Industry Overview
Ferrous Sulphate, commonly known as Copperas, Green Copperas or Green Vitriol, is represented by the chemical formula FeSO4·7H2O and occurs as pale green crystals that are soluble in water. It is commercially produced mainly as a byproduct of waste pickling liquors from galvanizing and tin plate plants, or by dissolving scrap iron in warm dilute sulphuric acid.
In the byproduct process, pickling liquor is treated with scrap iron to reduce free acidity, followed by neutralization, filtration and concentration through evaporation. Alternatively, scrap iron and sulphuric acid are added to the liquor at 180°F to increase its concentration to 43°Be. The concentrated hot liquor is then cooled in crystallizers, allowing ferrous sulphate heptahydrate crystals to separate. These crystals are filtered, washed, broken, screened and dried with warm air at 140°F. The mother liquor may be returned to the neutralizing tank or further concentrated.
Ferrous Sulphate is also obtained as a byproduct in titanium pigment and copper sulphate manufacture. For medicinal applications, it can be prepared by reacting iron with dilute sulphuric acid. Exsiccated Ferrous Sulphate is a grayish-white powder produced by drying the crystals at 40°C, removing part of the water of crystallization.
Cost Estimation
| Particulars | Value |
|---|---|
| Plant Capacity | 600 Ton/ Per Year |
| Land & Building (700 sq.mt.) | Rs. 1.05 Cr |
| Plant & Machinery | Rs. 30.00 Lacs |
| Working Capital for 2 Month | Rs. 31.76 Lacs |
| Total Capital Investment | Rs. 1.73 Cr |
| Rate of Return | 25% |
| Break Even Point | 65% |
Content Index
- INTRODUCTION
- THE COMMERCIAL METHODS OF ITS DERIVATION ARE:-
- PROPERTIES
- GRADES OF FERROUS SULPHATE
- CONTAINERS AND REGULATIONS
- USES AND APPLICATIONS
- (I) TECHNICAL GRADE
- (II) PURE GRADE
- B.I.S. SPECIFICATION
- SOLUBILITY:
- TABLE-1
- TABLE-II
- TABLE-III
- PACKING & MARKING:-
- SPECIFICATION OF FERROUS SULPHATE HEPTAHYDRATE
- FERROUS SULPHATE HEPTAHYDRATE AR/ACS MEETS ANALYTICAL SPECIFICATION OF IP, BP, USP, PH.EUR.
- MARKET POSITION OF FERROUS SULPHATE
- FERROUS SULFATE MARKET HITS GOLDMINE AS FERROUS SALTS GAIN POPULARITY TO TREAT ANEMIA
- FOCUS ON IMPROVING WATER QUALITY TRIGGERS DEMAND FOR FERROUS SULFATE
- KEY PRODUCT IN FERROUS SULFATE MARKET
- HIGH DEMAND FOR FERROUS SULFATE IN VARIOUS INDUSTRIES
- ASIA PACIFIC TO BE HIGHLY LUCRATIVE REGION OF FERROUS SULFATE MARKET
- FERROUS SULFATE MARKET: COMPETITION LANDSCAPE
- MANUFACTURING PROCESS OF FERROUS SULPHATE HEPTAHYDRATE (PHARMA GRADE)
- RAW MATERIALS
- CHEMICAL REACTION
- PROCESS FLOW DIAGRAM
- PROCESS IN DETAILS
- REACTION:
- FILTERATION:
- EVAPORATING:
- CENTRIFUGATION:
- DRYING:
- PROCEDURE:
- CALCULATION:
- PACKING:
- PURIFICATION:
- REAGENTS:
- METHOD OF FERROUS SULPHATE PRODUCTION
- PICKLE LIQUOR REMOVES OXIDE LAYER
- THE SULFATE PROCESS
- FORMULATIONS/PREPARATIONS
- PRODUCTION OF FERROUS SULPHATE HEPTAHYDRATE FROM FERROUS SULPHATE MONOHYDRATE
- POLLUTION CONTROL IN THE MANUFACTURE OF FERROUS SULPHATE
- PRINCIPLES OF PLANT LAYOUT
- PLANT LOCATION FACTORS
- PRIMARY FACTORS
- 1. RAW-MATERIAL SUPPLY:
- 2. MARKETS:
- 3. POWER AND FUEL SUPPLY:
- 4. WATER SUPPLY:
- 5. CLIMATE:
- 6. TRANSPORTATION:
- 7. WASTE DISPOSAL:
- 8. LABOR:
- 9. REGULATORY LAWS:
- 10. TAXES:
- 11. SITE CHARACTERISTICS:
- 12. COMMUNITY FACTORS:
- 13. VULNERABILITY TO WARTIME ATTACK:
- 14. FLOOD AND FIRE CONTROL:
- EXPLANATION OF TERMS USED IN THE PROJECT REPORT
- 1. DEPRECIATION:
- 2. FIXED ASSETS:
- 3. WORKING CAPITAL:
