Own business: lime production. Lime production technology

To say that it is difficult to engage in own lime production, to say nothing. This is a really time consuming process. Business is profitable and quickly paid back. You probably know why this product is popular. It kills germs, serves as a natural filter and much more. Let’s see how to establish lime production. It is not easy to do this, but it is quite possible, especially considering the degree of saturation of the modern market with similar products.

Some general information

Not everyone in the West can afford to use lime. The fact is that there it is quite expensive material. Lime can be technological, which is used in metallurgy, food and chemical industries.

There is also construction, it serves for whitewashing houses and the manufacture of special solutions. As for the classification according to the content of various silicates, it happens: hydraulic (hardens upon contact with water) and air (hardens in a dry environment). It is worthwhile once again to draw your attention to the fact that lime production is a rather laborious process, but incredibly profitable from a material point of view. Let's start from the beginning.

Lime production technology

So, as a raw material, we take limestones of various types, as well as chalk or dolomites. Dense limestones are the most popular. As for the production itself, these are several stages. On the first raw material enters the feeder hopper, and then fractions of 0-30 centimeters in size fall into the crusher for grinding.

At the end of the process, crushed raw materials fall on the conveyor belt and enter the screen. There, the limestone is sorted into the following fractions: 0.5-2 cm, 2-4 cm and less than 0.5 cm. The last fraction is processed (lime flour). The rest is weighed and mixed with fuel to feed into the furnace. Most often, shaft furnaces are used, as they are energy-intensive and have a low price. Heating to 1000 degrees Celsius.

Lime production: stage 2

After the raw material is heated to a temperature of 1000 degrees, cooling to 100-130 follows. As a result, we get a lumpy bowel, which in the future must be processed in a mill (grind). It turns ground slaked lime. On this process can be considered completed.

As for the blanking process, it is performed as follows. The crushed raw material of 0.3-0.5 cm is placed in a special drum, where for a certain time (30-35 minutes) the lime is extinguished by steam. This is followed by unloading from the drum and placing it in a hopper for aging and further blanking. This significantly increases product quality. Water quenching is performed at a temperature of 40-50 degrees. And now let's move on to the next, no less important, stage.

Prices for equipment and raw materials

It should be noted right away that the production line is quite voluminous and takes up a large amount of space. It is divided into several branches. The preparatory part includes a vibrating feeder (12,000 rubles), a crusher (600,000-800,000), a conveyor belt and a screw conveyor, the total cost of about 250,000 rubles. In addition to this, an important element is a bag filter that ensures quality.

Its cost is about 500 thousand. Still in the preparatory department includes a sorting machine at the price of 800 000 rubles, as well as a dispenser and an intermediate hopper (200 000). As for the burning department, the shaft furnace (about 800,000 rubles) will be the most expensive equipment.But it should be noted that lime production in rotary kilns is possible, which is slightly cheaper.

In addition, you will need to install a smoke exhauster and a gas burner, which in the end will cost 100,000 rubles. The total price of all equipment will be approximately 3,000,000 rubles, not taking into account the equipment for the warehouse, since it can be practically not used due to manual labor. By the way, it is worth noting that the cost of limestone is 250 rubles / ton.

How to choose a room and employees

The plant should consist of the following sections: crushing, mills, storage and mixing of products, as well as sections of a shaft furnace and a place for storage and packaging of finished goods. Using simple calculations, we can conclude that the optimal area should be about 2000 square meters.

Renting such a room will cost 250,000-350,000 rubles, depending on the location of the building. If you plan to produce approximately 50 tons of finished products per day, then you will need a crusher driver and two minders (elevator and conveyor). In the sorting department, you need to hire a screen mechanic and an assistant, as well as professionals to work with the elevator and conveyor.

Most of all people need to be in the roasting department, since there is most work here. It will take two minders for an elevator and a conveyor, a calciner and an aspirator. But that is not all. It is desirable that the section has a pump and conveyor driver. As for the support staff, these are cleaners, operators and locksmiths. In general, about 20 people will work in the production, and the salary will be approximately 500,000 per month.

A little bit about investments and payback periods

As an example, we take the production of about 50 tons of lime per day. At the same time, at the initial stage we will need about 5 million rubles. But, as noted above, there are a number of nuances. For example, the choice of material affects the price.

If this is the production of lime from chalk, then we will need a little less money, about 200,000 rubles, than when using solid limestone. The same applies to equipment. For example, if the crusher of lime flour is not new, but used, then this is another 200,000 rubles in savings. As for the costs per month, this is about 1.5 million.

Currently, prices look something like this: 2,000 rubles per ton of quicklime and 3,200 per ton of quicklime. For a month we will earn about 800,000 rubles. From this we can conclude that in a year we will reach a maximum of net earnings, which is very good.

Where to sell the product, or About the main consumers

Of course, one of the most important points. This is due to the fact that before you start, you must find a place from which it would be profitable to sell the goods. If this is lime production in Russia, the main consumers are construction companies that produce silicate brick and a variety of dry building mixtures.

It is also a public utilities and garbage processing industry. It will be useful to know that most of the factories that need such a product as technological lime produce it themselves. That is why it is recommended to pay more attention to building lime.

Currently occupies about 15-20% of the market. From this we can conclude that technological lime should not be excluded from its production. Almost all types of products are very popular. So, it is most preferable to produce quicklime, because it is much easier to produce, and the demand for it is great.

Security organization

It would be useful to say that the lime production process is not the safest. Therefore, measures must be taken to protect personnel and the environment. So that the kiln for burning raw materials does not cause a fire in the workshop, only highly qualified professionals should handle it.

Frequent poisoning with carbon dioxide or carbon monoxide.Based on this, manual labor cannot be used to load raw materials into the furnace; there are special containers for this. Across the workshop, it is necessary to place hydro-suppression installations of dust, which will protect personnel from damage to the skin and mucous membranes. Workshop employees must carry respirators and wear long-sleeve work clothing.

Conclusion

So we figured out all the important points. As you can see, lime production technology is quite complex and time-consuming. However, with the proper approach, you will receive a high-quality product that your customers will definitely enjoy. It is not recommended to save on raw materials, as this can reduce the performance of the product, which will certainly be noticed.

I would like to say that the transportation of finished goods should be carried out in covered transport. Slaked lime has an expiration date of about a month from the moment it is shipped to a potential buyer. As for quicklime, its properties last for about 3 weeks, but this is subject to proper storage.

Well, that’s all that can be said about how to establish your own production. As you can see, there are a lot of nuances and important points, in addition, the initial costs are quite large. Nevertheless, a quick payback along with the high quality of the goods will make it possible to achieve net profit in 8-12 months.