PAPA LIMES

SOAP AND
DETERGENT
Submission dateline: 25th November 2016

Group number: Group 33

Authors: Woo Pak Jie (016889) Vishno

Vardhan (017081) Prakkash
Rajantheran (016895) Tengku
Faiq (017567)

Supervisor: Dr. Show Pau Loke

Table of contents:
Section I & II: Brief literature on Equipment & Engineering Drawing
i) Woo Pak Jie.3
ii) Vishno Vardhan........13
iii) Prakkash..23
iv) Tengku Faiq..35

Section III:
Environmental Protection.39

Section IV
Safety Process Bow Tie Diagram..40

Section VI: Mass Safety Data Sheet.42

Section VI: Extended Summary

i) Woo Pak Jie..43
ii) Vishno Vardhan......43-44
iii) Prakkash..45
iv) Tengku Faiq46

Appendix..47

Section VI:
Citations & References..49
Woo Pak Jie (016889) Distillation Column

1) Brief literature search on the equipment

1.1) Introduction:

Distillation is an action that purifies a liquid through the process of heating

and cooling. The distillation column is an equipment that applies the term
itself. The distillation column is an essential equipment used in the
distillation of liquid mixtures to separate the mixture into its fractions or
component parts based on their difference in chemistry. Distillation is one
of the most energy-intensive separation processes. Effectiveness of the
distillation process depends on the height and diameter of the column. In
industrial areas, the distillation column may vary from 6 centimeters to 60
meters in range.

Figure 1: Distillation Column Process Flow

1.2) How Does It Work:

Feed is first introduced into the column. Feed overflows the distillation
plate and goes over each one until they settle at the bottom of the
column. The bottom-settled feed goes to the reboiler, where heating is
done. Components with higher boiling point are collected as a bottom
product. During the process of reboiling, vapor is produced. This
component with lower boiling point rises up and enters the condenser
where it is cooled down and stored in the reflux drum in liquid form. The
condensed liquid is also known as reflux. Some of the reflux proceeds to
be pumped back into the distillation column while the rest becomes an
overhead product. This process continues.

1.3) Main Components of The Equipment:

1) Vertical Shell Column

The vertical shell column is where the separation of liquid components is

carried out.

2) Distillation Plate

Column internals such as distillation plates/trays are used to enhance

component separations. A bubble cap tray is an example of a distillation
plate. A bubble cap tray has a riser, which is also known as a chimney is
fitted over each hole in the tray, and there is also a cap, which covers the
riser. They cap is mounted in order to have a space between the riser and
the cap, allowing vapor to flow.through. Vapor rises through the chimney
and is directed downwards by the cap.

Figure 1.1: Bubble Trap Tray

3) Reboiler

A reboiler is basically a heat exchanger required to provide the necessary

vaporization for the distillation process.

4) Condenser

The condenser is used to condense hot vapor leaving the top of the
distillation column. Normally, cooling water is used as a cooling medium.
Occasionally, some of the vapor may be partially condensed. As a result,
the partially condensed liquid is returned to the distillation column and it
is also known as reflux. A pump may be used to return the reflux liquid
back to the column.

5) Reflux Drum

The reflux drum is a tank used to hold the condensed vapor from the top
of the column so that liquid can be recycled back to it.

1.4) Supplier

Our supplier is from a company situated in China, Shandong and has its
own port based in Tianjin. (East of Shandong)

Figure 1.2: Shandong Port On The Eastern Side of China

As the capacity and dimension of the equipment is designed according to

the requirements of our plant; the distillation column has a price range
between USD 15,000 to USD 2,000,000. Upon contacting the supplier and
settling the purchase. The distillation may be exported with frames locked
in independent containers or by bulk carriers in PVC film, wooden cases or
steel frames.
Figure 1.3: Distillation Column Loaded Into Containers

1.5) Problems, Solutions and Maintenance

A distillation system is designed to operate within certain predetermine

limits. But when problems occur, quality and efficiency can suffer. The
feed rate is the rate in which the mixture is pumped into a column. An
optimum feed rate is often determined mathematically based on the
materials being processed and system equipment. If a systems feed rate
is too high, overloading may occur. Overloading is a condition in which the
vapor rising up the column is impeded by the liquid flowing down the
column. If overloading continues, more liquid will be backed up and the
rising vapor becomes blocked. A higher than normal reflux rate can also
have the same effect in overloading. In order to prevent overloading, the
feed rate and reflux rate have to be decreased.

In the reboiler, if too much heat is produced, this may cause the tubes in
the reboiler to expand unevenly. Thickness in the pipes that lead to the
reboiler are thicker in order to withstand the high temperature. Problems
commonly found in condensers are improper valve settings and also pump
problems.

Since our distillation column is 20 meters high, we will be having one

checkup every month. As a distillation columns cost is quite high, we will
also be providing special highly intensive training to our maintenance
workers in order to ensure the care of the equipment.
2) Engineering Equipment Drawing
 Side View:
4 3 2 1

Cross-section View:

D D

----Pump

Top View:

C C

Bottom View:

B B

DRAWN
Woo Pak Jie 21/11/2016 The University of Nottingham, Malaysia Campus
CHECKED

TITLE
A QA
A

MFG
Distillation Column Drawn by Autodesk
Inventor
APPROVED

SIZE DWG NO REV

 4 3 2 1

Cross-section View: Top View:

D D

2.5m

C =4m C

Bottom View:
20m 1m

6m
B B

=4m

2.5m

DRAWN
Woo Pak Jie 21/11/2016 The University Of Nottingham, Malaysia Campus
CHECKED

TITLE
A QA
A

MFG
Distillation Column Drawn by Autodesk
Inventor
APPROVED
 DWG NO REV
SIZE
 2.1) Additional Information Regarding Equipment

Based on the process flow diagram, the distillation column operates at a

temperature of 140C and under a pressure of 0.755 Bar.

