Zinc Sulfate
(33%, 21% & 12%)
Introduction
Zinc sulfate is a powder that is colorless and completely water-soluble. The product can be used in different applications, including some connected with maintaining good health. A number of over the counter products contain some level of zinc sulfate, as well as many prescription medications.
One application of zinc sulfate that may surprise some people is the use of the powder as a means to preserve wood products. The properties of the sulfate help it permeate the body of the wood and help to protect it from wear and tear from regular use as well as adverse weather conditions. The sulfate can be used safely with just about any type of wood product and eliminates the necessity of using other preservatives that have in recent years been proven to have adverse effects on the health of human beings.
In terms of healthcare uses, zinc sulfate is often included as an ingredient in products designed to treat skin conditions. In particular, over-the-counter medications for acne are likely to contain the compound. Lotions and topical creams that are used to treat boils are also likely to contain at least trace amounts of the sulfate.
The chemical compound is also helpful with a number of internal health issues as well. Products such as throat lozenges are likely to employ zinc sulfate as one of the ingredients. Many products that promote health hair and strong nails contain the compound.
The properties of zinc to promote the proper function of the oil glands are thought to indirectly support collagen and protein production, leaving the skin with a healthy appearance. An added bonus of the compound for skin is that the sulfate promotes conditions that encourage the healing of wounds.
Zinc sulfate is also helpful in promoting the efficient function of the immune system. This means that indirectly the product has an impact on just about every system in the body, as it helps to keep the immune system strong enough to deal with viruses and other types of infection. There is also a great deal of evidence that points to the importance of the zinc compound in the proper development of muscles and their maintenance.
It is not unusual for prescription medicine products used to treat various types of internal and external health issues also contain zinc sulfate. In most cases, the amount of sulfate present is greater than that of over the counter medications. As with many compounds, it is possible to ingest too much zinc sulfate and possibly disrupt the normal function of some systems. For this reason, it is important to follow the instructions of your healthcare professional when it comes to taking a prescription medication containing the sulfate.
Zinc sulfate is a very water soluble, transparent, colorless, crystalline compound. It is commonly used as the heptahydrate, ZnSO4 •7H2O, and is commonly called white vitriol; it occurs naturally as the mineral goslarite, and can be prepared by reacting zinc with sulfuric acid. It is used to supply zinc in animal feeds, fertilizers, and agricultural sprays; in making lithopone; in coagulation baths for rayon; in electrolyte for zinc plating; as a mordant in dyeing; as a preservative for skins and leather; and in medicine as an astringent and emitic.
Zinc sulfate is chiefly used in fertilizer applications and animal feed supplements. It is especially applied on crops such as pecan, deciduous fruits, peanuts, cotton, corn, and citrus, and added to feeds for swine and poultry. Zinc sulfate is the most common dry fertilizer and zinc chelates are the most common liquid material. Zinc sulfate’s high solubility in aqueous systems makes it a favored substance for delivering zinc values in agriculture applications. Zinc is one of the essential elements for plant and animal life. In plants, it serves as a growth hormone and influences protein synthesis. Zinc deficiency causes stunting of the plant, yellowing of the leaves and decreased yields of seed, grain, vegetables or fruit. Soil application of zinc sulfate is the most common and most successful long-term strategy for eliminating zinc deficiencies. Zinc sulfate can be applied as a broadcast treatment and tilled into the soil or applied in a band near the seed. Band application is most effective when placed to the side and below the seed. Zinc chelates are generally used as a rescue treatment and do not result in any benefits to following crops. Common rates of foliar zinc are 0.25-1.0 lb/a elemental zinc. Multiple applications of foliar zinc are usually required to achieve the same affect as 10 lbs/a zinc applied to the soil before planting.
Zinc sulfate solution may be used in the production of zineb (zinc ethylene bisdithiocarbamate). Zineb, and agricultural fungicide, is commonly employed to protect crops such as apples, pears, cabbage, broccoli and ornamentals as well as citrus, stone-fruit, cotton and wheat.
