PROJECT REPORT ON MASS BALANCE OF RR3 GRADE OF GREASE

ADDRESS: - PLOT NO. D-100, T.T.C. INDUSTRIAL AREA,

KUKSHET VILLAGE, TURBHE,

NAVI MUMBAI 400705.

TRAINING DURATION: - 7th MAY-7th JUNE 2012

SUBMITTED BY:

1. AKASH U. DHOBALE

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INDIAN OIL

CORPORATION

LIMITED

PROJECT REPORT ON MASS

BALANCE OF RR3 GRADE OF GREASE

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ACKNOWLEDGEMENT

My project would not be complete without acknowledging the

help, guidance and support I received from various people.

It gives me immense pleasure to thank Mr. V.S.Menon sir

(DGM), who provided me with an opportunity to do the in-plant

training at IOCL.

I deeply acknowledge with gratitude, my sincere thanks to Mr.

K. Ramesh Sir, Mr. R.K. Kelkar sir, Mr. A.S. Gitay Sir, Mr. S.S.

Sharma sir, Mr. Subodh Kumar, Mr. D. Prasad for their continuous

guidance and for helping me to understand the plant and project

work in a better way.

Besides, this internship program made me realize the value of

working together as a team and as a new experience in working

environment, which challenges us every minute. I would like to

thank my friends especially those who worked together as interns

at IOCL Vashi grease plant. I would also like to express my gratitude

to the heads of various departments and the operators of

respective department especially for giving their valuable time.

Last but not the least, I would like to thank all the workers

working in the plant and the people who helped me throughout my

stay at IOCL.

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INDEX

1. SOMETHING ABOUT LUBRICATING GREASE……………………………….……….………3

ADVANTAGE OR USE OF GREASE……………………………………………………..….....3

IMPORTANCE OF LUBRICATION….……………………..…………………….……….…….3

CLASSIFICATION OF GREASE……………………………………………………………….……4

GREASE COMPOSITION ………………………………………………………..………………..6

2. CHEMISTRY OF PROCESS STUDIED ……….……………………….………....……….….....6

3. MOLECULAR FORMULAE………………………………………………..………………….……...6

4. REACTIONS………………………………………………………………………..…....……………....7

5. PROPERTIES ………………………………………………………………………..….………………..8

6. EQUIPMENTS REQUIRED FOR PROCESSING……………………………..…….……….….20

REACTOR………………………………………………………………………………..………………20

KETTLE………….……………………………………………………………………………………....22

TANKS (BASE OIL CHARGING)….……………………………..………………………..…….23

HOMOGENIZER…………………..………………………………………..……………………..…25

OPERATION HYDROULIC VALVE ACTUATION…………………………………….……..25

7. MANUFACTURING PROCEDURE……………………………………………………….…..……28

8. PLANT UTILITIES…………………………………………….……………………………………......29

FURNACE…………………………………………………..…………………………..……..….…..29

BOILER…………………………………………………………..…………………………….……....32

COOLING TOWER……………………………………………...……………………………….….33

CHIMNEY……………………………………………………………………………..……….……...35

COMPRESSOR……………………………………………………..….……………..………..…...36

9. LABORATORY TESTS FOR QUALITY CONTROL…………………………..…………..…….37

10. CRITERIA OF GREASE SELECTION………………………………………………………….......41

11. FACTORS AFFECTING QUALITY OF GREASE………………….…………..………...........41

12. MASS BALANCE OF VARIOUS BATCHES…………………………………..……….………...43

13. TABULATION OF BATCHES COVERED……………………………………….………………..113

14. CONCLUSION………………………………………………………………………..………………….114

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:- SOMETHING ABOUT LUBRICATING GREASE

National Lubricating Grease Institute (NLGI) definition of grease:

A solid to semi-solid product of dispersion of a thickening agent in a liquid lubricant. Other ingredients may be added to it to impart special additional properties.

ADVANTAGES OR USE OF GREASE:

It is used to reduce friction between surfaces.

It prevents oils which would leak away or cause damage by dripping.

It is assured of increased life period of machineries.

To lubricate efficiently.

It Stay at application site due to its semi-solid nature.

Acts as a sealant to avoid ingress of dirt, dust, foreign matters and prevent

Corrosion.

Bearing enclosure designs simplified and Maintenance work reduced due to

absence of oil Pump.

Preferred for long time or packed for life applications e.g. Electrical Motors,

Wheel bearings of new generation cars, etc.

Dripping & Spattering avoided by using grease in food processing /

pharmaceutical industries.

Greases work in badly worn / old machinery.

IMPORTANCE OF LUBRICATION:

Reduce friction between moving parts

Reduce wear & tear

Sealant to contaminants

Prevent corrosion

Prevent rust

Heat transmission

Resist structural deterioration during prolonged use

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CLASSIFICATION OF GREASES:

I. BASED ON TYPE OF THICKENERS:

1) Calcium Base

2) Sodium Base

3) Lithium Base

4) Aluminum Base

5) Titanium Base

6) Clay Base

7) Polyurea Base

8) Non-soap Base

II. BASED ON APPLICATIONS:

1. INDUSTRIAL

High Temperature Application

Low Temperature Application

EP / Load Bearing Application

2. AUTOMOTIVE

Chassis Application

Wheel Bearing Application

Multipurpose Application

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III. BASED ON CONSISTENCY (NLGI CLASSIFICATION):

NLGI Grade Worked Penetration @ 25 o C

000 445-475

00 400-430

0 355-385

1 310-340

2 265-295

3 220-250

4 175-205

5 130-160

6 85-115

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GREASE COMPOSITION:

1) Base oils (lube oil) 75-90%

2) Thickening agents(Soap) 10-20%

3) Additives 0-10%

BASE FLUIDS:

Mineral Oils

Vegetable Oils

Synthetic Oils

THICKENING AGENTS:

Soaps

Non-soaps

Polymers

ADDITIVES:

Oxidation Stability

Rust / Corrosion Inhibitors

Extreme Pressure / Anti-wear Agents

Metal Deactivators

Structure Modifiers

Friction Modifiers

Solid Lubricant

Water Resistance

Low Temperature Pourability Agents

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CHEMISTRY OF PROCESS STUDIED:

The manufacturing of grease mainly consist of saponification reaction.

The reaction is carried out between higher fatty acids (such as 12-Hydroxy

stearic acid, Hydrogenated castor oil) and various metal hydroxides (eg.

LiOH.H2O, NaOH, Ca(OH)2...etc.)

Saponification reaction follows first order kinetics.

MOLECULAR FORMULAE:

1. HCO

CH3-(CH2)5-CH (OH)-(CH2)10-COOCH2

CH3-(CH2)5-CH (OH)-(CH2)9-COOCH

CH3-(CH2)5-CH (OH)-(CH2)10-COOCH2

2. 12-HSA

CH3-(CH2)5-CH (OH)-(CH2)10-COOH

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REACTIONS:

1) SAPONIFICATION OF HCO:

CH3-(CH2)5-CH (OH)-(CH2)10-COOCH2 CH3-(CH2)5-CH (OH)-(CH2)10-COOLi CH2 OH

CH3-(CH2)5-CH (OH)-(CH2)9-COOCH + 3 LiOH CH3-(CH2)5-CH (OH)-(CH2)10-COOLi + CH OH

CH3-(CH2)5-CH (OH)-(CH2)10-COOCH2 CH3-(CH2)5-CH (OH)-(CH2)10-COOLi CH2 OH

HYDROGENATED CASTOR OIL LITHIUM LITHIUM SALT OF HCO (SOAP) GLYCEROL HYDROXIDE

2) SAPONIFICATION OF HSA:

CH3-(CH2)5-CH (OH)-(CH2)10- COOH + LiOH.H2O CH3-(CH2)5-CH (OH)-(CH2)10-COOLi + H2O

12 Hydroxy Stearic Acid Lithium Lithium stearate Water Hydroxide monohydrate

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PROPERTIES:

HYDRATED CALCIUM GREASES:

Saponification of fats/fatty acids and lime in mineral oil.

