Detailed Project Report (DPR) on heptaldehyde & undecylenic acid (c7 & c11) & its derivatives

HEPTALDEHYDE & UNDECYLENIC ACID (C7 & C11) & ITS DERIVATIVES
[CODE NO. 2064]  


Castor oil is non- edible oil obtained from castor seeds. Castor plant, Ricinus communis belonging to family, Europhobiaceae. India and China account for 50% of global castor oil production. The area under cultivation of Castor in India is about 5,00,000 acres and Andhra Pradesh accounts for 73% of this area. Castor oil is extracted for the seeds of castor either by local conventional methods or industrially in large quantities. Thus castor oil is available in plenty in our country. Many castor oil derivatives with lot of potential industrial use are not being manufactured in our country and they are being imported. These derivatives are used for surface coating materials, textile auxiliaries, perfumery chemicals, polymeric compounds and surfactants. Thus there is plenty of scope for developing indigenous methods for the production of such derivatives in large scale due to the availability of castor seeds in the country. This will not help easy availability of these derivatives in the local market it can also reduce the import burden on the exchequer.

The derivatives can also tap export potential to earn foreign exchange for the country. There are two important derivatives of castor oil, namely, Heptaldehyde and Undecylenic acid, which are produced by standard techniques. Heptaldehyde, which is by product of pyrolysis of castor oil, is used in perfumery industry since it has a natural fruity flavour. Heptaldehyde is a colourless liquid, oily, fruity odour, penetrating, hygroscopic, soluble in water, ether and combustible. This is oxidized to yield a hepatonic acid and by reducing it produces heptyl alcohol, which combines to form heptyl heptanes, a perfume which combines well with Coumarins. Hapatonic acid esters have variety of fruity flavours.  Aldol condensation of heptaldehyde with bezakdehide yields amyl cinnamic aldehyde which is an important perfume.

Undecylenic acid as well as its zinc salt, are used as bactericidal, fungicidal and also used for diseases like athlete foot. Derivatives of this acid have extensive perfumery outlets. This alcohol has an intense penetrating odour and the saturated 11 carbon aldehyde is used in the modification of floral odours. Treatment of this acid with strong sulphuric acid gives gamma-Undecalcetone which is also called peach aldehyde.

 A volume outlet for Undecylenic acid lies in the preparation of nylon 11, 11. Hydrobromination of the acid in presence of peroxide catalysts yields the terminal bromide which on heating melts and then condenses in head to tail fashion to yield a 11,11- polyamide called Rilsan having melting point of about 188 0C. It is a colourless to pale yellow liquid with a waxy and creamy constitution having molecular weight of 184.28 grams.

 Undecylenic acid is the parent substance for the synthesis of several higher alcohals and aldehydes especially those containg nine and eleven carbon items. Noncyclic aldehyde can be obtained from Undecylenic acid or from heptaldehyde. Reduction of Undecylenic acid with sodium and alcohal converts its into Undecylenic alcohol which is chracterised by a flowery odour with a persisting fatty note. Reduction by  free  hydrogen  in  the presence  of colloidal palladum as catalyst saturates the  double bond  producing  Undecylenic  acid which can  be  converted  into Undecylic  alcohal a valuable modifier and a tip  note  compound. This alcohol can be oxdised to give the corresponding aldehyde an equally important product for the perfumery industry.

 Undecylenic acid is a synthetic unsaturated fatty acid. It is prepared from the natural product, ricinoleic acid, present in castor oil. Undecylenic acid is produced by cracking castor oil at high temperature and pressure.[not verified in body] It is the common name of 10 - undecenoic acid, abbreviated (CH2 = CH (CH2) 8COOH), and has two functional groups, a terminal alkene at one end, and a carboxylic acid at the other. It has use in synthetic chemistry and is used in the manufacture of pharmaceuticals, personal hygiene products, cosmetics, and perfumes. It also used as a topical antifungal agent.


COST ESTIMATION

Plant Capacity                                                10.00 Ton/day
Land & Building (8000 Sq.Mtr)                    Rs. 5.39  Cr
Plant & Machinery                                          Rs.5.00   Cr
W.C. for 2 Months                                           Rs. 10.24  Cr
Total Capital Investment                               Rs. 20.99  Cr
Rate of Return                                                41%
Break Even Point                                           43%


INTRODUCTION    
PROPERTIES    
PROPERTIES OF HEPTANOL    
USES & APPLICATION    
RAW METERIALS    
USES AND APPLICATION OF HEPTANOIC ACID    
USES AND APPLICATION OF HAPTANOL (HEPTYL ALCOHOL)    
PROPERTIES OF CASTOR OIL    
MARKET SURVAY    
PRODUCTION OF HEPTALDEHYDE AND UNDECYLENIC ACID    
IMPORT OF HEPTALDEHYDE AND UNDECYLENIC ACID    
EXPORT OF HEPTALDEHYDE AND UNDECYLENIC ACID    
APPARENT CONSUMPTION OF HEPTALDEHYDE AND UNDECYLENIC ACID    
ESTIMATED DEMAND    
IMPORT DATA OF UNDECYLENIC ACID    
IMPORT DATA OF HEPTALDEHYDE    
EXPORT DATA OF UNDECYLENIC ACID    
EXPORT DATA OF HEPTALDEHYDE    
SUPPLY AND DEMAND OF CASTOR OIL    
IMPORT OF COSTOR OIL    
EXPORT OF CASTOR OIL    
GLOBAL MARKET POSITION OF UNDECYLENIC ACID    
GLOBAL CASTOR OIL AND DERIVATION MARKET    
PRESENT MANUFACTURE OF HEPTALDEHYDE AND UNDECYLENIC ACID    
PRESENT MANUFACTURES (GLOBAL)    
MANUFACTURING PROCESS    
PROSSES DESCRIPTION    
PROCESS IN DETAILS    
IMPROVED METHOD FOR PRODUCTION OF HEPTALDEHYDE
AND UNDECYLENIC ACID    
MANUFACTURING PROCESS OF HEPTALDEHYDE AND UNDECYLENIC
ACID FROM METHYL RICINOLEATE    
RECOVERY OF UNDECYLENIC ACID FROM SPONGY MASS    
SAPONIFICATION NUMBER    
ACIDULATION OF THE SODIUM SALT OF UNDECYLENIC ACID    
PRODUCTION YIELD    
RAW METERIAL REQUIREMENTS    
MANUFACTURING DIAGRAM
MANUFACTURING PROCESS OF HEPTANAL (HEPTYL ALCOHOL)    
MANUFACTURING PROCESS OF HEPTANOIC ACID    
COMPARSION OF YIELD FOR PRODUCTION OF HEPTALDEHYDE AND
UNDECYLENIC ACID FROM CASTOR OIL AND FROM METHYL ESTER
OF COSTOR OIL    
METHOD OF ANALYSIS FOR HEPTALDEHYDE AND UNDECYLENIC ACID    
OTHER COMMERCIAL METHODS    
METHOD FOR PREPARING CLEAVED PRODUCTS FROM CASTOR OIL    
SYNTHESIS OF DIACIDS OR DIESTERS FROM NATURAL FATTY ACIDS    
SUPPLIERS OF PLANT AND MACHINERY    
SOURCES OF TECHNOLOGY SUPPLIERS    
COMPLETE PLANT AND MACHINERY SUPPLIERS    
RAW MATERIAL SUPPLIERS    
PLANT AND MACHENARY SUPPLIERS    

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