Ductile Pipe Manufacturing Plant (99663 Meters per day)

DUCTILE PIPE MANUFACTURING PLANT 

[EIRI/EDPR/4626] J.C.: 2843XL

India is one of the fastest developing economies in the world. Infrastructure lacuna has been an anathema to India's growth. Not surprisingly, India lags behind water infrastructure and sewerage development with only 33% of the total population having access to improved sanitation. In rural areas, where 72% of India's population lives, only 22% has better coverage for sanitation. The Indian pipes business has been growing rapidly since the past several years mainly due to increasing demand for pipes in the irrigation sector, for crude oil, real estate industry and growth in Gross domestic product (GDP) of the country. Among the several varieties of pipes available in the market, the demand for plastic pipes such as PVC, CPVC in particular, is on a rise due to its low cost, high quality and high durability. Other types of pipes, like steel pipes and ductile iron pipes also have major demand. Nationwide infrastructural development, urbanization, government’s focus on real estate, irrigation to drive agricultural growth have been identified as major factors facilitating the growth of the pipes industry in the country. The Government of India is launching new schemes in the irrigation and the real estate sector for significant investments. 

It is evident here that the focus of Indian government is on water supply for housing sector, which will only be fulfilled with effective use of pipelines. Therefore, this end-user is a major demand driver of pipes. Furthermore, strong demand for crude oil transportation is also adding to the demand of pipes across the country. The major grades demanded in the Indian markets is the K7 and K9 series, the governmental authorities and waste water authorities majorly demand DN 80 mm to DN 1000 mm diameter or sizes of specifications. 

COST ESTIMATION

Plant Capacity            99,663.43 Meters/Day  

Land & Building (15 Acres)    Rs. 17.87 Cr    

Plant & Machinery                    Rs. 101.55 Cr 

Working Capital for 1 Month    Rs. 241.00 Cr 

Total Capital Investment          Rs. 365.20 Cr 

Rate of Return                          95%

Break Even Point                      19%

CONTENTS

INTRODUCTION

DUCTILE IRON

FIG 1 TYPICAL MICRO STRUCTURE OF DUCTILE IRON

COMMON DUCTILE IRON GRADES

THE FAMILY OF DUCTILE IRON

PROPERTIES OF DUCTILE IRONS

BENEFITS OF DUCTILE IRON

THE FOLLOWING ARE THE BENEFITS OF DUCTILE IRON.

DUCTILE IRON PIPE

HISTORY OF DUCTILE IRON PIPES

CHARACTERISTICS OF DUCTILE IRON PIPE

TYPE OF JOINTS

THE FOLLOWING ARE THE TYPES OF JOINTS USUALLY USED FOR DUCTILE IRON PIPES

THERE ARE MAINLY THREE SECTIONS OF DUCTILE IRON PIPE:

1. SOCKET

2. BARREL

3. SPIGOT

RANGE OF PIPES

TECHNICAL DETAILS

PIPE DIMENSION

BASIC DIMENSION OF PIPES THICKNESS OF DUCTILE IRON PIPES

ADVANTAGES

ADVANTAGES OF DUCTILE IRON PIPES

DISADVANTAGES

USES AND APPLICATION

B.I.S. SPECIFICATION

PRODUCTION PROCESS

(1) RAW MATERIAL SELECTION

(2) DESULPHURISATION

(3) MELTING AND COMPOSITION CONTROL

(4) MAGNESIUM TREATMENT

NODULISING:

(5) INOCULATION

EFFECT OF INOCULATION

(7) CORE MAKING

(8) CASTING

CENTRIFUGAL CASTING

DE LAVAUD PROCESS

WET-SPRAY PROCESS

(9) INTERNAL GRINDING

(10) HEAT TREATMENT

(11) ZINC COATING

(12) CUT OFF AND CHAMFERING MACHINE

(13) HYDROSTATIC PRESSURE TESTING

(14) CEMENT MORTAR FEEDING AND LINING

(15) STEAM CURING

(17) INTERNAL POLISHING

(17) BITUMEN COATING

CROSS SECTIONAL DIAGRAM

ZINC COATING

CEMENT MORTAR LINING

BITUMINOUS COATING

RUBBER GASKET

(18) QUALITY CONTROL

QUALITY CONTROL CHECKS AT EVERY STAGE OF MANUFACTURING

(19) MARKING AND STENCILING

(20) STORAGE, PACKING AND DISPATCH

ELECTRIC INDUCTION FURNACES VERSUS CUPOLAS FOR MELTING IRON

INDUCTION FURNACE AND IMPORTANT OPERATIONAL ASPECTS

RAW MATERIALS AND ENERGY SOURCE

IMPORTANT ASPECTS OF OPERATION

OTHER ASPECTS OF INDUCTION FURNACE STEEL MAKING

FIG 1 TYPICAL HEAT BALANCE DIAGRAM OF CRUCIBLE

INDUCTION FURNACE

ENVIRONMENTAL EMISSIONS

SAFETY AND INDUCTION FURNACES

MARKET SURVEY FOR DI PIPE

DOMESTIC MANUFACTURERS OF DI PIPE

TOP MANUFACTURES OF DUCTILE IRON PIPE GLOBALLY:-

DUCTILE IRON PIPES MARKET GROWTH

DI PIPES MARKET OUTLOOK

DUCTILE IRON PIPES MARKET FORECAST FROM 2022 TO 2030

OPPORTUNITIES FOR DI PIPE MANUFACTURERS

INDIAN DI PIPE MARKET AND FOREIGN MANUFACTURERS

HOW ARE INDIAN POLICIES RAISING THE DEMAND FOR DI PIPES?

