Project Nebula

BASIC ENGINEERING

CONCEPT NOTES FOR

Galaxy KCP

Document Number
P090-TG59-01-006

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1.0 INTRODUCTION
Introduction:

Galaxy KCP (Potassium Cetyl Phosphate) is a solid product. It is an anionic surfactant which is
used as an emulsifier in creams & lotions. It is available in powder form.

Applications:
Galaxy KCP has wide range of applications:
Galaxy KCP is a highly effective oil-in-water anionic emulsifier without EO. It is skin compatible,
and is used in O/W creams/lotions with a broad spectrum of oils and emollients, especially
suitable for stable water-resistant sun-care formulations. It promotes the formation of intimate
mixtures of non-miscible liquids by altering the interfacial tension. The surfactant property
lowers the surface tension of cosmetic formulations as well as aids the even distribution of the
product when used.

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Aim:

• To create facility to manufacture 500 TPA of Galaxy KCP at G-59 Tarapur.

Background:

• Process of manufacturing Galaxy KCP includes two steps:

1. Manufacturing Cetyl Phosphate

75-80°C
2 + 2 +

R=C16 Cetyl Phosphoric

Polyphosphoric acid
Cetyl alcohol Phosphate acid

2. Polyphosphoric acid regeneration

P2O5 + 2H3PO4 → Polyphosphoric acid

3. Manufacturing Potassium Cetyl Phosphate

70-75°C
+ +

Cetyl Potassium Potassium Water

Phosphate Hydroxide Cetyl
Phosphate

• Side reactions:
1. Manufacturing Cetyl Phosphate:

▪ 3ROH + P2O5 → Cetyl phosphate + Di-Cetyl phosphate

▪ 4ROH + P2O5 → 2 Di-Cetyl phosphate

2. Manufacturing Potassium Cetyl Phosphate

▪ Tri-Cetyl Phosphate +KOH→ Di-Potassium Cetyl phosphate + Cetyl alcohol

▪ Tri- Cetyl Phosphate +KOH→ Potassium Cetyl phosphate + Cetyl alcohol

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• Q components for the process:

1. Manufacturing Cetyl Phosphate

1. Steam pressure:<2 kg/cm2 g

• Reaction temperature to be maintained is 80-85°C.higher temperature
degrades the color of final product

2. OrthoPhosphoric acid content:<4.5%

• As per the Customer Specification It needs to be with in Limit

3. Cetyl alcohol content: <2%

• As per the Customer Specification It needs to be with in Limit

4. Mono and Di- ester ratio:<=80:>=20

• As per the Customer Specification It needs to be with in Limit
• Note: This is only ration of Mono:Di, not their percentage in overall
product.( one can refer this as 4:1 ratio)
• Example: Mono-ester in product is 72% and Di-ester is 16%, and rest is
unreacted cetyl alcohol, orthophosphoric acid content, moisture,
metallic content etc. This gives ratio of Mono: di as 82:18 which is well
within specification

5. Nitrogen Atmosphere:0.1 kg/cm2 g to 0.3 kg/cm2 g

• Nitrogen atmosphere is maintained to avoid moisture contact.
• PPA, P2O5, Cetyl phosphate are hygroscopic in nature.
• Upon contact with water it forms phosphoric acid which indirectly affects
product quality.
• Also, it affects Cetyl phosphate color as well.

6. Slow addition of Polyphosphoric Acid

• On addition of PPA it generates exotherm, and this may lead to color
deterioration of Cetyl phosphate

7. Slow addition of P2O5:

• On addition of P2O5 it generates exotherm, and this may lead to color
deterioration of Cetyl phosphate

8. Reaction Temperature: 80°C>T>70°C

• Cetyl phosphate Melting point is 67.5°C
• On maintaining temperature near to melting point makes mixing difficult
as its viscosity will be higher
• On increasing temperature beyond limit, leads to color deterioration of
Cetyl phosphate

2. Flaking Process:

1. Feed line Heat tracing: to be ON for temperature 70-75°C

• In case of off, material will solidify in pipe

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• In case of more current than required, it may lead to overheating and can
hydrolyze Cetyl phosphate, which in turn directly affects the quality
parameters of Cetyl phosphate.

