1. Hexamine From Formaldehyde
2. Hydrochloric Acid (Hcl)
3. Barium Compounds
4. Glacial Acetic Acid
5. Silicone Emulsion
6. Sodium Tripoly Phosphate
7. Corrosion Controlling Chemicals (Pipe Lines)
8. Ethylene Diamine
9. Metal Naphthenates (As Driers For Paints)

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SILICONE EMULSION

INTRODUCTION

Silicon emulsion having wide applications and uses in the industry and domestic purposes. The property of the silicon emulsion is very partial to the industrial uses. Silicons use in the various uses i.e., alloying agent for steels, aluminium, bronze, copper and iron, production of halogenated silcons organo-silicons compounds, silicon carbide spring steels, deoxidizes in steel manufacture, semi-conductor in integrated circuits, and also in other refractories.

Properties also favourable tothe industrial uses i.e, good appearance, dispersibility, stability, good conductor of electricity, good conductor of heat, paint of immersion, temperature range 50 - 250 oC, low surface tension and excellent dielectric properties.

Occurance of the silicon; it does not occur free in nature but on the homogenous mixture. And it is in the forms of fluids, emulsion, solutions, resin, paste, elastomers.

Silicones are stable at high and low temperature, after good weather resistance and excellent electrical properties and are produced in resin, fluid gel, or elastomer form. Made from silicon, the most abundant elemental mineral on earth, silicones are semi-inorganic polymers that are used in almost every industry as well as in practically every home in the country. Silicon the base material constitutes 28 % of the earth's crust, must frequently exists as its oxide, sio in the form of sand, quartz and flint. It also exists in nature in combination with potassium, aluminium and magnesium: To obtain silicones commercially sand or quartz is reduced by carbon to silicon inan electric arc furnace and the product is crushed to a fine powder. By contacting this powder with methyl chloride in the presence of a catalyst under proper conditions a chlorosilane is formed which is hydrolysed with water and further reacted in presence of an end blocking agent to form a polymer of the type dimethyl -polysiloxane silicones are formed and can take the form of fluids of almost any viscosity, or resins. The fluids may be used alone combined with organic thickness to produce greases, or combined with inorganic fillers to produce water repellent dielectric compounds. The raw materials which make up the siloxane polymer sand, methyl chloride and water are inexpensive but the processing is complicated and costly.

USES AND APPLICATIONS

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Silicon emulsion is used to reduce or present adhesion between two surfaces.

They are used as mould releasing agent (in form of water dispersions) which are sprayed on themould in dilute forms.

They are used in rubber industry.

In plastic industry.

In metal Casting.

In polymer processing.

Production of pressure sensitive tapes and glass fabirications.

It is highly dielectric fluid, uses in the chemical industries.

Due its good lead conductor uses in the heating and cooling purposes.

Wetting and surfactant agent.

Uses in the textile industry in the final finishing.

Uses in the rubber industry as the vibrators deamping devices.

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Basic property of silicons is their ability to lubricate particularly in low and medium pressure applications. Very few substances-even adhesives will stick to the silicon polymer. Wide application is made of the property in the release of rubber and plastic parts from metal molds.

B.I.S. SPECIFICATION

The following I.S specification are available for reference.

<td>IS</td><td>:</td><td>7648 - 1975 Silicon compounds for application on high voltage procelain insulators. (Reaffirmed 1987)</td>

IS	:	8250 - 1976 Faundry painting agents.
IS	:	6884 - 1983 Dental silicate material.
IS	:	2024 - 1979 Silico chromium emulsion.

Above Specifications may be obtained from

Bureau of Indian Standards,

9, B. S. Zafar Marg,

New Delhi - 110 002.

MARKET SURVEY

There is lot of scope for the manufacture of silicon emulsion. The installed capacity is not known and so the production capacity cannot be given. But the present production capacity is not able to satisfy the present demand. The various products of silicon obtained from silicon metal can be estimated by demand and production estimates of silicon metal. Apparent consumption of silicon metal has increased at the rate of 13 percent during 1970-71 to 1981-82.

