Steel Recycling and Manufacturing
1. Scrap Recycling and Processing
Scrap metal is delivered to our scrap yard by individual scrap collectors. The scrap is then separated into different grates and loaded in our metal crusher. Crushing the scrap significantly reduces the melting time, as well as the energy to be used in the process. Additionally, a magnet will be used within the machine to separate the non-ferrous metals and the non-metals, which would have only create slag and generate more pollution.
Processed scrap is taken into the furnaces where it is melted to 1700 degree liquid. It then undergoes ladle treatments, such as alloying and degassing, in order to reach the required standards.
The molten steel is poured into the ladle where it is further treated then moved to the continuous casting machine (CCM) to be extruded.
4. Continuous Casting Machine (CCM)
From the ladle, the hot metal is transferred via a refractory shroud (pipe) to a holding bath called a tundish. The tundish allows a reservoir of metal to feed the casting machine while ladles are switched, thus acting as a buffer of hot metal, as well as smoothing out flow, regulating metal feed to the molds and cleaning the metal.
The mold is water-cooled to solidify the hot metal directly in contact with it; this is the primary cooling process. It also oscillates vertically (or in a near vertical curved path) to prevent the metal sticking to the mold walls. A lubricant will be added to the metal in the mold to prevent sticking, and to trap any slag particles—including oxide particles or scale—that may still be present in the metal and bring them to the top of the pool to form a floating layer of slag.
6. The Cooling Process
A thin shell of metal next to the mold walls solidifies before the middle section, now called a strand, exits the base of the mold into a spray-chamber. The strand is immediately supported by closely spaced, water cooled rollers; these act to support the walls of the strand against the ferrostatic pressure of the still-solidifying liquid within the strand. To increase the rate of solidification, the strand is also sprayed with large amounts of water as it passes through the spray-chamber; this is the secondary cooling process. Final solidification of the strand may take place after the strand has exited the spray-chamber.
After exiting the spray-chamber, the billet will pass through 9 strands of Horizontal and Vertical mills to bring down the thickness of the billet to the required size, the billet will be going through straightening rolls and withdrawal rolls.
Finally, the strand is cut into predetermined lengths by mechanical shears, is marked for identification and either taken to the next forming process.
Rider Industries is a privately held, global corporation. Our businesses employ over 3000 people and we operate throughout Europe, Middle East and Africa.
Rider Steel Ghana Limited
Tema Freezones Enclave, Tema-Ghana.
+233 26 782 6154 / +233 57 418 2720