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Dexter Technologies
RESIN MANUAL
KAMDHENU PAINTS
PROJECT KPJ-101
Client: Kamdhenu Paints, Gurgaon SPC.
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RESIN
Resins are the condensation / addition polymers which form by reacting monomer units. It
is the film forming material of the paint and provides gloss and adhesion to the paint.
Resin is the main ingredient of the paint system. Durability of paint depends on the quality
and quantity of resin used in the overall paint formulation.
Resin plays an important role in overall paint formulation. As different quality and quantity
of resins are used in the paint, it provides
(1) It converts liquid coating into solid film after application as a thin film by air-drying or
drying mechanism.
(2) It provides gloss to paint film.
(3) It gives flexibility and hardness to the paint film.
(4) Makes paint adhere to the surface.
(5) It provides resistance to water, alkali and abrasion.
(6) It disperses pigment and extender in uniform way on the substrate.
Resin is used as film forming substance and also used as binder, which binds the
pigment and extender to the substrate.
Very wide ranges of resins are used in surface coating industry. They are as follows
Resin
ALKYDS
Kienle originally used the Term “Alkyd” in 1927 to describe the reaction product of
polyalcohols and polybasic acids.
The word alkyd was coined as Al [ cohol ] , [ A ] cid or Alk [ C ] y [ I ] D ==> Alkyd .
However, definition become lucid when the esterification reaction with polyhydric Alcohol
and Polybasic acids, were termed as polyester formation but subsequently the usage of
the term “alkyd “ now tends to specify polyester products composed of polyhydric
alcohol‟s, polybasic acids and monobasic fatty acids obtained from oils. These materials
are used chiefly in the coating industry.
In coating industries the terms Alkyd, Alkyd Resin and Alkyd solution are used
interchangeably, even though most alkyds are handled as solutions in hydrocarbon
solvents.
Client: Kamdhenu Paints, Gurgaon SPC.
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On The Basis
On The Basis of Drying
of oil Length Characteristics
Soya, Sunflower, Tobacco seed, Niger seed oil based alkyds are the examples of
semidrying alkyds.
Non-drying Alkyd: - Normally has oils having iodine value less than 120.
Examples are Palm oil, Castor oil and Coconut oil based alkyds.
On the basis of oil content classification and the drying concept, an alkyd can be
described as 60 % oil - drying alkyd OR with less precision, a Long oil drying alkyd.
Question arises, what will be the nomenclature if monobasic fatty acids used in
place of oil? Comparison between the long oil, short oil systems and the fatty acid system
can be made by stoichiometrically converting the weight of fatty acid to the weight of an
equivalent molar amount of triglyceride.
Commonly in paint industry, the classification of long / short / medium oil alkyd can
be understood on the basis of the series. Examples the long oil alkyds are always named
as R 2---, Medium oil alkyds are named as R 3 ---, short oil alkyds are named as R 4---. (--
- Are the different numbers used for naming the different alkyds)
Raw Materials
The most common alkyd ingredients are as follows: -
Polybasic Acids
Phthalic anhydride Ajelaic Acid
Isophthalic Acid Succinic Acid
Maleic Anhydride Adipic Acid`
Tetra hydro phthalic anhydride Fumaric Acid
Oils
Linseed Oil Sunflower Oil
Soya Oil Cotton seed Oil
Castor Oil Dehydrated Castor Oil (DCO)
Tung Oil Coconut Oil
Polyhydric Alcohol
Glycerine Sorbitol
Pentaerythritol Propylene glycol
Ethylene glycol Trimethylol ethane
Trimethylol prophthalice Di propylene glycol
Neopentyl glycol Di ethylene glycol
Monobasic Acids
Fatty Acids obtained from oils Synthetic saturated fatty acids
Benzoic Acids
Client: Kamdhenu Paints, Gurgaon SPC.
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Monoglycerolysis Catalyst
Lead Acetate Trihydrate ( LATH ) Litharge
Cerium Octoate 6% Lithium Stearate
Calcium Oxide / hydroxide Sodium Naphthalene
Di-butyl tin oxide ( DBTO) Sodium Hydroxide
Anti Oxidant
Hypophosphorous Acid ( HPA ) Triphenyl phosphite ( TPP )
Solvents
Xylene M.T.O.
C - IX
C CH OH HO CH
CH OH
Pentaerythritol Glycerol
CH2OH
Sorbitol
The high functionality of Pentaerythritol makes it of wide interest as the polyol for long oil
alkyds containing 60 % or more fatty acid, because of its high functionality, Pentaerythritol
is often blended with either glycerol or glycol in alkyds containing less than 60 % fatty
acids.
Pentaerythritol containing alkyd tends to have higher viscosity and molecular weights, dry
more rapidly and give coatings of greater hardness with lower flexibility, better gloss and
gloss retention, better heat and yellowing resistance better chemical resistance, better
water resistance and better exterior durability than glycerol based alkyds of comparable oil
contents.
In paints, Pentaerythritol types also shows antisagging at equal brushing, brushability and
flow.
Client: Kamdhenu Paints, Gurgaon SPC.
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The higher functionality of pentaerythritol over glycerol is the main reason for many of
above mentioned advantages.
Our major quantity of the polyol used is pentaerythritol. We get three types pentaerythritol.
They are named as Penta - 88, Penta -98(Penta nitration grade) and Penta technical
(Kanoria Penta). The differences between these are based on the purity. Penta exists as
mono penta and dipenta.
Penta 98/nitration grade contains 98% of monopenta and 2% of dipenta. Penta 88
contains 88% of mono penta and 12% of dipenta and penta technical/ penta Kanoria
contains 96% of mono penta and 4% dipenta.
The higher the dipenta content higher the reaction rate. Hence there will be separate
formulation for every type of pentaerythritol. The formulation can be used depending on
the availability of penta.
Though Sorbitol has six hydroxyl groups, It undergoes intermolecular dehydration at alkyd
esterification temperature 210 - 260 deg C that‟s why use of Sorbitol is restricted.
CH2OH CH2
CH OH CH OH
CH OH CH OH
CH OH CH
CH2OH CH2OH
Client: Kamdhenu Paints, Gurgaon SPC.
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Polybasic Acids
COOH COOH
3
CO COOH
4
2
CH COOH
O ||
CHCOOH
1
5
CO COOH COOH 6 COOH Maleic Anhydride
Phthallic Anhydride Isophthallic Anhydride Tetrahydrophthallic Anhydride
Terphthallic Anhydride
( Cis - 4 - cyclohexene -
1,2 dicaroxylic Anhydride )
Phthalic anhydride is the most extensively used polybasic acid in Alkyd resins because of
its low cost and the excellent properties it imparts to Alkyd resin products.
In recent years Isophthalic acid has been more extensively used in place of phthalic
anhydride. Isophthalic acid compared to orthophthalic acids are claimed to have higher
molecular weight and higher viscosity, to have better drying characteristics and to give
hard and more durable films with better heat and chemical stability.
Isophthalic acid is more reactive than phthalic anhydride. The reason is intermolecular
cyclization in phthalic anhydride makes it less reactive than Isophthalic acid.
The para isomer of phthalic acid, terphthalic acid has very poor solubility in alkyd
ingredients It also has very high melting point (436 deg C), has made processing of
terphthalic acid based alkyds very difficult.
Other dibasic acids used in alkyds in limited amount includes THPA (Tetrahydro phthalic
anhydride), Maleic anhydride etc.
Maleic acid / anhydride often used to replace part (upto 10 % max on a molar basis) of the
phthalic anhydride in the alkyd resin. It reacts with the unsaturation in fatty acids, Its effect
is to increase the total functionality of the alkyd system, viscosity and polymer molecular
weights.
When Maleic anhydride is used in small amounts in phthalic anhydride alkyds they dry
more rapidly and give harder films with improved colour, better alkali resistance, better
exterior durability because of improved water resistance .
Catalyst
Alkyds are manufactured through different routes. One of the routes is through
Monoglycerolysis. Here a catalyst is required to convert oil (triglyceride) into
monoglyceride. E.g. Lead acetate Trihydrate (LATH), Di butyl tin oxide (DBTO), Cerium
Octoate 6%, Liocat etc.
Client: Kamdhenu Paints, Gurgaon SPC.
