R2 Report

Minex
Introducing itself as one of the pioneers, Minex organization is based

in India. Minex is an ISO 9001-2008 certified company serving
Aluminum, Iron & Steel Industries & Non-Ferrous Industries for 30
years. The company is in operation since 1984 and has 3 operating
plants in Central India, in the vicinity of Nagpur. In the past decade,
Minex has emerged as a benchmark in providing total alloying
solutions making it a $100 million company. The following products
are regularly being used by reputed foundry industries:
IRON FOUNDRIES:
Ferro Silicon Magnesium Alloys for S.G. Iron production.
Barium, Strontium, Calcium and Zirconium based inoculants.
Nickel Magnesium Alloys. Rare Earth and Mischmetal Cored wires
for S.G.Iron production, inoculating wires of various specifications
for S.G. Iron production.Minex Wire Injection system for injection of
Ferro Silico Magnesium cored wires and Inoculants cored wires.
STEEL FOUNDRIES:
Ferro, Aluminum Ferro, Silico, Calcium Ferro, Titanium Ferro, &
Zirconium Cored Wires.
ALUMINUM FOUNDRIES:
Titanium, Boron, Aluminum, Aluminum-Boron, Iron Tablets.

Aluminum-Chromium, Aluminum-Strontium, Aluminum-Iron Cored
Wire Injection System.
In the field of Cored Wire Feeder and Cored Wire, Minex is pioneer in
this part of the world, having introduced this technology during the
Eighties, initially with Wire Feeder and Metallurgical Cored Wires.
Minex has installed, provided technological support and evolved Wire
Injection System since 1988 and so far over 400 Minex Installations
are in operation within India and other south Asian countries for
various ladle size from 1 MT to 300 MT, with single-strand Wire
Injection to Four Strand Wire Injection. The Cored Wires are being
manufactured with either Horizontal or Vertical Flipping and shrink
wrapped and palletized as sea-worthy packing. Since 2001, Minex
ventured into the Export Market and is supplying to the following
companies directly, as well as through representatives:
UAE: (HADEED Saudi Iron & Steel Company, International Ductile
Iron Pipes Co. Ltd (INDIPCO), Saudi Arabian Ductile Iron Pipes
Company Ltd SADIP)
Egypt: (ARCOSTEEL, Helwan Iron Foundries)
Iran: (MSCO, Iran Tractor Foundry Co., Iran Alloy Steel Co.,
Esfahan Alloy Steel Complex, Luleh Va Machine Sazi Iran Co. (LMI
Co.), Hamoun Nyzeh Co.(IRALCO)
2
Malaysia, Sri Lanka: (Loadstar Pvt. Ltd),

Israel: (Modgal Metal Ltd),
Poland, Italy, Columbia & France: (PAM Saint Gobain)
Korea: (POSCO) & so on.
Quality Control
Quality control and internationally recognized quality assurance are
an integral feature of Minex. All the facilities are covered under ISO
9000 certification. The central lab at Nagpur is NABL accredited and
fully equiped with state of art analytical equipments.
Research and Development

R&D is an important activity for minex having pioneereed most of its
alloy and metallurgical process in the domestic market. The
Department recently added its own vacuum melting and casting for
production and development of master alloys.
Minexs policy of investment in production, process technology,
R&D, IT together with its experience and professional customer
service in the field, enables it to meet successfully the every stringent
and sophisticated demands of the worlds metal industry.
Ti Scrap vs Ti Turning
Titanium is a key Raw Material to Manufacture Ferro-Titanium 6570% Grade. The capacity of Nimji Plant is to Manufacture 200
Tons/Month. At present we are Manufacturing on an average 40
Tons/Month as we dont have orders and our competitors are selling
FeTi much Cheaper. It is being observed that if we reduce the price by
$0.1/kg we will be competitive in market. 160 Tons/ Month Of
Capacity is being Un-utilized. This Un-utilized capacity which is an
liability now can be a asset if the plant runs at maximum capacity.
For the production of FeTi 65-70% grade, 70% of Ti is required.
Hence to produce 200 Tons of FeTi 65-70% grade, we require 140
Tons of Titanium. At present we are using 50%Ti Scrap and 50% Ti
Turnings. The cost of Ti turning and Ti scrap is Rs 190/kg and Rs
322/kg respectively.
The Present Cost of Titanium in the production of 200 tons FeTi (6570%) will be Rs 3,58,40,000. If we use only Ti Turning the cost of
Titanium in the production of FeTi (65-70%) will be Rs 2,66,00,000.
Thus if we use only Ti turning our Per Month saving will be Rs
92,40,000.
Drawbacks of Ti Turning
Titanium turning comes inherently with impurities such as oil, grease
and dust. If these turning are used without processing, oil gets burned
and is converted into carbon. Thus the Carbon in the final product
increases to 5-7%, whereas the desired level of carbon is 0.1%. In
order to use Ti turning, it must be processed to remove oil.
Present Oil Removing Method

