TRAINING MANUAL - RESIN & CED

PAINT- PIGMENTED LIQUID

SOLID LIQUID PART

SOLID PART IS RESPONSIBLE FOR COLOUR , LIQUID PART IS RESPONSIBLE FOR ADHISION ,
OPACITY , RELOZICAL PROPERTIES & SPECIFIC CORROSION RESISTANCE, CURING AND TO MAKE
CHEMICAL & UV RESISTANCE A PAINTS APPLICABLE

TRUE PIGMENTS EXTENDER VOLATILE NON VOLATILE

USED FOR COLOUR , ARE USED FOR COST COMPLETELY VOLATILE PART OF THE SOLID PART OF THE VEHILE. IT INCLUDES
OPACITY & FOR SOME REDUCTION , OPACITY VEHILE. SOLVENTS RESINS AND ADDITIVE
RESISTANCE PROPERTY & RELOZICAL PROPERTY

ALL ETENDERS ARE

WHITE COLOUR WHITE & INORGANIC IN TRUE SOLVENT LATENT SOLVENT BINDER/RESIN ADDITIVE
NATURE CUTTING THE VISCOSITY PROVIDE ADDHISION & ANTISETTLING AGENT
& INCREASING VOLUME CORROSION RESISTANCE ANTIFUNGES, DRIERS
AND OTHER'S

INORGANIC INORGANIC ORGANIC TO INCREASE THE

IN NATURE IN NATURE IN NATURE VOLATILITY

RESINS-
RESINS ARE USED IN PAINTS TO PROVIDE THE ADDHISION OF PAINT FILM TO THE SUBTRATE. SELECTION OF RESIN FOR DIFFERENT PAINTS
ARE DEPAND UPON TYPE OF SUBTRATE, TYPE OF USE,TYPE OF APPLICATION & PROPERTIES REQUIRED.RESINS CAN BE CLASSIFIED IN TWO
TYPE.

RESINS

NATURAL RESINS SYNTHETIC RESINS

OUTDATED PRODUCT WIDELY USED IN PAINTS INDURTRY
SOURCES ARE NATURAL PRODUCED BY CHEMICAL REACTION

IN GNP JAINPUR WE ARE MANUFACTURING FOUR TYPE OF SYNTHETIC RESINS.

ALKYD RESINS

REACTION PRODUCT OF POLYHYDROXYLIC ALCOHOL & POLYBASIC ACID MODIFIED WITH OILS.
CLASSIFICATION OF ALKYD RESINS

ALKYD RESIN CAN BE CLASIIFIED IN THREE CATAGARY ON THE BASIS OF OIL LENGTH.

ALKYD

LONG OIL ALKYD MEDIUM OIL ALKYD SHOTH OIL ALKYD

OIL LENGTH-55TO60% OIL LENGTH-50TO550% OIL LENGTH-45TO 50%

RAW MATERIAL OF ALKYD

OILS OILS ARE THE TRY GLYCERIDE OF MIXED FATTY ACID.

CHEMICAL STRUCTURE OF OILS

H O

H C O C O R1

H C O C O R2

H C O C O R3

H O

R1
R2 CHAIN OF FATTY ACID
R3

OILS CAN BE CLASSIFIED IN THREE CATAGARY ON THE BASIS OF IODINE VALUE

OILS

DRYING OIL SEMIDRYING OIL NON DRYING OIL

IODINE VALUE 140-180 IODINE VALUE 125-140 IODINE VALUE < 125

PROPERTIES OF OIL

IODINE VALUE IODINE VALUE DEPENDE UPON UNSATURATION PRESENT IN OILS.

HIGHER I.V. HIGHER UNSATURATION

SAPONIFICATION VALUE
SAPONIFICATION VALUE INDICATE THE MOLECULAR WEIGHT OF OIL.

HIGHER S.V. HIGHER MOLECULAR WEIGHT

MAIN OIL USED IN PAINT INDUSTRY-

1*DEHYDRATED CASTOR OIL
2*SOYABEEN OIL
3*LINSEED OIL
4*COCONUT OIL
5*COTTON SHEED OIL

POLYOLS

MAIN POLYOLS USED IN PAINT INDUSTRY ARE GIVEN BELOW

1*NEO PENTYL GLYCOL

2*GLYCERINE
3*TRY METHYL PROPANE
4* PENTA ETHRYTOL
5*SORBITOL
POLYBASIC ACID
POLY BASIC ACID CAN BE CLASIFIED IN TWO CATAGARY

ACID

MONO BASIC ACID POLY BASIC ACID

MONO FUNCTIONAL ACT AS A CHAIN SYOPPER FUNCTIONALITY IS MORE THAN ONE. SUAITABLE FOR POLYMERIZATION
BEBZOIC ACID, ROSIN PHTHALIC ANHYDRIDE, HEXA HYDRO PHTHALIC ANHYDRIDE.

REACTION MECHANISM OF ALKYD RESIN

ALKYD RESIN REACTION TAKES PLACE IN TWO STAGE.

1*MONO GLYCERIDE FORMATION

TRIGLYCERIDE OF MIXED FATTY ACID REACT WITH POLYOLS AT HIGH TEMPRATURE IN PRSCENCE OF
CATALYST AND COVERTED IN A MONO GLYCERIDE.

250 °C +CATALYST
OILS + POLYOLS MONOGLYCERIDE

2*ESTRIFICATION REACTION REACTION BETWEEN MONOGLYCERIDE AND ACIDIC GROUP TAKES PLACE . WATER IS GENRATED AND SIMULTANEOUSLY
POLYMERIZATION TAKES PLACE.

CRITICAL FACTOR IN REACTION

1* % OF EXCESS OHTOTAL BASE EQUIVALENT - TOTAL ACID EQUIVALENT

*100
 TOTAL ACID EQUIVALENT

2*ALKYD CONSTANTTOTAL MOLES Mo. *100

TOTAL ACID EQ.Ea.

3* POINT OF GELLATION
2*TOTAL MOLES Mo
TOTAL ACID & BASE EQ.

4*THEORITICAL OH VALUE AT ZERO ACID VALUE

[BASE EQUIVALENT - ACID EQUIVALENT] * 56100

% NON VOLATILE

5*REACTION OF WATER
WATER OF REACTION WILL DEPEND UPON THE FUNCTIONALITY OF POLY BASIC ACID.

