Detailed Project Report on gypsum board and gypsum powder

GYPSUM BOARD AND GYPSUM POWDER [3566]

Gypsum has been known for centuries and is one of the oldest building materials in the world. For centuries now, gypsum has played a crucial role in construction. Today, all over the world’ principal interior wall material is gypsum wallboard. Often also referred to as drywall, rock, plasterboard, gyp-board, or by the trade names Sheetrock or Gyp-roc, gypsum drywall is a sheet of gypsum with a paper facing and backing with following composition: • The wallboard is approximately 92% gypsum (calcium sulfate dehydrate CaSO4 2H2O). • 7% paper, and 1% impurities and additives. Gypsum is found in every continent of the world and is one of the most widely used minerals. The chemistry of Gypsum board: Pure gypsum is a white to transparent mineral, but sometimes impurities color it grey, brown, or pink. Its chemical name is calcium sulphate dihydrate, and its chemical formula is CaSO4•2H2O.  When gypsum is heated, it loses about three quarters of its water and becomes hemihydrate gypsum (CaSO4•½H2O), which is soft and can be easily ground to a powder called hemihydrate gypsum plaster or Plaster of Paris. If this powder is then mixed with water to form a paste or slurry, then it will dry and set rock hard. The chemically combined water, previously driven off by heating, will recombine, and the material will revert to the original chemical composition of gypsum.  While the hemihydrate gypsum plaster is in slurry form, it can be poured between two paper layers to make wallboard, used to fill cracks and crevices, or poured into a mold. Plaster of Paris is a building material. Plaster of Paris is raw gypsum that is chemically altered by heat to remove much of the water contained in the gypsum molecule and then hydrated to make it useable as a plastering material. It remains a viable product to this day. Gypsum board is the technical product name used by manufacturers to define a specific gypsum-core board material that is typically installed on the walls and ceilings of the interior or exterior of a residential or non-residential structure. The product is defined by the ASTM C11 standard as “the generic name for a family of sheet products consisting of a noncombustible core primarily of gypsum with paper surfacing.” Drywall and plasterboard are non-technical synonyms for gypsum board. Gypsum board manufacturing companies also manufacture gypsum sheets products that do not have a paper facing. These products are called gypsum panel products and are defined  by  the  ASTM  C11  standard  as  “a  family  of  sheet  products  consisting essentially  of  gypsum.”  Glass  mat-faced  panels  and  panels  manufactured  without  a facing  that  have  a  gypsum  core  are  examples  of  gypsum  panel  products.  The commonality between the board and the panel definitions is the gypsum core. The core often contains additives, but to be considered a gypsum board or panel, and be regarded as drywall, the core must be predominantly gypsum.
 
COST ESTIMATION

Plant Capacity                           360 MT/Day  
Land & Building (4 Acres)         Rs. 17 Lacs
Plant & Machinery                    Rs. 35 Lacs
Working Capital for 2 Months   Rs. 7 Lacs
Total Capital Investment          Rs. 64 Lacs
Rate of Return                         23%
Break Even Point                     76%




