Detailed Project Report on billets manufacturing unit by scrap melting

BILLETS MANUFACTURING UNIT BY SCRAP MELTING
 [CODE NO. 3217]

The Project profile envisages to set up Con-cast plant for manufacturing of M.S Billet which is the main raw material of Iron & Steel finished products, e.g. T.M.T Bars, angles, channels and sections etc. used in construction activities. Con-cast plant can be simply defined as a mill that carries con-cast process in which the molten steel is poured into laddle mould to perform the gradual solidification of metal into desired forms and shapes. Swiftly, the molten metal is solidified and is drawn down the caster. This gradually gets transformed into a solid steel billet, bloom or slab.

The Induction furnace based on mini steel plant is a versatile installations where provisions are available for producing a range of steel products by Alloying and casting into various shape. The products of steel plants are in the form of Ingots, Billets, Sheets etc. These Induction furnace based steel casting units are suitable  for small scale industries and medium scale industries and yet have the capability to complete in the internal as well as international market at all counts. In mini steel plant operating under Indian conditions small Billets are Cast for rolling into structural sections, Mild steel billets are manufacturing by different types of furnaces such as Blast Furnace, Electric Arc furnace, Induction Furnace, Basic oxygen furnace etc.


COST ESTIMATION

Plant  Capacity                                                  :    200.00 MT./day
land & Building (10000 sq.mtrs)                   :    Rs. 6.66   Cr
Plant & Machinery                                             :    Rs. 13.30  Cr
Working Capital for 2 Months                        :    Rs. 32.66  Cr
Total Capital Investment                                 :    Rs. 54.08  Cr
Rate of Return                                                   :    61%
Break Even Point                                              :    43%


INTRODUCTION    
THE AVAILABLE SIZES OF THE STEEL BILLETS ARE    
IMPORTANT ASPECTS OF CONTINUOUS CASTING OF BILLETS    
FACTORS AFFECTING CASTING SPEED AND MACHINE PRODUCTIVITY    
MECHANICAL PROPERTIES OF STEEL AT ELEVATED TEMPERATURES    
SOLIDIFICATION OF THE STRAND    
CAST STRUCTURE    
SHELL GROWTH    
MACRO-SEGREGATION    
USES AND APPLICATION    
B.I.S. SPECIFICATION    
PROCESS FLOW CHART    
MANUFACTURING PROCESS    
1. PREPARATIOON OF SCRAP    
PROCESSES FOR SORTING AND PREPARATION OF STEEL SCRAP    
MECHANICAL PROCESSES    
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    
THERE ARE MAINLY TWO TYPES OF THE INDUCTION FURNACES.
   THEY ARE GIVEN BELOW.    
BATH AGITATION MECHANISM    
REFRACTORY LINING    
PRODUCTION OF MILD STEEL BY INDUCTION FURNACE    
COMPARISON WITH ELECTRIC ARC FURNACE STEEL MAKING PROCESS    
THE INDUCTION FURNACE HAS THE FOLLOWING TECHNICAL
   ADVANTAGES OVER ELECTRIC ARC FURNACE.    
THE DISADVANTAGES ARE    
KEY ADVANTAGES OF INDUCTION HEATING    
IMPORTANT ASPECTS OF OPERATION    
OTHER ASPECTS OF INDUCTION FURNACE STEEL MAKING    
ENVIRONMENTAL EMISSIONS    
SAFETY AND INDUCTION FURNACES    
(3) CONTINUOUS CASTING OF STEEL BILLETS
STEEL LADLE    
TUNDISH    
MOULD    
SECONDARY COOLING    
TUNDISH AND ITS ROLE IN CONTINUOUS CASTING    
TUNDISH-A METALLURGICAL VESSEL    
TUNDISH REFRACTORY LINING    
(4) BILLET INSPECTION AND CONDITIONING FACILITIES    
INSPECTION TECHNIQUES    
EDDY CURRENT TECHNIQUES    
FLUX LEAKAGE TECHNIQUES    
MICROWAVE TECHNIQUES    
OPTICAL TECHNIQUES    
THERMAL TECHNIQUES    
ULTRASONIC TECHNIQUES    
SELECTION OF INSPECTION TECHNIQUES    
BILLET CONDITIONING FACILITIES    
MARKET POSITION    
RECENT DEVELOPMENTS    
THE ECONOMIC OUTLOOK HAS WEAKENED    
STEEL MARKET SENTIMENT    
FIGURE 2. STEEL PURCHASING MANAGERS’ INDICES (PMIS)    
FIGURE 3. TSI SURVEY OF STEEL DEMAND EXPECTATIONS (NEXT
   THREE MONTHS)    
STEEL CONSUMPTION    
STEEL PRODUCTION    
WORLD STEEL TRADE    
STEEL PRICES    
STEELMAKING COSTS    
THE STEEL MARKET OUTLOOK: DEMAND WEAKNESS AND OVERSUPPLY    
GLOBAL MARKET POSITION    136
PRODUCTION DATA OF STEEL BILLET IN SRI LANKA    
DETAILED EXPORT DATA OF MILD STEEL BILLETS TO SRI LANKA    
PLANT LAYOUT    146
MANUFACTURERS/SUPPLIERS OF STEEL BILLET    
SUPPLIERS OF RAW MATERIALS    
STEEL SCRAP    
COKE    
LIME    
PICKLING CHEMICALS    
SUPPLIERS OF PLANT AND MACHINERIES    
CONCASTING MACHINE    
INDUCTION FURNACE    
METAL TESTING MACHINE    
PRECISION MEASURING TOOLS    
NDT INSPECTION EQUIPMENT    
ELECTRICAL MEASURING INSTRUMENTS    
EOT CRANES    
AIR POLLUTION CONTROL EQUIPMENTS    
AIR CONDITIONING EQUIPMENTS    
AIR COMPRESSORS    
WEIGHING MACHINE (PLATFORM TYPE)    
MATERIAL HANDLING EQUIPMENTS    
FIRE FIGHTING EQUIPMENTS    


APPENDIX – A:

 1.      COST OF PLANT ECONOMICS      
 2.      LAND & BUILDING                                      
 3.      PLANT AND MACHINERY                                  
 4.      FIXED CAPITAL INVESTMENT                             
 5.      RAW MATERIAL                                         
 6.      SALARY AND WAGES                                     
 7.      UTILITIES AND OVERHEADS                              
 8.      TOTAL WORKING CAPITAL                                
 9.      COST OF PRODUCTION                                   
10.      PROFITABILITY ANALYSIS                               
11.      BREAK EVEN POINT                                     
12.      RESOURCES OF FINANCE                           
13.      INTEREST CHART                                       
14.      DEPRECIATION CHART                                   
15.      CASH FLOW STATEMENT                                   
16.      PROJECTED BALANCE SHEET