The second major use for zinc sulfate is the manufacture of viscose rayon fiber. Zinc sulfate is one of the ingredients in the spinning bath along with sodium sulfate and sulfuric acid. A thin stream of viscose solution is injected into the spinning bath where it coagulates forming the fiber. The zinc sulfate promotes coagulation and crenullation of the fiber. Rayon of high strength is produced which is especially well suited for tires, rubber hoses, belting and other reinforcing applications.
Zinc sulfate is the ideal source of zinc for the production of zinc stearate. It is used as a catalyst in numerous chemical operations and in the production of butyl rubber. Zinc Sulfate Solution is used as the source of zinc in the manufacture of zinc dithiocarbamate rubber accelerators. In water treatment, zinc sulfate finds application as a corrosion inhibitor in cooling towers and secondary oil recovery. Zinc sulfate also finds use in production of pigments, preservation and clarification of glue, in flame-proofing compounds, as a mining flotation agent, wood preservative and in electrometallurgy and electrogalvanizing.
APPLICATION
Zinc Sulphate is used in agriculture as a weed killer and to give protection against pests. It is used to supply zinc in animal feeds and fertilizers; Zinc Sulphate is also an important constituent of the precipitating bath in the manufacture of viscose rayon and in electrolyte for zinc plating. Zinc Sulphate functions as a mordant in dyeing; as a preservative for skins and leather; and as an astringent and emetic in medicine.
RAW MATERIAL DETAILS
SULFURIC ACID
Sulfuric acid is a strong mineral acid with the molecular formula H2SO4. Its historical name is oil of vitriol. Pure sulfuric acid is a highly corrosive, colorless, viscous liquid. The salts of sulfuric acid are called sulfates. Sulfuric acid is soluble in water at all concentrations.
Sulfuric acid has many applications, and is a central substance in the chemical industry. Principal uses include lead-acid batteries for cars and other vehicles, ore processing, fertilizer manufacturing, oil refining, wastewater processing, and chemical synthesis.
ZINC ASH
Zinc ash is oxidised zinc that forms on the surface of molten zinc metal.
• The ash consists of a powdery material (the ash proper) and solid metallic pieces of an irregular shape.
• It is sometimes called zinc dross, zinc skimmings, zinc top dross or zinc oxide. In the galvanising industry itself, the term zinc ash prevails.
• Zinc ash usually arises from hot dip galvanising or other zinc coating processes.
• The ash is removed from the top of galvanising baths by skimming or straining.
• There are several major companies that process or recycle zinc ash domestically.
• One of these companies mechanically separates the metallic zinc from the ash.
• Another company does this and blends the zinc ash to make agricultural grade zinc oxide.
• A number of galvanising companies also mechanically separate the metallic zinc from the ash.
• The metallics are re-used in galvanising and other processes.
• Another company smelts both processed ashes and unprocessed ash to recover the zinc in metallic form.
• Export or import of zinc ash without a permit contravenes the Hazardous Waste (Regulation of Exports and Imports) Act 1989.
DIFFERENT TYPE OF ZINC ASH
Old Zinc Die Cast Scrap
Shall consist of miscellaneous old zinc base die castings, with or without iron and other foreign attachments. Must be free of borings, turnings, dross pieces, chunks, melted pieces and skimmings.
All unmeltables, dirt, foreign attachments, and volatile substances (such as rubber, cork, plastic, grease, etc.) are deductible. Material containing in excess of 30% iron will not constitute good delivery.
New Zinc Die Cast Scrap
Shall consist of new or unused, clean, zinc base die castings. Castings to be unplated , unpainted, and free from corrosion.
Zinc Die Cast Automotive Grilles
Shall consist of clean, old or used zinc base die cast automotive grilles, free from soldered material. All foreign attachments and extraneous materials are deductible.
New Plated Zinc Die Cast Scrap
Shall consist of new or unused clean, plated zinc base die castings, free from corrosion.
