M.S. Billet Casting from Scrap and Sponge Iron Using Induction Furnace

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M.S. BILLET CASTING FROM SCRAP AND SPONGE IRON USING INDUCTION FURNACE

[EIRI/EDPR/1433] J.C. 212

INTRODUCTION

The Project profile envisages to set up Con-cast plant for manufacturing of M.S Billet which is the main raw material of Iron & Steel finished products, e.g. T.M.T Bars, angles, channels and sections etc. used in construction activities. Con-cast plant can be simply defined as a mill that carries con-cast process in which the molten steel is poured into laddle mould to perform the gradual solidification of metal into desired forms and shapes. Swiftly, the molten metal is solidified and is drawn down the caster. This gradually gets transformed into a solid steel billet, bloom or slab.

The Induction furnace based on mini steel plant is a versatile installations where provisions are available for producing a range of steel products by Alloying and casting into various shape. The products of steel plants are in the form of Ingots, Billets, Sheets etc. These Induction furnace based steel casting units are suitable for small scale industries and medium scale industries and yet have the capability to complete in the internal as well as international market at all counts. In mini steel plant operating under Indian conditions small Billets are Cast for rolling into structural sections, Mild steel billets are manufacturing by different types of furnaces such as Blast Furnace, Electric Arc furnace, Induction Furnace, Basic oxygen furnace etc.

Billets are the basic products of steel from which different types of steel products are made such as sheets, Angles, Channels, Rods, etc. Mild steel Billets are the basic raw material for manufacturing various types of re-rolled products.

COST ESTIMATION

Plant Capacity 64 MT/Day

Land & Building (5000 sq.mt.) Rs. 3.57 Cr

Plant & Machinery Rs. 8.04 Cr

Working Capital for 2 Months Rs. 11.15 Cr

Total Capital Investment Rs. 24.00 Cr

Rate of Return 60%

Break Even Point 40%

CONTENTS

INTRODUCTION

THE AVAILABLE SIZES OF THE STEEL BILLETS ARE:-

USES AND APPLICATION

B.I.S. SPECIFICATION

MARKET POSITION

SOLUTIONS FOR PLANT OPTIMIZATION

FLEXIBLE MARKET PERFORMANCE

INDIAN STEEL INDUSTRY

STEEL MARKET IN INDIA:

COMPANIES SET FOR EXPANSION

CURRENT ECONOMIC SITUATION

OUTLOOK

PRIMARY STEEL PRODUCTION

DETAILED EXPORT DATA OF MS BILLETS

DETAILED IMPORT DATA OF MS INGOTS BILLET

MANUFACTURERS/SUPPLIERS OF M.S. BILLETS

MANUFACTURING PROCESS

BILLET MAKING PROCESS

STEEL MELTING SHOP

PROCESS FLOW

• INDUCTION FURNACE:

• WATER COOLED INDUCTION COIL:

• WATER-COOLED MAGNETIC YOKES:

• WATER COOLED CABLES:

• TILTING CYLINDERS:

• LINING FORMERS:

• OIL HYDRAULIC SYSTEM:

THIS WILL CONSIST OF FACTORY BUILT ASSEMBLY, COMPRISING OF:

GAUGE AND GAUGE SELECTOR

BILLET CASTING

MANUFACTURING PROCESS AND SOURCE OF TECHNOLOGY

SCRAP YARD

INDUCTION FURNACE

CONTINUOUS CASTING MACHINE

THE SIZES AVAILABLE IN ELECTROTHERM ARE:

BILLET YARD

ELECTROTHERM INDUCTION FURNACE MAY BE AVAILABLE AT:

SPECIFICATION OF INDUCTION FURNACE

OPERATION OF INDUCTION FURNACE

PROCESS FLOW CHART

PLANT LAYOUT

SUPPLIERS OF RAW MATERIALS

M.S. SCRAPS

PIG IRON

SPONGE IRON

PICKLING CHEMICALS

METALLURGICAL COKE

FOUNDRY FLUXES

SUPPLIERS OF PLANT AND MACHINERY

INDUCTION FURNACE

CONTINUOUS CASTING MACHINES

EOT CRANES

MATERIAL HANDLING EQUIPMENTS

MATERIAL TESTING EQUIPMENT

MEASURING INSTRUMENTS & EQUIPMENT

WORKSHOP MACHINE

EFFLUENT TREATMENT PLANT

COOLING TOWERS

DG SETS

ELECTRICAL POWER TRANSFORMER

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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