The introduction of mixed hydraulic gypsum into the production of building products began in 1949 in Zhdanov.

M.P. Demakov, chief engineer of the Azovstalstroy trust, and director of the gypsum and gypsum building products plant, engineer. B. D. Afanasiev quickly appreciated the importance of the new binder in the production of building products and, with the support of the manager of the trust, N. A. Poborchiy, made every effort to mass-produce a large range of products based on mixed hydraulic gypsum. With the direct participation of the employees of TsNIPS-ml. scientific collaborator G. F. Stefanenko, technicians A. G. Khotchenko, E. Kh. Molodova and the author for 1949 and 1951. The nomenclature of building products, consisting of about 70 items, was mastered in production.

During 1949, 1950 and 1951, the following building products were manufactured on a mass scale and fully used at the construction sites of the trust:

1. Partition plates 5-7-8 cm thick. 90000 zh2

2. Slabs for interfloor and attic floors, solid, reinforced trough

Type, Hollow and Reel .............................................. 32 862

3. Plates for ventilation ducts............................... 2 105 ,

4. Dry plaster slabs 10 mm thick

Without cardboard .............................................. ................. 2580 .

5. Blocks for laying cables .............................................. 60 050 rm. m

6. Wall cinder-concrete stones are solid

And three-hollow.................................................................. ........ 150000 pcs.

7. Floor beams for interfloor floors, hollow 73 m3

8. Architectural details for balconies, cornices, etc. 500 "

In addition to the listed products, other important building products were also manufactured in significant quantities, such as: the fence posts of the Park of Culture and Leisure, curbstones for sidewalks, facing tiles, etc. The author failed to take into account the full number of these products. Mixed hydraulic was also used in the manufacture of 6,000 m3 of plaster mortars for plastering the facades of buildings and industrial premises, where cement must be used in mortars.

According to the trust Azovstalstroy, as a result of the use of mixed hydraulic gypsum in mass building products, it was possible to replace in 1949-1951. 4,300 tons of cement and more than 16,000 m3 of sawn timber. It was not only a replacement for scarce materials, but also a means to reduce the cost of construction; Thus, according to the data of Glavchermetstroy of Donbass MSPTI, during the same period, savings were obtained from the use of mixed hydraulic. gypsum and products from it in the amount of 2,875 thousand rubles.

Savings in 1949 and for 9 months in 1950 were obtained from the use of products and solutions shown in Table. 43.

At the same time, it should be taken into account that the savings were obtained during the years of mastering production, when it was necessary to rebuild the technological process of production and produce equipment again, depending on the mastered product range.

The high-strength gypsum plant in 1949 produced only about 40% of the plan at a price of 200 rubles. 86 kop. for 1 g, and in. 1950 for 9 months of production, approximately 60% of the plan was produced at a price of 168 rubles. 40 kop. per 1 ton. Non-fulfillment of the plan naturally led to an increase in the cost of manufactured products.

Ground granulated slag in 1949 cost the plant 60 rubles. per 1 ton, and in 1950 due to a change in the plant from

Starting prices, ground granulated slag cost the plant 82 rubles. for 1 g. Building products were made on mixed hydraulic gypsum with a composition of 1: 1.25 (high-strength gypsum: ground granulated slag). The cost of 1 ton of binder at the prices of 1950 in this case was 120 rubles. 40 kop.

Wall slag concrete stones were made on mixed hydraulic gypsum with a ratio of 1:2; the cost of 1 g of such a binder, respectively, amounted to 110 rubles. 80 kop. Plaster solutions were prepared on mixed hydraulic gypsum with a composition of 1: 3; the cost of 1 ton of such a binder was 103 rubles. 60 kop.

On page 32 it was noted that when the plan is fulfilled, the cost of high-strength gypsum with imported raw materials is no more than 100-110 rubles. per 1 ton. Even at these prices, the cost of 1 ton of mixed hydraulic gypsum will be within 90 rubles.

Thus, the cost of a new binder during the development period turned out to be low compared to other binders.

