Detailed Project Report (DPR) on alkyd resins

ALKYD RESINS

[CODE NO.4191] 

Alkyd resins have been defined as the reaction product of polyhydric alcohols and polybasic acids. This definition includes polyester resins of which alkyds are a particular type. The specific definition that has gained wide acceptance is that alkyds are polyesters modified with mono-basic fatty acids. In recent years, the term nonoil or oil-free alkyd has come into wide use to describe polyesters formed by the reaction of polybasic acids with excess polyhydric alcohols. These products are best described as hydroxylated polyesters and they are finding increasing use in the coatings industry.

Classification:- There are many ways of expressing the composition of an alkyd and those in general use are often misleading in that they do not specific the alkyd. The most common compositions expressed are (a) alkyd ratio or polyhydric alcohol/phthallate ratio (b) oil length or percent oil (c) percent phthallic. If the three common components, glycerol, fatty acids and phthallic/anhydride, react in equimolar proportions to a low acid number, the individual molecules are undoubtedly mixed esters and consequently, there is very little free glycerol phthalate or free fatty acid triglyceride.

The alkyds, as finished solutions, are ready for cold blending with other resins or polymer solutions for use in clear finishes, or for use as vehicles in which to grind pigments prior to blending with other resin or polymer solutions for use in clear finishes; or for grinding with pigments to form finished alkyd paints. More than 90% of the alkyds produced are handled in one of these ways to produce some type of paint, varnish, or lacquer for industrial or home consumption. About half of the alkyds made are sold by their producers to others who carry out the final operations of manufacture of paint or other coating material.

Because of wide variety of commercial alkyds, they are further classified by the coatings industry. The following widely used classification is related chiefly to the kind of monobasic fatty acid in the alkyd.

1. Drying:- The monobasic fatty acid has an unsaturated structure present in sufficient quantity to cause a thin film (1-3 mils) of the alkyd to polymerize in the presence of oxygen at room temperature to give coherent, solid film.

2. Non-Drying:- The amount of unsaturated structure in the monobasic fatty acid is so low that little or no polymerization occurs with oxygen.

The drying alkyds are often used alone in coating vehicles, non-drying alkyds are blended with other polymeric materials to give finished products, obviously these classifications are somewhat arbitrary and various degrees of drying can-exist.

COST ESTIMATION

Plant Capacity                                     3 Ton/Day

Land & Building (4000 sq.mt.)  Rs. 2.63 Cr

Plant & Machinery                              Rs. 72 Lac

Working Capital for 2 Months    Rs. 1.86 Cr

Total Capital Investment                    Rs. 5.42 Cr

Rate of Return                                       33%

Break Even Point                                  51%

• INTRODUCTION
• USES AND APPLICATIONS
• OTHER LARGE SCALE MANUFACTURING OPERATIONS THAT USE 
• ALKYDS INCLUDE THE FOLLOWING;
• PROPERTIES AND SPPLICATION OF ALKYD RESIN
• APPLICATIONS
• B.I.S. SPECIFICATION
• MARKET OVERVIEW OF ALKYD RESIN
• SOME MAJOR APPLICATIONS
• KEY MANUFACTURERS WORKING OUT
• PROMINENT PLAYERS OPERATING IN THE GLOBAL ALKYD RESINS 
• MARKET INCLUDE
• MARKET SEGMENTATION OF SHORT OIL ALKYD RESIN
• ON THE BASIS OF GRADE
• ON THE BASIS OF CLASSIFICATION
• ON THE BASIS OF END USE
• SOME OF THE KEY MANUFACTURERS OF SHORT OIL ALKYD RESINS
• BASIS OF ALKYD RESIN TECHNOLOGY
• ALKYD RESINS ARE PRODUCED BY THREE MAIN PROCESSES:
• PROCESS DESCRIPTION OF ALKYD RESIN
• THE ADVANTAGES OF THIS PROCESS ARE:
• SYNTHESIS FROM OILS OR FATTY ACIDS
• MONOGLYCERIDE PROCESS:
• FATTY ACID PROCESS:
• MANUFACTURING PROCESS OF ALKYD RESIN
• MOST COMMON METHOD FOR THE PRODUCTION OF ALKYD RESIN IS.
• ALCOHOLYSIS METHOD
• FATTY ACID METHOD
• FORMULATION OF LONG ALKYD RESIN
• FORMULATION OF SHORT ALKYD RESIN
• FORMULATION OF MEDIUM ALKYD RESIN
• DETAILS OF ALKYD RESIN MANUFACTURE
• FATTY ACID METHOD
• FATTY ACID-OIL METHOD
• OIL-DILUTION METHOD
• ALCOHOLYSIS METHOD
• FUSION VERSUS SOLVENT PROCESSING
• GENERAL PROCESSING AND DESIGN CONSIDERATIONS
• CHOICE OF CONSTRUCTION MATERIALS
• 1. LINSEED OIL PENTAERYTHRITOL ALKYD RESIN
• 2. LINSEED OIL GLYCERINE SHORT OIL VARNISH ALKYD
• 3. SOYBEAN-OIL ALKYD MODIFIED WITH MALEIC
• 4. DEHYDRATED CASTOR OIL-PROPYLENE GLYCOL ALKYD
• PROCESS FLOW DIAGRAM
• PRINCIPLES OF PLANT LAYOUT
• MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE 
• SERVICE ARE:
• PLANT LOCATION FACTORS
• 1. RAW-MATERIAL SUPPLY:
• 2. MARKETS:
• 3. POWER AND FUEL SUPPLY:
• 4. WATER SUPPLY:
• 5. CLIMATE:
• 6. TRANSPORTATION:
• 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:
• EXPLANATION OF TERMS USED IN THE PROJECT REPORT
• 1. DEPRECIATION:
• 2. FIXED ASSETS:
• 3. WORKING CAPITAL:
• 4. BREAK-EVEN POINT:
• 5. OTHER FIXED EXPENSES:
• 6. MARGIN MONEY:
• 7. TOTAL LOAD:
• 8. LAND AREA/MAN POWER RATIO:
• PROJECT IMPLEMENTATION SCHEDULES
• INTRODUCTION
• PROJECT HANDLING
• PROJECT SCHEDULING
• PROJECT CONSTRUCTION SCHEDULE
• TIME SCHEDULE
• ADDRESSES OF RAW MATERIAL SUPPLIERS
• ADDRESSES OF PLANT & MACHINERY 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)