ALUMINIUM FOIL & SHEET PROJECT REPORT

7/22/2019 ALUMINIUM FOIL & SHEET PROJECT REPORT

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ALUMINIUM FOIL & SHEET [EDPR/0966] (J.C.9601)

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C A U T I O N

This project report has been prepared on the basis of

information available with our Institute and Project Coordinators.The intention here is to provide preliminary information to the

prospective entrepreneur. Prior to making a firm decision forinvestment in the project the entrepreneur must verify the

various feasibility aspects together along with the addressesfor the procurement of plant & machinery and raw materials

independently. The informations supplied in this report is

obtained from the reliable sources but it is not guaranteed, andthe money once paid will not be refunded back in any case. Claims

for incomprehensiveness of the project report will not be

entertained and no legal action in this regard would beentertained in any case (Subject to Rajkot Jurisdiction only).

Any matter relating to our standard points covered in the reportmay be modified with in 5 days time only from the date of

delivery.

INDIAN PROJECT RESEARCH INSTITUTE | Project Coordinator : Mr. Abhishek


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ALUMINIUM INGOTS FROM ALUMINIUM SCRAP[EDPR/0966] (J.C.9601)

C O T E N T S

1. INTRODUCTION 3

2. PROPERTIES OF ALUMINIUM 5

3. USES AND APPLICATIONS 7

4. B.I.S. SPECIFICATIONS 10

5. MARKET SURVEY 11

6. MANUFACTURER/SUPPLIER/EXPORTER

OF ALUMINIUM ALLOY INGOTS 22

7. MANUFACTURING PROCESS 32

8. PROCESS FLOW SHEET 36

9. PRINCIPLES OF PLANT LAYOUT 37

10. PLANT LOCATION FACTORS 42

11. EXPLANATION OF TERMS USED IN THE PROJECT REPORT 45

12. SUPPLIERS OF PLANT & MACHINERIES 47

13. SUPPLIERS OF RAW MATERIALS 68

APPENDIX - A

1. COST OF PLANT ECONOMICS A 1

2. LAND & BUILDING A 23. PLANT AND MACHINERY A 3

4. FIXED CAPITAL INVESTMENT A 5

5. RAW MATERIAL A 6

6. SALARY AND WAGES A 7

7. UTILITIES AND OVERHEADS A 8

8. TOTAL WORKING CAPITAL A 9

9. COST OF PRODUCTION A11

10. PROFITABILITY ANALYSIS A12

11. BREAK EVEN POINT A13

12. RESOURCES OF FINANCE A14


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INTRODUCTION

Aluminium is a metal with high strength-to-weight ratio, better

formability, high ductility, anti-corrosive properties, with thermal

and electrical conductivity. Because of these unique combination of

properties, aluminium(including its alloys) has substantially replaced

a number of traditional materials from their established uses e.g.

steel, copper, lead and zinc among metals and glass. Wood and paper

among non-metals. Aluminium is crucial for expansion of power

availability and electrification programme. It has a significant role

to play in saving energy in transportation sector, thus help reducing

the consumption petroleum products.

ALUMINIUM IN INDIAN ECONOMY:-

Aluminium plays a key role in the progress of industrial development

in India because it serves as basic input for a number of industries

apart from its use as a strafesic metal. Progressing a long way since

early fifties, with a meager production capacity of 5000 TPA it has

reached a level of 362000 tonnes by 1982-83. With the coming on stream

of National Aluminium Company (NALCO) project by 1987-88 asa major

producer in the country, the industry will attain a quantum jump to

the level of 580000 TPA. Thus, there will be a sea change in the

Indian aluminium scene. From a net importer of aluminium, India will

emerge as a country with surplus aluminium for some years to come

until the rising demand overtakes availability once again.

It is however, felt that the growth rate of demand could have been

higher but for the following factors.

a. Restricted indigenous availability of commercial grade aluminiuminhibitting the application of aluminium in place of other

conventinal materials in the transport building engineering and

other sectors.

b. Insufficient R & D efforts for new product application anddevelopment.

c. Inadequate market research and market development to diversifyinto new areas.

Development of high strength alloys good formability, improved

casting and welding techniques have opened up wide areas of

application of aluminium in the machinery and equipment sector.


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Another important area is the utensils, household appliances and

consumer durables. Aluminium due to its conductivity, light weight,

durability and non toxicity constitutes the most fuel efficient and

hence the ideal material for kitchenwares. Widespread usuage of

aluminium utensils is, therefore, necessary in the larger context of

fuel saving. With the development of high strength alloys, and

attractive utensils and for increasing consumption of aluminium in

this sector.

The country is now entering a phase when ensuring adequateavailability of alumina will not be a problem for some years to come.

The emphasis has to shift to developing the new application areas.


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PROPERTIES OF ALUMINIUM

Aluminium is a silvery and crystalline sold metal. It is a light

metal having no melting temperature and can be easily casted aluminium

forms a protective coating of Al2O3 about 50 A which, makes it highly

resistant to ordinary corrosion.

Aluminium is attached by concentrate and dilute solutions of HCl,

hot concentration H2SO4, and prechloric acid, aluminium is pretoxic

and is non-combustible except in powder form.

Pure aluminium is a relatively poor casting mateerial. It'scastings are actually produced from alloys. The casting alloys are

those having properties peculiary suited for casting purposes. For

these alloys two types of properties must be considered, the casing

properties, those characteristics of alloy which determine the ease or

difficulty of producing acceptable castings, and the engineering

properties.

The aluminium-base alloys may in general be characterised as

eutectic systems, containing intermediate compounds or elements as the

excess phase, because of the relatively low solubilities of most of

the alloying elements in aluminium and complexity of the alloys thatare produced, any one aluminium-base alloys may contain several

metallic phases, which sometimes are quite complex in composition.

The principal alloying elements in aluminium-base casting alloys

are copper, silicon, magnesium, zinc, chromium, manganese, tin and

titanium. Improvement in strength and hardness and response to heat

treatment are obtained with proper percentage of copper magnesium,

zinc or certain combination of magnesium and silicon in aluminium

alloys. Excessive percentages of these elements, however, result in

complete lots of ductility and toughness.

The Aluminium metal processed in various forms has been found to

be suitable for a variety of domestic and industrial uses. The reasons

of its usage in wide range of shapes and sizes can be found in

physical and chemical properties of this metal. The most significant

properties of this material:

a)Amenability to thermal and mechanical treatments or malleability,b)Lower specific gravity,c)Good conducting properties-thermal and electrical,


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d)Can be alloyed to obtain desired improvements in strength,

e)Resistant to chemical attacksIt has been possible to process this metal in various forms to

obtain the products with the requisite properties Thus, although the

earlier usage of Aluminium was restricted to pots and pans, Aluminium

is now being used for a variety of uses like in aircraft, electronics,

roofing, packaging, building industry, etc.

ALUMINIUM FOIL:-

The Foil is a continuous web of aluminium metal rolled to thicknessranging from 0.005 mm to a maximum of 0.15 mm. Foil is available in

many forms, Le., hard, soft (annealed), lubricated, non-lubricated

plain, coated, coloured, printed, embossed and laminated to a variety

of paper and synthetic films.

Aluminium foil has significant properties as given below:

a)Good thermal and electrical conductivity,b)Good formability,c)Impermeability and non-absorptivity to water, grease, oil &

light;

d)Odourless and tasteless,e)Good adhesion to a variety of compounds,f)Excellent printability,g)Resistance to oxidation and chemical attacksOwing to these properties, aluminium foil is preferred to other

packaging materials as flexible materials cannot match these

characteristics of aluminium foil.


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USES AND APPLICATIONS

Aluminium is the most widely used non-ferrous metal. Global

production of aluminium in 2005 was 31.9 million tonnes. It exceeded

that of any other metal except iron (837.5 million tonnes). Forecast

for 2012 is 4245 million tons, driven by rising Chinese output.

Aluminium is almost always alloyed, which markedly improves it

mechanical properties, especially when tempered. For example, thecommon aluminium foils and beverage cans are alloys of 92% to 99%

aluminium.

The main alloying agents are copper, zinc, magnesium, manganese,

and silicon (e.g., duralumin) and the levels of these other metals are

in the range of a few percent by weight.

Some of the many uses for aluminium metal are in:

Transportation (automobiles, aircraft, trucks, railway cars,marine vessels, bicycles, etc.) as sheet, tube, castings, etc.

Packaging (cans, foil, etc.) Construction (windows, doors, siding, building wire, etc.) A wide range of household items, from cooking

utensils to baseball bats, watches.

Street lighting poles, sailing ship masts, walking poles, etc. Outer shells of consumer electronics, also cases for equipment

e.g. photographic equipment.

Electrical transmission lines for power distribution MKM steel and Alnico magnets Super purity aluminium (SPA, 99.980% to 99.999% Al), used in

electronics and CDs.

