Calcium Carbonate Production from Lime and Carbon Dioxide
Calcium Carbonate Production Costs Report | Issue B | Q3 2024
Report Details |
50 kta United States-based plant | Q3 2024 | 107 pages |
This report presents a cost analysis of a 50 kta (kilo metric ton per annum) United States-based plant. You can add a customized cost analysis, assuming another location (country), when ordering a premium edition of this report.
Report Abstract
This report presents the economics of Calcium Carbonate production from lime in the United States, via a typical process. In this process, lime reacts with water producing calcium hydroxide, which is further carbonated with carbon dioxide to produce PCC.
The report provides a comprehensive study of Calcium Carbonate production and related Calcium Carbonate production cost, covering three key aspects: a complete description of the Calcium Carbonate production process examined; an in-depth analysis of the related Calcium Carbonate plant capital cost (Capex); and an evaluation of the respective Calcium Carbonate plant operating costs (Opex).
The Calcium Carbonate production process description includes a block flow diagram (BFD), an overview of the industrial site installations, detailing both the process unit and the necessary infrastructure, process consumption figures and comprehensive process flow diagrams (PFD). The Calcium Carbonate plant capital cost analysis breaks down the Capex by plant cost (i.e., ISBL, OSBL and Contingency); owner's cost; working capital; and costs incurred during industrial plant commissioning and start-up. The Calcium Carbonate plant operating costs analysis covers operating expenses, including variable costs like raw materials and utilities, and fixed costs such as maintenance, labor, and depreciation.
Process Schematic

The process under analysis comprises three major sections: (1) Slaking; (2) Carbonation; and (3) Finishing.
Slaking. Initially, the lime feedstock is fed to a stirred slaker tank, calcium oxide is hydrated (slaked) with water, forming a calcium hydroxide slurry (slaked lime or slake). Before carbonation, the impurities originating from the raw material are separated from the slake, producing a pure slaked lime.
Carbonation. The pure slaked lime is then fed to a set of atmospheric stirred reactors, where it is diluted and subsequently reacted with the carbon dioxide feed. The carbonation reaction is regulated by the equilibrium of the solution: as the calcium ions are converted to calcium carbonate and precipitated out, more calcium hydroxide dissolves to equalize calcium ions concentration.
Finishing. The slurry from the carbonators is sent to a filter press, which removes most of the water. Recovered water is recycled for further use in the slaking step. The Precipitated Calcium Carbonate (PCC) from the filter is dried with hot air, deagglomerated in grinders, packed, and stored.
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Production Process Information
Process Consumptions
Labor Requirements
Plant Capital Cost Summary
Operating Cost Summary
Production Costs Datasheet
Plant Capital Cost Details
Operating Cost Details
Plant Cost Breakdowns
Plant Capacity Assessment
Process Flow Diagrams
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Content Highlights
Plant Capital Cost Summary
Summary outlining the capital cost required for building the Calcium Carbonate production plant examined
Plant Capital Cost Details
Detailing of fixed capital (ISBL, OSBL & Owner’s Cost), working capital and additional capital requirements
Plant Cost Breakdowns
Breakdown of Calcium Carbonate process unit (ISBL) costs and infrastructure (OSBL) costs; plant cost breakdown per discipline
Operating Costs Summary
Summary presenting the operating variable costs and the total operating cost of the Calcium Carbonate production plant studied
Operating Cost Details
Detailing of utilities costs, operating fixed costs and depreciation
Plant Capacity Assessment
Comparative analysis of capital investment and operating costs for different Calcium Carbonate plant capacities
Production Process Information
Block Flow Diagram, descriptions of process unit (ISBL) and site infrastructure (OSBL)
Process Consumptions
Raw materials and utilities consumption figures, by-products credits, labor requirements
Process Diagrams
Process flow diagrams (PFD), equipment list and industrial site configuration
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