Magnesium Lauryl Sulfate

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1 CHAPTER 1 INTRODUCTION 1.1 BACKGROUND Magnesium lauryl sulphate is also known as magnesium dodecylsulphate. Its chemical formula is Mg(CH 3 (CH 2 ) 11 OSO 3 ) 2 . It exists in pale yellow liquid, mild odor, soluble in methanol,acetone and water but insoluble in kerosene. For reactivity profile, magnesium lauryl sulphate is soluble in water to produce a solution which has pH value higher than 7.0. It reacts as base to neutralize acid. It usually does not react as either oxidizing agents or reducing agents but such behaviour is not impossible. It is combustible. Figure 1.1 shows the structural formula of magnesium lauryl sulphate.

Transcript of Magnesium Lauryl Sulfate

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CHAPTER 1

INTRODUCTION

1.1 BACKGROUND

Magnesium lauryl sulphate is also known as magnesium dodecylsulphate. Its

chemical formula is Mg(CH3(CH2)11OSO3)2. It exists in pale yellow liquid, mild odor,

soluble in methanol,acetone and water but insoluble in kerosene. For reactivity profile,

magnesium lauryl sulphate is soluble in water to produce a solution which has pH

value higher than 7.0. It reacts as base to neutralize acid. It usually does not react as

either oxidizing agents or reducing agents but such behaviour is not impossible. It is

combustible.

Figure 1.1 shows the structural formula of magnesium lauryl sulphate.

Figure 1.1 Structural Formula Of Magnesium Lauryl Sulphate

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Magnesium lauryl sulphate is used mainly in industries for the production of

soap, detergents, cosmetic, skin care products, toothpaste, pesticide and others. It is an

anionic surfactant or surface-active agent and has been used widely as an ingredient of

cleaner.

The raw materials for the production of magnesium lauryl sulphate are lauric

acid and methanol. The raw materials undergo four main unit processes, namely

neutralisation, hydrogenation, sulphation and mixing. Methyl laureate will be

produced during the esterification reaction. It is then hydrogenated to form lauryl

alcohol. The lauryl alcohol is then sulphated to form lauryl sulphate before it is mixed

with magnesium hydroxide to form magnesium lauryl sulphate.

Magnesium lauryl sulpahte has its own unique physical properties. Table 1.1

shows the physical properties of Magnesium lauryl sulphate.

Table 1.1 Physical Properties Of Magnesium Lauryl Sulphate

Properties Magnesium lauryl sulphate

Molecular formula Mg(CH3(CH2)11OSO3)2

Molar mass 278.56g/mol

CAS number 3097-08-3

Appearance Liquid

Boiling point 174.4oC

Melting point -46oC

Specific gravity 0.935

Vapour density 6.2

Source: LookChem 2007

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CHAPTER 2

APPLICATION AND ECONOMY

2.1 PRODUCT USAGE

Magnesium lauryl sulfate is made by joining sulfate and lauric acid, two substances

which are both abundant throughout the body. Applications most relevant in terms of

public exposure include it used as a surfactant. Magnesium lauryl sulfate surfactants

consisting of both sulphates straight chain alcohol and fatty alcohol ether sulfate are

available primarily in the lauryl chain length. It is biodegradable. It provides high

foaming even in the present of hard water and exhibit good wetting and emulsifying

properties. Magnesium lauryl sulphate is used in car shampoo, bubble baths, shaving

creams, cleansing creams, industrial cleaner, foams and dust control, liquid household

detergents and others. (Flick, 1993)

Magnesium lauryl sulphate has its own advantages which are have good

foaming properties especially if some unsulfated alcohol is retained in the product.

Surfactant is a chemical compound that possesses great surface activity. Magnesium

lauryl sulphate is a good anionic surfactant which is used to make anionic detergent in

the absence of high water hardness ion such as magnesium ion. However, in the

absence of builders and presence of high water hardness, its effectiveness as cleaners

will be reduced. Magnesium lauryl sulphate has disadvantages and negative impacts

towards environment and daily life. It may cause skin and eye irritation. Hence

combination with other surfactants such as alkanolamides is necessary to lower

irritancy and to deliver desirable qualities (Gervajio, 2005).

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In modern technology, surfactants such as magnesium lauryl sulphate have

replaced soap as a foaming agent in most of the modern toothpaste. It has better

keeping properties are equally effective in either acid or alkaline media and do not

form precipitate of calcium salts with hard water or saliva. Surfactants can be

classified according to their odour and taste, their foaming, emulsifying and cleansing

properties, their stability to acids and alkalis and their compatibility with other

ingredients of the paste. (Board, 2000)

Magnesium lauryl sulfates is used in the carpet cleaner. It functions to pull the

dirt and grime out of the carpet fibre and then dries so that vacuum cleaning can

effectively remove the dirt. Magnesium lauryl sulphate is usually used in the

combination of sodium lauryl sulphate to wet the surface of the fibre where the most

of the dirt is collected. In particular, magnesium lauryl sulphate helps surround the

dislodge dirt into a more friable, dried mass on the surface of the fibre for easily

removal with a vacuum cleaner. (Nelson, 1990)

Cosmetics products are created for application on the body for the purpose of

cleansing, beautifying or altering appearance and enhancing attractive features

Magnesium lauryl sulphate has been included as ingredients for making cosmetic

product. (Flick, 1991). There are also product usages of magnesium lauryl sulfate

which include:

I- It is used in pesticides in preventing, destroying, repelling, or mitigating any

pest.

