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Mini Steel Plant

Mini Steel Plant. Production of TMT Bars, Flats, Angles, Channels and Girder. Steel Long Products Manufacturing Business

Steel is an alloy of iron and carbon containing less than 2% carbon and 1% manganese and small amounts of silicon, phosphorus, sulphur and oxygen. Steel is the world's most important engineering and construction material. It is used in every aspect of our lives; in cars and construction products, refrigerators and washing machines, cargo ships and surgical scalpels.

Mini steel mills are normally secondary steel producers located near consumer markets & based mainly on steel/iron scrap of different grades. The mini steel plant comprises of steel melting using induction furnace or electric furnace to melt scrap & sometimes mix of scrap and sponge iron/DRI; the billet making machine or CCM (continuous casting machine) to cast billets for further rolling of mainly of mainly long products.

Thermo-Mechanically Treated Bars, (TMT Bars), are Extra High Strength Reinforcing bars which replacing any form of cold twisting, the technology of yesteryears. In this process, the steel TMT bars receive a short, intensive cooling as they pass through the specially resigned Tempcore Water Cooling System after the last Rolling Mill Stand. The sudden quenching converts the surface layer of the steel bar to a hardened structure.

These bars have a great degree of elasticity. The soft ferrite-pearlite core of the TMT bars gives them superior bendability. These bars can be easily bent and moulded into any shape and used for a wide range of constructional purposes.

Flat Steel products refer to semi-finished steel products such as sheets and plates. Flat steel products are of immense importance to steelmakers since they are used in diverse applications across various end-use industries. Application in automobiles, construction, shipbuilding, industrial machinery, and domestic appliances are among the primary uses of flat steel.

Flat steel has a wide range of applications in thermal power plants, hydro power plants, oil & gas, solar, nuclear and wind energy industries. It is also used by various light bar industries, truck trailers, railways and automobile manufacturers.

Steel Angles are the most basic type of roll-formed steel. They are formed by bending a single angle in a piece of steel. Angle Steel is ‘L’ shaped; the most common type of Steel Angles are at a 90 degree angle. The legs of the “L” can be equal or unequal in length. Steel angles are used for various purposes in a number of industries. Framing is one of the most common uses for steel angles, but steel angles are also used for brackets, trim, reinforcements, and many other uses. The larger the steel angle, the more weight and stress it can bear.

Steel channel is a hot-rolled carbon steel made in a “C” shape. Constructed using a vertical web and top and bottom horizontal flanges with inside radius corners, it is available in a wide range of sizes and thicknesses. The shape provides superior structural support, making it an ideal product for frames and braces used for machinery, enclosure, vehicle, building and structural support applications.

Steel Girders are a type of steel beams. Girders are collector beams, they are the main horizontal supports of a structure which support the smaller beams. The Girders are widely used around the world for the construction of bridges due to their various advantages which include improvement in efficiency of installation and providing sustainable solutions. Indiana had foreseen this market demand in India and commenced the fabrication of Steel Girders.

Market Outlook

India was the world’s second-largest steel producer with production standing at 106.5 MT in 2018. The growth in the Indian steel sector has been driven by domestic availability of raw materials such as iron ore and cost-effective labour. Consequently, the steel sector has been a major contributor to India’s manufacturing output. The Indian steel industry is very modern with state-of-the-art steel mills. It has always strived for continuous modernization and up-gradation of older plants and higher energy efficiency levels. Indian steel industries are classified into three categories such as major producers, main producers and secondary producers.

Steel demand in India is expected to grow above 7 per cent in the current as well as next year. The wide range of continuing infrastructure projects is likely to support growth in steel demand above 7 per cent in both 2019 and 2020." In developing economies in Asia, excluding China, the demand is expected to grow by 6.5 per cent and 6.4 per cent in 2019 and 2020.

Steel

Demand: Past and Future

Year

(In Million Metric Tonne)

1990-91

15.30

2000-01

31.61

2001-02

32.87

2002-03

35.35

2003-04

39.28

2004-05

43.32

2005-06

47.65

2006-07

52.18

2007-08

56.90

2008-09

60.00

2009-10

63.20

2010-11

71.20

2011-12

75.90

2012-13

79.10

2013-14

79.55

2014-15

86.80

2015-16

95.25

2016-17

98.75

2017-18

110.00

2018-19

120.70

2019-20

129.80

2024-25

195.20

 

Rising population coupled with ever-increasing urbanization leads to rise in demand for infrastructure in emerging economies. There is rising demand for domestic and commercial buildings in China. This is accompanied with the rising industrial development caused due to infrastructural development in the region. India is an important emerging economy.

