PRODUCTION OPERATIONS & MANUFACTURING PROCESSES OF LABSA Essay

Sulphonation The ProcessMost electrophilic substitution receptions atomic number 18 irreversible precisely sulfonation is an exception. Treatment of benzene with oleum (a re resolve of SO3 in concent strided entropyic acidulated) pass on give the sulfonic acid, the electrophilic species being sulfur trioxide which is Lewis acidic. form 1 Sulphonation benzene equationThe sulfonic acid can be converted back by discourse with hot aqueous acid. The reason for this reversibility is the fact that the Wheland intermediate is overall inert and then more stable than separate, positively charged intermediates. Hence, under forcing reaction conditions, the energy difference in progressing in every the forward or backward sense from the Wheland intermediate is proportionately minusculeer compargond to the barrier to activating and hence discrimination is lost. shape 2 Progress of Reaction against nilThis micturates the SO3H a useful reign overing convention if it is desire d to break away our selective ortho substitution of a monosubstituted benzene possessing an ortho/para activating group. Under average circumstances, para substitution would dominate, despite the statistical favouring of the ortho jells out-of-pocket to steric hindrance of the original substituent. Initial sulfonation para gives a Disubstituted benzene in which both substituents direct to the same position. Subsequent directed electrophilic substitution and removal of the sulfonic acid group gives theortho disubstituted harvest-home.Process Involved In the Manufacture of science labSA public figure 3 flow sheet of the process behind the production of LABSA.The manufacturing of LABSA at Sasol gulf is a constant process. An interval of 1 day afterward a period of 20-21 years for the purpose of shut- slew and vex-up is ess abolishial for maintenance purposes. The key reactions involved in the constitution of LABSA ar as follows pedigree Drying mho Melting Ignition of s ec (S) to sulphur dioxide (SO2) SO3 production Oxidation of sulphur dioxide to sulphur trioxide (SO3) using catalyst vanadium pentoxide (V2O5) under optimum temperature. Film Sulphonation Reaction of Linear alkyl Benzene (LAB) with atomic number 16 trioxide to yield the end product LABSA. Ageing & angstrom Hydrolysis particle accelerator Separation & Gas Scrubbing Separation of LABSA from unreacted louse upes. line DryingThe charge interpreted from out(p)side is compressed and dehumidified by means of the succeeding(a) units1)Intermediate Cooling Unit.2) silicon dioxide colloidal gel Dehumidifying Tower.The cooling has the purpose to remove the humidity from the charge, up to a saturation humidity of 2 stop Celsius & as well to convey low temperature air to the dehumidifying rise, thereof favoring the pee absorption in the silicon dioxide gel. The silica gel air drying has the object to reduce to in truth low valuates (dew smudge -60 approx.) the wet conten t of air mean for the sulfur combustion, & consequently for change.This reduces to acceptable cheers the oleum quantity green groceriesd in the conversion unit, which depends directly to the quantity of water system contained in the air.WorkingThe air filtered is sucked by the compressor that sends the process air to the refrigerating group. This unit removes the compression shake up by water & moreover cools the air to 2 degree Celsius by the intermediate medium cooling unit which is kept at constant temperature. The equipment for air drying is a vertical cylindrical vessel, which is horizontally sh atomic number 18d in  devil constituents by a partition containing insulating strong. The two silica gel layers atomic number 18 placed on nets 2 spaces are left free above and below such(prenominal) layers for air recess and outlet respectively. On the plates, at the level of both silica gel layer, two lax glasses are located to check visually their conditions. S ome silica gel indicator is placed near the mess hall glasses, changing its wile accordingto the quantity of absorbed water thus saturating with water, it changes square-shouldered to pink.Fig 4 Boiler to produce and supply steam.Characteristics of Silica gelatineAppearance white coloring, granules of 3-6 mm approx.Bulk Density 700kg/dm3 approxThe regeneration is carried out by instigateing with air at 150 degree Celsius. A checking closely the effective regeneration is make by verifying the Silica gel indicator through the sight glasses, as well as by verifying the outlet temp., of the regeneration air on the arrangement thermometer. When the regeneration is accomplished the silica gel spate has a temperature kind of near 150 degree Celsius. Therefore it is necessary to cool the silica gel thus allowing it to adsorb the humidity of the air crossing it. note of hand The four way valves are provided with a drive by pneumatic piston chambers which are remote controlled en ergizing several(prenominal) solenoid valve suitably. radiate drying and coolingAir that is utilized in the production of LABSA has to be cooled first and then alter to ensure its feasibility for further reactions. Air is