Manufacturing of unsaturated Polymer Resins

8/16/2019 Manufacturing of unsaturated Polymer Resins

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SMB ENVIRONMENTAL PROJECTS PVT LTD ABSOLUTE TECHNOLOGIES

TECHNOLOGIES

Technical Know-how - A Gateway to Prosperity

A PROJECT REPORT

ON

UNSATURATED POLESTER RES!N

AT DA"AN

Prepared By

S.A. AZAD ( Alia B!r"aa# $ B.S%. Te%" ( C"e& Te%" $ ' DNIIT' DGM' DM'CEO ) SMB E#*ir+#&e#,al Pr+-e%, P*, L,d

E. Sr. Ma#a/er 0 HPCL ( Pr+-e%, Pla##i#/$

+r

Mr M. Meera Sahib,

QLIFFE TECHNOLOGY SERVICES PVT.LTD, B602, MANIKA APARTMENT,

MAHAKALI CAVES ROAD, ANDHERI EAST, Mumba ! "000#$,MH, I%&aM'b()*!+#!#-20- "6/, [email protected]

Da,e ) Sep,e&1er 23' 2456REG7D OICE) 8 RESIDENC9 ROAD' OPP ASHO:A RESTAURANT' SADAR' NAGPUR 0 664 445

Email : [email protected] , Mobile: +9198!24!852

5

mailto:[email protected]:[email protected]:[email protected]:[email protected]


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A PROJECT REPORT

ON

UNSATURATED POLESTER RES!N

AT DA"AN

S.No. CONTENTS Page No.

1. INTRODUCTION 3

2. MARKET POTENTIAL 6

3. QUALITY STANDARDS 12

4. BASIS & ASSUMPTIONS 15

5. PRODUCTION & TECHNICAL ASPECTS 21

6. PROJECT FACILITIES 45

7. COST ESTIMATES

& OPERATTIN E!P. 5"

". F#$%$#$' P()*)+%,+ & I$-$#/-+ 66

0. CASH FLO FINANCIAL ANALYSIS 60

1. THE FACTORY ACT 7611. INDUSTRIAL ESTABLISHMENT ACT 77

REG7D OICE) 8 RESIDENC9 ROAD' OPP ASHO:A RESTAURANT' SADAR' NAGPUR 0 664 445


2

mailto:[email protected]:[email protected]


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………………….. Page No 52 is the last page ……………

1.0 INTRODCTION

1.1 !"C#$ROND %

U$+%(%- *),-+-( (-+#$+ %(- - 8)+ )88)$, +- -(8)+- (-+#$+

#$ - 9)(,. M)(- %$ 2 8#,,#)$ )$$-+ ): $+%(%- *),-+-( (-+#$+ %(-

#,#;- ',)


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D%8%$ # #+ % '()9#$' )9$ %$ % *()8#+#$' $#)$ -((#)(. I #+

+(()$-


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1. "DN"T"$ES O' SE(ECTED (OC"TION %

T- *()*)+- *,%$ 9), )8- * )$ % N A #$+(#%, *,) ): % ,-%+

25 + : *,) ): ,%$ )9$- ,-%+-


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Mar4et pote)tial -o)ti)es….

2.0 M"R#ET POTENTI"(

2.1 LOBAL SCENARIOG

U$+%(%- *),-+-( (-+#$+ %(- - 8)+ )88)$, +- -(8)+- (-+#$+

#$ - 9)(,. M)(- %$ 2 8#,,#)$ )$$-+ ): $+%(%- *),-+-( (-+#$+ %(-

#,#;- ',)


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(-+#$+.

(ii Resi) Pa-4e i) Dr+s

T- ',)

+-( S-'8-$+G ,)


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F)(-%+= 213 > 210, - ',)20

(--++#)$ #$:,-$- - -/-,)*8-$ ): ',)


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I$ - $-%( :(-= %+ $-9 %**,#%#)$+ %$ -8%$ #+ '()9#$'= $+%(%-

*),-+-( (-+#$ #+ -*-- -(- 9#,,


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-(- %(- %**()#8%-, 3>4 8%#$ *()#)$ *,%$+= %$ - )%,

*()#/# #+ %**()#8%-, 1=154= )$+-%( #$,#$' A8-(#%

001= )$+-%(= C%$%% %**()#8%-, 01= )$+-%(= %$ M-#)

