Detailed Project Report (DPR) on Hydrated Lime (100 MT/Day)

HYDRATED LIME 

[EIRI/EDPR/4557] J.C.: 2774INR, 2774US$ 

INTRODUCTION

Lime is a calcium-containing inorganic mineral composed primarily of oxides, and hydroxide, usually calcium oxide and/ or calcium hydroxide. It is also the name for calcium oxide 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) of these minerals in a lime kiln converts them into the highly caustic material burnt lime, unslaked lime or quicklime (calcium oxide) 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.

When the term is encountered in an agricultural context, it usually refers to agricultural lime, which today is usually crushed limestone, not a product of a lime kiln. Otherwise it most commonly means slaked lime, as the more dangerous form is usually described more specifically as quicklime or burnt lime.

COST ESTIMATION

Plant Capacity            100 MT/Day  

Land & Building (10,000 sq.mt.)    Rs. 3.60 Cr    

Plant & Machinery                    Rs. 16.50 Cr 

Working Capital for 1 Month    Rs. 2.65 Cr 

Total Capital Investment          Rs. 23.31 Cr 

Rate of Return                          32%

Break Even Point                      57%

CONTENTS

INTRODUCTION

CYCLE

THE LIME CYCLE FOR HIGH-CALCIUM LIME

LIMESTONE IS SPARINGLY WATER SOLUBLE:

IN THESE ACID CONDITIONS, THE CARBONATE THEN REACTS READILY TO FORM BICARBONATE:

THUS WHEN CARBON DIOXIDE IS DISSOLVED IN THE WATER, THE FOLLOWING EQUILIBRIUM EXISTS:

PROPERTIES OF HYDRATED LIME

USES & APPLICATION OF HYDRATED LIME

HYDRATED LIME PRODUCTS:

STANDARD HYDRATED LIME

HIGH REACTIVITY HYDRATED LIME

LIQUID CALCIUM HYDROXIDE

MICROCAL® H CALCIUM HYDROXIDE

VITACAL® H FOOD GRADE CALCIUM HYDROXIDE

PETROCAL® H CALCIUM HYDROXIDE

STOVERCAL™ H

PROPERTIES OF QUICK LIME

GRADES OF HYDRATED LIME

GRADES OF HYDRATED LIME:

REQUIREMENTS FOR HYDRATED LIME FOR CHEMICAL INDUSTRIES

SPECIFICATION OF QUICK LIME

SCOPE

TERMINOLOGY

GRADES

REQUIREMENTS

PACKING AND MARKING

DIFFERENCES BETWEEN HYDRATED LIME AND QUICK LIME

HOW DO YOU DETERMINE WHETHER TO USE HYDRATED LIME OR QUICKLIME?

DISCHARGING AND DOSING SYSTEM OPERATING ON SODIMATE LIME SILOS

WHAT EQUIPMENT IS MAINLY USED WITH HYDRATED LIME?

HYDRATED LIME DATA SHEET

REACTIONS ARE AS FOLLOWS:

SPECIFICATION

HANDLING AND STORAGE

SAFETY INFORMATION

TYPICAL PROPERTIES

AVAILABLE LIME INDEX

APPLICATIONS

COMPOSITION OF QUICK LIME AND HYDRATED LIME

QUICKLIME (CALCIUM OXIDE)

HYDRATED LIME (CALCIUM HYDROXIDE)

MARKET OVERVIEW OF HYDRATED LIME

THE MAJOR TYPES OF HYDRATED LIME ARE:

THE MARKET CAN BE BROADLY CATEGORISED ON THE BASIS OF ITS APPLICATIONS INTO:

BASED ON END USES, THE MARKET IS DIVIDED INTO:

KEY PLAYERS IN GLOBAL MARKET

PRESENT MANUFACTURERS/SUPPLIERS OF HYDRATED LIME

PROCESS OF LIME CALCINATION

CALCINATING LIMESTONE IN THE LIME KILN

STEPS IN LIME CALCINATION

PROCESS FLOW OF LIME PRODUCTION LINE

STEP ONE: RAW MATERIAL PREPARATION

1. LIMESTONE:

2. FUEL:

STEP TWO: RAW MATERIAL FEEDING

STEP THREE: LIMESTONE CALCINATION

STEP FOUR: FINISHED PRODUCTS CONVEYING

DETAILS IN LIME MANUFACTURING

PROCESS FLOW DIAGRAM FOR LIME MANUFACTURING

SEQUENCES IN HYDRATED LIME MANUFACTURE

MANUFACTURING PROCESS OF HYDRATED LIME

REACTION

PROCESS IN DETAILS

METHODS OF

CLYDE HYDRATOR

PROCESS FLOW DIAGRAM

DETAILS OF LIME HYDRATION

REACTION

RAW MATERIALS REQUIRED/TON

REACTION

METHOD OF PRODUCTION HYDRATED LIME

PROCESS AND TECHNOLOGY OF LIME PROCESSING AND HYDRATED LIME

PROCESS FLOW DIAGRAM

PROCESS OF LIME AND CONVERSION TO BURNT LIME AND HYDRATED LIME

STEP 1 - QUARRYING

STEP 2 - CONVERSION

BURNT LIME

HYDRATED LIME

LIME PRODUCTION FROM LIME STONE

LIME PRODUCTION PROCESS INVOLVES FOUR STEPS:

1) MINING OR QUARRYING

2) STONE PREPARATION

3) LIME CALCINING (CONVERSION OF LIMESTONE (CACO3) TO LIME (CAO))

4) HYDRATING

APPLYING LE CHATELIER'S PRINCIPLE IN THE PRODUCTION OF LIMESTONE:

PRESSURE:

TEMPERATURE:

LIME PRODUCTION PROCESS (CALCINATIONS & HYDRATION)

PLANT LAYOUT

SUPPLIERS OF PLANT & MACHINERIES

SUPPLIERS OF PULVERIZERS

SUPPLIERS OF D.G. SETS

SUPPLIERS OF LABORATORY EQUIPMENTS

SUPPLIERS OF INSTRUMENTATION AND PROCESS CONTROL EQUIPMENTS

SUPPLIERS OF HAMMER MILLS

SUPPLIERS OF BELT CONVEYORS

SUPPLIERS OF ELEVATORS

SUPPLIERS OF RAW MATERIALS

SUPPLIERS OF BURNT LIME/LIME STONE

SUPPLIERS OF PACKAGING MATERIALS (HDPE BAGS) (HDPE LAMINATED BAGS)

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)