Detailed Project Report on Ferro Silicon

FERRO SILICON

[EIRI/EDPR/4385] J.C.: 2579NU, 2580INR 

INTRODUCTION

Ferrosilicon is an alloy of iron and silicon with typical silicon content by weight of 15–90%. It contains a high proportion of iron silicides. Ferrosilicon containing silicon is used extensively by the iron and steel industry, and silicon is present in most commercial grades of steel and cast iron.   

Ferroalloys Plays major role in Steel Production and industrial development. Ferro-alloys are iron based alloys with varied elements introduced in steel making to cater to the specific needs. These are specified additions to the production of steel for various applications.

Ferro alloys are iron bearing alloys with additives which are passed on to steel to meet specific needs. The Ferro alloys are brittle and can be crushed to any size to be added to the molten steel as additives. Generally the additives as in steel are invariably added in the form of Ferro alloys. These are established additives in the steel production to obtain specific needs. 

The market for ferrosilicon is largely in steel (85%) and cast iron (15%), with very small amounts used in non-ferrous alloys.

The demand for ferrosilicon has been increasing with that of alloy and special steels. Owing to the lack of a viable alternative that can meet the diverse applications, the global ferro alloys market is estimated to expand at an CAGR of 5.9% till 2025. A significant share of the bulk ferro alloys are used in the production of the steel because of the low prices of the bulk ferro alloys and high production around the major producing regions. The prosperity of the building and construction industry in a number of emerging economies is another key driver of the global ferro alloys market, wherein the development of lightweight and high strength steel grades is expected to open up opportunities.

COST ESTIMATION

Plant Capacity            40 MT/Day

Land & Building (22,405 sq.mt.)    Rs. 19.04 Cr

Plant & Machinery                    Rs. 7.03 Cr

Working Capital for 1 Month    Rs. 7.84 Cr

Total Capital Investment          Rs. 34.52 Cr

Rate of Return                          84%

Break Even Point                      45%

CONTENTS

INTRODUCTION

MARKET OVERVIEW

GLOBAL

HIGH DEMAND FOR STEEL IN AUTOMOTIVE, CONSTRUCTION, AND MANUFACTURING INDUSTRIES TO DRIVE MARKET

BURGEONING GROWTH OF AUTOMOBILE AND CONSTRUCTION INDUSTRIES TO BOOST FERROSILICON MARKET

INCREASE IN USAGE OF ALLOY STEEL AND CAST IRON IN AUTOMOBILE AND CONSTRUCTION INDUSTRIES TO AUGMENT MARKET

REGIONAL OUTLOOK OF GLOBAL FERROSILICON MARKET

ANALYSIS OF KEY PLAYERS IN FERROSILICON MARKET

KEY DEVELOPMENTS IN GLOBAL FERROSILICON MARKET

BHUTAN

USES/APPLICATIONS

THE FOLLOWING ARE THE COMMON APPLICATION AREAS OF FERROSILICON:

SPECIFICATIONS

PROPERTIES

FERROSILICON MSDS

HEALTH HAZARDS

FIRST AID MEASURES

PERSONAL PROTECTION

ACCIDENTAL RELEASE MEASURES

FIRE HAZARDS

HANDLING OF FERROSILICON

STORAGE OF FERROSILICON

RAW MATERIALS

PROCESS CHEMISTRY & OPERATING CONSIDERATIONS 

EQUILIBRIUM OF THE IRON SILICON SYSTEM

SEGREGATION IN ALLOYS AND DISINTEGRATION OF ALLOYS

PHYSICO-CHEMICAL CONSIDERATIONS IN FERRO-SILICON SMELTING

FORMATION OF SLAG DURING SMELTING

SHORTAGE OF REDUCER IN THE CHARGE MIX ALSO LEADS TO MORE AMOUNT OF SLAG

THE MAIN REDUCTION REACTIONS DURING THE SMELTING PROCESS ARE

FOR NORMAL GRADE OF FERRO-SILICON, THE REDUCED OXIDES ARE DISTRIBUTED BETWEEN METAL AND STACK LOSSES AS FOLLOWS:

OPERATING CONSIDERATIONS

MANUFACTURING PROCESS STEPS

PROCESS FLOW

ENGINEERING DESIGN CONSIDERATIONS

PLANT/MACHINERY (BROADLY)

PLANT & MACHINERY SUPPLIERS  (INDIA)

ELECTRIC ARC FURNACE

INDUCTION FURNACE

STEAM TURBINES

ELECTRICAL & POWER TRANSFORMERS

ELECTRICAL CONTROL PANELS & DISTRIBUTION BOARDS

COOLING TOWERS 

EFFLUENT TREATMENT PLANT

INDUSTRIAL WEIGHING SCALE

STEEL FABRICATORS

SUPPLIERS OF RAW MATERIALS

PRINCIPLES OF PLANT LAYOUT

MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE:

PLANT LOCATION FACTORS

PRIMARY FACTORS

RAW-MATERIAL SUPPLY:

MARKETS:

POWER AND FUEL SUPPLY:

WATER SUPPLY:

CLIMATE:

TRANSPORTATION:

WASTE DISPOSAL:

LABOR:

REGULATORY LAWS:

TAXES:

SITE CHARACTERISTICS:

COMMUNITY FACTORS:

FLOOD AND FIRE CONTROL:

GENERATION & MANAGEMENT OF WASTES/GREEN BELT

WASTE WATER (ESTIMATED)

WASTE (ESTIMATED)

SEWAGE AND WASTE TREATMENT FACILITY

HEALTH SAFETY AND ENVIRONMENT

ANTICIPATED ENVIRONMENTAL IMPACTS 

CONSTRUCTION PHASE 

OPERATION PHASE 

MITIGATION MEASURES (PROPOSED)

HSE REQUIREMENT

PROPOSED IMPLEMENTATION SCHEDULE

PROJECT FINANCIALS

BASIS & PRESUMPTIONS (FOR PROFITABILITY WORKINGS)

PRELIMINARY PLANT LAYOUT

CONCLUSIONS

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)