This action might not be possible to undo. Are you sure you want to continue?
HIGH GRADE IRON-ORE PELLETS PROJECT 19200 TPA FOR
PREPARED BY ANUP SNEH & ASSOCIATES Cell: + 91 94370 53451
PREPARED BY: ANUP SNEH & ASSOCIATES Cell: +91 94370 53451
TABLE OF CONTENTS
CHAPTER NO. DESCRIPTION EXECUTIVE SUMMARY 1. 1.1 1.2 1.3 1.4 INTRODUCTION THE COMPANY PRESENT STATUS PROMOTERS MANAGEMENT
2. 2.01 2.02 2.03 2.04 2.05 2.06 2.07 2.08
PROJECT DETAILS THE PROJECT THE PRODUCT PROJECT COST AND MENAS OF FINANCE LOCATION CAPACITY UTILISATION MANUFACTURING PROCESS QUALITY CONTROL AND TESTING SCHEDULE OF IMPLEMENTAION
PREPARED BY: ANUP SNEH & ASSOCIATES Cell: +91 94370 53451
10 PRESENT STATUS ON IMPLEMENTAION DEFAULTS AND LITIGATIONS 3.5 3. 3. THE INDUSTRY THE PRODUCT PRICES FUTURE PLANS ANNEXURES PREPARED BY: ANUP SNEH & ASSOCIATES Cell: +91 94370 53451 .2.3 3.3 4.01 4.7 INFRASTRUCTURAL FACILITIES LAND & SITE DEVELOPMENT BUILDING PLANT AND MACHINERY RAW MATERIALS UTILITIES EFFLUENTS MANPOWER 4.6 3.09 2.4 5.2 4.4 3.1 3. MARKET AND SELLING ARRANGEMENTS 4.2 3.
1.1 INTRODUCTION THE COMPANY PREPARED BY: ANUP SNEH & ASSOCIATES Cell: +91 94370 53451 .1.
In the first phase 19200 TPA iron – ore pellet plant will be set up and in second phase capacity will be enhanced to 6000 TPA.1. PREPARED BY: ANUP SNEH & ASSOCIATES Cell: +91 94370 53451 . to meet their raw material requirement which they are sourcing paying an exorbitant price charged by monopolistic mine owners. Promoters are well experienced entrepreneurs and are well supported by technical personal experienced to run such unit.4 MANAGEMENT The proposed company is limited by share promoted by M/s.3 PRESENT STATUS PROMOTERS 1.2 1.
2.01 PROJECT DETAILS THE PROJECT The company after assessing the market potential of the steel industry thoroughly decided to go in for iron-ore pellets in the first phase. etc.02 THE PRODUCT Blast Furnace IRON-ORE PELLETS to be manufactured by the company find use in Sponge iron and Blast furnace operation. beneficiated concentrate can not be used as such in iron-ore making by blast furnace or sponge iron kilns. briquetting and pelletisation are the different processes being adopted for agglomerating iron-ore fines.) for obtaining closed-sized feed generates substantial amount (40%) of fines (-6mm). Their presence in blast furnace and sponge iron kilns affects the operations and productivity. 2. Taking into account various factors such as economic size of the plant and machinery and the versatility to expand the capacity in future the project has been set at 19200 TPA. Beneficiation of low grade iron-ores produces fine-size concentrate. Sintering. besides a large proportion of fines usually carried of as flue dust. The fine.2. scrubbing. The highly encouraging response received on market survey also ruled favorably for the said project. Treatment of high grade iron-ore lumps(multi stage crushing. Sponge Iron Kiln PREPARED BY: ANUP SNEH & ASSOCIATES Cell: +91 94370 53451 . among which pelletisation is the best solution. Therefore it is imperative to agglomerate the high grade ore fines and fine beneficiated concentrates to render them suitable for iron making. The fine clog the space between the lumps and thereby prevent the free flow of reducing gases. screening.