2. Pressure of Cooling/chilling water:3.5 kg/cm2 g>P>2.5 kg/cm2 g

• Minimum pressure required for cooling/chilling water at the inlet of flaker is
2.5 kg/cm2 g as per flaker design. Design pressure of flaker drum is 3.5
kg/cm2 g. Hence PSV is provided at the inlet of cooling/chilling water

3. Steam Pressure: >2 kg/cm2 g

• To maintain the temperature in Feed tray as melting point of Cetyl
Phosphate is 67.5°C
• On increasing temperature beyond limit, leads to color deterioration of Cetyl
phosphate

4. Inlet temperature of cooling /chilling water:10°C ± 1°C

• If the temperature is higher, then flakes might not be form properly or will be
sticky and afterwards it may form lump in bag.
• If the temperature is lower, then flakes might break in midway of rotation
and part of it might fall back into feed tray.

5. Outlet temperature of cooling/chilling water:12 C ± 1°C

• If the temperature is higher, then check the thickness of flakes coming out
• If the temperature is lower, then this indicates less or no heat transfer
across drum. Check feed tray and knives arrangement.

6. Nature of flakes:
• It has color slightly off white and are of brittle nature.
• Cetyl phosphate is hygroscopic in nature, hence filled must not be kept
open for more than 5 minutes. It should be avoided as much as possible.
• Thickness of flakes: 1.1 mm to 1.25 mm

7. Inlet temperature of MEG to PHE:5°C ± 1°C

• Temperature lower than 4°C will arise problem of icing on hot side PHE
• Higher temperature might lead to inadequate cooling of water going to
flaker.

8. Outlet temperature of MEG from PHE:8°C ± 1°C

• If the temperature is higher, then check MEG 22% for lower flow rate, hot
side fluid for higher flow rate and higher temperature.
• If the temperature is lower, then check MEG 22% for higher flow rate, hot
side fluid for lower flow rate and lower temperature.

9. Level of water in 93V4.G: >=80%

• Level of water to be checked while flaker in operation. Lower level can
affect the cooling in flaker.

10. Pressure Drop across PHE: >0.5 kg/cm2 g

• If pressure drop is higher, then it won’t be able to reach the minimum
pressure required at flaker inlet.
• In that case, PHE cleaning must be done.
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3. Manufacturing Potassium Cetyl Phosphate
1. Slow addition of Cetyl phosphate
• On addition of Cetyl phosphate it generates exotherm, and this may lead to
color deterioration of KCP

2. Steam pressure:<2 kg/cm2

• Reaction temperature to be maintained is 70-75°C.higher temperature
degrades the color of final product

3. Reaction temperature: 70-75°C

• Digestion to be carried out at temperature 70-75°C

4. Drying of Potassium Cetyl Phosphate

1. Steam pressure:<2 kg/cm2

• Higher temperature degrades the color of final product and also affects the
quality parameter

2. Feed temperature: 70-75°C

• At lower temperature, Nature of KCP diluted mass(22%) becomes viscous
3. Hot air temperature: 100-120°C
• Higher temperature will lead to excessive drying, which may increase cetyl
alcohol content in final product.
• Lower temperature will lead to inadequate drying.

4. Scrubber water:
• Water to be changed at certain frequency for efficient scrubbing of water.(
to be decided after commissioning)

• S components for the process:

1. P2O5 Handling
• P2O5 is hygroscopic in nature and reacts violently with water. Wear
appropriate protective gloves and clothing to prevent skin exposure.
• It is incompatible with Strong oxidizing agents, Bases, Ammonia, copper.
• Keep it away from excess heat.
2. KOH handling
• KOH is corrosive in nature and irritant to skin. Proper PPE must be used
while handling.
3. H2O2 Handling
• It is strong Oxidizer. It may lead to fire or explosion.
• Keep it away from the excess heat. Heat may build pressure, rupturing
closed containers, spreading fire and increasing risk of burns and injuries.