PROJECT AT A GLANCE    
INTRODUCTION    
THE CHEMISTRY OF GYPSUM BOARD    
DEFINITION AND CATEGORIES OF GYPSUM BOARD    
PRODUCT RANGE    
DETAILS OF GYPSUM BOARD    
EDGE AND END PROFILES    
REQUIREMENTS    
TOLERANCE    
TRANSVERSE STRENGTH    
WATER ABSORPTION    
TESTS    
MEASUREMENT OF TAPER PROFILE    
TAPER WIDTH    
TAPER DEPTH    
SAMPLING AND CRITERIA FOR CONFORMITY    
SALE OF SAMPLING    
FINISH    
PACKING AND MARKING    
ADVANTAGE AND APPLICATION    
ADVANTAGES OF GYPSUM BOARD    
AREAS OF APPLICATIONS    
GYPSUM BOARD FOR ACOUSTIC APPLICATIONS    
GYPSUM BOARD FOR CEILING APPLICATION    
CONFIGURATION OF GYPSUM BOARD    
TYPICAL PROCESS OF MANUFACTURING GYPSUM BOARD    
1. RAW MATERIALS    
2. CRUSHER    
3. GRINDING MILL    
4. CALCINE SYSTEM    
5. STUCCO HOLDING TANK    
6. MIXER    
7. FORMING STATION    
8. BOARD LINE    
9. CUT-OFF KNIFE    
10. TRANSFER TABLE    
11. KILN    
12. BUNDLER AND STACKER    
PROCESSING CHART    
DOSING SECTION    
FORMING SECTION    
CUTTING AND DRYING SECTION    
EDGE TRIMMING AND STACKING SECTION    
GYPSUM BOARD PRODUCTION LINE PICTURES    
FORMING DEVICE    
RUBBER BELT CONVEYOR AND DRYING ROOM    
BLANK ROLLER CONVEYOR AND PRINTER    
TRANSFERRING CONVEYOR    
DISTRIBUTOR    
AIR BLOWER    
ELECTRICAL CABINET    
AVAILABILITY OF GYPSUM    
AVAILABILITY OF GYPSUM IN KILWA-TANZANIA    
ANNUAL REQUIREMENT OF RAW MATERIALS    
RECOMMENDED SOURCES OF RAW MATERIALS    
MARKET OVERVIEW OF GYPSUM BOARD AND POWDER    
GYPSUM BOARD – A PART REPLACEMENT TO WOOD    
CONSTRUCTION MATERIAL – BASED ON INDIGENOUS RAW MATERIALS    
GYPSUM BOARD – ENVIRONMENT FRIENDLY MATERIAL OF CONSTRUCTION    
WORLD MARKET SCENARIO    
MARKETS SCENARIO IN TANZANIA    
COMPETITIVE STRENGTH OF GYPSUM BOARD PRODUCED IN TANZANIA    
DEMAND FOR GYPSUM BOARDS IN TANZANIA & DEMAND SUPPLY GAP    
EXPORTS PROSPECTS    
FUTURE MARKET PROJECTIONS    
TARGET MARKET AND MARKETING STRATEGY    
BASIS    
GLOBAL MARKET OVERVIEW OF GYPSUM BOARD    
MANUFACTURERS OF GYPSUM BOARDS    
MANUFACTURING PROCESS OF GYPSUM BOARD    
TECHNOLOGY AND MANUFACTURING PROCESS    
TECHNOLOGIES EMPLOYED FOR PRODUCTION OF GYPSUM BOARD    
MANUFACTURING PROCESS    
PROCESS FLOWCHART FOR GYPSUM BOARD    
PLANT LOCATION & INFRASTRUCTURE  4
POTENTIAL LOCATIONS    
SELECTION OF SUITABLE LOCATIONS    
ENVIRONMENTAL ASPECT IN GYPSUM BOARD & POWDER MANUFACTURE    
ENVIRONMENTAL ASPECT OF MANUFACTURING PROCESS    
WASTE GENERATED AND MITIGATION MEASURES    
WASTE GENERATED DURING CONSTRUCTION PHASE    
RAW MATERIALS    
1.   ALBASTER    
2.   SELENITE    
3.   SATIN SPAR    
4.   ANHIDRITE    
5.   GYPSITE    
CHEMISTRY OF THE PROCESS & PHYSICAL PROPERTIES    
STEP 1 - PLASTER OF PARIS MANUFACTURE    
STEP 2 - REHYDRATION    
STEP 3 - SETTING    
ROLE OF THE LABORATORY    
ENVIRONMENTAL IMPLICATIONS    
DETAILS OF MANUFACTURING PROCESS FOR GYPSUM BOARD    
FOLLOWING ARE THE MAJOR STAGES IN PRODUCTION GYPSUM
   PLASTER BOARDS.    
1.   PREPARATION OF RAW MATERIALS    
2.   CALCINING OF GYPSUM    
3.   PREPARATION OF PASTE    
4.   MOULDING IN THE FORM OF BOARDS    
5.   DRYING OF BOARDS    
PROCESS FLOW SHEET    
DETAILS OF GYPSUM PROCESSING    
MANUFACTURE OF PLASTER OF PARIS    
DETAILS OF DRYWALL MANUFACTURE    
BLENDING OF ADDITIVES    
MAKING THE SANDWICH    
FINISHING THE EDGES    
CUTTING THE PANELS    
THE DRYING PROCESS    
THE FINISHED PRODUCT    
LIGHTWEIGHT GYPSUM BOARD    
CONTINUOUS PRODUCTION OF GYPSUM BOARD    
A. PRODUCTION OF FIBROUS STUCCO    101
SUPPLIERS OF RAW MATERIALS (INDIAN)    
GYPSUM    
FOAMING AGENT  
SUPPLIERS OF PLANT AND MACHINERIES (GLOBAL)    
COMPLETE PLANT SUPPLIERS ON TURNKEY BASIS    


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)