02 The cost of project is proposed to be funded in the following manner. No. 06.00 PREPARED BY: ANUP SNEH & ASSOCIATES Cell: +91 94370 53451 . PARTICULARS Term Loan From Banks/Finacial Institutions Equity Private Placement Promoters Contribution Total 0.00 90.02 AMOUNT 630.00 451. PARTICULARS Land and Site Development Building & Civil Constructions Plant & Machinery Misc.2. No. in Lacs Sl. 05. 01.48 76.00 23. In Lacs) Sl.88 899. 09. 08. 02. Fixed Assets Security Deposits Preliminary & Preoperative expenses Engineering & Technical Consultancy Charges Contingencies Working capital Margin Total AMOUNT 45.03 PROJECT COST AND MEANS OF FINANCE COST OF THE PROJECT AND MEANS OF FINANCE Annexure .2 (Rs. 07. 03.00 30.00 269. 02.00 45. 01. Rs.58 105. 04.02 899.08 32.
SITE CRITERIA Site location Temperature : : Altitude approximately yearly average Extreme minimum Extreme maximum yearly average Extreme minimum Extreme maximum average minimum main direction seismic zone Scale Factor “z” : : : : : : : : : : : : + 175 m 32 0 C 70C 48 0 C 44% 5% 98% 1. LOCATION The proposed unit will be located at _____________on a plot measuring 30 acres. Orissa and Chattisgarh because of easy availability of major raw input iron-ore and coal. Skilled and un-skilled labourers are also available easily. iron manufacturing units have tendered to cluster in the eastern zone of India namely in the state of Jharkhand.6 – 2. Traditionally. The location has a big advantage in its closed proximate to its market.1 Humidity : Wind velocity : Earthquake : PREPARED BY: ANUP SNEH & ASSOCIATES Cell: +91 94370 53451 .1 m/s S and SW II IV 0. Infrastructural and other utility services are easily available.2.04. Land for future expansion has been applied to the government for allotment.2 m/s 16.
19.6.06 MANUFACTURING PROCESS : : : : approx. PREPARED BY: ANUP SNEH & ASSOCIATES Cell: +91 94370 53451 .6. as follows: YEAR 1 YEAR 2 YEAR 3 ON WARDS 75% 80% 85% a.Soil load bearing strength : 20 t / m2 2. Plant Capacity and Availability Annual Capacity Hourly Production Rate Plant Availability Availability based on Calendar time 2.200 h per year (Corresponding to 300 days per Year) 82% Executive Summary This project is for an Iron-ore Pelletising Plant for a capacity of 19200 TPA. The process of pelletising of iron bearing ores to utilise fines by agglomeration to be used in blast furnace and direct reduction shaft and rotary kiln furnaces. such as sludge and similar waste materials and fines can be brought to use by the palletizing process after beneficiation.1 2.3 Raw material preparation.75 tons 7.2 2. The manufacturing process is divided into three stages: 2. Mixing and pelletisation.6.05 THE CAPACITY UTILISATION The proposed project will result in a year wise overall capacity utilization for the company as a whole.200 tons per year oxide pellets 2. Induration. Also hitherto unused wastes.
lime stone and coke powder are also stored in different silo.2. Green Pelletizing The production of green pellets is performed in three closed palletizing disc circuits. Mixing is performed in one high intensive bowl type mixer. The mixed material is received into the mixed material bins with a storage capacity of approximately 6 m3 each. From here the ore is feed to the drier to remove the moisture. The material discharge from each mixed material bin is done by a vibrating mouth and controlled by weigh feeders equipped with variable speed drivers. Pelletizing discs were selected over palletizing drums because of their minor space requirements. and To adjust the chemistry of the pellets to favor the production of mechanically resistant product pellets with a high compression strength and low abrasion indices. screening and heat treatment process. Here other additive like bentonite.01 RAW MATERIAL PREPARATION Iron-ore and Additive Handling By a loader iron-ore (-) 6mm is fed to the chute. and To adjust the chemistry of the product pellets to favor their reducibility during subsequent reduction processes ( in blast furnaces or direct reduction plants ).06. After the intensive mixing the mixed material is transferred by belt conveyors to the green palletizing area.02 MIXING & PELLETISING Mixing Iron ore powder is fed to steel silo for storage by help of pneumatic conveyor. thus feeding the PREPARED BY: ANUP SNEH & ASSOCIATES Cell: +91 94370 53451 . and their self-classifying effect. In the mixing area ground ore is mixed with a variety of additives in order to • • • Form green pellets with sufficient mechanical strength to withstand the subsequent transportation.06. 2. installed directly above the three discs. As per the composition set by the process requirement the material are fed to the mixture machine in correct quantity with help of belt weigh feeder. Here the moisture content of the material is controlled to approximately 9 – 10 %. After removal of the moisture the ore fed to the ball mill for micro fine grinding to 325 mesh.
