Project: Feasibility Plan of Large Size

Furnace
Course Title: Advance Topic in Project
Management
Submitted To: Dr. Abdul Aziz Niazi
Submitted By: Ahmad Hussain(530)

University of Engineering and Technology

Lahore.
 CONTENTS
BACKGROUND EXPERIENCE OF PROMOTER ...................................................................... 3
CURRENTLY WORKING/FUNCTIONING PROJECT .............................................................. 5
DETAIL OF PROPOSED PROJECT ............................................................................................. 5
PLANT CAPABILITY ................................................................................................................... 5
PRODUCTION CAPABILITY ...................................................................................................... 5
TECHNOLOGY (TECHNICAL KNOWHOW) ............................................................................ 6
MANAGEMENT ............................................................................................................................ 6
LAND/BUILDING/ MACHINERY ............................................................................................... 6
INFRASTRUCTURE ..................................................................................................................... 6
RAW MATERIAL (SUPPLY CHAIN) ......................................................................................... 6
POLLUTION (AIR, WATER, SMELL AND DUST) TREATMENT .......................................... 7
LABOR ........................................................................................................................................... 7
SCHEDULE OF IMPLEMENTATION ......................................................................................... 7
PROJECT COST ............................................................................................................................ 7
SOURCES OF FINANCE .............................................................................................................. 7
WORKING CAPITAL ................................................................................................................... 8
MARKETING AND SELLING ARRANGEMENT...................................................................... 8
PROFITABILITY AND CASH FLOW STATEMENT ................................................................ 8
GOVERNMENT APPROVAL(REGISTRATION) ....................................................................... 8
LOAN SECURITY ......................................................................................................................... 9
COLLATERAL SECURITY .......................................................................................................... 9
SUMMARY .................................................................................................................................... 9
BACKGROUND EXPERIENCE OF PROMOTER
In the 19th century, a number of men had employed an electric arc to melt iron. Sir Humphry Davy
conducted an experimental demonstration in 1810, welding was investigated by Pepys in 1815,
Pinchon attempted to create an electro thermic furnace in 1853 and, in 1878-79, Sir William
Siemens took out patents for electric furnaces of the arc type.
The first successful and operational furnace was invented by James Burgess Readman in
Edinburgh, Scotland in 1888 and patented in 1889. This was specifically for the creation of
phosphorus.
Further electric arc furnaces were developed by Paul Héroult, of France, with a commercial plant
established in the United States in 1907. The Sanderson brothers formed The Sanderson Brothers
Steel Co. in Syracuse, New York, installing the first electric arc furnace in the U.S. This furnace
is now on display at Station Square, Pittsburgh, Pennsylvania.
A schematic cross section through a Héroult arc furnace. E is an electrode (only one shown), raised
and lowered by the rack and pinion drive R and S. The interior is lined with refractory brick H,
and K denotes the bottom lining. A door at A allows access to the interior. The furnace shell rests
on rockers to allow it to be tilted for tapping.
Initially "electric steel" was a specialty product for such uses as machine tools and spring steel.
Arc furnaces were also used to prepare calcium carbide for use in carbide lamps. The Stassano
electric furnace is an arc type furnace that usually rotates to mix the bath. The Girod furnace is
similar to the Héroult furnace.
While EAFs were widely used in World War II for production of alloy steels, it was only later that
electric steelmaking began to expand. The low capital cost for a mini-mill—around US$140–200
per ton of annual installed capacity, compared with US$1,000 per ton of annual installed capacity
for an integrated steel mill—allowed mills to be quickly established in war-ravaged Europe, and
also allowed them to successfully compete with the big United States steelmakers, such as
Bethlehem Steel and U.S. Steel, for low-cost, carbon steel "long products" (structural steel, rod
and bar, wire, and fasteners) in the U.S. market.
When Nucor now one of the largest steel producers in the U.S decided to enter the long products
market in 1969, they chose to start up a mini-mill, with an EAF as its steelmaking furnace, soon
followed by other manufacturers. Whilst Nucor expanded rapidly in the Eastern U.S., the
companies that followed them into mini-mill operations concentrated on local markets for long
products, where the use of an EAF allowed the plants to vary production according to local
demand. This pattern was also followed globally, with EAF steel production primarily used for
long products, while integrated mills, using blast furnaces and basic oxygen furnaces, cornered the
markets for "flat products"—sheet steel and heavier steel plate. In 1987, Nucor made the decision
to expand into the flat products market, still using the EAF production method.

