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Ferrous and Non-Ferrous Metals Projects

Non-ferrous metals are used as raw or subsidiary materials to make products in virtually all manufacturing segments. Their use has further expanded into high-tech electronic and IT industries in recent years. In particular, their consumption has sharply increased in developing countries where high economic growth continues, with new infrastructure being built alongside active industrial production.

Industry expected to post CAGR of 7% over 2015-2020 driven by increasing steel production in India and capacity additions in aluminium industry. Turnover of basic precious and non-ferrous metals rises by 8% driven by 16% growth of precious metals. In 2015, steel production value increases by 12% boosting demand for non-ferrous metals such as zinc and tin. Imports of precious metals rise by 27% to Rs740 billion in 2015 driven by increased imported volume of gold and silver. Indian basic precious and non-ferrous metals market rises by 8.3% driven by increased demand for precious metals gold and silver.

Indian demand for non-ferrous metals is expected to grow at 8 per cent between 2016 and 2021. Non-ferrous metals include metals like aluminium, copper, zinc and lead that find application in many industrial and infrastructural uses like real estate, automotive, defence, rail, power etc.

The expected demand growth in the non-ferrous metals industry is even better than the healthy trend observed in the last five years, “Over 2016-17 to 2021-22, the demand for these metals is expected to grow by around 8 per cent in line with strong economic prospects, thrust on manufacturing sector, healthy growth in key end-use segments further aided by rising usage intensity,

Global non-ferrous metals market and is expected to reach 107 million metric tons by 2020. The growth in this region is attributed to the increasing consumption of non-ferrous metals in India, China, and Japan.

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COPPER WIRE DRAWING (From Higher Size to Very Thin Size Used in Electrical Cables) - Manufacturing Plant, Detailed Project Report, Profile, Business Plan, Industry Trends, Market Research, Survey, Manufacturing Process, Machinery, Raw Materials

Copper wire is an essential material for electrical cables, motor and transformer winding. It is available in different gauges. The gauge of the copper wire depends upon the winding required for the specific motor or transformer. On the basis of high conductivity, strength and ductility, copper wires are adopted as the best known economical material for such purposes. Copper is used mainly in the electrical industry for manufacturing parts of electrical apparatus, bus bars, wires etc. Another reason for its wide use is that the copper has resistance to atmospheric corrosion because of the formation of uniform layer of oxide on the surface of the metal. Besides these factors, copper has good mechanical properties viz. good of copper conductor wire is so high in India that despite a fair increase in installed capacity and actual productions of the units, import is continuing. Thus, some more new units need to enter the field.
Plant capacity: 500 Kg. / DayPlant & machinery: 68 Lakhs
Working capital: -T.C.I: Cost of Project : 167 Lakhs
Return: 43.00%Break even: 46.00%
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BILLETS FROM STEEL SCRAP BY ELECTRIC FURNACE - Manufacturing Plant, Detailed Project Report, Profile, Business Plan, Industry Trends, Market Research, Survey, Manufacturing Process, Machinery, Raw Materials, Feasibility Study, Investment Opportunities

Steel is the most widely used materials in a large variety of applications. Steel is one of the most recyclable material available-40% produced in the world is from recycling techniques. Carbon steel of many large cross-sections are used as structural steels while flats of steel corner the rest of the engineering uses hot rolled sheets & strips of steel are used in large qualities in various down stream industries for either fabrication methods. Under prevailing circumstances, India steel prices went up w.r.t. international prices. This high cost of steel production, in turn, affected the rate of consumption. Now, India per capita steel consumption is around at 19 kg. This is quite a low figure when compared with China (60 Kgs), USA (451.2 kgs), USSR (575 kg) & Japan (620kg.). The steel industry during the second half of 1980s has been moving towards capacity expansion & modernization. It is now being considered more beneficial than setting up green field capacities. The cost of modernization & expansion of an existing steel plant is much less expensive that setting up a green field.
Plant capacity: 1785000 MT / AnnumPlant & machinery: 836 Crores
Working capital: -T.C.I: Cost of Project : 1124 Crores
Return: 45.00%Break even: 52.00%
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IRON ORE PELLETIZATION PLANT - 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

Iron ore pellets are used in blast / electric furnaces for producing sponge iron and steels. Market by high productivity, lower fuel consumption and improved furnace control, pellets are now preferred all over the world for primary steel making. Very fine particles cant be directly used in the furnace for melting due to dust problem and economic considerations. So these fines are bonded together into feed able sizes by various agglomerating processes. Minerals are scare assets and their efficient use and conservation has become vital for future growth India is not fully endowed with requisite mineral resources for sustaining its cherished economic growth.
Plant capacity: 1008000 MT/AnnumPlant & machinery: 138 Crores
Working capital: -T.C.I: Cost of Project : 224 Crore
Return: 46.00%Break even: 55.00%
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INTEGRATED MELTING & ROLLING MILL - Manufacturing Plant, Detailed Project Report, Profile, Business Plan, Industry Trends, Market Research, Survey, Manufacturing Process, Machinery, Raw Materials, Feasibility Study, Investment Opportunities

