Detailed Project Report on ground calcium carbonate

GROUND CALCIUM CARBONATE

[CODE NO.4245] 

Limestone is a common sedimentary rock composed primarily of the calcium carbonate mineral, calcite (CaCO3). Limestone constitutes approximately 10 percent of the sedimentary rocks exposed on the earth’s surface. Either limestone or marble are used as the basis for crushed or ground calcium carbonate. Ground Calcium Carbonate, commonly referred to as GCC, is widely used as an industrial mineral. Three primary attributes - particle size, colour and chemical purity define the quality of the GCC and define the suitability of use for any given application.

Limestone, which is primarily Calcium Carbonate, is a sedimentary rock made from the minerals calcite or aragonite.  A large portion of limestone is made from the skeletal remains of sea creatures and organisms.  Ground Calcium Carbonate (GCC) differs from Precipitated Calcium Carbonate (PCC) in that the GCC is formed directly from grinding limestone rock into a powder, while PCC is chemically produced and precipitated out as powder.

Pure calcium carbonate is a relatively soft mineral/compound, with a Mohs hardness of 2.5 – 3.0.  However, mined limestone may have a minor portion of abrasive impurities such as quartz / sand.

One of the standard methods of milling Limestone/Calcium Carbonate is with the Air Classifying Mill (ACM).  The ACM has a rotating rotor disc with hammers which rotates with speeds up to 23,000 feet per minute.  The particle size is controlled by the internal air classifier, to provide sharp particle size distributions.  Various classifier designs are available, to produce from coarse (100 mesh) product down to a fineness of 635 mesh (20 µm) product or a D50 of less than 5 µm.  Abrasion resistant options are available, including tungsten carbide tipping, Ni-Hard or Ceramic liners to assist with abrasive impurities and to assist with long life of mill components.  Hot air can also be used to dry the product while milling.

An alternate to the ACM for coarser grade Calcium Carbonate is the Pulveriser Hammer & Screen Mill.  The Pulveriser uses swing-hammers with interchangeable screen liners to produce a variety of products from 50 mesh to 150 mesh products.  The Pulveriser Hammer & Screen Mill needs less air (less ancillary equipment) than the ACM and is a lower cost options for the coarser grind Calcium Carbonate products.

For ultra-fine (D50 < 5 µm) milling, the Hosokawa Alpine Super Orion Ball Mill and Air Classifier are the best option.  These units come in a variety of sizes to meet your application needs.

Ground Calcium Carbonate (GCC) as well as Precipitated Calcium Carbonate Market size was valued at USD 19.89 Billion in 2020 and is projected to reach USD 34.14 Billion by 2028, growing at a CAGR of 6.02% from 2021 to 2028.

It is intended to prepare a Feasibility Report to install a Ground Calcium Carbonate (GCC) production facility with an installed capacity of 36000 Tons / Year as a Green Field Project.

COST ESTIMATION

Plant Capacity                                   120 Tons/Day

Land & Building (6080 sq.mt.)  Rs. 3.83 Cr

Plant & Machinery                             Rs. 3.10 Cr

Working Capital for 3 Months    Rs. 6.62 Cr

Total Capital Investment                    Rs. 13.90 Cr

Rate of Return                                      35%

Break Even Point                                 52%

• INTRODUCTION 
• USES/APPLICATIONS/ADVANTAGES
• TYPICAL SPECIFICATION
• ASTM TESTING METHODS
• MARKET OVERVIEW
• RAW MATERIALS
• PROCESS STEPS - GROUND CALCIUM CARBONATE PRODUCTION
• UTILITY REQUIREMENT (ESTIMATED)
• PLANT & MACHINERY USED FOR THE PROCESS
• PLANT& MACHINERY SUPPLIER/TURNKEY CONSULTANTS
• WASTE GENERATION & MANAGEMENT/GREEN BELT
• HEALTH SAFETY AND ENVIRONMENT
• ANTICIPATED ENVIRONMENTAL IMPACTS
• MITIGATION MEASURES (PROPOSED)
• SAFETY & ENVIRONMENT MANAGEMENT PLAN
• SAFETY & OCCUPATIONAL MEASURE
• PROPOSED IMPLEMENTATION SCHEDULE
• PROJECT FINANCIALS

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)