ACKNOWLEDGMENTS

We would like to express our deepest gratitude to plant manager Mr. JEMAL and advisor
FASSIL for their guidance, support and advice throughout the study and preparation of this
report.We would also like to express our gratitude to department heads and staffs in the
quality control,Production, technical, marketing and promotion, purchasing and administration
of Reppi Soapand Detergent S. Co, for their valuable information and support during the
assessment work.We are indebted to Forman staffs, laboratory staffs, R and D staffs, chemists
and operator of powderand liquid detergent of Reppi soap and detergent factory S.CO for their
assistance and understanding.We are very much grateful to our parents, for their support and
encouragement. Thank you so much.
HISTORY OF DETERGENT
From ancient times, chemical additives were recognized for their ability to facilitate the
mechanical washing with water. The Italians used a mix of sulfur and water with charcoal to
clean cloth. Egyptians added ashes and silicates to soften water. Soaps were the first
detergents. The detergent effects of certain synthetic surfactants were noted in Germany in
1917, in response to shortages of soap during World War I. In the 1930s, commercially viable
routes to fatty alcohols were developed, and these new materials were converted to their
sulfate esters, such detergents were mainly used in industry until after World War II. By then,
new developments and the later conversion of aviation fuel plants to produce tetra propylene,
used in household detergents, caused a fast growth of domestic use in the late 1940s.At the
present time, soap has largely been displaced as the main cleaning agent in developed
countries. Soap is, by weight, relatively ineffective, and it is highly sensitive to deactivation by
hard water. By the 1950s, soap had almost been completely replaced by branched alkyl-
benzene-sulfonates, but these detergents were found to be poorly biodegradable. Linear alkyl-
benzene- sulfonates (LABs), however, proved to be both highly effective in cleaning and more
biodegradable than the branched relatives. LABs remain the main detergents used
domestically.

In Ethiopia the first soap and detergent factory is Repi soap and detergent factory which was
established in 1974 by the name Bianil Ethiopia Share Company by foreign investors of Swiss
and Greek origin.
INTRODUCTION
Detergents are any substance or preparation containing soaps and other surfactants intended
for washing and cleaning processes. Detergents may be in any form (liquid, powder, paste, bar,
cake, molded piece shape, etc.) and marketed for or used in household, institutional or
industrial purposes. A detergent is a surfactant or a mixture of surfactants with "cleaning
properties in dilute solutions. These substances are usually alkyl benzene sulfonates , a family
of compounds that are similar to soap but are more soluble in hard water, because the polar
sulfonates of detergents is less likely than the polar carboxyl of soap to bind to calcium and
other ions found in hard water. In most household contexts, the term detergent by itself refers
specifically to laundry detergent or dish detergent, as opposed to hand soap or other types of
cleaning agents. Detergents are commonly available as powders or concentrated solutions.
Detergents, like soaps, work because they are amphiphilic: partly hydrophilic (polar) and partly
hydrophobic (non-polar). Their dual nature facilitates the mixture of hydrophobic compounds
(like oil and grease) with water. Because air is not hydrophilic, detergents are also foaming
agents to varying degrees.
The manufacture of detergent involves the manufacture of the surfactant, followed by the
addition of other ingredients in appropriate quantities. The raw materials for surfactant
manufacture are petro chemically derived alkyl benzenes, fatty alcohols and sulphuric or
pyrosulphuric acid.

In Reppi soap and detergent companyit produce different kinds of soap and detergent those
are powder, liquid and bar detergent
1) Under powder
 normal rol,
 bio rol,
 basse powder(Essex)
 junior rol
 Vim
2) Under liquid
 normal largo,
 blue largo
 dishwash(Ajax),
 viscous multi porpose
 window cleaner
3 Under bar
 Diva,
 Tiffany and AJAX
Management structure
Overall organization and work flow

The detergent plant, work on producing of powder detergent and liquid detergent products where
its overall organizational work flow is listed by the following chart.
General objective
The general objective of this research is to conduct a plant design project on detergent production
technology and to produce laboratory scale liquid detergent in the case of Repi Soap and Detergent S.
Co.

Specific objective
The specific objectives of this study are to determine:

 Production technology
 Raw material selection
 Material and energy balance
 Economic and financial analysis
 Plant location and production program
 Environmental and safety

Also other specific objects of this project include encouragement of investors to do investment in this
sector of detergent production since there is available of market potential in Ethiopia that can be
economical for import substitution oriented product that is demanded greatly.
BACKGROUND HISTORY OF REPI WILMAR S.CO

Ethiopia/Singapore, 20 June 2014 – Repi Soap and Detergent S. Co. (Repi) and Willmar International
Limited (Willmar) have signed a joint investment agreement for the upgrading of an existing
manufacturing facility in Sabetha Road, Kolfe Karenio Sub City and building of a new integrated
manufacturing complex in Dima, Sebeta Town, Oromia Region in Ethiopia that will house an edible oil
refinery and packing plant, production plants for specialty fats, soft oils, soaps and detergents, as well as
a facility for sesame seed processing. Repi and Willmar will each have a 50% participation in the joint
investment.

About Repi

Less than a year after its formation it was nationalized by the government and was managed under the
branch of the National Chemical Corporation and was then re- established as a public enterprise in 1992
by the council of ministers and was recapitalized by birr 1,525,000.00. The company’s main vision was to
compete against local and imported powder detergent through its famous brand ‘ROL’. Due to the
machinery’s age and technological issues there was an issue of wastage which nearly bankrupted the
company but thanks to a pioneering idea of creating a detergent bar (Cake) in 1979, Repi gave birth to a
new line of product and a new brand ‘AJAX’. Production of a liquid detergent was then introduced in
1994 under the brand name “LARGO’.

About Wilmar International Limited, founded in 1991 and headquartered in Singapore, is today Asia’s
leading agribusiness group. Wilmar is ranked amongst the largest listed companies by market
capitalization on the Singapore Exchange. Wilmar’s business activities include oil palm cultivation,
oilseed crushing, edible oils refining, sugar milling and refining, specialty fats, oleo chemical, biodiesel
and fertiliser manufacturing, and grain processing. At the core of Wilmar’s strategy is a resilient
integrated agribusiness model that encompasses the entire value chain of the agricultural commodity
processing business, from origination and processing to branding, merchandising and distribution of a
wide range of agricultural products. It has over 450 manufacturing plants and an extensive distribution
network covering China, India, Indonesia and some 50 other countries. The Group is backed by a
multinational workforce of about 90,000 people.
Detergency
Is defined as “the action of surfactants that causes or aids the removal of foreign material
from solid surfaces by adsorbing at interfaces and reducing the energy needed to effect the
removal”.

Syndet An abbreviation for "synthetic detergent".

This is a cleansing agent made from non-natural (synthetic) compounds.

Group of Synthetic Detergent

 Powder detergent
 Liquid Detergent
 Bar Detergent

Soap
A cleansing agent made of “natural Detergent” from the reaction of an alkali and an animal fat.

Group of natural detergent

 Laundry Soap
 Toilet Soap
Raw material selection
Today’s detergent market has placed strict demands on the quality and specifications of raw
materials for detergents. Detergents have evolved to include significant variations in
composition, physical form, and dosage. For each product type there are both a well-defined
manufacturing process and a list of raw material specifications that must be met. In consumer
products, for example, the advent of compact or ultra -detergents have placed emphasis on
processes that produced concentrated and relatively dense products that deliver acceptable
performance at low dosage under normal use conditions. The suppliers of raw materials have
developed grades of the standard ingredients with variations intended to meet the
requirements of the finished product and the manufacturing process. The following parameters
are always considered in selecting a grade of an ingredient for detergent manufacturing.

Assay: Usually high assay is preferred for better quality and for extending the shelf life of the
finished product.

Density and particle size distribution: Segregation and flow properties are in part determined
by the density and particle size distribution of the solid ingredients, which also play a role in the
absorptivity of surfactants.

Friability: The tendency of a solid material to crumble or be easily pulverized is referred as

friability. This property may impact the particle size distribution in the finished product and
affected product segregation and flow properties. Friability is an important consideration
during product processing and shipment.

Hydration characteristics: Water is present in most detergent products, including detergents in

powder form. Often a solid ingredient will bind some of that water to form hydrates. The rate
of hydration and the stability of the resulting hydrated species affect the caking and flow
properties of powder detergents and the process ability and stability of liquid products.

Chemical stability:Detergent ingredients must be compatibility with each other and must be
stable enough to withstand the manufacturing process. This is especially critical in liquid
detergents and in powder detergents containing bleach, enzymes, or a high alkalinity
Raw material and their function
The raw materials used in the detergent production and their uses are summarized by the
following table.

