Detailed Project Report on Graphite Mining and Beneficiation Plant

GRAPHITE MINING AND BENEFICIATION PLANT

[EIRI/EDPR/0962] J: 9664,9665(US$)

INTRODUCTION

The mineral graphite is one of the allotropes of carbon. It was named by Abraham Gottlob Werner in 1789 from the Ancient Greek γράφω (graphō), "to draw/write”, for its use in pencils, where it is commonly called lead (not to be confused with the metallic element lead). Unlike diamond (another carbon allotrope), graphite is an electrical conductor, a semimetal. It is, consequently, useful in such applications as arc lamp electrodes. Graphite is the most stable form of carbon under standard conditions. Therefore, it is used in thermo chemistry as the standard state for defining the heat of formation of carbon compounds. Graphite may be considered the highest grade of coal, just above anthracite and alternatively called meta-anthracite, although it is not normally used as fuel because it is difficult to ignite.

There are three principal types of natural graphite, each occurring in different types of ore deposit:

1. Crystalline flake graphite (or flake graphite for short) occurs as isolated, flat, plate-like particles with hexagonal edges if unbroken and when broken the edges can be irregular or angular;

2. Amorphous graphite occurs as fine particles and is the result of thermal metamorphism of coal, the last stage of coalification, and is sometimes called meta-anthracite. Very fine flake graphite is sometimes called amorphous in the trade;

3. Lump graphite (also called vein graphite) occurs in fissure veins or fractures and appears as massive platy intergrowths of fibrous or acicular crystalline aggregates, and is probably hydrothermal in origin.

Highly ordered pyrolytic graphite or highly oriented pyrolytic graphite (HOPG) refers to graphite with an angular spread between the graphite sheets of less than 1°. This highest-quality synthetic form is used in scientific research. The name "graphite fiber" is also sometimes used to refer to carbon fiber or carbon fiber-reinforced polymer.

COST ESTIMATION

Plant Capacity            12 MT/Day

Land & Building (5 Acres)    Rs. 95.90 Lac

Plant & Machinery                    Rs. 2.74 Cr

Working Capital for 3 Months    Rs. 81.37 Cr

Total Capital Investment          Rs. 4.77 Cr

Rate of Return                          76%

Break Even Point                      30%

CONTENTS

INTRODUCTION

GRAPHITE OUTPUT IN 2005

GRAPHITE'S UNIT CELL

BALL-AND-STICK MODEL OF GRAPHITE (2 GRAPHENE LAYERS)

SIDE VIEW OF LAYER STACKING

PLANE VIEW OF LAYER STACKING

PROPERTIES

HISTORY

OTHER NAMES

USES OF NATURAL GRAPHITE

REFRACTORIES

STEELMAKING

EXPANDED GRAPHITE

INTERCALATED GRAPHITE

STRUCTURE OF CAC6

BRAKE LININGS

FOUNDRY FACINGS AND LUBRICANTS

OTHER USES

USES OF SYNTHETIC GRAPHITE

ELECTRODES

POWDER AND SCRAP

NEUTRON MODERATOR

OTHER USES

GRAPHITE MINING, BENEFICIATION, AND MILLING

GRAPHITE RECYCLING

FLOW CHART OF MAIN MANUFACTURING TECHNIQUES

I. TECHNOLOGICAL FLOW CHART OF GRAPHITE POWDER

II. TECHNOLOGICAL FLOW CHART OF GRAPHITE NODULE

TECHNOLOGICAL FLOW CHART OF MAIN PRODUCTS

3. TECHNOLOGICAL FLOW CHART OF GRAPHITE GRANULE

4. TECHNOLOGICAL FLOW CHART OF GRAPHITE SCRAP

CRYSTALLINE GRAPHITE

SPECIFICATIONS:

CHEMICAL PROPERTIES:

APPLICATIONS:

TECHNICAL SPECIFICATION DATA:

TECHNICAL SPECIFICATION DATA:

TECHNICAL SPECIFICATION DATA:

"INDIAN GRAPHITE POWDER MANUFACTURERS"

GRAPHITE PRODUCTION BY COUNTRY (METRIC TONS)

DIFFERENT PROCESS USED COMMERCIALLY

BENEFICIATION OF FLAKE GRAPHITE

THE DRAWINGS

DESCRIPTIONS

EXAMPLE 1

EXAMPLES 2 AND 3

EXAMPLE 4

EXAMPLE 5

EXAMPLE 6

PROCESS FOR GROWING GRAPHITE FIBERS

METHODS

THE DRAWING

DESCRIPTIONS

APPARATUS FOR PRODUCING THIN FLAKES

THE DRAWINGS

DESCRIPTIONS

PROCESS FOR GRINDING GRAPHITE

DESCRIPTIONS

EXAMPLE

RUN 1 (NO GRAPHITE GRINDING AID)

RUN 2 (WITH GRINDING GRAPHITE AID)

METHOD AND APPARATUS FOR PROVIDING FINELY DIVIDED POWDER

DRAWINGS

PROCESS FOR PURIFYING GRAPHITE

DESCRIPTIONS

EXAMPLE I

EXAMPLE II

METHOD FOR MANUFACTURING HIGH PURITY GRAPHITE MATERIAL

METHODS

THE DRAWING

DESCRIPTIONS

METHOD OF MANUFACTURING FLEXIBLE GRAPHITE

PRIOR ART

METHODS

THE DRAWING

DESCRIPTIONS

EXAMPLES

BENEFICIATION OF KISH GRAPHITE

METHODS

THE DRAWINGS

DESCRIPTIONS

EXAMPLES 1 TO 4

EXAMPLES 5 AND 6

EXAMPLE 7

GRAPHITE MANUFACTURING PROCESS

THE PROCESS OF GRAPHITE MANUFACTURING CONSISTS OF THE FOLLOWING PRINCIPAL STAGES:

POWDER PREPARATION

THE POWDER PREPARATION PROCESS IS PRESENTED IN THE SCHEME BELOW.

SHAPE FORMING

COLD ISOSTATIC PRESSING

EXTRUSION

DIE MOLDING

THE SCHEME OF THE DIE MOLDING METHOD IS PRESENTED IN THE PICTURE:

THE DIE MOLDING PROCESS CONSISTS OF THE FOLLOWING STAGES:

BAKING

GRAPHITIZATION

PYROLYTIC GRAPHITE

METHODS OF BENEFICATION

MEDIUM PURITY GRAPHITE CAN BE OBTAINED FROM RUN OF MINE GRAPHITE ORE IN THE FOLLOWING MANNER.

EXAMPLE II

A HIGH PURITY GRAPHITE CAN BE OBTAINED IN THE FOLLOWING MANNER.

MINING MACHINERY EQUIPMENT & ITS SPECIFICATIONS

WORKING PRINCIPLE:

TECHNICAL DATA:

GRINDING PLANT » RAYMOND MILL

STRUCTURE OF RAYMOND MILL:

WORKING PRINCIPLE:

TECHNICAL DATA:

FEEDING & CONVEYING » BELT CONVEYER

TECHNICAL DATA:

JAW CRUSHER

WORKING PRINCIPLE OF JAW CRUSHER:

CHARACTERISTICS OF JAW CRUSHER:

TECHNICAL DATA:

OPERATING PRINCIPLE OF HAMMER CRUSHER:

TECHNICAL DATA:

GRAPHITE DRYING MACHINE

TAIDA BRAND GRAPHITE DRYING MACHINE FEATURES:

GRAPHITE DRYING MACHINE USAGE:

GRAPHITE DRYING MACHINE CONSISTED:

SPECIFICATIONS OF GRAPHITE DRYING MACHINE:

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)