Detailed Project Report (DPR) on S.G. Iron & Alloy Steel Castings

S.G. IRON & ALLOY STEEL CASTINGS

[EIRI/EDPR/0689] (J.C.:9298)

THE PROJECT (AT A GLANCE)

Foundry  is  one of the oldest  industries.  However  Indian foundries  have  so far been of conventional type.  But,  in  the modern  industrial  arena,  competitiveness of a  foundry  is  of utmost importance.

The  foundry units are becoming more-and-more  automated  in order to improve efficiencies. Modern metal melting furnaces  are designed   from  the  view  points  of   minimising   pollutions, maximising energy savings and suitably to use frequently changing raw  materials.  Process parameters are strictly  controlled  and adjusted    automatically   with   the   built-in    devices    & instrumentations. All these latest provisions are required to  be introduced  in  foundries today which push up the  capital  costs greatly.  This  high  capital cost needs  to  be  compensated  by installing  high capacity furnace for large quantity  production. It  also  requires  to produce value added  products  as  far  as possible.   Certain  operational  precautions  are   additionally required,   loading   to  maximum  material   utilization,   less rejections and highest recovery.

This  project has been planned in this light.  S.G.iron  and alloy  steel  castings are in great demand in a large  number  of automobile,  railway,  general engineering, machine  tools,  pipe fittings & various other sectors.

A  special  technique is required to  produce  good  quality S.G.Iron  as  well  as  alloy steel  castings.  The  outlines  of technicalities  used, have been delineated in  required  details, however,  the  real  control  of  process  parameters  &   actual operation-details, process/materials/products design remain to be the part of technical know-how.

COST ESTIMATION

Plant Capacity            25 MT/Day

Land & Building (4000 sq.mt.)    Rs. 2.15 Cr

Plant & Machinery                    Rs. 1.36 Cr

Working Capital for 2 Months    Rs. 5.86 Cr

Total Capital Investment          Rs. 10.96 Cr

Rate of Return                          60%

Break Even Point                      49%

CONTENTS

THE PROJECT (AT A GLANCE)

INTRODUCTION

CLASSIFICATION OF FOUNDRY PRODUCTS:-

SPHEROIDAL GRAPHITE (S.G.) IRON:-

STEEL CASTINGS:-

STEEL CASTINGS ARE CLASSIFIED AS

ALLOYED STEELS ARE CATEGORISED AS:

MOULD MAKING & CASTING PROCESS:-

THE MOULDS USED FOR STEEL CASTING MUST FULFIL THE FOLLOWING REQUIREMENTS:-

B.I.S. SPECIFICATIONS

PROPERTIES & APPLICATION

(A) S.G. IRON:-

PROPERTIES & APPLICATIONS OF ALLOY STEEL CASTINGS

MECHANICAL PROPERTIES OF ALLOY STEELS INCLUDE:-

SIMILARLY, ENGG. PROPERTIES OF ALLOY STEELS INCLUDE:-

PHYSICAL PROPERTIES:-

DEFECTS IN STEEL CASTINGS:-

DEFECTS DUE TO POOR DESIGN:-

DEFECTS DUE TO INCORRECT CASTING PROCEDURES:-

DEFECTS DUE TO CARELESS FETTLING:-

DEFECTS DUE TO DEFECTIVE HEAT TREATMENT:-

MARKET SURVEY

CONSUMPTION PATTERN

EXPORT:

DISTRIBUTION OF FOUNDRY UNITS AT BELGAUM BY END-USE  MARKETS

DISTRIBUTION OF FOUNDRY UNITS AT COIMBATORE BY END-USE SEGMENTS

DISTRIBUTION OF FOUNDRY UNITS BY END-USE SEGMENTS

DISTRIBUTION OF FOUNDRY UNITS AT KOLHAPUR BY END-USE MARKETS

DISTRIBUTION OF FOUNDRY UNITS AT RAJKOT BY END-USE MARKETS

2.2 INTERNATIONAL SCENARIO

PRESENT MANUFACTURERS/EXPORTERS/SUPPLIERS

STATE-WISE LICENSED CAPACITY:-

CONCLUSION:-

SEQUENCE OF STEPS IN SAND PREPARATION

MOULDING PROCESSES:-

(A) HAND MOULDING:-

(B) MACHINE MOULDING:-

ADVANTAGES OF MACHINE MOULDING OVER HAND MOULDING:-

USE OF RISER IN THE MOULD:-

FLOW-CHART FOR RECLAMATION OF MOULDING SANDS

PARTING POWDERS & DUSTS:-

WASHES, PASTES, POWDERS & OTHER DRESSINGS:-

PROPERTIES OF MOULDING RAW MATERIALS FOR QUALITY STEEL CASTING

CLASSIFICATION OF NATURAL SAND

AVAILABILITY OF THESE SANDS AT:

COMPOSITION OF NATURAL SILICA SAND:-

CRUDE SILICA SAND:-

HIGH SILICA SANDS:-

SPECIAL SANDS:-

CHROMITE SAND FOR STEEL CASTING MOULDS

COMPOSITION OF CHROMITE SAND & ITS SPECIFICATIONS

ELECTRIC ARC FURNACES FOR STEEL INDUSTRY

DRAW BACKS OF AC-BASED EAF:-

CONSTRUCTION OF DC SUPPLY EAF

MELTING OPERATION:-

TYPICAL OPERATIONAL RESULTS OF A D.C-BASED EAF

ELECTRODE CONSUMPTION DATA AC VS DC EAFS

REFRACTORY LINING:-

POLLUTION EFFECTS:-

DRAW BACKS OF DC TYPE EAFS:-

ANNUAL COSTS FOR AC & DC TYPE EAFS

REFRACTORIES FOR MELTING FURNACES (EAF & LF)

REFRACTORIES ARE WELL SPECIFIED FOR THE FOLLOWING AREAS OF A UHP-EBT-EAF MELTING FURNACE:-

WASTE GAS CLEANING & RECOVERY IN STEEL MELTING PLANT

STUDY OF POWER CONSUMPTION IN AN EAF

SELECTION OF PARAMETERS:-

UNDER THE ELECTRICAL PARAMETERS, THE VARIABLE ARE:-

TAILOR-MADE MINI STEEL PLANTS

MELTSHOP CONFIGURATION OF MODERN MSPS:-

TYPICAL PLANT SPECIFICATIONS OF A 25-TONS CAPACITY MINI MILL:-

QUALITY STEELS FROM SPONGE IRON:-

MELTING TECHNIQUE

EFFECTS OF CONSTITUENT ELEMENTS IN S.G.IRON:-

(A) CARBON:-

(B) SILICON:-

(C) SULPHUR & MANGANESE:-

(D) PHOSPHOROUS:-

(E) NICKEL:-

(F) CHROMIUM:-

(G) CERIUM:-

MAGNESIUM:-

FOUNDRY TECHNIQUE

COMPOSITION OF S.G. IRON FOR VARIOUS APPLICATIONS:-

PROCESS FLOW SHEET

PLANT LAYOUT FOR S.G. IRON & ALLOY STEEL FOUNDRY

MACHINERY SUPPLIERS FOR SG IRON AND ALLOY STEEL CASTING

LIST OF PLANT AND MACHINERY SUPPLIERS

ELECTRIC ARC MELTING FURNACES

COMPRESSOR

PUMP

LABORATORY EQUIPMENTS

TRANSFORMERS MANUFACTURERS/SUPPLIERS

SUPPLIERS OF RAW MATERIALS

STEEL SCRAP

FERRO ALLOYS

PIG IRON

MANUFACTURER OF GRAPHITE ELECTRODES

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)