Industry Overview
Aluminium alloy ingots are large cast products generally produced with rectangular or square cross-sections, which may vary along their length. Aluminium alloy ingots are manufactured in grades such as LM-2, LM-4 and LM-6 for applications including gravity and sand casting, while pressure die casting alloys include LM-13, LM-14, LM-24, ADC-12 and ALSI-132. These alloys are produced according to applicable Indian and international standards.
The reported technical specification for the aluminium alloy ingot includes a weight range of 8–110 kg, a height of 70 mm, a width of 110 mm and a length of 600 mm. The manufacturing study covers production from aluminium dross and aluminium scrap, including scrap pretreatment, comminution, cleaning, sorting, decoating, charging, fluxing, melting, alloying, degassing, casting and quality control. It also addresses emissions and their control, shipment, market conditions, global and Indian aluminium industries, demand and supply, applications, competitive factors, pricing, trade data and industry outlook.
Cost Estimation
| Particulars | Details |
|---|---|
| Plant Capacity | 6 MT/Day |
| Land & Building | Rs. 6.34 Cr |
| Plant & Machinery | Rs. 2.93 Cr |
| Working Capital for 2 Months | Rs. 3.39 Cr |
| Total Capital Investment | Rs. 13.11 Cr |
| Rate of Return | 21% |
| Break Even Point | 63% |
Content Index
- INTRODUCTION
- GRADES OF AL INGOT
- TECHNICAL SPECIFICATION OF ALUMINIUM ALLOY INGOT
- ALUMINIUM ALLOY INGOT CHEMICAL COMPOSITION
- USES AND APPLICATION
- FIELDS OF APPLICATION:
- B.I.S. SPECIFICATION
- PROCESS FLOW CHART
- (A) FOR ALUMINIUM INGOT FROM ALUMINIUM DROSS
- (B) FORALUMINIUM INGOT FROM SCRAP
- MANUFACTURING PROCESS
- (A) ALUMINIUM INGOT FROM ALUMINIUM DROSS
- (B) ALUMINIUM INGOT FROM ALUMINIUM SCRAP
- (1) SCRAP PRETREATMENT –
- METHODS OF PRETREATMENT
- (A) COMMINUTION
- (B) CLEANING
- METHODS OF CLEANING
- (I) MECHANICAL CLEANING –
- (II) PYROMETALLURGICAL CLEANING -
- (III) HYDROMETALLURGICAL CLEANING -
- (C) SORTING
- METHODS OF SORTING
- (I) MAGNETIC SEPARATION
- (II) AIR SEPARATOR
- (III) EDDY CURRENT
- (IV) DENSE MEDIA SEPARATOR
- (V) HAND SORTING
- (VI) HOT CRUSH
- (VII) INNOVATIVE SORTING SOLUTIONS
- (D) DECOATING
- (2) CHARGING AND FLUXING
- CLASSIFICATION OF FLUXES FOR MELTING ALUMINUM
- (A) COVER FLUXES
- (B) DROSSING FLUXES
- (C) CLEANING FLUXES
- (D) WALL CLEANING FLUXES
- (E) DEGASSING FLUXES
- (F) GRAIN REFINERS
- (G) SILICON MODIFIERS
- (H) DEMAGGING FLUXES
- (3) MELTING PROCESS
- TEMPERATURE CONTROL
- SKIMMING
- ALLOYING
- (4) DEGASSING (MELT TREATMENT)
- (5) INGOT CASTING
- (6) QUALITY CONTROL
- (5) EMISSIONS AND CONTROLS
- (A) SCRAP PRETREATMENT EMISSIONS
- (B) SMELTING/REFINING EMISSIONS
- (6) SHIPMENT
- MARKET OVERVIEW
- THE OBJECTIVE OF THE RESEARCH IS
- GLOBAL ALUMINIUM INDUSTRY
- GLOBAL PRODUCTION
- ALUMINIUM PRODUCING COUNTRIES
- GLOBAL CONSUMPTION
- THE FOLLOWING ARE THE VARIOUS APPLICATIONS AREAS OF ALUMINIUM
- TOP GLOBAL COMPANIES IN PRIMARY ALUMINIUM
- INDIAN ALUMINIUM INDUSTRY
- HISTORY
- FEATURES OF INDIAN ALUMINIUM INDUSTRY
- PRIMARY ALUMINIUM PRODUCTION
- CONSUMPTION
- ANALYSIS OF INDIAN PRIMARY ALUMINIUM MARKET
- TYPE OF MARKET
- PROFILE OF KEY PLAYERS
- NATIONAL ALUMINIUM COMPANY (NALCO)
- HINDUSTAN ALUMINIUM COMPANY (HINDALCO)
- STERLITE INDUSTRIES LTD (VEDANTA)
- REASONS FOR INDIAN ALUMINIUM INDUSTRY BEING AN OLIGOPOLY (BARRIERS TO ENTRY)
- ECONOMIES OF SCALE
- HUGE CAPITAL INVESTMENTS
- TIME TO SETUP
- CONTROL OVER THE BAUXITE MINES
- SCARCITY OF POWER
- GOVERNMENT FACTOR
- LAND
- GEOGRAPHICAL FACTORS
- PORTERS COMPETITIVE FRAMEWORK
- 1. THREAT FROM SUBSTITUTE PRODUCT.
