project report on mass balance of rr3 grade of grease
DESCRIPTION
It's a project report on mass balance of RR3 grade of grease.Production at IOCL Vashi grease plant.It covers all the important aspects of grease production from raw materials to finished product.TRANSCRIPT
ADDRESS: - PLOT NO. D-100, T.T.C. INDUSTRIAL AREA,
KUKSHET VILLAGE, TURBHE,
NAVI MUMBAI 400705.
TRAINING DURATION: - 7th MAY-7th JUNE 2012
SUBMITTED BY:
1. AKASH U. DHOBALE
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INDIAN OIL
CORPORATION
LIMITED
PROJECT REPORT ON MASS
BALANCE OF RR3 GRADE OF GREASE
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ACKNOWLEDGEMENT
My project would not be complete without acknowledging the
help, guidance and support I received from various people.
It gives me immense pleasure to thank Mr. V.S.Menon sir
(DGM), who provided me with an opportunity to do the in-plant
training at IOCL.
I deeply acknowledge with gratitude, my sincere thanks to Mr.
K. Ramesh Sir, Mr. R.K. Kelkar sir, Mr. A.S. Gitay Sir, Mr. S.S.
Sharma sir, Mr. Subodh Kumar, Mr. D. Prasad for their continuous
guidance and for helping me to understand the plant and project
work in a better way.
Besides, this internship program made me realize the value of
working together as a team and as a new experience in working
environment, which challenges us every minute. I would like to
thank my friends especially those who worked together as interns
at IOCL Vashi grease plant. I would also like to express my gratitude
to the heads of various departments and the operators of
respective department especially for giving their valuable time.
Last but not the least, I would like to thank all the workers
working in the plant and the people who helped me throughout my
stay at IOCL.
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INDEX
1. SOMETHING ABOUT LUBRICATING GREASE……………………………….……….………3
ADVANTAGE OR USE OF GREASE……………………………………………………..….....3
IMPORTANCE OF LUBRICATION….……………………..…………………….……….…….3
CLASSIFICATION OF GREASE……………………………………………………………….……4
GREASE COMPOSITION ………………………………………………………..………………..6
2. CHEMISTRY OF PROCESS STUDIED ……….……………………….………....……….….....6
3. MOLECULAR FORMULAE………………………………………………..………………….……...6
4. REACTIONS………………………………………………………………………..…....……………....7
5. PROPERTIES ………………………………………………………………………..….………………..8
6. EQUIPMENTS REQUIRED FOR PROCESSING……………………………..…….……….….20
REACTOR………………………………………………………………………………..………………20
KETTLE………….……………………………………………………………………………………....22
TANKS (BASE OIL CHARGING)….……………………………..………………………..…….23
HOMOGENIZER…………………..………………………………………..……………………..…25
OPERATION HYDROULIC VALVE ACTUATION…………………………………….……..25
7. MANUFACTURING PROCEDURE……………………………………………………….…..……28
8. PLANT UTILITIES…………………………………………….……………………………………......29
FURNACE…………………………………………………..…………………………..……..….…..29
BOILER…………………………………………………………..…………………………….……....32
COOLING TOWER……………………………………………...……………………………….….33
CHIMNEY……………………………………………………………………………..……….……...35
COMPRESSOR……………………………………………………..….……………..………..…...36
9. LABORATORY TESTS FOR QUALITY CONTROL…………………………..…………..…….37
10. CRITERIA OF GREASE SELECTION………………………………………………………….......41
11. FACTORS AFFECTING QUALITY OF GREASE………………….…………..………...........41
12. MASS BALANCE OF VARIOUS BATCHES…………………………………..……….………...43
13. TABULATION OF BATCHES COVERED……………………………………….………………..113
14. CONCLUSION………………………………………………………………………..………………….114
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:- SOMETHING ABOUT LUBRICATING GREASE
National Lubricating Grease Institute (NLGI) definition of grease:
A solid to semi-solid product of dispersion of a thickening agent in a liquid lubricant. Other ingredients may be added to it to impart special additional properties.
ADVANTAGES OR USE OF GREASE:
It is used to reduce friction between surfaces.
It prevents oils which would leak away or cause damage by dripping.
It is assured of increased life period of machineries.
To lubricate efficiently.
It Stay at application site due to its semi-solid nature.
Acts as a sealant to avoid ingress of dirt, dust, foreign matters and prevent
Corrosion.
Bearing enclosure designs simplified and Maintenance work reduced due to
absence of oil Pump.
Preferred for long time or packed for life applications e.g. Electrical Motors,
Wheel bearings of new generation cars, etc.
Dripping & Spattering avoided by using grease in food processing /
pharmaceutical industries.
Greases work in badly worn / old machinery.
IMPORTANCE OF LUBRICATION:
Reduce friction between moving parts
Reduce wear & tear
Sealant to contaminants
Prevent corrosion
Prevent rust
Heat transmission
Resist structural deterioration during prolonged use
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CLASSIFICATION OF GREASES:
I. BASED ON TYPE OF THICKENERS:
1) Calcium Base
2) Sodium Base
3) Lithium Base
4) Aluminum Base
5) Titanium Base
6) Clay Base
7) Polyurea Base
8) Non-soap Base
II. BASED ON APPLICATIONS:
1. INDUSTRIAL
High Temperature Application
Low Temperature Application
EP / Load Bearing Application
2. AUTOMOTIVE
Chassis Application
Wheel Bearing Application
Multipurpose Application
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III. BASED ON CONSISTENCY (NLGI CLASSIFICATION):
NLGI Grade Worked Penetration @ 25 o C
000 445-475
00 400-430
0 355-385
1 310-340
2 265-295
3 220-250
4 175-205
5 130-160
6 85-115
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GREASE COMPOSITION:
1) Base oils (lube oil) 75-90%
2) Thickening agents(Soap) 10-20%
3) Additives 0-10%
BASE FLUIDS:
Mineral Oils
Vegetable Oils
Synthetic Oils
THICKENING AGENTS:
Soaps
Non-soaps
Polymers
ADDITIVES:
Oxidation Stability
Rust / Corrosion Inhibitors
Extreme Pressure / Anti-wear Agents
Metal Deactivators
Structure Modifiers
Friction Modifiers
Solid Lubricant
Water Resistance
Low Temperature Pourability Agents
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CHEMISTRY OF PROCESS STUDIED:
The manufacturing of grease mainly consist of saponification reaction.
The reaction is carried out between higher fatty acids (such as 12-Hydroxy
stearic acid, Hydrogenated castor oil) and various metal hydroxides (eg.
LiOH.H2O, NaOH, Ca(OH)2...etc.)
Saponification reaction follows first order kinetics.
MOLECULAR FORMULAE:
1. HCO
CH3-(CH2)5-CH (OH)-(CH2)10-COOCH2
CH3-(CH2)5-CH (OH)-(CH2)9-COOCH
CH3-(CH2)5-CH (OH)-(CH2)10-COOCH2
2. 12-HSA
CH3-(CH2)5-CH (OH)-(CH2)10-COOH
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REACTIONS:
1) SAPONIFICATION OF HCO:
CH3-(CH2)5-CH (OH)-(CH2)10-COOCH2 CH3-(CH2)5-CH (OH)-(CH2)10-COOLi CH2 OH
CH3-(CH2)5-CH (OH)-(CH2)9-COOCH + 3 LiOH CH3-(CH2)5-CH (OH)-(CH2)10-COOLi + CH OH
CH3-(CH2)5-CH (OH)-(CH2)10-COOCH2 CH3-(CH2)5-CH (OH)-(CH2)10-COOLi CH2 OH
HYDROGENATED CASTOR OIL LITHIUM LITHIUM SALT OF HCO (SOAP) GLYCEROL HYDROXIDE
2) SAPONIFICATION OF HSA:
CH3-(CH2)5-CH (OH)-(CH2)10- COOH + LiOH.H2O CH3-(CH2)5-CH (OH)-(CH2)10-COOLi + H2O
12 Hydroxy Stearic Acid Lithium Lithium stearate Water Hydroxide monohydrate
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PROPERTIES:
HYDRATED CALCIUM GREASES:
Saponification of fats/fatty acids and lime in mineral oil.
Water is used as a stabilizing agent.
Structure : Smooth, buttery
Dropping Point : 850 – 1100 C
Max. usable temp. : 650 C
Water Resistance : Excellent
Shear Stability : Fair to good
Oxidation Stability : Poor to good
Oil Separation : Poor to good
Rust Protection : Poor to excellent
Pumpability : Good to excellent
Application : General economical use
Cost : Low
Volume : Declining
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ANHYDROUS CALCIUM GREASES:
Saponification of fats/fatty acids and lime in mineral oil.
12 Hydroxy Stearic Acid used for saponifying contains a hydroxyl radical, which
acts as stabilizing agent.
Structure : Smooth, buttery
Dropping Point : 1300– 150
0 C
Max. usable temperature : 1100C
Water Resistance : Excellent
Mechanical Stability : Good to excellent
Oxidation Stability : Fair to excellent
Rust Protection : Poor to excellent
Oil Separation : Good
Pumpability : Fair to excellent
Application : Multipurpose
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SODIUM GREASES:
Saponification of fat / fatty acids with Sodium Hydroxide in mineral oil.
Structure : Fibrous
Dropping Point : 160 – 220C
Max. usable temp. : 110C
Water Resistance : Poor to fair
Oxidation Stability : Poor to good
Rust Protection : Good to excellent
Pump ability : Poor to fair
Shear Stability : Good
Oil Separation : Fair to good
Application : Closed Rolling Contact Bearing
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ALUMINUM GREASES:
Saponification of 12 Hydroxy Stearic Acid with Aluminum Hydroxide in mineral oil.
Structure : Smooth, clear
Dropping Point : 80 – 110C
Max. usable temp. : 70C
Water Resistance : Excellent
Shear Stability : Poor
Oxidation Stability : Excellent
Rust Protection : Good to excellent
Pump ability : Poor
Oil Separation : Good
Application : Thread lubrication
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LITHIUM GREASES:
Saponification of Hydrogenated Castor Oil or 12 Hydroxy Stearic Acid with Lithium
Hydroxide in mineral oil.
Structure : Smooth
Dropping Point : 1700 – 2100 C
Max. usable temperature : 1300 C
Water Resistance : Good
Oxidation Stability : Fair to excellent
Mechanical Stability : Good
Rust Protection : Poor to excellent
Oil Separation : Good to excellent
Storage Stability : Good to excellent
Pumpability : Fair to excellent
Compatibility with additives : Good
Application : Multipurpose, EP
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COMPLEX GREASES:
Thickener is formed by co-crystallization of two or more dissimilar acid based
salts.
Complex Soaps have high melting point thereby results in high drop points.
LITHIUM COMPLEX GREASES:
Saponification of Hydrogenated Castor Oil and / 12 Hydroxy Stearic / Salicylic /
Azelaic / Boric Acid, etc. with Lithium Hydroxide in mineral oil.
Structure : Smooth, buttery
Dropping Point : 2600 – 3000 C
Max. usable temperature : 1500 C
Water Resistance : Good to excellent
Oxidation Stability : Good
Mechanical Stability : Good to excellent
Storage Stability : Good to excellent
Rust Protection : Fair to excellent
Pump ability : Fair to excellent
Oil Separation : Good to excellent
Additive Compatibility : Good
Application : Multiservice Auto/Industrial use
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ALUMINUM COMPLEX GREASES:
Saponification of long chain fatty acids and benzoic acid with aluminum cation.
Aluminium Isopropoxide or its trimmer is used as the source of cation.
The soap formed thus is Aluminium Benzoate Stearate
Structure : Smooth, buttery
Dropping Point : > 2600 C
Max. usable temperature : 1500 C
Water Resistance : Good to excellent
Mechanical Stability : Good to excellent
Oxidation Stability : Fair to excellent
Rust Protection : Good to excellent
High Temperature Stability : Good
Oil Separation : Good to excellent
Pumpability : Fair to good
Reversibility Property : Yes
Additive Compatibility : Poor
Application : Multiservice Industrial
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CALCIUM SULFONATE COMPLEX GREASES:
Saponification of 12 Hydroxy stearic acid, acetic and boric acids with lime in
presence of over-based Calcium Petroleum Sulfonate in mineral oil.
