Calcium Carbonate (Filler) (Cap: 120 MT/Day)

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)