MS Ingot and Nonferrous Copper Based and Master Alloy Ingots (Cap: 30 MT/Day)

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MS INGOT AND NONFERROUS COPPER BASED AND MASTER ALLOY INGOTS

[EIRI/EDPR/4471] J.C.: 2685XL

Mild steel Ingots are the basic raw material for the manufacture of various types of re-rolled products, for e.g. rounds, flats, channels equal and unequal angles etc. A major part of this re-rolled products in the form of cold-twisted deformed bars are used in building construction as reinforcement.

Ingot is the product obtained by pouring liquid steel into cast iron mould of a shape appropriate for the subsequent processing generally by hot rolling or forging into semi-finished or finished products. The shape generally resembles a truncated pyramid or truncated cone. The side surfaces can be corrugated and the corners are more or less rounded. Depending on its subsequent conversion requirements, ingot can be dressed and/or hot scarred or cropped.

The usual cross section of ingot is square, rectangular, round, oval, or polygon. Ingots with square cross section are used for rolling into billets, rails and other structural sections, whereas, ingots with rectangular cross section, are generally used for rolling into flat products. These ingots usually have a width which is two times or higher than the thickness. Round ingots are used for the production of seamless pipes. Polygonal ingots are used to produce tyres, and wheels etc. Low capacity steel melting shops with induction furnaces produce very small cross section ingots which are called as pencil ingots.

COST ESTIMATION

Plant Capacity 30 MT/Day

Land & Building (6000 sq.mt.) Rs. 3.40 Cr

Plant & Machinery Rs. 2.07 Cr

Working Capital for 1 Month Rs. 10.73 Cr

Total Capital Investment Rs. 16.57 Cr

Rate of Return 50%

Break Even Point 43%

CONTENTS

INTRODUCTION

SPECIFICATION OF STEEL INGOT

STEEL INGOT SPECIFICATION:

M.S. INGOTS

COPPER BASED MASTER ALLOY

MASTER ALLOY

CHEMICAL COMPOSITION

APPLICATIONS

ALUMINIUM SILICON MASTER ALLOY INGOTS

AL3538 ALUMINUM-SILICON MASTER ALLOY INGOT (ALSI20)

ALUMINUM-SILICON MASTER ALLOY INGOT DESCRIPTION

ALUMINUM-SILICON MASTER ALLOY INGOT SPECIFICATIONS

PROPERTIES OF MILD STEEL

CHEMICAL PROPERTIES OF MILD STEEL

PHYSICAL PROPERTIES OF MILD STEEL

USES AND APPLICATION OF MS INGOTS

B.I.S. SPECIFICATION

MS INGOTS CASTING

CASTINGS

SEQUENCES IN MS INGOTS MAKING

STEEL INGOT SPECIFICATION:

TECHNOLOGY:

PROCESS:

