CHAPTER -1

1.1 INTRODUCTION
The term synthetic detergent means any cleaning compound which is available
for household use, laundry use, other personnel use or industrial use which is
composed of organic and/or inorganic compounds including soaps, water softener,
surface active agent, foaming agent, buffering agent, builders, filters, dyes,
enzymes and fabric softeners whether in the form of crystals, powders, flakes, bars,
liquids, sprays or any other form.
Detergents have been divided into four main groups:
Anionic detergent: one that produces negatively charged colloidal ions in the
solution
Cationic detergent: one that produces positively charged colloidal ions in the
solution
Non-ionic detergent: one that produces neutral colloidal particles in the solution
Amphoteric detergent: one that produces both positively as well as negatively
charged colloidal particles in the solution
The largest group consists of anionic detergent which is usually the sodium salts of
an organic sulfate or sulfonate.
Detergent may have two ingredients:
Surfactants(surface active agents) make water wetter by reducing surface tension
and letting fabric absorb it more quickly. They are biodegradable and easily broken
down in the ecosystem
Builders or phosphate are rarely used as they have been found to be harmful to the
environment and have been banned by government under clean detergent act in
many states.

USES:
In laundry
In dish washing
In the textile industry
In food and dairy industry
1

1.2 SPECIFICATION:

Laundry detergent: laundry detergent or washing powder is a substance that is added

when one is washing laundry to aid in getting the laundry cleaner. Laundry detergent has
traditionally been a powdered or solid granular, but the use of liquid laundry detergents
has gradually increased over the years, and the popularity of liquid detergent now rivals
that of solid detergent. Some brands also manufacture laundry soap in tablets and
dissolvable packets, so as to eliminate the need to measure soap for each load of laundry.
In some countries where washing clothes by hand is more popular, detergent bars are more
popular. Detergent may also be sold in pellets in some brands of laundry ball, although
many others do not contain detergent. Soap substitute plants are also used as laundry
detergents.
Laundry detergent typically consists of ionic and anionic surfactants which act as the
detergent to remove the dirt from the clothes, perfume, phosphors which make clothes
appear whiter (it is these that show up under ultraviolet light), and for powders anticaking
agents to prevent the powder becoming one large lump in the presence of moisture. For
liquid detergents, the bulk of the product is water; for concentrated liquids, somewhat less
water, but still the product is mostly water. Biological laundry detergents contain enzymes
which act as catalysts to "eat" the dirt off of the laundry; these function best at the kinds of
body temperatures found in warm-blooded creatures (30 to 50 C (86 to 122 F)) and will
perform no better, and sometimes worse, at higher temperatures. Detergents may have
other additives such as bleaches and fabric softeners and these are usually advertised
clearly on the packets as selling points
Hand dishwashing detergent: Dishwashing is probably subject to more variables than
any other household clean-up job. In theory at least, any detergent or soap can be used for
hand dishwashing, except an automatic dishwasher detergent. However, soap has become
almost extinct as a dishwashing product and many laundry detergents are not very
acceptable. Laundry detergents may leave spots and streaks, the powders may not
completely dissolve, or may discolor certain metals with soaking. A light-duty liquid hand
dishwashing detergent is the best choice. Regardless of brand, certain characteristics are
important in a hand dishwashing liquid: lasting suds, effective cleaning performance,
mildness to hands, safety for dishes and other washables, storage stability, pleasant
fragrance and appearance, convenient packaging and dispensing. In formulating a product
to meet these criteria, manufacturers, in general, use certain basic ingredients.
2

North woods: This economical multipurpose pine cleaner is composed of a combination