Furthermore, the region is characterized by substantial investment in the construction sector coupled with investment in the education and healthcare sector. Increasing industries are shaping the economy of this region. Economic development in the region has led to the construction of considerable number of bridges and roads that point toward better quality infrastructure. Therefore, infrastructural development increases demand for steel long products, as these products help strengthen structural integrity.

Steel long products are able to absorb extra heat energy and can offer better stability in case of extreme weather conditions. These factors help to strengthen the building and other construction, thus triggering the expansion of the global steel product industry. Increase in pollution causes frequent and sudden change in the climate, which increases the possibility of natural calamities. This, in turn, increases the need for better quality construction, thus boosting the prospects of the steel long products market during the forecast period.

The sale of construction materials including TMT bars are estimated to grow at a Compounded Annual Growth Rate (CAGR) of 6.18% in terms of volume. Currently, the size of the Indian construction industry is USD 2.8 billion. Recently the government has announced an early completion of 10 million rural houses by the end of 2018, ahead of 2018 deadline and 11.8 million urban houses by 2020 instead or 2022 deadline under the “Housing for All” initiative. This will require huge amount of TMT bars and we expect multifold growth in demand in the coming years.

Demand Forecast of Steel Rebars

Increase in demand for low cost reinforcement bars in construction projects such as dams and bridges drives the global thermo-mechanically treated (TMT) steel bars market. Rise in government support for the production of steel and coal propels the thermo-mechanically treated (TMT) steel bars market. Thermo-mechanically treated (TMT) steel bars are preferred over torsional bars, as these have high strength and ductility. This is a key factor boosting the demand for global thermo-mechanically treated (TMT) steel bars market. However, technical constraints such as the properties such as ductility and strength associated with high-grade thermo-mechanically treated (TMT) steel bars are anticipated to hamper the global thermo-mechanically treated (TMT) steel bars market.

Flat steel market revenue is expected to grow at a rapid growth rate, over the forecast period. The market is anticipated to perform well in the near future owing to the low cost of cold rolled steel sheets compared to hot rolled sheets and expanding industrialization. Moreover, increasing public sector expenditure and the rise in infrastructure investments are some of the factors that can propel the market revenue growth of flat steel soon.

Based on product type, sheets segment is projected to lead the global flat steel market over the forecast period attributed to the extensive use of hot rolled steel sheets for the development of the major sized structures such as heavy equipment, construction, and railroads, and high malleable property. On the other hand, the cold rolled sheets are a finished form of the sheet used when a surface finishing is required automotive parts. The cold steel is processed in cold reduction mills at room temperature along with tempers rolling which make steel closer dimensional tolerance, improve surface finish, and enhance the tensile strength.

On the basis of end-users, this market has been segmented into automobiles, construction & infrastructure, transport, and others. In developed countries, flat steel products are always in demand in the automobile sector. Due to the design flexibility, high strength, and increased durability, flat steel is used in the building & infrastructure sector. It also reduces the maintenance costs.

List of Ten Best Steel Companies in India:

·         Rashtriya Ispat Nigam Limited (RINL)

·         VISA Steel

·         Essar Steel

·         TATA Steel

·         JSW Steel

·         Bhushan Steel

·         MESCO Steel

·         FACOR Steel

·         Steel Authority of India Limited (SAIL)

·         Jindal Steel and Power

Some of the prominent players in the flat steel market are ArcelorMittal S.A., Allegheny Technologies Inc., Zeeco Metals, Inc., SSAB AB, Clingan Steel, Inc., United States Steel Corporation, AK Steel Holding Corporation, Hascall Steel Co., Essar Group ThyssenKrupp AG, Posco Co. Ltd., Precision Brand Products, Inc., Johnson Bros. Metal Forming Co., Voestalpine AG, Jindal Steel and Power Limited, JSW Steel Ltd., Tata Steel Limited, Nippon Steel & Sumitomo Metal Corp, Hyundai Steel Co., and Steel Authority of India Limited (SAIL), and many more.

 

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Niir Project Consultancy Services

An ISO 9001:2015 Company

106-E, Kamla Nagar, Opp. Spark Mall,

New Delhi-110007, India.

Email: npcs.ei@gmail.com  , info@entrepreneurindia.co

Tel: +91-11-23843955, 23845654, 23845886, 8800733955

Mobile: +91-9811043595

Website: www.entrepreneurindia.co  , www.niir.org

 

Tags

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ABOUT NPCS

 

NIIR PROJECT CONSULTANCY SERVICES (NPCS) is a reliable name in the industrial world for offering integrated technical consultancy services. NPCS is manned by engineers, planners, specialists, financial experts, economic analysts and design specialists with extensive experience in the related industries.

