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NPCS Newsletter -June 2011

 

Project Profiles of below projects can be viewed/ downloaded fromhttp://niir.org/profiles/

 

NPK FERTILIZERS

 

The Indian Fertilizer Industry is one of the allied sectors of the agricultural sphere. India has emerged as the third largest producer of nitrogenous fertilizers. The adoption of back to back Five Year plans has paved the way for self sufficiency in the production of food grains. In fact production has gone up to an extent that there is scope for the export of food grains. This surplus has been facilitated by the use of chemical fertilizers. Though the soil in India is rich in silt, it lacks chief plant nutrients like potassium, nitrogen and phosphate. The increase in the production of fertilizers and its consumption acts as a major contributor to overall agricultural development.NPK mixture fertilizers are formulated & recommended by agricultural scientists to enhance the output of the crops by giving it specific and exclusive blend of plant nutrients. All the major plant nutrients like Nitrogen, Phosphorus and Potash are mixed in different ratios to make it suitable for specific crops. These specific ratios of N P & K are called grades. The numbers in the grade’s name represents the percentage of N, P₂O₅ & K₂O respectively in the mixture. NPK fertilizer plants are used for production of complex with different concentrations and types, such as inorganic fertilizers and biological fertilizers……………………………….

 

 

PVC COMPOUNDS FROM PVC RESINS

 

Polymers have found uses in all spheres of life with demand for better materials, greater functional utility, more economical packaging and versatile and durable all-weather products. PVC is a chlorinated hydrocarbon andis a thermoplastic material. Thermoplastic materials are those that can be melted again and again. These materials can be heated to a certain temperature and will harden again as they cool. Its long life excellent resistance to chemicals, its self extinguishing resistance to chemicals, its self extinguishing and electrical properties and availability in a wide range of colours give it an edge over other plastic materials…………………

 

 

 

RE-REFINING OF ENGINE OIL, TRANSFORMER OIL & HYDRAULIC OIL

 

Engine oil, Transformer oil and hydraulic oil all are special grade petroleum oils, which had different specific gravity and viscosity. When these special grade oils are used, 60% of the oil is used in the engine, transformer and hydraulic oil and rest 40% of the oil is unused which can be further reused by purification. Mainly oil is contaminated by carbon, which can be separated by filtration and by thin film distillation technique. Thin film distillation technique is special type of distillation system, which is now largely used for making reclaimed engine oil, transformer oil and hydraulic oil……………………….

 

PRECIPITATED SILICA FROM RICE HUSK ASH

 

Rice husk is an agricultural residue easily available in rice producing countries. India is a major rice producing country, and the husk generated during milling is mostly used as a fuel in the boilers for processing paddy, producing energy through direct combustion & or by gasification. The rice husk contains about 75% organic volatile matter & the balance 25% of the weight of this husk is converted into ash during the firing process, is known as rice husk ash (RHA). This RHA in tern contains around 85%–92% amorphous silica. About more than 20 million tons of RHA are produced annually in India. Generally rice husk is not used as cattle feed since its cellulose & other sugar contents are low. So the RHA produced is a great environment threat causing damage to the land & the surrounding area in which it is dumped. Lots of ways are being through off for disposing them by making commercial use of this RHA…………………………

 

 

SPICE (100% EOU)

Spices constitute an important group of agricultural commodities which are virtually indispensable in the culinary art. Spices are natural products widely accepted by consumers. Spices are most important constituents of Indian food and cuisines, and are used not only for household purpose, but also in hotels, restaurants, eateries and food processing industries………………………………………………….

