Detailed Project Report (DPR) on oxygen lancing tube (pipe)

OXYGEN LANCING TUBE (PIPE)
[CODE NO. 3240]  


Oxygen is used in the manufacture of metals like steel, copper and zinc. Chlorine is used in the manufacture of Aluminum. These gases react with the undesirable impurities and form their respective oxide or chlorides. These oxides or chlorides then float to the surface of the molten metal and are removed.

To transfer these gases to the molten metal, a pipe is needed. This pipe is the lancing pipe and the process of injecting gases into molten metal is known as lancing.

Traditionally an ordinary pipe has been used. The material of construction is low carbon steel (Mild Steel), electrically resistance welded (ERW) in the shape of a pipe. Since the molten is steel or copper or zinc, and the pipe is of mild steel, the pipe melts into molten metal, at the end which is dipped into it. Besides because of high temperature of the molten metal, the pipe also gets oxidized and melts faster into the molten metal. Hence the pipe gets consumed and has to be replaced.

Generally large furnaces are non Tilting in Type and use bottom pouring method to take out the Molten Metal through the Tap Hole. When the Tap hole needs to be opened the same is done with the help of a High Frequency Induction Welded Low Carbon Mild Steel Tube which can sustain 750 PSI Pressure without leaking of Suitable Size 8mm NB,15mm NB or even 25mm NB in certain Cases. Oxygen at high pressure is injected through these tubes into the Tap Hole and the molten metal starts flowing. Depending on the type of Ferro alloy or Steel Plant or Copper or Zinc Smelter the Consumption of the Pipe is determined. These lancing pipes are basically used to open the Tap holes of Bottom Pouring Furnaces.


COST ESTIMATION

Plant  Capacity                                                    :       15.00 Ton/day     
land & Building (1500 Sq.Mtr)                          :        Rs. 1.22 Cr
Plant & Machinery                                               :        Rs. 1.12 Cr
Working Capital for 2 Months                           :        Rs  2.29 Cr
Total Capital Investment                                    :        Rs. 6.96 Cr
Rate of Return                                                     :        36%
Break Even Point                                                 :        50%


INTRODUCTION    
TYPES OF LANCING PIPES    
MS PLAIN LANCING PIPES    
SIZES    
TOLERANCES ON THICKNESS AND MASS    
CERAMIC COATED OXYGEN LANCING PIPE    
ADVANTAGES    
LOWER DOWN TIME    
THIS SAVING OF 450 HRS/YEARS GIVES THE FOLLOWING    
CONSTRUCTION OF PLAIN CERAMIC COATED PIPES.    
USES AND APPLICATION    
B.I.S. SPECIFICATION    
PROCESS FLOW CHART    
MANUFCTURING PROCESS    
MAIN STEPS ARE GIVEN BELOW    
1. UNCOILED, LAVELED AND WELDING OF STRIP    
2. STRIPPING    
3. LOOPING    
4. EDGE TRIMMING    
5. FORMING    
6. WELDING    
7. BEAD TRIMMING    
8. SIZING    
9. CUTTING    
10. NORMALISING    
11. END FACING AND THREADING    
12. TESTING    
ULTRASONIC TESTING    
EDDY-CURRENT TESTING    
MAGNETIC PARTICLE TESTING    
RADIOGRAPHIC (X-RAY) TESTING    
DYE-PENETRANT TEST    
HYDRAULIC TEST    
BEND TEST ON PIPES    
MARKING    
PACKING    
PLANT AND MACHINERY    
1. DUAL DE-COILER:    
2. SHEAR AND WELDER:    
3. SPIRAL STRIP ACCUMULATOR:    
4. STRIP GUIDING UNIT:    
5. FORMING MACHINE (TUBE MILL):
6. SEAM GUIDE UNIT:    
7. WELDING STAND:    
8. DOUBLE DE BURRING UNIT:    
9. COOLING LINE:    
10. SIZING MACHINE:    
MANUFACTURERS/SUPPLIERS OF OXYGEN LANING PIPE    
MARKET SURVEY    
INDIA STEEL PRODUCTION    
INDIA STEEL PRODUCTION NOTES    
INDIA STEEL PRODUCTION FORECAST 2016-2020    
COMPARE EMBED    
DETAILED EXPORT DATA OF LANCING PIPE SIZE    
TOTAL VALUE & VOLUME OF EXPORTS IN INDIA    
TOP SUPPLIERS    
TOP PORTS OF DISCHARGE    
DETAILED IMPORT DATA OF LANCING PIPE    
TOTAL VALUE & VOLUME OF IMPORTS IN INDIA    
TOP SUPPLIERS    
TOP PORTS OF DISCHARGE    
AN OVERVIEW OF STEEL SECTOR    
GLOBAL SCENARIO    
DOMESTIC SCENARIO    
PRODUCTION    
DEMAND - AVAILABILITY    
STEEL PRICES    
IMPORTS    
EXPORTS    
LEVIES ON IRON & STEEL    
SDF LEVY    
OPPORTUNITIES FOR GROWTH OF IRON    
AND STEEL IN PRIVATE SECTOR    
THE NEW INDUSTRIAL POLICY REGIME    
THE GROWTH PROFILE    
PRINCIPLES OF PLANT LAYOUT    
MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE:    
PLANT LOCATION FACTORS    
PRIMARY FACTORS    
SPECIFIC FACTORS    
EXPLANATION OF TERMS USED IN THE PROJECT REPORT    
PROJECT IMPLEMEATION SCHEDULES    
INTRODUCTION    
PROJECT HANDLING    
PROJECT SCHEDULING    
PROJECT CONSTRUCTION SCHEDULE    
TIME SCHEDULE    
PLANT LAYOUT    
SUPPLIERS OF MACHINERY (COMPLETE PLANT)    
SUPPLIERS OF HIGH FREQUENCY INDUCTION WELDER    
SUPPLIERS OF EOT CRANE    87
SUPPLIERS OF POWER TRANSFORMER    
SUPPLIERS OF ELECTRICAL PANEL    
SUPPLIERS OF COOLING TOWER    
SUPPLIERS OF RAW MATERIALS    
M.S STRIP COILS    98
PACKING MATERIALS    
PICKLING CHEMICALS    
RESSISTANCE WELDING ELECTRODE    
                           
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