Detailed Project Report (DPR) on unsaturated polyester resin 10 mt per day output

UNSATURATED POLYESTER RESIN
[CODE NO.3323]


Polyester resins are unsaturated synthetic resins formed by the reaction of dibasic organic acids and polyhydric alcohols. Maleic Anhydride is a commonly used raw material with diacid functionality. Polyester resins are used in sheet moulding compound, bulk moulding compound and the toner of laser printers. Wall panels fabricated from polyester resins reinforced with fiberglass so-called fiberglass reinforced plastic (FRP) are typically used in restaurants, kitchens, restrooms and other areas that require washable low-maintenance walls. They are also used extensively in Cured-in-place pipe applications. Departments of Transportation in the USA also specify them for use as overlays on roads and bridges. In this application they are known as PCO Polyester Concrete Overlays. These are usually based on isophthalic acid and cut with styrene at high levels usually up to 50%.

Unsaturated polyesters are condensation polymers formed by the reaction of polyols (also known as polyhydric alcohols), organic compounds with multiple alcohol or hydroxy functional groups, with saturated or unsaturated dibasic acids. Typical polyols used are glycols such as ethylene glycol; acids used are phthalic acid, isophthalic acid and maleic acid. Water, a by-product of esterification reactions, is continuously removed, driving the reaction to completion. The use of unsaturated polyesters and additives such as styrene lowers the viscosity of the resin. The initially liquid resin is converted to a solid by cross-linking chains. This is done by creating free radicals at unsaturated bonds, which propagate in a chain reaction to other unsaturated bonds in adjacent molecules, linking them in the process. The initial free radicals are induced by adding a compound that easily decomposes into free radicals. This compound is usually and incorrectly known as the catalyst. Initiator is the more correct term. Substances used are generally organic peroxides such as benzoyl peroxide or methyl ethyl ketone peroxide.
Polyester resins are thermosetting and, as with other resins, cure exothermically. The use of excessive initiator especially with a catalyst present can, therefore, cause charring or even ignition during the curing process. Excessive catalyst may also cause the product to fracture or form a rubbery material.

Polyester resins are the most widely used resin systems, particularly in the marine industry. By far the majority of dinghies, yachts and workboats built in composites make use of this resin system.

Polyester resins such as these are of the 'unsaturated' type. Unsaturated polyester resin is a thermoset, capable of being cured from a liquid or solid state when subject to the right conditions. It is usual to refer to unsaturated polyester resins as 'polyester resins', or simply as 'polyesters'. There is a whole range of polyesters made from different acids, glycols and monomers, all having varying properties.

There are two principle types of polyester resin used as standard laminating systems in the composites industry. Orthophthalic polyester resin is the standard economic resin used by many people. Isophthalic polyester resin is now becoming the preferred material in industries such as marine where its superior water resistance is desirable.


COST ESTIMATION

Plant  Capacity                                             :     10.00 MT./day
land & Building   (6000 sq.mtr)                 :    Rs.  3.04 Cr
Plant & Machinery                                        :    Rs.  1.23 Cr
Working Capital for 1 Month                      :    Rs.  2.58 Cr
Total Capital Investment                            :    Rs.  7.05 Cr
Rate of Return                                             :    28%
Break Even Point                                        :    49%

