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    Ferro Alloy with 6 MVA Furnace capacity (Silicon Manganese) (Production Capacity: 30 MT/Day)

    Ferro Alloy with 6 MVA Furnace capacity (Silicon Manganese) (Production Capacity: 30 MT/Day)
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    Ferro Alloy with 6 MVA Furnace capacity (Silicon Manganese) (Production Capacity: 30 MT/Day)
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      FERRO ALLOY with 6 MVA Furnace capacity (SILICON MANGANESE) (PRODUCTION CAPACITY: 30 MT/DAY)

      [EIRI/EDPR/4739] J.C.: 2959XL


      INTRODUCTION

      Silico manganese is a alloy of manganese silicon and Iron with small percentage of carbon and several elements. The silico Manganese have an important influence on the properties of steel depending on the amount added and the combined effect with other alloying metal. It has a strong affinity for oxygen and act as deoxidizer and play an important role in the manufacturing of steel as deoxidizing, desulphuring and alloying agents silico manganese is used as alloying elements in manufacturing of spraying steel, transformer steel and other type of alloy steels.

      Silico manganese is a metallic ferroalloy composed principally of manganese, silicon, and iron.  It is produced in a number of grades and sizes and is consumed in bulk form primarily in the production of steel as a source of both silicon and manganese, although some silicomanganese is used as an alloying agent in the production of iron castings.  Manganese, intentionally present in nearly all steels, is used as a steel desulfurizer and deoxidizer.  By removing sulfur from steel, manganese prevents the steel from becoming brittle during the hot rolling process.  In addition, manganese increases the strength and hardness of steel.  Silicon is a deoxidizer, aiding in making steels of uniform chemistry and mechanical properties.  As such, it is not retained in the steel, but forms silicon oxide, which separates from the steel as a component of the slag.  Silicomanganese generally contains 65 to 68 percent manganese and about 17 percent silicon

      Silico-manganese (Si-Mn) is a metallic ferro alloy which is being used to add both silicon (Si) and manganese (Mn) as ladle addition during steelmaking. Because of its lower carbon (C) content, it is a preferred ladle addition material during making of low carbon steels.

      Si-Mn is a ferroalloy composed principally of Mn, Si, and Fe (iron), and normally contains much smaller proportions of minor elements, such as C, phosphorus (P), and sulphur (S). The ferroalloy is also sometimes referred to as ferro-silicon-manganese.

      Both Mn and Si play an important role in the manufacturing of steel as deoxidizing, desulphurizing, and alloying agents. Si is the primary and more powerful deoxidizer. Mn is a milder deoxidizer than Si but enhances the effectiveness of the latter due to the formation of stable manganese silicates and aluminates. It also serves as desulphurizer. Mn is used as an alloying element in almost all types of steel. Of particular interest is its modifying effect on the iron-carbon (Fe-C) system by increasing the hardenability of the steel.

      There are two families of Mn alloys one is called Si-Mn while the other is known as ferro-manganese (Fe-Mn). Si-Mn adds additional silicon in liquid steel which is a stronger deoxidizer and which also helps to improve some mechanical properties of steel. In each family, content of C can be controlled and lowered when producing low C grades. Around 93% of all the Mn produced is in the form of Mn ferroalloys consists of the Fe-Mn grades and the Si-Mn grades.

      The Fe-Mn grades are high carbon (HC), medium carbon (MC), low-carbon (LC) and very low carbon (VLC), whereas the Si-Mn grades include medium carbon (MC) and low carbon (LC). The steel industry is the only consumer of these alloys. However as the average consumption of Mn in one ton of steel is around 7 Kg, the requirement of these two ferro alloys amounts to considerable tonnages.

      To cover the need for Mn and Si, the steelmaker has the choice of a blend of Si-Mn, HC Fe-Mn and Fe-Si governed of by specifications on C, Si, and Mn. Normally earlier a mixture of HC Fe-Mn and Fe-Si was used, but now a trend towards more use of Si-Mn is seen at the expense of the two others. This is primarily for economic reasons.


