Detailed Project Report on FERRO TITANIUM PROCESSING PLANT

The global steel production has increased continuously over the last few years and this trend is expected to continue in the years to come. The global crude steel output has been growing at about 5%and is expected to grow at a similar rate overall. The steel growth in India has been higher and is expected to grow @7%till 2030bywhen the production is expected to reach about 230 million tones. This consistent growth of crude steel production will have a direct correlation with the demand for ferro alloys i.e. Ferro Chrome, Silico Manganese and Ferro Manganese. Demand for Ferro Alloys is directly linked to steel production level. Looking at the projection of demand for steel and ferro alloys it can be realized that there remains a considerable gap between demand and supply of steel as well as ferro alloys by 2020-21. To meet the demand, new capacities have to be created.

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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 TITANIUM PROCESSING PLANT
[EIRI/EDPR/4701] J.C.: 2920US$

The global steel production has increased continuously over the last few years and
this trend is expected to continue in the years to come. The global crude steel
output has been growing at about 5%and is expected to grow at a similar rate
overall. The steel growth in India has been higher and is expected to grow @7%till
2030bywhen the production is expected to reach about 230 million tones. This
consistent growth of crude steel production will have a direct correlation with the
demand for ferro alloys i.e. Ferro Chrome, Silico Manganese and Ferro
Manganese. Demand for Ferro Alloys is directly linked to steel production level.
Looking at the projection of demand for steel and ferro alloys it can be realized
that there remains a considerable gap between demand and supply of steel as well
as ferro alloys by 2020-21. To meet the demand, new capacities have to be
created.

Ferroalloys are one of the important inputs in the manufacture of alloys and
special steel. They are used as deoxidisers and alloy additives in the steel
manufacturing process. They impart special properties to steel. The alloys provide
increased resistance to corrosion, improve hardness & tensile strength at high
temperature, impart wear and abrasion resistance and increases creep strength
etc.

The growth of Ferroalloys Industry is, thus, linked with the development of the
Iron and Steel Industry, Foundry Industry and to some extent Electrode Industry.
The principal ferroalloys are chromium, manganese and silicon. The product
series consists mainly of ferromanganese, silicomanganese, ferrosilicon and
ferrochrome. Ferroalloys are classified into two main categories, viz, bulk
ferroalloys and noble ferro alloys.

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Bulk ferroalloys is majorly used in stainless steel & carbon steel. Most of the boble
ferroalloys are made from rare-earth minerals and are expansive to produce as
compared to bulk ferroalloys. Owing to high cost of power, Ferroalloys Industry
has not been operating to its full capacity in India. Ferroalloys Industry spends 40
to 70% production cost on power consumption.

Ferroalloys are a group of materials which are alloys of iron that contain a high
percentage of one or more nonferrous metals as alloying elements. These alloys
are used for the addition of these other elements into liquid metal. They are
normally used as addition agents. More than 85 % of ferroalloys produced are
used primarily in the manufacture of steel.

Ferroalloys are usually classified into two main categories namely (i) bulk
ferroalloys and (ii) noble or special ferroalloys. Noble ferroalloys are of high value
and consumed in low proportions. These ferroalloys are one of the vital inputs
required for the production of special types of steels and are used as additive
inputs especially in the production of alloy and special steels.

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CONTENTS

INTRODUCTION
STATUS OF INDUSTRY NOBLE FERROALLOYS
FERRO TITANIUM
FERRO NICKEL
FERRO MOLYBDENUM
FERRO VANADIUM
FERRO TUNGSTEN
FERRO NIOBIUM
FERRO BORON
FERRO ALUMINUM
NOBLE FERROALLOYS
ABOUT FERRO TITANIUM MARKET
FERRO TITANIUM FOR STEELMAKING MARKET SIZE
FERRO TITANIUM FOR STEELMAKING MARKET
APPLICATIONS OF THE GROWTH OF THE FERRO TITANIUM MARKET
TYPES OF FERRO TITANIUM MARKET AVAILABLE IN THE MARKET
MAIN REGIONS ARE LEADING THE FERRO TITANIUM MARKET
LARGEST MANUFACTURERS OF FERRO TITANIUM MARKET WORLDWIDE
MARKET POSITION
BULK FERROALLOYS
WORLD PRODUCTION OF FERROALLOYS, 2016 TO 2018 (BY PRINCIPAL
COUNTRIES)
USES AND APPLICATION
USES
MAIN APPLICATIONS FOR FERRO TITANIUM INCLUDE:
CLEANSING AGENT
GRAIN REFINER
FERRO ALLOY USES

