Transcript Detergent Complex Based on Palm Stearin PIPOC 2007, Malaysia

Detergent Complex
Based on
Palm Stearin
PIPOC 2007, Malaysia
August 29, 2007
Agenda

About Trivedi Group

Basic Requirements and Process Chemistry

Products and Formulations

Cost Structure

Summary
Global Changes call for Action Now!
Hurricanes and natural disasters
Global warming
Fossil vs. Renewable
Food vs. Fuel
Organization Chart
TRIVEDI GROUP
(Since 1986)
TECHNOLOGY
&
ENGINEERING
SURFACTANT
MANUFACTURING
CHEMICAL
TRADING
PROJECT
SERVICES
Chemithon Engineers Pvt Ltd
 Sulfonation of alkylates
 Environmental Systems
TECHNOLOGY
&
ENGINEERING
Trivedi Industrial Research & Associates
 Oil Seeds Plantation
 Edible Oil/ Solvent Extraction
 Esterification & Fractionation Processes
 Detergent and HPC production
 Ethoxylation & Hydrogenation
 Glycerin Purification
 Pilot Plant Studies
Anionics
Amphoterics
Cationics
SURFACTANT
MANUFACTURING
Custom
Blends
Nonionics
Specialities
CHEMICAL TRADING
Palm Derivatives
Alcohols
Soap
Noodles
Surfactants
Specialities
Zeolites
Detergent
Alkylates
Ethoxylates
 Business Promotion
(NRDC)
 Market Studies
PROJECT
SERVICES
 Project Appraisal
(IFC)
 Feasibility Studies
 Project Co-ordination
 Energy Audit
Requirements for Palm Plantation Based
on Bio-Refinery
• Minimum Area: 60.000 Hectares
• FFB
Mass Balance
CPO with 5% FFA (1000 MT)
 CPO: 1000 TPD
 PKO: 100 TPD
Extraction
Refining
Vitamin E (1.5 – 2.0 MT)
PFAD (65 MT)
Fractionation
RBD Palm
Stearin
(185 MT)
RBD
Palmolein
(745 MT)
A detergent based complex of Palm Stearin creates
tangible advantages
•
Sustainable value creation from Palm Stearin
•
Independent revenue platforms
 Pharmaceuticals (Glycerine)
 Fuel (Biodiesel – C18 rich)
 Alkylates (C12-14, C16)
 Detergents and Home & Personal care products
•
Based on renewal resource
•
Environmentally friendly project
Typical mass balance highlighting various steps
in the process
RBD PS (185 MT)
Transesterification
Glycerine (18 MT)
C1214 Ester (2.5 MT)
C16 Ester (110 MT)
C18 Ester (71 MT)
Distillation
Hydrogenation
Amidation
/ Amides
Ethoxylation / ME Ethoxylates
Sulfonation
MES (145 MT)
Blending / Drying
HPC Products
Detergents (725 MT)
Step 1: Transesterification step converts a triglyceride
to esters and glycerol
CH2-OOC-R1
CH2-OH
R1-COO-R’
Catalyst
CH -OOC-R2
+ 3R’OH
CH2-OH
+
R3-COO- R’
CH2-OOC-R3
Triglyceride
@ 60 - 70˚C
R2-COO- R’
+ Alcohol
Esters
CH2-OH
+
Glycerol
Step 2: Distillation of fractions is done via a
three stage conversion column
C1214
C16
C18
Step 3: A continuous fixed bed column is used for
hydrogenation step
Step 4: Sulfonation of esters yields methyl ester
sulfonates (MES)
METHYL ESTER
1V0.1
SULFONATION
DIGESTION
BLEACHING
NEUTRALIZATION
DRYING
METHYL ESTER SULFONATES (MES)
(>85% ACTIVE AND <5% DISALT)
MeOH
RECOVERY
C16 MES(MW 372) has the typical mass balance as
shown in the flowsheet
Sulfur (95)
SO3 gas generation
C16 methyl ester (662)
Sulfonation
Methanol Recovery
MES
MESA digestion
Methanol Makeup (40)
50% H2O2 (35.6)
MESA bleaching
Distillation (226)
Neutralization
Drying
MES
843
Di-salt
49
Sodium methyl sulfate
50
Unsulfonated
20
Na2SO4
10
Moisture
26
Hydrogen Peroxide
1
Methanol
1
Total
50% Caustic (242)
kg
1,000
STILL AWAKE???
Different forms of MES dried and stripped can be
obtained as final product
Palm Kernel
C8-c18
Soya
C18
Coconut
C12-C14
Palm Stearin
C16-C18
Tallow
C16-C18
Some pictures of the Huish Plant
Flowsheet for Detergent Powder Plant
Typical Components in a Detergent Formulation
%
LAS
12
MES
8
Sodium Carbonate
20
Sodium Silicate
10
STPP
15
Sodium Sulfate
30
Moisture
5
Total
100
Huish products are used in a variety
of products both powder and liquid
Typical Components in a Soft Soap Formulation
%
MES
6
AES
9
Glycerine
3
Germicide
0.5
Viscosity Modified
2
Water
79.5
Total
100
Different Products containing MES in their formulation
Typical capital expenditure for a palm based detergent
complex is about $ 50 million
DETERGENT COMPLEX BASED ON PALM STEARIN
Estimate for a 300 TPD RBD PS
USD (million)
Infrastructure
7.0
Ester (300 TPD) + Glycerine (30 TPD)
13.0
Distillation (300 TPD) + Hydrogenation (180 TPD)
9.0
Sulfonation (40 KTA)
13.0
Detergents & HPC (30 KT/20 KTA)
8.0
Total CAPEX
50.0
Estimated costs for esterification, distillation
and MES production
USD (miilion)
Esterification
Distillation+ H2
MES
Raw Materials
598
704
797
Utilities
42
37
52
Operating Costs
6
6
14
Overheads
4
7
11
Financial Charges
6
7
15
Depreciation
9
7
29
Cost of Production/ Tonne
665
768
918
Recommended sale price
700
850
1050
Basis: RBD PS @ USD 650 PMT
Estimated production costs for soft soap
and detergents
USD
Soft Soap
Detergent
Without
MES
With
MES
Raw Materials
678
698
631
Utilities
44
42
41
Operating Costs
20
12
12
Overheads
23
14
14
Financial Charges
12
11
11
Depreciation
17
15
15
Cost of Production/ Tonne
794
792
724
1200
1200
1200
Recommended sale price
Project provides multiple advantages across
different platforms
•
Integrated complex with optimum value addition
•
Sustainability using renewable raw materials
•
MES in dry flakes form - convenience of use
•
Biodiesel EN 14214 compliant (summer grade)
•
Independent revenue platforms
“ The best way to predict the future is to create it”
Thank You!
Address: SHIV ANAND-A
1ST FLOOR, 372/374
S. V. ROAD, GOREAGAON (W)
MUMBAI - 400 104
INDIA
Website: www.trivedigroup.com
Email:
[email protected]