Steel is generally produced by removing impurities from pig iron in a basic oxygen furnace or an electric furnace. Steel products are broadly divided under two major groups “ non-flat or long products and flat product. Requirement of long products viz. bar, rods, angles, channels and beams are predominant in any developing country. Today, in India, wire rod form 40% of the total production of bars and rods. These are largely used in civil constructions starting from domestic buildings to large dams and bridges. Wire rod is, therefore, a very important product of steel industry and its requirement in India is going to multiply with time. There is good scope for new entrants.
Plant capacity: 50400 MT/AnnumPlant & machinery: 2815 Lakhs
Working capital: -T.C.I: Cost of Project : 3947 Lakhs
Return: 45.00%Break even: 56.00%
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STEEL BAR - 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

Steel is said to be the back bone of any national economy. In India SAIL units in public sector and TISCO in private sector are the integrated steel plants producing primary steels, using ore as the input material. They cover around 50% of the total steel requirement. Rest of the 50% need is met by minimum steel plants, re-rollers, etc. units plus import quantities. Export of Indian steels is minimal but pickling up our present consumption of steel is 20 kg per capita which is too low compared to Japans 650 kgs, USA (550 kgs) & UK (480 kgs). Most of the steel generally used are plain carbon and mild steel. The carbon content in the steel predominantly governs the steel properties. Carbon and mild steel bars have occupied a wide area of applications. Some of them are wires used for reinforcing concrete structures; wires for manufacturing cycle spokes; bridge and civil construction etc. India’s steel consumption is well set to go up very soon. A new entrepreneur can confidently venture into this field.
Plant capacity: 3000 MT / AnnumPlant & machinery: 88 Lakhs
Working capital: -T.C.I: Cost of Project : 275 Lakhs
Return: 42.00%Break even: 60.00%
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IRON POWDER FROM MILL SCALE SCRAP - Manufacturing Plant, Detailed Project Report, Profile, Business Plan, Industry Trends, Market Research, Survey, Manufacturing Process, Machinery, Raw Materials, Feasibility Study, Investment Opportunities, Plant Layout

Iron powder is used to produce particles in desired range for use in powder metallurgy and metallic pigments. Powder iron made electrolytically makes stronger parts than other types and electrolytic iron powder makes parts that are easier to machine and improved wear. In future, the demand from all these uses is expected to increase. All the end use industries except railways are estimated to increase their demand at their respective trend growth for the last ten years. In case of railways the demand is expected to grow according to the likely expansion in railway stocks and fluids allocated for repairs and maintenance of tracks. Accordingly, the demand from railway is estimated to increase at 12 percent per annum. Export demand is roughly part at 5% of total demand.
Plant capacity: 2 MT / DayPlant & machinery: 23 Lakhs
Working capital: -T.C.I: 176 Lakhs
Return: 46.00%Break even: 46.00%
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TMT BARS (SARIYA) PROJECT - 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

