A TECHNICAL REPORT ON

STUDENT INDUSTRIAL WORK EXPERIENCE SCHEME (SIWES)

UNDERTAKEN AT

KANAXO CHEM. IND. LTD.

BY

EGWUATU BLESSING

MATRIC NO: FOS/19/20/260669

SUBMITTED TO THE DEPARTMENT OF CHEMISTRY, FACULTY OF SCIENCE,DELTA

STATE UNIVERSITY ABRAKA, DELTA STATE

IN PARTIAL FUFILMENT OF THE REQUIREMENTS FOR THE AWARD OF

BACHELOR OF SCIENCE (B.Sc) DEGREE IN INDUSTRIAL CHEMISTRY.

JANUARY 2022
1
 Abstract

Over the years, there has been a great need for students to be

equipped with a practical understanding of their field of study. This

has poised a major problem for students since it has been very

difficult for them to really gain a comprehension of the practical

aspect of their course of study. The SIWES program has been very

key for students as it has helped them bridge the gap between the

theoretical aspect of their course and the practical aspect of it.

Like every other industry under the industrial chemical processing

industry, the job of the paint manufacturing industry involves taking

raw materials and facilitates a chemical reaction to convert the raw

materials into consumable goods.

This report contains details that explains the paint manufacturing

process, the raw materials used, different paint products etc.

Acknowledgement

First of all, I want to thank God almighty for this opportunity and for

granting me the grace to successfully complete this program.

2
I am extremely grateful to my industry based supervisor and all the

staffs of Kanaxol Chemical Industries Limited for their love and

devotion to teaching me throughout the period of my program.

I also appreciate my institution based supervisor in the person of

PROF. ASIAGWU AUGUSTINE from Delta state University for

his immense contribution, understanding and supervision during the

period of attachment

Lastly, I want to appreciate my parents MR. AND MRS.

EGWUATU for their continuous love and support.

Table of Content
3
1. Title Page………………………………………………….1

2. Abstract……………………………………………………2

3. Acknowledgement ……………………………………..…3

4. Introduction ……………………………………………….5

5. Safety Equipment…………………………………………6

6. Introduction to the Painting Industry……………………8

7. Raw Materials……………………………………………..10

8. Process in the Production of Emulsion Paint…………….23

9. Summary and Conclusions………………………………..28

10.Recommendations…………………………………………29

11.References…………………………………………………29

Chapter One – Introduction

About Kanaxol Chemical Industry Ltd.

4
This report is based on a six months industrial training done at

KANAXOL CHEMICAL INDUSTRY LTD. Located at NO. 15

Umuebu Road, Obiaruku, Delta State. The industrial training as

organized by the federal government through student’ industrial

work experience scheme (SIWES) is aimed at exposing students to

their field of study in order to acquire some skills in the labour

market and also put in practice, the practical aspect of their courses of

study. Thus justifying the degree given to them at the end of their stay

in school.

The aim of Kanaxol Chemical industry ltd. is to carry on the business

of manufacturing of chemical, production of paints, sales, processing,

packaging, importation, exportation, buying and distribution of all

kinds of industrial chemicals. They also deal on all kinds of paint,

royal grand texture, royal silk emulsion, royal matt. Texture, gloss

paint, emulsion paint, texcote paints, paint products used in the

production of paints for homes and industrial

Chapter Two - Safety Equipment

5
 Safety is a state in which hazards and conditions leading to physical,

psychological and material harm are controlled in order to preserve

the health and well-being of individuals. It is important that the health

and safety of workers be considered a priority in our industry. The

company of my IT placement demanded a strict adherence to their

safety policies. One of such policies was the compulsory use of

personal protective equipment (PPE). Prior to my resumption the

company provided me with a PPE kit which contained the following:

 Nosemask: This is used for protection against dust and other harmful

chemicals

 Overall: This is a protective covering for body protection

 Hand Gloves: Since a lot of works are done with the hand, hand

gloves are very important for protecting the hand and skin

6
 Safety Shoes: They protect the feet against strong and harmful

chemicals like Ammonia

7
 Chapter Three – Introduction to Painting Industry

A paint is essentially a coating or covering material applied on metallic or non-

metallic surfaces for decorative or protective purposes.

Most commonly they may be a protective as well as decorative finish.

Paint is used to decorate, protect and prolong the life of natural and synthetic

materials, and acts as a barrier against environmental conditions.

