Aluminium Extrusion Plant (10 TPD)
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ALUMINIUM EXTRUSION PLANT (10 TPD)
[EIRI/EDPR/4745] J.C.: 2965XL
Extrusion is a plastic deformation process in which a block of metal (billet) is forced to flow by compression through the die opening of a smaller cross-sectional area than that of the original billet Extrusion is an indirect-compression process. Indirect-compressive forces are developed by the reaction of the workpiece (billet) with the container and die; these forces reach high values. The reaction of the billet with the container and die results in high compressive stresses that are effective in reducing the cracking of the billet material during primary breakdown from the billet . Extrusion is the best method for breaking down the cast structure of the billet because the billet is subjected to compressive forces only.
Extrusion can be cold or hot, depending on the alloy and the method used. In hot extrusion, the billet is preheated to facilitate plastic deformation.
COST ESTIMATION
Plant Capacity 10 MT/Day
Land & Building (8000 sq.mt.) Rs. 9.82 Cr
Plant & Machinery Rs. 10.55 Cr
Working Capital for 2 Months Rs. 13.06 Cr
Total Capital Investment Rs. 34.08 Cr
Rate of Return 20%
Break Even Point 58%
CONTENTS
INTRODUCTION
ABOUT ALUMINUM
FACTORS AFFECTING EXTRUSION
ADVANTAGES OF THE EXTRUSION PROCESS:
THERE ARE SEVERAL ADVANTAGES OF THE MODERN EXTRUSION PROCESS
ALUMINUM EXTRUSION FEATURES & BENEFITS
LIGHTWEIGHT
STRONG
HIGH IN STRENGTH-TO-WEIGHT MATERIAL
RESILIENT
CORROSION RESISTANT
EXCELLENT THERMAL CONDUCTOR
NON-SPARKING
EXCELLENT ELECTRICAL CONDUCTOR
NON-MAGNETIC
NONCOMBUSTIBLE & NONTOXIC
REFLECTIVE
SEAMLESS
EASILY TAILORED
QUICK-TO-MARKET
EASY TO FABRICATE & ASSEMBLE
SUSTAINABLE
TYPES OF EXTRUDED PROFILES
CLASSIFICATION OF ALUMINIUM EXTRUSION
(A) DIRECT (FORWARD) EXTRUSION
(B) INDIRECT (BACKWARD) EXTRUSION
(C) HOT EXTRUSION
(D) COLD EXTRUSION AND WARM EXTRUSION
PROPERTIES
PROPERTIES OF ALUMINIUM
WEIGHT
STRENGTH
LINEAR EXPANSION
MACHINING
FORMABILITY
CONDUCTIVITY
JOINING
REFLECTIVITY
SCREENING EMC
CORROSION RESISTANCE
NON-MAGNETIC MATERIAL
ZERO TOXICITY
USES AND APPLICATION
USES
APPLICATION
B.I.S. SPECIFICATION
MATERIAL COMPARISONS:
TYPICAL TOOLING COST CHART
TYPICAL TOOLING LEAD TIMES CHART
ALUMINUM EXTRUSION VS ROLL FORMED STEEL, COPPER EXTRUSIONS
ALUMINUM EXTRUSION VS MOLDED PLASTIC, WOOD, VINYL
MANUFACTURING PROCESS
FOR ALUMINIUM BILLET
(1) SCRAP PRETREATMENT –
METHODS OF PRETREATMENT
(A) COMMINUTION
(B) CLEANING
METHODS OF CLEANING
(I) MECHANICAL CLEANING
(II) PYROMETALLURGICAL CLEANING
(III) HYDROMETALLURGICAL CLEANING
(C) SORTING
PROCESS FLOW CHART
FOR ALUMINIUM EXTRUSION
FOR ALUMINIUM BILLET
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
ENVIRONMENT MANAGEMENT
AIR ENVIRONMENT
WATER ENVIRONMENT
SOLID WASTE MANAGEMENT
NOISE ENVIRONMENT
THE FOLLOWING CONTROL MEASURES WILL BE IMPLEMENTED FOR THE PROPOSED PROJECT:
ENVIRONMENTAL MONITORING PROGRAM
(8) QUALITY CONTROL
PLANT AND MACHINERY FOR ENVIRONMENT MANAGEMENT
CONTROL TECNIQUES FOR AIR POLLUTION
(1) GRAVITATIONAL SETLING CHAMBER
ADVANTAGES:
DISADVANTAGES:
(2) CYCLONE SEPARATORS
ADVANTAGES:
DISADVANTAGES:
(3) FABRIC FILTERS
ADVANTAGES:
DISADVANTAGES:
(4) ELECTRO STATIC PRECIPITATORS
ADVANTAGES:
DISADVANTAGES:
E. WET COLLECTORS OR SCRUBBERS
(5) WET SCRUBBERS
ADVANTAGES:
DISADVANTAGES:
CONTROL OF WATER POLLUTION
THE TREATMENT OF THIS WASTE WATER IS CARRIED OUT IN THE FOLLOWING THREE STAGES:
THIS IS CALLED SECONDARY TREATMENT OF WATER. IT INVOLVES THE FOLLOWING PROCESSES
FOR ALUMINIUM EXTRUSION
ALUMINIUM EXTRUSION PROCESSING
THE STEPS IN THE EXTRUSION PROCESS ARE AS FOLLOWS:
ILLUSTRATION OF THE FLOW OF ALUMINUM AS IT PASSES THROUGH THE DIE.
