DUCTILE PIPE MANUFACTURING PLANT
[EIRI/EDPR/4626] J.C.: 2843XL
India is one of the fastest developing economies in the world. Infrastructure lacuna has been an anathema to India's growth. Not surprisingly, India lags behind water infrastructure and sewerage development with only 33% of the total population having access to improved sanitation. In rural areas, where 72% of India's population lives, only 22% has better coverage for sanitation. The Indian pipes business has been growing rapidly since the past several years mainly due to increasing demand for pipes in the irrigation sector, for crude oil, real estate industry and growth in Gross domestic product (GDP) of the country. Among the several varieties of pipes available in the market, the demand for plastic pipes such as PVC, CPVC in particular, is on a rise due to its low cost, high quality and high durability. Other types of pipes, like steel pipes and ductile iron pipes also have major demand. Nationwide infrastructural development, urbanization, government’s focus on real estate, irrigation to drive agricultural growth have been identified as major factors facilitating the growth of the pipes industry in the country. The Government of India is launching new schemes in the irrigation and the real estate sector for significant investments.
It is evident here that the focus of Indian government is on water supply for housing sector, which will only be fulfilled with effective use of pipelines. Therefore, this end-user is a major demand driver of pipes. Furthermore, strong demand for crude oil transportation is also adding to the demand of pipes across the country. The major grades demanded in the Indian markets is the K7 and K9 series, the governmental authorities and waste water authorities majorly demand DN 80 mm to DN 1000 mm diameter or sizes of specifications.
COST ESTIMATION
Plant Capacity 99,663.43 Meters/Day
Land & Building (15 Acres) Rs. 17.87 Cr
Plant & Machinery Rs. 101.55 Cr
Working Capital for 1 Month Rs. 241.00 Cr
Total Capital Investment Rs. 365.20 Cr
Rate of Return 95%
Break Even Point 19%
CONTENTS
INTRODUCTION
DUCTILE IRON
FIG 1 TYPICAL MICRO STRUCTURE OF DUCTILE IRON
COMMON DUCTILE IRON GRADES
THE FAMILY OF DUCTILE IRON
PROPERTIES OF DUCTILE IRONS
BENEFITS OF DUCTILE IRON
THE FOLLOWING ARE THE BENEFITS OF DUCTILE IRON.
DUCTILE IRON PIPE
HISTORY OF DUCTILE IRON PIPES
CHARACTERISTICS OF DUCTILE IRON PIPE
TYPE OF JOINTS
THE FOLLOWING ARE THE TYPES OF JOINTS USUALLY USED FOR DUCTILE IRON PIPES
THERE ARE MAINLY THREE SECTIONS OF DUCTILE IRON PIPE:
1. SOCKET
2. BARREL
3. SPIGOT
RANGE OF PIPES
TECHNICAL DETAILS
PIPE DIMENSION
BASIC DIMENSION OF PIPES THICKNESS OF DUCTILE IRON PIPES
ADVANTAGES
ADVANTAGES OF DUCTILE IRON PIPES
DISADVANTAGES
USES AND APPLICATION
B.I.S. SPECIFICATION
PRODUCTION PROCESS
(1) RAW MATERIAL SELECTION
(2) DESULPHURISATION
(3) MELTING AND COMPOSITION CONTROL
(4) MAGNESIUM TREATMENT
NODULISING:
(5) INOCULATION
EFFECT OF INOCULATION
(7) CORE MAKING
(8) CASTING
CENTRIFUGAL CASTING
DE LAVAUD PROCESS
WET-SPRAY PROCESS
(9) INTERNAL GRINDING
(10) HEAT TREATMENT
(11) ZINC COATING
(12) CUT OFF AND CHAMFERING MACHINE
(13) HYDROSTATIC PRESSURE TESTING
(14) CEMENT MORTAR FEEDING AND LINING
(15) STEAM CURING
(17) INTERNAL POLISHING
(17) BITUMEN COATING
CROSS SECTIONAL DIAGRAM
ZINC COATING
CEMENT MORTAR LINING
BITUMINOUS COATING
RUBBER GASKET
(18) QUALITY CONTROL
QUALITY CONTROL CHECKS AT EVERY STAGE OF MANUFACTURING
(19) MARKING AND STENCILING
(20) STORAGE, PACKING AND DISPATCH
ELECTRIC INDUCTION FURNACES VERSUS CUPOLAS FOR MELTING IRON
INDUCTION FURNACE AND IMPORTANT OPERATIONAL ASPECTS
RAW MATERIALS AND ENERGY SOURCE
IMPORTANT ASPECTS OF OPERATION
OTHER ASPECTS OF INDUCTION FURNACE STEEL MAKING
FIG 1 TYPICAL HEAT BALANCE DIAGRAM OF CRUCIBLE
INDUCTION FURNACE
ENVIRONMENTAL EMISSIONS
SAFETY AND INDUCTION FURNACES
MARKET SURVEY FOR DI PIPE
DOMESTIC MANUFACTURERS OF DI PIPE
TOP MANUFACTURES OF DUCTILE IRON PIPE GLOBALLY:-
DUCTILE IRON PIPES MARKET GROWTH
DI PIPES MARKET OUTLOOK
DUCTILE IRON PIPES MARKET FORECAST FROM 2022 TO 2030
OPPORTUNITIES FOR DI PIPE MANUFACTURERS
INDIAN DI PIPE MARKET AND FOREIGN MANUFACTURERS
HOW ARE INDIAN POLICIES RAISING THE DEMAND FOR DI PIPES?
