CALCIUM CARBONATE (FILLER) (CAP: 120 MT/DAY)
[EIRI/EDPR/4534] J.C.: 2751XL
INTRODUCTION
Filler materials are particles added to resin or binders (plastics, composites, concrete) that can improve specific properties, make the product cheaper, or a mixture of both. The two largest segments for filler material use are elastomers and plastics. Worldwide, more than 53 million tons of fillers (with a total sum of approximately US$ 18 billion) are used every year in application areas such as paper, plastics, rubber, paints, coatings, adhesives and sealants. As such, fillers, produced by more than 700 companies, rank among the world's major raw materials and are contained in a variety of goods for daily consumer needs. The top filler materials used are ground calcium carbonate.
Calcium carbonate is an inorganic chemical compound with the chemical formula CaCO3.
Calcium carbonate is one of the most popular chemicals which are first encountered in school classrooms, where the use of chalk (a form of CaCO3) is found. It is found in the earth’s crust. It is also found in many forms such as marble, limestone etc. Although they are available in various forms they are chemically similar and only differ physically. They are also referred to as calcite. It occurs in a wide variety of mineral forms, including limestone, marble, travertine and chalk. Calcium carbonate also occurs combined with magnesium as the mineral dolomite, CaMg (CO3)2. Stalactites and stalagmites in caves are made of calcium carbonate, as are a variety of animal products, notably coral, seashells, eggshells, and pearls.
Calcium carbonate has two major crystalline forms - two different geometric arrangements of the calcium ions and carbonate ions that make up the compound - aragonite and calcite. All calcium carbonate minerals are conglomerations of various-sized crystals of these two forms, packed together in different ways and containing various impurities. The large, transparent crystals known as Iceland spar, however, are pure calcite.
In its pure form, calcium carbonate is a white powder with a specific gravity of 2.71 in the calcite form or 2.93 in the aragonite form. When heated, it decomposes into calcium oxide (CaO) and carbon dioxide gas (CO2). It also reacts vigorously with acids to release a froth of carbon dioxide bubbles.
Calcium carbonate deposits can be formed in seawater when calcium ions dissolved from other minerals react with dissolved carbon dioxide (carbonic acid, H2 CO3). The resulting calcium carbonate is insoluble in water and sinks to the bottom.
Most of the calcium carbonate deposits found today were formed by sea creatures millions of years ago when oceans covered much of what is now land. They manufactured shells and skeletons of calcium carbonate using the calcium ions and carbon dioxide in the oceans, just as clams, oysters, and corals do today. When these animals died, their shells settled on the sea floor. Now, long after the seas have gone, they have been compressed into thick deposits of limestone.
COST ESTIMATION
Plant Capacity 120 MT/Day
Land & Building (6105 sq.mt.) Rs. 5.65 Cr
Plant & Machinery Rs. 5.57 Cr
Working Capital for 2 Months Rs. 6.99 Cr
Total Capital Investment Rs. 18.56 Cr
Rate of Return 23%
Break Even Point 59%
CONTENTS
INTRODUCTION
CALCIUM CARBONATE
KEY FACTS
OTHER NAMES:
FORMULA:
ELEMENTS:
COMPOUND TYPE:
MELTING POINT:
SOLUBILITY:
FILLER (MATERIALS)
TYPES
CALCIUM CARBONATE (CACO3)
KAOLIN
MAGNESIUM HYDROXIDE (TALC)
WOLLASTONITE (CASIO3)
GLASS MICROSPHERE FILLER (LEFT) AND FIBER FILLERS (RIGHT)
FLY ASHES
NANOFILLERS
POLYMER FOAM BEADS
MASONRY FILLER
OTHER FILLERS
TABLE OF FILLER MATERIALS AND PHYSICAL PROPERTIES
MASTERBATCHES
RAW MATERIAL
USES OF CALCIUM CARBONATE FILLER
CALCIUM CARBONATE IS USED FOR MAKING MASTERBATCHES:-
MASTERBATCH IS USED IN THE FOLLOWING AREAS:
APPLICATION
IN PRODUCING PLASTIC DOORS, CEILING PANELS, FRAMES
IN POWER CABLES PRODUCTION
IN BLOWING FILMS PRODUCTION
IN SPINNING PRODUCTION
IN PLASTIC COMPOSITES PRODUCTION
SELECTION OF COLORANTS
CALCIUM CARBONATE FILLERS FOR RAFFIA
WHAT IS RAFFIA TECHNOLOGY AND ITS OUTPUTS
TYPICAL SPECIFICATIONS
ASTM TESTING METHODS
MARKET OVERVIEW
GLOBAL MARKET OVERVIEW
SEGMENTATION ANALYSIS
MARKET, BY PRODUCT
MARKET, BY END-USER
MARKET, BY GEOGRAPHY
KEY PLAYERS
SOME OF THE MAJOR PLAYERS ARE
MERGERS AND ACQUISITION FORM KEY STRATEGY.