RAW MATERIAL FUNCTION

LABSA Surfactant-the main active ingredient
CASTIC SODA Neutralizes the LABSA
STPP Hardness control Alkalinity & Buffering Soil
dispersion & Peptization Processing Aid for
Powder Manufacturing (absorbs surfactants and
binds moisture) Controls Rheology and Stability of
Liquid Detergents

SODA ASH Alkalinity & Buffering It can absorb large quantities

of liquid material on to its surface & still remain
dry to touch and free flowing Soften water by
precipitating calcium & magnesium carbonates
Ensures optimum detergent function
SCMC Increase the negative charge on cellulosic fibers
such as cotton & rayon causing them to repel dirt
particles(which are positively charged)
Sodium Silicate Make surfactants more efficient Increase alkalinity
and create buffer solution Corrosion inhibitor It
has emulsifying & wetting properties, particularly
on glass & glazed surfaces making them suitable
for use in dish washing detergents
Zeolite Soften water by absorbing Ca2+ and Mg2+
TEA Alkalinity & Buffering, solubilizes oils & other
ingredients insoluble in water and it also act as
surfactant
Sodium sulphate Bulking and free-flowing agent Gives attractive
appearance & quick solubility to the detergent
Photin Convert ultra-violet to visible light which makes
the fiber look whiter and brighter.
Perfume Mask base odor of ingredients Provide pleasant
odor to cloth
Monestral blue Gives it a blue color Provide bluing action
Water Controls the thickness of the detergent
 Linear alkyl benzene sulfonic Acid (LABSA)
Molecular Formula:

R: C10-4 linear Alkyl

Syno Production Characterist Application Advantage Disadvantage Product

nyms ics Type
Starting Brown Main raw Highly water Less Household
material LAB liquid material for soluble and have a biodegradable detergents
is produced Specific synthetic relatively low Kow. Not applicable like laundry
by alkylation gravity 1.2 detergent The environmental for personal powders,
of benzene Partially industries in fate data indicate care products laundry
with parrafins soluble in the that these as it is irritant liquids,
in the water formulation of chemicals are Needs dishwashing
presence of Active detergent highly susceptible neutralization liquids and
hydrogen matter powder, to photo- and before use. other
fluoride or 96%minimu detergent biodegradation. Probable household
aluminum m cake, liquid Provides good carcinogen as cleaners.
chloride as a Free oil detergent, in wetting and it contains
catalyst. LAS 1.5%max textile industry cleaning property benzene.
is produced Water as a washing at low cost.
by the 1%MAX agent It can be dried to a
sulfonation of Free sulfuric stable powder.
LAB with acid 1.5
oleum in %MAX
batch
reactors.
 Lutensol AO 7
Molecular Formula:

Synony Production Characteristics Application Advantage Disadv Product

ms antage Type
C13 C15 Based on Primary Non ionic surfactants for Can be
Oxo saturated, detergency surfactants liquid & powder employed in
alcohol predominantly & stain for detergents as well light‐duty &
ethoxyla un branched removal. laundry As cleaners. high‐duty
tes + C13C15 Oxo Emulsification detergents Mainly detergents
7EO alcohol that power & & employed as in powder &
consists 67% solubility in Cleaners emulsifiers & Liquid form.
C13 Oil. Detergents. And in
& 33% C15. Effective for industrial &
Produced by removing fatty soil house hold
causing the From laundry. Can Cleaners.
C13C15 Oxo be readily
alcohol to combined with
react anionic, cationic,
with ethylene other non-ionic&
oxide in Auxiliaries. Can be
stoichiometry used in water &
Proportions. other organic
Solvents.
 Sodium tripolyphosphate (STPP)

Molecular Formula: Na6P3o10

Synonyms Produ Characteristics Application Advantage Disadvantag Product Type

ction e
wetting, Binds calcium Boosts Eutrophicati Laundry and
Triphospheri emulsification, Buffers at pH 9-11 Surfactants on of lakes, dish washing
acid penta lubrication Water softener Suspends soil River… detergent
sodium salt Coupling Prevent corrosion Very water Irritating to
activity and Suspended dirt in the soluble skin, eyes,
detergency. wash water and prevent it No throat or
Soluble in red positing of fabrics. environmenta respiratory
alcohol, and Emulsifier l system.
very soluble in Wetters Risk
water. Dispersants Maintaining
Water based lubricants alkalinity
Intermediate for the during
synthesis of other anionic washing
surfactants Not
dispersion flammable
 Sodium Carboxyl Methyl Cellulose (SCMC)

Molecular Formula: :C6H7O2(OH)x(OCH2COONa)y n

Synonyms Production Characteristic Applicatio Advantage Disadvantage Product Type

s n
cellulose gum It is It is emulsifier Adsorbs on More beneficial Liquid
,sodium synthesized It is stabilizer soil and in Cotton detergent
cellulose by alkali It is thickener substrate Laundering Shampoo
glycolate catalyzed rxn Odorless setting up Has high Powder
,sodium CMC of cellulose hygroscopic charge viscosity detergent
with granules barrier to Non-toxic
chloracetic Very soluble redeposit Do not promote
acid in water ion(anti allergic Rxn in
The redispositi humans
functional on agent ) Safe to use
properties of Viscosity
CMC depends modifier
on the degree Remove
of most dirty
substitution types than
of the other
cellulose detergent
structure not have
(hydroxyl SCMC
group)
 Caustic soda
Molecular Formula: NaoH

Synonyms Production Characteristics Application Advantage Disadvantage Product

Type
 Sodium Sodium hydroxide It is a strong To neutralize It is cheap Not safe for For all
Hydroxide produced by base LABSA & Small handling types of
treating sodium PH-regulating, Other quantity Can cause detergent
carbonate with ion exchanger inorganic need skin irritation product
calcium hydroxide in regenerating Reaction Faster It can ignite
a metathesis agent, To neutralize processing in
reaction. (Sodium catalyst acid or time flammables
hydroxide is Cleaning increase Highly Can cause
soluble while agent alkalinity of soluble in severe burns
calcium carbonate mixtures water Can cause
is not.) This process To Easily react respiratory
was called manufacturing with air problems
causticizing. of sodium Can cause
salts and inflammation
detergents of the lungs
For PH
regulation
Organic
synthesis
For
saponification
process
Used as
catalyst
Used as
cleaning agent
Prevent re
deposition
 Sodium Carbonate (Soda Ash)
Molecular Formula: Na2Co3

Synonyms Producti Characteristics Application Advantage Disadvantage Product

on Type
Solvay crystalline Precipitate Cheap source Skin irritation
Soda process compound calcium of reserve May cause
crystal calcium soluble in carbonate alkalinity respiratory
washin carbonate water Buffers at Can be post side effect
g soda (limestone) (absorbing pH 9-11 dosed to such as
moisture
was heated Used to product difficulty
from the air)
to release Insoluble in neutralize Widely breathing or
carbon alcohol. the available shortness of
dioxide -> forms a corrosive Has diverse breath
As the strongly effect of uses because Harmful if
carbon alkaline chlorine and of its swallowed very
dioxide water raise PH chemically toxic by
bubbled up solution Water stable inhalation.
through it, softener in compounded
sodium laundering and possess
bicarbonate Remove strong alkaline
precipitated grease &oil
-> The Neutralize
sodium of acids&
bicarbonate bases
was then
converted
to sodium
carbonate
by heating
it, releasing
water and
carbon
dioxide:
 Zeolite
Molecular Formula:
Synonyms Production Characteristics Application Advantage Disadvantage Product
Type
Produced pH=11 max Binds calcium High Insoluble Mainly
synthetically high thermo Give Good adsorption Best serves its used in
and naturally stability sensory capacity for purpose at powder
but the one resistance to property for liquid elevated pH dish wash
produced aggressive the component Environmentally: and
synthetically media powder/Water High Increment in laundry
is uniform, Have micro interaction stability suspended solids detergents
phase-pure porous Adsorbs during as it is insoluble as a water
state. structure which odorous and processing May cause softener.
Synthetically is used to polluting Effective fouling of pipe
it is produced selectively sort compounds. flow aid for work
by a slow molecules powder Significantly
crystallization based primarily Zeolite have increases sludge
of a silica- on a size no negative volume in
alumina gel in exclusion effect for sewage
the presence process. plant treatment
of alkalis and growth plants.
organic Inhibition of
tempelates. graying in
laundry
Inhibition of
dye transfer
Minimized
fiber
damage via
special
particle
morphology
High water
softening
capacity
Free of
legislative
restrictions
 Sodium Sulphate (Anhydrous)
Molecular Formula: Na2SO4

Synonyms Production Characteristi Application Advantage Disadvantag Product

cs e Type
Occurs in odor less Anti-cake Increase It may be For dry
Di sodium nature as hygroscopic agent and to ionic mildly toxic powder
sulfate,Glaub mirabilite white increase strength of by ingestion Laundry
er salt and powder solubility of wash and and dish
thernadit Neutral in powder solution irritation washing
Obtained water detergents Cheap detergen
from the Very soluble Use as a diluent-allow t
treatment of in water filler and attainment product
sodium Stable Cpd processing of required
chloride aid powder
with sulfuric Make the properties
acid and powder to Non-toxic
evaporating stay under
the homogeneo normal
crystallizatio us and not circumstanc
n stratifies es or
In Corrosion handling
laboratory inhibitor Widely
can be available
prepared by Not
the flammable
neutralizatio
n Rxn by
mixing
sodium
hydroxide
and sulfuric
acid.
 Sodium Chloride
Molecular Formula: NaCl

Synonyms Production Characteristics Application Advantage Disadvantage Product

Type
Odorless and To increase Cheap Corrosion of
Table Salt, NaCl colorless Bulk Positive metal(Machinery)
salt, halite formed crystal Density Of effect on
when An ionic Cpd Product detergency
sodium Soluble in To increase Cost
atoms water Viscosity Of effective
interact anionic Non-toxic
with detergent
chlorine solution
atoms 10% salt
It can Solution, in
provides powder
with formulation
chlorine effective on
and blood &
sodium woolen
hydroxide Garment
It can
render the
powder
hydroscopic
 Sodium Silicate
Molecular Formula: Na2SiO3

