Detailed Project Report (DPR) on Zinc Sulphate Monohydrate

ZINC SULPHATE MONOHYDRATE [3564]

Zinc sulphate is a widely used chemical and has been known under the name of "White Vitriol".  Although Zinc Sulphate  (mono hydrate)  occurs  in  nature  in  small  quantities  as   mineral Glosarite, this compound is normally manufactured synthetically. It is the colourless white free flowing powder. It exists in powder form of hydrates as, ZnSo4.H2O. Zinc sulphate is also found in three hydrates forms whose molecular formulas are ZnSo4.4H2O,ZnSo4.H2O. The unstable hydrates are more soluble than stable form. The solubility of the unstable hydrate is 58.7 gm in 10gm of water at 18oc while stable shows only 52.7 gm in 100 grams. The important & popular commercial form of the compound is ZnSo4.7H2O Heptahydrated (21%), & ZnSO4. H2O. In 1978 Mr. P.N. Thakar and Mr. N.S. Randhewa of Punjab Agriculture University Ludhiana worked on "Micronutrients in Indian Agiculture" and established the areas of Zinc deficiency based on sail test and crop responses. In reference to Bihar state they found that zinc deficiency varies from 25% to 75% and even more of the normal value.   It was   also shown that the response of zinc sulphate was good for rice potato tea in particular and for all the cereals as a whole. The  process used for the manufacture  of zinc  sulphate  on commercial  scale  is  simple but technical  grade  salt  can  be produced  by treating zinc ash or zinc dross (a waste by  product form  galvanizing units) with sulphuric acid and  then  filtering the slurry followed by concentration of the dilute zinc  sulphate solution  and  finally  during the  crystals  of  ZnSo4.7H2O  are separated   form  mother  liquor  in  a  high  speed   centrifuge crystallizer. The product is then dehydrated to ZnSo4.H2O. For analytical reagent grade Zinc sulphate the salt is preferably produced  from using zinc metal as the starting raw material because it is having the wide range of applications as fertilizers, rayon pulp, paper, paint & varnish, textile processing pigments, calico printing etc. It is having the high demand in the market, It is the third most important compound of zinc in comparison of zinc oxide and zinc dust. Zinc sulphate is available in technical, pharmaceutical & Chemically pure grades. It is sold as solid, as ZnSo4.H2O or Znso4.7H2O and also as a solution of zinc sulphate. Zinc sulphate  is  the most widely used zinc  salt  of  any  inorganic acid.  Its major use is probably in viscose rayon fibre manufacture.   As  the  viscose filament  are  ejected  from  the spinners  they  enter  a complex precipitating  bath  to  promote cremulation.  It is also used in textile dyeing & printing. The second largest use is in agriculture and animal nutrition. To correct zinc deficiency in soils it is applied to the soil alone or in fertilizers or incorporated pesticides sprays.   In animal nutrition it is used as a trace element in feeds.  Pure zinc sulphate solution is required for many  purpose particularly  for  the  preparation of lithophone zinc  sulphide,  phosphorous  and  for  the extraction  of  zinc  by  electrolytic refining. In a replicated experiment on wheat-groundnut experiment  on wheat  groundnut  rotation  in  a  sandy  loam  soil  of   punjab agricultural  University.  Ludhiana zinc was applied in the  form of  zinc  sulphate  at  the rate of 0, 2.8  5,6  and  11.2  kg/ha directly  to  wheat  and  the  residual  effect  was  studied  on groundnut. From these results it may be observed that in the first and second years the response to 2.8 kg zinc was 3.2 and 2.2 g/ha and it  also increased further with higher rate of zinc  application. In subsequent years.  However, the differences became smaller through still the effect of zinc was noticeable. In 49 field trials conducted in Andhra Pradesh on cultivators, fields, it was observed that 50 kg. Znso4, on an average, gave a yield increase of 1.9 to 6.2 g/ha.

COST ESTIMATION

Plant Capacity                                                      15 MT/Day  
Land & Building (4000 sq.mt)                            Rs. 2.17 Cr
Plant & Machinery                                                 Rs. 2.60 Cr
Working Capital for 2 Months                             Rs. 1.92 Cr
Total Capital Investment                                      Rs. 6.90 Cr
Rate of Return                                                        20%
Break Even Point                                                    65%

