RADIATOR COOLANT
[EIRI/EDPR/1077] J.C.: 9721XL
INTRODUCTION
What is Radiator Engine Coolant?
There are two types of Coolant.
1) Engine Coolant
2) Machine Coolant
Engine Coolant is a mixture of various types of glycols and highly formulates & researched various corrosive inhibitors. De-mineralized water is mixed with the coolant as per suggestion and used in the engine-radiator cooling system to remove excess heat of engine.
Why Coolant is required?
The purpose of Coolant is to remove excess heat produced from the engine operation, to control corrosion and scaling, antifreeze and boil over the radiator water. So many years ago water was used to reduce the temperature. Water is an effective heat transfer fluid but it boils at very low temperature. Highly corrosive and format scaling. It impure the cooling liquid by accumulating corrosive and scaled waste. So it chocks up tubes of radiator and finally engine overheats. The complexity is increased with the use of aluminum alloys in the head, water pump and radiators.
To protect against the heat, corrosion of aluminum and other metals & scaling; coolant creates a special protective film on all metals. Our this specially researched protective film have important role in the cooling system. This special corrosion inhibitors film technology is only researched and used by us in India.
Performance Advantage Coolant:
Coolants industry need scientifically advance research lab. The industry also need technically dynamic staff having experienced scientist and chemist. Coolant must be little bit different from other coolant because it is always thick and exceeds all major automotive performance protection international specification. It protects whole cooling system metals like Aluminum, Steel, High Lead Solder, Cast Iron, Copper, Brass, Low Lead Solder etc. against rust, surface and pitting corrosion. It is eco friendly and fully synthetic formulated coolant.
It incorporates state of art organic acid technology (OAT) in an Ethylene Glycol base for protection of whole cooling system metals including Aluminum. Most Coolant does not contain phosphates, silicates, borates, nitrates, nitrites and amines. It contains a high quality defoamer and does not harm gaskets, hoses, plastics or original vehicle paint.
The internal combustion engine is a heat engine, in which chemical energy of fuel is converted into heat energy by combustion and this heat energy is in trun converted into mechanical energy. Approximately one third of the heat energy is converted into mechanical energy, about one third is removed by the cooling system and one third by the exhaust system. There are minor losses due to friction, radiation and the lubrication system. For each 3.8 litres of fuel burned about 6.32 M J must be rejected to the cooling system. If this heat is not removed, the engine will be destroyed.
The cooling system consists of a (heat exchanger, thermostat, coolant pump, coolant jacket surrounding the cylinders and combustion chambers and various rubber hoses serving as flexible connections between the radiator and engine to allow complete circulation of the coolant.
The coolant pump circulates the coolant through the engine coolant jacket, where it picks up heat dissipated by the combustion chambers & cylinders and then through the radiator (heat exchanger), allowing the heat to be transferred to the outside air. The coolant is then returned to the engine block and the cycle is repeated.
COOLANT
The coolant used in this cooling system must fulfill the requirement of the engine, which is baiscally the removal of one third of heat produced during combustion of fuel.
COST ESTIMATION
Plant Capacity 500 Ltr./Day
Land & Building (1000 sq.mt.) Rs. 1.11 Cr
Plant & Machinery Rs. 68.20 Lac
Working Capital for 3 Months Rs. 69.49 Lac
Total Capital Investment Rs. 2.74 Cr
Rate of Return 18%
Break Even Point 68%
CONTENTS
INTRODUCTION
THERE ARE TWO TYPES OF COOLANT
WHY COOLANT IS REQUIRED?
