presentation of company | Esfarayen Industrial Complex

The History of Company

The main History of Industrial Complex of Esfarayen dates back to before the Islamic Revolution of Iran. Studies by consultants during that period and Economic Council resolutions in first half of the fifties indicated the need to create National industries, especially manufacturing industries which produce Industrial machinery, in order to develop industrial circumstance of the country and to decrease the level of dependence to foreign industries. In line with country’s objective and based on Foreign and domestic expert studies, industrial organizations were established to improve organizational development.

Among the institutions founded on this basic idea was "Esfarayen Industrial Foundation" which based onagreements with Plan and Budget Organization in 1354 was supposed to establish Industries such as melting (Steel, cast iron and nonferrous alloys), melting and ingot, forging (open and close mould),Machining, heat treatment and finishing products In a region adjacent to Esfarayen railway station building. Finally, heavy machinery factory building under the name of “Esfarayen great Industrial Foundation”was constructed with Soviet countries collaboration and support.

Because this project requires great funds in foreign currency, it was supposed that the budget will be supplied by selling natural gas to the Soviet in a long-term. But the plan changed because ofthe recession during the Islamic Revolution and was suspended.

Continuance of the implementation of mentioned project did not happen after the Revolution for some reasons. But because of the studies done by the experts, the project was revised and followed. A new policy was determined and the early project which was focused on manufacturing heavy machinery changed to smaller projects according to the needs of every region of the country. One of these small projects was “Kerman Machinery Manufacturing” for mining machinery and equipment manufacturing which it’s technical and economic studies were assigned to a consultant in 1361.Following this procedure, 37 representatives of Khorasan requested from the Prime Minister for development and implementation of the Esfarayen projects in 1367 which coincided with the beginning of the first five-year plan. Meanwhile, the need for the production of heavy industrial components as well as the need for the country’s development in heavy industries caused the critical role of the establishment of heavy industries such as Casting and Forging Industry In the development of heavy industries becomes obvious. With universalizing the previous schemes, the new scheme which was entitled “Casting and Heavy Parts Forging Factory establishment Plan "was proposed. After technical and economic review of the mentioned scheme by all authorities it was approved and the subject was mentioned by the president of Islamic consultative parliament in Industrial Cooperation Protocol between Iran and Soviet Union for the second time in 1368. But due to the failure of the project within the framework due to the collapse of Soviet Union, the implementation of the plan continued with the cooperation of other countries which supply machinery with the credit amounts to 51 billion Riyals ($ 300 million plus 30 billion riyals) in 1369. According to the Economic Council resolution, dated 10/10/1369, the implementation location of Esfarayen was determined and on29/09/1370 with the efforts of the executives the implementing operation plans of Training Center (the Center's current steel) began within Esfarayen and industrial construction established at the factory site in 10th Km of road Esfarayen - Bojnourd. Following the start of the construction, Esfarayen Industrial Complex Enterprises was registered on 20.12.1370 with the following specifications:

Registration No. 89046

Registration date: 20/12/1370

Operation date: 22/7/1377

Operation Number 31787

Current status

Regarding the aims of heavy components casting and forging factory establishment project, there are various manufacturing and ancillary sectors in original design such as melting and casting (steel, cast iron and Nonferrous alloys), melting and ingot, forging (open and closed cast), machining, heat treatment and finishing products. But In the next revisions, regarding Management and Planning Organization’s opinion, the entire project reduced to radial forging, heavy pressing, melting and casting, machining and heat treatment.

Radial Forging Workshop

This workshop is designed to supply particular products with high quality and mechanical properties. An important advantage of radial forging process is the ability to work in low tolerances and therefore is more efficient In the case of Particular steels and super alloys.

The main equipment of this workshop is:

_ Radial Forging Machine SXP-65, the maximum diameter of the client: 650 mm, made in GFM construction companies, Austria

_ Radial Forging Machine SXP-25, the maximum diameter of the client: 250 mm, made in GFM construction companies, Austria

_ Radial Forging Machine SXP-13, the maximum diameter of the client: 130 mm, made in GFM construction companies, Austria

_ 5 units of Forging & Forming furnace

_ 5 units of heat treatment furnace

_ Transport equipment for heavy and light workshop

_ Quality Control Equipment

This place has officially started its operation in 1377.