Paints may be broadly classified into Decorative paints, applied on site to decorate

and protect buildings and other objects, and Industrial coatings which are applied

in factories to finish manufactured goods such as cars.

The Paint Industry in Nigeria

The Nigerian paint industry has done fairly well since its inception even in the face

of unflinching obstacles. With this article info guide provides a brief summary of

the prospects, challenges, and a general overview of the Nigerian paint industry.

The nature and overview of the Nigerian paint industry

Paint manufacturing companies have been existing in Nigeria as early as the

nineteen sixties. Some of them operated as subsidiaries of foreign companies until

indigenous companies completely bought over their shares.

8
The industry has witnessed technological advancements in the methods of

production as a result of stiff competition within the industry as every paint

producer is forced to put in their best to ensure that the remain relevant in the

market.

The Nigerian paints industry operates in three different tiers which are determined

by product quality, company reputation and a large customer base. The first tier

consists of major player and producers of top quality paints like Dulux paints,

Berger paints, Meyer paints, IPWA, CAP Plc and premium paints.

They control the industry to a large extent and have been existing for decades as

importers of paint products but began to produce locally as the demand increased.

These key players actually laid the foundation of the indigenous paint industry in

Nigeria and have remained at the top by refusing to compromise on the quality of

their products.

The second tier consists of medium quality paint producers with a lesser control of

the market shares; they are mostly private owned companies that operate on a

smaller scale while the third tier consists of companies that produce basic quality

paint products they have a bigger market than the middle tier producers because,

their products are cheap and very affordable.

9
 Chapter Four – Raw Materials

The job of an industry involves majorly converting raw materials into finished

products for the good of man. The paint industry is not different in his job

description as it also involves converting certain raw materials into a finished

product (paint). It is important that we study this raw materials used in order to

fully grasp the paint production process. Below are the major raw materials used in

the manufacture of paint:

 pigment(s) - prime pigments to impart colour and opacity

 binder (resin) - a polymer, often referred to as resin, forming a matrix to hold the

pigment in place

 extender - larger pigment particles added to improve adhesion, strengthen the film

and save binder

 solvent (sometimes called a thinner) - either an organic solvent or water is used to

reduce the viscosity of the paint for better application. Water-borne paints are

replacing some paints that use volatile organic compounds such as the

hydrocarbons which are harmful to the atmosphere.

 additives - used to modify the properties of the liquid paint or dry film

10
 The binder (resin) and solvent together are sometimes known as the vehicle. The

binder may be dissolved as a solution or carried as a dispersion of microscopically

small particles in a liquid.

Depending on the type of paint and intended use, additives may include:

 dispersants - to separate and stabilise pigment particles

 silicones - to improve weather resistance

 thixotropic agents - to give paints a jelly-like consistency that breaks down to a

liquid when stirred or when a brush is dipped into it

 driers - to accelerate drying time

 anti-settling agents - to prevent pigment settling

 bactericides - to preserve water based paints in the can

 fungicides and algaecides - to protect exterior paint films against disfigurement

from moulds, algae and lichen

Paints are formulated according to their proposed use - primer, undercoat, special

finishes (matt, gloss, heat resistance, anti-corrosion, abrasion resistance). The

pigment powder is broken down into individual particles which are coated by and

dispersed in the binder (resin) - known as 'wetting out'. Solvent is then added to

give the required consistency. Each batch of ingredients is thoroughly mixed in

large, stirred containers with the required additives (Figure below). Amounts

ranging up to 40 000 dm3 of paint may be made in a single batch.

11
  

This unit discusses the most commonly used binders followed by the pigments.

Binders in paints

The three most important binders (resins) used in modern paints are:

 acrylic polymers (resins)

 alkyd polymers (resins)

 epoxy polymers (resins)

Acrylic polymers (resins)

The binder in many emulsion paints is based on homopolymers or co-polymers of

ethenyl ethanoate (vinyl acetate) and a propenoate (acrylic) ester.

12
Ethenyl ethanoate is manufactured by passing a mixture of ethanoic acid vapour,

ethene and oxygen over heated palladium(ll) and copper(ll) chlorides:

Ethenyl ethanoate and an acrylic ester (for example, methyl 2-methylpropenoate)

are then co-polymerized to form a random array, in which these groups link into a

linear chain:

Other acrylic esters used as co-monomers with ethenyl ethanoate are ethyl

propenoate, butyl propenoates, or a co-polymer of butyl propenoate and methyl 2-

methylpropenoate.

