Industry Overview
Aluminium sulfate (Al2(SO4)3), commonly known as alum, is a water-soluble, non-combustible material produced in crystalline, solid, and solution forms. The dry hydrate, Al2(SO4)3.14H2O, contains 17% Al2O3, while aluminium sulfate is also marketed as a 47% w/w solution containing 8% Al2O3. Solid alum is supplied in kibbled, ground, dust, lump, and other commercial forms.
Ferric and non-ferric alum are available in various grades. Ferric alum is generally produced from bauxite and contains iron, whereas non-ferric alum is generally produced from alumina. Historically, alum was prepared from alum shales by roasting and leaching. Potash alum has also been produced by crystallizing equivalent proportions of potassium sulfate and aluminium sulfate, followed by concentration and separation of crystals.
The principal application of alum is water treatment and clarification, where hydrolysis produces aluminium hydroxide that helps remove colloidal impurities. Another major application is paper sizing, where alum reacts with sodium resinate to form insoluble aluminium resinate and improve resistance to liquid penetration. Alum is also used in dyes, food, petroleum, pharmaceuticals, fire-proofing, tanning, and other industrial applications. Technical-grade aluminium sulfate is supplied as partially dehydrated solid and aqueous solution, while reagent-grade material is available as colourless crystals.
Cost Estimation
| Particulars | Value |
|---|---|
| Plant Capacity | 20 MT./Day |
| Land & Building (2000 sq.mt.) | Rs. 76 Lacs |
| Plant & Machinery | Rs. 93 Lac |
| Working Capital for 1 Month | Rs. 70 Lac |
| Total Capital Investment | Rs. 2.51 Cr |
| Rate of Return | 24% |
| Break Even Point | 73% |
Content Index
- INTRODUCTION
- CHARACTERISTICS & SPECIFICATION
- SPECIFICATION OF ALUM
- USES & APPLICATIONS
- APPLICATIONS:
- USES OF ALUM
- THE MAIN USES OF ALUM ARE:
- OTHER MAJOR USES
- WHAT HAPPENS AT A WATER TREATMENT PLANT?
- SCREENING:
- PRE-SEDIMENTATION:
- MICRO-STRAINING:
- CHEMICAL PRETREATMENT:
- SOFTENING:
- COAGULATION AND FLOCCULATION:
- SEDIMENTATION:
- FILTRATION:
- DISINFECTION:
- FLUORIDATION:
- TREATMENT TO REMOVE ORGANIC CONTAMINANTS
- TESTING:
- B.I.S. SPECIFICATIONS
- SPECIFICATIONS OF ALUMINIUM SULPHATE (NON FERRIC)
- QUALITY CONTROL AND STANDARD IS: 299-1989 (FERRIC ALUM)
- NON FERRIC ALUM
- NON FERRIC ALUM - PRODUCT CHARACTERISTICS:
- NON FERRIC ALUM - PRODUCT APPLICATION:
- NON FERRIC ALUM - BENEFITS
- SPECIFICATION OF ALUMINUM SULPHATE
- (NON-FERRIC ALUM) (SLABE/LUMPS/POWDER)
- (FERRIC ALUM) (SLABE/LUMPS)
- FERRIC & NON-FERRIC ALUM PLANT
- MANUFACTURING PROCESS:
- THE RAW MATERIALS ARE:
- FOR FERRIC ALUM:
- FOR NON FERRIC ALUM (ALUMINUM SULPHATE):
- SPECIFIC RAW MATERIAL CONSUMPTION (FOR ALUM CONTAINING ALUMINA AS AL2O3 16 %)
- RAW MATERIALS
- BAUXITE
- THE RANGE OF COMPOSITION OF BAUXITES IS USUALLY:
- THE BEST FRENCH WHITE BAUXITE CONTAINS:
- MARKET OVERVIEW OF ALUMINIUM SULPHATE
- ALUMINIUM SULPHATE MARKET, BY PRODUCT TYPE
- ALUMINIUM SULPHATE MARKET, BY END USER
- ALUMINIUM SULPHATE MARKET, BY GEOGRAPHY
- INDIAN DEMAND FOR ALUM
- PAPER INDUSTRY
- WATER TREATMENT
- MISCELLANEOUS APPLICATIONS
- IMPORTANT GLOBAL MANUFACTURERS
- PRESENT MANUFACTURERS/SUPPLIERS OF FERRIC & NON FERRIC ALUM
- TECHNIQUE IN ALUM PRODUCTION
- PROCESS OUTLINES FOR ALUMINIUM SULFATE MANUFACTURE
- RAW MATERIALS
- STEP 1 - REACTING THE RAW INGREDIENTS.
