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

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 000 00 0 1 2 3 4 5 6

Worked Penetration @ 25 o C 445-475 400-430 355-385 310-340 265-295 220-250 175-205 130-160 85-115

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 GREASE COMPOSITION: 1) Base oils (lube oil) 2) Thickening agents(Soap) 3) Additives BASE FLUIDS: Mineral Oils Vegetable Oils Synthetic Oils 75-90% 10-20% 0-10%

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)9-COOCH + 3 LiOH CH3-(CH2)5-CH (OH)-(CH2)10-COOCH2

HYDROGENATED CASTOR OIL LITHIUM HYDROXIDE

CH3-(CH2)5-CH (OH)-(CH2)10-COOLi

CH2 OH

CH3-(CH2)5-CH (OH)-(CH2)10-COOLi + CH OH CH3-(CH2)5-CH (OH)-(CH2)10-COOLi

LITHIUM SALT OF HCO (SOAP)

CH2 OH
GLYCEROL

2) SAPONIFICATION OF HSA:
CH3-(CH2)5-CH (OH)-(CH2)10- COOH + LiOH.H2O 12 Hydroxy Stearic Acid Lithium
Hydroxide monohydrate

CH3-(CH2)5-CH (OH)-(CH2)10-COOLi + H2O Lithium stearate Water

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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 Dropping Point Max. usable temp. Water Resistance Shear Stability Oxidation Stability Oil Separation Rust Protection Pumpability Application Cost Volume

: Smooth, buttery : 850 1100 C : 650 C : Excellent : Fair to good : Poor to good : Poor to good : Poor to excellent : Good to excellent : General economical use : Low : 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 Dropping Point Max. usable temperature Water Resistance Mechanical Stability Oxidation Stability Rust Protection Oil Separation Pumpability Application

: Smooth, buttery : 130 150 C : 1100C : Excellent : Good to excellent : Fair to excellent : Poor to excellent : Good : Fair to excellent : Multipurpose
0 0

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 SODIUM GREASES:

Saponification of fat / fatty acids with Sodium Hydroxide in mineral oil.

Structure Dropping Point Max. usable temp. Water Resistance Oxidation Stability Rust Protection Pump ability Shear Stability Oil Separation Application

: Fibrous : 160 220C : 110C : Poor to fair : Poor to good : Good to excellent : Poor to fair : Good : Fair to good : Closed Rolling Contact Bearing

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 ALUMINUM GREASES:

Saponification of 12 Hydroxy Stearic Acid with Aluminum Hydroxide in mineral oil.

Structure Dropping Point Max. usable temp. Water Resistance Shear Stability Oxidation Stability Rust Protection Pump ability Oil Separation Application

: Smooth, clear : 80 110C : 70C : Excellent : Poor : Excellent : Good to excellent : Poor : Good : 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 Dropping Point Max. usable temperature Water Resistance Oxidation Stability Mechanical Stability Rust Protection Oil Separation Storage Stability Pumpability Compatibility with additives Application

: Smooth : 1700 2100 C : 1300 C : Good : Fair to excellent : Good : Poor to excellent : Good to excellent : Good to excellent : Fair to excellent : Good : 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 Dropping Point Max. usable temperature Water Resistance Oxidation Stability Mechanical Stability Storage Stability Rust Protection Pump ability Oil Separation Additive Compatibility Application
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: Smooth, buttery : 2600 3000 C : 1500 C : Good to excellent : Good : Good to excellent : Good to excellent : Fair to excellent : Fair to excellent : Good to excellent : Good : Multiservice Auto/Industrial use

 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 Dropping Point Max. usable temperature Water Resistance Mechanical Stability Oxidation Stability Rust Protection High Temperature Stability Oil Separation Pumpability Reversibility Property Additive Compatibility Application : Smooth, buttery : > 2600 C : 1500 C : Good to excellent : Good to excellent : Fair to excellent : Good to excellent : Good : Good to excellent : Fair to good : Yes : Poor : 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 Dropping Point Max. usable temperature Water Resistance Mechanical Stability Rust Protection Oil Separation Special Feature Pump ability Application