Synonyms Production Characteristics Application Advantage Disadvantage Product

Type
Liquid Produced by Density2.61gm/cc Provides Widely Affects Specially
glass roasting Insoluble in reserve available Glassware used in
Water various alcohol; alkalinity to Can be Makes a powder
glass quantities of Strongly basic wash solution obtained precipitate and bar
Soluble soda ash and Colorless glass Helps to in liquid while de- soap
glass silica sand in like transparent structure form ionizing detergents
Silicate of a furnace at substance product Can water (binds as a builder
soda temperatures sometimes Provides perform with colloidal and filler.
Silicilic between commercially crispness and multiple molecules
acid about 1000- often greenish or good flow tasks creating
sodium 1400oC which blue owing to the properties for Thermo- larger
salt gives off CO2 presence of iron packing stable up aggregates
Sodium and produce containing Binds calcium to 1000oC that sink to
silicate Na2SiO3 impurities. Buffers which the bottom of
glass The solid can Stable in neutral, Provides anti- makes it the
Sodium be fed into basic or high Corrosion preferable detergent.)
silicate pressurized temperature Anti re- specially in
solution reactors for media. depositing powder
dissolving in agent detergents
hot water or Peroxide Soluble in
liquid sodium stabilizer water
silicate can be Aids in Stable in
directly detergent in neutral
produced by the removal and alkali
dissolving of fats and medias
silica sand oils, the
under neutralization
pressure in a of acids, and
heated the
aqueous breakdown of
solution of starches and
caustic soda. proteins.
Detergents are formulated from six groups of substances:

1) Surfactants
2) Builders
3) Fillers
4) Additives
5) Enzymes
6) Perfume

1, Surfactant
A chemical that is active at the surface or interface (the boundary between two different
substances). Taken from the phrase "surface active agent".

Function = reduction of surface tension

For a surfactant to be considered a good detergent,

 Must be a good wetting agent,

 Possess the ability to displace soil materials into the washing fluid,
 Be a good solubilizing agent, and
 Be a reasonable anti-re deposition agent.

“The most successful detergents are those forming surfactant micelles”

Classification of Surfactant
A. Anionic Surfactant
B. Non-ionic Surfactant
C. Cationic Surfactant
D. Alkaline substance

A. Anionic Surfactant
 Negative tension in water
 Contain anionic functional groups at their head, such as sulfate, sulphonate,
phosphate and carboxylates that acts as an active surface agent to lower the surface
tension of liquids. This allows them to bind to impurities and particles that are
suspended in the liquid which makes them effective cleaning agents in water.
B.Non-Ionic Surfactant

 Miscible with anionic and cationic

 Excellent degreasers
 Used in a smaller portion compared with anionic since they are expensive,
but give excellent performance
 They do not dissociate into ions in aqueous media unlike anionic & cationic
surfactants which have negative and positive charge during dissociation
 Dissolves in hard water compared with anionic & cationic surfactant
 Excellent solvency property

C.Cationic Surfactant

 Positive tension in water.

 Not miscible with anionic.
 They are mostly quaternary ammonium compounds called Quats.
 An alkyl group attached to NH4+
 They are surfactants mostly used as fabric softeners/antimicrobials
 More expensive than both anionic and nonionic hence they are used:
 As a bactericide.
 As a positively charged substance which is able to adsorb on negatively charged
substrates to produce antistatic and hydrophobant effect, often of great
commercial importance such as in corrosion inhibition.

D. Alkaline substances

Alkaline materials are bases in chemistry, meaning they are able to neutralize acids
The PH of an alkaline Material dissolved in water is above7 because these materials have a
relatively low concentration of hydrogen.

Function = dirt removing in an alkaline environment (hygroscopic properties)

2. Builders
A chemical used to chelate hardness and allow the surfactants to perform at their potential.
Some builders stay soluble when attached to hardness. Others, called precipitating builders,
fall out of solution when attached to hardness.
 Builders soften water by de activating hardness of minerals (metals ion like Caand Mg).
 Builders function by sequestering or precipitating the problematic ions.
 Chemicals that added to enhance the cleaning performance of the detergent.

Properties of builders

 Water Softening
 pH Control
 Dispersing Enhance the action of surfactants

3.Fillers

 Fillers enable the adjustment of the active matter in the detergent to the doses used.
Filler products include sodium sulphate in powders, water and solvents in liquids.
 Fillers are used as binding agents, which are used to give free-flowing properties to the
powders
 Fillers are added in detergents to alter their physical characteristics and properties.
 A chemical that adds no value to the performance of the solution.
 A chemical that adds to increase the output value of the product.
 A chemical that adds to correct the structure of the product

4. Additives
Additives are used to improve the performance of the detergent and include anti re-
deposition agents, bleach stabilizers, enzymes, fabric-whitening agents, foam
controllers, corrosion inhibitors, perfumes and colorants.

5. Enzymes
Enzymes are naturally occurring biological agents in many detergents in varying concentration.
These enzymes are similar to the enzymes used by our body to digest food. The majors are:
proteases (help break down proteins), lipases (help break down fat) and amylases (help break
down starches).These enzymes help break down food particles that are present on clothing by
catalyzing or speeding up the decomposition process. They also catalyze the degradation of
some stains and thus facilitate their elimination. A point to consider is that enzymes are
biological products that can break down over time. Therefore, detergents can also contain
enzyme stabilizers, which protect the enzymes and help those functions
 6. Perfumes

 Key sensory Cue

 Expensive Ingredients
 Pleasant Odor to powder
 Pleasant Odor to wash Solution
 Residual Perfume to clothes after drying

Formulation of Detergents
Laundry detergents are produced in two major types of formulations: Powder and Liquid. Powders are
generally more effective in removing clay and ground in dirt, while liquids work well on oily soils. Each
large manufacturer has particular secrets and know-how that make a difference in the final product. For
example, the simple application of a well-known process, such as spray drying a conventional powder,
will not always result in product with little sodium tri-poly phosphate breakdown, good flow properties,
and satisfactory behavior in the washing machine, Although there are numerous formulations of
phosphate detergents.

POWDER DETERGENT PRODUCTION

A detergent powder is a product formulated from the constituents such as surfactants, which perform
the primary cleaning and washing action by reducing the surface tension of water builders, which boost
the cleaning power of the surfactant and other additives. Detergent powder is proved to be effective in
hard water and cool or cold water, whereas soap is often wholly ineffective under both conditions. The
major use of detergent powders is in households for washing clothes and utensils. They are suitable for
hand washing and also for machine washing in laundries and dish washers.
Utilities

Energy most industry uses energy for a variety of purposes. Steam production via conventional boilers
and co-generators is the largest use. Electric motor drive, which includes motors and the corresponding
pumps, fans, compressors, and materials processing and handling is the next largest category.

Steam asteam-distribution and condensate-return system should deliver steam efficiently from the
boiler plant to heating systems and processing equipment and return condensate to the boiler for re-
use. Some energy is always lost from a steam and condensate system, most significantly in steam trap
loss. Others include heat loss from piping and fittings (insulated and un-insulated), leaks and flash losses,
condensate loss to drain and overall system losses.

Water supply inadequate water management is accelerating the depletion of surface water and ground
water resources. A facility may have several water systems, some for process use (process cooling
water, chilled water) and some for building services (potable water, domestic hot water).Whatever their
function; water systems tend to have similar inefficiencies and energy management opportunities.
Slurry preparation

When slurry is made batch wise, the main liquid ingredients are charged and the powders added to
them, as is necessary to maintain a mixable liquid through the process. It is obvious that if a sulphonic
acid is used as the basic material it must be neutralized, either continuously or batch-wise, and it is
essential to do this before the acid comes into contact with the rest of the ingredients of the slurry.
Otherwise, insoluble silica may be precipitated, the polyphosphate can easily be hydrolyzed to
orthophosphate; and the optical brightener may also be affected adversely. In continuous operations,
the Labsa and caustic soda should be fed into a neutralizing vessel with all the water required for the
slurry. This sodium sulphonate paste is then fed into the slurry preparation vessel, where the rest of the
ingredients are added.

After treatment of slurry

Some ageing of the slurry is desirable for the formation of sodium tri polyphosphate, as well as
necessary to provide a small buffer from which the drier can be fed; about 20-30 minutes is often
suitable. Conversion of the slurry into powder requires the use of pressures up to 8.0MPa. The most
practical means slurry transport uses a slowly moving three-plunger pump, usually preceded by a low-
variety. Between the storage vessel and the high-pressure pump, it is advantageous to provide a
magnetic separator, sieves, and /or wet-grinding mills for removing metallic objects and large particles
or agglomerates that might otherwise clog the spray nozzles. Bulk density can be increased by
evacuating the slurry, whereas deliberate introduction of air can be used to reduce the density, any
sudden changes in pressure in the high-pressure portions of the system are compensated in an air
vessel.

The changes are due to the influence of each of the four stages involved this slurry to convert powder,
namely:

1. Atomization of the feed solution.

2. Contact of spray with the hot gas.

3. Evaporation of moisture.

4. Particle separation.
1. Atomization
Atomization is the heart of spray drying, and is the first transformation process that the feed undergoes
during spray drying. Bringing fluid or solid substances into a state of minute division”. The breakup of
bulk liquid into a large number of droplets drives the rest of the spray drying process by reducing the
internal resistances to moisture transfer from the droplet to the surrounding medium. Atomization is
central to the spray drying process, owing to its influence on shape, structure, velocity and size
distribution of the droplets and, in turn, the particle size and nature of the final product. The purpose of
the atomizer is to meter flow into the chamber, produce populations of liquid particles of the desired
size and distribute those liquid particles uniformly in the drying chamber.

