Energy and Material Balance

Final product x
Production Capacity Separator

Specification x
Mass Mass flow Gravity

50000 tpa Component
(%) (kg/hr) Separator
Assumptions x
- consistent composition x
throughout slurry and
powder
-50000000
9% sodium carbonate,
kg/yr LAS 10.0 625.0 Airlift
9% sodium silicate
- sodium CMC used x
- sodium perborate in
mobohydrate form
- carbonate and silicate are
8000
ahydrous hr/yr lkyl ethoxylate) 4.0 250.0 Cyclone
- zeolite is hydrated x
- 5% water in final product x
(screenshots of Ref. in raw
materials
6250 document)
kg/hr te 4A (hydrated) 20.0 1250.0 Bag Filter
- sodium sulphate and water x
balance, free water only up x
to 10%
- complete conversion of Sodium
LABSA NaOH H2SO4 Perborate
Monohydrat 12.0 750.0
(stoichiometric quantities x
used) e
x
- 5% by mass of large lumps
remains in airlift to be
recycled
- assuming 5% by mass of Enzymes 0.5 31.3 Fraction Leaving Top o
fines are separated by the x
gravity separator x
- 2% losses from cyclone x
- 1% losses from bag filter Perfume Oil 0.5 31.3 4.50%
x
Perfume
Encapsulate 1.0 62.5 x
s x
Powder
Brighteners 0.5 31.3
Component
x
x
Polycarboxyl
ate
2.0 125.0 LAS
(Sodium
polyacrylate) x
x
Non-Ionic
Sodium Carboxymethyl Cellulose 0.5 31.3 (alkyl
x ethoxylate)
x
TAED
Bleach 3.0 187.5 x Zeolite 4A (hydrated)
Activator x
Sud-suppressor 0.5 31.3 x Sodium Polycarboxylate
x
Sodium Silicate 9.0 562.5 x Sodium CMC
x
Sodium Carbonate (anhyd) 9.0 562.5 Sodium Silicate

x
x
Sodium Sulphate (anhyd) approx. 22.5 1406.3 x Sodium Carbonate
x
Water approx. 5.0 312.5 x Sodium Sulphate
x
Total 100.0 6250.0 Total

x
x
x
x
x
x
Inlets
Neutralisati Stream
Neutraliser
on Reactor Number
R-101 Stream Sulphonic Caustic
R-101 Water
Name Acid Soda
Component kmol/hr kmol/hr kmol/hr
LABSA l - 1.80 -
Sulphuric Acid l - 0.03 -
Sodium Hydroxide aq - - 1.86
Water l 16.97 - 4.13
Sodium Sulphate aq - - -
LAS aq - - -
Total 16.97 1.83 6.00
Inlets
Crutcher Stream 4 Stream 14 Stream 12
Crutcher Mixer
M-101 Reactor Liquids Solids
M-101
Products Dosing Dosing
Active Content 630.8 939.8 3253.6
Water 413.4 1279.4 242.4
Total 1044.2 2219.2 3496.0
Total Inlet 6928.1
Total Outlet 6928.1
Stream Number
Crutcher Reactor Liquids
Composition Products Dosing
s Wet Dry Wet Dry
(wt %)
LAS 60.00% 99.32% - -
Non-Ionic - - 11.29% 26.67%
Zeolite - - - -
Polyacrylate - - 5.65% 13.33%
CMC - - - -
Sodium Silicate - - 25.41% 60.00%
Sodium Carbonate - - - -
Sodium Sulphate 0.41% 0.68% - -
Water 39.59% - 57.65% -
Total 100% 100% 100% 100%
Inlets
Spray Tower Stream 15 Stream 17 Stream 20
Spray Tower
T-101 D-201 Slurry Hot Air Cyclone
Feed Inlet Recycle
Dry Solids (s) 4849.7 - 219.9
Water (l) 2078.4 - -
Total Solids 6928.1 0.0 219.9
Dry Air (g) - 21445.6 -
Water (v) - 682.9 -
Total Gas 0.0 22128.5 0.0
Total Inlet 29543.3
Total Outlet 29543.3
Inlets Outlets
Cyclone Stream 18 Stream 20 Stream 19
Cyclone
S-201 Cyclone Fines Cyclone
S-101
Inlet Recycle Exhaust
Dry Solids (s) 229.1 219.9 9.2
Water (l) - - -
Total Solids 229.1 219.9 9.2
Dry Air (g) 21445.6 - 21445.6
Water (v) 2450.8 - 2450.8
Total Gas 23896.4 0.0 23896.4
Total Inlet 24125.5
Inlets
Gravity
Airlift Stream 21 Stream 24 Stream 22
Separator Air-Lift + Gravity Separator
A-201 + S-203 Blown Cool Air Rising in
A-101 S-103
Powder Inlet Air-Lift
Dry Solids (s) 5091.2 - 5065.8
Water (l) 326.6 - 324.9
Total Solids 5417.8 0.0 5390.7
Dry Air (g) - 11393.4 11393.4
Water (v) - 53.6 53.6
Total Gas 0.0 11447.1 11447.1
Total Inlet 16864.9
Inlets Outlets
Bag Filter Stream 26 Stream 27 Stream 28
Bag Filter
S-202 Bag Filter Fines Bag Filter
S-102
Inlet Recycle Air Outlet
Dry Solids (s) 253.3 250.8 2.5
Water (l) 16.2 16.1 0.2
Total Solids 269.5 266.8 2.7
Dry Air (g) 11393.4 - 11393.4
Water (v) 53.6 - 53.6
Total Gas 11447.1 0.0 11447.1
Total Inlet 11716.6
Inlets Outlets
Stream
Air Cooler
Number
Air Cooler
H-202
Stream Air Cooler Cooled Condensat
H-202 e
Name Inlet Air
Drainage
Dry Air (g) 11393.4 11393.4 -
Water (v) 312.2 53.6 258.6
Total Gas 11705.7 11447.1 258.6
Total Inlet 11705.7
Inlets Outlets
Stream
Furnace Number
Furnace
H-201 Stream Furnace Furnace
H-201 Name Inlet Exhaust
Dry Air (g) 21582.1 21445.6 Nitrogen (g)
Water (v) 407.5 682.9
Total Gas 21989.6 22128.5
Total Inlet 21989.6
keep in mind that oxygen being used up whilst water a
Inlets
Drum Mixer Stream 35 Stream 36 Stream 37
Drum Mixer
M-301 Dosed Optical Perfume
M-301
Powder Brighteners Oil
Dry Solids (s) 5843.8 - -
Water (l) 312.5 - -
Total Solids 6156.3 0.0 0.0
Liquids (l) - 31.25 31.25
Water (l) - 0.0 0.0
Total Liquids 0.0 31.25 31.25
Total Inlet 6250.0
Total Outlet 6250.0
Mass Separated Assumptions
% Exiting Neutraliser
- 0.5% by mass of large lumps
remains in airlift to be recycled
- assuming 5% by mass of fines
are separated by the gravity
Mass leaving as
separator Mass flow
95% Cooled Powder Component
- 2% losses from cyclone (kg/hr)
- 1% losses from bag filter
- 4.5% of blown powder exits
from top of spray tower
(handbookofindustrialdrying)
Mass rising
- consistent composition
99.5% up the Air-Lift LAS 626.52
throughout slurry and powder
Steps
- calculate mass of LAS leaving
neutraliser by working out losses Water (from
96% from cyclone and bag filter LABSA reaction) 32.41
- work out losses:
cyclone losses:
(LAS in Product)/(0.95*0.95) then
*4.5% then *2% Water (from
99% 1% fines escape
bag filter losses: 1.08
H2SO4 reaction)
(LAS in product)/(0.95)*0.05
then *1%
- same procedure can be applied Sodium

