needed in some places like the place near to the machine because the
cooling liquid and fractions. In that conditions you must wear goggles. Worker can find the
goggles in the engineering service the part where you can take anything you need or tools
you must have it. It is important to have a protection of footwear safety shoes is also needed
into the plant (working area). But the worker inside the offices no needed for them the safety
shoes. As it mentioned you can have it from the engineering services. Hearing protection is
more importance in the work area because the sound of machines are very loud. This
continuous noise is make many problems. So it needs to wearing an ear plugs and it will be
provided in the engineering services section.

All employees should be familiar with the material safety data sheets (MSDS). The MSDS is
provide some of specific safety information related to products and their use. The files of the
MSDS are maintained in places inside the plant. But some of the MSDS with the supervisors
if the employee need it he must talk to the responsible supervisor.

There are some rules inside the work area :

1- No smoking.
2- No drink or eat. ( accept the water in some cases of sultriness )
3- No glasses or hand watch.
4- Washing the hand before entering the area. (because it counted as food product/drink
product, it need a cleaning hands).
5- Walk with the yellow line not the green lines which is for the forklift.

2.2 Safe work practice and procedure :

A practice is a set of rules and instructions established to help workers in their job area .
5
A procedure is step by step process to performing a safely job from beginning to end. The safe
work practices may be combined with safe work procedures.

Benefits of safe work practices and procedure :

● provide a knowledge on how work is carried out.

● positively affect quality, and efficiency.

● prevent injury and illness by controlling potential hazards.

● legislative requirement.

● provide a standard for :

- training and orienting workers.

- reviewing work process with all workers.

- completing work activities safely.

- evaluating work performance .

There are some tips for developing safe work practices and procedures :

● involve the workers who regularly perform the job .

● put the steps in the correct sequence.

● number the steps, and identify the hazards associated with each step.

● evaluate the hazard based on severity and frequency.

● establish controls for the poisons recognized and evaluated.

● use the appropriate words with the workers, and write short clear sentences.

● ensure instructions are accurate and use consistent terminology.

● use active verbs for instructions.

● use consistent formatting.

● ask the workers to review prior to implementation.

Before getting into the safe work practices and procedures, the most important thing is to ask : "
Is this files/documents easy for employees to use ? " .

2.3 General Safety Equipment :

This is a list of safety clothing and equipment related to work :

6
- Acid resistant footwear
- Safety caps
- Chin straps for safety caps
- Ear plugs
- Protective ear muffs
- Face shields
- Foot wear with built-in safety features , such as safety toes , loggers' caulks or acid resistant
qualities – not including footwear designed solely for weather protection.
- Foot and leg protectors (metatarsal protectors, toe clips, shin guards, ice cleats)
- Gas masks ( including protection canisters )
- Gauntlets
- Gloves designed to be worn by worker with built-in safety features, such as reinforced
thumbs, palms or cuffs, designed to protect the wearer from physical harm.
- Chainsaw operator gloves, welders' aluminized asbestos gloves, gloves steel grip
- Traffic safety gloves if designed to enhance visibility .
- Safety goggles
- Insoles, puncture resistant
- Skid-masters
- Air hoses designed to connect the SCBA to an air source if the air hose is obtained together
with the SCBA. ( Self Contained Breathing Apparatus )
- Metatarsal protectors.
- Emergency locators transmitters
- Fire alarms
- Fire extinguishers, portable
- First aid kits – including dressings and medications
- Floater coats
- Safety helmets
- Locator transmitters
- Warnings devices for gas explosion hazards .
- Overalls
- Respirators

7
 .and here is the figure shows some of the safety stuff that the worker can use inside the plant

Fig2-1
- Boots
- Ear plugs
- Safety glasses
- Safety shoes
- Safety helmet
- Gloves

And other stuff as it mention in the page before .

8
Chapter III – Field Experiences
There is seven machine to product the finish goods inside the plant. In every machine a one line
to produce the finish good either pipes or sheets. Four machine for the pipes , two machine to
produce the small pipe size which is 20 to 23 diameter . One machine for medium size pipes
around 32 diameter, and one machine for the big pipe diameter also it might be reach 114
.diameter for the pipe

Another three machine, one for the slitting the coils ( cutting the coil in pieces of coils depend on
the sizes needed ). One machine is for making sheets either the simple sheet or checkered sheet,
and the way it works and make product is very simple just by cutting. Last machine is for
. making ribbed sheet but it is not working in our time now because no order

3.1 Row material in the plant :

There are five type of the row material but the most uses are four. It will be mentioned in the
following table some information and specification for each type. Each material can make pipes
and sheets, but this is all about what the customer needs. Well , the next explanation will
describe the types of material also the main type which is MS –mild steel- and what can produce
.and how much thickness

: Table of material of coils

Material name Thickness limit Product can made

HR – Hot rolled mm - 5.8 mm 1 Pipe and flat sheet

CR – cold rolled mm - 0.9 mm 0.5 Pipe and flat sheet

Galvanized mm - 4 mm 1.6 Pipe and sheet

Zinc mm - 2.0 mm 0.28 Ribbed sheet

Table 3-1

Each type of this material has the special order and customer. Most ordered is the HR coils. We
don’t forget the main material is the mild steel. It is good type to build and hold for factories and
.buildings

9
3.2The process in order to produce a pipe as following :

1- The customer headed to the sales office and decide his order upon his uses but most
ordered are the pipes in square shape and rounded shape .After the customer tell the sales
man what is the order and he confirmed it, then the sales man email the engineer
responsible in production to take the order and start working on it. The responsible
engineer gives the operational worker to start in the job . (see figure3-1)

Fig3-1

2- After the production engineer receipt the order from the sales section , he start to take
action and tell the operational about all the specification of the order that is written in the
10
email either pipes or sheets , diameter decided, quantity , width of coil , thickness of coil ,
type of coils , and how many row material coils needed by calculating.
The operation start to give order to the cranes guy to bring and left coils upon request
order before. (see Fig3-3)

Fig3-2

As it showing in the figure this is the coils and there is another types also they can use in
the factory but all is upon the order. The types of the coils will clarified in the beginning
lines of this chapter. ( see table 3-1 )

11
 Fig3-3

3- When they start loading the coils in the coil holder they do the programming for the sizes,
and this process does in the slitting machine which cutting the big coil into slices.
Operation guy do the rest from a to z, for example if they want small pipes so after they
choose the thickness needed they make slices upon the diameter needed.

Each type of material has limits of thickness, so they take the thickness needed with
diameter needed or the dimensions if it is square or triangle pipe and inter it into
programming of slitting machine and start on the operation process.

