Detailed Project Report on High Alumina Refractory Brick Plant

HIGH ALUMINA REFRACTORY BRICK PLANT

[EIRI/EDPR/1465] J.C. 246

INTRODUCTION

Refractories are materials that provide linings for high-temperature furnaces and other processing units. Refractories must be able to withstand physical wear, high temperatures (above 538°C [1000°F]), and corrosion by chemical agents. There are two general classifications of refractories, clay and nonclay. The six-digit source classification code (SCC) for refractory manufacturing is 3-05-005. Clay refractories are produced from fireclay (hydrous silicates of aluminum) and alumina (57 to 87.5 percent). Other clay minerals used in the production ofrefractories include kaolin, bentonite, ball clay, and common clay. Nonclay refractories are produced from a composition of alumina (<87.5 percent), mullite, chromite, magnesite, silica, silicon carbide, zircon, and other nonclays.

Refractories, a key input for iron and steel making, assume ever increasing role due to high stress on production of high quality sophisticated steels, which alone accounts for the consumption of nearly 70% of total refractories produced.Refractories in general, are the non-metallic materials that are hard to melt at high temperature and having enough mechanical strength and heat resistance to withstand rapid temperature change, including repeated heating and cooling and resistance to molten slag and metals.

Refractories are material having melting points with properties that make them suitable to act as heat-resisting barriers between high and low temperature zones. The value of refractories is judged not merely by the cost of the material itself, but by the nature of job and/or its performance in a particular situation. Specifically, the performance of a refractory depends on its qualities and quantities in three phases- solid, glass/liquid, and pores- which govern the ultimate property of a refractory material.

COST ESTIMATION

Plant Capacity            20 MT/Day  

Land & Building (2 Acres)    Rs. 3.80 Cr    

Plant & Machinery                    Rs. 7.79 Cr 

Working Capital for 1 Month    Rs. 75.11 Lac 

Total Capital Investment          Rs. 13.69 Cr 

Rate of Return                          2%

Break Even Point                      96%

CONTENTS

INTRODUCTION

CLASSIFICATION OF REFRACTORIES

CHEMISTRY AND PHASE MINERALOGY

TYPES AND CHARACTERISTICS OF PRODUCT

RAW MATERIALS USED IN ALUMINA REFRACTORIES

TYPES AND CHARACTERISTICS OF RAW MATERIALS USED

APPLICATIONS

APPLICATIONS OF ALUMINA REFRACTORIES

MANUFACTURING PROCESS

MACHINERY DESCRIPTION WITH TECHNICAL DETAILS

PROCESS FLOW DIAGRAM

PHOTOGRAPHS

MACHINERY

MARKET POTENTIAL

MANUFACTURERS OF HIGH ALUMINA REFRACTORY BRICKS

EMISSIONS AND CONTROLS IN REFRACTORY MANUFACTURING

PLANT LAYOUT

SUPPLIERS OF RAW MATERIALS

COMPLETE MACHINERY EQUIPMENT MANUFACTURER

EQUIPMENTS DETAILS & COST

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)