Detailed Project Report on lime calcination plant
Detailed Project Report on lime calcination plant
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LIME CALCINATION PLANT
[CODE NO.3888]
Quick lime which is also known as calcium oxide or burnt lime specifically for chemical industries. Quick lime/burnt lime is obtained by calcining pure limestone at high temperature.
Quick lime is used in mortar and plaster, in glass production and in metal production industries to remove impurities.
The elements calcium and magnesium that abound so widely in the earth's crust, most commonly occur in carbonate forms of rock, generally classified as lime stone. Chemically it is composed primarily of calcium carbonate, CaCO3, including varying percentage of impurities. Although these carbonates may occur in many other rocks areas and soils in its broadest interpretation a chemical prerequisite for lime stone is that it contains greater than 50% carbonate.
Lime stones most important chemical characteristic is that when subjected to high temperature, it decomposes chemically into lime, CaO decarbonation occurring through the expulsion of CO2 gas. This primary product, known as quicklime, may be dehydrated or slaked into hydrated lime, calcium hydroxide (Ca(OH)2, the water being chemically complete bined with calcium oxide in an unimolar ratio.
It occurs in varying degrees in nearly every country. It is one of the most bare raw materials employed in industry and construction and has been compared to one leg of a six legged stool around which modern industry revolves, the other legs being coal, oil, iron ore, sulphur and salt.
Lime is one of the oldest chemicals known to man; the process of lime burning is one of the oldest chemical industries. Lime plaster and mortar were used by the Greeks, Romans, Etruscaus, Arabian and Moors. Vitruvious, a Roman Architect under Augustus, wrote the first detailed lime Specifications.
Calcium oxide is also known as lime quicklime, burnt lime, calx, unslaked lime, fluxing lime.
It is a white or gregish white hard lumps, sometimes with a yello with or burnish tiut due to iron.
Regarding its production, calcium carbonate (lime stone) is roasted in limes until all the carbon dioxide is driven off.
The impurities present in calcium carbonate, magnesium, iron and aluminium oxides. Compared to one leg of a six legged stool around which modern industry revolves, the other legs being coal, oil, iron ore, sulphur and salt.
• Calcium oxide (CaO), commonly known as burnt lime, lime or quicklime, is a widely used chemical compound. It is a white, caustic and alkaline crystalline solid. As a commercial product lime often also contains magnesium oxide, silicon oxide and smaller amounts of aluminium oxide and iron oxide.
• Calcium oxide is a crystalline solid. Its crystal structure is Isometric with space group Fm3m. It is generally unstable when 553 moisture is present and exhibits a large exothermic reaction with water to form aqueous Ca(OH)2.
• Calcium oxide is produced by heating calcium carbonate to 2000 deg F where carbon dioxide disassociates as a gas from the calcium carbonate.
• CaO is representative of group II oxides (MgO, SrO etc). It can be prepared by intense roasting of the corresponding carbonate or hydroxide. The formation is reversible in the presence of CO2 or H2O, respectively.
• A lime process mainly contains the following basic steps: Winning of limestone, Limestone storage and preparation, Fuels storage and preparation, Calcinations of limestone, Quicklime processing, Quicklime hydration and slaking, Storage, handling and transport.
• More than 90% of the lime (burned or hydrated) produced in the United States is used for basic or industrial chemistry. The primary use is for steel manufacture (30%), metallurgy, air pollution control and water and sewage wastewater treatment (24%), cement and mortar, chemical manufacture, manufacture of glass and paper, diluents and carriers of pesticides such as lime-sulfur and Bordeaux mixture, and bleach production and other chemical manufacture.
• Lime typically sells for A$100 to A$120 per ton implying a total value of production of $80m. Import competition largely decides the price of lime.
• The lime industry is a captive industry to Western Australia. Lime producers are competitive through ready access to limestone, cheap energy, economies of scale and in particular by international freight that acts as a barrier to trade in both directions for this low value product. Though import competition serves mainly to determine local prices, it is possible if not probable, that the quality of lime produced in Western Australia will increase with increasing demand from resource companies especially those close to north western ports where import competition is inevitably greatest and with the future supply of higher grade lime from Swan Portland Cement.
