NIMIR

TABLE OF CONTENT
1.
2.
3.
4.
5.
6.
7.
8.
9.

10.
11.
12.
13.
14.
15.
16.
17.
18.

19.

20.

INTRODUCTION
HISTORY
NIMIR INDUSTRIAL CHEMICALS LIMITED
QUALITY POLICY
OTHER ASSOCIATED COMPANIES
HEALTH AND SAFETY ENVIORNMEN
VISION
MISSION STATEMENT
FATTY ACID
TYPES
SATURATED FATTY ACID
ESSENTIAL FATTY ACID
FREE FATTY ACID
RAW MATERIAL
COMPOSITION
OIL & FATS PRE-TREATMENT
INTRODUCTION
OLD TANK YARD
FATTY ACID PLANT
STEARIC ACID SECTION
BLOCK DIAGRAM
HYDROGENATION SECTION
BLOCK DIAGRAM
PROCESS DETAIL
DRYER
AUTOCLAVE REACTOR
HYDROGEN SOURCE
COOLER
FILTER PRESS
SPLITTING SECTION
BLOCK DIAGRAM
PROCESS DESCRIPTION
SPLITTER OPERATION
CONTROLLING PARAMETER
SCRUBBER
SKIMMER
GLYCERIN SECTION
PROCESS DESCRIPTION
BLOCK DIAGRAM
TREATMENT TANK
MULTI-EFFECT EVAPORATOR
ION EXCHANGE
CATION EXCHANGER
REGENERATION
ANION EXCHANGER
REGENERATION
STEPS OF REGENERATION

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21.
22.
23.
24.

25.
26.
27.
28.

29.
30.
31.

32.

DOUBLE EFFECT EVAPORATOR

DEHYDRATION COLUMN
DISTILLATION SECTION
TYPES
CONTINUIOUS DISTILLATION
FATTY ACID DISTILLATION
PROCESS DESCRIPTION
FURNACE
EJECTOR
STEAM JET EJECTOR
FD4
FD5
DIFFERENCE
FLAKERS
BLOCK DIAGRAM
GRADE OF STEARIC ACID
SOAP NOODLES PLANT
SAPONIFICATION
PROCESS DESCRIPTION
BLOCK DIAGRAM
SOAP
MANUFACTURING PROCESS DESCRIPTION
CRUTCHER
FILTER
HEAT EXCHANGER
VACCUM SPRAY DRYER
PLODDER
HOPPER
RANCIDITY
FACTORS OF RANCIDITY
SOAP ANALYSIS
BOILER
TYPES
WATER TUBE BOILER
BLOCK DIAGRAM
CONDENSATE TANK
DE-AERATION TANK
ECONOMIZER
STEAM DRUM
SUPER HEATER
STACK
WATER TREATMENT PLANT
CORE REASONS OF TREATMENT
CONDUCTIVITY
BOILER WATER
BOILER CONDENSATE
COOLING TOWER WATER
BIOLOGICAL GROWTH

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33.
34.
35.
36.
37.

OBJECTIVE
CATION EXCHANGER
DE-GASIFIER
ANION EXCHANGER
MIXED BED
LAB ANALYSIS
RAW MATERIAL
FATTY ACID PLANT
SOAP NOODLES PLANT
RAW WATER

INTRODUCTION
The basic purpose of this internship report is to jot down the experiences of the internship and
discuss the understanding of the operations of the chemical process of the Industry.
The report contains the History of Nimir Industrial Chemicals Limited and the management of
the organization. The report includes the information regarding the process activities going on in
the industry, the services provided by the industry, description of all the units of the Fatty Acid
Section. The report also includes the information on the work done by the different departments
and the analysis activities of the each section of the Fatty Acid plant.
However, the experience of working in a well- established Chemical Industry was in itself a treat.
In the end of the report some assignment work is attached.

History:
The company, formerly known as Ravi Alkalis Limited, was incorporated in 1994 and is
headquartered in Lahore, Pakistan. Nimir Industrial Chemicals Limited is a subsidiary of
Knightsbridge Chemicals Limited Bermuda.
We are proud of our technical and experienced engineers who are ready to face any challenge
regarding plant installation, commissioning, expansion, maintenance and production.

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Nimir Industrial Chemicals Limited:

Nimir Industrial Chemicals Limited engages in the manufacture and sale of stearic acid and
distilled fatty acids in Pakistan. Its product line primarily includes stearic acid for use in cosmetic,
textile, pharmaceutical, tyre and rubber, PVC, candle, water proofing, commercial and military
explosive, and lubricating greases industries, as well as in the manufacture of stearates; glycerin
for use in cosmetic, toilet soap, resins/paints, pharmaceutical, and commercial and military
explosive industries; and distilled fatty acid for use in cosmetic, toilet and laundry soap, and
textile sizing industries. The company also offers soap noodles, caustic soda, hydro chloric acid,
and sodium hypo chlorite. In addition, it engages in power generation.

Quality Policy:
Nimir Industrial Chemicals Limited (NICL) is a customer driven and result oriented Company
which produces

Stearic Acid
Distilled Fatty Acids
Glycerin
Soap Noodles
Caustic Soda
Sodium Hypochlorite
Hydrochloric Acid

NICL is committed to provide its customers products and services that meet the Highest Quality
Standards.

Health Safety and Environment:

The safety and well-being of our staff, neighboring communities, contractors and customers is of
paramount concern to Nimir. Therefore every one of our businesses has a Health, Safety and
Environment (HSE) policy which conforms to international best practice.

The equipment that we use is designed and operated to the highest standards. All our
businesses carry out regular internal audits to ensure that these standards are being
maintained.

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Staff at our production plants, and in the R&D laboratories, are all highly qualified and
work to strict HSE regulations.
Every storage tank and warehouse is periodically inspected to make sure that it meets our
rigid HSE standards.
All our employees are trained in emergency procedures.
We exercise strict controls on waste water and effluents.

VISION
To make Nimir Chemicals a customer driven and result oriented company which brings success
to all its stakeholders through a commitment to technical and managerial excellence, innovation,
creativity and social responsibility.

MISSION STATEMENT

To turn our business around into viable enterprise by reducing costs and increasing revenues

STATEMENT OF ETHICS & BUSINESS PRACTIVES

We believe in a stimulating and challenging team oriented work environment that encourages,
develops and rewards excellence. We are committed to diligently serving our community and
stakeholders while maintaining high standards of moral and ethical values.

Fatty Acid:
In chemistry, especially biochemistry, a fatty acid is a carboxylic acid with a long unbranched
aliphatic tail (chain), which is either saturated or unsaturated. The most occurring natural fatty
acids have an even number of carbon atoms.

How to Produce Fatty Acid?

Fatty acids are produced by the hydrolysis of the ester linkages in a fat or biological oil (both of
which are triglycerides), with the removal of glycerol.

Sources and Composition:

Fatty acids are aliphatic monocarboxylic acids derived from, or contained in esterified form in, an
animal or vegetable fat, oil, or wax. Natural fatty acids commonly have a chain of four to 28
carbons (usually unbranched and even numbered), which may be saturated or unsaturated.

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Types:

Three dimensional representations of several fatty acids.

Fatty acids can be saturated and unsaturated, depending on double bonds. They differ in length
as well. Unsaturated fatty acids are of similar form, except that one or more alkenyl functional
groups exist along the chain, with each alkene substituting a single-bonded " -CH2-CH2-" part
of the chain with a double-bonded "-CH=CH-" portion (that is, a carbon double-bonded to
another carbon).

Saturated Fatty Acids:

Saturated fatty acids are a long-chain carboxylic acid that usually has between 12 and 24 carbon
atoms that has no double bonds. Thus, saturated fatty acids are saturated with hydrogen (since
double bonds reduce the number of hydrogens on each carbon).