The polymers used in these paints are carried in water (water-borne emulsion

paints) which as described above are much better for the environment than paints

in which the binders are in organic solvents.

  
13
Emulsion paints are so-called as they are made by a process known as emulsion

polymerization, in which the liquid monomers to be polymerized are first dispersed

in water, as an emulsion. The polymers produced by this process typically have

relative molecular masses of 500 000 - 1 000 000. As such they are useful only as

dispersions since they would be extremely viscous if they were carried in solution

and this would make them unusable.

Graph showing relationship between relative molecular

mass and viscosity for solution and dispersion polymers.

Acrylic resins may also be used in industrial paints, either as water-borne emulsion

paints or as solvent-borne paints. Solvent-borne industrial paints can have a tough

protective finish and are widely used in industry as topcoats, for example on car

bodies. The paint frequently comes as two components which are mixed together

just before use: the main paint portion typically consists of an acrylic resin

produced by the polymerization of a propenoate ester formed from a polyhydric

14
alcohol (diols and triols). The resulting polyester has numerous hydroxyl groups (-

OH) pendant from the polymer backbone. The hydroxyl groups react with the other

compound often consisting of a polymeric isocyanate such as a trimer of 1,6-

diisocyanatohexane (hexamethylene diisocyanate):

Such a compound is known as a crosslinker for it produces, on reaction with the

resin, a three-dimensional structure similar to the polyurethane formed from a

polyol and an isocyanate.

When these two components are mixed together, a chemical reaction takes place

between the hydroxyl groups on the polymer (acrylic resin) and the isocyanate

groups on the cross linker:

15
This reaction proceeds relatively slowly at room temperature, allowing enough

time for the paint to be applied, after which the solvent thinner evaporates and the

painted item is placed in an oven to accelerate the chemical reaction. This greatly

increases the molecular mass of the polymer causing it to become a three-

dimensional molecule and form a hard film, resistant to chemicals.

Alkyd polymers (resins)

Decorative gloss paints typically contain alkyd polymers (resins). A typical resin is

that produced from a polyol such as propane-1,2,3-triol (glycerol) with a dibasic

acid such as benzene-1,2-dicarboxylic (phthalic) anhydride and a drying oil

(linseed or soybean oil). On being heated together, ester linkages are formed, and

water is a by-product. The name alkyd is derived from alcohol and anhydride.

The first step in making the alkyd polymer is the reaction between the triol and the

drying oil to produce a monoglyceride. For example:

16
The monoglyceride then reacts with the anhydride to form the alkyd polymer

(resin):

The alkyd resins, which generally have relative molecular masses in the range of

10 000 - 50 000, are usually carried in organic solvents (solvent-borne paints).

17
Turpentine extracted from trees was used in the past as the solvent, but this has

been replaced by solvents from petrochemical feedstock, such as 'white spirit'

which is a mixture of aliphatic and alicyclic hydrocarbons.

Once the alkyd resin is applied, the pendant oil drying groups react with oxygen in

the air to form a cross-linked, hard thermoset coating, with a high molecular mass.

Epoxy polymers (resins)

Epoxy resins are often used as the binder in industrial coatings (primers). They

give the paint excellent adhesion together with high resistance to chemicals

(corrosion), and physical resistance necessary, for example, on ships and chemical

storage tanks.

The epoxy resins are made from 1-chloro-2,3-epoxypropane (produced from 3-

chloropropene) and substituted phenols, such as bisphenol A:

The value of n can be controlled to give a range of resins varying from viscous

liquids to solids with high melting points. Epoxy resins can be carried in solvents

such as aromatic hydrocarbons, alcohols, ketones and esters (solvent-borne paints)

18
or as dispersions in water (water-borne paints) as true emulsions. They are not

normally used in topcoats for outdoors because they are susceptible to UV

degradation, but they make excellent interior coatings and exterior primers.

Epoxy resins are also used as adhesives (e.g. Araldite) and electrical insulators.

Pigments used in paints

Pigments give colour and opacity to paints. Amongst the organic pigments,

particularly important are azo-, phthalocyanine and anthraquinone derivatives.

