DESIGN OF A PLANT TO PRODUCE A TON PER BATCH OF

LIQUID DISH-WASHING SOAP

BY

". f
,~~-'

GROUP 1

A PROJECT SUB'MITTED TO THE

DE~ ARTMENT OF CHEMICAL ENGINEERING,
FEDERAL U~IVERSITY OF TECHNOLOGY, MINNA, NIGERIA

IN PARTIAL FULFILMENT OF THE REQUIREMENT FOR THE AWARD OF

BACHELOR OF -ENGINEERING (B. ENG) DEGREE IN CHEMICAL
ENGINEERING

NO,(EMBER,2010
 GENERAL INTRODUCTION

plant design titled 'The design of a plant to produce a ton per batch of liquid soap' was

out by the entire members of the plant design group 1. The introduction and literature

was done collectively by the group. The material and energy balances, equipment and

Imecnamlcal design was done by Adams Abdulrazaq (2005/21700 EH). Calculations on vessel

pressures and thicknesses was done by Eboh Uchechukwu (2005/21734 EH). The flowsheet

was drafted collectively by the group and drawn by Achanya Bridget (2005/21699 ElI). The

optimization of the plant was also done by the group. Safety and risk assessment was

conducted by Abiodun Folake (2005/21697 EH). The quality control was done by Aboderin

Toluwalase(2005/21698 ElI) with assistance from Adegbosin Solomon (2005121702 ElI)

and additions by Adanu Emmanuel (2005/21701 EH). The process control was done by

Abdulkareem Idris (2005/21695 ElI) with contributions from Abba Mansur (2005/21694

ElI). The piping and instrumentation diagrams were drawn by Eboh Uchechukwu

(2005/21734 EH) with assistance from Oriolowo Oloruntoba (2005/21788 ElI).

Environmental acceptability was done by Achanya Bridget (2005/21699 EH) while Adeniyi

Folashade (2005/21704 ElI) drafted the start up, emergency and shut down procedures for the

plant. The site for plant location and plant layout was done collectively by Achanya Bridget

(2005/21699 ElI), Abiodun Folake (2005/21697 ElI), Aboderin Toluwalase (2005121698

ElI). and Adeniyi Folashade (2005/21704 ElI). Economic analysis was done by Adams

Abdulrazaq (2005/21700 EH) and Adanu Emmanuel (2005/21701 EH). Finally, the typing of

the entire project work was done collectively by the group.

 DECLARATION

We declare that the work in the project (thesis) entitled 'Design of a plant to produce a ton

per batch of liquid soap' has been performed (carried out) by us under the supervision of

Prof. lO. Odigure. No part of this project report (thesis) was presented for another degree

or diploma elsewhere at any institution to the best of our knowledge.

Abba Mansur Signature Date

(2005/21694 EH)

Abdulkareem Idris Signature Date

~
(2005/21695 EH)

Abiodun Folake Emmanuel Signature Date

(2005/21697 EH)

Aboderin Toluwalase Ajibola Signature Date

(2005/21698 EH)

Achanya Bridget Ene Signature Date

(2005/21699 EH)

Adams Abdulrazaq Abiodun Signature Date

(2005/21700 EH)

AdanuEmmanuel Ngbede Signature Date

~
(2005/21701 EH)

Adegbosin Solomon Olalekan Signature Date

(2005/21702 EH)

Adeniyi Folashade Signature Date

(2005/21704 EH)

Eboh Uchechukwu Signature Date

(2005/21734 EH)

Oriolowo Oloruntoba gnature

. . ~1 \l.~;PS\~
Date
.(2005/21788 EH)
iii
 CERTIFICATION

This is to certify that this project report (thesis) entitled 'DESIGN OF A PLANT TO

PRODUCE A TON PER BATCH OF LIQUID SOAP' by GROUP ONE meets the

requirements for the partial fulfillment of the award of Bachelor of Engineering (B.Eng)

degree in Chemical Engineering, Federal University of Technology, Minna.

