Sodium Percarbonate Manufacturing Plant Project Report 2024

The report is the result of extensive primary and secondary research, offering a detailed analysis of current market trends. It profiles key industry players, giving insights into their market strategies, production capacities, and financial performance, which are crucial for benchmarking and competitive analysis.

It delves into historical, current, and forecasted price trends, helping stakeholders understand market dynamics and price volatility. The report provides a thorough analysis of the mass balance and raw materials requirements, ensuring a clear understanding of the input-output ratios essential for efficient production. Detailed examinations of the various unit operations integral to the sodium percarbonate manufacturing process are included, highlighting process optimisation techniques and technological advancements.

The report presents a comprehensive capital cost analysis, detailing the financial investment required for setting up a sodium percarbonate plant. This includes an exhaustive breakdown of costs associated with raw materials, catchem, utilities, labour, packaging, transportation, land acquisition, construction, and machinery. Additionally, it offers an in-depth look at the operating costs, providing clarity on the recurring expenses involved in running the plant.

Projected profit margins and optimal product pricing strategies are outlined, offering guidance on maximising profitability. The report also addresses regulatory frameworks, environmental impacts, and sustainability measures pertinent to the sodium percarbonate industry.

About Sodium Percarbonate

Sodium percarbonate, with the formula (2Na2CO3 · 3H2O2) is a white, crystalline compound that releases hydrogen peroxide and sodium carbonate when dissolved in water. Historically, it was first synthesised in 1899 by Ukrainian chemist Sebastian Moiseevich Tanatar. Since its development, it is being used as a bleaching agent in eco-friendly cleaning products and laundry detergents due to its oxidising properties. Today, sodium percarbonate is also favoured for its ability to provide oxygen for stain removal without the harshness of chlorine bleach.

Properties of Sodium Percarbonate

Sodium percarbonate is a white, odourless, crystalline powder with a density of 2.1 g/cm cube and a molecular weight of 157.01 g/mol. It has a melting point of 55°C and a boiling point of 100°C. The compound has a pH of approximately 10.5 in solution, indicating mild alkalinity. It is highly soluble in water, decomposing to release hydrogen peroxide and sodium carbonate. Sodium percarbonate has a solubility of 140 g/L in water at 20°C. It is hygroscopic, absorbing moisture from the air, and is toxic if ingested, posing risks to skin and eyes upon contact. The compound has an oxidation state of +2 for sodium and +6 for carbon. 

Manufacturing Process of Sodium Percarbonate

The production of sodium percarbonate begins with the dissolution of sodium carbonate in water to create a sodium carbonate solution. Next, a concentrated hydrogen peroxide solution is prepared. The two solutions are then mixed in a reaction vessel under controlled conditions, typically at a temperature of 10-25°C, with a mole ratio of hydrogen peroxide to sodium carbonate ranging from 0.7:1 to 1.3:1. This reaction leads to the formation of sodium percarbonate, which precipitates out of the solution. The precipitated product is then separated from the mother liquor and dried to remove excess moisture. Finally, the sodium percarbonate is packaged for distribution, completing the manufacturing process.

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Synthesis of Sodium Percarbonate

Below are the detailed steps involved in the production of sodium percarbonate (2Na2CO3 · 3H2O2):

Step 1: Preparation of Sodium Carbonate (Na2CO3)

Sodium carbonate can be produced through the Solvay process, which involves the reaction of sodium chloride (NaCl), ammonia (NH3), and carbon dioxide (CO2) in water. 

The key reactions are:

1.    Formation of ammonium bicarbonate: 

NH3 (aq) + CO2 (g) + H2O (l) → NH4HCO3 (aq)

2.    Reaction of ammonium bicarbonate with sodium chloride to form sodium bicarbonate:

NH4HCO3 (aq) + NaCl (aq) → NaHCO3 (s) + NH4Cl (aq)

3.    Decomposition of sodium bicarbonate to form sodium carbonate:

2NaHCO3 (s) → Na2CO3 (s) + CO2 (g) + H2O (g)

Step 2: Preparation of Hydrogen Peroxide (H2O2)

Hydrogen peroxide is typically produced by the anthraquinone process, which involves the reduction of anthraquinone to anthrahydroquinone, followed by the oxidation of anthrahydroquinone back to anthraquinone, producing hydrogen peroxide.

