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CHLORALKALI

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Monday, April 20, 2015

The term chlor-alkali refers to the two chemicals (chlorine and an alkali) which are simultaneously produced as a result of the electrolysis of a saltwater. The most common chlor-alkali chemicals are chlorine and sodium hydroxide (caustic soda) but can include potassium hydroxide and muriatic acid. There are 3 types of electrolytic processes used in the production of chlorine: (1) the diaphragm cell process, (2) the mercury cell process, and (3) the membrane cell process. In each process, a salt solution is electrolyzed by the action of direct electric current that converts chloride ions to elemental chlorine. The overall process reaction is: 2NaCl 2H2O → Cl2 H2 2NaOH  In all 3 methods, the chlorine (Cl2) is produced at the positive electrode (anode) and the caustic soda (NaOH) and hydrogen (H2) are produced, directly or indirectly, at the negative electrode (cathode). The 3 processes differ in the method by which the anode products are kept separate from the cathode products. With four product lines: chlor-alkali products, chlorinated ethylenes, calcium hypochlorite and specialty phosgene derivatives, Axiall Chlor-Alkali and Derivatives is a global producer of chemicals that are essential building blocks for countless products that the world depends upon each and every day. Chlor-Alkali also supplies eco chemicals, products related to re-use, recycling and eco-solutions, aiming at a positive and sustainable impact on the environment. Main applications for iron chloride are drinking water production, industrial applications and waste water treatment. Waste water treatment plants use our products and solutions to control sludge conditions by dosing the right chemicals into their process steps. CHLORALKALI MARKET The chlor-alkali industry produces bulk chemicals that are used in many industries for various applications. They are required in construction industry, food processing, water treatment, plastics etc. The chlor-alkali industry has three products that are, chlorine, caustic soda and soda ash. The chlor-alkali consumption is projected to grow from 193,384 KT in 2014 to 224,231 KT by 2019, a a CAGR of 3.00% during the same period. At a CAGR of 6.00%, the market is projected to reach $93,936 million in 2019 from $70,407 million in 2014 Demand : Past & Future Year                th MT 1990-91    990 1991-92    1030 1996-97    1700 1997-98    1755 1998-99    1715 1999-00    1800 2000-01    1938 2001-02    1982 2002-03    2177 2003-04    2051 2004-05    2114 2005-06    2156 2006-07    2210 2007-08    2276 2008-09    2356 2009-10    2450 2010-11    2524 2011-12    2587 2012-13    2652 2013-14    2718 2014-15    2785 2019-20    3153 MARKET STRUCTURE MARKET SEGMENTATION Segment                          Share (%) Paper / newsprint                  22 Textiles                                20 Soaps and detergents     11 Water treatment                  10 Aluminium                                  9 Dyestuffs                                  5 Pharmaceuticals                    4 Vanaspati                                  1 Others                                              22   MARKET GROWTH RATES 1990-91-1996-97    9.4% 1996-97-2001-02    3.8% 2001-02-2006-07    2.2% 2006-07-2011-12    3.2% 2011-12-2019-20    2.5%   Sensitivity Coefficient    4.5%

Source: NPCS Team

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And before diversifying/venturing into any product, wish to study the following aspects of the identified product:
  • Good Present/Future Demand
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  • Raw Material & Manpower Availability
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The report contains all the data which will help an entrepreneur find answers to questions like:
  • Why I should invest in this project?
  • What will drive the growth of the product?
  • What are the costs involved?
  • What will be the market potential?

The report first focuses on enhancing the basic knowledge of the entrepreneur about the main product, by elucidating details like product definition, its uses and applications, industry segmentation as well as an overall overview of the industry sector in India. The report then helps an entrepreneur identify the target customer group of its product. It further helps in making sound investment decision by listing and then elaborating on factors that will contribute to the growth of product consumption in India and also talks about the foreign trade of the product along with the list of top importing and top exporting countries. Report includes graphical representation and forecasts of key data discussed in the above mentioned segment. It further explicates the growth potential of the product. The report includes other market data like key players in the Industry segment along with their contact information and recent developments. It includes crucial information like raw material requirements, list of machinery and manufacturing process for the plant. Core project financials like plant capacity, costs involved in setting up of project, working capital requirements, projected revenue and profit are further listed in the report.