TOP PLAYERS IN THE MARKET INCLUDE:
CACO3 INDIA MARKET
ASIA-PACIFIC EXPECTED TO DOMINATE THE GLOBAL MARKET
LIST OF BUYERS IN INDIA
FACTORS TO BE CONSIDERED
RAW MATERIALS COMPOSITION
RAW MATERIAL COMPOSITION
THE PROPOSED PRODUCTION OF GROUND CALCIUM CARBONATE (GCC) IS 120 TPD.
MANUFACTURING PROCESS
PROCESS STEPS - GROUND CALCIUM CARBONATE PRODUCTION
PROCESS STEPS
THE PROPOSED TYPICAL SCHEMATIC IS AS FOLLOWS:
UTILITY REQUIREMENT (ESTIMATED) - MONTH
PLANT & MACHINERY BROADLY USED FOR THE PROCESS
A) JAW CRUSHER
JAW CRUSHER DIAGRAM
JAW CRUSHER WORKING PRINCIPLE
JAW CRUSHER FEATURES
HIGH RELIABILITY
HIGH STRENGTH
STRONG BEARING CAPACITY
BELT TYPE CONVEYOR
BELT CONVEYOR DESIGN
BELT CONVEYOR WORKING PRINCIPLE
CONE CRUSHER
AIR CLASSIFYING MILL
DESIGN & OPTIONS:
PULVERISER
DESIGN & OPTIONS:
JET MILL
PRINCIPLE OF OPERATION
APPLICATIONS
STORAGE SILO
SLACKED LIME PACKING MACHINE
PACKING MACHINE STRUCTURE
FEEDING DEVICE
MAIN TRANSMISSION DEVICE
POWER SUPPLY SYSTEM
ROTARY BIN
WEIGHING MECHANISM
BAGGING WEIGHING FRAME
CYLINDER CONTROL MECHANISM
DUST COLLECTING PLATE
PRINCIPLES OF PLANT LAYOUT
MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE:
PLANT LOCATION FACTORS
PRIMARY FACTORS
MARKETS:
WATER SUPPLY:
CLIMATE:
TRANSPORTATION:
WASTE DISPOSAL:
LABOR:
REGULATORY LAWS:
TAXES:
COST OF SITE
COMMUNITY FACTORS:
FLOOD AND FIRE CONTROL:
HEALTH SAFETY AND ENVIRONMENT
DUST EMISSIONS ARE ONE OF THE MOST SIGNIFICANT IMPACTS.
PROPOSED IMPLEMENTATION SCHEDULE
MARKET SURVEY
GLOBAL CALCIUM CARBONATE FILLER MASTERBATCH MARKET: SEGMENT ANALYSIS
THE CALCIUM CARBONATE FILLER MASTERBATCH MARKET ANALYSIS BY TYPES IS SEGMENTED INTO:
THE CALCIUM CARBONATE FILLER MASTERBATCH MARKET INDUSTRY RESEARCH BY APPLICATION IS SEGMENTED INTO:
BASED ON APPLICATIONS, THE CALCIUM CARBONATE FILLER MASTERBATCH MARKET FROM 2018 TO 2028 COVERS:
SUPPLIERS OF PLANT & MACHINERY/TURNKEY CONSULTANTS
BOILER
GENERATOR SET (DG SET)
COOLING TOWERS
BALL MILLS
SILO
PACKAGING MACHINE
WASTE GENERATION & MANAGEMENT/GREEN BELT
GREEN BELT
WASTE WATER
HEALTH SAFETY AND ENVIRONMENT
ANTICIPATED ENVIRONMENTAL IMPACTS
CONSTRUCTION PHASE
OPERATION PHASE
MITIGATION MEASURES (PROPOSED)
SAFETY & ENVIRONMENT MANAGEMENT PLAN
SAFETY & OCCUPATIONAL MEASURE (STORAGE/HANDLING OF RAW MATERIAL & PRODUCT)
PROPOSED IMPLEMENTATION SCHEDULE
PROJECT FINANCIALS
BASIS & PRESUMPTIONS (FOR PROFITABILITY WORKINGS)
MACHINERY PHOTOGRAPHS
PLANT & MACHINERY BROADLY USED FOR THE PROCESS
JAW CRUSHER
BELT TYPE CONVEYOR
CONE CRUSHER
AIR CLASSIFYING MILL
PULVERISER
JET MILL
STORAGE SILO
RAW MATERIAL PHOTOGRAPHS
PRODUCT PHOTOGRAPHS
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)
