|
Bee - Hive Metallurgical Coke
|
Product Code
|
:
|
N.A.
|
|
Quality and Standards
|
:
|
As per demand
|
|
Production Capacity
|
:
|
700 MT per year/shift
|
| Uploaded on |
: |
February 2007 |
Introduction
Metallurgical Cokes are hard coke used
in blast furnace for producing pig iron and in cupolas for
the production of grey iron castings. Integrated Steel Plants
have their own Coke oven battery in the premises to produce
better quality of Metallurgical coke. Cokes used in Cupola
are of inferior quality in comparison to coke used in the
blast furnace. Due to some inherent characteristics like hardness,
porosity, and abrasive strength, (Metallurgical cokes are
being used in these furnaces. Metallurgical coke is produced
by Carbonisation (heating of pulverised coking coal in absence
of air) of coking coal i.e. bituminous coal in coke oven battery.
Due to shortage of cooking coal in our country, now a days
coke is also being produced by blending of coking coal, Non–coking
and some additives.
Market Potential
There are a good number of units in small
scale sector engaged in producing grey iron casting, graded
cast iron castings and Malleable iron casting by melting the
charge in Cupola furnace. Metallurgical coke is one of the
main ingredients of the charge used for melting in cupola
furnace as it acts as a reducing agent and also fuel for melting
the charge hence metallurgical coke has got good market potential.
In mini blast furnace and mini cupola furnace, inferior quality
of metallurgical coke can also be used. Keeping in view the
good concentration of foundries for casting grey iron and
Malleable iron, it can be said that Metallurgical coke manufacturing
unit has wide scope in the small scale sector.
Basis and Presumptions
i. The Project is based on two shift basis
of 16 hrs. and 300 working days in a year.
ii. The rate of interest has been taken
a s 12% per annum for calculation purpose. This may vary from
place to place and time to time.
iii. The wages of labour have been taken
as per trend of market.
iv. The plant and machineries are indigenously
available.
v. There is scope for pollution control
and energy conservation for production of Metallurgical coke.
vi. Land and buildings: To be purchased
and constructed
vii. 2–3% heating losses may occur.
Technical Aspects
Process of Manufacture
i. Bituminous coal is pulverized by ball
mill into fine powder.
ii. Fine coal is heated in coke oven battery
at 700–900OC in absence of air. This process is called Carbonisation.
Soaking at this temperature for about 7–8 hrs. It is allowed
to cool in the furnace. Due to coking property of bituminous
coal powdered coal converts into lump size and becomes very
hard and highly porous.
iii. After cooling, the coke produced
is crushed into desired size. Strength of the coke, fixed
Carbon, sulphur content and ash content is determined in the
testing laboratory for justifying the quality of the coke.
iv. By-products like tar may also be collected
during carbonisation process.
Quality Control and Standards
Coking coal used should have low ash content,
low sulphur and should be highly coking in nature for better
quality of coke. Other properties like porosity, abrasive
strength and hardness must be checked in the laboratory for
maintaining the quality of Metallurgical coke.
Production Capacity (per annum)
|
Quantity
|
:
|
1400 MT
|
|
Value
|
:
|
Rs.
|
Pollution Control
Pollution may be created during pulversing,
crushing of coal and during carbonisation process. Hence,
anti pollution measures must be adopted.
Financial Aspects
A. Fixed Capital
|
(i) Land and Building
|
|
Total land Area = 1000 Sq. Mtrs.
@ 3500 Sq. Mtr
|
:
|
Rs. 350,000
|
|
Civil Construction:
Boundry wall, gates, roads inside
the factory
Factory building,
Utility buildings like DG. Set,
Pollution Control system, raw water system of bore well
and water storage and distribution
Raw material and finished goods
storage, store, laboratory, maintenance room workers
room, office, including sales marketing, accounts, purchase,
administration and security
Total construction area = 600 Sq.
Mtr.
|
:
|
Rs. 42,00,000
|
(ii) Plant and Machinery
|
Sl. No.
|
Description
|
Nos.
|
Value
(In Rs.)
|
|
1.
|
Coke oven battery to produce 800
kg Coke per batch including accessories self fabricated
|
3
|
15,00,000
|
|
2.
|
Coal crusher
|
2
|
4,00,000
|
|
3.
|
Ball Mill (cap. 400 kg.)
|
3
|
5,00,000
|
|
4.
|
Material handling equipments/tools
etc.
|
LS
|
3,00,000
|
|
5.
|
Testing laboratory having Muffle
Furnace, chemical balance, Glass wares, Asbestos rope,
chemicals etc.
|
LS
|
2,00,000
|
|
6.
|
Platform type weighing balance
|
1
|
2,00,000
|
|
7.
|
Office equipments
|
|
5,00,000
|
|
Total
|
36,00,000
|
B. Working Capital
(per month)
(i) Personnel
|
Sl. No.
|
Designation
|
Salary
(In Rs.)
|
No.
|
Amount
(In Rs.)
|
|
1.
