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7/28/2019 Iif Aluminium Day Chennai 16th April 2011
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Aluminium Day Celebration
Prof. K.S.S.Murthy, Hon. Gen. SecretaryAluminium Association of IndiaNo. 118, Ramanashree Arcade, First floor, 18, M.G.Road, Bangalore 560 001Tel : 080 2558 2197 / 2558 2757, Fax : 080 2559 4535e-mail : [email protected] / [email protected] : http//www:aluminium-india.org
IIF Seminaron
ALUMINIUM- THE METAL ON THE
ASCENDANCY
16TH April 2011, Chennai
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Amongst metals, Aluminium ranks second, next only to steel, interms of volumes used, due to its versatility, which stems from itsexcellent properties. It is exceptionally light, has high strengthwhen alloyed, is impervious to rust & possesses a high degree ofworkability. It is also a good conductor of heat and electricity and has a softluster, with an aesthetically pleasing appearance. Aluminium is highly recyclable and over 70% of the total metal
produced till date, is still in use. The proportion of recycled metalin total aluminum produced is constantly increasing Aluminium is the third most abundant element in the earths crust,after oxygen and silicon. It makes up about 8% by weight, of the
Earths solid surface. Aluminium is also considered to be a Green Metal, and the
Aluminium Industry is the only industry in the world to claim tobecome green house gas (GHG) neutral, by the year 2020.
2
ALUMINIUM Metal of the future
Aluminium
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ALUMINIUM GREEN METALAccording to the International Aluminium Institute (IAI), global production of new aluminium
stock account for 1% of the global human-induced greenhouse gas (GHG) emissions which cause
global warming. However, the energy savings that can be made through recycling the metal
repeatedly, fuel savings that can be obtained by light-weighting the vehicles and reduction of
emissions from vehicles made of aluminium cumulatively have a far greater positive impact on
the global environment and climate change. For example, every 100 kg of automotivealuminium replacing other heavier materials saves about 2 tonnes of carbon dioxide overthe vehicles lifetime on account of enhanced fuel efficiencyALUMINIUM ENERGY SAVERRecycling is the cornerstone ofAluminiums Sustainability.
Aluminium recycling reduces greenhouse gas emissions by 95%, compared to Primary Aluminiumproduction.
It only takes 5% of the energy required to produce Primary Aluminium to recycle it. Aluminium is an energy bank most of the original input can be recovered every time the
Aluminium product is recycled.
Aluminium can be recycled to infinity without any loss of quality or properties.
Over70% of the Aluminium ever produced worldwide is still in use today 450 million tonnes.
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4
Primary aluminium production by country (1950-2007)Primary aluminium production by country (1950-2007)
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CountriesProduction in 000 t
2008 % of total 2014 % of total
China 13,695 34 21,481 43
Russia 4,191 10 3,712 7
Canada 3,124 8 756 2
USA 2,658 7 1,754 3
Australia 1,978 5 1,727 3
Brazil 1,661 4 1,684 3
Norway 1,383 3 1,195 2
India 1,348 3 3,958 8
Dubai 899 2 1026 2
Others 9,194 23 13,042 26
Total 40,131 100 50,335 100
5
Major producing countries (Source: CRU & Industry data)
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Countries
Consumption in 000 t
2008 % of total 2014 % of total
China 12,604 34 22,088 44
Russia 5,147 14 5,505 11
Canada 2,319 6 2,259 4
USA 1,929 5 2,054 4
Australia 1,459 4 2,030 4
Brazil 1,089 3 3,800 8
Norway 951 3 869 2
India 937 3 1297 3
Dubai 933 3 1,198 2
Others 10,051 24 9,551 19
Total 37,419 100 50,651 100
6
Major Consuming Countries ( Source : CRU & Industry data)
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Chinese primary aluminium production
1,5002,0002,5003,000
3,5004,0004,5005,0005,5006,0006,5007,000
7,5008,0008,5009,0009,500
1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006
Production rate(000t/year)
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0
500
1000
1500
2000
2500
2006 2007 2008 2009-e 2010-e
Output
Capacity
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World : 46.6 million ton
FRPs33%
Extrusions29%
Castings23%
Wire & cable11%Others
4%
CY 094%
11%
23%
29%
India : 1.81 million tonFY 10 E
15%11%
11%37%
26%
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Global end-use markets for finishedAluminium products, 2007
27%
24%
13%
21%
15%Transport
Building &
Construction
Packaging
Engineering and
Cables
Other
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RECYCLING
Aluminium can be recycled over and over again without loss of properties.Aluminium recycling benefits present and future generations by conserving
natural resources and energy. Recycling saves up to 95 per cent of the energy
required for primary aluminium production, thereby avoiding corresponding
emissions, including greenhouse gases.
