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PIPOC 2007, Malaysia. Detergent Complex Based on Palm Stearin. 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 - PowerPoint PPT Presentation
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PIPOC 2007, MalaysiaPIPOC 2007, Malaysia
August 29, 2007August 29, 2007
Detergent Complex Detergent Complex
Based on Based on Palm StearinPalm Stearin
AgendaAgenda
About Trivedi GroupAbout Trivedi Group
Basic Requirements and Process ChemistryBasic Requirements and Process Chemistry
Products and FormulationsProducts and Formulations
Cost StructureCost Structure
SummarySummary
Global Changes call for Action Now!Global Changes call for Action Now!
Hurricanes and natural disastersHurricanes and natural disasters
Global warmingGlobal warming
Fossil vs. RenewableFossil vs. Renewable
Food vs. FuelFood vs. Fuel
TRIVEDI GROUP(Since 1986)
TECHNOLOGY&
ENGINEERING
SURFACTANTMANUFACTURING
PROJECT SERVICES
CHEMICALTRADING
Organization ChartOrganization Chart
TECHNOLOGY&
ENGINEERING
Chemithon Engineers Pvt Ltd
Sulfonation of alkylates
Environmental Systems
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
CustomBlends
Amphoterics
Nonionics
Cationics
Specialities
SURFACTANT MANUFACTURING
CHEMICAL TRADINGCHEMICAL TRADING
Palm Derivatives Alcohols
Detergent Alkylates
Surfactants
EthoxylatesZeolites
Specialities
Soap Noodles
PROJECT SERVICES
Business Promotion (NRDC)
Market Studies
Project Appraisal (IFC)
Feasibility Studies
Project Co-ordination
Energy Audit
CPO with 5% FFA (1000 MT)
Extraction
Refining
Fractionation
RBD Palm Stearin
(185 MT)
RBD Palmolein (745 MT)
Vitamin E (1.5 – 2.0 MT)
PFAD (65 MT)
Requirements for Palm Plantation Based Requirements for Palm Plantation Based on Bio-Refineryon Bio-Refinery
• Minimum Area: 60.000 HectaresMinimum Area: 60.000 Hectares
• FFB FFB
CPO: 1000 TPDCPO: 1000 TPD
PKO: 100 TPD PKO: 100 TPD
Mass Balance
A detergent based complex of Palm Stearin creates A detergent based complex of Palm Stearin creates tangible advantagestangible advantages
• Sustainable value creation from Palm StearinSustainable value creation from Palm Stearin
• Independent revenue platformsIndependent revenue platforms
Pharmaceuticals (Glycerine)Pharmaceuticals (Glycerine)
Fuel (Biodiesel – C18 rich)Fuel (Biodiesel – C18 rich)
Alkylates (C12-14, C16)Alkylates (C12-14, C16)
Detergents and Home & Personal care productsDetergents and Home & Personal care products
• Based on renewal resourceBased on renewal resource
• Environmentally friendly project Environmentally friendly project
RBD PS (185 MT)
Transesterification
Distillation
Hydrogenation
Sulfonation
Blending / Drying
C1214 Ester (2.5 MT)C16 Ester (110 MT) C18 Ester (71 MT)
Amidation / AmidesEthoxylation / ME Ethoxylates
Glycerine (18 MT)
HPC Products Detergents (725 MT)
MES (145 MT)
Typical mass balance highlighting various steps Typical mass balance highlighting various steps in the processin the process
GlycerolTriglyceride + Alcohol Esters +
CH2-OH
CH2-OH
CH2-OH
CH2-OOC-R1
CH -OOC-R2
CH2-OOC-R3
+ 3R’OH
R1-COO-R’
R2-COO- R’
R3-COO- R’
+Catalyst
@ 60 - 70˚C
Step 1: Transesterification step converts a triglyceride Step 1: Transesterification step converts a triglyceride to esters and glycerolto esters and glycerol
Step 2: Distillation of fractions is done via a Step 2: Distillation of fractions is done via a three stage conversion columnthree stage conversion column
C1214 C16 C18
Step 3: A continuous fixed bed column is used for Step 3: A continuous fixed bed column is used for hydrogenation stephydrogenation step
SULFONATION
DIGESTION
BLEACHING
NEUTRALIZATION
DRYING
METHYL ESTER1V0.1
METHYL ESTER SULFONATES (MES)(>85% ACTIVE AND <5% DISALT)
MeOH RECOVERY
Step 4: Sulfonation of esters yields methyl ester Step 4: Sulfonation of esters yields methyl ester sulfonates (MES)sulfonates (MES)
kg
MES 843
Di-salt 49
Sodium methyl sulfate 50
Unsulfonated 20
Na2SO4 10
Moisture 26
Hydrogen Peroxide 1
Methanol 1
Total 1,000
Methanol Recovery
C16 MES(MW 372) has the typical mass balance as C16 MES(MW 372) has the typical mass balance as shown in the flowsheetshown in the flowsheet
SO3 gas generation
Sulfonation
MESA digestion
MESA bleaching
Neutralization
Drying
MES
Sulfur (95)
50% Caustic (242)
50% H2O2 (35.6)
Methanol Makeup (40)
C16 methyl ester (662)
Distillation (226)
STILL AWAKE???
Palm KernelC8-c18 Coconut
C12-C14
Palm StearinC16-C18
SoyaC18 Tallow
C16-C18
Different forms of MES dried and stripped can be Different forms of MES dried and stripped can be obtained as final productobtained as final product
Some pictures of the Huish PlantSome pictures of the Huish Plant
Flowsheet for Detergent Powder PlantFlowsheet for Detergent Powder Plant
%%
LASLAS 1212
MESMES 88
Sodium CarbonateSodium Carbonate 2020
Sodium SilicateSodium Silicate 1010
STPPSTPP 1515
Sodium SulfateSodium Sulfate 3030
MoistureMoisture 55
TotalTotal 100100
Typical Components in a Detergent FormulationTypical Components in a Detergent Formulation
Huish products are used in a variety of products both powder and liquid
%%
MESMES 66
AESAES 99
GlycerineGlycerine 33
GermicideGermicide 0.50.5
Viscosity ModifiedViscosity Modified 22
WaterWater 79.579.5
TotalTotal 100100
Typical Components in a Soft Soap FormulationTypical Components in a Soft Soap Formulation
Different Products containing MES in their formulationDifferent Products containing MES in their formulation
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
Typical capital expenditure for a palm based detergent Typical capital expenditure for a palm based detergent complex is about $ 50 millioncomplex is about $ 50 million
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 costs for esterification, distillation Estimated costs for esterification, distillation and MES productionand MES production
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
Recommended sale price1200 1200 1200
Estimated production costs for soft soap Estimated production costs for soft soap and detergentsand detergents
• Integrated complex with optimum value additionIntegrated complex with optimum value addition
• Sustainability using renewable raw materialsSustainability using renewable raw materials
• MES in dry flakes form - convenience of useMES in dry flakes form - convenience of use
• Biodiesel EN 14214 compliant (summer grade)Biodiesel EN 14214 compliant (summer grade)
• Independent revenue platformsIndependent revenue platforms
Project provides multiple advantages across Project provides multiple advantages across different platformsdifferent platforms
Thank You!Thank You!
Address: SHIV ANAND-A 1ST FLOOR, 372/374 S. V. ROAD, GOREAGAON (W) MUMBAI - 400 104 INDIAWebsite: www.trivedigroup.comEmail: [email protected]
“ The best way to predict the future is to create it”