: Smooth, buttery : > 3000 C : > 1700 C : Excellent : Excellent : Excellent : Excellent : Excellent Inherent EP/AW : Fair to good : 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 Dropping Point Max. usable temperature Water Resistance Mechanical Stability Oxidation Stability Rust Protection High Temperature Stability Oil Separation Pump ability Salient Property Application

: Smooth, buttery : > 2900 C : 2000 C : Excellent : Good to excellent : Good to excellent : Good to excellent : Good : Fair to good : Fair to good : Inherent EP/AW/AO Properties : 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 Dropping Point Max. usable temp Water Resistance Mechanical Stability Rust Protection Oil Separation Pump ability Special Feature Application

: Smooth, buttery : > 2600 C (No dropping point) : > 1500 C : Poor to good : Fair to good : Poor to good : Good to excellent : Good : Excellent Inherent EP/AW Properties : 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 Dropping Point Max. usable temp Water Resistance Mechanical Stability Oxidation Stability Rust Protection Oil Separation Pump ability Special Feature Application : Smooth, buttery : > 2400 - 2600 C : 1500 C : Good to excellent : Fair to good : Excellent : Fair to excellent : Good to excellent : Good to excellent : Excellent EP Properties : 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.

Base oil

A
Hot oil return Cold oil return A

Vent

R101

A Plant air

Hot oil supply

Cold oil supply

A A Agitator

Plant air Blow down

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Reactor

 SPECIFICATIONS OF THE REACTOR:

1) 2) 3) 1) 2) 3) 1) 2) 3) 1) 2) 3) 1) 2) 3) 1) 1) 2) 3) Equipment name: CS Jacketed Reactor Design pressure: Shell : 13 kg/cm2 Tube: 11.5 kg/cm2 Jacket: 10.5 kg/cm2 Design temperature : Shell : 345 0C Tube: 345 0C Jacket: 345 0C Test pressure: Shell : 16.9 kg/cm2 Tube: 14.95 kg/cm2 Jacket: 13.65 kg/cm2 Corrosion allowance: Shell : 1.6 mm Tube: 1.6 mm Jacket: 1.6 mm Radiography: (Butt joint) Shell : Full Tube: Full Jacket: Full Capacity: Shell : 4.5 m3 Total empty weight: 10000 kg Weight when filled with water: 18500 kg Heat treatment: Shell yes Tube yes 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, V106etc.)

R101

V106

Pump

R102

K101

K102

K103

K104

K105

K106

Base Oil Charging

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 HOMOGENIZER:
TECHNICAL INFORMATION: Capacity Operating pressure (max) Max. Temperature Operating temperature 6000 m3/hr. 345 bar 200C 120 - 140C

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 BURNURE turn down Thermic fluid pressure available at heater outlet Thermic fluid flow rate Thermic fluid outlet temperature Thermic fluid temperature rise Thermic fluid recommended

1.5*106 Kcal/hr. 1:3 1.45kg/cm2gm 110 m3/hr. 2350c 10-12 0c a. High temp. mineral oil b. Synthetic oil

Tube material specification NCV of LDO LDO charging rate

LRW-B6359 10500 kcal/kg 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 Capacity Evaporation rate Output Fuel Voltage Phase Frequency Maximum pressure Working pressure Connected load Cleaning period Support

: 3 pass reverse flue smoke tube

Boiler : 3 tons/hr. : 3000 Kg/Hr. : 1.88 MW : LDO : 415 V : 3 Phases : 50 Hz : 10.5 Kg/cm2 : 10.3 Kg/cm2 : 15KW : 1year : 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 34 | P a g e

 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 1.200m 0.600m

Bottom diameter : Top diameter :

Furnace self supported chimney helps to discharge unwanted gases from furnace & hot oil heater to high attitude.

Boiler self supported chimney: Height Bottom diameter Top diameter : : : 30.30m 1.600m 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) 2) 3) 4) COMPRESSOR 201A COMPRESSOR 201B COMPRESSOR 202A COMPRESSOR 202B

TECHNICAL INFORMATION: UNIT TEST PRESSURE

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INTER COOLER 7.5 KG/CM2

 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) 2) 3) 4) Unworked Worked Prolong work 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.

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 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.
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 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.

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 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.