Fig3-4

As it showing in the figure the coil interring the machine as a one slice then the cutter cut
it into pieces depend on the size interred. After that the machine roll the slices again into

12
 the roller then they take it out as a many separated coils after finish and starting the next
step .

In this figure ( Fig3-5 ) the all process to produce the slitting coils in the slitting line to make the
coils ready for the next step in the welding pipe product line.

Fig3-5

In this operation goes by loading a one big coil on the slitting machine, where they put
the coil in a straight position then the coil is pulled inside iron breakers that cut the coil in
a linear position , after that it is rolled again in other side roller as slitting rolled with
different sizes, so it can be ready for loading in the pipe line production.

Now this is the slitting production, and the slitting coils now is ready for the customer to buy, but
the order in this way is less and not much order. So the slitting production most use for the pipe
produce either rounded pipe or square or triangle .

As it mention before this process is a preface to making pipes with different dimensions and
different shapes upon request from the customer. Also the four lines production has a space
before it so the crane can take and load the slitting coils in that space so it be easy to put the coils
in the production lines. Two small lines, one medium and one for big pipe line. Those four lines
has a limit of weight to hold the pipe. Each line has a different size limit for produce the pipe,
and this make each line work separate to the customer. In that way the factory or specially sales
section can accept more customer.

Every line has a limit of diameter or dimensions to produce. Some lines can be almost same
diameter or nearest, that mean one order for one customer can be divided on all lines, but we

13
don’t forget the possible weight can the machine hold it. This is a benefit to finish an order for a
customer in a day, it is also depend on how much and when the customer needs the order.

4- After they roll the cutting slices and take it off the holder, they start putting it in the next
other holder in the production line. The holder has four sides they fill it all with the coils
needed, so they can use it directly once it finish so the operation don’t stop.

There is an important step which is fixing profile. Fixing profile means that the shape
needed either square or rounded or triangle and what size included to operation process.

By the operational coworkers they choose and adjust the needed profile shape to make the pipes
. depend on the sizes and shape needed from the customer order as showing in Fig3-4

Fig3-6 Fig3-7

As we see in the figure there are many shapes with many sizes of profiles. The condition is
.choosing the right one from the production engineer and the coworkers

The time took to fix the profile about 30 minutes to 1 hour. In some cases they need more than
this time to fix it. Those shapes mostly make in the same factory in the workshop, but some
.cases they take it from other companies

14
Fig3-8 Fig3-9

Fig3-10

In the upper figures the process of changing the shape and sizes of the big pipe line. I added this
photos because it helps to understand how they changing the profiles. In condition of changing
and fixing the operational worker do the cleaning of shafts that hold the profile shapes. They also
. clean the old profile to keep it in good condition while they fix the desirable request profile size

In this case which I started already to describe is the pipe in square shape. The operations
process to produce a pipe is almost the same in all type of pipes either big or small. The sizes,
the shapes it is same process, but only they change the profile needed depend on the order. Shape
.might be changing every day, sometimes it can be one time every two days

15
However, the process still the same where the profile change or not. The key is to distribute the
total quantity of the orders came from the sales, to the lines without reach the limit loading of
. one machine to the other. The next step is describing inside the line process

5- After putting the profile shape and fix it with cleaning and everything, now the operators
do the programming inside the control panel in some information. The quantity ,
diameter, length of the pipe, and dimensions. After that they put the coil inside the line to
roll along the machine to start the shaping inside the forming profiles.

Fig3-11

There is a space in the production line this space has like a rollers to roll along the coil inside
a circles. The benefit from this process is to keep the coils always ready to go inside the
forming profiles, so f there is a broke up or maintenance the coils keep running into circles
and be ready to produce when the problem or the issue is solved.

This space which has the roller all the way can gold a 45 roll in to it, which helps the
operation process can complete without issues, and being ready all the time to finish goods.

16
 Fig3-12

As the figure shows the rolls all around the pipe to gather until it become full, but this case
only when there is a flute or issue to stop the machine immediately.

6- In this step the coil sheet start get in to the forming shape to bend the sheets from the
sides to get it start to weld the sides together with the high power voltage in rounded
shape at the beginning. After the welding, the pipe go through a scratcher, this scratcher
has the benefit of removing the tags. The scratcher is fixed to the hard metal not moving
at all, it scratch the tags all along the pipe.

7- Now the pipe go through the forming profile to take the last shape wanted either rounded,
square, or rectangle. As it mention before the shape is produced depend on the desirable
sizes so that the operation already fix the needed profiles with same sizes in the order.

After the forming the pipe goes to the measuring line to take the size and cut it depend on
the dimensions required from the sheet paper from sale section. The standard length is six
meter long, sometimes they receipt an order with four meter long for the pipe. Next step
is cutting the pipe with a fly hacksaw that moves all along with the pipe cut then back to
held another pipe and so on.

8- In this step which the last step in the production line the pipes are collected together in a
shape of packed pipe together prefacing to loading it in the area load or the warehouse.
Some cases the customer be on ready to take the goods so they pack and loading directly
in the track to move to the destination required.

Fig3-13 Fig3-14

17
 Fig3-15 Fig3-16

After finishing the goods the sales department call the client and give him a note that the order is
ready. The factory can provide a tracks to bring the order where the client need it, or the client
has his own track and deal with the factory to take the order.

This was the way of producing a pipe with different shapes and dimensions from the beginning
to the customer desirable place. The most order is the pipes, they produce the simple sheet, but it
is easy process by putting the coil and cut it then packing, so we didn’t explain it that much as
the pipes procedure. As it known the pipes most order those days even for government projects
and investment so factory of metal is on work most the time.

For the ribbed sheet the line is stopped from along ago, due less of order. As long as they have
the stock of the ribbed sheet so they don’t have to make new. If the customer ordered a ribbed
sheet they give it directly.

Finishing goods cost some things, damage, broke, wastes, and the maintenance. So the
maintenance department has the full responsibility to keep the lines running. Some flutes
happened, in that case the machine could stop temporary, maintenance team should be ready to
take that cases and issues to solve it as soon as possible. In the next chapter we will talk about
how maintenance work ? and some problems to solve. The maintenance also provide a full
maintaining to all stuff in the factory. Also if it is needed to improvise for making way of one
machine or another to work easily it will be on the maintenance department.

Maintenance should be accurate in working, any fault might be effect on the production line. The
faults cost a stopped line, but here in the plant the employees of maintenance always do the all
kind of maintenance in a full job.

3.2.1 Brief operation processes :

Production process for coil, sheets and pipes :

18
The process of production begins with the transfer of raw materials from the warehouse to the
production department, in preparation for processing according to need or according to the
production order .

