150 Thousand Tons of

Technoconsult Group for Engineering Works
Projects Management Department
Project Feasibility Study
For
Rebar rolling mill
Capacity 150000 Tons/year
Property of Technoconsult Group , not to be copied or disclosed prior to written approval

Introduction:
The project is intended to produce hot rolled steel rebars ( both plain and
ribbed ) according to the Egyptian standard specifications . Estimated
production capacity is 150000 Tons/year (Tpy).
Project main data :
- Production capacity
:
150000
Tpy
- Raw material
:
Billets of square cross-section
100 x 100 mm up to 130x130 mm and length up to 3000 mm
- Production variety
:
Rebar of 10mm to 25 mm in
diameter
- Needed electrical power
:
6
MW
- Needed Water
:
500
m3 / day
- Total Capital Needed
:
55089
MLE
- Capital Expenditure
:
36950
MLE
- Working Capital (One month) :
18094
MLE
- Project duration
:
12
months
- Land Area needed
:
26646
square meters
- No. of administration crew
:
employees
- No. of technicians
:
employees

TABLE OF CONTENTS
Section 1 : Technical Study
1.1. Project Introduction
1.2. Project Raw materials , utility and production supplies needs
1.3. Capital Expenditure details
1.4. Manufacturing expenses details
1.5. Overall capital needed for the project
Section 2 : Financial Study

1.1.
Project Introduction :
1.1.1. Production Capacity :

The estimated production volume of the plant is 150000 Tpy of steel
rebars (both plain and ribbed ) according to Egyptian standard
specifications , rolled from billets ranging from 100x100 mm to
130x130 mm . The capacity calculation assumptions are :
- Mean mill production capacity
:
30
Tons/hr
- Net working days
:
300 days
- No. of shifts
:
3
shifts/day
- No. of net working hours
:
7200 hours
- Average process reliability
:
75
%
- Actual production hours
:
5000 hours
- Annual production
:
150 Tpy
- Product type
:
Ribbed rebar
- Product size variety
:
10 25 mm
- Product Length
:
12
m
The following table indicates the actual capacity of the line for the
different sizes :
Product Size
(mm)
10
12
16
19
22 and up
Weight of
linear meter
(LM)
0.616
0.888
1.875
2.225
2.984
Rolling speed
(m/s)
12
8.6
5
3.8
3.1
Production
rate
(Tons/hour)
26.6
27.5
28.2
30.4
33.3
The table above indicates that the production line can deliver more than 30
Tons/hour at certain sizes .

1.1.2. Land and Utility needs :

1.1.2.1 Area of land and buildings :
Total Area
1.1.2.2. Utilities and services :
i.
Electrical power :
- Connected power
- Voltage
ii.
Industrial water :
- Utilization rate
iii. Domestic sewage :
Utilization rate
iv.
No of telephone lines
37440
m2
:
:
6
11(20)
MW
KV
120
m3/day
:
:
120
3
m3/day
lines
1.1.3 Main production equipment :

i.
ii.
Reheating furnace :
- Capacity
:
30
Tons/hour
- Type
:
Hydraulic pusher type
- Fuel
:
Diesel / natural gas
- Firing method
:
Air atomization (for
diesel)
- Size of used billets
:
100x100 130x130 mm
up to 4 m long
Roughing mill area :
Electrical motor ( either slip-ring or DC ) .
Flywheel complete with bearings and flexible
couplings
Speed reducer (gear box )
Pinion cage
Cardanic spindles between gear box and pinion cage
No. (1) three high roughing stand complete with entry
and delivery guides
Forced lubrication unit

-
iii.
No. (1) fixed roller table complete with rollers and

accessories
No. (1) tilting roller table complete with rollers and
accessories
Intermediate mill area :
No. (4) rolling stands complete with entry and
delivery guides
Gear box
Pinion cage
Cardanic spindles between pinion cage and stand
On stand instrumentation
Stands are driven via DC motors
iv.
Finishing mill area :

