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)