II- It is used in the production of soap that is used in daily life.

III- It act as a base for ceramic tiles adhesives, for wood and general purpose

adhesives in building industry

IV- It is a cleaning agent used in contact lens solution

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2.2 DEMANDS

Magnesium lauryl sulphate is a chemical which is used in the industries which are

producing soap, shampoo, detergent, cosmetic and skin care products. Its raw

materials are fatty acid, methyl ester, and lauryl alcohol, which both are

oleochemicals.

In Malaysia, the demand of magnesium lauryl sulphate is moderate. The

growth of the demand of magnesium lauryl sulphate in local market is not clear. There

is lack of reliable yet relevant commercial reports or articles to show the growth of the

demand and its production rate. The use of magnesium lauryl sulphate for productions

is not common. Sodium lauryl sulphate is used widely instead.

Based on an article from Indonesian Commercial Newsletter in 2002, the

production rate for oleochemical increased 8% per annum from 526,259 tons in 1997

to 712,012 tons in 2001. In 2001, the annual production capacity of fatty acid is

374,000 tons, 55,900 tons of glycerine, 90,000 tons of fatty alcohol and 10,000 tons of

methyl ester. The production of fatty acid has made 67% of the total production of

oleochemical. Based on the statistics given, the growth of the demand of fatty acid in

Indonesia shows positive sign to the market and it is estimated to be increased in the

following years.

Globally the production of fatty acid shows increment as the demand is

increased. Figure 2.1 shows the global fatty acid production capacity for areas from

1999 to 2006.

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America Europe Asia Total0

1

2

3

4

5

6

7

8

Global Fatty Acid Production Capacity

199920002001200220032006

Area

Pro

du

ctio

n C

apac

ity(

mill

ion

ton

nes

)

Figure 2.1: Global Fatty Acid Production Capacity From 1999-2006.

Source: MPOB, 2005

Fatty acid is the main raw material for the production of magnesium lauryl

sulfate. From the bar chart above, the global fatty acid production capacity is constant

for America and Europe from 1999 to 2006. Meanwhile for Asia, the production

capacity of fatty acid is increased over the years. Overall, the production has increased

from 5 million tones to 7million tones.

As a conclusion, the increasing production of fatty acid from 1999 to 2006 has

given a relationship that the demand of the magnesium lauryl sulfate is also increasing

as its raw material is highly produced.

Most of the application of magnesium lauryl sulphate is in the industry of

cleaner or soap. According to a data from Wikipedia, the demand of soap, detergents

and cleaners shows increment from 1997 to 2007. Figure 2.2 shows the growth of the

demand for chemical products from 1997 to 2007.

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Figure 2.2: The Growth Of The Demand For Chemical Products 1997-2007.

Source: Wikipedia, 2010

The demand for oleochemical products such as soap and detergents are

increased from 1997 to 2007. The graph has clearly shown that the oleochemical

products are needed worldwide in big capacity. There are about 120 million tonnes per

year of soap, detergents and other products produced to meet the huge global demand.

These oleochemical products are derived from oleochemical. Magnesium lauryl

sulphate is the main ingredient for these products. As the demand of the soap and

other oleochemical products is increasing, the demand for the magnesium lauryl

sulphate is also increasing for the production of oleochemical products.

Through Figure 2.1 and Figure 2.2, the raw material of the production of

magnesium lauryl sulphate which is fatty acid has shown increment over the years.

The global demand for oleochemical products such as soap and detergents also

Years

Demand (million tons) Graph Of Demand Of Chemicals Against Years

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increased. Magnesium lauryl sulphate is needed for the production of these

oleochemical products.

Hence an overall conclusion can made that the demand of magnesium lauryl

sulphate is also increased.

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2.3 DEMAND AND SUPPLY

Magnesium lauryl sulphate is mainly produced in Asia due to the growth of the new

modern oleochemical industry. Meanwhile the Europe also playing an important role

for supplying of this chemical. Overall, this chemical is produced mainly from China,

South Korea, USA and United Kingdom. Table 2.1 below shows a list of supplier of

magnesium lauryl sulphate over the countries.

Table 2.1 Supplier of Magnesium Lauryl Sulfate

Company Location

Carbone Scientific Co.Ltd United Kingdom

Molekula Ltd. United Kingdom

Eurolabs Limited United Kingdom

UK Green Scientific Co.Limited United Kingdom

Honest Joy Holdings Limited USA

2A Pharmachem USA USA

Chemical Land21 South Korea

Shanghai New Union Textra Import & Export Co. Ltd China

Nanjing Chemlin Chemical Co.Ltd China

Beijing Tianli Biological Chemical Co.Ltd China

Source: Chemical Book, 2010

The supplier of magnesium lauryl sulphate, UK Green Scientific Co. Limited

is located in United Kingdom. It is a professional company committed to provide the

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best international services to help the global drug discovery develop innovative

medicines and products to treat patients, ease suffering and to enhance the quality of

life. With a strong supplier network combining an advanced information exchanging

platform and world-class services, they offer flexible customer synthesis and bulk

chemicals in a timely, high purity and cost-effective manner with the assurance of

quality and confidentiality. ( Green Scientific, 2010 )

