MS INGOT AND NONFERROUS COPPER BASED AND MASTER ALLOY INGOTS
[EIRI/EDPR/4471] J.C.: 2685XL
Mild steel Ingots are the basic raw material for the manufacture of various types of re-rolled products, for e.g. rounds, flats, channels equal and unequal angles etc. A major part of this re-rolled products in the form of cold-twisted deformed bars are used in building construction as reinforcement.
Ingot is the product obtained by pouring liquid steel into cast iron mould of a shape appropriate for the subsequent processing generally by hot rolling or forging into semi-finished or finished products. The shape generally resembles a truncated pyramid or truncated cone. The side surfaces can be corrugated and the corners are more or less rounded. Depending on its subsequent conversion requirements, ingot can be dressed and/or hot scarred or cropped.
The usual cross section of ingot is square, rectangular, round, oval, or polygon. Ingots with square cross section are used for rolling into billets, rails and other structural sections, whereas, ingots with rectangular cross section, are generally used for rolling into flat products. These ingots usually have a width which is two times or higher than the thickness. Round ingots are used for the production of seamless pipes. Polygonal ingots are used to produce tyres, and wheels etc. Low capacity steel melting shops with induction furnaces produce very small cross section ingots which are called as pencil ingots.
COST ESTIMATION
Plant Capacity 30 MT/Day
Land & Building (6000 sq.mt.) Rs. 3.40 Cr
Plant & Machinery Rs. 2.07 Cr
Working Capital for 1 Month Rs. 10.73 Cr
Total Capital Investment Rs. 16.57 Cr
Rate of Return 50%
Break Even Point 43%
CONTENTS
INTRODUCTION
SPECIFICATION OF STEEL INGOT
STEEL INGOT SPECIFICATION:
M.S. INGOTS
COPPER BASED MASTER ALLOY
MASTER ALLOY
CHEMICAL COMPOSITION
APPLICATIONS
ALUMINIUM SILICON MASTER ALLOY INGOTS
AL3538 ALUMINUM-SILICON MASTER ALLOY INGOT (ALSI20)
ALUMINUM-SILICON MASTER ALLOY INGOT DESCRIPTION
ALUMINUM-SILICON MASTER ALLOY INGOT SPECIFICATIONS
PROPERTIES OF MILD STEEL
CHEMICAL PROPERTIES OF MILD STEEL
PHYSICAL PROPERTIES OF MILD STEEL
USES AND APPLICATION OF MS INGOTS
B.I.S. SPECIFICATION
MS INGOTS CASTING
CASTINGS
SEQUENCES IN MS INGOTS MAKING
STEEL INGOT SPECIFICATION:
TECHNOLOGY:
PROCESS:
CHARGING
MELTING
REMOVAL OF SLAG
REFINING
TAPPING
TECHNICAL DETAILS OF M.S. INGOT MANUFACTURE
PROCESS FLOW DIAGRAM
CASTING OF INGOT
MECHANISM OF SOLIDIFICATION OF LIQUID STEEL IN INGOT MOULD
MICRO-SEGREGATION AND MACRO-SEGREGATION IN STEEL INGOTS
FIG 1 THREE DISTINCT MACRO-STRUCTURE ZONES IN STEEL INGOTS
FIG 2 MACRO-SEGREGATION PHENOMENON DURING SOLIDIFICATION
IN INGOT MOULD
DEFECTS OF KILLED STEEL INGOTS
FIG 3 PIPE FORMATION DURING SOLIDIFICATION OF LIQUID STEEL
IN INGOT MOULD