Production of plain sheet with different lengths :

This process is done by placing the iron roll on the simple sheet cutting machine , Where the
sheet is separated according to the required length and then cutting , All stages of this process are
done automatically, and produces this machine (simplified sheet of different lengths) As in Fig
3-17

Fig3-17

Polygon sheet production with different lengths :

19
This process is performed by placing the colored iron roll on the corrugated board making
machine. The paper is recalibrated according to the required lengths, the cutting process is
completed and all stages of the process are completed automatically. This machine produces
polygon sheet with different lengths as in shape 3-18

Fig3-18

Production of strips of iron rolls :

This process is done by placing the iron roll on the dissection machine. The sheet is first
removed and the sheet is pulled between the iron cutters to cut the sheet lengthwise, and then
it is rewrapped to be wrapped in different sizes in order to convert it into welded pipe
production lines

Production Process (Welded Pipe) :

1- The slide is inserted into the molds to form
2- Bend the slide until it meets the two ends of the slide in preparation for welding process
using high voltage electricity
3- The welded pipe is inserted into molds to form a square or rectangle on
request
4- The pipe is cut according to the required length using a pilot saw

All the pipes are assembled in the assembly area for packing in order to transfer them to the
warehouse

20
21
Production process sequence :

22
How the customer order ?
1- In the beginning, the customer sends the requested product by mail to the company. It
is sent to the sales department where the product details in terms of sizes and
quantities.

2- After receiving the customer request, the application is transferred to the Engineer to
deliver the request to the worker in the autopsy device to put the roll iron and cut the
product requested by the client in terms of size and quantities and take the time of the
cutting process for dissection and note in the picture after the process of cutting.

Fig3-19

3- After the process of the story of the iron rolls are taken by crane to the cold drawing
machine then the iron roll is placed on the machine and the machine is started to start
the process of cold clouds and the speed of the machine at a specified speed, for
example if the customer wants a pipe shape square after the introduction of iron is
drawn on Several stages in the beginning are curvature and then become in the form of
circular pipes and then pass on the welding wire to be welded accurately and then pass
on the torso to become square shape as requested by the client.

4- After completion of the machine and its output as a product is assembled on quantities
and then is tumbled and then taken by the crane to be stored as in the form to be
delivered to the client .

23
 Fig3-20

3.3 Maintenance and recommendation :

① Daily maintenance:

Daily maintenance is the foundation of keeping machine smooth

operation. The operator can understand the status of the machine during
its operation.

The major job of the daily maintenance is to understand the pipe

output and its quality. It is unavoidable that the machine might have a
problem.
The daily maintenance can help the operator to find the
machine problem, and stop the machine immediately, and take further
trouble shooting.
It may reduce unnecessary loss on the production
efficiency and the quality.

A proper daily maintenance may reduce the breakdown of the machine

less than 1 hour per day, and run the machine full efficiency.
In order to minimize the loss of the material, a proper measure must be
brought out soon after the malfunction happens. It may avoid a further
loss of the material, an abnormal damage of the parts and a decrees of the machine efficiency.

Every day maintenance department check the all parameter of machine before starting the
machine.

The maintenances include an inspection on all the data of the air, oil leakage from piping and
cylinders, etc…

The operator must do close monitoring of operational process of the machine and they apply
action on the product and produce pipes as per quality standard,

Such as the robot hand of input-preform and the output-pipe. Besides, the daily maintenance is
not always invariable.

It may be adjusted and depending on the operator or the production line so as to get the
machines smooth running. When the machine shuts down due to any reason, or when no have
more requirement of the pipes it will be more advantageous to thoroughly inspect the machine.

24
The operator/Mechanics must pay attention to the oil level of the work pressure system, and the
lubricant in the precision division device. Check if their lubricant is enough.

[Note: The operator must write down in Production and there observation which he face during
process of daily production/maintenance, and brings it up for review before the weekly
maintenance, and take a prevent on measure for making a weekly maintenance project.]

② Cleaning:

Keep clean of their work area and there machine on daily bases it will be helpful to a smooth
operation. Use one piece of cloth to remove the redundant lube on the machine, such as the lube
above the holder and molds.

③ Safety device:

The operator must take care all safety instruction and use all safety tools and take care of
operation/control panel of the machine as per safety instruction.

④ Adjustment:

During the process of the maintenance, if there are any abnormalities, the data must be adjusted
to the normal values according to the Production regulation, or according to the adjustment
stated in the Operation Manual.

(2) The Items to Be Maintained Daily:

① Running Speed of The Machine:

Check the circulation timer on the operating box, and also use a meter to check if the output is
normal.

② Inspection:

Check the pipes quality.

③ Pneumatic System (Pneumatic pipes, connected pipes, fittings and control valves):
Firstly, check the pressure meters if the pneumatic cylinder is within the pressure limit.

25
Check visually or audibly if the cylinder leaks air. Check if the bolts and the nuts of the solenoid
valve of the pneumatic pressure, pressure checking valve are firmly tightened. Check if the pipes
are curled. Check if the parts of the pneumatic system become loose.

④ Pneumatic Cylinder:

Check if the working pressure is normal. The pneumatic pressure is per their requirement.

(3) Monthly Maintenance:

① Molds.
② Safety device (Also check the safety switches.)
③ Check the circulation systems of cooling liquid and chilling.
④ Pneumatic system: Check if the pressure regulating valve is normal, and if any pipes leak air.
⑤ Clean the electric control box and the control panel: Use filtered dry air to blow away the dust
on the electric control box and the control panel.
⑥ Clean the interior of the machine: Wipe away the unnecessary oil dirt. Keep the pipes and the
wires dry and clean for easy viewing on oil pipe status.
⑦ Check the oil level of the auto lubricating system.
⑧ Check the oil level of air control unit (F.R.L. combination).
⑨ Grease the mold plates.

(4) Quarterly Maintenance:

In addition to doing quarterly maintenance, please specially note if any

Wire insulations are damaged or crack. Also measure if the power is normal,
And check if any screws of the solenoid valves are loose.

(5) Yearly Maintenance:

In addition to doing the yearly maintenance, it is necessary to replace hydraulic oil.

