(Text Extract)Feasibility study report for daily output roofing tile 25,000pcs or split tile 3000m2

Feasibility study report (Text Extract)

Chapter 3 Proposal design

I Proposed production scale and design

 The complete production line can according the market to produce glazed tile and split tile at the same time or produce single product alone. Proposal production scale is daily output 25,000 pcs glazed tile or 3000M2 split brick, calculation based on normal production time 11 month, the annual output is 8,250,000 pcs glazed tile or 990,000M2 split tile.

1 Proposal for glazed clay roofing tiles

Mainly produce 310X310mm glazed clay roofing tile considering produce 280X280, 200X200 and other specifications and accessories.

2 Proposal for split tiles

Mainly produce 240X240MM broom-finish outer tile, at the same time can produce 115X250 square brick, floor tile and 96X200 wooden grain brick. It also can produce 50X240, 52X240, 115X240 and other specification brick by change mould and cutting length.

II Product quality standards

Product quality takes current Chinese building material industry standard, clay roofing tile use JC708-1998《Sintering tile》as standard. Main parameters as below:

①.Water absorption: 《=12%

② . Anti-bending strength: Ridge tile less than 1020N, S tile less than 1600N

③ .Thermal stability: 130±2℃-15±5℃ do not crack in three times

④ .Anti-frozen:  -20±3℃-15-25℃ 15 time within 3 hours do not damaged

⑤ .Allowed size difference

   Specification    Allow difference   Allowed distortion

     250≤B≤350       ± 4mm               ± 5mm

200≤B<250       ± 3mm                ± 4mm

 Split tile take JC/T457-2002《Extruded ceramic—fine stoneware tile》as standard, main technical parameter as below:

①    Water absorption: not more than 6%.

②    Fast cooling and heating stability: No crack and explosion during the experiment.

③    Anti-freezing: No crack and glaze take off during freezing 20 times.

④    Bending strength: the average value is not less than 20MPa, single value is not less than 18MPa.

⑤    Wear resistance: Non glaze brick volume loss is not more than 400m2. Glaze brick need the two sides agreed.

⑥ Anti-chemical corrosion: a. Acid resistance: The mass losses will not more than 4% when corrosion been takes place for Non-glaze brick, glazed brick not less than degree B. b, Alkali resistance The mass losses will not more than 10% when corrosion been takes place for Non-glaze brick, glazed brick not less than degree B

III Production technology design

  1. Production technology process

The material preparation of glazed clay tile and split tile are the same (the material formulas are not the same). Per inspection, the qualified material have been stock in raw material silo respectively, according to the formula weighting and batching the material, than use forklift sent to box feeder to put material uniformly into Lemon grinder, after crushing, the material powder will be sent to silo for stock, a belt conveyor will sent the raw material powder to double shaft mixer for mixing with water, then sent to a screen feeder for granulation, then stock into aging room.

Glaze clay roofing tiles production: After aging, the material will be sent to boxer feeder by forklift, the boxer feeder uniformly put the material into vacuum extruder for forming, after auto press machine press the tile, tiles will be load to drying frame automatically, after drying and auto glazing, it is fired in the tunnel kiln after double drying.

Split brick production: After aging, the material will be sent to boxer feeder by forklift, the boxer feeder uniformly put the material into vacuum extruder for forming,  tiles will be load to drying car manually, after drying, manually load the tile into kiln car, than fired in the tunnel kiln after double drying. The fired brick will be splitting by splitting machine automatically, than inspect for warehousing.

 (1)   Material preparation:

Weighting and batching→use forklift to 15m3 Box feeder(1 set) →belt conveyor→Lemon grinder(15T/h, 1 Set) →material bin(charging bucket 1~2) →belt conveyor→double shaft mixer(add water)(1 set) →belt conveyor→screen feeder→belt conveyor→Aging chamber(Chain type)(3 set)

(2)   Split tile forming technological process:

Aging room→Belt conveyor→5m3 box feeder→belt conveyor→de-airing extruder→turn plate tile cutting machine→drying car(manual) →tunnel drying kiln→manual unload drying car→manual load kiln car→second drying kiln→tunnel kiln→auto splitting machine→inspection and warehousing

3Clay roofing tiles production line

Aging room→Belt conveyor→5m3 box feeder→belt conveyor→de-airing extruder→tile cutting machine→tile press→auto load drying car→tunnel drying kiln→auto unload drying car→auto hang tile machine→auto glazing machine→manual load kiln car→second drying kiln→tunnel kiln→auto splitting machine→inspection and warehousing

2.Main production technological parameters

According to customer local material condition laboratory test, determine main production technology parameters as below:

