Industry Overview
Commercial-grade calcium carbonate is manufactured primarily in two forms: Precipitated Calcium Carbonate (PCC) and Activated Calcium Carbonate. The two forms differ in coating characteristics, with activated calcium carbonate incorporating a coating that is not present in the precipitated form. Both are widely used as fillers or extenders across chemical and allied industries, including PVC, rubber, dentifrice, cigarette paper, printing ink, and pharmaceutical applications.
The project considers a precipitated-grade product mix capable of covering a broad range of grades based on particle size, shape, and distribution. These physical properties can be varied along with bulk density, flow point, viscosity, and other characteristics according to individual customer requirements. The project also considers Activated Calcium Carbonate with different coating arrangements, together with pressure filtration and drying systems designed to support consistent product quality. The manufacturing process includes limestone calcination, quicklime hydration, carbonation of lime slurry, filtration, drying, and related processing operations. The report further covers product properties, specifications, applications, testing methods, market aspects, technology development, manufacturing processes, plant layout, and suppliers of plant, machinery, raw materials, and packaging materials.
Cost Estimation
| Particulars | Details |
|---|---|
| Plant Capacity | 20 MT/Day |
| Land & Building (2500 sq.mt.) | Rs. 3.80 Cr |
| Plant & Machinery | Rs. 3 Cr |
| Working Capital for 2 Months | Rs. 92 Lac |
| Total Capital Investment | Rs. 7.83 Cr |
| Rate of Return | 13% |
| Break Even Point | 71% |
Content Index
- INTRODUCTION
- PROCESS
- CALCIUM COMPOUNDS
- CALCIUM CARBONATE
- PRECIPITATED CALCIUM CARBONATE
- CALCIUM CARBONATE
- USES AND APPLICATIONS
- PLASTICS
- PAINTS AND SURFACE COATINGS
- COSMETICS/TOOTH PASTE
- PAPER
- FOOD AND PHARMACEUTICALS
- PUTTY, CAULKS AND SEALANTS
- TYPICAL PHYSICAL PROPERTIES OF CALCIUM CARBONATES
- SPECIFICATIONS OF CALCIUM CARBONATE
- RUBBER INDUSTRY
- DESCRIPTION
- COSMETIC INDUSTRY
- REQUIREMENTS
- EXPLOSIVE AND PYROTECHNIC INDUSTRY
- TYPES
- REQUIREMENTS FOR CALCIUM CARBONATE – PRECIPITATED & ACTIVATED FOR PAINTS
- TERMINOLOGY
- TYPES
- REQUIREMENTS
- TABLE REQUIREMENTS FOR CALCRJM CARBONATE, PRECIPITATED AND ACTIVATED, FOR PAINTS
- PACKING AND MARKING
- PROPERTIES
- PROPERTIES OF PURE CALCIUM CARBONATE:-
- PROPERTIES OF CALCITE:-
- PROPERTIES OF ARAGONITE:-
- PROPERTIES OF LIMES AND LIME STONE:-
- COLOUR :-
- ODOR:-
- TEXTURE:-
- B.I.S. SPECIFICATION
- SCOPE
- REQUIREMENTS
- PACKING AND MARKING
- TABLE 1 REQUIREMENT FOR PRECIPITATED CALCIUM CAREONATE FOR COSMETIC INDUSTRY
- SAMPLING
- QUALITY OF REAGENTS
- DETERMINATION OF FINENESS
- APPARATUS
- CALCULATION:-
- DETERMINATION OF LOSS ON DRYING:-
- DETERMINATION OF BULK DENSITY:-
- APPARATUS:-
- CALCULATION
- WHERE
- DETERMINATION OF CALCIUM CARBONATE
- REAGENTS
- CALCULATION:-
- METHOD B
- TEST FOR MAGNESIUM AND ALKALI SALTS
- DETERMINATION FO ALUMINIUM IRON PHOSPHATES AND MATTER INSOLUBLE IN HYDROCHLORIC ACID
- TEST FOR IRON:-
- TEST FOR ARSENIC:-
- TEST FOR HEAVY METALS:-
- TEST FOR CHLORIDES:-
- DETERMINATION OF PH OF AQUEOUS SUSPENSION
- TEST FOR BARIUM:-
- TEST FOR SULPHATES:-
- DETERMINATION OF FLOW POINT
- SAMPLING OF CALCIUM CARBONATE, PRECIPITATED FOR COSMETIC INDUSTRY
