Detailed Project Report (DPR) on Zirconium Carbonate from Zirconium Oxide Ore Residue (Cap: 17 MT/Day)

Detailed Project Report (DPR) on Zirconium Carbonate from Zirconium Oxide Ore Residue (Cap: 17 MT/Day)
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Industry Overview

Zirconium dioxide (ZrO2), commonly known as zirconia, is a white crystalline oxide of zirconium with significant importance in advanced ceramic applications. The naturally occurring form of zirconia is baddeleyite, which has a monoclinic crystal structure. Stabilized forms of zirconia, including cubic zirconia, are synthesized for specialized applications such as gemstones, ceramic materials, and high-performance industrial products.

Zirconia is chemically stable and exhibits excellent thermal, mechanical, and electrical properties. Its phase transformation characteristics have made it one of the most extensively studied ceramic materials. By incorporating stabilizing oxides such as yttrium oxide, magnesium oxide, calcium oxide, or cerium oxide, zirconia can retain desirable tetragonal or cubic phases, improving strength, toughness, and durability.

Stabilized zirconia is widely used because transformation toughening enhances fracture resistance and extends product reliability. Zirconium dioxide also serves as an important precursor material for various zirconium chemicals. Zirconium basic carbonate, with chemical formula Zr(CO3)2.H2O and CAS Number 57219-64-4, is a key zirconium compound supplied in high purity and reactive grades for applications including catalysis and production of paint driers.

Cost Estimation

Plant Capacity 17 MT/Day
Land & Building (6000 sq.mt.) Rs. 2.29 Cr
Plant & Machinery Rs. 3.70 Cr
Working Capital for 1 Month Rs. 11.64 Cr
Total Capital Investment Rs. 17.95 Cr
Rate of Return 43%
Break Even Point 38%

Content Index

INTRODUCTION
ZIRCONIUM BASIC CARBONATE
PROPERTIES OF ZIRCONIUM BASIC CARBONATE
ZIRCONIUM BASIC CARBONATE
ZIRCONIUM CARBONATE TYPICAL PROPERTIES
ZIRCONIUM CARBONATE PACKAGING AND SHIPPING
ZIRCONIUM CARBONATE STORAGE
USES OF ZIRCONIUM CARBONATE
RAW MATERIALS
ZIRCONIUM OXIDE
ZIRCONIUM OXIDE PROPERTIES (THEORETICAL)
ZIRCONIUM OXIDE HEALTH & SAFETY INFORMATION
PHYSICAL PROPERTIES
PROPERTIES OF ZIRCONIUM OXIDE
MARKET OVERVIEW OF ZIRCONIUM
MAJOR PLAYERS IN THE ZIRCONIUM MARKET ARE:
PRESENT MANUFACTURERS OF ZIRCONIUM CARBONATE
MANUFACTURING PROCESS OF ZIRCONIUM CARBONATE
METHOD OF PREPARING HIGH PURITY BASIC ZIRCONIUM CARBONATE
THE FOLLOWING ILLUSTRATION SHOWS THE PRESENT PROCESS:
ILLUSTRATION 1
ILLUSTRATION 2
ILLUSTRATION 3
MATERIAL SAFETY DATA SHEET ZIRCONIUM CARBONATE
CHEMICAL FORMULA:
PHYSICAL AND CHEMICAL PROPERTIES
PROPERTIES OF MATERIALS THAT MAY INITIATE OR CONTRIBUTE TO FIRE
INTENSITY
NON-FLAMMABLES THAT COULD CONTRIBUTE UNUSUAL HAZARDS TO A FIRE
ADDRESSES OF PLANT & MACHINERY SUPPLIERS

Appendix

APPENDIX – A:
1. PLANT ECONOMICS
2. LAND & BUILDING
3. PLANT AND MACHINERY
4. OTHER FIXED ASSESTS
5. FIXED CAPITAL
6. RAW MATERIAL
7. SALARY AND WAGES
8. UTILITIES AND OVERHEADS
9. 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

Zirconium basic carbonate is mainly used as a precursor material for producing zirconium-based products. It is supplied in high purity grades for catalysis applications and in reactive grades for manufacturing paint driers. Its chemical properties make it an important intermediate in zirconium chemical processing.

Zirconia is zirconium dioxide (ZrO2), a ceramic material known for high strength, thermal stability, and chemical resistance. It is widely studied and used in advanced ceramic applications because stabilized zirconia provides improved mechanical and thermal performance.

Zirconia is stabilized by adding small quantities of oxide dopants such as yttrium oxide, magnesium oxide, calcium oxide, or cerium oxide. These additives help retain desirable crystal phases and improve properties such as toughness, strength, and thermal performance.

Zirconium dioxide has excellent chemical resistance, high temperature stability, and strong mechanical properties. Its phase transformation behavior enables transformation toughening, which improves fracture resistance and extends the reliability of zirconia-based products.

Transformation toughening is a mechanism where metastable tetragonal zirconia changes to a monoclinic phase under stress. The resulting volume expansion creates compressive forces around cracks, slowing crack growth and improving material durability.

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