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Basis
Lux 20% CNO
Packed Lux 100 MT/day @ 72.5% TFM
Lux noodle for 3P 30 MT/day @ 76.5% TFM
Total Lux 130 MT/day
LB 15% CNO
Total LB 70 MT/day @ 73.5% TFM
Equivalent Base
Lux (20% CNO) 172 MT/day @ 61% FA
LB (15%CNO) 93 MT/day @ 61% FA
Points:
1. No capacity issue for oil and caustic storage
2. No. of bowser to be increased. Action: C&F
3. No C shift operation for bowser. Action : Production Store
Digital Scale
Capacity 9 MT/hr
Oil preheater
Lux Oil 111 MT/day
Cycle time/Batch 1 Hr
Capacity Utilization 88%
Equivalent Base
Lux 172 MT/d@ 61% FA
Bleacher # 1
Capacity 9 MT/batches Intermediate tank
Batch time 2 hr Capacity 20 MT
Lux Oil 111 MT/day
Capacity Utilization 114%
176
2 nos Leaf filter
Capacity 9 MT/hr Lux Oil Storage Tank
Lux Oil 111 MT/day Capacity 27 MT
Cycle time/batch 1.11 Hr
Capacity Utilization 63%
Centrifuge
Capacity 7 MT base/hr
Running hr 27 hr
Capacity 186 MT base/day
Capacity Utilization 93%
Bleaching ( Blend for LB
Equivalent Base
LB (15%CNO) 93 MT/day @ 61% FA
Digital Scale
Capacity 9 MT
Cycle time/batch 1 Hr
Bleacher 1
Capacity 9 MT
Cycle time 2 Hr
Storage Tank
New Storage tank 20 MT
T-8 9 MT
Jet Tank
Oil receive 4.6 Ton/Hr
Soap transfer (54% TFM) 8.092593 Ton/Hr
Oil requirement per shift 31.28
Oil requirement per day 93.84
Equivalent base 146.1443 Ton
Equivalent soap tablet 121.455 Ton
Lye Neutralization & Saponification
Oil receive 0.75 hr
Circulation 8 hr
settle 1 hr
Drop 1 hr
Sap 3 hr
DPU 5 hr
DPU Change over time 1 Hr
Total cycle time 19.75 hr
Batch size 24 MT oil
Pan 1 nos
Capacity 39 MT base
DPU 1
Operation time 5 Hr
Soap base transfer through DPU (54% TFM) 144.4721 Ton Base/Day
Fitting operation
TLT fit pan
DPU 5 hr
Preconditioning 2 hr
Settle 2 hr
Conditioining 2 hr
Centrifuge 6
Fitting Pan 3
17 hr
@ 95% FA
@ 95% FA
CU
118%
64%
85% efficiency 119%
Digital Scale
Capacity 9 MT
Cycle time/batch 1 Hr 183.6 Ton Oil/Day
Bleacher 2
Capacity 9 MT
Cycle time 2.5 Hr 73.44 Ton Oil/Day
Filter Press
Filtration 1 Hr
Air blowing 1 Hr
Filter washing 0.5 Hr
Cycle time /batch 2.5 Hr 73.44 Ton Oil/Day
Storage Tank
T-9 18 MT
Sap 3 hr
DPU 5 hr
Total cycle time 18.75 hr
Batch size 24 MT oil
Pan 3 nos
Capacity 122 MT base
DPU 2
Startup & shut down 1 hr
DPU operation 5 hr
Total cycle time 6 hr
Batch size 24 MT oil
DPU nos 1 nos
Capacity 127 MT base
Capacity Utilzation 73%
Fitting operation
TLT fit pan
DPU 6 hr
Preconditioning 2 hr
Settle 2 hr
Conditioining 2 hr
Centrifuge 6
18 hr 101 MT Base/Day
FA
FA
CU
100% 60 7.843137 Hr
81%
81%
76%
73%
92%
62%
Glycerine left with Lux base 1.0%
Glycerine left with LB base 1.0%
75 % efficiency assumed
because there could be time 1st Treatment Operation
delayes for external factors
Treatment Operation 1.5
Lye neutralization Settle 2
Lye neutralization capacity 101.25 MT/day Filteration 1.5
Lye neutralization Utilization 101% Total cycle time 5
Batch size 12.5
Tank nos 2
1. As present practice 15 MT oil is used for 30 MT lye Capacity 96
neutralization. After lye neutralization 9 MT oil is used for Capacity Utilzation 107%
completing saponification batch.
2. Lye neutralization time is increased with increased of
free alkali in sap soap
3. Lye neutralization time is increased with decreased of
free faty acid in oil blend
Probable Solution:
1.Jet & tank for saponification for Lux base. And
2. Inline fitting for Lux base
Benefits:
1.Eliminination of soap boiling from Lux saponification
and conditioning operation.
2. Controlled free alkali with sap soap and conditioned
soap,which altimatly help to increase lye neutralization
efficiency
3.Eliminination of DPU startup & shutdown time, which
altimatly increase Lux DPU capacity.
ment Operation 2nd Treatment Operation
hr 1st filtration 1.5 hr
hr Treatment Operation 0.5 hr Evaporator
hr Settle 1.5 hr Capacity 96
hr Filteration 1.5 hr Capacity Utilzation 107%
MT lye Total cycle time 5 hr
nos Batch size 12.5 MT lye
MT lye Tank nos 2 nos
Capacity 96 MT lye
Capacity Utilzation 107%
porator Still plant
MT lye Capacity 10 MT glyc
Capacity Utilzation 144%
Digital Scale
Capacity 9 MT/hr
Oil preheater
Lux & LB oi 162 MT/day
Capacity Ut 88%
243 MT is the lowest one between bleaching, Sap, DPU and fit/centrifuge oper
bleacher 1 & 2
Capacity 9 MT
Cycle time 2 Hr 172.8 Ton Oil/Day
Storage Tank
New Storage tank
T-9
T-8
Jet Tank
Oil receive 4.675 Ton/Hr
Soap transfer 8.224537 Ton/Hr 54%
Oil requirement per shift 37.4 102%
Oil requirement per day 112.2 102%
DPU
Operation time 6 Hr
Soap base transfer through DPU 157.9111
Fitting operation
TLT fit pan
DPU 5 hr
Preconditioning 2 hr
Settle 2 hr
Conditioining 2 hr
Centrifuge 6
17 hr 158 MT Base/Day
Intermediate tank
Capacity
Bleacher # 2
Capacity 9 MT/batches
Batch time 2 hr
Lux & LB oi 81 MT/day
Capacity Ut 88%
LB (15% CNO)
Digital Scale
Capacity 9 MT
Cycle time/batch 1 Hr 172.8 Ton Oil/Day
As per as requirement 6.0 Batch
Required time 7.22 Hr
Lux Oil Tank
Capacity
2 nos Leaf filter
Intermediate tank Capacity 9 MT/hr
20 MT Lux & LB oi 162 MT/day
Capacity Ut 88%
LB Oil Tank
Capacity
Lux Oil Tank
27 MT
LB Oil Tank
20 MT