2. The atomizer droplet-air contact

The central element of a spray dryer is the spray dry chamber. In the chamber, atomized liquid is
brought into contact with hot gas (usually air, at a vacuum), resulting in the evaporation of 95%+ of the
water contained in the droplets in a matter of a few seconds. The way in which the spray makes contact
with the air in the dryer influences the behavior of the droplet during the drying phase and has a direct
bearing on the properties of the dried product. The type of contact between the spray and the air is
determined by the position of the atomizer relative to the air inlet. Nozzle headers are usually located at
the top of the dryer and spray down.

3. Droplet drying Moisture

Evaporation takes place in two stages. During the first stage, the temperature in the saturated air at
the surface of the droplet is approximately equal to the wet-bulb temperature of the drying air. There is
sufficient moisture in the drop to replace the liquid evaporated at the surface and evaporation takes
place at a relatively constant rate. The second stage begins when there is no longer enough moisture to
maintain saturated conditions at the droplet surface, causing a dried shell to form at the surface.
Evaporation then depends on the diffusion of moisture through the shell, which is increasing in
thickness. The rate of evaporation falls rapidly during the second phase. Different products have
differing evaporation and particle-forming characteristics. Some expand, others contract, fracture or
disintegrate.

The resulting particles may be relatively uniform hollow spheres, or porous and irregularly shaped. In a
co-current dryer the spray is directed into the hot air entering the dryer and both pass through the
chamber in the same direction. Co- current dryers are the preferred design for heat- sensitive products
because the hottest drying air contacts the droplets at their maximum moisture content. Spray
evaporation is rapid, and the temperature of the drying air is quickly reduced by the vaporization of
water.

What is drying?

Drying is the process of removing liquid from solids by evaporation. The drying process has been
used for thousands of years to reduce transport weight and increase the storage life of numerous
products and materials. For centuries, drying meant spreading a product out in the open air and letting
the sun provide the energy for water evaporation. With the dawn of the industrial age, many different
drying processes have been developed to increase drying speed and improve product quality and
uniformity.
What is Spray Dry?

Spray drying is the transformation of feed from a fluid state into a dried particulate form by
spraying the feed into a hot drying medium. A spray dryer operates on convection mode. The principle
of working is moisture removal by application of heat to the feed product and controlling the humidity
of the drying medium. Here, the uniqueness is that the evaporation of moisture is promoted by spraying
the feed into a heated atmosphere, resulting in improved drying rate. The mechanism can be better
understood, when the spray drying process is divided into its constituent unit operations. A liquid feed
entering the spray dryer undergoes a series of transformations before it becomes powder.

Spray Dryer Type

Counter-current flow dryer

In this dryer design the spray and the air are introduced at opposite ends of the dryer, with the atomizer
positioned at the top and the air entering at the bottom. A counter-current dryer offers more rapid
evaporation and higher energy efficiency than a co- current design. Because the driest particles are in
contact with hottest air, this design is not suitable for heat-sensitive products. Counter-current dryers
normally use nozzles for atomization because the energy of the spray can be directed against the air
movement. Soaps and detergents are commonly dried in counter-current dryers.

Pressure nozzle

Pressure nozzles are the most commonly used atomizers for spray drying. Nozzles generally produce
coarser, freer flowing powders than rotary atomizers. Pressure nozzles used in spray drying are called
“vortex” nozzles because they contain features that cause the liquid passing through them to rotate. the
vortex is generated by the tangential inlet to the swirl. The rotating fluid allows the nozzle to convert
the potential energy of liquid under pressure into kinetic energy at the orifice by forming a thin, high-
speed film at the exit of the nozzle. As the unstable film leaves the nozzle, it disintegrates, forming first
ligaments and then droplets.

Pressure nozzles can be used over a large range of flow rates, and can be combined in multiple-nozzle
installations to give them a great amount of flow rate and particle size flexibility.
The range of operating pressure range for pressure nozzles used in spray drying is from about 250 PSI
(17.4 bar) to about 10,000 PSI (690 bar). (17.4 bar) to about 10,000 PSI (690 bar).

4. Separation

Following completion of drying, the particles of product must be separated from the drying air. Primary
separation is accomplished by the particles simply falling to the bottom of the chamber. A small fraction
of the particles remain entrained with the air and must be recovered in separation equipment.
Cyclones, bag filters, and electrostatic precipitators may be used for the final separation stage. Wet
scrubbers are then often used to purify and cool the air so that it can be released to atmosphere.

Simplified form of powder production in three stage;

1. Preparation of a mixture of liquid and solid raw materials (the ‘‘slurry’’), which can stand high
temperatures, and which is then atomized (‘‘spray drying’’).

2. The ‘‘base powder’’ thus produced is allowed to cool before the more sensitive ingredients are
added, that is ‘‘post dosing’’.

3. The final powder is packed.

Shows a simplified flow sheet for spray-drying powder detergent production

Process description and flow diagram of powder detergent production

Process description of powder detergent

The process of powder detergent production starts from the raw material preparation. First, the
concentration of caustic soda which is 99% by weight in flakes form is diluted up to 33% NaoH solution
by dissolving the NaoH with water. Since the process is batch process.

The active ingredients which are LABSA, WATER and NaoH are measured in measuring tanks. After raw
material preparation of LABSA, NaoH and WATER are mixed in the neutralizer (reactor) since the
reaction of LABSA and NaoH is exothermic we use jacketed reactor. The process of LABSA and NaoH
form neutralization.so, the preparation of water, caustic soda and Labsa are called paste preparation.
Then after a few minute builders like (soda ash light, sodium sulphate, sodium tri poly phosphate,
sodium chloride, SCMC, sodium silicate and Photin) are added to keep their addition procedure
respectively. After being mixed well by using steam in the mixing tank for a certain time. The reactor of
the mixing tank is batch reactor. Then after fled to the sieve. This sieve is traps all the impurities
(unwanted material and granules) are removed.so that it does not affect the nozzle and pump.
Thenafter the removal process the slurry is sent to the slurry storage homogenous tank. the type of
reactor for this slurry homogenous tank is semi-batch because input gain from the sieve for a certain
time but the output is continuous this used as store the slurry and further well mixed to make the slurry
softer.so that it will be easily pumped using high pressure pump to spray tower. After the well mixing of
homogenous tank the slurry is sent to the filter machine.

The filter machine is one of the unit operation.it has a continuous reactor input gain from temporarily
slurry storage continouslly the purpose of this machine is doing further filtration process. After the
finishing the filtration process fled to the high pressure pump. The high pressure pump is the machine
that used for by using high pressure transfer the slurry in to the spray nozzle by using this nozzle the
slurry is pumped ion to the tower.

In the spray drier hot air from the burner(air-pre heater) flows from the bottom of the tower and the
slurry is sprayed through the nozzle on the top of the tower by contacting counter current flows where
heat and mass takes place.in this case it form powder. the air that leaves at the top of the tower
contains burned and fine powder and it is trapped by cyclones before it is released into the
atmosphere.the dried powder is collected by belt conveyor at the bottom of the tower in which it is
sucked by an air lift. Where it is cooled and sent in to vibrating screen for separating the required
powder particle size and sent down to the perfume homogenizer drum for giving the powder good
fragrance. Finally the perfumed powder is stored in bags (silos) and then transferred by gravity force in
to packaging machine.The un-required (fine and granular particle) size from the vibrating screen and
cyclones is collected with sucks and can used for bar detergent (AJAX) production.

General flow diagram of powder detergent

 Flow diagram description of powder detergent

1. Caustic soda mixing tank is a tank which mixes caustic soda and water. The use of caustic
soda is to neutralize LABSA.
2. Watertank is a water tank which measured the water and fled to the mixer. The use of water is to
make a good mixing of the raw material.

3.Raw material mixing tank is the mixing tank of the raw material.in this case add steam the use of
steam in this tank is to heat the slurry, in order to prevent coagulation and speed up the reaction
process. Slurry is the mixture of raw materials.

4. Sieve is just like grate. Used to trap all the impurities (unwanted material and granules) are
removed.so, it does not affect the high pressure pump and spray nozzle.

5. Slurry homogenous tank is a tank which homogenize the slurry by using steam.in this tank further
well mixing of the slurry takes place to make the slurry softer.
 6. Temporarily slurry storage tank is a tanks which used to when the homogenize tank has a problem
the slurry is stored in this tank and also it receive the slurry when the high pressure has over carry slurry
is retrieve to this small tanks.
7. Homogeneous pump used to pump the slurry into filter tank

8. Filtration tank is the filter tank which used to take further filtration process.
9. Filteration pump is used to pump the slurry into high pressure pump

10. High pressure pump by using a high pressure pump slurry is sprayed into nozzle.

11. Furnace is an oil used to ignite the burner and stand up the boiler

12. Burner is produce (form) hot air by using furnace. This hot air used to dry the slurry

13 induced fan is used to input the air

14. Spray tower is a tower when slurry is sprayed through nozzle the hot air coming by contacting
counter courantly it form powder this process takes place in this tower.

15 Spray nozzle is used to spray the slurry into spray tower.

16. Belt conveyor is used to transfer the powder coming from the tower into the air lift.

17. Air-lift is a device that apply energy to trap the powder to a higher level and used to suck the
powder by using air and to cool the slurry and also quickly by sorting of the desired and undesired
products the quality detergent powder is desired product the granular particle of powder is undesired
product.

18 Fine powder trap that used to trap the fine powder from the air lift.

19. Fine powder trap pump is a pump that used to trap the fine powder from the perfume mixer using
pump

20. Vibrating screen it is one of unit operation under separating process which used to separate the
qualitative powder from granular particle by using sieve and also the required powder particle sent
down to the perfume mixer and the un required powder also removed.
21. Perfumed mixer after separating the powder spray perfeume in to the screening powder then
undergoes further mixing process between powder and perfeum. The perfeum that sprinkle in the
screening powder are sea maoutain and borsato kiss used to give the powder good fragrance.