Structure : Smooth, buttery
Dropping Point : > 3000 C
Max. usable temperature : > 1700 C
Water Resistance : Excellent
Mechanical Stability : Excellent
Rust Protection : Excellent
Oil Separation : Excellent
Special Feature : Excellent Inherent EP/AW
Pump ability : Fair to good
Application : Multipurpose, Extreme pressure
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TITANIUM COMPLEX GREASES:
Reaction of tetravalent Titanium cation with stearic acid as the fatty component
and complexes with dicarboxylic terephthalic acid.
Structure : Smooth, buttery
Dropping Point : > 2900 C
Max. usable temperature : 2000 C
Water Resistance : Excellent
Mechanical Stability : Good to excellent
Oxidation Stability : Good to excellent
Rust Protection : Good to excellent
High Temperature Stability : Good
Oil Separation : Fair to good
Pump ability : Fair to good
Salient Property : Inherent EP/AW/AO Properties
Application : Multiservice Industrial
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NON-SOAPS:
ORGANOPHILLIC CLAY GREASES:
Special class of clay – Bentonite / Smectonite is treated with Quaternary
Ammonium Compounds and is converted from hydrophilic to Oleophillic (Oil
Attracting).
These treated organophillic clays when put in oil, gels the oil. Structure Stabilizers
like glycol / Polypropylene carbonate / Isopropyl alcohol are used for deriving the
structures.
Structure : Smooth, buttery
Dropping Point : > 2600 C (No dropping point)
Max. usable temp : > 1500 C
Water Resistance : Poor to good
Mechanical Stability : Fair to good
Rust Protection : Poor to good
Oil Separation : Good to excellent
Pump ability : Good
Special Feature : Excellent Inherent EP/AW Properties
Application : High temp. with frequent relubrication
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POLYUREA GREASES:
Prepared from highly toxic raw materials such as diamines & isocyanates.
Resultant polymer polyurea thickens oil to form grease structure.
Bio-degradable
Ash less
PROPERTIES:
Structure : Smooth, buttery
Dropping Point : > 2400 - 2600 C
Max. usable temp : 1500 C
Water Resistance : Good to excellent
Mechanical Stability : Fair to good
Oxidation Stability : Excellent
Rust Protection : Fair to excellent
Oil Separation : Good to excellent
Pump ability : Good to excellent
Special Feature : Excellent EP Properties
Application : Multiservice Auto/Industrial use
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EQUIPMENTS REQUIRED FOR PROCESSING:
REACTOR:
For the saponification reaction C.S. Jacketed reactor is used. The jacket is
provided for heating and cooling. Hot oil is circulated through the jacket for
heating raw materials.
Agitator is provided for thorough mixing at the bottom. This tubular reactor
provided with Steiner just above the agitator, to protect the agitator. Reactor is
provided with exit valve at bottom which is operated automatically or manually in
case of failure.
A
Cold oil supply
Hot oil supply
A
A
Hot oil return
Cold oil return
A
S
A
A
Base oil
Vent
Plant air
R101
Plant air
Blow down Agitator
Reactor
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SPECIFICATIONS OF THE REACTOR:
Equipment name: CS Jacketed Reactor
Design pressure:
1) Shell : 13 kg/cm2
2) Tube: 11.5 kg/cm2
3) Jacket: 10.5 kg/cm2
Design temperature :
1) Shell : 345 0C
2) Tube: 345 0C
3) Jacket: 345 0C
Test pressure:
1) Shell : 16.9 kg/cm2
2) Tube: 14.95 kg/cm2
3) Jacket: 13.65 kg/cm2
Corrosion allowance:
1) Shell : 1.6 mm
2) Tube: 1.6 mm
3) Jacket: 1.6 mm
Radiography: (Butt joint)
1) Shell : Full
2) Tube: Full
3) Jacket: Full
Capacity:
1) Shell : 4.5 m3
Total empty weight: 10000 kg
Weight when filled with water: 18500 kg
Heat treatment:
1) Shell – yes
2) Tube – yes
3) Jacket – yes
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KETTLE: 1. Kettles are used for blending of grease and to mix various additives & lube oil
with reacted soap mass.
2.There are seven kettles situated in the plant out of which four are of 10 tones
capacity & remaining are of 5 tones capacity.
3. Kettles are provided with jackets for heating and cooling.
4. The kettle jacket is divided into two zones. There are separate inlet and out let
nozzles provided to each zone
5. Kettles K101, K102 and K107 are heated using steam from boiler house. While
kettle are cooled by cold water obtained from cooling tower.
6. Kettles K103, K104, K105 & K106 are heated by using hot thermic fluid from
furnace.
7. Kettles are provided with anchor type of agitator which is rotated at various
speeds ranging from 30-100 rpm. Scrappers are provided so that no grease sticks
on the inner side of kettle and thorough mixing takes place.
8. There is a thermocouple well provided near the bottom of kettle. This
thermocouple has its display near the kettle opening.
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BASE OIL CHARGING:
TANKS:
TANK SPECIFICATIONS:
Tank capacity: 250KL
Product : lube oil (Base oil).
Reference height: 7.7Metre (From the depth of hatch.)
Diameter : 5.0MTRS.
Safe filling height: 7.35 Meter
Cleaning period : After 9 years.
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There are six base oil tanks in plant connected to each other by pump & pipeline
system.
(T401, T402, T403, T404, T405, T406.)
From the tank base oil is transfer to the small tanks (V105, V106) & finely used in
reactor & kettle for blending.
Manholes are provided at the bottom of lube oil tanks for cleaning purpose.
Base oil is carried to the small storage tank for charging to the reactor & kettles
(V105, V106…etc.)
R101
R102 V106
K101 K102 K103 K104 K105 K106
Pump
Base Oil Charging
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HOMOGENIZER:
TECHNICAL INFORMATION:
Capacity 6000 m3/hr.
Operating pressure (max) 345 bar
Max. Temperature 200˚C
Operating temperature 120 - 140˚C
OPERATION:
WORKING PRINCIPLE-
HIGH PRESSURE RELIEF TECHNIQUE
HIGH PRESSURE PLUNGER PUMP
HOMOGENIZING VALVE ARRANGED IN DOWNSTREAM
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OPRATION HYDROULIC VALVE ACTUATION (HVA):
The hydraulic valve actuation system include a hydraulic realize valve
which has been carefully set to control the maximum desired homogenizing
pressure or maximum safe operating pressure of machine. Each stage of a two
stage homogenizing valve controlled by separate pressure reducing valve
permitting independent control of each stage.
In two stage machine relief valve and reducing valve are piped in series.
Pressure must be created by relief valve. Before reducing valve can be operate.
The pressure requires will depend on product temp, nature of product,
homogenizing valve condition and type and condition of pump valve. Flow
through homogenizer valve, accelerated extremely and relieved to a low pressure
level.
EFFECTS:
Surface intation, nodufication of viscosity, increases storage, economy on
additive, increased of solids content, disapture of biological cellular material,
decomposition of higher molecular chemical compound, and reduction of
reaction period. It can produce drop size of some hundred of nanometers for
emulsion.
APPLICATIONS:
Food industry
Chemical industry
Pharmaceutical industry
Biotechnical industry
Starch industry
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MANUFACTURING PROCEDURE:
At the initiation of batch, according to the grade corresponding base oil and metal
hydroxide is charged to the reactor and heated by means of hot oil circulation.
After achieving a desired temp. reaction starts, as the pressure of the reactor
increases, water vapors are formed. The vapors are sent to atm.by venting valve
and reactor gets depressurized. After completion of reaction, reactor contains
soap, base oil and glycerol. This product mixture is then blown to kettle. Certain
quantity of base oil is heated in the reactor for washing purpose and taken in the
same kettle. Now the sample of the mixture in the kettle is sent to the lab to
check the alkalinity content, and according to the report suggested quantity of
base oil is added to the kettle as cut back. Additives are added to improve the
quality of grease and they are very heat sensitive, so before its addition to the
kettle, the kettle mass is cooled down to a certain temperature. The grease
formed is then homogenized for one hour for making it smooth. Finally the
sample of grease is sent to laboratory for penetration test. After passing in test,
grease is filled in buckets or barrels according to consumers demand and allowed
for atmospheric cooling.
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PLANT UTILITIES:
FURNACE:
Technical information:
Heat output 1.5*106 Kcal/hr.
BURNURE turn down 1:3
Thermic fluid pressure available at heater outlet 1.45kg/cm2gm
Thermic fluid flow rate 110 m3/hr.
Thermic fluid outlet temperature 2350c
Thermic fluid temperature rise 10-12 0c
Thermic fluid recommended a. High temp. mineral oil
b. Synthetic oil
Tube material specification LRW-B6359
NCV of LDO 10500 kcal/kg
LDO charging rate 165 kg/hr.
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UTILITIES:
HEATER UNIT: The heater heat up the oil and oil flow through the coil take up
the heat realize by firing furnace oil through the heater. LDO fired by pressure
atomize burner mounted on heater.
AIR PREHEATER: Air preheated is shell and tube construction since the heater
heat up the oil to higher temperature to fuel gases living furnace is high. This
gives scope of air preheated to receive heat by heating up comb oil.
HOT OIL CIRCULATION ASSEMBLY: This consists of two pump, filter and
isolating valve. One pump is circulated and maintains the flow of oil through
heater.
EXPANTION TANK ASSEMBLY: This consists of tank with hold up of heated
medium this allows the thermal expansion of the hot oil when it is heated
from room temperature to operating temp.
The oil pumping system consists of motor driver fuel pump one operating and one
stand by.
There are two panels:-
1) Power panel
2) Instrument control panel
There is one forced draft fan to supply combustion air to the burner. The blower
drives air the air preheated and the main heater on the chimney
STORAGE TANK: this consists of tank to hold LDO to be filled into system or tank
for driving the system. There is also top of the assembly which helps to fill the
system LDO or top up whenever necessary.
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MAIN HEATER:-
The main assembly consist of a single shell with two cool concentric
two coil are in parallel with multiple start. Coil is placed in the lower half of the
shell and the top half is placed on it. The end cover is then assembling the burner
then assembles on the heater. Slide glass is provided to view the flame.
INSTALLATION:
The heater should be grounded only after the duct connecting to it is made.
Flanges should not be installed until the heater has run continuously for same
temp. this insures that the flanged do not leakage of heating.
Check level of unit by spirit level. Expansion point must e filled at the flue gas
outlet connected from heater. The hot oil pipe connection must have spiral
wound 69-gasket whenever rise case flanges are used other have CAF gasket.
High tensile nuts and bolt are required whenever high temp. and pressure is
encountered.
Shell and heater must be insulated.
MAINTENANCE :
There are two type of maintenance:-
Routine maintenance: Involves inspecting and running condition it check the
operational parameter installation temp. Should be around 20-300c above
ambient.
Over hailing maintenance: The heater is in major job. It involves cleaning of coil
surface, replacement of gasket insulation, refractory etc. Disassembly must be
carried out for this. Coil cleaned by scrubbing with brush and then by compressed
air. Crack and damage must be check. Hydraulic test must be carried out to
ensure the leakage.
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BOILER:
BOILER IS USED FOR THE GENERATION OF STEAM WHICH IS USED FOR HEATING
THE PRODUCT IN THE KETTLE NO K101, K102 & K 107.
BOILER SPECIFICATION:
BOILER MR 115
Type : 3 pass reverse flue smoke tube Boiler Capacity : 3 tons/hr.
Evaporation rate : 3000 Kg/Hr.
Output : 1.88 MW
Fuel : LDO
Voltage : 415 V
Phase : 3 Phases
Frequency : 50 Hz
Maximum pressure : 10.5 Kg/cm2
Working pressure : 10.3 Kg/cm2
Connected load : 15KW
Cleaning period : 1year
Support : Saddle
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Soft water is used in the boiler for generation of steam.
