Cements – EIRI – eBooks and Project Reports https://projectreports.eiriindia.org We Create Industrialist Thu, 20 Dec 2018 11:12:33 +0000 en-US hourly 1 https://wordpress.org/?v=6.8.3 https://projectreports.eiriindia.org/wp-content/uploads/2018/12/cropped-logo-1-32x32.jpg Cements – EIRI – eBooks and Project Reports https://projectreports.eiriindia.org 32 32 CEMENT PLANT https://projectreports.eiriindia.org/product/cement-plant/ Sat, 09 Jan 2016 07:09:25 +0000 http://projectreports.eiriindia.org/?post_type=product&p=6099   Cement   industry is one of the most important   basic industries on which depends the economic health of a developing country.   In fact are of the  important  indicators  of  the industrial vitality of a country is its per capita consumption of cement.  For Japan it is 670 Kgs. for Germany 544 Kgs, for the US 341 Kgs. and for singapore 540 kgs. unfortunately for India it is low at 32 kgs.  India is the eleventh largest producer of cement in  the world, with an installed capacity of 26.5 million  tons and  an investment of Rs. 280 crores in 55 units spread all  over the country providing employment to over 80,000 persons.

According to official projections on demand for and supply of cement during the sixth plan period, the total demand for the product has its increase to 38 million tons by the end of 1984-85  from 28 million tons in 1980-81.  A decisive role has  been assigned  to mini cement plants in the efforts to  equipment  the installed  capacity and strive for higher production the  working of   mini   cement  plant  based  on  vertical  shaft   koln   is technologically  feasible.  In fact such plant is already in operation throughout the world.

The  policy decisions relating to new units in the  industry were taken by Government in 1975, first that the minimum capacity should be 4 lakhs tones per annum and secondly that they  should use  the  more economical dry process.  These  requirements  were considered  to  be  well  within  the  capabilities  of  Indian fabricators.   By and large this is the policy likely to  the followed  in  future.   During the year  Government  announced  a scheme  of  soft  loans (at 7 1/2%) to current  units  whishi  to convert    from    wet   to   dry,   in     the    belief    that modernisation including such conversion would enhance  production in 9 units by as much as 1 million tons.

However  the  advent of th Mini-Cement Plant  with  vertical shaft  kiln,  which was introduced in India  by  an  enthusiastic protagonist  from Australia, has provided a diversion.   In  some quarters  the  Mini Cement plant has a keen following,  since  it opens  up possibilites of expliting small deposits of  limestones in  difficult tarrain and there by contributes to the  "Socialist pattern" on the other hand.  There is still some doubt as to the quality of clinker produced in these plants.  The six units so far a setup have yet to establish their commercial viability.  Nevertheless  the  Cement  Research  Institute  of  India   which possesses  the  known-how  for  manufacturing  these  plants,  is hopeful of setting up some 200 such plants around the country.

A development Council embracing representative of   all parties concerned with the industry including consumers has been set up. The council is intended to function as a watching, over seeing  all aspects of the industry, fixing  production  targets, monotoring  progress,  optimisting the use of raw  materials and attending  to such matters as standardisation, export  promotion, developing  the use of industrial wastes in  cement  manufacturer and production of special cements.

With the combination of all these developments the industry may, with luck play its full role in the national programme.

1.   INTRODUCTION
2.   PROPERTIES OF CEMENT
3.   USES AND APPLICATION
4.   MARKET POSITION
5.   MANUFACTURE OF CEMENT
6.   PROCESS FLOW CHART
7.   PLANT LAYOUT
8.   SUPPLIERS OF RAW MATERIALS
9.   SUPPLIERS OF PLANT AND MACHINERY