The furnace
The electric-arc furnace (EAF) is a squat, cylindrical vessel made of heavy steel plates. It has a
dish-shaped refractory hearth and three vertical electrodes that reach down through a dome-shaped,
removable roof (see figure). The shell diameter of a 10-, 100-, and 300-ton EAF is approximately
2.5, 6, and 9 meters. The shell sits on a hydraulically operated rocker that tilts the furnace forward
for tapping and backward for slag removal. The bottom—i.e., the hearth—is lined with tar-bonded
magnesite bricks and has on one side a slightly inclined tap hole and a spout or, as shown in the
figure, an oval hearth and a vertical tap hole. With this latter arrangement, a furnace needs be tilted
only 10° for tapping, producing a tight and short tap stream that decreases heat loss and reoxidation
of the liquid steel. Before charging, the vertical tap hole is closed from the outside by a movable
bottom plate and is filled with refractory sand.

An electric-arc furnace.
Most furnace walls are made of replaceable, water-cooled panels; these are covered inside by
sprayed-on refractories and slag for protection and to keep heat loss down. The roof is also made
of water-cooled panels and has three circular openings, equally spaced, for insertion of the
cylindrical electrodes. Another large roof opening, the so-called fourth hole, is used for off-gas
removal. Additional openings in the furnace wall, with water-cooled doors, are used for lance
injection, sampling, testing, inspection, and repair. The roof and electrodes can be lifted and moved
away for charging scrap and for hearth maintenance.
The graphite electrodes, produced to high standards by a specialized industry, are actually strings
of individual electrodes bolted end to end by short graphite nipples. This is done because shorter
electrodes are easier to manufacture, transport, and handle. Electrode diameters depend on furnace
size; a 100-ton EAF typically uses 600-millimetre electrodes. Three electrode strings are each
clamped to arms that extend over the furnace roof and that are bolted to a vertically movable mast
located beside the furnace. The mast controls the distance between each electrode tip and the scrap
or melt, thereby regulating the arc length and current flow. Power-supply equipment—normally a
step-down transformer, vacuum circuit breakers, a tap changer for electrode voltage control, and
a furnace transformer—is installed in a concrete vault a short distance from the furnace. Heavy
water-cooled cables and the power-carrying arms connect the furnace transformer with the
electrodes.
EAF plants are smaller and less expensive to build than integrated steelmaking plants, which, in
addition to basic oxygen furnaces, contain blast furnaces, sinter plants, and coke batteries for the
making of iron. EAFs are also cost-efficient at low production rates—e.g., 150,000 tons per year—
while basic oxygen furnaces and their associated blast furnaces can pay for themselves only if they
produce more than 2,000,000 tons of liquid steel per year. Moreover, EAFs can be operated
intermittently, while a blast furnace is best operated at very constant rates. The electric power used
in EAF operation, however, is high, at 360 to 600 kilowatt-hours per ton of steel, and the installed
power system is substantial. A 100-ton EAF often has a 70-megavolt-ampere transformer.

CURRENTLY WORKING/FUNCTIONING PROJECT

DETAIL OF PROPOSED PROJECT

PLANT CAPABILITY

PRODUCTION CAPABILITY
TECHNOLOGY (TECHNICAL KNOWHOW)

MANAGEMENT

LAND/BUILDING/ MACHINERY

INFRASTRUCTURE

RAW MATERIAL (SUPPLY CHAIN)

POLLUTION TREATMENT (AIR, WATER, SMELL AND
DUST)

LABOR

SCHEDULE OF IMPLEMENTATION

PROJECT COST

SOURCES OF FINANCE
WORKING CAPITAL

MARKETING AND SELLING ARRANGEMENT

PROFITABILITY AND CASH FLOW STATEMENT

GOVERNMENT APPROVAL(REGISTRATION)
LOAN SECURITY

COLLATERAL SECURITY

SUMMARY