MAZZONI LB S.p.A.

Plant Description:
SCTU+C&TPCP 15 t/h
BUSTO A. (Italy) Descrizione Impianto:
Customer: UNIOLEO - Indonesia Date / Data Rev. Job:
J.21039
Cliente: 22-mar-22 2 Commessa:

UTILITIES DATA AND CONSUMPTION LIST (TYPICAL & DESIGN)

Utilities consumption will vary according to production rate, recipe and raw materials temperature
Here below typical consumptions are reported
Process configurations:
- continuous saponification and dryer plants working with an integrated configuration (SCTU+C) to produce 15 t/h of toilet soap noodles from DFA or Neutral Oils at 14 ÷ 19% moisture depending on the desired final product

STEAM CONSUMPTION

B.L. conditions: saturated steam at 15 barg SCTU+C plant

SN8020 15 ÷ 17% moisture Snow White 14-18% moisture Swing 17-19% moisture
15 barg reduced to 4 barg for process S&T heat exchangers E 1262.01 and E 1262.02 550 ÷ 565 kg/h (1) 560 ÷ 575 kg/h (1) 760 ÷ 775 kg/h (1)
15 barg reduced to 4 and 2 barg for slop kettle PS 1242.03A/B 200 ÷ 400 kg/h x 2 (2)
15 barg reduced to 4 barg for soap plant SCTU+C heating services (i.e. reactor R 1262.02 heating) 250 ÷ 400 kg/h (3)
15 barg reduced to 4 barg for soap plant SCTU+C pipes cleaning 200 ÷ 300 kg/h (4)
15 barg reduced to 2 barg for tanks heating services (i.e. insulated storage tanks D 1262.01A, D 1262.01B, D 1172.06) 60 ÷ 400 kg/h (5)
15 barg reduced to 2 barg for soap plant SCTU+C tracing 100 ÷ 200 kg/h
Steam peak flow (for boiler design)
Swing 17-19% moisture
Soap plant SCTU+C at full capacity 775 kg/h (1)
Scrap kettle PS 1242.03A/B in operation 400 kg/h (2)
Various for soap plant SCTU+C (heating services, pipes cleaning and pipes tracing) 900 kg/h
Boiler design (about 20% safety / design margin including heat losses) 2500 kg/h
Boiler generator and relevant instrumentation are excluded from MLB's scope of supply
(1) Neutral oils available at about 60°C. If their temperature is different, the steam consumption will vary accordingly
(2) Discontinuous: batch operation to re-work the soap scraps in kettles PS 1242.03A/B (1 batch operation every 1 or 2 weeks); 200 ÷ 350 kg/h is a peak (for one kettle) value reached only during heating, melting and mixing operations, while steam consumption due to heat losses (kettles are insulated) is negligible (20 ÷ 30 kg/h)
(3) Discontinuous: peak value during start-up only
(4) Discontinuous: peak value during cleaning operations
(5) Temperature maintenance (steady state) and peak value in case of heating operations

INSTRUMENT AIR AND COMPRESSED AIR CONSUMPTION

B.L. conditions:
- instrument air at 6 barg, dehydrated (dew point +3°C), deoiled and free from impurities SCTU+C plant &TPCP system
- compressed air at 6 barg, deoiled and free from impurities
Steady state Peak consumption
Instrument air to soap plant SCTU+C&TPCP 30 Nm3/h 40 Nm3/h (1)
Compressed air to pneumatic conveying system TPCP 70 ÷ 300 Nm3/h 490 Nm3/h
Air compressor and air dryer flow rates (for design purpose)
3
Instrument air (safety / design margin included) 50 Nm /h (2)
Compressed air + Instrument air (safety / design margin included) 560 Nm 3 /h (2)
Air compressor, compressed air buffer tank, air dryer with filters and relevant instrumentation are excluded from Mazzoni's scope of supply
(1) Discontinuous: saponification reactor R 1262.02 cleaning / emptying operations
(2) Air compressor designed for 560 Nm3/h (compressed and instrument air streams); air buffer tank for compressed and instrument air streams of 5 m3; air dryer and relevant filters designed for minimum 50 Nm3/h (instrument air stream only)

