PIG IRON USING SUBMERGED ARC FURNACE (CAP: 1 MT/DAY)
[EIRI/EDPR/4782] J.C.: 3002XL
Pig iron is the product of blast furnace reduction of iron oxide in presence of limestone. About half the ore is converted to iron.
Pig iron is the basic raw material for steel and cast iron. In metal terminology, a pig is a bar or ingot of cooled metal.
Pig iron is produced by reducing iron ore in a blast furnace, electoe sunelter, or low-shaft furnace. At one time molten iron produced in the blast furnace was allowed to flow from a central launder into a sand bed to produce small blocks. This arrangement resembled a sow and her pigs, from which the term pig iron is derived.
Pig iron is used for making sponge iron, and, however, the predominant use of pig iron is as a raw material for steel making.
In the manufacture of sponge Iron from Pig Iron, the pig iron, which is used as a raw material is the product of blast furnace containing 3 to 4% carbon, 1 to 3% silicon, 0.3 to 1.5% phosphorus, 0.1 to 1.0% manganese, and under 1% sulphur.
COST ESTIMATION
Plant Capacity 1 MT/Day
Land & Building (2000 sq.mt.) Rs. 77.50 Lac
Plant & Machinery Rs. 81.50 Lac
Working Capital for 2 Months Rs. 23.52 Lac
Total Capital Investment Rs. 2.11 Cr
Rate of Return 69%
Break Even Point 40%
CONTENTS
INTRODUCTION
ANALYSIS OF PIG IRON
SPECIFICATIONS OF PIG IRON USED IN DIFFERENT INDUSTRIES
PROPERTIES
PROPERTIES
LUMPS OF SILICO-MANGANESE
PROPERTIES AND CHARACTERSITS OF PIG IRON
EFFECTS OF SPONGE IRON ON EAF OPERATION
USES AND APPLICATION
B.I.S. SPECIFICATION
MARKET OVER VIEW OF PIG IRON
OPPORTUNITIES:
PIG IRON MARKET SEGMENTATION ANALYSIS:
REGIONAL INSIGHTS OF PIG IRON MARKET:
COMPETITIVE LANDSCAPE
PIG IRON MARKET KEY PLAYERS:
MARKET OF INDIAN STEEL INDUSTRY
WORLD ECONOMY AT A GLANCE
GLOBAL CRUDE STEEL PRODUCTION
MAJOR OBSERVATIONS:
GLOBAL DRI PRODUCTION
INDIA LED GLOBAL DRI PRODUCTION IN JANUARY-AUGUST 2024
MAJOR OBSERVATIONS:
WORLD STEEL PRICE TRENDS
LONG PRODUCTS
FLAT PRODUCTS
RAW MATERIAL SCENARIO
NEWS AROUND THE GLOBE
INDIAN STEEL MARKET ROUND-U
OVERALL PRODUCTION
CONTRIBUTION OF OTHER PRODUCERS
CONTRIBUTION OF PUBLIC SECTOR UNITS (PSU)
CONTRIBUTION OF FLAT /NON-FLAT IN FINISHED STEEL
FINISHED STEEL PRODUCTION TRENDS
FINISHED STEEL EXPORT TRENDS
FINISHED STEEL IMPORT TRENDS
FINISHED STEEL CONSUMPTION TRENDS
MANUFACTURING PROCESS OF PIG IRON
MANUFACTURING DETAILS OF FERRO ALLOY (SILICO MANGANESE)
FLOW DIAGRAM OF FERRO ALLOYS
MANUFACTURING PROCESS IN DETAILS
ZONES OF A SILICO-MANGANESE FURNACE
THE MAIN PROCESS STEPS ARE GIVEN BELOW.
