HIGH CARBON FERROCHROME PRODUCTION PLANT
[EIRI/EDPR/4631] J.C.: 2848US$
High Carbon Ferrochrome/Charge Chrome are produced in Submerged Electric Arc Furnace is of stationary and semi-closed top.
The process adopted is high temperature smelting process, in which chrome ore is reduced with the help of the reductant like coke. The gangue material in the ore is removed by suitable fluxing material. The raw materials like chrome ore, coke and fluxes are selected to obtain desired grade in the output as per the requirement of the customer. All the incoming raw materials are analyzed for quality before feeding into the furnace.
The charge mix containing chrome, coke and flux is taken into the furnace with the help of computerized batching system. The necessary heat required for a process is provided by electric energy to the charge through the electrodes. At the tip of the electrode electric arcing taken place and generates high heat energy to smelt chrome ore into HC Fe Cr/Charge Chrome with coke (carbon) as reducing agent. In the process of smelting, gangue content in chrome ore forms the slag whose composition and fluidity are maintained by flux addition.
Both hot metal and slag are tapped at regular intervals depending upon the power consumption. The slag is granulated. The metal is handled through decantation process and skimming process before cast in the metal casting beds prepared with slag dust and plastic clay. The metal after cooling is handled manually into different size fractions as per the requirement of the customer. This is a continuous process in which charge mix is taken regularly and slag & metal taped at regular intervals. Stage wise inspection is carried out to get the quality product.
COST ESTIMATION
Plant Capacity 70 MT/Day
Land & Building (1,01,170 sq.mt.) US$ 19.85 Lac
Plant & Machinery US$ 42.00 Lac
Working Capital for 2 Months US$ 45.23 Lac
Total Capital Investment US$ 1.10 Cr
Rate of Return 79%
Break Even Point 37%
CONTENTS
INTRODUCTION
DEMAND – SUPPLY GAP
PROJECT BACKGROUND
PLANT RATING AND CAPACITY
CHROME ORE
RAW MATERIAL REQUIREMENT
WATER
POWER SUPPLY CONNECTIVITY
ENVIRONMENTAL ASPECTS
SOLID WASTE GENERATION
SOLID WASTE MANAGEMENT
LIQUID EFFLUENT/WATER POLLUTION MANAGEMENT
ENERGY CONSERVATION
IDENTIFICATION OF THE PROJECT & PROJECT PROPONENT
PROJECT
A. SMELTER:
B. BRIQUETTING PLANT:
NEED FOR THE PROJECT AND IT’S IMPORTANCE TO THE COUNTRY
PROJECT DESCRIPTION WITH PROCESS DETAILS
RAW MATERIALS REQUIRED ALONG WITH ESTIMATED QUANTITY, LIKELY SOURCE, MARKETING AREA OF FINANCIAL PRODUCT/S, MODE OF TRANSPORT OF RAW MATERIAL AND FINISHED PRODUCT
ANNUAL REQUIREMENTS OF MAJOR RAW MATERIALS
A. CHROME ORE
A. ANTHRACITE
B. COKE
C. BAUXITE
E. QUARTZITE
TABLE NO.3.3: COMPOSITION OF COMMERCIAL GRADES OF HIGH CARBON FERRO CHROME
BRIQUETTING PLANT
DESIGN BASIS
PLANT CAPACITY
FEED
CHEMICAL ANALYSES OF FEED ORE
ADDITIVES
CHARACTERISTICS OF MOLASSES AND HYDRATED LIME
PRODUCT
BRIQUETTE CHARACTERISTICS
PROCESS DESCRIPTION
SMELTER
QUANTITY OF WASTES SHOULD BE GENERATED (LIQUID AND SOLID) AND SCHEME FOR THEIR MANAGEMENT / DISPOSAL.
SOLID WASTE MANAGEMENT
LIQUID EFFLUENT/WATER POLLUTION MANAGEMENT
SMELTING OF HC FE-CR FERRO-ALLOY
FIG 1 SCHEMATICS OF FE-CR SMELTING IN SAF
ZONES IN A SAF
FIG 2 SCHEMATIC DIAGRAM OF THE REACTION ZONES IN SUBMERGED ARC FURNACE FOR FE-CR PRODUCTION
PROCESS REACTIONS
RAW MATERIALS
PRODUCTION PROCESS
THE FOLLOWING ARE THE IMPORTANT CHARACTERISTICS OF PRODUCTION PROCESS OF FE-CR IN A SAF:
HIGH CARBON FERROCHROME: – SPECIFICATIONS
USES AND APPLICATION
RAW MATERIALS
REDUCTANT
FLUX
AGGLOMERATION – BRIQUETTING PROCESS
METAL RECOVERY PLANT (MRP)
MARKET OVERVIEW
KEY MARKET INSIGHTS
GLOBAL FERROCHROME MARKET SEGMENT ANALYSIS:
GLOBAL FERROCHROME MARKET REGIONAL INSIGHTS:
GLOBAL FERROCHROME MARKET KEY PLAYER
RISING FOREIGN INVESTMENTS AND MANUFACTURING ACTIVITIES TO BOOST MARKET GROWTH
DRIVING FACTORS
HIGH USAGE IN THE STAINLESS STEEL INDUSTRY TO AID MARKET
EXPANSION
RESTRAINING FACTORS
AVAILABILITY OF SUBSTITUTES TO HINDER MARKET AUGMENTATION
SEGMENTATION
BY PRODUCT TYPE ANALYSIS
HIGH CARBON SEGMENT TO LEAD OWING TO INCREASING USE IN STEEL INDUSTRY
BY APPLICATION ANALYSIS
STAINLESS STEEL SEGMENT TO DOMINATE THE MARKET DUE TO HIGH ADOPTION IN CONSTRUCTION INDUSTRY
REGIONAL INSIGHTS
KEY INDUSTRY PLAYERS
STRATEGIC PLANNING ADOPTED BY COMPANIES TO STRENGTHEN THEIR MARKET SHARE
KEY INDUSTRY DEVELOPMENTS:
PRESENT MANUFACTURERS
RAW MATERIAL SUPPLIERS
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
SUPPLIERS OF PLANT AND MACHINERY
PACKAGING MACHINE
D.G. SET
LABORATORY TESTING EQUIPMENTS
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:
AMENITIES & FACILITIES
LABORATORY
REPAIR AND MAINTENANCE SHOP
STORES
PLANT OFFICE
ANCILLARY BUILDINGS
CANTEEN
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)
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