- GENERAL REQUIREMENTS OF SAMPLING
- SCALE OF SAMPLING
- TEST SAMPLES AND REFEREE SAMPLE
- PREPARATION OF TEST SAMPLES
- NUMBER OF TEST
- CRITERION FOR CONFORMITY
- SCOPE
- TERMINOLOGY
- TYPES
- REQUIREMENTS
- PACKING AND MARKING
- SAMPLING
- TESTS
- METHODS OF TEST FOR PRECIPITATED AND ACTIVATED CALCIUM CARBONATE FOR PAINTS
- DETERMINATION OF PARTICLE SIZE DISTRIBUTION
- DETERMINATION OF LOSS ON IGNITION
- DETERMINATION OF INSOLUBLE SILICEOUS MATTER
- DETERMINATION OF CALCIUM CARBONATE
- METHOD B:-
- REAGENTS
- CALCULATION:-
- DETERMINATION OF TOTLA FATTY MATTER
- MARKET SURVEY
- INSTALLED CAPACITY AND PRODUCTION OF CALCIUM CARBONATE
- EXPORT OF CALCIUM CARBONATE
- CONSUMPTION PATTERN OF CALCIUM CARBONATE
- IMPORT OF CALCIUM CARBONATE
- INSTALLED CAPACITY, PRODUCTION & CAPUTILIZATION OF CALCIUM CARBONATE
- APPARENT CONSUMPTION OF CALCIUM CARBONATE
- ESTIMATED DEMAND
- GROWTH RATE IN ANNUAL DEMAND OF PRECIPITATED CALCIUM CARBONATE
- GLOBAL OVERVIEW CALCIUM CARBONATE
- GLOBAL CONSUMPTION PATTERN OF PRECIPITATED LIME STONE
- SWOT ANALYSIS OF PRECIPITATED CALCIUM CARBONATES
- MANUFACTURERS/SUPPLIERS RAW MATERIALS
- LIMESTONE:-
- TECHNOLOGY DEVELOPMENT IN PRECIPITATED CALCIUM CARBONATES
- TECHNOLOGY DEVELOPMENTS
- ACID TOLERANT TECHNOLOGY
- CHEMISTRY OF THE PROCESS
- 1. CALCINATION OF LIMESTONE:-
- 2. HYDRATION OF QUICKLIME (MANUFACTURE OF MILK-OF-LIME SUSPENSION:-
- 3. CARBONATION OF MILK-OF-LIME TO PRODUCE CALCIUM CARBONATE
- PRECIPITATED CALCIUM CARBONATE PRODUCTION
- BURNING OF LIME:
- LACKING OF QUICKLIME
- PRECIPITATION
- MANUFACTURING PROCESS OF PRECIPITATED LIME STONE
- PROCESS FLOW DIAGRAM
- STEPS IN PRECIPITATED CALCIUM CARBONATE MANUFACTURE
- PROCESS IN DETAILS
- CALCINATION OF LIMESTONE TO PRODUCE QUICKLIME & CHEMICAL LIME
- HYDRATION OF QUICK LIME (MANUFACTURE OF HYDRATED LIME)
- CARBONATION OF LIME SLURRY WITH CARBON DIOXIDE GAS
- FILTERATION AND DRYING
- MANUFACTURE OF ACTIVATED CALCIUM CARBONATE
- CO2 GAS PURIFICATION
- PROCESS FLOW SHEET OF PRECIPITATED CACO3
- PRODUCTION OF INDUSTRIAL FILLERS BASED ON CALCIUM CARBONATE
- GCC PRODUCTION
- PCC PRODUCTION
- HIGH SPEED MANUFACTURING PROCESS FOR PRECIPITATED CALCIUM CARBONATE
- SYNTHETIC METHOD FOR PRECIPITATED CALCIUM CARBONATES
- TECHNICAL SPECIFICATION OF PRECIPITATED CALCIUM CARBONATES
- TECHNICAL DATA SHEET
- PRODUCT NAME / REFERENCE
- MAIN INTENDED USE
- CHEMICAL DESCRIPTION
- PACKAGING
- MATERIAL SAFETY DATA SHEET FOR CALCIUM CARBONATE (PRECIPITATED) FOR FOOD APPLICATION
- DESCRIPTION
- MAIN USES
- STANDARD SPECIFICATIONS
- TYPICAL BULK DENSITY
- TRANSPORT AND STORAGE CONDITIONS
- SAFETY DATA
- PLANT LAYOUT
- SUPPLIERS OF PLANT & MACHINERIES
- ROTARY KILNS
- JAW CRUSHER
- BUCKET ELEVATOR
- ROTARY DRYER MANUFACTURERS & EXPORTERS
- PULVERIZERS
- CENTRIFUGE
- HEAT EXCHANGER
- EFFLUENT TREATMENT PLANT (ETP PLANT)
- BOILERS
- MATERIAL HANDLING EQUIPMENTS
- LABORATORY EQUIPMENTS
- SUPPLIERS OF RAW MATERIALS
- PACKAGING MATERIALS (HDPE WOVEN LAMINATED BAGS)
Appendix
- APPENDIX – A:
- 01. PLANT ECONOMICS
- 02. LAND & BUILDING
- 03. PLANT AND MACHINERY
- 04. OTHER FIXED ASSESTS
- 05. FIXED CAPITAL
- 06. RAW MATERIAL
- 07. SALARY AND WAGES
- 08. UTILITIES AND OVERHEADS
- 09. TOTAL WORKING CAPITAL
- 10. TOTAL CAPITAL INVESTMENT
- 11. COST OF PRODUCTION
- 12. TURN OVER/ANNUM
- 13. BREAK EVEN POINT
- 14. RESOURCES FOR FINANCE
- 15. INSTALMENT PAYABLE IN 5 YEARS
- 16. DEPRECIATION CHART FOR 5 YEARS
- 17. PROFIT ANALYSIS FOR 5 YEARS
