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Ferrosilicon


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FERROSILICON - Manufacturing Plant, Detailed Project Report, Profile, Business Plan, Industry Trends, Market Research, Survey, Manufacturing Process, Machinery, Raw Materials, Feasibility Study, Investment Opportunities, Cost and Revenue, Plant Economics

Ferrosilicon, or ferrosilicium, is a ferroalloy an alloy of iron and silicon with between 15 and 90% silicon. It contains a high proportion of iron silicides. Its melting point is about 1200 °C to 1250 °C with a boiling point of 2355 °C. It also contains about 1 to 2% of calcium and aluminium. Ferrosilicon is used in steelmaking and foundries as a source of silicon in production of carbon steels, stainless steels, and other ferrous alloys for its deoxidizing properties, to prevent loss of carbon from the molten steel (so called blocking the heat); ferromanganese, spiegeleisen, silicides of calcium, and many other materials are used for the same purpose. It can be used to make other ferroalloys. Ferrosilicon is also used for manufacture of silicon, corrosion-resistant and high-temperature resistant ferrous silicon alloys, and silicon steel for electromotors and transformer cores. In manufacture of cast iron, ferrosilicon is used for inoculation of the iron to accelerate graphitization. In arc welding, ferrosilicon can be found in some electrode coatings. Ferrosilicon is a basis for manufacture of prealloys like magnesium ferrosilicon (FeSiMg), used for modification of melted malleable iron; FeSiMg contains between 3-42% of magnesium and small amounts of rare earth metals. Ferrosilicon is also important as an additive to cast irons for controlling the initial content of silicon. Ferrosilicon is also used in the Pidgeon process to make magnesium from dolomite. In contact with water, ferrosilicon may slowly produce hydrogen. Ferrosilicon is produced by reduction of silica or sand with coke in presence of scrap iron, millscale, or other source of iron. Ferrosilicons with silicon content up to about 15% are made in blast furnaces lined with acid fire bricks. Ferrosilicons with higher silicon content are made in electric arc furnaces. An overabundance of silica is used to prevent formation of silicon carbide. Microsilica is a useful byproduct. The usual formulations on the market are ferrosilicons with 15, 45, 75, and 90% of silicon. The remainder is iron, with about 2% of other elements like aluminium and calcium. Viewing the uses and applications of ferro silicon, it can be predicted that there is good future for the some and new entrepreneur can venture in to this field. Few Indian Major Players are as under: Hindustan Ferro & Inds. Ltd. Hindusthan Malleable & Forgings Ltd. Indian Metals & Ferro Alloys Ltd. Karthik Alloys Ltd. Kinjal Metals Ltd. Nava Bharat Ventures Ltd. Siddharth Ormet Ltd. Silcal Metallurgic Ltd. Snam Alloys Ltd. Tecil Chemicals & Hydro Power Ltd. V B C Ferro Alloys Ltd. V B C Industries Ltd. Valley Abrasives Ltd.
Plant capacity: 3000 MT/AnnumPlant & machinery: 243 Lakhs
Working capital: -T.C.I: Cost of Project : 816 Lakhs
Return: 41.00%Break even: 63.00%
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Ferrosilicon

Ferrosilicon is an alloy called silicon (Si02) with small percentage of Aluminium (Al203) and many other elements. Ferrosilicon is an alloy of iron and silicon with an average silicon content between 15 and 90 weight percent. This Ferro alloys are used for manufacturing different variety steels for different uses. Ferrosilicon is used as alloying element in manufacturing of spring steel, transformer steel and other types of alloys steels. Ferrosilicon is a alloy which helps in maintaining carbon contents in the steel at the desired level and makes it usable for different purposes. Ferrosilicon is used as a source of silicon to reduce metals from their oxides and to deoxidize steel and other ferrous alloys. This prevents the loss of carbon from the molten steel, ferromanganese, spiegeleisen, silicides of calcium, and many other materials are used for the same purpose. It can be used to make other ferroalloys. Ferrosilicon is also used for manufacture of silicon, corrosion-resistant and high-temperature-resistant ferrous silicon alloys, and silicon steel for electromotors and transformer cores. In the manufacture of cast iron, ferrosilicon is used for inoculation of the iron to accelerate graphitization. In arc welding, ferrosilicon can be found in some electrode coatings. The demand for ferrosilicon has been increasing with that of alloy and special steels. Owing to the lack of a viable alternative that can meet the diverse applications, the global ferro alloys market is estimated to expand at an CAGR of 5.9% till 2025. A significant share of the bulk ferro alloys are used in the production of the steel because of the low prices of the bulk ferro alloys and high production around the major producing regions. The prosperity of the building and construction industry in a number of emerging economies is another key driver of the global ferro alloys market, wherein the development of lightweight and high strength steel grades is expected to open up opportunities. On the other hand, stringent governmental regulations pertaining to the environment and high operational costs have stifled growth in the global ferro alloys market. The market for ferro alloys worldwide is projected to reach US$188.7 billion by 2025, up from US$112.8 billion in 2016. As a whole there is a good scope for new entrepreneur to invest in this business. Few Indian major players are as under: • Alok Ferro Alloys Ltd. • Bhartia Bright & Seamless Steels Ltd. • Bhaskar Shrachi Alloys Ltd. • Centom Industries Ltd. • Chhattisgarh Steel & Power Ltd. • Deepak Ferro Alloys Ltd. • Gaurang Alloys & Iron Ltd. • Hamco Mining & Smelting Ltd. • Hindustan Ferro & Inds. Ltd. • Hira Ferro Alloys Ltd. • Indian Metals & Ferro Alloys Ltd. • Indsil Hydro Power & Manganese Ltd. • Jai Balaji Inds. Ltd.
Plant capacity: 18,000 MT per annumPlant & machinery: 3694 Lakhs
Working capital: -T.C.I: Cost of Project:6670 Lakhs
Return: 26.00%Break even: 69.00%
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Start Ferrosilicon Production Business

