DESIGN OF A PLANT TO PRODUCE A TON PER BATCH OF LIQUID DISH-WASHING SOAP

Transcription

1 DESIGN OF A PLANT TO PRODUCE A TON PER BATCH OF LIQUID DISH-WASHING SOAP BY,~~-' ". f GROUP 1 A PROJECT SUB'MITTED TO THE DE~ ARTMENT OF CHEMICAL ENGINEERING, FEDERAL U~IVERSITY OF TECHNOLOGY, MINNA, NIGERIA IN PARTIAL FULFILMENT OF THE REQUIREMENT FOR THE AWARD OF BACHELOR OF -ENGINEERING (B. ENG) DEGREE IN CHEMICAL ENGINEERING NO,(EMBER,2010

2 GENERAL INTRODUCTION plant design titled 'The design of a plant to produce a ton per batch of liquid soap' was out by the entire members of the plant design group 1. The introduction and literature was done collectively by the group. The material and energy balances, equipment and Imecnamlcal design was done by Adams Abdulrazaq (2005/21700 EH). Calculations on vessel pressures and thicknesses was done by Eboh Uchechukwu (2005/21734 EH). The flowsheet was drafted collectively by the group and drawn by Achanya Bridget (2005/21699 ElI). The optimization of the plant was also done by the group. Safety and risk assessment was conducted by Abiodun Folake (2005/21697 EH). The quality control was done by Aboderin Toluwalase(2005/21698 ElI) with assistance from Adegbosin Solomon ( ElI) and additions by Adanu Emmanuel (2005/21701 EH). The process control was done by Abdulkareem Idris (2005/21695 ElI) with contributions from Abba Mansur (2005/21694 ElI). The piping and instrumentation diagrams were drawn by Eboh Uchechukwu (2005/21734 EH) with assistance from Oriolowo Oloruntoba (2005/21788 ElI). Environmental acceptability was done by Achanya Bridget (2005/21699 EH) while Adeniyi Folashade (2005/21704 ElI) drafted the start up, emergency and shut down procedures for the plant. The site for plant location and plant layout was done collectively by Achanya Bridget (2005/21699 ElI), Abiodun Folake (2005/21697 ElI), Aboderin Toluwalase ( ElI). and Adeniyi Folashade (2005/21704 ElI). Economic analysis was done by Adams Abdulrazaq (2005/21700 EH) and Adanu Emmanuel (2005/21701 EH). Finally, the typing of the entire project work was done collectively by the group.

3 DECLARATION We declare that the work in the project (thesis) entitled 'Design of a plant to produce a ton per batch of liquid soap' has been performed (carried out) by us under the supervision of Prof. lo. Odigure. No part of this project report (thesis) was presented for another degree or diploma elsewhere at any institution to the best of our knowledge. Abba Mansur (2005/21694 EH) Abdulkareem Idris (2005/21695 EH) Abiodun Folake Emmanuel (2005/21697 EH) ~ Aboderin Toluwalase Ajibola (2005/21698 EH) Achanya Bridget Ene (2005/21699 EH) Adams Abdulrazaq Abiodun (2005/21700 EH) AdanuEmmanuel Ngbede (2005/21701 EH) Adegbosin Solomon Olalekan (2005/21702 EH) ~ Adeniyi Folashade (2005/21704 EH) Eboh Uchechukwu (2005/21734 EH) Oriolowo Oloruntoba. (2005/21788 EH) iii gnature... ~1 \l.~;ps\~

4 CERTIFICATION This is to certify that this project report (thesis) entitled 'DESIGN OF A PLANT TO PRODUCE A TON PER BATCH OF LIQUID SOAP' by GROUP ONE meets the requirements for the partial fulfillment of the award of Bachelor of Engineering (B.Eng) degree in Chemical Engineering, Federal University of Technology, Minna. Prof.J.O.Odigure Project Supervisor Prof. F. Aberuagba Head of Department External Examiner iv

5 ACKNOWLEDGEMENT We are grateful to God Almighty (Allah) for His guidance and strength He bestowed on us that we may complete this project successfully., Our sincere appreciation to our supervisor, Prof. J.O. Odigure for his time, diligence and impressive supervision of this project work. We say a big thank you. To our colleagues and friends, we thank you and will miss you all.