 

ROLLER FLOUR MILL (ATTA, MAIDA & SUZI)

 

Flourmill consists of following machineries as blender, sieves, breaks rolls, smooth steel reduction, rolls aspirators, conveyors water washers etc. The RFM industry is basically agro-based processing industry engaged in the manufacture of products based on wheat, namely maida, sooji, atta and bran. In some states, under special arrangements RFM units produce whole meal atta to meet the requirements of various distribution programmes. Apart from direct consumption by general consumers, maida and sooji produced by RFM units serve as the most important raw material to more than 55 thousand units manufacturing bread, biscuit and bakery products all over the country. Besides this the resultant wheat bran serves as the poultry feed……………………………………

 

 

POTATO FLAKES

 

India is one of the leading potatoes producing country. Potatoes produced in states are suitable for value added processing like manufacturing of potato flakes and powder. Potato powder/flakes have wide application in the processed and snack food industries, it can be used in any recipe which requires mashed potatoes. Potato flakes/powder is used in bread, pancake and waffle recipes or as a thickener for smoother sauces, gravies and soups. Also used in fabricated potato chips, extruded snacks, snack pellets, battered breaded products etc. It is also used in gluten-free and allergy cooking. Potato flakes/powder is increasingly being used in a variety of food preparations like snack foods (mc Donald, Pringle, Haldiram Namkeens etc.), soups, ready to eat vegetable curries and other dishes as a thickening agent and stir fries. It has strong potato flavor. It can be a binding material for preparing kheer, tikki, chops, pakoda, cutlets, stuffed paratha, kofta and other products. Its use at present is mainly in hotels, restaurants, but acceptance in household is growing due to its inclusion in items like ready to cook soups, dal, curries, etc. It gives added flavors to curries. It can be used in gulab jamun, puri and paratha……………………………….

 

TOILET SOAP

 

Toilet soaps account for the largest single share of about 13% in the estimated Rs 530 bn FMCG market. The toilet soaps market is estimated at over 650,000 tpa, which includes some imports. The toilet soaps market is getting saturated at a high penetration level of 98% and is growing at a very modest rate of over 5% since 2000-01. The toilet soap, once only an urban phenomenon, has now penetrated practically all areas including remote rural areas. The incremental demand flows from population increase and rise in usage norm stimulated as it is by a greater concern for hygiene. Increased sales revenues would also expand from upgradation of quality or per unit value…………………………………………

 

HARD BOILED CANDY

 

The organized sector of the Indian confectionery market is estimated to be about Rs 1400 crore and it is estimated that the market is growing at a pace of 9 per cent per annum. The confectionery industry in India is the largest among the food processing industries. It has an annual turnover of around Rs 3,500 crores with huge potential to grow (Including the organized and the non-organized sector). There are four categories of confectionery in the organized sector - chocolate confectionery, sugar confectionery, gum and cereal bars. A large part of the confectionery industry in India comprise of the local subsidiaries of global confectionery majors like Perfetti, Lotte, Wrigley's and Cadbury. Korean confectionery company Lotte India……………

 

BIO PLASTIC PRODUCTS

 

Plastics have become an important part of modern life and are used in different sectors of applications like packaging, building materials, consumer products and much more. Plastic packaging is proving to be a major environmental problem. Most of today's plastics and synthetic polymers are produced from petrochemicals. As conventional plastics are persistent in the environment, improperly disposed plastic materials are a significant source of environmental pollution, potentially harming life. The plastic sheets or bags do not allow water and air to go into earth which causes reduction in fertility status of soil, preventing degradation of other normal substances, depletion of underground water source and danger to animal life. In the seas too, plastic rubbish - from ropes and nets to the plastic bands from beer packs -choke and entangle the marine mammals……………………………………..

 

CARBON BLACK FROM WASTE TYERS

(WASTE TYRE PYROLYSIS)

 

Pyrolysis has several advantages over other alternative tyre recycling methods. No toxic substances are emitted, and various commercial applications for all of the products obtained are possible. Carbon Black is the main product recycled by Pyrolysis technology. The amount of recycled carbon black is 30% to 35% (depending on the type of tyres) of the total amount of scrap tyres recycled in the system………………..

 

PAPER FROM WASTE PAPER

 

Paper is one of the most usable consumer items which has largely used throughout the world. It is generally prepared from cellulosic material by treating it with different type of chemicals and then process through roller and driers to make a suitable quality paper. The quality of paper depends upon the end use of the paper. As the demand for paper has increased, more timber has been needed to meet the demand for wood pulp. By using waste paper to produce new paper the demand can be met to some extent.Waste paper is an important raw material for paper and paper board manufacturing. Consumption of waste paper in India is very low compared to advanced countries. This is mainly due to lack of organized collection. However it is estimated that 25% of all paper consumed in India is now recycled……………..