4.27
to pre spray drying ingredients to Sulphate
work out total losses from
cyclone and bag filter
Water (from
Fraction Leaving Top of Spray Tower 74.42
NaOH solution)
of Blown Powder Water (to make 60% AM 305.50

paste)
Total Exiting Neutraliser
Cyclone
Bag Filter
Losses LAS 626.52
Losses (kg/h)
(kg/h)
1.190 0.329 Sodium Sulphate 4.27
0.48 0.13 Water 413.41
2.38 0.66 Total (kg/hr)

0.24 0.07 Entering Neutraliser
Mass flow
0.06 0.02 Component
(kg/hr)
1.07 0.30 LABSA 586.91
NaOH (for
1.07 0.30 72.01
LABSA reaction)
2.68 0.74 H2SO4 2.95
9.16 2.53 NaOH (from H2SO4 reaction) 2.41
Water (from
74.42
3.42 NaOH solution)
Water (to make 60% AM
paste) 305.50
Outlets
Stream
Number
Reactor
Stream 3 Water
Products
kmol/hr Component kmol/hr Mol Composition
- Water (l) 16.97 100%
- Total 16.97 100%
-
22.97
0.03
1.80
24.80
Stream
Inlets Outlets
Number
Stream 29 Stream 13 Stream 15 Stream 4
Recycle Saturated Crutcher
Component
Stream Steam Outlet
25.5 - 4849.7 LAS
1.6 141.6 2078.4 Sodium Sulphate
27.1 141.6 6928.1 Water (l)
Total
Solids Crutcher
Recycle
Dosing Outlet
Wet Dry Wet Dry Wet
- - 12.20% 12.99% 9.09%
- - 4.88% 5.19% 3.64%
35.84% 38.51% 24.41% 25.97% 18.18%
- - 2.44% 2.60% 1.82%
0.90% 0.96% 0.61% 0.65% 0.45%
- - 10.98% 11.69% 8.18%
16.13% 17.33% 10.98% 11.69% 8.18%
40.20% 43.19% 27.46% 29.22% 20.45%
6.93% - 6.03% - 30.00%
100% 100% 100% 100% 100%
Stream
Outlets
Number
Bag Filter Blown Gas Top Component
Recycle Powder Outlet
250.8 5091.2 229.1 LAS (s)
16.1 326.6 - Non-Ionic (s)
266.8 5417.8 229.1 Zeolite (s)
- - 21445.6 Polyacrylate (s)
- - 2450.8 CMC (s)
0.0 0.0 23896.4 Sodium Silicate (s)
Sodium Carbonate (s)
Sodium Sulphate (s)
Water (l)
Total
Stream Stream
Number Number
Stream 18 Cyclone Inlet Stream 20
Component kg/hr Composition Component
LAS (s) 29.8 13.0% LAS (s)

Non-Ionic (s) 11.9 5.2% Non-Ionic (s)
Zeolite (s) 59.5 26.0% Zeolite (s)
Polyacrylate (s) 5.95 2.6% Polyacrylate (s)
CMC (s) 1.49 0.6% CMC (s)
Sodium Silicate (s) 26.8 11.7% Sodium Silicate (s)
Sodium Carbonate (s) 26.8 11.7% Sodium Carbonate (s)
Sodium Sulphate (s) 66.9 29.2% Sodium Sulphate (s)
Water (l) - - Water (l)
Total Solids 229.1 100.0% Total
Nitrogen (g) 16553.3 69.3%
Oxygen (g) 4555.7 19.1%
Carbon Dioxide (g) 336.6 1.4%
Water (v) 2450.8 10.3%
Total Gas 23896.4 100%
Stream
Outlets
Number
Gravity Sep.
Recycle Gravity Sep.
Bottom Component
Stream Top Outlet
Outlet
25.5 253.3 4812.5 LAS (s)
1.6 16.2 308.7 Non-Ionic (s)
27.1 269.5 5121.2 Zeolite (s)
- 11393.4 - Polyacrylate (s)
- 53.6 - CMC (s)
0.0 11447.1 0.0 Sodium Silicate (s)
Sodium Sulphate (s)
Water (l)
Total
Stream Stream
Number Number
Stream 26 Bag Filter Inlet Stream 27
LAS (s) 32.9 12.20% LAS (s)

