plant design of inorganic zinc silicate paint (project report part 1)

Plant design of inorganic zinc silicate paint 2014

A PROJECT REPORT ON

PLANT DESIGN OF INORGANIC ZINC

SILICATE PAINT

Submitted to the University of Pune, Pune

in Partial Fulfillment of the Requirements

For the Award of the Degree of

BACHELOR OF ENGINEERING (CHEMICAL)

BY

Gajanan R. Hange

(Gr. No. 111251)

Pawan V. Jamadar

(Gr. No.111330)

Sandeep R. Bhagat

(Gr. No. 111020)

Department of Chemical Engineering

BRACT’S Vishwakarma Institute of Technology, 666, Upper Indiranagar, Bibwewadi, Pune – 411 037


Chemical Engineering – 2014 ii


Chemical Engineering – 2014 iii

ABSTRACT

Successful synthesis of nanocrystalline Zn2SiO4 powders using solid

state reaction of the ZnO powder precipitate and amorphous cristobalite

SiO2 powders from processed rice hull ash at 800≤T≤1000oC is presented

in this study. ZnO powders were grown by chemically reacting

stoichiometric NaOH and ZnSO4. The solid state reacted powders were

characterized using scanning electron microscopy (SEM) with energy

dispersive x-ray spectroscopy (EDX), Fourier transform Spectroscopy

(FTIR) and x-ray diffraction (XRD). Microscopic analyses of the

Annealed powders were consistent with reported morphological

structures of Zn2SiO4. FTIR results indicate the presence of ZnO4 and

SiO4 groups corresponding to Zn2SiO4. XRD results further revealed that

Zn2SiO4 powders were synthesized at the reaction temperatures of 900

and 1000oC with onset growth at 800oC. The method used in this study

shows that Zn2SiO4 can be grown at a much lower temperature

(800≤T≤1000oC) compared to the reported temperature of synthesizing

Zn2SiO4 through solid-state reaction. The Zn2SiO4powders exhibit

dominant a-axis orientation and the average crystallite size for zinc

silicate powders annealed at 1000oC is about 33 nm. The results suggest

that the Zn2SiO4 powders are promising materials for phosphor

applications. Using SiO2 from RHA in the synthesis of ZnSiO4 increases

the value of rice hulls and as a result becomes beneficial to rice farmers

and that RHA collection and utilization policies has to be incorporated in

local governments.


Chemical Engineering – 2014 iv

ACKNOWLEDGEMENT

It gives me a great pleasure to find an opportunity to express our deep and

sincere gratitude to all those who have been directly or indirectly related

to this project

I specially thank our internal guide Prof. A. R. Gangwal for his

tremendous support, timely guidance and for sharing his experience and

knowledge, for the valuable direction that keeps us going and inspires to

perform better

Also, I cannot overlook the fact that without the support of our Head of

Department Prof. Dr. D. S. Bhatkhande our work would not have been

accomplished in its entirety

Last but not the least we would like to convey our heartiest thanks to all

our friends who time to time have helped us with their valuable

suggestion during our project report

SANDEEP BHAGAT

GAJANAN HANGE

PAWAN JAMADAR

Bansilal Ramnath Agarwal Charitable Trust’s


Chemical Engineering – 2014 v

VISHWAKARMA INSTITUTE OF TECHNOLOGY

(An Autonomous Institute Affiliated to University of Pune)

666, Upper Indiranagar, Bibwewadi, Pune – 411 037

APRIL 2014

CERTIFICATE

It is certified that the project work entitled

“PLANT DESIGN OF INORGANIC ZINC SILICATE PAINT”

Submitted by

Gajanan R. Hange Gr. No. 111251 Roll No.22

Pawan V. Jamadar Gr. No. 111330 Roll No.23

Sandeep R. Bhagat Gr. No. 111020 Roll No.06

is the original work carried out by them under the supervision of Mr.Prof. A. R.

Gangwal and is approved for the partial fulfilment of the requirement of University

of Pune, Pune for the award of the Degree of Bachelor of Engineering (Chemical)

This Project Work has not been earlier submitted to any other Institute or University

for the award of any degree or diploma.

