ALUMINIUM EXTRUDED PRODUCTS (PROFILE CHANNELS ETC.) (LIGHT/HEAVY)

ALUMINIUM EXTRUDED PRODUCTS (PROFILE CHANNELS ETC.) (LIGHT/HEAVY) 

 [EIRI/EDPR/4787] J.C.: 3007XL

INTRODUCTION

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.

COST ESTIMATION

Plant Capacity                            15MT/Day 

Land & Building (10000 sq.mt.)  Rs. 6.05 Cr    

Plant & Machinery                            Rs. 10.46 Cr 

Working Capital for 2 Month    Rs. 14.58 Cr 

Total Capital Investment               Rs. 31.64 Cr 

Rate of Return                                  69%

Break Even Point                              29%

CONTENTS

INTRODUCTION

FACTORS AFFECTING EXTRUSION

ADVANTAGES OF THE EXTRUSION PROCESS:

ALUMINUM EXTRUSION FEATURES & BENEFITS

INDIRECT ALUMINIUM EXTRUSION PROCESS

FACTOR AFFECTING THE ALUMINIUM EXTRUSION PROCESS

TYPES OF EXTRUDED PROFILES

CLASSIFICATION OF ALUMINIUM EXTRUSION

(A) DIRECT (FORWARD) EXTRUSION

(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

ALUMINUM EXTRUSION VS ROLL FORMED STEEL, COPPER EXTRUSIONS

ALUMINUM EXTRUSION VS MOLDED PLASTIC, WOOD, VINYL

SEQUENCES IN ALUMINIUM PROCESS

MANUFACTURING PROCESS OF ALUMINIUM EXTRUTION

PROCESS IN DETAILS

FOR ALUMINIUM BILLET

(1) SCRAP PRETREATMENT –

METHODS OF PRETREATMENT

(A) COMMINUTION

(B) CLEANING

(I) MECHANICAL CLEANING

(II) PYROMETALLURGICAL CLEANING

(III) HYDROMETALLURGICAL CLEANING

(C) SORTING

PROCESS FLOW CHART

FOR ALUMINIUM EXTRUSION

FOR ALUMINIUM BILLET

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

(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

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

ALUMINIUM EXTRUSION PROCESSING

THE STEPS IN THE EXTRUSION PROCESS ARE AS FOLLOWS:

ILLUSTRATION OF THE FLOW OF ALUMINUM AS IT PASSES 

THROUGH THE IE.

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

MARKET OVERVIEW OF ALUMINIUM EXTRUDED PRODUCTS              

KEY MARKET TRENDS        

SEGMENTAL INSIGHTS        

REGIONAL INSIGHTS         

RECENT DEVELOPMENTS         

KEY MARKET PLAYERS         

MARKET OVERVIEW OF ALUMINIUM  IN INDIA         

KEY PLAYERS         

KEY MARKET SEGMENTATION                 

REGIONAL INSIGHTS        

KEY MARKET DRIVERS        

EMERGING TRENDS IN THE ALUMINIUM SECTOR         

CHALLENGES HINDERING GROWTH

OPPORTUNITIES FOR FUTURE GROWTH

GOVERNMENT INITIATIVES AND GEOPOLITICAL FACTORS

GOVERNMENT INTERVENTIONS

GEOPOLITICAL FACTORS

GLOBAL MARKET POSITION OF ALUMINIUM EXTRUTION

PRINCIPLES OF PLANT LAYOUT

PLANT LOCATION FACTORS

EXPLANATION OF TERMS USED IN THE PROJECT REPORT

1.   DEPRECIATION:

2.   FIXED ASSETS:

3.   WORKING CAPITAL:

4.   BREAK-EVEN POINT:

5.  OTHER FIXED EXPENSES:

9.   LAND AREA/MAN POWER RATIO:

UTILITIES

INDIAN MANUFACTURING INDUSTRY

INTRODUCTION

MARKET SIZE

INVESTMENT

GOVERNMENT INITIATIVES

ALUMINIUM EXTRUSION MACHINERY MANUFACTURER

SUPPLIERS OF ALUMINIUM PROFILE

SUPPLIERS OF RAW MATERIALS

SUPPLIERS OF ALUMINIUM BILLET

SUPPLIERS OF PICKLING CHEMICALS

SUPPLIERS OF SILICON POWDER

SUPPLIERS OF IRON 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 ELECTRICAL MEASURING INSTRUMENTS

FIREFIGHTING EQUIPMENTS MANUFACTURERS & SUPPLIERS

WEIGHING BREIDGE MANUFACTURER

LABORATORTY EQUIPMENTS MANUFACTURERS

D.G. SET MANUFACTURERS & SUPPLIERS

ELECRICAL GOOD & SWITCH MANUFACTURE

SWOT ANALYSIS

STRENGTHS

WEAKNESSES

OPPORTUNITIES

THREATS

ORGANIZATION CHART

IMPLEMENTATION SCHEDULE

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)