PLANT DESIGN PROJECT MANUFACTURE OF EPOXY RESIN

EPOXY RESINS

Introduction:

Among the most interesting polymers developed during the last ten years are the epoxy resins. They account for the major part of the commercial production .They based on ethylene oxide or its homologs or derivates, are one of the newer thermosetting resins in the process industries.

Epoxy Resins:

They are the thermosetting resins that contain three -member cyclic ether group commonly known as an Epoxy group (1,2 epoxide) or oxirane groups & secondary hydroxyl(gp)

Formation Of Epoxy Resins:

The epoxy resins are basically or fundamentally polyethers that are formed by poly condensation of of Epichlorohydrin with Bisphenol (polyphenols) or polyalcohols.

Mechanism:

There are two steps to making epoxy resins. First you have to make a diepoxy, and then you have to crosslink it with a diamine. So we're going to talk about those two steps separately. You can read about whichever you like first: Making the DiepoxyThis step is a type of Step-growth polymerization in its own right. We make the prepolymer using Bisphenol A and Epichlorohydrin.

STEPS INVOLVED IN MECHANISIM:FORMATION OF BISPHENOL A SODIUM SALT:NaOH does a little swap with the Bisphenol A, to give the Bisphenol A sodium salt:

FORMATION OF BISPHENOL A SODIUM SALT GROUP:The salt, as you will notice, has an oxygen with three pairs of electrons that it isn't sharing with anyone. Now this particular oxygen atom is generous, and wants to share its electrons with less fortunate atoms. So it finds a carbon atom on a nearby Epichlorohydrin which could use some electrons. That atom is the carbon atom right next to the chlorine. The chlorine is supposed to be sharing a pair of electrons with that carbon, but being electronegative as it is, tends to hog that pair. So the oxygen, being the kind atom it is, donates a pair of its electrons to the carbon. Carbon of course can only share four pairs of electrons at once, so one pair has to go if it wants to take the oxygen's pair. So it lets go of the electrons it has been sharing with chlorine, and sends the chlorine atom on its way, expelling it from the molecule.

We end up with a molecule similar to Bisphenol A, only with an epoxy group on it. And we also get NaCl. Sometimes the degree of polymerization is as high as 25. Sometimes they can be as small as this:

How big or small the prepolymer gets depends on the ratio of Epichlorohydrin to Bisphenol A in the reaction mixture. Let's put that ratio at two molecules of Epichlorohydrin for every molecule of Bisphenol A. Let's see what happens to the molecule we just made at this ratio:

What happens is we get an epoxy group on the other side, too. The reaction then stops, as there are no more Bisphenol A salt groups remain to left. But what if there are less than two molecules of Epichlorohydrin for every Bisphenol A molecule? Then not all of the Bisphenol A salt groups can react with Epichlorohydrin. Let's say our ratio now is three molecules of Epichlorohydrin for every two molecules of Bisphenol A. When all the Epichlorohydrin molecules have reacted we're left with a 50:50 mixture of these two molecules:

FORMATION OF EPOXY RESIN:We're left now with a dimer, which happens to be a sodium salt. Take special note of the negative charge on the oxygen atom. When a water molecule comes along (remember, we made a bunch of water molecules when we made the sodium salt of Bisphenol A) a pair of electrons from the oxygen will attack one of the water's hydrogens, stealing it from the water.

The oxygen now forms an alcohol group, and we get our NaOH back. CURING OF EPOXY RESIN:Curing of epoxy resin takes place to get finished products with outstanding chemical inertness, toughness, adhesion and dimensional stability. The most commonly used curing agents are aliphatic amines, aromatic amines, anhydrides, polyamines , polysulfide polymer, phenolic resins etc.

RAW MATERIALS FOR MANUFACTURING OF EPOXY RESINS:

There are following major raw materials used for forming Epoxy Resins.

1) Epichlorohydrin: -It Is Main Raw Material That Is Formed By Reaction Of Dichlorohydrin With Caustic Soda.2) Bisphenol: - It Is The Condensation Product Of Phenol & Acetone.3) NAOH (Alkaline Catalyst):-It is used as the alkaline catalyst.4) Methyl Iso butyl Ketone:-It is used to eliminate NaCl. Dependence Of Molecular Weight Of Epoxy Resins:The molecular wt of these resins depends largely on the molar ratio of the reactants. Epichlorohydrin used in large excess act as a chain stopper .The liquid resins are prepared by using an excess of 6-8 moles of Epichlorohydrin per mole of Bisphenol. Two moles of caustic soda are generally used & the reaction is preferably carried in the absence of water. The reaction temperature may vary between 50-100centigrade. The solid, higher mol.wt epoxy resins are obtained by decreasing the amount of Epichlorohydrin used. Here the Caustic soda is preferably added in aqueous solution.

METHODS FOR MANUFACTURING OF EPOXY RESINS: Resins of higher mol.wt can be prepared by following to 2 routes 1) Taffy process 2) Advancement process

1) TAFFY PROCESS: It is the process in which Bisphenol directly react with Epichlorohydrin in the presence of stoichiometric amount of caustic to yield Epoxy Resins that have medium molecular weightReaction Conditions:Temperature = 50-100 cReaction Time = 1hour

APPLICABILITY:The taffy process is generally employed only for medium molecular weight resins which means Bisphenol directly react with excess Epichlorohydrin in the presence of a stoichiometric amount of caustic soda.