(Prof. A. R. Gangwal) (Prof. Dr. D. S. Bhatkhande)

Guide, Head,

Department of Chemical Department of Chemical

Engineering Engineering

TABLE OF CONTENTS


Chemical Engineering – 2014 vi

Page

Abstract iii

Acknowledgements iv

Certificate v

Table of Contents vi

List of figures vii

Chapter 1 INTRODUCTION 1

1.1 Physical properties of inorganic zinc silicate paint 2

1.2 Chemical properties of inorganic zinc silicate paint

1.2.1 Curing mechanism

1.2.2 Film cure 1.2.3 Bubbling/Pinholes

1.2.4 Mud cracking

3

4

4

5

1.3 Methodology 6

1.4

1.5

Advantages and disadvantages of inorganic zinc silicate

Paint

Applications of zinc silicate paint

1.5.1 Segments

1.5.2 Objects

8

9

9

10

Chapter 2 LITERATURE SURVEY 11

2.1 History of paint science and technology 11

2.2 Components 14

2.2.1 Binder, vehicle, or resins 14

2.2.2 Diluent or Solvent 15

2.2.3 Pigment and Filler 16

2.2.4 Additives 17

2.3

2.4

2.5

2.6

Application of paint

Failure of paint

Dangers

Indian paint industry

2.6.1 Brief Introduction

2.6.2 Size of the Industry

2.6.3 Total contribution to the economy/ sales

2.6.4 Top leading Companies

2.6.5 Latest Development

18

19

21

22

22

22

23

23

23


Chemical Engineering – 2014 vii

Chapter 1

INTRODUCTION

The zinc silicate primer has to it’s the name the promise of perfection for

the long run. It is useful in highly corrosive areas like chemical factories

and refineries etc. Zinc is a self sacrificial metal its gives full protection

to the metal. Although inorganic coatings can be formulated with a

variety of inorganic binders, they are generally made from polymers

based on silicon chemistry. By the combination of metallic zinc powder

and silicate binders, inorganic zinc silicate primers have been formulated.

Since their introduction and use in the first part of this century, zinc

silicates have been recognized as the most effective corrosion resistant

primers in the protective industry. Inorganic topcoats are predominantly

formulated with silicon based binders, such as silicone resins, water and

solvent based silicates, silanes and mixtures of organic binders with

silicate binders. Traditionally, long term corrosion protection has been

obtained with inorganic zinc silicates. This is achieved by a combination

of the cathodic protection properties of metallic zinc and the inert

polymer matrix of the inorganic polysilicate binder. The polymeric

structure of the silicate binder, which surrounds the metallic zinc as a

matrix, is represented as a dense cross-linked inorganic polymer structure

of - Si - O - Si - chains. The resulting inorganic zinc silicate coatings

provide excellent resistance to numerous corrosive exposure

environments. They exhibit excellent corrosion protection and adhesion

to the metal substrate, inhibiting under-cutting and rust migration under

the film.


Chemical Engineering – 2014 viii

1.1 PHYSICAL PROPERTIES OF INORGANIC ZINC SILICATE

PAINT

Inorganic zinc silicate act as an anticorrosive primer for

protection of steel .

Inorganic zinc silicate paint is resistant to dry heat up to

4500 C .

Solid content by volume in inorganic zinc silicate paint is

69% .

Recommended dry film thickness for Inorganic zinc

silicate coatings is u to 75microns

Estimated spreading rate of inorganic zinc silicate paint is

up t the 9.2 sq m/l

One of the most important property of inorganic zinc

silicate coating is that it gives cathodic protection to the

metal

The paint is very sensible to application condition .

Drying time for top coating is about 24hrs.

Zinc rich coatings are abrasion resistant and rock hard


Chemical Engineering – 2014 ix

1.2 Chemical properties of inorganic zinc silicate primer

Inorganic zinc rich coatings afford superb corrosion resistance, they are

also rock hard and very abrasion-resistant. They make some of the best

anti-corrosive primers available. Ethyl silicate based inorganic zincs

(Galvit ES600 & Galvit ES510) should be applied at 75 microns (dft).