Our various services are: Detailed Project Report,  Business Plan for Manufacturing Plant, Start-up Ideas, Business Ideas for Entrepreneurs, Start up Business Opportunities, entrepreneurship projects, Successful Business Plan, Industry Trends, Market Research, Manufacturing Process, Machinery, Raw Materials, project report, Cost and Revenue, Pre-feasibility study for Profitable Manufacturing Business, Project Identification, Project Feasibility and Market Study, Identification of Profitable Industrial Project Opportunities, Business Opportunities, Investment Opportunities for Most Profitable Business in India, Manufacturing Business Ideas, Preparation of Project Profile, Pre-Investment and Pre-Feasibility Study, Market Research Study, Preparation of Techno-Economic Feasibility Report, Identification and Section of Plant, Process, Equipment, General Guidance, Startup Help, Technical and Commercial Counseling for setting up new industrial project and Most Profitable Small Scale Business.

NPCS also publishes varies process technology, technical, reference, self employment and startup books, directory, business and industry database, bankable detailed project report, market research report on various industries, small scale industry and profit making business. Besides being used by manufacturers, industrialists and entrepreneurs, our publications are also used by professionals including project engineers, information services bureau, consultants and project consultancy firms as one of the input in their research.

Our Detailed Project report aims at providing all the critical data required by any entrepreneur vying to venture into Project. While expanding a current business or while venturing into new business, entrepreneurs are often faced with the dilemma of zeroing in on a suitable product/line.

 


And before diversifying/venturing into any product, wish to study the following aspects of the identified product:


• Good Present/Future Demand
• Export-Import Market Potential
• Raw Material & Manpower Availability
• Project Costs and Payback Period


We at NPCS, through our reliable expertise in the project consultancy and market research field, Provides exhaustive information about the project, which satisfies all the above mentioned requirements and has high growth potential in the markets. And through our report we aim to help you make sound and informed business decision.

 

The report contains all the data which will help an entrepreneur find answers to questions like:

• Why I should invest in this project?
• What will drive the growth of the product?
• What are the costs involved?
• What will be the market potential?


The report first focuses on enhancing the basic knowledge of the entrepreneur about the main product, by elucidating details like product definition, its uses and applications, industry segmentation as well as an overall overview of the industry sector in India. The report then helps an entrepreneur identify the target customer group of its product. It further helps in making sound investment decision by listing and then elaborating on factors that will contribute to the growth of product consumption in India and also talks about the foreign trade of the product along with the list of top importing and top exporting countries. Report includes graphical representation and forecasts of key data discussed in the above mentioned segment. It further explicates the growth potential of the product.

The report includes other market data like key players in the Industry segment along with their contact information and recent developments. It includes crucial information like raw material requirements, list of machinery and manufacturing process for the plant. Core project financials like plant capacity, costs involved in setting up of project, working capital requirements, projected revenue and profit are further listed in the report.


Reasons for buying the report:

• This report helps you to identify a profitable project for investing or diversifying into by throwing light to crucial areas like industry size, demand of the product and reasons for investing in the product.

• This report provides vital information on the product like its definition, characteristics and segmentation.

• This report helps you market and place the product correctly by identifying the target customer group of the product.

• This report helps you understand the viability of the project by disclosing details like raw materials required, manufacturing process, project costs and snapshot of other project financials.

• The report provides forecasts of key parameters which helps to anticipate the industry performance and make sound business decision.

 

Our Approach:


• Our research reports broadly cover Indian markets, present analysis, outlook and forecast.

• The market forecasts are developed on the basis of secondary research and are cross-validated through interactions with the industry players. 

• We use reliable sources of information and databases.  And information from such sources is processed by us and included in the report.

 

Our Market Survey cum Detailed Techno Economic Feasibility Report Contains following information:

 

 

Ø  Introduction

·         Project Introduction

·         Project Objective and Strategy

·         Concise History of the Product

·         Properties

·         BIS (Bureau of Indian Standards) Provision & Specification

·         Uses & Applications

 

Ø  Market Study and Assessment

·         Current Indian Market Scenario

·         Present Market Demand and Supply

·         Estimated Future Market Demand and Forecast

·         Statistics of Import & Export

·         Names & Addresses of Existing Units (Present Players)

·         Market Opportunity

 

Ø  Raw Material

·         List of Raw Materials

·         Properties of Raw Materials

·         Prescribed Quality of Raw Materials

·         List of Suppliers and Manufacturers

 

Ø  Personnel (Manpower) Requirements

·         Requirement of Staff & Labor (Skilled and Unskilled) Managerial, Technical, Office Staff and Marketing Personnel

 

Ø  Plant and Machinery

·         List of Plant & Machinery

·         Miscellaneous Items

·         Appliances & Equipments

·         Laboratory Equipments & Accessories

·         Electrification

·         Electric Load & Water

·         Maintenance Cost

·         Sources of Plant & Machinery (Suppliers and Manufacturers)

