Kobe Works e
Kobe Works e
1
Pursuing high performance, achieving high quality
High value-added wire rods and steel bars are produced at the Kobe Wire Rod & Bar Plant.
Our wire rods for automobile valve springs, in particular, have more than 50% of the world market share.
Steering pinions
Stabilizers
Bearings
▲Constant-velocity joints (from steel bar)
Spark plugs
Valve springs
Suspension springs
Tie rods
▲Valve springs (from wire rod)
Piston rings
Connecting rods
Hubs
ベアリング
Suspension springs
Knuckle spindles
CVT pulleys
▲Suspension springs
Ball joints (from wire rod)
▲Crankshafts (from steel bar) Bearings Bearings
Bearings
Constant-velocity joints
Hubs
Knuckle spindles
▲Knuckle spindles
▲CVT pulleys (from steel bar) (from steel bar)
General office
No. 3 blooming mill
Kakogawa Works Kobe Wire Rod & Bar Plant ●Wire rod
Transportation by ship
Pellet
Shipping
Wire rod mill
KR de-P furnace
Ladle refining Wire rods: φ5.5∼22mm
Hot metal (component Pickling Heat treatment
pretreatment adjustment,
(de-P, de-S) degassing)
Coke Pulverized Blooming Billet processing
coal mill flaw check,
BOF (de-C)
( )
Continuous casting Steel materials are transported flaw removal,
to Kobe Works by roll-on ultrasonic 棒鋼圧延
Bloom (steel) Billet (steel) roll-off ships inspection Straightening ●Round bar
Blast furnace Torpedo car Bar mill
2CC:380×630mm flaw check, ●Square bar
( )
155×155mm
6CC:300×430mm Bars: φ18∼105mm flaw removal, ●Deformed bar
Heat treatment
Coal Wire rods: φ17∼60mm ultrasonic ●Hexagon bar
inspection
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Kakogawa Works carries out the ironmaking, steelmaking (refining), Billets are transported to Kobe Wire Rod & Bar Plant by roll-on
and blooming processes. roll-off ships
Iron ore and coke, a baked coal, are charged alternately into a Components are adjusted according to Roll-on roll-off ship Billet carrier
Blast blast furnace, and hot air (1,200°C) is blown into the furnace to
BOF
the intended application to produce
furnace induce a chemical reaction to reduce and melt the ore, high-quality steel.
creating molten iron.
●Facility specifications
Capacity 90,000 tons
No. 3
Billet yard Length (north to south) 71m
billet yard
Length (east to west) 304m
Total length 102.0m
▲No .3 Blast furnace ▲BOF Width 27.0m
Roll-on Depth 17.0m
Continuous Through continuous casting, semi-finished steel (slabs or Blooming Cast steel is passed through the blooming mill roll-off Total tonnage 6,249 tons
blooms) can be produced directly from molten steel refined in to create billets. Blooms are rolled into the
casting ship Deadweight tonnage 8,300 tons
the BOF, without the ingot-making or blooming processes. proper shapes for the subsequent processes.
Speed at sea 10 knots
Maximum number of pallets 28 pallets
Total length 13.7m
Total width 5.2m
Carrier
Height 1.6m
Weight 29 tons
■Billet conditioning
As extremely high quality is required for wire rods and bars, the automatic flaw detection/removal system, developed by Kobe
Steel, is used to inspect and remove surface flaws. Ultrasonic inspection machines are used to check internal quality.
Milling cutter
Spray of magnetic
particles
Billet
Signal
processing
▲No. 6 continuous caster ▲Blooming mill Free roller
device
[Kakogawa Works] Magnetizing unit
Process
●Specifications of the blast furnace facilities ●Specifications of the continuous casting facilities ●Specifications of the blooming mills Spindle unit
computer
Name Internal volume Nominal production capacity Name Nominal production capacity Name Number of stands Nominal production capacity
No. 1 4,550 m3 10,000 tons/day No. 2 (Bloom) 140,000 tons/month No. 1 blooming mill 1
●Facility specification
No. 2 5,400 m3 11,200 tons/day No. 3 (Slab) 250,000 tons/month No. 2 blooming mill 1 300,000 tons/month
No. 1 billet processing mill No. 3 billet processing mill
No. 3 4,844 m3 11,000 tons/day 1 strand 115,000 tons/month Continuous billet mill 6
No. 4 (Slab) Shot blaster 1 unit Shot blaster 1 unit
●Specifications of the BOF 2 strands 125,000 tons/month
No. 5 (Bloom)
[Kobe Wire Rod & Bar Plant] Automatic flaw detector 1 unit Magnetic particle surface tester 1 unit
Name Number of units Volume 140,000 tons/month
Automatic flaw remover 3 units Automatic ultrasonic tester 1 unit
Name Number of stands Nominal production capacity
LD-OTB 3 250 tons/charge Automatic ultrasonic tester 1 unit Billet grinder 2 unit
2,480 tons/month
No.3 blooming mill 2 Billet grinder 2 units
(daytime operation)
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Achieving High Quality
Wire rod rolling
▼Finishing block mill ▼Sizing mill
High-rigidity rolling mill capable of low-temperature rolling. High-rigidity rolling mill capable of low-temperature rolling. This mill is capable of high
(controlled rolling) dimensional accuracy rolling. (controlled rolling, dimensional control)
No.
