Detailed Project Report (DPR) on Water Treatment Chemicals (Corrosion Inhibitor, Surfactant, Coagulant, Anti foam, Flocculant (Polymer), Anti Scalant etc.)

WATER TREATMENT CHEMICALS (CORROSION INHIBITOR, SURFACTANT, COAGULANT, ANTI FOAM, FLOCCULANT (POLYMER), ANTI SCALANT ETC.)

Hardness in water is caused by dissolved salts of calcium and magnesium, such as the bicarbonates, sulphates and chlorides. The scale will insulate the heating surfaces from the cooling effect of the water and over-heating will occur. Over-heating can soften the metal so that, in the case of a furnace tube, it can collapse under the pressure of the steam with explosive force. This will endager any one in the vicinity and can cause extensive damage to plant and buildings. In a less dramatic way, scale build-up can cause extensive damage build-up can cause tube-end leakage, where smoke tubes are expanded into the end plates of the boiler, requiring expensive replacement and possible loss sof production.

Quite apart from the hazards arising from scaling, there is the energy conservation aspect. As scale builds up on heat transfer will steaidly drop, with a corresponding increase in fuel-gas temperature. The effect is similar to that build-up of root on the fine side of the boiler. Scale build-up could account for an increase in fuel consumption of 3 or 4% which is considerable on a boiler which may be using say, 1000 of fuel a week.

COST ESTIMATION

Plant Capacity            2000 Kg./Day  

Land & Building (1000 sq.mt.)    Rs. 1.65 Cr    

Plant & Machinery                    Rs. 71.50 Lac 

Working Capital for 2 Months    Rs. 1.10 Cr 

Total Capital Investment          Rs. 3.63 Cr 

Rate of Return                          32%

Break Even Point                      54%

CONTENTS

INTRODUCTION

1. HARDNESS SALTS:

NON-HARDNESS SALTS:

ORGANIC MATTER:

SILICA:

DISSOLVED GASES:

SUSPENDED MATTER:

PREVENTION OF SCALE

THE UNTREATED WATER CAN BE CLASSIFIED IN THREE MAIN GROUPS:

SOFT WATER

INTERMEDIATE WATER:

HARD WATER:

PROPERTIES

CRYSTALLINE:

RAW MATERIALS

THE REACTION INVOLVED IS

RAW MATERIAL FOR 1 TONS. OF VARIOUS PRODUCTS

COAGULATION AND FLOCCULATION IN WATER BAND WASTE WATER

THE COAGULANTS

FIGURE 1. STAGES IN THE BRIDGING MECHANISM:  DISPERSION; (II) ADSORPTION; (III) COMPRESSION OR SETTLING DOWN (SEE INSET); (IV) COLLISION2

WASTE WATER TREATMENT

FACTOR EFFECTING COAGULATION TEMPERATURE

TEMPERATURE

SEQUENCE OF CHEMICAL ADDITION

RESIDUAL ALUMINUM

RAPID MIXING

FLOCCULATION

MARKET OVREVIEW OF WATER TREATMENT CHEMICALS

END-USE INSIGHTS

REGIONAL INSIGHTS

PRODUCT INSIGHTS

APPLICATION INSIGHTS

KEY COMPANIES & MARKET SHARE INSIGHTS

KEY WATER TREATMENT CHEMICALS COMPANIES:

RECENT DEVELOPMENT

FORMULATION OF WATER TREATMENT CHEMICALS

FORMULATION OF CORROSION INHIBITOR (COOLING TOWER)

FORMULATION OF ANTISCALANT (DESALINATION PLANT)

CORROSION INHIBITOR FOR BOILER FEED WATER

FORMULATION OF ANTIFOAMS (THERMAL DESALINATION)

FLOCCULANT

COAGULANT

SURFACANT (COOLING TOWER)

WATER SOFTENING CHEMICAL (SEQUESTRANT FOR CALCIUM)

(NETHERLANDS PATENT - 92,202)

USES

PROCESS OF MANUFACTURE

PROCESS OF MANUFACTURING (WATER SOFTENING CHEMICAL)

BOILER COMPOUND

MANUFACTURING PROCESS OF BOILER COMPOUND

PROCESS FLOW SHEET FOR BOILER COMPOUND

FUNGICIDES FOR COOLING TOWERS

WATER TREATMENT CHEMICALS FOR BOILER & COOLING TOWER

FIRE PROOF COMPOUND

ALGAECIDES FOR WATER

MANUFACTURING PROCESS OF FIRE PROOF COMPOUND

PROCESS FLOW SHEET FOR FIRE PROOF COMPOUND

MANUFACTURING PROCESS OF ALGICIDES

(LIQUID SOLUTION) USED IN COOLING TOWERS

PROCESS FLOW SHEET OF ALGICIDES LIQUID SOLUTION FOR COOLING TOWER

BACTERIOCIDE FOR COOLING TOWER

MANUFACTURING PROCESS OF BACTERIOCIDE FOR COOLING TOWER

PROCESS FLOW SHEET FOR BACTERIOSTATIC

WOOD PRESERVATIVE (FUNGICIDE)