Steam
58.7 tonnes

Feed
391.6 tonnes
Glycerin
Figure 2:
332.9 tonnes
Flow
Diagram
For
Distillation Column

From the following figure above, it can be acknowledged that 58.7 tonnes
of steam and 332.9 tonnes of glycerin can be produced in one day. With
the information given, we can calculate the flow rate for steam and
glycerin respectively.

Flow rate for glycerin:

13.87 ton 1 hour 1000kg 1m3

1 hour 3600s 1 ton 1260 kg

= 3.06 x 10-3 m3/s

Flow rate for steam:

2.45 ton 1 hour 1000kg 1m3

1 hour 3600s 1 ton 1000 kg

=6.81 x 10-4 m3/s

2.2) Other Additional Information Regarding Equipment

Equipment Length, m Thickness, m Diameter, m

Distillation 2.5m 3.8m 4m

Column Head

Distillation 15m 3.8m 4m

Column Body

Tray Spacing 1.7143m - -

Tray 0.5m - 3m

Tray bubble cap 0.2m - 0.15m

height

Condenser 7m - 2m

Reboiler 8.25m - 2m

Pipes Length 1m Ranging from Ranging from

Each 0.23m to 0.28m 0.25m to 0.3m

Pump 1.43m - Ranging from

0.35m to 0.5m
AEU U Tube Heat Exchanger (VISHNO VARDHAN DEVADAS :
UNIMKL-017081)

INTRODUCTION
In manufacturing soap and detergent, there are saponification
reaction, separation, washing, neutralizing, drying and packaging
processes involved. The saponification is a chemical reaction that
occurred between vegetable oil/ animal fat and Alkali in the reactor
vessel.
Saponification Reaction:

(Figure 1: The Separation of Soap and Glycerine (Curious-

soapmaker.com, 2016))
The product of the reaction/ from the reactor is a mixture of soap
and spent lye/glycerine in a single phase. Glycerine is a by-product
and it is costly than soap in the market. Since soap (970kg/m3) is
less dense than glycerine (1050kg/m3). It can be easily separated
by cooling down the mixture.
Separation:

(Figure 2: The Separation of Soap and Glycerine

(Learnnext.com, 2016))
Therefore, the product from the reactor pumped to AEU U Heat
Exchanger, where the soap mixture is cooled and pump to the
static separator, in which the glycerine/ spent lye is separated and
go through a further purification processes.

PROCESS DESCRIPTION

The AEU U Tube Heat Exchanger is a type of shell and tube heat
exchanger in manufacturing industry. The soap mixture is directed
onto tubes containing cooling fluid in the heat exchanger. The both
soap mixture and the cooling fluid passes without mixing together
or direct contact.
 Initially soap and glycerine molecules are hot and they have high
kinetic energy than the molecules of the cooled tubes by the cooling
fluid. The kinetic energy is then transferred each other during the
collision. The cooled tubes have high conductivity of heat and
transfers heat easily between the hot soap mixture and the cooling
fluid. Therefore, the soap mixture is cooled from 130C to 95C by
convective heat transfer in the AEU U Tube Heat Exchanger.

The AEU U Tube Heat Exchangers has 4 main components.

(Figure 3: The cross sectional of a heat exchanger with the main

component)

1. Tube
This component plays the main role in the heat exchanger to
transfer heat of the soap mixture and the cooling fluid. There are
hundreds of tubes in the heat exchanger.

2. Baffles
Baffles is a vertical obstructing panel used in the heat exchanger,
which creates turbulence flow in the fluid to increase maximum
efficiency of heat transfer rate between the soap mixture and the
tubes.

3. Shell
Shell is a cylindrical layer containing bundles of tube and baffles in
it. The soap mixture flows in the shell through baffles and tubes for
the heat transfer process.

4. Tube sheet
Tube sheet is circular flat metal with drilled holes to hold tubes. It
prevents the soap mixture from mixing with the cooling fluid.
KEY FEATURES

TUBES

The tubes are 1-inch diameter and made from 90/10 Copper-
Nickel instead of 316 Stainless Steel.

Reason: 1. 90/10 Copper-Nickel has high cleanliness factor

than 316 Stainless Steel, the
growth of bio-fouling organism at the wall of 316
Stainless Steel is higher than 90/10 Copper-Nickel.
2. 90/10 Copper-Nickel is cheaper compared to
Stainless Steel and it serve better works of heat
transfer between both fluids.
The tubes are drawn seamless and finned.
Reason: 1. The finishing surface of the metal will be smooth
and increase the turbulence of the soap mixture.
This increases the better environment for a heat
transfer to take place.
The tubes are in U design.
Reason: 1. The risk of thermal expansion damage is lesser
than straight tube. The U design tube is connected
to tube sheet and shell which makes thermal
expansion without harm in the heat exchanger.
The tube layout is square (tubes are 90 to each other).

(Figure 4: The 4 types of tube layout in industry)

Reason: 1. Soap mixture contains soap and glycerine and it

will block the gaps between the tubes more often
and cleaning need to be done weekly. Therefore,
rotated triangular (tubes are 60 each other),
triangular (tubes are 30 each other) and rotated
square (tubes are 45 each other) are not suitable
choice.

BAFFLES

The baffle type used in this heat exchanger is single

segmental.

(Figure 5: The baffle segmentation types

(Zapthegreat.files.wordpress.com, 2016))
 Reason: 1. A better flow distribution between inlet and outlet
region.

The Baffle spacing is 0.4 times the shell diameter.

