Detailed Project Report (DPR) on recycling plant of metal

RECYCLING PLANT OF METAL

[CODE NO.4225]  

The metal recycling industry is growing rapidly. In fact, projections show that the metal recycling market will grow from 630.0 million tons to 890.7 million tons by 2025. In other words, there’s no question that there’s a growing demand for metal recycling for various reasons. One possible reason is the ever-growing demand for urbanization and manufacturing. Another possibility is that individuals and businesses in recent years have taken eco-friendly operations seriously, and rightfully so.

The process of manufacturing metal from raw materials is not only labor-intensive, but it also puts unnecessary strain on the environment. Manufacturing new metal not only requires a large amount of energy use but also produces large amounts of greenhouse gases. Because of the adverse environmental impact and the substantial cost of producing new metal, more companies seek recycled metal

Metal recycling is simply the process of taking waste metal, processing it and creating new metal material. This recycled metal can be used to make metal products which can then be recycled once used or not needed. There are many advantages to recycling metal, including environmental benefits as well as energy savings

Metal recycling is the process of separating, cleaning, and melting ferrous and non-ferrous scrap to be used again as a raw material for new products. Metal is a material that can be recycled over and over again without degradation of its properties. Besides the ecological benefit of metal recycling, there is also an economic benefit. Scrap metals have a monetary value, and there is always demand high quality sorted scrap metals for recycling.

For optimal scrap metal recycling, scrap metal must be source-separated at your warehouse or workshop. With the right scrap metal tools, you can collect, sort, and clean all of your scrap metal.

Your local scrap metal dealer can collect your separated streams of scrap metal. We recommend using a scale to weigh your scrap metal beforehand. Also, inform authoritative resources for the current scrap metal prices, since scrap metal prices are constantly changing.

Metal recyclers will sort and process the scrap metal further and remove any impurities. After this process, heavy and bulky scrap metals are shredded with a scrap metal shredder or compacted with an alligator or scrap shear into smaller chunks. These chunks are then melted in large furnaces for each type of metal. The melting process requires much energy, but the energy required to mine virgin metals is lots higher. So, therefore, metal recycling is more energy efficient.

After the melting process, the metals are purified to free the product of impurities. This benefits the quality of the metal. The metal is then cooled and solidified in metal bars, ready for transportation as raw material.

 Difference between ferrous and non-ferrous metals

All types of metal can be recycled. But to recycle the scrap metal, it is required to sort the ferrous metals from the non-ferrous metals at your facility. But what is the main difference between ferrous and non-ferrous metals? The main difference is that ferrous metal is magnetic and non-ferrous metals are nonmagnetic, so basically, you can identify ferrous from non-ferrous metals by using a magnet.

