Detailed Project Report (DPR) on tmt rolling mill (cap.12000 Ton/month)

TMT ROLLING MILL
[CODE NO. 1900]


What are TMT Steel Bars:-

    The full form of TMT is Thermo Mechanical Treatment; in this the steel bars are passed through a specially designed water-cooling system. After the bars pass, the outer surface of the bars solidifies while the core remains hot. This creates a temperature gradient in the bars. After the intensive cooling, the bar is exposed to air and the core re-heats the quenched surface layer by conduction, therefore tempering the external marten site. When the bars are taken out of the cooling system, the heat flows from the core to the outer surface, further tempering of the bars, which helps them attain higher yield strength. The resulting heat-treated structure imparts superior strength and toughness to the bars. Cooling process is illustrated below:

    The pre-determined cooling of the bar periphery transforms the peripheral structure to marten site and then annealed through the heat available at the core. The peripheral and core temperature difference finally equalizes at around 600 degree C and the resultant bar structure is of tempered marten site at the periphery and of fine-grained ferritepearlite at the core. Generally speaking, the resultant soft core forms about 65-75 per cent of the area (depending upon the desired minimum yield strength) and the rest is the hardened periphery. The equalizing temperature together with the final rolling temperature is the most important parameter to achieve the required mechanical properties. Finally, when the bar is discharged on to the Cooling Beds, the remaining austenite transforms into a very fine-grained pearlite structure.

    After this process of thermo mechanical treatment, a dark etched peripheral rim of tempered marten site and a grey core of ferrite pearlite get formed. The tempered marten site surface layer is very hard while the microstructure of the core is a very fine-grained ferrite and pearlite which is quite soft. The result is a structure withigh yield strength combined with high ductility.

    Hence from the above data it is seen that the sudden quenching is the key role in hardening the steel bars. The pressure of the water jets on the hot molten bars determines the thickness of the martensite structure and is controlled for the required hardness.


COST ESTIMATION

Plant Capacity                                   480.00 MT./day
Land & Building (12000 Sq.Mtr)     Rs. 7.42  Cr  
Plant & Machinery                             Rs. 12.49 Cr     
W.C. for 2 Months                              Rs. 99.10 Cr
Total Capital Investment                  Rs. 120.00 Cr          
Rate of Return                                   42%  
Break Even Point                              40%


1.•    INTRODUCTION    
•    PROPERTIES OF TMT BARS    
•    USES AND APPLICATIONS    
•    B.I.S. SPECIFICATIONS    
•    THE FOLLOWING ARE THE VARIOUS CHEMICAL TEST DONE ON THE RAW     MATERIAL    
•    QUALITY CONTROL    
•    MARKET POSITION OF TMT STEEL BARS (SARIYA)    
•    MANUFACTURERS AND SUPPLIERS OF TMT STEEL BARS    
•    FORECASTING STEEL DEMAND AND SUPPLY IN INDIA    
•    PRESENT STATUS OF INDIAN STEEL INDUSTRY AND ITS PERFORMANCE DURING THE 11TH FIVE YEAR PLAN (2007-12)    
•    ROLLING MILL    
•    STANDARD OPERATING PRACTICES IN ROLLING MILL    
•    MANUFACTURING PROCESS    
•    PROCESS FLOW CHART    
•    SUPPLIERS OF PLANT AND EQUIPMENTS    
•    COMPLETE INDIAN SUPPLIERS OF PLANT AND MACHINERY FOR RE-BARS    
•    SUPPLIERS OF RAW MATERIALS    


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