However, the economic effect of the use of mixed hydraulic gypsum depends not only on the cost of the binder itself, but also on its very valuable construction ability to quickly gain strength. From Table. 43 it can be seen that the Azovstalstroy trust receives the greatest savings from the production of cable blocks, which were also made on ordinary cement. In this case, great savings were obtained because the blocks prepared on mixed hydraulic gypsum can be freed from molds after 15-20 minutes. and send to the park without forms. Such blocks are made on mobile carts (Fig. 15 and 16), the productivity of which is three blocks per hour. Blocks made with cement binder

They come to steaming in forms, and in most cases in wooden ones; therefore, not only does the price increase, but often there is a defect, obtained both from the swelling of the forms, and when the products are stripped after steaming. A great economic effect is obtained with hollow reeling from mixed hydraulic gypsum. As can be seen from Table. 43, it is cheaper than rolling, prepared on Portland cement, by 23 rubles. 87 kop. for 1 m2.

This effect is explained not only by the cheapening of the binder, but mainly by the use of inventory mobile forms (Fig. 17). In each such form, from ■50 to 70 pieces are prepared. rolling in 1 shift. These products come to the steaming room without molds.

Experience in the manufacture of floor beams has shown the exceptional advantage of using mixed hydraulic gypsum. Hollow beams (Fig. 18) up to 4 m long are made in inventory mobile form (Fig. 19). Sealing is done by vibration. The release of the beam from the forms is carried out after 20-30 minutes. Ball-ki-flooring is delivered to the steam room without forms. As you know, when using conventional cement, the production of such beams costs a lot.

Expensive and requires a special, more complex process.

Products prepared on mixed hydraulic gypsum are not afraid of moisture; therefore, they do not require covered warehouses either at the factory where gypsum products are made (Fig. 20), or at the building where these products are used in business (Fig. 21).

Taking into account the great economic effect obtained from the use of mixed hydraulic gypsum, the Azov Trust - Steelstroy began the reconstruction of the high-strength gypsum plant and the gypsum products workshop in order to maximize their mechanization and increase the productivity of these enterprises by about 70%.

After the reconstruction, the trust plans to abandon imported cement at the operating plant for the production of cinder-concrete stones and organize the manufacture of stones on mixed hydraulic gypsum.

Caid. tech. Sciences A. M. Shchepetov, Ph.D. tech. Sciences N. V. Lobachev, ml. scientific collaborator G. F. Stefanenko and K. G. Krut, technicians M. D. Shifil-banskaya, E. X. Molodova and A. G. Hotchenko. Copyright certificate No. 87927.

Author's certificate No. 73705, class 80 in 6/01.

Designation of the plant

Equipment for building gypsum production is intended to obtain a binder that meets the requirements of GOST 125-79: Gypsum binders. Specifications.

Thermal unit at production of building gypsum on our installation is a gypsum boiler TOS165.

Depending on the compressive strength of the finished product in the gypsum boiler, building gypsum of the following grades can be obtained: G-4, G-5, G-6, G-7.

By adjusting the technological parameters of gypsum cooking, it is possible to obtain quick-hardening gypsum with index A, the beginning of setting no earlier than 2 minutes, the end no later than 15 minutes, and normal hardening B, the beginning of setting no earlier than 6 minutes, the end no later than 30 minutes.

Depending on the degree of grinding, gypsum of medium grinding with a 0.2 mm sieve residue of no more than 14% and fine grinding with a 0.2 mm sieve residue of no more than 2% can be obtained.

Upon receipt of a product with a fine grinding of less than 2%, the productivity of the equipment decreases.

plant productivity by production of building gypsum with an average grinding of 5-8% residue on a 0.2 sieve is 8 t/h.

Plant equipment according to production of building gypsum is placed on a technological shelf inside an unheated production premises.

During the construction of a new plant for the production of gypsum binder, sandwich panels are used as the enclosing structures of the production building.

Dimensions in terms of production rack may vary depending on terms of reference customer and available free space. The standard dimensions are 4.5 x 30 m and 9.0 x 18 m. Max Height equipment inside the production room 16 m.

Outside the dimensions of the production shelter, as a rule, they take out equipment for the crushing and transportation of gypsum stone and silo cans designed for storing and languishing the finished gypsum binder.