Heat sinks for electronic appliances suchas transistors and CPUs.

Substrate material of metal-core copper clad laminates used inhigh brightness LED lighting.

Powdered aluminium is used in paint, and in pyrotechnics suchas solid rocket fuels.

Aluminium can be reacted with hydrochloric acid or with sodiumhydroxide to prodce hydrogen gas.


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A variety of countries,including France, Italy, Poland, Finland, Romania, Israel, and

the former Yugoslavia, have issued coins struck in aluminium or

aluminium-copper alloys.

Some guitar models sports aluminium diamond plates on the surfaceof the instruments, usually either chrome or black.

The per capita consumption of aluminium in India is about 0.4 Kg as

compared to the average of about 4 Kgs. in the world, about 18 kgs.

Japan and 27 Kgs. of USA. This indicates an ample scope for promotion

of the use of aluminium in the country in the various sectors of our

economy.

The pattern of consumption relects the priorities of a country

consistent with its resources and stage of development. Where as in

India, a developing country, while over 50 % of the consumption is

accounted for by electrical sector reflecting compulsions of building

up the indusirial infra-structure for power generation and

distribution, in USA, containers and packaging is the largest sector

indicating the emphasis for proper packaging of consumer goods. In

Japan, the highest consumption to aluminium is in the building and

construction sector because of the need for light buildings.

The foil is used for packaging of many products, some of which are

given below:

Pharmaceutical tablets

Bulk & unitized packing of

tea and coffee

Prepared meals

Bakery products

Frozen meat, fish

Milk bottle caps

Wine Lube Oil, greases

Powdered milk

Confectionery

Biscuits

Photographic film

Gift wraps

Household wraps

Butter, margarine

Cigarettes


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Product Range

Light Gauge Foil:

7, 8, 9 and 12 micron

Medium Gauge Foil:

15-50 micron

Heavy Guage Foil:

60-200 micron

Tagger Foil/ Container

Foil:

50-100% micron

TRIPLE LAMINATE FOR

PACKAING

Web Stock Foil:

15, 20, 30 and 40 micron

Pharma Foil :

Unrprinted and Printed

(5 colours )

25, 30 and 40 micron

poly laminated foil

FOUR PLY PACKAGING Blister Pack Foil :

Unrprinted and Printed (5

colours )

20 , 25 and 30 micron

Cigarette Foil:

Plain and Coated

HOUSE FOIL Lidding Foil:

Unrprinted and printed

30-38 and 40 microns


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B.I.S. SPECIFICATIONS

IS: 617-1975 Aluminium and aluminium alloy ingots castings for gerierd

engineering purposes (IIIrd revision with mould metals).

IS: 20-1977 Cast aluminium alloys for manufacture of utensils (IIIrd

revision).

IS: 2066-1962 - Coading and classification for non ferrous scrap metal

& residues. Section I of this standard deals with non ferrous scrap

metal e.g. aluminium brass bronze copper lead tin nickle & zinc

section - II deals with metallurgical residues e.g. slags, skimming

drosses etc. An appendix specifies conditions of slags.

IS: 8970-1991 - Aluminium foil laminates for packaging (first

revision)

IS 7161:1973 - Vegetable parchment orgrease proof paper :

Aluminium foil laminate for wrapping butter

IS 10257:1982 - Aluminium foil stock

Above Specifications may be obtained from

Bureau of Indian Standards,

9, B.S. Zafar Marg,

New Delhi - 110 002.

NOTE :- The use of the ISI Certification Mark is governed by the

provisions of the Indian Standards Institution (Certification Marks)

Act and the Rules and Regulations made thereunder. The ISI Mark on

products covered by an Indian Standard conveys the assurance that they

have been produced to comply with the requirements of that standardunder a well-defined system of inspection, testing and quality control

which is devised and supervised by ISI and operated by the producer.

ISI marked products are also continuously checked by ISI for

conformity to that standard as a further safeguard. Details of

conditions under which a licence for the use of the ISI Certification

Mark may be granted to manufacturers or processors, may be obtained

from the Indian Standards Institution.


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MARKET SURVEY

Indian Aluminium Industry, though of comparatively origin, has

progressed very fast and at present it ranks first among nonferrous

metals, both in production and in consumption. The history of

aluminium industry in India started in 1929 with the manufacture of

aluminium utensils from imported aluminium sheets and coils.

India entered the field of aluminium smelting in 1943 when a

small plant was set up by the Indian Aluminium Company (INDAL) at

Alupuram in Keral. Excepting electricity, the plant operation was

based on imported raw materials. The production during the year of

inception was only 1292 tons. West Bengal was the state for the

setting-up of second Aluminium smelter in 1944 by Aluminium

Corporation of India (ALUCOIN) at Jaykay Nagar, Asnsol, having a

capacity of 9000 TPA.

It was only after 1960 that aluminium industry in India made a

rapid growth. At present there are five primary aluminium producing

companies in the country. Two of these namely Bharat Aluminium Company

(Balco) and National Aluminium Company (MALCO) are in private sector.

The aluminium corporation in India (ALUCOIN) started initially as

private sector company, is lying closed since 1973 but its fabrication

facilities have since been taken by BALCO.

It was only after 1960 that aluminium industry in India made a

rapid growth. At present there are five primary aluminium producing

companies in the country. Two of these namely Bharat Aluminium Company

(Balco) and National Aluminium Company (MALCO) are in private sector.

The aluminium corporation in India (ALUCOIN) started initially as

private sector company, is lying closed since 1973 but its fabrication

facilities have since been taken by BALCO.

The first public sector plant BALCO at Korba in MP came in

production in the year 1975 with its smelter capacity of 2500 TPA. At

present its production capacity is 100000 TPA. NALCO, which is the

latest and now the largest integrated plant, is expected to commence

its production in 1987 at Angul in Orissa and will have metal

production capacity of 21800 TPA.


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LICENSED AND INSTALLED CAPACITY OF PRIMARY ALUMINIUM IN INDIA

India is considered the fifth largest producer of aluminium in

the world, following Australia, Guinea, Brazil and Jamaica. It has

huge reserves of high-grade bauxite. It is estimated at about 3037

million tonnes for all categories of bauxite (proved, probable and

possible). With the present level of consumption of aluminum (assuming

1.2 million tonnes of aluminium production with 7 million tonnes of

bauxite), the identified reserves would have an estimated life of over

350 years. India's reserves are estimated to be 7.5 per cent of the

total deposits and installed capacity is about 3 per cent of the

world. In terms of demand and supply, the situation is not only self-

sufficient, but it also has export potential on a competitive basis.

India's annual export of aluminium is about 82,000 tonnes. The global

consumption of aluminium is estimated to grow at 3 to 4per cent from

2000 to 2007. This provides a market signal for potential growth of

Indian aluminium industry and export of both alumina and aluminium.

About a decade back, the primary Indian aluminium producers were

BALCO, NALCO, INDAL, HINDALCO and MALCO. Of the five, two (BALCO and

NALCO) were in the public sector while the other three were in the

private sector. MALCO was 'sick' and on the path to closure. Public

sector enterprises then enjoyed preferential treatment in the form of

explicit protectionism. Therefore, the cost of production of BALCO was

benchmarking the selling prices in the domestic market. With the

inception of NALCO in 1981, the production pattern shifted in favour

of the public sector. This happened as BALCO with a capacity of

100,000 tonnes per annum and NALCO with an installed capacity 230000


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TPA, boosted the output share of primary aluminium from the publicsector. The domestic market was dominated primarily by the public

sector though prior to this, HINDALCO and INDAL were the main players.

The shift from the private to the public sector and again from

the public sector back to the private sector has been a notable change

in Indian industry. Presently, of the 714,000 TPA installed capacity

in the country for production of primary aluminium, the public sector

commands 330,000 TPA (49.21 per cent) and the private sector accounts

for 384,000 TPA (53.78per cent.) This represents a gradual but

deterministic shift in the production pattern. With BALCO'S

disinvestments on the cards, the share of the private sector willincrease at the commensurate rate (i.e. expected to be 67.8 per cent

in private sector). Earlier, HINDALCO and BALCO were the trendsetters

for prices in the country. Earlier, domestic sale of aluminium had

administrative prices along with distribution controls.

With liberalisation, the prime strategies are the joint venture

investments, technology acquisition/offers, international marketing

tie-ups, buy back arrangements and subcontracting, technical,

managerial and marketing expertise. As a part of reform, several

policy changes have been enunciated to ensure hassle free entry of

private investment. Similarly, as part of moving towards

privatisation, the government is withdrawing its presence from as many

areas as possible, through closure and sale of equity or

disinvestments.

