Aluminothermic


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FERRO ALLOYS-FERRO MANGANESE, SILICO MANGANESE, FERRO SILICON BASED ON ALUMINOTHERMIC PROCESS

The primary objective of the study is to review the technological status of ferroalloys industry in the country in the area of bulk production of silicon. Bulk ferro alloys include ferro manganese, ferrosilicon etc. Manganese is used in metallurgical Industries in the form of ferro-manganese. Ferro-manganese contains about 80% Mn and 20% Fe. Generally ferro-manganese is produced in blast furnace or an electric furnace. There are no rigid ore-requirements for ferro-manganese produced in the blast furnaces. The high carbon ferromanganese is the most important grade of ferromanganese, which is produced by carbothermic reduction of high-grade Mn ores, and low iron content. Ferromanganese is used to add manganese in steel equivalent to 200 series stainless steel. Silicon manganese is produced by carbothermic reduction of Mn slag & quartzite. It should be noted that the derived level of phosphorus content in the ferromanganese is 0.35% max. Silico-manganese is used as a blocking agent to prevent the reaction of carbon & oxygen in steel. The most important consideration in the development of a satisfactory aluminothermic reaction is that the self-propagating reaction which occurs throughout the charge, consisting of an intimately mixed and finely divided mixture of aluminium powder and the metal oxide, shall produce enough heat to melt the products of reaction and to allow separation of the metal and the slag. The commercial development of the aluminothermic process was due largely to the work of H. Goldchmidt. The reaction is generally highly exothermic and the risk of explosion, therefore, sometimes considerable. Gold Schmidt developed satisfactory techniques for its control on a production basis. The excellent account of a modern aluminothermic plant has been given by them who list very fully the consideration, which leads to successful application of the process. The Ferro Alloy Industry was identified by DSIR (Department of Scientific And Industrial Research) as one of the best sectors. This industry has already completed three decades of existence. This is principal alloying agent used in steel manufacturing, steel iron casting etc. where it also acts as a strengthener & deoxidiser. Ferro Alloys are important materials required for the country’s steel production. So, there is good scope for new entrants in this field. Domestic ferro alloy industry is not able to meet the steel industry expectation in spite of having enough capacity to manufacture ferro alloys. According to the data published by Indian Ferro Alloys Producers' Association (IFAPA), capacity utilisation of the ferro alloy industry is only 65 percent for the manganese and chrome alloys. Both the manganese and chrome alloy manufacturers are starved for the basic raw material - the ores. In India, there are 133 companies producing ferro alloys in bulk with 252 furnaces. Most of the companies are manufacturing either manganese or chrome alloys. Few manufacturers concentrate on production of ferro silicon and the rest produce noble ferro alloys such as ferro vanadium, ferro molybdenum and other variants. Few Indian Major Players are as under: Aar Kay Steel Products Ltd. Aarti Steels Ltd. Adhunik Metaliks Ltd. Alok Ferro Alloys Ltd. Andhra Ferro Alloys Ltd. Anjaney Ferro Alloys Ltd. Baheti Metal & Ferro Alloys Ltd. Balasore Alloys Ltd. Baroda Ferro Alloys & Inds. Ltd. Castron Technologies Ltd. Century Plyboards (India) Ltd. Corporate Ispat Alloys Ltd. Dandeli Ferro Pvt. Ltd. Dinar Diamonds Ltd. Essel Mining & Inds. Ltd. Facor Alloys Ltd. Ferro Alloys Corpn. Ltd. G M R Ferro Alloys & Inds. Ltd. Gitanjali Exports Corporation Ltd. Gitanjali Gems Ltd. Godawari Power & Ispat Ltd. Haldia Steels Ltd. Hi-Tech Electrothermics & Hydro Power Ltd. Hindustan Ferro & Inds. Ltd. Hindusthan Malleable & Forgings Ltd. Hira Ferro Alloys Ltd. Impex Ferro Tech Ltd. India Thermit Corpn. Ltd. Indian Metals & Ferro Alloys Ltd. J S L Ltd. Jai Balaji Inds. Ltd. Jalan Forgings Ltd. Jeypore Sugar Co. Ltd. Kamdhenu Ispat Ltd. Karthik Alloys Ltd. Kemstar Metals Ltd. Kinjal Metals Ltd. Maharashtra Elektrosmelt Ltd. Maithan Alloys Ltd. Manganese Ore (India) Ltd. Marmagoa Steel Ltd. Minex Metallurgical Co. Pvt. Ltd. Monnet Ispat & Energy Ltd. Nagpur Power & Inds. Ltd. Natural Sugar & Allied Inds. Ltd. Nava Bharat Ventures Ltd. Orde Industries Ltd. Palco Metals Ltd. Parekh Platinum Ltd. Rajesh Exports Ltd. S A L Steel Ltd. Sarda Energy & Minerals Ltd. Sharp Ferro Alloys Ltd. Shri Girija Smelters Ltd. Shyam Ferro Alloys Ltd. Siddharth Ormet Ltd. Silcal Metallurgic Ltd. Snam Alloys Ltd. Sova Ispat Alloys Ltd. Srinivasa Ferro Alloys Ltd. Tata Steel Ltd. Tecil Chemicals & Hydro Power Ltd. Universal Ferro & Allied Chemicals Ltd. V B C Ferro Alloys Ltd. V B C Industries Ltd. Valley Abrasives Ltd. Visa Steel Ltd.
Plant capacity: 12 MT/Day, Ferro Manganese –6 MT/Day, Silico Manganese – 3 MT/Day, Ferro Silicon – 3 MT/DayPlant & machinery: 75 Lakhs
Working capital: -T.C.I: Cost of Project : 242 Lakhs
Return: 36.00%Break even: 79.00%
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FERRO ALLOYS – FERRO MANGANESE, SILICO MANGANESE, FERRO SILICON BASED ON ALUMINOTHERMIC PROCESS

