VISIT REPORT

INTRODUCTION
• Ezz steel is the Middle East's leading
producer of high-quality long and at
steel for use in a wide range of end
applications. Dependable products,
made to customer and international
specifications.

01/02/2024 2
 LABORATORIES
•Sample Preparation Process:
• Samples originate from the air pressure room.
• Transportation to the lab via air pressure tubes.
• Primary samples obtained from the electric arc furnace or laddle furnace.
• Using ASTM E8/E8M standard

•Processing Steps:
• Receipt of Samples:
• Samples arrive from production line.
• Initial handling in the air pressure room.
• Transportation:
• Sent through air pressure tubes to the laboratory.
• Lab Preparation:
• Samples from electric arc/laddle furnace are received.
• Size Adjustment:
• Cutting of large samples for manageable sizes.
• Surface Grinding:
3
• Smoothing and grinding of sample surfaces.
1. chemical Analysis Laboratory: Sample Preparation:
1. Samples collected from the production line or furnace.
2. Transported to the laboratory using air pressure tubes.
2. Analytical Techniques:
1. X-ray Spectroscopy:
1. Utilized for analyzing raw materials.
2. Provides insights into the composition of materials.
2. Spectroscopy:
1. Two spectroscopy methods in the lab.
2. One is specifically accurate for measuring nitrogen content.
3. X-ray Spectroscopy for Raw Materials:
1. Used to analyze the composition of raw materials.
2. Provides valuable data for quality control and process
optimization.
1. Microscopic Section Analysis: Sample Preparation:
1. Prepared samples undergo microscopic analysis.
2. Critical for understanding the structural
characteristics of the material.
2. Microscopy Techniques:
1. Optical Microscopy:
1. Used for examining the microstructure of
steel.
2. Provides insights into grain size, phase
composition, and defects.
2. Scanning Electron Microscopy (SEM):
1. Offers high-resolution images of the steel's
surface.
2. Allows for detailed examination of
microstructural features.
IRON MAKING
 DIRECT REDUCTION
PROCESS
1. Introduction:
1. A method of producing iron directly from iron ore without using a blast furnace.
2. Aimed at obtaining metallic iron with a lower level of impurities.

2. Raw Materials:
1. Utilizes iron ore as the primary raw material.
2. Commonly uses non-coking coal as a reducing agent.

3. Reduction Reaction:
1. Iron ore is reduced chemically in a reactor, often a rotary kiln or fluidized bed.
2. Carbon monoxide (CO) and hydrogen (H2) are typically involved in the reduction
reaction.

4. Temperature Control:
1. The process is carried out at a lower temperature compared to traditional blast
furnace methods.
2. Typically in the range of 800 to 1050 degrees Celsius.

5. Advantages:
1. Energy-efficient compared to traditional blast furnace methods.
2. Lower environmental impact with reduced emissions.

6. Products:
1. Produces Direct Reduced Iron (DRI) or sponge iron as the final product.
STEEL MAKING
 ELECTRIC ARC
FURNACE
1. Electric Arc Furnace (EAF): Utilizes an electric arc to
melt scrap steel and iron pellets in a high-temperature
environment.

2. Scrap as Feedstock: Recycled scrap steel is a primary

input, reducing the need for raw materials and energy-
intensive iron production.

3. Iron Pellets Addition: Iron pellets, containing concentrated

iron ore, are often added to adjust the chemical composition
and facilitate the steelmaking process.

4. High-Temperature Melting: The electric arc generates

intense heat, melting the scrap and iron pellets, and the
molten metal is then refined to produce high-quality steel.

5. Addition of the alloying element to certain amount

 1. Receiving Molten Steel:
1. The ladle furnace plays a pivotal role in the steel production process.
2. It receives molten steel from the Electric Arc Furnace (EAF).

2. Refinement and Composition Control:

1. Refining Process:

LADDLE FURNACE 1.
2.
The ladle furnace further refines the molten steel.
This refinement step allows for adjustments to the steel's chemical composition.
2. Additive Alloy for Precision:
1. Minor amounts of additive alloy are introduced during this stage.
2. The addition is crucial for controlling and ensuring the accuracy of the steel's chemical composition.
ROLLING MILL
BILLET
REHEATING
FURNACE
• Temperature in furnace reach
to 1200 degree (1:2 hour).
• Reheating of billet use to
facilities hot rolling process.
• transport the billet by rolls.
 • Three stages (roughing - immediate - finishing).
ROLLING STAND
• Usage: to reduce cross section of billet by compression.

• Water jet for rolls not for billet.

• Use saw to cut front and end of the billet because of surface oxidation. speed of rods 15 m/s.
THERMO MECHANICAL 1. Quenching:
TREATMENT (TMT) PROCESS1.2. The hot-rolled bars are rapidly quenched using water spray systems.
This quenching step is crucial for freezing the steel's microstructure at a specific phase,
imparting desirable properties.

2. Self-Tempering:
1. After quenching, the bars enter a chamber where the residual heat within the core induces a
controlled self-tempering process.
2. This self-tempering imparts a combination of strength and ductility to the steel.
 COOLING BED

• Cooling:

The bars are then allowed to cool in the air

naturally.
This controlled cooling phase further refines the
microstructure and ensures uniform properties
across the length of the bar.
• Cutting and Bundling:

Once the bars have reached the desired temperature,

they are cut to the required lengths.
The finished bars are then bundled and prepared for
further processing or distribution.
THANKS