Torkari Plant (Production Capacity: 36,000 TPA)

TORKARI PLANT (PRODUCTION CAPACITY: 36,000 TPA)

[EIRI/EDPR/4511] J.C.: 2727XL

INTRODUCTION

TOR-KARI steel reinforcement bars are made by a process of cold rolling from mild steel coils and consequently come out in small diameters from 4.5 mm to 9 mm. This range of sizes will not only cause structurally superior components in addition to savings in steel consumption, in comparison to the 40 Grade bars which come in a minimum dia of 8 mm. 

Conventional high strength deformed bars of Fe 415 grade of dia 8 mm and 10 mm can be conveniently replaced by High Strength TOR-KARI reinforcement bars (TOR 55 Grade) of dia 7mm and 9mm. TOR-KARI of dia 5mm can also economically replace mild steel bars of dia 6/6.8 mm often used as secondary reinforcement.

Due to the smaller diameters and High Strength, TOR-KARI steel reinforcement gets more closely placed and thus leads to smaller and more evenly distributed bending as well as shrinkage cracks in structural components.

Due to the smaller diameters available, there is unlimited possibility for use of High Strength TOR-KARI steel reinforcement bars in precast components.

Since TOR-KARI is available in smaller diameters and has far superior strength and bond properties compared to even Fe 415 grade steel (Tor 40 for example), it can be efficiently and effectively used to achieve maximum economy. The savings in cost is in the order of 8 to 10% when TOR-KARI is used in place of Fe415 grade steel and as much as 35% when used in place of plain MS.

It is intended to prepare a Feasibility Report to install a TOR KARI Plant with production capacity of 3000 Tons/Month as a Green Field Project.

COST ESTIMATION

Plant Capacity            120 MT/Day  

Land & Building (4575 sq.mt.)    Rs. 3.66 Cr    

Plant & Machinery                    Rs. 4.98 Cr 

Working Capital for 0.5 Months    Rs. 7.06 Cr 

Total Capital Investment          Rs. 16.30 Cr 

Rate of Return                          52%

Break Even Point                      48%

CONTENTS

INTRODUCTION

PROPERTIES/SPECIFICATIONS

SPECIFICATION

MECHANICAL PROPERTIES

CHEMICAL PROPERTIES

BENEFITS/ADVANTAGES

ADVANTAGES OF USING TORKARI

HIGH BOND PROPERTIES

ROLLING TOLERANCE

SIZE ADVANTAGE

SAVINGS IN STEEL CONSUMPTION

TECHNOLOGY 

RAW MATERIAL

MANUFACTURING PROCESS

RAW MATERIAL SUPPLIERS

SUPPLIERS OF PLANT AND EQUIPMENTS

WIRE STRAIGHTENING MACHINE

BULK BLOCK TYPE HEAVY DUTY WIRE DRAWING MACHINE

EOT CRANES

DG SETS

POWER TRANSFORMERS

ETP PLANTS

AIR CONDITIONING EQUIPMENTS

AIR POLLUTION CONTROL EQUIPMENTS

WEIGHING MACHINE

MATERIAL HANDLING EQUIPMENTS

ELECTRICAL MEASURING INSTRUMENTS

WIRE POINTING MACHINE

ETP FACILITY

ETP FLOW DIAGRAM (TYPICAL)

SEWAGE AND WASTE WATER EFFLUENT 

STP FLOW DIAGRAM (TYPICAL)

PRINCIPLES OF PLANT LAYOUT

MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE:

PLANT LOCATION FACTORS

PRIMARY FACTORS

RAW-MATERIAL SUPPLY:

MARKETS:

POWER AND FUEL SUPPLY:

WATER SUPPLY:

CLIMATE:

TRANSPORTATION:

WASTE DISPOSAL:

LABOR:

REGULATORY LAWS:

TAXES:

SITE CHARACTERISTICS:

COMMUNITY FACTORS:

FLOOD AND FIRE CONTROL:

ANTICIPATED ENVIRONMENTAL IMPACTS 

CONSTRUCTION PHASE 

OPERATION PHASE 

MITIGATION MEASURES (PROPOSED)

HEALTH SAFETY & ENVIRONMENT

PROPOSED IMPLEMENTATION SCHEDULE

PROJECT FINANCIALS

BASIS & PRESUMPTIONS (FOR PROFITABILITY WORKINGS)

PRELIMINARY LAYOUT

CONCLUSIONS

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)