Detailed Project Report (DPR) on Activated Bleaching Earth

ACTIVATED BLEACHING EARTH

[EIRI/EDPR/1367]J.C.:137INR, 138US$, 639

INTRODUCTION

Bentonite is an absorbent aluminium phyllosilicate, essentially impure clay consisting mostly of montmorillonite. There are different types of bentonite, each named after the respective dominant element, such as potassium (K), sodium (Na), calcium (Ca) and aluminium (Al). Experts debate a number of nomenclatorial problems with the classification of bentonite clays. Bentonite usually forms from weathering of volcanic ash, most often in the presence of water. However, the term bentonite, as well as a similar clay called tonstein, has been used to describe clay beds of uncertain origin. For industrial purposes, two main classes of bentonite exist: sodium and calcium bentonite. In stratigraphy and tephrochronology, completely devitrified (weathered volcanic glass) ash-fall beds are commonly referred to as K-bentonites when the dominant clay species is illite. Other common clay species, and sometimes dominant, are montmorillonite and kaolinite. Kaolinite-dominated clays are commonly referred to as tonsteins and are typically associated with coal.

Sodium betonies

Sodium bentonite expands when wet, absorbing as much as several times its dry mass in water. Because of its excellent colloidal properties, it is often used in drilling mud for oil and gas wells and for geotechnical and environmental investigations.

The property of swelling also makes sodium bentonite useful as a sealant, since it provides a self-sealing, low permeability barrier. It is used to line the base of landfills to prevent migration of leachate, for quarantining metal pollutants of groundwater, and for the sealing of subsurface disposal systems for spent nuclear fuel. Similar uses include making slurry walls, waterproofing of below-grade walls, and forming other impermeable barriers, e.g., to seal off the annulus of a water well, to plug old wells. It is also used to form a barrier around newly planted trees to constrain root growth so as to prevent damage to nearby pipes, footpaths and other infrastructure.

Sodium bentonite can also be "sandwiched" between synthetic materials to create geo-synthetic clay liners (GCL) for the aforementioned purposes. This technique allows for more convenient transport and installation, and it greatly reduces the volume of sodium bentonite required.

Sodium bentonite is also used in a variety of pet care items such as cat litter to absorb the odour and surround the feces.

Various surface modifications to sodium bentonite improve some rheological or sealing performance in geoenviromental applications, for example, the addition of polymers.

Calcium bentonite

Calcium bentonite is a useful adsorbent of ions in solution, as well as fats and oils, being a main active ingredient of fuller's earth, probably one of the earliest industrial cleaning agents. Calcium bentonite may be converted to sodium bentonite (termed sodium beneficiation or sodium activation) to exhibit many of sodium bentonite's properties by a process known as "ion exchange" (patented in 1935 by Germans U Hofmann and K Endell). In common usage, this means adding 5–10% of a soluble sodium salt such as sodium carbonate to wet bentonite, mixing well, and allowing time for the ion exchange to take place and water to remove the exchanged calcium.[citation needed] Some properties, such as viscosity and fluid loss of suspensions, of sodium-beneficiated calcium bentonite (or sodium-activated bentonite) may not be fully equivalent to those of natural sodium bentonite. For example, residual calcium carbonates (formed if exchanged cations are insufficiently removed) may result in inferior performance of the bentonite in geosynthetic liners

Potassium bentonite

Also known as potash bentonite or K-bentonite, potassium bentonite is a potassium-rich illitic clay formed from alteration of volcanic ash.

Activated bleaching earth, a highly effective adsorbent essential in the refining process for the purification and decolourisation of edible and non-edible oils, fats, tallow, petroleum jelly, paraffin oil and waxes. As a kind of decolouring agent used for refining Oils. It can absorb and eliminate the pigment, aflatoxin and the carcinogenic substance of 3-4 benzpyrene in vegetable oil, in addition, it has strong ability of oil decolorization, high speed of filtering oil and low oil retention of filter cake. We mine, process and market all types of Bleaching Earth for all type of Fruits Juice, edible oils, non-edible oil and Vanaspati plants. It is used by many refineries in India, Sri Lanka, Africa and Malaysia with quality and consistency.

Application of our Activated Bleaching Earth: 1. Refining of Vegetable/Edible oils like: Coconut, Cottonseed, Soybean, Sunflower, Rapeseed, Mustard, Peanut, Corn, Olive, Ricebran, Palm, Palm-kernel, Linseed, Castor, Jajoba Canola oils. 2 Refining of hydrogenated vanaspati ghee oils, Margarine shortening. 3. Refining of Animal Fats like tallow oil, fish oil, lard oil. 4. Refining of Mineral Oils like: Paraffins and waxes, Insulating oil, Rolling oil, Transformer Oil, White oil, Waste oil (lubricating oil), Industrial triglycerides and fatty acids used for paints, varnishes and soaps. 5. Other applications like: Solvents (for dry cleaning), Bleaching of sulphur, Effluent treatment plants.

