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2.2.1. Detergent powder (household formulation)
85% active LAB acid slurry Sodium carbonate (soda ash) Sodium meta-silicate Alkaline sodium silicate (47% liquid Na 2O:SiO2:1:2:2) Sodium bicarbonate Sodium sulphate (anhydrous) Sodium tri-polyphosphate (STPP) Sodium carboxy methyl cellulose Phthalocyanine blue colour or oil soluble yellow colour Optical whitener Perfume &
Premium grade (Weight, %) 18 35 2 6 10 20 10 1.5 0.1 0.3 0.1
Popular grade Weight, % 15 32 -7 10 25 7 1.0 0.1 0.2 0.1
Water
3
2.6
2.2.2. Liquid detergent formulations Light duty (weight %) 85% active LAB acid slurry Caustic soda (15% solution of Sodium hydroxide) Sodium sulphate Urea Perfume Water
Heavy duty (weight t%) 20
25
Qty required to bring pH to 7
Qty required to bring pH to 7
2 10 0.1 q.s.
2 15 0.1 q.s.
2.2.3. Detergent cakes/bars/tablets formulations
85% active LAB acid slurry Soda ash Sodium silicate (alkaline Na2O:SiO2:1:2:2) 47% soln. S.T.P.P. Starch (tapioca/maize) Talc Kaolin Paraffin wax Opt. Whitener Colour Perfume Sodium sulphate Water
Extruded bars/cakes (wt%) 18 15 10 15 20 10 3 4 0.3 0.05 0.1 q.s.
-
Mechanically pressed tablets (wt%) 16 20 10 10 5 12 0.3 0.1 0.1 10.0 q.s.
!"#$ %&#'$( Acid slurry is made by a large number of units in the country predominantly in small scale sector. There are reported to be more than 100 producers of Acid slurry in the country. 3
Important manufacturer of Acid Slurry include the following
*
Atul Limited Corporate Office : Agrochemicals Division P.O. Atul 396 020, Dist. Valsad
*
Amruteswari Enterprises No.92, Amruteswari Building, 6th Main, 4th Cross Ist Stage, 6th Phase W.C. Road, Industrial Town Bangalore-560 044
*
Panda Chemicals Pvt. Ltd. 24, Zone-II, M.P. Nagar, Bhopal-462 011
*
ABC Corporation 27, Western India House, Sir P.M. Road, Fort, Mumbai-400 001
*
Cee Sulfones Ltd. MCC050 B-7, Rajratan Apartments Ground Floor, Near Garden Service Road, Jogeshwari (E), Bombay-400 060 Factory : Plot No.146-149, Achhad Industrial Estate Taluka Talasari, Dist-Thane, Maharashtra
*
Meeta Trading Corporation, Unit No.7, Ground Floor, Bldg. No.5, Jogani Industrial Complex, Sion Chunabhati Road, Mumbai-400 022.
*
Memba Chem Industries Pvt. Ltd. 19, M.J. Building, Ground Floor, 187 Princess Street, Mumbai-400 002 Fax : 022-2016261
*
Navrang Chemical Industries, Opp. Mittal Estate, Andheri Kurla Road,Mumbai-400 059. )
*
Anand Chemicals 7th Cross, PIPDIC Industrial Estate Sedarapet-605 111
*
Bharani Chemical Industries, 41, Chairman Muthuramier Road,Madurai-625 009.
*
Gee Gee Khay Chemical Industry, 96, Nelson Manickam Road, Chennai-600 029 Factory : Maraimalai Nagar-603 209. Plot No. 16, A Type, PIPDIC Industrial Estate, Mettupalayam, Pondicherry-605 009
*
Ghuru Chemicals 16, A Type, 9th Cross, PIPDIC Indl. Estate, Mettupalayam-605 009
*
New India Surfactants A-86 & 87. PIPDIC Industrial Estate Sedarapet-605 111
*
Sunrise Chemical Industries, No.32, Periyathambi Mudali Street, Choolai, Chennai-600 112.
*
Southern Aromatic Chemical Industry R.S. No.35/5, Thuthipet Village, Sedarapet-605 111
*
Ultramarine & Pigments Ltd., Detergents Division : Plot No.25-B, SIPCOT Indl. Complex, Ranipet-632 403, Vellore District,
*
Varuni Chemicals (P) Ltd Admn. Office : 6/1,Manjanakara Street,Madurai-625 001. Factory : 63/5, Viraganoor Village, Madurai 625 009.
