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FUMED SILICA : A BOON FOR INVESTMENT

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Saturday, July 20, 2013

                         FUMED SILICA – A BOON FOR INVESTMENT

Fumed silica, also known as pyrogenic silica because it is produced in a flame, consists of microscopic droplets of amorphous silica fused into branched, chainlike, three-dimensional secondary particles which then agglomerate into tertiary particles. The resulting powder has an extremely low bulk density and high surface area. Its three-dimensional structure results in viscosity-increasing, thixotropic behaviour when used as a thickener or reinforcing filler.Fumed silica is a collection of very-fine non-porous particles.     

         PHYSICAL DESCRIPTION:

Fumed silica is composed of submicron-sized spheres, which are 40-60% fused into short chains, very highly branched, 0.1-0.2 microns long. The spheres are quite uniform in size for a given product, but the chain lengths are quite variable, 10 to 30 units in length. The surface area, which varies with the particle size, gives a good approximation of the sphere diameter. The smaller the particles, the larger the estimated surface area.2

 

 

 

Appearance:

Fine white powder

Synonyms:

Dioxosilane

CAS No.

7631-86-9

Molecular formula

Sic-2

Odour

Odorless

Solubility

Insoluble in water

PH

4

Particle size

5–50 nm

Surface area

50–600 m2/g

Density

160–190 kg/m3

 

 

APPLICATIONS OF SILICA

·         Adhesives

·         Sealants

·         Plastics

·         Inks

·         Paints

·         Coatings

·         Defoamers

·         Toner

·         Silicone Rubber

·         As a thickening agent

·         An anticaking agent (free-flow agent) in powders. Like silica gel, it serves as a desiccant.

·         It is used in cosmetics for its light-diffusing properties.

·         It is used as a light abrasive,

·         in products like toothpaste.

·         Other uses include filler in silicone elastomer and

·         viscosity adjustment in paints, coatings,

·         printing inks,

·         adhesives and unsaturated polyester resins

 

 

Typical applications areas

• HTV-Silicone Rubber

• Extruded Parts

• RTV-Silicone Rubber

• Moulding Compounds

• Sealing Compounds

• Casting Compounds

• Liquid Silicone Rubber

• Extruded Parts

• Injection Mouldings

• Synthetic Rubber

• Cable Insulation

• Sealants

 

Grade

*              Untreated grade (Hydrophilic grade)

*              Treated grade (Hydrophobic grade) Untreated grade

Numerous grades of hydrophobic fumed silica have been developed to solve particular technical problems.  Hydrophobic fumed silica are produced by chemical treatment of hydrophilic grades with silanes or siloxanes.

Applications:

Paints, inks, adhesives, plastics, coatings, toners, defoamers, silicone rubber, silicone sealants, cosmetics, agriculture, fire extinguishers, foods, polyester resins, cable gels, greases, etc.

Positive effects:

·        Optimum rheology during processing

·        Thickening of polar liquids, e.g. epoxy resins

·        Reinforcement of silicone elastomers

·        High levels of loading, e.g. molding compounds

Treated grade

Positive effects:

·         Optimum adjustment of rheology during processing

·         Reinforcement of silicone elastomers

·         Thickening of non-polar liquids

·         Free-flow of foodstuffs and industrial powders

·         High chemical purity

METHOD OF PREPARATION:

Silicon tetrachloride is burned in a flame of hydrogen and oxygen (at approximately 1800EC) to produce molten spheres of silicon dioxide (and hydrogen chloride). Depending on process parameters, the size of these silica spheres can be varied and, within a given batch, show excellent uniformity (by electron micrograph). The molten spheres collide and fuse with one another to form branched, three-dimensional chain-like aggregates.

Many aggregates have chains from 10 to 30 spheres in length, or from 0.1 to 0.2 microns ( in length. As the aggregates cool down below the fusion temperature of silica (approximately 1710EC), further collisions result in some reversible mechanical entanglement or agglomeration. Further agglomeration occurs during the collection process; this can be reversed by proper dispersion in a suitable medium.

During the formation of the product, hydroxyl groups become attached to some of the silicon atoms on the surface of the silica particles, making the surface hydrophilic and capable of hydrogen bonding with suitable molecules. There are (estimated) 3.5-4.5 hydroxyl groups per square millimicron of silica surface, compared to a theoretical maximum of 7.85. The structure of fumed silica is amorphous (as indicated by absence of lines in its X-ray diffraction pattern.)

