This document provides information about Esfarayen Industrial Complex (E.I.CO) located in North Khorasan, Iran. It discusses the company's history, facilities, equipment, certifications, products, and areas of activity. E.I.CO has extensive steelmaking, casting, and machining facilities capable of producing heavy ingots, forged products, and machined components up to 80 metric tons for industries such as oil/gas, power, railway, mining, naval, automotive, and others. It has certifications like ISO 9001 and produces a variety of steel grades including tool steels, stainless steels, and other alloy and carbon steels.

1. Address:North Khorasan, Esfarayen, 12 Km of Esfarayen-Bojnourd St.,
Tell: +98-58-372-172-719
www.esfst.com,info@esfst.commail:-E
sale.esfarayen@yahoo.com
ESFARAYEN
INDUSTRIAL
COMPLEX (E.I.CO)

2. History
Equipment
Certificates
Awards
Steel
grades
Areas of
Activities
Oil, Gas &
petrochemical
Power
Generation
Railway
Industry
Mining
Industry
Iron & Steel
Industry
Naval
Industry
Automotive
Industry
E.I.CO IN A NUTCHELL
2

3. History of
E.I.CO
3

4. 4
Ø The initial plan was designed in 1970s under the name of “Esfarayen Industrial Foundation”
Ø In 1991 the plan was approved in Iranian parliament as a “Heavy Castings and Forgings
Manufacturing Company”. Subsequently, E.I.CO was registered in 1992 as a company
(register #89046).

5. 5
Ø The company is located in 12km of Boujnourd-Esfarayen highway in North
Khorasan of Northern Iran.
Getting to E.I.CO
q Through Tehran-Mashhad railway- E.I.CO is located 70 kms away in Neghab
station .
q Air plane
a) Through Mashhad airport- about 300 km far from Mashhad
b) Through Boujnourd airport- about 50 km far from Boujnourd
c) Through Sabzevar airport- about 110 km far from Sabzevar

6. EQUIPMENT
&
FACILITIES
6

7. 7

8. 8
Different grades of steel scrap are stored in divided partitions to
facilitate charging in the EAF. They are carefully checked for safety
before charging into the furnace.

9. 9
Capacity: 50 MT is capable of producing melt with phosphor level below
0.005 (P<0.005). It is also equipped with EBT system to inject gas from the
bottom.

10. 10
Ø Capacity: 50 MT
Ø Argon injection system with high purity: to achieve high level of compositional,
temperature homogeneity as well as desulphurization (S<0.005)

11. 11
Ø Vacuum Degassing (VD): 50 MT capacity, for degassing of the melt under vacuum
(below 2 mbar) and for steels that are required to have H<1.5PPM, N<60PPM,
S<50PPM, O<30PPM
Ø Vacuum Oxygen Decarburization (VOD): To produce stainless steel grades and low
carbon steel grades (C<0.03)
Ø Vacuum Stream Degasing (VSD): To produce heavy ingots that require very low gas
level; pouring under 2mbar vacuum

12. 12
q ESR to produce ingots with high level of compositional & elemental homogeneity and at the
same time to achieve high purity product.
q Annual Capacity: 6000 MT
q With three melting stations capable of producing ingots with 6000 mm length, 1200 mm
diameter in central shaking mold. Also ingots with 2700 mm length, and 900 mm diameter can
be produced in extra fixed molds.
q To prevent gas absorption the machine is equipped with a neutral gas injection system (Ar, N2)

13. 13
No Specification
1
Max Ingot Dimension For retractable base plate melt station
Length: max. 6000 mm
Diameter: 450 ,800,1000,1200 mm
Weight : max. 52900 Kg
2
Max Ingot Dimension For static mold melt station
Length: max. 2700 mm
Diameter : 900 mm
Weight : max. 15000 Kg
3
Final Products (After Pressing or Forging )
Heat Treatable& Case Hardening Steels: Diameter: max. 700 mm
Tool &Stainless steels: Diameter: max. 600 mm

14. 14
Oxygen Content in Output Ingots:
Low Alloy Steels (up to 0.25%C): 35-50 ppm
Low Alloy Steels (0.25-0.5%C): 25-40 ppm
13% Cr, 0.2% C Steels: 40-60 ppm
High Alloy Steels: 45-70 ppm
Desulphurization: in Air Remelting Mode: 50-60%
Non-Metallic Microscopic Inclusions: Based on ASTM E45 and DIN
50602
Max. Deviation of Chemical Analysis in Output Ingots: Ti: ± 0.05%,
Si: ± 0.03%, Al: ± 0.01%

15. 15
Ø Capable of casting ingots with different diameters ranging from 500 mm
to 1850 mm and up to 80 MT (up 110 MT capacity is underway).
Ø Argon production is applied during pouring.
Ø An adjustable pouring speed during casting is applied.
https://www.researchgate.net/figure/230541140_fig7_Figure-1-Schematic-illustration-of-uphill-teeming-of-steel-ingot-casting