- 4. BREAK-EVEN POINT:
- 5. OTHER FIXED EXPENSES:
- 6. MARGIN MONEY:
- 7. TERM LOANS:
- 8. TOTAL LOAD:
- 9. LAND AREA/MAN POWER RATIO:
- PROJECT IMPLEMENTATION SCHEDULES
- INTRODUCTION
- PROJECT HANDLING
- PROJECT SCHEDULING
- PROJECT CONSTRUCTION SCHEDULE
- TIME SCHEDULE
- SUPPLIERS OF RAW MATERIALS
- SUPPLIERS OF PLANT AND MACHINERY
Appendix
- 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
Ferrous sulphate is an iron salt commonly available as ferrous sulphate heptahydrate, FeSO4·7H2O. It forms pale green crystals that are soluble in water. The material has applications across industrial, agricultural, water-treatment and medicinal fields, depending on its grade and specification. Commercial production can involve recovery from waste pickling liquors or reaction of iron-containing materials with sulphuric acid.
Ferrous sulphate heptahydrate can be manufactured by reacting scrap iron with dilute sulphuric acid or by processing suitable waste pickling liquors. The process generally involves reaction and acid reduction, followed by neutralization or conditioning, filtration, concentration, crystallization, centrifugation, washing and drying. The report describes concentration of the liquor followed by cooling in crystallizers so that heptahydrate crystals separate. Process conditions and purification requirements vary according to the intended product grade.
Scrap iron, sulphuric acid and suitable ferrous-containing pickling liquors are the principal materials associated with the production routes described in the report. In a direct production route, iron reacts with dilute sulphuric acid to form ferrous sulphate. In a byproduct route, waste pickling liquor is processed and may be treated with scrap iron to reduce free acid. The precise raw-material requirements depend on the manufacturing method, feed composition and desired grade.
Ferrous sulphate is used in several industrial and commercial applications, with its use depending on product grade and purity. The report identifies medicinal applications and discusses demand associated with water quality improvement and various industries. It is also produced as a byproduct in titanium pigment and copper sulphate manufacture. Pharmaceutical and analytical applications require appropriate grades and compliance with relevant specifications, while technical applications may have different purity and handling requirements.
Ferrous sulphate heptahydrate contains seven waters of crystallization, whereas exsiccated ferrous sulphate is produced by controlled drying that removes part of this crystallization water. The report describes the heptahydrate as pale green crystals and exsiccated material as a grayish-white powder. Exsiccated ferrous sulphate is used therapeutically and is slowly but almost completely soluble in freshly boiled and cooled water. The physical form and hydration state therefore distinguish the two materials.
Oxidation can be controlled by maintaining suitable process conditions and a slight excess of sulphuric acid in the crystals, as described in the report. Surface oxidation may also be counteracted by adding a small quantity of iron to the liquor during heating and settling operations. Control of heating, settling, concentration and exposure conditions is important because ferrous compounds can oxidize during processing. The exact operating practice should be established according to the feedstock, product grade and process design.
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