Detailed Project Report on Copper Wire Drawing & Enamelling Plant (Cap: 1 MT/Day)

 COPPER WIRE DRAWING & ENAMELLING PLANT (CAP: 1 MT/DAY)

[EIRI/EDPR/1727] J.C. 556XL

INTRODUCTION

Copper   wire  is  an  essential  material  for  motor   and transformer  winding.   Copper  wire is  available  in  different gauges  (32  gauge to 18 gauge).  The gauge of  the  copper  wire depends  upon  the  winding required for the  specific  motor  or transformer.

The  wire having conductor diameter from 0.500 to 4.000  mm, is suitable for submersible motor winding.

There  is  a heavy market for copper  wire/enamelled  copper wire in motor and transformer manufacturers and this wire is also used in rewinding of motors and transformers.

Reasons  for its wide use is that the copper has  resistance to  atmospheric  corrosion because of the  formation  of  uniform layer  of oxide on the surface of metal.  Besides  these,  copper has good mechanical properties viz - good mechanical malleability &  formability  which.  It can easily welded  or  soldered.   The melting temperature of copper is 1083oC.

Plant  and  machinery  as well as  technical  know-how  are indigenously   available  and  no  imported  plant/equipment   is required.

Though  the  major attention has been  concentrated  on  the formulation of resins for improving the quality of coatings,  the coating  methods have remained more or less the same.  From  this point of view the recently developed technique of electro coating appears  to  be  of interest.  The method  is  supposed  to  give extremely  uniform,  continuous, adherent, smooth  coatings  with better  mechanical  properties as compared to  other  methods  of coating.  These qualities are essential in coating of wires as is known generally.  Thought at present this technique is being used in other fields,s it is worthwhile considering its application to wire  coating  and  if successful, it may lead  to  reduction  in coating  thickness  with further advantage in size  reduction  of various equipment.

PVC insulated winding wire is used for all type of  electric motor.   The  wire used for winding is always copper  because  it provides strength and is good conductor of electricity.

On  account of copper being expensive, aluminium  wires  are being  used for winding electrical equipments. Super enamelled aluminium wire is, thus, helping the user industries in selective cases  an  the face of acute shortage of super  enamelled  copper wires.

Wire is made by cold drawing hot-rolled wire rod through one or  more  dies, to decrease its size and  increase  the  physical properties.  The wire rod about 7/32" (6mm) in diameter is rolled from a single billet and cleaned in an acid bath to remove scale, rust  and coating.  The coating is applied to prevent  oxidation, neutralize  any  remaining acid and to act as a  lubricant  or  a coating to which a later applied lubricant may cling.

Both  single  draft or continuous drawing processes  may  be used.   In the first method a coil is placed on a reel  or  frame and  the  end of the rod pointed so that it will enter  the  die.  The end is grasped by tongs on a drawbench and pulled through  to such length as may be wound around a drawing block or reel.  From there  on, the rotation of the draw block pulls the wire  through the die and forms it into a coil.  There operations are  repeated with smaller dies and blocks until the wire is drawn to its final size.

In continuous drawing, the wire is fed through several  dies and  draw  blocks arranged in series. This permits  drawing  the maximum  amount in one operation befoir annealing  is  necessary.  The number of dies in the series will depend on the kind of metal or  alloy  being processed and may vary from 4 to  12  successive drafts. The dies  are usually made  from  tungsten  carbide, alongwith diamond dies can be used for drawing small dimeters.

This  project proposes to use copper scraps as  initial  raw material to produce wire rod.  Thus, wire rods will be  available economically  for  drawing  it to specified  diameter  ranges  of copper  wires.   The facilities will be  installed  in-plant  for testing  of  material  at different stages  of  production,  heat treatments and enamelling.

Thus, the  proposed unit will be a full  fledged  unit  for producing super enamelled winding wires of copper where secondary copper wire rods will be self produced.

COST ESTIMATION

Plant Capacity            1 MT/Day

Land & Building (1000 sq.mt.)    Rs. 91.50 Lac

Plant & Machinery                    Rs. 48.00 Lac

Working Capital for 2 Months    Rs. 1.42 Cr

Total Capital Investment          Rs. 2.98 Cr

Rate of Return                          52%

Break Even Point                      44%

CONTENTS

1.   INTRODUCTION

2.   USES AND APPLICATIONS

3.   BIS SPECIFICATIONS

4.   RAW MATERIALS

5.   MECHANICAL PROPERTIES OF COPPER RODS/BARS

6.   MANUFACTURE OF WIRE ROD FROM SCRAP COPPER

7.   SMELTING, CONVERSION & REFINING OF COPPER

8.   PROCESS FLOW SHEET DIAGRAM

9.   WIRE DRAWING OPERATIONS & EQUIPMENTS

10.  DRAWING DIES

11.  HEAT TREATMENTS OF COPPER WIRES

12.  ENAMELLING OF COPPER WIRES FOR MOTOR WINDING

13.  PROCESS & FLOW DIAGRAM FOR COPPER WIRE ENAMELING

14.  MARKET SURVEY

15.  PRESENT MANUFACTURERS

16.  SUPPLIERS OF TESTING EQUIPMENTS

17.  SUPPLIERS OF PLANT & MACHINERY

18.  SUPPLIERS OF RAW MATERIALS

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)