Detailed Project Report on Aluminium Dross Processing and Scrap Melting Unit

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ALUMINIUM DROSS PROCESSING AND SCRAP MELTING UNIT

[EIRI/EDPR/3699] J.C.: 1786

INTRODUCTION

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.)

GRADES OF AL INGOT

Aluminium Alloy Ingots Iike LM-2, LM-4, LM-6 which are commonly used in Gravity and Sand Casting, Pressure Die Casting Alloys like LM-13, LM-14, LM-24, ADC-12, ALSI-132 etc are also being manufactured as per the Indian and International standards.

TECHNICAL SPECIFICATION OF ALUMINIUM ALLOY INGOT

WT IN KG : 8-110

HEIGHT : 70MM

WIDTH : 110MM

LENGTH : 600MM

COST ESTIMATION

Plant Capacity 6 MT/Day

Land & Building (10,000 sq.mt.) Rs. 6.34 Cr

Plant & Machinery Rs. 2.93 Cr

Working Capital for 2 Months Rs. 3.39 Cr

Total Capital Investment Rs. 13.11 Cr

Rate of Return 21%

Break Even Point 63%

CONTENTS

INTRODUCTION

GRADES OF AL INGOT

TECHNICAL SPECIFICATION OF ALUMINIUM ALLOY INGOT

ALUMINIUM ALLOY INGOT CHEMICAL COMPOSITION

USES AND APPLICATION

FIELDS OF APPLICATION:

B.I.S. SPECIFICATION

PROCESS FLOW CHART

(A) FOR ALUMINIUM INGOT FROM ALUMINIUM DROSS

(B) FORALUMINIUM INGOT FROM SCRAP

MANUFACTURING PROCESS

(A) ALUMINIUM INGOT FROM ALUMINIUM DROSS

(B) ALUMINIUM INGOT FROM ALUMINIUM SCRAP

(1) SCRAP PRETREATMENT –

METHODS OF PRETREATMENT

(A) COMMINUTION

(B) CLEANING

METHODS OF CLEANING

(I) MECHANICAL CLEANING –

(II) PYROMETALLURGICAL CLEANING -

(III) HYDROMETALLURGICAL CLEANING -

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

(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

MARKET OVERVIEW

THE OBJECTIVE OF THE RESEARCH IS

GLOBAL ALUMINIUM INDUSTRY

GLOBAL PRODUCTION

ALUMINIUM PRODUCING COUNTRIES

GLOBAL CONSUMPTION

THE FOLLOWING ARE THE VARIOUS APPLICATIONS AREAS OF ALUMINIUM

TOP GLOBAL COMPANIES IN PRIMARY ALUMINIUM

INDIAN ALUMINIUM INDUSTRY

HISTORY

FEATURES OF INDIAN ALUMINIUM INDUSTRY

PRIMARY ALUMINIUM PRODUCTION

CONSUMPTION

ANALYSIS OF INDIAN PRIMARY ALUMINIUM MARKET

TYPE OF MARKET

PROFILE OF KEY PLAYERS

NATIONAL ALUMINIUM COMPANY (NALCO)

HINDUSTAN ALUMINIUM COMPANY (HINDALCO)

STERLITE INDUSTRIES LTD (VEDANTA)

REASONS FOR INDIAN ALUMINIUM INDUSTRY BEING AN OLIGOPOLY (BARRIERS TO ENTRY)

ECONOMIES OF SCALE

HUGE CAPITAL INVESTMENTS

TIME TO SETUP

CONTROL OVER THE BAUXITE MINES

SCARCITY OF POWER

GOVERNMENT FACTOR

LAND

GEOGRAPHICAL FACTORS

PORTERS COMPETITIVE FRAMEWORK

1. THREAT FROM SUBSTITUTE PRODUCT.

2. THREAT OF ENTRY.

3. BARGAINING POWER OF BUYERS.

4. BARGAINING POWER OF SUPPLIERS.

5. INTENSITY OF RIVALRY AMONG EXISTING COMPETITORS.

PRICING OF PRIMARY ALUMINIUM

EXPORT DATA OF ALUMINIUM INGOTS

IMPORT DATA OF ALUMINIUM INGOTS

FUTURE OF ALUMINIUM INDUSTRY IN INDIA

ALUMINIUM PRODUCING COUNTRIES

GLOBAL CONSUMPTION

THE FOLLOWING ARE THE VARIOUS APPLICATIONS AREAS OF ALUMINIUM.

