Detailed Project Report on condenser cleanout sponge rubber balls

CONDENSER CLEANOUT SPONGE RUBBER BALLS
[CODE NO.3483]  

The sponge rubber balls are necessary to maintain the inner side of condenser and heat exchanger tubes clean in power plants and process industries. Any kind of deposition inside the tube reduces the heat-exchange coefficient drastically. The sponge rubber balls can clean all the deposits on the inner side of the tube, and ensure that the equipment runs efficiently. Our Sponge Balls are sold to Power Plants, Various types of industries and for HVAC condenser tube cleaning applications.

Automatic cleaning of heat exchangers and condensers tubes by means of sponge balls is well known since the early fifties, with expanding application from steam power plants to process industry to industrial cooling and air conditioning systems. Main benefits bottom-lined in cost savings are generally considered as: elimination of maintenance down-time and need for chemical and more efficient operation of process and plant.

The sponge rubber balls are necessary to maintain the inner side of condenser and heat exchanger tubes clean in power plants and process industries. Any kind of deposition inside the tube reduces the heat-exchange coefficient drastically. The sponge rubber balls can clean all the deposits on the inner side of the tube, and ensure that the equipment runs efficiently.

The cleaning balls are the active part of the tube cleaning system.

The choice of the ball type depends on the exchanger design and operating conditions. In particular water quality and flow, tubes material and sizes.


Benefits

Continuous injection of sponge balls through the exchanger tubes will prevent any build-up of scaling and/or biofouling. A clean tube means maintaining a high heat exchange rate and a power plant’s high electrical output. Technos cleaning balls are also highly efficient when used in other manufacturers’ equipment.


COST ESTIMATION

Plant  Capacity                                               :       48000.00 Nos/day                   
land & Building  (4000 Sq.Mtr)                    :    Rs. 4.07  Cr
Plant & Machinery                                          :    Rs. 51.00 Lacs
Working Capital for 2 Months                      :    Rs. 1.18  Cr
Total Capital Investment                               :    Rs. 6.05  Cr
Rate of Return                                                :    25%
Break Even Point                                           :    64%


INTRODUCTION    
BENEFITS    
PROPERTIES    
BALL LIFETIME    
BALL NOMENCLATURE (EXAMPLE)    
BALL TYPE (SPONGE RUBBER BALL)    
HARDNESS DEGREE (ELASTICITY)    
RUBBER RECIPE (COLOUR)    
BALL Ø FIELD OF TOLERANCE (IN MM)    
USES AND APPLICATION    
USES    
APPLICATION OF SPONGE RUBBER BALL    
B.I.S. SPECIFICATION    
PROCESS FLOW CHART    
MANUFACTURING PROCESS    
CURING PROCESS OF SPONGY RUBBER    
MOLDING AND VULANISATION PROCESS    
PLANT AND MACHINERY    
MIXING - EQUIPMENTS    
THERE ARE THREE CATEGORIES OF MIXERS:    
MIXING MILL    
INTERNAL MIXERS    
CROSS SECTION INTERNAL MIXER:    
CONTINUOUS MIXERS    
EQUIPMENTS FOR MOLDING    
(1) PRESSES    
(2) MOULDS    
EXPORT DATA OF RUBBER SPONGE BALL    
EXPORT DATA OF SPONGE BALL    
IMPORT DATA OF CLEAN BALL    
IMPORT DATA OF SPONGE BALL    
PLANT LAYOUT    
MANUFACTURERS/SUPPLIERS OF SPONGY RUBBER BALL    
SUPPLIERS OF RAW MATERIALS    
NBR RUBBER    
SUPPLIERS OF SULPHER    
SUPPLIERS OF STEARIC ACID    
SUPPLIERS OF SODIUM CARBONATE    
SUPPLIERS OF COMPLETE RUBBER PROCESSING PLANT    
(MACHINERY SUPPLIERS)    
SUPPLIERS OF RUBBER CURING OVEN    
BOILERS    
SUPPLIERS OF PRECISION MEASURING TOOLS    
RUBBER TESING EQUIPMENTS    
SUPPLIERS OF MOLDS    
SUPPLIERS OF COOLING TOWER    
SUPPLIERS OF EFFLUENT TREATMENT PLANT (ETP PLANT)    
SUPPLIERS OF AIR POLLUTION CONTROL EQUIPMENTS    
SUPPLIERS OF AIR CONDITIONING EQUIPMENTS    
SUPPLIERS OF AIR COMPRESSURE    
SUPPLIERS OF PLATEFARM WEIGHING MACHINE    
SUPPLIERS OF MATERIAL HANDLING EQUIPMENT    
SUPPLIERS OF FIRE FIGHTING EQUIPMENT    
SUPPLIERS OF JIGS AND FIXTURE    
SUPPLIERS OF SUBMERSIBLE WATER PUMP    

        
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