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Line # 1 Line # 2 Line # 3 Line # 5 Line # 6

Brand Lux Lux Lux LB LB

Capacity, MT/day 38 33 29 35 35

Basis

Lux 20% CNO

Packed Lux 100 MT/day @ 72.5% TFM

Lux noodle for 3P 30 MT/day @ 76.5% TFM

Total Lux 130 MT/day

LB 15% CNO

Total LB 70 MT/day @ 73.5% TFM

Equivalent Oil ( Assume 10% extra oil Handling)

Lux (20% CNO) 111 MT/day @ 95% FA

LB (15%CNO) 59.6 MT/day @ 95% FA

Equivalent Base

Lux (20% CNO) 172 MT/day @ 61% FA

LB (15%CNO) 93 MT/day @ 61% FA

Caustic required 47.63 MT/day @ 49% NaOH

Oil issue per shift to PR

Lux (20% CNO) 37 MT/day Equivalent 4 batch per Shift

LB (15%CNO) 20 MT/day Equivalent 2 batch per Shift

Base Required per shift to SFD

Lux (20% CNO) 57 MT/day

LB (15%CNO) 31 MT/day

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Tank farm Oil Receiving

Oil bowser required 21 Nos/day

Caustic bowser required 5 Nos/day

Current oil bowser 16 Nos/day

Current caustic bowser 5 Nos/day

Increased oil bowser 5 Nos/dayIncreased caustic bowser 0 Nos/day

Oil storage capacity 1100 MT

Caustic storage Capacity 390 MT

Points:

1. No capacity issue for oil and caustic storage

Oil & caustic issue to Panroom

Caustic issue requiredCaustic Requirment 47.63 MT/day @ 49% Caustic

Only A & B shift operation for caustic transferring to panroom

Oil issue required

Lux & LB Oil issue Required 170 MT

Digital scale Capacity 9 MT/hr

Digital Scale will be engage 22 Hr @ 85% Efficiency So

2. No. of bowser to be increased. Action: C&F

3. No C shift operation for bowser. Action : Production Store

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C shift manning required in Production Store

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Bleaching

Digital Scale

Capacity 9 MT/hr Oil preheater

Lux Oil 111 MT/day

Cycle time/Batch 1 Hr

Capacity Utilization 88%

Bleacher Capacity 97.2 MT oil

Equivalent 151.38 MT base

Equivalent Base

Lux 172 MT/d@ 61% FA

Lux

Lye Neutralization & Saponification

Oil receive 0.75 hr JET & Tank Saponification Circulation 8 hr

Oil fl 4.6 Ton/Hr settle 1 hr

Soa 8.09 Ton/Hr Drop 1 hr

Sap 3 hr

Cap 146 MT base DPU 5 hr

Cap 100% Total cycle time 18.75 hr

Batch size 24 MT oil

Pan 1 nos

Capacity 41 MT base

Jet & tank capacity 146 MT Base Capacity Utilization 64%

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( Blend for LUX 20% CNO)

Bleacher # 1

Capacity 9 MT/batches Intermediate tank

Batch time 2 hr Capacity 20 MT

Lux Oil 111 MT/day


(20% CNO) base process operations

Fit pan operation

DPU 1 Operation DPU operation 5 hr Preconditioning 2 hr

DPU op 5 hr Settle 2 hr

Total c 5 hr Conditioining 2 hr

Batch s 24 MT oil Centrifuge 6.0 hr

DPU no 1 nos Total cycle time 17 hr

Capacit 144 MT base Batch size 24 MT oil

Capacit 119% Fit pan 3 nos

Capacity 161 MT base

Capacity Utilzation 107%

176

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2 nos Leaf filter

Capacity 9 MT/hr Lux Oil Storage Tank

Lux Oil 111 MT/day Capacity 27 MT

Cycle time/batch 1.11 Hr


Centrifuge

Capacity 7 MT base/hr

Running hr 27 hr

Capacity 186 MT base/day


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Bleaching ( Blend

Digital Scale Blea


Capacity

LB Oil 60 MT/day Batch time

Cycle time/Batch 1 Hr LB Oil

Capacity Utilization 100% Capacity Utilization

Bleacher Capacity 73.44 MT oil


Equivalent Base


LB(15% CNO) basLye neutralizationSaponification

Oil receive 0.75 hr

Circulation 8 hr DPU 2 Operationsettle 1 hr Startup & shut down 1 hr

Drop 1 hr DPU operation 5 hr

Sap 3 hr Total cycle time 6 hr

DPU 5 hr Batch size 24 MT oil

Total cycle time 18.75 hr DPU nos 1 nos

Batch size 24 MT oil Capacity 127 MT base

Pan 3 nos Capacity Utilzation 73%



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for LB 15% CNO)