Ti turnings are washed with Hot water(52C) and Caustic Soda in a
Cement Mixer and than dried. Washed Ti Turning are dried with the
help of 2 hot plates or are sun dried as and when weather permits. The
capacity of Cement Mixer is 50 Kg. One Batch of Ti Turnings i.e
50kg requires 500 liters of water and 3 kg of caustic soda. The total
time taken to process one batch of Ti turning is 2-3 Hrs. In a day
maximum 400Kg of Ti turnings can be washed in one cement mixer.
If the present method is used to process Ti Turning, the quantity so
processed is directly proportional to the number of cement mixer.
Time & Motion Study of Ti Turning Washing Method

We performed a time and motion study on the workers working in
Titanium Turning Processing.
Following is a schematic Timeline.
Description
1) Putting 50 Kg Turning in Mixer
Time Required is 4 Mins and 28 sec (5mins)
To fill the Mixer with 50kg of turning, a man fills a tub 13 times
and empties it 13 times in Mixer (A Conical )
2) Heating the water and Pouring it in Mixer
Time required 49 Mins and 13 sec
A Tub 1 is kept bellow the geaser. It Takes 41mins and 2 sec to

fill the tub with 200 lit of water. The temperature of the water is
511C
The worker then fills another tub 2 which is kept on a trolley
with the help of a bucket (he fills the bucket from Tub1 and then
pours it in tub 2). The time taken is 2 Min and 6 sec
The tub 2 which is on trolley is taken near Mixer, Time taken is
54 sec
The water from tub2 is poured in Mixer using bucket. The time
taken is 2mins and 40 sec. The Temperature of the water drops
48.3
3) 2kg caustic soda is added

Time required is 28 sec
4) The Mixer is started, and the turnings are washed for 40-50 mins
depending upon the oil which can be seen visually.
5) Taking the turning out and drying.
Time Required is 92 mins and 32 sec
The Mixing Pot is inclined at level so that the wastewater is
drained off, Time requied is 2 min 7 sec
After removal of water the pot is rotated to take the turnings out,
Time requied is 1 min and 15 sec
This turnings are than spread over a plastic sheet for Sun
Drying, time required is 88 mins
The above steps/process is for only one wash of 50 kg batch. The

above process is carried out 2-3 times depending upon the visual
inspection of oil in Ti turning.
Observations
o No SOPs
o Lots of time and energy is wasted for carrying out simple
processes and task
o Unefficient machines being used
o No Proper Supervision
Our Proposal
Instead of Using Caustic Soda various Alkaline Powder or Chemicals
which are more efficient than caustic soda. If we use Alkaline Powder
or Chemicals we will save 200 Litres of water per Batch. The Time
required For One Batch can Be Reduced to 50-55 mins from 2-3 Hrs.
Instead Of using Cement Mixer Some other Machine or technology
can be used to Process Ti turnings.
Vacuum furnace can also be used to process Ti turnings.
Alternate
Solvents
1) ACCEPTA 3528
Accepta 3528 is an advanced, highly alkaline industrial detergent and
cleaning agent available in a concentrated powder form. It is
scientifically formulated for the effective cleaning and removal of oil,
grease, carbon, rust, scale and paint from surfaces.
Accepta 3528 is a technically advanced industrial cleaning product
that has a detergent type action, penetrating the surface film and
mechanically lifting deposits from the underlying sound material,
breaking them up and dispersing them into the body of the solution.
As the cleaning operation of this high performance product is a
surface action, it ceases as soon as the base material is clean,
eliminating the risk of dissolution or pitting of the base metal.
Accepta 3528's integral dispersants also ensure that contamination
removed from dirty surfaces is held in solution to prevent re-soiling.
Unlike many acid cleaners, there are no harmful or corrosive vapours
and as Accept 3528 does not attack sound ferrous metals, the need for
rubber-lined tanks and stainless steel equipment is eliminated and
mild steel tanks and trays are adequate for the cleaning process.
Accept 3528 is a high efficiency, low maintenance industrial cleaning
product that is the safe and economical answer to most degreasing
problems.
Product Benefits
Removes oil, grease, carbon, rust, scale and paint