① Raw material granularity preparation: 40   mesh    for glazed clay roofing tile, 80 mesh for split tile

② Ageing period: 》=24h

③ Extruding moisture: 17-19%

④ Max. first drying temperature is 50-85℃, drying period is 24h, residual moisture<5%

 ⑤ Max. second drying temperature is 120-200℃, drying period is 8-10h, , residual moisture<0.5%

⑥ Max. firing temperature for clay roofing tile is 1050-1200℃, firing period is 17H

⑦ Max. firing temperature for clay roofing tile is 1170-1210℃, firing period is 21H

IV Material balance

1Tile body material110T/day

1.1 Clay roofing tile calculation based on below parameters:

Tiles size

310X310

Tiles weight

3.2kg

Firing loss

6%

Product Qualified Rate

95%

Clay loss

5%

Design allowance

15%

Daily clay consumption for roof tiles: 25000*0.0034/〔0.95*(1-5%)〕*1.15=108T

1.2 Split tile calculation based on below parameters:

Tiles size

240X60X11

Tiles weight

21kg

Firing loss

6%

Product Qualified Rate

90%

Clay loss

5%

Design allowance

15%

Daily clay consumption for split tiles 3000*0.021/(0.94*0.9*0.95) *1.15=90T

According below calculation, design clay consumption is 78~90T, considering to design allowance, daily actual material preparation capacity should be 110T

2 Glaze: 1.7T/day

Split tile no need glaze, clay roofing tile size based on 310X310mm, glaze loss is 10%, design allowance is 15%, daily glaze consumption is 0.050*25000/0.9/0.85=1.7T

  2 Fuel: generator gas (heat value 1200Kcal) around 37000m3/day

According related factory date, our experience, test and calculation:

 25000m3*3000m2/2200m2=34000m3

Split tile: According related factory date, our experience, test and calculation, energy consumption for split tile is 13636 kcal/m2 or 13636/`8=757 kcal/kg, when capacity is 3000m2/day, coal gas consumption is around :

25000m3*3000m2/2200m2=34000m3

Clay roofing tile: According related factory date, our experience, test and calculation, energy consumption for split tile is 1786 kcal/pcs or 1786/8=558 kcal/kg, when capacity is 25,000pcs/day, coal gas consumption is around:

 5000*1786/1200=37208m3

From above calculation, we select gas furnace model ¢2.4mm or ¢2.6mm, daily coal consumption is 12~15T.

4. Water consumption 50T/day

As adopt dry powder production technology, the water consumption mainly is used for powder humidification, extruding moisture is around 20%, raw material process requirement is 110T, needed water is around: 110/0.8*0.2=27.5, water consumption for glaze is around 17*0.8=1.36T, besides water consumption for clean, cooling and staff daily consumption, the total daily water consumption will be not more than 50T.

Detail list show as below chart 1.

Chart 1 Material consumption chart

Yearly consumption

Monthly consumption

Daily consumption

Remark

Clay

36300T

3300T

110T

Glaze

561T

51T

1.7T

Water

16500T

1500T

50T

Electricity

Material preparation workshop

3133020Kwh

284820Kwh

2201kwh

Around 200KWX12.8h*0.86

Forming workshop

4816Kwh

Around 280KW*20h*0.86

Firing workshop

2477Kwh

Around 120KW*24h*0.86

Coal(coal gas)

4950T

450T

15T

Heat value 5000Kcal/kg

 V Machines selection

    Main equipments selection principle:

1. Raw material preparation machines selection

Daily raw material process requirement is 110T, working time is 2 shifts, each shift is 8 hours, supposed average effective working time is 80%, machine normal working time is 16*0.8=12.8h, so raw material process capacity is required 110/12.8=8.59T/h.

According to designed production technology, raw material need crush and grind by Raymond grinder firstly, the machine capacity is 8.59T/h, and material granule should pass 80 meshes. We suggest use 5R(5 grinding head, inner diameter of head is 1200mm) Raymond grinder.  Box feeder, storage bin, double shaft mixer, pug mill, de-airing extruder is selected according to raw material process capacity requirement, the details show as below chart 2.

2. Forming machine selection

When produce clay roofing tile, daily output 25000pcs, qualify rate based on 95, design allowance based on 10%, required forming capacity is: 25,000/(0.95*0.9)=29,000pcs/day

Core equipment of clay roofing tile machine use WYJ-100 fully automatic press, the capacity is 15pcs/min, daily working time is three shift 24 hours, supposed effective working time is 85%, thus a press daily capacity is 15*60*24*85%=18360pcs/set, it need 2 sets when capacity meet 29,000pcs, at the same time, it also need two sets of small box feeder, de-airing extruder, cutting machine.

