Detailed Project Report on white fused alumina

WHITE FUSED ALUMINA

[CODE NO.4300] 

White Fused Alumina (WFA) is a highly pure form of aluminium oxide which is suitable for use with stainless steel and aluminium. This iron-free, reusable blasting medium is angular, brittle and hard. It has a powerful abrasive effect on the surface being blasted. White fused alumina belongs to the group of fused alumina.

 It is also called White Fused Aluminium Oxide, named by its white colour, belongs to the electro fused artificial corundum group and is an important mineral used widely for refractory bricks, refractory castables, pre-cast refractory shapes, other unshaped refractory products, ceramic shapes, metal &ceramic surface preparation, grinding wheels, sandpapers, sanding belts, sandblasting media, lapping and polishing. It’s obtained from reduced fusion of high purity calcined alumina in electric arc furnaces. Calcined alumina is the most important material in aluminium making industry. 

After the fusion process, the materials become liquid, then cooled down and crushed into different sizes for different applications. Magnetic contents are removed and materials are reshaped by relevant equipments, and then sieved into standard sizes (ANSI) of standard particle distribution. It is characterized by high purity (Al2O3 content=99%), great self-sharpening, acid and alkali resistance, high temperature resistance and stable thermal performance, which make it to be prefect raw material for all kinds of abrasive tools, including grinding high carbon steel, high speed steel, stainless steel and other fine-grained abrasives, it also can be used for precision casting and high-refractory materials.

 White Fused Alumina is a hard, chemically stable and relevantly fragile material with high alumina content, low impurity and stability in high temperatures. It has durable abrasives ability, high fireproof and refractory characters, making it an very important raw material in refractory, bonded abrasives and coated abrasives industries. Similar materials we make are Brown Fused Alumina and Vice White Fused Alumina.

 White Fused Alumina Characters

High Alumina

White Fused Alumina has an Aluminium Oxide (Al2O3) content of more than 99%. The high alumina content is ensured from its raw material which is calcined alumina. The high content of Al2O3 makes it perform well in fireproof and refractory applications.

Little Impurities

White Fused Alumina has very little impurities, usually less than 0.4% Na2O, less than 0.15 SiO2 and less than 0.15 Fe2O3. It is chemically stable and little impurities make it ideal for refractory uses.

High Hardness

The high content of Al2O3 (Aluminium Oxide) makes it to be with very high hardness (Mosh Hardness=9) and It’s usually utilized for grinding ,cutting, lapping, sandblasting, polishing, surface preparing and also for coated abrasive application, including sandpaper and sand belt. It’s not easy to break and good for abrasives. In abrasives industries, it is used for cutting wheels, grinding wheels etc, also used for coated abrasives applications like sandpapers. It’s white colour and little impurities also make it excellent grinding and sandblasting media for preparing and polishing surface of metal, ceramic products etc. WFA fines are also a good material for polishing and water jetting in electronics industry.

Sharp Edges

White Fused Alumina is a crystal mineral with sharp edges and widely used in sandblasting, cutting and grinding abrasives.

Abrasive white aluminium oxide is a white abrasive made from industrial alumina powder (Al2O3) with a content of over 98% and a small amount of iron oxide and silicon oxide. It is a white abrasive which is melted at high temperature. Its hardness is slightly higher than that of brown corundum and its toughness is slightly lower. It is made by smelting and cooling above 2000 degrees in arc, grinding and shaping, removing iron by magnetic separation, and sieving into many kinds of granularity. It is compact in texture, high in hardness and sharp in shape.

White Fused Alumina (WFA) is obtained from the fusion of high purity calcined alumina in electric arc furnaces. WFA is raw material characterized with high hardness, yet friable with high purity, chemical stability, a high melting point, and large crystal size.

The global White Fused Alumina market is valued at 447.8 million USD in 2020 is expected to reach 522.4 million USD by the end of 2026, growing at a CAGR of 2.2% during 2021-2026.

It is intended to prepare a Feasibility Report to install a White Fused Alumina production facility with an installed capacity of 14400 Tons / Year as a Green Field Project.

COST ESTIMATION

Plant Capacity                                    48 Tons./Day

Land & Building (7180 sq.mt.)  Rs. 7.41 Cr

Plant & Machinery                              Rs. 4.67 Cr

Working Capital for 4 Months    Rs. 21.94 Cr

Total Capital Investment                  Rs. 34.39 Cr

Rate of Return                                    44%

Break Even Point                               45%

• INTRODUCTION
• USES/APPLICATION/ADVANTAGES
• MARKET OVERVIEW
• PHYSICAL PROPERTIES & CHEMICAL ANALYSIS (TYPICAL)
• PHYSICAL & CHEMICAL INDEX OF WHITE FUSED ALUMINA
• RAW MATERIAL SOURCE
• BIS SPECIFICATION
• MANUFACTURING STEPS/PROCESS SCHEMATIC/PROCESS FLOW
• PLANT & MACHINERY
• ELECTRIC ARC FURNACE (EAF) - TECHNICAL ASPECT
• PLANT & MACHINERY - OTHER
• PLANT & MACHINERY SUPPLIER/TURNKEY CONSULTANTS
• PREVENTIVE ENVIRONMENTAL MANAGEMENT/ENVIRONMENT IMPACT ASSESSMENT (EIA)
• PROJECT CYCLE
• PRINCIPLES OF PLANT LAYOUT
• PLANT LOCATION FACTORS
• UTILITY REQUIREMENT (ESTIMATED) - MONTH
• GENERATION AND MANAGEMENT OF WASTES
• HEALTH SAFETY AND ENVIRONMENT
• ANTICIPATED ENVIRONMENTAL IMPACTS 
• MITIGATION MEASURES (PROPOSED)
• HSE REQUIREMENT
• SAFETY & OCCUPATIONAL MEASURE 
• PROPOSED IMPLEMENTATION SCHEDULE
• PROJECT FINANCIALS
• PRELIMINARY PLANT LAYOUT
• SAFETY DATA SHEET (WHITE FUSED ALUMINA)

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)