Emirates Steel Rolling Mills Overview

General Overview of ES Rolling Mills

• Understand the details of Rolling Mills in Emirates Steel and its process, as well as its application.
• Rolling is the process of shaping steel, where material is passed between rolls, reducing its cross-sectional area.

Basics of HOT Rolling Principle

• Rolling is a process that grips and deforms the material by the rolls, with its cross-sectional area being reduced.
• The rolls rotate at the same speed but in opposite directions (clockwise and counterclockwise).

Types of Rolling Mills @ Emirates Steel

• Emirates Steel has 5 rolling mills: RM1, RM2, RM3, RM4, and RM5.
• Rolling Mill 1, 2, and 5 are rebar mills; Rolling Mill 3 is a wire rod mill, and Rolling Mill 4 is a heavy section mill.

Introduction to RM1, RM2, RM3, RM4, and RM5 Plants

• Rolling Mill 1 is the first rolling mill plant in Emirates Steel, with a design capacity of 500,000 tons per year.
• Rolling Mill 2 is a rebar mill, commissioned in 2007, producing quality deformed bars with a maximum speed of 35 meters per second.
• Rolling Mill 3 is a wire rod mill, producing plain wire rod and deformed bars in coils, with a maximum speed of 100 meters per second.
• Rolling Mill 4 is a heavy section mill, producing beams, channels, angles, and sheet piles.

Rolling Mill Equipment

• Reheating Furnace: heats the steel billet to the required temperature for rolling.
• Descale: removes accumulated scales from the billet.
• Roughing Mill: reduces the cross-sectional area of the stock.
• Crop & Cobble Shear: cuts the head and tail of the bar for smooth entry to the intermediate mill.
• Vertical Stand: consists of two high cartridge stands with both rolls mounted vertically.
• Horizontal Stand: consists of two high cartridge stands with both rolls mounted horizontally.
• Fast Finishing Block: a compact rolling block with cantilever tungsten carbide rings.
• Cooling Bed: cools the bars after rolling.
• Cold Shear: cuts the rolled products into desired customer lengths.
• Quenching Unit: increases the mechanical properties of deformed bars.
• Bars Screw Counter Station: processes bar layers and counts the bars as per the preset numbers.
• Pinch Roll: drags the bar at the right speed.
• Wire Binding Machine: binds the bundle of rebars with wire.
• Dividing Shear: cuts the bars into multiple lengths according to the desired length.
• Removal Area: consists of storage roller tables, disappearing stop, and lifting chain transfer.
• Forming Station: produces final coils with better coil shape compactness and homogeneity.
• C Hook Conveyor: lifts and carries the coils from the forming station to the compactor.
• Coil Compactor: a horizontal compactor with four binding units for automatic compacting and binding.
• Unloading Station: the final station where the coils are picked up by forklift and transferred to the storage area.

ES Products

• Rebars: used in civil engineering and building projects, produced as deformed bars in straight lengths or coils.

• Wire Rods: used in various applications, including springs, electrodes, fencing wires, fasteners, cycle spokes, nails, and GI wires.

• Heavy Sections: used in construction, industrial, and engineering applications, including beams, channels, angles, and sheet piles.### Profile Gauge for Dimension Measurement

• Breakdown Mill: divides products in the cooling bed

• Cooling bed: cools products from 850°C to 80°C

• Straightening machine: uses spray marking on products

• Layer preparation and quality inspection: prepares products for further processing

Rolling Mill 5 (Rebar Mill)

• Designed to produce rebar and plain bars
• Equipped with 18 stands in horizontal and vertical configuration
• Produces rebars and plain bars from billets

Glossary

• Rolling: shaping and reducing steel through rotating rolls
• Rolling Mill: a factory or machine for rolling steel into different products
• Billet: a type of raw material
• Wire rod: a finished product rolled from a billet in a wire rod mill, formed into coils
• Reheating furnace: heats raw material to required rolling temperature
• Descaler: equipment with pressurized water to remove scales from hot steel
• Roughing mill: reduces the cross-section of the stock
• Intermediate mill: further reduces rolled stock
• Finishing mill: where final shaping stage of hot rolling takes place
• Finishing block: stands with cantilever carbide rings placed 90° to each other
• Tempcore/Quenching: rapid cooling of bars to improve mechanical properties

Rolling Mill 5 Facts and Figures

• Annual production capacity: 500,000 tons
• Raw material: Billet 150mm x 150mm x 12m and 130mm x 130mm x 12m
• Pusher type furnace: 80 Ton per hour capacity
• Continuous rolling mill: with 18 stands in H and V configuration
• In-line Quenching process: rapid cooling of bars
• Cooling bed: cools bars cut to length from mill
• Dividing shear: cuts bars to length
• Cold shear: flying cold shear type for cutting different lengths
• Tying machines: bind final product bundles