This document provides information on calcium carbide, including its properties, manufacturing process, uses, packaging and international standards. Some key points:
- Calcium carbide is produced through heating limestone and coke to 2200-2500°C in an electric furnace. It reacts with water to produce acetylene gas.
- Its main uses are in producing acetylene for welding/cutting and calcium cyanamide as a fertilizer. It also acts as a dehydrating/reducing agent.
- The BIS specification outlines purity levels and gas yield requirements for different grades of calcium carbide. International standards also provide size classifications.
- Calcium carbide is packed in moisture
Electrometallurgy uses electrolysis to extract metals from their ores. Key points:
- Electrolysis uses electricity to reduce metal ions at the cathode. Common metals extracted this way include aluminum, magnesium, zinc, and copper.
- Electrowinning is the electrolytic extraction of metals from aqueous solutions produced via leaching. This is used for copper extraction through a series of tanks with alternating anodes and cathodes.
- Molten salt electrolysis can extract reactive metals like sodium and is advantageous due to operating at high temperatures in a non-aqueous medium.
Includes a discussion of Voltaic and electrolytic cells, the Nernst equation and the relationship between electrochemical processes, chemical equilibrium and free energy.
**More good stuff available at:
www.wsautter.com
and
http://www.youtube.com/results?search_query=wnsautter&aq=f
The document discusses extractive metallurgy processes for zinc extraction. It describes the major zinc ores and details several pyrometallurgical and hydrometallurgical extraction processes. The key processes are roasting to produce zinc oxide from zinc sulfide ores, followed by leaching and electrolysis to recover zinc. Approximately 80% of zinc is produced via hydrometallurgical routes like roast-leach-electrowinning.
The document outlines learning outcomes for a chapter on electrochemistry. It will describe investigations into classifying substances as conductors or non-conductors, distinguish between metallic and electrolytic conduction, define key terms like electrolysis, electrodes, and ions. It will also cover predicting reactions and products of electrolysis, calculating quantities produced using Faraday's constant, and discussing industrial applications of electrolysis.
This document provides an overview of electrochemistry. It discusses electron transfer reactions, oxidation and reduction, voltaic cells, cell potentials, and balancing redox reactions. Key points include:
- Electron transfer reactions are oxidation-reduction or redox reactions that result in the generation of an electric current.
- Oxidation is the loss of electrons and reduction is the gain of electrons. Reduction cannot occur without oxidation providing electrons.
- A voltaic cell uses the energy from a spontaneous redox reaction to generate an electric current by transferring electrons through an external circuit between the anode and cathode.
This document discusses corrosion and corrosion prevention. It provides definitions of corrosion and explains that corrosion is an electrochemical process that causes the deterioration of materials. Corrosion results in significant economic losses. The document then covers the principles of corrosion including thermodynamics, electrochemistry, metallurgy, and different forms of corrosion such as uniform corrosion, galvanic corrosion, pitting, stress corrosion cracking, and hydrogen embrittlement.
Intergranular corrosion occurs along grain boundaries and preferentially attacks the boundaries rather than the grain interiors. It is caused by compositional differences at grain boundaries that create galvanic cells. Sensitization can occur during heating when chromium carbides precipitate out at grain boundaries, leaving the adjacent metal depleted in chromium and more susceptible to corrosion. Two types of intergranular corrosion that can occur during welding are knife line attack, which affects a narrow band of metal near the weld fusion line, and weld decay, which develops farther from the weld in non-stabilized steels. Prevention methods include using stabilized grades of stainless steel and performing post-weld heat treatments.
Electrometallurgy uses electrolysis to extract metals from their ores. Key points:
- Electrolysis uses electricity to reduce metal ions at the cathode. Common metals extracted this way include aluminum, magnesium, zinc, and copper.
- Electrowinning is the electrolytic extraction of metals from aqueous solutions produced via leaching. This is used for copper extraction through a series of tanks with alternating anodes and cathodes.
- Molten salt electrolysis can extract reactive metals like sodium and is advantageous due to operating at high temperatures in a non-aqueous medium.
Includes a discussion of Voltaic and electrolytic cells, the Nernst equation and the relationship between electrochemical processes, chemical equilibrium and free energy.
**More good stuff available at:
www.wsautter.com
and
http://www.youtube.com/results?search_query=wnsautter&aq=f
The document discusses extractive metallurgy processes for zinc extraction. It describes the major zinc ores and details several pyrometallurgical and hydrometallurgical extraction processes. The key processes are roasting to produce zinc oxide from zinc sulfide ores, followed by leaching and electrolysis to recover zinc. Approximately 80% of zinc is produced via hydrometallurgical routes like roast-leach-electrowinning.
The document outlines learning outcomes for a chapter on electrochemistry. It will describe investigations into classifying substances as conductors or non-conductors, distinguish between metallic and electrolytic conduction, define key terms like electrolysis, electrodes, and ions. It will also cover predicting reactions and products of electrolysis, calculating quantities produced using Faraday's constant, and discussing industrial applications of electrolysis.
This document provides an overview of electrochemistry. It discusses electron transfer reactions, oxidation and reduction, voltaic cells, cell potentials, and balancing redox reactions. Key points include:
- Electron transfer reactions are oxidation-reduction or redox reactions that result in the generation of an electric current.
- Oxidation is the loss of electrons and reduction is the gain of electrons. Reduction cannot occur without oxidation providing electrons.
- A voltaic cell uses the energy from a spontaneous redox reaction to generate an electric current by transferring electrons through an external circuit between the anode and cathode.
This document discusses corrosion and corrosion prevention. It provides definitions of corrosion and explains that corrosion is an electrochemical process that causes the deterioration of materials. Corrosion results in significant economic losses. The document then covers the principles of corrosion including thermodynamics, electrochemistry, metallurgy, and different forms of corrosion such as uniform corrosion, galvanic corrosion, pitting, stress corrosion cracking, and hydrogen embrittlement.
Intergranular corrosion occurs along grain boundaries and preferentially attacks the boundaries rather than the grain interiors. It is caused by compositional differences at grain boundaries that create galvanic cells. Sensitization can occur during heating when chromium carbides precipitate out at grain boundaries, leaving the adjacent metal depleted in chromium and more susceptible to corrosion. Two types of intergranular corrosion that can occur during welding are knife line attack, which affects a narrow band of metal near the weld fusion line, and weld decay, which develops farther from the weld in non-stabilized steels. Prevention methods include using stabilized grades of stainless steel and performing post-weld heat treatments.
Necmettin Erbakan Üniversitesi
Mühendislik ve Mimarlık Fakültesi
Metalurji ve Malzeme Mühendisliği Bölümü
İleri Teknoloji Seramikler Dersi
Emre AVCI
Aralık 2020
Borürler, Titanyum Diborür, Lantanyum Hekzaborür
,borides ,borür ,titanyum diborür ,lantanyum hekzaborür ,titanium diboride ,tanhanum hexaboride ,titanyum diborür uygulamaları ,lantanyum hekzaborür kullanım alanları ,borürlerin üretimi ,titanyum diborür üretimi
This document provides an overview of phase diagrams and microstructure development in multicomponent materials systems. It defines key terms like component, phase, solubility limit, and microstructure. It also explains concepts such as equilibrium, metastable states, and lever rule for determining phase compositions and amounts. Different types of binary phase diagrams are discussed, including eutectic and isomorphous systems. The development of microstructure during equilibrium and non-equilibrium cooling of alloys is described for both eutectic and isomorphous systems.
1. The document describes the relationship between concentration and purification processes using solvent extraction in hydrometallurgy.
2. Solvent extraction is a well-established process that separates an impure aqueous stream into two streams, one containing most impurities and the other containing most valuable metal ions.
3. Examples of concentration and purification discussed include solvent extraction being used to produce pure copper electrolytes from impure leach solutions, and to recover uranium from acidic leach liquors while removing impurities like iron and thorium.
The document discusses the extraction of three important metals - iron, aluminum, and copper. It describes how these metals are commonly found as ores and the multi-step processes required to extract the pure metals. Iron is extracted from its ore, hematite, using a blast furnace. Aluminum is extracted via electrolysis of aluminum oxide in molten cryolite. Copper is extracted through concentration, roasting, smelting and refining processes including bessemerization to produce blister copper from chalcopyrite ore.
Crystal defects occur when the regular patterns of atoms in crystalline materials are interrupted. There are several types of crystal defects including point defects, line defects, and plane defects. Point defects are defects that occur at or around a single lattice point and include vacancies, interstitials, and substitutions. Vacancies occur when an atom is missing from its normal position in the crystal lattice. Interstitials occur when an atom occupies a position between normal lattice sites. Substitutions occur when a foreign atom replaces a host atom in the lattice. The presence of defects is necessary for crystals to have stability at any non-zero temperature due to the contribution of defects to entropy.
1) The document discusses the Gibbs paradox in thermodynamics, which involves an apparent contradiction between the mixing of identical gases versus non-identical gases.
2) Several approaches are described to resolve this paradox, including those proposed by Gibbs, von Neumann, and Lin Shu Kun. Lin's approach draws connections between entropy, information theory, and the degree of symmetry/similarity between particles.
3) The key point of resolution is that entropy increases continuously with the similarity or symmetry between particles, as similarity corresponds to greater information loss. This allows entropy to increase for both identical and non-identical gas mixing in accordance with the second law of thermodynamics.
Mass and heat balance for duplex stainless steel production by conarc processIJESFT
Mass balance and heat balance calculations are carried out for estimating inflow and outflow of materials and energy respectively in a process. Such calculations are required to get accurate composition of product with available raw materials. CONARC is a new electric steel making process using a twin shell electric arc furnace (EAF) which can handle raw materials input of solid steel scrap and hot metal in varying proportions.
In the present study an attempt has been made to develop a mathematical model for mass and heat balance for duplex stainless steel production by CONARC process. Case studies have been carried out by varying the amount of hot metal in the charge from 0% to 100%. Such variation shows proportionate increase in the amount of oxygen required, lime consumption and amount of slag formed along with the increase in chemical energy available for the process. However, electrical energy consumption reduces for SAF 2205 and 3RE60 duplex stainless steel production.
On the basis of the above case studies, it has been found that increased amount of hot metal increases the available chemical energy for the process and in turn it reduces the electrical energy requirement of CONARC process, ultimately leading to reduction in the power consumption and overall production cost.
Electrochemistry involves redox reactions in galvanic cells that convert chemical energy to electrical energy. In a galvanic cell, oxidation occurs at the anode and reduction occurs at the cathode. A salt bridge completes the circuit between the two half cells and maintains electrical neutrality. When a zinc rod is used as the anode in a copper sulfate solution with a copper cathode, the zinc rod loses weight as it oxidizes while copper precipitates and the solution warms due to heat released, demonstrating the spontaneous conversion of chemical to electrical energy in a galvanic cell.
