Industry Overview
Lime is a calcium-based inorganic material in which calcium oxide (quicklime) and calcium hydroxide (hydrated or slaked lime) are the predominant compounds. Historically, lime has been widely used as a building material, particularly in mortar, where its adhesive properties help bind bricks and stones. It continues to play an important role in construction through its use in cement, concrete, mortar, and other limestone-based products, while also serving as a valuable chemical feedstock, sugar refining agent, and wastewater treatment material.
Lime is primarily produced from naturally occurring limestone, chalk, marble, and other calcium carbonate-rich rocks. These raw materials are extracted from quarries or mines, crushed or processed as required, and then subjected to calcination at approximately 1,000°C in lime kilns. This process converts calcium carbonate into quicklime (calcium oxide). Quicklime is subsequently hydrated by adding water in a process known as slaking, producing hydrated lime or slaked lime (calcium hydroxide). Depending on the quantity of water used, slaking may be carried out as either dry slaking, which produces a fine powder, or wet slaking, which produces lime putty.
Limestone used for lime production generally contains 80% or more calcium or magnesium carbonates and may be classified according to its composition, including high-calcium, dolomitic, argillaceous, siliceous, conglomerate, and other varieties. Owing to its alkaline and binding properties, lime finds extensive application across construction, engineering, environmental treatment, and numerous industrial manufacturing processes.
Cost Estimation
| Particular | Value |
|---|---|
| Plant Capacity | 50 MT/Day |
| Land & Building (4000 sq.mt.) | Rs. 1.91 Cr |
| Plant & Machinery | Rs. 2.60 Cr |
| Working Capital for 2 Months | Rs. 2.95 Cr |
| Total Capital Investment | Rs. 7.76 Cr |
| Rate of Return | 31% |
| Break Even Point | 54% |
Content Index
- INTRODUCTION
- CYCLE
- IT IS AVAILABLE IN THREE FORMS:
- CLASSIFICATION OF QUICKLIME
- (A) ACCORDING TO PARTICLE SIZE:
- (B) ACCORDING TO CHEMICAL COMPOSITION:
- (C) ACCORDING TO USE:
- PROPERTIES OF QUICK LIME
- LIME AND ITS PRODUCTION
- LIME BURNING
- LIME SLAKING
- LIME CARBONATION
- TYPES OF LIMES
- 1. QUICK LIME
- 2. SLAKED LIME
- 3. FAT LIME
- 4. HYDRAULIC LIME
- CLASS A – EMINENTLY HYDRAULIC
- CLASS B – SEMI HYDRAULIC
- CLASS C – NON-HYDRAULIC (OR FAT LIME)
- USES AND APPLICATION OF PRECIPITATED CALCIUM CARBONATE
- FACTORS AFFECTS THE QUALITY OF QUICK LIME
- 1. NATURAL LIMESTONE
- A. IMPURITIES
- B. CRYSTALLINE STRUCTURE OF STONE
- C. DENSITY OF LIMESTONE AND CRYSTALLINE STRUCTURE
- 2. CALCINATION PROCESS
- A. KILN TEMPERATURE
- B. RATE OF TEMPERATURE RISE
- C. RETENTION IN THE KILN
- D. CO2 CONCENTRATION IN KILN
- E. PHYSICAL SIZE OF LIMESTONE/TYPES OF KILNS
- F. TYPE OF FUEL USED
- G. PRE-HEATING AND COOLING
- 3. METHOD OF STORAGE OF LIME (CAO)
- 4. SIZE CLASSIFICATION
- THE MOST COMMON SIZES ARE:
- 5. METHOD OF TRANSPORTATION
- 6. METHOD OF STORAGE AT THE SITE
- SPECIFICATIONS OF QUICK LIME FOR CHEMICAL INDUSTRIES
- USES AND APPLICATION OF LIME
- B.I.S. SPECIFICATION
- CALCIUM CARBONATE MARKET ANALYSIS
- CALCIUM CARBONATE MARKET TRENDS
- PAPER SECTOR TO DOMINATE THE MARKET
- ASIA-PACIFIC EXPECTED TO DOMINATE THE GLOBAL MARKET
- GROWTH OF PRECIPITATED CALCIUM CARBONATE
- PRECIPITATED CALCIUM CARBONATE MARKET SEGMENTATION ANALYSIS
- BY TYPE ANALYSIS
- LIST OF KEY COMPANIES IN PRECIPITATED CALCIUM CARBONATE MARKET
- SCENARIO OF BURNT LIME
- MANUFACTURERS/SUPPLIERS OF QUICK LIME
- PROCESSING DETAILS OF PRECIPITATED CALCIUM CARBONATE (PCC)
- PROCESS DESCRIPTION OF LIME MANUFATURING
- PROCESS FLOW DIAGRAM FOR LIME MANUFACTURING
- EMISSIONS AND CONTROLS
- MANUFACTURING PROCESS OF QUICK LIME & SLAKED LIME
- THERE ARE BASICALLY THREE TYPES OF LIME SLAKER AVAILABLE.
