Detailed Project Report on ALUMINIUM EXTRUSION PLANT (10 TPD)

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.

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ENGINEERS INDIA RESEARCH INSTITUTE
4/54, Roop Nagar, Delhi-110007 (India)
Phone: [phone]
E-mail: [email protected]
Website: www.eiriindia.org



ALUMINIUM EXTRUSION PLANT (10 TPD)
[EIRI/EDPR/4745] J.C.: 2965XL

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.

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CONTENTS

INTRODUCTION

ABOUT ALUMINUM

FACTORS AFFECTING EXTRUSION

ADVANTAGES OF THE EXTRUSION PROCESS:

THERE ARE SEVERAL ADVANTAGES OF THE MODERN EXTRUSION PROCESS

ALUMINUM EXTRUSION FEATURES & BENEFITS

LIGHTWEIGHT

STRONG

HIGH IN STRENGTH -TO-WEIGHT MATERIAL

RESILIENT

CORROSION RESISTANT

EXCELLENT THERMAL CONDUCTOR

NON-SPARKING

EXCELLENT ELECTRICAL CONDUCTOR

NON-MAGNETIC

NONCOMBUSTIBLE & NONTOXIC

REFLECTIVE

SEAMLESS

EASILY TAILORED

QUICK-TO -MARKET

EASY TO FABRICATE & ASSEMBLE

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SUSTAINABLE

TYPES OF EXTRUDED PROFILES

CLASSIFICATION OF ALUMINIUM EXTRUSION

(A) DIRECT (FORWARD) EXTRUSION

(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

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USES

APPLICATION

B.I.S. SPECIFICATION

MATERIAL COMPARISONS:

TYPICAL TOOLING COST CHART

TYPICAL TOOLING LEAD TIMES CHART

ALUMINUM EXTRUSION VS ROLL FORMED STEEL, COPPER EXTRUSIONS

ALUMINUM EXTRUSION VS MOLDED PLASTIC, WOOD, VINYL

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

PROCESS FLOW CHART

FOR ALUMINIUM EXTRUSION

FOR ALUMINIUM BILLET

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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 SOLUT IONS

(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

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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

ENVIRONMENT MANAGEMENT

AIR ENVIRONMENT

WATER ENVIRONMENT

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 MANAGEMENT

CONTROL TECNIQUES FOR AIR POLLUTION

(1) GRAVITATIONAL SETLING CHAMBER

ADVANTAGES:

DISADVANTAGES:

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(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

ALUMINIUM EXTRUSION PROCESSING

THE STEPS IN THE EXTRUSION PROCESS ARE AS FOLLOWS:

ILLUSTRATION OF THE FLOW OF ALUMINUM AS IT PASSES THROUGH THE
DIE.

DESCRIPTION OF PROCESS

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(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

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TENSILE TEST

WELDABILITY CHECK

WORKABILITY CHECK

CORROSION RESISTANCE

FLAMMABILITY TESTING

HARDNESS TEST

WEATHERING RESISTANCE TESTING

ABRASION RESISTANCE

CHEMICAL RESISTANCE

DESCRIPTION OF EXTRUSION PRESS

HOLLOW DIE TOOL STACK

MARKET POSITION

ALUMINIUM EXTRUSIONS - THE PROS AND CONS

PRINCIPLES OF PLANT LAYOUT

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:

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SPECIFIC FACTORS

6. TRANSPORTATION:

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. TERM LOANS:

8. TOTAL LOAD:

9. LAND AREA/MAN POWER RATIO:

UTILITIES

POWER

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WORKING

TOTAL MANPOWER AND PAYROLL

INDIAN MANUFACTURING INDUSTRY

INTRODUCTION

MARKET SIZE

INVESTMENT

GOVERNMENT INITIATIVES

ROAD AHEAD

ALUMINIUM EXTRUSION MACHINERY MANUFACTURER

SUPPLIERS OF ALUMINIUM PROFILE

SUPPLIERS OF RAW MATERIALS

SUPPLIERS OF ALUMINIUM BILLET

SUPPLIERS OF PICKLING CHEMICALS

SUPPLIERS OF SILICON POWDER

SUPPLIERS OF IRON 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

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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 ELECTRICAL MEASURING INSTRUMENTS

