DUCTILE IRON PIPE (DI PIPE) (PRODUCTION RATE – 50,000 TPA)
[EIRI/EDPR/4726] J.C.: 2946XL
Ductile iron is a family of cast graphitic irons which possess high strength, ductility and resistance to shock. Annealed cast ductile iron can be bent, twisted or deformed without fracturing. Its strength, toughness and ductility duplicate many grades of steel and far exceed those of standard gray irons. Yet it possesses the advantages of design flexibility and low-cost casting procedures similar to gray iron. The difference between ductile iron and gray iron is in the graphite formation. Ordinary gray iron is characterized by a random flake graphite pattern in the metal. In ductile iron the addition of a few hundredths of 1 % of magnesium or cerium causes the graphite to form in small spheroids rather than flakes. These create fewer discontinuities in the structure of the metal and produce a stronger, more ductile iron. This nodular graphite structure inhibits the creation of linear cracks hence the ability to withstand distortion.
With ductile iron, the safety and reliability of process equipment is improved. The improved mechanical properties increase its resistance to breakage from physical load, or mechanical and thermal shock far above that of gray iron. The corrosion resistance of ductile iron is equal or superior to gray cast iron and to cast steel in many corrosives. Its wear resistance is comparable to some of the best grades of steel and superior to gray iron in heavy load or impact load situations. Since it can be cast with the same low-cost procedures used for gray cast iron, it is considerably less expensive than cast steel and only moderately more expensive than gray iron. The substantial advantages obtained from its high yield strength and ductility make it an economical choice for many applications.
COST ESTIMATION
Plant Capacity 167 MT/Day
Land & Building (13505 sq.mt.) Rs. 16.88 Cr
Plant & Machinery Rs. 110.63 Cr
Working Capital for 1 Month Rs. 20.22 Cr
Total Capital Investment Rs. 153.52 Cr
Rate of Return 41%
Break Even Point 54%
CONTENTS
INTRODUCTION
TYPICAL MICRO STRUCTURE OF DUCTILE IRON
WHILE THERE ARE MANY DIFFERENT DUCTILE IRON SPECIFICATIONS, FOUNDRIES ROUTINELY OFFER 3 COMMON GRADES;
PROPERTIES
PROPERTIES OF DUCTILE IRON PIPE
RANGES & DIMENSIONS
RANGES
DIMENSION OF PIPES THICKNESS OF DUCTILE IRON PIPES
BENEFITS
CHARACTERISTICS
THE FOLLOWING ARE THE TYPES OF JOINTS USUALLY USED FOR
DUCTILE IRON PIPES
THERE ARE MAINLY THREE SECTIONS OF DUCTILE IRON PIPE:
SOCKET
BARREL
SPIGOT
ADVANTAGES/DISADVANTAGES
ADVANTAGES
DISADVANTAGES
USES/APPLICATIONS
BIS SPECIFICATION
MARKET OVERVIEW
INDIA DUCTILE IRON PIPES MARKET TRENDS
DUCTILE IRON PIPES MARKET DYNAMICS:
DUCTILE IRON PIPES MARKET REGIONAL INSIGHTS:
DUCTILE IRON PIPES MARKET KEY PLAYERS
MANUFACTURERS/SUPPLIERS
RAW MATERIALS SUPPLIERS
PIG IRON
CAST IRON SCRAP
STEEL SCRAP
SILICON CARBIDE
FERRO SILICON
MAGNESIUM INGOT
FERRO MANGANESE
FIRE CLAY
BENTONITE
COAL DUST
GRAPHITE POWDER
SILICA SAND
LIME STONE
MANUFACTURING PROCESS STEPS
RAW MATERIAL SELECTION
DESULPHURISATION
MELTING AND COMPOSITION CONTROL
MAGNESIUM TREATMENT
NODULISING
INOCULATION
EFFECT OF INOCULATION
MOULD CONDITIONING
CORE MAKING
CASTING
CENTRIFUGAL CASTING
ESSENTIALLY, TWO WORKING METHODS ARE USED:
DE LAVAUD PROCESS
WET-SPRAY PROCESS
INTERNAL GRINDING
HEAT TREATMENT
ZINC COATING
CUT OFF AND CHAMFERING MACHINE
HYDROSTATIC PRESSURE TESTING
CEMENT MORTAR FEEDING AND LINING
STEAM CURING
INTERNAL POLISHING
BITUMEN COATING
QUALITY CONTROL
MARKING AND STENCILING
STORAGE, PACKING AND DISPATCH
PROCESS FLOW
INDUCTION FURNACE & OPERATIONAL ASPECTS
RAW MATERIALS AND ENERGY SOURCE
IMPORTANT ASPECTS OF OPERATION
OTHER ASPECTS OF INDUCTION FURNACE STEEL MAKING
ENVIRONMENTAL EMISSIONS
SAFETY & INDUCTION FURNACE
REASONS OF MOST ACCIDENTS IN THE MELT SHOPS WITH INDUCTION FURNACES ARE
ENGINEERING DESIGN CONSIDERATIONS
ETP FACILITY
ETP FLOW DIAGRAM (TYPICAL)
SEWAGE AND WASTE WATER EFFLUENT
STP FLOW DIAGRAM (TYPICAL)
WASTE GENERATION & MANAGEMENT/GREEN BELT
GREEN BELT
UTILITY REQUIREMENT (ESTIMATED) - MONTH
PLANT & MACHINERY SUPPLIERS
ANNEALING FURNACE
HEATREATMENT FURNACE
INDUCTION FURNACE
SAND MIXTURE AND MULLER
SAND SIEVING MACHINE
SQUEEZE MOLDING MACHINE
SHAKEOUT MACHINE
CORE SHOOTER MACHINE
DRYING OVEN
MOLDING BOXES
METAL TESTING MACHINE
PRECISION MEASURING TOOLS
PRECISION MEASURING TOOLS
NDT INSPECTION EQUIPMENT
DRILLING, LATHE, TAPING MACHINES
GRINDING MACHINE
EOT CRANE
POWER TRANSFORMERS
ELECTRICAL PANEL
ELECTRIC MOTOR
EFFULENT TREATMENT PLANT (ETP PLANT)
AIR POLLUTION CONTROL EQUIPMENTS
AIR CONDITIONING EQUIPMENTS
AIR COMPRESSORS
PLATFORM WEIGHING MACHINE
MATERIAL HANDLING EQUIPMENTS
FIRE FIGHTING EQUIPMENTS
SHOT BLASTING MACHINE
JIGS AND FIXTURE
PRELIMINARY LAYOUT
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)
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)