Because they have a tendency to grip unlike most other coatings, they

may be applied to the faying surfaces of bolted steel joints. Inorganic

zinc-rich primers have excellent resistance to temperatures up to the

melting point of zinc (above 400oC). Inorganic zincs should not be

exposed to acids and alkalis. However, their resistance to organic solvents

and organic chemicals is excellent. The term “zinc-rich” refers to the

percent by weight of metallic zinc in the cured coating film, which may

range from 50% to 90%. The film is a hard, adherent coating composed

of metallic zinc powder suspended in a silicate matrix

Fig no 1.1 Zinc particles embedded in a silicate matrix


Chemical Engineering – 2014 x

1.2.1 Curing mechanism

These coatings cure by hydrolysis or reaction with moisture following the

evaporation of solvent. These coatings are typically resistant to rain

showers in one hour or less. High humidity conditions usually accelerate

the cure of ethyl silicates. When the relative humidity is less than 40%,

water may be sprayed on the coating surface to complete the curing

process.

1.2.2 Film cure

To determine if a film has cured a clean cloth soaked in methyl ethyl

ketone (MEK) is rubbed over the coating. A properly cured film should

have no zinc transfer onto the cloth.

1.2.3 Bubbling/Pinholes

The zinc silicate matrix film is quite porous, which can result in bubbling

or pinholes when a subsequent coating is applied. To overcome bubbling

and/or pinholes excessive film builds and overspray should be avoided

and/or removed prior to topcoating. For best control over the spray

application conventional spray is preferred over airless equipment. When

topcoating, apply a mist/tack coat of suitable product, thinned

approximately 25% to seal off the zinc prior to application of a full coat.


Chemical Engineering – 2014 xi

1.2.4 Mud Cracking

Mud cracking (Diagram 1.2) can occur due to a number of reasons, these

include:

Low blast profiles

Excessive film build

Poor ambient drying conditions

Old Product Insufficient ventilation, which is pronounced in concave

corners and cavities

Fig 1.2 mud cracking


Chemical Engineering – 2014 xii

1.3 Methodology

Zinc silicate (Zn2SiO4) is synthesized using equimolar concentrations of

zinc sulphate (ZnSO4) and sodium hydroxide (NaOH) producing zinc

hydroxide (Zn(OH)2). The addition of strong electrolyte (ZnSO4) and

strong base (NaOH) in an aqueous solution results to the exchange of

ions. The formation Zn(OH)2 and Na2SO4 is the product of ion exchange.

Zn(OH)2 is insoluble in water thus it remains as solid in an aqueous

solution. On the other hand, Na2SO4 is soluble in water hence it is in

liquid phase. The reaction proceeds as follows

ZnSO4 (aq) + 2NaOH (aq ) Zn(OH)2(s) + Na2SO4(l).

The resulting solution is filtered and washed with distilled water. The

precipitate is mixed with appropriate amount of silicon dioxide (SiO2) in

water with constant stirring at an elevated temperature of 80oC. Neither

Zn(OH)2 and SiO2 are soluble in water. Thus, no chemical reaction is

expected in the mixing of Zn(OH)2 and SiO2. However, the water is

used as an amalgamation medium to promote the adhesion of Zn(OH)2

particles on the surface of SiO2 creating a nucleation site where Zn(OH)2

particles coat SiO2. The reaction mechanism for this process is

Zn(OH)2(s) + SiO2(s) Zn(OH)2(s) + SiO2(s) + H2O(g).

The precipitate is washed with distilled water and dried at 100oC. The

dried precipitate is annealed at 800, 900 and 1000oC. Solid-solid diffusion

is expected to occur at these temperatures. The mixing stage promote the

adhesion of smaller particle Zn(OH)2 to the surface of SiO2 allowing the

formation of Zn2SiO4 at lower temperature. Thus, the powders annealed

at 800To 1000oC are expected to contain Zn2SiO4 following the process


Chemical Engineering – 2014 xiii

2 Zn(OH)2(s) + SiO2(s) Zn2SiO4 + H2O (g).

The resulting powders are characterized using scanning electron

microscopy

(SEM) equipped with energy dispersive x-ray spectroscopy (EDX),

Fourier

transform infrared spectroscopy (FTIR) and x-ray diffraction (XRD).