of synthetic detergents and real pine oil. This fast-acting formulation is designed to
emulsify and safely remove all types of grime, grease, oil, dye, carbon, rust, and other soils
from all metal, stainless, concrete, rubber, plastic, porcelain, vinyl, Formica, and other
hard surfaces. Following effective cleaning, the pine oil leaves a fresh pine fragrance
which lingers to provide residual deodorizing protection. This product wipes or rinses
clean leaving no oily film or residue. Environmentally safe, Pine Deodorizing Cleaner is
non-toxic, non-flammable, and biodegradable .
synthetic and laundry alkalis and sours: The ultimate sour is for the professional
laundry. It Combines maximum neutralization of excess alkalis with reasonable cost and
Prevents yellowing of fabrics in the dryer or flatwork ironer. It leaves all fabrics soft and
static free. Removes all traces of detergent alkali residue .
1.3 DETERGENT ENZYMES :
Enzymes
The biggest single revolutionary trend in the detergent industry in the latter years has been
the use of enzyme additives. Enzymes as aids to washing are not new to the industry.
Proteolytic enzymes had been tried as additives to washing powders in Germany in the
1920s with only moderate success and again in Switzerland in the 1930s. Enzymes, which
can be called organic catalysts, tend to hasten reactions and the proteolytic enzymes
convert or 'break down' proteins wholly or partially into amino acids. The action is rather
slow and the production costs high, but with improved methods of production and
purification, strains of enzymes, usually in admixture with a proportion of amylase which
breaks down starches, were developed which were relatively fast acting. These were added
initially to 'pre-soak' detergents and found immediate acceptance in the European
countries where washing habits were such that washing was normally soaked for a period
prior to the wash proper.
Better and better strains of enzymes were developed, with stability to a wider pH spectrum,
stability against perborate and quicker action. In the United States detergent
manufacturers resisted the incorporation of enzymes into their powders for some years
after this type of powder had almost completely swept the board in Europe but in 1968
enzymatic powders started appearing there as well. The position at present is that
enzymatic powders are now holding a large proportion of the household detergent market
and formulations appeared made for machine washing. Some washing-machine
manufacturers are now producing automatic washing machines with a 'Bio' programme
which allows the washing to remain in contact with the detergent solution for an extended
period of time at a relatively low temperature before beginning the washing and heating
cycle. The future of enzymes is at the moment obscure as the production of enzymatic
powders has raised its own problems, and one Scandinavian firm has already decided to
3

withdraw its powder containing enzymes from the market, but other large firms are taking
enzymes out of some of their powders while forging ahead with others.

Synthetic Enzymes :
Detergent enzymes are well established as normal ingredients in both powder and liquid
detergents all over the world. The enzymatic hydrolysis of tri-glycerides in alkaline
solutions is used as a measure of detergent efficiency (4). Many synthetic enzymes are
derived from quaternary ammonium compounds (5,6). Quaternary ammonium compounds
are frequently used as pseudo-enzymes to study the catalytic hydrolysis of organic
compounds (1,2).
The rate of hydrolysis of food residues can be greatly increased in the presence of phase
transfer catalysts such as quaternary ammonium halides and polyols. In phase transfer
catalysis (PTC) a substrate in an organic phase is reacted chemically with a reagent
present in another phase (which is usually aqueous). Reaction is achieved by means of an
enzymatic transfer agent; this agent or catalyst being capable of dissolving in both aqueous
and organic phases, the latter in the form of highly reactive ion pairs. The hydrolytic
activity of the PTC ion pair is considerably greater in organic media since it is less
hydrated.
These cationic enzymes will strongly bind to organic substrates including exposed hands
and will remain on the skin even after 16 rinses (9).
This raises concern about the danger of employing chemical agents in detergents which
may be absorbed by the skin and eventually into the blood stream where these catalysts
could continue to randomly degrade protein matter and even interfere with DNA
reproductive processes.
Environmental regulations :
Environmental regulations for personal care and laundry cleaning products require more
and more money for testing and production. More consumers are asking for environment
friendly products. There is growing demand for raw materials, which contain no animal
by products and for products, which are not tested on animals. Many soaps and detergent
manufacturers are now rethinking their whole production lines to respond to the
concerns of consumers. Efforts are there to establish industry guidelines for
environmental claims and labeling are under way, and advertising and labeling are
already changing to meet the new requirements.
The soap and detergent industry is becoming more global and integration through
mergers and divestitures has paced the move toward globalization. Corporate investment
4

strategy, advertising, and R&D are changing from a stress on local markets to
international markets.

Present Market Trend (Globalization) :

Due to the saturation of traditional markets and in order to tackle the slow growth in
domestic markets, organizations now days, are creating sophisticated infrastructures and
rationalizing their production so as to make the production process centralized in fewer
but larger plants. This has contributed to standardization of the soap and detergent
ingredients across the globe. Manufacturers are striving to adopt basic formulations for
all consumers all across the world, which can be varied by the addition of some
ingredients to satisfy the trends in local markets.
Competitive Landscape :
Population growth, especially households with children, drives demand in the consumer
sector, while growth in economy drives demand in the commercial sector. The
profitability of individual companies depends on several factors, such as efficient
operations and effective sales and marketing. Large companies have scale advantages in
domains like buying, manufacturing, distribution, and marketing. Small companies can
effectively compete with large companies by formulating specialized products, offering
superior customer service, or catering a local market. The industry is capital-intensive
with average annual revenue per worker more than $700,000. The industry is evenly split
between the commercial and consumer sectors, both being highly competitive with large
companies spending millions to maintain market share.
The modifications in the cleaning products were also spurred by technical innovation,
availability of improved ingredients, such as bleach additives, better optical brighteners,
and improved technologies to improve the performance of soap and detergent products.
Marketers packaged products differently to meet the needs and requirements of
specialized users like households with infants or with men performing tasks that are
traditionally associated with women. To meet the requirements of different market
segments, the industry saw a development of brands and varieties. For example, a
specific large super-market might contain more than 40 different varieties of soaps and
detergent detergents including both liquids and powders.

