Detailed Project Report (DPR) on Radiator Coolant

RADIATOR COOLANT

[EIRI/EDPR/1077] J.C.: 9721XL

INTRODUCTION

What is Radiator Engine Coolant?

There are two types of Coolant.

1) Engine Coolant

2) Machine Coolant

Engine Coolant is a mixture of various types of glycols and highly formulates & researched various corrosive inhibitors. De-mineralized water is mixed with the coolant as per suggestion and used in the engine-radiator cooling system to remove excess heat of engine.

Why Coolant is required?

The purpose of Coolant is to remove excess heat produced from the engine operation, to control corrosion and scaling, antifreeze and boil over the radiator water. So many years ago water was used to reduce the temperature. Water is an effective heat transfer fluid but it boils at very low temperature. Highly corrosive and format scaling. It impure the cooling liquid by accumulating corrosive and scaled waste. So it chocks up tubes of radiator and finally engine overheats. The complexity is increased with the use of aluminum alloys in the head, water pump and radiators.

To protect against the heat, corrosion of aluminum and other metals & scaling; coolant creates a special protective film on all metals. Our this specially researched protective film have important role in the cooling system. This special corrosion inhibitors film technology is only researched and used by us in India.

Performance Advantage Coolant:

Coolants industry need scientifically advance research lab. The industry also need technically dynamic staff having experienced scientist and chemist. Coolant must be little bit different from other coolant because it is always thick and exceeds all major automotive performance protection international specification. It protects whole cooling system metals like Aluminum, Steel, High Lead Solder, Cast Iron, Copper, Brass, Low Lead Solder etc. against rust, surface and pitting corrosion. It is eco friendly and fully synthetic formulated coolant.

It incorporates state of art organic acid technology (OAT) in an Ethylene Glycol base for protection of whole cooling system metals including Aluminum. Most Coolant does not contain phosphates, silicates, borates, nitrates, nitrites and amines. It contains a high quality defoamer and does not harm gaskets, hoses, plastics or original vehicle paint.

The internal combustion engine is a heat engine, in which chemical energy of fuel is converted into heat energy by combustion and this heat energy is in trun converted into mechanical energy. Approximately one third of the heat energy is converted into mechanical energy, about one third is removed by the cooling system and one third by the exhaust system. There are minor losses due to friction, radiation and the lubrication system. For each 3.8 litres of fuel burned about 6.32 M J must be rejected to the cooling system. If this heat is not removed, the engine will be destroyed.

The cooling system consists of a (heat exchanger, thermostat, coolant pump, coolant jacket surrounding the cylinders and combustion chambers and various rubber hoses serving as flexible connections between the radiator and engine to allow complete circulation of the coolant.

The coolant pump circulates the coolant through the engine coolant jacket, where it picks up heat dissipated by the combustion chambers & cylinders and then through the radiator (heat exchanger), allowing the heat to be transferred to the outside air. The coolant is then returned to the engine block and the cycle is repeated.

COOLANT

The coolant used in this cooling system must fulfill the requirement of the engine, which is baiscally the removal of one third of heat produced during combustion of fuel.

COST ESTIMATION

Plant Capacity            500 Ltr./Day

Land & Building (1000 sq.mt.)    Rs. 1.11 Cr

Plant & Machinery                    Rs. 68.20 Lac

Working Capital for 3 Months    Rs. 69.49 Lac

Total Capital Investment          Rs. 2.74 Cr

Rate of Return                          18%

Break Even Point                      68%

CONTENTS

INTRODUCTION

THERE ARE TWO TYPES OF COOLANT

WHY COOLANT IS REQUIRED?