Y AXIS
6*VISCISITY & ACID VALUE RELATION
VISCOSITY

V
A
L
U
E ACID AVLUE

X AXIS
TIME

EXAMPLE-ALKYD FORMULATION IS GIVEN BELOW

R/M QT EQ.WT BASE EQ. Eb ACID EQ.EaTOTAL EQ Eo. FUNCTIONALITY

TOTAL MOL.
wt /eq.wt base wt /eq.wt acid
total acid/base Mo=Eo/F
DCO OIL 25.96 293 0.09 0.09 0.09 1 0.09
SOYA OIL 8.61 293 0.03 0.03 0.03 1 0.03
CAT. 0.18 -------- --------- --------
PENTA 7.28 34 0.21 0.21 4 0.05
PENTA 1.09 34 0.03 0.03 4 0.01
P.ANHYDRIDE 12.22 74 --------- 0.17 0.17 2 0.08
TOTAL 55.34 -------- 0.36 0.28 0.53 0.26
R.OF WATER 1.49 -------- ------ -----
N.V. 53.85 -------- -----
SOLVENT 44.66 -------- -----

1*OIL LENGTH- OIL QUANTITY*100 64.18%

NON VOLATILE

2*% EXCESS OH- TOTAL Eb-TOTAL Ea *1000.3642 - 0.2831*100 28.64%

TOTAL Ea 0.28
3* ALKYD CONSTANT- TOTAL MOLES 0.93
TOTAL ACID EQ

4*P gel 2*TOTAL MOLES 99.36%

TOTAL ACID EQ

5*THERITICAL OH VALUE AT ZERO ACID VALUE

( Eb-Ea) *56100 84.49

% NV

MANUFACTURING PROCESS OF ALKYD RESIN'

MTO

XYLYNE

OIL TANK SOLVENT TANK

VENT

WATER OUTLET

CHARGING CHUT CONDENSER

SWAN NECK

WATER INLET

SEPARATOR

SAMPLE VALVE REFLUX LINE

UPPER JACKET

VENT

LOWER JACKET

WATER OUTLET

REACTOR

CONDENSER

FLUSH BOTTOM VALVE WATER INLET

DIRECT DRAIN LINE

VERTICAL

TANK

DIRECT BARREL FILLING BLENDER

FLOW

TRANSFER PUMP BUCKET FILTER

FLOW DIAGRAM OF BRP-1

MANUFACTURING PROCESS
CHARGE OIL HEAT TO 260°C ADD CATALYST & 85% POLYOLS HOLD AT 260°TILL MG PASS
(1:3 RATIO WITH METHENOL - CLEAR SOLUTION)

START HEATING ADD ACID AT 160°C ADD REST POLYOLS AT 220°C START COOLING

ADD REFLUX SOLVENT HEAT UP TO 240°C CHECK VISCOSITY & ACID UNLOAD THE MATERIAL IN THINNING
AT 180°C SLOWLY VALUE AT EVERY HOUR MIXER

CRITICAL POINT IN ALKYD MANUFACTURING.

1* QUANTITY OF OIL .
2* MONOGLYCERIDE STAGE. ( IT IS VERY IMPORTANT THAT TO ENSURE THE COMPLETION OF MONOGLYCERIDE BECAUSE ONLY MONOGLYCERIDE
IS COMPATIBLE WITH PHTHALIC. IF MONOGLYCERIDE IS NOT COMPLTED AND PHTHALIC IS CHARGED THEN BATCH WILL BE GELLED.
3* IN THE LAST STAGE OF ESTERIFICATION REACTION VISCOSITY PICK-UP IS VERY FAST . MAXIMUM CARE TO BE GIVEN IN TERM OF SAMPLE CKECKING
IN RIGHT TIME AND UNLOADING WITHIN VISCOSITY SPECIFICATION.

ALWAYS REMEMBER THE FOLLOWING

SR.NO INCIDENT IMMEDIATE ACTION PREVENTIVE MEASURE

1 If viscosity is not increasing. check acid at point and compare with std.Very much dependent upon quantity& quality of raw material
If acid value in range then remove reflux solvent
Ensure correct charging
through seprator.
add small quantity of phthalic.
check temprature of kettle

2* If acid value is not falling. check the condition of reflux. Ensure correct quality of OIL.
add small amount of reflux solvent Ensure correct quantity of reflux solvent.
ployol may be added Clean the condenser tubes.

3* If Bottom valve is chocked at the timeApply

of back pressure. Regular cleaning of reactor is required.
unloading. Immediately start addition of solvent in reactor
 it self through sepratoe very-very slowly.

4* If batch is going towards gellation. Immediately stop firing of boiler and start ONLY
coolingPOSSIBLE IF R/M QUALITY IS BAD
Immediately start unloading in blender. OR CHARGING IS WRONG OR NO PROPER
Immediately start thinning in reactor it self.
CARE DURING ESTERIFICATION.
If situation is not under control add ROSIN or
BENZOIC ACID.

5* If reactor is pressurized. STOP STIRRER IMMEDIATELY. CHECK ALL VALVE.

( material is coming out from sampleSTART
valve COOLING OF MASS. CHECK CHOCKING OF REFLUX LINE.
or any other point) REMOVE ALL PERSON FROM AFFECTED
CHECK CHOCKING OF SWAN NECK.
AREA CHECK CHOCKING OF CONDENSER.
WAIT TILL COOLING. MOST PROBABLE REASON IS WRONG POSITION
OF VALVE.

ACRYLIC RESIN

ACRYLIC RESIN CAN BE DEVIDED IN TWO DISTNICT CATEGORIES.

ACRYLIC RESIN

THERMOPLASTIC POLYMER THERMOSETTING POLYMER

THERMOPLASTIC POLYMER.

THE THERMOPLASTIC TYPES ARE LONG CHAIN POLYMER'S WITH HIGH MOLECULAR WEIGHTS AND THEY FORM FILM WITHOUT ANY EXTERNAL
CHEMICAL REACTION. THEMOPLASTIC FILMS HARDEN BY SOLVENT EVOPERATION.

