Home » Project Reports & Profiles » Cenosphere Processing - Manufacturing Plant, Detailed Project Report, Profile, Business Plan, Industry Trends, Market Research, Survey, Manufacturing Process, Machinery, Raw Materials, Feasibility Study, Investment Opportunities, Cost And Revenue

Cenosphere Processing - Manufacturing Plant, Detailed Project Report, Profile, Business Plan, Industry Trends, Market Research, Survey, Manufacturing Process, Machinery, Raw Materials, Feasibility Study, Investment Opportunities, Cost And Revenue

The word Cenosphere is derived from two Greek words Kens (hollow) and Sphaira (sphere). Cenospheres are light weight, inert hollow sphere comprising largely of silica & alumina and filled with air or inert gas. Cenospheres are a naturally occurring by product of the burning process of pulverized coal fired boilers. They are formed during the molten state of ash and attain spherical shape to have minimum surface tension. Any gas bubbles (generally inert gases e.g. N2, Co2, unburnt coal particles etc.) flowing along the combustion gas stream, are also trapped inside the spheres. These bubbles cause the production of Cenosphere; bubbles may occur in multiple forms within the frozen particles, or as a single, concentric form, that are nearly as great as the diameter of the particle. They are found floating on the surface of fly ash lagoon. Cenospheres are unique free flowing powders composed of hard shelled, hollow, minute spheres. A small proportion of the pulverised fuel ash (PFA) produced from the combustion of coal in power stations is formed as Cenospheres. Cenospheres are made up of silica, iron and alumina. Cenospheres have a size range from 1 to 500 microns with an average compressive strength of 3000+ psi. Colors range from white to dark gray. They are also referred to as microspheres, hollow spheres, hollow ceramic microspheres, micro balloons, or glass beads. Cenosphere are chemically inert & are reclaimable and labeled as Environmentally sound. Advantages The Advantages of Cenospheres are: Spherical Shape, Lightweight, Inert, Free Flowing, Insulating, High Melting Point, Hard, Electrical Properties, Low Oil Absorption & Good Packing Factor Applications Cenospheres is versatile filler with applications in a wide variety of products, both commercial and industrial. These are as diverse as oil well cementing and PVC cushion vinyl flooring. However, in each case, Fillite is used for its unique properties, such as strength, low density and chemical resistance. Below are the main applications areas in which Fillite is commonly used. Applications in Polyurethane, Cement, Latex Emulsions, PVC, Epoxy Resins & Unsaturated Polyester Resins. Market Survey Cenosphere are a by-product from coal ash. These hollow light weight spheres are produced around the world. Most all of the Cenosphere produced today are recovered from ash ponds or lagoons typically onsite at the coal fired power plant. Fly ash, or the residue from coal after combustion, has been a long-standing challenge for the Indian power sector, which is dominated by coal. Currently, 53 per cent of the total installed power capacity in the country is based on coal. Given that Indian coal has a very high ash content, in the range of 35 to 45 percent, the country currently generates approximately 160 million tones of fly ash, of which only 80 million tones is being utilized. Cenosphere Processing is a 100% export oriented Unit. Improvements in the durability and strength of manufacturers’ end products and a reduction in product weight enhance marketing strategies. SSI (Sphere Services Inc) was one of the first companies to introduce Cenosphere to the world on the internet. Since that time the Cenosphere have become more widely used and demand has increased for the product. Since the demand has increased supply has been coming from overseas from other Countries. Sometimes new suppliers will have trouble developing quality control measures for the material. Having a quality product chemically and physically on a consistent basis is critical for the end use customer.
Plant capacity: 480 MT/AnnumPlant & machinery: 57 Lakhs
Working capital: -T.C.I: Cost of Project : 132 Lakhs
Return: 27.00%Break even: 59.00%
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