This document discusses various forms of corrosion that can occur in metals. It begins by defining corrosion and explaining the factors that influence it. It then describes several specific types of corrosion: general/uniform corrosion, galvanic corrosion, crevice corrosion, pitting corrosion, intergranular corrosion, dealloying, erosion corrosion, stress corrosion, hydrogen damage including hydrogen blistering and hydrogen embrittlement. For each type of corrosion, the document discusses the mechanism and provides methods for prevention.
TRAINING FOR VACUUM DEGASSING AND SECONDARY METALLURGY BY CVS MAKINAmetudgn
This document provides an overview of a training on vacuum degassing (VD) technology. It will cover the theoretical background and operation of VD equipment. Topics include metallurgy processes like secondary metallurgy and vacuum metallurgy, VD and VOD treatment methods, stainless steel grades, and the impact of alloy additions and temperature changes. The training will also review safety, the VD plant layout, individual equipment components, and emergency procedures. Attendees will learn how to safely operate and maintain the VD system.
Oxidation is the loss of electrons, while reduction is the gain of electrons. The atom that loses electrons is the oxidizing agent, and the atom that gains electrons is the reducing agent. For example, in the reaction Mg + Cl2 → MgCl2, magnesium (Mg) is oxidized as it loses electrons and becomes Mg2+, while chlorine (Cl) is reduced as it gains electrons and becomes Cl-. Magnesium serves as the reducing agent and chlorine serves as the oxidizing agent.
I Hope You all like it very much. I wish it is beneficial for all of you and you can get enough knowledge from it. Clear and appropriate objectives, in terms of what the audience ought to feel, think, and do as a result of seeing the presentation. Objectives are realistic – and may be intermediate parts of a wider plan.
The document summarizes extraction and uses of magnesium. It describes common magnesium minerals like dolomite and magnesite. It discusses challenges in extracting magnesium through pyrometallurgical and electrometallurgical processes. The Pidgeon and Magnetotherm processes are described for pyrometallurgical extraction. The Dow process extracts magnesium from seawater through precipitation and electrolysis. Magnesium has non-structural uses like alloying, deoxidation, and cathodic protection. Structural uses include aircraft and transportation applications due to magnesium's high strength to weight ratio.
El documento describe el proceso hidrometalúrgico para extraer cobre de minerales. Este proceso involucra lixiviación, donde el cobre se disuelve de los minerales usando ácido sulfúrico, extracción por solventes para concentrar la solución de cobre, y electro-obtención donde el cobre se recupera electrolíticamente en forma de cátodos de alta pureza. El documento también explica cada una de estas etapas en más detalle.
Metallurgy is a domain of materials science and engineering that studies the physical and chemical behavior of metallic elements, their intermetallic compounds, and their mixtures, which are called alloys. Metallurgy is also the technology of metals: the way in which science is applied to the production of metals, and the engineering of metal components for use in products for consumers and manufacturers. The production of metals involves the processing of ores to extract the metal they contain, and the mixture of metals, sometimes with other elements, to produce alloys. Metallurgy is distinguished from the craft of metalworking, although metalworking relies on metallurgy, as medicine relies on medical science, for technical advancement.
Metallurgy is subdivided into ferrous metallurgy (sometimes also known as black metallurgy) and non-ferrous metallurgy or colored metallurgy. Ferrous metallurgy involves processes and alloys based on iron while non-ferrous metallurgy involves processes and alloys based on other metals. The production of ferrous metals accounts for 95 percent of world metal production.
The document discusses silicon feedstock for the solar industry. It covers the following key points in 3 sentences:
1) Most PV systems are built using crystalline silicon, which is the second most abundant element in the Earth's crust after oxygen. Metallurgical grade silicon is produced in large quantities but requires further refining for solar cell use.
2) Solar grade silicon is produced through chemical processes using trichlorosilane or silane gases, or through metallurgical upgrading of metallurgical grade silicon. The dominant production technology is the Siemens process using trichlorosilane.
3) The polysilicon industry is consolidating with the largest producers having over 100,000 metric
This document discusses the uses of electrolysis in industries, including the purification of metals, electroplating of metals, and extraction of metals. It provides examples of how electrolysis is used to purify copper, electroplate metals like tin onto cans, and extract reactive metals like aluminum from ores. The document also notes some of the potential pollution problems caused by electrolysis in industry, such as releasing heavy metals and altering the pH of water resources.
Group VII elements are called halogens. They exist as diatomic molecules (F2, Cl2, Br2, I2) and have seven electrons in their outer shell. Fluorine has the smallest atomic radius while iodine has the largest due to more electron shells. Melting and boiling points decrease from fluorine to iodine due to weaker van der Waals forces between larger molecules. Electronegativity decreases from fluorine to iodine as the nucleus attracts electrons less. Halogens can gain electrons to form ions or share electrons to form covalent bonds. More reactive halogens can displace less reactive ones from solutions.
The document discusses various metallurgical processes including hydrometallurgy, electrometallurgy, and pyrometallurgy. It focuses on pyrometallurgy and describes roasting as a pyrometallurgical process where ore is heated in air below its melting point to purify metals. There are different types of roasts including oxidizing, sulfatizing, reducing, and chloridizing roasts. Roasting is used to convert sulfides to oxides through oxidation and remove sulfur as sulfur dioxide gas. Various types of roasters are used including multiple hearth, flash, rotary kiln, and fluidized bed roasters.
This document provides background information for revising the AP-42 Section on calcium carbide manufacturing. It describes the industry, the manufacturing process, emissions sources, and control technologies. Test data from two facilities are summarized, including particulate matter and CO2 emissions from electric arc furnaces controlled by fabric filters. The document also reviews eleven references used in the previous AP-42 section and summarizes emission test data and factors reported in these sources.
The document discusses metakaolin, which is produced through calcination of the clay mineral kaolinite. Metakaolin can be produced via flash calcination using high temperatures for a few seconds, or through rotary kiln calcination at 750°C for 5 hours. Flash calcination results in rounded metakaolin particles while rotary kiln calcination produces a plate-like structure. Both types of metakaolin have similar pozzolanic reactivity and can be used to improve the strength and durability of cement, mortar and concrete through the formation of calcium silicate hydrates. The production of metakaolin has benefits for the environment due to the low calcination temperature and reduced CO2 emissions compared to
Necmettin Erbakan Üniversitesi
Mühendislik ve Mimarlık Fakültesi
Metalurji ve Malzeme Mühendisliği Bölümü
İleri Teknoloji Seramikler Dersi
Emre AVCI
Aralık 2020
Borürler, Titanyum Diborür, Lantanyum Hekzaborür
,borides ,borür ,titanyum diborür ,lantanyum hekzaborür ,titanium diboride ,tanhanum hexaboride ,titanyum diborür uygulamaları ,lantanyum hekzaborür kullanım alanları ,borürlerin üretimi ,titanyum diborür üretimi
This document provides an overview of phase diagrams and microstructure development in multicomponent materials systems. It defines key terms like component, phase, solubility limit, and microstructure. It also explains concepts such as equilibrium, metastable states, and lever rule for determining phase compositions and amounts. Different types of binary phase diagrams are discussed, including eutectic and isomorphous systems. The development of microstructure during equilibrium and non-equilibrium cooling of alloys is described for both eutectic and isomorphous systems.
1. The document describes the relationship between concentration and purification processes using solvent extraction in hydrometallurgy.
2. Solvent extraction is a well-established process that separates an impure aqueous stream into two streams, one containing most impurities and the other containing most valuable metal ions.
3. Examples of concentration and purification discussed include solvent extraction being used to produce pure copper electrolytes from impure leach solutions, and to recover uranium from acidic leach liquors while removing impurities like iron and thorium.
The document discusses the extraction of three important metals - iron, aluminum, and copper. It describes how these metals are commonly found as ores and the multi-step processes required to extract the pure metals. Iron is extracted from its ore, hematite, using a blast furnace. Aluminum is extracted via electrolysis of aluminum oxide in molten cryolite. Copper is extracted through concentration, roasting, smelting and refining processes including bessemerization to produce blister copper from chalcopyrite ore.
Crystal defects occur when the regular patterns of atoms in crystalline materials are interrupted. There are several types of crystal defects including point defects, line defects, and plane defects. Point defects are defects that occur at or around a single lattice point and include vacancies, interstitials, and substitutions. Vacancies occur when an atom is missing from its normal position in the crystal lattice. Interstitials occur when an atom occupies a position between normal lattice sites. Substitutions occur when a foreign atom replaces a host atom in the lattice. The presence of defects is necessary for crystals to have stability at any non-zero temperature due to the contribution of defects to entropy.
1) The document discusses the Gibbs paradox in thermodynamics, which involves an apparent contradiction between the mixing of identical gases versus non-identical gases.
2) Several approaches are described to resolve this paradox, including those proposed by Gibbs, von Neumann, and Lin Shu Kun. Lin's approach draws connections between entropy, information theory, and the degree of symmetry/similarity between particles.
3) The key point of resolution is that entropy increases continuously with the similarity or symmetry between particles, as similarity corresponds to greater information loss. This allows entropy to increase for both identical and non-identical gas mixing in accordance with the second law of thermodynamics.
Mass and heat balance for duplex stainless steel production by conarc processIJESFT
Mass balance and heat balance calculations are carried out for estimating inflow and outflow of materials and energy respectively in a process. Such calculations are required to get accurate composition of product with available raw materials. CONARC is a new electric steel making process using a twin shell electric arc furnace (EAF) which can handle raw materials input of solid steel scrap and hot metal in varying proportions.
In the present study an attempt has been made to develop a mathematical model for mass and heat balance for duplex stainless steel production by CONARC process. Case studies have been carried out by varying the amount of hot metal in the charge from 0% to 100%. Such variation shows proportionate increase in the amount of oxygen required, lime consumption and amount of slag formed along with the increase in chemical energy available for the process. However, electrical energy consumption reduces for SAF 2205 and 3RE60 duplex stainless steel production.
On the basis of the above case studies, it has been found that increased amount of hot metal increases the available chemical energy for the process and in turn it reduces the electrical energy requirement of CONARC process, ultimately leading to reduction in the power consumption and overall production cost.
Electrochemistry involves redox reactions in galvanic cells that convert chemical energy to electrical energy. In a galvanic cell, oxidation occurs at the anode and reduction occurs at the cathode. A salt bridge completes the circuit between the two half cells and maintains electrical neutrality. When a zinc rod is used as the anode in a copper sulfate solution with a copper cathode, the zinc rod loses weight as it oxidizes while copper precipitates and the solution warms due to heat released, demonstrating the spontaneous conversion of chemical to electrical energy in a galvanic cell.
