Calcium Carbonate finds applications in diversified sectors like Plastics (PVC), Paints & Surface Coatings, Paper, Pharmaceuticals, Cosmetics (toothpaste), Printing inks – filler, Joint cement compounds, Flue gas desulphurization - Calcium Carbonate traps the sulfur oxygen compounds produced in the combustion of coal. In Insecticides, polishes, shoe dressings, as filler in matches, pencils, crayons etc. In linoleum, insulating compounds, welding rods. For water analysis and in preparing Calcium Carbonate solutions for standardizing soap solutions. 

Precipitated Calcium Carbonate is produced using the most economic process existing today. Limestone is converted into calcium oxide and carbon dioxide by means of calcinations at temperatures in excess of 900 - 1100°C in a Vertical Shaft Kiln or a Rotary Kiln. To ensure a high level of purity, the calcinations process is carried out using natural gas. After the calcinated lime has been slaked with water, the resulting milk of lime is purified and carbonized with the carbon dioxide obtained from the calcinations process.

After the total carbonization, a suspension of CaCO3 results. A cake comprising 40% - 60% solid matter (depending on particle diameter) is then obtained by filtration. This filter cake is then dried and subsequently disagglomerated in grinders. The fineness of the grain, as well as the crystal form (aragonite, calcite), is controlled by temperature, concentration of reactants and time. Depending on the chemical composition of the milk of lime used and on the purifying stages during production both, technical as well as foodstuff and pharmaceutical grades can be produced.

Bromine being a highly reactive material, finds wide applications in many Chemical Industries like, Organic Intermediates, Dyestuffs, Agrochemical, Fire retardants etc.

Bromine can be recovered from
• Industrial Bromides (NaBr, KBr, HBr.)
• Bittern

Aqueous Bromide solution is reacted with chlorine vapour in reaction column. The Chlorine liberates elemental bromine from the dissolved bromide. This is stripped out by live steam feed from the bottom of column.

Crude bromine is then distilled to get Bromine purity of minimum 99%. The solution is not always so simple though, as feeds are often contaminated with organic material from process. These organic impurities have to be removed by pre-treatment before feeding to the plant.

Typical plant consists of stripping column, Heat Exchangers Phase Separator, Purification Column collection pot, Reboiler, Scrubber with associated Glass Piping and Fittings. All wetted components are made from Borosilicate glass and PTFE which are corrosion resistant even at elevated temperature.

Anhydrous Hydrogen Bromide Gas Generator

This is an All-Glass plant used for generating Anhydrous Hydrogen Bromide Gas using Hydrogen Gas from cylinders and reacting it with fumes of liquid Bromine at high temperature. The Tubular Flow Reactor used is made of Quartz.

The plant is very compact and easy to operate and maintain. The Anhydrous Hydrogen Bromide Gas generated can be used to manufacture 48%, 62% Hydrobromic Acid, 33% HBr in Acetic acid and for purging HBr gas in Organic solvents like n-Butanol and IPA.

Many aliphatic compounds are oxidized by concentrated nitric acid, the carbon atoms being split off in pairs, with the formation of oxalic acid. This disruptive oxidation is shown by many carbohydrates, e.g., cane sugar, where the chains of secondary alcohol groups, present in the molecule break down particularly readily to give oxalic acid.

In the production of oxalic acid by oxidation with nitric acid, the nitrogen oxides resulting from the oxidation are usually absorbed by water in a conventional plant. However, in this process the gaseous mixture containing 60-70 per cent nitrogen oxides can be recycled to give more oxalic acid. If oxygen replaces air for the oxidation of nitrogen monoxide, the nitrogen oxide can flow sequentially through four or five sets of the same equipment. Oxalic acid is mainly used as bleaching agent in pharmaceutical and fiber sectors, as cleaning agent to remove pig iron pollution and also as precipitating agent for rare earth metals and in film processing of aluminum alloys. The rapid development of rare earth metal smelting and the demand increase of oxalic acid in recent years have created favorable conditions to the development of the oxalic acid sector.