Example;
1.
2.
3.
4.
5.

Lauric acid (C 12 )
Myristic acid (C 14)
Palmatic acid (C 16)
Stearic acid (C 18)
Arachidic acid (C 20 )

Essential Fatty Acids:

The human body can produce all but two of the fatty acids it needs. These two, linoleic acid (LA)
and alpha-linolenic acid (ALA) are widely distributed in plant oils. In addition, fish oils contain
the longer-chain omega-3 fatty acids eicosapentaenoic acid (EPA) and docosahexaenoic acid
(DHA). Other marine oils, such as from seal, also contain significant amounts of
docosapentaenoic acid (DPA), which is also an omega-3 fatty acid.
Since they cannot be made in the body from other substrates and must be supplied in food, they
are called essential fatty acids. Mammals lack the ability to introduce double bonds in fatty acids
beyond carbons 9 and 10. Hence linoleic acid and alpha-linolenic acid are essential fatty acids for
humans.
Function of Fatty Acid in Human Body:
In the body, essential fatty acids are primarily used to produce hormone-like substances that
regulate a wide range of functions, including blood pressure, blood clotting, blood lipid levels, the

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immune response, and the inflammation response to injury infection.
Free Fatty Acids:
Fatty acids can be bound or attached to other molecules, such as in triglycerides or phospholipids.
When they are not attached to other molecules, they are known as "free" fatty acids. The
uncombined fatty acids or free fatty acids may come from the breakdown of a triglyceride into
its components (fatty acids and glycerol).
Reaction of Fatty Acids:
Fatty acids react just like any other carboxylic acid, which means they can undergo esterification
and acid-base reactions. Reduction of fatty acids yields fatty alcohols. Unsaturated fatty acids can
also undergo addition reactions, most commonly hydrogenation, which is used to convert
vegetable oils into margarine.
Raw Materials:
Following are the raw materials used to produce Fatty Acid, Glycerin, and Stearic Acid.

Palm Stearin
Palm Kernel Oil
Coconut Oil
Lauric Acid

Composition of Palm Stearin:

Palm stearin is naturally occurring from palm trees. It contains numbers of fatty acids. The most
essential fatty acids that can be extracted from palm oil are:
Stearic acid
Palmatic acid
Linoleic acid
Oleic acid
Oil and Fats Pretreatment:
The treatment involves removing of impurities. Depending on the feed stock, either water
degumming is applied, or regular bleaching where a small amount of phosphoric acid is added
and intensively mixed with oil to precipitate the gum s and impurities which then be removed
along with bleaching earth.
Introduction:
How to de-canting the raw material from tankers?
Introduce live steam of 2.5 bars into tanker.
Open the discharge valve of tank when sufficient amount of material is to be melt.
Transfer the material from tank to de-canting pit through flexible hose pipe.
Pump the material from pit to storage tanks.
Major elements of de-canting process:
1. Steam (2.5 bars)
2. Centrifugal pump (is used for filtration purpose).

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Old Tank Yard:
1st Section:
Tank Specification
DAY TK-01
RM TK-01
RM TK-01
RM TK-02
RM TK-03
RM TK-04
2nd Section:
Tank Specification
TK-01
TK-02
TK-04
TK-03
TK-05
3rd Section:
Tank Specification
HRBDO-02
TK-01
TK-02
TK-03
TK-04

Capacity
50 m3
50 m3
150 m3
150m3
40 m3
300m3

Material to be stored
Feed tank of Palm Stearin
Storage tank of Palm Stearin
Storage tank of Palm Stearin
Storage tank of Palm Stearin
Storage tank of Palm Kernel Oil
Storage tank of PST/Palm oil Blend

Capacity
50 m3
50 m3
50 m3
50 m3
50 m3

Material to be stored
HCFA(Hydrogenated Crude Fatty Acid )
HCFA
HCFA
Residue (from splitters)
Residue (from splitters)

Capacity
25 m3
25 m3
25 m3
25 m3
25 m3

Material to be stored
Feed tank of HCFA
Feed tank of HCFA
DFA
DFA
DFA

Fatty Acid Plant:

Stearic Acid Section:
There are basically four sections on Fatty Acid Plant.
1.
Hydrogenation
2.
Splitting
3.
Distillation
4.
Flaking

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Block Diagram:
Palm
Oil,
Palm
Stearin,
Palm Kernel
Oil

De-canting/
unloading of
feed Oil

Storage of Palm
Oil/ Palm Stearin

Hydrogenation
Section
(HRBDO)

Un-Hydrogenated
HRBDO Storage

Splitting

HCFA Storage

Sweet
Water/Glycerin
Storage

Pre treatment

Distillation
Ion Exchange

Splitting Section

HCFA
Storage

Distillation
section

HDFA Storage
Evaporators

HDFA Storage

Soap Noodles
Distillation & Refining
Sold to
Market

Drummed

Flakers

Bagging

Hydrogenation Section:
Definition:
Hydrogenation is the chemical reaction that results from the addition of hydrogen (H2). The
process is usually employed to reduce or saturate organic compounds. The process typically
constitutes the addition of pairs of hydrogen atoms to a molecule. Catalysts are required for the
reaction to be usable; non-catalytic hydrogenation takes place only at very high temperatures.
Hydrogen adds to double and triple bonds in hydrocarbons.

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Process Description:
Palm Strearin is pumped from the feed tank to the dryer and moisture is removed by increasing
temperature of feed. The dry feed is introduced in an autoclave reactor for hydrogenation recation
in the presence of Nickel catalyst. Hydrogenation is an exothermic reaction and feed is cooled by
cooler before introducing the saturated oil to filter. Filtered material is then pumped to storage
tank.

Block Dia gram:

Compressed

Catalyst

Hydrogen gas

Palm
Stearin

AutoDryer

clave

Storage

Cooler

Reactor

Storage

Filter Press

Tank

Process Detail:
Dryer:
Take the batch of 5 tons of Palm Stearin from the feed tank into the dryer. Then the steam
of 2.5 bars is introduced in the coils of dyer to raise the temperature up to 120C. The
material is agitated continuously to facilitate the smooth and uniform process moisture is
removed from the dryer by the vacuum system and shifted to the reactor for the
hydrogenation process.
Autoclave Reactor:
Dry feed from the dryer is fed to the Autoclave reactor. Introduce the steam of 15-20 bars
in the coils of the reactor. First heat the feed up to 190C. As the required temperature is
achieved then introduces the Ni (+23%) catalyst of 3 kgs in batch of 5 tons. catalyst
speed up the reaction of hydrogenation. The reaction is highly exothermic the
temperature of the process rises up to 240C.Each batch takes at-least the residence time
of 2 hours for the completion of reaction and thats checked by analyzing the Iodine
Value (less than One) and Melting point (56-58C) of the product. Finally the material
(Palm Stearin) is sent to the cooler by the vacuum system (-0.6kg/cm2).
Unsaturated Fatty Acid + Hydrogen Gas
Ni
Saturated Fatty Acid

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Iodine Value:
The average degree of un-saturation (double and triple bonds) presents in a fatty material
expressed as Iodine Value or Iodine Number. It is usually determined via the reaction of iodine
chloride with fatty material; IV is expressed as centigrams of iodine consumed by per gram of test
substance.

Source of Hydrogen Gas:

Natural Gas cracking (Natural gas is being crack at high temperature.)

From Caustic Soda Plant

Hydrogen Holder:
Hydrogen gas for the hydrogenation of Palm Stearin is provided by the Caustic Soda
plant. Hydrogen gas is lighter and insoluble in water so rises in the vessel and stored in
the storage tank.
Hydrogen Receiver:
Hydrogen gas from the hydrogen holder is sent to the receiver through the positive displacement
compressor. The gas is compressed up to 16 bars pressure before introducing in the reactor.

