Detailed Project Report on copper metal

COPPER METAL [CODE NO.3758]  


Copper was a scarce metal with respect to India but recent setting up of copper smelters has entirely changed the scenario of copper production/availability in the country. However, these copper smelters, except that of HCL, are producing copper based on the imported concentrates. In the recent past the country’s status has changed from a net importer to a net exporter

Over the years the use of copper has witnessed growth in electrical, transport, Consumer durables, engineering, construction, telecommunication etc. sectors. In the present survey the demand has been projected up to 2024-25 in the above sectors keeping in view the economic growth in future. The domestic demand works out to be 2.3 million tones. To meet the demand in future the copper industry has already geared up. The supply projection of 2.8 million tons by 2024-25will satisfy the domestic demand in addition to exports demand.

The world scenario vis-à-vis India is necessary to find out the country’s position. The world’s leading producers with their present and future projects are also discussed in the report. The global consumption of copper has been projected at 31 million tons by 2025.

The prices are the dominating economic indicators to control the copper production activity. Enough weightage is given to this aspect by analysing the prices for present and future.

With this background, Indian Bureau of Mines has taken up for the first time a Market Survey Study on metal namely copper. In this study an attempt has been made to study the present and future availability of metal from primary as well as secondary sources and their demand in present and future based on the role in overall development of end-user industry.

COST ESTIMATION

Plant Capacity        30 MT/Day  
Land & Building (8000 sq.mt.)  Rs. 9.22 Cr    
Plant & Machinery                    Rs. 2.04 Cr
Working Capital for 2 Months   Rs. 53.87 Cr
Total Capital Investment          Rs. 65.51 Cr
Rate of Return                         34%
Break Even Point                     36%


INTRODUCTION    
TYPES OF COOPER ORE    
PROPERTIES OF COPPER    
TABLE 1. TYPICAL PROPERTIES OF COPPER POWDER PRODUCED
   BY VARIOUS METHODS    
USES AND APPLICATION    
B.I.S. SPECIFICATION    
PROCESS FLOW CHART    
SIMPLIFIED FLOW CHART LEACH – SOLVENT EXTRACTION – ELECTRO
   WINNING PROCESS    
PRODUCTION PROCESS OF COOPER    
RAW MATERIAL    
SULFIDE ORES    
OXIDE ORES    
COPPER IS EXTRACTED FROM ITS ORES EITHER BY    
A) PYROMETALLURGICAL PROCESSES    
B) HYDROMETALLURGICAL PROCESSES    
LEACH SOLUTIONS    
1. ACIDS AND OXIDANTS    
2. ALKALIS AND AMMONIA-BASED REAGENTS    
3. BACTERIALLY-MEDIATED LEACHING    
INFLUENCING FACTORS ON HYDROMETALLURGICAL LEACHING    
ADVANTAGES OF HYDROMETALLURGICAL PROCESS    
DISADVANTAGES OF HYDROMETALLURGICAL    
PROCESSING OF COPPER ORES    
(A) COMMINUTION    
(I) CRUSHING    
(II) GRINDING    
(III) SIZING/CLASSIFICATION    
(B) LEACHING TECHNOLOGY    
LEACHING PROCESS    
B) TANK LEACHING    
PROCESSES    
(C) SOLVENT EXTRACTION    
(D) ELECTRO WINNING    
WASTE TREATMENTS    
ENVIRONMENTAL IMPACTS OF HYDROMETALLURGICAL LEACHING    
POLLUTION CONTROL TECHNIQUES    
SOURCES OF POLLUTION    
CRUSHING AND SIZE REDUCTION    
HYDROMETALLURGICAL PROCESSES    
LEACHING    
HEAP LEACHING    
ATMOSPHERIC LEACHING (OPEN TANK)    
PRESSURE LEACHING (AUTOCLAVE)    
SOLVENT EXTRACTION    
ELECTROCHEMICAL PROCESSES    
ELECTRO-WINNING    
ELECTRO-REFINING    
PREVENTION & CONTROLLING METHODS OF ENVIRONMENTAL POLLUTION    
USE INDOOR OR COVERED STOCKPILES.    
TREATMENT    
SULPHUR DIOXIDE TREATMENT    
SX/EW SLUDGE    
SPENT ELECTROLYTE    
SPENT LEACHING SOLUTION    
POTENTIAL SOURCES OF CONTAMINATION    
(A) RELEASES FROM ACTIVE LEACH UNITS    
MARKET SURVEY    
COPPER PRODUCTION IN INDIA    
MAJOR PLAYERS    
COPPER CONSUMPTION GROWTH DRIVERS - INDIA    
COPPER INDUSTRY SNAPSHOT    
COPPER INDUSTRY SNAPSHOT - INDIA    
REFINED COPPER CONSUMPTION - INDIA    
POWER SECTOR - INDIA    
INDIA REFINED COPPER INDUSTRY - CHALLENGES    
RISK OF SUBSTITUTION    
SWOT – INDIAN COPPER INDUSTRY    
CUSTOM SMELTER VALUE CHAIN    
SUPPLIERS OF COPPER CATHODE    
PLANT LAYOUT    
SUPPLIERS OF RAW MATERIALS    
SUPPLIERS OF COOPER ORE    
SUPPLIERS OF SULFURIC ACID    
SUPPLIERS OF NITRIC ACID    
SUPPLIERS OF HYDROCLORIC ACID    
SUPPLIERS OF PLANT AND MACHINERY    
SUPPLIERS OF COPPER LEACHING PLANT    
SUPPLIERS OF CRUSHING PLANT    
SUPPLIERS OF BALL MILL    
SUPPLIERS OF METAL TESTING MACHINE    
SUPPLIERS OF PRECISION MEASURING TOOLS    
SUPPLIERS OF DG SETS    
SUPPLIERS OF EOT CRANE    
SUPPLIERS OF POWER TRANSFORMERS    
SUPPLIERS OF ELECTRICAL PANEL    
SUPPLIERS OF ELECTRIC MOTOR    
SUPPLIERS OF COOLING TOWER    
SUPPLIERS OF EFFULENT TREATMENT PLANT (ETP 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    
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)