CMC (s) 1.6 0.61% CMC (s)
Water (l) 16.2 6.03% Water (l)
Total Solids 269.5 100% Total
Nitrogen (g) 8738.7 76.34%
Oxygen (g) 2654.8 23.19%
Water (v) 53.6 0.47%
Total Gas 11447.1 100%
Stream Stream
Number Number
Stream Stream
Air Cooler Inlet
Name Name
Nitrogen (g) 8738.65 74.7% Nitrogen (g)

Oxygen (g) 2654.78 22.7% Oxygen (g)
Water (v) 312.23 2.7% Water (v)
Total 11705.66 100% Total
Stream Stream
Number Number
Stream Stream
Furnace Inlet Furnace Exhaust
Name Name
Component kg/hr Composition Component kg/hr
Nitrogen (g) 16553.28 75.3% Nitrogen (g) 16553.28

Oxygen (g) 5028.85 22.9% Oxygen (g) 4555.70
Water (v) 407.47 1.9% Carbon Dioxide (g) 336.60
Total 21989.60 100% Water (v) 682.87
Total Gas 22128.45
being used up whilst water and carbon dioxide are produced
Outlets Stream
Number
Stream 38 Stream 39 Stream 35 Dosed Powder
Sud-
Detergent
Suppressor Component kg/hr
s Powder
- 5843.8 LAS (s) 625.0
- 312.5 Non-Ionic (s) 250.0
0.0 6156.3 Zeolite (s) 1250.0
31.25 93.75 Polyacrylate (s) 125.0
0.0 0.0 CMC (s) 31.25
31.25 93.75 Sodium Silicate (s) 562.5
Sodium Carbonate (s) 562.5
Sodium Sulphate (s) 1406.3
Perborate Monohydrate(s)
750.0
Enzymes (s) 31.25
Perfume Encapsulates (s) 62.50
TAED (s) 187.5
Water (l) 312.5
Total 6156.3
Assumptions Assumptions
ng Neutraliser - complete conversion of NaOH, Component Flow Ra
- assuming dry solids & blown
LABSA, H2SO4 powder composition wont
change
Non-
Steps Ionic
Mw Mol- LAS
Flowleaving neutralisation
Streammixer LAS Steps
(alkyl-
Zeolite 4A
(kg/kmol) (kmol/hr)
= (LAS in powder+LAS lost from just keep (hydrated)
- ethoxy an eye on, that, for
cyclone+LAS lost from bag filter) sulphate,
late) theres some sulphate
- 1:1 ratio of consumption and coming from neutraliser, so need
production from reaction to be careful when calculating the
- therefore 1.7987 mol of LABSA dosing
348 and NaOH enteringFinal
1.80 neutraliser
Product 625.00 250.00 1250.00
(assuming complete conversion)
- use Mws to find mass flow of
LABSA and NaOH
Then: Gravity
(mass flow LABSA/(1-0.5%))
Separator-
18 1.80
(mass flow LABSA) =2.95kg/hr
Bottom of 625.00 250.00 1250.00
sulphuric acid which is Outlet
0.03kmol/hr
- H2SO4:NaOH react in a 1:2
molar ratio Gravity
18 0.06 Separator
- moles of water produced in 32.89 13.16 65.79
Top Outlet
H2SO4 reaction (is equal to moles
of NaOH used) & moles of
sodium sulphate produced (is
equal to moles of H2SO4)Air-Lift
142 0.03 657.89 263.16 1315.79
Top NaOH
- water from 50% (w/w) Outletis
equal to the total mass of NaOH
entering neutraliser
- water added to bringRecycle
the
product to 60% active Stream
matter
18 4.13
paste (so do LAS/0.6 (from
to get Air-
total 3.31 1.32 6.61
stream flow rate), then do (total
Lift)
stream - everything else) to get
the remaining water Bag Filter
18 16.97 0.33 0.13 0.66
Top Outlet
Bag Filter
iting Neutraliser Bottom 32.57 13.03 65.13
Outlet
Spray-Dryer
348 1.80 Bottom 661.20 264.48 1322.40
Oulet
Spray Dryer
142 0.03 29.75 11.90 59.51
Top Outlet
Cyclone
18 22.97 1.190 0.48 2.38
Top Oulet
Cyclone
1044.2 Bottom 28.56 11.43 57.13
Oulet
Drop Tank
ng Neutraliser 629.83 251.93 1259.65
Outlet
Mw Mol Flow Crutcher
629.83 251.93 1259.65
(kg/kmol) (kmol/hr) Outlet
Solids/Liquid
s
326 1.80 0.00 250.61 1253.04
Dosing
(Crutcher)
Neutraliser
40 1.80 626.52 0.00 0.00
Outlet
98 0.03
Zeolite
40 0.06 4A Sodium
Non-Ionic (hydrat Polycarboxyl
LAS (alkyl-ethoxylate) ed) ate
18 4.13
12.20 4.88 24.41 2.44
18 16.97
MASS PERCENTAGES
Coming out G.Sep

