Detailed Project Report on Aluminium Ingot from Scrap (Cap: 15 Tons/Day)

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ALUMINIUM INGOT FROM SCRAP (CAP: 15 TONS/DAY)

[EIRI/EDPR/4662] J.C.: 2879XL

INTRODUCTION

The treatment of aluminum scrap to produce new aluminum metal and alloys is an alternative to primary Al production. The chemical composition of the alloys is strictly related to the scrap quality. Therefore, recycled aluminum presents a certain amount of impurities, generally not present in primary alloys, and the alloying elements are more difficult to manage.

Nowadays, this distinction is not completely exhausting. By properly selecting high quality scrap, a purity level close to primary alloys can be achieved in secondary alloys too.

Iron (Fe) plays an important role in distinguishing between primary and secondary Al alloys. This element cannot be easily removed from the molten metal and it forms generally brittle intermetallic compounds that influence the final mechanical properties of the components.

Primary Al alloys present low Fe content and so they are used for applications where the best exploitation of some specific properties is required (mechanical strength, ductility, corrosion resistance, workability, weldability, electrical conductivity); secondary alloys show good castability, which, combined with the natural low volume density of Al alloys, makes them suitable in high-pressure die casting.

COST ESTIMATION

Plant Capacity 15 MT/Day

Land & Building (10,000 sq.ft.) Rented

Plant & Machinery Rs. 1.97 Cr

Working Capital for 1 Month Rs. 6.69 Cr

Total Capital Investment Rs. 8.90 Cr

Rate of Return 43%

Break Even Point 44%

CONTENTS

INTRODUCTION

PROPERTIES

LIGHT WEIGHT

CORROSION RESISTANCE

ELECTRICAL AND THERMAL CONDUCTIVITY

REFLECTIVITY

DUCTILITY

STRENGTH AT LOW TEMPERATURES

IMPERMEABLE AND ODORLESS

NON-MAGNETIC

NON-TOXIC

SOUND AND SHOCK ABSORPTION

NON-SPARKING

RECYCLABILITY

ALUMINUM INGOT SPECIFICATION

USES/APPLICATIONS

APPLICATIONS:

BIS SPECIFICATIONS

MANUFACTURING PROCESS/PROCESS FLOW

SCRAP PRETREATMENT

(A) MECHANICAL CLEANING

(B) PYRO METALLURGICAL CLEANING

MELTING

MOC-SKELNER FURNACE

TEMPERATURE CONTROL

DEGASSING

POURING

CLEANING

EMISSIONS AND CONTROLS

(A) SCRAP PRETREATMENT EMISSIONS

(B) SMELTING/REFINING EMISSIONS

SHIPMENT

PROCESS FLOW

MARKET OVERVIEW

ALUMINIUM RECYCLING ECONOMY

ALUMINIUM RECYCLING AND ITS SOCIO-ECONOMIC IMPLICATIONS

RECYCLING ISSUES: LIFETIMES OF METAL PRODUCTS

BRIGHT FUTURE OF INDUSTRY

GLOBAL ALUMINIUM SCRAP EXPORTERS

RECOMMENDATIONS ON INDIAN ALUMINIUM RECYCLING

IMPORT-EXPORT OF ALUMINIUM PRODUCTS

ALUMINIUM IMPORTS

ALUMINIUM EXPORTS

SWOT ANALYSIS

STRENGTH

WEAKNESS

OPPORTUNITY

THREAT

PRELIMINARY LAYOUT

PRINCIPLES OF PLANT LAYOUT

MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE:

PLANT LOCATION FACTORS

PRIMARY FACTORS

MARKETS:

POWER AND FUEL SUPPLY:

WATER SUPPLY:

CLIMATE:

SPECIFIC FACTORS

TRANSPORTATION:

WASTE DISPOSAL:

REGULATORY LAWS:

TAXES

A. STATE AND LOCAL TAXES

B. LOW ASSESSMENT OR LIMITED TERM EXEMPTIONS TO ATTRACT INDUSTRY

SITE CHARACTERISTICS:

COMMUNITY FACTORS:

VULNERABILITY TO WARTIME ATTACK:

FLOOD AND FIRE CONTROL:

SUPPLIERS OF ALUMINIUM INGOT

SUPPLIERS OF RAW MATERIALS

SUPPLIERS OF ALUMINIUM CABLE SCRAP

SUPPLIERS OF PLANT & MACHINERY

SUPPLIERS OF SKELNER FURNACE

SUPPLIERS OF INGOT CASTING MACHINE

SUPPLIERS OF SHREDDER

SUPPLIERS OF DE-COATER

SUPPLIERS OF MAGNETIC SEPARATOR

SUPPLIERS OF SPECTROMETER

SUPPLIERS OF POROSITY TESTING MACHINE

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 EQUIPMENTS

SUPPLIERS OF FIRE FIGHTING EQUIPMENTS

SUPPLIERS OF ELECTRICAL MEASURING INSTRUMENTS

ENGINEERING DESIGN CONSIDERATIONS

ETP FACILITY

ETP FLOW DIAGRAM (TYPICAL)

SEWAGE AND WASTE WATER EFFLUENT

STP FLOW DIAGRAM (TYPICAL)

WASTE GENERATION & MANAGEMENT/GREEN BELT

GREEN BELT

WATER (ESTIMATED)

WASTE (ESTIMATED)

FLUE GAS (ESTIMATED)

UTILITIES PER MONTH (ESTIMATED)

HEALTH SAFETY AND ENVIRONMENT

ANTICIPATED ENVIRONMENTAL IMPACTS

CONSTRUCTION PHASE

OPERATION PHASE

MITIGATION MEASURES (PROPOSED)

HSE REQUIREMENT

PROPOSED IMPLEMENTATION SCHEDULE

PROJECT FINANCIALS

BASIS & PRESUMPTIONS (FOR PROFITABILITY WORKINGS)

CONCLUSIONS

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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