Detailed Project Report (DPR) on Metallic Stearate

METALLIC STEARATE

[EIRI/EDPR/1618] J.C.420

INTRODUCTION

Stearates of aluminium, calcium, magnesium and zinc are known as driers and metallic soaps. It has long been established that the metal or cattier of the metallic soap is the active principle which accelerates the oxidation and polymerization reactions associated with the drying of oils. As many as twenty four metals are known to have activity, but the soaps of cobalt, manganese, lead, iron, calcium, zinc and zirconium account for the major share of present-day-use. Of these cobalt, manganese, lead and iron soaps are the primary driers. Calcium, zinc and zirconium soaps alone do not promote drying. They are useful only in conjunction with one or more of the primary driers and thus are termed auxiliary driers. The organic or a main portions of the metallic soaps used as driers act as carrying and solubilizing agents. Because of their stability, excellent salability and low cost, soaps based on naphthenic acid, tall oil and 2- ethylhexoic acid account for the major portion of the driers in use today. Driers made with resin, oleic and linoleic acids have declined in use, but are still manufactured for special purposes. Driers based on newly available synthetic, tertiary organic acids have been developed. These acids are in the 9-11 carbon range and thus have a higher acid value than those with a larger number of carbon atoms, permitting driers of higher metal content. Driers are available as liquids, solids and pastes, depending on the preference of the trade. The paint industry shows almost universal preference for low-viscosity liquids because of their handling, constant and reliable metal content and ready solubility. Solid soaps are used only where solvents are objectionable because of dilution of unwanted contamination, because the volatility of the solvent is objectionable, or because fire hazard is present. Pastes are used primarily in printing inks where the consistency is matched to that of the ink. The exact mechanism of the role of driers in the forming of solid, elastic protective films evolve carbon dioxide and water during drying. Linseed oil, containing driers and exposed in pure oxygen, absorbs large volumes of the gas over a period of several days. The total amount of oxygen taken up by linseed oil films at solidification is lower when drier is present. At the time approximately the same amount of carbon dioxide is evolved whether drier is present or absent. 

During the drying of a film of the synthetic linolenic glyceride, the iodine valve of the film gradually decreased and the apparent molecular weight increased, indicates a decrease in unsaturation and a degree of polymerisation. Later studies of the drying process using newer instruments and techniques have indicated same of the intermediate stages and substantiated the early oxidation and polymerisation theories. The type and amount of drier used in paint and printing ink is governed by many factors as is condensed by the variety of  products available. Cobalt soaps are powerful oxidizing catalysts and are added in quantities 0.005-0.4% cobalt based on the vehicle content. They are the primary driers used in printing inks where the thin ink must dry rapidly. In paints, excess of cobalt cause skimming because surface oxidation and drying is more rapid than polymerization. For this reason lead soaps are used in conjunction with cobalt. From 0.05 to 2.0% of lead is the usual amount required. Manganese soaps are both oxidizing and polymerizing catalysts and produce soaps in outside paint, floor finishes, and backing enamels. Dosage ranges from 0.01 to 0.1% of the metal contained in the soap, based on vehicle. Iron soaps have little effect at ordinary temperatures, but are extremely active under baking conditions, exhibiting a strong polymerizating effect. Because of their dark colour the iron soaps are limited in use to darkc1oloured finished. Calcium, zinc and zirconium soaps are ancillary driers. Used alone these soaps show little activity, but when mixed with active driers they produce films with desirable properties. Calcium soaps in combination with cobalt or manganese produce hard films. Zinc soaps also promote hardening and are useful in wetting and grinding pigments. Zirconium soaps promote hardness and adhesion and improve color retention. The amount of metallic soaps used depends on the service expected of the completed lubricant. Light spindle oils are made with less than 1% soap. Heavy bodied greases contain up to 50% of soap. Calcium and Sodium soaps accounts for about 70% of metallic soaps used in grease making. Soaps of aluminium, calcium, sodium, magnesium and zinc form gel with mineral oil. Lead naphthenate is incorporated in lubricants made by heating lubricating oils with sulphur for high-pressure applications such as hypoid gears. Greases and heavy-duty lubricants which are essentials to the efficient operation of modern mechanical equipment, can be made by heating mineral oils or synthetic organic liquids with metallic soaps. Metallic soaps of alkali and alkaline earth metals and aluminium have asteep solubility curve.  

COST ESTIMATION

Plant Capacity            2 MT/Day

Land & Building (600 sq.mt.)    Rs. 92.00 Lac

Plant & Machinery                    Rs. 18.00 Lac

Working Capital for 1 Month    Rs. 79.98 Lac

Total Capital Investment          Rs. 1.95 Cr

Rate of Return                          29%

Break Even Point                      52%

CONTENTS

INTRODUCTION

PRODUCT USES & APPLICATION

B.I.S SPECIFICATIONS AND PROPERTIES

PROPERTIES AND CHARACTERISTICS OF METALLIC STEARATE

DESCRIPTION AND PROCESSING OF CALCIUM STEARATE

MARKET SURVEY

PRESENT MANUFACTURER OF METALLIC STEARATE

PROCESS OF MANUFACTURE

PURE AND LIGHT ZINC STEARATE

MANUFACTURING PROCESSES OF METALLIC STEARATES

SELECTION OF PROCESS

MANUFACTURING PROCESS (PRECIPITATION PROCESS)

PROCESS FLOW DIAGRAM (PRECIPITATION PROCESS)

MANUFACTURING PROCESSES OF METALLIC STEARATE 

BY FUSION PROCESS

GENERAL REACTION

PROCESS FLOW DIAGRAM (FUSION PROCESS)

MANUFACTURING PROCESS OF CALCIUM STEARATE FROM ANIMAL FATS

PROCESS FLOW DIAGRAM FOR THE MANUFACTURE OF CALCIUM

CHLORIDE FROM ANIMAL FATS (TALLOW)

PURITY ASSESMENT OF METALLIC STEARATE

PROPERTIES OF RAW MATERIALS

PLANT LAYOUT

SOURCES OF AVAILABILITY

SUPPLIERS OF RAW MATERIALS

SUPPLIERS OF PLANT AND MACHINERIES

RAW MATERIAL CALCULATION

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)