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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.