CRUSHING AND GRINDING OF THE ORE:
CONCENTRATION OR BENEFICIATION OF THE ORE:
MAGNETIC SEPARATION OF IMPURITIES:
THE EQUILIBRIUM IS DETERMINED BY THE FOLLOWING REACTION
CHARGING:
SMELTING:
TAPPING/POURING:
METAL RECOVERY PLANT:
CRUSHING AND SCREENING:
SEPARATION OF METAL FROM SLAG:
RE-CRUSHING OF MIDDLING:
PLANT AND MACHINERY FOR MANGANESE METAL
1. FURNACE SHELL
2. EXHAUST HOOD
3. CONNECTING DUCT AND CHIMNEY
4. ELECTRODE SYSTEM
5. SUSPENSION FRAME
6. MANTLE FRAME/ COOLING SHIELD
7. PRESSURE RING
8. REFRECTORIES
9. COPPER WATER
10. HYDRAULIC POWER PACK
11. SLIPPING MECHANISM
12. TAPPING ARRANGEMENTS (OPTIONAL)
13. CONTROL PANEL
14. SUB STATION
15. BATCHING SYSTEM
15 (A) WEIGHING & BATCHING OPERATION
15 (B) FURNACE FEEDING SYSTEM
16. FINISHING PRODUCT HANDLING
17. FURNACE TRANSFORMER
18. MISC.
19. POLLUTION CONTROL EQUIPMENT
20. PUMP ROOM
(1) SUBMERGED ELECTRIC ARC FURNACE
THE 1ST LAYER
THE 2ND LAYER
THE 3RD LAYER
SUBMERGED ARC FURNACE
SUBMERGED ARC FURNACE PROFILE
PRINCIPLE AND CHARACTERISTICS OF SAF
FEATURES OF SAF
(2) DESCRIPTION OF VIBRATING FEEDER
CHARACTERISTIC OF VIBRATE FEEDING:
(3) JAW CRUSHER:
STRUCTURE OF JAW CRUSHER:
FEATURES OF JAW CRUSHER:
OPERATING PRINCIPLE OF JAW CRUSHER:
(3) DESCRIPTION OF VIBRATING SCREEN:
WORK PRINCIPLE OF VIBRATING SCREENS:
FEATURES OF VIBRATING SCREEN:
(4) INTRODUCTION OF BALL MILL:
WORKING PRINCIPLE OF BALL MILL:
APPLICATION OF BALL MILL:
(5) MAGNETIC SEPARATOR
APPLICATION OF MAGNETIC SEPARATOR:
ADVANTAGES OF MAGNETIC SEPARATOR:
(6) FLOATATION MACHINE:
(7) INTRODUCTION OF SPIRAL CLASSIFIER:
(8) INTRODUCTION OF BELT CONVEYOR:
WORKING PRINCIPLE OF BELT CONVEYOR:
MANUFACTURERS/SUPPLIERS OF LOW CARBON SILCO MANGANESE
SUPPLIERS OF RAW MATERIALS
SUPPLIERS OF MANGANESE ORE
SUPPLIERS OF PEARL COKE
SUPPLIERS OF DOLOMITE
SUPPLIERS OF QUARTAZ POWDER
SUPPLIERS OF HDPE BAGS
ADDRESSES OF PLANT AND MACHINERY SUPPLIERS
SUPPLIERS OF MANGANESE BENEFICIATION PLANT
SUPPLIERS OF SUBMERGED ARC FURNACE
SUPPLIERS OF DG SETS
SUPPLIERS OF EOT CRANES
SUPPLIERS OF POWER TRANSFORMERS
SUPPLIERS OF ELECTRICAL PANEL
SUPPLIERS OF ELECTRIC MOTOR
SUPPLIERS OF COOLING TOWER
SUPPLIERS OF EFFLUENT TREATMENT PLANT (ETP PLANT)
SUPPLIERS OF AIR POLLUTION CONTROL EQUIPMENT'S
SUPPLIERS OF AIR CONDITIONING EQUIPMENT'S
SUPPLIERS OF AIR COMPRESSORS
SUPPLIERS OF PLATFORM WEIGHING MACHINE
SUPPLIERS OF MATERIAL HANDLING EQUIPMENT'S
SUPPLIERS OF FIRE FIGHTING EQUIPMENT'S
SUPPLIERS OF SHOT BLASTING MACHINE
SUPPLIERS OF JIGS AND FIXTURE
SUPPLIERS OF SUBMERSIBLE WATER PUMP
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)
