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Tyre Industry Saponification processes are chemical soap manufacturing processes that produce soap from fatty acid derivatives. Saponifiable substances are the soaps and detergent ingredients that can be converted into soap. Uni Klinger offers complete solution in supply of steam engineering accessories required in evaporator and other processes.
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- The first step of this process is to split natural fats into fatty acids and glycerin. The equipment used is a vertical stainless steel column with the diameter of a barrel called a hydrolizer. It may be as tall as 80 feet (24 m). Pumps and meters attached to the column allow precise measurements and control of the process.
- After hydrolizer the fat raises again the aqueous phase which also dissolves glycerol in reaction. The fatty acids are discharged from the hydrolyser to a flash tank called decanter where excess of water is separated.
- After removing water the fatty acids are then distilled for purification. The distillate is collected as overhead and bottoms are stored for recovery.
- The distillate neutralized by caustic soda in a continuous neutralizer so the purified fatty acids are mixed with a precise amount of alkali to form soap. Other ingredients such as abrasives and fragrance are also mixed in.
- Here the pasty mass is missed with air and cooled to 65 0C the soap is continuously extracted and collected into soap frames where it solidifies on cooling. Then it is cut into bars as usual. The particular process delivers the product in a day whereas the batch process operates for few more days.
- Activated carbon is separated from the solution. 99% white glycerin is produced. The yield is 30 – 35kg per ton of soap produced.
- For removing color, yellow glycerin is treated with activated carbon in mixer.
- The glycerin obtained from vacuum still is called yellow glycerin. It is used for industrial use.
- After removing the water from Glycerin, it is then distilled for further purification. The steam produced from evaporator is used in vacuum still to further concentrate the glycerin.
- A multiple-effect evaporator is an apparatus for efficiently using the heat from steam to evaporate water. In this water is boiled in a sequence of vessels, each held at a lower pressure than the last. The product stream from ion exchanger is sent to triple effect evaporator. The glycerin solution is concentrated in evaporator.
- Ion exchange is an exchange of ions between two electrolytes or between an electrolyte solution and a complex. 15 – 20% glycerin along with impurities from the hydrolyser goes for ion exchange. Here salt and colour is removed from glycerin.
- A tank which receives condensate return from the steam system and make up water as required in a plant. Boiler feed water is an essential part of boiler operations.
- A boiler is a device used to create steam by applying heat energy to water.
