Heavy Melting Steel Essay Example

Heavy Melting Steel Essay It is one of the leading Steel Re-Rolling Mills in Bangladesh and is engaged in manufacturing Deformed Bar of Prime Quality GR-60/40 (sizes from 5. 5 mm to 32 mm). It is situated at Baizid Bostami Industrial Area in Port City Chittagong. In order to establish the backward linkage of RSRM, RSRM sets up two separate manufacturing concerns – namely Ratanpur Steel Mills Limited (RSRM) and Modern Steel Mills Limited (MSML) in 1984 and 2005 respectively. MSML produce raw material (MS Billet) for RSRM. RSRM is situated in 176, Baizid Bostami Industrial Area of Chittagong. RSRM is a sophisticatedly equipped plant with modern machineries and equipments managed by efficient and expert human resources. Through its devoted research works, strict quality control and application of the best and exact raw materials and workmanship, RSRM successfully produces one of the best products in the market and it has achieved confidence and reliability of the valuable customers and goodwill in the market. [pic] Mr M. Rahman is the founder and Chairman of Ratanpur Steel Re – Rolling Mills Limited (RSRM). He was born in 1950 in an educated and respectable family of a little village namely Ratanpur in Feni District. Mr. Rahman is a graduate and an eminent freedom fighter. After liberation he engaged himself in steel business and in 1984 he established RSRM as a hand rolling mill. While engaged in steel businesses he visited many steel plants around the world and gathered the knowledge of steel making procedures and grading. In course of time RSRM grows and in 2008 he established a steel melting shop namely Modern Steel Mills Limited (MSML) and then automated the hand rolling mill into an automatic rolling mill. We will write a custom essay sample on Heavy Melting Steel specifically for you for only $16.38 $13.9/page Order now We will write a custom essay sample on Heavy Melting Steel specifically for you FOR ONLY $16.38 $13.9/page Hire Writer We will write a custom essay sample on Heavy Melting Steel specifically for you FOR ONLY $16.38 $13.9/page Hire Writer Using his vast wisdom and practical knowledge and under his leadership the businesses is expanding day by day and now he becomes one of the bona fide industrialists of the country. He is the top decision maker of the company with the help of Managing Director Director. He communicates and keeps liaison with Government body, Financial Institutes, Top listed suppliers buyers and ensure the smooth operation of this organization through sharing his valuable expertise opinion. Mr. Mizanur Rahman, the eldest son of our Chairman, is the Managing Director. He was born in 1982 and obtained his MBA degree. He shared his opinion regarding the management of the company with the Hon’ble Chairman. Production chief reports to him and he directly monitors the international sourcing and makes purchase decision with the help of Chairman and Director. Mr. Md. Yonus Bhuiyan, the youngest brother of our Chairman, is the Director of RSRM. He was born in 1960 and the youngest brother of our Chairman. He completed his Post Graduation in Mathematics from Chittagong University. He supervises the daily operation of the company as Local purchase, L/C monitoring, Bank Operation etc. [pic] |Ratanpur Steel Re-Rolling Mills Limited |Modern Steel Mills Limited | |S/N |Name of the Department / Section |Number of Employee(s) |S/N |Name of the Department / Section |Number of Employee(s) | |01. |Production |56 |01. Production (Furnace) |29 | |02. |Electrical |18 |02. |Production (CCM) |41 | |03. |Mechanical |23 |03. |Electrical |13 | |04. |Workshop |14 |04. |Mechanical |25 | |05. |Physical Lab |3 |05. Chemical Lab |7 | |Sub Total (A) |114 |Sub Total (B) |115 | |General | |S/N |Name of the Department / Section |Number of Employee(s) | |01. Finance Accounts |5 | |02. |Commercial |2 | |03. |Purchase |2 | |04. |Marketing Customer Service |29 | |05. HR Administration |5 | |06. |Security |43 | |07. |Imam |1 | |08. |Computer Operator |2 | |09. Driver |14 | |10. |Peon |10 | |11. |Cook |2 | |12. |Cl eaner |2 | |Sub Total (C) 117 | |Grand