Detailed Project Report on aluminium notch bar/cubes/shots manufacturing unit from scrap cap:20 tpd

ALUMINIUM NOTCH BAR/CUBES/SHOTS MANUFACTURING UNIT FROM SCRAP CAP: 20 TPD
[CODE NO.3369]

Aluminum recycling is the process through which scrap aluminum is reprocessed to be used in products after its initial production. Aluminum producers and recyclers in the aluminum industry work with individuals, businesses, and communities to enable both curbside and industrial recycling programs. For most aluminum products, the metal is not consumed during the products lifetime, but it is simply used making it easy to recycle without losing its intrinsic properties. Used beverage container (UBC) recycling is the most recognized of the aluminum recycling programs. However, end of life recycling of certain products like building parts and cars allows for the production of recycled materials like Aluminium knotch bar, shots and cubes.

Advantages of Aluminum Recycling

Aluminum recycling is a common practice that has been around since the early 1900s. It is a very important process because of the numerous advantages as can be seen below:


1. Saves Energy

Used beverage containers are among the largest components of aluminum scrap. Most of the scrap metal is recycled back into cans. The other largest user of the recycled aluminum is the automotive industry. According to the Aluminum Association President, Mr. Steve Larkin, recycling of old aluminum cans into new ones requires less energy (95%) than producing new ones from the scratch. He states that the recycling process also produces 95% reduced greenhouse gas emissions than entirely making new cans.

2. Prevents Depletion of a Valuable Commodity

Aluminum is a metal that is mined from the earth’s crust as Bauxite ore. This therefore means that, recycling prevents continuous mining and depletion of this valuable commodity. Each year, recycling prevents approximately five percent of the total Bauxite ore mining in the world.


3. Reduction of the Carbon Footprint

Increased environmental awareness and the need for social responsibility have led to the increased aluminum recycling among many countries and companies today. Did you know that recycling aluminum helps in preventing more than approximately 90,000,000 tons of toxic carbon dioxide from being let free into the air every year? Yes, recycling a single drink can made of aluminum prevents carbon dioxide emission that equals a single mile car ride and it saves adequate energy to power a typical television set for about two to three hours. Today, every country has the responsibility to do whatever it can to reduce carbon emission. This means that if all countries focus on the reduction of carbon dioxide emissions there will be little concern about global warming.


4. Helps in Satisfying the Increasing Demand

As the population increases so does the need for aluminum products. Today, aluminum has more uses and applications other metals. This means that there should be a continuous production of this metal so as to meet the increasing demand. Mining alone is not sufficient enough to meet this demand. Recycling therefore comes in to bridge the gap. In fact half of the aluminum cans are recycled. Manufacturers today use approximately 35 percent of the recycled aluminum and approximately 65 percent of the natural aluminum to meet up their manufacturing needs. Therefore, it is necessary to recycle aluminum.


COST ESTIMATION

Plant  Capacity                                           :    20.00 MT./day                                                    
land & Building (8000 sq.Mt)                   :    Rs. 7.68  Cr
Plant & Machinery                                      :    Rs. 1.40  Cr
Working Capital for 2 Months                  :    Rs. 11.54 Cr
Total Capital Investment                           :    Rs. 20.90 Cr
Rate of Return                                             :    28%
Break Even Point                                         :    49%

