Detailed Project Report on Sponge Iron from Pig Iron

SPONGE IRON FROM PIG IRON

EIRI/EDPR/0299] (J.C.:7839)

INTRODUCTION

Sponge iron a finely divided porous form of iron made by reducing an iron oxide at such low temperatures that melting does not occur, usually by mixing iro0n oxide and coke and applying limited increase in temperature.

In blast furnace, the irons are is reduced and melted to yield liquid iron. Other additives and reactants are in corporated and the melt is refined to achieve the required composition of resulting pig iron for use in steel making or foundries. For large tonuage production, blast furnace pig iron is quite suitable but for small tonuage production, direct reduction of are into solid spongy substance, having 92 to 95% iron content is more economical.

The state of a country's iron and steel industry provides an index of its industrial progress. A universally accepted yardstick for measuring a country's level of economic development is its per capita Consumption of steel. Judged by the Yardstick, the depressing fact remains that India is among the countries with the lowest per capita consumption of steel in the world with only 14 Kg Developed countries such as Sweedon, West Germany, Japan and U.S.A. have high per capita consumption figures.

The history of iron & steel making in India goes back to over 2,500 years, making India of the earliest uses of iron and steel in the world. In anevent times, India has attained a remarkably high degree of skill in iron smelting and the making of iron products.

COST ESTIMATION

Plant Capacity            450 MT/Day

Land & Building (10 Acres)    Rs. 4.46 Cr

Plant & Machinery                    Rs. 5.15 Cr

Working Capital for 2 Months    Rs. 33.18 Cr

Total Capital Investment          Rs. 93.55 Cr

Rate of Return                          35%

Break Even Point                      46%

CONTENTS

INTRODUCTION                                      

PROPERTIES OF SPONGE IRON                           

PIG IRON                                          

ANALYSIS OF PIG IRON                               

SPECIFICATIONS OF PIG IRON USED IN DIFFERENT INDUSTRIES SPONGE IRON FROM PIG IRON                         

PROPERTIES & CHARACTERISTICS OF PIG IRON           

EFFECTS OF SPONGE IRON ON EAF OPERATION            

EFFECTS OF SPONGE IRON ON EAF ECONOMICS             

USES & APPLICATIONS OF SPONGE IRON                 

B.I.S. SPECIFICATIONS                                

MARKET SURVEY                                      

PRESENT MANUFACTURERS OF SPONGE IRON              

PROCESS OF MANUFACTURE OF SPONG IRON FROM PIG IRON

PRODUCT OF BLAST FURNACE (PIG IRON)               

PROCESS FLOW DIAGRAM FOR THE MANUFACTURE OF SPONGE IRON FROM PIG IRON                        

PLANT LAYOUT                                                   

PRINCIPLES OF PLANT LAYOUT                                 

PLANT LOCATION FACTORS                                       

EXPLANATION OF TERMS USED IN THE PROJECT REPORT       

ADDRESSES OF PLANT & MACHINERY SUPPLIERS              

ADDRESSES OF RAW MATERIAL SUPPLIERS (PIG IRON)            

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)