ECONOMIC GROWTH
DEMAND FOR WATER
DEMAND ANALYSIS FOR DI PIPES
THE DEMAND DRIVERS FOR PIPES IN GENERAL AND DI PIPES IN PARTICULAR ARE:
INVESTMENT IN WATER PROJECTS AND ROLE OF GOVERNMENT
BODIES
EXTERNAL AID
PLANT LAYOUT
DUCTILE IRON PIPE MANUFACTURERS
DUCTILE IRON PIPE PLANT & MACHINERY MANUFACTURERS
SUPPLIERS OF RAW MATERIALS
SUPPLIERS OF PIG IRON
SUPPLIERS OF CAST IRON SCRAP
SUPPLIERS OF STEEL SCRAPE
SUPPLIERS OF SILICON CARBIDE
SUPPLIERS OF FERRO SILICON
SUPPLIERS OF MAGNESIUM INGOT
SUPPLIERS OF FERRO MANGANESE
SUPPLIERS OF FIRE CLAY
SUPPLIERS OF BENTONITE
SUPPLIERS OF COAL DUST
SUPPLIERS OF GRAPHITE POWDER
SUPPLIERS OF SILICA SAND
SUPPLIERS OF LIME STONE
SUPPLIERS OF PLANT AND MACHINERY
SUPPLIERS OF ANNEALING FURNACE
SUPPLIERS OF HEATREATMENT FURNACE
SUPPLIERS OF INDUCTION FURNACE
SUPPLIERS OF ALUMINIUM PATTERNS
SUPPLIERS OF INTENSIVE SAND MIXTURE AND MULLER
SUPPLIERS OF SAND SIEVING MACHINE
SUPPLIERS OF SQUEEZE MOLDING MACHINE
SUPPLIERS OF SHAKEOUT MACHINE
SUPPLIERS OF CORE SHOOTER MACHINE
SUPPLIERS OF DRYING OVEN
SUPPLIERS OF FOUNDRY TOOLS
SUPPLIERS OF MOLDING BOXES
SUPPLIERS OF METAL TESTING MACHINE
SUPPLIERS OF PRECISION MEASURING TOOLS
SUPPLIERS OF PRECISION MEASURING TOOLS
SUPPLIERS OF NDT INSPECTION EQUIPMENT
SUPPLIERS OF DRILLING, LATHE, TAPING MACHINES
SUPPLIERS OF GRINDING MACHINE
SUPPLIERS OF EOT CRANE
SUPPLIERS OF POWER TRANSFORMERS
SUPPLIERS OF ELECTRICAL PANEL
SUPPLIERS OF ELECTRIC MOTOR
SUPPLIERS OF COOLING TOWER
SUPPLIERS OF EFFULENT TREATMENT PLANT (ETP PLANT)
SUPPLIERS OF AIR POLLUTION CONTROL EQUIPMENTS
SUPPLIERS OF AIR CONDITIONING EQUIPMENTS
SUPPLIERS OF AIR COMPRESSORS
SUPPLIERS OF PLATFORM WEIGHING MACHINE
SUPPLIERS OF MATERIAL HANDLING EQUIPMENTS
SUPPLIERS OF FIRE FIGHTING EQUIPMENTS
SUPPLIERS OF SHOT BLASTING MACHINE
SUPPLIERS OF JIGS AND FIXTURE
PRINCIPLES OF PLANT LAYOUT
STORAGE LAYOUT:
EQUIPMENT LAYOUT:
SAFETY:
PLANT EXPANSION:
FLOOR SPACE:
UTILITIES SERVICING:
BUILDING:
MATERIAL-HANDLING EQUIPMENT:
RAILROADS AND ROADS:
PLANT LOCATION FACTORS
PRIMARY FACTORS
1. RAW-MATERIAL SUPPLY:
2. MARKETS:
3. POWER AND FUEL SUPPLY:
4. WATER SUPPLY:
5. CLIMATE:
SPECIFIC FACTORS
6. TRANSPORTATION:
A. AVAILABILITY OF VARIOUS SERVICES AND PROJECTED RATES
7. WASTE DISPOSAL:
8. LABOR:
9. REGULATORY LAWS:
10. TAXES:
11. SITE CHARACTERISTICS:
12. COMMUNITY FACTORS:
13. VULNERABILITY TO WARTIME ATTACK:
14. FLOOD AND FIRE CONTROL:
EXPLANATION OF TERMS USED IN THE PROJECT REPORT
1. DEPRECIATION:
2. FIXED ASSETS:
3. WORKING CAPITAL:
4. BREAK-EVEN POINT:
5. OTHER FIXED EXPENSES:
6. MARGIN MONEY:
7. TERM LOANS:
8. TOTAL LOAD:
9. LAND AREA/MAN POWER RATIO:
STATUTORY APPROVALS FROM GOVERNMENT
DOCUMENTS REQUIRED FOR LICENSES
LIST OF DOCUMENTS:
SWOL ANALYSIS
STRENGTHS
OPPORTUNITIES
WEAKNESS
LIMITATIONS
ORGANIZATION CHART
IMPLEMENTATION SCHEDULE
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)