High alkaline powder concentrate effective for a range of
surface films
9
Lifts deposits and disperses them into the solution preventing resoiling
Process stops as soon as the base material is clean
Eliminates the risk of dissolution or pitting the base metal
Added water softeners ensure no loss of the products power
Effective even in hard water conditions
No harmful or corrosive vapours
Will not attack sound ferrous meals
No specialist equipment required
Application & Dosage Information
Concentrations between 50 g/litre and 200 g/litre heated to 90-100C
should be employed.
2) ASFOCLEAN-310
Asfoclean-310 is a coarse granular powder, consisting of a blend of
strong alkalies, penetrants and dispersing agents. It was developed for
rapid removal of unwanted materials from ferrous metal parts. It
penetrates the contaminants, reacts chemically with the metal surface
and thereby removing all exterior deposits on the metal surface.
Uses:
Asfoclean-310 when dissolved in water, provides an easy means of
removing oils, dirts, carbonaceous products, paints and varnishes
from iron and steel. Its main use will be found in the reconditioning,
and in the reclaiming of rejected components. Asfoclean-310 can be
used on copper and aluminium but with great caution, and only at low
concentrations as it may cause excessive attack to the base metal.
Applications:
10
It is normally used at concentration of 5 10% in water in a hot soak

tank preferably fitted with means of agitation. The most rapid results
are obtained if the operation is carried out at higher temperature of
60C - 90C. In every case we recommend a final rinse in boiling or
near boiling water.
3) ETHANOL
First step of the conditioning, drying of the turnings was performed at
120 C for evaporation of water, which is a major component of
commercially used lubricants. In order to remove the remaining oilbased lubricant components, the turnings were washed in ethanol,
then again dried at 100 C. Subsequently, both turning qualities were
mixed and then compressed to compacts of approximately 300 g each
at a density of 1.5 kg/dm3. Although this accounts for only one third
of the theoretical density, it is sufficient for a satisfactory energy input
during vacuum induction melting. The necessary applied force for
briquetting depends on the fine/bulky turnings ratio, ranging from 150
t for 100 % bulky turnings to 50 t for 100 % fine turnings. A fine-tobulky ratio of 2:1 was chosen for further processing, taking into
account the higher market share of Ti-6Al-4V. As final conditioning
step, the briquettes were heated to a temperature of 400 C.
4) ALLCLEAN-100
ALLCLEAN-100 is a compound of inorganic hydrocarbons and
wetting agents and inhibitor. It removes all types of oil from the all
metal without affecting its property. It is non-flammable liquid.
Allclean-100 can be used to remove oil from ferrous or non ferrous
metallic components. It is very easy to use Allclean-100, just dip the
metal piece into the Allclean-100 for few seconds
and take it out, the metal piece will become dry in few seconds. It
does not require external Heat.
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Machines/Patents
1) AquaChemical Microfiltration System
The Titanium scrap metal processor began a search for a better
solution to the problems associated with the wash system. The
objectives were to extend the useful bath life, reduce the wastewater
volume generated, ensure the quality of the washed turnings exiting
the wash system, and reduce the drag-out of oils from the turnings
into the rinse water to help meet discharge regulations. The
AquaChemical system employs a ceramic microfiltration membrane
to filter and recycle aqueous alkaline cleaning solutions. The
microfilter has a porosity of approximately 0.2 microns. The
AquaChemical system removes emulsified oil from wash water, but is
not designed to remove excessive quantities of free floating,
unemulsified tramp oil, which is almost always present in these
operations. These types of oils can reduce the AquaChemical system's
throughput if not properly pretreated. A device called the Suparator,
manufactured by Aqueous Recovery Resources, Inc., of Bedford
Hills, NY accomplishes this objective very well by removing
unemulsified tramp oil from the wash solution and enables the
AquaChemical system to work at its optimum level.
The result is that the processor is washing titanium turnings with a
wash solution that is consistently better over the long-term than
before, which has resulted in fewer interruptions and better carbon
numbers for the recovered turnings from the wash system. The wash
solution itself is cleaner, with regards to oil content; thus the rinse
water has less oil content from drag-out than previously seen. The
drying process now produces less smoke from oil residue burning;
thus the working environment has improved, which was an
unforeseen, but welcome improvement to the processing line. With
the use of the AquaChemical and Suparator systems, the processor has
significantly improved productivity, cut operating costs, reduced
waste, and improved product quality from the washing operations
conducted on scrap titanium turnings.
12
2) US3627289 (Patent)
An apparatus and method are provided for use in removing oil from
metal turnings. The apparatus includes an arrangement used to
suspend oily turnings in a stream of hot combustion gases which
13
vaporize oil contained on the turnings, and a combustion chamber

