Detailed Project Report on manufacturing aluminium ingot from aluminium scrap

MANUFACTURING ALUMINIUM INGOT 

FROM ALUMINIUM SCRAP

[CODE NO.4136]  

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.

Industry and Recycling Trend

The production of secondary aluminium in Europe and United States of America. The contribution of individual European countries is also analyzed. While the production is almost steady in the USA, a continuous growth is evident in Europe, with a production of more than 3 million metric tons in 2014. About half of the total production is concentrated in Germany and Italy. In the considered period, Italy doubled its production from about 500 to 1000 thousand metric tons, becoming the main European producer. Austria, Spain, and Hungary show similar trends with a strong increment in recent years, while France and the Netherlands show an opposite trend. Norway in 2014 recorded a quadruple production increase compared to 1998, but the progress decreases over the next few years until 2014.

 Secondary aluminum production from 1998 to 2014 in Europe and some European countries. The production in the USA is also reported. Data elaborated from.

Aluminium properties

Physically, chemically and mechanically, aluminum is a metal similar to steel, brass, copper, zinc, lead or titanium. It can be melted, cast, formed and machined in a similar way to these metals and conducts electric currents. In fact, often the same equipment and fabrication methods are used as for steel.

Light Weight

Aluminum is a very light metal with a specific weight of 2.7 g/cm3, about a third of that of steel. This cuts the costs of manufacturing with aluminum. Again, its use in vehicles reduces dead-weight and energy consumption while increasing load capacity. This also reduces noise and improves comfort levels.

Its strength can be adapted to the application required by modifying the composition of its alloys. Aluminum-magnesium-manganese alloys are an optimum mix of formability with strength, while aluminum-magnesium-silicon alloys are ideal for automobile body sheets, which show good age-hardening when subjected to the bake-on painting process.

Corrosion Resistance

Aluminum naturally generates a protective thin oxide coating which keeps the metal from making further contact with the environment. It is particularly useful for applications where it is exposed to corroding agents, as in kitchen cabinets and in vehicles. In general, aluminum alloys are less corrosion-resistant than pure aluminum, except for marine magnesium-aluminum alloys. Different types of surface treatment such as anodising, painting or lacquering can further improve this property.

Electrical and Thermal Conductivity

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Aluminum is an excellent heat and electricity conductor and in relation to its weight is almost twice as good a conductor as copper. This has made aluminum the first choice for major power transmission lines. It is also a superb heat sink for many applications that require heat to be drained away rapidly, such as in computer motherboards and LED lights.

Reflectivity

Aluminum is a good reflector of visible light as well as heat, and that together with its low weight, makes it an ideal material for reflectors in, for example, light fittings or rescue blankets. Cool roofs made of coated aluminum are invaluable in reducing internal solar heat within a house, by reflecting up to 95% of sunlight.

Ductility

Aluminum is ductile and has a low melting point and density. It can be processed in several ways in a molten condition. Its ductility allows aluminum products to be formed close to the end of the product’s design. Whether sheets, foil, geometrical configurations, tubes, rods or wires, aluminum is up to them all.

Strength at Low Temperatures

In contrast to steel, which rapidly becomes brittle at low temperatures, aluminum shows increased tensile strength as temperatures drop.

Impermeable and Odorless

Aluminum foil is only 0.007 mm in thickness, but is still durable and completely impermeable, keeping any food wrapped in it free of external tastes or smells. It keeps out ultraviolet rays as well.

Moreover, the metal itself is non-toxic and odorless, which makes it ideal for packaging sensitive products such as food or pharmaceuticals. The fact that recycled aluminum can be used reduces the carbon footprint for this stage of food and beverage manufacturers as well.

Non-magnetic

Aluminum is non-magnetic, making it useful for electrical shielding as in computer disks, dish antennas, bus bars or magnet housings.

Non-toxic

Aluminum is non-toxic and is used to make woks, pressure cookers and many other cooking utensils without fear. It is easily cleaned and does not contaminate the food at any stage.

Sound and Shock Absorption

Aluminum is an excellent sound absorber and is used for constructing ceilings. It is also used in auto bumpers due to its shock-absorbing properties.

