Sintering Plant
Sintering Plant
SALIENT FEATURES
B. INTRODUCTION
1. General
2. Constitution
C. PROJECT
D. PRODUCT
3. Locational Advantages
E. PROCESS
2. Manufacturing Process
F. MARKETING
4. Machinery Statement
6. Production Facilities
G. ECONOMICS
4. D.S.C.R. Statement
6. Depreciation Calculation
7. Interest Calculation
9. Implementation Schedule
A. SALIENT FEATURES
1.GENERAL: Manganese ore and its alloys play an important role in the metallurgical
and non metallurgical industries. Metallurgical applications probably account for 97 to
98 percent of the total manages consumption while the rest is being used in the
manufacture of dry cell batteries and chemicals. It may be pointed out that steel, no
matter what grade or type, cannot be made and shaped without the appropriate amount
of manganese. It is estimated that about 95 per cent of the total manages ore is
ultimately consumed in the production of iron and steel, either directly as ore in the
blast furnaces or as ferro-manganese and metal in steel making.
Manganese ore is mined by both underground and surface methods depending upon the
geological setting of the deposits. The manganese ore is usually hand sorted into lump
ore and fines. The manganese content in the lump ore is higher compared to that of
the fines. At present, the manual sizing and sorting of manganese ore practice in India
give an yield of about 30 to 55 per cent of saleable manganese ore from and the ore
fines are being stockpiled at the mines, since there is no market for the same. Taking
into consideration the relevant factors in the Indian situation, namely manganese being
an essential ingredient for steel making, limited reserves of proved manganese ore, low
recovery of saleable ore and progressive growth of steel production of the country, the
installation of suitable beneficiation including agglomeration facilities to beneficiate
the low grade manganese ore fines and agglomerate them and also to improve the lump
recovery, is considered absolutely necessary for the conservation of the country’s
limited reserves.
In the process of mining of ores, a lot of fines is generated. Similarly in operations such
as crushing, screening, transporting & stacking a large quantity of fines is generated.
For smelting operation in furnace, raw materials in a particular size fraction are
required, since fines in the ore reduce the porosity of the charge adversely affecting the
smelting operation. The fines therefore have to be screened out before being using
the ore in the furnace for metallurgical processing. It is estimated that on an average
20 – 30% fines is discarded of the total ores utilized. Thus huge quantity of fines is
getting accumulated both at mines site and at the plant lying unused for the last so
many years. Moreover there is a growing demand for richer ore with stringent
stipulation of size in the domestic and international market. This has resulted in
accumulation of large quantities of inferior grade ore fines at the mines because of
limited demand. In order to put these inferior grade ore fines to productive use and
make them saleable, systematic beneficiation of the fines followed by agglomeration of
the concentrate is gaining greater importance in the manganese ore producing countries
all over the world.
Beneficiation of ores may be defined as the method of upgrading and enriching the
useful mineral content of the ores by removing undesirable and deleterious components.
The process adopted depend on the physical and chemical characteristics of the ore
minerals, to take advantage of properties like specific gravity, magnetism, surface
characteristics etc. The beneficiation process normally employed are washing, gravity
conception – jigging heavy media separation, spiraling and tabling and magnetic
separation and floatation.
Most of the manganese ores are being presently subjected to beneficiation ranging from
simple crushing, classification, washing and jigging to heavy media separation, also
known as sink float separation, to achieve higher recovery of saleable ore and to obtain
a high grade concentrate. There have been significant developments in recent years
in sink float separation technology.