THERMOSETTING POLYMER.

THE THERMOSETTING TYPE OF ACRYLIC ARE SHORTER CHAIN POLYMER'S CONTAINING REACTIVE GROUPS WHICH CAN BE CURED BY THE
APPLICATION OF HEAT OR USALLY BY REACTION WITH ANOTHER CHEMICAL TO FORM A CROSSLINKED FILM.

CHEMISTRY OF ACRYLIC RESIN ACRYLIC RESINS ARE FORM BY ADDITION POLYMERIZATION REACTION AND FREE
RADICAL MECHANISM. REACTION TAKES PLACE IN THREE STAGES.

INITIATION INITIATOR ( CATALYST ) AT HIGHER TEMPRATURE AND FORM FREE RADICAL.

R R1 R* + R1*
Initiator Free Free
Radical Radical

R* + CH2 = CHX RCH2--- CHX*

Free MONOMER MONOMER
Radical REDICAL
 CN CN CN

H3C C N=N C CH3 2H3C C N*

CH3 CH3 CH3

AZO BIS ISOBUTYL NITRITE FREE RADICAL

PROPAGATION ONCE THE MONOMER RADICAL HAS BEEN FORMED POROPAGATION PROCEEDS RAPIDLY AS THE NUMBER OF
MONOMER UNITS INCREASED SUCCESSIVELY TO PRODUCE A GROWING POLYMER CHAIN . AFTER EACH SUCCESSIVE
ADDITION THE FREE RADICAL IS RETAINED ON THE VINYL CARBON ATOM OF THE END CHAIN UNIT.

R CH2 CHX* + CH2 = CHX R CH2 CHX CH2 CHX*

R CH2 CHX [ CH2 CHX ] n CH2 CHX *

nCH2 = CHX

TERMINATION IN ORDER TO TERMINATE A GROWING POLYMER CHAIN, IT IS NECESSARY TO EFFECT THE REMOVAL OF THE
FREE RADICAL FROM THE POLYMER CHAIN.

R CH2 CHX * + * XHC CH2 [ CH2 CHX ] n XHC CH2 R

R CH2 CHX XHC CH2 [ CH2 CHX ]n XHC CH2 R

RAW MATERIAL MAIN RAW MATERIAL USED FOR ACRYLICS ARE.

1* CATALYST
2* MONOMER
3* SOLVENT

CATALYST TWO TYPE CATALYST ARE USED IN ACRYLIC.

1* AIBN CN CN

H3C C N=N C CH3

CH3 CH3

AZO BIS ISOBUTYL NITRITE

2* BENZOYAL PEROXIDE
O

C
O OH
MONOMER FOLLOWING MONOMER ARE USED IN ACRYLIC RESIN. SELECTION OF MONOMER IS DEPEND UPON THEIR PROPERTIES.

SR.NO HOMO HARDNESS FLEXIBILITY UV ALKALI GLOSS SOLUBILITY

POLYMER RESISTANCERESISTANCE
RESISTANCE

1 a methyl - Very poor Excellent Very poor

Styrene
2 Styrene Poor Excellent Poor
3 Acrylonitrile Fair/ Poor Poor Poor
4 Methyl Meth- Very good Very good Very good
acrylate
5 Ethyl Metha- Excellent Excellent Excellent
acrylate
6 Butyl Metha- Excellent Excellent Excellent
acrylate
7 Methyl - Poor Very good Poor
acrylate
8 Ethyl acrylate Fair Very good Good
9 Butyl acrylate Very good Very good Very good

MANUFACTURING PROCESS OF ACRYLIC RESIN'

MONOMER TANK CATALYST TANK

CHARGING PUMP

MONOMER ADDITION LINE

SEPRATER
 UPPER JACKET

U BENT

LOWER JACKET

REACTOR

FLUSH BOTTOM VALVE

SPARKLER FILTER PUMP

MANUFACTURING PROCESS

Test Monomer for polymer test Charge monomer in monomer tank Add catalyst in monomer tank

Raise temp. as req Start heating Take Solvent in reactor START COOLING & maintain temprature below 20°C

Start monomer addition Maintain temprature Complete Monomer addition Start holding at required temprature for spacified time
with req.constant rate Within Spec. in required Time

Complete catalyst addition Maintain temprature Start catalyst addition Prepare catalyst solution in
in required Time Within Spec. with req.constant rate catalyst tank

Start holding at required temprature for spacified time Start cooling

CRITICAL POINTS OF PROCESS

1*MONOMER TANK TEMPRATURE MUST BE MAINTAINED BELOW 20°C

2*MONOMER RATE & KETTLE TEMPRATURE MUST BE IN LIMIT.

AMINO RESIN
REACTION PRODUCT OF URAE OR MALAMINE WITH FORMELDHEHYDE UNDER GO ETHERIFICATION REACTION WITH BUTANOL

TYPES OF AMINO RESIN

AMINO RESIN

UREA FORMELDEHYDE MALAMINE FORMELDEHYDE

REACTION MECHANISM OF AMINO RESIN

REACTION OF AMINO RESIN TAKES PLACE IN TWO STAGES.

METHYLOLATION

IN THE FIRST STAGE OF REACTION ONE MOLE OF MALAMINE REACT WITH MAXIMUM SIX MOLE OF FORMELDEHYDE AND FORM METHYLOL GROUP.
( ADDITION REACTION )

H N H CH2OH N CH2OH

N C C N N C C N
O
H H Slightly alkaline H H
N N + 3* H C N N
In prscence of catalyst
H
C C

H N H H N CH2OH

ETHRIFICATION

METHYLOL GROUP IS REACT WITH HYDROXYL GROUP OF BUTANOL IN SLIGHTLY ACIDIC ATMOSPHERE . WATER IS GENRATED AND POLYMERIZATION TAKES PLACE.

H H
Slightly acidic
C O H + H O C4H9 C C4H9

IMPORTANT POIN OF REACTION

1* MALAMINE : FORMELDEHYDE RATIO

 NUMBER OF METHYLOL GROUP DEPEND UPON THE RATIO OF MALAMINE : FORMELDEHYDE. MAXIMUM RATIO POSSIBLE
IS 1:6.
2* PH OR ACID VALUE.