Chemical Engineering – 2014 xiv

1.4 ADVANTAGES AND DISADVANTAGES OF ZINC SILICATE

PRIMER

Some important advantages and disadvantages of inorganic zinc silicate

paint are listed below. These factors are to be considered while its

application to the industrial and on household equipments

1.4.1 ADVANTAGES OF ZINC SILICATE PRIMER

Inorganic zinc silicate paint primer are Very good corrosion

protection

Inorganic zinc silicate paint primer are Very good solvent

resistance

High heath resistance is offered by Inorganic zinc silicate paint

primer

(max 400oC)

Very high mechanical strength is the main advantage of Inorganic

zinc silicate paint primer

Very good adhesion to blast cleaned steel is the useful property of

Inorganic zinc silicate paint primer

Relatively good recoat ability is there for Inorganic zinc silicate

paint primer

1.4.2 DISADVANTAGES OF ZINC SILICATE PRIMER

Alkyl enamels cannot be applied directly over Inorganic zinc

silicate paint primer

Higher application skill required for the application of Inorganic

zinc silicate paint primer

Inorganic zinc silicate paint primer takes long time to dry.

Inorganic zinc silicate paint primer recoat time is more.

Greater than recommended film thickness of Inorganic zinc silicate

paint primer causes mud cracking


Chemical Engineering – 2014 xv

1.5 APPLICATIONS OF ZINC SILICATE PRIMERS

1.5.1 Segments: 1) ships 2) offshore 3) Industry

One of the most important application of Inorganic zinc silicate primer

Is that it is used in marine areas where most of the equipments comes in

to contact with corrosional substances. As zinc is the self sacrificial metal

, it protects the equipments from corrosion . zinc provides the cathodic

protection to the metal against the galvanic corrosion.


Chemical Engineering – 2014 xvi

1.5.2 Objects: New constructions / Maintenance Exterior and interior

design , above and below water .

Popular application of Inorganic zinc silicate primer is that it is used in

building sections areas where most of the equipments comes in to contact

with corrosional substances. As zinc is the self sacrificial metal , it

protects the equipments from corrosion . zinc provides the cathodic

protection to the metal against the galvanic corrosion.

Inorganic zinc silicate paint have also found many applications in

Maintenance Exterior and interior design.


Chemical Engineering – 2014 xvii

Chapter 2

Literature survey

2.1 History of paint science and technology

In 2011, South African archaeologists reported finding a 100,000-year-

old human-made ochre-based mixture that could have been used like

paint.

Cave paintings drawn with red or yellow

ochre, hematite, manganese oxide, and charcoal may have been made by

early Homo sapiens as long as 40,000 years ago.

Ancient colour walls at Dendera, Egypt, which were exposed for years to

the elements, still possess their brilliant colour, as vivid as when they

were painted about 2,000 years ago. The Egyptians mixed their colours

with a gummy substance, and applied them separately from each other

without any blending or mixture. They appear to have used six colours:

white, black, blue, red, yellow, and green. They first covered the area

entirely with white, then traced the design in black, leaving out the lights

of the ground colour. They used minium for red, and generally of a dark

tinge

Pliny mentions some painted ceilings in his day in the town of Ardea,

which had been done prior to the foundation of Rome. He expresses great

surprise and admiration at their freshness, after the lapse of so many

centuries.

Paint was made with the yolk of eggs and therefore, the substance would

harden and adhere to the surface it was applied to. Pigment was made

from plants, sand, and different soils. Most paints used either oil or water

as a base (the dilutant, solvent or vehicle for the pigment).


Chemical Engineering – 2014 xviii

A still extant example of 17th-century house oil painting is Ham

House in Surrey, England, where a primer was used along with several

undercoats and an elaborate decorative overcoat; the pigment and oil

mixture would have been ground into a paste with a mortar and pestle.

The process was done by hand by the painters and exposed them to lead

poisoning due to the white-lead powder.