16. 16
Car bottom pre-heating furnace: Capacity up to 200 MT and maximum
heating temperature up to 1200 oC
Heavy ingots are then carried to the forging machine area by crane with
capacity up 80 MT

17. 17
Ø Two columned hydraulic press with 6300 MT
capacity:
§ With a manipulator of 80 MT capacity
§ And a motor chain of 110 MT capacity

18. 18
Press Shop Capabilities
ProductDimensionLength (mm)Weight (MT)
Round, Square and Flat Bars500-2000L=1500-18000Max 80
Hot and Cold Milling RollsD=400-1600L=3000-8000Max 80
Cylinders, BushesOD=600-2500L=MAX 6000Max 30
RingsOD=650-4000H=600-2500Max 50
DiscsD=1500-3000H=250-550Max 50
Mold Blocks
A=300-1500
B=160-800
L=MAX 208Max 60
Dimensions can be changed according to customers’ need)

19. 19
Four rotary forging machines (SXP 65- SXP 25- SXP 13- SXP 10) and one SHP 06
rotary forging machine are available at E.I.CO.

20. 20Dimensions can be changed according to customers’ need

21. 21
Hot Cutting Machine: Capable of hot cutting of up to 1500 mm diameter pieces

22. 22
Car bottom heat treatment furnaces: capacity up to 120 MT
Furnaces Capabilities:
Temperature Accuracy: ± 5 oc
Heating Rate: 50-150 oc/h
Cooling Rate: 10-70 oc/h
Quenching: 2 Tanks (Water & Polymer)
With Dimensions of : (6*6*6 m/7*3*2 m)
Very Good Applicability for :
Austenite Quenching in Stainless Steels
Martensite Quenching in Tool & Heat Treatable Steels

23. 23
Heat Treatment Furnaces
Max Temp (oC)Capacity (MT)Dimensions (mm)Name
1100±5402200-2500-8000H6
1100±5602200-2400-13000H7
1100±51203400-3700-9000H11
1100±51202900-2700-12000H12
Up Coming Heat Treatment Furnaces
Max Temp (oC)Capacity (MT)Dimensions (mm)Name
1150±51008000-500-3500HW01
1150±510012000-3500-3500HW02
950±5801000-2500-2500HW03
950±5808000-2500-2500HW04
Quenching Media
Cooling MediaDimensions (m)Name
Water/Oil3*6*12Q.T.1
Oil1.5*3*12Q.T.2
Oil2.5*6*6Q.T.3
Water3*6*8Q.T.4
Upcoming Quenching Media
Cooling MediaDimensions (m)Name
Polymer/Oil6*6*6/7*3*2Q.T.1
Water6*6*6/7*3*2Q.T.2

24. 24
CNC lathe machines with the following specifications:
ü Height of centers 1250mm, Distance between centers 12000mm, Workpiece weight 80 MT
ü Height of centers 1100mm, Distance between centers 6000mm, Workpiece weight 60 MT
ü Height of centers 265 mm, Distance between centers 2000mm
ü Height of centers 265 mm, Distance between centers 3000mm
CNC milling machine:
Ø Positioning of the table lengthwise 5000 mm, Positioning of the table crosswise 2000mm, Positioning of
the table vertically 1500mm, Mounting surface of the table 2000mm, Workpiece weight 54 MT
CNC boring machine:
Ø Spindle diameter 160mm, Position. Horizontally 5000mm, Positioning vertically 3000mm, Spindle is
capable to extend by max. 1800mm, Workpiece weight 80 MT
Deep Hole Drilling: Distance between centers up to 10 m
And many other heavy and light machining equipment: Distance between centers up to 12m, Height of
centers of 1000 mm

25. 25
Certified by Turkak of Turkey with ISO/IEC 17025
We are able to conduct the following tests in our
laboratories:
q Quantometery
q Tensile testing: 1200 KN on rounded and flat
specimens
q Impact testing: up to 450 J and down to -45°C
q Hardness measurement: Rockwell, Brinell and
Vickers
q Ultrasonic testing
q Jominy Test for hardenability measurement
q Chemical Analysis
q Heat Treatment
q Metallography
q Calibration
Services and Equipment in Quantometery Lab
TestingStandardEquipment
Determining The
Chemical Composition Of
Steel
ASTM E1086, ASTM
E415
ARL 3460 & Spectra Lab
M8
Measuring O, N, C, S, H in
steel
ASTM E1019
ON-MAT 8500
CS-MAT 6250
Bruker G8 & H-MAT 2500

26. 26
Services and Equipment in Chemistry Lab
TestingEquipment
Titration ferroalloy
XRF: Model AXIOS Panalytical
Atomic absorption: Model Shimadzu
Analysis of samples of unknown minerals, slag,
refractories etc.
XRF: Model AXIOS Panalytical
Atomic absorption: Model Shimadzu
Testing water for drinking and industrial applications,
corrosion control
Spectrophotometer: Model Merck
Services and Equipment in Metallography Lab
TestingStandardEquipment
MicrostructureASTM E3, E407
Light microscope
Nikon ME600 &
Olympus BX51M
With image analysis
Software
Grain sizeASTM E112
Inclusion content
ASTM E45
DIN 50602
Depth of
decarburization
ASTM E1077
Micro-hardnessASTM E348
Macro EtchASTM E381
Sulfur PrintISO 4968

