OTELU ROSU STEEL PLANT





































Otelu Rosu
BRIEF OVERVIEW
OTELU ROSU STEEL PLANT is the melting shop unit, part of DUCTIL STEEL company. OTELU ROSU produces low, mid, high carbon and highly alloyed steel billets for further rolling of concrete reinforcement bars, wire and special steels. Designed production capacity is 850,000 tons/year liquid steel. The total area of land owned by Otelu Rosu plant is 85.3695 ha.
LOCATION
Address: Street Mihai Eminescu No. 10, zip code 325700, Otelu Rosu, Caras-Severin County
AUXILIARY ACTIVITIES
Other auxiliary capacities (for example: micro-hydropower plants Maru and Glimboca, penstocks, capture station, sand trap station etc.) are placed on lands owned by Otelu Rosu plant, situated in Zavoi and Glimboca communes.
UTILITIES
Electricity; Natural gas; Waste steam; Argon, nitrogen, air; Cooling water (recycled).On the territory of Otelu Rosu steel works Linde Gas built a new oxygen plant, which ensures the necessary volume of industrial gases, including argon, nitrogen and oxygen.



GEOGRAPHICAL POSITION AND DISTANCES
OTELU ROSU STEEL PLANT is placed on an industrial platform located in the west of Romania, in Valea Bistrei.

The main distances are:
  • 132 km to Drobeta Turnu Severin
    (river port to Danube)
  • 470 km to Bucharest
    (the capital of Romania)
  • 690 km to Constanta
    (seaport, Black Sea)
  • 185 km to Nădlac
    (border crossing to Hungary)
  • 129 km to Oraviţa
    (border crossing to Serbia)
  • 410 km to Valea Vişeului
    (border crossing to Ukraine)

Otelu Rosu

SHORT HISTORY

1796 • The first forge is built by Frantz Martinschnitz.

1842 • The plant’s first rolling mill is built.

1891 • The plant’s first open-hearth furnace is built.

1948 • The plant is nationalized. While under state control, the plant had Romania’s first continuous casting machine installed, put into operation an electric furnace and mastered the production of new grades of steel.

2005 • Otelu Rosu melting plant is acquired and consolidated by Ductil Steel Buzau metallurgical plant.

2008 • Otelu Rosu part of Ductil Steel Buzău becomes part of Mechel group.

2013 • Mechel group sold all its Romanian assets, including Otelu Rosu Plant, to Romanian based company Invest Nikarom.

CURRENT SITUATION
OTELU ROSU is a part of a metallurgic group in Romania, along with other 4 metallurgical plants: COS Targoviste, Ductil Steel Buzău, Laminorul Brăila and Industria Sarmei Campia Turzii.

Major shareholder of all these metallurgical companies is Romanian company Invest Nikarom.

Starting from February 2013 all these companies are under the Judicial Reorganisation Procedure, continuing its activity under the supervision of a judicial administrator.

OTELU ROSU plant is on temporary close-down since 2013, but still connected to and ready to use all necessary utilities (electrical power, industrial and potable water, gas etc).

According to Reorganization Plan, Otelu Rosu Melting Plant is for sale under the asset deal, free of any encumbrances.
Otelu Rosu

Otelu Rosu
MAIN PRODUCTION EQUIPMENT:
100 tons EBT electric arc furnace modernized in 2011 and equipped with COSS scrap metal preheating system (Fuchs Technology).

LF1, LF2 installations modernized in 2011.

STS continuous casting machine modernized in 2011

CONCAST continuous casting machine 2

Dedusting Plant System for the electric furnace and the LF installation, equipped with filters with 2,200,000 cbm/h sacks (Tecoaer Company).

SIERRA T800 shears (2 pieces), for cutting the scrap.

The supply of the furnace with scrap is performed through a scrap preheating chamber. The heated scrap is inserted into the furnace with a hydraulic pusher.