Requirements for the source material - gypsum stone

Occurs with the use of gypsum stone meeting the requirements of GOST 4013-82 grade 1 with a CaSO4 x 2H2O content of at least 95% and grade 2 gypsum stone with a CaSO4 x 2H2O content of at least 90%. A high-quality binder in a gypsum boiler of at least G4 grade can be obtained using grade 3 gypsum stone with a CaSO4 x 2H2O content of at least 80% on a hard gypsum stone.

To obtain a gypsum binder in a gypsum boiler, a gypsum stone of a fraction of 60 - 300 mm is used. The coarse stone is the cleanest without inclusions of foreign material. There are more inclusions of non-gypsum rock in fine crushed stone of a fraction of 0-60 mm, which reduces the properties of the finished gypsum binder when cooking gypsum.

Building plaster production technology

Technology production of building gypsum with a gypsum boiler TOS165 consists of three main technological stages: 1 - Crushing of gypsum stone, 2 - Drying and grinding of gypsum gravel, 3 - Cooking of building gypsum in a gypsum boiler TOS165.

Crushing gypsum stone

Crushing of gypsum stone with a fraction of 60 - 300 mm takes place in a jaw crusher.

The stone is loaded into the crusher's receiving hopper with a front-end or clamshell loader from the accumulation warehouse.

For the smooth operation of gypsum production, a 15-day supply of raw materials must be stored in the warehouse.

The gypsum stone is fed into the jaw crusher by a swinging feeder.

The size of the crushed gypsum fraction after the crusher is regulated by the size of the crusher's exit gap. After the crusher, gypsum gravel is fed for further processing to the grinding department and drying along the belt conveyor.

The crushing department is usually located outside the closed production room, in which drying, grinding and cooking of gypsum is carried out.

The crushed material after passing the iron separator is fed into the hammer axial mill.

Axial hammer mill is designed for fine grinding of crushed gypsum stone of medium hardness with its simultaneous drying. The material is fed into the mill by a swinging feeder from the supply hopper.

Gypsum powder ground and dried in a mill in a stream of hot gases enters the dust and gas cleaning system. Hammer axial mills belong to the group of high-speed hammer mills. The crushed stone is fed into the mill in the direction of rotation of the rotor. As a result of blows, the crushed stone is crushed into powder. The fineness of grinding material depends on the feed rate, the volume of the ventilating agent and on the angle of installation of the blades of the built-in separator. Exhaust flue gases of the gypsum boiler are used as a heat carrier and a ventilating agent.

The temperature of the flue gases at the entrance to the mill, depending on the selected thermal regime of gypsum firing in the boiler, can vary from 250 to 500 0 С.

Crushed, dried and separated to a residue of no more than 5-8% on a sieve No. 02, gypsum powder is carried out in a dusty air stream to the dust settling system. Cyclones are used as the first stage of purification, two-section TOS 3.8 bag filters are used as the second stage of purification. To eliminate the hanging of the material in the hopper of the cyclone, pneumatic impact devices are installed. The cyclone and the bag filter are thermally insulated.

Regeneration of the bag filter is carried out by back blowing the bags with compressed air when one of the sections is turned off by the automation system. As a fabric for the sleeves, a fabric of the "Metaaramid" type is used. The fabric withstands operating temperatures up to 230 0C. In the event of an unplanned increase in the temperature of the outgoing heat carrier above the specified temperature, the dilution damper installed in front of the filter opens automatically and the outside air enters the aspiration system. Compressed air is supplied with a temperature exceeding the dew point temperature by at least 5-10 0 С.

As a traction unit, a smoke exhauster Dn is used.

The powder caught by cyclones and filters by hose conveyors by screw conveyor system enters the heat-insulated raw meal bunker. Sluice gates are used to eliminate suction in cyclones and bag filters.

Building gypsum cooking - dehydration of gypsum powder occurs in a gypsum boiler with flue gases with a temperature of 600-950 0 C, supplied through external channels created by the boiler lining and flame tubes. The heat carrier in these passages is the products of combustion of gaseous fuel in the combustion chamber adjacent to the lining.

