manufacturing of unsaturated polymer resins
TRANSCRIPT
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SMB ENVIRONMENTAL PROJECTS PVT LTD ABSOLUTE TECHNOLOGIES
TECHNOLOGIES
Technical Know-how - A Gateway to Prosperity
A PROJECT REPORT
ON
UNSATURATED POLESTER RES!N
AT DA"AN
Prepared By
S.A. AZAD ( Alia B!r"aa# $ B.S%. Te%" ( C"e& Te%" $ ' DNIIT' DGM' DM'CEO ) SMB E#*ir+#&e#,al Pr+-e%, P*, L,d
E. Sr. Ma#a/er 0 HPCL ( Pr+-e%, Pla##i#/$
+r
Mr M. Meera Sahib,
QLIFFE TECHNOLOGY SERVICES PVT.LTD, B602, MANIKA APARTMENT,
MAHAKALI CAVES ROAD, ANDHERI EAST, Mumba ! "000#$,MH, I%&aM'b()*!+#!#-20- "6/, [email protected]
Da,e ) Sep,e&1er 23' 2456REG7D OICE) 8 RESIDENC9 ROAD' OPP ASHO:A RESTAURANT' SADAR' NAGPUR 0 664 445
Email : [email protected] , Mobile: +9198!24!852
5
mailto:[email protected]:[email protected]:[email protected]:[email protected]
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SMB ENVIRONMENTAL PROJECTS PVT LTD ABSOLUTE TECHNOLOGIES
A PROJECT REPORT
ON
UNSATURATED POLESTER RES!N
AT DA"AN
S.No. CONTENTS Page No.
1. INTRODUCTION 3
2. MARKET POTENTIAL 6
3. QUALITY STANDARDS 12
4. BASIS & ASSUMPTIONS 15
5. PRODUCTION & TECHNICAL ASPECTS 21
6. PROJECT FACILITIES 45
7. COST ESTIMATES
& OPERATTIN E!P. 5"
". F#$%$#$' P()*)+%,+ & I$-$#/-+ 66
0. CASH FLO FINANCIAL ANALYSIS 60
1. THE FACTORY ACT 7611. INDUSTRIAL ESTABLISHMENT ACT 77
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………………….. Page No 52 is the last page ……………
1.0 INTRODCTION
1.1 !"C#$ROND %
U$+%(%- *),-+-( (-+#$+ %(- - 8)+ )88)$, +- -(8)+- (-+#$+
#$ - 9)(,. M)(- %$ 2 8#,,#)$ )$$-+ ): $+%(%- *),-+-( (-+#$+ %(-
#,#;- ',)
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D%8%$ # #+ % '()9#$' )9$ %$ % *()8#+#$' $#)$ -((#)(. I #+
+(()$-
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1. "DN"T"$ES O' SE(ECTED (OC"TION %
T- *()*)+- *,%$ 9), )8- * )$ % N A #$+(#%, *,) ): % ,-%+
25 + : *,) ): ,%$ )9$- ,-%+-
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Mar4et pote)tial -o)ti)es….
2.0 M"R#ET POTENTI"(
2.1 LOBAL SCENARIOG
U$+%(%- *),-+-( (-+#$+ %(- - 8)+ )88)$, +- -(8)+- (-+#$+
#$ - 9)(,. M)(- %$ 2 8#,,#)$ )$$-+ ): $+%(%- *),-+-( (-+#$+ %(-
#,#;- ',)
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(-+#$+.
