ZEOLITE

CONTENTS
SECTION

PRODUCT CHARACTERISTICS AND SPECIFICATION

SECTION

II

PRODUCT APPLICATIONS

SECTION

III

INDIAN MANUFACTURERS

SECTION

IV

IMPORT/EXPORT LEVEL

SECTION

PRICE DETAILS

SECTION

VI

INDIAN DEMAND

SECTION

VII

BROAD OUTLINE OF MANUFACTURING PROCESS

SECTION

VIII

RAW MATERIAL REQUIREMENTS, UTILITY

AND AVAILABILITY

SECTION

IX

GLOBAL SCENARIO

SECTION

DISCUSSIONS ON ECONOMIC CAPACITY,

PROJECT COST AND PROFITABILITY PROJECTIONS

SECTION

XI

SWOT ANALYSIS

SECTION

XII

FACTORS INFLUENCING THE POSITION FOR

A NEW INDUSTRY AND RECOMMENDATIONS

SECTION - I
PRODUCT CHARACTERISTICS AND SPECIFICATION
1.1.

General details

Chemical name
Chemical formula
Grade
Appearance
Molecular weight
Colour
Mean particle size
Bulk density
Weight loss at 800 deg.C
pH of 1% dispersion
Ion exchange capacity
Calcium exchange capacity

1.2.

]Sodium Alumino Silicate

Na12(AlO2.SiO2.)12 27H2O
Detergent grade
Free Flowing Powder
2190
White
4 to 6 micron
25 to 30 lb/ft3
18 to 22% flowing powder
10.1 to 11.1 flowing powder
5.6 meq./g. Zeolite (7.0
meq./g. anhydrous Zeolite
300 mg. CaCO3/g. Zeolite
(anhydrous basis)

Special characteristics

Zeolite-4A, is used for low/non-waste technology in detergent industry, and has the
following characteristics.
*.

Higher sequestering power even at higher temperature.

*.

Alkali reaction with pH less than 12.

*.
Average particle size less than 4 micron and maximum size not exceeding 20
micron. This has made it suitable to pass through the mesh size of clothes and preventing
graying thereby.
*.
Due to the cubic shape with rounded corners and edges of Zeolite crystals,
Zeolite-4A would not remain on fabrics and are easily removed on rinsing.
*.
The unwanted water soluble molecules from the dirt do not finish up on the other
articles but are absorbed on Zeolite particles.
*.
Zeolite-4A coagulates the colloidal particles and pigments causing removal from
the aqueous phase.

*.
During the deposition of sparingly soluble compounds, Zeolite 4A particles act in
competition with the textile fabrics and reduces incrustation of the laundry.
*.

Zeolite 4A does not show fertilising effect.

*.
Biological degradation of linear alkyl benzene sulphonate does not interfere by
the presence of Zeolite A.
*.
Zeolite 4A particulates tend to form aggregates with other sewage constituents
and are largely eliminated in the pre sedimentation of sewage treatment.
*.
Toxicologically Zeolite 4A is safe. The acute toxicity is given as LD50 of 10
gm/kg. (mouse, oral intake) and toxicity to water organism is greater than 100 mg/1.
*

Uniform, molecular level size

*.

High surface area (350 to 1000 m2/g)

*.

High adsorption capacities even at low adsorbate concentrations (0.2 to 0.4 cm/g.)

*.
Qualitative change in adsorption surface from highly polar or hydrophilic to non
polar organophilic or hydrophobic surface by changing Si/Al ratio. Acidity can be
manipulated by Si/Al ratio.
*.

Pore dimension and adsorption properties can be manipulated by different cations.

*.
High thermal and hydrothermal stability can withstand temperature upto 800 Deg
C even in presence of steam.
*.

Zeolite 4A are environmentally safe.

1.3.