Prospects for the aluminium industry seem to be bright as

aluminium is being used increasingly in energy efficient vehicles. For

instance, the space shuttle, the HUMMER vehicle, and the Ferrari 360

Modena all are made of high performance aluminium. Material automakers

are increasingly choosing to improve fuel economy, reduce emission and

enhance vehicle performance.

Aluminum is likely to surpass plastic in the coming years as it

will be used more in light vehicles. The recent announcement from the

Ford Motor Company to improve fuel economy in its SUVs is another

signal that aluminium usage will increase even faster. Automakers are

responding to consumer demands for cleaner, more efficient and safer

cars and trucks. Hybrid-electric technologies get much attention, but

cost and complexity are preventing their immediate, widespread use. It

is a recognised fact that aggressive weight reduction is the best way

to improve fuel economy, emissions and performance. For these reasons,


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as well as improved corrosion resistance and recyclability, automakersare more and more turning to lightweight, high-strength aluminium.

NALCO and BALCO have been identified for disinvestments. The

government has decided to disinvest up to 51 per cent of equity held

in BALCO through sale to strategic partners. NALCO has authorised

capital worth Rs 1300 crore and Rs 644.31 crore paid up capital and

loan of 980 million of Euro-dollar. The government's stake in NALCO is

about 87 per cent, which may be diluted further as it has set a target

of disinvesting upto Rs 10,000 crore through the sale of equity held

by the government in PSUs.

As a result of the process of liberalisation of trade in

aluminium, India has emerged as a net exporter of aluminium, on

competitive terms. Government monopoly, in terms of aluminium

production, removal of price and distribution control over aluminium,

has been diluted in favour of private sector. The ownership pattern in

private sector has undergone changes. With the takeover of INDAL by

the HINDALCO, it has emerged as the major producer of aluminium in the

country. It could be safe to conclude that Indian aluminium industry

is a success story of the reforms, liberalisation, globalisation and

privatisation drive in India.

Demand prospects bright for aluminium

Domestic aluminium producers will be relieved, as aluminium

prices ended the year on a firm note, after falling halfway through

the year.

On Wednesday, Hindalco Industries Ltd touched a new 12-month high

of Rs. 243 before closing a bit lower. The rise in its share price may

have been prompted either by expectations of better performance in its

domestic operations or even at its Canadian subsidiary Novelis Inc.Domestic aluminium producers will be relieved, as aluminium prices

ended the year on a firm note, after falling halfway through the year.

Aluminium prices on the London Metal Exchange (LME) have risen by

just 7% to $2,404 (Rs. 1,08,420) a tonne, compared with the year's

opening level. That is a meagre increase, especially when you consider

that its base metal cousin, copper, did extremely well, rising by

about 26% in the same period. But aluminium has done well since June,

when it fell to a low of about $1,850 a tonne.


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Demand for aluminium was quite solid during the year, as theworld economy overall was in better shape, despite China's efforts to

cool economic growth and shivers caused by Europe's economic worries.

Alcoa Inc. estimated aluminium production in 2010 to increase by 13%.

Global primary aluminium production rose by 3.5% in 2010, till

November, compared with the year-ago period, based on data from the

International Aluminium Institute(IAI).

Despite a 3.5% increase in production, LME inventories fell from

4.6 million tonnes (mt) in January 2010 to 4.3 mt. Physical

inventories of primary aluminium with companies, measured by the IAI,

have risen marginally, by about 5% to 1.3 mt. Alcoa forecasts worldaluminium consumption to increase from 39 mt in 2010 to 73 mt in 10

years, achieving a compounded annual growth rate of 6.5%.

In the April-November period, India's aluminium output rose by

8%, chiefly due to ramp-up of production at Vedanta Aluminium Ltd's

Jharsuguda smelter, according to the ministry of mines statistics.

Domestic players are expanding capacity, anticipating rising demand

which cannot be catered to by existing capacities.

Most global players, too, are expanding capacities. Despite an

increase in supply, Alcoa expects that the market will remain tight in

the next decade, due to demand outstripping supply. Indian firms are

expanding existing capacities and also setting up new plants. Some

have come up in 2010, but the bigger plants will come up in the next

few years. India's demand is expected to grow faster than global

demand, as its industrial growth sustains momentum, especially the

major users of aluminium industries such as real estate, automobiles

and engineering.

Aluminium prices are influenced by demand from financial

investors and from actual users of the metal. The current rush forcommodities provides a firm floor for prices, but it could quickly

disappear causing prices to wobble. This was visible in June, as fears

surrounding Europe spooked investors. The inventory overhang in

aluminium too continues but, having weathered it for a year, it does

not seem to be worrying investors. UC Rusal, a large aluminium

producer, believes that most LME inventories are covered by financial

transactions and will not come into the market before mid-2012.

Indian aluminium producers are in a good position, with aluminium

prices already up about 30% since the lows of June. But it has


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underperformed compared with commodities such as copper. The questionis if that will change in 2012, for that will determine how much of an

upside there is for investors in aluminium stocks. As of now, there is

little to suggest a runaway movement in aluminium prices. In 2011,

Indian firms will benefit more from their capacity additions, which

will contribute to a better financial performance.

Hindalco Industries Limited Q3 FY 2007-2008 Results

Hindalco Industries Ltd., the flagship company of the Aditya

Birla Group, today announced its unaudited financial results for the

quarter ended December 31, 2007.

Net sales and operating revenues stood at Rs.4,531.7 crores as

compared to Rs.4,656.2 crores in the corresponding period in FY 07.

The net profit for the quarter is Rs.542.7 crores vis-avis Rs. 643.9

crores in the corresponding period of previous year.

These results need to be viewed in the context of macroeconomic

parameters as these adversely impacted the quarter under review.

Domestic Aluminium ingot prices are down by around 20% due to the

rupee appreciation. A 10% lower aluminium LME, 41% lower Tc/Rc in

copper and soaring international crude prices have exerted

considerable pressure on margins. This was mitigated to some extent by

sweating capacities, improving realization through an enriched

product/market mix, optimizing efficiency levels and producing highest

ever aluminium metal in a quarter. Of the total revenues of Rs.

4,531.7crores, the aluminium business contributed Rs. 1,729 crores.

Aluminum metal sales volume rose by 12% along with higher proportion

of value added products.

The profit before interest and tax for aluminium business was at

Rs.578.9 crores as against Rs. 755.5 crores in the correspondingquarter in the earlier year, as stated earlier, mainly due to the

rising rupee and fall in global alumina realization.

In the copper business, revenues stood at Rs.2806.2 crores driven

by higher sales volumes and an enriched product mix. The profit before

interest and tax was Rs. 94 crores against Rs. 159.5 crores in the

corresponding quarter last year.

As mentioned earlier, a 41% lower TcRc and lower duty

differential on imports constrained the copper business.The effect of


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these were partially offset by improvement in the market mix withhigher sales in domestic market, lower grid power usage on improved

captive power availability, energy consumption and better realization

from by-product sale. Moreover, steep appreciation of Indian Rupee

against US Dollar adversely impacted segment results of Copper by an

estimated Rs.54 crores for the quarter under review as a result of

restatement of net foreign currency exposures as on December 31, 2007.

For the corresponding quarter of the previous year, this had an

estimated favourable impact of Rs.86 crores on such results.

Consequently, the Copper segment results for the quarter under review

are lower than the corresponding quarter of the previous year by an

estimated noncash impact of Rs.140 crores on this account.

Operational review

All the aluminium plants operated at consistently high capacity

utilisation. Brownfield expansions have resulted in increasing metal

production by 9%. The downstream assets purchased in the last two

years are fully utilized, in addition to consistent production from

other plants. Production of value added products (VAP) viz. Rolled

products and Extrusions production extended by 6 per cent and 10 per

cent respectively. Alumina production was marginally less than last

year predominantly due to the hooking of existing alumina refinery

with expanded facility at Muri.

Copper

Copper cathodes and CC rods production increased by 7% and 38 %

respectively on YoY basis on the back of the ramp up of the copper-III

smelter and consistent production from smelter-I. The operations at

copper smelter -II continue to be suspended.

Expansion projectsMuri

The expansion of the Muri Alumina refinery from 110,000 tpa to

450,000 tpa is under commissioning in a phased manner. The entire

steam and power requirement is being met by the new captive power

plant. The production from the expanded facility is expected to be

stepped up progressively in Q4FY08.

Hirakud


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Phase II of the expansion of the smelting capacity from 100,000tpa to 143,000 tpa is on track. The scaling up of the power generation

capacity from 267.5MW to 367.5MW will go on stream by the fourth

quarter of this fiscal.

Belgaum

The allotment of the lease for bauxite mines for expanding the

alumina refinery capacity at Belgaum, Karnataka from 350 ktpa to 650

ktpa is awaited.