%**()#8%-, 72= )$+-%(. T- $+%(%- *),-+-( (-+#$

8%$:%(-(+ #$ -+-($ E()*- %(- (-,%#/-, +%-(-= - :%)(#-+ %(-

8%$= %$ - (-,%#/-,


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%8)$ ) 2="= )$+= 9# %$$%, %/-(%'- (%- ): #$(-%+-

%**()#8%-, 5. T- -/-,)*8-$ *(#)(# ): $+%(%- *),-+-( (-+#$

#$ - US= -+-($ E()*- %$ J%*%$ #+ 8%#$, (-+#$ 8)#:#%#)$ %$

-*%$+#)$= %$ #$ - :(-= - %**,#%#)$ :#-,+ ): $+%(%- *),-+-(

(-+#$ 9#,,


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8%(?- #+ -*-- ) (-% 445 8#,,#)$ *)$+ R+. 55 ()(-+


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UPR 677 H%; 6 1.11 15 36 2 45 "3 14 75 12

.2 "PP(IC"TIONS%

T- (-+#$+ )$:)(8#$' ) %


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')) 8-%$#%, *()*-(#-+= %$ #+ :%+ (#$'. I #+ +#%*=

RTM= %$ )-( 8),#$' -$#-+ %$ %$

%-,-(%-= #)()*#= )( ,)9 /#+)+# (-+#$

Mei+ Rea-ti*e Sperior Resi)

T#+ #+ % 8-#8 (-%#/- +*-(#)( '(%- O()*%,# A#


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BROAD SPECIFICATIONS OF SOME IMPORTANT RESINS:

Properties Resin 1 Resin 2

TypeIsophthalic / MP Diol based

brushable Gelcoat

Orthophthalic / MP Diol

brushable based Gelcoat

Appearance Haze thiotropic li!uid Haze thiotropic li!uid

"iscosity at #$%& '&ps( )*+++ , -#*+++ )*+++ , -#*+++

Thiotropic inde .$ , 0$ .$ , 0$

Acid 1alue 'm2 3OH / 2m( 4-$ 4##

Properties Resin 3 Resin 4

Type PET based GP 5esin PET based Putty 5esin

Appearance 6li2ht yello7 haze 6li2ht yello7 haze

"iscosity at #$%& '&ps( $$+ , 0++ $$+ , 0++

Acid 1alue 'm2 3OH / 2m( 4-$ 4-$

6peci8ic 2ra1ity at #$%& --# --#

Gel time at #$%& 'Min( a -$ 9 $ $+ 9 -+

"#M$"%&'()*$ '&-%'(-#":

UNSATURATED POLYESTER RESINS

PRODUCTCODE

DESCRIPTION APPLICATION

ORTOPTALATES

OP1!!1 General Purpose aminatin2 &onstruction*Automoti1e*Electrical*6ports*



5


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5esin eisure

OP1!!4 &ultured Marble &ultured Marble*Polymer &oncrete

OP1!1! ;ire retardant 5esin &onstruction*Automoti1e*Electrical

OP1!12 5esin Trans8er Mouldin2 Automoti1e*;urniture*6ports*Industrial

OP1!1" Putty 5esin Polyester Putty

OP1!1# 5esin 8or 6M&/DM& Automoti1e*Electrical

OP1O2# ;ilament


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'E2!!1 =o1alac Epoy 1inylester 5esin

&orrosion resistant linin2s*chemical

e!uipment

'E2!!2=o1alac Epoy 1inylester5esin'Hi2h HDT(

'E3!!1>rominated epoy 5esin based;ire 5etardant "inylester 5esin

&orrosion ? ;ire resistant linin2s*chemicale!uipment

SATURATED POLYESTER RESINS

PP1!1$6ol1ent '@ylenol / 6ol1asso-$+(based polyester 5esin

6to1in2 enamel

PP1!!2


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…….!asis 9 "ss+ptio)s -o)ti)es

3.0 !"SIS 9 "SSMPTIONS

3.1 PRO'I(E O' PRODCTION COMP(E< %

T- *()- 9),


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T- 8%)( )*-(%#)$+ #$/),/- #$ - 8%$:%(- ): *),-+-( (-+#$ %(-

-+-(:#%#)$ %$


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T- *()8)-(+ *,%$ ) :#$%$- 25 :()8 -#( )9$ (-+)(-+ ()' -

-# ()-= 9#,- 75 ): - %*#%, )+ +%,,


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C)++ ): RM G P()*,-$- ',), G R+. 11 K'= 8%,-# %$(#- G R+.

