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BRIEF SUMMARY
This chapter presents the type, need, location & size of the project, major resources
required for proposed project, project schedule, technological consideration, process
/ technical description and likely environmental effects due to the proposed project
and mitigation measures to be adopted.
The proposed project of Power Soaps Private Limited is sulphonation of Linear Alkyl
Benzene (LAB) to produce 72 TPD (18,000 TPA) of 96% Linear Alkyl Benzene
Sulphonic Acid (LABSA). The major plant facilities proposed for the project are SO3
Gas Plant, SO3 Absorber System, Sulphonation System and Effluent Gas Treatment
System.
The use of Linear Alkyl Benzene Sulphonic Acid (LABSA) in the detergent
manufacturing units have substantial demand in the country and has Export
potential also. The demand for the detergents cakes and powders are increasing due
to the increasing population and their literacy rate. As the project proponents
operating 5 nos. of detergent manufacturing units, they need adequate quantity of
LABSA.
To fulfil the increasing demand for LABSA in their detergent plants and to earn
valuable foreign exchange, Power Soaps Private Limited proposes to install a new
production facility and increase its overall production capacity.
The project site is located in Plot nos. B – 41, 42, 43, 44, 45, 46, 47, 59, 60, 61, 62,
63, 64 & 65, PIPDIC’s Industrial Estate, Sedarapet, Villianur Commune Panchayat,
Pondicherry district, Puducherry.
The proposed production capacity of the plant will be 72 TPD (18,000 TPA). The
estimated cost of the proposed project is about INR. 575 Lakhs. The details of the
resource requirements like land, raw materials, power, water and manpower for the
proposed project is described in this section.
The total land allotted for this plant at PIPDIC, Sedarapet is 0.9072 ha (2.24 acres).
The land is already an industrially specified area and thus there will not be much
change in the present land use at the plant site. The land use break-up is given in
Table-1.1.
BRIEF SUMMARY
TABLE-1.1
LAND USE BREAK-UP
The major raw materials required for the proposed sulphonation plant are Linear
Alkyl Benzene and Sulphur. The annual requirement of various raw materials and
their sources is given in Table-1.2.
TABLE - 1.2
RAW MATERIALS REQUIREMENT DETAILS
Sr.
Material Quantity Source Transportation Storage
No.
Raw Material
1. Organic Alkylate 55.44 TPD Indigenous By Road C. Steel Tank
2. Sulphur 8.28 TPD Indigenous By Road Closed shed
Other Chemicals
3. Caustic Soda Lye 50 TPA Indigenous By Road S. Steel Tank
4. Vanadium 600 Lit/A Indigenous By Road Closed shed
pentoxide
The total power required for the proposed plant is about 900 KW, which will be met
from the Puducherry state grid. To meet the emergency power requirement during
the grid failure, diesel generator set having capacity of 1000 KVA each are
proposed. The fuel required in the plant is only High Speed Diesel (HSD), which is
used as fuel in generators. The requirement of HSD is about 350 lit/hr.
Water requirement in the plant is for cooling tower make-up, scrubber make-up, DM
plant, floor wash and domestic usages. The water requirement of the proposed plant
will be sourced from PIPDIC. The water requirement details are presented in Table-
1.3.
TABLE - 1.3
WATER REQUIREMENT
Sr. No. Category Quantity (KLD)
1. Cooling tower make-up 32.0
2. Scrubber make-up 8.0
3. DM Plant 7.0
4. Domestic Requirement 1.5
Total 48.5
BRIEF SUMMARY
During more recent years it has become standard practice to use gaseous sulphur
trioxide as sulphonating agent in an approximately stoichiometric quantity, then
age the resulting mixture during which time the reaction mixture proceeds further
towards completion, and next add a small quantity of water which is believed to
hydrolyse any anhydrides present in the reaction mixture thereby stabilizing
reaction. This current practice is described in, for example, "Sulphonation
Technology in the Detergent Industry" by W Herman de Groot 1991. When
carrying out this conventional practice the sulphur trioxide is normally diluted
with some other gas which does not react. Air can be used. It is possible to carry
out the reaction using an excess of sulphur trioxide but this leads to
disadvantages. One disadvantage is the formation of coloured impurities. If a
substantial excess of sulphur trioxide is used, the mixture obtained contains
unwanted sulphuric acid which must be removed or tolerated as an impurity just
as with the older processes using sulphuric acid or oleum. This is less of a
problem if there is only a small excess of sulphur trioxide but, as will be explained
below, this leads to the presence of undesirable impurities.
BRIEF SUMMARY
BRIEF SUMMARY
Ageing of the reaction mixture after addition of the sulphuric acid preferably takes
place with some agitation of the reaction mixture and at a temperature somewhat
above normal room temperature, e.g. in the range from 30 to 70°C. The ageing
period will generally not exceed 12 hours although longer periods may be
employed if desired. An ageing period in the range from 2 to 8 hours is preferred.
At the end of this ageing period some water may be added to the reaction
mixture to hydrolyse any remaining sulphur trioxide and stabilise the reaction
mixture, in accordance with conventional practice for sulphonation.