When produce split tile, TCJ 350 de-airing extruder daily capacity is 1200m2, for meeting daily capacity 3000m2, the green split tile capacity should meet 3000/0.9=3300m2, thus it need 3 set de-airing extruders.

According to calculation and related experience, the machines selection as below chart 2.

3. Drying and firing kiln selection

1The first time dryer

Drying car design

For save investment and easy operation, designed drying car of clay roofing tiles and split tiles are the same. Each drying car has 6 layers.

Length: The length of wet green tile is 260-270mm, designed based on 2900mm, 2900mm*6=1.74m

Width: The width of wet green tile is 37mm, designed based on 50mm, 20*50mm=1.1m.

Height: considering producing width 115mm split tile, wet green tile is 127mm, space between layers is 140mm, layer frame steel thickness is 30mm, thus effective length is 170*6=1020mm.

Designed diameter of drying car wheel is ¢200, bottom frame steel thickness is 50mm, axle is ¢30mm, thus total length of drying car is 1020+100+50+15=1185mm

According to above date, designed drying car specification is: 1.75(L) X1.1 (W) X1.2m (H)

Dryer design:

Height: according to drying car specification, designed dryer length is 1.25m

Width: 2 sets side by side, thus the designed width is 1.1*2+0.2=2.4m

Length: According to customer raw material condition, the split tile drying time is 24 hours, according deign experience, design length for each dryer is 60m, thus hours moving length is 60/24=2.5m/h, drying car enter speed is 2.5/1.75=1.428car/h, enter period interval is 60/1.428=42min, enter times is 24*60/42=34time/day, every dryer include drying car 68 sets, every kiln car capacity is 20.5m2, thus every dryer drying capacity is 68*20.5=1394m2/day,3300/1394=2.36, when produce split tile, dryer needed: 3300/1394=2.36, thus need 3 sets.

When produce clay roofing tile, every layer only can place 3 lines and 5 rows, total 6 layers, thus each kiln car can place clay roofing tile 72 pcs. When drying period is 17h, 60/17=2.52m/h, every dryer daily capacity is 24*3.52/1.75*2*97*72=6984pcs, for meeting daily output 25,000pcs, dryer need: (25000/0.95)/6984=3.76, thus need 4 sets.

Considering producing both of clay roofing tile and split, the final design is 4 sets.

Drying car quantity: inside dryer is 4*60*2/1.75=274 sets

Outside dryer is 76 sets, total is 350 sets.

2The second time dryer

The inner width of the second time dryer is the same with tunnel kiln, according to design experience, designed length is 60m. At the same time, for guarantee thermal supply is enough, it required a coal gas hot stove with diameter 1.2m.

3Tunnel kiln design

Kiln effective inner width is 2.6m, effective inner height is 0.45m, kiln car specification is 2.6×2.5m, according production technology requirement, firing period is 14 hours, calculate kiln length as below:

When produce clay roofing tile, every kiln car can load 310X310 S shape tile in 6 lines and 6 rows, total 350pcs/car, take quality rate as 95% for calculation, kiln loading capacity should meet 25000/95%=26316pcs, 26316/360=73.1/24=3.04(car/h)or 24*60/73.1=19.73min/car, finished firing within 14 hours thus the total length is 14*60/19.73*2.5=106.4m,

When produce split tile (240X60X11), every car can load tiles in 55 rows, 8 lines, and 5 layers, total is 55*8*5/35=62.86m2/car.

For meet daily capacity 3300m2, it required 3300/62.86=52.4car/day, as 52.4*2.5/24=5.46m/h, firing period is 20 hours, thus the total length is 20*5.46=109.2m.

 The final kiln design is : LXWXH=110MX2.6MX0.5M

 Chart 2 Equipment list and quotation                       

SN

Name

Model

QTY

Unit Price

Amount

Remark

1

Box feeder

TCIW15

1set

2

Raymond grinder

1set

Already have

3

Double shaft mixer

1set

4

Pug mill

TCJ250

1set

 Already have

5

Box feeder

TCIW5

3set

6

De-airing extruder

TCJ350

3set

7

Auto cutter

WDQ-Ⅱ

2set

8

Auto tile press

 WYJ100-1

2set

9

Auto dryer load system

WDZ-1

1set

Include tile tray conveyor

10

Auto dryer unload system

WDX-1

1set

Include tile tray conveyor

11

Auto glaze system

WDSGW-1

1set

Include tile tray conveyor

12

Turn plate cutter

WDQ-5

2set

13

Splitter

KZ-13

1set

14

Ball mill

ZQ1

2set

15

Dryer

16

Tunnel kiln

110m

(include kiln car 90 sets)

