1 SODIUM CHLORATE CONTENTS SECTION I PRODUCT CHARACTERISTICS AND SPECIFICATION SECTION II PRODUCT APPLICATIONS SECTION III INDIAN MANUFACTURERS SECTION IV IMPORT/EXPORT LEVEL SECTION V PRICE DETAILS SECTION VI INDIAN DEMAND SECTION VII BROAD OUTLINE OF MANUFACTURING PROCESS SECTION VIII RAW MATERIAL REQUIREMENTS, UTILITY AND AVAILABILITY SECTION IX GLOBAL SCENARIO SECTION X DISCUSSIONS ON ECONOMIC CAPACITY, PROJECT COST AND PROFITABILITY PROJECTIONS SECTION XI SWOT ANALYSIS SECTION XII FACTORS INFLUENCING THE POSITION FOR A NEW INDUSTRY AND RECOMMENDATIONS
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SODIUM CHLORATE
CONTENTS
SECTION I PRODUCT CHARACTERISTICS AND SPECIFICATION SECTION II PRODUCT APPLICATIONS SECTION III INDIAN MANUFACTURERS SECTION IV IMPORT/EXPORT LEVEL SECTION V PRICE DETAILS SECTION VI INDIAN DEMAND SECTION VII BROAD OUTLINE OF MANUFACTURING PROCESS SECTION VIII RAW MATERIAL REQUIREMENTS, UTILITY
AND AVAILABILITY SECTION IX GLOBAL SCENARIO SECTION X DISCUSSIONS ON ECONOMIC CAPACITY, PROJECT COST AND PROFITABILITY PROJECTIONS SECTION XI SWOT ANALYSIS
SECTION XII FACTORS INFLUENCING THE POSITION FOR A NEW INDUSTRY AND RECOMMENDATIONS
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SECTION - I
PRODUCT CHARACTERISTICS AND SPECIFICATION 1.1. General Details Appearance Colourless, odourless crystals or white
granules Chemical formula NaClO3 Molecular weight 106.45 Purity Around 99% Odour Odourless Density 2.5 g/cm3 Melting poin
t
248 deg.C Solubility in cold water Soluble in about 1 ml Solubility in boiling water 0.5 ml
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SECTION - II
PRODUCT APPLICATIONS
Application sector
As bleaching agent in pulp and paper manufacture.
Other applications:- In matches Tanning and finishing leather. As an oxidiser in the manufacture of dyes and also used in printing fabrics.
To produce chlorine dioxide.
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SECTION - III
INDIAN MANUFACTURERS
General Details It is possible to produce both Sodium Chlorate and Potassium Chlorate in the same facilities, if the plant would be designed accordingly. Indian Producers * Chemfab Chlorates Ltd. Cuddalore Main Road, Abishegapakkam, Pondicherry-605 007 The chlorate production facility near Pondicherry has been expanded to about 3,500 tonnes per year. * TCM Ltd., (Formerly Travancore Chemical & Mfg. Co. Ltd.,) Factory 1 :P.B. No. 19, Kalamassery - 683 104 (Kerala) * Shree Chlorates 101-102, Block "B" Radhakrishna Complex, 10/1, Manoramaganj, A.B. Road, Indore-452 001 * Chemofine Industries, 6/258, S.F.S. Mansarovar Jaipur-302 020
Indian installed capacity Around 9000 tonnes per annum
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SECTION - IV
IMPORT/EXPORT LEVEL
4.1. Present import level 3500 tonnes per annum Countrywise Imports Period April 2001 to March 2002 Country Quantity in Kgs
Finland 2760328 France 321666 German F REP 400000 Sweden 21000 4.2. Present export level Around 25 tonnes per annum Countrywise Exports of Sodium Chlorate Period April 2001 to March 2002 Country
Quantity in Kgs
Albania 19619 Tanzania REP 6000
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SECTION - V
PRICE TRENDS
Basic price Rs.30000 per tonne Taxes and duties Extra as applicable
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SECTION -VI
INDIAN DEMAND
User sector Sodium chlorate is predominently used in the pulp and paper industry as a bleaching aid. The paper has to be bleached to increase the whiteness of the paper and to remove lignin components of the paper. The bleaching process is one of the environmental bottlenecks in the paper process. However, by choosing the right chemicals, much improvement can be achieved here. Bleaching agents used in the paper sector Oxidative reagent Chemical formula
De-oxidative reagent Chemical formula Industrially available Sodium dithionite Na2S2O4 Hardly available Zinc dithionite ZnS2O4 Sodium bisulphite NaHSO4 Sulphur dioxide SO2 Sodium borohydride NaBH4 Calcium dithionite CaS2O4
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Comparsion of substitution products for bleaching in paper industry The following comparison of important properties and common applications of such substitution products namely chlorine compounds, ozone and hydrogen peroxide highlights the importance of the products and their comparative merits. Characteristics Chloride Sodium
hypochlorite Stable bleaching powder of available chloride 60 to 70%
Chlorine dioxide
Ozone Hydrogen peroxide
Chemical formula Cl2 NaOCl CaOcl granules ClO2 O3 H2O2 Form Liquid gas solution - Gas Gas Liquid Commercial strength 100 12-15 70 Upto 0.35 2 35-70 Percent stability Stable tank cars Light Yellow