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Raw material and Finished goods:

• The raw material required for Galaxy KCP manufacturing are:

o Cetyl Alcohol (C16H34O)
o Polyphosphoric acid (HO-(HPO3)n-H)
o Phosphorous pentoxide (P2O5)
o Hydrogen Peroxide (H2O2)
o Potassium Hydroxide (KOH)

Handling and Specifications of RM and FG:

1. Cetyl alcohol (C16H34O)

o Cetyl alcohol is available in 25 kg bags
o This material will be stored in warehouse at the ambient temperature.
o The registered suppliers for Cetyl alcohol are Godrej and VVF
o The specification requirement checked for Cetyl alcohol is;

# Specifications Limit Impurities/Deviation Impact

1 Purity C16 >98% It will change the carbon Product will
chain distribution not meet
demanded by customer. market
requirement

2. Polyphosphoric acid (HO-(HPO3)n-H)

o Polyphosphoric acid is available in 45 kg, 65 kg, 300 kg drums
o This material to be stored at ambient conditions
o The registered suppliers for Polyphosphoric acid are Prasol and Punjab Chemicals
o The specification requirement checked for Polyphosphoric acid are;

# Specifications Limit Impurities/Deviation Impact

1 Purity (as H3PO4), % 118 Contribute to less free Product will
phosphoric acid content not meet
market
requirement

3. Phosphorous pentoxide (P2O5)

o Phosphorous pentoxide is available in 25 kg bags.
o This material to be stored at ambient conditions
o The registered suppliers for Phosphorous pentoxide are Prasol and Punjab
Chemicals
o The specification requirement checked for Phosphorous pentoxide are;

# Specifications Limit Impurities/Deviation Impact

1 Assay, % >98% Contribute to less free Product will
phosphoric acid content not meet
market
requirement

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4. Hydrogen Peroxide (H2O2)
o Hydrogen Peroxide is available in 50 Lt HDPE carboys
o This material to be stored at ambient conditions
o The registered suppliers for Hydrogen Peroxide are GACL, National Peroxide
o The specification requirement checked for Hydrogen Peroxide is;

# Specifications Limit Impurities/Deviation Impact

1 Assay, % >50% Used for Bleaching Product will
purpose only, does not not meet
take part in reaction market
requirement

5. Potassium Hydroxide (KOH)

o Potassium Hydroxide is available in 50 Lt HDPE carboys
o This material to be stored at ambient conditions
o The registered suppliers for Potassium Hydroxide is GACL
o The specification requirement checked for Potassium Hydroxide is;

# Specifications Limit Impurities/Deviation Impact

1 Assay, % >48% Incomplete Product will
Neutralization of Cetyl not meet
phosphate market
requirement

6. Cetyl phosphate (CP)

o Cetyl phosphate will be stored in 25/300 kg bags
o This material to be stored at ambient conditions
o The specification requirement for Cetyl phosphate are;

# Specifications Limit
1 Mono-ester: Di-ester > 80.0: < 20.0
2 H3PO4, % < 6.0
3 Cetyl alcohol, % < 2 .0
4 Moisture content, % by mass < 2.0

7. Potassium Cetyl Phosphate (KCP)

o Potassium Cetyl alcohol is available in kg bag
o This material to be stored at ambient conditions
o The specification requirement for Potassium Cetyl alcohol are;

# Specifications Limit
1 Appearance Flakes/ Powder
2 Color White to Off-White
3 Acid value, mg KOH/ g 130-155
4 Alkalinity, mg eq./ g 2.2 – 2.6

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5 pH (1 % aq. solution) 6.5-8.5
6 Cetyl alcohol, % < 2 .0
7 Moisture content, % by mass < 2.0
8 Total Heavy metals (Pb, Ni,
< 20
Cr, Cd, Co, As, Hg, Sb), ppm
9 10%:>93.688
PSD:(micron) 50%:>312.868
90%:>680.588
99%:>1074.968

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2.0 PHILOSOPHY
Process:

• Process block diagram:

Step 1: Cetyl phosphate process:

Step 2: Potassium cetyl phosphate process:

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Proposed system:

• All Raw material will be stored in warehouse and will be taken to plant building via lift.
• 93R1.G will be of 3.75kL and will be utilized for Cetyl phosphate manufacturing. (Batch
Size: 3000 kg). Reactor will be Jacketed with Agitator.
• 93R2.G will be of 5kL and will be utilized for Potassium Cetyl phosphate manufacturing.
(Batch Size: 700 kg). Reactor will have limpet with Agitator.
• 93R3.G will be of 7 kL and will be utilized as holding vessel for Dryer Feed. It will have
limpet with Agitator. Despite of being just a holding vessel agitator will be given because
KCP diluted mass has tendency to settle solid when kept still. Hence gentle mixing is
needed.
• Cetyl phosphate molten mass from 93R1.G will be flaked and stored in warehouse. Line
going from 93R1.G to flaker will be of duplex and will be heat traced to avoid solidification
of material in pipe.
• Flaker will be provided with chilled water of 10⁰ C by cooling water using MEG 22% in
plate type heat exchanger. 93V4.G (1 kL) will be used as flaker utility water tank
• Flakes will be utilized whenever batch in 93R2.G has to be taken.
• 93R2.G will be used for neutralization of Cetyl Phosphate i.e. for making KCP diluted
mass.
• Once the batch is prepared it will be transferred to 93R3.G by 93P1.G.(7 m3/hr)
• From 93R3.G, KCP diluted mass will be fed to Dryer 93DDD1.G at rate of 330 kg/hr.
• Polyphosphoric acid will be added using 93P3.G, KOH will be added using 93P5.G.
• H2O2 50% will be added to vessel 93V2.G by 93P4.G and will be added to reactor by
93P6.G
• Insulation will be applied to wherever required.

Process details:

BCT considered for process is:

Batch cycle time consideration for design:

Description Time Reactor

Step I:Cetyl phosphate Process
Charging of Cetyl alcohol 120 min
Melting of Cetyl alcohol 60 min
Polyphosphoric Acid addition 30 min
Cetyl alcohol and Polyphosphoric Acid reaction 720 min Reactor 1
P2O5 addition 30 min
Reaction with P2O5 480 min 37.5 hrs
Cetyl alcohol addition 30 min
Cetyl alcohol Reaction 720 min
Hydrogen peroxide addition for color 60 min
Flaking of Cetyl phosphate 480 min Flaker 8 hrs
Step II:Potassium Cetyl phosphate Process
Addition of KOH, water & stirring 30 min
Addition of Cetyl phosphate & stirring 60 min Reactor 2
Heating Time 30 min
Mixing 360 min 8 hrs
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Process details for Galaxy KCP:

1.Cetyl phosphate process:

• Cetyl alcohol flakes i.e. 60% of total require for reaction (2250 x 0.6= 1350 kg) will be
charged manually from bags to 93R1.G.Its melting will be carried out under nitrogen
Atmosphere at 50°C.Temperature will be achieved by Steam in Jacket.
• Once the agitator impeller is dipped, agitator will be started.
• To this Polyphosphoric acid (575 kg) will be added using 93P3.G. After the full addition of
PPA temperature will be raised to 65-70°C by exotherm of reaction itself, once temperature
becomes steady increase temperature by using steam in Jacket up to 75-80⁰C. Reaction
mass will be kept for digestion for 12 hrs.
• Sample will be taken after this step to check Mono:Di-ester ratio, unreacted Cetyl alcohol
content, free phosphoric acid content.
• Phosphorous pentoxide (265 kg) will be added using solid charging system and reaction
mass will be kept for digestion for 8 hrs at temperature 75-80°C.
• Sample will be taken after this step to check Mono:Di-ester ratio, unreacted Cetyl alcohol
content, free phosphoric acid content.
• After this remaining 40% of total Cetyl alcohol flakes (2250 x 0.4= 900 kg) will be added
using solid charging system and reaction mass will be kept for digestion for 12 hrs at
temperature 75-80°C.
• Sample will be taken after this step to check Mono:Di-ester ratio, unreacted Cetyl alcohol
content, free phosphoric acid content.
• After this to improve color Hydrogen Peroxide will be added from 93V4.G using 93P6.G
and will be stirred for additional 1 hour.
• Once Hydrogen peroxide is added, flaker utility water circulation loop (93V4.G to 93P2.G
to 93E2.G to 93FL1.G to back to 93V4.G) will be started, so that after above mentioned 1
hr digestion flaker will be ready for operation.
• Cetyl phosphate molten mass then will be flaked in flaker at temperature of 67°C.
• Molten mass will be sent to flaker by nitrogen pressure.
• Cetyl Phosphate flakes will be packed in 25/300kg bags from flaker chutes.
• Bags of Cetyl phosphate will be stored in warehouse.
• Weighing balance will be provided at suitable areas for weighing.

