Mobarakeh Steel Complex Research Articles

Identification and Weighting of Supply Chain Risks with the Help of Fuzzy Analytical Hierarchy Process Approach (Case Study: Mobarakeh Steel Complex of Isfahan)

Identification and Weighting of Supply Chain Risks with the Help of Fuzzy Analytical Hierarchy Process Approach (Case Study: Mobarakeh Steel Complex of Isfahan)

Improvement of Elevated Temperature Wear Resistance of Side Guides Using Microstructural Engineering (Case Study: Hot Rolling Line of Mobarakeh Steel Complex)

Improvement of Elevated Temperature Wear Resistance of Side Guides Using Microstructural Engineering (Case Study: Hot Rolling Line of Mobarakeh Steel Complex)

Optimized design of water-saving system in-slab cooling plant of Mobarakeh steel complex

The aim of this paper is to provide a solution to decrease water consumption in the slab-cooling unit of Mobarakeh Steel Complex in Iran. The plan should give an hourly decline in water consumption during a one-year operation period to calculate the annual reduction in water consumption of the proposed process. Recommended solutions for the conversion scheme of an existing wet cooling tower to a dry or hybrid cooling system require modeling of the slab cooling process. The curves of temperature drop in slabs are extracted in this paper by modeling the transient heat transfer of the slabs in the cooling process. This will reduce the computational volume. Then, the design and optimization of the hybrid cooling system done by the Genetic Algorithm (GA) is investigated. Accordingly, the objective function (reducing the costs of construction, operation, waste of water during the year) is chosen by single-objective method, and the modeling of the series hybrid system is done for the off-design mode during one year. The present design is for different scenarios and various savings of water consumption. The results demonstrate that if the control system is fitted with the sensitivities of the ambient temperature and also is based on the water consumption reduction and equipment design according to reliable standards, then the annual water consumption will be reduced by 88.3% (1.89 million m3). The payback period will be 3.63 years for the proposed system.

Water-energy nexus approach for optimal design of hybrid cooling system in direct reduction of iron plant

Direct reduction of iron process in steel industry has special production conditions. Low quality cooling water, low cold and high hot cooling water temperature, space limitation for new equipment installation, high value-added of product and severe effect of cooling water temperature on production rate are of these conditions. Considering technical and economic constraints and limitations, this situation makes this process an attractive case study for converting the existing wet cooling tower to hybrid cooling system. In this paper, based on integration of process, dry and wet cooling system and ambient conditions profiles, a new method for designing hybrid cooling system has been proposed. The calculation program has been developed as a MATLAB code and resulted: 1) Calculation of annual water saving and energy consumption with reasonable accuracy, 2) Control system of dry and wet cooling blocks to maximize water saving under various ambient conditions, 3) Closed loop simulation of cooling system considering thermal feedback of process to cooling system and 4) Obtaining optimum values for 16 design parameters of dry block cooling (consisting air cooled heat exchanger and plate heat exchanger). The optimization has been done via genetic algorithm, considering annual response of each design under various ambient temperature and relative humidity. Considering design standards for new equipment and operational and technical constraints, made the optimization model reliable as well as checking the design parameters with process equipment constructors. In optimum point, converting existing wet cooling tower to hybrid cooling system in direct reduction of iron plant of Mobarakeh Steel Complex located in Isfahan province in Iran, will decrease the annual water consumption by 70.15% and production loss by 98% with payback period of 1 years and 10 months.

