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Index
Sr.No. Name Page No.
1 Introduction 01
-Alkyd resin 01
-Microwave synthesis 10
reactor
2 Aim of present project work 30
3 Experimental work 31
5 References 49
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1. Geometry i.e. Materials that are thick & therefore difficult & time consuming to
process by conventional heating means.
2. Temperature sensitivity i.e. Material adversely affected by using usual processing
temperature.
3. Cost, costly material generally can tolerate the higher cost of microwave processing.
4. Uniqueness, a unique product or attribute of a product is obtained by the use of
microwave heating.
5. Batch to continuous processing, where batch process can be converted to a
continuous process because of a substantial reduction in a process time.
When microwave are intercepted by dielectric material such as food, they interact with
dielectric material, giving of energy which result in a increase in temperature of material. There
are two mechanisms by which microwaves produce heat in the dielectric material.
1) Ionic polarization 2) Dipole rotation
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As an alternating field is applied. The polarity of the field is varied at the rate of microwave
frequency and the molecules attempt to align themselves with the change in field. Heat is
generated as the result of the rotation of the molecule.
Microwave heating is also dependent on the physical state of the material i.e. ice in which the
movement of the water molecule in microwave field is restricted. The amount of microwave
energy converted to heat in the dielectric material is given by the equation
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One can broadly characterize how bulk materials behave in a microwave field. Materials
can absorb the energy, they can reflect the energy, or they can simply pass the energy. It should
be noted that few materials are either pure absorbers, pure reflectors, or completely transparent to
microwaves. The chemical composition of the material, as well as the physical size and shape,
will affect how it behaves in a microwave field.
In all conventional means for heating reaction mixtures, heating proceeds from a surface,
usually the inside surface of the reaction vessel. Whether one uses a heating mantle, oil bath,
steam bath, or even an immersion heater, the mixture must be in physical contact with a surface
that is at a higher temperature than the rest of the mixture.
In conventional heating, energy is transferred from a surface, to the bulk mixture, and
eventually to the reacting species. The energy can either make the reaction thermodynamically
allowed or it can increase the reaction kinetics.
In conventional heating, spontaneous mixing of the reaction mixture may occur through
convection, or mechanical means (stirring) can be employed to homogeneously distribute the
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reactants and temperature throughout the reaction vessel. Equilibrium temperature conditions can
be established and maintained.
Although it is an obvious point, it should be noted here that in all conventional heating of
open reaction vessels, the highest temperature that can be achieved is limited by the boiling point
of the particular mixture. In order to reach a higher temperature in the open vessel, a higher-
boiling solvent must be used.
Microwave heating occurs somewhat differently from conventional heating. First, the
reaction vessel must be substantially transparent to the passage of microwaves. The selection of
vessel materials is limited to fluoropolymers and only a few other engineering plastics such as
polypropylene, or glass fiber filled PEEK (poly ether-ether-ketone). Heating of the reaction
mixture does not proceed from the surface of the vessel; the vessel wall is almost always at a
lower temperature than the reaction mixture. In fact, the vessel wall can be an effective route for
heat loss from the reaction mixture.
Second, for microwave heating to occur, there must be some component of the reaction
mixture that absorbs the penetrating microwaves. Microwaves will penetrate the reaction
mixture, and if they are absorbed, the energy will be converted into heat. Just as with
conventional heating, mixing of the reaction mixture may occur through convection, or
mechanical means (stirring) can be employed to homogeneously distribute the reactants and
temperature throughout the reaction vessel.
Despite the variety of cavities available, there are in reality only two basic types: single-
mode (often referred to as monomode), and multimode. It is important to recognize the essential
difference between the two types. Far more important is for synthetic chemists to recognize how
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cavities are the same in every important aspect with regard to chemical reactions. The distinction
between cavity types is determined by the design characteristics, not by the processes that can be
performed inside the cavity. The design characteristics are determined by many factors that have
nothing to do with the reaction chemistry.