Product specification

Commercial form

Dried powder

Impurities

Ash
Fe total
Fe free

Solubility

Water, Alkali
None
Acid
Under decomposition
Capacity @ 25 deg.C. > 160 mg CaO/g (atro)

Average particle size

Sieve residue(>50 micron sieve by
mocker)
Bulk density
Tapped density
Density
Ignition loss(1 hr @800 deg.C.)
Atro content
Relative brightness
pH of 5% suspension
Crystalline type A Zeolite (X-ray
diffraction method)

< 5 micron
0.30%
400g/lit.
500 g/lit
2.00 g/cm3
19 to 21%
79 to 81%
>95%
11
Min.95%

< 3 ppm
< 300ppm
< 50 ppm

SECTION - II
PRODUCT APPLICATIONS
Zeolite 4A is used as detergent builder
General details
Zeolite 4A have major industrial applications as adsorbent, ion exchanger and catalyst.
By its ion exchange property, it can be used as a detergent builder.
Zeolite 4A is used as builder in detergent. The single largest use of Zeolite A is as
detergent builder, to soften detergents by removing Calcium and Magnesium.
Zeolite 4A is the best substitute for Sodium Tri poly phosphate (STPP) because it is
environmentally safe and also has excellent ion exchange capacity.

SECTION - III
INDIAN MANUFACTURERS
*

Henkel SPIC India Ltd.,

(Formerly known as SPIC Fine Chemicals Ltd.)
Peralam Main Road, Thirunallar, Karaikal-609 607.
Office: Temple Tower, Third Floor,
No.672 (New), 476/6 (Old) , Anna Salai, Nandanam,
Chennai-600 035.

Background details of Henkel Spic India Ltd.,

Henkel Spic India, was initially incorporated as Spic Fine Chemicals and got its present
name in April 1996. The company was promoted jointly by Tamil Nadu Petroproducts
Ltd (SPIC Group Company), Chennai and Henkel, Germany.
The German collaborator provided the technology for the plant situated at Karaikal,
Union Territory of Pondicherry. Henkel ranks third in the world in the manufacture of
Zeolite/ Detergents after Levers and Procter and Gamble.
The installed capacity of the plant is 15,000 tonnes per annum each for detergent powder
and detergent bar and 10,000 tonnes per annum of Zeolite 4A.
The detergent products of SPIC Fine Chemical has been launched, under the Trade name
`Zymo'. These products are the first phosphate free, Zeolite based detergent bars and
powders to be introduced in the country.
Name Change
The company's name has been changed from SPIC Fine Chemicals Limited to Henkel
SPIC India Ltd. with effect from 3rd April, 1996 thereby identifying the Foreign
Collaborator, who are pioneers in the field of detergents and allied products, more closely
with the company.
The company has not been doing well since its inception. Being a new and unknown
entrant and given the supremacy of Nirma and Hindustan Lever in the detergent market.
Henkel Spic took time to establish itself. Initially, to sustain itself, the company also
manufactured Surf for Hindustan Lever at its plant.
Henkel SPIC India Ltd., has acquired Calcutta Chemicals Co., and Detergent India Ltd.,
which are subsidiaries of Shaw Wallace Ltd., and which produce and market the `Margo'
and `Chek' brands of soap, respectively.
6

Exports
Company has successfully made some inroads in exporting Detergents &
Zeolite to Oman, Iran and Far East markets. Negotiations are also on with various Henkel
Companies around the world for export of Zeolite.
Based on trial order export of Zeolite, to Iran & Oman the Company was able to
successfully secure repeat orders as the product was well accepted both in terms of
quality and performance. The company continues to constantly explore export market for
detergents and Zeolite.
After a trial export order of 500 tonnes . to Iran, approval has been granted recently, by
the Iranian Govt. authorities for incorporation of Zeolite in detergent formulations. This
would lead to an offtake of 2000 tonnes per annum.
*

Hindustan Lever Ltd.,

Chemicals Division,
ICT Link Road,
B.D. Sawat Marg,
Chakala, Andheri (E),
Bombay - 400 099.

Installed capacity :

6250 tonnes per annum

Production level

Around 4000 tonnes per annum

The entire production is used for captive consumption.

*

Chemicals India,
17, Ahmednagar Indl.Estate,
Nagar Poona Road,
Ahmedabad 414 005,
Maharashtra.