Water is used as a stabilizing agent.

Structure : Smooth, buttery

Dropping Point : 850 – 1100 C

Max. usable temp. : 650 C

Water Resistance : Excellent

Shear Stability : Fair to good

Oxidation Stability : Poor to good

Oil Separation : Poor to good

Rust Protection : Poor to excellent

Pumpability : Good to excellent

Application : General economical use

Cost : Low

Volume : Declining

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ANHYDROUS CALCIUM GREASES:

Saponification of fats/fatty acids and lime in mineral oil.

12 Hydroxy Stearic Acid used for saponifying contains a hydroxyl radical, which

acts as stabilizing agent.


Dropping Point : 1300– 150

0 C

Max. usable temperature : 1100C


Mechanical Stability : Good to excellent

Oxidation Stability : Fair to excellent


Oil Separation : Good

Pumpability : Fair to excellent

Application : Multipurpose

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SODIUM GREASES:

Saponification of fat / fatty acids with Sodium Hydroxide in mineral oil.

Structure : Fibrous

Dropping Point : 160 – 220C

Max. usable temp. : 110C

Water Resistance : Poor to fair

Oxidation Stability : Poor to good

Rust Protection : Good to excellent

Pump ability : Poor to fair

Shear Stability : Good

Oil Separation : Fair to good

Application : Closed Rolling Contact Bearing

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ALUMINUM GREASES:

Saponification of 12 Hydroxy Stearic Acid with Aluminum Hydroxide in mineral oil.

Structure : Smooth, clear

Dropping Point : 80 – 110C

Max. usable temp. : 70C


Shear Stability : Poor

Oxidation Stability : Excellent


Pump ability : Poor

Oil Separation : Good

Application : Thread lubrication

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LITHIUM GREASES:

Saponification of Hydrogenated Castor Oil or 12 Hydroxy Stearic Acid with Lithium

Hydroxide in mineral oil.

Structure : Smooth


Max. usable temperature : 1300 C

Water Resistance : Good


Mechanical Stability : Good


Oil Separation : Good to excellent

Storage Stability : Good to excellent

Pumpability : Fair to excellent

Compatibility with additives : Good

Application : Multipurpose, EP

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COMPLEX GREASES:

Thickener is formed by co-crystallization of two or more dissimilar acid based

salts.

Complex Soaps have high melting point thereby results in high drop points.

LITHIUM COMPLEX GREASES:

Saponification of Hydrogenated Castor Oil and / 12 Hydroxy Stearic / Salicylic /

Azelaic / Boric Acid, etc. with Lithium Hydroxide in mineral oil.




Water Resistance : Good to excellent

Oxidation Stability : Good


Storage Stability : Good to excellent

Rust Protection : Fair to excellent

Pump ability : Fair to excellent


Additive Compatibility : Good

Application : Multiservice Auto/Industrial use

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ALUMINUM COMPLEX GREASES:

Saponification of long chain fatty acids and benzoic acid with aluminum cation.

Aluminium Isopropoxide or its trimmer is used as the source of cation.

The soap formed thus is Aluminium Benzoate Stearate


Dropping Point : > 2600 C






High Temperature Stability : Good


Pumpability : Fair to good

Reversibility Property : Yes

Additive Compatibility : Poor

Application : Multiservice Industrial

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CALCIUM SULFONATE COMPLEX GREASES:

Saponification of 12 Hydroxy stearic acid, acetic and boric acids with lime in

presence of over-based Calcium Petroleum Sulfonate in mineral oil.



Max. usable temperature : > 1700 C


Mechanical Stability : Excellent

Rust Protection : Excellent

Oil Separation : Excellent

Special Feature : Excellent Inherent EP/AW

Pump ability : Fair to good

Application : Multipurpose, Extreme pressure

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TITANIUM COMPLEX GREASES:

Reaction of tetravalent Titanium cation with stearic acid as the fatty component

and complexes with dicarboxylic terephthalic acid.






Oxidation Stability : Good to excellent


High Temperature Stability : Good

Oil Separation : Fair to good

Pump ability : Fair to good

Salient Property : Inherent EP/AW/AO Properties

Application : Multiservice Industrial

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NON-SOAPS:

ORGANOPHILLIC CLAY GREASES:

Special class of clay – Bentonite / Smectonite is treated with Quaternary

Ammonium Compounds and is converted from hydrophilic to Oleophillic (Oil

Attracting).

These treated organophillic clays when put in oil, gels the oil. Structure Stabilizers

like glycol / Polypropylene carbonate / Isopropyl alcohol are used for deriving the

structures.


Dropping Point : > 2600 C (No dropping point)

Max. usable temp : > 1500 C

Water Resistance : Poor to good

Mechanical Stability : Fair to good

Rust Protection : Poor to good


Pump ability : Good

Special Feature : Excellent Inherent EP/AW Properties

Application : High temp. with frequent relubrication

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POLYUREA GREASES:

Prepared from highly toxic raw materials such as diamines & isocyanates.

Resultant polymer polyurea thickens oil to form grease structure.

Bio-degradable

Ash less

PROPERTIES:


Dropping Point : > 2400 - 2600 C

Max. usable temp : 1500 C


Mechanical Stability : Fair to good

Oxidation Stability : Excellent

Rust Protection : Fair to excellent


Pump ability : Good to excellent

Special Feature : Excellent EP Properties

Application : Multiservice Auto/Industrial use

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EQUIPMENTS REQUIRED FOR PROCESSING:

REACTOR:

For the saponification reaction C.S. Jacketed reactor is used. The jacket is

provided for heating and cooling. Hot oil is circulated through the jacket for

heating raw materials.

Agitator is provided for thorough mixing at the bottom. This tubular reactor

provided with Steiner just above the agitator, to protect the agitator. Reactor is

provided with exit valve at bottom which is operated automatically or manually in

case of failure.

A

Cold oil supply

Hot oil supply

A

A

Hot oil return

Cold oil return

A

S

A

A

Base oil

Vent

Plant air

R101

Plant air

Blow down Agitator

Reactor

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SPECIFICATIONS OF THE REACTOR:

Equipment name: CS Jacketed Reactor

Design pressure:

1) Shell : 13 kg/cm2

2) Tube: 11.5 kg/cm2

3) Jacket: 10.5 kg/cm2

Design temperature :

1) Shell : 345 0C

2) Tube: 345 0C

3) Jacket: 345 0C

Test pressure:

1) Shell : 16.9 kg/cm2

2) Tube: 14.95 kg/cm2

3) Jacket: 13.65 kg/cm2

Corrosion allowance:

1) Shell : 1.6 mm

2) Tube: 1.6 mm

3) Jacket: 1.6 mm

Radiography: (Butt joint)

1) Shell : Full

2) Tube: Full

3) Jacket: Full

Capacity:

1) Shell : 4.5 m3

Total empty weight: 10000 kg

Weight when filled with water: 18500 kg

Heat treatment:

1) Shell – yes

2) Tube – yes

3) Jacket – yes

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KETTLE: 1. Kettles are used for blending of grease and to mix various additives & lube oil

with reacted soap mass.