Basically, ferrosilicon is an alloy of silica and iron that contains between 15% and 90% silicon. Ferrosilicon, a "heat-blocker," is frequently employed in the production of carbon and stainless steels. Additionally, it is used in the production of cast iron because it hastens graphitization. Ferrosilicon is added to an alloy to improve the resultant compound's physical properties, such as corrosion resistance and high temperature heat resistance. It also possesses a variety of physical traits, including as a high specific gravity, high magnetism, and resistance to abrasion. A mixture of silicon (Si02), aluminium (Al203), and a few other elements is known as ferrosilicon. Ferrosilicon is an alloy of silicon and iron with an average silicon concentration of 15 to 90% by weight. A number of steels with a range of uses are made using this ferro alloy. Ferrosilicon is used as an alloying element in the production of spring steel, transformer steel, and other alloy steels. Uses and Applications The ferrosilicon alloy contributes to the steel's ability to maintain the correct quantity of carbon at all times, making it appropriate for a range of applications. Ferrosilicon is used as a source of silicon to deoxidize steel and other ferrous alloys and extract metals from their oxides. This prevents the molten steel from losing carbon, and other substances like ferromanganese, spiegeleisen, and calcium silicides are used for the same purpose. It is able to create various ferroalloys. As well as silicon, ferrous silicon alloys that resist corrosion and high temperatures, and silicon steel for electromotor and transformer cores, ferrosilicon is used to produce other materials. To speed up graphitization, ferrosilicon is introduced into the iron during the casting process. Ferrosilicon is an element found in several in arc welding, electrode coatings. Ferrosilicon is used as a base material to create magnesium ferrosilicon (MgFeSi), which is used to create ductile iron. MgFeSi is primarily composed of magnesium, with trace amounts of rare earth metals. For controlling the initial silicon content, ferrosilicon is essential as a cast iron additive. Ferrosilicon is also used in the Pidgeon technique, which turns dolomite into magnesium. The process of processing high-silicon ferrosilicon with hydrogen chloride yields trichlorosilane for industrial use. Market outlook Ferrosilicon commonly comes in two different states: milled ferrosilicon and atomized ferrosilicon. Ferrosilicon is used in a variety of industries, including those that produce stainless steel, electrical steel, cast iron, magnesium, carbon and other alloy steel, and other materials. Increased demand for steel and metal alloys, as well as growth in the construction and automotive industries, are driving the ferrosilicon market. Due to growing environmental concerns, governments in several countries are focused on ferrosilicon consumption. Many international organisations give money to underdeveloped countries so they can use ferrosilicon more frequently. The demand for ferrosilicon has been increasing along with the demand for alloy and specialty steels. At the beginning of the previous decade, it was almost 500,000 tonnes, but by 1997–1998 it had increased to over 700,000 tonnes. Despite spreading so slowly, it is still growing. The sector has shown a very significant rise from 2001–2002. Between 2002 and 2007, it increased by almost 8%, and it is projected to increase by about 4% through 2011–12. After that, there will be a couple brief minor spikes at about 5.5 percent. Ferrosilicon's market is expected to reach a value of $11.0 billion in 2021 and grow at a CAGR of 2.4 percent from 2022 to 2030. Ferrosilicon is anticipated to lead the market because it is being employed as a deoxidizer in the steel industry and as an inoculant in cast iron. The increased demand for steel is forcing producers to increase their manufacturing capacity. For instance, a memorandum of understanding between AM/NS India and the Gujarati government was signed in January 2022 and calls for the company to invest more than USD 22.0 billion in six projects across the state. In order to raise its annual steel production from 8.6 to 18.0 million tonnes, the Hazira factory would invest USD 5.97 billion. Industry Major Market Players: • Elkem ASA • Eurasian Resources Group • Ferro Alloys Corporation Limited (FACOR) • FINNFJORD AS • Ferroglobe • IMFA • OM Holdings Ltd. • Russian Ferro-Alloys Inc. • SINOGU CHINA • VBC Ferro Alloys Limited
Plant capacity: 26.7 MT per dayPlant & machinery: 19 Cr
Working capital: -T.C.I: Cost of Project:39 Cr
Return: 26.00%Break even: 63.00%
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