unstable Liquid Stable
Greenish yellow gas explosive high
Unstable Stable
Toxicity to Microorganisms
High High High High High Medium
Hazards associated with handling and use
High Medium Medium High High Medium
Corrosion High Medium Medium High High Low Deodorizing High Medium Medium High High High Cost Low Medium Medium Medium High High Applications Control of slime
growth H2S and odour, ROD reduction, fly control, sludge bulking and foaming control ammonia oxidation disinfection
Control of slime growth disinfection
Control of slime growth disinfection
Control of slime growth and odour disinfection
Odour control BOD reduction oxidation of refractory organic compounds disinfection
Control of slime growth H2S and odour, sludge bulking
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Use level of Sodium chlorate in Indian paper sector Traditionally, liquid Chlorine has been used for bleaching purposes in Indian paper mills. However, in recent times, considerable objections have been raised all over the world by the environmentalists about the use of Chlorine in paper mills. Considering such environmental factors as well as efficacy levels and factors of economy, number of substitutes such as Stable Bleaching powder of available Chlorine 60 to 70%, Chlorine dioxide and Hydrogen peroxide are now being used. In India, the use of Chlorine dioxide and Hydrogen peroxide are still not extensive. Several paper mills are now switching over to Stable Bleaching powder of available Chlorine 60 to 70% and Chlorine dioxide for bleaching purposes. It is the general view that the use of Chlorine in paper mills for bleaching purposes would ultimately be given up all over the world; sooner in developed countries and perhaps latter in developing countries. Chlorine dioxide is the likely substitute in the near future. Large paper mills like JK Paper mills are presently planning to use Chlorine dioxide in large quantities. Chlorine dioxide considerably reduces the environmental impact of chlorinated organic compounds in effluent from the bleaching plant. Sodium chlorate, which is used as a bleaching agent in pulp and paper mills, is rapidly gaining market share as an alternative to elemental Chlorine, By the end of this year EPA (Environmental Authority) is expected to finalise its cluster rules, which will define regulations on emissions from pulp and paper plants. These will probably include an eventual ban on elemental Chlorine as a bleaching agent giving a boost to Sodium chlorate, which is elemental Chlorine free. Demand level for Sodium chlorate Growth rate in demand The growth rate in demand is likely to be in the region of 8 to 9% per annum in the coming years, in view of the environmental compulsions facing pulp and paper industry.
Estimated demand Around 11000 tonnes per annum
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SECTION - VII
BROAD OUTLINE OF MANUFACTURING PROCESS
General details Sodium Chlorate is manufactured by the electrolytic oxidation of Sodium Chloride using Titanium substrate anodes. Sodium Chloride is thrown out from the solution by evaporation and Sodium chlorates crystallizes on cooling. Sodium Chlorate is produced from an acid solution of Sodium Chloride, which is heated and electrolyzed , with Sodium chlorate crystallising out. Energy accounts for more than 45 to 50% of the manufacturing cost by global standards. By products The only byproduct in the manufacture of Sodium Chlorates is Hydrogen gas. Hydrogen comes out of chlorate cells contaminated with about 3% Oxygen and 0.5% of Chlorine. In Indian factories, Hydrogen is being blown out, after scrubbing the Chlorine by alkali. In developed countries abroad,the Sodium Chlorate units use Hydrogen for burning as fuel or as raw material for producing Hydrogen peroxide and other chemicals or is compressed and sold in cylinders. The recovery of Hydrogen involves substantial investment which may not be worthwhile for small units. Outline of manufacturing process The manufacture of Sodium chlorate is carried out by the electrolysis of saturated acidulated brine containing some Sodium dichromate (about 2 gms per litre of brine). The Sodium dichromate present in the electrolyte reduces the corrosive action of hypochlorous acid formed by the hydrochloric acid present. The brine solution (solution of common salt NaCl) is first made free from any Ca and Mg impurities and introduced into an undivided rectangular steel cell, the temperature of which is maintained at 40 deg.C by cooling water. At Cathode, OH- ions liberated by the reduction of water react with Na+ ions to give Sodium hydroxide. Chlorine liberates at Anode.