The invention will be further explained and illustrated by the following example in
which all amounts and proportions are by weight unless otherwise stated. Alkyl
benzene having a molecular weight of approximately 218 corresponding to a
formula in which the average value of x is 10 was sulphonated in a commercial
sulphonation plant with a multi-tube falling film reactor. Sulphonation was
affected using sulphur trioxide and air in an approximate ratio of 1.00.
Quantities of reaction mixture leaving the falling film reactor were taken, mixed
with varying amounts of 98% sulphuric acid, and then aged at 50°C for up to 4
hours. Samples were taken out of the mixtures after various intervals of time and
neutralised to the sodium salt of the acid under conditions calculated to give
approximately 25% sodium alkyl benzene sulphonate in the neutralised mixture.
These neutralised mixtures were analysed to determine the actual content of
sulphonic acid and also to determine the content of Non-Detergent Organic Matter
(NDOM). This NDOM consists principally of unreacted Linear Alkyl benzene (LAB)
and of sulphone by-product. The amounts of these materials were determined
from the infra-red spectrum of the NDOM.
1.6.1 Sulfonation
The term “sulfonation” will indicate both the sulfonation and sulfation reactions,
such a term meaning any reaction arising from the addition of SO 3 with an
organic material regardless of the functional group characterizing the end
product.
The sulfonation reaction takes place simple by contact between the organic
substance to be sulfonated and sulphur trioxide. The latter being a highly active
reagent cannot be used in the concentrated form otherwise it would destroy the
organic matter; consequently it is used at an approximate concentration of 4% by
volume in dry air.
Since reaction is highly exothermic the product has to be cooled as the reaction
proceeds to avoid deterioration of the product which is heat-sensitive.
Vimta Labs Limited, Hyderabad/Coimbatore C2-5
Application for the proposed LABSA Manufacturing plant at PIPDIC’s Industrial
Estate, Sedarapet, Puducherry
BRIEF SUMMARY
Undesired reactions (2) and (3) take place only when the resulting by-products
are almost entirely eliminated in the subsequent aging and hydrolysation steps.
BRIEF SUMMARY
SULPHUR
STEAM
MELTING
CATALYST V2O5
DIGESTER
HYDROLYSER
STORAGE VESSEL
DISPATCH
FIGURE – 1.1
PROCESS FLOW CHART
BRIEF SUMMARY
1.8.2 Aging
This operation eliminates partly the products of reaction (2) increasing at the
same time the yield of useful products as the excess SO3 reacts with the
unsulfonated organic matter.
This operation eliminates the excess SO3 both dissolved and contained in the
products of reactions (2) and (3) which would lead later to the acid degradation
The proposed project would comprise various production facilities such as SO3 gas
plant, SO3 absorber system, Sulphonation system and Effluent gas treatment
system. These would therefore lead to release of emissions to the air, generation
of wastewater and solid wastes. The sources and nature of pollution from the
proposed plant and the types of environmental pollution likely to occur are
presented in Table-1.4.
TABLE – 1.4
AIR POLLUTION – SOURCES & MANAGEMENT
The principal air pollution control systems proposed for the sulphonation plant
would be Candle filter, Electrostatic Precipitator and Alkali Scrubber.
The SO2 and Acid mist coming from the sulfonation process would be cleaned by
taking the gas through an ESP to remove the acid mist followed by alkali scrubber
to remove the SO2 gas. The clean gas will be discharged into atmosphere through
as stack of 35.0-m height.
BRIEF SUMMARY
The main source of effluent in the proposed sulfonation plant is cooling tower
blow down, boiler blow down, alkali scrubber bleed-off, DM plant reject and
domestic usages.
TABLE – 1.5
WATER POLLUTION – SOURCES & TREATMENT
Major solid wastes generated from the proposed sulfonation plant would include
TABLE – 1.6
SOLID WASTES – SOURCES & MANAGEMENT
Sr.
Solid waste Categ. Quantity Treatment or Disposal
No
1 Sulphur sludge 34.3 0.003 TPA Stored temporarily in HDPE bags and
sent to secured landfill facility,
Gummidipoondi
2 Spent catalyst 35.2 0.3 TPA Stored temporarily in polyethylene
bags and send back to manufacturers
for rebinding the same
3 Sulphur ash 36.2 0.7 TPA Stored temporarily in HDPE bags and
sent to secured landfill facility,
Gummidipoondi
4 Scrubber residue 36.1 4.5 TPA Concentrated and used in detergent
industry
The major sources of noise generation from the proposed plant are fixed plant
installations and external transport movements. The noise generating
machineries are blowers, centrifugal pumps, compressors and stand by DG set
which will be maintained within the standard limits of 90-dB(A).
All rotary equipment like fans, blowers, pumps & compressors would be of low
noise design. The grouting of this equipment will be made free from vibrations.
The work zone noise exposure of the operating personnel would be avoided by
remote operation from the control rooms. The adequate noise control measures
will be adopted and work zone noise levels will be controlled to less than 85-
dB(A).
BRIEF SUMMARY
The capital cost of the project is about Rs. 10.0 Crores. It is proposed to invest
about Rs. 2.5-Crores, i.e. 33.3 % of the capital cost on pollution control,
treatment, green belt development, rainwater harvesting, environmental
monitoring systems and others. The break-up of the investment is given in Table
– 1.7.
TABLE – 1.7
COST PROVISION FOR ENVIRONMENTAL MEASURES