Global aluminium recycling rates are high, approximately 90 per cent for
transport and construction applications and about 60 per cent for beverage cans.At the global level, one-third of all aluminium metal entering the market is from
recycled material. Recycled material accounted for around 15 million tonnes (IAI
estimates). This comprises 7.7 million tonnes returned from customers after
fabrication processes and 7.4 million tonnes of product returned from end-ofuse
(for example, aluminium content of used motor vehicles and used beverage cans
UBCs).The global energy saving is around 215,000 GWh,
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Global Metal Use- 1950, 1980 and 2007
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Most recent forecasts from IAIs Global Aluminium Recycling Committee show
growth in recovered scrap from 2010 at approximately 9.5 million tonnes to almost
17 million tonnes in 2020, following the life cycle analysis of the various product
groups and taking into account projected collection and recycling rates.
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15
Functioning of Global Aluminium Flow Model with Data Inputs and Annual Outputs
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Sand Casting Shell Moulding and Core Making
Centrifugal Casting
Investment Casting
Plaster Mould Casting
Expanded Polyestyrene Casting Technology
Permanent Mould Casting (Gravity Die Casting)
Low Pressure Die Casting (LPDC) High Pressure Die Casting (HPDC)
Prominent and promising technologies
Squeeze casting Semi-solid forming
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Lower temperature and short dwell time lead to longer die life.
Short process cycle and automation results in higher productivity
Raw material is heated to semi solid condition, so it consumes 35% less energy than
conventional casting methods.
Fluid flow filling die cavity under high final pressure enables the filling of thinnersections.
Semi-solid charge produces less liquid / solid shrinkage and less micro-porosity
Laminar flow of the molten metal when filling the die will avoid the gas entrapment and
porosity.
Rapid quench in the forging press avoids expensive solution treatment to obtain higherproperties.
High wall thicknesses and different wall thicknesses can be designed
Low gas porosity due to laminar filling and good airing
Low solidification porosity due to a high solid fraction proportion (fsolid ~50%) Production of thin walled components
Allows for the casting of wide range of alloys inclusive of high strength wrought alloys.
Joining by LASER, MIG or WIG welding possible
Heat treatment from T0 - T7 possible
Near netshape or netshape parts production * Improved tool life
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Wide range of applications: automotive, aerospace, defence and structural
applications
SSF components: 30-35% increased strength compared to parts processed throughconventional casting processes
Ability to process high strength wrought alloys
Improved mechanical properties and ability to produce
thin walls, considerable energy savings and low
machining costs
Near net shape manufacturing
Applications of SSM Technology in the Automotive Industry
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19
India is positioned in 6th place with a bauxite resource base of about 770Mt.
Almost 85% of these resources consist of the metallurgical grade bauxite, which is
used in aluminium production. High quality bauxite ore and low labour and power
costs has established India as one of the lowest cost producers of primaryaluminium worldwide. Indian companies lie in the least quartile of the global
primary aluminium cost curve. Indias primary production capacity at the end-
March 2009 was 1.53Mt, which is an increase from 1.20Mt at the end- March
2008..
Indias remarkably low per capita consumption of 1.6kg offers immense potential
for growth in its domestic market.
Indias domestic aluminium consumption tripled between 2002 - 2009 from 0.5Mt
to 1.4Mt a CAGR growth of 12%. The industry has been closely following the
robust growth in demand by increasing domestic capacity at a CAGR of 10% from
0.75Mt to 1.32Mt in the same period.
Domestic production also increased at a CAGR of 11% from 0.6Mt to 1.5Mt.
Between 2009 and 2014, however, demand is expected to grow at a CAGR 9.5% to
2Mt driven by the automotive and construction sectors, which are each likely to
grow at a CAGR of 10% during
the same period.
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Indian Aluminium Industry consists of primary integrated producers (who
procure Bauxite and process into aluminium) and secondary fabrication units
(who convert aluminium ingots into rolled and extruded products).
The Three major producers are:Hindalco, Vedanta Group and the state owned Nalco, who mine / procure
bauxite and convert it into Aluminium ingots
These three together account for the majority of share of total domestic
aluminium production in India
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APPLICATIONS SECTORS
Aluminium is a key component of so many aspects of our life from the buildings we work
in, to the cars we drive, from the cans we drink out of, to the flights we take. Its unique
combination of properties make it ideal for an almost endless range of applications, and
an essential part of modern day life.===========================================================================
Building & Construction
The Building and Construction industry is today faced with many
environmental challenges - its impact on climate change, to its
choice of materials and methods of waste disposal. Aluminium is
one of the most abundant metals in the world, Aluminiumsformability, high strength-to-weight ratio, corrosion resistance, and
ease of recycling makes it the ideal material for a wide range of
building applications such as form-work, curtain-walling, doors
and windows.
