Detailed Project Report on precipitated lime stone (precipitated calcium carbonate)
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PRECIPITATED LIME STONE (PRECIPITATED CALCIUM CARBONATE) [3579]
The commercial grade of calcium carbonate in manufactured in two forms. * Precipitated Calcium Carbonate, * Activated Calcium Carbonate. These two forms of calcium carbonate differ in respect of coating which the former does not have and later has. Both the forms of calcium carbonate are being used in various industries as filler or extender, thus assumes crucial importance in chemical and allied industries. PVC Rubber, denitrifice, cigarette paper, printing ink, pharmaceutical are some of the calcium carbonate using industries. In this offer we have considered the product mix of Precipitated Grade which could cover very wide range of grades in terms of Particle Size, Shape and Distribution. It will be possible to vary any of the three physical properties alongwith other physical properties, such as Bulk Density, Flow Point, Viscosity, as required by individual customers as per their need. We have also considered 40 Tons per day capacity Activated Calcium Carbonate with different coating arrangement as well as sophisticated Pressure Filtration and Drying System to ensure the quality product. High Grade Lime stone containing more than 90% CaO is calcined in a lime kiln fired by coal to obtain burnt lime (CaO). For manufacture of Precipitated Calcium Carbonate, the burnt lime is converted into a thin slurry containing 15-20% of calcium hydroxide by adding required quantity of water and stirring in a mixing tank. The solution is passed through a cyclone separator for removing impurities like sand. The clean slurry is transferred into a carbonating tower. The flue gases from the lime kiln containing 20-30% carbon-dioxide are collected and scrubbed with water in a scrubbing tower to remove dust and other impurities. The clean gas in compressed with the help of compressor and bubbled through the lime slurry solution in the carbonating tower. The calcium hydroxide in the solution reacts with carbon di oxide in the gas to form calcium carbonates. The contents of the carbonator are kept under circulation with the help of a pump to prevent settlement of the product. After completing the carbonation, the slurry is passed through a vacuum rotary filter to obtain precipitated calcium carbonate in the form of wet cake containing 40-50% moisture. The filtered water is collected and recycled for making lime slurry. The wet cake of calcium carbonate is dried in a tray drier and pulverized to the required mesh in a micro pulverized. The product after testing is packed in polythene bags of 50% kgs. Each for marketing. Calcium Compounds. Calcium compounds such as calcium carbonate, calcium phosphate and calcium sulphate are widely distributed in nature. A large number of them are manufactured on account of there applications in industry. Calcium oxide and sulphate are extensively employed in building and chemical industries Calcium phosphate, nitrate are useful as fertilizers Calcium carbide forms the source of acetylene which is an important starting material for the synthesis of many organic chemicals. A large number of calcium organic compounds find use in pharmacy. Calcium carbonate, CaCO3 forms a major constituent of the earths crust and occurs as massive beds of limestone, chalk and marble. It is found as dolomite in which a part of the calcium is replaced by magnesium. The term precipitated Calcium Carbonate applies to the commercial type of compound obtained by chemical means and distinguishes it from the material produced by mechanical treatment of natural varieties of Calcium carbonate such as calcite, marble, limestone and sea shells. Precipitated calcium carbonate is produced in a number of different grades which range in particle size from 9.03 to 15 micron I.P. grade precipitated calcium carbonate is used indentificers, foods, cosmetics, pharmaccuticals, and antibiotics. Technical grades are used as in ingredients in the manufacture of ceramics, putty, polishes, insecticides, inks, shoe dressings and as a filler in the production of adhesives, matches, linoleum and welding rods. Precipitated Calcium Carbonate is manufactured by passing carbon dioxide gas through a slurry of Calcium hydroxide milk of lime suspension. Calcium carbonate has the basic starting route as under follows. Limestone -> Qucik Lime -> Hydrated -> Lime -> Precipitated calcium Carbonate -> Activated Calcium Carbonate. The proposed unit is based on the production of precipitated Calcium Carbonate using the lime slurry (10% Calcium hydroxide solution and carbondixoide from the CO2 plant.
