Industry Overview
Quick lime, also known as calcium oxide (CaO), burnt lime, or calx, is produced by calcining limestone at high temperature to drive off carbon dioxide. Limestone primarily consists of calcium carbonate (CaCO3) with varying amounts of impurities, including magnesium, iron, aluminium, and silicon compounds. During calcination, calcium carbonate decomposes to form quicklime, which can subsequently be hydrated or slaked with water to produce calcium hydroxide.
Lime is one of the oldest chemicals known to mankind, with lime burning and the use of lime plaster and mortar documented in ancient civilizations. Today, quicklime is an important industrial raw material used across chemical processing, metallurgy, steelmaking, water and sewage treatment, construction materials, agriculture, glass, ceramics, pulp and paper, and other applications.
The manufacture of lime generally involves limestone winning, storage and preparation, fuel preparation, calcination, quicklime processing, hydration or slaking where required, and product storage, handling, and transportation. Calcination may be carried out in rotary or vertical kilns, depending on process and operating requirements. The report also covers limestone calcination technology, kiln types, plant layout and location factors, environmental aspects, product specifications, applications, project implementation, and plant and machinery requirements.
Cost Estimation
| Particulars | Value |
|---|---|
| Plant Capacity | 150 MT/Day |
| Land & Building (6400 sq.mt.) | Rs. 3.96 Cr |
| Plant & Machinery | Rs. 3.80 Cr |
| Working Capital for 2 Months | Rs. 1.71 Cr |
| Total Capital Investment | Rs. 9.77 Cr |
| Rate of Return | 32% |
| Break Even Point | 54% |
Content Index
- INTRODUCTION
- B.I.S. SPECIFICATION
- SPECIFICATIONS OF QUICK LIME FOR CHEMICAL INDUSTRIES
- QUICK LIME FOR CHEMICAL INDUSTRIES
- PROPERTIES
- TEMPERATURE:
- SPECIFIC HEAT:
- ON EXPOSURE TO MOIST AIR
- SOLUBILITY IN ACID
- REACTION WITH WATER
- GRADES
- HAZARD
- USES & APPLICATIONS
- SAND - LIME BRICK & BLOCK:
- CELLULAR CONCRETE:
- INSULATION MATERIALS:
- ROAD CONSTRUCTION:
- AGRICULTURAL USES:
- FERTILIZER FILLER:
- MINERAL FEED:
- CHEMICALS PROCESS & METALLURGICAL INDUSTRIES:
- ALUMINA:
- NON-FERROUS METAL SMELTING:
- CALCIUM CARBIDE:
- SALTS & ORGANIC CHEMICALS:
- DESICCANT:
- SANITATION
- WATER TREATMENT:
- SEWAGE TREATMENT:
- OTHER USES:
- PAPER PULP:
- GLASS & CERAMICS:
- MISCELLANEOUS:
- MARKET OVERVIEW OF CALCINED LIME
- KEY MARKET TRENDS
- INCREASING DEMAND FROM THE METALLURGICAL INDUSTRY
- UNITED STATES TO DOMINATE THE NORTH AMERICA REGION
- IMPORTANT FACTORS OF LIMESTONE CALCINATION
- USES OF QUICK LIME
- AGRICULTURE
- GLASS
- METAL REFINING
- PULP AND PAPER
- CAUSTIC SODA
- SOIL STABILIZATION
- STEELMAKING
- SUGAR
- WATER TREATMENT
- PROCESS OF MANUFACTURE OF LIME CALCINATION
- PROCESS INVOLVES FOLLOWING STEPS:-
- (1) LIMESTONE PREPARATION:
- CALCINATION
- THERMAL REQUIREMENTS:-
- OFTEN MAXIMUM THERMAL.
- KILNS:-
- ROTARY - KILN:-
- VERTICAL KILNS;-
- COOLING
- DETAILS OF LIME STONE CALCINATION
- CALCINATION OF LIMESTONE
- CALCINATION PROCESS:
- CALCINING KILNS
- FIG: ROTARY KILN WITH PREHEATER AND CONTACT COOLER
- FIG: SCHEMATICS OF A PREHEATER
- FIG: DIFFERENT TYPES OF KILNS FOR LIMESTONE CALCINATION
- TAB: COMPARISON OF VARIOUS TYPES OF CALCINING KILNS
- PROCESS DESCRIPTION OF LIME MENUFACTURING
- PROCESS FLOW DIAGRAM FOR LIME MANUFACTURING.
- PROCESS FLOW DIAGRAM FOR MANUFACTURE OF CALCIUM OXIDE (CALCINED LIME)
- PRODUCTION OF QUICKLIME
- SHAFT KILN
- FIGURE: SCHEMATIC OF SHAFT KILN.