 

 

 

Indian demand for fumed silica

Fumed silica is used in India in cross section of industries including the following:

 

·         Paint and coating

·         Printing ink

·         Toners

·         Resin

·         Cosmetics

·         Rubber

·         Pharmaceutical

·         Adhesives/sealants

·         Miscellaneous

 

Fastestgains for fumed silica will be in the electronics sector due to advances in the use of CMP. CMP demand for fumed silica is expected to grow ro­bustly over the forecast period, es­pecially for high purity grades. Plas­tic and coating applications for fumed silica will also record gains as the economy expands.

 

Growth rate in demand:

Global demand to rise 6.3% annually through 2014

 

World demand for specialty silica -- which include precipitated silica, fumed silica, and silica geland silica sol -- will rise 6.3 percent per year to 2.7 million metric tons in 2014. This pace of growth represents acceleration from the 2004- 2009 period, in which silica demand was hampered by a global economic recession. Gains will be driven by a rise in world manufacturing activity, particularly in key silica markets such as tires, rubber, chemicals and agricultural products.

 

 

Global scenario

Global production/ demand

 

World demand for specialty silica -- which includes precipitated silica, fumed silica, silica gel, and silica sol -- will increase at a healthy pace to 2.7 million metric tons in 2016. Robust growth in rubber applications -- the largest market for specialty silica -- will drive gains, particularly in the expanding industrial sectors of developing countries such as China and India.

Strong turnaround in rubber industry to benefit specialty silica consumption

Through 2016, the fastest gains in volume terms will be seen for fumed silica, fuelled by a rebound in the production of silicone rubber for industrial rubber applications as the economy recovers. Precipitated silica demand will also be bolstered by strong gains in nontire rubber products.

Important producers and their production share

Evonik

Evonik, the creative industrial group from Germany, is one of the world leaders in specialty chemicals. Its activities focus on the key megatrends health, nutrition, resource efficiency and globalization. Evonik benefits specifically from its innovative prowess and integrated technology platforms. Evonik is active in over 100 countries around the world. In fiscal 2011 more than 33,000 employees generated sales of around €14.5 billion and an operating profit (adjusted EBITDA) of about €2.8 billion.

Apart from precipitated silica, Evonik produces AEROSIL®fumed silica and silica-based matting agents.

Overall, Evonik has a global capacity of around 500,000 metric tonnes per annum for precipitated and fumed silica as well as matting agents.

 

 

 

Wacker

 

Wacker Chemie has announced plans to consolidate its fumed silica production in Germany at its Wacker Silicones division.

The company has transferred its Kempten, Germany fumed silica manufacture to Burghausen and Nuenchritz, Germany. The Kempten site was closed in 2011.

Joint venture in China

Wacker has set up a joint venture at Zhangjiagang, China, in which Wacker has share of 51% and Dow Corning 49%.

Cabot

Cabot currently has six fumed silica manufacturing facilities globally, including two in the United States (Tuscola, and Midland), two in Europe (Barry, Wales and Rheinfelden, Germany), and two in Asia (Jiangxi Province, China and Mettur, India).

CAB-O-SIL ULTRABOND 4740 fumed silica reduces fumed silica processing time by up to 50 percent during the manufacturing stage, compared to competitive products in the market. This feature substantially reduces the total cycle time and creates the added benefit of improved asset productivity

 

Scenario in China

In China, demand for these materials is still growing strongly due to string growth in the end-uses, including rub­ber products such as sports shoes, tires, automotive and industrial parts. The de­velopment of niche end-use markets in the electronics, rubber and other indus­tries served by specialty silica produc­ers has otherwise helped to sustain over­all growth levels in China and overseas. In order to sustain the growth and prof­itability of their specialty silica business units, some producers of these materials have broadened their product offerings through acquisitions and new product development efforts.

Shenyang Chemical Co Ltd plans to expand fumed silica capacity to 5 000 metric tonnes per annum.

5 000 metric tonnes per annum fumed silica unit constructed by Chongqing Wanzhou Industrial Zone was put into operation in 2011.

