Detailed Project Report on Ferro Silicon (From Mineral Ingredients)

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FERRO SILICON (FROM MINERAL INGREDIENTS)

[EIRI/EDPR/1383]J.C.159

INTRODUCTION

Ferro alloys are used in making alloy steels and castings of different special types as addition agents. Ferro alloys are usually made in electric-are furnaces. Alloy steel have often greater limitations on tramp element concentrations than plain carbon steels.

Municipal ferrows scraps is largely used as part of the furnace charge to produce ferro alloys. Incinerated scrap is preferred because all of the consuminats are eleminiated though this source leaves a significant proportion of tin & copper impurities, yes due to the fact that ferro alloy is typically only a small addition to the final steel, the dilution of impurities, contained in the ferro alloy, results in acceptable concentrations.

Addision Agents:

In steel making, various elements are added to the molten metal to effect various properties, eg. deoxidasion grain controly improvement of mechanical/ thermal/ corrosion properties etc.

Chemicals added into steels in the bath consists of iron and the elements intended to be incorporated, hence called ferroalloys. These ferro alloys are produced in electric & many other types of furnaces. A number of ferro alloys produced today contain very little of iron. Ferro alloys are, thus, a special class of addition agents. Ferroalloys/addition agents can be added to the charge in the furnace, the molten bath near finishing period, laddle or in the mould.

Aluminium, baron, calcium, chromium, manganese, molybdenum, nickle, nitrogen, phosphorous, niobium, selenium, titanium & zirconium are the main addition elements used in steel. However, aluminium, boron, calcium, cobalt, copper, magnesium & sulphar are not introduced in the steel as ferroalloy rather these are used in their pure mitallic form.

The ferro alloys under the Govt's broad banning scheme are classified as:

1. Bulk ferroalloys

2. Noble ferroalloys.

Bulk ferroalloys include ferro chrome/chargechrome ferro manganex, ferrosilicon etc. while niobium, nickel, titanium, tantalum, tungsten and vanadium form noble ferroalloys. Two or more of these elements can be associated with any one ferroalloy in known proportions for metalhirgical in known proporation for metalligical uses.

Depending on affinity for oxygen compared to iron, copper, molybdenum & nickel can be added with the charge or during melting and are fully recovered cr & mn elemnets are easily oxidized and hence, need to be added late during melting or in ladle. Al, Ti, V & Zr easily oxides and are added need in ladle only to minimaige oxidation losses.

COST ESTIMATION

Plant Capacity 200 MT/Day

Land & Building (1,00,000 sq.mt.) Rs. 1.99 Cr

Plant & Machinery Rs. 6.62 Cr

Working Capital for 2 Months Rs. 68.70 Cr

Total Capital Investment Rs. 78.21 Cr

Rate of Return 72%

Break Even Point 70%

CONTENTS

INTRODUCTION

USES & APPLICATIONS

B.I.S. SPECIFICATION

PROPERTIES

MARKET POSITION

INDIAN FERRO ALLOYS INDUSTRY AT CROSS ROADS

MANUFACTURERS/EXPORTERS/SUPPLIERS

PRODUCTION OF FERRO-SILICON TYPICAL FLOW DIAGRAM

MANUFACTURING PROCESS

PROCESS FLOW DIAGRAMS

PLANT LAYOUT

SUPPLIERS OF RAW MATERIALS

LIME POWDER

METAL SCRAP

WOOD CHARCOAL

SUPPLIERS OF PLANT AND MACHINERY

INDUCTION FURNACE

STEAM TURBINES

ELECTRICAL & POWER TRANSFORMERS

ELECTRICAL CONTROL PANELS & DISTRIBUTION BOARDS

COOLING TOWERS

EFFLUENT TREATMENT PLANT

INDUSTRIAL WEIGHING SCALE

STEEL FABRICATORS

PRINCIPLES OF PLANT LAYOUT

PLANT LOCATION FACTORS

EXPLANATION OF TERMS USED IN THE PROJECT REPORT

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)

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