      COST ESTIMATION

      Plant Capacity            30 MT/Day

      Land & Building (24,000 sq.mt.)    Rs. 13.26 Cr

      Plant & Machinery                    Rs. 4.03 Cr

      Working Capital for 2 Months    Rs. 10.90 Cr

      Total Capital Investment          Rs. 29.07 Cr

      Rate of Return                          27%

      Break Even Point                      75%


      CONTENTS

      INTRODUCTION

      PROPERTIES

      PROPERTIES

      USES AND APPLICATION

      B.I.S. SPECIFICATION

      MANUFACTURING DETAILS OF FERRO ALLOY (SILICO MANGANESE)

      FLOW DIAGRAM OF FERRO ALLOYS

      MANUFACTURING PROCESS

      CRUSHING AND GRINDING OF THE ORE:

      CONCENTRATION OR BENEFICIATION OF THE ORE:

      MAGNETIC SEPARATION OF IMPURITIES:

      THE EQUILIBRIUM IS DETERMINED BY THE FOLLOWING REACTION

      CHARGING:

      SMELTING:

      TAPPING/POURING:

      METAL RECOVERY PLANT:

      CRUSHING AND SCREENING:

      SEPARATION OF METAL FROM SLAG:

      RE-CRUSHING OF MIDDLING:

      THE STANDARD COMPOSITION OF HIGH CARBON FERRO CHROME (HCFC) IS AS GIVEN BELOW:

      PLANT AND MACHINERY FOR MANGANESE METAL

      1. FURNACE SHELL

      2. EXHAUST HOOD

      3. CONNECTING DUCT AND CHIMNEY

      4. ELECTRODE SYSTEM

      5. SUSPENSION FRAME

      6. MANTLE FRAME/ COOLING SHIELD

      7. PRESSURE RING

      8. REFRECTORIES

      9. COPPER WATER

      10. HYDRAULIC POWER PACK

      11. SLIPPING MECHANISM

      12. TAPPING ARRANGEMENTS (OPTIONAL)

      13. CONTROL PANEL

      14. SUB STATION

      15. BATCHING SYSTEM

      15 (A) WEIGHING & BATCHING OPERATION

      15 (B) FURNACE FEEDING SYSTEM

      16. FINISHING PRODUCT HANDLING

      17. FURNACE TRANSFORMER

      18. MISC.

      19. POLLUTION CONTROL EQUIPMENT

      20. PUMP ROOM

      (1) SUBMERGED ELECTRIC ARC FURNACE

      THE 1ST LAYER

      THE 2ND LAYER

      THE 3RD LAYER

      SUBMERGED ARC FURNACE

      SUBMERGED ARC FURNACE PROFILE

      PRINCIPLE AND CHARACTERISTICS OF SAF

      FEATURES OF SAF

      THE MAJOR NORMAL FEATURES OF AC BASED FURNACES ARE AS FOLLOWS

      (2) DESCRIPTION OF VIBRATING FEEDER

      CHARACTERISTIC OF VIBRATE FEEDING:

      (3) JAW CRUSHER:

      STRUCTURE OF JAW CRUSHER:

      FEATURES OF JAW CRUSHER:

      OPERATING PRINCIPLE OF JAW CRUSHER:

      (3) DESCRIPTION OF VIBRATING SCREEN:

      WORK PRINCIPLE OF VIBRATING SCREENS:

      FEATURES OF VIBRATING SCREEN:

      (4) INTRODUCTION OF BALL MILL:

      WORKING PRINCIPLE OF BALL MILL:

      APPLICATION OF BALL MILL:

      (5) MAGNETIC SEPARATOR

      APPLICATION OF MAGNETIC SEPARATOR:

      ADVANTAGES OF MAGNETIC SEPARATOR:

      (6) FLOATATION MACHINE:

      (7) INTRODUCTION OF SPIRAL CLASSIFIER:

      (8) INTRODUCTION OF BELT CONVEYOR:

      WORKING PRINCIPLE OF BELT CONVEYOR:

      MARKET OVERVIEW OF FERRO ALLOY

      ROLE OF FERRO ALLOYS

      DEMAND DRIVERS OF FERRO ALLOYS

      TYPES OF FERRO ALLOYS

      FERRO ALLOYS AS DE-OXIDANT FOR STEELMAKING

      MANUFACTURERS/SUPPLIERS OF LOW CARBON SILCO MANGANESE

      SUPPLIERS OF RAW MATERIALS

      SUPPLIERS OF MANGANESE ORE

      SUPPLIERS OF PEARL COKE

      SUPPLIERS OF DOLOMITE

      SUPPLIERS OF QUARTAZ POWDER

      SUPPLIERS OF HDPE BAGS

      ADDRESSES OF PLANT & MACHINERY SUPPLIERS

      SUPPLIERS OF MANGANESE BENEFICIATION PLANT

      SUPPLIERS OF SUBMERGED ARC FURNACE

      SUPPLIERS OF DG SETS

      SUPPLIERS OF EOT CRANES

      SUPPLIERS OF POWER TRANSFORMERS

      SUPPLIERS OF ELECTRICAL PANEL

      SUPPLIERS OF ELECTRIC MOTOR

      SUPPLIERS OF COOLING TOWER

      SUPPLIERS OF EFFLUENT 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

      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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