Detailed Project Report on aluminium ingot from aluminium scrap

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ALUMINIUM INGOT FROM ALUMINIUM SCRAP [3585]

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.). 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.

COST ESTIMATION

Plant Capacity                           20 MT/Day
Land & Building (10000 sq.mt)     Rs. 10.70 Cr
Plant & Machinery                    Rs. 2.93 Cr
Working Capital for 2 Months   Rs. 11.43 Cr
Total Capital Investment          Rs. 25.50 Cr
Rate of Return                         54%
Break Even Point                     36%

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
MANUFACTURING PROCESS
(1) SCRAP PRETREATMENT –
METHODS OF PRETREATMENT
(A) COMMINUTION
(B) CLEANING
METHODS OF CLEANING
(I) MECHANICAL CLEANING –
(II) PYROMETALLURGICAL CLEANING –
(III) HYDROMETALLURGICAL CLEANING –
(C) SORTING
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
(C) CLEANING 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 POSITION
PROCESS OF MANUFACTURING ALUMINIUM
BAUXITE
ALUMINA
ALUMINIUM
FINANCIALS OF THE ALUMINIUM INDUSTRY
CONCLUSION/OUTLOOK
PLANT LAYOUT
MANUFACTURERS/SUPPLIERS OF ALUMINIUM ALLOY INGOT
SUPPLIERS OF RAW MATERIALS
SUPPLIERS OF ALUMINIUM SCRAP
SILICON POWDER
IRON POWDER
COPPER POWDER
MAGNESIUM POWDER
NICKEL POWDER
ZINC POWDER
LEAD POWDER
TIN POWDER
PACKING MATERIALS
PICKLING CHEMICALS
SUPPLIERS OF PLANT AND MACHINERIES
CRUCIBLE FURNACE
INGOT CASTING MACHINE
SILICON CARBIDE CRUCIBLE
SHEREDDER
DE-COATER
MAGENETIC SEPARATOR
CASTING LADDLE
SPECROMETER
POROSITY TESTING MACHINE
EOT CRANE
DG SETS
POWER TRANSFORMERS
COOLING TOWER
EFFULENT TREATMENT PLANT (ETP PLANT)
AIR POLLUTION CONTROL EQUIPMENTS
AIR CONDITIONING EQUIPMENTS
AIR COMPRESSORS
PLATFORM WEIGHING MACHINE
MATERIAL HANDLING EQUIPMENTS
NDT INSPECTION EQUIPMENT
FIRE FIGHTING EQUIPMENTS
ELECTRICAL MEASURING INSTRUMENTS
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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Detailed Project Report (DPR) includes Present Market Position and Expected Future Demand, Technology, Manufacturing Process, Investment Opportunity, Plant Economics and Project Financials. comprehensive analysis from industry covering detailed reporting and evaluates the position of the industry by providing insights to the SWOT analysis of the industry.

Each report include Plant Capacity, requirement of Land & Building, Plant & Machinery, Flow Sheet Diagram, Raw Materials detail with suppliers list, Total Capital Investment along with detailed calculation on Rate of Return, Break-Even Analysis and Profitability Analysis. The report also provides a birds eye view of the global industry with details on projected market size and then progresses to evaluate the industry in detail.

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