CALCINATION PLANT FOR PYROPHYLLITE AND DIASPORE MINERALS
[EIRI/EDPR/1565] J.C: 360,361
INTRODUCTION
Pyrophyllite is a hydrous aluminum silicate that is generally described by the molecular formula Al2O3•4SiO2•H2O. This alteration mineral is light green or white with a waxy texture. In nature, pyrophyllite rarely exists in its pure form and is normally associated with accessory minerals such as quartz, kaolin, diaspore, corundum, andalusite, boehmite, sericite, chlorite, and alunite. Pyrophyllite ores can also include iron-containing impurities such as pyrite, hematite, and limonite; therefore, different mineral samples that are classified as pyrophyllite can contain various combinations of accessory minerals and have different chemical compositions. It is important to understand the origins and distributions of pyrophyllite deposits in order to extend pyrophyllite applications. This chapter therefore describes basic methods for the mineral’s identification and analysis.
In Japan, pyrophyllite mined in the Mitsuishi District of the Okayama Prefecture was used in engraving from around 1800 until the early 1900s. With the introduction of primary school education in 1886, pyrophyllite ores began to be processed and used for slate pencils. During the 20th century, the demand for pyrophyllite ores as raw materials for ceramics—particularly refractory materials— grew in response to the increasing needs of industry. Quality checks during mining and strict quality control during the crushing and grinding processes are essential because the major, accessory, and trace ingredients of the raw ores determine the properties of the products, including refractory characteristics, coefficients of thermal expansion and contraction, melting point, hardness, and color.
Pyrophyllite ores have been used for many years in a range of applications. The quality requirements, however, have recently become much stricter as a result of competition from several minerals with similar properties. Consumption is also decreasing for a number of reasons, including advances in paper-manufacturing techniques, in which pyrophyllite is used as a filler; decreases in the number of dustings with insecticides because of improvements in agrochemicals; and the trend toward the use of longer-lasting bricks in the refractory industry.
Research is needed to expand the potential applications and, therefore, the demand for pyrophyllite ores. Low-quality ores might be used after removing impurities and by developing energy-saving furnaces that can operate at lower temperatures. In addition, advances in powder technologies are likely to increase the uses of pyrophyllite ores in fine ceramics. Efficient usage remains important, however, because these ores have limited distributions and worldwide reserves.
Diaspore is a dimorphous form of boehmite, with chemical composition Al2O3.H2O (betamonohydrate of aluminium). It is an important constituent of bauxite. Because of its good refractory properties, it is used chiefly for making high-alumina refractory bricks. It is also used as a filler in plastic industry.
COST ESTIMATION
Plant Capacity 30 MT/Day
Land & Building (1500 sq.mt.) Rs. 1.81 Cr
Plant & Machinery Rs. 1.75 Cr
Working Capital for 1 Month Rs. 67.81 Lac
Total Capital Investment Rs. 4.39 Cr
Rate of Return 27%
Break Even Point 58%
CONTENTS
INTRODUCTION
DIASPORE
PROPERTIES
OF PYROPHYLLITE AND DISPARE MINERALS
PRODUCT GRADE AND SPECIFICATION OF PYROPHYLLITE
B.I.S. SPECIFICATIONS
USES AND APPLICATION OF PYROPHYLLITE AND DISPARE MINERALS
MARKET SURVEY
PRESENT MANUFACTURERS
CLASSIFICATION OF PYROPHYLLITE ORES
GLOBAL PRODUCTION, CONSUMPTION AND TRADE OF PYROPHYLLITE
MINERALOGY AND CHEMICAL PROPERTIES OF PYROPHYLLITE
MINING AND PROCESSING OF PYROPHYLLITE
DIASPORE MINERAL DATA
MANUFACTURING PROCESS OF CALCINATION PLANT FOR PYROPHYLLITE AND DIASPORE
PROCESS FLOW DIAGRAM
MANUFACTURING PROCESS OF CALCINATION OF DIASPARE MINERALS BY USING VERTICAL SHAFT KILN
PROCESS FLOW DIAGRAM
DETAILS OF CALCINATION
TECHNICAL DATA OF CALCINED DIASPORE
COMPARISON BETWEEN CALCINATION OF DIASPORE AND PYROPHYLLITE MINERAL THROUGH VERTICAL SHOFT KELIN AND ROTARY KILN
SUPPLIERS OF PLANT & MACHINERY
SUPPLIERS OF RAW MATERIALS
PRINCIPLES OF PLANT LAYOUT
PLANT LOCATION FACTORS
EXPLANATION OF TERMS USED IN THE PROJECT REPORT
PROJECT IMPLEMENTATION SCHEDULES
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)