This document discusses various forms of corrosion that can occur in metals. It begins by defining corrosion and explaining the factors that influence it. It then describes several specific types of corrosion: general/uniform corrosion, galvanic corrosion, crevice corrosion, pitting corrosion, intergranular corrosion, dealloying, erosion corrosion, stress corrosion, hydrogen damage including hydrogen blistering and hydrogen embrittlement. For each type of corrosion, the document discusses the mechanism and provides methods for prevention.
TRAINING FOR VACUUM DEGASSING AND SECONDARY METALLURGY BY CVS MAKINAmetudgn
This document provides an overview of a training on vacuum degassing (VD) technology. It will cover the theoretical background and operation of VD equipment. Topics include metallurgy processes like secondary metallurgy and vacuum metallurgy, VD and VOD treatment methods, stainless steel grades, and the impact of alloy additions and temperature changes. The training will also review safety, the VD plant layout, individual equipment components, and emergency procedures. Attendees will learn how to safely operate and maintain the VD system.
Oxidation is the loss of electrons, while reduction is the gain of electrons. The atom that loses electrons is the oxidizing agent, and the atom that gains electrons is the reducing agent. For example, in the reaction Mg + Cl2 → MgCl2, magnesium (Mg) is oxidized as it loses electrons and becomes Mg2+, while chlorine (Cl) is reduced as it gains electrons and becomes Cl-. Magnesium serves as the reducing agent and chlorine serves as the oxidizing agent.
I Hope You all like it very much. I wish it is beneficial for all of you and you can get enough knowledge from it. Clear and appropriate objectives, in terms of what the audience ought to feel, think, and do as a result of seeing the presentation. Objectives are realistic – and may be intermediate parts of a wider plan.
The document summarizes extraction and uses of magnesium. It describes common magnesium minerals like dolomite and magnesite. It discusses challenges in extracting magnesium through pyrometallurgical and electrometallurgical processes. The Pidgeon and Magnetotherm processes are described for pyrometallurgical extraction. The Dow process extracts magnesium from seawater through precipitation and electrolysis. Magnesium has non-structural uses like alloying, deoxidation, and cathodic protection. Structural uses include aircraft and transportation applications due to magnesium's high strength to weight ratio.
El documento describe el proceso hidrometalúrgico para extraer cobre de minerales. Este proceso involucra lixiviación, donde el cobre se disuelve de los minerales usando ácido sulfúrico, extracción por solventes para concentrar la solución de cobre, y electro-obtención donde el cobre se recupera electrolíticamente en forma de cátodos de alta pureza. El documento también explica cada una de estas etapas en más detalle.
Metallurgy is a domain of materials science and engineering that studies the physical and chemical behavior of metallic elements, their intermetallic compounds, and their mixtures, which are called alloys. Metallurgy is also the technology of metals: the way in which science is applied to the production of metals, and the engineering of metal components for use in products for consumers and manufacturers. The production of metals involves the processing of ores to extract the metal they contain, and the mixture of metals, sometimes with other elements, to produce alloys. Metallurgy is distinguished from the craft of metalworking, although metalworking relies on metallurgy, as medicine relies on medical science, for technical advancement.
Metallurgy is subdivided into ferrous metallurgy (sometimes also known as black metallurgy) and non-ferrous metallurgy or colored metallurgy. Ferrous metallurgy involves processes and alloys based on iron while non-ferrous metallurgy involves processes and alloys based on other metals. The production of ferrous metals accounts for 95 percent of world metal production.
The document discusses silicon feedstock for the solar industry. It covers the following key points in 3 sentences:
1) Most PV systems are built using crystalline silicon, which is the second most abundant element in the Earth's crust after oxygen. Metallurgical grade silicon is produced in large quantities but requires further refining for solar cell use.
2) Solar grade silicon is produced through chemical processes using trichlorosilane or silane gases, or through metallurgical upgrading of metallurgical grade silicon. The dominant production technology is the Siemens process using trichlorosilane.
3) The polysilicon industry is consolidating with the largest producers having over 100,000 metric
This document discusses the uses of electrolysis in industries, including the purification of metals, electroplating of metals, and extraction of metals. It provides examples of how electrolysis is used to purify copper, electroplate metals like tin onto cans, and extract reactive metals like aluminum from ores. The document also notes some of the potential pollution problems caused by electrolysis in industry, such as releasing heavy metals and altering the pH of water resources.
Group VII elements are called halogens. They exist as diatomic molecules (F2, Cl2, Br2, I2) and have seven electrons in their outer shell. Fluorine has the smallest atomic radius while iodine has the largest due to more electron shells. Melting and boiling points decrease from fluorine to iodine due to weaker van der Waals forces between larger molecules. Electronegativity decreases from fluorine to iodine as the nucleus attracts electrons less. Halogens can gain electrons to form ions or share electrons to form covalent bonds. More reactive halogens can displace less reactive ones from solutions.
The document discusses various metallurgical processes including hydrometallurgy, electrometallurgy, and pyrometallurgy. It focuses on pyrometallurgy and describes roasting as a pyrometallurgical process where ore is heated in air below its melting point to purify metals. There are different types of roasts including oxidizing, sulfatizing, reducing, and chloridizing roasts. Roasting is used to convert sulfides to oxides through oxidation and remove sulfur as sulfur dioxide gas. Various types of roasters are used including multiple hearth, flash, rotary kiln, and fluidized bed roasters.
This document provides background information for revising the AP-42 Section on calcium carbide manufacturing. It describes the industry, the manufacturing process, emissions sources, and control technologies. Test data from two facilities are summarized, including particulate matter and CO2 emissions from electric arc furnaces controlled by fabric filters. The document also reviews eleven references used in the previous AP-42 section and summarizes emission test data and factors reported in these sources.
The document discusses metakaolin, which is produced through calcination of the clay mineral kaolinite. Metakaolin can be produced via flash calcination using high temperatures for a few seconds, or through rotary kiln calcination at 750°C for 5 hours. Flash calcination results in rounded metakaolin particles while rotary kiln calcination produces a plate-like structure. Both types of metakaolin have similar pozzolanic reactivity and can be used to improve the strength and durability of cement, mortar and concrete through the formation of calcium silicate hydrates. The production of metakaolin has benefits for the environment due to the low calcination temperature and reduced CO2 emissions compared to
The document summarizes several industrial chemical processes:
1) The Haber process produces ammonia from nitrogen and hydrogen at 300 atmospheres of pressure, 450°C, using an iron and potassium hydroxide catalyst.
2) Ammonia is converted to nitric acid in the Ostwald process at 10 atmospheres, 900°C, using a platinum-rhodium catalyst.
3) Sulfuric acid is made via the Contact process, reacting sulfur dioxide with oxygen at 430°C and 2 atmospheres using a vanadium pentoxide catalyst.
4) Aluminum is extracted through electrolysis of aluminum oxide dissolved in molten cryolite.
Soda ash manufacturing and process flow diagramUsama Pervaiz
The document discusses the production of sodium carbonate and baking soda via the Solvay process. It begins with an overview of the uses of sodium carbonate and its raw materials. It then provides the overall reaction and a process flow diagram depicting the major steps. These steps include: 1) ammonia absorption into salt water, 2) production of carbon dioxide from limestone, 3) carbonation to form sodium bicarbonate, 4) thermal decomposition to produce sodium carbonate, 5) regeneration of ammonia. The document concludes with some questions about the process.
INHIBITION OF CO2 CORROSION BY FORMATE FLUIDS IN HIGH TEMPERATURE ENVIRONMENTS John Downs
Presentation to the Royal Society of Chemistry's "Chemicals in the Oilfield" conference, November 2005
The paper describes how formate brines protect steels against CO2 corrosion. It also shows the results of stress corrosion cracking tests on CRA steel samples exposed to high-density completion brines containing oxygen at 160 deg C. The 13Cr, 22Cr and 25Cr steels all cracked in the presence of calcium bromide brine containing oxygen.
This document discusses the role of chemistry in power plants. It covers various aspects of feedwater treatment including removal of insoluble and soluble impurities. It discusses parameters for boiler water quality at different plant capacities. Methods for physical and chemical deaeration of feedwater like use of hydrazine are explained. Boiler water chemistry including use of volatile alkalis like ammonia for pH control is covered. Methods for detecting and addressing condenser leaks are summarized. Quality guidelines for steam and requirements for monitoring systems are provided.
This document reviews copper etching processes using cupric chloride (CuCl2) as the etchant. It discusses how CuCl2 provides a high etch rate and easy regeneration compared to other etchants like ferric chloride. The effects of etchant concentration, additives, and etching temperature on the etch rate are examined. Regeneration processes for waste CuCl2 using chemicals like chlorine gas, hydrogen peroxide, and sodium chlorate are also discussed which allow for recycling of the etchant. Copper etching with CuCl2 is an important process in printed circuit board manufacturing in the electronics industry.
This document discusses iron carbides and their use in steelmaking. Some key points:
- Iron carbide is produced from iron ore using natural gas and can be used as a premium-quality feedstock for electric arc furnaces and basic oxygen furnaces.
- The process is simple and produces iron carbide, water, and carbon dioxide as byproducts. Iron carbide has benefits for nitrogen control and is easy to inject into furnaces.
- Compared to other iron production methods, iron carbide production has lower carbon emissions and the carbon dioxide byproduct can be more easily captured. Commercial plants have been built that can produce over 1,000 metric tons per day of iron carbide.
Surface activation of Calcium bentonite clayS k Parida
Clay is a fine grained natural rock or soil material that combines one or more clay minerals with traces of metal oxide and organic matter found abundantly on earth’s crust. Chemically it consists essentially of hydrated silicates of aluminum.
Generally clays are used as solid acid catalysts, which can function as both Bronsted and Lewis acids in their natural and ion-exchanged form and also known as radical catalyst. Using clay catalysts, environmentally benign green chemistry can be done both at industrial and laboratory scale.The objective of this work is to study the behavior of calcium bentonite clay treated with sulfuric acid of 3N concentration under mechanical stirring and refluxing condition separately.The XRF and SEM studies indicated clearly the leaching and disintegration of the clay sheet upon thermo-chemical treatment.
XRD studies of the acid treated clay indicated the structural transformation of the clay sheet upon acid treatment and became amorphous .
As the treatment of 3N sulfuric acid chemically and thermo-chemically occur, Al2O3, TiO2 and Na2O contents in the acid treated material decreased progressively simultaneously increasing the SiO2 content.