Explanation:In this process , the polymerization reaction result in a highly viscous product (emulsion of water & resins) & the condensation reaction becomes very dependent on agitation .At the completion of the reaction , the heterogeneous mixture consists of an alkaline solution & a water -resins emulsion & recovery of a product is accomplished by separation of phases , washing of the taffy resins with water & removal of water under vacuum

The Relationship Between Mole Ratio Of (Epichlorohydrin---Bisphenol) & Resultant Epoxy Equivalent Wt Of The Resin:The relationship between mole ratio of Epichlorohydrin -Bisphenol & the resultant epoxy equivalent weight of the resin product.

As we decrease the amount of Epichlorohydrin then higher molecular weight of resin will formed. As we decrease the amount of Epichlorohydrin due to which the ratio of Epichlorohydrin -Bisphenol is decreased, so the higher molecular weight resin will obtained that have also high epoxy equivalent weight.

DISADVANTAGES:

Occurrence Of Side Reactions:Slide reaction , are more likely in the taffy process , lead to branching of polymer chain to give an increase in melting point & viscosity that is not desired yield , so by which our desired productivity yield is decreased .

Expansibility:

Due to excess consumption of raw materials, this process increases the expansibility.

2) ADVANCEMENT PROCESS: It is the process in which liquid epoxy resin is chain extended with Bisphenol directly in the presence of a catalyst to yield higher polymerized products i.e. (solid epoxy resins).Reaction Conditions :Temperature = 60-80c Reaction Time =1-1.5 Hour

Dependence of Molecular Weight of Resin: The molecular weight of resin is a function of the ratio of excess liquid epoxy resin to Bisphenol.

Applicability:It is utilized for the manufacturing of high molecular weight resins directly.

ADVANTAGES:

Enhancement of Desired Yield: Since no by -products are generated, hence our desired yield is increased.

Minimization of Difficulties During Resin Purification:This procedure also helps to overcome the difficulties in purification encountered while removing sodium chloride from a high molecular wt resin because the molecular weight of resin is very high due to its pore size is also high so the (NaCl used as a catalyst does not trapped in the pores of these resins , it passes through these resins .

Preference: Since no by -products are generated in advancement process , hence it is more convenient than the taffy processes..

Industrial Applications of Epoxy Resins: Epoxy Resin find useful application in industry because of their outstanding properties such as Adhesion to various materials, chemical inertness, low shrinkage during cure , stability at elevated temperature flexibility & toughness .

In Protective Surface Coating: The Epoxy Resins are used as a protective surface coating materials because of their high chemical resistance & adhesions.

In Both Molding & Laminating Techniques: Epoxy Resins can be used in both molding & laminating techniques to makes glass fiber-reinforced articles with better mechanical strength & chemical resistance.

In Manufacturing of Plastic Machine Tools:The manufacture of plastic machine tools is a major field for epoxy resins, which are especially.

