Detailed Project Report (DPR) on copper ingots from scrap

COPPER INGOTS FROM SCRAP
[CODE NO.3501]  


Copper is an important non-ferrous metal used in various forms for different applications. Copper being a major industrial metal, ranks third after iron and aluminium in terms of quantity consumed. Copper is a reddish malleable and ductile metal valued for its excellent thermal and electrical conducting qualities and resistance to corrosion. Copper combines with a number of elements to form a wide variety of copper minerals and ores.

Copper ingots are generally required by the Non-ferrous casting units which are engaged in the casting of different engineering components of brass, gun metal, bronze etc., the agricultural machinery, automobile industries and railway components. These ingots are also required for manufacturing of rods, tubes, strips, wires etc. The copper ingots manufactured from copper scrap are generally known as commercial quality ingots & do not come under the group of electrolytic copper as these are secondary quality ingots.

Copper is one of the oldest metals ever used and has been one of the important materials in the development of civilization. Copper is an important non-ferrous base metal having wide industrial applications. Today it has become a major industrial metal, ranking 3rd after iron and aluminum in terms of quantities consumed.

Copper today is a 8 billion US dollar industry in India having created 50,000 direct and indirect jobs and growing at a CAGR 5-7% per annum. India has a huge growth potential in copper consumption for the next 20-25 years as the government increases focus on smart cities, rapid urbanization and investments in infrastructure.

Local demand for copper metal (produced from refined copper and recycled scrap) is projected to advance 4.2 percent per year through 2019 to 36.0 million metric tons, valued at $261 billion. Robust gains in building construction expenditures are expected to boost the use of copper wire, tube, and other mill products in applications such as building wire and plumbing. Increased infrastructure investment, particularly in developing countries, will further benefit copper suppliers as updates to national power grids drive the production of wire and cable. In addition, advances in global manufacturing output are expected to bolster the use of copper metal in transportation equipment, industrial machinery, domestic appliances, and other durable goods.


COST ESTIMATION (US Dollars)

Plant  Capacity                                            :     8.00 MT/day                   
land & Building  (10000 Sq.Mtr)               :    US$. 13.71 Lacs
Plant & Machinery                                       :    US$. 3.63 Lacs
Working Capital for 2 Months                   :    US$. 27.57 Lacs
Total Capital Investment                            :    US$. 45.30 Lacs
Rate of Return                                             :    42%
Break Even Point                                        :    40%


INTRODUCTION    
COPPER    
TOP COUNTRIES WHERE COPPER INGOTS IS EXPORTED FROM INDIA    
PROPERTIES OF COPPER INGOT    
PHYSICAL PROPERTIES:    
CHEMICAL PROPERTIES    
ACTION OF AIR:    
ACTION OF WATER:    
ACTION OF ALKALIS:    
ACTION OF ACIDS:    
A) WITH HNO3:    
B) WITH H2SO4:    
C) WITH HCL:    
5) DISPLACEMENT REACTION:-    
USES AND APPLICATION    
USES OF COPPER:-    
APPLICATION    
B.I.S. SPECIFICATION    
PROCESS FLOW DIAGRAM    
PRODUCTION PROCESS    
(1) RAW MATERIAL    
(2) PRETREATMENT OF SCRAP    
(A) STRIPPING    
(B) BRIGUETTING    
(C) SIZE REDUCTION    
(D) CRUSHING    
(E) RESIDUE CONCENTRATION    
(F) RESIDUE PELLETIZING AND ROLL BRIQUETTING    
(G) DRYING    
(H) BURNING    
(I) SWEATING    
(3) MELTING PROCESS    
(4) SLAG TREATMENT    
(5) REFINING PROCESS    
(A) FIRE REFINING    
(B) ELECTROLYTIC REFINING    
(6) CASTING    
(7) EMISSIONS AND CONTROLS    
MARKET SURVEY    
INDUSTRY CHALLENGES    
MARKET LEADERS    
COPPER USAGE TRENDS AND ITS EFFECT ON MANUFACTURING
    AND SCRAP METAL    
TOTAL COPPER MINE PRODUCTION IN AFRICA FROM 2005 TO 2020
    (IN 1,000 METRIC TONS)*    
COPPER INDUSTRY: GLOBAL OVERVIEW    
PLANT LAYOUT    
MANUFACTURERS/SUPPLIERS OF COPPER INGOT    
SUPPLIERS OF RAW MATERIALS    
COPPER SCRAP    
SUPPLIERS OF NITRIC ACID    
HYDROCLORIC ACID    
DEGREASING CHEMICAL    
PICKLING CHEMICALS    
SULFURIC ACID    
(HCL) PICKLING ACIDS    
SUPPLIERS OF PLANT AND MACHINERIES    
SUPPLIERS OF COPPER RECYCLING PLANT    
SUPPLIERS OF INDUCTION FURNACE    
SUPPLIERS OF INGOT CASTING MACHINE    
METAL TESTING MACHINE    
PRECISION MEASURING TOOLS    
NDT INSPECTION EQUIPMENT    
ELECTRICAL MEASURING INSTRUMENTS    
EOT CRANES    
POWER TRANSFORMERS    
ELECTRICAL PANEL    
COOLING TOWER    
EFFLUENT TREATMENT PLANT    
AIR POLLUTION CONTROL EQUIPMENTS    
AIR CONDITIONING EQUIPMENTS    
AIR COMPRESSORS
WEIGHING MACHINE (PLATFORM TYPE)    
MATERIAL HANDLING EQUIPMENTS    
FIRE FIGHTING EQUIPMENTS    
SUPPLIERS OF SUBMERSIBLE WATER PUMP    

       
        
APPENDIX – A:

 1.      COST OF PLANT ECONOMICS      
 2.      LAND & BUILDING                                      
 3.      PLANT AND MACHINERY                                  
 4.      FIXED CAPITAL INVESTMENT                             
 5.      RAW MATERIAL                                         
 6.      SALARY AND WAGES                                     
 7.      UTILITIES AND OVERHEADS                              
 8.      TOTAL WORKING CAPITAL                                
 9.      COST OF PRODUCTION                                   
10.      PROFITABILITY ANALYSIS                               
11.      BREAK EVEN POINT                                     
12.      RESOURCES OF FINANCE                           
13.      INTEREST CHART                                       
14.      DEPRECIATION CHART                                   
15.      CASH FLOW STATEMENT                                   
16.      PROJECTED BALANCE SHEET