Detailed Project Report on silicone emulsion used as release agent for rubber industry

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SILICONE EMULSION USED AS RELEASE AGENT FOR RUBBER INDUSTRY

[CODE NO.3873]

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 group 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, fluoro alky, 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.

COST ESTIMATION

Plant Capacity 500 KG/Day

Land & Building (1000 sq.mt.) Rs. 46 Lac

Plant & Machinery Rs. 18 Lac

Working Capital for 1 Month Rs. 20 Lac

Total Capital Investment Rs. 90 Lac

Rate of Return 39%

Break Even Point 62%

INTRODUCTION

PROPERTIES

SILICONE FLUIDS AND SILICONE EMULSION

DEFINITION AND PROPERTIES OF SILICONES

TYPES OF SILICONE FLUIDS

THERE ARE BASICALLY TWO TYPES

USES AND APPLICATIONS

B.I.S. SPECIFICATION

TYPES OF SILICONE EMULSION

DETAILS OF SILICONE FLUIDS

ENVIRONMENTAL FATE AND EFFECTS:

MARKET POSITION

CONSTRUCTION AND E&E MOST IMPORTANT GROWTH MOTORS

ASIA INCREASING WORLD MARKET SHARE

ELASTOMERS AND SILICONE OILS MOST IMPORTANT PRODUCTS

PRODUCTION AND TRADE

INSTALLED CAPACITY, PRODUCTION AND CAPACITY UTILIZATION

OF SILICONE EMULSION

APPARENT CONSUMPTION OF SILICONE EMULSION

ESTIMATED DEMAND

PRESENT MANUFACTURERS/SUPPLIERS OF SILICON EMULSIONS

BUYERS OF SILICONE EMULSION

FORMULATING, HANDLING & USE FOR SILICONE EMULSION

USE AND HANDLING TIPS

EMULSIFIER TYPES

HOW SURFACTANTS WORK

MICROBIAL CONTAMINATION – EMULSIONS

APPLYING RELEASE AGENTS TO NEW MOLDS

DILUTION LEVELS FOR RELEASE AGENTS

RELEASE AGENTS FOR HIGH-TEMPERATURE APPLICATIONS

RUST INHIBITORS FOR DILUTED RELEASE AGENT EMULSIONS

APPLYING AMINO SILICONE SOFTENERS TO FABRIC

RAW MATERIALS

DOW CORNING DC-203 FLUID

FORMULATION OF SILICONE EMULSION

OTHER FORMULATION OF SILICONE EMULSIONS

SILICONE OIL EMULSION (MOULD RELEASING AGENT)

FORMULATION - 1:-

FORMULATION - 2:-

FORMULATION OF SILICONE EMULSION (MOULD RELEASE AGENT)

FOR RUBBER INDUSTRIES

FOR PLASTIC INDUSTRIES

FOR PU FOAM

MORE FORMULATION OF SILICONE EMULSION

FORMULATION OF SILICONE EMULSION FOR PU

FORMULATION NO. 1

FORMULATION NO. 2

FORMULATION OF SILICONE EMULSION FOR AUTOMOBILE

FORMULATION OF SILICONE EMULSION FOR STABLE AESTHETIC

PRODUCTS

ANTICAKING AGENTS

PROCESS FLOW DIAGRAM

PROCESS FOR CREATING EMULSION

PROCESS IN DETAILS

EXAMPLES 1 AND 2

EXAMPLES 3 AND 4

EXAMPLES 5 AND 6

EXAMPLES 7 TO 9

EXAMPLES 12 AND 13

PACKAGING HANDLING AND REMOVAL METHOD OF SILICONE EMULSION

MATERIAL SAFETY DATA SHEET FOR SILICONE EMULSION

SECTION I: IDENTIFICATION OF THE SUBSTANCE & THE COMPANY

SECTION II: HAZARDS IDENTIFICATION

EMERGENCY OVERVIEW

POTENTIAL HEALTH EFFECTS:

SECTION III: COMPOSITION/INFORMATION ON INGREDIENTS

SECTION IV: FIRST AID MEASURES

SECTION V: FIRE FIGHTING MEASURES

SECTION VI: ACCIDENTAL RELEASE MEASURES

SECTION VII: HANDLING AND STORAGE

KEEP AWAY FROM CHILDREN.

SECTION VIII: EXPOSURE CONTROLS/PERSONAL PROTECTION

ENGINEERING CONTROLS

EXPOSURE GUIDELINES

SECTION IX: PHYSICAL & CHEMICAL PROPERTIES

SECTION X: STABILITY AND REACTIVITY

SECTION XI: TOXICOLOGICAL INFORMATION

SECTION XII: ECOLOGICAL INFORMATION

SECTION XIII: DISPOSAL CONSIDERATIONS

SECTION XIV: TRANSPORT INFORMATION

SECTION XV: REGULATORY INFORMATION

SECTION XVI: OTHER INFORMATION

ANALYSIS OF SILICONES

COMMON METHODS APPLIED TO THE ANALYSIS OF SILICONES

TABLE: TYPICAL 29SI NMR CHEMICAL SHIFTS

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 SILICON OILS

SUPPLIERS OF CARBOPOL

SUPPLIERS OF PROPYLENE GLYCOL

SUPPLIERS OF PACKAGING MATERIALS

SUPPLIERS OF SODIUM HYDROXIDE

SUPPLIERS OF PLANT AND MACHINERY

SUPPLIERS OF COLLOID MILL

SUPPLIERS OF STAINLESS STEEL STORAGE VESSEL

SUPPLIERS OF FILTER

SUPPLIERS OF PACKAGING MACHINES

SUPPLIERS OF LABORATORY EQUIPMENT

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

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