Detailed Project Report (DPR) on pharma grade ferrous sulphate heptahydrate

PHARMA GRADE FERROUS SULPHATE HEPTAHYDRATE
[CODE NO.3884]  


Ferrous Sulphate 'Copperas' Green Copperas, Green Vitriol; FeSO4. 7H2O is obtained as pale green crystals soluble in water. It is produced as a byproduct from waste pickling liquors of galvanizing and tin plates plants or by dissolving scrap iron in warm dilute sulphuric acid. In the bye product process the liquor is treated with scrap iron to reduce the free acid content, neutralized with alkali, filtered and concentrated in evaporators. Alternately, scrap iron and sulphuric acid are added at 180oF, to the liquor to raise the concentration to 430Be. The hot concentrated liquor is introduced into crystallizers and cooled to room temperature. Crystals of heptahydrate separate until the specific gravity falls to 260Be. The crystals are filtered, washed in a centrifuge, broken, screened and dried with warm air at 140oF in rotary drum, dryers. The mother liquor is returned to the neutralizing tank or further concentrated in evaporators. A slight excess of sulphuric acid is usually maintained in the crystals to prevent oxidation; surface oxidation may be counteracted by adding a small quantity of iron to the liquor during the heating and settling operations.

Ferrous Sulphate is also obtained as a bye product in the manufacture of titanium pigment and copper sulphate. For medicinal use, it is prepared by the action of dilute sulphuric acid on iron. Exsiccated Ferrous Sulphate used in therapy is a grayish white powder prepared by drying Ferrous Sulphate crystals at 40oC when a part of the water of crystallization is removed. It is slowly but almost completely soluble in freshly boiled cooled water.


COST ESTIMATION


Plant Capacity                    600 Ton/ Per Year         
Land & Building (700 sq.mt.)    Rs. 1.05  Cr                         
Plant & Machinery               Rs. 30.00 Lacs                            
Working Capital for 2 Month     Rs. 31.76 Lacs       
Total Capital Investment        Rs. 1.73  Cr
Rate of Return                    25%                   
Break Even Point             65%            


INTRODUCTION    
THE COMMERCIAL METHODS OF ITS DERIVATION ARE:-    
PROPERTIES    
GRADES OF FERROUS SULPHATE    
CONTAINERS AND REGULATIONS    
USES AND APPLICATIONS    
(I) TECHNICAL GRADE    
(II) PURE GRADE    
B.I.S. SPECIFICATION    
SOLUBILITY:    
TABLE-1    
TABLE-II    
TABLE-III    
PACKING & MARKING:-    
SPECIFICATION OF FERROUS SULPHATE HEPTAHYDRATE    
FERROUS SULPHATE HEPTAHYDRATE AR/ACS MEETS ANALYTICAL
    SPECIFICATION OF IP, BP, USP, PH.EUR.    
MARKET POSITION OF FERROUS SULPHATE    
FERROUS SULFATE MARKET HITS GOLDMINE AS FERROUS SALTS
   GAIN POPULARITY TO TREAT ANEMIA    
FOCUS ON IMPROVING WATER QUALITY TRIGGERS DEMAND
    FOR FERROUS SULFATE    
KEY PRODUCT IN FERROUS SULFATE MARKET    
HIGH DEMAND FOR FERROUS SULFATE IN VARIOUS INDUSTRIES    
ASIA PACIFIC TO BE HIGHLY LUCRATIVE REGION OF FERROUS
    SULFATE MARKET    
FERROUS SULFATE MARKET: COMPETITION LANDSCAPE    
MANUFACTURING PROCESS OF FERROUS SULPHATE
    HEPTAHYDRATE (PHARMA GRADE)   
RAW MATERIALS    
CHEMICAL REACTION    
PROCESS FLOW DIAGRAM    
PROCESS IN DETAILS    
REACTION:    
FILTERATION:    
EVAPORATING:    
CENTRIFUGATION:    
DRYING:    
PROCEDURE:    
CALCULATION:    
PACKING:    
PURIFICATION:    
REAGENTS:    
METHOD OF FERROUS SULPHATE PRODUCTION    
PICKLE LIQUOR REMOVES OXIDE LAYER    
THE SULFATE PROCESS    
FORMULATIONS/PREPARATIONS    
PRODUCTION OF FERROUS SULPHATE HEPTAHYDRATE
    FROM FERROUS SULPHATE MONOHYDRATE    
POLLUTION CONTROL IN THE MANUFACTURE
    OF FERROUS SULPHATE    37
PRINCIPLES OF PLANT LAYOUT    
PLANT LOCATION FACTORS    
PRIMARY FACTORS    
1.   RAW-MATERIAL SUPPLY:    
2.   MARKETS:    
3.   POWER AND FUEL SUPPLY:    
4.   WATER SUPPLY:    
5.   CLIMATE:    
6.   TRANSPORTATION:    
7.   WASTE DISPOSAL:    
8.   LABOR:    
9.   REGULATORY LAWS:    
10.  TAXES:    
11.  SITE CHARACTERISTICS:    
12.  COMMUNITY FACTORS:    
13.  VULNERABILITY TO WARTIME ATTACK:    
14.  FLOOD AND FIRE CONTROL:    
EXPLANATION OF TERMS USED IN THE PROJECT REPORT    
1. DEPRECIATION:    
2. FIXED ASSETS:    
3. WORKING CAPITAL:    
4. BREAK-EVEN POINT:    
5. OTHER FIXED EXPENSES:    
6. MARGIN MONEY:    
7. TERM LOANS:    
8. TOTAL LOAD:    
9.   LAND AREA/MAN POWER RATIO:    
PROJECT IMPLEMENTATION SCHEDULES    
INTRODUCTION    
PROJECT HANDLING    
PROJECT SCHEDULING    
PROJECT CONSTRUCTION SCHEDULE    
TIME SCHEDULE    
SUPPLIERS OF RAW MATERIALS    
SUPPLIERS OF PLANT AND MACHINERY    

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)