Total Ou 5417.80 ### 0.819387755
Stream Stream Stream

Number Number Number
Stream 1 Sulphonic Acid Stream 2 Caustic Soda Stream 4
Component kmol/hrMol Composition
Component kmol/hr Mol Composition
Component
LABSA (l) 1.80 98.36%Caustic Soda (aq) 1.86 31.03% LAS (aq)
Sulphuric Acid (l) 0.03 1.64% Water (l) 4.13 68.97%
Sodium Sulphate (aq)
Total 1.83 100% Total 6.00 100% Water (l)
Total
Stream Stream
Numbe Numbe
Stream
r Stream
r
Reactor Products Liquids Feed Saturated Steam
14 13
kg/hr Composition Component kg/hr Composition Component kg/hr
626.5 60.0% Non-Ionic (l) 250.6 11.3% Sat. Steam (v) 141.6
4.27 0.4% Polyacrylate (aq)125.3 5.6% Total 141.6
413.4 39.6%Sodium Silicate (aq)
563.9 25.4%
1044.2 100% Water (l) 1279.4 57.7%
Total 2219.2 100%
Crutcher
Outlet
Dry
12.99%
5.19%
25.97%
2.60%
0.65%
11.69%
11.69%
29.22%
-
100%
Stream Stream
Numbe Numbe
Slurry Feed r 17
Stream Hot Air Inlet Stream
r Cyclone Recycle
20
629.8 9.1% Nitrogen (g) 16553.3 74.8% LAS (s) 28.6
251.9 3.6% Oxygen (g) 4555.7 20.6% Non-Ionic (s) 11.4
1259.7 18.2% Carbon Dioxide (g)336.6 1.5% Zeolite (s) 57.1
126.0 1.8% Water (v) 682.9 3.1% Polyacrylate (s) 5.7
31.5 0.5% Total 22128.5 100% CMC (s) 1.4
566.8 8.2% Sodium Silicate (s)25.7
566.8 8.2% Sodium Carbonate (s) 25.7
1417.1 20.5% Sodium Sulphate (s)64.3
2078.4 30.0% Water (l) -
6928.1 100% Total 219.9
Stream
Numbe
Cyclone Recycle r 19
Stream Cyclone Exhaust
kg/hr Composition Component kg/hr Composition
28.6 13.0% LAS (s) 1.19 13.0%

11.4 5.2% Non-Ionic (s) 0.48 5.2%
57.1 26.0% Zeolite (s) 2.38 26.0%
5.71 2.6% Polyacrylate (s) 0.24 2.6%
1.43 0.6% CMC (s) 0.06 0.6%
25.7 11.7% Sodium Silicate (s)1.07 11.7%
25.7 11.7%Sodium Carbonate (s)1.07 11.7%
64.3 29.2%Sodium Sulphate (s)2.68 29.2%
- - Water (l) - -
219.9 100% Total Solids 9.16 100%
Nitrogen (g) 16553.3 69.3%
Oxygen (g) 4555.7 19.1%
Carbon Dioxide (g)336.6 1.4%
Water (v) 2450.8 10.3%
Total Gas 23896.4 100%
Stream Stream
Numbe Numbe
r r
Stream
Blown Powder Stream 24 Cool Air Inlet Rising in Air-Lift
22
661.20 12.2% Nitrogen (g) 8738.7 76.3% LAS (s) 657.9
264.48 4.9% Oxygen (g) 2654.8 23.2% Non-Ionic (s) 263.2
1322.40 24.4% Water (v) 53.63 0.5% Zeolite (s) 1315.8
132.24 2.4% Total 11447.1 100% Polyacrylate (s) 131.6
33.06 0.6% CMC (s) 32.89
595.08 11.0% Sodium Silicate (s)592.1
595.08 11.0% Sodium Carbonate 592.1
(s)
1487.70 27.5% Sodium Sulphate (s)
1480.3
326.55 6.0% Water (l) 324.9
5417.80 100% Total Solids 5390.7
Nitrogen (g) 8738.7
Oxygen (g) 2654.8
Water (v) 53.63
Total Gas 11447.1
Stream
Numbe
Fines Recycle r 28
Stream Bag Filter Air Outlet
32.57 12.2% LAS (s) 0.33 12.2%

13.03 4.9% Non-Ionic (s) 0.13 4.9%
65.13 24.4% Zeolite (s) 0.66 24.4%
6.51 2.4% Polyacrylate (s) 0.07 2.4%
1.63 0.6% CMC (s) 0.02 0.6%
29.31 11.0% Sodium Silicate (s)0.30 11.0%
29.31 11.0%Sodium Carbonate (s)0.30 11.0%
73.27 27.5%Sodium Sulphate (s)0.74 27.5%
16.08 6.0% Water (l) 0.16 6.0%
266.8 100% Total Solids 2.70 100%
Nitrogen (g) 8738.7 76.3%
Oxygen (g) 2654.8 23.2%
Water (v) 53.63 0.5%
Total Gas 11447.1 100%
Stream
Numbe
r
Stream
Cooled Air Condensate Drainage
Name
8738.65 76.3% Water (l) 258.60 100.0%

2654.78 23.2% Total 258.60 100%
53.63 0.5%
11447.06 100%
Furnace Exhaust
Composition
74.8%
20.6%
1.5%
3.1%
100%
Stream Stream
Number Number
Dosed Powder Stream 36 Optical Brighteners Stream 38 Sud-Suppressors
Composition Component kg/hr Composition Component kg/hr Composition
10.15% Brighteners (l) 31.25 100.0% Sud-suppressor (l) 31.25 100.0%

4.06% Water (l) 0.00 0.0% Water (l) 0.00 0.0%
20.30% Total 31.25 100% Total 31.25 100%
2.03%
0.51%
9.14%
9.14%
22.84%
12.18%
0.51%
1.02%
3.05%
5.08%
100%
ns
Component Flow Rates (kg/hr)
dry solids & blown
mposition wont
Sodium
Sodium CMC
Sodium Silicate Sodium Carbonate Sodium Sulphate sum
Polycarboxylate
an eye on, that, for
heres some sulphate
m neutraliser, so need
ul when calculating the
125.00 31.25 562.50 562.50 1406.25
4812.50
125.00 31.25 562.50 562.50 1406.25
4812.50
6.58 1.64 29.61 29.61 74.01