MANUFACTURING PROCESS
1. PREPARATION OF SCRAP
PROCESSES FOR SORTING AND PREPARATION OF STEEL SCRAP
MECHANICAL PROCESSES
FIG 1 PROCESSES FOR PREPARATION OF STEEL SCRAP
MAGNETIC SEPARATION PROCESS
EDDY CURRENT SEPARATION PROCESS
HEAVY MEDIA SEPARATION PROCESS
SEPARATION BY PHYSICAL AND CHEMICAL CHARACTERISTICS
DECOATING PROCESSES
DEZINCING PROCESS FOR STEEL SCRAP
DETINNING PROCESS FOR STEEL SCRAP
DECOPPERIZATION PROCESS FOR STEEL SCRAP
INCINERATION
RECENT STEEL SCRAP SORTING TECHNOLOGIES
PORTABLE OPTICAL EMISSION SPECTROMETERS
COLOUR SORTING PROCESS
PROCESS UTILIZING LASER INDUCED BREAKDOWN SPECTROSCOPY
2. MELTING
OPERATION OF INDUCTION FURNACE
FIG 1 SCHEMATICS OF AN INDUCTION FURNACE
FIG 2 A CORELESS INDUCTION FURNACE
BATH AGITATION MECHANISM
FIG 3 POWER DISTRIBUTION (LEFT) AND FLOW PATTERN (RIGHT)
REFRACTORY LINING
PRODUCTION OF MILD STEEL BY INDUCTION FURNACE
COMPARISON WITH ELECTRIC ARC FURNACE STEEL MAKING PROCESS
THE DISADVANTAGES ARE
KEY ADVANTAGES OF INDUCTION HEATING
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
CASTING OF BILLET
MECHANISM OF SOLIDIFICATION OF LIQUID STEEL IN INGOT MOULD
MICRO-SEGREGATION AND MACRO-SEGREGATION IN STEEL INGOTS
FIG 1 THREE DISTINCT MACRO-STRUCTURE ZONES IN STEEL INGOTS
FIG 2 MACRO-SEGREGATION PHENOMENON DURING SOLIDIFICATION
IN INGOT MOULD
DEFECTS OF KILLED STEEL INGOTS
FIG 3 PIPE FORMATION DURING SOLIDIFICATION OF LIQUID STEEL
IN INGOT MOULD
QUALITY CONTROL
OVERVIEW OF STEEL INGOTS
STAINLESS STEEL
MILD STEEL
INFRASTRUCTURE
POWER SECTORS
TRANSPORTATION
INDUSTRIAL
GROWTH FACTORS OF THE STEEL INGOTS MARKET
MARKET OVERVIEW OF STEEL INDUSTRY
CHART 1: TREND IN GLOBAL STEEL PRICES
CHART 2: TREND IN IMPORT AND EXPORT OF FINISHED STEEL
TABLE 1: INDIA’S STEEL SCENARIO DURING H1FY21 AND H2FY21
INDIAN GOVERNMENT ROLE
NON FERROUS METAL INDUSTRY
A. INDUSTRY RISK:
SIZE AND MARKET SHARE:
DOWNSTREAM PRODUCT DIVERSITY:
MARKET OVERVIEW OF NON FERROUS METAL
WHAT IS THE GLOBAL PROCESSED NONFERROUS METAL MARKET?
THE GLOBAL PROCESSED NONFERROUS METAL MARKET IS SEGMENTED:
SUPPLIERS OF MS INGOT
SUPPLIERS OF RAW MATERIALS
SUPPLIERS OF STEEL SCRAPE
SUPPLIERS OF COKE
SUPPLIERS OF LIME
SUPPLIERS OF FERRO ALLOY
SUPPLIERS OF PICKLING CHEMICALS
SUPPLIERS OF PLANT AND MACHINERY
SUPPLIERS OF SHREDDER
SUPPLIERS OF DE-COATER
SUPPLIERS OF MAGNETIC SEPARATOR
SUPPLIERS OF INDUCTION FURNACE
SUPPLIERS OF INGOT CASTING MACHINE
SUPPLIERS OF METAL TESTING MACHINE
SUPPLIERS OF PRECISION MEASURING TOOLS
SUPPLIERS OF NDT INSPECTION EQUIPMENT
SUPPLIERS OF ELECTRICAL MEASURING INSTRUMENTS
SUPPLIERS OF EOT CRANE
SUPPLIERS OF POWER TRANSFORMERS
SUPPLIERS OF ELECTRICAL PANEL
SUPPLIERS OF COOLING TOWER
SUPPLIERS OF EFFULENT TREATMENT 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
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)