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

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]]> MINI CEMENT PLANT (CAP: 400 TPD ROTARY KILN PROCESS) https://projectreports.eiriindia.org/product/mini-cement-plant-cap-400-tpd-rotary-kiln-process/ Fri, 15 May 2015 11:23:08 +0000 http://projectreports.eiriindia.org/?post_type=product&p=4799      Cement   industry is one of the  most  important   basic industries  on which depends the economic health of a  developing country. In fact are of the  important  indicators  of  the industrial vitality of a country is its per capita consumption of cement.  For Japan it is 670 Kgs. for Germany 544 Kgs, for the US 341 Kgs. and for singapore 540 kgs. unfortunately for India it is low at 32 kgs.  India is the eleventh largest producer of  cement in  the world, with an installed capacity of 26.5 million  tonnes and  an investment of Rs. 280 crores in 55 units spread all  over the country providing employment to over 80,000 persons.

INTRODUCTION
PROPERTIES OF CEMENT
TYPES OF CEMENT
USES AND APPLICATION
MARKET SURVEY
PRESENT SCENARIO OF CEMENT INDUSTRY
MARKET SIZE AND INVESTMENT IN CEMENT INDUSTRY
PROCESS OUTLINE FOR CEMENT MANUFACTURING  USING DRY METHOD
MANUFACTURE OF CEMENT
RAW MATERIAL PREPARATION
HORIZONTAL ROTARY KILN FIRING & HEATING PROCESS
DRY-PROCESS KILNS, SUSPENSION PREHEATERS, AND PRECALCINERS
PROCESS FLOW CHART HORIZONTAL ROTARY KILN
FLOW CHART
PROCESS DESCRIPTION OF CEMENT MANUFACTURE
COMPUTER CONTROL
QUALITY CONTROL
STOCK LEVEL FOR STORES ITEMS
PRODUCTION ECONOMICS
PLANT LOCATION
PROVISIONS FOR FUTURE EXPANSION & DIVERSIFICATION
STAFF & LABOUR REQUIREMENT
SWOT ANALYSIS OF CEMENT INDUSTRY
EMISSION AND ITS CONTROL FOR CEMENT INDUSTRIES
SUPPLIERS OF PLANT AND MACHINERIES
SUPPLIERS OF COMPLETE CEMENT PLANT
(SABOO ROTARY KILN CEMENT PLANTS)
TURNKEY PLANT SUPPLIERS FOR CEMENT PLANT
SUPPLIERS OF RAW MATERIALS
RAW MATERIAL CALCULATION FOR CEMENT PLANT
MINI CEMENT PLANT (ROTARY KILN PROCESS)

APPENDIX – A :

.      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

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]]> ACRYLIC CEMENT PAINT (DRY POWER) https://projectreports.eiriindia.org/product/acrylic-cement-paint-dry-power/ Thu, 11 Dec 2014 13:47:42 +0000 http://projectreports.eiriindia.org/?post_type=product&p=4026              Acrylic cement Paint is new innovation  is paint industry and exhibits  superiority over the conventionally used cement  paint, that  unlike  the  cement paint, it needs no curing,  ie,  it  is applied on the wall without water curing, and after wetting  with water it is applied on wall.

It  is  Acrylic Polymer base paint and is  incorporated  with polymer  Acrylic  resin, white cement, Anti-Hair  crack  Additive, water-  repellent additive, U.V Resistant chemical,  fillers  viz calcium carbonate, Fine marble, Sodium Silicate, etc.

Desired  Colours asper requirement may be added  in  quantity sufficient (Q.S.) to the above ingredients for the desired  shade of the final product.

Project Report Covers:

Introduction
Uses and Applications
Properties
Market Survey with future aspects
Present Manufacturers
B.I.S. Specifications
Manufacturing Process with Formulae
Cost Economics with Profitability Analysis
Capacity
Land & Building Requirements with Rates
List & Details of Plant and Machinery with their Costs
Raw Materials
Details/List and Costs
Power & Water Requirements
Labour/Staff Requirements
Utilities and Overheads
Total Capital Investment
Turnover
Cost of Production
Break Even Point
Profitability
Land Man Ratio
Suppliers of Plant & Machineries and Raw Materials.