The next company that produce magnesium lauryl sulfate is Nanjing Chemlin

Chemical Industry Co., Ltd. It was established in December of 1999. Business scope

covers Commodity Chemicals, intermediates & fragments and custom synthesis &

manufacture. Their products include bulk commodities, lab agents, intermediates &

fragments, special chemicals, agro-chemicals, APIs, natural ingredients etc., handling

quantity from milligrams to multi-kgs. They have established long-term relation with

various international professional suppliers for many products by way of spot

transaction, agency dealing, or contracted production, and co-developing, etc. With

the rapid growth of this company, they are step-forwarding to set up more cooperation

chance with their clients for mutual interest and benefits. ( TM Chemlin, 2009)

Chemicalland21.com is also one of the companies that produced magnesium

lauryl sulfate which located in South Korea. They aim to be a resource of industrial

chemical information including technical data, safety data, market prices and related

compounds. ( Chemicalland 21, 2008)

Magnesium lauryl sulphate is not a common chemical compared to other fatty

acid alcohol sulphate in the production of several oleochemical industries. Due to its

low popularity, the clear figure of its supply is not available. Qualitatively, the global

production rate of fatty acid (Figure 2.1) and the demand for oleochemical products

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(Figure 2.2) has brought a important message that the demand of the magnesium

lauryl sulphate meet the supply of this chemical.

2.4 FUTURE MARKETING POTENTIAL

Magnesium lauryl sulfate has been used in many industries and household

applications over the years. The chemical is widely use as detergents, lubricants,

surfactants, emulsifier, and also pesticides.

Based on Figure 2.1, the production of fatty acid is increasing from 1999 to

2006. The increasing production is necessary to meet the demand of magnesium lauryl

sulphate. Besides that other oleochemicals such as methyl ester and lauryl alcohol

shown increment in production at 8% per annum. (High Beam Research, 2002).

Based on Figure 2.2, the growth of the demand of oleochemical products

especially soap and detergents has given a good sign to investor on this industry. The

increasing demand of manufactured products and high production of its raw materials

are evidence for a good marketing potential of magnesium lauryl sulphate.

Although it is not as common as sodium lauryl sulphate, there is a space for its

growth. With the references of the statistics shown, the future market for magnesium

lauryl sulphate is positive and prosperous. Investment is necessary for more rapid

growth.

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CHAPTER 3

PROCESS DESCRIPTION

3.1 CHEMICAL REACTION

There are four main reactions for the production of magnesium lauryl sulphate. Raw

material used for the production is lauric acid or dodecanoic acid and methanol. The

processes involved in the production are esterification, hydrogenation, sulfation and

the reaction with magnesium hydroxide. Chemical reactions occurred is shown below:

(i)Esterification of Lauric acid and Methanol

H2SO4

(Sulphuric acid)

CH3(CH2)10COOH(l) + CH3OH(l) CH3(CH2)10COOCH3(l)+ H2O(l) (3.1)

(Lauric acid) (Methanol) (Methyl Laureate) (Water)

(ii)Hydrogenation of Methyl laureate

(CuCr)

(Copper Chromite)

CH3(CH2)10COOCH3(l) + 2H2(g) CH3(CH2)11OH(l) + CH3OH(l) (3.2)

(Methyl Laureate) (Hydrogen) (Lauryl alcohol) (Methanol)

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(iii)Sulfation of Lauryl alcohol

CH3(CH2)11OH(l) + SO3(g) CH3(CH2)11OSO3H(l) (3.3)

(Lauryl alcohol) (Sulphur trioxide) (Lauryl sulphate)

(iv)Mixing of Lauryl sulphate with Magnesium hydroxide

2CH3(CH2)11OSO3H(l) + Mg(OH)2(aq) Mg (CH3(CH2)11OSO3)2(l) + 2H2O(l) (3.4)

(Lauryl sulphate) (Magnesium hydroxide) (Magnesium lauryl sulphate)

(Water)

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3.2 BLOCK DIAGRAM

Esterification of Lauric Acid and Methanol

Hydrogenation of Methyl Laureate

Sulphation of Lauryl Alcohol

Mixing Lauryl Sulphate with Magnesium Hydroxide

Magnesium Lauryl Sulphate Collected

Catalyst = Sulphuric Acid, H2SO4

Catalyst = Copper Chromite, CuCr

Sulphating Agent = Sulphur Trioxide, SO3

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3.3 DESCRIPTION OF PROCESS FLOW

(i)Esterification of Lauric acid and Methanol

H2SO4

(Sulphuric acid)

CH3(CH2)10COOH(l) + CH3OH(l) CH3(CH2)10COOCH3(l) + H2O(l) (3.5)

(Lauric acid) (Methanol) (Methyl Laureate) (Water)

Lauric acid and methanol are the raw materials for the production of

magnesium lauryl sulphate. The two feeds are firstly heated before they are fed into

the reactor (V101). Esterification is occurred in the reactor at 140oC with the presence

of sulphuric acid, H2SO4 as catalyst. Methyl laureate and water are produced from the

reaction. Next the products and unreacted lauric acid and methanol entered fractional

distillation column (D101) where distillation is occurred. Methyl laureate is separated

from the mixture and is pumped to next unit process. Water is a waste which is been

sent out for waste treatment. The unreacted lauric acid and methanol are sent back to

reactor again for more complete reaction.