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Castor oil 85
Coconut oil 9
If an oil or fatty acid has Iodine value of 125 - 135 or more, indicating about 1.5 double
bonds per fatty acid, it gives satisfactory drying properties to the alkyd. Below this range of
iodine value, the oil either don‟t dry or take extremely long time to form a dry films.
Client: Kamdhenu Paints, Gurgaon SPC.
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DCO and linseed oil gives the best drying time because in these oils, fatty acid groups of
multiple unsaturation predominate over others.
The oils or fatty acids, with higher iodine values not only show faster drying properties but
also give coating of greater hardness and better gloss.
Anti Oxidants
All these oil-modified alkyds are processed at higher temperature (210 - 265deg C).
Oxidation of oil will take place at higher temperature resulting in charring of the oil and
hence high colour of the resin. To prevent this anti oxidants are added. E.g. Triphenyl
phosphite (TPP) and Hypo phosphorous acid. The oxygen present in the reaction vessel
will react with TPP and tri phenyl phosphate will get generated. Also nitrogen purging is
done to create an inert atmosphere inside reaction vessel. This will further prevent material
coming in contact with air inside the reaction vessel at high temperature.
Azeotropic solvent
In alkyd, it is a condensation reaction between polyol and polybasic acid. Water will get
generated and it will be removed azeotropically by using a solvent. E.g. xylene, butanol
Azeotrope:- Two immiscible liquid of different boiling point when mixed will boil at a lower
boiling point of both the liquids.
E.g. water boils at 100 deg C and xylene boils at around 145 deg C. A mixture of xylene
and water boils at around 95 deg C.
Modifiers
Alkyd modification was defined as a chemical reaction during alkyd preparation which
incorporates the alkyd chemical agents which don‟t fit in the classification of alkyd
ingredients: - namely Polyhydric alcohol‟s, polybasic acids or oils / fatty acids.
The primary reasons for modification are either for economy (cost factor) or to confer some
desired properties.
The amount of modifier may be as high as 40 % of the total alkyd, but usually 10 - 25 %
are common.
Client: Kamdhenu Paints, Gurgaon SPC.
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Effects of modifier
The chemical reaction occurs during the alkyd processing are as follows: -
B) Etherification: -
At the alkyd processing temp (210 deg to 250 deg C) etherification reaction can occur in
alcohols: -
In an observation made by a scientist, he found that at 240 deg C temp with glycerol 7-8 %
esterification can be possible. He reported lesser etherification
(Approximately negligible) with pentaerythritol.
While sorbitol is found to be more prone to etherification than glycerol because it is
capable of internal etherification: -
CH2OH CH2
CH OH CH OH
CH OH CH OH
CH OH CH
CH2OH CH2OH
Client: Kamdhenu Paints, Gurgaon SPC.
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These reactions are special cases of esterification as only hydroxyl, carboxyl, and ester
groups are involved.
A partial alcoholysis of a triglyceride is: -
CH2(OCOR)CH(OCOR)CH2COOR + C(CH2OH)4
CH2(OCOR)CH(OCOR)CH2COOR + C6H4(COOH)2
CH2(OCOR)CH(OCOR)CH2OCOC6H4COOH
+ RCOOH
Both alcoholysis and acidolysis are reactions used in the preparation of alkyds from oil. If
polyol and phthalic anhydride are added to the oil simultaneously, substantial amount of
insoluble polyol phthalate forms. To avoid this difficulty, either alcoholysis or acidolysis is
employed to make partial esters of the polyol or acid, respectively before proceeding.
Client: Kamdhenu Paints, Gurgaon SPC.
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Solvent Thinning
Charging ( Blender Stage )
In M.G. Process, Oil, which is triglyceride, is first converted into monoglyceride by reacting
it with polyol. The resulting mixture is reacted with polybasic acid for further polymerisation
reaction.
(a) Charging:
General Checks
Charge Oil to the reactor.
Maintain appropriate water level in separator.
Start heating as per SPI, stirring and pass N 2 through the batch at approximate 200
litres/hr.
Client: Kamdhenu Paints, Gurgaon SPC.
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Charge the Catalyst and stir for 5-10 minutes and then charge Polyol (Part-1) Raise to
M.G. temperature as specified in SPI.
Maintain the temperature till the desired tolerance for M.G. with specified alcohol is
obtained. If the tolerance for M.G. is not in range, proceed further only after passing
phthalic anhydride compatibility test.
Cool the batch to 1800C or below and stop N2 purging.
Charge Polyol (Part-2), Polybasic Acid, Monobasic Acid, antioxidant & Xylene in
sequence.
Start heating and N2 purging.
Heat and maintain at 170+-5 for 1hr.
Temp of Oil 100 - 120 deg C Temp of Oil 70 to 100oc Temp of Oil 100 to 160oc
N2 Purging
No. of coil operated
TP Outlet temperature
TPP Charging , Post Cooling the batch M.G. Check Heating for M.G. Temp
M.G. Charging to 150 - 160 deg C Cleared for 240 - 250 deg C
M.G.
No
No
D
Heating kept open
Maintain Temp.
N2 Purging
No. of coil operated
TP Outlet temperature Removal of WOR
D No
Maintenance of reflux rate
Check
Heating to 170 -180 deg Maintenance for 1 hrs. Heating for poly. for dv Is dv &Dil.Visc.= 68 - 80 sec
Acid Value = 10 - 16
Max. 250 deg & AV AV ok
Yes
Agitation of blender
Blender should have
some material
Flushing of
Discharging to Cooling of the batch Stop heating / reduce
Reactor Blender Quenching & temp. Red. 200 deg C RPM
Clean Reactor Temp. at 180 - 200 deg C Batch cooled to 200 deg C
CH2OH CH2OH
(CH2OH)2 O O CH2OH
CH2OCOCH2 - C - CH2O O-- C O O-C C - O - CH2 - C - CH2 - 0 - C
COOH
CHOCOR2
CH2OH n
CH2OCOCH2
O O CH2OH O
Alkyd
Client: Kamdhenu Paints, Gurgaon SPC.
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Acidolysis process is also known as half ester process. In this process, oil (CCO) reacts
with phthalic anhydride. During this, one acidic group of phthalic anhydride reacts with
hydroxyl group of ricinoleic acid which is present in the castor oil and ester groups are
formed without removal of water. In the second part, when pentaerythritol or sorbitol is
added along with phthalic anhydride or rosin further esterification reaction takes place.
(a) Charging :
General Checks
Charge oil to the reactor.
Start heating, stirring and N2 purging at the rate of 200 litre / hr.
Charge Polybasic Acid (part-1) and xylene part I.
Raise the temperature to 170 -1800C.
Maintain the temperature till the desired acid value is obtained in the specified
time and range . Cool the batch to the desired temperature.
Charge Monobasic Acid (Rosin) if specified, Sorbitol solution in the specified time at
specified temperature.
Remove water of Sorbitol and charge other Polyol and Polybasic Acid (part-2), Xylene
and add antioxidant.
N2 Purging
No. of coil operated
TP Outlet temperature
Castor Oil Charging Heating of Oil Polybasic Acid and Heating for Acidolysis
Xylene Charging 170 - 180 deg C
Is MTO Check
Tol., dv for dv Removal of WOR
Heating For Dehydration
& AV & AV Dehyd. at temp 260 - 265 deg C
N2 Purging
Achieved Maintenance of reflux rate
MTO
NO tolerance
Keep Heating on and
Maintain temp. at 260 - 2650
Removal of WOR
D No
N2 Purging
Maintenance of reflux rate
Yes Cooling of the batch to
Check
210 - 220 deg and
Heating for poly. for dv Is dv &
Xylene part III addition Max. 240 deg & AV AV ok
Max. Temp. 240 deg C
Yes
Agitation of blender
Blender should have
some material
Flushing of
Discharging to Cooling of the batch Stop heating / reduce
Reactor Blender Quenching & temp. Red. 180 - 200 deg C RPM
Clean Reactor Temp. at 180 - 200 deg C Batch cooled to 180 - 200 deg C
(a) Charging :
General Checks
Charge Oil to the reactor.
Start heating, stirring and N2 purging at the rate of 200 Lit/hr.
Charge Monobasic Acid (Rosin) at 100-1250C, Polyol and Xylene.
