Aluminium Recycling Plant. Production of Aluminium Ingots From Aluminium Scrap.-123979
Aluminium Recycling Plant. Production of Aluminium Ingots From Aluminium Scrap.-123979
Aluminium Recycling Plant. Production of Aluminium Ingots From Aluminium Scrap.-123979
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Introduction
Aluminium recycling is the process by which scrap aluminium
can be reused in products after its initial production. The
process involves simply re-melting the metal, which is far less
expensive and energy intensive than creating new aluminium
through the electrolysis of aluminium oxide (Al2O3), which
must first be mined from bauxite ore and then refined using
the Bayer process. Recycling scrap aluminium requires only
5% of the energy used to make new aluminium. For this
reason, approximately 31% of all aluminium produced in the
United States comes from recycled scrap.
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Aluminium recycling is economically beneficial to both the
aluminium and recycling industry. The capital cost for the
production of recycled aluminium is already recognized to be far
lower than making new aluminium. The financial benefit has also
spurred the development of the recycling program.
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Aluminium Ingot
Ingot and billet play an integral part in the production of many
aluminium products. Plate, sheet, foil, wire, rod, and bar
products are all produced by pressing or rolling ingot and billet.
Ingot and billet are cast from molten aluminium. In the cast
house, crucibles of molten aluminium empty their silvery liquid
either directly into molds or into a holding furnace where the
metal is kept molten at temperatures between 1,200 and 1,500
degrees Fahrenheit. Alloying elements are then added.
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The process of casting aluminum ingots takes place through
the fusion and refining of aluminum scrap previously retrained
through the use of specific technological installations. The
process that allows to obtain aluminum ingots from aluminum
scrap is called smelting process.
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Aluminium Ingots are produced through the smelting process.
Various grades of ingots are produced which are used for
production of castings in Auto Industry as well as electrical
applications. Ingots of various dimensions with maximum
purity of 99.7%. Ingots are the material that is cast into a
shape suitable for further processing. Ingots usually require a
second procedure of shaping, such as cold/hot working,
cutting, or milling to produce a useful final product. Aluminium
Ingots are re-melted and further processed into a large number
of products for various downstream applications.
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Aluminum ingots can be used in different sectors, including
automotive, household appliances, lighting, construction,
mechanics and household goods. The ingots are sent to other
process or flattened into thin sheets, which are then used to
make new cans. Aluminum is becoming a favourite with
architects and builders opening up a potential for increasing
use of metal in the construction industry. Likewise, the use of
the metal is increasing in the auto sector.
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Aluminium plays a major role in the modern world through its
innumerable applications, because of its intrinsic and versatile
properties of lightness, strength to weight ratio, corrosion
resistance, electrical and thermal conductivity, nontoxicity
etc. Secondary Aluminum Production is the process of
recycling aluminum scrap into aluminum that can be used
again—an environmentally sound process that is 92 percent
more energy efficient than primary production. In fact,
aluminium scrap recycling has proven so valuable—both
economically and ecologically—that recovery and recycling has
become its own industry, and a highly successful one.
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The aluminum industry works hard to encourage consumer
recycling by educating the public and advocating for the
expansion of municipal recycling programs. The recycling of
aluminium generally produces significant cost savings over the
production of new aluminium, even when the cost of collection,
separation and recycling are taken into account. Over the long
term, even larger national savings are made when the reduction
in the capital costs associated with landfills, mines, and
international shipping of raw aluminium are considered.
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The Indian Aluminium industry’s enthusiasm to grow smelting
capacity on an ambitious scale here and abroad. Aluminium
industry in India is moving towards overcapacity, since supply
is likely to grow in excess of demand going forward. Demand for
aluminium is estimated to grow at 4 to 6% per annum. The
demand for the metal is expected to pick up as the scenario
improves for user industries like power, infrastructure and
transportation, which are all on the move. From around 1.6 mn
tonne of demand in 2013-14, the demand by end 2019-20 is
expected to touch a near 2.4 mn tonne, and is projected at
close to 3.4 mn tonne by 2024-25.
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Cost Estimation
Capacity: 25 MT/Day
Plant and Machinery: 200 Lakhs
Working Capital: 1500 Lakhs
Rate of Return (ROR): 58%
Break Even Point (BEP): 30%
Cost of Project: 1800 Lakhs
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Machinery/ Equipment Photographs
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INGOT CASTING ROTARY CONVEYOR
FUEL STORAGES
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Major Queries/Questions Answered in the Report?