Modified Epoxy Resin:Epoxy resins form adducts with vinyl, acrylic, polyester resins, phenol novolac (9003-35-7), cresol novolac (37382-79-9), bis-[4(2,3-epoxy propyoxy) phenyl] methane (2467-02-9), and phenol hydrocarbon novalac Structure:Ethylene oxide is cyclic ether. The carbon atoms in oxirane are trigonally sp2 hybridized. One orbital from each carbon atom overlaps with the atomic orbitals of the oxygen atom to form molecular orbital in the center of the ring. Atomic p orbitals, in the plane of the ring, overlap sideways. This explains the conjugative ability of epoxy ring, and results in a bent bond structure. Since the H-C-H bond is 116 15, the carbon will be sp2 hybridized. But it also shares the triangular ring, so it is possible to give the correct hybridization structure. Very often the epoxy groups deform to keep the area of the ring constant. The ring atoms do not lie along the lines of greatest electron density of the atomic orbitals from the neighboring atoms. The smaller amount of overlapping is more than offset by a decrease in the strain energy.Characterization And Properties:The end groups epoxy, hydroxide, glycol, chlorine, and Bisphenol A estimated by the usual chemicalMethods. Researchers have found aqueous concentrated hydrochloric acid with dioxane to be a suitable reagent for estimating epoxide content. Curing agents such as amines are characterized by refractive index and specific gravity. Thin-layer chromatography has been used for identification. The reactive dye labeling technique has also been used for studying the curing reaction. The epoxy resins do not soften at a specific temperature but appear to undergo a gradual and imperceptible change. The softening of epoxy resins can be empirically graded by the ring and ball method. The curing of epoxy resins is an exothermic process, resulting in the production of limited-size molecules, having molecular weights of a few thousands. Their weight is determined by the usual physical methods. The number average molecular weight (Mn) is determined by gas density, and cryoscopic, ebulioscopic, and osmotic pressure methods. The weight average molecular weight (Mw) is estimated by viscosity and light scattering methods. Solubility parameters and critical surface tension (surface tension below which a liquid drop makes zero contact angle) have been used to find the molecular weights between the cross-links (Mc). Epoxy resins have a very wide molecular weight distribution. This can be estimated by comparing the Mw and Mn values. The greater the difference, the wider the distribution. Gel permeation chromatography has been used for finding this distribution. Liquid epoxy resins or their solids in 40% diethylene glycol solution do not behave as Newtonian liquids. The kinematic or intrinsic viscosities of epoxy resins are measured by viscometers, which can measure the dependence of viscosity on shear rate. Viscosity studies also provide information regarding the formation of networks and their aging. The linear viscoelastic response of epoxies displays the internal characteristics of tensile relaxation and fracture response. Chemorheology studies display the changes in deformation and flow properties of the resin. Continuous and intermittent stress relaxation measures the appearance of network formation. Researchers have used a variety of techniques to study the thermal and environmental stability of epoxy polymers. The effect of moisture on epoxy resins has been studied from the point of view of both absorption that brings about degradation and of sorption behavior itself. Water absorption has been found to decrease the Tg because of strong hydrogen bonds. It has been shown that in amine-cured resins, water is homogeneously distributed as a plasticizer and that water clusters are present at microcracks. The strength and toughness of epoxy resins below the glass transition temperature Tg depend on the mechanism of the movement of short segments in the solid state, and above Tg mechanical properties are influenced by cross-linking density and Mc. Epoxy resins shrink on curing. Thus both the density and refractive index increase. It is necessary to distinguish between shrinkage in the liquid stage and shrinkage in the gel or solid state. Shrinkage in the gel or solid state introduces stress. Thus gelation temperature has a direct effect on the degree of shrinkage. Refractometry or dilatometric measurements are used to measure shrinkage, which determines the cure rate. Epoxy resins are noncrystalline, and cured resin finds its structural applications below the heat distortion or glass transition temperature (Tg). Continuous and intermittent stress relaxation measures the appearance of network formation. A variety of techniques have been used to study the thermal and environmental stability of epoxy polymers. Several mechanical properties of epoxy resins are closely related with chemical composition and internal cohesive energy of the resin. This has been found to be true well below the transition temperature, where rotational motion related to configurational entropy and stress relaxation processes do not occur. Epoxy resins undergo alpha, beta, and gamma thermal transition through proper selection of epoxy monomers and curing agents. The temperature, location, and magnitude of these transitions directly influence the thermo-mechanical properties of the resins. These transitions also are influenced by the mechanism of cross linking produced by amines, BF3-amine complex, and anhydride curing agents. These transitions can be studied by DYNAMIC MECHANICAL ANALYSIS (DMA) AND NUCLEAR MAGNETIC RESONANCE (NMR).Epoxy resins have good electrical insulation properties. They have a 3-6 dielectric constant, a low dissipation and loss factor, and good arc, surface, and volume resistance. These properties are affected by moisture and increase in temperature. The resins can be made conductive and semi conductive by use of suitable fillers and curing agents.Applications:FoamsEpoxy resins are used to form rigid, lightweight, foamy structures with good insulation properties. They are particularly used for foam-in-place applications in the potting process, as well as in casting. They are produced either by chemical reaction or by incorporating prefoamed filler in the liquid system. AdhesivesThe versatile properties of epoxy resins make them valuable as adhesives in civilian and military applications. About five percent of total epoxy resin production is consumed as adhesive in a wide range of structural applications. Epoxy resin adhesives form strong bonds with almost all surfaces, with the exception of some nonpolar substrates. Very often special modifiers and curing agents must be used to produce specific properties. The formulation of epoxy adhesives into a serviceable adhesive binding system is a highly specialized technology. Adhesives based on epoxide resins are available as room-temperature-curing two-component liquids, heat-curing liquids, powders, hot-melt adhesives, films, and tapes. Adhesive formulation based on epoxy resins requires a wide variety of curing and modifying agents. Generally DGEBA and oligomers are used, but to produce some specific effects alicyclic or heterocyclic epoxides are also included. Polyvinyl modified resins are used to increase flexibility and as toughening agents. Epoxy polyurethane resins make high-strength structural adhesives. Acrylates are also used to modify epoxy adhesives. Rubber- and elastomer-modified resins have been used to produce adhesive that cures under water.ConstructionEpoxy resins are now used as binders in materials for construction. 32 Generally a two-component system containing liquid epoxy resin, diluents, fillers, thickening agents, and curing agents is used. They are used to bond concrete, and to produce industrial seamless thin-set tarrazzo floors. This use has been extended to the laying of roads, construction of buildings, and filling cracks in concrete structures.MoldingMolding can be broadly classified as simple molding and embedding processes. In the simple molding process, the molding powder under certain definite conditions assumes the shape of the mold. This process can be further subdivided as compression molding, injection molding, liquid injection molding, reaction injection molding, foam reservoir molding, and transfer molding. In embedment, material is packed to protect it from a hostile environment. Embedment implies complete encasement in some uniform external shape. Encapsulation, by contrast, is a coating process in which the final surface is irregular. Embedment may be further divided into casting and potting, and impregnation. These processes are common in electrical and electronic assemblies.Epoxy PowdersThe most commonly used epoxy powders are based on B-stage resins with aromatic amines or methaneDiamine. Dicyanodiamide or guanidine is also used, and inert fillers include silica, clay, and calcium carbonate. These resins are also used in foundry molding. Special molds are not required for epoxy resin molding powders. For no reinforced materials such as coil covering and electrical cases, aluminum molds are used. Epoxy-molded compounds display excellent resistance to most acids, bases, solvents, salts, and other chemicals. In addition to flexibility enhancers such as polyamide, carboxylated polymers, and polysulphides, fatty diamines and thermally and electrically conductive materials also are used.Composites and LaminatesComposites and laminates are materials produced by reinforcing the polymers with continuous fibers. These can be fabricated into structural materials. This industry consumes 27.6% of the epoxy resins produced.LaminatesLaminated epoxy insulations are largely used as sheets, rods, and tubes. Sheets of woven glass, paper, andpolyaramid fabric or cotton prepregnated with the B-stage epoxy resins are laminated in large multiple pattern presses. These are used in preparing assemblies of copper-clad glass or polyaramid fibers for printed circuit boards in the electronics industry. Laminated epoxy structures are used in building construction for concrete molds, honeycomb cores, facing for foams, wood, metal assemblies, and reinforced pipes. Both wet impregnated and dry epoxy resin systems are used in aircraft construction. Carbon and polyaramid fibers are used in the laminates. Epoxy laminates also find application in marine industries; epoxy resins are replacing polyesters in special applications in which underwater strength is important.CompositesThe fibers that dominate the field of advanced composites are carbon, graphite, glass, aluminum, boron, and aromatic polyamides. 35, 36 These fibers possess the desirable properties of low density [1.44-2 4.27 g/cm2] and extremely high strength (80-550 GPa). When combined with the resin binder and laminated to support applied load, they provide mechanical properties.