27. 27
Services and Equipment in Mechanical testing Lab
TestingStandardEquipment
Tensile
properties
ASTM E8/E8M
ASTM A370
ISO6892
Tensile Machine: ZWICK
Model Z1200 Y
Impact
energy
ISO 148
Impact tester: Roell
Amsler, Model RKP450
Owen Julaab, Model
FP50
Notch condition: U, V
HardenabilityASTM A255Jominy tester
Hardness
ASTM E10
ASTM E18
Hardness EMCO tester
Equipment for Ultrasonic testing (UT)
TestingStandardEquipment
Ultrasonic
testing
SEP1921-
A388-EN
10228
CPOCH XT-
PANAMETRICS – NDT
(OLYMPUS)
Ultrasonic
testing
SEP1921-
A388-EN
10228
USN52L-
KARUTKERAMER

28. CERTIFICATES
28

29. 29
IMS
17025

30. 30
ISO 9001:2008
ISO 14001:2004
OHSAS 18001:2007
ISO 50001:2011

31. AWARDS
31

32. 32
National award for excellency
and organization improvement

33. STEEL GRADES
UNDER PRODUCTION
33

34. 34
K100(1.2080), K107(1.2436), K110(1.2379), 100Cr6(1.3505)Cold Work Tool SteelGroup 1
W302(1.2344), W500(1.2714), H11(1.2343),
46CrSiMoV7(1.2329)
Hot Work Tool SteelGroup 2
40CrMnMoS8-6(1.2312)Steel For Plastic MoldGroup 3
17-4PH(1.4542), 15-5PH(C-450), X10Cr13(1.4006),
09CH16N4B
Martensitic Stainless Steel, and
Precipitation Hardening Martensitic Steel
Group 4
X5CrNi18-10(1.4301)Austenitic Stainless SteelGroup 5
EN24, A517, 30CrNiMo8,42CrMoS4, 41CrAlMo7,
16MnCr5, Ck15
Heat Treatable Steel Sensitive For Hydrogen
Cracking, Construction Steel
Group 6

35. 35

36. AREAS OF
ACTIVITIES
36

37. OIL, GAS &
PETROCHEMICAL
INDUSTRIES
37

38. 38

39. POWER GENERATION
INDUSTRY
39

41. RAILWAY
INDUSTRY
41

42. 42
Axle
Material: C35E
Weight: 380 Kg

43. MINING &
CEMENT
INDUSTRIES
43

44. 44

45. IRON & STEEL
INDUSTRY
45

46. 46

47. 47

48. NAVAL
INDUSTRY
48

49. 49

50. AUTOMOTIVE
INDUSTRY
50

51. 51

52. THANK YOU
52
Presentation produced by Dr. Hashem Mousavi
hashemmousavi@gmail.comEmails:
hashemmousavi@esfst.com

53. APPENDIX
(SOME MORE
EXAMPLES)
53

54. Ø An 80 MT ingot mold for the production of initial ingot for back up rolls and similar products
was casted in melting shop of E.I.CO
Ø The weight of this ingot mold was about 59 MT, length 2900 mm, diameter 1950 mm, with 24
faces. Compared to similar ingot mold in the market it is distinguished with its H/D, Taper,
number of faces and other metallurgical specifications.
Ø TO produce this ingot mold, a new design, casting of cast-iron in EAF, simultaneous casting
of two 50 MT ladles, and in-house machining were employed. 54

55. The largest Slag pot in Iran with 40 MT capacity (3m length, volume of 30m3) for carrying slag
was produced at E.I.CO. Esfarayen Industrial Complex is one of the few plants in the world that
can produce such a ladle.
55

56. Ø For the first time in the Middle East VSD melting was successfully performed at E.I.CO With this method it
is now possible to produce high quality products with excellent mechanical properties.
Ø In this method super heavy slabs with the weights of 50, 80 and 110 MT were put under vacuum for the
subsequent casting process.
Ø The main advantage of this method compared with conventional methods (at atmosphere casting) is to
minimize the absorption of undesired gases in steel. Such a gases would cause problem in further processing
of the steel down the road.
Ø Reducing these unwanted gases is very beneficial in production of shafts for turbines and large shafts for
other sensitive industrial applications.
56

57. For the firs time in the Middle East back-up rolls are produced with forging
method for Mobarakeh Steel Co. in Isfahan, Iran. The weight range is 30-45 MT
57

58. Ø The weight of initial ingot for this piece is 60 MTs (the heaviest ingot being cast in Iran)
Ø The country became self-sufficient for importing heavy forged products up to 45 MT
58