CHARGING

MELTING

REMOVAL OF SLAG

REFINING

TAPPING

TECHNICAL DETAILS OF M.S. INGOT MANUFACTURE

PROCESS FLOW DIAGRAM

CASTING OF INGOT

MECHANISM OF SOLIDIFICATION OF LIQUID STEEL IN INGOT MOULD

MICRO-SEGREGATION AND MACRO-SEGREGATION IN STEEL INGOTS

FIG 1 THREE DISTINCT MACRO-STRUCTURE ZONES IN STEEL INGOTS

FIG 2 MACRO-SEGREGATION PHENOMENON DURING SOLIDIFICATION

IN INGOT MOULD

DEFECTS OF KILLED STEEL INGOTS

FIG 3 PIPE FORMATION DURING SOLIDIFICATION OF LIQUID STEEL

IN INGOT MOULD

MANUFACTURING PROCESS

1. PREPARATION OF SCRAP

PROCESSES FOR SORTING AND PREPARATION OF STEEL SCRAP

MECHANICAL PROCESSES

FIG 1 PROCESSES FOR PREPARATION OF STEEL SCRAP

MAGNETIC SEPARATION PROCESS

EDDY CURRENT SEPARATION PROCESS

HEAVY MEDIA SEPARATION PROCESS

SEPARATION BY PHYSICAL AND CHEMICAL CHARACTERISTICS

DECOATING PROCESSES

DEZINCING PROCESS FOR STEEL SCRAP

DETINNING PROCESS FOR STEEL SCRAP

DECOPPERIZATION PROCESS FOR STEEL SCRAP

INCINERATION

RECENT STEEL SCRAP SORTING TECHNOLOGIES

PORTABLE OPTICAL EMISSION SPECTROMETERS

COLOUR SORTING PROCESS

PROCESS UTILIZING LASER INDUCED BREAKDOWN SPECTROSCOPY

2. MELTING

OPERATION OF INDUCTION FURNACE

FIG 1 SCHEMATICS OF AN INDUCTION FURNACE

FIG 2 A CORELESS INDUCTION FURNACE

BATH AGITATION MECHANISM

FIG 3 POWER DISTRIBUTION (LEFT) AND FLOW PATTERN (RIGHT)

REFRACTORY LINING

PRODUCTION OF MILD STEEL BY INDUCTION FURNACE

COMPARISON WITH ELECTRIC ARC FURNACE STEEL MAKING PROCESS

THE DISADVANTAGES ARE

KEY ADVANTAGES OF INDUCTION HEATING

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

CASTING OF BILLET

MECHANISM OF SOLIDIFICATION OF LIQUID STEEL IN INGOT MOULD

MICRO-SEGREGATION AND MACRO-SEGREGATION IN STEEL INGOTS

FIG 1 THREE DISTINCT MACRO-STRUCTURE ZONES IN STEEL INGOTS

FIG 2 MACRO-SEGREGATION PHENOMENON DURING SOLIDIFICATION

IN INGOT MOULD

DEFECTS OF KILLED STEEL INGOTS

FIG 3 PIPE FORMATION DURING SOLIDIFICATION OF LIQUID STEEL

IN INGOT MOULD

QUALITY CONTROL

OVERVIEW OF STEEL INGOTS

STAINLESS STEEL

MILD STEEL

INFRASTRUCTURE

POWER SECTORS

TRANSPORTATION

INDUSTRIAL

GROWTH FACTORS OF THE STEEL INGOTS MARKET

MARKET OVERVIEW OF STEEL INDUSTRY

CHART 1: TREND IN GLOBAL STEEL PRICES

CHART 2: TREND IN IMPORT AND EXPORT OF FINISHED STEEL

TABLE 1: INDIA’S STEEL SCENARIO DURING H1FY21 AND H2FY21

INDIAN GOVERNMENT ROLE

NON FERROUS METAL INDUSTRY

A. INDUSTRY RISK:

SIZE AND MARKET SHARE:

DOWNSTREAM PRODUCT DIVERSITY:

MARKET OVERVIEW OF NON FERROUS METAL

WHAT IS THE GLOBAL PROCESSED NONFERROUS METAL MARKET?

THE GLOBAL PROCESSED NONFERROUS METAL MARKET IS SEGMENTED:

SUPPLIERS OF MS INGOT

SUPPLIERS OF RAW MATERIALS

SUPPLIERS OF STEEL SCRAPE

SUPPLIERS OF COKE

SUPPLIERS OF LIME

SUPPLIERS OF FERRO ALLOY

SUPPLIERS OF PICKLING CHEMICALS

SUPPLIERS OF PLANT AND MACHINERY

SUPPLIERS OF SHREDDER

SUPPLIERS OF DE-COATER

SUPPLIERS OF MAGNETIC SEPARATOR

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 CRANE

SUPPLIERS OF POWER TRANSFORMERS

SUPPLIERS OF ELECTRICAL PANEL

SUPPLIERS OF COOLING TOWER

SUPPLIERS OF EFFULENT TREATMENT 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

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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