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 CRITERIA FOR GREASE SELECTION:Sr. No. 1 Factors High load/shock load Expected properties Grease with high viscosity oil Grease with low viscosity oil Heat resistant grease Grease that does not form residue at high temp. Grease with nlgi-3 & above grades Soft grease of nlgi0/1/2 grade Grease with low viscosity oil & good adhesive properties

Low temp.

3 4

High temp. High temp./re-lubrication

Dusty environment

Frequent relubrication

High speed

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.

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44 | P a g e

Batch no.: 0118 Date: 23/05/2012 Penetration: 230/232

Reactor: R-102
Kettle: K-105

RAW MATERIAL REQUIRED FOR CHARGING IS:COMPONENT BASE OIL 500 N 12 HYDROXY STEARIC ACID HCO LITHIUM HYDROXIDE MONOHYDRATE WATER TOTAL QUANTITY 2800 1000 300 200 10 4310

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 12 HSA HCO LiOH WATER LiOH.H2O SOAP OF 12 HSA SOAP OF HCO MOLECULAR WEIGHT 309.534 938 23.95 18 42 305.914 306

45 | P a g e

 OVERALL MASS BALANCE OVER REACTOR DURING REACTION:-

STEAM

VENT BASE OIL

+ SOAP IN VENT (LOSSES)

12 HSA
HCO SOAP

REACTOR

LiOH.H2O

WATER

Now, INPUT = OUTPUT HCO + 12HSA + LiOH.H2O + BASE OIL + WATER = SOAP + VENT 300 + 1000 + 200 + 2800 + 10 = SOAP + VENT 4310=SOAP +VENT .. (1)

46 | P a g e

 OVERALL MASS BALANCE OVER REACTOR DURING WASHING:-

VENT

150 BS BASE OIL

REACTOR

WASHED OIL

KETTLE

BRIGHT STOCK FOR WASHING = WASHED OIL + VENT 2500 = WASHED OIL + VENT .. (2)

47 | P a g e

 OVERALL MASS BALANCE OVER KETTLE: -

WASHED OIL

SOAP FROM REACTOR

CUTBACK/CORRECTION OIL

ADDITIVES KETTLE

EXHAUST

TO FILLING

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)

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 WATER/VOLATILES BALANCE: WATER IN CHARGING: Water= 10 kgs

WATER OF CRYSATALISATION OF LiOH.H 2 O: 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

49 | 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

50 | 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.

51 | 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

52 | 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

53 | 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.

54 | P a g e

Batch no.: 0136 Date: 28/05/2012 Penetration: 230/232

Reactor: R-101
Kettle: K-105

RAW MATERIAL REQUIRED FOR CHARGING IS:COMPONENT BASE OIL 500 N 12 HYDROXY STEARIC ACID HCO LITHIUM HYDROXIDE MONOHYDRATE WATER TOTAL QUANTITY 2805 1000 300 200 10 4315

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 12 HSA HCO LiOH WATER LiOH.H2O SOAP OF 12 HSA SOAP OF HCO MOLECULAR WEIGHT 309.534 938 23.95 18 42 305.914 306

55 | P a g e

 OVERALL MASS BALANCE OVER REACTOR DURING REACTION:-

STEAM

VENT BASE OIL

+ SOAP IN VENT (LOSSES)

12 HSA
HCO SOAP

REACTOR

LiOH.H2O

WATER

Now, INPUT = OUTPUT HCO + 12HSA + LiOH.H2O + BASE OIL + WATER = SOAP + VENT 300 + 1000 + 200 + 2805 +10 = SOAP + VENT 4315=SOAP +VENT .. (1)

56 | P a g e

 OVERALL MASS BALANCE OVER REACTOR DURING WASHING:-

VENT

150 BS BASE OIL

REACTOR

WASHED OIL

KETTLE

BRIGHT STOCK FOR WASHING = WASHED OIL + VENT 2500 = WASHED OIL + VENT .. (2)

57 | P a g e

 OVERALL MASS BALANCE OVER KETTLE: -

WASHED OIL

SOAP FROM REACTOR

CUTBACK/CORRECTION OIL

ADDITIVES KETTLE

EXHAUST

TO FILLING

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)

58 | P a g e

 WATER/VOLATILES BALANCE: WATER IN CHARGING: Water= 10 kgs

WATER OF CRYSATALISATION OF LiOH.H 2 O: 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

59 | 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

60 | 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.