Undersize and oversize green pellets are recycled by belt conveyors back to the green palletizing area. This belt weigh feeder is used for mass balancing and services as a standby signal for the speed control of the induration machine. according to mixed material properties. A control loop. In case of emergency and also during start – up of a disc when the green pellets do not have the required properties. The green pellets produced are discharged onto a reversible belt conveyor. Green pellets are distributed onto the wide belt conveyor by the reciprocating head of belt conveyor The head pulley of this conveyor is supported in a reciprocating carriage. The forward velocity of the carriage with the heady pulley is identical to the belt speed and during the backward stroke the green pellets are discharged onto the wide belt conveyor. The green pellets are formed in the discs with a diameter of 6 feet each. The bins filling degree is measured by load cells. Belt weigh feeder will measure the amount of green pellet under and over size. PREPARED BY: ANUP SNEH & ASSOCIATES Cell: +91 94370 53451 . The charging is done automatically in accordance with a pre-set time schedule. desired green pellet diameter and feed-rate. which moves the head pulley over the width of the downstream perpendicular – arranged wide belt conveyor. On – space green pellets 6. The rotary speed of the disc can also be varied during operation by means of frequency-controlled motors. with simultaneous and variable addition of water.3 mm. is superimposed on this schedule for determining the destination of feed. the disc discharge can thus be recycled or discharged to an emergency stockpile by means of another reversible belt conveyor. depending on the palletizing characteristic of the concentrate mixtures.3 – 16 mm are rerolled on the lower deck and evenly distributed over the width of the pallets of the induration machine. The wide belt conveyor discharges the green pellets onto the double deck roller screen which consists of an upper and a lower roller deck.required amount of mixed material onto the corresponding palletizing disc. governed by the filling degree of the bins. A belt weigh feeder is installed in this belt conveyor for weighing the total amount of green pellets discharged from the palletizing discs. The inclination of each disc is variable and optimum setting will be determined during start-up. The weigh feeder discharges into the disc feeding chutes are equipped with fluffier for a disintegration of any compacted material as well as for distribution of the mixed material on the palletizing disc. which ensures the smooth handling of the green pellets. During normal operation the green pellets are discharged to the green pellet collecting belt conveyor. The upper deck screens our oversize green pellets ( > 16 mm ) and the lower deck has the function to screen out undersize green pellets of < 6.
