Detailed Project Report on Superabsorbent Polymer Using Continuous Gel Polymerization (Production Rate – 1000 TPM)

Detailed Project Report on Superabsorbent Polymer Using Continuous Gel Polymerization (Production Rate – 1000 TPM)

SUPERABSORBENT POLYMER USING CONTINUOUS GEL POLYMERIZATION (PRODUCTION RATE – 1000 TPM)

[EIRI/EDPR/4585] J.C.: 2802XL


INTRODUCTION

Superabsorbent polymers are primarily used as an absorbent for water and aqueous solutions for diapers, adult incontinence products, feminine hygiene products, and similar applications. Undoubtedly, in these applications, superabsorbent materials will replace traditional absorbent materials such as cloth, cotton, paper wadding, and cellulose fiber.


Commercial production of superabsorbent polymers began in Japan in 1978, for use in feminine napkins. This early superabsorbent was a crosslinked starch-g-polyacrylate. Polyacrylic acids eventually replaced earlier superabsorbents, and is the primary polymer employed for superabsorbent polymers today.1 In 1980, European countries further developed the superabsorbent polymer for use in baby diapers. This first diapers employing this technology used only a small amount of polymer, approximately 1-2 g. In 1983, a thinner diaper using 4-5 grams of polymer and less fluff was marketed in Japan.


COST ESTIMATION

Plant Capacity            33.334 MT/Day  

Land & Building (3815 sq.mt.)    Rs. 4.76 Cr    

Plant & Machinery                    Rs. 9.92 Cr 

Working Capital for 0.5 Months    Rs. 13.93 Cr 

Total Capital Investment          Rs. 29.50 Cr 

Rate of Return                          48%

Break Even Point                      37%


CONTENTS
INTRODUCTION
USES/APPLICATIONS
ADVANTAGE OF SUPERABSORBENT POLYMER IN AGRICULTURE
MARKET OVERVIEW
TYPES OF SUPERABSORBENT POLYMER
ABSORBENT VERSUS SUPERABSORBENT MATERIALS
CLASSIFICATION AND PREPARATION OF SUPERABSORBENT POLYMERS
SUPER ABSORBENT POLYMER AND ITS CHEMISTRY
COMPARISON TO OTHER SOLIDIFICATION MEDIA
MECHANISMS OF SWELLING IN SUPERABSORBENT POLYMERS
OVERVIEW OF SUPERABSORBENT POLYMER MANUFACTURING
FORMULATIONS
RAW MATERIALS
RAW MATERIAL SUPPLIERS
MANUFACTURING PROCESS STEPS
TEST METHODS
SPECIFICATIONS
ENGINEERING DESIGN CONSIDERATIONS
ETP FACILITY
SEWAGE AND WASTE WATER EFFLUENT
WASTE GENERATION & MANAGEMENT/GREEN BELT
PLANT/MACHINERY (BROADLY)
SUPPLIERS OF PLANT & MACHINERIES/TURNKEY
UTILITIES PER MONTH (ESTIMATED)
PRINCIPLES OF PLANT LAYOUT
PLANT LOCATION FACTORS
HEALTH SAFETY & ENVIRONMENT
ANTICIPATED ENVIRONMENTAL IMPACTS
SAFETY & OCCUPATIONAL MEASURE
PROPOSED IMPLEMENTATION SCHEDULE
PROJECT FINANCIALS
PRELIMINARY LAYOUT
COMPARISONS OF DIFFERENT MANUFACTURING PROCESSES
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)

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