2.There are seven kettles situated in the plant out of which four are of 10 tones

capacity & remaining are of 5 tones capacity.

3. Kettles are provided with jackets for heating and cooling.

4. The kettle jacket is divided into two zones. There are separate inlet and out let

nozzles provided to each zone

5. Kettles K101, K102 and K107 are heated using steam from boiler house. While

kettle are cooled by cold water obtained from cooling tower.

6. Kettles K103, K104, K105 & K106 are heated by using hot thermic fluid from

furnace.

7. Kettles are provided with anchor type of agitator which is rotated at various

speeds ranging from 30-100 rpm. Scrappers are provided so that no grease sticks

on the inner side of kettle and thorough mixing takes place.

8. There is a thermocouple well provided near the bottom of kettle. This

thermocouple has its display near the kettle opening.

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BASE OIL CHARGING:

TANKS:

TANK SPECIFICATIONS:

Tank capacity: 250KL

Product : lube oil (Base oil).

Reference height: 7.7Metre (From the depth of hatch.)

Diameter : 5.0MTRS.

Safe filling height: 7.35 Meter

Cleaning period : After 9 years.

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There are six base oil tanks in plant connected to each other by pump & pipeline

system.

(T401, T402, T403, T404, T405, T406.)

From the tank base oil is transfer to the small tanks (V105, V106) & finely used in

reactor & kettle for blending.

Manholes are provided at the bottom of lube oil tanks for cleaning purpose.

Base oil is carried to the small storage tank for charging to the reactor & kettles

(V105, V106…etc.)

R101

R102 V106

K101 K102 K103 K104 K105 K106

Pump

Base Oil Charging

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HOMOGENIZER:

TECHNICAL INFORMATION:

Capacity 6000 m3/hr.

Operating pressure (max) 345 bar

Max. Temperature 200˚C

Operating temperature 120 - 140˚C

OPERATION:

WORKING PRINCIPLE-

HIGH PRESSURE RELIEF TECHNIQUE

HIGH PRESSURE PLUNGER PUMP

HOMOGENIZING VALVE ARRANGED IN DOWNSTREAM

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OPRATION HYDROULIC VALVE ACTUATION (HVA):

The hydraulic valve actuation system include a hydraulic realize valve

which has been carefully set to control the maximum desired homogenizing

pressure or maximum safe operating pressure of machine. Each stage of a two

stage homogenizing valve controlled by separate pressure reducing valve

permitting independent control of each stage.

In two stage machine relief valve and reducing valve are piped in series.

Pressure must be created by relief valve. Before reducing valve can be operate.

The pressure requires will depend on product temp, nature of product,

homogenizing valve condition and type and condition of pump valve. Flow

through homogenizer valve, accelerated extremely and relieved to a low pressure

level.

EFFECTS:

Surface intation, nodufication of viscosity, increases storage, economy on

additive, increased of solids content, disapture of biological cellular material,

decomposition of higher molecular chemical compound, and reduction of

reaction period. It can produce drop size of some hundred of nanometers for

emulsion.

APPLICATIONS:

Food industry

Chemical industry

Pharmaceutical industry

Biotechnical industry

Starch industry

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MANUFACTURING PROCEDURE:

At the initiation of batch, according to the grade corresponding base oil and metal

hydroxide is charged to the reactor and heated by means of hot oil circulation.

After achieving a desired temp. reaction starts, as the pressure of the reactor

increases, water vapors are formed. The vapors are sent to atm.by venting valve

and reactor gets depressurized. After completion of reaction, reactor contains

soap, base oil and glycerol. This product mixture is then blown to kettle. Certain

quantity of base oil is heated in the reactor for washing purpose and taken in the

same kettle. Now the sample of the mixture in the kettle is sent to the lab to

check the alkalinity content, and according to the report suggested quantity of

base oil is added to the kettle as cut back. Additives are added to improve the

quality of grease and they are very heat sensitive, so before its addition to the

kettle, the kettle mass is cooled down to a certain temperature. The grease

formed is then homogenized for one hour for making it smooth. Finally the

sample of grease is sent to laboratory for penetration test. After passing in test,

grease is filled in buckets or barrels according to consumers demand and allowed

for atmospheric cooling.

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PLANT UTILITIES:

FURNACE:

Technical information:

Heat output 1.5*106 Kcal/hr.

BURNURE turn down 1:3

Thermic fluid pressure available at heater outlet 1.45kg/cm2gm

Thermic fluid flow rate 110 m3/hr.

Thermic fluid outlet temperature 2350c

Thermic fluid temperature rise 10-12 0c

Thermic fluid recommended a. High temp. mineral oil

b. Synthetic oil

Tube material specification LRW-B6359

NCV of LDO 10500 kcal/kg

LDO charging rate 165 kg/hr.

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UTILITIES:

HEATER UNIT: The heater heat up the oil and oil flow through the coil take up

the heat realize by firing furnace oil through the heater. LDO fired by pressure

atomize burner mounted on heater.

AIR PREHEATER: Air preheated is shell and tube construction since the heater

heat up the oil to higher temperature to fuel gases living furnace is high. This

gives scope of air preheated to receive heat by heating up comb oil.

HOT OIL CIRCULATION ASSEMBLY: This consists of two pump, filter and

isolating valve. One pump is circulated and maintains the flow of oil through

heater.

EXPANTION TANK ASSEMBLY: This consists of tank with hold up of heated

medium this allows the thermal expansion of the hot oil when it is heated

from room temperature to operating temp.

The oil pumping system consists of motor driver fuel pump one operating and one

stand by.

There are two panels:-

1) Power panel

2) Instrument control panel

There is one forced draft fan to supply combustion air to the burner. The blower

drives air the air preheated and the main heater on the chimney

STORAGE TANK: this consists of tank to hold LDO to be filled into system or tank

for driving the system. There is also top of the assembly which helps to fill the

system LDO or top up whenever necessary.

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MAIN HEATER:-

The main assembly consist of a single shell with two cool concentric

two coil are in parallel with multiple start. Coil is placed in the lower half of the

shell and the top half is placed on it. The end cover is then assembling the burner

then assembles on the heater. Slide glass is provided to view the flame.

INSTALLATION:

The heater should be grounded only after the duct connecting to it is made.

Flanges should not be installed until the heater has run continuously for same

temp. this insures that the flanged do not leakage of heating.

Check level of unit by spirit level. Expansion point must e filled at the flue gas

outlet connected from heater. The hot oil pipe connection must have spiral

wound 69-gasket whenever rise case flanges are used other have CAF gasket.

High tensile nuts and bolt are required whenever high temp. and pressure is

encountered.

Shell and heater must be insulated.

MAINTENANCE :

There are two type of maintenance:-

Routine maintenance: Involves inspecting and running condition it check the

operational parameter installation temp. Should be around 20-300c above

ambient.

Over hailing maintenance: The heater is in major job. It involves cleaning of coil

surface, replacement of gasket insulation, refractory etc. Disassembly must be

carried out for this. Coil cleaned by scrubbing with brush and then by compressed

air. Crack and damage must be check. Hydraulic test must be carried out to

ensure the leakage.

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BOILER:

BOILER IS USED FOR THE GENERATION OF STEAM WHICH IS USED FOR HEATING

THE PRODUCT IN THE KETTLE NO K101, K102 & K 107.

