Detailed Project Report (DPR) on Ferro Titanium Processing Plant (14 MT/Day)

FERRO TITANIUM PROCESSING PLANT 

[EIRI/EDPR/4701] J.C.: 2920US$

The global steel production has increased continuously over the last few years and this trend is expected to continue in the years to come. The global crude steel output has been growing at about 5%and is expected to grow at a similar rate overall. The steel growth in India has been higher and is expected to grow @7%till 2030bywhen the production is expected to reach about 230 million tonnes. This consistent growth of crude steel production will have a direct correlation with the demand for ferro alloys i.e. Ferro Chrome, Silico Manganese and Ferro Manganese. Demand for Ferro Alloys is directly linked to steel production level. Looking at the projection of demand for steel and ferro alloys it can be realized that there remains a considerable gap between demand and supply of steel as well as ferro alloys by 2020-21. To meet the demand, new capacities have to be created.

Ferroalloys are one of the important inputs in the manufacture of alloys and special steel. They are used as deoxidisers and alloy additives in the steel manufacturing process. They impart special properties to steel. The alloys provide increased resistance to corrosion, improve hardness & tensile strength at high temperature, impart wear and abrasion resistance and increases creep strength etc. 

The growth of Ferroalloys Industry is, thus, linked with the development of the Iron and Steel Industry, Foundry Industry and to some extent Electrode Industry. The principal ferroalloys are chromium, manganese and silicon. The product series consists mainly of ferromanganese, silicomanganese, ferrosilicon and ferrochrome. Ferroalloys are classified into two main categories, viz, bulk ferroalloys and noble ferro alloys. 

Bulk ferroalloys is majorly used in stainless steel & carbon steel. Most of the boble ferroalloys are made from rare-earth minerals and are expansive to produce as compared to bulk ferroalloys. Owing to high cost of power, Ferroalloys Industry has not been operating to its full capacity in India. Ferroalloys Industry spends 40 to 70% production cost on power consumption. 

Ferroalloys are a group of materials which are alloys of iron that contain a high percentage of one or more nonferrous metals as alloying elements. These alloys are used for the addition of these other elements into liquid metal. They are normally used as addition agents. More than 85 % of ferroalloys produced are used primarily in the manufacture of steel.

Ferroalloys are usually classified into two main categories namely (i) bulk ferroalloys and (ii) noble or special ferroalloys. Noble ferroalloys are of high value and consumed in low proportions. These ferroalloys are one of the vital inputs required for the production of special types of steels and are used as additive inputs especially in the production of alloy and special steels.

COST ESTIMATION

Plant Capacity            14 MT/Day

Land & Building (6 Acres)    US$ 24.32 Lac

Plant & Machinery                    US$ 38.83 Lac

Working Capital for 3 Months    US$ 29.49 Lac

Total Capital Investment          US$ 94.30 Lac

Rate of Return                          66%

Break Even Point                      31%

CONTENTS

INTRODUCTION

STATUS OF INDUSTRY NOBLE FERROALLOYS

FERRO TITANIUM

FERRO NICKEL

FERRO MOLYBDENUM

FERRO VANADIUM

FERRO TUNGSTEN

FERRO NIOBIUM

FERRO BORON

FERRO ALUMINUM

NOBLE FERROALLOYS

ABOUT FERRO TITANIUM MARKET

FERRO TITANIUM FOR STEELMAKING MARKET SIZE

FERRO TITANIUM FOR STEELMAKING MARKET

APPLICATIONS OF THE GROWTH OF THE FERRO TITANIUM MARKET

TYPES OF FERRO TITANIUM MARKET AVAILABLE IN THE MARKET

MAIN REGIONS ARE LEADING THE FERRO TITANIUM MARKET

LARGEST MANUFACTURERS OF FERRO TITANIUM MARKET WORLDWIDE

MARKET POSITION

BULK FERROALLOYS

WORLD PRODUCTION OF FERROALLOYS, 2016 TO 2018 (BY PRINCIPAL COUNTRIES)

USES AND APPLICATION

USES

MAIN APPLICATIONS FOR FERRO TITANIUM INCLUDE:

CLEANSING AGENT

GRAIN REFINER

FERRO ALLOY USES

QUALITY CONTROL

RAW MATERIAL TESTING

CONTINUOUS BATCH TESTING DURING PRODUCTION

FINAL SAMPLE TESTING

GRADES

CHEMICAL COMPOSITION OF VARIOUS GRADES OF FERRO TITANIUM PRODUCTS

PRESENT MANUFACTURERS OF DIFFERENT FERRO ALLOY

RAW MATERIAL SUPPLIERS

PRODUCTION PROCESS

FERRO ALLOYS / AND OTHER NOBLE FERRO ALLOYS

TERMITE PROCESS

FOLLOWING ACTIVITIES ARE CARRIED ON:

PROCESS FLOW CHART

SELECTION OF SITE & LOCATION OF PLANT

ENVIRONEMENTAL MANAGEMENT PLAN

SOURCES OF POLLUTION

THE VARIOUS MEASURES PROPOSED TO MITIGATE THE IMPACT OF THESE POLLUTION SOURCES ON THE ENVIRONMENT ARE DISCUSSED BELOW:

POLLUTION CONTROL MEASURES

AIR POLLUTION

WATER POLLUTION

NOISE POLLUTION

SOLID WASTE MANAGEMENT

DISPOSAL OF SLAG FROM FERRO ALLOYS:

PLANTATION

SELECTION CRITERIA OF PLANT SPECIES FOR GREEN DEVELOPMENT PLANT

SPECIFICATIONS/ DESIGN DETAILS OF THE SUBMERGED ARC FURNACES (SAF)

PLANT LAYOUT

THE LAYOUT OF THE PLANT SHOULD BE FOLLOWING CONSIDERATIONS:

SUPPLIERS OF PLANT AND MACHINERY

STORAGE TANK MANUFACTURER /SUPPLIER

PACKAGING MACHINE MANUFACTURER /SUPPLIER

D.G. SET MANUFACTURER /SUPPLIER

LABORATORY TESTING EQUIPMENTS MANUFACTURER /SUPPLIER

SS PIPE & TUBE MANUFACTURERE

ELECTRICAL PANEL & BOARD MANUFACTURERS

PRINCIPLES OF PLANT LAYOUT

PLANT LOCATION FACTORS

PRIMARY FACTORS

1. RAW-MATERIAL SUPPLY:

2. MARKETS:

3. POWER AND FUEL SUPPLY:

4. WATER SUPPLY:

5. CLIMATE:

SPECIFIC FACTORS

6. TRANSPORTATION:

A. AVAILABILITY OF VARIOUS SERVICES AND PROJECTED RATES

7. WASTE DISPOSAL:

8. LABOR:

9. REGULATORY LAWS:

10. TAXES:

11. SITE CHARACTERISTICS:

12. COMMUNITY FACTORS:

13. VULNERABILITY TO WARTIME ATTACK:

14. FLOOD AND FIRE CONTROL:

EXPLANATION OF TERMS USED IN THE PROJECT REPORT

1. DEPRECIATION:

2. FIXED ASSETS:

3. WORKING CAPITAL:

4. BREAK-EVEN POINT:

5. OTHER FIXED EXPENSES:

6. MARGIN MONEY:

7. TERM LOANS:

8. TOTAL LOAD:

9.   LAND AREA/MAN POWER RATIO:

UTILITIES

POWER

WORKING

TOTAL MANPOWER AND PAYROLL

AND DISPOSAL

STEAM

POWER

POWER REQUIREMENT

AMENITIES & FACILITIES

LABORATORY

REPAIR AND MAINTENANCE SHOP

STORES

PLANT OFFICE

ANCILLARY BUILDINGS

CANTEEN

PLANT FACILITIES –

RAW MATERIAL HANDLING SYSTEM

SUBMERGED ARC FURNACE

HOT METAL HANDLING

STATUTORY APPROVALS FROM GOVERNMENT

DOCUMENTS REQUIRED FOR LICENSES

LIST OF DOCUMENTS:

SWOL ANALYSIS

STRENGTHS

OPPORTUNITIES

WEAKNESS

LIMITATIONS

ORGANIZATION CHART

PROJECT CONSULTANT

IMPLEMENTATION SCHEDULE

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)