Detailed Project Report (DPR) on Plaster of Paris for Construction Purpose

PLASTER OF PARIS FOR CONSTRUCTION PURPOSE

[EIRI/EDPR/1111] J.C.: 9756XL

INTRODUCTION

Plaster is one of the oldest known synthetic building materials: it was used by the Egyptians at least 4000 years ago in the construction of the pyramids, and the Greeks were producing decorative plaster work by 500 BC. The chemistry of the conversion of gypsum to plaster was also investigated early on by chemists such as Le Chatelier (1850 - 1936) and van’t Hoff (1852 - 1911).

Plaster is made by heating gypsum (CaSO4.2H2O) powder, thus converting it to calcium sulphate hemihydrate (CaSO4.½H2O). The hemihydrate is also known as stucco or Plaster of Paris. Probably so named because of the very large deposit of pure gypsum found beneath Paris. When water is added to the stucco, the material rehydrates to give a solid mass of gypsum. This rehydration is accompanied by an increase in temperature and a slight expansion of the plaster, causing the gypsum to perfectly fill a mould.

Plaster of Paris (POP) chemically is hemi-hydrate of calcium sulfate produced by calcinations / heat treatment of gypsum, a di-hydrate of calcium sulfate. It finds its application in various areas of construction, ceramic, chalk pieces, medical (dental and surgical), sculpting, etc. Physically POP is described in a and (3 form, a referring to crystalline form and 03 referring to amorphous form. In India only (3 form is produced and all further discussion refers to only this form. The Chemical reactions involved in the production of POP are as under.

COST ESTIMATION

Plant Capacity            100 MT/Day

Land & Building (5000 sq.mt.)    Rs. 6.28 Cr

Plant & Machinery                    Rs. 1.59 Cr

Working Capital for 1 Month    Rs. 7.96 Cr

Total Capital Investment          Rs. 16.15 Cr

Rate of Return                          43%

Break Even Point                      34%

CONTENTS

INTRODUCTION

USES OF PLASTER

MARKET SURVEY

1.3 CLASSIFICATION OF POP INDUSTRY:

1.4 POP CAPACITY UTILIZATION, CONSUMPTION AREAS AND MARKETS:

1.5 FUTURE GROWTH PROSPECTUS:

PRODUCTION PROCESS

2.1 PRINCIPLES OF POP PRODUCTION:

2.2 RAW MATERIAL CLEANING

2.3 RAW MATERIAL CRUSHING

2.3.1 ATTRITION MILLS:

2.3.2 JAW CRUSHER

2.3.3 HAMMER MILL

2.4 SCREENING

2.5 CALCINATION

2.5.1 ROTARY DRUM CALCINER

2.5.2 PAN TYPE CALCINER

2.5.3 KETTLE CALCINER

2.6 PULVERIZATION

3.1 AIR POLLUTION

3.1.1 EMISSION DURING RAW MATERIAL CRUSHING OPERATION

3.1.2 EMISSIONS DURING CALCINATION

3.1.3 EMISSIONS FROM PRODUCT GRINDING SECTION

3.1.4 EMISSIONS DURING MATERIAL HANDLING AND TRANSFER

3.1.5 EMISSION FROM STOCKPILES

3.1.6 EMISSION TO AMBIENT AIR:

3.2 WATER POLLUTION

3.3 SOLID WASTE

3.4 NOISE POLLUTION

3.5 FOR LARGE SCALE UNITS

3.6 CONCLUSIONS

FILED STUDY: MATERIAL AND ENERGY BALANCE

4.1 OVERALL MATERIAL BALANCE FOR PRODUCING 1TON OF POP

4.1.1 MATERIAL BALANCE BASIS:

4.1.2 ASSUMPTIONS:

4.1.3 MATERIAL BALANCE:

4.2 ENERGY CONSUMPTION PATTERN:

FIG 4.2: EXISTING AND RECOMMENDED FURNACE FLUE PATH.

APPLICABLE CONTROL SYSTEMS & THEIR COST ECONOMICS

INTRODUCTION:

5.1 BASE LINE DATA:

5.2 COST COMPARISON OF TECHNICAL ALTERNATIVES:

THE MANUFACTURING PROCESS

STEP 1 - PLASTER OF PARIS MANUFACTURE

STEP 2 - REHYDRATION

TABLE 1 - COMMON PLASTER ADDITIVES

CONTAINING A HIGH CONCENTRATION OF CALCIUM IONS)

PLASTER BOARD PRODUCTION

STEP 3 - SETTING

ROLE OF THE LABORATORY

ENVIRONMENTAL IMPLICATIONS

OTHER METHODS

QUICK DRYING PLASTER

EXAMPLES

COMPARATIVE EXAMPLE 1

COMPARATIVE EXAMPLE 2

EXAMPLE 3

EXAMPLE 4

CALCIUM SULPHATE HEMIHYDRATE PLASTER

EXAMPLE 1

PREPARATION OF PROMOTOR SLURRY

EXAMPLE 2

EXAMPLE 3

EXAMPLE 4

EXAMPLE 5

EXAMPLE 6

EXAMPLE 7

EXAMPLE 8

EXAMPLE 9

EXAMPLE 10

APPARATUS FOR STABILIZING PLASTER

METHOD FOR PRODUCING HARD PLASTER OF PARIS

EXAMPLE

PROCESS FOR TREATING PLASTER OF PARIS

MANUFACTURERS/SUPPLIERS OF MACHINERY

ATTRITION MILLS

HAMMER MILLS

BUCKET ELEVATOR

VACUUM TRAY DRYER

ROTARY DRYER MANUFACTURERS & EXPORTERS

PULVERIZERS

BOILERS

DG SETS

SUPPLIERS OF RAW MATERIALS

CALCIUM SULFATE

COMPLETE PLANT SUPPLIERS FOR PLASTER OF PARIS

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)