BOILER SPECIFICATION:

BOILER MR 115

Type : 3 pass reverse flue smoke tube Boiler Capacity : 3 tons/hr.

Evaporation rate : 3000 Kg/Hr.

Output : 1.88 MW

Fuel : LDO

Voltage : 415 V

Phase : 3 Phases

Frequency : 50 Hz

Maximum pressure : 10.5 Kg/cm2

Working pressure : 10.3 Kg/cm2

Connected load : 15KW

Cleaning period : 1year

Support : Saddle

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Soft water is used in the boiler for generation of steam.

Ion exchange system is provided before the inlet provision of water into the

boiler.

Ion exchange system removes Ca++ & Mg++ ions from hard water to make it soft

for boiler use.

Generally hardness of water should be reduced to 5-8 ppm / pH range 8.5-9.5.

Inside boiler hot gases pass through horizontal tubes and water moves over

the outer surface so as to generate steam.

Flue gases produced are discharged to atmosphere by chimney.

COOLING TOWER:

It is spray tower consist of square type tank having dome shape at the top.

From the top water flows downward in the tank & air is circulated from bottom.

Air flowing from bottom is continuously cooled the water, which is flowing from

top, by forced convection. After cooling the water it sent to the boiler for further

process.

Fig: COUNTERFLOW TYPE COOLING TOWER

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ADVANTAGES AND FUNCTIONAL FEATURES:

MODERN CONSTRUCTION:

Natural cooling tower are of vertical induced draft counter flow design. The tower

ideal with regards space economy and cooling efficiency.

F.R.P body: the body of the tower is made up of tough fiber glass reinforced

plastic it has a sufficient structural strength to with stand high industrial vibration

and wind velocity. It has resistance to local impact and even if damage is

sustained local repairs can easily be done.

SPECIAL MOTOR (IP 55):

Continuous rating shock proofed totally enclosed type as per IP 55 and suitable

for outdoor mounting.

FAN:

Fan is directly driven and axially flow type the fan blades are of cast aluminum

completely free from problem encountered with belt and gear drive.

DRIFT ELIMINATOR:

It present spray entrainment reduces carry over losses of water. The eliminator of

rigid PVC.

PVC FILL:

Corrosion resistant fill are of polyvinyl chloride in honey comb design.

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FIXED SPRINKLER WITH SPRAY NOZZLE:

Fixed sprinkler with spray nozzle for uniform distribution of water over the fill

area and fill can be observed clearly any reappearing can be done through the

window.

INSPECTION WINDOW:

Easy operating window is provided to inspect from where water distribution and

fill can be observed easily and reappearing can be done through the window.

MOST ECONOMICAL:

Smaller HP motor is used for the tower to make the great deal of difference in

operating cost aiming to deliver quality at most economical prize.

MAINTAINANCE:

Considerably reduce the cost because fan is the only moving part of the cooling

tower. Fixed distribution system instead of rotating sprinkler which eliminate all

bearing and frictional problem.

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CHIMNEYS:

Chimneys are used to discharge hazardous gases to high attitude.

Chimneys in the plant are:

1) Furnace self supported chimney.

2) Boiler self supported chimney.

Furnace self supported chimney:

Height : 30.30m

Bottom diameter : 1.200m

Top diameter : 0.600m

Furnace self supported chimney helps to discharge unwanted gases from furnace

& hot oil heater to high attitude.

Boiler self supported chimney:

Height : 30.30m

Bottom diameter : 1.600m

Top diameter : 0.800m

Boiler self supported chimney used to discharge gases generated at the time of

steam generation.

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COMPRESSOR:

Compressor makes balance opposed compressor is high efficiency, heavy duty

compressor developed with latest technology obtained from m/s Fives Coul

Babcol, who have decades of experience in industries. The basic feature of balance

opposed horizontal compressor whether single stage or multistage design is

composed of two cylinder lines opposed at 180*C.

Compressor is driven either by electrical engine or by diesel engine or directly

through suitable coupling.

The two piston of each line which is moving in opposite direction have equal

masses, thereby the forces resulting from compression & from inertia of motion.

Work is always balanced in the two cylinder of same lining. There resultant forces

being different produce an axial torque without any reaction on bearing. The

primary & secondary forces also counter balance each other thereby nullifying any

possibility of vibration or knocking.

Compressor is used to compress air so that It can be used for a lot of application.

All the valves operated from the DCS are pneumatic valves. These valves are

controlled with increase or decrease in air pressure on the diaphragm of the valves.

Also compressed air is used to maintain pressure in the reactor as well as to blow

grease from the pipelines while filling operation is taking place.

There are 4 compressors viz.

1) COMPRESSOR 201A

2) COMPRESSOR 201B

3) COMPRESSOR 202A

4) COMPRESSOR 202B

TECHNICAL INFORMATION:

UNIT INTER COOLER

TEST PRESSURE 7.5 KG/CM2

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LABORATORY TESTS FOR QUALITY CONTROL:

METHOD 1: Test method for determination of free acidity and alkalinity of grease

Scope: The method is intended for the determination of free acidity or alkalinity

in the grease

Outlines of method: Grease is dispersed in hexane 50ml of neutral rectified spirit

is added followed by 10ml 0.5N HCl and reflux for 10-15min. cooled and titrate

against standard alkali.

METHOD 2: Cone penetration of lubricating grease.

Scope: The method is intended for determination of four procedure of measuring

consistency of lubricating grease by penetration of standard cone i.e.

1) Unworked

2) Worked

3) Prolong work

4) Block

Penetration maximum limit is 475 that can be measured .this helps to establish

consistency (category) of grease within (NLGI) consistency grade .prolong working

penetration gives shear stability of under condition of test.

Outlines of Method:

The penetration is determined at 250c by releasing the cone assembly from the

penetrometer & allowing the cone to drop freely in to the grease for 5 sec.

40 | P a g e

DEFINITION:

Penetration: It is the depth in the tenths of millimeter that a standard cone

penetrates the sample under prescribed condition of weight, time & temp.

Working: It is the subjection of lubricating grease to shearing action of standard

grease worker.

Unworked penetration: It is the penetration at 25 0c of grease which is

transferred in grease worker cup &leveled with minimum working.

Work penetration: It is the penetration of grease sample subjected to 60 double

strokes in standard grease worker &penetration is done at 250c.

Block penetration: It is the penetration at 250c or grease sample that is

sufficiently hard to hold its shape determined on the freshly prepared face of a

cube cut from a block of the grease.

METHOD 3: Test method for working stability of grease in presence of water

Scope: The method is intended for the determination of change in consistency

when subjected to work in presence of water.

Outline of the Method:

Grease is filled in cup & exposed to prolong mechanical working in presence of

water (10 % wt.) and in absence of water & difference in penetration is

determined

METHOD 4: Test method for determination of dropping point of grease.

Scope: The method covers the determination of dropping point of lubricating

grease. This point is being the temperature at which first drop of material fall

from cup (from the bottom).

Outline of the method: Small quantity of grease is taken in drop point cup &

heated slowly to the temperature at which first drop of oil comes out from the

whole at the bottom of the test cup. The temperature at which this drop falls is

noted as dropping point of the grease.

41 | P a g e

METHOD 5: Test method for copper corrosion test.

Scope: The test is intended for the determination of corrosive substances in the

lubricating grease, oil, fat & additives. As the grease is employed under diversity

of conditions it is not possible to specify either temperature or duration of test. It

is recommended that temperature be not higher than 20*c below the drop point

of grease.

