Detergent Complex Based on Palm Stearin PIPOC 2007, Malaysia August 29, 2007
Agenda About Trivedi Group Basic Requirements and Process Chemistry Products and Formulations Cost Structure Summary
Global Changes call for Action Now! Hurricanes and natural disasters Global warming Fossil vs. Renewable Food vs. Fuel
Organization Chart TRIVEDI GROUP (Since 1986) TECHNOLOGY & ENGINEERING SURFACTANT MANUFACTURING CHEMICAL TRADING PROJECT SERVICES
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
Anionics Amphoterics Cationics SURFACTANT MANUFACTURING Nonionics Custom Blends Specialities
CHEMICAL TRADING Palm Derivatives Alcohols Surfactants Soap Noodles Specialities Detergent Alkylates Zeolites Ethoxylates
Business Promotion (NRDC) Market Studies PROJECT SERVICES Project Appraisal (IFC) Feasibility Studies Project Co-ordination Energy Audit
Requirements for Palm Plantation Based on Bio-Refinery Minimum Area: 60.000 Hectares FFB CPO: 1000 TPD PKO: 100 TPD Mass Balance CPO with 5% FFA (1000 MT) Extraction Vitamin E (1.5 2.0 MT) Refining PFAD (65 MT) Fractionation RBD Palm Stearin (185 MT) RBD Palmolein (745 MT)
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
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)
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 Catalyst @ 60-70 C R 2 -COO- R R 3 -COO- R + CH 2 -OH CH 2 -OH Triglyceride + Alcohol Esters + Glycerol
Step 2: Distillation of fractions is done via a three stage conversion column C1214 C16 C18
Step 3: A continuous fixed bed column is used for hydrogenation step
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)
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
STILL AWAKE???
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
Some pictures of the Huish Plant
Flowsheet for Detergent Powder Plant
Typical Components in a Detergent Formulation % LAS MES Sodium Carbonate Sodium Silicate STPP Sodium Sulfate Moisture Total 12 8 20 10 15 30 5 100
Huish products are used in a variety of products both powder and liquid
Typical Components in a Soft Soap Formulation MES AES Glycerine Germicide Viscosity Modified Water Total % 6 9 3 0.5 2 79.5 100
Different Products containing MES in their formulation
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 7.0 13.0 9.0 13.0 8.0 50.0
Estimated costs for esterification, distillation and MES production USD (miilion) Esterification Distillation+ H2 MES Raw Materials 598 704 797 Utilities 42 37 52 Operating Costs 6 6 14 Overheads 4 7 11 Financial Charges 6 7 15 Depreciation 9 7 29 Cost of Production/ Tonne 665 768 918 Recommended sale price 700 850 1050 Basis: RBD PS @ USD 650 PMT
Estimated production costs for soft soap and detergents USD Raw Materials Utilities Operating Costs Overheads Financial Charges Depreciation Soft Soap 678 44 20 23 12 17 Detergent Without MES With MES 698 631 42 41 12 12 14 14 11 11 15 15 Cost of Production/ Tonne 794 792 724 Recommended sale price 1200 1200 1200
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 14214 compliant (summer grade) Independent revenue platforms
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 - 400 104 INDIA Website: www.trivedigroup.com Email: strivedi@trivedigroup.com