FTIR study of the acid treated clay shows that the acid treatment did not cause much variation in the peak pattern, however thermo-acid treatment in same acid strength the peak intensity was found to decrease progressively and indicating the dehydroxylation and successive leaching of the Al ions from the octahedral layer.
Again, the BET surface area analysis of the samples indicated that method can be useful for manufacturing a surface active and high surface area material which can be used for catalyst as well as an adsorbent.
Manufacture of caustic soda and chlorine using electrolysis process ...Ankush Gupta
This document discusses the manufacture of chlorine and caustic soda using electrolysis processes. It provides background on the chlor-alkali industry and describes the three main electrolysis processes: diaphragm cell, mercury cell, and membrane cell. The membrane cell process is highlighted as the most energy efficient and environmentally friendly option. Properties and production details of chlorine, caustic soda, and hydrogen are also outlined. A literature review covers previous research on improving chlor-alkali cell efficiency and treating wastewater from the process.
Isolated Iridium Sites on Potassium-Doped Carbon-nitride wrapped Tellurium Na...Pawan Kumar
Many industrial processes such transesterification of fatty acid for biodiesel production, soap manufacturing and biosynthesis of ethanol generate glycerol as a major by-product that can be used to produce commodity chemicals. Photocatalytic transformation of glycerol is an enticing approach that can exclude the need of harsh oxidants and extraneous thermal energy. However, the product yield and selectivity remain poor due to low absorption and unsymmetrical site distribution on the catalyst surface. Herein, tellurium (Te) nanorods/nanosheets (TeNRs/NSs) wrapped potassium-doped carbon nitride (KCN) van der Waal (vdW) heterojunction (TeKCN) is designed to enhance charge separation and visible-NIR absorption. The iridium (Ir) single atom sites decoration on the TeKCN core-shell structure (TeKCNIr) promotes selective oxidation of glycerol to glyceraldehyde with a conversion of 45.6% and selectivity of 61.6% under AM1.5G irradiation. The catalytic selectivity can reach up to 88% under 450 nm monochromatic light. X-ray absorption spectroscopy (XAS) demonstrates the presence of undercoordinated IrN2O2 sites which improved catalytic selectivity for glycol oxidation. Band energies and computational calculations reveal faile charge transfer in the TeKCNIr heterostructure. EPR and scavenger tests discern that superoxide (O2•−) and hydroxyl (•OH) radicals are prime components driving glycerol oxidation.
This document summarizes a study that utilized waste from carbide lime production to synthesize precipitated calcium carbonate (PCC). The researchers found that carbide lime waste, which contains calcium hydroxide, can be used to produce milk of lime for PCC precipitation when bubbling carbon dioxide gas through it. They investigated how different reaction parameters like milk of lime concentration, carbon dioxide flow rate, and reaction time influence the purity, morphology, and particle size of the synthesized PCC. Under optimized conditions of 2M milk of lime concentration, 90 minute reaction time, and 452.30 mL/min carbon dioxide flow rate, they were able to produce high purity PCC (99%) with a desirable scalenohedron
Utilization of milk of lime (MOL) originated from carbide lime waste and oper...Patrick Okoye
High purity (>99%) precipitated calcium carbonate, PCC was synthesized from abundant waste material (carbide sludge), generated during acetylene gas production. The reaction influencing parameters based on temperature, flow rate, total dissolved solid and carbide lime concentration were investigated.
Alkynes can be prepared through several methods:
1. From calcium carbide by reacting calcium carbide with water to produce acetylene.
2. From vicinal dihalides by treating them with alcoholic potassium hydroxide to undergo dehydrohalogenation and form alkyne.
3. Alkynes readily react with hydrogen in the presence of catalysts like nickel, platinum or palladium through a reaction called hydrogenation.
The document discusses various carbon materials used for steelmaking, including anthracite coal, metallurgical coke, calcined petroleum coke, fluid coke, and artificial graphite. It describes the production processes and characteristics of each material and their uses in basic oxygen furnaces, electric arc furnaces, and ladle treatment. The key uses of carbon in steelmaking are as charge carbon to control oxygen levels, injection carbon for slag foaming, and recarburizer added in ladles.
This presentation discusses problems encountered in boiler water such as scale, corrosion, and carryover. Scale is caused by poor pretreatment, contamination, or inadequate chemical treatment and forms on boiler tubes. Common scales include calcium carbonate, calcium phosphate, and iron oxides. Scale reduces heat transfer and causes equipment issues. Corrosion is an electrochemical process where metal returns to its oxidized state. Methods to prevent scale and corrosion include maintaining water quality, using recommended chemicals, and controlling blowdown. Sodium aluminate and phosphate conditioning are discussed as internal treatment methods. Sludge and scale formation, as well as their disadvantages, are also summarized.
Objective Capital's Industrial Metals, Minerals & Investment Summit 2010
London Chamber of Commerce and Industry
3 November 2010
Speaker: Michael Priestnall, Cambridge Carbon Capture
This document provides information on various carbon materials used in steelmaking processes. It discusses the production and properties of anthracite coal, metallurgical coke, calcined petroleum coke, fluid coke, and artificial graphite. It then outlines the uses of carbon in basic oxygen furnaces, induction furnaces, and electric arc furnaces, including as charge carbon, injection carbon for slag foaming, recarburizer, and graphite electrodes. The ideal material depends on the process and desired properties like carbon content, sulfur level, and gas generation. Lower-cost materials like anthracite and coke are commonly used when quality is less critical.
Similar to Calcium_Carbide_Project_Report_Sample (20)
2. Page No - 2 OSL/IOS/PJT/575
CALCIUM CARBIDE
C O N T E N T S
PAGE NO.
1. INTRODUCTION 3
2. PROPERTIES OF CALCIUM CARBIDE 4
3. USES AND APPLICATIONS 6
4. B. I. S. SPECIFICATION 7
5. PACKING AND MARKING 10
6. MARKET SURVEY 14
7. PRESENT MANUFACTURERS 16
8. RAW MATERIALS 17
9. PRINCIPAL OF MANUFACTURE 18
10. PROCESS OF MANUFACTURING 19
11. WEIGHING AND MIXING OF RAW MATERIALS 21
12. PRECAUTION 24
13. FLOWSHEET OF CALCIUM CARBIDE MANUFACTURE 25
14. PLANT LAYOUT 26
15. PLANT LOCATION FACTORS 27
16. SUPPLIERS OF LIMESTONE 30
17. PRINCIPLES OF PLANT LAYOUT
18. SUPPLIERS OF PLANT & MACHINERIES
19. SUPPLIERS OF JAW CRUSHER, PEBBLE & ROLLING MILLS
20. EXPLANATION OF TERMS USED IN PROJECT REPORTS
21. ADDRESSES OF STATE INDUSTRIAL DEVELOPMENT CORPORATION
22. ADDRESSES OF FINANCIAL INSTITUTIONS
23. ADDRESSES OF REVELANT GOVERNMENT OFFICES
24. SUGGESTED STEPS
APPENDIX - A
1. COST OF PLANT ECONOMICS A 1
2. LAND & BUILDING A 2
3. PLANT AND MACHINERY A 3
4. OTHER FIXED ASSETS A 5
5. FIXED CAPITAL INVESTMENT A 6
6. RAW MATERIAL A 7
7. SALARY AND WAGES A 8
8. UTILITIES AND OVERHEADS A 9
9. TOTAL WORKING CAPITAL A 10
10. COST OF PRODUCTION A 11
11. PROFITABILITY ANALYSIS A 12
12. BREAK EVEN POINT A 13
13. RESOURCES OF FINANCE A 14
14. INTEREST CHART A 15
15. DEPRECIATION CHART A 16
16. CASH FLOW STATMENT A 17
17. PROJECTED BALANCE SHEET A 18
3. Page No - 3 OSL/IOS/PJT/575
CALCIUM CARBIDE
INTRODUCTION
Cacium carbide, CaC2 when pure, is transparent and colourless, with a specific gravity of
2.22 at 180oC. It may be prepared in the laboratory by the thermal decomposition under
vacuum of pure calcium cyanamide in the presence of carbon to produce absolutely white
calcium carbide. Pure CaC2 is variety, and the general properties of calcium carbide have
been determined by extrapolation from values obtained on high - purity commercial carbide.
Commercial calcium carbide varies in colour from Steel-grey to reddish brown, depending on
impurities and the method of manufacture. It is made from lime and coke in the electric
furnace at temperature of 2200 - 2500oC, using large amount of electric power.
Industrial calcium carbide is about 80% pure remaining is calcium oxide and 2-5% other
impurities. Its outstanding property is that of reacting with water to produce acetylene gas.
Commercial calcium carbide is the main source of acetylene, and acetylene is used
principally in the synthesis of a series of organic chemicals, resins, and plastics and in
oxyacetylene welding and cutting of metals. Large amounts of carbide are also made for the
production of calcium cyanamide by the fixation of atmospheric nitrogen. The cyanamide is, in
turn, used as a fertilizer and as the basis for a series of chemicals and resins. Smaller
amounts of calcium carbide are used as a dehydrating agent and as a reducing and
desulfurizing agent in metallurgical processes.
Calcium carbide was made in the laboratory by early workers such as Hare and Wohler. It
also was formed as a side reaction product in various industrial processes, but it was not
isolated or recognized.
4. Page No - 4 OSL/IOS/PJT/575
CALCIUM CARBIDE
PROPERTIES OF CALCIUM CARBIDE
Crystallography
Commercial calcium carbide occurs in four different crystalline modifications- cube,
tetragonal, and two of a lower order of symmetry. The cubic form designated CaC2 ‘IV’ is
stable at 447oC, the tetragonal form, CaC2‘I’ is stable between 447oC and 25oC, and the
form CaC2‘II’ below 25oC, the form CaC2‘III’ is known only as a metastable phase. The
tetragonal form CaC2‘I’ is the one most common in commercial carbide.
Melting Point
The most extensive data on technical carbide are those of all who use more than eighty
sample in which the calcium carbide content ranges from 4 to 94%. By extrapolation of the
two ends of the curve, the melting points of calcium carbide and calcium oxide were indicated
to be about 2300 to 2500oC.
Composition
Microscopic examinations of different samples of the system by all showed clearly the two
components CaC2 and CaO in the form of black crystals in a lighter background of the two
autectics. Thus phyical chemical and optical methods of examination have indicated the
presence of the compound CaC2, CaO.This compound is unsuitable and easily decomposed
at temperature approaching the melting point of the compound. Its heat of formation from
CaO and CaC2 as determined form its heat of solution in dilute hydrochloric acid in 37.4 Kcal
gm-mole (exothermic).