Old Scrap Zinc
Shall consist of clean dry scrap zinc, such as sheets, jar lids, clean unalloyed castings and anti-corrosion plates. Borings and turnings are not acceptable. Material must not be excessively corroded or oxidized. All foreign attachments and extraneous materials are deductible.
New Zinc Clippings
Shall consist of any new pure zinc sheets or stampings free from corrosion. To contain no foreign material or attachments. Printers zinc, such as engravers zinc, lithograph sheets and addressograph plates subject to special arrangements. Printers zinc to be free of routings.
ZINC ASH (Zinc Dust, Zinc powder)
CAS : 7740-68-6
Molecular Formula : Zn
Molecular Weight : 65.38
Property : Grayish Powder
Zinc for Crop Production
Zinc (Zn) is an essential nutrient required in some fertilizer programs for crop production. While some soils are capable of supplying adequate amounts for crop production, addition of zinc fertilizers is needed for others. Zn may be needed in fertilizer programs for production of corn, sweet corn, and edible beans.
The Role of Zinc in the Plant
The specific role of Zn in growth and development of plants is not known. This nutrient is an important component of various enzymes that are responsible for driving many metabolic reactions in all crops. Growth and development would stop if specific enzymes were not present in plant tissue.
Zinc, however, is needed in very small amounts. Plant uptake of this nutrient is calculated in terms of ounces per acre instead of pounds per acre. Therefore, Zn is classified as a micronutrient.
Deficiency Symptoms
Plants fail to develop normally when they are deficient in Zn and certain characteristic deficiency symptoms will appear. With corn, these symptoms usually appear in the first two or three weeks of the growing season. If the deficiency of Zn is severe, these symptoms may last throughout the entire season.
A deficiency of Zn in corn is characterized by the development of broad bands of striped tissue on each side of the midrib of the leaf. These stripes begin on the part of the leaf closest to the stalk and appear first on the upper part of the plant A Zn deficient corn plant also appears to be stunted. The lack of normal elongation in a corn plant.
Zinc deficiency in edible beans first appears as a yellowing of the lower leaves. As the season progresses, this yellowing develops into a bronze or brown color. The leaves have a rusty appearance. For this crop, however, care must be taken to avoid confusing sunburned leaves with Zn deficiency.
For both corn and edible beans, suspected deficiency symptoms should be confirmed with plant analysis.
MANUFACTURING PROCESS
Plant Capacity – 20 MT/day or 6000 MT/Annum
Zinc Sulfate 33% 1500 MT/Annum
Zinc Sulfate 21% 3000 MT/Annum
Zinc Sulfate Soln. 12% 4100 KLs/Annum
Technological process consists from:
1. suspension preparation
2. leaching
3. refining
4. solution thickening
5. crystallization
6. centrifugation and packing of zinc sulphate
Production machinery involve are :
• suspension basins
• dissolving basin
• refining basins
• evaporators
• crystallizator
• filter
• filtration screen
• centrifuge
• packing line
• collateral technological equipment: pressure vessels, collecting vessels, sulphuric acid reservoir
Material Preparation
Zinc ash is generally available in the form of lumps and chips. It is, therefore, first crushed and then pulverized to separate out zinc metallic from fine ash.
Raw Material Required –
Zn Ash
3720 MT/annum
Sulfuric Acid
3240 MT/annum
Leaching
The fine ash is then treated with sulphuric acid. Zinc is rendered soluble according to the following reaction, using agitated reactors:
ZnO + H2SO4 = ZnSO4 + H2O
During this operation, compressed air and pyrolusite (MnO2) are added to oxidize ferrous iron to ferric state. Small quantity of steam, if required, is also added to leach zinc at about 60°C to get better extraction. Leaching is continued till pH of the slurry reaches 4.5 to 5 where the oxidized impurity of iron is hydrolyzed to ferric hydroxide precipitate and is thus removed from the solution:
3ZnO + Fe2(SO4)3 + 3H2O = 3ZnSO4 + 2 Fe(OH)3
The slurry is then discharged to a thickener for solid-liquid separation. For quicker settling, suitable flocculent is added to slurry at the time of discharge. The thickener, overflow, which is a clear solution of ZnSO4, is sent for evaporation from their 12% solution take a out as product.
