Macro Polymers Plans to Set Up Synthetic Resins Manufacturing Plant
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Macro Polymers Plans to Set Up
Synthetic Resins Manufacturing Plant
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(Update : Ref Our Earlier Report of 24.04.2012)
Macro Polymers Pvt Ltd. plans to set up a Manufacturing Unit to produce Synthetic Resin having Capacity of 15,000 Ton/Month
and Formulation of Resin of 20,000 Ton/Month at Chacharvadi Village, Sanand Taluk in Ahmedabad District, Gujarat..
Capacity :
Synthetic Resin : 15,000 Ton/Month
1. Alkyd Resins : 5,000 Ton/Month
2. Polyamide Resins : 2,500 Ton/Month
3. Polyester Resin : 2,500 Ton/Month
4. Amino Resin : 2,000 Ton/Month
5. Ketonic Resin : 5,00 Ton/Month
6. Acrylic Resins : 2,000 Ton/Month
7. Rosin Esters & Deri. : 5,00 Ton/Month
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Resin Total : 15,000 Ton/Month
Formulation Plant : 20,000 Ton/Month
1. Resin Solution : 10,000 Ton/Month
2. Resin Solution : 10,000 Ton/Month
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Formulation : 20,000 Ton/Month
By Product :
Caustic Lye -45% : 3,650 Ton/Month
Location :
Chacharvadi Village, Sanand Taluk
Ahmedabad District, Gujarat
As on December 20, 2012 : The Project is under Planning Stage.
The unit would come up on about 28,166 sq.m of Land .
Out of this 5635 sq.m of Land will be developed as Green Belt.
IMPORTANT: As per the discussion we had last with
Macro Polymers Pvt Ltd. on 12.12.2012, the project is under planning stage.
The company has obtained First Level Environment Clearance and Is now waiting for final clearance
The Project is Scheduled to be Completed in 7 to 8 months from zero date, latest by December, 2013.
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So, this is the RIGHT TIME to contact and Follow Up at following address obtain the detailed Enquiry of each product in time and to submit your quotation subsequently.
The Main Scope of Supply includes:
Boiler : 1TPH – 1 No.
Fuel : Coal/ Lignite/ Agroresidue/ Bio coal
( Consumtion : 2 Ton/hour)
Stack : 35 Meter
Thermic Fluid Heater : 4 Nos.
Capacity : 25,00,00 Kcal/Hour
Fuel : Coal/ Lignite/ Agroresidue/ Bio coal
( Consumtion : 1 Ton/hour)
Stack : 35 Meter
Heat Exchanger, Air Preheater
Pullution Control Equipment:
Lignite/coal/Agro-residue/Bio coal will be used as fuel in boiler &
thermic fluid heater.
The flue gas emitted from this facility will pass through Cyclone Separator and Centrifugal scrubbing system. Then these cleaned gases will be released through 35 m. of stack for proper dispersion of gases.
As the unit will set up adequate air pollution control system, the pollutants emission will be almost within the stipulated emission standards.
Fugitive emissions :
Fugitive emissions of Resin may result from the
Storage Tanks
Distillation Reactor
Condenser
Vacuum lineSample ports, and
Vents of the processes.
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MANUFACTURING PROCESS
ALKYD RESINS
• Crude glycerin is first taken for distillation and distilled glycerin is obtained. Glycerin residue at bottom is collected and sold of.
• Distilled glycerin is taken for alkyd resin manufacturing along with
vegetable Oils or their Fatty Acid & Poly functional Alcohol reacted at
250 Dec C. under constant stirring alcoholysis or Acidolysis
• It is further with dibasic acid with the aid of catalyst under constant
stirring till required specifications are achieved. The material thin
down with required solvent filtered & packed.
POLYAMIDE RESINS
• Dimer Acid, Fatty Acid & polyamines are reacted with the aid of
Catalyst at elevated temperature under constant stirring till required
specifications achieved.
• Material discharged in trays, broken in small pieces, grinded & packed
or filtered and packed in barrels.
POLYESTER RESINS:
• Mono/di/Polyacid Acid and Polyols/Glycols reacted at 240 Deg C till
desired specifications in Acid Value & Viscosity parameters are attained.
• The material thin down with required solvent to desired nonvolatile contents and cooled filtered & packed.
AMINO RESINS:
• Formaldehyde is made alkaline with caustic solution and then
Butanol is added.