No. (6) finishing stands (roller bearings type)
complete with entry and delivery guides
Gear box unit reducing speed and acting as pinion
cage
On stand instrumentation
Cardanic spindles
Stands are driven via DC motors
v.
Pinch roll :
To transfer the finished product from the rolling mill
to the cooling bed .
Flying shear :
To cut-to-length the rebar at 24 m to allow for entry to
cooling bed
Cooling bed :
Rebar receiving system and delivery to cooling bed
Mechanical cooling bed 30 m long
Accumulating roller table to enter the cold shear
Cold shear :
To cut the rebar to either 6 or 12 m lengths
Bundling and tying equipment .
vi.
vii.
viii
ix

1.1.4. Utility equipment :

1.1.4.1.
1.1.4.2.
1.1.4.3.
1.1.4.4.
1.1.4.5.
Industrial water treatment plant :

Pumping station
Filters
Piping and fittings
Total capacity of 300 m3/hour
Make-up rate for water 5 m3/hour
Compressed air station :
No. (2) air compressors 1500 l/min at 6 bar
Piping and fittings and filters
Drying unit
Receiving tank 4 cubic meters
Fuel pumping station :
No. (2) gear pumps
Control and metering equipment
100 cubic meter fuel tank
Daily tank
Pipes and fittings
Over-head cranes :
Rolling mill cranes :
- capacity
:
10
Tons
- Span
:
20
m
- Hook travel
:
8/10 m
- Number of cranes
:
2
Shipping bay cranes :
- Magnet capacity
:
5
Tons
- Span
:
20
m
- Hook travel
:
8/10 m
- No. of cranes
:
2 (equipped with
magnets)
Maintenance work-shop:
Rolls grooving lathe
Notching machine
Conventional lathe 2 m
Spark erosion trade mark machine
Milling machine

-
Shaping machine
Drill
Reciprocating saw
Hand tools
Work-shop tables
Electric arc welding machines
1.1.4.6
Testing laboratory :
Tensile testing machine
Hardness tester
Scale
Measuring tools
1.1.4.7
Weighing bridge :
Capacity 100 Tons
1.1.4.8.
Fire fighting system :

Hand-held fire extinguishers (Carbon dioxide and
powder filled)
Transformers room fire fighting equipment
Fire fighting loop and pumps
1.1.5.
1.1.6.
Transportation and handling equipment :

No. (1) 1.5 Tons capacity truck
No. (2) cars
No. (1) fork truck
Transformers station :
Transformers :
- No. of transformers
:
- Capacity of Transformers
:
- Inlet Voltage
:
- Exit Voltage
:
Medium voltage panels 11(20) KV
Low voltage panels
Operation and PLC panels
2
1.5 MW
11(20)KV
400/500 V

1.1.7.
1.1.7.1.
Civil Works :
Land leveling works :
Will be determined after selecting the site
1.1.7.2Fencing and internal roads :
Fencing :
Total length
Height
Type of fencing
brick walls
Security Buildings
Internal Roads :
Area
Type of roads
roads
1.1.7.3.
1.1.7.4.
:
788 m
:
3
m
: Concrete frame +
:
6800 m2
: Asphalt paved
Rolling mill bay :

- Length of bay
- Width of bay
- Area of bay
- Type of building
- Approx. weight of structure
- Corrugated sheet area
:
180 m
:
20
m
:
3600 m2
: Steel Structure
:
400 Ton
:
6600 m2
Furnace bay :
- Length of bay
- Width of bay
- Area of bay
- Type of building
- Approx. weight of structure
- Corrugated sheet area
:
330 m
:
20
m
:
6600 m2
: Steel Structure
:
350 Ton
:
8400 m2

1.1.7.5.
Raw material and finished product ware-houses:

- Total area
:
17600m2
- Type of building
: Open yards
- Floors
: Compressed soil
1.1.7.6.
Foundations + machine foundations and floors :

- Excavation
:
9600 m3
- Back-filling
:
2000 m3
Reinforced concrete :
- Steel structure foundations
:
800 m3
- Machine foundations
:
1560 m3
- Trenches for cables and pipes :
- Total reinforced concrete
:
-
Plain concrete for a/m works