The cooling zone of the indurating machine is designed to cool down fired pellets in normal operation to temperatures of 100 – 120 0 C. A product screen mainly consists of vibrating screen decks and four chutes to further convey 4 size fractions of fired pellets : Undersize pellets < 5 mm Product pellets 5 – 10 mm The fines < 5 mm will be transported via a conveyor to a stockpile. PREPARED BY: ANUP SNEH & ASSOCIATES Cell: +91 94370 53451 . The belt speed is controlled by the level of the hearth and side layer bin.2. The cooling air. Conveyor is equipped with a variable speed drive. which is used to cool down hot pellets > 120 0 C in case of emergency only. Sized pellets are used as hearth layer to avoid clogging of side layer chutes and improve the permeability of the heart layer. Screened hearth and side layer is transported by belt conveyors and to the hearth layer bin at the feed end of the indurating machine. mounted on load cells. The arrangement and sizing of the burners ensures a uniform hot gas temperature over the width of the pellet bed. and thus reduce pressure drop and energy consumption of this system. The Product belt conveyors is equipped with a water spray system. In shaft kiln hot combustion gases enter the firing zone by the direct recuperation principle. In shaft kiln pellets are uniformly cooled since the total pellet layer remains undisturbed while being transported through the total induration and cooling stages. Burners are arranged opposite to each other on the longitudinal sides of the firing zone. The vibrating product screen finally screens out undersize material from the product pellets and to separate a certain quantity of fired pellets which will be recycled as hearth layer to the indurating machine. which becomes heated after passing through the hot pallets and the hot pellet bed.06.03 INDURATION Pellet Induration The pellets are completely heat hardened and cooled on one shaft kiln. which means that hot gases from the cooling zone are recuperated. heated air streams are recycled to the process as a “heat carrier”. Screening and Product Handling The indurated and cooled pellets are discharged from the indurating machine into the discharge bin.
A sampler is installed in the discharge chute of product conveyor.Belt weigh feeder registers the production rate of the plant. PREPARED BY: ANUP SNEH & ASSOCIATES Cell: +91 94370 53451 . which takes samples for pellet quality control.
Rejected material can be easily re-processed. PREPARED BY: ANUP SNEH & ASSOCIATES Cell: +91 94370 53451 . Small batch preparation of new raw materials would be carried out before commercialization. Quality inspection would be carried out at every stage by collecting sample and thoroughly analyzing them.2. Annual budget on R & D has been pegged.07 QUALITY CONTROL AND TESTING The new laboratory will be built with all necessary equipments and sophisticated apparatus to make evaluation of the finished products.
Schedule of implementation will be 12 months from the ground breaking ceremony. Procurement & Erection Electrical Instrumentation Trial Run & Commercial Production Implementation Schedule of 19200 TPA Pelletisation Project PREPARED BY: ANUP SNEH & ASSOCIATES Cell: +91 94370 53451 . The company has already successfully marketed its trial production from the pilot plant.2. Activity Description Milestones Process & Plant Engineering Months 12 Civil Work Structural Steel Plant & MachineryDesign.08 SCHEDULE OF IMPLEMENTATION The most important aspect in the implementation of the project is its successful commercialization.
Total cost of land acquisition is expected to be around Rs. Details are as given in Annexure – 3 PREPARED BY: ANUP SNEH & ASSOCIATES Cell: +91 94370 53451 .1 20t/m2 Humidity : Wind velocity : Earthquake : Soil bearing strength : A suitable land measuring 5 Acres has been located by the promoter having easy road and rail accessibility.22. Detailed soil investigation shall be conducted in construction drawing design stage.01.6– 2. earth cutting and filling. No problems are foreseen in acquiring the proposed area. drains and boundary walls with a gate and security office has been estimated at Rs. SITE CRITERIA Site location Temperature : : Altitude approximately yearly average Extreme minimum Extreme maximum yearly average Extreme minimum Extreme maximum average Minimum Main direction seismic zone Scale Factor “z” : : : : : : : : : : : : + 175 m 32 0 C 70C 48 0 C 44% 5% 98% 1. Lakhs. Geographic condition is as the base of foundation design. Cost of land site development including the laying of intervals roads. for which necessary application for land acquisition has been already made to the state government.5 Lakhs. 3.3. INFRASTRUCTURAL FACILITIES LAND AND SITE DEVELOPMENT The proposed plant will be constructed on a freehold land of area measuring 30-45 Acres.1 m/s S and SW II IV 0.2 m/s 16.