IF IN THE METHLOLATION STAGE PH WILL BE ON ACIDIC SIDE THEN THERE WILL BE VERY FAST & UNCONTROLLED
REACTION TAKES PLACE.

3* BUTYLATION

HARDNESS OF RESIN IS DIRECTLY RELATED WITH THIS STEP. IF BUTYLATION WILL BE MORE THAN WATER GENRATION
WILL BE MORE & NO. OF FREE REACTIVE GROUP WILL BE LESS RESULTING LESS HARDNESS IN PAINTS.

MANUFACTURING PROCESS OF MALAMINE FORMELDEHYDE RESIN'

SOL. TANK VACCUME HEDDER

SEPRATER

UPPER JACKET

U BENT

LOWER JACKET

REACTOR

FLUSH BOTTOM VALVE

 SPARKLER FLTER

PUMP TANK SPARKLER FLTER PUMP RECOVERY VESSELS PUMP

MANUFACTURING PROCESS

Take recovery solvent in reactor Carry out analysis of recovery sovent Addjust the quantity of malamine, pharaform, water & butanol
in batch

complete water start heating Maintain acid value adjustment time Start heating up to 80°C and adjust acid value/ PH
recovery

Start solvent recovery

under vaccume / atm.

CRITICAL POINT OF REACTION

1* ACID VALUE ADJUSTMENT IS VERY CRITICAL POINT. VALUE & OBSERVATION TO BE VERY CORRECT
2*TIME OF WATER RECOVERY IS CRITICAL. IF TIME IS MORE THAN THERE WILL BE OVERPOLYMERIZATION
3*TIME OF SOLVENT RECOVERY IS TO BE MAINTAIND AGAINST STANDARD TIME.

ALWAYS REMEMBER THE FOLLOWING

SR.NO INCIDENT IMMEDIATE ACTION PREVENTIVE MEASURE

1 If steam boiler faild after charging Always keep stirrer on. If stirrer will be stopped
Regular preventive maintance
than pharaform & malamine will be settled at
bottom.

2* If adjsted acid value is more than spec.

Do not continue the batch .First adjust again
Studdy
withthe previous batches and add acid in part
specified amine
 3* If excessive solvent loss is observedStart chilling in condenser and keep reactor
Regular cleaning of condenser
during recovery temprature on lower side of specification

CATHIODIC ELECTRODIPOSITION RESIN

CTHODIC ELECTRO DIPOSITION RESINS ARE BASICLY EPOXY MODIFIED WITH AMINES URETHANE AND POLYMIDE. THESE RESINS ARE WATER SOLUBLE.

TOTAL CED RESIN CAN BE CLASSIFIED IN TWO CATAGARY.

CED RESIN

F-1 RESIN F-2 RESIN

DDE-650M P-500ED EM-706 RESIN EM-460RESIN

DIE-110 CED-148 DAK-2BASE CED-177 EAK-1BASE

DIE-120
P-500ED 194-ED
CED-601 EAK-1BASE
DAK-2BASE PB-LOFA
CUB-620
90% 9-BIP
CED-605 EAK-1BASE
DAK-2BASE
CUB-620
CU-555

KH-303
first we will discusses about intermediate resins

74 % EAK-1 BASE-:

FOR MANUFACTURING CED RESINS 74% EAK-1 BASE IS USED AS AN AMINE INGREDIENT WHICH REACT WITH EPOXY RESIN . BECAUSE
74% EAK-1BASE IS KETIMINIZED AMINE , EPOXY GROUP REACTS WITH OH- GROUP OF EAK-1BASE.

CH3 CH3
OH-CH2-CH2-NH2 + O =C OH CH2CH2 N=C + H2O
CH CH3 WATER
CH2 CH3 HC CH3
MONO ETHANOL AMINE MIBK
CH2

CH3
74% EAK-1 BASE ( M.W- 143)
THIS IS A IREVERCIBLE REACTION. KITAMINE GROUP OF EAK-1BASE CAN BE HYDROLIZED & CONVERTED IN AMINE GROUP. REACTION OF EAK-1BASE
IS CONTROLLED ON THE BASIS OF OF KITAMINE CONTENT.

REACTANT REACTANT
MIXTURE MIXTURE
Raw Material %qt in formula.
Equivalent weight
No of equivalent
Mono ethanol amine 33.46 61 0.55
MIBK(I) 62.7 100 0.63
MIBK(II) 3.84 100 0.04

84 % DAK-2 BASE-:

FOR MANUFACTURING CED RESINS 84% DAK-2 BASE IS ALSO USED AS AN AMINE INGREDIENT WHICH REACT WITH EPOXY RESIN .
CH3
CH2 - CH2- NH2 CH3 CH2 - CH2- N- C
KETIMINIZATION C4H9
NH +2 O = C NH
- 2H2O CH3
CH2 - CH2- NH2 C4H9 CH2 - CH2- N- C
C4H9
1 MOLE DETA 2 MOLE MIBK DAK-2BASE (M.W- 267)

REACTANT MIXTURE
Raw Material %qt in formula.
Equivalent weight
No of equivalent
DiethyleneTri amine 30.03 51.5 0.58
MIBK(I) 69.97 100 0.7

90 % CUB=620-:

FOR MANUFACTURING CED RESINS 90% CUB-620 IS ALSO USED AS AN OXIME INGREDIENT WHICH REACT WITH EPOXY RESIN .

CH3 CH3
OCN- (CH2)6-NCO + HO-N=C OCN-(CH2)6 - NH-C-O-N=C
CH2CH3 O CH2CH3
HMDI(M.W-168) MEK-OXIME (M.W-87) 90% CUB-620 ( M.W-255)

NCO VALUE=
NCO EQUIVALENT * 42000
90

REACTANT MIXTURE
Raw Material %qt in formula.
Equivalent weight
No of equivalent
H.M.D.I 50.64 84 0.6
MIBK (I) 9.55
MEK-OXIME 39.36 87 0.45
MIBK(II) 0.45

CHEMICL REACTION OF BACK BONE RESINS for emulsion EM-706

CED -148 RESIN

REACTION OF THIS TAKES PLACE IN FOUR STAGES.