(ii Resi) Pa-4e i) Dr+s
T- ',)
+-( S-'8-$+G ,)
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F)(-%+= 213 > 210, - ',)20
(--++#)$ #$:,-$- - -/-,)*8-$ ): ',)
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I$ - $-%( :(-= %+ $-9 %**,#%#)$+ %$ -8%$ #+ '()9#$'= $+%(%-
*),-+-( (-+#$ #+ -*-- -(- 9#,,
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-(- %(- %**()#8%-, 3>4 8%#$ *()#)$ *,%$+= %$ - )%,
*()#/# #+ %**()#8%-, 1=154= )$+-%( #$,#$' A8-(#%
001= )$+-%(= C%$%% %**()#8%-, 01= )$+-%(= %$ M-#)
%**()#8%-, 72= )$+-%(. T- $+%(%- *),-+-( (-+#$
8%$:%(-(+ #$ -+-($ E()*- %(- (-,%#/-, +%-(-= - :%)(#-+ %(-
8%$= %$ - (-,%#/-,
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%8)$ ) 2="= )$+= 9# %$$%, %/-(%'- (%- ): #$(-%+-
%**()#8%-, 5. T- -/-,)*8-$ *(#)(# ): $+%(%- *),-+-( (-+#$
#$ - US= -+-($ E()*- %$ J%*%$ #+ 8%#$, (-+#$ 8)#:#%#)$ %$
-*%$+#)$= %$ #$ - :(-= - %**,#%#)$ :#-,+ ): $+%(%- *),-+-(
(-+#$ 9#,,
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8%(?- #+ -*-- ) (-% 445 8#,,#)$ *)$+ R+. 55 ()(-+
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UPR 677 H%; 6 1.11 15 36 2 45 "3 14 75 12
.2 "PP(IC"TIONS%
T- (-+#$+ )$:)(8#$' ) %
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')) 8-%$#%, *()*-(#-+= %$ #+ :%+ (#$'. I #+ +#%*=
RTM= %$ )-( 8),#$' -$#-+ %$ %$
%-,-(%-= #)()*#= )( ,)9 /#+)+# (-+#$
Mei+ Rea-ti*e Sperior Resi)
T#+ #+ % 8-#8 (-%#/- +*-(#)( '(%- O()*%,# A#
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BROAD SPECIFICATIONS OF SOME IMPORTANT RESINS:
Properties Resin 1 Resin 2
TypeIsophthalic / MP Diol based
brushable Gelcoat
Orthophthalic / MP Diol
brushable based Gelcoat
Appearance Haze thiotropic li!uid Haze thiotropic li!uid
"iscosity at #$%& '&ps( )*+++ , -#*+++ )*+++ , -#*+++
Thiotropic inde .$ , 0$ .$ , 0$
Acid 1alue 'm2 3OH / 2m( 4-$ 4##
Properties Resin 3 Resin 4
Type PET based GP 5esin PET based Putty 5esin
Appearance 6li2ht yello7 haze 6li2ht yello7 haze
"iscosity at #$%& '&ps( $$+ , 0++ $$+ , 0++
Acid 1alue 'm2 3OH / 2m( 4-$ 4-$
6peci8ic 2ra1ity at #$%& --# --#
Gel time at #$%& 'Min( a -$ 9 $ $+ 9 -+
"#M$"%&'()*$ '&-%'(-#":
UNSATURATED POLYESTER RESINS
PRODUCTCODE
DESCRIPTION APPLICATION
ORTOPTALATES
OP1!!1 General Purpose aminatin2 &onstruction*Automoti1e*Electrical*6ports*
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5esin eisure
OP1!!4 &ultured Marble &ultured Marble*Polymer &oncrete
OP1!1! ;ire retardant 5esin &onstruction*Automoti1e*Electrical
OP1!12 5esin Trans8er Mouldin2 Automoti1e*;urniture*6ports*Industrial
OP1!1" Putty 5esin Polyester Putty
OP1!1# 5esin 8or 6M&/DM& Automoti1e*Electrical
OP1O2# ;ilament
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'E2!!1 =o1alac Epoy 1inylester 5esin
&orrosion resistant linin2s*chemical
e!uipment
'E2!!2=o1alac Epoy 1inylester5esin'Hi2h HDT(
'E3!!1>rominated epoy 5esin based;ire 5etardant "inylester 5esin
&orrosion ? ;ire resistant linin2s*chemicale!uipment
SATURATED POLYESTER RESINS
PP1!1$6ol1ent '@ylenol / 6ol1asso-$+(based polyester 5esin
6to1in2 enamel
PP1!!2
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…….!asis 9 "ss+ptio)s -o)ti)es
3.0 !"SIS 9 "SSMPTIONS
3.1 PRO'I(E O' PRODCTION COMP(E< %
T- *()- 9),
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T- 8%)( )*-(%#)$+ #$/),/- #$ - 8%$:%(- ): *),-+-( (-+#$ %(-
-+-(:#%#)$ %$
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T- *()8)-(+ *,%$ ) :#$%$- 25 :()8 -#( )9$ (-+)(-+ ()' -
-# ()-= 9#,- 75 ): - %*#%, )+ +%,,
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C)++ ): RM G P()*,-$- ',), G R+. 11 K'= 8%,-# %$(#- G R+.
1 *-( K'. C%%,+ 8%-(#%, %**. R+. 1 K'.
R-#(-8-$ ): P G 5376 .44 2365 K'+
R-#(-8-$ ): MA G 5376 .56 311 K'+
R-#(-8-$ ): %%,+ 2 = 1 K'+
T- *),8-( #+ #++),/- #$ - +(-$- 8)$)8-( :)( :)(8#$' % ()++
,#$?#$' :#$%, *),8-( *()= 9# #+ #$ - (%#) ): 2 G 1.
