PLASTER OF PARIS FOR CONSTRUCTION PURPOSE
[EIRI/EDPR/1111] J.C.: 9756XL
INTRODUCTION
Plaster is one of the oldest known synthetic building materials: it was used by the Egyptians at least 4000 years ago in the construction of the pyramids, and the Greeks were producing decorative plaster work by 500 BC. The chemistry of the conversion of gypsum to plaster was also investigated early on by chemists such as Le Chatelier (1850 - 1936) and van’t Hoff (1852 - 1911).
Plaster is made by heating gypsum (CaSO4.2H2O) powder, thus converting it to calcium sulphate hemihydrate (CaSO4.½H2O). The hemihydrate is also known as stucco or Plaster of Paris. Probably so named because of the very large deposit of pure gypsum found beneath Paris. When water is added to the stucco, the material rehydrates to give a solid mass of gypsum. This rehydration is accompanied by an increase in temperature and a slight expansion of the plaster, causing the gypsum to perfectly fill a mould.
Plaster of Paris (POP) chemically is hemi-hydrate of calcium sulfate produced by calcinations / heat treatment of gypsum, a di-hydrate of calcium sulfate. It finds its application in various areas of construction, ceramic, chalk pieces, medical (dental and surgical), sculpting, etc. Physically POP is described in a and (3 form, a referring to crystalline form and 03 referring to amorphous form. In India only (3 form is produced and all further discussion refers to only this form. The Chemical reactions involved in the production of POP are as under.
COST ESTIMATION
Plant Capacity 100 MT/Day
Land & Building (5000 sq.mt.) Rs. 6.28 Cr
Plant & Machinery Rs. 1.59 Cr
Working Capital for 1 Month Rs. 7.96 Cr
Total Capital Investment Rs. 16.15 Cr
Rate of Return 43%
Break Even Point 34%
CONTENTS
INTRODUCTION
USES OF PLASTER
MARKET SURVEY
1.3 CLASSIFICATION OF POP INDUSTRY:
1.4 POP CAPACITY UTILIZATION, CONSUMPTION AREAS AND MARKETS:
1.5 FUTURE GROWTH PROSPECTUS:
PRODUCTION PROCESS
2.1 PRINCIPLES OF POP PRODUCTION:
2.2 RAW MATERIAL CLEANING
2.3 RAW MATERIAL CRUSHING
2.3.1 ATTRITION MILLS:
2.3.2 JAW CRUSHER
2.3.3 HAMMER MILL
2.4 SCREENING
2.5 CALCINATION
2.5.1 ROTARY DRUM CALCINER
2.5.2 PAN TYPE CALCINER
2.5.3 KETTLE CALCINER
2.6 PULVERIZATION
3.1 AIR POLLUTION
3.1.1 EMISSION DURING RAW MATERIAL CRUSHING OPERATION
3.1.2 EMISSIONS DURING CALCINATION
3.1.3 EMISSIONS FROM PRODUCT GRINDING SECTION
3.1.4 EMISSIONS DURING MATERIAL HANDLING AND TRANSFER
3.1.5 EMISSION FROM STOCKPILES
3.1.6 EMISSION TO AMBIENT AIR:
3.2 WATER POLLUTION
3.3 SOLID WASTE
3.4 NOISE POLLUTION
3.5 FOR LARGE SCALE UNITS
3.6 CONCLUSIONS
FILED STUDY: MATERIAL AND ENERGY BALANCE
4.1 OVERALL MATERIAL BALANCE FOR PRODUCING 1TON OF POP
4.1.1 MATERIAL BALANCE BASIS:
4.1.2 ASSUMPTIONS:
4.1.3 MATERIAL BALANCE:
4.2 ENERGY CONSUMPTION PATTERN:
FIG 4.2: EXISTING AND RECOMMENDED FURNACE FLUE PATH.
APPLICABLE CONTROL SYSTEMS & THEIR COST ECONOMICS
INTRODUCTION:
5.1 BASE LINE DATA:
5.2 COST COMPARISON OF TECHNICAL ALTERNATIVES:
THE MANUFACTURING PROCESS
STEP 1 - PLASTER OF PARIS MANUFACTURE
STEP 2 - REHYDRATION
TABLE 1 - COMMON PLASTER ADDITIVES
CONTAINING A HIGH CONCENTRATION OF CALCIUM IONS)
PLASTER BOARD PRODUCTION
STEP 3 - SETTING
ROLE OF THE LABORATORY
ENVIRONMENTAL IMPLICATIONS
OTHER METHODS
QUICK DRYING PLASTER
EXAMPLES
COMPARATIVE EXAMPLE 1
COMPARATIVE EXAMPLE 2
EXAMPLE 3
EXAMPLE 4
CALCIUM SULPHATE HEMIHYDRATE PLASTER
EXAMPLE 1
PREPARATION OF PROMOTOR SLURRY
EXAMPLE 2
EXAMPLE 3
EXAMPLE 4
EXAMPLE 5
EXAMPLE 6
EXAMPLE 7
EXAMPLE 8
EXAMPLE 9
EXAMPLE 10
APPARATUS FOR STABILIZING PLASTER
METHOD FOR PRODUCING HARD PLASTER OF PARIS
EXAMPLE
PROCESS FOR TREATING PLASTER OF PARIS
MANUFACTURERS/SUPPLIERS OF MACHINERY
ATTRITION MILLS
HAMMER MILLS
BUCKET ELEVATOR
VACUUM TRAY DRYER
ROTARY DRYER MANUFACTURERS & EXPORTERS
PULVERIZERS
BOILERS
DG SETS
SUPPLIERS OF RAW MATERIALS
CALCIUM SULFATE
COMPLETE PLANT SUPPLIERS FOR PLASTER OF PARIS
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)
