detergent complex based on palm stearin - chemithon based on pal… · feasibility studies ......
TRANSCRIPT
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
PROJECTSERVICES
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
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 Bioon Bio--RefineryRefinery
•• 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 Fuel (Biodiesel –– C18 rich)C18 rich)
Alkylates (C12Alkylates (C12--14, C16)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)
kgMES 843Di-salt 49Sodium methyl sulfate 50Unsulfonated 20Na2SO4 10Moisture 26Hydrogen Peroxide 1Methanol 1Total 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)
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
100100TotalTotal
55MoistureMoisture
3030Sodium SulfateSodium Sulfate
1515STPPSTPP
1010Sodium SilicateSodium Silicate
2020Sodium CarbonateSodium Carbonate
88MESMES
1212LASLAS
%%
Typical Components in a Detergent FormulationTypical Components in a Detergent Formulation
100100TotalTotal79.579.5WaterWater
22Viscosity ModifiedViscosity Modified0.50.5GermicideGermicide33GlycerineGlycerine99AESAES66MESMES%%
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
50.0Total CAPEX
8.0Detergents & HPC (30 KT/20 KTA)
13.0Sulfonation (40 KTA)
9.0Distillation (300 TPD) + Hydrogenation (180 TPD)
13.0Ester (300 TPD) + Glycerine (30 TPD)
7.0Infrastructure
USD (million)Estimate for a 300 TPD RBD PS
DETERGENT COMPLEX BASED ON PALM STEARIN
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
1050850700Recommended sale price
Basis: RBD PS @ USD 650 PMT
918768665Cost of Production/ Tonne2979Depreciation1576Financial Charges1174Overheads1466Operating Costs523742Utilities797704598Raw MaterialsMESDistillation+ H2Esterification
USD (miilion)
Estimated costs for esterification, distillation Estimated costs for esterification, distillation and MES productionand MES production
USD
1200
792
1511141242698
WithoutMES
Detergent
1200
724
1511141241631
WithMES
1200
794
1712232044678
Soft Soap
Recommended sale price
Cost of Production/ Tonne
DepreciationFinancial ChargesOverheadsOperating CostsUtilitiesRaw Materials
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 MES in dry flakes form -- convenience of useconvenience 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-A1ST FLOOR, 372/374S. V. ROAD, GOREAGAON (W)MUMBAI - 400 104INDIA
Website: www.trivedigroup.comEmail: [email protected]
“ The best way to predict the future is to create it”