Detailed Project Report on silicone emulsion using dow corning dc-203 silicone fluid

 
SILICONE EMULSION USING DOW CORNING DC-203 SILICONE FLUID
 [CODE NO. 1978]


Silicones are synthetic polymers having an inorganic skeleton of alternate silicone and oxygen atoms, the silicone valences not taken up by oxygen being saturated with organic grpoupe and other groups. They occupy an intermediate position between inorganic and organic compounds. Because of this dual nature they have many properties which have made them very useful in many applications. Silicones are produced in several forms including fluids, rubbers and resins. Silicones emulsions are formed from silicone fluids and water with the help of a suitable emulsifier, and find various applications.

The term silicone denotes a polymer with the structural formula (RnSiO(4-n)1/2)m where n is between 0 and 3 and m is 2 or more. It contains a repeating silicone oxygen chain having organic groups R, attached to a significant portion of the silicone atom by silicone carbon bonds. In commercial silicones most of the R groups are methyl, longer alkyl, fluoroalky, phenyl, vinyl and a few others. Silicone fluids the Si-O chain is unbanked.

Silicone fluids are generally, dimethyl polysiloxane, methyl hydrogen polysiloxane or silicones consisting of copolymers of dimethyl siloxane with methyl phenyl, methyl-hydrogen, diphenyl, methyl-alkyl and other siloxanes. Linear poly-dimethyl siloxanes or dimethyl polysiloxanes are the most important of all the silicones. These fluids with hexamethyl disiloxane. For relating low viscosity fluids  are manufacured by reacting dimethyl silicone fluids the process is run for several hours at 180oC in glass lined kettles with acid chloride catalysts or at lower temperature with sulphuric acid. Alkaline catalysts are used for the production of high viscosity fluids or gums. Silicone fluids have m.wt. of 2000 to 15000 and viscosities from 10  to  10,000 cps.


Dimethyl silicone fluids are colourless, odorless and nontoxic and are resistant to oxidation and chemicals. They have good lubricating action. They reduce surface tension and have water repellent properties, together with foam inhibition. Inclusion of phenyl groups into the silicone structure increase their thermal and oxidative stability, while lowering the pour point. Thus methyl phenyl silicone fluids have higher viscosity, temperature coefficient and lower pour point and lower flash points than dimethyl silicone fluids of the same viscosity. Fluids with chlorinated phenyl groups attached to silicone, e.g. methyl alkyl fluids where alkyl is octyl to tetradecyl are good lubricants but have higher viscosity temperature coefficients and poorer oxidative stability than methyl fluids.

In general, the dimethyl silicone fluids are soluble in aliphatic and aromatic hydrocarbons and chlorinated hydrocarbons. Lower m. wt. fluids are more soluble than higher fluids. They are insoluble in methanol, ethanol, acetone, ethylene, gylcol, polyglycol ethers, gylcerol cyclohexanol and water. Methyl-phenyl silicones are more soluble than the corresponding dimethyl silicones.
     

COST ESTIMATION

Plant capacity                                    500.00 KGS/day   
Land & Building (400 Sq.Mtr)             Rs. 44.00 Lacs
Plant & Machinery                              Rs. 5.00 Lacs
W.C. for 2 Months                              Rs. 38.33 Lacs
Total Capital Investment                     Rs. 88.53 Lacs
Rate of Return                                   36%
Break Even Point                                47%


INTRODUCTION                                            
PROPERTIES                                            
SILICONE FLUIDS AND SILICONE EMULSION                        
TYPES OF SILICONE FLUIDS                                    
USES AND APPLICATIONS                                    
B. I. S.  SPECIFICATION                                        
TYPES OF SILICONE EMULSION                                
DETAILS OF SILICONE FLUIDS                                
MARKET SURVEY                                            
INSTALLED CAPACITY, PRODUCTION AND CAPACITY UTILIZATION
OF SILICONE EMULSION                                    
APPARENT CONSUMPTION OF SILICONE EMULSION                    
ESTIMATED DEMAND                                        
PRESENT MANUFACTURERS/SUPPLIERS OF SILICON EMULSIONS        
FORMULATING, HANDLING & USE, FOR SILICONE EMULSION            
RAW MATERIALS                                            
FORMULATION OF SILICONE EMULSIONUSING DC-203 SILICONE FLUID    
FORMULATION OF SILICONE EMULSION                            
OTHER FORMULATION OF SILICONE EMULSIONS                    
FORMULATION OF SILICONE EMULSION(MOULD RELEASE AGENT)        
PROCESS FLOW DIAGRAM                                    
PROCESS IN DETAILS                                        
RAW MATERIAL CALCULATION                                
PACKAGING HANDLING AND REMOVAL METHOD OF SILICONE EMULSION    
MATERIAL SAFETY DATA SHEET FOR SILICONE EMULSION            
ANALYSIS OF SILICONES                                    
PLANT LAYOUT                                            
PRINCIPLES OF PLANT LAYOUT                                
PLANT LOCATION FACTORS                                    
EXPLANATION OF TERMS USED IN THE PROJECT REPORT                
PROJECT IMPLEMENTATION SCHEDULES                        
SUPPLIERS OF RAW MATERIALS                                
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