Pre Feasibility Report For PRODUCTION OF ACID SLURRY

24 Pages·2017·1.07 MB·English

Pre Feasibility Report

For
PRODUCTION OF ACID SLURRY (LABSA 100%)

At

Plot No.70, Village-Kajipalasiya (khudel)
Tehsil-Indore, Dist.- Indore (M.P.)

Proposed By

M/s Bhaskar Venkatesh Products Pvt. Ltd. (Unit-II)
Indore (M.P.)
1. Identification of project and project proponent
The Proposed Acid Slurry (LABSA 100%) project is proposed within the existing Premises Detergent unit
with capacity of 9000 TPA and By product Spent Acid 7500TPA at, Village-Kajipalasiya Tehsil-Indore Dist.-
Indore (MP). The project is proposed by M/s Bhaskar Venkatesh Products Pvt. Ltd. which is occupied by Shri
Akash Goyel having 15 years experience in business and industry. He is also Managing Director of the
Company.

BHASKAR VENKATESH PRODUCTS PVT. LTD. is a joint venture company of DAINIK BHASKAR GROUP and
ANANT GROUP.

BHASKAR VENKATESH - a customer-focused company, dedicated to produce enriched quality products and
services to the customers that meet their essential needs. The company is committed in better value to its
consumers by offering them the quality products and services at affordable prices.

BHASKAR VENKATESH PRODUCTS PVT. LTD came into existence on 12th May 2006 and entered into edible
SALT market with the brand name BHASKAR. During its expansion period, we have launched the FMCG items
i.e. ATTA and DETERGENT under the brand name of TAN MAN.

2. Brief Description of Nature of The Project
The Proposed Acid Slurry (LABSA 100%) project is proposed within the existing Premises Detergent Unit
area. The proposed new project involves the production of “Acid Slurry” which are Synthetic Organic
Chemicals, for the proposed project, the company intends to procure the available latest technology for
manufacturing the proposed products.
The industrial sector in the past years has seen a drastic boom and also the keeping in mind the globalization
trend, we have identified the demand for the proposed products and with continuous R&D found that it can be
developed in-house and produce commercially for domestic market as well as an eye more on export markets.
As per the EIA notification- 2006 as amended the proposed project involves the production of “Acid Slurry”
which falls under item no. “5(f) - Synthetics organic Chemicals industries” hence requires Prior
Environmental Clearance.
This project profile in detail foresees setting up of unit to produce ACID SLURRY (LABSA 100%) LABSA has
been the major surfactant used in detergents for more than thirty five years and continues to represent a
substantial portion of the surfactants market today. Supporting this history of safe usage is a large archive of
environmental research that has been conducted on LABSA. This environmental research, performed by top
environmental scientists and research agencies, has investigated virtually every part of the environment that
could have been exposed to LABSA. The studies have repeatedly proven LABSA's environmental acceptability
and safety. Because of LABSA's environmental safety, cleaning effectiveness and cost competitiveness, LABSA
has experienced 45 years of ever-increasing use around the world.
Linear alkyl benzene (LAB), the material used to produce LABSA, is derived exclusively from petroleum bi-
products--benzene and paraffin derived from kerosene. LAB currently represents the active ingredients in
detergents worldwide.
Linear alkyl benzene is the raw material used to manufacture linear alkyl benzene sulfonate (LABSA), an
active ingredient in the formulation of detergents. LABSA eliminates dirt by its physicochemical mechanism
and it is one of the surfactants most widely used in liquid cleaners and in powder. LABSA has been used for
more than 45 years in the manufacture of detergents and it is known for its excellent quality/price ratio.

3. Need for the project and its importance to the country and or region
The proposed new project will provide a potential growth opportunity for the company. We identified
the demand for the proposed products and it can be produce commercially for domestic market as
well as an eye more on export markets. Its export and also increase the foreign revenue. The products are
now well established and acceptable in the international markets.
4. Demand –Supply gap
The products have very high demand in Synthetic Detergent Industry and other chemical industries. The
proposed new of unit will to some extent help to meet this consumption indigenously fulfill the demand
supply gap

5. Imports vs. Indigenous production
Proposed products manufacturing in the country will be very much economical compare to Imports of the
same.

6. Export possibility
There is a huge demand of the proposed products in the export market. Our products are widely used and are
in demand in the Synthetic Detergent Industry and other chemical industries etc.

7. Employment generation (direct and indirect) due to the project
During operation skilled, semi-skilled and un-skilled labours approximately 150 numbers will be required for
operation etc.
Indirect employment-
Driver, cleaner for loader & dumper, loading and unloading points where labours are required
8 Project description
1. Types of project: Acid Slurry (Labsa 100%) Manufacturing Unit
2. Location of the Project

District/ State Taluka Village Khasra no.
Indore( MP) Indore Kajipalasia (Khudel) 32 (New-70)

The area lies at the cross section of longitude 76 deg. 01’ 30.12” E East & Latitude 22 deg. 41’ 11.93” N
North and Topo sheet No-55 B/2. The area is fully developed and all infrastructure facilities including
Transportation, communication, proximity to market etc. conductive to growth of an industry are
abundantly available.

