High Carbon Ferrochrome Production Plant (70 MT/Day)

HIGH CARBON FERROCHROME PRODUCTION PLANT

[EIRI/EDPR/4631] J.C.: 2848US$

High Carbon Ferrochrome/Charge Chrome are produced in Submerged Electric Arc Furnace is of stationary and semi-closed top.

The process adopted is high temperature smelting process, in which chrome ore is reduced with the help of the reductant like coke. The gangue material in the ore is removed by suitable fluxing material. The raw materials like chrome ore, coke and fluxes are selected to obtain desired grade in the output as per the requirement of the customer. All the incoming raw materials are analyzed for quality before feeding into the furnace.

The charge mix containing chrome, coke and flux is taken into the furnace with the help of computerized batching system. The necessary heat required for a process is provided by electric energy to the charge through the electrodes. At the tip of the electrode electric arcing taken place and generates high heat energy to smelt chrome ore into HC Fe Cr/Charge Chrome with coke (carbon) as reducing agent. In the process of smelting, gangue content in chrome ore forms the slag whose composition and fluidity are maintained by flux addition. 

Both hot metal and slag are tapped at regular intervals depending upon the power consumption. The slag is granulated. The metal is handled through decantation process and skimming process before cast in the metal casting beds prepared with slag dust and plastic clay. The metal after cooling is handled manually into different size fractions as per the requirement of the customer. This is a continuous process in which charge mix is taken regularly and slag & metal taped at regular intervals. Stage wise inspection is carried out to get the quality product.

COST ESTIMATION

Plant Capacity            70 MT/Day  

Land & Building (1,01,170 sq.mt.)    US$ 19.85 Lac    

Plant & Machinery                    US$ 42.00 Lac 

Working Capital for 2 Months    US$ 45.23 Lac 

Total Capital Investment          US$ 1.10 Cr 

Rate of Return                          79%

Break Even Point                      37%

CONTENTS

INTRODUCTION

DEMAND – SUPPLY GAP

PROJECT BACKGROUND

PLANT RATING AND CAPACITY

CHROME ORE

RAW MATERIAL REQUIREMENT

WATER

POWER SUPPLY CONNECTIVITY

ENVIRONMENTAL ASPECTS

SOLID WASTE GENERATION

SOLID WASTE MANAGEMENT

LIQUID EFFLUENT/WATER POLLUTION MANAGEMENT

ENERGY CONSERVATION

IDENTIFICATION OF THE PROJECT & PROJECT PROPONENT

PROJECT

A. SMELTER:

B. BRIQUETTING PLANT:

NEED FOR THE PROJECT AND IT’S IMPORTANCE TO THE COUNTRY 

PROJECT DESCRIPTION WITH PROCESS DETAILS 

RAW MATERIALS REQUIRED ALONG WITH ESTIMATED QUANTITY, LIKELY SOURCE, MARKETING AREA OF FINANCIAL PRODUCT/S, MODE OF TRANSPORT OF RAW MATERIAL AND FINISHED PRODUCT

ANNUAL REQUIREMENTS OF MAJOR RAW MATERIALS

A. CHROME ORE

A. ANTHRACITE

B. COKE

C. BAUXITE

E. QUARTZITE

TABLE NO.3.3: COMPOSITION OF COMMERCIAL GRADES OF HIGH CARBON FERRO CHROME

BRIQUETTING PLANT

DESIGN BASIS 

PLANT CAPACITY

FEED

CHEMICAL ANALYSES OF FEED ORE

ADDITIVES

CHARACTERISTICS OF MOLASSES AND HYDRATED LIME

PRODUCT

BRIQUETTE CHARACTERISTICS

PROCESS DESCRIPTION

SMELTER

QUANTITY OF WASTES SHOULD BE GENERATED (LIQUID AND SOLID) AND SCHEME FOR THEIR MANAGEMENT / DISPOSAL.