 

AAC BLOCKS (AUTOCLAVED AERATED CONCRETE BLOCKS) FLY ASH BASED

 

Autoclaved Aerated Concrete (AAC) is a non-combustible, lime-based, cementitious building material that is expanding into new worldwide markets. As a single-component building material, AAC has achieved acceptance in new markets throughout the world……………….

 

BUTT WELDED CARBON STEEL FITTING AND STEEL FLANGES

 

Butt welded steel pipe fittings are extensively used in a piping system to change direction or function which is mechanically used to the system. The main types of fittings are, various types of elbows, bends, reducers, cross and cap etc.

A pipe fitting is defined as a part used in a piping system to change direction or function, which is mechanically joined to the system. Butt joints in pipe work are normally welded by the metal arc process, but argon-arc and semi-automatic methods are used when appropriate.  Pipe flanges are used as couplings to join lengths of pipe. Traditionally there have been two main types of flanges. Butt-weld i.e. weld neck for very high pressure and slip-on flanges for the medium and low pressure. However in the past few years more companies are using the slip-on variety of flanges. Even for very high pressures.  The reason for this is the high and consistent quality of steel plate, and also the cost……………………………….. 

 

 

FLY ASH BRICKS FROM LIMESTONE

 

Fly Ash bricks are alternative to burnt clay bricks in the construction sector in India. Fly ash bricks are an environment friendly cost saving building product. These fly ash bricks are three times stronger than conventional bricks with consistent strength. This is proving to be a revolutionary invention that produces bricks without the sintering process and consequently no greenhouse gases are emitted. The ultimate product is none other than FaL – G Brick which is well qualified as emission-abating project to receive the benefits of carbon credits.India produces about 70 million tons of coal ash per year from burning about 200 million tons of coal per year for electric power generation. Coal-ash management poses a serious environmental problem for India and requires a mission-mode approach. Currently, about one acre per MW of land is needed for ash disposal. The Ministry of Power, Govt. of India estimates 1800 million tons of coal use every year and 600 million tons of fly ash generated by 2031-2032. The country consumes about 180 billion tonnes bricks, exhausting approximately 340 billion tonnes of clay every year and about 5000 acres of top soil land is made unfertile for a long period. The Government is seriously concerned over soil erosion for production of massive quantities of bricks, in the background of enormous housing needs…………………………………………

 

PAINT INDUSTRY

 

The paint industry worldwide is classified into two segments viz. decorative and industrial segment in India constitutes nearly 70% of the market whereas the scenario is just the reverse in the developed countries. In India, the market for industrial paints (30% of the overall market) is growing faster than that for decorative paints. The paints majors were switching over to industrial paints sensing better prospects of the segment. The industrial paints are produced principally by the organized sector as this segment is relatively more technology driven.Decorative Segment is dominated by the unorganized sector which now accounts for 70% of the total paint production as against 75% three to four years ago. The unorganized sector has an advantage over the organized sector since it is fully exempted from the 20% excise duty and other government levies. The major players in the decorative segment are Asian Paints, Kansai Nerolac (earlier Goodlass Nerolac), Berger Paints, ICI, Jenson & Nicholson, Shalimar Paints and Garware Paints. Each company has its relative strength in one or the other types of paints: Asian Paints has the widest range; Kansai Nerolac is strong in distempers; Berger Paints and ICI focus on emulsions; and Jenson & Nicholson in enamel paints. Kansai Nerolac has a higher proportion of industrial paints while others generally have a high proportion of decorative paints. Most of these major players, however, also produce other types of paints in which they are not dominant…………..