Floors (25 cm thick) Area
:
:
360 m3
3120 m3
1300 m3
9600 m2
Note : These amounts are approximate and will be revised after

selecting the land and gathering proper data regarding the
typology of the land .
1.1.7.7.
Other Buildings :
Administration Building and dressing rooms :
- No. of floors
:
3
- Area of each floor
:
160
- Total Area
:
480
Transformers station :
- Needed area
:
720
Work-shops and store rooms :
- Needed Area
:
1640
m2
m2
m2
m2

1.1.8. Installation works :

1.1.8.1
Mechanical installation :
Installation supplies ( anchors , grouting material ,
bolts and hand-tools )
Machine laying and anchoring works
Piping works for fuel , compressed air and water
including fittings
Trained labor
Cranes and handling equipment
1.1.8.2. Electrical installation :
Installation supplies including cables ,wiring , cable
trays and connections and fittings etc.
Trained labor
1.1.9. Pre-operational expenses :
Hiring reputable specialized technical firms as
consultants
Issuing needed approvals and licenses from
governmental authorities
Construction follow-up
Hiring the needed management and technical staff
Contracts finalization for equipment
Miscellaneous managerial and technical tasks
Travel and training for technology transfer
1.1.10. Furniture and office equipment :
Office furniture
Computers
Telephones and Fax
Dressing room lockers
First aid equipment

1.1.11. Technical support :
Design and planning for the project
Local manufacturing supervision
Construction supervision and commissioning
1.1.12.
Working force (Management and technical teams ) :

Area
Production Department :
Production manager
Production engineers
Crane operators
Furnace operators
Rolling mill operators
Pulpit operators
Cooling bed crew
Tying machines operators
Finished product area
Department total :
Mechanical Maintenance :
Maintenance Manager
Maintenance engineers
Maintenance technician
Work-shop crew
Cranes maintenance crew
WTP maintenance crew
WTO operators
Department Total :
Electrical Maintenance :
Maintenance Manager
Maintenance engineers
Work-shop crew
Motors maintenance technician
Electrical technician
Department Total :
Needed No.
1
4
9
6
15
6
12
6
6
65
1
3
12
2
1
3
3
25
1
4
1
1
12
17

Ware-houses :
Ware-house manager
Ware-house attendant
Weigh bridge operators
Department Total :
Quality Assurance :
Quality Manager
Lab operator
Line quality operator
Department Total :
Technical Office :
Manager
Supervisor
Department Total :
Work-shop :
Engineer
Lathe operator
Notching machine operator
Facing machine operator
Milling machine operator
Helper
Department Total :
Cylinder work-shop:
Supervisor
Technicians
Department Total :
Guides Work-shop :
Engineer
Technicians
Department Total :
Cleaning crew :
Cleaner
Tea boy
Gardner
Department Total :
1
6
3
10
1
6
7
1
1
2
1
6
2
1
3
1
14
1
6
7
1
5
6
6
2
2
10

Security :
Supervisor
Security crew
Department Total :
Administrative manager
Accountants
Personnel
Plant Total :
1
12
13
1
2
2
180

Project Raw materials , utility and production supplies needs :
1.2.1. Billets :
- Needed volume
:
150000
Tons
- Manufacturing losses
:
5-6
%
- Total billets needed
:
158000
Tons
Note : The losses of 5-6% consist of oxides inside the re-heating furnace +
the head and tail cropping and these are divided as follows :
2% oxidation rate inside furnace
3% head and tail cropping and defined in-process
losses
1.2.2. Electrical Power :
- Connected power
- Needed Voltage
- Needed power for rolling / Ton
- Average yearly power consumption
:
:
:
:
6
11(20)
120
18
MW
KV
KWh/Ton
MMKWh
1.2.3. Industrial water :

- Water consumption rate
- Yearly consumption
:
:
5
40000
m3 / hour
m3 / hour
4800
Tons/ year
:
:
145
20
barrels/year
barrels/year
1.2.4. Fuel :
- Diesel oil
or equivalent in natural gas
1.2.5. Lubricants :
- Oils
- Greases
1.2.6. Production supplies :