which generates hot combustion gases from a mixture of air and
vaporized oil removed from the turnings and recirculates a portion of
the combustion gases to the dryer. In addition, the apparatus is
provided with a natural gas burner which generates secondary
combustion gases for the combustion chamber when insufficient heat
is generated by the combustion of the air-vaporized oil mixture alone,
a blower which circulates air vaporized oil and secondary combustion
gases to the combustion chamber and a control assembly to balance
the flow of the air-vaporized oil mixture and secondary combustion
gases.
3) US1743465 (Patent)
This machine uses Alkaline solution and water at 90-100C to remove

oil from metal surface. Pumps are installed to remove the top layer of
water which contains oil
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Problem Associated with Alkaline Solution/Washing

One Of the Biggest Problem related with Ti Turning Process is the
disposal of waste water, the present quantity of waste water is 3200
l/day & to wash 5.6 tons turnings per day, we require 56000
Litre/day water. Waste Water contains Oil & Grease which when left
untreated can Pollute Environment. Water comes at a cost, at present
our monthly cost of water for washing Ti turning is Rs 32000 & to
wash 140 tons of turning per month, the water cost will be Rs 5.6
lakh
At Present this waste water is drained off, thus polluting the
environment. To Prevent Pollution of environment and minimizing
the cost associated with the water, it should be treated to remove oil
and reused. Various Chemicals and Absorbent Material/ filters can be
used to remove oil & grease from the water such as-
1) TIGG OMC
DESCRIPTION
TIGG OMC is a granulated surface modified substrate typically used
to absorb oil, hydrocarbons and heavy metals from water. The
substrate is modified with quaternary ammonium compounds which
attract and hold hydrocarbons. This active ingredient is capable of
absorbing at least 1-2 times its own weight of contaminant, depending
on the specific gravity and molecular weight. The product is offered
mixed with anthracite in a 70:30 ratio of anthracite to active
ingredient. Thus, the capacity for oil ranges from 30-60wt% of the
total weight of the media. Contact TIGG Corporation for applications
involving metals removal.
TYPICAL APPLICATIONS
Some of the areas where OMC has been used to absorb free and/or
mechanically emulsified oil from ground water, landfill leachate,
stormwater, steam condensate, the discharge from oil/water separators
15
and DAF units. It is also used as pretreatment to activated carbon, ion