The coolant, passing through the channels in the boiler lining and flame tubes with a temperature of 250-500 0 C, without contact with the material, is taken out of the boiler. Gypsum in the digester does not directly come into contact with gases, its temperature is 121-160 0 C. The process of roasting gypsum is accompanied by an intensive release of water of crystallization. During this period, boiling of gypsum powder is observed.

The gypsum boiler is a vertical steel drum equipped with a stirrer and closed with a lid on top, equipped with nozzles for loading powder and removing a mixture of steam with gypsum particles.

The residence time of the material is regulated by the mode of loading and unloading, depending on the required temperature of the material inside the boiler. The material is fed into the boiler by a screw conveyor from the raw meal hopper. Loading performance is controlled by changing the number of revolutions of the screw conveyor. In continuous mode, raw gypsum is loaded continuously above the material level in the boiler through a nozzle installed on the boiler cover. The vertical discharge chute placed inside the boiler is open at the bottom.

The material is unloaded continuously by overflow from the top of the discharge chute. To improve the transportation of gypsum from the bottom of the discharge chute to the top, compressed air is supplied to the bottom with a pressure of 2 atm.

Vacuum in the smoke channels of the boiler is created by a smoke exhauster, which is also the traction unit of the axial hammer mill. Water vapor and gypsum particles formed during gypsum hydration in the boiler, as well as excess dust-air mixture of the languishing hopper are removed from the boiler. The semi-aqueous gypsum obtained in the gypsum boiler is unloaded into the languishing bunker.

Automated control system

Automated control system building gypsum production ensures the operation of all elements technological equipment in automatic, semi-automatic and manual modes to ensure technological process production of building gypsum.

The system is a complex of hardware and software that jointly perform the task of managing the process.

System architecture

The control system can be conditionally divided into three levels:

The lower (field) level is represented by sensors and actuators. As sensors in the system, there are temperature sensors, pressure sensors, level indicators, motor current control devices, inductive sensors, limit position indicators and additional contacts signaling the status and mode of operation of the engines.

The actuators of the system are motors with contactors for direct starting, motors with variable speed, controlled by frequency-controlled drives, electromechanical positioners for controlling the throttle valves of smoke exhausters and a switch for the direction of gypsum supply to the silos.

At the middle level, the system is represented by a programmable logic controller (PLC) with input-output modules for analog and discrete signals. The PLC is responsible for receiving signals from sensors and issuing control signals to actuators in accordance with the program embedded in it.

At the top level, the system is represented by a human-machine interface device. This is a computer connected to a controller industrial network, and with specialized software installed on it.

Controller equipment, switching and ballast equipment are supplied mounted in industrial cabinets. The instrument is supplied separately in its original packaging.

All ballasts, circuit breakers, contactors and VFDs manufactured by Siemens.

Programmable Logic Controller

The system uses a Siemens Simatic S7 300 controller as a PLC with a set of discrete and analog inputs and outputs, sufficient to connect all sensors and actuators, and with a reserve determined at the design stage.

The controller must be mounted in a cabinet, which must be installed in a control room with temperature regime 0-50 oC.

A brief description of the algorithms embedded in the controller will be discussed below.

Human Machine Interface

As a human-machine interface system, an operator station (OS) with an installed operating system Microsoft Windows XP and Siemens Simatic WinCC SCADA system. This station is connected to the PLC industrial network MPI to obtain information about the flow of the process.

The main functions of the OS are:

• Displaying the state of the technological process and equipment in the form of mnemonic diagrams, tables, trends and messages on the computer monitor.
• Providing the operator with the opportunity to adjust the technological modes of operation of the installation.
• Manual control of some elements of the installation.
• Display and archiving of emergency and service messages.
• Storage of historical data about the process with the ability to view them.

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Feasibility study (feasibility study) for the creation of a plant for the production of sand-lime bricks (article: 16760 29658)

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It is planned to build a new plant for the production of silicate bricks by the autoclave method in the Republic of Dagestan.

The key point in the project is that the project initiator owns a sand deposit, and sand is the main component in the production of sand-lime bricks.