Aditya Aluminium

Aditya Aluminium, the integrated aluminium project, encompassing

1-1.5 million tpa alumina refinery, 260,000-325,000 tpa aluminium

smelter and 750 MW captive power plant is progressing as planned. The

major portion of the total land required for the project has been

acquired. Environmental clearances have been obtained for Smelter, the

Captive Power Plant (CPP) and the refinery. Joint venture Company is

formed for the coal block. The water drawal agreement is also

finalized. Construction power already in place, the regulatory

clearances obtained for transmission lines for operation power. The

Smelter is expected to be commissioned by March, 2011 and the refinery

by May, 2011.

Mahan

The Mahan Aluminum project with a smelter capacity of 325 ktpa

and CPP of 750 MW is on schedule. The land acquisition for the project

is underway. The Company has been allotted a coal block in a JV withthe Essar group for the coal requirement of the CPP. Preliminary

Environmental clearances have been obtained. The power connectivity

for commencing construction has been approved. The Water resource

department has provided the necessary facilities as well. The

production of coal is likely to start by Oct'09. The Smelter is

expected to roll on by September 2012.

Latehar


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For the Latehar project with a smelter capacity of 325 ktpa andCPP of 750 MW, Tubed Coal mine has been allocated jointly with Tata

Power. Preliminary Environmental clearances have been obtained. Land

acquisition is in progress. Power for construction activity is

sanctioned. The expected date of commissioning is September 2013.

Utkal

Work on Utkal Alumna's 1.5 MTPA Alumina Refinery is underway. The

Company has acquired the land for the plant and facilities. Mining

activities will start by March 2009. The civil works for Alumina

refinery and CPP is in progress. The commissioning of the Plant isexpected by March 2010. Hindalco Almex Aerospace Limited

This project for manufacture of high strength aluminium alloys

for applications in the aerospace, sporting goods and surface

transport industries is on target. Key equipment has begun to arrive

at site for installation.

Industry outlook

Global primary aluminium consumption has witnessed a strong

growth of 10 % from April through December 2007. US production levels

have seen a high growth but demand from residential construction

market and transport markets continues to remain weak. Demand from

Western Europe has been relatively stronger due to firm transport and

engineering markets. China is the strongest driver of the demand as

the metal grew at 34.7%, in this period, with demand from the power,

transport and construction markets bolstering growth.

Copper

The bullish run on the copper prices has been halted due toglobal economic and financial woes and the trend is likely to be

downward. With many major smelters announcing annual maintenance

shutdown during April -June'07, the availability of concentrates would

improve, resulting in a higher spot TCRC.

Company outlook

Going forward, higher volumes from asset sweating of existing

plants, the brownfield expansions and continued cost focus together

with effective working capital management to maximise free cash flow


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will be the major growth drivers. However a stronger Rupee willcontinue put pressure on the profit margins.

Source: Hindalco Industries Limited (Business Wire India)

CHARACTERISTICS OF ALUMINIUM FOIL MARKET

The applications of Foil could be divided into two major groups

i.e packaging applications and non-packaging applications Packaging

applications include the products given above For these products, the

requirement of packaging is such that it should protect the product

from physical and chemical changes and climatic hazards Non-packagingapplications include heat exchangers tube fins in air conditioners,

capacitors and cable wraps, in which specific properties of the foil

such as conductivity are used.

As compared to other flexible packaging material, aluminium foil

has proved to be the superior material as far as protection of

material, convenience in usage and surface finish are concerned.

However, in India, aluminium foil has proved to be costly because of

higher price of basic material and higher excise duty. Many a time, it

is not available in requisite quantity.

Owing to the high price and uncertain availability of the foil in

the past, many of the user industries like pharmaceutical industry

switched over to other packaging material such as glasine poly

laminate Some companies introduced blister packs and some companies

reduced thickness of the foil Circumstances have thus proved that

usage of packaging medium for consumer items depends on its

availability, price, and shelf-life desired for the product Depending

upon the situation, the appropriate packaging medium is selected

The usage pattern, being very sensitive to price andavailability, keeps on changing from time to time depending upon the

economies of usage of aluminium foil vis-a-vis that of other materials

In India aluminium foil industry, there are frequent changes in

the usage patterns and specifications of foils, as compared to the

foreign countries and therefore, the usage of the foil has remained

restricted in variety as well as in quantitative terms


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The growth of foil industry, has thus not kept pace with thegrowth of its major user industries The past production of foil shows

an overall growth rate of about 7% only.


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Market Break Down of Usages Aluminium

Range of Properties and Uses of Aluminium Alloy


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MANUFACTURER/SUPPLIER/EXPORTER OF ALUMINIUM ALLOY INGOTS

Ashapura Steel

Address: 114/ A, R.K. Wadi,

Shop No. 8, 2nd Parsiwada Lane,

Mumbai, Maharashtra - 400 004

Phone: +(91)-(22)-66394870/66394492

Fax: +(91)-(22)-23821566

Mobile / Cell Phone: +(91)-9820469696/9320006141

Website: http://www.ashapurasteel.com/non-ferrous.html

Jindal Impex

Address: E-384, Phase-VI,

Focal Point, Ludhiana,

Punjab - 141 010, India

Phone: +(91)-(161)-5021500

Fax: +(91)-(161)-2678784


Website: http://www.jindalimpex.com/

J J Aluminium Private Limited

Address: Plot No. 117, Road No.6,

Kathwada G.I.D.C., Kathwada, Odhav,

Ahmedabad, Gujarat - 382 430, India

Phone: +(91)-(79)-22901182

Fax: +(91)-(79)-22901182


Vijay Prakash Gupta & Sons

Address: No. 3019, Street No. 2,

Chuna Mandi, Paharganj,

New Delhi - 110 055, India

Phone: +(91)-(11)-23586472/23584321

Fax: +(91)-(11)-23585757

Mobile / Cell Phone: +(91)-9811125181

Nisarg Casting

Address: 54/b/1, Changodar Industrial Estate,

Near Presion Bearing, Chnagodar,



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Phone: +(91)-(2717)-250128Mobile / Cell Phone: +(91)-9978914205/9426015205

G. K. Founders Private Limited

Address: No. 13, Ranka House,

Kale Marg, Bail Bazar Road,

Mumbai, Maharashtra - 400 070, India

Phone: +(91)-(22)-25141266

Fax: +(91)-(22)-32569042


Maruti Alluminium Private LimitedAddress: Plot No.- 380,

Raod No.- 9, G.I.D.C. Kathwada,

Opposite Odhav Octroi Naka,

Odhav, Ahmedabad, Gujarat - 382 430, India

Phone: +(91)-(79)-22901347/22901330

Fax: +(91)-(79)-22901347


Manaksia Limited

Address: 8/1, Lal Bazar Street,

Kolkata, West Bengal - 700 001, India

Phone: +(91)-(33)-22210051


Gold Star Alloys

Address: Plot No.276, Sector No. 7,

Opposite Sahani Gas Industrial PCNDTA,

Bhosari, Pune, Maharashtra - 411 026, India


Kamala MetachemAddress: No. 3, British Indian Street,

3rd Floor, Room No. 3D,

Beside Great Eastern Hotel,


Phone: +(91)-(33)-22100681

Fax: +(91)-(33)-22435682


Vijay Prakash Aeromarine Metals Pvt Ltd

Address: B-101, FF, Plot No. 2,


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R. G. Complex, Motia Khan,D. B. Gupta Road,


Phone: +(91)-(11)-23544854


Alloy Tech, Bangalore

Address: Plot No 22 E, 3rd Main,

5th Cross, Athibele Industrial Area,

Anekal, Taluk, Bengaluru, Karnataka - 562 107, India

Phone: +(91)-(80)-27820540/25729183

Fax: +(91)-(80)-25729859/30616039Mobile / Cell Phone: +(91)-9886788183/8105011880

M. G. Metallinkers Private Limited

Address: E-6, Government Industrial Area,

Bahadurgarh, Haryana - 124 507, India

Phone: +(91)-(1276)-242389/23544451

Fax: +(91)-(1276)-242445


Krishna Metals And Alloys Industries

Address: No. B-34, Krisna Gopal Estate,

Opposite S.B.I. Bank Memco,

Char Rasta, Naroda Road,


Phone: +(91)-(79)-22201882

Fax: +(91)-(79)-22201882


Kiran Aluminium India Private Limited

Address: 229-A, 2nd Floor,

Kewal Industrial Estate,Next To Big Bazaar,

Senapati Bapat Marg,

Lower Parel West, Mumbai,

Maharashtra - 400 013, India

Phone: +(91)-(22)-30406700/30406701

Fax: +(91)-(22)-30406703


Krum Alloys Industries Private Limited

Address: W-46 M I D C.Shiroli,


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Kolhapur, Maharashtra - 416 212, IndiaPhone: +(91)-(230)-2469331