Total (A+B+C) |346 | Note: Besides, along with the permanent employees, for daily operation of the factories on an average 150 nos. of contractual labor work on daily basis under 3 nos. labor contractors. ORGANOGRAM OF FACTORY (Production Related) ORGANOGRAM OF MARKETING CUSTOMER SERVICE DEPARTMENT SKILLS COMPETENCIES LEVEL MATRIX POSITION(S)|Educational Qualification | |201 |No. 1 Heavy Melting Steel 3 feet x 18 inches: Wrought iron and/or steel scraps 1/4 inch and over in thickness. | | |Individual pieces not over 36 x 18 inches (charging box size) prepared in a manner to insure compact charging. | |202 |No. 1 Heavy Melting Steel 5 feet x 18 inches: Wrought iron and/or steel scraps 1/4 inch and over in thickness. | |Individual pieces not over 60 x 24 inches (charging box size) prepared in a manner to insure compact charging. | |203 |No. 2 Heavy Melting Steel: Wrought iron and steel scraps, black and galvanized, 1/8 inch and over in thicknes s, | | |box size to include material not suitable as No. 1 heavy melting steel. Prepared in a manner to insure compact | | |charging. | |204 |No. 2 Heavy Melting Steel: Wrought iron and steel scraps, black and galvanized, maximum size of 36 x 18 inches. | | |May include all automobile scraps properly prepared. |205 |No. 2 Heavy Melting Steel 5 feet x 18 inches: Wrought iron and steel scraps, black and galvanized, maximum size | | |of 36 x 18 inches. May include automobile scraps properly prepared, however, to be free of sheet iron or thin | | |gauged materials. | |206 |No. 2 Heavy Melting Steel 5 feet x 18 inches: Wrought iron and steel scraps, black and galvanized, maximum size | | |of 60 x 18 inches. May include automobile scraps properly prepared, however, to be free of sheet iron or thin | | |gauged materials. |208 |No. 1 Bundles: New black steel sheet scraps, clipping or skeleton scraps, compressed or hand bundled, to charging | | |box size, and weighing not less 75 pounds per cubic foot. (Hand bundles are tightly secured for handling with a | | |magnet). May include Stanley balls or mandrel wound bundles or skeleton reel, tightly secured. May include | | |chemically detained materials. May not include old auto body or fender stock. Free of metal coated, limed, | | |vitreous enameled and electrical sheet containing over 0. percent silicon. | |210 |Shredded Scraps: Homogeneous iron and steel scraps, magnetically separated, originating from automobiles, | | |unprepared no. 1 and no. 2 steel, miscellaneous baling and sheet scraps. Average density 50 pounds per cubic foot. | |211 |Shredded Scraps: Homogeneous iron and steel scraps, magnetically separated, originating from automobiles, | | |unprepared no. 1 and no. 2 steel, miscellaneous baling and sheet scraps. Average density 70 pounds per cubic foot. | 229 |Billet, Bloom and Forge Crops: Billet, Bloom, Axle, Slab, Heavy Plate and Heave Forge Crops containing not over 0. 05 percent | | |of phosphorus or sulp hur and not over 0. 5 percent silicon, free from alloys. Dimensions not less than 2 inches in thickness, | | |not over 18 inches in width and not over 36 inches in length. | |230 |Bar Crops and Plate Scraps: Bar Crops, Plate Scraps, Forgings, Bits, Jars and Tool Joints containing not over 0. 05 percent of| | |phosphorus or sulphur and not over 0. percent silicon, free from alloys. Dimensions not less than 1/2 inches in thickness, | | |not over 18 inches in width and not over 36 inches in length. | |231 |Plate and Structural Steel, 5 feet and Under: Cut Structural and Plate Scraps, 5 feet and under. Clean open hearth steel | | |plates, structural shapes, crop ends, shearing or broken steel tires. Dimensions not less than 1/4 inches in thickness, not | | |over 5 feet in length and 18 inches in width. Phosphorus or sulphur not over 0. 05 percent. |232 |Plate and Structural Steel, 5 feet and Under: Cut structural and plate scraps, 5 feet and under. Clean open hearth steel | | |plates, s tructural shapes, crop ends, shearing or broken steel tires. Dimensions not less than 1/4 inches in thickness, not | | |over 5 feet in length and 24 inches in width. Phosphorus or sulphur not over 0. 