COPPER PRODUCTS
[CODE NO.3754]
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 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 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 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 lobal 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
Plant Capacity 10 MT/Day
Land & Building (6597 sq.mt.) Rs. 6.04 Cr
Plant & Machinery Rs. 23.16 Cr
Working Capital for 2 Months Rs. 18.98 Cr
Total Capital Investment Rs. 50.75 Cr
Rate of Return 24%
Break Even Point 60%
INTRODUCTION
PROPERTIES
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 CHART
MANUFACTURING PROCESS
DEVELOPMENT PROCESS
CONTINUOUS CASTER- PRODUCTION PER MONTH
ELECTRO METALLURGICAL MANUFACTURING PROCESS
MANUFACTURING PROCESS FOR COOPER INGOT
(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
(8) QUALITY CONTROL
EXTRUSION PROCESS OF COPPER
HYDRAULIC METAL FORMING PRESS
COLD DRAWING
HOT ROLLING
COPPER WIRE DRAWING PROCESS
(1) DRAWING
(2) ANNEALING
(3) STRANDING
(4) QUALITY CONTROL
MARKET SURVEY
ELECTRICAL INDUSTRY
POWER CABLE AND WIRE
TELECOMMUNICATIONS CABLE AND WIRE
REFRIGERATION & AIR CONDITIONING
INDUSTRIAL AND ENGINEERING APPLICATIONS
A) HEAT EXCHANGERS AND CONDENSERS
B) VALVES, PUMPS, PIPES AND VESSELS
BUILDING AND CONSTRUCTION
TRANSPORT
COINAGE
ORDNANCE
COPPER COMPOUNDS
COPPER ALLOY
THERE ARE THREE TYPES OF WROUGHT ALLOY BRASSES:
COMPARISON OF ESTIMATED WORLD REFINED CONSUMPTION
OF COPPER, 2011 TO 2025 (000’TONNES)
1) DEMAND FORECAST OF COPPER ON CAGR & GDP
INTERNAL APPARENT DEMAND FORECAST OF COPPER 2010-11
TO 2024-25 (BASE YEAR 2008-09DEMAND OF 496 THOUSAND TONNES)
2) DEMAND PROJECTION BASED ON SECTOR WISE GROWTH
DEMAND FORECAST OF COPPER METAL AS PER SECTOR-WISE GROWTH, 2010-11 TO 2024-25 (BASE YEAR 2008-09 APPARENT DEMAND OF 496 THOUSAND TONNES)
PRESENT MANUFACTURERS/SUPPLIERS
SUPPLIERS OF COOPER WIRE
SUPPLIERS OF COPPER INGOT
SUPPLIERS OF COOPER EXTRUSION
SUPPLIERS OF RAW MATERIALS
SUPPLIERS OF COPPER SCRAP
SUPPLIERS OF NITRIC ACID
SUPPLIERS OF HYDROCLORIC ACID
SUPPLIERS OF DEGREASING CHEMICAL
SUPPLIERS OF PICKLING CHEMICALS
SUPPLIERS OF (HCL) PICKLING ACIDS
SUPPLIERS OF PLANT AND MACHINERY
SUPPLIERS OF COPPER RECYCLING PLANT
SUPPLIERS OF INGOT CASTING MACHINE
SUPPLIERS OF WIRE DRAWING MACHINE
SUPPLIERS OF COOPER EXTRUSION MACHINE
SUPPLIERS OF INDUCTION FURNACE
SUPPLIERS OF METAL TESTING MACHINE
SUPPLIERS OF PRECISION MEASURING TOOLS
SUPPLIERS OF NDT INSPECTION EQUIPMENT
SUPPLIERS OF ELECTRICAL MEASURING INSTRUMENTS
SUPPLIERS OF DG SETS
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
SUPPLIERS OF SUBMERSIBLE WATER PUMP
LIST OF PLANT & MACHINERY
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)
