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Industry Overview
Cement is a hydraulic binding material used extensively in civil engineering and construction. Portland cement develops strength primarily through the hydration of di- and tri-calcium silicates and forms a hardened paste when mixed with water. Its principal raw materials include limestone, clay and iron ore, with gypsum added to control setting properties and support compressive strength.
Clinker is the nodular intermediate product formed during cement manufacture by heating the raw mix to approximately 1400°C–1500°C in a rotary kiln. The clinker is subsequently cooled and finely ground with gypsum and limestone to produce cement. Raw material quality, mineral reserves, chemical composition, moisture, grindability, burnability and proximity to the plant are important factors influencing production economics.
The report also examines the use of alternative raw materials and industrial by-products, including fly ash, iron slag, gypsum waste, casting sand and other materials, to reduce dependence on natural resources. It covers mudstone geology and reserves, clinker composition and thermochemistry, physical properties and testing, kiln technologies, fuels and combustion, manufacturing processes, environmental impacts, the cement market in India, regional production and consumption, market segmentation, plant layout, and suppliers of raw materials, clinker, machinery, testing equipment and supporting plant systems.
Cost Estimation
| Particular | Value |
|---|---|
| Plant Capacity | 500 MT/Day |
| Land & Building (8000 sq.mt.) | Rs. 6.75 Cr |
| Plant & Machinery | Rs. 5.63 Cr |
| Working Capital for 2 Months | Rs. 15.64 Cr |
| Total Capital Investment | Rs. 29.29 Cr |
| Rate of Return | 37% |
| Break Even Point | 48% |
Content Index
- INTRODUCTION
- TYPES OF CEMENTS:
- PORTLAND CEMENT:
- AN APPROXIMATE ANALYSIS FOR RAW MIX ON IGNITED BASIS, OR FOR CLINKER, IS:
- MATERIALS, AS MINED, THEREFORE, ARE TYPICALLY PROPORTIONED:
- A TYPICAL ANALYSIS OF CLINKER IS GIVEN IN THE TABLE BELOW:
- CLINKER COMPOSITION
- 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:
- THE CHEMICAL ANALYSIS OF CLINKER IS USUALLY GIVEN IN OXIDE FORM, AS FOLLOWS (IN OXIDE WEIGHT %):
- THERMOCHEMISTRY OF CLINKER
- TYPES OF CLINKER
- SULFATE RESISTANT CLINKER
- LOW HEAT CLINKER
- WHITE CLINKER
- LOW-ALKALI CLINKER
- BELITE CALCIUMSULFOALUMINATE TERNESITE (BCT)
- ADVANTAGE OF CEMENT PLANT USING CLINKER
- GLOBAL PRODUCTION AND ENVIRONMENTAL IMPACTS
- FIGURE: GLOBAL CEMENT PRODUCTION
- TABLE: SUMMARY OF GASES EMISSION DURING CEMENT MANUFACTURINGPROCESSES EXPRESSED IN G/KG * CEMENT AND G/KG ** CLINKER
- TABLE: SPECIFIC THERMAL ENERGY CONSUMPTION IN A CLINKERMANUFACTURING PROCESS
- PROPERTIES
- PHYSICAL PROPERTIES
- THE PHYSICAL PROPERTIES OF CEMENT
- SETTING TIME
- TESTS:
- CONSISTENCY
- SOUNDNESS
- TEST FOR SOUNDNESS
- FINENESS
- TEST FOR FINENESS
- STRENGTH
- DURATION OF TESTING
- TYPICALLY, DURATIONS OF TESTING ARE:
- COMPRESSIVE STRENGTH
- USES AND APPLICATIONS
- B.I.S. SPECIFICATION
- PROCESS FLOW CHART
- 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 RAWMIX
- BURNABILITY OF RAW MIX
- CLINKERISATION
- INFLUENCE OF THE RAW MIX ON CLINKER FORMATION AND BURNABILITY
- TYPES OF KILN
- TYPES OF KILNS - WET, DRY & SEMI-DRY
- 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
- 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:
- FUEL
- TYPES OF FUEL
- COAL
- TYPICAL PETROLEUM COKES
- PROXIMATE ANALYSIS OF COAL:
- ULTIMATE 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
- THE MINIMUM AMOUNT OF OXYGEN REQUIRED FOR COMBUSTION, OMIN, CAN BE CALCULATEDBY:
- THEREFORE THE REQUIRED AMOUNT OF AIR, LMIN, IS:
- THE TOTAL VOLUME OF THE COMBUSTION GAS IS:
- PROCESS GAS
- MARKET OVERVIEW OF CEMENT IN INDIA
- MARKET OVERVIEW
- EXPORT AND IMPORT OF CEMENT
- INSTALLED CAPACITY & KEY MARKETS IN EACH OF THE GEOGRAPHICREGIONS
- RECENT STRATEGIES
- SUCCESSFUL USE OF ALTERNATE FUELS IN CEMENT PRODUCTION
- GROWTH DRIVERS AND OPPORTUNITIES
- GOVERNMENT BUDGET ALLOCATION AND SCHEMES
- INVESTMENT SCENARIO
- MARKET POSITION
- MARKET SIZE
- INVESTMENTS
- GOVERNMENT INITIATIVES
- INDIAN CEMENT INDUSTRY ANALYSIS
- GEOGRAPHICAL DISTRIBUTION OF CEMENT INDUSTRY IN INDIA
- 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 (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
- PLANT LAYOUT
- SUPPLIERS OF CEMENTS
- SUPPLIERS OF RAW MATERIALS
- SUPPLIERS OF CLINKER
- SUPPLIER OF CALCIUM ALUMINO FERRITE
- SUPPLIER OF FREE LIME
- CHINE SUPPLIERS OF CLINKER GRINDING PLANT
- SUPPLIERS OF PLANT AND MACHINERY
