CEMENT PLANT

  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