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CONTENTS
SECTION
SECTION
II
PRODUCT APPLICATIONS
SECTION
III
INDIAN MANUFACTURERS
SECTION
IV
IMPORT/EXPORT TRENDS
SECTION
PRICE TRENDS
SECTION
VI
INDIAN DEMAND
SECTION
VII
SECTION
VIII
SECTION
IX
GLOBAL SCENARIO
SECTION
SECTION
XI
SWOT ANALYSIS
SECTION
XII
SECTION I
PRODUCT CHARACTERISTICS AND SPECIFICATION
1.1.General details
Form
Chemical formula
Appearance
1.2.
Specification of Alum
2
1.3.
Al2O3
17%
15-16%
7%
Insoluble form
Nil
4.5%
Nil
Form
powder
Slab 20.kg
Solution of 2 pH
General Details
ALG is Iron free and is delivered in a granulated form for easy and safe handling. It is
produced by International organisations such as Kemira of Finland.
The granules are free flowing and easy to feed with a screw feeder with a minimum of
dust.
The granules dissolves easily if handled in the right way. There is no risk of clogging.
The granules have a high density. This is an advantage in terms of both freight cost and
storage space.
Specifications of Aluminium Sulphate Granulated
Al2O3 total acc.to Din 19600
Total Fe as Fe2O3
Crystal water
Al2O3 free
Insoluble matter in water
17.2%
0.07%
435
0.5%
0.03%
SECTION II
PRODUCT APPLICATIONS
Application sector
Nature of application
Water Treatment
Sizing of Paper
Miscellaneous Applications
SECTION III
INDIAN MANUFACTURERS
There are number of Alum manufacturers in the country in the small scale sector.
The manufacturers include the following.
*
Kalpana Chemicals
E/186, First Floor,
B.G. Tower, O/s. Delhi Gate
Ahmedabad-380 004
National Industries
Plot No. 155/C/A-3,
GIDC., Ankleshwar, Dist. Bharuch-393 002
Tinco Chemicals
Patel Society,Vallabh Baug Lane,
Opp. Indian Overseas Bank,
Ghatkopar (E), Mumbai - 400 077.
Metroblue Industries
P.B. No.5, 1, Quarry Road,
Evergreen Nagar, Thirupparam Kundram,
Madurai-625 005
Pondicherry Chemicals
B-188, PIPDIC Industrial Estate
Mettupalayam-605 009
SECTION IV
IMPORT/EXPORT DETAILS
4.1.
Imports
4.1.1.
4.1.2.
Countrywise Imports
Quantity in Kgs
Janpan
Singapore
UK
USA
13200
3888
20000
150
4.2.
Exports
4.2.1.
4.2.2.
Countrywise Exports
Quantity in Kgs
Bangladesh
Chinese Taipei
Colombia
France
Kenya
Malagasy RP
Malaysia
Mauritious
Nepal
New Zealand
Oman
Philippines
Slovenia
South Africa
Spain
Sri Lanka
Sudan
Tanzania REP
2000
50000
200000
326000
1314500
135000
450
118000
395510
84000
43000
4000
26000
52650
22000
2938226
315000
1466000
7
Uganda
U Arab Emts
USA
Zimbabwe
43000
727100
146000
64000
Value in Rs.
Country
Date
Port
Quantity in
tonnes
25
147469
Dubai
Mumbai
MK Aromatics Ltd.,
150
656078
Victoria
Adheshwara Exports
P.Ltd.
150
480675
Colombo
01.05.2002 to
31.05.2002
16.05.2002 to
31.05.2002
11.07.2002 to
31.07.2002
Chennai
Chennai
SECTION V
PRICE TRENDS
5.1.
Period:
November, 2002
Basic price
Extra at actuals
SECTION VI
INDIAN DEMAND
The assessment of demand for Alum is made for the following sector
Ferric alum is an important chemical used in the paper industry and in water treatment.
Paper industry
The most important use of Alum is in the paper industry for sizing of papers.
The paper industry uses Aluminium Sulphate for the clarification of process water, pH
control of pulp slurries, setting of dyes and precipitating colloidal clay and dissolved
resin into the size on the fibres of the paper (setting of size).
A paper mill consumes Ferric and non Ferric Alum at the rate of around 4 kgs/100 kgs of
finished paper.
Water treatment
The next important outlet is in water and sewage treatment as a coagulant: Reaction of
Alum with alkali in the water produces an Aluminium hydrate floc which drags down
various impurities and aids in removing bacteria and in controlling the taste of water.
Alum sold to municipalities for these uses is required to be basic to a slight excess of
Al2O3.
The Alum used for this applications is usually in the solution form. Frequently it is
acidic containing a slight excess of Sulphuric acid for potable and waste water treatment
processes.
Miscellaneous applications
In addition to this, Alum also finds application in textile units, soaps. cosmetics, fire
extinguishers etc.
Demand
The estimated demand of Aluminium sulphate in the country is around 1,50,000 tonnes
per annum.
The estimated growth rate in demand is 6 to 7% per annum.
10
SECTION VII
BROAD OUTLINE OF MANUFACTURING PROCESS
Production of Aluminium sulphate in India starts from bauxite.
Bauxite from Jamnagar (Gujarat) which contains high percentage of Alumina and low
Iron content continues to be the best source for the manufacture of this heavy chemical.
Technology and process
There is batch process as well as continuous process for the manufacture of Alum. The
batch process is adopted in the country.
Bauxite ore containing preferably less than 3% Iron is transported to the plant site and
crushed to a size of 50 to 75 mm. The crushed ore is further powdered by using a
pulveriser.