PRESENT MANUFACTURERS

1.	M/s. Kanchan Chemical Work Ltd.,
	7, Ravindra Sarani
	4 th Floor,
	Calcutta -1.

2.	M/s. Chemic Plast Industries
	404, Rewa Chambers
	4th floor
	New Marine Line
	Bombay -400028.

3.	M/s. Bina Corpn.,
	Commersairal Building
	5th Floor
	231 DR. DN Road,

PROCESS OF MANUFACTURE

Formulation should in so far as possible take into consideration the intended manufacturing procedure. The emulsification usually promotes case of formation of the emulsion as well as stability. It may be stated as a general rule that the greater the mechanical energy input the less demand there is for quantity of emulsifier. In laboratory preparation batch kettle is used. In plants Homogneniser with a pressure relief valve is used. Based on the laboratory test it is wish to establish a specific procedure to prepare an emulsion on plant scale. Apparently small duration in procedure may result in a totally different end product. As regards addition of ingredients in many cases a given order and rate of addition results in acceptance or rejection of the product. Specific procedure should be worked out for each formulation. In most instance of liquid emulsification ambents temperature is to be preferred. Each emulsion must be studied to detemine the rate of cooling if fast or slow.

The choice of emulsification equipment is usually dictated by the application of the resulting emulsions. The purpose of emulsification equipment, disperse the internal phase in the external phase so that the particle size of the resulting emulsion is sufficiently small to regard coalescenced and resulting liveakdown of the emulsion in the required time of stability. The major concern in the choice of emulsifying equipments are :

1. Formation of silicon emulsion from the silicon oil and morphonic oleate and with the solvent oleate water is easy and more feasible. The number of equipments require is less and yield is comparative to others is high. We use one mixer (jacketed) and homogeniser for the ferfect corization and mixing of silicon and water.

SUPPLIERS OF PLANT AND MACHINERY

1.	M/s. ACMEC India Corporation
	16, Marine Mansion,
	Old Cartoon,
	Bombay-1

2.	M/s. Bengal Fabricaties (P) Ltd.,
	20 Strand Road,
	Calcutta-1
3.	M/s. Srabhai Engg. Corpn.
	Shahibaj House
	Shahibag,
	Ahmedabad, Gujrat.

4.	M/s. Billy Engineering Enterprises
	761, T.M. Road,
	Madras - 600 081.

5.	M/s. Cosyur Engineering Company
	15, Laxmi Co-op. Industrial Estate
	Near Nagarvel Hanuman Mandir,
	Amrawadi Road,
	Ahmedabad - 380 026.

6.	Ms. Chemtex
	13, Laxmi Co-op. Industrial Estate
	Near Nagarvel Hanuman Mandir
	Amrawadi Road
	Ahmedabad - 380 026.

SUPPLIERS OF RAW MATERIALS

1.	M/s. All chemcial Corporation
	Sai chambers
	4 the Floor, 356669,
	Narsi Nath Street,
	Bombay

2.M/s. Protex Industries, Mulchand Ashram Building, Off. Madhav Bag, Ahmadabad-380022
3.M/s. Metroark Pvt Ltd., 7-12, Lenin Sarani, Calcutta-13./tr]
4.M/s. Consolidated Solvent & Chemcial Coroporation, [52/53, Babu Genu Road, Jivraj Sharmai Building, [1st Floor , Bombay-400002.

5.	M/s. KSN Business Associates,
	214, DDA Commercial Complex
	Jhandewalan,
	New Delhi-55.

6.	M/s. Alpha Remedies P. Ltd.
	65, Dharampeth Extension
	Nagpur - 440 010.

7.	M/s. Medispass Ltd.
	10-2-257/1,
	Road No. - 11
	West Maredpalli
	Secunderabad - 500 026.

PLANT ECONOMICS

Rated Plant capacity =0.50 MT/Day

LAND & BUILDING

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LandRs.1,00,000.00

BuildingRs.2,75,000.00

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TOTALRs.3,75,000.00

PLANT & MACHINERY

1.Storage tank for silicone fluid Construction 3000 litrs capacity Rs.50,000.00

2.Silicone fluid feed tank S.S construction 1000 litres capacity Rs.30,000.00

3.Stainless steel raction vessel fitted with paddle type agitation complete with cooling jacket and access Rs. 1,20,000.00

