Industry Overview
Silica is a group of minerals composed of silicon and oxygen, with the chemical formula SiO2. It occurs most commonly in crystalline form, particularly as quartz, and also occurs in amorphous forms. Silica sand consists primarily of finely divided quartz produced through the natural breakdown of quartz by water and wind. Other mineral components can include aluminium, feldspar and iron-bearing minerals.
Industrial silica sand is distinguished from ordinary construction sand by its high purity, controlled grain size and physical characteristics such as grain shape, strength and refractoriness. For industrial and manufacturing applications, deposits yielding products of at least 95% SiO2 are preferred. High-purity, well-sorted silica sand is particularly important for glassmaking, where metallic impurities must also be strictly controlled.
Silica sand and quartz have extensive industrial applications, including glass production, foundry operations, ceramics, abrasives, building products, silicon and silicon carbide production, pigments, hydraulic fracturing and water filtration. Quartz is also used in ceramic and metallurgical industries, while quartzite is an important raw material for silica refractories. The proposed project is a Green Field Project to establish a Quartz Processing Facility with a production capacity of 200 TPD.
Cost Estimation
| Particulars | Value |
|---|---|
| Plant Capacity | 200 MT/Day |
| Land & Building (8050 sq.mt.) | Rs. 5.52 Cr |
| Plant & Machinery | Rs. 3.14 Cr |
| Working Capital for 1 Month | Rs. 1.58 Cr |
| Total Capital Investment | Rs. 10.64 Cr |
| Rate of Return | 18% |
| Break Even Point | 68% |
Content Index
- INTRODUCTION
- QUARTZ POWDER
- PROPERTIES
- PROPERTIES OF SILICA SAND
- GRADES OF SILICA SAND
- HAZARDS
- PROPERTIES
- SPECIFICATION AND COMPOSITION
- ANALYSIS AND APPLICATION OF QUARTZ POWDER
- QUARTZ [SILICA POWDER]
- QUARTZ [SILICA POWDER] IS USED IN ALL LEADING INDUSTRIAL USES.
- USES AND APPLICATIONS
- INDUSTRIAL SAND APPLICATIONS
- GRADES OF SILICA SAND FOR GLASSMAKING
- BIS SPECIFICATIONS
- MARKET OVERVIEW
- MARKET INSIGHTS
- PRODUCT INSIGHTS
- END-USER INDUSTRY INSIGHTS
- REST OF THE MIDDLE EAST AND AFRICA QUARTZ MARKET BY END-USER INDUSTRY
- RAW MATERIALS
- MINERAL PROPERTIES
- QUARTZ POWDER DESCRIPTION
- QUARTZ POWDER PHYSICAL PROPERTIES AVAILABLE:
- QUARTZ POWDER STANDARD GRANULATIONS AVAILABLE:
- GRAVEL SIZES:
- POWDER SIZES
- RAW MATERIAL SUPPLIERS
- QUARTZ LUMPS
- PROCESS OF MANUFACTURE OF QUARTZ POWDER
- PROCESS FLOW
- MAIN STEPS
- RAW MATERIAL PREPARATION
- CRUSHING PROCESS
- GRINDING PROCESS
- THE PRINCIPLE PURPOSES OF GRINDING ARE:
- THE TWO STAGES OF GRINDING ARE:
- COARSE GRINDING:
- FINE GRINDING:
- SIZING
- THERE ARE TWO METHODS OF INDUSTRIAL SIZING.
