Detailed Project Report on Sodium Silicate from Quartz and Caustic Lye

SODIUM SILICATE FROM QUARTZ AND CAUSTIC LYE

[EIRI/EDPR/0803] J.C. 9418XL

INTRODUCTION

Sodium silicates, popularly called water glass or soluble glass are generally classified according to their SiO2, Na2O ratio, which varies between 0.5 and 4 and with various proportions of water based upon this ratio, a series of compounds are known ranging in properties from strongly alkaline to nearly neutral and from crystalline, to glassy solids, to viscous liquids. The important silicates are sodium orthosilicate, Na4SiO4, Sodium met silicate (Na2SiO3) and their hydrates and sodium sequisilicate (Na6Si2O7) and their hydrates.

A variety of Sodium Silicates ranging in chemical composition from Na2O. 4SiO2 to 2Na2SiO2 is produced by the fusion of Silica or sand with Soda-ash or by Quartz & Caustic Lye. Silicates with Na2O:SiO2 ratio between 1:1.6 and 1:4 are available both in anhydrous and hydrated forms. They are water soluble and generally sold as 20-50% aqueous solutions. These are known as "Water glass" while the more siliceous sodium silicates are glasses. The biggest use of Sodium Silicate is in Soap and detergent industry followed by the use in adhesives for paper boards and corrugated containers. Sodium Silicate is also used alone or together with many other materials as adhesive for plywood, wall board, flooring and foils. Sodium Silicate is also used in different places.

Sodium silicate was first come into existence when the sodium compound was red-hot heated with the sand, after that other processes have also been evolved.

Sodium silicates are among the basic alkalies of industry. For a few applications potassium and, recently lithium and ammonium silicates are prepared. The first and the foremost demand of the sodium silicate is in the soap industry as a builder, both in bar soaps and liquid detergents. The other uses of sodium silicate are as adhesive in corrugated boxes in making silica gel (either pure or as complex), as soluble silicate cements, coating, textile, bleaching, abrasives coal treatment and oil treatment etc.

Commercially sodium silicate is also used as silicate of soda. Previously in U.S.A. it was also known as water glass. The commercial sodium silicate are amorphous vitreous of or crystalline hydrated and anhydrous compounds (powders) and also liquid acquous with viscosity ranging from 0.5 to 600,000 poise at 20oC. The typical properties of sodium silicate are follows:

COST ESTIMATION

Plant Capacity            100 MT/Day

Land & Building (40,470 sq.mt.)    Rs. 10.23 Cr

Plant & Machinery                    Rs. 2.80 Cr

Working Capital for 3 Months    Rs. 9.76 Cr

Total Capital Investment          Rs. 23.10 Cr

Rate of Return                          37%

Break Even Point                      39%

CONTENTS

INTRODUCTION

PROPERTIES OF SODIUM SILICATE

TYPICAL COMMESCIAL SODIUM & POTASSIUM SLICATE

USES AND APPLICATIONS

USE PATTERN OF SODIUM SILICATE

B.I.S. SPECIFICATION

MARKET POTENTIAL

PRESENT MANUFACTURE OF SODIUM SILICATE

PROCESS OF MANUFACTURE OF SODIUM SILICATE BY QUARTZ AND CAUSTIC LYE (HYDRO THERMAL PROCESS)

HANDLING AND STORAGE OF SODIUM SILICATE

ANALYTICAL TESTS FOR SODIUM SILICATE

PROCESS FLOW DIAGRAM FOR MANUFACTURE OF SODIUM SILICATE FROM QUARTZ AND CAUSTIC LYE

PLANT LAYOUT

TURNKEY CONSULTANTS FOR SODIUM SILICATE PLANT

ADDRESSES OF PLANT & MACHINERY SUPPLIERS

ADDRESSES OF RAW MATERIAL SUPPLIERS

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)