METALLIC STEARATE
[EIRI/EDPR/1618] J.C.420
INTRODUCTION
Stearates of aluminium, calcium, magnesium and zinc are known as driers and metallic soaps. It has long been established that the metal or cattier of the metallic soap is the active principle which accelerates the oxidation and polymerization reactions associated with the drying of oils. As many as twenty four metals are known to have activity, but the soaps of cobalt, manganese, lead, iron, calcium, zinc and zirconium account for the major share of present-day-use. Of these cobalt, manganese, lead and iron soaps are the primary driers. Calcium, zinc and zirconium soaps alone do not promote drying. They are useful only in conjunction with one or more of the primary driers and thus are termed auxiliary driers. The organic or a main portions of the metallic soaps used as driers act as carrying and solubilizing agents. Because of their stability, excellent salability and low cost, soaps based on naphthenic acid, tall oil and 2- ethylhexoic acid account for the major portion of the driers in use today. Driers made with resin, oleic and linoleic acids have declined in use, but are still manufactured for special purposes. Driers based on newly available synthetic, tertiary organic acids have been developed. These acids are in the 9-11 carbon range and thus have a higher acid value than those with a larger number of carbon atoms, permitting driers of higher metal content. Driers are available as liquids, solids and pastes, depending on the preference of the trade. The paint industry shows almost universal preference for low-viscosity liquids because of their handling, constant and reliable metal content and ready solubility. Solid soaps are used only where solvents are objectionable because of dilution of unwanted contamination, because the volatility of the solvent is objectionable, or because fire hazard is present. Pastes are used primarily in printing inks where the consistency is matched to that of the ink. The exact mechanism of the role of driers in the forming of solid, elastic protective films evolve carbon dioxide and water during drying. Linseed oil, containing driers and exposed in pure oxygen, absorbs large volumes of the gas over a period of several days. The total amount of oxygen taken up by linseed oil films at solidification is lower when drier is present. At the time approximately the same amount of carbon dioxide is evolved whether drier is present or absent.
During the drying of a film of the synthetic linolenic glyceride, the iodine valve of the film gradually decreased and the apparent molecular weight increased, indicates a decrease in unsaturation and a degree of polymerisation. Later studies of the drying process using newer instruments and techniques have indicated same of the intermediate stages and substantiated the early oxidation and polymerisation theories. The type and amount of drier used in paint and printing ink is governed by many factors as is condensed by the variety of products available. Cobalt soaps are powerful oxidizing catalysts and are added in quantities 0.005-0.4% cobalt based on the vehicle content. They are the primary driers used in printing inks where the thin ink must dry rapidly. In paints, excess of cobalt cause skimming because surface oxidation and drying is more rapid than polymerization. For this reason lead soaps are used in conjunction with cobalt. From 0.05 to 2.0% of lead is the usual amount required. Manganese soaps are both oxidizing and polymerizing catalysts and produce soaps in outside paint, floor finishes, and backing enamels. Dosage ranges from 0.01 to 0.1% of the metal contained in the soap, based on vehicle. Iron soaps have little effect at ordinary temperatures, but are extremely active under baking conditions, exhibiting a strong polymerizating effect. Because of their dark colour the iron soaps are limited in use to darkc1oloured finished. Calcium, zinc and zirconium soaps are ancillary driers. Used alone these soaps show little activity, but when mixed with active driers they produce films with desirable properties. Calcium soaps in combination with cobalt or manganese produce hard films. Zinc soaps also promote hardening and are useful in wetting and grinding pigments. Zirconium soaps promote hardness and adhesion and improve color retention. The amount of metallic soaps used depends on the service expected of the completed lubricant. Light spindle oils are made with less than 1% soap. Heavy bodied greases contain up to 50% of soap. Calcium and Sodium soaps accounts for about 70% of metallic soaps used in grease making. Soaps of aluminium, calcium, sodium, magnesium and zinc form gel with mineral oil. Lead naphthenate is incorporated in lubricants made by heating lubricating oils with sulphur for high-pressure applications such as hypoid gears. Greases and heavy-duty lubricants which are essentials to the efficient operation of modern mechanical equipment, can be made by heating mineral oils or synthetic organic liquids with metallic soaps. Metallic soaps of alkali and alkaline earth metals and aluminium have asteep solubility curve.
COST ESTIMATION
Plant Capacity 2 MT/Day
Land & Building (600 sq.mt.) Rs. 92.00 Lac
Plant & Machinery Rs. 18.00 Lac
Working Capital for 1 Month Rs. 79.98 Lac
Total Capital Investment Rs. 1.95 Cr
Rate of Return 29%
Break Even Point 52%
CONTENTS
INTRODUCTION
PRODUCT USES & APPLICATION
B.I.S SPECIFICATIONS AND PROPERTIES
PROPERTIES AND CHARACTERISTICS OF METALLIC STEARATE
DESCRIPTION AND PROCESSING OF CALCIUM STEARATE
MARKET SURVEY
PRESENT MANUFACTURER OF METALLIC STEARATE
PROCESS OF MANUFACTURE
PURE AND LIGHT ZINC STEARATE
MANUFACTURING PROCESSES OF METALLIC STEARATES
SELECTION OF PROCESS
MANUFACTURING PROCESS (PRECIPITATION PROCESS)
PROCESS FLOW DIAGRAM (PRECIPITATION PROCESS)
MANUFACTURING PROCESSES OF METALLIC STEARATE
BY FUSION PROCESS
GENERAL REACTION
PROCESS FLOW DIAGRAM (FUSION PROCESS)
MANUFACTURING PROCESS OF CALCIUM STEARATE FROM ANIMAL FATS
PROCESS FLOW DIAGRAM FOR THE MANUFACTURE OF CALCIUM
CHLORIDE FROM ANIMAL FATS (TALLOW)
PURITY ASSESMENT OF METALLIC STEARATE
PROPERTIES OF RAW MATERIALS
PLANT LAYOUT
SOURCES OF AVAILABILITY
SUPPLIERS OF RAW MATERIALS
SUPPLIERS OF PLANT AND MACHINERIES
RAW MATERIAL CALCULATION
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)