Raise to homogeneity temperature within 2-4
Maintain the temperature till the desired acid value for homogeneity is obtained.
Cool the batch to 1800C or below and stop N2 flow.
In this process, all the raw materials viz. fatty acid, polybasic acid , polyols , monobasic
acid , xylene are charged at single stage.
(a) Charging :
General Checks
Charge fatty acid into reactor.
Charge all other raw material into reactor.
Raise the temperature to 1700C or as specified and maintained for 1hour.
N2 Purging
No. of coil operated
TP Outlet temperature Removal of WOR
D No
Time of maintaining the temp. Maintenance of reflux rate
Check
Heating to 170 -180 deg Maintenance for 1 hrs. Heating for poly. for dv Is dv &Dil.Visc.as per SPI
Acid Value as per SPI
Max. 240 deg & AV AV ok
Temperature at 170-180 deg C Max. Temp. 240 deg C
Yes
Agitation of blender
Blender should have
some material
Flushing of
Discharging to Cooling of the batch Stop heating / reduce
Reactor Blender Quenching & temp. Red. 200 deg C RPM
Clean Reactor Temp. at 180 - 200 deg C
Heat input from Thermopac Heat blender to Materail at 140 - 150 deg C temp.
Agitation kept on 140 - 150 deg C
Start Filtration
Check
Finish
No
No Check
Should be 7
Is Finish
O.K.? D Finish
Is Finish
Should be 7
O.K.?
Yes
Yes
If the quantity of Soya / RLO charged in any Soya / RLO based formulation is more,
then the viscosity pick up in the batch will be slow, resulting in higher cycle time. If the
quantity charged is less, then the pick up in viscosity of the batch will be higher.
If the quantity of DCO (m) charged in any Soya + DCO (m) based formulation is more,
then the viscosity picks up in the batch will be higher. If the quantity charged is less,
then the pick up in viscosity of the batch will be higher due to lesser oil content in the
batch.
If the quantity of CCO charged in acidolysis batch is more, then AV at acidolysis stage
will be low and if the quantity is less, then the AV will be high. The effect this low / high
AV on the batch are as follows
2. Catalyst
If the quantity of the catalyst charged is less, it will result in higher time for achieving
MG or less Alcohol tolerance.
Extra quantity addition of catalyst will effect the clarity of the medium, further process
and filtration. LATH reacts with phthalic anhydride and forms lead phthalate, which is
an insoluble , sticky compound . During filtration , it sticks to filter cloth and affects the
rate of filtration.
3. Polyol
Higher quantity of polyol in pre MG stage will result in low clarity in MG tolerance and
lower quantity of polyol, results in lesser MG tolerance.
4. Phthalic anhydride
Less quantity of phthalic will result in lower acid value and stagnancy in viscosity
pickup.
Higher quantity will result in high acid value , high viscosity pickup. The reaction may
go uncontrollable.
5. Maleic anhydride
The quantity of maleic is very critical, a slight higher quantity can lead to very high
viscosity pick up and gelation .
6. Xylene
If the quantity of the xylene charged in less, this will result in low reflux rate, high acid
value, reactor temperature shoot up, wrong discharging of the batch( batch will be
under polymerised), stripping at wrong viscosity ( this will cause stagnation of the
batch)
If the quantity of xylene charged is higher, this will result in high reflux rate, low acid
value ( lower than the specification), maximum process temperature will not be
achieved (this will effect the cycle time), wrong discharging of the batch( over
polymerised batch - this may result in filtration problem.)
7. Antioxidant
If not charged as per sequential order or not charged than colour value of the batch will
be higher.
8. Nitrogen purging
If not done colour value of the batch will be higher. Nitrogen purging also helps in
enhancing the reflex rate, hence reduction in acid value.
Operation related
If the temperature of batch is not raising
Check xylene content in the batch by keeping controlling solids .( Controlling solid is
less means higher solvent contents )
ACRYLIC RESIN
Acrylic resins are the homopolymers or copolymers based on acrylic acid and their esters .
However polymers based on styrene are also classified as acrylic resins . Thus acrylic
resins are structurally macromolecules of saturated C-C chain obtained by addition of the
individual monomer units across the vinyl group.
Raw Materials :-
A) Initiators :-
Initiates free radical Reaction. E.g. di tertiary butyl peroxide(DTBP), AIBN and Di benzyl
peroxide.
B) Monomer :-
ACRYLATES CH2 = CH - C O O R
CH = CH2 Methyl acrylates R - > CH 3 ( 8 Deg )
Ethyl acrylates R - > C2H5 ( -22 Deg )
n-Butyl acrylate R - > C4H9 ( - 54 Deg )
CH2 = CH - CO O H CH3
|
CH2 = C - C O O H METHACRYLATE CH3
|
ACRYLLIC ACID METHACRYLLIC STYRENE CH2 = C - C O O R
ACID
MMA R - > CH3 ( 105 Deg )
EMA R - > C2H5 ( 65 Deg )
HEMA R - > C2H4OH
( 55 DEg )
[C] Solvents:-
(1) Acrylic ester polymers with short side chain are polar and require polar solvents like
ketone, esters ethers or alcohol.
(2) As the side becomes longer the polymer becomes less polar and can dissolve in non
polar solvents like aliphatic hydrocarbon.
Most widely used commercial process in preparing acrylic co polymers is the free radical
polymerisation, which involves three stages-
a) Initiation:
NC - C - N = N - C - CN 2 NC -C . + N2
I-I 2 I .
b)Propagation:
Initiator free radical attacks the monomer molecule to propagate the reaction.
I . + CH2 = CH - R I - CH2 - CH - R
.
I - CH2 - CH - R + CH2 = CH - R
.
I - ( CH2 - CH - R ) n - ( CH2 - CH - R )
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C) Termination:
This takes place when reactive sites on the polymer chain have rendered inactive.
-
Free radical polymerisation of acrylic monomer may be carried out in any of four basic
polymerisation system.
Processing Solids- High processing solid polymerisation reduces chain transfer activity
of solvents resulting in higher molecular weight system.
Since monomer concentration and initiator concentration play important role in determining
the molecular weight of resin , the weighing should be perfect.
Molecular weight also depends upon monomer concentration or processing solids. Faster
rate of addition will tend to increase the monomer concentration resulting in higher
molecular weight resin . On the other hand slower addition rate will give low molecular
weight resin . Hence controlled rate of addition using metering pump is necessary to have
desired molecular weight and viscosity.
AMINO RESIN
Amino resins are produced as a result of condensation reactions between amino
compounds and formaldehyde . The most common amino compounds used are urea ,
melamine , hexamethoxymethyl melamine and benzoguanamine.
(a) Paraform
(b) Melamine / Urea / Benzoguanamie
(compound containing -NH2 group.)
(c) Alcohol (methanol / butanol)
Preparation of formaldehyde
Ag/Cu catalyst
CH3OH HCHO +H2 -20kcal.
NH2
C C
// \ O // \
||
N N H2N - C - NH2 N N
| || | ||
C C C C
\\ / \\ /
NH 2 N NH 2 NH 2 N NH 2
C. Alcohol‟s
Methanol
Butanol
Isobutanol
EPOXY RESINS
These are the condensation product of Bis phenol (Bis A) and epichlorohydrin(ECH).
Alkali is used as condensing agent [lye= NaOH in DM water]
Chemically epoxy means a compound containing 3 members cyclic ring of “oxirane”
O
C C
A )Taffy process:
Bis A + ECH
using stoichiometric NaOH
catalyst
Liquid epoxy -----------------------> highly polymer products
(low mol.wt.) Bis A
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Toughness
Flexibility
Adhesion
Chemical resistance
Hardness
Solvent resistance
Electrical resistance
Poor exterior durability
High stowing schedule
Little compatibility with other resins
Interior water resistance
Less stability in solvents
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EMULSION
What is emulsion polymerisation ?
In this polymerisation reaction , low molecular weight monomers are converted to high
molecular weight polymer . When a solvent is used as a vehicle for polymerisation than
such process is termed as “ solvent polymerisation” and when water is used as a vehicle
than such process is termed as “ Suspension polymerisation “ or “ Emulsion
polymerisation “.