05 percent. | |233 |Cast Steel: Steel casting not over 48 inches long or 18 inches wide, and 1/4 inches and over in thickness, containing not | | |over 0. 5 percent phosphorus or sulphur, free from alloys and attachments. May include heads, gates and risers. | |234 |Punching and Plate Scraps: Punching or stampings, plate scraps, and bar crops containing not over 0. 05 percent phosphorus or | | |sulphur and not over 0. 5 percent Silicon, free from alloys. All materials cut 12 inches and under, and with the exception of | | |punching or stampings, at least 1/8 inch in thickness. Punching or stamping less than 6 inches in diameter may be and gauge. |235 |Electric Furnace Bundles: New Black Steel sheet scraps hydraulically compressed into bundles of size and weight as specified | | |by cons umer. | |249 |Chargeable Slab Crops: Chargeable Slab Crops for material to be suitable and acceptable to the consumer containing not over | | |0. 05 percent phosphorus and 0. 05 percent sulphur and not over 0. 05 percent Silicon; free of alloys. | |N. B. |Cleanliness: All grades should be free of dirt, nonferrous metals or foreign materials of any kind, and excessive rust and | | |corrosion. However the terms â€Å"free of dirt, nonferrous metals, or foreign materials of any kind† are not intended to preclude| | |the accidental inclusion of negligible amounts where it can be shown that this amount is unavoidable in the customary | | |preparation and handling of the particular grade involved. | 1. HBI/DRI: As per HBIA, A typical Chemistry is given below: Fe (total): 90-94% Fe (Metallic): 83-88% C (Carbon): 0. 8-1. 70% P (Phosphorus): 0. 02-0. 11% S (Sulphur):0. 003-0. 30% Gangue:2-5. 0% Residuals:Trace (min) Metallization: 92-95% [pic] RSRM Produces deformed bars on demand conforming to the standard specification of BDS 6935:2006, ASTM A 615, Grade 40 60, BS 4449 JISG 3112 by maintaining strict adherence to buyers’ specification in terms of steel grade, tensile strength, unit mass and close dimensional tolerances. 100 M. Ton Capacity Universal Testing Machine ensures yield stress, ultimate tensile strength, elongation and band test of our finished products. Our laboratory technicians are working round the clock in the laboratory; Samples of each batch of production are collected tested simultaneously in our laboratory. The Manager of Production sincerely incorporates with the results of the laboratory tests in order to obtain quality product. Mechanical properties of our MS Bars are the nearest equivalent to Grade – 40 and 60 of ASTM A 615: |Grade |Bar Size |Yield Stress Psi |Tensile Strength Psi |Elongation Percent of gauge|Bend Test at 180o | | |(mm dia) |(MPa) min. |(MPa) min. |length: | | | | | | |200 mm (min. | | |Grade – 40 |10 to 25 |40,000 (275) |60,000 (415) |12 |Should be | | | | | | |satisfactorily bend | | | | | | |without crack | |Grade – 60 |10 to 25 |60,000 (415) |90,000 (920) |7 |Should be | | | | | | |satisfactorily bend | | | | | | |without crack | N. B. : Test bends 180o unless noted otherwise. We also have a sophisticated Chemical Lab to analyze the chemical composition of incoming raw materials (known as Billet) the finished products. The main objective of the chemical analysis is to determine the existing percentage of Carbon (C), Silicon (Si), Manganese (Mn), Sulphur (S), Phosphorous (P) etc. in raw materials and in our finished products. We maintain chemical composition of billets of Grade – 40 and 60 as per following: Grade |% C |% Si |% Mn |% P Max. |% S Max | |Grade – 40 |0. 18-0. 25 |0. 20-0. 35 |0. 60-0. 90 |0. 050 |0. 050 | |Grade – 60 |0. 29-0. 35 |0. 20-0. 35 |1. 30-1. 60 |0. 050 |0. 050 | We have optical Emission spectrometer (PDA-7000) which can analyze 18 elements of steel within 20 seconds. Highly experienced Chemists are engaged to ensure proper composition as per requirement to meet the standard specification of ASTM A 615. It is also approved by BSTI (BDS-ISO-6935:2/2006). Schematic diagram of sample analysis is given below: Sample collection from Furnace Cooled Sample Cutting Polished by Polishing Machine Cleaning Spectrometric Analysis Computerized Results. The following elements are determined with the help of Spectrometer in 20 seconds: C, Si, Mn, P, S, Ni, Cr, Mo, Cu, Co, Al, Pb, W, Ti,V, B, Sb, Sn Fe Volumetric Analysis: Volumetric analysis is performed by the following apparatus: 1. Strolein Apparatus (Carbon Sulphur Determinator): This instrument is used for the determination of C% (Carbon percentage) and S% (Sulphur percentage). 