How Much Does A 12 Year Old Weight On Average Defining Production Capacity for an Iron and Steel Plant

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Defining Production Capacity for an Iron and Steel Plant

Iron and steel production is generally recognized as a fixed-cost activity. Therefore, it is important to increase the utilization of assets, while operating the company at the level of capacity utilization. This begs the question, however, as to how one should define iron dexterity.

Determining the company’s capacity

The capacity of the named plant is often determined by the supplier of plant and equipment according to the specific operating conditions. In general, the nominal capacity is calculated based on 21 operations (meaning three shifts per day, 7 days per week) with conditions for the maintenance period is normal and assumes a ‘normal’ product mix. Often, however, the situation may differ from these conditions.

Some variables

Some common variables may have the highest impact possibly steel factory production (ie capacity) includes:

  • Product size: For small diameters, for example, the maximum yield will generally be lower than the average diameter. [e.g. 12mm versus 16mm average diameter]. A similar situation also occurs if thin gauge coils are constructed [e.g. 1mm rather than 2.5mm average coil thickness]. This is best explained in terms of less steel moving through the mill at the same time. Therefore, mixing products can have a significant impact on capacity, with an impact of plus or minus 25% or more.
  • Mixing notes: Difficult grades (eg those that require special heat treatment and mechanical stop-turn schedules) may take longer to pass through the mill than commodity grades. Likewise, alloy grades may require more work than carbon steel, which reduces machineability.
  • Order size: In mills making various product shapes (such as square, round and angular long bar products) a small average size can result in a larger setup time – with a negative impact on milling capacity – if the milling schedule is not properly planned. by increasing the batch size
  • Coating weight: For some lines, steel is added weight during the production process. This happens, for example, with zinc coating, which can add up to 250 g per square meter on each side of the steel plate. Depending on the weight of the coating (which can be 25 g / square meter) the weight of the final product sold can vary greatly. In fact, we have seen several coating lines that exceeded 100% capacity utilization for this reason
  • An unplanned break: It is clear that if a machine stops working for an unexpected reason (for example due to a ‘cobble’ or ‘breakout’), it will be affected for a period of time. With modern methods of mill maintenance, especially when the ‘proactive’ maintenance method is applied, this problem is less common than in buildings using the ‘reactive’ maintenance method. However, it should be remembered that in some parts of the world, mills can be 50 years old or more. In such cases, frequent outages can have a significant impact on capacity
  • Capacity creep: This term refers to the steel sector in the tendency of a workplace to produce more products every year, because it is easier to have less power outages, less investment related to production (may affect on scheduled breaks), increased understanding of operators, etc. The trend may increase the company’s capacity by no more than 1% per year; but in 10 or 20 years the overall impact on potential outcomes can be enormous.

Common sense?

It can be seen from the above that skills are not always what they seem. If in doubt, our recommendation is to first check the nameplate opportunity provided by the equipment supplier, to double check the highest yield in the last season and if possible to discuss the yield with the local management. This approach should at least provide a consensus answer, and one that is supported by actual performance.

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