Industry Overview
Aluminium sulfate (Al2(SO4)3), commonly known as alum, is a water-soluble, non-combustible material available in white crystalline, solid, lump, kibbled, ground, dust and solution forms. The dry hydrate, Al2(SO4)3.14H2O, contains 17% Al2O3, while aluminium sulfate is also marketed as a 47% w/w solution containing 8% Al2O3.
Ferric and non-ferric alum are marketed in different grades and serve applications including water treatment and other industrial processes. Ferric alum is aluminium sulfate containing iron and can be obtained from bauxite ore, while potash alum is associated with naturally occurring minerals such as alunite and ratinite. The report describes the historical preparation of alum from alum shales as well as production through crystallization of equivalent proportions of potassium sulfate and aluminium sulfate, followed by concentration and separation of crystals.
The project report covers the characteristics and specifications of alum, applications, B.I.S. specifications, raw materials, bauxite composition, manufacturing processes for ferric and non-ferric alum, chemical reactions, heating and cooling requirements, environmental implications, quality testing, sampling, packing and marking, safety information, plant layout, suppliers and export-related formalities. It also addresses the market overview, Indian demand, installed capacity, production, capacity utilization, apparent consumption, estimated demand and the global scenario of alum.
Cost Estimation
| Particulars | Value |
|---|---|
| Plant Capacity | 20 MT/Day |
| Land & Building (2000 sq.mt.) | Rs. 1.33 Cr |
| Plant & Machinery | Rs. 2 Cr |
| Working Capital for 2 Months | Rs. 1 Cr |
| Total Capital Investment | Rs. 4.54 Cr |
| Rate of Return | 27% |
| Break Even Point | 62% |
Content Index
- INTRODUCTION
- CHARACTERISTICS & SPECIFICATION
- SPECIFICATION OF ALUM
- USES & APPLICATIONS
- APPLICATIONS
- USES OF ALUM
- THE MAIN USES OF ALUM ARE
- OTHER MAJOR USES
- WHAT HAPPENS AT A WATER TREATMENT PLANT?
- TREATMENT TO REMOVE ORGANIC CONTAMINANTS
- B.I.S. SPECIFICATIONS
- SPECIFICATIONS OF ALUMINIUM SULPHATE (NON FERRIC)
- NON FERRIC ALUM
- NON FERRIC ALUM - PRODUCT CHARACTERISTICS
- NON FERRIC ALUM - PRODUCT APPLICATION
- NON FERRIC ALUM - BENEFITS
- SPECIFICATION OF ALUMINUM SULPHATE
- (NON-FERRIC ALUM) (SLABE/LUMPS/POWDER)
- (FERRIC ALUM) (SLABE/LUMPS)
- FERRIC & NON-FERRIC ALUM PLANT
- MANUFACTURING PROCESS
- THE RAW MATERIALS ARE FOR FERRIC ALUM FOR NON FERRIC ALUM (ALUMINUM SULPHATE)
- SPECIFIC RAW MATERIAL CONSUMPTION (FOR ALUM CONTAINING ALUMINA AS AL2O3 16 %)
- QUANTITY REQUIRED DAILY FOR 25 TPD ALUM PLANT
- RAW MATERIALS
- BAUXITE
- THE RANGE OF COMPOSITION OF BAUXITES IS USUALLY
- THE BEST FRENCH WHITE BAUXITE CONTAINS
- MARKET SURVEY
- MARKET OVERVIEW OF ALUMINIUM SULPHATE
- INDIAN DEMAND FOR ALUM
- INSTALLED CAPACITY PRODUCTION AND CAPACITY UTILIZATION OF ALUM
- APPARENT CONSUMPTION OF ALUM
- ESTIMATED DEMAND
- GLOBAL SCENARIO OF ALUM
- IMPORTANT GLOBAL MANUFACTURERS
- PRESENT MANUFACTURERS/SUPPLIERS OF FERRIC & NON FERRIC ALUM
- PROCESS OUTLINES FOR ALUMINIUM SULFATE MANUFACTURE
- RAW MATERIALS
- STEP 1 - REACTING THE RAW INGREDIENTS.