COST ESTIMATION
Plant Capacity 150 MT/Day
Land & Building (6400 sq.mt.) Rs. 3.96 Cr
Plant & Machinery Rs. 3.80 Cr
Working Capital for 2 Months Rs. 1.71 Cr
Total Capital Investment Rs. 9.77 Cr
Rate of Return 32%
Break Even Point 54%
INTRODUCTION
B.I.S. SPECIFICATION
SPECIFICATIONS OF QUICK LIME FOR CHEMICAL INDUSTRIES
QUICK LIME FOR CHEMICAL INDUSTRIES
PROPERTIES
TEMPERATURE:
SPECIFIC HEAT:
ON EXPOSURE TO MOIST AIR
SOLUBILITY IN ACID
REACTION WITH WATER
GRADES
HAZARD
USES & APPLICATIONS
SAND - LIME BRICK & BLOCK:
CELLULAR CONCRETE:
INSULATION MATERIALS:
ROAD CONSTRUCTION:
AGRICULTURAL USES:
FERTILIZER FILLER:
MINERAL FEED:
CHEMICALS PROCESS & METALLURGICAL INDUSTRIES:
ALUMINA:
NON-FERROUS METAL SMELTING:
CALCIUM CARBIDE:
SALTS & ORGANIC CHEMICALS:
DESICCANT:
SANITATION
WATER TREATMENT:
SEWAGE TREATMENT:
OTHER USES:
PAPER PULP:
GLASS & CERAMICS:
MISCELLANEOUS:
MARKET OVERVIEW OF CALCINED LIME
KEY MARKET TRENDS
INCREASING DEMAND FROM THE METALLURGICAL INDUSTRY
UNITED STATES TO DOMINATE THE NORTH AMERICA REGION
IMPORTANT FACTORS OF LIMESTONE CALCINATION
USES OF QUICK LIME
AGRICULTURE
GLASS
METAL REFINING
PULP AND PAPER
CAUSTIC SODA
SOIL STABILIZATION
STEELMAKING
SUGAR
WATER TREATMENT
PROCESS OF MANUFACTURE OF LIME CALCINATION
PROCESS INVOLVES FOLLOWING STEPS:-
(1) LIMESTONE PREPARATION:
CALCINATION
THERMAL REQUIREMENTS:-
OFTEN MAXIMUM THERMAL.
KILNS:-
ROTARY - KILN:-
VERTICAL KILNS;-
COOLING
DETAILS OF LIME STONE CALCINATION
CALCINATION OF LIMESTONE
CALCINATION PROCESS:
CALCINING KILNS
FIG: ROTARY KILN WITH PREHEATER AND CONTACT COOLER
FIG: SCHEMATICS OF A PREHEATER
FIG: DIFFERENT TYPES OF KILNS FOR LIMESTONE CALCINATION
TAB: COMPARISON OF VARIOUS TYPES OF CALCINING KILNS
PROCESS DESCRIPTION OF LIME MENUFACTURING
PROCESS FLOW DIAGRAM FOR LIME MANUFACTURING.
PROCESS FLOW DIAGRAM FOR MANUFACTURE OF CALCIUM
OXIDE (CALCINED LIME)
PRODUCTION OF QUICKLIME
SHAFT KILN
FIGURE: SCHEMATIC OF SHAFT KILN.
FIGURE: THE HEAT FLOW IN A PFR SHAFT KILN
ROTARY KILN
SCHEMATIC FIGURE OF A TYPICAL ROTARY KILN. THE LIMESTONE IS TRANSPORTED THROUGH THE KILN DUE TO THE ROTATING MOTION
AND THE SMALL GRADIENT OF THE KILN
DISTRIBUTION OF KILN TYPES
CHART SHOWING THE DISTRIBUTION OF LIMEKILNS USED IN THE WORLD
ENVIRONMENTAL ASPECTS OF LIME BURNING
FIGURE: DISTRIBUTION OF CO2-EMISSIONS WITHIN THE LIME INDUSTRY
(IN MILLION TONNES).
SLAKED LIME
LARGEST QUICKLIME PRODUCING COUNTRIES
FIGURE: COUNTRIES WITH 90% OF THE TOTAL WORLD LIME PRODUCTION
(IN MILLION TONNES)
PRINCIPLES OF PLANT LAYOUT
MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE
PLANT LOCATION FACTORS
PRIMARY FACTORS
1. RAW-MATERIAL SUPPLY:
2. MARKETS:
3. POWER AND FUEL SUPPLY:
4. WATER SUPPLY:
5. CLIMATE:
6. TRANSPORTATION:
7. WASTE DISPOSAL:
8. LABOR:
9. REGULATORY LAWS:
10. TAXES:
11. SITE CHARACTERISTICS:
12. COMMUNITY FACTORS:
13. VULNERABILITY TO WARTIME ATTACK:
14. FLOOD AND FIRE CONTROL:
EXPLANATION OF TERMS USED IN THE PROJECT REPORT
1. DEPRECIATION:
2. FIXED ASSETS:
3. WORKING CAPITAL:
4. BREAK-EVEN POINT:
5. OTHER FIXED EXPENSES:
6. MARGIN MONEY:
7. TERM LOANS:
8. TOTAL LOAD:
9. LAND AREA/MAN POWER RATIO:
PROJECT IMPLEMENTATION SCHEDULES
INTRODUCTION
PROJECT HANDLING
PROJECT SCHEDULING
PROJECT CONSTRUCTION SCHEDULE
TIME SCHEDULE
SUPPLIER OF PLANT & MACHINERY
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)
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