The global inventory of aluminium in use has grown from 90
million tonnes in 1970 to about 600 million tonnes today andis forecast to reach more than 1 billion tonnes in 2020. This
is creating a vast material and energy storage bank for
future recycling use. The building sector is forecasted to
represent up to 35%, transport 28% and engineering plus
cable 27% of the 2020 inventory in use.
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Packaging
Aluminium, the ideal material for Packaging hasmade significant inroads into the packaging sector,
and is already a well established packaging raw
material in the western world. Aluminium is used
extensively for the protection, storage and
preparation of food and beverages as well as
medicines and cosmetics. The key geographical
areas for growth in packaging, are the developingcountries. Aluminium foil has excellent barrierproperties which keeps out air & moisture and
makes it superior to paper packaging.
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Power
The Electrical sector is still a major consuming sector for
Aluminium, in India. Aluminium or Aluminium alloy
electrical conductors are widely used in overhead electricaltransmission and distribution cables, power systems and
substations . Aluminium is particularly well suited to theseuses because of its high electrical conductivity, low weight
and good resistance to corrosion..
There are really only a few application sectors where aluminium is not used. Use isexpected to grow as its properties are especially appreciated by designers, architects
and engineers as well as by the manufacturers and end users of the product.
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Transportation
This is one of the most important application sectors for Aluminium, both in terms of
current volumes and growth prospects. The combination of lightweight, strength andformability characteristics of Aluminium, make it the ideal material for transport
applications, such as aerospace, automotive & marine. Currently, Europe is usingapprox 140kg of Aluminium /car, which is expected to increase to 160 kg/car in the
next 2-3 years.
The automobile industry is the biggest consumer of aluminium on the global market, andapprox. 21% of primary aluminium is used here.
(Source: CRU Photo: Audi.com)
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26
Indian Automobile Industry-High Growth in allSegments
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2,200
150 120 200
10,230
420 40
5,100
670 360 390
22,100
710 100170-190
940-1,050
30,000-33,500
540-600470-530
1,100-1,220
8,700 - 9700
Passenger
vehicles
SCVs LCVs M&HCVs Two & Three
wheelers
Tractors Construction
equipments*
In
'000
units
2009 2015 (E) 2020 (E)
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27
Aluminium Applications in the AutomotiveIndustry are Growing
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29
887785
9281003
1229
0
200
400
600
800
1000
1200
1400
Ref.- Car Primary state-of-the-artweight
Primary latest-technology
weight
Upper finalweight(Al-Car)
Lower finalweight(Al-Car)
weig
ht[kg]
Minimumsecondary weight saving Maximumsecondary weight
saving
Primarystate-of-the-art
weightreduction
Primarylatest-
technologyweightreduction
Aluminium helps light weighting Cars
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30Aluminium solutions for sustainable future
CO2 Reduction Potential in Transport with Aluminum
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GDP Growth
Primary Aluminium consumption in India has
grown from 450 kt in 1991, to 1,140 kt in 2008
and currently accounts for 3.1 % of global
consumption. Total Aluminium consumption(Primary + Recycled) has grown significantly, at a
CAGR of around 15% during 2002-09 and
reached 1.5 million tonnes. As per Mckinsey &
Co., Indian Aluminium use will grow 9 to 11
per cent to 2.10 to 2.75 million tonnes, by
2015.
As per Mckinsey & Co.,the growth drivers of theIndian economy are as follows:
Indian incomes will triple over next two decades
India will emerge as the fifth largest consumer
economy. A large urban middle class will
develop, but the rural sector will benefit too
Patterns of consumption will shift rapidly,towards discretionary spending.
The Aluminum consumption follows the GDP
growth curve, hence these would also be growth
drivers for the consumption of Aluminium
0
100
200
300
400
500
600
700
800
1990
1995
2000
2001
2002
2003
2004
2005
2006
0
0.2
0.4
0.6
0.8
1
1.2
1.4
GDP per cap ita(LHS)
Per c apita Al cons (RHS)
India GDP v/s Al cons. Per capita
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INDIA TO AUGMENT ALUMINIUM PRODUCTION
Aluminum industry in India is moving towards overcapacity, since supply is likely to
grow in
excess of demand going forward. Considering that all aluminum projects would begincommercial production with expanded capacity as planned, there could be at least 2
million
tonnes of additional capacity for exports by 2013.
Fitch Ratings report recently said that Indias aluminum productions will more than
treble to 4.4 Million tonnes by mid 2012 with new capacities coming on stream, along
with requisite captive Power generation capacities.