- 18. PROJECTED BALANCE SHEET FOR (5 YEARS)
Frequently Asked Questions
Precipitated calcium carbonate (PCC) is a manufactured form of calcium carbonate produced through a controlled chemical precipitation process. It is used as a filler or extender in industries where particle size, shape, distribution, and other physical properties need to be controlled. PCC is used in applications such as plastics, paints and surface coatings, paper, rubber, cosmetics, dentifrice, food, and pharmaceutical products. Its characteristics can be adjusted to meet different application and customer requirements.
Activated calcium carbonate is a coated form of calcium carbonate designed to provide modified surface characteristics. The coating can influence properties such as compatibility, dispersion, flow, and interaction with other materials. Activated grades are commonly considered for applications where surface treatment improves the performance of calcium carbonate as a filler or extender. The report specifically considers different coating arrangements along with pressure filtration and drying systems for producing a consistent quality product.
Calcium carbonate is widely used as a filler or extender across several industrial sectors. Major applications covered in the report include plastics, rubber, paints and surface coatings, paper, cosmetics and toothpaste, food and pharmaceuticals, putty, caulks and sealants, and other chemical applications. The suitability of a particular grade depends on requirements such as particle size, particle shape, distribution, purity, bulk density, flow characteristics, and other product properties.
Precipitated calcium carbonate is manufactured through a sequence involving limestone calcination, quicklime hydration, carbonation, filtration, and drying. Limestone is first processed to produce quicklime, which is hydrated to form a lime slurry or milk-of-lime suspension. Carbon dioxide is then introduced to carbonate the slurry and precipitate calcium carbonate. Subsequent filtration and drying produce the required product. The report also discusses CO2 gas purification and alternative production approaches for industrial calcium carbonate fillers.
Limestone is the principal raw material identified in the report for precipitated calcium carbonate production. It is processed through calcination to produce quicklime, followed by hydration and carbonation. The quality and characteristics of the limestone can influence the quality of the resulting calcium carbonate. The report also includes sections covering suppliers of raw materials and packaging materials, reflecting the importance of raw-material sourcing and supporting materials in establishing a calcium carbonate manufacturing operation.
Calcium carbonate manufacturing can require a range of process and utility equipment depending on the selected process and product grade. Equipment covered in the report includes rotary kilns, jaw crushers, bucket elevators, rotary dryers, pulverizers, centrifuges, heat exchangers, effluent treatment plants, boilers, material handling equipment, and laboratory equipment. The appropriate equipment configuration depends on raw-material characteristics, product specifications, process design, capacity, filtration and drying requirements, and the desired quality of the final calcium carbonate.
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