Mild Steel Wire Drawing (Production Capacity – 7200 TPA)

MILD STEEL WIRE DRAWING (PRODUCTION CAPACITY – 7200 TPA) 

[EIRI/EDPR/4508] J.C.: 2724XL

INTRODUCTION

Mild Steel wire is produced by cold-drawn from Mild Steel rod of appropriate composition through one or more carbide or diamond dies. As the steel rod passes through each die, the diameter is reduced and the length is necessarily increased. Variables such as initial rod diameter, final wire diameter, and end-user applications determine the number of reductions that must take place. The percent of reduction in cross-sectional area occurring at each die determines the extent of work hardening and dictates whether or not further reduction can take place prior to annealing. Annealing is required to soften the work-hardened wire per minute. Due to appearance, hardness, smoothness, non-corrosiveness, and resistance to elevated temperatures, Mild Steel wire is required, or is preferred to other base-metal wires, for particular end-use applications.

COST ESTIMATION

Plant Capacity            24 MT/Day  

Land & Building (5000 sq.mt.)    Rs. 4.00 Cr    

Plant & Machinery                    Rs. 3.39 Cr 

Working Capital for 0.5 Months    Rs. 1.97 Cr 

Total Capital Investment          Rs. 9.91 Cr 

Rate of Return                          47%

Break Even Point                      48%

CONTENTS

INTRODUCTION

PROPERTIES

WORK HARDENING OF STAINLESS STEEL

DUCTILITY OF STAINLESS STEEL

HIGH STRENGTH

USES AND APPLICATION

TECHNICAL SPECIFICATION

B.I.S. SPECIFICATION

MANUFACTURERS/SUPPLIERS

MANUFACTURING PROCESS

THE MAIN STEPS ARE GIVEN BELOW.

(2) RAW MATERIAL (WIRE ROD) PREPARATION

(A) MECHANICAL DESCALING OF WIRE ROD

(B) CHEMICAL DESCALING (PICKLING) OF WIRE ROD

(3) DRAWING

(A) DRY DRAWING OF WIRE

(B) WET DRAWING OF WIRE

(4) HEAT TREATMENT OF WIRE

(A) BATCH ANNEALING

(B) CONTINUOUS (IN-LINE) ANNEALING

(C) CONTINUOUS (IN-LINE) ANNEALING

(D) PATENTING

(E) OIL HARDENING AND TEMPERING (OIL TEMPERING)

(F) STRESS-RELIEVING

(5) IN-LINE PICKLING

(6) FINAL INSPECTION

(7) PACKAGING & DISPATCH

PROCESS FLOW CHART

PLANT LAYOUT

SUPPLIERS OF RAW MATERIALS

PICKLING ACIDS

SUPPLIERS OF PLANT AND MACHINERY

WIRE DRAWING MACHINE

WIRE STRAIGHTENING MACHINE

ANNEALING FURNACE

BULK BLOCK TYPE HEAVY DUTY WIRE DRAWING MACHINE

WIRE MAKING PLANT

BUTT WELDING MACHINE

BENCH GRINDER

DRILLING MACHINE

EOT CRANES

DG SETS

POWER TRANSFORMERS

COOLING TOWER

ETP PLANTS

AIR POLLUTION CONTROL EQUIPMENTS

AIR CONDITIONING EQUIPMENTS

AIR COMPRESSOR

WEIGHING MACHINE

MATERIAL HANDLING EQUIPMENTS

FIRE FIGHTING EQUIPMENTS

ELECTRICAL MEASURING INSTRUMENTS

WIRE POINTING MACHINE

ETP FACILITY

ETP FLOW DIAGRAM (TYPICAL)

SEWAGE AND WASTE WATER EFFLUENT

STP FLOW DIAGRAM (TYPICAL)

WASTE GENERATION & MANAGEMENT / GREEN BELT

GREEN BELT

WATER (ESTIMATED)

WASTE (ESTIMATED)

FLUE GAS (ESTIMATED)

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:

ANTICIPATED ENVIRONMENTAL IMPACTS

CONSTRUCTION PHASE

OPERATION PHASE

MITIGATION MEASURES (PROPOSED)

HEALTH SAFETY & ENVIRONMENT

PROPOSED IMPLEMENTATION SCHEDULE

PROJECT FINANCIALS

BASIS & PRESUMPTIONS (FOR PROFITABILITY WORKINGS)

PRELIMINARY 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)