ECONOMIC GROWTH

DEMAND FOR WATER

DEMAND ANALYSIS FOR DI PIPES

THE DEMAND DRIVERS FOR PIPES IN GENERAL AND DI PIPES IN PARTICULAR ARE:

INVESTMENT IN WATER PROJECTS AND ROLE OF GOVERNMENT

BODIES

EXTERNAL AID

PLANT LAYOUT

DUCTILE IRON PIPE MANUFACTURERS

DUCTILE IRON PIPE PLANT & MACHINERY MANUFACTURERS

SUPPLIERS OF RAW MATERIALS

SUPPLIERS OF PIG IRON

SUPPLIERS OF CAST IRON SCRAP

SUPPLIERS OF STEEL SCRAPE

SUPPLIERS OF SILICON CARBIDE

SUPPLIERS OF FERRO SILICON

SUPPLIERS OF MAGNESIUM INGOT

SUPPLIERS OF FERRO MANGANESE

SUPPLIERS OF FIRE CLAY

SUPPLIERS OF BENTONITE

SUPPLIERS OF COAL DUST

SUPPLIERS OF GRAPHITE POWDER

SUPPLIERS OF SILICA SAND

SUPPLIERS OF LIME STONE

SUPPLIERS OF PLANT AND MACHINERY

SUPPLIERS OF ANNEALING FURNACE

SUPPLIERS OF HEATREATMENT FURNACE

SUPPLIERS OF INDUCTION FURNACE

SUPPLIERS OF ALUMINIUM PATTERNS

SUPPLIERS OF INTENSIVE SAND MIXTURE AND MULLER

SUPPLIERS OF SAND SIEVING MACHINE

SUPPLIERS OF SQUEEZE MOLDING MACHINE

SUPPLIERS OF SHAKEOUT MACHINE

SUPPLIERS OF CORE SHOOTER MACHINE

SUPPLIERS OF DRYING OVEN

SUPPLIERS OF FOUNDRY TOOLS

SUPPLIERS OF MOLDING BOXES

SUPPLIERS OF METAL TESTING MACHINE

SUPPLIERS OF PRECISION MEASURING TOOLS

SUPPLIERS OF PRECISION MEASURING TOOLS

SUPPLIERS OF NDT INSPECTION EQUIPMENT

SUPPLIERS OF DRILLING, LATHE, TAPING MACHINES

SUPPLIERS OF GRINDING MACHINE

SUPPLIERS OF EOT CRANE

SUPPLIERS OF POWER TRANSFORMERS

SUPPLIERS OF ELECTRICAL PANEL

SUPPLIERS OF ELECTRIC MOTOR

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 SHOT BLASTING MACHINE

SUPPLIERS OF JIGS AND FIXTURE

PRINCIPLES OF PLANT LAYOUT

STORAGE LAYOUT:

EQUIPMENT LAYOUT:

SAFETY:

PLANT EXPANSION:

FLOOR SPACE:

UTILITIES SERVICING:

BUILDING:

MATERIAL-HANDLING EQUIPMENT:

RAILROADS AND ROADS:

PLANT LOCATION FACTORS

PRIMARY FACTORS

1. RAW-MATERIAL SUPPLY:

2. MARKETS:

3. POWER AND FUEL SUPPLY:

4. WATER SUPPLY:

5. CLIMATE:

SPECIFIC FACTORS

6. TRANSPORTATION:

A. AVAILABILITY OF VARIOUS SERVICES AND PROJECTED RATES

7. WASTE DISPOSAL:

8. LABOR:

9. REGULATORY LAWS:

10. TAXES:

11. SITE CHARACTERISTICS:

12. COMMUNITY FACTORS:

13. VULNERABILITY TO WARTIME ATTACK:

14. FLOOD AND FIRE CONTROL:

EXPLANATION OF TERMS USED IN THE PROJECT REPORT

1. DEPRECIATION:

2. FIXED ASSETS:

3. WORKING CAPITAL:

4. BREAK-EVEN POINT:

5. OTHER FIXED EXPENSES:

6. MARGIN MONEY:

7. TERM LOANS:

8. TOTAL LOAD:

9. LAND AREA/MAN POWER RATIO:

STATUTORY APPROVALS FROM GOVERNMENT

DOCUMENTS REQUIRED FOR LICENSES

LIST OF DOCUMENTS:

SWOL ANALYSIS

STRENGTHS

OPPORTUNITIES

WEAKNESS

LIMITATIONS

ORGANIZATION CHART

IMPLEMENTATION SCHEDULE

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)