The most common inorganic pigment is white titanium dioxide (titanium(IV)

oxide) which provides over 70% of total pigments used (Unit 51). It has a high

refractive index and gives a 'gloss' to the paint. Another widely used inorganic

pigment is finely divided calcium carbonate. This has a low refractive index and is

used, together with titanium dioxide, to produce 'matt' paints. Other pigments

include iron oxides (black, yellow and red), zinc oxide and carbon black.

Powdered metals such as zinc and some metal compounds, for example zinc

phosphate, have corrosion inhibiting properties.

Paint drying

As the paint dries, a film is formed which adheres to the surface of the material to

which it is being applied.

19
 Emulsion paints dry by a physical process involving the evaporation of water

followed by coalescence of the polymer droplets and their subsequent integration

into a hard polymer matrix that acts as a binder for the pigment.

On applying gloss paints, the alkyd polymer cross-links by an oxidation reaction

with oxygen in the air once the solvent has largely evaporated. This reaction is

accelerated using salts of transition metals (for example, cobalt and manganese

naphthenates). The transition metal ion (with variable oxidation state) catalyses

cross linking of the polymer chains, producing a hard surface film to the paint.

Properties of an ideal paint

These vary greatly according to the particular end use. The requirements for an

automotive topcoat, for example, will be very different to those for a decorative

ceiling paint.

Some of the typical attributes required can include:

 ease of application

 good flow out of application marks (e.g. brush-marking)

 forming a continuous protective film

 high opacity

 quick drying

 corrosion resistance

20
 water resistance

 heat resistance

 colour stability (i.e. against visible and ultraviolet radiation)

 abrasion and scratch resistance

 durability

 flexibility

 easily cleaned

Application methods

Numerous methods are used including: brush, roller, dipping, flowcoating,

spraying, hot spraying, electrostatic spraying, airless spraying, electrodeposition,

powder coating, vacuum impregnation and immersion.

Environmental issues

Lead compounds are no longer used in decorative paints and automotive paints.

The quantity of lead compounds still being used in specialised industrial paints has

been greatly reduced and eventually alternatives will be found. This also applies to

chromates which, although they perform well and in the past have been extensively

used on motor vehicles, are very toxic.

21
 Because volatile hydrocarbons can lead to pollution in the troposphere, coatings

with lower organic solvent content are required. The routes to achieve this include:

 water-based polymers (emulsion paints)

 higher solids content polymers (using less solvent)

 powder coatings

Water-based gloss paints are now available but the initial gloss of the finish is

usually not as high as organic solvent based paints. The customer's choice is

between a high performance product and a more environmentally friendly one.

Intense research effort continues to improve these paints.

High solids paints (which are solvent-based) are now available but not without

compromises in cost and performance. The relative molecular masses of the

polymer resins are reduced to a maximum of ca 1000 compared to 5000 in

conventional paints. This allows the proportion of the polymer to be increased

from 20-30% to 40%, hence the term high solids. The main problem is the need to

maintain a low viscosity. As the amount of solids increases so does the viscosity,

reaching a point at which the paint cannot be applied properly. The lower

proportion of solvent tends to slow down the drying and film hardening process, so

changes are made to the structure of the polymer - increased branching tends to

reduce viscosity for the same molecular mass. The application of the paint is more

difficult. If applied by aerosol, the paint has to be under pressure. Sometimes the

22
 paint is applied hot. It is difficult to get as good a finish in appearance using a high

solids paint.

Powder coatings are used in particular for goods such as bicycles and white goods

(refrigerators, washing machines). The powder is made up of a resin (often an

epoxy resin), pigments, a catalyst to promote cross-linking when the powder is

heated, and additives. The powder is sprayed on to the article using an electrostatic

spray gun and is then heat cured to produce a hard coating. Recently acrylic

powder coatings have been introduced as clear-coats on car bodies. Although an

ideal solution for many applications, curing is achieved at high temperature in an

oven and is therefore not universally applicable (e.g. painting of wood and

plastics).

Chapter Five - Process in the Production of Emulsion Paint

Raw Materials Needed

1. Water actinide

2. Calgon

3. Silicate

4. Titanium oxide

5. Calcium carbonate

23
6. Genepor

7. Deformer

8. PVA

9. Formalin

10.Nitrosol

11.Ammonium solution

12.Coloured paste

Chemicals

The following are the chemicals used in the production of emulsion paint:

1. Water

2. Titherni (used only for the production of white paint)

3. Calcium carbonate (calcium)

4. Coloriute

5. PVA

6. Formalin

7. Nitro sol

8. Ammonia

9. Hydrosol

10.Marble dust

11.Acrydex

12.Geniple
24
13.K14

14.Barma cork

Functions of the Chemicals

1. Water: water is used to mix all the chemicals together. It must not be a hot water.

You can use any type of clean and neat water with normal water temperature.