2. Muffle Furnace: This instrument is used for the determination of Volatile matters of Hard Coke, Graphite, Ferrous (Fe-Mn, Si-Mn, Fe-Si) Non-Ferrous and Refractory Materials. All data from the testing and inspection are feed back to production units and stored by them in order to improve the quality of the product. The customer liaison wing (Sales Marketing Department) takes care of complains from any customer. Our quality control team continuously checks the production process at each and every stage. We also conduct the laboratory test in BUET in order to verify the correctness of the result of our own laboratory test. We usually supply the esting report of BUET on request of our valuable customers. LIST OF APPARATUS EQUIPMENTS FOR LABROTARY IN RSRM |S/N |Name of the Apparatus and Equipments |Number | |01. |Optical Emission Spectrometer PDA-7000 |1no. | | |(Shimadzu, Japan) | | |02. |Carbon Sulphur Determinator |2 nos. | |03. |Muffle Furnace |1 no. | | |Operating Temp: Approx. 2 50oC | | | |Maximum Temp: 1350oC | | | |Inner Size |200(W)x400(D)x200(H)mm | |04. |Universal Testing Machine |1no. | |05. |Air Oven |1 no. | |06. |Hot Plate |2 nos. | |07. |Combustion Boats |5000 pcs. | |08. Combustion Tube |100 pcs. | |09. |Electric Dying Oven |2 pcs. | |10. |Electric Water Distillation |1 no. | | |Capacity 5 L/H | | |11. |Direct Reading Glass electrode PH Meter |1 no. | | |With Standard Solution | | |12. Metallurgical Microscope with accessories | | | |Magnification |1 no. | | |Accessories |: 20 to 1500 | | | |: Specimen Polisher 1 no. | | | |: Specimen Dryer 1 no. | |13. |Double Ended Bench Grinder |1 no. | |14. |Abrasive Cutting Disc |1 no. | ITEMS/APPARATUS |# Analytical vessel etc. |Burettes with stopper |(10, 25, 50 CC) |10 NOS. each | |Measuring pipett |(10, 25, 50 CC) |10 NOS. each | |Graduate pipett |(1, 5, 10, 20 CC) |10 NOS. each | |Measuring flasks with stopper |(100, 250, 500, 1000 CC) |10 NOS. each | |Measuring cylinder |(10, 50, 100, 500, 1000 CC) |1 0 NOS. ach | |Celcius Thermometer |(100, 200, 360oC) |10 NOS. each | |Evaporating dish of porcelain |(100, 200 mm dia) |10 NOS. each | |Watch Glass |(120, 200 mm dia) |20 NOS. each | |Watch Glass |(60, 90 mm dia) |20 NOS. each | |Beakers of Glass |(100, 300, 500, 1000 CC) |30 NOS. ach | |Washing Bottles |(300, 500 CC) |10 NOS. each | |Reagent Bottle, Narrow Mouth |(100, 300, 500, 1000 CC) |20 NOS. each | |Reagent Bottle, Narrow Mouth |(100, 300, 500, 1000 CC) |20 NOS. each | |(Brown Body) | | | |Reagent Bottle, Wide Mouth |(100, 300, 500, 1000 CC) |10 NOS. ach | |Porcelain Crucible |(15, 30 CC) |50 NOS. each | |Glass Funnel |(70 mm dia) |50 NOS. each | |Glass Funnel |(150, 250 mm dia) |10 NOS. each | |Separating Funnel with stopper |(250, 500 CC) |10 NOS. each | |Filter Funnel of Porcelain |(90, 110 mm dia) |10 NOS. ach | |Filter Funnel with Glass Filter | |10 NOS. | |Glass Rod |(5-20 mm dia, together) |5 kg. | |Glass Tube |(2-20 mm dia, together) |10 kg. | |Glass Desiccators |(240 mm dia) |10 NOS. | [pic] |S/N |Name of the Apparatus and Equipments |Functions | |01. |Optical Emission Spectrometer PDA-7000 |It determines the ercentage of C (Carbon), Si (Silicon), Mn (Manganese), P (Phosphorus), S | | | |(Sulphur), Cr (Cromium), Mo (Molybdenum), V (Vanadium), Ni (Nickel), Cu (Copper), Co (Cobalt), Pb | | | |(Lead), Sn (Tin), Sb (Antimony), Ti (Titanium), W (Tungsten), B (Boron) and Al (Aluminium) in | | | |steel samples during and after production to ensure quality of the production of MS Billets which | | | |subsequently will be used in rolling mill for the production of MS Deformed Bars. Here steel | | | |samples are tested in the form of cube or cylindrical block. | |02. |Carbon Sulphur Determinator |It helps analyze to determine the percentages of C (Carbon) and