Detailed Project Report on copper powder (atomized)

COPPER POWDER (ATOMIZED) [3519]

Copper powder is finely granulated copper that has many metallurgic functions. The powder is cheaper than regular cast copper, so engineers can save money on supplies, and it often helps conserve materials because less copper will be needed. Copper powder also can be made to have different densities if handled by a powder metallurgist, meaning the copper can be porous and impregnated with oils or other metals, or it can be non-porous like cast copper. Powdered copper is used as an alloy, in metal-plastic combinations, and in structural applications. Generally, the powder obtained has fine particle sizes with relatively low apparent densities and high green strength. Application Copper powder often is used as an alloying powder and is somewhat easier to work with than cast copper. This is because, in its powdered form, copper is easier to heat up and mix with other metals. Copper is often alloyed with iron & tin and powdered copper can work the same as cast copper in this arena. As a powder, it also can be mixed with non-metals such as plastic to create new substances that are commonly used for decoration. Around 70 percent of powdered copper is used in making self lubricating bearings, which take advantage of powdered copper’s porous nature. The properties of the granular copper powders produced by the methods described are indicated in Table 1. As has been noted, the purity is influenced by the purity of the raw material and the method of preparation. Electrolytic powder is produced from high purity cathode copper and the powder is consistently more than 99% pure. Powder produced by the hydrometallurgical process, in which copper is dissolved preferentially from the raw material, also is a high purity product consistently greater than 99% copper. No refining occurs during atomization or solid state reduction and the purity of the powder depends on that of the raw material used as feed, which is selected to produce powder with 99% purity.

COST ESTIMATION

Plant Capacity                                               3 MT/Day  
Land & Building (2000 sq.mt)                    Rs. 2.52 Cr
Plant & Machinery                                         Rs. 1.75 Cr
Working Capital for 1 Month                       Rs. 3.68 Cr
Total Capital Investment                             Rs. 8.32 Cr
Rate of Return                                              29%
Break Even Point                                         54%


INTRODUCTION    
PROPERTIES OF COPPER POWDER    
TABLE 1.TYPICAL PROPERTIES OF COPPER POWDER PRODUCED
   BY VARIOUS METHODS    
AMONG ITS VALUABLE PROPERTIES MENTION MAY BE MADE OF THE FOLLOWING.    
USES AND ITS APPLICATION    
THE MAIN USES OF COPPER POWDER ARE FOUND IN:    
B.I.S. SPECIFICATION    
PROCESS FLOW CHART    
MANUFACTURING PROCESS    
(1) PROCUREMENT OF RAW MATERIAL    
TYPES OF COPPER SCRAP    
(2) PREPARATION AND TREATMENT OF COPPER SCRAP    
(2) PRETREATMENT OF SCRAP    
(A) STRIPPING    
(B) BRIQUETTING    
(C) SIZE REDUCTION    
(D) CRUSHING    
(E) RESIDUE CONCENTRATION    
(F) RESIDUE PELLETIZING AND ROLL BRIQUETTING    
(G) DRYING    
(H) BURNING    
(I) SWEATING    
(3) MELTING PROCESS    
(4) ATOMIZATION    
THIS USES HIGH PRESSURE FLUID JETS TO BREAK UP A MOLTEN METAL
   STREAM INTO VERY FINE DROPLETS, WHICH THEN SOLIDIFY INTO FINE
   PARTICLES.    
MECHANISM OF ATOMIZATION    
TYPES OF ATOMIZATION    
PARTS OF ATOMIZATION UNIT    
(D) ATOMIZING NOZZLES    
I) FREE FALLING, II) CONFINED DESIGN
(E) ATOMIZING MEDIUMS    
(F) ATOMIZATION PROCESS PARAMETERS    
(G) CLEANING OF POWDERS:    
MARKET POSITION    
IN INDIA MARKET, THE TOP PLAYERS INCLUDE    
SPLIT BY PRODUCT TYPES/CATEGORY, COVERING    
SPLIT BY APPLICATIONS/END USE INDUSTRIES, COVERS    
GLOBAL ATOMIZING COPPER POWDER MARKET    
DEMAND FORECAST OF COPPER ON CAGR & GDP    
TABLE-6.3: INTERNAL APPARENT DEMAND FORECAST OF COPPER
2010-11 TO 2024-25    
(BASE YEAR 2008-09 DEMAND OF 496 THOUSAND TONES)    
DEMAND PROJECTION BASED ON SECTOR WISE GROWTH    
GROWTH IN ELECTRICAL AND TELECOMMUNICATION INDUSTRY    
TRANSPORT SECTOR    
APPLIANCES AND CONSUMER DURABLES    
GROWTH IN BUILDING AND CONSTRUCTION INDUSTRY    
GENERAL ENGINEERING    
OTHERS INDUSTRIES INCLUDING PROCESS INDUSTRIES    
FUTURE SUPPLY SCENARIO    
RESOURCES    
PRODUCTION OF COPPER CATHODES    
DEMAND SUPPLY ANALYSIS    
EXPORT DATA OF COPPER POWDER    
IMPORT DATA OF COPPER POWDER    
PLANT LAYOUT    
MANUFACTURERS/SUPPLIERS OF COPPER POWDER    
SUPPLIERS OF RAW MATERIALS    
SUPPLIERS OF COPPER SCRAP    
SUPPLIERS OF NITROGEN GAS    
SUPPLIERS OF NITRIC ACID    
HYDROCLORIC ACID    
DEGREASING CHEMICAL    
PICKLING CHEMICALS    
SULFURIC ACID    
(HCL) PICKLING ACIDS    
SUPPLIERS OF COMPLETE ATOMIZATION    
COPPER POWDER PLANT    
SUPPLIERS OF INDUCTION FURNACE    
EOT CRANE    
SUPPLIERS OF POWER TRANSFORMER    
SUPPLIERS OF ELECTRICAL PANEL    
SUPPLIERS OF COOLING TOWER    
SUPPLIERS OF EFFLUENT TREATMENT PLANT (ETP PLANT)    
AIR POLLUTION CONTROL EQUIPMENTS    
AIR CONDITIONING EQUIPMENTS    
AIR COMPRESSORS    
PLATFORM WEIGHING MACHINE    
MATERIAL HANDLING EQUIPMENTS    
FIRE FIGHTING EQUIPMENTS    
SUPPLIERS OF SUBMERSIBLE WATER PUMP    


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