Ion exchange system is provided before the inlet provision of water into the
boiler.
Ion exchange system removes Ca++ & Mg++ ions from hard water to make it soft
for boiler use.
Generally hardness of water should be reduced to 5-8 ppm / pH range 8.5-9.5.
Inside boiler hot gases pass through horizontal tubes and water moves over
the outer surface so as to generate steam.
Flue gases produced are discharged to atmosphere by chimney.
COOLING TOWER:
It is spray tower consist of square type tank having dome shape at the top.
From the top water flows downward in the tank & air is circulated from bottom.
Air flowing from bottom is continuously cooled the water, which is flowing from
top, by forced convection. After cooling the water it sent to the boiler for further
process.
Fig: COUNTERFLOW TYPE COOLING TOWER
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ADVANTAGES AND FUNCTIONAL FEATURES:
MODERN CONSTRUCTION:
Natural cooling tower are of vertical induced draft counter flow design. The tower
ideal with regards space economy and cooling efficiency.
F.R.P body: the body of the tower is made up of tough fiber glass reinforced
plastic it has a sufficient structural strength to with stand high industrial vibration
and wind velocity. It has resistance to local impact and even if damage is
sustained local repairs can easily be done.
SPECIAL MOTOR (IP 55):
Continuous rating shock proofed totally enclosed type as per IP 55 and suitable
for outdoor mounting.
FAN:
Fan is directly driven and axially flow type the fan blades are of cast aluminum
completely free from problem encountered with belt and gear drive.
DRIFT ELIMINATOR:
It present spray entrainment reduces carry over losses of water. The eliminator of
rigid PVC.
PVC FILL:
Corrosion resistant fill are of polyvinyl chloride in honey comb design.
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FIXED SPRINKLER WITH SPRAY NOZZLE:
Fixed sprinkler with spray nozzle for uniform distribution of water over the fill
area and fill can be observed clearly any reappearing can be done through the
window.
INSPECTION WINDOW:
Easy operating window is provided to inspect from where water distribution and
fill can be observed easily and reappearing can be done through the window.
MOST ECONOMICAL:
Smaller HP motor is used for the tower to make the great deal of difference in
operating cost aiming to deliver quality at most economical prize.
MAINTAINANCE:
Considerably reduce the cost because fan is the only moving part of the cooling
tower. Fixed distribution system instead of rotating sprinkler which eliminate all
bearing and frictional problem.
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CHIMNEYS:
Chimneys are used to discharge hazardous gases to high attitude.
Chimneys in the plant are:
1) Furnace self supported chimney.
2) Boiler self supported chimney.
Furnace self supported chimney:
Height : 30.30m
Bottom diameter : 1.200m
Top diameter : 0.600m
Furnace self supported chimney helps to discharge unwanted gases from furnace
& hot oil heater to high attitude.
Boiler self supported chimney:
Height : 30.30m
Bottom diameter : 1.600m
Top diameter : 0.800m
Boiler self supported chimney used to discharge gases generated at the time of
steam generation.
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COMPRESSOR:
Compressor makes balance opposed compressor is high efficiency, heavy duty
compressor developed with latest technology obtained from m/s Fives Coul
Babcol, who have decades of experience in industries. The basic feature of balance
opposed horizontal compressor whether single stage or multistage design is
composed of two cylinder lines opposed at 180*C.
Compressor is driven either by electrical engine or by diesel engine or directly
through suitable coupling.
The two piston of each line which is moving in opposite direction have equal
masses, thereby the forces resulting from compression & from inertia of motion.
Work is always balanced in the two cylinder of same lining. There resultant forces
being different produce an axial torque without any reaction on bearing. The
primary & secondary forces also counter balance each other thereby nullifying any
possibility of vibration or knocking.
Compressor is used to compress air so that It can be used for a lot of application.
All the valves operated from the DCS are pneumatic valves. These valves are
controlled with increase or decrease in air pressure on the diaphragm of the valves.
Also compressed air is used to maintain pressure in the reactor as well as to blow
grease from the pipelines while filling operation is taking place.
There are 4 compressors viz.
1) COMPRESSOR 201A
2) COMPRESSOR 201B
3) COMPRESSOR 202A
4) COMPRESSOR 202B
TECHNICAL INFORMATION:
UNIT INTER COOLER
TEST PRESSURE 7.5 KG/CM2
39 | P a g e
LABORATORY TESTS FOR QUALITY CONTROL:
METHOD 1: Test method for determination of free acidity and alkalinity of grease
Scope: The method is intended for the determination of free acidity or alkalinity
in the grease
Outlines of method: Grease is dispersed in hexane 50ml of neutral rectified spirit
is added followed by 10ml 0.5N HCl and reflux for 10-15min. cooled and titrate
against standard alkali.
METHOD 2: Cone penetration of lubricating grease.
Scope: The method is intended for determination of four procedure of measuring
consistency of lubricating grease by penetration of standard cone i.e.
1) Unworked
2) Worked
3) Prolong work
4) Block
Penetration maximum limit is 475 that can be measured .this helps to establish
consistency (category) of grease within (NLGI) consistency grade .prolong working
penetration gives shear stability of under condition of test.
Outlines of Method:
The penetration is determined at 250c by releasing the cone assembly from the
penetrometer & allowing the cone to drop freely in to the grease for 5 sec.
40 | P a g e
DEFINITION:
Penetration: It is the depth in the tenths of millimeter that a standard cone
penetrates the sample under prescribed condition of weight, time & temp.
Working: It is the subjection of lubricating grease to shearing action of standard
grease worker.
Unworked penetration: It is the penetration at 25 0c of grease which is
transferred in grease worker cup &leveled with minimum working.
Work penetration: It is the penetration of grease sample subjected to 60 double
strokes in standard grease worker &penetration is done at 250c.
Block penetration: It is the penetration at 250c or grease sample that is
sufficiently hard to hold its shape determined on the freshly prepared face of a
cube cut from a block of the grease.
METHOD 3: Test method for working stability of grease in presence of water
Scope: The method is intended for the determination of change in consistency
when subjected to work in presence of water.
Outline of the Method:
Grease is filled in cup & exposed to prolong mechanical working in presence of
water (10 % wt.) and in absence of water & difference in penetration is
determined
METHOD 4: Test method for determination of dropping point of grease.
Scope: The method covers the determination of dropping point of lubricating
grease. This point is being the temperature at which first drop of material fall
from cup (from the bottom).
Outline of the method: Small quantity of grease is taken in drop point cup &
heated slowly to the temperature at which first drop of oil comes out from the
whole at the bottom of the test cup. The temperature at which this drop falls is
noted as dropping point of the grease.
41 | P a g e
METHOD 5: Test method for copper corrosion test.
Scope: The test is intended for the determination of corrosive substances in the
lubricating grease, oil, fat & additives. As the grease is employed under diversity
of conditions it is not possible to specify either temperature or duration of test. It
is recommended that temperature be not higher than 20*c below the drop point
of grease.
Outline of the method: Clean & polished copper strip is immersed in the sample
which is then maintain in the specified temperature & duration. The strips are
removed, wash with petroleum spirit & examined for evidence of etching, pitting
& discoloration.
Method 6: Evaporation loss of lubricating grease.
Scope: This method covers the determination of the evaporation loss in
lubricating grease.
Outline of the method: The sample is weighted in petrel or glass dish & kept for2
hrs in an oven maintained at 105+or-10*c. The loss in mass is calculated as an
evaporation loss of the sample.
METHOD 7: Test method for oxidation stability of lubrication grease by the
oxygen bomb method
Scope: The test method is intended determine resistance of lubricating grease to
oxidation when stored statically n an oxygen atmosphere in seated system at an
elevated temp. Under oxidation of test.
Outline of the method: The sample of grease is oxidation in a bomb hated to
2100c /990c and filled with oxygen at 110psi (7.5bar) pressure is observed. The
degree at stated interval. The degree of oxidation after a given period of time is
determination by corresponding decreases in oxygen pressure.
42 | P a g e
METHOD 8: Water washes out characteristics of lubricating grease
Scope: This method of test is intended to evaluate the resistance of lubricating
grease to wash out by water from the bearing. When tested at 380c/800c under
prescribed laboratory condition.
Outline of the method: The grease is packed in boll bearing. The bearing is then
inserted in housing with specified clearance and rotates at 600+or-30rpm. Water
collected at the specified test temp. Impinges on the bearing housing at the rate
of 5+or-0.5ml/sec. The amount of grease wash out in 1hr is a measure of
resistance of grease to water washes out.
METHOD 9: Method for determination of storage stability of grease
Scope: This method described a procedure for determine the storage stability of
grease
Outline of the method: The consistency, both worked and unworked penetration
of material is determined by cone penetration test. Sample of original material
are stored in dark in a container for six month at 38+or-3*c. The consistency, both
worked and unworked penetration of the stored sample is then determined.
43 | P a g e
CRITERIA FOR GREASE SELECTION:-
Sr. No. Factors Expected properties
1 High load/shock load Grease with high
viscosity oil
2 Low temp. Grease with low
viscosity oil
3 High temp. Heat resistant grease
4 High temp./re-lubrication Grease that does not
form residue at high
temp.
5 Dusty environment Grease with nlgi-3 &
above grades
6 Frequent relubrication Soft grease of nlgi-
0/1/2 grade
7 High speed Grease with low
viscosity oil & good
adhesive properties
FACTORS AFFECTING QUALITY OF GREASE:
Rate of saponification reaction
Acidity / alkalinity
Rate / sequence of addition of additives and oil
Temperature of grease formation
Temperature of additive addition.
Temperature and duration of de-aeration, filtration and homogenization.
