Detailed Project Report on cold rolled steel sheet manufacturing plant

COLD ROLLED STEEL SHEET MANUFACTURING PLANT
[CODE NO 3198]


Metal sheets in coil form are flat products wound into rolls and having a rectangular cross-section, the width of which is much larger than the thickness. A distinction is drawn between hot- and cold-rolled sheet.

Hot-rolled sheet in coil form is produced from semifinished products (slabs or billets), which are reduced to certain thicknesses by rolling and annealing and wound into a roll.

Cold-rolled sheet in coil form is produced by removing rust from hot-rolled sheet by "pickling" it in a weak acid solution, then washing, brushing, drying, oiling and unrolling the sheet and finally performing cold-rolling by passing the sheet through a reducing mill under pressure and winding it into a roll.

Cold-rolled steel is a more highly finished product and has a smoother surface, greater dimensional accuracy (thickness, width, length) and greater strength.

Cold rolled sheet is produced from a precisely manufactured hot rolled processed sheet, which is then cold-reduced to the desired thickness. These sheets are rolled to a close tolerance and possess a fine surface finish, superior to pickled and oiled.

Typical thickness between 0.15 - 3 mm. Typical width between 600 - 2100 mm.

The primary feature of cold reduction is to reduce the thickness of hot-rolled coils into thinner thicknesses that are not generally attainable in the hot rolled state.


COST ESTIMATION

Plant  Capacity                                                :   400.00 MT./day           
land & Building (10000 Sq.Mtr)                   :    Rs. 11.04  Cr
Plant & Machinery                                          :    Rs. 5.75   Cr
Working Capital for 2 Months                      :    Rs. 89.99  Cr
Total Capital Investment                              :    Rs. 107.42 cr
Rate of Return                                               :    83%
Break Even Point                                           :    20%


    
INTRODUCTION    
DIMENSIONAL SPECIFICATION OF COLD ROLLED CLOSE ANNEALED SHEETS    
PHYSICAL AND CHEMICAL SPECIFICATION OF COLD ROLLED STEEL SHEET    
DIMENSION TOLERANCE:    
THICKNESS    
WIDTH:    
LENGTH: (UNIT:MM)    
ADVANTAGES:    
PPGI STEEL SHEET    
PPGI ADVANTAGES    
USES AND APPLICATION    
APPLICATIONS    
B.I.S. SPECIFICATION    
MARKET POSITION    
INDIA’S STEEL INDUSTRY    
FLAT PRODUCTS OVERVIEW    
INDIA'S FINISH FLAT PRODUCT MIX    
STUDY ONGP/GC MARKET    
WHAT IS PPGI?    
INDIA'S GP/GC IMPORT-EXPORT ANALYSIS    
INDIA’S GP/GC EXPORT ANALYSIS    
CONSUMPTION ANALYSIS OF GP/GC    
SECTOR-WISE APPARENT CONSUMPTION ANALYSIS OF GP/GC    
EXPORT DATA OF PRIME COLD ROLLED STEEL SHEET    
IMPORT DATA OF COLD ROLLED STEEL SHEETS    
EXPORT DATA OF PPGI STEEL COILS    
IMPORT DATA OF PPGI STEEL COILS    
PRESENT MANUFACTURERS/SUPPLIERS    
PROCESS FLOW CHART    
MANUFACTURING PROCESS    
PROCESS OVERVIEW    
COLD ROLLING MILLS (CR STRIP MILLS)    
CONTINIOUS PICKLING LINE    
ANNEALING    
TEMPERING ALSO IMPROVES STRIP FLATNESS    
COATING PROCESS    
TESTS CONDUCTED FOR QUALITY CHECK OF THE COATED STEEL    
APPLICATIONS    
ADVANTAGES    
PLANT AND MACHINERY FOR COLD ROLLING MILL    
SCALE AND ITS ORIGIN    
SCALE REMOVAL    
PICKLING LINE    
TYPES OF PICKLING LINES    
TYPES OF ROLLING MILL STANDS    
TYPES OF ROLLING MILL    
TEMPER ROLLING OR SKIN PASS ROLLING OF ANNEALED STRIP    
ROLLING OF HOT STRIP AND STRIP DEFECTS    
PROCESS OF GALVANIZING    
GI SHEETS SPECIFICATION    
APPLICATION OF GI SHEETS    
ADVANTAGES WITH USE OF GI SHEETS    
COATING PROCESS    
TESTS CONDUCTED FOR QUALITY CHECK OF THE COATED STEEL    
APPLICATIONS    
ADVANTAGES    
AIR POLLUTION CONTROL DEVICES    
DUST CATCHERS    
CYCLONES    
FABRIC FILTERS (BAG HOUSES)    
ELECTROSTATIC PRECIPITATORS    
SCRUBBERS    
PLANT LAYOUT    
SUPPLIERS OF PLANT AND MACHINERIES    
UN COILERS AND COILERS    
SUPPLIERS OF STRIP SLITTING AND CUTTING TO LENGTH TO LENGTH LINE    
SUPPLIERS OF PICKLING LINE    
SUPPLIERS OF BELL ANNEALING FURNACE    
SUPPLIERS OF COLD ROLLING MILL    
SUPPLIERS OF TESTING EQUIPMENT    
SUPPLIERS OF COLD ROLLING MILL    
SUPPLIERS OF TESTING EQUIPMENT    
SUPPLIERS OF EOT CRANES    
SUPPLIERS OF D.G. SETS    
SUPPLIERS OF POWER TRANSFORMERS    
SUPPLIERS OF COOLING TOWER    
SUPPLIERS OF ETP PLANTS
SUPPLIERS OF AIR POLLUTION CONTROL EQUIPMENTS    
AIR CONDITIONING EQUIPMENTS    
AIR COMPRESSORS    
WEIGHING MACHINE (PLATFORM TYPE)    
MATERIAL HANDLING EQUIPMENTS    
NDT INSPECTION EQUIPMENT    
FIRE FIGHTING EQUIPMENTS    
ELECTRICAL MEASURING INSTRUMENTS    
SUPPLIERS OF COLOUR COATING LINE    
SUPPLIERS OF GALVANISING LINE    
SUPPLIERS OF SUBMERSIBLE WATER PUMP    
SUPPLIERS OF RAW MATERIALS    
HR M.S STEEL SHEET    
MINERAL OIL    
PICKLING CHEMICALS    
HYDROCLORIC ACID    
OIL AND GREASE    
ZINC INGOT    
COLOURS FOR COATING    
PACKING MATERIALS    


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