1 *-( K'. C%%,+ 8%-(#%, %**. R+. 1 K'.

R-#(-8-$ ): P G 5376 .44 2365 K'+

R-#(-8-$ ): MA G 5376 .56 311 K'+

R-#(-8-$ ): %%,+ 2 = 1 K'+

T- *),8-( #+ #++),/- #$ - +(-$- 8)$)8-( :)( :)(8#$' % ()++

,#$?#$' :#$%, *),8-( *()= 9# #+ #$ - (%#) ): 2 G 1.

T% 8-%$+ #+ 5 TPD UPR= %:-( 8##$' 9# +(-$- 8)$)8-( 9#,,

:)(8 % :#$%, U$+%(%- P),-+-( (-+#$ ): 7.5 TPD *() %/%#,%


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# Purchase o8 land : - month

Preparation o8 Detailed En22 ? Desi2n: # month

. Arran2ement o8 ;inances # month

$ >uildin2 construction : months

0 Arran2ement o8 Po7er : # month

B Procurement o8 Plant ? Machinery: month

C Erection o8 Plant ? Machinery : # month

) Appointment o8 sta88 ? labor : - month

-+ Trial production ?

Trouble shootin2 : - month

3..1 CONCRRENT "ND SE6ENTI"( "CTIITIES %

Out o8 abo1e listed acti1ities* in order to minimize the o1erall implementation time* the

acti1ities can be di1ided and pursued into 8ollo7in2 concurrent and se!uential proect

phases

P,-ses (ro+p o. /on/+rrent -/ti0ities Tot-* Tie

Phase I 5e2istration* land Ac!uisition* Detailed En22

And Arran2ement o8 ;inance # months

Phase II &ompound 7all* >uildin2 &onstruction* Procurement O8 Plants

? Machineries* Arran2in2 o8


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Phase

III

Erection* &ommissionin2* Trial production* 5ecruitment o8

Manpo7er* &ommercial Production ? MarFetin2

=et

months

Thus* the total time re!uired 8or the commencement o8 commercial production:

o8 cotton bales and other related products 7ill be around C months

.. Pro-tio) 9 Te-h)i-al -o)ti)es..

5.0 PRODCTION 9 TEC&NIC"( "SPECTS

5.1 C&EMISTR8%

T- $+%(%- *),-+-( (-+#$+ %(- :)(8- :()8 - (-%#)$ ): % #), %

8),-,- )$%#$#$' +-/-(%, (), '()*+ %$ %$ $+%(%- #*()#

%#. T- (-+,#$' *),-+-( %#$+ %(- #++),/- #$ % (-%#/- +),/-$. T-

%#$+ ()++,#$? ) :)(8 % %(= +()$' (-+#$ 9# #+ +- #$ 8%?#$' -

,,+ ):


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HO@C COH HO 9OH CO9OCCO@9 # H2O

O OC O O O

A$ %$'- #$ *- )( *()*)(#)$ ): (-%%$+ (-+,+ #$ % %$'- #$

*()*-(#-+ ): - *),8-(# *() +) %$ #$:#$#- $8


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2 A$ %# %$(#- + %+ 8%,-# %$(#- #+ 9% ) 9), '- #:

) (-%- 9) 8),-+ ): % *%(#,%( %(*%,# %$(#- #+ -

8)+ )88)$ %$ #+ +- #$ '-$-(%, *(*)+- :)(8,%#)$+ +- #$


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5.2 The +a):a-tri)g pro-ess%



2=



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5.2.1 Ra; Materials%

1. M%,-#%$(#- #+ % 9#- (+%,,#$- +),#= 8.*. 52C>53C

M%,-#%$(#- #+ *(-:-((- ) 8%,-#%# +#$- # #+ 8)(- (-%#/-

%$ '#/- (#+- ) ,-++ 9%-( )$ -+-(#:%#)$.

