SILICONE EMULSION USED AS RELEASE AGENT

FOR RUBBER INDUSTRY

[EIRI/EDPR/3873] J.C. 1987

INTRODUCTION

Silicones are synthetic polymers having an inorganic skeleton of alternate silicone

and oxygen atoms, the silicone valences not taken up by oxygen being saturated
with organic group and other groups. They occupy an intermediate position
between inorganic and organic compounds. Because of this dual nature they have
many properties which have made them very useful in many applications.
Silicones are produced in several forms including fluids, rubbers and resins.
Silicones emulsions are formed from silicone fluids and water with the help of a
suitable emulsifier, and find various applications.

The term silicone denotes a polymer with the structural formula (RnSiO(4-n)1/2)m
where n is between 0 and 3 and m is 2 or more. It contains a repeating silicone
oxygen chain having organic groups R, attached to a significant portion of the
silicone atom by silicone carbon bonds. In commercial silicones most of the R
groups are methyl, longer alkyl, fluoro alky, phenyl, vinyl and a few others.
Silicone fluids the Si-O chain is unbanked.

Silicone fluids are generally, dimethyl polysiloxane, methyl hydrogen polysiloxane

or silicones consisting of copolymers of dimethyl siloxane with methyl phenyl,
methyl-hydrogen, diphenyl, methyl-alkyl and other siloxanes. Linear poly-dimethyl
siloxanes or dimethyl polysiloxanes are the most important of all the silicones.
These fluids with hexamethyl disiloxane. For relating low viscosity fluids are
manufacured by reacting dimethyl silicone fluids the process is run for several
hours at 180oC in glass lined kettles with acid chloride catalysts or at lower
temperature with sulphuric acid. Alkaline catalysts are used for the production of
high viscosity fluids or gums. Silicone fluids have m.wt. of 2000 to 15000 and
viscosities from 10 to 10,000 cps.

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Dimethyl silicone fluids are colourless, odorless and nontoxic and are resistant to
oxidation and chemicals. They have good lubricating action. They reduce surface
tension and have water repellent properties, together with foam inhibition.
Inclusion of phenyl groups into the silicone structure increase their thermal and
oxidative stability, while lowering the pour point. Thus methyl phenyl silicone
fluids have higher viscosity, temperature coefficient and lower pour point and
lower flash points than dimethyl silicone fluids of the same viscosity. Fluids with
chlorinated phenyl groups attached to silicone, e.g. methyl alkyl fluids where alkyl
is octyl to tetradecyl are good lubricants but have higher viscosity temperature
coefficients and poorer oxidative stability than methyl fluids.

In general, the dimethyl silicone fluids are soluble in aliphatic and aromatic
hydrocarbons and chlorinated hydrocarbons. Lower m. wt. fluids are more soluble
than higher fluids. They are insoluble in methanol, ethanol, acetone, ethylene,
gylcol, polyglycol ethers, gylcerol cyclohexanol and water. Methyl-phenyl silicones
are more soluble than the corresponding dimethyl silicones.

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 CONTENTS

INTRODUCTION
PROPERTIES
SILICONE FLUIDS AND SILICONE EMULSION
DEFINITION AND PROPERTIES OF SILICONES
TYPES OF SILICONE FLUIDS
THERE ARE BASICALLY TWO TYPES
USES AND APPLICATIONS
B.I.S. SPECIFICATION
TYPES OF SILICONE EMULSION
DETAILS OF SILICONE FLUIDS
ENVIRONMENTAL FATE AND EFFECTS:
MARKET POSITION
CONSTRUCTION AND E&E MOST IMPORTANT GROWTH MOTORS
ASIA INCREASING WORLD MARKET SHARE
ELASTOMERS AND SILICONE OILS MOST IMPORTANT PRODUCTS
PRODUCTION AND TRADE
INSTALLED CAPACITY, PRODUCTION AND CAPACITY UTILIZATION
OF SILICONE EMULSION
APPARENT CONSUMPTION OF SILICONE EMULSION
ESTIMATED DEMAND
PRESENT MANUFACTURERS/SUPPLIERS OF SILICON EMULSIONS
BUYERS OF SILICONE EMULSION
FORMULATING, HANDLING & USE FOR SILICONE EMULSION
USE AND HANDLING TIPS
EMULSIFIER TYPES
HOW SURFACTANTS WORK
MICROBIAL CONTAMINATION – EMULSIONS
APPLYING RELEASE AGENTS TO NEW MOLDS
DILUTION LEVELS FOR RELEASE AGENTS
RELEASE AGENTS FOR HIGH-TEMPERATURE APPLICATIONS
RUST INHIBITORS FOR DILUTED RELEASE AGENT EMULSIONS
APPLYING AMINO SILICONE SOFTENERS TO FABRIC
RAW MATERIALS
DOW CORNING DC-203 FLUID
FORMULATION OF SILICONE EMULSION
FORMULATION OF SILICONE EMULSION
OTHER FORMULATION OF SILICONE EMULSIONS
SILICONE OIL EMULSION (MOULD RELEASING AGENT)
FORMULATION - 1:-