Factors affecting delays in rail transportation projects using Analytic Network Process: the case of Iran

Delays in the implementation and commissioning of rail transportation projects can cause economic damages to project stakeholders and the cities linked by such rail networks. Hence, the current study aims to investigate the key delay factors and provides salient recommendations. In this study, multi-criteria decision-making – the Analytic Network Process (ANP) and the DEMATEL (Decision Making trial and evaluation laboratory) method was employed to help decision-makers in prioritizing these delay factors and evaluating their interactions, respectively. A Delphi approach was used to validate the study’s findings via expert questionnaire surveys – based on a rail transportation development project for the Mobarakeh Steel Complex (MSC). The study’s findings revealed the management factors as the most important delay factors, followed closely by the financial, design, and implementation factors. Other potent issues include the existence of numerous decision-making stations, lack of central role, and sufficient authority for the project managers are responsible for project delays. Overall, the results show that resolving problems with the ‘management’ domain can significantly avoid or alleviate the extent of delays in rail transportation development projects. The study’s findings and recommendations can serve as a policy and consultative instrument for the relevant stakeholders in the railway industry.

Using recycled chemical sludge as a coagulant aid in chemical wastewater treatment in Mobarakeh Steel Complex

Coagulation–flocculation is a process commonly applied to treat many types of industrial wastewater. However, chemicals used in a wastewater treatment plant, including coagulants/flocculants, are costly. This study evaluated the feasibility of recycling the chemical sludge of the Mobarakeh Steel Complex (MSC), and using it as a coagulant aid in the process of wastewater treatment. The experiments were conducted in a jar test apparatus in consecutive cycles by adding a fraction of the settled sludge to samples. The response surface methodology (RSM) was employed to design the experiments and optimize the process. The response in the RSM model was residual turbidity, and the factors affecting the response included the sludge recycle ratio and return sludge cycle number. The sludge volume index (SVI) of the chemical sludge was also examined in each cycle of the tests to assess the sludge quality. The results revealed that recycling the sludge reduced the use of chemicals up to 60%. Finally, it was concluded that flocculation sludge could be considered as an alternative to chemicals, without adversely affecting the removal efficiency. Furthermore, SVI results showed that an increase in the number of cycles led to a decrease in SVI in each cycle, resulting in sludge volume reduction, better dewatering, and decreased sludge treatment costs.

Estimating biomass and carbon sequestration of plantations around industrial areas using very high resolution stereo satellite imagery

Abstract: Plantations established in highly-pollutant industrial areas have a crucial role to absorb greenhouse gases, particularly CO2. A thorough monitoring of their aboveground biomass and carbon balance is essential to ensure their beneficial effects. This can be operationally supported by using a combination of field and multispectral stereo remote sensing data to provide surface height information with high resolution and wide coverage. We estimated the fresh and dry aboveground biomass and the carbon sequestration from pairs of Pleiades satellite imagery of 25-year-old monoculture plantations of Pinus eldarica Medw., Cupressus arizonica Greene, Morus alba L. and Robinia pseudoacacia L., around the Mobarakeh Steel Complex near the megacity Isfahan. This complex is the largest-scale of its kind in semi-arid Iran. Tree heights were derived from a Canopy height model (CHM) at plantation management unit level. Parsimonious regression models were developed, and the accuracy was assessed by the coefficient of determination, bias and root mean square errors (RMSEs) at plot level. This resulted in R2 of total biomass, dry biomass, carbon sequestration, tree height and tree count of 0.90, 0.90, 0.91, 0.89, and 0.88, respectively. Moreover, mixed bias (with lowest value of -0.12 m for tree height) and NRMSE% (with lowest value of 5.93 % for tree carbon sequestration) values were obtained. The results demonstrated that pairs of stereo imageries can be effectively used for predicting forest biomass and carbon sequestration across semi-arid plantations, hence enabling a continuous monitoring of vegetation established around pollutant industrial areas.