In 1718, Marshall Smith invented a "Machine or Engine for the Grinding

of Colours" in England. It is not known precisely how it operated, but it

was a device that increased the efficiency of pigment grinding

dramatically. Soon, a company called Emerton and Manby was

advertising exceptionally low-priced paints that had been ground with

labour-saving technology:


Chemical Engineering – 2014 xix

In simple commercial context, the first graph below shows how, in the

US at least (from Census Bureau data), the paint industry continues to be

important and grows with the economy and suffers with the economy. In

fact, as long as one needs to control the appearance of useful or amusing

things, or they need protection, we will always need paint. Even modern

nano- or bio-materials are more often employed as coatings than any

thing else


Chemical Engineering – 2014 xx

In contrast with the sales figures before, the graph below places the rise

of paint technology in the context of some of the external influences

The last graph labels the rise in paint technology with events that

were important from the point of view of alkyd paint


Chemical Engineering – 2014 xxi

2.2 components:

2.2.1 Binder, vehicle, or resins

The binder, commonly called the vehicle, is the film-forming component

of paint. It is the only component that must be present. Components listed

below are included optionally, depending on the desired properties of the

cured film.

The binder imparts adhesion and strongly influences properties such as

gloss, durability, flexibility, and toughness.

Binders include synthetic or natural resins such as alkyds, acrylics, vinyl-

acrylics, vinyl acetate/ethylene

(VAE), polyurethanes, polyesters, melamine resins, epoxy, or oils.

Binders can be categorized according to the mechanisms for drying or

curing. Although drying may refer to evaporation of the solvent or

thinner, it usually refers to oxidative cross-linking of the binders and is

indistinguishable from curing. Some paints form by solvent evaporation

only, but most rely on cross-linking processes.

Paints that dry by solvent evaporation and contain the solid binder

dissolved in a solvent are known as lacquers. A solid film forms when the

solvent evaporates, and because the film can re-dissolve in solvent,

lacquers are unsuitable for applications where chemical resistance is

important. Classic nitrocellulose lacquers fall into this category, as do

non-grain raising stains composed of dyes dissolved in solvent and more

modern acrylic-based coatings such as 5-ball Krylon aerosol.

Performance varies by formulation, but lacquers generally tend to have

better UV resistance and lower corrosion resistance than comparable

systems that cure by polymerization or coalescence.


Chemical Engineering – 2014 xxii

The paint type known as Emulsion in the UK and Latex in the USA is a

water-borne dispersion of sub-micrometer polymer particles. These terms

in their respective countries cover all paints that use synthetic polymers

such as acrylic, vinyl acrylic (PVA), styrene acrylic, etc. as binders. The

term "latex" in the context of paint in the USA simply means an aqueous

dispersion; latex rubber from the rubber tree is not an ingredient. These

dispersions are prepared by emulsion polymerization. Such paints cure by

a process called coalescence where first the water, and then the trace, or

coalescing, solvent, evaporate and draw together and soften the binder

particles and fuse them together into irreversibly bound networked

structures, so that the paint cannot redissolve in the solvent/water that

originally carried it. The residual surfactants in paint, as well

as hydrolytic effects with some polymers cause the paint to remain

susceptible to softening and, over time, degradation by water. The general

term of latex paint is usually used in the USA, while the term emulsion

paint is used for the same products in the UK and the term latex paint is

not used at all. Paints that cure by oxidative cross linking are generally

single package coatings. When applied, the exposure to oxygen in the air

starts a process that cross links and polymerizes the binder component.

Classic alkyd enamels would fall into this category. Oxidative cure

coatings are catalysed by metal complex driers such as cobalt naphthenes.

Paints that cure by polymerization are generally one or two package

coatings that polymerize by way of a chemical reaction, and cure into a

cross linked film. Depending on composition they may need to dry first,

by evaporation of solvent. Classic two

package epoxies or polyurethanes would fall into this category.


Chemical Engineering – 2014 xxiii

2.2.2 Diluent or Solvent

The main purposes of the diluent are to dissolve the polymer and adjust

the viscosity of the paint. It is volatile and does not become part of the

paint film. It also controls flow and application properties, and in some

cases can affect the stability of the paint while in liquid state. Its main

function is as the carrier for the non volatile components. To spread

heavier oils (for example, linseed) as in oil-based interior house paint,

thinner oil is required. These volatile substances impart their properties

temporarily—once the solvent has evaporated, the remaining paint is

fixed to the surface. This component is optional: some paints have

no diluent. Water is the main diluent for water-borne paints, even the co-

solvent types. Solvent-borne, also called oil-based, paints can have

various combinations of organic solvents as the diluent,

including aliphatics, aromatics, alcohols, ketones and white spirit.

