Aluminium Extrusion (Cap: 12,000 MT/Annum)

ALUMINIUM EXTRUSION (CAP: 12,000 MT/ANNUM)

[EIRI/EDPR/4615] J.C.: 2832INR, 2832AED

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.

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.

The preferred billet temperature is that which provides acceptable surface and tolerance conditions and, at the same time, allows the shortest possible cycle time. The ideal is billet extrusion at the lowest temperature which the process will permit. An exception to this is the so-called press-quench alloys, most of which are in the 6000 series. With these alloys, solution heat-treat temperatures within a range of 930°-980° F must be attained at the die exit to develop optimum mechanical properties.

At excessively high billet temperatures and extrusion speeds, metal flow becomes more fluid. The metal, seeking the path of least resistance, tends to fill the larger voids in the die face, and resists entry into constricted areas. Under those conditions, shape dimensions tend to fall below allowable tolerances, particularly those of thin projections or ribs.

COST ESTIMATION

Plant Capacity            36.3637 MT/Day  

Land & Building (12,000 sq.mt.)    Rs. 9.25 Cr    

Plant & Machinery                    Rs. 28.72 Cr 

Working Capital for 2 Months    Rs. 26.80 Cr 

Total Capital Investment          Rs. 65.88 Cr 

Rate of Return                          46%

Break Even Point                      38%

CONTENTS

INTRODUCTION

FACTORS AFFECTING EXTRUSION

ADVANTAGES OF THE EXTRUSION PROCESS:

TYPES OF EXTRUDED PROFILES

CLASSIFICATION OF ALUMINIUM EXTRUSION

(A) DIRECT (FORWARD) 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

USES AND APPLICATION

USES

APPLICATION

B.I.S. SPECIFICATION

PROCESS FLOW CHART

FOR ALUMINIUM BILLET

FOR ALUMINIUM EXTRUSION

MANUFACTURING PROCESS

FOR ALUMINIUM BILLET

(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

SUMMARY FOR ENVIRONMENT MANAGEMENT

AIR ENVIRONMENT

WATER ENVIRONMENT

WATER POLLUTION MANAGEMENT AND WATER CONSERVATION MEASURES

SOLID WASTE MANAGEMENT

NOISE ENVIRONMENT

THE FOLLOWING CONTROL MEASURES WILL BE IMPLEMENTED FOR THE PROPOSED PROJECT:

ENVIRONMENTAL MONITORING PROGRAM

(8) QUALITY CONTROL

PLANT AND MACHINERY FOR ENVIRONMENT ANAGEMENT

CONTROL TECNIQUES FOR AIR POLLUTION

(1) GRAVITATIONAL SETLING CHAMBER

ADVANTAGES:

(2) CYCLONE SEPARATORS

ADVANTAGES:

DISADVANTAGES:

(3) FABRIC FILTERS

ADVANTAGES:

DISADVANTAGES:

(4) ELECTRO STATIC PRECIPITATORS

ADVANTAGES:

DISADVANTAGES:

E. WET COLLECTORS OR SCRUBBERS

(5) WET SCRUBBERS

ADVANTAGES:

DISADVANTAGES:

CONTROL OF WATER POLLUTION

THE TREATMENT OF THIS WASTE WATER IS CARRIED OUT IN THE FOLLOWING THREE STAGES:

THIS IS CALLED SECONDARY TREATMENT OF WATER. IT INVOLVES THE FOLLOWING PROCESSES

FOR ALUMINIUM EXTRUSION

THE STEPS IN THE EXTRUSION PROCESS ARE AS FOLLOWS:

ILLUSTRATION OF THE FLOW OF ALUMINUM AS IT PASSES THROUGH THE DIE

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

SOLID DIE TOOL STACK.

HOLLOW DIE TOOL STACK.

GLOBAL ALUMINIUM CONSUMPTION

ALUMINIUM CONSUMPTION BY REGION

ALUMINIUM SEMI-FINISHED PRODUCTS CONSUMPTION BY REGION 2015 – 2030, MT

ALUMINIUM SEMI-FINISHED PRODUCTS CONSUMPTION GROWTH BY REGION, 2020 VS 2030, MT

ALUMINIUM SEMI-FINISHED PRODUCTS CONSUMPTION IN ASIA. EX CHINA, 2015 – 2030, MT

ALUMINIUM CONSUMPTION BY SECTOR  

ALUMINIUM SEMI-FINISHED PRODUCTS CONSUMPTION BY SECTOR 2015 – 2030, MT

ALUMINIUM SEMI-FINISHED PRODUCTS CONSUMPTION GROWTH BY SECTOR, 2020 VS 2030, MT

ALUMINIUM CONSUMPTION IN CHINA

ALUMINIUM SEMI-FINISHED PRODUCTS CONSUMPTION BY SECTOR IN CHINA, 2020 VS 2030, MT

GOING FORWARD, CHINA’S ALUMINIUM CONSUMPTION IS EXPECTED TO GROW BY 12.3 MT, REACHING A TOTAL OF 56.1 MT IN 2030:

ALUMINIUM CONSUMPTION IN ASIA EX. CHINA

ALUMINIUM SEMI-FINISHED PRODUCTS CONSUMPTION BY SECTOR IN ASIA EX. CHINA, 2020 VS 2030, MT

ALUMINIUM CONSUMPTION IN EUROPE

ALUMINIUM SEMI-FINISHED PRODUCTS CONSUMPTION BY SECTOR IN EUROPE, 2020 VS 2030, MT

ALUMINIUM CONSUMPTION IN NORTH AMERICA

ALUMINIUM SEMI-FINISHED PRODUCTS CONSUMPTION BY SECTOR IN NORTH AMERICA, 2020 VS 2030, MT

ALUMINIUM EXTRUSION MARKET IN MEA

ALUMINIUM MARKET IN UAE

GLOBAL ALUMINIUM EXTRUSION MARKET

PLANT LAYOUT

ALUMINIUM EXTRUSION SECTIONS

SUPPLIERS OF ALUMINIUM PROFILE

SUPPLIERS OF RAW MATERIALS

SUPPLIERS OF ALUMINIUM SCRAP

SUPPLIERS OF PICKLING CHEMICALS

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 PLANT AND MACHINERY

SUPPLIERS OF ALUMINIUM EXTRUSION PLANT

SUPPLIERS OF BILLET CASTING MACHINE

SUPPLIERS OF ALUMINIUM RECYCLING PLANT

SUPPLIERS OF SHEREDDER

SUPPLIERS OF DE-COATER

SUPPLIERS OF MAGENETIC SEPARATOR

SUPPLIERS OF SPECROMETER

SUPPLIERS OF POROSITY TESTING MACHINE

SUPPLIERS OF EOT CRANES

SUPPLIERS OF POWER TRANSFORMER

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

SUPPLIERS OF SILICON CARBIDE CRUCIBLE

SUPPLIERS OF MATERIAL HANDLING EQUIPMENTS

SUPPLIERS OF NDT INSPECTION EQUIPMENT

SUPPLIERS OF FIRE FIGHTING EQUIPMENTS

SUPPLIERS OF ELECTRICAL MEASURING INSTRUMENTS

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)