(ii)Hydrogenation of Methyl laureate

(CuCr)

(Copper Chromite)

CH3(CH2)10COOCH3(l) + 2H2(g) CH3(CH2)11OH(l) + CH3OH(l) (3.6)

(Methyl Laureate) (Hydrogen) (Lauryl alcohol) (Methanol)

Methyl laureate from the distillation tower entered fixed bed reactor (F101)

where catalyst is “fixed” as a bed inside the reactor. The catalyst used is copper

chromite which is in the form of compact pelletized. The reaction in the reactor is

conducted in the vapour phase where part of the feed is vaporised in an excess of

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hydrogen gas (20-25moles) through preheater (E107) before passing through the fixed

catalyst bed reactor (F101). Hydrogenation is occurred in the reactor at pressure

20,000-30,000 kPa and temperature 200-250oC. The reaction mixture leaving the

reactors is cooled and is separated into gas phases and liquid phases. Gas phase

consists mainly hydrogen is then recycled. Liquid phase is expanded into a flash tank

(L101) to strip off methanol from the lauryl alcohol or dodecan-1-ol. The operating

condition is comparatively mild, so that the lauryl alcohol does not require further

processing due to its high quality. Catalyst comsumption is claimed not exceeding

1.0% meanwhile the yield for this fixed bed process is high.

(iii)Sulphation of Lauryl alcohol

CH3(CH2)11OH(l) + SO3(g) CH3(CH2)11OSO3H(l) (3.7)

(Lauryl alcohol) (Sulphur trioxide) (Lauryl sulphate)

Lauryl alcohol is then fed into multitude film sulphation reactor.(F201) The

latest technology in the manufacture of lauryl sulphate is the direct use of sulphur

trioxide gas, SO3 as the sulphating agent. The sulphur trioxide gas from pipeline is fed

into the reactor with lauryl alcohol for sulphation to occur. The feeds entered from the

top section of the reactor and flew concurrently downward inside the tube. As the

reaction is almost instantaneous and exothermic, cooling water at controlled flow is

introduced into the jacket of the reactor to maintain the reaction temperature at 45-

50oC. A reaction yield of 97% is achieved.

(iv)Mixing of Lauryl sulphate with Magnesium hydroxide

2CH3(CH2)11OSO3H(l) + Mg(OH)2(aq) Mg (CH3(CH2)11OSO3)2(l) + 2H2O(l) (3.8)

(Lauryl sulphate) (Magnesium hydroxide) (Magnesium lauryl sulphate) (Water)

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Lauryl sulphate that is produced from sulphation is quite unstable and needed

to be neutralized immediately. Excess SO3 gas is sent to scrubber unit for rectification

and to be reuse. Meanwhile lauryl sulphate is sent to mixer (M101) for homogenous

neutralisation reaction. Magnesium hydroxide, Mg (OH) 2 is fed into the mixer from

pipeline. Magnesium lauryl sulphate is collected.

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3.5 SOURCE OF RAW MATERIAL

Magnesium lauryl sulphate can be produced by serial reactions. There are four basic

processes, include esterification of lauric acid and methanol, hydrogenation of methyl

laureate, sulfation of lauryl alcohol and the reaction between magnesium hydroxide

with lauryl sulphate.

Reactions:

(i)Esterification of Lauric acid and Methanol

H2SO4

(Sulphuric acid)

CH3(CH2)10COOH(l) + CH3OH(l) CH3(CH2)10COOCH3(l)+H2O(l) (3.9)

(Lauric acid) (Methanol) (Methyl Laureate) (Water)

(ii)Hydrogenation of Methyl laureate

CuCr

(Copper Chromite)

CH3(CH2)10COOCH3(l) + 2H2(g) CH3(CH2)11OH(l) + CH3OH(l) (3.10)

(Methyl Laureate) (Hydrogen) (Lauryl alcohol) (Methanol)

(iii)Sulfation of Lauryl alcohol

CH3(CH2)11OH(l) + SO3(g) CH3(CH2)11OSO3H(l) (3.11)

(Lauryl alcohol) (Sulphur trioxide) (Lauryl sulphate)

(iv)Mixing of Lauryl sulphate with Magnesium hydroxide

2CH3(CH2)11OSO3H(l)+Mg(OH)2(aq) Mg(CH3(CH2)11OSO3)2(l)+2H2O(l) (3.12)

(Lauryl sulphate) (Magnesium hydroxide) (Magnesium lauryl sulphate) (Water)

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Based on the reaction above, the raw materials that are used to produce

magnesium lauryl sulphate are lauric acid and methanol. Lauric acid comes from

carboxyl group (carboxylic acid) while methanol comes from hydroxyl group

(alcohol).

3.5.1 LAURIC ACID

Lauric acid is a saturated fatty acid which comes from carboxyl group. It is also

known as dodecanoic acid with molecular formula CH3(CH2)2COOH. It exist as white

and powdery solid with faint odor of bay oil and soap.

Melting point :440C

Boiling point : 298oC

It is steam volatile and dissolve readily in alcohol and ether,but is only very

slightly soluble in water. Lauric acid is the main acid in coconut oil and in palm kernel

oil. It is believed to have antimicrobial properties. It is inexpensive, has a long shelf-

life and safe to handle.

Lauric acid can be obtained by hydrolysis and splitting process of its

triglycerides (coconut oil). Glycerine is the byproduct for this fat splitting process.