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]]> CEMENT FROM RICE HUSK https://projectreports.eiriindia.org/product/cement-rice-husk/ Thu, 06 Nov 2014 12:44:35 +0000 http://projectreports.eiriindia.org/?post_type=product&p=3778                 Cement has been successfully produced from the  agricultural waste,  rice  husk ash. For this production, rice husk  was  pre-carbonized  in a pilot-plant and was further decarbonized  in  an electric  furnace to produce rice husk ash. 24.5% rice  husk  ash was  mixed  with  other  raw  materials  (sourced  locally)   for producing white Portland cement and the cement produced was  used to  make a concrete slab.

              The formulated cement slab,  commercial cement  and slab were tested for their  physical  characteristics and  chemical  composition. The results of tests  confirmed  that produced  cement  was of similar standard to  commercial  cement. Based on the results, the production of cement from rice husk has been  recommended  for developing countries since it  would  help reduce problems of rice husks as farm wastes.

Project Report Covers:

Introduction
Uses and Applications
Properties
Market Survey with future aspects
Present Manufacturers
B.I.S. Specifications
Manufacturing Process with Formulae
Cost Economics with Profitability Analysis
Capacity
Land & Building Requirements with Rates
List & Details of Plant and Machinery with their Costs
Raw Materials
Details/List and Costs
Power & Water Requirements
Labour/Staff Requirements
Utilities and Overheads
Total Capital Investment
Turnover
Cost of Production
Break Even Point
Profitability
Land Man Ratio
Suppliers of Plant & Machineries and Raw Materials.

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]]> CEMENT TILES https://projectreports.eiriindia.org/product/cement-tiles/ Tue, 21 Oct 2014 13:14:02 +0000 http://projectreports.eiriindia.org/?post_type=product&p=2970 Cement  tiles have been used as surfacing for  roofs,  walls and  floors  for thousands of years because of their  beauty  and durability.  They  have been produced in most  countries  of  the world  because  of  the abundance of the  raw  material  and  the simplicity  of  the  manufacturing technology.  These  tiles  are produced in a number of shapes and sizes.

The tiles which laying over R.C.C. roofs are water resistive tiles.  These  composed of cement (portland),  sand,  colour  and cement  water  proofing  compound, felspar,  marble,  stone  chip dolomite powder, gypsum etc.

Project Report Covers:

  •     Introduction
  •     Uses and Applications
  •     Properties
  •     Market Survey with future aspects
  •     Present Manufacturers
  •     B.I.S. Specifications
  •     Manufacturing Process with Formulae
  •    Cost Economics with Profitability Analysis
  •     Capacity
  •     Land & Building Requirements with Rates
  •     List & Details of Plant and Machinery with their Costs
  •     Raw Materials
  •     Details/List and Costs
  •     Power & Water Requirements
  •     Labour/Staff Requirements
  •     Utilities and Overheads
  •     Total Capital Investment
  •     Turnover
  •     Cost of Production
  •     Break Even Point
  •     Profitability
  •     Land Man Ratio
  •     Suppliers of Plant & Machineries and Raw Materials.

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]]> PORTLAND CEMENT PLANT https://projectreports.eiriindia.org/product/portland-cement-plant/ Tue, 30 Sep 2014 09:30:06 +0000 http://projectreports.eiriindia.org/?post_type=product&p=2873 However  the advent of the Cement Plant with vertical  shaft kiln,   which  was  introduced  in  India  by   an   enthusiastic protagonist  from Australia, has provided a diversion.   In  some quarters  the  Mini Cement plant has a keen following,  since  it opens  up possibilites of exploiting small deposits of  limestone in  difficult  tarrain and thereby contributes to the  "Socialist pattern" on the other hand.  There is still some doubt as to  the quality  of clinker produced in these plants.  The six  units  so far   setup   have yet to establish their  commercial  viability.

Nevertheless  the  Cement  Research  Institute  of  India   which possesses  the  known-how  for manufacturing  these  plants,   is hopeful of setting up some 200 such plants around the country.