4.Homogeniser Rs.1,50,000.00

5.Silicone emulsion storage tank Rs.60,000.00

6.Packing machine Rs.40,000.00

7.Testing equipments Rs.20,000.00

8.Pumps, valves and pipe lines Rs.70,000.00

9.Electrification and fittings Rs.30,000.00

10.Miscellaneous Rs.50,000.00

TOTAL6,20,000.00

OTHER FIXED ASSETS

1.	Office equipment, furniture plus other equipment & accessories	Rs.	30,000.00
2.	Electrical Installation	Rs.	50,000.00
3.	Water Resource	Rs.	25,000.00
4.	Technical know how	Rs.	20,000.00
5.	Telephone	Rs.	25,000.00
	TOTAL	Rs.	1,50,000.00

FIXED CAPITAL

1.	LAND & BUILDING	Rs.	3,75,000.00
2.	PLANT & MACHINERY	Rs.	6,20,000.00
3.	OTHER FIXED ASSETS	Rs.	1,50,000.00
TOTAL	Rs.	11,45,000.00

WORKING CAPITAL REQUIREMENT/MONTH

RAW MATERIALS

1.	Silicone oil 4.375mt @ Rs. 200/- per kg	Rs.	8,75,000.00
2.	Morphline oleate 0.875 mt @ Rs. 50/- per kg	Rs.	43,750.00
	TOTAL	Rs.	9,18,750.00

SALARY & WAGES / MONTH

1.	Manager (chemical technologist)	1 No.	Rs.	6,000.00
2.	Maintenace engineer	1 No.	Rs.	4,000.00
3.	Chemist	1 No.	Rs.	3,000.00
4.	Skilled worker	2 No.	Rs.	4,000.00
5.	Unskilled workers	6 No.	Rs.	9,000.00
6.	Accountant	1 No.	Rs.	3,500.00
7.	Clerk/typist	1 No.	Rs.	2,000.00
8.	Store Assistant	1 No.	Rs.	2,500.00
9.	Electrician	1 No.	Rs.	2,000.00
10.	Peon /chowkidar	1 No.	Rs.	1,500.00
	TOTAL		Rs.	37,500.00
	Plus perks @ 10% p.a.		Rs.	3,750.00
	TOTAL		Rs.	41,250.00

UTILITIES AND OVERHEADS

1.	Power Consumption of 5000 Kwatt hrs @ Rs. 3 per Kwatt hr.	Rs.	15,000.00
2.	Water Consumption of 100 KLs @ Rs. 2.00 per KL	Rs.	200.00
3.	Office Expense	Rs.	5000.00
4.	Conveyance	Rs.	5000.00
	TOTAL	Rs.	25,200.00
	Total load is 28 Kwatts

TOTAL WORKING CAPITAL/MONTH

1.	RAW MATERIAL	Rs.	9,18,750.00
2.	SALARY & WAGES	Rs.	41,250.00
3.	UTILITIES & OVERHEADS	Rs.	25,200.00
	TOTAL	Rs.	9,85,200.00

1.	WORKING CAPITAL FOR 3 MONTHS	Rs.	29,55,600.00
2.	MARGIN MONEY FOR W/C LOAN	Rs.	7,38,900.00

COST OF PROJECT

	TOTAL FIXED CAPITAL	Rs.	11,45,000.00
	MARGIN MONEY	Rs.	7,38,900.00
	TOTAL	Rs.	18,83,900.00

TOTAL CAPITAL INVESTMENT

	TOTAL FIXED CAPITAL	Rs.	11,45,000.00
	TOTAL WORKING CAPITAL FOR 3 MONTHS	Rs.	29,55,600.00
	TOTAL	Rs.	41,00,600.00

COST OF PRODUCTION/ANNUM

1.	Working Capital for 1 year	Rs.	1,18,22,400.00
2.	Interest @ 15% on T.C.I	Rs.	6,15,090.00
3.	Depreciation @ 6.50% on buildings	Rs.	17,875.00
4.	Depreciation @ 25.00% on Plant and Machinery	Rs.	1,55,000.00
5.	Depreciation @ 20.00% on office equipment & furnitures	Rs.	6,000.00
	TOTAL	Rs.	1,26,16,365.00

TURN OVER/ANNUM

By sale of 150 MT Silicon Emulsion @ Rs.100/- per kg		=		Rs.	1,50,00,000.00
PROFIT		=		Rs	23,83,635.00
RATE OF RETURN		=			58.12 %
B.E.P.		=			31.82%

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