EPOXY RESIN
[EIRI/EDPR/5359] J.C.: 1582XL
INTRODUCTION
The word 'Epoxy' comes from the Greek prefix meaning 'over' or 'between' and the English suffix for Oxygen. Thus an epoxy material may be regarded as an 'Oxygen between compound'.
Epoxy resins are thermosetting viscous liquids or brittle solids of which most widely used are those derived from the condensation reaction between epichlorohydrin and bisphenol. A commercial exploitation was first initiated about the middle of 1530 by I.S. Farben and this work was later followed independently by P. Custan, in Switzerland and then in U.S.A. around 1938. Developments were slowed down by the Second World War and relatively high price and scarcity of epichlorohydrin. However, at the end of the war, epichlorohydrin, which war then obtained as an intermediate from the production of glycol, became commercially available and led to wider uses for epoxy resins.
The seed of modern IV Epichlorohydrin (ECh)-Diphenyl-Propane (DPP) based epoxy resins sown by castan, was a land-mark in the history of resins.
In 1950, the market was only about 2 million lbs., used almost exclusively in coatings, applications. In 1964, approximately 85 million lbs. were used for coatings, adhesives, structural applications, electrical laminates and for a wide range of other uses. Coating application, however, still account for approximately half of all expoxy resin used.
The epoxy resins have steadily grown in their use in the plastic and related industries due to the variety of forms in which they may be processed.
As thermosetting materials, they can be combined with hardening agents to form a cross-linked polymer network. By the selection of the appropriate resin-hardener combination, the process can obtain both the desired handling characteristics and desired properties in the finished product. Toughness, corrosion or chemical resistance and good dielectric properties are common to virtually all epoxy resin systems. In addition, because of their structure and method of cure, epoxy resins provide two unique advantages over other thermosetting resins.
(1) No reaction by product or volatile is lost during cure. Large castings or thick sections can, therefore, be made without bubbles or voids.
(2) A low degree of shrinkage takes place upon cure. Accurate reproduction of molds is possible and very little internal stress is left to affect adhesion, thermal stock resistance, or other properties.
Epoxy resins are now produced in most of the developed countries of the world. But in India, although this item war introduced in late fifties, but indigenous production started in late sixties.
The wide and highly useful spectrum of properties exhibited by cured epoxy resins has identified then to be the most superior, unique and extremely versatile synthetic resins. No other synthetic resins than epoxy resins have got so many extremely useful properties together.
Epoxy resins are supplied in liquid or solids, depending on the resin type and end use applications. They are converted to thermostet by any one of the numerous compounds referred to as curing agents. The conversion is acomplished at room temperature or elevated temperature depending upon optimum condition or desired end properties. A further modification of the properties is possible by the incorporation of reactive diluents plasticizers, fillers and other additives.
ECh and DPP are the basic raw materials necessary for the manufacture of Epoxy Resins. Though DPP is manufactured in the country, but still today ECh is to be imported. As the raw materials are very expensive, hence the cost of production is high in comparison with other resins.
The seed of Modern Npichlorohydrin (ECH)-Diphenyol-Propane (DPP) based epoxy resins was first shown by castan, a suiss chemist. His patents were licenced to CIBA A.G. of Bosle. In 1946, an industrial Fair was Organised in Switserland. This Swiss company demonstrated the use of an epoxy resin adhesive namely resin coatings to four suies electrical, Electrical company remarkable materials begin with the introduction to industries.
COST ESTIMATION
Plant Capacity 1.38 Ton/Day
Land & Building (450 sq.mt.) Rs. 10.97 Lac
Plant & Machinery Rs. 20.08 Lac
Working Capital for 1 Month Rs. 29.29 Lac
Total Capital Investment Rs. 68.61 Lac
Rate of Return 45%
Break Even Point 58%
CONTENTS
INTRODUCTION
USES AND APPLICATIONS
B.I.S. SPECIFICATIONS
MARKET SURVEY
NAME OF EPOXY RESIN MANUFACTURERS
MANUFACTURERS OF EPOXY RESINS
PROPERTIES
HEAT DEFLECTION TEMPERATURE (HDT)
PROPERTIES OF EPOXY SYSTEMS
RAW MATERIALS
RAW MATERIAL REQUIREMENTS
MANUFACTURING PROCESS
SYNTHESIS OF DIGLYCIDYL ETHER OR BISPHENOL-A
FLOW SHEET OF EPOXY-RESIN PRODUCTION
SOME BASIC FORMULATIONS OF EPOXY RESINS
SUPPLIERS OF RAW MATERIALS
SUPPIERS OF PLANT AND MACHINERY
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)