Compressor:
The compressor takes the suction of 5mm H2O from the Caustic Soda Plant and after
compressing its discharge at the pressure of 16 bars.
Definition: Compressors are used to increase the pressure of gas (compressible fluid).its increase
the pressure for instrument air, transport gases (such as Hydrogen gas, Nitrogen gas, Fuel gas) in
the chemical plant.
Positive displacement compressor
Centrifugal compressor

Positive Displacement; Reciprocating Compressor:

The reciprocating compressor is capable of developing the high pressure at the relatively low
capacities. Pressures from as low as a few kilo Pascals to as high as 240 MPa can be raised in the
reciprocating compressors.
The reciprocating motion of the piston propels the gas through the successive stages of the
expansion, suction, and compression and discharge. Single stage and multi stage operation are
common, while double acting cylinders are frequently used. The overall efficiency of the most of
the reciprocating compressors exists in the range of 65-80 per cent.

Cooler:
Hydrogenated fatty acid is first cooled in autoclave reactor. Coils of reactor is multipurpose, that
can be used for heating and maintaining temperature of fatty acid in hydrogenation process and
after hydrogenation process completion its being served for cool down (pre cooler) of process
material up to 120C in cooler the cool water is introduced in coil from the top that takes heat
from the process feed and leaves from bottom of cooler. And finally the feed material is cooled
up to 100C.

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Filter Press:
The Hydrogenated fatty acid from the cooler is sent to filter press for the filtration. And finally
pump to the storage tanks.

Splitting Section:
Definition:
Hydrolysis of fatty acids at high temperature and pressure is known as splitting process.

Block Diagram:
S
P
L
I
T
T
E
R

De-min
Water

HRBDO

Water
C
F
A

S
W

Scrubber

Drain
Skimmer
Storage
Tank

Storage Tank

To Glycerin Plant

Process Description:
Hydrogenated material from the storage tank is fed from the bottom of splitting column at high
temperature and Demin water is introduced from the top of the column through the spargers to
increase the contact area between fatty acid and water. The temperature of process is control and
maintained by introducing the steam in through spargers at top and as well as at the bottom of the
column to carry out the uniform and smooth process. The high volatile vapors are collected from
the top of the collected from the top of column and sweet water collected from the bottom of the
column separately in the expansion vessels. Sweet water is sent to the skimmer for the removal of
the impurities (fatty acid traces).

HRBDO + Water

Crude Fatty Acid + Sweet Water

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Splitters:
Equipment used to carry out the splitting process under high pressure and temperature is known
as splitter. Basically there are two types of splitters
1. Batch Splitters
2. Continuous Splitters

Construction (Continuous Splitter):

It consists of three zones.
Two heating zones
One reaction zone
The column height is 60ft (20m). The spargers are installed to provide the steam for heating
purpose for the uniform operation. The inner body of the splitting column is constructed of
Stainless Steel while the sheet of column is of Mild Steel. Its production capacity is 1 tons per
hour.

Operation of Splitting Column:

First of all maintain the temperature of the column to carry out the smooth and uniform splitting
operation. The batch is filled with HRBDO in the 2 hours with the flow rate of 1ton\hr. Then
introduce the 50 bars steam in the Spargers at the top and the bottom of the column. The plunger
pumps the Demin water and reaction of splitting will start up in the column. The feed Demin
water and HRBDO are pre-heated. Demin water is pre-heated by the mean of bundle of plates and
heat transferred between the stream of cold Demin water and hot fluid, from the splitters outlet
(240C) to attain temperature of 80-90C. Similarly HRBDO is pre-heated by maintaining the
level of 1meter of hot sweet water at the bottom of splitting column. First, finally the hydrolysis
of HRBDO will take place in the reaction zone at high pressure of 43 bars and temperature of
250C. HRBDO will split up into Crude Fatty Acid and Sweet Water that is collected into the
separate expansion vessels from the top and bottom of the splitting column respectively. Check
the Acid Value (200) and Brix Value (6-8) of the final products. Pump the CFA from the bottom
of expansion vessel to the storage tank. And the low crude fatty acid is recycled to the splitting
column.

Acid Value:
Definition:
Its measures of free acid content of a substance. It is expressed as the number of milligrams of
KOH neutralized by the free acid present in one gram of the substance.
Or

It measure extraction amount of Crude Fatty Acid from HRBDO.

This value is sometimes used in connection with the end-group method of determining the
molecular weight of polyesters. It is also used in evaluating plasticizers, in which acid values
should be as low as possible.

Brix Value:
It measure the amount of Glycerol is obtained from the HRBDO, Palm Stearin, & blend etc.

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Controlling Parameters:

HRBDO level
Demin water level
Optimum pressure
Optimum temperature
Ratio of Fatty acid and Demin Water

Pumps:
The fluid motive devices used to transport the fluid are called pumps.

Types of Pumps:
The major classifications of pumps are
1. Positive Displacement pump
2. Centrifugal pump

Positive Displacement Pump:

Plunger Pump:
These pumps have one or more constant diameter plungers which move back and forth through
packing and glands and displace liquid from the cylinders. A plunger differs from a piston in that
plunger is longer than the stock whereas piston is shorter than the stock. Also in the case of piston
pumps, the packing is laid on the piston rim to ensure a tight seal whereas in the case of plunger
pumps, the packing is stationary and is placed either centrally or externally. Plunger is always
single acting means only one end of the plunger is used in pumping the liquid. Plunger pump are
used for high pressure e up to 140 MN/m2 or more plungers are used.

Scrubber:
Light fractions (vapors) from the expansion vessel top are injected to the scrubber bottom. The
Demin water is showered from the top of the scrubber and form FOAM with water. The foam
is drained from bottom of scrubber, which is collected into the pit.

Skimmer:
Sweet water from the bottom of the expansion vessel is sent to the skimmer for the skimming of
fatty acids traces from the top. Fatty acid and sweet water is separated into two layers on the
bases of density difference. Fatty acid layer is collected from the top of the skimmer whereas the
sweet water from the bottom is pumped to the storage tanks.

Glycerin from Glycerol:

Process Description:
The glycerol solution is first sent to the treatment tank to separate the fats from the solution by
adding the chemicals. The treated solution is then filter by the filter press. And then solution of
10% glycerin is concentrated up to 99%.
1st pass the solution from the triple effect evaporator and then pass 47% solution is filter again by
the filter press. Filter solution is introduced to the ION EXCHANGER to remove the ion from the
glycerin solution. The water is removed up to 87% and finally the solution is passed from the

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Dehydration Column to obtain the 99% concentrated solution.

Block Diagram:
Treatment
Tank

99%
Glycerin
solution

Filter Press

Dehydration
Column

Triple
Effect
Evaporator
Double
Effect
Evaporator

Carbon Tank

AIE

Ion
Exchange
r

Filter Press

BIE

Filling Drum
Treatment Tank:
Feed batch of 17 tons of the Glycerol in the treatment tank. Add HCl (PH 2-3) to break the
emulsions of the fats. Give continuous supply of Air in the tank for the easy mixing. Add NaOH
that neutralize (PH 7) the solution. The steam of 2.5 bars is being introduced in the coil for heat
the solution up to 70-80C. Allow to separate the layer on the top of the tank and 10% sweet
water is being pumped from the bottom of tank to the filter press for the removal of the fats
contamination and finally stored to the storage tanks. The concentrated is about brix 7-10.

