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Cement project

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To select a process most suitable for raw materials and fuels proposed to be used,

To use technology and designs and machinery that would require minimum inputs,

To take into account infrastructural facilities in designing the layout and related aspects,

To have facilities to make different cements and different modes of dispatching them to cater the present and future market needs,

To design process control and instrumentation and quality control facilities to ensure consistent production of high quality at optimum costs,

To leave adequate room for expansion,

To keep investment costs within the limits of the resources of the entrepreneur.

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Basic Approach in setting up a Cement Plant

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Introduction to Cement Plant

Cement being a high bulk and low-value commodity, outward freight accounts

for close to one-fifth of the total cost.

In addition, for every ton of cement produced, close to

1.7 tons of raw material (including coal) have to be

transported.

In this scenario, the location of a cement plant

assumes crucial importance

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Factors influencing the site selection

Availability of suitable Limestone and additive materials like Silica sand, Iron ore, additives etc. for

the manufacture of cement clinker.

Availability of adequate Power, Fuel and Water.

Availability of sufficient flat / semi flat land in case of hilly

areas for the plant.

Availability of transports, communication facility.

Nearer to the market, for product sale.

Vicinity to the social infrastructural facilities, market center, educational institutions,

local transports, and entertainment centers, medical

facilities, township etc.

The land required for mining and plant should not be a part of

declared forest area.

Scope for increasing further capacity.

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Govt Clearances Reqd for obtaining Mining Lease

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Approvals/Clearances Required Department to be Approached and ConsultedIncorporation of Company Registrar of Companies

Registration/IEM/Industrial license DIC for SSI/SIA for large and mediumindustries

Allotment of land State DI/SIDC/Infrastructure Corporation /SSIDC

Permission for land use a. State DIb. Dept. of Town and CountryPlanning

NOC and consent under Water and Air Pollution Control Acts State Pollution Control Board

Approval of construction activity and building plan a. Town and country planningb. Municipal and local authoritiesc. Chief Inspector of Factoriesd. Pollution Control Board

Weights and Measures Inspector of Weights and Measures

Quality Marking Certificate Quality Marking Center of the State Government

Clearances and Approvals Required

NCBM normsThe estimated reserves for a 2.0 million tonnes per annum cement plant for a life span of 60 years 102 million tonnes of proved category for 30 years, 78 million tonnes of indicated reserves for 15 years 142 million tonnes of inferred reserves for an additional life of 15 years

NCBM – National Council for Building Materials

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Wet kilns1892: 1.8x18 m35 TPD1967: 7.6x232 m3500 TPD

Preheater kilns1970: 6.0x96 m4000 tpd

Precalciner kilns1984: 5.0x80 m5500 TPD1990: 6.0x96 m≥10,000 tpd2006 →: 6.6x93 m≥12,000 tpd

History of kiln capacity development

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To there ☺

Going from here

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Cement Manufacturing Process

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Low Technology Plants Modern Plants Global Technology

Mining & Material Handling

Conventional Computer aided Computer aided

Crushing Two stage Single stage In-pit crushing & conveying

Conveying of Limestone

Dumpers/Ropeway/ Tippers

Belt conveyors Pipe conveyors, Belt conveyors

Grinding Ball Mills with / without conventional classifier

VRM’s Roll Presses with dynamic classifier VRM’s, Roll Presses, Horo Mills with dynamic classifier

Pyro Processing Wet Semi Dry Dry - 4 stage preheater - Conventional cooler - Single channel burner

Dry - 5/6 stage preheater - High Efficiency Cooler - Multi Channel Burner

Dry - 6 stage preheater - High Efficiency Cooler - Multi Channel Burner - Co-processing of WDF - Co-generation of power - Low NOx/SO2 emission technologies

Blending & Storage Batch-Blending Silos Continuous Blending silos - Continuous Blending - Multi-Chamber Silos - Dome silos

Packing & Despatch Bag - Bag - Bulk

- Bulk - Palletizing & Shrink Wrapping

Process Control Relay Logic / Hard Wired / PLC

- DDC - Fuzzy Logic expert system

- DDC - Neurofuzzy expert system

Plant Size, TPD 300-1800 3000-6000 6000-12000

Present Status of Technology

Trend in Cement Plant Size

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New Player - >3000TPD of Clinker Production. Approx. 1.3Million Tons of Cement

per Annum

Existing Market Player - >6000TPD of Clinker Production. Approx.

2.5Million Tons of Cement per Annum

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Proposed Plant Capacity

Clinker Production :- 5000 TPD (1.5 MTPA)

Cement Production :- 6000 TPD (1.98 MTPA)

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Project at Glance

Plant Capacity – Clinker Production 5000 TPD

Plant Capacity – Cement Production 6000 TPD

No of days Plant operation per annum 330 days

Cement production proportion

OPC 60%

PPC 40%

Cement Production - OPC 3600 TPD

Cement Production - PPC 2400 TPD

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Plant Infrastructure

Land Requirement – for Mines Minimum 1000 acres

Land Requirement – for Plant 200 acres (Plant and colony)

Power Requirement 32 MW (Captive thermal power plant (CPP) of 10MW with Waste Heat Recovery System of 6 MW, which supplements state grid supplied power to meet the 32MW power needs of the plant

