To design and fabricate scrap feeder for steel industries

Project Title

To design and fabricate scrap feeder for steel industries

Project Area of Specialization Mechanical EngineeringProject Summary

Presently Pakistan produces around six million metric tons of steel per year. This includes raw products (iron ore and scrap), flat products (sheets and plates, used in the automotive sector), and long products (steel bars, wire rods, rails, and structures used in infrastructure development and tubes and pipes). However, per capita, steel consumption in Pakistan is very low at 23. 5 kg. With the critical role of steel in the development of roads, railways, dams, and power infrastructure, as well as the current pace of development projects being pursued in the country, the demand for steel and allied products is expected to increase significantly. To meet this higher demand, the industry has to shift towards modern tools and infrastructure and have to enhance the capability of production, cost-effectivity, and quality of the product and this can be done by involving new, safe, efficient, and cost-effective equipment from starting to the ending of the production of steel.

Pak steel re-rolling mill is located in Hattar Industrial state. The mill is among the leaders in engineered special bar quality products in Pakistan. The firm produces a wide range of product shapes, sizes, grades, and finishes. Pak Steel Re-Rolling Mills manufactures hot-rolled carbon steel bars in deformed, round, square, flat, and special shapes.

Pak Steel strictly adheres to ASTM and BSI international standards. The company's quality control department samples each batch of steel products and inspects quality at several stages of production. Main products sold include debar and plain bar, steel bars for reinforcement of concrete according to ASTM A-615 (Grade 40 & 60), ASTM A-706, ASTM A-36, ASHTO 31; cold-worked bar according to the BS-4449 standard; structural steel including angles, U-channels, Tee iron, girders.

Scrap in the Pak Steel plant is obtained both locally and imported from other countries. Reusable items from the scrap are sorted out, while the remaining is recycled. Magnetic cranes are also used for lifting the scrap in scrap inventory. Scrap can be fed into the furnace both manually and motor-driven system.  In the manual method, the scrap is driven from the inventory directly to the furnace by labor-driven trollies.  In the motor-driven system, the scrap is first put into the scrap feeder crane using a crane. Scrap is transferred to the furnace by a manually controlled motor-driven system. The feeding system is the initial and the most important one in steel production. which is the key to produce the steel safely and cost-effectively. we are going to design the scrap feeder for steel industries to tackle above mentioned needs Project Objectives

The scrap occurs in a great variety of shapes and dimensions, this project is aimed to reduce this scatter.

The objectives of the project are

1. To obtain a proper distribution of scrap size, which is required by the subsequent steps
2. To increase the production rate and quilty of steel
3. To enhance the safety and working environment

Project Implementation Method

1. Literature review about scrap feeders
2. Current usage of scrap feeders in steel industries
3. Collection of data about production of steel in Pakistan and consumption per capita. 
4. Visits in different steel industries in Pakistan.
5. Data collection of production rate, etc.
6. Designing
7. Fabrication
8. Report 

Benefits of the Project

Pakistan’s steel industry is characterized by small plants, most of which are utilizing obsolete technology. In particular, scrap feeding, most melting, re-rolling, and fabricating firms have small-size plants compared to their competitors in steel exporting countries. Similarly, the use of outdated (and energy inefficient) technology raises these firms’ cost of production and results in output with low quality and varying standards. As a result, these products cannot compete with cheaper imports, particularly from India and China, where manufacturers enjoy benefits from economies of scale Moreover, Pakistan’s steel industry is characterized by small plants, most of which are utilizing obsolete technology. In particular, most melting, re-rolling, and fabricating firms have small-size plants compared to their competitors in steel exporting countries. Similarly, the use of outdated (and energy inefficient) technology raises these firms’ cost of production and results in output with low quality and varying standards. As a result, these products cannot compete with cheaper imports, particularly from India and China, where manufacturers enjoy benefits from economies of scale Moreover, Pakistan’s steel industry is characterized by small plants, most of which are utilizing obsolete technology. In particular, most melting, re-rolling, and fabricating firms have small-size plants compared to their competitors in steel exporting countries. Similarly, the use of outdated (and energy inefficient) technology raises these firms’ cost of production and results in output with low quality and varying standards. As a result, these products cannot compete with cheaper imports, particularly from India and China, where manufacturers enjoy benefits from economies of scale and more efficient production processes.

Few other benefits of this project are listed below

1. Very fast as compared to manual charging of furnace thereby enabling optimum use of the melting system.
2. Extremely controlled charging of material into the furnace.
3. Prevents damage to the furnace lining since the material is properly guided into the furnace to avoid the material from hitting the furnace walls.
4. No direct exposure of manpower to the furnace thereby preventing dangerous accidents due to metal splash (since the operator can carry out the operations at a very safe distance.
5. Minimum heat loss of the furnace since the charging process can be maintained continuously at the required rate.

Technical Details of Final Deliverable

scrap feeding system is the key for various prospectives in production.it is the main part which controlls the production rate safety quality and cost of thee product so it should be as so it comes in favour with all these things 

scrap feeder are used to feed the furnace in a controlled manner to utilize tha maximum power of the furnace and increase the production of melted steel and for the safety of worker and furnace 

we are going to design a vibratory scrap feeder which concist of a hooper a tray .springs and vibro motors along with the movinng trolly

when scrap will be needed to furnace the trolly will come along with frrder the vibro motor will start to rotate with un even distributed massed which results in vibration thes vibrations will be then passed to tray by springs and then be used for feeding.

Final Deliverable of the Project Hardware SystemCore Industry ManufacturingOther Industries Others Core Technology OthersOther TechnologiesSustainable Development Goals Industry, Innovation and Infrastructure, Responsible Consumption and ProductionRequired Resources

Item Name	Type	No. of Units	Per Unit Cost (in Rs)	Total (in Rs)
			Total in (Rs)	70000
Computers	Equipment	1	30000	30000
Control system	Equipment	1	15000	15000
Raw material	Equipment	1	15000	15000
Manufacturing bills ,etc.	Miscellaneous	1	5000	5000
Visits	Miscellaneous	1	5000	5000