exchange and reverse osmosis systems.
2) TIGG OMC-P
DESCRIPTION
TIGG OMC-P is a granulated surface modified substrate typically
used to absorb oil, hydrocarbons and heavy metals from water. The
substrate is modified with quaternary ammonium compounds which
attract and hold hydrocarbons. This active ingredient is capable of
absorbing at least 1-2 times its own weight of contaminant, depending
on the specific gravity and molecular weight. Contact TIGG
Corporation for applications involving metals removal.
TYPICAL APPLICATIONS
Some of the areas where OMC-P has been used to absorb free and/or
mechanically emulsified oil from ground water, landfill leachate,
storm water, steam condensate, the discharge from oil/water
separators and DAF units. It is also used as pre-treatment to activated
carbon, ion exchange and reverse osmosis systems.
3) LATERITE BRICKS
The experiment was carried out using the process of adsorption in
which Laterite material was used as the adsorbent. A synthetic
wastewater sample was used for the study. The study was done by
passing this wastewater in a zigzag path through a channel provided
with Laterite brick baffles. Various parameters such as wastewater
flow rate, length of the flow channel, contact area, baffle spacing and
baffle orientation are considered and oil removal efficiency was
observed.
After stabilization of flow, samples of wastewater were collected
from regular intervals of 1.5 m along the length of the channel. These
samples were tested for oil and grease concentration in the
laboratory by using suitable method. Then oil removal efficiency was
determined.
In Stage I, initially a baffle spacing of 0.25 m centre to centre (c/c)
was adopted, with straight orientation
16
Samples were collected for different flow rates. Trials are repeated
for 0.33 m and 0.44 m c/c spacing. In Stage II, orientation of baffle
was changed and baffle bricks were placed at an inclination of 450 to
channel wall Experimental trials were conducted for various flow
rates. In Stage III, extra bricks were placed in such way that flowing
wastewater touched the underneath portion of the baffles. Thus
contact area between wastewater and adsorbent increased. Collected
samples were tested and analysed for oil and grease concentrations
17
Based on the results obtained in the different stages of this

experiment, it is quite evident that Laterite is a powerful adsorbing
medium. For closer baffle spacing and slower flow rates, the contact
period with adsorbent increased and thus efficiency increased. In
addition, as the length of channel increased efficiency also increased.
Thus optimum results may be obtained for slower flow rates, closer
baffle spacing and higher channel length. Since Laterite is cheaply
and easily available, expenses and maintenance incurred are very low
as compared to other system. Hence this method can be conveniently
employed in the vehicle service stations and may be adopted as
pretreatment unit in biological treatment plants. However further
investigations may be necessary on performance of adsorbent for
continuous wastewater flow and its reuse potential.
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Vacuum Furnace for Processing Ti Turning

If we use washing technique to Process 8 Tons of Ti Turning, we
require 32 Tons of water. Disposal of waste water is an issue.If we use
Vacuum Furnace for Processing Ti Turning no water is required,
Hence no problem related to disposal of Waste Water. We can Process
333 kg of Ti Turning and the time required will be reduced to 1Hr.
Through vacuum we can reduce the boiling point of oil. Vacuum
Furnace Processing works on the principle that boiling point of oil is
lower than melting point of metal.
Experiments
We conducted 18 trials in vacuum furnace for processing Ti turning.
On First day, we conducted 6 trials at 10 in Hg vacuum & we where
able to reduce carbon from 10% to 0.5067%. On second day, we
varied vacuum from 10 in Hg to 29.5 in Hg & repeated the first trial
where we got 0.7306% carbon. On third day, 5 trials were carried out
and carbon was reduced to 0.2931%.
First Trial
Heat in a vacuum furnace, pressure at 10 in Hg.
1. 2 min hold with heater at 10 KWH.
2. 8 min hold without heater.
3. Again 2 min hold with heater at 10 KWH.
Carbon % - 0.507
Second Trial
Sample weight 40 g
19

Carbon % - 8.77
Third Trial
Sample Weight 40 g
2. 1 hr hold without heater.
Carbon % - 10.7
Fourth Trial
Sample weight 40 g
Carbon % - 10.77
Fifth Trial (Repeat of Trial 1)
Sample weight 40 g
1.
2.
3.
4.
5.
6.
2 min hold with heater at 10 KWH.

8 min hold without heater.
Again 2 min hold with heater at 10 KWH.
20
Carbon % - 0.7306
Sixth Trial
Sample weight 40 g
3. Again 1.5 min hold with heater at 10 KWH.
4. 8.5 min hold without heater.
Carbon % - Not Tested, physically some traces of oil where found
Seventh Trial
Sample weight 40 g
10.
Carbon % - 0.2931
Eighth Trial
Sample weight 40 g
21

3. Again 45 sec hold with heater at 10 KWH.
10.
3.5 min hold without heater.
Ninth Trial
Sample weight 40 g
10.
11.
Again 30 sec hold with heater at 10 KWH.
12.
Carbon % - 4.733
Tenth Trial
Sample weight 40 g
22

Eleventh Trial
Sample weight 40 g
3. Again 1 min 15 sec hold with heater at 10 KWH.
7. Again 1 min 15 sec hold with heater at 10 KWH
8. 4 min hold without heater
Carbon % - 2.76
Twelfth Trial
Sample weight 40 g
1.
2.
3.
4.
5.
6.
7.
2 min hold with heater at 10 KWH.