The project provides for the acquisition modern equipment and machinery, construction of all necessary infrastructure (including the railway line), as well as providing the enterprise with its own fleet of vehicles.

Sales of products are expected in the Northwestern Federal District and the Southern Federal District, in all regions.

Project performance indicators

Simple payback period - ** months.

Discount rate - **%.

Discounted payback period - ** months.

Net present value (NPV) - *** thousand rubles.

Internal rate of return (IRR) - 25%.

Feasibility study

Calculations are made in EXCEL in the financial model.

Terms of Service

This project is individually finalized in accordance with the wishes of the client.

Project completion time: 10 working days.

1. Project summary

2.1. general description project and intended products

3. Production plan

3.1. Description of buildings and premises

3.2. Features of construction (repair) of premises

3.3. Construction cost calculation

3.4. Equipment Description

3.5. Description of the technological process

3.6. Other technological issues

3.7. Raw materials, materials and components

3.8. Production personnel

4. Organizational plan

4.1. Personnel plan (administrative and managerial personnel)

4.2. Organizational structure enterprises

4.3. Sources, forms and conditions of financing

4.4. Sales program

5. Project environment

5.1. Legal aspect

5.2. Environmental aspect

5.3. Social aspect

5.4. State regulation

6. Financial plan

6.2. Nomenclature and prices

6.3. Investment costs

6.5. Tax deductions

6.7. Cost calculation

6.8. Revenue calculation

6.9. Profit and Loss Forecast

6.10. Cash flow forecast

6.11. Project efficiency analysis

6.11.1. Project performance indicators

6.11.2. Methodology for evaluating the effectiveness of the project

6.11.3. Net Present Value (NPV)

6.11.3.1. Internal rate of return (IRR)

6.11.3.3. Payback period (PBP)

6.11.3.4. Discounted payback period (DPBP)

6.11.3.5. Project break-even point (BEP)

6.11.3.6. Other indicators

6.11.4. Investment efficiency

6.11.5. Profitability indicators

6.12. Project risk analysis

6.12.1. Qualitative Analysis risks

6.12.2. Quantitative risk analysis

6.13. Project Sensitivity Analysis

6.14. Project break-even point

7. Applications

7.1. Commercial offers from equipment suppliers

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Introduction

In recent years, dry building mixtures have been increasingly used in the construction industry, which are mixtures for various purposes carefully prepared at the factory, consisting of mineral binders, aggregates and fillers of strictly consistent granulometry and polymer modifying additives.

To impart special properties, the composition of the mixtures may include hardening accelerators or retarders, blowing agents and defoamers, coloring, water-repellent and other additives.

Unlike commercial mixes prepared according to traditional technology in a ready-to-use form, dry mixes are delivered to objects in a dry form. Bringing dry mixtures to readiness for use is achieved by mixing them with water in accordance with the manufacturer's recommendations. In some cases, after mixing the dry mixture with water, it is recommended to hold it for 10-15 minutes, then mix it again.

Dry building mixes have a number of significant advantages over traditional commercial mixes. These include:

stability of the composition, ensured by careful preparation and precise dosing of the components;

long-term storage before use without changing properties;

Possibility of transportation and storage at negative temperatures;

higher homogeneity of ready-to-use mixtures, since they are prepared immediately before use;

· increased cohesiveness of finished mixtures and, as a result, higher non-separation and water-retaining capacity;

better adhesion to the bases and higher strength of the applied layers;

the possibility of spending dry mixes in small portions as needed, which eliminates their irreparable losses;

Reducing material consumption due to the possibility of applying thinner layers;

· increase in labor productivity both due to the lower labor intensity of their application, and due to obtaining higher quality surfaces that do not require labor-intensive operations to prepare them for final finishing work.

Dry building mixes are produced, as a rule, in a wide range, which makes it possible to choose the best option for performing a particular type of work.

Feasibility study of the project

The mass application of new technologies in construction has become an impetus for the development of the production of dry building mixtures. Today it is one of the most profitable and dynamic industries. If the growth rate of demand (30% per year) continues for several more years, then there will be room for another 200-300 enterprises on the market, in addition to those 100 that are currently operating.

