Active Zinc Oxide (Production Rate- 3 Tons Per Day)

ACTIVE ZINC OXIDE (PRODUCTION RATE – 3 TONS PER DAY)

[EIRI/EDPR/4570] J.C.: 2787US$

INTRODUCTION

In recent years, nanomaterials have received more concerns because of their prominent characteristics and it has various applications such as rubber, biomedical, energy, paint, coating, and cosmetics. With the development of nanomaterials, metal oxide nanoparticles show promising and far-ranging prospect in rubber industry, especially for gloves, tyre and other rubber products.  

Because of their superior physical and chemical properties, ZnO metal oxide nanoparticles with high surface area (ZnO-H) are among the most significant and widely used in many fields. The rubber industry is where ZnO-H is initially used since it can make rubber composites more resistant to wear, boost the performance of high polymers by increasing their toughness, intensity, and antiaging properties, among other things. ZnO-H is increasingly employed in personal care products including sunscreen and cosmetics due to its potent UV absorption capabilities. 

Moreover, ZnO-H also has strong UV blocking and great antibacterial and antimicrobial capabilities. As a result, in the textile sector, finished fabrics with ZnO-H added displayed the desirable properties of resistance to UV and visible light, anti-bacterial, and deodorant. In addition to the uses listed above, zinc oxide can also be utilized in a variety of other industrial sectors, such as the manufacturing of concrete, photocatalysis, electronics, electrotechnology, and so forth. It is well recognized that all bodily tissues, including as the brain, muscle, bone, and skin, contain significant amounts of zinc, an essential trace element. 

Zinc participates in the body's metabolism and is a key element in the production of proteins and nucleic acids, hematopoiesis, and neurogenesis. It is also a key component of many enzyme systems. Small particle size nano-ZnO makes zinc easier for the body to absorb. Nano-ZnO is therefore frequently employed as a food ingredient. 

Moreover, the US Food and Drug Administration has classified ZnO as a drug that is "generally regarded as safe" (GRAS) (FDA). ZnO-H has attracted increased interest in gloves and bio-medical applications due to these characteristics. Compared to other metal oxide nanostructures, ZnO-H is relatively cheap and has a small size.

Zinc waste is generated as a waste material from metal industry which causes environmental issues. Also, it is difficult to transport from one country to another, as it is categorized under hazardous waste. In general, the ash is usually processed to obtain Zinc oxide (ZnO) mainly for paint / rubber industry and zinc sulfate for agriculture industry. Waste to product conversion can adopt either pyrometallurgical or hydrometallurgical processes which are practiced globally to treat Zinc wastes and convert it to either Metallic Zinc or Zinc oxide as a final product.  

The two important processing routes were pyrometallurgical and hydrometallurgical.  

Pyrometallurgical process required carbon for easy segregation and make ZnO powder.  In this process, production of normal Zinc oxide is possible but it could not tune the size and its surface area. Moreover, emission of CO2 gas occurs during the reaction when carbon power is being mixed with the Zinc waste.  To conduct this reaction without carbon mixture requires more power to vaporize Zinc from Zinc waste. 

Conventional hydro-metallurgical process required acids and alkali for leaching and precipitation. Low surface area of 4.5 to 5 m2/gm of ZnO was synthesized. To achieve the active zinc with desired porosity, surface area and pore volume, need to use any template assisted synthesis to obtain the above properties, but it is very tedious. 

To overcome the above bottlenecks, in this work suitable material has been mixed during the precipitation process and produced the desire surface area, pore volume and porosity with a maximum purity of 95% ZnO was manufactured.

Active Zinc oxide is an inorganic compound with the formula ZnO. ZnO is a white powder that is insoluble in water, which is widely used as an additive in numerous materials and products including plastics, ceramics, glass, cement, lubricant, paints, ointments, adhesives, sealants, pigments, foods (source of Zn nutrient), batteries, ferrites, fire retardants, and first aid tapes. It occurs naturally as the mineral zincite but most zinc oxide is produced synthetically.

In materials science, ZnO is a wide-bandgap semiconductor of the II-VI semiconductor group (since oxygen was classed as an element of VIA group (the 6th main group, now referred to as 16th) of the periodic table and zinc, a transition metal, as a member of the IIB (2nd B), now 12th, group). The native doping of the semiconductor (due to oxygen vacancies) is n-type. This semiconductor has several favorable properties, including good transparency, high electron mobility, wide bandgap, and strong room-temperature luminescence. Those properties are used in emerging applications for transparent electrodes in liquid crystal displays, in energy-saving or heat-protecting windows, and in electronics as thin-film transistors and light-emitting diodes.