(6) Precautions of Maintenance:

[Maintain the machine according to the regulations shown below, or it is very

easy to cause human injure, machine and the peripheral equipment
damages. ]
26
① Be sure to switch off the main power before maintaining or repairing the machine. Then,
place a warning board “NO OPERATION”. Use the electric meter to check if there is any
remaining electricity. If for repair, a warning board “Under Repair “must be hung on the
machine.
② The maker has preset the pressure of the release valve. If the operating pressure is over our
standard high pressure, the machine service life will be shortened.
③In order to protect the operators, we install control panel to the moving parts of the machine,
and install the guard cover to the heating box. Do not remove these safety devices without
permission. It is strictly forbidden to approach or handle the machine during operation. Inspect
the safety devices daily.
④ When you adjust the machine near the mold plates or the pneumatic pressure system, be
especially careful to avoid being gripped.
⑤ the pneumatic components used for the machine are all of high pressure withstanding parts.
They are pneumatic control valve, pneumatic cylinder, pipe fittings, high pressure pipes, etc…

Before replacing any of these parts, please regulate the pneumatic pressure to down to 0 kg/cm²,
After the work is finished, or for periodical maintenance, please spread soap water on the
connecting areas to check if there is any air leakage. The safety valve of the pneumatic system
must be inspected every half one year.

⑥Before repairing or maintaining the pipe machine or its electric system, the power switch
must be at OFF position. If the electric box is with lock, please lock it for safety.

⑦Check irregularly if cooling liquid leaks. Do not let the electric parts touch water. Molds,
material pipes and gear box need water. For repairing, please check if the connecting areas of the
pipes leak

⑧Replace or fill lubricant into the pipe machine when the machine stops.

⑨ Use our standard tools to maintain or inspect the machine. Tighten the bolts and nuts with
proper torsion.

⑩Be sure to inspect the parts, consuming parts and each meter of the pipe machine periodically.

⑪ In case that repair of an electric ware must be under the supply of electricity, the repairman
must wear an insulation outfit (such as clothes, shoes, gloves, safety helmet, etc…) with
insulation tools (such as screwdrivers, clips, etc…) Remove the rings, bracelets, necklace and
other metal articles before working. It is better that two or more than two people to work
together for mutual verification.

⑫ When the machine stops, be sure to switch off the main power.

⑬ Keep wet hands off the electric equipment.

⑭The cooling pipes, the pneumatic pipes and the pressure used in buyer’s factory must conform
to the requirement of our pipe machines. The high pressure pipes, fitting control valves, etc…
must conform to the specifications of high pressure.

⑮ Hints for installing the electric equipment and its wire connection –
27
(a) A proper pole plate and a ground wire must be connected to the machine or a proper place
where the machine is installed.

(b) Please use the non-fuse brakes with correct capacity.

(c) Use original maker’s insulation cables for the electric parts.

⑯ After the repair is finished, check the repaired parts. If it works normally, then supply the
electricity again so as to avoid problems or errors.

Chapter IV – Theoretical background

4.1 Material :
Steel is made up of carbon and iron, with much more iron than carbon. In fact, at the most, steel
can have about 2.1 percent carbon. Mild steel is one of the most commonly used construction

28
materials. It is very strong and can be made from readily available natural materials. It is known
as mild steel because of its relatively low carbon content.

Mild steel (iron containing a small percentage of carbon, strong and tough but not readily
tempered), also known as plain-carbon steel and low-carbon steel, is now the most common form
of steel because its price is relatively low while it provides material properties that are acceptable
for many applications. Mild steel contains approximately 0.05–0.25% carbon making it
malleable and ductile. Mild steel has a relatively low tensile strength, but it is cheap and easy to
form; surface hardness can be increased through carburizing

In applications where large cross-sections are used to minimize deflection, failure by yield is not
a risk so low-carbon steels are the best choice, for example as structural steel. The density of
mild steel is approximately 7.85 g/cm3 (7850 kg/m3 or 0.284 lb/in3) and the Young's modulus is
200 GPa (29,000 ksi).

Low-carbon steels suffer from yield-point runout where the material has two yield points. The
first yield point (or upper yield point) is higher than the second and the yield drops dramatically
after the upper yield point. If a low-carbon steel is only stressed to some point between the upper
and lower yield point then the surface develops Lüder bands. Low-carbon steels contain less
carbon than other steels and are easier to cold-form, making them easier to handle.

What is Mild Steel ?

Mild steel is a type of carbon steel with a low amount of carbon – it is actually also known as
“low carbon steel.” Although ranges vary depending on the source, the amount of carbon
typically found in mild steel is 0.05% to 0.25% by weight, whereas higher carbon steels are
typically described as having a carbon content from 0.30% to 2.0%. If any more carbon than that
is added, the steel would be classified as cast iron.

Mild steel is not an alloy steel and therefore does not contain large amounts of other elements
besides iron; you will not find vast amounts of chromium, molybdenum, or other alloying
elements in mild steel. Since its carbon and alloying element content are relatively low, there are
several properties it has that differentiate it from higher carbon and alloy steels.

Less carbon means that mild steel is typically more ductile, machinable, and weldable than high
carbon and other steels, however, it also means it is nearly impossible to harden and strengthen
through heating and quenching. The low carbon content also means it has very little carbon and
other alloying elements to block dislocations in its crystal structure, generally resulting in less
tensile strength than high carbon and alloy steels. Mild steel also has a high amount iron and
ferrite, making it magnetic.

The lack of alloying elements such as those found in stainless steels means that the iron in mild
steel is subject to oxidation (rust) if not properly coated. But the negligible amount of alloying
29
elements also helps mild steel to be relatively affordable when compared with other steels. It is
the affordability, weldability, and machinability that make it such a popular choice of steel for
consumers.

How is Mild Steel Made ?

Mild steel is made similar to how other carbon steels are made. A common way this is done
involves a combination of iron ore and coal. Once the coal and iron ore are extracted from the
earth, they are melted together in a blast furnace. Once melted, the mixture is moved to another
furnace to burn off any impurities that they may have, as well as to make any other adjustments
to the mild steel’s chemical composition. Following that, the steel is allowed to solidify into a
rectangular shape. This slab of mild steel is then usually brought down to the desired size using
processes called hot rolling or cold drawing, although there are other methods that can also be
used.

Chemistry:
Mild steel usually contains 40 points of carbon at most. One carbon point is .01 percent of
carbon in the steel. This means that it has at most .4 percent carbon. Most steels have other
alloying elements other than carbon to give them certain desirable mechanical properties. 1018
steel, a common type of mild steel, contains approximately .6 percent to .9 percent manganese,
up to .04 percent phosphorus, and up to .05 percent sulphur. Varying these chemicals affects
properties such as corrosion resistance and strength.

Physical Properties :-
Strength :

Mild steel is very strong due to the low amount of carbon it contains. In materials science,
strength is a complicated term. Mild steel has a high resistance to breakage. Mild steel, as
opposed to higher carbon steels, is quite malleable, even when cold. This means it has high
tensile and impact strength. Higher carbon steels usually shatter or crack under stress, while mild
steel bends or deforms.