Specific examples are organic solvents such as petroleum

distillate, esters, glycol ethers, and the like. Sometimes volatile low-

molecular weight synthetic resins also serve as diluents.

2.2.3 Pigment and Filler

Pigments are granular solids incorporated in the paint to contribute

colour. Fillers are granular solids incorporate to impart toughness,

texture, give the paint special properties, or to reduce the cost of the paint.

Alternatively, some paints contain dyes instead of or in combination with

pigments.

Pigments can be classified as either natural or synthetic. Natural pigments

include various clays, calcium carbonate, mica, silica’s, and talcs.

Synthetics would include engineered molecules, calcined clays, blanc

fixes, precipitated calcium carbonate, and synthetic pyrogenic silica.


Chemical Engineering – 2014 xxiv

Hiding pigments, in making paint opaque, also protect the substrate from

the harmful effects of ultraviolet light. Hiding pigments include titanium

dioxide, phthalo blue, red iron oxide, and many others.

Fillers are a special type of pigment that serve to thicken the film, support

its structure and increase the volume of the paint. Fillers are usually

cheap and inert materials, such as diatomaceous earth, talc, lime, barytes,

clay, etc. Floor paints that must resist abrasion may contain fine quartz

sand as a filler. Not all paints include fillers. On the other hand, some

paints contain large proportions of pigment/filler and binder.

Some pigments are toxic, such as the lead pigments that are used in lead

paint. Paint manufacturers began replacing white lead pigments with

titanium white (titanium dioxide), before lead was banned in paint for

residential use in 1978 by the US Consumer Product Safety Commission.

The titanium dioxide used in most paints today is often coated with

silica/alumina/zirconium for various reasons, such as better exterior

durability, or better hiding performance (opacity) promoted by more

optimal spacing within the paint film.

2.2.4 Additives

Besides the three main categories of ingredients, paint can have a wide

variety of miscellaneous additives, which are usually added in small

amounts, yet provide a significant effect on the product. Some examples

include additives to modify surface tension, improve flow properties,

improve the finished appearance, increase wet edge, improve pigment

stability, impart antifreeze properties, control foaming, control skinning,

etc. Other types of additives include catalysts, thickeners,

stabilizers, emulsifiers, texturizers, adhesion promoters, UV stabilizers,

flatteners (de-glossing agents), biocides to fight bacterial growth, and the


Chemical Engineering – 2014 xxv

like. Additives normally do not significantly alter the percentages of

individual components in a formulation.

2.3 Application of paint

Paint can be applied as a solid, a gaseous suspension (aerosol) or a liquid.

Techniques vary depending on the practical or artistic results desired.

As a solid (usually used in industrial and automotive applications), the

paint is applied as a very fine powder, and then baked at high

temperature. This melts the powder and causes it to adhere to the surface.

The reasons for doing this involve the chemistries of the paint, the surface

itself, and perhaps even the chemistry of the substrate (the object being

painted). This is called "powder coating" an object.

As a gas or as a gaseous suspension, the paint is suspended in solid or

liquid form in a gas that is sprayed on an object. The paint sticks to the

object. This is called "spray painting" an object. The reasons for doing

this include:

1) The application mechanism is air and thus no solid object touches the

object being painted;

2) The distribution of the paint is uniform, so there are no sharp lines;

3) It is possible to deliver very small amounts of paint;

4) A chemical (typically a solvent) can be sprayed along with the paint to

dissolve together both the delivered paint and the chemicals on the

surface of the object being painted;

5) Some chemical reactions in paint involve the orientation of the

paint molecules.

In the liquid application, paint can be applied by direct application

using brushes, paint rollers, blades, other instruments, or body parts such

as fingers and thumbs.


Chemical Engineering – 2014 xxvi

Rollers generally have a handle that allows for different lengths of poles

to be attached, allowing painting at different heights. Generally, roller

application requires two coats for even colour.

2.4 Failure of paint

The main reasons of paint failure after application on surface are the

applicator and improper treatment of surface.

Application Defects can be attributed to:

Dilution

This usually occurs when the dilution of the paint is not done as per

manufacturer’s recommendation. There can be a case of over dilution and

under dilution, as well as dilution with the incorrect diluent.