17

Gas stove

¢2400-2600

1set

 Already have

Total

401.3

 VI Size of personnel force

People needed for split tile production is more than clay roofing tile when forming and inspection, the detail as below chart 3 and chart 4

Chart 3 size of personnel force for split tile production

 S/N

Item

People/shift

Shifts

People

Remark

01

Raw material preparation

3

2

6

Include forklift driver

02

Forming

12

2

24

03

Kiln load

4

3

12

04

Firing

2

3

6

Include enter and exit kiln

05

Kiln unload

4

3

12

06

Inspection

1

10

10

07

Electrician

1

3

3

08

Maintenance

1

3

3

09

Technologist

1

2

2

Total

78

Chart 4 size of personnel force for clay roofing tile production

 S/N

Item

People/shift

Shifts

People

Remark

01

Raw material preparation

3

2

6

Include forklift driver

02

Forming

3

2

6

03

Kiln load

4

3

12

Include glazing worker

04

Firing

2

3

6

Include enter and exit kiln

05

Kiln unload

2

3

6

06

Inspection

4

1

4

07

Electrician

1

3

3

08

Maintenance

1

3

3

09

Technologist

1

2

2

Total

48

VII Installed capacity

SN

Item

Model

Qty

Motor power

Total KW

1

Box feeder

TCIW15

1

7.5+2.2

9.7

2

Raymond grinder

1

75+55+7.5+15

152.5

3

Stock bin

2

4

Double shaft mixer

22KW

1

22

22

5

Pug mill

TCJ250

1

30

30

6

20M3 chain type aging chamber

 TCIW20

3

7

Box feeder

TCIW5

3

7.5+2.2

29.1

8

De-airing extruder

TCJ3505

3

55

165

9

Auto cutting machine

WDQ-Ⅱ5

2

0.75

0.75

10

Auto tile press

WYJ-100

2

6.6+7.5

28.2

11

Auto drying car load machine

WDZ-1

1

7.5

7.5

12

Auto drying car unload machine

WDX-1

1

7.5

7.5

13

Auto hang tile machine

WDSGW-1

1

1.8

1.8

15

Auto glazing machine

WDSY-Ⅰ

1

2.2

2.2

16

Manual glazing machine

WDSD

1

2.2

2.2

17

chain delivery machanism

WDLT

1

3.0

3.0

18

Basket device

WDDL

1

30

3.0

19

Turn plate cutter

WDQ-5

3

1.1

4.4

20

Splitter

KZ-13

1

4.0

4.0

21

Belt conveyor

140

5.5X10

55

22

Ball mill

ZQ1.0

2

15

30

23

Dryer and kiln

120

120

Total

664.65

 Chapter Four Economic and Efficiency Analysis

I. Total investment computation

Investment orientation

Area

Unit price

Amount

Water and power system

15.0

Workshop

3000m2

500

150.0

office building

580m2

750

43.5

Workers Dormitory

580m2

550

31.9

Others

20.0

Sub total:

260.4

Machinery and kiln

401.3

Unexpected pay

20

Working capital

100

 Total

781.7

 II .Production cost analysis (USD: RMB=1:6.3)

According domestic condition and actual customer local condition,

1.Clay roofing tile production cost computation: 1.647Yuan/pcs

1)        Raw material cost: RMB 0.17+0.22=0.39 Yuan/pcs

Clay cost: Single S shape clay roof tile weight is 3.2kg, clay consumption is around 4.2kg, clay price is around RMB 40yuan/Ton, clay cost is 4.2*0.04=0.17yuan/pcs. Glaze cost: bright glaze is 5000~8000yuan/Ton, matte glaze is 1500~4000yuan/T, supposed average price is 4000yuan/T, every tile cost glaze is around 55g, 0.055*4=0.22yuan/pcs.

2)        Labor cost: 0.10Yuan/pcs

The production line is semi auto clay roofing tile production line, need 50 labors, according customer’ local condition, average salary is 1500 Yuan/month,  1500*30/(25000*30)=0.10 Yuan /pcs

3)        Fuel cost: 0.4 Yuan/pcs

From above material balance computation, 37280m3 coal gas can produce 25,000pcs, coal consumption is 12~15T, coal price based on 800Yuan/T, thus 800*15/25000=0.48Yuan

4)        Water consumption0.003Yuan/pcs

Daily output 25,000pcs clay roof tile need clay around 100 tons, according to 20% proportion to add water is 20 tons, considering to other water consumption, the total water consumption for a clay roof tile plant will not exceed 50 tons/month, water price based on 1.5yuan/ton, the cost is 1500*1.5/(30*25000)=0.003yuan/pcs.

