Detailed Project Report (DPR) on Precipitated Calcium Carbonate/Burnt Lime

PRECIPITATED CALCIUM CARBONATE/BURNT LIME 

[EIRI/EDPR/4766] J.C.: 2986XL

Lime is a calcium-containing inorganic mineral in which oxides and hydroxides predominate. In the strict sense of the term, lime is calcium oxide or calcium hydroxide. It is also the name of the natural mineral (native lime) CaO which occurs as a product of coal seam fires and in altered limestone xenoliths in volcanic ejecta. The word lime originates with its earliest use as building mortar and has the sense of sticking or adhering.

These materials are still used in large quantities as building and engineering materials (including limestone products, cement, concrete, and mortar), as chemical feedstocks, and for sugar refining, among other uses. Lime industries and the use of many of the resulting products date from prehistoric times in both the Old World and the New World. Lime is used extensively for wastewater treatment with ferrous sulfate.

The rocks and minerals from which these materials are derived, typically limestone or chalk, are composed primarily of calcium carbonate. They may be cut, crushed, or pulverized and chemically altered. Burning (calcination) converts them into the highly caustic material quicklime (calcium oxide, CaO) and, through subsequent addition of water, into the less caustic (but still strongly alkaline) slaked lime or hydrated lime (calcium hydroxide, Ca(OH)2), the process of which is called slaking of lime. Lime kilns are the kilns used for lime burning and slaking.

In the lime industry, limestone is a general term for rocks that contain 80% or more of calcium or magnesium carbonates, including marble, chalk, oolite, and marl. Further classification is by composition as high calcium, argillaceous (clayey), silicious, conglomerate, magnesium, dolomite, and other limestones. Uncommon sources of lime include coral, sea shells, calcite and ankerite.

Limestone is extracted from quarries or mines. Part of the extracted stone, selected according to its chemical composition and optical granulometry, is calcinated at about 1,000°C (1,830°F) in different types of lime kilns to produce quicklime.

Before use, quicklime is hydrated, that is combined with water, called slaking, so hydrated lime is also known as slaked lime.

Dry slaking is when quicklime is slaked with just enough water to hydrate the quicklime, but remain as a powder and is referred to as hydrated lime. In wet slaking, a slight excess of water is added to hydrate the quicklime to a form referred to as lime putty.

Because lime has an adhesive property with bricks and stones, it is often used as binding material in masonry works. It is also used in whitewashing as wall coat to adhere the whitewash onto the wall.

COST ESTIMATION

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%

CONTENTS

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

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

5. METHOD OF TRANSPORTATION

6. METHOD OF STORAGE AT THE SITE

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 – 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)