QUARTZ PROCESSING
[EIRI/EDPR/4332] J.C.: 2515XL
INTRODUCTION
Silica is the name given to a group of minerals composed of silicon and oxygen, the two most abundant elements in the earth's crust. Silica is found commonly in the crystalline state and rarely in an amorphous state. It is composed of one atom of silicon and two atoms of oxygen resulting in the chemical formula SiO2 Sand consists of small grains or particles of mineral and rock fragments. Although these grains may be of any mineral composition, the dominant component of sand is the mineral quartz, which is composed of silica (silicon dioxide). Other components may include aluminium, feldspar and iron-bearing minerals. Sand with particularly high silica levels that is used for purposes other than construction is referred to as silica sand or industrial sand.
For a particular source of sand to be suitable for glassmaking, it must not only contain a very high proportion of silica but also should not contain more than strictly limited amounts of certain metallic elements. Silica sand is also normally required to be well-sorted, i.e. to have grains of an approximately uniform size. Most sources of sand used by the construction industry do not satisfy these requirements and are not, therefore, suitable for glassmaking.
Industrial uses of silica sand depend on its purity and physical characteristics. Some of the more important physical properties are: grain size and distribution, grain shape, grain strength and refractoriness.
Industrial sand is a term normally applied to high purity silica sand products with closely controlled sizing. It is a more precise product than common concrete and asphalt gravels.
Silica is the name given to a group of minerals composed solely of silicon and oxygen, the two most abundant elements in the earth’s crust. In spite of its simple chemical formula, SiO2, silica exists in many different shapes and crystalline structures. Found most commonly in the crystalline state, it also occurs in an amorphous form resulting from weathering or plankton fossilization.
For industrial and manufacturing applications, deposits of silica yielding products of at least 95% SiO2 are preferred. Silica is hard, chemically inert and has a high melting point, attributable to the strength of the bonds between the atoms. These are prized qualities in applications like foundries and filtration systems. Quartz may be transparent to translucent and has a vitreous lustre, hence its use in glassmaking and ceramics. Industrial sand’s strength, silicon dioxide contribution and non-reactive properties make it an indispensable ingredient in the production of thousands of everyday products.
Quartz Powder
Some silica sand deposits may cater for the used primarily as metallurgical sand. The copper and zinc at some smelter uses the sand as a fluxing agent which, in the molten state, reacts with various impurities in the ore and produces a slag. The slag is drawn off with the impurities, leaving a more refined metal behind. Silica sands have a large number of other industrial uses depending on their characteristics.
• Production of glass
• Foundry sand
• Ceramics
• Sandblasting and other abrasives
• building products
• Filler and extender
• Production of silicon and silicon carbide
• Pigments
• Hydraulic fracturing and propping in the oil industry
• Water filtration
Silica, The most common occurrence of silica (qv) is in the form of quartz. Silica is the primary ingredient in glass and is usually obtained from high purity sandstones or quartzites by crushing and grinding, or from high-grade sand deposits. The term glass sand may refer to a deposit of sand or, more commonly it is used to refer to the sand after it has been beneficiated from sandstones, quartzites, or natural sands.
Quartz is used extensively in the ceramic and metallurgical industries. Large single crystals, found in hydrothermal veins in Brazil, are suitable for utilizing the piezoelectric effect found in this mineral. As a refractory it is used in the manufacture of firebrick, and as a network former it is used on a massive scale in the glass industry.
When pure, it is a colourless hard material given to conchoidal fracture.
When impure it has many colours that make it an attractive gemstone: agate, onyx, amethyst, topaz, and opal, a gel form containing appreciable water, are examples.
Quartzite, the only primary raw material for silica brick, is a very hard, but unmetamorphosed sandstone consisting chiefly of micro crystals of quartz which have been so completely and firmly cemented with secondary silica that the rock breaks across or through the individual grains rather than around them. This cement grows in optical and crystallographic continuity around each quartz grain, thereby lightly interlocking the grains as the original pore spaces are completely filled with secondary enlargements developed on the grains of quartz. It is almost pure silica having the common crystal form of hexagonal prism with ends of positive and negative rhombohedra. Its refractive index is close to that of balsma. It has a weak birefringence and positive elongation. Its hardness is 7 and specific gravity 2.65.
Quartzite, which is distinct from quartz and suitable for the manufacture of silica refractories, generally occurs as surface out-crop. This rock is abundantly available in most of the countries of the world. The best quality quartzite in India is available only in and around Bihar Sharif in Bihar.
The most common mineral in the Earth's continental crust is quartz, and most silica sand is made up of broken down quartz crystals. Silica is another name for silicon dioxide, SiO2, of which quartz is a specific latticed structure. So silica sand is quartz that over the years, through the work of water and wind, has been broken down into tiny granules. These granules can be used for many different purposes, and can be found in most non-tropical regions of the world.
Silica sand is used throughout the world, and in so many different ways it is hard to imagine a world without it. From water filtration, to glass manufacture, to industrial casting, to sand blasting, to producing concrete, to adding texture to slick roads, silica sand impacts every aspect of daily life. Many industrial suppliers carry silica sand in bulk quantities, while some smaller household stores sell it in smaller amounts for home or home construction use. One of the major uses of silica sand in the modern world is as an ingredient in industrial concrete. Silica sand produces the bulk of a great deal of concrete, although some concrete bypasses its use for safety and strength reasons.