SOLID WASTE MANAGEMENT

LIQUID EFFLUENT/WATER POLLUTION MANAGEMENT

SMELTING OF HC FE-CR FERRO-ALLOY

FIG 1 SCHEMATICS OF FE-CR SMELTING IN SAF

ZONES IN A SAF

FIG 2 SCHEMATIC DIAGRAM OF THE REACTION ZONES IN SUBMERGED ARC FURNACE FOR FE-CR PRODUCTION

PROCESS REACTIONS

RAW MATERIALS

PRODUCTION PROCESS

THE FOLLOWING ARE THE IMPORTANT CHARACTERISTICS OF PRODUCTION PROCESS OF FE-CR IN A SAF:

HIGH CARBON FERROCHROME: – SPECIFICATIONS

USES AND APPLICATION

RAW MATERIALS

REDUCTANT

FLUX

AGGLOMERATION – BRIQUETTING PROCESS

METAL RECOVERY PLANT (MRP)

MARKET OVERVIEW

KEY MARKET INSIGHTS 

GLOBAL FERROCHROME MARKET SEGMENT ANALYSIS:

GLOBAL FERROCHROME MARKET REGIONAL INSIGHTS:

GLOBAL FERROCHROME MARKET KEY PLAYER

RISING FOREIGN INVESTMENTS AND MANUFACTURING ACTIVITIES TO BOOST MARKET GROWTH

DRIVING FACTORS

HIGH USAGE IN THE STAINLESS STEEL INDUSTRY TO AID MARKET 

EXPANSION

RESTRAINING FACTORS

AVAILABILITY OF SUBSTITUTES TO HINDER MARKET AUGMENTATION

SEGMENTATION

BY PRODUCT TYPE ANALYSIS

HIGH CARBON SEGMENT TO LEAD OWING TO INCREASING USE IN STEEL INDUSTRY

BY APPLICATION ANALYSIS

STAINLESS STEEL SEGMENT TO DOMINATE THE MARKET DUE TO HIGH ADOPTION IN CONSTRUCTION INDUSTRY

REGIONAL INSIGHTS

KEY INDUSTRY PLAYERS

STRATEGIC PLANNING ADOPTED BY COMPANIES TO STRENGTHEN THEIR MARKET SHARE

KEY INDUSTRY DEVELOPMENTS:

PRESENT MANUFACTURERS

RAW MATERIAL SUPPLIERS

SELECTION OF SITE & LOCATION OF PLANT

ENVIRONEMENTAL MANAGEMENT PLAN

SOURCES OF POLLUTION

THE VARIOUS MEASURES PROPOSED TO MITIGATE THE IMPACT OF THESE POLLUTION SOURCES ON THE ENVIRONMENT ARE DISCUSSED BELOW:

POLLUTION CONTROL MEASURES

AIR POLLUTION

WATER POLLUTION

NOISE POLLUTION

SOLID WASTE MANAGEMENT

DISPOSAL OF SLAG FROM FERRO ALLOYS:

PLANTATION

SELECTION CRITERIA OF PLANT SPECIES FOR GREEN DEVELOPMENT PLANT

SPECIFICATIONS/DESIGN DETAILS OF THE SUBMERGED ARC FURNACES (SAF) 

PLANT LAYOUT

SUPPLIERS OF PLANT AND MACHINERY

PACKAGING MACHINE

D.G. SET

LABORATORY TESTING EQUIPMENTS

PRINCIPLES OF PLANT LAYOUT

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:

AMENITIES & FACILITIES

LABORATORY

REPAIR AND MAINTENANCE SHOP

STORES

PLANT OFFICE

ANCILLARY BUILDINGS

CANTEEN

STATUTORY APPROVALS FROM GOVERNMENT

DOCUMENTS REQUIRED FOR LICENSES 

LIST OF DOCUMENTS:

SWOL ANALYSIS

STRENGTHS

OPPORTUNITIES

WEAKNESS

LIMITATIONS

ORGANIZATION CHART

PROJECT CONSULTANT

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)