STAGE-1 EPOXY CHAIN EXTENSION

REACTION TAKES PLACE BETWEEN LOWMOLECULAR EPOXY WITH BISPHENOL-A .

O CH3 O

CH2 CH CH2 O 0 C 0 O CH2 CH CH2

CH3
EPOXY -828 EL ( EQUIVALENT WT- 188)

CH3

OH 0 C 0OH

CH3

BIS- PHENOL -A ( EQUIVALENT WT- 114)

O O

CH2 CH CH2 CH2 CH CH2

OH

EXTENDED EPOXY ( R OH )

REACTANT MIXTURE
Raw Material %qt in formula.
Equivalent weight
No of equivalent
Epoxy-828EL 39.94 188 0.21
Bis-Phenol A 3.57 114 0.03

STAGE-2 GRAFT POLYMERIZATION OF CAPROLACTN

O O

CH2 CH CH2 CH2 CH CH2

 OH

O
C

O CAPROLACTOM

O O

CH2 CH CH2 CH2 CH CH2

O C ( CH2) 5 OH

REACTANT MIXTURE
Raw Material %qt in formula.
Equivalent weight
No of equivalent
Caprolactom 10.06 114 0.09
STAGE-3 EPOXY CHAIN EXTENSION

O O

CH2 CH CH2 CH2 CH CH2

O C ( CH2) 5 OH

CH3

OH 0 C 0OH

CH3
 IN PRSCENCE CH2CH2OH
OF CATALYST NH
CH2CH2OH
DI ETHANOL AMINE

O O

CH2 CH CH2 O O CH2 CH CH2

O C ( CH2) 5 OH
REACTANT MIXTURE
Raw Material %qt in formula.
Equivalent weight
No of equivalent
Diethanol amine 0.66 52.5 0.13
Bis-Phenol A 13.26 114 0.12
STAGE-4 AMINE ADDITION

O O

CH2 CH CH2 O O CH2 CH CH2

O C ( CH2) 5 OH

+ CH3
CH2CH2N = C
CH2CH2OH C4H9
NH & NH
CH2CH2OH CH3
CH2CH2N = C
DI ETHANOL AMINE DAK-2 BASE C4H9

CH3
HOH2CH2C CH2CH2N=C
C4H9
NH2CHC CHCH2N
 CH3
HOH2CH2C OH OH CH2CH2N=C
O C4H9

O C ( CH2) 5 OH
73% CED-148

REACTANT MIXTURE
Raw Material %qt in formula.
Equivalent weight
No of equivalent
Diethanol amine 4.52 52.5 0.09
Dak-2 Base 3 267 0.01

CED -601 RESIN

REACTION OF THIS TAKES PLACE IN FOUR STAGES.

STAGE-1 EPOXY CHAIN EXTENSION

REACTION TAKES PLACE BETWEEN LOWMOLECULAR EPOXY WITH BISPHENOL-A IN PRSCENCE OF CATALYST( EAK-1BASE)

O CH3 O

CH2 CH CH2 O 0 C 0 O CH2 CH CH2

CH3
EPOXY -828 EL ( EQUIVALENT WT- 188)

CH3

OH 0 C 0OH

CH3

CH3
OH CH2CH2 N=C

HC CH3

CH2

CH3
74% EAK-1 BASE ( M.W- 143)

O O

CH2 CH CH2 O CH2 O CH CH2

 EXTENDED EPOXY CHAIN

REACTANT MIXTURE
Raw Material %qt in formula.
Equivalent weight
No of equivalent
Epoxy-828EL 35.44 188 0.19
Bis-Phenol A 13.39 114 0.12
Eak-1base 0.73 143 0

STAGE-2 MODIFICATION WITH EAK-1 BASE

O O

CH2 CH CH2 O CH2 O CH CH2

EXTENDED EPOXY CHAIN

CH3
OH CH2CH2 N=C

HC CH3

CH2

CH3
74% EAK-1 BASE

O CH3

CH2 CH CH2 O O CH2 CH CH2 O C2H4 N =C

OH C4H9

REACTANT MIXTURE
Raw Material %qt in formula.
Equivalent weight
No of equivalent
Extended Epoxy 49.56 737.5 0.07
74% Eak-1 base 10 143 0.05

STAGE-3 REACTION WITH DAK-2 BASE

 O CH3

CH2 CH CH2 O O CH2 CH CH2 O C2H4 N =C

OH C4H9

CH3
CH2CH2N = C
C4H9
NH
CH3
CH2CH2N = C
DAK-2 BASE C4H9

CH3
C N CH2 CH2 CH3
C4H9
N CH2 CH CH CH2 O C2H4N C
CH3
C N CH2 CH2 OH OH C4H9
C4H9

REACTANT MIXTURE
Raw Material %qt in formula.
Equivalent weight
No of equivalent
Extended Epoxy 59.56 3867 0.02
Dak-1 base 2.96 267 0.01

STAGE-4 MODIFICATION WITH PARTIALLY BLOCKED ISOCYNATE

CH3
C N CH2 CH2 CH3
C4H9
N CH2 CH CH CH2 O C2H4N C
CH3
C N CH2 CH2 OH OH C4H9
C4H9
 +

CH3
OCN-(CH2)6 - NH-C-O-N=C
O CH2CH3
90% CUB-620

CH3
C N CH2 CH2 CH3
C4H9
N CH2 CH CH CH2 O C2H4N C
CH3
C N CH2 CH2 O O C4H9
C4H9
O C C O

NH NH

(CH2)6 (CH2)6

NH NH

O C C O

CH3 O O CH3

C N N C

C2H5 C2H5

CED-601

CED -605 RESIN

REACTION OF THIS TAKES PLACE IN FOUR STAGES.

STAGE-1 EPOXY CHAIN EXTENSION

REACTION TAKES PLACE BETWEEN LOWMOLECULAR EPOXY WITH BISPHENOL-A .

