For each ton of molten pig iron, you need: 2600 lbs iron ore or iron ore pellets, 1000 lbs coke 300 lbs of flux (slag, dolomite, limestone, etc).

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1 Steel Mills

2 Steel Process Flow For each ton of molten pig iron, you need: 2600 lbs iron ore or iron ore pellets, 1000 lbs coke 300 lbs of flux (slag, dolomite, limestone, etc).

3 Steel Mill - Raw Materials Scrap Iron Ore Coke

4 Scrap Processing Scrap processing companies are often set up on the steel mill property where the scrap is shredded and/or bailed. On-site scrap yards may even load charging boxes which are brought directly in the mill for furnace charging.

5 Charging Box

6 Liners

7 Charging Box Lid The wear is clearly visible. These plates will bind the ram and begin to destroy the machine

8 Grooved Wear Plates Liner plates which have machined grooves on the ram and liner prevent material from binding between the ram and liner.

9 This ½ AR400 chute liner will replace the worn out one below Scrap Chutes

10 Abrasion resistant cyclones are used for separating particulate matter out of the shredder exhaust.

11 This is the rotor which shreds the cars. AV bar is very effective for swing hammer pins The rotor segments can be flame cut out of AV plate

12 Below is a 6 thick impact plate for the shredder. Materials range from castings to A514 to Astralloy V can be used in this application A cast hammer for the shredder

13 Scrap Scrap cars or boxes are filled and transported into the mill for charging the furnace. These boxes are often made of mild steel. A spare box is usually on hand to be re-lined and switched out when one wears out. Good opportunity to upgrade from mild steel

14 Massive scrap conveyors may be used in lieu of charging boxes to transport scrap from the yard to the furnace. These conveyors are lined with wear plate. Scrap

15 Scrap Charging Chute

16 Stacker Reclaimers These are massive machines. Train cars are in the foreground. The raw materials are scooped up by a series of buckets mounted on a wheel and conveyed into the mill. Every time material changes direction a chute is involved

17 Stacker Reclaimer Buckets These stacker reclaimer buckets have been re-lined. Notice the configuration of wear plates

18 The coke is pushed out of the battery and into a transfer car. This wears on the transfer plate and exposes it to heat for a short period of time. AR400 has been used for these wear plate. Astralloy V would be better suited to the elevated temperature. COKE

19 Scrap Charging Chute

20 Ladle Hooks & Wear Pads

21 Electric Arc Furnace Baghouse Capacity: 1,385,000 cfm 3 462,000 ACFM each, 17in w.g. at 150degF 16 Compartments w/228 Bags each = 3648 total bags 11.75in dia x 34ft long 3 each 2500HP, 720RPM Fan Motors Ductwork: 19ft ID and 16ftID Bag House

22 Continuous Casting Diagram

23 Rigid Dummy Bars

24 Rigid Dummy Bars can be the bottom of this picture. The strand continues under the dummy bar. Continuous Casting

25 Dummy Bar Chain

26 Down Coiler Shafting

27 Plate Mill Guides - Skirts

28 De-Scaling Hood

29 A514 Mill Chain Links

30 Rolling Mill in Action

31 A Roll Stand w/chrome carbide overlay rolls refurbished & mounted

32 Worn rolls are turned down, chrome carbide overlay is re-applied and roll is machined to the proper diameter

33 You can see the thickness of the overlay from the rolls end Chrome Carbide Overlay Rolls

34 Refurbished Rolls

35 Skip Hoist Buckets

36 Flat Top coil chain with external rollers -Flat Top coil chain with central roller -High Saddle Top coil chain -Low Saddle Top coil chain -Skew Top coil chain - V Top coil chain -Universal coil chain -Single/Double wide coil chains -Helper Drive Chains -Custom Chain -Stock Rollers -Stock Axles -New and rebuilt coil chain Coil Chain

37 Heavy duty apron and piano hinge chains for hot lime conveyors, foundry scrap / sand/ casting conveyors, steel mill scrap conveyors, and others.

38 Cooling Bed Rollers

39 Cooling Bed Rollers

40 Sprockets Heavy-duty sprockets and head/tail shafts for coil chain, Draw bench chains, bar chains, apron chains, Piano hinge chains, crop chains, and oven chains.

41 Slag Processing Slag is crushed, screened and sold for various aggregate applications

42 Screens, chutes and hoppers wear out quickly. Slag Screening