CONTENTS

INTRODUCTION    
USES & APPLICATIONS    
RESPONSE OF GROUNDNUT TO ZINC APPLICATION    
DIRECT  AND  RESIDUAL  EFFECT  OF APPLIED  ZINC  ON  YIELD,  
ZINC CONCENTRATION AND TOTAL UPTAKE OF ZINC BY GROUNDNUT
CROP AND AVAILABLE ZINC STATUS OF SOILS.    
MICRONUTRIENTS REQUIREMENTS OF DIFFERENT CROPS    
MARKET SURVEY    
CONSUMPTION PATTERN OF ZINC SULPHATE    
INSTALLED CAPACITY, PRODUCTION AND CAPACITY UTILIZATION OF ZINC SULPHATE    
APPARENT CONSUMPTION OF ZINC SULPHATE    
ESTIMATED DEMAND OF ZINC SULPHATE    
EXPORT DATA OF ZINC SULPHATE MONOHYDRATE    
IMPORT DATA OF ZINC SULPHATE MONOHYDRATE    
PRESENT MANUFACTURERS OF ZINC SULPHATE    
BUYERS ADDRESSES OF ZINC SULPHATE    
OVERVIEW OF ZINC FERTILIZER    
ZINC DEFICIENCY IN SOILS AND PLANTS    
SOIL AND PLANT ANALYSIS    
TREATMENT OF ZINC DEFICIENT SOILS AND PLANTS    
ZINC FERTILIZER COMPOUNDS TABLE. ZINC CONTAINING COMPOUNDS    
ZINC FERTILIZER APPLICATIONS    
BENEFITS AND IMPACTS OF ZINC FERTILIZERS TABLE. YIELD INCREASE AND BENEFIT-TO-COST RATIO ON SOME KEY CROPS IN INDIA    
CONCLUSION    
GLOBAL MARKET POSITION OF ZINC SULPHATE    
THE GLOBAL ZINC SULPHATE MARKET BY TYPES IS CLASSIFIED INTO:    
THE GLOBAL ZINC SULPHATE MARKET BY APPLICATION IS CLASSIFIED INTO    
ROLE OF ZINC SULPHATE IN SOIL APPLICATION    
ZINC (ZN)    
ROLE:    
DEFICIENCY SYMPTOMS:    
DOSE AND APPLICATION METHOD:    
CROP RESPONSE:    
SPECIFICATION OF ZINC SULPHATE    
SPECIFICATION OF ZINC SULPHATE HEPTAHYDRATE    
SPECIFICATION OF ZINC SULPHATE MONOHYDRATE    
B.I.S. SPECIFICATION    
SCOPE       
REQUIREMENTS     
REQUIREMENT FOR ZINC SULPHATE AGRICULTURAL GRADE    
PACKING & MARKING        
SAMPLING:    
METHODS FOR TEST    
FOR ZINC SULPHATE AGRICULTURAL GRADE    
TESTING & SPECIFICATION FOR CERTIFICATION OF ZINC SULPHATE HEPTAHYDRATE AGRICULTURAL GRADE    
ZINC SULPHATE, HEPTAHYDRATE    
AGRICULTURAL GRADE    
PROPERTIES OF ZINC SULPHATE, HEPTAHYDRATED (21%) (ZNSO4 7H2O)    
PROPERTIES OF THE ZINC SULPHATE MONOHYDRATE    
DENSITY:    
MELTING POINT:    
CRYSTALLIZATION RANGE    
MAGNETIC SUSCEPTIBILITY    
IMPORTANT DETAILS OF ZINC SULPHATE    
MARKET    
ZINC SULPHATE (ZNSO4)    
MANUFACTURING PROCESS    
APPLICATION    
ZINC SULPHATE MONOHYDRATE 28%    
ZINC SULPHATE HEPTAHYDRATE 21%    
ZINC SULPHATE MONOHYDRATE 33%    
PLANT LOCATION    
RAW MATERIAL POSITION IN INDIA    
PROCESS FOR THE MANUFACTURE OF ZINC SULPHATE    
COMPOSITION OF ZINC ASH:    
METALLIC IMPURITIES LIKE PB.CD, CU, NI, CO. AL, ETC.    
PROCESS FLOW DIAGRAM    
MANUFACTURING PROCESS OF ZINC SULPHATE MONOHYDRATE (POWDER) (33%)    
REACTION    
PROCESS FLOW DIAGRAM    
OTHER PROCESSES    
FOR THE MANUFACTURE OF ZINC SULPHATE    
GENERAL SPECIFICATION OF ZINC SULPHATE    
HEPTAHYDRATE 21%    
ZINC SULPHATE MONOHYDRATE 33%    
PACKING    
PLANT LAYOUT    
COMPLETE PLANT    
AND MACHINERY SUPPLIERS ON TURNKEY    
SUPPLIERS OF RAW MATERIALS    
ZINC ASH    
SULPHURIC ACID    
SUPPLIERS OF PLANT AND MACHINERY    
SPRAY DRYER    
REACTORS    
FILTER PRESS    
STORAGE TANK    
PULVERIZERS    

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)