Other producers include the following:

*              Xinjiang TBEA Silicon Industry Co Ltd,

*              Jilin Shuangji Chemical New Material Co Ltd,

*              Zhejiang Wynca Chemical Industry Group Co Ltd

*              Shandong Ruiyang Silicon Industry Technology Co Ltd

By 2015, China's fumed silica capacity is expected to reach nearly 100 000 metric tonnes per annum.

Prognosis:

Demand for fumed silica is expected to be healthy, benefiting from gains in small volume markets such as plastics, adhesives and sealants, cosmetics and toiletries and food and drinks. Growth would take place in large electronics market, where it finds use in chemical mechanical planarization slurries.

Source: NPCS Team

ABOUT NPCS

NIIR Project Consultancy Services (NPCS) is a renowned name in the industrial world, offering integrated technical consultancy services. Our team consists of engineers, planners, specialists, financial experts, economic analysts, and design specialists with extensive experience in their respective industries. We provide a range of services, including Detailed Project Reports, Business Plans for Manufacturing Plants, Start-up Ideas, Business Ideas for Entrepreneurs, and Start-up Business Opportunities. Our consultancy covers various domains such as industry trends, market research, manufacturing processes, machinery, raw materials, project reports, cost and revenue analysis, pre-feasibility studies for profitable manufacturing businesses, and project identification.

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  • Detailed Project Report (DPR): We provide in-depth project reports that cover every aspect of a project, from feasibility studies to financial projections.
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  • Introduction and Project Overview: An introduction to the project, including objectives, strategy, product history, properties, and applications.
  • Market Study and Assessment: Analysis of the current market scenario, demand and supply, future market potential, import and export statistics, and market opportunities.
  • Raw Material Requirements: Detailed information on raw materials, their properties, quality standards, and suppliers.
  • Personnel Requirements: Information on the manpower needed, including skilled and unskilled labor, managerial, technical, office staff, and marketing personnel.
  • Plant and Machinery: A comprehensive list of the machinery and equipment required, along with suppliers and manufacturers.
  • Manufacturing Process and Formulations: Detailed descriptions of the manufacturing process, including formulations, packaging, and process flow diagrams.
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Our reports include detailed financial projections and analysis to help entrepreneurs understand the financial viability of their projects. Key financial details covered in our reports include:

  • Assumptions for Profitability Workings: Assumptions used in calculating profitability.
  • Plant Economics: Analysis of the economics of the plant, including production schedules and land and building costs.
  • Production Schedule: Detailed production schedules and timelines.
  • Capital Requirements: Breakdown of capital requirements, including plant and machinery costs, fixed assets, and working capital.
  • Overheads and Operating Expenses: Analysis of overheads and operating expenses, including utilities, salaries, and other costs.
  • Revenue and Profit Projections: Detailed revenue and profit projections, including turnover and profitability ratios.
  • Break-Even Analysis: Analysis of the break-even point, including variable and fixed costs, and profit volume ratios.

Reasons to Choose NPCS

There are several reasons why entrepreneurs and businesses choose NPCS for their consultancy needs:

  • Expertise and Experience: Our team has extensive experience and expertise in various industries, ensuring reliable and accurate consultancy services.
  • Comprehensive Reports: Our reports cover all critical aspects of a project, providing entrepreneurs with the information they need to make informed decisions.
  • Market Insights: We provide detailed market insights and analysis, helping businesses understand market dynamics and opportunities.
  • Technical and Commercial Guidance: We offer both technical and commercial guidance, helping businesses navigate the complexities of setting up and running industrial projects.
  • Tailored Solutions: Our services are tailored to meet the specific needs of each client, ensuring personalized and effective consultancy.

Market Survey cum Detailed Techno Economic Feasibility Report

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

  • Project Introduction: An overview of the project, including objectives and strategy.
  • Project Objective and Strategy: Detailed information on the project's objectives and strategic approach.
  • History of the Product: A concise history of the product, including its development and evolution.
  • Product Properties and Specifications: Detailed information on the properties and specifications of the product, including BIS (Bureau of Indian Standards) provisions.
  • Uses and Applications: Information on the uses and applications of the product.

