Heavy Casting of Grey Cast Iron

Introduction

This scheme covers grey cast iron castings of Heavy Mass upto 1.5 M.T.

For Example:

1. Roller castings for sugar mills.
2. Rack and gear boxes for General Engg. Works.
3. Ingot moulds for mini-Steel Plants.

Market Potential

The market potential of heavy grey iron castings is good and expected to be bright in future. These Castings are required by sugar mills, General Engineering Works and Mini-Steel Plants. The demand for such castings is increasing continuously due to rapid industrialization.

Basis and Presumptions

1. The project profile has been prepared on the basis of three shifts of 8 hrs. a day and 300 working days in a year at 75% efficiency.

2. It is presumed that in the first year, the capacity utilization will be 70% followed by 85% in the next year and 100% in the subsequent year.

3. The rates quoted in respect of salaries and wages for skilled workers, and others are on the basis of minimum rates in the State of U.P.

4. Interest rate for the fixed and working capital has been taken @ 12% on an average whether financed by Bankers or Financial Institutions.

5. The margin money required is minimum (30% of the total capital investment)

6. The land and civil construction cost has been taken in to account.

7. The rate quoted in respect of machinery, equipment and raw materials are those prevailing at the time of preparation of the project profile and are likely to vary from place to place and suppliers to suppliers. When a tailor-made project profile is prepared, necessary changes are to be made.

8. The pay back period may be 5 years after the initial gestation period.

9. The gestation period in implementation of the project may be to the tune of 6 to 9 months which includes making all arrangements, completion of all formalities, market surveys and tie-ups etc. Once all the above arrangements are made and quality/standards achieved, the 100% project capacity may be achieved at the end of three years. However, a detailed PERT/CPM chart with implementation period has been given in the report.

Implementation Schedule

The implementation of the project includes various jobs/exercises such as procurement of technical know how, transfer of technology, market surveys and tie-ups, preparation of project report, selection of site, registration, financing of project, procurement of machinery and raw materials etc., recruitment of staff, erection/commissioning of machines, trial production and commercial production etc. In order to efficiently and successfully implement the project in the shortest period, the slack period is curtailed to minimum possible and as far as possible simultaneous exercises are carried out. In view of above, a CPMPERT Chart has been illustrated below, according to which a minimum period of 227 days is involved in finally starting the project on commercial basis. By following this process a time period of 82 days can be saved.

 Details of Activities

C.P M .

Technical Aspects

Process of Manufacture

Grey cast Iron heavy castings are produced by melting pig iron and C.I. scrap in cupola furnace. The molten metal is poured in dry sand moulds to avoid the mould dilution. Cores are made of silicon sands dried and coated with graphite paste. Graphite paste is prepared from graphite powder and Betonite mixed in water. The cores are dried in coal fired chamber properly before use in mould. Molten metal is poured in moulds cavity with the help of a ladle. Castings are taken out of the mould after getting cooled. After breaking the runner and risers castings are fettled properly.

Quality Control and Standards

Product as per requirements of the customer. The relevant standards of BIS are given below:

Production Capacity (per annum)

Motive Power

Pollution Control

1. This industry involves pollution to some extent for which State Pollution Control Board has to be approached.

2. Minimum height of shed will be maintained with exhaust fans installed for removing decongestion, proper ventilation, removal of cokes, fumes etc.

Energy Conservation

The following steps may be taken for the conservation of energy:

1. Machinery and Equipment parts, which are revolving and reciprocating should be properly, lubricated from time to time with suitable lubricant oil.

2. Layout of the unit should be in such a way that no back tracking of material is there.

3. All electric switches may be kept off, when not required.

4. The entire transmission belt will be tightened before starting the work wherever applicable.

5. Fluorescent tube with electronic Chokes may be used for energy saving. Further recently developed compact fluorescent tubes called (CFT) of 10-15 watts Philips/Glaux made may be used for energy saving and decoration. These self ballasted fluorescent lamps are high efficiency replacements for ordinary bulbs. For same light output, CFLEBs consume about one-fifth the power consumed by ordinary bulbs, thereby saving a lot of energy. The savings get further multiplied when CFLEBs are used in air-conditioned areas, since the saving of energy by using CFLEBs also corresponds to less heat dissipation reducing load on air conditioners. The life of CFLEBs is about 8000/10000 hours i.e. about 10 times that of ordinary bulb.

The typical payback period in terms of savings of energy bills and cost of ordinary lamps is about 6 months operation. Unlike ordinary bulbs, these CFLEBs provide choice of three colours designated A, B and C, to suit individual requirements.

Electronic Ballast, with protection against high voltage spikes, along with high quality CFLs make these composite CFLEBs (or self ballasted CFLs) slim, lightweight, efficient and reliable units.

6. As far as possible Solar Energy and daylight will be used keeping all the other lights off.

7. As far as possible, inductive load of motor will be reduced and high power factor will be used with the aid of capacitors of appropriate sizes.

Financial Aspects

A. Fixed Capital

(ii) Machinery and Equipments

B. Working Capital (per month)

(i) Personnel

Staff and Labour

(ii) Raw Material (per month)

C. Total Capital Investment

Machinery Utilization

It is expected that during first year machine utilization will be 70% and during second year 85% and 100% in subsequent years.

Financial Analysis

(2) Turn Over (per annum)

(6) Break-even Point

Addresses of Machinery and Raw Material Suppliers

1. M/s. The Wasman Engg. Co. Ltd.
1/2, Allenby Road,
Kolkata-700020
For Foundry Equipment

2. M/s. SANAS Foundry Project Engineers
28, Vijay Nagar Colony, 2130,
Sadashiv Path,
Pune-411030

For Foundry Equipment and Consultants

3. M/s. Pioneer Equipment Co. P. Ltd.
432, Padra Road,
Baroda

For Foundry Equipment

4. M/s. Met International
No. 8, O.T.C. Road,
Nagarthpaet,
Bangalore-560-002.

5. M/s. Steel Authority of India Ltd.
For Pig Iron

6. M/s. Raw Material Dipot of State Directorate
of Industries
For Pig Iron

7. M/s. Open Market
For C.I. Scrap

8. M/s. IVP Ltd.
Jolly Bhawan No. 2, Marine Lines,
Mumbai
(Branches all over India)
For Foundry Chemical

9. M/s. Fincast Foundry Flux Company,
Plot No. 303, GiDC Estate, ODHAV,
Ahmedabad-382415
For Foundry Chemical

10. M/s. Sagri Industries
2, Mercantile, Apartments Opp.
Basant Cinema, Chembur,
Mumbai-74
For Foundry Chemical

Contact for more information:

Information Manager
TIMEIS Project
E-mail: timeis@ficci.com