Fax: +(91)-(230)-2469331


Metal Cast & Alloys

Address: 39, Industrial Estate,

Phase-1, Yamunanagar,

Haryana - 135001, India

Phone: +(91)-(1732)-251315

Fax: +(91)-(1732)-251515


Baldev Metals Private Limited

Address: B-22 Phase 1,

Maya Puri Industrial Area.,

New Delhi - 110064, India

Phone: +(91)-(11)-28117476


Anurag Alloys And Diecast Private Limited

Address: Plot No. 57, Sector- 6,

Faridabad, Haryana - 121 006, India

Phone: +(91)-(129)-2243709

Fax: +(91)-(129)-4061446


Thalco

Address: Bileshwar Estate,

Kathwada G.I.D.C.,

Ahmedabad, Gujarat, India


G.K.Founders.Private LimitedAddress: Survey No. 331/2,

Plot 5/B, Tipco Road,

Masat, Dnh,, Silvassa,

Dadra And Nagar Haveli - 396230, India

Phone: +(91)-(260)-3290990

Fax: +(91)-(260)-2631812

Strategic Metals Private Limited

Address: 106, Commerce Centre,

Vishveshwar Nagar Off Aarey Road,


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Gujarat Indl Compound, Mumbai,Maharashtra - 400 063, India

Phone: +(91)-(22)-28739670/28739671

Fax: +(91)-(22)-28739673


Srg Aluminium Private Limited

Address: 31 Industrial Estate,

Gwalior, Madhya Pradesh - 474004, India

Phone: +(91)-(751)-4040120


Navkar Metal

Address: 94/100, Fanaswadi,

Runghta Bhawan Room No.30,

2nd Floor, Mumbai,


Phone: +(91)-(22)-66518883/66595328


Manju Metals

Address: No. 118,

Konnur High Road,

Ayanavaram, Chennai,

Tamil Nadu - 600 023, India

Phone: +(91)-(44)-26744009

Fax: +(91)-(44)-26744009


Prism Metals (P) Ltd.

Address: B-28, Mayapuri Industrial Area,

Phase- I, New Delhi - 110064, India

Phone: +(91)-(11)-66130300Fax: +(91)-(11)-45082434

International Business Combines

Address: The Industrial Square,

No. 17-9/2, Begampur,

Industrial Area, Sector-35,

39th KM Stone, NH-8, Gurgaon,

Haryana - 122 001, India

Phone: +(91)-(124)-2210981/26143895

Fax: +(91)-(11)-46039660


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Padmavati Metals

Address: No. 902/290, Street No. 9,

Shalimar Industrial Area,


Phone: +(91)-(11)-27494609


Century Metal Recycling Private Limited

Address: Village Tatarpur,

Teh. Palwal, Faridabad,Haryana - 121 102, India


N. F. Casting India

Address: No. 1567, Shiv Shanker Nagar,

Near Hindu Girls College, Jagadhri,

Yamunanagar, Haryana - 135 003, India

Phone: +(91)-(1732)-222315

Fax: +(91)-(1732)-222315


Bharath Aluminium Company Limited

Address: Welfare Building, Plant I,

Commercial Deptartment Balco Nagar,

Korba, Chattisgarh - 495 684, India

Phone: +(91)-(7759)-240383/242052

Fax: +(91)-(7759)-240626


Sainath Industries

Address: 34, Rungta Bhavan,

94/100, Fanaswadi, Mumbai,Maharashtra - 400002, India

Phone: +(91)-(22)-56394493

Fax: +(91)-(22)-56548412

Univenture Corporation

Address: No. 4, Sial Layout,

Nelson Square, Nagpur,


Phone: +(91)-(712)-2594567

Fax: +(91)-(712)-6629645


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Kundan Traders, Kolkata

Address: 57/6 B.T.Road,


Phone: +(91)-(33)-25573131

Pankaj Metals Corporation

Address: S/15, Vikram Chambers Ashram Road,

Ahmedabad, Gujarat - 380009, India

Phone: +(91)-(79)-27546252/27546964/32951521

Fax: +(91)-(79)-66611515

Maken AlloysAddress: Logate More, Kathua,

Jammu & Kashmir - 184102, India

Phone: +(91)-(1922)-203241/203242

Fax: +(91)-(1922)-237794/236114


J. S. B. Aluminium

Address: Phase 1, Lane No. 7,

S.I.D.C.O., I.G.C.,

Samba, Jammu & Kashmir - 184 121, India

Phone: +(91)-(1923)-246385/28525421

Fax: +(91)-(11)-28525421


Maruti Alluminium Private Limited

Address: Plot No: 380,

Road No: 9, Gidc Kathwada,

Kathwada,, Ahmedabad, Gujarat - 382430, India

Phone: +(91)-(79)-22901330/22901347

Harsh InternationalAddress: 634, G.I.D.C.,

Phase-Ii Dared, Jamnagar,

Gujarat - 361004, India

Phone: +(91)-(288)-2730417/2730125

Fax: +(91)-(0288)-2730517


Monarch Overseas

Address: 315, G.I.D.C.,

Phase Ii, Dared Jamnagar,

Jamnagar, Gujarat - 361004, India


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Phone: +(91)-(288)-2730217Fax: +(91)-(288)-2730339

N. H. Engineering Industries

Address: Plot No. 15, Phase No. 2,

G.I.D.C., Vithal Udyognagar

Post Karamsad, Anand, Gujarat - 388 120, India

Phone: +(91)-(2692)-237226

Fax: +(91)-(2692)-230346


Sagar International Private Limited

Address: 5, Hanuman Road,Delhi - 110 005, India

Phone: +(91)-(11)-23658876

Sri Venkateshwara Non Ferrous Foundry

Address: 19/5, Industrial Area,

Azamabad, Hyderabad,

Andhra Pradesh - 500 020, India

Phone: +(91)-(40)-27603829

Fax: +(91)-(40)-27656218

Perfect Aluminium Alloys

Address: 578 N. H. Road, Marakadai,

Near To Bangalore Hotel, Coimbatore,

Tamil Nadu - 641 001, India

Phone: +(91)-(422)-2391671

Samsung Overseas Limited

Address: 104, Adishwar Apartments,

Firozshah Road, New Delhi - 110 016, India

Phone: +(91)-(11)-45727272

Fax: +(91)-(11)-45727272Mobile / Cell Phone: +(91)-9811067809

Bhawani Wire & Cable

Address: Lane No.3, Phase-I,

SIDCO Industrial Complex,

Bari Brahmana, Jammu,

Jammu & Kashmir - 181 133, India

Phone: +(91)-(1923)-220878


Shri Ganesh Metal Rolling Mill & Engineering Works


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Address: Unit-Ii, Block No. 271/1-C/1 Gokul,Hubli, Karnataka - 580 026, India

Phone: +(91)-(836)-2210674/2310434

Fax: +(91)-(836)-2310385


Lila Aluminium Industries Private Limited

Address: Gut No. 16, Naigaon Khandewadi,

Paithan Taluka, Aurangabad,


Phone: +(91)-(240)-2694533


Maken Alloys

Address: Logate More,

Near Railway Crossing Kathua,

Kathua, Jammu & Kashmir - 184102, India

Phone: +(91)-(1922)-203241


Utlak Aluco Limited

Address: F-140, Delta-i,

Greater Noida, Noida,

Uttar Pradesh - 201 305, India

Phone: +(91)-(120)-2572245


We or Our Organization are not concerned with any of the contacts provided above. We

do not bear any responsibility or guarantee Quality of their product. We do not know

them neither do they.


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MANUFACTURING PROCESS

When aluminium is to be fabricated it is important to start with

Ingots/billets or slabs as free from segregation and blow holes as

possible.

MANUFACTURING OF INGOT FROM SCRAPE

A methods is being used where by molten aluminium is fed to a

water cooled mold with a moveable bottoms. The rate of flow of metal

is synchronised with the rate of solidification and the bottom of the

mold is lowered at the calculated rate. The solidified metal shrinks

away from the wall of the mold and allows the resulting Ingots to drop

with a moveable bottom and a solid uniform casting of any desired

length is thus obtained.

The furnace contain molten aluminium which flows through the

discharge spout. Two ingots can be simultaneously cast with the flow

each adjusted by valve.

MELTING & TREATMENT OF SECONDARY ALUMINIUM :-

The treatment of aluminium scrap has become complicated by the

increasing number of aluminium alloys which have come on the market in

recent year.

Some degree of sorting is possible based on the uses to which the

object composing the scrap have been put. Bending test are also used

and in some plants the spectrograph /spectrometer is employed. The men

engaged in sorting have in many cases become highly skillful by

experience.