Site Address Village-Kajipalasiya, Tehsil-Indore,Dist.-Indore (M.P.)
Production Capacity Linear Alkaline Sulfonic Acid(LABSA)-9000 MTPA
Spent Acid(By Product)- 7500 MTPA
Cost of Project 17 Crore
Raw Material Requirement Linear Alkaline benzene (LAB)-6000 MTPA
Sulphuric Acid(H2SO4)-9000 MTPA
Water -1500 MTPA
Fuel Diesel: 12Lit/Hr for one D.G. Set For Capacity of 100
KVA
Net fresh Water Requirement The water requirement for proposed unit will be 04
KLD and total requirement for existing and proposed
unit will be 12 KLD, whereas domestic requirement
will be about 15 KLD. The water is/will be supplied
by the tankers.
Power Requirement 350 HP
Capital Cost for Environmental measures
15 Lacs
( proposed )
Proposed area for plantation 18426 Sq.mt.
Existing area of plantation 1535 Sq.mt.
Alternative Source of Power DG set of 100 KVA
Land acquired The Total land area available with the unit is 37452.1
sq.mt. Out of that 9254 sq.mt. Land is required for
the proposed LABSA plant.
Solid /Hazardous waste Generation No solid waste Generation in our process.
Nearest Highway Nemawar Road (NH-59) -0.14 km
Nearest Railway Station Indore- 17 km
Nearest Airport Indore -23 km
Nearest Forest/ Sanctuary/Eco- No Such Areas within 10 km raidus
sensitive zone.

22°41'12.86"N - 76°01'31.79"E 22°41'9.96"N - 76°01'32.79"E
22°41'8.82"N - 76°01'28.63"E 22°41'11.91"N - 76°01'27.43"E
Proposed Unit Layout Plan

The features of the layout are as follows:

Process plants will be consolidated into comprehensive production unit requiring short conveying distances
and lengths of gas ducts; Sufficient space will be provided for ease of operation and maintenance; The lengths
of power cables will be minimized by suitably locating load distribution centers in respect of process
departments; toward movements of materials from customers/suppliers will be segregated from internal
plant traffic; and Safety requirements will be kept in mind while locating the workshops and vehicular
movement inside the plant.

3. Details of alternate site:
Detergent Plant has already been established at same plot. Proposed LABSA Plant is interlinked with
Existing unit. Hence No alternative sites are considered as the proposed activities.

4. Size or magnitude of operation:
The proposed capacity of the plant is 9000 TPA.

5. Project description with process details:

List of Product (MT/Month)
Quantity, MT/Month
S.No. Product Existing Product Addition Total After proposed
Addition
1. Detergent Powder 6000 - 6000
(Non EC Product)
2. Detergent cake 3000 - 3000
(Non EC product)
3. LABSA (EC Product) - 750 750
4. By Product(Spent Acid) - 625 625
The overall process is shown on the attached Block Flow Diagram, and Process Flow Diagrams.

Product -1: Detergent Powder (Existing Product)-
For Manufacturing of the Detergent powder it is required to mix soda ash, Dolomite powder, vacuum salt,
SIPP, and Perfume in standard proposition and simultaneously required to add/mix acid slurry in standard
propitiation. Therefore color and water solution to be mixed fro decorating the product which further
required the process of dry, grind and filtration through fine mesh net. After all process of dry, grind and
filtration through fine mesh net. After all process it result in to finished product in loose form. Lastly loose
finished product is to be weighed, filled and packed in polythene bag of 1 kg, 500 gms and 250 gms etc .and it
is also to be packed in 50 kg.25 Kg. Jute/Polythene bags for transportation purpose.

Product-2: Detergent Powder (Existing Product)-
Soda ash, China clay, soap stone, Acid Slurry, Calcide, STPP, Starch, Lime stone and other minerals and items
will be added in standard proportion along with water this mix will be kept in mixer for half an hour therefore
by machine cakes will be available for sale.

Product-3: Proposed Product Addition of LABSA-
For manufacturing lf LABSA first of all Lab(Linear Alkyl Benzene) will be pumped from its storage tank to
dosing tank in which we can measure to required quantity and then after measuring the required quantity it
will be dropped into stirrer and after it we will pump H2SO4 (Sulphuric Acid)into dosing tank to measure its
quantity after measuring it we will drop it in the stirrer which is already mixing LAB, we will mix it for nearly
3-4 hours after completion of mixing we will add little amount of water and the whole batch will be drop in
the separator.
We will allow to separate it for 4-5 hours resulted the bottom part would be of spent Acid9By product) and
the upper part as LABSA (slurry)then both liquids will be transferred to their individual storage tank.