Quantitative Physical Properties:

Mild steel has a density of .248 pounds per cubic inch. It melts at 2,570 degrees Fahrenheit. It
has a specific heat of around .122 British Thermal Units (BTU) per pound, per cubic inch.

General usability:

Mild steel is especially desirable for construction due to its weld ability and machinability.
Because of its high strength and malleability, it is quite soft. This means that it can be easily

30
machined compared to harder steels. It is also easy to weld, both to itself and to other types of
steel. It takes on a nice finish and is polish able. However, it cannot be hardened through heat
treatment processes, as higher carbon steels can. This is not entirely a bad thing, because harder
steels are not as strong, making them a poor choice for construction projects.

Common Applications of Mild Steel :

Here are some examples of where it is used in the world:

 Structural steel
 Signs
 Automobiles
 Furniture
 Decorations
 Wire
 Fencing
 Nails

Steel is one of the most common materials in the world, representing an industry that
produces 1.3 billion tons a year, and it is a material used throughout the construction of
many architectural fabrications.
There are many sub-categories of steel and depending on the various qualities and
characteristics of a particular build, the choice of steel selected may vary.
The properties that vary the most between steel types are strength, ductility, hardness,
aesthetics, and cost. Depending on your scope of work, selecting the proper steel type for
the job can benefit the quality of the project and cost.

Stainless steel:
It is defined as a steel alloy with a minimum of 11.5 w.t% chromium content. Stainless steel does
not stain, corrode or rust as easily as ordinary steel (it “stains less”), but it is not stain-proof.
31
It is also called corrosion resistant steel when the alloy type and grade are not detailed,
particularly in the aviation industry. There are different grades and surface finishes of stainless
steel to suit the environment to which the material will be subjected in its lifetime. Common uses
of stainless steel are cutlery and watch straps.
Stainless steel differs from carbon steel by amount of chromium present. Carbon steel rusts when
exposed to air and moisture. This iron oxide film is active and accelerates corrosion by forming
more iron oxide. Stainless steels have sufficient amount of chromium present so that a passive
film of chromium oxide forms which prevents further corrosion.
 

Mild steels:
Carbon steel is sometimes referred to as ‘mild steel’ or ‘plain carbon steel’. The American Iron
and Steel Institute defines a carbon steel as having no more than 2 % carbon and no other
appreciable alloying element. Carbon steel makes up the largest part of steel production and is
used in a vast range of applications.
Typically carbon steels are stiff and strong. They also exhibit ferromagnetism (i.e. they are
magnetic). This means they are extensively used in motors and electrical appliances. Welding
carbon steels with a carbon content greater than 0.3 % requires that special precautions be taken.
However, welding carbon steel presents far fewer problems than welding stainless steels. The
corrosion resistance of carbon steels is poor (i.e. they rust) and so they should not be used in a
corrosive environment unless some form of protective coating is used.

What is the difference between steel and mild steel?

Steel is less malleable and harder than mild steel.
Mild steel s less brittle than steel.
Steel is more resistant to corrosion.
Mild steel can be further strengthened through the addition of carbon.
The basic difference is that s/s has very little carbon and is alloyed with chromium, nickel,
molybdenum and other elements to improve its mechanical and chemical properties.
 

So Why and Where do we use Mild Steel?

If you aren’t going to see the steel surface, i.e.: the final piece is going to be painted or coated.
If a piece requires a large volume of metal, where stainless isn’t cost effective.
If you need steel for structural components that are internal to the piece and not visible or
effecting the overall visual concept.
If you are bending or welding the metal.

 
Generally speaking, Aluminum is also a great lightweight option, when weight-baring isn’t a
factor. For larger projects requiring strength, steel is a much stronger option. Pearlite Steel is a
leading stainless steel tube manufacturer and exporter from India, provides high quality stainless
steel pipe and tubing solutions around the globe.

32
 Fig4-1 Fig4-2

Multi operation processes :

In the figures below some manufacturing processes with the mild steel HR, and mild steel CR
coils and sheets.

33
 Fig4-3

Fig4-4

4.2 Pipe history

MS Pipe and MS Tube refers to Mild Steel Pipe or a Mild Steel Tubes.

34
Mild Steel (MS) pipes are manufactured using low carbon (less than 0.25%) steel. Due to low
carbon content the pipes do not harden and are easy to use. As MS Pipes are made from mild
steel they can easily be welded and formed in various shapes and sizes for pipelining and tubing
purposes.

These are generally used for drinking water supply i.e. Plumbing, Firefighting, HVAC but can
also be used in various other Industrial and Engineering applications. These pipes are usually
coated with other metals/paints/varnish. to prevent it from rusting but extra care should be taken
to prevent it under extreme conditions.

MS Pipe Manufacture in India:

Jindal Pipes Ltd. (JPL) manufactures high quality MS pipes in India. The raw material of MS
Pipes i.e. MS Steel Coils has been procured from trusted Steel manufacturer i.e. Steel Authority
of India (SAIL), which is a public sector company and is the largest integrated iron and steel
producer in India. At Jindal Pipes we provide our customers with exceptional product quality,
services and flexibility of production rate to meet their schedule. We not only manufacture high
quality products but also a trustworthy relationship with our customers.
We manufacture MS Pipes in a various sizes, grades and specifications as per various national
and international specifications (IS, BS API, ASTM, DIN). Jindal Pipes has been constantly
executing need based demanding orders for MS Pipes to meet the requirement of sectors like,
Agriculture, Oil and Gas, Public Health, Housing, Irrigation, Engineering etc.

Fig4-5

35
People have used pipes for thousands of years. Perhaps the first use was by ancient
agriculturalists who diverted water from streams and rivers into their fields. Archeological
evidence suggests that the Chinese used reed pipe for transporting water to desired locations as
early as 2000 B.C. Clay tubes that were used by other ancient civilizations have been discovered.

During the first century A.D. , the first lead pipes were constructed in Europe. In tropical
countries, bamboo tubes were used to transport water. Colonial Americans used wood for a
similar purpose. In 1652, the first waterworks was made in Boston using hollow logs.

Development of the modern day welded steel pipe can be traced back to the early 1800s. In
1815, William Murdock invented a coal burning lamp system. To fit the entire city of London
with these lights, Murdock joined together the barrels from discarded muskets. He used this
continuous pipeline to transport the coal gas. When his lighting system proved successful a
greater demand was created for long metal tubes. To produce enough tubes to meet this demand,
a variety of inventors set to work on developing new pipe making processes.

