CEMENT PLANT
(CAP: 600,000 TON/ANNUM)
CODE NO. 3340
Dipon Infrasturcture Services Ltd. Bangladesh (CLIENT), intend to set up a cement manufacturing plant at Moheshkhali, Bangladesh. Considering market requirements, one new cement plant is proposed at Moheshkhali in Bangladesh by CLIENT. The total capacity of the plant will be 600,000 MT per year. The Plant will have all basic required facilities for normal plant operation, control facilities, fire and safety requirements & export.
The local Bangladeshi economy is growing at a rapid rate and the investment volume (foreign and local) have ensured the growth shall be sustained for the coming years. One such location is the Moheshkhali region where several new industries, infrastructure, and construction projects will cause a significant boom in the demand for cement.
Raw materials such as clinker and other materials are not available locally in Bangladesh and therefore is required to be imported from international suppliers. This feasibility report shall consider the availability of raw materials from nearby markets.
Currently, the cement industry of Bangladesh is the 40th largest market in the world. Bangladesh is one of the fastest developing countries and is thus expected to have major infrastructure, housing and services development in the coming years. Thus, expecting a growth in demand for cement is considered logical. Since the liberation war in 1971, major urbanization and industrialization took place in the country, which led to a rise in demand for cement. As the companies saw an opportunity in the field, they undertook capacity expansion plans. However, multiple factors like, delay in the construction project of Padma Bridge, political unrest, economic slowdown and also the downfall in the real estate sector have greatly impacted the industry growth. Thus, the expectations regarding the increase in demand were not met.
For commodities like cement, which requires strong consumer confidence, competitive price is not the sole factor ensuring the demand, brand name is also important. Thus, global players have an advantage in this regard, as customers finds them more trust worthy due to their worldwide presence. On the other hand, senior local brands are also being able to sell their brand name as they have gained customer loyalty. Hence, the new comers are likely to face a difficult time entering the market, unless they plan for higher marketing budget.
COST ESTIMATION
Plant Capacity : 2000.00 MT./day
land & Building (30 Acres) : Rs. 49.38 Cr
Plant & Machinery : Rs. 140.00 Cr
Working Capital for 2 Months : Rs. 42.00 Cr
Total Capital Investment : Rs. 237.50 Cr
Rate of Return : 31%
Break Even Point : 49%
INTRODUCTION
PROPERTIES OF CEMENT
TYPES OF CEMENT
PRINCIPAL CHEMICAL REQUIREMENTS
FOR PORTLAND CEMENT ASTM C150-63
PRINCIPAL PHYSICAL REQUIREMENTS
FOR PORTLAND CEMENT (ABBREVIATED) ASTM C150-63
TYPICAL COMPOSITIONS OF VARIOUS CEMENTS
TYPICAL POTENTIAL COMPOUND COMPOSITION
OF VARIOUS CEMENTS
ORDINARY PORTLAND CEMENT
PORTLAND BLAST FURNACE SLOP CEMENT
USES AND APPLICATION
MARKET SURVEY
CEMENT INDUSTRY OF BANGLADESH
FACTORS DRIVING THE DEMAND FOR CEMENT IN BANGLADESH
FALL IN INWARD REMITTANCE HAS POSED A THREAT TO THE
CEMENT INDUSTRY AS INDIVIDUAL HOMEBUILDERS’ ABILITY
TO SPEND ON CONSTRUCTION HAS DECLINED CORRESPONDINGLY
NATIONAL ELECTION TO BE HELD BY THE END OF 2018 OR IN THE
BEGINNING OF 2019 IS A CRITICAL TIME FOR CEMENT INDUSTRY
INDUSTRY OUTLOOK
BRAZIL BECOMES THE FOURTH-LARGEST GLOBAL CONSUMER OF CEMENT
CEMENT CONSUMPTION TO DOUBLE IN INDIA BY 2025
QATAR CEMENT DEMAND TO DOUBLE BY 2017
INDONESIA CEMENT CONSUMPTION EXPECTED TO RISE BY MORE
THAN 10% IN 2013
PROCESS OUTLINE FOR CEMENT MANUFACTURING USING DRY METHOD
MANUFACTURE OF CEMENT
PROPORTIONING OF RAW MATERIALS
RAW MATERIAL PREPARATION
BURNING
GRINDING
HORIZONTAL ROTARY KILN
FIRING & HEATING PROCESS
DRY-PROCESS KILNS, SUSPENSION
PREHEATERS, AND PRECALCINERS
PROCESS FLOW CHART
HORIZONTAL ROTARY KILN
PROCESS DESCRIPTION OF CEMENT MANUFACTURE
COMPUTER CONTROL
QUALITY CONTROL
ENVIRONMENTAL POLLUTION CONTROL
SAFETY MEASURES
TOTAL POWER CONSUMPTION
SCHEDULE OF MAINTAINANCE OF PLANT MACHINERY
STOCK LEVEL FOR STORES ITEMS
PLANT LOCATION
GENERAL LAYOUT
PROVISIONS FOR FUTURE EXPANSION & DIVERSIFICATION
STAFF & LABOUR REQUIREMENT
OPERATION
EMISSION AND ITS CONTROL FOR CEMENT INDUSTRIES
EMISSIONS AND CONTROLS1
SUPPLIERS OF PLANT AND MACHINERIES
SUPPLIERS OF COMPLETE CEMENT PLANT
TURNKEY PLANT SUPPLIERS FOR CEMENT PLANT
SUPPLIERS OF RAW MATERIALS
LIME STONE
CEMENT PLANT
DETAILS OF PLANT & MACHINERY FOR 6,00,000 TON/ANNUM
APPENDIX – A:
1. COST OF PLANT ECONOMICS
2. LAND & BUILDING
3. PLANT AND MACHINERY
4. FIXED CAPITAL INVESTMENT
5. RAW MATERIAL
6. SALARY AND WAGES
7. UTILITIES AND OVERHEADS
8. TOTAL WORKING CAPITAL
9. COST OF PRODUCTION
10. PROFITABILITY ANALYSIS
11. BREAK EVEN POINT
12. RESOURCES OF FINANCE
13. INTEREST CHART
14. DEPRECIATION CHART
15. CASH FLOW STATEMENT
16. PROJECTED BALANCE SHEET