Specific Gravity
Determination of the specific gravity diagram by the pyonometer method, on this series of
compounds by all confirm the existence of the compound CaC2, CaO at about 52% calcium
carbide with a specific gravity of 2.54. By extrapolation of the specific volume curve, the sp.
gravity of CaC2 was indicated to be 2.155 within an accuracy of 0.8%. The sp. gravity of
commercial calcium carbide thus depends upon its CaC2 content, and for the 80%
commercial carbide the specific gravity of the solid at 15oC is 2.28-2.32, and for the liquid at
2000oC, it is 1.85.
Electrical Conductivity
The electrical conductivity of the system CaO-CaC2 was determined by Asll at 20oC, and the
resulting curve indicates a falling conductivity form calcium carbide. to that of lime, the two
minim with abscissas at 75 and 38% CaC2 correspond to the two eutectics formed by CaC2
CaO with CaC2 and with CaO whereas the maximum occurs at about the composition of the
compound CaC2Cao. The electrical conductivity of this compound is indicated to be about
0.30-Cm-1. As also showed that the conductivity of carbide increases with the temperature
and that this increase is linear.
5. Page No - 5 OSL/IOS/PJT/575
CALCIUM CARBIDE
Hardness
The hardness curve for the CaC2-CaCo system was determined by the monotron method, in
which the load required to press a diamond indenter a standard depth into the specimen in a
measure a generally rising hardness from that of calcium carbide to that of lime, with smooth
maxima at 70 and 36% CaC2 (corresponding to the eutectics) and a minimum at about 50%
CaC2. This composition again indicated the presence of the compound CaC2Cao which had
a hardness of 12.5 kg and hardness for CaC2 of 5.5 kgs was indicated by extrapolation of the
curve. Commercial 80% carbide has hardness by 30-80 Bhn.
Thermal Properties
The theoretical heat of formation of calcium carbide based on the heats of reaction of CaO,
Co, and CaC2 has been calculated as 111.3 kcal/gm-mole for 100% CaC2 the latent heat of
fusion is reported as 120 cal/gm and the average specific heat between 0 and 2000oC as
0.28 cal/gm. For other grades of carbide this data must be corrected with regard to the lime
and impurities content. At 25oC, the heat content is given as H 298 = - 14,500 + 1200 gal/g-
mole.
Reaction with Water
This is one of the most important the chemical reactions of calcium carbide, it is highly
reactions of exothermic and is the source of most of the acetylene used in the industry. The
reaction equation is given below: -
CaC2 + 2H 2O ———————C2H2 + Ca(OH)2 + 29.2 Kcal
with a deficiency of water or in the presence of partially slacked carbide, the following reaction
occurs.
CaC2 + (CA(OH)2 ———————C2H2 + 2CaO.
The reaction proceeds slowly at ambient temperature but at about 100 - 120oC it is
stoichiometrically complete in 3-4 days. At still higher temperatures (above about 150oC) the
generated acetylene partially decomposes to form acetylene polymers which coat the carbide
particles an slow or stop the reactions.
Reaction with Nitrogen
Another important reactions of calcium carbide is that with nitrogen which produces
cyanamide according to the following equation: -
CaC2 + N2 —————CaCN2 + C + 70.7 kcal
The product which contains about 10% carbon plus the impurities originally present in the
carbide, is a grey black sintered mass known as industrial cyanamide. The reaction is carried
out at 1000- 1200oF by passing nitrogen through more or less finely crushed carbide heated
electrically to initiate the reactions as the reaction in strongly exothermic it proceeds b itself
after the initial reaction.
6. Page No - 6 OSL/IOS/PJT/575
CALCIUM CARBIDE
USES AND APPLICATIONS
The chief applications of calcium carbide are in the manufacture of calcium cyanamide,
acetylene required in oxyacetylene welding, synthesis of solvents and organic compounds
required in the pharmaceutical and dyestuff industries and manufacture of synthetic rubber
and plastics. It is also used in signal fires. Sodium cyanide used for the recovery of gold in the
ore-treatment process is manufactured from calcium carbide.
As a dehydrating agent, calcium is employed in electrostatic work and in the food and solvent
industries. It finds application in the steel hardening, in the manufacture of graphite and
hydrogen, and in the reduction of copper sulphide and metallic oxide.
The carbide goes directly from the crushing and screening plant, and then, after purification,
to the synthesis of organic chemicals such as acetaldehyde, acetic acid, acetic anhydride
vinyl acetate, polyvinyl compounds, butanol, and chlorinated derivatives.
Another important use of calcium carbide is in the production of cyanamide, where it serves
as a nitrogen fixative. Cyanamide, CaCN2 is used as a fertilizer and as a raw material for the
production of a series of nitrogenous compounds of which dicyanamide, guaniddine, and
melamine are the most important. Carbide is used in metallurgy as a disulfurizing and
deoxidizing agent as a modulizing agent in the production of domulr graphite in iron, and as a
finishing slag component in ferrous and non-ferrous refining.
It is also used in certain industrial process as a reducing and dehydrating agent.
7. Page No - 7 OSL/IOS/PJT/575
CALCIUM CARBIDE
B.I.S. SPECIFICATION
IS: 1040 - 1978 - Calcium Carbide Technical.
This standard prescribes the requirements and the methods of test for calcium carbide.
Technical in graded sizes. The material at present is used for the production of acetylene gas
for illumination, welding, and cutting of steel.
According to this standard, the material shall be graded so that the size of pieces graded are
within one of the following limits.
mm mm
1 - 2 15 - 25
2 - 4 25 - 50
4 - 7 50 - 80
7 - 15 80 - 120
When tested according to the method prescribed in Appendix, all the pieces ranging in
original and previously unbroken and unopened factory packages, in each and the quantity of
dust shall comply with requirement of the following table.
8. Page No - 8 OSL/IOS/PJT/575
CALCIUM CARBIDE
TABLE
Screen analysis of various grades of calcium carbide technical:
Sl.
No. Characteristic Requirement
Method of test (ref.)
to clause No. in
mapp. B
1. Passing through a sieve having round
holes of a size equal to larger dimension,
per cent by weight min,
100 B – 2.1
2. Retained on the sieve having round
holes of the smaller dimension % by
weight min.
86 B - 2.1
3. Dust per cent by wt. max. 5 B - 2.3
When tested according to the method prescribed in Appendix ‘C’ the material shall yield the
volume of gas (measured day or corrected to dry basis) calculated at 27o and 760 mm
pressure appropriate to its quality as specific in the following table.
Material within the tolerance of minus 5 per cent shall be deemed to comply with the
requirement of gas yield given in the following table.
TABLE
GAS YIELD OF CALCIUM CARBIDE
Sl. No. Grade Size Quantity A.
GAS YIELD
Litre per kg.
Quantity B.
Cu. ff per lb.
Quantity A.
Quantity B
1. 15 – 120 311 288 4.98 4.60
2. 7 – 15 301 275 4.81 4.42
3. 4 – 7 287 267 4.59 4.28
4. 2 – 4 273 251 4.36 4.01
5. 1 – 2 257 236 4.25 3.77
Acetylene gas obtained from the material shall also comply with the requirements in the
following tables, when tested according to the methods prescribed in Appendices D and E.
9. Page No - 9 OSL/IOS/PJT/575
CALCIUM CARBIDE
TABLE
Requirements forSl.
No. Characteristics
Quality A Quality B.
1. Acetylene % by vol. min 99.0 99.0
2. Sulphur compounds as (H2S) % by
Vol. Max.
0.15 0.15
3. Phosphorous compounds as (PH3)
% by vol. Max
0.06 0.08
4. Arsenic compounds as (A3H3)% by
vol. max.
0.001 0.0001
5. Nitrogen compounds as (NH3)% by
vol. max
0.10 0.10
10. Page No - 10 OSL/IOS/PJT/575
CALCIUM CARBIDE
PACKING AND MARKING
1. Subject to the regulations made from time to time by the authorities governing the
transport, storage and use of calcium carbide, the material shall be packed in moisture
proof, suitable steel containers as agreed between the purchaser and the
manufacturer.
2. Each container shall be securely sealed and marked with the manufacturers name
weight and grade size of the material in the package, registered trademark if any, and
the month and year of manufacture of the material.
3. Each container shall contain only one size grade, the size limits of which shall be
clearly marked on the outside of the package.
4. The container shall also be clearly marked with the wording calcium carbide
dangerous if not kept dry.
5. The packages may also be marked with Indian Standard Certification mark.
11. Page No - 11 OSL/IOS/PJT/575
CALCIUM CARBIDE
INTERNATIONAL STANDARDS
Standard sizes of calcium carbide in the U.S. specifications are given in Table below, together
with the yield of acetylene at 60oF and 30 inch barometric pressure.
TABLE - 1
Name and size of U.S. Specification Carbide
Name Screen size
(Square to pass
opening)
Screen size in
(Square opening
retained)
Min. Average C2H2
evolved at 600
F and
760 in Ft/lb.
Lump 4.20 1.50 4.5
Engg. 2.00 0.375 4.5
Nut 1.06 0.250 4.5
1/2 x 1/4
(Mineral)
0.500 0.250 4.5
1/2 x 1/12 0.265 0.066 4.5
Rice 0.132 0.033 4.3
14 ND 0.066 0.0165 4.3
The U.S. Specification state that the acetylene evolved shall contain not more than 0.05% by
volume phosphine, where as the British specify a maximum of 0.06% phosphine, 0.15%
hydrogen sulphide, and 0.001% origin by volume.
The U.S. specification states that unless otherwise specified, calcium carbide for domestic
shipment shall be packed in industrial with mouth, screw cover, 100 lbs., 26 gauge metal
drums. The drums must be marked calcium carbide “Dangerous” if not “Keep dry”. In the
carbide trade, contracts are usually based on size specification and gas yield specification,
with penalties for carbide, which fails to meet specified gas yields. In general gas yields range
from 4.60 to 4.80 ft3lb., depending on the screw size of the carbide.
Methods of testing are specified in the U.S. specifications and the British specification. The
most important test is the gas - yield test. Standard sampling, sample preparation procedure,
slaking the prepared sample in specified equipment and collecting and measuring the volume
of evolved acetylene. This volume is calculated to standard conditions. The phosphorus,
sulphur and arsenic content of the calcium carbide is checked by determining the phosphine,
by hydrogen sulphide and arsine content of the evolved acetylene according to the same U.S.
Federal or British standard specified procedures.
12. Page No - 12 OSL/IOS/PJT/575
CALCIUM CARBIDE
Phosphine may be determined by absorption in iodine solution followed by precipitation of the
phosphomolybdate complex. Sulphur and arsenic are determined by absorption in sodium
hypochlorite solution followed by precipitation of barium sulphate in the case of sulphur and
by acidification of the solution and volatilization by arsine by Gutzeit procedure in the case of
arsenic.