An early notable method for producing metal tubes quickly and inexpensively was patented by
James Russell in 1824. In his method, tubes were created by joining together opposite edges of a
flat iron strip. The metal was first heated until it was malleable. Using a drop hammer, the edges
folded together and welded. The pipe was finished by passing it through a groove and rolling
mill.

Russell's method was not used long because in the next year, Comelius Whitehouse developed a
better method for making metal tubes. This process, called the butt-weld process is the basis for
our current pipe-making procedures. In his method, thin sheets of iron were heated and drawn
through a cone-shaped opening. As the metal went through the opening, its edges curled up and
created a pipe shape. The two ends were welded together to finish the pipe. The first
manufacturing plant to use.

Welded pipe is formed by rolling steel strips through a series of grooved rollers that mold the
material into a circular shape. Next, the un welded pipe passes by welding electrodes. These
devices seal the two ends of the pipe together.

this process in the United States was opened in 1832 in Philadelphia.

Gradually, improvements were made in the Whitehouse method. One of the most important
innovations was introduced by John Moon in 1911.
He suggested the continuous process method in which a manufacturing plant could produce pipe
in an unending stream. He built machinery for this specific purpose and many pipe
manufacturing facilities adopted it.
While the welded tube processes were being developed, a need for seamless metal pipes arouse.
Seamless pipes are those which do not have a welded seam. They were first made by drilling a
hole through the center of a solid cylinder. This method was developed during the late 1800s.

36
These types of pipes were perfect for bicycle frames because they have thin walls, are
lightweight but are strong. In 1895, the first plant to produce seamless tubes was built.
As bicycle manufacturing gave way to auto manufacturing, seamless tubes were still needed for
gasoline and oil lines. This demand was made even greater as larger oil deposits were found.
As early as 1840, ironworkers could already produce seamless tubes. In one method, a hole was
drilled through a solid metal, round billet. The billet was then heated and drawn through a series
of dies which elongated it to form a pipe.
This method was inefficient because it was difficult to drill the hole in the center.
This resulted in an uneven pipe with one side being thicker than the other. In 1888, an improved
method was awarded a patent. In this process the solid billed was cast around a fireproof brick
core. When it was cooled, the brick was removed leaving a hole in the middle.
Since then new roller techniques have replaced these methods.

4.3 Pipe design

There are two types of steel pipe, one is seamless and another has a single welded seam along its
length. Both have different uses. Seamless tubes are typically more light weight, and have
thinner walls.
They are used for bicycles and transporting liquids. Seamed tubes are heavier and more rigid.
The have a better consistency and are typically straighter. They are used for things such as gas
transportation, electrical conduit and plumbing. Typically, they are used in instances when the
pipe is not put under a high degree of stress.
Certain pipe characteristics can be controlled during production. For example, the diameter of
the pipe is often modified depending how it will be used. The diameter can range from tiny pipes
used to make hypodermic needles, to large pipes used to transport gas throughout a city.
The wall thickness of the pipe can also be controlled. Often the type of steel will also have an
impact on pipe's the strength and flexibility. Other controllable characteristics include length,
coating material, and end finish.

4.4 The Manufacturing Process

Steel pipes are made by two different processes. The overall production method for both
processes involves three steps. First, raw steel is converted into a more workable form. Next, the
pipe is formed on a continuous or semi continuous production line. Finally, the pipe is cut and
modified to meet the customer's needs.

Ingot production:-

 1) Molten steel is made by melting iron ore and coke (a carbon-rich substance that results
when coal is heated in the absence of air) in a furnace, then removing most of the carbon
by blasting oxygen into the liquid. The molten steel is then poured into large, thick-
walled iron molds, where it cools into ingots.
 2) In order to form flat products such as plates and sheets, or long products such as bars
and rods, ingots are shaped between large rollers under enormous pressure.

37
Producing blooms and slabs :-

3 ) To produce a bloom, the ingot is passed through a pair of grooved steel rollers that are
stacked. These types of rollers are called "two-high mills." In some cases, three rollers are used.
The rollers are mounted so that their grooves coincide, and they move in opposite directions.
This action causes the steel to be squeezed and stretched into thinner, longer pieces.

When the rollers are reversed by the human operator, the steel is pulled back through making it
thinner and longer. This process is repeated until the steel achieves the desired shape. During this
process, machines called manipulators flip the steel so that each side is processed evenly.

4) Ingots may also be rolled into slabs in a process that is similar to the bloom making process.
The steel is passed through a pair of stacked rollers which stretch it. However, there are also
rollers mounted on the side to control the width of the slabs. When the steel acquires the desired
shape, the uneven ends are cut off and the slabs or blooms are cut into shorter pieces.

Further processing :-

5 ) Blooms are typically processed further before they are made into pipes. Blooms are converted
into billets by putting them through more rolling devices which make them longer and more
narrow. The billets are cut by devices known as flying shears. These are a pair of synchronized
shears that race along with the moving billet and cut it. This allows efficient cuts without
stopping the manufacturing process. These billets are stacked and will eventually become
seamless pipe.

6 ) Slabs are also reworked. To make them malleable, they are first heated to 2,200° F (1,204°
C). This causes an oxide coating to form on the surface of the slab. This coating is broken off
with a scale breaker and high pressure water spray. The slabs are then sent through a series of
rollers on a hot mill and made into thin narrow strips of steel called skelp. This mill can be as
long as a half mile. As the slabs pass through the rollers, they become thinner and longer. In the
course of about three minutes a single slab can be converted from a 6 in (15.2 cm) thick piece of
steel to a thin steel ribbon that can be a quarter mile long.

7 ) After stretching, the steel is pickled. This process involves running it through a series of tanks
that contain sulfuric acid to clean the metal. To finish, it is rinsed with cold and hot water, dried
and then rolled up on large spools and packaged for transport to a pipe making facility.

Pipe making:-

8 ) Both skelp and billets are used to make pipes. Skelp is made into welded pipe. It is first
placed on an unwinding machine. As the spool of steel is unwound, it is heated. The steel is then
passed through a series of grooved rollers. As it passes by, the rollers cause the edges of the
skelp to curl together. This forms an unwelded pipe.

9 ) The steel next passes by welding electrodes. These devices seal the two ends of the pipe
together. The welded seam is then passed through a high pressure roller which helps create a
38
tight weld. The pipe is then cut to a desired length and stacked for further processing. Welded
steel pipe is a continuous process and depending on the size of the pipe, it can be made as fast as
1,100 ft (335.3 m) per minute.

