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)
