Detailed Project Report (DPR) on potassium silicate

POTASSIUM SILICATE [3514]

Potassium silicate is the potassium salt of silicic acid, and, in formulation, is readily absorbed by the plant. Silicon comprises 32% of the Earth’s crust, and silicic acid salts (silicates) are the most common form of silicon. Consequently exposure to silicates is widespread in activities involving contact with soil and natural water. The other part of the chemical, potassium is a required element for survival of both plants and animals, as is silicon. Potassium silicate is an active ingredient to be used as a fungicide, insecticide and miticide. Potassium silicate will be used as a broad spectrum, preventative fungicide with optimum control obtained when used under a scheduled preventative spray program. Potassium silicate also provides suppression of mites, whiteflies, and other insects. It is approved for use on agricultural crops, fruits, nuts, vines, turf and ornamentals. Potassium silicate is a soluble silicate. They can be produced over a wide range of stochiametric and non-stochiometric composition and are distinguished by the ratio of silica to alkali. Soluble silicates have a long history as adhesive and cements. These are used widely for palletizing, granulating and briquetting finely divided particles, eg. Ores, fertilizers and clays. The ability to form sols and gals is one of the most interesting and characteristic properties of soluble silicate. Potassium silicate being soluble silicate is a very important industrial chemical having varied uses, which will be discussed later on. It is sold either as glass or as liquids. Potassium silicates are important bonding agents in a large variety of ceramic cement and refractory applications because of their heat stability and resistance to chemicals. Potassium silicate has wide applications in coatings of many different substrates, such as metal and paper. Potassium silicate find extensive use as coatings cohere blooming (surface crystallization of sodium sulfate or carbonate) is a drawback. The resistance of potassium silicates to temperature above 550 deg.C makes them almost unique among industrial binders as five resistant adhesive, as impregnants for asbestos and other insulation and for paints resistance to high temperatures. Potassium silicate are also available in different grades and can be produced with no or different water molecules of crystallization. It is also available with different mole ratio of Sio2: K2 O varying from lowest 2.83 rations to 3.93. Solids and powders of potassium silicate are packed in drums, barrels, bags, cans and bottles: whereas solution is packed in tankers, drums, barrels and bottles. But, any case they must not be packed in aluminium galvanized iron or zinc containers otherwise chemical reaction between the metal and potassium silicate will take place and metal will be eaten way. Potassium is among the most abundant elements of the earth's Crust (av K2O Central, 3.1%) at is an essential constituent of plants and animals; potassium ions play an important part in Cellular metabolism. Potassium as a metal is very similar to Sodium and the compounds of Potassium closely resemble to corresponding compounds of Sodium in chemical properties. Consequently there existed ancient world of Chemistry a good deal of confusion on the nomenclature of compound of sodium and potassium. The word potash has originally applied to potassium carbonated, the earliest known compound of Potassium, recovered from word ashes. In trade the term potash is now after applied to any compound which is sold in bulk for its potassium content. In the common practice to express the total figures on production and potassium content of ores and fertilizers in terms of equivalent K2O content. The principal potassium salts of commerce are the chloride and the sulphate. Potassium forms both organic and inorganic compounds. There are more than 110 compounds of potassium reported in chemical literature. The compounds of potassium find numerics application but there may as use is as fertilizer industry, which accounts for nearly 90% of the total prodution of potash chloride, sulphate and nitrate of potassium are the main potassic fertilizers of which the chloride is by far the most important.