PERFORMANCE ADVANTAGE COOLANT:
GLYCOL BASED ANTIFREEZE COOLANT
MANUFACTURING PROCESS INVOLVES FOLLOWING MAJOR STEPS:
REQUIREMENT OF COOLANTS
DISADVANTAGES OF WATER:-
WORKING PROCEDURE:-
ENGINE COOLANT:-
USES AND APPLICATIONS
SERVICE PERIOD
PERFORMANCE OF COOLANT
FREEZING PROTECTION:-
BOILING POINTS:-
COOLANT LOSSES:-
FOAMING:-
EFFECT ON ELASTOMERS:-
EFFECT ON POINT:-
CORROSION AND INHIBITORS:-
SERVICE LIFE:-
PHYSICAL PROPERTIES OF ETHYLENE GLYCOL
PHYSICAL PROPERTIES OF ACCEPTABLE ANTIFREEZE COMPOUNDS
B I S SPECIFICATIONS AND REQUIREMENTS
MARKET POSITION WITH FUTURE DEMAND
AUTO POLICY OF GOVERNMENT OF INDIA
AUTOMOBILE INDUSTRY PERFORMANCE DURING 2006-2007
LIST OF MANUFACTURERS
INDIA AS AN ASIAN BASE:-
PRESENT MANUFACTURERS
RADIATOR COOLANTS
MANUFACTURING PROCESS
A. ORGANIC COMPOUNDS
B. INORGANIC COMPOUNDS
C. SILICONS
FORMULATION- - (VERY GOOD QUALITY ENGINE COOLANT)
MANUFACTURING PROCESS
ENGINE COOLANT (MEDIUM QUALITY FORMULATION):-
ENGINE COOLANT (CHEAPER QUALITY) FORMULATION:-
SODIUM MERCAP TO BENZOTHIAZLE - (SOD. MBT)
SODIUM SILICATE
DIMETHYL SILCONE:- (SILICONE OIL)
TRISODIUM PHOSPHATE:- (TSP)
MINERAL OIL
PLANT SKETCH FOR ENGINE COOLANT MANUFACTURING
ENGINE ANTIFREEZE COOLANT COMPOSITION
ANTIFREEZE COMPOSITIONS
EXAMPLE 1
EXAMPLE 2
EXAMPLE 3
EXAMPLE 4
CORROSION INHIBITING COOLANT COMPOSITIONS
COOLANT INHIBITOR CONCENTRATE
EXAMPLE 1
PROCEDURE
EXAMPLE 2
PROCEDURE
EXAMPLE 3
LIQUID COOLANT COMPOSITIONS WITH ANTI-CORROSIVE PROPERTY CONTAINING MAGNESIUM AND CALCIUM COMPOUNDS
THE TEST RESULTS ARE SHOWN IN TABLE 1.
ANTIFREEZE COOLANT COMPOSITION HAVING HIGH HEAT-OXIDATION RESISTANCE
EXAMPLES 1-6
PREPARATION OF AN ANTIFREEZE LIQUID
COMPARATIVE EXAMPLES 1-7
MATERIAL OF CONSTRUCTION OF PLANT & MACHINERY
1. REACTION VESSEL (JACKETED):-
2. PIPE LINE FILTER:-
3. STORAGE TANKS/WEIGHING, FILLING TANKS:-
QUALITY TESTING OF ETHYLENE GLYCOL
REQUIREMENTS OF COOLANT:-
GENERAL REQUIREMENTS:-
COLOURATION OF LIQUID:-
SPECIFIC REQUIREMENT:-
KEEPING QUALITY:-
PACKING & MARKING:-
PACKING:-
MARKING:-
CAUTIONS ON HANDLING:-
BIS CERTIFICATION MARKING:-
SAMPLING:-
TABLE 1 REQUIREMENTS FOR ANTIFREEZE COOLANTS
PLANT LAYOUT FOR ENGINE COOLANT MANUFACTURING UNIT
PROJECT IMPLEMENTATION SCHEDULE
PROCESS FLOW SHEET
MANUFACTURERS & SUPPLIERS OF RAW MATERIALS
DISTILLED WATER
SODIUM SILICATE
WHITE MINERAL OIL
PLANT AND MACHINERY SUPPLIERS
REACTION VESSEL
OIL STORAGE TANKS
LABORATORY EQUIPMENT AND LAB TESTING EQUIPMENT
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)