PipesEpoxy resins are used in filament-bound, glass-reinforced pipes and tubes.Matrix EffectsMatrices play an important role in maintaining the orientation and spacing of the fiber and in transmitting uniform shear load between the layers of the fibrous laminate. Epoxy and modified epoxy resins have been used in composite structure. The composite property in an epoxy matrix improves with increasing fiber wet-out, which can be further improved by increasing the laminating pressure. The adhesion of matrix-dot graphite fiber was increased by finishing the surface of the fiber. The glass fiber is coated with a sizing material or coupling agent (e.g., silane) to give adequate finish. Ammonia plasma has been used to improve the finish of the fibers. A mechanism has been worked out to remedy adhesion failure between matrix and the substrate. The ultimate strength of the composite depends on the flow of resin during cure, which can be improved by adding flow agents.COATINGSThe coatings industry is the biggest consumer of epoxy resins. These resins are used mostly as chemical and special purpose coatings. Epoxy resins provide thin-layer durable coatings having mechanical strength and good adhesion to a variety of substrates. They are resistant to chemicals, corrosion, and solutions. They find applications in washing machines and appliances, ships and bridges, pipelines and chemical plants, automobiles, farm implements, containers, and floor coatings. Epoxy coating formulations are available as liquid resins, solid resins, high molecular weight thermoplastic resins, multifunctional resins, radiation curable resins, and special purpose Resins. Aliphatic amines, aromatic amines, and ketamines are used as curing agents for package epoxy systems. Epoxy baking finishes are obtained by high molecular weight epoxy resins cross linked by phenolic or amino resins. These resins are used as lining for tanks, cars, drums, pails, pipes, down hole oilfield tubing, and food cans. Epoxy acrylic systems provide excellent coatings for appliances, kitchen cabinets, outdoor furniture, aluminum siding, and other metal products. High-solid coating solution formulations attain maximum film properties (adhesion, appearance, and freedom from defects). These are based on liquid epoxy resin acrylic adducts with epoxy resins. These adducts have proved useful in automotive primers. Epoxy resins cured with aliphatic amines, polyamides, or aliphatic liquid amine adducts are used in seamless floors. Industrial floors require extra epoxy resin. Waterborne coatings are made by dispersing or emulsifying the resins with surfactants. Such coatings also have been based on emulsified liquid epoxy resins cured with emulsified polyamide resins. These formulations are used in anionic electrodeposited coatings. They provide exterior and interior coatings for underground pipes, and electrical equipment appliances reinforcement. High-solid coatings have an additional advantage, as they are useful on steel, brass, metal furniture, buildings, and miscellaneous products. Application of powders is accomplished by electrostatic spray fluidized-bed coating and electrostatic fluidized-bed coating. For marine use, epoxy resins that cure under water or are resistant to seawater have been developed.

OTHER APPLICATIONS Epoxy resins improve the crease resistance or breaking of fibers. They are also used as intermediates for stabilizers and plasticizers.

All Raw Materials Specification:99% HIGH QUALITY SODIUM HYDROXIDEUS $ 480 - 520 / Ton

Color: White Appearance1: flakes Appearance2: solid

Appearance3: pearl Flakes Price: USD480.00-490.00/MT Solid Price: USD520.00-530.00/MT

Pearl Price: USD500.00-520.00/MT

Bisphenol A (BPA)US $ 2,100 - 2,500 / Metric Ton

Name: BPA Melting Point: 155-158 Boiling Point: 250-252

Flash Point: 79.4 Density kg/m3: 1.195 Molecular Weight: 228

Epichlorohydrin, ECHUS $ 2,000 - 3,000 / Ton

Epichlorohydrin ECH, 3-Chloro-1, 2 - epoxypropene, chloropropylene oxide (ECH for short) Molecular Formula: CH2OCHCH2Cl, C3H5OCl Uses: Applicable to the production of epoxy resin, pharmaceutical intermediates, accelerant, and thinner. Properties: It is a volatile, unstable colorless liquid with irritating odor similar to chloroform and ether. Molecular weight is 92.85, density, 1.1806g/cm3, boiling point, 116.11C, freezing point, -57.2C, refractive index (nd20), 1.4382, flash point (open cup), 40.6C, and ignition point, 415C. It is slightly soluble in water, miscible with many organic solvents, and able to generate azeotrope with a variety of organic liquids.Quality Index: HG 2 - 1379-80METHYL ISO BUTYL KETONE MIBKFOB Price:US $ 1,600 - 1,960 / Ton