- 2. THREAT OF ENTRY.
- 3. BARGAINING POWER OF BUYERS.
- 4. BARGAINING POWER OF SUPPLIERS.
- 5. INTENSITY OF RIVALRY AMONG EXISTING COMPETITORS.
- PRICING OF PRIMARY ALUMINIUM
- EXPORT DATA OF ALUMINIUM INGOTS
- IMPORT DATA OF ALUMINIUM INGOTS
- FUTURE OF ALUMINIUM INDUSTRY IN INDIA
- ALUMINIUM PRODUCING COUNTRIES
- GLOBAL CONSUMPTION
- THE FOLLOWING ARE THE VARIOUS APPLICATIONS AREAS OF ALUMINIUM.
- TOP GLOBAL COMPANIES IN PRIMARY ALUMINIUM
- INDIAN ALUMINIUM INDUSTRY
- CHARACTERISTICS AND FEATURES OF INDIAN ALUMINIUM INDUSTRY
- INDIA’S POSITION IN WORLD RANKING
- PRIMARY ALUMINIUM PRODUCTION
- CONSUMPTION
- TRANSPORTATION SECTOR
- BUILDING AND CONSTRUCTION SECTOR
- PACKAGING SECTOR
- ENGINEERING EQUIPMENT, ELECTRONICS AND CABLES & OTHER SECTORS
- FORECASTING
- TABLE 2: FORECASTING TABLE
- CONCLUSION
- INDIAN ALUMINIUM OVERVIEW
- ALUMINIUM INDUSTRY IN INDIA
- DOMESTIC DEMAND
- DOMESTIC SUPPLY
- INDUSTRIES DEMAND
- IMPOSITION OF EXPORT DUTY ON ALUMINA
- REDUCING IMPORT DUTY ON ALUMINIUM FLUORIDE
- INCREASING OF EXPORT DUTY ON BAUXITE
- INCREASE IN BASIC CUSTOMS DUTY ON ALUMINIUM PRODUCTS FROM 5% TO 10%
- CUSTOMS DUTY ON ALUMINIUM SCRAP AT PAR WITH THE DUTY ON THE METAL PRODUCTS
- INCLUSION OF ALUMINIUM INGOTS UNDER INTEREST SUBVENTION SCHEME
- OUR ASSESSMENT
- GLOBAL ALUMINIUM PRICES TO PLUNGE FURTHER IN 2016
- LOW REALISATION WILL STRESS FINANCIALS
- GROWTH IN EXPORTS WILL ALSO MODERATE
- INDUSTRIES DEMAND & KEY BUDGET PROPOSALS – UNION BUDGET 2016-17
- ESTIMATED IMPACT
- DATA TABLES
- A. DEMAND SUPPLY - INDIA
- B. DEMAND SUPPLY – GLOBAL
- SUPPLIERS OF ALUMINIUM ALLOY INGOT
- SUPPLIERS OF RAW MATERIALS
- SUPPLIERS OF ALUMINIUM DROSS
- SUPPLIERS OF ALUMINIUM SCRAP
- SUPPLIERS OF SILICON POWDER
- SUPPLIERS OF IRON POWDER
- SUPPLIERS OF COPPER POWDER
- SUPPLIERS OF MAGNESIUM POWDER
- SUPPLIERS OF NICKEL POWDER
- SUPPLIERS OF ZINC POWDER
- SUPPLIERS OF LEAD POWDER
- SUPPLIERS OF TIN POWDER
- SUPPLIERS OF PACKING MATERIAL
- SUPPLIERS OF PICKLING CHEMICALS
- SUPPLIERS OF PLANT AND MACHINERY
- SUPPLIERS OF CRUCIBLE FURNACE
- SUPPLIERS OF INGOT CASTING MACHINE
- SUPPLIERS OF SILICON CARBIDE CRUCIBLE
- SUPPLIERS OF ALUMINIUM RECYCLING PLANT
- SUPPLIERS OF SHEREDDER
- SUPPLIERS OF DE-COATER
- SUPPLIERS OF MAGENETIC SEPARATOR
- SUPPLIERS OF CASTING LADDLE
- SUPPLIERS OF SPECROMETER
- SUPPLIERS OF POROSITY TESTING MACHINE
- SUPPLIERS OF EOT CRANE
- SUPPLIERS OF DG SETS
- SUPPLIERS OF COOLING TOWER
- SUPPLIERS OF EFFULENT TREATMENT PLANT (ETP PLANT)
- SUPPLIERS OF AIR POLLUTION CONTROL EQUIPMENTS
- SUPPLIERS OF AIR CONDITIONING EQUIPMENTS
- SUPPLIERS OF AIR COMPRESSORS
- SUPPLIERS OF PLATFORM WEIGHING MACHINE
- SUPPLIERS OF MATERIAL HANDLING EQUIPMENTS
- SUPPLIERS OF NDT INSPECTION EQUIPMENT
- SUPPLIERS OF FIRE FIGHTING EQUIPMENTS
- SUPPLIERS OF ELECTRICAL MEASURING INSTRUMENTS
- SUPPLIERS OF SUBMERSIBLE WATER PUMP
Appendix
- APPENDIX – A:
- 01. PLANT ECONOMICS
- 02. LAND & BUILDING
- 03. PLANT AND MACHINERY
- 04. OTHER FIXED ASSESTS
- 05. FIXED CAPITAL
- 06. RAW MATERIAL
- 07. SALARY AND WAGES
- 08. UTILITIES AND OVERHEADS
- 09. TOTAL WORKING CAPITAL
- 10. TOTAL CAPITAL INVESTMENT
- 11. COST OF PRODUCTION
- 12. TURN OVER/ANNUM
- 13. BREAK EVEN POINT
- 14. RESOURCES FOR FINANCE
- 15. INSTALMENT PAYABLE IN 5 YEARS
- 16. DEPRECIATION CHART FOR 5 YEARS
- 17. PROFIT ANALYSIS FOR 5 YEARS
- 18. PROJECTED BALANCE SHEET FOR (5 YEARS)
Frequently Asked Questions
Aluminium alloy ingots are cast aluminium products made in specified alloy compositions and shapes for subsequent casting and manufacturing applications. The report describes ingots used in gravity casting, sand casting and pressure die casting. Grades such as LM-2, LM-4, LM-6, LM-13, LM-14, LM-24, ADC-12 and ALSI-132 are identified in the study. Their properties and chemical compositions depend on the alloy grade and applicable standards, making controlled melting, alloying and quality inspection important parts of the manufacturing process.
