K J TECHNOLOGIES

(CHEMICAL PLANT CONSULTANCY SERVICES)

D , Vadapakkam, Krishnapuram (PO), Kumbakonam (Taluk),
Thanjavur (Dt), Tamilnadu state, India. Pin code: 612 401
Phone: +91 435 2000736, Mobile: +91 9445179207 / 9444842216
Email: kjtechnologies@gmail.com , Website: www.kjas.bloombiz.com
Date: 04-04-08
To,
Mr. J. Alam
Marketing Executive
M/s Jak International
Bangladesh.
Dear Sir,

Sub: MANUFACTURE OF SODIUM SILICATE

CAPACITY:

30 MT/day solid Sodium silicate production.

COMPOSITION:

Solid glass in the ratio 1(Na2O) : 2.2 (SiO2)

ANNUAL PRODUCTION:

9,000 MT Solid glass

Or
19,000 MT Water glass (aq. Silicate Soln.)
52 Be (47% wt. solid content)

RAW MATERIALS REQUIRED: i) Sand

ii) Soda ash
iii) Preferably fuel gas or Fuel oil
I.

PROCESS:
Soda ash and sand are reacted in a glass tank furnace heated by a fuel such as
furnace oil or gas at a temperature 1200 1400C to form Sodium silicate

with ratio 1(Na2O) : 2.2 (SiO2) or with the ratio of 2.0 to 3.0 depending upon
the end user requirement. The solid glass can be stored/sold as such or can be
dissolved in water heated with steam in an agitated vessel most preferably an
autoclave. The aq. Soln. with solid content of 47% wt. (52 Be) can be
shipped in tanker car or in MS drums to the consumers.
II.

RAW MATERIALS / UTILITIES CONSUMPTION:

Basis:

1 ton of 47% wt. Sodium silicate soln.

Solid ratio 1(Na2O) : 2.2 (SiO2)

S.No.
1
2
3
4
5

ITEM
Soda ash
Sand
Fuel oil/gas
Electricity
Water
TOTAL

CONSUMPTION
254 kgs
350 kgs
100 kgs
30 KWH
0.80 KL

PRICE INR. TOTAL COST INR.

14.00*/kg
3556
1.00/kg
350
20.00**/kg
2000
5.00/KWH
150
100.00/KL
80
6136

NOTE:
* The cost of Soda ash is taken with tax benefits.
** The cost of fuel oil is taken as INR.20/kg. If you locate the plant near gas wells the
cost of gas is less than INR.10/kg.
III.

ESTIMATED COST OF PLANT AND MACHINERIES:

TOTAL

S.No. ITEM

Glass

CAPACITY

tank

furnace

with

all 15

QUANTITY

MT/day 2

COST
INR.
LAKHS
140.00

accessories such as oil/gas burners, solid glass

combustion air blower, waste heat
recovery

boilers

with

support

burners, induced draft flue gas fan

with chimney height of 60 ft.
including structures and foundations
requirements. Raw material mixing
and screw feeding arrangement and
conveyors.
Fuel oil storage facility with pumps

and pipings.
Solid glass dissolving tanks with

agitators.
Product liquid silicate storage with

pumps and piping.

Raw water storage

facilities,

borewell connections.
Pipes,
valves,
fittings

and

instruments.
MS barrels.
Pollution control devices.
Portable gas analyzer
QC Lab
Fire, safety and first aid.
Other tools/hardwares and handling

7
8
9
10
11
12

machines.
Cost of installation works including

13

electrification
14
Contingency on estimate @ 5%
TOTAL
IV.
FACILITIES REQUIRED:
i)

50 KL

20.00

15 KL

25.00

100 KL

30.00

200 KL

10.00

----

As required.

20.00

200 Ltrs.
---------

2000
--1
-----

15.00
15.00
7.00
7.00
10.00

---

---

10.00

---

---

15.00

----

----

16.00
340.00

Civil works:
a) Building area:

Cost INR.Lakhs

- Plant shed

---------

- Solid product storage

------ 750 sq.m.

- RM (Soda ash) storage

----

- Office and other buildings ----TOTAL

--

900 sq.m.
750 sq.m.
150 sq.m.
2550 sq.m.

100.00

b) Land required for the factory:

10,000 sq.m.

40.00

c) Other civil works:

20.00

TOTAL
ii)

Water requirement

iii)

Electricity

iv)

Man power required:

S.No.
1
2
3
4
5
6
7
8
9
10
11

V.

------------

160.00
50 KL/day

150 HP, 415V, 50c/s LT supply

CATEGORY
Plant Manager
Adm./Account Manager
Shift supervisors
Skilled operators
Unskilled workers
Fitter
Electrician
Office assistants
Marketing/stores
Security
Sweepers

NUMBERS
1
1
4
6
15
2
2
2
2
4
2

WORKING CAPITAL REQUIRED:

INR. 150 Lakhs

PROFITABILITY OF THE PROJECT:

Basis: i) Production capacity 19,000 Mt aq. Sodium silicate soln.
ii) 300 operational days in year.
iii) Sale price for 1 Mt of Sodium silicate soln. 52 Be (47% wt. solid
content) INR. 8,000 / Mt.
S.No
.
1
2
3
4
5
6

COST ITEM

COST IN INR. LAKHS

Annual sales realization 19,000 Mt @ INR.8,000/Mt

Annual cost of inputs @ INR.6136, 19,000Mt
Annual contribution
Annual salaries and wages @ INR.1.5 lakhs/month
Annual office expenses @ INR.0.50 lakhs/month
Interest on investment @ 12.5%

1520.00
1165.80
354.20
(-) 18.00
(-) 6.00
(-) 82.00
4

7
8

Depreciation @ Avg. 8%
Gross profit

(-) 40.00
208.20

1) Profit ratio on investment -----------

32%

2) Profit ratio on sales turnover -------

13.7%

3) B.E.P

------

41%

CONSULTANCY FEES:

INR. 30.00 Lakhs

Regards,
K.JAYARAMAN B.E. (Chem) Hons
Technical Partner