1.4 PROCESS DESCRIPTION

Detergent alkylate:
The UOP detergent alkylate process can be designed for three types of operation :
1. Production of DDB by starting with propylene tetramer, either purchased or
produced in propylene polymerization operations such as the UOP Catalytic
Condensation Process, and then alkylated with benzene, which can be purchased or
produced by solvent extraction of platformate by means of sulfolane process
2. Production of LAB by starting with linear paraffins either purchased or produced by
solid bed adsorption from a hydrotreated kerosene feedstock, such as the UOP Molex
process. The linear paraffins are then catalytically dehydrogenated to linear
monoolefins of the same carbon number as the linear paraffin feed in a UOP Pacol
Dehydrogenation Process. The Pacol linear olefins are then alkylated with benzene
in the UOP Detergent Alkylate Process using anhydrous HF acid as the catalyst.

3. Production of both DDB and LAB in the same UOP Detergent Alkylation Process by
operating the alkylation unit blocked-out on either the propylene tetramer branched
olefin feed or the Pacol linear olefin feed, thus producing DDB or LAB as needed.
This is particularly advantageous where there is current need to produce DDB, but
there is definite expectation that future events will dictate the need to gradually phase
out DDB production while beginning and increasing the production of LAB.

Alternative routes to production of detergent alkylate

1. Chlorination of n-paraffins to form primarily a monochloroparaffin; the
monochloroparaffin is alkylated with benzene using aluminium chloride catalyst.
2. Chlorination of n-paraffins followed by dehydrochlorination and alkylation of
resulting olefins with benzene using an acid catalyst
6

Chemithon: a process for making detergents by continuous sulfonation of hydrocarbons

with sulfur trioxide or oleum offered by Lurgi
Detal (detergent alkylation): a process for making detergent alkylate ie alkyl aromatic
hydrocarbons such as linear alkyl benzenes as intermediates for the manufacture of
detergents by reacting C10-C13 olefins with benzene in a fixed bed of n acid catalyst
developed by UOP and CEPSA as a replacement for their Detergent alkylate process,
which uses liquid hydrogen fluoride as the catalyst. Demonstrated in a pilot plant in 1991
and first commercialized in Canada 1996 offered by UOP
Pacol process (paraffin conversion,linear): a process for converting C10-C20 linear
aliphatic hydrocarbons to the corresponding olefins by catalytic dehydrogenation, used
mainly for the production of linears intermediates for detergents. Used also in combination
with olex, for akying mono olefins. The catalyst is a platinum metal on an alumina
support; several generations of the catalyst have been developed; the latest is known as
DEH-7 developed by UOP in 1960 and first commercialized in 1968.
DETAILED DESCRIPTION OF MODIFIED SELECTED PROCESS :
The detergent manufacturing plant involves following reactions to be carried out
sequentially.
Benzene + do-decene Alkyl benzene
Do-decene + H2SO4 Alkyl benzene sulfonic acid
(linear alkyl benzene sulfonic acid) LABSA
LABSA + NaOH Sodium salt of LABSA i.e. Na+LABSA
Na+LABSA is also known as SYNDET that is, synthetic detergent.
These three unit processes are carried out in the unit 1 of synthetic detergent plant.
The basic reactions which occur in the unit 1 are the following
Alkylation:C6H6 + C12H24 C6H5.C12H25
7

Sulfonation:C6H5.C12H25 + H2SO4C12H25.C6H4.SO3H +H2O

Neutralization:C12H25.C6H4.SO3H + NaOH C12H25.C6H4.SO3Na +H2O
A literature search indicates that yields of 85 to 95 percent have been obtained in the
alkylation step, while yields for the sulfonation process are substantially 100 percent, and
yield for the neutralization step are always 95 percent or greater. All three steps are
exothermic and require some form of jacketed cooling around the stirred reactor to
maintain isothermal reaction temperatures.
Laboratory data for the sulfonation of alkylbenzene, described in the literature, provide
additional information useful for a rapid material balance. This is summarized as follows:
1. Sulfonation is essentially complete if the ratio of 20% oleum to alkylbenzene is
maintained at 1.25
2. Spent sulfuric acid removal is optimized with the addition of 2.44 lb of water to settler
for each 1.25 lb of 20% oleum added in the sulfonation step.
3. A 25% excess of 20% NaOH is suggested for the neutralization step.

Composition of components
The following composition was followed in the calculations of the manufacture of 500
tonnes per day of Synthetic detergent.