- SUPPLIERS OF CLINKER GRINDING PLANT
- SUPPLIERS OF CEMENT BAG PACKING MACHINE
- SUPPLIERS OF CEMENT TESTING EQUIPMENT
- SUPPLIERS OF DG SETS
- SUPPLIERS OF POWER TRANSFORMERS
- SUPPLIERS OF COOLING TOWER
- SUPPLIERS OF ETP PLANTS
- SUPPLIERS OF MEASURING AND TESTING INSTRUMENTS
- SUPPLIERS OF AIR POLLUTION CONTROL EQUIPMENTS
- SUPPLIERS OF AIR CONDITIONING EQUIPMENTS
- SUPPLIERS OF AIR COMPRESSORS
- SUPPLIERS OF ASSEMBLY LINE
- SUPPLIERS OF EOT CRANE
- SUPPLIERS OF ELECTRICAL PANEL
- SUPPLIERS OF ELECTRIC MOTOR
- SUPPLIERS OF AIR POLLUTION CONTROL EQUIPMENTS
- SUPPLIERS OF AIR CONDITIONING EQUIPMENTS
- SUPPLIERS OF AIR COMPRESSORS
- SUPPLIERS OF MATERIAL HANDLING EQUIPMENTS
- SUPPLIERS OF FIRE FIGHTING EQUIPMENTS
- SUPPLIERS OF SHOT BLASTING MACHINE
- SUPPLIERS OF JIGS AND FIXTURE
- SUPPLIERS OF SUBMERSIBLE WATER PUMP
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
The main raw materials used in cement manufacturing are limestone, clay and iron ore, with gypsum added during cement grinding. Other materials such as shale, slate, blast furnace slag, silica sand, fly ash and alternative industrial by-products may also be used depending on the required composition. The report emphasizes that raw material chemical properties, moisture, homogeneity, grindability and burnability are important factors affecting cement production.
Clinker is the nodular intermediate material produced during the high-temperature kiln stage of cement manufacturing. It is formed when the principal components of the raw mix react during heating and subsequently becomes the main binder component of cement. After cooling, clinker is finely ground with gypsum and, where applicable, limestone to produce cement. Because dry clinker can be stored for extended periods without significant quality degradation, it can also be traded internationally and used when suitable raw materials are scarce.
Portland cement is manufactured through a sequence of raw material preparation, grinding, homogenization, pre-heating, kiln processing, clinker cooling and final grinding. Limestone and other raw materials are first quarried and crushed before being proportioned and ground into a suitable raw mix. The mix is heated in a rotary kiln to form clinker. The hot clinker is cooled and then ground finely with gypsum and limestone to obtain the finished cement. Process laboratories and control systems monitor chemical and physical properties throughout production.
The report discusses wet, dry and semi-dry kiln systems and identifies several dry-process configurations, including long dry kilns, SP kilns, ILC-E kilns, ILC kilns, SLC kilns, SLC-S kilns and SLC-I kilns. Kiln selection affects heat transfer, fuel utilization, process control and overall plant operation. The report also covers preheater operation, volatile circulation, burning characteristics, chemical control and the influence of raw mix properties on clinker formation and burnability.
Cement quality control includes physical and chemical evaluation, with the report specifically covering consistency, soundness, fineness, setting time and strength. Compressive strength is also addressed along with the duration of testing. Cement plant laboratories perform frequent tests during manufacturing and analyze finished cement to verify compliance with applicable specifications. The report also includes discussion of clinker composition and chemical control because raw material and clinker characteristics directly influence the properties of the finished cement.
Cement kiln operations can use coal, petroleum coke, fuel oil, gas and waste fuels, subject to suitable process and combustion controls. The report discusses fuel types, coal and petroleum coke characteristics, proximate and ultimate analysis, chemical analysis, heat value, fuel oil, gas, waste fuels, coal fineness, drying, ash content and combustion air requirements. Proper fuel selection and combustion control are important for maintaining kiln performance, clinker quality and efficient heat utilization.
Alternative raw materials discussed in the report include sludge, gypsum and gypsum waste, bleaching waste, sludge waste, casting sand, iron dust, tufal, fly ash, iron slag and excavation soil sludge land. These materials can be incorporated into the cement raw mix at controlled rates to contribute to the required composition. Their use can reduce dependence on virgin mineral resources and may help extend the life of existing mineral reserves, provided that their chemical and physical characteristics are suitable for the manufacturing process.
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