- STEP 2 - MAKING THE FINAL PRODUCT
- ENVIRONMENTAL IMPLICATIONS
- MANUFACTURING PROCESS OF NON FERRIC ALUM
- MASS BALANCE
- PROCESS FLOW DIAGRAM WITH MATERIAL BALANCE BASIS: 1 TON
- DETAILED PROCESS DESCRIPTION
- (A) BAUXITE PREPARATION SECTION:-
- (B) REACTION SECTION:-
- WASTE & EMISSION'S:-
- PACKING & MARKING:-
- PACKING:-
- MARKING:-
- REQUIREMENT FOR ALUMINIUM SULPHATE (NON FERRIC)
- METHODS OF TEST FOR ALUM, NON FERRIC (ALUMINIUM SULFATE)
- QUALITY OF REAGENTS:-
- PREPARED SAMPLE:-
- PROCEDURE:-
- DETERMINATION OF INSOLUBLE MATTER
- REAGENTS:-
- PROCEDURE:-
- DETERMINATION OF PH:-
- PROCEDURE:-
- DETERMINATION OF HEAVY METALS:-
- OUTLINE OF THE METHOD:-
- APPARATUS:-
- REAGENTS:-
- STANDARD LEAD SOLUTION:-
- PROCEDURE:-
- DETERMINATION OF IRON:-
- OUTLINE OF THE METHOD:-
- APPARATUS:-
- REAGENTS:-
- BUTANOLIC POTASSIUM THIOCYANATE SOLUTION:-
- STANDARD IRON SOLUTION:-
- PROCEDURE:-
- TEST FOR CHLORIDES:-
- REAGENTS:-
- PROCEDURE:-
- DETERMINATION OF ARSENIC
- PROCEDURE:-
- DETERMINATION OF THE AMMONIUM SALTS
- OUTLINE OF THE METHOD:-
- APPARATUS:-
- REAGENTS:-
- NESSLER SOLUTION:-
- STANDARD AMMONIUM CHLORIDE SOLUTION:-
- PROCEDURE:-
- DETERMINATION OF ALUMINIUM
- TWO METHODS ARE PRESCRIBED, NAMELY
- GRAVIMETRIC METHOD
- REAGENTS:-
- PROCEDURE:-
- EDTA METHOD:-
- REAGENTS:-
- ABSOLUTE ALCOHOL
- ACETIC ACID:-
- AMMONIUM ACETATE BUFFER SOLUTION:-
- PROCEDURE:-
- CALCULATION:-
- DETERMINATION OF SODIUM:-
- DETERMINATION OF POTASSIUM:-
- SAMPLING OF ALUM, NON FERRIC (ALUMINIUM SULPHATE)
- GENERAL REQUIREMENTS OF SAMPLING:-
- SCALE OF SAMPLING:-
- TABLE 2 SCALE OF SAMPLING
- PREPARATION OF TEST SAMPLES
- NUMBER OF TESTS
- CRITERION FOR CONFORMITY
- BLOCK DIAGRAM TO PRODUCE ALUMINIUM SULPHATE NON FERRIC (17% TO 18%) ALUMINA CONTENT IN GRANULES (2MM TO 4MM) AND FLAKES FORM
- CHEMICAL COMPOSITION OF FERRIC ALUM:
- GRADE 3
- CHEMICAL COMPOSITION OF NON-FERRIC ALUM:
- USES:
- METHOD OF PRODUCING ALUMINIUM SULFATE SOLUTION
- MATERIAL SAFETY DATA SHEET OF ALUMINIUM SULPHATE
- HAZARDS IDENTIFICATION
- EMERGENCY OVERVIEW
- POTENTIAL HEALTH EFFECTS
- CARCINOGEN STATUS:
- COMPOSITION/INFORMATION ON INGREDIENTS
- FIRST AID MEASURES
- GENERAL INFORMATION:
- FIRE FIGHTING MEASURES
- ACCIDENTAL RELEASE MEASURES
- HANDLING AND STORAGE
- PHYSICAL AND CHEMICAL PROPERTIES:
- STABILITY AND REACTIVITY
- DISPOSAL CONSIDERATIONS
- TRANSPORT INFORMATION
- MATERIAL SAFETY DATA SHEET FOR DRY ALUM
- COMPLETE PLANT SUPPLIERS OF FERRIC & NON-FERRIC ALUM PLANT
- ADDRESSES OF PLANT AND MACHINERY SUPPLIERS
- SUPPLIERS OF RAW MATERIALS
- TO GET REQUIRED CERTIFICATION & OTHER FORMALITES FOR EXPORTING NON FERRIC ALUMINIUM SULPHATE
- ADDRESSES OF CONSULTANTS
- ADDRESSES OF PILOT PLANT SUPPLIERS
- SUPPLIERS OF RAW MATERIAL (INDIAN)
- SUPPLIERS OF BAUXITE
- SUPPLIERS OF SULPHURIC ACID
- SUPPLIERS OF BARIUM SULPHIDE
- SUPPLIERS OF RAW MATERIALS (GLOBAL)
- OTHERS EQUIPMENTS SUPPLIERS
- SUPPLIERS OF REACTOR
- SUPPLIERS OF EVAPORATORS
- SUPPLIERS OF GRADING SCREEN/ VIBRATING SCREEN
- SUPPLIERS OF COOLING TOWERS
- SUPPLIERS OF BOILERS
- SUPPLIERS OF CRUSHER
- SUPPLIERS OF MATERIAL HANDLING EQUIPMENTS
- SUPPLIERS OF LABORATORY TESTING EQUIPMENTS
- SUPPLIERS OF PLANT AND MACHINERIES (IMPORTED)
Appendix
- APPENDIX – A:
- 01. PLANT ECONOMICS
- 02. LAND & BUILDING
- 03. PLANT AND MACHINERY
- 04. OTHER FIXED ASSESTS
- 05. FIXED CAPITAL
- 06. RAW MATERIAL
- 07. SALARY AND WAGES
- 08. UTILITIES AND OVERHEADS
- 09. TOTAL WORKING CAPITAL
- 10. TOTAL CAPITAL INVESTMENT
- 11. COST OF PRODUCTION
