ALUMINIUM EXTRUSION (CAP: 12,000 MT/ANNUM)
[EIRI/EDPR/4615] J.C.: 2832INR, 2832AED
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.
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 36.3637 MT/Day
Land & Building (12,000 sq.mt.) Rs. 9.25 Cr
Plant & Machinery Rs. 28.72 Cr
Working Capital for 2 Months Rs. 26.80 Cr
Total Capital Investment Rs. 65.88 Cr
Rate of Return 46%
Break Even Point 38%
CONTENTS
INTRODUCTION
FACTORS AFFECTING EXTRUSION
ADVANTAGES OF THE EXTRUSION PROCESS:
TYPES OF EXTRUDED PROFILES
CLASSIFICATION OF ALUMINIUM EXTRUSION
(A) DIRECT (FORWARD) EXTRUSION
TRADITIONALLY, THE PROCESS HAS BEEN DESCRIBED AS HAVING THREE DISTINCT REGIONS
(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
PROCESS FLOW CHART
FOR ALUMINIUM BILLET
FOR ALUMINIUM EXTRUSION
MANUFACTURING PROCESS
FOR ALUMINIUM BILLET
(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
SUMMARY FOR ENVIRONMENT MANAGEMENT
AIR ENVIRONMENT
WATER ENVIRONMENT
WATER POLLUTION MANAGEMENT AND WATER CONSERVATION MEASURES
SOLID WASTE MANAGEMENT
NOISE ENVIRONMENT
THE FOLLOWING CONTROL MEASURES WILL BE IMPLEMENTED FOR THE PROPOSED PROJECT:
ENVIRONMENTAL MONITORING PROGRAM
(8) QUALITY CONTROL
PLANT AND MACHINERY FOR ENVIRONMENT ANAGEMENT
CONTROL TECNIQUES FOR AIR POLLUTION
(1) GRAVITATIONAL SETLING CHAMBER
ADVANTAGES:
(2) CYCLONE SEPARATORS
ADVANTAGES:
DISADVANTAGES:
(3) FABRIC FILTERS
ADVANTAGES:
DISADVANTAGES:
(4) ELECTRO STATIC PRECIPITATORS
ADVANTAGES:
DISADVANTAGES:
E. WET COLLECTORS OR SCRUBBERS
(5) WET SCRUBBERS
ADVANTAGES:
DISADVANTAGES:
CONTROL OF WATER POLLUTION
THE TREATMENT OF THIS WASTE WATER IS CARRIED OUT IN THE FOLLOWING THREE STAGES:
THIS IS CALLED SECONDARY TREATMENT OF WATER. IT INVOLVES THE FOLLOWING PROCESSES
FOR ALUMINIUM EXTRUSION
THE STEPS IN THE EXTRUSION PROCESS ARE AS FOLLOWS:
ILLUSTRATION OF THE FLOW OF ALUMINUM AS IT PASSES THROUGH THE DIE
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
SOLID DIE TOOL STACK.
HOLLOW DIE TOOL STACK.
GLOBAL ALUMINIUM CONSUMPTION
ALUMINIUM CONSUMPTION BY REGION
ALUMINIUM SEMI-FINISHED PRODUCTS CONSUMPTION BY REGION 2015 – 2030, MT
ALUMINIUM SEMI-FINISHED PRODUCTS CONSUMPTION GROWTH BY REGION, 2020 VS 2030, MT
ALUMINIUM SEMI-FINISHED PRODUCTS CONSUMPTION IN ASIA. EX CHINA, 2015 – 2030, MT
ALUMINIUM CONSUMPTION BY SECTOR
ALUMINIUM SEMI-FINISHED PRODUCTS CONSUMPTION BY SECTOR 2015 – 2030, MT
ALUMINIUM SEMI-FINISHED PRODUCTS CONSUMPTION GROWTH BY SECTOR, 2020 VS 2030, MT
ALUMINIUM CONSUMPTION IN CHINA
ALUMINIUM SEMI-FINISHED PRODUCTS CONSUMPTION BY SECTOR IN CHINA, 2020 VS 2030, MT
GOING FORWARD, CHINA’S ALUMINIUM CONSUMPTION IS EXPECTED TO GROW BY 12.3 MT, REACHING A TOTAL OF 56.1 MT IN 2030:
ALUMINIUM CONSUMPTION IN ASIA EX. CHINA
ALUMINIUM SEMI-FINISHED PRODUCTS CONSUMPTION BY SECTOR IN ASIA EX. CHINA, 2020 VS 2030, MT
ALUMINIUM CONSUMPTION IN EUROPE
ALUMINIUM SEMI-FINISHED PRODUCTS CONSUMPTION BY SECTOR IN EUROPE, 2020 VS 2030, MT
ALUMINIUM CONSUMPTION IN NORTH AMERICA
ALUMINIUM SEMI-FINISHED PRODUCTS CONSUMPTION BY SECTOR IN NORTH AMERICA, 2020 VS 2030, MT
ALUMINIUM EXTRUSION MARKET IN MEA
ALUMINIUM MARKET IN UAE
GLOBAL ALUMINIUM EXTRUSION MARKET
PLANT LAYOUT
ALUMINIUM EXTRUSION SECTIONS
SUPPLIERS OF ALUMINIUM PROFILE
SUPPLIERS OF RAW MATERIALS
SUPPLIERS OF ALUMINIUM SCRAP
SUPPLIERS OF PICKLING CHEMICALS
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 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 FIRE FIGHTING EQUIPMENTS
SUPPLIERS OF ELECTRICAL MEASURING INSTRUMENTS
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)