*
Royel Emulsifiers
%
#3, Pilkington Road, Ayanavaram Chennai 600 023
#
Around 1.2 million tonnes per annum
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Synthetic Dete rgents 35
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24.89 21.83
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Powders 60%
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19.15 7.51
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Nirma 15%
Hindustan Lever 65%
Godrej Soaps 8%
Colgate Palmolive Others 5% 7%
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Karnataka Soaps 2%
Nirma 28% Unorganised sector 28%
Henkel SPIC 2% P&G 10%
Hindustan Lever 30%
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#2"'* <#(; 0#"=& (&"1*&1"
" + * +* , 6.1.5. India Percapita Consumption of detergent Year 1988-89 1989-90 1990-91 1991-92 1992-93 1993-94 1994-95 1995-96 2000-01
Demand in ‘000 tonnes 1031 1176 1335 1426 1522 1623 1732 1848 2550
Percapita consumption (kg per annum) 1.24 1.40 1.55 1.63 1.71 1.80 1.88 1.97 2.48
World average percapita consumption of synthetic detergents is 9 kg. 3
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8.1
Raw material requirements:
Basic One tonne of Acid Slurry LAB
300 kgs
Oleum (20%)
360 kg
8.2
Raw Material availability
Linear Alkyl Benzene (LAB) is the important raw material for the production of Acid Slurry. Typical characteristics of LAB: Sulphonability,% 98 min. Bromine Number 0.05 max. Colour, Saybolt 25 min. Doctor Test Negative Biodegradability of 92.0 min. Sulphonate, % Molecular weight 236 to 243 or 251 to 258 Distillation, 95% recovery 320 Deg C max.
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Indian Petrochemicals Corporation Ltd., P.O. Petrochemicals, Township, Vadodara Gujarat
*
Reliance Industries Ltd., Gujarat Tulsiani Chambers, Nariman Point, Mumbai-400 021
*
Tamilnadu Petroproducts, Ltd.,Tamil Nadu Manali Express Highway, Manali Chennai – 600 068
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Economic capacity
:
900 tonnes per annum
Project cost
:
Rs.130 lakhs
Assessment of project cost 1.
Land
S.No.
Description
1.1 1.2
Cost of land of 0.5 acre at Rs.5 .5 per acre Cost of levelling, laying internal roads/fencing and compound wall Subtotal
Cost Rs.in lakhs
1'$%'!/
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2.75 0.28 3.03
S.No.
Description
2.1 2.2
Factory building of area 420 sq.m. at Rs.3200/sq.m. Non-factory building of area 50 sq.m.at Rs.4500/sq.m. Subtotal
3.
Cost Rs.in lakhs
Cost of Plant & Machinery
S.No.
Description
3.1 3.2 3.3 3.4
Cost of basic plant and machinery Instrumentation and control Pipelines and valves Structurals for erection Subtotal Octroi, excise duty, sales tax, etc.at 12% Packaging and insurance charges (2%) Transportation charges (2%) Machinery stores and spares (2%) Foundation charges (2%) Installation charges (2%) Total cost of plant and Machinery
3.5 3.6 3.7 3.8 3.9 3.10
4.
Technical know-how fees
5.
Miscellaneous fixed assets
Cost Rs.in lakhs
Description
5.1. 5.2. 5.3. 5.4. 5.5. 5.6. 5.7.
Electrification Steam boiler and auxillaries Water storage tank, borewell etc. Fuel storage tank Laboratory equipment Office machinery & equipment Material handling equipment, packaging machinery, weigh balance, etc. Diesel generator Effluent treatment Total
6.
30 2.25 3 1.5 36.75 4.41 0.74 0.74 0.74 0.74 0.74 44.86 Rs.2.5 lakhs
S.No.
5.8. 5.9.
13.44 2.25 15.69
Cost Rs.in lakhs
Preliminary & Pre-operative expenses: !
3 4 1.2 1.2 1.4 1.8 1.5 6 1.5 21.6
S.No.
Description
Cost Rs.in lakhs
6.1. 6.2. 6.2.1 6.2.2 6.2.3 6.2.4 6.2.5 6.2.6 6.2.7
Preliminary expenses Pre-operative expenses:Establishment Rent rates and taxes Travelling expenses Interest and commitment charges on borrowings Insurance during construction period Other preoperative expenses and deposits Interest on deferred payment Total
0.5 0 0.8 0.8 1.5 3.8 1.5 0 0 8.9
7.
Provision for contingency
Rs.6.4 lakhs
8.
Working capital margin
Rs.27 lakhs
9.
Total project cost
Rs. 129.98 lakhs Say
Rs.130 lakhs
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10.
Means of Finance
Total project cost Promoter's contribution Term loan from financing institutions
Rs.130 lakhs Rs.52 lakhs Rs.78 lakhs
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