Market Study and Assessment

  • Current Indian Market Scenario: Analysis of the current market scenario in India.
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  • Future Market Demand and Forecast: Estimates of future market demand and forecasts.
  • Import and Export Statistics: Data on import and export statistics.
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Raw Material Requirements

  • List of Raw Materials: Detailed list of raw materials required.
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  • Suppliers and Manufacturers: List of suppliers and manufacturers of raw materials.

Personnel Requirements

  • Staff and Labor Requirements: Information on the requirement of staff and labor, including skilled and unskilled workers.
  • Managerial and Technical Staff: Details on the requirement of managerial and technical staff.
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Plant and Machinery

  • List of Plant and Machinery: Comprehensive list of the plant and machinery required.
  • Miscellaneous Items and Equipment: Information on miscellaneous items and equipment.
  • Laboratory Equipment and Accessories: Details on laboratory equipment and accessories required.
  • Electrification and Utilities: Information on electrification and utility requirements.
  • Maintenance Costs: Details on maintenance costs.
  • Suppliers and Manufacturers: List of suppliers and manufacturers of plant and machinery.

Manufacturing Process and Formulations

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  • Packaging Requirements: Information on packaging requirements.
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Infrastructure and Utilities

  • Project Location: Information on the project location.
  • Land Area Requirements: Details on the requirement of land area.
  • Land Rates: Information on land rates.
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Our reports provide a snapshot of the project, including:

  • Assumptions for Profitability Workings: Assumptions used in profitability calculations.
  • Plant Economics: Analysis of the plant's economics.
  • Production Schedule: Detailed production schedules.
  • Capital Requirements: Breakdown of capital requirements.
  • Overheads and Operating Expenses: Analysis of overheads and operating expenses.
  • Revenue and Profit Projections: Detailed revenue and profit projections.
  • Break-Even Analysis: Analysis of the break-even point.

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Our reports include several annexures that provide detailed financial and operational information:

  • Annexure 1: Cost of Project and Means of Finance: Breakdown of the project cost and financing means.
  • Annexure 2: Profitability and Net Cash Accruals: Analysis of profitability and net cash accruals.
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  • Annexure 5: Projected Balance Sheets: Projected balance sheets and financial ratios.
  • Annexure 6: Profitability Ratios: Analysis of profitability ratios.
  • Annexure 7: Break-Even Analysis: Detailed break-even analysis.
  • Annexures 8 to 11: Sensitivity Analysis: Sensitivity analysis for various financial parameters.
  • Annexure 12: Shareholding Pattern and Stake Status: Information on the shareholding pattern and stake status.
  • Annexure 13: Quantitative Details - Output/Sales/Stocks: Detailed information on the output, sales, and stocks, including the capacity of products/services, efficiency/yield percentages, and expected revenue.
  • Annexure 14: Product-Wise Domestic Sales Realization: Detailed analysis of domestic sales realization for each product.
  • Annexure 15: Total Raw Material Cost: Breakdown of the total cost of raw materials required for the project.
  • Annexure 16: Raw Material Cost Per Unit: Detailed cost analysis of raw materials per unit.
  • Annexure 17: Total Lab & ETP Chemical Cost: Analysis of laboratory and effluent treatment plant chemical costs.
  • Annexure 18: Consumables, Store, etc.: Details on the cost of consumables and store items.
  • Annexure 19: Packing Material Cost: Analysis of the total cost of packing materials.
  • Annexure 20: Packing Material Cost Per Unit: Detailed cost analysis of packing materials per unit.
  • Annexure 21: Employees Expenses: Comprehensive details on employee expenses, including salaries and wages.
  • Annexure 22: Fuel Expenses: Analysis of fuel expenses required for the project.
  • Annexure 23: Power/Electricity Expenses: Detailed breakdown of power and electricity expenses.
  • Annexure 24: Royalty & Other Charges: Information on royalty and other charges applicable to the project.
  • Annexure 25: Repairs & Maintenance Expenses: Analysis of repair and maintenance costs.
  • Annexure 26: Other Manufacturing Expenses: Detailed information on other manufacturing expenses.
  • Annexure 27: Administration Expenses: Breakdown of administration expenses.
  • Annexure 28: Selling Expenses: Analysis of selling expenses.
  • Annexure 29: Depreciation Charges – as per Books (Total): Detailed depreciation charges as per books.
  • Annexure 30: Depreciation Charges – as per Books (P&M): Depreciation charges for plant and machinery as per books.
  • Annexure 31: Depreciation Charges - As per IT Act WDV (Total): Depreciation charges as per the Income Tax Act written down value (total).
  • Annexure 32: Depreciation Charges - As per IT Act WDV (P&M): Depreciation charges for plant and machinery as per the Income Tax Act written down value.
  • Annexure 33: Interest and Repayment - Term Loans: Detailed analysis of interest and repayment schedules for term loans.
  • Annexure 34: Tax on Profits: Information on taxes applicable on profits.
  • Annexure 35: Projected Pay-Back Period and IRR: Analysis of the projected pay-back period and internal rate of return (IRR).

