HIGH ALUMINA REFRACTORY BRICK PLANT
[EIRI/EDPR/1465] J.C. 246
INTRODUCTION
Refractories are materials that provide linings for high-temperature furnaces and other processing units. Refractories must be able to withstand physical wear, high temperatures (above 538°C [1000°F]), and corrosion by chemical agents. There are two general classifications of refractories, clay and nonclay. The six-digit source classification code (SCC) for refractory manufacturing is 3-05-005. Clay refractories are produced from fireclay (hydrous silicates of aluminum) and alumina (57 to 87.5 percent). Other clay minerals used in the production ofrefractories include kaolin, bentonite, ball clay, and common clay. Nonclay refractories are produced from a composition of alumina (<87.5 percent), mullite, chromite, magnesite, silica, silicon carbide, zircon, and other nonclays.
Refractories, a key input for iron and steel making, assume ever increasing role due to high stress on production of high quality sophisticated steels, which alone accounts for the consumption of nearly 70% of total refractories produced.Refractories in general, are the non-metallic materials that are hard to melt at high temperature and having enough mechanical strength and heat resistance to withstand rapid temperature change, including repeated heating and cooling and resistance to molten slag and metals.
Refractories are material having melting points with properties that make them suitable to act as heat-resisting barriers between high and low temperature zones. The value of refractories is judged not merely by the cost of the material itself, but by the nature of job and/or its performance in a particular situation. Specifically, the performance of a refractory depends on its qualities and quantities in three phases- solid, glass/liquid, and pores- which govern the ultimate property of a refractory material.
COST ESTIMATION
Plant Capacity 20 MT/Day
Land & Building (2 Acres) Rs. 3.80 Cr
Plant & Machinery Rs. 7.79 Cr
Working Capital for 1 Month Rs. 75.11 Lac
Total Capital Investment Rs. 13.69 Cr
Rate of Return 2%
Break Even Point 96%
CONTENTS
INTRODUCTION
CLASSIFICATION OF REFRACTORIES
CHEMISTRY AND PHASE MINERALOGY
TYPES AND CHARACTERISTICS OF PRODUCT
RAW MATERIALS USED IN ALUMINA REFRACTORIES
TYPES AND CHARACTERISTICS OF RAW MATERIALS USED
APPLICATIONS
APPLICATIONS OF ALUMINA REFRACTORIES
MANUFACTURING PROCESS
MACHINERY DESCRIPTION WITH TECHNICAL DETAILS
PROCESS FLOW DIAGRAM
PHOTOGRAPHS
MACHINERY
MARKET POTENTIAL
MANUFACTURERS OF HIGH ALUMINA REFRACTORY BRICKS
EMISSIONS AND CONTROLS IN REFRACTORY MANUFACTURING
PLANT LAYOUT
SUPPLIERS OF RAW MATERIALS
COMPLETE MACHINERY EQUIPMENT MANUFACTURER
EQUIPMENTS DETAILS & COST
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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