CH 3054

Energy efficiency and Conservation

Steam Network Design
Sasha Personal Care Products

Date of submission: 14.10.2022

Group number: G16
WICKRAMARATHNA M.P.T.T. – 190685K

WICKRAMASINGHE W.M.A.S. – 190689C

WIJERATHNE R.A.P.W. – 190704V

WIJERATNE D.G.B.B. – 190706E

Department of Chemical and Process Engineering
WIJESOORIYA K.M.P.A. – 190711Nof Moratuwa
University
Moratuwa
WIMALAWEERA L.W.S.H. – 190716J
(Batch 19)

Department of Chemical and Process Engineering

University of Moratuwa
 Table of Content

1. Introduction.............................................................................................................................2
2. Production process..................................................................................................................3
2.1. Toothpaste
2.2. Shampoo
2.3. Body lotion
2.4. Soap
3. Capacity of the plant...............................................................................................................6
3.1. Shampoo
3.2. Body lotion
3.3. Toothpaste
3.4. Soap
4. Processing units and equipment which require steam............................................................8
4.1. Toothpaste, body lotion, and shampoo
4.2. Soap
5. Layout………………………………………………………………………………………10
6. Material and Energy Balance……………………………………………………………….11
7. References………………………………………………………………………...………...19

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1. Introduction

The four main systems we constantly come across as chemical and process engineers are
thermal systems, compressed air systems, refrigeration systems, and steam systems. These steam
systems are mainly used for transferring heat energy through the industrial plant. Various qualities of
steam, including the high heat content, cheapness, and high availability, are a few of the advantages of
using steam.

The personal care products industry is one of the industries out there that uses steam for
transferring heat energy. An industrial plant that produces toothpaste, body lotion, soap, and shampoo
is used as an example of steam usage in an industrial plant in this project. The production process is
done in batches. After a batch of toothpaste is produced, the same equipment is used to produce a batch
of body lotion and then a batch of shampoo. A different set of equipment is used to produce soap.

Steam requirements for each process are calculated using the material and energy balance
data. 200 kg of toothpaste is considered a single batch, while 500 kg of lotion is considered a single
batch of lotion, and 2000 l of shampoo is considered a single batch. 1000kgs of raw material is used to
produce a single batch of soap. A single batch of a product is manufactured every day, and the production
plant is active only on five days a week. The production plant is run for 300 days a year. These data are
used to calculate material and energy balance, which in turn are used to calculate the steam requirements
of the plant.

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2. Production Processes
2.1. Toothpaste

Raw materials –

There are several types of raw materials used in making toothpaste. Binders are used to
thicken the toothpaste. They are the materials that keep the appearance of the toothpaste the way it
is. Bentonite and sodium alginate are two of the well-known binders used in toothpaste production.
Abrasives are the material that makes the particles in the teeth come loose. Hydrated silica and
calcium carbonate are good examples of abrasives. Sudsers are the foam agents added to make
toothpaste bubbles when mixed with water. Humectants are added to make the toothpaste as a paste,
with liquid and solid phases mixed. Fluorides are added to reduce decay and increase the strength of
teeth. Other materials are also added to change the color, taste, and smell of toothpaste.

Procedure –

After raw materials are weighed manually and mechanically to ensure accuracy. The
materials are mixed in a mixing vessel while the humidity and temperature are monitored closely.
After the mixing process is done, the mixture is then filled into tubes mechanically. Before being
filled, the tube goes through a blower and a vacuum to ensure cleanliness. After the tubes are filled
with the mixture and packed into boxes to be shipped. This is mostly done by hand. (“How toothpaste
is made - manufacture, history, used, components, product, industry, machine, Raw Materials,” n.d.)

2.2. Shampoo

Raw materials –

Raw materials used in shampoo are decided by researchers after determining the attributes
of the shampoo. Raw materials used for shampoo can also be divided into a few categories. The
main component of shampoo is water. Other than that, detergents, foam boosters, thickeners, and
preserving agents are also added. Modifiers are added to change special characteristics of the
shampoo, such as the opacity. Conditioning agents are added to soften the effect of other materials
in the shampoo so it does not damage hair or the head.

