What is a zinc oxide by chemical process project report?
A zinc oxide by chemical process project report is a detailed project report (DPR) for a plant that makes zinc oxide from zinc ash or dross. The zinc is leached in sulphuric acid, purified, precipitated as basic zinc carbonate and calcined. The report sets out machinery, raw materials, project cost, finance, projections, DSCR and break-even.
Promoters use it to size the plant and raise a term loan, and banks use it to judge whether the plant can repay.
Also known as: zinc oxide wet process project report, precipitated zinc oxide plant DPR, active zinc oxide project report, zinc oxide manufacturing business plan.
Zinc oxide by chemical process plant cost in India
Our sample project report on zinc oxide by chemical process models a 3.7 MT per day plant, or 1,221 MT per year over 330 working days. It starts at 60% of capacity and reaches 80% in Year 5, selling at ₹2,30,000 per MT before GST.
Plant and machinery is about half the project cost. Reactors, filter presses and the calcination kiln make up most of it. Lining material and kiln size move the total more than any other choice.
| Land and site development | 113.22 |
|---|---|
| Building and civil works | 294.50 |
| Plant and machinery | 629.01 |
| Other fixed assets | 88.63 |
| Contingencies | 46.18 |
| Preliminary and pre-operative | 29.29 |
| Working capital margin | 63.01 |
| Total | 1,263.84 |
| Promoter's contribution (25%) | 315.96 |
|---|---|
| Term loan from bank (75%) | 947.88 |
| Cash credit limit (separate) | 189.03 |
| Total project cost | 1,263.84 |
Term loan at 10.5% with a 6-month moratorium and 54 monthly instalments; lowest DSCR in any year is 1.69. All figures are illustrative.
Zinc oxide by chemical process: manufacturing process
The chemical route turns impure secondary zinc into a clean zinc sulphate solution first, and only then into oxide. Most quality problems in the final powder start in the purification stages, not in the kiln.
- Acid leaching
Zinc ash or dross is fed slowly into dilute sulphuric acid in rubber-lined, agitated reactors. The zinc dissolves as zinc sulphate, and the insoluble residue is filtered off.
- Iron and manganese removal
An oxidising agent converts ferrous iron to the ferric form. Raising the pH to about 4.5 then settles iron and manganese as hydroxides for filtration.
- Zinc dust cementation
Fine zinc dust is stirred in to displace copper, cadmium and lead from solution. These metals decide whether the oxide can be sold as feed or pharma grade.
- Precipitation
Soda ash solution is dosed into the pure zinc sulphate at controlled pH and temperature. Basic zinc carbonate precipitates; the rate of addition sets particle size.
- Filtration and washing
The precipitate is filtered on presses and washed until leftover sodium sulphate falls below the grade limit, because residual sulphate harms rubber curing.
- Drying and calcination
The cake is flash dried and calcined in a rotary kiln, which drives off water and carbon dioxide. A lower temperature keeps the high surface area of active grade.
- Milling and packing
The oxide is pulverised and air classified, tested for zinc oxide content, lead and sieve residue, and packed in lined HDPE bags.
Chemical process vs French and American process
Zinc oxide is made by three main routes. The right one depends on the zinc source you can buy and the grade your buyers want.
| French (indirect) process | Refined zinc metal is boiled and the vapour is burnt in air. It gives a pure, fine white oxide for rubber, paint and ceramics, but needs costly zinc ingot as feed. |
|---|---|
| American (direct) process | Zinc ores or residues are reduced with coal and the zinc vapour is re-oxidised in one furnace. Feed is cheaper, but the oxide carries more impurities. |
| Chemical (wet) process | Zinc ash or dross is dissolved in acid, purified in solution and precipitated. It suits active zinc oxide with a high surface area and low-lead feed and pharma grades. |
| What the wet route costs you | More reactors, filters and an effluent plant per tonne, plus a sodium sulphate stream to handle. In return, purity is set by chemistry you control, not by the grade of zinc you buy. |
Raw materials for zinc oxide by chemical process
Zinc ash and dross from hot-dip galvanisers are the main zinc source, and their zinc content varies from lot to lot. By chemistry, each tonne of zinc oxide needs about 1.2 tonnes of sulphuric acid (as 100% acid) and 1.3 tonnes of soda ash, before process losses.
| Raw material | Share of cost | Year 3 (₹ lakh) |
|---|---|---|
| Zinc ash and zinc dross | 62% | 537.49 |
| Soda ash | 17% | 147.38 |
| Sulphuric acid | 14% | 121.37 |
| Zinc dust and oxidising agents | 7% | 60.68 |
| Total | 100% | 866.92 |
Raw materials are 44.1% of sales in the sample. Buy ash and dross on assayed zinc content, not on gross weight.
