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    Ferro Titanium Processing Plant (14 MT/Day)

    Ferro Titanium Processing Plant (14 MT/Day)
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    Ferro Titanium Processing Plant (14 MT/Day)
    US $ 0.00
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      FERRO TITANIUM PROCESSING PLANT 

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


      INTRODUCTION

      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.

      Noble ferroalloys (Fig 1) are ferro nickel (Fe-Ni), ferro molybdenum (Fe-Mo), ferro vanadium (Fe-V), ferro  tungsten (Fe-W), ferro niobium (Fe-Nb), ferro titanium (Fe-Ti), ferro aluminum (Fe-Al), ferro boron (Fe-B). There are some noble ferroalloys which are having more than one nonferrous metal as alloying elements. Examples are ferro silico magnesium (Fe-Si-Mg), ferro silico zirconium (Fe-Si-Zr), ferro nickel magnesium (Fe-Ni-Mg) etc.


      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)

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