13. Page No - 13 OSL/IOS/PJT/575
CALCIUM CARBIDE
HEALTH AND SAFETY FACTORS
There are no undue health or safety factors involved in the manufacture of calcium carbide.
The usual precautions must be observed around the high-tension electrical equipment, which
supplies power to the furnace. The carbon monoxide formed in the carbide reaction, if
collected in closed furnaces, is usually handled through blowers, scrubbers, and then to a
pipe transmission system. This gas is highly poisonous and explosive, therefore the handling
equipment must be maintained in airtight condition and periodic checks of the atmosphere
around the equipment and furnace must be made. As calcium carbide exposed to water
readily generates acetylene, the numerous cooling sections required in the high temperature
furnace equipment require constant maintenance to prevent and detect leaks which might
generate sufficient acetylene to cause an explosion. When acetylene is generated proper
precautions must be taken to prevent admixture with air due to the explosibility of this mixture
over wide range of acetylene concentrations (from 2.5 to 83%) by volume and the
flammability of 82-100% mixtures under certain conditions. In the presence of small amount of
water, carbide may become incandescent and ignite and evolved acetyulene air mixture. To
prevent sparks on opening carbide drums or when working in the neighbourhood of acetylene
generating equipment, non- sparking too should be used.
Superficially slaked carbide may provide enough slaked lime to react with the carbide to give
acetylene and calcium oxide, this reaction is probably responsible for the acetylene odour
which may be noticed when drums of carbide are opened.
14. Page No - 14 OSL/IOS/PJT/575
CALCIUM CARBIDE
MARKET SURVEY
Calcium Carbide is a basic inorganic chemical. It is used in production of Acetylene Gas and
PVC Resins and is the starting raw material in the manufacture of many organic chemicals
like perchlortrichlorethylene, acetylene black etc. Apart from these three important uses,
Calcium Carbide is purchased by garages and service stations to produce acetylene gas.
Ordinary acetylene gas from calcium carbide is used in welding of steel and also for the
purposes of lighting burners and lamps in villages.
The main raw materials required for the manufacture of the product are limestone containing
at least 98 per cent of calcium carbide, charcoal and petroleum coke.
Calcium carbide is produced in large-scale sector only. At present, there are 3 units in India
manufacturing calcium carbide with total capacity of 1,18,000 tonnes, The production was
98,826 tonnes in 2002-2003.
The calcium carbide has wide range of industrial as well as miscellaneous applications.
15. Page No - 15 OSL/IOS/PJT/575
CALCIUM CARBIDE
TABLE
NUMBER OF UNITS, INSTALLED CAPACITY,
PRODUCTION & CAPACITY UTILISATION
YEARS NO. OF UNITS INSTALLED
CAPACITY
PRODUCTION
1 2 3 4
1999-00 10 1,32,000 81,200
2000-01 10 1,32,000 84,700
2001-02 10 1,32,000 86,500
2002-03 10 1,32,000 92,100
TABLE ESTIMATED DEMAND
DEMANDSL.
NO.
END USE INDUSTRY
2003 - 2004 2000 - 2001
1. Dissolved Acetylene Gas 69,236 74,775
2. PVC Resins 59,900 59,900
3. Miscellaneous uses 32,284 44,892
TOTAL 1,61, 420 1,79,567
16. Page No - 16 OSL/IOS/PJT/575
CALCIUM CARBIDE
PRESENT MANUFACTURERS
1. M/s. Calcium Carbide & Gases Ltd.
Birla Building
9/1, R.N. Mukherjee Road
Kolkata - 700001
Phone: (033) - 2201680, 2202380, 2204370
Fax: (033) - 2482872, 2487988, 2489110
E-mail: bjilbs@giascl01.vsnl.net.in
Regd. Office:
Uco Bank building
4th Floor, Parliament Street
Delhi - 1
Phone: 3714851, 2, 3, 4, 5, 3716221
2. M/s. DCM Shriram Consolidated Ltd.
5th Floor, Kanchenjunga
18 Barakhamba Road
New Delhi - 110001
Phone: 011 - 3316801-8
Fax: 011-3318072.
E-mail: dscl@dscl.com
Website: http://www.dscl.com
3. M/s. Kadiravam Chemicals (P) Ltd.
Ambasamudram Road
Munneerpallam
Tirunelveli - 627356
Phone: (0462) - 352531
There is a good market for production and to satisfy the demand of different industries a new
entrepreneur can well venture in this field by installing project of calcium carbide.
17. Page No - 17 OSL/IOS/PJT/575
CALCIUM CARBIDE
RAW MATERIALS
For commercial production the requirements per ton of Calcium Carbide are :-
Anthracite or coke 0.7 MT
Lime 1.1 MT
Coal pitch, retort Carbon and tar 0.05 MT
Retort Carbon, Coal Tar & Pitch:
Retort carbon is used to reduce the ash content of the electrode paste. It is available from
Digboi refineries of Assam Oil Company and in small amounts from Oriental Gas Co., Kolkata
and Bombay Gas Co. Mumbai, Coal tar and pitch of the required specifications are available
in abundance.
18. Page No - 18 OSL/IOS/PJT/575
CALCIUM CARBIDE
PRINCIPLE OF MANUFACTURE
Calcium carbide is produced when lime and carbon are mixed together in proper proportions
and heated to a temperature of 2000oC, the lime is reduced, and the liberated calcium
combines with excess of carbon to form calcium carbide.
CaO + 3C —————— CaC2 + CO - 177,800 Cal.
650 tonnes of carbon and 875 tonnes of lime are required for producing 1000 tonnes of
commercial carbide.
The successful manufacture of calcium carbide has been rendered possible by the
development of the industrial electrical furnace. Arc-resistance furnaces, in which heating is
due partly to the resistance offered by the charge and mostly to sparking across, are
employed in carbide manufacture.
19. Page No - 19 OSL/IOS/PJT/575
CALCIUM CARBIDE
PROCESS OF MANUFACTURING
The manufacture of calcium carbide, string from limestone, coal and coke can be divided into
two section viz.
Section – 1
Manufacture of lime from lime stone and coal and,
Section – 2
Manufacture of calcium carbide from lime and coke.
Each section here will be discussed in details.
Section – 1
Manufacture of lime consists of the following operation.
BREAKING OF LIMESTONE AND COAL
Limestone, as it comes from the mines, is in varying size, starting from 12-14" lumps to 4-6"
size. It is broken into a uniform size range of 4-6" manually.
Coal in the same fashion is broken to a uniform size range of 2 x 4" and is screened to
remove the dust coal.
CHARGING OF THE VERTICAL SHAFT KILN
Limestone and coal, after breaking and screen are mixed in the desired proportion so that mix
can contain around 80% of limestone and 20% coal. This mix is transferred to the kiln-top by
means of vertical hoist and fed continuously to the kiln.
KILN-OPERATION OR CALCINING
The vertical shaft kiln is of cylindrical shape and half-open top circumferentially to feed the
raw material into it. The discharge is taken out intermittently from the four holes provided at
the bottom of the kiln for this purpose. The calcination takes around 48-72 hrs. by the time the
raw material travels from the top to the bottom. The temperature in the calcination zone is
around 900oC. The gases evolved in the combustion preheats the incoming raw-mix and is
vented off. The kiln is kept more than 3/4th of its height filled with the limestone coal mix. The
level of the furnace is kept horizontal to avoid any over-heating or under-heating of the raw
materials.
SORTING OF GOOD QUALITY LIME
The lime, discharged from the bottom of the kiln, is spread over the ground and is sorted out
for good burnt lime. The undesired under-burnt limestone and coal are separated out and
reefed to the kiln.
20. Page No - 20 OSL/IOS/PJT/575
CALCIUM CARBIDE
STORAGE OF LIME
Lime so obtained of desired quality is stored in water -proof covered space to check it from
hydrating the contact of water. From here it is transferred continuously to the carbide kiln site.
SECTION ‘B’
The manufacture of calcium carbide from lime and coke consists of the following steps. : -
1. Weighing and mixing of raw materials.
2. Charging the mix into the furnace
3. Furnace operation
4. Tapping
5. Crushing and screening
6. Product packing
7. Storage
21. Page No - 21 OSL/IOS/PJT/575
CALCIUM CARBIDE
WEIGHING AND MIXING OF THE RAW MATERIALS
The lime and coke are proportioned from stock bins by automatic weighing scales. The
charge generally receives sufficient mixing in the weighing and subsequent handling to the
mix-bins above the furnace so that no special mixing equipment is necessary. The
composition of the mix is usually kept as :-
Anthracite or coke 0.7 MT
Lime 1.1 MT
Coal, Pitchretort carbon and tar 0.5 MT
Per tonne of calcium carbide to be produced. This ratio, however, has to be adjusted
according to the purity of the raw materials, the operating characteristics of the furnace and
the grade of carbide desired.
FURNACE
Calcium Carbide is made in the electro thermal low shaft furnace. Its main components are
the furnace vessel with the tapping device and the devices for the introduction of electric
power and raw materials. The furnace vessel is made of welded or riveted iron and reinforced
against distortions. The bottom of the vessel is covered with carbon bricks or lined with
refractory material.
Most furnaces are operated by three phase - current electric power supplied by three
electrodes. These may be arranged in series in which case the furnace vessel is rectangular.
They may also be arranged at the corners of an equilateral triangle, in which case the vessel
is round or has the form of triangle rounded off at the corners.
All furnace vessels have three tap holes through which the liquid carbide flows into cast iron
crucibles.
All the electrodes used in most open-arc furnaces are prefabricated and are made either of
dense graphite or of regular graphite. Carbon electrodes seldom are used in melting furnaces
and those that are used are being replaced by graphite electrodes because of the latter’s
higher conductivity, smaller diameter, lower weight and smaller diameter electrode circle for a
given size transformer. Regular density electrodes are available in sizes of 178-610 mm
diameter. Carbon electrodes are usually rated at electric current or current density of 4.5 - 9
A/cm2 and graphite electrodes at 15.5 - 46.5A/Cm2. The electrode diameter normally is
selected on the basis of its current carrying capability and its mechanical strength.
22. Page No - 22 OSL/IOS/PJT/575
CALCIUM CARBIDE
The standard three phase furnaces are available in sizes of 200 kg to 500 t and shell
diameters of 1-12 m. Furnace transformer ratings are available from 200 to > 150,000 KVA.
The electrode arms are raised or lowered to maintain the desired arc characteristics, arc
voltage, and arc current. This action takes place within fraction of a second after the error
signals are generated; the degree of movement depends upon the strengths of these signals.
