POLYCARBOXYLATE ETHER SUPERPLASTICIZER (PCE) [3635]
Superplasticizers (SPs) are recognized as important admixtures for their applications in modern concrete technology. Efforts have long been made by scientists and technologists to keep fresh concrete fluid to provide homogeneous transport of all particles in the building industry. Traditional techniques which use the superplasticizers such as sulfonated melamine formaldehyde condensate (SMF) and sulfonated naphthalene formaldehyde condensate play a positive role in maintaining high fluiding concrete. The superplasticizers interact with the surface of cement particles and involve dispersion and decreasing of the natural tendency to coagulate in concrete. Polycarboxylates (PC) are recently commonly used as superplasticizers to disperse cement particles in concrete and mortar. However, it has been known that the dispersing force of PC for cement and its time variation are significantly affected by even slight differences in concrete components or mixing conditions. Such instability of the dispersing force is explained by the incompatibility between cement and PC. Moreover, the side chain of the copolymer-type PC is composed of polyethylene oxide units. The methyl oxide bonds are easy to break under heat and oxygen. Furthermore, as a new generation water-reducing agent, the PC water-reducing agent would face the problem of short resources in the near future for nonregenerate ability of crylic acid derived from petroleum, so melamine superplasticizer has shown great advantage. Melamine superplasticizer is one of the most commonly employed due to its colorless, nontoxic, and good thermal stability. However, the application of traditional melamine water reducing agent is becoming less and less due to the complex production process, high cost, and relatively inferior slump loss. Along with the architecture industrial development and on the concrete performance requirements to improve, the development of high performance superplasticizer is imperative. Water-reducing admixtures or plasticizers are all hydrophilic surfactants which, when dissolved in water, deflocculate and disperse particles of cement. By preventing the formation of conglomerates of cement particles in suspension, less water is required to produce a paste of a given consistency or concrete of particular workability. Maintaining low water contents whilst achieving an acceptable level of workability results in higher strengths for given cement content as well as lower permeability and reduced shrinkage. An important consequence of the reduction in the permeability is a major enhancement of its durability. The permeability of concrete to gases (oxygen, CO2), and water (carrying chlorides, sulfates, acids and carbonates) is of major importance with respect to its durability. Retarding admixtures, which extend the hydration induction period and thereby lengthening the setting times, are often treated together with plasticizing admixtures as the main components used for retarding mixtures are also present in water-reducing admixtures. As a result, many retarders tend to reduce mixing water and many water reducers tend to retard the setting of concrete. A much greater reduction in the volume of mixing water can be achieved using socalled superplasticizers or high-range water-reducing admixtures in case of concretes of normal workability. Normal water reducers are capable of reducing water requirement by about 10-15%. Further reductions can be obtained at higher dosages but this may result in undesirable effect on setting, air content, bleeding, segregation and hardening characteristics of concrete. Superplasticizers are capable of reducing water contents by about 30%. Plasticizers (UK: plasticisers) or dispersants are additives that increase the plasticity or viscosity of a material. The dominant applications are for plastics, especially polyvinyl chloride (PVC). The properties of other materials are also