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NEW PROJECT IDEAS
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Biobased Chemicals, Polymers & Additives
Biobased Building Blocks for Intermediate Chemicals & Polymers Source: Nova Institute Biobased Plasticizers, Chemicals & Polymers Bio-Plasticizer produced from castor oil (The Bio-plasticizer is acetic acid ester of monoglycerides made from fully hydrogenated castor oil) Renewable, agricultural, non-edible oil based bio plasticizer is well placed to replace phthalate based and other competing plasticizers in soft PVC compounds without sacrificing product performance at a competitive cost. Castor Oil based plasticizer is an ideal choice due to its abundant availability in India, non-edible nature and its chemistry that enables production of plasticizer with superior functionality. Bio-plasticizers can be based also manufactured from other oil-seeds like cottonseed oil, palm oil, rice bran oil, linseed oil etc. Food grade plasticizers can be produced from plant / agricultural based glycerine derivatives. Examples of such food grade plasticizers are Acetylated Monoglycerides (AMG), Acetylated Citric Acid Esters of Monoglyceride (ACMG), Polyglycerol Esters of Fatty Acids (PGE), Calcium or Zinc Stearoyl Lactylate etc. Polybutylene succinate (PBS) is biodegradable and currently mostly fossil-based but could in theory be 100% bio-based. PBS is produced from 1,4-butanediol (1,4-BDO) and succinic acid. Both building blocks are available bio-based but 1,4-BDO is not commercially available yet, but is expected soon. Poly(butylene adipate-co-terephthalate) (PBAT) is also currently mostly fossil-based. PBAT is produced from 1,4-BDO, TPA and adipic acid. PBAT is biodegradable. PBAT can theoretically be up to 50% bio-based since bio-based adipic acid is not available yet. We can provide know-how for such biobased chemicals & polymers project and assist you in its planning and implementation. As a first step we can prepare a Techno Economic Project Feasibility Report that will provide a realistic picture and help you to take an informed business decision. One you decide to go ahead with the project we can provide complete assistance for the project implementation i.e. selection and sourcing of plant & machinery, plant layout and factory design, selection & sourcing of utilities and support equipment, recruiting technical manpower, commissioning of plant, sourcing of raw material and chemicals, process know-how, quality control and testing systems, product technical qualification, target market segments, end application know-how, market intelligence, REACH compliance for export etc. NEW PROJECT IDEAS Given below is a list of new and innovative projects that can be actively considered by entrepreneurs. Some of the projects are relatively new to India but well established world-over. There is a growing demand for such new technologies and products. Most of the projects involve high technology level, have clean manufacturing process, are non-polluting and carbon positive, have very low labour requirement and attractive project pay-back periods. A) Recycling of waste Tyres into Reclaimed Rubber (used to partly replace virgin rubber in products such as automotive tyre, bicycle tyre & tube, tyre re-treading material, conveyor belting, footwear etc.). Manufacture of special grade reclaimed rubber like High Tensile reclaim, Butyl reclaim, EPDM reclaim, NBR reclaim etc.B) Recycling of post consumer Waste PET Bottles 1) Recycling of Waste PET Bottles into Re-generated Polyester Staple Fiber used in production of Polyester Yarn, Fiber Fill, Non-woven Textiles (exhibition carpets, carpet backing, automotive insulation, filtration fabric, geo-textiles etc.) 2) Recycled PET (rPET) pellets which are used to partially or completely replace Virgin PET resin in applications such as non-food packaging applications (bottles & containers, clear rigid sheet for thermoformed packaging), Strapping Tape etc. Solid state poly-condensation and crystallization is carried out to increase polymer intrinsic viscosity for demanding applications requiring higher physical properties. 3) Value added products like extruded Clear Rigid Sheet for Thermoformed Packaging (electronics, cosmetics, bakery etc.), Strapping Tape, Non-food contact Bottles & Containers (shampoo, hair oil, detergent, hand-wash, cleaning fluid etc.) 4) Recycled Polyester Filament Yarn (also known as polyester oriented yarn –POY) and Drawn Textured Yarn (DTY) from waste PET bottle flakes. 5) Bottle grade PET Resin (US FDA approved) from waste PET Bottles C) Wood - Plastic Composite (WPC) Materials Wood Plastic Composite (WPC) is a combination of low-cost cellulosic filler (like wood flour, rice husk, bagasse, bamboo etc) and thermoplastics (like HDPE, PVC, PP etc.) that provide number of advantages over conventional wooden products and plywood. 