pulp synopsis

7/23/2019 pulp synopsis

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NAME : LALICHETTI SURESH

ROLL NUMBER : 04/S4/128

REGISTRATION NUMBER : M/111/10/29

TITLE OF THE PROBLEM : Manufacturing of

Sodium od!c"# $!n%!n! Su#fonat! of 10&000&000

'g /annum(

1



NOP I

2



INTRODUCTION

T)! *a+)ing indu+tr"& u+ua##" ,no*n a+ t)! +oa- indu+tr"& )a+ root+

o.!r 2000 "!ar+ in t)! -a+t& a +oa- factor" )a.ing !!n found in t)!

om-!ii !ca.ation+( Ho*!.!r& among t)! man" c)!mica# -roc!++

indu+tri!+& non! )a+ !-!ri!nc!d +uc) a fundam!nta# c)ang! in c)!mica#

ra* mat!ria#+ a+ )a.! t)! *a+)ing indu+tri!+( It )a+ !!n g!n!ra##"

acc!-t!d t)at t)! -!rca-ita u+! of toi#!t +oa- i+ a r!#ia#! guid! to t)!

+tandard of #i.ing for an" countr"(

Soa- it+!#f *a+ n!.!r actua##" 3di+co.!r!d& ut in+t!ad gradua##" !.o#.!d

from t)! crud! mitur!+ of a#,a#in! and fatt" mat!ria#+( #in" and E#d!r

d!+cri!d t)! manufactur! of ot) )ard and +oft +oa- in t)! 5r+t c!ntur"&

ut it *a+ not unti# t)! t)irt!!nt) c!ntur" t)at +oa- *a+ -roduc!d in +uc)

6uantiti!+ to ca## it an indu+tr"( U- to t)! !ar#" 1800+ +oa- *a+ !#i!.!d to

! a m!c)anica# mitur! of fat and a#,a#i7 t)!n C)!.r!u#& a r!nc) c)!mi+t&

+)o*!d t)at +oa- formation *a+ actua##" a c)!mica# r!action( om!i!r

com-#!t!d )i+ r!+!arc) on t)! r!co.!r" of g#"c!rin from +a-oni5cation

mitur!+ in t)i+ -!riod(

T)! ra* mat!ria# +)ortag!+ of or#d ar I #!d t)! :!rman+ to d!.!#o-

3+"nt)!tic +oa-+ or !t!rg!nt+( T)!+! *!r! com-o+!d of +)ortc)ain!d

a#,"# na-)t)a#!n! +u#fonat!+& *)ic) *!r! good *!tting ag!nt+ ut on#" fair

in d!t!rg!nt action( T)i+ +-ar,!d t)! int!r!+t *or#d*id! in d!.!#o-ing

;



d!t!rg!nt+& and n!* d!.!#o-m!nt+ ar! continuing to t)! -r!+!nt tim!(

rom t)! origina# +)ortc)ain com-ound+ t)! d!.!#o-m!nt )a+ -rogr!++!d

t)roug) #ong c)ain a#co)o# +u#fat!+ in t)! 1920+ and 19;0+& t)roug) t)!

a#,"#ar"# #ong c)ain +u#fonat!+ in t)! 1940+&to ranc)!d c)ain com-ound+

in t)! 19<0+ and 19=0+( uring t)! 19=0+ t)! r!6uir!m!nt of

iod!gradai#it" !cam! im-ortant and cau+!d t)! r!turn to #in!ar #ong

c)ain+& !cau+! on#" t)! #in!ar c)ain+ can ! !a+i#" iod!grad!d(

!t!rg!nt+ di>!r from +oa- in t)!ir action in )ard *at!r( Soa-+ form

in+o#u#! com-ound+ *it) t)! ca#cium and magn!+ium ion+ -r!+!nt in

)ard *at!r( T)!+! in+o#u#! com-ound+ -r!ci-itat! out and r!duc!

