Detailed Project Report on cardanol from c.n.s.l. cashewnut shell liquid

CARDANOL FROM C.N.S.L. OIL (CASHEWNUT SHELL LIQUID)
 [CODE NO 3271]  
 
Cardanol oil, a renewable raw material well known by product of the cashew industry, has been used as the starting material for the synthesis of novel fulleropyrrolidines cardanol based. In this work, cardanol has been used as building block for the preparation of target cardanol based precursors obtained by the way of the convenient transformation of the functional groups (aromatic ring, -OH group or the double bonds of the side chain) of the cardanolic structure. Pure 3-n-pentadecylphenol and its derivatives having homogeneous chemical composition, used as the precursor of any fulleropyrrolidines, have been prepared by hydrogenation of the un-saturated side chain and subsequent alkylation of the aromatic ring of cardanol. The reactivity of olefinic double bond present in the side-chain which can undergo easy transformation i.e. oxirane formation as well as metathesis reactions affording various interesting fulleropyrrolidines is also described.

Cashew  nut shell liquid or oil obtained by  heat  treatment contains about 10% cardol and about 90% cardanol (a vessicant oil liquid)  resulting  from decarboxylating anacordic acid  and  its polymers.  Formerly,  a  moister product  of  the  cashew  kernel industry  in  southern India, Cashew nut shell oil has  become  a valuable  raw  material  in the manufacture  of  many  industrial product. It condenses with formaldehyde and other chemicals into resin  that  can  be  used in many  unique  combination  for  the manufacture  of brake lining, clutch and other friction  facings, insulating  and water proofing varnishes and  coating  laminating resins, molding composition oil & acid proof cement &  industrial floor  tile,  type  writer  rolls,  and  myriad  other  products, varnishes  made  with  these  resin are  resistant  to  acid  and alkalies  and possess unusual resistance to the softening  action of mineral oil; they are used to coat paper for bottle cap liners and for many other water proofing and insulating purposes.

The  polymerized  liquid is used as a potting  compound  for magnetoelectric  machine armatures in air planes because of its high  heat  resistance subsequent treatment of the polymerized product with formaldehyde, trioxymethylene, paraformaldehyde  or furfuraldehyde  at room temperature for 24-72  h produced  a substantially  infusible  solid resin that retains  high  binding power at elevated temperature without softening hydrogenation  of the  phenol  in the oil produced many useful products such  as  a cosolvent  for rotovore in the preparation of insecticides. The hydrogenaled oil has none of the vesicant action of the original liquid cashew nut shell oil also is used in India for  protecting wood  and  paper  against termites and  for  motor  roofing  and preserving fish nets, textiles and lumber.


The cashew nut shell liquid (CNSL) is a by product & the cashewnut  processing industry cashew nut trees are  found  in Kamataka,  Kerela, and Tamil Nadu, Maharashtra etc. About 60,000 tons of nuts are collected annually for processing into kernels ;and in addition 50,000 tons and received from East Africa. Oil is extracted from 1/3 rd of the available nuts.


Almost all the cashew processing factories are in the small scale sector. These units adopt either the Drum Roasting Method & nut-oil  Butts  Process  while  processing  cashew  nuts.  It  is reported that raw cashewnuts contain over 20% oil in the  shells. In  the  old Drum Roasting Process, such if the  oil  gets  burnt during  roasting where as in the oil-Bath process about 10%  good quality shell oil can be recovered from the oil in  the  process itself  as a bye-product. This oil is of good quality and finds ready market. The shell still contains 10 to 12 percent oil which can be recovered either by solvent extraction or by using expellers.

Cashew nut shell liquid is a versatile raw material. The potential availability by CNSL is estimated at 40,000 tons but the actual average production is only by the order by 9,000 tons, primarily due to look of market.

The industrial application & CNSL are based open  its  polymerization  to a rubber like material under the influence  by acids  and  on  the formation of a  wide  range  of  condensation products with aldehydes.

COST ESTIMATION

Plant  Capacity                                                 :       10.00 MT/day
land & Building (4000 Sq.Mtr)                       :       Rs.  1.37  Cr
Plant & Machinery                                           :       Rs.  1.26  Cr
Working Capital for 2 Month                         :       Rs.  1.77  Cr
Total Capital Investment                               :        Rs.  4.51  Cr
Rate of Return                                                :        34%
Break Even Point                                           :         49%


1.    INTRODUCTION    
2.    PROPERTIES    
3.    USES & APPLICATION    
4.    B.I.S. SPECIFICATION    
5.    MARKET SURVEY    21
6.    MANUFACTURING PROCESS    
7.    PROCESS FOR THE PRODUCTION OF CARDANOL    
8.    PROCESS ACCORDING TO THE METHOD    
9.    DETERMINATION OF COLOR STABILITY    
10.    CARDANOL BASED DIMERS    
11.    PROCESS FLOWSHEET FOR THE MANUFACTURE OF CARDANOL RESIN    
12.    COMPLETE PLANT AND EQUIPMENTS SUPPLIERS    
    FOR CARDANOL RESIN    
13.    MANUFACTURERS/SUPPLIERS/EXPORTERS OF CARDANOL RESIN    
14.    RAW MATERIAL SUPPLIERS    
15.    PLANT & MACHINERIES SUPPLIERS ADDRESS    
16.    PRINCIPLES OF PLANT LAYOUT    
17.    PLANT LOCATION FACTORS    
18.    EXPLANATION OF TERMS USED IN THE PROJECT REPORT    
19.    PROJECT IMPLEMENTATION SCHEDULES    
20.    GENERAL PLANT LAYOUT    
21.    TOLERANCE LIMITS FOR INDUSTRIAL EFFLUENT DISCHARGE    
22.    EQUIPMENT REQUIREMENTS    
23.    LIST OF FOOD AND AGRO PROCESSING CONSULTANTS    
24.    PLANT LAYOUT    
25.    IMPLEMENTATION SCHEDULE    
26.    CALCULATION    

            
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