Reason: 1. A optimum space between baffles makes better
heat transfer coefficient and pressure drop.
The baffle cut is 45% since it is single segmental baffle
Reason: 1. This make sure an even flow of soap mixture on
the tubes and also avoid cross mixing between the
baffles.

TUBESHEET

(Figure 6: The front view of tube sheet (Encrypted-

tbn0.gstatic.com, 2016))

The tube and the tube sheet is connected by hydraulic

expansion.
Reason: 1. To make sure there is no leakage between the
tubes and the shell.
The tube sheet joints are seal welded with mechanical
strength.
Reason: 1. To reduce the maintenance cost and also to
ensure no leakage in the system.

Tube sheet made of 90/10 Copper-Nickel

Reason: 1. The alloy used is cheaper and serve a better heat
transfer between the fluids

SHELL
E-type shell.

Single Pass Shell Two Pass Shell

(Figure 7 and Figure 8: The 2 type of shells (Engineeringpage.com,

2016))
 Reason: 1. E-type shell is a single pass shell which give
optimum space till 3 baffles.
Minimum clearance between shell and baffles
Reason: 1. To maximize the heat transfer rate between the
soap mixture and the tubes.

FRONT END STATIONARY HEAD

A-type front head.

A-type front head B-type front head

Figure 9 and Figure 10: The 2 type of front head

(Engineeringpage.com, 2016))

Reason: 1. A-type is suitable because it is easy to remove and

clean the bundles.

REAR END STATIONARY HEAD

U-tube bundle

(Figure 11: The u tube bundle at the rear head (Engineeringpage.com,

2016))

Reason: 1. It is easily removed for cleaning purpose.

2. It is the low costly bundle in the market.
3. The thermal expansion is minimum.

SPECIFICATION OF DESIGNED HEAT EXCHANGER

Components Dimensions Material Type/Quantity Justification

Diameter =
Tubes Square 1. Low growth of
1-inch 90/10 biological Foul
Copper- Orientated Rate.
Length = Nickel
 90 2. Cheaper alloy than
63-inch Stainless Steel.
3. Easy to clean
(60 Tubes)

1. Minimizes Foul
Baffles Thickness rate of biological
= growth.
90/10 2 Baffles 2. Same type of alloy
3-inch Copper- used as the tubes
Nickel 3. A stable heat
Diameter = transfer rate

16- inch

Tubesheet Thickness 1. Same Type of alloy

= 90/10 used as the tubes.
Copper- 2. Better hydraulic
4-inch Nickel expansion/welding
of the tubes and
Diameter = the tube sheet.

16.5-
inch

Shell
Length = 1. The shell not easily
316 E type rust.
63-inch Stainless single phase 2. Strong outer layer
Steel
Diameter =

16.5-
inch

Front Head Thickness 1. Easy to remove

= 316 A type head and clean the
Stainless bundle frequently.
4-inch Steel

Diameter =

16.5-inch

Rear Head Thickness

= U type bundle
 316 1. Minimizes the
4-inch Stainless thermal expansion
Steel of the tubes.
Diameter = 2. Low cost bundle in
industry.
16.5- 3. Easy to be cleaned.
inch

EQUIPMENT DESIGN JUSTIFICATION

1. Foul

A. The tendency to foul of a fluid is minimum in the AEU U

Tube Heat Exchanger.
B. The sedimentation in the inner part of the AEU U Tube
Heat Exchanger is cleaned 2 weeks once.
Crystallization of soap or glycerine may occur in the heat
exchanger.
Biological Growth may occur on the shells.
C. During the cleaning period, a spare heat exchanger is
fixed to the system to ensure minimum disrupt on the
process to produce soap and detergent.

2. Seal

The connection between,

i. Tube + Tube Sheet
ii. Front Head + Tube Sheet
iii. Shell + Front Head
iv. Shell + Inlet/Outlet
v. Baffle + Tubes

are sealed/weld without having gaps. There is no leakage in

the system of Heat exchanging process.

3. A constant
i. flow rate of inlet/outlet streams.
ii. pressure and temperature in inlet/outlet of the soap
mixture.
iii. pressure and temperature of cooling fluid into the tubes.
iv. turbulence flow of soap mixture from shell onto the
tubes and baffles.
v. pressure drop of the soap mixture.
vi. physical property (viscosity, density, specific heat) of
the soap and glycerin molecule.

occurred in the AEU U Tube Heat Exchanger.

 MARKET COST OF AEU U TUBE HEAT EXCHANGER

Components Material Dimension (A x h) Cost

(USD)
Tubes 90/10 60 x pi[(0.5)]^2 x 63 2030
Copper- =2,968.80 cubic inch
Nickel =0.0486 cubic metre

Baffles 90/10 2 x 3 x pi[(8)]^2 838

Copper- =1206.40 cubic inch
Nickel =0.0198 cubic metre

Tube Sheet 90/10 4 x pi[(8.25)]^2 585

Copper- =855.30 cubic inch
Nickel =0.014 cubic metre

Shell 316 [63 x pi[(8.25)]^2]- 532

Stainless [63xpi[7.75]^2]
Steel =1583 cubic inch
=0.026 cubic metre

Front Head 316 4 x pi[(8.25)]^2 287

Stainless =855.30 cubic inch
Steel =0.0014 cubic metre

TOTAL 4272(USD)

SAFETY PRECAUTIONS

1. The pressure of the AEU U Tube Exchanger is notified by

Integrated Circuit, which will activate the alarm in the
control room if there is any problem in it.
2. A special sound frequency detector is placed on the
equipment, and the graph of the sound is notified by well-
trained worker and also the control room.
3. The AEU U Tube Heat Exchanger is cleaned 2 weeks once.
EQUIPMENT CALCULATION

