ALUMINIUM NOTCH BAR/CUBES/SHOTS MANUFACTURING UNIT FROM SCRAP CAP: 20 TPD

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.

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