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Hence the products of electrolysis are actually Sodium hydroxide and Chlorine at the Cathode and Anode respectively. NaCl ---------> Na+ + Cl- <------- 2H2O + 2e- ----------> H2 + 2OH - At cathode <--------- Na+ + OH- NaOH Cl- - e ------------> Cl Cl + Cl <----------> Cl2 At anode Since the cell is undivided (contains no diaphragm), the products of electrolysis (NaOH and CL2) react to form Sodium hypochlorite, which is then oxidised to Sodium chlorate. NaCl + 3H2O --------> NaClO3 + 3H2 Source of technology
* Central Electrochemical Research Institute (Council of Scientific & Industrial Research) Karaikudi - 630 006, TamilNadu. Major plant and machinery suppliers Name of the equipment
Name of the company
HT switch panel, comprising of 1 No. Incoming 11 kv OCB complete with ammeter, volmeter, selector switches for earth fault and instaneous and oil switches (2) for rectifier transformer (2) for auxiliary transformer.
Switzer Instruments Ltd. No.9, South Boag Road, T. Nagar, Chennai-600 017 Flameproof Equipments Pvt. Ltyd., House No.28, 1st Floor, V Cross Street, Lake Area Nungambakkam, Chennai-600 034
Rectifier transformer for 4000 A DC output with 40-80-120 volt regulation regulator controlled rectifier panel, control cubicle and necessary batteries for control voltage supply.
The Andrew Yule & Company Ltd. (A Govt. of India Enterprise) Yule House, 8 Dr. Rajendra Prasad Sarani Calcutta-700 001 Bharat Bijlee Ltd. P.B. No.100, Belapur Road Kalwa, Thane-400 061
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Transformer suitable for out out door location 100 kva transformer 11 kv/440 v
The Andrew Yule & Company Ltd. (A Govt. of India Enterprise) Yule House, 8 Dr. Rajendra Prasad Sarani Calcutta-700 001 Bharat Bijlee Ltd. P.B. No.100, Belapur Road Kalwa, Thane-400 061
Motor control centre for MV distillation to various load centre
Electrical contractors
Copper busbars for rectifier to cells, interconnection of cells and back to rectifier transformer to suit the layout and ration BI/P
Electrical contractors
Cables 11 kv/433 v pilc cables to the requirement of load centres BI/P
Flameproof Equipments Pvt. Ltyd., House No.28, 1st Floor V Cross Street, Lake Area Nungambakkam, Chennai-600 034 Sagar Steel Pvt. Ltd., 39, SNS Plaza, 41, Kumara Krupa Road, Bangalore-560 001
Sundry items like bush button stations cable glands etc.
Flameproof Equipments Pvt. Ltyd., House No.28, 1st Floor V Cross Street, Lake Area Nungambakkam, Chennai-600 034 Sagar Steel Pvt. Ltd., 39, SNS Plaza, 41, Kumara Krupa Road, Bangalore-560 001
Pulveriser with motor and other accessories (capacity 120 kg per hour)
1. Power 5800 unit 2. Fuel 160 litres Raw material availability Sodium chloride There is no constraints for the supply of Sodium chlorde Hydrochloric acid The nearby sources for the supply of Hydrochloric acid include the following. * Chemfab alkalies, pondicherry * The Travancore Cochin Chemicals Ltd.,Kerala
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SECTION - IX
GLOBAL SCENARIO 9.1. Global demand 2.5 million tonnes per annum 9.2. Global regionwise demand pattern
USA38%
Canada16%
Europe30%
South America8%
Other countries8%
9.3. Demand forecast in North America(In '000 tonnes) 1995 2000 % annual growth
9.4. Global use pattern by end use Most of the Sodium Chlorate produced in the world is used for paper pulp bleaching. The next important use in the manufacture of perchlorates.