S (Sulphur) in steel when steel | | | |samples is in the form of chips or infinitely divided particles. | |03. |Muffle Furnace |It is used mainly for heating the substances in closed condition. Volatile matters, ash content | | | |and fixed carbon are determined in hard coke, CPC, graphite, etc. Also used in determining the | | | |percentages of SiO2, Fe2O3, Al2O3, etc. in refractory materials and ferrosilicon and silicon | | | |manganese are tested here. | |04. |Universal Testing Machine |Mechanical properties such as yield strength, Tensile strength, Elongation percent, Bend Test and | | | |Brinell hardness tests of finished deformed bars and carried out here. | |05. |Air Oven |For hot air purpose. | |06. Hot Plate |For the purpose of boiled water and heating chemical substances for analysis. | |07. |Combustion Boats |Used steel samples holder and the sample are inserted in combustion tube furnace for analysis of | | | |steel samples. | |08. |Combustion Tube |Ceramic Tube high heat resistant to be used in Combustion Furnace. | |09. |Electric Dying Oven |Used for the purpose of demoisturizing the chemical substances. | |10. |Electric Water Distillation |For the production of distilled water. | |11. |Direct Reading Glass electrode PH Meter |To determine PH value of water. | |12. Metallurgical Microscope |To carry out microscopic examination of steel samples. | |13. |Double Ended Bench Grinder |For grinding steel samples. | |14. |Abrasive Cutting Disc |For the purpose of cutting steel samples. | Besides above, some other tests can be carried out such as, Apparent Porosity Percent, Bulk Density, Percentage of Water Absorption and compressive strength of refractory bricks, castables, etc. [pic] ? Prime quality 60/40 graded Deformed Bar. ? Length  ± 12 meters. ? Size 5. 5 mm to 32 mm. or according to customer requirement. ? Produced from best quality billet. ? Manufactured from automated mill. Certified by ISO-9001:2000. ? Equivalent to ASTM A615. ? Approved BSTI (BDS-ISO-6935:2/2006) ? Tested by BUET. ? Cost effective. ? Accurate weight. ? Perfect diameter. ? Uniform strength long lasting. ? Earthquake absorbent. [pic] We always pay highest importance to our customers. Schedule delivery, accurate weight and quick transportation of goods are some of the key points of our customer services. Schedule Delivery: Delivery of goods is executed within the shortest possible time on receiving of work order from customer. Our Sales Marketing department processes Purchase order of, maintains liaison with, and quick responds to, the customers. Accurate Weighment: We have modern and accurate bridge scale within the premises of our mill. Our technicians constantly check-up and monitor the scale to ensure the highest degree of accuracy in weighment of goods for complete satisfaction of our valued customers. Quick Transportation: We have good communication with the Truck and Trailer Owner’s Association, and for that reason we can deliver our goods to the desired points of our customers as their requirements. Our own deliverymen accompany the loaded vehicles from loading points to the delivery points of the customers. Evaluation Customer: We are careful about our valuable customers. For that reason we have â€Å"Customer’s Satisfaction Questionnaire† and â€Å"Customer’s Complain Register†. In the Customer’s Satisfaction Questionnaire, we give the scope to our customer to make comment about our products and services. In the Customers Complain Register we compile customers complain. We review complains of the customers in our Management Review Meeting and we strictly maintain this practice and take necessary action. [pic] Needless to mention here that steel plant is one of the vulnerable sectors in regard with injuries related to work, hazards and environmental degradation. Fully aware of the situation and the facts, we are committed to ensure a work place where these threats are eliminated in a reasonable quantity. In our production procedure while ensuring the quality of product simultaneously we aware our work force and strictly maintain and follow the motto which carries the slogan of â€Å"SAFETY FIRST†. With