improved when blended with plasticizers including concrete, clays, and related products. According to 2014 data, the total global market for plasticizers was 8.4 million metric tons. Plasticizers or water reducers, and superplasticizer or high range water reducers, are chemical admixtures that can be added to concrete mixtures to improve workability. Unless the mix is "starved" of water, the strength of concrete is inversely proportional to the amount of water added or water-cement (w/c) ratio. In order to produce stronger concrete, less water is added (without "starving" the mix), which makes the concrete mixture less workable and difficult to mix, necessitating the use of plasticizers, water reducers, superplasticizers or dispersants. Plasticizers are also often used when pozzolanic ash is added to concrete to improve strength. This method of mix proportioning is especially popular when producing high-strength concrete and fiber-reinforced concrete. Adding 1-2% plasticizer per unit weight of cement is usually sufficient. Adding an excessive amount of plasticizer will result in excessive segregation of concrete and is not advisable. Depending on the particular chemical used, use of too much plasticizer may result in a retarding effect. Plasticizers are commonly manufactured from pop lignosulfonates, a by-product from the paper industry. Superplasticizers have generally been manufactured from sulfonated naphthalene condensate or sulfonated melamine formaldehyde, although newer products based on polycarboxylic ethers are now available. Traditional lignosulfonate-based plasticisers, naphthalene and melamine sulfonate-based superplasticisers disperse the flocculated cement particles through a mechanism of electrostatic repulsion (see colloid). In normal plasticisers, the active substances are adsorbed on to the cement particles, giving them a negative charge, which leads to repulsion between particles. Lignin, naphthalene and melamine sulfonate superplasticisers are organic polymers. The long molecules wrap themselves around the cement particles, giving them a highly negative charge so that they repel each other. Polycarboxylate ether superplasticizer (PCE) or just polycarboxylate (PC), work differently from sulfonate-based superplasticizers, giving cement dispersion by steric stabilisation, instead of electrostatic repulsion. This form of dispersion is more powerful in its effect and gives improved workability retention to the cementitious mix. Ductile iron is a ternary Fe-C-Si alloy, in which the concentrations of carbon and silicon vary typically from 3.5 to 3.9% and from 1.8 to 2.8%, respectively. The selection of the composition is dictated by the casting section size and by the targeted mechanical properties. The output characteristics depend on the matrix structure and the shape, size, and distribution of the graphite spheroids. Matrix and spheroids, in their turn, depend on the chemical composition of the melt, on the desulphurizing and spheroidizing methods applied in the treatment ladle, onthe inoculation method and finally, on the time elapsing between these events and the casting in the mould . Moreover, the mechanics of spheroid formation itself has not yet been completely understood and many models are still in competition. Production of ductile iron is influenced by a large number of metallurgical, technological, heat transfer, and designing parameters. The first step of the production of ductile iron castings is careful selection of the charge materials. Manganese and chromium have the strongest influence on mechanical properties of the ductile iron. For this reason, their concentration in the metal is of particular importance. These elements arise in the charge from the steel scrap, pig iron, and returns. It is a recommended practice to surchage steel scrap so that the average Cr content remains below 0.1 percent. Ideally, the same advice would be given for Mn but, unfortunately, all steel scraps contain Mn, mostly about 0.5 percent. The amount of steel scrap in the charge must ensure the production of castings that are as free of carbides as possible. It is necessary not to mix grey iron return scrap with the ductile iron one, because grey iron castings have an increased manganese and chromium content. Ductile iron return scrap has a large silicon and a small sulphur content. However, if spheroidizing elements are present in excessive concentration they act as despheroidizers.