Multi Effect Evaporator:

The 10% solution of glycerin is concentrated to the 47%. Introduce feed to 1st effect evaporator,
give 2.5 bars steam in the First effect and water vapours from first effect separator is sent to the
second effect as a heating media, similarly the water vapours from the second effect separator
will be shifted to the third effect to achieve the required concentration. And fraction of hot
solution is sent back to evaporators to achieve the better operation, 47% solution is pumped to the
storage tank.
Barometric Condenser:
Vapours 1st , 2nd & 3rd effect separator enter from the bottom of condenser and raw water is being
showered from top and leave from the bottom, created vacuum is pumped to vacuum pot.
Pressures and Temperature range
1st effect -0.5 to -0.7 kg/cm2 & (100C)
2nd effect 0.0 kg/cm2 & (80C)
3rd effect -0.7 kg/cm2 & (60C)
The final solution after condensing is stored in the Carbon tank and then pumped to the filter
press to remove the contamination of fats from the solution.
The 47% solution has the following properties
PH 5--5.5
Brix 32-35
Temperature maintained 40-45C

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Ion Exchange:
The 47% solution from the BIE (Before Ion Exchange) is pumped to the Candle filter for the
filtration of the trace of fats and then introduced to the series of the ion exchangers
The arrangements of Ion Exchangers are:
K1 (1st Cation)
A1 (1st Anion)
A2 (2nd Anion)
K2 (2nd Cation)
A3 (3rd Anion)
A4 (4th Anion)
Mixed Bed
The 47% glycerin solution is showered from the top of the column that passes from the bed of the
exchanger and leaves from the bottom of the column after exchanging the ions. The solution from
the 1st column from the bottom will enter the 2nd column top and finally the solution from the
bottom of the mixed bed ion exchanger is pumped to the AIE (After Ion Exchange) storage tanks.

Cation Exchange Process

The exchange resin contains an exchangeable hydrogen ion and can be employed to remove all
cations.
For Bicarbonates

Ca
Mg (HCO3)2
Na2

2 HR

Ca
Mg R
Na2

+ 2 H2O +

2 CO2

Calcium
Calcium
Magnesium
Bi
Cation
Magnesium
Water
Carbon
and / or
Carbonate
Exchanger
and / or Sodium
Dioxide
Sodium
Cation Exchanger
(Soluble)
(Insoluble)
(Insoluble)
(Soluble)
The symbol R represents the complex radical for the Cation Exchange Resin.
For Sulfates & Chlorides
Ca
Mg
Na2

SO4
Cl2

2 HR

Ca
Mg R
Na2

Calcium
Calcium
Magnesium Sulfate
Cation
Magnesium
and / or
and / or Exchanger
and / or Sodium
Sodium Chloride
Cation Exchanger
(Soluble)
(Insoluble)
(Insoluble)

16

+ 2 H2 SO4
Cl2
Sulfuric
and / or
Hydrochloric
Acid
(Soluble)

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Regeneration with Hydrochloric Acid
Ca
Mg
Na2

Calcium
Magnesium
and / or Sodium Acid
Cation Exchanger
(Insoluble)

2 HCl

Hydrochloric

(Soluble)

CaCl2
MgCl2
2NaCl

2 HR

Calcium
Magnesium
Cation
and / or Sodium Exchanger
Chlorides
(Soluble)
(Insoluble)

Anion Exchange Process

The exchange resin contains an exchangeable OH ion and can be employed to remove acids.
H2SO4
(Soluble)

2 R4NOH
(Insoluble)

(R4N)2SO4
(Insoluble)

2 H2O
(Soluble)

R4NOH
(Insoluble)

(R4N)Cl
(Insoluble)

H2O
(Soluble)

2 NaOH
(Soluble)

2 R4NOH
(Insoluble)

Na2SO4
(Soluble)

R4N represents the complex Anion Exchanger radical.

HCl
(Soluble)

For regeneration
(R4N)2SO4 +
(Insoluble)

Regeneration of Ion Exchangers:

Sweeting off process is used to carry out the regeneration process.

Cut off the flow of sweet water and allow the Demin water in the exchanger.
The solution from the mixed bed is pumped to the BIE tanks.
Take at least 2-3 hours to regenerate the exchanger.

Steps of Regeneration:
1.
2.
3.
4.
5.

6.
7.
8.
9.

Back wash to loosen the bed.

Mix or introduce Air to make the flow easy.
Inject Chemicals from the top to bottom of column.
HCl (10-11%) for Cation and NaOH (3-4%) for Anion exchanger.
End result is measured from the concentration of the injected chemicals. If concentration
remains same before and after injection of the chemicals. Its indicate regeneration has
been completed.
Slow rinse means allow the water to flow at the low rate to remove the excess amount of
chemicals, It takes approx. 1 hour.
Final rinse means increase the flow rate of water to obtain the required PH of the
exchangers; it takes approx. 6-8 hours for completion.
In case of mixed bed regeneration the steps will remain same but we inject the chemicals
one by one. Its takes approx. 8 hours.
The whole regeneration process takes time of 48 hours.

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Note: (Mixed Bed)
Cations are heavier than Anions, so the Cations will settle down in the exchanger while Anions
remain suspended in the air.

Double Effect Evaporator:

The solution from the AIE storage tank is pumped to the pre-heater (vapours on the shell side
from top of 1st effect separator is heating media in the pre-heater), pre-heated solution enter 1st
effect evaporator, solution from bottom of separator is introduced to the 2 nd effect evaporator
achieve the required concentration of 87% & Brix 65, and vapors is sucked from the separator by
vacuum pressure (-0.6kg/cm2) is developed by vacuum ejector. The 87% solution is pumped to
storage tank.

Dehydration Column:
The solution is pumped from the 87% solution storage tank (in closed circulation) to final
evaporator. The steam of 15 bars is used to remove the moisture from the solution. And finally
enters the dehydration column, vapours and concentrated solution is separated in final separator
and circulate to dehydration column.
The temperature range in the distillation column
Bottom 100-110C
Mid 80-90C
Top 70-80C
Barometric Condenser:
Vapours from final separator enter from the bottom of condenser and raw water is being
showered from top and leave from the bottom, created vacuum is pumped to vacuum pot.
The 99% solution is condensed, then sent to heat exchanger to transfer heat to the 87% feed and
pumped to the storage tanks and drummed.

Distillation Section:
Distillation:
It is a method of separating mixtures based on differences in their volatilities in a boiling liquid
mixture. Distillation is a unit operation, or a physical separation process, and not a chemical
reaction.
Types of Distillation:
1. Batch distillation
2. Continuous distillation
CONTINUOUS DISTILLATION; PROCESS DESCRIPTION:
The separation of liquid mixtures by distillation depends on differences in volatility between the
components. Greater the relative volatilities, easier the separation. Vapor flows up the column
and liquid counter-currently down the column. The vapour and liquid are brought into contact on
plates, or packing. Part of the condensate from the condenser is returned to the top of the column

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to provide liquid flow above the feed point (reflux), and part of the liquid from the base of the
column is vaporized in the re-boiler and returned to provide the vapour flow.
In the section below the feed, the more volatile components are stripped from the liquid and this
is known as the stripping section. Above the feed, the concentration of the more volatile
components is increased and this is called the enrichment, or more commonly, the rectifying
section. A column producing two product streams, referred to as tops and bottoms, from a single
feed. Columns are occasionally used with more than one feed, and with side streams withdrawn at
points up the column.
This does not alter the basic operation, but complicates the analysis of the process, to some
extent. If the process requirement is to strip a volatile component from a relatively non-volatile
solvent, the rectifying section may be omitted, and the column would then be called a stripping
column.

Simple Distillation:
In the simple distillation, all the hot vapors produced are immediately channeled into a condenser
that cools and condenses the vapors.

Steam Distillation:
In steam distillation, steam is introduced into the column to lower the partial pressure of the
volatile components. It is used for the distillation of heat sensitive products and for compounds
with a high boiling point. It is an alternative to vacuum distillation. The products must be
immiscible with water. Live steam can be injected directly into the column base.

Fractional Distillation:
The multi components are separated on the difference of the relative volatility and in their boiling
points. And the final product is being collected from the distillation column at the different point.