O CH3 O

CH2 CH CH2 O 0 C 0 O CH2 CH CH2

CH3
 EPOXY -828 EL ( EQUIVALENT WT- 188)

CH3

OH 0 C 0OH

CH3

O O

CH2 CH CH2 CH2 CH CH2

OH

EXTENDED EPOXY ( R OH )

REACTANT MIXTURE
Raw Material%qt in formula.
Equivalent weight
No of equivalent
Epoxy-828EL 35 188 0.19
Bis-Phenol A 3.84 114 0.03

STAGE-2 GRAFT POLYMERIZATION OF CAPROLACTN

O O

CH2 CH CH2 CH2 CH CH2

OH

O
C

O CAPROLACTOM
 O O

CH2 CH CH2 CH2 CH CH2

O C ( CH2) 5 OH

REACTANT MIXTURE
Raw Material%qt in formula.
Equivalent weight
No of equivalent
Caprolactom 7.04 114 0.06
Extended Epoxy 38.85 254.7 0.15

STAGE-3 EPOXY CHAIN EXTENSION WITH BISPHENOL-A & EAK-1 BASE

O O

CH2 CH CH2 CH2 CH CH2

O C ( CH2) 5 OH

CH3

OH 0 C 0OH

CH3

IN PRSCEN-
CE OF
EAK-1BASE
AS A
CATALYST

O O
 CH2 CH CH2 O O CH2 CH CH2

O C ( CH2) 5 OH
REACTANT MIXTURE
Raw Material %qt in formula.
Equivalent weight
No of equivalent
Eak-1base 1.56 143 0.01
Bis-Phenol A 9.6 114 0.08

STAGE-4 AMINE MODIFICATION WITH EAK-1 BASE

O O

CH2 CH CH2 O O CH2 CH CH2

O C ( CH2) 5 OH

CH3
OH CH2CH2 N=C

HC CH3

CH2

CH3
74% EAK-1 BASE

O
CH3
CH2 CH CH2 O O CH2 CH CH2 O C2H4N=C
C4H9
OH
O
 O C ( CH2) 5 OH

REACTANT MIXTURE
Raw Material %qt in formula.
Equivalent weight
No of equivalent
Eak-1base 8.91 143 0.06

STAGE-5 AMINE MODIFICATION WITH DAK-2 BASE

O
CH3
CH2 CH CH2 O O CH2 CH CH2 O C2H4N=C
C4H9
OH
O

O C ( CH2) 5 OH

CH3
CH2CH2N = C
C4H9
NH
CH3
CH2CH2N = C
DAK-2 BASE C4H9

CH3
C N CH2 CH2 CH3
C4H9
N CH2 CH CH CH2 O C2H4N C
CH3
C N CH2 CH2 OH OH C4H9
C4H9 O

O C (CH2)5 OH

REACTANT MIXTURE
Raw Material %qt in formula.
Equivalent weight
No of equivalent
Dak-1base 2.15 267 0.01
STAGE-6 MODIFICATION WITH PARTIALLY BLOCKED ISOCYNATE

CH3
C N CH2 CH2 CH3
C4H9
N CH2 CH CH CH2 O C2H4N C
CH3
C N CH2 CH2 OH OH C4H9
C4H9 O

O C (CH2)5 OH

CH3
OCN-(CH2)6 - NH-C-O-N=C
O CH2CH3
90% CUB-620

CH3
C N CH2 CH2 CH3
C4H9
N CH2 CH CH CH2 O C2H4N C
CH3
C N CH2 CH2 OH OH C4H9
C4H9 O
O

O C (CH2) O C

NH O CH3

(CH2)6 NH C O N

70% CED-605 C2H5

90% CU-555 RESIN

STAGE-1 PARTIALLY BLOCKING OF DI-ISOCYNATE

O H
CH3 H3C
OCN (CH2)6 NCO
+ OH N C C N O C N (CH2)6 NCO
CH2CH3 H3CH2C
HEXA METHYL DI ISOCYNATE + MEK-OXIME
 O H +

CH3 O H H O CH2OC N (CH2)6 NCO CH2OH

C N O C N (CH2)6 N C OCH2 C CH2CH3

OHH2C C CH2OH

C2H5 CH2OC N (CH2)6 NCO CH2OH

TRI METHYL PROPANE
O H

REACTANT MIXTURE
Raw Material %qt in formula.
Equivalent weight
No of equivalent
HMDI 49.12 84 0.58
MEK-OXIME 25.45 87 0.29
TMP 10.98 46 0.24

STAGE-2 COMPLETE BLOCKING

O H

CH3 O H H O CH2OC N (CH2)6 NCO

CH3
C N O C N (CH2)6 N C OCH2 C CH2CH3
+ OH N C
CH2CH3
C2H5 CH2OC N (CH2)6 NCO MEK-OXIME

O H

O H
CH3
CH3 O H H O CH2OC N (CH2)6 O N C
CH2CH3
C N O C N (CH2)6 N C OCH2 C CH2CH3
CH3
C2H5 CH2OC N (CH2)6 O N C
CH2CH3
O H
90% CU-555

REACTANT MIXTURE
Raw Material %qt in formula.
Equivalent weight
No of equivalent
MEK-OXIME 5.1 87 0.59
90% KH -303 RESIN (Acrylic resin )

CH3 CH3 CH3

CH2 C + CH2 C + CH2 C

CH3
COOCH2 CH CH3 COOCH2CH2OH COOCH2CH2 N
CH3
CH3
ISO-BUTYL ACRYLATE HYDROXY ETHYL M.A.DIMETHYL AMINO ETHYL METHACRYLATE

AIBN FREE RADICAL ADDITION

INITIATOR POLYMERISATION

CH3 CH3

C=O C=O

O O

C2H4 C2H4

OH N

CH3 CH3

CHEMICL REACTION OF BACK BONE RESINS for emulsion EM-460

77% CED -177 RESIN

REACTION OF THIS TAKES PLACE IN THREE STAGES.

