Detailed Project Report on copper scrap recycling
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COPPER SCRAP RECYCLING
[CODE NO.3805]
Copper is an important non-ferrous metal used in various forms for different applications. Copper being a major industrial metal, ranks third after iron and aluminium in terms of quantity consumed. Copper is a reddish malleable and ductile metal valued for its excellent thermal and electrical conducting qualities and resistance to corrosion. Copper combines with a number of elements to form a wide variety of copper minerals and ores.
Copper ingots are generally required by the Non-ferrous casting units which are engaged in the casting of different engineering components of brass, gun metal, bronze etc., the agricultural machinery, automobile industries and railway components. These ingots are also required for manufacturing of rods, tubes, strips, wires etc. The copper ingots manufactured from copper scrap are generally known as commercial quality ingots & do not come under the group of electrolytic copper as these are secondary quality ingots.
Copper is one of the oldest metals ever used and has been one of the important materials in the development of civilization. Copper is an important non-ferrous base metal having wide industrial applications. Today it has become a major industrial metal, ranking 3rd after iron and aluminum in terms of quantities consumed.
Copper today is a 8 billion US dollar industry in India having created 50,000 direct and indirect jobs and growing at a CAGR 5-7% per annum. India has a huge growth potential in copper consumption for the next 20-25 years as the government increases focus on smart cities, rapid urbanization and investments in infrastructure.
Global demand for copper metal (produced from refined copper and recycled scrap) is projected to advance 4.2 percent per year through 2019 to 36.0 million metric tons, valued at $261 billion. Robust gains in building construction expenditures are expected to boost the use of copper wire, tube, and other mill products in applications such as building wire and plumbing. Increased infrastructure investment, particularly in developing countries, will further benefit copper suppliers as updates to national power grids drive the production of wire and cable. In addition, advances in global manufacturing output are expected to bolster the use of copper metal in transportation equipment, industrial machinery, domestic appliances, and other durable goods.
Copper
Demand : Past and Future
Year (In '000 Metric Tonne)
1990-91 135
2000-01 288
2001-02 315
2002-03 397
2003-04 415
2004-05 438
2005-06 486
2006-07 545
2007-08 616
2008-09 702
2009-10 810
2010-11 895
2011-12 970
2012-13 1035
2013-14 1110
2014-15 1185
2015-16 1260
2016-17 1375
2017-18 1450
2018-19 1590
2019-20 1725
2024-25 2560