COST ESTIMATION
Plant Capacity 200 MT/Day
Land & Building (4 Acre) Rs. 6.35 Cr
Plant & Machinery Rs. 30 Cr
Working Capital for 2 Months Rs. 7.07 Cr
Total Capital Investment Rs. 43.92 Cr
Rate of Return 32%
Break Even Point 51%
INTRODUCTION
PROCESS 10
CALCIUM COMPOUNDS
CALCIUM CARBONATE
PRECIPITATED CALCIUM CARBONATE
USES AND APPLICATIONS
PLASTICS
PAINTS AND SURFACE COATINGS
COSMETICS/TOOTH PASTE
PAPER
FOOD AND PHARMACEUTICALS
PUTTY, CAULKS AND SEALANTS
SPECIFICATIONS OF CALCIUM CARBONATE
RUBBER INDUSTRY
DESCRIPTION
COSMETIC INDUSTRY
REQUIREMENTS
EXPLOSIVE AND PYROTECHNIC INDUSTRY
TYPES
REQUIREMENTS FOR CALCIUM CARBONATE – PRECIPITATED
& ACTIVATED FOR PAINTS
TERMINOLOGY
REQUIREMENTS
TABLE REQUIREMENTS FOR CALCRJM CARBONATE, PRECIPITATED
AND ACTIVATED, FOR PAINTS
PACKING AND MARKING
PROPERTIES
PROPERTIES OF PURE CALCIUM CARBONATE:-
PROPERTIES OF CALCITE:-
PROPERTIES OF ARAGONITE:-
PROPERTIES OF LIMES AND LIME STONE:-
COLOUR :-
ODOR:-
TEXTURE:-
BIS SPECIFICATION
SCOPE
REQUIREMENTS
PACKING AND MARKING
TABLE 1 REQUIREMENT FOR PRECIPITATED CALCIUM CAREONATE FOR COSMETIC INDUSTRY
SAMPLING
QUALITY OF REAGENTS
DETERMINATION OF FINENESS
APPARATUS
DETERMINATION OF LOSS ON DRYING:-
DETERMINATION OF BULK DENSITY:-
DETERMINATION OF CALCIUM CARBONATE
TEST FOR MAGNESIUM AND ALKALI SALTS
DETERMINATION FO ALUMINIUM IRON PHOSPHATES AND MATTER
INSOLUBLE IN HYDROCHLORIC ACID
TEST FOR IRON:-
TEST FOR ARSENIC:-
TEST FOR HEAVY METALS:-
TEST FOR CHLORIDES:-
DETERMINATION OF PH OF AQUEOUS SUSPENSION
TEST FOR BARIUM:-
DETERMINATION OF FLOW POINT
SAMPLING OF CALCIUM CARBONATE, PRECIPITATED FOR COSMETIC
INDUSTRY
GENERAL REQUIREMENTS OF SAMPLING
SCALE OF SAMPLING
TEST SAMPLES AND REFEREE SAMPLE
PREPARATION OF TEST SAMPLES
CRITERION FOR CONFORMITY
PACKING AND MARKING
METHODS OF TEST FOR PRECIPITATED AND ACTIVATED
CALCIUM CARBONATE FOR PAINTS
DETERMINATION OF PARTICLE SIZE DISTRIBUTION
DETERMINATION OF LOSS ON IGNITION
DETERMINATION OF INSOLUBLE SILICEOUS MATTER
DETERMINATION OF CALCIUM CARBONATE
DETERMINATION OF TOTLA FATTY MATTER
MARKET SURVEY
INSTALLED CAPACITY AND PRODUCTION OF CALCIUM CARBONATE
EXPORT OF CALCIUM CARBONATE
CONSUMPTION PATTERN OF CALCIUM CARBONATE
IMPORT OF CALCIUM CARBONATE
INSTALLED CAPACITY, PRODUCTION & CAPUTILIZATION OF CALCIUM
CARBONATE
APPARENT CONSUMPTION OF CALCIUM CARBONATE
ESTIMATED DEMAND
GROWTH RATE IN ANNUAL DEMAND OF PRECIPITATED CALCIUM CARBONATE
GLOBAL CONSUMPTION PATTERN OF PRECIPITATED LIME STONE
SWOT ANALYSIS OF PRECIPITATED CALCIUM CARBONATE
MANUFACTURERS/SUPPLIERS
RAW MATERIALS
LIMESTONE:-
TECHNOLOGY DEVELOPMENT
IN PRECIPITATED CALCIUM CARBONATE
TECHNOLOGY DEVELOPMENTS
ACID TOLERANT TECHNOLOGY
CHEMISTRY OF THE PROCESS
MANUFACTURING PROCESS OF PRECIPITATED LIME STONE
PROCESS FLOW DIAGRAM
STEPS IN PRECIPITATED CALCIUM CARBONATE MANUFACTURE
PROCESS IN DETAILS
CALCINATION OF LIMESTONE TO PRODUCE QUICKLIME AND CHEMICAL LIME
HYDRATION OF QUICK LIME (MANUFACTURE OF HYDRATED LIME)
CARBONATION OF LIME SLURRY WITH CARBON DIOXIDE GAS
FILTERATION AND DRYING
MANUFACTURE OF ACTIVATED CALCIUM CARBONATE
CO2 GAS PURIFICATION
PROCESS FLOW SHEET OF PRECIPITATED CACO3
SYNTHETIC METHOD FOR PRECIPITATED
CALCIUM CARBONATE
TECHNICAL SPECIFICATION OF PRECIPITATED
CALCIUM CARBONATE
TECHNICAL DATA SHEET
MATERIAL SAFETY DATA SHEET FOR CALCIUM CARBONATE
(PRECIPITATED) FOR FOOD APPLICATION
STANDARD SPECIFICATIONS
TYPICAL BULK DENSITY
TRANSPORT AND STORAGE CONDITIONS
SAFETY DATA
PLANT LAYOUT
SUPPLIERS OF PLANT & MACHINERIES
ROTARY KILNS
JAW CRUSHER
BUCKET ELEVATOR
ROTARY DRYER MANUFACTURERS & EXPORTERS
PULVERIZERS
CENTRIFUGE
HEAT EXCHANGER
EFFLUENT TREATMENT PLANT (ETP PLANT)
BOILERS
MATERIAL HANDLING EQUIPMENTS
LABORATORY EQUIPMENTS
SUPPLIERS OF RAW MATERIALS
PACKAGING MATERIALS (HDPE WOVEN LAMINATED BAGS)
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)
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