STAGE-1 EPOXY CHAIN EXTENSION

REACTION TAKES PLACE BETWEEN LOWMOLECULAR EPOXY WITH BISPHENOL-A IN PRSCENCE OF CATALYST( EAK-1BASE)

O CH3 O

CH2 CH CH2 O 0 C 0 O CH2 CH CH2

CH3
EPOXY -828 EL ( EQUIVALENT WT- 188)

+
 CH3

OH 0 C 0OH

CH3

CH3
OH CH2CH2 N=C

HC CH3

CH2

CH3
74% EAK-1 BASE ( M.W- 143)

O O

CH2 CH CH2 O CH2 O CH CH2

EXTENDED EPOXY CHAIN

REACTANT MIXTURE
Raw Material %qt in formula.
Equivalent weight
No of equivalent
Epoxy-828EL 27.62 188 0.15
Bis-Phenol A 11.45 114 0.1
Eak-1base 0.52 143 0

STAGE-2 AMINE MODIFICATIONAMINE MODIFICATION WITH EAK-1BASE

O O

CH2 CH CH2 O CH2 O CH CH2

CH3
OH CH2CH2 N=C

HC CH3

CH2

CH3
74% EAK-1 BASE ( M.W- 143)
 O
CH3
CH2 CH CH2 O OCH2 CH CH2 O C2H4 N C
C4H9
OH

REACTANT MIXTURE
Raw Material %qt in formula.
Equivalent weight
No of equivalent
Eak-1base 6 143 0.04

STAGE-3 POLYAMIDE ADDITION

O
CH3
CH2 CH CH2 O OCH2 CH CH2 O C2H4 N C
C4H9
OH

REACTION WITH POLYAMIDE

C NH2 OH
CH3
N CH2 CH CH2 O OCH2 CH CH2 O C2H4 N C
C4H9
C NH2 OH

77% CED-177

66% CED -194 RESIN

- H2O DILUTION WITH CED-177

R-COOH HOOC-R + PbO R-CO-O-Pb-O-CO-R 194ED
ROSIN LITHARGE

REACTANT MIXTURE
Raw Material %qt in formula.
Equivalent weight
No of equivalent
ROSIN 13.34 340 0.04
 PbO LITHARGE 3.98 111.5 0.04

83% LEAD LOFA SALT

- H2O
R-COOH HOOC-R + PbO R-C-O-Pb-O-C-R LEAD LOFA SALT
LIN.OIL F.ACID LITHRAGE O O

REACTANT MIXTURE
Raw Material %qt in formula.
Equivalent weight
No of equivalent
LIN. OIL F.ACID 56.75 280 0.2
PbO LITHARGE 22.6 111.5 0.2

90% 9- BIP

H3C NCO
H3C CH3
+ 2HO-N=C
C2H5
H3C CH2-NCO

IPDI MEK-OXIME

H O
CH3
H3C N C O N C
H3C C2H5

CH3
H3C CH2 NH C O N C
C2H5
O
MOL WT ( 396 ) 90% 9-BIP

REACTANT MIXTURE
Raw Material %qt in formula.
Equivalent weight
No of equivalent
IPDI 50.45 111 0.45
MEK-OXIME 39.94 87 0.46

CHEMICL REACTION OF BACK BONE RESINS for pigment paste F-1

MAIN F-1 RESIN DDE-650M IS SOLUTION OF THREE IMTERMEDIATE

DDE-650M DIE-110 + DIE-120 + P-500ED

84% DIE- 110

STAGE-1 PARTIALLY URETHANISATION REACTION TAKES PLACE BETWEEN IPDI & OCTANOL IN PRSCENCE OF CATALYST

H3C NCO
H3C
+ OH CH2 CH (CH2)3 CH3

H3C CH2-NCO C2H5

IPDI OCTANOL
IN PRSCENCE OF CH3
CATALYST OH CH2 CH2 N
CH3
( DIMETHYL ETHANOL AMINE)

H3C NH C O CH2 CH (CH2)3 CH3.

H3C
C2H5

H3C CH2-NCO

REACTANT MIXTURE
Raw Material %qt in formula.
Equivalent weight
No of equivalent
IPDI 35.16 111 0.32
OCTANOL 20.51 130 0.16
Dimethyl E amine 0.11 89 0

STAGE-2 COMPLETE URETHANISATION

H3C NH C O CH2 CH (CH2)3 CH3.

H3C
C2H5
 H3C CH2-NCO

CH3
OH CH2 N CH2
CH3
( DIMETHYL ETHANOL AMINE)

O C2H5

H3C NH C O CH2 CH (CH2)3 CH3.

H3C

CH3
H3C CH2 NH C O CH2 CH2 N
CH3
O

REACTANT MIXTURE
Raw Material %qt in formula.
Equivalent weight
No of equivalent
Dimethyl E amine 13.98 89 0.16

STAGE-3 NEUTRALIZATION

O C2H5

H3C NH C O CH2 CH (CH2)3 CH3.

H3C

CH3
H3C CH2 NH C O CH2 CH2 N
CH3
O

H3C CHOH

COOH
LACTIC ACID
 O C2H5

H3C NH C O CH2 CH (CH2)3 CH3.

H3C
O
CH3
H3C CH2 NH C O CH2 CH2 NO H
C (+)
CH (-)
CH3
CH3
O OH

DIE-110

85% DIE- 120

STAGE-1 COMPLETE URETHANISATION

H3C NCO CH3

H3C + OH CH2 CH2 N
CH3

H3C CH2-NCO
IPDI ( DIMETHYL ETHANOL AMINE)

O
CH3
H3C NH C O CH2 CH2 N
H3C CH3

CH3
H3C CH2 NH C O CH2 CH2 N
CH3
O

REACTANT MIXTURE
Raw Material %qt in formula.
Equivalent weight
No of equivalent
IPDI 32.41 111 0.29
Dimethyl E amine 26.01 89 0.29

STAGE-2 NEUTRALIZATION

O
CH3
H3C NH C O CH2 CH2 N
 H3C CH3

CH3
H3C CH2 NH C O CH2 CH2 N
CH3
O

H3C CHOH

COOH
LACTIC ACID

O
CH3O
H3C NH C O CH2 CH2 (-) N H (+)
H3C CH3
O C CH CH3

CH3 O OH
H3C CH2 NH C O CH2 CH2 N (-)H (+)
CH3 O C CH CH3
O
OH
REACTANT MIXTURE
Raw Material %qt in formula.
Equivalent weight
No of equivalent
LACTIC ACID 29.86 90 0.33

P-500 ED

STAGE-1

CH3 CH3
OH CH2 CH2
N + CH3CH(OH) -COOH OH-CH2-CH2-N(+) HOOC (OH) CH-CH3
CH3 CH3
DIMETHYL ETHANOL AMINE LACTIC ACID

REACTANT MIXTURE
Raw Material %qt in formula.
Equivalent weight
No of equivalent
IPDI 32.43 111 0.29
LACTIC ACID 26.01 89 0.29

STAGE-2

O O
CH3
CH2 CH CH2 CH2 CH CH2
OH-CH2-CH2-N(+)
+ HOOC (OH) CH-CH3
 ARALDITE 6071 CH3

QUATERTNIZATION

H3CHC(OH)C=O O=C(OH)CHCH3

O O
(-) (-)
H3C (+) (+) CH3
NCH2 CH CH2 CH2 CH CH2N
H3C CH3

HOH2CH2C CH2CH2OH
P-500ED

JAINPUR CED PLANT COTAINS 5NOS OF KETTLE.