foaming and c#!aning action( !t!rg!nt+ ma" r!act *it) t)! )ard *at!r

ion+& ut t)! r!+u#ting -roduct+ ar! !it)!r +o#u#! or r!main co##oida# in

com-o+ition and manufactur!( Sci!nti5ca##"& t)! t!rm d!t!rg!nt co.!r+

ot) +oa- and +"nt)!tic d!t!rg!nt+& or 3+"nd!t+ a+ it i+ *id!#" u+!d to

indicat! +"nt)!tic c#!aning com-ound+& a+ di+tingui+)!d from +oa-(

MANUFACTURING METHODS

Lin!ar a#,"# !n%!n! ?LA$@ i+ manufactur!d in #arg! +ca#! indu+tria#

-roc!++!+ "

A#,"#ating !n%!n! *it) #in!ar monoo#!5n+ or a#,"# )a#id!+ +uc) a+ c)#oro

-aran+ " u+ing H or A#C#; a+ t)! a#,"#ation cata#"+t(

4



1@ B.!r )!t!rog!n!ou+ +o#id +u-!r acid+ in a 5!d !d r!actor(

A#,"#ation *it) A#C#; *a+ t)! 5r+t comm!rcia# -roc!++ u+!d in mid =0+

*)!n ranc)!d od!c"# $!n%!n! *a+ r!-#ac!d " Lin!ar A#,"# $!n%!n!

?LA$@( At t)! !nd of t)! =0+ t)! H t!c)no#og" *a+ a--#i!d for t)! 5r+t

tim! and imm!diat!#" it !cam! t)! -r!f!rr!d t!c)no#og" to ! u+!d

around t)! *or#d to -roduc! LA$(

In t)! mid 90+ a n!* a#,"#ation t!c)no#og" a+!d on t)! )!t!rog!n!ou+

cata#"+t in a 5!d!d r!actor& !ta#& a--!ar!d on t)! mar,!t and *a+

ra-id#" ado-t!d& a+ t!+ti5!d " +!.!ra# n!* unit+ r!c!nt#" in+ta##!d *it)

t)i+ t!c)no#og"( T)! n!* t!c)no#og" o>!r+ con+id!ra#! ad.antag!+ o.!r

t)! o#d on!+& nam!#"D -roc!++ +im-#i5cation& !#imination of acid )and#ing

and di+-o+a# ?H& HC#& A#C#;@ a+ *!## a+ an o.!ra## -roduction "i!#d

im-ro.!m!nt(

Tota# LA$ *or#d -roduction ca-acit" in t)! "!ar 2000 *a+ !+timat!d to !

n!ar#"

; mi##ion ton+& *it) a +-#it " t!c)no#og" a+ fo##o*+D 80H& 10A#C#;&

10 5!d!d( S!.!ra# comm!rcia# -roc!++!+ ar! foundD MBLEF ?UB@&

EGSBR$ ?EFFBG@& ISBSIEE ?Union Carid!@ !tc((

PROCESS DESCRIPTION:

<



T)! -roc!++ in.o#.!+ r!action of od!c!n!?C12H24@ *it) !n%!n!?C=H=@ in

t)! -r!+!nc! of A#uminium C)#orid!?A#C#;@ cata#"+t& fractionation of t)!

r!+u#ting crud! mitur! to r!co.!r t)! d!+ir!d oi#ing rang! of

dod!c"#!n%!n!?C=H<C12H2<@& +u#fonation of t)! dod!c"#!n%!n! and

+u+!6u!nt n!utra#i%ation of t)! +u#fonic acid *it) cau+tic +oda?GaBH@&

#!nding t)! r!+u#ting +#urr" *it) c)!mica# ui#d!r+ and dr"ing(

od!c!n! i+ c)arg!d into a r!action .!++!# containing !n%!n! and

a#uminiumc)#orid!( T)! r!action mitur! i+ agitat!d and coo#!d to

maintain t)! r!action t!m-!ratur! of aout 4<0C( An !c!++ of !n%!n! i+

u+!d to +u--r!++ t)! formation of "-roduct+( A#uminiumc)#orid!