Dinesh Chandra Industries

330, Narshi Natha St., Mumbai-400 009..
Products : Zeolite A (Detergent grade)

National Aluminium Company (NALCO)

Damanjodi,
Orissa.
Installed capacity:

10000 tonnes per annum

Installed capacity:

Indian Installed Capacity

Around 30000 tonnes per annum

SECTION - IV
IMPORT/EXPORT LEVEL
Present import level

Small quantity

Present export level

Around 1000 tonnes per annum

10

SECTION - V
PRICE DETAILS
Basic price

Rs.32 per kg

Taxes and duties

Extra at actuals

11

SECTION - VI
INDIAN DEMAND
Factors in favour of Zeolite 4A
Preferred builder for detergent
A general problem in washing is the greying of laundry caused by redeposition of soil
during repeated wash cycles. Zeolite 4A can minimise this effect by adsorption of
molecularly dissolved matter and by heterocoagulation with soil. Another problem is dye
transfer to non coloured textiles which is enhanced by a high concentration of sodium
ions in the wash water.
Againm, Zeolite 4A can reduce this effect by adsorption of dissolved dyes or
heterocoagulation with pigment dyes. Compared with water soluble builders Zeolite 4A
releases fewer sodium ions and consequently is the preferred builder for detergents
designed specifically for brightly coloured clothing (`colour detergents'). Furthermore,
Zeolite 4A increases the efficiency of bleaching agents by the removal of metal ions in
the wash and supports the foam suppressing action of soaps.
Zeolite as replacement for STPP in India
Though, it is evident that STPP has a few advantages over Zeolite, Zeolite could still be
preferred over STPP in view of the fact that the phosphates have the effect of causing
pollution as explained earlier.
It has to be recognised that Zeolite A can not be the sole substitute as builder in the non
phosphate detergent formulation, as it would not contribute to soil suspension, alkalinity
and binding Magnesium effectively.
When Zeolite A is used in combination with buffer like Sodium carbonate and soil
suspension anti redeposition agents like Sodium carboxy methyl cellulose in the presence
of co-builders like citrate, it can have almost equivalent cleaning agent as the old high
phosphate formulations.
While India is yet to formally ban the use of STPP, there are expectations of a phase out
on account of the progressive introduction of stringent water pollution regulations.

12

Demand Level for Zeolite-4A

A number of detergent units were contacted to ascertain the demand level for Zeolite
amongst the detergent units. Though a number of units particularly in the small scale
sector do not consume Zeolite, the medium and large scale units generally do so.
There appears to be considerable awareness amongst them about the relevance of Zeolite
in detergent formulations.
Replacement market for Zeolite-4A
Since Zeolite A is only the replacement product for STPP, the demand for Zeolite would
depend on the share of the STPP in detergents that could be replaced by Zeolite.
Though Zeolites as builders have now entered the Indian fabric wash detergent scene,
they will continue in their current minor role in formulations.
The reason for this is that condensed phosphates are the most efficient builders known
and have other useful functions besides their water softening role. Zeolites also adversely
affect processability of spray dried powders and have a narrower operating window for
processing. In syndet, bars they adversely affect bar building leading to poor in use
properties.

Indian estimated demand for

Zeolite A

Around 10000 tonnes per annum

Growth rate in demand

The growth rate in demand for Zeolite 4A in indigenous market can be considered to be
around 10% per annum, considering the fact that Zeolite-4A has to gain its market share
by displacing STPP usage to some extent.
Since there is no likelyhood of ban of the use of STPP in the immediate future, the STPP
is likely to largely hold its place.
Export growth rate is considered as 10% per annum.

13

SECTION - VII
BROAD OUTLINE OF MANUFACTURING PROCESS
Process chemistry
The preparation of Zeolite 4A starts with gel formation. The gel is defined as a hydrous
metal aluminosilicate prepared from aqueous solutions of alkali metal silicate and
aluminate. Analysis of many aluminosilicate gel samples showed that Si/A1 ratio always
exceeds one, whereas Na/Al ratio is close to one. Aluminium in gel skeleton is
coordinated 4-fold within the common (Si, Al,)) framework whereas alkaline cations
compensate excess negative charges of aluminium oxygen tetrahedera.
The gel is subjected to crystallization in the temperature range of ambient to 175 deg.C or
sometime upto 300 deg.C. The growth of Zeolite first requires the formation of a nucleus.
The smallest structural secondary building units are the single 4 or 6 membered rings,
which after sufficient induct on period exceeds critical size to form nucleous.
+

Na2SiO3
(aqueous)

NaOH
(aqueous)

NaAl(OH)4
(aqueous)

Naa(AlO2)b

(SiO2)c + NaOH + H2O (gel)

Nax(AlO2)

(SiO)2)y H2O + solution

Zeolite A

The above system can be presented in simplified form of equation as follows.

