Detailed Project Report on Aluminium Alloy Plant

ALUMINIUM ALLOY PLANT

[EIRI/EDPR/1550] J.C.345

INTRODUCTION

Aluminium alloys are alloys in which aluminium (Al) is the predominant metal. The typical alloying elements are copper, magnesium, manganese, silicon and zinc. There are two principal classifications, namely casting alloys and wrought alloys, both of which are further subdivided into the categories heat-treatable and non-heat-treatable. About 85% of aluminium is used for wrought products, for example rolled plate, foils and extrusions. Cast aluminium alloys yield cost-effective products due to the low melting point, although they generally have lower tensile strengths than wrought alloys. The most important cast aluminium alloy system is Al–Si, where the high levels of silicon (4.0–13%) contribute to give good casting characteristics. Aluminium alloys are widely used in engineering structures and components where light weight or corrosion resistance is required.

Alloys composed mostly of aluminium have been very important in aerospace manufacturing since the introduction of metal skinned aircraft. Aluminium-magnesium alloys are both lighter than other aluminium alloys and much less flammable than alloys that contain a very high percentage of magnesium.

Aluminium alloy surfaces will formulate a white, protective layer of corrosion aluminium oxide if left unprotected by anodizing and/or correct painting procedures. In a wet environment, galvanic corrosion can occur when an aluminium alloy is placed in electrical contact with other metals with more negative corrosion potentials than aluminium, and an electrolyte is present that allows ion exchange. Referred to as dissimilar metal corrosion this process can occur as exfoliation or intergranular corrosion. Aluminium alloys can be improperly heat treated. This causes internal element separation and the metal corrodes from the inside out. Aircraft mechanics deal daily with aluminium alloy corrosion.

Aluminum alloy materials can be classified into wrought alloys such as plates, bars, rods, and wire, and cast/die-cast alloys for sand/mold casting. They all have various characteristics and are designated by four digit JIS numbers*. The alloys are assigned 1000 class numbers and the lower two digits denote the associated information. For example, 99.7% aluminum is A1070 and AL-Mg alloy is A5052.

COST ESTIMATION

Plant Capacity            100 MT/Day

Land & Building (2500 sq.mt.)    US$ 3.24 Lac

Plant & Machinery                    US$ 3.43 Lac

Working Capital for 2 Months    US$ 1.02 Cr

Total Capital Investment          US$ 1.10 Cr

Rate of Return                          101%

Break Even Point                      20%

CONTENTS

INTRODUCTION

USES AND APPLICATIONS

B.I.S. SPECIFICATIONS

UST OF REFERRED INDIAN STANDARDS

MARKET SURVEY

REALITY AND PROSPECTS OF ALUMINUM INDUSTRY

IN THE EMIRATE OF ABU DHABI

REALITY AND PROSPECTS OF ALUMINUM INDUSTRY IN THE EMIRATE OF ABU DHABI

REALITY AND PROSPECTS OF ALUMINUM INDUSTRY IN THE EMIRATE OF ABU DHABI

REALITY AND PROSPECTS OF ALUMINUM INDUSTRY IN THE EMIRATE OF ABU DHABI

FUTURE OF ALUMINIUM INDUSTRY IN INDIA

INDUSTRY PROCESS AND TECHNOLOGY

RAW MATERIALS FOR ALUMINIUM ALLOY

PROCESS FLOW DIAGRAM

MANUFACTURING PROCESS OF ALUMINIUM ALLOY INGOT

MANUFACTURERS/SUPPLIERS/EXPORTERS OF ALUMINIUM ALLOY

SUPPLIERS OF PLANT AND MACHINERIES

SUPPLIERS OF RAW MATERIALS

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)