Detailed Project Report (DPR) on quartz and feldspar manufacturing

QUARTZ AND FELDSPAR MANUFACTURING

 [CODE NO.3263]  

(A)QUARTZ
    
Quartz is a mineral, which is a member of silica groups. It is present in silica rich-igneous rocks and it is the basic materials of sandstone and is found in metamorphic rock lime gneisses, schists, charnockites and khondalites If pure, quartz is a colorless, transparent, and very hard crystalline material of glass-like look. The well-known rock crystals - six-sided prisms with a six-sided pyramid at their ends - are simply well formed crystals of quartz.

Quartz appears in a number of colored varieties, like amethyst (violet), citrine (yellow), or smoky quartz (gray, brown to black). It also occurs in dense forms with no visible crystals, like the multi-colored agate and the gray flint.

The term 'quartz' is often referred to as a synonym for silica. Silica (SiO2) is one of the ubiquitous materials in the earth's crust. Quartz, quartz crystals, quartzite, silica sand, sand (others) and moulding sand are all coined together in one generic name 'silica minerals'. This is because all these commodities are essentially crystalline silicon dioxide (SiO2) with variations mostly related to their crystalline structure and presence of minor or trace impurities. Silica occurs in several forms giving rise to different varieties.

Crystalline Varieties

The important varieties of crystalline quartz are vein quartz (massive crystalline quartz); milky quartz (white, translucent to opaque); ferruginous quartz (containing brown limonite and red haematite and almost opaque); aventurine quartz (containing glistening flakes of mica or haematite); cat's eye (opalescent greenish quartz with fibrous structure); rock crystal (clear, colourless, well-crystallised transparent quartz); amethyst (clear-purple or violet-blue), transparent quartz; rose quartz; smoky quartz; etc. Occurrences of massive crystalline quartz in veins or pegmatites have been recorded in almost all the states.


Clastic or Granular Varieties

These varieties include sand consisting largely of unconsolidated quartzose grains (0.06 mm to 2 mm diameter), gravel consisting largely of unconsolidated coarse quartzose grains or pebbles (2 mm to 8 mm in diameter), sandstone and quartzite. The occurrences are reported from Andhra Pradesh, Bihar, Delhi, Haryana, Karnataka, Kerala, Madhya Pradesh, Rajasthan, Tamil Nadu, Uttar Pradesh, etc. The silica sand from Naini area in Allahabad district, Uttar Pradesh is of a very high quality.


Cryptocrystalline Varieties

This group includes chalcedony, agate, jasper, onyx, flint and chert. These varieties appear noncrystalline (amorphous) in hand specimens, but under microscope show double refraction which reveals their concealed crystalline nature. These varieties are reported from Gujarat, Uttar Pradesh, Tamil Nadu, Andhra Pradesh, Maharashtra, Madhya Pradesh, Karnataka and Punjab. The most important occurrences of agate are in Ratnapur, Rajpipla area and further west between Tapi and Narmada rivers in Bharuch district, Gujarat, where it is found as pebbles in varying sizes associated with clay washed down by the river flow. Other occurrences of economic importance are reported from Amravati, Aurangabad, Buldhana, Chandrapur, Nashik and Pune districts in Maharashtra; beds of Krishna and Godavari rivers in Andhra Pradesh; Dumka district in Jharkhand; Dhar, Mandsaur, Sihore and Shahdol districts in Madhya Pradesh; and Kachchh district in Gujarat.

COST ESTIMATION

Plant  Capacity                                              :       1200.00 MT/day     
land & Building (10000 sq.mt)                   :    Rs.  2.82   Cr
Plant & Machinery                                          :    Rs.  3.30   Cr
Working Capital for 1 Month                        :    Rs.  6.47   Cr
Total Capital Investment                              :    Rs.  12.92  Cr
Rate of Return                                                :            42%
Break Even Point                                            :            49%


INTRODUCTION                                            
CLASSIFICATION                                            
PROPERTIES                                            
VARIETIES AND TRADE NAMES                                
(1)MOONSTONE OR ADULARIA                                
(2)SUNSTONE                                            
(3)AVENTURINE                                            
(4)LABRADORITE                                            
(5)AMAZONITE, OR AMAZON STONE                            
PROPERTIES                                            
USES AND APPLICATION                                    
(A)FOR QUARTZ                                            
(B) FOR FELDSPAR                                        
B.I.S. SPECIFICATIONS                                        
MARKET SURVEY                                            
QUARTZITE                                                
PRINCIPAL PRODUCERS OF QUARTZITE, 2014-15                    
PRODUCTION OF QUARTZITE, 2012-13 TO 2014-15(BY STATES)            
PRODUCTION OF QUARTZITE, 2013-14 & 2014-15                    
(BY SECTORS/STATES/DISTRICTS)                                
QUARTZ                                                
FELSPAR                                                
RESOURCES                                            
EXPLORA TION                                            
PRODUCTION, STOCKS & PRICES                                
MINING & MARKETING                                        
USES                                                    
SPECIFICA TIONS                                            
CONSUMPTION                                            
WORLD REVIEW                                            
FOREIGN TRADE                                            
FUTURE OUTLOOK                                        
MANUFACTURERS/SUPPLIERS OF QUARTZ POWDER                    
FELDSPAR POWDER                                        
MANUFACTURING PROCESS    OF QUARTZ AND FELDSPAR                
GENERAL                                                
(2) CRUSHING PROCESS                                    
PLANT AND MACHINERY                                    
PROCESS FLOW CHART                                    
PLANT LAYOUT                                            
SUPPLIERS OF PLANT AND EQUIPMENTS                            
CRUSHING PLANT                                        
BALL MILL                                                
POWER TRANSFORMER                                    
ELECTRICAL PANEL                                        
SHOT BLASTING MACHINE                                    
AIR POLLUTION CONTROL EQUIPMENTS                            
AIR CONDITIONING EQUIPMENTS                                
AIR COMPRESSOR                                        
PLATFORM WEIGHING MACHINE                                
MATERIAL HANDLING EQUIPMENTS                            
FIRE FIGHTING EQUIPMENTS                                
SUPPLIERS OF RAW MATERIALS                                
QUARTZ LUMPS                                            
FELDSPAR LUMPS                                        
HDPE BAGS                                            

            
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