The furnace usually oil or gas fired are used for melting and theatmosphere in regulated to minimize oxidation. It is desirable when

possible to immerse thin scrap below the surface of the bath to

inhibit oxidation during melting. A furnace is in used for melting

aluminium scrap in which a portion of the hearth is external but

contiguous with the interior portion. This scrap is submersed in the

exterior portion of the bath and subjected to slow agitation to

promote rapid melting. The agitation together with the rather high

heat conductivity of the bath promotes heat exchange with the heated

interior and prevents the exterior portion from solidifying.


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FLUXING AND FLUSHING

Fluxing and flusing of aluminium melts is practiced mainly for

two reasons.

A)To provide more effective separation of metal and dross.B)To remove dissolved hydrogen and entrapped dross.Gaseous fluxes used to flush or purge the melt include nitrogen,

helium, argon and chlorine. The gases are slowly bubbled through the

melt for hydrogen removal. Hydrogen dissolved in the aluminium

diffuses into the gas bubbled and is carried away. Dross separation is

probably a mechanical action of the inert gas bubbles carrying oxides

to the surface. Flushing is carried out by skimming off surface dross

and then bubbling the dry gas through the melt.

Fluxing with solid fluxes is a simpler procedure, flux to the

extent of about 0.10lb per 100lb i.e of metal is added to the melt by

forcing it to the bottom of the bath in a perforated container.Aluminium and Zinc chloride, as well as a number of proprietary

composition containing these compounds, are used as solid fluxes.

MANUFACTURING OF SHEET & FOIL

There are two methods of producing Aluminum Sheet/Foil. One from

using Caster where molten metal is directly used to manufacture sheet

and foil and the other is from ingot. The method of producing using

Caste i.e. directly from molten metal is relatively new and is costly.

Also, for manufacturing sheet/foil from scrap, it is less suitable as,

it is difficult to maintain the composition of molten metal due to

unknown composition of scrape. Thus, currently for Indian market,

manufacturing using Aluminum Ingot is more suitable, as the

composition of Ingots can be easily maintained and fresh aluminum

Ingots can be used whenever necessary.

The ingot is usually cooled after casting to room temperature and

then re-heated to around 500 C prior to successive passes through a


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hot rolling mill where it is reduced in thickness to about 4 - 6 mm.The temperature of pre-heat of the ingot and the time held at that

temperature is important for some alloys since a process of

homogenization takes place which renders the material in the best

condition for rolling and the achievement of subsequent properties.

The strip from the hot rolling mill is coiled for transport to

the cold mill which might be on the same site or elsewhere. Cold

mills, in a wide range of types and sizes are available; some are

single stand, others 3 stand and some 5 stand. Cold rolling speeds vary

but modern mills operate at exit speeds as high as 3000 m per minute.

The foil of uniform gauge and desired tolerance is made by subjecting

this foil-stock through a series of cold rolling passes, on one or anumber of rolling mills The minimum thickness to which the foil is

cold rolled, is 0.006 mm, achieved through pack rolling, i.e., rolling

of two foils together.

At the end of cold rolling operations, the foil is annealed

in order to fully soften it and impart the characteristics like

dead fold and easy Work ability. Annealing also burns off the oil

left on the foil surface. Annealing thus makes the foil free from oil

and fully sterile.

The annealed foil, is then subjected to the various treatments as

per requirements:

a) Separation of pack rolled foils,

b) Slitting to desired widths, including edge trimming,

c) Embossing,

d) Sheet making and cutting to length,

e) Application of adhesives, wax, lacquer etc.,

f) Lamination with paper, paper board, LDPE,

g) Single or multi colour printing,

h) Slitting of laminated composite,

i) Packing in desired lengths or weights


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A modern complex including melting furnaces, asting facilities,

pre-heat furnaces, hot mill, cold mill and annealing furnaces involves

a very large capital investment which can only be fully justified on

financial grounds if a big market is assured. Obviously, if such

facilities are not fully utilized the economic viability is

threatened. As indicated above, however, hot mill coil can be obtained

for further reduction in cold mills of lower capacity/speed/complexity.


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PROCESS FLOW SHEET(Ingot to Scrape)

Flow sheet of Aluminum Sheet/Foil manufacturing is same as that

given in 3D graphics in Process description.


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PRINCIPLES OF PLANT LAYOUT

Some of the guiding principles for detailed plant layout will be

discussed for the benefit of those making layout decisions for the

first time.

Storage Layout: Storage facilities for raw materials and intermediate

and finished products may be located in isolated areas or in adjoining

areas. Hazardous materials become a decided menace to life andproperty when stored in large quantities and should consequently be

isolated. Storage in adjoining areas to reduce materials handling may

introduce an obstacle toward future expansion of the plant. Arranging

storage of materials so as to facilitate or simplify handling is also

a point to be considered to design. Where it is possible to pump a

single material to an elevation so that subsequent handling can be

accomplished by gravity into intermediate reaction and storage units,

costs may be reduced. Liquids can be stored in small containers,

barrels, horizontal or vertical tanks and vats, either indoors or out

of doors.

Equipment Layout: In making a layout, ample space should be assigned

to each piece of equipment; accessibility is an important factor for

maintenance.

It is extremely poor economy to fit the equipment layout too

closely into a building. A slightly larger building appears necessary

will cost little more than one that is / that crowded. The extra cost

will indeed be small in comparison with the penalties that will be

extracted if, in order to iron out the kines, the building must be

expanded.

The operations that constitute a process are essentially a series

of unit operations that may be carried on simultaneously. These

include filtration, evaporation, crystallization, separation, and

drying. Since these operations are repeated several times in the flow

of materials, it should be possible to arrange the necessary equipment

into groups of the same kinds. This sort of layout will make possible

a division of operation labor so that one or two operators can be

detailed to tend all equipment of a like nature.


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The relative levels of the several pieces of equipment and theiraccessories determine their placement. Although gravity flow is

usually preferable, it is not altogether necessary because liquids can

be transported by blowing or by pumping, and solids can be moved by

mechanical means. Gravity flow may be said to cost nothing to operate,

whereas the various mechanical means of transportation involve the

first cost of the necessary equipment and the cost of operation and

maintenance. But material must be elevated to a level where gravity

flow must start. However, gravity flow usually means a multistory

layout, whereas the factors favoring a single-story plant may largely,

if not entirely, compensate for the cost of mechanical transportation.

Access for initial construction and maintenance is a necessary

part of planning. For example, overhead equipment must have space for

lowering into place, and heat-exchange equipment should be located

near access areas where trucks or hoist can be placed for pulling and

replacing tube bundles. Thus, space should be provided for repair and

replacement equipment, such as cranes and forked trucks, as well as

access way around doors and underground hatches.

Safety: A great deal of planning is governed by local and national

safety and fire code requirements. Fire protection consisting of

reservoirs, mains, hydrant, hose houses, fire pumps, reservoirs,

sprinklers in building, explosion barriers and directional routing of

explosion forces to clear areas, and dikes for combustible-product

storage tanks must be incorporated to protect costly plant investment

and reduce insurance rates.

Plant Expansion: Expansion must always be kept in mind. The question

of multiplying the number of units or increasing the size of the

prevailing unit merits must be studied. Suffice it to say that one

must exercise engineering judgment; that as a penalty for bad

judgment, scrapping of present serviceable equipment constitutes butone phase, for shutdown due to remodeling may involve a greater loss

of money than that due to rejected equipment. Nevertheless, the cost

of change must sometimes be borne, for the economies of larger units

may, in the end, make replacement imperative.

Floor Space: Floor space may or may not be a major factor in the

design of a particular plant. The value of land may be a considerable

item. The engineers however, follow the rule of practicing economy of

floor space, consistent with good housekeeping in the plant land with

proper consideration given to line flow of materials, access to


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equipment, space to permit working on parts of equipment that needfrequent servicing, and safety and comfort of the operators. Utilities

Servicing: The distribution of gas, air, water, steam, power, and

electricity is not always a major item, in as much as the flexibility

of distribution of these services permits designing to meet almost any

condition. But a little regard for the proper placement of each of

these services, practicing good design, aids in of operation,

orderliness, and reduction in costs of maintenance. No pipes should be

laid on the floor or between the floor and the 7-ft. level, where the

operator must pass or work. Chaotic arrangement of piping invites

chaotic operation of the plant. The flexibility of standard pipe

fittings and power-transmission mechanisms renders this problem one ofminor difficulty.

Building: After a complete study of quantitative factors, the

selection of the building or buildings must be considered. Standard

factory buildings are to be desired, but, if none can be found

satisfactory to handle the space and process requirements of the

chemical engineer, then a competent architect should be consulted to

design a building around the process - not a beautiful structure into

which a process must fit. It is fundamental in chemical engineering

industries that the buildings should be built around the process,

instead of the process being made to fit building of conventional

design.