Approximately 25 years ago, when the wages of a West German builder reached 20 marks per hour, employers noticed how much time was spent on the regular preparation by hand of small (so as not to catch on) portions of mortar for plaster or tile encapsulation. Hence the decision arose: to mix cement with sand or gypsum, adding special chemical modifiers that provide mixtures with certain properties (depending on the purpose of the solution), in the factory, and in construction - only dilute it all with water.

The new technology allowed builders to process the whole room in the time that used to be spent on puttying one wall. The production of mixtures in the factory has opened up space for the introduction of know-how - the use to improve adhesion, provide mixtures with frost or water resistance of complex chemical modifiers, which an ordinary builder has no idea about.

This made it possible to produce separate mixtures for laying tiles in the habitable room and in the bathroom, for "black" and "finish" putty, for plastering walls in the room and on the facade of the house - all of which, to date, almost 300 types of dry building mixtures have been invented that are most adapted to certain type of work.

A stable demand for dry building mixes in Ukraine appeared when wealthy citizens rushed together to make European-style repairs, on which they spared no expense. It was then that the builders considered that although, per square meter, laying tiles on glue is three times more expensive than on mortar, but the cost of the material is in any case borne by the customer, and the quantity square meters, which can be put in at the same time, and, accordingly, the earnings of the masters themselves when using mixtures grow by 4-6 times.

On the other hand, foreign manufacturers of dry building mixes, seeing that more and more of their products are being sold in Ukraine, considered that the opening of production near the consumer would make the price competitive. Of course, domestic products, even under similar conditions, are almost always cheaper than imported ones, but in the industry of dry building mixes this competitive advantage appears especially brightly. Their main components are cement, sand, gypsum and chalk, and these are materials that are very unprofitable to carry over long distances. So “foreign investments” came to Ukraine in the form of equipment decommissioned by transnational companies from their Polish factories.

At the same time, domestic entrepreneurs also tried their hand at the production of dry mixes. Depending on who was counting on which market and how much money they had, they installed lines with a capacity of 5 to 100 thousand tons per year. For example, enterprises that are part of the group of market leaders - Henkel (TM Ceresit) Polyrem, Fomalhaut (TM Polymin), Pavlogradzhitlobud (TM BudMaister) have production capacity 50-100 thousand tons per year each.

They produce dry building mixes in Ukraine using equipment of various origins. Some bought production lines from Western firms that produced it in Germany or Poland "paying" from 40 thousand to 5 million dollars, depending on the capacity. For example, a line with a capacity of 5 thousand tons per year costs 40 thousand dollars, and an enterprise needs at least two lines - for cement-sand and cement-gypsum mixtures.

The Kyiv company "Miks", one of the founders of which is the ZhBK plant No. 5, has found a way to significantly save on equipment. “The plant had such a large and strong repair shop that we were able to manufacture equipment for the production of dry mixes on our own,” says Alexander Timko, director of the company, “and it turned out to be 10-15 times cheaper than bringing it from abroad.”

However, there is no longer any need to bring equipment from abroad - recently, after the Kiev company "Fomalhaut" bought out a controlling stake, it began to be produced by the Zhytomyr plant "Budmash".

In general, over the past 10 years, according to the estimates of the President of the Association of Producers of Dry Building Mixes, Yuriy Spektor, more than 100 firms and firms that produce dry mixes have appeared in Ukraine. In the next few years, according to Mr. Spector, their number may grow to 300-400, because the demand for dry mixes is growing rapidly. Over the past 5-6 years, it has increased from 2 to 10 kg per person per year, and in 3-4 years, market operators confidently predict its growth to 25 kg per year, that is, to the level that is already observed in Poland or Russia . Only during the current season, according to manufacturers, the market volumes will grow by 30-40% and exceed half a million tons, of which only 30% is able to "cover" imported products.

