ALUMINIUM DROSS PROCESSING AND SCRAP MELTING UNIT
[EIRI/EDPR/3699] J.C.: 1786
INTRODUCTION
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.)
GRADES OF AL INGOT
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.
TECHNICAL SPECIFICATION OF ALUMINIUM ALLOY INGOT
WT IN KG : 8-110
HEIGHT : 70MM
WIDTH : 110MM
LENGTH : 600MM
COST ESTIMATION
Plant Capacity 6 MT/Day
Land & Building (10,000 sq.mt.) Rs. 6.34 Cr
Plant & Machinery Rs. 2.93 Cr
Working Capital for 2 Months Rs. 3.39 Cr
Total Capital Investment Rs. 13.11 Cr
Rate of Return 21%
Break Even Point 63%
CONTENTS
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
(A) FOR ALUMINIUM INGOT FROM ALUMINIUM DROSS
(B) FORALUMINIUM INGOT FROM SCRAP
MANUFACTURING PROCESS
(A) ALUMINIUM INGOT FROM ALUMINIUM DROSS
(B) ALUMINIUM INGOT FROM ALUMINIUM SCRAP
(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 OVERVIEW
THE OBJECTIVE OF THE RESEARCH IS
GLOBAL ALUMINIUM INDUSTRY
GLOBAL PRODUCTION
ALUMINIUM PRODUCING COUNTRIES
GLOBAL CONSUMPTION
THE FOLLOWING ARE THE VARIOUS APPLICATIONS AREAS OF ALUMINIUM
TOP GLOBAL COMPANIES IN PRIMARY ALUMINIUM
INDIAN ALUMINIUM INDUSTRY
HISTORY
FEATURES OF INDIAN ALUMINIUM INDUSTRY
PRIMARY ALUMINIUM PRODUCTION
CONSUMPTION
ANALYSIS OF INDIAN PRIMARY ALUMINIUM MARKET
TYPE OF MARKET
PROFILE OF KEY PLAYERS
NATIONAL ALUMINIUM COMPANY (NALCO)
HINDUSTAN ALUMINIUM COMPANY (HINDALCO)
STERLITE INDUSTRIES LTD (VEDANTA)
REASONS FOR INDIAN ALUMINIUM INDUSTRY BEING AN OLIGOPOLY (BARRIERS TO ENTRY)
ECONOMIES OF SCALE
HUGE CAPITAL INVESTMENTS
TIME TO SETUP
CONTROL OVER THE BAUXITE MINES
SCARCITY OF POWER
GOVERNMENT FACTOR
LAND
GEOGRAPHICAL FACTORS
PORTERS COMPETITIVE FRAMEWORK
1. THREAT FROM SUBSTITUTE PRODUCT.
2. THREAT OF ENTRY.
3. BARGAINING POWER OF BUYERS.
4. BARGAINING POWER OF SUPPLIERS.
5. INTENSITY OF RIVALRY AMONG EXISTING COMPETITORS.
PRICING OF PRIMARY ALUMINIUM
EXPORT DATA OF ALUMINIUM INGOTS
IMPORT DATA OF ALUMINIUM INGOTS
FUTURE OF ALUMINIUM INDUSTRY IN INDIA
ALUMINIUM PRODUCING COUNTRIES
GLOBAL CONSUMPTION
THE FOLLOWING ARE THE VARIOUS APPLICATIONS AREAS OF ALUMINIUM.
TOP GLOBAL COMPANIES IN PRIMARY ALUMINIUM
INDIAN ALUMINIUM INDUSTRY
CHARACTERISTICS AND FEATURES OF INDIAN ALUMINIUM INDUSTRY
INDIA’S POSITION IN WORLD RANKING
PRIMARY ALUMINIUM PRODUCTION
CONSUMPTION
TRANSPORTATION SECTOR
BUILDING AND CONSTRUCTION SECTOR
PACKAGING SECTOR
ENGINEERING EQUIPMENT, ELECTRONICS AND CABLES & OTHER SECTORS
FORECASTING
TABLE 2: FORECASTING TABLE
CONCLUSION
INDIAN ALUMINIUM OVERVIEW
ALUMINIUM INDUSTRY IN INDIA
DOMESTIC DEMAND
DOMESTIC SUPPLY
INDUSTRIES DEMAND
IMPOSITION OF EXPORT DUTY ON ALUMINA
REDUCING IMPORT DUTY ON ALUMINIUM FLUORIDE
INCREASING OF EXPORT DUTY ON BAUXITE
INCREASE IN BASIC CUSTOMS DUTY ON ALUMINIUM PRODUCTS FROM 5% TO 10%
CUSTOMS DUTY ON ALUMINIUM SCRAP AT PAR WITH THE DUTY ON THE METAL PRODUCTS
INCLUSION OF ALUMINIUM INGOTS UNDER INTEREST SUBVENTION SCHEME
OUR ASSESSMENT
GLOBAL ALUMINIUM PRICES TO PLUNGE FURTHER IN 2016
LOW REALISATION WILL STRESS FINANCIALS
GROWTH IN EXPORTS WILL ALSO MODERATE
INDUSTRIES DEMAND & KEY BUDGET PROPOSALS – UNION BUDGET 2016-17
ESTIMATED IMPACT
DATA TABLES
A. DEMAND SUPPLY - INDIA
B. DEMAND SUPPLY – GLOBAL
SUPPLIERS OF ALUMINIUM ALLOY INGOT
SUPPLIERS OF RAW MATERIALS
SUPPLIERS OF ALUMINIUM DROSS
SUPPLIERS OF ALUMINIUM SCRAP
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 PACKING MATERIAL
SUPPLIERS OF PICKLING CHEMICALS
SUPPLIERS OF PLANT AND MACHINERY
SUPPLIERS OF CRUCIBLE FURNACE
SUPPLIERS OF INGOT CASTING MACHINE
SUPPLIERS OF SILICON CARBIDE CRUCIBLE
SUPPLIERS OF ALUMINIUM RECYCLING PLANT
SUPPLIERS OF SHEREDDER
SUPPLIERS OF DE-COATER
SUPPLIERS OF MAGENETIC SEPARATOR
SUPPLIERS OF CASTING LADDLE
SUPPLIERS OF SPECROMETER
SUPPLIERS OF POROSITY TESTING MACHINE
SUPPLIERS OF EOT CRANE
SUPPLIERS OF DG SETS
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 NDT INSPECTION EQUIPMENT
SUPPLIERS OF FIRE FIGHTING EQUIPMENTS
SUPPLIERS OF ELECTRICAL MEASURING INSTRUMENTS
SUPPLIERS OF 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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