In many cases only the control area requires housing, with the

process equipment erected outdoors. This is known as outdoor

construction and such layouts should be considered for many types of

plants. What consideration must be given to buildings depends upon

conditions. If the designer must adapt his design to fit an old

building or building space already erected, his problem is cut out for

him and he has limiting conditions. However, the selection of the

design of a new building to meet the requirements of the process ismore scientific. In this case, one finds before him practically all

types of standard building, built in units, interlocking or otherwise,

ready for shipment and erection.

Throughout chemical industry, much thought must be given to the

disposal of waste liquors, fumes, dusts, and gases. Ventilation, fume

elimination, and drainage may require the installation of extra

equipment. This may involve the design of the individual pieces of

operating equipment, or it may require the installation of isolated

equipment. If the latter be the case, the location of such equipment


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where it will not interfere with the flow of materials in processshould be practiced. The selection of the proper piece of equipment

for doing this service is also an important point; the less attention

the ventilating, fume, or waste-elimination systems require, the

better service they may render. Sometimes air conditioning of the

plant is called for and may require an elaborate setup. But the

installation of such equipment, when needed, pays in better service

from operators, less discomfort, greater production, and a better

morale than when such conditions are left to nature.

It must be recognized that there is not only one solution to the

problem of layout of the equipment. There are many rational designs.Which plant to adopt must be decided upon after exercise of

engineering judgement and after striking a balance between the

advantages and disadvantages of each possible choice.

Material-handling Equipment: Consideration of equipment for materials

handling is only a minor factor in most cases of arrangement, because

of the multiplicity of available materials handling devices. But where

this operation is paramount in a process, serious thought must be

given to it. Again it should be said that engineering judgement must

be exercised. Whenever possible, one should take advantage of the

topography of the site location, and the process involved.

Railroads and Roads: Existing or possible future railroads and

highways adjacent to the plant must be known in order to plan rail

siding and access roads within the plant. Railroad spurs and roadways

of the correct capacity and at the right location should be provided

for in a traffic study and over-all master track and road plan of the

plant area. Some of the factors in rail-track planning are:

1. Existing and future off-site main rail facilities

2. Permissible radius of curvature for spurs - consult local railauthorities.

3. Provision for traffic handling - arrangement of spurs and ladder

track and switching.

4. Adequate spur facilities

a. Loading and unloading facilities for initial plant

construction and subsequent operations.

b. Rack stations for liquid handling

c. Storage space for full and empty cars

d. Space for cleaning and car repairs.


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Major provisions in road planning for multipurpose service are:1)A means of interplant movement for road traffic, both

pedestrian and vehicular

2)Heavier and wider roads for large-scale traffic.3)Routing of heavy traffic outside the operational areas4)Roadways for access to initial construction, maintenance, and

repair points.

5)Roadways to isolated points, storage tanks, and safety equipment,such as fire hydrants.


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PLANT LOCATION FACTORS

Factors which generally apply to the economic and operability

aspect of plant site location are classified into two major groups.

The primary factors listed apply to choice of a region, whereas the

specific factors looked at in choosing an exact site location within

the region. All factors are important in making a site location

selection.

Primary Factors

1. Raw-material supply:a. Availability from existing or future suppliers

b. Use of substitute materials

c. Distance

2. Markets:

a. Demand versus distance

b. Growth or decline

c. Inventory storage requirements

d. Competition - present and future.

3. Power and fuel supply:a. Availability of electricity and various type of fuel

b. Future reserves

c. Costs

4. Water supply:

a. Quality - temperature, mineral content, bacteriological

content

b. Quantity

c. Dependability - may involve reservoir construction

d. Costs.

5. Climate:

a. Investment required for construction

b. Humidity and temperature conditions

c. Hurricane, a tornado, and earthquake history

Specific Factors

6. Transportation:


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3

a. Availability of various services and projected rates1. Rail - dependable for light and heavy shipping over all

distances

2. Highways - regularly used for short distance and

generally small quantities

3. Water - cheaper, but may be slow and irregular

4. Pipeline - for gases and liquids, particularly for

petroleum products

5. Air - for business transportation of personnel

7. Waste disposal:

a. Regulations lawsb. Stream carry-off possibilities

c. Air-pollution possibilities

8. Labor:

1. Availability of skills

2. Labor relations - history and stability in area

3. Stability of labor rates

9. Regulatory laws:

a. Building codes

b. Zoning ordinances

c. Highway restrictions

d. Waste-disposal codes

10. Taxes:

a. State and local taxes

1. Income

2. Unemployment insurance

3. Franchise

4. Use

5. Propertyb. Low assessment or limited term exemptions to attract industry.

11. Site characteristics:

a. Contour of site

b. Soil structure

c. Access to rail, highway, and water

d. Room for expansion

e. Cost of site

f. Site and facilities available for expansion on present


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company-owned property

12. Community factors:

a. Rural or Urban

b. Housing costs

C. Cultural aspects - churches, libraries, theatres

d. School system

e. Recreation facilities

f. Medical facilities - hospitals, doctors

13. Vulnerability to wartime attack:

a. Distance important facilitiesb. General industry concentration

14. Flood and fire control:

a. Fire hazards in surrounding area

b. Floor history and control


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EXPLANATION OF TERMS USED IN THE PROJECT REPORT

1. DEPRECIATION:

This represents reduction in the utility and value of a capital

asset because of wear and tear, lapse of time, obsolescence etc. The

use of an asset helps in the generation of revenue for the business. A

part of the cost of the asset, estimated to be equal to the reduction

in the utility and economic life of the asset, because of its use, is

charged off by way of depreciation charge against such revenue to

arrive at the true profits.

2. FIXED ASSETS:

Represent those assets which remain permanently (till their

useful lives) with the business and are not meant for resale. These

assets are acquired for use in the operation of business and help in

the generation of revenue for the business. These include land and

building, plant and machinery etc.

3. WORKING CAPITAL:

This represents the total expenses on Raw materials, utilities &

overheads, and salaries & wages, for a specified period of time.

4. BREAK-EVEN POINT:

This represents the level of output and sales at which the firm

is able to recover all its expenses-both fixed and variable. In other

words it indicates the level of output and sales at which the firm is

neither making profit nor incurring any loss. Level of output more

than the Break-Even Level generates profit for the firm.

5. OTHER FIXED EXPENSES:

These represent expenses which remain fixed irrespective of

changes in level of output. In other words these are the expenses

which the firm has to incur whether there is production or not. These

include expenses such as preliminary and Preoperative expenses,

Insurance and Freight, Technical Know-how and Consultancy, Erection &

Commissioning etc. building, insurance, etc.


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6. MARGIN MONEY:

This represents that part of the cost of project which the

promoter has to meet from his own resources. This is the contribution

which the promoter must make to the equity of the project for becoming

eligible for assistance from financial institutions/Banks.

7. TERM LOANS:

Represent Loans which are repayable over a long period of time.

These loans are meant for meeting capital expenditure of the project.

8. TOTAL LOAD:

It is the ratio of the maximum power consumed in KWH in a

particular period of time to the number of operating hours of the unit

in that particular period.

9. LAND AREA/MAN POWER RATIO:

It is the ratio of manpower utilised per unit area of land

required for operating the unit.


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SUPPLIERS OF PLANT & MACHINERIES

FURNACE

HIGH TEMP FURRNACES LTD.

1C, PHASE-II,

PEENYA IND. AREA,

BANGALORE - 560 058

KARNATAKA,

PH: 91-80-28395917, 28394076

D. N. Reddy, MDA P MOTRONIX PVT LTD

3-18-3, Pragathi Nagar, Ramanthapur

Hyderabad-500013, Andhra Pradesh

Phone: 040-27038560/27031929

Email: [email protected]

Mr. Manwani

ADOR TECHNOLOGIES LTD

Plot No.53, 54 & 55,

F-II Block, MIDC, Pimpri

Pune-411018, MaharashtraPhone: 020-7470225/7476009


Mg. Director

ADVANCE HEATING SYSTEMS

207, Vardhman Complex 8,

Facility Centre,

Mayapuri Industrial Area-II

New Delhi-110064

Phone:011-25139315, 25403798, (r) 25613649


Mg. Director

AJANTA SCIENTIFIC INDUSTRIES

Science Market,

Near Hargotal Dharmashala

Ambala Cantt.-133001, Haryana

Phone:0171-2642428, 2630814 (O), (R) 2650316



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Mg. DirectorAMBICA ENGINEERING WORKS

# 16/A, 1st Main,

Modi Hospital Road,

West Of Chord Road, 2nd Stage

Bangalore, Karnataka

Phone:080-3495370

V. S. Prasanna, Marketing Mgr

APNA SCIENTIFIC SUPPLIES PVT LTD

M-2, Industrial Estate, Guindy

Chennai-600032, Tamil NaduPhone: +91 44 22340963, 22340630

Mr. Kapahi

ASSOCIATED INDUSTRIAL FURNACES PVT LTD

F-9, Sector-Xl

Noida-201301, Uttar Pradesh

Phone: 0120-2529187, 2529169

Email: [email protected];[email protected]