Such high growth rates of the market and optimistic forecasts have a serious background - the revival of multi-apartment housing construction and its current specifics. The fact is that housing is currently being built, performing finishing work separately for individual orders (elite housing), or transferring them on the shoulder of buyers (inexpensive housing). And in fact, and in the second case, people who are not poor buy apartments, and therefore, they are prone to the use of modern materials, in particular dry mixes. Another factor in the growth of the market for dry building mixes is the insulation of facades, during which heat-insulating mineral wool boards are glued to them with the help of dry mixes.

The prospects for further market growth attract investors, and in terms of profitability, the production of dry building mixes is not in last place. According to market operators, the profitability of the production of the simplest and cheapest mixtures, which are produced by almost all manufacturers (tile adhesive), barely exceeds 10%, but on high-tech expensive mixtures that contain up to 12-14 components (self-leveling floor, frost-resistant tile adhesives, decorative plasters), you can still have 20-25% profitability.

For some large and medium-sized firms, these figures are even higher, thanks to their own raw material preparation areas. The fact is that, despite the rather large domestic reserves, manufacturers of dry mixes to provide High Quality gypsum and chalk had to be imported.

“In the products of our gypsum factories, impurities larger than 0.18 mm (sand, earth and God knows what else) amounted to 5-15%, although for finishing putty even one such particle is already a marriage,” says Alexander Timko. Gypsum with the characteristics required by the producers of mixtures was produced only in Moldova, and chalk - in the Belgorod region.

Brought to Kyiv, Moldovan gypsum cost almost 400 UAH / t (domestic - 270 UAH / t), imported chalk also had to be overpaid twice. “When there were shortages with Moldovan gypsum, I was offended and bought a separator for $50,000. - said the director of the company "Fomalhaut" Sergei Ershov. Now the company can buy gypsum cheaper and without any harm to the quality of the final product.”

However, in the future, perhaps even next season, the need for self-preparation of raw materials may disappear. Experts expect that the new owners of the Stromgips plant in Artemovsk, the French group Lafarge, will produce products of acceptable quality for manufacturers of dry building mixes, not lower than that of Moldovan gypsum at the moment, at an affordable price. Therefore, the price of raw materials for dry building mixes and the cost of the necessary set of equipment can reduce the cost, so that production can become even more profitable.

Gypsum is construction material inorganic origin, which is suitable for creating solutions or objects. By itself, it is white and viscous, but has a gray tint. Its advantage is to quickly become hard. The disadvantage is that it does not hold water. Gypsum looks like a powder that thickens when interacting with a liquid. In air, this mixture becomes solid in a short time. Gypsum production is a profitable business, as there is always a demand for this material.

• Where to start the production of gypsum?
• Necessary equipment for production
• List of Documents Required to Start a Gypsum Production Business
• Tax regime
• How much can you earn on plaster?
• How much money is needed for production?

Where is gypsum used?

By type, gypsum is divided into building, high-strength, anhydrite and polymer.

Gypsum material is used for construction work:

• added to concrete
• dilute mortar for plaster or masonry
• used as a material for the manufacture of objects and molds

If concrete is diluted with powdered gypsum, then small houses and separate extensions to buildings can be built from this mixture.

Where to start the production of gypsum?

To start a business in this area, you will need a room to house the plant. It should be spacious enough (at least 100 square meters). The performance indicators are statistically good, since one enterprise of this kind can produce about 100 thousand tons of gypsum during the year. For effective work 30 employees will be required who will be directly involved in the dressing and manufacture of powdered gypsum, administration and production management.

Necessary equipment for production

Equipment for the production of gypsum in open conditions:

• surface miners
• hammer crushers
• roller pendulum mills
• flue boilers
• kilns for roasting

Combines without interruption crush the gypsum stone with the help of a drum. All parts of the mechanism are connected by clamps (bolts), in which cutters are built. On the cutting element there are inserts made of hard alloy.

The shape of the harvester segments is similar to the auger. They participate in two stages, which the technology provides, in extraction and transportation. The drum of the equipment is designed in such a way that the material entering the combine is sorted, since the raw material should not be more than 300 mm in size.

The segments are at a decent distance from each other, and the size of the teeth can vary. Without these parameters, the operation of the mechanism cannot be carried out. For the enterprise, the quality of the equipment that they purchase for subsequent operation is very important. German manufacturers occupy a leading position among all surface miner developers. And the concern for the construction of Wirtgen machines is considered the most prestigious.

