SUPERABSORBENT POLYMER USING CONTINUOUS GEL POLYMERIZATION (PRODUCTION RATE – 1000 TPM)
[EIRI/EDPR/4585] J.C.: 2802XL
INTRODUCTION
Superabsorbent Polymers (SAP) are primarily used as an absorbent for water and aqueous solutions for diapers, adult incontinence products, feminine hygiene products, and similar applications. Undoubtedly, in these applications, superabsorbent materials will replace traditional absorbent materials such as cloth, cotton, paper wadding, and cellulose fiber.
Commercial production of superabsorbent polymers began in Japan in 1978, for use in feminine napkins. This early superabsorbent was a crosslinked starch-g-polyacrylate. Polyacrylic acids eventually replaced earlier super absorbents, and is the primary polymer employed for superabsorbent polymers today.1 In 1980, European countries further developed the superabsorbent polymer for use in baby diapers. This first diapers employing this technology used only a small amount of polymer, approximately 1-2 g. In 1983, a thinner diaper using 4-5 grams of polymer and less fluff was marketed in Japan.
The use of superabsorbent polymers revolutionized the diaper industry. Diaper manufacturers began to design diapers to take advantage of the amazing liquid retention ability of the polymer. Superabsorbent polymers absorb, and retain under a slight mechanical pressure, about 30 times their weight in urine.2 the swollen gel holds the liquid in a solid, rubbery state and prevents the liquid from leaking onto the baby’s skin and clothing.
Superabsorbent polymers are prepared from acrylic acid and a cross linker by solution or suspension polymerization. The type and quantity of cross linker control both the swelling capacity and gel modulus.2 the synthesis and use of crosslinked polyacrylate super absorbents have been a popular topic in the polymer literature. However, very little information about manufacturing processes has been given due to its proprietary content.
The properties of superabsorbent polymers can be employed in many different applications. The largest use of superabsorbent polymers is in personal hygiene products. These consumer products include, in order of volume of super absorbents used, disposable infant diapers, children’s training pants, adult incontinence articles, and feminine sanitary napkins.
COST ESTIMATION
Plant Capacity 33.334 MT/Day
Land & Building (3815 sq.mt.) Rs. 4.76 Cr
Plant & Machinery Rs. 9.92 Cr
Working Capital for 0.5 Months Rs. 13.93 Cr
Total Capital Investment Rs. 29.50 Cr
Rate of Return 48%
Break Even Point 37%
CONTENTS
INTRODUCTION
USES/APPLICATIONS
ADVANTAGE OF SUPERABSORBENT POLYMER IN AGRICULTURE
MARKET OVERVIEW
TYPES OF SUPERABSORBENT POLYMER
ABSORBENT VERSUS SUPERABSORBENT MATERIALS
CLASSIFICATION AND PREPARATION OF SUPERABSORBENT POLYMERS
SUPER ABSORBENT POLYMER AND ITS CHEMISTRY
COMPARISON TO OTHER SOLIDIFICATION MEDIA
MECHANISMS OF SWELLING IN SUPERABSORBENT POLYMERS
OVERVIEW OF SUPERABSORBENT POLYMER MANUFACTURING
FORMULATIONS
RAW MATERIALS
RAW MATERIAL SUPPLIERS
MANUFACTURING PROCESS STEPS
TEST METHODS
SPECIFICATIONS
ENGINEERING DESIGN CONSIDERATIONS
ETP FACILITY
SEWAGE AND WASTE WATER EFFLUENT
WASTE GENERATION & MANAGEMENT/GREEN BELT
PLANT/MACHINERY (BROADLY)
SUPPLIERS OF PLANT & MACHINERIES/TURNKEY
UTILITIES PER MONTH (ESTIMATED)
PRINCIPLES OF PLANT LAYOUT
PLANT LOCATION FACTORS
HEALTH SAFETY & ENVIRONMENT
ANTICIPATED ENVIRONMENTAL IMPACTS
SAFETY & OCCUPATIONAL MEASURE
PROPOSED IMPLEMENTATION SCHEDULE
PROJECT FINANCIALS
PRELIMINARY LAYOUT
COMPARISONS OF DIFFERENT MANUFACTURING PROCESSES
CONCLUSIONS
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)
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