10 ) When seamless pipe is needed, square billets are used for production. They are heated and
molded to form a cylinder shape, also called a round. The round is then put in a furnace where it
is heated white-hot. The heated round is then rolled with great pressure. This high pressure
rolling causes the billet to stretch out and a hole to form in the center. Since this hole is
irregularly shaped, a bullet shaped piercer point is pushed through the middle of the billet as it is
being rolled. After the piercing stage, the pipe may still be of irregular thickness and shape. To
correct this it is passed through another series of rolling mills.

Final processing:-

 11) After either type of pipe is made, they may be put through a straightening machine.
 They may also be fitted with joints so two or more pieces of pipe can be connected. The
most common type of joint for pipes with smaller diameters is threading—tight grooves
that are cut into the end of the pipe. The pipes are also sent through a measuring machine.

This information along with other quality control data is automatically stenciled on the
pipe. The pipe is then sprayed with a light coating of protective oil. Most pipe is typically
treated to prevent it from rusting. This is done by galvanizing it or giving it a coating of
zinc. Depending on the use of the pipe, other paints or coatings may be used.

Quality Control
A variety of measures are taken to ensure that the finished steel pipe meets specifications. For
example, x-ray gauges are used to regulate the thickness of the steel. The gauges work by
utilizing two x rays. One ray is directed at a steel of known thickness. The other is directed at the
passing steel on the production line.
If there is any variance between the two rays, the gauge will automatically trigger a resizing of
the rollers to compensate.
Pipes are also inspected for defects at the end of the process. One method of testing a pipe is by
using a special machine. This machine fills the pipe with water and then increases the pressure to
see if it holds. Defective pipes are returned for scrap.

4.5 Scrap and recycling

An Introduction to Metal Recycling:

Metals can be recycled repeatedly without altering their properties. According to the American
Iron and Steel Institute (AISI), steel is the most recycled material on the planet. The other highly
recycled metals include aluminum, copper, silver, brass, and gold.

39
Why Do We Recycle Metals?

Metals are valuable materials that can be recycled again and again without degrading their
properties. Scrap metal has value, which motivates people to collect it for sale to recycling
operations.

In addition to a financial incentive, there is also an environmental imperative. The recycling of

metals enables us to preserve natural resources while requiring less energy to process than the
manufacture of new products using virgin raw materials. Recycling emits less carbon dioxide
and other harmful gasses.

More importantly, it saves money and allows manufacturing businesses to reduce their

production cost. Recycling also creates jobs.

Quick Metal Recycling Facts

Although almost every kind of metal can be recycled again and again without degradation of
properties, currently, only 30 percent of metal is recycled. Below are some additional facts:

Nearly 40 percent of worldwide steel production is made using recycled steel.

Around 42 percent of crude steel in the United States is made of recycled materials.

In the United States alone, around 100 million steel and tin cans are used every day.

Steel and iron are the most recycled materials in the world due in part to the opportunity to
recover large structures as well as the ease of reprocessing. The use of magnets in the sorting
process enables recyclers to easily separate them from the mixed waste stream.

Every year, around 400 million tons of metal are recycled worldwide.

Currently, the single most recycled consumer product in the U.S. is the aluminum can.Throwing
away a single aluminum can waste energy equivalent to the same can filled with gasoline.

Types of Metals Recycled

Metals can be classified as ferrous, or non-ferrous. Ferrous metals are combinations of iron with
carbon. Some common ferrous metals include carbon steel, alloy steel, wrought iron, and cast
iron.

40
On the other hand, non-ferrous metals include aluminum, copper, lead, zinc, and tin. Precious
metals are non-ferrous. The most common precious metals include gold, platinum, silver,
iridium, and palladium.

The Metal Recycling Process :

The main stages of the metal recycling process are as follows:

1. Collection

The collection process for metals differs than that for other materials because of higher scrap
value. As such, it is more likely to be sold to scrap yards than sent to the landfill. The largest
source of scrap ferrous metal in the U.S. is from scrap vehicles.

Other sources include large steel structures, railroad tracks, ships, farm equipment, and of
course, consumer scrap. Prompt scrap, which is created in the course of new product
manufacturing, accounts for one-half of ferrous scrap supply.

2. Sorting

Sorting involves separating metals from the mixed scrap metal stream or the mixed multi-
material waste stream. In automated recycling operations, magnets and sensors are used to aid in
material separation.

At the entrepreneurial level, scrappers may employ a magnet, as well as to observe the material
color or weight to help determine the metal type. For example, aluminum will be silver and light.
Other important colors to look for are copper, yellow (for brass) and red, for red brass. Scrappers
will improve the value of their material by segregating clean metal from the dirty material.

3. Processing

To allow further processing, metals are shredded. Shredding is done to promote the melting
process as small shredded metals have a large surface to volume ratio.

As a result, they can be melted using comparatively less energy. Normally, aluminum is
converted into small sheets, and steel is changed into steel blocks.

4. Melting

Scrap metal is melted in a large furnace. Each metal is taken to a specific furnace designed to
melt that particular metal. A considerable amount of energy is used in this step.

Still, as mentioned above, the energy required to melt and recycle metals is much less than the
energy that is needed to produce metals using virgin raw materials. Based on the size of the
furnace, the degree of heat of the furnace and volume of metal, melting can take from just a few
minutes to hours.

5. Purification

41
Purification is done to ensure the final product is of high quality and free of contaminants. One
of the most common methods used for purification is Electrolysis.

6. Solidifying

After purification, melted metals are carried by the conveyor belt to cool and solidify the metals.
In this stage, scrap metals are formed into specific shapes such as bars that can be easily used for
the production of various metal products.

7. Transportation of the Metal Bars

Once the metals are cooled and solidified, they are ready to use. They are then transported to
various factories where they are used as raw material for the production of brand new products.

When the products made of these metal bars come to the end of their useful life, the metal
recycling process cycles again.

Metal Recycling Technologies :

Modern recycling technologies can effectively identify many different kinds of metals, though
there is still the need for even more effective recycling technologies to separate non-ferrous
metals.

Separating ferrous metals from non-ferrous metals is one of the most important steps in the
sorting process. As ferrous metals contain iron, they are attracted by magnets and easily pulled
out of the mixed waste stream. In scrap yards, cranes fitted with an electromagnet can remove
larger pieces of ferrous scrap.

When sorting metals from a mixed stream of recyclable material, the paper is removed first,
leaving only plastics and metals. Then, electric currents are induced across the stream where
only metals get affected.

This process is called Eddy Current Separation. Although aluminum is not magnetic, this
technology can levitate it and allow plastics to drop out of the process.

Recovering precious metals such as palladium, platinum, gold and other valuable metals such as
copper, lead, and silver from electronic waste becomes economically viable only if enough scrap
is collected. Such separation takes more technologically advanced and sophisticated recycling
equipment.