Contamination

Foreign contaminants added without the manufacturers consent can cause

various film defects.

Peeling/Blistering

Most commonly due to improper surface treatment before application and

inherent moisture/dampness being present in the substrate.

Chalking

Chalking is the progressive powdering of the paint film on the painted

surface. The primary reason for the problem is polymer degradation of

the paint matrix due to exposure of UV radiation in sunshine and

condensation from dew. The degree of chalking varies as epoxies react

quickly while acrylics and polyurethanes can remain unchanged for long

periods. The degree of chalking can be assessed according

to International Standard ISO 4628 Part 6 or 7 or American Society of

Testing and Materials(ASTM) Method D4214 (Standard Test Methods

for Evaluating the Degree of Chalking of Exterior Paint Films).


Chemical Engineering – 2014 xxvii

Cracking

Cracking of paint film is due to the unequal expansion or contraction of

paint coats. It usually happens when the coats of the paint are not allowed

to cure/dry completely before the next coat is applied. The degree of

cracking can be assessed according to International Standard ISO 4628

Part 4 or ASTM Method D661 (Standard Test Method for Evaluating

Degree of Cracking of Exterior Paints).

Erosion

Erosion is very quick chalking. It occurs due to external agents like air,

water etc. It can be evaluated using ASTM Method ASTM D662

(Standard Test Method for Evaluating Degree of Erosion of Exterior

Paints).

Blistering

Blistering is due to improper surface exposure of paint to strong sunshine.

The degree of blistering can be assessed according to ISO 4628 Part 2 or

ASTM Method D714 (Standard Test Method for Evaluating Degree of

Blistering of Paints).

Degradation

The fungi Aureobasidium pullulans consumes wall paints.


Chemical Engineering – 2014 xxviii

2.5 Dangers

Volatile organic compounds (VOCs) in paint are considered harmful to

the environment and especially for people who work with them on a

regular basis. Exposure to VOCs has been related to organic solvent

syndrome, although this relation has been somewhat controversial

In the US, environmental regulations, consumer demand, and advances in

technology led to the development of low-VOC and zero-VOC paints and

finishes. These new paints are widely available and meet or exceed the

old high-VOC products in performance and cost-effectiveness while

having significantly less impact on human and environmental health.


Chemical Engineering – 2014 xxix

2.6 Indian paint industry

2.6.1 Brief Introduction

There is a phenomenal growth on the housing sector front with rapid

urbanization and availability of easy to secure housing loans which have

become the prime drivers of growth in the decorative paint segment,

which comprises 70% of the $2 billion Indian Paint industry. An average

increase of growth of about 10% in the automobile sector contributes to

50% of the revenues in the industrial paints segment. Paints can be

classified as Decorative Paints & Industrial Paints.

Decorative Paints are usually meant for the housing sector. Distemper is

mostly affordable by all and used in the suburban and rural markets.

Interestingly, 20% of all decorative paints in India are distempers. Indian

Paint products are highly in demand in countries of United States, China,

India, United Kingdom, Australia, Pakistan, Hong Kong, Canada, etc

forming the turning points in the Paint Industry of India.

2.6.2 Size of the Industry

A large number of Paint outlet or shops have automated/manual dealer

tinting systems. Today India has more than 20,000 outlets in operation,

probably the highest for any country. There are only approximately 7,000

tinting systems in China for a market two and half times of India's size.

30% to the paint industry revenue in India is accumulated from Industrial

Paints. The size of the Paint Indian industry is around 940 million litres

and is valued at approximately $2 billion. The organized sector comprises

54% of the total volume and 65% of the value. In the last ten years, the

Indian Paint Industry has grown at a compounded annual growth rate

(CAGR) of 12-13%.


Chemical Engineering – 2014 xxx

2.6.3 Total contribution to the economy/ sales

The market for paints in India is expected to grow at 1.5 times to 2 times

GDP growth rate in the next five years. With GDP growth expected to be

over and above 7% levels, the top three players are likely to clock above

industry growth rates. There are high volumes of low cost distempers sold

in India, which amounts to approximately 200,000 tons per annum at an

average cost of Rs35 per kg ($0.88) at the present rate.