Company 2009 2013
Hindalco Industries 0.488 1.138
Nalco 0.403 1.000
Vedanta Resources 0.638 2.000
Others 0.200 0.300
Aluminum meter production in million tonnes
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35
All major producers have chalked out future mega expansion plans
Company Location Aluminium (kt) Alumina (kt)
Project Cost -
(USD Amt Million)
Hindalco Orissa 1500
7029.877
Orissa 100
Madhya Pradesh 360
Jharkhand 360
Orissa 360 1500
Vedanta Orissa 1750 35009666.081
Chattisgarh 325
Jindal Andhra Pradesh 250 1500 1977.153
Ashapura 1000 768.893
Nalco Orissa 735 1400 5052.724
Andhra Pradesh 1400 1537.786
Secondary producers 219.684
Total 4240 11800 26252.197
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36
CONCLUSIONS
The world is changing, competition reigns, and natural
selection has been refining and perfecting business globally.
Against this background, successful aluminum companies
have been adapting their respective structures to address new
market realities, improving management and production and
devising optimum strategies.
The aluminum business shows dynamic development, and the
outlook for the metal as a structural material is bright. It is
indispensable both for achieving higher standards of living and
for supporting solutions to such crucial global issues as energyand material savings and ecological safety.
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6th to 8th December 2011
At Hyderabad InternationalConvention Centre, (HICC)Hyderabad. India's first purpose - built and state -of -the- art convention facility with In-house 5-starbanqueting service, connected to Novotel Hyderabad
Convention Centre. HICC is the winner of the BestConvention Centre National Tourism Award byIncredible India
SIXTH INTERNATIONAL CONFERENCE ON ALUMINIUMThe Sixth International Conference on Aluminium INCAL11 is being organized by the AAI, to bring the internationalaluminium fraternity together on one platform where the
current issues will be discussed and ideas will be exchanged
on the growth and development of aluminium
WHEN
WHERE
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In conjunction with this globally important conference INCAL 11, an Exhibition isbeing organized alongside the Conference. The exhibition will focus on the state-of-
the-art technologies, showcasing new technologies, processes & products and inturn enhance business. The exposition will be open to delegates and other industryprofessionals.
Exhibition
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INCAL-2011 is also being organized under the aegis of Ministry of Mines,
Government of India, which has been a practice since the first Conference held in
1985
Honble Minister of State of Mines is the CHIEF PATRON
Secretary Ministry of Mines is the PATRON,
Additional Secretary, Ministry of Mines, Director Aluminium, Ministry of Mines
& Jt.Secretary Ministry of Mines as the M e m b e r s .
Besides Primary Producers and Downstream industries over 25 leading overseas anddomestic companies have already confirmed their participation at INCAL 2011- ie.,
International Aluminium Institute, European Aluminium Association, The
Aluminium Association, Rio Tinto Alcan, ALCOA, Novelis, Aura International
Private Limited, CSIRO, CRU, Fluorosis Research & Rural Development
Foundation,, Alstom etc.
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WHY SHOULD YOU ATTEND
To witness a congregation of some of the best experts in the global aluminium
industry from among primary metal producers, secondary producersie.,extruders, fabricators, foil & can manufactuers, etc., researchers,academicians, and end-users,
To get an insight into the latest developments & data on Market Trends /Applications, Process Technologies, R&D, Equipment and Environment, techno
economic issues to help the Indian Aluminium Industry to effectively meet theglobal challenges and competition, technological developments and on variousapplications of aluminium, all of which are significant to India, which is on thethreshold of becoming a prominent global player.
To understand the growth pattern and emerging trends
To interact and network with the stakeholders and policy makers of futuremarket.
TYPES OF
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INCAL 11 will focus on High Quality Papers ( all Invited),
with the Exposition serving Product, Technology,Equipment & Information suppliers presenting
themselves to Indias Aluminium producers.
Plenary- Pre Lunch Session: 9.30 am
1:00 pm 30 min Presentation + 10 min Q & A
Total 12 papers in 3 days
Two Parallel Sessions-Post Lunch:2.00 pm5.30pm
25 min Presentation + 5 min Q & A
Total 44 papers in 3 days
Inauguration & Panel Discussion - Ideas to be firmed
up
Plenary & Parallel sessions
PRESENTATION
1. General /Visionary:
2. Technology Process andEquipments:
3. Marketing andApplications:
4. Recycling :
5. R & D :
6. Environment &
Energy :
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Utilize Hall 3 of Hyderabad Convention Centre
Have 2000 sq mts of display stall space
Provide facility for one to one discussions
Cafeteria planned in the Exposition area
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FOR FURTHER DETAILS PLEASE CONTACT
INCAL-2011 SECRETARIAT
Aluminium Association of IndiaRamanashree Arcade, # 118, First Floor,
18, M.G.Road, Bangalore 560 001
Ph : 91-080-2558 2197/2558 2757 Fax : 91-080-2559 4535E-mail : [email protected]/
[email protected] : http://www.aluminium-india.org
mailto:[email protected]/mailto:%[email protected]:%[email protected]:%[email protected]:%[email protected]:[email protected]/mailto:[email protected]/