Industry Overview
Aluminium alloy ingots are large casting products that are generally larger than blooms, billets, and slabs. They commonly have a rectangular or square cross-section, although the cross-section may vary along the length of the ingot. Aluminium alloy ingots are produced in grades such as LM-2, LM-4, and LM-6 for applications including gravity and sand casting, as well as LM-13, LM-14, LM-24, ADC-12, and ALSI-132 for pressure die casting. These alloys can be manufactured in accordance with applicable Indian and international standards.
The reported technical specifications include weights ranging from 8-110 kg, a height of 70MM, a width of 110MM, and a length of 600MM. The manufacturing process covers scrap pretreatment, comminution, cleaning, sorting, decoating, charging and fluxing, melting, alloying, degassing, ingot casting, and quality control. The report also addresses emissions and environmental management, pollution-control techniques, market position, aluminium industry structure, plant layout, and suppliers of raw materials, equipment, and supporting utilities.
Cost Estimation
| Particulars | Value |
|---|---|
| Plant Capacity | 40 MT/Day |
| Land & Building (6000 sq.mt.) | Rs. 2.67 Cr |
| Plant & Machinery | Rs. 4.24 Cr |
| Working Capital for 2 Months | Rs. 27.32 Cr |
| Total Capital Investment | Rs. 34.86 Cr |
| Rate of Return | 62% |
| Break Even Point | 46% |
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
- EMISSIONS AND CONTROLS
- (A) SCRAP PRETREATMENT EMISSIONS -
- (B) SMELTING/REFINING EMISSIONS -
- SUMMARY FOR ENVIRONMENT MANAGEMENT
- AIR ENVIRONMENT
- WATER ENVIRONMENT
- SOLID WASTE MANAGEMENT
- NOISE ENVIRONMENT
- ENVIRONMENTAL MONITORING PROGRAM
- (8) QUALITY CONTROL
- PLANT AND MACHINERY FOR ENVIRONMENT MANAGEMENT
- CONTROL TECHNIQUES FOR AIR POLLUTION
- (1) GRAVITATIONAL SETLING CHAMBER
- (2) CYCLONE SEPARATORS
- (3) FABRIC FILTERS
- (4) ELECTRO STATIC PRECIPITATORS
- (5) WET SCRUBBERS
- CONTROL OF WATER POLLUTION
- MARKET POSITION
- THE ALUMINIUM INDUSTRY: STRUCTURAL EVOLUTION AND RECENT DYNAMICS
- BAUXITE EXTRACTION
- ALUMINA REFINING
- PRIMARY AND SECONDARY PRODUCTION OF RAW ALUMINIUM
- SEMI-FINISHED PRODUCTS
- EXTRUSIONS
- ROLLED PRODUCTS
- FOUNDRY CASTINGS
- THE ALUMINIUM INDUSTRY IN THE EU: FOOD FOR THOUGHT
- PLANT LAYOUT
- MANUFACTURERS/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 COPPER RECYCLING PLANT
- SUPPLIERS OF INDUCTION FURNACE
- SUPPLIERS OF INGOT CASTING MACHINE
- SUPPLIERS OF METAL TESTING MACHINE
- SUPPLIERS OF PRECISION MEASURING TOOLS
- SUPPLIERS OF NDT INSPECTION EQUIPMENT
- SUPPLIERS OF ELECTRICAL MEASURING INSTRUMENTS
- SUPPLIERS OF EOT CRANES
- SUPPLIERS OF POWER TRANSFORMERS
- SUPPLIERS OF ELECTRICAL PANEL
- 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 FIRE FIGHTING EQUIPMENTS
- 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 large cast products made from aluminium alloys for subsequent casting and manufacturing applications. They generally have rectangular or square cross-sections, although their dimensions can vary along their length. Depending on alloy composition and grade, aluminium ingots can be used for gravity casting, sand casting, and pressure die casting. Their production typically involves scrap preparation, melting, alloying, melt treatment, casting, and quality control to achieve the required chemical and physical characteristics.
The report covers aluminium alloy grades used for different casting applications, including LM-2, LM-4, LM-6, LM-13, LM-14, LM-24, ADC-12, and ALSI-132. The selection of an alloy grade depends on the intended casting process and the required material characteristics. The report indicates that these alloys may be manufactured according to Indian and international standards, with chemical composition and technical specifications forming important parts of quality control.
The main manufacturing stages include scrap pretreatment, charging and fluxing, melting, alloying, degassing or melt treatment, ingot casting, and quality control. Scrap pretreatment can involve comminution, cleaning, sorting, and decoating before the material enters the melting operation. During melting, temperature control, skimming, alloying, and flux management are important process activities. Melt treatment helps control impurities and dissolved gases, while casting converts the treated molten alloy into the required ingot form.
Scrap pretreatment is important because it helps prepare aluminium scrap for efficient and controlled melting. Activities such as size reduction, cleaning, sorting, and decoating can reduce unwanted materials and improve the consistency of the furnace charge. Sorting technologies may include magnetic separation, air separation, eddy current separation, dense media separation, and hand sorting. Proper pretreatment can support better furnace operation, improved material recovery, and more consistent alloy quality while helping manage contaminants and process emissions.
Aluminium melting operations can use different fluxes for specific metallurgical functions. The report identifies cover fluxes, drossing fluxes, cleaning fluxes, wall cleaning fluxes, degassing fluxes, grain refiners, silicon modifiers, and demagging fluxes. Their selection depends on the charge material, alloy composition, furnace operation, and required melt quality. Appropriate flux management can help protect molten aluminium, facilitate impurity removal, control dross, and support the production of metal with characteristics suitable for subsequent casting.
Environmental controls for an aluminium alloy ingot plant address air emissions, water, solid waste, and noise. The report discusses control technologies including gravitational settling chambers, cyclone separators, fabric filters, electrostatic precipitators, and wet scrubbers for air pollution management. Water pollution control and effluent treatment are also considered. Effective environmental management generally combines suitable control equipment, waste-handling practices, monitoring programs, and operational controls designed around the plant's processes and applicable environmental requirements.
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