2.Potassium Cetyl phosphate process:

• DM water(2.3 kL) will be charged to the 93R2.G.
• 50%(w/w) KOH solution (220 kg) will be added by 93P5.G from HDPE carboy
• After this cooling water is kept on to main temperature around 30-35⁰C
• Cetyl Phosphate Flakes will be added manually and it will be stirred for 1 hour at ambient
temperature.
• After that temperature will be increased upto 70-75°C.Heating will be done by steam in
Reactor limpet.
• This KCP diluted mass will then transferred to 93R3.G by 93P1.G.
• KCP diluted mass from 93R3.G will be sent to dryer at temperature of 70-75°C.
• KCP will be dried in Double drum dryer.
• Dried product i.e. Galaxy KCP will be then packed in kg bags
• Evaporated water vapors will be passed through scrubber before leaving it in
atmosphere.

Image below is only for understanding reference:

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Utility:
• Steam in 93R1.G, 93R2.G, 93R3.G, 93FL1, 93DDD1
• MEG 22% 93E2.G
• DM water in 93R3.G
• Utility soft water: Makeup water in scrubber
• Water for cleaning 93FL1, 93DDD1
• Cooling water for seal cooling 93R1.G, 93R2.G, 93R3.G, 93FL1, 93DDD1
• Nitrogen for blanketing in 93R1.G , for line flushing, to send Cetyl molten mass to flaker,
Seal pot of 93R1.G, 93R2.G, 93R3.G
• Compressed air in 93FL1.G, 93DDD1.G
• *condensate: all the condensate will be sent to centralized condensate recovery stystem.

Effluent Characteristics*:
• TDS:5300 ppm
• BOD: 16200 ppm
• COD:47808 ppm
• Chloride: 1242 ppm
• Sulphate: 5289 ppm

*this data is of reactor cleaning water. Dryer evaporated water data is not available as trial
conducted for drying never had option of water vapor scrubbing or cooling.

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Mechanical:

Note: Material compatibility for new products were done by innovation team and data was shared,
MOCs for mechanical equipment are decided accordingly.
Cetyl phosphate is not compatible with SS304, SS316, SS316L but compatible with Duplex.
Potassium cetyl phosphate is not compatible with SS304 but compatible with SS316L.

1)93R1
• The requirements for Cetyl phosphate reactor are;
o Size – 3.7 m3
o Design – Full vacuum to 6 bar and 200°C, Jacket design for 6 bar and 200°C
o MOC –MS GLR
• The reactor will have nozzle provision as below;
1. Nitrogen blanketing
2. Sight Glass
3. Light glass
4. PSV
5. Pressure indicator
6. Bottom outlet
7. RM inlet (Solid)
8. RM inlet (Liquid)
9. Thermowell -1
10. Manhole
11. Agitator
12. Jacket inlet
13. Jacket outlet
14. Vent
15. Spare nozzles as on need

2)93R2
• The requirements for KCP reactor are;
o Size – 5 m3
o Design – Full vacuum to 6 bar and 250°C, Limpet design for 12 bar and 280°C
o MOC –SS316L shell, SS304 jacket
o Details – baffles with external limpet for heating
• The reactor will have nozzle provision as below;
1. Sight glass
2. light glass
3. PSV
4. Pressure indicator
5. Bottom outlet
6. Water inlet
7. RM inlet (Liquid)
8. Thermowell -1
9. Manhole
10. Agitator
11. Limpet inlet
12. Limpet outlet
13. Vent
14. Spare nozzles as on need
2)93R3