- FIGURE: THE HEAT FLOW IN A PFR SHAFT KILN
- ROTARY KILN
- SCHEMATIC FIGURE OF A TYPICAL ROTARY KILN. THE LIMESTONE IS TRANSPORTED THROUGH THE KILN DUE TO THE ROTATING MOTION AND THE SMALL GRADIENT OF THE KILN
- DISTRIBUTION OF KILN TYPES
- CHART SHOWING THE DISTRIBUTION OF LIMEKILNS USED IN THE WORLD
- ENVIRONMENTAL ASPECTS OF LIME BURNING
- FIGURE: DISTRIBUTION OF CO2-EMISSIONS WITHIN THE LIME INDUSTRY (IN MILLION TONNES).
- SLAKED LIME
- LARGEST QUICKLIME PRODUCING COUNTRIES
- FIGURE: COUNTRIES WITH 90% OF THE TOTAL WORLD LIME PRODUCTION (IN MILLION TONNES)
- PRINCIPLES OF PLANT LAYOUT
- MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE
- PLANT LOCATION FACTORS
- PRIMARY FACTORS
- 1. RAW-MATERIAL SUPPLY:
- 2. MARKETS:
- 3. POWER AND FUEL SUPPLY:
- 4. WATER SUPPLY:
- 5. CLIMATE:
- 6. TRANSPORTATION:
- 7. WASTE DISPOSAL:
- 8. LABOR:
- 9. REGULATORY LAWS:
- 10. TAXES:
- 11. SITE CHARACTERISTICS:
- 12. COMMUNITY FACTORS:
- 13. VULNERABILITY TO WARTIME ATTACK:
- 14. FLOOD AND FIRE CONTROL:
- EXPLANATION OF TERMS USED IN THE PROJECT REPORT
- 1. DEPRECIATION:
- 2. FIXED ASSETS:
- 3. WORKING CAPITAL:
- 4. BREAK-EVEN POINT:
- 5. OTHER FIXED EXPENSES:
- 6. MARGIN MONEY:
- 7. TERM LOANS:
- 8. TOTAL LOAD:
- 9. LAND AREA/MAN POWER RATIO:
- PROJECT IMPLEMENTATION SCHEDULES
- INTRODUCTION
- PROJECT HANDLING
- PROJECT SCHEDULING
- PROJECT CONSTRUCTION SCHEDULE
- TIME SCHEDULE
- SUPPLIER OF PLANT & MACHINERY
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
Quick lime is calcium oxide (CaO) produced by calcining limestone at high temperature. Limestone is primarily composed of calcium carbonate, which decomposes during calcination and releases carbon dioxide, leaving calcium oxide as the main solid product. The manufacturing process generally includes limestone preparation, fuel preparation, calcination in a suitable kiln, cooling, quicklime processing, and storage and handling. The selection of kiln type and operating conditions depends on limestone characteristics, product requirements, fuel considerations, and plant design.
Quicklime is used extensively in metallurgy, chemical processing, water treatment, construction, agriculture, glass and ceramics, pulp and paper, and soil stabilization. It is an important material in steelmaking and metal refining and is also used in the manufacture of calcium carbide, salts, and organic chemicals. Other applications include sanitation, wastewater treatment, fertilizer-related uses, mineral feeds, and construction products such as sand-lime bricks and cellular concrete. Its broad chemical reactivity makes it useful across numerous industrial processes.
The main steps in lime manufacturing are limestone winning, storage and preparation, fuel storage and preparation, calcination, cooling, quicklime processing, and product storage and transportation. During calcination, prepared limestone is heated in a kiln so that calcium carbonate decomposes into calcium oxide and carbon dioxide. Depending on the required product and process configuration, the quicklime may subsequently undergo hydration or slaking. Proper material handling and process control are important for maintaining product quality and efficient plant operation.
Rotary kilns and vertical or shaft kilns are major kiln types used for limestone calcination. Rotary kilns transport limestone through a rotating inclined vessel and can be integrated with preheaters and coolers. Shaft kilns provide a vertical process configuration and include designs such as regenerative systems. The appropriate kiln depends on factors including limestone characteristics, required product quality, plant scale, fuel availability, energy efficiency, and operating requirements. The report discusses different kiln configurations and compares their characteristics.
A quicklime plant location should provide reliable access to limestone, markets, power and fuel, water, transportation, labor, and waste-disposal facilities. Site characteristics, climate, taxes, regulatory requirements, community factors, and provisions for flood and fire control should also be evaluated. Since limestone is the principal raw material, proximity to suitable deposits can significantly influence logistics and operating economics. Transportation infrastructure is particularly important because limestone and finished lime require efficient movement between the plant, suppliers, and customers.
Quicklime reacts strongly and exothermically with water to form calcium hydroxide, commonly known as hydrated or slaked lime. The reaction chemically combines water with calcium oxide and releases substantial heat. Because of this strong reaction, industrial handling requires suitable equipment, controlled addition of water, and appropriate safety measures. Hydrated lime has applications different from those of quicklime and is used in areas such as construction, water treatment, chemical processing, and other industrial applications.
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