 Ferrous and non-ferrous metals

COST ESTIMATION

Plant Capacity                              120 MT/Day

Land & Building (10,000 sq.mt.) Rs. 12.64 Cr

Plant & Machinery                         Rs. 5.17 Cr

Working Capital for 2 Months   Rs. 22.16 Cr

Total Capital Investment            Rs. 40.94 Cr

Rate of Return                               20%

Break Even Point                           66%

• INTRODUCTION
• DIFFERENCE BETWEEN FERROUS AND NON-FERROUS METALS
• FERROUS AND NON-FERROUS METALS
• WHAT IS FERROUS METAL?
• CHARACTERISTICS:
• WHAT IS NON-FERROUS METAL?
• CHARACTERISTICS:
• IMPORTANT OF RECYCLE METAL
• 1. PRESERVATION OF NATURAL RESOURCES
• 2. REDUCTION OF EMISSIONS
• 3. ECONOMIC DEVELOPMENT
• 4. MANAGEMENT OF ENERGY CONSUMPTION
• 5. MAKE ROOM IN LANDFILLS FOR NON-RECYCLABLE ITEMS
• 6. IMPROVES AIR QUALITY AND GROUNDWATER
• 7. BUSINESS OPPORTUNITIES IN METAL RECYCLING
• 8. SAVES YOU MONEY
• ADVANTAGES OF RECYCLING METAL
• DIVERT WASTE FROM LANDFILL
• REDUCE ENERGY USE
• PROTECT NATURAL RESOURCES
• BENEFIT ECONOMY
• ENDLESS RECYCLING
• THE METAL RECYCLING PROCESS
• 1. COLLECTION
• 2. SORTING
• 3. PROCESSING
• 4. CRUSHING
• 5. SHREDDING OR GRANULATING
• 6. MELTING
• 7. PURIFICATION
• 8. SOLIDIFYING OF THE METAL
• (A) RECYCLING OF FERROUS METAL
• CLASSIFICATION OF FERROUS METAL SCRAP
• HOME SCRAP:
• NEW SCRAP:
• OLD SCRAP:
• EQUIPMENT FOR FERROUS METALS RECYCLING:
• RECYCLING PROCESS
• RECEIVING AND SORTING
• CUTTING SCRAP
• METAL CLEANING
• REMELTING SCRAP
• ELECTRIC FURNACES CAN BE:
• APPLICATIONS & RECYCLING FACTS
• ALUMINIUM
• BUILDING & CONSTRUCTION:
• TRANSPORTATION:
• PACKAGING:
• ELECTRICITY:
• COPPER
• ELECTRICAL APPLICATIONS:
• PIPING:
• HOUSEHOLD ITEMS:
• LEAD
• ZINC
• GALVANIZATION:
• BATTERIES:
• BRASS:
• TIN
• CANS:
• CAR PRODUCTION:
• NON-FERROUS METAL
• RECYCLING PROCESS
• SORTING AND DISMANTLING:
• BALING:
• SHEARING:
• SHREDDING:
• FURTHER SEPARATION:
• MELTING:
• METHODS OF NON FERROUS METAL RECYCLING
• 1. ELECTRO WINNING
• 2. PRECIPITATION
• 3. METAL SENSORS
• B.I.S. SPECIFICATION
• PROCESS FLOW CHART FOR STEEL SCRAP
• RECYCLING PROCESS OF METALS
• STEEL SCRAP AND SCRAP SORTING AND PREPARATION PROCESSES
• 1. SCRAP PREPARATION
• PROCESSES FOR SORTING AND PREPARATION OF STEEL SCRAP
• MECHANICAL PROCESSES
• BALING –
• BRIQUETTING –
• SHEARING –
• SHREDDING –
• 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
• 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
• 3. CASTING OF STEEL 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
• PIPE FORMATION –
• FIG 3 PIPE FORMATION DURING SOLIDIFICATION OF LIQUID STEEL IN INGOT MOULD
• BLOW HOLES –
• NON-METALLIC INCLUSIONS –
• INGOT CRACKS –
• MARKET OVERVIEW
• MARKET GROWTH
• KEY MARKET PLAYERS
• PRINCIPLES OF PLANT LAYOUT
• STORAGE LAYOUT:
• EQUIPMENT LAYOUT:
• SAFETY:
• PLANT EXPANSION:
• FLOOR SPACE:
• UTILITIES SERVICING:
• BUILDING:
• MATERIAL-HANDLING EQUIPMENT:
• RAILROADS AND ROADS:
• MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE:
• 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. TOTAL LOAD:
• 8. LAND AREA/MAN POWER RATIO:
• PROJECT IMPLEMENTATION SCHEDULES
• INTRODUCTION
• PROJECT HANDLING
• PROJECT SCHEDULING
• PROJECT CONSTRUCTION SCHEDULE
• TIME SCHEDULE
• PLANT LAYOUT
• SUPPLIERS OF M.S. INGOT
• SUPPLIERS OF RAW MATERIALS
• SUPPLIERS OF STEEL SCRAP
• SUPPLIERS OF FERRO ALLOY
• SUPPLIERS OF PICKLING CHEMICALS
• SUPPLIERS OF PLANT AND MACHINERY
• SUPPLIERS OF SHREDDER
• SUPPLIERS OF DE-COATER
• SUPPLIERS OF MAGNETIC 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 CRANES
• SUPPLIERS OF POWER TRANSFORMERS
• SUPPLIERS OF ELECTRICAL PANEL
• SUPPLIERS OF COOLING TOWER
• SUPPLIERS OF EFFLUENT TREATMENT PLANT (ETP 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)