For 2.45 GHz microwaves, the length of a single full wave is 12.2 cm. A single-mode
cavity for 2.45 GHz microwaves must be dimensioned such that a whole-number multiple of the
full or half wavelength fits inside the confines of the cavity.
The second consequence is far more important. There are specific positions inside the
single-mode cavity where items to be heated must be placed. The intensity of the field is greatest
at the peaks of the standing wave, and actually goes to zero at the nodes of the standing wave.
There are positions in the single-mode cavity (the nodes) where no heating will occur. Only in
the volume of the peak envelopes can transfer of microwave energy to a target absorbing
material occur. This substantially limits the physical dimensions of objects (such as reaction
vessels) that can be placed in a single-mode cavity and be heated effectively.
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The third consequence is probably the most important. Anything placed inside a single-
mode cavity can disrupt the standing wave pattern. For this reason, it is quite uncommon for
single-mode cavities to be designed to accept more than one target object (such as a vessel) to be
heated at a time.
A final consequence of single-mode cavity design is the fact that there is no practical way
to scale up processes. One must recognize from the outset that microwave processes developed
on a small scale may need to be transferred to a larger scale for production. One cannot extend
the dimension of a standing wave cavity indefinitely, nor can one simply purchase components
off the shelf to generate a standing wave of just any delivered power.
There are two principal approaches to achieving this goal. First, the dimensions of the
cavity must be carefully controlled to avoid whole-number multiples of the microwave full or
half wavelength. Second, some means must be employed to physically disrupt any standing
waves that may form as a consequence of items placed in the cavity. This is best performed with
a mechanical mode stirrer, typically a periodically moving metal vane that continuously changes
the instantaneous field pattern inside the cavity. The shape of the vane and its movement is such
that the microwave field is continually stirred, and therefore the field intensity is homogeneous
in all directions and all locations throughout the entire cavity.
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heated. Of course, if the intensity of the field is controlled, then the heating rate can be
controlled, some sort of temperature monitoring and feedback control scheme can be
implemented, etc.
The second consequence is far more important. In a properly designed multimode cavity,
there is no specific position inside the cavity where items to be heated must be placed. Because
the field is homogeneous everywhere and in all directions, every position in the cavity is like
every other position.
The third consequence is perhaps the most important. Since the field in a multimode
cavity is continuously re-homogenized (stirred), nothing placed inside the cavity will
permanently affect the distribution of the field intensity. This means that there are no limitations
on the size and shape of the objects placed inside the cavity. If they will physically fit inside the
cavity and if they absorb microwaves, then they will be heated.
This also means that multiple objects (for example, multiple reaction vessels) can be
processed simultaneously, just as effectively as single objects. This is a dominant advantage of
multimode cavity design.
A final consequence of multimode cavity design is the fact that practical scale-up of
processes is easy. Any process that is developed in a bench-top multimode microwave lab station
can be scaled up to production or pilot plant capacities. A multimode cavity can, in theory, be
infinitely extended in every dimension. With a multimode design, additional field intensity to fill
that extended cavity can easily be had by simply adding additional magnetrons to the system.
These facts of cavity design can be important considerations when first exploring the
microwave advantage. The user must carefully assess how the microwave system will be used in
the lab today, and the possible applications and configurations for the future. Only a multimode
cavity provides the opportunity to go beyond a single reaction format to multiple reactions
simultaneously and uniformly. Only a multimode cavity allows you to progress from discovery
through to production, in any form factor, with confidence.
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Instrument Description:-
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Figure No. 1
• Display –
Displays menus, method parameters and instrument status on a 4 line x 20 character
vacuum fluorescent display.
• Keypad –
Allows the operator to create, edit, store and recall methods start and stop methods and
change programmed parameters during operation.
• Attenuator –
Provides access to the instrument cavity while preventing microwave leakage during
operation. The attenuator can be installed or removed with a “twist-lock” action (no tools
required).