5)        Electricity consumption: 0.144Yuan/pcs

0.144yuan/pcsThe clay roofing tile production line installed capacity is around 600KW, daily electricity consumption is 6000Kwh, 6000/25000=0.24kwh,electricity price is 0.6RMB/degree, thus 0.24*0.6=0.144=0.144Yuan/pcs

6)        Maintenance0.07 Yuan/pcs

According to the experience of related the same capacity tile factory, monthly maintenance charge is RMB 50,000Yuan, thus 5/2.5*30=0.07Yuan/pcs

7)        Management expenses: 0.11Yuan/pcs

The clay roofing tile production line installed capacity is around 600KW, daily electricity consumption is 6000Kwh, 6000/25000=0.24kwh,electricity price is 0.6RMB/degree, thus 0.24*0.6=0.144=0.144Yuan/pcs

8)        Depreciation expense: 0.14Yuan/pcs

Plant building investment is RMB5,450,000, depreciation time is supposed be 20 years, machinery and kiln investment is RMB 1,054,000, depreciation time is supposed be 10 years, residual value is supposed be 5%, thus (545*0.95/20+1054*0.95/10)/12/2.5/30=0.14Yuan/pcs

9)        Tax 0.21

According to local law, the turnover tax rate is 6%, the other tax is around 10% of turnover tax, the sales price is supposed be 3.2Yuan/pcs, thus 2.5*30*11*3.2 *0.06/825 *1.1=0.21Yuan/pcs

Yearly total tax: RMB 825*0.21=1,730,000

 

2. Split tile production cost calculation

1)        Raw material cost:2.8

Clay consumption is around 28kg/m2, material price is supposed be 100Yuan/t, material cost is 2.8Yuan/M2.

2)        1.90 Electricity consumption

Actual electricity when producing split tile is 3.8Kwh/m2, thus production cost is 3.8X0.5=1.90Yuan/m2

3)        4.0 Coal consumption

Take daily coal consumption is 15T for calculation, coal price is RMB 800Yuan, daily output split tile 3000m3, thus coal consumption is 800*15/3000=4.0Yuan/m2.

4)        2.0 Salary

Average monthly salary is 1500Yuan according customer local condition, total 80 staff, thus 1500×80/9000=1.4Yuan/m2

5)        0.03 Water consumption

Daily water consumption is 20T, the price is 2Yuan/T, thus 50*2=/3000=0.03Yuan

6)        1.80/m2 Packing 1.80Yuan/m2

Used carton for packing, at present the packing expense is 1.2Yuan/m2.

7)        According customers actual condition, maintenance expense is 0.6Yuan/m2.

8)        Depreciation expense 1.17

Monthly depreciation expense is 105,000Yuan; monthly capacity is 90,000m2, thus 10.5/9=1.17Yuan/m2

9)        Management expense 0.89Yuan/m2

According the same capacity factory experience, management cost is 80,000Yuan/Month, 8/9=0.89Yuan/m2.

10)    Tax 1.98

According to local law, the turnover tax rate is 6%, the other tax is around 10% of turnover tax, the sales price is supposed be 30Yuan/m2, thus 3000*30*6%*1.1/3000=1.98Yuan/m2

  Yearly total tax: RMB 1.98*0.3*30*11=196,000Yuan

 

III Yearly production cost= yearly capacity*unit cost

Clay roof tiles: 1.647*8250000=13,587,800

Split tiles: 16.12*99=15,958,800

IV Yearly sale amount= yearly sales quantity*unit price

Mainly produce S310X310 clay roofing tiles, sales price is 3.2~3.5Yuan/pcs, split tile price is 30~35Yuan/m2.

Produce clay roofing tile: 3.2*8250000=26,400,000

Produce split tile: 30*990000=29,700,000.

V Yearly profit= Yearly sales amount-yearly production cost

Produce clay roofing tiles: 2640-1358.78=12,810,000Yuan

Produce split tile: 2970-1596=13,740,000Yuan

VI Rate of return on investment= Yearly profit/total investmentX100%

Produce clay roofing tiles:1281/1949.8*100%=657%

Produce split tile:1374/1949.8*100%=70.47%

VIII Investment recovery period=1/ Rate of return on investment

Produce clay roofing tiles:1/0.657=1.5 years

Produce split tile:1/0.7047=1.4 years

 

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