Vacuum Distillation:
In the vacuum distillation the process is carried out under vacuum that serves for the different
purpose.
1. Vacuum decreases the boiling point of the liquid.
2. Vacuum increases the relative volatility of liquid.
3. Enhance the product purity.
4. Vacuum distillation buys economy in the re-boiler energy required.
5. Increase the efficiency of the process.

Fatty Acid Distillation:

The distillers are towers with structured packing to fractionate heavy and light boiling impurities
and to ensure that the fatty acids are distilled at the lowest possible temperature.
Squeezing of the residue is carried out in the separate distiller. Condensation is carried out inside
the tower over packing with cooling of the external pump around or outside the tower in the shell
and tube condensers. In both cases heat is recovered generating low pressure steam. Centrifugal
pump with suppressed vaporization re-boiler is proposed according to the case.

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Process Description:
Start up the furnace for heating the Heat Transfer Oil. Then start the ejector to develop and
providing the vacuum to the system. Introduce the Crude Fatty Acid is distill to pure Fatty Acid
(Stearic Acid). The top product of the splitter is pumped to the flash drum\ feed tank and
introduced in to the distiller (FD4, FD5) from bottom of the column. High volatile vapors are
collected from the top of the distillation column. The vapors are cooled down and condensate in
the Main condenser and vapor is cooled by transferring the heat by Heat Transfer Exchanger type
cooler. The condensed highly volatile vapors are then sent to the scrubber where low volatile
vapors are separated from high volatile vapors and recycled to distill column. The condensed
vapors are partially sent back to the distill column as reflux. HFA is stored in the tank. Residue is
collected from the bottom of the column and the heat is recovered from the residue by passing it
from the shell and tube type Heat Exchanger that providing the live steam in the column.

Furnace:
Before starting the process of distillation start up the furnace. The Heat Transfer oil is introduced
in the tube side of the furnace and heat is provided into the furnace by the combustion of the fuel
gas with air in the burner at the top of the furnace and fuel gases exit from the stack. HTO is
heated up to 300-325C and rise temperature of the fuel uniformly with the interval of 50C/hour
to avoid the thermal shocks. The heat of HTO transfers to heat to the feed of distillation column
and sent back (recycled) to furnace. Ratio of natural gas to air is kept 1:9 for the complete
burning and running the smooth operation.

Ejector:
After startup of the furnace, start the Vacuum system to run the smooth operation. Many chemical
plants, particularly distillation columns, operate at low pressures, and pumps are required to
create and maintain the vacuum. Vacuum pumps take in gas at very low pressures and normally
discharge at the atmospheric pressure, and pressure ratios are therefore high.

Steam Jet Ejector:

It is most commonly used in the process industries since it has no moving parts and will handle
large volumes of vapors at low pressures. The steam required increases with the compression
ratio so that a single stage unit will operate down to about 17 KN/m2 corresponding to
compression ratio of 6:1. For lower final pressures multistage units are used, and shows the
relationship between the number of stages, steam pressure and vacuum required. If the cooling
water is applied between the stages an improved performance will be obtained.
As a guide, a single-stage unit gives a vacuum to 13.5 KN/m2, a double stage form 3.4 to 13.5
KN/m2, and a three-stage unit form 0.67 to 2.7 KN/m2.

Working:
The steam of high pressure 15bars and low velocity passes through the nozzle develop the static
pressure 3-5mbars and high velocity.

Distillation Column (FD4):

The Crude Fatty Acid is pumped from the storage tank to the feed tank and it is first preheated in
the shell and tube heat exchanger1 with the help of 2.5 bars steam that result the rise in
temperature up to 100-120C.

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Introduce the preheated feed into the flash tank to remove the moisture form the feed with the
help of vacuum and finally fed to the distillation column candles. Candles are co-centric pipes the
feed is introduced in the inner pipes and steam is on the outer pipe side. So heating media is
Steam in FD4. And the temperature of the feed is obtained up to 200C. Live steam of 50 bars is
given in to the column to carry the operation at optimum conditions (High temp 240C). The
vacuum of 3-5mbars from the vacuum pump is given at the top of the column to collect the highly
volatile vapors from the top. The collected vapors (at 240C) are condensed in the condenser
shell and tube type heat exchanger the vapors are introduced in the tube side and cooling water is
introduced on shell side from the top of the exchanger and leaves from the bottom and sends back
to the cooling tower. The condensed vapors leaves from the bottom and finally sent to the
scrubber where the LFA is being separated from the distilled fatty acid. Distilled Fatty Acid is
pumped to the storage tanks and some part of DFA is sent back to the distill column from the top
as reflux to increase the purity and productive. LFA is pumped to the separate vessel. Residues
are continuously removed from the bottom of the distill tower and is pumped (at 80-90C) to the
residue tanks after transferring their heat to the feed (CFA).

Distillation Column (FD5):

In the FD5 re-boiler is installed at the bottom of the column, in which HTO is being circulated to
give up it heat. For the heating of HTO we use furnace operating at the temperature of 300C.
Column temperature is kept at 240C and 43 bars pressure. DF5 is consisting of pack and trays to
increase the contact area between CFA and steam to increase the yield. The plates spacing are 2ft
in the column.

Difference Between FD4 & FD5:

FD4
Heating media is Steam.
Candles are installed for pre-heating the feed.
Packing is used to increase the contact area.

FD5
Heating media is Heat Transfer Oil.
Re-boiler is installed for pre-heating the feed.
Packing and trays are used to increase the area.

Flakers:
It is the process of converting the liquid into the flakes. The DFA from the distillation section is
introduced into flakers basin and the level is controlled by the Auto lever. Chilled water is
circulated in the drum at the temperature of 2-3C and drum is rotated at 5-6 rpm. When Stearic
acid comes in contact with the chilled water its solidified and continuously removed from the
drum by the knife/blades attached the drum. The final product in the form of flakes is sent for
bagging and the each bag is of 25kgs.

Block Diagram:

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Chilled water
(2-3C)

Stearic Acid

Flakes &
Bagging

Flaker

Storage

Refrigeration
Cycle
Grade of Stearic Acid:
There is basically two types of Stearic Acid is supplied.
1. Stearic Acid DP (Double Press)
2. Stearic Acid TP (Triple Press)
Stearic Acid TP:
Its Iodine Value ranges less than ONE.
Stearic Acid DP:
Its Iodine Value ranges between 2-3.

Soap Noodles Plant:

Saponification:
Definition:
Saponification is the chemical reaction that occurs when fats or oils (fatty acids) come into
contact with lye (a base.) Saponification literally means "soap making" from the root word,
"sapo", which is Latin for soap. The by-products of the saponification reaction are glycerin and
soap.
Oils and fats will also have what is called a saponification value, which is the amount of lye
needed to completely neutralize them into soap with no lye left over. Each Oil has a different
value, which is why its important to always run your recipes through a lye calculator.

Process Description:
The measured amount Blended DFA, Caustic Soda liquor, Hot Demin Water, CNO\PKO are
introduced in the Crutcher, and the saponification process will take place. The mixture is
continuously agitated in the presence of air for easy mixing. After completion of the reaction the
Neat Soap is transferred through the pump to Filter to remove the impurities from the Neat Soap
originated during Saponification. Finally the Neat Soap is shifted to the Feed Tank, and pumped
to the Shell and Tube type Heat Exchanger on the Tube side, while the steam is given on the Shell
side and after transferring its heat to the soap it self condensed and leave the exchanger from the
bottom. The Neat Soap is injected to the Vacuum Spray Chamber through a revolving Nozzle,
which sprays a thin film of soap on the internal walls of the Chamber. As the Plant is under
vacuum, evaporation takes place. The quantity of water evaporated and the temperature of the

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Neat Soap on the heat content of Neat Soap and related vacuum in the system.
The dry and cooled mass is removed from the Chamber and shifted to the plodder that,
homogenizes, refines, compresses and extrudes the dried Soap in the form of the Noodles. And
send to the Hopper through the Conveyer Belt. And finally the Soap Noodles are packed and
bagged.