• Interlock Assembly –
Monitors mating of the attenuator to the cavity. If the attenuator is not installed properly,
the instrument will not deliver microwave power nor permit the system to operate.
Discover System - Front View:-
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Figure No.2
• Edit –
Press to access the System Setup options such as sensor configuration and calibration or
system parameters.
• Home –
Press to return to the main screen from any menu in the software. Within the System
Setup portion of the software, press this key to return to the previous menu.
• File –
Press to access the programming options in the software. These options include; Quick
Test, New Method, or a list of methods from the method library.
• C/CE –
Press to clear a key entry or delete a method from the method library when using the
delete method function.
• Enter –
Press to accept entries while editing or creating a method or in System Setup.
• 0-9 –
Press to enter method parameter values such as power, temperature, pressure, ramp time,
run time and hold time.
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• Start/Pause –
Press to start the current method or press during method operation to pause or suspend
operation. Pressing the key again will restart the method from the paused point.
• Stop –
Press to stop any process. Pressing this key when performing a method will stop system
operation and launch the cooling function. Pressing this key during the cooling cycle will abort
the cooling cycle and return the system to the home screen.
• Arrows –
Press these keys to navigate through method programming or System Setup steps.
• Power –
Press this key followed by the appropriate numeric keys to change the maximum applied
microwave power setting. This does not stop or pause a method but updates the setting in real
time. The updated setting is not captured as part of the saved method file in the method library.
• Temperature –
Press this key followed by the appropriate numeric keys to change the temperature set
point before or during a method. This does not stop or pause a method but updates the setting in
real time. The updated setting is not captured as part of the saved method file in the method
library.
• Time –
Press this key followed by the appropriate numeric keys to change the time value during
or after a method. Pressing during the Run Time cycle allows for real time changes to this value.
Pressing during the Hold Time cycle allows for real time changes to this value. This does not
stop or pause a method but updates the setting in real time. The updated setting is not captured as
part of the saved method file in the method library.
• Pressure –
Press this key followed by the appropriate numeric keys to change the pressure set point
during a method. This does not stop or pause a method but updates the setting in real time. The
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updated setting is not captured as part of the saved method file in the method library. This key
can also be pressed when the instrument is idle to open or close the IntelliVent.
• Cooling –
Press this to perform the cooling function during a method. This does not stop or pause a
method but updates the setting in real time. The updated setting is not captured as part of the
saved method file in the method library. The cooling key can also be pressed prior to beginning a
method to turn Power Max “on” or “off.” To cool a vial when a method is not in progress, from
the Main Menu, press the “Home” key; then from the temperature screen, press the cooling key.
• Power Switch –
Turns AC power on and off to the instrument.
• Cooling Gas Line –
Connects cooling gas supply to instrument
Figure
No.3
Temperat ure
Control System
Options
1. Infrared
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Figure No.4
Bench Mate Option:-
During routine use, the Bench Mate should remain connected to the 7-pin connector
located on the back of the Discover.
1. Plug the Bench Mate into the 7-pin connector located on the back of the Discover instrument.
2. Place the Bench Mate on top of the Bench Mate attenuator, ensuring that the notches on the
Bench Mate are aligned with the slits on the attenuatgor. Lock the Bench Mate onto the
attenuator by pushing down on the sides of the Bench Mate.
3. Tighten the Bench Mate by turning the top of the Bench Mate clockwise until resistance is
felt.
1. Sample Stirrer:-
Based on system design, the sample stirrer is a rotating plate containing either electromagnetic
coils or permanent magnets positioned beneath the instrument cavity floor. It works in
conjunction with stirring bars or “fleas” placed in the reaction vessel to affect stirring and ensure
a homogeneous sample. An initial supply of magnetic stir bars or “fleas” are provided.
Additional stir bars can be purchased from CEM Corporation. Any commercially available
magnetic stir bars or “fleas” are acceptable for use with the Discover system.