 

 

 

 

GOOD PROSPECTS IN WASTE TYRE PYROLYSIS

With the phenomenal increase in number of automobiles in India during recent years the demand of tyres as original equipment and as replacement has also increased. As every new tyre produced is destined to go to waste stream for disposal or recycling or reclamation, despite its passage through retreading process, the number of used tyres being discarded is going to increase significantly. However, as the waste tire can be comprehensive utilization, most of them are become the industry waste. This phenomena is not only a kind of wasting massive available resources, but also caused the black pollution. Therefore, it influenced our life quality seriously, and became a big problem on the environmental protection. The developed countries take the waste tire regeneration seriously and all passed the Legislation and established corresponding organization to give fiscal subsidy or provide the tax-free preferential benefit, and so on in order to give fully support to the regeneration of the waste tire. Nowadays, with highly development of the rubber industry and automobile industry in our country, the enormous waste tire, scraped rubber production and its waste corner material increased rapidly. Since the rubber is not easy to purify, also with the increase of the waste rubber production, it has been the big barrier for the environment protection and intensified year by year. At present, the discarded tires, waste rubber are rich in resources all over the country……………………………………………………………..

 

CHLORINATED PARAFFIN WAX

The term chlorinated paraffins is usually taken to encompass a wide range of liquids and solids from C₁₀ to >C₂₄ and containing 30-72% chlorine content. It is aColourless to amber or yellow viscous liquid. Properties (including ecotoxicology) differ significantly across this range and for this reason, they are best considered in three separate groups…………………….

 

FORMIC ACID

 

Formic acid is a clear, colourless, mobile liquid with a pungent odour. It is highly corrosive and a moderate fire hazard. Formic acid is mainly used in pharmaceutical, pesticide, leather, textile, rubber, steel, paper, food industry etc. Most applications require concentrations of 85% (the industry standard is most common), 90%, 94% or 98-99%, which accounts for 28% of world demand.

The largest use, accounting for about 19% of global demand, is as a silage additive in Europe, while almost 15% of global demand is as a preservative in animal feed. Formic acid is used in various stages of leather and textile processing and in natural rubber manufacturing. Formic acid products are widely used in biomaterial preservation and as antibiotics replacers in industrial animal feed…………………..

 

Ethylene Propylene Diene Monomer (EPDM)

 

Ethylene Propylene Diene Monomer (M-Class) rubber or Ethylene-propylenerubbers & elastomers (also called EPDM and EPM) continue to be one of the most widely used and fastest growing synthetic rubbers having both specialty and general-purpose applications. The E refers to Ethylene, P to Propylene, D to diene and M refers to its classification in ASTM standard D-1418. The “M” class includes rubbers having a saturated chain of the polymethylene type. The diene(s) currently used in the manufacture of EPDM rubbers are DCPD (dicyclopentadiene), ENB (ethylidene norbornene) and VNB (vinyl norbornene).

The ethylene content is around 45% to 75%. The higher the ethylene content the higher the loading possibilities of the polymer, better mixing and extrusion. Peroxide curing these polymers gives a higher crosslink density compared with their amorphous counterpart. The amorphous polymers are also excellent in processing. This is very much influenced by their molecular structure. The dienes, typically comprising between 2.5 wt% up to 12 wt% of the composition serve as crosslinks when curing with sulphur and resin, with peroxide cures the diene (or third monomer) functions as a coagent, which provide resistance to unwanted tackiness, creep or flow during end use.Ethylene-propylene rubbers are valuable for their excellent resistance to heat, oxidation, ozone and weather aging due to their stable, saturated polymer backbone structure. Properly pigmented black and non-black compounds are color stable. Versatility in polymer design and performance has resulted in broad usage in automotive weather-stripping and seals, glass-run channel, radiator, garden and appliance hose, tubing, belts, electrical insulation, roofing membrane, rubber mechanical goods, plastic impact modification, thermoplastic vulcanizates and motor oil additive applications…………………………..

CHLORINATED POLYETHYLENE

 

Chlorinated polyethylene (CPE) is one kind of high molecule elastic material developed in late years, which is one of the random chloride produced through reaction of polyethylene and chlorine. It is an odorless nontoxic and white or pale yellow powder  having a chemical formula (-CH2-CHCl-)n  CPE has good aging resistance and stability, perfect weather ability and can have long service life under bad weather conditions, bending and cracked deformation resistance, chemical resistance and organic Solvent resistance, excellent low-temperature resistance and electrical specifications, and superior high filling property, the physical property cannot be changed after adding A lot of filling agent into CPE.

