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A document containing a general manufacturing process of detergents.
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Chemical Process Technology II - Lab
CHEMICAL PROCESS TECHNOLOGY II - LAB
Process description of a Chemical Industry
Submitted to: Ms. Zahra Khan
Date: 13-6-2013
Prepared by:
NOAMAN AHMED CIIT/SP10-BEC-037/LHR
Department of Chemical Engineering
COMSATS Institute of Information Technology
Defence Road off Raiwind Road Lahore
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Noaman Ahmed CIIT/SP10-BEC-037/LHR
Chemical Process Technology II - Lab
Detergents
A detergent is a chemical compound that is commonly used for washing and cleaning of various
materials, surfaces, and products such as clothes, floors, tableware, chemical processing equipment
etc. Detergents can be classified into various types based on their application. Some common types
include,
Detergent Powders – Used for washing clothes
Liquid Detergents – Used for washing tableware
Floor detergents – Used for cleaning floors
Metal cleaning detergents – Specially formulated detergents for cleaning metals
Oil/Grease removal detergents – Specially formulated detergents for removal of oil and grease
stains from clothes and various surfaces
Based on their physical appearance and manufacture, detergents can be classified as,
Powdered detergents
Detergent bars or cakes
Liquid detergents
Detergent paste
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Noaman Ahmed CIIT/SP10-BEC-037/LHR
Chemical Process Technology II - Lab
Raw Materials
Detergents may contain varying percentages of linear alkyl benzene sulfonates, sulfates, fatty acids,
fatty alcohols and amines. Most of inorganic materials such as oleum (H2S2O7), NaOH, various sodium-
phosphates and a large number of builders and additives are also added during the manufacture of
detergents.
1. Surfactants
These are organic derivatives such as sodium salts of high molecular weight alkyl sulfates and
sulfonates.
2. Builders
These are inorganic chemicals that are added to detergents. Builders boost detergent power and
prevent re-deposition of soil from the wash water on fabrics. Complex phosphates such as Sodium Tri-
Polyphosphate (STPP) and Tetra-Sodium Pyrophosphate, are used as builders. Although, zeolites are
being used as substitutes for phosphates.
3. Additives
These chemicals enhance the properties of detergents and act as a medium for distinguishing various
brands of detergents based on their additive power and enhanced capabilities. Some common type of
additives include,
Corrosion inhibitors
Fabric shiner
Fabric softener
Bluing agents (improvement of whiteness of clothes)
Enzymes (help remove stains consisting of proteins)
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Noaman Ahmed CIIT/SP10-BEC-037/LHR
Chemical Process Technology II - Lab
Chemical Reactions
The chemical reaction that occurs during the manufacture of detergents is linear alkyl benzene
sulfonation. This reaction is divided into one main reaction and two secondary reactions
Main Reaction
Alkyl benzene reacts with oleum to form alkyl benzene sulfonate and sulphuric acid. The reaction is
exothermic.
R-C6H5 + H2SO4.SO3 R-C6H4-SO3H + H2SO4 ΔH = -420 kJ/kg
Secondary Reactions
Alkyl benzene sulfonate reacts with oleum to form di-sulfonate and sulphuric acid.
R-C6H4-SO3H + H2SO4.SO3 R-C6H3-(SO3H)2 + H2SO4
Alkyl benzene sulfonate reacts with alkyl benzene to form sulfone and water.
R-C6H4-SO3H + R’- C6H5 R-C6H4-SO2-C6H4-R’ (1%) + H2O
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Noaman Ahmed CIIT/SP10-BEC-037/LHR
Chemical Process Technology II - Lab
Manufacturing Process
Figure 1 –Simplified continuous flowchart for the production of heavy-duty detergent granules (Procter & Gamble Co.) Source: George T. Austin, “Shreve’s Chemical Process Industries”, 3rd ed., 1998.
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Noaman Ahmed CIIT/SP10-BEC-037/LHR
Chemical Process Technology II - Lab
SURFACTANT MANUFACTURE
Sulfonator unit
The main reaction, as mentioned previously, occurs in the sulfonator unit. Alkyl benzene and oleum
are added to the sulfonator unit where the reaction takes place and alkyl benzene sulfonate is formed.
As the reaction is exothermic, cooling coils are integrated with the reactor to cool off the excess heat.
Sulfator unit
The secondary reactions take place in the sulfator and disulfonate and sulfone are formed. Oleum and
the alkyl benzene sulfonate, from the sulfonator, are added to the sulfator unit and maintained at
operating temperature of 55°C.
Mixer
The product streams from the sulfonator and the sulfator are properly mixed in a mixer and passed
on to the surge tank.
Surge Tank and Cooler
The product from the mixer is pumped into the surge tank. The surge tank’s function is to mitigate
pressure variations that occur due to rapid changes in the velocity of the mixer product stream. Once
the required pressure condition is obtained, the product stream is passed on to the cooler where it is
cooled down to a specified temperature. After cooling, the product stream is passed on to the
neutralizer.
Neutralizer
Sodium hydroxide is added to the neutralizer to neutralize the surfactant mixture stream and this
process also helps to clean the mixed stream. Any unprocessed or un-neutralized product is recycled
to the mixer and follows through the surge tank and back into the neutralizer. After the neutralization,
the newly made surfactants are sent to a warehouse or a storage building to be stored as raw material
for detergent manufacture.
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Noaman Ahmed CIIT/SP10-BEC-037/LHR
Chemical Process Technology II - Lab
DETERGENT MANUFACTURE
Crutcher
The crutcher is a mixing unit that is steam and water jacketed from inside and is incorporated with
agitators for homogenous mixing. Raw materials for detergents which include surfactants, builders,
and additives are added to the crutcher. Various other chemicals such as colour pigments,
naphthalene and TiO2 are added to the crutcher unit. Naphthalene acts as a germicide. During the
crutching process, water is removed from the detergent mixture and a thick paste is formed which is
then forwarded to a drop tank, which is also used for pressure adjustment of the detergent paste
being pumped into the tank. From the drop tank, the detergent mixture is passed on to the spray
tower.
Spray Tower
The spray tower is usually a 24 m high column-shaped vessel which is primarily used for granulating
the detergent paste/mix. A furnace is integrated with the spray tower and the temperature inside the
spray tower is maintained at 115°C for proper/optimum granulation. Dried granules of acceptable size,
density and shape are obtained at the optimum operating conditions. The spray tower is also
integrated with a cyclone separator and a stack removal system in order to remove light weight
impurities and flue gases, thus forming an environmental protection approach.
Cyclone Separator, Screening and Filtration
The granules from the spray tower are passed on to the cyclone separator which separates the heavy
granules from the light ones on the principle of centrifugal forced separation. The product from the
cyclone separator is subjected to a screening chamber where granules of required size pass through
and the remaining are sent to the filter unit.
The light weighted granules from the cyclone separator are also sent to the filter unit, in order to
separate granules of required size.
Perfume addition and Packing
Finally, perfume and fragrant smells are added to the detergent granules. Afterwards, the granules
are forwarded to the packing section for sale and distribution.
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Noaman Ahmed CIIT/SP10-BEC-037/LHR
Chemical Process Technology II - Lab
References
George T. Austin, Shreve’s Chemical Process Industries, 3rd ed., McGraw Hill Publications, 1998.
http://en.wikipedia.org/wiki/Surge_tank
http://en.wikipedia.org/wiki/Detergent