ENGINEERINGS T E E L P L A N T

Developed by:

Cristiano dos Santos LessaMarlon Marques Corradi

Organization Organization ChartChart

Shareholders

Advisor to the BoardBernardo Wolfgang Werner

President

Alcantaro Corrêa

Finance

José M. Barbieri

Accounting

Osmar Pamplona

Control

Denis Carlos Roeder

Human Resources

Antônio Jamir Duque

Adm. of Materials

Luiz Antônio da Silva

Commercial Director

Duncan R. McKay

Sales Planning and Control

Círio da Silva

Exporting

Pedro Crestani

Industrial Director

Cacídio Girardi

Industrial Costs

Ivan Hubert

Engineering

Steel Plant

Cristiano dos Santos Lessa

Total Quality Management

Marcos Correa

Maintenance

Joelson de Souza

HeatTreatment/Jet/Gate Cutting

Bernardo Kostetzer

Machining

Gilson Alves

Special Alloys Unit

João Plinio Philippi

Jobbing Foundry

Danilo Correa

Repeat Product Unit

Francisco C.B. Vilaboim

Assessor

Civil Engineering

Lothar Alex Hass

Ivan Hubert

PCS IndustrialCosts

EngineeringProcesses

CommercialCritical Analysis

EngineeringProjects

Inspections(E.N.D)

Finishing HeatTreatment

Molding

Steel PlantMachiningManufactingStorage

Finance MaintenanceHumanResources

PurchasingAccounting ControlT.Q.M.

-Representative-Order Estimate-Client-Order- COC

-Estimate-ACVO-Production Notes -Price Analysis

-Welding -Steel Plant

-Heat Treatment-Machining -Product

-Time-Production Program-Pre-Production-Turnover

-Pattern Design-Pattern Completion-PDC-Technical Confirmation-Pattern Storage

-Core Shop-Clamping of Boxes-Shakeout-Sand Laboratory

-Pouring-Chemical Laboratory

-Gate Cutting-Blast-Metallurgy Lab.-Hardness

-Grinding-Welding-Adjustment-Press

-Ultrasound-Magnetic Particle-Penetrating Liquid-Radiography

-Packaging-Dispatch

Abbreviations:PCS – Planning and Control of SalesCOC – Customer Order ConfirmationACVO - Análise Crítica de Viabilidade e OfertaPDC – Pattern Dimensional ControlTQM – Total Quality Management

Process Flow

PouringScheduling

Load Calculation

PouringlMolding Lines

AuxiliaryMaterial

RawMaterial

Storage BuildingMaterials Steel Plant

Laboratory / Spectrometry

analysisreceipt

Spectrometry

STEEL PLANT

AODInduction

Arc (fusion) refining

Scrap YardLoadmaking

Unproductive Steel

Return/Alloy

ProcessChart

Steel Plant

Steel Liquid:Steel Liquid:► MeltingMelting► Refining Refining ► PouringPouring

Production Process

► Daily Production MeetingDaily Production Meeting

Load Formulation► Alloy/ScrapAlloy/Scrap

► 7336 - 5.0507336 - 5.050► RETURN 7336 2.550RETURN 7336 2.550► RETURN 10306 100RETURN 10306 100► SCRAP Nº 1 850SCRAP Nº 1 850► SCRAP 18/8 850SCRAP 18/8 850► Fe Cr B2 300Fe Cr B2 300► SCRAP 316 ES.BA 400SCRAP 316 ES.BA 400► GRAPHITE 16GRAPHITE 16

► 06129 - 4.30006129 - 4.300► COMMON RETURN 2.100COMMON RETURN 2.100► Stamping shop scrap 1.010Stamping shop scrap 1.010

SCRAP

► Types of scrap used in the manufacturing of steel: Scrap steel from stamping shop; Return (gates, fins, surplus steel); Ferroalloys; Auxiliary Materials

Specification of Raw Materials e Ferroalloys

The chemical laboratory is the sector responsible for the identification and analysis of materials.

Arc and Electric

Furnaces ► The Arc Furnaces enable two metallurgical stages to

be carried out.

Stages in the Process

► Melting: Consists of raising the temperature of the metallic load until there is a complete transformation to the liquid phase, for this to happen the equipment has to supply enough energy.

► Boiling/Refining : In these two stages there is a reduction mainly in the content of C , Si, P, S, N e O.

Induction Furnace

Melting Process by way of Magnetic Currents.

AOD ( Argon Oxygen Decarburization)

Converter► The AOD process is a secondary refinement of

liquid steel.

Before Pouring

► Making of a Pouring Ladle

Heating the Ladles

► Fundamental Procedure in the Pouring ProcessFundamental Procedure in the Pouring Process..

Pouring

► Transference of the liquid metal to the ladles happens after the preparation of the steel.

► Final deoxidization treatment occurs in the pouring ladles.

Spectrometer:

►Sample Analysis

STEEL PLANT CONTROLS

• Lack of Steel Unproductive Steel Furnace Average Production Energy Consumption Electrode Consumption

COPRAL

2006

Getting to know ALTONA’S processes.