Detailed Project Report on Integrated Scrap Yard

INTEGRATED SCRAP YARD

[EIRI/EDPR/1448] J.C.229

INTRODUCTION

A typical metal recycling facility recycles a variety of materials, including ferrous and nonferrous scrap metals, vehicles and parts, communication cables, radiators, and batteries. The recycling process includes receiving, sorting, processing, packaging, storing and shipping the materials or metals to other facilities where they can be reused or reprocessed. Sorting is either done manually or by machines such as shaker beds, cranes, or magnets. Large scrap metal parts are cut with shears or torches into smaller pieces. The scrap metal is then compressed and packaged, commonly by balers for storage and transportation.

Lead is a ubiquitous metal, and a known environmental and industrial hazard (1). Many of the materials being recycled, such as batteries, radiators, and metals contain lead. It may be in the coatings on the scrap metal (lead-based paint or galvanized coatings) (2). It may also be present in the metal as an additive, alloy element or contaminant (3, 4, 5, 6). When metal recycling workers cut, shear, bale or sort scrap metals, they can be exposed to lead dust and fume.

Lead can be absorbed into the body by inhalation (breathing) and ingestion (eating) (7). Once lead gets into the body, it travels in the blood to the “soft tissues” such as the liver, kidneys, lungs, brain, spleen, muscles, and heart before it moves to the bones and teeth where it may stay for decades (8). Elevated blood lead levels in adults can damage the cardiovascular, central nervous, reproductive, hematologic, and renal systems (7). The mean blood lead level (BLL) of adults in the United States is less than three micrograms of lead per deciliter of whole blood (μg/dL) (9). The U.S. Department of Health and Human Services recommends that BLLs among all adults be less than 25 μg/dL (9). According to the U.S. Occupational Safety and Health Administration’s (OSHA) lead standard for general industry, a worker must be removed from further lead exposure when the worker’s BLL is at or above 60 μg/dL1 or the average of the worker’s last three BLLs is at or above 50 μg/dL1 (7). The worker cannot return to work unless his or her BLL is reduced to below 40 μg/dL1.

COST ESTIMATION

Land & Building (20 Acre)                          Rs. 52.15 Lacs
Plant & Machinery                                       Rs. 1.39 Cr  
W.C. for 1 Month                                         Rs. 1.66 Cr 
Total Capital Investment                             Rs. 3.61 Cr    
Rate of Return                                             38%   
Break Even Point                                        53%

CONTENTS

INTRODUCTION

MARKET POSITION

IRON AND STEEL

CURRENT STEEL RECYCLING

CLASSIFICATION OF STEEL SCRAP, INTERMEDIARY PRODUCTS AND WASTE

NEW STEEL SCRAP SORTING TECHNOLOGIES

COMMON GRADES OF CAST IRON SCRAP

WASTE FROM THE STEEL-MAKING INDUSTRY

STAINLESS STEEL CLASSIFICATIONS

SCHEMATIC DIAGRAM OF SCRAP PROCESSING PLANT

IMPLEMENTATION SCHEDULE

EFFLUENT TREATMENT AND DISPOSAL

MANPOWER

PLANT LAYOUT

LIST OF PLANT AND MACHINERY SUPPLIERS

LIST OF PAPER, PLASTIC SHREDER/CUTTING MACHINES

list of plastic carry bags recycler

INDUSTRIAL ETP PLANT MANUFACTURE/SUPPLIER

REFERENCES

METALS - FERROUS SCRAP » CAST IRON GRADES

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)