44 | P a g e
45 | P a g e
Batch no.: 0118 Reactor: R-102
Date: 23/05/2012 Kettle: K-105
Penetration: 230/232
RAW MATERIAL REQUIRED FOR CHARGING IS:-
FOR CALCULATING AVG. MOL. WT. OF FATS:-
SAP VALUE of 12 HSA=181.24
SO, 181.24 Gms of KOH = 1000 Gms of 12HSA
FOR 56.1 Gms of KOH =
=309.534 Gms of 12 HSA
COMPONENT MOLECULAR WEIGHT 12 HSA 309.534 HCO 938 LiOH 23.95 WATER 18 LiOH.H2O 42 SOAP OF 12 HSA 305.914 SOAP OF HCO 306
COMPONENT QUANTITY BASE OIL 500 N 2800 12 HYDROXY STEARIC ACID 1000 HCO 300 LITHIUM HYDROXIDE MONOHYDRATE 200 WATER 10 TOTAL 4310
46 | P a g e
OVERALL MASS BALANCE OVER REACTOR DURING REACTION:-
Now,
INPUT = OUTPUT
HCO + 12HSA + LiOH.H2O + BASE OIL + WATER = SOAP + VENT
300 + 1000 + 200 + 2800 + 10 = SOAP + VENT
4310=SOAP +VENT ………………………….. (1)
BASE OIL
12 HSA
HCO
REACTOR LiOH.H2O
WATER
SOAP
VENT
STEAM
+
SOAP IN
VENT
(LOSSES)
47 | P a g e
OVERALL MASS BALANCE OVER REACTOR DURING WASHING :-
BRIGHT STOCK FOR WASHING = WASHED OIL + VENT
2500 = WASHED OIL + VENT ………………………….. (2)
KETTLE
REACTOR 150 BS BASE OIL
VENT
WASHED OIL
48 | P a g e
OVERALL MASS BALANCE OVER KETTLE:-
SOAP + WASHED OIL + ADDITIVES + CORRECTION/CUTBACK OIL+12 HSA = EXHAUST + OUTPUT
(GREASE)
SOAP + WASHED OIL + 40+45+36 + 702 + 1300 + 25 = EXHAUST + 8736
SOAP + WASHED OIL +2148 = EXHAUST + 8736 …………………. (3)
KETTLE EX
HA
UST
TO
FILLING
SOAP FROM REACTOR
CUTBACK/CORRECTION OIL
ADDITIVES W
ASH
ED O
IL
49 | P a g e
WATER/VOLATILES BALANCE:-
WATER IN CHARGING:
Water= 10 kgs
WATER OF CRYSATALISATION OF LiOH.H 2O:
42 Kg LiOH.H2O = 18 Kg of WATER
200 Kg of LiOH.H2O = X Kg of WATER
Hence, X = 200*18/42
X = 85.714 Kg
WATER RELEASED DURING REACTION:
I Mole HSA= 1 Mole Water
309.534 gm HSA =18 gm Water
1025 kg HSA = Y Kg Water
Y=
= 59.61 kg of Water as Steam
MOISTURE CONTENT OF FATTY ACIDS (0.25%):
TOTAL Amount of FATTY ACID = 1325 Kg (1000+300+25)
Hence, total Amount of moisture in that = 1325*0.25/100
Hence, = 3.31 Kg of MOISTURE
50 | P a g e
VOLATILE AND MOISTURE CONTENT OF BASE OIL:
FOR 1 mg of BASE OIL = 400 ppm of (WATER & VOLITILE)
Hence, For 7302 Kg of BASE OIL = 7302*400*10-6
= 2.92 Kg of (WATER & VOLITILE)
TOTAL AMOUNT OF WATER RELEASED=85.714+59.61+3.31+2.92+10
TOTAL AMOUNT OF WATER RELEASED =161.55 Kgs of water …………………. (4)
WATER BALANCE OVER REACTOR:-
1. DURING REACTION:
WATER ADDED + WATER/VOLATILES IN BASE OIL + WATER IN FATTY ACID + WATER OF
CRYSTALISATION + WATER RELEASED DURING REACTION = STEAM VENTED
10+ 2800*400*10-6 + 1300*0.25% + 85.714 + 59.61 = STEAM VENTED
10+1.12+3.25+85.714+59.61= STEAM VENTED
159.69 Kgs = STEAM VENTED FROM REACTOR ……………………. (5)
NOTE: DUE TO MANUAL ERRORS SOMETIMES SOME AMOUNT OF SOAP IS LOST WHILE
VENTING
FROM OBSERVATIONS, IT IS AROUND 35 KGS PER BATCH
SO,
SOAP LOST IN VENT=35 KGS
TOTAL VENT FROM REACTOR= 159.69 + 35 =194.69 Kgs
51 | P a g e
Now from equation 1,
4310=SOAP +VENT FROM REACTOR ………………………….. (From 1)
4310 = soap + 194.69
Soap = 4115.31 Kgs
2. DURING WASHING:-
2500 = WASHED OIL + VENT
Water content of 150 BS =400ppm
Hence, water in base oil = vent
=400*10-6*2500
VENT DURING WASHING =1.00 kg…………………. (6)
WATER BALANCE OVER KETTLE:-
WATER IN SOAP+WATER/VOLATILES IN BASE OIL + WATER IN ADDITIVES + WATER IN FATTY
ACID = WATER IN EXHAUST+ WATER IN OUTPUT (GREASE)
0 + (702+1300)*400*10-6 + 25*0.25% + 0 = EXHAUST + 0
EXHAUST = 0.8633 Kgs ………………………….. (7)
FROM EQUATIONS (4), (5), (6) & (7),
TOTAL AMOUNT OF WATER RELEASED = STEAM VENTED FROM REACTOR +
VENT DURING WASHING + EXHAUST
=159.69+1.00+0.8633
=161.55 Kgs of water
THUS, WATER IS BALANCED.
52 | P a g e
ALKALI BALANCE:-
Stoichiometric proportion:
1 mole of LiOH.H2O = 1 mole of Lithium Stearate
= 1 mole of 12 HSA
309.534 KG OF 12 HSA = 42 KG LiOH.H2O
1025 KG OF 12 HSA = X KG LiOH.H2O
X=
= 139.1 kg of LiOH.H2O
3 moles of LiOH.H2O = 1 mole of HCO
938 KG of HCO = 42*3 KG LiOH. H2O
300 KG of HCO = X KG LiOH. H2O
X=
= 40.30 kg of LiOH.H2O
Free alkali content= 0.15% wt. of LiOH
Total quantity fed = 4310 kg
Free alkali content=
= 6.465 kg of LiOH
Hence, LiOH content=
= 11.31 kg of free alkali
53 | P a g e
Qty of alkali for base oil TAN
TAN value of base oil = 0.03%
0.03 kgs of KOH=1000 kgs of BASE OIL
7302 kgs of base oil req= 7302 *
*
= 0.164 kg of LiOH.H2O
Total qty of alkali required =139.1+40.3+11.31+0.164
TOTAL QTY OF ALKALI REQUIRED (theoretical) =190.874 KGS
PRACTICAL QTY. FED TO REATOR=200 KG
Excess alkali=200-190.874
EXCESS ALKALI=9.126 KGS
NOW, OVERALL BALANCE
TOTAL INPUT = OUTPUT + LOSSES
TOTAL INPUT = 8958 kgs
TOTAL OUTPUT = NO. OF BARRELS *182(+VE OR –VE VARIATION)
= 48 *182.5
= 8760 Kgs
PROCESS LOSS = 8958-8760
= 198 Kgs
ACTUAL % LOSS = 198*100/8958
= 2.21 %
THEORITICAL LOSS = MASS LOST AS STEAM
= 161.55 Kgs
54 | P a g e
THEORITICAL % LOSS= 161.55*100/8958
= 1.8 %
Hence, DEVIATION = 1.8 – 2.21
DEVIATION = -0.4 % (LOSS)
LOSSES ENCOUNTERED=MASS LOST AS STEAM + SOAP LOST IN VENT + FILLING
LOSSES + OTHER LOSSES
198 = 161.55 + 35 + OTHER LOSSES
Hence, OTHER LOSSES = 1.45 Kgs
NOTE:-
FILLING LOSSES CONSTITUTE THE MASS DISCARDED INITIALLY, CALIBRATION ERROR, SET POINT AND THE
MASS REMAINED AFTER FILLING THE LAST BARREL.
OTHER LOSSES CONSTITUTE LOSSES DUE TO INCOMPLETE REACTION BECAUSE OF IMPROPER REACTION
CONDITIONS, MANUAL ERRORS, AND MASS REMAINED IN THE KETTLE AFTER FILLING, ETC.
55 | P a g e
Batch no.: 0136 Reactor: R-101
Date: 28/05/2012 Kettle: K-105
Penetration: 230/232
RAW MATERIAL REQUIRED FOR CHARGING IS:-
FOR CALCULATING AVG. MOL. WT. OF FATS:-
SAP VALUE of 12 HSA=181.24
SO, 181.24 Gms of KOH = 1000 Gms of 12HSA
FOR 56.1 Gms of KOH =
=309.534 Gms of 12 HSA
COMPONENT MOLECULAR WEIGHT 12 HSA 309.534 HCO 938 LiOH 23.95 WATER 18 LiOH.H2O 42 SOAP OF 12 HSA 305.914 SOAP OF HCO 306
COMPONENT QUANTITY BASE OIL 500 N 2805 12 HYDROXY STEARIC ACID 1000 HCO 300 LITHIUM HYDROXIDE MONOHYDRATE 200 WATER 10 TOTAL 4315
56 | P a g e
OVERALL MASS BALANCE OVER REACTOR DURING REACTION:-
Now,
INPUT = OUTPUT
HCO + 12HSA + LiOH.H2O + BASE OIL + WATER = SOAP + VENT
300 + 1000 + 200 + 2805 +10 = SOAP + VENT
4315=SOAP +VENT ………………………….. (1)
BASE OIL
12 HSA
HCO
REACTOR LiOH.H2O
WATER
SOAP
VENT
STEAM
+
SOAP IN
VENT
(LOSSES)
57 | P a g e
OVERALL MASS BALANCE OVER REACTOR DURING WASHING :-
BRIGHT STOCK FOR WASHING = WASHED OIL + VENT
2500 = WASHED OIL + VENT ………………………….. (2)
KETTLE
REACTOR 150 BS BASE OIL
VENT
WASHED OIL
58 | P a g e
OVERALL MASS BALANCE OVER KETTLE:-
SOAP + WASHED OIL + ADDITIVES + CORRECTION/CUTBACK OIL = EXHAUST + OUTPUT (GREASE)
SOAP + WASHED OIL + 40+45+36+ 2206 = EXHAUST + 8918
SOAP + WASHED OIL +2327 = EXHAUST + 8918 …………………. (3)
KETTLE EX
HA
UST
TO
FILLING
SOAP FROM REACTOR
CUTBACK/CORRECTION OIL
ADDITIVES W
ASH
ED O
IL
59 | P a g e
WATER/VOLATILES BALANCE:-
WATER IN CHARGING:
Water= 10 kgs
WATER OF CRYSATALISATION OF LiOH.H 2O:
42 Kg LiOH.H2O = 18 Kg of WATER
200 Kg of LiOH.H2O = X Kg of WATER
Hence, X = 200*18/42
X = 85.714 Kg
WATER RELEASED DURING REACTION:
I Mole HSA= 1 Mole Water
309.534 gm HSA =18 gm Water
1000 kg HSA = Y Kg Water
Y=
= 58.15 kg of Water as Steam
MOISTURE CONTENT OF FATTY ACIDS (0.25%):
TOTAL Amount of FATTY ACID = 1300 Kg (1000+300)
Hence, total Amount of moisture in that = 1300*0.25/100
Hence, = 3.25 Kg of MOISTURE
60 | P a g e
VOLATILE AND MOISTURE CONTENT OF BASE OIL:
FOR 1 mg of BASE OIL = 400 ppm of (WATER & VOLITILE)
Hence, For 7511 Kg of BASE OIL = 7511*400*10-6
= 3.00 Kg of (WATER & VOLITILE)
TOTAL AMOUNT OF WATER RELEASED=85.714+58.15+3.25+3.0+10
TOTAL AMOUNT OF WATER RELEASED =160.114 Kgs of water …………………. (4)
WATER BALANCE OVER REACTOR:-
3. DURING REACTION:
WATER ADDED + WATER/VOLATILES IN BASE OIL + WATER IN FATTY ACID + WATER OF
CRYSTALISATION + WATER RELEASED DURING REACTION = STEAM VENTED
10+ 2805*400*10-6 + 1300*0.25% + 85.714 + 58.15 = STEAM VENTED
10+1.12+3.25+85.714+58.15= STEAM VENTED
158.234 Kgs = STEAM VENTED FROM REACTOR ……………………. (5)
NOTE: DUE TO MANUAL ERRORS SOMETIMES SOME AMOUNT OF SOAP IS LOST WHILE
VENTING
FROM OBSERVATIONS, IT IS AROUND 35 KGS PER BATCH
SO,
SOAP LOST IN VENT=35 KGS
TOTAL VENT FROM REACTOR= 158.234 + 35 =193.234 Kgs
61 | P a g e
Now from equation 1,
4315=SOAP +VENT FROM REACTOR ………………………….. (From 1)
4315 = soap + 193.234
Soap = 4121.766 Kgs
4. DURING WASHING:-
2500 = WASHED OIL + VENT
Water content of 150 BS =400ppm
Hence, water in base oil = vent
=400*10-6*2500
VENT DURING WASHING =1.00 kg…………………. (6)
WATER BALANCE OVER KETTLE:-
WATER IN SOAP+WATER/VOLATILES IN BASE OIL + WATER IN ADDITIVES = WATER IN EXHAUST+
WATER IN OUTPUT (GREASE)
0 + (506+1700)*400*10-6 + 0 = EXHAUST + 0
EXHAUST = 0.88 Kgs ………………………….. (7)
FROM EQUATIONS (4), (5), (6) & (7),
TOTAL AMOUNT OF WATER RELEASED = STEAM VENTED FROM REACTOR +
VENT DURING WASHING + EXHAUST
=158.234+1.00+0.88
=160.114 Kgs of water
THUS, WATER IS BALANCED.