Aluminium dross and aluminium scrap are identified as the principal feed materials covered by the report. Depending on the required alloy composition, additional alloying materials may also be introduced during melting. The report specifically discusses suppliers of silicon, iron, copper, magnesium, nickel, zinc, lead and tin powders. Scrap preparation can include comminution, cleaning, sorting and decoating before charging into the melting system, helping prepare the feedstock for controlled processing and alloy production.
The main manufacturing steps include scrap pretreatment, charging and fluxing, melting, alloying, degassing, ingot casting and quality control. Pretreatment may involve comminution, cleaning, sorting and decoating. During melting, temperature control, skimming and alloy adjustment are important process operations. Melt treatment can include degassing before the molten aluminium is transferred for casting. Finished ingots are then inspected to verify conformity with the required specifications and alloy characteristics before shipment.
Scrap sorting is important because different materials and alloy compositions can affect the quality and chemistry of the final aluminium product. The report identifies magnetic separation, air separators, eddy current separation, dense media separation, hand sorting, hot crushing and innovative sorting solutions among the methods used for scrap preparation. Appropriate sorting can help separate unwanted materials and improve feed consistency before melting, alloying and refining, supporting more controlled production of aluminium alloy ingots.
Fluxes are used during aluminium melting to support different melt-treatment and furnace-cleaning functions. The report classifies fluxes into cover fluxes, drossing fluxes, cleaning fluxes, wall cleaning fluxes, degassing fluxes, grain refiners, silicon modifiers and demagging fluxes. Their selection depends on the particular process requirement and desired melt condition. Proper flux management forms part of controlled melting practice and can contribute to efficient dross handling, melt treatment and preparation of aluminium for subsequent casting.
Quality control for aluminium alloy ingots focuses on verifying alloy composition, physical characteristics and casting quality against the required specifications. The report includes quality control as a dedicated manufacturing stage and lists equipment such as spectrometers and porosity testing machines among plant and machinery suppliers. Chemical analysis helps verify alloying elements, while inspection and testing can identify casting-related defects. Consistent process control from raw material preparation through melting, degassing and casting is therefore important for producing conforming ingots.
Aluminium alloy ingots are primarily used as feedstock for casting and component manufacturing across multiple industrial applications. The report specifically discusses gravity and sand casting as well as pressure die casting applications. Its wider industry analysis covers transportation, building and construction, packaging, engineering equipment, electronics, cables and other sectors where aluminium products are used. The exact application depends on the alloy grade, chemical composition, mechanical requirements and casting process selected for the finished component.
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