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    Detailed Project Report on High Alumina Refractory Brick Plant

    Detailed Project Report on High Alumina Refractory Brick Plant
    Detailed Project Report on High Alumina Refractory Brick Plant
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      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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