Monomers
Most of the properties of emulsion depend on the nature of monomers. Among the
commonly used monomer some are often termed as „hard‟ as their homopolymers are
very hard and brittle ( High Tg monomer ) . While some monomers are termed as „ soft „
monomer as their homopolymer are tacky , soft and flexible ( Low Tg polymers ).
A combination of hard and soft monomer is often used to produce a emulsion having
intermediate properties like toughness , flexibility , tack freeness etc.
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E.g. :- Methyl methacrylate , Glacial methacrylic acid , Butyl acrylate , Styrene monomer ,
2 - Ethyl hexyl acrylate monomer .
Emulsifier ( Surfactants )
Surfactants reduces the inter facial tension between two insoluble phases i.e. water and
monomer as a result the monomer gets dispersed in the form of fine droplets , which are
stabilised by the surfactant layer on their surfaces.
Catalysts ( Initiator )
Catalysts used for emulsion polymerisation are also known as “ free radical initiators “. On
heating they form free radicals which initiate polymerisation of monomers .
Water
Almost 50 % of the emulsion are water . Water containing insoluble as well as soluble
impurities like salts are very harmful for polymerisation reaction as well as for emulsion
stability . Filtered and de - ionised water of certain specification is only recommended for
emulsion polymerisation.
Use of deviated property water can result in following problems :-
Acceleration or inhibition of reaction
Discoloration of product
Variation in particle size of product
Coagulation in emulsion during or after processing
Buffers
During polymerisation disturbance in the specified pH of the solution affects the rate of
reaction as well as emulsion stability hence buffers like sodium bicarbonate are used to
stabilise the pH of the system.
The role is to control the molecular weight . E.g. . Tertiary dodecyl mercapten
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Chaser catalyst
To eliminate the possibility of free monomer in emulsion system , IInd part addition of the
catalyst is done and it is known as chaser catalyst
Alkali ( Neutralisers )
Certain emulsion i.e. 100 % acrylic , styrene acrylic , should be neutralised for stability
before packing . Alkali like ammonia is used for the same .
Protective Colloids
Protective colloids are a water soluble polymer added in small quantity during emulsion
polymerisation of Vinyl acetate co - polymer to stabilise the emulsion . No protective colloid
is necessary for 100 % acrylic as well as styrene acrylic emulsions.
Preservatives
There are several ingredients in emulsion like surfactants , protective colloids which are
prone to bacterial attack due to bacterial attack surfactants and protective colloids get
degraded as a result the emulsion looses viscosity and stability . To eliminate the
possibility of the same , preservatives are added into emulsion system.
Defoamer
TEST METHOD
Following are the regularly used test methods :-
Procedure:
2. M T O Tolerance
Reagents :
Apparatus:
Procedure:
Apparatus :
Procedure:
Weigh dish containing U clip and about 1-1.2 gm castor oil (M1).
Transfer 0.8-1.2 gm (M2) of well mixed sample to the dish and note the weight
accurately and quickly before there is a loss of weight due to evaporation.
Spread the material evenly with the help of U clip
Make sure that castor oil and material is evenly spread over the surface of disk.
Heat the content (dish along with material ) in oven, which is being maintained at
120oC for 2 hours.
Remove the dish after two hours and cool it to room temperature.
Weigh the dish .(M3).
Reagents:
Procedure:
Weigh accurately to the nearest 0.01 gm ,about 1-2 gm ,depending on the free acids of
material into a conical flask .
Add nearly 10-15 ml of Xylene/Butanol mixture (1:1 Xylene:Butanol neutralised with
0.1 N alcoholic potassium hydroxide solution) or Toluene -Isopropanol mixture(1:1
toluene: isopropanol neutralised
with 0.1 N alcoholic potassium hydroxide.
Shake and warm if necessary.
Titrate the solution with standard 0.1 N potassium hydroxide solution using
phenolphthalein as indicator.
10 ml measuring cylinder.
SS cup and spatula.
Hot plate.
Reagents:
Procedure:
MG Test
Take M.G. sample and Phthalic anhydride in SS cup in ratio by as the quantities of
resin charge.
Stir with the spatula and heat the mixture till the melting temperature of phthalic
anhydride is attained
Keep the mixture stirring till the sublimed Phthalic Anhydride starts getting collected
along the edges of the cup.
Take a drop of sample on glass plate and cool it to room temperature.
Check for the clarity .It should be clear.
Procedure :
Place the ford cup on the stand. Level the cup by adjusting the screws of the stand
.The same may be ensured by using screw level.
Strain the sample through sieve or nylon cloth ,wherever required.
Adjust the temperature of the resin and the Ford Cup to the specified temperature( upto
30oC )
Close the orifice by the forefinger . Fill the cup slowly to avoid formation of air bubbles
till the sample overflows into the gallery.
Scrape the excess with a spatula over the entire rim of the cup.
Place the receiver under the cup .The distance between cup and orifice and the base
of the receiver should be about 15 cms.
Remove the finger and simultaneously start the stop-watch. Stop it as soon as first
break occurs in the stream.
Time in seconds until the first break occurs denotes viscosity of the resin at that
temperature.
Client: Kamdhenu Paints, Gurgaon SPC.
M04-101
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Apparatus:
Constant temperature water bath : Any suitable constant temperature bath capable of
maintaining the temperature at 25.0 +_ 1.0 deg oC or any other temperature as
specified in the specifications of the product .
Empty PRS Tubes of clear glass and flat bottoms.
Standard PRS tubes
Viscosity tube corks
Thermometer
Procedure:
Fill a viscosity tube with the material under test till the meniscus touches lower
marking line .Fit the cork properly.
Transfer the tube to a constant temperature water bath maintained at 25 oC or at a
temperature as specified in the specification of the product . Keep it for 10 min. Adjust
the level of the liquid so that bottom meniscus will be in level with the 100mm line .Fit
the cork so that the bottom of the cork is in level with the 108 mm line . This will
ensure a bubble of suitable and uniform size.
Choose the proper standard tubes(based on expectation ) or as indicated in the
specification for comparing t he viscosity . Allow these standard tubes along with the
tube filled with sample to remain in constant temperature bath for 20 minutes.
Take out the tubes and invert the tubes ( sample and standard) quickly in such a
manner that the tubes are in perfect vertical plain and the bubble start rising towards
the flat end of the tube .The bottom meniscus of the bubble should be used for
comparing the speed of the bubble . The slower the speed the higher the viscosity .For
this tube holder may be used.
Due to differences in bubbles sizes and shapes of the ends of the ,it may be necessary
to align the positions of the bubble at the same level initially in-order to have a proper
comparison of the speed of the speed of the bubble .Ensure the observation by
repeating the above procedure.
Identify the standard tubes that matches with the speed of the bubble in the sample
tube or one having viscosity higher and lower than the sample.
Client: Kamdhenu Paints, Gurgaon SPC.
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Calculation:
Weight of Potassium Hydrogen phthalate
Normality of alcoholic KOH solution =-----------------------------------------------------
0.20442 x Titration reading
Transfer 2-4 gms. Anhydrous Na2CO3 to a petridish or crucible and dry at 120deg C
for four hrs. Cool in a dessicator.
To standardise against 0.1 N solution Weigh accurately 0.22+-0.01 gms. of dried
Na2CO3, and transfer to 500 ml. conical flask . Add 50 ml. Of water, swirl to dissolve
the carbonate, add drops of 0.1N solution. Of Methyl Red in alcohol. Titrate with Hcl
solution. To first appearance of red colour and boil the solution. Carefully to avoid loss
until the colour is discharged Cool to the room temperature And continue the titration ,
alternating the addition of Hcl solution And the boiling and the cooling to the first
appearance of a faint red colour that is not discharged on further heating.
Client: Kamdhenu Paints, Gurgaon SPC.
M04-101
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The weight of dried Na2CO3 suitable for other normalities of HCl solution are given in the
table-
Calculations:
Standardisation of Hydrochloric acid solution can also be done using standard Sodium
Hydroxide solution as per TM.
Client: Kamdhenu Paints, Gurgaon SPC.
M04-101
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COOLING TOWER
Cooling tower is considered to be the main utility in any chemical plant. It is a packed unit
and can be termed as a heat exchanger.