Copper and copper products are widely used in fields of electric power, electronic, energy and petro chemistry, machinery and metallurgy, transportation, light industry and emerging industry. It ranks the second in China’s non-ferrous metal consumption only second to aluminum.
Top countries where Copper Ingots is exported from India
Country Value
Germany 36.01
United Arab Emirates 31.29
Netherlands 22.27
France 20.81
Japan 19.06
Thailand 17.14
Malaysia 17.07
Denmark 14.74
COST ESTIMATION
Plant Capacity 40 MT/Day
Land & Building (20,000 sq.mt.) Rented
Plant & Machinery Rs. 5.57 Cr
Working Capital for 2 Months Rs. 94 Cr
Total Capital Investment Rs. 106.91 Cr
Rate of Return 86%
Break Even Point 24%
- INTRODUCTION
- COPPER
- TOP COUNTRIES WHERE COPPER INGOTS IS EXPORTED FROM INDIA
- PROPERTIES OF COPPER INGOT
- PHYSICAL PROPERTIES:
- CHEMICAL PROPERTIES
- ACTION OF AIR:
- ACTION OF WATER:
- ACTION OF ALKALIS:
- ACTION OF ACIDS:
- DISPLACEMENT REACTION:-
- USES AND APPLICATION
- USES OF COPPER:-
- APPLICATION
- B.I.S. SPECIFICATION
- PROCESS FLOW DIAGRAM
- PRODUCTION PROCESS
- (1) RAW MATERIAL
- (2) PRETREATMENT OF SCRAP
- (A) STRIPPING
- (B) BRIGUETTING
- (C) SIZE REDUCTION
- (D) CRUSHING
- (E) RESIDUE CONCENTRATION
- (F) RESIDUE PELLETIZING AND ROLL BRIQUETTING
- (G) DRYING
- (H) BURNING
- (I) SWEATING
- (3) MELTING PROCESS
- OPERATING PRINCIPLE
- TYPES OF INDUCTION FURNACE
- BEST OPERATING PRACTICES FOR INDUCTION FURNACE
- FURNACE LINING PREPARATION
- PREPARATION OF RAW MATERIAL
- SCRAP CHARGING
- POWER INPUT
- DE-SLAGGING AND SAMPLING
- (4) SLAG TREATMENT
- (5) REFINING PROCESS
- (A) FIRE REFINING
- (B) ELECTROLYTIC REFINING
- (6) CASTING
- (7) EMISSIONS AND CONTROLS
- (A) SCRAP PRETREATMENT EMISSIONS
- (B) SMELTING/REFINING EMISSIONS
- SUMMARY FOR ENVIRONMENT MANAGEMENT
- AIR ENVIRONMENT
- WATER ENVIRONMENT
- SOLID WASTE MANAGEMENT
- NOISE ENVIRONMENT
- ENVIRONMENTAL MONITORING PROGRAM
- (8) QUALITY CONTROL
- PLANT AND MACHINERY FOR ENVIRONMENT MANAGEMENT
- CONTROL TECNIQUES FOR AIR POLLUTION
- (1) GRAVITATIONAL SETLING CHAMBER
- (2) CYCLONE SEPARATORS
- (3) FABRIC FILTERS
- (4) ELECTRO STATIC PRECIPITATORS
- E. WET COLLECTORS OR SCRUBBERS
- (5) WET SCRUBBERS
- CONTROL OF WATER POLLUTION
- MARKET POSITION
- MARKET OPPORTUNITIES FOR COPPER
- MAJOR END USE SECTORS
- ESTIMATED SECTORWISE COPPER CONSUMPTION IN INDIA
- GROWTH OF METAL INDUSTRY DEPENDS ON
- COPPER ORE AVAILABILITY
- ACHIVEMENTS OF FABRICATING INDUSTRIES
- ADOPTION OF LATEST TECHNOLOGIES —
- IMPROVED QUALITY ASSURANCE THROUGH
- MARKET GROWTH OPPORTUNITIES
- KEY DRIVERS FOR DEMAND GROWTH
- EXISTING MARTKET - WITH HIGH GROWTH POTENTIAL
- ELECTRICAL
- ELECTRICITY CONSUMPTION PER CAPITA (KWH/YEAR)
- ELECTRICAL
- TRANSPORT
- RELATIVELY NEW MARKET
- FUTURE POSSIBILITIES
- EXPORT STATUS
- COPPER MARKET OUTLOOK:
- KEY DEVELOPMENTS SINCE THE LAST ‘COPPER TO THE WORLDCONFERENCE’
- SHORTAGES STILL EXPECTED BUT SIZE OF DEFICITS REDUCED AND TRANSITION INTO DEFICIT DELAYED
