ACTIVE ZINC OXIDE (PRODUCTION RATE – 3 TONS PER DAY)
[EIRI/EDPR/4570] J.C.: 2787US$
INTRODUCTION
In recent years, nanomaterials have received more concerns because of their prominent characteristics and it has various applications such as rubber, biomedical, energy, paint, coating, and cosmetics. With the development of nanomaterials, metal oxide nanoparticles show promising and far-ranging prospect in rubber industry, especially for gloves, tyre and other rubber products.
Because of their superior physical and chemical properties, ZnO metal oxide nanoparticles with high surface area (ZnO-H) are among the most significant and widely used in many fields. The rubber industry is where ZnO-H is initially used since it can make rubber composites more resistant to wear, boost the performance of high polymers by increasing their toughness, intensity, and antiaging properties, among other things. ZnO-H is increasingly employed in personal care products including sunscreen and cosmetics due to its potent UV absorption capabilities.
Moreover, ZnO-H also has strong UV blocking and great antibacterial and antimicrobial capabilities. As a result, in the textile sector, finished fabrics with ZnO-H added displayed the desirable properties of resistance to UV and visible light, anti-bacterial, and deodorant. In addition to the uses listed above, zinc oxide can also be utilized in a variety of other industrial sectors, such as the manufacturing of concrete, photocatalysis, electronics, electrotechnology, and so forth. It is well recognized that all bodily tissues, including as the brain, muscle, bone, and skin, contain significant amounts of zinc, an essential trace element.
Zinc participates in the body's metabolism and is a key element in the production of proteins and nucleic acids, hematopoiesis, and neurogenesis. It is also a key component of many enzyme systems. Small particle size nano-ZnO makes zinc easier for the body to absorb. Nano-ZnO is therefore frequently employed as a food ingredient.
Moreover, the US Food and Drug Administration has classified ZnO as a drug that is "generally regarded as safe" (GRAS) (FDA). ZnO-H has attracted increased interest in gloves and bio-medical applications due to these characteristics. Compared to other metal oxide nanostructures, ZnO-H is relatively cheap and has a small size.
Zinc waste is generated as a waste material from metal industry which causes environmental issues. Also, it is difficult to transport from one country to another, as it is categorized under hazardous waste. In general, the ash is usually processed to obtain Zinc oxide (ZnO) mainly for paint / rubber industry and zinc sulfate for agriculture industry. Waste to product conversion can adopt either pyrometallurgical or hydrometallurgical processes which are practiced globally to treat Zinc wastes and convert it to either Metallic Zinc or Zinc oxide as a final product.
The two important processing routes were pyrometallurgical and hydrometallurgical.
Pyrometallurgical process required carbon for easy segregation and make ZnO powder. In this process, production of normal Zinc oxide is possible but it could not tune the size and its surface area. Moreover, emission of CO2 gas occurs during the reaction when carbon power is being mixed with the Zinc waste. To conduct this reaction without carbon mixture requires more power to vaporize Zinc from Zinc waste.
Conventional hydro-metallurgical process required acids and alkali for leaching and precipitation. Low surface area of 4.5 to 5 m2/gm of ZnO was synthesized. To achieve the active zinc with desired porosity, surface area and pore volume, need to use any template assisted synthesis to obtain the above properties, but it is very tedious.
To overcome the above bottlenecks, in this work suitable material has been mixed during the precipitation process and produced the desire surface area, pore volume and porosity with a maximum purity of 95% ZnO was manufactured.
Active Zinc oxide is an inorganic compound with the formula ZnO. ZnO is a white powder that is insoluble in water, which is widely used as an additive in numerous materials and products including plastics, ceramics, glass, cement, lubricant, paints, ointments, adhesives, sealants, pigments, foods (source of Zn nutrient), batteries, ferrites, fire retardants, and first aid tapes. It occurs naturally as the mineral zincite but most zinc oxide is produced synthetically.
In materials science, ZnO is a wide-bandgap semiconductor of the II-VI semiconductor group (since oxygen was classed as an element of VIA group (the 6th main group, now referred to as 16th) of the periodic table and zinc, a transition metal, as a member of the IIB (2nd B), now 12th, group). The native doping of the semiconductor (due to oxygen vacancies) is n-type. This semiconductor has several favorable properties, including good transparency, high electron mobility, wide bandgap, and strong room-temperature luminescence. Those properties are used in emerging applications for transparent electrodes in liquid crystal displays, in energy-saving or heat-protecting windows, and in electronics as thin-film transistors and light-emitting diodes.
It is intended to prepare a Feasibility Report for Active Zinc Oxide Production facility with an installed capacity of 3 Tons / Day as a Green Field Project.