Project Report Covers:

  •     Introduction
  •     Uses and Applications
  •     Properties
  •     Market Survey with future aspects
  •     Present Manufacturers
  •     B.I.S. Specifications
  •     Manufacturing Process with Formulae
  •    Cost Economics with Profitability Analysis
  •     Capacity
  •     Land & Building Requirements with Rates
  •     List & Details of Plant and Machinery with their Costs
  •     Raw Materials
  •     Details/List and Costs
  •     Power & Water Requirements
  •     Labour/Staff Requirements
  •     Utilities and Overheads
  •     Total Capital Investment
  •     Turnover
  •     Cost of Production
  •     Break Even Point
  •     Profitability
  •     Land Man Ratio
  •     Suppliers of Plant & Machineries and Raw Materials.

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]]> PRE-STRESSED CONCRETE RAILWAY SLEEPERS & P.C.C POLES https://projectreports.eiriindia.org/product/pre-stressed-concrete-railway-sleepers-p-c-c-poles/ Sat, 27 Sep 2014 12:52:38 +0000 http://projectreports.eiriindia.org/?post_type=product&p=2800              Prestressed  concrete  is the concrete  in  which  permanent internal   stresses  are  deliberately  introduce,   usually   by tensioned  steel,  to  counteract to  the  designed  degree,  the stresses caused in the member in service.

Pre-tensioning  is the method  of prestressing  concrete  in which the tenons are tensioned before concreting.  Where as post-tensioning  is  the  method of  prestressing  concrete  in  which prestressing  steel is tensioned against the  hardened  concrete.

Initial tension is the maximum stress induced in the prestressing tenon  at  the  time  of  the  stressing  operation  and  initial prestress  is the stress in the concrete at  transfer.   Although the  first experiments were made in USA and the first patent  for prestressed  concrete  was  issued in 1988 for  P.H.  Jackson  of Sanfransisco, it was developed in Europe. French, German & Danish engineers  tried various ways of prestressing concrete, but  none was successful till 1930 when in France, the high strength  steel wire was used for prestressing concrete.  After 1950s,  actually, the  prestressed concrete has found its major uses in  fabricated constructions  where  it can be shop controlled &  tested.   Lift slab constructions were precast or cast on-site.  Today it can be well seen that prestressed concrete is finding its varied uses in various types of constructions.

Project Report Covers:

  •     Introduction
  •     Uses and Applications
  •     Properties
  •     Market Survey with future aspects
  •     Present Manufacturers
  •     B.I.S. Specifications
  •     Manufacturing Process with Formulae
  •    Cost Economics with Profitability Analysis
  •     Capacity
  •     Land & Building Requirements with Rates
  •     List & Details of Plant and Machinery with their Costs
  •     Raw Materials
  •     Details/List and Costs
  •     Power & Water Requirements
  •     Labour/Staff Requirements
  •     Utilities and Overheads
  •     Total Capital Investment
  •     Turnover
  •     Cost of Production
  •     Break Even Point
  •     Profitability
  •     Land Man Ratio
  •     Suppliers of Plant & Machineries and Raw Materials.

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]]> CEMENT PLANT – 500 TPD https://projectreports.eiriindia.org/product/cement-plant-500-tpd/ Thu, 25 Sep 2014 10:29:43 +0000 http://projectreports.eiriindia.org/?post_type=product&p=2772 Cement   industry  is  one  of  the  most  important   basic industries  on which depends the economic health of a  developing country.   In  fact  are  of  the  important  indicators  of  the industrial vitality of a country is its per capita consumption of cement.  For Japan it is 670 Kgs. for Germany 544 Kgs, for the US 341 Kgs. and for singapore 540 kgs. unfortunately for India it is low at 32 kgs.  India is the eleventh largest producer of  cement in  the world, with an installed capacity of 26.5 million  tonnes and  an investment of Rs. 280 crores in 55 units spread all  over the country providing employment to over 80,000 persons.

