IN-PLANT TRAINING

PRESENTATION
At Godrej Industries Ltd., Ambernath
From 19
th
May 2014 to 4
th
July 2014

Presented By,
Nikhil Chipade
11OIL1014
Overview of Presentation
About Godrej and its products
Major Processes at Godrej and their description
Projects Completed
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About Godrej
Godrej Industries Ltd. is a part of the Godrej Group of
Industries which includes Godrej and Boyce, Godrej
Properties and Godrej Interio.
Godrej specializes in the making of mainly two types of
chemicals:
Oleochemicals
Surfactants
There are two manufacturing facilities of Godrej, namely
Ambernath, Thane, Maharashtra
Valia, Ankleshwar, Gujarat
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Godrej, Ambernath Facility
The Ambernath facility is spread over 25 acres of land in
the MIDC area of additional Ambernath.
The Ambernath Facility consists of equipment from the
former Vikhroli facility along with new technology.
The major products at the Ambernath Facility are:
AlphaOlefin Sulphonate 40% active(Surfactant)
Fatty Acids from oils like Rapeseed oil, RBD Palm Oil
Unsaturated fatty acids like Erucic
Saturated Fatty Acids like Behenic Acid
Glycerin USP Grade
The Fatty Acids sold could be fractionated, hydrogenated or could
be a natural mixture as obtained from the oil.
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Major Plants at Godrej, Ambernath
The facility at Ambernath consists of the following
manufacturing plants:
AlphaOlefin Sulphonate(AOS) from AlphaOlefin and Sulphur
Fatty Acid Splitting Plant(FSP) Batch and Continuous for
production of fatty acid mixtures from edible oils.
Fatty Acid Distillation Plant(FADP) Fractionation and distillation of
fatty acid mixtures obtained from FSP
Hydrogenation Plant Conversion of unsaturated fatty acids to
saturated fatty acids
Glycerin Distillation Plant(GDP) - Glycerin recovered as a by-
product of the splitting reaction.
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Alpha-Olefin Sulphonate Plant
AOS is a surfactant used as a raw material for detergents,
fabric cleansers etc.
It has better bio-degradability and lesser sting than other
common surfactants such as SLS and SDS.
Chemistry:


Process:
Raw Materials: Sulphur and AlphaOlefin.
S is converted to SO
3

Reaction carried out at 85
o
C in a Falling Film Reactor between SO
3
and Alpha-Olefin.
Neutralization of the sulphonic acid produced using Caustic Lye
followed by hydrolyser.
The capacity of the plant is 50tpd of 40% active surfactant as
obtained from the hydrolyser.
Acid Sulphonic AlphOlefin SO AO
3
Sulphonate nSodium AlphaOlefi NaOH Acid nSulphonic AlphaOlefi
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Fatty Acid Splitting Plant
Edible oils are tri-glycerides which when hydrolyzed
produce a number of fatty acids.
FSP involves hydrolysis of oils in the presence of a acid
catalyst or high temperature.
Chemistry:

The plant at Ambernath involved both Batch(capacity of
40tpd) and Continuous Processes(150tpd).
The yield of the process is defined as %split given as,
%split =

3 8 3 3 2 1 2 3 2 1 6 5 6
3 O H C COOH R COOH R COOH R O H R R R O H C
100
Value tion Saponifica
Value Acid
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FSP - Continuous
A 44m tall column maintained at 260
o
C via high pressure
steam and at a pressure of 50-60 bar, oil and water are
contacted counter-currently.
%split = 96-98
Fatty acid produced rises up in the column because of its
low density and a aqueous solution of glycerin(5-8%) is
obtained at the bottom of the column as sweet water
which is sent for further treatment and glycerin recovery.
Plant Capacity: 150 tpd
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Sweet Water Treatment and Glycerin
Recovery
The by-product of the splitting reaction is glycerin which is
recovered and sold separately by Godrej.
The components of treatment include:
Open air evaporators
Falling film Evaporators(3)
Rising film Calendria(3)
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Glycerin Distillation
Glycerin is distilled to give two grades of glycerin, 2
nd

