Superabsorbent Polymer Using Continuous Gel Polymerization (Production Rate – 1000 TPM)

SUPERABSORBENT POLYMER USING CONTINUOUS GEL POLYMERIZATION (PRODUCTION RATE – 1000 TPM)

[EIRI/EDPR/4585] J.C.: 2802XL

INTRODUCTION

Superabsorbent Polymers (SAP) are primarily used as an absorbent for water and aqueous solutions for diapers, adult incontinence products, feminine hygiene products, and similar applications. Undoubtedly, in these applications, superabsorbent materials will replace traditional absorbent materials such as cloth, cotton, paper wadding, and cellulose fiber.

Commercial production of superabsorbent polymers began in Japan in 1978, for use in feminine napkins. This early superabsorbent was a crosslinked starch-g-polyacrylate. Polyacrylic acids eventually replaced earlier super absorbents, and is the primary polymer employed for superabsorbent polymers today.1 In 1980, European countries further developed the superabsorbent polymer for use in baby diapers. This first diapers employing this technology used only a small amount of polymer, approximately 1-2 g. In 1983, a thinner diaper using 4-5 grams of polymer and less fluff was marketed in Japan.

The use of superabsorbent polymers revolutionized the diaper industry. Diaper manufacturers began to design diapers to take advantage of the amazing liquid retention ability of the polymer. Superabsorbent polymers absorb, and retain under a slight mechanical pressure, about 30 times their weight in urine.2 the swollen gel holds the liquid in a solid, rubbery state and prevents the liquid from leaking onto the baby’s skin and clothing.

Superabsorbent polymers are prepared from acrylic acid and a cross linker by solution or suspension polymerization. The type and quantity of cross linker control both the swelling capacity and gel modulus.2 the synthesis and use of crosslinked polyacrylate super absorbents have been a popular topic in the polymer literature. However, very little information about manufacturing processes has been given due to its proprietary content.

The properties of superabsorbent polymers can be employed in many different applications. The largest use of superabsorbent polymers is in personal hygiene products. These consumer products include, in order of volume of super absorbents used, disposable infant diapers, children’s training pants, adult incontinence articles, and feminine sanitary napkins. 

COST ESTIMATION

Plant Capacity            33.334 MT/Day  

Land & Building (3815 sq.mt.)    Rs. 4.76 Cr    

Plant & Machinery                    Rs. 9.92 Cr 

Working Capital for 0.5 Months    Rs. 13.93 Cr 

Total Capital Investment          Rs. 29.50 Cr 

Rate of Return                          48%

Break Even Point                      37%

CONTENTS

INTRODUCTION

USES/APPLICATIONS

ADVANTAGE OF SUPERABSORBENT POLYMER IN AGRICULTURE

MARKET OVERVIEW

TYPES OF SUPERABSORBENT POLYMER

ABSORBENT VERSUS SUPERABSORBENT MATERIALS

CLASSIFICATION AND PREPARATION OF SUPERABSORBENT POLYMERS

SUPER ABSORBENT POLYMER AND ITS CHEMISTRY

COMPARISON TO OTHER SOLIDIFICATION MEDIA

MECHANISMS OF SWELLING IN SUPERABSORBENT POLYMERS

OVERVIEW OF SUPERABSORBENT POLYMER MANUFACTURING

FORMULATIONS

RAW MATERIALS

RAW MATERIAL SUPPLIERS

MANUFACTURING PROCESS STEPS

TEST METHODS

SPECIFICATIONS

ENGINEERING DESIGN CONSIDERATIONS

ETP FACILITY

SEWAGE AND WASTE WATER EFFLUENT 

WASTE GENERATION & MANAGEMENT/GREEN BELT

PLANT/MACHINERY (BROADLY)

SUPPLIERS OF PLANT & MACHINERIES/TURNKEY

UTILITIES PER MONTH (ESTIMATED)

PRINCIPLES OF PLANT LAYOUT

PLANT LOCATION FACTORS

HEALTH SAFETY & ENVIRONMENT

ANTICIPATED ENVIRONMENTAL IMPACTS 

SAFETY & OCCUPATIONAL MEASURE 

PROPOSED IMPLEMENTATION SCHEDULE

PROJECT FINANCIALS

PRELIMINARY LAYOUT

COMPARISONS OF DIFFERENT MANUFACTURING PROCESSES 

CONCLUSIONS

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)