No.77wire
wire rod
rod mill
mill
How rolling proceeds:
The heated steel (billet) passes through several ▲Product water cooling zone
set of rolls that have grooves. The material is Rolling temperature is controlled (controlled rolling)
deformed by the grooves and its cross section is
r
eyo
reduced gradually.
onv
Automated
●Facility specification coil
gc
warehouse
olin
No. 7 wire rod mill
Co
Heating furnace 1 unit
Roughing train 8 stands
Intermediate train 12 stands
Intermediate water cooling zone 4 zones
Finishing block mill 8 stands
Finishing water cooling zone 3 zones
Sizing mill 4 stands
Product water cooling zone 4 zones Cooling conveyor▶
Cooling rate is controlled
Cooling conveyor 90 meters (controlled cooling).
Automated warehouse 9,300 tons
Automated warehouse
▼
After rolling, wire rods are unloaded from
hook converyor and directly stored in the
▲Roughing and intermediate trains Hot steel is passed through automated werehouse.
▲Heating furnace Billets are heated to about 1,000°
C the grooved rolls to reduce its cross-sectional area.
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Achieving High Quality
Bar rolling and Bar conditioning
Reh
eatin
g fur
nace
●Facility specifications Rou
ghin Finis
g tra hing
in train
Bar mill
Heating furnace 1 unit Inter
med
iate
Roughing train 8 stands rollin
g tra
in
Intermediate train 4 stands
▲Cooling bed
Finishing train 4 stands
This cooling bed ensures uniform cooling for the entire length of the bars
Finishing block mill 5 stands
Bar
Bar mill
mill Finis
hing
in order to minimize deflection.
bloc
k mil
l
Wire
rod
■Bar conditioning hand
ling fa
cility
This process removes surface flaws and
inspects the internal quality.
●Facility specifications
Flaw detection (surface, internal)
Magnetic leakage flux testing (surface) 3 units Cold
shea
r fac
Automatic ultrasonic inspection (internal) 3 units ility
Straighteners
Two-roll straighteners 3 units
Multi-roll straighteners 1 units
Stee
l bar
cooli
ng b
ed
▲Heating furnace Billets are heated to about 1,000° C. ▲Roughing train Hot steel is passed through the grooved rolls to reduce its cross-sectional area. ▲Magnetic leakage flux testing ▲Automatic ultrasonic inspection tester
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Achieving High Quality Achieving High Quality
Wire rod secondary processing Steel bar secondary processing
Rolled wire rod is processed in response to customers needs Rolled steel bar is processed in response to customers needs
Wire rod processing including heat treatment, acid pickling and wiredrawing are performed to meet customers Steel bar processing including heat treatment and straightening are performed to meet customers requests
requests and applications. and applications.
●Main equipment
▲Roller hearth quenching furnace
Large-diameter wire drawing machine
Number of boilers: single boiler ▲Automatic pickling and surface treatment equipment
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Every member is responsible for quality assurance. Field quality
Aiming to provide products of high quality and reliability, Kobe Works was enhancement meeting
accredited for ISO 9001 in 1997. All participants are working to
In 2017, we shifted to the year 2015 version and promoted a quality management system, achieve their targets.
setting quality targets to ensure customer satisfaction.
Every member is responsible for quality assurance and is conducting improvement activities.
Achieving high quality(Kobe Wire Rod & Bar Plant)
QC liaison conference
Kobe Works shares quality
control problems on a
company-wide basis and
promotes activities to reduce
quality risks.
