Industry Overview
Cement is a binding material that joins solid bodies such as aggregates by hardening from a plastic state. The cement used extensively in civil engineering and construction is Portland cement, a hydraulic cement that develops strength primarily through the hydration of di- and tri-calcium silicates. Unlike lime, which hardens through reaction with carbon dioxide in the air, cement paste can harden under water.
Clinker is a nodular material produced during the kiln stage of cement manufacturing and serves as the principal binder in many cement products. Clinker nodules are generally 3-25 mm in diameter and dark grey in colour. They are produced by heating limestone and clay to approximately 1400°C-1500°C in a rotary kiln. Grinding clinker finely with gypsum controls the setting properties of cement and contributes to the required compressive strength. Because clinker can be stored for extended periods under dry conditions without significant degradation, it can also be traded internationally and used where cement raw materials are scarce or unavailable.
The cement industry is capital intensive and requires suitable-quality mineral reserves to support investment. Important factors influencing production costs include the chemical properties of the ore beds, their proximity to the plant, removability, fragility, grindability, burnability, moisture content, and homogeneity.
Cost Estimation
| Particulars | Value |
|---|---|
| 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% |
Content Index
- 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
- 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
Frequently Asked Questions
Cement is a binding material that hardens and joins solid bodies such as aggregates. Portland cement is a hydraulic cement used extensively in construction and civil engineering. Its strength develops primarily through the hydration of di- and tri-calcium silicates. Because it is hydraulic, cement paste can harden under water. This characteristic distinguishes hydraulic cement from materials such as lime, which harden primarily through reaction with carbon dioxide in the air.
Cement clinker is a nodular intermediate product formed during the kiln stage of cement manufacturing. It is produced by heating limestone and clay to approximately 1400°C-1500°C in a rotary kiln. The resulting dark grey nodules are generally 3-25 mm in diameter. Clinker is subsequently ground with gypsum to produce cement. Its ability to remain stable for extended periods when kept dry also makes clinker suitable for storage, transportation, and international trade.
Gypsum is added during clinker grinding primarily to control the setting properties of cement. Without suitable control of setting, cement can react too rapidly with water and become difficult to handle during construction. The report specifically identifies gypsum as a material used to control setting properties and ensure compressive strength. The amount and form of gypsum used are therefore important considerations in producing cement with the desired performance characteristics.
Cement production costs are strongly influenced by the quality and characteristics of the raw materials and their location relative to the plant. Important factors identified in the report include chemical properties of the ore beds, proximity to the plant, removability, fragility, grindability, burnability, moisture content, and homogeneity. Because cement manufacturing is capital intensive, the availability of suitable-quality reserves is also important when evaluating an investment in a cement project.
The main clinker manufacturing stages covered in the report are extraction and preparation of raw materials, homogenization, pre-heating, the kiln phase, cooling and storing, and cement clinker grinding. Raw materials are prepared and proportioned before entering the thermal processing system. The preheater and kiln facilitate the reactions required for clinker formation, after which clinker is cooled and stored. The clinker is then finely ground, with gypsum added to control cement setting properties.
The report discusses several kiln configurations used in cement clinker production. These include wet kiln, dry kiln, long dry kiln, SP kiln, ILC-E kiln, ILC kiln, SLC kiln, SLC-S kiln, and SLC-I kiln systems. The report also addresses topics associated with kiln operation, including ash absorption, volatile matter, circulation of volatile components, alkali salt behaviour, burning characteristics, and chemical control during operation. Selection and operation of kiln systems influence thermal processing, fuel use, clinker quality, and overall plant performance.
Cement manufacturing can use several fuel types, including coal, fuel oil, gas, and waste fuels, as addressed in the report. Fuel selection and combustion management affect kiln operation and thermal efficiency. The report also covers coal and oil, proximate and chemical analysis, heat value, fineness of coal, drying, ash content, gas content, air requirements, combustion gas volume, process gas, and excess air. Proper fuel and combustion control are important for maintaining stable kiln operation and achieving the required clinker quality.
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