Outline of the method: Clean & polished copper strip is immersed in the sample

which is then maintain in the specified temperature & duration. The strips are

removed, wash with petroleum spirit & examined for evidence of etching, pitting

& discoloration.

Method 6: Evaporation loss of lubricating grease.

Scope: This method covers the determination of the evaporation loss in

lubricating grease.

Outline of the method: The sample is weighted in petrel or glass dish & kept for2

hrs in an oven maintained at 105+or-10*c. The loss in mass is calculated as an

evaporation loss of the sample.

METHOD 7: Test method for oxidation stability of lubrication grease by the

oxygen bomb method

Scope: The test method is intended determine resistance of lubricating grease to

oxidation when stored statically n an oxygen atmosphere in seated system at an

elevated temp. Under oxidation of test.

Outline of the method: The sample of grease is oxidation in a bomb hated to

2100c /990c and filled with oxygen at 110psi (7.5bar) pressure is observed. The

degree at stated interval. The degree of oxidation after a given period of time is

determination by corresponding decreases in oxygen pressure.

42 | P a g e

METHOD 8: Water washes out characteristics of lubricating grease

Scope: This method of test is intended to evaluate the resistance of lubricating

grease to wash out by water from the bearing. When tested at 380c/800c under

prescribed laboratory condition.

Outline of the method: The grease is packed in boll bearing. The bearing is then

inserted in housing with specified clearance and rotates at 600+or-30rpm. Water

collected at the specified test temp. Impinges on the bearing housing at the rate

of 5+or-0.5ml/sec. The amount of grease wash out in 1hr is a measure of

resistance of grease to water washes out.

METHOD 9: Method for determination of storage stability of grease

Scope: This method described a procedure for determine the storage stability of

grease

Outline of the method: The consistency, both worked and unworked penetration

of material is determined by cone penetration test. Sample of original material

are stored in dark in a container for six month at 38+or-3*c. The consistency, both

worked and unworked penetration of the stored sample is then determined.

43 | P a g e

CRITERIA FOR GREASE SELECTION:-

Sr. No. Factors Expected properties

1 High load/shock load Grease with high

viscosity oil

2 Low temp. Grease with low

viscosity oil

3 High temp. Heat resistant grease

4 High temp./re-lubrication Grease that does not

form residue at high

temp.

5 Dusty environment Grease with nlgi-3 &

above grades

6 Frequent relubrication Soft grease of nlgi-

0/1/2 grade

7 High speed Grease with low

viscosity oil & good

adhesive properties

FACTORS AFFECTING QUALITY OF GREASE:

Rate of saponification reaction

Acidity / alkalinity

Rate / sequence of addition of additives and oil

Temperature of grease formation

Temperature of additive addition.

Temperature and duration of de-aeration, filtration and homogenization.

44 | P a g e

45 | P a g e

Batch no.: 0118 Reactor: R-102

Date: 23/05/2012 Kettle: K-105

Penetration: 230/232

RAW MATERIAL REQUIRED FOR CHARGING IS:-

FOR CALCULATING AVG. MOL. WT. OF FATS:-

SAP VALUE of 12 HSA=181.24

SO, 181.24 Gms of KOH = 1000 Gms of 12HSA

FOR 56.1 Gms of KOH =

=309.534 Gms of 12 HSA

COMPONENT MOLECULAR WEIGHT 12 HSA 309.534 HCO 938 LiOH 23.95 WATER 18 LiOH.H2O 42 SOAP OF 12 HSA 305.914 SOAP OF HCO 306

COMPONENT QUANTITY BASE OIL 500 N 2800 12 HYDROXY STEARIC ACID 1000 HCO 300 LITHIUM HYDROXIDE MONOHYDRATE 200 WATER 10 TOTAL 4310

46 | P a g e

OVERALL MASS BALANCE OVER REACTOR DURING REACTION:-

Now,

INPUT = OUTPUT

HCO + 12HSA + LiOH.H2O + BASE OIL + WATER = SOAP + VENT

300 + 1000 + 200 + 2800 + 10 = SOAP + VENT

4310=SOAP +VENT ………………………….. (1)

BASE OIL

12 HSA

HCO

REACTOR LiOH.H2O

WATER

SOAP

VENT

STEAM

+

SOAP IN

VENT

(LOSSES)

47 | P a g e

OVERALL MASS BALANCE OVER REACTOR DURING WASHING :-

BRIGHT STOCK FOR WASHING = WASHED OIL + VENT

2500 = WASHED OIL + VENT ………………………….. (2)

KETTLE

REACTOR 150 BS BASE OIL

VENT

WASHED OIL

48 | P a g e

OVERALL MASS BALANCE OVER KETTLE:-

SOAP + WASHED OIL + ADDITIVES + CORRECTION/CUTBACK OIL+12 HSA = EXHAUST + OUTPUT

(GREASE)

SOAP + WASHED OIL + 40+45+36 + 702 + 1300 + 25 = EXHAUST + 8736

SOAP + WASHED OIL +2148 = EXHAUST + 8736 …………………. (3)

KETTLE EX

HA

UST

TO

FILLING

SOAP FROM REACTOR

CUTBACK/CORRECTION OIL

ADDITIVES W

ASH

ED O

IL

49 | P a g e

WATER/VOLATILES BALANCE:-

WATER IN CHARGING:

Water= 10 kgs

WATER OF CRYSATALISATION OF LiOH.H 2O:

42 Kg LiOH.H2O = 18 Kg of WATER

200 Kg of LiOH.H2O = X Kg of WATER

Hence, X = 200*18/42

X = 85.714 Kg

WATER RELEASED DURING REACTION:

I Mole HSA= 1 Mole Water

309.534 gm HSA =18 gm Water

1025 kg HSA = Y Kg Water

Y=

= 59.61 kg of Water as Steam

MOISTURE CONTENT OF FATTY ACIDS (0.25%):

TOTAL Amount of FATTY ACID = 1325 Kg (1000+300+25)

Hence, total Amount of moisture in that = 1325*0.25/100

Hence, = 3.31 Kg of MOISTURE

50 | P a g e

VOLATILE AND MOISTURE CONTENT OF BASE OIL:

FOR 1 mg of BASE OIL = 400 ppm of (WATER & VOLITILE)

Hence, For 7302 Kg of BASE OIL = 7302*400*10-6

= 2.92 Kg of (WATER & VOLITILE)

TOTAL AMOUNT OF WATER RELEASED=85.714+59.61+3.31+2.92+10

TOTAL AMOUNT OF WATER RELEASED =161.55 Kgs of water …………………. (4)

WATER BALANCE OVER REACTOR:-

1. DURING REACTION:

WATER ADDED + WATER/VOLATILES IN BASE OIL + WATER IN FATTY ACID + WATER OF

CRYSTALISATION + WATER RELEASED DURING REACTION = STEAM VENTED

10+ 2800*400*10-6 + 1300*0.25% + 85.714 + 59.61 = STEAM VENTED

10+1.12+3.25+85.714+59.61= STEAM VENTED

159.69 Kgs = STEAM VENTED FROM REACTOR ……………………. (5)

NOTE: DUE TO MANUAL ERRORS SOMETIMES SOME AMOUNT OF SOAP IS LOST WHILE

VENTING

FROM OBSERVATIONS, IT IS AROUND 35 KGS PER BATCH

SO,

SOAP LOST IN VENT=35 KGS

TOTAL VENT FROM REACTOR= 159.69 + 35 =194.69 Kgs

51 | P a g e

Now from equation 1,

4310=SOAP +VENT FROM REACTOR ………………………….. (From 1)