04 RAW MATERIAL The major raw material required is iron – ore which will be procured from mines located in Orissa. design of buildings will be simple.02 BUILDING 3. chimney adopts RCC structure. As per the process. 3.3. water pool. auxiliary building with smaller size and span adopt mixed brick structure. Detail of the proposed plant and machinery are given in Annexure V. pelletising unit and the induration unit. Ball mills with steel grinding media will be used for grinding iron ore and additives. Jharkhand. The oil fired induration furnace is proposed to be constructed as per the consultant design at site and bought out equipment will be procured from Indian casting supplier or from China._______Lakhs. 3. Equipment foundation with heavy load such as Ball Mill.03 PLANT AND MACHINERY Near about all the plant and machinery required for the project will be procured from indigenous sources. The disc pelletizes beneficiating equipment. adopts RCC slice raft foundation. ground belt conveyer corridor adopts light steel structure. The company proposed to buy grinding mills from the established manufacturer from the country whose similar ball mills are running successfully in Cement Plants. A shaft furnace fired by oil and capable of reaching temperature over 1300 0 C is proposed. Workshop and building will be made with brick structure. good looking with architectural view. drainage duct.01 Type Selection for Building Structure Criteria and regulation of civil construction has been designed according to the process. Workshop with single layer and larger span adopts RCC trestle frame structure. will be procured from China and Indian manufacturer.02. etc. workshop with multi-layers adopts local pouring frame structure. In this project. underground belt conveyer corridor adopts RCC structure. foundation for Grate furnace. Total cost of plant and machinery come to Rs. adopt RCC structure.adding RC block. maintaining structure adopts light air. The major sections of the plant are the grinding units. economic.. PREPARED BY: ANUP SNEH & ASSOCIATES Cell: +91 94370 53451 . other support of pipeline. frame structure adopts RCC independent foundation under columns. Chatisgarh and crusher plant situated near to mines. These will be in line with the similar units in the country. pump house. etc. chimney.
Other minor raw material required are:Bentonite Limestone / Dolomite Coke fines All the raw materials are available indigenously and no problems are foreseen regarding regular supply. PREPARED BY: ANUP SNEH & ASSOCIATES Cell: +91 94370 53451 . Lime stone / Dolomite are available in plenty from local mines. Bentonite is available in abundance in Gujrat will be procured by road transport and by railway. Coke fines will be procured from the non-recovery type coke oven plant all over the country and in particular in Dhanbad and Chirkunda area of Jharkhand.
Technical staff required in project will be located from near by cement plants and integrated steel plants. 3. Flue gasses from the chimney will be free from any dust particle as the process does not generate any dust. sponge iron.06 EFFLUENTS The unit will not be generating any effluents that would require treatment. material handling and for general lighting purposes. steel. coal washeries. A new transformer for stepping down the 33 KVA State Electricity Board Supply will be used. grinding. Some of the technical persons will also be appointed from existing pellet plants in the country. It is mainly used in blast furnaces and DRI plants after crushing and screening. 3. The estimated connected load of the unit is 500 kva. The company proposes to employ local staffs and send them for training to different equipment supplier and consultant.3. 4. cement.07 MAN POWER There are ____ persons in plant operation and 21 persons for administration. All the dust collected in the various dust collectors will be mixed with the fresh raw material for pelletisation. foundry etc. All the drying. mixing and conveying equipments where there will be dust generation will be taken cared by pulse jet type dust collectors.05 POWER UTILITIES The total consumption of power at 100% capacity utilization for the unit is estimated at __________ units. Iron ore is the basic raw material for many industries like pig iron. Sintering or Pelletization after PREPARED BY: ANUP SNEH & ASSOCIATES Cell: +91 94370 53451 . . pelletising and induration. This includes requirements for raw material grinding. Ferro-alloys.01 MARKET AND SELLING ARRANGEMENTS THE INDUSTRY Minerals are valuable natural resources being finite and non renewable. The detail break up of the production staff and administration personal proposed to be recruited is given in Annexure 13.