cher # 2 Filter press

9 MT/batches Capacity 9 MT/hr LB Oil Storage Tan

2.5 hr LB Oil 60 MT/day Capacity 18

60 MT/day Cycle tim 2.5 Hr

81% Capacity 81%

process operations

Fit pan operation

DPU operation 6 hr Preconditioning 2 hr Centrifuge

Settle 2 hr Capacity 7 MT base/hr

Conditioining 2 hr Running h 21 hr

Centrifuge 6.0 hr Capacity 150 MT base/day

Total cycle time 18 hr Capacity 62%


Fit pan 2 nos


Capacity Utilzatio 92%

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k

MT

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Lux 20% CNO

Packed Lux 100 MT/day

Lux noodle for 3P 30 MT/day

Total Lux 130 MT/day




Digital Scale

Capacity 9 MT

Cycle time/batch 1 Hr

Bleacher 1Capacity 9 MT

Cycle time 2 Hr

Inter mediate/ Buffer tank 30 min

Leaf filter 1 & 2

Startup 30

1st batch 35

2nd batch 45

3rd batch 60

LF washing 30

Cycle time for 3 batch 3.33 Hr

Storage Tank

New Storage tank 20 MT

T-8 9 MT

Jet Tank

Oil receive 4.6 Ton/Hr

Soap transfer (54% TFM) 8.09 Ton/Hr

Oil requirement per shift 31.28

Oil requirement per day 93.84

Equivalent base 146.14 Ton

Equivalent soap tablet 121.46 Ton

Lye Neutralization & SaponificationOil receive 0.75 hr

Circulation 8 hr

settle 1 hr

Drop 1 hr

Sap 3 hr

DPU 5 hr

DPU Change over time 1 Hr

Total cycle time 19.75 hr


Pan 1 nos

Capacity 39 MT base

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DPU 1

Operation time 5 Hr

Soap base transfer through DPU (54% TFM) 144.47Ton Base/Day

Fitting operation

TLT fit pan

DPU 5 hr

Preconditioning 2 hr

Settle 2 hr

Conditioining 2 hr

Centrifuge 6

Fitting Pan 3

17hr

Centrifuge capacity 26.51 hr

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@ 72.5% TFM

@ 76.5% TFM

@ 95% FA

@ 95% FA

Equivalent 4 batch per Shift

CU

183.6 Ton Oil/Day 88% 125.05

97.2 Ton Oil/Day 114%

174.96 Ton Oil/Day 63%

118%

85% efficiency 100% Consider 100% CU in Jet & Tank

Equivalent Oil 93.84

Equivalent base 146.14

Equivalent soap tablet 121.46

64%

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85% efficiency 119%

161 MT Base/Day 107%

185.57 MT Base/Day 93%

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LB 15% CNO

Total LB 70 MT/day @ 73.5%

LB (15%CNO) 60 MT/day @ 95%

LB (15%CNO) Base 93 MT/day @ 95%

LB (15%CNO) 20 MT/day Equivalent 2 batch per

Digital Scale

Capacity 9 MT

Cycle time/batch 1 Hr 183.6 Ton Oil/Day

Bleacher 2

Capacity 9 MT

Cycle time 2.5 Hr 73.44 Ton Oil/Day

Filter Press

Filtration 1 Hr

Air blowing 1 Hr

Filter washing 0.5 Hr

Cycle time /batch 2.5 Hr 73.44 Ton Oil/Day

Storage Tank

T-9 18 MT

Lye Neutralization & Saponification

Oil receive 0.75 hr

Circulation 8 hr settle 1 hr

Drop 1 hr

Sap 3 hr

DPU 5 hr

Total cycle time 18.75 hr


Pan 3 nos


DPU 2

Startup & shut down 1 hr

DPU operation 5 hr

Total cycle time 6 hr


DPU nos 1 nos



Fitting operationTLT fit pan

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DPU 6 hr


Settle 2 hr

Conditioining 2 hr

Centrifuge 6

18 hr 101 MT Base/Day

Centrifuge capacity 21.49 hr 150.43 MT Base/Day

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TFM

FA

FA

hift

CU

100% 60 7.84 Hr

81%

81%

76%

73%

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92%

62%

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Glycerine left with Lux base 1.0%