DESCRIPTION OF PROCESS
(1) BILLET PREHEATING
TABLE 1 TYPICAL BILLET TEMPERATURES OF SOFT AND MEDIUM-GRADE ALUMINUM ALLOYS
TABLE 2 TYPICAL BILLET TEMPERATURES OF HARD ALUMINUM ALLOYS
(2) EXTRUSION
(3) QUENCHING
(4) STRETCHING
(5) CUTOFF
(6) ARTIFICIAL AGING
TABLE 3 TYPICAL HEAT TREATMENT PARAMETERS OF SOME 6XXX ALLOYS
(7) INSPECTION AND TESTING
EXTRUSION MATERIALS INSPECTION
ALUMINUM ALLOY CHECK
EXTRUSION DYE CHECK
ADDITIVES CHECK
EXTRUSION VISUAL INSPECTION
VISUAL DEFECTS CHECK
COLOR AND GLOSSINESS CHECK
DIMENSIONAL INSPECTION
COATING AND FINISHING CHECK
WEIGHT AND DENSITY CHECK
EXTRUSION PERFORMANCE INSPECTION
TENSILE TEST
WELDABILITY CHECK
WORKABILITY CHECK
CORROSION RESISTANCE
FLAMMABILITY TESTING
HARDNESS TEST
WEATHERING RESISTANCE TESTING
ABRASION RESISTANCE
CHEMICAL RESISTANCE
DESCRIPTION OF EXTRUSION PRESS
HOLLOW DIE TOOL STACK
MARKET POSITION
ALUMINIUM EXTRUSIONS - THE PROS AND CONS
PRINCIPLES OF PLANT LAYOUT
MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE:
PLANT LOCATION FACTORS
PRIMARY FACTORS
1. RAW-MATERIAL SUPPLY:
2. MARKETS:
3. POWER AND FUEL SUPPLY:
4. WATER SUPPLY:
5. CLIMATE:
SPECIFIC FACTORS
6. TRANSPORTATION:
7. WASTE DISPOSAL:
8. LABOR:
9. REGULATORY LAWS:
10. TAXES:
11. SITE CHARACTERISTICS:
12. COMMUNITY FACTORS:
13. VULNERABILITY TO WARTIME ATTACK:
14. FLOOD AND FIRE CONTROL:
EXPLANATION OF TERMS USED IN THE PROJECT REPORT
1. DEPRECIATION:
2. FIXED ASSETS:
3. WORKING CAPITAL:
4. BREAK-EVEN POINT:
5. OTHER FIXED EXPENSES:
6. MARGIN MONEY:
7. TERM LOANS:
8. TOTAL LOAD:
9. LAND AREA/MAN POWER RATIO:
UTILITIES
POWER
WORKING
TOTAL MANPOWER AND PAYROLL
INDIAN MANUFACTURING INDUSTRY
INTRODUCTION
MARKET SIZE
INVESTMENT
GOVERNMENT INITIATIVES
ROAD AHEAD
ALUMINIUM EXTRUSION MACHINERY MANUFACTURER
SUPPLIERS OF ALUMINIUM PROFILE
SUPPLIERS OF RAW MATERIALS
SUPPLIERS OF ALUMINIUM BILLET
SUPPLIERS OF PICKLING CHEMICALS
SUPPLIERS OF SILICON POWDER
SUPPLIERS OF IRON POWDER
SUPPLIERS OF PLANT AND MACHINERY
SUPPLIERS OF ALUMINIUM EXTRUSION PLANT
SUPPLIERS OF BILLET CASTING MACHINE
SUPPLIERS OF ALUMINIUM RECYCLING PLANT
SUPPLIERS OF SHEREDDER
SUPPLIERS OF DE-COATER
SUPPLIERS OF MAGENETIC SEPARATOR
SUPPLIERS OF SPECROMETER
SUPPLIERS OF POROSITY TESTING MACHINE
SUPPLIERS OF EOT CRANES
SUPPLIERS OF POWER TRANSFORMER
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 SHOT BLASTING MACHINE
SUPPLIERS OF SILICON CARBIDE CRUCIBLE
SUPPLIERS OF MATERIAL HANDLING EQUIPMENTS
