CEMENT PLANT USING CLINKER
(INSTEAD OF MINING LIMESTONE AND GYPSUM)
[CODE NO.3948]
Cement is a material that binds together solid bodies (aggregate) by hardening from a plastic state. Many materials act as adhesives or cement according to this definition. The cement referred to above, which is used for civil engineering and the construction industry, is portland cement. Portland cement is hydraulic and develops strength primarily by the hydration of the di- and tri-calcium silicates it contains. Hydraulic means that the paste of cement and water will harden under water. Lime, on the other hand, will harden due to the reaction with carbon dioxide from the air.
Clinker is a nodular material produced in the kilning stage during the production of cement and is used as the binder in many cement products. The lumps or nodules of clinker are usually of diameter 3-25 mm and dark grey in color. It is produced by heating limestone and clay to the point of liquefaction at about 1400°C-1500°C in the rotary kiln. Clinker, when added with gypsum (to control the setting properties of cement and ensure compressive strength) and ground finely, produces cement. Clinker can be stored for long periods of time in a dry condition without degradation of quality, hence it is traded internationally and used by cement manufacturers when raw materials are found to be scarce or unavailable.
Since the cement industry requires high investment capital, high quality (tenor) and reserves are needed to start the necessary investment in the sector. The chemical properties of the ore beds used in cement production, as well as their chemical properties, closeness to the plant, their removability, fragility, grindability and burnability, low moisture content and homogeneity are the most important factors affecting the production cost.
COST ESTIMATION
Plant Capacity 1000 MT/Day
Land & Building (40000 sq.mt.) US$. 40.46 Lac
Plant & Machinery US$. 20.79 Lac
Working Capital for 1 Month US$. 15.40 Lac
Total Capital Investment US$. 78.82 Lac
Rate of Return 38%
Break Even Point 41%
INTRODUCTION
HISTORY OF CEMENT
COMPOSITION
BASIC CALCULATION/FORMULATIONS - CHEMICAL SHORTHAND
THE MOST COMMON COMPOUNDS IN CEMENT CHEMISTRY ARE:
A TYPICAL ANALYSIS OF CLINKER IS GIVEN IN THE TABLE BELOW:
CLINKER COMPOSITION
SCIENTIFIC NAME & BOTANICAL DESCRIPTION
AN APPROXIMATE ANALYSIS FOR RAW MIX ON IGNITED BASIS, OR FOR CLINKER, IS:
MATERIALS, AS MINED, THEREFORE, ARE TYPICALLY PROPORTIONED:
MODULES
THE SILICA MODULUS IS DEFINED AS THE RATIO OF SILICA TO THE SUM OF
ALUMINA AND IRON OXIDE:
THE ALUMINA MODULUS IS DEFINED AS:
THE LSF FORMULA FOR CEMENT IS THEN:
MINERAL COMPOSITION
TYPES OF CEMENT
THE MOST COMMON TYPES OF CEMENT CAN BE DIVIDED INTO THREE MAIN GROUPS:
PORTLAND CEMENTS:
COMPOSITE CEMENTS
C) OIL WELL CEMENTS
C) OIL WELL CEMENTS
ASTM CEMENT TYPES
COMPRESSIVE STRENGTHS – FOR ASTM C109 CUBES
ASTM CEMENT TYPES
AIR CONTENT, FINENESS, SOUNDNESS AND SETTING TIME
TABLES BELOW SHOWS SOME OF THE PHYSICAL REQUIREMENTS AND CATEGORY
DEFINED BY EUROPEAN STANDARD.
TYPES OF CEMENT FOR CONCRETE (BS EN 197-1)
EUROPEAN STANDARD EN 197-1 TYPES OF CEMENT
EUROPEAN STANDARDS FOR STRENGTHS
ASTM CHEMICAL SPECIFICATIONS
COMPOSITION OF CLINKER
THE COMPOSITION OF CLINKER IS EXAMINED BY TWO SEPARATE APPROACHES:
THE FOUR MAIN COMPONENTS OF CLINKER ARE:
OTHER SUBSTANCES MAY BE PRESENT IN SMALL AMOUNTS:
THERMOCHEMISTRY OF CLINKER
TYPES OF CLINKER
SULFATE RESISTANT CLINKER
WHITE CLINKER
LOW-ALKALI CLINKER
