Detailed Project Report (DPR) on improving drop point (melting point) of paraffin wax from 45-50 Deg C to 75-80 Deg.C)

IMPROVING DROP POINT (MELTING POINT)
OF PARAFFIN WAX FROM 45-50OC TO 75-80OC)
 [CODE NO. 3075]  


Paraffin wax, although it is not crude wax, is a hydrocarbon mixture having physical properties of wax. Paraffin waxes are compared primarily of straight chain molecules with a relatively small amount of branches chains. Usually the branching that occurs is only one carbon chain which is located near one end of the main chain. There is an over all average of less than one branched, chain carbon atom per molecule. Cyclic amounts are present in paraffin wax is only minute amounts.

The word "wax" usually refers to a variety of organic substances that are solid at ambient temperature but become
free-flowing liquids at slightly higher temperatures. The chemical composition of waxes is complex, but normal alkanes are
always present in high proportion and molecular weight profiles tend to be wide. The main commercial source of wax is crude
oil but not all crude oil refiners produce wax. "Mineral" wax can also be produced from lignite. Plants, animals and even
insects produce materials sold in commerce as "wax."
Waxes are typically long, linear or branched n-paraffin chains within produced hydrocarbons and primarily consist of
paraffin hydrocarbons (C18 - C36) and naphthenic hydrocarbons (C30 - C60).

Hydrocarbon components of wax can exist in various states of matter (gas, liquid or solid) depending on their temperature
and pressure. When the wax freezes, it forms crystals referred to as macrocrystalline wax. Those formed from naphthenes are
known as microcrystalline wax. The solid forms of paraffin, called paraffin wax, are from the heaviest molecules from
phytane (C20H42) to lycopane (C40H82).
Paraffin wax is a white, odorless solid with a typical melting point between about 115°F  and 154°F (46 and 68°C) having a
density of around 0.9 g/cm3 . Waxes have low thermal conductivity, a high heat capacity, and are insoluble in water. While
constant deposition of wax can block production lines, it can also act as insulation due to its low thermal conductivity and
high heat capacity, resulting in higher arrival temperatures during steady flowing conditions and longer cooldown times
during shutdowns. Paraffin wax is soluble in ether, benzene and certain esters, while being unaffected by most common
chemical reagents.

At temperatures below the cloud point, the n-paraffin components begin to crystallize into solid wax particles. These can
adhere to each other when the wax-containing hydrocarbon comes in contact with any surface that has a temperature below the
wax appearance temperature (WAT) and provides a heat sink. Although WAT and cloud point are often used interchangeably, the
distinction is that the cloud point refers to the temperature at which the first wax crystals are observed in solution. The
WAT is generally a slightly lower temperature that represents the point at which the bulk of the wax crystallizes. Pour
point is another paraffin-related temperature and is the point at which the oil begins to solidify and will not flow without
applying force.

The predominant mechanisms proposed to describe paraffin deposition are shear dispersion and molecular dispersion. Shear
dispersion describes the relationship between deposition rate and shear rate. Shearing of the wax molecules occurs due to
the hydrodynamic drag of the flowing fluid and depends mostly on the flowrate and viscosity of the fluid. Higher viscosity
and low flowrates result in high wax deposition rates. However, in highly turbulent flow, deposition rates decrease with
increased flow as wax is mechanically sheared off the deposits on the pipe wall. As the deposit thickness increases, so does
the shear rate due to the decrease in the flow area and increase in flow velocity. This increase in shear rate causes an
increase in the shear stress on wax molecules and formed wax crystals which serves to diminish the overall wax deposition
rate.

Molecular diffusion describes the process by which the radial temperature gradient in the line causes a concentration
gradient of dissolved paraffin components in the liquid phase. This concentration gradient causes paraffin to diffuse to the
pipe wall, where it is assumed to deposit. The widely recognized transport methods contributing to wax thickness on the pipe
wall are molecular diffusion of dissolved wax, particle transport of precipitated wax, and sloughing of previously deposited
wax.


COST ESTIMATION

Plant  Capacity                             :       1.00 Ton/day
Land & Building (400 Sq.MT)    :    Rs. 48.00 Lacs
Plant & Machinery                        :    Rs. 8.00  Lacs
Working Capital for 1 Months    :    Rs. 31.20 Lacs
Total Capital Investment             :    Rs. 89.20 Lacs
Rate of Return                               :    32%
Break Even Point                           :    52%



PRODUCT INTRODUCTION    
PROPERTIES AND CHARACTERISTICS OF PARAFFIN WAX    
USES & APPLICATION    
B.I.S. SPECIFICATION    
MAJOR WAX MARKETS    
TYPES AND VERSATILITY OF WAXES    
MARKET POSITION OF PARAFFIN WAX    
RAW MATERIALS    
STANDARD FOR PETROLEUM WAXES    
SPECIFICATION FOR PARAFFIN WAX FOR EXPLOSIVE
  AND PYROTECHNIC INDUSTRY    
FORMULATION OF IMPROVING DROP POINT OF PARAFFIN WAX    
MANUFACTURE OF HIGH MELTING POINT PARAFFIN WAX    
PROCESS IN DETAILS    
PRINCIPLES OF PLANT LAYOUT    
PLANT LOCATION FACTORS    
EXPLANATION OF TERMS USED IN THE PROJECT REPORT    
PROJECT IMPLEMENTATION SCHEDULES    
SUPPLIERS OF RAW MATERIALS    
SUPPLIERS OF PLANT & 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