253.29
131.58 32.89 592.11 592.11 1480.26
5065.79
0.66 0.17 2.98 2.98 7.44
25.46
0.07 0.02 0.30 0.30 0.74
2.53
6.51 1.63 29.31 29.31 73.27

250.76
132.24 33.06 595.08 595.08 1487.70
5091.25
5.95 1.49 26.78 26.78 66.95
229.11
0.24 0.06 1.07 1.07 2.68
9.16
5.71 1.43 25.71 25.71 64.27

219.94
125.97 31.49 566.84 566.84 1417.11
4849.65
125.97 31.49 566.84 566.84 1417.11
4849.65
125.30 31.33 563.87 563.87 1405.39
4193.40
0.00 0.00 0.00 0.00 4.27
630.79
Sodium CMCSodium Silicate

Sodium Carbonate Sodium Sulphate Free Water
0.61 10.98 10.98 27.46 6.03
Reactor Products
kmol/hr Mol Composition
1.80 7.26%
0.03 0.12%
22.97 92.62%
24.8 100%
Stream Stream
Number
Stream Number
Stream
Saturated Steam Solids Feed Recycle Stream
12 29
Composition Component kg/hr Composition Component kg/hr
100.0% Zeolite (s) 1253.0 35.8% LAS (s) 3.31
100% CMC (s) 31.33 0.9% Non-Ionic (s) 1.32
Sodium Sulphate (s)
1405.4 40.2% Zeolite (s) 6.61
563.9 16.1% Polyacrylate (s) 0.66
Water (l) 242.4 6.9% CMC (s) 0.17
Total 3496.0 100% Sodium Silicate (s) 2.98
Sodium Carbonate (s)2.98
Sodium Sulphate (s)7.44
Water (l) 1.63
Total 27.1
Stream Stream
Number Number
Cyclone Recycle Stream 27 Bag Filter Recycle Stream 21 Blown Powder
13.0% LAS (s) 32.6 12.2% LAS (s) 661.2
5.2% Non-Ionic (s) 13.0 4.9% Non-Ionic (s) 264.5
26.0% Zeolite (s) 65.1 24.4% Zeolite (s) 1322.4
2.6% Polyacrylate (s) 6.51 2.4% Polyacrylate (s) 132.2
0.6% CMC (s) 1.63 0.6% CMC (s) 33.1
11.7% Sodium Silicate (s)29.3 11.0% Sodium Silicate (s) 595.1
11.7%Sodium Carbonate (s)29.3 11.0% Sodium Carbonate (s) 595.1
29.2% Sodium Sulphate (s)73.3 27.5% Sodium Sulphate (s)1487.7
- Water (l) 16.1 6.0% Water (l) 326.6
100% Total 266.8 100% Total 5417.8
Stream Stream
Number Number
Rising in Air-Lift Stream 29 Recycle Stream Stream 26 Gravity Sep. Top Outlet

12.2% LAS (s) 3.31 12.2% LAS (s) 32.89
4.9% Non-Ionic (s) 1.32 4.9% Non-Ionic (s) 13.16
24.4% Zeolite (s) 6.61 24.4% Zeolite (s) 65.79
2.4% Polyacrylate (s) 0.66 2.4% Polyacrylate (s) 6.58
0.6% CMC (s) 0.17 0.6% CMC (s) 1.64
11.0% Sodium Silicate (s)2.98 11.0% Sodium Silicate (s) 29.61
11.0%Sodium Carbonate (s)2.98 11.0% Sodium Carbonate (s) 29.61
27.5% Sodium Sulphate (s)7.44 27.5% Sodium Sulphate (s)74.01
6.0% Water (l) 1.63 6.0% Water (l) 16.25
100% Total 27.09 100% Total Solids 269.5
76.3% Nitrogen (g) 8738.7
23.2% Oxygen (g) 2654.8
0.5% Water (v) 53.63
100% Total Gas 11447.1
Stream Stream
Number Number
Stream 37 Perfume Oil Stream 39 Detergent Powder
Component kg/hr Composition Component kg/hr Composition
Perfume Oil (l) 31.25 100.0% LAS (s) 625.0 10.0%

Water (l) 0.00 0.0% Non-Ionic (s) 250.0 4.0%
Total 31.25 100% Zeolite (s) 1250.0 20.0%
Polyacrylate (s) 125.0 2.0%
CMC (s) 31.25 0.5%
Sodium Silicate (s) 562.5 9.0%
Sodium Carbonate (s) 562.5 9.0%
Sodium Sulphate (s) 1406.3 22.5%
Perborate Monohydrate(s) 750.0 12.0%
Enzymes (s) 31.25 0.5%

Perfume Encapsulates (s) 62.50 1.0%
TAED (s) 187.5 3.0%
Perfume Oil (l) 31.25 0.5%
Brighteners (l) 31.25 0.5%
Sud-suppressor (l) 31.25 0.5%
Water (l) 312.5 5.0%
Total 6250.0 100%
Assumptions
Entering & Leaving Free Moisture Mass flow
- the blown powder won't Pre Spray-Drying Adds
Drum Mixer Content (%) (kg/hr)
rehydrate
- All water exiting spray tower is
vapour (110'C)
Mass flow
Component Sodium Sulphate 0% 0
Steps(kg/hr)
- working out all the moisture
coming from raw materials, pre
and post drying
Sodium - then start water balance Sodium
Perborate working way back
750.0 Carboxymethyl 1% 0.32
Monohydrate Cellulose
THEN: Need to calculate the
amount of water to be added to
bring slurry moisture up to 35%
Polycarboxylate
Enzymes 31.3correctional water, the
- without (Sodium 60% 187.50
slurry moisture content (SMC) polyacrylate)
was: 20.65%
however, the desired SMC is 30
to 35%
Perfume Oil 31.3 Non-Ionic (alkyl ethoxylate) 0% 0
Perfume
62.5 Zeolite 4A (hydrated) 16% 238
Encapsulates
Brighteners 31.3 Sodium Silicate 66% 1091.91
TAED Bleach Activator 187.5 Sodium Carbonate 0.70% 3.94
Free Moisture Mass flow

