Detailed Project Report on synthetic slag plant

SYNTHETIC SLAG PLANT
[CODE NO.3705]  



Synthetic slag consists of prepared mixture of several individual oxides which is used during secondary steelmaking to assist the steel treatment in the ladle from the viewpoint of effective refinement. Synthetic slag practice is normally used to obtain clean steels and also for the desulphurization of the liquid steel.

Secondary steelmaking is a critical quality control step between the primary steelmaking and the continuous casting of the liquid steel. A key feature for success with the secondary steelmaking processes is the slag control. Use of synthetic slag which is specifically designed to have the required chemical composition and physical properties helps in the slag control.

The  desirable properties of the synthetic slag include (i) slag is to have high sulphide capacity, (ii) it is to be basic in nature, (iii) it is to be fluid to obtain faster reaction rates, and (iv) it is not to cause excessive refractory wear.

The secondary steelmaking slag is in liquid form in the ladle and floats on the surface of liquid steel which is usually at temperature of 1,600 deg or higher. It acts like a sponge to absorb the impurities consisting mainly of sulphur and non-metallic inclusions. The design of the slag is a critical step impacting the efficiency of the steel refining processes during the secondary steelmaking.

Slag regime in secondary steelmaking significantly influences the final quality of the produced steel, particularly with respect to the achieved desulphurization of steel. One of the possibilities for influencing the slag regime is the application of synthetic slags to the ladle slag, formed from slag-making additions during the liquid steel tapping. Synthetic slag practice during secondary steelmaking maximizes the efficiency of the steel refining process by (i) improving steel quality, (ii) improving productivity, (iii) reducing costs, and (iv) protecting the environment (since it removes the need of addition of fluorspar also called fluorite).



COST ESTIMATION


Plant Capacity            40 MT/Day       
Land & Building (8000 sq.mt.)      Rs. 2.47 Cr         
Plant & Machinery                      Rs. 1.30 Cr     
Working Capital for 2 Months     Rs. 4.96 Cr
Total Capital Investment              Rs. 8.43 Cr
Rate of Return            19%                   
Break Even Point             61%                
          


INTRODUCTION    
USES & APPLICATION    
OVERVIEW OF INDIAN STEEL INDUSTRY    
FAVOURABLE OUTLOOK FOR STEEL CONSUMPTION    
MARKET POSITION OF INDIAN STEEL    
PRODUCTION    
FINISHED STEEL PRODUCTION - PRODUCER    
FINISHED STEEL PRODUCTION - NON-ALLOYED STEEL - FLAT
   & NON-FLAT PRODUCTS    
FLAT STEEL PRODUCTION – NON-ALLOYED STEEL – NON-FLAT    
EXPORTS & IMPORTS OF STEEL    
PRESENT MANUFACTURING OF SYNTHETIC SLAG    
SYNTHETIC SLAG PRACTICE IN STEEL INDUSTRY    
DESULPHURIZATION OF STEEL    
COMPOSITION OF PREMELTED SYNTHETIC SLAG    
PREMELTED SYNTHETIC SLAG FOR LADLE DESULFURIZING MOLTEN STEEL    
SYNTHETIC SLAG FOR STEEL MAKING AND ITS COMPOSITION    
CHEMICAL COMPOSITION    
DESIGN OF SYNTHETIC SLAG
CALCIUM ALUMINATE SYSTEM    
PHASE DIAGRAM FOR CALCIUM ALUMINATE SYSTEM    
CHEMICALS IN THE FORMATION OF SYNTHETIC SLAG    
TRICALCIUM ALUMINATE    
DODECALCIUMHEPT-THE ALUMINATE    
MONOCALCIUM ALUMINATE    
FORMULATION OF SYNTHETIC SLAG    
MANUFACTURING PROCESS OF SYNTHETIC SLAG    
PROCESS FLOW DIAGRAM    
PRODUCTION OF SYNTHETIC SLAG    
REFINING OF STEEL BY USING SYNTHETIC SLAG    
FLUX USED FOR CONDITIONING OF STEEL SLAG    
BLAST FURNACE IRON MAKING    
REACTIONS IN THE UPPER ZONE    
REACTIONS IN THE MIDDLE ZONE    
REACTIONS IN THE LOWER ZONE    
BLAST FURNACE SLAG AND ITS FUNCTION    
FUNCTIONS OF SLAG:-    
INTERNAL ZONES IN A BLAST FURNACE    
PRINCIPLES OF PLANT LAYOUT    
PLANT LOCATION FACTORS    
EXPLANATION OF TERMS USED IN THE PROJECT REPORT    
PROJECT IMPLEMENTATION SCHEDULES    
PLANT LAYOUT    
SUPPLIERS OF RAW MATERIALS    
SUPPLIERS OF PLANT AND MACHINERY    
SUPPLIERS OF RIBBON BLENDER    
SUPPLIERS OF JAW CRUSHER    
SUPPLIERS OF BELT FEEDER    
SUPPLIERS OF PACKAGING MACHINE    
SUPPLIERS OF MATERIAL HANDLING EQUIPMENTS    
SUPPLIERS OF INSTRUMENTATION & PROCESS CONTROL EQUIPMENTS    
SUPPLIERS OF DG SETS    
SUPPLIERS OF PLANT AND MACHINERY (IMPORTED

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)