Detailed Project Report on aluminium extrusion and anodising plant

ALUMINIUM EXTRUSION AND ANODISING PLANT
[CODE NO.3773]


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.



COST ESTIMATION (US$)


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 Month     US$ 12.67 Lac
Total Capital Investment        US$ 33.82 Lac
Rate of Return                    33%                   
Break Even Point             55%            


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)