Heavy-Presses Workshop
forging operation on large sections of steel requires special and unique technology. In sections with a diameter more than mm 700due to high weight and strength, forging and altering the form of ingots requires a lot of power Therefore in order to create self-sufficiency in the production of large forged sections in the country, the installation of a hydraulic press with 6300ton capacity and other necessary equipment such as heat treatment equipment has been design and implemented in heavy-press workshop of this complex.

The main equipment of this Workshop is:
_ Hydraulic presses with 6300tons of power
_ 80 tons Manipulator
_ 5 units ofForging & Forming furnace
_ 5units of heat treatment furnace
_ Light and heavy workshop transport equipment
_ Quality Control Equipment
This place has officially started its operation in 1383.

Melting and Casting Workshop
production of special alloy steel requires a process that results in a homogeneous alloy, clean from the presence of non-metallic wastes, and with the least amount of unwanted elements such as sulfur, phosphorus, and gas production. Therefore the melting and casting workshop of the complex has been implemented for preparing high-quality alloy steel bars including the processes of melting, secondary metallurgy, and ingot casting.

The main equipment and machines of workshop are:
_ Electric arc melting furnace(EAF)with a capacity of 50tons
_ Ladle furnace(LF)
_ Gas and carbon debugging system in vacuum(VD / VOD),With a capacity of 50tons
_ Current Gas debugging system in vacuum(VSD)with a capacity of 80 tons
_ Full dust control system
_ The oxygen and industrial gases production unit
_Light and heavy workshop transport equipment
_ Scrap preparation equipment
_ Quality Control Equipment
This unit has started operation since 1383.

Manufacturing capacity and capabilities
Esfarayen industrial complex, as the largest producer of forged alloy steels sections in Iran, has the capabilities to supply the country needs for many strategic and fundamental parts indifferent industries.

Production abilities of these complexes can be summarized as follows:
_ The central parts with different shapes :rectangular, hexagonal, Octagonal,round, flat and Hybrid forms and stepped axis

_ all semi-functional parts

_ Gears, forging dies, rings, drilling pipe, thick lenses light and heavy rolls, discs, flanges, pipe systems planning dies high pressure seamless pipes, power station parts such as axis turbines and etc.

This complex’sgeneratorshave annual production capacity of81.000tons fromalltypes of theseproducts.

The future prospect
in order to reach their predeterminedgoalsandenter global marketsandcreatethepossibility tocompete withpowerfulforeigncompetitors, thiscomplexandother country’s alloy steelproducersshould have theability toproduce productswithhighadded valueand global qualitystandards. To achieve this goal,thisComplex has also put different plansinitsagenda including:

_ Completion ofexistingprojectsandworkshops, including installation ofdevicessuch asrim straitening, deplating,andshot blast.
_ Laboratory equipmentand quality control
_establishment of continuous castingunitin order toproduceingotswith a diameter of250to 560mm, with ContinuousCastingmethodto provide the requirements of LoolehGostar Co. in Esfarayenand Esfarayenindustrial complex.
_Establishment of Electroslag Remeltingunit(ESR)for re-meltingThe finalINFILTRATION of ingotswith the diameter of450 to1100Mm
_Establishment of light and heavyheat treatment workshopsincludingfurnacesin order toperform annealing and normalheat treatment, , stress relievingand necessaryequipment forquenchandtemperandsurface hardness

_ Establishment oflight and heavymachineworkshopincludingCNC lathes,grinding, drilling, Karosel, cutting, andmilling machines.

Withthe

implementation ofthese projects, Esfarayenindustrialcomplexcan eliminate

the country’sneedsto Strategiccomponents and product and help the

country’s industry to become independent of foreignproducers can and

also enter Asianand globalmarkets

andtake an important steptowards economic and industrialindependency o

f the coun