Detergent Complex Based on Palm Stearin - Chemithon Based on Pal… · Feasibility Studies ... DETERGENT COMPLEX BASED ON PALM STEARIN ... Soft Soap Recommended sale price Cost of

PIPOC 2007, MalaysiaPIPOC 2007, Malaysia

August 29, 2007August 29, 2007

Detergent Complex Detergent Complex Based on Based on

Palm StearinPalm Stearin

AgendaAgenda

About Trivedi GroupAbout Trivedi Group

Basic Requirements and Process ChemistryBasic Requirements and Process Chemistry

Products and FormulationsProducts and Formulations

Cost StructureCost Structure

SummarySummary

Global Changes call for Action Now!Global Changes call for Action Now!

Hurricanes and natural disastersHurricanes and natural disasters

Global warmingGlobal warming

Fossil vs. RenewableFossil vs. Renewable

Food vs. FuelFood vs. Fuel

TRIVEDI GROUP(Since 1986)

TECHNOLOGY&

ENGINEERING

SURFACTANTMANUFACTURING

PROJECTSERVICES

CHEMICALTRADING

Organization ChartOrganization Chart

TECHNOLOGY&

ENGINEERING

Chemithon Engineers Pvt Ltd

Sulfonation of alkylates

Environmental Systems

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

CustomBlends

Amphoterics

Nonionics

Cationics

Specialities

SURFACTANT MANUFACTURING

CHEMICAL TRADINGCHEMICAL TRADING

Palm Derivatives Alcohols

Detergent Alkylates

Surfactants

EthoxylatesZeolites

Specialities

Soap Noodles

PROJECT SERVICES

Business Promotion (NRDC)

Market Studies

Project Appraisal (IFC)

Feasibility Studies

Project Co-ordination

Energy Audit

CPO with 5% FFA (1000 MT)

Extraction

Refining

Fractionation

RBD Palm Stearin

(185 MT)

RBD Palmolein (745 MT)

Vitamin E (1.5 – 2.0 MT)

PFAD (65 MT)

Requirements for Palm Plantation Based Requirements for Palm Plantation Based on Bioon Bio--RefineryRefinery

•• Minimum Area: 60.000 HectaresMinimum Area: 60.000 Hectares

•• FFB FFB

CPO: 1000 TPDCPO: 1000 TPD

PKO: 100 TPD PKO: 100 TPD

Mass Balance

A detergent based complex of Palm Stearin creates A detergent based complex of Palm Stearin creates tangible advantagestangible advantages

•• Sustainable value creation from Palm StearinSustainable value creation from Palm Stearin

•• Independent revenue platformsIndependent revenue platforms

Pharmaceuticals (Glycerine)Pharmaceuticals (Glycerine)

Fuel (Biodiesel Fuel (Biodiesel –– C18 rich)C18 rich)

Alkylates (C12Alkylates (C12--14, C16)14, C16)

Detergents and Home & Personal care productsDetergents and Home & Personal care products

•• Based on renewal resourceBased on renewal resource

•• Environmentally friendly project Environmentally friendly project

RBD PS (185 MT)

Transesterification

Distillation

Hydrogenation

Sulfonation

Blending / Drying

C1214 Ester (2.5 MT)C16 Ester (110 MT)C18 Ester (71 MT)

Amidation / AmidesEthoxylation / ME Ethoxylates

Glycerine (18 MT)

HPC Products Detergents (725 MT)

MES (145 MT)

Typical mass balance highlighting various steps Typical mass balance highlighting various steps in the processin the process

GlycerolTriglyceride + Alcohol Esters +

CH2-OH

CH2-OH

CH2-OH

CH2-OOC-R1

CH -OOC-R2

CH2-OOC-R3

+ 3R’OH

R1-COO-R’

R2-COO- R’

R3-COO- R’

+Catalyst

@ 60 - 70˚C

Step 1: Transesterification step converts a triglyceride Step 1: Transesterification step converts a triglyceride to esters and glycerolto esters and glycerol

Step 2: Distillation of fractions is done via a Step 2: Distillation of fractions is done via a three stage conversion columnthree stage conversion column

C1214 C16 C18

Step 3: A continuous fixed bed column is used for Step 3: A continuous fixed bed column is used for hydrogenation stephydrogenation step