 

CPE is mainly used as impact modifier for PVC or compounded with LDPE or HDPE film to improve toughness.  Its films are used as pond liners and for agricultural applications. It is also used for rubber processing industry. It can be solely or cross-blended with other materials to Produce plastic profile shapes, waterproof winding materials, anti-flaming conveyer belts, wire and Cable covers, color bike tires and magnetic adhesive strips of refrigerator. It is a kind of Perfect modifier for hard plastic products and plasticizer of Soft plastic products………………………..

CELLULOSE ACETATE

 

Cellulose acetate is a man-made substance that is derived from the naturally occurring organic compound - cellulose. Cellulose is the main structural ingredient of plants, and is usually considered to be the most common organic compound on earth. Cellulose acetate fibres are used for textiles and clothing. Cellulose acetate is also used in filtering and other applications like magnetic computer tape, wound dressings, personal hygiene products, absorbent cloths and wipes, as specialty papers, as filter media, including cigarette filters etc. Such materials are often referred to as “tow”. Cellulose acetate film is also used in photography. Cellulose acetate polymers have some good properties like good toughness, deep gloss, and high transparency with a feel that can be described as “natural”.

Commercially, cellulose acetate is made from processed wood pulp. The pulp is processed using acetic anhydride to form acetate flake from which products are made. Coming from wood pulp, means that unlike most man-made fibres, it comes from a renewable resource and is biodegradable. Another technique for producing cellulose acetate involved treating cotton with acetic acid, using sulfuric acid as a catalyst. Cellulose acetate is available in the form of flake, powder, granules of fibre and the flakes, which are non hazardous…………………………………..

CITRIC ACID

 

Citric acid or 2-hydroxy-1, 2, 3-propanetricarboxylic acid, HO2 CCH2 C (OH) (CO2 H) CH2 CO2 H, is a weak organic carboxylic acid. Citric acid is a white crystalline powder. It can exist either in an anhydrous (water-free) form or as a monohydrate. The anhydrous form crystallizes from hot water, whereas the monohydrate forms when citric acid is crystallized from cold water. The monohydrate can be converted to the anhydrous form by heating above 78°C. Citric acid also dissolves in absolute (anhydrous) ethanol (76 parts of citric acid per 100 parts of ethanol) at 15°C.

Citric acid exists in greater than trace amounts in a variety of fruits and vegetables, most notably citrus fruits. Citric acid is found in many citrus fruits: pineapples, gooseberries, limes, plums, lemons, peaches, oranges, and grapefruit. Lemons and limes have particularly high concentrations of the acid; it can constitute as much as 8% of the dry weight of these fruits (about 47 g/L in the juices).…………….

 

POTASSIUM PERMANGANATE

 

Potassium permanganate is an inorganic chemical compound with the formula KMnO4. It is a strong oxidizing agent. As an oxidant, potassium permanganate can act as an antiseptic in water treatment. A primary use of permanganate is iron and manganese removal. The other major application of KMnO4 is as a reagent for the synthesis of organic compounds like ascorbic acid, chloramphenicol, saccharin, isonicotinic acid, and pyrazinoic acid. It is also used in fruit ripening process.

The Indian demand for potassium permanganate is around 8300 metric tonnes per annum. The global production of potassium permanganate is around 0.2 million tonnes per annum. Municipal consumption for drinking and wastewater treatment remains the primary use for potassium permanganate and accounts for about three quarters of current U.S. demand. The growth rate in demand for potassium permanganate is around 2% per annum…………………………………

 

 

Project Profiles of above projects can be viewed/ downloaded from http://niir.org/profiles/

 

 

Market Survey Cum Detailed Techno Economic Feasibility Report on above projects can be had from NPCS

Regards,

Manager
NIIR PROJECT CONSULTANCY SERVICES
AN ISO 9001 : 2008 CERTIFIED COMPANY
106-E, Kamla Nagar, Delhi – 110 007 (India)
Tel: 91-11-23843955, 23845886, 23845654, +918800733955
Fax: 91-11-23841561
E-mail: [email protected]; [email protected]  
Website: www.niir.org

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