22. Fine powder trap that used to trap the fine powder from the perfume mixer
23. Powder Silos is used to carry the powder.

24. Packaging is the final process of good powder is packed.

25. Exhausted fan is a machine or engine used to waste gas that come out of vehicle.

26. Cyclones is trapped the unwanted(fine and burned) powder from the tower before it release to the
atmosphere.
Major unit operation of powder detergent
In the powder detergent process there are three major unit operation are takes place. Those unit
operation are

1. Mixing unit operation

2. Drying unit operation
3. Separation unit operation

1. Mixing unit operation

It is one of the major unit operation powder detergent production in this process mixing of raw
materials keeping their order and measured in order to get good slurry. This unit operation consists;

 Mixing tank
 Slurry homogeneous tank
 Perfume homogenizer

2. Drying unit operation

It is the second major unit operation of powder detergent production process. In This operation
drying process is takes place. After filteration process the pure slurry sprayed in to the tower so drying
process is occurred.it consist

 Spray tower
3. Separation unit operation

It is the third major unit operation of production in this process separation of granular, fine ,dust and
burned powder are separated from pure powder. It consists

 Sieve
 Vibrating screen
 Filteration tank are grouped

Spray and Powder Terminology

1.Droplet subdivision of the feed being sprayed from the atomizer. As long as there is surface moisture
in the spray, it is said to be composed of droplets.

2. Particle A subdivision of the dried product. The shape of a particle depends on how the droplet was
formed and how it behaved during drying.

3.Agglomerate an agglomerate is composed of two or more particles adhering to each other.

4. Particle Size The size of a spherical particle is expressed as its diameter. For non-spherical particles,
the size can be represented as an apparent diameter.

5. Particle shapethe process of atomizing and drying produces many particles that are non-spherical in
shape. A “shape factor” is used to express the divergence of a particle shape from spherical.
6. Bulk density
Bulk density is the weight of dried powder per unit volume. This is a critical factor for most spray drying
operations since it determines the size (or fullness) of containers and influences the handling and
shipping costs. Bulk density is constantly monitored during the spray drying process.

Factors that affect bulk density

• Increasing feed rate increases bulk density if the residual moisture increases
• For easily atomized feeds, increased temperature can lower bulk density.
• Bulk densities often increase on powder cooling.
• A coarse homogenous powder has a lower bulk density than a fine homogenous powder.
• A powder with a wide distribution of particle sizes will have a higher bulk density than a powder with a
narrower distribution of particle sizes.
• Increasing feed solids generally increases bulk density.
• Increasing residual moisture content increases bulk density.
• Increasing inlet air temperature decreases bulk density.
• Co-current dryers produce powders with lower bulk densities than counter-current dryers.

Storage and packing

PAKCAGING

In order for the product of the company to be competitive in the market the quality of final product is
very important. The final step in the manufacture of detergent powder is packaging. The powder must
be stored in ambient relative humidity exceeding 30% the risk of lump fermentation can be minimized
by discharging the powder from spray tower without list of three quarter of the stable moisture content.
If a powder must be stored in ambient relative humidity exceeding 60 per cent, the risk of lump
formation can be minimized by discharging the powder from the spray-tower with at least three
quarters of the stable moisture content. It is economically unsound to dry a powder to 1 per cent
moisture content when the powder must revert to, say 7 per cent. The operation would be a lot more
efficient if the powder were dried to 7 per cent in the first place. After storage, the product obtained is
then put into packets, boxes, or drums equipped with a dosing system. the selection of packaging
material and containers involve consideration of product capability and stability coasty ,packaging
safety, solid waste impact self and others the quantity and parameters which are checked during the
quality control and packaging process are consider the following criteria;

 Bulk density of detergent powder

 Moisture content of packaged detergent
 Average weight of packed powder detergent
 Average weight of packed carton
 Packed box leakages
 Checking the quality packaging material
Application of powder detergent products

Products Application

Rol normal For laundary cloths,

Rol bio For institutional especially hospitals and hotels.
Stain remover, tropical essence and quick wash
Rol junior For kitchen, cloths and dishwash
Essex For machine washing and launddry washing
O2 Vim For toilet, stain dishes hard surface cleaner
ceramic

BOILER
Boilers are pressure vessels designed to heat water or produce steam, which can then be used
to provide space heating and/or service water heating to a building. In most commercial building
heating applications, the heating source in the boiler is a natural gas fired burner. Oil fired burners and
electric resistance heaters can be used as well. Steam is preferred over hot water in some applications,
including absorption cooling, kitchens, laundries, sterilizers, and steam driven equipment.

Boilers are often one of the largest energy users in a building and also detergent company .Boiler
operation and maintenance is therefore a good place to start when looking for ways to reduce energy
use and save money.

How Boilers Work

Both gas and oil fired boilers use controlled combustion of the fuel to heat water. The key boiler
components involved in this process are

 the burner
 combustion chamber
 heat exchanger
 controls
The burner mixes the fuel and oxygen together and, with the assistance of an ignition device, provides a
platform for combustion. This combustion takes place in the combustion chamber, and the heat that it
generates is transferred to the water through the heat exchanger. Controls regulate the ignition, burner
firing rate, fuel supply, air supply, exhaust draft, water temperature, steam pressure, and boiler
pressure.

Hot water produced by a boiler is pumped through pipes and delivered to equipment throughout the
building, which can include hot water coils in air handling units, service hot water heating equipment,
and terminal units. Steam boilers produce steam that flows through pipes from areas of high pressure
to areas of low pressure, unaided by an external energy source such as a pump. Steam utilized for
heating can be directly utilized by steam using equipment or can provide heat through a heat exchanger
that supplies hot water to the equipment.

Boilers are classified into different types based on their working pressure and temperature, fuel type,
draft method, size and capacity, and whether they condense the water vapor in the combustion gases.
Here inRepi soap and detergent s.co they uses fire tube boiler
Fire-Tube Boiler

 The fire tube boiler, the oldest design, is made so the products of combustion pass through
tubes surrounded by water in a shell.
 The furnace/flame volume can either be inside or external to the shell that contains the water.
 The upper steam capacity of fire tube boilers is about 20,000Ibm/hr. and the peak pressure
obtainable is limited by their large shells to about 300 psi.
 Fire-tube boilers are used for heating systems.

Combustion in Boilers

There are four important factors that control combustion in boiler furnace:

1. Air supply-Need adequate air for complete combustion.

The rating (capacity) of a boiler can be increased by supplying additional air (think of the effect of
bellows on a small fire).

Too much air can result in excessive stack losses.

2. Mixing of fuel and air-fuel and air molecules must be brought into close proximity in order for
combustion to occur.

The larger the fuel "particles" the greater the difficulty in achieving good mixing-

•easiest for gaseous fuels,

•more difficult for liquid fuels and pulverized solids,

•most difficult for stoker coal, bark or large trash clumps.

3. Temperature -all combustion reactions proceed exponentially more rapidly with increasing T
Temperatures too low:

•incomplete combustion, waste fuel

•unburned hydrocarbons and soot emissions greatly increased Temperatures too high:

•equipment failure, metal strength drops off quickly at high T

•NO emissions greatly increased.

4. Combustion time-fuel "particles" must be given sufficient time (residence time) in the furnace to
achieve complete combustion.

Like fuel/air mixing, the required residence time is least for gases and most for large solid fuels:

•Gases and fine liquid sprays-10 -20 ms burnout

Fuel Considerations

Natural gas and fuel oil burners. The fuel is brought to a burner at elevated pressure and jetted (gas) or
sprayed (oil) into the furnace. Relatively simple and low cost.
What is Steam?

Like other substances water can exist in the form of a solid, a liquid or a gas, gaseous form of water is
called STEAM.

 It is HOT
 It is Powerful
 It is Easy

Properties of steam

 Limited application
 Expensive
 Difficult to regulate
 Difficult to monitor contact time and temperature
 It is a physical hazard

Why use Steam?

Made from water, which is relatively inexpensive and, plentiful commodity available throughout the
world in a small mass Carries relatively large amounts of energy in a small mass can be adjusted
accurately by controlling its temperature can be adjusted accurately by controlling its pressure using
control valves

 Environmental friendly
 Relatively inexpensive to generate when firing with wood

Here in Repi soap and detergent s.co also use boiler.the purpose of this boiler is to produce
steam this steam used for the

 mixing agent,
 to prevent mixing temperature in the transferring line
 used for cleaning of valves and
 Slurry transferring line.

Killers of a steam system

Dirt

 Damage the valves and seats

 Obstruction to tight sealing resulting in leakage
Water

 Reduced heat content

 Barrier for effective heat transfer
 Water hammer dangerous
 Wire drawing of valves
 Water logging of traps and valves

Air

 Air Barrier for effective heat transfer

 Air binding of process vessels, traps, valves, pumps etc.

Hard water:

 has high mineral content (mainly Ca2+ and Mg2+ ) metal cations,
 sometimes other dissolved compounds such as bicarbonates and sulfates
 Soft water : mainly content Na+ ion
 Hardness in water is defined as the presence of multivalent cations.
 Hardness also be defined as water that doesn’t produce lather (foam) with soap
solutions, but produces white precipitate (scum)
 Hardness in water can cause water to form scales and a resistance to soap.

Soften the Water

• It is often desirable to soften hard water, as it does not readily form lather with soap.