2. P()*,-$- ',), #+ - *(-:-((- #), 5 L +%#$,-++

+--, ?-,-+ :,, -#**- :)( -%#$'= )),#$'= *(-++(-= /%8 (-:,#$'

%$ #+#,,%#)$. T- 8#(- #+ ))?- % * ) 22 )C :)(


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A:-( ))?#$' - *),8-( #+ )),- %$ #++),/- #$) +(-$-= %

*),8-(#+%22C :)( 1>2 )(+ %$ 9%-( #+

)$#$)+, #+#,,- :()8 - (-%)(.

S)8-#8-+ ,-$-#+ %- ) - (-%#)$ 8#(- ) %++#+ #$ - (-8)/%,

): 9%-(

),-$-+,*)$#%# #+ %- ) (-- - (-%#)$ #8-.REG7D OICE) 8 RESIDENC9 ROAD' OPP ASHO:A RESTAURANT' SADAR' NAGPUR 0 664 445


23



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I$ )(-( ) *(-/-$ #+),)(%#)$= - (-%#)$ #+ %((#- ) #$ %$ #$-(

%8)+*-(- ): -#-( %(


30/49


B %$'#$' - (-%#)$ #8-= *),8-(#;%#)$ #8- %$ +)8- -8*-(%(-

/%(#%#)$+ (#$' - *()-++= #::-(-$ *-+ ): $+%(%- (-+#$+ )()=

#+) %$ -( *%,%- *-+ %(- ).0 PROECT '"CI(ITIES



;4



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T#+ *()- 9#,, %/- % +%- ): - %( 8%$:%(#$' :%#,# +#$' ,%-+

8)-($ P,%$ +**,-8-$- 9# :,, %)8%# ++-8+ %$ 8%#$-+

#8*)(- #: $--++%( :()8 (-$)9$- E()*-%$ )( C#$-+-

8%$:%(-(+. T-+- 8%#$-+ %(- ,%-+ #$ -$),)' 9# %)8%#)$ ):

#'-+ -'(-- *)++#%.

>.1 Reire+e)t o: la) a) !ili)g %

I #+ -+#8%- % % 25 + :-- ,%$ *,) 9#,, +::#-. H)9-/-(=

*()8)-(+ 8% 9#+ ) ?--* %$)-( 1= + : %+ (-+-(/- :)( :(-

-*%$+#)$ %$ %$ -8*,)-- 9-,:%(- :%#,##-+ % 8%


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Pro-tio) -+ "+i) !ili)g Pro-t Dispat-h Se-tio)

>.2 P("NT 9 M"C&INERIES %

Ⅰ% 5000 ( Rea-tor Co):igratio)%

1. I$-( +-,, 8%-(#%, %$ *,%- #?$-++G34 SS *,%-. " 88

2. J%?- 8%-(#%, %$ *,%- #?$-+G C%(


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3. E,-(# 8))( *)9-(G 1 ?9 3 *%+- -#*- 9# -%( (--(

4. R)%#)$ S*--G 65 RPM =P%,- *- A'#%)(

5. M-%$#%, +-%,

6. H-%#$' 8-) G T-(8%, O#, H-%#$' S-%8 H-%#$'

7G I$$-( #+>


34/49


Ⅲ%Oil / =ater Separator% 500 ( FSS 03G

Ⅳ% &oriHo)tal -o)e)ser% FMaterial% SS 03G

Ⅴ% 'ra-tio)ati)g Col+)% i) 2 se-tio)s ;ith a) elbo; F MOC / SS03G

Ⅵ% !::er ta)4% 00( Carbo) steel 625 -oate ;ith ")ti/rst

Pai)t

Ⅶ% a-+ p+p% 10 4; 1 Set

% !ab7 !oiler% 200,000 # Calorie F$as 'ire @Oil'ire @ Coal 'ire

% I)ter-o))e-ti)g Pipeli)es

Q%,# C)$(), L%


35/49


>.2.. Polltio) Co)trol Measres

A** 5 ,#(-+ *-( % ): )$%8#$%- *()-++ 9%-( #+ -*-- )


36/49


.2 !ili)g %

a. -ost o: pro-tio) she 3500 s :t ? Rs. 1000 A Rs. 35 (a4hs

b. -ost o: a+. blo-4, 1000 :t2 ? Rs. 2000

A Rs. 20 (a4hs

-. Dispat-h se-tio), 10,000 B 100 A 10 (a4hs

. Co+po) ;all A Rs. 10 (a4hs

Total bili)g -ost A Rs. 5 la4hs …… F"G

. P("NT 9 M"C&INER8

S.No 'a-ilities 6a)tit7 "+o)t

Rs. (a4hs

1 M%#$ P,%$ & M%#$-+ 1 +- 7

2 L%


37/49


%$ )88#++#)$#$' )+

Total Pla)t 9 Ma-hi)es 130

TOT"( P("NT 9 M"C&INES A Rs. 130 (a4hs……..!