Rolling cylinders
Rolling guides for all stands
Complete spare rolling stands ( including cylinders , bearings and
guides )
Transmission belts , hoses , oil and water seals
Maintenance supplies for compressed air system and control valves
Work-shop supplies

-
Pipes , valves and fittings

Chains and power chains and accessories
Contract manufacturing
Miscellaneous
1.2.7. Spare parts :

Mechanical spare parts for rolling equipment ( gears , flexible
joints, cardanic spindles ..etc .)
Electric and automation spare parts
Spare electric motors
Bearings for gear boxes , stands , pinion cages , guides and utility
equipment
Cranes and handling equipment spare parts
Spare refractory materials for the furnace
Miscellaneous

1.3.
Capital Expenditure details :

1.3.1. Land :
- Area
- Price
Total land price
:
:
:
26646
281.49
7500
m2
LE/ m2
MLE
1.3.2. Utilities :
1.3.2.1. Electricity :
- Connected Power
MW
1.3.2.2. Industrial water :

- Consumption
120
m3 / day
1.3.2.3. Domestic sewage :

- Discharge rate
300
m3 / day
1.3.2.4. Telephones :
- No. of lines
lines
Total Utilities
3250
MLE
1.3.3. Main production equipment :

Re-heating furnace and accessories
Rougher unit and accessories
Intermediate rolling mill and accessories
Finishing rolling mill and accessories
Different shears
Maintenance work-shop
Water treatment plant
Fuel station
Cooling bed and accessories
Transformers , E-panels and control panels
Transportation , customs clearance and sales tax .
Total Equipment
:
12864
MLE

1.3.4. Transportation and handling equipment :

Truck
Fork-truck
Two passenger cars + ambulance truck
Total Transportation
180
MLE
13200
750
16800
m2
Ton
m2
1.3.5.2.
Land leveling works :
- Area
:
60000
m2
1.3.5.3.
Fencing and internal roads :
- Length of fencing
:
- Area of fencing
:
960
4100
m
m2
1.3.5.4.
Foundations and floors :
- Re-inforced concrete :
- Plain concrete
:
- Floors
:
6700
1440
9600
m3
m3
m3
1.3.5.5.
Billets and re-bars ware-houses :
- Area
:
5600
m2
1.3.5.6.
Other Buildings :
- Total Area
:
m2
1.3.5. Civil works :

1.3.5.1.
Steel Structures :
- Area
:
- Weight
:
- Corrugated sheets
:
Total Civil Works
2110
:
7350
MLE
1.3.6. Construction Works :

- Electro-mechanical installation :
3500
MLE

1.3.7. Pre-operational Expenses :
- Total Pre-Ops expenses
26
MLE
1.3.8. Furniture and office equipment :

- Total
:
30
MLE

1.4. Manufacturing expenses details :
The total manufacturing expenses per Ton of finished re-bar ready for
shipping is 1383.25 LE on average and following are the details :
1.4.1. Direct Expenses :
The direct expenses are 1371.37 LE on average , consisting of the
following :
- Raw materials :
- Weight of billet to produce one Ton :
1.05 Tons
- Billet cost/Ton
:
1225 LE
- Total expense
:
1286 LE/Ton
Electrical Power :
- Power needed to roll one Ton
:
118 KWh
- Price of KWh
:
0.20 LE
- Total expense
:
23.50 LE
Fuel :
- Fuel needed / Ton
:
17
Kg
- Total expense
:
6.80 LE
Industrial Water:
- Consumption / Ton
:
0.50 m3 /Ton
- Price of cubic meter
:
1.00 LE
- Total Expense
:
0.50 LE
Lubricants :
- Consumption / Ton
:
0.10 Kg
- Average cost of Kg
:
5
LE
- Total Expense
:
0.50 LE
Spare parts and production supplies :
- Cylinders and guides
:
12
LE
- Spare parts
:
8
LE
- Tools and work-shop equipment
:
3
LE
- Contract manufacturing
:
4
LE
- Miscellaneous
:
5
LE
- Total Expense
:
32
LE
Wages and Benefits :
- Total wages / year
:
1608 MLE
- Total Expense
:
7.12 LE