Investigation of Biological Removal of Nickel (II) Using the Isolated Bacteria from Industrial Wastewater of Mobarakeh Steel Complex in Isfahan

Investigation of Biological Removal of Nickel (II) Using the Isolated Bacteria from Industrial Wastewater of Mobarakeh Steel Complex in Isfahan

Impact of Wastewater Irrigation on Soil Mechanical Properties in the Green Space of Mobarakeh Steel Complex

Impact of Wastewater Irrigation on Soil Mechanical Properties in the Green Space of Mobarakeh Steel Complex

An industrial image processing-based approach for estimation of iron ore green pellet size distribution

Green pellets are spherical objects mainly made from crushed iron and water in rotating pelletizing disk. Pellets play an important role in the process of direct reduction steel manufacturing. For high quality steel production, pellets should be of an appropriate size. Oversized pellets cannot be properly cooked in furnace and undersized pellets may pass through metal grid of the furnace, which affects the performance of the process. In most of the steel manufacturing companies, operators use sequential sampling and traditional methods to measure size of pellets, however, limited number of tested pellets, low speed of the quality control and human errors are the most common drawbacks of this method. A solution to these shortcomings is continuous monitoring and accurate measurement through a fully-automatic approach. In this paper, a method using image processing technique is proposed and verified for estimating size distribution of iron-ore green pellets. For segmentation of single and multiple pellets in images captured from live video, we have utilized morphological methods, watershed algorithm, and linear searching. Then, a Support Vector Machine (SVM) is employed for classification of segmented pellets. The proposed method has already been implemented in Mobarakeh Steel Complex, where the method was tested on about 1000 sample pellets. Results show that the accuracy of method is 95.1% in detection of single pellet elements.

Performance assessment of thermophotovoltaic application in steel industry

The potential for using Thermophotovoltaic (TPV) generators as an alternative for recovering energy losses in steel production industry is assessed. A mathematical model for the assessment of the performance of TPV application in the iron and steel industry has been developed. In order to support the mathematical model, a sample TPV apparatus in laboratory scale based on an IR emitter has been designed and assembled. The key modeling parameters of TPV generator include: the open circuit voltage, the short circuit current density and fill factor of the TPV cell. These parameters have been considered in the model as functions of several variables such as: the emitter (hot steel slab) temperature, the cell temperature, the distance between the cells and emitter, the spectral response and the cell energy gap. The External Quantum Efficiency (EQE) as an important indicator of the cell׳s spectral response is included in the model. Moreover, the variation of the emitter temperature has been considered. Several tests have been carried out for different values of the cell-emitter gap. It has been found that when the GaSb cells are used for energy recovery, a minimum temperature of 873°C is required. The upper limit of the emitter temperature is usually determined in steel production process associated with hot rolling process which has a temperature around 1250°C. Finally, the total efficiency of the system was obtained to 4.12%, when GaSb cell with temperature of 27°C and slab emitters with temperature of 1257°C are used. The results of the simulation of the model in a casting process at the Mobarakeh Steel Complex have shown a potential of energy recovery of 26.987MJ per year.

Analysis of the Factors Affecting Customer Satisfaction in Steel Industry by Integrated Approach of Gray Relation Analysis and Fuzzy VIKOR

The present article has been conducted aiming at rating factors affecting customer satisfaction of the steel industry. Studying theoretical principles and background of the research show that many different factors are influencing satisfaction. Therefore, in this study only factors affecting approach to customer relationship management have been studied. In this study, the factors mentioned in Isfahan Mobarakeh Steel Complex were identified, using fuzzy Delphi method and rated combining the two approaches of gray relation analysis and fuzzy VIKOR. After analysis, the results show that timely delivery of goods, product quality, paying by credits, skills of salesperson, customer awareness, advice and technical support, quality of complaints investigation, customer relationship management, product diversification, speed of complaints investigation, customer training, increased centers of service and packaging products influence customer satisfaction in Mobarakeh Steel Complex, respectively.

