Cement production workshop opened
Cement is created by combining limestone, gypsum, clay, mineral additives and other components. The technology and type of cement are varied; it is obtained through various technologies.
Cement production is a fairly profitable business that is highly competitive. This type of entrepreneurship can be opened only after a detailed study of the market, taking into account regional characteristics and the current economic situation.
Development of an individual business plan is required to implement this idea. On the Internet you can find a standard package of contracts and requirements for the production of cement. The main investment will be equipment costs.
One of the most popular and demanded building materials on the market - cement - is quite difficult to produce.
The cement production process is divided into two main stages:
- Obtaining clinker - an intermediate specific product, which is granules mixed mechanically and heated to 1500 degrees of clay and lime (or other materials of similar bulk composition). Clinker granules form the basis of any cement. This is a difficult and time-consuming stage, the most costly.
- Grinding of clinker together with gypsum (or other additives). In other words, the preparation of Portland cement.
The process of making cement is complicated by the fact that the chemical and mineralogical composition of raw materials varies widely enough (moisture, uniformity, hardness). Plants and factories specializing in the production of this material, which operate on imported raw materials, are most affected by this factor.
There are natural and technical varieties of raw materials that differ, for example, in purity and moisture. For each of their types, one of the existing production methods is selected, providing fine grinding and uniform mixing of the components, using a minimum amount of energy.
The conditions for the extraction of material, its transportation and storage, as well as the "human factor" in working with it are important.
Cement production methods:
- a wet method of grinding a mixture of raw materials is used and is produced in water to obtain mixed ingredients (charge) in the form of a suspension;
- dry method - does not require water in production technology and the charge is a crushed powder, the components of which are specially dried before mixing;
- a combined method based on one of the previous ones. The result is a mixture with a moisture content of up to 20%.
In the basic dry method, the initially prepared mixture is granulated by adding up to 14% water. With the wet base method, the mixture of raw materials at the outlet is dehydrated by 16-18%.
Cement production today is a fairly lucrative business. And even though there is high competition in this area, every novice entrepreneur has the opportunity to create his own successful business. However, before purchasing equipment and starting production, you need to carefully consider all the details of the business plan, taking into account the specifics of your region, the current economic situation and the activity of direct competitors.
What is cement?
We all know that construction is impossible without this material. How to make cement? To create it, limestone, gypsum, clay, mineral additives and other components are combined. There are various types of this material, as well as technologies for its production. We offer you a closer look at the main stages of opening such a business.
Cement Production Technology
The manufacturing process of this material consists of two main stages. At the first of them, clinker is obtained, which is a specific intermediate product in the form of mechanically mixed and heated to one and a half thousand degrees of lime and clay granules (or other materials of a similar composition). The resulting clinker granules are the basis of any cement. Their production process is very complex and the most expensive. The next stage is the production of Portland cement, resulting from grinding clinker with gypsum or other additives.
Cement production is complicated by the fact that the mineralogical and chemical composition of raw materials (homogeneity, hardness, moisture) varies widely. Enterprises that manufacture this material on the basis of imported raw materials know this firsthand.
Technical and natural varieties of raw materials are also taken into account, which may differ, for example, in moisture and purity. For each of them, the production of cement is carried out in a special way that ensures uniform mixing and fine grinding of the components, using the minimum possible amount of energy.
The conditions of raw materials extraction, storage and transportation, as well as the human factor play a very important role.
Cement Production Methods
There are three main options for creating this material:
1. Wet method: grinding of raw materials and production takes place in water, as a result of which mixed ingredients (or mixtures) are obtained in the form of a suspension.
Investments: from 580 970 000 rubles
Payback: from 15 months
Construction today is considered the most cost-effective and highly profitable industry. It's no surprise that building materials will always generate income. In this article, we will analyze a cement production business idea.
Cement is a popular building material. Its production is considered high-tech and profitable. This material is used both independently and is one of the components of concrete, reinforced concrete products.
The cement manufacturing process is divided into two stages. The most costly will be to obtain clinker (durable brick). It takes about 70% of the cost of the building material itself. Clinker granules are the basis for any type of cement. Then it is crushed with gypsum and made Portland cement.
There are three main methods of cement production.
The first (wet) is to grind raw materials in water and get a suspension of mixed ingredients.
The second (dry) is carried out without water, and the charge (mixture of materials) is a crushed powder. Its constituent parts are specially dried in advance.
The third option is combined and can be implemented on the basis of the first or the second. The peculiarity of this type - as a result, the moisture content of the resulting mixture will be up to 20%.
If you choose the dry method as the main one, then in advance it is necessary to granulate the prepared mixture by adding 10% of water. If the base is a wet method, then the sludge (waste) as a result is forcibly dehydrated to 16%.
The main buyers of cement are shops, construction companies, enterprises for the production of concrete or reinforced concrete, individuals.
Description of the mini-plant - differences from large-scale production lines
According to official statistics, the demand for cement is growing by 5% every year. To meet the local deficit in a specific area of a city or region, it makes sense to organize a small production. In this case, it makes no sense to build a large-scale plant.
The mini-line can be installed near the construction site and not spend additional funds on transportation, which will reduce the cost of production. And the construction company will benefit from this, since the retail price of cement will also decrease. Companies often conclude contract agreements with mini-factories, place the complex on their territory and have more favorable conditions.
Advantages of a mini-cement plant:
Its only disadvantage is lower productivity compared to large factories, however, and this has an advantage - no need for large storage facilities. And if there is an agreement with construction companies, then you can supply cement for them without packaging - this will reduce the cost.
Components of the production complex
A mini-plant for the production of cement should include the following mechanisms and ties:
Technical characteristics of equipment on the example of mini-plant T-100-190, country of origin - Russia.
Less productive complex - Dry Mill from Rosatech. Features:
Chinese production complexes will cost much more, for example, LUN-PRC, with a capacity of 120,000 tons per year, the price is 137,700,000 rubles.
The production process consists of several stages:
Cement production is a very complex and expensive process, but upon completion, one of the most demanded building materials in the world is obtained. That is why making concrete is considered a profitable and highly profitable process. This is especially effective if the base for the extraction of raw materials is located near the shop.
Raw materials used
Features of the composition
The main components for the production of one ton of cement can be:
They are used to adjust building properties and impart special qualities to concrete and mortar.
Additives to the composition are classified in accordance with GOST 24640-91. Each type of additional substance is used to improve the quality of the finished solution
The specified guest classifies the following types of additives:
The method is selected based on technical, economic and technological factors: raw ingredients, homogeneity and moisture content of the mixture, the presence of certain furnaces, fuel room, etc.
This technology does not use water.