SUPPLIERS OF NDT INSPECTION EQUIPMENT
SUPPLIERS OF ELECTRICAL MEASURING INSTRUMENTS
FIREFIGHTING EQUIPMENTS MANUFACTURERS & SUPPLIERS
WEIGHING BREIDGE MANUFACTURER
LABORATORTY EQUIPMENTS MANUFACTURERS
D.G. SET MANUFACTURERS & SUPPLIERS
ELECRICAL GOOD & SWITCH MANUFACTURE
SWOT ANALYSIS
STRENGTHS
WEAKNESSES
OPPORTUNITIES
THREATS
ORGANIZATION CHART
PLANT LAYOUT
IMPLEMENTATION SCHEDULE
ADDRESSES OF RELEVANT GOVERNMENT OFFICES
ADDRESSES OF FINANCIAL INSTITUTIONS
KEY REGULATIONS AND POLICIES
INDUSTRY SPECIFIC REGULATIONS
BUREAU OF INDIAN STANDARDS ACT, 2016(“BIS ACT”)
THE LEGAL METROLOGY ACT, 2009 AND LEGAL METROLOGY (PACKAGED COMMODITIES) RULES, 2011 (“LM RULES”)
STEEL AND STEEL PRODUCTS (QUALITY CONTROL) ORDER, 2020 (“QC ORDER”)
ENVIRONMENT LAWS AND REGULATIONS
THE ENVIRONMENT (PROTECTION) ACT, 1986 AND THE ENVIRONMENT (PROTECTION) RULES, 1986
THE ENVIRONMENTAL IMPACT ASSESSMENT NOTIFICATION, 2006 (“EIA NOTIFICATION”)
THE WATER (PREVENTION AND CONTROL OF POLLUTION) ACT, 1974 (“WATER ACT”)
THE AIR (PREVENTION AND CONTROL OF POLLUTION) ACT, 1981 (“AIR ACT”)
THE HAZARDOUS AND OTHER WASTES (MANAGEMENT AND TRANSBOUNDARY MOVEMENT) RULES, 2016 (“HAZARDOUS WASTE RULES”)
INDUSTRIAL, EMPLOYMENT AND LABOUR LAWS
THE PUBLIC LIABILITY INSURANCE ACT, 1991 & THE PUBLIC LIABILITY INSURANCE RULES, 1991
THE FACTORIES ACT, 1948
THE CODE ON WAGES, 2019
THE OCCUPATIONAL SAFETY, HEALTH AND WORKING CONDITIONS CODE, 2020
THE CODE ON SOCIAL SECURITY, 2020
THE INDUSTRIAL RELATIONS CODE, 2020
THE CHILD AND ADOLESCENT LABOUR (PROHIBITION AND REGULATION) ACT, 1986
THE SEXUAL HARASSMENT OF WOMEN AT WORKPLACE (PREVENTION, PROHIBITION AND REDRESSAL) ACT, 2013
INTELLECTUAL PROPERTY LAWS
THE PATENTS ACT, 1970 (“PATENTS ACT”)
THE TRADE MARKS ACT, 1999 (“TRADE MARKS ACT”)
THE COPYRIGHT ACT, 1957 (“COPYRIGHT ACT”)
THE DESIGNS ACT, 2000 (“DESIGNS ACT”)
FOREIGN TRADE REGULATIONS
FOREIGN EXCHANGE MANAGEMENT ACT, 1999 (“FEMA”)
THE FOREIGN TRADE (DEVELOPMENT AND REGULATION) ACT, 1992 AND FOREIGN TRADE (REGULATION) RULES, 1993
LAWS IN RELATION TO TAXATION
INCOME TAX ACT, 1961
GOODS AND SERVICES TAX ACT, 2017
GENERAL LAWS
THE CONSUMER PROTECTION ACT, 2019
THE COMPETITION ACT, 2002
THE COMPANIES ACT, 2013 (“COMPANIES ACT”)
THE INDIAN CONTRACT ACT, 1872
INDIAN STAMP ACT, 1899
THE REGISTRATION ACT, 1908
THE NEGOTIABLE INSTRUMENTS ACT, 1881
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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