However, soft water is preferable to cold water as it helps to mix the paints more

easily

2. Titherni: It is whitening chemical in powder form. You can always get it where

they are selling paint chemicals, or rather industrial chemicals. It ensures that

your paint is shinning and not dull. Though it can be used in other colours of

paint but it’s usually advisable to use it for white paint

3. Calcium Carbonate: This chemical is also in powder form. It is packaged in bags.

It is of two types; dolomite and calcite. Both are good but dolomite is

recommended if you are producing white paint and calcite is better off in off

white (dirty white) paint

4. Colourite: This involves the ability to some colours to get a desired result.

Yellow (popularly called cream by painters), red, black, blue and green are the

basic colours that all other colours are derived from. All other colours are gotten

from a combination of any of these five colours

5. P.V.A.: When used properly, it prevents the painted surface from being dusty

after paint has been applied.

25
6. Formaline: It does the function of preservative

7. Nitrosol: It helps to hold the paint together i.e it is a thickener and when used

correctly, makes the paint more durable on the wall

8. Ammonia: This is also used to make the paint more durable and serves as a

preservative also

9. Marble Dust: It is generally used in the production of textcoat paints. It is of two

types; rough and smooth. The preference is determined by what you want to

achieve. If you want sandy textcote you use rough. However a combination of

both will yield a better result

10.Hydrosol: This is the chemical that integrates the colours and brings out the best

in them. It is used to correct dullness in paint

11.Acrydex: This is used as a thickener. It holds seemingly watery paints together

12.Geniple: This one just does the function of giving the painter a scintillating

perfume as he does his job

13.K14: It is also a preservative

14.Bama Cork: It performs the same function as nitrosol. If you use bama cork you

do not need to use nitroso

Methods

Emulsions are those ordinary paints that are not roughened with sand-like objects.

Below are the procedures in producing an emulsion paint

26
Procedures

Step 1

Mix Calcium with water; for one bucket production (hence we shall be referring to

bucket of paint i.e. normal litres of paint as drum). Pour water in the bucket up to

half. You can always increase the volume of water at any stage if necessary. Add

less than half bag of calcium (add until the mixture rises to about 17 litres ini the

bucket). By now the drum should be only about quarter empty.

Note: If you are producing white paint, you will mix titherni in water before adding

calcium – spoons of tithermi are enough. Mix very well.

Step 2

Add your colour. It is assumed that by now you must have diluted the colours as

required with water if they are oxides. Now put colour in small rations and keep

turning until you get your desired result. Supposed you added more yellow than

you need, you can correct it by adding more calcium (but not after this stage). Bear

in mind that the colour may be deeper when wet and lighter when the paint is dried

Step 3

27
Add P.V.A. to the mixture. After turning add half glass cup of nitrosol. Nitrosol is

always in powdered form so you must dilute in small water before you add to your

mixture. Next add formalin and ammonia and then hydrosol. Turn very well at any

addition of a new chemical

Final Step

When you have completed the above steps, make sure you turn the above mixture

very well. Add thickener (nitrosol) to the mixture and turn, add small quantity

until you get the thickness you desire

Chapter Seven – Summary and Conclusions

The paint manufacturing industry is an industry with so much potential and

also an exciting field for chemist.

The SIWES scheme has even presented me an opportunity to gain more

practical experience as a chemist. I have been equipped through the six

months to face the challenges faced by industrial chemist in world outside the

four walls of the classroom.

After the completion of my degree, I hope continue exploring the paint

manufacturing industry

Recommendation

28
 Considering the importance of this program, I strongly recommend that SIWES

remain a key factor in the curriculum of learning for all students.

I also recommend that more funds should be made available by Government to aid

paint industries in the country, thereby ensuring that they are able to meet global

standards in paint production.

Reference

 R. Norris Shreve, 1956, the chemical process industries, second edition, Mc Graw-

Hill company, Tokyo

 Rodger Talbert, 2008, Paints Technology Handbook, Taylor & Francis group,

Boca Ration & New York & London

 Google

 Wikipedia

29