Iif Aluminium Day Chennai 16th April 2011

7/28/2019 Iif Aluminium Day Chennai 16th April 2011

1/44

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


2/44

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

solutions for sustainable future
http://en.wikipedia.org/wiki/File:Aluminium_bar_surface_etched.jpghttp://en.wikipedia.org/wiki/File:Aluminium-4.jpg


3/44

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.

Aluminium



4/44

4

Primary aluminium production by country (1950-2007)Primary aluminium production by country (1950-2007)

Aluminium



5/44

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)

Aluminium



6/44

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)

Aluminium



7/44

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)

Aluminium



8/44

0

500

1000

1500

2000

2500

2006 2007 2008 2009-e 2010-e

Output

Capacity

Aluminium



9/44

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%

Aluminium



10/44

Global end-use markets for finishedAluminium products, 2007

27%

24%

13%

21%

15%Transport

Building &

Construction

Packaging

Engineering and

Cables

Other

Aluminium



11/4411

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,

Aluminium



12/4412

Global Metal Use- 1950, 1980 and 2007

Aluminium



13/4413

Aluminium



14/44

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.

Aluminium



15/44

15

Functioning of Global Aluminium Flow Model with Data Inputs and Annual Outputs

Aluminium



16/44

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

Aluminium



17/44

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


18/44

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


19/44

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.

Aluminium



20/44

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

20Aluminium



21/44

21Aluminium



22/44

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.

Aluminium

http://talknsell.com/images/ALUMINIUM%20BUILDING%20PRODUCTS.jpghttp://photohome.com/pictures/texas-pictures/houston/enron-center-14a.jpg


23/44

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.

Aluminium

http://www.inmagine.com/fs919/fs919005-photohttp://www.google.co.in/imgres?imgurl=http://www.embaltech.fr/emballages/1.jpg&imgrefurl=http://www.embaltech.fr/embaltech-manufacture-of-aluminium-packaging.html&h=300&w=450&sz=26&tbnid=X5uSM-hc7RLJ5M:&tbnh=85&tbnw=127&prev=/images%3Fq%3Daluminium%2Bpackaging%2Bpictures&zoom=1&q=aluminium+packaging+pictures&hl=en&usg=__t7kq3Tnrwz4nrdXwPm2LMv2VHQc=&sa=X&ei=jO_cTNf8EISyccSd8MEL&ved=0CAkQ9QEwAA


24/44

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.

Aluminium

http://www.aluplanet.com/http://www.aluplanet.com/


25/44

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)

Aluminium



26/44

26

Indian Automobile Industry-High Growth in allSegments

Aluminium


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)


27/44

27

Aluminium Applications in the AutomotiveIndustry are Growing

Aluminium



28/44

Aluminium



29/44

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

Aluminium



30/44

30Aluminium solutions for sustainable future

CO2 Reduction Potential in Transport with Aluminum


31/44

Aluminium



32/44

Aluminium



33/44

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

Aluminium



34/44

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

Aluminium



35/44

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

Aluminium



36/44

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.

Aluminium



37/44


38/44

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


39/44

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


40/44

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.


41/44

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


42/44

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 :


43/44

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


44/44

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]/

Documents

Iif Aluminium Day Chennai 16th April 2011