Again 1 min 15 sec hold with heater at 10 KWH.
23

Thirteenth Trial
Sample weight 40 g
1. 1.5 min hold with heater at 10 KWH.
Carbon % - Carbon Not Tested
Fourteenth Trial (Repeat of Seventh Trial)
Sample weight 40 g
10.
Carbon % - 2.68
Fifteenth Trial
Sample weight 40 g
24

Carbon %- 2.24
Sixteenth Trial (Repeat of Seventh Trial)
Sample weight 40 g
10.
Carbon % - 1.02
Seventeenth Trial
Sample weight 40 g
Heat in a vacuum furnace, pressure at 3-5 in Hg.
1. 2.5 min hold wth heater at 10 KWH.
Eighteenth Trial
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Sample weight 40 g
Heat in a vacuum furnace, pressure at 29.5 in Hg.
1. 2.5 min hold with heater at 10 KWH.
Results:
Trial Nos.
Initial
First
Second
Third
Sample
40 g
40 g
40 g
Carbon
9.7%
0.507%
8.77%
10.7%
Remarks
Turnings were partially burnt
Turnings were not burnt but carbon % very high.
Sample variation
Fourth
40 g
10.77%
Turnings were not burnt but carbon % very high.
Fifth
40 g
0.73%
Repeat of First Trial
Sixth
40 g
Not Tested
Some traces of oil where felt
Seventh
40 g
0.29%
Eighth
40 g
Not Tested
Sample caught fire after taking it out from

vacuum furnace , but was looking oil free before
Ninth
40 g
4.73%
catching fire
Tenth
40 g
Not Tested
Traces of oil where felt
Eleventh
40 g
2.276%
Twelth
40 g
Not Tested
Physically oil traces found
Thirteenth
40 g
Not Tested
Fourteenth
40 g
2.68%
Repeat of Seventh Trial
Fifteenth
40 g
2.24%
Repeat of First Trial at 3 in Hg
Sixteenth
40 g
1.02%
Repeat of Seventh Trial
Seventeenth
40 g
Not Tested
Eighteenth
40 g
Not Tested
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A Study On Ideal Grain Refiner For Al Foil

Aluminium
Aluminium is the most recently discovered of the metals that modern
industry utilizes in large amounts. Alumina, Aluminium
Compounds were used to prepare medicines in ancient Egypt. By the
early eighteenth century, scientists suspected that these compounds
contained a metal, and, in 1807, the English chemist Sir Humphry
Davy attempted to isolate it. Although his efforts failed, Davy
confirmed that alumina had a metallic base. In 1825, a Danish chemist
named Hans Christian Orsted successfully isolated aluminium.
Twenty years later, a German physicist named Fried wohler was able
to create larger particles of the metal. The first Aluminium bars made
were displayed in 1855 at the Paris Exposition.
Aluminium is a good thermal and electrical conductor, having 59%
the conductivity of copper, both thermal and electrical, while having
only 30% of copper's density. Aluminium is capable of being
a superconductor, with a superconducting critical temperature of
1.2 kelvin and a critical magnetic field of about 100 gauss.
27
Aluminium Foil
Aluminium foil, often referred to as tin foil, is aluminium prepared in