Procedure –

Raw materials are poured into the batch tank according to the proportions specified in the
shampoo formula. The mixing process of the raw materials is monitored by workers called
compounders. Water and primary detergents are supplied directly to the batch tank. The heating or
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 cooling processes are entirely dependent on the formula of the shampoo. After mixing, a sample is
taken to the quality control lab to conduct quality control tests. After gaining approval from the
quality control lab, the mixture in the batch tank is moved into the holding tank. The empty bottles
are aligned properly inside and transported to the filling carousel via a conveyor belt. After the
bottles are filled, caps that were also aligned inside a hopper are put on the now-filled bottles. The
bottles are then transported to the labeling area, where they are labeled and then packaged into
cardboard boxes to be transported. (“How shampoo is made - material, manufacture, making,
history, used, structure, steps, product, industry,” n.d.)

2.3. Body Lotion

Raw materials –

There are four main types of raw materials used to make body lotion. They are water, oil,
emulsifier, and preservatives. Any natural oil type can be used as oil. Coconut oil and palm oil are
examples of oils that can be used. Emulsifiers are added to bind oil and water together.
Preservatives prevent any sort of harmful substances from forming in the lotion.

Procedure –

The production procedure for body lotions is the same as that of the production procedure
for shampoo.

2.4. Soap

Raw Materials –

There are four types of raw materials used to make soap. Namely oil and fats, sodium or
potash lye, brine, and additives. The natural fat that is used in soap making is triglycerol. As for oil,
it can be coconut, palm, or other types of oil. The making of soap happens when a strong alkali is
added to triglycerol. To make it happen, either sodium lye or potash lye can be used. Brine is used
to recovering glycerol after saponification. The rest of the materials used to improve the color, smell,
texture, and other qualities of the soap are known as additives.

Procedure –

There are three methods to make soap. The cold method, the semi-boiled method, and the
hot process (full-boiled method). In the cold method, saponification occurs at room temperature. In

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the semi-boiled method, the reaction occurs near the boiling point. In the full-boiled method, the
reactants are boiled at least once. We selected the semi-boiled method as our method of soap making.
The oils and fats are subjected to saponification in the reaction chamber by adding sodium lye or
potash lye. A heating coil is used to heat the reaction chamber to 75 0C. This makes the reaction
occur faster.

Furthermore, steam is required to heat the low-pressure vessel to evaporate the excess water
in the soap. The vessel should be heated up to 120 ℃. (“Industrial Soap Production and
Manufacturing Process | Saponification,” n.d.)(“US4772434A - Soap making process - Google
Patents,” n.d.)

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 3. Capacity of the plant

Identifying a suitable production capacity determines the effectiveness of the process. It

determines the size of the product, and time consumed for a cycle and the quality of the product.
Capacity inspection is important to determine the amount of feedstock, time, and energy (Electricity,
Heat, etc.) before starting the process to see if the plant is maintainable.

3.1. Shampoo Manufacturing Process

Usually, a shampoo manufacturing plant has a capacity of 200 liters to 20000 liters. We
decided to build a plant not so low and not so high on the limits since it is easier to study. (“Shampoo
Manufacturing Plant , Shampoo Mixer , Shampoo Making Plant,” n.d.)

Raw material Amount (l)

Water (70%) 1400
Wax (30%) 600
Batch Size 2000
Table 1:Raw material composition for shampoo

A single batch of shampoo can produce shampoo to fill 10000, 200ml shampoo bottles.

3.2. Lotion Manufacturing process

A usual lotion manufacturing plant has a capacity of 10 kg to 5000kg. Hence, we decided to

select a batch size of 500kg.

Raw material Amount (kg)

Water (70%) 350
Wax (30%) 150
Batch Size 500
Table 2:Law material composition for lotion

We are producing 50g body lotion tubes, and a single batch can produce 10000 tubes.

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3.3. Toothpaste Manufacturing process

A toothpaste manufacturing plant has a capacity of 5 kg to 1000kg. We decided to study a

plant not so low and not so high on the limits since it is easier to study.

Raw material Amount (kg)

Water (30%) 60
Wax (70%) 140
Batch 200
Table 3:Raw material composition for tooth paste

A single toothpaste tube is 120g that is produced in the factory. And factory can produce 1666 tubes
of toothpaste per batch.

3.4. Soap Manufacturing process

A soap manufacturing plant planned to build has a capacity of up to 1000kg per hour.

Raw material Amount (kg)

Water (2.29%) 22.9
Fatty acid (71.82%) 718.2
Caustic (21.84%) 218.4
Brine (4.05%) 40.5
Batch 1000
Table 4:raw material composition for soap

In the factory, 1000kgs of raw material is used to produce a single batch of soap. That produces
around 800kg of soap per batch, which is equivalent to 8000 soap bars.(“US4772434A - Soap
making process - Google Patents,” n.d.)