Grade and USP grade(1
st
grade, >99.7%).
Capacity: 25 tpd of 1
st
Grade Glycerin
The main components of the plant are:
Distillation Column(Under Vacuum at 160
o
C)
Scrubber
Pump Around Tank
Deodorizer
Bleacher
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Fatty Acid Distillation
Fatty Acid mixture obtained from the splitting plant is
fractionated and distilled to yield specific acids from a
mixture.
Vacuum Distillation conducted at 260
o
C at 3-5 mbar.
The FADP-6 system is used to produce 90% erucic acid
and C6-C8 residue which are sold separately.
The system consists of two columns, one pre-cut column
and one distillation column, both columns being packed.

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Hydrogenation Reaction
A number of saturated fatty acids like behenic are
commercially useful.
Capacity: 100tpd of product
Raw Materials Unsaturated Fatty Acid, Pure H
2
, Raney
Ni catalyst.
Components of Process:
Catalyst acid mixer
Reactor with sparger, internal jet loop recycle for greater
conversion and recycle of gas space H
2

Filters for catalyst product separation.
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Projects Completed
The training involved the completion of two projects:
Determining the efficiency of steam utilization of the plant and
condensate recovery and steam distribution network.
Determining the utility of the boiler installed for thermic fluid in
FADP-6
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Plant Utilities
My project was based on the working of the steam utility.
The utilities in the plant were:
Steam 2 HP Boiler, 1 MP Boiler and 2 LP Boilers
Cooling Towers Dirty and Clean
Vacuum Systems
Thermic Fluid for FADP
Chilling Water in AOS Plant
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Steam Efficiency of the Plant
This project was done two-fold:
The efficiency of steam delivery to each plant from the boiler was
determined.
The efficiency of use of enthalpy of steam used in each plant.
The results are as follows:


Steam Boiler Efficiency Enthalpy
Efficiency
LP Steam(17.5
bar at boiler)
91% 50%
MP Steam(31 bar
at boiler)
N/A N/A
HP Steam(50-65
bar at boiler)
89% 100%
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Individual Plant - Steam Utilization
The second part of the project involved computing mass
and energy balances across each plant and then
determining the percentage of enthalpy of incoming steam
used in the plant. The results are as follows:
GDP & FSP has zero discharge in terms of condensate recovery.
FSP Steam Efficiency 75%
Glycerine Distillation Plant Steam efficiency 72%.
AOS partially recovers condensates to its waste heat boiler which
is about 130 LPH.
The efficiency of steam usage(in terms of enthalpy) in AOS Plant
exceeds 75%.

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Comments regarding steam utilization
The HP boiler is best located in front of the FSP plant
which is its only consumer.
In AOS Plant complete condensate recovery is possible
by increasing waste heat boiler capacity.
Recalibration of Flow Meters should be done.
The enthalpy of condensates in GDP and FSP can be
used to preheat feed of the respective plants.
Further the enthalpy of condensates of the FADP plant
can be routed back to the economizer of the boiler to
decrease the fuel consumption.
Condensate from traps can be utilized by rerouting them
back to the boilers.
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Thermic Fluid Utilization
The plant houses a 14000 kcal boiler for heating thermic
fluid to 280
o
C. This project involves investigating, if boiler
such capacity is actually required.
It was found that the boiler was being run at 40% of its
capacity than the required operation in FADP-6.

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What else you will find in report??
Detailed Process description.
Process Technology
Pumps
Valves
Quality Control.
Parameters
Procedure
Standards
Instruments
Detailed Project Methodology.
Small report on visit to Godrej, Valia Facility.
About Valia Facility
Small comparison between Ambernath and Valia Facility

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Comments??
Suggestions??
Questions??
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