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)
