Detailed Project Report on Aluminium Rolling Mill
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ALUMINIUM ROLLING MILL
[EIRI/EDPR/4364] J.C.: 2550XL
INTRODUCTION
Aluminum Sheet/Plate is the most widely used form of aluminum which undergoes the process of transformation of the metal into flat pieces or thin sheets of aluminum metal. Aluminum sheets are produced by rolling ingots under specific pressure according to the desired thickness.
Thickness of aluminum sheet is less than 6mm, also called as leaf or foil. Aluminum is one of the most widely used materials for making sheets due to its cost effectiveness, ductility, and robustness. Aluminum can be easily moulded into various shapes, grades or in number of forms which has led to increased usage of aluminum sheets in different industrial application. Aluminum sheets are popularly used for industrial applications including aerospace (panel of planes), transportation-(auto panel body), packaging (can bodies) and construction (buildings).
Aluminum sheets exhibit excellent anti-corrosion property and hence are widely being used for marine applications. Aluminum sheets are excellent option for industrial as well as structural application due to its high strength and flexible nature. The global aluminum sheet market is anticipated to grow at a moderate CAGR over the forecast period.
Aluminium is the world’s most abundant metal and is the third most common element, comprising 8% of the earth’s crust. The versatility of aluminium makes it the most widely used metal after steel. Although aluminium compounds have been used for thousands of years, aluminium metal was first produced around 170 years ago. In the 100 years since the first industrial quantities of aluminium were produced, worldwide demand for aluminium has grown to around 29 million tons per year.
About 22 million tons is new aluminium and 7 million tons is recycled aluminium scrap. The use of recycled aluminium is economically and environmentally compelling. It takes 14,000 kWh to produce 1 ton of new aluminium. Conversely it takes only 5% of this to remelt and recycle one ton of aluminium. There is no difference in quality between virgin and recycled aluminium alloys. Pure aluminium is soft, ductile, and corrosion resistant and has a high electrical conductivity. It is widely used for foil and conductor cables, but alloying with other elements is necessary to provide the higher strengths needed for other applications.
Aluminium is one of the lightest engineering metals, having strength to weight ratio superior to steel. By utilizing various combinations of its advantageous properties such as strength, lightness, corrosion resistance, recyclability and formability, aluminium is being employed in an ever-increasing number of applications. This array of products ranges from structural materials through to thin packaging foils.
COST ESTIMATION
Plant Capacity 200 MT/Day
Land & Building (40360 sq.mt.) Rs. 49.23 Cr
Plant & Machinery Rs. 265.31 Cr
Working Capital for 1 Month Rs. 119.38 Cr
Total Capital Investment Rs. 440.92 Cr
Rate of Return 31%
Break Even Point 52%
CONTENTS
INTRODUCTION
MARKET-O-NOMICS:
PROPERTIES
STRENGTH TO WEIGHT RATIO
CORROSION RESISTANCE
ELECTRICAL AND THERMAL CONDUCTIVITY
LIGHT AND HEAT REFLECTIVITY
TOXICITY
RECYCLING
PHYSICAL PROPERTIES OF ALUMINIUM
OTHER INFORMATION ABOUT ALUMINIUM
USES
ALUMINIUM SHEETS/PLATES