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2. Cooling:-
The cooling feature directs a gas source onto the outside wall of the reaction vessel. This
provides the ability to rapidly cool (quench) a reaction after the application of microwave
energy. The cooling feature is either “on or off” and is part of the method.
The feature consists of
• “plumbing” to direct the gas from the inlet point of the Discover to the reaction vessel
in the cavity, a solenoid valve connected to the CPU (controller) board to turn the gas
flow on and off,
• A hose fitting to connect the Discover to the gas source via a hose,
• 8 feet (2.44 meters) of ¼ inch (6.35 mm) inside diameter air hose.
The gas source is user supplied. CEM Corporation recommends either nitrogen or
“clean” air at a minimum pressure of 20 psig (~ 1.5 bar). This will provide a fl ow rate of 25
liters per minute and will cool a 5mL volume of propylene glycol in a 10mL reaction vessel from
150 °C to less than 40 °C in less than 2 minutes.
3. User Interface:-
The user interface consists of the keypad, LCD display, and two serial ports. This
provides the means for the user to input information into and output information from the
Discover System.
The input functions are performed with the keypad and provide the ability to
• create new methods and edit existing methods,
• recall and delete methods,
• change operating parameters during method operation in real time,
• start, pause and stop operation,
• set up a computer, and
• configure the sensor options and system options.
The output functions are obtained from the LCD Display and computer port. The LCD
display provides visual information of the keypad entry and permanently stored instrument
information. The computer port provides the option of using an off-board PC to program the
system and to collect data.
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6. Power-Time Control:-
The Power-Time Control option is the simplest programming option. It provides the user
the most direct method to energize reaction systems. This option applies a specified amount of
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energy for a specified amount of time. Maximum temperature and pressure limits stop instrument
operation if either is reached. The user programs
1. The amount of microwave power applied,
2. A maximum run time (the total time the system applies microwave energy),
3. A maximum temperature (a temperature above which the system will not apply
microwave energy),
4. A maximum pressure (a pressure above which the system will not apply microwave
energy),
5. Optional stirring function, and
6. Optional cooling function.
The Power-Time Control option can be programmed for five (5) stages for multiple
irradiation steps. It does not provide the flexibility to maintain critical control points; thus, it
provides the least amount of control.
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The petroleum products are sourcing in price and availability, we have to search for
alternatives particularly from vegetable sources. Being of natural origin, these derivatives
are expected to be fairly biodegradable.
Therefore, the present work is aimed at developing novel polymeric material based
mainly on plant extracts like castor oil, Rosin etc.
In this project we are trying to devolve polymeric material from natural origin,
which can be used in the paints or detergents. In this way we are trying to replace the
petroleum based raw materials used in detergents and paints to the maximum extent that
can be possible.
In this project we are also trying to use the different method of manufacturing that
is microwave synthesis reactor method.
In this study we are going to compare the properties of polymeric material prepared
on microwave synthesis reactor with that prepared on conventional batch reactor. We are
also going to compare the products prepared from both of these polymeric materials.
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3 EXPERIMENTAL WORK
Temperature: 2250C
Time: 10 min
Power: 225 W
In the preparation of the resin all the raw materials are mixed properly and that mixed
properly and whole mass is added in to the wire of the microwave synthesis reactor batch wise.
At a time 7 ml resin can be prepared in the one batch of microwave synthesis reactor. In this way
200ml resin is prepared.
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Weight about 1.2 gm of resin sample in flat bottom flask. Add 20 ml neutral alcohol in it.
Keep the flask on hot water bath till the solution in the flask homogeneous. Add few drops of
phenolphthalein indicator and titrate the solution of the flask against 0.1 N alcoholic KOH. The
acid value obtained by following formula.
Acid Value = (56.1 × N × V) / W
Where,
N= Normality of KOH.
V= Volume of KOH required.
W= Weight of oil in the flask.
Standardization of KOH:-
Weigh accurately 0.1 to 0.2 gm of oxalic acid and mix it into 20 to 25 ml of distilled
water. Shake and mixed well to dissolve oxalic acid. Add 2 to 3 drops of phenolphthalein
indicator and titrate it against 0.1N KOH till pink color obtained.
