STEEL FROM IRON ORE (PIG IRON)
[EIRI/EDPR/3143] J.C.: 1187
INTRODUCTION
Pig iron is the basic material from which, wrought iron and steels are produced. It is obtained by smelting (chemical reduction) of iron ore in the blast furnace. In addition to iron, Pig iron contains varying quantities of other elements such as carbon, silicon, manganese, sulphur and phosphorus. These may amount to as much as 10% of the weight and 25% of the volume of pig iron.
Pig iron is obtained by smelting (chemical reduction) of iron ore in the blast furnace.
The basic materials used for the manufacture of pig iron are iron ore, coke, and limestone. The coke is burned as a fuel to heat the furnace; as it burns, the coke gives off carbon monoxide, which combines with the iron oxides in the ore, reducing them to metallic iron. This is the basic chemical reaction in the blast furnace;
It has the equation: Fe2O3 + 3CO = 3CO2 + 2Fe.
The limestone in the furnace charge is used as an additional source of carbon monoxide and as a “flux” to combine with the infusible silica present in the ore to form fusible calcium silicate. Without the limestone, iron silicate would be formed, with a resulting loss of metallic iron. Calcium silicate plus other impurities form a slag that floats on top of the molten metal at the bottom of the furnace. Ordinary pig iron produced by blast furnaces contains about 92% Iron, 3 to 4% carbon, 0.5 to 3% silicon, 0.25 to 2.5% manganese, 0.04 to 2% phosphorus and a trace of sulphur.
COST ESTIMATION
Plant Capacity 5,14,800 MT/Annum
Land & Building Rs. 5.15 Cr
Plant & Machinery Rs. 300.50 Cr
Working Capital for 2 Months Rs. 81.48 Cr
Total Capital Investment Rs. 397.44 Cr
Rate of Return 49%
Break Even Point 42%
CONTENTS
INTRODUCTION
CLASSIFICATION OF PIG IRON
USES AND APPLICATION
B.I.S. SPECIFICATION
MARKET SURVEY
PROCESS FLOW CHART
MANUFACTURING PROCESS OF PIG IRON
RAW MATERIAL CHARACTERISTICS
PROCESS OF SINTERING
DIFFERENT ZONES OF BLAST FURNACE
CASTING PROCESS OF PIG IRON
QUALITY CONTROL
PLANT LAYOUT
SUPPLIERS OF PLANT AND MACHINERY
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)