Uses :-
To cool water and circulate the same to plant accessories / equipment as a service fluid for
cooling i.e. :- Mechanical seal of pumps , to condense vapours into liquid ( used in
condensers ) , Reactor gland cooling , Reactor cooling ( Cooling of the batch )
Evaporating Cooling :-
When water changes its state from liquid to vapour or steam an input of heat energy must
take place which is known as the latent heat of evaporation ; this input energy must either
be supplied from fuel as in boiler or be extracted from surroundings , Cooling tower works
on this change of state by creating conditions in which hot water evaporates in the
presence of moving air ; by this heat is extracted from water and transferred to the air and
the process is known as Evaporating cooling.
Casing or shell :-The structure enclosing the heat transfer process reinforced as
necessary to carry out the other main items
Air inlet and air outlet :- The position at which cool air enters , and warmed air leaves
the cooling tower . In natural draught towers the inlet normally protected by drip - proof
louvers and the outlet by a suitable grill . where as induced draught fan is used the
outlet is the fan casing ; with forced draught the fan casing provides the inlet .
Drift elimination :- These are positioned in the outlet air stream so as to prevent water
droplets from being carried away from the tower by the air stream .
Warm water inlet :- The point from which process water ( warm water ) enters in
cooling tower
Water distribution system :- Water entering in the tower must be spread as evenly as
possible over the cross section of the tower ( Spray nozzles are provided for this
purpose )
Client: Kamdhenu Paints, Gurgaon SPC.
M04-101
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Packing :- Consists essentially of a system of baffles which slows the progress of the
warm water through the tower and ensures maximum contact between water droplets
and cooling air by maximising surface area and minimising water film thickness.
Cold water basin ( Tank / Sump ) :- The point at which the cooled water is collected
return to the process.
Cold water outlet :- The point, which the cooled water, leaves the tower .
Air Outlet
Fan
Drift
Casing of
eliminator
Shell
Inlet
Conn. Water
Distribution
System
Packing
Louvers
Air Inlet
Over flow connection
O Make up
Outlet
Connection
Cold water basin
Figure :- Schematic arrangement of a mechanical draught cooling tower
The factors which influences the performance of the cooling tower can be summarised as:
Point No. 6 is important, because much greater cooling is possible at higher temp as the
total heat or enthalpy of saturated air rises exponentially with temperature
Convected Heat
Radiant
Heat
In the given figure illustrated a single droplet of water in the tower . The droplet is
surrounded by a thin film of air, which is saturated and remains almost undisturbed by the
passing air stream . It is throughout his static film of saturated air that the transfer of heat
takes place in three ways i.e. :-
Client: Kamdhenu Paints, Gurgaon SPC.
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By , radiation from the surface of the droplet : this is a very small proportion of the total
amount of heat flow and it is usually neglected.
By , conduction and convection between water and air ; the amount of heat transferred
will depend on the temperature Of air and water . It is a significant proportion of the
whole , and may be as much as one - quarter of the one - third.
By , evaporation ; this accounts for the majority of heat transfer and is the reason why
the whole process is termed „ evaporative cooling „ .
The evaporation that occurs when air and water are in contact is caused by the difference
in pressure of water vapour and in the air . These vapour pressure are functions of the
water temperature Sand the degree of saturation of the air , respectively .
Evaporation , will take place throughout the pack .The amount of evaporation depends on
the total surface area as well as the amount of air flow. The greater the air flow more
cooling can be achieved. This is because as the air rate increases , the effect of the water
on its temperature and humidity will become less , and the partial pressure differences
throughout the pack will increased .
Reasons:
Failure of pump- Cooling water pump fails due to electrical or mechanical problem
.Effectiveness of pump also gets reduced due to air lock.
Poor water supply- This can be due to choking up of on-line strainer, level of water in
basin goes down, air locking
Leakage in cooling water line
Due to power failure.
High humidity.
Cooling tower fan not working.
Water distribution on the top of cooling tower not uniform ( due to choking)
Terminology
Saturated Air :-
The maximum amount of water vapour which air can absorb depends on the temperature
of the air and when this maximum is reached the air is said to be saturated air.
Client: Kamdhenu Paints, Gurgaon SPC.
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Dew Point :-
The temperature at which a mixture of air and water vapour become saturate .
Client: Kamdhenu Paints, Gurgaon SPC.
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THERMOPAC
What is thermopac ?
Thermopac is a forced circulation heater using a non - toxic , non - corrosive oil called
thermic fluid as a heating medium . Temperature upto 300 deg C can be obtained at near
atmospheric pressure . Thus eliminating the use of high pressure vessels and piping.
Constructional features
The thermopac is a fully automatic, coil type, oil fired,3 pass, forced drought, packaged
thermic fluid heater. The helical coil fabricated from steel tubes is constructed to form the
combustion chamber & is paced at the centre of two shells, one inside the other. The shell,
which is adjacent to the coil, is called the inner shell & the one outside the inner shell is
called the outer shell. The inner shell & the helical coil are concentric with the outer shell.
Mineral oil called thermic fluid is circulated through the coil.
The fuel burner is situated at the top centre of the helical coil. The burner is down firing
forced draught type with direct electric spark ignition. The combustion air fan & fuel pump
is at the front base of the unit.
Operational features:
The centrifugal type chemical process pump, near the unit circulates the thermic fluid
through the unit & the system. The thermic fluid returning from the user equipment is fed to
the circulating pump through a combined deaerator & expansion tank. Vapours ,gases etc.
are separated from the thermic fluid in this tank. The deaerator tank is connected to the
expansion tank by pipes. The function of the expansion tank is to accommodate the
increased volume of the thermic fluid ,when it is heated. Thermic fluid expands by 7% of its
total volume for every 100 C rise in temperature.
Heat liberated by burning fuel in the combustion chamber is utilised for heating the thermic
fluid in the coil. The products of the combustion after they exchange their heat with the
thermic in the coil are let out of the unit through the flue gas outlet.
Combustion air preheating is achieved by circulation the fresh air for combustion through a
double jacket formed by the inner shell surrounding the combustion chamber. A high
degree of combustion air preheating ensures high thermal efficiency.
After the rotary switch is put in “BURNER ON” position, the burner starts & the
temperature of the thermic fluid goes on increasing to the required degree.
Client: Kamdhenu Paints, Gurgaon SPC.
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The return temperature combistat ( & an outlet temperature combistat in case of TP-10 )
keep the thermic fluid temperature under control by making the burner to work either ON-
OFF or on modulation as the case may be.
Thermoapac is basically either oil fired or gas fired . The sequence of operation of oil fired
units are described below:
2. When the electric main switch is put on, supply comes to the panel box.
3. After the FO temperature Reaches 90 deg C , the push button switch for fuel circulation
to be kept pressed . Fuel oil preheating starts when the rotary is put on ( applicable to
furnace oil or LDO ) .The fuel oil temperature combistat indicates & controls the fuel oil
temperature. It normally indicates the actual temperature . The set pointer 1 is set to
control the minimum temperature & the set pointer 2 is set to control the maximum
temperature . Normally the set pointer 1 is set at 105 C & the pointer 2 at 120 C ) .The
burner can be fired only when the fuel oil temperature is above 105 C.TP-01 & TP-02
operates only on LDO/HSD. for other units two oil preheating tanks can be provided, one
electrically operated & the other thermic fluid operated.
4.The blower motor (which also drives the fuel pump) starts & the circulation of fuel oil
starts through the fuel oil preheating tank & the burner rod. The fuel oil temperature
increases . Simultaneously the rotary switch for Thermic fluid pump is also put on .
Thermic fluid circulating pump starts & the flow of thermic fluid is established in the coil &
circuit.
5.On observing the pump pressure gauge & circuit pressure gauge is showing steady
pressure & after the fuel oil temperature crosses the minimum temperature mark of 105C,
the rotary switch is put in “ BURNER ON” position.
6. The blower motor starts . The blower pushes air through combustion chamber ,driving
away combustible gases ,if any, from the combustion chamber. This is known as
prepurging. At the same time ,fuel oil pressure is also developed ,as the blower & the fuel
pump are driven simultaneously
7.After prepurging
Sparking starts
Burner solenoid valve energises & oil is sprayed into the combustion
chamber.
Flame is established & sparking stops.
Heating of thermic fluid starts.
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8. Hot oil is supplied to the user equipment. It exchanges its heat with the material being
processed & returns to the circulating pump through the combined deaerator & expansion
tank.