Solid Content7:-
The percentage of solid in the resin was calculated as follows.
%Solid = (100 – Volatile Content)
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Conclusions:-
1. As per the formulation and given procedure both resins are prepared and analyzed
according to standard procedure.
2. As per the analysis formulation II is preferred than the formulation I as formulation II has
very high acid value.
3. At the start of project our aim was to use the rosinated castor oil alkyd resin in the paints.
As the acid value of the prepared resin is too high we can use that resin in the formulation
of water based distemper only. Use of the resin prepared from the microwave synthesis in
the formulation of distemper or cement paint will not be cost effective. Hence it is
concluded that the prepared resin cannot be used in the formulation of paints.
4. Above prepared resin has sufficient acid value to use that in the formulation of liquid
detergent.
5. To use the resin in the formulation of liquid detergent it is necessary to neutralize the
resin. Resin is neutralized by using 30% KOH till its PH become 8. After the
neutralization is over 2% tri ethanol amine is added to it.
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Resin prepared by the Formulation II is used in the liquid detergents. This resin is used in
the liquid detergent in various proportions and analyzed for its effect.
Formulation of liquid detergent based on the rosinated castro-alkyd resin (formulation I):-
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A number of methods for the measurement of surface tension are known. One of them is
described as follows
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Procedure
Foam characteristics are measured in terms of volume. The following are carried out for
it
1. Take 1000 ml cylinder provided with stopper. Add to it, 100 ml solution of
particular concentration whose foam characteristic is to be measured.
2. Give it 30 up-down rotation within time period of 30 seconds.
3. Keep that cylinder on table and observe the foam above liquid level and note
down reading at zero minute.
4. The readings were measured after 5, 10, 15 minutes respectively.
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5. Same procedure is carried out for the solution of different concentration like
0.1 %, 0.25 %, 0.5 % and 1%.
From above experiment we can easily find out the foam stability and change in
foam characteristics with time.
Component %
Carbon black 28.4
Coconut oil 35.8
Lauric acid 17.9
Mineral oil 17.5
The mixture of carbon black and lauric acid along with mineral oil is taken in pastel and
mortar. Coconut oil is added slowly to form thick paste of it. The all component were grinding in
pastel mortar for 1-2 hrs to get fine grinding. Smooth feeling of the mixture can test the fine
grinding.
Soil solution:
This is prepared by adding 2 gm of above paste in 500 ml carbon tetrachloride. Mix it
well and use for further cloth sample preparation.
Methods of application:
The cotton cloth of size 24 × 32 cm was prepared. Take 50 ml of soil solution in beaker.
Dip this cloth sample in it for 5 min. this is kept outside for drying in open atmosphere for 2 hrs.
Than this cloth is cut in to test samples size of 6 × 8 cm2 these samples were used for washing
purposes.
Methods of washing:
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The solutions of different concentration were prepared. Dip soiled cloth sample in it for
5 min. and given to form 10 hand washes. Washing is carried out in distilled water only. After
rising this sample it is kept for drying purposes.
Percentage detergency:
The samples, which are washed dried and ironed, are used for percentage detergency. The
% detergency is finding out by using Lambert and slandered formula
%Detergency = [(Rw –Rs) × 100] / (Ro- Rs)
Where,
Rw = Reflectance measured on washed cloth.
Rs = Reflectance measured on soiled cloth.
Ro = Reflectance measured on clean cloth.
The reflectance of the cloth samples were measured by using “reflectance meter”
manufactured by Universal Engg. Corporation, Ambala road, Saharanpur (UP). This is digital
instrument. This is first standardizing by using the magnesium oxide or tile, which is provided
along with the instrument. Once this is adjusted, then samples were kept on the instrument and
note down the digital.