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4. Processing Units and Equipment Which Requires Steam as The Heating Medium

The industrial plant we have been assigned to design the steam network produces soap,
toothpaste, body lotion, and shampoo. Because the production process is a batch process and the
products mentioned above, except soap, require the same equipment, processing units, and
equipment that require steam as the heating medium are the same for all the other three production
processes. Three main pieces of equipment require steam as the heating medium.

They are,

• Water phase vessel

• Wax phase vessel
• Manufacturing vessel

Also, there is one process that requires steam.

Which is,

• Clean-in-place process

For soap manufacturing, three pieces of equipment require steam as the heating medium.

• Saponification mixer
• Low-pressure vessel
• Clean-in-place process

4.1. Toothpaste, body lotion, and shampoo manufacturing process

Water phase vessel

The water phase vessel is a jacketed cylindrical tank with tori spherical dish ends which
consists of a propeller stirrer for dissolving the ingredients. This propeller stirrer is driven by a motor.
The jacket in this vessel supports the vessel’s heating by steam based on the requirement of the
manufacturing process of each product.

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 Wax phase vessel

This vessel is also a jacketed cylindrical tank with tori spherical dish ends which has a
propeller-type stirrer for agitating the wax or oil. A conical filter filters out the impurities before the
wax is transferred to the manufacturing vessel. As in the water phase vessel, there is a jacket to
support the vessel’s heating by steam. Also, there is a temperature controller and a safety pressure
valve in this vessel.

Manufacturing vessel

The manufacturing vessel is a jacketed cylindrical vessel with a conical bottom and an
anchor-type agitator. It is used to mix the viscous product from the water and wax phase vessels. As
in the above two vessels, the vessel’s heating is done through a jacket, and steam is used for the
heating. There is an agitator mixer with a self-pressure Teflon scrapper, which works on both sides.

Clean-in-place process

Clean-in-place (CIP) is a method that operates without extensive disassembly to perform

automated cleaning of the inside surfaces of pipes, vessels, equipment, filters, and related fittings.
For this process, water which is at room temperature, is heated to 80 degrees Celsius, and steam is
used for that as the heating medium.

4.2. Soap manufacturing process

Saponification Mixer

In this mixer, there is a heated coil to heat the saponification mixture to a temperature of
750C, and for that, steam is used as the heating medium. This process allows baking soda to be
adjusted before removing the dirty soap and for better recycling product waste.

Low-pressure vessel

In the finishing process, the soap is heated to about 1200C and sprayed into a low-pressure
chamber. The soap is sprayed into the low-pressure vessel, where the water particles evaporate.

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5. Layout

01 09

02 10

03 11
08

12
04 05

13
06 07

14

15 16 17 18 19

Figure 1:Plant layout

01 - Warehouse 11 - Soap cutting machine

02 - Lotion filling machine 12 - Low pressure vessel
03 - Homogenizer 13 - Perforated vessel
04 - Mixing vessel 01 14 - Saponification mixer
05 - Mixing vessel 02 15 - Oil / wax storage tank
06 - Water phase vessel 16 - Water storage tank
07 - Wax phase vessel 17 - Oil storage tank
08 - Boiler 18 - Alkali storage tank
09 - Warehouse 19 - Brine storage tank
10 - Soap packing machine

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6. Material and Energy Balance
6.1. Lotion Manufacturing Process

Figure 2:Plant layout for lotion

• Latent heat of vaporization of steam at 1 bar = 2257.97kJ/kg (“energy - specific heat capacity,”
n.d.)
• Batch size = 500kg
• Water = 350kg
• Wax = 150kg

The processes that require steam are drawn in the above diagram. The water & wax phase (additives)
are at room temperature initially They are heated to 400C inside two separate vessels. Then they are
missed inside a mixing vessel at 500C.

Assumptions

(1) It is assumed that pipes are well insulated.

(2) No heat is absorbed or released when mixing happens.

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(3) The specific heat capacity of the wax phase is the same as water which is 4.187kJ/kgK and
density is also same (1000kgm-3). (“Saturated Steam - Properties for Pressure in Bar,” n.d.;
“Steam Tables Pressure vs Temperature,” n.d.)
(4) Steam at 1 bar is used for heating purposes.

