Zastraka Iron Castings Private Limited

PROJECT REPORT

1. INTRODUCTION
M/s. ZASTRAKA IRON CASTING PVT LIMITED is manufacturing of Iron castings using iron scrap and is
located at 38-P-2-B, III Phase, Kooragalli Industrial Area, Mysore.

A foundry is a factory that produces metal castings. Metals are cast into shapes by melting them into a liquid,
pouring the metal into a mold, and removing the mold material after the metal has solidified as it cools. The
most common metals processed are aluminum and cast iron. However, other metals, such as bronze, brass,
steel, magnesium, and zinc, are also used to produce castings in foundries. In this process, parts of desired
shapes and sizes can be formed. Foundries are one of the largest contributors to the manufacturing recycling
movement, melting and recasting millions of tons of scrap metal every year to create new durable goods.
Moreover, many foundries use sand in their molding process. These foundries often use, recondition, and
reuse sand, which is another form of recycling.

Strength, reliability and economy are the desired characteristics for application in automobile industry.
Foundry components possess these characteristics, thus making both forged and foundry parts suitable for
application in automobile industry. Foundry components possess good shock absorbing capacity and therefore
are found at points of shock and stress such as axle beams, wheel spindles, shafts, kingspin, torsion bars, ball
studs, pitman arms, idler arms, and steering arms. Both Foundry and Forged products and parts also find
application in the powertrain, where connecting rods, drive shafts, transmission shafts, differential gears,
clutch hubs and yokes are often forged. Forging and foundry complement each others.

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TABLE 1.1: SALIENT FEATURES OF THE PROJECT

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Name of the Zastraka Iron Castings Private Limited
project
Zastraka Iron Castings Private Limited
Type of Manufacturing of the following the products
Project
Sl. Name of the Product Quantity
No Per Month
1 Cast Iron / Spiroidal grey casting by melting CRCA / Other 600 TPM
Scrap @ 1000 TPM in 0.5 Tons x 3 Nos. (1 Standby)
induction furnace, Casting in Green Sand moulding, Shot
blasting & Fetling.

Location Zastraka Iron Castings Private Limited

Plot No. 38-P-2-B, III Phase, Kooragalli Industrial Area,
Mysore 570018.
Project Cost 9,57,00,000

Total site area 4645 Sq.m

Land Details Sl.No LAND USE AREA (Sqm) % age

1. Built up area 2601.2 56%
2. Vacant Land 411.8 9.0%
3. Green Belt 1632 35%
Total Area 4645 Sq.m 100%
Number of 70 No’s
Employees
Source of Source of Electricity Supply is from CHESCOM.
Power
Power 1.25 MW
requirement
(connected
load)
Back up DG DG set – 125 KVA
sets
Water Water Water Wastewater Treatment Final Disposal
consumed Consumpti Discharge Units
Requirements
for on (KLD) (KLD) Provided

Domestic 3.15 2.52 Sewage Soak Pit

effluent shall
be disposed of
into Septic
tank and soak
pit.
Cooling 1.0 -- Completely Recycled gips 3
0.5 -- -- --
 Zastraka Iron Castings Private Limited

2.0 LAND ENVIRONMENT

2.1 SITE LOCATION
Zastraka Iron Castings Private Limited Plot No. 38-P-2-B, III Phase, Kooragalli Industrial Area, Mysore
570018. Figure 3.1 shows the Aerial view of the project site.

FIGURE 2.1: GOOGLE SATELLITE MAP OF THE PROPOSED SITE

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TABLE 2.1: PROJECT REQUIREMENTS IN TERMS OF RESOURSE USE AND COMMUNITY

INFRASTRUCTURE FACILITIES AND POWER REQUIREMENT
Latitude Latitude: 12º21′18.94′′N
Longitude Longitude: 76º34′42.10′′E
Plot Area 4645 Sq.m (100%)

Land details Sl.N

LAND USE AREA (Sqm) % age
o
1. Built up area 2601.2 56%
2. Vacant Land 411.8 9.0%
3. Green Belt 1632 35%
Total Area 4645 Sq.m 100%
Nearest Highway Ring road– 1.5 km
Nearest Railway station Maddur Railway Station-15 km
Nearest Airport Mysore Airport – 30 km
Nearest Town/City City-Mysore

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3.0 MANUFACTURING PROCESS

Scrap Metal

Furnace

Alloys Addition Spectro analysis

Pouring Ladle

Mould pouring/Cooling

Fettling

Finishing

FIGURE 3.1: MANUFACTURING PROCESS FLOW CHART

3.1: MANUFACTURING PROCESS DESCRIPTION:

There are many different kinds of foundry processes available; however, in a simple diagram the
process can be summarized as given above.
The input of raw material is normally scrap. However original steel ingots may be also used. The input
materials for the electrically fires Furnace are iron scrap.

The raw materials are stored right next to the furnace for ease of operation. They are weighed in the
right proportion and charged into the furnace

The furnace crucible is charged with the requisite quantity of iron scrap. Furnace gets hot and the
scrap starts to melt. Heating is continued till the entire metal mass melts to liquid state. At this stage, a
little time is available for adding inclusions like ferro alloys and carbon, if necessary. A sample of
molten metal is sent to the laboratories for analysis. Based on the analysis report, ferro alloys and
other alloys materials are added after proper weight. The temperature of the metal bath will be
adjusted suitably by adjusting power into the furnace to ensure proper mixing of alloys in the bath.
After sometime, when the metal bath has reached the appropriate temperature, sample is send to the
laboratories and the process is repeated till the desired quality is obtained. The molten metal is now
ready for pouring into the moulds.