- PROCESS FLOW DIAGRAM OF QUICK LIME/SLAKED LIME
- MANUFACTURING PROCESS OF QUICK LIME IN DETAILS
- QUICK LIME PROCESSES MAINLY CONTAINS THE FOLLOWING BASIC STEPS
- 1. PROCUREMENT OF RAW MATERIAL (LIME STONE)
- 2. LIME STONE STORAGE AND PREPARATION
- 3. CRUSHING PROCESS OF RAW MATERIAL
- 4. SCREENING PROCESS
- 5. WASHING PROCESS
- 6. STORAGE OF LIME STONE
- 7. FUEL STORAGE AND PREPARATION
- 8. CALCINATION PROCESS
- THE LIME BURNING PROCESS TYPICALLY INVOLVES:
- HIGH-CALCIUM LIME
- DOLOMITIC LIME
- HEAT TRANSFER IN LIME BURNING CAN BE DIVIDED INTO THREE STAGES:
- (A) SHAFT KILNS
- CHARGING OF RAW MATERIAL
- DRAWING OF LIME
- STILL MORE SOPHISTICATED DRAWING MECHANISMS ARE USED, SUCH AS;
- THIS DESIGN IS USED ON SOME MIXED-FEED KILNS.
- COMBUSTION
- TYPES OF SHAFT KILN
- I) MIXED-FEED SHAFT KILN
- II) DOUBLE-INCLINED SHAFT KILN
- III) THE MULTI-CHAMBER SHAFT KILN
- IV) ANNULAR SHAFT KILN
- V) PARALLEL-FLOW REGENERATIVE KILN
- THE METHOD OF OPERATION DESCRIBED ABOVE INCORPORATES TWO KEY PRINCIPLES:
- (B) ROTARY KILNS
- I) LONG ROTARY KILN
- II) PREHEATER ROTARY KILN
- 9. GRINDING PROCESS OF QUICK LIME
- 10. TESTING
- 11. STORAGE AND HANDLING OF QUICK LIME
- STORAGE
- HANDLING
- LIME STONE AND FACTOR AFFECTING THE QUALITY OF QUICKLIME
- PLANT LAYOUT
- ADDRESSES OF PLANT & MACHINERY SUPPLIERS
- CHINA SUPPLIERS OF ROTARY KILN
- SUPPLIERS OF ROTARY KILNS
- SUPPLIERS OF COOLING TOWER
- SUPPLIERS OF ETP PLANTS
- SUPPLIERS OF AIR POLLUTION CONTROL EQUIPMENTS
- SUPPLIERS OF AIR COMPRESSOR
- SUPPLIERS OF PLATFORM WEIGHING MACHINE
- SUPPLIERS OF FIRE FIGHTING EQUIPMENTS
- SUPPLIERS OF SUBMERSIBLE WATER PUMP
- SUPPLIERS OF RAW MATERIALS
Appendix
- 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
Lime is produced by calcining limestone and then hydrating it when required. Limestone containing high levels of calcium carbonate is heated in a lime kiln at high temperatures to produce quicklime (calcium oxide). When water is added through the slaking process, quicklime is converted into hydrated or slaked lime (calcium hydroxide), depending on the intended industrial application.
The primary types of lime are quick lime, slaked lime, fat lime, and hydraulic lime. Each type is produced or processed differently and is selected according to its chemical composition, strength, setting characteristics, and intended application. Hydraulic lime is further classified into different grades based on its hydraulic properties.
Lime is widely used in construction, chemical processing, wastewater treatment, sugar refining, and environmental applications. Its strong alkaline properties make it suitable for neutralization, water treatment, masonry work, whitewashing, cement manufacturing, and several industrial processes requiring high-purity calcium compounds.
The quality of quick lime depends on raw limestone characteristics and process control. Important factors include impurities, crystalline structure, limestone density, kiln temperature, heating rate, retention time, carbon dioxide concentration, fuel type, particle size, cooling practices, storage conditions, and transportation methods.
Quick lime is calcium oxide, while hydrated lime is calcium hydroxide produced by adding water to quick lime. Quick lime is highly reactive and caustic, whereas hydrated lime is comparatively less caustic and easier to handle. The appropriate material is selected based on the specific industrial or construction application.
Calcination is the key process that converts limestone into usable quick lime. During this stage, limestone is heated in a kiln to release carbon dioxide, producing calcium oxide. Proper control of temperature, residence time, and kiln operation is essential to obtain consistent product quality and efficient production.
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