Sud-suppressor 31.3 Post Spray-Drying Adds
Content (%) (kg/hr)
Sodium
Perborate 0% 0
Monohydrate
Enzymes 0% 0
Perfume Oil 0% 0
Perfume
0% 0
Encapsulates
Brighteners 0% 0
TAED Bleach Activator 2% 3.83
Sud-suppressor 0% 0
Stream
Number
Recycle Stream Stream 15 Crutcher Outlet
Composition Component kg/hr Composition
12.2% LAS (s) 629.8 9.1%
4.9% Non-Ionic (s) 251.9 3.6%
24.4% Zeolite (s) 1259.7 18.2%
2.4% Polyacrylate (s) 126.0 1.8%
0.6% CMC (s) 31.49 0.5%
11.0% Sodium Silicate (s) 566.8 8.2%
11.0% Sodium Carbonate (s) 566.8 8.2%
27.5% Sodium Sulphate (s) 1417.1 20.5%
6.0% Water (l) 2078.4 30.0%
100% Total 6928.1 100%
Stream
Number
Blown Powder Stream 18 Gas Top Outlet
12.2% LAS (s) 29.8 13.0%
4.9% Non-Ionic (s) 11.9 5.2%
24.4% Zeolite (s) 59.5 26.0%
0.6% CMC (s) 1.5 0.6%
6.0% Water (l) - -
100% Total Solids 229.1 100%
Nitrogen (g) 16553.3 69.3%
Oxygen (g) 4555.7 19.1%
Water (v) 2450.8 10.3%
Total Gas 23896.4 100%
Stream
Number
Gravity Sep. Top Outlet Stream 30 Gravity Sep.Bottom Outlet

12.2% LAS (s) 625.0 12.2%
4.9% Non-Ionic (s) 250.0 4.9%
24.4% Zeolite (s) 1250.0 24.4%
0.6% CMC (s) 31.25 0.6%
6.0% Water (l) 308.7 6.0%
100% Total 5121.2 100%
76.3%
23.2%
0.5%
100%
Free Water (Liquid)
Stream Other Information / Calculation
(kg/hr)
SMC Prior to
Final Product 312.50
Correction
Gravity Separator
308.67 Desired SMC
Bottom Outlet
Gravity Separator Slurry (kg/hr)

Top Outlet 16.25 without ANY water
Air-Lift Total Slurry Water

324.92
Top Outlet (kg/hr) for Desired %
Recycle Stream Added Water (kg/hr) to

1.63
(from Air-Lift) Raise SMC to Desired %
Bag Filter PMC (Powder

0.16
Top Outlet Moisture Content)
Bag Filter 16.08 Total Water Evaporated in

Bottom Outlet Spray Drying
Spray-Dryer
326.55
Bottom Oulet
Spray Dryer
1767.95
Top Outlet (vap.)
Cyclone
1767.95
Top Oulet (vap.)
Cyclone
0.00
Bottom Oulet
Drop Tank Outlet 1936.80

Prior to SMC correction
Crutcher Outlet
Prior to SMC correction 1936.80
Additional Crutcher Water

141.62
(to Raise SMC)
Drop Tank Outlet

2078.42
After SMC correction
From Raw Materials

1521.77
into Crutcher
Neutraliser
413.41
Outlet
Gas
er Information / Calculation Stream
(kg/hr)
28.54% Fed to Furnace #REF!
Fed to Spray
30% #REF!
Tower
Spray Dryer
4849.65 Top Outlet #REF!
2078.42
141.62
6.03%
1767.95
0.00
Stream 3 Water
Component kmol/hr Mol Compositi
Stream 2 Caustic Soda Water (l) 16.97 100%
Component kmol/hr Mol Composition Total 16.97 100%
Caustic Soda (aq) 1.86 31.03%
Water (l) 4.13 68.97%
Total 6.00 100%
33
Stream 1 Sulphonic Acid
2 44
LABSA (l) 1.80 98.36%
Sulphuric Acid (l) 0.03 1.64% 11
Total 1.83 100%
M-101
Stream 4 Reactor Products Stream 14 Liquids Feed

LAS 626.5 60.0% Non-Ionic (l) 250.6 11.3%
Sodium Sulphate 4.27 0.4% Polyacrylate (aq) 125.3 5.6%
Water (l) 413.4 39.6% Sodium Silicate (aq) 563.9 25.4%
Total 1044.2 100% Water (l) 1279.4 57.7%
Total 2219.2 100%
14
Stream 29 Recycle Stream
Component kg/hr Composition
12
LAS (s) 3.31 12.2% 4
Non-Ionic (s) 1.32 4.9%
29 15
Zeolite (s) 6.61 24.4%
Polyacrylate (s) 0.66 2.4% 13
CMC (s) 0.17 0.6% M-102
Sodium Carbonate (s) 2.98 11.0% Stream 13 Saturated Steam
Sodium Sulphate (s) 7.44 27.5% Component kg/hr Composition
Water (l) 1.63 6.0% Sat. Steam (v) 141.6 100.0%
Total 27.09 100% Total 141.6 100%
Stream 18 Gas Top Outlet Stream 20 C