Each electrode arm is continually moving because its characteristics are changing continually
as scrap falls away from or against the electrodes as the electrode erodes, and the
atmosphere in the furnace changes. Each electrode arm’s electrical conductors are
connected through flexible cables to the bars or tubes of the delta closure extensions and
onto a multi voltage tap transformer. Furnace transformers of <7500 KVA also contain a
multitap reactor to provide sufficient inductive reactance to offset the negative characteristic of
the arc.
FURNACE CHARGING
The level of the charge in the furnace is controlled by adding fresh mix every few minutes to
open furnace or continuously to the closed furnace. In the open furnace the fresh charge must
be rabbled around the electrodes to replace the charge descending to the reaction zones, for
the closed furnace the charge is delivered by feed pipes located above and around the
electrodes.
FURNACE OPERATION
At the surface of the charge the coke and lime are heated only by the escaping gases. As the
charge descends it becomes progressively hotter and from 10 to 12 inch below the surface it
is hot enough to carry on appreciable part of the current from electrode to electrode. About
36-40 inch below the surface the charge reaches the electrode tips, where, at a temperature
of 1600-2000oC it is conductive but not hot enough to melt the lime. Below the level of the
electrode tips, the mix is still solid and granular. About 10-20 inch below the electrodes tips
the temperature is not enough to melt the lime (2200- 2500oC), the coke does not melt but
does react with the required liquid lime to form liquid calcium carbide and carbon monoxide.
As this liquid carbide travels towards the hearth of the furnace, the calcium carbide liquid
becomes richer in its carbide content. The ease with which the furnace gas escapes has an
important bearing on the smooth operation of the furnace. An evenly operating furnace is
essential for the efficient production of carbide. Smooth operation is indicated by: -
1. Steady electrode penetration of the charge as indicated by the distance of electrode tip
above the tap-hole.
2. Regular descent of the mix through the charging chute and,
3. Regular tapping of carbide.
4. Constant coke to lime ratio in the mix.
TAPPING
The carbide from the furnace is tapped from each of the 3 tap holes in turn, usually at 20-40
minutes intervals thereby maintaining on temperature profile and uniform about the electrode.
The liquid carbide tapped from the carbide furnace is collected in cast-iron crucible. In some
plants, the blocks are allowed to cool in the crucibles, whereas in others they are removed
after 2-4 hours and allowed to cool. In order to avoid losses of acetylene, the blocks are
crushed at 400oC
23. Page No - 23 OSL/IOS/PJT/575
CALCIUM CARBIDE
CRUSHING AND SCREENING
The treatment of carbide pigs requires special machinery. For use in acetylene production the
clean ingots are broken to lumps first in jaw crusher and later is slow rolls to minimize dust
formation. The pieces are screened to 2" size for large acetylene generators, peasize for
miners’ lamps, and 16-30 mesh size for atmosphere automobile lamps. For the production of
sodium cyanide the crushed carbide is passed through a pebble mill to yield a power 80% of
which passes through a 40-mesh screen. It is further powdered in a tube mill to milled
carbide, 85% of which passes through a 200-mesh screen. The grinding is carried out in an
atmosphere of nitrogen to prevent the formation of an explosive mixture.
PACKING
The ground carbide is filled in steel drums of cap. of 100,110,2000 and 220 lbs. of cap. net
and small tins containing 1 - 25 lb. of carbide.
STORING
The product is stored in water- proof covered sheds.
24. Page No - 24 OSL/IOS/PJT/575
CALCIUM CARBIDE
PRECAUTION
In normal furnace operation, the calcium forming according to these reactions is converted
into carbide in the cooler regions of the furnace by reacting with carbon.
However the partial pressure of calcium rises rapidly above 2000oC, and above 2200oC, the
carbide decomposes by violent eruption. As a result, the operation of the furnace is
interrupted and considerable damage may be caused.
Furnace operation is effected by dissociation of the carbide.
CaC2 -------------> Ca + 2C
and by the reaction of carbide with excessive CaO.
Cac2 + 2Cao ---------> 3Ca + 2Co
For these reasons, the temperature in the melting zone must not increase excessively. This
can be avoided by feeding the raw material in such a way that the carbon concentration
remains stable and by ensuring that the components, in particular carbon, react rapidly
enough at lower temperatures.
25. Page No - 25 OSL/IOS/PJT/575
CALCIUM CARBIDE
FLOWSHEET OF CaC2 MANUFACTURING PROCESS
LIME PRODUCTION FROM LIMESTONE
CALCIUM CARBIDE PRODUCTION
Breaking the limestone &
Coal
Charging into Kiln
Sorting of Lime CALCINATION
STORAGE OF LIME
Mixing of Raw Material Charging in the furnace
COOLING TAPPING
CRUSING &
SCREENING
PACKAGING STORAGE
26. Page No - 26 OSL/IOS/PJT/575
CALCIUM CARBIDE
PLANT LAYOUT
PRODUCTION SHED
STOGRAGE
LAB
ADMIN
BLOCK
55 M
18.18
26 M
19.23 M
GATE
60 MTS
50 M
GATE
XXX
27. Page No - 27 OSL/IOS/PJT/575
CALCIUM CARBIDE
PLANT LOCATION FACTORS
Factors which generally apply to the economic and operability aspect of plant site location are
classified into two major groups. The primary factors listed apply to choice of a region,
whereas the specific factors looked at in choosing an exact site location within the region. All
factors are important in making a site location selection.
Primary Factors
1. Raw-material supply:
a. Availability form existing or future suppliers
b. Use of substitute materials
c. Distance
2. Markets:
a. Demand versus distance
b. Growth or decline
c. Inventory storage requirements
d. Competition - present and future.
3. Power and fuel supply:
a. Availability of electricity and various type of fuel
b. Future reservers
c. Costs
4. Water supply:
a. Quality - temperature, mineral content, bacteriological content
b. Quantity
c. Dependability - may involve reservoir construction
d. Costs
28. Page No - 28 OSL/IOS/PJT/575
CALCIUM CARBIDE
5. Climate:
a. Investment required for construction
b. Humidity and temperature conditions
c. Hurricane, a tornado, and earthquake history
Specific Factors
6. Transportation:
a. Availability of various services and projected rates
1. Rail - dependable for light and heavy shipping over all distances
2. Highways - regularly used for short distance and generally small quantities
3. Water - cheaper, but may be slow and irregular
4. Pipeline - for gases and liquids, particularly for petroleum products
5. Air - for business transportation of personnel
7. Waste disposal:
a. Regulations laws
b. Stream carry-off possibilities
c. Air-pollution possibilities
8. Labor:
1. Availability of skills
2. Labor relations - history and stability in area
3. Stability of labor rates
9. Regulatory laws:
a. Building codes
b. Zoning ordinances
c. Highway restrictions
d. Waste-disposal codes
29. Page No - 29 OSL/IOS/PJT/575
CALCIUM CARBIDE
10. Taxes:
a. State and local taxes
1. Income
2. Unemployment insurance
3. Franchise
4. Use
5. Property
b. Low assessment or limited term exemptions to attract industry
11. Site characteristics:
a. Contour of site
b. Soil structure
c. Access to rail, highway, and water
d. Room for expansion
e. Cost of site
f. Site and facilities available by expansion on present company-owned property
12. Community factors:
a. Rural or Urban
b. Housing costs
c. Cultural aspects - churches, libraries, theaters
d. School system
e. Recreation facilities
f. Medical facilities - hospitals, doctors
13. Vulnerability to wartime attack:
a. Distance form important facilities
b. General industry concentration
14. Flood and fire control:
a. Fire hazards in surrounding area
b. Floor history and control
30. Page No - 30 OSL/IOS/PJT/575
CALCIUM CARBIDE
SUPPLIERS OF LIMESTONE
31. Page No - A1 OSL/IOS/PJT/575
PLANT ECONOMICS
Rated Plant capacity = 4.00 MT/day
= 1200.00 MT/annum
CALCIUM CARBIDE
Basis
No. of working days = 25 days/month
= 300 days/annum
No. of shifts = 1 per day
One shift = 8 hours
Currency - Rs.