MIBK is a clear, colorless, volatile flammable liquid with an odor. It is soluble in all proportions in water, and is used in many solvent applications as well as an ingredient in many chemical reactions. is produced from liquid acetone and gaseous hydrogen by contacting with a catalyst.USES:is used for solvent of nitro celluloses, gums, lacquer and recovery of used Uranium. MIBK is also used in the pharmaceutical and electroplate industry. In addition to these applications, new filed is semiconductor industryCommon name: MIBK Chemical name: 2-Propanone; Dimethyl Ketone Formula: CH3COCH2C(CH3)2

EQUIPMENTS SPECIFICATIONS:HOT SALE Epoxy Resin ReactorUS $ 0 - 70,000 / Set

Specifications1. Jacket/ Out-coil Reaction Vessel 2.Material: SS/CS 3.steam/oil heating 4.Long service time 5.Heating ways: Electric/ Heat Oil/ Steam6. Capacity: 50~60000L

EvaporatorGlass-lined film evaporator High vacuum and low temperature Corrosion-resistance property of glassed lineGlass-lined film evaporator It is the pioneer product in China solving the problem of refining distillation of high boiler with strong corrosion and heat instable chemicals, which can greatly promote the recovery efficiency and quality of high boiler and heat instable chemicals, covering the advantages as: 1.The high vacuum and low temperature evaporation can make the compound difficult to decompose, so the product has high recovery efficiency. 2.The evaporation area is large with high efficiency. 3.The material retention time is short (within 10 seconds approximately), and the compound difficult to decompose, so the product has high recovery efficiency. 4. It has the corrosion-resistance property of glassed line.

External Gear PumpUS $ 500-1350000 per Unit

SpecificationsApplications: Oils, Fuel Oils, Lubricating Liquid, Resins, PaintsCapacity: 0.1 to 500 m3/hrDischarge Pressure: 300 BarTemperature : -30 to 540 CViscosity : 1 to 1000000 cpsMaterial of Consturction : CI, CS, SS304, SS316, SS316L, Duplex, A20, TitaniumBenefits Extensive viscosity range Large temperature spectrum Large pressure range High degree of efficiency thanks to application-specific clearances Reliability and many years' experience Long lifetime Operational safety

GRE pipe

US $ 10-1000 /METER

GRE pipe performance features:1.corrosion resistance2.strong bearing3.light weight, easy to install4,smooth internal face, low friction5.high, middle, low pressure rating satisfy different medium delivery6.fine tightness with steel pipe

RTRP (Reinforced Thermosetting Resin Plastic) Pipe

US $ 5.8-8 /KG

Diameter: 40mm-800mm Pressure: 3.5Mpa-25Mpa Temperature: -35-65 or -35-125

GRE(GlassReinforcedEpoxy)Sometimes,greandfrp/grp(fiber/glassreinforcedplastic)areregardedasthesameMaterialwithdifferentnames,butinmostcases,sincegrechoiceepoxyresinasmaterial,ithasstrongerperformances.it is the thermosetting plastic products combining the reinforced material of fiberglass roving with the base material of epoxy resin.it is made by mechanical filament wound process controlled by computer.so it is a kind of composite material. Seamless Pipe /EN10024/ Epoxy Resin/ManufactureUS$ 750-1200 /METRIC TON

Standard: GB, DIN, ASTM, API

Grade: 20#, 45#, 16Mn, A53(A,B), A106(B,C), St3...

Outer Diameter: 33.4 - 610 mm Thickness: 2.5 - 33 mm

Application: Structure Pipe

Ultrasonic Screen Vibrating For Epoxy ResinUS $ 1,000 - 100,000 / Set

color: gray or other material: SUS304/316L,Carbon steel

voltage: optional current: AC frequency: 50Hz

screen mesh: 5~500mesh application: epoxy resin certificate: ISO 9001:2008&CE

cleaning system: ultrasonic power: 0.18Kw~2.2Kw

Technical Parameter

Calculations:Material Balance:Production rate 20000 kg per hourYield on polymer100%Conversion 95%Catalyst 250kg per 1000kg monomerWash water 1kg per 1kg polymerRecovery column, yield (98% EPH recovered)Polymer losses in Evaporator, phase separator(1%) Evaporator feed(5% H2O), product specification BASIS 1 houra) STEP 1:

DETERMINATION OF ACTUAL MASS OF POLYMER OBTAINED:Actually, when the product goes into P.S & evaporator then in these section , 1% product losses , so with 1% loss , the actual product obtained or overall reactor yield obtained is 20000kg *99%/100 = 19,800kgb) STEP 2:DETERMINATION OF MASS AMOUNT OF EPH (feed):We have Conversion =amount of EPH consumed/amount of EPH in feed According to specification conversion is 95% So, 0.95 =19,800kg /amount of EPH in feedAmount of EPH in feed =19,800kg /0.95Amount of EPH in feed =20,842.10526kg

Step 3:DETERMINATION OF UN REACTED EPH FROM REACTOR: Un reacted EPH =amount of EPH (feed ) Product yield or overall reaction yield or product formedUN reacted EPH =20,842.10526kg-19,800kgUN reacted EPH=1042.105263kg