2.6.4 Top leading Companies

Asian Paints India

Nerolac India Paints

Berger

Dulux India Paints

Shalimar Paints

2.6.5 Latest Development

Indian Paint Industry today is about Rs 49 billion sector which has

demands for paints which is relatively price-elastic but is linked to

the industrial and economical growth.


Chemical Engineering – 2014 xxxi

Indian per capita consumption of paints is at 0.5 kg per annum if

compared with 4 kgs in the South East Asian nations and 22 kgs in

developed countries.

Organized sector in India controls 70% of the total market with the

remaining 30% being in the hands of nearly 2000 small-scale units.

In India 30% accounts for the industrial paint segment in paint

Industry while the decorative paint segment accounts for 70 % of

paints sold in India.

Globally, Indian Industrial Paints segment accounts for a major share

which indicates that this segment offers many opportunities for paint

manufacturers. In June 2009 with a recovery in realty sector, the

production volumes in the sector have substantially recovered. In the year

2009-2010 the Production of paints grew by a robust 25.2% during as

compared to a 40 basis points drop in production in the corresponding

year-ago period.

As the production of passenger cars is expected to grow by 15.3% in

2010-11 the demand for automotive paints will continue to remain

healthy as sales are expected to grow in double-digits. And with realty

majors launching new projects, construction activity is expected to gain

momentum and generate demand for decorative paints. Rise in demand is

expected to be supported by higher supply as the industry is expected to

commission additional capacity in 2010-11.


Chemical Engineering – 2014 xxxii

Chapter 3

Objectives and future plans

Process Flow Diagram.

Material and Energy Balance

Detail Equipment Design.

Piping and Instrumentation Diagram.

Plant Layout.

Costing and Economics.

Safety and Environmental Studies.


Chemical Engineering – 2014 xxxiii

REFERENCES

[1] Alavi, S., Dexpert-Ghys, J., & Caussat, B. (2008). High temperature

annealing of micrometric Zn2SiO4:Mn phosphor powders in fluidized

bed. Materials Research Bulletin, 43, 2751-2762

[2] Catoire, L. & Naudet, V. (2004), A Unique Equation to Estimate

Flash Points of Selected Pure Liquids Application to the Correction of

Probably Erroneous Flash Point Values. Journal of Physical and

Chemical Reference Data, 33, 1083-1111

[3] Chakradhar, R. S., Nagabhushana, B. M., Chandrappa, G. T., Ramesh,

K. P., & Rao, J. L. (2004). Solution combustion derived nanocrystalline

Zn2SiO4:Mn

phosphors: A spectroscopic view. Journal of Chemical Physics, 121,

1025010259 El Mir, L., Amlouk, A., Barthou, C., & Alaya, S. (2007).

[4] Synthesis and luminescence properties of ZnO/Zn2SiO4 /SiO2

composite based on nanosized zinc oxide- fi . : Condensed Matter, 68,

412417

[5] Inoue, Y., Toyoda, T., & Morimoto, J. (2008). Photoacoustic spectra

on Mn-doped zinc silicate powders by evacuated sealed silica tube

method. Journal of Materials Science, 43, 378-383

[6] Lee, B. I., & Lua, S. W. (2000). Synthesis of nanoparticles via surface

modification for electronic applications. Journal of Ceramic Processing

Research, 1 (1), 20-26


Chemical Engineering – 2014 xxxiv

[7] Mai, M., Feldmann, & Claus. (2009). Two-color emission of

Zn2SiO4:Mn from ionic liquid mediated synthesis. Solid State Sciences,

11, 528-532

[8] Natarajan, V., Murthy, K., & Kumar, M. J. (2005).

Photoluminescence

investigations of Zn2SiO4 co-doped with Eu3+and Tb3+ ions. Solid State

Communications, 134, 261-264

[9] Takesue, M., Hayashi, H., & Smith, R. L. (2009). Thermal and

chemical methods for producing zinc silicate (willemite): A review.

Progress in Crystal Growth and Characterization of Materials, 55, 98-124

[10 ] Tani, T., Takatori, K., & Pratsinis, S. E. (2004). Evolution of the

Morphology of

Zinc Oxide/Silica Particles by Spray Combustion. Journal of the

American

Ceramic Society, 87, 365-370