ANALYSIS OF ENERGY EFFICIENCY ASPECTS IN ENERGY MANAGEMENT MODEL OF BUNSE IN MANUFACTURE CASE STUDY: MANUFACTURING MANAGERS OF MOBARAKEH STEEL COMPLEX, 2013

Correct energy management and its efficiency have b een emphasized in industrial and manufacturing firm s’ policy makings for different reasons. Different studies focus on avail able potentials of these firms in the field of their energy efficiency. From among them just the fewest numbers of manufacturing enterprise s could exploit them. Therefore the researcher inte nds to study some aspects of energy management model of Bunse in manufacture. Al so by finding the differences and gaps between theo ries and available circumstance of the industry, this study encourages the Mobarakeh Steel Complex to execute energy effi ciency management correctly. The results of the statistical analysis show that a lthough there is not significant gap between indust ry’s requirements and scientific literatures, based on the comparison of the present case and ideal circumstance of managers’ point of view and because of the complex approximately proper condition, this comple x has differences with worlds and scientific ideal standards.

Investigation of the effect of swimming programs on improving vocational relationships

Article history: Received September 1, 2011 Received in Revised form October, 22, 2011 Accepted 24 September 2011 Available online 27 September 2011 Recreational activities play important role on workers' health conditions and improve people's creativity. Steel industry is one of industries, where workers mainly face with hard working conditions. There are various techniques to help human resources increase their potentials such as providing recreational centers, athletic facilities, etc. In this paper, we study the impact of regular swimming exercises on improving the efficiency of employees in management level in a steel complex unit called Mobarakeh Steel Complex. In this company, there were about 85 middle level managers and supervisors and the proposed study selects 30 people, randomly and divides them into two equal groups. In the first stage of the study, questionnaire of vocational relation are distributed among the participants of this study and some important factors, which could improve vocational relationships are measured. Next, the experimental groups are invited to take part in some selective aerobic programs for 8 weeks and 3 sessions per week and 1 hour and 15 minutes per session, regularly. Finally, we repeat the same experiments after the aerobic programs end and compare the results with the first one. The preliminary results indicate that the routine swimming programs have increased people self confidence, creativity and working group skills. © 2012 Growing Science Ltd. All rights reserved.

Thermal modeling of strip across the transfer table in the hot rolling process

Abstract The transfer table is a fundamental stage between the roughing and finishing rolling stands in a hot-strip rolling process. The high temperature of the strip and the long time of its exposure to air at this stage lead to a considerable heat loss in the strip that accounts for its heterogeneous temperature distribution, non- uniform surfaces, reduced product quality, and increased production costs. Strip temperature prediction is essential for calculating the rolling force required and forecasting the resulting micro-structure. Reliable prediction of strip temperature is also essential for the proper set up of a hot strip mill. The use of thermal shields on the transfer table is considered to be an effective exterior tool for saving energy and improving the product quality. This paper investigates the temperature distribution and heat loss from a strip passing through the transfer table. For this purpose, the hot rolling process operating at Mobarakeh Steel Complex (MSC), Isfahan, Iran is used under three cases, namely, in the absence of a thermal shield, in the presence of a thermal shield, and using both a thermal shield and a heat source. The results from the numerical solution indicate that the last case is the most beneficial for reducing heat losses and achieving a better temperature distribution in the strip.

Investigation of the effect of selected aerobic programs on improving vocational relationships

Article history: Received April 1, 2011 Received in Revised form June, 7, 2011 Accepted 8 June 2011 Available online 14 June 2011 The new millennium has commenced with an increase awareness of precious value of human resources. Many large firms have increased to use new human resources mobilization policies and the importance of human potential in business has developed, dramatically. There different methods to help human resources increase their potentials such as providing recreational centers, athletic facilities, etc. In this paper, we study the impact of providing exercise facilities on improving the efficiency of employees in management level in the biggest steel producers in Iran called Mobarakeh Steel Complex. In this company, there were about 85 middle level managers and supervisors and the proposed study selects 30 people, randomly and divides them into two equal groups. In the first stage of the study, questionnaire of vocational relation are distributed among the participants of our experiment and we measure some important factors, which could improve vocational relationships. Next, the experimental groups are invited to take part in some selective aerobic programs for 8 weeks and 3 sessions per week and 1 hour and 15 minutes per session, regularly. Finally, we repeat the same experiments after the aerobic programs end and compare the results with the first one. The preliminary results indicate that there is a meaningful difference between the healthcares of these two groups. © 2011 Growing Science Ltd. All rights reserved.