Step 4:DETERMINATION OF AMOUNT OF CATALYST:Catalyst at 250kg/1000kg monomer=20,842.10526kg*250*10-3=5210.526315kg

Step 5:DETERMINATION OF AMOUNT OF BPA IN FEED :Since in book , the ratio of EPH/BPA is 6:1 Mol. wt of EPH =92.5kg Mol.wt of BPA 232kg So, 6*92.5kg EPH combines with 1*232kg BPA20,842.10526kg EPH combines with 20,842.10526 *232/555 =8712.3755321kg BPA

Step 6:DETERMINATION OF AMOUNT OF WATER IN POLYMER TO EVAPORATOR: Water in polymer =19,800kg *5/100 =990kg

Step 7:DETERMINATION OF AMOUNT OF UN REACTED MONOMER RECYCLED TO REACTOR: Amount=1042.105263kg*98%/100 =1021.263158kgStep 8:DETERMINATION OF AMOUNHT OF FRESH FEED OF EPH: Amount of fresh feed of EPH =19,800kg-1021.263158kg =18778.73684kgSTEP 9:

DETERMINATION OF AMOUNT OF WATER USED IN WASHING:1kg polymer require 1kg water 10000kg polymer require =10000*1=10000kg water

STEP 10:DETERMINATION OF AMOUNT OF SOLVENT (ISO METHYL BUTYL KETONE) USED ON FINAL REACTOR:Solvent used is 80% of polymer yield so,Amount of solvent used = 19800kg/100*80%Amount of solvent used =15840kgSTEP 11:DETERMINATION OF AMOUNT OF SOLVENT RECYCLED TO SOLVENT INPUT STREAM:Solvent recycling is 75% of polymer yield so,Amount of solvent recycled =19800kg/100*75%Amount of solvent recycled =14850 kg

ENERGY BALANCE

STEP 1:* ENERGY BALANCE ON REACTOR:

Energy = Energy Required to deliver reactor + energy required to drive pump . (Pumps is one)Energy consumption of pump = 10KWEnergy consumption of reactor =32KWNo. of pumps used in both input & output streams. Total No of pump Energy=32KW + (4*10) =32 + 40 = 72 KW

STEP 2:* ENERGY BALANCE ON PHASE SEPARATOR:

Energy = Energy required to deliver output stream (brine+product) + water+unreacted EPH.

Energy = 2*10KW

Energy = 20KW

STEP 3:*ENERGY BALANCE ON EVAPORATOR:

REFERENCE: Evaporation energy=10KWEnergy =Energy required for evaporator + Energy required for pump

= 10KW + 3*10KWEnergy = 40KW

STEP 4:*ENERGY BALANCE IN FINAL REACTOR:

Energy = Energy for final reactor + Energy for pumps + Energy required to conveyer belt to send product.

REFERENCE: Conveyer belt = 20KW = 32KW +( 3* 10) +20 = 32KW + 30 + 20 Energy = 82KW STEP 5:*ENERGY BALANCE ON WASHING:

Energy = Energy for pump + Energy for vibratory screen because water is also present along with E.R that as to be separated by it .

Energy = (2*10) + 2.2KW = 12 + 2.2 = 14.2KW

STEP 6:*ENERGY BALANCE ON EVAPORATOR:

Energy = Energy for evaporator + Energy to derive purified product (epoxy resins) + Energy required to recycled solvent recycled.

= 10KW + 20KW +10KW = 40 KW

Total Energy Balance = 72 +20 +40 +82 + 14.2 + 40= 268.2 KW

Cost EvaluationOPERATING COST FOR THE PLANT (RAW MATERIAL COSTS)a) Price of Bisphenol A (BPA) =US $ 2,500 / Metric Ton So price of 8.7123755321tons Bisphenol A (BPA)8.7123755321tons *2500=21780.93883US $

b) Price of Epichlorohydrin ECH= US $ 3,000 / TonSo price of 20.84210 tons of Epichlorohydrin ECH20.84210*3000 $=62526.3157 US $

c) Price of Methyl Iso Butyl Ketone MIBK= US $ 1,960 / Ton so price of 10 tons of MIBK=15840 US $

d) Price of 99% High Quality Sodium Hydroxide= US $ 520 / TonSo price of 5.21052 tons of catalyst Sodium Hydroxide5.21052*520=2709.47368 US $

Fixed costPrice of two 60000 liters reactor=US $ 70000*2= US $ 140000Price of Ultrasonic Screen Vibrating =US $ 90,000Price of four pumps for heating oil delivery to reactors Capacity : 0.1 to 365 m3/hr Discharge Pressure : 14 Bar Viscosity : 1000000 cps Temperature : 430 C US $ 25,000 per unit*4= US $ 100000 Price of evaporator for drying of polymer US $ 30000*2=60,000 US $Price of Phase separator for the separation of organic and inorganic phase=US $ 20000*2= US $ 40000 Land cost= 1111111.11 US $Price of 1000 meters pipe=500/meter *1000= US $ 500000Payback Period

Cost of project= US $ 2.011 million

Price of 19800 kg/hr product production=Raw material cost + energy costsRaw material cost/year=123914.6*365*24=1085500US $/yearPrice of 1 unit= 20 rupees or 0.2222 US $Energy cost=268.2kw* 0.2222 US $*24*365=522008 US $/year

So,Product production per year=173448 tons/yearPrice of 173448 tons/year product production=1085500 +522008=1607508 US $/yearPrice of 1 kg product production=6.26 US $/kgPrice of 1 kg epoxy resin in market= 10 US $/KgTotal cash inflows per year=648690 US $ per yearSo payback period=2.01 million/648690=3.1 years

SAFETY:

MATERIAL SAFETY DATA SHEET

West System Inc.MSDS #105-11b Last Revised: 22JUN11

1. CHEMICAL PRODUCT AND COMPANY IDENTIFICATION

PRODUCT NAME:.............................................WEST SYSTEM 105 Epoxy Resin.

