Detailed Project Report on aluminium sheet and coil

ALUMINIUM SHEET AND COIL

[CODENO.4229] 

Aluminium is the world’s most abundant metal and is the third most common element, comprising 8% of the earth’s crust. The versatility of aluminium makes it the most widely used metal after steel. Although aluminium compounds have been used for thousands of years, aluminium metal was first produced around 170 years ago. In the 100 years since the first industrial quantities of aluminium were produced, worldwide demand for aluminium has grown to around 29 million tons per year. About 22 million tons is new aluminium and 7 million tons is recycled aluminium scrap. The use of recycled aluminium is economically and environmentally compelling. It takes 14,000 kWh to produce 1 tonne of new aluminium. Conversely it takes only 5% of this to remelt and recycle one tonne of aluminium. There is no difference in quality between virgin and recycled aluminium alloys. Pure aluminium is soft, ductile corrosion resistant and has a high electrical conductivity. It is widely used for foil and conductor cables, but alloying with 

other elements is necessary to provide the higher strengths needed for other applications. Aluminium is one of the lightest engineering metals, having strength to weight ratio superior to steel. By utilising various combinations of its advantageous properties such as strength, lightness, corrosion resistance, recyclability and formability, aluminium is being employed in an ever-increasing number of applications. This array of products ranges from structural materials through to thin packaging foils.

PROPERTIES

The major advantages of using aluminium are tied directly to its’ remarkable properties. Some of these properties are outlined in the following sections.

(1) STRENGTH TO WEIGHT RATIO 

Aluminium has a density around one third that of steel and is used advantageously in applications where high strength and low weight are required. This includes vehicles where low mass results in greater load capacity and reduced fuel consumption.

(2) CORROSION RESISTANCE 

When the surface of aluminium metal is exposed to air, a protective oxide coating forms almost instantaneously. This oxide layer is corrosion resistant and can be further enhanced with surface treatments such as anodising.

(3) ELECTRICAL AND THERMAL CONDUCTIVITY 

Aluminium is an excellent conductor of both heat and electricity. The great advantage of aluminium is that by weight, the conductivity of aluminium is around twice that of copper. This means that aluminium is now the most commonly used material in large power transmission lines. The best alternatives to copper are aluminium alloys in the 1000 or 6000 series. These can be used for all electrical conduction applications including domestic wiring. Weight considerations mean that a large proportion of overhead, high voltage power lines now use aluminium rather than copper. They do however, have a low strength and need to be reinforced with a galvanised or aluminium coated high tensile steel wire in each strand.

(4) LIGHT AND HEAT REFLECTIVITY

Aluminium is a good reflector of both visible light and heat making it an ideal material for light fittings, thermal rescue blankets and architectural insulation.

(5) TOXICITY

Aluminium is not only non-toxic but also does not release any odours or taint products with which it is in contact. This makes aluminium suitable for use in packaging for sensitive products such as food or pharmaceuticals where aluminium foil is used

(6) RECYCLING 

The recyclability of aluminium is unparalleled. When recycled there is no degradation in properties when recycled aluminium is compared to virgin aluminium. Furthermore, recycling of aluminium only requires around 5 percent of the input energy required to produce virgin aluminium metal.

The combination of two remarkable properties of aluminium makes the need to recycle the metal obvious. These first of these factors is that there is no difference between virgin and recycled aluminium. The second factor is that recycled aluminium only uses 5% of the energy required to produce virgin material. Currently around 60% of aluminium metal is recycled at the end of its lifecycle but this percentage can still be vastly improved.

Aluminium is a chemical element in the boron group with symbol Al and atomic number 13. It is a silvery white, soft, ductile metal. Aluminium is the third most abundant element and the most abundant metal in the Earth's crust. It makes up about 8% by weight of the Earth's solid surface.

