Precipitated Calcium Carbonate (Production Capacity – 50 TPD)

PRECIPITATED CALCIUM CARBONATE (PRODUCTION CAPACITY – 50 TPD)

[EIRI/EDPR/4521] J.C.: 2738US$

Precipitated calcium carbonate (PCC) is an innovative product derived from lime, which has many industrial applications.  PCC is made by hydrating high-calcium quicklime and then reacting the resulting slurry, or “milk-of-lime”, with carbon dioxide.  The resulting product is extremely white and typically has a uniform narrow particle size distribution.  PCC is available in numerous crystal morphologies and sizes, which can be tailored to optimize performance in a specific application.

Precipitated calcium carbonate (PCC) is used in applications where, for example, higher brightness or a narrow particle size distribution is required.

PCC, Precipitated Calcium Carbonate, is also known as purified, refined or synthetic calcium carbonate. It has the same chemical formula as other types of calcium carbonate, such as limestone, marble and chalk: CaCO3. The calcium, carbon and oxygen atoms can arrange themselves in three different ways, to form three different calcium carbonate minerals. Calcium carbonates, including PCC, are considered to be non-toxic. As long as the PCC meets certain purity requirements, it can be used as a direct food additive, as a pharmaceutical or as an indirect additive in paper products that come in contact with food. Similar acceptances and approvals exist around the world where PCCs are widely used in these applications. 

Precipitated calcium carbonate (PCC) is filler used in many applications, like papers, plastics, rubbers, paints, drugs and so on. Its high purity, well-ordered particle size and morphology makes it the white filler of choice.1 In paint production, PCC has established itself as a primary extender due to its unique properties such as its low basic colour, high weather resistance, relative abrasiveness, low electrolyte content, non-toxicity and the pH stabilizing effect. Different kinds of crystal are suitable for a particular application and only the right PCC can boost the quality of the end products. Precipitated calcium carbonate (PCC) produced with a prismatic and rhombohedral-shape has maximum light dispersion at 0.4 to 0.5 µm sized particles. 

PCC is generally made from a high purity calcium carbonate rock called limestone. This limestone deposit is the result of a very thick layer of prehistoric sea animal shells and skeletons being laid down on the ocean floor. These shells and skeletons were largely composed of calcium carbonate. Over a period of five hundred million years this deposit was under high temperature and high pressure, and the deposit changed to a coarsely crystallized limestone. All of the organic matter that was in the deposit was removed by oxidation, a process called diagenesis.

The advantage of PCC lies in the prospect of tailor making the products with definite particle morphology, particle size and distribution as well as specific surface area. PCC is a refined natural form of limestone using techniques. The purity can be increased to 99.9 % or 99.999 %, and grain size can be controlled in a range from submicron to more than 10 micron.

COST ESTIMATION

Plant Capacity            50 MT/Day  

Land & Building (5260 sq.mt.)    US$ 7.20 Lac    

Plant & Machinery                    US$ 6.12 Lac 

Working Capital for 1 Month    US$ 2.28 Lac 

Total Capital Investment          US$ 16.34 Lac 

Rate of Return                          27%

Break Even Point                      63%

CONTENTS

INTRODUCTION

USES/APPLICATIONS/ADVANTAGES

TYPICAL SPECIFICATION

ASTM TESTING METHODS

MARKET OVERVIEW

RAW MATERIALS

FORMULATION

CHEMISTRY OF FORMULATION PROCESS

PROCESS STEPS-PRECIPITATED CALCIUM CARBONATE PRODUCTION

CRITICAL PROCESS CONDITION/REQUIREMENTS

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)