Detailed Project Report on pvc solvent cements manufacture with process and formula (upvc & cpvc)

PVC SOLVENT CEMENTS MANUFACTURE WITH PROCESS AND FORMULA (UPVC & CPVC) [3594]

The  operation of solvent cement may be broadly  defined  as the  formation  of  a  Joint where in a  self  bond  between  two polymeric  component is promoted by the presence of a solvent  in temporarily high concentration. The onion between two parts of a Joint is brought with the aid of solvents, solvent cement or adhesives. The type of joint best suited to solvent bonding is  a  lap joint.  The nutuod in not normally used for but.  Joint where these   are likely to experience  significant  stresses.   The essential features of bond formation in this method are the intes diffusion  of  polymer molecules across  the  original  interface between  the two components of the joint, and the  promotion  and acceleration  of this process by the swelling of the  polymer  of the joint components at the clubface, caused by sorption of  the solvent.  The  solvent concentration in the  polymer,  originally high,  is ultimately reduced to a lord constant value mainly the further  penetration  inwards and also by  evaporation  from  the edges of the bond zone. PVC or poly vinyl chloride is insoluble in common cow cost solvents, but is  soluble  in  cyclohexane,  tetra   hydrofuram nitrohenzene  and a value of others. In solvent of this type it can  be used for bonding rigid PVC pipe work since  the  solvents soften the santenial of the pipes and as form of solvent weld  in produced.  It is sometimes tenght that by virtue of  its  polymer content,  a solvent cement is gap-filling. This is not the case with solvent cements for PVC card indeed not with  most  such cements formulated for other plastics. Mainly because the amount of  polymer they contain is proportionately low. It is therefore essential for good  results that the surfaces of  parts  to  be joined should fit closely tog ether with no gaps. The  polymeric components of PVC solutions used  as  solvent cements  for bonding pipes, pipe fittings and certain  other  PVC products  may  be  homo  polymers,  co  polymers,  standard   PVC compounds or the actual compositions of the moldings etc. to  be bonded.  By defination, the two essential components  of  a  PVC solution  must be PVC polymer (S) and solvent. The solvation  so obtained  is  used  for some  practical  application  (e.g.  some solvent  cements, film casting salvations) are just  such  simple systems. Most PVC applications, i.e. the ones they are designed  for, do  not  require  very  critical  procedure  for  joining  pieces together,  because most of the time the fluid going through  them is not under pressure. However, certain high-strain applications, such as Spud Gunning, require that the joints are strong and airtight. The way to achieve that is proper solvent welding. The stuff that you get at the store to put together pieces of PVC is labeled "Cement." This is a misnomer.  The “cement" class  of adhesives, such as contact cement, rubber cement,  etc, all are used to bond two, usually dissimilar, materials together. PVC cement is actually a solvent. Welding involves melding  two pieces of the same material into one. When you solvent weld PVC, you are actually turning the  two sides that you are joining into PVC mush, the molecules all blend together,  and what you are left with is essentially  one  single piece of PVC. The Solvent cement is used for jointing PVC pipes & Fittings. Proper care is always taken to ensure stringent quality checks on the product at al I stages, without compromising on the quality. This is a simple process for jointing Rigid PVC Pipes with molded  or fabricated fittings. The tools required are a hacksaw with fine teeth, sandpaper, cotton waste, a soft brush, a  knife and solvent cement.

COST ESTIMATION

Plant Capacity                           2 Ton/Day  
Land & Building (800 sq.mt)     Rs. 1.06 Cr
Plant & Machinery                    Rs. 45 Lac
Working Capital for 1 Month    Rs. 72 Lac
Total Capital Investment          Rs. 2.30 Cr
Rate of Return                         33%
Break Even Point                     50%