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FORMULATION - 2:-
FORMULATION OF SILICONE EMULSION (MOULD RELEASE AGENT)
FOR RUBBER INDUSTRIES
FOR PLASTIC INDUSTRIES
FOR PU FOAM
MORE FORMULATION OF SILICONE EMULSION
FORMULATION OF SILICONE EMULSION FOR PU
FORMULATION NO. 1
FORMULATION NO. 2
FORMULATION OF SILICONE EMULSION FOR AUTOMOBILE
FORMULATION OF SILICONE EMULSION FOR STABLE AESTHETIC
PRODUCTS
ANTICAKING AGENTS
PROCESS FLOW DIAGRAM
PROCESS FOR CREATING EMULSION
PROCESS IN DETAILS
EXAMPLES 1 AND 2
EXAMPLES 3 AND 4
EXAMPLES 5 AND 6
EXAMPLES 7 TO 9
EXAMPLES 12 AND 13
PACKAGING HANDLING AND REMOVAL METHOD OF SILICONE EMULSION
MATERIAL SAFETY DATA SHEET FOR SILICONE EMULSION
SECTION I: IDENTIFICATION OF THE SUBSTANCE & THE COMPANY
SECTION II: HAZARDS IDENTIFICATION
EMERGENCY OVERVIEW
POTENTIAL HEALTH EFFECTS:
SECTION III: COMPOSITION/INFORMATION ON INGREDIENTS
SECTION IV: FIRST AID MEASURES
SECTION V: FIRE FIGHTING MEASURES
SECTION VI: ACCIDENTAL RELEASE MEASURES
SECTION VII: HANDLING AND STORAGE
KEEP AWAY FROM CHILDREN.
SECTION VIII: EXPOSURE CONTROLS/PERSONAL PROTECTION
ENGINEERING CONTROLS
EXPOSURE GUIDELINES
SECTION IX: PHYSICAL & CHEMICAL PROPERTIES
SECTION X: STABILITY AND REACTIVITY
SECTION XI: TOXICOLOGICAL INFORMATION
SECTION XII: ECOLOGICAL INFORMATION
SECTION XIII: DISPOSAL CONSIDERATIONS
SECTION XIV: TRANSPORT INFORMATION
SECTION XV: REGULATORY INFORMATION
SECTION XVI: OTHER INFORMATION

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ANALYSIS OF SILICONES
COMMON METHODS APPLIED TO THE ANALYSIS OF SILICONES
TABLE: TYPICAL 29SI NMR CHEMICAL SHIFTS
PLANT LAYOUT
PRINCIPLES OF PLANT LAYOUT
PLANT LOCATION FACTORS
EXPLANATION OF TERMS USED IN THE PROJECT REPORT
PROJECT IMPLEMENTATION SCHEDULES
SUPPLIERS OF RAW MATERIALS
SUPPLIERS OF SILICON OILS
SUPPLIERS OF CARBOPOL
SUPPLIERS OF PROPYLENE GLYCOL
SUPPLIERS OF PACKAGING MATERIALS
SUPPLIERS OF SODIUM HYDROXIDE
SUPPLIERS OF PLANT AND MACHINERY
SUPPLIERS OF COLLOID MILL
SUPPLIERS OF STAINLESS STEEL STORAGE VESSEL
SUPPLIERS OF FILTER
SUPPLIERS OF PACKAGING MACHINES
SUPPLIERS OF LABORATORY EQUIPMENT

APPENDIX – A:
01. PLANT ECONOMICS
02. LAND & BUILDING
03. PLANT AND MACHINERY
04. OTHER FIXED ASSESTS
05. FIXED CAPITAL
06. RAW MATERIAL
07. SALARY AND WAGES
08. UTILITIES AND OVERHEADS
09. TOTAL WORKING CAPITAL
10. TOTAL CAPITAL INVESTMENT
11. COST OF PRODUCTION
12. TURN OVER/ANNUM
13. BREAK EVEN POINT
14. RESOURCES FOR FINANCE
15. INSTALMENT PAYABLE IN 5 YEARS
16. DEPRECIATION CHART FOR 5 YEARS
17. PROFIT ANALYSIS FOR 5 YEARS
18. PROJECTED BALANCE SHEET FOR (5 YEARS)

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 COST ESTIMATION

Plant Capacity 500 KG/Day

Land & Building (1000 sq.mt.) Rs. 46 Lac
Plant & Machinery Rs. 18 Lac
Working Capital for 1 Month Rs. 20 Lac
Total Capital Investment Rs. 90 Lac
Rate of Return 39%
Break Even Point 62%

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