T% 8-%$+ #+ 5 TPD UPR= %:-( 8##$' 9# +(-$- 8)$)8-( 9#,,
:)(8 % :#$%, U$+%(%- P),-+-( (-+#$ ): 7.5 TPD *() %/%#,%
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# Purchase o8 land : - month
Preparation o8 Detailed En22 ? Desi2n: # month
. Arran2ement o8 ;inances # month
$ >uildin2 construction : months
0 Arran2ement o8 Po7er : # month
B Procurement o8 Plant ? Machinery: month
C Erection o8 Plant ? Machinery : # month
) Appointment o8 sta88 ? labor : - month
-+ Trial production ?
Trouble shootin2 : - month
3..1 CONCRRENT "ND SE6ENTI"( "CTIITIES %
Out o8 abo1e listed acti1ities* in order to minimize the o1erall implementation time* the
acti1ities can be di1ided and pursued into 8ollo7in2 concurrent and se!uential proect
phases
P,-ses (ro+p o. /on/+rrent -/ti0ities Tot-* Tie
Phase I 5e2istration* land Ac!uisition* Detailed En22
And Arran2ement o8 ;inance # months
Phase II &ompound 7all* >uildin2 &onstruction* Procurement O8 Plants
? Machineries* Arran2in2 o8
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Phase
III
Erection* &ommissionin2* Trial production* 5ecruitment o8
Manpo7er* &ommercial Production ? MarFetin2
=et
months
Thus* the total time re!uired 8or the commencement o8 commercial production:
o8 cotton bales and other related products 7ill be around C months
.. Pro-tio) 9 Te-h)i-al -o)ti)es..
5.0 PRODCTION 9 TEC&NIC"( "SPECTS
5.1 C&EMISTR8%
T- $+%(%- *),-+-( (-+#$+ %(- :)(8- :()8 - (-%#)$ ): % #), %
8),-,- )$%#$#$' +-/-(%, (), '()*+ %$ %$ $+%(%- #*()#
%#. T- (-+,#$' *),-+-( %#$+ %(- #++),/- #$ % (-%#/- +),/-$. T-
%#$+ ()++,#$? ) :)(8 % %(= +()$' (-+#$ 9# #+ +- #$ 8%?#$' -
,,+ ):
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HO@C COH HO 9OH CO9OCCO@9 # H2O
O OC O O O
A$ %$'- #$ *- )( *()*)(#)$ ): (-%%$+ (-+,+ #$ % %$'- #$
*()*-(#-+ ): - *),8-(# *() +) %$ #$:#$#- $8
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2 A$ %# %$(#- + %+ 8%,-# %$(#- #+ 9% ) 9), '- #:
) (-%- 9) 8),-+ ): % *%(#,%( %(*%,# %$(#- #+ -
8)+ )88)$ %$ #+ +- #$ '-$-(%, *(*)+- :)(8,%#)$+ +- #$
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5.2 The +a):a-tri)g pro-ess%
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5.2.1 Ra; Materials%
1. M%,-#%$(#- #+ % 9#- (+%,,#$- +),#= 8.*. 52C>53C
M%,-#%$(#- #+ *(-:-((- ) 8%,-#%# +#$- # #+ 8)(- (-%#/-
%$ '#/- (#+- ) ,-++ 9%-( )$ -+-(#:%#)$.
2. P()*,-$- ',), #+ - *(-:-((- #), 5 L +%#$,-++
+--, ?-,-+ :,, -#**- :)( -%#$'= )),#$'= *(-++(-= /%8 (-:,#$'
%$ #+#,,%#)$. T- 8#(- #+ ))?- % * ) 22 )C :)(
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A:-( ))?#$' - *),8-( #+ )),- %$ #++),/- #$) +(-$-= %
*),8-(#+%22C :)( 1>2 )(+ %$ 9%-( #+
)$#$)+, #+#,,- :()8 - (-%)(.
S)8-#8-+ ,-$-#+ %- ) - (-%#)$ 8#(- ) %++#+ #$ - (-8)/%,
): 9%-(
),-$-+,*)$#%# #+ %- ) (-- - (-%#)$ #8-.REG7D OICE) 8 RESIDENC9 ROAD' OPP ASHO:A RESTAURANT' SADAR' NAGPUR 0 664 445
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I$ )(-( ) *(-/-$ #+),)(%#)$= - (-%#)$ #+ %((#- ) #$ %$ #$-(
%8)+*-(- ): -#-( %(
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B %$'#$' - (-%#)$ #8-= *),8-(#;%#)$ #8- %$ +)8- -8*-(%(-
/%(#%#)$+ (#$' - *()-++= #::-(-$ *-+ ): $+%(%- (-+#$+ )()=
#+) %$ -( *%,%- *-+ %(- ).0 PROECT '"CI(ITIES
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T#+ *()- 9#,, %/- % +%- ): - %( 8%$:%(#$' :%#,# +#$' ,%-+
8)-($ P,%$ +**,-8-$- 9# :,, %)8%# ++-8+ %$ 8%#$-+
#8*)(- #: $--++%( :()8 (-$)9$- E()*-%$ )( C#$-+-
8%$:%(-(+. T-+- 8%#$-+ %(- ,%-+ #$ -$),)' 9# %)8%#)$ ):
#'-+ -'(-- *)++#%.
