advances in sulfonation technologies
TRANSCRIPT
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Advances In Sulfonationand Sulfation Technologies
Luigi Peranifor
2nd International Conference on Soaps, Detergents & Cosmetics
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Trends
Plants becoming larger, regional facilitiesIncreased emphasis on operational economicsMore multi-product capabilityHigh solids production
lower shipping costsIncreased formulation flexibility
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Trends
20MT Multi-Product Facility in North America
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Trends
Partial Iso for 20MT Multi-Product Facility
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Trends
Green products methyl ester sulfonatesalcohol and ethoxylate sulfates
Markets are demanding -wider range of higher quality productshigher yieldsgreater plant reliability more automationlower waste stream volumes higher efficiencies
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Improving Productivity
Multiple reactors Gas flow splitting arrangements
SymmetricalAsymmetrical
Variable gas concentrations
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Improving Productivity
Can use both AFFR and MTR reactors in a single plant to promote flexibility
Can install inline spare equipment
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Improving Productivity
“Micro” mole ratio control meansLower free oils Reduced carryoverBetter “on stream” factors
Reactor distribution design improvementsPost reaction systems
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Improving Productivity
MTR with reaction distribution cartridge and “post-reaction”contactor section
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Energy Efficiency
Reducing energy consumption byWaste heat recovery systemsMore efficient rotary equipmentLonger running/lower maintenance pumps and blowersTurbo Tube® & other drying techniques
Energy vs. Yield and Quality
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Energy Efficiency
Waste Heat Recovery Boilers
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Energy Efficiency
Use of more efficient drying methods such as
Drum Dryer – a “direct contact” typeWiped Film Evaporator – an “indirect” typeFlash Evaporator – an “indirect” typeTurbulent Convective Evaporation – an “indirect” type
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1,4-Dioxane Reduction
Upgrading sulfation plants to reduce 1,4-dioxane levels
Basic types for 3:1 reductionEnhanced types for up to 9:1 reduction
Replacing older generation reactor designsUpgrading piping design to reduce 1,4-dioxane formation
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1,4-Dioxane Reduction
One of the latest type DRS systemsCan approach a 9:1 reduction ratio
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Process Control
Upgrading to more modern PLC standards, such as the Allen-Bradley CompactLogix and ControlLogix
Faster responseGreater reliabilityAdditional system variables
Integration with plant-wide DCS systems
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Process Control
Premium program architectures, such as the Profibus-PA or –DP
Single cable/buss typeMulti-task capabilityLayered communications protocol
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Process Control
Schematic for a Siemens Profibus-PA Multi-System Type
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Co-Actives
Active mixtures with synergistic detergent properties superior to a single active
Such as detergency + foamingOften found in LAS and MES mixtures
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Pilot Plant Studies
Commercially scalable systems from 5 to 20 kg/hr to develop processes and formulation technologiesStatistical designed experiments for process modeling and optimization
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Pilot Plants
5 kg Research Pilot Plant