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Block Diagram:
Blended
DFA
Caustic
Soda
Hot DW

PKO\CNO

C
R
U
T
C
H

Vacuum
system

Feed
Tank

Filter

E
R

Packing

Heat
Exchanger

Hopper

Spray
Chamber

Plodder

Soap:
The alkali and ammonium salt of fatty acid (metallic soaps are excluded) that have an appropriate
combination of cleaning; lathering and surfactant properties are called Soap.
Fatty acids of 8-22 chain length are the most common constituents of the commercially
produced soaps.
Most soap has some degree of water solubility.
Both saturated and unsaturated fatty acids are used in the production of soaps.
The final product is not only a mixture of alkali salts of several fatty acids but it also contains
many other substances which are designed to increase its cleansing power, to make it more stable,
to improve its appearance and to make it attractive to the end user.

Soap Manufacturing Process:

When an oil or fat is boiled with a solution of Caustic Soda the resultant products are soap and
glycerin. It is manufactured from Triglycerides. In practice any oil or fat can be used for making
soap and its usage depends upon its suitability, availability, and price. These Triglycerides are
obtained from both nature (seed oil) and animal (animal fat).

Detail Factors:
Reaction between neutral fats and caustic alkali dont start spontaneously. For the initiation of
reactions of this kind, certain conditions must be fulfilled. The saponification reactions will starts
when one of the following condition will fulfilled:

Fats contains low molecular weights (Coconut Oil, Palm Kernel Oil) are agitated with
highly conc. Caustic Alkali solution at low temperature.
When oil or fats is mixed with conc. NaOH at low temperature in the presence of suitable
catalyst.
By mixing preheated fats and concentrated alkali and maintaining an evaluated
temperature (90C) during agitation.
By boiling the fats with Aqueous Caustic Soda of various concentrations.

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By heating fats with alkali under pressure.

Crutcher:

(DFA: CNO/PKO 90:10)

90% of (out of total requirement for one batch) liquid Caustic Soda is taken in the
Crutcher, simultaneously the steam in the jacket is also turned on. The agitator of the
Crutcher is also started.
Pre heat Fatty acid (60-70C) from the feed tank is slowly added in to the Crutcher with
constant agitation.
A good exothermic reaction will take place. The addition of Fatty Acid is controlled such
that the soap mass doesnt over flow from the Crutcher.
After adding all the Fatty Acid the mass is allowed to mix for 10-15 minutes. Soap
sample is taken and tested the Free Alkali.
Based on the Free Alkali result calculated amount of Caustic Soda is added to the
Crutcher and mass is allowed to mix for 15 min.
After the sample is analyzed for the Free Alkali, and final Alkali adjustment is done by
adding required amount of the Caustic Soda or Fatty Acid.
After the final adjustment the mass is mixed thoroughly, and some water is added to keep
the mass in a good fluid condition.
Preservatives and other required chemicals are mixed with the mass, and the Neat Soap is
discharged or shifted to filter.

Filter:
Neat Soap transfer pump feeds the Neat Soap through a Soap Filter to Soap Feed Tank. Filter
removes the impurities from the Neat Soap that are originated during Saponification.

Heat Exchanger:
The Soap from the Neat Soap Storage tank or Feed Tank is constantly fed by a Gear Pump in to a
Heat Exchanger to heat the Soap to get required temperature (90C). The Shell and Tube type
heated the soap counter currently with the steam that is on the Shell side of the Exchanger. The
feed pump is coupled with variable speed drive, such that the flow rate of the Soap to the Dryer
can be adjusted as per requirement.

Vacuum Spray Dryer:

The heated soap at 80-90C is sprayed through a revolving nozzle at the angle of 180 in to the
vacuum spray chamber. Vapours are flashed off and the cooled soap film formed on the internal
walls of the chamber is removed by rotating scrapers. The soap in irregular shaped flakes falls in
to a simplex plodder which converts into noodles.

Function Of Plodder:
Plodder worm performs three functions: refining, compression, and extrusion. The chilled water
is to be circulated through the plodder to control the product temperature passing through the
rolls.

Vacuum Formation & Condensation:

A vacuum pump generates and maintains the operating level in the system. The vapors are

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condensed in a Barometric or surface condenser.

Hopper:
The Soap Noodles are transferred to the hopper through the conveyer belt for packing in the bags.

Rancidity:
Its show change in the Color, Odour, spoilage, and potential toxicity substances.

Problem Of Rancidity:
Of all the enemies, which reduce the shelf life of bar soap product, the development of the
rancidity is the most foreseen. The following factors critically influence the development of
rancidity of off-odours, spoilage, and potentially toxic substances.

Factors Causing Rancidity:

Fat Blend
Free Fatty Acid
Temperature of Operation
Degree of Un-saturation
Metal Ions
Operating Conditions of Process

Soap Analysis:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.

Acid Value
Iodine Value
Free Fatty Acid
Moisture and Volatile Matter
Free Caustic Alkali
Un-saponifiable Matter
Color
Odour
Whiteness of Sodium Soap
Rancidity Test

Boiler:
A boiler is defined as "a closed vessel in which water or other liquid is heated, steam or vapor is
generated, steam is superheated, or any combination thereof, under pressure or vacuum, for use
external to itself, by the direct application of energy from the combustion of fuels, from
electricity or nuclear energy."

Type Of Boilers:
There are basically two types of boilers.
1. Water tube boiler.
2. Fire tube boiler

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Water-Tube Boiler:
A water tube boiler is a type of boiler in which water circulates in tubes heated externally by the
fire. Water tube boilers are used for high-pressure boilers. Fuel is burned inside the furnace,
creating hot gas which heats water in the steam-generating tubes. In smaller boilers, additional
generating tubes are separate in the furnace, while larger utility boilers rely on the water-filled
tubes that make up the walls of the furnace to generate steam.

Diagram Of A Marine-Type Water Tube Boiler:

Explanation:
The heated water then rises into the steam drum. Here, saturated steam is drawn off the top of the
drum. In some services, the steam will reenter the furnace through a super heater to become
superheated. Superheated steam is used to drive turbines. Since water droplets can severely
damage turbine blades, steam is superheated to 730 F (388 C) or higher to ensure that there is
no water entrained in the steam.
Cool water at the bottom of the steam drum returns to the feed water drum via large-bore 'downcomer tubes', where it pre-heats the feed water supply. (In 'large utility boilers', the feed water is
supplied to the steam drum and the downcomers supply water to the bottom of the water walls).
To increase economy of the boiler, exhaust gases are also used to pre-heat the air blown into the
furnace and warm the feed water supply. Such water tube boilers in thermal power station are
also called steam generating units.

Fire-Tube Boiler:
The older fire-tube boiler design in which the water surrounds the heat source and the gases
from combustion pass through tubes through the water space is a much weaker structure and is
rarely used for pressures above 350 psi (2.4 MPa). A significant advantage of the water tube
boiler is that there is less chance of a catastrophic failure: there is not a large volume of water in
the boiler nor are there large mechanical elements subject to failure.

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Block Diagram:
Condensate

De-aeration

Tank

Boiler

Process

SNP
CSP

Steam
Reducing

Steam

Distribution

Header

50 Bars

Head

FAP

Economizer
(E1, E2)

Steam Drum

Super

Heaters

(S1, S2)

Condensate Tank:
It is main condensate feed tank which collect the condensate from the plant and sent for treatment
to de-aeration tank.