These days, in large recycling facilities, the use of sensors to identify metals through infra-red
scanning and x-ray has become popular. Three common categories of metal sensing processes
include biotechnology, hydrometallurgy, and pyrometallurgy.

The use of these technologies can effectively improve metal recovery rates.

Business Opportunities in Metal Recycling

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Traditionally, metal recycling has been regarded as a profitable business opportunity. In recent
years, however, depressed prices have proved to be challenging. At an entrepreneurial level, a
common entry point into the metal recycling business is through starting scrap metal collection
business or becoming a scrap metal vendor.

Environmental Impacts of Steel :-

As steel is an alloy of iron and carbon, it requires a lot of energy to produce heat during the
production process. Most of the electricity is generated by burning fossil fuels, which releases
greenhouse gases into the atmosphere, thus contributing to global warming. However, the most
beneficial feature of steel is that it is 100% recyclable and is long lasting, thereby making it an
ideal environmental performer to remain in use for many decades.

Stainless steel products help man to maintain a healthier life and a cleaner environment. Some
examples are detailed below:

New catalytic converters use stainless steel for the holding and transportation of catalytic
substances so as to improve its energy efficiency

Stainless steel converters decrease pollution from motor vehicles, generator sets, forklifts,
mining equipment, trucks, buses and trains

Stainless steel condensing boilers provide a 100% efficiency rating

Stainless steel pipes in drinking systems keep water clean and quality standards high. It helps
prevent formation of any medium on which bacteria can grow

Newer versions of diesel filters use stainless steel to improve removal of smoke and soot
particles from the exhaust gas of a diesel engine.

Recycling steel benefits :

Steel can be recycled over and over again without losing any of its properties. An interesting fact
is that recycling 1 t of steel helps to save 1.8 barrels of oil, 10.9 million Btu's of energy, 642
kWh of energy, and 2.3 m3 of landfill space.

Applications of Recycled Steel

Recycled steel can be used for the same applications as steel produced from virgin material.
Products that are made of recycled steel include:

 Electrical appliances
 Automobiles and other vehicles
 Office supplies
 Hardware such as bolts, nuts, screws etc.
 Construction materials
 Cans and containers

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Scrap :
consists of recyclable materials left over from product manufacturing and consumption, such as
parts of vehicles, building supplies, and surplus materials. Unlike waste, scrap has monetary
value, especially recovered metals, and non-metallic materials are also recovered for recycling.

Scrap prices may vary markedly over time and in different locations. Prices are often negotiated
among buyers and sellers directly or indirectly over the Internet. Prices displayed as the market
prices are not the prices that recyclers will see at the scrap yards. Other prices are ranges or older
and not updated frequently. Some scrap yards' websites have updated scrap prices.

In the US, scrap prices are reported in a handful of publications, including American Metal
Market, based on confirmed sales as well as reference sites such as Scrap Metal Prices and
Auctions. Non-US domiciled publications, such as The Steel Index, also report on the US scrap
price, which has become increasingly important to global export markets. Scrap yards directories
are also used by recyclers to find facilities in the US and Canada, allowing users to get in contact
with yards.

With resources online for recyclers to look at for scrapping tips, like web sites, blogs, and search
engines, scrapping is often referred to as a hands and labor-intensive job. Taking apart and
separating metals is important to making more money on scrap, for tips like using a magnet to
determine ferrous and non-ferrous materials, that can help recyclers make more money on their
metal recycling. When a magnet sticks to the metal, it will be a ferrous material, like steel or
iron.

This is usually a less expensive item that is recycled but usually is recycled in larger quantities of
thousands of pounds. Non-ferrous metals like copper, aluminum, and brass do not stick to a
magnet.

Some cheaper grades of stainless steel are magnetic, other grades are not. These items are higher
priced commodities for metal recycling and are important to separate when recycling them.

The prices of non-ferrous metals also tend to fluctuate more than ferrous metals so it is important
for recyclers to pay attention to these sources and the overall markets.

Scrap in BAZ factory :

They use the scrap in different faces. One is taking and reusing by making a holders, tables, or
walls. This is useful way to use the goods. Most of scrap is used by maintenance department.
They do maintaining for molds and profiles.
They do turning for the metal , also they do drilling and welding to make useful shapes and stuff.
Other face is to sale the scrap to some clients. Depend on the world prices or the quantity of
scrap they sale it . As it mention before this way either that way they deal with the scrap. In that
way the company can make extra profit from the scrap.

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 Fig4-6

Chapter V – Conclusion

At the end, the training was helpful to fix the knowledge inside the student or the trainee person .
The co-op is a good program to complete the studies in a prober face of studding . In the training
we got more experience than the regular study. Without the training the student may not see all
the thing which he already taken it in the passes semesters and also during the studding, the
student may not see the real work experiences.

The co-op is very important after finishing a group of courses. Co-op helps the student to know
the regulations and natural of the job, and how to deal with the companies in the future when
need to presenting in any companies. Taking a feedback about companies and how to deal with
an occupational stuffs, contract , benefits, salary, insurances, and other things. All this things the
student might not know about it before the co-op. During the weeks I have learn lot of things and

45
gained more experience everyday theoretical and practical . We got impressed from something
we didn’t know like the mechanism of how it made a pipes and big sheets.

The company is offering a jobs during the year. It is actually good company and good dealing
with the employees with offering a housing and meals during the day and in all shifts . We
recommend our friend to start making a contract with this company . With this company we
would rather to everyone who search for the experience to go directly to this company . Finally
we really enjoyed with the co-op training , and it was an awesome experiment.

Recommendations :

The industries in an environment of global competition. For these suppliers of raw

materials and semi-finished goods, quality is a requirement, rather than a
differentiator. Successful companies are able to manufacture high-quality products
at the lowest possible cost.

In this cost-constrained business environment, in-house process control groups are

becoming smaller or even being eliminated. Hence, the industries are becoming
increasingly dependent on suppliers of process control systems, even for ongoing
optimization. At the same time, even though process control systems can give
companies a technological advantage, new process control technologies will not be
implemented unless they will have an immediate effect on current operations.

The development of improved process control technologies depends on cooperative

efforts by multidisciplinary teams. The capabilities required to develop and
implement new process control technologies vary significantly depending on the
specific process science involved and on the maturity of the technology. Success
depends on the integration of several technologies, which may include the
following:

 process control science and engineering

 computer science and software engineering

 signal processing engineering

 measurement science

 process engineering
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 manufacturing

References

1- www.jindal.com

2- www.thebalancesmb.com

3- www.sciencing.com

4- www.metalsupermarkets.com

5- www.pearlitesteel.com
6- www.madehow.com

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