COPPER INGOTS FROM SCRAP
[CODE NO.3501]
Copper is an important non-ferrous metal used in various forms for different applications. Copper being a major industrial metal, ranks third after iron and aluminium in terms of quantity consumed. Copper is a reddish malleable and ductile metal valued for its excellent thermal and electrical conducting qualities and resistance to corrosion. Copper combines with a number of elements to form a wide variety of copper minerals and ores.
Copper ingots are generally required by the Non-ferrous casting units which are engaged in the casting of different engineering components of brass, gun metal, bronze etc., the agricultural machinery, automobile industries and railway components. These ingots are also required for manufacturing of rods, tubes, strips, wires etc. The copper ingots manufactured from copper scrap are generally known as commercial quality ingots & do not come under the group of electrolytic copper as these are secondary quality ingots.
Copper is one of the oldest metals ever used and has been one of the important materials in the development of civilization. Copper is an important non-ferrous base metal having wide industrial applications. Today it has become a major industrial metal, ranking 3rd after iron and aluminum in terms of quantities consumed.
Copper today is a 8 billion US dollar industry in India having created 50,000 direct and indirect jobs and growing at a CAGR 5-7% per annum. India has a huge growth potential in copper consumption for the next 20-25 years as the government increases focus on smart cities, rapid urbanization and investments in infrastructure.
Local demand for copper metal (produced from refined copper and recycled scrap) is projected to advance 4.2 percent per year through 2019 to 36.0 million metric tons, valued at $261 billion. Robust gains in building construction expenditures are expected to boost the use of copper wire, tube, and other mill products in applications such as building wire and plumbing. Increased infrastructure investment, particularly in developing countries, will further benefit copper suppliers as updates to national power grids drive the production of wire and cable. In addition, advances in global manufacturing output are expected to bolster the use of copper metal in transportation equipment, industrial machinery, domestic appliances, and other durable goods.
COST ESTIMATION (US Dollars)
Plant Capacity : 8.00 MT/day
land & Building (10000 Sq.Mtr) : US$. 13.71 Lacs
Plant & Machinery : US$. 3.63 Lacs
Working Capital for 2 Months : US$. 27.57 Lacs
Total Capital Investment : US$. 45.30 Lacs
Rate of Return : 42%
Break Even Point : 40%
INTRODUCTION
COPPER
TOP COUNTRIES WHERE COPPER INGOTS IS EXPORTED FROM INDIA
PROPERTIES OF COPPER INGOT
PHYSICAL PROPERTIES:
CHEMICAL PROPERTIES
ACTION OF AIR:
ACTION OF WATER:
ACTION OF ALKALIS:
ACTION OF ACIDS:
A) WITH HNO3:
B) WITH H2SO4:
C) WITH HCL:
5) DISPLACEMENT REACTION:-
USES AND APPLICATION
USES OF COPPER:-
APPLICATION
B.I.S. SPECIFICATION
PROCESS FLOW DIAGRAM
PRODUCTION PROCESS
(1) RAW MATERIAL
(2) PRETREATMENT OF SCRAP
(A) STRIPPING
(B) BRIGUETTING
(C) SIZE REDUCTION
(D) CRUSHING
(E) RESIDUE CONCENTRATION
(F) RESIDUE PELLETIZING AND ROLL BRIQUETTING
(G) DRYING
(H) BURNING
(I) SWEATING
(3) MELTING PROCESS
(4) SLAG TREATMENT
(5) REFINING PROCESS
(A) FIRE REFINING
(B) ELECTROLYTIC REFINING
(6) CASTING
(7) EMISSIONS AND CONTROLS
MARKET SURVEY
INDUSTRY CHALLENGES
MARKET LEADERS
COPPER USAGE TRENDS AND ITS EFFECT ON MANUFACTURING
AND SCRAP METAL
TOTAL COPPER MINE PRODUCTION IN AFRICA FROM 2005 TO 2020
(IN 1,000 METRIC TONS)*
COPPER INDUSTRY: GLOBAL OVERVIEW
PLANT LAYOUT
MANUFACTURERS/SUPPLIERS OF COPPER INGOT
SUPPLIERS OF RAW MATERIALS
COPPER SCRAP
SUPPLIERS OF NITRIC ACID
HYDROCLORIC ACID
DEGREASING CHEMICAL
PICKLING CHEMICALS
SULFURIC ACID
(HCL) PICKLING ACIDS
SUPPLIERS OF PLANT AND MACHINERIES
SUPPLIERS OF COPPER RECYCLING PLANT
SUPPLIERS OF INDUCTION FURNACE
SUPPLIERS OF INGOT CASTING MACHINE
METAL TESTING MACHINE
PRECISION MEASURING TOOLS
NDT INSPECTION EQUIPMENT
ELECTRICAL MEASURING INSTRUMENTS
EOT CRANES
POWER TRANSFORMERS
ELECTRICAL PANEL
COOLING TOWER
EFFLUENT TREATMENT PLANT
AIR POLLUTION CONTROL EQUIPMENTS
AIR CONDITIONING EQUIPMENTS
AIR COMPRESSORS
WEIGHING MACHINE (PLATFORM TYPE)
MATERIAL HANDLING EQUIPMENTS
FIRE FIGHTING EQUIPMENTS
SUPPLIERS OF SUBMERSIBLE WATER PUMP
APPENDIX – A:
1. COST OF PLANT ECONOMICS
2. LAND & BUILDING
3. PLANT AND MACHINERY
4. FIXED CAPITAL INVESTMENT
5. RAW MATERIAL
6. SALARY AND WAGES
7. UTILITIES AND OVERHEADS
8. TOTAL WORKING CAPITAL
9. COST OF PRODUCTION
10. PROFITABILITY ANALYSIS
11. BREAK EVEN POINT
12. RESOURCES OF FINANCE
13. INTEREST CHART
14. DEPRECIATION CHART
15. CASH FLOW STATEMENT
16. PROJECTED BALANCE SHEET