Date
Prof.J.O.Odigure

Project Supervisor

Date
Prof. F. Aberuagba

Head of Department

External Examiner Date

iv
 ACKNOWLEDGEMENT
We are grateful to God Almighty (Allah) for His guidance and strength He bestowed on us

that we may complete this project successfully.

,
Our sincere appreciation to our supervisor, Prof. J.O. Odigure for his time, diligence and

impressive supervision of this project work. We say a big thank you.

To our colleagues and friends, we thank you and will miss you all.
 ABSTRACT

The title of the design work is "The design of a plant to produce a ton per batch of dish

washing liquid soap". In order to achieve this, preliminary studies of the soap production

process was carried out. With the knowledge of the basis, the material and energy balances

were done for the process on a basis of 100 kmollbatch; the proc.ess flow sheet was drawn

and mechanical design of the equipment was done. A detailed process control with a piping

and instrumentation diagram was done for the plant. Start up and shut down procedures for

the plant was drafted. Environmental impact and risk: assessme'nt cum safety and quality

control for the plant and products produced were conducted in order to evaluate and ensure

the longevity ofthe plant and maintain a high quality for the products. The cost and economic

analysis were carried out using the detailed factorial method, the total capital investment was

determined to be N 6,299,021.80 and the annual production cost was N 54,993,183.58. With

a net income of N 28,829,621.34, the pay-back time was 2 years 3 months corresponding to a

rate of return of 44.61 . The plant was estimated to have a project life of 20 years.

v
 TABLE OF CONTENT

Cover page

11
Declara~ion

iii
Acknowledgment

iv

-
Certification

v
Abstract

VI
Table of content

Chapter one

1.0 Introduttion
f

1.1 Soaps

1-.1.1 History of Soap Making

2
1. ].2 Soap Making

3
1.1.3 Dish Washing Liquid Soap

3
1.2 Fats and oils

5
1.2.1 Blend of Oils

6
1.3 Coconut oils

7
i.3. i Physical Properties of Coconut Oil
"

7
1.3.2 .Chemical Properties of Coconut Oil
....

7
1.3.3 Application of Coconut Oil

8
1.4 Alkali (lye)

8
1.5 Caustic potash from agricultural waste

I 8
1.5.1 Physicochemical Properties of Caustic Potash

9
1.6 Glycerine
....
<)
1.6.1 Uses of Glycerine

9
1.7 Design data

I()
1.8 Problem statement

10
1.9 Product specification

10
1.10 Methodology

-
Chapter Two

II
2.0 Literature review

I1
2.1 Chemical reaction kinetics and mechanism of soap making

12
2.1.1 Reaction Kinetics

32
2.1.2 Reaction Mechanism

33
2.1.3 Factors Affecting the Chemical Reaction

34
~1.4 Ways of Improving the Saponification Reaction

35
2.2 Description of various processing Technologies

35
2.2.1 The Cold Process
....

, 36
2.2.2 Semi Boiled Process

37
2.2.3 Full Boiled Process

38
2.2.4 Alternative Technique for Full Boiled Process

40
'2.2.5 Continuous Process

41
2.3 Detailed prbcess of the selected Technology
,

43
2.4 Justification of the selected Technology

Chapter Three

45
3.0 Material Balance

Chapter Four

56
4.0 Energy balance
-
Chapter Five

67
5.0 Flow sheet

Chapter Six
6X
6.0 Equipment design

68
6.1 Equipment design of oil mixer

68
6.2 Equipment design of caustic mixer
...
69
6.3 Equipment sizing of reactor
69
6.4 Equipment sizing of finishing mixer (neat)

69
6.5 Equipment sizing of finishing mixer(nigre)
Chapter Seven

7.0 Mechanical design 70

7.1 Design of the oil mixer (agitator) to blend the oils 70

-
7.1.1 Determination of the required agitation intensity 70

7.1.2 Computation of required impeller pumping capacity 71

7.3 Design of a mixer to dissolve alkali in water 77

,I
,,
i
7.4 Design of the reactor 81

7.5 Design of the finishing mixer 86

7.6 Design of decanter 88

7.7 Vessel pressures and thicknesses 89

Chapter Eight

8.0 Reactor/ Equipment Optimization 95

Chapter Nine

9.0 Safety

9.1 Basic preventive and protective measures

9.2 Safety measures of the liquid soap plant 97

97
9.2.1 Personal Safety.