- STEP 2 - MAKING THE FINAL PRODUCT
- ENVIRONMENTAL IMPLICATIONS
- MANUFACTURING PROCESS OF NON FERRIC ALUMINIUM SULPHATE (ALUM)
- CHEMICAL REACTION
- HEATING AND COOLING REQUIREMENTS
- HEATING REQUIREMENT
- COOLING REQUIREMENT
- DETAILED PROCESS DESCRIPTION
- (A) BAUXITE PREPARATION SECTION
- (B) REACTION SECTION
- WASTE & EMISSION'S
- PACKING & MARKING
- PACKING
- MARKING
- REQUIREMENT FOR ALUMINIUM SULPHATE (NON FERRIC)
- METHODS OF TEST FOR ALUM, NON FERRIC (ALUMINIUM SULFATE)
- QUALITY OF REAGENTS
- PREPARED SAMPLE
- DETERMINATION OF INSOLUBLE MATTER
- REAGENTS
- PROCEDURE
- CALCULATION
- DETERMINATION OF PH
- PROCEDURE
- DETERMINATION OF HEAVY METALS
- APPARATUS
- REAGENTS
- STANDARD LEAD SOLUTION
- PROCEDURE
- DETERMINATION OF IRON
- APPARATUS
- REAGENTS
- BUTANOLIC POTASSIUM THIOCYANATE SOLUTION
- STANDARD IRON SOLUTION
- PROCEDURE
- TEST FOR CHLORIDES
- REAGENTS
- PROCEDURE
- DETERMINATION OF ARSENIC
- PROCEDURE
- DETERMINATION OF THE AMMONIUM SALTS OUTLINE OF THE METHOD
- APPARATUS
- REAGENTS
- NESSLER SOLUTION
- STANDARD AMMONIUM CHLORIDE SOLUTION
- PROCEDURE
- DETERMINATION OF ALUMINIUM
- GRAVIMETRIC METHOD
- REAGENTS
- PROCEDURE
- EDTA METHOD
- REAGENTS
- ABSOLUTE ALCOHOL
- ACETIC ACID
- AMMONIUM ACETATE BUFFER SOLUTION
- PROCEDURE
- DETERMINATION OF SODIUM
- DETERMINATION OF POTASSIUM
- SAMPLING OF ALUM, NON FERRIC (ALUMINIUM SULPHATE)
- GENERAL REQUIREMENTS OF SAMPLING
- SCALE OF SAMPLING
- TABLE 2 SCALE OF SAMPLING
- PREPARATION OF TEST SAMPLES
- NUMBER OF TESTS
- CRITERION FOR CONFORMITY
- SEQUENCES IN ALUM MANUFACTURE
- BLOCK DIAGRAM TO PRODUCE ALUMINIUM SULPHATE NON FERRIC (17% TO 18%) ALUMINA CONTENT IN GRANULES (2MM TO 4MM) AND FLAKES FORM
- ALUM (FERRIC AND NON-FERRIC)
- MANUFACTURING PROCESS
- WHAT IS ALUM AND HOW DOES IT CONTROL ALGAE?