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QUALITY CONTROL
RAW MATERIAL TESTING
CONTINUOUS BATCH TES TING DURING PRODUCTI ON
FINAL SAMPLE TESTING
GRADES
CHEMICAL COMPOSITION OF VARIOUS GRADES OF FERRO TITANIUM
PRODUCTS
PRESENT MANUFACTURERS OF DIFFERENT FERRO ALLOY
RAW MATERIAL SUPPLIERS
PRODUCTION PROCESS
FERRO ALLOYS / AND OTHER NOBLE FERRO ALLOYS
TERMITE PROCESS
FOLLOWING ACTIVITIES ARE CARRIED ON:
PROCESS FLOW CHART
SELECTION OF SITE & LOCATION OF PLANT
ENVIRONEMENTAL MANAGEMENT PLAN
SOURCES OF POLLUTION
THE VARIOUS MEASURES PROPOSED TO MITIGATE THE IMPACT OF THESE
POLLUTION SOURCES ON THE ENVIRONMENT ARE DISCUSSED BELOW:
POLLUTION CONTROL MEASURES
AIR POLLUTION
WATER POLLUTION
NOISE POLLUTION
SOLID WASTE MANAGEMENT
DISPOSAL OF SLAG FROM FERRO ALLOYS:
PLANTATION
SELECTION CRITERIA OF PLANT SPECIES FOR GREEN DEVELOPMENT PLANT
SPECIFICATIONS/ DESI GN DETAILS OF THE SUBMERGED ARC FURNACES
(SAF)
PLANT LAYOUT
THE LAYOUT OF THE PLANT SHOULD BE FOLLOWING CONSIDERATIONS:
SUPPLIERS OF PLANT AND MACHINERY
STORAGE TANK MANUFACTURER /SUPPLIER
PACKAGING MACHINE MANUFACTURER /SUPPLIER

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D.G. SET MANUFACTURER /SUPPLIER
LABORATORY TESTING EQUIPMENTS MANUFACTURER /SUPPLIER
SS PIPE & TUBE MANUFACTURERE
ELECTRICAL PANEL & BOARD MANUFACTURERS
PRINCIPLES OF PLANT LAYOUT
PLANT LOCATION FACTORS
PRIMARY FACTORS
1. RAW-MATERIAL SUPPLY:
2. MARKETS:
3. POWER AND FUEL SUPPLY:
4. WATER SUPPLY:
5. CLIMATE:
SPECIFIC FACTORS
6. TRANSPORTATION:
A. AVAILABILITY OF VARIOUS SERVICES AND PROJECTED RATES
7. WASTE DISPOSAL:
8. LABOR:
9. REGULATORY LAWS:
10. TAXES:
11. SITE CHARACTERISTICS:
12. COMMUNITY FACTORS:
13. VULNERABILITY TO WARTIME ATTACK:
14. FLOOD AND FIRE CONTROL:
EXPLANATION OF TERMS USED IN THE PROJECT REPORT
1. DEPRECIATION:
2. FIXED ASSETS:
3. WORKING CAPITAL:
4. BREAK-EVEN POINT :
5. OTHER FIXED EXPENSES:
6. MARGIN MONEY:
7. TERM LOANS:
8. TOTAL LOAD:
9. LAND AREA/MAN POWER RATIO:

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UTILITIES
POWER
WORKING
TOTAL MANPOWER AND PAYROLL
AND DISPOSAL
STEAM
POWER
POWER REQUIREMENT
AMENITIES & FACILITIES
LABORATORY
REPAIR AND MAINTENANCE SHOP
STORES
PLANT OFFICE
ANCILLARY BUILDINGS
CANTEEN
PLANT FACILITIES –
RAW MATERIAL HANDLING SYSTEM
SUBMERGED ARC FURNACE
HOT METAL HANDLING
STATUTORY APPROVALS FROM GOVERNMENT
DOCUMENTS REQUIRED FOR LICENSES
LIST OF DOCUMENTS:
SWOL ANALYSIS
STRENGTHS
OPPORTUNITIES
WEAKNESS
LIMITATIONS
ORGANIZATION CHART
PROJECT CONSULTANT
IMPLEMENTATION SCHEDULE

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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)

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COST ESTIMATION

Plant Capacity 14 MT/Day

Land & Building (6 Acres) US$ 24.32 Lac

Plant & Machinery US$ 38.83 Lac

Working Capital for 3 Months US$ 29.49 Lac

Total Capital Investment US$ 94.30 Lac

Rate of Return 66%

Break Even Point 31%