Detailed Project Report (DPR) on ALUMINIUM PIPE (SEAMLESS EXTRUDED)

ALUMINIUM PIPE (SEAMLESS EXTRUDED) 

EIRI/EDPR 4806 3027 JC XL

INTRODUCTION

ABOUT ALUMINUM

Aluminum is the most abundant mineral in the earth's crust, although it does not typically appear in its pure form in nature. Aluminum is derived from bauxite, a mineral mined in several parts of the world, and it was not until 1888 that an economically feasible process was developed for the commercial production of aluminum.

The mined bauxite is crushed and sprayed with water. Clay and silica are removed as by-products and the remaining bauxite is kiln-dried, mixed with soda ash and lime. The resulting mixture undergoes a number of processing steps before being heated in a calcinating kiln. The resultant material is alumina, a powdery chemical combination of oxygen and aluminum.

To yield the aluminum that provides the raw material for the extrusion process, alumina must go first through a smelting and then through an alloying process, during which minor quantities of alloying elements like copper, magnesium, silicon and manganese are added to create specific material properties.

Aluminium extrusion refers to a process that transforms aluminium alloy into objects for many uses with a definitive cross-sectional profile. This technique involves heating aluminium billets and forcing them through a die to create various shapes, such as rods, bars, and tubes. The versatility as well as durability of aluminium make it an ideal material for extrusion, contributing significantly to industries like construction, automotive, aerospace, and consumer goods. One of the primary advantages of aluminium extrusion is its ability to create complex cross-sections that are both strong and lightweight, which are essential qualities in modern engineering and design. Additionally, extruded aluminium products are suitable for both functional and aesthetic applications.

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.

Factors Affecting Extrusion

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                                    100MT/Day 

Land & Building (12000 sq.mt.)  Rs. 10.10  Cr    

Plant & Machinery                            Rs. 15.55  Cr 

Working Capital for 2 Month            Rs. 133.24 Cr 

Total Capital Investment                   Rs. 159.57 Cr 

Rate of Return                                  32%

Break Even Point                              33%

CONTENTS

INTRODUCTION

ABOUT ALUMINUM

ALUMINUM EXTRUSION FEATURES & BENEFITS

TYPES OF EXTRUDED PROFILES

CLASSIFICATION OF ALUMINIUM EXTRUSION

PROPERTIES

PROPERTIES OF ALUMINIUM

USES AND APPLICATION

APPLICATION

B.I.S. SPECIFICATION

MATERIAL COMPARISONS:

TYPICAL TOOLING COST CHART

TYPICAL TOOLING LEAD TIMES CHART

ALUMINUM EXTRUSION VS ROLL FORMED STEEL, COPPER EXTRUSIONS

ALUMINUM EXTRUSION VS MOLDED PLASTIC, WOOD, VINYL

MANUFACTURING PROCESS

FOR ALUMINIUM BILLET

PROCESS FLOW CHART

FOR ALUMINIUM EXTRUSION

FOR ALUMINIUM BILLET

METHODS OF SORTING

TEMPERATURE CONTROL

(4) DEGASSING (MELT TREATMENT)

(5) INGOT CASTING

(6) QUALITY CONTROL

(5) EMISSIONS AND CONTROLS

(A) SCRAP PRETREATMENT EMISSIONS

(B) SMELTING/REFINING EMISSIONS

(6) SHIPMENT

ENVIRONMENT MANAGEMENT

AIR ENVIRONMENT

WATER ENVIRONMENT

SOLID WASTE MANAGEMENT

NOISE ENVIRONMENT

ENVIRONMENTAL MONITORING PROGRAM

(8) QUALITY CONTROL

PLANT AND MACHINERY FOR ENVIRONMENT MANAGEMENT

CONTROL TECNIQUES FOR AIR POLLUTION

(1) GRAVITATIONAL SETLING CHAMBER

(2) CYCLONE SEPARATORS

(3) FABRIC FILTERS

(4) ELECTRO STATIC PRECIPITATORS

E. WET COLLECTORS OR SCRUBBERS

(5) WET SCRUBBERS

CONTROL OF WATER POLLUTION

FOR ALUMINIUM EXTRUSION

DESCRIPTION OF PROCESS

DESCRIPTION OF EXTRUSION PRESS

INSPECTION & TESTING

MARKET POSITION

PRINCIPLES OF PLANT LAYOUT

PLANT LOCATION FACTORS

EXPLANATION OF TERMS USED IN THE PROJECT REPORT

UTILITIES

INDIAN MANUFACTURING INDUSTRY

INTRODUCTION

MARKET SIZE

INVESTMENT

GOVERNMENT INITIATIVES

ROAD AHEAD

ALUMINIUM EXTRUSION MACHINERY MANUFACTURER

SEAMLESS PIPE MANUFACTURERS

SUPPLIERS OF RAW MATERIALS

SUPPLIERS OF ALUMINIUM BILLET

SUPPLIERS OF PICKLING CHEMICALS

SUPPLIERS OF SILICON POWDER

SUPPLIERS OF IRON POWDER

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 MATERIAL HANDLING EQUIPMENTS

SUPPLIERS OF NDT INSPECTION EQUIPMENT

SUPPLIERS OF ELECTRICAL MEASURING INSTRUMENTS

FIREFIGHTING EQUIPMENTS MANUFACTURERS & SUPPLIERS

WEIGHING BREIDGE MANUFACTURER

LABORATORTY EQUIPMENTS MANUFACTURERS

ELECRICAL GOOD & SWITCH MANUFACTURE

SWOT ANALYSIS

ORGANIZATION CHART

PLANT LATOUT

IMPLEMENTATION SCHEDULE

ADDRESSES OF RELEVANT GOVERNMENT OFFICES

ADDRESSES OF FINANCIAL INSTITUTIONS

KEY REGULATIONS AND POLICIES

INDUSTRY SPECIFIC REGULATIONS

ENVIRONMENT LAWS AND REGULATIONS

INDUSTRIAL, EMPLOYMENT AND LABOUR LAWS

INTELLECTUAL PROPERTY LAWS

FOREIGN TRADE REGULATIONS

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)