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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
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/day
Increased 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
2. No. of bowser to be increased. Action: C&F
3. No C shift operation for bowser. Action : Production Store

Oil & caustic issue to Panroom

Caustic issue required


Caustic 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 C shift mannin
So C shift manning required in Production Store
Bleaching ( Blend for

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/day
@ 61% FA

Lux(20% CNO) base


Lye Neutralization & Saponification
Oil receive 0.75 hr
JET & Tank Saponification Circulation 8 hr
Oil flow rate 4.6 Ton/Hr settle 1 hr
Soap Flow rate 8.09 Ton/Hr Drop 1 hr
Sap 3 hr
Capacity 146 MT base DPU 5 hr
Capacity Utilzation 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%
hing ( 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
Capacity Utilization 114%

Lux(20% CNO) base process operations


Fit pan operation
DPU 1 Operation DPU operation 5 hr
Preconditioning 2 hr
DPU operation 5 hr Settle 2 hr
Total cycle time 5 hr Conditioining 2 hr
Batch size 24 MT oil Centrifuge 6.0 hr
DPU nos 1 nos Total cycle time 17 hr
Capacity 144 MT base Batch size 24 MT oil
Capacity Utilzation119% Fit pan 3 nos
Capacity 161 MT base
Capacity Utilzation 107%

176
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
Capacity Utilization 63%

Centrifuge
Capacity 7 MT base/hr
Running hr 27 hr
Capacity 186 MT base/day
Capacity Utilization 93%
Bleaching ( Blend for LB

Digital Scale Bleacher # 2


Capacity 9 MT/hr Capacity
Oil preheater
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 114.37 MT base

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

LB(15% CNO) base process


Lye neutralizationSaponification
Oil receive 0.75 hr
Circulation 8 hr DPU 2 Operation
settle 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%
Capacity 122 MT base
Capacity Utilzation 76%
Blend for LB 15% CNO)

Bleacher # 2 Filter press


9 MT/batches Capacity 9 MT/hr LB Oil Storage Tank
2.5 hr LB Oil 60 MT/day Capacity 18
60 MT/day Cycle time/batch 2.5 Hr
81% Capacity Utilization
81%

NO) base 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 hr 21 hr
Centrifuge 6.0 hr Capacity 150 MT base/day
Total cycle time 18 hr Capacity Utilization
62%
Batch size 24 MT oil
Fit pan 2 nos
Capacity 100 MT base
Capacity Utilzation 92%
Storage Tank
MT
Lux 20% CNO
Packed Lux 100 MT/day
Lux noodle for 3P 30 MT/day
Total Lux 130 MT/day

Lux (20% CNO) 111 MT/day


Lux (20% CNO) 172 MT/day

Lux (20% CNO) 37 MT/day

Digital Scale
Capacity 9 MT
Cycle time/batch 1 Hr

Bleacher 1
Capacity 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 & Saponification
Oil 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
Batch size 24 MT oil
Pan 1 nos
Capacity 39 MT base
DPU 1
Operation time 5 Hr
Soap base transfer through DPU (54% TFM) 144.47 Ton Base/Day

Fitting operation
TLT fit pan
DPU 5 hr
Preconditioning 2 hr
Settle 2 hr
Conditioining 2 hr
Centrifuge 6
Fitting Pan 3
17 hr

Centrifuge capacity 26.51 hr


CNO
@ 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%
85% efficiency 119%

161 MT Base/Day 107%

185.57 MT Base/Day 93%


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 Shift

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
Batch size 24 MT oil
Pan 3 nos
Capacity 122 MT base

DPU 2
Startup & shut down 1 hr
DPU operation 5 hr
Total cycle time 6 hr
Batch size 24 MT oil
DPU nos 1 nos
Capacity 127 MT base
Capacity Utilzation 73%

Fitting operation
TLT fit pan
DPU 6 hr
Preconditioning 2 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


TFM

FA
FA

2 batch per Shift

CU

100% 60 7.84 Hr

81%

81%

76%

73%
92%

62%
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

75 % efficiency assumed
because there could be
time delayes for external 1st Treatment Operation
factors 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
1. As present practice 15 MT oil is used for 30 MT lye Capacity 96
neutralization. After lye neutralization 9 MT oil is used for Capacity Utilzation 107%
completing saponification batch.
2. Lye neutralization time is increased with increased of
free alkali in sap soap
3. Lye neutralization time is increased with decreased of
free faty acid in oil blend

Probable Solution:
1.Jet & tank for saponification for Lux base. And
2. Inline fitting for Lux base

Benefits:
1.Eliminination of soap boiling from Lux saponification
and conditioning operation.
2. Controlled free alkali with sap soap and conditioned
soap,which altimatly help to increase lye neutralization
efficiency
3.Eliminination of DPU startup & shutdown time, which
altimatly increase Lux DPU capacity.
ment Operation 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
Capacity Utilzation 107%
porator Still plant
MT lye Capacity 10 MT glyc
Capacity Utilzation 144%

1799 MT crude glycerine to be sell


Bleaching (

Digital Scale
Capacity 9 MT/hr
Oil preheater
Lux & LB oil 162 MT/day
Capacity Utilization
88%

Bleacher Capacity
183.6 MT oil
Equivalent 285.93 MT base

243 MT is the lowest one between bleaching, Sap, DPU and fit/centrifuge oper

Lux (20% CNO)


Digital Scale
Capacity 9 MT
Cycle time/batch 1 Hr 172.8 Ton Oil/Day

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
Operation time 6 Hr
Soap base transfer through DPU 157.91

Fitting operation
TLT fit pan

DPU 5 hr
Preconditioning 2 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


Bleaching ( Same blend for LUX & LB)
Bleacher # 1
Capacity 9 MT/batches
Batch time 2 hr
Lux & LB oil 81 MT/day
Capacity Utilization
88%

Intermediate tank
Capacity

Bleacher # 2
Capacity 9 MT/batches
Batch time 2 hr
Lux & LB oil 81 MT/day
Capacity Utilization
88%

Sap, DPU and fit/centrifuge operation

LB (15% CNO)

LB (15%CNO) 54 MT/day @ 95% FA

Digital Scale
Capacity 9 MT
Cycle time/batch 1 Hr 172.8 Ton Oil/Day
As per as requirement 6.0 Batch
Required time 7.22 Hr
Lux Oil Tank
Capacity
2 nos Leaf filter
Intermediate tank Capacity 9 MT/hr
20 MT Lux & LB oil 162 MT/day
Capacity Utilization
88%
LB Oil Tank
Capacity
Lux Oil Tank
27 MT

LB Oil Tank
20 MT