Chelated Zinc 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 chelated zinc 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 chelated zinc 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 chelated zinc industry.

About Chelated Zinc

Chelated zinc refers to a form of zinc supplement where zinc is bound to a chelating agent, which enhances its absorption in the body. This process allows for better bioavailability compared to non-chelated forms, making it particularly beneficial for individuals with zinc deficiencies. Common types of chelated zinc include zinc picolinate and zinc gluconate, both known for their effectiveness in supporting immune function, protein synthesis, and wound healing. Today, chelated zinc is widely used not only as a dietary supplement to address deficiencies but also in various applications such as skincare products, cold remedies, and agricultural fertilisers to enhance crop health. The knowledge of zinc dates to ancient civilisations, with references found in texts like the Charaka Samhita around 300-500 AD. Zinc was not widely produced until the 12th century in India. By the 18th century, European scientists started isolating and studying zinc, leading to its recognition as an essential nutrient.

Properties of Chelated Zinc

Chelated zinc appears as a white to off-white, odourless powder with low hygroscopicity, meaning it resists moisture absorption and maintains a free-flowing texture ideal for supplements. Its solubility in water is high, ranging from 10 mg/mL to over 100 mg/mL, depending on the chelating agent used. Chemically, the molecular weight of zinc varies based on the chelating agent; for instance, zinc picolinate has a molecular weight of approximately 165.4 g/mol. Chelated zinc complexes exhibit high stability constants (log K values often above 10), indicating strong binding between zinc and the chelating agent. Additionally, these forms can remain stable across a wide pH range (approximately pH 4 to pH 8), enhancing their absorption in the gastrointestinal tract.

Manufacturing Process of Chelated Zinc

The production process of chelated zinc begins with raw material preparation, where inorganic zinc sources, such as zinc oxide or zinc sulfate, are gathered alongside appropriate chelating agents like EDTA or HEIDA. Next, in the mixing stage, these materials are combined in a mixing vessel. The mixture is then subjected to a first solid-state reaction by heating it to a temperature between 30-80 °C while maintaining stirring for 8-20 hours to initiate the reaction. After this, the mixture is allowed to cool to room temperature under controlled conditions.

Following cooling, a second solid-state reaction occurs, where the temperature is adjusted to between 50-200 °C, and the reactants are stirred for another 8-20 hours to ensure complete reaction. Once this step is finished, the product undergoes final cooling and pulverisation to achieve the desired particle size. Quality control tests are then performed to assess the purity, solubility, and stability of the chelated zinc product. Finally, the product is packaged for distribution and sale.

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Synthesis of Chelated Zinc

Below is the process involved in making of chelated zinc:

1. Preparation of Zinc Salt Solution:

ZnO (s) + 2HCl (aq) → ZnCl₂ (aq) + H₂O (l)

Zinc oxide (ZnO) or another zinc compound is dissolved in an appropriate acid, such as hydrochloric acid (HCl), to produce a soluble zinc salt like zinc chloride (ZnCl₂). Alternatively, zinc sulfate (ZnSO₄) can be prepared using sulfuric acid (H₂SO₄):

ZnO (s) + H₂SO₄ (aq) → ZnSO₄ (aq) + H₂O (l)

2. Chelation Reaction:

Zn²⁺ (aq) + Ligand (L) → [Zn-L] (aq)

In this step, the zinc ions (Zn²⁺) react with an organic ligand (L) to form a chelated complex. Common ligands include amino acids (e.g., glycine) or EDTA. For example:

ZnCl₂ (aq) + 2NH₂CH₂COOH (aq) → [Zn(NH₂CH₂COO)₂] (aq) + 2HCl (aq)

Here, zinc chloride reacts with glycine (NH₂CH₂COOH) to produce zinc glycinate chelate.

3. Purification and Drying:

The chelated zinc solution is purified to remove unreacted ligands or byproducts. The final product is then dried to obtain chelated zinc in powder or granule form.

Industrial Considerations

Chelated zinc production involves controlling the pH, reaction temperature, and molar ratios to ensure complete chelation and stability of the product. Common applications include:

• Fertiliser additives: Enhances zinc uptake in plants.
• Animal feed supplements: Improves bioavailability of zinc for livestock.
• Dietary supplements: Provides a stable and absorbable form of zinc for human consumption.

Applications and Drivers of Chelated Zinc

The chelated zinc market is driven by its significant applications in agriculture and healthcare, which addresses critical nutrient deficiencies. In agriculture, it is particularly effective in enhancing crop yields; for example, studies indicate that the foliar application of chelated zinc at 0.3% resulted in paddy yields of 4.50 t/ha, comparable to mineral zinc's 4.67 t/ha. This is crucial as approximately 37% of Indian soils are affected by zinc deficiency, a figure that has risen by 2% since 2020. Chelated zinc helps improve nutrient uptake in crops like wheat, rice, and maize, which are vital for food security. In healthcare, chelated zinc supplements are essential for boosting immune function and addressing deficiencies in vulnerable populations. Government initiatives promoting sustainable agriculture and awareness of micronutrient importance further drives demand for chelated zinc products.

Key Features of the Chelated Zinc Production Cost Report:

This production cost analysis report by Expert Market Research scrutinises the chelated zinc 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 chelated zinc 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 chelated zinc production plant:

• Market Dynamics and Trends: This section analyses the prevailing market conditions, growth drivers, and trends impacting the chelated zinc industry. It offers a thorough examination of demand fluctuations and projections.
• Geographic Analysis: Detailed insights into the major regions active in chelated zinc production and consumption, highlighting regional market specifics and growth potential.
• Key Industry Players: Profiles of leading manufacturers in the chelated zinc 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 chelated zinc 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 chelated zinc, 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 chelated zinc 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 chelated zinc production and strategies to mitigate them.

Key Questions Addressed:

• What are the detailed unit operations for chelated zinc 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 chelated zinc plant?
• How can profitability be maximised in the chelated zinc market?
• What pricing strategy should be adopted for chelated zinc to remain competitive?

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