NaOH + NaSlO2 + Na2O.SiO2 + H2O ----->Na2O.Al2O3. 1.8 SiO2.4.5 H2O + NaOH
Zeolite A
Zeolite -A being a complex compound, above equation cannot be balanced
atochimetrically, but depending upon the % constituents present in different raw
materials, one has to calculate the requirement of all the raw materials to get the final
composition stated above.
Source of technology
14

Central Salt and Marine Chemicals Research Institute,

Gijubhai Badeka Marg,
Bhavnagar -364 002

Plant and machinery Equipment

Name of the equipment

Name of the company

Reactor

Chemitherm Plants & Systems P. Ltd.,

30, Anandha Street
Alwarpet, Chennai-600 018
Texel Fabricators Pvt. Ltd.,
335, Sidco Industrial Estate,
Ambattur, Chennai-600 098, Tamil Nadu

Boiler

Cethar Vessels Ltd.,

No.4, Dindigul High Road,
Trichy
Firetech Boilers Pvt. Ltd.
No.211, 2nd Cross,
38th Main, B.T.M. Layout
2nd Stage, Bangalore-68

Ageing reactor

Chemitherm Plants & Systems P. Ltd.,

30, Anandha Street
Alwarpet, Chennai-600 018
Texel Fabricators Pvt. Ltd.,
335, Sidco Industrial Estate,
Ambattur, Chennai-600 098, Tamil Nadu

Filter press

Fluid Control Equipments

77/574, Mount Road, Chennai-600 006
Sri Ranga Industries
SF, 739, Ramraj Nagar,
Goldwins, Coimbatore-641 014

Dryer

The Anup Engineering Ltd.,

Behind 66 KV Electric Sub Station
Odhav Road, Ahmedabad-382 415
ATRE Thermal Products Pvt. Ltd.,
Pushpa Heights, 1st Floor,
Bibwewadi Corner, Pune-411 037

Pulveriser

ACE Pack Machines

15

23, V.N. Industrial Estate

Bharathi Colony,Near Athiparasakthi Temple
Peelamedu, Coimbatore-641 004
Frigmaires Engineers
PO Box 16353, 8, Janata Industrial Estate
Senapati Bapat Marg
Opp Phoenix Mill, Lower Parel (W)
Mumbai-400 013

16

SECTION VIII
RAW MATERIAL REQUIREMENTS, UTILITY AND AVAILABILITY
Raw material requirements
Basis:

One tonne of Zeolite 4A

Sodium aluminate

0.74 tonnes

Sodium silicate

0.931 tonnes

Utility requirements
Power
Fuel
Water

190 units per tonne of product

160 litres
30 K.L per tonne of product

Source of raw materials availability

Name of the raw materials

Name of the company

Sodium Aluminate

Eastern Chemicals,Calcutta
Chandra Chemical Industries, Maharashtra
Bajaj Alchem Pvt.Ltd.Calcutta

Sodium silicate

Sharda Silicate & Chemical Industries,Coimbatore

Sebase Chemicals P.Ltd.Madras
Prabha Chemicals & Allied Products,Hyderabad
Ricasil Industries,Gujarat.
Kiran Silicates (P) Ltd.,Nagapatinam,

17

SECTION - IX
GLOBAL SCENARIO
In most of the countries, Europe, North America, Japan, in most of the detergents, the
predominant builders used now are Zeolite, Carbonate and Silicate systems supported by
Polyacrylate dispersants. The secondary but important role of insoluble Zeolite as a
process aid in particle formation will guarantee the use of these materials for a long time.
Zeolite is most widely used as builder in phosphate free laundry powders and some
liquids formulations.
Regionwise Consumption pattern
Far East Asia
17%

Others
3%

North America
25%
Western Europe
55%

European capacity is as under.:

Producers

Capacity in '000 TPA

Degussa, Germany
Henkel, Germany
Enimont, Italy
Benkiser Mira Lanza, Italy
RP Laviora, Spain
Saprolit, Belgium
Birac, Yugoslavia

135
80
75
25
35
40
45

SECTION X
18

DISCUSSIONS ON ECONOMIC CAPACITY, PROJECT COST AND

PROFITABILITY PROJECTIONS
Economic capacity

: 600 tonnes per annum

Project cost

: Rs.115 lakhs

Assessment of project cost

1.

Land

S.No.