thin metal leaves with a thickness less than 0.2 mm (7.9 mils); thinner
gauges down to 6 micrometres (0.24 mils) are also commonly used.
[1]
In the United States, foils are commonly gauged in thousandths of
an inch or mils. Standard household foil is typically 0.016 mm (0.63
mils) thick, and heavy duty household foil is typically 0.024 mm
(0.94 mils). The foil is pliable, and can be readily bent or wrapped
around objects. Thin foils are fragile and are sometimes laminated to
other materials such as plastics or paper to make them more useful.
Aluminium foil supplanted tin foil in the mid 20th century.
Foil made from a thin leaf of tin was commercially available before
its aluminium counterpart. Tin foil was marketed commercially from
the late nineteenth into the early twentieth century. The term "tin foil"
survives in the English language as a term for the newer aluminium
foil. Tin foil is less malleable than aluminium foil and tends to give a
slight tin taste to food wrapped in it. Tin foil has been supplanted by
aluminium and other materials for wrapping food.
Tin was first replaced by aluminium in 1910, when the first
aluminium foil rolling plant, "Dr. Lauber, Neher & Cie." was opened
in Emmishofen, Switzerland. The plant, owned by J.G. Neher & Sons,
the aluminium manufacturers, started in 1886 in Schaffhausen,
Switzerland, at the foot of the Rhine Falls, capturing the falls' energy
to produce aluminium. Neher's sons, together with Dr. Lauber,
discovered the endless rolling process and the use of aluminium foil
as a protective barrier in December 1907.
In 1911, Bern-based Tobler began wrapping its chocolate bars in
aluminium foil, including the unique triangular chocolate bar,
Toblerone By 1912, aluminium foil was being used by Maggi (today a
Nestl brand) to pack soups and stock cubes.
Aluminium foil is produced by rolling sheet ingots cast from
molten billet aluminium, then re-rolling on sheet and foil rolling mills
to the desired thickness, or by continuously casting and cold rolling.
28
To maintain a constant thickness in aluminium foil production, beta

radiation is passed through the foil to a sensor on the other side. If the
intensity becomes too high, then the rollers adjust, increasing the
thickness. If the intensities become too low and the foil has become
too thick, the rollers apply more pressure, causing the foil to be made
thinner.
The continuous casting method is much less energy intensive and has
become the preferred process. For thicknesses below 0.025 mm
(1 mil), two layers are usually put together for the final pass and
afterwards separated which produces foil with one bright side and one
matte side.[8] The two sides in contact with each other are matte and
the exterior sides become bright, this is done to reduce tearing,
increase production rates, control thickness, and get around the need
for a smaller diameter roller.
Aluminium becomes work hardened during the cold rolling process
and is annealed for most purposes. The rolls of foil are heated until
the degree of softness is reached, which may be up to 340 C (644 F)
for 12 hours. During this heating, the lubricating oils are burned off,
leaving a dry surface. Lubricant oils may not be completely burnt off
for hard temper rolls, which can make subsequent coating or printing
more difficult.The rolls of aluminium foil are then slit on slitter
rewinding machines into smaller rolls. Roll slitting and rewinding is
an essential part of the finishing process.
Aluminium foils thicker than 25 m (1 mil) are impermeable to
oxygen and water. Foils thinner than this become slightly permeable
due to minute pinholes caused by the production process.
29
Grain Refiner
Grain Refinement is a process of producing Smaller Grains in cast &
Final Products of Al. It is used to provide Strengthening of casting
material. They are widely used in aluminium casthouses and
foundries, worldwide. The Process of Grain refinement improves
Productivity by increasing the recovery. It increases the speed in DC
ingot casting. Grain Refinement increases the resistance to hotcracking by Improving surface finish and mechanical properties
Methods of Grain Refinement
Methods of grain refinements used in casting process are mainly
classified into following three groups
Thermal method i.e. Cooling rate control
Chemical method i.e. Grain size refiners addition
Mechanical method i.e. agitation of melt during solidification
Cooling Curve
30
Comparison of Effect of Grain Refinement
TiAl3 crystals are poor nuclei.