It is often seen that finer the size of bauxite, quicker would be the reaction rate. Usually
ground bauxite of size 100 to 140 mesh is used in the process. It is essential that the
Ferric oxide content shall be less than 3% in the ore, to obtain a satisfactory product
containing less than 0.1% Iron.
Prepared Ore is subjected to reaction with Sulphuric acid in open lead lined digesters at a
temperature of around 105 deg.C.
The desired strength of Sulphuric acid in open lead lined digesters is 52 deg. Be.
total reaction time is around 12 to 16 hrs.
The
The reacted solution is taken to a settling tank. After settling ,the sludge is removed and
discarded. The clear solution is concentrated in open pan evaporators.
The concentrated solution is poured into large wooden vats, where it solidifies. This
block is broken down into smaller pieces and sold. Where powdered form is required, it
is subjected to pulverisation.
11
Source of technology
*
Boilers
Reactors
Centrifuge
Mixer
12
Dryers
Pulveriser
13
SECTION VIII
RAW MATERIAL REQUIREMENTS AND AVAILABILITY
Raw material requirement
Basis: 10 tonnes per day of Alum
Bauxite containing 60% (Al2O3) and
Ferric oxide(Fe2O3) less than 3%
Sulphuric acid 98% concentration
4.0 tonnes
60,000 litres
Fuel
Air at 30 Psig pressure
Flaked glue
Black ash (Barium sulphide)
Power
480 litres
20 M3 per hour
2000 gms per tonne
90 kgs per tonne
249240 units
5.5 tonnes
Sulphuric acid
14
SECTION IX
GLOBAL SCENARIO
Aluminium sulphate hydrate is commonly marketed in the technical or commercial grade
The commercial grade is dissoluble both as Alum or granular solid containing 17 to
17.5% Al2O3 and as a solution containing 7.5 to 8.5% Al2O3.
In the USA, it is usually produced by reacting bauxite or clay with sulphuric acid.
Bauxite is more expensive than clay. The clay, generally kaolin, is roasted to remove
organic materials and to break down its crystalline structure, there by increasing the
alumina values available for extraction.
Roasting is an energy intensive process. In addition, both clays and bauxite vary
considerably with respect to the undesirable impurites of Iron and potassium.
Thus, the choice of the raw material, roasted clay or bauxite, is governed by the overall
economics of producing a satisfactory product.
The optimum conditions for roasting the clay and the optimum strength of the sulphuric
acid depend upon the particular source of the bauxite or clay. Finely ground baxuite or
roasted clay is digested in sulphuric acid near the boiling point of the solution
(100 to 120 deg.C) The clay or bauxite to acid ratio is adjusted to produce, either acidic
or basic alum. Solids are removed by sedimentation. If necessary, the solution can be
treated to remove iron.
The iron free grade is produced by using pure Alumina trihydrate in place of bauxite or
clay. Excess iron may lead to staining and discolouration of the product containing the
aluminium sulphate.
15
Kali-Chemie AG
Hans-Boeckler-Allee 20
D-3000 Hannover 1
Cosmocel, S.A
Via Matamoros 1501, Apdo. No.1, Suc.A,
San Nicolas De Los Garza,
Nuevo Leon 66480, Mexico.
16
SECTION X
DISCUSSIONS ON ECONOMIC CAPACITY, PROJECT COST AND
PROFITABILITY PROJECTION
Economic capacity
Project cost
Rs.134 lakhs
Description
1.1
1.2
2.
Building
Description
2.1
2.2
Cost
Rs.in lakhs
12.8
1.8
14.60
S.No.
Description
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
3.9
3.10
0.55
6.05
S.No.
3.
Cost
Rs.in lakhs
5.5
17
Cost
Rs.in lakhs
44
3.3
4.4
2.2
53.9
6.47
1.08
1.08
1.08
1.08
1.08
65.77
4.
5.
Rs.2.2 lakhs
S.No.
Description
5.1.
5.2.
5.3.
5.4.
5.5.
5.6.
5.7.
Electrification
Steam boiler and auxillaries
Water storage tank, borewell etc.
Fuel storage tank
Laboratory equipment
Office machinery & equipment
Material handling equipment, packaging machinery,
Weigh balance, etc.
Diesel generator
Effluent treatment
Total
5.8.
5.9.
6.
Cost
Rs.in lakhs
2.7
2.7
1.4
1.4
1.4
1.4
1.4
5
2.5
19.9
S.No.
Description
6.1.
6.2.
6.2.1
6.2.2
6.2.3
6.2.4
6.2.5
6.2.6
6.2.7
Preliminary expenses
Pre-operative expenses:Establishment
Rent rates and taxes
Travelling expenses
Interest and commitment charges on borrowings
Insurance during construction period
Other preoperative expenses and deposits
Interest on deferred payment
Total
Cost
Rs.in lakhs
1.65
1.5
1.5
1.5
7.0
1.75
14.9
7.
Rs.7.24 lakhs
8.
Rs.2.31 lakhs
9.
Rs.134
10.
Means of Finance
Promoter'
s contribution
Term loan from financing institutions
Total project cost
Rs.54 lakhs
Rs.80 lakhs
Rs.134 lakhs
18
11.
A
Variable cost
Raw material and utilities
Spares and maintenance
Selling expenses
Total Variabel cost
B.
Fixed Cost
Salaries and wages
Interest on term loan and working capital loan
Depreciation
Administrative expenses
Total fixed cost
C.
Total cost of production(A + B)
D.
Selling price per kg. in Rupees
E.
Annual sales turnover
F
.Net profit before tax (E-C)
G.
Breakeven point in %
71.8
4.0
7.5
83.3.
7.2
16
8
4.5
35.7
119
5
150
.31
54%
SECTION XI
19
SWOT ANALYSIS
Strength
Weakness
Competitive conditions
Opportunity
Threat
SECTION XII
20
21