GRAPHITE CRUCIBLE
[EIRI/EDPR/4574] J.C.: 2791INR, 2791US$
INTRODUCTION
Refractories are manufactured from naturally occurring substances in the earth’s crust- graphite. Graphite materials do not occur in their pure form hence needs some treatment before manufacturing. Initial processing may include an extensive survey of the deposit, selective mining, stockpiling by grade, and beneficiation techniques such as weathering, grinding, washing, heavy media separation, froth flotation etc are employed.
Though some can be used without pre-processing, many must be subjected to heat treatment. Calcination is also carried out in some of the pre-treatment. Originally, calcinations refer specifically to the treatment of calcareous minerals to remove CO2. The term has come to be used to indicate heat treatment to sinter or burn (dead burn) the refractory grain to stable dense material as well as to decompose minerals. The materials obtained after calcinations are hard burnt materials and they are called grain, clinker or grog.
Graphite is an allotrope of carbon and it is gray to black, opaque, very soft, has a low density and a metallic lustre. It is flexible and exhibits both metallic and nonmetallic properties, making it suitable for diverse industrial applications.
Global natural graphite production is approximately 1 to 1.2 million tonnes (Mt) per annum, of which flake graphite is estimated to be about 600-800 kt per year, amorphous graphite about 300 kt and vein graphite around 4 kt. The leading world producers of flake graphite in 2018 were China and Brazil. Mozambique is ramping up production significantly, having produced around 0.1 Mt in 2018, it is anticipated to overtake Brazil and become the second largest global producer in 2019.
China is also seeing increased flake graphite production, mainly from Heilongjiang Province, to supply the battery anode market. The major uses of graphite are in refractories, batteries, expandable graphite, plus brake linings, lubricants and steelmaking and foundry operations.
At Superbmelt, we produce our crucibles from graphite made from processing petroleum coke and pitch coke. The graphite used in the manufacturing of crucibles go through some degree of processing with our sophisticated equipment, dedicated for such a function. The primary components of our graphite are:
Pitch coke (produced from coal tar that appears during coke production). Pitch coke is manufactured by coking the destructive distillation of coal tar pitch from high purity carbon residue. It has high content of carbon and low content of sulphur and ash. Pitch coke also has high thermal conductivity. It is a byproduct of coal gas manufacturing.
Petroleum coke (petcoke) is the gray-to-black solid carbonaceous residue left by the destructive distillation of petroleum residua. Petcoke is used in the production of graphite, smelting and chemical industries.
A graphite crucible is a container made of graphite and it is used to melt and hold metals. They can be used at temperatures of up to 1600 degrees celsius and are suitable for refining and melting precious metals and base metals and other products. The graphite crucible is the crucible of choice for many users due to its outstanding properties, which include:
High thermal conductivity:
Due to the use of graphite, and other raw materials in high thermal conductivity, it ensures good thermal conductivity, shortens the time to melt and reduces energy consumption.
Heat shock resistance:
The heat shock performance of graphite crucible is strong, it is not easy to break for the urgent cold, urgent heat and any process.
High heat resistance:
Graphite crucibles have figures as high temperature and it is high temperature resistant 1200 to 1600 degree celsius.
Corrosion resistance:
Uniform and fine matrix design graphite of crucible make it strong to erosion against melt and delay the erosion degree of the product.
The production technology and quality assurance system of high pressure forming method of graphite crucible fully guarantee the stability of the melting quality.
COST ESTIMATION
Plant Capacity 1.5 MT/Day
Land & Building (4000 sq.mt.) Rs. 2.23 Cr
Plant & Machinery Rs. 52 Lac
Working Capital for 2 Months Rs. 94 Lac
Total Capital Investment Rs. 3.92 Cr
Rate of Return 43%
Break Even Point 55%
CONTENTS
INTRODUCTION
HIGH THERMAL CONDUCTIVITY:
HEAT SHOCK RESISTANCE:
HIGH HEAT RESISTANCE:
CORROSION RESISTANCE:
ANTI-MECHANICAL SHOCK:
OXIDATION RESISTANCE:
ANTI ADHESION:
RESISTANCE TO SLAG REMOVAL:
ACID RESISTANCE:
QUALITY STABILITY:
USES AND APPLICATION OF GRAPHITE CRUCIBLE
GRAPHITE CRUCIBLE
FUEL FIRED FURNACE
TAPERED GRAPHITE CRUCIBLE
ELECTRIC RESISTANCE FURNACE
GRAPHITE CRUCIBLE
INDUCTION FURNACE
SILICON CARBIDE GRAPHITE CRUCIBLE
REMOVABLE CRUCIBLE FURNACES
HAND POURING SHANK
TILTING FURNACE
TILTING FURNACE CRUCIBLE
PIT FURNACE
PIT FURNACE
METALS MELTED IN GRAPHITE CRUCIBLE
GRAPHITE CRUCIBLE METALS
COPPER
MELTED COPPER
ALUMINUM
MOLTEN ALUMINUM
GOLD
MELTED GOLD
SILVER
MELTED SILVER
BRASS
BRASS
FORM OF GRAPHITE
SYNTHETIC GRAPHITE
GRAPHITE ELECTRODES
NUCLEAR GRAPHITE
COMMERCIAL PRODUCTS
NATURAL GRAPHITE
PENCIL LEAD
REFRACTORIES
BATTERIES
STEELMAKING
BRAKE LININGS
FOUNDRY
TECHNICAL DETAILS OF GRAPHITE CRUCIBLE MANUFACTURE
PRODUCTION OF SYNTHETIC GRAPHITE
POWDER PREPARATION
SHAPE FORMING
EXTRUSION:
VIBRATION:
ISOSTATIC:
BAKING
PITCH IMPREGNATION
GRAPHITIZATION
PRODUCTION WITH NATURAL GRAPHITE
SILICON CARBIDE
SILICON CARBIDE POWDER
GRAPHITE
GRAPHITE FLAKES
MIXING AND BONDING
KNEADING MACHINE
MOLDING
HAND:
ROTARY:
COMPRESSION:
COKING
IMPREGNATION
GLAZING
KILN
SHUTTLE KILN
TESTING
QUALITY:
DURABILITY:
TEMPERATURE:
MEASURING:
FINAL FINISHING
MANUFACTURE OF GRAPHITE CRUCIBLE
ISOSTATIC PRESSING
ISOSTATIC MOLDING
COMPRESSION MOLDING
COMPRESSION MOLDING
VIBRATION MOLDING
CARE OF GRAPHITE CRUCIBLES
INSPECTION
STACKING
IMPROPERLY STACKED CRUCIBLES
THERMAL SHOCK
CHARGING
CRUCIBLE CRACKED BY BEING PACKED TOO TIGHTLY
FLUX
DIRECT FLAME
DAMAGE CAUSED BY DIRECT CONTACT WITH THE BURNER FLAME
DROSS
CLEANING
TEMPERATURE LIMIT
PREHEATING
CRUCIBLE TONGS
PROCESS LEVELS FOR SUPERMELT GRAPHITE CRUCIBLE
MOULDED GRAPHITE PROCESS
ISOSTATIC PRESSED GRAPHITE PROCESS
MEDIUM COARSE GRAPHITE PROCESS
PRECISION CNC MACHINING
TESTING
MAXIMIZE CRUCIBLE SERVICE LIFE
MARKET OVERVIEW OF GRAPHITE CRUCIBLE
TOP FEATURED COMPANIES DOMINATING THE GLOBAL
GRAPHITE CRUCIBLE MARKET
PRODUCT DEFINITION:
SILICON CARBIDE (SIC) CRUCIBLES:
CLAY-GRAPHITE CRUCIBLES:
REGIONAL ANALYSIS:
GROWTH FACTORS:
FORMULATION OF GRAPHITE CRUCIBLE
MANUFACTURING PROCESS OF GRAPHITE CRUCIBLE
PRINCIPLES OF PLANT LAYOUT
STORAGE LAYOUT:
EQUIPMENT LAYOUT:
SAFETY:
PLANT EXPANSION:
FLOOR SPACE:
UTILITIES SERVICING:
BUILDING:
MATERIAL-HANDLING EQUIPMENT:
RAILROADS AND ROADS:
MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE:
PLANT LOCATION FACTORS
PRIMARY FACTORS
1. RAW-MATERIAL SUPPLY:
2. MARKETS:
3. POWER AND FUEL SUPPLY:
4. WATER SUPPLY:
5. CLIMATE:
SPECIFIC FACTORS
6. TRANSPORTATION:
A. AVAILABILITY OF VARIOUS SERVICES AND PROJECTED RATES
7. WASTE DISPOSAL:
8. LABOR:
9. REGULATORY LAWS:
10. TAXES:
11. SITE CHARACTERISTICS:
12. COMMUNITY FACTORS:
13. VULNERABILITY TO WARTIME ATTACK:
14. FLOOD AND FIRE CONTROL:
EXPLANATION OF TERMS USED IN THE PROJECT REPORT
1. DEPRECIATION:
2. FIXED ASSETS:
3. WORKING CAPITAL:
4. BREAK-EVEN POINT:
5. OTHER FIXED EXPENSES:
6. MARGIN MONEY:
7. TOTAL LOAD:
8. LAND AREA/MAN POWER RATIO:
PROJECT IMPLEMENTATION SCHEDULES
INTRODUCTION
PROJECT HANDLING
PROJECT SCHEDULING
PROJECT CONSTRUCTION SCHEDULE
TIME SCHEDULE
ADDRESSES OF RAW MATERIAL SUPPLIERS
ADDRESSES OF PLANT AND SUPPLIERS
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)