Trigyceride (coconut oil) + water fatty acid (lauric acid) + glycerine (3.13)

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The salt and esters of lauric acid are called laureates. Lauric acid is used as a

stabiliser for PVC and as an intermediate for production of softener and emulsifiers

such as magnesium lauryl sulphate. (Wikipedia,2010)

3.5.2 METHANOL

Methanol is the most simple alcohol comes from hydroxyl group. Its molecular

formula is CH3OH.Methanol is light,volatile, colorless, flammable and is liquid with a

distinctive odor that is very similar to but slightly sweeter than ethanol.

Melting point :-97oC

Boiling point : 64.7oC

Methanol can be produced naturally by anaerobic metabolism of bacteria and

is found in small fraction in the atmosphere. Besides, methanol can be produced from

the methane component in natural gas. There are three processes which are

commercially practised.

CH4(g)+ H2O(g) → CO(g) + 3 H2 (g) (3.14)

Syn gas is produced according to the chemical reaction above. The gas is then

pass through a process called shift reaction to adjust the ratio of CO and H2.

CO (g) + H2O(g) → CO2 (g)+ H2 (g) (3.15)

The carbon monoxide and hydrogen is then combined to form methanol .

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CO(g) + 2 H2(g)→ CH3OH (l) (3.16)

Methanol is used in esterification process of fatty acid to form methyl ester.

(Wikipedia,2010)

Table 3.1 shows the physical property of reactants used for the production of

magnesium lauryl sulphate.

Table 3.1: Physical Property Of Reactants

Chemical Reactants Physical Properties Property Values

Lauric Acid

CH3(CH2)10COOH

Molar mass

CAS number

Appearance

Boiling point

Melting point

200.32 g/mol

143-07-7

White powder

298.9 °C

43.2 °C

Methanol

CH3OH

Molar mass

CAS number

Appearance

Boiling point

Melting point

32.04 g/mol

67-56-1

Liquid

64.6 °C

-97 °C

Sulphur Trioxide

SO3

Molar mass

CAS number

Appearance

Boiling point

Melting point

80.06 g/mol

7446-11-9

Liquid

45 °C

16.8 °C

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Magnesium Hydroxide

Mg(OH)2

Molar mass

CAS number

Appearance

Boiling point

Melting point

58.32 g/mol

1309-42-8

White solid

-

350 °C (decomposes)

Source: Sciencelab.com, 2010

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CHAPTER 4

ENVIRONMENTAL AND SAFETY ISSUES

4.1 WASTE GENERATION

Water is produced at the final stage of the chemical reaction. A portion of water is

evaporated during the distillation process. Part of water generated is also used as a

medium for heat to transfer in heat exchanger while the rest is treated before being

discharged. Methanol is used in excess during the esterification of lauric acid and

methanol. It is recycled back to the reactor for future reaction after been fractionated

out from fractional distillation tower. It is also been produced during second stage of

the production, that is hydrogenation where it comes out with lauryl alcohol. The

methanol separated from the product and stored in gasometer.

4.2 IMPACT ON THE ENVIRONMENT

The production process of magnesium lauryl sulfate, as in any other chemical process,

has its own effect on the environment. Studies shows that this production process

could do some damage, especially to the water environment in the long term. When

tested on rat and guinea pig, this chemical shows a high toxicity level. As for human,

the damage can only be seen if contact occurs on a high dosage.

Since the waste is released to the sewerage system, the main pollution concern

is related to the river. More than 90% of the chemical that is released to the river tend

to stay there. So it is a cause for concern. For this particular reason, companies

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producing chemicals has to follow a certain disposing limit. This limit is called

discharge limit.

Discharge limit were designed to protect designated uses of surface waters,

such as supporting aquatic life or recreation. For this particular product, if unaltered

by use, may be disposed of by treatment at a permitted facility or as advised by the

local hazardous waste regulatory authority. Residue from fires extinguished with this

material may be hazardous. Thus, controlling discharge from entering the

environment, particularly the navigable waters, are very important.

To control the waste disposal in Malaysia, an act has been created related to

prevention, abatement, control of pollution and enhancement of the environment. This

act is called Environmental Quality Act 1974.

4.3 RELEVANT ENVIRONMENT ACT

In Malaysia, there are at least two well known act or regulation related closely to this

particular situation and issues. Those two are Environmental Quality Act (1974) and

Environmental Quality Regulations (1979). Following is a more detailed description

of these regulations.

4.3.1 ENVIRONMENTAL QUALITY ACT 1974

The Environmental Quality Act 1974 is under the Act 127, Law of Malaysia. The

section that is related to this particular issue is Section 25 entitled “Restrictions on

pollution of inland waters”. This section stated that “No person shall, unless licensed,

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emit, discharge or deposit any environmentally hazardous substances, pollutants or

wastes into any inland waters in contravention of the acceptable conditions” (Malaysia

Environment, 1974). The existence of this act ensures the chemical processing

company to follow and obey the designated discharge limit that has been stated.

4.3.2 ENVIRONMENTAL QUALITY (SEWAGE AND INDUSTRIAL

EFFLUENTS) REGULATIONS, 1979

Part three of this regulation is about the acceptable condition of discharge into the

inland waters. The following is among the regulations:

1. No inflammable solvent shall be discharge into the inland waters. The same

also goes for any tar or other liquids that is immiscible with water.

2. Effluent that is to be discharge also must be analyzed in accordance to the

specified method (United Nation, 1979)

4.4 SAFETY PRECAUTION

Magnesium lauryl sulfate is a very flammable substance. Inhalation may cause

irritation of the respiratory tract. It is also harmful if swallowed and can cause

difficulty in ingestion. If contact occurs with bare skin, it may cause allergic skin

reaction to some type of skin. Direct contact with eye should also be avoided.

