Magento – How to add another flat rate shipping option

Create a below custom module

create a Prashant_Flatrate2.xml file at app\etc\modules\Prashant_Flatrate2.xml

<?xml version="1.0"?>
    <config>
        <modules>
            <Prashant_Flatrate2>
                <active>true</active>
                <codePool>local</codePool>
            </Prashant_Flatrate2>
        </modules>
    </config>

Create a config.xml at app\code\local\Prashant\Flatrate2\etc\config.xml

<?xml version="1.0"?>

<config>

    <modules>
        <Prashant_Flatrate2>
            <version>0.0.1</version>
        </Prashant_Flatrate2>
    </modules>

    <global>
        <models>
            <flatrate2>
                <class>Prashant_Flatrate2_Model</class>
            </flatrate2>
        </models>

        <helpers>
            <flatrate2>
                <class>Prashant_Flatrate2_Helper</class>
            </flatrate2>
        </helpers>

    </global>

    <default>
      <carriers>
        <flatrate2>
            <active>1</active>
            <sallowspecific>0</sallowspecific>
            <model>flatrate2/carrier_flatrate2</model>
            <title>Flat Rate 2</title>
            <type>I</type>
            <specificerrmsg>This shipping method is currently unavailable. If you would like to ship using this shipping method, please contact us.</specificerrmsg>
            <handling_type>F</handling_type>
        </flatrate2>
       </carriers>
    </default>
</config>

create a system.xml file at app\code\local\Prashant\Flatrate2\etc\system.xml

<?xml version="1.0"?>
<config>
    <sections>
        <carriers>
            <groups>
                <flatrate2 translate="label" module="flatrate2">
                    <label>Flat Rate 2</label>
                    <frontend_type>text</frontend_type>
                    <sort_order>21</sort_order>
                    <show_in_default>1</show_in_default>
                    <show_in_website>1</show_in_website>
                    <show_in_store>1</show_in_store>
                    <fields>
                        <active translate="label">
                            <label>Enabled</label>
                            <frontend_type>select</frontend_type>
                            <source_model>adminhtml/system_config_source_yesno</source_model>
                            <sort_order>1</sort_order>
                            <show_in_default>1</show_in_default>
                            <show_in_website>1</show_in_website>
                            <show_in_store>0</show_in_store>
                        </active>
                        <name translate="label">
                            <label>Method Name</label>
                            <frontend_type>text</frontend_type>
                            <sort_order>3</sort_order>
                            <show_in_default>1</show_in_default>
                            <show_in_website>1</show_in_website>
                            <show_in_store>1</show_in_store>
                        </name>
                        <price translate="label">
                            <label>Price</label>
                            <frontend_type>text</frontend_type>
                            <validate>validate-number validate-zero-or-greater</validate>
                            <sort_order>5</sort_order>
                            <show_in_default>1</show_in_default>
                            <show_in_website>1</show_in_website>
                            <show_in_store>0</show_in_store>
                        </price>
                        <handling_type translate="label">
                            <label>Calculate Handling Fee</label>
                            <frontend_type>select</frontend_type>
                            <source_model>shipping/source_handlingType</source_model>
                            <sort_order>7</sort_order>
                            <show_in_default>1</show_in_default>
                            <show_in_website>1</show_in_website>
                            <show_in_store>0</show_in_store>
                        </handling_type>
                        <handling_fee translate="label">
                            <label>Handling Fee</label>
                            <frontend_type>text</frontend_type>
                            <validate>validate-number validate-zero-or-greater</validate>
                            <sort_order>8</sort_order>
                            <show_in_default>1</show_in_default>
                            <show_in_website>1</show_in_website>
                            <show_in_store>0</show_in_store>
                        </handling_fee>
                        <sort_order translate="label">
                            <label>Sort Order</label>
                            <frontend_type>text</frontend_type>
                            <sort_order>100</sort_order>
                            <show_in_default>1</show_in_default>
                            <show_in_website>1</show_in_website>
                            <show_in_store>0</show_in_store>
                        </sort_order>
                        <title translate="label">
                            <label>Title</label>
                            <frontend_type>text</frontend_type>
                            <sort_order>2</sort_order>
                            <show_in_default>1</show_in_default>
                            <show_in_website>1</show_in_website>
                            <show_in_store>1</show_in_store>
                        </title>
                        <type translate="label">
                            <label>Type</label>
                            <frontend_type>select</frontend_type>
                            <source_model>adminhtml/system_config_source_shipping_flatrate</source_model>
                            <sort_order>4</sort_order>
                            <show_in_default>1</show_in_default>
                            <show_in_website>1</show_in_website>
                            <show_in_store>0</show_in_store>
                        </type>
                        <sallowspecific translate="label">
                            <label>Ship to Applicable Countries</label>
                            <frontend_type>select</frontend_type>
                            <sort_order>90</sort_order>
                            <frontend_class>shipping-applicable-country</frontend_class>
                            <source_model>adminhtml/system_config_source_shipping_allspecificcountries</source_model>
                            <show_in_default>1</show_in_default>
                            <show_in_website>1</show_in_website>
                            <show_in_store>0</show_in_store>
                        </sallowspecific>
                        <specificcountry translate="label">
                            <label>Ship to Specific Countries</label>
                            <frontend_type>multiselect</frontend_type>
                            <sort_order>91</sort_order>
                            <source_model>adminhtml/system_config_source_country</source_model>
                            <show_in_default>1</show_in_default>
                            <show_in_website>1</show_in_website>
                            <show_in_store>0</show_in_store>
                            <can_be_empty>1</can_be_empty>
                        </specificcountry>
                        <showmethod translate="label">
                            <label>Show Method if Not Applicable</label>
                            <frontend_type>select</frontend_type>
                            <sort_order>92</sort_order>
                            <source_model>adminhtml/system_config_source_yesno</source_model>
                            <show_in_default>1</show_in_default>
                            <show_in_website>1</show_in_website>
                            <show_in_store>0</show_in_store>
                        </showmethod>
                        <specificerrmsg translate="label">
                            <label>Displayed Error Message</label>
                            <frontend_type>textarea</frontend_type>
                            <sort_order>80</sort_order>
                            <show_in_default>1</show_in_default>
                            <show_in_website>1</show_in_website>
                            <show_in_store>1</show_in_store>
                        </specificerrmsg>
                    </fields>
                </flatrate2>
            </groups>
        </carriers>
    </sections>
</config>

