Detailed Project Report on battery grade (99.5% Pure) sulphuric acid plant

BATTERY GRADE (99.5% PURE) SULPHURIC ACID PLANT
[CODE NO.3059]  


Sulfuric acid molecular formula written as H2SO4, with other names includes oil of vitriol, battery acid, and king of chemicals. Sulfuric acid composed of hydrogen, oxygen, and sulfur and available forms include dilute sulfuric acid, concentrated sulfuric acid.

Sulfuric acid is formed naturally by the oxidation of sulfide minerals, such as iron sulfide. On earth, sulfuric acid does not exist in a natural form. But on the planet Venus, there are lakes of the sulfuric acid exist. The sulfuric acid from lakes will evaporate to form clouds, leading to sulfuric acid rain on the Venerean surface.

Sulfuric acid is the largest volume industrial chemical produced in the world i.e., 200 million tons per year. 93-98 per cent (concentrated) sulfuric acid is used in the manufacture of fertilizers, explosives, dyes, petroleum products, domestic acidic drain cleaner, lead-acid batteries, mineral processing, fertilizer manufacturing, oil refining, wastewater processing, and chemical synthesis.

International commerce of sulfuric acid, lists sulfuric acid under Table II of the convention as a chemical frequently used in the illicit manufacture of narcotic drugs or psychotropic substances.

In laboratories or industries if you spill a drop of sulfuric acid on your hand, it will burn tissue instantly. It also causes skin dehydration. Other severe effects of sulphuric acid are fumes cause blindness, and damage the lungs if inhaled. Even dilute sulfuric acid is dangerous.


Sulphuric acid forms the basis of so many of the  most important heavy chemical sued by the industriers that it may well be  regarded as the foundation on which  the main structure of the heavy chemical industries. It is hard to find any branch  of economy in which either sulphuric acid or products  made  from it are not used. It is universally acknowledged that the extent of manufactures of H2SO4 is a sure index of the state of  the industrial life of a country. It would be rather appropriate  to say that country's economy depends upon the consumption of the sulphuric acid.

There is hardly any important industry which is not directly or indirectly dependent to some  extent  on sulphuric acid,  one of its derivatives or it salts. The versatile use of sulphuric acid has cripped in to almost all industrial fields and have gained enough popularity after second world war.  The amount consumption  and production of sulphuric acid in the country is proportional to the economic  growth of the country. This industry takes the target there of industrial market. It is obvious that although fertilizer and chemical  take  up  the targets proportion of the acid produced and reset to this  stands Rayon and steel industry.

The  sulphuric acid is the only acid which has thousands  of uses in form of acid, salts and derivatives interestingly  enough the  uses  of sulphuric acid  starts with english  alphabets  'a' and ends at 'z' . The 'A' alphabet indicates the use as an  acid, 'B'  indicates use is in battery, 'C'  in  chemical industry  'D' drugs , 'E'  as explosives, 'F' forfeiting, 'G' galvanizing  ,'H' as herbicides, I as insecticides, J as joint cleaning , and so on (I  as  leather industry, M as metallurgical  industry O  as  Oil refining etc.,)

The  conception  of  sulphuric  acid  is  lacking  behind   in cooperation  to  western  world.  Inspite  of  versatile  use   and application  the   exact demand of sulphuric acid is  not  properly surfaced.  If the country has to raise the economic condition  then this industry should be manifold.


COST ESTIMATION

Plant  Capacity                                  :       40.00 MT./day
Land & Building (12,000 Sq.Mtr)    :    Rs, 5.48  Cr
Plant & Machinery                              :    Rs. 15.00 Cr
Working Capital for 2 Months          :    Rs. 1.32  Cr
Total Capital Investment                   :    Rs. 22.05 Cr
Rate of Return                                     :    18%
Break Even Point                                 :    64%

INTRODUCTION    
SPECIFICATION OF SULPHURIC ACID (COMMERCIAL AND BATTERY GRADE)    
USES AND APPLICATION    
PROPERTIES AND CHARACTERISTICS    
B.I.S. SPECIFICATIONS    
SPECIFICATION OF SULPHURIC ACID (BATTERY GRADE)    
SPECIFICATION OF SULPHURIC ACID (ELECTROLYTE GRADE)    
MARKET SURVEY    
GLOBAL MARKET POSITION OF SULPHURIC ACID    
EXPORT DATA OF BATTERY GRADE    
PRESENT MANUFACTURERS OF SULPHURIC ACID (BATTERY GRADE)    
PROCESS TECHNOLOGY OF SULPHURIC ACID    
PRODUCTION PROCESSES OF SULPHURIC ACID    
MANUFACTURING PROCESS OF SULPHURIC ACID (BATTERY GRADE) 99.5% PURE    
PROCESS FLOW DIAGRAM    
AIR POLLUTION CONTROL IN SULFURIC ACID PLANT    
PLANT AND EQUIPMENT DETAILS    
PROCESS DESCRIPTION FOR SULPHURIC ACID    
EMISSION IN SULPHURIC ACID PLANT    
SAFETY DATA SHEET FOR SULPHURIC ACID    
BATTERY GRADE ACID AND SPECIFIC GRAVITY TEST PROCEDURE    
PRECAUTIONARY STEPS TO HANDLE SULFURIC ACID    
SULFURIC ACID BATTERY GRADE DILUTION    
SUPPLIERS OF PLANT AND MACHINERY    


APPENDIX – A:

 1.      COST OF PLANT ECONOMICS  
 2.      LAND & BUILDING                                      
 3.      PLANT AND MACHINERY                                  
 4.      FIXED CAPITAL INVESTMENT                             
 5.      RAW MATERIAL                                         
 6.      SALARY AND WAGES                                     
 7.      UTILITIES AND OVERHEADS                              
 8.      TOTAL WORKING CAPITAL                                
 9.      COST OF PRODUCTION                                   
10.      PROFITABILITY ANALYSIS                               
11.      BREAK EVEN POINT                                     
12.      RESOURCES OF FINANCE                           
13.      INTEREST CHART                                       
14.      DEPRECIATION CHART                                   
15.      CASH FLOW STATEMENT                                   
16.      PROJECTED BALANCE SHEET