61 | 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

62 | 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 %

63 | 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.

64 | P a g e

Batch no.: 0131 Date: 26/05/2012 Penetration: 228/232

Reactor: R-101
Kettle: K-105

RAW MATERIAL REQUIRED FOR CHARGING IS:COMPONENT BASE OIL 500 N 12 HYDROXY STEARIC ACID HCO LITHIUM HYDROXIDE MONOHYDRATE WATER TOTAL QUANTITY 2801 1000 300 200 5 4306

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 12 HSA HCO LiOH WATER LiOH.H2O SOAP OF 12 HSA SOAP OF HCO MOLECULAR WEIGHT 309.534 938 23.95 18 42 305.914 306

65 | P a g e

 OVERALL MASS BALANCE OVER REACTOR DURING REACTION:-

STEAM

VENT BASE OIL

+ SOAP IN VENT (LOSSES)

12 HSA
HCO SOAP

REACTOR

LiOH.H2O

WATER

Now, INPUT = OUTPUT HCO + 12HSA + LiOH.H2O + BASE OIL + WATER = SOAP + VENT 300 + 1000 + 200 + 2801 + 5 = SOAP + VENT 4306=SOAP +VENT .. (1)

66 | P a g e

 OVERALL MASS BALANCE OVER REACTOR DURING WASHING:-

VENT

150 BS BASE OIL

REACTOR

WASHED OIL

KETTLE

BRIGHT STOCK FOR WASHING = WASHED OIL + VENT 2500 = WASHED OIL + VENT .. (2)

67 | P a g e

 OVERALL MASS BALANCE OVER KETTLE: -

WASHED OIL

SOAP FROM REACTOR

CUTBACK/CORRECTION OIL

ADDITIVES KETTLE

EXHAUST

TO FILLING

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)

68 | P a g e

 WATER/VOLATILES BALANCE: WATER IN CHARGING: Water= 5 kgs

WATER OF CRYSATALISATION OF LiOH.H 2 O: 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

69 | 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

70 | 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.

71 | 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

72 | 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 %

73 | 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.

74 | P a g e

Batch no.: 0142 Date: 29/05/2012 Penetration: 228/232

Reactor: R-102
Kettle: K-107

RAW MATERIAL REQUIRED FOR CHARGING IS:COMPONENT BASE OIL 500 N 12 HYDROXY STEARIC ACID HCO LITHIUM HYDROXIDE MONOHYDRATE WATER TOTAL QUANTITY 2805 1000 300 200 10 4315

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 12 HSA HCO LiOH WATER LiOH.H2O SOAP OF 12 HSA SOAP OF HCO MOLECULAR WEIGHT 309.534 938 23.95 18 42 305.914 306

75 | P a g e

 OVERALL MASS BALANCE OVER REACTOR DURING REACTION:-

STEAM

VENT BASE OIL

+ SOAP IN VENT (LOSSES)

12 HSA
HCO SOAP

REACTOR

LiOH.H2O

WATER

Now, INPUT = OUTPUT HCO + 12HSA + LiOH.H2O + BASE OIL + WATER = SOAP + VENT 300 + 1000 + 200 + 2805 +10 = SOAP + VENT 4315=SOAP +VENT .. (1)

76 | P a g e

 OVERALL MASS BALANCE OVER REACTOR DURING WASHING:-

VENT

150 BS BASE OIL

REACTOR

WASHED OIL

KETTLE

BRIGHT STOCK FOR WASHING = WASHED OIL + VENT 2500 = WASHED OIL + VENT .. (2)

77 | P a g e

 OVERALL MASS BALANCE OVER KETTLE: -

WASHED OIL

SOAP FROM REACTOR

CUTBACK/CORRECTION OIL

ADDITIVES KETTLE

EXHAUST

TO FILLING

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)

78 | P a g e

 WATER/VOLATILES BALANCE: WATER IN CHARGING: Water= 10 kgs

WATER OF CRYSATALISATION OF LiOH.H 2 O: 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

79 | 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

80 | 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.

