SMC
Company Description & Market Outlook
- Est. in April 2010 as an LLC, SMC is a steel manufacturing company, located in Sagamu, Ogun State, Nigeria licensed under RC 882535
- The SAADI family has been tremendously successful since the inception of SONIT, an international trading company specialized in industrial Fishing, Agri Food as well as exporters of coffee and cocoa. SONIT also owns Real Estate in the MENA and Africa region
- With the success of SONIT the SAADI family was able to establish and fund SMC
- Our Mission is to produce highly standardized steel products for both the constructional and industrial sectors in the market. Our project constitutes of 4 phases.
- The factory has finished its first and second Phase and started manufacturing high quality reinforced rebar and wire rod in coils of various sizes and length
- The size of the land which the company owns is 69,000 m2
- The land includes 70 residential flats for the accommodation of the technical staff and 26 flats for the accommodation of the management staff
- At the end of 2018, SMC is able to produce locally all its products with low forex exchange risk which is the major risk today in Nigeria, and all West Africa.
Phase I Commissioning
- Rolling Mill with Gas preheating Furnace for a minimum capacity of 260,000MT/Annual Rebar with sizes ranging from 10mm to 42mm.
- 150,000MT/Annual Wire Rods with sizes from 5.5mm to 8.0mm with different Standards and Grades depending on customers and Market requirement
- 4 Turbines of 17 MVA with an infrastructure ready for 5 additional Turbines
- 132KV Substation of 100MW capacity
- l Gas Station, 1 Oil reserve Plant, Real Estate of 42 flats, 2 Batching Plants, Water Pool Aux., MV & LV room ,2 Generators of 1250KW (Black Start), Office Building, 3 warehouses, and 3 Deep Water Boreholes with a capacity of 50 m3/hour each.
- The rolling Mill has 2 path of billets A & B to increase production capacity. At this moment.
Phase II Commissioning
- Phase ll started in 2014 when a purchase agreement was signed with Danieli.
- Power stability " This is the first plant in the world that can operate on ‘full island mode' using Gas Turbine Generators for power supply, which leads to stability during production cycles.
- integrated to Phase I to the preheating Furnace, for efficiency and cost reductions.
- Ready for an expansion to be integrated to another input plant "DRl & Beneficiation iron Ore Plant".
- Ready for any upgrading by increasing the production capacity or adding a new development.
- Melt shop (EAF) is commissioned and Tested on Q3 of 2018 and achieved designed capacity per month (260000T per Annum).
- The Plant contains Electrical Arc Furnace (EAF) and Ladle Refinery Furnace (LRF) Continues Casting Machine (CCM).
- The LRF is meant to refine and treat the liquid steel to achieve the required quality.
- The Plant can produce a variety of Billets (Billet 130 x 130 x 6,000 and 12,000 mm to Billet 200 x 200 x 6,000 and 12,000 mm) according to product standards: ASTM, DlN, JlS, BS etc.
Extension Plants
Air Separation Plant (ASP) produces:
- Oxygen 2500Nm3/hour excess of 40% for the Market
- Nitrogen 2500 Nm3/hour excess of 80% for the Market
- Argon 40 Nm3/hour excess of 10% for the Market
- Liquid oxygen and Nitrogen 25m3/hour.
Fume Treatment Plant (FTP):
- SMC decided from day one to have a plant meeting the required Environmental, Health and Safety Standard requirements.
- SMC invested 5.4M$ in purchasing the plant. lt collects and filtrates all the dust and fumes that come from the EAF during arcing and from other equipment during operations. The Dust is then turned into ZINC and can be offered to the local and international market.
Power Generation Plant:
- 4 Solar turbines with a capacity of 60MW. Powers all the plants independent from national grid
- During the Project Risk Assessment, the Risk Department found that Nigeria has a lot of trouble supplying consistent power which lead to the investment decision of purchasing unique plant working on island mode. (first in the world to have this structure)
- Looking into adding another 5 extra turbines due to energy demand
- The Turbines are dual fuel Gas/Diesel. Steam turbines will be integrated to recover the heat coming from the turbines in order to generate 50 % cost-free additional power.
- A power management system is installed to monitor and control activities. The PMS will be integrated with the SCADA system for data acquisition and control
induction Furnace
- Induction Furnace was commissioned in 2016 with a production capacity of 40,000MT/year. This plant will remanufacture the scrap coming from the Rolling Mill "Phase I" to turn it into raw material again.
Water Treatment Plant:
- This plant is an auxiliary plant for the Steel Melt shop. The EAF is an extensive user of indirect water as well as direct water. indirect includes (water cooled duct, panels, roof, electrode clamps, and arms). Direct cooling water is used for slag cooling, electrodes cooling and spray cooling system (quenching tower).
- Ladle Furnace: water used in LF is like the EAF. indirect water is used to cool the roof, arms, electrodes and clamps.
- The importance of water in steel melt shops and in rolling mill plants is obvious, especially for the direct cooling circuits where the polluted water is treated in order to reuse it in the plant. For this reason, SMC has three deep water boreholes with a capacity of 50 m3 per hour each to meet the demand of water in the plant.
- Our mission is to improve the quality of steel products, guarantee a long life for the equipment, and limit the environmental impacts by reducing the amount of makeup water and waste water at an attractive cost.
- Our most important goals are to obtain high reliability, to guarantee low maintenance and low energy consumption, to respect the environmental thresholds, to respect the technical requirements and to guarantee the quality required.
Mission: improve the quality of steel products, guarantee a long life for the equipment, and limit the environmental impacts by reducing the amount of makeup water and waste water at an attractive cost.
Goals: to obtain a high reliability, guarantee low maintenance and low energy consumption, respect the environmental thresholds, abide by the technical requirements, and guarantee an unrivaled quality.
Automation:
- SMS & Auxiliary plants are integrated with level 1 & 2 of automation to reduce errors and occupy preventive and corrective actions.
- Reduces the human error and increases time efficiency, as it gives the ability to monitor and control during production.
- Level 2 of automation can be merged with level 3 of the manufacturing execution system to be fully integrated with the corporate ERP system.
Electrical Bank Compensator Filter:
- During the melting process, the EAF will generate harmonics and fluctuations: the "Compensator "will deal with the harmonics and fluctuations to assure the safety any electrical equipment.
Additional Information
Residential Building & Canteens:
- Our aim is to reduce manpower turnover to guarantee stability and to maintain a solid corporate image in the market.
- SMC built residential buildings and canteens to accommodate most of their 1,500 employees.
Recruiting Policy - SMC seeks to have an international pool of talented employees coming from but not Limited to (Nigeria, Italy, China, Lebanon, Syria, Pakistan, India, and Ukraine) for different know how and wide experience.