Steel Asia Case Study
STEEL ASIA MANUFACTURING CORPORATION: Company Case Study
STEEL ASIA MANUFACTURING CORPORATION
COMPANY DESCRIPTION
Steel Asia Manufacturing Corporation (SAMC), a joint venture with TATA Steel from India, is located in Bulacan in the Philippines and produces reinforcing steel bars (also referred to as rebar) for use in construction. The plant was commissioned in 1996 and currently has 400 employees. Annual production is 360,000 tons of steel bars compared to its 400,000 tons annual designed capacity, which is mostly consumed by the domestic market. The company participated in the project to sustain their effort to improve the operation, cut down on production cost through energy efficiency and cleaner production and prepare for an application for Integrated Management System (ISO 9001, ISO 14001 and OSHAS 18000) certification.
PROCESS DESCRIPTION
§ Preheating: Steel billets are received and charged directly in a re-heat walking hearth furnace through the charging door of the furnace. They are reheated for 75 minutes to 1100º using Bunker C (Type #6) fuel oil. The furnace can reheat billets at a maximum rate C of 65 tons per hour. Rolling: Once billets reach the required temperature for rolling, they leave the furnace through the discharging doors and are rolled along a series of 18 tandem (horizontal/vertical) continuous rolling mill stands to obtain the desired size and shape. Each rolling stand is controlled throughout the process by a computerized control system. Cutting and Testing: The bars are then cut to lengths required by customers. Samples are subjected to physical, mechanical and chemical tests in a fully equipped laboratory certified to ISO 17025. Instruments used for quality control include a spectrometer and two universal testing machines. Bundling and Tagging: Finally, the product is then bundled and tagged before being placed in a storage facility.
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METHODOLOGY APPLICATION
The draft Company Energy Efficiency Methodology was
STEEL ASIA MANUFACTURING CORPORATION
COMPANY DESCRIPTION
Steel Asia Manufacturing Corporation (SAMC), a joint venture with TATA Steel from India, is located in Bulacan in the Philippines and produces reinforcing steel bars (also referred to as rebar) for use in construction. The plant was commissioned in 1996 and currently has 400 employees. Annual production is 360,000 tons of steel bars compared to its 400,000 tons annual designed capacity, which is mostly consumed by the domestic market. The company participated in the project to sustain their effort to improve the operation, cut down on production cost through energy efficiency and cleaner production and prepare for an application for Integrated Management System (ISO 9001, ISO 14001 and OSHAS 18000) certification.
PROCESS DESCRIPTION
§ Preheating: Steel billets are received and charged directly in a re-heat walking hearth furnace through the charging door of the furnace. They are reheated for 75 minutes to 1100º using Bunker C (Type #6) fuel oil. The furnace can reheat billets at a maximum rate C of 65 tons per hour. Rolling: Once billets reach the required temperature for rolling, they leave the furnace through the discharging doors and are rolled along a series of 18 tandem (horizontal/vertical) continuous rolling mill stands to obtain the desired size and shape. Each rolling stand is controlled throughout the process by a computerized control system. Cutting and Testing: The bars are then cut to lengths required by customers. Samples are subjected to physical, mechanical and chemical tests in a fully equipped laboratory certified to ISO 17025. Instruments used for quality control include a spectrometer and two universal testing machines. Bundling and Tagging: Finally, the product is then bundled and tagged before being placed in a storage facility.
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METHODOLOGY APPLICATION
The draft Company Energy Efficiency Methodology was