Component kg/hr Composition Component kg
LAS (s) 29.8 13.0% LAS (s) 28
Non-Ionic (s) 11.9 5.2% Non-Ionic (s) 11
Zeolite (s) 59.5 26.0% Zeolite (s) 57
18
Polyacrylate (s) 6.0 2.6% Polyacrylate (s) 5
CMC (s) 1.5 0.6% CMC (s) 1
Sodium Silicate (s) 26.8 11.7% 20
Sodium Silicate (s) 25
27
Sodium Carbonate (s) 26.8 11.7% Sodium Carbonate (s) 25
Sodium Sulphate (s) 66.9 29.2% 15 Sodium Sulphate (s) 64
Total Solids 229.1 100% Total 21
Nitrogen (g) 16553.3 69.3%
Polyacrylate (s) 6.0 2.6% Polyacrylate (s) 5
CMC (s) 1.5 0.6% CMC (s) 1
Sodium Silicate (s) 26.8 11.7% Sodium Silicate (s) 25
Sodium Carbonate (s) 26.8 11.7% Sodium Carbonate (s) 25
Sodium Sulphate (s) 66.9 29.2% 15 Sodium Sulphate (s) 64
Total Solids 229.1 100% Total 21
Nitrogen (g) 16553.3 69.3%
Oxygen (g) 4555.7 19.1%
Stream 27 Ba
Carbon Dioxide (g) 336.6 1.4% Component kg
Water (v) 2450.8 10.3%
LAS (s) 32
Total Gas 23896.4 100%
Non-Ionic (s) 13
Stream 15 Slurry Feed 17
Zeolite (s) 65
Stream 17 Hot Air Inlet 21 Polyacrylate (s) 6.
Component kg/hr Composition D-201 CMC (s) 1.
Nitrogen (g) 16553.3 74.8% Stream 21 Blown Powder Sodium Silicate (s) 29
Oxygen (g) 4555.7 20.6% Component kg/hr Composition Sodium Carbonate (s) 29
Carbon Dioxide (g) 336.6 1.5% LAS (s) 661.2 12.2% Sodium Sulphate (s) 73
Water (v) 682.9 3.1% Non-Ionic (s) 264.5 4.9% Water (l) 16
Total 22128.5 100% Zeolite (s) 1322.4 24.4% Total 26
CMC (s) 33.1 0.6%
Water (l) 326.6 6.0%
Total 5417.8 100%
Stream 19 Cyclone Exhaust

LAS (s) 1.19 13.0%
Cyclone
Non-Ionic (s) 0.48 5.2%
Zeolite (s) 2.38 26.0%
S-201
Dry Solids (
19 Polyacrylate (s) 0.24 2.6%
CMC (s) 0.06 0.6% Water (l)
Sodium Silicate (s) 1.07 11.7% Total Solid
Stream 18 Cyclone Inlet 18
Sodium Carbonate (s) 1.07 11.7% Dry Air (g)
Sodium Sulphate (s) 2.68 29.2% Water (v)
Water (l) - -
Total Gas
Total Solids 9.16 100%
Nitrogen (g) 16553.3 69.3%
Total Inlet 24
S-201 Oxygen (g) 4555.7 19.1% Total Outlet 24
20 Water (v) 2450.8 10.3%
Stream 20 Cyclone Recycle Total Gas 23896.4 100%
Stream 22 Rising in Air-Lift Stream 26 Gravity Sep. Top Outlet
LAS (s) 657.9 12.2% 26 LAS (s) 32.89 12.2%

Non-Ionic (s) 263.2 4.9% S-203 Non-Ionic (s)
Zeolite (s)
13.16
65.79
4.9%
24.4%
Zeolite (s) 1315.8 24.4%
Polyacrylate (s) 131.6 2.4% Polyacrylate (s) 6.58 2.4%
CMC (s) 1.64 0.6%
CMC (s) 32.89 0.6%
Sodium Silicate (s) 592.1 11.0% 22 Sodium Silicate (s) 29.61 11.0%
Water (l) 16.25 6.0%
Water (l) 324.9 6.0%
Total Solids 5390.7 100% Nitrogen (g) 8738.7 76.3%
Nitrogen (g) 8738.7 76.3% Oxygen (g) 2654.8 23.2%
Oxygen (g) 2654.8 23.2% Water (v) 53.63 0.5%
Water (v) 53.63 0.5% Total Gas 11447.1 100%
Total Gas 11447.1 100%
Stream 30 Gravity Sep.Bottom Outlet

LAS (s) 625.0 12.2%
Stream 21 Blown Powder 21 Non-Ionic (s) 250.0 4.9%
Zeolite (s) 1250.0 24.4%
Stream 24 Cool Air Inlet
30 Polyacrylate (s) 125.0 2.4%
CMC (s) 31.25 0.6%
Nitrogen (g) 8738.7 76.3% 24 Sodium Carbonate (s) 562.5 11.0%
Oxygen (g) 2654.8 23.2% Sodium Sulphate (s) 1406.3 27.5%
Water (v) 53.63 0.5%
29 Water (l) 308.7 6.0%
Total 11447.1 100% Stream 29 Recycle Stream Total 5121.2 100%
Stream 28 Bag Filter Air Outlet

LAS (s) 0.33 12.2%
28
Non-Ionic (s) 0.13 4.9%
Zeolite (s) 0.66 24.4%
Stream 26 Bag Filter Inlet 26 Polyacrylate (s) 0.07 2.4%
CMC (s) 0.02 0.6%
S-202 Water (l) 0.16 6.0%
27 Nitrogen (g) 8738.7 76.3%
Stream 27 Fines Recycle Oxygen (g) 2654.8 23.2%
Water (v) 53.63 0.5%
Total Gas 11447.1 100%
Stream 36 Optical Brighteners Stream 38 Sud-Suppressors Stream 37 Perf
Component kg/hr Composition Component kg/hr Composition Component kg/hr C
Brighteners (l) 31.25 100.0% Sud-suppressor (l) 31.25 100.0% Perfume Oil (l) 31.25
Water (l) 0.00 0.0% Water (l) 0.00 0.0% Water (l) 0.00
Total 31.25 100% Total 31.25 100% Total 31.25
Stream 35 Dosed Powder Stream 39