NITROGEN CONSUMPTION

B.L. conditions: nitrogen at minim 6 barg and about 30°C (room temperature) SCTU+C

Steady state Peak consumption

Nitrogen for blanketing of tanks D 1262.01A and D 1262.01B 4 ÷ 14 Nm3/h 40 Nm3/h
Nitrogen flow rate (for design purpose)
Nitrogen flow rate (about 25% safety / design margin included) 50 Nm 3 /h
Nitrogen, relevant dinstribution system and instrumentation up to B.L. is supplied by Customer

CHILLED WATER CONSUMPTION

B.L. conditions: chilled water at 3 barg and maximum 10 ÷ 12°C SCTU+C plant &TPCP system

3
Chilled water to plate heat exchanger E 2062.03/4 (ICS) 220 ÷ 240 m /h 1090000 ÷ 1200000 kcal/h (1)
Chilled water to vacuum pump P 2062.01 8.5 m3/h 35000 ÷ 40000 kcal/h
Chilled water to soap fines worm extruder / conveyor PL 2052.03's jacket 1 m3/h Neglectable
Chilled water to plodder PL 2042.01 4.7 m3/h x 2 19100 kcal/h x 2
Chilled water to conveying air refrigerator E 2502.01 42 m3/h (peak 48 m3/h) 208000 kcal/h (peak 240000 kcal/h)
Chiller duty (for design purpose)
Total chiller duty (about 20% safety / design margin included) 1750000 kcal/h
Total chilled water flow rate (about 15% safety / design margin included) 350 m 3 /h (2)
Chiller, recirculation pump and relevant instrumentation are excluded from MLB's scope of supply
(1) Indicative ranges: 1090000 ÷ 1100000 kcal/h for for plant running at max. capacity
(2) Chilled water system is a closed circuit: real water consumption is a make-up (as softened water) related to water losses

SOFTENED WATER CONSUMPTION (MECHANICAL SEALS CLOSED CIRCUIT)

B.L. conditions: softened water at 8-10 barg, about 30°C (room temperature) and 10 ÷ 20°f (hardness) SCTU+C plant

Softened water to pumps' seals (soap plant SCTU+C) 650 - 900 l/h (1)
Softened water flow rate (for design purpose)
Softened water flow rate (design flow rate) 1500 l/h
Softened water is supplied by Customer
(1) Mechanical Seals water system is a closed circuit: real water consumption is a make-up (as softened water) related to water losses

SOFTENED WATER CONSUMPTION

B.L. conditions: softened water at 2-3 barg, about 30°C (room temperature) and 10 ÷ 20°f (hardness) SCTU+C plant

Softened water to salt dissolving tank PS 121.03 10 m3/h (1)

Softened water for various consumptions 4 m3/h (2)
Fresh Softened water to reactor R 1262.02 0 ÷ 2.8 m3/h (3) (4)
Softened water flow rate (for design purpose)
3
Softened water flow rate (design flow rate) 6 m /h (5)
Softened water is supplied by Customer
(1) Discontinuous: peak value for brine preparation (filling of PS 121.03); brine solution to be prepared three times per day. About 300 ÷ 480 l/h of water as continuous consumption (brine at 20% in water)
(2) Discontinuous: peak value for semibarometric condenser C 2062.03 first filling; periodical make-up to restore the losses of water of the auxiliary systems is negligible
(3) Softened water fed to saponification by pump P 1262.03 (4 m3/h and about 67 m head - MLB's supply) from water daily tank D 1262.03 (process water)
(4) Process water consumption may vary according to production rate, working conditions, soap required moisture and recovered water from barometric section
3 3
(5) Suggested design value for softener: continuous production of 6 m /h of softened water, peak of 13 m /h to be absorbed by main water storage tank ("buffer")

CITY WATER CONSUMPTION

B.L. conditions: city water at 2 ÷ 3 barg and about 30°C (room temperature) SCTU+C plant

City water for various consumptions 3 m3/h (1) (2)