(d) Density:-
Procedure
1) Thoroughly clean the density bottle with the mixture of nitric or chromic acid
then wash with water. Rinse both stopper and bottle with distill water and finally
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Observation
1) Weight of density bottle = W1 gm
2) Weight of the bottle + water = W2 gm
3) Weight of the bottle + liquid = W3 gm
4) Temperature of Expt. = t0 C
Calculation
wt of the liquid
ρ= × Density of water at t 0 C
wt of equal volume of water
W3 − W1
= × Density of water at t 0 C
W2 − W1
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detergent 0 5 10 15 (Dynes/c
sample m)
LD1
0.25% 440 415 400 375 0.982 29.57
0.5% 585 565 550 525 0.984 28.02
1% 720 695 675 655 0.988 26.05
LD2
0.25% 460 425 410 385 0.980 30.01
0.5% 610 585 570 550 0.982 28.29
1% 740 715 700 670 0.985 26.93
3.3 STUDY THE EFFECT OF THE POWER ON THE ACID VALUE OF RESIN IN
THE MICROWAVE SYNTHESIS REACTOR.
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While studying the effect of various parameters of the microwave synthesis reactor we
have studied the effect of power on the various properties of resin. We have observed that the
change in the power of the microwave synthesis reactor greatly affect the acid value of the resin.
Hence we compare the acid value of resin by continuously increasing the power of the
microwave synthesis reactor. All other parameters are remained same.
Procedure: -
1. All the raw materials of resin formulations are mixed in the one container.
Results: -
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Conclusions: -
From above experiments we can conclude that by increasing the power of the microwave
synthesis reactor acid value of the decreases. As the power goes on increasing the required
temperature is attained in lesser time so resin is exposed to maximum temperature for more time
and hence acid value goes on reducing.
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Aim: -
In this our aim is to compare the properties of resin having the same formulation but
prepared with different methods. In this comparison is made of a resin prepared by microwave
synthesis with the resin prepared by batch i.e. by using normal reactor.
1. In this first we prepared resin using microwave synthesis reactor with a parameters,
which are mentioned earlier.
2. Then we prepared a resin with a same formulation as above but in the normal batch
reactor.
3. We analyzed both the resin prepared above.
4. Both the resins are then use in the same type of application. Here we prepare liquid
detergent with both these resins.
5. Analysis of above liquid detergent is carried out. By comparing the properties of liquid
detergents prepared from resin manufactured by different method, the effect of
manufacturing technique of resin on the liquid detergent is observed.
6. In this way comparison is carried out.
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Analysis of resin: -
1. Analysis of LD (a): -
Graph 3 – Foam height of LD (a) from resin prepared on microwave synthesis reactor.
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2. Analysis of LD (b): -
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5 REFERENCES
1. Taylor, C.J.A and S. Marks, Paint technology manual- part III Convertible
coatings. Chapman and Hall publications, London (1972).
2. Payne, I.I.F, Organic coating technology, Vol II, John Wiley Sons, New York (1961).
3. Taylor, C.J and Marks, O.C.C.A. Part III, Page 88-90, London (1972).
4. Taylor, C.J and Marks, O.C.C.A. Part III, Page 92-94, London (1972).
7. Bayuy A. D. “Polymeric surfactant and their use in industrial product,” Paint India
(March 1993) pp.45-52.
9. Annul book of ASTM Standard American society for testing and material, Vol-
6.01d, 1639-81. (1981), ASTM standard Method for acid value of organic coating
materials.
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10. Annul book of ASTM Standard American society for testing and material, Vol-
6.01d, 1639-61. (1981) ASTM standard Method for non volatile contains of resin
solutions.
11. Annul book of ASTM standard American society for testing and material 6.01 D
1259-61 (For non volatile contains of resin), 1980.
13. P. S. Kalsi, “Spectroscopy of organic compound” Text book, pp: 103-104, 114, 125.
14. Brittany L. Hayes, “Microwave Synthesis Chemistry”, CEM Publication, 2002, pp:
11-25.
15. www.milestone.com
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