PERFORMANCE ADVANTAGE COOLANT:

GLYCOL BASED ANTIFREEZE COOLANT

MANUFACTURING PROCESS INVOLVES FOLLOWING MAJOR STEPS:

REQUIREMENT OF COOLANTS

DISADVANTAGES OF WATER:-

WORKING PROCEDURE:-

ENGINE COOLANT:-

USES AND APPLICATIONS

SERVICE PERIOD

PERFORMANCE OF COOLANT

FREEZING PROTECTION:-

BOILING POINTS:-

COOLANT LOSSES:-

FOAMING:-

EFFECT ON ELASTOMERS:-

EFFECT ON POINT:-

CORROSION AND INHIBITORS:-

SERVICE LIFE:-

PHYSICAL PROPERTIES OF ETHYLENE GLYCOL

PHYSICAL PROPERTIES OF ACCEPTABLE ANTIFREEZE COMPOUNDS

B I S SPECIFICATIONS AND REQUIREMENTS

MARKET POSITION WITH FUTURE DEMAND

AUTO POLICY OF GOVERNMENT OF INDIA

AUTOMOBILE INDUSTRY PERFORMANCE DURING 2006-2007

LIST OF MANUFACTURERS

INDIA AS AN ASIAN BASE:-

PRESENT MANUFACTURERS

RADIATOR COOLANTS

MANUFACTURING PROCESS

A. ORGANIC COMPOUNDS

B. INORGANIC COMPOUNDS

C. SILICONS

FORMULATION- - (VERY GOOD QUALITY ENGINE COOLANT)

MANUFACTURING PROCESS

ENGINE COOLANT (MEDIUM QUALITY FORMULATION):-

ENGINE COOLANT (CHEAPER QUALITY) FORMULATION:-

SODIUM MERCAP TO BENZOTHIAZLE - (SOD. MBT)

SODIUM SILICATE

DIMETHYL SILCONE:- (SILICONE OIL)

TRISODIUM PHOSPHATE:- (TSP)

MINERAL OIL

PLANT SKETCH FOR ENGINE COOLANT MANUFACTURING

ENGINE ANTIFREEZE COOLANT COMPOSITION

ANTIFREEZE COMPOSITIONS

EXAMPLE 1

EXAMPLE 2

EXAMPLE 3

EXAMPLE 4

CORROSION INHIBITING COOLANT COMPOSITIONS

COOLANT INHIBITOR CONCENTRATE

EXAMPLE 1

PROCEDURE

EXAMPLE 2

PROCEDURE

EXAMPLE 3

LIQUID COOLANT COMPOSITIONS WITH ANTI-CORROSIVE PROPERTY CONTAINING MAGNESIUM AND CALCIUM COMPOUNDS

THE TEST RESULTS ARE SHOWN IN TABLE 1.

ANTIFREEZE COOLANT COMPOSITION HAVING HIGH HEAT-OXIDATION RESISTANCE

EXAMPLES 1-6

PREPARATION OF AN ANTIFREEZE LIQUID

COMPARATIVE EXAMPLES 1-7

MATERIAL OF CONSTRUCTION OF PLANT & MACHINERY

1. REACTION VESSEL (JACKETED):-

2. PIPE LINE FILTER:-

3. STORAGE TANKS/WEIGHING, FILLING TANKS:-

QUALITY TESTING OF ETHYLENE GLYCOL

REQUIREMENTS OF COOLANT:-

GENERAL REQUIREMENTS:-

COLOURATION OF LIQUID:-

SPECIFIC REQUIREMENT:-

KEEPING QUALITY:-

PACKING & MARKING:-

PACKING:-

MARKING:-

CAUTIONS ON HANDLING:-

BIS CERTIFICATION MARKING:-

SAMPLING:-

TABLE 1 REQUIREMENTS FOR ANTIFREEZE COOLANTS

PLANT LAYOUT FOR ENGINE COOLANT MANUFACTURING UNIT

PROJECT IMPLEMENTATION SCHEDULE

PROCESS FLOW SHEET

MANUFACTURERS & SUPPLIERS OF RAW MATERIALS

DISTILLED WATER

SODIUM SILICATE

WHITE MINERAL OIL

PLANT AND MACHINERY SUPPLIERS

REACTION VESSEL

OIL STORAGE TANKS

LABORATORY EQUIPMENT AND LAB TESTING EQUIPMENT

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)