COST ESTIMATION
Plant Capacity 5 Ton/Day
Land & Building (0.5 Acre) Rs. 1.24 Cr
Plant & Machinery Rs. 80 Lac
Working Capital for 2 Months Rs. 3.27 Cr
Total Capital Investment Rs. 5.66 Cr
Rate of Return 29%
Break Even Point 50%
INTRODUCTION
CHEMISTRY OF SUPER PLASTICIZER FOR CONCRETE
SUPERPLASTICIZERS
GENERATIONS OF SUPERPLASTICIZERS:
SUPERPLASTICIZERS – HIGH WATER REDUCERS:
SUPERPLASTICIZERS IN SELF COMPACTING CONCRETE
MIX DESIGN METHOD IN BRIEF
RAW MATERIALS
METHACRYLIC ACID (MAA)
METHOXY POLYETHYLENE GLYCOL
ADVANTAGE PCE SUPERPLASTICIZER
MARKET SURVEY
GLOBAL MARKET POSITION OF POLYCARBOXYLATE
ETHER SUPERPLASTICIZER
HIGH DEMAND FROM EMERGING ECONOMIES
USAGE OF SULPHONATED NAPHTHALENE FORMALDEHYDE (SNF)
IS EXPECTED TO INCREASE
ASIA-PACIFIC TO HAVE HIGHEST CAGR FOR THE SUPERPLASTICIZER MARKET
MAJOR PLAYERS IN SUPERPLASTICIZER MARKET
OVERVIEW OF CONSTRUCTION CHEMICALS
CONSTRUCTION CHEMICALS TAKE CONCRETE SHAPE
CONSTRUCTION CHEMICAL SEGMENTS
ADMIXTURES
FLOORING AGENTS
WATERPROOFING AGENTS
REPAIR & REHABILITATION
SUBCATEGORIES
CURING COMPOUNDS
MAJOR PLAYERS
CHALLENGES
CHARACTERISTICS OF PLASTICIZER FOR CONCRETE
CHARACTERISTICS OF THE DIFFERENT CHEMICALS
MECHANISM OF ACTION OF WATER REDUCERS
MANUFACTURERS/SUPPLIERS OF POLYCARBOXYLATE ETHER
SUPERPLASTICIZER
MANUFACTURING PROCESS OF POLYCARBOXYLATE ETHER SUPER PLASTICIZER (PCE)
THE SYNTHESIS CONDITION AND STEPS ARE AS FOLLOWS
PROCESS FLOW DIAGRAM
COMPOSITION OF HIGH PERFORMANCE POLY CARBOXYLATED
BASED SUPERPLASTICIZER
COMMON PLASTICIZER BY TYPES
MECHANISMS OF DISPERSION
ADDITIVES FOR CONCRETE PLASTICIZER
THIS EFFECT CAN BE USED IN TWO WAYS
TABLE: TYPES OF ADDITIVES WATER REDUCING/HIGH WATER REDUCING
TABLE: TYPES OF SUPERPLASTICIZER ADDITIVES (CHEMICAL STRUCTURE)
THE SUPERPLASTICIZERS CAN BE CLASSIFIED INTO TWO GROUPS
WATER REDUCING/PLASTICIZING
ADMIXTURE AND ITS MECHANISM
FIGURE: THE EFFECT OF A WATER REDUCING ADMIXTURE ON THE DISPERSION OF CEMENT PARTICLES
FIGURE: FLOCCULATING CEMENT PARTICLES TRAPPING THE MIX WATER
SUPERPLASTICIZERS
POLYCARBOXYLATES
POLYCARBOXYLATE HIGH-EFFICIENCY CONCRETE WATER REDUCER
PRODUCT DESCRIPTION
MATERIAL SUFETY DATA SHEET FOR POLY CARBOXYLATE ETHER
HAZARDS IDENTIFICATION
LABEL ELEMENTS
MIXTURES
FIRST AID MEASURES
FIREFIGHTING MEASURES
ACCIDENTAL RELEASE MEASURES
METHODS AND MATERIAL FOR CONTAINMENT AND CLEANING UP
HANDLING AND STORAGE
MATERIAL SAFETY DATA SHEET OF HIGH PERFORMANCE POLY CARBOXYLATED
ETHER BASED SUPERPLASTICIZER
HAZARDS IDENTIFICATION
FIRST-AID MEASURES
FIRE-FIGHTING MEASURES
ACCIDENTAL RELEASE MEASURES/SPILLS AND LEAKS
HANDLING & STORAGE
EXPOSURE CONTROLS/PERSONAL PROTECTION
VENTILATION
PHYSICAL & CHEMICAL PROPERTIES
STABILITY & REACTIVITY
TOXICOLOGICAL INFORMATION
OPTIMIZING POLYCARBOXYLATE BASED SUPERPLASTICIZER DOSAGE
WITH DIFFERENT CEMENT TYPE
EXPERIMENTAL METHODS
MATERIALS AND MIXTURES
TEST METHODS
RESULTS AND DISCUSSIONS
EFFECT OF SUPER PLASTICIZER TYPE AND WATER-TO-CEMENT RATIO
BENEFITS OF CONCRETE PLASTICIZER
SUPERPLASTICIZERS (HIGH RANGE WATER REDUCER)
PLANT LAYOUT
SUPPLIERS OF RAW MATERIALS
METHACRYLIC ACID
METHOXY POLYETHYLENE GLYCOL
SUPPLIERS OF PLANT AND MACHINERY
SUPPLIERS OF MIXING TANKS
SUPPLIERS OF CONDENSER
SUPPLIERS OF NEUTRALIZATION TANK
SUPPLIERS OF BOILERS
SUPPLIERS OF PACKAGING MACHINE
SUPPLIERS OF MATERIAL HANDLING EQUIPMENTS
SUPPLIERS OF INSTRUMENTATION & PROCESS CONTROL EQUIPMENTS
SUPPLIERS OF LABORATORY EQUIPMENTS
SUPPLIERS OF STORAGE VESSEL (STORAGE TANKS)
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)
