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

PROJECT SERVICES

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 Bio-Refineryon Bio-Refinery

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

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

  kg

MES 843

Di-salt 49

Sodium methyl sulfate 50

Unsulfonated 20

Na2SO4 10

Moisture 26

Hydrogen Peroxide 1

Methanol 1

Total 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

%%

LASLAS 1212

MESMES 88

Sodium CarbonateSodium Carbonate 2020

Sodium SilicateSodium Silicate 1010

STPPSTPP 1515

Sodium SulfateSodium Sulfate 3030

MoistureMoisture 55

TotalTotal 100100

Typical Components in a Detergent FormulationTypical Components in a Detergent Formulation

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

%%

MESMES 66

AESAES 99

GlycerineGlycerine 33

GermicideGermicide 0.50.5

Viscosity ModifiedViscosity Modified 22

WaterWater 79.579.5

TotalTotal 100100

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

DETERGENT COMPLEX BASED ON PALM STEARIN

Estimate for a 300 TPD RBD PS USD (million)  

Infrastructure 7.0

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

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

Sulfonation (40 KTA) 13.0

Detergents & HPC (30 KT/20 KTA) 8.0

Total CAPEX 50.0

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

  USD (miilion)

  Esterification Distillation+ H2 MES

Raw Materials 598 704 797

Utilities 42 37 52

Operating Costs 6 6 14

Overheads 4 7 11

Financial Charges 6 7 15

Depreciation 9 7 29

Cost of Production/ Tonne 665 768 918

Recommended sale price 700 850 1050

Basis: RBD PS @ USD 650 PMT

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

USD

  Soft Soap Detergent

Without

MES

With

MES

Raw Materials 678 698 631

Utilities 44 42 41

Operating Costs 20 12 12

Overheads 23 14 14

Financial Charges 12 11 11

Depreciation 17 15 15

Cost of Production/ Tonne 794 792 724

Recommended sale price1200 1200 1200

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 - convenience of useMES in dry flakes form - convenience 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-A 1ST FLOOR, 372/374 S. V. ROAD, GOREAGAON (W) MUMBAI - 400 104 INDIAWebsite: www.trivedigroup.comEmail: strivedi@trivedigroup.com

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