4310 = soap + 194.69

Soap = 4115.31 Kgs

2. DURING WASHING:-

2500 = WASHED OIL + VENT

Water content of 150 BS =400ppm

Hence, water in base oil = vent

=400*10-6*2500

VENT DURING WASHING =1.00 kg…………………. (6)

WATER BALANCE OVER KETTLE:-

WATER IN SOAP+WATER/VOLATILES IN BASE OIL + WATER IN ADDITIVES + WATER IN FATTY

ACID = WATER IN EXHAUST+ WATER IN OUTPUT (GREASE)

0 + (702+1300)*400*10-6 + 25*0.25% + 0 = EXHAUST + 0

EXHAUST = 0.8633 Kgs ………………………….. (7)

FROM EQUATIONS (4), (5), (6) & (7),

TOTAL AMOUNT OF WATER RELEASED = STEAM VENTED FROM REACTOR +

VENT DURING WASHING + EXHAUST

=159.69+1.00+0.8633

=161.55 Kgs of water

THUS, WATER IS BALANCED.

52 | P a g e

ALKALI BALANCE:-

Stoichiometric proportion:

1 mole of LiOH.H2O = 1 mole of Lithium Stearate

= 1 mole of 12 HSA

309.534 KG OF 12 HSA = 42 KG LiOH.H2O

1025 KG OF 12 HSA = X KG LiOH.H2O

X=

= 139.1 kg of LiOH.H2O

3 moles of LiOH.H2O = 1 mole of HCO

938 KG of HCO = 42*3 KG LiOH. H2O

300 KG of HCO = X KG LiOH. H2O

X=


Free alkali content= 0.15% wt. of LiOH

Total quantity fed = 4310 kg

Free alkali content=

= 6.465 kg of LiOH

Hence, LiOH content=

= 11.31 kg of free alkali

53 | P a g e

Qty of alkali for base oil TAN

TAN value of base oil = 0.03%

0.03 kgs of KOH=1000 kgs of BASE OIL

7302 kgs of base oil req= 7302 *

*


Total qty of alkali required =139.1+40.3+11.31+0.164

TOTAL QTY OF ALKALI REQUIRED (theoretical) =190.874 KGS

PRACTICAL QTY. FED TO REATOR=200 KG

Excess alkali=200-190.874

EXCESS ALKALI=9.126 KGS

NOW, OVERALL BALANCE

TOTAL INPUT = OUTPUT + LOSSES

TOTAL INPUT = 8958 kgs

TOTAL OUTPUT = NO. OF BARRELS *182(+VE OR –VE VARIATION)

= 48 *182.5

= 8760 Kgs

PROCESS LOSS = 8958-8760

= 198 Kgs

ACTUAL % LOSS = 198*100/8958

= 2.21 %

THEORITICAL LOSS = MASS LOST AS STEAM

= 161.55 Kgs

54 | P a g e

THEORITICAL % LOSS= 161.55*100/8958

= 1.8 %

Hence, DEVIATION = 1.8 – 2.21

DEVIATION = -0.4 % (LOSS)

LOSSES ENCOUNTERED=MASS LOST AS STEAM + SOAP LOST IN VENT + FILLING

LOSSES + OTHER LOSSES

198 = 161.55 + 35 + OTHER LOSSES

Hence, OTHER LOSSES = 1.45 Kgs

NOTE:-

FILLING LOSSES CONSTITUTE THE MASS DISCARDED INITIALLY, CALIBRATION ERROR, SET POINT AND THE

MASS REMAINED AFTER FILLING THE LAST BARREL.

OTHER LOSSES CONSTITUTE LOSSES DUE TO INCOMPLETE REACTION BECAUSE OF IMPROPER REACTION

CONDITIONS, MANUAL ERRORS, AND MASS REMAINED IN THE KETTLE AFTER FILLING, ETC.

55 | P a g e


Date: 28/05/2012 Kettle: K-105







=309.534 Gms of 12 HSA



56 | P a g e


Now,

INPUT = OUTPUT


300 + 1000 + 200 + 2805 +10 = SOAP + VENT

4315=SOAP +VENT ………………………….. (1)

BASE OIL

12 HSA

HCO

REACTOR LiOH.H2O

WATER

SOAP

VENT

STEAM

+

SOAP IN

VENT

(LOSSES)

57 | P a g e



2500 = WASHED OIL + VENT ………………………….. (2)

KETTLE


VENT

WASHED OIL

58 | P a g e


SOAP + WASHED OIL + ADDITIVES + CORRECTION/CUTBACK OIL = EXHAUST + OUTPUT (GREASE)

SOAP + WASHED OIL + 40+45+36+ 2206 = EXHAUST + 8918


KETTLE EX

HA

UST

TO

FILLING

SOAP FROM REACTOR


ADDITIVES W

ASH

ED O

IL

59 | P a g e


WATER IN CHARGING:

Water= 10 kgs




Hence, X = 200*18/42

X = 85.714 Kg





Y=



TOTAL Amount of FATTY ACID = 1300 Kg (1000+300)



60 | P a g e








3. DURING REACTION:



10+ 2805*400*10-6 + 1300*0.25% + 85.714 + 58.15 = STEAM VENTED

10+1.12+3.25+85.714+58.15= STEAM VENTED



VENTING


SO,



61 | P a g e



4315 = soap + 193.234

Soap = 4121.766 Kgs

4. DURING WASHING:-




=400*10-6*2500



WATER IN SOAP+WATER/VOLATILES IN BASE OIL + WATER IN ADDITIVES = WATER IN EXHAUST+

WATER IN OUTPUT (GREASE)

0 + (506+1700)*400*10-6 + 0 = EXHAUST + 0

EXHAUST = 0.88 Kgs ………………………….. (7)

FROM EQUATIONS (4), (5), (6) & (7),



=158.234+1.00+0.88



62 | P a g e

ALKALI BALANCE:-



= 1 mole of 12 HSA



X=





X=





= 6.465 kg of LiOH



63 | P a g e





*











= 49 *182.5

= 8942.5 Kgs

PROCESS LOSS = 9142-8942.5

= 199.5 Kgs

ACTUAL % LOSS = 199.5*100/9139

= 2.2 %

64 | P a g e


= 158.234


= 1.73 %





199.5 = 158.234 + 35 + OTHER LOSSES


NOTE:-





65 | P a g e


Date: 26/05/2012 Kettle: K-105







=309.534 Gms of 12 HSA



66 | P a g e


Now,

INPUT = OUTPUT


300 + 1000 + 200 + 2801 + 5 = SOAP + VENT

4306=SOAP +VENT ………………………….. (1)

BASE OIL

12 HSA

HCO

REACTOR LiOH.H2O

WATER

SOAP

VENT

STEAM

+

SOAP IN

VENT

(LOSSES)

67 | P a g e



2500 = WASHED OIL + VENT ………………………….. (2)

KETTLE


VENT

WASHED OIL

68 | P a g e





KETTLE EX

HA

UST

TO

FILLING

SOAP FROM REACTOR


ADDITIVES W

ASH

ED O

IL

69 | P a g e


WATER IN CHARGING:

