Project Profile-SCHEME
ON ACID SLURRY
INTRODUCTION:
This project profile in detail foresees setting up
of unit to produce ACID SLURRY
LAS have
been the major surfactant used in detergents for more than
thirty years and continues to represent a substantial portion
of the surfactants market today. Supporting this history
of safe usage is a large archive of environmental research
that has been conducted on LAS. This environmental research,
performed by top environmental scientists and research agencies,
has investigated virtually every part of the environment
that could have been exposed to LAS. The studies have repeatedly
proven LAS's environmental acceptability and safety.
Because
of LAS's environmental safety, cleaning effectiveness and
cost competitiveness, LAS has experienced 30 years of ever-increasing
use around the world.
Linear
alkyl benzene (LAB), the material used to produce LAS, is
derived exclusively from petroleum bi-products--benzene
and paraffin derived from kerosene. LAB currently represents
one-third of the active ingredients in detergents worldwide.
Linear
alkyl benzene is the raw material used to manufacture linear
alkyl benzene sulfonate (LAS), an active ingredient in the
formulation of detergents. LAS eliminate dirt by its physicochemical
mechanism and it is one of the surfactants most widely used
in liquid cleaners and in powder. LAS have been used for
more than 25 years in the manufacture of detergents and
it is known for its excellent quality/price ratio.
BASIS AND PRESUMPTIONS: -
1. Single shift of 8 hours a day, 25 days a month and
300 days in a year is presumed. Efficient machines and workers
are also presumed.
2. Minimum 2 year period is considered for achieving full
capacity utilization
3. Labour rates are as per the prevailing rates.
4. An average interest rate of 14% is considered.
5. The estimates are drawn for a production capacity generally
considered techno-economically viable for model type of
manufacturing activity.
6. The information supplied is based on a standard type
of manufacturing activity viable for model type of manufacturing
activity.
7. The information supplied is based on a standard type
of manufacturing activity utilizing conventional techniques
of production at optimum level of performance.
8. Costs in machinery and equipment, raw materials and
the selling prices of the finished products etc., are generally
prevailing at the time of preparation of the project profiles
and may vary depending upon various factors.
9. Whereas some names of manufacturers, suppliers of machinery
and equipment, raw materials etc. are indicated at the end
of the profile, those are by no means exclusive or exhaustive.
IMPLEMENTATION SCHEDULE:
-
Normally
eighteen months are required for the complete implementation
of the project, including machinery erection, raw materials
procurement etc.
| Nature of Activity |
Period in
Month(Estimated) |
| |
|
| Preparation of project report and approval |
1 |
| SSI registration |
1 |
| Sanction of Loan |
2 |
| Placement of order of delivery of machine |
3 |
| Installation of machine |
3 |
| Power connection |
1 |
| Trial run |
2 |
| Commencement of production |
5 |
Acid Slurry: -
| Active Matter As Alkyl BenzeneSulphonic
Acid,Percent By Mass , Min |
88 + 1% |
| Free Alkyle Benzene, Percent By Mass, Max |
1-2 % |
| Free Sulphuric Acid, Percent By Mass, Max |
5 - 6 % |
| Moisture |
3 - 4 % |
| Formula |
Ch3(Ch2)11c6h4so3h |
| Mol Wt. |
326.49 |
| Toxicity |
Oral Rat Ld50: 650 Mg/Kg |
| Derivation |
Linear Alkylbenzene, S |
| Classification |
Anionic Surfactant |
| Physical State |
Brown Liquid |
| Melting Point |
10 C |
| Boiling Point |
315 C |
| Specific Gravity |
1.2 |
| Solubility In Water |
Partially Soluble |
| NFPA Ratings |
Health: 2 ; Flammability: 0; Reactivity : 0 |
| Flash Point |
149 C |
| Stability |
Stable Under Ordinary Conditions |
QUALITY AND STANDARDS: -
IS 8401:
1987
PRODUCTION TARGET: -
Acid slurry-
½ MT per day/ shift or 150 TPA
TECHNICAL ASPECTS: -
Raw material
consumption per tones of 85-88% acid slurry is Linear alkyl
benzene 700-750 kg, Sulphonating agent 20% oleum 800-900
kg, 98% sulphuric acid 1100-1200kg.
