Production Cost Report | Agriculture, Farming and Commodity

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Cement Production Cost Breakup From Limestone, Sand, Clay, and Bauxite

Details: Germany - based plant Q2 2023  | From $ USD

This report consists of a detailed cost evaluation of cement. Limestone, sand, clay (silicon, aluminium, iron), and bauxite are raw materials that are crushed into smaller pieces by a crusher. Secondary crushers further reduce the size of the ingredients and prepare them for pyro processing. A homogenous mixture with additives is prepared for cement production in a kiln. The raw mix is dried (moisture less than 1%) and crushed with a roller to form a fine paste and then fed into a kiln, where the raw material is turned into oxides to be burned in the kiln.

A series of chemical reactions take place between calcium and silicon dioxide compounds in the clinker. After exiting the kiln, the clinker is cooled down to a temperature of 100-200°C from 2000°C by passing air over it. At this stage, different additives such as gypsum, ethylene glycol, and triethanolamine are added to enhance the properties of cement. In the final stage, the final mixture is cooled down and ground into a fine powder by rotating drums with steel balls. The final product is transferred to silos where the cement is packed.

The project economic analysis provided in the report discusses a Germany-based plant and incorporates:

  • Manufacturing Process
    • Process Flow
    • Material Flow
    • Material Balance
  • Raw Material and Product/s Specifications
    • Raw Material Consumption
    • Product and Co-Product Generation
    • Capital Investment
  • Land and Site Cost
    • Offsites/Civil Works
    • Equipment Cost
    • Auxiliary Equipment Cost
    • Contingency
    • Engineering and Consulting Charges
    • Working Capital
  • Variable Cost
    • Raw Material
    • Utilities
  • Fixed Cost
    • Labor Requirement & Wages
    • Overhead Expenses
    • Maintenance Charges
  • Financing Costs
    • Interest on Working Capital
    • Interest on Loans
  • Depreciation Charges
  • General Sales and Admin Costs
  • Production Cost Summary
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Report Content

Key Process Information

Evaluation of significant technical parameters along with process descriptions such as:

  • Consumption of Raw Material
  • Product Creation
  • Block Flow Diagram
  • Description of the Manufacturing Facility

Utilities Consumption

Evaluation of utilities consumed during the entire process based on:

  • Consumption per unit of product generated
  • Utility cost split and share of each utility in the total cost

Process Flow Diagram

Representation of various operations involved including:

  • Step-wise process
  • Utility consumption in each operation

Capital Cost Analysis

In-depth analysis of costs involved in setting up a new manufacturing unit, including:

  • Cost of Building a Process Unit
  • Cost of Setting Up the Infrastructure
  • Working Capital
  • Commissioning & Start-Up of the Plant

Implementation Schedule

Time frame of the project design, which includes:

  • Plant Start-Up
  • Plant Construction
  • Engineering Fundamentals
  • Raw Material Procurement

Construction Cost Details

Detailed analysis of costs involved in the operation of various functional units in the process unit and infrastructure.

Operating Cost Analysis

Evaluation of costs associated with the production of the final product, namely:

  • Procurement of Raw Materials
  • Consumption of Utilities
  • Fixed Costs
  • Depreciation

Economic Analysis

Analysis of the way in which process economics are impacted by plant capacity.

  • Construction Cost
  • Working Capital
  • Fixed and Variable Operating Costs
  • Corporate Overhead
  • Depreciation

Customized Analyses

Detailed cost estimates of any industrial plant depending on your requirements, including plant capacity and location as per the need.

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