9. Heat is given to the user equipment & is absorbed in the user equipment . If heat
absorbed from the thermic fluid is less, then the temperature of the thermic fluid returning
from the process increases. When the return temperature of the thermic fluid reaches a
value set on the return temperature combistat, the burner stops firing. The circulating
pumps keeps on circulating the thermic fluid. The burner restarts as soon as the return
temperature of the thermic fluid drops below the set valve. This is known as “ON-OFF”
operation of the unit.
10.In the case of TPA-10,TPA-15 & TPA-20 the return temperature switch controls the
„high flame-low flame‟ operation of the burner. When the return temperature of the thermic
fluid is less than the value set on the return temperature controller, the burner keeps on
firing at high flame & the unit gives full rated heat output. As soon as the return
temperature reaches the set value of PID controller burner goes into low flame. This is
called the “low flame operation” of the burner .Thus in low flame operation ,the unit gives
only 33% of the full rated heat output. The burner goes to high flame again as soon as the
return temperature drops below the value set on the return temperature controller
.Similarly in some of the thermopak outlet temperature controller controls the ON_OFF
operation of the burner.
11.The outlet temperature switch serves as a ultimate safety against overheating of the
thermic fluid. The burner goes to electrical lock out giving alarm when the temperature of
the thermic fluid reaches the valve set on the outlet temperature switch. In such case, the
reason should be sorted out.
Note :-
Modulation Mechanism :-
1. Modulation motor is provided to control air by throttling the side damper and oil by
regulating the opening of ball valve by means of corresponding linkages.
2. Modulation will be from 33 % to 100 % i.e. in low flame output will be 33 % of the rated
output end in high flame it will be 100 % of the rated output.
3. Initially unit will run in low flame and then unit switches over to high flame when the
toggle switch is put “ ON”.
The sequence controller in conjunction with the flame detector ensures the following:
Scavenging of the combustion chamber before every fresh firing of the burner.
No delay in the firing of the fuel & hence no accumulation of fuel inside the combustion
chamber which eliminates the danger of backfiring.
Pressure taping are taken across the unit inlet & outlet & fed to the differential
pressure switch. This switch does not allow the unit to function in case the flow of
thermic fluid through the coil of the unit is insufficient. Any attempt in electrical lock-
out sounding an alarm . On a working unit ,if flow of fluid decreases, burner stops
firing & alarm is sounded.
The inlet temperature switch indicates & controls the temperature of thermic fluid at
the inlet of the unit. This makes the burner to work ON-OFF in TP-01 to TP-06
models & in case of TPA-10, TPA-15 & TPA-20 it makes the burner to work on
modulation .The outlet temperature switch indicates & controls the temperature of
thermic fluid at the outlet & in case this temperature exceeds the pre-set limit, the
burner goes into electrical lock-out sounding an alarm.
If the level in the deaerator & expansion tank is below the required level of this
switch it makes the burner trip.
This control shut off the burner & makes the unit to go into electrical lock-out
position in case the stack temperature rises beyond its set value.
Client: Kamdhenu Paints, Gurgaon SPC.
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In case the TP tube chokes heavily the heat transfer in the TP is affected due to
reduced flow, this increase the stack temperature
On over firing due to excessive wear out of burner nozzle the stack temp would
increase.
If a puncture occurs in TF tube in furnace the leaking fluid would catch fire immediately
increasing the stack temperature.
This controls & maintains FO temperature to a pre-set valve by making the electric
heaters to work ON-OFF
This switch shuts off the burner & makes the unit to go into electrical lockout
position in case the level of the thermic fluid goes beyond tolerable limits. When this
switch takes over, the alarm is sounded.
The purpose of a safety valve in TF circuit is to maintain a constant flow rate in the
circuit and the unit . The safety valve safeguards reduced flow . If one of the user
equipment is cut off by shutting valves, the total flow in the system will reduce while
the circuit pressure will increase. If circuit pressure increases beyond a pre-set limit,
the safety valve opens and cut circuit partially the supply and return line.
Trouble shooting
Faults:
1. Flame Failure
Action to be taken:
Check electrical connection to burner solenoid valve and rectify. Clean photocell with
cotton from both sides. Clean furnace oil strainers and remove air lock. Check furnace oil
pump and pump pressure gauge. Remove and clean burner assembly. Clean burner
nozzle , check burner setting. Adjust air damper on regulator.
Client: Kamdhenu Paints, Gurgaon SPC.
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Action to be taken:
Get rectified the setting of relief valve. Get rectified NRV. Check all circuit valve and
ensure that they are in required position .[open/closed].Rectify the gauge.
Action to be taken:
Reduce airflow, adjust oil flow. Stop burner firing and check burner setting.
Action to be taken
BOILER (Optional)
The “REVOMAX BOILER” is an oil-fired, coil type steam generators. The three
pass, reverse flue, membrane coil design is a blend of proven techniques in
combustion & heat transfer technology. It is an instant steam generator of water
tube design. It is a fully automatic packaged unit consisting of the boiler & its
accessories mounted on a chassis & enclosed by outer shell .
The boiler consists of a membrane coil fitted in a shell which in turn is enclosed by
an air jacket. The coil forms the combustion chamber (furnace). Burning fuel
generates heat, which produces steam. High pressure supplies water & fuel to the
boiler & air is supplied by a blower fan.
Working principle
Chemical energy in the fuel is released in the form of heat during combustion .The
products of combustion, the flue gases, transfer this heat to the coil carrying water
by radiation & convection. Residual heat in the flue gases is absorbed in the
economiser, where feed water is heated to expel dissolved gases. The blower
supplies air for combustion. Before the fuel is burned it is atomised by passing
through a swirler in the nozzle under pressure. Light Diesel Oil (LDO) has a low
viscosity so that it can easily atomised. While furnace oil or Low Sulphur Heavy
Stock (LSHS) are too viscous at room temperature & have to be heated to reduce
their viscosity .In our plant we use LDO as a fuel in the Boilers.
The Revomax has a reverse flue type furnace. The flame travels down in the
furnace & the flue gases forms an envelope around the flame, so that the flame
does not touch the coil.
Construction
The Boiler is bolted on a bottom chases. Blower control panel & their panels are
also bolted on the chases. The structure is supported by a top chases. Coil is at
the centre of the boiler, enclosed by a pair of concentric shells. Blower is
connected to the boiler by an air duct at the bottom.
A duct joins the economiser to the boiler flue gas outlet. The economiser is a shell
& tube type heat exchanger having a number of vertical steel tubes welded
between two tube plates. The chimney duct is bolted above the economiser.
A heat optimiser is located near the economiser. It is a tube-in-tube heat
exchanger. In RX-04 & RX-06 fuel pump & motor connected by a coupling are
mounted on a common base frame bolted on the module frame. The water pump is
bolted on hinged platform of the module frame. The burner assembly is on the top
plate. Flexible metallic hoses are attached for fuel supply. The control panel
houses the electrical controls, like switches & indicator lamps etc. The control
panel is mounted on its front.
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Water systems
Soft water enters the unit & passes from the shell side of the heat optimiser. It
receives heat from the hot water coming from the economiser. This warm water
then enters the economiser .The hot flue gases passing through economiser tube
bank heat the water. The dissolved gases in the water are released as it is heated
& are vented out through the air vent connection.
Water enters the coil at the bottom evaporates & steam comes out of the top of
coil. Steam pressure & temperature sensing connections are provided on the outlet
header. Steam pressure gauge & the pressure switch (which controls the on-off
operation of the unit )are connected via copper tubes. The steam temperature
indicator cum controller (combistate) senses the steam temperature via its capillary
bulb.
Safety valve ,main steam valve & auxiliary steam valve are mounted on the same
header.
Fuel system:
Fuel from the service tank passes through a filter before entering the fuel pump
in the unit. In RX-04 & RX-06, separate motor drives fuel pump.
The fuel under pressure is filtered again through a fine mesh strainer . A ball valve
is provided for draining off the dirt collected by the strainer. Fuel pressure gauge
indicates the pressure at this point.
When the burner solenoid coil energises, fuel enters the burner rod & is sprayed
through the nozzle. The fuel used in the boiler in our plant is LDO, which is less
viscous hence is directly used instead of passing through the preheater as in the
case of FO.