create Flatrate2.php at app\code\local\Prashant\Flatrate2\Model\Carrier\Flatrate2

    <?php

class Prashant_Flatrate2_Model_Carrier_Flatrate2
    extends Mage_Shipping_Model_Carrier_Flatrate
    implements Mage_Shipping_Model_Carrier_Interface
{

    protected $_code = 'flatrate2';

          /**
     * Enter description here...
     *
     * @param Mage_Shipping_Model_Rate_Request $data
     * @return Mage_Shipping_Model_Rate_Result
     */
    public function collectRates(Mage_Shipping_Model_Rate_Request $request)
    {
        if (!$this->getConfigFlag('active')) {
            return false;
        }

        $freeBoxes = 0;
        if ($request->getAllItems()) {
            foreach ($request->getAllItems() as $item) {

                if ($item->getProduct()->isVirtual() || $item->getParentItem()) {
                    continue;
                }

                if ($item->getHasChildren() && $item->isShipSeparately()) {
                    foreach ($item->getChildren() as $child) {
                        if ($child->getFreeShipping() && !$child->getProduct()->isVirtual()) {
                            $freeBoxes += $item->getQty() * $child->getQty();
                        }
                    }
                } elseif ($item->getFreeShipping()) {
                    $freeBoxes += $item->getQty();
                }
            }
        }
        $this->setFreeBoxes($freeBoxes);

        $result = Mage::getModel('shipping/rate_result');
        if ($this->getConfigData('type') == 'O') { // per order
            $shippingPrice = $this->getConfigData('price');
        } elseif ($this->getConfigData('type') == 'I') { // per item
            $shippingPrice = ($request->getPackageQty() * $this->getConfigData('price')) - ($this->getFreeBoxes() * $this->getConfigData('price'));
        } else {
            $shippingPrice = false;
        }

        $shippingPrice = $this->getFinalPriceWithHandlingFee($shippingPrice);

        if ($shippingPrice !== false) {
            $method = Mage::getModel('shipping/rate_result_method');

            $method->setCarrier('flatrate2');
            $method->setCarrierTitle($this->getConfigData('title'));

            $method->setMethod('flatrate2');
            $method->setMethodTitle($this->getConfigData('name'));

            if ($request->getFreeShipping() === true || $request->getPackageQty() == $this->getFreeBoxes()) {
                $shippingPrice = '0.00';
            }


            $method->setPrice($shippingPrice);
            $method->setCost($shippingPrice);

            $result->append($method);
        }

        return $result;
    }

    public function getAllowedMethods()
    {
        return array('flatrate2' => 'Flatrate 2');
    }

}

create a Data.php file at app\code\local\Prashant\Flatrate2\Helper\Data.php

<?php

class Prashant_Flatrate2_Helper_Data extends Mage_Core_Helper_Abstract
{
}

Login to Admin > System > Configuration > Sales > Shipping Method you will find Flaterate2 as below

Frontend: