Description
SAPONIFICATION, COOLING AND FINISHING PLANT
CAPACITY OF 2,000 KG/H
This quotation covers all the required equipment to produce 2,000 kg/h soap noodles at different TFM concentration.
Plant is designed to work in three shifts, 24 h/day.
1. BRIEF PROCESS DESCRIPTION
See flow sheet FS-4067-D (SOLUTION 1)
Plant is designed to produce soap noodles at different TFM contents.
Raw materials are pumped through Filters into the Saponification Jet (J-2401) by a Dosing Group consisting of gear pumps and flow-meters (DG-2301).
The reaction between the ingredients starts in the Jet and continues into the Crutcher(s) (CR2401-(2)) where the saponification is completed and, if required, fillers are added through Powder Feeder (DS2401)(optional).
Soap is transferred to a Feed Tank (FT-2301) used like a buffer between Saponification Crutcher and Drum Flaker/Pelletizer
The final TFM content is determined by the concentration of caustic soda solution. The combination of the Jet and the crutcher allows the start of the saponification process even with high concentrations of caustic soda therefore it is possible to obtain a neat soap at 74% TFM.
The finished neat soap is then pumped by a high viscosity pump through a filter (F-2304) to the Drum Flaker/Pelletizer (CP-3001) for cooling and solidification. Solidified soap is then scrapped off the rolls forming soap flakes which fall in a Pelletizer (optional) and are transformed into noodles (pellets) easy to be conveyed and stocked.
Whole process is monitored and controlled through Electrical Control Panel (QE2301).
2. EQUIPMENT LIST
Item Q.ty Description
DT-2301 1 Oil Buffer Tank (AISI 304 stainless steel)
(local supply with our drawing)
F-2301 1 Oil Filter (AISI 304 stainless steel)
Basket type, hot water jacket
DIN flanged connection
DT-2302 1 Caustic Soda Buffer Tank (mild steel)
(local supply with our drawing)
F-2302 1 Caustic Soda Filter (AISI304 stainless steel)
Basket type, hot water jacket
DIN flanged connection
DT-2303 1 Water Buffer Tank (mild steel)
(local supply with our drawing)
F-2303 1 Water Filter (AISI304 stainless steel) – Local supply
DG-2301 1 Raw Materials Dosing Group complete with:
– P2301: Gear Pump for Oil. Made in stainless steel.
– FM2301: Mass Flow-Meter (PROMASS )
– P2302: Gear Pump for Caustic Soda. Made in stainless steel.
– FM2302: Magnetic Flow-Meter (PROMAG)
– P2303: Gear Pump for Water or Brine. Made in stainless steel.
– FM2303: Magnetic Flow-Meter (PROMAG)
– Electronic panel and Frequency Inverters
ET2401/2 1 Brine and/or Liquid Filler Dosing Elevated Tank (mild steel)
(local supply with our drawing)
J 2301 1 JET unit
Manufactured in AISI 316 stainless steel
The device consists of a VENTURI unit with central supply of steam and separate concentric supplies of oil blend and caustic soda.
It consists of three inlets and one outlet:
• Inlet of oil blend
• Inlet of caustic soda solution
• Inlet of steam (small quantity)
• Outlet of an emulsion of soap with oils and caustic soda
CR 2401 1 Crutcher(s) CR-4000
Internal volume available for required production.
Equipped with internal enclosed screw stirrer driven by a gear motor to provide for vigorous mixing necessary for a complete reaction. Provided with all the connections to the process. Part in contact with the product of AISI 304 stainless steel.
It is supplied with its support feet. The insulation is not provided and should be made on site. The relevant platform and stairs are not included.
P2304 1 Transfer Pump
Delivery Head: 2 bars Special design suitable to pump viscous materials such as concentrated neat soap. Oversized flange.Hollow disc type, complete with gear motor, flexible coupling and steel base. Equipped with internal safety valve and heated body. Body in cast iron and rotor in special steel
FT2301 1 Soap Feed Tank
Soap buffer tank, of 6 ton/batch, built in stainless steel, to act as a buffer in between the saponification crutcher and the Drum flaker.
Equipped with heating jacket and necessary connections to the process. Equipped with Stirrer.
P2305 1 Filtration Pump
Delivery Head: 2 bars
Special design suitable to pump viscous materials such as concentrated neat soap. Oversized flange.
Hollow disc type, complete with gear motor, flexible coupling and steel base. Equipped with internal safety valve and heated body. Body in cast iron and rotor in special steel
F2304 1 Soap Filter
Basket type. Body and basked in Stainless Steel. Equipped with heating jacket.
CP-3001 1 Drum Flaker (Chill Rolls) + Pelletizer
Suitable for high-viscosity products.
Drum-Flaker: CC-900, two drums (rolls) of 900 mm. of diameter each.
Pelletizer: PB-250, screw (worm) of 250 mm. of diameter.
The Drum Flaker is an extremely simple and reliable machine that cools/solidifies neat soap, thus preparing it for final plodding. It has two stainless steel rolls that are internally cooled. Neat soap pumped on the rolls, is spread evenly among them, in a 0.5 mm thick layer that is quickly cooled down and solidified. This soap is then scraped off the rolls and fall on a Pelletizer which is built-in below the rolls. The machine is equipped with all the necessary valves and instruments for the control of the cooling water. The product out of the Pelletizer is in form of noodles (pellets).
CX-3001 1 Water Chiller
To provide chilled water for the Double Drum Flaker / Pelletizer
Suitable to cool the neat soap at 85-90°C down to 30°C.
QE-2301 1 Electrical Control Panel
Containing push buttons, motor starters and everything necessary for proper operation of the plant.
Built in accordance with EC standards, IP 55 protection grade
PVF 1 Piping, Valves and Fittings
Set of pipes of trade length and a set of valves, flanges and fittings made of AISI 304 stainless steel, necessary for a completion of piping.
INSTR 1 Instruments
Set of instruments necessary to control the plant.
ENG 1 Engineering
Design standards – Inpakt supplies the necessary documents for the plant erection, operation and maintenance inside its battery limits Engineering will be supplied in English language using metric system and in accordance with the following standards/codes: Pressure vessels: ASME codes and approved by independent inspectors, Piping: DIN, Electrical: IEC, Instrumentation: ISO. Other standards can be used, on request
The following engineering documents will be supplied:
Process – P&I diagrams, General Lay-out, Utility specifications
Equipment and machinery – Item list, Equipment & machinery specifications
Piping – Line list, Piping classes, Material list (pipes, valves, flanges)
Instrumentation – Instrument list and data sheets
Electrical – Load list, Electrical panel specification and wiring diagrams
Plant manuals – Operation manual, including instruction for the plant operations, start-up, shut-down and emergency shut-down procedure, certificates, operating and maintenance manuals
3. UTILITIES PLANT REQUIREMENTS’
| “SWING” Jet Saponification, Cooling and Finishing Plant 2,000 kg/h | |||||||
| Item | Q.ty | Description | A
Kg/h |
B
m3/h |
C
kcal/h |
D
kW |
E
m3/h |
| DT-2301 | 1 | Oil Buffer Tank | 35 | – | – | – | – |
| F-2301 | 1 | Oil Filter | – | – | – | – | – |
| DT-2302 | 1 | C. Soda Buffer Tank | – | – | – | – | – |
| F-2302 | 1 | Caustic Soda Filter | – | – | – | – | – |
| DT-2303 | 1 | Water Buffer Tank | – | – | – | – | – |
| F-2303 | 1 | Water Filter | – | – | – | – | – |
| DG-2301 | 1 | Raw Materials Dosing Group | – | – | – | 2 | |
| ET-2401/2 | 1 | Brine and/or liquid Filler Dosing Elevated Tank | – | – | – | – | – |
| J-2301 | 1 | JET | 75 | – | – | – | – |
| CR2401(2) | 1 | Saponification Crutcher(s) CR-4000 | 200 | – | – | 18,5 | – |
| 1 | Platform for Crutcher | – | – | – | – | – | |
| P-2304 | 1 | Transfer Pump | – | – | – | 2,2 | – |
| FT-2301 | 1 | Feed tank 6m3 with Stirrer | – | – | – | 3 | – |
| P-2305 | 1 | Filtration Pump | – | – | – | 0,75 | – |
| F-2304 | 1 | Soap Filter | – | – | – | – | – |
| CC-3001 | 1 | Double Drum Flaker (Chill Rolls) + Pelletizer CC900-PB250 | – | – | * | 24 | – |
| CX-3001 | 1 | Water Chiller 165980 | – | – | – | 73,5 | – |
| QE-2301 | 1 | Electrical Control Panel | – | – | – | – | – |
| PVF | 1 | Piping, Valves and Fittings | – | – | – | – | – |
| INST | 1 | Instruments | – | – | – | – | – |
| ENG | 1 | Engineering | – | – | – | – | – |
| TOTALS | 310 | – | * | 123,9 | – | ||
It is assumed that the utilities at disposition comply with following:
- Saturated steam at 6 to 12 bar.g.
- Cooling water at locally declared temperature and min. 1,5 bar.g. pressure.
- Requested k/cal.
- Electricity at local voltage and frequency, 3 phase
- Instrument air free from oil, moisture and impurities, having a min. pressure of 5,5 bar.g.