2NOS 3TKETTLE
2NOS 400LITKETTLE
1NOS 875LITKETTLE

WATER OUTLET DIFF OF 2 TO 3 °C

CED FLOW FROM VACCUME PUMP

DIAGRAM VACCUME HEDDER

30 M*M
VENT

WATER INLET

(COOLING TOWER ) INLET T.22 TO 25 °C

7.5 HP VARIABLE SPEED 20 TO 150 SEPRATER

TYRE COUPLING
 UPPER LIMPED COIL
OIL HEATED U BENT

INLET TEMP-90 -260

LOWER JACKET PRODUCT B/S Y
3T REACTOR CED-148 2300K 2270K
CED-601 2300K 2270K
CED-605 2350K 2320K
FLUSH BOTTOM VALVE CED-177 2300K 2270K
DDE-650M 2300K 2270K

BUCKET FILTER

FOR DIRECT FILLING

BARREL FILLING PUMP

WATER OUTLET

CED FLOW
DIAGRAM
ADDITION TANK

300 LTR CAP 100 LTR 7.5 M*M

CHILLING WATER INLET OUT LET

MONOMER VESSEL VENT

WATER INLET

(FROM COOLING TOWER) 22 TO 24°C

5HP SINGLE SPEED SEPRATER

RPM-110 UNIAN COUPLING

UPPER JACKET

PADDEL U BENT
FILLING STEAM HEATED 1 KG MAX TYPE PRODUCT B/S Y
LOWER JACKET CUB-620 292K 285K
400LIT REACTOR KH-303 300K 296K
CU-555 296K 292K
BIP-9% 300K 295K
FLUSH BOTTOM VALVE DIE-110 350K 345K
DIE-120 330K 325K
P-500 ED 350K 345K

FOR DIRECT FILLING

BARREL FILLING PUMP

WATER OUTLET APPOX 3 TO 5 °C DIFFERENCE

CED 875 FLOW FROM VACCUME PUMP

DIAGRAM VACCUME HEDDER

30 M*M

WATER INLET

( FROM COOLING TOWER) 22 TO 24 °C

7.5 HP 67 RPM SINGLE SPEED

BELT DRIVE SEPRATER

VENT

SINGLE LIMPED COIL WATER RECOVERY

OIL HEATED U BENT

INLET T.160 TO 225 °C STIRRER PADDEL TYPE

875LIT REACTOR PRODUCT B/S Y

 EAK-1 BASE 600K 504 K
DAK-2 BASE 600K 390 K
FLUSH BOTTOM VALVE 194 -ED 800K 740 K
PB LOFA 600 K 565 K

FOR DIRECT FILLING

BARREL FILLING PUMP CURRENTLY DISMENTALED

PRODUCT COMPOSETION

CED PRIMER

F-1 F-2
DDE-650M
P-500ED
EM-460 EM-706
DIE-110 EAK-1 BASE----->CED-177 EAK-1 BASE+ DAK-2 BASE CED-601---->CUB
DIE120 9-BIP EAK-1 BASE+ DAK-2 BASE CED-605----->CUB
P-500 ED PL-LOFA DAK-2 BASE CED-148
194-ED CU-555
EAK-1 BASE KH-303

CED PAINT
Product Equipm. Capacity B.Size YIELD Cycle time

F-1 AL-MILL 4,5 KL 2507 2450 24 HRS

F-1 AL-MILL 2,5 KL 1275 1220 24 HRS
F-2 E.TANK 5,0 KL 4400 4350 6 HRS

TOTAL F-1 0
TOTAL F-2 217500
TOTAL CED 305530
F-1 : F-2 = 1:4
F-1CAP 54375(IN ratio)
F-2 CAP 217500(in ratio)
CED CAP 271875
RESIN REQUIREMENT FOR ABOVE QUANTITY
 SR.NO PRODUCT REQ. IN QT, REQ/BATCH TOTAL REQ STD B/SIZE YIELD NO. of batch Process hr/b Total Process hrs QT.PRODUCE Reactor
1 DDE-650 F-1 301 10896 2230 2205 5 15 75 11150 3T
2 CED-601 EM-706 359 16155 2300 2270 8 20 160 18400 3T
3 CED-605 EM-706 290 13050 2350 2320 6 27 162 14100 3T
4 CED-148 EM-706 765 34425 2300 2270 16 27 432 36800 3T
5 CED-177 em-460+194 652 3260 2300 2265 2 20 40 4600 3T
7 DIE-110 DDE-650M 345 1725 350 345 5 12 60 1750 400LT
8 DIE-120 DDE-650M 180 900 330 325 3 10 30 990 400LT
9 P-500 ED f-1+dde-650 13+163 1296 330 325 4 10 40 1320 400LT
10 KH-303 EM-706 40 1800 300 295 7 9 63 2100 400LT
11 CU-555 EM-706 44 1980 296 292 7 12 84 2072 400LT
12 CUB-620 601+605 280 3920 290 280 14 8 112 4060 400LT
13 9-BIP EM-460 72 360 300 295 2 7 14 600 400LT
14 PB-LOFA EM-460 17 85 700 640 1 15 15 700 875LT
15 194-ED EM-460 18 90 700 600 1 20 20 700 875LT
16 EAK-1BASE 601+605+177 250+250+200 4500 600 520 9 19 171 5400 875LT
17 DAK-2BASE 601+605+148 70+50+70 1980 600 520 4 19 76 2400 875LT

( RAHUL NALGUNE.)
( RESIN PLANT.)