9.3 Relevant safety instructions in operating the liquid soap plant 98

98
9.3.1 Operational Instructions
 99
9.3.2 Maintenance

i 99
9.3.3 Using Electricity

99
~.4 Avoidiilg fire or Explosion

99
9.3.5 Handling poisons or toxic materials

100
9.3.6 Noise In Plant Operation

100
9.4 Risk Assessment

101
9.4.1 Quantitative Risk Assessment

102
9.5 Hazard identification

102
cf.5.1 Safety Design Checklist

103
9.5.2, Processing Unit

106
9.6 Hazard a~d Operability study

111
9.7 Quality control

11 1
9.7.1 Requirement

\ 112
9.8 Sampling and characterization of the liquid soap

112
9.8.l Analysis for cation test

112
9.8.2 Analysis for anion test

113
9.8.3 Determination of the % free fatty acid of coconut oil

113
9.8.4 Determination of tot a} fatty matter (TFM) in the soap

113
9.8.5 Determination of% free alkali (% FA)
9.8.6 Determination of viscosity of liquid soap using a ford cup 113

114

-
9.8.7 Determination of Saponification value of oils

9.8.8 Determination ofNa2C03 content of liquid soap 114

9.8.9 Test for the presence of formalin in liquid product 115

9.8.10 Determination of insoluble matter 116

I
9.8.11 Me~surement of pH value 116

9.8.12 Determination of rinsing properties 117

9.8.13 Determination of moisture and volatile matter 117

....

9.8.14 Determination of inorganic salts 118

Chapter Ten

10.0 Process Control and instrumentation 119

10.1 Instrument 119

10.1.1 Instrumentation and Control Objectives 119

1'0.2 Typical Control systems 120

10.2.1 Level Control 120

10.2.2 Pressure Control 121

10.2.3 Flow Control 121

10.2.4 Reactor Control 121

10.2.6 Cascade Control 123

...
 123
10J Alarms and Safety trips
....
Chapter Eleven

134
11.0 Environmental Acceptability

Chapter Twelve

135
12.0 Start up and shut down procedure

136
12.1 Start up procedure

136
12.2 Shut down procedure

136
12J Emergency shutdown

Chapter Thirteen

138
13.0 Plant location and site selection

138
13.1 Marketing Area

138
13.2 Raw Materials

138
UJ Transport

138
13.4 Local community considerations

139
13.5 Land (site considerations)

139
13.6 Climate

139
13.7 Political and strategic considerations

139
13.8 Availability of labour

140
f3.9 Utilities (services)
0.10 Environmental impact, and effluent disposal 140

13.11 Selection of site 140

13.12 Justification of selected site 140

13 .12.1 Raw Material 140

13 .12.2 Transport 141

13 .12.3 Availability of Labour 141

13.12.4 Utilities 141

13.12.5 Climate 14 I

13.12.6 Market 142

13.13 Plant layout 142

Chapter Fourteen

14.0 Economic Analysis 144

, .
14.1 Costing of oil mixer 144

14.2 Costing of caustic'mixer 144

,
144
14.3 Costing ofreactor

144
14.4 Costing of finishing mixer

144
14.5 Costing of decanter

. 1,.4.6 Purcha~e cost of miscellaneous Equipment 145

146
14.7 Raw mhterial cost
14.7.1 Variable Costs 147

14.7.1 Fixed Costs 147

Chapter Fifteen

15.0 Recommendation to the industrialist 149

....