• Soap is wasted when trying to form lather, and in the process, scum forms.
• Hard water may be treated to reduce the effects of scaling and to make it more suitable
for laundry and bathing.
Water softeners remove those ions by exchanging them for sodium or potassium ions.
 How make soft water

Ion exchange:
Complex of sodium salt
Hard water

Ion exchange resin

Solution precipitation

Na+, anion Ca2+, Mg2+, etc.

De-ionized water

Deionization is

 Use resin
 Change cations by hydrogen and anion by hydroxide
 Cations sticked on the resin H+ + OH- → H2O

Hard water
Advantages
 tastes great
 supplies needed minerals in the diet
 When rinsing soap - removes all traces of it.

Disadvantages

 tends to crust up water using/heating devices

 bad for soap action (less suds, less cleaning power)
 Fades clothes in washers.
 It hard to make foam
Soft water
Advantages
 keeps water using/heating appliances clean and deposit free
 Soap works better (suds up (soap forming) better, gentler washing cycles)
 It is good for foam boasting

Disadvantages
 often adds salt to environment
 can have slimy/soapy feeling even when completely rinsed
 Not as good for you to drink (less minerals).
 Soft water contains more sodium ions than hard water does. Sodium is linked to heart
disease.
 Soft water dissolves metals such as such as cadmium and lead from metal pipes.
o Lead is poisonous.
o Cadmium has been linked to hypertension
Material balance on powder detergent
The general balance equation

Raw material inputproduct out put

Process unit

A balance (inventory) on material in a system (a single process unit, a collection of units or an entire
process) may be written in the following general way

Input + generation - output – consumption = accumulation

The accumulation term for steady state continuous process is zero. So, the above equation became

Input + generation = output +consumption the law of conservation of mass is called the mass of material
balance

Massin = Massout +Massstored

Material balance on powder detergent part of calculation

Material balance on caustic soda dissolved tank based on the recipe of Repi soap and detergent
s.co
Basis; 1 batch
Waterin=450kg
XH2o=1

NaoH=250KgNaoH(aq)
NaoH dissolved
Xsolid=0.99xsolid=? tank

xH2O=0.01xH2O=?

There is no chemical reaction so, generation and consumption will be zero. And assume the
process is become zero. The balance equation is
Input+generation-output-consumption=accumulation
Input=output
General balance equation
NaoHin+Waterin=NaoHaq

250kgNaoHin+450kgH2Oin=700kgNaoH (aq)

Solid balance on NaoH (out)

NaoHin solid*mNaoH=NaoHout solid

=0.99*250kg=700kg*XNaoH solid

=247.5kg=700kg*XNaoH solid

XNaoHsolid=247.5kg/700kg

XNaoH=0.35

The output solid content in caustic soda tank is 0.35 Water balance on NaoHout

H2O*XH20+XH20in*mNaoHin=mNaoH*XH2Oout

450kg*10+250kg*0.01=700kg*XH2Oout

450kg+2.5kg=700kg*XH2Oout

XH2Oout=452.5kg/700kg

XH2O=O.65

Material balance on paste preparation

Material balance in paste preparation tank on LABSA is 96% means 96% is not have water the rest 4%is
water and other impurity NaoHin=17.24
Xsolid=0.99
XH2O=0.01

LABSA=140Kgmpasteout=?
Paste preparation
Xsolid=0.96Xsolid=0.5 tank

XH2O=0.04XH2O=0.5
mH2O=?
XH2O=1
Overall mass balance
LABSA+NaoH+H2O=mpaste
140.52kg+17.24kg+H2O=Paste……………..eqn 1

Component balance
Water balance
Labsa*Xsolid+NaoH*Xsolid+H2O=Xsolidpaste*paste out
=0.04*140.52kg+0.01*17.24kg+H2O=0.5*Paste
=5.608kg+0.17kg+H2O=0.5*Paste……………eqn
In order to get the value of paste by using simultaneous eqn by subtracting simultaneously the
eqn (1)and eqn(2)
140.52kg+17.24kg+H20=mpaste
5.608kg+0.17kg+H2O=0.5*mPaste
134.9kg+17.07kg=0.5*mPaste
151.97kg/0.5kg=mPaste
MPaste=303.94kg
In order to solve the value of H2O added in the paste preparation tank insert the value of
mPaste in the eqn 1
=140.52kg+17.24kg+H2O=303.94kg
=157.76kg+H2Oin=303.94kgion
=H2Oin=146.18kgs
In the paste preparation tank neutralization reaction is takes place this reaction is called
exothermic reaction. In this process water is generated. In order to find the amount of this
generated water the following reaction is used
Basis:1 batch

C12H25c6H4so3+NaoH c12H25c6H4so3+H2o+Heat
LABSA Caustic soda SABS Water

Molecular weight of LABSA=326 g/mol

c18=18*12=216 g/mol
H30=30*1=30 g/mol
S16=32*1=32 g/mol
O3=16*3=48 g/mol
Total=326g/mol
Molecular weight of NaoH=40g/mol
Na = 23*1g =23g/mol
O= 16*1g= 16g/mol
H= 1*1= 1g/mol
Total=40g/mol

Molecular weight of SABS 348g/mol

C18 = 18*12g =216Gg/mol
H29= 29*1g = 29g/mol
O3 =3*16g =48g/mol
S = 1*32g = 32g/mol
Na = 23*1g = 23g/mol
Total=348g/mol

Molecular weight of water18g/mol

H2 =2*1g = 2 g/mol
O 1*16g =16g/mol
Total=18g/mol

In this reaction the limiting reactant is LABSA

To get the amount of solid paste in kg by using the formula

Solid paste Xsolid paste *Xmpaste solid paste =0.5*303.94kg =151.97kg

LABSA balance 1mol SABS=1molLABSA

348g SABS= Xlabsa
Xlabsa =142362.7g or 142.36kg/batch

NaoH balance
1molsabs = 1molNaoH
348g SABS= 40g NaoH
151970g=XNaoH
XNaoH =1746.8g or 17.46kg/batch

WATER balance
Molecular weight of LABSA = molecular weight of water
Given mass of LABSA given mass of water

326. = 18g, then XH2o= 7.86kg, therefor the water generated in the reaction is 7.8kg
142.36 Xkg H2o

Over all material balance on paste preparation

Input material + input water + generated water= output (paste)
LABSA + NaoH + H2Oadd +H2Ogain = Mpaste
142.46kg/v +17.46kg +146.18kg +7.86kg =313.86kg
Mpaste 313.86kg
The above value is by using the calculation value of input raw material we can get
313.86kg of output (paste)
Material balance on slurry preparation tank
We calculate material balance in slurry preparation tank we use the raw material of rol
normal powder detergent in repi soap and detergent s.co

Paste=300kg
Xsolid= 0.5
XH2O =0.5

Raw material in= 878.2k Slurry preparation

tank

Slurry = xkg
Xsolid = 0.6
XH2O =0.4

The solid and H2O amount of slurry we get from moisture analyzer by using some
amount of sample.
 General balance
Balance equation
Input material +paste=slurry
878 .2kg + 300kg = 1178.2kg paste

Solid balance of raw material on slurry preparation tank

Balance equation
Mpaste *Xsolid +Mrawmaterial = 1178.2kg
878.2kg*Xsolid raw material 556.92kg
Xsolid raw material = 0.634

Water balance on raw material on slurry preparation tank

Balance equation
Mpaste *XH2Oin paste +Mrawmaterial * XH2Oin raw material
Mslurry *XH2Oin slurry
300kg *0.5 +878.2kg*XH2Oin raw material=1178.2kg*0.4
150kg +878.2kg*XH2Oin raw material = 71.28kg
878.2kg*XH2Oin raw material =471.28kg
XH2Oin raw material =0.365

Water input in slurry = total water in paste –water formed in the reaction –water
associated in caustic soda……………1
Total water in paste =water in paste +water formed in the reaction + associated water
with caustic soda……….2
Total water in the paste =146.18kg +7.86kg water associated with caustic soda
Water associated with =MNaoH*XH2ONaoH
=water associated with caustic soda =17.46*0.01
=water associated with caustic soda =0.175kg

Insert the value in the above equation

Total water in paste = 146.18kg + 7.86kg +0.175kg
Total paste = 154.21kg
Substitute the above value in equation (1)
Water in slurry = 154.21kg -7.86kg +0.175kg
Water in slurry =146.175kg
Total amount of water in slurry output
Mslurry*XH2Oin slurry = total H2Oin slurry
1178.2kg*0.4 – total H2O in slurry
Total water in slurry = 471.28kg*
Total solid content in slurry = Mslurry * Xsolid in slurry
Total solid content in the slurry = 706.92kg

Water balance generation in slurry

In the slurry preparation tank there is a material input that have high amount of water content
e.g. silicate if it has 50% up to 80% water.
These types of raw material in the time of mixing and react to other generate water. To
calculate this water generation the following formula used by ignoring the water that evaporate
on the slurry homogeneous tank.
Water generation in slurry tank; total H2O in paste + total H2O in slurry by substituting this value
by total H2O in slurry
H2O gain in slurry = total H2Oinput slurry – total H2Oinput in slurry
71.28kg – 154.2kg -146.175kg
H2Ogain in slurry = 170.89kg

Material balance on slurry storage homogeneous tank

Input slurry=1178kgOutput=?
Slurry storage
Xsolid =?Xsolid=0.6
Homogeneous
XH2O=?XH2O=0.4
tank