62 | P a g e
ALKALI BALANCE:-
Stoichiometric proportion:
1 mole of LiOH.H2O = 1 mole of Lithium Stearate
= 1 mole of 12 HSA
309.534 KG OF 12 HSA = 42 KG LiOH.H2O
1000 KG OF 12 HSA = X KG LiOH.H2O
X=
= 135.687 kg of LiOH.H2O
3 moles of LiOH.H2O = 1 mole of HCO
938 KG of HCO = 42*3 KG LiOH. H2O
300 KG of HCO = X KG LiOH. H2O
X=
= 40.30 kg of LiOH.H2O
Free alkali content= 0.15% wt. of LiOH
Total quantity fed = 4310 kg
Free alkali content=
= 6.465 kg of LiOH
Hence, LiOH content=
= 11.31 kg of free alkali
63 | P a g e
Qty of alkali for base oil TAN
TAN value of base oil = 0.03%
0.03 kgs of KOH=1000 kgs of BASE OIL
7511 kgs of base oil req= 7511 *
*
= 0.168 kg of LiOH.H2O
Total qty of alkali required =135.69+40.3+11.31+0.168
TOTAL QTY OF ALKALI REQUIRED (theoretical) =187.74 KGS
PRACTICAL QTY. FED TO REATOR=200 KG
Excess alkali=200-187.47
EXCESS ALKALI=12.53 KGS
NOW, OVERALL BALANCE
TOTAL INPUT = OUTPUT + LOSSES
TOTAL INPUT = 9142 kgs
TOTAL OUTPUT = NO. OF BARRELS *182(+VE OR –VE VARIATION)
= 49 *182.5
= 8942.5 Kgs
PROCESS LOSS = 9142-8942.5
= 199.5 Kgs
ACTUAL % LOSS = 199.5*100/9139
= 2.2 %
64 | P a g e
THEORITICAL LOSS = MASS LOST AS STEAM
= 158.234
THEORITICAL % LOSS= 158.234*100/9139
= 1.73 %
Hence, DEVIATION = 1.73 – 2.2
DEVIATION = -0.47 % (LOSS)
LOSSES ENCOUNTERED=MASS LOST AS STEAM + SOAP LOST IN VENT + FILLING
LOSSES + OTHER LOSSES
199.5 = 158.234 + 35 + OTHER LOSSES
Hence, OTHER LOSSES = 6.266 Kgs
NOTE:-
FILLING LOSSES CONSTITUTE THE MASS DISCARDED INITIALLY, CALIBRATION ERROR, SET POINT AND THE
MASS REMAINED AFTER FILLING THE LAST BARREL.
OTHER LOSSES CONSTITUTE LOSSES DUE TO INCOMPLETE REACTION BECAUSE OF IMPROPER REACTION
CONDITIONS, MANUAL ERRORS, AND MASS REMAINED IN THE KETTLE AFTER FILLING, ETC.
65 | P a g e
Batch no.: 0131 Reactor: R-101
Date: 26/05/2012 Kettle: K-105
Penetration: 228/232
RAW MATERIAL REQUIRED FOR CHARGING IS:-
FOR CALCULATING AVG. MOL. WT. OF FATS:-
SAP VALUE of 12 HSA=181.24
SO, 181.24 Gms of KOH = 1000 Gms of 12HSA
FOR 56.1 Gms of KOH =
=309.534 Gms of 12 HSA
COMPONENT MOLECULAR WEIGHT 12 HSA 309.534 HCO 938 LiOH 23.95 WATER 18 LiOH.H2O 42 SOAP OF 12 HSA 305.914 SOAP OF HCO 306
COMPONENT QUANTITY BASE OIL 500 N 2801 12 HYDROXY STEARIC ACID 1000 HCO 300 LITHIUM HYDROXIDE MONOHYDRATE 200 WATER 5 TOTAL 4306
66 | P a g e
OVERALL MASS BALANCE OVER REACTOR DURING REACTION:-
Now,
INPUT = OUTPUT
HCO + 12HSA + LiOH.H2O + BASE OIL + WATER = SOAP + VENT
300 + 1000 + 200 + 2801 + 5 = SOAP + VENT
4306=SOAP +VENT ………………………….. (1)
BASE OIL
12 HSA
HCO
REACTOR LiOH.H2O
WATER
SOAP
VENT
STEAM
+
SOAP IN
VENT
(LOSSES)
67 | P a g e
OVERALL MASS BALANCE OVER REACTOR DURING WASHING :-
BRIGHT STOCK FOR WASHING = WASHED OIL + VENT
2500 = WASHED OIL + VENT ………………………….. (2)
KETTLE
REACTOR 150 BS BASE OIL
VENT
WASHED OIL
68 | P a g e
OVERALL MASS BALANCE OVER KETTLE:-
SOAP + WASHED OIL + ADDITIVES + CORRECTION/CUTBACK OIL = EXHAUST + OUTPUT (GREASE)
SOAP + WASHED OIL + 45+54+36+ 2300 = EXHAUST + 8918
SOAP + WASHED OIL +2435 = EXHAUST + 8918 …………………. (3)
KETTLE EX
HA
UST
TO
FILLING
SOAP FROM REACTOR
CUTBACK/CORRECTION OIL
ADDITIVES W
ASH
ED O
IL
69 | P a g e
WATER/VOLATILES BALANCE:-
WATER IN CHARGING:
Water= 5 kgs
WATER OF CRYSATALISATION OF LiOH.H 2O:
42 Kg LiOH.H2O = 18 Kg of WATER
200 Kg of LiOH.H2O = X Kg of WATER
Hence, X = 200*18/42
X = 85.714 Kg
WATER RELEASED DURING REACTION:
I Mole HSA= 1 Mole Water
309.534 gm HSA =18 gm Water
1000 kg HSA = Y Kg Water
Y=
= 58.15 kg of Water as Steam
MOISTURE CONTENT OF FATTY ACIDS (0.25%):
TOTAL Amount of FATTY ACID = 1300 Kg (1000+300)
Hence, total Amount of moisture in that = 1300*0.25/100
Hence, = 3.25 Kg of MOISTURE
70 | P a g e
VOLATILE AND MOISTURE CONTENT OF BASE OIL:
FOR 1 mg of BASE OIL = 400 ppm of (WATER & VOLITILE)
Hence, For 7601 Kg of BASE OIL = 7601*400*10-6
= 3.04 Kg of (WATER & VOLITILE)
TOTAL AMOUNT OF WATER RELEASED=85.714+58.15+3.25+3.04+5
TOTAL AMOUNT OF WATER RELEASED =155.154 Kgs of water …………………. (4)
WATER BALANCE OVER REACTOR:-
5. DURING REACTION:
WATER ADDED + WATER/VOLATILES IN BASE OIL + WATER IN FATTY ACID + WATER OF
CRYSTALISATION + WATER RELEASED DURING REACTION = STEAM VENTED
5+ 2801*400*10-6 + 1300*0.25% + 85.714 + 58.15 = STEAM VENTED
5+1.12+3.25+85.714+58.15= STEAM VENTED
153.234 Kgs = STEAM VENTED FROM REACTOR ……………………. (5)
NOTE: DUE TO MANUAL ERRORS SOMETIMES SOME AMOUNT OF SOAP IS LOST WHILE
VENTING
FROM OBSERVATIONS, IT IS AROUND 35 KGS PER BATCH
SO,
SOAP LOST IN VENT=35 KGS
TOTAL VENT FROM REACTOR= 153.234 + 35 =188.234 Kgs
71 | P a g e
Now from equation 1,
4306=SOAP +VENT FROM REACTOR ………………………….. (From 1)
4306 = soap + 188.234
Soap = 4117.766 Kgs
6. DURING WASHING:-
2500 = WASHED OIL + VENT
Water content of 150 BS =400ppm
Hence, water in base oil = vent
=400*10-6*2500
VENT DURING WASHING =1.00 kg…………………. (6)
WATER BALANCE OVER KETTLE:-
WATER IN SOAP+WATER/VOLATILES IN BASE OIL + WATER IN ADDITIVES = WATER IN EXHAUST+
WATER IN OUTPUT (GREASE)
0 + (500+1800)*400*10-6 + 0 = EXHAUST + 0
EXHAUST = 0.92 Kgs ………………………….. (7)
FROM EQUATIONS (4), (5), (6) & (7),
TOTAL AMOUNT OF WATER RELEASED = STEAM VENTED FROM REACTOR +
VENT DURING WASHING + EXHAUST
=153.234+1.00+0.92
=155.155 Kgs of water
THUS, WATER IS BALANCED.
72 | P a g e
ALKALI BALANCE:-
Stoichiometric proportion:
1 mole of LiOH.H2O = 1 mole of Lithium Stearate
= 1 mole of 12 HSA
309.534 KG OF 12 HSA = 42 KG LiOH.H2O
1000 KG OF 12 HSA = X KG LiOH.H2O
X=
= 135.687 kg of LiOH.H2O
3 moles of LiOH.H2O = 1 mole of HCO
938 KG of HCO = 42*3 KG LiOH. H2O
300 KG of HCO = X KG LiOH. H2O
X=
= 40.30 kg of LiOH.H2O
Free alkali content= 0.15% wt. of LiOH
Total quantity fed = 4310 kg
Free alkali content=
= 6.465 kg of LiOH
Hence, LiOH content=
= 11.31 kg of free alkali
73 | P a g e
Qty of alkali for base oil TAN
TAN value of base oil = 0.03%
0.03 kgs of KOH=1000 kgs of BASE OIL
7601 kgs of base oil req= 7601 *
*
= 0.17 kg of LiOH.H2O
Total qty of alkali required =135.69+40.3+11.31+0.17
TOTAL QTY OF ALKALI REQUIRED (theoretical) =187.47 KGS
PRACTICAL QTY. FED TO REATOR=200 KG
Excess alkali=200-187.47
EXCESS ALKALI=12.53 KGS
NOW, OVERALL BALANCE
TOTAL INPUT = OUTPUT + LOSSES
TOTAL INPUT = 9241 kgs
TOTAL OUTPUT = NO. OF BARRELS *182(+VE OR –VE VARIATION)
= 49 *182.3
= 8932.7 Kgs
PROCESS LOSS = 9241-8932.7
= 308.3 Kgs
ACTUAL % LOSS = 308.3*100/9241
= 3.33 %
74 | P a g e
THEORITICAL LOSS = MASS LOST AS STEAM+SOAP LOST
= 155.154+35
=190.154 Kgs
THEORITICAL % LOSS= 190.154*100/9241
= 2.05 %
Hence, DEVIATION = 2.05 – 3.33
DEVIATION = -1.28 % (LOSS)
LOSSES ENCOUNTERED=MASS LOST AS STEAM + SOAP LOST IN VENT + FILLING
LOSSES + OTHER LOSSES
308.3 = 155.154 + 35 + OTHER LOSSES
Hence, OTHER LOSSES = 117.846 Kgs
NOTE:-
FILLING LOSSES CONSTITUTE THE MASS DISCARDED INITIALLY, CALIBRATION ERROR, SET POINT AND THE
MASS REMAINED AFTER FILLING THE LAST BARREL.
OTHER LOSSES CONSTITUTE LOSSES DUE TO INCOMPLETE REACTION BECAUSE OF IMPROPER REACTION
CONDITIONS, MANUAL ERRORS, AND MASS REMAINED IN THE KETTLE AFTER FILLING, ETC.