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After controlling the composition and temperature, the molten metal is transferred into a ladle
and poured into a mould, where it solidifies to produce CAST IRON semi-finished or finished
products.

4.0 REQUIREMENTS OF THE PROJECT

4.1 RAW MATERIAL REQUIREMENTS

Following are the raw materials used for the production and products manufactured.

TABLE 4.1: RAW MATERIALS REQUIREMENTS:

Sl. Name of Raw Materials Quantity in MTPM

No
1. CRCA Scrap 450 MTPM

2. Pig Iron 50 MTPM

3. Boring Returns 111.7 MTPM

4. Foundry Returns 388.3 MTPM

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4.2: MATRIAL BALANCE FOR CAST IRON

Raw Material
1000 MTPM Scrap Inspection

1000 MTPM Induction Furnace Slag Waste 2.7 MTPM

Burning Losses 9 MTPM

Pouring Ladle

Mould pouring/Cooling

Fettling

Foundry returns 388.3 MTPM-

will be reused for casting
Finishing Product
Cast Iron-600 MTPM

Foundry Returns
Material Losses as burning losses and Reused for
balance Input Slag Out Put casting
1000 MTPM 9 + 2.7 = 11.7 MTPM 600 MTPM 388.3 MTPM
Material
balance 1000 MTPM = 1000 MTPM

5.0 WATER ENVIRONMENT

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5.1: WATER REQUIREMENT DETAILS

The source of water supply will be supplied from KIADB.

TABLE 5.1: WATER CONSUMPTION AND WASTEWATER DISCHARGE DETAILS

Water Water Wastewater Treatment Final Disposal

consumed for Consumption Discharge Units Provided
(KLD) (KLD)
Domestic 3.15 2.52 Sewage effluent Soak Pit
shall be disposed of
into Septic tank and
soak pit.
Cooling 1.0 -- Completely Recycled

Process 0.5 -- -- --
TOTAL 4.65 KLD 2.52 KLD

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KIADB
4.65 KLD

Domestic Cooling Process

3.15 KLD 1.0 KLD 0.5 KLD

Discharge to
Septic tank 2.5
Completely recycled
KLD

Soak Pit

FIGURE 5.1: WATER BALANCE FLOW CHART

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5.2:DESIGN OF SEPTIC TANK AND SOAK PIT

a) SEPTIC TANK

Number of people=70
Water Consumption=45 lpcd
Water requirement= 70 X 45 (As per NBC 2016, BIS) =3.15 KLD
Assuming Wastewater generated is 80% of consumption
Quantity of sewage generated=2.52 KLD
Septic tank and soak pit is designed for 3 KLD capacity
Volume of sludge storage/year =70 X 30 =2100 liters
Capacity of septic tank=3000 + 2100 =5100 litres=5.1 m3
Assuming depth as 1.0 m
Area=5.1 Sq. m
Dimensions= 2.25 m X 2.25 m X 1.0 m

b) SOAK PIT
Sewage flow = 2520/day
Percolation rate = 1250 l/cum/day
Volume = 2.0 cum

Depth = 1.0 m

Area = 2.0 Sq.m

Dia=1.6 m

Dimensions=1.6 m Dia and 1.0 m Depth

Sewage

SEPTIC TANK
SOAK PIT

FIGURE 5.2: FLOWCHART OF SEPTIC TANK AND SOAK PIT

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6.0 AIR ENVIRONMENT

Detailed polluting sources and its control equipment’s present in the industry is depicted in the table
below.

TABLE 6.1 AIR POLLUTION SOURCES:

Sl. Air Chimney Rate of Emission Standards Air pollution control

No. pollution height in m emissio constituents in Mg/Nm3 equipment
sources (AGL) ns
(Nm3 /
Hr)
1 Induction 18 m ARL - PM 150 Movable fume exhaust
furnace of followed by duct
capacity 500 connected to bag filter
Kgs x 3 Nos. & common chimney
(Operation
one at a
time)
2 Shot blasting 3.0 m ARL or - PM - Dust extraction &
machine 500 9.0 m AGL connected to Common
kg/Batch whichever cyclone followed by
is higher bag filter in closed
room
3 Knock out, 3.0 m ARL or - PM - Dust extraction &
Bucket 9.0 m AGL connected to Common
Elevator & whichever cyclone followed by
Sand mixer is higher bag filter in closed
room
4 Sand 3.0 m ARL or - PM - Dust extraction &
reclamation 9.0 m AGL connected to Common
machine whichever is cyclone followed by
higher bag filter in closed
room
5 125 KVA 3.0 m ARL - SO2 & - Acoustic enclosures
DG Set NOx

 Proposed 125 KVA DG set

H= ht + 0.2 (root KVA)
H = Theoretical height of proposed stack in mts

H = 0.2 (√125)
H = 0.2 (11.18)
H= 2.23 m say 3.0 m ARL

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7.0 NOISE ENVIRONMENT

7.1 NOISE ENVIRONMENT IN THE INDUSTRY

In the production, noise will be generated mainly from the DG set and other source such as vehicular
movement. The DG set shall be isolated from the outside environment and proper acoustic treatment
shall be given to control the noise generated. But both these activities- DG set and vehicular
movement will not have any significant impact on the people residing in the area. Adequate exhaust
mufflers are provided as per norms to limit the noise. Sufficient green belt will be done to help in
reducing noise levels in the campus.

TABLE 7.1: MONITORING SCHEDULE FOR NOISE

Important
Sr. Monitoring
Particulars Duration of monitoring parameters for
No. frequency
monitoring

1 Noise Quality Half yearly once 24 Hrs Monitoring Noise levels in dB (A)

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