EBT ELECTRIC ARC FURNACE – FUCHS
characteristics
Bottom walls metal thickness: 35 mm
EAF wall thickness: 35 mm.
Metal bath volume: 22 cbm.
Slag volume: 10 cbm.
Metal bath height: 1,100 mm.
Metal bath surface: 32 sq. m.
EAF shell height: 1,100 mm.
EAF walls refractory structure thickness: 456 mm.
EAF bottom refractory structure thickness: 750 mm.
Total liquid steel capacity: 130-140 tons.
Furnace volume: 150 cbm.
EAF shell diameter 6100 mm.
Electrodes diameter: 610 mm.
Electrodes panhandle diameter: 1,350 mm.
Tapping steel weight: 100 tons.
Molten steel : 30-40 tons.
EAF bottom radius: 9,000 mm.
Transformer features: apparent power – 66 MVA;
overload – 20%; mean power – 52.8 Mw.


Otelu Rosu

Otelu Rosu


SCRAP PREHEATING COSS
Launch in 2011
COSS is standing for Continuous Optimized Shaft System.

COSS uses heat from waste gases for preheating scrap metal, enabling the plant to significantly cut expenses (on raw materials and power) and improve the quality of steel.

This technology was designed and installed by German company FUCHS Technology.



Improved performances with COSS
Production costs - 47$ /tonne
Scrap consumption - 4%
Power consumption -48%
Gas consumption -75%

Otelu Rosu
COSS. HOW IT WORKS
The COSS is a scrap preheating and charging device. It has the capacity to contain 2 scrap basket volume. It is movable on wheels and actuated by hydraulic cylinders.

It is important to set the COSS position as close as possible to the furnace shell. The gap should not be larger than 20 mm. The purpose is to minimise the air ingress (or the fumes escape) and the amount of the pieces which could fall in the “ash tray” collector box down below.

The shaft itself is not water cooled, the consequence is that it should not remain empty for more than one heat (emergency situation) to avoid any damage or excessive wear. Only the frame is water cooled, to provide enough sturdiness. The bottom and lower side are cooled with outside spray water nozzles, as they are the parts submitted to high temperature, especially close to the furnace.

Otelu Rosu


LF1 INSTALLATION – FERALPI
Modernised in 2011
Water-cooled roof.

3 300 mm electrodes.

25 MVA transformer.

Ladle.

Nitrogen or argon stirring installation.

Grated lime input installation.

SiCa coil input installation.



LF2 INSTALLATION – MANNESMAN
Modernised launching in 2011
Liquid steel casting pot capacity: max. 115 tons, nominal 110 tons.
Pot freeboard: 400 mm.
Transformer: 30 + 20% MVA (apparent power) of which, used: approx. 20 MVA.
Heating rate: 4 degrees Celsius/minute.
Vault type: water-cooled tubular structure.
Vault lifting: 400 mm.
Electrodes lifting: approx. 3,000 mm.
Electrodes diameter: 650 mm.
Vault and electrodes lifting system: hydraulic.
Hydraulic fluid used: mineral oil.
Pressure: 55 bar.
Cooling water: total flow approx. 350 cbm/h; pressure 5 bars; input temperature 35 degrees Celsius, output temperature 15 degrees Celsius.
Dry compressed air, without oil: pressure 5 bars, flow 0.5 Ncbm/h.
Argon, purity 99%: cap pressure 7 bars, flow 25-300 dcbm/min.
Otelu Rosu

CONTINUOUS CASTING MACHINE 1 – STS
Revamped in 2011
Casting section, displaying the following features:

2 cranes (1042 and 1043), with 27.5 m openings and 175 tons lift capacity.

2 casting identical casting installations,
MT1 and MT2, with the following features:
• 4-strend casting;
• forming: 100-160 mm.
• casting radius: 6 m.
• chrome copper tubular moulds.
The casting installation consists of:
• rotating tower with electric and pneumatic drive;
• distributor trolley truck;
• crystallizer;
• stands;
• rollers.
2 fixed stands.
2 vertical stands using marsh gas for heating and drying the pots.
1 horizontal stand.
1 tilting stand – to view and repair the casting pots.
One building stand
2 stands for drying gunite distributors.
Trolleys with tubs to transport slag.
CONTINUOUS CASTING MACHINE 2 – CONCAST
Continuous Casting Machine 2 can cast up 260 mm billets, and is fully equipped technically, including moulds for 180 sections, with a 10 m casting radius.