COST ESTIMATION
Plant Capacity 3 MT/Day
Land & Building (3975 sq.mt.) US$ 6.83 Lac
Plant & Machinery US$ 10.81 Lac
Working Capital for 0.5 Months US$ 1.08 Lac
Total Capital Investment US$ 19.50 Lac
Rate of Return 17%
Break Even Point 69%
CONTENTS
INTRODUCTION
PROPERTIES
CRITICAL PROPERTIES
CHEMICAL PROPERTIES
BASES ALSO DEGRADE THE SOLID TO GIVE SOLUBLE ZINCATES:
HOPEITE
MECHANICAL PROPERTIES
ELECTRICAL PROPERTIES
STANDARDS AND SPECIFICATIONS
PRODUCT DETAILS
SPECIFICATIONS
STANDARDS
FORMS OF ZINC OXIDE
FOR INSTANCE,
POSSIBILITIES OF ZINC OXIDE POWDER PRODUCTION WITH VARIOUS DIMENSION
APPLICATIONS
RUBBER MANUFACTURE
CONCRETE INDUSTRY
MEDICAL
CIGARETTE FILTERS
FOOD ADDITIVE
PIGMENT
COATINGS
CORROSION PREVENTION IN NUCLEAR REACTORS
POTENTIAL APPLICATIONS
ELECTRONICS
THEREFORE, THEY CAN BE USED AS FIELD EMITTERS.
ZINC OXIDE NANOROD SENSOR
SPINTRONICS
PIEZOELECTRICITY
SAFETY
MARKET OVERVIEW
NANO-ZINC OXIDE
PARTICLE GRADE
SUPER-FINE
RUBBER
COATING
CERAMICS
PHARMACEUTICAL
REGIONAL INSIGHTS
CONSUMPTION OF ACTIVE ZINC OXIDE
KEY COMPANIES & MARKET SHARE INSIGHTS
PRESENT MANUFACTURER OF ZINC OXIDE
RAW MATERIALS AND ITS AVAILABILITY
PROCESS
FOR INDUSTRIAL USE, ACTIVE ZNO IS PRODUCED BY THREE MAIN PROCESSES:
INDIRECT (FRENCH) PROCESS
DIRECT (AMERICAN) PROCESS
WET CHEMICAL PROCESS
MANUFACTURING PROCESS/PROCESS FLOW
PROCESS FLOW
EXPOSURE LIMITS
EXPOSURE SOURCES AND CONTROL METHODS
RESPIRATORY PROTECTION
RESPIRATORS MAY BE USED:
PERSONAL PROTECTIVE EQUIPMENT
PERSONAL HYGIENE PROCEDURES
PRELIMINARY LAYOUT
SUPPLIERS OF PLANT & MACHINERY
ZINC MELTING FURNACE
ENGINEERING DESIGN CONSIDERATIONS
ETP FACILITY
ETP FLOW DIAGRAM (TYPICAL)
SEWAGE AND WASTE WATER EFFLUENT
STP FLOW DIAGRAM (TYPICAL)
WASTE GENERATION & MANAGEMENT/GREEN BELT
GREEN BELT
PRINCIPLES OF PLANT LAYOUT
MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE:
PRINCIPLES OF PLANT LAYOUT
PLANT LOCATION FACTORS
PRIMARY FACTORS
1. RAW-MATERIAL SUPPLY:
2. MARKETS:
3. POWER AND FUEL SUPPLY:
4. WATER SUPPLY:
5. CLIMATE:
SPECIFIC FACTORS
6. TRANSPORTATION:
A. AVAILABILITY OF VARIOUS SERVICES AND PROJECTED RATES
7. WASTE DISPOSAL:
8. LABOR:
9. REGULATORY LAWS:
10. TAXES:
11. SITE CHARACTERISTICS:
12. COMMUNITY FACTORS:
13. VULNERABILITY TO WARTIME ATTACK:
14. FLOOD AND FIRE CONTROL:
ANTICIPATED ENVIRONMENTAL IMPACTS
CONSTRUCTION PHASE
OPERATION PHASE
MITIGATION MEASURES (PROPOSED)
HEALTH SAFETY & ENVIRONMENT
PROPOSED IMPLEMENTATION SCHEDULE
PROJECT FINANCIALS
BASIS & PRESUMPTIONS (FOR PROFITABILITY WORKINGS)
CONCLUSIONS
APPENDIX – A:
01. PLANT ECONOMICS
02. LAND & BUILDING
03. PLANT AND MACHINERY
04. OTHER FIXED ASSESTS
05. FIXED CAPITAL
06. RAW MATERIAL
07. SALARY AND WAGES
08. UTILITIES AND OVERHEADS
09. TOTAL WORKING CAPITAL
10. TOTAL CAPITAL INVESTMENT
11. COST OF PRODUCTION
12. TURN OVER/ANNUM
13. BREAK EVEN POINT
14. RESOURCES FOR FINANCE
15. INSTALMENT PAYABLE IN 5 YEARS
16. DEPRECIATION CHART FOR 5 YEARS
17. PROFIT ANALYSIS FOR 5 YEARS
18. PROJECTED BALANCE SHEET FOR (5 YEARS)