= 1 1 (
)
= 2 2 ( )
=
[ ( 1 )(
(2 1 2 )
)
1 2
=

( 1
2)

m1= mass flow rate of soap mixture

log
cp1= specific heat of soap mixture Input results
Tin1= Inlet temperature of soap mixture
m1= 18888kg/hr
Tout1= Outlet temperature of soap mixture
cp1= 3.1 kJ/(kg C)
M2= mass flow rate of cooling water
Tin1= 130C
cp2= specific heat of cooling water
Tout1= 95C
Tin2= Inlet temperature of cooling water
Tout2= Outlet temperature of cooling water cp2= 4.2 kJ/(kg C)
DT(lm)= Log mean temperature of the fluid Tin2= 30C
U= Coefficient estimated overall heat transfer Tout2= 60C
A= Heat Transfer Area
Calculation:
Log mean temperature of the fluid = 67.5C

Heat Transfer Area = 12.41 square metre

Mass flow rate of cooling fluid = 16303kg/hr

ACCREDITATION

All the key design features on the AEU U Tube Heat

Exchanger are assured according The Tubular Exchanger
Manufacturers Association, Inc. (TEMA) quality needs.
2) Engineering Equipment Drawing
 TUBULAR REACTOR (PRAKKASH RAJANTHERAN: UNIMKL-016895)

Introduction
In the industry that chemical based usually have reactor come with vary
in size from a few cm3 to the vast structures that are often depicted in
photographs of industrial plants. Kilns that produce lime from limestone may
be over 25 meters high and hold, at any one time, well over 400 tonnes of
materials are some example of the sizes of reactor. The design of the reactor
is determined by many factors but of particular importance are the
thermodynamics and kinetics of the chemical reactions being carried out.
There is various type of reactor. Design of reactors based on features like
operation mode or phases present types or the reactors geometry. They know
as:

Table 1: Types of Operations

No Types of Operation Example

1 Mode
i. Batch process

ii. Continuous process

2 Phases present
i. Homogeneous

ii. Heterogeneous

They are also classified as:

Table 2: Types of Reactor

No Types of Reactors

1 Tubular Reactor

2 Stirred Tank Reactor

3 Fluidized Bed Reactor

4 Packed Bed Reactor

depending upon the flow pattern and manner in which the phases make contact
with each other. Table 3 is tabulated in order to show the comparison between
various chemical reactors in details.
Table 3: Comparison of Chemical Reactors
PROCESS DESCRIPTION

Figure 1: Continuous Process of Saponification Reactor

Figure 2: Continuous Process in Soap Industry

 Table 4: Laws of Thermodynamics

Therefore, the design of an industrial chemical reactor must satisfy the following
requirements:
Table 5 : Requirement for Chemical Reactor Design
Design Procedure and Reactor Designing

An industrial chemical reactor is a complex device in which heat

transfer, mass transfer, diffusion and friction must be considered and it must
be safe and controllable. In large vessels, problem of mixing of reactants, flow
distribution, residence time distribution and 13 efficient utilization of the
surface of porous catalysts also arise. A successful commercial unit is an
economic balance of all these factors. A general procedure for reactor design is
outlined below:

Table 6: Procedure for reactor design

In choosing the reactor conditions, and optimizing the design, the interaction of
the reactor design with the other process operations must not be overlooked.
The degree of conversion of raw materials in the reactor will determine the size
and the cost of any equipment needed to separate and recycle unreacted
materials. In these circumstances the reactor and associated equipment must be
optimized as a unit.
2) Engineering Equipment Drawing
CROSS SECTION
TENGKU FAIQ MUIZZUDDIN BIN TENGKU SHAHRIMAN 017567

Brief Literature on Filter Press

Introduction

One of the key components in the process of producing soap is the filter press.
The filter press is an economical and efficient machine which basically separates
liquids and solids using pressure filtration. There are 3 types of filter press
available, which is the plate and frame filter press, the automatic filter press and
the recessed plate filter press. For production of soap, the plate and frame filter
press is used. This is due to its ability to accumulate complete filter cakes in the
filter frames in between the chambers, unlike the other filter press where it may
cause the cakes to be uneven.
Its main use in the soap production is to separate sludge from glycerin. To
specify, the filter press consist of filter plates, forming chambers to trap and
collect solids. Filter cloths of two filter plates are used to separate each
chambers. A conveying pump is used to transfer the liquid transport the
products by pumping pressure from chamber to chamber and to filter out the
liquids and leftover solids. The sludge is accumulated after the glycerine is
pressured out of the chambers after separating chamber is filled. The glycerine is
then transferred to the glycerine storage tank whilst the sludge is removed from
the machine.

Operation Process

The operation begins when slurry of unfiltered glycerine taken from the soap is
pumped into the filter press from the second glycerine treatment vessel. The
slurry then goes through the filter plates, causing some of the solids to be
trapped by the filter cloth. The filter plates are then pressed by the hydraulic
press, thus trapping the remaining solids on the filter cloth. The filtered slurry
then exits the filter press through the filtrate outlet to the double vacuum
evaporator as 70% of pure glycerine. The solids trapped in the filter cloth then
forms filter cake. The filter cake is then removed by pulling the filter plates apart.
Filter cake will drop from the plates then collected.

