Detailed Project Report on aluminium recycling

ALUMINIUM RECYCLING

[CODE NO.4113] 

Promoter Details:

Name: Chimaladhari Bhanu Vasisht, 

Father’s Name: Chimaladari Prahlad.

Age: 23 years (DOB: 09/07/1998)

Qualification: B. Tech in Metallurgy and Material Science from Indian Institute of 

Technology Bhubaneswar.

Industrial Experience:

• 2 months vocational training at National Aluminium Company, Angul, Orissa. assigned in SMELTER plant. 

• 2 months paid internship at Birla Copper, Dahej, Gujarat. Designation - research fellow, assigned in Continuous Copper Rod Plant.

• Completed my B. Tech thesis on “Effect of Grain size and Texture on Mechanical Properties of Pure Aluminum”.

• Also completed my academic project on “Hardening and Strengthening of Al-2618 alloy”.

The treatment of Al scrap to produce new Al 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                                            6 MT/Day

Land & Building (4000 sq.mt.)                  Rs. 2.17 Cr

Plant & Machinery                                       Rs. 77  Lac

Working Capital for 2 Months                   Rs. 4.17 Cr

Total Capital Investment                            Rs. 7.86 Cr

Rate of Return                                              49%

Break Even Point                                         40%

• INTRODUCTION
  
• PROMOTER DETAILS
• INDUSTRY AND RECYCLING TREND
• ALUMINIUM PROPERTIES
• ALUMINUM INGOT SPECIFICATION
• USES AND APPLICATION
• APPLICATIONS
• B.I.S. SPECIFICATIONS
• PROCESS FLOW DIAGRAM
• MANUFACTURING PROCESS
• SCRAP PRETREATMENT
• MECHANICAL CLEANING
• PYROMETALLURGICAL CLEANING
• HYDROMETALLURGICAL CLEANING
• MELTING
• MOC -SKELNER FURNACE
• TEMPERATURE CONTROL
• DEGASSING
• POURING
• CLEANING
• EMISSIONS AND CONTROLS
• SCRAP PRETREATMENT EMISSIONS
• SMELTING/REFINING EMISSIONS
• SHIPMENT PROCESS FOR INGOT
• MARKING
• STRAPPING
• PACKING LIST & TEST CERTIFICATE
• LOADING
• LOGISTICS AND WAREHOUSES
• BUNDLING
• MARKET OVERVIEW OF ALUMINIUM RECYCLING INDUSTRY
• GLOBAL ALUMINIUM INDUSTRY STRUCTURE
• INDIAN ALUMINIUM INDUSTRY
• ALUMINIUM RECYCLING ECONOMY
• ALUMINIUM RECYCLING AND ITS SOCIO-ECONOMIC IMPLICATIONS
• RECYCLING ISSUES: LIFETIMES OF METAL PRODUCTS
• ALUMINIUM RECYCLING IN INDIA HAS A GREAT FUTURE.
• GLOBAL ALUMINIUM SCRAP EXPORTERS
• RECOMMENDATIONS ON INDIAN ALUMINIUM RECYCLING
• ALUMINIUM AS A CORE INDUSTRY
• ALUMINIUM AS A STRATEGIC SECTOR
• EXPORT POLICY FOR DOWNSTREAM INDUSTRY
• ZERO WASTE CONCEPT FOR THE INDUSTRY
• QUALITY CONTROL OF RECYCLED ALUMINIUM PRODUCTS
• POLLUTION CONTROL
• IMPORT-EXPORT OF ALUMINIUM PRODUCTS
• ALUMINIUM IMPORTS
• ALUMINIUM EXPORTS
• INDIA-ASEAN FREE TRADE AGREEMENT
• SWOT ANALYSIS
• STRENGTHS
• WEAKNESS
• OPPORTUNITY
• THREATS
• PLANT LAYOUT
• SUPPLIERS OF ALUMINIUM INGOT
• 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 COMPRESSURE
• SUPPLIERS OF PLATFORM WEIGHING MACHINE
• SUPPLIERS OF MATERIAL HANDLING EQUIPMENT
• NDT INSPECTION EQUIPMENT
• SUPPLIERS OF FIRE FIGHTING EQUIPMENT
• SUPPLIERS OF ELECTRICAL MEASURING INSTRUMENTS
• SUPPLIERS OF ALUMINIUM CABLE SCRAP
• EXPORTER OF ALUMINIUM INGOT
• DOMESTIC BUYER
• SUPPLIERS FOR ALUMINIUM NOTCH BAR, SHOTS AND CUBES
• SUPPLIERS OF ALUMINIUM FOIL
• SUPPLIERS OF ALUMINIUM CONDUCTOR
• ALUMINIUM EXTRUSION SECTIONS
• SUPPLIERS OF ALUMINIUM PROFILE
• 1. LIST OF LICENSE REQUIRED FOR ALUMINIUM RECYCLING INDUSTRY
• 2. RELEVANT ACTS/RULES/ NORMS FOR RECYCLING ACTIVITY. SCRAP RECYCLING UNITS ARE TO ADHERE TO BELOW MENTIONED STATUTES AND ANY OTHER RELEVANT GUIDELINES ISSUED BY GOVERNMENT FROM TIME TO TIME:
• 3. SCRAP RECYCLING CENTERS SHOULD PREFERABLY ACCREDIT THEIR CENTERS/ UNITS WITH THE LATEST VERSION OF QUALITY STANDARDS VIZ.
• ALUMINIUM ALLOYS AND ITS CLASSIFICATION
• LIST OF ALUMINUM ALLOYS
• IDENTIFYING ALUMINUM ALLOYS
• WHAT IS THE STRONGEST ALUMINUM ALLOY?
• ALUMINUM ALLOY CLASSIFICATION
• LIST OF PUBLIC SECTOR UNDERTAKING (PSUS) USED ALUMINIUM AS A RAW MATERIALS
• FOR LICENSE AND EXPORT OF ALUMINIUM INGOTS
• BIS SPECIFICATION OF ALUMINIUM INGOTS
• IMPORTER OF ALUMINIUM SCRAP IN INDIA
• BUYER’S OF ALUMINIUM INGOTS

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)