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Our Market Survey cum Detailed Techno Economic Feasibility Report Contains following information:

Introduction
  • Project Introduction
  • Project Objective and Strategy
  • Concise History of the Product
  • Properties
  • BIS (Bureau of Indian Standards) Provision & Specification
  • Uses & Applications
Market Study and Assessment
  • Current Indian Market Scenario
  • Present Market Demand and Supply
  • Estimated Future Market Demand and Forecast
  • Statistics of Import & Export
  • Names & Addresses of Existing Units (Present Players)
  • Market Opportunity
Raw Material
  • List of Raw Materials
  • Properties of Raw Materials
  • Prescribed Quality of Raw Materials
  • List of Suppliers and Manufacturers
Personnel (Manpower) Requirements
  • Requirement of Staff & Labor (Skilled and Unskilled) Managerial, Technical, Office Staff and Marketing Personnel
Plant and Machinery
  • List of Plant & Machinery
  • Miscellaneous Items
  • Appliances & Equipments
  • Laboratory Equipments & Accessories
  • Electrification
  • Electric Load & Water
  • Maintenance Cost
  • Sources of Plant & Machinery (Suppliers and Manufacturers)
Manufacturing Process and Formulations
  • Detailed Process of Manufacture with Formulation
  • Packaging Required
  • Process Flow Sheet Diagram
Infrastructure and Utilities
  • Project Location
  • Requirement of Land Area
  • Rates of the Land
  • Built Up Area
  • Construction Schedule
  • Plant Layout and Requirement of Utilities

Project at a Glance

Assumptions for Profitability workings
Plant Economics
Production Schedule
Land & Building
  • Factory Land & Building
  • Site Development Expenses
Plant & Machinery
  • Indigenous Machineries
  • Other Machineries (Miscellaneous, Laboratory etc.)
Other Fixed Assets
  • Furniture & Fixtures
  • Pre-operative and Preliminary Expenses
  • Technical Knowhow
  • Provision of Contingencies
Working Capital Requirement Per Month
  • Raw Material
  • Packing Material
  • Lab & ETP Chemical Cost
  • Consumable Store
Overheads Required Per Month And Per Annum
  • Utilities & Overheads (Power, Water and Fuel Expenses etc.)
  • Royalty and Other Charges
  • Selling and Distribution Expenses
Salary and Wages
Turnover Per Annum
Share Capital
  • Equity Capital
  • Preference Share Capital
Annexure 1:: Cost of Project and Means of Finance
Annexure 2:: Profitability and Net Cash Accruals
  • Revenue/Income/Realisation
  • Expenses/Cost of Products/Services/Items
  • Gross Profit
  • Financial Charges
  • Total Cost of Sales
  • Net Profit After Taxes
  • Net Cash Accruals
Annexure 3 :: Assessment of Working Capital requirements
  • Current Assets
  • Gross Working. Capital
  • Current Liabilities
  • Net Working Capital
  • Working Note for Calculation of Work-in-process
Annexure 4 :: Sources and Disposition of Funds
Annexure 5 :: Projected Balance Sheets
  • ROI (Average of Fixed Assets)
  • RONW (Average of Share Capital)
  • ROI (Average of Total Assets)
Annexure 6 :: Profitability ratios
  • D.S.C.R
  • Earnings Per Share (EPS)
  • Debt Equity Ratio
Annexure 7 :: Break-Even Analysis
  • Variable Cost & Expenses
  • Semi-Var./Semi-Fixed Exp.
  • Profit Volume Ratio (PVR)
  • Fixed Expenses / Cost
  • B.E.P
Annexure 8 to 11:: Sensitivity Analysis-Price/Volume
  • Resultant N.P.B.T
  • Resultant D.S.C.R
  • Resultant PV Ratio
  • Resultant DER
  • Resultant ROI
  • Resultant BEP
Annexure 12 :: Shareholding Pattern and Stake Status
  • Equity Capital
  • Preference Share Capital
Annexure 13 :: Quantitative Details-Output/Sales/Stocks
  • Determined Capacity P.A of Products/Services
  • Achievable Efficiency/Yield % of Products/Services/Items
  • Net Usable Load/Capacity of Products/Services/Items
  • Expected Sales/ Revenue/ Income of Products/ Services/ Items
Annexure 14 :: Product wise domestic Sales Realisation
Annexure 15 :: Total Raw Material Cost
Annexure 16 :: Raw Material Cost per unit
Annexure 17 :: Total Lab & ETP Chemical Cost
Annexure 18 :: Consumables, Store etc.,
Annexure 19 :: Packing Material Cost
Annexure 20 :: Packing Material Cost Per Unit
Annexure 21 :: Employees Expenses
Annexure 22 :: Fuel Expenses
Annexure 23 :: Power/Electricity Expenses
Annexure 24 :: Royalty & Other Charges
Annexure 25 :: Repairs & Maintenance Exp.
Annexure 26 :: Other Mfg. Expenses
Annexure 27 :: Administration Expenses
Annexure 28 :: Selling Expenses
Annexure 29 :: Depreciation Charges – as per Books (Total)
Annexure 30 :: Depreciation Charges – as per Books (P & M)
Annexure 31 :: Depreciation Charges - As per IT Act WDV (Total)
Annexure 32 :: Depreciation Charges - As per IT Act WDV (P & M)
Annexure 33 :: Interest and Repayment - Term Loans
Annexure 34 :: Tax on Profits
Annexure 35 ::Projected Pay-Back Period And IRR