Detailed Project Report on Aluminium Extrusion and Anodising Plant

ALUMINIUM EXTRUSION AND ANODISING PLANT

[EIRI/EDPR/3773] J.C.: 1867US$

INTRODUCTION

Extrusion

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

Factors Affecting Extrusion

Shape is a determining factor in the part's cost and ease with which it can be extruded. In extrusion a wide variety of shapes can be extruded, but there are limiting factors to be considered. These include size, shape, alloy, extrusion ratio, tongue ratio, tolerance, finish, factor, and scrap ratio. If a part is beyond the limits of these factors, it cannot be extruded successfully.

The size, shape, alloy, extrusion ratio, tongue ratio, tolerance, finish, and scrap ratio are interrelated in the extrusion process as are extrusion speed, temperature of the billet, extrusion pressure and the alloy being extruded.

In general, extrusion speed varies directly with metal temperature and pressure developed within the container. Temperature and pressure are limited by the alloy used and the shape being extruded. For example, lower extrusion temperatures will usually produce shapes with better quality surfaces and more accurate dimensions. Lower temperatures require higher pressures. Sometimes, because of pressure limitations, a point is reached where it is impossible to extrude a shape through a given press.

COST ESTIMATION

Plant Capacity            10 MT/Day

Land & Building (10,000 sq.mt.)    US$ 7.83 Lac

Plant & Machinery                    US$ 11.30 Lac

Working Capital for 2 Months    US$ 12.67 Lac

Total Capital Investment          US$ 33.82 Lac

Rate of Return                          33%

Break Even Point                      55%

CONTENTS

INTRODUCTION

EXTRUSION

FACTORS AFFECTING EXTRUSION

ADVANTAGES OF THE EXTRUSION PROCESS:

TYPES OF EXTRUDED PROFILES

CLASSIFICATION OF ALUMINIUM EXTRUSION

TRADITIONALLY, THE PROCESS HAS BEEN DESCRIBED AS HAVING THREE DISTINCT REGIONS

(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

ANODIZING OF ALUMINUM

WHAT IS ANODISING?

PURPOSE OF ANODIZING

TYPES OF ANODISING

TYPE-I-CHROMIC ACID ANODISING

TYPE-II-SULPHURIC ACID ANODISING

TYPE-III-HARD ANODISING

USES AND APPLICATION

USES

APPLICATION

APPLICATIONS OF EXTRUDED ALUMINUM

B.I.S. SPECIFICATION

PROCESS FLOW CHART

(A) FOR EXTRUSION

(B) FOR ANODISING

MANUFACTURING PROCESS

(A) FOR EXTRUSION

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

(B) ANODISING

(1) SURFACE PREPARATION

TECHNOLOGIES OF SURFACE PREPARATION

A. MECHANICAL CLEANING

G. ANODIC ELECTROCLEANING (REVERSE ELECTROCLEANING).

H. PERIODIC-REVERSE ELECTROCLEANING.

I. ACID ACTIVATION.

(2) ANODISING PROCESS

(A) CHROMIC ACID ANODIZING, I.E., TYPE 1

A CHROMIC ACID ANODIZING SOLUTION SHOULD NOT BE USED UNLESS:

(B) CONVENTIONAL SULFURIC ACID ANODIZING, I.E., TYPE 2

(D) HARDCOAT ANODIZING, I.E., TYPE 3

ANODIZING EQUIPMENT AND PROCESS CONTROL

(A) FOR CHROMIC ACID ANODIZING.

(B) FOR SULFURIC ACID ANODIZING.

(C) FOR HARD ANODIZING.

POWER REQUIREMENTS FOR THE PRINCIPAL ANODIZING PROCESSES ARE AS FOLLOWS:

(A) FOR CROMIC ACID ANODISING

(B) FOR SULFURIC ACICD ANODISING

(C) FOR HARD COAT ANODISING

(3) RACKING PROCESS

(4) SEALING PROCESS

(5) COLOURING PROCESS

MARKET POSITION

THE GROWING DEMAND OF ALUMINIUM EXTRUSIONS

ALUMINIUM EXTRUSIONS - THE PROS AND CONS

THE PLAYERS

THE FUTURE

SPREADING AWARENESS

FUTURE OUTLOOK

THE SCENARIO OF THE ALUMINUM EXTRUSION INDUSTRY

FUTURE OUTLOOK

CHALLENGES IN THE INDIAN EXTRUSIONS MARKE

RISKS AND AREAS OF CONCERN

PRESENT MANUFACTURERS

ALUMINIUM EXTRUSION SECTIONS

SUPPLIERS OF ALUMINIUM PROFILE

PLANT LAYOUT

SUPPLIERS OF RAW MATERIALS

SUPPLIERS OF ALUMINIUM ALLOY BILLET

SUPPLIERS OF DEGREASING CHEMICAL

SUPPLIERS OF PICKLING CHEMICALS

SUPPLIERS OF OIL AND GREASE

SUPPLIERS OF ANODISING MATERIAL

SUPPLIERS OF CAUSTIC SODA

SUPPLIERS OF HYDROCLORIC ACID

SUPPLIERS OF ZINC AMONIUM CLORIDE

SUPPLIERS OF SULFURIC ACID

SUPPLIERS OF CHROME SALT AND CHROMIC ACID

SUPPLIERS OF PLANT AND MACHINERY

CHINA SUPPLIERS FOR ALUMINIUM EXTRUSION AND ANODISING PLANT

INDIAN SUPPLIERS OF ALUMINIUM EXTRUSION PLANT

SUPPLIERS OF EOT CRANE

SUPPLIERS OF POWER TRANSFORMERS

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

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)