MINI CEMENT PLANT

JASLIN SINGH
GYANVENDRA SINGH
ANURAG AGRAWAL
Cement is one of the most important and commonly-used building
materials throughout the world. The total cement production in the
world was 1145 million tons in 1991. Most of this production was from
large cement plants, with capacities ranging from 2000 to 20,000 tons
per day (tpd) and transported to the place of use in bulk or in bags.
 Advantages of small cement plants

• Small cement plants offer some specific technical and economic advantages in given
situations. These include:
•  
• (a) Lower capital investment per unit of production without sacrificing the quality of the
product;
• (b) Lower gestation period which helps in realizing quicker returns on capital invested;
• (c) Bringing cement manufacture within the financial capacity of the smaller
entrepreneur;
• (d) Creating employment opportunities in rural areas;
• (e) Setting up a cement industry in locations where movement of heavy machinery is
difficult;
• (f) Exploitation of small deposits of limestone as well as limited quantities of calcareous
industrial wastes;
• (g) Reducing the average unit cost of transporting cement through the dispersal of
cement-production facilities.
 Small plant & machinery
In India, there are near about 200 small
cement plants in operation; most of these
being designated earlier as 200 tpd in order to
derive incentives offered by the Government
in terms of reduced excise duty and free
market. However, most of these plants are
using kilns of 3 m dia and 40 or 45 m length
-which, under Indian conditions are rated as
300 tpd.
 Finish grinding

To obtain better setting properties it is desirable that

the granulometry of cement is in a wide range with
more fines. Keeping this requirement in mind,
generally the open-circuit tube-ball grinding mill
with two/three compartments or two-compartment
ball mills with a mechanical air separator should be
chosen. Between the above two, an open-circuit
mechanical air-separator mill requires more
auxiliary equipment and space but requires less
power per ton of cement ground.
• Salient Features
Our Mini-Cement plant comprises all the constituents as per
International measures & sizes. All of its components can be
easily replaced. Following are the salient features of our Mini-
cement plants: Extremely energy efficient
• Fully automatic operation
• High authentic plant
• Low capital cost per ton of cement produced
• Require less maintenance
• Cement produced to International standards
• Clean emissions within acceptable norms
 PLANT DESCRIPTION
• A small cement plant essentially consists of the
following important sections/units:
• (a) Raw-materials storage
(b) Raw-mix proportioning and grinding unit;
(c) Raw-meal blending and storage section;
(e) Cement-grinding unit;
(f) Cement storage, packing and handling section;
(g) Power supply unit;
(h) Ancillaries and services section.
 MARKET ASSESSMENT
• We have gone through a survey where chhatisgarh is a new
developing state many development is going on there. There
is a wider scope & demand of cement. Which is must for
infrastructure develpoment.
 Features of mini cement plant
• The main factors which should be considered when fixing the capacity of a small
cement plant are:
•  
• * Demand for cement produced within an economic radius.
• * Availability of raw materials in terms of quality and quantity so that the plant
can operate for a period of at least 40 years.
• * Availability of sufficient fuel, electricity, water and other infrastructural facilities.
• Apart from the above factors, the availability of finance to the promoters
sometimes limits the size of the plant. Since the cement industry is a mineral-
based industry and the quantity of limestone required is approximately 50 per
cent more than the quantity of the finished product, it is desirable to locate the
plant near the source of limestone, provided other important factors like
availability of market, availability of labour etc, do not outweigh this
consideration.
 Plant project
Plants Supplied TPD 50 100 200 300
Land (Sq. M) 8000 10000 12000 16000

Power(Kw) 375 750 1500 2300

Project Lead Time(months) 6-8 6-8 10-12 10-12
Raw material TPD
clinker 20 40 80 120
Slag 30 60 120 180

Manpower
Administrative 3 3 3 6
Technical 9 9 9 1s2
Skiiled worker 9 9 12 15
Unskilled 18 18 24 30
current q uarter 288000

Previo us q uq rter 30000

g o d o wn charg es 1,0 9 ,9 4 2

p ro d uctio n o verhead 2 ,0 0 ,0 0 0

Selling & ad minis t ratio n 7,2 5,8 8 0

Tax 8 ,10 ,6 58

Net Op eratio nal Flo ws 4 8 2 3 552 0

Cap it al Outflo ws

p rincip al rep ayment 12 50 0 0 0 0

rep ayment o f lo an 10 0 0 0 0 0 0

net cap ital flo ws 2 573 552 0

clo s ing b alance 2 573 552 0

 Particulars
Operation Cash
Inflows 126000000
Sales Revenue
Collection
Currentr Quarter 48000000
Previous Quarter 78000000
operations Cash
OUTFLOWS
rawmaterials 7,69,53,822
current quarter 28800000
Previous quqrter 46800000
direct labour
current quarter 288000
Previous quqrter 30000
godown charges 1,09,942
production
overhead 2,00,000
Selling &
administration 7,25,880
Tax 8,10,658
Net Operational
Flows 48235520
Capital Outflows
principal
repayment 12500000
repayment of
loan 10000000
net capital flows 25735520

closing balance 25735520

Expected growth of over plant

Series 1
500
450
400
350
300 Series 1
250
200
150
100
50
0
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