Non-sparking

Aluminum produces no sparks when it comes into contact with itself or non-ferrous metals.

Recyclability

Aluminum is 100% recyclable and recycled aluminum is identical to the virgin product. This makes it a much more cost-effective source material for production runs. The re-melting of aluminum requires little energy: only about 5% of the energy required to produce the primary metal initially is needed in the recycling process.

Ingots are very large casting products, greater in size and shape than blooms, billets and slabs. Ingot generally has rectangular/square cross section, but it is not necessary that it should be uniform throughout its length. (Ingot may have variable cross section.)

Aluminum Ingot Specification

Chemical composition

Al 99.72

Si 0.09

Fe 0.19

Cu 0.01

Zn 0.02

COST ESTIMATION

Plant Capacity                                   25 MT/Day

Land & Building (5000 sq.mt.)        Rs. 7.75  Cr

Plant & Machinery                             Rs. 1.94  Cr

Working Capital for 2 Months         Rs. 18.19 Cr

Total Capital Investment                  Rs. 28.11 Cr

Rate of Return                                   25%

Break Even Point                              52%

• INTRODUCTION
• INDUSTRY AND RECYCLING TREND
• ALUMINIUM PROPERTIES
• LIGHT WEIGHT
• CORROSION RESISTANCE
• ELECTRICAL AND THERMAL CONDUCTIVITY
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• REFLECTIVITY
• DUCTILITY
• STRENGTH AT LOW TEMPERATURES
• IMPERMEABLE AND ODORLESS
• NON-MAGNETIC
• NON-TOXIC
• SOUND AND SHOCK ABSORPTION
• NON-SPARKING
• RECYCLABILITY
• ALUMINUM INGOT SPECIFICATION
• USES AND APPLICATION
• APPLICATIONS:
• B.I.S. SPECIFICATIONS
• PROCESS FLOW DIAGRAM
• MANUFACTURING PROCESS
• (1) SCRAP PRETREATMENT –
• (A) MECHANICAL CLEANING –
• (B) PYROMETALLURGICAL CLEANING -
• (C) HYDROMETALLURGICAL CLEANING -
• MELTING
• MOC -SKELNER FURNACE
• TEMPERATURE CONTROL
• DEGASSING
• POURING
• CLEANING
• (3) EMISSIONS AND CONTROLS
• (A) SCRAP PRETREATMENT EMISSIONS -
• (B) SMELTING/REFINING EMISSIONS -
• SHIPMENT PROCESS FOR INGOT:
• MARKET POSITION
• 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
• SWOT ANALYSIS
• 1. STRENGHTS:
• 2. WEAKNESS:
• 3. OPPORTUNITY:
• 4. THREATS:
• PLANT LAYOUT
• PRINCIPLES OF PLANT LAYOUT
• MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSESERVICE IS:
• PLANT LOCATION FACTORS
• 1. RAW-MATERIAL SUPPLY:
• 2. MARKETS:
• 3. POWER AND FUEL SUPPLY:
• 4. WATER SUPPLY:
• 5. CLIMATE:
• 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. TOTAL LOAD:
• 8. LAND AREA/MAN POWER RATIO:
• PROJECT IMPLEMENTATION SCHEDULES
• INTRODUCTION
• PROJECT HANDLING
• PROJECT SCHEDULING
• PROJECT CONSTRUCTION SCHEDULE
• TIME SCHEDULE
• SUPPLIERS OF ALUMINIUM INGOT
• SUPPLIERS OF ALUMINIUM CABLE SCRAP
• SUPPLIERS OF PLANT AND 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 CONDITIONING EQUIPMENTS
• SUPPLIERS OF AIR COMPRESSORS
• SUPPLIERS OF PLATFORM WEIGHING MACHINE
• SUPPLIERS OF MATERIAL HANDLING EQUIPMENTS
• SUPPLIERS OF NDT INSPECTION EQUIPMENT
• SUPPLIERS OF FIRE FIGHTING EQUIPMENTS
• SUPPLIERS OF ELECTRICAL MEASURING INSTRUMENTS

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)