32. Page No - A2 OSL/IOS/PJT/575
LAND & BUILDING
1. Land Area Required 4000 sq.mts.
@ Rs.500/- per sq.mtr. Rs. 20,00,000.00
2. Covered Area: production shed 1500 sq.mts.
@ Rs.3000/-per sq.mtr. Rs. 45,00,000.00
3. Storage of raw material and finished product 500 sq.mts.
@ Rs.2000/-per sq.mtr. Rs. 10,00,000.00
4. Office & Laboratories 150 sq.mts.
@ Rs.4000/-per sq.mtr. Rs. 6,00,000.00
5. Storage Silos Rs. 2,00,000.00
6. Site development, Roads, Sewage
Boundary wall, gate, etc. Rs. 5,50,000.00
----------------------------
TOTAL Rs. 88,50,000.00
----------------------------
Calcium Carbide
33. Page No - A3 OSL/IOS/PJT/575
PLANT & MACHINERY
1. A) LIME SECTION:
1. Vertical Shaft kiln, equipped with vertical hoist, motor half- Rs. 0.01
2. Covered roof (platform) trolly and rolls for the movement of trolly,
limed with high temperature- Rs. 0.01
3. Refractory bricks in the calenining zone, provided with four outlet at
the bottom reinforced with steel- Rs. 0.01
4. Strips cap. 1.00 Mt per hour 1 No. Rs. 0.01
5. 2. Vibrating Screen
b) Section of Carbide
1. Three-phase electric Arc furnace Rs. 0.01
6. Continuous type equipped 3 Nos. provided with vertical hoist motor,
platform provided at the top of the Rs. 0.01
7. Furnace, hopper to feed the raw materials limed with high temp.
refractory bricks & pitch cap. - Rs. 0.01
8. = 0.5 MT per hour output. 1 No. Rs. 0.01
9. Jaw crusher cap. 0.5 MT/hr in put size 4-8 inch out put size 2"1 1 No. Rs. 0.01
10. Rolling mill slow movement, cap. 0.5 MT/hr output 20-30 mesh. 1 No. Rs. 0.01
11. Pebble mill input size less than 2" output size 85 % to pass through
300 mesh cap. 0.5 MT per hr. 1 No. Rs. 0.01
12. Vibrating screen with a set of sieves cap. 0.5 mt/hr. 1 No. Rs. 0.01
13. GENERAL SECTION
1. Automatic weighing scale 2 Nos. Rs. 0.02
Calcium Carbide
34. Page No - A4 OSL/IOS/PJT/575
14. 2. Workshop tools M/c and auxiliary Rs. 0.01
15. Laboratory set-up with all equipment testing materials Rs. 0.01
16. Electric Insulation charges Rs. 0.01
17. Service facilities charges Rs. 0.01
18. Other miscellaneous M/c as pipe, valve, cooling system, etc. Rs. 0.01
19. Total Machineries Cost Rs. 25,00,000.00
-----------------------------
TOTAL Rs. 25,00,000.19
-----------------------------
Calcium Carbide
35. Page No - A5 OSL/IOS/PJT/575
OTHER FIXED ASSETS
1. Office equipment, furniture plus
other equipment & accessories Rs. 50,000.00
2. Installation costs for water,
electricity, fuel etc. Rs. 2,00,000.00
3. Pre-operative & preliminary expenses Rs. 2,00,000.00
4. Installation erection, commissioning Rs. 4,00,000.00
5. Technical Knowhow Rs. 3,00,000.00
6. Miscellaneous Expenses Rs. 2,00,000.00
----------------------------
TOTAL Rs. 13,50,000.00
----------------------------
36. Page No - A6 OSL/IOS/PJT/575
FIXED CAPITAL
1. LAND & BUILDING Rs. 88,50,000.00
2. PLANT & MACHINERY Rs. 25,00,000.19
3. OTHER FIXED ASSETS Rs. 13,50,000.00
-----------------------------
TOTAL Rs. 1,27,00,000.19
-----------------------------
Calcium Carbide
37. Page No - A7 OSL/IOS/PJT/575
WORKING CAPITAL REQUIREMENT/MONTH
RAW MATERIALS
1. Lime stone 220 MT
@ Rs.1000/-per MT Rs. 2,20,000.00
2. Coal, Steam Coal 44 MT Rs. 70,400.00
3. Coke 70 MT
@ Rs.2000/-per Mt (Incld. Transport) Rs. 1,40,000.00
4. Coal pitch, retort carbon and tar. Total 50 MT
@ Rs.2000/-per MT (average) Rs. 1,00,000.00
----------------------------
TOTAL Rs. 5,30,400.00
----------------------------
Calcium Carbide
39. Page No - A9 OSL/IOS/PJT/575
UTILITIES AND OVERHEADS
1. Power Consumption of 4000Kwatt hrs
@ Rs. 4.50 per Kwatt hr. Rs. 18,000.00
2. Water Consumption of 500 KLs
@ Rs. 2.00 per KL Rs. 1,000.00
3. Stationery, Postage, Telephone etc. Rs. 5,000.00
4. Conveyance & Transportation etc. Rs. 7,000.00
5. Publicity & Sales Promotion Rs. 15,000.00
6. Repairs & maintenance Rs. 10,000.00
7. Miscellaneous Rs. 3,000.00
8. Electrode consumption 3125 kgs. per month
@ Rs.40/-per kg. Rs. 1,25,000.00
9. Packaging drum 50 kgs. each cap 3000 Nos.
@ Rs.80/-per drum Rs. 2,40,000.00
---------------------------
TOTAL Rs. 4,24,000.00
---------------------------
Total load is 22 Kwatts
Calcium Carbide
40. Page No - A10 OSL/IOS/PJT/575
TOTAL WORKING CAPITAL/MONTH
1. RAW MATERIAL Rs. 5,30,400.00
2. SALARY & WAGES Rs. 1,50,290.00
3. UTILITIES & OVERHEADS Rs. 4,24,000.00
----------------------------
TOTAL Rs. 11,04,690.00
----------------------------
1. WORKING CAPITAL FOR 3 MONTHS Rs. 33,14,070.00
2. MARGIN MONEY FOR W/C LOAN Rs. 8,28,517.50
COST OF PROJECT
TOTAL FIXED CAPITAL Rs. 1,27,00,000.19
MARGIN MONEY Rs. 8,28,517.50
-----------------------------
TOTAL Rs. 1,35,28,517.69
-----------------------------
Calcium Carbide
41. Page No - A11 OSL/IOS/PJT/575
TOTAL CAPITAL INVESTMENT
TOTAL FIXED CAPITAL Rs. 1,27,00,000.19
TOTAL WORKING CAPITAL FOR 3 MONTHS Rs. 33,14,070.00
--------------------------
TOTAL Rs. 1,60,14,070.19
--------------------------
COST OF PRODUCTION/ANNUM
1. Working Capital for 1 year Rs. 1,32,56,280.00
2. Interest @ 12.00% on T.C.I. Rs. 19,21,688.42
3. Depreciation @ 6.50% on buildings Rs. 4,45,250.00
4. Depreciation @ 25.00% on Plant
and Machinery Rs. 6,25,000.05
5. Depreciation @ 20.00% on office
equipment & furnitures Rs. 10,000.00
--------------------------
TOTAL Rs. 1,62,58,218.47
--------------------------
42. Page No - A12 OSL/IOS/PJT/575
TURN OVER/ANNUM
1. By sale of calcium carbide 1200 MT
@ Rs.16600/-per MT. Rs. 1,99,20,000.00
--------------------------
TOTAL Rs. 1,99,20,000.00
--------------------------
PROFIT = RECEIPTS - COST OF PRODUCTION
= 1,99,20,000.00 - 1,62,58,218.47
= 36,61,781.53
PROFIT SALES RATIO = Profit / Sales x 100
36,61,781.53
= ----------------------------------- X 100
1,99,20,000.00
= 18.38 %
RATE OF RETURN = Operating profit / T.C.I x 100
36,61,781.53
= ---------------------------------- X 100
1,60,14,070.19
= 22.87 %
43. Page No - A13 OSL/IOS/PJT/575
BREAK EVEN POINT (B.E.P.)
Fixed Costs of the plant are as under -
1. Interests Rs. 19,21,688.42
2. Depreciation Rs. 10,80,250.05
3. 40.00% of salaries Rs. 7,21,392.00
4. 40.00% of overheads Rs. 20,35,200.00
--------------------------
TOTAL Rs. 57,58,530.47
--------------------------
FIXED COSTS
B.E.P. = ------------------------------------------------- X 100
FIXED COSTS + PROFIT
57,58,530.47
= ------------------------------------------------------ X 100
57,58,530.47 + 36,61,781.53
= 61.13 %
LAND MAN RATIO = Total land / Manpower
4000 : 28 :: 143 : 1
44. Page No - A14 OSL/IOS/PJT/575
RESOURCES FOR FINANCE
1. Term loans from Financial institutions (65.00 % of fixed capital)
at @12.00% p.a. rate of interest Rs. 82,55,000.12
2. Bank loans for 3 months (65.00 % of working capital)
at @ 12.00% p.a. rate of interest Rs. 21,54,145.50
3. Self raised capital from even funds & loans from close ones to
meet the margin money needs at a @ 12.00% p.a rate of interest Rs. 56,04,924.57
---------------------------
TOTAL Rs. 1,60,14,070.19
---------------------------
45. Page No - A15 OSL/IOS/PJT/575
INSTALMENT PAYABLE IN 5 YEARS
===========================================================================
Year To Financial To Commercial To others Total
institutions banks
(Rs. 8255000) (Rs. 2154146) (Rs. 5604925)
===========================================================================
1 16,51,000.02 4,30,829.10 11,20,984.91 32,02,814.04
2 16,51,000.02 4,30,829.10 11,20,984.91 32,02,814.04
3 16,51,000.02 4,30,829.10 11,20,984.91 32,02,814.04
4 16,51,000.02 4,30,829.10 11,20,984.91 32,02,814.04
5 16,51,000.02 4,30,829.10 11,20,984.91 32,02,814.04
===========================================================================
INTEREST PAYABLE IN 5 YEARS
===========================================================================
Year On term loans On bank loans On self loans Total
(Rs. 8255000) (Rs. 2154146) (Rs. 5604925)
@ 12.00 % P.A. @ 12.00 % P.A. @ 12.00 % P.A.
===========================================================================
1 9,90,600.01 2,58,497.46 6,72,590.95 19,21,688.42
2 7,92,480.01 2,06,797.97 5,38,072.76 15,37,350.74
3 5,94,360.01 1,55,098.48 4,03,554.57 11,53,013.05
4 3,96,240.01 1,03,398.98 2,69,036.38 7,68,675.37
5 1,98,120.00 51,699.49 1,34,518.19 3,84,337.68
===========================================================================
46. Page No - A16 OSL/IOS/PJT/575
TOTAL REPAYMENT SCHEDULE FOR 5 YEARS
============================================================
Year Interest Instalments Total
============================================================
1 19,21,688.42 32,02,814.04 51,24,502.46
2 15,37,350.74 32,02,814.04 47,40,164.78
3 11,53,013.05 32,02,814.04 43,55,827.09
4 7,68,675.37 32,02,814.04 39,71,489.41
5 3,84,337.68 32,02,814.04 35,87,151.72
============================================================
DEPRECIATION CHART FOR 5 YEARS
=============================================================================
Year Building costs Plant & Machinery Fur. & office equip. Total
(Rs. 6850000.00) (Rs. 2500000.19) (Rs. 50000.00)
@ 6.50 % P.A. @ 25.00 % P.A. @ 20.00 % P.A.
=============================================================================
1 4,45,250.00 6,25,000.05 10,000.00 10,80,250.05
2 4,16,308.75 4,68,750.04 8,000.00 8,93,058.79
3 3,89,248.68 3,51,562.53 6,400.00 7,47,211.21
4 3,63,947.52 2,63,671.90 5,120.00 6,32,739.41
5 3,40,290.93 1,97,753.92 4,096.00 5,42,140.85
=============================================================================
47. Page No - A17 OSL/IOS/PJT/575
PROFIT ANALYSIS FOR 5 YEARS
===============================================================================================
YR CAP Sales Mfg. Gross Depreciation Interest Net profit Net profit
UTIL Expenses Profit @ 38.85% before tax after tax
==============================================================================================
1 70% 13944000 9279396 4664604 1080250 1921688 1662666 1016720
2 80% 15936000 10605024 5330976 893059 1537351 2900566 1773696
3 80% 15936000 10605024 5330976 747211 1153013 3430752 2097905
4 90% 17928000 11930652 5997348 632739 768675 4595933 2810413
5 100% 19920000 13256280 6663720 542141 384338 5737241 3508323
===============================================================================================
CASH FLOW STATEMENT FOR 5 YEARS
==========================================================================
YR CAP. Net profit Depreciation Cash Repayment of Net surplus
UTIL (after tax) in hand Instalment
==========================================================================
1 70% 1016720 1080250 2096970 2081829 15141
2 80% 1773696 893059 2666755 2081829 584926
3 80% 2097905 747211 2845116 2081829 763287
4 90% 2810413 632739 3443153 2081829 1361323
5 100% 3508323 542141 4050464 2081829 1968635
==========================================================================