75 | P a g e
Batch no.: 0142 Reactor: R-102
Date: 29/05/2012 Kettle: K-107
Penetration: 228/232
RAW MATERIAL REQUIRED FOR CHARGING IS:-
FOR CALCULATING AVG. MOL. WT. OF FATS:-
SAP VALUE of 12 HSA=181.24
SO, 181.24 Gms of KOH = 1000 Gms of 12HSA
FOR 56.1 Gms of KOH =
=309.534 Gms of 12 HSA
COMPONENT MOLECULAR WEIGHT 12 HSA 309.534 HCO 938 LiOH 23.95 WATER 18 LiOH.H2O 42 SOAP OF 12 HSA 305.914 SOAP OF HCO 306
COMPONENT QUANTITY BASE OIL 500 N 2805 12 HYDROXY STEARIC ACID 1000 HCO 300 LITHIUM HYDROXIDE MONOHYDRATE 200 WATER 10 TOTAL 4315
76 | P a g e
OVERALL MASS BALANCE OVER REACTOR DURING REACTION:-
Now,
INPUT = OUTPUT
HCO + 12HSA + LiOH.H2O + BASE OIL + WATER = SOAP + VENT
300 + 1000 + 200 + 2805 +10 = SOAP + VENT
4315=SOAP +VENT ………………………….. (1)
BASE OIL
12 HSA
HCO
REACTOR LiOH.H2O
WATER
SOAP
VENT
STEAM
+
SOAP IN
VENT
(LOSSES)
77 | P a g e
OVERALL MASS BALANCE OVER REACTOR DURING WASHING :-
BRIGHT STOCK FOR WASHING = WASHED OIL + VENT
2500 = WASHED OIL + VENT ………………………….. (2)
KETTLE
REACTOR 150 BS BASE OIL
VENT
WASHED OIL
78 | P a g e
OVERALL MASS BALANCE OVER KETTLE:-
SOAP + WASHED OIL + ADDITIVES + CORRECTION/CUTBACK OIL = EXHAUST + OUTPUT (GREASE)
SOAP + WASHED OIL + 40+45+36+ 2203 = EXHAUST + 8918
SOAP + WASHED OIL +2324 = EXHAUST + 8918 …………………. (3)
KETTLE EX
HA
UST
TO
FILLING
SOAP FROM REACTOR
CUTBACK/CORRECTION OIL
ADDITIVES W
ASH
ED O
IL
79 | P a g e
WATER/VOLATILES BALANCE:-
WATER IN CHARGING:
Water= 10 kgs
WATER OF CRYSATALISATION OF LiOH.H 2O:
42 Kg LiOH.H2O = 18 Kg of WATER
200 Kg of LiOH.H2O = X Kg of WATER
Hence, X = 200*18/42
X = 85.714 Kg
WATER RELEASED DURING REACTION:
I Mole HSA= 1 Mole Water
309.534 gm HSA =18 gm Water
1000 kg HSA = Y Kg Water
Y=
= 58.15 kg of Water as Steam
MOISTURE CONTENT OF FATTY ACIDS (0.25%):
TOTAL Amount of FATTY ACID = 1300 Kg (1000+300)
Hence, total Amount of moisture in that = 1300*0.25/100
Hence, = 3.25 Kg of MOISTURE
80 | P a g e
VOLATILE AND MOISTURE CONTENT OF BASE OIL:
FOR 1 mg of BASE OIL = 400 ppm of (WATER & VOLITILE)
Hence, For 7508 Kg of BASE OIL = 7508*400*10-6
= 3.003 Kg of (WATER & VOLITILE)
TOTAL AMOUNT OF WATER RELEASED=85.714+58.15+3.25+3.0+10
TOTAL AMOUNT OF WATER RELEASED =160.114 Kgs of water …………………. (4)
WATER BALANCE OVER REACTOR:-
7. DURING REACTION:
WATER ADDED + WATER/VOLATILES IN BASE OIL + WATER IN FATTY ACID + WATER OF
CRYSTALISATION + WATER RELEASED DURING REACTION = STEAM VENTED
10+ 2805*400*10-6 + 1300*0.25% + 85.714 + 58.15 = STEAM VENTED
10+1.12+3.25+85.714+58.15= STEAM VENTED
158.234 Kgs = STEAM VENTED FROM REACTOR ……………………. (5)
NOTE: DUE TO MANUAL ERRORS SOMETIMES SOME AMOUNT OF SOAP IS LOST WHILE
VENTING
FROM OBSERVATIONS, IT IS AROUND 35 KGS PER BATCH
SO,
SOAP LOST IN VENT=35 KGS
TOTAL VENT FROM REACTOR= 158.234 + 35 =193.234 Kgs
81 | P a g e
Now from equation 1,
4306=SOAP +VENT FROM REACTOR ………………………….. (From 1)
4315 = soap + 193.234
Soap = 4121.766 Kgs
8. DURING WASHING:-
2500 = WASHED OIL + VENT
Water content of 150 BS =400ppm
Hence, water in base oil = vent
=400*10-6*2500
VENT DURING WASHING =1.00 kg…………………. (6)
WATER BALANCE OVER KETTLE:-
WATER IN SOAP+WATER/VOLATILES IN BASE OIL + WATER IN ADDITIVES = WATER IN EXHAUST+
WATER IN OUTPUT (GREASE)
0 + (503+1700)*400*10-6 + 0 = EXHAUST + 0
EXHAUST = 0.88 Kgs ………………………….. (7)
FROM EQUATIONS (4), (5), (6) & (7),
TOTAL AMOUNT OF WATER RELEASED = STEAM VENTED FROM REACTOR +
VENT DURING WASHING + EXHAUST
=158.234+1.00+0.88
=160.114 Kgs of water
THUS, WATER IS BALANCED.
82 | P a g e
ALKALI BALANCE:-
Stoichiometric proportion:
1 mole of LiOH.H2O = 1 mole of Lithium Stearate
= 1 mole of 12 HSA
309.534 KG OF 12 HSA = 42 KG LiOH.H2O
1000 KG OF 12 HSA = X KG LiOH.H2O
X=
= 135.687 kg of LiOH.H2O
3 moles of LiOH.H2O = 1 mole of HCO
938 KG of HCO = 42*3 KG LiOH. H2O
300 KG of HCO = X KG LiOH. H2O
X=
= 40.30 kg of LiOH.H2O
Free alkali content= 0.15% wt. of LiOH
Total quantity fed = 4310 kg
Free alkali content=
= 6.465 kg of LiOH
Hence, LiOH content=
= 11.31 kg of free alkali
83 | P a g e
Qty of alkali for base oil TAN
TAN value of base oil = 0.03%
0.03 kgs of KOH=1000 kgs of BASE OIL
7508 kgs of base oil req= 7508 *
*
= 0.168 kg of LiOH.H2O
Total qty of alkali required =135.69+40.3+11.31+0.168
TOTAL QTY OF ALKALI REQUIRED (theoretical) =187.74 KGS
PRACTICAL QTY. FED TO REATOR=200 KG
Excess alkali=200-187.47
EXCESS ALKALI=12.53 KGS
NOW, OVERALL BALANCE
TOTAL INPUT = OUTPUT + LOSSES
TOTAL INPUT = 9139 kgs
TOTAL OUTPUT = NO. OF BARRELS *182(+VE OR –VE VARIATION)
= 49 *182.3
= 8932.7 Kgs
PROCESS LOSS = 9139-8932.7
= 206.3 Kgs
ACTUAL % LOSS = 206.3*100/9139
= 2.25 %
84 | P a g e
THEORITICAL LOSS = MASS LOST AS STEAM
= 158.234
THEORITICAL % LOSS= 158.234*100/9139
= 1.73 %
Hence, DEVIATION = 1.73 – 2.25
DEVIATION = -0.52 % (LOSS)
LOSSES ENCOUNTERED=MASS LOST AS STEAM + SOAP LOST IN VENT + FILLING
LOSSES + OTHER LOSSES
206.3 = 158.234 + 35 + OTHER LOSSES
Hence, OTHER LOSSES = 13.07 Kgs
NOTE:-
FILLING LOSSES CONSTITUTE THE MASS DISCARDED INITIALLY, CALIBRATION ERROR, SET POINT AND THE
MASS REMAINED AFTER FILLING THE LAST BARREL.
OTHER LOSSES CONSTITUTE LOSSES DUE TO INCOMPLETE REACTION BECAUSE OF IMPROPER REACTION
CONDITIONS, MANUAL ERRORS, AND MASS REMAINED IN THE KETTLE AFTER FILLING, ETC.
85 | P a g e
Batch no.: 0120 Reactor: R-102
Date: 29/05/2012 Kettle: K-107
Penetration: 230/235
RAW MATERIAL REQUIRED FOR CHARGING IS:-
FOR CALCULATING AVG. MOL. WT. OF FATS:-
SAP VALUE of 12 HSA=181.24
SO, 181.24 Gms of KOH = 1000 Gms of 12HSA
FOR 56.1 Gms of KOH =
=309.534 Gms of 12 HSA
COMPONENT MOLECULAR WEIGHT 12 HSA 309.534 HCO 938 LiOH 23.95 WATER 18 LiOH.H2O 42 SOAP OF 12 HSA 305.914 SOAP OF HCO 306
COMPONENT QUANTITY BASE OIL 500 N 2805 12 HYDROXY STEARIC ACID 1000 HCO 300 LITHIUM HYDROXIDE MONOHYDRATE 200 WATER 5 TOTAL 4310
86 | P a g e
OVERALL MASS BALANCE OVER REACTOR DURING REACTION:-
Now,
INPUT = OUTPUT
HCO + 12HSA + LiOH.H2O + BASE OIL + WATER = SOAP + VENT
300 + 1000 + 200 + 2805 + 5 = SOAP + VENT
4310=SOAP +VENT ………………………….. (1)
BASE OIL
12 HSA
HCO
REACTOR LiOH.H2O
WATER
SOAP
VENT
STEAM
+
SOAP IN
VENT
(LOSSES)
87 | P a g e
OVERALL MASS BALANCE OVER REACTOR DURING WASHING :-
BRIGHT STOCK FOR WASHING = WASHED OIL + VENT
2503 = WASHED OIL + VENT ………………………….. (2)
KETTLE
REACTOR 150 BS BASE OIL
VENT
WASHED OIL
88 | P a g e
OVERALL MASS BALANCE OVER KETTLE:-
SOAP + WASHED OIL + ADDITIVES + CORRECTION/CUTBACK OIL = EXAUST + OUTPUT (GREASE)
SOAP + WASHED OIL + 45+54+36 + 500+2000 = EXAUST + 8918
SOAP + WASHED OIL + 2635 = EXAUST + 8918 …………………. (3)
KETTLE EX
HA
UST
TO
FILLING
SOAP FROM REACTOR
CUTBACK/CORRECTION OIL
ADDITIVES W
ASH
ED O
IL
89 | P a g e
WATER/VOLATILES BALANCE:-
WATER IN CHARGING:
Water= 5 kgs
WATER OF CRYSATALISATION OF LiOH.H 2O:
42 Kg LiOH.H2O = 18 Kg of WATER
200 Kg of LiOH.H2O = X Kg of WATER
Hence, X = 200*18/42
X = 85.714 Kg
WATER RELEASED DURING REACTION:
I Mole HSA= 1 Mole Water
309.534 gm HSA =18 gm Water
1000 kg HSA = Y Kg Water
Y=
= 58.152 kg of Water as Steam
MOISTURE CONTENT OF FATTY ACIDS (0.25%):
TOTAL Amount of FATTY ACID = 1300 Kg (1000+300)
Hence, total Amount of moisture in that = 1300*0.25/100
Hence, = 3.25 Kg of MOISTURE
90 | P a g e
VOLATILE AND MOISTURE CONTENT OF BASE OIL:
FOR 1 mg of BASE OIL = 400 ppm of (WATER & VOLITILE)
Hence, For 7808 Kg of BASE OIL = 7808*400*10-6
= 3.12 Kg of (WATER & VOLITILE)
TOTAL AMOUNT OF WATER RELEASED=85.714+58.152+3.25+3.12+5
TOTAL AMOUNT OF WATER RELEASED =155.236 Kgs of water …………………. (4)
WATER BALANCE OVER REACTOR:-
9. DURING REACTION:
WATER ADDED + WATER/VOLATILES IN BASE OIL + WATER IN FATTY ACID + WATER OF
CRYSTALISATION + WATER RELEASED DURING REACTION = STEAM VENTED
5 + 2805*400*10-6 + 1300*0.25% + 85.714 + 58.152 = STEAM VENTED
5+1.12+3.25+85.714+58.151= STEAM VENTED
153.235 Kgs = STEAM VENTED FROM REACTOR ……………………. (5)
NOTE: DUE TO MANUAL ERRORS SOMETIMES SOME AMOUNT OF SOAP IS LOST WHILE
VENTING
FROM OBSERVATIONS, IT IS AROUND 35 KGS PER BATCH
SO,
SOAP LOST IN VENT=35 KGS
TOTAL VENT FROM REACTOR= 153.235 + 35 =188.235 Kgs
91 | P a g e
Now from equation 1,
4310=SOAP +VENT FROM REACTOR ………………………….. (From 1)
4310 = soap + 188.235
Soap = 4121.765 Kgs
10. DURING WASHING:-
2503 = WASHED OIL + VENT
Water content of 150 BS =400ppm
Hence, water in base oil = vent
=400*10-6*2503
VENT DURING WASHING =1.001 kg…………………. (6)
WATER BALANCE OVER KETTLE:-
WATER IN SOAP+WATER/VOLATILES IN BASE OIL + WATER IN ADDITIVES = WATER IN EXHAUST+
WATER IN OUTPUT (GREASE)
0 + (500+2000)*400*10-6 + 0 = EXHAUST + 0
EXHAUST = 1.000 Kgs ………………………….. (7)
FROM EQUATIONS (4), (5), (6) & (7),
TOTAL AMOUNT OF WATER RELEASED = STEAM VENTED FROM REACTOR +
VENT DURING WASHING + EXHAUST
=153.235+1.001+1.00
=155.236 Kgs of water
THUS, WATER IS BALANCED.