Water= 5 kgs




Hence, X = 200*18/42

X = 85.714 Kg





Y=






70 | P a g e








5. DURING REACTION:



5+ 2801*400*10-6 + 1300*0.25% + 85.714 + 58.15 = STEAM VENTED

5+1.12+3.25+85.714+58.15= STEAM VENTED



VENTING


SO,



71 | P a g e



4306 = soap + 188.234

Soap = 4117.766 Kgs

6. DURING WASHING:-




=400*10-6*2500





0 + (500+1800)*400*10-6 + 0 = EXHAUST + 0

EXHAUST = 0.92 Kgs ………………………….. (7)

FROM EQUATIONS (4), (5), (6) & (7),



=153.234+1.00+0.92



72 | P a g e

ALKALI BALANCE:-



= 1 mole of 12 HSA



X=





X=





= 6.465 kg of LiOH



73 | P a g e





*











= 49 *182.3

= 8932.7 Kgs


= 308.3 Kgs

ACTUAL % LOSS = 308.3*100/9241

= 3.33 %

74 | P a g e

THEORITICAL LOSS = MASS LOST AS STEAM+SOAP LOST

= 155.154+35

=190.154 Kgs


= 2.05 %





308.3 = 155.154 + 35 + OTHER LOSSES


NOTE:-





75 | P a g e


Date: 29/05/2012 Kettle: K-107







=309.534 Gms of 12 HSA



76 | P a g e


Now,

INPUT = OUTPUT


300 + 1000 + 200 + 2805 +10 = SOAP + VENT

4315=SOAP +VENT ………………………….. (1)

BASE OIL

12 HSA

HCO

REACTOR LiOH.H2O

WATER

SOAP

VENT

STEAM

+

SOAP IN

VENT

(LOSSES)

77 | P a g e



2500 = WASHED OIL + VENT ………………………….. (2)

KETTLE


VENT

WASHED OIL

78 | P a g e





KETTLE EX

HA

UST

TO

FILLING

SOAP FROM REACTOR


ADDITIVES W

ASH

ED O

IL

79 | P a g e


WATER IN CHARGING:

Water= 10 kgs




Hence, X = 200*18/42

X = 85.714 Kg





Y=






80 | P a g e








7. DURING REACTION:



10+ 2805*400*10-6 + 1300*0.25% + 85.714 + 58.15 = STEAM VENTED

10+1.12+3.25+85.714+58.15= STEAM VENTED



VENTING


SO,



81 | P a g e



4315 = soap + 193.234

Soap = 4121.766 Kgs

8. DURING WASHING:-




=400*10-6*2500





0 + (503+1700)*400*10-6 + 0 = EXHAUST + 0

EXHAUST = 0.88 Kgs ………………………….. (7)

FROM EQUATIONS (4), (5), (6) & (7),



=158.234+1.00+0.88



82 | P a g e

ALKALI BALANCE:-



= 1 mole of 12 HSA



X=





X=





= 6.465 kg of LiOH



83 | P a g e





*











= 49 *182.3

= 8932.7 Kgs


= 206.3 Kgs

ACTUAL % LOSS = 206.3*100/9139

= 2.25 %

84 | P a g e


= 158.234


= 1.73 %





206.3 = 158.234 + 35 + OTHER LOSSES


NOTE:-





85 | P a g e


Date: 29/05/2012 Kettle: K-107







=309.534 Gms of 12 HSA



86 | P a g e


Now,

INPUT = OUTPUT


300 + 1000 + 200 + 2805 + 5 = SOAP + VENT

4310=SOAP +VENT ………………………….. (1)

BASE OIL

12 HSA

HCO

REACTOR LiOH.H2O

WATER

SOAP

VENT

STEAM

+

SOAP IN

VENT

(LOSSES)

87 | P a g e



2503 = WASHED OIL + VENT ………………………….. (2)

KETTLE


VENT

WASHED OIL

88 | P a g e


SOAP + WASHED OIL + ADDITIVES + CORRECTION/CUTBACK OIL = EXAUST + OUTPUT (GREASE)

SOAP + WASHED OIL + 45+54+36 + 500+2000 = EXAUST + 8918

SOAP + WASHED OIL + 2635 = EXAUST + 8918 …………………. (3)

KETTLE EX

HA

UST

TO

FILLING

SOAP FROM REACTOR


ADDITIVES W

ASH

ED O

IL

89 | P a g e


WATER IN CHARGING:

Water= 5 kgs




Hence, X = 200*18/42

X = 85.714 Kg





Y=






90 | P a g e








9. DURING REACTION:



5 + 2805*400*10-6 + 1300*0.25% + 85.714 + 58.152 = STEAM VENTED

5+1.12+3.25+85.714+58.151= STEAM VENTED



VENTING


SO,



91 | P a g e



4310 = soap + 188.235

Soap = 4121.765 Kgs

10. DURING WASHING:-




=400*10-6*2503





0 + (500+2000)*400*10-6 + 0 = EXHAUST + 0

EXHAUST = 1.000 Kgs ………………………….. (7)

FROM EQUATIONS (4), (5), (6) & (7),



=153.235+1.001+1.00



92 | P a g e

ALKALI BALANCE:-



= 1 mole of 12 HSA



X=





X=





= 6.465 kg of LiOH



93 | P a g e





*







NOW, OVERALL BALANCE:


TOTAL INPUT =9448 kgs


= 49 *182 + 5

= 8923 Kgs

PROCESS LOSS = 9448 - 8923

= 525 Kgs

ACTUAL % LOSS = 525*100/9448

= 5.55 %


= 155.236 Kgs

94 | P a g e


= 1.64 %





525 = 155.236 + 35 + 100 + OTHER LOSSES


NOTE:-

FILLING LOSSES CONSTITUTE THE MASS DISCARDED INITIALLY AND THE MASS REMAINED AFTER FILLING

THE LAST BARREL.



95 | P a g e


Date: 30/05/2012 Kettle: K-105







=309.534 Gms of 12 HSA



96 | P a g e


Now,

INPUT = OUTPUT


300 + 1000 + 200 + 2805 + 10 = SOAP + VENT

4315=SOAP +VENT ………………………….. (1)

BASE OIL

12 HSA

HCO

REACTOR LiOH.H2O

WATER

SOAP

VENT

STEAM

+

SOAP IN

VENT

(LOSSES)

97 | P a g e



2500 = WASHED OIL + VENT ………………………….. (2)

KETTLE


VENT

WASHED OIL

98 | P a g e



SOAP + WASHED OIL + 40+45+36 + 503 + 1500 = EXAUST + 8736


KETTLE EX

HA

UST

TO

FILLING

SOAP FROM REACTOR


ADDITIVES W

ASH

ED O

IL

99 | P a g e


WATER IN CHARGING:

Water= 10 kgs




Hence, X = 200*18/42

X = 85.714 Kg





Y=






100 | P a g e








11. DURING REACTION:



10 + 2805*400*10-6 + 1300*0.25% + 85.714 + 58.152 = STEAM VENTED

10+1.12+3.25+85.714+58.151= STEAM VENTED



VENTING


SO,



101 | P a g e



4315 = soap + 193.235

Soap = 4121.765 Kgs





=400*10-6*2500





0 + (503+1500)*400*10-6 + 0 = EXHAUST + 0

EXHAUST = 0.8012 Kgs ………………………….. (7)

FROM EQUATIONS (4), (5), (6) & (7),



=158.235+1.00+0.8012



102 | P a g e

ALKALI BALANCE:-



= 1 mole of 12 HSA



X=


1 mole of LiOH.H2O = 1 mole of HCO



X=





= 6.465 kg of LiOH



103 | P a g e





*



TOTAL QTY OF ALKALI REQUIRED (theoretic al) =1 KGS




NOW, OVERALL BALANCE TOTAL INPUT = OUTPUT + LOSSES


TOTAL OUTPUT = NO. OF BARRELS *182

= 48 *182

= 8736 Kgs


= 203 Kgs

ACTUAL % LOSS = 203*100/8939

= 2.27 %


= 160.036 Kgs

104 | P a g e


= 1.79 %





203 = 160.236 + 35 + FILLING LOSSES + OTHER LOSSES

FILLING LOSSES + OTHER LOSSES = 7.764 Kgs

NOTE:-

FILLING LOSSES CONSTITUTE THE MASS DISCARDED INITIALLY AND THE MASS REMAINED AFTER FILLING

THE LAST BARREL.