In this tank physical process is tank place there is no chemical process so accumulation
becomes zero. We can we assume it is steady state by this case also generation consumption
become zero but some amount of water is evaporated.
Balance equation
Input slurry=evaporated H2O *X solid +output slurry *X solid
Input slurry * Xsolid=evaporated H2O *Xsolid +Output slurry * Xsolid………1
= 1178.2 kg * 0.6=evaporated H2O *0 +output slurry * 0.6
706.92 kg =output slurry*0.6
Output slurry=706.92kg
0.6
Output slurry= 1178.2 kg
Insert the above value in equation………..1
Input slurry=evaporated H2O + output + slurry
1178.2 kg = evaporated H2O +1178.2kg
Evaporated H2O = 0
Meaning negligible amount of water evaporated

Material balance on spray dryer(tower)

Mass of H2O Evaporated

XH2O=?
Input slurry =1178kgmass of product
Xsolid = 0.6Xsolid=0.95
XH2O =0.4XH2O =0.05 Spray tower
Generation balance equation
Input =mass of product (powder) + mass of H2O evaporate
1178.2kg = mass of powder + mass of water evaporated …….1

Solidity balance
Input *Xsolid input= mass of powder*Xsolid +mass of H2O evaporated *Xsolidevaporated
1178.2kg*0.6 = mass of powder*0.95 +mass of H2O evaporated *0
Mass of powder = 744.13kg/batch
Insert the above value in equation (1) to get evaporated H2O
Input = mass of product + mass of evaporated H2O
1178.2KG = 744.13Kg + mass of evaporated H2O
Mass of evaporated = 434.07 kg/batch
ROL JUNIOR DRY MIXING
Dry mixing is one method of powder manufacturing system, this method is run physical
process. That means there is chemical reaction between] the mixing rawmaterial, accumulation
becomes zero Assume the reaction is steady state by this case the consumption and generation
are also zero.

Normal Essex dry mixing

Normal Essex is one type from the dry mixing powder.It is also physically processed.no
chemical reaction is applicable ,between the raw material, by this case accumulation become
zero. And assume steady state generation and consumption terms become zero.

O2 Vim dry mixing

O2 Vim dry is also one types of dry mixing powder.it made by physical process without
chemical reaction, between raw material by the time of mixing. We take an assumption it is
steady state process. So, accumulation generation and consumption becomes zero.
 1. Energy balance on powder
Energy balance takes many forms, such as heat, kinetic energy, chemical energy, potential energy but
because of interconversions it is not always easy to isolate separate constituents of energy balances.
However, under some circumstances certain aspects predominate.

Energy balances can be calculated on the basis of external energy used per kilogram of product, or raw
material processed, or on dry solids or some key component.
General energy balance equation

Just as mass is conserved also energy is conserved. The energy coming in to the unit operation can be
balanced with the energy coming out and the energy stored.

Energy in = energy out + energy stored

∑ER = ∑EP+∑EW+∑EL+∑ES

Where ∑= sum of all terms

EP =product energy
EW= wasted energy

EL= loss energy

ES= stored energy

Meaning

∑ER= ER1 +ER2 + ER3………. total energy entering

∑EP= EP1 + EP2 + EP3……… Total energy leaving

∑EW= EW1 + EW2 +EW3……… total energy leaving with waste material

∑EL= EL1 + EL2 + EL3 ………... Total energy lost to surrounding

∑ES= ES1 +ES2 +ES3 ………… total energy stored

Energy balance are often complicated because forms of energy can interconverted
E.g. mechanical energy to heat energy but overall the quantities must be balanced
Energy in products

Energy in EP1 EP2 EP3

heat, work, Energy stored Energy in waste EW1, EW2,
Combustion
chemical, EW3
ES1, ES2, ES3
electrical
ER1,ER2,ER3 Energy losses to
surrounding EL1 EL2
EL3

EL1 EL2 EL3

 Principles of combustion
Combustion refers to the rapid oxidation of fuel accompanied by the production of heat or heat and
light. Complete combustion of fuel is possible only in the presence of an adequate supply of oxygen

Oxygen (O2) is one of the most common element on earth making up 20.9% of our air. Rapid fuel
oxidation results in large amount of heat. Solid and liquid fuel must be changed to gas, before they will
burn. Fuel gases will burn in normal state. If enough air is present

The objective of good combustion is release all of the heat in the fuel.
Heat

Heat
Co2
N2,
H2O O2
Co2N
Perfect 2 H2O
Fuel (H2,C ) combustion Air (O2,N2)

Good combustion

Fuel Air

In complete (H2, (O2,

Fuel (H2, C) Smoke
Co and heat C) N2)
combustion

Air

(O2,
N2

Heating of oil to correct viscosity

When atomizing oil it is necessary to heat it enough to get the desired viscosity. This pre-
heating is required for heavy oil(furnace) the lighter furnace do not usually required pre-
heating the efficiency of a boiler,burner or furnace depend on efficiency of combustion system
combustion process for burning of 1 kg of a typically fuel oil containing 86% carbon ,12%
hydrogen and 2% others. Theoretically the required quantity of air is 14.1kg. This is the
minimum air that would be required quantity if mixing of fuel and air by the burner and
combustion is perfect.
Calculating of stoichiometric air

The specification of a furnace oil from lab analysis is given below

Carbon=85.9% Nitrogen=0.5%
Hydrogen=12% Sulphur =0.5% G.c.u=10880kcol/kg
Oxygen=0.7% Water=0.35%
Ash=0.05%
Calculation for requirement of theoretical amount of air

Considering a sample of 100kg of furnace oil.the chemical reaction are;-

Element Molecular weight kg/kgmol

C 12
O2 32
H2 2
S 32
N2 28
CO2 44
SO2 64
H2O 18

C+O2 CO2
H2 +1/2 O2H20
S+O2SO2

constituent of fuel
C+ O2CO2
12+32 44

12kg of carbon required 32 kg of oxygen to form 44 CO2 therefor 1kgcarbon required 2.67kg of oxygen.

(85.9)C + (85.9×2.67) O2 315.25CO2

2H2+O22H2O

4+3236

4kg hydrogen requires 32kg of oxygen to form 36 kg of there for 1kg of H needed 8kg of
oxygen.
(12)H2+(12×8) O2(12*9) S+O2

32 + 32 64
32kg of sulphur required 32kg of oxygen toform 64kg of SO2 therefor 1kgof sulphur need to 1kg
of oxygen
(0.5)5+(0.5×1)O21.0 SO2
Total oxygen required
229.07+96+0.5=325.57kg
The amount of oxygen already present=0.7kg
Additional oxygen required 325.57-0.7=324.85kg
Theoretical air required 1412.45/100=14.12kg of air/kg of fuel
Energy balance on spray dryer
Our practical energy balance is based on the data that we collect in 16/01/17 E.C.The fuel
composition of spray dryer for 18hr(6hr down time) is 1013.7l. The total output of this dryer
6470kg, this output is included normal recycle, fineparticle, coarse recycle and base powder. In
the burner the above amount of fuel change to energy by using 14.1kg of air for each litter of
furnace.
To change 1013.7 litter furnace to energy the following formula is used
1 litter furnace=10500kcal/k.kg
1kcal/k.kg=4200kJ
1 litter furnace=44100Kj/k.kg
1013.7litter=X
X=44704170KJ
In the above x value is the amount of energy needed for 6470kg of powder gain. in the previous
report(material balance).we calculated the amount of water in one batch slurry which is equal
to 434.07 kg.to calculate the amount of water evaporated to get 6470 kg base powder the
formula is used below.
744kg of powder have evaporated 434.07 kg of water
744kg=434.07kg
6470kg=x
x=3774.7kg
To evaporate 3774.7kg of water needed 44704170kj this value change to one batch.
3774.7kg=44704170kj
434.07kg=x
x=5140736.7kj
The above amount of energy needed for evaporating 434.07kg of water or 1 batch of slurry
(1178.2kg).this amount change to 1 kg of water
434.07kg=5140736.7kj
1kg=x
x=11843.1kj
Now we change the above energy that we used to evaporate 1kg of water change to litter of
furnace.
1kg=11843.1kj
1littre furnace=44100kj
x = 11843.1kj
x=0.27littre
Then we can convert the above amount to one batch slurry.
1kg H2o=0.27furnace
434.07kg H2o=xlitter furnace
x=116.5littre
The above amount of furnace is consumed for 1 batch slurry or to evaporate 434.07kg of water.
The above calculation is based on practical consumption.now calculate the amount of energy
needed for evaporating 434.07kg or 1 batch slurry theoretically by using the formula.

Where
Q=mcp∆T m=mass of water
m=434.07kg cp=specific heat capacity
Cp=4200J/K.Kg ∆T=Change in temperature
=4.2kJ/k.kg
∆T is the average of input minus output temperature
Input temperature=(250+300)℃
2
Tin=275℃
Tout=100℃
∆T= (275-100) ℃
∆T=175℃=175k
Q=mcp∆T
Q=434.07Kg*4.2kj/k.kg*175k
Q=319041.45KJ
The above energy convert of litter
1littre=44100kj
X=319041.45kj
X=7.23littre
Comparison between theoretical and practical energy value for one batch
Practical energy
E=5140736.7KJ
In litter=116.5littre furnace
Theoretical energy
E=
In litter
From the above comparison the value of theoretical and practical values are very difference.by
this case the company lost high amount of energy cost.
The reason behind those losses are as followed;-
 The material that used for heat transmission are not well insulated.
 The oldness of the machine by this case they do not work properly.