- CHEMICAL COMPOSITION OF FERRIC ALUM
- GRADE 3
- CHEMICAL COMPOSITION OF NON-FERRIC ALUM
- METHOD OF PRODUCING ALUMINIUM SULFATE SOLUTION
- MATERIAL SAFETY DATA SHEET OF ALUMINIUM SULPHATE
- HAZARDS IDENTIFICATION
- EMERGENCY OVERVIEW
- POTENTIAL HEALTH EFFECTS
- CARCINOGEN STATUS
- COMPOSITION/INFORMATION ON INGREDIENTS
- FIRST AID MEASURES
- GENERAL INFORMATION
- FIRE FIGHTING MEASURES
- ACCIDENTAL RELEASE MEASURES
- HANDLING AND STORAGE
- PHYSICAL AND CHEMICAL PROPERTIES
- STABILITY AND REACTIVITY
- DISPOSAL CONSIDERATIONS
- TRANSPORT INFORMATION
- PLANT LAYOUT
- COMPLETE PLANT SUPPLIERS OF FERRIC & NON-FERRIC ALUM PLANT
- SUPPLIERS OF RAW MATERIALS
- SUPPLIERS OF PLANT AND MACHINERY
- TO GET REQUIRED CERTIFICATION & OTHER FORMALITES FOR EXPORTING NON FERRIC ALUMINIUM SULPHATE
- ADDRESSES OF CONSULTANTS
- ADDRESSES OF PILOT PLANT SUPPLIERS
- SUPPLIERS OF RAW MATERIAL (INDIAN)
- BAUXITE
- SULPHURIC ACID
- BARIUM SULPHIDE
- SUPPLIERS OF RAW MATERIALS (GLOBAL)
- SUPPLIERS OF PLANT & MACHINERY
- REACTOR
- EVAPORATORS
- GRADING SCREEN/ VIBRATING SCREEN
- COOLING TOWERS
- BOILERS
- CRUSHER
- MATERIAL HANDLING EQUIPMENTS
- LABORATORY TESTING EQUIPMENTS
- SUPPLIERS OF PLANT AND MACHINERIES (IMPORTED)
Appendix
- 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)
Frequently Asked Questions
Aluminium sulfate is a water-soluble chemical compound commonly known as alum. It is available in solid and solution forms and can occur as white crystalline material. The report covers aluminium sulfate in both ferric and non-ferric forms, including different physical forms such as lumps, granules, powder and flakes. Its properties, specifications, manufacturing methods, testing procedures, applications and safety considerations are addressed throughout the project report.
Alum is widely associated with water treatment and has several other industrial applications. The report specifically covers its applications in water treatment, including processes used to address contaminants, and discusses its role in controlling algae. It also provides separate sections on the main uses, other major uses, product applications and benefits of non-ferric alum. The precise application depends on the grade, composition, physical form and quality requirements of the intended process.
Ferric and non-ferric alum differ primarily in their iron content and resulting product characteristics. The report describes ferric alum as aluminium sulfate containing iron, while non-ferric alum is addressed separately through its specifications, characteristics, applications, benefits and testing requirements. The report also includes separate chemical-composition sections and manufacturing information for both types, reflecting the importance of selecting the appropriate grade according to the required product specification and end-use conditions.
The raw materials depend on the type and manufacturing route of alum being produced. The report discusses bauxite, sulphuric acid and barium sulphide in its raw-material supplier sections and provides separate treatment of raw materials for ferric and non-ferric alum. Bauxite is examined in detail, including its composition and quality characteristics. The report also describes the reaction, preparation and processing stages required to convert the selected raw ingredients into aluminium sulfate products.
Aluminium sulfate manufacturing generally involves preparing the raw materials, carrying out the required chemical reaction, and processing the resulting product into the desired form. The report divides the process into stages including bauxite preparation and the reaction section, followed by heating, cooling, product formation and packing. It also covers detailed process descriptions, chemical reactions, heating and cooling requirements, waste and emissions, and the production of aluminium sulfate solution. The exact sequence depends on the selected manufacturing process and product grade.
Quality testing for non-ferric alum can include checks for physical and chemical characteristics specified for the product. The report covers determination of insoluble matter, pH, heavy metals, iron, chlorides, arsenic, ammonium salts, aluminium, sodium and potassium. It also describes sampling requirements, preparation of test samples, number of tests and criteria for conformity. These procedures support quality control and help establish whether aluminium sulfate meets the applicable product specifications and intended quality requirements.
Alum manufacturing equipment depends on the selected process, product form and plant configuration. The report identifies equipment categories including reactors, evaporators, grading or vibrating screens, cooling towers, boilers, crushers, material-handling equipment and laboratory testing equipment. The project report also includes plant layout information and supplier sections covering raw materials, plant and machinery, pilot plants and imported machinery. Equipment selection should be based on process requirements, product specifications, capacity, material compatibility, safety requirements and applicable quality standards.
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