COPPER WIRE DRAWING & ENAMELLING PLANT (CAP: 1 MT/DAY)
[EIRI/EDPR/1727] J.C. 556XL
INTRODUCTION
Copper wire is an essential material for motor and transformer winding. Copper wire is available in different gauges (32 gauge to 18 gauge). The gauge of the copper wire depends upon the winding required for the specific motor or transformer.
The wire having conductor diameter from 0.500 to 4.000 mm, is suitable for submersible motor winding.
There is a heavy market for copper wire/enamelled copper wire in motor and transformer manufacturers and this wire is also used in rewinding of motors and transformers.
Reasons for its wide use is that the copper has resistance to atmospheric corrosion because of the formation of uniform layer of oxide on the surface of metal. Besides these, copper has good mechanical properties viz - good mechanical malleability & formability which. It can easily welded or soldered. The melting temperature of copper is 1083oC.
Plant and machinery as well as technical know-how are indigenously available and no imported plant/equipment is required.
Though the major attention has been concentrated on the formulation of resins for improving the quality of coatings, the coating methods have remained more or less the same. From this point of view the recently developed technique of electro coating appears to be of interest. The method is supposed to give extremely uniform, continuous, adherent, smooth coatings with better mechanical properties as compared to other methods of coating. These qualities are essential in coating of wires as is known generally. Thought at present this technique is being used in other fields,s it is worthwhile considering its application to wire coating and if successful, it may lead to reduction in coating thickness with further advantage in size reduction of various equipment.
PVC insulated winding wire is used for all type of electric motor. The wire used for winding is always copper because it provides strength and is good conductor of electricity.
On account of copper being expensive, aluminium wires are being used for winding electrical equipments. Super enamelled aluminium wire is, thus, helping the user industries in selective cases an the face of acute shortage of super enamelled copper wires.
Wire is made by cold drawing hot-rolled wire rod through one or more dies, to decrease its size and increase the physical properties. The wire rod about 7/32" (6mm) in diameter is rolled from a single billet and cleaned in an acid bath to remove scale, rust and coating. The coating is applied to prevent oxidation, neutralize any remaining acid and to act as a lubricant or a coating to which a later applied lubricant may cling.
Both single draft or continuous drawing processes may be used. In the first method a coil is placed on a reel or frame and the end of the rod pointed so that it will enter the die. The end is grasped by tongs on a drawbench and pulled through to such length as may be wound around a drawing block or reel. From there on, the rotation of the draw block pulls the wire through the die and forms it into a coil. There operations are repeated with smaller dies and blocks until the wire is drawn to its final size.
In continuous drawing, the wire is fed through several dies and draw blocks arranged in series. This permits drawing the maximum amount in one operation befoir annealing is necessary. The number of dies in the series will depend on the kind of metal or alloy being processed and may vary from 4 to 12 successive drafts. The dies are usually made from tungsten carbide, alongwith diamond dies can be used for drawing small dimeters.
This project proposes to use copper scraps as initial raw material to produce wire rod. Thus, wire rods will be available economically for drawing it to specified diameter ranges of copper wires. The facilities will be installed in-plant for testing of material at different stages of production, heat treatments and enamelling.
Thus, the proposed unit will be a full fledged unit for producing super enamelled winding wires of copper where secondary copper wire rods will be self produced.
COST ESTIMATION
Plant Capacity 1 MT/Day
Land & Building (1000 sq.mt.) Rs. 91.50 Lac
Plant & Machinery Rs. 48.00 Lac
Working Capital for 2 Months Rs. 1.42 Cr
Total Capital Investment Rs. 2.98 Cr
Rate of Return 52%
Break Even Point 44%
CONTENTS
1. INTRODUCTION
2. USES AND APPLICATIONS
3. BIS SPECIFICATIONS
4. RAW MATERIALS
5. MECHANICAL PROPERTIES OF COPPER RODS/BARS
6. MANUFACTURE OF WIRE ROD FROM SCRAP COPPER
7. SMELTING, CONVERSION & REFINING OF COPPER
8. PROCESS FLOW SHEET DIAGRAM
9. WIRE DRAWING OPERATIONS & EQUIPMENTS
10. DRAWING DIES
11. HEAT TREATMENTS OF COPPER WIRES
12. ENAMELLING OF COPPER WIRES FOR MOTOR WINDING
13. PROCESS & FLOW DIAGRAM FOR COPPER WIRE ENAMELING
14. MARKET SURVEY
15. PRESENT MANUFACTURERS
16. SUPPLIERS OF TESTING EQUIPMENTS
17. SUPPLIERS OF PLANT & MACHINERY
18. SUPPLIERS OF RAW MATERIALS
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)