BELITE CALCIUMSULFOALUMINATE TERNESITE (BCT)
CEMENT QUALITY - MAIN FACTORS
ADVANTAGE OF CEMENT PLANT USINGCLINKER
GLOBAL PRODUCTION AND ENVIRONMENTAL IMPACTS
TABLE. SPECIFIC THERMAL ENERGY CONSUMPTION IN A CLINKER MANUFACTURING
PROCESS
USE OF CLINKER: CONVERSION TO CEMENT
MARKET SURVEY
MARKET SIZE
INVESTMENTS
GOVERNMENT INITIATIVES
INDIAN CEMENT INDUSTRY ANALYSIS
GEOGRAPHICAL DISTRIBUTION OF CEMENT INDUSTRY IN INDIA
1. MADHYA PRADESH
2. ANDHRA PRADESH
3. RAJASTHAN
4. KARNATAKA
5. GUJARAT
6. JHARKHAND
7. UTTAR PRADESH
8. PUNJAB
9. MAHARASHTRA
10. WEST BENGAL
REGIONWISE CEMENT PRODUCTION IN INDIA
CEMENT PRODUCTION CAPACITY OF INDIA BETWEEN FY 2018 AND FY 2021
(IN MILLION METRIC TONS)
NORTHERN REGION
EASTERN REGION
SOUTHERN REGION
WESTERN REGION
CENTRAL REGION
CONSUMPTION VOLUME OF CEMENT IN INDIA FROM FINANCIAL YEAR 2009
TO 2018 WITH AN ESTIMATE FOR FINANCIAL YEAR 2019(IN MILLION METRIC TONS)
TOP KEY MANUFACTURERS IN WORLDWIDE CEMENT CLINKER MARKET ARE:
ABOUT CEMENT CLINKER MARKET:
CEMENT CLINKER MARKET SEGMENTATION ANALYSIS:
CEMENT CLINKER MARKET SEGMENTS BY TYPES:
CEMENT CLINKER MARKET SEGMENTS BY APPLICATION:
GEOGRAPHICAL SEGMENTATION:
COMPETITIVE LANDSCAPE AND CEMENT CLINKER MARKET SHARE ANALYSIS
EXPORT AND IMPORT OF CEMENT
INSTALLED CAPACITY AND KEY MARKETS IN EACH OF THE GEOGRAPHIC REGIONS
RECENT STRATEGIES
SUCCESSFUL USE OF ALTERNATE FUELS IN CEMENT PRODUCTION
GROWTH DRIVERS AND OPPORTUNITIES
HOUSING AND REAL ESTATE
PUBLIC INFRASTRUCTURE
INDUSTRIAL DEVELOPMENT
CEMENT CLINKER MANUFACTURING PROCESS
EXTRACTION AND PREPARATION OF RAW MATERIALS
HOMOGENIZATION
PRE-HEATING
KILN PHASE
COOLING AND STORING
CEMENT CLINKER GRINDING
FLOW CHART OF BALL MILL FOR CEMENT CLINKER GRINDING:
PHYSICAL CONTROL AND COMPOSITION OF RAW MIX
BURNABILITY OF RAW MIX
INFLUENCE OF THE RAW MIX ON CLINKER FORMATION AND BURNABILITY
TYPES OF KILN
WET KILN
DRY KILN
LONG DRY KILN
SP KILN
ILC-E KILN
ILC KILN
SLC KILN
SLC-S KILN
SLC-I KILN
ASH ABSORPTION
VOLATILE MATTER
CIRCULATION OF VOLATILE IN SIMPLE KILN SYSTEM
FOR ONE UNIT OF FEED: A = 1 THE MATERIAL BALANCE IS:
MELTING AND BOILING POINTS OF ALKALI SALTS
TO ENSURE TROUBLE FREE OPERATION OF A PREHEATER KILN THE FOLLOWING
LIMITS APPLY:
MAIN FEATURES DURING BURNING
CHEMICAL CONTROL DURING OPERATION OF THE KILN SYSTEM IS DIVIDED INTO
THE FOLLOWING:
TYPES OF FUEL
COAL
PROXIMATE ANALYSIS OF COAL:
CHEMICAL ANALYSIS:
HEAT VALUE:
FUEL OIL
TYPICAL ANALYSIS FOR OIL IS:
GAS
WASTE FUELS
COMBUSTION
COAL & OIL
FINENESS OF COAL
DRYING OF COAL
ASH CONTENT
GAS CONTENT
MINOR COMPONENTS
REQUIREMENT FOR AIR
THEREFORE THE REQUIRED AMOUNT OF AIR, LMIN, IS:
THE TOTAL VOLUME OF THE COMBUSTION GAS IS:
PROCESS GAS
THIS AMOUNT HAS TO BE INCREASED BY THE EXCESS AIR:
PROCESS FLOW DIAGRAM
MACHINERY SUPPLIERS
MACHINERY PHOTOGRAPHS
CYCLONE PRE-HEATER IN CEMENT PLANT
CEMENT PACKING MACHINE
CEMENT ROTARY KILN
HEAVY WHEEL TYPE ROLLERS AND ROTATING TABLE
5-STAGE VERTICAL CYCLONE PREHEATER IN CEMENT ROTARY KILN CALCINING
PROCESS
ROTARY KILN
ROTATING BALL MILL
SILOS
RAW MATERIALPHOTOGRAPHS
COAL
GYPSUM
SLUDGE
SLAG
PRODUCT PHOTOGRAPHS
APPENDIX – A:
1. COST OF PLANT ECONOMICS
2. LAND & BUILDING
3. PLANT AND MACHINERY
4. FIXED CAPITAL INVESTMENT
5. RAW MATERIAL
6. SALARY AND WAGES
7. UTILITIES AND OVERHEADS
8. TOTAL WORKING CAPITAL
9. COST OF PRODUCTION
10. PROFITABILITY ANALYSIS
11. BREAK EVEN POINT
12. RESOURCES OF FINANCE
13. INTEREST CHART
14. DEPRECIATION CHART
15. CASH FLOW STATEMENT
16. PROJECTED BALANCE SHEET
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