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

ALUMINUM INGOT SPECIFICATION

USES/APPLICATIONS

BIS SPECIFICATIONS

MANUFACTURING PROCESS/PROCESS FLOW

MARKET OVERVIEW

SWOT ANALYSIS

PRELIMINARY LAYOUT

PRINCIPLES OF PLANT LAYOUT

PLANT LOCATION FACTORS

SUPPLIERS OF ALUMINIUM INGOT

SUPPLIERS OF RAW MATERIALS

SUPPLIERS OF PLANT & MACHINERY

ENGINEERING DESIGN CONSIDERATIONS

ETP FACILITY

SEWAGE AND WASTE WATER EFFLUENT

WASTE GENERATION & MANAGEMENT GREEN BELT

UTILITIES PER MONTH (ESTIMATED)

HEALTH SAFETY AND ENVIRONMENT

ANTICIPATED ENVIRONMENTAL IMPACTS

MITIGATION MEASURES (PROPOSED)

HSE REQUIREMENT

PROPOSED IMPLEMENTATION SCHEDULE

PROJECT FINANCIALS

CONCLUSIONS

APPENDIX – A:

01. PLANT ECONOMICS

02. LAND & BUILDING

03. PLANT AND MACHINERY

04. OTHER FIXED ASSETS

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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