81 | 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

82 | 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 %

83 | 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.

84 | P a g e

Batch no.: 0120 Date: 29/05/2012 Penetration: 230/235

Reactor: R-102
Kettle: K-107

RAW MATERIAL REQUIRED FOR CHARGING IS:COMPONENT BASE OIL 500 N 12 HYDROXY STEARIC ACID HCO LITHIUM HYDROXIDE MONOHYDRATE WATER TOTAL QUANTITY 2805 1000 300 200 5 4310

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 12 HSA HCO LiOH WATER LiOH.H2O SOAP OF 12 HSA SOAP OF HCO MOLECULAR WEIGHT 309.534 938 23.95 18 42 305.914 306

85 | P a g e

 OVERALL MASS BALANCE OVER REACTOR DURING REACTION:-

STEAM

VENT BASE OIL

+ SOAP IN VENT (LOSSES)

12 HSA
HCO SOAP

REACTOR

LiOH.H2O

WATER

Now, INPUT = OUTPUT HCO + 12HSA + LiOH.H2O + BASE OIL + WATER = SOAP + VENT 300 + 1000 + 200 + 2805 + 5 = SOAP + VENT 4310=SOAP +VENT .. (1)

86 | P a g e

 OVERALL MASS BALANCE OVER REACTOR DURING WASHING:-

VENT

150 BS BASE OIL

REACTOR

WASHED OIL

KETTLE

BRIGHT STOCK FOR WASHING = WASHED OIL + VENT 2503 = WASHED OIL + VENT .. (2)

87 | P a g e

 OVERALL MASS BALANCE OVER KETTLE: -

WASHED OIL

SOAP FROM REACTOR

CUTBACK/CORRECTION OIL

ADDITIVES KETTLE

EXHAUST

TO FILLING

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)

88 | P a g e

 WATER/VOLATILES BALANCE: WATER IN CHARGING: Water= 5 kgs

WATER OF CRYSATALISATION OF LiOH.H 2 O: 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

89 | 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

90 | 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.

91 | 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

92 | 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

93 | 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.

94 | P a g e

Batch no.: 0146 Date: 30/05/2012 Penetration: 232/235

Reactor: R-102
Kettle: K-105

RAW MATERIAL REQUIRED FOR CHARGING IS:COMPONENT BASE OIL 500 N 12 HYDROXY STEARIC ACID HCO LITHIUM HYDROXIDE MONOHYDRATE WATER TOTAL QUANTITY 2805 1000 300 200 10 4315

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 12 HSA HCO LiOH WATER LiOH.H2O SOAP OF 12 HSA SOAP OF HCO MOLECULAR WEIGHT 309.534 938 23.95 18 42 305.914 306

95 | P a g e

 OVERALL MASS BALANCE OVER REACTOR DURING REACTION:-

STEAM

VENT BASE OIL

+ SOAP IN VENT (LOSSES)

12 HSA
HCO SOAP

REACTOR

LiOH.H2O

WATER

Now, INPUT = OUTPUT HCO + 12HSA + LiOH.H2O + BASE OIL + WATER = SOAP + VENT 300 + 1000 + 200 + 2805 + 10 = SOAP + VENT 4315=SOAP +VENT .. (1)

96 | P a g e

 OVERALL MASS BALANCE OVER REACTOR DURING WASHING:-

VENT

150 BS BASE OIL

REACTOR

WASHED OIL

KETTLE

BRIGHT STOCK FOR WASHING = WASHED OIL + VENT 2500 = WASHED OIL + VENT .. (2)

97 | P a g e

 OVERALL MASS BALANCE OVER KETTLE: -

WASHED OIL

SOAP FROM REACTOR

CUTBACK/CORRECTION OIL

ADDITIVES KETTLE

EXHAUST

TO FILLING

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)

98 | P a g e

 WATER/VOLATILES BALANCE: WATER IN CHARGING: Water= 10 kgs

WATER OF CRYSATALISATION OF LiOH.H 2 O: 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

99 | 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

100 | 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. 101 | 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

102 | 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

103 | 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.