>.1 Reire+e)t o: la) a) !ili)g %
I #+ -+#8%- % % 25 + :-- ,%$ *,) 9#,, +::#-. H)9-/-(=
*()8)-(+ 8% 9#+ ) ?--* %$)-( 1= + : %+ (-+-(/- :)( :(-
-*%$+#)$ %$ %$ -8*,)-- 9-,:%(- :%#,##-+ % 8%
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Pro-tio) -+ "+i) !ili)g Pro-t Dispat-h Se-tio)
>.2 P("NT 9 M"C&INERIES %
Ⅰ% 5000 ( Rea-tor Co):igratio)%
1. I$-( +-,, 8%-(#%, %$ *,%- #?$-++G34 SS *,%-. " 88
2. J%?- 8%-(#%, %$ *,%- #?$-+G C%(
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3. E,-(# 8))( *)9-(G 1 ?9 3 *%+- -#*- 9# -%( (--(
4. R)%#)$ S*--G 65 RPM =P%,- *- A'#%)(
5. M-%$#%, +-%,
6. H-%#$' 8-) G T-(8%, O#, H-%#$' S-%8 H-%#$'
7G I$$-( #+>
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Ⅲ%Oil / =ater Separator% 500 ( FSS 03G
Ⅳ% &oriHo)tal -o)e)ser% FMaterial% SS 03G
Ⅴ% 'ra-tio)ati)g Col+)% i) 2 se-tio)s ;ith a) elbo; F MOC / SS03G
Ⅵ% !::er ta)4% 00( Carbo) steel 625 -oate ;ith ")ti/rst
Pai)t
Ⅶ% a-+ p+p% 10 4; 1 Set
% !ab7 !oiler% 200,000 # Calorie F$as 'ire @Oil'ire @ Coal 'ire
% I)ter-o))e-ti)g Pipeli)es
Q%,# C)$(), L%
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>.2.. Polltio) Co)trol Measres
A** 5 ,#(-+ *-( % ): )$%8#$%- *()-++ 9%-( #+ -*-- )
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.2 !ili)g %
a. -ost o: pro-tio) she 3500 s :t ? Rs. 1000 A Rs. 35 (a4hs
b. -ost o: a+. blo-4, 1000 :t2 ? Rs. 2000
A Rs. 20 (a4hs
-. Dispat-h se-tio), 10,000 B 100 A 10 (a4hs
. Co+po) ;all A Rs. 10 (a4hs
Total bili)g -ost A Rs. 5 la4hs …… F"G
. P("NT 9 M"C&INER8
S.No 'a-ilities 6a)tit7 "+o)t
Rs. (a4hs
1 M%#$ P,%$ & M%#$-+ 1 +- 7
2 L%
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%$ )88#++#)$#$' )+
Total Pla)t 9 Ma-hi)es 130
TOT"( P("NT 9 M"C&INES A Rs. 130 (a4hs……..!