Water Requirement 3000 m3 / day for the plant operation

Manpower Requirement 513

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Basic Raw Materials RequiredS.No. Description Qty. (Lakh MTPA) Source

1. Limestone 24.00 Captive Mines

2. Laterite / Iron ore 1.03 Local market

3. Coal 2.75 Singareni Collieries

4. Gypsum 1.0 Coromandel Fertilizers

5. Fly Ash 3.2 VTPS / KTPS

6. HDPE Bags 50000 nos Local market

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Technical SpecificationS.No Equipment Capacity Quantity

1 Lime stone crusher 900 Tph 1

2 Lime stone stockpile 35000 T 2

3 Additive crusher 125 Tph 1

4 Additive stockpile 7500 T 2

5 Raw Mill (VRM) 450 Tph 1

6 Raw meal silo 15000 T 1

7 Preheater type 6-stage single string 1

8 Kiln 5000 Tpd 1

9 Cooler 5000 Tpd 1

10 Clinker stockpile 50000 T 1

11 Roll press 1100 Tph 1

12 Cement mill 270 Tph 1

13 Cement silo 18000 T 2

14 Fly ash silo 5000 T 1

15 Packers 175 Tph 2

16 Coal crusher 150 Tph 1

17 Raw coal stockpile 10000 T 1

18 Coal Mill (VRM) 55 Tph 1

19 Gypsum stockpile 3000 T 2

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Plant Layout

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Project CostS.NO. PARTICULARS TOTAL COST in Lakhs

1.0 Land & Site Development 3465.00

2.0 Buildings 13860.00

3.0 Plant & Machinery including WHRS 33264.00

4.0 Technical Know How, Training and Expenses on Foreign Technicians 519.75

 

5.0 Miscellaneous Fixed Assets including CPP 8316.00

6.0 Pre-operative Expenses 3465.00

7.0 Provision for Contingencies 4158.00

8.0 Margin money for Working Capital 2252.25

TOTAL 69300.00

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Production Cost

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PARTICULARS UNIT RATE Rs

(A) MATERIAL COST Limestone 1.5004 125 187.55 Laterite 0.031 1060 32.86 Iron ore 0.0186 1235 22.971 (B) POWER 50 9 450 (C) FUEL 16.00% 4500 720

(D) WATER (cub. m) 0.3 5 1.5 (E) STORES & SPARES 1 35 35 Total Clinker Cost RS./MT 1449.88

(F) Cost of Cement PPC OPCClinker 65% 1449.9 942.42 95% 1449.88 1377.39

Gypsum 5% 1800 90 5% 1800 90.00Power 47.5 9 427.50 38.00 9.00 342.00Water 0.2 5 1 0.2 5 1Fly Ash 35% 100 35 0 0 0Stores & Spares 1 20 20 1 20 20Contract Labour 1 20 20 1 20 20Total Cost of Cement RS./MT 1535.92 RS./MT 1850.39

Contribution from Cement UNIT RATE

(D) Net Sales Realization

Gross Sales realization 1 6000 6000 1 5800 5800

Less: Transportation Cost 750 750

5250 5050

Less: Sales Tax @ 12.36% 1 14.00% 735 1 14% 707

4515 4343

Less: Excise duty on Cement 1 12.00% 185.40 1 185.40

Less: Dealers Margin 150 150

Less: Packing Material Cost 1 200 1 200

Net Sales Realization RS./MT. 3979.60 3807.60

Contribution from Cement RS./MT. 2443.68 1957.21

Fixed cost 567.106 567.106

Contribution after fixed cost RS./MT. 1986.57 1390.11

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Man Power requirement

The key to success of modern Cement Plants, which are designed to achieve sustained operating efficiency and quality of product, Well-planned and effective organizational support. Optimum deployment of trained manpower.

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Manpower

Summary of Plant Manpower

Plant Admn. Total Quarry G Total

M& E: Managerial & Executive Staff 105 51 154 10 164

JS : Junior Staff 20 11 31 2 33

SKD : Skilled 88 88 40 128

SSKD : Semi Skilled 28 5 33 13 46

UNSKD: Unskilled 62 62 62

Grand Total 303 67 370 65 435

Manpower for Packing & security 80

Grand Total Manpower Quarry, Plant & Admn 515

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LNVT – SINOMA Capabilities

• Feasibility study• Proposal stage and signing of contract• Design and order handling stage• Civil design and construction• Erection, start-up,• Commissioning, handover, guarantees• Production, operation and maintenance of the plant

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LNVT Background

LNV Technology Private Limited (LNVT) was formed in the year 2001 as a joint venture between M/s LV Technology Public Company Limited of Thailand and Mr. V C Rao an Indian Entrepreneur. After 12 remarkable years of service to the Cement Industry in India and abroad, LNVT now had a strategic alliance with Global Leader M/s Sinoma International Engineering Company Limited, China.

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LNVT Back ground

Company were focused Retrofit using advance technology to enhance

production, productivity and energy savings in existing cement plants.

Proven results over the years in more than 200 projects and achieved customer satisfaction

In the year 2008, LNVT started doing full scale cement plants with its first turnkey Project.

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SINOMA Back ground

Sinoma brings its International experience in handling more than 150 projects worldwide and more than 1000 projects in China

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THANK YOU

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