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Copyright 2008 by IIT Srl and The Chemithon Corp.: Used by Permission
Advances In Sulfonationand Sulfation Technologies
Luigi Peranifor
2nd International Conference on Soaps, Detergents & Cosmetics
Copyright 2008 by IIT Srl and The Chemithon Corp.: Used by Permission
Trends
Plants becoming larger, regional facilitiesIncreased emphasis on operational economicsMore multi-product capabilityHigh solids production
lower shipping costsIncreased formulation flexibility
Copyright 2008 by IIT Srl and The Chemithon Corp.: Used by Permission
Trends
20MT Multi-Product Facility in North America
Copyright 2008 by IIT Srl and The Chemithon Corp.: Used by Permission
Trends
Partial Iso for 20MT Multi-Product Facility
Copyright 2008 by IIT Srl and The Chemithon Corp.: Used by Permission
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
Copyright 2008 by IIT Srl and The Chemithon Corp.: Used by Permission
Improving Productivity
Multiple reactors Gas flow splitting arrangements
SymmetricalAsymmetrical
Variable gas concentrations
Copyright 2008 by IIT Srl and The Chemithon Corp.: Used by Permission
Improving Productivity
Can use both AFFR and MTR reactors in a single plant to promote flexibility
Can install inline spare equipment
Copyright 2008 by IIT Srl and The Chemithon Corp.: Used by Permission
Improving Productivity
“Micro” mole ratio control meansLower free oils Reduced carryoverBetter “on stream” factors
Reactor distribution design improvementsPost reaction systems
Copyright 2008 by IIT Srl and The Chemithon Corp.: Used by Permission
Improving Productivity
MTR with reaction distribution cartridge and “post-reaction”contactor section
Copyright 2008 by IIT Srl and The Chemithon Corp.: Used by Permission
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
Copyright 2008 by IIT Srl and The Chemithon Corp.: Used by Permission
Energy Efficiency
Waste Heat Recovery Boilers
Copyright 2008 by IIT Srl and The Chemithon Corp.: Used by Permission
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
Copyright 2008 by IIT Srl and The Chemithon Corp.: Used by Permission
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
Copyright 2008 by IIT Srl and The Chemithon Corp.: Used by Permission
1,4-Dioxane Reduction
One of the latest type DRS systemsCan approach a 9:1 reduction ratio
Copyright 2008 by IIT Srl and The Chemithon Corp.: Used by Permission
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
Copyright 2008 by IIT Srl and The Chemithon Corp.: Used by Permission
Process Control
Premium program architectures, such as the Profibus-PA or –DP
Single cable/buss typeMulti-task capabilityLayered communications protocol
Copyright 2008 by IIT Srl and The Chemithon Corp.: Used by Permission
Process Control
Schematic for a Siemens Profibus-PA Multi-System Type
Copyright 2008 by IIT Srl and The Chemithon Corp.: Used by Permission
Co-Actives
Active mixtures with synergistic detergent properties superior to a single active
Such as detergency + foamingOften found in LAS and MES mixtures
Copyright 2008 by IIT Srl and The Chemithon Corp.: Used by Permission
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
Copyright 2008 by IIT Srl and The Chemithon Corp.: Used by Permission
Pilot Plants
5 kg Research Pilot Plant
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