92 | P a g e
ALKALI BALANCE:-
Stoichiometric proportion:
1 mole of LiOH.H2O = 1 mole of Lithium Stearate
= 1 mole of 12 HSA
309.534 KG OF 12 HSA = 42 KG LiOH.H2O
1000 KG OF 12 HSA = X KG LiOH.H2O
X=
= 135.687 kg of LiOH.H2O
3 moles of LiOH.H2O = 1 mole of HCO
938 KG of HCO = 42*3 KG LiOH. H2O
300 KG of HCO = X KG LiOH. H2O
X=
= 40.30 kg of LiOH.H2O
Free alkali content= 0.15% wt. of LiOH
Total quantity fed = 4310 kg
Free alkali content=
= 6.465 kg of LiOH
Hence, LiOH content=
= 11.31 kg of free alkali
93 | P a g e
Qty of alkali for base oil TAN
TAN value of base oil = 0.03%
0.03 kgs of KOH=1000 kgs of BASE OIL
7808 kgs of base oil req= 7808 *
*
= 0.175 kg of LiOH.H2O
Total qty of alkali required =135.687+40.30+11.31+0.175
TOTAL QTY OF ALKALI REQUIRED (theoretical) =187.47 KGS
PRACTICAL QTY. FED TO REATOR=200 KG
Excess alkali=200-187.47
EXCESS ALKALI=12.53 KGS
NOW, OVERALL BALANCE:
TOTAL INPUT = OUTPUT + LOSSES
TOTAL INPUT =9448 kgs
TOTAL OUTPUT = NO. OF BARRELS *182(+VE OR –VE VARIATION)
= 49 *182 + 5
= 8923 Kgs
PROCESS LOSS = 9448 - 8923
= 525 Kgs
ACTUAL % LOSS = 525*100/9448
= 5.55 %
THEORITICAL LOSS = MASS LOST AS STEAM
= 155.236 Kgs
94 | P a g e
THEORITICAL % LOSS= 155.236*100/9448
= 1.64 %
Hence, DEVIATION = 1.64 – 5.55
DEVIATION = -3.91 % (LOSS)
LOSSES ENCOUNTERED=MASS LOST AS STEAM + SOAP LOST IN VENT + FILLING
LOSSES + OTHER LOSSES
525 = 155.236 + 35 + 100 + OTHER LOSSES
Hence, OTHER LOSSES = 234.764 Kgs
NOTE:-
FILLING LOSSES CONSTITUTE THE MASS DISCARDED INITIALLY AND THE MASS REMAINED AFTER FILLING
THE LAST BARREL.
OTHER LOSSES CONSTITUTE LOSSES DUE TO INCOMPLETE REACTION BECAUSE OF IMPROPER REACTION
CONDITIONS, MANUAL ERRORS, AND MASS REMAINED IN THE KETTLE AFTER FILLING, ETC.
95 | P a g e
Batch no.: 0146 Reactor: R-102
Date: 30/05/2012 Kettle: K-105
Penetration: 232/235
RAW MATERIAL REQUIRED FOR CHARGING IS:-
FOR CALCULATING AVG. MOL. WT. OF FATS:-
SAP VALUE of 12 HSA=181.24
SO, 181.24 Gms of KOH = 1000 Gms of 12HSA
FOR 56.1 Gms of KOH =
=309.534 Gms of 12 HSA
COMPONENT MOLECULAR WEIGHT 12 HSA 309.534 HCO 938 LiOH 23.95 WATER 18 LiOH.H2O 42 SOAP OF 12 HSA 305.914 SOAP OF HCO 306
COMPONENT QUANTITY BASE OIL 500 N 2805 12 HYDROXY STEARIC ACID 1000 HCO 300 LITHIUM HYDROXIDE MONOHYDRATE 200 WATER 10 TOTAL 4315
96 | P a g e
OVERALL MASS BALANCE OVER REACTOR DURING REACTION:-
Now,
INPUT = OUTPUT
HCO + 12HSA + LiOH.H2O + BASE OIL + WATER = SOAP + VENT
300 + 1000 + 200 + 2805 + 10 = SOAP + VENT
4315=SOAP +VENT ………………………….. (1)
BASE OIL
12 HSA
HCO
REACTOR LiOH.H2O
WATER
SOAP
VENT
STEAM
+
SOAP IN
VENT
(LOSSES)
97 | P a g e
OVERALL MASS BALANCE OVER REACTOR DURING WASHING :-
BRIGHT STOCK FOR WASHING = WASHED OIL + VENT
2500 = WASHED OIL + VENT ………………………….. (2)
KETTLE
REACTOR 150 BS BASE OIL
VENT
WASHED OIL
98 | P a g e
OVERALL MASS BALANCE OVER KETTLE:-
SOAP + WASHED OIL + ADDITIVES + CORRECTION/CUTBACK OIL = EXAUST + OUTPUT (GREASE)
SOAP + WASHED OIL + 40+45+36 + 503 + 1500 = EXAUST + 8736
SOAP + WASHED OIL + 2124 = EXAUST + 8736 …………………. (3)
KETTLE EX
HA
UST
TO
FILLING
SOAP FROM REACTOR
CUTBACK/CORRECTION OIL
ADDITIVES W
ASH
ED O
IL
99 | P a g e
WATER/VOLATILES BALANCE:-
WATER IN CHARGING:
Water= 10 kgs
WATER OF CRYSATALISATION OF LiOH.H 2O:
42 Kg LiOH.H2O = 18 Kg of WATER
200 Kg of LiOH.H2O = X Kg of WATER
Hence, X = 200*18/42
X = 85.714 Kg
WATER RELEASED DURING REACTION:
I Mole HSA= 1 Mole Water
309.534 gm HSA =18 gm Water
1000 kg HSA = Y Kg Water
Y=
= 58.152 kg of Water as Steam
MOISTURE CONTENT OF FATTY ACIDS (0.25%):
TOTAL Amount of FATTY ACID = 1300 Kg (1000+300)
Hence, total Amount of moisture in that = 1300*0.25/100
Hence, = 3.25 Kg of MOISTURE
100 | P a g e
VOLATILE AND MOISTURE CONTENT OF BASE OIL:
FOR 1 mg of BASE OIL = 400 ppm of (WATER & VOLITILE)
Hence, For 7308 Kg of BASE OIL = 7308*400*10-6
= 2.92 Kg of (WATER & VOLITILE)
TOTAL AMOUNT OF WATER RELEASED=85.714+58.152+3.25+2.92+10
TOTAL AMOUNT OF WATER RELEASED =160.036 Kgs of water …………………. (4)
WATER BALANCE OVER REACTOR:-
11. DURING REACTION:
WATER ADDED + WATER/VOLATILES IN BASE OIL + WATER IN FATTY ACID + WATER OF
CRYSTALISATION + WATER RELEASED DURING REACTION = STEAM VENTED
10 + 2805*400*10-6 + 1300*0.25% + 85.714 + 58.152 = STEAM VENTED
10+1.12+3.25+85.714+58.151= STEAM VENTED
158.235 Kgs = STEAM VENTED FROM REACTOR ……………………. (5)
NOTE: DUE TO MANUAL ERRORS SOMETIMES SOME AMOUNT OF SOAP IS LOST WHILE
VENTING
FROM OBSERVATIONS, IT IS AROUND 35 KGS PER BATCH
SO,
SOAP LOST IN VENT=35 KGS
TOTAL VENT FROM REACTOR= 158.235 + 35 =193.235 Kgs
101 | P a g e
Now from equation 1,
4315=SOAP +VENT FROM REACTOR ………………………….. (From 1)
4315 = soap + 193.235
Soap = 4121.765 Kgs
12. DURING WASHING:-
2500 = WASHED OIL + VENT
Water content of 150 BS =400ppm
Hence, water in base oil = vent
=400*10-6*2500
VENT DURING WASHING =1.00 kg…………………. (6)
WATER BALANCE OVER KETTLE:-
WATER IN SOAP+WATER/VOLATILES IN BASE OIL + WATER IN ADDITIVES = WATER IN EXHAUST+
WATER IN OUTPUT (GREASE)
0 + (503+1500)*400*10-6 + 0 = EXHAUST + 0
EXHAUST = 0.8012 Kgs ………………………….. (7)
FROM EQUATIONS (4), (5), (6) & (7),
TOTAL AMOUNT OF WATER RELEASED = STEAM VENTED FROM REACTOR +
VENT DURING WASHING + EXHAUST
=158.235+1.00+0.8012
=160.036 Kgs of water
THUS, WATER IS BALANCED.
102 | P a g e
ALKALI BALANCE:-
Stoichiometric proportion:
1 mole of LiOH.H2O = 1 mole of Lithium Stearate
= 1 mole of 12 HSA
309.534 KG OF 12 HSA = 42 KG LiOH.H2O
1000 KG OF 12 HSA = X KG LiOH.H2O
X=
= 135.687 kg of LiOH.H2O
1 mole of LiOH.H2O = 1 mole of HCO
938 KG of HCO = 42*3 KG LiOH. H2O
300 KG of HCO = X KG LiOH. H2O
X=
= 40.30 kg of LiOH.H2O
Free alkali content= 0.15% wt. of LiOH
Total quantity fed = 4310 kg
Free alkali content=
= 6.465 kg of LiOH
Hence, LiOH content=
= 11.31 kg of free alkali
103 | P a g e
Qty of alkali for base oil TAN
TAN value of base oil = 0.03%
0.03 kgs of KOH=1000 kgs of BASE OIL
7308 kgs of base oil req= 7308 *
*
= 0.164 kg of LiOH.H2O
Total qty of alkali required =135.687+40.30+11.31+0.164
TOTAL QTY OF ALKALI REQUIRED (theoretic al) =1 KGS
PRACTICAL QTY. FED TO REATOR=200 KG
Excess alkali=200-187.46
EXCESS ALKALI=12.54 KGS
NOW, OVERALL BALANCE TOTAL INPUT = OUTPUT + LOSSES
TOTAL INPUT =8939 kgs
TOTAL OUTPUT = NO. OF BARRELS *182
= 48 *182
= 8736 Kgs
PROCESS LOSS = 8939 - 8736
= 203 Kgs
ACTUAL % LOSS = 203*100/8939
= 2.27 %
THEORITICAL LOSS = MASS LOST AS STEAM
= 160.036 Kgs
104 | P a g e
THEORITICAL % LOSS= 160.036*100/8939
= 1.79 %
Hence, DEVIATION = 1.79 – 2.27
DEVIATION = -0.48 % (LOSS)
LOSSES ENCOUNTERED=MASS LOST AS STEAM + SOAP LOST IN VENT + FILLING
LOSSES + OTHER LOSSES
203 = 160.236 + 35 + FILLING LOSSES + OTHER LOSSES
FILLING LOSSES + OTHER LOSSES = 7.764 Kgs
NOTE:-
FILLING LOSSES CONSTITUTE THE MASS DISCARDED INITIALLY AND THE MASS REMAINED AFTER FILLING
THE LAST BARREL.
