1 Checked By VEYSEL ÇELİK (Mechanical Engineer MSC) İSDEMİR Project Directorship GAZIANTEP UNIVERSITY ENGINEERING FACULTY MECHANICAL ENGINEERING DEPARTMENT ME 399 ORIENTATION PROGRAMME SUBMITTED TO: Asist. Prof. Mehmet Akif KÜTÜK SUBMITTED BY : ERDİ KARAÇAL Contact Adresses: [email protected]Phone Number: 0553 455 3779 SEPTEMBER 2013
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İSDEMİR Erdi Karaçal Mechanical Engineering 3rd Year Orientation Programme Report
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CHAPTER 1 PAGES 1) DESCRIPTION OF THE COMPANY…………………………...….4
1.1 NAME OF THE COMPANY………………………………………..…..4 1.2 LOCATION OF THE ORGANIZATION………………………………4 1.3 BRIEF INFORMATION ABOUT FACTORY…………………………5 1.4 COMPANY PROFILE………………………………………………….6
1.4.1 General Information About Personel………………….……….6 1.4.2 Number of Engineers Employed………………………………6 1.4.3 Operation Capacity…………………………………………….7
CHAPTER 2
INTRODUCTION……………………………………………………..8
2.1 PRODUCTS OF FACTORY………………………………….…..9 2.1.1 MAIN PRODUCTS AND WORKING AREAS……………………..9
2.1.2 BY-PRODUCTS AND WORKING AREAS………………………...10
2.2 PRODUCTION STEPS OF PROCESSES………………………..11 2.2.1 Isdemir Harbour………………………………………………………11
2.2.2 Sintering Plant and Ore Preparation…………………………………..12
2.2.3 Coke and By-Product Plant…………………………………………...13
2.2.4 Iron Making Plants (Blast Furnaces)………………………………….14
Main product range of ISDEMIR consists of pig iron, billet, coil, slab, hot rolled coils
and plates. Besides these products, by-products such as coke, oxygen, nitrogen, argon,
ammonium sulphate, granulated slag, coal tar and benzene are also obtained.
BILLET
Steel billets are produced via continuous casting of liquid steel, which is obtained from basic oxygen furnaces. Billet is a semi-finished product mainly used in manufacturing of wire rod, reinforcing steel bar, steel profiles and seamless pipe.
WIRE ROD
Wire rod is used in the production of commercial products such as mesh, wire, nail as well as it is used in the production of industrial products such as bolt, spring, electrode and welding wire.
SLAB
Steel slabs are produced via continuous casting of liquid steel, which is obtained from basic oxygen furnaces. Slab is a semi-finished product mainly used in manufacturing of hot rolled coil and hot rolled plate.
With the modernization and transformation investments (MTI) made, besides the long products, also flat products production started of at August 2008.ISDEMIR’s hot strip mill has a capacity of 3.5 million ton per year.
Usage: Automotive industry and ship building, can and tin production, pipe and profile
2.1.2 BY PRODUCTS AND WORKING AREAS
During steel production process, a variety of by-products are produced.ISDEMIR use some of them in the factory.
For example in the coke factory ,when making the coal as coke so many coke gases rise.Gas holders collects these gases and pumped to another department to use.
Another example is ; when producing steel ,many slags occur.Isdemir sell this slags to the cement factory.
When producing steel from pig iron sulfür content must be reduced.when doing this, sulfur is collecting and ammonium sulphate is producing.Isdemir sell this products to fertilizer (gübre) factory.
Granulated Blast Slag 500.000 tons/year (is selling to the Cement Factory) Coke coal : Melting of the pig iron for casting operations. Crude Benzene(Light Oil) (ham benzol) 30.000 tons/year (chemistry sector) Ammonium Sulphate (Fertilizer) 40.000 tons/year (is selling to fertilizer
4.3 PURCHASING DEPARTMENT This department aims to procure materials at required time and place, with minimum stock level, reasonable cost, sustainable competitive approach and long-term cooperations. Accordingly, Purchasing Department operates procurements covering all of the following processes excluding raw material and service:
Procurement of steel scrap, refractory materials, ferroalloys, fuel-oil products, mineral oil, dyes-chemical materials, machine components and other general consumables from domestic and foreign resources.
Domestic and international transportation of materials, customs clearance and warehousing operations, delivery to our plant.
Raw Materials Purchasing
Raw Material Purchasing Department is working with a head of Vice President Purchasing for purchasing raw material as iron ore, coal, manganese etc.
Raw materials as iron ore, coking coal, metallurgical coke, manganese, manganese with iron, quartzite, dolomite, limestone, silica send, dunite, magnesite, metallurgical lime are purchasing from domestic or imported resources with sea way, rail way or high way transportations. Raw Material Purchasing Department also making deals with contracting firms for exploiting licenced mines of ISDEMIR.