Study of Effective Cultural, Social Economical Factors on Making Work Stress among Workers in Mobarakeh Steel Complex

The aim of the study is to analysis of effective cultural, social economical factors on making work stress among workers in Mobarakeh Steel Complex. The present research method is measurement base with survey of questionnaire that is placed on descriptive research, according to research's results it can be considered as practical one. Studied statistical society is all workers of Mobarakeh Steel Complex who are working in different level of work and vacation. They have been distributed by kurgan formula; number of 100 persons is randomly selected. In this study questionnaire is used for gathering information7 containing of 20 questions relating to 5 assumptions that its purpose is measurement of workers' view about causes of work stress. Findings show that level of income, religious opinions, stress base, education level and training while working most important effective factors on stress of working people in Mobarakeh Steel Complex.

A new combined method in active filter design for power quality improvement in power systems

The voltage & current harmonics produced by nonlinear loads in power systems cause a reduction in power quality. In order to improve the power quality, active power filters (APFs) can be used. In this paper, a new control system for designing active filters despite nonlinear loads of electric arc furnaces (EAFs) is presented. The system is composed of three main parts: computation of reference currents, regulation of DC capacitor voltage, and production of firing pulses. In the first part, the active filter control system is presented based on the combination of the synchronous detection method and instantaneous power theory. In the second part, the DC capacitor voltage regulator is applied, producing a reference current and a proper voltage regulator is developed. For the third part of the control system, we use a PI controller to provide some conditions that follow the reference current in a complete cycle, and generate firing pulses by the hysteresis method. The proposed control system not only reduces the voltage and current harmonics in power systems but can also improve the power quality indices. The above design was implemented in the EAF system of the Mobarakeh steel complex (Isfahan, Iran). The simulation results show the effectiveness of the APFs in improving the power quality indices.

An Investigation on Continuous Steel Slabs Casting Line and Mechanical Design of a 3R Robot for Sampling from Melting Arc Furnaces

Automation of industrial activities is one of the most essential needs in recent years since the operator has smaller role in the process. Creation of the various robotic systems in the different industries causes relaxing the operators from working in hard positions, increases the accuracy, efficiency and velocity in the process and decreases the wastage and price of product. In this paper, the study on melting station and continuous casting line in Mobarakeh Steel Complex is provided. The needs for elimination of difficulties and increasing the automation level of steel slabs casting line with checking the all stations from robotic and automation point of view for stations with the capability of automation system necessitates a suitable robotic system. In this case, selected robot should be able to support the velocity, accuracy, load capacity and other characteristics. Considering the sensitive conditions around the electric arc furnace (E.A.F), a suitable sampling robot with 3-degree freedom in which all three joints moves in revolute form (RRR) has been designed.

Guided local search algorithm for hot strip mill scheduling problem with considering hot charge rolling

This study investigates the hot strip mill scheduling problem which is one of the most important planning problems in the steel industry. The problem is formulated using the prize collecting vehicle routing problem. The new proposed formulation considers more details and more realistic constraints than those used in previous studies. The hot charge technique leads to considerable savings in energy and other benefits in the process of steel production. In our proposed formulation, the necessary provisions required for obtaining an initial level of hot charge have been taken into consideration. A search algorithm has been developed that consists of three major phases including separation of slabs that can be scheduled, generation of an initial solution, and improvement of the solution. Generation of the initial solution is accomplished using a greedy constraint satisfaction algorithm and solution improvement through a guided local search. Proposed model and search algorithm have been tested on random and collected instances from practical production data in Mobarakeh Steel Complex. The experimental results show the high accuracy and efficiency of the proposed model and search algorithm.