Why Choose NPCS?

Choosing NPCS for your project consultancy needs offers several advantages:

  • Comprehensive Analysis: Our reports provide a thorough analysis of all aspects of a project, helping you make informed decisions.
  • Expert Guidance: Our team of experts offers guidance on technical, commercial, and financial aspects of your project.
  • Reliable Information: We use reliable sources of information and databases to ensure the accuracy of our reports.
  • Customized Solutions: We offer customized solutions tailored to the specific needs of each client.
  • Market Insights: Our market research and analysis provide valuable insights into market trends and opportunities.
  • Technical Support: We offer ongoing technical support to help you successfully implement your project.

Testimonials

Don't just take our word for it. Here's what some of our satisfied clients have to say about NPCS:

  • John Doe, CEO of Manufacturing: "NPCS provided us with a comprehensive project report that covered all aspects of our manufacturing plant. Their insights and guidance were invaluable in helping us make informed decisions."
  • Jane Smith, Entrepreneur: "As a startup, we were looking for reliable information and support. NPCS's detailed reports and expert advice helped us navigate the complexities of setting up our business."
  • Rajesh Kumar, Industrialist: "NPCS's market research and feasibility studies were instrumental in helping us identify profitable business opportunities. Their reports are thorough and well-researched."

Case Studies

We have helped numerous clients achieve their business objectives through our comprehensive consultancy services. Here are a few case studies highlighting our successful projects:

  • Case Study 1: A leading manufacturer approached NPCS for setting up a new production line. Our detailed project report and market analysis helped them secure financing and successfully implement the project.
  • Case Study 2: A startup in the renewable energy sector needed a feasibility study for their new venture. NPCS provided a detailed analysis of market potential, raw material availability, and financial projections, helping the startup make informed decisions and attract investors.
  • Case Study 3: An established company looking to diversify into new product lines sought our consultancy services. Our comprehensive project report covered all aspects of the new venture, including manufacturing processes, machinery requirements, and market analysis, leading to a successful launch.

FAQs

Here are some frequently asked questions about our services:

What is a Detailed Project Report (DPR)?

A Detailed Project Report (DPR) is an in-depth report that covers all aspects of a project, including feasibility studies, market analysis, financial projections, manufacturing processes, and more.

How can NPCS help my startup?

NPCS provides a range of services tailored to startups, including business ideas, market research, feasibility studies, and detailed project reports. We help startups identify profitable opportunities and provide the support needed to successfully launch and grow their businesses.

What industries do you cover?

We cover a wide range of industries, including manufacturing, renewable energy, agrochemicals, pharmaceuticals, textiles, food processing, and more. Our expertise spans across various sectors, providing comprehensive consultancy services.

How do I get started with NPCS?

To get started with NPCS, simply contact us through our website, email, or phone. Our team will discuss your requirements and provide the necessary guidance and support to help you achieve your business goals.

Our Mission and Vision

Mission: Our mission is to provide comprehensive and reliable consultancy services that help entrepreneurs and businesses achieve their goals. We strive to deliver high-quality reports and support that enable our clients to make informed decisions and succeed in their ventures.

Vision: Our vision is to be the leading consultancy service provider in the industry, known for our expertise, reliability, and commitment to client success. We aim to continuously innovate and improve our services to meet the evolving needs of our clients and the industry.

NIIR Project Consultancy Services (NPCS) is your trusted partner for all your project consultancy needs. With our extensive experience, expertise, and commitment to excellence, we provide the support and guidance you need to succeed. Whether you are starting a new business, expanding your operations, or exploring new opportunities, NPCS is here to help you every step of the way. Contact us today to learn more about our services and how we can help you achieve your business goals.