INTRODUCTION    
ADVANTAGES OF ALUMINUM RECYCLING    
1. SAVES ENERGY    
2. PREVENTS DEPLETION OF A VALUABLE COMMODITY    
3. REDUCTION OF THE CARBON FOOTPRINT    
4. HELPS IN SATISFYING THE INCREASING DEMAND    
5. IT NEVER WEARS OUT    
6. REDUCTION OF LANDFILL    
(A) ALUMINIUM SHOTS    
GRADES    
CHEMICAL PROPERTIES:    
SIZES AND SHAPES    
PROPERTIES    
(B) NOTCH BAR    
CHEMICAL PROPERTIES:    
SIZES AND SHAPES    
(C) ALUMINIUM CUBES    
USES AND APPLICATION    
B.I.S. SPECIFICATION    
OTHER OUTPUTS OF ALUMINIUM WHICH COULD PRODUCE IN FUTURE
   (SOME PRODUCT WHICH HAS HIGH VALUE ADDDITION BEYOND INGOT
    STAGE)    
OTHER OUT PUTS    
CLEARANCE CERTIFICATES FOR ALUMINIUM PLANT    
(1) DISCOM-DEPARTMENT OF ENERGY    
(2) CHIEF ELECTRICAL INSPECTORATE- DEPARTMENT OF ENERGY    
(3) DEPARTMENT OF MUNICIPAL ADMINISTRATION & URBAN
     DEPARTMENT (MAUD)    
(4) IRRIGATION & CAD DEPARTMENT    
(4) GROUND WATER DEPARTMENT    
(5) DIRECTORATE OF FACTORIES-DEPARTMENT OF LABOUR
      EMPLOYMENT TRAINING    
(6) DIRECTORATE OF FIRE SERVICES-DEPARTMENT OF HOME    
(7) COMMERCIAL TAX- DEPARTMENT OF REVENUE    
(8) STATE POLLUTION CONTROL BOARD (SPPCB)    
(9) LAND ADMINISTRATION- DEPARTMENT OF REVENUE    
TOP FIVE ALUMINIUM SCRAP EXPORTING    
COUNTRIES IN THE WORLD    
UNITED STATES    
GERMANY    
UK    
FRANCE    
SAUDI ARABIA    
MARKET POSITION    
EXPORT DATA OF ALUMINIUM CUBES    
IMPORT DATA OF ALUMINIUM CUBES    
EXPORT DATA OF ALUMINIUM SHOTS    
IMPORT DATA OF ALUMINIUM SHOTS    
MANUFACTURERS/SUPPLIERS FOR ALUMINIUM    
NOTCH BAR, SHOTS AND CUBES    
PROCESS FLOW CHART    
MANUFACTURING PROCESS    
GENERAL    
1. PROCUREMENT OF RAW MATERIAL    
TYPES OF ALUMINIUM SCRAP    
(A) LOW VOLATILE SCRAP    
(B) MEDIUM VOLATILE SCRAP    
(B) HIGH VOLATILE SCRAP    
2. PREPARATION OF SCRAP    
(A) SIZING    
(I) CROPPING    
(II) FRAGMENTATION    
(III) BALE BREAKING    
(IV) SHREDDING    
(I) HAMMER MILLS    
(II) SHEAR    
(B) GRADING + SEPARATION    
(I) GRADING    
(II) SEPARATION    
(C) CLEANING    
(I) MECHANICAL CLEANING –    
(II) PYROMETALLURGICAL CLEANING –    
(III) HYDROMETALLURGICAL CLEANING –    
(D) DE-COATING    
(E) MELTING AND REFINING    
CHARGING, MELTING AND FLUXING    
CHARGING CONSISTS OF PLACING PRETREATED    
REFINING    
DEMAGGING    
DEGASSING    
ALLOYING    
SKIMMING    
(F) CASTING    
(G) GRADING AND TESTING    
(H) QUALITY CONTROL AND STANDARDS    
PLANT LAYOUT    
SUPPLIERS OF RAW MATERIALS    
ALUMINIUM SCRAP    
SILICON POWDER    
IRON POWDER    
COPPER POWDER    
MAGNESIUM POWDER    
NICKEL POWDER    
ZINC POWDER    
LEAD POWDER    
TIN POWDER    
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    
ETP PLANTS    
AIR POLLUTION CONTROL EQUIPMENTS    
AIR CONDITIONING EQUIPMENTS    
AIR COMPRESSORS    
PLATEFARM WEIGHING MACHINE    
MATERIAL HANDLING EQUIPMENTS    
NDT INSPECTION EQUIPMENT    
FIRE FIGHTING EQUIPMENTS    
ELECTRICAL MEASURING INSTRUMENTS    
SUBMERSIBLE WATER PUMP    

APPENDIX – A:

 1.      COST OF PLANT ECONOMICS      
 2.      LAND & BUILDING                                      
 3.      PLANT AND MACHINERY                                  
 4.      FIXED CAPITAL INVESTMENT                             
 5.      RAW MATERIAL                                         
 6.      SALARY AND WAGES                                     
 7.      UTILITIES AND OVERHEADS                              
 8.      TOTAL WORKING CAPITAL                                
 9.      COST OF PRODUCTION                                   
10.      PROFITABILITY ANALYSIS                               
11.      BREAK EVEN POINT                                     
12.      RESOURCES OF FINANCE                           
13.      INTEREST CHART                                       
14.      DEPRECIATION CHART                                   
15.      CASH FLOW STATEMENT                                   
16.      PROJECTED BALANCE SHEET