FERRO SILICON (FROM MINERAL INGREDIENTS)
[EIRI/EDPR/1383]J.C.159
INTRODUCTION
Ferro alloys are used in making alloy steels and castings of different special types as addition agents. Ferro alloys are usually made in electric-are furnaces. Alloy steel have often greater limitations on tramp element concentrations than plain carbon steels.
Municipal ferrows scraps is largely used as part of the furnace charge to produce ferro alloys. Incinerated scrap is preferred because all of the consuminats are eleminiated though this source leaves a significant proportion of tin & copper impurities, yes due to the fact that ferro alloy is typically only a small addition to the final steel, the dilution of impurities, contained in the ferro alloy, results in acceptable concentrations.
Addision Agents:
In steel making, various elements are added to the molten metal to effect various properties, eg. deoxidasion grain controly improvement of mechanical/ thermal/ corrosion properties etc.
Chemicals added into steels in the bath consists of iron and the elements intended to be incorporated, hence called ferroalloys. These ferro alloys are produced in electric & many other types of furnaces. A number of ferro alloys produced today contain very little of iron. Ferro alloys are, thus, a special class of addition agents. Ferroalloys/addition agents can be added to the charge in the furnace, the molten bath near finishing period, laddle or in the mould.
Aluminium, baron, calcium, chromium, manganese, molybdenum, nickle, nitrogen, phosphorous, niobium, selenium, titanium & zirconium are the main addition elements used in steel. However, aluminium, boron, calcium, cobalt, copper, magnesium & sulphar are not introduced in the steel as ferroalloy rather these are used in their pure mitallic form.
The ferro alloys under the Govt's broad banning scheme are classified as:
1. Bulk ferroalloys
2. Noble ferroalloys.
Bulk ferroalloys include ferro chrome/chargechrome ferro manganex, ferrosilicon etc. while niobium, nickel, titanium, tantalum, tungsten and vanadium form noble ferroalloys. Two or more of these elements can be associated with any one ferroalloy in known proportions for metalhirgical in known proporation for metalligical uses.
Depending on affinity for oxygen compared to iron, copper, molybdenum & nickel can be added with the charge or during melting and are fully recovered cr & mn elemnets are easily oxidized and hence, need to be added late during melting or in ladle. Al, Ti, V & Zr easily oxides and are added need in ladle only to minimaige oxidation losses.
COST ESTIMATION
Plant Capacity 200 MT/Day
Land & Building (1,00,000 sq.mt.) Rs. 1.99 Cr
Plant & Machinery Rs. 6.62 Cr
Working Capital for 2 Months Rs. 68.70 Cr
Total Capital Investment Rs. 78.21 Cr
Rate of Return 72%
Break Even Point 70%
CONTENTS
INTRODUCTION
USES & APPLICATIONS
B.I.S. SPECIFICATION
PROPERTIES
MARKET POSITION
INDIAN FERRO ALLOYS INDUSTRY AT CROSS ROADS
MANUFACTURERS/EXPORTERS/SUPPLIERS
PRODUCTION OF FERRO-SILICON TYPICAL FLOW DIAGRAM
MANUFACTURING PROCESS
PROCESS FLOW DIAGRAMS
PLANT LAYOUT
SUPPLIERS OF RAW MATERIALS
LIME POWDER
METAL SCRAP
WOOD CHARCOAL
SUPPLIERS OF PLANT AND MACHINERY
INDUCTION FURNACE
STEAM TURBINES
ELECTRICAL & POWER TRANSFORMERS
ELECTRICAL CONTROL PANELS & DISTRIBUTION BOARDS
COOLING TOWERS
EFFLUENT TREATMENT PLANT
INDUSTRIAL WEIGHING SCALE
STEEL FABRICATORS
PRINCIPLES OF PLANT LAYOUT
PLANT LOCATION FACTORS
EXPLANATION OF TERMS USED IN THE PROJECT REPORT
APPENDIX – A:
01. PLANT ECONOMICS
02. LAND & BUILDING
03. PLANT AND MACHINERY
04. OTHER FIXED ASSESTS
05. FIXED CAPITAL
06. RAW MATERIAL
07. SALARY AND WAGES
08. UTILITIES AND OVERHEADS
09. TOTAL WORKING CAPITAL
10. TOTAL CAPITAL INVESTMENT
11. COST OF PRODUCTION
12. TURN OVER/ANNUM
13. BREAK EVEN POINT
14. RESOURCES FOR FINANCE
15. INSTALMENT PAYABLE IN 5 YEARS
16. DEPRECIATION CHART FOR 5 YEARS
17. PROFIT ANALYSIS FOR 5 YEARS
18. PROJECTED BALANCE SHEET FOR (5 YEARS)
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