Industry Overview
Zircon, or zirconium silicate (ZrSiO4 or ZrO2-SiO2), occurs naturally as an accessory mineral in silica-rich igneous rocks such as granite, nepheline syenite and pegmatite, as well as in metamorphic and sedimentary rocks. Although rarely present in economically mineable concentrations within these rocks, weathering and erosion release zircon grains, which can become concentrated with other heavy minerals by natural gravitational processes in river, delta and ocean beach deposits. Zircon is commercially recovered mainly from unconsolidated mineral sands, with Australia and South Africa being major exporters.
Zirconium silicate is valued for its chemical stability, resistance to acids and alkalis, high melting point, low coefficient of thermal expansion and refractory properties. It is widely used in ceramic, glass, steel and foundry applications. In foundries, zircon provides effective mould-facing properties and high thermal conductivity, while its dimensional stability and chemical resistance make it suitable for precision casting. Zirconium-containing abrasives are also used for grinding steel and steel alloys because of their hardness and toughness. Zircon is additionally used in glass applications, including television tubes, due to its X-ray absorption properties and ability to improve glass toughness.
Where zircon-bearing sand is collected from river-side areas, the report states that a licence from the Ministry of Environment is essential.
Cost Estimation
| Particulars | Details |
|---|---|
| Plant Capacity | 25 Ton/Day |
| Land & Building (10,000 sq.mt.) | Rented |
| Plant & Machinery | US$ 6 Lac |
| Working Capital for 3 Months | US$ 9.47 Lac |
| Total Capital Investment | US$ 23.02 Lac |
| Rate of Return | 34% |
| Break Even Point | 54% |
Content Index
- INTRODUCTION
- USES & APPLICATIONS
- PROPERTIES & CHARACTERISTICS OF ZIRCONIUM SILICATE (ZIRCON)
- PROPERTIES AND CHARACTERISTICS
- CHEMICAL AND PHYSICAL CHARACTERISTICS OF ZIRCONIUM SILICATE
- ZIRCONIUM SILICATE PLAYS AN IMPORTANT ROLE IN CERAMIC INDUSTRY, WHICH CAN BE LISTED AS FOLLOW:
- PROPERTIES AND CHARACTERISTICS OF RAW MATERIALS USED
- ZIRCONIUM OXIDE
- GRADES OF ZIRCONIA
- SILICA (SILICON DIOXIDE SIO2).
- GRADES OF SILICA
- B.I.S. SPECIFICATION
- MARKET SURVEY
- THE MAJOR PLAYERS
- MARKET OVERVIEW OF ZIROCONIUM
- PRODUCTION OF ZIROCONIUM SILICATE POWDER
- MANUFACTURE OF ZIRCON SAND
- MANUFACTURING PROCESS OF ZIRCONIUM SILICATE FROM MINERAL SAND ZIRCON SAND)
- DETAILED MANUFACTURING PROCESS OF ZIRCONIUM SILICATE FROM MINERAL SAND (ZIRCON SAND)
- VIBRATORY MILLS (VIBRO MILL)
- OTHER CHARACTERISTICS OF VIBRO MILL ARE GIVEN IN THE FOLLOWING TABLE CHARACTERISTICS OF SWECO VIBRATORY MILLS
- PERFORMANCE
- GRINDING MEDIA
- WET GRINDING
- DRYING (IN FLUIDIZED BED DRYERS)
- GRINDING
- MICROPULVERIZING
- MICRO-PULVERIZER
- PROCESS FLOW DIAFRAM FOR THE MFG OR ZERCONIUM SILICATE FROM INERAL SAND
- MANUFACTURING PROCESS OF ZIRCONIUM SILICATE FROM ZIRCONIA
- CRUSHING & GRINDING
- MIXING OF PULVERIZED ZIRCONIA AND SILICAS FOR AN INTIMATE MIX
- HEATING IN AN ELECTRIC FURNANCE
- COOLING
- PULVERIZING FOR FINE POWDER OF ZIRCONIUM SILICATE
- SIEVING
- QUALITY CHECK-UP
- PACKAGING
- MARKING
- TESTING
- CLAY CONTENT
- MOISTURE CONTENT
- GRAIN FINENESS
- COMPARATIVE SIEVE DESIGNATIONS OF IS, BS, AND ASTM TEST SIEVES
- PROCESS FLOW DIAGRAM FOR THE MANUFACTURE OF ZIRCONIUM SILICATE (ZIRCON)
- METHODS OF CHEMICAL ANALYSIS OF ZIRCON SAND
- SCOPE
- DETERMINATION OF LOSS ON IGNITION
- CALCULATION
- RAW MATERIAL CALCULATIONS
- PROCESS TECHNOLOGIES OF ZIRCONIUM SILICATE
- THE EVALUATE OF THE ZIRCONIUM SILICATE POWDER
- RECOVERY OF ZIRCONIA FROM ZIRCON SANDS
- THERMAL DISSOCIATION
- DECOMPOSITION BY FUSION
- FUSION WITH SODIUM HYDROXIDE
- FUSION WITH SODIUM CARBONATE
- FUSION WITH CALCIUM OXIDE AND MAGNESIUM OXIDE
- FUSION WITH POTASSIUM FLUOROSILICATE
- FUSION WITH CALCIUM CARBONATE (OR LIME)
- MATERIAL SAFETY DATA SHEET OF ZIRCONIUM SILICATE
- HAZARDS IDENTIFICATION
- LABEL ELEMENTS
- COMPOSITION/INFORMATION ON INGREDIENTS