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• The requirements for KCP reactor are;
o Size – 7 m3
o Design – Full vacuum to 6 bar and 250°C, Limpet design for 12 bar and 280°C
o MOC –SS316L shell, SS304 jacket
o Details – baffles with external limpet for heating
• The reactor will have nozzle provision as below;
1. Sight glass
2. light glass
3. PSV
4. Pressure indicator
5. Bottom outlet
6. Material inlet
7. Thermowell -1
8. Manhole
9. Agitator
10. Vent
11. Spare nozzles as on need

3)Agitators
• The agitator must be able to provide uniform mixing and efficient heat transfer.
• All agitator will have double mechanical seal.
• Seal pots will have Glycerin and will be kept pressurized by Nitrogen.
• The motor will be flameproof, Protection class- IP55 and Efficiency class –IE3.
• Agitator type and MOC
o 93A1.G
▪ Reactor: 93R1.G
▪ MOC: MS glass lined
▪ Type:3 bladed RCI at bottom+ 3 bladed 45⁰ PBT at top
▪ Rpm: 93
▪ VFD: yes
▪ RCI at the bottom will give strong radial flow to keep solids (cetyl alcohol,
P2O5) in dispersion form avoiding its settling and this will contribute to faster
reaction. PBT at top will provide both axial as well as radial component. Axial
component will give through mixing parallel to impeller axis and radial
component will help in mixing in-between added solids (Addition at the top)
to spread evenly across perpendicular to impeller axis. Here combine Axial
and radial component of PBT will mix reaction mass thoroughly.
▪ As solid are involved in the process and to avoid settling of it at the bottom,
this agitator will have lower clearance between shell bottom and agitator
o 93A2.G
▪ Reactor: 93R2.G
▪ MOC: SS316L
▪ VFD: yes
▪ Type:4 bladed PBT+ 4 bladed PBT
▪ Rpm:92
▪ Cetyl phosphate by nature is insoluble in water. Upon its addition in water,
due to it forms emulsion (when reaction has not yet started just mixing is
happening). Because of this stage it requires higher flow. Hence PBT was
selected. Hydrofoil option was evaluated with vendor but because of above
mentioned emulsion stage and requirement of higher flow number, PBT is
considered.

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o 93A3.G
▪ Reactor: 93R3.G
▪ MOC: SS316L
▪ VFD: no, motor VFD compatible
▪ Type:4 bladed PBT
▪ Rpm:60
▪ Requirement in this reactor was just to keep material in motion so that KCP
diluted mass is not still and it does not settle, because of this despite of it
being a bigger reactor than 93R2.G only one impeller stage is provided.
Though there is provision for installation of second stage if in future it needs
to be.

4)Flaker
• Capacity: 375 kg/hr cetyl phosphate
• Wetted surface area: 6 m2
• Utility water in/out temperature: 10/12 ⁰C
• Utility water flow rate: 10 m3/hr
• Steam flow rate: 15 kg/hr
• Drum MOC: Duplex 2507 with external chrome hard plating.
• Drum design pressure: 3.5 kg/cm2 g
• Drum Cooling: by spraying nozzle system of SS304
• Feed tray MOC: Duplex 2507 with external SS304 Limpet
• Feed tray limpet design pressure: 6 kg/cm2 g
• Feed tray construction: Feed tray will have drain, overflow provisions along with trough
raising system for ease in operation.
• Scrapper blade: SS spring steel quality scraping edge sandwiched between top Duplex
2507 pressure plate and Duplex Steel 2507 lined Carbon Steel base plate. The blade will
have pneumatic arrangement to adjust pressure against the drum and also retract on the
opposite side for cleaning purposes.
• End Scrapper: generally material tend to fall from both end of drum hence End scrappers
of Duplex 2507 are provided.
• Flaker will be enclosed from above by SS316L hood.
• Nitrogen blanketing provision is provided.
• To minimize the size, at the end before packing flake breakers are provided. This will help
in KCP reaction. Smaller the size it will mix easily.
• No. of Chutes: 2
• Packing will be done manually. (From tieing bag to flaker chute to weigh it and stitch it )
• Motor: FLP, IP55, IE3, VFD compatible
• Details of cooling loop equipment 93E2.G, 93V4.G, 93P1.G are mentioned ahead.