Thermo Mechanical Treatment (TMT) process for reinforcement bars is opening up new vistas in composite RCC, the re-enforcing steel is the costliest constituent (30 to 40% Per Cu. M. of concrete). This cost can be substantially reduced by using higher grades of steel re-enforcing bars. The higher yield strength of re-bars lowers the steel requirement, which results in reduced cost of construction. In India, high strength re-bars of yield strength up to 500 N/sq. mm. are produced either by cold twisting or micro-alloying or a combination of both which adds considerably to the cost of the re-enforcement bars. During the last 30 years, high strength cold twisted deformed bars with yield strength of 415 MPa conforming to IS:1786/85 are widely produced and marketed in our country. These cold twisted bars, though in extensive use at present, continue to have inherent problem of inferior ductility, weld-ability and increased rate of corrosion. Production of re-bars by the addition of micro-alloys gives the desired results of high strengths but at a cost, which is prohibitive. The need for reduction in the steel used for concrete re-enforcement has prompted most countries to switch to re-bars of higher yield strengths of 500 and 550 MPa. The need for cutting down the cost of production of high strength re-bars has initiated the involvement of a more economical and competitive process – the Thermo Mechanical Treatment (TMT) Process. The use of Thermo Mechanical Treatment process has not only helped produce re-bars of high yield strength but also having superior ductility, wild-ability, bend-ability, better corrosion resistance and thermal resistance creating a revolution in re-enforcement engineering. The TMT bars are widely used in construction works such as high rise building, industrial structures, flyovers and bridges etc. The Indian iron and steel industry has come to occupy a dominant position in the socio-economic development of the country and it is certainly a matter of pride that India is the 7th largest crude steel-producing nation in the world. After having gone through the highs and lows of business cycles over time, today the Indian steel industry is on the threshold of a major change as it gears up to give substance to an expansion plan that is ambitious by any standard. Joining forces with the ‘Main Producers’ are the ‘Secondary Producers’ as well, whose emergence in the post-liberalized decade in the Indian steel scene had been initially modest but over the years, they have made a significant contribution to the growth of the domestic iron and steel industry, in terms of spread, capacity, production and commodity basket, necessitation thereby, a fresh look at the segment, traditionally labeled as the ‘Secondary’ Producers, under the Indian context. Steel production in India got a momentum with the announcement of the Industrial Policy Resolution of 1956 when three SAIL plants were set up in the public sector in the late 1950s and the fourth in early 1970. These plants along with IISCO (now, a part of SAIL), VISL and TISCO (now Tata Steel Ltd) were the only integrated steel producers till the eighties. Vizag Steel plant/RINL came into production in the early nineties. The 70s saw the emergence of the Secondary sector – small scale steel producers who opted for the scrap-DRI based electric arc furnace/induction furnace routes – to meet primarily local demand. The semi finished ingots/billets produced by this segment, in turn led to the commissioning of a large number of re-rolling units to convert the semi finished steel into bars and rods, to be used mainly by the construction industry. Moving over the Re-rolling segment, challenges include facing the market downs, specially prices and operational factors like high energy consumption. Prospect for future growth may be considered bright, given the pace and scale of infrastructure / construction activities. Such prospects are captured in the projections for the 11th Five Year Plan of the Government of India, which indicates that share of Secondary Producers in total crude steel production would rise from the present below-50% mark to 53% at the end-of the plan period, as the Secondary sector consolidates their position further. The Indian steel industry has ended 2006-07 on a buoyant note, in the backdrop of Indian economy, growing by a projected 9% growth rate. As the steel industry, including the foreign steel giants setting up steel plants in India, prepares to launch their dream projects, the future of steel in India is awaits a new chapter to be written – a phase which would in all likelihood would witness the Secondary Steel sector further increase their dominance and criticality in the overall operations of the Indian iron and steel industry. If we were to pause for a moment to think about the growth of human civilization, we would find that the pace of social and economic growth has been closely linked to the proficiency with which people have been able to use of shape materials. Steel is one of the critical inputs required to sustain the growth of the economy. In fact it is the basic input for all kinds of economic activity. With the sustained growth of the Indian economy, there has also been a remarkable growth of the Steel Industry. The growth of infrastructures, roads and bridges, civil construction projects, and modern town ship complexes will ensure continued demand of TMT bars.
Plant capacity: -Plant & machinery: -
Working capital: -T.C.I: -
Return: 1.00%Break even: N/A
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Alumina from Bauxite (By Calcination Process) - Manufacturing Plant, Detailed Project Report, Profile, Business Plan, Industry Trends, Market Research, Survey, Manufacturing Process, Machinery, Raw Materials, Feasibility Study, Investment Opportunities

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Plant capacity: 66.66 MT/DayPlant & machinery: Rs. 671 Lakhs
Working capital: -T.C.I: Rs. 2112 Lakhs
Return: 46.00%Break even: 38.00%
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Forging Unit for Automobile Spare Parts - Manufacturing Plant, Detailed Project Report, Profile, Business Plan, Industry Trends, Market Research, Survey, Manufacturing Process, Machinery, Raw Materials, Feasibility Study, Investment Opportunities

The forging industry as it known today, make use of various type of forging equipments for the practical duplication of forged part for commercial use services. The era of modern growth in India has its first foot print on automobile industry. New model of cars, scooter, buses etc not only provided increased oxygen to auto ancillary industry but to many industries like steel forging and casting, automobile, paint etc. However, the trend in steel forging is encouraging in the automobile industry in last ten years. Automobile Industry share 70% of consumption of steel forging. The remaining is consumed by other end use segment mainly by capital goods sector which manufacture machinery, turbine, electric motor etc. The current demand of direct and indirect consumption is estimated at 320 thousand tonnes. In automobile sector, all the vehicle requires forged product for steering, gear etc. It is understood that higher the gross weight of vehicle higher is consumption of steel in tonnage. Today on an average, a heavy and medium duty vehicle require around 300 kg whereas car and jeep require 150 kg. The demand of forged parts in automobile sector is very good, so there is wide scope for new entrepreneurs to venture into this project.
Plant capacity: 6 MT / DayPlant & machinery: 217 Lakhs
Working capital: -T.C.I: Cost of Project : 435 Lakhs
Return: 42.00%Break even: 63.00%
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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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  • 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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