Specifications

Dimension of Filter Press (mm) 2522 x 735 x 1250

Size of Filter Plate (mm) 614 x 614
Number of Filter Plate 20
Power of Motor (kW) 5
Voltage (v) 380
Material Carbon Steel
Filter Cake Thickness (mm) (Estimated) 30
Key Design Features

One of the key components in the filter press is the filter plates. There are 3
types of filter plates, which is the plate and frame filter plates, recessed
chambers filter plates and the diaphragm squeeze filter plates. As mentioned in
the introduction, the filter plates used are the plate and frame filter plates. Using
a 20 plate filter press, and using 614 x 614 mm sized plates, the filter plates are
used to accumulate the filter cakes of the sludge when the slurry is pumped
through the chambers. The size of the filter plates can be chosen depending on
the size of filter press and and the number of filter plates used.
A conveying pump is also present in the filter press. Controlled by the
hydraulic control panel, the pump is used to ensure the remaining solids are
removed from the equipment, and to transfer the slurry through the chambers.
Its capability to create instantaneous vacuum flow and high velocity allows the
slurry to flow at high speed without any interference or lagging. With its
efficiency in the function and its reliability, it is a useful and important feature in
the filter press.

Figure 1:An example of a plate and frame filter press.

Another key feature in the filter press is the filter cloth, which is also known
as the filter media. Its function is to separate the debris and particles from the
slurry when it is pumped against the filter cloth, and thus causes the forming of
filter cakes. It is basically where the solids are separated from the liquid of the
slurry. The filter cloth is held together by the filter frame, along with the filter
plates. There are 3 types of filter cloth which is the head cloth, tail cloth and
intermediate cloth. The head cloth is for the first plate with a single cloth with a
small hole whilst the tail cloth is the last plate but it does not contain any hole.
Meanwhile, the intermediate cloth is for the plates in between the first plate and
last plate. Its uses double cloth, with one on each side of a plate, and contains a
hole in the centre of each side which is connected by a short cloth tube.

The hydraulic press plays an essential part of the operations of filter press.
Its main use is that it presses the plates after slurry is pumped into the chamber
to trap the unwanted solids. The pressure used for the hydraulic can be
controlled, using the hydraulic control panel. A cylinder-shaped object, it keeps
its balance between squeezing the plates and the filling pressure induced by the
conveying pump throughout the filtration process.
2) Engineering Equipment Drawing
CROSS SECTION
Environmental Protection and Safety Process

i) Environmental Protection

Safety of a plant is of paramount importance as its sustainability or profitability. It

has been evident throughout the history where flawed designs, human errors and
under unpredictable circumstances where vast amount of lifes were taken leaving
destruction and chaos for generations. However, the nature of safety is that it can never be
hundred percent assured although it is possible to predict various scenarios for individual
incidents in order to take measures to prevent them.

In the process of making soap and detergents, careful and preventive measures have to
be taken care into, when discharging waste from the plant. Most soap and detergents are
formulated to be used with water and go into wastewater treatment plants.

Impacts of the products ingredients have to be evaluated before releasing to natural flowing
resources. From our research above in Site Study. Pasir Gudang has been chosen as the
location in building the plant.

As Pasir Gudang is close to the sea, precautions are to be taken into discharging waste
products. The usage of surfactant plays an important role in soap and detergent making, as it
increases cleaning power. With great power, comes great responsibility.

Surfactants can be harmful to fish and aquatic life. Before discharging, the waste products in our
plant go through a process known as electro flotation. The following process is based on water
electrolysis. The process results the surfactant to foam at the top of the solution, making it
easier to be collected and then discharged.

Phosphates are also used in the process of soap and detergent making. When phosphates
detergents are used, the disposal of wastewater is an issue. If untreated wastewater flows into
the sea, phosphates cause an imbalance of the aquatic ecosystem.

This issue encourages the growth of algae, since no sunlight can reach the sea; this causes the
algae to die. Decomposition will take place on the algae, during this process, bacteria will
deplete the amount of oxygen dissolved in water. Because of this, living organisms in the sea
will die.

HAZOP is a method which is used to analyze such situations in order to prevent

unfortunate incidents. HAZOP follows a series of systematic analysis to categorize situations and
evaluate solutions.

A hazop study is carried out for the reactor since it has the highest probability of causing
a fatal incident compared to the rest of the equipment. The study is done by considering
parameters of process variables and possible situation that can occur. Solutions are suggested
to overcome, avoid or prevent each type of failure.

A bow- tie diagram for the methanol reactor is also constructed, choosing the major
incident as an explosion in the reactor. Causes which lead to the incident,
preventive barriers, counter-measure, post-incident handling procedures are
suggested.
Bow-Tie Diagram

Hazard Prevention Incident Escalation

Consequences
Toxins and Water
Malfunction hazardous pollution
of the substances
chemical Weekly condition seep into the
check-up of the soil
plant

Discharge Eutrophicatio
Leakage of Untreated
of phosphates go
n
vessels
untreated into the sea
wastewater and
encourages
into the sea plant growth