OTHER LOSSES CONSTITUTE LOSSES DUE TO INCOMPLETE REACTION BECAUSE OF IMPROPER REACTION
CONDITIONS, MANUAL ERRORS, AND MASS REMAINED IN THE KETTLE AFTER FILLING, ETC.
105 | P a g e
Batch no.: 0150 Reactor: R-102
Date: 30/05/2012 Kettle: K-106
Penetration: 230/235
RAW MATERIAL REQUIRED FOR CHARGING IS:-
FOR CALCULATING AVG. MOL. WT. OF FATS:-
SAP VALUE of 12 HSA=181.24
SO, 181.24 Gms of KOH = 1000 Gms of 12HSA
FOR 56.1 Gms of KOH =
=309.534 Gms of 12 HSA
COMPONENT MOLECULAR WEIGHT 12 HSA 309.534 HCO 938 LiOH 23.95 WATER 18 LiOH.H2O 42 SOAP OF 12 HSA 305.914 SOAP OF HCO 306
COMPONENT QUANTITY BASE OIL 500 N 2803 12 HYDROXY STEARIC ACID 1000 HCO 300 LITHIUM HYDROXIDE MONOHYDRATE 200 WATER 5 TOTAL 4308
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OVERALL MASS BALANCE OVER REACTOR DURING REACTION:-
Now,
INPUT = OUTPUT
HCO + 12HSA + LiOH.H2O + BASE OIL + WATER = SOAP + VENT
300 + 1000 + 200 + 2803 + 5 = SOAP + VENT
4308=SOAP +VENT ………………………….. (1)
BASE OIL
12 HSA
HCO
REACTOR LiOH.H2O
WATER
SOAP
VENT
STEAM
+
SOAP IN
VENT
(LOSSES)
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OVERALL MASS BALANCE OVER REACTOR DURING WASHING :-
BRIGHT STOCK FOR WASHING = WASHED OIL + VENT
2501 = WASHED OIL + VENT ………………………….. (2)
KETTLE
REACTOR 150 BS BASE OIL
VENT
WASHED OIL
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OVERALL MASS BALANCE OVER KETTLE:-
SOAP + WASHED OIL + ADDITIVES + CORRECTION/CUTBACK OIL = EXAUST + OUTPUT (GREASE)
SOAP + WASHED OIL + 45+54+36 + 500+1400 = EXAUST + 8736
SOAP + WASHED OIL + 2035 = EXAUST + 8736 …………………. (3)
KETTLE EX
HA
UST
TO
FILLING
SOAP FROM REACTOR
CUTBACK/CORRECTION OIL
ADDITIVES W
ASH
ED O
IL
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WATER/VOLATILES BALANCE:-
WATER IN CHARGING:
Water= 5 kgs
WATER OF CRYSATALISATION OF LiOH.H 2O:
42 Kg LiOH.H2O = 18 Kg of WATER
200 Kg of LiOH.H2O = X Kg of WATER
Hence, X = 200*18/42
X = 85.714 Kg
WATER RELEASED DURING REACTION:
I Mole HSA= 1 Mole Water
309.534 gm HSA =18 gm Water
1000 kg HSA = Y Kg Water
Y=
= 58.152 kg of Water as Steam
MOISTURE CONTENT OF FATTY ACIDS (0.25%):
TOTAL Amount of FATTY ACID = 1300 Kg (1000+300)
Hence, total Amount of moisture in that = 1300*0.25/100
Hence, = 3.25 Kg of MOISTURE
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VOLATILE AND MOISTURE CONTENT OF BASE OIL:
FOR 1 mg of BASE OIL = 400 ppm of (WATER & VOLITILE)
Hence, For 7204 Kg of BASE OIL = 7204*400*10-6
= 2.88 Kg of (WATER & VOLITILE)
TOTAL AMOUNT OF WATER RELEASED=85.714+58.152+3.25+2.88+5
TOTAL AMOUNT OF WATER RELEASED =154.995 Kgs o f water …………………. (4)
WATER BALANCE OVER REACTOR:-
13. DURING REACTION:
WATER ADDED + WATER/VOLATILES IN BASE OIL + WATER IN FATTY ACID + WATER OF
CRYSTALISATION + WATER RELEASED DURING REACTION = STEAM VENTED
5 + 2803*400*10-6 + 1300*0.25% + 85.714 + 58.152 = STEAM VENTED
5+1.12+3.25+85.714+58.151= STEAM VENTED
153.235 Kgs = STEAM VENTED FROM REACTOR ……………………. (5)
NOTE: DUE TO MANUAL ERRORS SOMETIMES SOME AMOUNT OF SOAP IS LOST WHILE
VENTING
FROM OBSERVATIONS, IT IS AROUND 35 KGS PER BATCH
SO,
SOAP LOST IN VENT=35 KGS
TOTAL VENT FROM REACTOR= 153.235 + 35 =188.235 Kgs
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Now from equation 1,
4308=SOAP +VENT FROM REACTOR ………………………….. (From 1)
4308 = Soap + 188.235
Soap = 4119.765 Kgs
14. DURING WASHING:-
2501 = WASHED OIL + VENT
Water content of 150 BS =400ppm
Hence, water in base oil = vent
=400*10-6*2501
VENT DURING WASHING =1.00 kg…………………. (6)
WATER BALANCE OVER KETTLE:-
WATER IN SOAP+WATER/VOLATILES IN BASE OIL + WATER IN ADDITIVES = WATER IN EXHAUST+
WATER IN OUTPUT (GREASE)
0 + (500+1400)*400*10-6 + 0 = EXHAUST + 0
EXHAUST = 0.7600 Kgs ………………………….. (7)
FROM EQUATIONS (4), (5), (6) & (7),
TOTAL AMOUNT OF WATER RELEASED = STEAM VENTED FROM REACTOR +
VENT DURING WASHING + EXHAUST
=153.235+1.00+0.76
=154.995 Kgs of water
THUS, WATER IS BALANCED.
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ALKALI BALANCE:-
Stoichiometric proportion:
1 mole of LiOH.H2O = 1 mole of Lithium Stearate
= 1 mole of 12 HSA
309.534 KG OF 12 HSA = 42 KG LiOH.H2O
1000 KG OF 12 HSA = X KG LiOH.H2O
X=
= 135.687 kg of LiOH.H2O
3 mole of LiOH.H2O = 1 mole of HCO
938 KG of HCO = 126 KG LiOH. H2O
300 KG of HCO = X KG LiOH. H2O
X=
= 40.29 kg of LiOH.H2O
Free alkali content= 0.15% wt. of LiOH
Total quantity fed = 4310 kg
Free alkali content=
= 6.465 kg of LiOH
Hence, LiOH content=
= 11.31 kg of free alkali
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Qty of alkali for base oil TAN
TAN value of base oil = 0.03%
0.03 kgs of KOH=1000 kgs of BASE OIL
7204 kgs of base oil req= 7204 *
*
= 0.162 kg of LiOH.H2O
Total qty of alkali required =135.687+40.30+11.31+0.162
TOTAL QTY OF ALKALI REQUIRED (theoretical) =187.46 KGS
PRACTICAL QTY. FED TO REATOR=200 KG
Excess alkali=200-187.46
EXCESS ALKALI=12.54 KGS
NOW, OVERALL BALANCE TOTAL INPUT = OUTPUT + LOSSES
TOTAL INPUT =8844 kgs
TOTAL OUTPUT = NO. OF BARRELS *182
= 48*182
= 8736 Kgs
PROCESS LOSS = 8844 - 8736
= 108 Kgs
ACTUAL % LOSS = 108*100/8844
= 1.22 %
THEORITICAL LOSS = MASS LOST AS STEAM
= 154.995 Kgs
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THEORITICAL % LOSS= 154.995*100/8844
= 1.75 %
Hence, DEVIATION = 1.75 – 1.22
DEVIATION = +0.53 % (ADVANTAGEOUS)
NOTE:
THERE MAY BE ERROR IN CALIBRATION OF FLOWMETER OF BASE OIL
INPUT.
SOMETIMES CERTAIN AMOUNT OF GREASE REMAINS IN THE KETTLE THAT
IS ADDED TO THE OUTPUT OF THE UPCOMING BATCHES.
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TABULATION OF BATCHES COVERED:
BATCH NO.
DATE TOTAL INPUT
OUTPUT THEORITICAL
% LOSS ACTUAL % LOSS
% DEVIATION
PENETRATION
118 23/05/12 8958 8760 1.8 2.21 -0.4 230/232
136 28/05/12 9142 8942.5 1.73 2.2 -0.47 228/232
142 29/05/12 9139 8932.7 1.73 2.25 -0.52 228/232
150 30/05/12 8844 8736 1.75 1.22 +0.53 230/235
120 29/05/12 9448 8923 1.64 5.55 -3.91 230/235
131 26/05/12 9241 8932.7 2.05 3.33 -1.28 228/232
146 30/05/12 8939 8736 1.79 2.27 -0.48 232/235
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CONCLUSION:
PROBLEMS ENCOUNTERED SUGGESTED RECTIFICATIONS
FLOWMETERS FOR BASE OIL INPUT ARE CALIBERATED CONSIDERING A SPECIFIC DENSITY OF OIL AS STANDARD.BUT SOMETIMES THE DENSITY OF OIL MAY DIFFER COZ OF VARYING AMBIENT CONDITIONS.
CERTAIN PARAMETER FOR ADJUSTING THE FLOWRATE SHOULD BE THERE IN THE FLOWMETERS AND IT SHOULD BE ADJUSTED ACCORDING TO THE CHANGING DENSITY.
PROPER REACTION CONDITIONS (OPTIMUM PRESSURE & TEMPERATURE), IF NOT MAINTAINED, RESULTS IN INCOMPLETE SAPONIFICATION OF FATS WHICH SUBSEQUENTLY SHOWS IT’S EFFECTS ON THE YIELD OF THE BATCH.
PROPER MONITORING OF THE PROCESS SHOULD BE DONE BY THE OFFICER IN-CHARGE.
SOMETIMES THE PRESSURE IS VENTED MORE THAN 30% AT HIGH PRESSURE.BECAUSE OF THIS, SOME AMOUNT OF SOAP IS LOST WHILE VENTING.THIS CONTRIBUTES TO LOSS IN OUTPUT.
PROPER MAINTENANCE OF PRESSURE SHOULD BE THERE TO AVOID HIGH VENTING RATE.
MANUAL ERRORS DURING CHARGING MAY RESULT IN DEVIATION OF YIELD.
AUTOMATION SHOULD BE DONE FOR CHARGING.
ADDITIVE ADDITION IS DONE AT TEMPERATURE OF AROUND 100-1150C. THIS RESULTS IN THE ADDITIVES NOT IMPARTING THE DESIRED PROPERTIES TO GREASE FULLY.
ADDITIVE ADDITION SHOULD BE DONE AT TEMP. LESS THAN 90OC AS SUGGESTED BY THE QC.
TEMPERATURE INDICATORS OF CERTAIN KETTLES SHOW ERROR IN TEMPERATURE
MEASUREMENT.THAT SHOULD BE RECTIFIED.
THE HEATING RATE OF THE REACTORS SHOULD BE INCREASED SO AS TO ATTAIN THE
REQUIRED TEMPERATURE IN LEAST POSSIBLE TIME.THIS WOULD RESULT IN MORE BATCHES
PER DAY AND INCREASED PRODUCTION RATE.
CERTAIN LOSSES LIKE SOAP VENT TO REACTOR, LOSSES DUE TO INCOMPLETE REACTION,
MANUAL ERRORS SHOULD BE MINIMISED BY PAYING PROPER ATTENTION WHILE
WORKING.
THERE ARE LOSSES DUE TO OVERFILLING, WHICH CAN BE REDUCED BY ADJUSTING PROPER
SET POINT, REPLACING THE OBSELETE WEIGHING DEVICES WITH NEW ADVANCED ONES
FOR ACCURATE MEASUREMENT.