S.NUMBER
1
2
3
4
5
6
7
8
9
10
11
12

COMPONENT
Sodium tripolyphosphate (water softener, loosens
dirt)
Sodium alkane sulphonate (surfactant)
Sodium perborate tetrahydrate (oxidising agent)
Soap (sodium alkane carboxylates)
Sodium sulphate (filler, water softener)
Sodium carboxymethyl cellulose (dirt-suspending
agent)
Sodium metasilicate (binder, loosens dirt)
Bacillus protease (3% active)
Fluorescent brighteners
Foam-controlling agents
Perfume
Water

%
38
25
25
3
2.5
1.6
1
0.8
0.3
Trace
Trace
100%

Basis: one operating day

There are following equipments where material and energy balance is required
1.
2.
3.
4.
5.
6.
7.

Benzene tank
Do-decene Tank
Alkylator
Distillation column 1, 2
Sulfonator
Neutralizer
Mixer
9

CHAPTER -2
2.1Material balance
Basis: Quantity in kg per day
Input + generation = output + accumulation
Benzene tank :
The benzene tank is assumed to be storing the benzene irrespective of the requirement.
There would be recycle of unreacted benzene and similarly of do-decene.
Do-decene tank :
The do-decene tank is also assumed to be storing the do-decene irrespective of the
requirement. There would be recycle of unreacted do-decene.
Alkylator:Input + generation = output + accumulation
Input: benzene + Do-decene
Output: Alkylbenzene + Unreacted Benzene and Do-decene
At steady state, the accumulation is zero.

10

FLOW DIAGRAM :

Figure 2.1 flow sheet of synthetic detergent plant

Benzene 1:
n1Benzene + n12Benzene = n3Benzene

(Dodecene Benzene =Alkyl Benzene)

(Linear Alkyl Benzene Sulfonate = LABS)

Dodecen 2:
n2Dodecen + n13Dodecene =n4Dodecene
Reactor :
n3Benzene n3Benzene * 0.9 =n5Benzene
n4Dodecene n3Benzene * 0.9=n5Dodecene
0 +n3Benzene * 0.9 =n5Alkylbenzene
11

Distillation column 1:
n5Benzene =n12 Benzene
n5Dodecene=n6Dodecene
n5Alkylbenzene = n6Alkylbenzene
Distillation column 2:
n6Dodecene = n13Dodecene
n6Alyklbenzene = n7Alkylbenzene
Sulfonator :
n14H2SO4SO3 = 1.25 * N7Alkylbenzene
n8LABS = n7Alkylbenzene
Purifier :
n16H20 = (2.44 * n8LABS) *1/m.wtH2O
n9LAB =n8LABS
Nutralizer:
n10LABSNa = n9LABS
Mixer :
n10LABSNa + n17additives = W11Syntheticdetergent
W11Syntheticdetergent = 500 TPD
W11LABSNa = 0.25*500*10^3

(All values in K.gs)

12

Table:2.1 Material balance across Alkylator :

ALKYLATOR
SERIAL
NUMBER
1
2
3

COMPONENT
BENZENE
DO-DECENE
LAB
TOTAL =

INPUT
31040.1
66855.6
0

GENERATION
0
0
0

OUTPUT
3104
6686
88107

97896

97897

The components coming out of the alkylator are passed through reactor and sent to the
Distillation column 1 for separation of the benzene.
Table: 2.2 Material balance across distillation column 1
DISTILLATION COLUMN
SERIAL
NUMBER
1
2
3

COMPONENT INPUT GENERATION DISTILLATE BOTTOMS

BENZENE
3104
0
3104
0
DO-DECENE
6686
0
0
6686
LAB
88107
0
0
88107

The recycle benzene is sent to the benzene storage tank.

Table: 2.3 Material balance across distillation column 2
DISTILLATION COLUMN 2
SERIAL
NUMBER
1
2
3

COMPONENT INPUT GENERATION DISTILLATE BOTTOMS

BENZENE
DO-DECENE
LAB

0
6686
88107
13

0
0
0

0
6686
0

0
0
88107

Table: 2.4 Material balance on sulfonator :

SULFONATOR
SERIAL
NUMBER
1
2
3
4
5
6

COMPONENT
BENZENE
DO-DECENE

INPUT
0
0

LAB
OLEUM
WATER
LABSA

88107.36
43874.6
0
0

GENERATION ACCUM
0
0
0
0
0
0
0
0

0
0
0
0

OUTPUT
0
0
0
0
15221
116760.16

Table: 2.5 Material balance on neutralizer :

NEUTRALIZER
SERIAL
NUMBER
1
2
3
4
5
6
7
8

COMPONENT INPUT GENERATION ACCUM/REACT OUTPUT

BENZENE
0
0
0
0
DO-DECENE
0
0
0
0
LAB
0
0
0
0
OLEUM
0
0
0
0
WATER
0
0
0
46605.5
LABSA
116760.16
0
0
0
NaOH
54843.25
0
0
0
NaLABSA
0
0
124997.84