Air system
The blower drives air into the bottom of the air jacket of the boiler. It is heated as it
passes through the jacket & enters the burner. The flame-cone diffuser plate
combination causes vigorous mixing of air with atomised fuel. The flame is shot
downward in the furnace. Flue gases reverse from the bottom refractory & travel
upward back to the top of the coil. Gases then pass through the gap between coil
& inner shell & enter the economiser from bottom, After passing through
economiser tubes, they are let out of the chimney duct.
Client: Kamdhenu Paints, Gurgaon SPC.
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The boiler operates on 415 V, 50 Hz, 3 phase, 4 wire electrical supply. The control
circuit voltage is 230 V.
1.Three phase supply is given to blower motor, water pump motor & fuel pump
motor.
2.Single-phase supply is connected to the control circuit through the control fuse.
Neutral is connected to the N.Control circuit works on 230 V AC supplies.
3.When the “fill” switch is put on, water pump motor contactors energised, contact
closes & water pump motor starts.
4.The-safety contactor coil is energised only when all the safeties are in the
healthy condition. Its contact is connected in the burner solenoid valve circuit. If
this contact is open at the time of firing, fuel is not sprayed in the furnace. The unit
goes in electrical lockout giving alarm.
5.When-fire switch is put on, supply reaches fuel pump motor contactor & the
motor starts.
6.After filling up the boiler coil with water, the fire switch may be put on. Supply
reaches terminal 8 of the sequence controller.
Supply reaches contactor coils of blower, water pump & fuel pump motors
through SC terminal 4 & the motor starts.
8.When flame is established ,the photoresistor XA senses the light & its electrical
resistance reduces. Ignition stops & the firing sequence is over.
9.When all safeties remain in healthy condition, firing continues till the supply is
available at Sc terminal 8.When steam demand decreases, pressure increases till
pressure controller trips at the pre-set pressure. Supply to SC terminal 8 is then cut
off & firing stops. Green light PRESSURE CONTROL comes on. When pressure
falls pressure controller cut in & burner firing sequence is repeated.
10.The firing sequence may not take place because of any of the following
reasons. This will cause burner trip with alarm.
Flame has not been established. Photoresistor does not sense light & offers
large resistance to current, hence very small current flows between SC
terminals 1 & 2.
One or more of the auxiliary contacts of motors are open. No current flows
between SC terminal 1 & 2 .May happen due to tripping of o/l relays of the
motors.
One or more of the safety devices are not sensing healthy condition.
11.Burner trip with alarm, results in tripping of thermal relay coincide the sequence
controller. Supply reaches SC terminal 7 & hooter starts sounding. Hooter stops
when FIRE Switch is put off. Restarting the unit requires manual resetting.
Client: Kamdhenu Paints, Gurgaon SPC.
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Filtration is an Unit Operation which remove solid particles, gel particles or any other
impurities to separate clear filtrate by means of filter media.
Filtration is carried out using Sparkler filter machine. Filtration of medium is done after
completion of the batch. Medium is pumped into the filter machine by using Gear pump.
Construction:
Filterpress assembly consists of number of horizontal circular plates, which are enclosed,
in a vertical cartridge one above another to make a complete system. The stack of the
plates is completely enclosed within the pressure tight shell.
Each of the circular plate consists of cloth and sieve plate. Material is pumped into the
filterpress by using Gear Pump. Filter media used is either Woven yarn (filter cloth) or
Paper cloth which have pores on the surface. These pores may get clogged with particles
after passing the medium. To prevent this and to increase area of filtration filter aid such
as Dicamol 4254 \ Celite 545 is coated (pre-coat) on each filter cloth. Solvent is used for
precoating.
Principle of Operation
The liquid enters the filter by way of filter intake and finds its way to the top of several filter
media of the cartridge through the circular opening in the sides of plates. The media arrest
the suspensions and allow the liquid to pass through them and the supporting perforated
screen and then to run down the central vertical channel formed by interposing cups and
go out through the outlet valve.
In model with scavenger features , the bottom bed of the filter is an auxiliary bed used for
scavenging the last part of the liquid remaining in the tank . This bed is connected to
scavenger valve ( an independent valve ). When scavenger is not desired , this bed can be
used for extra capacity.
Client: Kamdhenu Paints, Gurgaon SPC.
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Formed powder
cake on filteration
Filter Aid
Screen
Clips
Spacer Cup
O
Plate v
O
O O
O O O
O O O
Central Tie Rod
Compression Ring Compression Cup
O
Cartridge of plates
Working:
If the finish of the material is clear 7+, release the material to tank / barrel. If not
circulate it for some time, check the finish again, still not achieved stop the filter
machine and clean the machine again.
Ensure that the filter press is clean and ready for use.
Before starting the filtration, ensure that the auto system is functioning.
Ensure that strainer on discharge line of blender is cleaned and fitted before starting
the filtration.
In case of power failure , to prevent medium overflow from the finishing vessel by
closing the valves.
For ensuring efficient filtration, adjust the pressure of the filter machine below the
maximum permissible pressure.
Client: Kamdhenu Paints, Gurgaon SPC.
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Safety
Basic Principal Related to Raw Material Hazardous
Flammability of liquid
Any material presents a fire risk if it will continue to burn in air after the source of ignition has
been removed.
Flammability of vapor
When a flammable liquid is vaporised to form an intimate admixture with air (or o2) and a
source of ignition is subsequently applied, combustion may be propagated with explosion
SOLV CIX DIST Irritation of eyes and skin if Safety goggles, Sampling,
contacted. If inhaled may cause chemical resistant Addition/Charging
damage to respiratory tract, cause gloves, safety cloths.
3 headache and dizziness. In case of
ingestion may cause bronchio
pneumonia.
ISO PROP Vapour causes mild irritation to eyes organic vapour mask, Sampling , Lab
ALCOHOL & upper respiratory tracts. High face shield, rubber cleaning
conc. may be anesthetic. Liquid hand gloves, apron and
5 irritates eyes and may cause injury. shoes
Harmless to skin. If ingetsed causes
drunkenness and vomiting.
METHANOL Exposure to vapours cause eye Air supply respirator, Sample checking
irritation, headache, fatigue, Boots , safety goggles,
drowsiness. High concs. can protective apron and
produce CNS depressions & optic rubber gloves
6 nerve damage. 50000 ppm will
probably cause death in 1- 2 hrs.
Can absorbed to skin. Swallowing
may cause death or eye damage.
Client: Kamdhenu Paints, Gurgaon SPC.
M04-101
Issued Pg
By
66 OF 80
MMA Inhalation & Ingestion: Irritation of Provide self contained During charging ,
nose. throat,nausea,vomiting. Skin breathing apparatus, sample checking
& Eyes:Liquid causes severe side covered safety
irritation goggles/face shield ,
9 rubber han d gloves,
protective over
clothing and shoes.
STYRENE Causes moderate irritation of eyes Safety goggles, Face During charging ,
MONOMER and skin. High vapor concentration shield, hand gloves, sample checking
causes dizziness, drunkenness and shoes , air supplied
10 anesthesia. Ingestion: Causes painful mask.
irritation of mouth and stomach
PHOSPHORIC Causes burns of mouth and lips, Face shield, rubber During charging
ACID sour acrid taste, severe hand gloves, protective
gastointestinal irritation, nausea, overclothing and shoes
vomiting, bloody diarrhea, difficult
13 swallowing, severe abdominal pain,
thirst, acidemia, difficult breathing,
convulsions, collapse, shock and
death
AMMONIA Causes burning pain in mouth, Rubber boots, Hand During charging
throat, stomach,constriction of gloves , apron, safety
throat and coughing, followed by goggles. Use of
14
vomitting of blood, Severe eye and protective oil will
skin irritant. reduce irritation
LAFFSOLVE- Inhalation: Vapors irritate nose and Organic respirator, side During charging
MEB throat. Ingestion: Causes headche, covered safety
nausea, vomiting, dizziness. goggles/face shield,
18 rubber hand gloves,
body overclothing and
shoes
PHTH ANHYD Solid irritates skin and eyes, causing Rubber apron, Rubber During charging
ASN coughing and sneezing. Liquid shoes,, face shield,
causes severe thermal burns approved vapor
19 respirator, leather or
rubber gloves and
shoes.