|
Plant Manager, Sales, purchase,
accounts and finance and administration staff
|
|
|
1,00,000
|
|
2.
|
Skilled worker
|
5000
|
8
|
40,000
|
|
3.
|
Unskilled worker/ helper
|
3000
|
12
|
48,000
|
|
4.
|
Watchman/peon
|
3000
|
5
|
15,000
|
|
Total
|
2,03,000
|
|
Perquisites @ 22%
|
45,000
|
|
Grand Total
|
2,48,000
|
|
(ii) Raw Material (per month)
|
(Rs.)
|
|
1.
|
Coking Coal 120 MT @ Rs. 7500 MT
|
9,00,000
|
|
(iii) Utilities (per month)
|
(Rs.)
|
|
1.
|
Electricity lump sum
|
30,000
|
|
2.
|
Steam Coal
|
60,000
|
|
Total
|
90,000
|
|
iv) Misc, Expenses (per month)
|
(Rs.)
|
|
1.
|
Stationery and telephone
|
25,000
|
|
2.
|
Repair and maintenance
|
9,000
|
|
3.
|
Chemicals/consumables etc.
|
20,000
|
|
4.
|
Insurance
|
3,000
|
|
5.
|
Transportation/publicity
|
50,000
|
|
6.
|
Other expenses
|
20,000
|
|
Total
|
1,27,000
|
|
(v) Total Working Capital (per
month)
|
(Rs.)
|
|
1.
|
Staff and Labour
|
2,48,000
|
|
2.
|
Raw Materials
|
9,00,000
|
|
3.
|
Utilities
|
90,000
|
|
4.
|
Misc. Expenses
|
1,27,000
|
|
Total
|
13,65,000
|
C. Total Capital Investment
|
1.
|
Fixed capital
|
Rs. 1,13,00,000
|
|
2.
|
Working capital for three months
|
Rs. 54,60,000
|
|
Total
|
Rs. 1,67,60,000
|
Financial Analysis
|
(1) Cost of Production (per annum)
|
(Rs.)
|
|
1.
|
Recurring expenditure
|
2,18,40,000
|
|
2.
|
Depreciation on coke oven Battery
@ 20%
|
3,00,000
|
|
3.
|
Depreciation on other plant and
machinery @ 10%
|
2,10,000
|
|
4.
|
Interest on total capital investment
@ 12%
|
20,11,000
|
|
5. Depreciation on civil construction
|
2,10,000
|
|
Total
|
2,45,71,000
|
|
(2) Total Sale (per annum)
|
|
1400 MT Metallurgical Coke @ Rs.
20,880 per ton
|
Rs. 2,92,33,000
|
|
(3) Profitability
|
|
|
=
|
Profit per annum (Before Tax)
|
|
|
=
|
Total sale – Cost of Production
|
|
|
=
|
Rs. 2,92,33,000 – 2,45,71,000
|
|
|
=
|
Rs. 46,62000
|
|
(4) % Profit on Sale
|
|
|
=
|
Net Profit ×100
-------------------
|
|
|
|
Total Sale
|
|
|
|
|
|
|
=
|
46,62,000 ×100
--------------------
|
|
|
|
2,92,33,000
|
|
|
|
|
|
|
=
|
15.95%
|
|
(5) % Rate of Return of Capital
|
|
|
=
|
Net Profit ×100
---------------------------
|
|
|
|
Total Capital Investment
|
|
|
|
|
|
|
=
|
46,62,000 ×100
---------------------------
|
|
|
|
1,67,60,000
|
|
|
|
|
|
|
=
|
27.8%
|
(6) Break-even Point
|
Fixed Cost (per annum)
|
(Rs.)
|
|
1.
|
Interest
|
20,11,000
|
|
2.
|
Total Depreciation,
|
7,20,000
|
|
3.
|
40% salary of staff and labour
|
11,90,000
|
|
4.
|
40% of other expenses
|
6,10,000
|
|
Total
|
45,31,000
|
|
B.E.P.
|
|
|
|
|
=
|
Fixed Cost ×100
--------------------
|
|
|
|
Fixed Cost + Profit
|
|
|
|
|
|
|
=
|
45,31,000 ×100
---------------------
|
|
|
|
45,31,000 + 46,62,000
|
| |
|
|
|
|
=
|
49.8%
|
Addresses of Plant and Machinery Suppliers
1. Coke Oven Battery
Locally fabricated by Skilled Fabricator.
If necessary guidelines may be taken from Central Fuel Research
Institute, Dhanbad.
2. Jaw Crusher, Ball Mill
i. M/s. Batliboi and Co. (P) Ltd.
26, R.N. Mukherjee Road,
Kolkata-700001
ii. M/s. National Mechanical Works
72-A M.M. Road,
Paharganj,
New Delhi
Addresses of Coking Coal Suppliers
M/s. Bharat Coking Coal Ltd.
Local Marketing Division.
Contact for more information:
Information Manager
TIMEIS Project
E-mail: timeis@ficci.com
|
