Detailed Project Report (DPR) on china clay processing plant

CHINA CLAY PROCESSING PLANT
 [CODE NO. 2067]

Kaolin, also known as china clay, is a natural clay formed by chemical weathering of aluminium silicate minerals like felspars through a complex sequence of events. It is relatively pure clay predominantly consisting of kaolinite (Al2Si2O5(OH)4), associated with other clay minerals like dickite, halloysite, nacrite and anauxite. Kaolin is commercially valued for its whiteness and fine particle size which distinguish it from other clays, such as, ball clay and fireclay. Other physical characteristics that influence commercial utility include brightness, glossiness, abrasiveness and viscosity. It often contains small amounts of impurities in the form of rock fragments, hydrous oxides and colloidal materials. Kaolin is produced and consumed in the country in crude & processed forms. The major use of crude china clay in is in Cement Industry and of processed china clay is in Ceramic Industry. The insitu clay deposits in India is often soft and easily extracted with no blasting required.

China clay owes its name to the fact that originally it was used in china under the name Kaolin; for the production of fine white procelain. China clay or Kaolin is a  microcrystalline hydrated silicate of aluminium, approximately Al2O3, 2SiO3, 2H2O, corresponding to 46 percent of silica, 40 percent of alumina and 14  percent of water commercial grades generally contents small amounts of quartz,  oxides of iron and titanium, oxides and silicate of calcium and magnesium, potash and soda.    

This clay is formed as the result for the decomposition of granite in situ granite is an igneous rock composed of associated crystals of mica, quartz feldspar, the  latter consisting essentially of slicates of alumina, with variable proportions of silicates of potash, soda or lime under the prolonged influence of weathering and exposure to water and carbon dioxide under great pressure the feldspar crystals are decomposed, the soda or potash being extracted, leaving the hydrated silicate of alumina. This process known as kaolinisation, converts the granite into a friable mass of clay mixed with the under decomposed crystals of quartz and mica, and the quantity of china clay depends on the completeness with which the alkalies, iron and other constituents have been leached out during the decomposition.

Clay material is composed of extremely small particles of clay minerals. These mineral are generally crystalline but in some cases their organization is so poor  that diffraction indicates them to be amorphous clay minerals are essentially hydrous aluminium silicates with iron or magnesium proxying wholly or in part for the aluminium with alkali or alkaline earths present as essential constituets besides some non-clay constituents like feldspar quarts & calcite.

For use in the paint and other industries, china clay is obtained by directing high pressure jets of water on the faces of clay deposits. Where by a watery and sludge is formed from  which the heavy impurities in the clay separates out, the sludge passes on to further settling tanks where further coarse, mica, ceouse particles  settles cut. The refinement process consists for washing, settling and filtering and ends with the production of a wet cake of purified clay which is then broken down, dried in hot kilns and dry-ground for dispatch to the users.

Sources of supply of china clay are widespread, largest producer being the United States, United Kingdom, France, Germany, Czechoslovakia and India (Jaipur). In our country this is also available in abundance.


COST ESTIMATION

Plant Capacity                                                20.00 MT/day             
Land & Building (6000 Sq.Mtr)                    Rs. 3.00      Cr
Plant & Machinery                                          Rs.  2.50     Cr
W.C. for 2 Months                                           Rs.65.51 Lacs
Total Capital Investment                               Rs. 6.33    Cr
Rate of Return                                                 26%
Break Even Point                                            57%


INTRODUCTION                                            
PROPERTIES                                            
GRADES OF CHINA CLAY                                    
GRADE -2 MICRONIZED (FINALLY GROUND) 32 MICRON                
PROPERTIES OF CHINA CLAY                                    
B I S SPECIFICATION                                        
INDUSTRIAL USES                                        
REQUIREMENT AND PACKAGING OF CHINA CLAY                    
TESTING METHOD FOR CHINA CLAY                            
MARKET POSITION AND SCOPE                                
PRODUCTION OF KAOLIN                                    
CONSUMPTION OF RAW CHINA CLAY                            
GLOBAL MARKET POSITION OF KAOLIN                            
PRODUCERS OF KAOLIN                                    
PRESENT MANUFACTURERS OF CHINA CLAY                        
MINING AND PROCESSING OF CHINA CLAY                        
METHOD OF CHINA CLAY PROCESSING                            
PROCESS FLOW DIAGRAM                                    
PROCESS OF MANUFACTURE                                
FLOW CHART                                            
PLANT LAYOUT                                            
PRINCIPLES OF PLANT LAYOUT                                
PLANT LOCATION FACTORS                                    
EXPLANATION OF TERMS USED IN THE PROJECT REPORT                
PROJECT IMPLEMENTATION SCHEDULES                        
SUPPLIERS OF RAW MATERIALS                                
SUPPLIERS OF PLANT AND MACHINERY                            
SUPPLIERS OF PLANT AND MACHINERY (IMPORTED)                    
                            

APPENDIX – A :

 1.      COST OF PLANT ECONOMICS      
 2.      LAND & BUILDING                                      
 3.      PLANT AND MACHINERY                                  
 4.      FIXED CAPITAL INVESTMENT                             
 5.      RAW MATERIAL                                         
 6.      SALARY AND WAGES                                     
 7.      UTILITIES AND OVERHEADS                              
 8.      TOTAL WORKING CAPITAL                                
 9.      COST OF PRODUCTION                                   
10.      PROFITABILITY ANALYSIS                               
11.      BREAK EVEN POINT                                     
12.      RESOURCES OF FINANCE                           
13.      INTEREST CHART                                       
14.      DEPRECIATION CHART                                   
15.      CASH FLOW STATEMENT                                   
16.      PROJECTED BALANCE SHEET