Breathing this substance’s vapours or spray mist would not be a good idea (MP

Biomedical, 2006).

Avoid contact on eyes, skin, or even on clothing. It is advised to wear personal

protective equipment and cloth. After used, remove and wash the contaminated

clothing before reuse. Also, it is best to clean the whole body thoroughly after

handling. For some unfortunate event, if large spills occur, use water to disperse the

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vapour and also avoid the liquid chemicals from entering any waterways or sewer

system.

For transferring purpose, use ground and bond containers. Also, make sure to

keep this chemical away from open flames, hot surfaces or any type of source for

ignition. This particular precaution step should not be taken lightly since it is

flammable. It is best not to re-use empty containers for transferring this chemical.

The first step of the production of magnesium lauryl sulfate is the

etherification process. This process takes place with lauric acid and methanol as the

reactant. Methanol has a very high flammability characteristic (Science Lab.com,

2008). The National Fire Protection Association (NFPA), an international nonprofit

organization has rated methanol a level three on the flammability scale.

During the sulphonation process, sulphur trioxide is used as one of the

reactant. Sulphur trioxide is a very corrosive compound (Science Lab.com, 2008).

Therefore to handle the compound, high grade stainless steel or titanium must be used

in the reactor. The storage tank is constructed of tile-lined steel or concrete. As for

piping, it made of high grade stainless steel, polyvinyl chloride or fibreglass-

reinforced polyester.

In this processing plant there are many pumps, pipes and valve required to make sure

the process run smoothly and in complete condition. When working on pumps, pipes, or

valves there is a high possibility of the liquid being squirt out especially if there is any

damage or leakage occur. The production crew have to wear goggles or a face shield

to prevent direct contact with any of these hazardous chemicals. If there is such

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incident happen the construction crews must know the location of the nearest

emergency shower and eyewash station.

Most of the process involved in this production is operated at a high

temperature. To make sure all the accident in plant process will not occur, the

production crew should be made aware of any emergency procedures that are in place.

If there is an evacuation plan involving special assembly areas or the use of self-

rescue equipment such as respirators, these precautions must be fully explained to all

workers in the plant. The plant should have some kind of alarm system to warn people

of a gas leak or any process problem.

Other self protection equipment includes safety glass with side shields. This

safety equipment would be very useful in the event of any device leakage, since the

liquid chemicals might squirt out directly to the worker’s face. In this case, the regular

safety glass would not be sufficient to cover the eye part.

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CHAPTER 5

MASS BALANCE AND ENERGY BALANCE

5.1 MASS BALANCE

Based on an article from Indonesian Commercial Newsletter in 2002, the production

rate for oleochemical increased 8% per annum from 526,259 tons in 1997 to 712,012

tons in 2001. In 2001, the annual production capacity of methyl ester is 10,000 tons.

According to Equation 5.1, the product of the esterification reaction is methyl laureate

and water.

H2SO4

(Sulphuric acid)

CH3(CH2)10COOH(l) + CH3OH(l) CH3(CH2)10COOCH3(l) + H2O(l)

(5.1)

(Lauric acid) (Methanol) (Methyl Laureate) (Water)

(LA) (M) (ML) (W)

The production rate for esterification reaction is 10,000,000 kg in year 2001. Based on

the increment rate which is 8% per annum, it is estimated that the production of

methyl laureate in year 2010 is 30,000,00 kg. The equilibrium constant for

esterification of lauric acid and methanol is estimated to be 4.4. The percentage of

conversion is estimated 90% (X.L.Hou et al, 2006). Figure 5.1 shows the process flow

diagram for unit process of esterification from iCON® while Figure 5.2 shows the

block diagram for esterification.

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30

Figure 5.1: Process Flow Diagram For Unit Process (Esterification)

NiLA=?

NiM =?

Figure 5.2: Block Diagram For Esterification

Assumption: The production is carried out 30 days in every month per year and the

process is operated 24 hours per day.

Mass flow rate of methyl laureate (ML) :

Reactor

X= 0.9NoM=?

NoML=16 kmole/h

NoW=?

NoLA=?

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31

¿30000000 kg1 year

×1 year12 months

×1 month30 days

×1 day24 hours

= 3472 kg h-1

The molar mass for input and output components:

Molar mass for lauric acid, MLA = 200.32 g/mole

Molar mass for methanol, MM = 32.04 g/mole

Molar mass for methyl laureate, MML = 214.35 g/mole

Molar mass for water, Mw = 18.02 g/mole

Table 5.1: Stoichiometric Coefficient

Lauric Acid Methanol Methyl Laureate Water-1 -1 1 1

Degree of Freedom Analysis:

Number of unknown =7

Number of independent equation = 4 + 2

Basis = 1

Degree of freedom = 7- (4+2) – 1 = 0.