5)Double drum dryer system:

• Capacity: 264 kg/hr evaporation capacity

• Wetted surface area: 20 m2
• Feed rate: 330 kg/hr
• Product rate: 66 kg/hr
• Steam flow rate required: 400 kg/hr @ 3 kg/cm2 g
• Double drum dryer system will include Hot air generator, Double drum dryer, Blower, wet
scrubber with pump.
• Drum MOC: Duplex 2507 with external chrome hard plating

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• Feed inlet arrangement: The feed will be fed in nip between two drums. The feed pipe and
base plates of and dam will Duplex Steel 2507 grade construction
• Scrapper blade: SS spring steel quality scraping edge sandwiched between top Duplex
2507 pressure plate and Duplex Steel 2507 lined Carbon Steel base plate. The blade will
have pneumatic arrangement to adjust pressure against the drum and also retract on the
opposite side for cleaning purposes.
• DDD will be enclosed from above by SS316L hood
• Hot air generation system: fin tube heat exchanger with aluminium fins and SS304 tubes
and body
• Vapor carrier system line will have MOC of SS304.
• Scrubber system: purpose of this is to quench the water vapours coming from the product.
Scrubber will be of SS304 body without any packing. Water will be recirculated through
centrifugal pump 93P7.G which is also SS304 in construction to scrubber back through
spraying nozzles.
• No. of Chutes: 3+3 (both sides) with flap valve
• Packing will be done manually. (From tieing bag to flaker chute to weigh it and stitch it )
• Motor: FLP, IP55, IE3, VFD compatible

6) 93P1.G
• Capacity: 7 m3/hr
• Type: lobe pump
• Motor: FLP, IP55, IE3, VFD compatible
• Seal: single mechanical seal
• MOC of wetted parts: SS316L
• Elastomer: Kalrez, comparion is as following table: (As Kalrez elastomer shows no
effect/little (less than 10% swell) after exposure to the chemicals such as CA, Phosphoric
acid, potassium salts, KOH, potassium phosphate (acid/alkaline) etc., hence it is
recommended to go with Kalrez elastomer)

Chemicals EPDM Viton Kalrez

Cetyl Alcohol Not Compatible Compatible Compatible
Phosphoric Acid Compatible Not Compatible Compatible
KOH (50%) Compatible Not Compatible Compatible
Potassium Phosphate Compatible Not Compatible Compatible
(Acid/Alkaline)

Potassium salts Compatible Compatible Compatible

7)93P2.G
• Capacity: 12 m3/hr
• Type: Inline vertical centrifugal pump
• Motor: FLP, IP55, IE3, VFD compatible
• Seal: single mechanical seal
• MOC of wetted parts: SS304

8)93V2.G

• The requirements for H2O2 vessel are;

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o Size – 90 lit (considering quantity for 3 batches, so that frequency of filling vessel
will come once a week)
o Design – Full vacuum to 6 bar and 150°C
o MOC –SS316L
• The reactor will have nozzle provision as below;
1. Nitrogen blanketing
2. Sight Glass
3. LT
4. Pressure indicator
5. Bottom outlet
6. Inlet
7. Thermowell
8. Vent
9. Spare nozzles as on need

8)93V4.G

• The requirements for Water vessel are;

o Size – 1kL
o Design – atm and 100°C
o MOC – SS304
• The reactor will have nozzle provision as below;
1. Fresh water
2. Recirculation
3. Overflow
4. Drain
5. Level indicator
6. Bottom outlet
7. Vent
8. Thermowell
9. Manhole
10. Return water