1) Wood - PVC Foamed Celuka Board (high performance furniture board) 2) Wood - PVC Extruded Door Board & Door Frame 3) Wood - PVC Extruded Profiles like decorative wall panel, skirting, home & office partition 4) Wood - HDPE Composite (outdoor decking, wall panel, railing, fencing, pallets etc.) 5) Injection Moulded WPC products made of Bamboo Fiber, Bagasse fiber reinforced plastics (tableware, kitchenware, home appliance parts, automotive indoor trims, toys, containers, rigid packaging etc.) D) Specialty PVC based building & construction products 1) PVC Co-extruded Foamed Board (used in furniture cabinets, wall cladding & partitions, signage boards, indoor & outdoor decoration) 2) PVC Foamed Board with Integral Skin (usage as above) 3) Three Layer Co-extruded Rigid PVC Roofing Sheet (much lower weight than Galvalume or Galvanized Steel leading to lower structural cost, no rust or corrosion, longer life, no fading of colour, high impact strength etc.) 4) Chlorinated PVC (C-PVC) pipes for plumbing (hot / cold) water pipes, long life water supply pipes, industrial pipes. 5) Synthetic Marble or PVC Imitation Marble (an environment friendly, light weight and lower cost substitute for marble tiles & moulding) 6) PVC Siding / Wall Panel / Wall Partition with decorative surface designs 7) PVC Edge-banding and Veneer for furniture lamination E) Flexible Packaging Films 1) Multilayer Co-extruded Blown films (3 layer polyolefin based) used for food packaging, shrink collation film, stretch hood film, surface protection film, agricultural film, medical packaging, Lidding films, cling film etc. 2) Multilayer Co-extruded Blown films (5 layer barrier film) incorporate a Nylon or EVOH barrier layer in the middle. Typical construction is LDPE / Tie / Nylon or EVOH / Tie / LDPE. Nylon and EVOH barriers highly reduce transmission of oxygen and moisture through the package thus protecting the perishable food products from deterioration and increasing their shelf life. Main end applications include Edible Oil pouch, Pure Ghee pouch, Meat / Fish / Dairy products, Basmati Rice, Sauce, Condiments, Spices etc. 3) Multilayer co-extruded BOPP films used in packaging (snack food, candy wraps, cigarette box wrap etc.) 4) Multilayer laminated films used in flexible packaging of food using LDPE, LLDPE, PET, BOPET, PP, BOPP, Aluminum Foil, Paper (Lamination can be with solvent or by solvent – less process) F) Specialty Polymer Products & Projects 1) EVA Hollow Coil Mattress Core and Cushion material (3D interconnected structure provides natural spring action, high level of support and flexibility, high degree of breathability, can be washed, mite / rot / fungus / bacteria proof, 100% recyclable) 2) EVA Encapsulation Film used in Solar PV modules, PET Back-layer & PVB Interlayer Film used in Laminated Glass (automotive, architectural etc.) 3) Synthetic Paper made from PP & Calcium Carbonate (water, tear & insect resistant; eco-friendly as compared to pulp based paper - saves forest resources, waste water and no effluent produced) 4) Flexible, Transparent & Sterilized Infusion Bags / Pouches made of PVC / PP / TPE used in medical field (For large nos. Gamma Irradiation sterilization is used while for smaller nos. dry / wet steam is used) 5) PVC - O (Oriented PVC) pressure pipes based on western technology 6) PVC / TPO Roofing Membrane for heat reflection & waterproofing 7) Injection Moulding of PET Preforms and Stretch Blow Moulding of PET Bottles and Containers (Two Step process) 8) Single Step Injection - Stretch Blow Moulding of PET Containers and Bottles thereby increasing productivity and greatly reducing production time, energy and tooling cost. 9) High Density Paper Composite – made form waste / recycled paper and Thermoset resins used for making end products like Kitchen Countertops, Sink, Bathtub, Tiles etc. 10) PET extruded Optical Film for Mobile phone, tablet, laptop, LED TV screen guard 11) PE Air Bubble Film (2, 3 & 7) layers - laminated with paper for e-commerce packaging 12) Flexible Printed Circuit (FPC) Film for substrate (base) and coverlay (PET, PEN, Polyimide) 13) Flexible PVC / TPO flooring sheet (marble / wood effect) 14) Plastic Geo-cell and Geo-nets for building and construction sector 15) MDPE pipes for PNG / CNG piping, PP-R Pipes (Polypropylene Random Co-polymer) 16) Coal Fly-ash Thermoplastic (PP, HDPE, PU) Composites 17) Bio based plasticizer made form castor oil to replace phthalate plasticizers 18) Chlorinated Polyethylene (CPE) based on foreign production technology G) Recycling of Engineering Plastics (Nylon, ABS) and Thermoplastics • Nylon 6 & 66 (from post industrial tire cord waste & carpet backing yarn waste) • ABS from white goods like refrigerators • PP from end of life automotive bumpers • HDPE & MDPE from end of life pipes • LLDPE / LDPE / BOPP from film edge trimmings H) Projects in Rubber Field 1) Automotive Tyre – Truck, Light Truck, Motorcycle, Scooter, Three Wheeler, Small Commercial Vehicle (cross-ply tyres). Improvement in Rolling Resistance. 2) Bicycle Tyre & Tube 3) Rubber covered Industrial Rolls (used in paper, textile, steel, printing industry) 4) Coated Fabric with Thermoplastic Elastomer (TPE / TPV) for Flexible Luggage, Rainwear, Inflated Boats etc. 5) Air Spring (Rubber bellow for air suspension) used in Bus, Truck, Metro Trains, Railway etc. 6) Bridge Bearing Pad / Seismic Isolation Pad 7) Special Auto components based on high performing Elastomer / polymer |
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