Now we call the mixture of all the constituents of the outlet as syndet irrespective of the
composition of the outlet.
From above calculations we obtained Basic Raw material required :Fresh Benzene = 27936.48 kg
Fresh Dodecene = 60170.8 kg
14

CHAPTER-3
3.1Aspen Plus Simulation
Selecting the property method

Figure 3.1

Components

Figure 3.2
15

Stoichiometry of reactor:

Figure 3.3

Kinetics of reactor:

Figure 3.4

16

Inputs:
Benzene and Dodecene

Figure 3.5

Figure 3.6
17

Flow sheet using Aspen Plus software

Figure 3.7

Stream table

3.1 stream table

18

3.2 SIZING OF EQUIPMENTS

3.2.1REACTOR VOLUME
Length of reactor=32 meters
Diameter of the reactor=8 meters
From length and diameter

82
32 =
4
Volume of the reactor =1607.68m3

3.2.2 SULFONATOR VOLUME

Length of the reactor =100 meters
Diameter of the reactor =25 meters
From length and diameter

252
4

100 =

Volume of the reactor =49062m3

19

3.2.2DISTILLATION COLUMN
For distillation column 1
Minimum reflux ratio =0.040
Actual reflux ratio=0.1082
Minimum number of stages =3.928
Number of actual stages =11
For distillation column 2
Minimum reflux ratio =0.778
Actual reflux ratio=1.518
Minimum number of stages =4.154
Number of actual stages =7

20

CHAPTER-4
4.1 MECHANICAL DESIGN OF SULFONATOR

4.1.1 Reactor (sulfonator)

Vessel shell internal diameter 1.72m
Internal pressure 2.04 Kg/cm2
Design pressure 2.44 Kg/ cm2
Material openhearth steel (IS-2002)
Allowable stress 980 Kg/cm2
Shell thickness:
ts = PDi/(2fJ P)
J = Joint efficiency factor
= 0.85
ts = (2.44 x 1720)/(2 x 0.85 x 980 2.44)
= 2.52 mm
Use 4 mm thickness including corossion allowance
4.1.2 Agitator:
Diameter of agitator 525 mm (Da)
Speed (maximum) 200 rpm
Overhang of agitator shaft between bearing and agitator 1300 mm (l)
Agitator blades 6 (n)
Width of the blade 75 mm (w)
Thickness of blade 8 mm (t)
Shaft material commercial cold rolled steel
Permissible shear stress in shaft 550 Kg/cm2
Elastic limit in tension 2460 Kg/cm2
Modulus of elasticity 19.5 x 105 Kg/cm2 (E)
Permissible stress for key (carbon steel)
Shear 630 Kg/cm2
Crushing 1300 Kg/cm2
Stuffing box ( carbon steel) - 950 Kg/cm2
Studs and bolts (hot rolled carbon stee l)
Permissible stress 587 Kg/cm2
21

It is assumed that vessel geometry conforms to the standard tank configuration

Nda2/ = 1.4 x 103 x 200/60 x (500/1000)2/1.7 x 10-2
`

= 683.52 x 102 > 10,000

From power curve, Np = 6

Power , P = NP N3 Da5/(gc x 75)
= (6 x 1.4 x 103x (200/60)3)x (500/1000)5 ) / (9.81 x 75)
= 13.22 hp
Gland losses (10%) 1.322 hp
Power input = 13.22 + 1.3 = 14.52 hp
Transmission system losses (20%) = 14.52 x 0.2
= 2.904 hp
Total hp = 14.52 + 2.904 = 17.42
This will be taken as 18.5 hp to allow for fitting losses
Shaft design
Continuous average rated torque on the agitator shaft,
Tc= (hp x 75 x 60)/ (2 N)
= (18.5 x 75 x 60)/ (2 x 200)
= 66.25 Kg m
Polar modulus of the shaft,
Zp = Tm/fs
Tm = 1.5 Tc
fs shear stress 550 kg/cm2
Zp =(1.5 x 66.25 x 100) /550
= 18.07 cm3
d3/16 = 18.07
d = 4.5 cm
Diameter of shaft = 5 cm
Force, Fm = Tm/0.75Rb
Rb Radius of blade
Fm =(1.5 x 66.25 x 100) / (0.75 x 25)
= 530 Kg

Maximum bending momentum

M = Fm x l
22

= 530 x 1.3
= 689 Kg-m
Equivalent bending moment

=692.5 Kg .m
The stress due to equivalent bending
F = Mc/Z
Z = (5)3/32 (Modulus of reaction of the shaft cross section)
=12.27
f = (692.5 x 100)/12.27
= 5642.9kg/cm2

Stress f is higher than the permissible elastic limit (2460 Kg/Cm2). Therefore use a 7 cm
diameter shaft for which the stress will be
f = 2056 Kg/cm2

23

CHAPTER -5
5.1 Identification of utilities
Benzene,do-decene,LAB ,LABSA etc which catch fire easily. These can react with other
substances, corrode the tanks and may make flammable mixtures with air if spillage takes
place. The following safety precautions must be told to the workers in the factory.