9)93P4.G
10)93P6.G
11)93P5.G
12)93F1.G

Civil:
• Details will be included in plant concept notes

Electrical:
• The system will be considered under flameproof area.
• The motors used will be of IE3 class for all the running equipment.
• It will have proper lighting arrangement for proper illumination in night.
• All running equipment’s will have local emergency stop button with protection.
• All the equipment and structure will have double earthing.
• Further more details will be included in concept notes of electrical

Instrumentation:

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• Temperature transmitter will be provided to 93R1, 93R2, 93R3.
• Temperature guages will be provided in utility lines,Flaker feed line, Dryer Feed line.
• Pressure gauges will be provided at steam inlet, cooling water inlet and outlet of 93R1,
93R2, 93R3, Across 93E2.G, Steam line to DDD and flaker, cooling water line to Flaker,
at the outlet of 93P2.G, 93P1.G.
• PT will be installed on 93R1, 93R2, 93R3.
• LT will be provided in 93V2
• Turbine type Flow meter in DM water line will be provided.
• Flaker feed rate will be through control valve which will be interlocked with level of material
in feed tray.
• DDD steam flow rate will be interlocked with level of feed in the DDD middle nip.
• LG will be provided in 93V2 and 93V4

Warehouse and Storage:

• All imported raw material will have inventory of minimum 15 days.
• All domestic raw materials within 500 km will have inventory of 7 days and above 500 km
distance will have inventory of 15 days.
• All consumables and IP materials will have inventory of 15 days
• All finished goods will have inventory of 15 days.

Safety:
• 93R1,93R2,93R3 will have pressure safety valves.
• Limpet/Jacket of 93R1,93R2,93R3 will have pressure safety valve.
• Since steam required is of pressure less than 3 kg/cm2, piping and fittings for it will be non
IBR. Steam inlet line will have PRV and PSV.
• P2O5, KOH, H2O2 will be handled with all appropriate PPEs
• H2O2 system

Statutory Aspects:
• It will be covered in separate concept notes

3.0 SIZING
Tentative list of equipment is as follows:

Description Tag No. Capacity Dimensions (m)

Reactor-1 for CP 93R1 3.75 kL
Reactor-2 for KCP 93R2 5 kL
Holding Vessel 93R3 7 kL
Flaker 93FL1 500 kg/hr
Dryer 93DDD1 300 kg/hr
Scrubber 93C1
Scrubber recirculation pump 93P7 3 m3/hr
93R2 to 93R3 transfer pump 93P1 7 m3/hr
Flake utility water tank 93V4 1kL
Flaker utility pump 93P2 12 m3/hr
PPA pump 93P3
Hydrogen peroxide pump( carboy 93P4
to 93V2)

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 Project Nebula
KOH pump 93P5
Hydrogen peroxide pump(93V2 to 93P6
93R1)
Hydrogen peroxide vessel 93V2 90 lit

4.0 NEW CONCEPTS

1. Solid charging system for P2O5

o P2O5 is hygroscopic powder, Corrosive Material, Water reactive, Non-
combustible; substance itself does not burn but may decompose upon heating to
produce corrosive and/or toxic fumes.
o For batch of 3T of CP, P2O5 required is 267 kg.
o There must be robust solid charging system for safer environment.
o System for this will be evaluated and implemented.

2. Avoiding Flaking and directly neutralizing CP

o Thought Process:
▪ First flaking CP and Storing & second Chraging this CP to 93R2, It is
tedious job operation wise and also more energy consuming.
▪ If we can directly use molten CP , mix it with water and then neutralize ;
then this will make operations easy (Considering product quality comes as
per specification)
o Way Forward:
▪ Trials as above will be carried out and will be evaluated.

3. Reutilization of evaporated water

o Thought Process:
▪ Water evaporated from the dryer will be sent to scrubber from which this
water will go to ETP.
▪ Part of this water can be evaluated to be recycled back in the coming
batches
o Way Forward:
▪ This option will be evaluated for its quality characteristics and system will
be developed for the same.

5.0 LAYOUT

6.0 ANNEXURE
MSDS Document no.

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