Project Report Covers:

  •     Introduction
  •     Uses and Applications
  •     Properties
  •     Market Survey with future aspects
  •     Present Manufacturers
  •     B.I.S. Specifications
  •     Manufacturing Process with Formulae
  •    Cost Economics with Profitability Analysis
  •     Capacity
  •     Land & Building Requirements with Rates
  •     List & Details of Plant and Machinery with their Costs
  •     Raw Materials
  •     Details/List and Costs
  •     Power & Water Requirements
  •     Labour/Staff Requirements
  •     Utilities and Overheads
  •     Total Capital Investment
  •     Turnover
  •     Cost of Production
  •     Break Even Point
  •     Profitability
  •     Land Man Ratio
  •     Suppliers of Plant & Machineries and Raw Materials.

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]]> CONCRETE ADMIXTURE https://projectreports.eiriindia.org/product/concrete-admixture/ Wed, 24 Sep 2014 12:29:16 +0000 http://projectreports.eiriindia.org/?post_type=product&p=2743         What is Ready Mixed Concrete

Ready  Mixed  Concrete, or RMX as it  is  popularly  called, refers to concrete that is specifically manufactured for delivery to  the  customer's  construction site in  a  freshly  mixed  and plastic  or  unhardened state. Concrete itself is  a  mixture  of Portland Cement, water and aggregates comprising sand and  gravel or  crushed  stone.  In traditional work  sites,  each  of  these materials   is  procured  separately  and  mixed   in   specified proportions  at  site to make concrete. Ready Mixed  Concrete  is bought  and sold by volume - usually expressed in  cubic  meters. RMX can be custom-made to suit different applications.

Project Report Covers:

  •     Introduction
  •     Uses and Applications
  •     Properties
  •     Market Survey with future aspects
  •     Present Manufacturers
  •     B.I.S. Specifications
  •     Manufacturing Process with Formulae
  •    Cost Economics with Profitability Analysis
  •     Capacity
  •     Land & Building Requirements with Rates
  •     List & Details of Plant and Machinery with their Costs
  •     Raw Materials
  •     Details/List and Costs
  •     Power & Water Requirements
  •     Labour/Staff Requirements
  •     Utilities and Overheads
  •     Total Capital Investment
  •     Turnover
  •     Cost of Production
  •     Break Even Point
  •     Profitability
  •     Land Man Ratio
  •     Suppliers of Plant & Machineries and Raw Materials.

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]]> WATER PROOFING CHEMICALS https://projectreports.eiriindia.org/product/water-proofing-chemicals/ Thu, 18 Sep 2014 09:20:01 +0000 http://projectreports.eiriindia.org/?post_type=product&p=2624         Water  resistance  or  proofing is an  important  factor  in health  and  comfort  of building occupants.   Several  texts  on concrete  construction describe the methods for  achieving  water proofing.  The term waterproof describes concrete and masonary is completely impervious to water and  water vapour, whether or  not the  water is under pressure.  Water proof  construction  implies the  use  of  a membrane or a film that provides  a  barrier  and covers  all  surface  pores  or  capillaries.   The  term   water repellent  describes  concrete  or masonary  that  repells  water without  significantly reduced permeability of the  structure  to the passage of water vapour.

Project Report Covers:

  •     Introduction
  •     Uses and Applications
  •     Properties
  •     Market Survey with future aspects
  •     Present Manufacturers
  •     B.I.S. Specifications
  •     Manufacturing Process with Formulae
  •    Cost Economics with Profitability Analysis
  •     Capacity
  •     Land & Building Requirements with Rates
  •     List & Details of Plant and Machinery with their Costs
  •     Raw Materials
  •     Details/List and Costs
  •     Power & Water Requirements
  •     Labour/Staff Requirements
  •     Utilities and Overheads
  •     Total Capital Investment
  •     Turnover
  •     Cost of Production
  •     Break Even Point
  •     Profitability
  •     Land Man Ratio
  •     Suppliers of Plant & Machineries and Raw Materials.

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