Brief Description Proposed Product LABSA-
Raw material consumption per tones of 89+/- 1% acid slurry is Linear alkyl benzene 670-690 kg,
Sulphonating agent 98% Sulphuric acid 1050 +/100kg. LABSA is anionic surfactant with molecules
characterized by a hydrophobic and a hydrophilic group. Alpha-olefin sulfonates (AOS) alkyl sulfates (AS) are
also examples of commercial anionic surfactants. They are nonvolatile compounds produced by sulfonation.

LABSA is a 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 starting 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 LABSA differ in physical and
chemical properties according to the alkyl chain length, resulting in formulations for various applications in
laundry and home care products.
The starting material LAB (linear alkyl benzene) is produced by the alkylation of benzene with n-paraffins in
the presence of hydrogen fluoride (HF) or aluminium chloride (AlCl3) as a catalyst, the latest is DETAL
process by UOP.LABSA is produced by the sulfonation of LAB with sulphuric acid in batch reactors.
Other sulfonation alternative reagents are oleum, diluted sulfur trioxide, chlorosulfonic acid and sulfamic acid
on falling film reactors.

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. Linear alkylbenzene sulfonic acid is mainly
used to produce household detergents including laundry powders, laundry liquids, dishwashing liquids and
other household cleaners as well as in numerous industrial applications like as a coupling agent and as an
emulsifier for agricultural herbicides and in emulsion polymerization.
Because they are stable, sulfonic acids can be isolated, stored and shipped as an article of commerce. SO3 is
an aggressive electrophilic reagent that rapidly reacts with any organic compound containing an electron
donor group.
Sulfonation is a difficult reaction to perform on an industrial scale because the reaction is rapid and highly
exothermic; releasing approximately 380 kJ/kg SO3 (800 BTUs per pound of SO3) reacted.
Most organic compounds form a black char on contact with pure SO3 due to the rapid reaction and heat
evolution. Additionally, the reactants increase in viscosity between 15 and 300 times as they are converted
from the organic feedstock to the sulfonic acid.This large increase in viscosity makes heat removal difficult.
The high viscosity of the formed products reduces the heat transfer coefficient from the reaction
mass. Effective cooling of the reaction mass is essential because high temperatures promote side reactions
that produce undesirable by-products. Also, precise control of the molar ratio of SO3 to organic is essential
because any excess SO3, due to its reactive nature, contributes to side reactions and by-product formation.
Therefore, commercial scale sulfonation reactions require special equipment and instrumentation that allows
tight control of the mole ratio of SO3 to organic and rapid removal of the heat of reaction.
Sulfuric acid (H2SO4) is widely used as sulfonating agent. It is an equilibrium process, as water is formed in
the reaction and the resultant water dilutes the sulfuric acid. The sulfonation reaction stops when the sulfuric
acid concentration drops to approximately 80%. This process has the dual advantage of low SO3 cost and low
capital equipment cost as compared to the gas sulphonation route. However, it has the disadvantage of being
an equilibrium process which leaves large quantities of un-reacted sulfuric acid. This waste acid must be
separated from the reaction mixture and subsequently used in manufacture of SSP and other fertilizers.

Sulfuric acid can be used to sulfonate aromatics and alcohols in either batch or continuous equipment. For
detergent alkylates, the batch equipment is used which is a Reactor, with a provision for and cooling to
remove the heat of reaction and maintain suitable temperature during the reaction. The detergent alkylate is
first added to the reaction vessel then the Sulphuric acid is slowly added over a period time. The reaction is
highly exothermic and the acid addition rate is determined by the ability to remove the heat of reaction. The
temperature should be maintained below 65°C for optimum product quality.
Frequently the heat of reaction is removed by pumping the reaction mixture through an external heat
exchanger. Because it is an equilibrium reaction, except for the special case of azeotropic sulfonation of
hydrotropes with sulfuric acid, a large surplus of sulfuric acid forms. When the sulfonation reaction is
complete,the sulfuric acid may be separated from the sulfonated detergent alkylate by adding water. The
water addition (typically about 6 to 8% by weight of the reaction mixture) causes a phase separation to occur
between the sulfonic acid and the diluted sulfuric acid called spent acid.

The separation usually takes place in a separate, lined vessel and occurs over a period of about for 1/2 hour.
After separation, the sulfonic acid is transferred in to a storage tank from which material is dispatched.
Material is sold either in lorry tankers or in HDPE barrels. An automatic barrel filling machine is used to make
sure that correct weight of material is filled in to each barrel. Road tankers are weighed in weighbridges
before dispatch. Spent acid is likewise transferred to a separate storage tank to be used in manufacture of SSP.

