Detailed Project Report (DPR) on flame ratardant paints

FLAME RETARDANT PAINTS
[CODE NO. 3006]  


The term, “fire retardant paint,” is a composition that, when applied to a flammable material, provides thermal protection for the material. In general, this may be done by reducing or perhaps even eliminating the tendency of the material to burn and/or reducing the rate of flame spread along the surface of the material. Preferably, use of the fire retardant paint, for example, on a solid material as the substrate, reduces surface burning characteristics significantly, say, at least about 10%, at least about 25%, or at least about 50%, when compared to untreated material, as tested by an appropriate test. For example, the test may be the ASTM E84 Steiner Tunnel Test. Without being bound by any theory, although it looks and applies like regular paint, its chemical composition changes drastically when introduced to heat. Thus, when heat is applied, the fire retardant paint may “foam up” to form an intact, fire-resistive “char-barrier” to protect the treated surface. As a result, fire is robbed of fuel and oxygen, generates less heat and smoke, and may in some circumstances extinguish itself. Fire retardant paint formulations can vary.

Flame retardant coatings are designed for application overa range of combustible or non-combustible surfaces. FR coat-ings are distinguished by their ability to release non-flammablegases when contacted by fire or when heat is generated. These gases interfere with the rate of spreading flame and also reduceits intensity. Flame retardants are divided into five groups characterized by their chemical composition: (i) halogen compounds; (ii) metallic oxides and sulfides; (iii) phosphorus compounds; (iv) inorganic hydrates, hydroxy compounds, boric compounds, silicates, carbonates; and (v) nitrogen compounds. Looking back in history the oldest FR besides water has beena nitrogen–phosphorous compound, namely ammonia phosphate. Various nitrogen–phosphorus (N–P) containing compounds were proposed to impart flame retardancy to polymers. Among them, compounds based on bisphosphoramidates is most widely studied and known to act as thermally stable compounds. Other types of N–P FRs were reported for highly thermally stable compounds based on aromatic substituted and spiro-aromatic-substituted phosphazenes. High molecular weightpoly (dichlorophosphazene) and cyclic chlorophosphazenes hasbeen prepared by various methods and the thermal stabilitywas studied. And recently micro capsulated chlorocy-clophosphazenes were synthesized and showed high thermal stability. The flammability and mechanical properties of micro-capsulated chlorocyclophosphazene were also studied. Themost successful flame retardant additives on the market todayare halogenated flame retardant additives. Halogenated com-pounds can be either physically introduced or reacted with thepolymer chain. However, halogenated compounds canhave negative environmental and toxicological impacts. Asa result of this environmental concern, flame retardant alkydpaints are becoming popular for various reasons. A technique forpreparing flame retardant polymer is based on the scavengingof radicals formed during combustion. This can be best achievedby halogenated compounds; chlorine and bromine have beenreported as the best radical scavengers. Long oil alkyd, styrenated alkyd and chlorinated alkyd resins were made flameretardant. Incorporation of chlorine into rubber seed oil alkydresulted in better coating properties and the chlorinated rubberseed oil alkyd became fire retardant.

COST ESTIMATION

Plant Capacity                                               1.00 Ton/day
Land & Building (7000 Sq.Mtr)                   Rs.69.00 Lacs
Plant & Machinery                                         Rs. 80.00 Lacs
W.C. for 1 Month                                            Rs. 63.00 Lacs
Total Capital Investment                             Rs.  2.23  Cr
Rate of Return                                              53%
Break Even Point                                         44%

INTRODUCTION    
MARKET SURVEY    
OVERVIEW OF PAINT INDUSTRIES IN INDIA    
MANUFACTURERS/SUPPLIERS    
RAW MATERIALS    
NON - INTUMESCENT FIRE RETARDANT COATING    
MELAMINE POLYIMIDE COMPOSITE FIRE RESISTANT INTRUMESCENT COATINGS    
FORMULATION OF FLAME RETARDANT PAINT    
FORMULATION OF FIRE RETARDANT PAINT    
FORMULATION OF FLAME RETARDANT PAINTS
FORMULATION OF OIL BASED FIRE RETARDANT PAINT    
OTHER’S FORMULATION OF FIRE RETARDANT PAINTS    
A MORE PARTICULAR BASE IN TUMESCENT FIRE RETARDANT LATEX PAINT FORMULATION FOLLOWS:    
FORMULATION OF LOW DENSITY EPOXY COATING    
MANUFACTURING PROCESS    
PROCESS FLOW DIAGRAM    
BASIC STUDIES ON INTUMESCENT COATING    
PLANT LAYOUT    
SUPPLIERS OF RAW MATERIALS    
SUPPLIERS OF PLANT AND MACHINERY    

APPENDIX – A :

 1.      COST OF PLANT ECONOMICS      
 2.      LAND & BUILDING                                      
 3.      PLANT AND MACHINERY                                  
 4.      FIXED CAPITAL INVESTMENT                             
 5.      RAW MATERIAL                                         
 6.      SALARY AND WAGES                                     
 7.      UTILITIES AND OVERHEADS                              
 8.      TOTAL WORKING CAPITAL                                
 9.      COST OF PRODUCTION                                   
10.      PROFITABILITY ANALYSIS                               
11.      BREAK EVEN POINT                                     
12.      RESOURCES OF FINANCE                           
13.      INTEREST CHART                                       
14.      DEPRECIATION CHART                                   
15.      CASH FLOW STATEMENT                                   
16.      PROJECTED BALANCE SHEET