r!6uir!m!nt i+ < to 10*t of dod!c!n!( A#uminiumc)#orid! i+ a +trong

L!*i+ acid( It r!act+ .igorou+#" and !ot)!rmica##" *it) *at!r forming HC#&

*)ic) i+ ot) corro+i.! and -oi+onou+( An" +-i##+ ar! to ! c#!an!d

imm!diat!#"( :ranu#ar A#C#; ?J 4 to 14 m!+)@ i+ -r!f!rr!d m!ta# )a#id! to

!m-#o"( It i+ !a+" to )and#! in air *it)out fuming -ro#!m+ and )a+ good

Ko* -ro-!rti!+(

Aft!r r!mo.a# of A#C#; cata#"+t +#udg!& t)! r!action mitur! i+

fractionat!d to r!co.!r !c!++ !n%!n! ?*)ic) i+ r!c"c#!d to t)! r!action

.!++!#@ unr!act!d dod!c!n! and dod!c"# !n%!n!(

Su#fonation of t)! dod!c"# !n%!n! ma" ! carri!d out continuou+#"

or atc)*i+! und!r a .ari!t" of o-!rating condition+ u+ing +u#furic acid

?100@& B#!um ?u+ua##" 20 SB;@ or an)"drou+ +u#furtrioid!( T)!

=



o-timum +u#fonation t!m-!ratur! i+ u+ua##" in t)! rang! of ;oC to =0oC

d!-!nding on t)! +tr!ngt) of acid !m-#o"!d& m!c)anica# d!+ign of t)!

!6ui-m!nt& !tc( R!mo.a# of t)! +-!nt +u#furic acid from t)! +u#fonic acid

i+ faci#itat!d " adding *at!r to r!duc! t)! +u#furic acid +tr!ngt) to aout

8( T)i+ di#ution -rior to n!utra#i%ation r!+u#t+ in a 5na# n!utra#i%!d +#urr"

)a.ing a--roimat!#" 8< acti.! ag!nt a+!d on t)! +o#id+( T)! in!rt

mat!ria# in t)! 5na# -roduct i+ !++!ntia##" GaSo4(

T)! +u#fonic acid i+ n!utra#i%!d *it) 20 to <0 cau+tic +oda ?GaBH@

+o#ution to a -H of 8 at a t!m-!ratur! of aout <00C( C)!mica# ui#d!r+

+uc) a+ tri+odium -)o+-)at!& t!tra+odium-)o+-)at!& +odium +i#icat!&

+odiumc)#orid!& +odium+u#fat!& caro"m!t)"# c!##u#o+! !tc ar! add!d to

!n)anc! t)! d!t!r+i.!& *!tting or ot)!r d!+ir!d -ro-!rti!+ in t)! 5ni+)!d

-roduct( A Ka,!d& dri!d -roduct i+ otain!d " drum dr"ing or a !ad

-roduct i+ otain!d " +-ra" dr"ing(

T)! a+ic r!action+ *)ic) occur in t)! -roc!++ ar! t)! fo##o*ing(

ALKYLATION

Reaction 1

C6H

6 + C

12H

24 C

6H

5C

12H

25

SULFONATION

Reaction 2



C6H5C12H25 + H2SO4 C12H25C6H4SO3H + H2O

NEUTRALISATION

Reaction 3

C12H25C6H4SO3H + NaOH C12H25C6H4SO3Na + H2O

Reaction 4

H2SO4 + 2NaOH Na2SO4 + 2H2O

A #it!ratur! +!arc) indicat!+ t)at "i!#d+ of 8< to 9< )a.!

!!n otain!d in t)! a#,"#ation +t!-& *)i#! "i!#d+ for t)! +u#fonation

-roc!++ ar! +u+tantia##" 100(i!#d+ for t)! n!utra#i%ation +t!- ar!

a#*a"+ 9< or gr!at!r (A## t)! r!action +t!-+ ar! !ot)!rmic and r!6uir!