Glycerine left with LB base 1.0%

Glycerine with lux spent lye 14%

Glycerine with LB spent lye 14%

Spent lye ex lux 66.65 MT/day @ 14% Glyc

Spent lye ex LB 35.93 MT/day @ 14% Glyc

Lux L/F 0.60

LB L/F 0.60

Average L/F 0.60

Total lye 102.57 MT/day @ 14% Glyc

Equivelent crude 17.95 MT/day @ 80% Glyc

Equivelent Glyc 14.36 MT/day @ 100% Glyc

1st Treatment Operati

Treatment Operation 1.5

Lye neutralization Settle 2

Lye neutralization capacity 101.25 MT/day Filteration 1.5

Lye neutralization Utilization 101% Total cycle time 5

Batch size 12.5

Tank nos 2

Capacity 96


Probable Solution:

1.Jet & tank for saponification for Lux base. And

2. Inline fitting for Lux base

Benefits:

1. As present practice 15 MT oil is used for 30 MT lyeneutralization. After lye neutralization 9 MT oil is used forcompleting saponification batch.

2. Lye neutralization time is increased with increased offree alkali in sap soap

3. Lye neutralization time is increased with decreased offree faty acid in oil blend

1.Eliminination of soap boiling from Lux saponificationand conditioning operation.

2. Controlled free alkali with sap soap and conditionedsoap,which altimatly help to increase lye neutralizationefficiency

3.Eliminination of DPU startup & shutdown time, whichaltimatly increase Lux DPU capacity.

75 % efficiency assumedbecause there could betime delayes for externalfactors

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on 2nd Treatment Operation

hr 1st filtration 1.5 hr

hr Treatment Operation 0.5 hr Evaporator

hr Settle 1.5 hr Capacity 96

hr Filteration 1.5 hr Capacity Utilzation 107%

MT lye Total cycle time 5 hr

nos Batch size 12.5 MT lye

MT lye Tank nos 2 nos

Capacity 96 MT lye


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Still plant

MT lye Capacity 10 MT glyc


1799 MT crude glycerine to be sell

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Bl

Digital Scale


Lux & LB o 162 MT/day

Capacity U 88%

Bleacher C 183.6MT oil


243 MT is the lowest one between bleaching, Sap, DPU

Lux (20% CNO)

Digital Scale

Capacity 9 MT


bleacher 1 & 2

Capacity 9 MT

Cycle time 2 Hr 172.8 Ton Oil/Day

Inter mediate/ Buffer tank 30 min

Leaf filter

Startup 30

1st batch 35 62

2nd batch 45

3rd batch 60

LF washing 30

Cycle time for 3 batch 3.33 Hr 155.52

Storage Tank

New Storage tank

T-9

T-8

Jet Tank

Oil receive 4.68 Ton/Hr

Soap transfer 8.22 Ton/Hr 54%

Oil requirement per shift 37.4 102%

Oil requirement per day 112.2 102%

DPU

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Operation time 6 Hr

Soap base transfer through DPU 157.91

Fitting operation

TLT fit pan

DPU 5 hr


Settle 2 hr

Conditioining 2 hr

Centrifuge 6

17 hr 158 MT Base/Day

Centrifuge capacity 23.25 hr 162.75 MT Base/Day

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aching ( Same blend for LUX & LB)

Bleacher # 1

Capacity 9 MT/batchesBatch time 2 hr

Lux & LB o 81 MT/day

Capacity U 88%

Int

Capacity

Bleacher # 2

Capacity 9 MT/batches

Batch time 2 hr

Lux & LB o 81 MT/dayCapacity U 88%

nd fit/centrifuge operation

LB (15% CNO)


Digital Scale

Capacity 9 MT


As per as requirement 6.0 Batch

Required time 7.22 Hr

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Capacity

2 nos Leaf filter

rmediate tank Capacity 9 MT/hr

20 MT Lux & LB o 162 MT/day

Capacity U 88%

Capacity

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ux Oil Tank

27MT

B Oil Tank

20MT

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cu 15% &20%cno (single)

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