cooled by passing it through a light exchanger containing the coolant mono-ethylene glycol at a temperature of 0 to -2 degree Celsius. The coolant ensures condensation of air to around 5 degree Celsius. afterward cooling air to the postulate temperature it has to be dried to remove traces of moisture pre direct in it. For this purpose air is passed through a cylinder filled with silica gel. The silica-gel brings the dew point of the water in the air ingest to stay -40 degrees Celsius. This means that the air is dry as if the air was cooled down to -40 degrees Celsius. In practice two cylinders with silica-gel are use one for drying the air, the other(a) is reconditioned. In general the changing of the cylinders is through with(p) automatically.Fig 5 Air Dry ing ProcessFig 6 Glycol TowerIn high society to remove the compression lovingness energy and to condense the moisture, the air is first cooled by cooling water and then by a glycol solution in the glycol tower. The air flow is then conveyed at a constant temperature (less than 5) to the silica gel dryers. process MeltingSulphur is melted to allow Sulphur that has been acquired has to be melted prior to its ignition. This is done by heating it in the melter at temperatures of one hundred thirty-five to one hundred forty-five. If the temperature exceeds 145 it would result in vaporisation of sulphur while temperatures less than 135 would be insufficient to melt sulphur. Therefore a temperature of 140 is well-kept to prevent wastage of sulphur due to the above mentioned causes.Fig 7Sulphur Melting Tank.The solid sulphur is melted and filtered to avoid the manage valves back up and then ply to the sulphur burner by a proportioning nerve. The viscosity of break up sulphur is mi nimum between 135 to 140 .Fig 8 Viscosity Of SulphurMolten sulphur is cater under mass control by means of a mass flow meter. The pump and the relevant piping are steam heated in revisal to to keep thetemperature constant and to minimize sulphur viscosity.Fig 9 Sulphur BurningSO ProductionThe oxidation reaction of sulphur dioxide and trioxide is exoergic and heat produced by it is rather sufficient to keep the catalyst layers at the inevitable at the required temp. to obtain a good conversion progress. In read to get the best force, the bollix inlet temperature in the first catalyst layer has to be about 420 degree Celsius.To start the reaction, the catalyst layers of the first & here and now stage of the conversion tower gravel to be brought to the necessary temperature. This is reached by preheating with hot air and the pep pill part of the catalyst tower is heated upto a temperature of 400-420 degree Celsius.Fig 10 Catalyst BedSulphur Dioxide & Sulphur Trioxid e ProductionThe sulphur combustion furnace has been designed for this special purpose. In the furnace, the sulphur is feed through a pipe and falls on a move up of refractory balls, while the combustion air is supplied in counter current, thus obtaining the realized combustion of sulphur without its spraying through a olfactory organ which might often clog owing to sulphur impurities.This strategy is quite simple it does not require both maintenance and the gas patch does not change. The temperature of the gas at the burner outlet is around 700 degree Celsius (corresponding roughly to a SO2 concentration of 7% by volume). Thereafter a heat exchanger cools the gas so that it reaches the conversion tower at the required temperature. The conversion tower is composed of three layers of vanadium pentoxide (V2O5) catalyst. The gas, passing from a layer to next one, crosses a heat exchanger to take the gas temperature to optimum conversion taxs on every stage. In order to allow qu ick startup, a preheating system has been provided. The main characteristics of Ballestra pre-heating system deliver been provided noelectric pre-heater is required because if it were utilize, being in the presence of SO3, it would be corroded very quickly. Moreover, with Ballestra system there is no need to either arc off or regulate values in the band of conversion lines, which should operate a temperature of about 500 degree Celsius in the presence SO2 / SO3, thus being easily corroded. The gas temperature is of course as well high to be suitable for sulphonation therefore some heat exchangers in the series are used to cool the gas down to correct sulphonation temperature. The hot air coming from SO3 coolers is utilized for silica gel regeneration.6 Fig 11 SO2 / SO3 ProductionFilm SulphonationThis group is composed by a record nuclear reactor, multi- pipage type, having dimensions and number of tubes proportional to the plant capacity. The sulphonation gas is automati cally fed on the reactor top and distributed in part strictly fitted on each of the pipes composing the reactor. The desolate solid to be sulphonated is fed in co-current with the gas. Outside the reaction tubes in the reactor jacket the cooling water circulates in co-current with the film, thus allowing a control of the reaction temperature by heat removing.The distribution of the gas and the product to be sulphonated is designed in order to ensure a constant ratio