TECHPERT Process Industries has technical expertise in process and mechanical design, manufacturing of various capacity plants for Detergent Powder Our capacity varies from 1Ton Per Day to 100 KL Per Day. We use TEMA/ API/ DIN/ JIS standards for mechanical design and ISA / IEEE for electrical and instrumentation design.
PROCESS DESCRIPTION
Dodecyl benzene sulfonic acid bought from outside, packed in drums, is unloaded into Sulfonic Acid unloading tank manually, then pumped to Sulfonic Acid Tank by Sulfonic Acid Pump.
Caustic soda solution from tank truck is unloaded into caustic soda unloading tank then pumped to caustic soda tank by caustic pump. Sodium silicate in liquid form is charged to Silicate unloading tank then to silicate tank by silicate pump. Diesel oil is unloaded into fuel tank, and by fuel pump sent to spray drying.
Sulfonic acid comes by Sulfonic acid pump into head tank, and then is dosed into weighing hopper for sulfonic acid, while caustic soda, process water and silicate come into their respective head tank and by respective pumps, and are dosed in weighing hopper for liquids. Sulfonic Acid is neutralized by Caustic soda in Crutcher, equipped with powerful agitator. The reaction results in forming sodium alkyl benzene sulfonate (Active Matter). The two crutchers work lternatively.
Solid materials, such as such as STPP (Sodium tri-polyphosphate), Sodium carbonate, and odium silicate, CMC (Carboxy Methyl Cellulose) in bags are transported to workshop and lifted by motor hoist, moving along overhead rail, up-to third floor. CMC is fed to crutcher manually. While STPP, Sodium Carbonate and Sodium Silicate fed to crutcher through weighing hopper after weighing in proper quantities.
The contents are subject to mixing and heating. The slurry then flows by gravity through Mechanical Filter and Magnetic Filter, then to the Aging Tank, where it is aged and homogenized, ready to the spray dried.
The Slurry is further homogenized in homogenizing pump, and then comes into High-Pressure Pump. By the Pump the detergent slurry is transferred to the spray jets in the Spray Drying Section. The Recovered slurry is sent back to Crutcher by Pump.
There are two sets of Homogenizing Pump and High Pressure Pump; when one is in operation the other set is in stand-by. The above mentioned sets have Mono-Pump for each; the mono-pump is act as a booster pump to raise the working efficiency of the homogenizing Pump.
The slurry is dried in the Spray Drying Tower by hot air, which is prepared in the hot air generator. Burner burning diesel oil is used to generate heat. The hot air is diluted by cool air supplied by Quench Air Fan. The Spray Tower is working in counter-current way. The detergent particles fall down from the top where the spray jets are located, and hot air produced by Hot Air
Generator comes into tower near the lower part of the tower. The detergent particles are dried and formed into hollow beads with specified bulk density and come out the tower on the Belt Conveyor at tower bottom. The Powder is transferred from here into the inlet if Airlift Duct and carried by air sucked in by an Air Lift Fan, moving upwards into Airlift Separator where the powder is separated from air and falls down onto a Vibrating Sieve. The target powder is falling into Product Powder Silos in post Dry Dosing Section. The air going out from the top of Airlift Separator, which contains detergent fines which are filtered out in Airlift Bag Filter on the top of the separator, before it is vented to atmosphere.
In this section the base powder is mixed with heat sensitive solid and liquid ingredients, e.g. perborate, CMC, non-ionic, perfume etc. So the product detergent powder will meet the specified formulation. The base powder from vibrating Sieve is stored in the Base Powder Bin. From there the base powder is dosed by Base Powder Weighing Belt. Perborate, from a perborate Bin, is dosed by a separate Perborate Weighing Belt. The base powder and perborate are then go together by gravity into a Post Blending Rotary Mixer, The liquid ingredients, e.g. non-ionic perfume are dosed by Nonionic Dosing Pump and Perfume Doing Pump respectively fed by separate kettles, are sent into the same rotary mixer. The solid liquid ingredients will be mixed together in there. The mixed powder from here is transported by a Distributing Belt and fed to one of the Product Powder Silo.
Final product in powder form is stored in storage silos. From these silos the power is conveyed to bagging machine.
A separate de-dusting system is provided for packing section. Specially designed blower is to be supplied to suck the particles which are spilled during the packaging of the material.