COST ESTIMATION

Plant Capacity            90 MT/Day

Land & Building (15,000 sq.mt.)    Rs. 22.31 Cr

Plant & Machinery                    Rs. 4.57 Cr

Working Capital for 2 Months    Rs. 9.73 Cr

Total Capital Investment          Rs. 38.29 Cr

Rate of Return                          50%

Break Even Point                      36%

CONTENTS

INTRODUCTION

TYPES

SODIUM BETONIES

CALCIUM BENTONITE

POTASSIUM BENTONITE

PRODUCT DESCRIPTION AND APPLICATION

USES AND APPLICATIONS

MEDICAL

IN THAI FARMING

BENTONITE SLURRY WALLS IN MODERN CONSTRUCTION

CHEMICAL COMPOSITION

PHYSICAL PROPERTIES

SALIENT FEATURES

BLEACHING EFFICIENCY:

RETENTION OF OIL:

ACID VALUE:

RATE OF FILTRATION:

CONTACT TIME IN THE BLEACHER:

GRADES:

B.I.S. SPECIFICATIONS

MARKET OVERVIEW

PROJECTED DEMAND

PRICING AND DISTRIBUTION

PRESENT MANUFACTURERS OF ACTIVATED BLEACHING EARTH

REQUIREMENTS FOR BLEACHING EARTH OF INDIAN ORIGIN USED FOR BLEACHING VEGETABLE OILS

METHODS OF SAMPLING AND TEST FOR BLEACHING EARTH

GENERAL PRECAUTIONS

SCALE OF SAMPLING

TABLE 1: NUMBER OF CONTAINERS TO BE SELECTED FOR SAMPLING    (CLAUSES 2.2.2 AND 2.2.3.1)

TEST SAMPLES AND REFEREE SAMPLES

NUMBER OF TESTS

CRITERION FOR CONFORMITY

TABLE 2 CRITERIA FOR CONFORMITY

QUALITY OF REAGENTS

MOISTURE CONTENT

BULK DENSITY

SIEVE ANALYSIS

B) APPARATUS

D) CALCULATION

BLEACHING EFFICIENCY

B) REAGENTS

C) APPARATUS

D.2.1. CALCULATION

ASH

B) APPARATUS

D) CALCULATION

PERFORMANCE TEST

REQUIREMENTS

TABLE 1 REQUIREMENTS FOR SPENT BLEACHING EARTH

PACKING AND MARKING

SAMPLING

RAW MATERIAL AND ITS PROPERTIES

MONTHLY RAW MATERIAL REQUIREMENTS

BLEACHING CLAYS

NOMENCLATURE

ACID-ACTIVATION VS. ACID-TREATMENT OF THE CLAY

OTHER TYPES OF ACTIVATION OF BENTONITES AND OF DIFFERENT INERALS

NATURE OF THE ACID ACTIVATION OF NON-SWELLING-SMECTITES

CRYSTAL STRUCTURE OF THE SMECTITE CLAY MINERALS

THE IMPORTANCE OF THE INTERLAYER EXCHANGEABLE CATIONS

THE EFFECT OF THE ACID TREATMENTS ON THE CRYSTAL STRUCTURE OF THE SMECTITES

MANUFACTURING PROCESS

FLOW DIAGRAM FOR ACTIVATED BLEACHING EARTH

PRODUCTION PROCESS

PLANT LAYOUT

OTHER RELATED INFORMATIONS

ADSORPTION OF ACID DYES FROM AQUEOUS SOLUTION ON ACTIVATED    BLEACHING EARTH

MATERIALS AND METHODS

MATERIALS

ADSORPTION KINETICS

TABLE 1: SOME PROPERTIES OF THE ACID DYES USED IN THE PRESENT STUDY A

FIG. 1: MOLECULAR STRUCTURES OF ACID DYES USED IN THIS STUDY: (A) ACID ORANGE 51, (B) ACID BLUE 9, AND (C) ACID ORANGE 10

TABLE 2: PROPERTIES OF ACTIVATED BLEACHING EARTH USED IN THIS STUDY A

CONCLUSIONS

COMPLETE PLANT SUPPLIERS

SUPPLIERS OF PLANT AND MACHINERY

FILTER PRESS

CONVEYOR BELT

PULVERISER/GRINDER

STAINLESS STEEL TANKS

BALL MILL

KILN

DISINTEGRATORS

JAW CRUSHER

BUCKET ELEVATORS

BOILERS

DIESEL GENERATOR

SUPPLIER OF RAW MATERIALS

SULPHURIC ACID

BENTONITE

POLYTHENE BAGS

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)