S.G. IRON & ALLOY STEEL CASTINGS
[EIRI/EDPR/0689] (J.C.:9298)
THE PROJECT (AT A GLANCE)
Foundry is one of the oldest industries. However Indian foundries have so far been of conventional type. But, in the modern industrial arena, competitiveness of a foundry is of utmost importance.
The foundry units are becoming more-and-more automated in order to improve efficiencies. Modern metal melting furnaces are designed from the view points of minimising pollutions, maximising energy savings and suitably to use frequently changing raw materials. Process parameters are strictly controlled and adjusted automatically with the built-in devices & instrumentations. All these latest provisions are required to be introduced in foundries today which push up the capital costs greatly. This high capital cost needs to be compensated by installing high capacity furnace for large quantity production. It also requires to produce value added products as far as possible. Certain operational precautions are additionally required, loading to maximum material utilization, less rejections and highest recovery.
This project has been planned in this light. S.G.iron and alloy steel castings are in great demand in a large number of automobile, railway, general engineering, machine tools, pipe fittings & various other sectors.
A special technique is required to produce good quality S.G.Iron as well as alloy steel castings. The outlines of technicalities used, have been delineated in required details, however, the real control of process parameters & actual operation-details, process/materials/products design remain to be the part of technical know-how.
COST ESTIMATION
Plant Capacity 25 MT/Day
Land & Building (4000 sq.mt.) Rs. 2.15 Cr
Plant & Machinery Rs. 1.36 Cr
Working Capital for 2 Months Rs. 5.86 Cr
Total Capital Investment Rs. 10.96 Cr
Rate of Return 60%
Break Even Point 49%
CONTENTS
THE PROJECT (AT A GLANCE)
INTRODUCTION
CLASSIFICATION OF FOUNDRY PRODUCTS:-
SPHEROIDAL GRAPHITE (S.G.) IRON:-
STEEL CASTINGS:-
STEEL CASTINGS ARE CLASSIFIED AS
ALLOYED STEELS ARE CATEGORISED AS:
MOULD MAKING & CASTING PROCESS:-
THE MOULDS USED FOR STEEL CASTING MUST FULFIL THE FOLLOWING REQUIREMENTS:-
B.I.S. SPECIFICATIONS
PROPERTIES & APPLICATION
(A) S.G. IRON:-
PROPERTIES & APPLICATIONS OF ALLOY STEEL CASTINGS
MECHANICAL PROPERTIES OF ALLOY STEELS INCLUDE:-
SIMILARLY, ENGG. PROPERTIES OF ALLOY STEELS INCLUDE:-
PHYSICAL PROPERTIES:-
DEFECTS IN STEEL CASTINGS:-
DEFECTS DUE TO POOR DESIGN:-
DEFECTS DUE TO INCORRECT CASTING PROCEDURES:-
DEFECTS DUE TO CARELESS FETTLING:-
DEFECTS DUE TO DEFECTIVE HEAT TREATMENT:-
MARKET SURVEY
CONSUMPTION PATTERN
EXPORT:
DISTRIBUTION OF FOUNDRY UNITS AT BELGAUM BY END-USE MARKETS
DISTRIBUTION OF FOUNDRY UNITS AT COIMBATORE BY END-USE SEGMENTS
DISTRIBUTION OF FOUNDRY UNITS BY END-USE SEGMENTS
DISTRIBUTION OF FOUNDRY UNITS AT KOLHAPUR BY END-USE MARKETS
DISTRIBUTION OF FOUNDRY UNITS AT RAJKOT BY END-USE MARKETS
2.2 INTERNATIONAL SCENARIO
PRESENT MANUFACTURERS/EXPORTERS/SUPPLIERS
STATE-WISE LICENSED CAPACITY:-
CONCLUSION:-
SEQUENCE OF STEPS IN SAND PREPARATION
MOULDING PROCESSES:-
(A) HAND MOULDING:-
(B) MACHINE MOULDING:-
ADVANTAGES OF MACHINE MOULDING OVER HAND MOULDING:-
USE OF RISER IN THE MOULD:-
FLOW-CHART FOR RECLAMATION OF MOULDING SANDS
PARTING POWDERS & DUSTS:-
WASHES, PASTES, POWDERS & OTHER DRESSINGS:-
PROPERTIES OF MOULDING RAW MATERIALS FOR QUALITY STEEL CASTING
CLASSIFICATION OF NATURAL SAND
AVAILABILITY OF THESE SANDS AT:
COMPOSITION OF NATURAL SILICA SAND:-
CRUDE SILICA SAND:-
HIGH SILICA SANDS:-
SPECIAL SANDS:-
CHROMITE SAND FOR STEEL CASTING MOULDS
COMPOSITION OF CHROMITE SAND & ITS SPECIFICATIONS
ELECTRIC ARC FURNACES FOR STEEL INDUSTRY
DRAW BACKS OF AC-BASED EAF:-
CONSTRUCTION OF DC SUPPLY EAF
MELTING OPERATION:-
TYPICAL OPERATIONAL RESULTS OF A D.C-BASED EAF
ELECTRODE CONSUMPTION DATA AC VS DC EAFS
REFRACTORY LINING:-
POLLUTION EFFECTS:-
DRAW BACKS OF DC TYPE EAFS:-
ANNUAL COSTS FOR AC & DC TYPE EAFS
REFRACTORIES FOR MELTING FURNACES (EAF & LF)
REFRACTORIES ARE WELL SPECIFIED FOR THE FOLLOWING AREAS OF A UHP-EBT-EAF MELTING FURNACE:-
WASTE GAS CLEANING & RECOVERY IN STEEL MELTING PLANT
STUDY OF POWER CONSUMPTION IN AN EAF
SELECTION OF PARAMETERS:-
UNDER THE ELECTRICAL PARAMETERS, THE VARIABLE ARE:-
TAILOR-MADE MINI STEEL PLANTS
MELTSHOP CONFIGURATION OF MODERN MSPS:-
TYPICAL PLANT SPECIFICATIONS OF A 25-TONS CAPACITY MINI MILL:-
QUALITY STEELS FROM SPONGE IRON:-
MELTING TECHNIQUE
EFFECTS OF CONSTITUENT ELEMENTS IN S.G.IRON:-
(A) CARBON:-
(B) SILICON:-
(C) SULPHUR & MANGANESE:-
(D) PHOSPHOROUS:-
(E) NICKEL:-
(F) CHROMIUM:-
(G) CERIUM:-
MAGNESIUM:-
FOUNDRY TECHNIQUE
COMPOSITION OF S.G. IRON FOR VARIOUS APPLICATIONS:-
PROCESS FLOW SHEET
PLANT LAYOUT FOR S.G. IRON & ALLOY STEEL FOUNDRY
MACHINERY SUPPLIERS FOR SG IRON AND ALLOY STEEL CASTING
LIST OF PLANT AND MACHINERY SUPPLIERS
ELECTRIC ARC MELTING FURNACES
COMPRESSOR
PUMP
LABORATORY EQUIPMENTS
TRANSFORMERS MANUFACTURERS/SUPPLIERS
SUPPLIERS OF RAW MATERIALS
STEEL SCRAP
FERRO ALLOYS
PIG IRON
MANUFACTURER OF GRAPHITE ELECTRODES
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)