Steel bars of different specifications play a vital role in the construction of various infrastructures, such as housing, roads, bridges, and subways, which all use large amounts of steel bars. As global urbanization accelerates, demand for housing, office buildings, business centers, and infrastructure continues to grow. This not only accelerates the growth of the demand for steel bars but also requires continuous improvement in the quality and performance of steel bars. Therefore, steel bar production and processing factories have emerged in large numbers. So, if you want to build a steel bar production line to produce 12-length steel bars with a diameter of 8-32mm and a production capacity of 20t/h, what conditions need to be considered?
This article takes long-process technology as an example to introduce in detail the construction of a factory that produces 12-15m long, 8-32mm diameter steel bars, and a production capacity of 20t/h from five aspects: equipment, infrastructure, site, investment return cycle and environmental protection.
There are two processes for producing steel bars, one is the short process and the other is the long process.
The long-process steel bar production process refers to the production process from scrap steel as raw material to finished steel bars.
There is a lot of equipment in the steel bar production line. However, if you want to save your production cost, you can just drop some (optional) out of the list.
Under normal circumstances, scrap steel does not need a crusher and can be put into the steel melting furnace for melting using a feeding trolley or electromagnetic chuck. However, some scrap materials are larger and need to be broken into smaller sizes before they can be put into the melting furnace. A smaller furnace charge has two advantages. First, it saves space in the furnace and can put as much scrap as possible to be melted. Second, it can improve the melting efficiency to a certain extent.
Equipment for adding scrap steel to the melting furnace.
Since the output of the entire production line is 20t/h, the total capacity of the melting furnace must be higher than 20t. Considering that a single melting furnace with a capacity of 20t may have some unexpected problems during use. Therefore, if you want to ensure the smooth operation of the production line, it is recommended to use two 15t or three 8t steel melting furnaces. In the beginning, several melting furnaces were smelting at the same time. As the production line enters normal operation, several melting furnaces alternate melting and casting to ensure the smooth operation of the entire production line.
A continuous casting machine is a production equipment that continuously casts high-temperature molten steel into a slab with a certain cross-sectional shape and size. Its core equipment includes ladles, crystallizers, dummy rods, cutting equipment, and conveying equipment. Continuous casting machines are widely used in the field of metal forging. Their emergence simplifies the production process, improves production efficiency and metal yield, saves energy consumption, greatly reduces production costs, and at the same time improves the quality of steel billets. If you want to produce 8-32mm steel bars to achieve a steel bar output of 20t/h, the minimum cross-section of the original steel billet is 100*100mm. Therefore, it is recommended to use an R3.5M or R4M arc-shaped all-in continuous casting machine to ensure that the cross-section meets the requirements without causing the casting speed to be too low. The continuous casting billet is cut into billets of about 1.5m.
The steel billet with a cross-section of 100*100mm requires a billet roughing rolling mill with a rolling force of more than 90t for rolling. The rolling force of the 400 three-roll mill is 100t, which just meets the rolling requirements and has a slight safety margin, so it is the best choice.
After calculation, from 100*100mm steel billet to 8-32mm steel bar, 14 consecutive passes are required. Therefore, the continuous rolling mill uses 10 300 one-to-one rolling mills and four 250-to-one rolling mills.
Cut the rolled steel bar into a length of 12m or 15m. Cut-to-length scissors use simple gantry scissors or crocodile scissors, each with its advantages and disadvantages. The biggest advantage of simple gantry shears is that they can effectively avoid the occurrence of flat ends and improve the quality of steel bars.
Equipment for temporary storage and cooling of finished steel bars. If there are sufficient economic conditions and space, you can consider installing a step-by-step cooling bed, which has a high degree of automation and can reduce labor input. If you don’t have enough space and budget, you can also find an open space and place the steel bars directly on the ground to cool down.
Electricity: Because almost all equipment in the entire production line is driven by electricity, sufficient electricity is a prerequisite to ensure smooth production. In this production line, the total power required is approximately 5000KW. If you want to build such a production line, you should first consider whether there is enough power.
Water: When it comes to water, you also need to prepare two 80-ton closed cooling towers and several pools to cool the equipment. Water is mainly used for cooling equipment in the production process. If water is scarce in your area, water costs may be higher.
The installation of the equipment requires a large amount of land. To completely install this steel bar production line, a site approximately 200m long, 40m wide, and 12m high is required.
Although the current steel bar production line has a high degree of automation, we still need a certain number of workers to ensure the smooth operation of the entire production line. The specific labor conditions are as follows:
| Equipment | Workers Needed |
| Steel Melting Furnace | 6 |
| Continuous Casting Machine | 10 |
| Rolling Mills | 11 |
| Packing | 6 |
| Warehouse | 2 |
| Electrician | 2 |
| Scrap Steel Pretreatment | 10 |
| Total | 47 |
Return on investment is a relatively sensitive topic and will not be introduced in detail here. What we can guarantee is that a large amount of customer data statistics show that after the entire production line is installed and debugged and begins operation, profitability can be achieved in 6-12 months.
As it involves the processing of scrap steel and the production of steel bars, the factory needs to comply with strict environmental regulations and be equipped with corresponding environmental protection facilities, such as waste gas treatment, wastewater treatment, and solid waste treatment systems.
Establishing a steel bar production line to produce steel bars with a length of 12m, a diameter of 8-32mm, and an output of 20t per hour from scrap steel requires consideration of multiple conditions, including raw material supply, site, infrastructure, equipment, environmental protection requirements, labor, capital, etc. Please note that the above content is for reference only, we need to adjust the specific required equipment and facilities according to the actual situation.
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