It is intended to prepare a Feasibility Report to install a Quartz Processing Facility with a production capacity of 200 TPD as a Green Field Project.
COST ESTIMATION
Plant Capacity 200 MT/Day
Land & Building (8050 sq.mt.) Rs. 5.52 Cr
Plant & Machinery Rs. 3.14 Cr
Working Capital for 1 Month Rs. 1.58 Cr
Total Capital Investment Rs. 10.64 Cr
Rate of Return 18%
Break Even Point 68%
CONTENTS
INTRODUCTION
QUARTZ POWDER
PROPERTIES
PROPERTIES OF SILICA SAND
GRADES OF SILICA SAND
HAZARDS
PROPERTIES
SPECIFICATION AND COMPOSITION
ANALYSIS AND APPLICATION OF QUARTZ POWDER
QUARTZ [SILICA POWDER]
QUARTZ [SILICA POWDER] IS USED IN ALL LEADING INDUSTRIAL USES.
USES AND APPLICATIONS
INDUSTRIAL SAND APPLICATIONS
GRADES OF SILICA SAND FOR GLASSMAKING
BIS SPECIFICATIONS
MARKET OVERVIEW
MARKET INSIGHTS
PRODUCT INSIGHTS
END-USER INDUSTRY INSIGHTS
REST OF THE MIDDLE EAST AND AFRICA QUARTZ MARKET BY END-USER INDUSTRY
RAW MATERIALS
MINERAL PROPERTIES
QUARTZ POWDER DESCRIPTION
QUARTZ POWDER PHYSICAL PROPERTIES AVAILABLE:
QUARTZ POWDER STANDARD GRANULATIONS AVAILABLE:
GRAVEL SIZES:
POWDER SIZES
RAW MATERIAL SUPPLIERS
QUARTZ LUMPS
PROCESS OF MANUFACTURE OF QUARTZ POWDER
PROCESS FLOW
MAIN STEPS
RAW MATERIAL PREPARATION
CRUSHING PROCESS
GRINDING PROCESS
THE PRINCIPLE PURPOSES OF GRINDING ARE:
THE TWO STAGES OF GRINDING ARE:
COARSE GRINDING:
FINE GRINDING:
SIZING
THERE ARE TWO METHODS OF INDUSTRIAL SIZING.
QUALITY CONTROL
PACKING
MARKING
THE BAGS SHALL BE MARKED WITH THE FOLLOWING:
PLANT & MACHINERIES
MACHINERY USED ARE BROADLY DETAILED BELOW
TRANSPORTATION TECHNOLOGIES
CRUSHING TECHNOLOGIES
JAW CRUSHERS
GYRATORY (CONE) CRUSHERS
HAMMER CRUSHER
IMPACTOR/IMPACT BREAKERS:-
ROTOPOCTOR
SCREENING TECHNOLOGIES
GRIZZLIES TYPE SCREENS
VIBRATING SCREEN
ROTARY SCREEN
WASHING TECHNOLOGIES
MATERIAL HANDLING TECHNOLOGIES USED IN CRUSHING UNITS
FEEDERS
CONVEYORS
TYPES OF CONVEYORS ARE AS FOLLOWS
BUCKET ELEVATORS
MANUFACTURERS/SUPPLIERS OF QUARTZ POWDER
SUPPLIERS OF PLANT AND EQUIPMENTS
CRUSHING PLANT
BALL MILL
POWER TRANSFORMER
ELECTRICAL PANEL
SHOT BLASTING MACHINE
AIR POLLUTION CONTROL EQUIPMENTS
AIR CONDITIONING EQUIPMENTS
AIR COMPRESSOR
PLATFORM WEIGHING MACHINE
MATERIAL HANDLING EQUIPMENTS
FIRE FIGHTING EQUIPMENTS
HDPE BAGS
UTILITIES REQUIREMENT (ESTIMATED - MONTH)
WASTE EFFLUENT/FLUE GAS EMISSION (ESTIMATED)
GREEN BELT
WATER
PRINCIPLES OF PLANT LAYOUT
MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE:
PLANT LOCATION FACTORS
PRIMARY FACTORS
RAW-MATERIAL SUPPLY:
MARKETS:
POWER AND FUEL SUPPLY:
WATER SUPPLY:
CLIMATE:
SPECIFIC FACTORS
TRANSPORTATION:
WASTE DISPOSAL:
LABOR:
REGULATORY LAWS:
TAXES:
SITE CHARACTERISTICS:
COMMUNITY FACTORS:
FLOOD AND FIRE CONTROL:
ANTICIPATED ENVIRONMENTAL IMPACTS
CONSTRUCTION PHASE
OPERATION PHASE
MITIGATION MEASURES (PROPOSED)
HEALTH SAFETY & ENVIRONMENT
PROPOSED IMPLEMENTATION SCHEDULE
PROJECT FINANCIALS
BASIS & PRESUMPTIONS (FOR PROFITABILITY WORKINGS)
PRELIMINARY PLANT LAYOUT
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)