- QUALITY CONTROL
- PACKING
- MARKING
- THE BAGS SHALL BE MARKED WITH THE FOLLOWING:
- PLANT & MACHINERIES
- MACHINERY USED ARE BROADLY DETAILED BELOW
- TRANSPORTATION TECHNOLOGIES
- CRUSHING TECHNOLOGIES
- JAW CRUSHERS
- GYRATORY (CONE) CRUSHERS
- HAMMER CRUSHER
- IMPACTOR/IMPACT BREAKERS:-
- ROTOPOCTOR
- SCREENING TECHNOLOGIES
- GRIZZLIES TYPE SCREENS
- VIBRATING SCREEN
- ROTARY SCREEN
- WASHING TECHNOLOGIES
- MATERIAL HANDLING TECHNOLOGIES USED IN CRUSHING UNITS
- FEEDERS
- CONVEYORS
- TYPES OF CONVEYORS ARE AS FOLLOWS
- BUCKET ELEVATORS
- MANUFACTURERS/SUPPLIERS OF QUARTZ POWDER
- 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
- HDPE BAGS
- UTILITIES REQUIREMENT (ESTIMATED - MONTH)
- WASTE EFFLUENT/FLUE GAS EMISSION (ESTIMATED)
- GREEN BELT
- WATER
- PRINCIPLES OF PLANT LAYOUT
- MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE:
- PLANT LOCATION FACTORS
- PRIMARY FACTORS
- RAW-MATERIAL SUPPLY:
- MARKETS:
- POWER AND FUEL SUPPLY:
- WATER SUPPLY:
- CLIMATE:
- SPECIFIC FACTORS
- TRANSPORTATION:
- WASTE DISPOSAL:
- LABOR:
- REGULATORY LAWS:
- TAXES:
- SITE CHARACTERISTICS:
- COMMUNITY FACTORS:
- FLOOD AND FIRE CONTROL:
- ANTICIPATED ENVIRONMENTAL IMPACTS
- CONSTRUCTION PHASE
- OPERATION PHASE
- MITIGATION MEASURES (PROPOSED)
- HEALTH SAFETY & ENVIRONMENT
- PROPOSED IMPLEMENTATION SCHEDULE
- PROJECT FINANCIALS
- BASIS & PRESUMPTIONS (FOR PROFITABILITY WORKINGS)
- PRELIMINARY PLANT LAYOUT
Appendix
- 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)
Frequently Asked Questions
Silica sand is sand that contains a high proportion of silica, primarily in the form of quartz. It is formed largely through the natural breakdown of quartz crystals by water and wind. Unlike ordinary construction sand, industrial silica sand is generally selected for its purity, controlled grain size and physical properties. Depending on its characteristics, it can be used in glassmaking, foundries, ceramics, abrasives, building products and filtration applications.
Silica sand is widely used in glass production, foundry operations, ceramics, abrasives, building products and water filtration. It is also used in the production of silicon and silicon carbide, pigments and certain industrial applications in the oil industry. Its usefulness comes from the combination of silicon dioxide content, hardness, strength, chemical inertness and suitable particle characteristics. The required quality and specification vary according to the end use.
High-purity silica sand is important for glassmaking because unwanted mineral and metallic impurities can affect the quality and properties of the finished glass. The report notes that suitable glassmaking sand should contain a very high proportion of silica and only strictly limited amounts of certain metallic elements. Consistent grain sizing is also important because glass manufacturing requires a controlled and uniform raw material. These requirements make many ordinary construction sands unsuitable for glass production.
Quartz powder is used across several industrial applications where the properties of silica are required. Quartz and silica-based materials are used in glass and ceramic manufacturing, foundry applications, abrasives, refractories and other industrial products. Quartz is valued for its hardness, chemical stability and high melting point. The specific application determines the required particle size, purity, physical characteristics and processing specification of the quartz powder.
Quartz powder is manufactured through a sequence of material preparation, crushing, grinding and sizing operations. The report identifies raw material preparation, crushing and grinding as key processing stages, followed by sizing to obtain the required particle characteristics. Crushing reduces the feed material to smaller pieces, while grinding produces finer material. Industrial sizing then separates material according to particle size so that the finished product can meet the requirements of its intended application.
Quartz processing can require crushing, grinding, screening, material handling and supporting equipment. The report identifies equipment such as jaw crushers, gyratory or cone crushers, hammer crushers, impact breakers, rotopactors, vibrating screens, rotary screens, feeders, conveyors, bucket elevators and ball mills. Supporting systems can include electrical equipment, air pollution control equipment, compressors, weighing equipment, firefighting equipment and other plant utilities. The final equipment configuration depends on the raw material and required product specifications.
A quartz processing plant location should be selected by considering raw-material supply, markets, power and fuel, water availability, climate and transportation. The report also identifies waste disposal, labour, regulatory laws, taxes, site characteristics, community factors, and flood and fire control as relevant considerations. A suitable location should support reliable material movement and utilities while providing adequate space for plant operations, environmental management, safety provisions and future operational requirements.
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