Not checking of furnace. Mean that the furnace is come from market but not pass through
checkingprocess. When the amount of carbon less than 86%or the amount of hydrogen,sulphur
and ash increase it affect the calorific value or reducing the energy releasing power.
The company have not habit of doing energy balance.in this case the problem is not known and
not find the solution.
In the spray dryer there is high amount of accumulation.in the case of suction of heat. if there is
suction of heat in the dryer a lot of energy is loss without work.
Our combustion material are old they consume high amount of furnace without releasing of
energy.
The above problem and other case is happen high amount of energy loss.those problems lower
the spray dryer efficiency
ᶯ=the amount of energy needed*100
the amount of energy entered
ᶯ=

Energy balance on boiler

In this day the fuel consumption of boiler is 340 Littre. The working time of boiler is 16hr
because of shift in that day there is no slurry preparation. Because of this the boiler not
produce steam.
In the above calculation we calculate that the energy consumption of evaporating 1kg of water.
We use that value to calculate how many litters (kg of water)change to steam.
1kg=11843.1kj
1litre furnace=x
X=14994000kj
To calculate the steam amount of water input is equal to the amount of steam output
1kg=11843.1kj
X=14994000kjx=1266kg of water is consumed

The total pressure of this steam is 8 bar from this 7 bar is going to factory and the other one bar
is used for furnace heating and soft water heating in the aluminum tank.
To calculate the amount of steam going to factory is;
%steam=pressure of steam entering to the factory/total pressure of steam produced*100%
%steam=7bar/8bar*100
%steam= 87.5%
87.5% of steam from the total production is used for slurry preparation and line cleaning and
also sometimes used for slurry heating in the storage tank.
The above percent of steam change to energy and litter of furnace
Water amount=1266kg*87.5/100
=1107.75 of water used for steam factory
To change material into energy
1266kg=14994000kj
1107.75=x
X=13119750kj
This amount of energy used for slurry preparation and line cleaning
The amount of energy loss in the factory by the safety valve around slurry storage is assume the
pressure is minimum 0.2 bar
7ba=13119750kj
0.2 bar=x
X=374850kj
The above amount change to litter of furnace
1 litter furnace=44100kj
X=344850kj
X=8.5l/16hr
Heat balance in a boiler
A Heat balance is an attempt to balance the total energy entering a system.e.g a boiler that
leaving the system in different forms. The figure illustrates the heat balance and different losses
occurring while generating steam.
73.8% heat in steam

12.7% dry fuel gas loss

8.1% heat loss due to hydrogen
100%1.7% heat loss due to moisture in the fuel
0.3% heat loss due to moisture in the air
0.24%heat loss due to UNburnt in residue
1.0% heat loss due to radiation and UN countered loss

Boiler casing losses

Most refuse fired boilers are well insulated to prevent casing destruction by acid gases.so
casing losses are less than other boilers of similar size casing surface area. The data needed for
this analysis is ambient air conditions and boiler casing segment surface temperature. The heat
losses can be molded as natural convection and radiation. The casing temperature are usually
not high lost through convection is predominant.
Energy balance on mixing tank
In the factory always some amount of steam used for line cleaning.it is difficult to estimate the
accurate value. Weought to(obligate to assume some amount of energy. Assume 0.5 bar per
day used for line cleaning.
So from the entering to factory energy 0.2 bar losses by safety valve, 0.5 bar for line cleaning
the remains 6.3 bar is used for slurry preparation process.
The above steam pressure change to percent
%steam=6.3/7*100
=90%
90% of the entering steam to factory used for slurry preparation process
The above percent change to water amount and energy
7bar=1107.75kg
6.3bar=xX=996.975kg of water
Used for slurry preparation steam
Change the above amount of water to energy from 1107.75 kg have 13119750kj and from
996.975 kg how much
1107.75kg=13119kj
996.975=x
X=11807.775kj
=11807.775MJ
Change the above energy to Littre of furnace
1littre=44100kj
X=11807775kj
X=267.75littre for 6 batch slurry
In order to find for 1 batch slurry
=267.75/6
=44.625littre
Convert the above value to energy
1 Littre=44100kj
44.625littre=x
X=1967962.5kj for one batch slurry preparation process
Exothermic reaction of heat balance
In the mixing tank there is a reaction between NaoH and Labsa this reaction exothermic
reaction is takes place this exothermicreaction is called neutralization reaction.this
neutralization reaction have realized heat to calculate the amount of energy in this reaction we
used the followed formula
Q=mcp∆T
Where m=Mass balance of LABSA and NaoH
Cp=specific heat capacity of LABSA and NaoH
∆T=changing temperature
Q for LABSA

Q1=mcp∆T m=mass of LABSA=142.36kg/batch

Cp=specific heat capacity of LABSA = 3.057(from table)
∆T=released temperature=80 ℃
Enviroment temperature=23℃
∆T= 80℃-23℃ = 57℃
QLABSA=142.36kg*3.057KJ/K.KG*57℃ +142.54kg*-155kj/k.kg
QLABSA=2740.3KJ
Q for NaoH
Q=mcp∆T m=mass of NaoH=17.46KG
Cp=specific heat capacity=28.23kj/k.kg
∆𝑇 =Change in temperature is similar to Labsa=57℃
QNaoH=17.46 KG *28kj/k.kg*57℃+17.46kg*(-470.1)kj/k.kg
QNaoH=19887KJ
Total energy produced by exothermicreaction is equal to
QT=QLABSA+QNaoH
QT=2740.3KJ+19887KJ
QT=22627.3KJ
Definition of liquid detergent
Liquid detergent is a detergent in liquid form. It is cleansing agent that differs from soap and
powder but can also emulsify oils and hold dirt in suspension and it is also a multipurpose
cleanse. Liquid soap is also known as liquid detergent (dirt-agent).
The biggest advantage with liquid detergents is from the manufacture point of view. Liquid
detergents can be made by use of simple inexpensive equipment’s unlike in case of detergent
cakes, powder, compacts, pastes and tablets that all require relatively more sophisticated plant
equipment and operating conditions.
The primary surfactant used in washing up liquid formulation includes Linear alkyl benzene
sulphonate (LABS), neutralized with sodium, ammonium, and magnesium hydroxide or
sometimes with triethanol amine. Although these are good emulsifiers they are sensitive to
water hardness. Linear alkyl benzene sulphonate obtained
Major categories of liquid detergents are

1. Washing up liquids / Dishwashing liquid detergents.

2. Light duty laundry liquid detergents.
3. Heavy-duty laundry liquid detergents.

1. WASHING UP LIQUIDS / DISHWASHING LIQUID DETERGENTS.

Washing up liquids is used mainly to wash soiled dishes and cooking utensils in the kitchen. Washing up
liquids is a blend of primary surfactants with additives that include viscosity modifiers, fragrance
preservatives, UV absorbers, color, etc. Soiled dishes normally have mixed oils, fats, starches, cellulose,
protein, etc.
2. LIGHT DUTY LAUNDRY LIQUID DETERGENT.

Light duty liquid detergents are used for washing delicate fabrics. Like wool, silk, and synthetics. Light
duty liquid detergents evolved from washing up liquid detergent formulations that are made by use of
more expensive raw materials. Light duty liquid detergents have a very similar formula as washing up
liquid detergent when intended for a hand wash product. However, the emphasis is more on the fabric
cleaning ability.
3.Heavy-duty liquid detergents
Are distinctive because of their relatively high surfactant level, sometimes even up to 40%. However,
due to stability and solubility problems most of the products in the market do not contain builders or
bleaching agents. Heavy-duty liquid detergents are effective in removing grease and greasy soil at wash
temperatures below 60 degrees centigrade at much lower dosage levels.

Liquid Detergent Production

Liquid detergents can be made from a variety of starting materials, but in every case the plant is the
same. A vessel equipped with a slow-speed stirrer is all that is required and the stirrer should be
positioned so that it is well under the surface of the liquid, so as not to cause foaming. It is, however,
necessary that the vessel be of a non-corrodible material. Stainless steel is satisfactory, but expensive;
concrete or asbestos cement vessels are eminently suitable, and so are those of glass-fiber reinforced
plastics. To the user, the advantages are that they are instantaneously dispersed in water; the material
can be perfumed and be given a very attractive appearance. Liquid detergents are produced through
both batch and continuous blending processes. In the typical blending process, dry and liquid
ingredients are combined and blended to a uniform mixture using in-line or static mixers.
Liquid detergents are distinctive because of their relatively high surfactant content (up to 40%). For
reasons of solubility and stability, they seldom contain builders and generally are devoid of bleaching
agents. Liquid detergents can be packed in a range of containers including glass bottles and drums, but
plastic bottles of various shapes and sizes are now normal for the domestic trade. Types of polythene of
varying rigidity are most usual. Some products are packed in rigid bottles, but flexible squeeze bottles,
with caps provided with a small hole, are virtually standard for dishwashing liquids. Packaging lines can
be very simple, with hand operations and semi-automatic fillers; but with the very large tonnages now
being produced by major companies, the trend is to highly mechanized, high-speed, lines.

The main ingredients of liquid detergents in Repi soap and detergent factory

For largo production are

1. LABSA
2. NaoH
3. TEA
4. demineralized water
5. SLES
6. Sodium chloride
7. palm kernel oil
8. Water
9. Perfume (cocunt)
10. preservative
 Liquid detergent process flow diagram

Below is the liquid detergent process flow diagram being described above?

Liquid detergent process flow diagram, (“RDS” = Repi detergent and soap factory)
Application of liquid detergent products

Raw material Function

Viscous Drilling the mineral site
Normal largo Clean cloth

Medicated largo For medical purpose, to remove from laboratory

equipment
Simple Chain lubricant
Blue largo
Multiple purpose Multiple clean purpose
Dish wash Clean dishes
Window cleaner Used for clean windows