Detailed Project Report on aluminium ingot from aluminium scrap

ALUMINIUM INGOT FROM ALUMINIUM SCRAP [3585]

Ingots are very large casting products, greater in size and shape than blooms, billets and slabs. Ingot generally has rectangular/square cross section, but it is not necessary that it should be uniform throughout its length. (Ingot may have variable cross section.). Aluminium Alloy Ingots Iike LM-2, LM-4, LM-6 which are commonly used in Gravity and Sand Casting, Pressure Die Casting Alloys like LM-13, LM-14, LM-24, ADC-12, ALSI-132 etc are also being manufactured as per the Indian and International standards.

COST ESTIMATION

Plant Capacity                           20 MT/Day  
Land & Building (10000 sq.mt)     Rs. 10.70 Cr
Plant & Machinery                    Rs. 2.93 Cr
Working Capital for 2 Months   Rs. 11.43 Cr
Total Capital Investment          Rs. 25.50 Cr
Rate of Return                         54%
Break Even Point                     36%



INTRODUCTION    
GRADES OF AL INGOT    
TECHNICAL SPECIFICATION OF ALUMINIUM ALLOY INGOT    
ALUMINIUM ALLOY INGOT CHEMICAL COMPOSITION    
USES AND APPLICATION    
FIELDS OF APPLICATION:    
B.I.S. SPECIFICATION    
PROCESS FLOW CHART    
MANUFACTURING PROCESS    
(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    
MARKET POSITION    
PROCESS OF MANUFACTURING ALUMINIUM    
BAUXITE    
ALUMINA    
ALUMINIUM    
FINANCIALS OF THE ALUMINIUM INDUSTRY    
CONCLUSION/OUTLOOK    
PLANT LAYOUT    
MANUFACTURERS/SUPPLIERS OF ALUMINIUM ALLOY INGOT    
SUPPLIERS OF RAW MATERIALS    
SUPPLIERS OF ALUMINIUM SCRAP    
SILICON POWDER    
IRON POWDER    
COPPER POWDER    
MAGNESIUM POWDER    
NICKEL POWDER    
ZINC POWDER    
LEAD POWDER    
TIN POWDER    
PACKING MATERIALS    
PICKLING CHEMICALS    
SUPPLIERS OF PLANT AND MACHINERIES    
CRUCIBLE FURNACE    
INGOT CASTING MACHINE    
SILICON CARBIDE CRUCIBLE    
SHEREDDER    
DE-COATER    
MAGENETIC SEPARATOR    
CASTING LADDLE    
SPECROMETER    
POROSITY TESTING MACHINE    
EOT CRANE    
DG SETS    
POWER TRANSFORMERS    
COOLING TOWER    
EFFULENT TREATMENT PLANT (ETP PLANT)    
AIR POLLUTION CONTROL EQUIPMENTS    
AIR CONDITIONING EQUIPMENTS    
AIR COMPRESSORS    
PLATFORM WEIGHING MACHINE    
MATERIAL HANDLING EQUIPMENTS    
NDT INSPECTION EQUIPMENT    
FIRE FIGHTING EQUIPMENTS    
ELECTRICAL MEASURING INSTRUMENTS    
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)