Detailed Project Report on FERRO ALLOY with 6 MVA Furnace capacity (SILICON MANGANESE) (PRODUCTION CAPACITY: 30 MT/DAY)

Silico manganese is a alloy of manganese silicon and Iron with small percentage of carbon and several elements. The silico Manganese have an important influence on the properties of steel depending on the amount added and the combined effect with other alloying metal. It has a strong affinity for oxygen and act as deoxidizer and play an important role in the manufacturing of steel as deoxidizing, desulphuring and alloying agents silico manganese is used as alloying elements in manufacturing of spraying steel, transformer steel and other type of alloy steels.

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ENGINEERS INDIA RESEARCH INSTITUTE
4/54, Roop Nagar, Delhi-110007 (India)
Phone: [phone]
E-mail: [email protected]
Website: www.eiriindia.org




FERRO ALLOY with 6 MVA Furnace capacity
(SILICON MANGANESE) (PRODUCTION
CAPACITY: 30 MT/DAY)
[EIRI/EDPR/4739] J.C.: 2959XL


Silico manganese is a alloy of manganese silicon and Iron with small percentage of
carbon and several elements. The silico Manganese have an important influence
on the properties of steel depending on the amount added and the combined effect
with other alloying metal. It has a strong affinity for oxygen and act as deoxidizer
and play an important role in the manufacturing of steel as deoxidizing,
desulphuring and alloying agents silico manganese is used as alloying elements in
manufacturing of spraying steel, transformer steel and other type of alloy steels.

Silico manganese is a metallic ferroalloy composed principally of manganese,
silicon, and iron. It is produced in a number of grades and sizes and is consumed
in bulk form primarily in the production of steel as a source of both silicon and
manganese, although some silicomanganese is used as an alloying agent in the
production of iron castings. Manganese, intentionally present in nearly all steels,
is used as a steel desulfurizer and deoxidizer. By removing sulfur from steel,
manganese prevents the steel from becoming brittle during the hot rolling process.
In addition, manganese increases the strength and hardness of steel. Silicon is a
deoxidizer, aiding in making steels of uniform chemistry and mechanical
properties. As such, it is not retained in the steel, but forms silicon oxide, which
separates from the steel as a component of the slag. Silicomanganese generally
contains 65 to 68 percent manganese and about 17 percent silicon

Silico-manganese (Si-Mn) is a metallic ferro alloy which is being used to add both
silicon (Si) and manganese (Mn) as ladle addition during steelmaking. Because of
its lower carbon (C) content, it is a preferred ladle addition material during making
of low carbon steels.

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Si-Mn is a ferroalloy composed principally of Mn, Si, and Fe (iron), and normally
contains much smaller proportions of minor elements, such as C, phosphorus (P),
and sulphur (S). The ferroalloy is also sometimes referred to as ferro-silicon-
manganese.

Both Mn and Si play an important role in the manufacturing of steel as
deoxidizing, desulphurizing, and alloying agents. Si is the primary and more
powerful deoxidizer. Mn is a milder deoxidizer than Si but enhances the
effectiveness of the latter due to the formation of stable manganese silicates and
aluminates. It also serves as desulphurizer. Mn is used as an alloying element in
almost all types of steel. Of particular interest is its modifying effect on the iron-
carbon (Fe-C) system by increasing the hardenability of the steel.

There are two families of Mn alloys one is called Si-Mn while the other is known as
ferro-manganese (Fe-Mn). Si-Mn adds additional silicon in liquid steel which is a
stronger deoxidizer and which also helps to improve some mechanical properties
of steel. In each family, content of C can be controlled and lowered when
producing low C grades. Around 93% of all the Mn produced is in the form of Mn
ferroalloys consists of the Fe-Mn grades and the Si-Mn grades.

The Fe-Mn grades are high carbon (HC), medium carbon (MC), low-carbon (LC)
and very low carbon (VLC), whereas the Si-Mn grades include medium carbon
(MC) and low carbon (LC). The steel industry is the only consumer of these alloys.
However as the average consumption of Mn in one ton of steel is around 7 Kg, the
requirement of these two ferro alloys amounts to considerable tonnages.

To cover the need for Mn and Si, the steelmaker has the choice of a blend of Si-
Mn, HC Fe-Mn and Fe-Si governed of by specifications on C, Si, and Mn. Normally
earlier a mixture of HC Fe-Mn and Fe-Si was used, but now a trend towards more
use of Si-Mn is seen at the expense of the two others. This is primarily for
economic reasons.

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CONTENTS

INTRODUCTION

PROPERTIES

PROPERTIES

USES AND APPLICATION

B.I.S. SPECIFICATION

MANUFACTURING DETAILS OF FERRO ALLOY (SILICO MANGANESE)

FLOW DIAGRAM OF FERRO ALLOYS

MANUFACTURING PROCESS

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:

THE STANDARD COMPOSITION OF HIGH CARBON FERRO CHROME (HCFC) IS
AS GIVEN BELOW:

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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

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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

THE MAJOR NORMAL FEATURES OF AC BASED FURNACES ARE AS FOLLOWS

(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:

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(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:

MARKET OVERVIEW OF FERRO ALLOY

ROLE OF FERRO ALLOYS

DEMAND DRIVERS OF FERRO ALLOYS

TYPES OF FERRO ALLOYS

FERRO ALLOYS AS DE-OXIDANT FOR STEELMAKING

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 & MACHINERY SUPPLIERS

SUPPLIERS OF MANGANESE BENEFICIATION PLANT

SUPPLIERS OF SUBMERGED ARC FURNACE

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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 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


APPENDIX – A:

01. PLANT ECONOMICS

02. LAND & BUILDING

03. PLANT AND MACHINERY

04. OTHER FIXED ASSESTS

05. FIXED CAPITAL

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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)

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COST ESTIMATION

Plant Capacity 30 MT/Day

Land & Building (24,000 sq.mt.) Rs. 13.26 Cr

Plant & Machinery Rs. 4.03 Cr

Working Capital for 2 Months Rs. 10.90 Cr

Total Capital Investment Rs. 29.07 Cr

Rate of Return 27%

Break Even Point 75%