Unusual fire and explosion hazard:

Small Fires: Use a dry chemical, C02, water spray or AFFF foam.
Large Fires: Water spray, fog or AFFF foam. Use water spray or fog: Do not use
Straight streams. Move containers from fire area if you can do it without risk.

5.2 Toxicological properties/Hazard Identifications

Way of penetration: Skin, eye contact, vapour inhalation and ingestion
EFFECTS OF OVEREXPOSURE
Acute overexposure: Irritation, dizziness, nausea.
Chronic overexposure: Unknown.

TOXICITY DATA
The following effects have been reported in the studies with animals exposed separately,
by a variety of routes, to similar alkyl benzene. Weight loss, food consumption and material
weight gain effects on offspring (no effect in standard tests at low dose); liver toxicity;
increased tumors following lifetime dermal exposure at skin damaging concentration (skin
damage confound the interpretation of the significance of these effects for human health).
Skin contact: A single semi-occlusive application of LAB to intact rabbit skin for four
hours elicits slight to well defined dermal reactions. LAB elicites very slight to well defined
erythema and oedema disappears after eight days.
Eye contact: Instillation of LAB/LABSA into the rabbit eye elicits no corneal opacification
or iridial inflammation. Transient well-defined conjunctivitis irritation only is observed.
Instillation of LAB/LABSA elicited dulling of the cornea and well defined to moderate
conjunctivitis irritation. The eyes were normal after five to seven days after instillation.
24

HAZARDS
Eyes: liquid contact or exposure to high vapor concentration may result in irritation.
Skin: Repeated or prolonged skin contact may result in irritation or drying of skin
progressions to dermatitis.
Inhalation: Due to low volatility, this product is not hazardous under normal
circumstances. Prolonged exposure to high vapor concentrations may cause dizziness and
headaches.
Ingestion: Ingestion of small amounts may result in nausea and vomiting.

ACCIDENTAL RELEASE MEASURES

STEP TO BE TAKEN IF MATERIAL IS RELEASED OR SPILLED
Eliminate all ignition sources (no smoking sparks or flames in immediate area). All
equipment used when handling the product must be grounded. Do not touch or walk
through spilled material. Stop leak if you can do it without risk. Prevent entry into
waterways, sewers, basement or confined areas. A vapor suppressing foam may be used to
reduce vapors. Absorb or cover with dry earth, sand or other non- sparking tools to collect
absorbed material.
MAJOR SPILL
Dike, far ahead of liquid, spill for later disposal. Water spray may reduce vapor; but may
not prevent ignition in closed spaces.
FIRST AID MEASURES
Eyes: Flush thoroughly with water for at least 20 minutes. Seek medical attention.
Skin: Remove contaminated clothing and wash it before reuse. Flush affected areas with
large amounts of water for at least 20 minutes. Wash area with mild soap and water. If
irritation occurs, seek medical attention.
Inhalation: Move person to fresh air. If breathing has stopped, administer artificial
respiration, oxygen or cardiopulmonary resuscitation if needed. Seek medical attention.
Ingestion: DO NOT INDUCE VOMITING. Never give anything by mouth to an
unconscious person. Seek medical attention.
25

5.3 HANDELLING AND STORAGE

Usual shipping containers: Tank cars, Tank trucks, Drums
Type of material: carbon steel, baked epoxy or phenolic resin
coatings, Aluminum.
Electrostatic accumulation hazard: No proper bonding and grounding, when loading and
unloading hydrocarbon material is always a proper safety measure.
Storage/transport pressure: Atmospheric
Loading/unloading temperature: Ambient
Storage/transport temperature: Ambient.
SPECIFIC PERSONAL PROTECTIVE EQUIPMENT
Respiratory: N.I.O.S.H - approved organic vapor air-purifying spaces or air supplied
equipment depending on concentration.
Eyes: Chemical goggles or face shield.
Hands: Rubber gloves or other similar impervious material to prevent repeated contact
Other clothing and Equipment: Impervious clothing (boots, slickersuits)as needed to
prevent prolonged skin contact.
DISPOSAL CONSIDERATIONS
Wastes can be Incinerated under controlled conditions or Iandfilled according to official
regulations.
5.4 PROTECTION FROM ENZYMES
Proteinases are sold to the public in spray laundry products. It is recommended that an
appropriate warning, such as "Caution: avoid breathing spray", should be included on
the label of spray laundry products containing proteinases to ensure that the spray is not
inhaled.
It is also recommended that the droplet size of spray laundry products containing
proteinases should not be in the respirable range, that is less than 7 micro.m.
Encapsulation
Good quality encapsulate and careful handling of the granulates are necessary in order
to avoid the generation and dispersion of enzyme dust.
Detergent manufacturers should obtain a copy of the elutriation test results for each batch
of enzymes to ensure that they are using good quality encapsulated material.

