FERRO SILICON
[EIRI/EDPR/4385] J.C.: 2579NU, 2580INR
INTRODUCTION
Ferrosilicon is an alloy of iron and silicon with typical silicon content by weight of 15–90%. It contains a high proportion of iron silicides. Ferrosilicon containing silicon is used extensively by the iron and steel industry, and silicon is present in most commercial grades of steel and cast iron.
Ferroalloys Plays major role in Steel Production and industrial development. Ferro-alloys are iron based alloys with varied elements introduced in steel making to cater to the specific needs. These are specified additions to the production of steel for various applications.
Ferro alloys are iron bearing alloys with additives which are passed on to steel to meet specific needs. The Ferro alloys are brittle and can be crushed to any size to be added to the molten steel as additives. Generally the additives as in steel are invariably added in the form of Ferro alloys. These are established additives in the steel production to obtain specific needs.
The market for ferrosilicon is largely in steel (85%) and cast iron (15%), with very small amounts used in non-ferrous alloys.
The demand for ferrosilicon has been increasing with that of alloy and special steels. Owing to the lack of a viable alternative that can meet the diverse applications, the global ferro alloys market is estimated to expand at an CAGR of 5.9% till 2025. A significant share of the bulk ferro alloys are used in the production of the steel because of the low prices of the bulk ferro alloys and high production around the major producing regions. The prosperity of the building and construction industry in a number of emerging economies is another key driver of the global ferro alloys market, wherein the development of lightweight and high strength steel grades is expected to open up opportunities.
COST ESTIMATION
Plant Capacity 40 MT/Day
Land & Building (22,405 sq.mt.) Rs. 19.04 Cr
Plant & Machinery Rs. 7.03 Cr
Working Capital for 1 Month Rs. 7.84 Cr
Total Capital Investment Rs. 34.52 Cr
Rate of Return 84%
Break Even Point 45%
CONTENTS
INTRODUCTION
MARKET OVERVIEW
GLOBAL
HIGH DEMAND FOR STEEL IN AUTOMOTIVE, CONSTRUCTION, AND MANUFACTURING INDUSTRIES TO DRIVE MARKET
BURGEONING GROWTH OF AUTOMOBILE AND CONSTRUCTION INDUSTRIES TO BOOST FERROSILICON MARKET
INCREASE IN USAGE OF ALLOY STEEL AND CAST IRON IN AUTOMOBILE AND CONSTRUCTION INDUSTRIES TO AUGMENT MARKET
REGIONAL OUTLOOK OF GLOBAL FERROSILICON MARKET
ANALYSIS OF KEY PLAYERS IN FERROSILICON MARKET
KEY DEVELOPMENTS IN GLOBAL FERROSILICON MARKET
BHUTAN
USES/APPLICATIONS
THE FOLLOWING ARE THE COMMON APPLICATION AREAS OF FERROSILICON:
SPECIFICATIONS
PROPERTIES
FERROSILICON MSDS
HEALTH HAZARDS
FIRST AID MEASURES
PERSONAL PROTECTION
ACCIDENTAL RELEASE MEASURES
FIRE HAZARDS
HANDLING OF FERROSILICON
STORAGE OF FERROSILICON
RAW MATERIALS
PROCESS CHEMISTRY & OPERATING CONSIDERATIONS
EQUILIBRIUM OF THE IRON SILICON SYSTEM
SEGREGATION IN ALLOYS AND DISINTEGRATION OF ALLOYS
PHYSICO-CHEMICAL CONSIDERATIONS IN FERRO-SILICON SMELTING
FORMATION OF SLAG DURING SMELTING
SHORTAGE OF REDUCER IN THE CHARGE MIX ALSO LEADS TO MORE AMOUNT OF SLAG
THE MAIN REDUCTION REACTIONS DURING THE SMELTING PROCESS ARE
FOR NORMAL GRADE OF FERRO-SILICON, THE REDUCED OXIDES ARE DISTRIBUTED BETWEEN METAL AND STACK LOSSES AS FOLLOWS:
OPERATING CONSIDERATIONS
MANUFACTURING PROCESS STEPS
PROCESS FLOW
ENGINEERING DESIGN CONSIDERATIONS
PLANT/MACHINERY (BROADLY)
PLANT & MACHINERY SUPPLIERS (INDIA)
ELECTRIC ARC FURNACE
INDUCTION FURNACE
STEAM TURBINES
ELECTRICAL & POWER TRANSFORMERS
ELECTRICAL CONTROL PANELS & DISTRIBUTION BOARDS
COOLING TOWERS
EFFLUENT TREATMENT PLANT
INDUSTRIAL WEIGHING SCALE
STEEL FABRICATORS
SUPPLIERS OF RAW MATERIALS
PRINCIPLES OF PLANT LAYOUT
MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE:
PLANT LOCATION FACTORS
PRIMARY FACTORS
RAW-MATERIAL SUPPLY:
MARKETS:
POWER AND FUEL SUPPLY:
WATER SUPPLY:
CLIMATE:
TRANSPORTATION:
WASTE DISPOSAL:
LABOR:
REGULATORY LAWS:
TAXES:
SITE CHARACTERISTICS:
COMMUNITY FACTORS:
FLOOD AND FIRE CONTROL:
GENERATION & MANAGEMENT OF WASTES/GREEN BELT
WASTE WATER (ESTIMATED)
WASTE (ESTIMATED)
SEWAGE AND WASTE TREATMENT FACILITY
HEALTH SAFETY AND ENVIRONMENT
ANTICIPATED ENVIRONMENTAL IMPACTS
CONSTRUCTION PHASE
OPERATION PHASE
MITIGATION MEASURES (PROPOSED)
HSE REQUIREMENT
PROPOSED IMPLEMENTATION SCHEDULE
PROJECT FINANCIALS
BASIS & PRESUMPTIONS (FOR PROFITABILITY WORKINGS)
PRELIMINARY PLANT LAYOUT
CONCLUSIONS
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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