Estimated conversion = 0.9

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Estimated mole flow rate of methyl laureate = 3472 kg1h

×1 mole214.35 g

= 3472000 g1 h

×1 mole214.35 g

=16197.80732 m/h

= 16 kmole/h

Estimated equilibrium constant, Ke = 4.4

Mole balance for components:

(a) Methy laureate,

Given No=16 kmole/h

No=Ni+αr

16 = 0+(1)r

r = 16 kmole/h

(b) Water,

No=Ni+αr

=0+(1)(16)

=16 kmole/h

(c) Lauric Acid,

No=Ni+αr

Conversion, X= Ni-NoNi

XNi= Ni-No

XNi= -αr

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33

(0.9)Ni= -(-1)(16)

Ni=18 kmole/h

No=Ni+αr

=18 + (-1)(16)

=2 kmole/h

From equilibrium constant:

Ke= Ʃ (Nik + αkr)αk

=

(NiML +αML r) α ML × (Ni W +α W r)α W

(NiLA +αLA r)αLA ×( NiM+ αM r)

α M

= (16 ) (16)

(18-16) (N iM -16)

4.4 = 256(2 )(N iM -16)

NiM = 45 kmole/h

(d) Methanol,

No=Ni+αr

No= 45 + (-1) (16)

= 29 kmole/h

To determine the limiting reactant,

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For lauric acid (LA) = N iLA-∝LA

= 18 kmole/h-(-1)

= 18 kmole/h

For methanol (M) = N iM-∝M

= 45 kmole/h- (-1)

= 45 kmole/h

Hence, the limiting reactant is lauric acid (LA).

Total input molar flow rate, NiT = NiLA + NiM

= (18 + 45) kmole/h

= 63 kmole/h

Total output molar flow rate, NoT = NoLA + NoM + NoML + NoW

= (2 + 29 + 16 + 16) kmole/h

= 63 kmole/h

Composition of input components:

Lauric acid, xiLA = N iN iT

= 1863

= 0.2857

Methanol, xiM = N iN iT

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35

= 4563

= 0.7143

Composition of output components:

Lauric acid, xoLA = N oN oT

= 263

= 0.0317

Methanol, xoM = N oN oT

= 2963

= 0.4603

Methyl laureate, xoML= N oN oT

= 1663

= 0.2540

Water, xoW = N oN oT

= 1663

= 0.2540

Mass flow rate for input components :

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Lauric acid (LA) FiLA = NiLA × MLA

= 3606 kg/h

Methanol (M) FiM = NiM × MM

= 1442 kg/h

Total input mass flow rate = FiLA + FiM = 5048 kg/h

Mass flow rate for output components :

Lauric acid (LA) FoLA = NoLA × MLA

= 401 kg/h

Methanol (M) FoM = NoM × MM

= 929 kg/h

Methyl laureate (ML) FoML = NoML × MML

= 3430 kg/h

Water (W) FoW = NoW × MW

=288 kg/h

Total output mass flow rate = FoLA + FoM + FoML + FoW = 5048 kg/h

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Table 5.2 and 5.3 show the results of mole flow balance and mass flow balance in

reactor.

Table 5.2: Mole Flow Rate (kmol/h)

Components Nin(kmol/h) Nout(kmol/h)

Lauric Acid 18 2

Methanol 45 29

Methyl Laureate 0 16

Water 0 16

Total 63 63

Table 5.3: Mass Flow Rate (kg/h)

Components Fin(kg/h) Fout(kg/h)

Lauric Acid 3606 401

Methanol 1442 929

Methyl Laureate 0 3430

Water 0 288

Total 5048 5048

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5.2 ENERGY BALANCE

From the calculation of mass balance, the mole flow rate for each component is determined. The reactor is assumed non-adiabatic.

NoL

Figure 5.2: Block Diagram For Esterification.

Esterification of Lauric Acid and Methanol

H2SO4

(Sulphuric acid)

CH3(CH2)10COOH(l) + CH3OH(l) CH3(CH2)10COOCH3(l) + H2O(l) (5.2)

(Lauric acid) (Methanol) (Methyl Laureate) (Water)

(LA) (M) (ML) H2O

The Cp value of each inflow and outflow component is determined by using:

Cp= A + BT + CT2 + DT3 (J/mol.K)

Reactor

X= 0.9

NiLA= 18 kmole/h

NiM= 45 kmole/h

NoLA= 2 kmole/h

NoM= 29 kmole/h

NoML= 16 kmole/h

NoLA= 16 kmole/h

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Table 5.4: Heat Capacity of Liquid

A B C DLauric Acid 50.801 2.258 -4.966×10-3 4.377×10-6

Methanol 13.431 -51.28×10-3 131.13×10-6

Methyl Laureatae

77.645 2.5348 -5.9489×10-3 5.682×10-6

Water 8.712 1.25×10-3 -0.18×10-6

Table 5.5: ∆Hof of Formation

∆Hof(kj/mol)

Lauric Acid -682.00Methanol -238.66

Methyl Laureate -693.42Water -285.83

The change of enthalpy, ∆H of each inflow and outflow component is determined by using:

∆H= ∫298.15

313.15

C p dT

∆H= A( T2 - T1 ) + B( T22 - T1

2 )/2 + C( T23 - T1

3 )/3+D( T24 - T1

4)/4

For inflow components:

Lauric Acid (LA),

∆H = ∫298.15

313.15

C p dT

= ( 50.801)(313.15-298.15) + (2.258)( 313.152-298.152) /2 +

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(-4.966x10-3)( 313.153-298.153)/3 + (4.377x10-6)( 313.154-

298.154)/4

= 6030 kJ/mol

Methanol (M),

∆H = ∫298.15

313.15

C p dT

= (13.431)(313.15-298.15) + (-51.28x10-3)( 313.152-298.152) /2 +

(131.13x10-6)(313.153-298.153)/3

=150 kJ/mol

For outflow components:

Lauric Acid (LA),

∆H = ∫298.15

393.15

C p dT

= (50.801)(393.15-298.15) + (2.258)( 393.152-298.152) /2 +

(-4.966x10-3)(393.153-298.153)/3 + (4.377x10-6)( 393.154-

298.154)/4

= 39748 kJ/mol

Methanol (M),

∆H = ∫298.15

393.15

C p dT

= (13.431)( 393.15-298.15) + (-51.28x10-3)( 393.152-298.152) /2

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41

+(131.13x10-6)(393.153-298.153)/3

= 9061 kJ/mol

Methyl Laureate (ML),

∆H = ∫298.15

393.15

C p dT

= ( 77.645)( 393.15-298.15) + (2.5348)( 393.152-298.152) /2 +

(-5.9489x10-3)(393.153-298.153)/3 + (5.682x10-6)( 393.154-

298.154)/4

= 45378 kJ/mol

Water (W),

∆H = ∫298.15

393.15

C p dT

= (8.712)( 393.15-298.15) + (1.25x10-3)( 393.152-298.152) /2 +

(-0.18x10-6)(393.153-298.153)/3

= 7200 kJ/mol

For total inflow enthalpy, ∆Hin,

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42

∆Hin = (∆HiLA x NiLA ) + (∆HiM x NiM)

= ( 6030 kJ/kmol x 18 kmol/h) + (150 kJ/kmol x 45 kmol/h)

= 115290 kJ/h

For total outflow enthalpy, ∆Hout,

∆Hout= (∆HLA x NoLA ) + (∆HM x NoM) + (∆HoML x NoML) + (∆HoH2O x NoH2O)

= (9061 kJ/kmol x 2 kmol/h) + (39748kJ/kmol x 29kmol/h) +

(45378kJ/kmol x 16 kmol/h) + (7200 kJ/kmol x 16 kmol/h)

= 2012062 kJ/h

For Heat of formation in the reactor, Hof

= ∑∆Hofproduct - ∑∆Ho

freactant

= (-693.42kJ/mol – 285.83 kJ/mol ) – ( -682 kJ/mol – 238.66 kJ/mol)

= -59 kJ/kmol

Hence,

Q = ∆Hout - ∆Hin + r∆Hof

= 2012062 kJ/h – 115290 kJ/h + (16 kmol/h x -59kJ/kmol)

= 526619 J/s

= 526619 W.

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5.3 RESULT OF ICON® `S SIMULATION

(a) Result For Input Stream

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(b) Result For Reactor.

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(c) Result For Output Stream

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Comparison:

Mass Balance:

Table 5.6: Result from iCON ®

Total mass

balance(kg/h)

Calculated

value(kg/h)

iCON® value

(kg/h)

Percentage

error(%)

Inlet 5048 5047.45 0.01

Outlet 5048 5047.45 0.01

Energy Balance:

Table 5.7: Result form iCON®

Calculated

value(J/s)

iCON® (J/s) Percentage

error(%)

Heat flow rate,Q 526619 293921.0695 79

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CONCLUSION

Magnesium lauryl sulphate is a chemical that is widely used in the health care

industries. Most of world demand of this chemical is going towards the production of

soap, shampoo, detergent, cosmetic and skin care products. In Malaysia, the demand

of magnesium lauryl sulphate is at a moderate level. Most of the production company

prefer to use sodium lauryl sulphate instead of magnesium lauryl sulphate due to its

availability. Sodium lauryl sulphate is also more popular because it is safer to use and

yields minimum health hazard. As for the global market, Brazil has been recorded as

the main contributor for the health care products, which is the main usage for

magnesium lauryl sulphate. Based on the global market trend, it can be said that this

chemical substance would have increasing demand in the near future.

The production of magnesium lauryl sulphate required lauric acid (or

commonly known as fatty acid) and methanol as the main raw material. As for the

waste generated from the production process, there is only a small amount of water.

The high purity of water that is released to the sewage system makes this process as an

environmental friendly process. However the constant release of the waste water

would pollute the aquatic environment in the future as a long term effect. So to reduce

the possibility of this from happening, a good prevention plan would be necessary.

The production plant should consider other method of discharging the waste water

instead of just releasing it to the river. By building a waste water treatment facility, the

water generated would have a better place to be released to. This will at least reduce

the possibility of the aquatic environment being polluted in the near future.

The mass and energy balance calculation for the first process has also been

included. Most of the research has been done through internet search and discussion

with the lecturers and among fellow students. Manual search through books at the

library has also been conducted. Magnesium lauryl sulfate has a wide range of

Page 52: Magnesium Lauryl Sulfate

52

application, but most of the demand comes from the cosmetic and personal care

industry. The mass balance equations result at the reactor is 5048 kg/h. The factors

that influence rate are the concentration difference and also the molecular distance.

For the energy balance equation, the result at the reactor is 526619 J/s. Factors that

influence the heat transfer rate is the temperature gradient, phase material, and the

surface area. These results have been compared with the result obtained from the

calculation using iCON®, which is 293921.0695 J/s. The percentage error obtained

when these two values was compared is 79%.

Magnesium lauryl sulphate could be an important chemical in the future. The

increasing trend shows that it has gaining popularity among the personal care

production company. Given a good solution can be found to prevent the production

process from damaging the environment, magnesium lauryl sulphate would have a

bright future and a good potential. Less environmental effect and lesser in production

cost would be a high plus.

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