Total Capital EBpe)itre A F"G J F!G

A A 5 J 130 A 225 (a4hs

.2 =OR#IN$ C"PIT"( %

.2.1 Ra; Materials %

Cost o: R@M per a7 F re:er basis 9 ass+ptio)sG A Rs. .5 (a4hs

Per +o)th F 25 a7s G A 212.5

Cost o: Ra; Material per 7ear ? 100K -ap tiliHatio) A 2550 (a4hs

.2.2 (ease re)tal :or la)

I)strial plot lease to the proe-t

? Rs. 23 (a4hs per a))+

Mo)thl7 re)tal A 2 (a4hs

.2. Ma)po;er%

DEPARTMENT N) ): *-)*,- (-#(-

P()#)$ 6



;8



38/49


*%?#$' 2

8%#$-$%$- 6

A)$+ %$A8 -*

4

M%$%'-(#%,+%::

2

T)%,M%$*)9-(

2

A/' 9%'-+ % R+.25 8)$#$,#$'


39/49


Mo)thl7 po;er J p-4g > (a4hs

.2.3 Cost o: Po;er 9 P-4g. per 7ear A > B 12 A 2 (a4hs

F Note % " D$ set o: appB. 5 #" rati)g shall be pt p to -ater to

e+erge)-7 ser*i-es i) -ase o: po;er otages G

.2.5 $ENER"( "DM 9 M"INTEN"NCE E


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1 9)(?#$' %*#%, 11 5>

H)9-/-(= - %+ :,)9 9)(?- ) %+ *-( %


41/49


Capa-it7 tiliHatio),

K

>0 0 0 0 100

a. R%9 M%-(#%,+ 153 17"5 2142 241 267"

b. P)9-(= P?'. &)-( E*-$+-+

5 50 71 "3 ""

-. M%$*)9-( "4 "4 0 0 0

.R-$%, 24 24 24 24 24

-. D-*>B,'. 5 5 5 5 5 5: . D-* P&M 16.66

,#:- 6 (+24 24 24 24 24

COST O'PRODCTION

F a to : G

11 11 25> 2> 20

… Cash 'lo; 9 'i)a)-ial ")al7sis -o)ti)es….

.0 'IE 8E"RS C"S& '(O= 9 'IN"NCI"( "N"(8SIS

.1 C"S& '(O=%

"ss+ptio)s %

1 T- +%,-+ #+ (-,%- ) %*%# #,#;%#)$ #$ *()#)$. F,,

%*%# *()#)$ 9#,,


42/49


4 S-,,#$' *(#- % ((-$ *(#-+ ): (-+#$ #+ #$ - (-'#)$ ): 13 ) 15

*-( K'. O$ - )$+-(/%#/- +#-= *(#- #+ %?-$ %+ R+. 14 K'. #$

- 9),-+%,- -*)( 8%(?-. T- *(#- 9#,, #$(-%+- 5 #$ -

3( -%( %$ 9#,, (-8%#$ )$+%$ :)( - $- 2 -%(+.

5 R%9 8%-(#%,+V )++ :)( #::-(-$ )8*)$-$+= - :)(8,%#)$+

%$ - )+ -%#,+ %(- )/-(- #$ - %*-( B%+#+ &

A++8*#)$+ . A'%#$ - )+ 9#,, #$(-%+- 5 #$ - 3 ( -%( %$

9#,, -$ (-8%#$ )$+%$ :)( - $- 2 -%(+.

7. I$-(-+ (%-+ :)( -(8 ,)%$ %++8- %+ 14

". C)(*)(%- T% #+ %++8- 3 )$ - *():# %:-( #$-(-+.