Energy Balance to The Water Phase Vessel

mcØ = mL

350kg × 4.187kJ/kgK × (40-25) ℃ = St1 ×2257.92 kJ/kg

St1 = 9.7353kg

Energy Balance to The Wax Phase Vessel

150kg × 4.187kJ/kgK × (40-25) ℃ = St2 ×2257.92 kJ/kg

St2 = 4.1723kg

Energy Balance to The Manufacturing Vessel

500kg × 103kgm-3 × 4.187kJ/kgK × (50-40) ℃ = St3 ×2257.92 kJ/kg

St3 = 9.2718kg

500L of water which was at room temperature (250C), heated to 800C to CIP process

If the steam requirement for that is St4,

500L × 10-3m3 × 103kgm-3 × 4.187kJ/kgK × (80-25) ℃ = St4 ×2257.92kJ/kg

St4=50.9949kg

Total steam requirement for a batch of lotion = St1+ St2+ St3+ St4

= 74.1743kg

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6.2. Shampoo Manufacturing Process
• Latent heat of vaporization of steam at 1 bar = 2257.97kJ/kg
• Batch size = 2000l
• Water = 2000l × 70% = 1400l
• Wax = 2000l × 30% = 600l

The processes that require steam are drawn in the above diagram. The water & wax phase (additives)
are at room temperature initially They are heated to 500C inside two separate vessels. Then they are
missed inside a mixing vessel at 600C.

Assumptions

(1) It is assumed that pipes are well insulated.

(2) No heat is absorbed or released when mixing happens.
(3) The specific heat capacity of the wax phase is the same as water which is 4.187kJ/kgK and the
density is also the same (1000kgm-3).
(4) Steam at 1 bar is used for heating purposes.

Energy Balance to The Water Phase Vessel

mcØ = mL

1400×10-3 m3 × 1000 kg/m-3 × 4.187 kJ/kgK × (50-25) ℃ = St1 × 2257.92 kJ/kg

St1 = 64.9026 kg

Energy Balance to The Wax Phase Vessel

600×10-3 m3 × 1000 kg/m-3 × 4.187 kJ/kgK × (50-25) ℃ = St2 × 2257.92 kJ/kg

St2 = 27.8154 kg

Energy Balance to The Manufacturing Vessel

2000×10-3 m3 × 1000 kg/m-3 × 4.187 kJ/kgK × (60-50) ℃ = St3 × 2257.92 kJ/kg

St3 = 37.0872 kg

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 500L of water which was at room temperature (250C), heated to 800C to CIP process

If the steam requirement for that is St4,

500L × 10-3m3 × 103kgm-3 × 4.187kJ/kgK × (80-25) ℃ = St4 ×2257.92kJ/kg

St4=50.9949kg

Total steam requirement for a batch of lotion = St1+ St2+ St3+ St4

= 180.8001kg

6.3. Toothpaste Manufacturing Process

Figure 3:Plant layout for toothpaste

• Latent heat of vaporization of steam at 1 bar = 2257.97kJ/kg

• Batch size = 200 kg
• Water = 60 kg
• Wax = 140 kg

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The processes that require steam are drawn in the above diagram. The water & wax phase (additives)
are at room temperature initially They are heated to 400C inside two separate vessels. Then they are
missed inside a mixing vessel at 500C.

Assumptions

(1) It is assumed that pipes are well insulated.

(2) No heat is absorbed or released when mixing happens.
(3) The specific heat capacity of the wax phase is the same as water which is 4.187kJ/kgK and the
density is also the same (1000kgm-3).
(4) Steam at 1 bar is used for heating purposes.

Energy Balance to The Water Phase Vessel

mcØ = mL

60kg × 4.187kJ/kgK × (40-25) ℃ = St1 ×2257.92 kJ/kg

St1 = 1.6689 kg

Energy Balance to The Wax Phase Vessel

140kg × 4.187kJ/kgK × (40-25) ℃ = St2 ×2257.92 kJ/kg

St2 = 3.8941 kg

Energy Balance to The Manufacturing Vessel

200kg × 103kgm-3 × 4.187kJ/kgK × (50-40) ℃ = St3 ×2257.92 kJ/kg

St3 = 3.7087kg

500L of water which was at room temperature (250C), heated to 800C to CIP process

If the steam requirement for that is St4,

500L × 10-3m3 × 103kgm-3 × 4.187kJ/kgK × (80-25) ℃ = St4 ×2257.92kJ/kg

St4=50.9949kg

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 Total steam requirement for a batch of lotion = St1+ St2+ St3+ St4

= 60.2666kg

6.4. Soap manufacturing process

Steam is required for two processes in soap manufacturing. Those are in semi–boiled saponification
process & finishing process Saponification process is done at 750C. In contrast, the finishing process is
done at 1200C to evaporate the water in the soap 1000kg of raw material is used in a single batch of soap
and the initial composition of the mixture is as follows.

