DESIGN OF 500 KILOGRAM PER BATCH OF

DOMESTIC PAINT PILOT PLANT

BY

MUHAMMAD AUWAL ABDULLAHI

PGD/ENG/3970/2011-2012

A DESIGN PROJECT

DEPARTMENT OF CHEMICAL
ENGINEERING,
AHMADU BELLO UNIVERSITY, ZARIA

JUNE, 2013
 INTRODUCTION
Paint isa liquidthatsolidify when exposed
to air which are used to cover surfaces for
decorative and protective purposes
(Beetsma and Hofland , 1998).
Coatings are used almost everywhere in
our daily life; such as on buildings,
furniture, cabinets, refrigerators, wires of
electrical motors, cassettes and videotapes,
compact discs, inside and outside of cans,
ships, aircrafts, steel bridges, storage
tanks, cars. They are used for decoration
purposes as well (Morgans, 1990).
 PROBLEM STATEMENT
The importation of raw materials for
the production of paint by in Nigeria
has led to a huge drain in the nations
foreign exchange earnings as well as
a high rate of unemployment, there is
need to design a pilot plant for the
production of domestic paint which
will maximize local available raw
materials so as to combat this
challenges.
 AIM AND OBJECTIVES
The aim of this project is to design a pilot plant that is
capable of producing domestic paint with a production
capacity of 500kg per batch.
OBJECTIVES
To select and design an economical and environmentally

friendly pilot plant capable of producing 500kg per

batch of Paint from locally sourced raw materials.
To carry out material and energy balance of all the

processes
Design of the equipment.

Design the plant layout and determine the control

parameters
Carry out environmental impact assessment (EIA) of the

plant.
The economic analysis of the plant.
 JUSTIFICATION
The huge loss in foreign
exchange earnings
Local raw materials availability.
The creation of employment for
the unemployed youths
The plant is safe and simple to
set up.
 SCOPE
To design a pilot plant for
paint production whose plant
capacity is 500 kg per batch.
 LITERATURE REVIEW
Paint refers to a solution of a
pigment in water, oil, or organic
solvent, used to cover wood or
metal articles either for
protection or for appearance.
The industrial paint process
consists of four ingredients
which include the pigment,
resins, solvents and additives
LITERATURE REVIEW (CONT.)
The component and functions of paint
are:
Pigments; provide colour, opacity,

gloss, and other properties.

Solvents: provide a liquid medium for

applying the film-forming ingredients.

Binders or resins bind all the

components together.
Additives provide a number of special

properties (Beetsma and Hofland ,

1998).
MATERIAL AND METHOD

MATERIALS
Additives: Deformer, Ammonia,

Sodium metasilicate and Actinide.

Binder: PVA.

Solvent: Kerosene and Water.

Pigments: CaCO Kankara kaolin

3,
clay and TiO2
MATERIAL AND
METHOD(CONT)
Table 1: Materials
Component and Location
Quanti location (source)
ty
Water 2.6liters A.B.U Dam water, Zaria
Titanium Oxide 0.2kg Innovate Enterprise, Kaduna
(TiO2)
Kankara kaolin 0.17 Kankara village, Kastina
clay State
Calcuim 3kg Rich Quarries Nigeria
Carbonate Limited, Kaduna
(CaCO3)
Kerosene 0.10liters Valid Petrol Station, Kaduna
PVA 0.45kg Innovate Enterprise, Kaduna
Acticide 0.009kg Innovate Enterprise, Kaduna
(Preservative)
Sodium 0.05kg Innovate Enterprise, Kaduna
metasilicate
Ammonia Liqour 0.02kg Innovate Enterprise, Kaduna
Defoamer 0.02kg Innovate Enterprise, Kaduna
 DESIGN
Table 2: Pump specifications
SPECIFICATIONS ( PO1) (PO2) (PO3)
Diameter of 0.017 0.018 0.018
Pipe, (m)
Relative 2.195e-3 2.195e-3 2.195e-3
Roughness
Reynolds 100.814 95.846 95.846
Number
Flow Laminar Laminar Laminar
Characteristic
Friction Factor 0.005 0.005 0.005
Total length, (m) 1.838 1.838 1.838
Pressure Drop, 19.80 15.86 15.86
(kPa)
Efficiency 75 75 75
Power |Rating, 0.02 0.018 0.018
 DESIGN (CONT.)
Table 3: Specification of the tanks

Process Units Volume (L) Diameter (m) Height (m) Material

TO1 286.97 0.715 0.861 Carbon steel

TO2 11.174 0.242 0.292 Carbon steel

TO3 41.738 0.376 0.453 Carbon steel

TO4 3.024 0.157 0.189 Carbon steel

MO1 333.917 0.752 0.906 Carbon steel

MO2 534.256 0.879 1.060 Carbon steel

Equipment under
Constrution
Equipment under
Constrution
Equipment under
Constrution
Equipment under
Constrution
PLANT LAYOUT
 MATERIAL BALANCE
Assumptions
100% material recovery across all units

The purity of the raw materials used is

100%.
The materials :Water, Kankara kaolin

clay, CaCO3 and kerosene where

considered local raw materials because
of their availability.
A batch time of 40 minutes is used so as

to ensure homogeneity during mixing.

 ENERGY BALANCE
Assumption
The reference temperature is 25 0C

(Perry, 1998)
There is no significant change in the

enthalpies of components across pumps

and storage tanks (Obasanjo, 2009).
There is a maximum exit temperature of

300C
Total energy requirement (T.E.R) is
1.024 kW
 ECONOMIC ANALYSIS
Table 4: Economic analysis of plant
ITEMS COST (NAIRA)

Working capital 981400

Annual Operating Cost 3150000

Profit After Tax 43070000

Pay Back Time 0.137 (approx. 2months)

Return on Investment 731.5%

Cost of Equipments 1,232,000

TOTAL INVESTMENT 5,889,000

 CONCLUSION
The paint plant design gave a
economic analysis of total
capital investment of
5,889,000, and profit after tax
gave 4,307,000. The payback
period was approximately 2
months with a return on
investment of 731.5%.
 RECOMMENDATION
Personnel should undergo
routine training about new work
ethic and equipments to
improve the overall plant
productivity.
The implementation of this
design work must be adequately
supervised by the experts.
 REFERENCE
Beetsma, J., Hofland, A. (1998). Surface Coating Industries. p491
Bentley, J., Turner, A. (1998). Introduction to Paint Chemistry and

Principles of Paint technology., Chapman&Hall.

Elvers, B. (1991). Ullmanns Encyclopedia of Industrial Chemistry

5thed, Vol 18, VCH Publishers.

Flick, J., and Ernest, W. (1989). Handbook of Paint Raw Materials,

2nd ed. Noyes Data Corp.

Morgans, W. M. (1990). Outlines of Paint Technology, 3rd ed. John

Wiley & Sons.

Obansanjo, A. (2009). Design of a mobile pilot plant for the

production of 500 liters per day of biodiesel from Jatropha curcus oil.
A final year design project, Department of Chemical Engineering,
Ahmadu Bello University, Zaria, Kaduna State, Nigeria.
Perry, R. F., and Green, D. W. (1998). Perrys Chemical Engineers

Handbook, 7th Edition, McGraw-Hill Book Company, New York, USA.

Thank you