- CHINA’S ECONOMIC TRANSITION IS UNDERWAY BUT SOME GROWTH IS STILL EXPECTED
- TOTAL CHINESE COPPER DEMAND BY END-USE (INCLUDING SCRAP), 2017 VS 2022, '000 TONNES
- AS CHINESE GROWTH SLOWS, THE REST OF THE WORLD STARTS TO PICK-UP
- GROWTH IN WORLD REFINED COPPER CONSUMPTION AND VOLUME GROWTH IN SELECTED 5-YEAR PERIODS
- LONGER TERM, ELECTRIC VEHICLES WILL PROVIDE SIGNIFICANT BOOST TO COPPER DEMAND
- GLOBAL DEMAND GROWTH HAS BEEN UPGRADED MAINLY ON EV STORY
- WORLD REFINED COPPER CONSUMPTION FORECASTS MADE IN 2017 AND IN 2018, INDEX 2014=100
- STRUCTURE OF PRESENTATION
- GROWTH IN GLOBAL MINE OUTPUT IS TAPERING OFF
- GLOBAL MINE PRODUCTION; ‘000T OF CONTAINED COPPER
- RESERVE EXHAUSTION REMAINS AN ISSUE: MANY KEY MINES TOCEASE PRODUCTION IN COMING YEARS
- PEAK ANNUAL COPPER PRODUCTION (‘000T) VS EXPECTED END OF LIFE (YEAR)
- PIPELINE OF LARGE PROJECTS REMAINS THIN…
- PROJECTS THAT HAVE RECENTLY STARTED-UP OR ARE DUE TO START-UP, LOM CAPACITY >100,000T/Y, ’000T
- …BUT SEVERAL SMALLER PROJECTS, MANY WITH CHINESE BACKING, HAVE BEEN GIVEN THE GREEN LIGHT
- COPPER MINE PROJECTS 2017-2022 WITH CAPACITY OF >=50,000T/Y AND <100,000; LOM COPPER PRODUCTION CAPACITY; ’000T
- PLENTY MORE INVESTMENT NEEDED: ALMOST ALL UNCOMMITTED PROJECTS ARE REQUIRED BY 2035
- FORECAST COMMITTED COPPER MINE PRODUCTION AND POTENTIAL FROM UNCOMMITTED PROJECTS*
- MOST POTENTIAL PRODUCTION IS LOCATED IN SOUTH AMERICA, ESPECIALLY CHILE…
- MINE PROJECTS BY REGION AND STATUS AND WITH START-UP DATES OF BETWEEN NOW AND 2035
- ROBUST MARGINS SHOULD ASSIST NEW PROJECT DEVELOPMENT
- PRODUCER MARGINS AT 90TH AND 50TH CENTILES OF NET OF BY-PRODUCT CASH COST
- PRICES WILL MOVE HIGHER BUT RISK OF SUBSTITUTION EXISTS
- CONCLUSIONS
- PLANT LAYOUT
- PRESENT MANUFACTURERS/SUPPLIERS OF COPPER INGOT
- SUPPLIERS OF RAW MATERIALS
- SUPPLIERS OF COPPER SCRAP
- SUPPLIERS OF NITRIC ACID
- SUPPLIERS OF HYDROCLORIC ACID
- SUPPLIERS OF DEGREASING CHEMICAL
- SUPPLIERS OF PICKLING CHEMICALS
- SUPPLIERS OF SULFURIC ACID
- SUPPLIERS OF (HCL) PICKLING ACIDS
- SUPPLIERS OF PLANT AND MACHINERY
- SUPPLIERS OF COPPER RECYCLING PLANT
- SUPPLIERS OF INDUCTION FURNACE
- SUPPLIERS OF INGOT CASTING MACHINE
- SUPPLIERS OF METAL TESTING MACHINE
- SUPPLIERS OF PRECISION MEASURING TOOLS
- SUPPLIERS OF NDT INSPECTION EQUIPMENT
- SUPPLIERS OF ELECTRICAL MEASURING INSTRUMENTS
- SUPPLIERS OF EOT CRANES
- SUPPLIERS OF POWER TRANSFORMERS
- SUPPLIERS OF ELECTRICAL PANEL
- SUPPLIERS OF COOLING TOWER
- SUPPLIERS OF EFFULENT TREATMENT PLANT (ETP PLANT)
- SUPPLIERS OF AIR POLLUTION CONTROL EQUIPMENTS
- SUPPLIERS OF AIR CONDITIONING EQUIPMENTS
- SUPPLIERS OF AIR COMPRESSORS
- SUPPLIERS OF PLATFORM WEIGHING MACHINE
- SUPPLIERS OF MATERIAL HANDLING EQUIPMENTS
- SUPPLIERS OF FIRE FIGHTING EQUIPMENTS
- SUPPLIERS OF SUBMERSIBLE WATER PUMP
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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