Styrene Acrylic Copolymer Emulsion (Cap: 1960 Kg./Day)

STYRENE ACRYLIC COPOLYMER EMULSION (CAP: 1960 KG./DAY)

[EIRI/EDPR/4496] J.C.: 2712INR, 2712US$

INTRODUCTION

Styrene-acrylic emulsion polymers are based on a group of chemicals that are true workhorses in the field of polymer chemistry. Known as acrylates, this group includes acrylic acid and its esters — methyl acrylate, butyl acrylate, ethyl acrylate, and 2-ethylhexyl acrylate. All of these acrylic monomers are highly reactive chemicals, which means they readily combine with themselves or other monomers to form commercially important polymers.One of the most important polymer reactions, occurring via emulsion polymerization, involves acrylic-based monomers combining with styrene to form a styrene-acrylic emulsion polymer. The versatility of this class of polymers owes much to the wide-ranging family of acrylic monomers, which, when combined with styrene, can build random copolymers with specific glass transition temperatures (Tg). Styrene-acrylic polymer emulsions are ubiquitous in every market where water-based systems are used because of the array of specific properties that can be achieved.

In addition to versatility, cost is another significant advantage. The price of styrene is lower than chemicals found in the acrylate family. That makes styrene-acrylic polymers cost-effective alternatives to pure acrylics.

Styrene-acrylic polymers offer excellent hydrophobic characteristics, which means they have superior water resistance and moisture vapor transmission rate (MVTR) when compared to all-acrylic polymers. Also, styrene itself is a hydrophobic monomer, making it possible to produce styrene-acrylic polymers with low particle sizes. This results in polymers that are ideal for certain applications, such as primers for the construction industry or binders for paper coatings.

COST ESTIMATION

Plant Capacity            1960 Kg./Day  

Land & Building (600 sq.mt.)   Rs. 90.00 Lac    

Plant & Machinery                   Rs. 39.00 Lac 

Working Capital for 1 Month    Rs. 56.93 Lac 

Total Capital Investment          Rs. 2.06 Cr 

Rate of Return                          37%

Break Even Point                     57%

CONTENTS

INTRODUCTION

MARKET OVERVIEW OF STYRENE ACRYLIC EMULSION

MANUFACTURERS OF ACRYLIC EMULSION

USES AND APPLICATION

ACRYLIC MONOPOLYMER PROPERTIES

B.I.S. SPECIFICATION

SPECIFICATION OF STYRENE ACRYLIC COPOLYMER EMULSION

BENEFITS OF STYRENE ACRYLIC COPOLYMER

MANUFACTURING PROCESS OF STYRENE ACRYLIC COPOLYMER EMULSION

PROCESS FLOW DIAGRAM

MATERIAL BALANCE

EMULSION POLYMERIZATION

COMMERCIAL PRODUCTION CONSISTS OF THREE SERIES.

(1) PREPARATION OF FEED:

(2) POLYMERIZATION:

(3) POST REACTION PROCESSION:

TECHNICAL DATA SHEET FOR ACRYLIC STYRENE COPOLYMER

DEMPOL ST 470 N

EMULSION PROPERTIES

APPLICATION

RECOMMENDED RECIPE

SAFETY

PERSONAL PROTECTION:

SKIN CONTACT:

EYE CONTACT:

HANDLING & STORAGE

HANDLING:

STORAGE:

EMULSION POLYMERS

MANUFACTURE AND TESTING

EMULSION POLYMERIZATION:

TWO STAGE ACRYLIC EMULSION POLYMERIZATION:

PROCESS VARIABLES:

MONOMER ADDITION TECHNIQUE:

STAGE PROCESS:

DELAYED ADDITION PROCESS:

ALTERNATIVE PROCESSES:

SURFACTANT ADDITION TECHNIQUES:

AGITATION:

TIME:

TEMPERATURE:

EFFECT OF PH:

EMULSION TESTING:

PH:

VISCOSITY:

SHELF AND THERMAL STABILITY:

FREEZE-THAW STABILITY:

COMPATIBILITY:

ULTRACENTRIFUGATION:

SOAP TITRATION:

MINIMUM FILM FORMING TEMPERATURE (MFFT) :

SAMPLE FORMULA, ACRYLIC COPOLYMER

PROCEDURE:

OTHER RELATED INFORMATIONS

ACRYLIC EMULSION COPOLYMERS

EXAMPLE 1

EXAMPLE 2

COMPARATIVE EXAMPLE 2

EXAMPLE 3

EXAMPLE 4

COMPARATIVE EXAMPLE 4

EXAMPLE 5

EXAMPLE 6

EXAMPLE 7 A

ORGANOPOLYSILOXANE/ACRYLATE ESTER COPOLYMER EMULSION

EXAMPLE 1

EMULSION A (PRESENT METHOD)

EMULSION B (COMPARISON EXAMPLE)

EMULSION C (COMPARISON EXAMPLE)

(1) PRELIMINARY TESTING

(2) EMULSION STABILITY

(3) STAINING RESISTANCE TEST

(4) OLIGOMER TRANSFER TEST BASED ON RESIDUAL ADHESIVE FORCE

EXAMPLE 2

EXAMPLE 3

LOW MOLECULAR WEIGHT (METH) ACRYLATE COPOLYMER EMULSIONS

EXAMPLE 1

EXAMPLE 2

MACROMONOMER

MIXTURE 1

MIXTURE 2

MIXTURE 3

EXAMPLE 7

BLOCK COPOLVMER

EXAMPLES 8 TO 14

COMPARATIVE EXAMPLE 1

COMPARATIVE EXAMPLE 2

COMPARATIVE EXAMPLE 3

COMPARATIVE MACROMONOMER EXAMPLE 1

SELF-ADHESIVE ACRYLATE COPOLYMERS

EXAMPLE 1

EXAMPLE 2

ADDRESSES OF PLANT AND MACHINERY SUPPLIERS

POLYMERIZATION REACTION KETTLES

CENTRIFUGE

DEIONIZATION PLANT

COOLING TOWER

CHEMICAL STORAGE TANKS

STEAM BOILERS

GEN SET

AUTOMATIC FILLING MACHINE

WEIGHBRIDGES

ADDRESSES OF RAW MATERIALS SUPPLIERS

AMMONIUM PER SULPHATE

METHYL METHA ACRYLATE

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)