SULFONATION

DIGESTION

BLEACHING

NEUTRALIZATION

DRYING

METHYL ESTER1V0.1

METHYL ESTER SULFONATES (MES)(>85% ACTIVE AND <5% DISALT)

MeOH RECOVERY

Step 4: Sulfonation of esters yields methyl ester Step 4: Sulfonation of esters yields methyl ester sulfonates (MES)sulfonates (MES)

kgMES 843Di-salt 49Sodium methyl sulfate 50Unsulfonated 20Na2SO4 10Moisture 26Hydrogen Peroxide 1Methanol 1Total 1,000

Methanol Recovery

C16 MES(MW 372) has the typical mass balance as C16 MES(MW 372) has the typical mass balance as shown in the flowsheetshown in the flowsheet

SO3 gas generation

Sulfonation

MESA digestion

MESA bleaching

Neutralization

Drying

MES

Sulfur (95)

50% Caustic (242)

50% H2O2 (35.6)

Methanol Makeup (40)

C16 methyl ester (662)

Distillation (226)

STILL AWAKE???

Palm KernelC8-c18 Coconut

C12-C14

Palm StearinC16-C18

SoyaC18 Tallow

C16-C18

Different forms of MES dried and stripped can be Different forms of MES dried and stripped can be obtained as final productobtained as final product

Some pictures of the Huish PlantSome pictures of the Huish Plant

Flowsheet for Detergent Powder PlantFlowsheet for Detergent Powder Plant

100100TotalTotal

55MoistureMoisture

3030Sodium SulfateSodium Sulfate

1515STPPSTPP

1010Sodium SilicateSodium Silicate

2020Sodium CarbonateSodium Carbonate

88MESMES

1212LASLAS

%%

Typical Components in a Detergent FormulationTypical Components in a Detergent Formulation

Huish products are used in a variety of products both powder and liquid

100100TotalTotal79.579.5WaterWater

22Viscosity ModifiedViscosity Modified0.50.5GermicideGermicide33GlycerineGlycerine99AESAES66MESMES%%

Typical Components in a Soft Soap FormulationTypical Components in a Soft Soap Formulation

Different Products containing MES in their formulationDifferent Products containing MES in their formulation

50.0Total CAPEX

8.0Detergents & HPC (30 KT/20 KTA)

13.0Sulfonation (40 KTA)

9.0Distillation (300 TPD) + Hydrogenation (180 TPD)

13.0Ester (300 TPD) + Glycerine (30 TPD)

7.0Infrastructure

USD (million)Estimate for a 300 TPD RBD PS

DETERGENT COMPLEX BASED ON PALM STEARIN

Typical capital expenditure for a palm based detergent Typical capital expenditure for a palm based detergent complex is about $ 50 millioncomplex is about $ 50 million

1050850700Recommended sale price

Basis: RBD PS @ USD 650 PMT

918768665Cost of Production/ Tonne2979Depreciation1576Financial Charges1174Overheads1466Operating Costs523742Utilities797704598Raw MaterialsMESDistillation+ H2Esterification

USD (miilion)

Estimated costs for esterification, distillation Estimated costs for esterification, distillation and MES productionand MES production

USD

1200

792

1511141242698

WithoutMES

Detergent

1200

724

1511141241631

WithMES

1200

794

1712232044678

Soft Soap

Recommended sale price

Cost of Production/ Tonne

DepreciationFinancial ChargesOverheadsOperating CostsUtilitiesRaw Materials

Estimated production costs for soft soap Estimated production costs for soft soap and detergentsand detergents

•• Integrated complex with optimum value additionIntegrated complex with optimum value addition

•• Sustainability using renewable raw materialsSustainability using renewable raw materials

•• MES in dry flakes form MES in dry flakes form -- convenience of useconvenience of use

•• Biodiesel EN 14214 compliant (summer grade)Biodiesel EN 14214 compliant (summer grade)

•• Independent revenue platformsIndependent revenue platforms

Project provides multiple advantages across Project provides multiple advantages across different platformsdifferent platforms

Thank You!Thank You!

Address: SHIV ANAND-A1ST FLOOR, 372/374S. V. ROAD, GOREAGAON (W)MUMBAI - 400 104INDIA

Website: www.trivedigroup.comEmail: [email protected]

“ The best way to predict the future is to create it”