26

Batches of enzyme should be randomly checked by the detergent manufacturer using the
alutriation test to ascertain whether damage to the encapsulate is occurring during
transportation.

Engineering Controls
The detergent manufacturing process should be as automated as possible. If the liquid
detergent plan gravity feed should be used where possible to reduce pressure.
Enclosure
The enzyme feed area should be enclosed.
The egglaim area should be enclosed.
Enzyme handling equipment, which includes conveyors, storage tanks and mixing
tanks should be enclosed.
The filling machine should be enclosed.
Any pump and pipe flanges carrying enzymatic detergents should be encased.
In the liquid detergent plant gravity feed should be used where possible to reduce
pressure in process.
Personal Protective Equipment

Workers who may come into direct contact with proteinase include:

Workers undertaking normal operations in the enzyme feed rooms such as

replacing big bags or connecting pipes to Schutz containers

Workers cleaning and maintaining equipment including ventilation equipment

which has contained proteinase and workers who clean up enzyme spills or clean
up major spills of enzymatic detergents

Air Monitoring
Atmospheric enzyme and total dust levels should be monitored routinely. Atmospheric
monitoring provides a measure of worker exposure identifies areas where high levels are
found and provides a basis for measuring the effectiveness of control improvements.
Sampling time should be the minimum time practicable to indicate peak level of airborne
enzymes.
27

Air samplers should be located in the enzyme feed room, the enzyme dosing area, filling
area and reclaim room. Records of enzyme and dust levels should be kept and made
accessible to employees.
Consideration should be given to developing monitoring methods which allow for the
measurement to peak enzyme levels in air.
Effluent treatment
There are two effluents in the plant namely the plant air and the plant waste water.
Air
The air which comes out of the entire plant has suspended particles of detergents, which
have to be removed. These are removed with the help of cyclone separators. An additional
system of electrostatic precipitators can be used if the pollution norms are not being met
in the collection system that has been proposed. If a very clean air output is required then
there should be a fiber glass bag filter although it unnecessarily increases the pumping
requirements.
There are volatile products which have to be removed from the system. For their removal
and recovery, we ensure low storage temperatures and advanced coverage systems. We
ensure floating heads for the storage tanks of benzene and other volatile substances.
Water
The effluent of the plant contains water sources which come from two different systems.
These are cooling water and the sulfonator systems. The sulfonator produces Na+LABSA
and unreacted oleum. This low concentration sulfuric acid must be collected in separate
storage tanks and should be sent to the oleum manufacturing plant. No special treatment
is required as far as the detergent plant is concerned.
The cooling water should be treated in filers, and their dissolved solid content,
turbidity etc must be checked periodically to ensure that the cooling water is free from
scaling agents. The cooling water should also be checked periodically for the presence of
chemicals in it.

28

CHAPTER-6
PLANT LOCATION AND LAYOUT

6.1.1 Introduction
A suitable site must be found for a new project, and the site and equipment layout planned.
Provision must be made for the ancillary buildings and services needed for plant
operation; and for the environmentally acceptable disposal of effluent.
6.1.2 Plant location and site selection
The location of the plant can have a crucial effect on the profitability of a project, and the
scope for future expansion. Many factors must be considered when selecting a suitable site,
and only a brief review of the principle factors are given below. The principle factors to
consider are:

1. Location, with respect to the marketing area.

2. Raw material supply.
3. Transport facility.
4. Availability of labor.
5. Availability of utilities: water, fuel, power.
6. Availability of suitable land.
7. Environmental impact and effluent disposal.
8. Local community considerations.
9. Climate.