PROPERTIES OF ALUMINIUM SHEET METAL
ITS MOST VALUABLE PROPERTIES INCLUDE:
ALUMINUM SHEET ADVANTAGES
CONTINUOUSLY RECYCLABLE SHEET METAL
HIGH-PERFORMANCE ARMOR
ALUMINUM SHEET GAUGE
SPECIFICATION OF COIL
ROOFING –
ARTISTIC CEILINGS –
BALCONIES –
DRINKS CANS, BEER BARRELS AND OTHER FOOD INDUSTRY CONTAINERS –
CABLE SHEATHINGS –
CLADDING AND FASCIA PANELS –
CRANES, TRUSSES, SUPPORTS AND LIFTING GEAR –
HIGH STRESS APPLICATIONS –
LAMP REFLECTORS –
SHELTERS –
CARAVANS –
FLOORING AND WALLS –
BIS SPECIFICATION
MARKET OVERVIEW
GLOBAL ALUMINUM SHEET MARKET DYNAMICS
GLOBAL ALUMINUM SHEET MARKET REGIONAL OUTLOOK
TOP ALUMINIUM PLATE AND SHEET MANUFACTURERS
ARCONIC
ALERIS
CONSTELLIUM
HULAMIN
CHALCO
SWOT ANALYSIS
STRENGTH
WEAKNESS
OPPORTUNITIES
THREATS
RAW MATERIALS
RAW MATERIAL SUPPLIERS
THE RAW MATERIALS ARE AVAILABLE ON PAN INDIA MARKET
SUPPLIERS OF PICKLING CHEMICALS
SUPPLIERS OF ALUMINIUM SHEET AND COIL
MANUFACTURING PROCESS STEPS/PROCESS FLOW
ROLLING PROCESS
MEANING OF ROLLING:
HOT ROLLING
COLD ROLLING MILLS
FOIL MILLS
DEFECTS IN ROLLED PRODUCTS:
SOME OF THE COMMON DEFECTS IN ROLLED PRODUCTS ARE GIVEN BELOW:
(I) EDGE CRACKING:
(II) FOLDS:
(III) ALLIGATORING:
(IV) SCALE FORMATION:
PROCESS FLOW
ENGINEERING DESIGN CONSIDERATIONS
ETP FACILITY
SEWAGE AND WASTE TREATMENT FACILITY
WASTE GENERATION & MANAGEMENT/GREEN BELT
GREEN BELT
WATER (ESTIMATED)
WASTE (ESTIMATED)
FLUE GAS (ESTIMATED)
PLANT & MACHINERY (BROADLY)
ROLLING MILL AND EQUIPMENTS
4-HI REVERSING ROLLING MILL
SLITTER MACHINE
CUT TO LENGTH MACHINE
ANNEALING FURNACE (ELECTRICALLY HEATED)
SUPPLIERS OF PLANT & MACHINERY/TURNKEY SUPPLIERS
ALUMINIUM ROLLING MILL
EUROPEAN SUPPLIERS OF ALUMINIUM FOIL MILL
INDIAN SUPPLIERS FOR ALUMINIUM SHEET AND COIL MILL
EUROPEAN SUPPLIERS OF ANNEALING FURNACE
SUPPLIERS OF ANNEALING FURNACES
EUROPEAN SUPPLIERS OF AUTOMATIC FLATNESS CONTROL, AUTOMATIC GAUGE CONTROL AND SEPARATOR
SUPPLIERS OF FOIL PRINTING MACHINE, LAMINATING MACHINE AND EMBOSSING MACHINE
SUPPLIERS OF METAL TESTING MACHINE
SUPPLIERS OF PRECISION MEASURING TOOLS
SUPPLIERS OF NDT INSPECTION EQUIPMENT
SUPPLIERS OF ELECTRICAL MEASURING INSTRUMENTS
SUPPLIERS OF MILLING MACHINE
SUPPLIERS OF CNC LATHE MACHINE
SUPPLIERS OF BOARING MACHINE
SUPPLIERS OF POWER HACKSAW
SUPPLIERS OF GRINDING MACHINE
SUPPLIERS OF DRILLING, LATHE, TAPING MACHINES
SUPPLIERS OF DG SETS
SUPPLIERS OF EOT CRANES
SUPPLIERS OF POWER TRANSFORMERS
SUPPLIERS OF ELECTRICAL PANEL
SUPPLIERS OF COOLING TOWER
SUPPLIERS OF WASTE TREATMENT 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
SUPPLIERS OF JIGS AND FIXTURE
SUPPLIERS OF SUBMERSIBLE WATER PUMP
PRELIMINARY LAYOUT
PRINCIPLES OF PLANT LAYOUT
MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE:
PLANT LOCATION FACTORS
PRIMARY FACTORS
RAW-MATERIAL SUPPLY:
MARKETS:
POWER AND FUEL SUPPLY:
WATER SUPPLY:
CLIMATE:
TRANSPORTATION:
WASTE DISPOSAL:
LABOR:
REGULATORY LAWS:
TAXES:
SITE CHARACTERISTICS:
COMMUNITY FACTORS:
FLOOD AND FIRE CONTROL:
HEALTH SAFETY AND ENVIRONMENT
ANTICIPATED ENVIRONMENTAL IMPACTS
CONSTRUCTION PHASE
OPERATION PHASE
MITIGATION MEASURES (PROPOSED)
HSE REQUIREMENT
SAFETY & OCCUPATIONAL MEASURE (STORAGE/HANDLING OF RAW MATERIAL & PRODUCT)
POTENTIAL RISKS
PROPOSED IMPLEMENTATION SCHEDULE
PROJECT FINANCIALS
BASIS & PRESUMPTIONS (FOR PROFITABILITY WORKINGS)
CONCLUSIONS
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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