FRMULATION 1

FORMULATION 2

MANUFACTURING PROCESS OF WOOD PRESERVATIVE (FUNGICIDES)

HERBICIDE CONCENRTRATES (EMULISIFIABLE)

FORMULATION 1

FORMULATION 2

FORMULATION 3

FORMULATION 4

FORMULATION 5

FORMULATION 6

PROCESS FLOW SHEET OF HERBICIDES (LIQUID)

FUNGUS CONTROL LIQUID

FORMULATION 1

FORMULATION 2

PROCESS OF MANUFACTURE (FUNGUS CONTROL LIQUID)

PROCESS FLOW SHEET OF FUNGUS CONTROL LIQUID

TECHNICAL DETAILS OF CORROSION INHIBITOR

CHROMATE PROGRAMS

TABLE: A TYPICAL “STANDARD” FORMULATION FOR A CHROMATE PRODUCT

STABILIZED PHOSPHATE PROGRAMS

STABILIZED PHOSPHATE PROGRAMS

TABLE: A TYPICAL FORMULATION OF PHOSPHATE PROGRAM A

TABLE: A TYPICAL FORMULATION OF PHOSPHATE PROGRAM B

TABLE: THE REQUIREMENT OF PRODUCT A AND B FOR DIFFERENT CONCENTRATIONS OF CALCIUM HARDNESS

ALKALINE ZINC/ORGANIC PROGRAMS

SOME KEY FEATURES OF THESE PROGRAMS ARE DISCUSSED HERE:

ALKALINE PHOSPHATE PROGRAMS:

ALKALINE ZINC PROGRAMS:

ZINC/POLYMER/PHOSPHONATE PROGRAMS:

ZINC/PHOSPHATE/ORGANIC PROGRAMS:

TABLE: THE TYPICAL FORMULATION OF ALKALINE ZINC/ORGANIC PROGRAM

TABLE: THE TYPICAL FORMULATION OF ZN/ORGANIC PROGRAM

TABLE: THE TYPICAL PH RANGES OF THESE PROGRAMS

MOLYBDATE PROGRAMS

TABLE: TWO EXAMPLES OF TRADITIONAL MOLYBDATE FORMULATIONS

ALL ORGANIC PROGRAMS

TABLE: AN EXAMPLE OF THE ALL ORGANIC PROGRAM

SOFT AND LEAN WATER AND ENVIRONMENTAL PROGRAMS

TABLE: A TYPICAL FORMULATION FOR SOFT AND LEAN WATER

CLOSED-LOOP PROGRAMS

TABLE: A TYPICAL FORMULATION FOR CLOSED-LOOP PROGRAM

HOT-WATER INHIBITOR

INHIBITORS FOR ALKALINE SOLUTION

BOILER WATER INHIBITORS

EXTRUDE DISSOLVED O2 AND CO2

ADDING ALKALI

ADDING INHIBITORS

PRINCIPLES OF PLANT LAYOUT

STORAGE LAYOUT:

EQUIPMENT LAYOUT:

SAFETY:

PLANT EXPANSION:

FLOOR SPACE:

UTILITIES SERVICING:

BUILDING:

MATERIAL-HANDLING EQUIPMENT:

RAILROADS AND ROADS:

MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE:

PLANT LOCATION FACTORS

PRIMARY FACTORS

1. RAW-MATERIAL SUPPLY:

2. MARKETS:

3. POWER AND FUEL SUPPLY:

4. WATER SUPPLY:

5. CLIMATE:

SPECIFIC FACTORS

6. TRANSPORTATION:

A. AVAILABILITY OF VARIOUS SERVICES AND PROJECTED RATES

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. TOTAL LOAD:

8. LAND AREA/MAN POWER RATIO:

PROJECT IMPLEMENTATION SCHEDULES

INTRODUCTION

PROJECT HANDLING

PROJECT SCHEDULING

PROJECT CONSTRUCTION SCHEDULE

TIME SCHEDULE

ADDRESSES OF PLANT AND MACHINERY

BOILER

TANKS: STORAGE

DRYERS & DRYING OVENS

REACTION VESSELS

FILTER PRESS

EVAPORATOR

RAW MATERIAL SUPPLIERS

PHOSPHORIC ACID

SODA ASH

STARCH

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)