The Promoters have contemplated to establish this Mineral Beneficiation and
Sintering Plant Unit in Industrial Growth Centre, Bobbili after making several searches
and conducting various studies, studying the advantages of the Sinter Plant at the
present situation had identified this Unit. This unit falls under the broad category of
Metallurgical applications of Minerals and utilization of Manganese Fines and Inferior
grade ores. The promoters has identified this kind of Unit as per the needs of the
existing Ferro Alloy units in the Industrial growth centre situated in Bobbili and had
contemplated to set up this Unit. So, the establishment of this Unit in Industrial
Growth centre is the order of the day and is badly needed in this area as number of
Units are already functioning and some of the Units are to be established. Similar type
of large scale Units viz., Nava Bharat Ferro Alloys Ltd., Palvanch, Universal Ferro &
Allied Chemicals Ltd., Tumsar, Sandur Manganese Iron Ores Ltd., Hospet etc. The
performance of these Units are excellent and the technology is closed. One of the
promoter has worked long back and acquired all the production techniques and
marketing channels while he was employed and hence got experience in this line of
business. The main Raw material for this Unit is the Manganese Ore Fines and Inferior
grade ore and coke. The Manganese Ore Fines and Inferior grade Ores are
available locally as lot of Fines is generated in the process of mining of Ores. The
manganese ore deposits confined entirely to the rocks of Pre Cambrian age, are
scattered throughout the country. The mostly occur in Maharashtra, Madhya Pradesh,
Andhra Pradesh, Bihar, Orissa, Karnataka, Goa and Gujarat. In Andhra Pradesh,
Srikakulam and Vizianagaram Districts are having Manganese Ore Deposits and hence the
Raw Materials are available. Coke is also available locally. After studying the various
advantages, the promoter has decided to set up this Unit of Beneficiation and
Sintering of low grade manganese ore fines unit under in the name and style of " SREE
RAJA RAJESWARI METALS & ORE PVT LTD.,". The proposed installed capacity of the
Unit is less than the total consumption of all the Ferro Manganese Units in the Industrial
growth centre. The promoters are capable of pooling necessary resources. The
Total Outlay required to be invested to establish this Unit is estimated at Rs. 268.86
Lacs apart from Industrial site which was contributed by their own sources. Major
investment of funds will be on Buildings , Plant & Machinery, Preliminary and Pre
operative expenses and Working Capital Margin etc., The promoters are meeting
their contribution from their own sources and decided to approach the Financial
Institutions for necessary Term Loan and Working Capital requirements.
2. CONSTITUTION
This is a Private Limited Company in the name and style of M/s SREE
RAJA RAJESWARI METALS & ORES PRIVATE LIMITED incorporated to take up the said
Project for processing of Sintering and Mineral Beneficiation of Manganese Ore at Plot
No: 160, Industrial Growth Centre, BOBBILI of Vizianagaram District. The Company
consists of the following Three Directors. The Company was already registered with
the Registrar of Companies, Hyderabad, Andhra Pradesh with Registration No.
C. PROJECT
During the course of mining of ores, lumps and fines are produced. Lumpy manganese
ore is used in blast furnace as well as in ferro manganese plant leaving a large quantity
of manganese ore depending upon the physical characteristics of ore. These fines are
of varying grades. To conserve our natural resources it is necessary that the fines
produced in different mines should also be used in the industry. The fines produced
can be utilized after agglomeration. Low grade fines produced can be beneficiated by
gravity methods for utilization. Various agglomeration techniques such as pelletisation,
sintering and briquetting are to be explored for conserving high grade fines.
Pelletisation process has become un economical for manganese ore agglomeration due
to steep increase in oil prices. Briquettes with sufficient high temperature strength
could be produced only by employing sodium silicate as binder. Since sodium will have
detrimental effect on ferro manganese furnace refractory, briquetting has been
abandoned leaving sintering as the only alternative. As pelletisation and briquetting
cannot be employed due to techno economic reason, the only alternative left is
sintering.
The high degree of reduction achieved during sintering indicate that a substantial
reduction of power, reluctant, flux and electrode paste etc. per ton of ferro manganese
produced would be possible compared to direct smelting of the ore.
The Sinters had very high porosity compared to the lumpy ore. The high porosity
indicates very high surface are and hence much better reducibility. Thus during
smelting, sinters shall reduce to the metal at a faster rate compared to the lumpy ores.
The ferro manganese furnace productivity is bound to go up when sinters are used in the
furnace burden. Metalisation will be noticed in the sinters. Thus part of the reduction
of the ore will be achieved during sintering itself, expending little power and rejected
coke fines. There will be appreciable saving in the coke and electric power per ton of
ferro manganese when such a sinter is used in the furnace burden.
Every ton of sinter used brings about saving of one tone of lumpy ore. In India, ferro
manganese plants alone generates one lakh ton/year of fines. If the entire fines are
sintered and utilized we can conserve one lakh ton/year of high grade ore.
Accumulation of unutilized Manganese Ore fines at the plants pose pollution as well as
storage space problems. Both these can be solved if Manganese Ore fine are utilized
through Sintering.
The main raw material required for processing of Sinters is Manganese Ore Fines,
Impurities and Coal Fines.