• Then Urea and Melamine is added and temperature is raised to 70 DegC and maintained for certain time.
• And finally again raised to 120 DegC during which catalyst and
Butanol is added stepwise till final specification is achieved.
• Material is filtered and packed in barrels.
KETONIC RESIN:
• Formaldehyde is made alkaline with Caustic Solution and then
cyclohexanone is added.
• Then temperature is raised to 70 Deg C and maintained for certain time.
• And finally again raised to 120 Deg C during which condensation
polymerization takes place.
• Material is applied vacuum to remove water and packed in bags
after drying.
ACRYLIC RESINS:
• Methacrylate Monomers like M.M.A., Acrylate monomers like Ethyl Acrylate, and Styrene are charged into reactor along with solvents like Xylene/Toluene and Polymerized at temperature of 100 Deg C in presence of peroxide initiators till required degree of polymerization is attained.
• Then cooled, filtered and packed into barrels
Rosin Esters and Derivatives
• Rosin & Poly functional Alcohol reacted at 250 Deg C under constant
stirring alcoholysis or Acidolysis it is further with dibasic acid with the aid of catalyst under constant stirring till required specifications are achieved.
• The material thin down & packed..
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Cooling Tower : 4 Nos.
4 Nos. Induced Draft Cooling Tower of 250 TR will be installed for cooling requirements for operation phase.
Each cooling tower will have Recirculation rate of 250 m3 /hr and 60 HP total power consumption.
Chiller : 1 No
Capacity : 100 TR
DG Set : 4 Nos
will be installed to meet the power requirement for Emergency
( ie. During Power Failure)
Fuel : HSD
Storage Tank
1. For Phenol (Barrels) : 10 MT – 1 No.
2. For Formaldehyde (SS Tank) : 50 MT – 2 Nos
3. For Methanol (SS Tank) : 25 MT – 2 Nos
4. For Butanol (SS Tank) : 25 MT – 2 Nos
5. For Monomers (SS Tank) : 25 MT – 4 Nos
6. For Xylene/Toluene (SS Tank) : 50 MT – 4 Nos
7. For Poly amines (Barrels) : 25 MT – 1 No
8. For Cyclohexane (SS Tank) : 25 MT – 1 No.
9. For Butyl Acetate (SS Tank) : 25 MT – 1 Nos
Compressors
Agitators
Distillation Reactor
Material handling
The all material handling will be carried out in close container or
through piping. This piping would be of corrosion resistant material
adequately maintained and scheduled preventive checks for leakage
control will be carried out.
Water Treatment Plant :
Pumps, Valves, Custom Pipeline Work, Plumbing Work
(Oxidisation Chamber, , IRF, Activated Carbon Filter,
R.O. Plant, DM Plant etc. )
Total ground water requirement will be 45 m3/day..
The total water requirement will be met from Bore Well.
Details of Water Consumption
Gardening : 8 KLD
Domestic : 25 KLD
Utilities (Boiler + Cooling) : 12KLD
Process ------
Washing ------
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TOTAL : 45 KLD
Water Treatment Plant shall contain following units:
1. Activated Carbon Filter
2. Micron Filters
3. Ultra-filtration
4. Nano-filtration
• Mixed stream of treated effluent and raw water will be first fed to activated carbon filter for removing trace organics.
• Treated water from ACF will be further polished by Micron Filtration and then ultra-filtration.
• Product from ultra-filtration shall be fed to Nano-filtration for generation water suitable for using as boiler feed water andcooling tower make up water. Reject from UF shall be 5% of feed and taken back to equalization tank.
• The Nano-filtration shall have 90% recovery. The reject will be reused as scrubbing water/on campus horticulture.
Effluent Treatment Plant:
Details of Waste Water Generation
Gardening --
Domestic : 23 KLD
Utilities (Boiler + Cooling) : 6 KLD
Process 34 KLD*
Washing ------
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TOTAL : 63 KLD
*There shall not be any water required in process/reaction. Wastewater will
be generated from the manufacturing process due to presence of moisture
contents in the raw materials (i.e. glycerin, alcohols etc.) and as a by product of esterification reaction.
**63 KLD wastewater will be generated which will be treated in ETP and
finally passed through Nano-filtration (NF) along with 12 KLD fresh water.