LAS are
anionic surfactants with molecules characterized by a hydrophobic
and a hydrophilic group. Alpha-olefin sulfonates (AOS) alkyl
sulfates (AS) are also examples of commercial anionic surfactants.
They are nonvolatile compounds produced by sulfonation.
LAS are
complex mixtures of homologues of different alkyl chain
lengths (C10 to C13 or C14) and phenyl positional isomers
of 2 to 5-phenyl in proportions dictated by the starting
materials and reaction conditions, each containing an aromatic
ring sulfonated at the Para position and attached to a linear
alkyl chain at any position with the exception of terminal
one (1-phenyl).
The properties
of LAS differ in physical and chemical properties according
to the alkyl chain length, resulting in formulations for
various applications.
The starting
material LAB (linear alkyl benzene) is produced by the alkylation
of benzene with n-paraffins in the presence of hydrogen
fluoride (HF) or aluminium chloride (AlCl3) as a catalyst.
LAS are produced by the sulfonation of LAB with oleum in
batch reactors.
Other sulfonation
alternative reagents are sulfuric acid, diluted sulfur trioxide,
chlorosulfonic acid and sulfamic acid on falling film reactors.
LAS are
then neutralized to the desired salt (sodium, ammonium,
calcium, potassium, and triethanolamine salts).
Surfactants are widely used in the industry needed to improve
contact between polar and non-polar media such as between
oil and water or between water and minerals.
Linear alkylbenzene
sulfonic acid is mainly used to produce household detergents
including laundry powders, laundry liquids, dishwashing
liquids and other household cleaners as well as in numerous
industrial applications like as a coupling agent and as
an emulsifier for agricultural herbicides and in emulsion
polymerization.
Because
they are stable, sulfonic acids can be isolated, stored
and shipped as an article of commerce.
SO3 is an
aggressive electrophilic reagent that rapidly reacts with
any organic compound containing an electron donor group.
Sulfonation
is a difficult reaction to perform on an industrial scale
because the reaction is rapid and highly exothermic; releasing
approximately 380 kJ/kg SO3 (800 BTUs per pound of SO3)
reacted.
Most organic
compounds form a black char on contact with pure SO3 due
to the rapid reaction and heat evolution.
Additionally,
the reactants increase in viscosity between 15 and 300 times
as they are converted from the organic feedstock to the
sulfonic acid.
This large
increase in viscosity makes heat removal difficult. The
high viscosity of the formed products reduces the heat transfer
coefficient from the reaction mass.
Effective
cooling of the reaction mass is essential because high temperatures
promote side reactions that produce undesirable by-products.
Also, precise
control of the molar ratio of SO3 to organic is essential
because any excess SO3, due to its reactive nature, contributes
to side reactions and by-product formation.
Therefore,
commercial scale sulfonation reactions require special equipment
and instrumentation that allows tight control of the mole
ratio of SO3 to organic and rapid removal of the heat of
reaction.
Sulfuric
acid (H2SO4) and oleum (SO3 ??H2SO4) are widely used as
sulfonating agents.
Oleum is
used to sulfonate alkyl benzene and sulfate fatty alcohols
for heavy duty detergents.
It is an
equilibrium process, as water is formed in the reaction
and the resultant water dilutes the oleum and/or sulfuric
acid.
The sulfonation
reaction stops when the sulfuric acid concentration drops
to approximately 90%.
Oleum sulfonation
can be operated as either a batch or continuous process.
This process has the dual advantage of low SO3 cost and
low capital equipment cost.
However,
it has the disadvantage of being an equilibrium process
which leaves large quantities of un-reacted sulfuric acid.
This waste acid must be separated from the reaction mixture
and subsequently disposed.
Oleum and
sulfuric acid can be used to sulfonate aromatics and alcohols
in either batch or continuous equipment.
For detergent
alkylates, the batch equipment is used which is a stirred,
sealed, glass lined or stainless steel kettle with a provision
for heating and cooling.
The detergent
alkylate is first added to the reaction vessel then the
oleum is slowly added over a period of several hours.
The reaction
is highly exothermic and the oleum addition rate is determined
by the ability to remove the heat of reaction.
