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Summary

This video showcases a sustainable process of manufacturing train rails from recycled steel. Scrap steel from various sources is melted at 1650°C, mixed with additives for durability, and shaped into blooms. The blooms are then reheated and rolled into rails, which are cooled, straightened, inspected, and cut to the required lengths, often 25 meters. The process highlights efficient recycling and production methods.

Takeaways

• 🚄 The train wheels run on the inside of the rail to maintain stability on the tracks.
• 🔄 The plant manufactures train rails using 100% recycled steel sourced from scrap yards, food cans, and leftover materials from the rail-making process.
• 🧲 Electromagnets are utilized to lift and move scrap steel into a charging bucket for processing.
• 🔥 A furnace with an intense electric current melts the scrap steel at a high temperature of 1650 degrees Celsius.
• 🛠️ Carbon, manganese, and other elements are added to the molten steel to enhance its durability and strength.
• 🛢️ The alloy is protected from oxygen exposure by flowing it through a ceramic tube, ensuring the quality of the metal.
• 🗜️ The molten metal is then shaped into continuous rectangular blocks called blooms through molds.
• 🔥 The blooms are reheated in a furnace for 5 to 7 hours at 1250 degrees Celsius to soften the steel for further shaping.
• 🏗️ A Rolling Mill is used to elongate each bloom, more than quadrupling its length for rail formation.
• ✂️ The rails are cut to size, with the cut-off pieces returned to the scrap yard for recycling.
• 🔍 After cooling, rails undergo a quality check, including a visual inspection using a mirror to examine both the top and bottom surfaces.

Q & A

What is the purpose of the train wheels rim running on the inside of the rail?

The train wheels rim runs on the inside of the rail to keep the train on the track.

Where does the steel for the train rails come from?

The steel for the train rails comes entirely from recycled steel sourced from scrap yards, food cans, and recycled pieces from the rail-making process itself.

How are the scraps collected for the rail production?

Electromagnets are used to pick up the scrap steel and dump it into a charging bucket.

What is the role of the furnace in the rail production process?

The furnace melts the scrap steel at 1650 degrees Celsius.

What elements are added to the molten steel to make it more durable?

Carbon, manganese, and other elements are added to the molten steel to enhance its durability.

Why is a ceramic tube used in the process?

A ceramic tube is used to shield the alloy from exposure to oxygen, which would otherwise ruin the metal.

What are the continuous rectangular blocks called that are extruded from the molds?

The continuous rectangular blocks extruded from the molds are called blooms.

How long does it take to reheat the blooms in the furnace?

It takes five to seven hours to reheat the blooms in the furnace to 1250 degrees Celsius.

What does the Rolling Mill do to the reheated blooms?

The Rolling Mill elongates each bloom more than quadrupling its length.

How are the rails cooled after being cut to size?

The rails are laid out to cool to about 500 degrees Celsius, then piled in a holding box by an electromagnet where they sit for 10 hours until they cool to about 90 degrees Celsius.

What is the purpose of the rollers at the end of the production line?

The first set of rollers flexes the rail vertically to straighten out any slight curvature caused by heating, shaping, and cooling.

What is the standard length of the rails ordered by railways?

The standard length of the rails ordered by railways is most often 25 meters.

Outlines

00:00

🚂 Recycled Steel Train Rails Production

This paragraph describes the process of manufacturing train rails from recycled steel. Scrap steel from various sources such as scrap yards, food cans, and previous rail production is collected and melted in a furnace at 1650 degrees Celsius. The molten steel is then treated with carbon, manganese, and other elements to enhance its durability. The alloy is shielded from oxygen during pouring into molds, forming blooms. These blooms are reheated and shaped in a rolling mill, where they are elongated and cut to size. The rails are cooled, inspected, and finally cut to the required length, often 25 meters, for railway orders.

Keywords

💡Recycled Steel

Recycled steel refers to steel that has been processed and reused from scrap materials, such as food cans and rail manufacturing leftovers. In the video, this concept is central as the plant featured manufactures train rails entirely from recycled steel, emphasizing sustainability and resource reuse. The script mentions that scrap steel from various sources is collected and melted down to create new, durable train rails.

💡Electromagnets

Electromagnets are devices that generate a magnetic field when an electric current is passed through them. They play a crucial role in the script by picking up scrap steel and moving it to a charging bucket for processing. This technology is showcased as an efficient method for handling and sorting metal materials in the rail production process.

💡Furnace

A furnace is a large, enclosed chamber used for heating materials, typically to high temperatures. In the context of the video, a furnace is used to melt the scrap steel at 1650 degrees Celsius, which is a critical step in the recycling and production process. The intense heat allows the steel to be liquefied and prepared for further processing into train rails.

