Industry Overview
Aluminium alloy ingots are large cast products that are generally greater in size than blooms, billets, and slabs. They typically have a rectangular or square cross-section, although the cross-section may vary along their length. Aluminium alloy ingots are produced in a range of grades for different casting and engineering applications. Common gravity and sand casting alloys include LM-2, LM-4, and LM-6, while pressure die casting alloys include LM-13, LM-14, LM-24, ADC-12, and ALSI-132. These alloys are manufactured to meet applicable Indian and international standards.
The manufacturing process involves scrap pretreatment, including comminution, cleaning, sorting, and decoating, followed by charging and fluxing, melting, temperature control, skimming, alloying, degassing, and ingot casting. Quality control is an integral part of production to ensure that the finished ingots meet the required chemical and technical specifications. The project also addresses emissions and their control, shipment, market position, aluminium production fundamentals, plant layout, and the financial aspects of the aluminium industry. Supporting sections cover raw materials, plant and machinery suppliers, utilities, pollution-control systems, material handling, testing equipment, and other infrastructure required for aluminium alloy ingot manufacturing.
Cost Estimation
| Particulars | Details |
|---|---|
| Plant Capacity | 20 MT/Day |
| Land & Building (10000 sq.mt) | Rs. 10.70 Cr |
| Plant & Machinery | Rs. 2.93 Cr |
| Working Capital for 2 Months | Rs. 11.43 Cr |
| Total Capital Investment | Rs. 25.50 Cr |
| Rate of Return | 54% |
| Break Even Point | 36% |
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
- MANUFACTURING PROCESS
- (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 POSITION
- PROCESS OF MANUFACTURING ALUMINIUM
- BAUXITE
- ALUMINA
- ALUMINIUM
- FINANCIALS OF THE ALUMINIUM INDUSTRY
- CONCLUSION/OUTLOOK
- PLANT LAYOUT
- MANUFACTURERS/SUPPLIERS OF ALUMINIUM ALLOY INGOT
- SUPPLIERS OF RAW MATERIALS
- SUPPLIERS OF ALUMINIUM SCRAP
- SILICON POWDER
- IRON POWDER
- COPPER POWDER
- MAGNESIUM POWDER
- NICKEL POWDER
- ZINC POWDER
- LEAD POWDER
- TIN POWDER
- PACKING MATERIALS
- PICKLING CHEMICALS
- SUPPLIERS OF PLANT AND MACHINERIES
- CRUCIBLE FURNACE
- INGOT CASTING MACHINE
- SILICON CARBIDE CRUCIBLE
- SHEREDDER
- DE-COATER
- MAGENETIC SEPARATOR
- CASTING LADDLE
- SPECROMETER
- POROSITY TESTING MACHINE
- EOT CRANE
- DG SETS
- POWER TRANSFORMERS
- COOLING TOWER
- EFFULENT TREATMENT PLANT (ETP PLANT)
- AIR POLLUTION CONTROL EQUIPMENTS
- AIR CONDITIONING EQUIPMENTS
- AIR COMPRESSORS
- PLATFORM WEIGHING MACHINE
- MATERIAL HANDLING EQUIPMENTS
- NDT INSPECTION EQUIPMENT
- FIRE FIGHTING EQUIPMENTS
- ELECTRICAL MEASURING INSTRUMENTS
- 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)
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