It is intended to prepare a Feasibility Report for Active Zinc Oxide Production facility with an installed capacity of 3 Tons / Day as a Green Field Project.

COST ESTIMATION

Plant Capacity            3 MT/Day  

Land & Building (3975 sq.mt.)    US$ 6.83 Lac    

Plant & Machinery                    US$ 10.81 Lac 

Working Capital for 0.5 Months    US$ 1.08 Lac 

Total Capital Investment          US$ 19.50 Lac 

Rate of Return                          17%

Break Even Point                      69%

CONTENTS

INTRODUCTION

PROPERTIES 

CRITICAL PROPERTIES 

CHEMICAL PROPERTIES

BASES ALSO DEGRADE THE SOLID TO GIVE SOLUBLE ZINCATES:

HOPEITE

MECHANICAL PROPERTIES

ELECTRICAL PROPERTIES

STANDARDS AND SPECIFICATIONS 

PRODUCT DETAILS

SPECIFICATIONS

STANDARDS

FORMS OF ZINC OXIDE

FOR INSTANCE, 

POSSIBILITIES OF ZINC OXIDE POWDER PRODUCTION WITH VARIOUS DIMENSION

APPLICATIONS

RUBBER MANUFACTURE

CONCRETE INDUSTRY

MEDICAL

CIGARETTE FILTERS

FOOD ADDITIVE

PIGMENT

COATINGS

CORROSION PREVENTION IN NUCLEAR REACTORS

POTENTIAL APPLICATIONS

ELECTRONICS

THEREFORE, THEY CAN BE USED AS FIELD EMITTERS.

ZINC OXIDE NANOROD SENSOR

SPINTRONICS

PIEZOELECTRICITY

SAFETY

MARKET OVERVIEW

NANO-ZINC OXIDE

PARTICLE GRADE

SUPER-FINE

RUBBER

COATING

CERAMICS

PHARMACEUTICAL

REGIONAL INSIGHTS

CONSUMPTION OF ACTIVE ZINC OXIDE       

KEY COMPANIES & MARKET SHARE INSIGHTS

PRESENT MANUFACTURER OF ZINC OXIDE

RAW MATERIALS AND ITS AVAILABILITY

PROCESS

FOR INDUSTRIAL USE, ACTIVE ZNO IS PRODUCED BY THREE MAIN PROCESSES:

INDIRECT (FRENCH) PROCESS

DIRECT (AMERICAN) PROCESS

WET CHEMICAL PROCESS

MANUFACTURING PROCESS/PROCESS FLOW 

PROCESS FLOW

EXPOSURE LIMITS

EXPOSURE SOURCES AND CONTROL METHODS

RESPIRATORY PROTECTION

RESPIRATORS MAY BE USED:

PERSONAL PROTECTIVE EQUIPMENT

PERSONAL HYGIENE PROCEDURES

PRELIMINARY LAYOUT

SUPPLIERS OF PLANT & MACHINERY

ZINC MELTING FURNACE

ENGINEERING DESIGN CONSIDERATIONS

ETP FACILITY

ETP FLOW DIAGRAM (TYPICAL)

SEWAGE AND WASTE WATER EFFLUENT 

STP FLOW DIAGRAM (TYPICAL)

WASTE GENERATION & MANAGEMENT/GREEN BELT

GREEN BELT

PRINCIPLES OF PLANT LAYOUT

MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE:

PRINCIPLES OF PLANT LAYOUT

PLANT LOCATION FACTORS

PRIMARY FACTORS

1. RAW-MATERIAL SUPPLY:

2. MARKETS:

3. POWER AND FUEL SUPPLY:

4. WATER SUPPLY:

5. CLIMATE:

SPECIFIC FACTORS

6. TRANSPORTATION:

A. AVAILABILITY OF VARIOUS SERVICES AND PROJECTED RATES

7. WASTE DISPOSAL:

8. LABOR:

9. REGULATORY LAWS:

10. TAXES:

11. SITE CHARACTERISTICS:

12. COMMUNITY FACTORS:

13. VULNERABILITY TO WARTIME ATTACK:

14. FLOOD AND FIRE CONTROL:

ANTICIPATED ENVIRONMENTAL IMPACTS 

CONSTRUCTION PHASE 

OPERATION PHASE 

MITIGATION MEASURES (PROPOSED)

HEALTH SAFETY & ENVIRONMENT

PROPOSED IMPLEMENTATION SCHEDULE

PROJECT FINANCIALS

BASIS & PRESUMPTIONS (FOR PROFITABILITY WORKINGS)

CONCLUSIONS

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)