between the two phases, inside each reaction tube. The sulphonated or sulphated product, coming out of the reactor is suitably degassed, aged and stabilized according to the fed raw material and fed to the neutralization unit.In this connection the Ballestra sulphonation / sulphation system by film reactor has great advantages towards the other existing systems on the market since in the case of power failure an emergency system, included in the supply, avoids either damage to the product and the necessity of cleanin g the reactor before resuming operation. This system can be also used during plant startup the material to be sulphonated is fed and recycled to the reactor until optimum SO2-SO3 conversion is reached.Main nuclear reactorFig 12 Top view of the Reactor Fig 13 Bottom Nozzles Of the ReactorThis SO3 is sent to the reactor where it reacts with Linear alkyl group Benzene. referable to presence of some water vapours in air some oleum is also formed. This should be avoided as it can cause blockage. The reactor has clear tubes in which the SO3 passes and the LAB passes through its sides. The main reaction takes place at bottom of these tubes and during maintenance these tubes are thoroughly cleaned because if the LAB leaks to the centre part then the reaction will take place there unaccompanied and no SO3 will pass through.Then this medley of LABSA (desired product), LAB, SO3 and a mixture of other waste materials including oleum is sent to a separator. The unstable product is sent t o the aging vessel and the gases are sent to cyclone.Fig 14 Sulphonation whole kit and caboodle ArrangementAgeing & HydrolysisThis is used to stabilize the sulphonated DDB. It is composed by an aging unit and stabilizer. The product after being sulphonated overflows into the bottom of the ageing unit. It is then conveyed into the stabilizer together with water. Afterwards it is transferred with the help of a pump to the neutralization unit.Fig 15 Ageing VesselGas Seperation cyclonical separation is a method of removing particulates from an air (or gas) menstruation, without the use of filters, through fling separation. Rotational effects and gravity are used to separate mixtures of solids and fluids.hither a high speed rotating air-flow is established within a cylindrical or conical container called a cyclone. Air flows in a turbinate pattern, beginning at the top (wide end) of the cyclone and ending at the bottom (narrow) end before exiting the cyclone in a straight floa t through the bone marrow of the cyclone and out the top.Larger (denser) particles in the rotating air stream have likewise much inertia to follow the tight curve of the air stream and strike the outside wall, falling then to the bottom of the cyclone where they can be removed. In a conical system, as the rotating air-flow moves towards the narrow end of the cyclone the rotational radius of the air stream is reduced, separating olive-sizeder and smaller particles from the stream. The cyclone geometry, together with air flow rate, defines the cut point of the cyclone.This is the size of particle that will be removed from the air stream with a 50% efficiency. Particles big than the cut point will be removed with a greater efficiency and smaller particles with a lower efficiency. The liquid product and reactants which still have to react are sent to the aging vessel but the product in the form of vapour and gases are sent to static Precipitator.Fig 16 Gas SplittingGas Scrubbing / Exhaust Gas TreatmentThe unit is designed to treat exhaust gas stream coming from the sulphonation reactor before being sent to the atmosphere in order to remove any possible organic, unreacted SO traces and unpersuaded SO. The exhausted gas coming from the reactor pass through a cyclone which provides to separate the acid mist before getting into the electrostatic precipitator and SO2 scrubber column.Fig 17 Exhaust Gas TreatmentIn the electrostatic precipitator the organic substances and unreacted SO3 are separated and eliminated. The residual unconverted SO2 is absorbed in the scrubbing column in which a water and caustic soda solution is continuously recycled. The gas stream is contacted with a controlled stream of fresh organic raw material.Fig 18 Electrostatic Precipitator Functionality DetailsFig 19 Electro Static Precipitator anatomical structure DetailsAn electrostatic precipitator (ESP) or electrostatic air unused is a particulate collection device that removes particl es from a flowing gas (such as air) using the force of an induced electrostatic charge. The LABSA is separated and sent to the ageing vessel.Types of Heat Exchangers berate and Tube heat exchangerShell and tube heat exchangers consist of a series of tubes. One redact of these tubes contains the fluid that must(prenominal) be either heated or cooled. The second fluid runs over the tubes that are being heated or cooled so that it can either provide the heat or absorb the heat required. A set of tubes is called the tube bundle and can be do up of several types of tubes plain, longitudinally finned etc. Shell and Tube heat exchangers are typically used for high pressure applications (with pressures greater than 30 bar and temperatures greater than 260C. This is because the shell and tube heat exchangers are robust due to their shape. There are several thermal design features that are to be taken into account when designing the tubes in the shell and tube heat exchangers. These includ eTube diameter Using a small tube diameter makes the heat exchanger both economical and compact. However, it is more likely for the heat exchanger to foul up faster and the small size makes mechanical cleaning of the fouling difficult. To prevail over the fouling and cleaning problems, larger tubediameters can be used. Thus to determine the tube diameter, the ready(prenominal) space, cost and the fouling nature of the fluids must be considered.Tube burdensomeness The thickness of the wall of the tubes is usually determined to ensure oThere is enough room for wearing awayoThat flow-induced vibration has resistanceoAxial strengthoAbility to easily stock spare separate cost Sometimes the wall thickness is determined by the level best pressure differential across the wall.Tube length heat exchangers are usually cheaper when they have a smaller shell diameter and a long tube length. Thus, typically there is an aim to make the heat exchanger as long as possible. However, there are so me limitations for this, including the space available at the site where it is going to be used and the need to ensure that there are tubes available in lengths that are twice the required length (so that the tubes can be withdrawn and replaced). Also, it has to be remembered that lone, thin tubes are difficult to take out and replace. Tube riffle when designing the tubes, it is practical to ensure that the tube pitch (i.e. the centre-centre distance of neighboring tubes) is not less than 1.25 times the tubes outside diameterLAS/LABSA ( Linear Alkyl Benzene Suplhonic Acid ) The ProductDescription of LASLinear alkylbenzene sulfonic acid is the largest-volume synthetical surfactant because of its relatively low cost, good performance, the fact that it can be dried to a stable powder and the biodegradable environmental favor as it has straight compass. LAS is an non-ionic detergent surfactants with molecules characterized by a hydrophobic and a hydrophilic group. Alpha-olefin su lfonates (AOS) alkyl sulfates (AS) are also examples of commercial anionic surfactants. They are nonvolatile compounds produced by sulfonation. LAS are complex mixtures of homologues of different alkyl chain lengths (C10 to C13 or C14) and phenyl positional isomers of 2 to 5-phenyl in proportions dictated by the jump materials and reaction conditions, each containing an aromatic ring sulfonated at the para position and attached to a linear alkyl chain at any position with the exception of terminal one (1-phenyl). The properties of LAS differ in somatogenetic and chemical properties according to the alkyl chain length, resulting in formulations for various applications. The commencement material LAB (linear alkylbenzene) is produced by the alkylation of benzene with n-paraffins in the presence of atomic number 1 fluoride (HF) or aluminium chloride (AlCl3) as a catalyst. LAS is produced by the sulfonation of LAB with oleum in batch reactors. Other sulfonation alternative reage nts are sulfuric acid, diluted sulfur trioxide, chlorosulfonic acid and sulfamic acid on falling film reactors. LAS are then neutralized to the desired salt ( atomic number 11, ammonium, calcium, potassium, and triethanolamine salts). Surfactants are widely used in the industry needed to improve contact between polar and non-polar media such as between oil and water or between water and minerals.MASS DENSITY AT 20 DEGREES C 1.070 g/cm3 viscosity AT 20 DEGREES C 1500 2000 mPa.s.MELTING RANGE 10 DEGREES C. turn POINT 315 DEGREES C.VAPOUR PRESSURE at 20 DEGREES c below 0.15 (0.001 mm Hg). FLASH POINT (PMcc) >200 DEGREES C.DECOMPOSITION TEMPERATURE > 100 DEGREES C.Ph 2.Applications of LASAlkylbenzene sulfonic acid, as the raw material of detergent, is used to produce alkylbenzene sulfonic acid sodium (LAS), which has the performances of cleaning, wetting, foaming, emulsifying and dispersing, etc. The rate of biodegradation is more than 90%. The product is widely used for producing various detergents and emulsifiers for agricultural herbicides and in emulsion polymerization. It is mainly used to produce household detergents such as washing powder, detergent of dishware, detergent of light or hard dirt, cleaner of textile industry, dyeing assistant, degreaser of platingand lather making industry, and the deinking agent of paper-making industry, etc.CharacteristicsGood Surface active properties disordered cost surfactant for detergentsEasy processing into dried powdersDesirable solvability in both liquid and powder formulation Biodegradable congenial with other surface active agentsSales SpecificationsAPPEARANCEViscous Light Brown liquidACTIVE MATTER96.0% minACID VALUE180 190FREE OIL1.5% gooWATER1.0% maxCOLOR, KLETTE50 max (5% Sol. pH=7, 40mm cell)FREE SULFURIC ACID1.5% maxAdvantagesCost effective, anionic surfactant.Biodegradable.Due to its stable foam, suitable for detergent