TOP GLOBAL COMPANIES IN PRIMARY ALUMINIUM

INDIAN ALUMINIUM INDUSTRY

CHARACTERISTICS AND FEATURES OF INDIAN ALUMINIUM INDUSTRY

INDIA’S POSITION IN WORLD RANKING

PRIMARY ALUMINIUM PRODUCTION

CONSUMPTION

TRANSPORTATION SECTOR

BUILDING AND CONSTRUCTION SECTOR

PACKAGING SECTOR

ENGINEERING EQUIPMENT, ELECTRONICS AND CABLES & OTHER SECTORS

FORECASTING

TABLE 2: FORECASTING TABLE

CONCLUSION

INDIAN ALUMINIUM OVERVIEW

ALUMINIUM INDUSTRY IN INDIA

DOMESTIC DEMAND

DOMESTIC SUPPLY

INDUSTRIES DEMAND

IMPOSITION OF EXPORT DUTY ON ALUMINA

REDUCING IMPORT DUTY ON ALUMINIUM FLUORIDE

INCREASING OF EXPORT DUTY ON BAUXITE

INCREASE IN BASIC CUSTOMS DUTY ON ALUMINIUM PRODUCTS FROM 5% TO 10%

CUSTOMS DUTY ON ALUMINIUM SCRAP AT PAR WITH THE DUTY ON THE METAL PRODUCTS

INCLUSION OF ALUMINIUM INGOTS UNDER INTEREST SUBVENTION SCHEME

OUR ASSESSMENT

GLOBAL ALUMINIUM PRICES TO PLUNGE FURTHER IN 2016

LOW REALISATION WILL STRESS FINANCIALS

GROWTH IN EXPORTS WILL ALSO MODERATE

INDUSTRIES DEMAND & KEY BUDGET PROPOSALS – UNION BUDGET 2016-17

ESTIMATED IMPACT

DATA TABLES

A. DEMAND SUPPLY - INDIA

B. DEMAND SUPPLY – GLOBAL

SUPPLIERS OF ALUMINIUM ALLOY INGOT

SUPPLIERS OF RAW MATERIALS

SUPPLIERS OF ALUMINIUM DROSS

SUPPLIERS OF ALUMINIUM SCRAP

SUPPLIERS OF SILICON POWDER

SUPPLIERS OF IRON POWDER

SUPPLIERS OF COPPER POWDER

SUPPLIERS OF MAGNESIUM POWDER

SUPPLIERS OF NICKEL POWDER

SUPPLIERS OF ZINC POWDER

SUPPLIERS OF LEAD POWDER

SUPPLIERS OF TIN POWDER

SUPPLIERS OF PACKING MATERIAL

SUPPLIERS OF PICKLING CHEMICALS

SUPPLIERS OF PLANT AND MACHINERY

SUPPLIERS OF CRUCIBLE FURNACE

SUPPLIERS OF INGOT CASTING MACHINE

SUPPLIERS OF SILICON CARBIDE CRUCIBLE

SUPPLIERS OF ALUMINIUM RECYCLING PLANT

SUPPLIERS OF SHEREDDER

SUPPLIERS OF DE-COATER

SUPPLIERS OF MAGENETIC SEPARATOR

SUPPLIERS OF CASTING LADDLE

SUPPLIERS OF SPECROMETER

SUPPLIERS OF POROSITY TESTING MACHINE

SUPPLIERS OF EOT CRANE

SUPPLIERS OF DG SETS

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 NDT INSPECTION EQUIPMENT

SUPPLIERS OF FIRE FIGHTING EQUIPMENTS

SUPPLIERS OF ELECTRICAL MEASURING INSTRUMENTS

SUPPLIERS OF SUBMERSIBLE WATER PUMP

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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