Total Capital EBpe)itre A F"G J F!G
A A 5 J 130 A 225 (a4hs
.2 =OR#IN$ C"PIT"( %
.2.1 Ra; Materials %
Cost o: R@M per a7 F re:er basis 9 ass+ptio)sG A Rs. .5 (a4hs
Per +o)th F 25 a7s G A 212.5
Cost o: Ra; Material per 7ear ? 100K -ap tiliHatio) A 2550 (a4hs
.2.2 (ease re)tal :or la)
I)strial plot lease to the proe-t
? Rs. 23 (a4hs per a))+
Mo)thl7 re)tal A 2 (a4hs
.2. Ma)po;er%
DEPARTMENT N) ): *-)*,- (-#(-
P()#)$ 6
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*%?#$' 2
8%#$-$%$- 6
A)$+ %$A8 -*
4
M%$%'-(#%,+%::
2
T)%,M%$*)9-(
2
A/' 9%'-+ % R+.25 8)$#$,#$'
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Mo)thl7 po;er J p-4g > (a4hs
.2.3 Cost o: Po;er 9 P-4g. per 7ear A > B 12 A 2 (a4hs
F Note % " D$ set o: appB. 5 #" rati)g shall be pt p to -ater to
e+erge)-7 ser*i-es i) -ase o: po;er otages G
.2.5 $ENER"( "DM 9 M"INTEN"NCE E
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1 9)(?#$' %*#%, 11 5>
H)9-/-(= - %+ :,)9 9)(?- ) %+ *-( %
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Capa-it7 tiliHatio),
K
>0 0 0 0 100
a. R%9 M%-(#%,+ 153 17"5 2142 241 267"
b. P)9-(= P?'. &)-( E*-$+-+
5 50 71 "3 ""
-. M%$*)9-( "4 "4 0 0 0
.R-$%, 24 24 24 24 24
-. D-*>B,'. 5 5 5 5 5 5: . D-* P&M 16.66
,#:- 6 (+24 24 24 24 24
COST O'PRODCTION
F a to : G
11 11 25> 2> 20
… Cash 'lo; 9 'i)a)-ial ")al7sis -o)ti)es….
.0 'IE 8E"RS C"S& '(O= 9 'IN"NCI"( "N"(8SIS
.1 C"S& '(O=%
"ss+ptio)s %
1 T- +%,-+ #+ (-,%- ) %*%# #,#;%#)$ #$ *()#)$. F,,
%*%# *()#)$ 9#,,
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4 S-,,#$' *(#- % ((-$ *(#-+ ): (-+#$ #+ #$ - (-'#)$ ): 13 ) 15
*-( K'. O$ - )$+-(/%#/- +#-= *(#- #+ %?-$ %+ R+. 14 K'. #$
- 9),-+%,- -*)( 8%(?-. T- *(#- 9#,, #$(-%+- 5 #$ -
3( -%( %$ 9#,, (-8%#$ )$+%$ :)( - $- 2 -%(+.
5 R%9 8%-(#%,+V )++ :)( #::-(-$ )8*)$-$+= - :)(8,%#)$+
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1! O TO SET UP TIS FACTORY
-+1 IMPORTANT DECISIONS TO BE MADE:
∗ O&ATIO= O; I=D6T5 , I=D6T5IA POT I= DAMA=
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…. Co)tL 1.0 'a-tories "-t
11.0 T&E '"CTORIES "CT
11.1 Objectives
- To ensure adequate safety measures and to promote the health and
welfare of the workers employed in fatories!
- To pre"ent hapha#ard $rowth of fatories throu$h the pro"isions
related to the appro"al of plans %efore the reation of a fatory!
11.2 Scope and coverage
- &e$ulates workin$ ondition in fatories!- 'asi minimum requirements for ensurin$ safety( health and welfare
of
workers!
- )pplia%le to all workers!
- )pplia%le to all fatories usin$ power and employin$ *+ or more
workers( and if not usin$ power( employin$ ,+ or more workers on any
day of the preedin$ *, months!
11.3 Main provisions
- Compulsory appro"al( lienin$ and re$istration of fatories!
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- Health measures!
- Safety measures!
- elfare measures!
- orkin$ hours!
- Employment of women and youn$ persons!
- )nnual lea"e pro"ision!
- )ident and oupational diseases!
- .an$erous operations!
- /enalties!
- O%li$ations and ri$hts of employees! when to onsult and refer
- On startin$ a fatory!
- Throu$hout the life of the fatory!
…. nd!stria" #stab"is$%ent &ct contin!es….
12.0 T&E INDSTRI"( EST"!(IS&MENT "CT
12.1 Objectives
- To re$ulate the onditions of reruitment( dishar$e( disiplinaryation(
holidays( et! of workers employed in industrial undertakin$s andesta%lishments!
12.2 Scope and coverage
- )pplia%le to industrial esta%lishments wherein 0+ or more workmen
are or ha"e %een employed in the preedin$ *, months!
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esta%lishments employin$ less than 0+ persons( as in the ase of 1/
and est 'en$al!
- In )ssam it is applia%le to onerns employin$ *2 or more workers!
12.3 Main provisions
- Su%mission of draft standin$ orders!
- Certi3ations of standin$ orders!
- 4odi3ation of standin$ orders!
- &e$istration of standin$ orders!
- )mendments of the )t!
- /enalties!
- O%li$ations and ri$hts of employers!
- O%li$ations and ri$hts of employees!
hen to onsult and refer
- )t the time of e5pansion of the onern( when the num%er ofworkmen may inrease( omin$ within the pro"ision of the )t!
- hen re"isin$ standin$ orders!
E) o: Proe-t Report
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