the help of our limited resources we already have taken the following measures to ensure an accident free work place: ? It has been made mandatory to all workers, staffs, engineers, officers to wear PPE (Personal Protective Equipment) while in the work place. ? Company provides the PPE like safety helmet, goggles, hand gloves, safety uniform, Safety shoes etc. to all. ? Company bears the whole medical expenses regarding any injuries to our workmen while in work place. ? A Company provided microbus stands still in the premises of factory for any emergency duty of transportation of injured person to the nearest hospital. Company in its own expense trains from engineers to supervisors regarding health and safety issues in the work place in addition of In – house training. Th us we can claim our engineers to supervisors and trained in health and safety issues. Besides, our HR division continuously monitoring the incidents and when such incident occurred an ACCIDENT RECORD FORM filled by interviewing the injured person and the related personnel to identify the reasons and take necessary actions eliminate the facts that may another time responsible to occur the same accident. Our Environment Clearance Certificate is on process and we are in continuous touch with the Environmental Department of the government of Peoples’ Republic of Bangladesh in this regard. Our management is committed and feels the obligation of ensuring an accident free and hazardless environment in the work place and continuously working in this section for introducing more and more advance technology for safeguard and building awareness to the workmen to decrease the accident proneness. [pic] ? We are an ISO 9001:2000 certified company Certificate awarded by Bureau Veritas Certification (India) Private Limited on 06 July, 2009. Certificate Number: IND93237 dated 07. 07. 2009 ? Our Product is Bangladesh Standards and Testing Institution (BSTI) Certified CM Licence Number: CM/L – 11714 ? Our sister organization Modern Steel Mills Limited has got the Environmental Clearance Certificate from the Environment Department of Government of People’s Republic of Bangladesh Clearance number: 5339 And our process of obtaining the clearance certificate from the same authority is on process. Legal position of RSRM: ( Certificate of Incorporation No. # C15492 / 1058 of 1985-1986 ( TIN Number # 341-200-1150/CO-2 ( Vat Registration No. # 2021000362 ( Trade License No. # ID/75000/P/00139 [pic] Some important establishments using our MS Rod: †¢ Imperial Hospital, Foy’s Lake, Chittagong (Country’s largest and foreign funded) †¢ Flyover from Chittagong Port to Dewanhat by Bengal Development Corporation †¢ New project of Chittagong Medical College by Delta Engineers †¢ Akhtaruzzaman Center †¢ Khulna Diabetic Hospital †¢ Sheikh Abu Naser Hospital, Khulna Khulna Medical College †¢ Khustia Technical University †¢ Dapdopia Bridge, Barisal †¢ National University, Gazipur Some National, Private and eminent Developers using our MS Rod: †¢ 16 Engineer Construction Battalion (Special Works Organization) Bangladesh Army †¢ Proje ct Builders Limited †¢ Joint Venture Engineering Limited †¢ Concord Group †¢ Rupayan Housing Estate Limited †¢ Navana Real Estate Limited †¢ Rangs Properties Limited †¢ Development 2000 Limited †¢ Imperial Development Holdings Limited †¢ Wintake Development 2000 Limited †¢ Pioneer Builders Limited †¢ O K Enterprise (Pvt. ) Limited †¢ Prosimo Development Limited †¢ Eternal Design Developments Limited Impulse Properties Limited †¢ RF Properties Limited †¢ Equity Properties Management Limited †¢ S K D L †¢ Binimoy Properties Limited †¢ Alien Holdings Limited †¢ Keary Limited †¢ C A Properties Development Limited SR SR Exe SR SR SR SR SR Dis. Supr Sr. Ex Exe Exe Exe Exe Exe Exe Sr. Ex Sr. Ex Sr. Ex Sr. Ex Sr. Ex Sr. Ex Manager (Event Management) Assistant Manager Deputy Manager Manager AGM DGM Distribution In – Charge Executive(s) (Distribution) Junior Executive(s) (Distribution) Dis tribution Assistant GM (Marketing Sales) Executive Director (Sales) Executive Director (Promotion) Director (Marketing) Board of Director (s) 24