Machinery for a zinc oxide chemical plant
Everything that touches acid or wet sulphate liquor must be lined or made of acid-resistant material. The leaching reactors are the largest item in the sample, followed by the rotary kiln.
| Machine | What it does | Sample cost (₹ lakh) |
|---|---|---|
| Rubber-lined leaching reactors | Dissolve zinc ash and dross in acid | 113.23 |
| Purification tanks with agitators | Remove iron, manganese, copper and cadmium | 69.19 |
| Filter presses | Separate residue, purification cake and precipitate | 88.06 |
| Precipitation reactors | Form basic zinc carbonate with soda ash | 62.90 |
| Washing tanks and centrifuge | Wash out sodium sulphate | 50.32 |
| Flash dryer | Dries the washed cake | 62.90 |
| Rotary calcination kiln | Converts carbonate to oxide | 100.64 |
| Pulveriser with air classifier | Grinds to the fineness buyers specify | 50.32 |
| Fume scrubber and effluent plant | Captures acid mist and treats liquor | 31.45 |
| Total plant and machinery | 629.01 | |
Costs are the sample report's estimates for a 3.7 MT per day plant. Get current quotations before you finalise.
Manpower for a 3.7 MT per day zinc oxide plant
A wet-process plant runs round the clock in shifts, because leaching and precipitation batches cannot stop halfway. The sample plant employs 46 people, including a chemist for in-process tests.
| Category | Number | Monthly wage (₹) | Year 1 (₹ lakh) |
|---|---|---|---|
| Management, supervision and administration | 7 | 32,500 | 27.30 |
| Skilled workers and operators | 16 | 20,500 | 39.36 |
| Semi-skilled and unskilled workers | 23 | 13,500 | 37.26 |
| Total | 46 | 103.92 |
Power and fuel, mostly for the dryer and kiln, come to 6.4% of sales in the sample.
Licences and approvals for a zinc oxide plant
The approvals that take longest are the pollution consent and the hazardous waste registration, so start them alongside land purchase.
| Business registration | Udyam (MSME) registration and GST registration |
|---|---|
| Pollution board consent | Consent to establish and to operate from the State Pollution Control Board. States set the category; Punjab's Red list, for example, covers basic chemicals and their derivatives, so plan for Red-category conditions until your board confirms |
| Hazardous waste registration | Registration with the pollution control board to recycle zinc ash, dross and skimmings under the Hazardous and Other Wastes Rules. CPCB and state boards publish lists of registered recyclers |
| Product standard | IS 3399:2013, zinc oxide for the rubber industry. BIS lists it under voluntary certification as of October 2026 |
| Acid storage | Compliance with the Manufacture, Storage and Import of Hazardous Chemical Rules for sulphuric acid tanks, where the quantity thresholds apply |
| Factory and fire | Factory licence under the Factories Act and a fire NOC; rules vary by state |
Market for chemically made zinc oxide
Rubber and tyre makers are the largest buyers of zinc oxide in India, because it activates sulphur vulcanisation. A wet-process plant earns more on grades the French process does not suit well. These are active zinc oxide, which lets rubber compounders use less oxide, and low-lead grades for feed and pharma.
Most buyers approve a new supplier only after trial lots pass their own tests, so plan for several months of sample supplies before regular orders begin.
- Tyre and rubber goods manufacturers
- Ceramic tile, glaze, frit and ferrite makers
- Animal feed premix and micronutrient fertiliser companies
- Paint and coating manufacturers
- Pharmaceutical and cosmetic formulators
- Chemical traders and exporters
Where a new plant wins: a site close to galvanising clusters buys ash and dross with less freight and can test each lot before it is unloaded. That control over feed quality matters more than plant size.
Mistakes that weaken a zinc oxide project report
- Costing zinc ash by weight, not zinc content
Ash and dross vary widely in zinc. A report that assumes one fixed content overstates output from a poor lot and understates raw material cost.
- Leaving out the sodium sulphate stream
Each tonne of zinc oxide made with soda ash leaves about 1.7 tonnes of sodium sulphate in the filtrate. Its treatment or sale must be costed.
- Pricing every tonne as premium grade
Feed and pharma grades need tight lead and cadmium limits. Some lots will only pass as rubber or ceramic grade, at a lower price.
- No plan for leach residue
The insoluble residue from leaching holds lead and other metals. Its disposal through an authorised facility is a running cost, not a one-time item.
- Undersized filtration and washing
Filter presses set the real output of a wet plant. Too few presses leave sulphate in the product and cut daily tonnage.
How NPCS helps you set up a zinc oxide plant
- Grade and capacity planChoose between active, rubber, feed and pharma grades and size the plant to your zinc ash supply.
- Process and machineryLeaching, purification and calcination design, with lined equipment and kiln quotations.
- Bank-ready project reportProjections, DSCR and working capital, including effluent and residue costs, in your lender's format.
- Approvals and layoutPlant layout, pollution consent, hazardous waste registration and acid storage for your state.
NPCS's client list shows 269 assignments in specialty chemicals, and the NPCS project team has prepared reports for chemical plants since 1994.
