Industry Overview
High Carbon Ferrochrome (HC Fe-Cr) and Charge Chrome are produced through a high-temperature smelting process in stationary and semi-closed top Submerged Electric Arc Furnaces (SAF). The process involves the reduction of chrome ore using carbon-based reductants such as coke, while gangue materials are removed through the addition of suitable fluxes. Raw materials including chrome ore, coke, and fluxes are carefully selected and analyzed to achieve the required product quality and customer specifications.
The furnace receives the prepared charge mix through a computerized batching system. Electrical energy supplied through electrodes generates the heat required for smelting, converting chrome ore into ferrochrome with carbon acting as the reducing agent. During smelting, slag is formed from gangue materials, and its composition and fluidity are controlled through flux addition.
Hot metal and slag are tapped at regular intervals based on power consumption. The slag undergoes granulation, while the metal is processed through decantation and skimming before casting. After cooling, the ferrochrome is manually handled into different size fractions according to customer requirements. The continuous production process includes regular charging, tapping, and stage-wise inspection to ensure consistent quality of the final product.
Cost Estimation
| Particulars | Details |
|---|---|
| Plant Capacity | 70 MT/Day |
| Land & Building (1,01,170 sq.mt.) | US$ 19.85 Lac |
| Plant & Machinery | US$ 42.00 Lac |
| Working Capital for 2 Months | US$ 45.23 Lac |
| Total Capital Investment | US$ 1.10 Cr |
| Rate of Return | 79% |
| Break Even Point | 37% |
Content Index
- INTRODUCTION
- DEMAND – SUPPLY GAP
- PROJECT BACKGROUND
- PLANT RATING AND CAPACITY
- CHROME ORE
- RAW MATERIAL REQUIREMENT
- WATER
- POWER SUPPLY CONNECTIVITY
- ENVIRONMENTAL ASPECTS
- SOLID WASTE GENERATION
- SOLID WASTE MANAGEMENT
- LIQUID EFFLUENT/WATER POLLUTION MANAGEMENT
- ENERGY CONSERVATION
- IDENTIFICATION OF THE PROJECT & PROJECT PROPONENT
- PROJECT
- A. SMELTER:
- B. BRIQUETTING PLANT:
- NEED FOR THE PROJECT AND IT’S IMPORTANCE TO THE COUNTRY
- PROJECT DESCRIPTION WITH PROCESS DETAILS
- RAW MATERIALS REQUIRED ALONG WITH ESTIMATED QUANTITY, LIKELY SOURCE, MARKETING AREA OF FINANCIAL PRODUCT/S, MODE OF TRANSPORT OF RAW MATERIAL AND FINISHED PRODUCT
- ANNUAL REQUIREMENTS OF MAJOR RAW MATERIALS
- BRIQUETTING PLANT
- DESIGN BASIS
- PROCESS DESCRIPTION
- SMELTER
- SMELTING OF HC FE-CR FERRO-ALLOY
- PROCESS REACTIONS
- PRODUCTION PROCESS
- HIGH CARBON FERROCHROME: – SPECIFICATIONS
- USES AND APPLICATION
- AGGLOMERATION – BRIQUETTING PROCESS
- METAL RECOVERY PLANT (MRP)
- MARKET OVERVIEW
- KEY MARKET INSIGHTS
- GLOBAL FERROCHROME MARKET SEGMENT ANALYSIS:
- GLOBAL FERROCHROME MARKET REGIONAL INSIGHTS:
- GLOBAL FERROCHROME MARKET KEY PLAYER
- DRIVING FACTORS
- RESTRAINING FACTORS
- SEGMENTATION
- REGIONAL INSIGHTS
- KEY INDUSTRY PLAYERS
- KEY INDUSTRY DEVELOPMENTS:
- PRESENT MANUFACTURERS
- RAW MATERIAL SUPPLIERS
- SELECTION OF SITE & LOCATION OF PLANT
- ENVIRONEMENTAL MANAGEMENT PLAN
- POLLUTION CONTROL MEASURES
- SPECIFICATIONS/DESIGN DETAILS OF THE SUBMERGED ARC FURNACES (SAF)
- PLANT LAYOUT
- SUPPLIERS OF PLANT AND MACHINERY
- PRINCIPLES OF PLANT LAYOUT
- PLANT LOCATION FACTORS
- AMENITIES & FACILITIES
- STATUTORY APPROVALS FROM GOVERNMENT
- DOCUMENTS REQUIRED FOR LICENSES
- SWOL ANALYSIS
- ORGANIZATION CHART
- PROJECT CONSULTANT
- IMPLEMENTATION SCHEDULE
Appendix
- 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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