Pig Iron using Submerged ARC Furnace (Cap: 1 MT/Day)

PIG IRON USING SUBMERGED ARC FURNACE (CAP: 1 MT/DAY)

[EIRI/EDPR/4782] J.C.: 3002XL

INTRODUCTION

Pig iron is the product of blast furnace reduction of iron oxide in presence of limestone. About half the ore is converted to iron.

Pig iron is the basic raw material for steel and cast iron. In metal terminology, a pig is a bar or ingot of cooled metal.

Pig iron is produced by reducing iron ore in a blast furnace, electoe sunelter, or low-shaft furnace. At one time molten iron produced in the blast furnace was allowed to flow from a central launder into a sand bed to produce small blocks. This arrangement resembled a sow and her pigs, from which the term pig iron is derived.

Pig iron is used for making sponge iron, and, however, the predominant use of pig iron is as a raw material for steel making.

In the manufacture of sponge Iron from Pig Iron, the pig iron, which is used as a raw material is the product of blast furnace containing 3 to 4% carbon, 1 to 3% silicon, 0.3 to 1.5% phosphorus, 0.1 to 1.0% manganese, and under 1% sulphur.

COST ESTIMATION

Plant Capacity            1 MT/Day

Land & Building (2000 sq.mt.)    Rs. 77.50 Lac

Plant & Machinery                    Rs. 81.50 Lac

Working Capital for 2 Months    Rs. 23.52 Lac

Total Capital Investment          Rs. 2.11 Cr

Rate of Return                          69%

Break Even Point                      40%

CONTENTS

INTRODUCTION

ANALYSIS OF PIG IRON

SPECIFICATIONS OF PIG IRON USED IN DIFFERENT INDUSTRIES

PROPERTIES

PROPERTIES

LUMPS OF SILICO-MANGANESE

PROPERTIES AND CHARACTERSITS OF PIG IRON

EFFECTS OF SPONGE IRON ON EAF OPERATION

USES AND APPLICATION

B.I.S. SPECIFICATION

MARKET OVER VIEW OF PIG IRON

OPPORTUNITIES:

PIG IRON MARKET SEGMENTATION ANALYSIS:

REGIONAL INSIGHTS OF PIG IRON MARKET:

COMPETITIVE LANDSCAPE

PIG IRON MARKET KEY PLAYERS:

MARKET OF INDIAN STEEL INDUSTRY

WORLD ECONOMY AT A GLANCE

GLOBAL CRUDE STEEL PRODUCTION

MAJOR OBSERVATIONS:

GLOBAL DRI PRODUCTION

INDIA LED GLOBAL DRI PRODUCTION IN JANUARY-AUGUST 2024

MAJOR OBSERVATIONS:

WORLD STEEL PRICE TRENDS

LONG PRODUCTS

FLAT PRODUCTS

RAW MATERIAL SCENARIO

NEWS AROUND THE GLOBE

INDIAN STEEL MARKET ROUND-U

OVERALL PRODUCTION

CONTRIBUTION OF OTHER PRODUCERS

CONTRIBUTION OF PUBLIC SECTOR UNITS (PSU)

CONTRIBUTION OF FLAT /NON-FLAT IN FINISHED STEEL

FINISHED STEEL PRODUCTION TRENDS

FINISHED STEEL EXPORT TRENDS

FINISHED STEEL IMPORT TRENDS

FINISHED STEEL CONSUMPTION TRENDS

MANUFACTURING PROCESS OF PIG IRON

MANUFACTURING DETAILS OF FERRO ALLOY (SILICO MANGANESE)

FLOW DIAGRAM OF FERRO ALLOYS

MANUFACTURING PROCESS IN DETAILS

ZONES OF A SILICO-MANGANESE FURNACE

THE MAIN PROCESS STEPS ARE GIVEN BELOW.

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:

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

(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:

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 AND 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 EQUIPMENT'S

SUPPLIERS OF AIR CONDITIONING EQUIPMENT'S

SUPPLIERS OF AIR COMPRESSORS

SUPPLIERS OF PLATFORM WEIGHING MACHINE

SUPPLIERS OF MATERIAL HANDLING EQUIPMENT'S

SUPPLIERS OF FIRE FIGHTING EQUIPMENT'S

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)