Process Block diagram for manufacture of LABSA (100%)-
MASS BALANCE OF LINEAR ALKYL BENZENE SULPHONIC ACID (LABSA)

Raw material Qty. Mt.(300 Days) % stage
Input
Linear Alkaline benzene(LAB) 6000 36.36
Sulphuric Acid (H2SO4) 9000 54.55
Water 1500 9.09
16500 100
Output
Linear Alkyl Benzene Sulphonice Acid 9000 54.55
Spent Acid 7500 45.45
16500 100

Storage Tank Capacity Tank quantity
Reactor (6500 kgs) each with suitable Gearbox and motor 4 no.
Settler(6500 kgs each) 4 no.
Dosing Tank(3500 kgs each) 4 no.
Slurry Storage tank(50 mt each) 3 no.
Lab storage tank(100 mt each) 2 no.
Acid Storage tank(50 mt each) 2 no.
Spent storage tank(50 mt each) 2 no.
Pumps(for transfer of material we are using below given pumps)
Slurry 2 no. (1Gear pump + 1 spare )
LAB 2 no. (1monoblock + 1 spare)
Acid 2 no. (1 SS seal pump + 1 spare)
Spent Acid 2 no.( 1 PP seal pump + 1 Spare)

INFRASTRUCTURE, MACHINERIES, EQUIPMENT & TECHNOLOGIES
Installation of the plants and machineries and latest technology will be required to manufacturing the
products. To get the best results in terms of quality and quantity, the company will invests in the latest
available plant and machinery and leverages state-of-the-art technologies to get excellent results.
Plant & machineries-
Plant & Machineries Cake And Powder
Dump Hopper, STP, ETP, Dust Collector, Load Cell, weighing machine, level sensor, various valves, Transfer
pumps, Motors, Gear Box, Hoist, Gear Motor, MS Structure, SS Structure, MS Pipe line, SS Pipe line, SS Sheets,
Mixers, Screening Machines, Vertical Packing Machine, Horizontal Packing Machine, Pouch Sealing Machine,
Tub Detergent Cake Mixer, Roll Mill, Extruder Machine, Cake Cutting Machine, Rotary Cutter, Pneumatic bar
cutter, Pneumatic Cutter, Auto Stamper, Bin Activators, Dump Hoppers, conveyors, Elevators, Transfer
conveyors, Cartooning Machine, Dyes, Multi screw mill, cage mill, Crutches, Big MS / SS Tubs, Kadav, Multi
Discharge, ETP, Laboratory Accessories and Equipments, Ink Jet Printer, Printing Machines, Offset Machines,
ROTO Gravure, Sleeting machine, Pouching machine, Various Sealing machine, tape machine, VFD, electrical
panel, transformer, compressor, DG set, cables, wires, other electrical accessories and equipment, welding
transformers, leth machines, drill machines, grinders, pulveriser, Machine, Wrapping Machine, Stamping
Machine, cylinders, workshop accessories and equipment, sewing machine, various belts, chains, coupling,
pulley, nuts and bolts, washer, welding rod, hand sewing machine, Grinder, Flour mill etc.

Plant & Machineries Labsa Plant
Stirrer Vessel, M.S. Settler, Storage Tanks, Reactor, Load Cell, weighing machine, level sensor, various valves,
Transfer pumps, Motors, Gear Box, Hoist, Gear Motor, MS Structure, SS Structure, MS Pipe line, SS Pipe line, SS
Sheets

6. Raw material required along with estimated quantity, likely source, marketing area of final
product/s, mode of transport of raw Material and finished product:
Detailed raw material requirement along with estimated quantity, likely source, marketing are of final
products mode of transport of raw material and finish production.
List of Raw material-
Soda, Alluminium sulphate, Bleaching powder, magnesium, L.A.B., China Clay, Coco, Diaethinol amide,
SCMC,T.S.P.,T.C.C.,Conditior,C.P.A.B.,S.L.E.S.,Silica,E.G.M.S.,S.M.P.,E.D.T.A.,SulphuricAcid,AminoAside,Flaim,Pro
tin,Hydro lysate, Olium,Acid slury, Ficldspar powder, filtrocin, A.O.S. potine, S.T.P.P., Sodium chloride, Lauric
Acid, Sodium salphates, Dolomite, Parafide, calcite, Citric Acid, calcium carbonate, Caustic, Urea, Zeolire,
optical brightner, perfume, Precipitated Silica, Sodium Silicate, Enzyme, Lime, Starch, Tale powder, Soap
Stone, global salt, common salt, magnesium carbonate, colour, polymers, Optical brightness etc.