C"S& '(O= T"!(E

'igs i) Rs. (a4hs

&ea @ 8ear 1 2 3 5

Capa-it7

tiliHatio),

K

>0 0 0 0 100

S%,-+

R-/-$-+

1"0 225 2646 2077 33"

Total Sales 10 2205 2>3> 2 0

P()#)$

)+ @ (-:-(11 11 25> 2> 20



62



43/49


%


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1. F()8 - %


45/49


5. T- *()- #+ +)#%,, (-,-/%$ %+ # %#8+ ) -/-,)* %$ $-(

-/-,)*- (-'#)$ ): M%(%9%% %$ %?-+ #$) )$+#-(%#)$ %

#'-( /%,- ): - :%(8 *()- %+ #+ #$*= %$ -$-


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1! O TO SET UP TIS FACTORY

-+1 IMPORTANT DECISIONS TO BE MADE:

∗ O&ATIO= O; I=D6T5 , I=D6T5IA POT I= DAMA=

∗ P5EPA5ATIO= O; >6I=E66 PA= ? P5OE&T 5EPO5T

• 6O5&I=G O; TE&H=OOG* 5A< MATE5IA6* MA&HI=E5IE6

• I=;5A6T5&T5E A=D ? >IDI=G* MIT THE APPI&ATIO= AO=G A=36 / ;I=A=&IA I=6TITTE6 ;O5 GETTI=G THE5ELI5ED OA= ;O5 THE P5OE&T



6=



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* PE5MI66IO=6/&EA5E=&E6 5ELI5ED ;5OM A= OTHE5 GO"TDEPA5TME=T / MI=I6T5

…. Co)tL 1.0 'a-tories "-t

11.0 T&E '"CTORIES "CT

11.1 Objectives

- To ensure adequate safety measures and to promote the health and

welfare of the workers employed in fatories!

- To pre"ent hapha#ard $rowth of fatories throu$h the pro"isions

related to the appro"al of plans %efore the reation of a fatory!

11.2 Scope and coverage

- &e$ulates workin$ ondition in fatories!- 'asi minimum requirements for ensurin$ safety( health and welfare

of

workers!

- )pplia%le to all workers!

- )pplia%le to all fatories usin$ power and employin$ *+ or more

workers( and if not usin$ power( employin$ ,+ or more workers on any

day of the preedin$ *, months!

11.3 Main provisions

- Compulsory appro"al( lienin$ and re$istration of fatories!



68



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- Health measures!

- Safety measures!

- elfare measures!

- orkin$ hours!

- Employment of women and youn$ persons!

- )nnual lea"e pro"ision!

- )ident and oupational diseases!

- .an$erous operations!

- /enalties!

- O%li$ations and ri$hts of employees! when to onsult and refer

- On startin$ a fatory!

- Throu$hout the life of the fatory!

…. nd!stria" #stab"is$%ent &ct contin!es….

12.0 T&E INDSTRI"( EST"!(IS&MENT "CT

12.1 Objectives

- To re$ulate the onditions of reruitment( dishar$e( disiplinaryation(

holidays( et! of workers employed in industrial undertakin$s andesta%lishments!

12.2 Scope and coverage

- )pplia%le to industrial esta%lishments wherein 0+ or more workmen

are or ha"e %een employed in the preedin$ *, months!

- Central and state $o"ernments an make this )t applia%le toREG7D OICE) 8 RESIDENC9 ROAD' OPP ASHO:A RESTAURANT' SADAR' NAGPUR 0 664 445


63



49/49


esta%lishments employin$ less than 0+ persons( as in the ase of 1/

and est 'en$al!

- In )ssam it is applia%le to onerns employin$ *2 or more workers!

12.3 Main provisions

- Su%mission of draft standin$ orders!

- Certi3ations of standin$ orders!

- 4odi3ation of standin$ orders!

- &e$istration of standin$ orders!

- )mendments of the )t!

- /enalties!

- O%li$ations and ri$hts of employers!

- O%li$ations and ri$hts of employees!

hen to onsult and refer

- )t the time of e5pansion of the onern( when the num%er ofworkmen may inrease( omin$ within the pro"ision of the )t!

- hen re"isin$ standin$ orders!

E) o: Proe-t Report

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Manufacturing of unsaturated Polymer Resins

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