The thickener underflow is pumped to another reactor, where it is subjected to water washing. The pulp is filtered in a drum filter to get soluble zinc.
The residual cake is discarded to secured landfill facility and the filtrate goes to effluent treatment plant for making zinc hydroxide.
Further, rest solution sent for crystallizer. Zinc Sulfate crystal takes place and suspended in the solution.
These are separated out by centrifuge, and liquid filtrate recycled & zinc sulfate cake sent for drying. On drying heptrahydrate take in out as 21% & further drying to monohydrate take in out as 33% zinc sulfate.
These 21% & 33% zinc sulfate lumps subjected to grinding/Pulverilzering & screening.
PACKING
Zinc Sulfate 33 %, 21 % is packed into standard 25 kg HDPE bags with inner liner. Zinc Sulfate 12 % solution packed in the 25 litre plastic container,
PLANT ECONOMICS
Rated Plant capacity = 20.00 MT/day
= 6000.00 MT/annum
ZINC SULFATE 33%, 21%, AND 12% SOLN
Basis
No. of working days = 25 days/month
= 300 days/annum
No. of shifts = 3 per day
One shift = 8 hours
ZINC SULFATE 33% 1500 MT/ANNUM
ZINC SULFATE 21% 3000 MT/ANNUM
ZINC SULFATE SOLN 12%
4100 KL/ANNUM
Currency - Rs.
INDIAN CURRENCY
LAND & BUILDING Cost Rs. 166.4 Lakh
PLANT & MACHINERY
1. Storage Tank
2. Reactor
3. Evaporators
4. Crystallizer
5. Filtration/Centrifuge
6. Dryer
7. Grinder/Crusher
8. Storage Tank
9. Bagging Machine
10. Air Compressor
11. Refrigration System
12. Cooling Tower
13. Boiler
14. Fuel Storage
15. Pipelines, Pumps etc.
16. Miscellaneous Material Handling Equipments
17. Erection & Installation TOTAL Rs. 131 Lakhs
FIXED CAPITAL
1. LAND & BUILDING Rs. 166.4 Lakhs
2. PLANT & MACHINERY Rs. 131 Lakhs
3. OTHER FIXED ASSETS Rs. 72 Lakhs
TOTAL Rs. 369.4 Lakhs
WORKING CAPITAL REQUIREMENT/MONTH
RAW MATERIALS
1. Zn Ash
2. Sulfuric Acid
3. Packing 25 Kgs Plastic lined bags
4. Packing 25 Ltrs. Plastic Containers
5. Other labels, gum, tape and consumables
6. Laboratory & ETP Chemicals TOTAL Rs. 113.6 Lakhs
TOTAL WORKING CAPITAL/MONTH
1. RAW MATERIAL Rs. 113.6 Lakhs
2. SALARY & WAGES Rs. 6.6 Lakhs
3. UTILITIES & OVERHEADS Rs. 7.64 Lakhs
TOTAL Rs. 127.84 Lakhs
COST OF PROJECT
TOTAL FIXED CAPITAL Rs. 369.4 Lakhs
MARGIN MONEY Rs. 63.9 Lakhs
TOTAL Rs. 433.3 Lakhs
TOTAL CAPITAL INVESTMENT
TOTAL FIXED CAPITAL Rs. 369.4 Lakhs
TOTAL WORKING CAPITAL FOR 2 MONTHS Rs. 255.5 Lakhs
TOTAL Rs. 624.9 Lakhs
TURN OVER/ANNUM = Rs. 1946 Lakhs
PROFIT SALES RATIO = 16.13%
RATE OF RETURN = 50.24%
BREAK EVEN POINT (B.E.P.) = 34.77%