City water flow rate (for design purpose)
City water flow rate (design flow rate) 3 m 3 /h (1)
City water is supplied by Customer
(1) City water transferred to LW header directly by city distribution system
(2) Discontinuous: peak value for tank cleaning operations
MAZZONI LB S.p.A. Plant Description:
SCTU+C 15 t/h
BUSTO A. (Italy) Descrizione Impianto:
Customer: UNIOLEO - Indonesia Date / Data Rev. Job:
J.21039
Cliente: 22-mar-22 2 Commessa:

EFFLUENT LIST

OVERFLOW FROM SEMIBAROMETRIC CONDENSER SECTION

B.L. conditions: water at atmospheric pressure (free, gravity discharge from semibarometric overflow) and 15 ÷ 35°C SCTU+C plant

Semibarometric water from discharge valve LV 206.1 0 ÷ 2050 l/h (1) (2)
Water from semibarometric condenser C 2062.03 is recovered and recycled to water daily tank D 1262.03 through control valve LV 206.1. As alternative it is discharged by gravity (free, gravity discharge) into a trench and has to be sent to wastewater treatment plant before being disposed of
(1) Condensed water vapours from saponification plant (traces of entrained and dissolved soap are present); COD: 800 - 1500 mgO2/l (peak value: 2000 mgO2/); BOD: 320-600 mgO2/l (peak value: 800 mgO2/)
(2) Condensed water is recycled back to water daily tank D 1262.03 and re-used as process water; depending on plant capacity, soap formulation and moisture, the wastewater flow to treatment plant is within the following range: 0 ÷1000 l/h; 2050 l/h is to be considered the maximum / design flow (without water recovery)

CONDENSATE FROM HEAT EXCHANGERS, COILS AND TRACING

B.L. conditions: 4 barg Steam condensate at 2.5 ÷ 3.5 barg and about 138 ÷ 148°C
2 barg Steam condensate at 1 ÷ 1.5 barg and about 120 ÷ 128°C SCTU+C plant
15 barg Steam condensate at 13 ÷ 14 barg and about 195 ÷ 198°C
15 barg steam condensate (steam header) from soap plant SCTU+C 20 ÷ 60 kg/h
4 barg steam condensate (heating services) from soap plant SCTU+C 550 ÷ 775 kg/h (peak 1125 kg/h)
2 barg steam condensate (tracing services) from soap plant SCTU+C 160 ÷ 600 kg/h
Condensate from soap plant SCTU+C will be sent to recovery system (by Customer) and transferred back to steam boiler unit

CONDENSATE FROM VACUUM PUMP

B.L. conditions: condensate at 20 ÷ 30°C SCTU+C plant

Condensate from vacuum pump P 2062.01 5 ÷ 15 kg/h

Condensate from vacuum pump P 2062.01 is discharged by gravity into a trench and sent to wastewater treatment or sewer

CONDENSATE FROM CONVEYING AIR REFRIGERATOR

B.L. conditions: condensate at 0.1 barg and 20 ÷ 30°C TPCP system

Condensate from conveying air refrigerator E 2502.01 Maximum 150 kg/h

Condensate from conveying air refrigerator E 2502.01 is discharged by gravity into a trench and sent to wastewater treatment or sewer

ADDITIONAL NOTES ABOUT EFFLUENTS:

Chemical water discharged into trenches has to be treated before being disposed of
Effluents are composed by the continuous and discontinuous effluents of the plant and have to be treated before being disposed of:
- Discontinuous effluents come from drains, cleaning, manufacturing and operational activities. These could be: neutral oils / fatty acids, caustic soda, water (city / tap water and softened water), brine (NaCl), EDTA, EHDP, glycerine, soap, steam, instrument and compressed air pipelines impurities and all the additives used for the soap production. Other could be the lubricant
oils and greases foreseen commonly for motors and gear reducers, but also the detergents to clean the floor and chemical reagents for soap quality control (i.e. phenolphthalein).
- Continuous effluents: condensate from semibarometric condenser C 2062.03's overflow (discharged continuously through LV 206.1), steam condensate, condensate from conveying air refrigerator E 2502.01 and vaccum pump P 2062.01
There is no special / additional production of waste water during shut-down