Give proper
training and Aquatic life may Fishermen
Poor explaining about consume catch
handling of the plant harmful polluted
equipment substances and fishes and
by workers become they are
poisoned consumed by
 There is always a risk in the production of a chemical plant. A lot of incidents and
accidents may happen due to the lack of knowledge, especially in the safety aspect.
Safety is the most important thing in producing a plant, regardless of whether its a
small production plant or not. So, we must learn the proper way to control the plant and
know the hazards that might occur. The bow-tie diagram above summarizes the safety
process, showing the hazards and ways to prevent it and also the consequences if safety
measures are not taken into consideration. The main incident that may happen to our
chemical plant is the discharge of untreated wastewater into the sea, which may lead to
pollution thus causing damage to the environment and to living things.
The sustainability of a chemical plant must always be ensured. A malfunction of the
chemical plant may cause serious damage to the not only the equipments, but also the
chemical plant as a whole. As a precaution, a weekly condition check-up of the plant
must be done. Workers must always check on the equipments, ensuring the
maintenance is up to date and the repairs to be done immediately when needed.
Supervisors must present daily or weekly reports to ensure the operations of the plant
consistently run smoothly and to give a clear overview of the operations. By doing these
few steps, malfunctions and damages to the plant may be avoidable.
Workers with no experience in this line of business may cause trouble. It is not as
easy as it looks to control and maintain a chemical plant, many procedures and rules
must be obliged to ensure smooth flowing of the operations. Thus, workers must
undergo professional training before being given the job. All aspects of the plant
regarding the operations and equipments and how they must be handled must be
briefed to the workers, before and after getting the job. Supervisors play an important
part in these situations, as they must ensure workers follow the rules and protocols, to
avoid accidents or damage from occurring.
Leakage of pipe vessels is also a hazard that must be avoided. Leakage of the pipe
vessel may cause serious injuries to the workers as chemicals are being exposed. Pipe
vessels can be leaked due to numerous reasons, which includes the mishandling of the
pressure that is pumped in and its condition. Thus, workers must know how to handle
the pressure being pumped into the pipe, so that the materials can be transferred
smoothly and quick. Extremely high pressure may cause the pipe vessel to be blocked,
and may cause a small explosion of the pipe vessel and causing the surrounding to be
exposed to the chemicals. Workers must also check on the wear and tear of the pipes,
ensuring that they are safe to use and still able to operate. Other than that, valves can
also be installed at the end of every pipeline. This is to control the ins and outs of the
materials, ensuring that when there is a leakage or blockage, the valves can be closed
so that other materials in other equipments are not affected.
If issues regarding the hazards are not taken seriously, the major incident that may
occur is the discharge of untreated wastewater into the sea. It may become a
complication to the environment including human lives. Toxins and hazardous chemical
substances from the process of the soap production may be exposed to surroundings. If
the substances are exposed, it may seep into soils thus directly causing land and sea
pollution. This will undoubtedly affect human lives, as water is used as a necessity.
Phosphorus is one of the chemicals obtained during the process. When untreated
phosphorus is released into the sea, it pollutes the water as it encourages growth of
algae. The rise of the amount of algae causes the occurrence of eutrophication, which is
the decrease of oxygen in water hence resulting in death to aquatic life. The polluted
water is harmful to humans as bacteria may be present.
Not only eutrophication affects aquatic life, but it also affects the people on land. Fish
is consumed as food, but if fishes are exposed to the harmful substances, it may cause
them to become poisoned. Nonetheless, fishermen may unknowingly catch the polluted
fishes and sell them to markets. According to research, toxicity remains and increases
up the food chain. This is a perfect example of how disruption of an ecosystem can
come back to hurt humans in many ways.
 As a precaution to avoid these tragedies from happening, a proper drainage system
lined up with catalysts may be built alongside with the factory. Should any leakage
happen, the spilled chemicals could be treated before entering the sea using the drain.
If we chose not to treat the waste products ourselves, another great alternative
would be to store our waste products initially. We could then pay a different company
whose specialization is in treating the waste products.

MATERIAL SAFETY DATA SHEET

CHEMICAL PRODUCT & COMPANY IDENTIFICATION
Product Name: 1. Papalime bar soap.
2. Papalime detergent.
Product Chemical Name : 1. Sodium Laurate (active ingredient)
2. sodium Dodecyl Benzene Sulphonate (active ingredient)
Manufacturer: Papalime Soap & Detegent sdn.bhd
INGREDIENT INFORMATION ON COMPOSITION
1. Sodium Laurate (active ingredient)
CAS#: 8030-37-6 wt%: 0.055 OSHA PEL: 2 mg/m^3 ACGIH TLV: 2 mg/m^3

2. sodium Dodecyl Benzene Sulphonate (active ingredient)

CAS#: 8040-30-3 wt%: 0.060 OSHA PEL: 2.5 mg/m^3 ACGIH TLV: 2.5 mg/m^3

HAZARDS IDENTIFICATION
Health Effects: Eye and skin irritation.
FIRST AID MEASURES
Eye Contact: Flush with plenty of water for 1 minutes. CONTACT A PHYSICIAN
FIRE AND EXPLOSION
Flammability: Flammable
Auto-ignition Temperature: Not Applicable
Flash Points: Not Applicable
Flammability Limits: Not Applicable
Products of Combustion: Carbon Monoxide, Carbon Dioxide, Nitrogen
Dioxide
Fire Hazards in Presence of Various Substances: Not Applicable
Explosion Harzards in Presence of Various Substances: Not Applicable
Fire Fighting Media: Water Spray or Class B extinguisher
Special Remarks on Fire Hazards: Wear breathing apparatus and
protective clothing to prevent
chemicals onto skin contact
ACCIDENTAL RELEASE MEASURES
Small Spill: Wipe and clean up any excess residue
Large Spill: Create a perimeter, contact head authorities

TOXICOLOGICAL INFORMATION
Routes of Entry: Eye contact, ingestion, skin absorption
Toxicity to Animals: Ionic & anionic surfactants
Chronic Effects on Animals: When ingested in small
Amounts, cause GI upset (excessive drooling,
Vomiting or diarrhea.)
Toxicity to Humans: Damaging or corrosive acids
Chronic Effects on Humans: Severe change in acid level pH of blood,
Vomiting, Low blood pressure that develops
Rapidly, skin burns and irritation
TRANSPORT INFORMATION
Protective Equipment: Gloves, Goggles, Protective Clothing
Extended Summary done by Woo Pak Jie

