Detailed Project Report on Silica Ramming Mass

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SILICA RAMMING MASS

[EIRI/EDPR/1084] J.C.: 9728

INTRODUCTION

Acidic Ramming Mass, also known as Silica Ramming Mass or Mix, is used in Coreless Induction Furnaces, for melting of scrap. It is a dry lining refractory that can be used for all types of iron and steel and in both mini steel plants as well as foundries.

High performance Silica Ramming Mixes (also known as Acidic Ramming Mass in generic terms), designed to minimize erosion in induction melting. We are the first company in India to have a three-stage beneficiation, purification process plant and mixing plant. The highly controlled Silica and a particle size distribution has been kept at an optimum level, according to the furnace capacity and make, gives a high density, trouble free and consistent linings. We are the only company to have separate grade for different furnaces.

Application

It is widely used in the low cost melting of ductile and malleable iron, Stainless Steel, Mild Steels, Low Alloy Steels, all types of iron foundry operations, ranging from periodic melting to continuous holding applications. In addition to being suitable for many iron alloys, such as Ni-hard, Ni-resist and chrome irons, it may also be used for selected high temperature nonferrous applications and is suitable for coreless induction furnace of all sizes and types.

It can be installed employing any one of the several techniques utilizing vibrators, mechanical impacting tools or hand ramming.

Chemistry

Reactivity of the metal, sintering characteristics, reactivity temperature and strength of the lining has been kept in mind while formulating the Chemical composition. During service these grains transform to Tridymite and Cristobalite with a very large increase in volume. This places the partially constructed lining under high compression, forcing the particles very tightly together and making refractory lining: The low to high temperature modifications of Quartz, Tridymite and Cristobalite take place rapidly. Above 16500C, the volume of all forms of Silica remains relatively constant. This is why linings show outstanding resistance to thermal spalling and cracking above this temperature.

COST ESTIMATION

Plant Capacity 9 TON/Day

Land & Building (2000 sq.mt.) Rs. 1.79 Cr

Plant & Machinery Rs. 56.10 Lac

Working Capital for 3 Months Rs. 2.25 Cr

Total Capital Investment Rs. 4.85 Cr

Rate of Return 75%

Break Even Point 30%

CONTENTS

INTRODUCTION

APPLICATION

CHEMISTRY

PROPERTIES

PROPERTIES OF SILICA RAMMING MASS

GRADES OF SILICA RAMMING MASS

HAZARDS

CONTAINER

SILICA

USES OF THE SILICA RAMMING MASS

MARKET SURVEY

REFRACTORY INDUSTRY

INTRODUCTION:

SILICA BRICKS/SHAPES:

BASIC BRICKS/SHAPES:

MONOLITHICS:

SPECIAL PRODUCTS:

FUTURE OUTLOOK:

MANUFACTURERS OF SILICA RAMMING MASS

SILICA RAMMING MASS

RAMMING MASS

TYPES OF RAMMING MASS

MANUFACTURING PROCESS

SINGLE -MASS VIBRATING SYSTEM EXCITED BY PENDULUM UNBALANCED

MOTOR

SINGLE-MASS VIBRATING SYSTEM EXCITED BY TWO UNBALANCED

MOTORS

THE TECHNICAL DATA OF THIS SYSTEM INCLUDE:

THROW AND TRANSPORT SPEED OF A PARTICLE

RAMMING COMPOSITIONS

EXAMPLE I

A RAMMING COMPOSITION WAS PREPARED BY MIXING THE FOLLOWING COMPONENTS TOGETHER IN THE STATED WEIGHT PERCENTAGES:

EXAMPLE II

A RAMMING COMPOSITION WAS PREPARED BY MIXING THE FOLLOWING

COMPONENTS TOGETHER IN STATED WEIGHT PERCENTAGES:

REFRACTORY CASTING, RAMMING OR STAMPING MASS

EXAMPLE 1

EXAMPLE 2

EXAMPLE 3

REFRACTORY MASS AND MIXTURE FOR FORMING A REFRACTORY MASS

THE PRESENT METHOD WILL NOW BE ILLUSTRATED IN MORE DETAIL WITH THE AID OF THE EXAMPLES WHICH FOLLOW

EXAMPLE 1

EXAMPLE 2

EXAMPLE 3

EXAMPLE 4

REFRACTORY RAMMING MIX

EXAMPLE

CERAMIC MASS FOR BRICK MAKING AND WAY OF PRODUCTION

INDUSTRIAL APPLICABILITY

PROCESS FLOW DIAGRAM

SILICA RAMMING MASS

USEFUL FOR MELTING:

METHOD OF INSTALLATION:

SUPPLIERS OF PLANT AND MACHINERY

WET GRINDERS

JAW CRUSHER

STONE CRUSHER

PULVERIZERS

SCREENING MACHINERY

CONVEYOR BELT

FURNACE, INDUSTRIAL OVENS & ALLIED EQUIPMENTS

VIBRATING MACHINES

ELEVATORS, ESCALATORS, ROPEWAYS & RELATED PRODUCTS

SUPPLIERS OF RAW MATERIALS

CALCIUM OXIDE

ACTIVATED ALUMINA

SUPPLIERS OF SILICA RAMMING MACHINERY

RAMMING MASS MIXER 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)

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