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)
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