The ferro alloys are classified as bulk ferro alloys & noble ferro alloys. Bulk ferro alloys include ferro chrome/charge chrome ferro manganese, ferro silicon, etc. while niobium, nickel, titanium, tantalum, tungsten, and vanadium form noble ferroalloys. Two or more of these elements can be associated with any one ferroalloy in known proportions for metallurgical uses. Depending on affinity for oxygen compared to iron, copper, molybdenum and nickel can be added with the charge or during melting and are fully recovered chromia and manganese elements are easily oxidized, and hence, need to be added late during melting or in ladle. Al, Ti, V & Zr easily oxides and are added in ladle only to minimize oxidation losses. The demand for ferro alloys has been increasing with that of alloy and special steels. There are six leading players and over 30 small producers. The industry has tied up with companies in Europe for technology inputs. The major users of alloy steel are: auto industry, railways, forgings, tubes, springs and other engineering industries. The leading players are Alloy Steel (SAIL), Mukand (Advanced Design Materials Corp., USA), Mahindra Ugine, Sunflag Irons & Steel, Vishveshvarya Steel, Kalyani Steel, Panchmahal, Indian Seamless, Shah Alloy Kalyani Carpenter, and Garg Furnace. Ferro manganese along with Fe-Si, Fe-Cr, is a bulk ferro-alloy; Manganese is also added in steels in the form of silico manganese. It dissolves in iron in all proportions, Iron for Farm implements uses upto 1.75% Mn and also in automobile parts. Ship construction industry uses steels with even higher content; riffle barrels and heat treated forgings necessarily use ferro manganese as an alloying additive. Ferro manganese is a principle alloying agent used in steel production steel/iron casting etc, where it also acts as a strengthener and deoxidizer. It imparts corrosion resistance to the products. There is an increased demand of the Indian silico-manganese in the European market. This has strengthened the position of Indian manufacturers for its sale to other countries. The mood of the ferro alloys manufacturers in the International market is very positive. There is a good scope to venture into this field for new entrepreneurs. Few Indian Major Players are as under: Acme Ferro Alloys Pvt. Ltd. Alok Ferro Alloys Ltd. Andhra Ferro Alloys Ltd. Anjaney Ferro Alloys Ltd. Baheti Metal & Ferro Alloys Ltd. Balasore Alloys Ltd. Baroda Ferro Alloys & Inds. Ltd. Bhaskar Shrachi Alloys Ltd. Bhupco Alloys Ltd. Castron Technologies Ltd. Corporate Ispat Alloys Ltd. Cronimet Alloys India Ltd. Dandeli Ferro Pvt. Ltd. Facor Alloys Ltd. Ferro Alloys Corpn. Ltd. Hi-Tech Electrothermics & Hydro Power Ltd. Hindustan Ferro & Inds. Ltd. Hira Ferro Alloys Ltd. Impex Ferro Tech Ltd. Indian Metals & Alloys Ltd. Indian Metals & Carbide Ltd. Indian Metals & Ferro Alloys Ltd. Indsil Hydro Power & Manganese Ltd. Jagat Alloys Pvt. Ltd. Karthik Alloys Ltd. Maharashtra Elektrosmelt Ltd. Maithan Alloys Ltd. Mishra Dhatu Nigam Ltd. Muskan Ferro Silicons Ltd. Nagpur Power & Inds. Ltd. Quality Steels & Forgings Ltd. R G Foundry Forge Ltd. Sarda Energy & Minerals Ltd. Sharp Ferro Alloys Ltd. Shri Ganesh Ferro Alloys Ltd. Shri Girija Smelters Ltd. Shyam Ferro Alloys Ltd. Silcal Metallurgic Ltd. Snam Alloys Ltd. Sova Ispat Alloys Ltd. Srinivasa Ferro Alloys Ltd. Standard Chrome Ltd. Star Metallics & Power Pvt. Ltd. Universal Ferro & Allied Chemicals Ltd. V B C Ferro Alloys Ltd. V B C Industries Ltd.
Plant capacity: 1800 MT/Annum Ferro Manganese, 900 MT/Annum Silico Manganese, 900 MT/Annum Ferro SiliconPlant & machinery: 87 Lakhs
Working capital: -T.C.I: Cost of Project : 283 Lakhs
Return: 40.00%Break even: 74.00%
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Information
  • One Lac / Lakh / Lakhs is equivalent to one hundred thousand (100,000)
  • One Crore is equivalent to ten million (10,000,000)
  • T.C.I is Total Capital Investment
  • We can modify the project capacity and project cost as per your requirement.
  • We can also prepare project report on any subject as per your requirement.
  • Caution: The project's cost, capacity and return are subject to change without any notice. Future projects may have different values of project cost, capacity or return.

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