PRODUCT CODE:.............................................105

CHEMICAL FAMILY:.........................................Epoxy Resin.

CHEMICAL NAME:............................................Bisphenol A based epoxy resin.

MANUFACTURER: EMERGENCY TELEPHONE NUMBERS:West System Inc. Transportation102 Patterson Ave. CHEMTREC:.................... 800-424-9300 (U.S.)Bay City, MI 48706, U.S.A. 703-527-3887 (International)Phone: 866-937-8797 or 989-684-7286 Non-transportationwww.westsystem.com Poison Hotline: ................. 800-222-1222

2. HAZARDS IDENTIFICATION

EMERGENCY OVERVIEW

HMIS Hazard Rating: Health - 2 Flammability - 1 Physical Hazards - 0WARNING! May cause allergic skin response in certain individuals. May cause moderate irritation to the skin. Clear to light yellow liquid with mild odor.

PRIMARY ROUTE(S) OF ENTRY:...................................................... Skin contact.

POTENTIAL HEALTH EFFECTS:

ACUTE INHALATION:........................................................................ Not likely to cause acute effects unless heated to high temperatures. If product is heated, vapors generated can cause headache, nausea, dizziness and possible respiratory irritation if inhaled in high concentrations.

CHRONIC INHALATION: ................................................................... Not likely to cause chronic effects. Repeated exposure to high vapor concentrations may cause irritation of pre-existing lung allergies and increase the chance of developing allergy symptoms to this product.

ACUTE SKIN CONTACT:...................................................................May cause allergic skin response in certain individuals. May cause moderate irritation to the skin such as redness and itching.

CHRONIC SKIN CONTACT:............................................................... May cause sensitization in susceptible individuals. May cause moderate irritation to the skin.

EYE CONTACT: .................................................................................May cause irritation.

INGESTION:....................................................................................... Low acute oral toxicity.

SYMPTOMS OF OVEREXPOSURE: .................................................. Possible sensitization and subsequent allergic reactions usually seen as redness and rashes. Repeated exposure is not likely to cause other adverse health effects.

MEDICAL CONDITIONS AGGRAVATED BY EXPOSURE:................ Pre-existing skin and respiratory disorders may be aggravated by exposure to this product. Pre-existing lung and skin allergies may increase the chance of developing allergic symptoms to this product.

3. COMPOSITION/INFORMATION ON HAZARDOUS INGREDIENTS

INGREDIENT NAME CAS # CONCENTRATIONBisphenol-A type epoxy resin 25085-99-8 > 50%Benzyl alcohol 100-51-6 < 20%Bisphenol-F type epoxy resin 28064-14-4 < 20%

4. FIRST AID MEASURES

FIRST AID FOR EYES........................................................................ Flush immediately with water for at least 15 minutes. Consult a physician.

FIRST AID FOR SKIN......................................................................... Remove contaminated clothing. Wipe excess from skin. Remove with waterless skin cleaner and then wash with soap and water. Consult a physician if effects occur.

FIRST AID FOR INHALATION............................................................ Remove to fresh air if effects occur. West System Inc. Page 2 of 4 WEST SYSTEM 105 ResinMSDS #105-11b Last Revised: 22JUN11

FIRST AID FOR INGESTION.............................................................. No adverse health effects expected from amounts ingested under normal conditions of use. Seek medical attention if a significant amount is ingested.

5. FIRE FIGHTING MEASURES

FLASH POINT:................................................................................... >200F (Tag Closed Cup)

EXTINGUISHING MEDIA: .................................................................. Foam, carbon dioxide (CO2), dry chemical.

SPECIAL FIRE FIGHTING PROCEDURES: .......................................Wear a self-contained breathing apparatus and complete full-body personal protective equipment. Closed containers may rupture (due to buildup of pressure) when exposed to extreme heat.

FIRE AND EXPLOSION HAZARDS: .................................................. During a fire, smoke may contain the original materials in addition to combustion products of varying composition which may be toxic and/or irritating. Combustion products may include, but are not limited to: phenolics, carbon monoxide, carbon dioxide.

6. ACCIDENTAL RELEASE MEASURESSPILL OR LEAK PROCEDURES: ...................................................... Stop leak without additional risk. Dike and absorb with inert material (e.g., sand) and collect in a suitable, closed container. Warm, soapy water or non-flammable, safe solvent may be used to clean residual.

7. HANDLING AND STORAGE

STORAGE TEMPERATURE (min./max.): .......................................... 40F (4C) / 120F (49C)

STORAGE:......................................................................................... Store in cool, dry place. Store in tightly sealed containers to prevent moisture absorption and loss of volatiles. Excessive heat over long periods of time will degrade the resin.