The production process for cement consists of drying, grinding and mixing limestone and additives like bauxite and iron ore into a powder known as “raw meal”. The raw meal is then heated and burned in a pre-heater and kiln and then cooled in an air cooling system to form a semi-finished product, known as a clinker. Clinker (95%) is cooled by air and subsequently ground with gypsum (5%) to form Ordinary Portland Cement (“OPC”). Other forms of cement require increased blending with other raw materials. Blending of clinker with other materials helps impart key characteristics to cement, which eventually govern its end use.

There are two general processes for producing clinker and cement in India: a dry process and a wet process.

The basic differences between these processes are the form in which the raw meal is fed into the kiln, and the amount of energy consumed in each of the processes. In the dry process, the raw meal is fed into the kiln in the form of a dry powder resulting in energy saving, whereas in the wet process the raw meal is fed into the kiln in the form of slurry. There is also a semi-dry process, which consumes more energy than the dry process but lesser than the wet process.

Limestone is crushed to a uniform and usable size, blended with certain additives (such as iron ore and bauxite) and discharged on a vertical roller mill, where the raw materials are ground to fine powder. An electrostatic precipitator dedusts the raw mill gases and collects the raw meal for a series of further stages of blending. The homogenized raw meal thus extracted is pumped to the top of a preheater by air lift pumps. In the preheaters the material is heated to 750°C. Subsequently, the raw meal undergoes a process of calcination in a precalcinator (in which the carbonates present are reduced to oxides) and is then fed to the kiln. The remaining calcination and clinkerization reactions are completed in the kiln where the temperature is raised to between 1,450°C and 1,500°C. The clinker formed is cooled and conveyed to the clinker silo from where it is extracted and transported to the cement mills for producing cement. For producing OPC, clinker and gypsum are used and for producing Portland [Pozzolana] Cement (“PPC”), clinker, gypsum and fly ash are used. In the production of Portland Blast Furnace Stag Cement (“PSC”), granulated blast furnace slag from steel plants is added to clinker.

Castor Oil Derivatives

Technology / Process

Castor oil, when subjected to pyrolysis or destructive distillation at temperature of over 450° C under vacuum, under goes decomposition to yield mainly Undecylenic acid and Heptaldehyde, in roughly equal quantities ( 28% approx). The presence of water vapor has been found to enhance the yields of both acid and aldehyde. The spongy mass left behind, consisting principally of polymerized Undecylenic acid, which can be used in recovering of some quantity of Undecylenic acid.

Esters of Undecylenic acid are used as input for perfumery chemicals.

Heptaldehyde is having characteristic Jasmine flavor in it and typically it is also known as Jasmine aldehyde, and it can be converted to Heptanoic acid and Heptanol which are used in manufacture of many perfumery compounds.

Perfumery Raw Materials

Many synthetic perfumery raw materials are used by the flavour & fragrance manufacturers. Many Perfumery Compounds for Agarbatti & Perfumes are formulated locally by perfumers to make their own branded products using these synthetic raw materials which resemble to the fragrance & flavour of many natural fruits & flora. Manufacture of these products requires very small space and compact plants. Small Glass plants which are easy to operate and require very less power & manpower can be put up to make these products on a small scale.

1. Esters of Phenyl Ethyl Alcohol
2. Phenyl Ethyl Methyl Ester (Kevda base)
3. Alpha Amyl Cinnamic Aldehyde (Jasmine)
4. Aldehyde C14 (Peach Aldehyde)
5. Aldehyde C16 (Strawberry Aldehyde)
6. Aldehyde C11
7. Aldehyde C12

Herbal Cosmetics & Aroma Soaps

Today the demand for natural products has been increasing. Many big corporate Cosmetic Manufacturers have started making Herbal products. Even Aromatherapy has come in demand along with Ayurvedic medicines. To start up a Herbal cosmetics unit can be done with very less investment and space. Products like creams, lotions, shampoos, oils, gels can be manufactured with very small equipment and hand packed to start with. Aroma soaps, cream soaps, transparent soaps of various shapes & designs can be hand made as per requirement.