FERRIC AND NON FERRIC ALUM PRODUCTION

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Aluminium sulfate (Al2(SO4)3), commonly called alum, is produced as white crystals which are non-combustible and soluble in water. This dry, hydrate (Al2(SO4)3.14H2O) is 17% Al2O3 and is also sold as a 47% w/w aluminium sulfate solution which is 8% Al2O3. It is also sold in solid form as kibbled, ground or dust.

Ferric and Non Ferric Alum is marketed in various grades. The cheapest grade called “alum cake”. Potash alum also known as alum alumen.

Ferric alumin is aluminium sulphate containing iron obtained from the bauxite ore. Potash alum is prepared from its naturally occurring minerals such as alunite and Ratinite, but in India these do not occur in appreciable quantities. Alum was formerly prepared from alum shales by roasting them in year and leaching it out with water. Alum is now produced in India by crystallizing together equivalent produced in India by Crystallizing together equivalent proportion of potassium sulphate and aluminium sulphate. The solution is concentrated and the crystals are separated out are melted to yield lump alum or recrystalized to obtain large crystals.

There are two broad categories of Alum as follows: Ferric Alum which is generally made from Bauxite and Iron free Alum (non Ferric Alum), generally made from Alumina. Commercially, hydrated AluminumSulphate is called Alum and is sold under such names as Filler Alum, Commercial Alum, and Paper Maker’s Alum etc. Technical grade AluminumSulphate is provided in two forms: a partially dehydrated solid and an aqueous solution of this material containing about 27% Al2 (SO4)3… The reagent grade Al2 (SO4)3.18H2O is slightly, odorless, colorless monoclinic crystals, having a specific gravity of 1.69. The solid material, `Dry Alum’ is partially crystalline and may be discolored to a brownish-green owing to impurities (chiefly iron) in the ores from which it is made. The solution form, `liquid Alum’ may exhibit a similar discoloration. The major area of use for Alum is in water treatment and clarification. Its clarifying action is attributed to Aluminum hydroxide formation by hydrolysis. This, in turn, carries down all the colloidal impurities and forms a slimy layer at the bottom. Sizing of Paper the other major areas of use is in sizing of paper. It reacts with sodium resinate to give insoluble Aluminumresinate. For sizing of paper, Alum should be free from Ferric ions or else the paper will be discolored. Ferrous ions do not harm since they form a soluble colorlessresinate which, however, would represent a loss of resinate. Alum imparts certain degree of resistance to penetration by liquids during sizing of paper. Alum is also required in various other industries like Dyes, Food, Petroleum, Pharmaceuticals, fire-proofing, tanning etc.

