Detailed Project Report (DPR) on cement grinding unit

CEMENT GRINDING UNIT

[CODE NO.4099]  

Cement is a material with adhesive and cohesive properties which make it capable of bonding minerals fragments into a compact whole. For constructional purposes, the meaning of the term "cement" is restricted to the bonding materials used with stones, sand, bricks, building stones, etc.

TYPES OF CEMENTS:

Cement may be hydraulic or non-hydraulic: 

1) Non-hydraulic cements (e.g. gypsum plaster) must be kept dry in order to retain their strength. 

2) Hydraulic cements harden because of hydration, chemical reactions that occur independently of the mixture's water content; they can harden even underwater or when constantly exposed to wet weather. The chemical reaction that results when the anhydrous cement powder is mixed with water produces hydrates that are not water-soluble. 

Hydraulic cement may be: 

i) Portland cements 

ii) Natural cements 

iii) Expansive cements 

iv) High-alumina cements

PORTLAND CEMENT.  It is hydraulic cement that hardens in water to form a water-resistant compound. Made by finely clinker

The cements of interest in the making of concrete have the property of setting and hardening under water by virtue of a chemical reaction with it and are, therefore, called hydraulic cement. The name "Portland cement" given originally due to the resemblance of the color and quality of the hardened cement to Portland stone – Portland Island in England.

Portland cement is the most common type of cement in general usage in many parts of the world, as it is a basic ingredient of concrete, mortar, stucco and most non-specialty grout. It is a fine powder produced by grinding Portland cement clinker (the solid material produced by the cement kiln stage that has sintered into lumps or nodules, typically of diameter 1-25 mm) (more than 90%), a maximum of about 5% gypsum which controls the set time, and up to 5% minor constituents (as allowed by various standards). As defined by the European Standard EN197.1, "Portland cement clinker is a hydraulic material which shall consist of at least two-thirds by mass of calcium silicates (3CaO.SiO2 and 2CaO.SiO2), the remainder consisting of aluminium- and iron-containing clinker phases and other compounds. The ratio of CaO to SiO2 shall not be less than 2.0. The magnesium content (MgO) shall not exceed 5.0% by mass."

Portland cement clinker is made by heating, in a kiln, a homogeneous mixture of raw materials to a sintering temperature, which is about 1450 °C for modern cements. The aluminium oxide and iron oxide are present as a flux and contribute little to the strength.

COST ESTIMATION

Plant Capacity                                       250 Ton/Day

Land & Building (8000 sq.mt.)              Rs. 4.92 Cr

Plant & Machinery                                   Rs. 4.17 Cr

Working Capital for 1 Month               Rs. 2.76 Cr

Total Capital Investment                        Rs. 12.23 Cr

Rate of Return                                         28%

Break Even Point                                    59%

• INTRODUCTION
  
• TYPES OF CEMENTS:
• HYDRAULIC CEMENT MAY BE:
• TYPES OF PORTLAND CEMENT
• 1. WHITE CEMENT
• 2. MODIFIED PORTLAND CEMENT
• 3. RAPID HARDENING OR HIGH EARLY STRENGTH CEMENT (TYPE III)
• 4. QUICK SETTING CEMENT
• 5. LOW HEAT CEMENT
• 6. SULPHATE RESISTANT PORTLAND CEMENT
• 7. WATER REPELLENT PORTLAND CEMENT
• 8. WATER PROOF PORTLAND CEMENT
• 9. HIGH ALUMINA CEMENT
• 10. PORTLAND SLAG CEMENT
• 11. AIR ENTRAINING CEMENT
• 12. PORTLAND POZZOLANA CEMENT
• 13. SUPERSULPHATED CEMENT
• 14. MASONRY CEMENT
• 15. EXPANSIVE OR EXPANDING CEMENT
• BASICS OF CEMENT INDUSTRY
• PROPERTIES
• PHYSICAL PROPERTIES
• THE PHYSICAL PROPERTIES OF CEMENT
• SETTING TIME
• TESTS:
• CONSISTENCY
• THE DEPTH DEPENDING ON THE CONSISTENCY
• SOUNDNESS
• TEST FOR SOUNDNESS
• FINENESS
• TEST FOR FINENESS
• STRENGTH
• DURATION OF TESTING
• TYPICALLY, DURATIONS OF TESTING ARE:
• COMPRESSIVE STRENGTH
• RAW MATERIALS AND CEMENT
• USES AND APPLICATIONS
• B.I.S SPECIFICATION
• MARKET OVERVIEW OF CEMENT IN INDIA
• MARKET OVERVIEW
• EXPORT AND IMPORT OF CEMENT
• INSTALLED CAPACITY & KEY MARKETS IN EACH OF THE GEOGRAPHIC REGIONS
• RECENT STRATEGIES
• SUCCESSFUL USE OF ALTERNATE FUELS IN CEMENT PRODUCTION
• GROWTH DRIVERS AND OPPORTUNITIES
• GOVERNMENT BUDGET ALLOCATION AND SCHEMES
• INVESTMENT SCENARIO
• SEQUENCES IN CEMENT GRINDING
• MANUFACTURING PROCESS
• STEPS
• TRANSFER OF CEMENT TO SILO:
• PROCESS OF PACKING AND LOADING PLANT:
• 1. TRANSFER OF CEMENT FROM SILO TO PACKERS:
• 2. PACKING OF CEMENT BAGS:
• 3. LOADING OF CEMENT BAGS AND BULK LOADING:
• PROCESS FLOW CHART
• PROCESSING DETAILS IN CEMENT GRINDING
• COMPOSITION OF CEMENT GRINDING UNIT
• QUALITY CONTROL
• BALL MILL
• PACKAGING & SHIPPING
• QUALITY ASSURANCE
• FAQ ABOUT CEMENT CLINKER GRINDING PLANT
• CEMENT GRINDING UNIT
• SUPPLIERS OF RAW MATERIAL
• SUPPLIERS OF CLINKER
• SUPPLIERS OF GYPSUM
• COMPLETE PLANT AND MACHINERY SUPPLIERS
• SUPPLIERS OF RAW MATERIALS
• SUPPLIERS OF CLINKER
• SUPPLIERS OF GYPSUM
• COMPLETE PLANT SUPPLIERS
• SUPPLIERS OF PLANT AND MACHINERIES
• SUPPLIERS OF AUTOMATIC GRINDING MACHINE
• SUPPLIERS OF JAW CRUSHER
• SUPPLIERS OF BUCKET ELEVATOR
• SUPPLIERS OF BELT CONVEYOR
• SUPPLIERS OF BALL MILL
• SUPPLIERS OF BAG PACKAGING MACHINES
• SUPPLIERS OF DG SETS
• SUPPLIERS OF LABORATORY EQUIPMENT

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)