Detailed Project Report (DPR) on Calcination Plant for Pyrophyllite and Diaspore Minerals

CALCINATION PLANT FOR PYROPHYLLITE AND DIASPORE MINERALS 

[EIRI/EDPR/1565] J.C: 360,361

INTRODUCTION

Pyrophyllite is a hydrous aluminum silicate that is generally described by the molecular formula Al2O3•4SiO2•H2O. This alteration mineral is light green or white with a waxy texture. In nature, pyrophyllite rarely exists in its pure form and is normally associated with accessory minerals such as quartz, kaolin, diaspore, corundum, andalusite, boehmite, sericite, chlorite, and alunite. Pyrophyllite ores can also include iron-containing impurities such as pyrite, hematite, and limonite; therefore, different mineral samples that are classified as pyrophyllite can contain various combinations of accessory minerals and have different chemical compositions. It is important to understand the origins and distributions of pyrophyllite deposits in order to extend pyrophyllite applications. This chapter therefore describes basic methods for the mineral’s identification and analysis.

In Japan, pyrophyllite mined in the Mitsuishi District of the Okayama Prefecture was used in engraving from around 1800 until the early 1900s. With the introduction of primary school education in 1886, pyrophyllite ores began to be processed and used for slate pencils. During the 20th century, the demand for pyrophyllite ores as raw materials for ceramics—particularly refractory materials— grew in response to the increasing needs of industry. Quality checks during mining and strict quality control during the crushing and grinding processes are essential because the major, accessory, and trace ingredients of the raw ores determine the properties of the products, including refractory characteristics, coefficients of thermal expansion and contraction, melting point, hardness, and color.

Pyrophyllite ores have been used for many years in a range of applications. The quality requirements, however, have recently become much stricter as a result of competition from several minerals with similar properties. Consumption is also decreasing for a number of reasons, including advances in paper-manufacturing techniques, in which pyrophyllite is used as a filler; decreases in the number of dustings with insecticides because of improvements in agrochemicals; and the trend toward the use of longer-lasting bricks in the refractory industry.

Research is needed to expand the potential applications and, therefore, the demand for pyrophyllite ores. Low-quality ores might be used after removing impurities and by developing energy-saving furnaces that can operate at lower temperatures. In addition, advances in powder technologies are likely to increase the uses of pyrophyllite ores in fine ceramics. Efficient usage remains important, however, because these ores have limited distributions and worldwide reserves.

Diaspore is a dimorphous form of boehmite, with chemical composition Al2O3.H2O (betamonohydrate of aluminium). It is an important constituent of bauxite. Because of its good refractory properties, it is used chiefly for making high-alumina refractory bricks. It is also used as a filler in plastic industry.

COST ESTIMATION

Plant Capacity            30 MT/Day

Land & Building (1500 sq.mt.)    Rs. 1.81 Cr

Plant & Machinery                    Rs. 1.75 Cr

Working Capital for 1 Month    Rs. 67.81 Lac

Total Capital Investment          Rs. 4.39 Cr

Rate of Return                          27%

Break Even Point                      58%

CONTENTS

INTRODUCTION

DIASPORE

PROPERTIES

OF PYROPHYLLITE AND DISPARE MINERALS

PRODUCT GRADE AND SPECIFICATION OF PYROPHYLLITE

B.I.S. SPECIFICATIONS

USES AND APPLICATION OF PYROPHYLLITE AND DISPARE MINERALS

MARKET SURVEY

PRESENT MANUFACTURERS

CLASSIFICATION OF PYROPHYLLITE ORES

GLOBAL PRODUCTION, CONSUMPTION AND TRADE OF PYROPHYLLITE

MINERALOGY AND CHEMICAL PROPERTIES OF PYROPHYLLITE

MINING AND PROCESSING OF PYROPHYLLITE

DIASPORE MINERAL DATA 

MANUFACTURING PROCESS OF CALCINATION PLANT FOR PYROPHYLLITE AND DIASPORE

PROCESS FLOW DIAGRAM

MANUFACTURING PROCESS OF CALCINATION OF DIASPARE MINERALS BY USING VERTICAL SHAFT KILN

PROCESS FLOW DIAGRAM

DETAILS OF CALCINATION

TECHNICAL DATA OF CALCINED DIASPORE

COMPARISON BETWEEN CALCINATION OF DIASPORE AND PYROPHYLLITE MINERAL THROUGH VERTICAL SHOFT KELIN AND ROTARY KILN

SUPPLIERS OF PLANT & MACHINERY

SUPPLIERS OF RAW MATERIALS

PRINCIPLES OF PLANT LAYOUT

PLANT LOCATION FACTORS

EXPLANATION OF TERMS USED IN THE PROJECT REPORT

PROJECT IMPLEMENTATION SCHEDULES

PLANT LAYOUT

APPENDIX – A:

01. PLANT ECONOMICS

02. LAND & BUILDING

03. PLANT AND MACHINERY

04. OTHER FIXED ASSESTS

05. FIXED CAPITAL

06. RAW MATERIAL

07. SALARY AND WAGES

08. UTILITIES AND OVERHEADS

09. TOTAL WORKING CAPITAL

10. TOTAL CAPITAL INVESTMENT

11. COST OF PRODUCTION

12. TURN OVER/ANNUM

13. BREAK EVEN POINT

14. RESOURCES FOR FINANCE

15. INSTALMENT PAYABLE IN 5 YEARS

16. DEPRECIATION CHART FOR 5 YEARS

17. PROFIT ANALYSIS FOR 5 YEARS

18. PROJECTED BALANCE SHEET FOR (5 YEARS)