COST ESTIMATION

Plant Capacity                                                  16.67 MT/Day  
Land & Building (4000 sq.mt)                      Rs. 3 Cr
Plant & Machinery                                           Rs. 1.50 Cr
Working Capital for 1 Month                         Rs. 1.69 Cr
Total Capital Investment                               Rs. 6.40 Cr
Rate of Return                                                24%
Break Even Point                                           61%



INTRODUCTION    
USES AND APPLICATIONS    
1) DETERGENTS AND CLEANING COMPOUNDS    
2) ADHESIVE AND CEMENTS    
3) BONDING AGENTS    
4) COATINGS    
5) SOLES AND GELS    
6) OTHER IMPORTANT APPLICATIONS    
PROPOSED USES AND APPLICATION METHODS FOR POTASSIUM SILICATE INCLUDE THE FOLLOWING:    
FOOD CLEARANCES/TOLERANCES    
PHYSICAL AND CHEMICAL PROPERTIES ASSESSMENT    
TABLE. PRODUCT CHEMISTRY DATA REQUIREMENTS:    
TABLE. PHYSICAL AND CHEMICAL PROPERTIES FOR TECHNICAL
    POTASSIUM SILICATE    
PROPERTIES    
TYPICAL AMORPHOUS COMMERCIAL POTASSIUM SILICATE    
B.I.S SPECIFICATIONS    
SCOPE    
GRADES    
REQUIREMENTS    
PACKING AND MARKING:-    
METHODS OF TEST FOR POTASSIUM SILICATE, TECHNICAL:    
QUALITY OF REAGENTS:    
PREPARATION OF SAMPLE SOLUTION:
MATTER INSOLUBLE IN WATER:    
RELATIVE DENSITY:    
APPARATUS    
PROCEDURE    
TOTAL SOLUBLE SILICA:    
REAGENTS    
PROCEDURE:    
TOTAL ALKALINITY:    
VOLUMETRIC METHOD    
REAGENTS    
GRAVIMETRIC METHOD    
REAGENTS    
CONCENTRATED HYDROCHLORIC ACID.
TOTAL SOLUBLE SILICATES:    
RATIO OF TOTAL ALKALINITY TO TOTAL SOLUBLE SILICA    
IRON    
APPENDIX- B    
SAMPLING    
GENERAL REQUIREMENTS:    
SCALE OF SAMPLING    
TABLE 2 NUMBER OF DRUMS TO BE SELECTED
TEST SAMPLES AND REFEREE SAMPLES    
PREPARATION OF TEST SAMPLES    
NUMBER OF TESTS:    
CRITERIA FOR CONFORMITY:    
MARKET POSITION OF POTASSIUM SILICATE    
MANUFACTURERS/SUPPLIERS OF POTASSIUM SILICATE    
MANUFACTURING PROCESS OF POTASSIUM SILICATE (FUSION PROCESS)    
PROCESS FLOW DIAGRAM    
PROCESS IN DETAILS    
1)  FUSION PROCESS    
2)  ION EXCHANGE PROCESS    
THE COMPOSITION IS GIVEN AS FOLLOWS:    
THE BRIEF OUTING OF THE PROCESS IS GIVEN AS FOLLOWS:    
CHARGING THE FURNACE WITH RAW MATERIAL    
1) COOLING    
2) GRINDING    
3) DISSOLVING    
4) SETTLING    
5) INSPECTION AND PACKING    
FROM AUTOCLAVE METHOD    
HYDROTHERMAL PROCESS FOR MANUFACTURE    
OF POTASSIUM SILICATE    
POTASSIUM SILICATE FOLIAR FERTILIZER GRADE FROM GEOTHERMAL
    SLUDGE AND PYROPHYLLITE    
MATERIAL SAFETY DATA SHEET    
OF POTASSIUM SILICATE    
ACCIDENTAL RELEASE MEASURES    
RAW MATERIALS CALCULATION    
PLANT LAYOUT    
COMPLETE PLANT AND EQUIPMENTS AND TURNKEY CONSULTANT
    FOR POTASSIUM SILICATE    
SUPPLIERS OF RAW MATERIALS    
SUPPLIERS OF PLANT AND MACHINERY    
FUSION FURNACE    
HAMMER MILLS    
SIEVING MACHINE    
EVAPORATORS    
FILTER PRESS    
LABORATORY EQUIPMENTS    
MATERIAL HANDLING EQUIPMENTS    
PACKAGING MACHINE    
INSTRUMENTATION & PROCESS CONTROL EQUIPMENTS    
    
        
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