Indian manganese ore deposits occur mainly as metamorphosed bedded sedimentary
deposits available in Madhya Pradesh, Maharashtra, Gujarat, Odisha (Ganjam and
Koraput districts) and Andhra Pradesh ( Srikakulam & Visakhapatnam Districts). The
total resources of manganese ore in the country as on 01.04.2010 are placed at 430
million tones as per UNFC System. Out of these 142 million tones are categorized as
reserves and balance 288 million tones are in the remaining resource category. Odisha
tops the total resources with 44% share followed by Karnataka 22%. Madhya Pradesh
13%, Maharashtra 8%, Andhra Pradesh 4% and Jharkhand & Goa each 3%. Rajasthan,
Gujarat and West Bengal together shared the remaining about 3% resources.
The Production of manganese ore at 2.88 million tones during 2010-11 increased by 16%
as compared to that in the previous year owing to increase in market demand.
As regards grade wise composition of production in 2010-2011 production, 66% of
production was of lower grade (below 35% of Mn) 22% of medium grade (35 – 46% Mn)
and 10% was of high grade (46% of Mn and above).
Not only in the process of mining of ores but also in operation such as crushing,
screening, transporting & stacking a large quantity of fines and impurities are
generated. In addition to this, the smelter will also produce lot of impurities and fines
during the course of production.
As large quantities are available from the districts in neighbouring state and home state
and also smelters operating in around the proposed sintering plant, lot of Raw Materials
are available throughout the year. The Coal fines are also available locally as large
number of distributors are spread throughout the state and in the neighboring state.
3. LOCATIONAL ADVANTAGES
1 Since the unit is located Industrial Growth Centre, all the infrastructure
facilities will be provided by APIIC and the skilled labour are available in the existing
Ferro Alloy Units.
3. There are nationalised Banks such as Andhra Bank in Bobbili and other
nationalized Banks such as State Bank of India Branches, State Bank of Hyderabad,
Indian Overeseas Bank, Andhra Bank, Union Bank of India, Central Bank of India, axis
bank and Karur Vysya Bank branches. So, Banking facility is also available.
E. PROCESS
1. MANUFACTURING PROCESS
SINTERING : Manganese ore fines is mixed with 6% coke fines of – 3 mm size and 30%
return fines. The mixture after thoroughly drying is changed into a Muller Mixer
where 6% water is added. The Muller Mixer revolves at a speed of 10-15 RPM. The
pellets are transported by hoist and bucket elevator to the cast iron pan above the
sintering strand. In this process, a 25 mm layer of pellets is made followed by a bed
of 150 mm depth of charge, which is then ignited by oil fired burner at temps between
1100 C to1150C. The movement of the Sintering strand is maintained at 2000 mm per
minute and the vacuum is also maintained at 150 mm by a suction fan. The charge
gets sintered layer by layer in Cast iron pan and lumpy sinter are formed. The lumpy
sinters are lifted through hoist. The lumpy sinter from the screen + 6 mm is broken
into the size range of 10 to 50 mm for charging into the smelting furnace.
Coke - 6%
Return fines (below 6 mm) - 25%
Manganese - 60%
Moisture - 7%
Bed depth - 150 mm
Hearth Layer - 25 mm
Vacuum - 150 mm of water guage
Machine speed - 200 mm / minute
________________________________________________________________________
BASIC -PROCESS FLOW DIAGRAM OF SINTERING PLANT
Sinter fines
Sinter Cake Air
(Lifting through Size: 0.20mm
Hoist)
Pollution MS Duct
Hoist
Mn Ore Trucks / Mixed Raw MS Duct MS Duct Control
C.I. Pan Blower System
Mines Lorry materials Mullar
Mixer
HE HE
BF
BF
IDF
IDF
Chimney
Chimney
H2 H4
F. MARKETING
Marketing and Marketing Strategies:
The proposed Unit is in the midst of Ferro manganese smelting units in the Industrial
Growth Centre, Bobbili. At present there are about 10 Units operating and some of
the Units are coming in near future. The proposed Plant’s installed capacity is 30000
Tonnes per annum on single shift basis. The requirement of the One Unit per annum is
much more than the Installed operating capacity of the proposed Unit. The existing
Units are making enquiries about the starting of the production of the Unit. There is a
lot of demand for the Finished Product of the unit because of its advantage discussed
above. The Unit could not supply the requirements of a single smelting Unit even if it
works on three shift basis. The promoters are very much confident of marketability of
their product and there are no specific strategies are required for selling the product.
