Detailed Project Report (DPR) on manufacturing of ms ingot

MANUFACTURING OF MS INGOT

[CODE NO.4142]  

A steel ingot is a semi-finished solid metal form, which is produced through a continuous casting process.

Mild steel Ingots are the basic raw material for the manufacture of various types of re-rolled products, for e.g. rounds, flats, channels equal and unequal angles etc. A major part of this re-rolled products in the form of cold-twisted deformed bars are used in building construction as reinforcement.

Ingot is the product obtained by pouring liquid steel into cast iron mould of a shape appropriate for the subsequent processing generally by hot rolling or forging into semi-finished or finished products. The shape generally resembles a truncated pyramid or truncated cone. The side surfaces can be corrugated and the corners are more or less rounded. Depending on its subsequent conversion requirements, ingot can be dressed and/or hot scarred or cropped.

The usual cross section of ingot is square, rectangular, round, oval, or polygon. Ingots with square cross section are used for rolling into billets, rails and other structural sections, whereas, ingots with rectangular cross section, are generally used for rolling into flat products. These ingots usually have a width which is two times or higher than the thickness. Round ingots are used for the production of seamless pipes. Polygonal ingots are used to produce tyres, and wheels etc. Low capacity steel melting shops with induction furnaces produce very small cross section ingots which are called as pencil ingots.

Typically ingots used for the production of rolled products have weights in the range of 5 tons to 35 tons. Pencil ingots are used for the rolling of merchant long products and reinforcement bars and have weights typically in the range of 100 kg to 200 kg. Ingots used for the production by forging of the heavy equipment/components can be extremely large ingots weighing even 600 tons and more.

Ingot is a conventional crude steel product, but presently it constitutes a very small percentage of global crude steel production. However, ingots are still fundamental for specific low-alloy steel grades and for special forging applications, where products of large dimension, high quality or small lot size are needed. These large dimension ingots are being used these days in the power engineering industry (e.g. shafts for power generation plants, turbine blades), the oil and gas industry (conveying equipment, seamless tubes), the aerospace industry (shafts, turbines, engine parts), ship building (shafts for engines and drives), tool making and mechanical engineering (heavy forgings, cold, hot and high-speed steels, bearing, drive gears) as well as automotive engineering (shafts, axes).

As the demand of heavy ingot increases nowadays, especially from the power engineering industry and ship industry, there is a tendency of producing extremely large ingots, which are mainly applied for pressure retaining components such as reaction vessels for nuclear power plant and rotating components like drive shafts of gas turbines and generator rotors.

The general macrostructure that is often seen in the steel ingot can be divided into three distinct zones namely (i) the outer chill zone with small crystals of approximately equal size, (ii) the intermediate columnar zone with elongated columnar dendrites, and (iii) the central equiaxed zone with relatively large equiaxed grains. Besides the referred three zones, a region where the outer columnar dendritic structure transfers to the inner equiaxed grain structure is commonly observed. This region is named as the ‘columnar to equiaxed transition’ zone.

As the demand of heavy ingot increases nowadays, especially from the power engineering industry and ship industry, there is a tendency of producing extreme large ingots over 600 t and continuous cast strands with thickness over 450 mm and rounds with diameter up to 800 mm, which are mainly applied for pressure retaining components such as reaction vessels for nuclear power plant and rotating components like drive shafts of gas turbines and generator rotors.