Raw Material Purchasing Department work in a coordination with concerned departments in order to take necessary precautions while purchasing, using and stocking of raw materials and auxiliary raw materials. Stock levels and analyses values of raw materials and auxiliary raw materials are followed up constantly. All prepared reports are submitted to concerned departments.
Raw material and auxiliary raw material requirements of ISDEMIR;
Iron ore are purchased from foreign countries and domestic suppliers. Our domestic supplier are; ERDEMIR Maden and other companies which have licence belong to third people.
Coking coal, metallurgical coke, pulvarised injection coal and anthracite are purchased from foreign countries (Australia, China, U.S.A., Russia, Canada, Poland)
Limestone, dolomite, quartz, dunite and silica sand from ISDEMIR’s licenced mine areas.
Manganese, ferromanganese and magnesite from domestic suppliers Metallurgical lime from domestic rolling mills and factories near surroundings of
ISDEMIR laboratories operates internationally to service specializing in the analysis of a variety of sample types (soil, sediment, rock cuttings, raw materials, lime stone, iron ore, slags, sinter, ferro alloys, refractories, coal, initial product, in-process product and finished product steel). ISDEMIR plants provides to companies and customers with a broad range of laboratory services from raw material to finished product analysis. ISDEMIR laboratories have TSE Laboratory Certificate of TS EN ISO/IEC 17025 that is; the general requirements for the competence of testing and calibration laboratories.
ISDEMIR laboratories provide following list of services:
Raw Materials Analysis
Lime stone Iron ore Coal, slags Ferroalloys Refractories Fe-Ti & Ca-Si cored steel
These analysis are made by using XRF spectrometer, ICP & AAS machines.
Initial - In process - Final Products Analysis
Pig iron Billets Wire rods Slab Coil Hot rolling roll and plate
These analysis are made by using Optical Emission Spectrometers and also N-H-O elements can be determined by LECO.
Physical & Mechanical Tests
Physical Tests
Breaking Grinding Elimination Resistance Density
Mechanical Tests
Pull Tilt Hardness Press Shock
Physical & mechanical tests are made according to the type of the material.
Technological tests are made by RUL test, LTD test, RDI test and FSI test machines. ISDEMIR provide a comprehensive range of metallurgical and mechanical testing services with a dedicated machine shop to provide specimen preparation.
As ISDEMIR Their Occupational Health and Safety Policy is;
To recognize our employees as the most valuable resource of our company by adopting the “Human First” and “Zero Accident” concepts, to provide a healthier and safer work environment.
To obey the current laws, rules and regulations in the scope of “Occupational Health and Safety”.
To implement TS 18001 Occupational Health and Safety Systems that set in ISDEMIR and to assure the sustainability of this system.
To consider the “Occupational Health and Safety” concept as a first priority in all activities.
To enhance the consciousness level of our employees by realizing training and other improving activities and to progress behaviour change in a positive way in the scope of Occupational Health and Safety matters.
To cooperate with the companies in our region, to be involved in an organization which enables common interference to the disasters and emergency situations.
To minimize the occupational health and safety risks and to prevent occupational injuries and illnesses in our company and improve the system in a continuous way by utilizing new technologies and using resources efficiently.
I completed my orientation programme at ISDEMIR which is one of the biggest and integrated factory in Turkey..ISDEMIR has huge production area.I have never been such a big factory before.Over 5000 people are worked there.Their coordination is very hard.Lots of department and lots of people focus on production.I am very happy to been there.Twenty day was not enough to travel all of the departments.Isdemir is huge factory.
I have done my orientation programme at the department of Project Directorship and as a unit of Mechanical Spare Part.
In my department 7 mechanical engineers work.I also realize that in Isdemir about 40 percent of engineers are graduated from Gaziantep University.Wherever I went in the factory there was an engineer who is graduated from Gaziantep University.I am very lucky because there is 4 engineer who are graduated from my university in my department.So many times I talked with them.This is very strange because they are graduated from my university before 10 years or 15 years and they recognize our teacher.One of engineers said me IS MR. BAYSEC is stil there I said him yes he is stil there. They give me good advice about my future life after graduation from my university.
I have been lots of departments due to chance of been Project Directorship.Engineers who work in this department is improved themself about design and development.I also improve myself about computer programming which they use there, like Solidworks and Autocad Mechanical.I have drawn lots of mechanical parts which are comes from departments.They are drawn in my department to make mechanical spare part.Engineers in my department make analyses and they work on how to improve the design.
I think this orientation programme will be very useful for my future life.I also realize that each lessons which we learn in university connect with practical area.