Detergent Complex Based on Palm Stearin
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1 Detergent Complex Based on Palm Stearin PIPOC 2007, Malaysia August 29, 2007
2 Agenda About Trivedi Group Basic Requirements and Process Chemistry Products and Formulations Cost Structure Summary
3 Global Changes call for Action Now! Hurricanes and natural disasters Global warming Fossil vs. Renewable Food vs. Fuel
4 Organization Chart TRIVEDI GROUP (Since 1986) TECHNOLOGY & ENGINEERING SURFACTANT MANUFACTURING CHEMICAL TRADING PROJECT SERVICES
5 Chemithon Engineers Pvt Ltd Sulfonation of alkylates Environmental Systems TECHNOLOGY & ENGINEERING 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 Amphoterics Cationics SURFACTANT MANUFACTURING Nonionics Custom Blends Specialities
7 CHEMICAL TRADING Palm Derivatives Alcohols Surfactants Soap Noodles Specialities Detergent Alkylates Zeolites Ethoxylates
8 Business Promotion (NRDC) Market Studies PROJECT SERVICES Project Appraisal (IFC) Feasibility Studies Project Co-ordination Energy Audit
9 Requirements for Palm Plantation Based on Bio-Refinery Minimum Area: Hectares FFB CPO: 1000 TPD PKO: 100 TPD Mass Balance CPO with 5% FFA (1000 MT) Extraction Vitamin E ( MT) Refining PFAD (65 MT) Fractionation RBD Palm Stearin (185 MT) RBD Palmolein (745 MT)
10 A detergent based complex of Palm Stearin creates tangible advantages Sustainable value creation from Palm Stearin Independent revenue platforms Pharmaceuticals (Glycerine) Fuel (Biodiesel C18 rich) Alkylates (C12-14, 14, C16) Detergents and Home & Personal care products Based on renewal resource Environmentally friendly project
11 Typical mass balance highlighting various steps in the process RBD PS (185 MT) Transesterification Distillation Glycerine (18 MT) C1214 Ester (2.5 MT) C16 Ester (110 MT) C18 Ester (71 MT) Amidation / Amides Ethoxylation / ME Ethoxylates Hydrogenation Sulfonation Blending / Drying MES (145 MT) HPC Products Detergents (725 MT)
12 Step 1: Transesterification step converts a triglyceride to esters and glycerol CH 2 -OOC-R 1 R 1 -COO-R CH 2 -OH CH -OOC-R 2 CH 2 -OOC-R 3 + 3R OH C R 2 -COO- R R 3 -COO- R + CH 2 -OH CH 2 -OH Triglyceride + Alcohol Esters + Glycerol
13 Step 2: Distillation of fractions is done via a three stage conversion column C1214 C16 C18
14 Step 3: A continuous fixed bed column is used for hydrogenation step
15 Step 4: Sulfonation of esters yields methyl ester sulfonates (MES) METHYL ESTER 1V 0.1 SULFONATION DIGESTION BLEACHING NEUTRALIZATION MeOH RECOVERY DRYING METHYL ESTER SULFONATES (MES) (>85% ACTIVE AND <5% DISALT)
16 C16 MES(MW 372) has the typical mass balance as shown in the flowsheet Sulfur (95) SO3 gas generation C16 methyl ester (662) Sulfonation Methanol Recovery kg Methanol Makeup (40) MESA digestion MES 843 Di-salt 49 Sodium methyl sulfate 50 Unsulfonated 20 50% H 2 O 2 (35.6) MESA bleaching Na2SO4 10 Moisture 26 Hydrogen Peroxide 1 50% Caustic (242) Neutralization Distillation (226) Methanol 1 Total 1,000 Drying MES
17 STILL AWAKE???
18 Different forms of MES dried and stripped can be obtained as final product Palm Kernel C8-c18 Coconut C12-C14 Soya C18 Palm Stearin C16-C18 Tallow C16-C18
19 Some pictures of the Huish Plant
20 Flowsheet for Detergent Powder Plant
21 Typical Components in a Detergent Formulation % LAS MES Sodium Carbonate Sodium Silicate STPP Sodium Sulfate Moisture Total
22 Huish products are used in a variety of products both powder and liquid
23 Typical Components in a Soft Soap Formulation MES AES Glycerine Germicide Viscosity Modified Water Total %
24 Different Products containing MES in their formulation
25 Typical capital expenditure for a palm based detergent complex is about $ 50 million DETERGENT COMPLEX BASED ON PALM STEARIN Estimate for a 300 TPD RBD PS USD (million) Infrastructure Ester (300 TPD) + Glycerine (30 TPD) Distillation (300 TPD) + Hydrogenation (180 TPD) Sulfonation (40 KTA) Detergents & HPC (30 KT/20 KTA) Total CAPEX
26 Estimated costs for esterification, distillation and MES production USD (miilion) Esterification Distillation+ H2 MES Raw Materials Utilities Operating Costs Overheads Financial Charges Depreciation Cost of Production/ Tonne Recommended sale price Basis: RBD USD 650 PMT
27 Estimated production costs for soft soap and detergents USD Raw Materials Utilities Operating Costs Overheads Financial Charges Depreciation Soft Soap Detergent Without MES With MES Cost of Production/ Tonne Recommended sale price
28 Project provides multiple advantages across different platforms Integrated complex with optimum value addition Sustainability using renewable raw materials MES in dry flakes form - convenience of use Biodiesel EN compliant (summer grade) Independent revenue platforms
29 The best way to predict the future is to create it Thank You! Address: SHIV ANAND-A 1 ST FLOOR, 372/374 S. V. ROAD, GOREAGAON (W) MUMBAI INDIA Website: strivedi@trivedigroup.com
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