Pulp & Paper94%
Perchlorates4%
Mining1%
Others1%
Source: Consulting Resources Corp (Lexington, MA). 9.5. Important global producers Company Location Capacity
in ‘000 tonnes per year
EUROPE
Aragonesas
Sabinanigo,Spain 45
Caffaro
Brescia, Italy 12
Eka Chemicals Oulu, Finland 55 Ambes, France 70 Mo-i-Rana, Norway 50 Aloby, Sweden 70 Stockvik Sweden
45
Elf Atochem
Jarrie, France 85
Finnish Chemicals Aetsa, Finland 135 Joutseno,Finland
65
Solvay Portugal Povoa de Santa Iria, Portugal
18
Simonis BV.,Netherlands
Natron Chemie, Netherlands
18
UNITED STATES OF AMERICA
CXY Chemicals
Taft,LA 140
Eka Chemicals Columbus,MS 221 Moses Lake,WA
65
Elf Atochem
Portland,OR 50
Georgia Gulf
Plaquemine,LA 28
Huron Tech Claiborne, AL 47 Augusta, GA 140 Eastover, SC
90
Kerr-McGee
Hamilton,MS 143
Sterling Pulp
Valdosta,GA 110
Western Electrochemical Cedar City, UT 7 CANADA
Albchem Bruderheim,AB
86
BC Chemicals Prince George,BC
73
CXY Chemicals Amherstburg, On 55 Beauhamois,PQ 48 Brandon,MB 110 Bruderheim, AB 72 Nanaimo,BC
20
Eka Chemicals Magog,PQ 160 Valleyfield,PQ
124
Norkraft Quevillon Lebel-sur-Quevillon, PQ
17
PCI Chemicals Dalhousie,NB
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Saint Anne Chemical Nackawie, NB
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Sterling Pulp Buckingham,PQ 143 Grand Prairie,AB 57 Thunder Bay, ON 57 Saskatoon,SK 55 Vancouver,BC
6.1. Preliminary expenses 4.00 6.2. Pre-operative expenses:- 6.2.1 Establishment 4.00 6.2.2 Rent rates and taxes 5.00 6.2.3 Travelling expenses 6.00 6.2.4 Interest and commitment charges on borrowings 12.00 6.2.5 Insurance during construction period 11.00 6.2.6 Other preoperative expenses and deposits - 6.2.7 Interest on deferred payment - Total 42.00 7. Provision for contingency Rs.45.40 lakhs 8. Working capital margin Rs.62.55 lakhs 9. Total project cost Rs.750 lakhs 10. Means of finance Promoter's contribution Rs.300 lakhs Term loan from financing institutions Rs.450 lakhs Total project cost Rs.750 lakhs
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11. Financial statements Cost of production A Variable cost
Rs. in lakhs
Raw material and utilities 302.28 Spares and maintenance 26.90 Selling expenses 45.00 Total variable cost (A)
374.18
B Fixed cost
Salaries and wages 24.00 Interest on term loan and working capital loan 114.78 Depreciation 54.88 Administrative expenses 27.00 Total fixed cost (B)
220.65
C. Total cost of production (A+B)
594.83
D. Selling price per kg. (in Rupees)
30
E. Annual sales turnover
900
F. Net profit before tax (E-C)
305.17
G. Breakeven point in %
42
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SECTION - XI
SWOT ANALYSIS
Strength Product importance
Infrastructural facilities
Weakness Power intensive project
Opportunity Excellent market Exports
Threat Power cost Chlorine price
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SECTION - XII
FACTORS INFLUENCING THE POSITION FOR A NEW INDUSTRY AND
RECOMMENDATIONS Sodium Chlorate project should be viewed from various factors as given below: Power Sodium Chlorate project is power intensive. 50 to 60% of the cost of the production would be constituted by the power cost. Effluent There would be no discharge of effluent from the project. Water The requirement of water for the project is minimal. Demand The demand for the product is going steadily at the rate of 8 to 9% per annum. The product is highly relevant to the country’s industrial growth pattern. Exports In view of the steady increase in demand for the product in the global market, Sodium Chlorate project offers good export opportunity. Recommendation The fact remains that the project is power intensive. One of the pre conditions for success of the project is the adequate availability of power and also price of the power at competitive cost.