INTRODUCTION    
COMPONENTS OF POLYESTER RESINS    
TYPES OF POLYESTER RESINS    
SATURATED POLYESTER RESIN    
UNSATURATED POLYESTER RESIN    
FIRE RESISTANT POLYESTER RESIN    
ELECTRICAL RESISTANT POLYESTER RESIN LOW STYRENE
EMISSION POLYESTER RESIN    
ISOPHTHALIC POLYESTER RESINS FOR FIBERGLASS FABRICATIONS    
THE DIFFERENT POLYESTER RESINS    
CHARACTERISTICS AND BENEFITS OF POLYESTER RESIN    
PERFORMANCE CHARACTERISTICS    
SUGGESTED USE    
RECOMENDED CATALYST    
TYPICAL LIQUID RESIN PROPERTIES    
TYPICAL CAST UNFILLED RESIN PROPERTIES    
ADVANTAGE OF POLYESTER RESIN    
PROPERTIES OF ISOPHTHALIC POLYESTER RESIN    
AND ORTHOPHTHALIC POLYESTER RESIN    
PROPERTIES AND USES    
ELECTRICAL PROPERTIES OF CURED RESIN:    
B.I.S. SPECIFICATIONS    
THE FOLLOWING SPECIFICATIONS ARE AVAILABLE FOR REFERENCE:    
MARKET SURVEY (GLOBAL)    
GLOBAL UNSATURATED POLYESTER RESINS: MARKET TAXONOMY    
BY PRODUCT TYPE    
BY END-USER INDUSTRY    
TOP FIVE EXPORT DESTINATIONS OF UNSATURATED POLYESTER RESIN    
TOP FIVE SOURCES (COUNTRIES) OF IMPORT OF UNSATURATED
POLYESTER RESIN DURING 2012-13    
DETAILED IMPORT DATA OF POLYESTER RESIN UNSATURATED    
DETAILED EXPORT DATA OF UNSATURATED POLYESTER RESIN    
UNSATURATED POLYESTER RESIN    
A) VARIOUS GRADES OF K'ESTER UNSATURATED POLYESTER RESIN
BASED ON ORTHO    
B) POLYESTER RESIN BASED ON TERPHTHALIC ACID    
TYPICAL UNSATURATED    
POLYESTER RESIN FORMULATION    
MANUFACTURING PROCESS OF UNSATURATED POLYESTER RESIN    
PROCESS DETAILS    
BLENDING OPERATION:    
PACKAGING:    
SYNTHESIS OF ISOPHTHALATE UPR     
FORMULATION OF ISOPHTHALATE UPR    
PROCESS DETAILS    
1 .PROCESS DIAGRAM    
2. PROCESS DESCRIPTION    
CHEMISTRY    
PROCESS OF CROSS-LINKING    
FILLING AND MONO-ESTER FORMATION    
ESTERIFICATION    
DILUTION PHASE    
POLYESTER RESIN (FOR REINFORCED PLASTICS) G. P. GRADE    
PROPERTIES OF (REINFORCED GRADE POLYESTER RESIN)    
POLYESTER RESIN (LAMINATE GRADE):-    
PROCESS OF MANUFACTURING OF POLYESTER RESIN (LAMINATE GRADE)    
POLYESTER VARNISH PREPARATION:-    72
MANUFACTURING PROCESS OF POLYESTER RESIN (ELECTRICAL GRADE)    
POLYESTER VARISH:-    
UNSATURATED POLYESTER RESINS    
MODIFIED ACRYLIC UNSATURATED POLYESTER RESIN    
RESIN FORMULATION 1    
RESIN FORMULATION 2    
RESIN FORMULATION 3    
RESIN FORMULATION 4    
TECHNICAL DATA SHEET    
OF ORTHOPHTHALIC POLYESTER RESIN    
APPLICATION:    
PACKING AND SHELF-LIFE:    
SUPPLIERS OF PLANT AND MACHINERIES (GLOBAL)    
SUPPLIERS OF RAW MATERIALS (GLOBAL)    
SUPPLIERS OF COMPLETE PLANT AND EQUIPMENTS FOR
UNSATURATED POLYESTER RESINS    
REACTORS    
MIXERS    
STORAGE TANK/ REACTION VESSELS    
BOILER    
LABORATORY EQUIPMENTS/LABORATORY TESTING EQUIPMENTS    
SUPPLIERS OF RAW MATERIALS    
POLYPROPYLENE GLYCOL    
PHTHALIC ANHYDRIDE    
MALEIC ANHYDRIDE    
POLYETHYLENE GLYCOL    
STYRENE MONOMER    
ANTIFOAMING AGENTS    
STABILIZERS    
PLANT LAYOUT    
                                              

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