+om! form of Nac,!t!d coo#ing around t)! +tirr!d r!actor to maintain

i+ot)!rma# r!action t!m-!ratur!+(

RAW MATERIALS REQUIREMENT

T)! c)!mica#+ t)at ar! r!6uir!d in t)! manufactur! of Sodium od!c"#

$!n%!n! Su#fonat! ?C12H25C6H4SO3Na in.o#.! t)! fo##o*ing(

1@ $!n%!n! ? C6H6 @2@ o!c!n! ?C12H24 @;@ A#uminium C)#orid! ? A!C!3 @4@ B#!um ? H2S2O" @<@ Sodium H"droid! ? NaOH @=@ at!r ? H2O @

8



PROCESS DESIGN OF THE EQUIPMENT

T)! -roc!++ d!+ign of t)! !6ui-m!nt in.o#.!+ d!+ign of a R!actor and a

i+ti##ation Co#umn( T)! R!actor t)at i+ in.o#.!d i+ a Continuou+ Stirr!d

Tan, R!actor t"-! )a.ing a .o#um! of 2<m; *it) a *a## t)ic,n!++ of (004m

and )a.ing a diam!t!r of 2(=<m and a )!ig)t of ;( m& )a+ to ! d!+ign!d

for t)! -roc!++( T)! i+ti##ation Co#umn t)at )a+ to ! d!+ign!d i+ of a

inar" i+ti##ation Co#umn t"-! )a.ing t)! #ig)t!r ,!" a+ 3$!n%!n! and

t)! )!a.i!r ,!" a+ 3od!c!n!& *)ic) o-!rat!+ at 1 'g/cm2 -r!++ur!

and )a.ing an o.!r)!ad t!m-!ratur! of 8;0C and a ottom t!m-!ratur! of

2=<0C(

MECHANICAL DESIGN OF THE EQUIPMENT

T)! Continuou+ Stirr!d Tan, R!actor t)at i+ u+!d +)ou#d ! mad! of Ca+t

St!!# )a.ing a diam!t!r of 2(=<m& )!ig)t of ;(m *it) a *a## t)ic,n!++ of (

004m )a.ing an o-!rating -r!++ur! of 1'g/cm2(T)! di+ti##ation co#umn t)at

)a+ to ! d!+ign!d +)ou#d ! mad! of Ca+t St!!#& o-!rat!+ at a -r!++ur! of

1'g/cm2 )a.ing an o.!r)!ad t!m-!ratur! of 8;0C and a ottom )!ad

t!m-!ratur! of 2=<0C(

9



CONSIDERATION OF SAFETY AND POLLUTION OF THE

PLANT

Lin!ar A#,"# $!n%!n! +u#fonat!+ a+ ad!6uat!#" iod!grada#!( T)!+!

ar! io 3+oft +urfactant+( $ut t)!" ar! not ro,!n do*n a+ r!adi#" and

com-#!t!#" a+ +oa-+ and ot)!r +urfactant+ d!ri.!d from fat+ or

+"nt)!+i%!d to contain a com-#!t!#" unranc)!d c)ain *it) an !.!n

num!r of caron atom+ and no !n%!n! ring( !ar+ of +"+t!matic

monitoring of +!*ag! tr!atm!nt -#ant+ and ri.!r+ )a+ +)o*n t)at in

g!n!ra# t)! r!+idua# conc!ntration of +urfactant+ in +tr!am+ i+ !tr!m!#"

+ma##(

$iod!gradation in +!*ag! tr!atm!nt -#ant mod!#+ +)o*+

rimar" $iod!gradation

BEC con5rmator" t!+t 90 O 9<

M$A/$iAS/AS r!mo.a#

U#timat! $iod!gradation

Cou-#!d unit+ t!+t& ;J= ?C@

C/CB/r!mo.a#

10



Hig) iod!grada#! anionic +urfactant+ a##o*!d " t)! #a* ar!

of on#" margina# toicit" to 5+)( It i+ +)o*n t)at toicit" i+ in.!r+!#"

-ro-ortionat! to iod!gradai#it"(

Toicit" data of a#,"#!n%!n! +u#fonat!

?mg/#@

LC<0 ?5+)!+@ ; 10

LC<0 ?da-)nai!@ 8 <0

GBEC ?a#ga!& gro*t) in)iition@ ;0 O ;00

or anionic +urfactant+ t)! #!ngt) of t)! a#,"# c)ain )a+ !!n

found to ! c#o+!#" r!#at!d to +,in irritai#it"( Straig)t c)ain or Lin!ar a#,"#

!n%!n! +u#fonat! +)o* *!a, !>!ct+ to +,in& +inc! t)!" ar! io+oft(

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pulp synopsis