ALUMINIUM INGOT FROM SCRAP (CAP: 15 TONS/DAY)
[EIRI/EDPR/4662] J.C.: 2879XL
INTRODUCTION
The treatment of aluminum scrap to produce new aluminum metal and alloys is an alternative to primary Al production. The chemical composition of the alloys is strictly related to the scrap quality. Therefore, recycled aluminum presents a certain amount of impurities, generally not present in primary alloys, and the alloying elements are more difficult to manage.
Nowadays, this distinction is not completely exhausting. By properly selecting high quality scrap, a purity level close to primary alloys can be achieved in secondary alloys too.
Iron (Fe) plays an important role in distinguishing between primary and secondary Al alloys. This element cannot be easily removed from the molten metal and it forms generally brittle intermetallic compounds that influence the final mechanical properties of the components.
Primary Al alloys present low Fe content and so they are used for applications where the best exploitation of some specific properties is required (mechanical strength, ductility, corrosion resistance, workability, weldability, electrical conductivity); secondary alloys show good castability, which, combined with the natural low volume density of Al alloys, makes them suitable in high-pressure die casting.
COST ESTIMATION
Plant Capacity 15 MT/Day
Land & Building (10,000 sq.ft.) Rented
Plant & Machinery Rs. 1.97 Cr
Working Capital for 1 Month Rs. 6.69 Cr
Total Capital Investment Rs. 8.90 Cr
Rate of Return 43%
Break Even Point 44%
CONTENTS
INTRODUCTION
PROPERTIES
LIGHT WEIGHT
CORROSION RESISTANCE
ELECTRICAL AND THERMAL CONDUCTIVITY
REFLECTIVITY
DUCTILITY
STRENGTH AT LOW TEMPERATURES
IMPERMEABLE AND ODORLESS
NON-MAGNETIC
NON-TOXIC
SOUND AND SHOCK ABSORPTION
NON-SPARKING
RECYCLABILITY
ALUMINUM INGOT SPECIFICATION
USES/APPLICATIONS
APPLICATIONS:
BIS SPECIFICATIONS
MANUFACTURING PROCESS/PROCESS FLOW
SCRAP PRETREATMENT
(A) MECHANICAL CLEANING
(B) PYRO METALLURGICAL CLEANING
(C) HYDROMETALLURGICAL CLEANING
MELTING
MOC-SKELNER FURNACE
TEMPERATURE CONTROL
DEGASSING
POURING
CLEANING
EMISSIONS AND CONTROLS
(A) SCRAP PRETREATMENT EMISSIONS
(B) SMELTING/REFINING EMISSIONS
SHIPMENT
PROCESS FLOW
MARKET OVERVIEW
ALUMINIUM RECYCLING ECONOMY
ALUMINIUM RECYCLING AND ITS SOCIO-ECONOMIC IMPLICATIONS
RECYCLING ISSUES: LIFETIMES OF METAL PRODUCTS
BRIGHT FUTURE OF INDUSTRY
GLOBAL ALUMINIUM SCRAP EXPORTERS
RECOMMENDATIONS ON INDIAN ALUMINIUM RECYCLING
IMPORT-EXPORT OF ALUMINIUM PRODUCTS
ALUMINIUM IMPORTS
ALUMINIUM EXPORTS
SWOT ANALYSIS
STRENGTH
WEAKNESS
OPPORTUNITY
THREAT
PRELIMINARY LAYOUT
PRINCIPLES OF PLANT LAYOUT
MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE:
PLANT LOCATION FACTORS
PRIMARY FACTORS
MARKETS:
POWER AND FUEL SUPPLY:
WATER SUPPLY:
CLIMATE:
SPECIFIC FACTORS
TRANSPORTATION:
WASTE DISPOSAL:
REGULATORY LAWS:
TAXES
A. STATE AND LOCAL TAXES
B. LOW ASSESSMENT OR LIMITED TERM EXEMPTIONS TO ATTRACT INDUSTRY
SITE CHARACTERISTICS:
COMMUNITY FACTORS:
VULNERABILITY TO WARTIME ATTACK:
FLOOD AND FIRE CONTROL:
SUPPLIERS OF ALUMINIUM INGOT
SUPPLIERS OF RAW MATERIALS
SUPPLIERS OF ALUMINIUM CABLE SCRAP
SUPPLIERS OF PLANT & MACHINERY
SUPPLIERS OF SKELNER FURNACE
SUPPLIERS OF INGOT CASTING MACHINE
SUPPLIERS OF SHREDDER
SUPPLIERS OF DE-COATER
SUPPLIERS OF MAGNETIC SEPARATOR
SUPPLIERS OF SPECTROMETER
SUPPLIERS OF POROSITY TESTING MACHINE
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 EQUIPMENTS
SUPPLIERS OF FIRE FIGHTING EQUIPMENTS
SUPPLIERS OF ELECTRICAL MEASURING INSTRUMENTS
ENGINEERING DESIGN CONSIDERATIONS
ETP FACILITY
ETP FLOW DIAGRAM (TYPICAL)
SEWAGE AND WASTE WATER EFFLUENT
STP FLOW DIAGRAM (TYPICAL)
WASTE GENERATION & MANAGEMENT/GREEN BELT
GREEN BELT
WATER (ESTIMATED)
WASTE (ESTIMATED)
FLUE GAS (ESTIMATED)
UTILITIES PER MONTH (ESTIMATED)
HEALTH SAFETY AND ENVIRONMENT
ANTICIPATED ENVIRONMENTAL IMPACTS
CONSTRUCTION PHASE
OPERATION PHASE
MITIGATION MEASURES (PROPOSED)
HSE REQUIREMENT
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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