TiB2 particles are excellent nuclei.
(Mostly used)
AlB2 is the best nucleus.
31
(Not Suitable for Industry)
Best Grain Refinement Practices
32
Al-Si Alloys : like A356 and A357 best result by adding 10-20
ppm of boron in the form of Al-5Ti-1B or Al-3Ti-1B rod.
Al-Cu Alloys: for Al-4.5%Cu-0.5%Mn alloys best result by
titanium less than 0.05% and adding 10-20 ppm of boron as Al5Ti-1B or Al-3Ti-B rod.
Al-Si-Cu Alloys : like A319 alloys (Al-3%Cu-5.5%Si) best 1020 ppm of boron in the form of Al-5Ti-1B or Al-3Ti-1B rod.
Al-Zn-Mg Alloy: For these alloys best result found with 0.02 to
0.05% of titanium and addition of 10-20 ppm of boron as Al5Ti-1B or Al-3Ti-1B rod.
Al-Mg Alloys: like 535 alloys (Al-7%Mg) best result found with
addition of 30 ppm B in the form of Al-3%Ti-1%B master alloy.
33
Suggestions
Job description & responsibilities
communicated to the employees
should
be
clearly
SOPs should be there for each processes and followed properly

There should be proper ergonomics like proper shed in monsoon
During purchase of raw materials blocking of working capital
should be considered
CRM should be adopted
There should be a dedicated marketing team
Mission & vision statement should be specific & shorten
Vacuum Furnace method for processing of Ti Turnings Should
be used.
34
BIBLOGRAPHY
Challenges in Titanium Recycling- B. Rotmann, C. Lochbichler,
B. Friedrich
(Reference:-Research paper 2011_Rotmann_Friedrich ethanol )
Grain Refinement of Al Alloys by Subrata Saha
International Journal of Emerging Technology and Advanced
Engineering
The Challenge in removing surface oil OILSKIMMERS.INC
Grain refinement by AlTiB alloys in aluminium melts:a study
of the mechanisms of poisoning by zirconium
G. P. JONES and J. PEARSON: Metall. T rans
www.tigg.com
www.google.com/patents
Natural Gas and Water Treatment
35
Annexure:
Feasability Report for Laterite Bricks
No. of Bricks required
Price per brick (approx)
Total Costing (RS)
Savings
water for a batch of 50kg
caustic soda
Total Savings/batch
No of days Bricks last
(approx)
No of batches per day
Total batch for 15 days
Total saving for 15 days
Saving/loss (per Month)
60
30
1800
Quantity
Required
Price/Uni Total
t
Price
400
0.4
160
2
40
80
240
15
8
120
28800
54000
36

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Minex

Introducing itself as one of the pioneers, Minex organization is based

Titanium, Boron, Aluminum, Aluminum-Boron, Iron Tablets.

Malaysia, Sri Lanka: (Loadstar Pvt. Ltd),

Research and Development

Present Oil Removing Method

Time & Motion Study of Ti Turning Washing Method

A Tub 1 is kept bellow the geaser. It Takes 41mins and 2 sec to

3) 2kg caustic soda is added

The above steps/process is for only one wash of 50 kg batch. The

Removes oil, grease, carbon, rust, scale and paint

It is normally used at concentration of 5 10% in water in a hot soak

vaporize oil contained on the turnings, and a combustion chamber

This machine uses Alkaline solution and water at 90-100C to remove

Problem Associated with Alkaline Solution/Washing

and DAF units. It is also used as pretreatment to activated carbon, ion

Based on the results obtained in the different stages of this

Vacuum Furnace for Processing Ti Turning

1. 1 min hold with heater at 10 KWH.

2 min hold with heater at 10 KWH.

Heat in a vacuum furnace, pressure at 10 in Hg.

Heat in a vacuum furnace, pressure at 10 in Hg.

2 min hold with heater at 10 KWH.

8. 5 min hold without heater.

1. 2 min hold with heater at 10 KWH.

Turnings were not burnt but carbon % very high.

Repeat of First Trial

Some traces of oil where felt

Turnings were partially burnt

Sample caught fire after taking it out from

Traces of oil where felt

Turnings were partially burnt

Physically oil traces found

Traces of oil where felt

Repeat of Seventh Trial

Repeat of First Trial at 3 in Hg

Repeat of Seventh Trial

Traces of oil where felt

Traces of oil where felt

A Study On Ideal Grain Refiner For Al Foil

Aluminium foil, often referred to as tin foil, is aluminium prepared in

To maintain a constant thickness in aluminium foil production, beta

Comparison of Effect of Grain Refinement

TiAl3 crystals are poor nuclei.

(Not Suitable for Industry)

Best Grain Refinement Practices

SOPs should be there for each processes and followed properly

Saving/loss (per Month)

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