 

Ø  Manufacturing Process and Formulations

·         Detailed Process of Manufacture with Formulation

·         Packaging Required

·         Process Flow Sheet Diagram

 

Ø  Infrastructure and Utilities

·         Project Location

·         Requirement of Land Area

·         Rates of the Land

·         Built Up Area

·         Construction Schedule

·         Plant Layout and Requirement of Utilities

 

Project at a Glance

Along with financial details as under:

 

  •     Assumptions for Profitability workings

  •    Plant Economics

  •    Production Schedule

  •    Land & Building

            Factory Land & Building

            Site Development Expenses

  •    Plant & Machinery

             Indigenous Machineries

            Other Machineries (Miscellaneous, Laboratory etc.)

  •    Other Fixed Assets

            Furniture & Fixtures

            Pre-operative and Preliminary Expenses

            Technical Knowhow

            Provision of Contingencies

  •   Working Capital Requirement Per Month

             Raw Material

            Packing Material

            Lab & ETP Chemical Cost

           Consumable Store

  •   Overheads Required Per Month And Per Annum

         Utilities & Overheads (Power, Water and Fuel Expenses etc.)

             Royalty and Other Charges

            Selling and Distribution Expenses

  •    Salary and Wages

  •    Turnover Per Annum

  •   Share Capital

            Equity Capital

            Preference Share Capital

 

  •    Annexure 1:: Cost of Project and Means of Finance

  •    Annexure 2::  Profitability and Net Cash Accruals

                Revenue/Income/Realisation

                Expenses/Cost of Products/Services/Items

                Gross Profit

                Financial Charges     

                Total Cost of Sales

                Net Profit After Taxes

                Net Cash Accruals

  •   Annexure 3 :: Assessment of Working Capital requirements

                Current Assets

                Gross Working. Capital

                Current Liabilities

                Net Working Capital

                Working Note for Calculation of Work-in-process

  •    Annexure 4 :: Sources and Disposition of Funds

  •    Annexure 5 :: Projected Balance Sheets

                ROI (Average of Fixed Assets)

                RONW (Average of Share Capital)

                ROI (Average of Total Assets)

  •    Annexure 6 :: Profitability ratios

                D.S.C.R

                Earnings Per Share (EPS)

               

             Debt Equity Ratio

   •     Annexure 7   :: Break-Even Analysis

                Variable Cost & Expenses

                Semi-Var./Semi-Fixed Exp.

                Profit Volume Ratio (PVR)

                Fixed Expenses / Cost 

                B.E.P

  •   Annexure 8 to 11:: Sensitivity Analysis-Price/Volume

            Resultant N.P.B.T

            Resultant D.S.C.R

   Resultant PV Ratio

   Resultant DER

  Resultant ROI

          Resultant BEP

  •    Annexure 12 :: Shareholding Pattern and Stake Status

        Equity Capital

        Preference Share Capital

  •   Annexure 13 :: Quantitative Details-Output/Sales/Stocks

        Determined Capacity P.A of Products/Services

        Achievable Efficiency/Yield % of Products/Services/Items 

        Net Usable Load/Capacity of Products/Services/Items   

       Expected Sales/ Revenue/ Income of Products/ Services/ Items   

  •    Annexure 14 :: Product wise domestic Sales Realisation

  •    Annexure 15 :: Total Raw Material Cost

  •    Annexure 16 :: Raw Material Cost per unit

  •    Annexure 17 :: Total Lab & ETP Chemical Cost

  •    Annexure 18  :: Consumables, Store etc.,

  •    Annexure 19  :: Packing Material Cost

  •    Annexure 20  :: Packing Material Cost Per Unit

  •    Annexure 21 :: Employees Expenses

  •    Annexure 22 :: Fuel Expenses

  •    Annexure 23 :: Power/Electricity Expenses

  •    Annexure 24 :: Royalty & Other Charges

  •    Annexure 25 :: Repairs & Maintenance Exp.

  •    Annexure 26 :: Other Mfg. Expenses

  •    Annexure 27 :: Administration Expenses

  •    Annexure 28 :: Selling Expenses

  •    Annexure 29 :: Depreciation Charges – as per Books (Total)

  •   Annexure 30   :: Depreciation Charges – as per Books (P & M)

  •   Annexure 31   :: Depreciation Charges - As per IT Act WDV (Total)

  •   Annexure 32   :: Depreciation Charges - As per IT Act WDV (P & M)

  •   Annexure 33   :: Interest and Repayment - Term Loans

  •   Annexure 34   :: Tax on Profits

  •   Annexure 35   ::Projected Pay-Back Period And IRR