COST ESTIMATION

Plant Capacity                                  400 MT/Day

Land & Building (18,588 sq.mt.)    Rs. 12.14 Cr

Plant & Machinery                            Rs. 120.43 Cr

Working Capital for 2 Months    Rs. 471.72 Cr

Total Capital Investment                   Rs. 605.71 Cr

Rate of Return                                     60%

Break Even Point                                 28%

• INTRODUCTION
• PROPERTIES
• (1) STRENGTH TO WEIGHT RATIO
• (2) CORROSION RESISTANCE
• (3) ELECTRICAL AND THERMAL CONDUCTIVITY
• (4) LIGHT AND HEAT REFLECTIVITY
• (5) TOXICITY
• (6) RECYCLING
• PHYSICAL PROPERTIES OF ALUMINIUM
• OTHER INFORMATION ABOUT ALUMINIUM
• USES OF ALUMINIUM
• ALUMINIUM SHEETS AND COIL
• PROPERTIES OF ALUMINIUM SHEET METAL
• ITS MOST VALUABLE PROPERTIES INCLUDE:
• SPECIFICATIONS
• USES
• ALUMINUM SHEET ADVANTAGES
• CONTINUOUSLY RECYCLABLE SHEET METAL
• HIGH-PERFORMANCE ARMOR
• ALUMINUM SHEET GAUGE
• THE COLDER THE TEMPERATURE, THE STRONGER THE ALUMINUM
• SPECIFICATION OF COIL
• USES AND APPLICATION
• APPLICATIONS
• PACKAGING INDUSTRY
• HOME APPLIANCES
• BUILDING & CONSTRUCTION INDUSTRY
• B.I.S. SPECIFICATION
• PROCESS FLOW CHART
• MANUFACTURING PROCESS
• ROLLING PROCESS
• MEANING OF ROLLING:
• HOT ROLLING
• COLD ROLLING MILLS
• FOIL MILLS
• DEFECTS IN ROLLED PRODUCTS:
• SOME OF THE COMMON DEFECTS IN ROLLED PRODUCTS ARE GIVEN BELOW:
• (I) EDGE CRACKING:
• (II) FOLDS:
• (III) ALLIGATORING:
• (IV) SCALE FORMATION:
• ROLLING MILL AND EQUIPMENTS
• KEY EQUIPMENTS
• KEY EQUIPMENTS IN SHEET DIVISION
• 1. 4-HI REVERSING ROLLING MILL
• SPECIFICATIONS
• 2. SLITTER MACHINE
• SPECIFICATIONS
• 3. CUT TO LENGTH MACHINE
• SPECIFIVATIONS
• 4. ANNEALING FURNACE (ELECTRICIALLY HEATED)
• SPECIFICATIONS
• MARKET POSITION
• TOP ALUMINIUM PLATE AND SHEET MANUFACTURERS
• ARCONIC
• ALERIS
• CONSTELLIUM
• HULAMIN
• CHALCO
• MARKET GROWTH
• INDUSTRY TRENDS
• PRINCIPLES OF PLANT LAYOUT
• STORAGE LAYOUT:
• EQUIPMENT LAYOUT:
• SAFETY:
• PLANT EXPANSION:
• FLOOR SPACE:
• UTILITIES SERVICING:
• BUILDING:
• MATERIAL-HANDLING EQUIPMENT:
• RAILROADS AND ROADS:
• MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE:
• PLANT LOCATION FACTORS
• PRIMARY FACTORS
• 1. RAW-MATERIAL SUPPLY:
• 2. MARKETS:
• 3. POWER AND FUEL SUPPLY:
• 4. WATER SUPPLY:
• 5. CLIMATE:
• SPECIFIC FACTORS
• 6. TRANSPORTATION:
• A. AVAILABILITY OF VARIOUS SERVICES AND PROJECTED RATES
• 7. WASTE DISPOSAL:
• 8. LABOR:
• 9. REGULATORY LAWS:
• 10. TAXES:
• 11. SITE CHARACTERISTICS:
• 12. COMMUNITY FACTORS:
• 13. VULNERABILITY TO WARTIME ATTACK:
• 14. FLOOD AND FIRE CONTROL:
• EXPLANATION OF TERMS USED IN THE PROJECT REPORT
• 1. DEPRECIATION:
• 2. FIXED ASSETS:
• 3. WORKING CAPITAL:
• 4. BREAK-EVEN POINT:
• 5. OTHER FIXED EXPENSES:
• 6. MARGIN MONEY:
• 7. TOTAL LOAD:
• 8. LAND AREA/MAN POWER RATIO:
• PROJECT IMPLEMENTATION SCHEDULES
• INTRODUCTION
• PROJECT HANDLING
• PROJECT SCHEDULING
• PROJECT CONSTRUCTION SCHEDULE
• TIME SCHEDULE
• PLANT LAYOUT
• SUPPLIERS OF ALUMINIUM SHEET AND COIL
• SUPPLIERS OF ALUMINIUM FOIL FOR FOOD AND PHARMACEUTICALINDUSTRY
• SUPPLIERS OF RAW MATERIALS
• SUPPLIERS OF ALUMINIUM SLAB
• SUPPLIERS OF PICKLING CHEMICALS
• SUPPLIERS OF PLANT AND MACHINERY
• SUPPLIERS OF ALUMINIUM ROLLING MILL
• EUROPEAN SUPPLIERS OF ALUMINIUM SHEET AND COIL MILL
• INDIAN SUPPLIERS FOR ALUMINIUM SHEET AND COIL MILL
• EUROPEIAN SUPPLIERS OF ANNEALING FURNACE
• SUPPLIERS OF ANNEALING FURNACES
• EUROPEAN SUPPLIERS OF AUTOMATIC FLATNESS CONTROL, AUTOMATIC GAUGE CONTROL AND SEPARATOR
• SUPPLIERS OF FOIL PRINTING MACHINE, LAMINATING MACHINE AND EMBOSSING MACHINE
• SUPPLIERS OF METAL TESTING MACHINE
• SUPPLIERS OF PRECISION MEASURING TOOLS
• SUPPLIERS OF NDT INSPECTION EQUIPMENT
• SUPPLIERS OF ELECTRICAL MEASURING INSTRUMENTS
• SUPPLIERS OF MILLING MACHINE
• SUPPLIERS OF CNC LATHE MACHINE
• SUPPLIERS OF BOARING MACHINE
• SUPPLIERS OF POWER HACKSAW
• SUPPLIERS OF GRINDING MACHINE
• SUPPLIERS OF DRILLING, LATHE, TAPING MACHINES
• SUPPLIERS OF DG SETS
• SUPPLIERS OF EOT CRANES
• SUPPLIERS OF POWER TRANSFORMER
• SUPPLIERS OF ELECTRICAL PANEL
• SUPPLIERS OF ELECTRIC MOTOR
• SUPPLIERS OF COOLING TOWER
• SUPPLIERS OF EFFLUENT 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 JIGS AND FIXTURE
• SUPPLIERS OF SUBMERSIBLE WATER PUMP

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)