The temperature
should be maintained below 35°C for optimum product
quality.
Frequently
the heat of reaction is removed by pumping the reaction
mixture through an external heat exchanger.
Because
it is an equilibrium reaction, except for the special case
of azeotropic sulfonation of hydrotropes with sulfuric acid,
a large surplus of sulfuric acid forms.
When the
sulfonation reaction is complete,the sulfuric acid may be
separated from the sulfonated detergent alkylate by adding
water.
The water
addition (typically about 10% by weight of the reaction
mixture) causes a phase separation to occur between the
sulfonic acid and the diluted sulfuric acid.
The separation
usually takes place in a separate, glass lined vessel and
occurs over a period of about for 10 hours.
After separation,
the sulfonic acid may be neutralized with aqueous sodium
hydroxide, usually in a separate neutralization vessel.
Including
neutralization, total batch time is 15 to 20 hours.
The product
contains about 15% sodium sulfate after neutralization if
the acid is separated, and about 60% sodium sulfate if not.
Without separation, the product's application is limited
to low active, traditional detergent powders where the large
content of sodium sulfate is used as a filler.
Sulphonator:
Several
types of commercial sulfonators are available.
Film reactors
are the most common in detergent processing for consumer
products, especially to produce cosmetic quality materials
from oleo chemical feed stocks.
In a film
reactor, the organic feedstock is extruded onto the wall
of the reactor (reaction surface) as a continuous film.
Organic
feed rate to the reactor vessel is measured by a highly
accurate mass flow meter and controlled by a variable speed
driven gear pump.
The proper
organic feed rate is based on the preset sulfur-to-organic
mole ratio. The SO3, diluted with very dry air, flows over
the film of organic material.
The SO3
diffuses into the organic film and reacts to form a sulfonic
acid.
In almost
all commercial reactors both the organic and SO3 flow concurrently
from the top of the reactor to the bottom.
The heat
of reaction is removed by cooling water, which flows through
cooling jackets underneath the reaction surface of the reactor.
Cooling jackets on the reactor remove most of the heat of
reaction.
The product
exiting the reactor is instantly quench cooled by removing
the acid, pumping it through a heat exchanger to cool, then
returning it to the bottom of the reactor.
This cooling
process reduces the time that the sulfonic acid is held
at an elevated temperature and results in better product
quality.
FINANCIAL ASPECTS: -
A. Fixed
Capital: -
CAPITAL REQUIREMENTS
SI. No. |
Capital Requirements |
Rs. |
1. |
Land and building Land 1000 sq.m. Building-350 sq.m
|
1,00,000 |
2. |
Factory shed including laboratory/ water arrangements
etc. |
2,00,000 |
3. |
Store/Go down |
|
4. |
Office |
3,00,000 |
| |
Total |
6,00,000 |
PLANT AND MACHINERY: -
1. |
Sulphonator: Stainless steel vertical
and cylindrical vessel fitted within agitator with MS
jacket and complete motor, Cap 1 m³ |
|
2,50,000 |
2. |
Chilling plant |
|
2,00,000 |
3. |
Settling tank-MS vertical dished bottom, lead line
with agitator and motor Cap 3.5 m³ |
|
1,50,000 |
4. |
LAB feed tank: vertical cylindrical tank , MS Cap.