- 12. TURN OVER/ANNUM
- 13. BREAK EVEN POINT
- 14. RESOURCES FOR FINANCE
- 15. INSTALMENT PAYABLE IN 5 YEARS
- 16. DEPRECIATION CHART FOR 5 YEARS
- 17. PROFIT ANALYSIS FOR 5 YEARS
- 18. PROJECTED BALANCE SHEET FOR (5 YEARS)
Frequently Asked Questions
Aluminium sulfate, commonly called alum, is a water-soluble aluminium salt used extensively in industrial applications. It is produced in crystalline, partially dehydrated solid, and aqueous solution forms. The report identifies ferric and non-ferric alum as two broad categories, with ferric alum generally made from bauxite and non-ferric alum generally made from alumina. Commercial material is supplied under several names and in forms such as lumps, granules, powder, flakes, kibbled material, and liquid solution.
The main uses of alum are water treatment and paper sizing. In water treatment, alum assists clarification by forming aluminium hydroxide through hydrolysis, which helps carry colloidal impurities into a removable sludge layer. In paper manufacturing, alum reacts with sodium resinate to form insoluble aluminium resinate and contributes to resistance against liquid penetration. The report also identifies applications in dyes, food, petroleum, pharmaceuticals, fire-proofing, tanning, and other industries.
Ferric alum contains iron, whereas non-ferric alum is intended to be substantially free from ferric ions. The report states that ferric alum is generally produced from bauxite and non-ferric alum is generally produced from alumina. This distinction is important for applications where iron impurities can affect product colour or performance, particularly paper sizing. The two product categories can therefore require different raw materials, specifications, quality-control procedures, and process considerations.
Alum is primarily used as a coagulant to assist the clarification of water. When aluminium sulfate hydrolyses, aluminium hydroxide is formed and helps capture colloidal and suspended impurities, allowing them to be separated during subsequent treatment. A conventional water-treatment process can include screening, pre-sedimentation, chemical pretreatment, coagulation and flocculation, sedimentation, filtration, and disinfection. The appropriate treatment sequence depends on the characteristics of the source water and the required finished-water quality.
The report identifies bauxite as a principal raw material for ferric alum and alumina as a principal raw material for non-ferric aluminium sulfate. It also contains sections covering sulphuric acid and other raw-material requirements and suppliers. The precise raw-material combination depends on the selected manufacturing route, product grade, required aluminium content, and impurity limits. Industrial production therefore requires controlled raw-material quality together with suitable reaction, concentration, crystallization, and finishing operations.
Quality testing for non-ferric aluminium sulfate can include checks for insoluble matter, pH, heavy metals, iron, chlorides, arsenic, ammonium salts, aluminium, sodium, and potassium. The report includes detailed sections on reagent quality, sample preparation, analytical procedures, apparatus, standard solutions, calculations, sampling, number of tests, and conformity criteria. Such testing helps verify that the finished alum meets its specified chemical and physical requirements and is suitable for its intended industrial application.
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