Detailed Project Report on Ground Calcium Carbonate Micronization Plant

GROUND CALCIUM CARBONATE MICRONIZATION PLANT

[EIRI/EDPR/1653] (J.C.459 (INR) 460 (US$)

INTRODUCTION

Calcite is a carbonate of calcium (CaCO3) containing 56% CaO and 44% CO2. It is one of the important industrial minerals also known as 'Calc Spar'. Pure crystallised transparent variety of calcite is known as 'Iceland Spar' which is used as Nicol prism in optical instruments using polarised light.

Calcite is the most abundant crystalline form of calcium carbonate (CaCO3) Calcite limestone refers to a high-calcium limestone. As for hardness of calcite is concerned, pure calcite has a hardness of 3 Mohs, whereas naturally occurring limestone’s lie in the range of 2-4 Mohs.

Regarding the formation and occurrence of limestone/calcite mineral, this is widely distributed throughout the world in deposits of varying sizes and degrees of purity.

The process of this mineral formation is believed to have started with the extraction of calcium salts from the earliest forms of igneous rocks by the combined effects of erosion by the weather and corrosion by dissolved acids e.g. sulphurous acid and carbon dioxide.

Under certain conditions of concentration and temperature, calcium carbonate precipitated from the solution of calcium salts.

The calcium carbonate became contaminated by waterborne clays and silts. The mineral deposits became covered with other materials and were subjected to solvent action under high pressure and temperature. This consolidated the deposits and caused recrystallization to varying degrees. The sequence marl, chalk, limestone and marble shows progressive consolidation and change of structure. Soft marls are porous and contain well-defined fossils. The grain size ranges from less than 5 um for marls and clays to over 250 um for some marbles and calcite.

Calcite (CaCo3) is the most common form of natural calcium carbonate. Dogtooth spar, Iceland spar, nail-head spar and satin spar are varieties of calcite are essential ingredients of limestone marble and chalk.

Size reduction or comminution is the process, Whereby particulate materials are mechanically reduced in size, to increase their value and to bring them to a suitable size to use in important operations in various industries, eg. Cement, Stone, Coal, thermal power plants etc. Comminution processes are energy-intensive. In the mineral industries, coarse size reduction (from mined lump size to 1 cm.) is normally achieved by explosive shattering followed by crushing & grinding.

Where individual pieces are reduced in size by compression or impact, fine size is done by compression or impact. Fine size reduction (from 1 cm. down to 10 micron) is typically achieved by grinding in tumbling mills, where particles break by probablistic impact in a loosaly tumbling grinding media. Ultrafine size reduction (ie. smaller size is achieved by pulverizing where size reduction results by abrasion & attrition.

Solids may be homogeneous or heterogenous, crystalline or amorphous, hard or soft, brittle or ductile, However, most of the commercially important materials are heterogenous & brittle, which fail catastrophically when stressed to a material can be measured by stressing a sample under closely controlled conditions of compression, tension or shear. Comminution machines work through compression or impact.

The devices used for comminution, are required to provide a means for moving material into a stress-application zone, for Appling stresses to material for effecting comminution, and then, permitting the material to exit.

COST ESTIMATION

Plant Capacity            30 MT/Day

Land & Building (1500 sq.mt.)    Rs. 2.15 Cr

Plant & Machinery                    Rs. 98.00 Lac

Working Capital for 2 Months    Rs. 53.87 Lac

Total Capital Investment          Rs. 3.79 Cr

Rate of Return                          24%

Break Even Point                      58%

CONTENTS

INTRODUCTION

SPECIFICATION OF CALCIUM CARBONATE (CALCITE)

NATURAL OCCURRENCE OF FORMATION OF CALCITE

USES OF CALCITE IN PETROLEUM WELL DRILLING

USES & APPLICATIONS

USE IN AGRICULTURE

USE IN METALLURGICAL PROCESSES

FLUE GAS DESULFURIZATION

RESOURCES EXPLORATION AND DEVELOPMENT IN INDIA

PROPERTIES AND CHARACTERISTICS OF CALCITE

REQUIREMENT FOR LIMESTONE FOR CHEMICAL INDUSTRY

ASTM SPECIFICATIONS

MARKET SURVEY

PRODUCTION OF CALCITE

PRODUCTION OF CALCITE BY SECTOR/STATE/DISTRICT

MINING AND MARKETING

PRESENT MANUFACTURERS/SUPPLIERS OF MICRONIZED CALCIUM 

EQUIPMENTS

PLANT & MACHINERY

MICRONIZER

ADVANTAGES OF MICRONIZED POWDER PRODUCTON

AIR POLLUTION CONTROL SYSTEM

CALCITE PRODUCTION

CALCITE PROCESSING

MANUFACTURING PROCESS

HAMMER MILLS WITHOUT INTERNAL AIR CLASSIFIERS

MICRO PULVERIZER PERFORMANCE

METHOD OF TEST FOR CALCITE FOR CHEMICAL INDUSTRY

FLOW CHART

MANUFACTURING PROCESS

ECONOMICS OF LIME STONE PRODUCTION

PROCESS FLOW DIAGRAM

PLANT LAYOUT

SUPPLIERS OF RAW MATERIAL

SUPPLIERS OF PLANT AND MACHINERY

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)