Detailed Project Report on quick lime/slaked lime

QUICK LIME/SLAKED LIME [3580]

Lime is a calcium-containing inorganic mineral in which oxides, and hydroxides predominate. In the strict sense of the term, lime is calcium oxide or calcium hydroxide. It is also the name of the natural mineral (native lime) CaO 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) converts them into the highly caustic material quicklime (calcium oxide, CaO) 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. Lime kilns are the kilns used for lime burning and slaking. In the lime industry, limestone is a general term for rocks that contain 80% or more of calcium or magnesium carbonates, including marble, chalk, oolite, and marl. Further classification is by composition as high calcium, argillaceous (clayey), silicious, conglomerate, magnesium, dolomite, and other limestones. Uncommon sources of lime include coral, sea shells, calcite and ankerite. Limestone is extracted from quarries or mines. Part of the extracted stone, selected according to its chemical composition and optical granulometry, is calcinated at about 1,000°C (1,830°F) in different types of lime kilns to produce quicklime. Before use, quicklime is hydrated, that is combined with water, called slaking, so hydrated lime is also known as slaked lime. Dry slaking is when quicklime is slaked with just enough water to hydrate the quicklime, but remain as a powder and is referred to as hydrated lime. In wet slaking, a slight excess of water is added to hydrate the quicklime to a form referred to as lime putty. Because lime has an adhesive property with bricks and stones, it is often used as binding material in masonry works. It is also used in whitewashing as wall coat to adhere the whitewash onto the wall. The process by which limestone (calcium carbonate) is converted to quicklime by heating, then to slaked lime by hydration, and naturally reverts to calcium carbonate by carbonation is called the lime cycle. The conditions and compounds present during each step of the lime cycle have a strong influence of the end product, thus the complex and varied physical nature of lime products.

COST ESTIMATION

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%


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    7
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 – 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)