Detailed Project Report on integrated unit of lime stone to lime, sodium carbonate & bicarbonate and caustic soda

                                                
INTEGRATED UNIT OF LIME STONE TO LIME, SODIUM CARBONATE & BICARBONATE AND CAUSTIC SODA

[CODE NO. 1737]

Alkali chemical constitutes the oldest segment of the chemical industry. These chemicals serve as key inputs for a number of industries such as aluminium, soap, detergent, glass, tyre, rubber, pulp and paper, pharmaceutical, water treatment, textiles, leather, fiber etc. The key chemicals in the chlor-alkali industry are

•    Caustic Soda
•    Chlorine (including liquid chlorine)
•    Soda Ash

Caustic Soda (chemically known as Sodium Hydroxide) and Chlorine are produced
together through the electrolysis of common salt solution (Sodium Chloride or Brine).

Caustic Soda and Chlorine are generated in the ratio of 1:0.89. Demand for chlorine drives caustic soda production globally, but in India the industry has developed in line with the demand-supply balance of caustic soda.


COST ESTIMATION (RUPEES IN LACS)

Plant Capacity                                    500.00 MT/day
Land & Building (40 Acres)                   Rs. 6.775
Plant & Machinery                               Rs 9.586       
W.C. for 3 Months                               Rs.7.162
Total Capital Investment                        Rs.26.128           
Rate of Return                                     58%  
Break Even Point                                 34%

INTRODUCTION                                            
DENSE SODA ASH                                        
USES AND APPLICATION                                    
USES OF CHLORINE                                        
LIME & LIME STONE                                        
PROPERTIES OF LIME STONE                                
AIR POLLUTION CONTROL SYSTEM                                
REQUIREMENT OF SODIUM CARBONATE                            
TABLE-REQUIREMENTS FOR SODIUM CARBONATE                    
PROPERTIES OF SODA ASH                                    
PROPERTIES OF SODIUM BICARBONATE                            
BIS SPECIFICATION                                        
MARKET SURVEY                                            
PROPERTIES BY APPLICATIONS                                
MODIFIED SOLVAY PROCESS                                
RECENT CONSOLIDATION AND ACQUISITION IN THE INDUSTRY        
FACTORY   OVERHEADS,   EMPLOYES   COSTS   AND   SELLING   & ADMINISTRATIVE COSTS FORM ALMOST 50% OF TOTAL COSTS.            
GLOBAL MARKET POSITION OF SODIUM BICARBONATE                
MANUFACTURERS/SUPPLIERS/EXPORTERS    OF CAUSTIC SODA        
PROCESS OVERVIEW DIAPHRAGM CELL                            
MEMBRANE CELL                                        
PROCESS FLOW SHEET                                    
CHLORINE PRODUCTION FROM MEMBRANE CELLS                    
PROCESS OF MANUFACTURE                                
RAW MATERIAL REQUIRMENTS                                
PROCESS DESCRIPTION                                    
ELECTROLYTIC PROCESS FOR CHLORINE AND CAUSTIC SODA            
PROCESS DETAILS , EMISSION AND ITS CONTROLS                    
OPERATIONAL OF MEMBRANE CELL PLANTS BACKGROUND OF THE FIRST MEMBRANE CELL PLANT IN INDIA                                
SPECIAL FEATURES OF THE PLANT                            
TREATMENT OF EFFLUENTS RELEASING FROM CHLORO ALKALI PLANT    
BLOCK DIAGRAM TO MANUFACTURE CAUSTIC SODA (MEMBRANCE CELL TECHNOLOGY)                                            
TECHNOLOGY AND ENERGY CONSERVING POTENTIAL                
PRODUCTION PROCESS AND ENERGY SAVING TECHNOLOGY            
MANUFACTURING PROCESS OF SODIUM CARBONATE                
CALCINATION SECTION    
PROCESS FLOWSHEET FOR PRODUCTION OF SODA ASH
BY SOLVAY PROCESS                                        
VARIOUS CHEMICAL PROCESS OF SODA ASH                        
MANUFACTURING PROCESS OF SODIUM BICARBONATE                             
FLOW - DIAGRAM                                                     
METHOD OF LIME STONE PRODUCTION & PROCESSING                    
LIMESTONE PROCESSING                                        
POLLUTION PROBLEM                                            
ECONOMICS OF LIME STONE PRODUCTION                            
PROCESS FLOW DIAGRAM                                        
CONTINUOUS PROCESS OF SODIUM BICARBONATE PRODUCTION BY SOLVAY METHOD                                                    
PROCESS DETAILS OF SODIUM HYDROGEN CARBONATE AND SODIUM CARBONATE                                                
SUPPLIERS OF PLANT AND MACHINERY                               
SUPPLIERS OF PLANT AND MACHINERIES (IMPORTED)                    
SUPPLIERS OF CAUSTIC SODA PLANT AND EQUIPMENTS ON
TURNKEY BASIS                                                    
SUPPLIERS OF RAW MATERIALS                                        

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