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PIPOC 2007, Malaysia August 29, 2007 Detergent Complex Based on Palm Stearin.

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Presentation on theme: "PIPOC 2007, Malaysia August 29, 2007 Detergent Complex Based on Palm Stearin."— Presentation transcript:

1 PIPOC 2007, Malaysia August 29, 2007 Detergent Complex Based on Palm Stearin

2 Agenda About Trivedi Group About Trivedi Group Basic Requirements and Process Chemistry Basic Requirements and Process Chemistry Products and Formulations Products and Formulations Cost Structure Cost Structure Summary Summary

3 Global Changes call for Action Now! Hurricanes and natural disasters Global warming Global warming Fossil vs. Renewable Fossil vs. Renewable Food vs. Fuel Food vs. Fuel

4 TRIVEDI GROUP (Since 1986) TECHNOLOGY & ENGINEERING SURFACTANT MANUFACTURING CHEMICAL TRADING PROJECT SERVICES Organization Chart

5 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

6 Anionics Custom Blends Amphoterics Nonionics Cationics Specialities SURFACTANT MANUFACTURING

7 CHEMICAL TRADING Palm DerivativesAlcohols Detergent Alkylates Surfactants EthoxylatesZeolites Specialities Soap Noodles

8 PROJECT SERVICES Business Promotion (NRDC) Market Studies Project Appraisal (IFC) Feasibility Studies Project Co-ordination Energy Audit

9 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 on Bio-Refinery Minimum Area: Hectares Minimum Area: Hectares FFB FFB CPO: 1000 TPD CPO: 1000 TPD PKO: 100 TPD PKO: 100 TPD Mass Balance

10 A detergent based complex of Palm Stearin creates tangible advantages Sustainable value creation from Palm Stearin Sustainable value creation from Palm Stearin Independent revenue platforms Independent 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 products Detergents and Home & Personal care products Based on renewal resource Based on renewal resource Environmentally friendly project Environmentally friendly project

11 RBD PS (185 MT) Transesterification Distillation Hydrogenation Sulfonation Blending / Drying C1214 Ester (2.5 MT) C16 Ester (110 MT) C18 Ester (71 MT) Amidation / Amides Ethoxylation / ME Ethoxylates Glycerine (18 MT) HPC ProductsDetergents (725 MT) MES (145 MT) Typical mass balance highlighting various steps in the process

12 GlycerolTriglyceride+AlcoholEsters+ CH 2 -OH CH 2 -OOC-R 1 CH -OOC-R 2 CH 2 -OOC-R 3 + 3ROH R 1 -COO-R R 2 -COO- R R 3 -COO- R ˚C Step 1: Transesterification step converts a triglyceride to esters and glycerol

13 Step 2: Distillation of fractions is done via a three stage conversion column C1214 C16C18

14 Step 3: A continuous fixed bed column is used for hydrogenation step

15 SULFONATION DIGESTION BLEACHING NEUTRALIZATION DRYING METHYL ESTER 1V 0.1 METHYL ESTER SULFONATES (MES) (>85% ACTIVE AND <5% DISALT) MeOH RECOVERY Step 4: Sulfonation of esters yields methyl ester sulfonates (MES)

16 kg MES843 Di-salt49 Sodium methyl sulfate50 Unsulfonated20 Na2SO410 Moisture26 Hydrogen Peroxide1 Methanol1 Total1,000 Methanol Recovery C16 MES(MW 372) has the typical mass balance as shown in the flowsheet SO3 gas generation Sulfonation MESA digestion MESA bleaching Neutralization Drying MES Sulfur (95) 50% Caustic (242) 50% H 2 O 2 (35.6) Methanol Makeup (40) C16 methyl ester (662) Distillation (226)

17 STILL AWAKE???

18 Palm Kernel C8-c18 Coconut C12-C14 Palm Stearin C16-C18 Soya C18 Tallow C16-C18 Different forms of MES dried and stripped can be obtained as final product

19 Some pictures of the Huish Plant

20 Flowsheet for Detergent Powder Plant

21 % LAS12 MES8 Sodium Carbonate 20 Sodium Silicate 10 STPP15 Sodium Sulfate 30 Moisture5 Total100 Typical Components in a Detergent Formulation

22 Huish products are used in a variety of products both powder and liquid

23 % MES6 AES9 Glycerine3 Germicide0.5 Viscosity Modified 2 Water79.5 Total100 Typical Components in a Soft Soap Formulation

24 Different Products containing MES in their formulation

25 DETERGENT COMPLEX BASED ON PALM STEARIN Estimate for a 300 TPD RBD PSUSD (million) Infrastructure7.0 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 CAPEX50.0 Typical capital expenditure for a palm based detergent complex is about $ 50 million

26 USD (miilion) EsterificationDistillation+ H2MES Raw Materials Utilities Operating Costs6614 Overheads4711 Financial Charges6715 Depreciation9729 Cost of Production/ Tonne Recommended sale price Basis: RBD USD 650 PMT Estimated costs for esterification, distillation and MES production

27 USD Soft SoapDetergent Without MES With MES Raw Materials Utilities Operating Costs2012 Overheads2314 Financial Charges1211 Depreciation1715 Cost of Production/ Tonne Recommended sale price 1200 Estimated production costs for soft soap and detergents

28 Integrated complex with optimum value addition Integrated complex with optimum value addition Sustainability using renewable raw materials Sustainability using renewable raw materials MES in dry flakes form - convenience of use MES in dry flakes form - convenience of use Biodiesel EN compliant (summer grade) Biodiesel EN compliant (summer grade) Independent revenue platforms Independent revenue platforms Project provides multiple advantages across different platforms

29 Thank You! Address: SHIV ANAND-A 1 ST FLOOR, 372/374 S. V. ROAD, GOREAGAON (W) MUMBAI INDIA Website: The best way to predict the future is to create it


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