29

Marketing area
For materials that are produced in bulk quantities such as Styrene-butadiene Rubber
where the cost of the product per ton is relatively low and the cost of transport a significant
fraction of the sales price, the plant should be located close to the primary market. This
consideration will be less important for low volume production, high-priced products;
Pharmaceuticals.
In an international market, there may be an advantage to be gained by locating the plant
within an area with preferential tariff agreements;
Raw Materials
The availability and price of suitable raw materials will often determine the site location.
Plants producing bulk chemicals are best located close to the source of the major raw
material; where this is also close to the marketing area.
Transport
The transport of materials and products to and from the plant will be an overriding
consideration in site selection. If practicable, a site should be selected that is close to at
least two major forms of transport: road, rail, waterway (canal or river), or a sea port.
Road transport is being increasingly used, and is suitable for long- distance transport of
bulk chemicals. Air transport is convenient and efficient for the movement personnel and
essential equipment and supplies, and the proximity of the site to a major air port should
be considered.
Availability of labour
Labour will be needed for construction of the plant and its operation. Skilled construction
workers will usually be brought in from outside the site area, but there should be an
adequate pool of unskilled labour availability locally; and labour suitable for training to
operate the plant. Skilled tradesmen will be needed for plant maintenance. Local trade
union customs and restrictive practices will have to be considered when assessing the
availability and suitability of the local labour for recruitment and training.

30

6.1.3 Utilities (Services)

Chemical processes invariably require large quantities of water for cooling and general
process use, and the plant must be located near a source of water of suitable quality.
Process water may be drawn from a river, from wells, or purchased from a local authority.
At some sites, the cooling water required can be taken from a river or lake, or from the
sea; at other locations cooling towers will be needed.
Electrical power will be needed at all sites. Electrochemical processes that require large
quantities of power need to be located close to a cheap source of power. A competitively
priced fuel must be available on site for steam and power generation.
Environmental impact and effluent disposal
All industrial processes produce waste products, and full consideration must be given to
the difficulties and cost of their disposal. The disposal of toxic and harmful effluents will
be covered by local regulations, and the appropriate authorities must be consulted during
the initial site survey to determine he standards that must be met.
An environmental impact assessment should be made for each new project or major
modification or addition or an existing process.
Local community considerations
The proposed plant must be fit in with and be acceptable to the local community. Full
consideration must be given to the safe location of the plant so that it does not impose a
significant additional risk to the community.
On a new site, the local community must be able to provide adequate facilities for the plant
personnel: schools, banks, housing, and recreational and cultural facilities.
Land (site considerations)
Sufficient suitable land must be available for the proposed plant and for future expansion.
The land should ideally be flat, well drained and have suitable load-bearing
characteristics. A full site evaluation would be made to determine the need for piling or
other special foundations.

31

Climate
Adverse climatic conditions at a site will increase costs. Abnormally low temperatures will
require the provision of additional insulation and special heating for equipment and pipe
runs. Stronger structures will be needed at locations subject to high winds
(cyclone/hurricane) or earthquakes.
Political and strategic considerations
Capital grants, tax concessions, and other inducements are often given by governments to
direct new investment to preferred locations; such as areas of high unemployment. The
overriding of such grants can be the overriding considerations in site selection.

6.2 Site layout

The process units and ancillary buildings should be laid out to give the most economical
flow of materials and personnel around the site. Hazardous processes must be located at
a safe distance from other buildings. Consideration must be given to the future expansion
of the site. The ancillary buildings and services required on a site, in addition to the main
processing units (buildings), will include:
1. Storages for raw materials and products: tank farms and warehouses.
2. Maintenance workshops.
3. Stores, for maintenance and operating supplies.
4. Laboratories for process control.
5. Fire stations and other emergency services.
6. Canteens and other amenity buildings, such as medical Centre.

6.2.1 Plant layout

The economic construction and efficient operation of the process unit will depend on how
well the plant and equipment specified on the process flow-sheet is laid out.
The principal factors to be considered are:
1. Economic considerations: construction and operating costs.
32

2. The process requirements.

3. Convenience of operation.
4. Convenience of maintenance
5. Safety.
6. Future expansion.
Keeping all these considerations in mind, the plant layout is given overleaf

CHAPTER-7
7.1 CONCLUSION
We done material and energy balance for some equipment present in the plant
design
Sizing of the equipment is done for reactor,sulfonator and distillation column
By using Aspen Plus simulation we calculated some equipment properties
Further we need to do cost analysis of equipment

33

7.2 REFERENCES
1. DRYDENS OUTLINES OF CHEMICAL TECHNOLOGY
AUTHOR: M GOPALARAO & MARSHALL
2. HAND BOOK OF DETERGENTS PART A :Production edited BY Guy Broze
3. PERRYS CHEMICAL ENGINEERS HANDBOOK
AUTHOR: R.H. PERRY & DON. W. GREEN
VOL-7; Mc GRAW HILL INTERNATIONAL EDITION
4. PLANT DESIGN AND ECONOMICS FOR CHEMICAL ENGINEERS
AUTHOR: MAX S PETERS & KLAUS TIMMERHAUS
Mc-GRAW HILL BOOK COMPANY; 3rd EDITION

34

35