COOLING TOWER

Lalit Narang, Proprietor

A TO Z ENGINEERS & CONSULTANTS

915, Vishal Towers,

10, District Centre,

Janakpuri, New Delhi-110058

Phone: +91 11 25619462, 25551832


Yogesh Pujari, Export Mgr

ADVANCE REINFORCED PLASTICS PVT LTD

405/406, Span Centre,

R K Mission Marg, Santacruz (W)

Mumbai-400054, Maharashtra

Phone: 022-26001067, 26001068


Mr. Kailash Magolra

ALBATRON FINE CHEM LTD


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40, Dlf Industrial Area,Alishan Building, Kirti Nagar

New Delhi-110015

Phone: 011-25161151/25114789/25100768

Mr. Ravinder

B D T LTD

Sri Madurakripa Towers,

2nd Floor, New No. 51,

North Boag Road, T. Nagar

Chennai-600017, Tamil Nadu

Phone: 044-28235971/28235977


Mr T S Rao

EAST COAST STRUCTURALS

96/3, Sidco Estate, Ambattur

Chennai-600098, Tamil Nadu

Phone: 044-26252850

Davindar Sapru, Sales Mgr

AADI HEAT EXCHANGER PVT LTD

D-83, Hosiery Complex, Phase II Ext.

Noida-201305, Uttar Pradesh

Phone: +91 120 2460073, 2460073


Mr. Ajay

D M POLYMERS

Near, Chungi,, Daultabad Road,

Gurgaon, Haryana

Phone:0124-2469780, 3095483, 9810074583


WATER PUMP

MR. A S THAPAR (CHAIRMAN)

ALLENA AUTO INDUSTRIES LTD

B-68, WAZIRPUR, INDL. AREA

DELHI-110052

Phone: 011-27373704, 27121008



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0

MR. MANISH PATEL

AMIDHARA INDUSTRIES

L-92, GIDC ESTATE,

BEHIND OLD WATER TANK,

ODHAV AHMEDABAD-382415, GUJARAT

Phone: 079-3870420/2876420

M. Z. BANDUKWALA, MD

ANCO MOTORS

248/250,, ABDUL REHMAN STREET

MUMBAI-400003, MAHARASHTRAPhone: +91 22 3424764 3400605


MRS. MUKHERJEE

B E PUMPS PVT LTD

C/401, CRYSTAL PLAZA,

NEW LINK ROAD, ANDHERI (WEST),

MUMBAI-400053, MAHARASHTRA

Phone:912226733510


MR. BABU KHAN & MR. DISHAD KHAN (DIR)

B K HI-TECH ENGINEERING,

C-334,, SECTOR-10,

NOIDA-201301, UTTAR PRADESH

Phone: 0120-2557355, 9811642485,

MR. A K BEHAR

B S PUMPS PVT LTD

BASAI ROAD

GURGAON-122001, HARYANA

Phone: 0124-2321052, 2329934Email: [email protected];[email protected]

MR. C P DAHRA/MR. SAMIR DAHRA

DAHRA ENGG CO

35 VISHWAKARMA INDL. AREA,

SECTOR 24, NEAR DHARAMKANTA,

MUJESSAR, FARIDABAD-121005, HARYANA

Phone: 0129-2232388, 2232684, 4023153, 9811211965, 2241519

Email: [email protected], [email protected]


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1

MR. DINESH PATELDEV INDUSTRIES

13, PRAGATI INDUSTRIAL ESTATE,

OPP. JAGANNATH ESTATE,

GUJARAT BOTTLING ROAD, RAKHIAL

AHMEDABAD-380023, GUJARAT

Phone: 079-2748716/98250-38773

HARGOVIND BATRA, MD

H F H AUTO PUMPS

SURVEY NO. 115, HISSA NO. 6,

GHODBUNDER ROADTHANE-401104, MAHARASHTRA

Phone: +91 22 285 50156,28550158

MR. KAPIL BHATIA (EXP MGR)

HAMMER AUTO INDUSTRIES

374 PUNJA SHARIF, KASHMERE GATE

DELHI-110006

Phone: 011-23975863


R. K. BANSAL, PARTNER

HINDUSTAN TRADING CORP

4, LIBERTY HOUSE, MAVDI PLOT

RAJKOT-360004, GUJARAT

Mobile:Phone: +91 281 388 541,388630

Email: [email protected]; [email protected]

MR. KAMAL KAPURIA (DIR)

IAEL PUMPS LTD

C-60-B, KALKAJI

NEW DELHI-110019Phone: 011-26447880, 26473243,


JAYANT DAVE, OWNER

JAYANT ENGINEERING WORKS

46/2/1B, KALA HALAI INDUSTRIAL ESTATE,

PUNE SATARA ROAD

PUNE-411009, MAHARASHTRA

Phone: +91 20 422 0244



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2

B. LANGETARTELS

K B S PUMPS LTD

MAKER CHAMBERS,

NO. III/126, NARIMAN POINT

MUMBAI-400021, MAHARASHTRA

Phone: 022-22854237/4242/22840614


Mg. Director

KAFILA GROUP OF COMPANIES

32, RAJSTHANI UDYOG NAGAR,G T ROAD, AZADPUR

NEW DELHI-110033

Phone:011-55457319

RAKESH KAD, MD

KAD ENTERPRISES

13-Y, THE MALL

PATIALA-147001, PUNJAB

Phone: +91 175 354 433

Mg. Director

KHADIKAR SALES & SERVICES LTD

1ST FLOOR VRAJ BHOOMI COMPLEX,

C G ROAD, NAVRANGPURA


Phone: 079-26420318


Mg. Director

KISHOR PUMPS PVT LTD

C-46, BALI NAGAR,NEAR RAJA GARDEN

NEW DELHI-110015

Phone:011-25933920, 25464912


MR. RAKESH KOCHHAR

KOCHHAR BROTHERS

HADIABAD, PHAGWARA, PUNJAB

Phone:01824-62307/(R)2220578



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3

MR. ANIL MALHOTRA

MOON PAPER & MACHINERY PVT LTD

32, RAJASTHANI UDYOG NAGAR,

G T KARNAL ROAD, DELHI-110033

Phone: 011-27139462, 27243593, 27139463,


MR. MILIND S. WALVEKAR

OM ENTERPRISES

D-113, ANGOL INDL. ESTATE,

BELGAUM, KARNATAKAPhone: 918312441694


MR. ASHISH SHAH

PARAS ENGINEERING COMPANY

ROYAL BUILDING,

OPP MAHALAXMI PETROL PUMP,

KADIAKUI, RELIEF ROAD,


Phone: 917922131338/55441600

Mg. Director

PENTAFOUR PRODUCTS LTD AUTO DIVN

PENTAFOUR TOWERS,

1ST MAIN ROAD, UNITED COLONY

CHENNAI-600024, TAMIL NADU

Phone: 044-24836934


MR. D. C. POTTADAR

POWER & MACHINERY INDIA PVT LTD3, MANGOE LANE, GROUND FLOOR

KOLKATA-700001, WEST BENGAL

Phone: 033-248-2047

MR. HITESH D. RAMANI

RADHA ENTERPRISES

10/3, BHAKTINAGAR ST. PLOT

RAJKOT-360002, GUJARAT

Phone: 0281-2462206


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MR A V SHANKARANRAPID AUTO COMP PVT LTD

21-B, BALAJI NAGAR, PADI

CHENNAI-600050, TAMIL NADU

Phone: 044-26541819

MR. RAMBHAI PATEL

SAGAR PUMPS(INDIA)LTD

135, BANNER INDIA ESATE OPP,

SOMA TEXTILE, RAKHIAL


Phone: 079-2743182/2742579

K. SAMPATHKUMAR, MD

SAM TURBO INDUSTRY LTD

BHARATI PARK, CROSS ROAD NO 7,

P B NO 2725, COIMBATORE-641011,

TAMIL NADU

Phone: +91 422 436264, 441155

P. D. JOSHI, MANAGER

SHREE SAINATH INDUSTRIES

S S HOUSE, OPP. SUMIN PARK,

G.D. HIGH SCHOOL ROAD, SAIJPUR BOGHA


Phone: +91 79 2820363, 2821763


Mg. Director

SUGUNA MACHINE WORKS LTD

707, AVANASHI ROAD

COIMBATORE-641018, TAMIL NADU

Phone: 0422-2215512Email: [email protected]

Mg. Director

WALKAR AUTOMOTIVES PVT LTD

20, SECTOR-4,, BALLABGARH

FARIDABAD, HARYANA

Phone: 0129-2240061,62,


COMPRESSOR


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Raj Patni, Director

Documents

ALUMINIUM FOIL & SHEET PROJECT REPORT