De-aeration Tank:
The feed from condensate tank is pumped to the de-aeration tank. In this section the process is
carried out in two sections. In the top of the tank the physically the dissolved oxygen is removed
by passing the feed through the number of plates attached to the walls of the tank. In the bottom
section the process is carried out by the chemicals means for complete removal of the DO from
the feed water of the boiler. The steam of 2.5 bars is provided through the spargers at the bottom
of the tank and Ammonia, N2H4, & Sodium phosphate is added for the removal of DO from
boiler feed water.
Phosphate Injection:
To remove sludge and scale formation, Sodium Phosphate reacts with Ca to form Tri-calcium
phosphate. Ca, Mg removed by blow down.
Hydrazine Injection:
Oxygen originated directly from Boiler feed water/condensate. A portion will be flashed/leave
boiler with steam. Dissolved Oxygen attack the boiler metals.
N2H4 + O2

2H2O + N2

Boiler:
The feed water enters the boiler. Fuel (Natural Gas, or Diesel) and air mixture (in definite ratio)
combust in burner and provide the heat energy. The temperature of the burner is about 1200C
and that transfer its energy before leaving from stack.

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Economizer:
Its some sort of heat recovery unit. The high temperature fuel gases passes through the
economizer after passing through super heater. The heat is transfer to boiler feed water before
introducing to the boiler to convert it in to steam. The boiler feed water is pre-heated by the fuel
gases heat transfer. The water in the tube of the boiler converted in to the steam.

Steam Drum:
The feed water in the tubes of the boiler is converted to the steam and sent to the steam drum.

Super Heater:
The steam from the Steam Drum is finally passes through the super heaters (S1, S2) and being
super-heated.

Stack:
The high temperature fuel gases first passes through the super heater and then through the
economizer and transfer its heat energy leaves through the stack at 150C.

Steam Header:
The high pressure steam of 50 bars is finally sent to the steam header to distribute the steam to
SNP, CSP, FAP and PH.

Water Treatment plant:

Water Treatment:
Describes those processes used to make water more acceptable for a desired end-use. These can
include use as drinking water, industrial processes, medical and many other uses. The goal of all
water treatment process is to remove existing contaminants in the water, or reduce the
concentration of such contaminants so the water becomes fit for its desired end-use. One such use
is returning water that has been used back into the natural environment without adverse
ecological impact. The processes involved in treating water for drinking purpose may be solids
separation using physical such as settling and filtration, chemical such as disinfection and
coagulation.
Biological processes are also employed in the treatment of wastewater and these processes may
include, for example, aerated lagoons, activated sludge or slow sand filters.

Core Reason Of Water Treatment For Boilers And Cooling Tower:

Boilers and cooling towers share two major water related problems: deposits and corrosion. As
steam is generated by a boiler or water evaporating from a cooling tower, dissolved minerals are
left behind, increasing the concentration of these minerals. Additional minerals are introduced via
the water added to makeup the water lost to steam/evaporation. Eventually, the minerals reach a
level (or cycle) of concentration that will cause either loss of efficiency due to scale or damage
from corrosion. This correlated to a conductivity or TDS range. Most people recognize problems
associated with corrosion. Effects from scale deposits, however, are equally important. For
example, as little as 1/8 of scale can reduce the efficiency of a boiler by 18% or a cooling tower
heat exchanger by 40%!

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A variety of water treatment methods are employed in an effort to control these problems. Even
with water treatment, it is still necessary to regularly blow down or bleed off part of the
concentrated water and make up with lower salinity water to reduce the overall mineral
concentration. To conserve water and treatment chemicals, it is desirable to allow the dissolved
minerals to reach a maximum cycle of concentration while still avoiding problems. Because feed
water/make-up waters vary in the types and amounts of minerals present, the allowable cycles of
concentration will vary. As a result, regular testing of boiler and cooling waters is essential to
optimize water treatment programs and blow down schedules. Tests commonly performed
include conductivity or TDS, pH

Conductivity:
Conductivity is the measurement of a solutions ability to transmit an electrical current. It is
usually expressed in micro Siemens / cm (micromhos / cm). Pure water is actually a poor
electrical conductor (18,200,000 ohms/cm of resistance). It is the amount of ionized substances
(or salts) dissolved in water which determines the conductivity. Because the vast majority of the
dissolved minerals in water are these conductive inorganic impurities, conductivity measurement
is an excellent indicator of mineral concentration.

Boiler Water:
Corrosion, scale and deposits cause piping and mechanical failures, and increased fuel
consumption by reducing heat transfer efficiency. Water treatment programs control scale,
corrosion and sludge build-up on heat transfer surfaces and throughout your boiler systems.
Solutions maintain steam purity and quality, and help reduce energy and maintenance costs while
maximizing asset life and efficiency.
Boiler water requirements can range from very pure to more than 6500 micro siemens, depending
on size, pressure, application, and feed water. Once the maximum cycles of concentration has
been established, a conductivity instrument can conveniently help you to determine if the blow
down schedule is adequate. Samples should be cooled to at least 160F/71C to ensure accurate
temperature compensated readings.

Boiler Condensate:
Boiler condensate samples are often tested to determine if there is any carry-over of boiler water
solids or contaminants entering from outside the system. Condensate is relatively pure water, and
values of 2-100 micro siemens are common. Because of these low values, a multiple-range
instrument is recommended to increase the resolution and accuracy of the reading. Monitoring the
pH of condensate is also important since condensate is very corrosive at low PHS. Treatment
additives are often added to elevate the pH to minimize corrosion in condensate lines.

Cooling Tower Water:

Cooling water treatment programs are designed to control mineral deposits, debris build-up and
bio-film growth. Our chill water programs can significantly reduce energy and maintenance costs
and help to insure environmental regulation compliance.
Cooling tower water has become more challenging since the reduced use of acid and the
elimination of chromate. Monitoring conductivity and pH has become imperative to maintain a
proper treatment program. Although many systems have controls on these parameters, the
possibility of a system upset is always present. Even slight upsets can cause rapid scaling of heat

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exchangers.

Biological Growth:
Biological growth is another extremely important facet to proper cooling water management.
Microbes can cause corrosion, fouling, and disease. Oxidizing biocides (chlorine, chlorine
dioxide, ozone and bromine) have been employed to keep bacteria under control. Monitoring of
the ORP (Oxidation Reduction Potential)/REDOX are very useful in its ability to correlate
millivolt readings to sanitization strength of the water. Corrosion and scale inhibitors protect
multi-metal systems from a wide range of mineral deposits and corrosive processes. Dispersants
effectively remove rust, sand, mud and other debris from tower and pipe surfaces, and our EPAapproved biocides safely and reliably control algal, fungal and bacterial slimes.

Objective:

The main purposes to treat the raw water are:

To remove completely dissolved solids.
To remove chemical minerals.

Process Description:
The raw water after removal is stored in the storage tank is pumped to the Cation exchanger
vessel to remove cations and then sent to de-gasifier to remove the carbon dioxide from the water.
Introduce water from the de-gasifier to Anion exchanger vessel to remove anions from water.
And finally pass water through the Mixed Bed to improve the process water quality.

Cation Exchanger:

40 m3/hr raw water is feed to the cation exchanger.

There are two vessel of Cation bed vessel. One is taken in operation and second is Stand By.
Cation exchanger contains Cation Resins.
Raw water is showered at the top of the bed and water flows through the bed while
exchanging positively charged Metallic Ions.
Residence time depend on the concentration of the dissolved solid.
Main reactions that take place in Cation exchanger.

Na2
Ca (HCO3)2 + RH2
Mg

Na2
R Ca + 2H2CO3
Mg

2NaCl
Na2SO4 + RH2

HCl
RNa2 + H2CO3
2HNO3
RMg + H2SiO3

MgSiO3 + RH2

Out let of cation water contains FMA and Nil hardness.

