Industry Overview
Calcium carbonate (CaCO3) is one of the most widely occurring and versatile mineral compounds, comprising more than 4% of the earth’s crust. Its principal natural forms are chalk, limestone, and marble, which are chemically similar but differ in purity, whiteness, thickness, and homogeneity. Calcium carbonate has a molecular weight of 100.08 g/mol and occurs naturally in minerals such as calcite and aragonite, as well as in limestone, marble, shells, pearls, and eggshells.
Industrial calcium carbonate is primarily obtained through mining and quarrying. High-purity material for food and pharmaceutical applications may be produced from pure quarried sources, while precipitated calcium carbonate (PCC) is manufactured by reacting calcium hydroxide with carbon dioxide. PCC is a purified, refined or synthetic form of calcium carbonate and can be produced with controlled particle characteristics and crystal structures.
Calcium carbonate has extensive applications across plastics, paper, toothpaste, cosmetics, rubber, paints, pharmaceuticals, and health products. Ground calcium carbonate (GCC) has traditionally been used as a filler, while the smaller particles of PCC have enabled additional applications, including polymer nanocomposites where they can contribute to improved mechanical properties. The production process generally includes calcination, slaking, carbonation, filtration or decantation, and drying.
Cost Estimation
| Cost / Financial Parameter | Value |
|---|---|
| Plant Capacity | 240 MT/Day |
| Land & Building (15000 sq.mt.) | US$ 16 Lac |
| Plant & Machinery | US$ 12 Lac |
| Working Capital for 1 Month | US$ 7 Lac |
| Total Capital Investment | US$ 38 Lac |
| Rate of Return | 39% |
| Break Even Point | 44% |
Content Index
- INTRODUCTION
- MOLECULAR WEIGHT: 100.08 G/MOL
- HISTORY OF PCC
- FEATURES OF PRECIPITATED CALCIUM CARBONATE (PCC)
- COMPARISON BETWEEN PCC & GCC
- DIFFERENCE BETWEEN PCC AND GCC
- PRODUCTION PROCESS
- CHEMICAL COMPOSITION, SHAPE, SIZE
- PRODUCTS AND THEIR APPLICATION
- PLASTIC INDUSTRY:
- TOOTHPASTE AND DENTIFICE:
- CIGERATTE TISSUE PAPERS AND OTHER TISSUE PAPERS:
- COSMETIC
- RUBBER INDUSTRY
- PAINT INDUSTRY:
- PHARACEUTICAL AND HEALTH PRODUCT:
- PROPERTIES
- PHYSICAL PROPERTIES
- CHEMICAL PROPERTIES
- MANUFACTURING PROCESS
- PROCESS DESCRIPTION
- CALCINATION
- THE COMPOSITION OF PRODUCER GAS -
- TYPICAL ANALYSIS OF KILN GAS -
- SLAKING (HYDRATION OF QUICK LIME)
- CARBONATION OF LIME SLURRY
- SIEVING/DECANTATION (FILTERATION)
- DRYING
- MAJOR EQUIPMENTS
- PROCESS FLOW DIAGRAM
- MARKET POSITION
- MARKET DYNAMICS
- RESTRAINTS: INCREASING COST DUE TO HIGH TRANSPORTATION CHARGES
- OPPORTUNITY: POTENTIAL APPLICATIONS
- CHALLENGE: DECLINING PAPER INDUSTRY DUE TO INCREASING DIGITIZATION
- INCREASING DEMAND FROM THE PAPER INDUSTRY
- ASIA-PACIFIC IS EXPECTED TO LEAD THE CALCIUM CARBONATE MARKET
- COMPETITIVE LANDSCAPE
- RAW MATERIAL SUPPLIERS
- LIME STONE
- SUPPLIERS OF PLANT AND MACHINERY
- LIME KILNS
- SLAKERS
- REACTORS
- FLASH DRYERS
- REFRIGERATION PLANT
- BOILER
- VACUUM FILTERS
- ROTARY SIEVES
- SETTLEMENT TANKS
- MACHINERY PHOTOGRAPHS
- JAW CRUSHER
- LIME KILNS
- SLAKERS
- REACTORS
- FLASH DRYERS
- REFRIGERATION PLANT
- BOILER
- VACUUM FILTERS
- ROTARY SIEVES
- SETTLEMENT TANKS
- PRODUCT PHOTOGRAPHS
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
Precipitated calcium carbonate (PCC) is a purified, refined or synthetic form of calcium carbonate produced through a controlled chemical process. It has the same chemical formula, CaCO3, as naturally occurring limestone, marble and chalk. PCC can be manufactured with controlled particle size and crystal structure, making it useful in applications where specific physical characteristics are required. It is used in industries such as plastics, paper, paints, rubber, toothpaste, cosmetics, pharmaceuticals and other products.
Precipitated calcium carbonate is generally manufactured by converting calcium oxide into calcium hydroxide and then reacting the lime slurry with carbon dioxide. The process can include calcination of limestone, slaking or hydration of quick lime, carbonation, sieving or filtration, and drying. These stages allow the manufacturer to obtain calcium carbonate with controlled characteristics suitable for different industrial applications. The report identifies calcination, slaking, carbonation, filtration or decantation and drying as key stages of the manufacturing process.
PCC is manufactured through a controlled precipitation process, whereas GCC is produced by grinding naturally occurring calcium carbonate minerals. Both materials have the same basic chemical formula, but their particle characteristics, morphology and applications can differ. PCC generally provides greater control over particle size and crystal form, which can make it suitable for specialized applications. GCC has traditionally been used extensively as a cost-reducing filler, particularly in industrial materials, while PCC has expanded into applications requiring more controlled performance.
Calcium carbonate is widely used as a filler, functional additive and raw material across several industries. Major applications identified in the report include plastics, toothpaste and dentifrice, tissue papers, cosmetics, rubber, paints, pharmaceuticals and health products. Its usefulness is associated with properties such as its mineral composition, particle characteristics and chemical behavior. PCC is particularly relevant where controlled particle size and crystal structure are important for product performance.
Calcium carbonate is used in plastics primarily as a filler that can reduce material costs and, in suitable formulations, contribute to material performance. The report notes that PCC particles, being smaller than conventional GCC particles, have enabled additional applications in polymer nanocomposites. Research has also indicated that PCC nanoparticles can serve as fillers while improving certain mechanical properties of polymers. The actual performance depends on particle characteristics, polymer type, formulation and processing conditions.
Limestone is a commonly used raw material for producing calcium oxide, which is subsequently processed into PCC. The manufacturing route described in the report involves calcining limestone to produce quick lime, hydrating it to form calcium hydroxide, and then passing carbon dioxide through the lime slurry to precipitate calcium carbonate. Raw material quality is important because impurities in the source material can affect the quality and characteristics of the final calcium carbonate product.
A PCC manufacturing plant requires equipment covering raw material preparation, lime production, hydration, carbonation, separation and drying. The report lists jaw crushers, lime kilns, slakers, reactors, flash dryers, refrigeration plants, boilers, vacuum filters, rotary sieves and settlement tanks among the major equipment. The exact equipment configuration depends on the selected production process, product specifications, plant capacity, raw material characteristics and required level of process control.
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