G. PROJECT DETAILS
B. MEANS OF FINANCE:
268.86
________________________________________________________________________________
PLANT AND MACHINERY: The Company have estimated an amount of Rs. 120.86
Lakhs towards cost of New Plant and Machinery and Electrical Equipment to be
erected. The Company estimated the cost on the basis of competitive quotations from
the various reputed suppliers of Plant and Machinery. The New main machinery
comprises of 12 Nos of C I Mouth pieces , Two numbers of Miller Mixers, SS Plate for
Fabrication and Erection of Ducts, 630 KVA Transformer, 4 Nos of Centrifugal Fans,
Venturi Scrubber Unit for Pollution Control, Wire Rope Electrical Hoist and Water Line
and Air Line. All these machines will be acquired from the suppliers who have been
in this trade for long several years and the machines have proved efficiency.
WORKING CAPITAL MARGIN : The promoters have estimated that the unit requires
Working Capital Limit of Rs. 120.00 Lacs in a comprehensive manner as per the
proposed operating capacity. The promoter – Directors will bring Rs. 30.00 Lacs as
their margin and will approach the funding financial institution for necessary working
capital limit of Rs. 90.00 Lakhs for smooth functioning of the Unit.
SHARE CAPITAL : The Company's present Authorised Capital is Rs. 75.00 Lakhs.
The present paid up Capital of the Company is Rs. 74.00 Lakhs. The Promoters
have estimated that the Total of the Scheme shall be Rs. 268.86 Lakhs towards the
cost of the Buildings, Plant and Machinery and Working Capital Margin. All these
items of the scheme are arrived at conservative costs. The promoter worked out his
stake of investment at 25% of the Cost of the items of Buildings, Plant and Machinery
only and Working Capital Margin. However, the promoters are investing an amount
of Rs. 110.00 Lakhs from their own funds as Share Capital and Rs. 2.86 Lakhs towards
Unsecured Loans and for the balancing amount of Rs. 156.00 Lakhs they decided to
approach the Bank for necessary term loan requirements.
UNSECURED LOANS : The Promoter-Directors will bring Rs. 2.86 Lakhs from
their relatives as Unsecured Loans in lieu of Long Term Capital for augmenting the
funds during the implementation period which carry no interest and they undertake
to keep the entire loan amount till the Term Loan is repaid to the financing bank.
TERM LOAN: The Company desires to avail a Term Loan of Rs. 156.00 Lakhs from
Financial Institution to meet the part cost of the Project Cost, which works out to
58.02% of the Total Project Cost of Rs. 268.86 Lakhs. The amount would be
repayable in 24 Quarterly Installments of Rs. 6.50 Lakhs each with a moratorium of
two years. However, the interest on the Term Loan would be payable as and when it is
applied on.
PRODUCTION FACILITIES
A) POWER: The Company requires power 300 H.P. of Power Supply under
H.T.Limits connected load from the Contracted Load of 680 H.P. No Problems are
anticipated with regard to obtaining of 300 H.P. Power Supply as the Unit has already
made arrangements for supply of contracted load of 680HP.
B) WATER: The Company requires 10,000 Liters of Water per day which is used for
Domestic purpose. The Unit was already connected with Bore well which is sufficient
for catering the industrial and domestic needs. .
IMPLEMENTATION SCHEDULE
S.No. Particulars Month Start Month Completion
01. Acquisition of Land Completed
02.
Development of Land Completed
03. Civil Works factory Building, June 2014 Nov 2014
Machinery Foundation.
04. Plant & Machinery Placement of May 2014 July 2014
Order
05. Delivery at Site Nov 2014 Jan 2014
06. Arrangement for Power May 2014 Jun 2014
07. Arrangement for Water Available
08. Erection of Equipment Dec 2014 Feb 2015
09. Initial Procurement of Raw-Material Mar 2015
10. Training of Personnel Mar 2015
11. Trail Run Mar 2015 Mar 2015
12. Commercial Production Apr 2015
ON
SINTERING &
MINERAL BENEFICIATION
PREPARED BY
B.R.MANIKYALA RAO
Chartered Accountant
Main Road, Bobbili,
Vizianagaram Dist
Phones: 08944-255464(O) 255465®
Mobile : 9440 123143