Client: Kamdhenu Paints, Gurgaon SPC.
M04-101
Issued Pg
By
68 OF 80
MORPHOLINE Toxic by inhalation and ingestion. Wear goggles and During charging
21 Irritant toskin and get absorb by skin plastic or rubber gloves
TRIETHYL Vapors irritate nose, throat and Provide self contained During charging
AMINE lungs, causing coughing, choking breathing apparatus ,
and difficulty in breathing. Eyes: side covered safety
Causes severe burns. Skin: Clothing goggles/ face shield,
23 wet with this chemical causes burns. rubber gloves,
protective over
clothing shoes
NITROGEN ( Inhalation : Can cause asphyxiation, Provide self contained During reactor
COMPRESSED ) if atmosphere does not contain breathing apparatus processing,
oxygen. Dizziness, unconsciousness, where insufficient air is Generation
even death can result. Contact of present. Provide safety
liquid with skin and eyes causes face shield, insulated
26 frostbite, burns gloves, long sleeved
trousers worn outside
boots or overhigh top
shoes to shed the
spilled liquid.
ETHYL Irritation of eyes, nose and throat, Safety goggles, all Sampling
ALCOHOL Headache and drowsiness may purpose cannisters,
occur. Liquid causes intoxication. protective overcolthing
28 The substance affects nervous and shoes.
system and may damage liver.
Client: Kamdhenu Paints, Gurgaon SPC.
M04-101
Issued Pg
By
69 OF 80
CYMEL 1130 Can be harmful if swallowed or solvent mask, solvent During charging
vapors are inhaled. Cause slight skin resistant gloves, safety
31 irritation and eye irritation. goggles, protective
clothing and safety
shoes
DIETHYLENE Ingestion: Causes stupor or coma safety goggles, hand During charging
32 GLYCOL may lead to fatal kidney injury. gloves, apron, safety
Inhalation: Dullness and nausea. shoes and apron.
1. Handling of Glassware: Use lubricant while inserting glass tubing into the rubber.
Use suitable hand gloves
Ensure that exposed wire, open switches and loose wiring are not used.
Only qualified persons should be allowed to do repairing of electrical equipment.
Ensure also that earthling and electrical circuit breakers are provided wherever
necessary.
Handle all electrical equipment with care: do not attempt any repairs while
equipment is on. Keep off from moving parts.
3. Vacuum distillation / distillation: Avoid rapid changes in pressure, which can push
liquid violently out of flask. Use a trap, slow heating rate and release / apply vacuum
carefully in fume cupboard.
5. Mechanical problem: Ensure that moving parts are guarded and access to
machinery is easy and safe. Keep instructions for operation of equipment‟s /
instruments at working place wherever necessary. Get defective machinery
repaired.
Do not store the inflammable / solvent based material near equipment, which may
generate heat or sparks.
Do not discharge inflammable / solvent based materials in the sink but dispose
them off in the barrel kept for the purpose.
Client: Kamdhenu Paints, Gurgaon SPC.
M04-101
Issued Pg
By
71 OF 80
8. Housekeeping:
Avoid loose electrical connections, chemical spillage and disposal of waste by
improper method.
Ensure that the containers with solvent-based materials are not kept open.
Turn off all electrical equipment‟s, water taps and other utilities at the end of the
day.
Avoid contact of chemicals and vapours with the skin, eyes, and respiratory
system by prompt use of gloves, goggles and masks.
Client: Kamdhenu Paints, Gurgaon SPC.
M04-101
Issued Pg
By
72 OF 80
PPEs:
Introduction: -
Safety products are a positive aid to Safety and contribute in protecting against injuries, or even loss of life.
Certain occupational hazards are present in any normal working environment and employees must be made
aware of the nature of these hazards and should be encouraged to use safety products as a preventive
measure against these hazards.
Personal Protective Equipment (PPE) is such safety product. They are however not a substitute for
engineering, work practice, or administrative controls. Personal protective equipment should be used in
conjunction with these controls to provide for employee safety and health at the work place. Personal
protective equipment includes all clothing and other work accessories designed to create a barrier against
the workplace hazards.
Following pages describe the types of equipment most commonly used for protecting the head, eyes, face,
torso, arms, hands, and feet.
The details of the PPE being used to handle the raw materials in the
section are as under:
Protective equipments including PPE for eyes, face, head, protective clothing, respiratory devices, protective
shields and barriers shall be provided, used and maintained in a reliable condition as required by the
hazards, processes or environment.
PART OF BODY
HAZARD PPE TO BE USED
NEEDING
PROTECTION
Head Exposure to falling and or flying objects , Safety helmet
striking against obstruction
Exposure to head during powder charging Safety caps
Ear Muffs 3 M- 1435- Roomy & durable Should be fitted properly to the ear.
ear cups provide reliable Should be worn at all times of exposure to
protection for everyday use. noise.
Client: Kamdhenu Paints, Gurgaon SPC.
M04-101
Issued Pg
By
75 OF 80
The lightweight design and Should be kept in the area devoid of any
flexible headband provide an kind of contamination. Eg. Dust, vapours,
easy fit and comfort to the user. mist etc.
PVC Hand Gloves PVC hand gloves with inside Gloves contaminated with toxic / infectious
(Yellow colour) Hosiery cotton lining. Best /corrosive material shall not be left
quality gloves designed to give unidentified.
maximum resistance against The contaminated gloves shall be
acid, alkalis, oils, fats, fuel, decontaminated before being disposed off.
printing inks, inorganic salts,
organic chemicals steam and
grease.
Rubber hand gloves Orange colour thin gloves made Gloves contaminated with toxic / infectious
(Orange colour) from pure latex rubber. /corrosive material shall not be left
unidentified.
The contaminated gloves shall be
decontaminated before being disposed off
appropriately.
Surgical Gloves White coloured gloves made Gloves contaminated with toxic / infectious
from latex rubber. /corrosive material shall not be left
unidentified.
The contaminated gloves shall be
decontaminated before being disposed off
appropriately
Plastic disposable Light weight and Hygienic. It is
polythene hand gloves transparent and used in Should be disposed off after one or two
Catering. uses.
Welding leather gloves Leather gloves for welding. Gloves should be cleaned by using soap
and mild detergent.
Should be checked for worn outs and
replaced if not in usable condition.
Electrical Gloves Electrical safety gloves Gloves should be thoroughly checked for
which provide electrical cuts and any kind of damage.
safety. Gloves should not be wet before usage.
Safety Shoe Protective footwear shall Safety shoe should be mandatory
comply to IS code for following requirement for all employees in the plant.
parameters. Gumboots should not be used in the areas
Impact where there is possibility of impact injuries.
Compression
Clearance
Eg. Bata/ Liberty warrior
Electrical Safety All exposed external metal Personnel working near open electrical
footwear parts should be non-ferrous and circuits shall not use conductive footwear.
the design of the soles and
Client: Kamdhenu Paints, Gurgaon SPC.
M04-101
Issued Pg
By
76 OF 80
OAE is the measure of the overall efficiency, capacity ( productiveness) of the Machine /
Equipment under study. It aims at delivering the best out of any machine ( fixed asset ).
Where,
One of the ways to measuring the performance / asset utilisation effectiveness has been
RATE INDEX. The procedure to compute the Rate Index is as follows :
Process time available = Total time available for production ( should not exclude
downtimes) idle times for the want of material time lost for cleaning between
batches.
“The Rate Index of 1.0 signifies that the OAE with respect to benchmark rate has been
achieved.”
Mandays per ton is the measure of Manpower Utilisation in a section. It is the no. of
manpower (operators) used to produce one ton of solid resin.
3. EFFICIENCY
Norms delivered
% Efficiency = ------------------------------------ 100
Standard Shift Norms
A non-conforming batch or an NCP as it is commonly referred to, is a batch that does not
conform to the specifications . A batch may be deemed non-conforming because it fails the
approval tests at QA or even if it fails critical in-process checks during any stage of
processing of the batch.
It is a batch that does not conform to one (or two) of the specifications and a decision may
be taken to release the batch conditionally.
5. Specific consumption
All the sectional work-practices and activities carried out in the section must be in
Compliance to the OCPs (Operational Control Procedures) and Work-Instructions as listed
in the Manuals..
7. Housekeeping Standards
8. Safety