💡Alloy

An alloy is a mixture of metals, usually fused together to create a material with desirable properties. The script describes adding carbon, manganese, and other elements to the steel to make it more durable. This process of alloying is essential for enhancing the strength and longevity of the train rails produced by the plant.

💡Ceramic Tube

A ceramic tube, as mentioned in the script, is used to shield the molten metal from oxygen, which could otherwise cause oxidation and weaken the steel. This protective measure ensures the purity and quality of the metal as it moves through the production process, highlighting the importance of controlled environments in metallurgy.

💡Blooms

Blooms are large, rectangular blocks of metal that are formed during the initial stages of metalworking. In the video, the molten metal is extruded into blooms, which are then reheated and further shaped into train rails. This term is indicative of the intermediate product form that the metal takes before being transformed into its final use.

💡Rolling Mill

A rolling mill is a machine used to shape and reduce the thickness of metal by passing it through rollers. The script describes how the reheated blooms are elongated more than four times their original length in a rolling mill. This process is essential for shaping the blooms into the desired dimensions of train rails.

💡Scrap Yard

A scrap yard is a place where waste materials, such as metal scraps, are collected and stored for recycling or disposal. The script mentions that cut-off pieces from the rail production process are sent back to the scrap yard, illustrating the continuous cycle of material reuse and the commitment to sustainability in the rail manufacturing process.

💡Electromagnet

An electromagnet is used again in the script to pile the cooled rails into a holding box. This demonstrates the versatility of electromagnets in handling heavy metal objects, contributing to the efficiency of the rail production line.

💡Rollers

Rollers are cylindrical devices used to convey or shape materials in manufacturing processes. In the video, rails run through two sets of rollers after cooling. The first set flexes the rail vertically, which is a crucial step in straightening the rails that may have curved during the heating and shaping process. This ensures the rails are uniformly straight and ready for use.

💡Standard Length

The standard length refers to the common measurement at which items are produced or sold. In the context of the video, most train rails are cut to a standard length of 25 meters to meet the typical requirements of railway orders. This standardization facilitates the manufacturing process and ensures compatibility with various railway systems.

Highlights

Train wheels run on the inside of the rail to keep the train on the track.

The plant manufactures train rails entirely from recycled steel.

Recycled materials include scrap steel from scrap yards, food cans, and waste from the rail-making process.

Electromagnets are used to pick up and move the scrap steel.

A crane drops the scrap steel into a furnace for melting.

An intense electric current melts the scrap steel at 1650 degrees Celsius.

Carbon, manganese, and other elements are added to the molten steel to enhance durability.

The alloy is shielded from oxygen exposure during the pouring process to prevent metal degradation.

Molten metal is extruded into continuous rectangular blocks called blooms.

Blooms are reheated in a furnace to 1250 degrees Celsius for further shaping.

A Rolling Mill elongates each bloom, more than quadrupling its length.

Scrap from the cutting process is recycled back to the scrap yard.

Rails are cooled to about 500 degrees Celsius before being stacked.

Electromagnets are used to stack rails in a holding box for further cooling.

Rails cool to about 90 degrees Celsius before being removed from the holding box.

Rails are straightened through a vertical flexing process after cooling.

Inspectors examine the rails using mirrors to check both the top and bottom surfaces.

Rails are cut to the specific length ordered by the railway, often the standard length of 25 meters.

Transcripts

foreign

the train Wheels Rim runs on the inside

of the rail to keep the Train on the

track

this plant makes train rails entirely

out of recycled steel from scrap yards

food cans and recycled pieces from the

rail making process itself

electromagnets pick up the scrap

and dump it in a charging bucket

a truck hauls the bucket inside where a

crane drops the contents into a furnace

an intense electric current melts the

scrap steel at 1650 degrees Celsius

it then flows into a large bricklined

Ladle where they add carbon manganese

and other elements to make the steel

more durable

the alloy then runs down a ceramic tube

that Shields it from exposure to oxygen

which would ruin the metal

from there the molten metal flows into

molds which extrude it into continuous

rectangular blocks called blooms

a crane then transfers the blooms to a

furnace which over the next five to

seven hours reheats them to 1250 degrees

Celsius

this softens the steel for further

shaping

then the reheated blooms enter a machine

called a Rolling Mill which elongates

each bloom more than quadrupling its

length

next a saw slices off about 30

centimeters to square off the ends

the cut off pieces go back to the scrap

yard

meanwhile the rails are laid out until

they cool to about 500 degrees Celsius

then an electromagnet piles them in a

holding box where they sit for 10 hours

until they cool to about 90 degrees

Celsius

when they come out of the box they run

through two sets of rollers

the first set flexes the rail vertically

this flexing process straightens out the

rails which curved slightly due to all

that heating shaping and Cooling

next each rail passes over a mirror

enabling inspectors to examine the

bottom as well as the top

finally a saw cuts the rails to whatever

size the railway ordered most often the

standard length of 25 meters