FIREFIGHTING EQUIPMENTS MANUFACTURERS & SUPPLIERS

WEIGHING BREIDGE MANUFACTURER

LABORATORTY EQUIPMENTS MANUFACTURERS

D.G. SET MANUFACTURERS & SUPPLIERS

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ELECRICAL GOOD & SWITCH MANUFACTURE

SWOT ANALYSIS

STRENGTHS

WEAKNESSES

OPPORTUNITIES

THREATS

ORGANIZATION CHART

PLANT LAYOUT

IMPLEMENTATION SCHEDULE

ADDRESSES OF RELEVANT GOVERNMENT OFFICES

ADDRESSES OF FINANCIAL INSTITUTIONS

KEY REGULATIONS AND POLICIES

INDUSTRY SPECIFIC REGULATIONS

BUREAU OF INDIAN STANDARDS ACT, 2016(“BIS ACT”)

THE LEGAL METROLOGY ACT, 2009 AND LEGAL METROLOGY (PACKAGED
COMMODITIES) RULES, 2011 (“LM RULES”)

STEEL AND STEEL PRODUCTS (QUALITY CONTROL) ORDER, 2020 (“QC
ORDER”)

ENVIRONMENT LAWS AND REGULATIONS

THE ENVIRONMENT (PROTECTION) ACT, 1986 AND THE ENVIRONMENT
(PROTECTION) RULES, 1986

THE ENVIRONMENTAL IMPACT ASSESSMENT NOTIFICATION, 2006 (“EIA
NOTIFICATION”)

THE WATER (PREVENTION AND CONTROL OF POLLUTION) ACT, 1974 (“WATER
ACT”)

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THE AIR (PREVENTION AND CONTROL OF POLLUTION) ACT, 1981 (“AIR ACT”)

THE HAZARDOUS AND OTHER WASTES (MANAGEMENT AND TRANSBOUNDARY
MOVEMENT) RULES, 2016 (“HAZARDOUS WASTE RULES”)

INDUSTRIAL, EMPLOYMENT AND LABOUR LAWS

THE PUBLIC LIABILITY INSURANCE ACT, 1991 & THE PUBLIC LIABILITY
INSURANCE RULES, 1991

THE FACTORIES ACT, 1948

THE CODE ON WAGES, 2019

THE OCCUPATIONAL SAFETY, HEALTH AND WORKING CONDITIONS CODE,
2020

THE CODE ON SOCIAL SECURITY, 2020

THE INDUSTRIAL RELATIONS CODE, 2020

THE CHILD AND ADOLESCENT LABOUR (PROHIBITION AND REGULATION) ACT,
1986

THE SEXUAL HARASSMENT OF WOMEN AT WORKPLACE (PREVENTION,
PROHIBITION AND REDRESSAL) ACT, 2013

INTELLECTUAL PROPERTY LAWS

THE PATENTS ACT, 1970 (“PATENTS ACT”)

THE TRADE MARKS ACT, 1999 (“TRADE MARKS ACT”)

THE COPYRIGHT ACT, 1957 (“COPYRIGHT ACT”)

THE DESIGNS ACT, 2000 (“DESIGNS ACT”)

FOREIGN TRADE REGULATIONS

FOREIGN EXCHANGE MANAGEMENT ACT, 1999 (“FEMA”)

THE FOREIGN TRADE (DEVELOPMENT AND REGULATION) ACT, 1992 AND
FOREIGN TRADE (REGULATION) RULES, 1993

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LAWS IN RELATION TO TAXATION

INCOME TAX ACT, 1961

GOODS AND SERVICES TAX ACT, 2017

GENERAL LAWS

THE CONSUMER PROTECTION ACT, 2019

THE COMPETITION ACT, 2002

THE COMPANIES ACT, 2013 (“COMPANIES ACT”)

THE INDIAN CONTRACT ACT, 1872

INDIAN STAMP ACT, 1899

THE REGISTRATION ACT, 1908

THE NEGOTIABLE INSTRUMENTS ACT, 1881

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

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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)

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COST ESTIMATION

Plant Capacity 10 MT/Day

Land & Building (8000 sq.mt.) Rs. 9.82 Cr

Plant & Machinery Rs. 10.55 Cr

Working Capital for 2 Months Rs. 13.06 Cr

Total Capital Investment Rs. 34.08 Cr

Rate of Return 20%

Break Even Point 58%