applications in combination with other surfactants. Compatible with enzymes and builders.Outstanding performance with other anionic surfactants due to its synergetic effect. Consumes less alkali for neutralisation.Ideal for liquid detergent application due to high solubility and low salt content.Packaging & supermanLABFirst the truck is parked in the heavy warhead station directly under a valve. Laborers enter the truck and micturate metal rods in grooves near the door. Then a cardboard delimitation is set up in order to provide support. A flexi-bag is feast out on the bottom of the container, above and within the cardboard perimeter. A hose is connected to the valve and to the flexi-bag. The initial reading is taken from the main LAB tank. The flexi-bag can withstand 20-25 tons of LAB. Calculations are carried out to transfer an approx. 20 tons. The meter reading must reduce by 52cm.Fig 20 Flexi Bags within cardboard perimeterSulphonic AcidThe sulphonic acid is corrosive in nature and therefore requires a vehicle with a pre-fitted tanker . The tanker is made of a special material (commonly stainless steel) Also the tank must be able to keep the sulphonic acid at a coveted temperature.Fig 21 Fitted TankLABSALABSA is packaged into plastic drums and then transported. for each one drum contains 210kg of the product. Sasol buys second hand drums in order to cut costs. at once the drums are loaded with LABSA on a wooden platform a forklift will move them to the storage shed. At the time of loading the forklift will carry these drums to a loading station with an adjustable ramp. The forklift will carry the containers into the truck and load them there.Fig 22 Plastic Drums for packaging digestEvery two hours, regular analysis of the product is carried out to make sure the lineament of the product is maintained. A standard of the product is takenin a beaker and taken to the analysis room.Color Klett DeterminationA Klett colorimeter allows light to pass through and determines the colour Klett of the substance. The beak er is put on the colorimeter and the value of the color Klett is obtained. Lesser the color Klett, better the quality of the product. The standard value for Klett is around 50%(maximum). Here at Sasol, it ranges from 5-10% and is therefore great in quality. necessary EquipmentsKlett ColorimeterBlue Filter No. 42 with 400-465mm wavelength rangePair of cells with 40mm path lengthBalanceRequired ReagentsEthanol 99.9% GPRMethanol GPRPropan-2-ol ( Isopropyl alcohol ) GPRDistilled waterProcedurePrepare solvent of ethanol 99.99%, methanol, propan-2-ol or distilled water or a mix of all. iron 5g of active substance and dilute with a weighed amount of solvent so that a solution of 5% m/m is prepared for color bill.In case of 5% m/n color measurement , weigh 5g of active substance, then times the volume of solvent required by relevant solvent density and weigh solvent.Mix upto complete dissolution.Fill 40mm path length cell (clean and dry) with mixture and other cell as reference cell. Color imeter must be switched on 15 mins prior to thetest.Acid value determinationAfter finding the color Klett, the sample of the product is then titrated with ethanol, drop by drop after adding the indicator. Through this, the amount of ethanol required to reach the n point is noted and the acid level of the product is calculated. It should be approx. 180. If the acid value is higher or lower than the required value, the air flow rate is adjusted and analysis is carried out till the desired acid value is obtained.Required equipments250ml conical flaskful10ml BuretteLab analytic poise reading upto 3 decimal placesRequired ReagentsDistilled waterSodium hydrated oxide Volumetric SolutionPhenolphthaleinEthanolThis method covers determination of acid value for sulphonic acid, however it can also be used for pure roly-poly acids.ProcedureWeigh accurately about 2g of sulphonic acid into the conical flask and note the weight. Add 25ml of ethanol and mix well to ensure the sample is dissolved completely. Titrate with NaOH solution using phenolphthalein until the solution retains a weak pink colour. Note T1.CalculationAcid Value = ( T1 x one thousand of NaOH x 56.1 ) / WtFree Acid % = ( T1 x Molarity of NaOH x titrated acid molecular weight ) 10ConclusionIn a nutshell, the previous calendar month at Sasol has been very productive in terms of the knowledge gained regarding the manufacturing operations of the LABSA plant in Dubai, UAE.Future ScopeThis is a detailed get over on Production Operations and Manufacturing Processes of LABSA. It is highly informative on processes such as Air Drying, SO Production, SO Treatment, Linear Alkyl Benzene Sulphonation etc. The report can be used to bring about the following functionalitySet up companiesSet up detergent raw material supplyImprove plant production quality castrate production costsReferences1 www.wikipedia.com2 www.sasol.com3 www.uaeincorp.com4 www.users.ox.ac.uk5 Sasol Gulf Operation Manual6 Sulphonation Technology in the Detergent Industry by W. Herman de Groot 7 www.lasinfo.org8 www.mixmedicine.com9 www.chemicalland21.com10 Test Method Control fashion File