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Description

INTRODUCTION
CHARACTERISTICS & SPECIFICATION
SPECIFICATION OF ALUM
USES & APPLICATIONS
APPLICATIONS:
USES OF ALUM
THE MAIN USES OF ALUM ARE:
OTHER MAJOR USES
WHAT HAPPENS AT A WATER TREATMENT PLANT?
SCREENING:
PRE-SEDIMENTATION:
MICRO-STRAINING:
CHEMICAL PRETREATMENT:
SOFTENING:
COAGULATION AND FLOCCULATION:
SEDIMENTATION:
FILTRATION:
DISINFECTION:
FLUORIDATION:
TREATMENT TO REMOVE ORGANIC CONTAMINANTS
TESTING:
B.I.S. SPECIFICATIONS
SPECIFICATIONS OF ALUMINIUM SULPHATE (NON FERRIC)
QUALITY CONTROL AND STANDARD IS: 299-1989 (FERRIC ALUM)
NON FERRIC ALUM
NON FERRIC ALUM – PRODUCT CHARACTERISTICS:
NON FERRIC ALUM – PRODUCT APPLICATION:
NON FERRIC ALUM – BENEFITS
SPECIFICATION OF ALUMINUM SULPHATE
(NON-FERRIC ALUM) (SLABE/LUMPS/POWDER)
(FERRIC ALUM) (SLABE/LUMPS)
FERRIC & NON-FERRIC ALUM PLANT
MANUFACTURING PROCESS:
THE RAW MATERIALS ARE:
FOR FERRIC ALUM:
FOR NON FERRIC ALUM (ALUMINUM SULPHATE):
SPECIFIC RAW MATERIAL CONSUMPTION (FOR ALUM CONTAINING ALUMINA AS AL2O3 16 %)
RAW MATERIALS
BAUXITE
THE RANGE OF COMPOSITION OF BAUXITES IS USUALLY:
THE BEST FRENCH WHITE BAUXITE CONTAINS:
MARKET OVERVIEW OF ALUMINIUM SULPHATE
ALUMINIUM SULPHATE MARKET, BY PRODUCT TYPE
ALUMINIUM SULPHATE MARKET, BY END USER
ALUMINIUM SULPHATE MARKET, BY GEOGRAPHY
INDIAN DEMAND FOR ALUM
PAPER INDUSTRY
WATER TREATMENT
MISCELLANEOUS APPLICATIONS
IMPORTANT GLOBAL MANUFACTURERS
PRESENT MANUFACTURERS/SUPPLIERS OF FERRIC & NON FERRIC ALUM
TECHNIQUE IN ALUM PRODUCTION
PROCESS OUTLINES FOR ALUMINIUM SULFATE MANUFACTURE
RAW MATERIALS
STEP 1 – REACTING THE RAW INGREDIENTS.
STEP 2 – MAKING THE FINAL PRODUCT
ENVIRONMENTAL IMPLICATIONS
MANUFACTURING PROCESS OF NON FERRIC ALUM
MASS BALANCE
PROCESS FLOW DIAGRAM WITH MATERIAL BALANCE BASIS: 1 TON
DETAILED PROCESS DESCRIPTION
(A) BAUXITE PREPARATION SECTION:-
(B) REACTION SECTION:-
WASTE & EMISSION’S:-
PACKING & MARKING:-
PACKING:-
MARKING:-
REQUIREMENT FOR ALUMINIUM SULPHATE (NON FERRIC)
METHODS OF TEST FOR ALUM, NON FERRIC (ALUMINIUM SULFATE)
QUALITY OF REAGENTS:-
PREPARED SAMPLE:-
PROCEDURE:-
DETERMINATION OF INSOLUBLE MATTER
REAGENTS:-
PROCEDURE:-
DETERMINATION OF PH:-
PROCEDURE:-
DETERMINATION OF HEAVY METALS:-
OUTLINE OF THE METHOD:-
APPARATUS:-
REAGENTS:-
STANDARD LEAD SOLUTION:-
PROCEDURE:-
DETERMINATION OF IRON:-
OUTLINE OF THE METHOD:-
APPARATUS:-
REAGENTS:-
BUTANOLIC POTASSIUM THIOCYANATE SOLUTION:-
STANDARD IRON SOLUTION:-
PROCEDURE:-
TEST FOR CHLORIDES:-
REAGENTS:-
PROCEDURE:-
DETERMINATION OF ARSENIC
PROCEDURE:-
DETERMINATION OF THE AMMONIUM SALTS
OUTLINE OF THE METHOD:-
APPARATUS:-
REAGENTS:-
NESSLER SOLUTION:-