INTRODUCTION    
HOW TO SOLVENT WELD PVC PIPE AND FITTINGS    
SOLVENT CEMENT    
THE JOINTING PROCEDURE IS AS UNDER    
APPLICATIONS    
AVAILABLE SIZES    
MECHANISM OF THE SOLVENT CEMENT OPERATION    
PROPERTIES AND CHARACTERISTICS OF PVC SOLVENT CEMENT    
USES & APPLICATION    
INSTALL NEW PLUMBING PIPES IN YOUR HOME    
REPAIR SMALL HAIRLINE CRACKS IN PVC PIPE    
MARKET OVERVIEW    
FUTURE DEMAND    
EXPORT DATA    
DETAILED IMPORT DATA OF PVC SOLVENT CEMENT    
OVERVIEW OF PVC AND CPVC PIPES    
PVC PIPING SEGMENT    
OPPORTUNITIES AHEAD:    
AGRICULTURE/RIGID PIPE SEGMENT –OPPORTUNITY CONTINUES    
THE RECENT INITIATIVES BY THE NDA GOVERNMENT:    
PLUMBING PIPES –A FUTURE LIES HERE    
KEY GROWTH DRIVERS:    
CPVC PIPE –GAINING POPULARITY DAY BY DAY    
HOW CPVC PIPES HAVE EVOLVED IN INDIA?    
FEATURES OF CPVC PIPE    
CPVC PIPE MARKET IN INDIA    
PRODUCTION OF PVC AND CPVC PIPES FROM 2007 TO 2016    
TREND IN INCREASE IN DEMAND    
ENHANCED RECYCLING PROPERTIES FOR PVC PIPES    
OVERVIEW OF PVC IN INDIA    
INDIAN SCENARIO    
FIGURE: PVC PRODUCTION AND IMPORTS IN INDIA    
FIGURE: PVC DEMAND IN INDIA - HISTORY    
FIGURE: APPLICATION BREAK-UP OF PVC – INDIA    
FIGURE: APPLICATION BREAK-UP OF PVC – GLOBAL    
FIGURE: PVC CONSUMPTION IN INDIA (2001-2015)    
FIGURE: DOMESTIC MANUFACTURERS AND CAPACITIES (KT)    
PRESENT MANUFACTURERS/SUPPLIER OF PVC SOLVENT CEMENT    
SPECIFICATION OF CPVC RESIN    
REQUIREMENT OF PVC SOLVENT CEMENT    
REFERENCED DOCUMENTS    
ASTM STANDARDS:    
TERMINOLOGY    
MATERIALS AND MANUFACTURE    
TECHNICAL SPECIFICATION OF LOW    
VOC PVC SOLVENT CEMENT    
GENERAL PRODUCT SPECIFICATIONS:    
CONFORMANCE STANDARDS AND APPROVALS:    
PACKAGING, SHIPPING & TRANSPORTATION INFORMATION:    
THE FOLLOWING IS GENERAL INFORMATION FOR GROUND SHIPPING,
   SEE SDS PVC37-6 FOR ADDITIONAL DETAIL.    
SAFETY & USE PRECAUTIONS:    
FIRST AID    
INSTALLATION & INSTALLER TRAINING    
AVOID USE AROUND DRY GRANULATED CALCIUM HYPOCHLORITE    
FORMULATIONS OF PVC SOLVENT    
FORMULATION -1    
UPVC SOLVENT CEMENT    
FORMULATION -2    
CPVC SOLVENT CEMENT    
FORMULATION -3    
CPVC SOLVENT CEMENT (HEAVY DUTY)    
MANUFACTURING PROCESS OF PVC SOLVENT CEMENT    
PROCESS FLOW DIAGRAM    
DETAILS OF UNIVERSAL SOLVENT CEMENT    
ACRYLIC RESIN    
SOLVENT    
ADDITIONAL RESINS    
OTHER INGREDIENTS    
VISCOSITY    
UNIVERSAL SOLVENT CEMENT    
FORMULATION    
TESTING, MARKING AND HANDLING OF PVC SOLVENT CEMENT    
TEST METHODS    
BOND STRENGTH:    
LAP SHEAR STRENGTH:    
HYDROSTATIC BURST STRENGTH:    
RETEST AND REJECTION    
QUALITY ASSURANCE    
GUIDE OF PVC SOLVENT CEMENT SELECTION    
TABLE  PVC CEMENTS FOR SCHEDULE 40 AND INTERFERENCE FIT    
TABLE  PVC CEMENTS FOR SCHEDULE 80 AND NONINTERFERENCE FITS    
WORKING METHOD WITH SOLVENT CEMENT    
STORING    
SOLVENT CEMENTING WITH A PRIMER    
STEP 1 CUT    
STEP 2 DEBURR    
STEP 3 CLEAN    
STEP 4 CUT    
STEP 5 CHOOSE APPLICATOR    
STEP 6 PRIMING    
STEP 7 CEMENTING    
DO NOT TEST WITH AIR.    
THINGS TO REMEMBER WHEN SOLVENT CEMENTING IN COLD WEATHER:    
PRECAUTIONS    
READ ALL INFORMATION CAREFULLY BEFORE USING THIS PRODUCT    
PLANT LAYOUT    
PRINCIPLES OF PLANT LAYOUT    
PLANT LOCATION FACTORS    
EXPLANATION OF TERMS USED IN THE PROJECT REPORT    
PROJECT IMPLEMENTATION SCHEDULES    
SUPPLIERS OF RAW MATERIALS    
PVC RESIN    
SOLVENT    
PVC STABILIZER    
SUPPLIERS OF PLANT AND MACHINERIES    
REACTION VESSELS    
STORAGE VESSEL    
D.G. SETS (DIESEL GENERATOR)    
LABORATORY EQUIPMENTS/LABORATORY TESTING EQUIPMENTS    
CONSULTANT AND TECHNOLOGY PROVIDER FOR PVC SOLVENT CEMENTS    


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)