104 | P a g e

Batch no.: 0150 Date: 30/05/2012 Penetration: 230/235

Reactor: R-102
Kettle: K-106

RAW MATERIAL REQUIRED FOR CHARGING IS:COMPONENT BASE OIL 500 N 12 HYDROXY STEARIC ACID HCO LITHIUM HYDROXIDE MONOHYDRATE WATER TOTAL QUANTITY 2803 1000 300 200 5 4308

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 12 HSA HCO LiOH WATER LiOH.H2O SOAP OF 12 HSA SOAP OF HCO MOLECULAR WEIGHT 309.534 938 23.95 18 42 305.914 306

105 | P a g e

 OVERALL MASS BALANCE OVER REACTOR DURING REACTION:-

STEAM

VENT BASE OIL

+ SOAP IN VENT (LOSSES)

12 HSA
HCO SOAP

REACTOR

LiOH.H2O

WATER

Now, INPUT = OUTPUT HCO + 12HSA + LiOH.H2O + BASE OIL + WATER = SOAP + VENT 300 + 1000 + 200 + 2803 + 5 = SOAP + VENT 4308=SOAP +VENT .. (1)

106 | P a g e

 OVERALL MASS BALANCE OVER REACTOR DURING WASHING:-

VENT

150 BS BASE OIL

REACTOR

WASHED OIL

KETTLE

BRIGHT STOCK FOR WASHING = WASHED OIL + VENT 2501 = WASHED OIL + VENT .. (2)

107 | P a g e

 OVERALL MASS BALANCE OVER KETTLE: -

WASHED OIL

SOAP FROM REACTOR

CUTBACK/CORRECTION OIL

ADDITIVES KETTLE

EXHAUST

TO FILLING

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)

108 | P a g e

 WATER/VOLATILES BALANCE:-

WATER IN CHARGING: Water= 5 kgs

WATER OF CRYSATALISATION OF LiOH.H 2 O: 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

109 | P a g e

 VOLATILE AND MOISTURE CONTENT OF B ASE 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

110 | P a g e

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.

111 | 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 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

112 | 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 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) =1 87.46 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

113 | P a g e

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.

114 | P a g e

TABULATION OF BATCHES COVERED:

BATCH NO.

DATE

TOTAL INPUT

OUTPUT

THEORITICAL % LOSS

ACTUAL % LOSS

% DEVIATION

PENETRATION

118 136 142 150 120 131 146

23/05/12 28/05/12 29/05/12 30/05/12 29/05/12 26/05/12 30/05/12

8958 9142 9139 8844 9448 9241 8939

8760 8942.5 8932.7 8736 8923 8932.7 8736

1.8 1.73 1.73 1.75 1.64 2.05 1.79

2.21 2.2 2.25 1.22 5.55 3.33 2.27

-0.4 -0.47 -0.52 +0.53 -3.91 -1.28 -0.48

230/232 228/232 228/232 230/235 230/235 228/232 232/235

115 | P a g e

CONCLUSION:
PROBLEMS ENCOUNTERED 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. PROPER REACTION CONDITIONS (OPTIMUM PRESSURE & TEMPERATURE), IF NOT MAINTAINED, RESULTS IN INCOMPLETE SAPONIFICATION OF FATS WHICH SUBSEQUENTLY SHOWS ITS EFFECTS ON THE YIELD OF THE BATCH. 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. MANUAL ERRORS DURING CHARGING MAY RESULT IN DEVIATION OF YIELD. ADDITIVE ADDITION IS DONE AT TEMPERATURE OF AROUND 100-1150C. THIS RESULTS IN THE ADDITIVES NOT IMPARTING THE DESIRED PROPERTIES TO GREASE FULLY. SUGGESTED RECTIFICATIONS CERTAIN PARAMETER FOR ADJUSTING THE FLOWRATE SHOULD BE THERE IN THE FLOWMETERS AND IT SHOULD BE ADJUSTED ACCORDING TO THE CHANGING DENSITY.

PROPER MONITORING OF THE PROCESS SHOULD BE DONE BY THE OFFICER INCHARGE.

PROPER MAINTENANCE OF PRESSURE SHOULD BE THERE TO AVOID HIGH VENTING RATE.

AUTOMATION SHOULD BE DONE FOR CHARGING. 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.
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