Detailed Project Report (DPR) on Epoxy Resin

EPOXY RESIN

[EIRI/EDPR/5359] J.C.: 1582XL

INTRODUCTION

The word 'Epoxy' comes from the Greek prefix meaning 'over' or 'between' and the English suffix for Oxygen. Thus an epoxy material may be regarded as an 'Oxygen between compound'.

Epoxy resins are thermosetting viscous liquids or brittle solids of which most widely used are those derived from the condensation reaction between epichlorohydrin and bisphenol. A commercial exploitation was first initiated about the middle of 1530 by I.S. Farben and this work was later followed independently by P. Custan, in Switzerland and then in U.S.A. around 1938. Developments were slowed down by the Second World War and relatively high price and scarcity of epichlorohydrin. However, at the end of the war, epichlorohydrin, which war then obtained as an intermediate from the production of glycol, became commercially available and led to wider uses for epoxy resins.

The seed of modern IV Epichlorohydrin (ECh)-Diphenyl-Propane (DPP) based epoxy resins sown by castan, was a land-mark in the history of resins.

In 1950, the market was only about 2 million lbs., used almost exclusively in coatings, applications. In 1964, approximately 85 million lbs. were used for coatings, adhesives, structural applications, electrical laminates and for a wide range of other uses. Coating application, however, still account for approximately half of all expoxy resin used.

The epoxy resins have steadily grown in their use in the plastic and related industries due to the variety of forms in which they may be processed.

As thermosetting materials, they can be combined with hardening agents to form a cross-linked polymer network. By the selection of the appropriate resin-hardener combination, the process can obtain both the desired handling characteristics and desired properties in the finished product. Toughness, corrosion or chemical resistance and good dielectric properties are common to virtually all epoxy resin systems. In addition, because of their structure and method of cure, epoxy resins provide two unique advantages over other thermosetting resins.

(1) No reaction by product or volatile is lost during cure. Large castings or thick sections can, therefore, be made without bubbles or voids.

(2) A low degree of shrinkage takes place upon cure. Accurate reproduction of molds is possible and very little internal stress is left to affect adhesion, thermal stock resistance, or other properties.

Epoxy resins are now produced in most of the developed countries of the world. But in India, although this item war introduced in late fifties, but indigenous production started in late sixties.

The wide and highly useful spectrum of properties exhibited by cured epoxy resins has identified then to be the most superior, unique and extremely versatile synthetic resins. No other synthetic resins than epoxy resins have got so many extremely useful properties together.

Epoxy resins are supplied in liquid or solids, depending on the resin type and end use applications. They are converted to thermostet by any one of the numerous compounds referred to as curing agents. The conversion is acomplished at room temperature or elevated temperature depending upon optimum condition or desired end properties. A further modification of the properties is possible by the incorporation of reactive diluents plasticizers, fillers and other additives.

ECh and DPP are the basic raw materials necessary for the manufacture of Epoxy Resins. Though DPP is manufactured in the country, but still today ECh is to be imported. As the raw materials are very expensive, hence the cost of production is high in comparison with other resins.

The seed of Modern Npichlorohydrin (ECH)-Diphenyol-Propane (DPP) based epoxy resins was first shown by castan, a suiss chemist. His patents were licenced to CIBA A.G. of Bosle. In 1946, an industrial Fair was Organised in Switserland. This Swiss company demonstrated the use of an epoxy resin adhesive namely resin coatings to four suies electrical, Electrical company remarkable materials begin with the introduction to industries.

COST ESTIMATION

Plant Capacity            1.38 Ton/Day

Land & Building (450 sq.mt.)    Rs. 10.97 Lac

Plant & Machinery                    Rs. 20.08 Lac

Working Capital for 1 Month    Rs. 29.29 Lac

Total Capital Investment          Rs. 68.61 Lac

Rate of Return                          45%

Break Even Point                      58%

CONTENTS

INTRODUCTION                                      

USES AND APPLICATIONS                             

B.I.S. SPECIFICATIONS                          

MARKET SURVEY                                    

NAME OF EPOXY RESIN MANUFACTURERS                

MANUFACTURERS OF EPOXY RESINS                    

PROPERTIES                                       

HEAT DEFLECTION TEMPERATURE (HDT)              

PROPERTIES OF EPOXY SYSTEMS                      

RAW MATERIALS                                    

RAW MATERIAL REQUIREMENTS                        

MANUFACTURING PROCESS                            

SYNTHESIS OF DIGLYCIDYL ETHER OR BISPHENOL-A     

FLOW SHEET OF EPOXY-RESIN PRODUCTION           

SOME BASIC FORMULATIONS OF EPOXY RESINS          

SUPPLIERS OF RAW MATERIALS                       

SUPPIERS OF PLANT AND MACHINERY                  

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)