De-gasifier:
Now water is sent to the de-gasifier. Water is sprayed from top over the packed bed of rashing
rings. Air from de-gasifier blower rises and come in contact counter-currently with falling water
droplets. H2CO3 (weak acid) in the de-gasifier, due to partial pressure difference CO2 carried out

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with air. And 80-85% CO2 leaves the water. Carbon dioxide comes out of the solution

accordance to Henry & Dalton s law

Amount of CO2 is proportional to partial pressure of gas in atmosphere.
Amount of CO2 is inversely proportional to the temperature.
H2CO3

H2O + CO2

Anion Exchanger:
The water from the de-gasifier is sent to the Anion exchanger for the removal of anions.
Water from the weak anions are treated here as in the same manner of cations are treated.
Strong acid are retained by the bed of anions.
2HCl
H2SO4 + ROH

Cl2
R2SO4 + 2H2O
NO3
Weak acids like H2CO3 and H2SiO3 shows nil FMA and dont show the acidity.
H2SiO3 + 2ROH
H2CO3 + 2ROH

R2SiO3 + 2H2O
R2CO3 + 2H2O

Demineralized water conductivity is 1-3

PH 7.5-8.5
Mixed Bed:
The water is finally sent to the mixed bed for the purification.
Here the dissolved solid is reduced to the <0.1PPm
And Silica is reduced to about <0.005PPm
Regeneration:
General Indication of Regeneration:
1.
If FMA at outlet decreases by 2-3ppm (cations).
2.
If FMA at outlet >3 ppm (anions).
3.
PH<7.5
4.
Slippage of FMA
5.
Hardness from Cations boosts up conductivity at Anion outlet, PH decrease.
6.
Permissible limit of SiO2 is 0.05ppm.
7.
If at outlet of Anion >0.05ppm.
8.
Flow rate becomes more, causes slippage of Na+, SiO2.
Cation Resins:
Na2
CaR + 2HCl
Mg

Na2
RH2 + CaCl2
Mg

32

NIMIR
Anion Resins:
Cl2
RSO4 + 2NaOH
(NO3)2
RCO3 + 2NaOH
SiO3

Cl2
R (OH) 2 + Na2SO4
(NO3)2
R (OH) 2 + Na2CO3
SiO3

Lab Analysis:
Raw Material:

Acid
Value

Iodine
Value
(Min.)

Free Fatty
Acid %
(Max.)

Slip
Melting
Point oC
(Max.)

Moisture
% (Max.)

Saponificat
ion Value

Total
Fatty
Matter

Per
Oxide
Value

01.

Palm Stearin

--

32
Min.

0.4 %
(as
Palmetic)

54 Max.

0.2%
Max.

199 Min.

99%
Min.

10 Max.

6.0

--

15
Max.

02.

Palm Oil

--

50
Min.

0.12%
(as Oleic)

38 Max

0.1%
Max.

198 Min.

99%

1.0 Max.

--

--

03
Max.

03.

Palm Stearin
- Blended

--

42
Min.

0.4% (as
Palmetic)

51 Max.

0.2%
(Max.)

198.0

99%

10 Max.

6.0

--

15
Max.

Fatty Acids Plant:

Method /
Equipment

Frequency

Sampling
Location

Specifications

Responsible
for Test

Acid
Value

By Titration

02, 02 / Shift

Splitters # 1, 2, 3

Depend upon the nature

of material (Min. 190 for
Palm Stearin)

Analyst

Brix

Refractometer

02, 02 / Shift

Splitters # 1, 2, 3

05 ~ 10

Analyst

Brix

Refractometer

04 / Shift

Glycerin 47%

25 ~ 32

Analyst

Brix

Refractometer

04 / Shift

Glycerin 87%

60 ~ 63

Analyst

Brix

Refractometer

04 / Shift

Glycerin 99%

68 ~ 71

Analyst

Iodine
Value

Wijis Titration
Method

Batch wise (1
batch = 5
tons)

Auto Clave
(Hydrogenation)

Less than 1

Analyst

Iodine
Value

Wijis Titration
Method

01 / Shift

Flaker

Less than 1

Analyst

Slip Melting
Point

Batch wise (1
batch = 5
tons)

Auto Clave
(Hydrogenation)

56 ~ 58

Analyst

01 / Shift

Flaker

54 1

Analyst

01 / Shift

Splitter # 03

50 1

Analyst

Test

Melting
Point
Melting
Point
Melting

Unit

C
C

Slip Melting
Point
Slip Melting

33

Color
(Lovibond
5.25")
Yellow

Red

Type of
Material

Color
(G.Scale)

S.
No.

NIMIR
Point

Point

Melting
Point

Slip Melting
Point

01 / Shift

Distillation # 01

50 1

Analyst

Moisture
Contents

Oven Method
(loss in weight)

01 / Shift

Flaker

Max. 0.5%

Analyst

By Tintometer
(Lovibond)

04, 04 / Shift

Distillation # 01 &
02 + Flaker

Depends upon the nature

of material (for Palm
Stearin, Palm Oil, Palm
Blend) Y = 1.4 & R = 0.3
Max.

Analyst

Color

Boiling
Point

Direct Heat to
boil

01 / Shift

Glycerin 99%

250 1

Analyst

H.T.T

By Tintometer
(Lovibond)

01 / Shift

Glycerin 99%

Y = 1.5 & R = 0.3 Max.

Analyst

Soap Noodles Plant:

Test

Unit

Method /
Equipment

Frequency

Sampling
Location

Specifications

Responsibility

Moisture

By Moisture
Analyzer

Batch wise (01

batch = 03 tons)

C.R. 5

30 1

Analyst

Moisture

By Moisture
Analyzer

01 / Shift

C.R. 1

0.5% Max.

Analyst

Acid Value

By titration

01 / Shift

C.R. 1

208 ~ 214

Analyst

Color

Tintometer

01 / Shift

C.R. 1

Y = 1.4 & R=
0.3(Max. Range)

Analyst

Slip Melting
Point

01 / Shift

C.R. 1

50 1

Analyst

Iodine
Value

Wijis Titration
Method

01 / Shift

C.R. 1

41 1

Analyst

Per Oxide
Value

By Titration

01 / Shift

C.R. 1

5.0 Max.

Analyst

Reflux Titration
Method

01 / Shift

C.R. 5

0.03 Max.

Free Fatty
Acids

Reflux Titration
Method

01 / Shift

C.R. 5

Less than 1.0

Iodine
Value

Wijis Titration
Method

01 / Shift

C.R. 5

32 ~ 37

Melting
Point

Na2O

Analysis on Raw Water:

S.
No.

Type of Material

01.

Cooling Water

02.

Demin
.
Water

Cation

Chloride

pH

PPM

PPM

250 Max.

6.7 ~
6.8

--

3.2 ~
3.3

SiO2

FM
A

N2H
4

Hardne
ss

PO4

OH (Alkalinity)

19 ~
22

--

--

--

--

--

--

--

--

22
~
25

--

--

--

--

TH

Ca++H

Mg++H

TDS

CrO4

PPM

PPM

PPM

PPM

PPM

1500 ~
2000

800 ~
850

600 ~
650

200 ~
230

1100 ~
1140

--

--

--

--

--

Cond.

34

NIMIR

03.

Boiler
Water

Anion

--

8~9

< 10

--

--

--

--

--

0.05
Max.

--

--

--

--

--

Mix.
Bed

--

5.3 ~
5.7

<1

--

--

--

--

--

0.02
Max.

--

--

--

--

--

Blow
Down

--

10 ~
10.8

150 ~
200

--

--

--

--

--

< 10

--

Nill

Nill

4~6

20 ~ 30

Feed
Water

--

9 ~ 9.8

9 ~ 15

--

--

--

--

--

0.02
Max.

--

0.2 ~
0.5

Nill

--

--

Conde
nsate

--

8.8 ~
9.5

9 ~ 15

--

--

--

--

--

0.02
Max.

--

--

Nill

--

--

35