Underground mining equipment

Underground mining of gypsum stone is widely used in large enterprises located in the locations of gypsum stones. For underground mining, autonomous chambers are used, with the help of which only what is needed for gypsum production is pulled out of the entire rock. Also, to select the desired material and clean workplace using the following equipment:

• core perforators, which are fastened with winches;
• machines for drilling deep into the rock;
• excavators acting as bulldozers;
• dump trucks.

Gypsum stone, located underground, looks like a layer with heterogeneous inclusions of clay, carbonate or sand. Since various components are included in the rock, they are crushed in different ways. Therefore, impact mills and crushers are used, which provide selective grinding, adapting to the degree of hardness of each impurity. This significantly reduces the cost of energy that is spent during the operation of the equipment. Less electricity is needed to grind less solid impurities. The selection of materials depends on the speed of the crusher.

Gypsum stone is loaded to the place where it will be dried with the help of pipes. A screw conveyor is used for transportation.

In terms of technology, rotary kilns are more suitable for firing. They work non-stop than digesters. Another advantage of ovens is that larger material can be processed in them. They are produced in lengths of 15 meters. With the help of the furnace, 5-15 tons of material can be fired within an hour.

Raw material

Gypsum is made from gypsum rock, which is located in a certain geographical area. Therefore, there are several options: either to purchase raw materials and make gypsum from it, or to open a plant on the territory of quarries with deposits of gypsum stones. In the first case, the cost of purchasing equipment for rock crushing will not be required.

But the second option also has its drawbacks - the high cost of transporting the finished material.

List of Documents Required to Start a Gypsum Production Business

Creating your own enterprise, which will specialize in the manufacture of gypsum, is possible only in the form legal entity, usually LLC or joint-stock company. The registration procedure with the Federal Tax Service, Rosstat, Pension Fund, social and medical insurance funds, in this case, is no different from paperwork for other areas of commercial activity.

You must prepare copies of passports and TIN of business organizers, founding documents firms, pay the state duty and write a corresponding application to the Federal Tax Service. Another important point! Do not forget that a code is provided for this industry, according to the All-Russian classifier, this OKVED 26.53.

In addition, for legal activities, you must have permits from Rospotrebnadzor, papers on compliance with the requirements of fire safety rules and on the compliance of your products state standards, and for enterprises that operate in foreign markets - the appropriate licenses.

Tax regime

Experienced businessmen are well aware that enterprises of such a level as gypsum producers are, as a rule, tax payers on a general basis. But there are rare exceptions when it comes to small firms, with poor performance. Their founders can write an application to tax office, on the choice of a simplified taxation system. It is much simpler and does not require deep knowledge of the basics. accounting, but this mode is not suitable for representatives of large businesses.

There are two ways in which you can get gypsum. The first method is underground, the second is open. Which one to use depends on the geological area in which the production of gypsum is located.

The entire production process is carried out in places where there are appropriate natural rocks suitable for processing. Gypsum dressing is carried out by special workers employed at the enterprise.

Open cast mining of gypsum

This method is very efficient and therefore economical. Raw materials do not deteriorate during processing, so there is quite a lot of finished powder. The technology of the process is based on the search for raw materials, their transportation and processing. It goes through several steps.

How much can you earn on plaster?

The gypsum business is quite profitable. The price for one kilogram of gypsum is 200-300 rubles. The amount of manufactured goods per day depends on the productivity of the equipment. Large enterprises produce more than 100 kg per day of powdered gypsum.

How much money is needed for production?

To open a business, at least 2 million rubles will be required, which will be used to purchase production lines, rent premises, install equipment, and more.

With a competent management approach, the business will pay off within two years.

The management of the gypsum factory must take into account the points that may adversely affect the health of workers. The authorities must provide the plant with all the necessary cleaning devices so that people do not breathe dust during the processing of raw materials.

A high-quality binder from gypsum rock is obtained only if the technology is followed. First, the raw materials are crushed with a combine, then dried and brought to a powder, after which they are fired.