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5. What is the structure of the Aluminium Ingots
Manufacturing Business and who are the
key/major players ?
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9. Who are the Suppliers and Manufacturers of Plant
& Machinery for setting up Aluminium Ingots
Manufacturing plant ?
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13. What is the total size of land required for setting up
Aluminium Ingots Manufacturing plant ?
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18. What are the Personnel (Manpower)
Requirements for setting up Aluminium Ingots
Manufacturing Business?
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23. What are the Profitability Ratios of Aluminium
Ingots Manufacturing Project?
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27. What are the Market Opportunities for setting
up Aluminium Ingots Manufacturing plant?
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Table of Contents
of the
Project Report
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1. PROJECT LOCATION
2. INTRODUCTION
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4. PROPERTIES OF ALUMINIUM
5. B.I.S. SPECTIFICATIONS
6. MARKET SURVEY
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7.6.4. Location of Plant
7.6.5. Capital Expenditure Projects
7.6.6. Name of Raw Material(S) Consumed With Quantity & Cost
7.7. Section – II
7.7.1. Assets
7.7.2. Cash Flow
7.7.3. Cost as % Ge of Sales
7.7.4. Forex Transaction
7.7.5. Growth in Assets & Liabilities
7.7.6. Growth in Income & Expenditure
7.7.7. Income & Expenditure
7.7.8. Liabilities
7.7.9. Liquidity Ratios
7.7.10. Profitability Ratio
7.7.11. Profits
7.7.12. Return Ratios
7.7.13. Structure of Assets & Liabilities (%)
7.7.14. Working Capital & Turnover Ratios
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8.1. Export Statistics Data on Aluminium Ingot
8.2. Import Statistics Data on Aluminium Ingot
9. PRESENT MANUFACTURERS
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Project Financials
• Project at a Glance Annexure
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• Plant & Machinery……………………………………………..……..5
Indigenous Machineries
Other Machineries (Miscellaneous, Laboratory etc.)
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• Overheads Required Per Month and Per Annum………….…….…8
Utilities & Overheads (Power, Water and Fuel Expenses etc.)
Royalty and Other Charges
Selling and Distribution Expenses
• Share Capital…………………………………………………….....11
Equity Capital
Preference Share Capital
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• Annexure 1 :: Cost of Project and Means of Finance
Revenue/Income/Realisation
Expenses/Cost of Products/Services/Items
Gross Profit
Financial Charges
Total Cost of Sales
Net Profit After Taxes
Net Cash Accruals
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• Annexure 3 :: Assessment of Working Capital requirements
Current Assets
Gross Working Capital
Current Liabilities
Net Working Capital
Working Note for Calculation of Work-in-process
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• Annexure 5 :: Projected Balance Sheets
D.S.C.R
Earnings Per Share (EPS)
Debt Equity Ratio
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• Annexure 7 :: Break-Even Analysis
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• Annexure 8 to 11 :: Sensitivity Analysis-Price/Volume
Resultant N.P.B.T
Resultant D.S.C.R
Resultant PV Ratio
Resultant DER
Resultant ROI
Resultant BEP
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• Annexure 12 :: Shareholding Pattern and Stake Status
Equity Capital
Preference Share Capital
• Annexure 13 :: Quantitative Details-Output/Sales/Stocks
Determined Capacity P.A of Products/Services
Achievable Efficiency/Yield % of Products/Services/Items
Net Usable Load/Capacity of Products/Services/Items
Expected Sales/ Revenue/ Income of Products/ Services/
Items
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• Annexure 14 :: Product wise Domestic Sales
Realisation
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• Annexure 21 :: Employees Expenses
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• Annexure 29 :: Depreciation Charges – as per Books (Total)
• Annexure 30 :: Depreciation Charges – as per Books (P &
M)
• Annexure 31 :: Depreciation Charges - as per IT Act WDV
(Total)
• Annexure 32 :: Depreciation Charges - as per IT Act WDV
(P & M)
• Annexure 33 :: Interest and Repayment - Term Loans
• Annexure 34 :: Tax on Profits
• Annexure 35 :: Projected Pay-Back Period and IRR
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• Good Present/Future Demand
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• Project Costs and Payback Period
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