Industry Overview
Lime is a calcium-containing inorganic mineral in which calcium oxides and hydroxides predominate. In the strict sense, lime refers to calcium oxide (CaO) or calcium hydroxide [Ca(OH)2]. Limestone and chalk, which are primarily composed of calcium carbonate, are the principal raw materials used to manufacture lime products. Through calcination at about 1,000°C, limestone is converted into quicklime (calcium oxide), which can subsequently be hydrated with water to produce slaked or hydrated lime.
Lime has been used since prehistoric times and remains an important material in construction, engineering, chemical processing, sugar refining, masonry, whitewashing, and wastewater treatment. Its adhesive and alkaline properties make it suitable for a wide range of industrial applications. The lime cycle comprises calcination, hydration or slaking, and carbonation, with operating conditions at each stage influencing the physical and chemical characteristics of the final product.
The quality of quicklime depends on factors including limestone composition, impurities, crystalline structure, calcination temperature, retention time, kiln design, fuel type, storage, particle size, transportation, and handling practices. Modern lime manufacturing involves raw-material preparation, crushing, screening, washing, calcination, grinding, testing, and appropriate storage and handling. Shaft kilns and rotary kilns are among the principal kiln technologies used for lime burning.
Cost Estimation
| Particulars | Value |
|---|---|
| Plant Capacity | 600 MT/Day |
| Land & Building (10 Acre) | Rs. 13.87 Cr |
| Plant & Machinery | Rs. 75 Cr |
| Working Capital for 2 Months | Rs. 18.35 Cr |
| Total Capital Investment | Rs. 108.05 Cr |
| Rate of Return | 23% |
| Break Even Point | 58% |
Content Index
- 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)
- 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
- 5. METHOD OF TRANSPORTATION
- 6. METHOD OF STORAGE AT THE SITE
- SPECIFICATIONS OF QUICK LIME FOR CHEMICAL INDUSTRIES
- USES AND APPLICATION
- B.I.S. SPECIFICATION
- MARKET POSITION
- THE GLOBAL LIME MARKET HAS BEEN SEGMENTED AS FOLLOWS:
- LIME MARKET: PRODUCT TYPE ANALYSIS
- LIME MARKET: END-USE ANALYSIS
- LIME MARKET: REGIONAL ANALYSIS
- GLOBAL LIME MARKET: SNAPSHOT
- QUICK LIME TO REMAIN POPULAR OVER FORECAST PERIOD
- PRODUCTION OF LIME STONE IN INDIA
- EXPORT DATA OF QUICK LIME
- IMPORT DATA OF QUICK LIME
- MANUFACTURERS/SUPPLIERS OF QUICK LIME
- OVERVIEW OF LIMESTONE IN INDIA
- RESOURCES
- PRODUCTION AND STOCKS
- LIMESTONE
- RESERVES/RESOURCES OF LIMESTONE AS ON 01.04.2015 (BY GRADES/STATES)
- RESERVES/RESOURCES OF MARL AS ON 01.04.2015 (BY GRADES/STATES)
- PRODUCTION OF LIMESTONE, 2014-15 TO 2016 -17 (BY STATES)
- PRODUCTION OF LIMESTONE, 2015-16 AND 2016-17 (BY FREQUENCY GROUPS)
- PRINCIPAL PRODUCERS OF LIMESTONE
- PROCESS DESCRIPTION OF LIME MANUFATURING
- PROCESS FLOW DIAGRAM FOR LIME MANUFACTURING.
- EMISSIONS AND CONTROLS
- MANUFACTURING PROCESS OF QUICK LIME & SLAKED LIME
- 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
- 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
- SUPPLIERS OF PLANT AND MACHINERY
- CHINA SUPPLIERS OF ROTARY KILN
- ROTARY KILNS
- COOLING TOWER
- ETP PLANTS
- AIR POLLUTION CONTROL EQUIPMENTS
- AIR COMPRESSOR
- PLATFORM WEIGHING MACHINE
- FIRE FIGHTING EQUIPMENTS
- SUBMERSIBLE WATER PUMP
- SUPPLIERS OF RAW MATERIALS
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
Quicklime is calcium oxide (CaO) produced by calcining limestone at high temperature. During calcination, calcium carbonate decomposes to form calcium oxide and carbon dioxide. Quicklime is a highly alkaline and caustic material that requires appropriate handling and storage. It is widely used in construction, chemical processing, metallurgy, water and wastewater treatment, sugar refining, and other industrial applications. The quality of quicklime depends on the characteristics of the limestone and the conditions maintained during calcination.
Quicklime is manufactured by crushing and preparing limestone and then heating it in a suitable lime kiln. The manufacturing sequence generally includes raw-material procurement, storage, crushing, screening, washing where required, fuel preparation, and calcination. During calcination, limestone is heated sufficiently to convert calcium carbonate into calcium oxide. Depending on the required product characteristics and plant design, shaft kilns or rotary kilns may be used. After burning, the quicklime can be cooled, ground, tested, stored, and handled according to its intended application.
Quicklime is calcium oxide (CaO), while slaked lime is calcium hydroxide [Ca(OH)2] produced by adding water to quicklime. The hydration reaction is known as slaking. Depending on the quantity of water used, slaking can produce hydrated lime as a powder or lime putty. Both materials are strongly alkaline, but they differ in chemical composition, physical form, and handling characteristics. Their selection depends on the requirements of applications such as construction, water treatment, chemical processing, and other industrial operations.
The quality of quicklime is affected by both the raw limestone and the calcination process. Important factors include limestone impurities, crystalline structure, density, particle size, kiln temperature, rate of temperature rise, retention time, carbon dioxide concentration, kiln type, fuel selection, and preheating and cooling conditions. Post-production practices also matter, including storage, transportation, size classification, and site handling. Controlling these factors helps achieve consistent chemical and physical properties appropriate for the intended industrial application.
Common lime products include quicklime, slaked lime, fat lime, and hydraulic lime. Quicklime is calcium oxide produced by calcination, whereas slaked lime is calcium hydroxide produced through hydration. Hydraulic lime is classified according to its hydraulic characteristics, while fat lime is generally associated with non-hydraulic or highly workable lime. The appropriate type depends on the required setting behavior, chemical properties, strength characteristics, and intended application in construction or industrial processing.
Lime burning commonly uses shaft kilns and rotary kilns. Shaft kiln designs include mixed-feed, double-inclined, multi-chamber, annular, and parallel-flow regenerative kilns. Rotary kiln configurations include long rotary kilns and preheater rotary kilns. The choice of kiln depends on factors such as limestone characteristics, required product quality, fuel considerations, operating requirements, and plant configuration. Proper kiln operation is essential because temperature, residence time, combustion conditions, and heat transfer directly influence the quality and consistency of the resulting quicklime.
Lime is used across construction, chemical processing, environmental treatment, sugar refining, and other industries. It serves as a binding material in masonry and can be used in whitewashing and engineering applications. Lime products are also used in wastewater treatment and as chemical feedstocks. Their alkaline and reactive characteristics make them useful for process control and treatment operations. The specific lime product selected depends on its chemical composition, particle size, reactivity, and the technical requirements of the application.
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