What's inside the zinc oxide by chemical process sample report
- Introduction
- Uses and applications
- Market potential
- Manufacturing process
- Raw materials
- Plant and machinery
- Land, building and utilities
- Manpower
- Licences and approvals
- Project cost and means of finance
- Working capital
- Projected profitability
- Cash flow statement
- Projected balance sheet
- Depreciation
- Term loan repayment
- Debt service coverage
- Break-even analysis
- Financial ratios
- Key assumptions
- Conclusion
- Monthly loan repayment schedule
19 pages, five-year projections, illustrative figures.
Open sample reportFree sample or a report for your project?
| What you get | Free sample | NPCS report for your project |
|---|---|---|
| Capacity and location | Typical unit | Your capacity, site and state |
| Figures | Illustrative | Built on current prices and quotations |
| Machinery suppliers and quotations | No | Yes |
| Market survey for your region | No | Yes |
| Bank or scheme format (PMEGP, term loan) | No | Yes |
| Use for a loan application | No | Yes |
Real NPCS zinc oxide by chemical process project reports
These are zinc oxide by chemical process project reports NPCS has prepared, with the plant capacity, total capital investment, rate of return and break-even worked out in each. Costs have moved since some were written, so we bring any of them up to date for your capacity and location.
| Project report | Plant capacity | Total investment | Rate of return | Break-even | Action |
|---|---|---|---|---|---|
| Zinc Oxide (by Chemical Process) | 1500 MT/Annum | ₹2.42 crore | 54.9% | 31.3% | Get this report |
Figures as worked out in each NPCS report. Total investment includes plant and machinery, land and building, and working capital.
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Zinc Oxide by Chemical Process project report: frequently asked questions
How much does a zinc oxide by chemical process plant cost in India?
A 1–2 MT per day plant needs roughly ₹5–8 crore and a 5–8 MT per day plant about ₹15–25 crore, including land, building and working capital margin. Our sample report models a 3.7 MT per day plant at ₹1,263.84 lakh. These ranges are indicative; your report works out the cost for your capacity, grade and site.
What raw materials are used to make zinc oxide by the chemical process?
Zinc ash or zinc dross from galvanising plants is the zinc source, dissolved in sulphuric acid. Soda ash precipitates the zinc, and zinc dust with an oxidising agent purifies the solution. In our sample report zinc ash and dross make up 62% of raw material cost, soda ash 17% and sulphuric acid 14%.
How is the chemical process different from the French process?
The French process boils refined zinc metal and burns the vapour in air, giving a pure, fine oxide used widely in rubber and paint. The chemical process works in solution from cheaper secondary zinc. It needs more purification and handles effluent, but it can make active zinc oxide with a high surface area and low-lead grades.
Is zinc oxide manufacturing by chemical process profitable?
In our illustrative sample, a 3.7 MT per day plant earns a 24% return on investment in Year 3. It breaks even at about 35% of capacity and pays back in about 3.3 years. Real profit depends on the zinc content you pay for in ash and dross, recovery in leaching, the grade mix you sell and effluent cost.
Which licences does a zinc oxide plant need?
Expect Udyam and GST registration, consent to establish and operate from the State Pollution Control Board, a factory licence and fire NOC. Using zinc ash or dross needs registration as a recycler under the Hazardous and Other Wastes Rules. IS 3399 is the BIS standard for rubber-grade zinc oxide and is voluntary as of October 2026.
Is the sample report free and can I use it for a bank loan?
The sample is free to view and download as a PDF. It shows the format and depth of an NPCS report. Its figures are illustrative and not from a real project, so do not submit it to a bank. For a loan, NPCS prepares a report for your own capacity, grade, location and lender.
Sources and references
- IS 3399:2013 Zinc oxide for rubber industry, specification (third revision)Bureau of Indian Standards, checked Oct 2026
- List of industries registered for environmentally sound recycling of zinc ash, dross and skimmingsCentral Pollution Control Board (hosted by Punjab Pollution Control Board), checked Oct 2026
- List of non-ferrous metal reprocessorsMaharashtra Pollution Control Board, checked Oct 2026
- List of Red category industriesPunjab Pollution Control Board, checked Oct 2026
The NPCS project team, led by Ajay Kumar Gupta
This page and its sample report are prepared and reviewed by the NPCS project team, which has written techno-economic feasibility studies and detailed project reports since 1994.
Ajay Kumar Gupta founded Niir Project Consultancy Services (NPCS) and leads the organisation. With 40 years of experience in MSME project consulting, he has built the team that has delivered more than 28,000 project reports for clients worldwide, helping entrepreneurs plan and finance profitable manufacturing businesses.
- Published
- Last updated
- Next review
- Oct 2027
- Reviewed by
- NPCS project team
This page is reviewed every 12 months, or sooner when scheme limits, GST rates, BIS rules or pollution categories change. The sample report is illustrative: its figures are generated from industry-typical ratios for a unit of this size, checked so every statement balances, and are not taken from any client project.