- Depreciation :
- Depreciation / Ton
- TOTAL DIRECT EXPENSES /TON
:
:
14.70 LE
1371.37 LE
1.4.2. In-Direct Expenses :

The in-direct expenses /Ton are 11.88 LE and following are the
details:
- Salaries :
- Total yearly salaries
:
750 MLE
- Total Expense / Ton
:
5
LE
Administrative and general expenses :
Payments for financial controllers
Legal fees
Bank charges
Advertisement and campaigns
Mail and telephones
Office supplies
Travel expenses and accommodation
Treatment and medication
Total yearly Expenses
:
580 MLE
Expense per Ton
:
3.85 LE
In-Direct Depreciation :
- Consultancy (20%)
:
5.20 MLE
- Technical support (20%)
:
300 MLE
- Deferred .. (20%) :
150 MLE
Total In-Direct Expenses per Ton
:
11.88 LE
Summary of Expense / Ton:
Direct Expenses
LE
In-Direct Expenses
:
Total Manufacturing Expenses per Ton
LE
1371.37
11.88
LE
:
1383.25

150 Thousand Tons of

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150 Thousand Tons of

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Technoconsult Group for Engineering Works

Projects Management Department

Project Feasibility Study

Property of Technoconsult Group , not to be copied or disclosed prior to written approval

Technoconsult Group for Engineering Works

Property of Technoconsult Group , not to be copied or disclosed prior to written approval

Technoconsult Group for Engineering Works

Property of Technoconsult Group , not to be copied or disclosed prior to written approval

Technoconsult Group for Engineering Works

1.1.1. Production Capacity :

Property of Technoconsult Group , not to be copied or disclosed prior to written approval

Technoconsult Group for Engineering Works

1.1.2. Land and Utility needs :

1.1.3 Main production equipment :

Property of Technoconsult Group , not to be copied or disclosed prior to written approval

Technoconsult Group for Engineering Works

No. (1) fixed roller table complete with rollers and

Finishing mill area :

Property of Technoconsult Group , not to be copied or disclosed prior to written approval

Technoconsult Group for Engineering Works

1.1.4. Utility equipment :

Industrial water treatment plant :

Property of Technoconsult Group , not to be copied or disclosed prior to written approval

Technoconsult Group for Engineering Works

Fire fighting system :

Transportation and handling equipment :

Property of Technoconsult Group , not to be copied or disclosed prior to written approval

Technoconsult Group for Engineering Works

Rolling mill bay :

Property of Technoconsult Group , not to be copied or disclosed prior to written approval

Technoconsult Group for Engineering Works

Raw material and finished product ware-houses:

Foundations + machine foundations and floors :

Plain concrete for a/m works

Note : These amounts are approximate and will be revised after

Property of Technoconsult Group , not to be copied or disclosed prior to written approval

Technoconsult Group for Engineering Works

1.1.8. Installation works :

Property of Technoconsult Group , not to be copied or disclosed prior to written approval

Technoconsult Group for Engineering Works

Working force (Management and technical teams ) :

Property of Technoconsult Group , not to be copied or disclosed prior to written approval

Technoconsult Group for Engineering Works

Property of Technoconsult Group , not to be copied or disclosed prior to written approval

Technoconsult Group for Engineering Works

Property of Technoconsult Group , not to be copied or disclosed prior to written approval

Technoconsult Group for Engineering Works

1.2.3. Industrial water :

1.2.6. Production supplies :

Technoconsult Group for Engineering Works

Pipes , valves and fittings

1.2.7. Spare parts :

Property of Technoconsult Group , not to be copied or disclosed prior to written approval

Technoconsult Group for Engineering Works

Capital Expenditure details :

1.3.2.2. Industrial water :

1.3.2.3. Domestic sewage :

1.3.3. Main production equipment :

Property of Technoconsult Group , not to be copied or disclosed prior to written approval

Technoconsult Group for Engineering Works

1.3.4. Transportation and handling equipment :

1.3.5. Civil works :

Total Civil Works