Chemical Reaction:

C14H10O2 (anthraquinone) + H2 (hydrogenation) → C14H12O2 (anthrahydroquinone)

C14H12O2 (anthrahydroquinone) + O2 → C14H10O2 (anthraquinone) + H2O2

Step 3: Production of Sodium Percarbonate (2Na2CO3 · 3H2O2)

Sodium percarbonate is produced by the reaction of sodium carbonate with hydrogen peroxide. This reaction is typically carried out in an aqueous solution, followed by crystallisation.

Chemical Reaction:

Na2CO3 (aq) + 1.5H2O2 (aq) → 2Na2CO3 · 3H2O2 (s)

Applications and Drivers of Sodium Percarbonate

The sodium percarbonate market is driven by its diverse applications, particularly in the detergent industry, where it serves as a bleaching and cleaning agent. It is valued for its ability to release hydrogen peroxide when dissolved in water, making it effective for stain removal and fabric brightening. Beyond detergents, sodium percarbonate is used in environmental applications for wastewater treatment, as a disinfectant in healthcare, and in household cleaning products. Its role as an algaecide and fungicide further expands its market potential, catering to agricultural and industrial needs.

Key Features of the Sodium Percarbonate Production Cost Report:

This production cost analysis report by Expert Market Research scrutinises the sodium percarbonate manufacturing process, offering a comprehensive overview necessary for stakeholders considering venturing into this sector. Based on the latest economic data, the report encompasses detailed insights into the primary process flow, raw material requirements, reactions involved, utility costs, operating costs, capital investments, pricing strategies, and profit margins. This report is an indispensable resource for entrepreneurs, investors, researchers, consultants, business strategists, and all those who have any kind of stake in the sodium percarbonate industry. It equips them with essential information and strategic insights to effectively navigate the complexities of the market.

The following sections detail the comprehensive scope of the prefeasibility report for a sodium percarbonate production plant:

• Market Dynamics and Trends: This section analyses the prevailing market conditions, growth drivers, and trends impacting the sodium percarbonate industry. It offers a thorough examination of demand fluctuations and projections.

• Geographic Analysis: Detailed insights into the major regions active in sodium percarbonate production and consumption, highlighting regional market specifics and growth potential.

• Key Industry Players: Profiles of leading manufacturers in the sodium percarbonate sector, outlining their market share, strategic positions, and operational strengths.

• Price Fluctuations: Analysis of historical, current, and projected price trends, providing stakeholders with essential pricing intelligence.

• Technical Specifications and Process Description: A detailed overview of the sodium percarbonate production process including the technology used and innovations within the industry.

• Raw Material Requirements and Sourcing: Evaluation of necessary raw materials, their sourcing strategies, and cost implications.

• Utility Requirements and Costs: Detailed analysis of utilities needed to produce sodium percarbonate, such as electricity, steam, and process water along with their cost assessments. 

• Labour Force Dynamics: Insights into manpower requirements, including skill specifications and labour cost projections.

• Packaging Needs: Overview of packaging requirements for sodium percarbonate to ensure product integrity and cost efficiency.

• Logistics and Transportation: Examination of transportation needs and logistics planning for distribution and supply chain efficiency.

• Capital and Operating Costs: An in-depth look at investment requirements, including land acquisition and its development cost, civil work costs, construction, machinery procurement, and ongoing operational expenses, such as salaries and wages, plant overheads, tax and insurance as well as packaging, transportation, and administration costs.

• Financial Performance and Profitability Analysis: Projected profit margins and return on investment based on current market and operational parameters.

• Product Pricing Strategy: Recommendations on pricing mechanisms based on industry benchmarks and production costs.

• Environmental Impact and Regulatory Compliance: Analysis of environmental considerations and compliance with local and international regulations.

• Risk Assessment and Mitigation Strategies: Identification of potential risks associated with sodium percarbonate production and strategies to mitigate them.

Key Questions Addressed:

• What are the detailed unit operations for sodium percarbonate production?

• Who are major technology licensors with their process evaluation?

• How are raw materials or catchem procured and what are their cost implications?

• What utilities are essential for production and what will they cost?

• What are the labour requirements and how does this affect operational costs?

• What packaging solutions are optimal for cost and efficiency?

• What logistical arrangements are necessary for efficient product distribution?

• What are the estimated land and construction costs for a new sodium percarbonate plant?

• How can profitability be maximised in the sodium percarbonate market?

• What pricing strategy should be adopted for sodium percarbonate to remain competitive?

This prefeasibility report aims to equip potential investors and existing manufacturers with crucial insights to make informed decisions in the sodium percarbonate industry.