Refer Fig. India ranks fourth in the world iron ore production and ninth in steel production.beneficiation are the measure process to utilise the fines ( .6 mm. India’s export of iron ore is around 52% of the total production. Today. 1 The competitiveness of the India steel sector will be helped by the successful development of the Iron Ore Industry Development of a competitive and cost effecter iron ore sector with associated infrastructure would benefit the Indian Steel Industry Increasing the efficiency and scale of operations would lower costs and improve product quality / consistency Encourage private Investment in infrastructure Use of advance mine planning techniques would optimize the use of resources Encourage new exploration and resource development Minimise environmental impact of mining Other constraints need also to be addressed Domestic sources of high non coking coals mean DRI will be particularly well suited to India PREPARED BY: ANUP SNEH & ASSOCIATES Cell: +91 94370 53451 . ) generated after crushing and concentrate produced after beneficiation.
rail. PREPARED BY: ANUP SNEH & ASSOCIATES Cell: +91 94370 53451 .SUMMARY Rapid growth in demand for Iron ore has brought high cost suppliers into the market. RTIO has a large expansion program underway – mine. port and infrastructure assets – on schedule and on budget. Economic growth is expected to drive an acceleration in Indian steel consumption but from a low base. Major exporters are bringing on new capacity but continued growth in the market means supply will remain tight in the short to medium term. The time is right to develop an internationally competitive domestic iron ore industry to complement the growing steel industry.
Since the company is manufacturing a product which is very high in demand. the unit IS USING low grade iron-ore available in abundance after beneficiation.2 MTPA.ore fines which otherwise find no buyer in India. Indeed. PREPARED BY: ANUP SNEH & ASSOCIATES Cell: +91 94370 53451 . the company’s product fills a long standing gap in the industry. by use of abundant and easily available iron .ore is increasing and constantly echoed at various apex bodies. The need of high quality sized iron . no difficulties are forcing regarding its marketability. AFTER COMPLETION AND STABILISATION OF THE FIRST PHASE. THE COMPANY WILL GO FOR CAPACITY ENHANCEMENT TO I. Moreover.
SERVICE COVERAGE RATIO BREAK EVEN ANALYSIS AT OPTIMUM LEVEL OF CAPACITY UTILIASATION COMPUTATION OF INTERNAL RATE OF RETURN SENSITIVITY ANALYSIS ANNEXURE – 1 :: ANNEXURE – 2 :: ANNEXURE – 3 :: ANNEXURE – 4 :: ANNEXURE – 5 :: ANNEXURE – 6 :: ANNEXURE – 7 :: ANNEXURE – 8 :: ANNEXURE – 9 :: ANNEXURE – 10 :: ANNEXURE –11:: ANNEXURE – 12:: ANNEXURE – 13:: ANNEXURE –14:: ANNEXURE –15:: ANNEXURE – 16:: ANNEXURE – 17:: ANNEXURE –18:: ANNEXURE – 19:: ANNEXURE – 20:: ANNEXURE – 21:: PREPARED BY: ANUP SNEH & ASSOCIATES Cell: +91 94370 53451 . CALCULATION OF INTEREST CALCULATION OF INCOME TAX WORKING CAPITAL REQUIREMENT CALCULATION OF DEBT. RAW MATERIAL CONSUMPTION AND SALES CONTINGENCY AND POWER AND FUEL COST MANPOWER REQUIREMENT WAGES AND SALARY CALCULATION OF DEPRECIATION REPAYMENT OF TERM LOAN. FIXED ASSETS DETAILS OF PRELIMINARY EXPENSES DETAILS OF PREOPERATIVE EXPENSES CASH FLOW STATEMENT PROJECTED BALANCE SHEET CAPACITY UTILISATION.5.0 ANNEXURES PROJECTED PROFITABILITY ANALYSIS COST OF PROJECT AND MEANS OF FINANCE LAND AND SITE DEVELOPMENT COST DETAILED COST OF BUILDINGS COST OF PLANT AND MACHINERY DETAILS OF MISC.
This action might not be possible to undo. Are you sure you want to continue?
We've moved you to where you read on your other device.
Get the full title to continue listening from where you left off, or restart the preview.