STANDARD AMMONIUM CHLORIDE SOLUTION:-
PROCEDURE:-
DETERMINATION OF ALUMINIUM
TWO METHODS ARE PRESCRIBED, NAMELY
GRAVIMETRIC METHOD
REAGENTS:-
PROCEDURE:-
EDTA METHOD:-
REAGENTS:-
ABSOLUTE ALCOHOL
ACETIC ACID:-
AMMONIUM ACETATE BUFFER SOLUTION:-
PROCEDURE:-
CALCULATION:-
DETERMINATION OF SODIUM:-
DETERMINATION OF POTASSIUM:-
SAMPLING OF ALUM, NON FERRIC (ALUMINIUM SULPHATE)
GENERAL REQUIREMENTS OF SAMPLING:-
SCALE OF SAMPLING:-
TABLE 2 SCALE OF SAMPLING
PREPARATION OF TEST SAMPLES
NUMBER OF TESTS
CRITERION FOR CONFORMITY
BLOCK DIAGRAM TO PRODUCE ALUMINIUM SULPHATE NON FERRIC (17% TO 18%) ALUMINA CONTENT IN GRANULES (2MM TO 4MM)
AND FLAKES FORM
CHEMICAL COMPOSITION OF FERRIC ALUM:
GRADE 3
CHEMICAL COMPOSITION OF NON-FERRIC ALUM:
USES:
METHOD OF PRODUCING ALUMINIUM SULFATE SOLUTION
MATERIAL SAFETY DATA SHEET OF ALUMINIUM SULPHATE
HAZARDS IDENTIFICATION
EMERGENCY OVERVIEW
POTENTIAL HEALTH EFFECTS
CARCINOGEN STATUS:
COMPOSITION/INFORMATION ON INGREDIENTS
FIRST AID MEASURES
GENERAL INFORMATION:
FIRE FIGHTING MEASURES
ACCIDENTAL RELEASE MEASURES
HANDLING AND STORAGE
PHYSICAL AND CHEMICAL PROPERTIES:
STABILITY AND REACTIVITY
DISPOSAL CONSIDERATIONS
TRANSPORT INFORMATION
MATERIAL SAFETY DATA SHEET FOR DRY ALUM
COMPLETE PLANT SUPPLIERS OF FERRIC & NON-FERRIC ALUM PLANT
ADDRESSES OF PLANT AND MACHINERY SUPPLIERS
SUPPLIERS OF RAW MATERIALS
TO GET REQUIRED CERTIFICATION & OTHER FORMALITES FOR
EXPORTING NON FERRIC ALUMINIUM SULPHATE
ADDRESSES OF CONSULTANTS
ADDRESSES OF PILOT PLANT SUPPLIERS
SUPPLIERS OF RAW MATERIAL (INDIAN)
SUPPLIERS OF BAUXITE
SUPPLIERS OF SULPHURIC ACID
SUPPLIERS OF BARIUM SULPHIDE
SUPPLIERS OF RAW MATERIALS (GLOBAL)
OTHERS EQUIPMENTS SUPPLIERS
SUPPLIERS OF REACTOR
SUPPLIERS OF EVAPORATORS
SUPPLIERS OF GRADING SCREEN/ VIBRATING SCREEN
SUPPLIERS OF COOLING TOWERS
SUPPLIERS OF BOILERS
SUPPLIERS OF CRUSHER
SUPPLIERS OF MATERIAL HANDLING EQUIPMENTS
SUPPLIERS OF LABORATORY TESTING EQUIPMENTS
SUPPLIERS OF PLANT AND MACHINERIES (IMPORTED)

APPENDIX – A:

01. PLANT ECONOMICS
02. LAND & BUILDING
03. PLANT AND MACHINERY
04. OTHER FIXED ASSESTS
05. FIXED CAPITAL
06. RAW MATERIAL
07. SALARY AND WAGES
08. UTILITIES AND OVERHEADS
09. TOTAL WORKING CAPITAL
10. TOTAL CAPITAL INVESTMENT
11. COST OF PRODUCTION
12. TURN OVER/ANNUM
13. BREAK EVEN POINT
14. RESOURCES FOR FINANCE
15. INSTALMENT PAYABLE IN 5 YEARS
16. DEPRECIATION CHART FOR 5 YEARS
17. PROFIT ANALYSIS FOR 5 YEARS
18. PROJECTED BALANCE SHEET FOR (5 YEARS)

Additional information

Plant Capacity

20 Nos./Day
Land & Building

(2000 sq.mt.)
Plant & Machinery

US$ 132857
Rate of Return

24%
Break Even Point

73%

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