COST ESTIMATION

Plant Capacity                                    60 MT/Day  

Land & Building (10,000 sq.mt.)  Rs. 6.66 Cr    

Plant & Machinery                            Rs. 5.17 Cr 

Working Capital for 2 Months    Rs. 11.76 Cr 

Total Capital Investment                  Rs. 24.56 Cr 

Rate of Return                                 39%

Break Even Point                             58%

• INTRODUCTION
• SPECIFICATION OF STEEL INGOT
• STEEL INGOT SPECIFICATION:
• M.S. INGOTS
• PROPERTIES
• CHEMICAL PROPERTIES OF MILD STEEL
• PHYSICAL PROPERTIES OF MILD STEEL
• USES AND APPLICATION
• B.I.S. SPECIFICATION
• PROCESS FLOW CHART
• CASTING OF INGOT
• MECHANISM OF SOLIDIFICATION OF LIQUID STEEL IN INGOT MOULD
• MICRO-SEGREGATION AND MACRO-SEGREGATION IN STEEL INGOTS
• FIG 1 THREE DISTINCT MACRO-STRUCTURE ZONES IN STEEL INGOTS
• FIG 2 MACRO-SEGREGATION PHENOMENON DURING SOLIDIFICATION 
•    IN INGOT MOULD
• DEFECTS OF KILLED STEEL INGOTS
• FIG 3 PIPE FORMATION DURING SOLIDIFICATION OF LIQUID STEEL 
•    IN INGOT MOULD
• MANUFACTURING PROCESS
• 1. PREPARATION OF SCRAP
• PROCESSES FOR SORTING AND PREPARATION OF STEEL SCRAP
• MECHANICAL PROCESSES
• FIG 1 PROCESSES FOR PREPARATION OF STEEL SCRAP
• MAGNETIC SEPARATION PROCESS
• EDDY CURRENT SEPARATION PROCESS
• HEAVY MEDIA SEPARATION PROCESS
• SEPARATION BY PHYSICAL AND CHEMICAL CHARACTERISTICS
• DECOATING PROCESSES
• DEZINCING PROCESS FOR STEEL SCRAP
• DETINNING PROCESS FOR STEEL SCRAP
• DECOPPERIZATION PROCESS FOR STEEL SCRAP
• INCINERATION
• RECENT STEEL SCRAP SORTING TECHNOLOGIES
• PORTABLE OPTICAL EMISSION SPECTROMETERS
• COLOUR SORTING PROCESS
• PROCESS UTILIZING LASER INDUCED BREAKDOWN SPECTROSCOPY
• 2. MELTING
• OPERATION OF INDUCTION FURNACE
• FIG 1 SCHEMATICS OF AN INDUCTION FURNACE
• FIG 2 A CORELESS INDUCTION FURNACE
• BATH AGITATION MECHANISM
• FIG 3 POWER DISTRIBUTION (LEFT) AND FLOW PATTERN (RIGHT)
• REFRACTORY LINING
• PRODUCTION OF MILD STEEL BY INDUCTION FURNACE
• COMPARISON WITH ELECTRIC ARC FURNACE STEEL MAKING PROCESS
• THE DISADVANTAGES ARE
• KEY ADVANTAGES OF INDUCTION HEATING
• IMPORTANT ASPECTS OF OPERATION
• OTHER ASPECTS OF INDUCTION FURNACE STEEL MAKING
• FIG 1 TYPICAL HEAT BALANCE DIAGRAM OF CRUCIBLE INDUCTION 
•    FURNACE
• ENVIRONMENTAL EMISSIONS
• SAFETY AND INDUCTION FURNACES
• CASTING OF BILLET
• MECHANISM OF SOLIDIFICATION OF LIQUID STEEL IN INGOT MOULD
• MICRO-SEGREGATION AND MACRO-SEGREGATION IN STEEL INGOTS
• FIG 1 THREE DISTINCT MACRO-STRUCTURE ZONES IN STEEL INGOTS
• FIG 2 MACRO-SEGREGATION PHENOMENON DURING SOLIDIFICATION IN INGOT MOULD
• DEFECTS OF KILLED STEEL INGOTS
• FIG 3 PIPE FORMATION DURING SOLIDIFICATION OF LIQUID STEEL 
•     IN INGOT MOULD
• QUALITY CONTROL
• MARKET OVERVIEW OF STEEL INDUSTRY
• CHART 1: TREND IN GLOBAL STEEL PRICES
• CHART 2: TREND IN IMPORT AND EXPORT OF FINISHED STEEL
• TABLE 1: INDIA’S STEEL SCENARIO DURING H1FY21 AND H2FY21
• SOME OF THE MAJOR INVESTMENTS IN THE INDIAN STEEL 
•     INDUSTRY ARE AS FOLLOWS:
• INDIAN GOVERNMENT ROLE
• SOME OF THE OTHER RECENT GOVERNMENT INITIATIVES IN 
•     THIS SECTOR ARE AS FOLLOWS:
• PLANT LAYOUT
• SUPPLIERS OF MS INGOT
• SUPPLIERS OF RAW MATERIALS
• SUPPLIERS OF STEEL SCRAPE
• SUPPLIERS OF COKE
• SUPPLIERS OF LIME
• SUPPLIERS OF FERRO ALLOY
• SUPPLIERS OF PICKLING CHEMICALS
• SUPPLIERS OF PLANT AND MACHINERY
• SUPPLIERS OF SHEREDDER
• SUPPLIERS OF DE-COATER
• SUPPLIERS OF MAGENETIC SEPARATOR
• SUPPLIERS OF INDUCTION FURNACE
• SUPPLIERS OF INGOT CASTING MACHINE
• SUPPLIERS OF METAL TESTING MACHINE
• SUPPLIERS OF PRECISION MEASURING TOOLS
• SUPPLIERS OF NDT INSPECTION EQUIPMENT
• SUPPLIERS OF ELECTRICAL MEASURING INSTRUMENTS
• SUPPLIERS OF EOT CRANE
• SUPPLIERS OF POWER TRANSFORMERS
• SUPPLIERS OF ELECTRICAL PANEL
• SUPPLIERS OF COOLING TOWER
• SUPPLIERS OF EFFULENT TREATMENT PLANT
• SUPPLIERS OF AIR POLLUTION CONTROL EQUIPMENTS
• SUPPLIERS OF AIR CONDITIONING EQUIPMENTS
• SUPPLIERS OF AIR COMPRESSORS
• SUPPLIERS OF PLATFORM WEIGHING MACHINE
• SUPPLIERS OF MATERIAL HANDLING EQUIPMENTS
• SUPPLIERS OF FIRE FIGHTING EQUIPMENTS
• 
  

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)