A distillation column is an equipment where liquids are separated into different fractions
due to their difference in chemistry. Liquids with higher boiling component tend to be collected
at the bottom of the column and liquids with lower boiling component are collected at the top of
the column. Inside a distillation column, there are distillation plates. They are used to enhance
component separations. Few examples are such as bubble cap trays, sieve trays and valve
trays. A condenser and a reboiler are connected to a distillation column. A condenser condenses
hot vapor and collects it as a overhead product while a reboiler provides the necessary
vaporization for the distillation process. Lastly, a reflux drum is to hold condensed water and the
water is either recycled back into the column or collected back as an overhead product.
Bubble cap trays have a price range from USD 10,000 to USD 900,000. A condenser has
a price range from USD 1,000 to USD 10,000 and a reboiler has a price range from USD 6,000
to USD 150,000. Assuming the overall assembly equipment has a base range of USD 1,000,000
and each of the main equipment has a minimum price itself. An estimated calculated cost in
building the equipment from scratch would be relatively cheaper compared to buying in bulk
from suppliers. This is because suppliers who supply the bulk goods may charge higher as they
would want to get profit.
Areas of uncertainties regarding the equipment lie in the dimensions of the equipment.
The designed equipment may not necessarily fit in order to function well, according to the
dimensions given. Input and output pipes are an uncertainty as well. It is rather hard to
determine whether the rate of flow may apply with the given pipe dimensions. There may be a
possibility where over flooding may occur. A walkway may be built for every 5 meters along the
column. This is convenient to maintenance workers as it would ease them walking up along the
walkway instead of climbing the column.
In this coursework, I learnt to design a chemical equipment. It was highly knowledgeable
as I could do research regarding my equipment and its relatively specifications. This enables me
a better vision of what I am supposed to come in contact with and what I am supposed to do in
the working field.

EXTENDED SUMMARY (VISHNO VARDHAN DEVADAS 017081)

~ AEU HEAT EXCHANGER
Equipment Features
Features:
The tubes of the heat exchanger are seamed to 1-inch diameter and it is made of 90/10
Copper-Nickel in square layout.
Reason:
1. Seamed: The tubes are seamed instead welded because to encourage better turbulence
flow of the soap mixture from the shell onto the tubes.
2. 1-inch diameter: The tubes can be cleaned easily by a hard rubber which (1x1). This
rubber is placed in one end of the tube and pumped high pressure till the rubber come out
from the other end of the tube. This can scrap the fouls on the wall of tube along the
rubber projection.
3. 90/10 Copper-Nickel: 90/10 Copper-Nickel is having higher cleanliness factor (Growth of
Bio-Fouling Organism) than 316 Stainless Steel. The tubes can be cleaned easier than 316
Stainless steel, it is because the 90/10 Copper-Nickel has smooth surface than 316
Stainless Steel.
4. Square Layout: Square layout has bigger gap than Rotated-Square; this makes the
cleaning process easier.
Equipment Process Economic Analysis

Analysis:
The AEU Heat Exchanger is equipped by 2 main component,
1. 90/10 Copper-Nickel.
2. 316 Stainless Steel.

A) The tube, baffle, tubesheet is made of 90/10 Copper-Nickel, shell and front head is
made of 316 Stainless Steel.
B) The 90/10 Copper-Nickel is 41700USD per cubic meter and 316 Stainless Steel is
20400USD.
C) The total surface area used
1. 90/10 Copper-Nickel = 0.0824 cubic meter.
2. 316 Stainless Steel = 0.0274 cubic meter.
D) 90/10 Copper-Nickel metal component cost total of 3713USD.
316 Stainless Steel metal component cost total of 559USD.
Therefore, the AEU Heat Exchanger costs 4272USD.
E) The maintenance criteria of this equipment,
1. Time taken to clean: 2hr
2. Labours needed: 2people (RM18/hr)
3. Water Consumed : RM 20
The total maintenance cost of this equipment is less RM150.
Reason:

1. Since 75% of the equipment is 90/10 Copper-Nickel it is more costly than 316 Stainless
Steel.
Therefore, the cost of the AEU Heat Exchanger is high.
Area of Uncertainty
Uncertainties:
1. The properties of the soap and glycerine/spent lye is hard to obtain and it varies with the
raw material condition.
2. The soap mixture pumped to AEU Heat Exchanger does not have a constant phase.
3. The turbulence of the soap mixture is not constant throughout the heat exchanging
process.
4. The flow rate, pressure, temperature of the soap mixture into the shells and the flowrate,
pressure, temperature of water into the tubes varies.
Equipment Design to be Improved
1. A graphical monitoring should be made on the properties of the soap mixture. This can
obtain an average properties of the mixture. This can improve the calculation to design
the equipment.
2. A valve should be placed and controlled before the mixture is being pumped to the AEU
Heat Exchanger, this to ensure a constant flow rate.
Conclusion
All our Group member
1. Contribute equally on completing the task given.
2. Learned how to brief search to design the equipment.
3. Learned to design an equipment for a manufacturing process.
4. Get to know the importance of standardization on the equipment by the Association.
5. Get to know the importance of Environmental protection.
EXTENDED SUMMARY (PRAKKASH RAJANTHERAN 016895) ~ TUBULAR REACTOR

Equipment Features
This coursework is main about the production of soap and detergent. The major
equipment inside the plant is the tubular reactor. Tubular reactor is chosen as part of the
equipment because this type of reactor having less maintenance cost and enhance the
production of soap to be carry out more efficiently. The most significant and noticeable features
inside this tubular equipment is the heat exchange part. The tubes using boiler feed water is
mainly use to remove the excess heat produce during the reaction. Heat is absorbed and turn
into steam by the boiler feed water.

Stainless steel material is used mainly in the reactor. As the production of soap and
detergent chemical based plant, stainless steel material is suitable material to be used because
it resists high chemical damage cause the NaOH. NaOH is highly flammable and volatile. By
using stainless steel material, sudden increase in temperature can be avoided. Stainless steel
material is expensive though long lasting compare to other materials and compatible for soap
and detergent producing plant.