It is connected to all utilities, gas, and water. Although the electrical infrastructure is on site, it lacks the electrical equipment.
Otelu Rosu

Otelu Rosu


GAS COLLECTING AND DUSTING INSTALLATION – TECOAER
To collect the gas from the EBT and LF furnaces, a bi-linear (circuit) emission exhaust system is used:

The primary suction line, which collects the emissions from the hood of the furnace through the fourth hole in the melting stage

The secondary suction line, which collects the emissions through the canopy hood in the melting stage and in the loading stage.

The two circuits join in a mixing point, after which the gas flows through the dedusting equipment.

The primary aspiration line– the scrap metal preheating system – collection is performed only in the melting stage, through the (scrap) preheating chamber, with a square 6000 x 6000 mm section and a duct composed of water-cooled pipes (Q cooling water = 2000 cbm/h), 2900 mm in diameter, connected to the post combustion chamber.

The secondary emission line– collects the gas from the EBT modernized furnace in the loading and melting stages. The canopy hood is inserted in the ceiling of the structure, above the EBT modernized furnace. The hood is equipped with a collector for absorption of gas resulted from loading and for natural steelwork ventilation during the melting procedure.



SCRAP PROCESSING AREA
The optimisation of this sector was started in 2010, with a new bridge allowing a good traffic with the main road. Also the storing area was enlarged and modernised for a reliable usability.

The processing capacity was increased at 40 tonnes per hour. Modernised metal scrap processing equipment (ZDAZ), a 7 million dollars investment, allows an efficient and fast working process, cutting pieces up 200cm large and 1,5 m length in small enough parts to easily full the furnace. It operates since 20th of July 2010.

Three concrete platforms, S3, 4, 5 = 4,730 sq. m, placed alongside the steelworks hall, are equipped with SIERRA T800 shears (2 pieces). After cutting, the disposal of scrap shall be performed in the bunkers within the hall.
Otelu Rosu

Otelu Rosu


STORAGE AND CHARGE OF SCRAP
The unloading of scrap from the wagons onto the platforms is performed with SENNEBOGEN 825 M cranes (4 pieces) working with a claw with scrap loading-discharging capacity of 25-60 tons/h and SENNEBOGEN 835 M (2 pieces) only working with a claw with loading-discharging capacity of 100 tons/h. .

The storage of scrap shall be performed on the company premises, on concrete platforms. There are 5 platforms arranged for this purpose. The scrap, stored in the hall based on quality, was loaded in buckets using the cranes equipped with magnet and claws. Inside the melting shop, the buckets loaded with scrap shall be transported to the melting bay, where the cranes shall supply the electric furnace.

The supply of the furnace with scrap is performed through a scrap preheating chamber. This consists of a metallic structure composed of water-cooled panels, placed on rolls on the lower side, which allows moving within the furnace axis and linked with the furnace shell, where the scrap is added to the furnace itself and where the fumes exhaust from the furnace.



THE SUPPLY OF RAW MATERIAL
Romanian scrap market is well developed; Romania has a surplus of scrap.

Annual Collection of scrap over the country exceeds 3.000.000 tones, while the intern consumption is less than 50%, rest of the quantity is exported, mainly to Turkey (over 90%).

The supply of scrap to Otelu Rosu plant shall be performed by vehicle and by railway, in wagons.
Otelu Rosu

Otelu Rosu
For futher information, direct meeting and visit to the location please don’t hesitate to contact us.
ADRIAN PĂUNESCU
e-mail: Administrator.Special@ductilsteel.ro
AdrianAndrei.Paunescu@eemc.ro
phone: +40 758689065
+40 238405104
BUSINESS PERSPECTIVES
OTELU ROSU STEEL PLANT is on temporary close-down since the end of 2012. There are 26 persons employed for maintenance and security.

However in the eventual situation of launching the production process in Otelu Rosu plant, there are no major investments to be done. Equipment is ready to use, main authorizations (including environmental one) are still available.

There is a possibility to install a rolling mill for finished products in the shop, next to the melting shop. Due to the close location of these shops, billets from continuous casting machine can be transferred to the rolling mill without additional heating.

Domestic construction market reached 10,2 billion Euros in 2016, over 9,8 billion Euros in 2015.

Steel consumption in EU-28 market was constant (155 billion tonnes in 2016 and 152 billion tonnes in 2015 ).