6 ABSTRACT The title of the design work is "The design of a plant to produce a ton per batch of dish washing liquid soap". In order to achieve this, preliminary studies of the soap production process was carried out. With the knowledge of the basis, the material and energy balances were done for the process on a basis of 100 kmollbatch; the proc.ess flow sheet was drawn and mechanical design of the equipment was done. A detailed process control with a piping and instrumentation diagram was done for the plant. Start up and shut down procedures for the plant was drafted. Environmental impact and risk: assessme'nt cum safety and quality control for the plant and products produced were conducted in order to evaluate and ensure the longevity ofthe plant and maintain a high quality for the products. The cost and economic analysis were carried out using the detailed factorial method, the total capital investment was determined to be N 6,299, and the annual production cost was N 54,993, With a net income of N 28,829,621.34, the pay-back time was 2 years 3 months corresponding to a rate of return of The plant was estimated to have a project life of 20 years. v

7 TABLE OF CONTENT Cover page Declara~ion Acknowledgment Certification - Abstract 11 iii iv v Table of content VI Chapter one 1.0 Introduttion f 1.1 Soaps History of Soap Making 1. ].2 Soap Making Dish Washing Liquid Soap 1.2 Fats and oils Blend of Oils 1.3 Coconut oils i.3. i Physical Properties of Coconut Oil " Chemical Properties of Coconut Oil

8 Application of Coconut Oil 1.4 Alkali (lye) 1.5 Caustic potash from agricultural waste I Physicochemical Properties of Caustic Potash 1.6 Glycerine Uses of Glycerine 1.7 Design data 1.8 Problem statement 1.9 Product specification 1.10 Methodology Chapter - Two 2.0 Literature review 2.1 Chemical reaction kinetics and mechanism of soap making Reaction Kinetics Reaction Mechanism Factors Affecting the Chemical Reaction ~1.4 Ways of Improving the Saponification Reaction 2.2 Description of various processing Technologies The Cold Process <) 9 I() II I

9 ..., Semi Boiled Process Full Boiled Process Alternative Technique for Full Boiled Process '2.2.5 Continuous Process Detailed prbcess of the selected Technology, 2.4 Justification of the selected Technology Chapter Three 3.0 Material Balance 45 Chapter Four 4.0 Energy balance - Chapter Five 5.0 Flow sheet Chapter Six 6.0 Equipment design 6.1 Equipment design of oil mixer 6.2 Equipment design of caustic mixer Equipment sizing of reactor 6.4 Equipment sizing of finishing mixer (neat) 6.5 Equipment sizing of finishing mixer(nigre) 6X

10 Chapter Seven 7.0 Mechanical design Design of the oil mixer (agitator) to blend the oils Determination of the required agitation intensity Computation of required impeller pumping capacity Design of a mixer to dissolve alkali in water I,, i 7.4 Design of the reactor Design of the finishing mixer Design of decanter Vessel pressures and thicknesses 89 Chapter Eight 8.0 Reactor/ Equipment Optimization 95 Chapter Nine 9.0 Safety 9.1 Basic preventive and protective measures 9.2 Safety measures of the liquid soap plant Personal Safety. 9.3 Relevant safety instructions in operating the liquid soap plant Operational Instructions

11 9.3.2 Maintenance i Using Electricity ~.4 Avoidiilg fire or Explosion Handling poisons or toxic materials Noise In Plant Operation 9.4 Risk Assessment Quantitative Risk Assessment 9.5 Hazard identification cf.5.1 Safety Design Checklist , Processing Unit 9.6 Hazard a~d Operability study 9.7 Quality control Requirement \ 9.8 Sampling and characterization of the liquid soap 9.8.l Analysis for cation test Analysis for anion test Determination of the % free fatty acid of coconut oil Determination of tot a} fatty matter (TFM) in the soap Determination of% free alkali (% FA)

12 9.8.6 Determination of viscosity of liquid soap using a ford cup Determination of Saponification value of oils Determination ofna2c03 content of liquid soap Test for the presence of formalin in liquid product Determination of insoluble matter 116 I Me~surement of ph value Determination of rinsing properties Determination of moisture and volatile matter Determination of inorganic salts 118 Chapter Ten 10.0 Process Control and instrumentation Instrument Instrumentation and Control Objectives 119 1'0.2 Typical Control systems Level Control Pressure Control Flow Control Reactor Control Cascade Control

13 10J Alarms and Safety trips... Chapter Eleven 11.0 Environmental Acceptability Chapter Twelve 12.0 Start up and shut down procedure 12.1 Start up procedure 12.2 Shut down procedure 12J Emergency shutdown Chapter Thirteen 13.0 Plant location and site selection 13.1 Marketing Area 13.2 Raw Materials U J Transport 13.4 Local community considerations 13.5 Land (site considerations) 13.6 Climate 13.7 Political and strategic considerations 13.8 Availability of labour f3.9 Utilities (services)

14 0.10 Environmental impact, and effluent disposal Selection of site Justification of selected site Raw Material Transport Availability of Labour Utilities Climate Market Plant layout I Chapter Fourteen 14.0 Economic Analysis, Costing of oil mixer 14.2 Costing of caustic'mixer, 14.3 Costing ofreactor 14.4 Costing of finishing mixer 14.5 Costing of decanter. 1,.4.6 Purcha~e cost of miscellaneous Equipment 14.7 Raw mhterial cost

15 Variable Costs Fixed Costs 147 Chapter Fifteen 15.0 Recommendation to the industrialist