HANDLING PRECAUTIONS: ............................................................. Avoid prolonged or repeated skin contact. Wash thoroughly after handling. Launder contaminated clothing before reuse. Avoid inhalation of vapors from heated product. Precautionary steps should be taken when curing product in large quantities. When mixed with epoxy curing agents this product causes an exothermic, which in large masses, can produce enough heat to damage or ignite surrounding materials and emit fumes and vapors that vary widely in composition and toxicity.

8. EXPOSURE CONTROLS/PERSONAL PROTECTION

EYE PROTECTION GUIDELINES: ..................................................... Safety glasses with side shields or chemical splash goggles.

SKIN PROTECTION GUIDELINES:....................................................Wear liquid-proof, chemical resistant gloves (nitrile-butyl rubber, neoprene, butyl rubber or natural rubber) and full body-covering clothing.

RESPIRATORY/VENTILATION GUIDELINES:................................... Good room ventilation is usually adequate for most operations. Wear a NIOSH/MSHA approved respirator with an organic vapor cartridge whenever exposure to vapor in concentrations above applicable limits is likely.Note: West System, Inc. has conducted an air sampling study using this product or similarly formulated products. The results indicate that the components sampled for (epichlorohydrin, benzyl alcohol) were either so low that they were not detected at all or they were significantly below OSHAs permissible exposure levels.

ADDITIONAL PROTECTIVE MEASURES:......................................... Practice good caution and personal cleanliness to avoid skin and eye contact. Avoid skin contact when removing gloves and other protective equipment. Wash thoroughly after handling. Generally speaking, working cleanly and following basic precautionary measures will greatly minimize the potential for harmful exposure to this product under normal use conditions.

OCCUPATIONAL EXPOSURE LIMITS: ............................................. Not established for product as whole. Refer to OSHAs Permissible Exposure Level (PEL) or the ACGIH Guidelines for information on specific ingredients.

9. PHYSICAL AND CHEMICAL PROPERTIESPHYSICAL FORM: ............................................................................. Liquid.COLOR: ............................................................................................. Clear to pale yellow.ODOR:................................................................................................ Mild.BOILING POINT: ................................................................................ > 400F.MELTING POINT/FREEZE POINT:..................................................... No data.VISCOSITY:........................................................................................ 1,000 cPs.pH: ..................................................................................................... No data.SOLUBILITY IN WATER: ................................................................... Slight.SPECIFIC GRAVITY:.......................................................................... 1.15BULK DENSITY: ................................................................................ 9.6 pounds/gallon.VAPOR PRESSURE:.......................................................................... < 1 mmHg @ 20C.VAPOR DENSITY:.............................................................................. Heavier than air.% VOLATILE BY WEIGHT: ................................................................ ASTM D 2369-07 was used to determine the Volatile Content of mixed epoxy resin and hardener. Refer to the hardener's MSDS for information about the total volatile content of the resin/hardener system.

10. STABILITY AND REACTIVITYWest System Inc. Page 3 of 4 WEST SYSTEM 105 ResinMSDS #105-11b Last Revised: 22JUN11

STABILITY: ........................................................................................ Stable.

HAZARDOUS POLYMERIZATION:....................................................Will not occur by itself, but a mass of more than one pound of product plus an aliphatic amine will cause irreversible polymerization with significant heat buildup.

INCOMPATIBILITIES: ........................................................................ Strong acids, bases, amines and mercaptans can cause polymerization.

DECOMPOSITION PRODUCTS: ........................................................ Carbon monoxide, carbon dioxide and phenolics may be produced during uncontrolled exothermic reactions or when otherwise heated to decomposition.

11. TOXICOLOGICAL INFORMATIONNo specific oral, inhalation or dermal toxicology data is known for this product. Specific toxicology information for a bisphenol-A basedepoxy resin present in this product is indicated below:Oral:...................................................................LD50 >5000 mg/kg (rats)Inhalation: ..........................................................No Data.Dermal: ..............................................................LD50 = 20,000 mg/kg (skin absorption in rabbits)TERATOLOGY: .................................................Diglycidyl ether bisphenol-A (DGEBPA) did not cause birth defects or other adverse effects on the fetus when pregnant rabbits were exposed by skin contact, the most likely route of exposure, or when pregnant rats or rabbits were exposed orally.REPRODUCTIVE EFFECTS:..............................DGEBPA, in animal studies, has been shown not to interfere with reproduction.MUTAGENICITY: .................................................DGEBPA in animal mutagenicity studies were negative. In vitro mutagenicitytests were negative in some cases and positive in others.CARCINOGENICITY:NTP............................................................................................ Product not listed.IARC........................................................................................... Product not listed.OSHA......................................................................................... Product not listed.No ingredient of this product present at levels greater than or equal to 0.1% is identified as a carcinogen or potential carcinogen by OSHA, NTP or IARC. Ethylbenzene, present in this product < 0.1%, is not identified by OSHA or NTP as a carcinogen, but is identified by NTP as a Group 2B substance possibly carcinogenic to humans. Many studies have been conducted to assess the potential carcinogenicity of diglycidyl ether of bisphenol-A. Although some weak evidence of carcinogenicity has been reported in animals, when all of the data are considered, the

weight of evidence does not show that DGEBPA is carcinogenic. Indeed, the most recent review of the available data by the International Agency for Research on Cancer (IARC) has concluded that DGEBPA is not classified as a carcinogen. Epichlorohydrin, an impurity in this product (