• Water 2.29%
• Fatty acid 71.82 %
• Caustic 21.84 %
• Brine 4.05%

Assumptions

(1) It is assumed that pipes are well insulated.

(2) No heat is absorbed or released when mixing happens.
(3) The specific heat capacity of the wax phase is the same as water which is 4.187kJ/kgK, and the
density is also the same (1000kgm-3).

Let’s first consider the Saponification of the mixture.

▪ Cp , water = 4.187kJ/kgK
▪ Cp , fatty acid = 2,2kJ/kgK
▪ Cp , caustic soda = 3.90kJ/kgK
▪ Cp , brine = 3.11kJ/kgK
▪

Applying Energy Balance to The Saponification Mixture

mcØ = mL

[(22.9kg×4.187kJ/kgK)+(718.2kg×2.2kJ/kgK)+(218.4kg×3.90kJ/kgK)+(40.5kg×3.11kJ/kgK)}
(75-25) 0C = St1 ×2257.92kJ/Kg

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St1 =58.7628Kg

It is said that, in semi-boiled saponification process soaps made with caustic soda, 0.77 grams of
glycerin are created for every gram of NaOH used.

Glycerin removed after saponification process = 218.4kg × 0.77

= 168.168kg

The total mixture passed to the low-pressure vessel

=1000kg – 168.168kg

=831.832kg

It assumed that the specific heat capacity of the mixture is the same as water, and the mixture is cool
down to room temperature when entering the pressure vessel. since the mixture should heated to
1200C, steam @ 5 bar is used for heating purposes.

Latent heat of vaporization of steam @ 1 bar =2257.92kJ/kg

Latent heat of vaporization of steam @ 5 bar =2107.42kJ/kg

Specific heat of steam @ 1 bar =2.0267KJ/kgK

The water in the mixture is being vaporized.

Applying Energy Balance to The Low-Pressure Vessel

[831.832kg ×4.187kJ/kgK × (100-25)0C] + [22.9kg ×2257.92kJ/kgK]+[808.932kg ×4..187kJ/kgK ×

(120-100)0C ]+[22.9kg ×2.0267kJ/kgK × (100-25)0C ]= St2 × 2107.42kJ/kg

St2 = 181.070kg

Steam Requirement for Soap Production

1 bar steam = 58.7628 kg

5 bar steam = 181.070 kg

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 Total steam Steam usage Steam flow
Residence
Product/Process usage considering the rate required
time
(kg) errors (kg) (kg/h)
Lotion 3 hours 74.1743 81.5917 28
Shampoo 4 hours 180.8001 198.8801 50
Toothpaste 3 hours 60.2666 66.2932 22
Soap 8 hours 239.8328 263.8160 33
CIP (per batch) 2 hours 50.9949 56.0943 28
Table 5:Required steam flow rate

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References

energy - specific heat capacity [WWW Document], n.d. URL

http://www.dynamicscience.com.au/tester/solutions1/chemistry/energy/specificheatcapacity.htm
(accessed 10.14.22).

How shampoo is made - material, manufacture, making, history, used, structure, steps, product, industry
[WWW Document], n.d. URL http://www.madehow.com/Volume-3/Shampoo.html (accessed
10.14.22).

How toothpaste is made - manufacture, history, used, components, product, industry, machine, Raw
Materials [WWW Document], n.d. URL http://www.madehow.com/Volume-3/Toothpaste.html
(accessed 10.14.22).

Industrial Soap Production and Manufacturing Process | Saponification [WWW Document], n.d. URL
https://www.chemistryscl.com/industrial/soap-production-manufacturing-process-
saponification/index.php (accessed 10.14.22).

Saturated Steam - Properties for Pressure in Bar [WWW Document], n.d. URL
https://www.engineeringtoolbox.com/saturated-steam-properties-d_457.html (accessed 10.14.22).

Shampoo Manufacturing Plant , Shampoo Mixer , Shampoo Making Plant [WWW Document], n.d. URL
https://www.applepackprocess.com/products/shampoo-manufacturing-plant/ (accessed 10.14.22).

Steam Tables Pressure vs Temperature [WWW Document], n.d. URL

https://www.valvesonline.com.au/references/steam-tables/ (accessed 10.14.22).

US4772434A - Soap making process - Google Patents [WWW Document], n.d. URL
https://patents.google.com/patent/US4772434A/en (accessed 10.14.22).

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