Description

1.1
1.2

Cost of land of 1acre at Rs.5.5 lakh per acre

Cost of levelling, laying internal roads/fencing and
compound wall
Subtotal

2.

6.05

Building

S.No.

Description

2.1
2.2

Factory building of area 300 sq.m. at Rs.3200/sq.m.

Non-factory building of area 70 sq.m.at Rs.4500/sq.m.
Subtotal

3.

Cost
Rs.in lakhs

9.60
3.15
12.75

Cost of Plant & Machinery

S.No.

Description

3.1
3.2
3.3
3.4

Cost of basic plant and machinery

Instrumentation and control
Pipelines and valves
Structurals for erection
Subtotal
Octroi, excise duty, sales tax, etc.at 12%
Packaging and insurance charges (2%)
Transportation charges (2%)
Machinery stores and spares (2%)
Foundation charges (2%)
Installation charges (2%)
Total cost of plant and Machinery

3.5
3.6
3.7
3.8
3.9
3.10

Cost
Rs.in lakhs
5.5
0.55

19

Cost
Rs.in lakhs

36.00
2.70
3.60
1.80
44.10
5.29
0.88
0.88
0.88
0.88
0.88
53.80

4.

Technical know-how fees

5.

Miscellaneous fixed assets

Rs.2 lakhs

S.No.

Description

5.1.
5.2.
5.3.
5.4.
5.5.
5.6.
5.7.

Electrification
Steam boiler and auxillaries
Water storage tank, borewell etc.
Fuel storage tank
Laboratory equipment
Office machinery & equipment
Material handling equipment, packaging machinery,
weigh balance, etc.
Diesel generator
Effluent treatment
Total

5.8.
5.9.
6.

Cost
Rs.in lakhs
1.20
3.00
1.00
1.00
1.40
1.20
1.20
4.00
1.50
15.50

Preliminary & Pre-operative expenses:

S.No.

Description

6.1.
6.2.
6.2.1
6.2.2
6.2.3
6.2.4
6.2.5
6.2.6
6.2.7

Preliminary expenses
Pre-operative expenses:Establishment
Rent rates and taxes
Travelling expenses
Interest and commitment charges on borrowings
Insurance during construction period
Other preoperative expenses and deposits
Interest on deferred payment
Total

Cost
Rs.in lakhs
0.80

0.80
1.00
1.20
2.60
1.60
8.00

7.

Provision for contingency

Rs. 5.95 lakhs

8.

Working capital margin

Rs. 14.45 lakhs

9.

Total project cost

Rs.115 lakhs

10.

Means of Finance

Promoter's contribution
Term loan from financing institutions
Total project cost

Rs.46 lakhs
Rs.69 lakhs
Rs.115 lakhs

20

11.

Financial statements

Variable cost

Rs. in lakhs
117.54
3.23
9.60
130.37

Raw material and utilities

Spares and maintenance
Selling expenses
Total variable cost (A)

Fixed cost
6.00
20.27
7.31
5.76
39.34

Salaries and wages

Interest on term loan and working capital loan
Depreciation
Administrative expenses
Total fixed cost (B)
C.

Total cost of production (A+B)

D.

Selling price per kg. (in Rupees)

E.

Annual sales turnover

F.

Net profit before tax (E-C)

G.

Breakeven point in %

169.71
32
192
22.29
64%

21

SECTION XI
SWOT ANALYSIS
Strength

Ready availability of raw material

Weakness

Low demand in the country

Opportunity

The demand can be increased due to

environmental reasons

Threat

Lack of competitiveness in the global

market due to small capacity plants

22

SECTION - XII
FACTORS INFLUENCING THE POSITION FOR A NEW INDUSTRY AND
RECOMMENDATION
In considering the Zeolite-4A project, the following factors have to be kept in view.
* Zeolite-4A is essentially a substitute product for STPP.
* In the absence of imposition of ban on use of STPP in India due to environmental
reasons, the demand for Zeolite-4A is unlikely to go up substantially in quantitative
terms. There is unlikely to be ban on STPP in the immediate future in the country.
Considering the various aspects as above, it is necessary to have captive use for Zeolite4A, by setting up a detergent plant along with Zeolite-4A plant.
Since Detergent is highly competitive market, it is necessary to carefully study the
capability of the project promoter to operate in the competitive detergent market.

23