Cement project

LNVT

Basic Approach in setting up a Cement Plant

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

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

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

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

To leave
adequate room
for expansion,

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 transports,
communication facility.

Availability of adequate Power,

Fuel and Water.

Availability of sufficient flat /

semi flat land in case of hilly areas
for the plant.

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.

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Scope for increasing further

capacity.

Govt Clearances Reqd for obtaining Mining

Lease

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Clearances and Approvals Required

Approvals/Clearances Required

Department to be Approached and Consulted

Incorporation of Company

Registrar of Companies

Registration/IEM/Industrial license

DIC for SSI/SIA for large and medium

industries

Allotment of land

State DI/SIDC/Infrastructure Corporation /SSIDC

Permission for land use

a. State DI
b. Dept. of Town and Country
Planning

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 planning

b. Municipal and local authorities
c. Chief Inspector of Factories
d. Pollution Control Board

Weights and Measures

Inspector of Weights and Measures

Quality Marking Certificate

Quality Marking Center of the State Government

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NCBM norms
The 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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History of kiln capacity development

Wet kilns
1892: 1.8x18 m
35 TPD
1967: 7.6x232 m
3500 TPD

Preheater kilns
1970: 6.0x96 m
4000 tpd

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Precalciner kilns
1984: 5.0x80 m
5500 TPD
1990: 6.0x96 m
10,000 tpd
2006 : 6.6x93 m
12,000 tpd
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Going from here

To there

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Cement Manufacturing Process

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Present Status of Technology

Mining

&

Low Technology Plants

Modern Plants

Global Technology

Material Conventional

Computer aided

Computer aided

Single stage

In-pit crushing & conveying

Belt conveyors

Pipe conveyors, Belt conveyors

Handling
Crushing

Conveying

Two stage

of Dumpers/Ropeway/

Limestone

Tippers

Grinding

Ball

Mills

with

/ VRMs Roll Presses with dynamic classifier

VRMs, Roll Presses, Horo Mills with dynamic classifier

without conventional
classifier
Pyro Processing

Wet

Dry

Dry

Semi Dry

- 5/6 stage preheater

- 6 stage preheater

Dry

- High Efficiency Cooler

- High Efficiency Cooler

- 4 stage preheater

- Multi Channel Burner

- Multi Channel Burner

- Conventional cooler

- Co-processing of WDF

- Co-generation of power

Single

channel

burner
Blending & Storage

Batch-Blending Silos

- Low NOx/SO2 emission technologies

Continuous Blending silos

- Continuous Blending
- Multi-Chamber Silos
- Dome silos

Packing & Despatch

Process Control

Plant Size, TPD

Bag

- Bag

- Bulk

- Bulk

- Palletizing & Shrink Wrapping

Relay Logic / Hard - DDC

Wired / PLC

- Fuzzy Logic expert system

300-1800

3000-6000

- DDC

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- Neurofuzzy expert system

6000-12000

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Trend in Cement Plant Size

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 Required

S.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 Specification
S.No

Equipment

Capacity

Quantity

Lime stone crusher

900 Tph

Lime stone stockpile

35000 T

Additive crusher

125 Tph

Additive stockpile

7500 T

Raw Mill (VRM)

450 Tph

Raw meal silo

15000 T

Preheater type

6-stage single string

Kiln

5000 Tpd

Cooler

5000 Tpd

10

Clinker stockpile

50000 T

11

Roll press

1100 Tph

12

Cement mill

270 Tph

13

Cement silo

18000 T

14

Fly ash silo

5000 T

15

Packers

175 Tph

16

Coal crusher

150 Tph

17

Raw coal stockpile

10000 T

18

Coal Mill (VRM)

55 Tph

19

Gypsum stockpile

3000 T

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Plant Layout

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Project Cost
S.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
PARTICULARS

UNIT

RATE Rs

(A) MATERIAL COST

Limestone
Laterite
Iron ore
(B) POWER
(C) FUEL

1.5004
0.031
0.0186
50
16.00%

125
1060
1235
9
4500

187.55
32.86
22.971
450
720

0.3
1

5
35
RS./MT

1.5
35
1449.88

(D) WATER (cub. m)

(E) STORES & SPARES
Total Clinker Cost
(F) Cost of Cement
Clinker
Gypsum
Power
Water
Fly Ash
Stores & Spares
Contract Labour
Total Cost of Cement

65%
5%
47.5
0.2
35%
1
1

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PPC
1449.9

942.42

95%

1800
9
5
100
20
20
RS./MT

90
427.50
1
35
20
20
1535.92

5%
38.00
0.2
0
1
1

OPC
1449.88

1377.39

1800
9.00
5
0
20
20
RS./MT

90.00
342.00
1
0
20
20
1850.39

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Contribution from Cement

UNIT

RATE

6000

(D) Net Sales Realization

Gross Sales realization
Less: Transportation Cost
Less: Sales Tax @ 12.36%

14.00%

6000

12.00%

Less: Dealers Margin

Less: Packing Material Cost

750

5250

5050

735

185.40
200

14%

707
4343

150
1

5800

750

4515
Less: Excise duty on Cement

5800

185.40
150

200

Net Sales Realization

RS./MT.

3979.60

3807.60

Contribution from Cement

RS./MT.

2443.68

1957.21

567.106

567.106

1986.57

1390.11

Fixed cost

Contribution after fixed cost

RS./MT.

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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

20

11

31

33

88

40

128

33

13

46

: Junior Staff

SKD : Skilled

88

SSKD : Semi Skilled

28

UNSKD: Unskilled

62

Grand Total

303

Manpower for Packing & security

80

Grand Total Manpower Quarry, Plant & Admn

515

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62
67

370

62
65

435

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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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