Equipment Process Economic Analysis

i. Reactor core

745 closely packed locations with fuel at the centre, nickel surrounding reflectors, thoria
blankets and steel reflectors are found at the core. The shape of subassemblies is hexagon.
The core was rated for 40 MW t and had 65 fuel subassemblies, three test steel
subassemblies,143 nickel reflector,342 thoria blanket, six control rods and 163 steel reflector
subassemblies as the initial design. In the outermost steel row, there are 23 storage
locations.

Area of Uncertainty

The volume of the reactor and the volume of each tubes are the area of uncertainties in
this equipment design. The volume of reactor is estimated larger than the volume of input tubes
into the reactor. On the other hand, the uncertainties in this design are the volumes of the tube
and number of the tube remains.

Equipment Design to be Improved

Safety feature should be installed in this equipment as an improvement. This reactor

should be equipped with temperature sensor and pressure probe. As to maintain a standard
reaction temperature, temperature sensor should be installed. Besides, this sensor is part of the
safety features as this sensor will trigger and alert is given out when the reactor temperature
increases. Same as for pressure probe, pressure probe is used to make sure the
desired pressure for reaction reached and prevent the reactor exceed critical
pressure.

Conclusion

Further study and researches should be carry out to obtain more accurate data in
this design project to reach the desired output of the soap and detergent and also improve
the equipment for long term of production. the project drawing is confident and satisfaction, the
further improvement and challenge will be in the 3-dimension equipment design which
could make the indication more clearly. On the other hand, people can have a
better visual understanding on the detail.
 Tengku Faiq Muizzuddin bin Tengku Shahriman 017567

The main component of the filter press is the hydraulic press. The hydraulic press is an
automatic system controlled by the hydraulic control panel. Two types of hydraulic press are
available, which are the automated hydraulic press and the manual hydraulic press. The
automated hydraulic press is preferred, as it is less time consuming. It plays an important part
of the filtration as it presses the filter plates together after the slurry is pumped in, causing the
filter cloth which is connected to the filter frame to collect the unwanted solids.

Upon research and study of the equipment, the average price of a plate and frame filter press
is 10,000.00 USD. Its cost is not too hefty and it is very beneficial as it enables the filtration of
glycerine so that it can be sold. At the end of the filtration process of glycerine, a total of 332.9
ton per day is produced. With the price of glycerine being 600.00 USD per ton, glycerine can be
sold as a secondary product and a huge amount of profit can be made thus the investment
made on the filter press can be easily be reclaimed.

There are still certain uncertainties regarding the filter press. The best example of the
uncertainty is the pressure used during the squeezing of the filter plates. Uncontrolled pressure
may cause the filter plates and filter frames to break, and cause major damage to the
equipment. Workers must have knowledge on the equipment and how to use it properly to
ensure the efficiency of the production.

To improve the design of the filter press, an improvement on the filter cloth can be done.
Using a plate and frame filter cloth, a latex edging can be done on the cloth to improve the seal
and to decrease the possibility of a leakage from occurring. This will help with the filtration as
well, as the well-covered cloth on the filter plates will collect the more solids and thus produce a
clearer filtrate.

Overall, design of the filter press can be considered good and well measured but if a complete
study on a real-life version of the equipment is conducted, the design can be improved. There
are minor issues and uncertainties about the equipment due to a lack of knowledge about it, and
this can be solved by a full research.
 Appendix

HAZOP (Hazard and Operability Study)

Parameter Guide Deviation Cause Consequences Action

word

Temperature Less Decrease in Malfunction Less production Install

temperature of gas temperature
burner/ probe to monitor
insufficient temperature
fuel levels/sensor on
Which is gas burner to
used to ensure fuel is
heat the being regulate
reactor

High Increase in Malfunction Rupture of Automatic

temperature of cooling reactor indication of high
system temperature

Regulator
malfunction Explosion/fire/ Routine check up
of gas meltdown on gas burner
burner
Pressure Less Decrease in Reactor Implementing a
pressure Insufficient implodes vacuum break
supply of valve
reactants

High Increase in Unexpected Damage to Pressure control

pressure increase in catalysts tubes valve is installed
the flow in the between the
rate reactor/Less reactors and pipes
conversion
efficiency of the
reactants due to
less resident
time.

Incorrect Structural Check-ups every

set damage (or time before
pressures explosion) to starting the
for vents reactor and process/emergency
tubes relief system
to reduce build
up pressure
Flow Less Less Valve closed Less reactants in Flow rate
flowrate the reactor regulating valves
hence less to be installed at
product critical point
produced
High Higher Pump Reactions ratios Routine
flowrate malfunction are interrupted equipment
and affects the check-ups
product

Reverse Flowrate Issue with Reactants and Install valves at

reversed pump products mix critical points
with each other
and separation
becomes
harder/damage
of equipment

Level Low Lower level Faulty level Reactor Implement

measurement acceptable feed programs to
level is the systems that
overreached and correlates
damage caused reactor level at a
to structure an given time with
internal multiple
equipment variables that
gives a
calculated
prediction on
what the level
should be.
High Higher level Blocked Reactor over Install
outlet pressurizes and emergency relief
cause structural valves or pipe
damage routes/sensors
to notify
blockage
Composition Other Undesired Incorrect Harmful side Auto -shut -off
than composition operation reactions or auto -correct
occurring leading programs
to reactor failure installed in
or catastrophic system/Alarm
incidents indications or
sirens for wrong
operations
As Impurities Leakage in Catalyst flowing Routine analysis
well in the flow catalyst through the of outflow
as tube outlet ,blocking sample to check
the out-let or for irregularities
damaging
pumps and other
equipment while
the flow is
proceeding
/catalyst mixed
with the boiler
water feed,
wastage of
catalyst
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