1 m³ |
|
25,000 |
5. |
Oleum/Acid slurry feed tank vertical cylindrical Tank
Cap 2.5 m³ |
|
25,000 |
6. |
LAB main storage tank horizontal cylindrical tank
Cap 2.5 m³ |
|
75,000 |
7. |
Oleum/Acid slurry feed tank horizontal cylindrical
Tank Cap 2.5 m³ |
|
35,000 |
8. |
Pumps barrel type with motor |
|
35,000 |
9. |
Misc.equipment including valvers pipelines, exhaust,
weighing machines etc. and laboratory equipment |
|
75,000 |
10. |
Office furniture & equipments |
|
30,000 |
11 |
Installation/electrification |
|
6,000 |
|
Total |
|
3,06,000/- |
Fixed Capital = 6, 00,000 + 3, 06,000
=
9, 06,000/-
(a) Raw Materials Required (Monthly)
SI.No. |
Raw material
(for 12.5MT) |
Quantity in
Kg. |
Rs/MT |
Value |
1. |
Linear alkyl benzene |
9 MT |
40,000 |
3,60,000 |
2. |
Sulphuric acid 98% and oleum |
14 MT |
6,000 |
84,000 |
| |
Total |
|
|
4,44,000 |
(b) Man Power (Monthly)
1. |
Manager / Chemist |
1 No. |
6,000/- |
2. |
Plant Operator |
2 No. |
5,000/- |
3. |
Un-skilled Workers |
2 No. |
3,000/- |
4. |
Store Keeper – Cum- Clerk |
1 No. |
3,000/- |
5. |
Watchman cum Peon |
2 No. |
4,000/- |
|
Total |
|
21,000/- |
|
Add 15% perks |
|
3,150/- |
|
Total |
|
24,150/- |
(c) Utilities (Monthly)
1. |
Electricity |
5,000/- |
2. |
Water |
5,000/- |
|
Total |
10,000/- |
(d) Other Expenditure (Monthly)
1. |
Postage and stationery |
1,000/- |
2. |
Telephone |
1,000/- |
3. |
Traveling |
3,500/- |
4. |
Transportation |
2,000/- |
5. |
Insurance, Raw Materials and Machinery’s |
2,000/- |
6. |
Repair & Maintenance |
2,000/- |
7. |
Other misc. expenses |
1,500/- |
|
Total |
13,000/- |
| Total of (a)
+ (b) + (c) + (d) |
|
| Say 444000+24150+10000+13000
|
4,91,150/- |
TOTAL INVESTMENT
| 1. |
Plant & Machinery |
9,06,000/- |
| 2. |
Working Capital (for 3 months) |
14,73,450/- |
| |
Total |
23,79,456/- |
FINANCIAL ANALYSIS
1. |
Cost of Production per Annum |
|
A. |
Total cost of Raw materials |
53,28,000/- |
B. |
Total cost of staff & labour |
2,89,800/- |
C. |
Total cost of power |
1,20,000/- |
D. |
Total cost of other expenses |
1,56,000/- |
E. |
Interest on capital @ 14% on 2379450 |
3,33,123/- |
F. |
Depreciation on Machinery and Equipments @ 10% on
306000 |
30,600/- |
|
Total |
62,57,523/- |
2. Total sale of 150MTs of acid slurry @45,000/MT
6750000/-
3. Profit per year
Sales per year - Cost of Production per year
6750000
- 6257523 =
492477/-
4. Net profit Ratio on sales
Profit ( per year) x 100 / Sales (per Year) = 492477 X
100 / 6750000
= 11.1 %
5. Rate of Return
Profit ( per year) x 100 / Total capital int.per year
= 492477 x 100 /2379450 = 20.69%
BREAK EVEN ANALYSIS: -
Fixed cost per annum
1. Interest on capital investment -
333123
2. Depreciation -
30600
3. 40% of salaries and wages -
115920
4. 40% of other expenses-
62400
Total-------------------------------
208920
B.E.P = Fixed Cost x 100 / Fixed cost
+ Profit
208920
X 100 / 208920 + 492477 = 29.8 %
SUPPLIERS OF MACHINERY: -
M/S. Mazz
India (P) Ltd.
C/o.K.S.Krishnan
and Associates
15, Community
Centre,
East of
Kailash
New delhi-110024
M/s Pioneer
Engg Co.
57, Bombay
Samachar Marg,
Fort, Mumbai-23
M/s. Precision
Machanist
36 (D) Kandivili
Indl.Estate,
Kandivili
(W)
Mumbai-67
Ms.Sethi
Engg. Works
31-A G.T
Road, Indl.Area
Delhi-110033
ADDRESS OF RAW MATERIAL DISTRIBUTORS
M/s. IPCL
Petrochemicals
P: O,
Vadodara
Gujarat-391346
M/s. Tamilnadu
Petro products Ltd.
Manali,
Tamil nadu
M/s. Reliance
Industries Ltd.
Patalganga,
Maharashtra
M/s. Dharamsi
Morarji Chemical Limited
317/21,
Dr.D.N.Road
Fort, Mumbai-1