- FIRST AID MEASURES
- FIREFIGHTING MEASURES
- ACCIDENTAL RELEASE MEASURES
- HANDLING AND STORAGE
- EXPOSURE CONTROLS/PERSONAL PROTECTION
- SUPPLIERS OF RAW MATERIALS
- SUPPLIERS OF PLANT AND MACHINERY
- SUPPLIERS OF JAW CRUSHER
- SUPPLIERS OF BALL MILL
- SUPPLIERS OF DRYERS
- SUPPLIERS OF VIBRATORY SCREEN
- SUPPLIERS OF MAGNETIC SEPARATORS
- SUPPLIERS OF MATERIAL HANDLING EQUIPMENTS
- INSTRUMENTATION & PROCESS CONTROL EQUIPMENTS
- SUPPLIERS OF LABORATORY EQUIPMENTS
Appendix
- 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
Zirconium silicate is a naturally occurring mineral compound commonly known as zircon. It is represented chemically as ZrSiO4 and is also described as ZrO2-SiO2. Zircon occurs in igneous, metamorphic and sedimentary geological environments and is commercially recovered from mineral sands. Its high melting point, chemical stability and low coefficient of thermal expansion make it useful in refractory, ceramic, glass and foundry applications. It can occur in several colours, including brown, grey, red and colourless forms.
Zirconium silicate is mainly used in ceramics, refractories, glass manufacturing and foundry applications. In foundries, zircon can serve as a mould material or mould-facing material because of its thermal and chemical properties. It is also used in applications requiring resistance to high temperatures and chemical attack. Zircon-containing materials can contribute to improved toughness and performance in certain glass products, while zirconium-based abrasive grains are used for grinding steel and steel alloys because of their hardness, strength and sharp surface characteristics.
Zircon is used in foundries because its thermal and chemical characteristics support mould and precision-casting applications. Its relatively high thermal conductivity can provide faster cooling compared with some other mould materials. Its high melting point, low coefficient of thermal expansion and chemical stability also make it suitable as a mould-facing material. These characteristics can help support dimensional stability and surface quality in demanding casting processes, particularly where resistance to thermal conditions and chemical interaction with molten metal is important.
Zirconium silicate can be produced from zircon-bearing mineral sand through a sequence of mineral processing and size-reduction operations. The report covers processes involving grinding, drying, vibratory milling, micropulverizing, screening and quality checking. Depending on the process route and feed material, separation and material handling operations may also be required. The final product is subjected to relevant quality checks before packaging and marking. Process selection depends on the characteristics of the zircon sand, required product specifications and the desired particle size.
The report describes zircon mineral sand as a principal feed material and also covers a manufacturing route based on zirconia and silica. Zirconium oxide, or zirconia, and silica are therefore important raw-material subjects within the report. Their grades and characteristics influence the manufacturing route and product quality. When producing zirconium silicate from zirconia and silica, the materials are described as being crushed and ground, intimately mixed, heated, cooled, pulverized and sieved before quality checking, packaging and marking.
Important quality parameters covered in the report include clay content, moisture content and grain fineness. Chemical analysis and loss on ignition are also addressed. Sieve analysis is relevant for determining particle-size characteristics, and the report includes comparative sieve designations under IS, BS and ASTM systems. Quality control helps ensure that the processed zircon material meets the intended product requirements. The specific testing programme should be established according to the applicable product specification, customer requirements and relevant standards.
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