105 | P a g e


Date: 30/05/2012 Kettle: K-106







=309.534 Gms of 12 HSA



106 | P a g e


Now,

INPUT = OUTPUT


300 + 1000 + 200 + 2803 + 5 = SOAP + VENT

4308=SOAP +VENT ………………………….. (1)

BASE OIL

12 HSA

HCO

REACTOR LiOH.H2O

WATER

SOAP

VENT

STEAM

+

SOAP IN

VENT

(LOSSES)

107 | P a g e



2501 = WASHED OIL + VENT ………………………….. (2)

KETTLE


VENT

WASHED OIL

108 | P a g e



SOAP + WASHED OIL + 45+54+36 + 500+1400 = EXAUST + 8736


KETTLE EX

HA

UST

TO

FILLING

SOAP FROM REACTOR


ADDITIVES W

ASH

ED O

IL

109 | P a g e


WATER IN CHARGING:

Water= 5 kgs




Hence, X = 200*18/42

X = 85.714 Kg





Y=






110 | P a g e






TOTAL AMOUNT OF WATER RELEASED =154.995 Kgs o f water …………………. (4)


13. DURING REACTION:



5 + 2803*400*10-6 + 1300*0.25% + 85.714 + 58.152 = STEAM VENTED

5+1.12+3.25+85.714+58.151= STEAM VENTED



VENTING


SO,



111 | P a g e



4308 = Soap + 188.235

Soap = 4119.765 Kgs





=400*10-6*2501





0 + (500+1400)*400*10-6 + 0 = EXHAUST + 0

EXHAUST = 0.7600 Kgs ………………………….. (7)

FROM EQUATIONS (4), (5), (6) & (7),



=153.235+1.00+0.76



112 | P a g e

ALKALI BALANCE:-



= 1 mole of 12 HSA



X=


3 mole of LiOH.H2O = 1 mole of HCO

938 KG of HCO = 126 KG LiOH. H2O


X=





= 6.465 kg of LiOH



113 | P a g e





*







NOW, OVERALL BALANCE TOTAL INPUT = OUTPUT + LOSSES


TOTAL OUTPUT = NO. OF BARRELS *182

= 48*182

= 8736 Kgs


= 108 Kgs

ACTUAL % LOSS = 108*100/8844

= 1.22 %


= 154.995 Kgs

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= 1.75 %


DEVIATION = +0.53 % (ADVANTAGEOUS)

NOTE:

THERE MAY BE ERROR IN CALIBRATION OF FLOWMETER OF BASE OIL

INPUT.

SOMETIMES CERTAIN AMOUNT OF GREASE REMAINS IN THE KETTLE THAT

IS ADDED TO THE OUTPUT OF THE UPCOMING BATCHES.

115 | P a g e

TABULATION OF BATCHES COVERED:

BATCH NO.

DATE TOTAL INPUT

OUTPUT THEORITICAL

% LOSS ACTUAL % LOSS

% DEVIATION

PENETRATION

118 23/05/12 8958 8760 1.8 2.21 -0.4 230/232

136 28/05/12 9142 8942.5 1.73 2.2 -0.47 228/232

142 29/05/12 9139 8932.7 1.73 2.25 -0.52 228/232

150 30/05/12 8844 8736 1.75 1.22 +0.53 230/235

120 29/05/12 9448 8923 1.64 5.55 -3.91 230/235

131 26/05/12 9241 8932.7 2.05 3.33 -1.28 228/232

146 30/05/12 8939 8736 1.79 2.27 -0.48 232/235

116 | P a g e

CONCLUSION:

PROBLEMS ENCOUNTERED SUGGESTED RECTIFICATIONS

FLOWMETERS FOR BASE OIL INPUT ARE CALIBERATED CONSIDERING A SPECIFIC DENSITY OF OIL AS STANDARD.BUT SOMETIMES THE DENSITY OF OIL MAY DIFFER COZ OF VARYING AMBIENT CONDITIONS.

CERTAIN PARAMETER FOR ADJUSTING THE FLOWRATE SHOULD BE THERE IN THE FLOWMETERS AND IT SHOULD BE ADJUSTED ACCORDING TO THE CHANGING DENSITY.

PROPER REACTION CONDITIONS (OPTIMUM PRESSURE & TEMPERATURE), IF NOT MAINTAINED, RESULTS IN INCOMPLETE SAPONIFICATION OF FATS WHICH SUBSEQUENTLY SHOWS IT’S EFFECTS ON THE YIELD OF THE BATCH.

PROPER MONITORING OF THE PROCESS SHOULD BE DONE BY THE OFFICER IN-CHARGE.

SOMETIMES THE PRESSURE IS VENTED MORE THAN 30% AT HIGH PRESSURE.BECAUSE OF THIS, SOME AMOUNT OF SOAP IS LOST WHILE VENTING.THIS CONTRIBUTES TO LOSS IN OUTPUT.

PROPER MAINTENANCE OF PRESSURE SHOULD BE THERE TO AVOID HIGH VENTING RATE.

MANUAL ERRORS DURING CHARGING MAY RESULT IN DEVIATION OF YIELD.

AUTOMATION SHOULD BE DONE FOR CHARGING.

ADDITIVE ADDITION IS DONE AT TEMPERATURE OF AROUND 100-1150C. THIS RESULTS IN THE ADDITIVES NOT IMPARTING THE DESIRED PROPERTIES TO GREASE FULLY.

ADDITIVE ADDITION SHOULD BE DONE AT TEMP. LESS THAN 90OC AS SUGGESTED BY THE QC.

TEMPERATURE INDICATORS OF CERTAIN KETTLES SHOW ERROR IN TEMPERATURE

MEASUREMENT.THAT SHOULD BE RECTIFIED.

THE HEATING RATE OF THE REACTORS SHOULD BE INCREASED SO AS TO ATTAIN THE

REQUIRED TEMPERATURE IN LEAST POSSIBLE TIME.THIS WOULD RESULT IN MORE BATCHES

PER DAY AND INCREASED PRODUCTION RATE.

CERTAIN LOSSES LIKE SOAP VENT TO REACTOR, LOSSES DUE TO INCOMPLETE REACTION,

MANUAL ERRORS SHOULD BE MINIMISED BY PAYING PROPER ATTENTION WHILE

WORKING.

THERE ARE LOSSES DUE TO OVERFILLING, WHICH CAN BE REDUCED BY ADJUSTING PROPER

SET POINT, REPLACING THE OBSELETE WEIGHING DEVICES WITH NEW ADVANCED ONES

FOR ACCURATE MEASUREMENT.

PROJECT REPORT ON MASS BALANCE OF RR3 GRADE OF GREASE

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