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▶Research and Development Laboratory ▶Technical Development Group
Pursuing High Quality ● Wire Rod & Bar Products Development Department
● Steelmaking Development Department
●
●
Materials Research Laboratory
Production Systems Research Labora tory
Material design technologies Performance evaluation of steel parts Secondary processing technologies
We are developing material design technologies that control The fatigue properties of valve springs used in engines, suspen- In secondary processing, hot-rolled wire rods go through the processes of heat treatment, descaling, coating and wire drawing
fine metal structure, in order to improve the performance of sion springs for the underbody, and gears used in automobile to make wires that can be used for manufacturing parts such as bolts and springs.
a wide range of products, including valve springs for transmissions are examined under a variety of real-world
automobile engines and the main ropes for bridges. conditions to evaluate the durability of new materials.
Descaling, Wire drawing,
Wire rods Heat treatment Parts
coating flaw detection
Evaluation of manufacturing properties Simulation technologies Trial manufacturing can be performed at our testing and Development technologies are used for mass production at the
evaluation facility that can simulate manufacturing conditions secondary processing plant (Wire Rod & Bar Products
The machining properties of steel bars used in automobiles A variety of simulation technologies have been developed to at the customer s site. We are developing various secondary Manufacturing Section) of Kobe Wire Rod & Bar Plant to produce
and parts used for manufacturing bolts are examined to estimate machining properties and the results of cold forging. processing technologies applicable to mass production. high-quality and high-performance wire rods.
develop steel materials with good machining properties. They have been used to develop innovative materials.
Temperature
distribution
Extruding
backward
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Kobe Wire Rod & Bar Plant that grows with the community.
Kobe Wire Rod & Bar Plant has been addressing environmental conservation, energy saving, resource
recycling and other issues for much years in order to achieve and maintain clean steelworks.
Community exchange facilities
In addition, we value contact with local residents by using exchange facilities and participating in
local activities.
▲Environment monitor
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To Arima
ma Ons
Onsen
N biki H
Nunobiki bG
Herb d
Garden Mt.Rokko
Mt
M R
Rokko
kk Rokkosan
Ex Pasture
pr H
es o
s R ku
ail shin
wa Maya
y Rokkosan Pasture
Weathercock House Sh Ropeway
in
Ko
way
be
Rope
Tu
nn Ma
el ya
Cab
Kobe
Sanroku bypa leca
ss r
Shin
Hakutsuru Art Museum
Sanyo Shinkansen
Weathercock Scales House Shin Kobe station
House Oji Zoo
Venus Bridge
Rokko
Kitano Ijinkan Street Ko
en
Oji
ay
bw
Maya Rokko-michi
Su
Sourakuen Garden Sumiyoshi
Nada
be
Nankin machi Luminarie
Ko
Hyogo Prefectural Office
way
yu Rail Route No. 2
k
Han Ishoan
JR Iwaya Shinzaike
Science
Kobe Square
Port Tower
Nadahama
ay Sports Zone
Subw Harborland Hyogo Prefectural
Kobe Power Plant
ogo be
Kobe hway Museum of Art
Hy Ko Maritime or Hig
Museum Harb
umie Nadahama Garden Baden
Meriken Park
Mosaic
Meriken Park
Noebia
Stadium
Kobe
W isak
M
Rokko Island
Port Island
Harbor Land
To Kobe Airport
Port of Kobe
Marine Air
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Kyoto Lake
Hyogo Prefecture Prefecture Biwa
Maizuru-
Wakasa Otsu
Expressway Kyoto
Chugoku
Expressw
ay
Sanyo Exp Shin-Meishin Expressway
ressway
Osaka
International
Airport
Kakogawa
Kobe Wire Rod
& Bar Plant Kinki
Expressway
Kobe
Kakogawa Osaka Nara
Works
Kobe Kobe Airport
Works Osaka Bay
Kobe- Kansai
Awaji- International
Osaka
Naruto Airport Prefecture
Expressway
Awajishima
Wakayama
TOKYO
KOBE
KAKOGAWA
Head Offices
Kobe Head Office
2-4 Wakinohama Kaigandori 2-chome, Chuo-ku, Kobe 651-8585, Japan
Tel. 81-78-261-5111, Fax. 81-78-261-4123
Tokyo Head Office
9-12 Kitashinagawa 5-chome, Shinagawa-ku, Tokyo 141-8688, Japan
Tel. 81-3-5739-6000, Fax. 81-3-5739-6903