NF Permeate will be around 68 KLD and used as feed water for utilities.
Estimated NF reject will be around 7 KLD which will be utilized for campus
irrigation/wet scrubbing of boiler and thermic fluid heater gases.
Effluent Treatment Process :
Source of water pollution is mainly from manufacturing process and
utilities.
It will be treated by two stage biological treatment (Anaerobic + Aerobic).
The treated effluent will be fed to water treatment plant and feed water for boiler and cooling tower will be generated from it. Rejected stream from the WTP will be reused in campus gardening/flue gas scrubbing.
The ETP shall comprise of the following unit processes/operations:
1. Equalization tank for collection of raw effluent generated from
plant for homogenization of the quantity and quality.
2. Anaerobic biological treatment for removal of most of the
suspended and dissolved organic impurities–It includes a buffer
tank, an Up Flow Anaerobic Sludge Blanket Reactor followed by
a tube setter type settling tank (Clarifier–1).
3. Aerobic biological treatment unit for polishing of aerobically
treated effluent to achieve statutory disposal norms–It includes
an Aeration Tank followed by a Settling tank.
4. Polishing treatment units: for further purification of treated
effluent-It includes chlorination and duel media pressure filtration
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List of Main Equipments
for Effluent Tretment Plants
1. Oil & Grease trap, 1.5 m L x 1.0 m W x 0.9 m SWD
2. Bar screen Chamber 1.5 m L x 1.0 m W x 0.9 m SWD
3. Equalization Tank 3.5 m L x 3.0 m W x 3.0 m SWD
4. Buffer Tank 3.5 m L x 1.5 m W x 3.0 m SWD
5. UASB Reactor 12.0 m I.D. x 7.5 m SWD
6. Clarifier 1 (for UASB) 3.5 m L x 3.0 m W x 3.0 m SWD
7. Biogas Receiver Tank 1.8 m I.D. x 1.5 m SWD
8. Aeration Tank 8.5 m L x 6.0 m W x 7.0 m SWD
9. Clarifier 2 (Aerobic) 3.5 m L x 3.0 m W x 3.0 m SWD
10. Treated water collection sump 3.5 m L x 1.5 m W x 3.0 m SWD
11. Chlorination system Online
12. Dual Media Filter 0.75 I.D. x 2.1 m H
13. Sludge Decanter --
14. Treated Water Collection Tank 3.5 m L x 3.0 m W x 3.0 m SW
Supply Of Other Equipments:
Material Handling Equipment : Conveying Systems, Hydraulic Equipments, Screen,
Acid Pumps, Motors, Heat Exchangers, Agitators and Mixers ,Valves, Dryers, Vessels, Cables, Rollers, Custom Pipelines, Storage Tank .
Complete Laboratory Instrument
Fire Fighting Equipment
• First Aid Fire extinguishers to be be installed in the plant area.
• Flame arrestors to be provided at all vent lines at solvent tanks.
• Suitable first aid fire extinguishers, such as, DCP, CO2 & foam type to
be kept in every plant area at easily approachable spots and in
sufficient numbers.
• Fire hydrant points with sufficient length of hose reel will be provided
at major emergency spots.
Scope Of Entire Civil & Construction Work:
Construction of Office Building, factory , Substation-Control Panel- Electrical Work, Plumbing Work, Structural Steel fabrication and Erection Work, Fabrication Storage Tank, Vessels etc. etc.
Companies/ General Industries/ Manufacturers / Contractors/ Sub Contractors/ Manufacturers of Boiler, Air Pollution Control Equipment Water & Effluent Treatment Plant , Material Handling Equipment : Conveying Systems,Motors, Heat Exchangers, Agitators and Mixers ,Valves, Dryers, Vessels, Custom Pipelines, Storage Tank , Fire Fighting Equipment, Air Conditioning, Cables, Automatic Weighing Machines for Bulk & Liquid Materials, Complete Laboratory Equipments , etc. and related to Paper Machineries for the above project may Contact for Specified Enquiry at :
Macro Polymers Pvt Ltd.
165, Maha Gujarat Industrial Estate, Opp. Nova Petrochem,
Sarkhej-Bavla Road, PO Moraiya
Taluk Sanand, Ahmedabad, Gujarat, India
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Tel : + 91-9228010801
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Email : purc...@synresin.com /
Website : www.macropolymers.com/ www.synresin.com
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