LAS (s) 625.0 10.15% LAS (s)
CMC (s) 31.25 0.51% CMC (s)
36 38 37 Perborate Monohydrate(s)
Perborate Monohydrate(s) 750.0 12.18%
Enzymes (s) 31.25 0.51% Enzymes (s)
Perfume Encapsulates (s) 62.50 1.02% Perfume Encapsulates (s)
TAED (s)
TAED (s) 187.5 3.05%
35 Perfume Oil (l)
Water (l) 312.5 5.08% 39
Brighteners (l)
Total 6156.3 100%
Sud-suppressor (l)
M-301
Water (l)
Total
Component Cp Units Reference

LABSA (l) 1.60 kJ/kg K (De Groot, 1995)
521.6 kJ/kmol K
LAS (100% AM) 2.00 kJ/kg K (De Groot, 1995)
696.0 kJ/kmol K
Water (l) 4.19 kJ/kg K (Felder and Rousseau, 2005)
75.40 kJ/kmol K
(v) 1.94 kJ/kg K (Engineering ToolBox, 2005)
NaOH 50% w/w (aq) 3.22 kJ/kg K (O'Brien et al., 2005)
80.03 kJ/kmol K
H2SO4 1.34 kJ/kg K (Engineering ToolBox, 2003)
131.3 kJ/kmol K
Sodium Sulphate (s) 1.10 kJ/kg K (Yaws, 2004)
(aq) 463.2 kJ/kmol K (Kobe and Anderson, 1936)
Sodium Polyacrylate 0.11 kJ/kg K (Gaur and Lau, 1982)
CMC 1.30 kJ/kg K (Hurst and Harrison, 1992)
Non-Ionic 1.97 kJ/kg K
Sodium Silicate 2.55 kJ/kg K (Vail, 1952)
Zeolite 4A 0.90 kJ/kg K (Qiu et al., 2000)
Sodium Carbonate (s) 1.05 kJ/kg K (Chase, 1998)
(l) 1.79 kJ/kg K
Air (g) 1.006 kJ/kg K (Engineering ToolBox, 2004)
CMC 1.30 kJ/kg K (Hurst and Harrison, 1992)
Zeolite 4A 0.90 kJ/kg K (Qiu et al., 2000)
Sodium Carbonate (s) 1.05 kJ/kg K (Chase, 1998)
(l) 1.79 kJ/kg K
Air (g) 1.006 kJ/kg K (Engineering ToolBox, 2004)
Water
mol/hr Mol Composition
16.97 100%
16.97 100%
Stream 4 Reactor Products

LAS (aq) 1.80 7.26%
4
Sodium Sulphate (aq) 0.03 0.12%
Water (l) 22.97 92.62%
Total 24.80 100%
Stream 12 Solids Feed Inlets

ds Feed
Component kg/hr Composition Crutcher Mixer Stream 4 Stream 14 Stream 12 Strea
Composition
Zeolite (s) 1253.0 35.8% Reactor Liquids Solids Rec
11.3% M-101
CMC (s) 31.33 0.9% Products Dosing Dosing Stre
5.6% Active Content 630.8 939.8 3253.6 25
Water 413.4 1279.4 242.4 1
Total 1044.2 2219.2 3496.0 27
100% Water (l) 242.4 6.9%
Total Inlet 6928.1
Total 3496.0 100%
Total Outlet 6928.1
Stream 15 Crutcher Outlet
LAS (s) 629.8 9.1%
Non-Ionic (s) 251.9 3.6%
Zeolite (s) 1259.7 18.2%
CMC (s) 31.49 0.5%
ted Steam Sodium Carbonate (s) 566.8 8.2%
omposition Sodium Sulphate (s) 1417.1 20.5%
100.0% Water (l) 2078.4 30.0%
100% Total 6928.1 100%
Stream 20 Cyclone Recycle

LAS (s) 28.6 13.0%
Non-Ionic (s) 11.4 5.2%
Zeolite (s) 57.1 26.0%
Inlets Out
Polyacrylate (s) 5.7 2.6% Spray Tower Stream 15 Stream 17 Stream 20 Stream 27 Stream 21
CMC (s) 1.4 0.6% D-201 Slurry Hot Air Cyclone Bag Filter Blown
Sodium Silicate (s) 25.7 11.7% Dry Solids (s) 4849.7 - 219.9 250.8 5091.2
Sodium Carbonate (s) 25.7 11.7% Water (l) 2078.4 - - 16.1 326.6
Sodium Sulphate (s) 64.3 29.2% Total Solids 6928.1 0.0 219.9 266.8 5417.8
Water (l) - - Dry Air (g) - 21445.6 - - -
Total 219.9 100% Water (v) - 682.9 - - -
Total Gas 0.0 22128.5 0.0 0.0 0.0
Polyacrylate (s) 5.7 2.6% Spray Tower Stream 15 Stream 17 Stream 20 Stream 27 Stream 21
CMC (s) 1.4 0.6% D-201 Slurry Hot Air Cyclone Bag Filter Blown
Sodium Silicate (s) 25.7 11.7% Dry Solids (s) 4849.7 - 219.9 250.8 5091.2
Sodium Carbonate (s) 25.7 11.7% Water (l) 2078.4 - - 16.1 326.6
Sodium Sulphate (s) 64.3 29.2% Total Solids 6928.1 0.0 219.9 266.8 5417.8
Water (l) - - Dry Air (g) - 21445.6 - - -
Total 219.9 100% Water (v) - 682.9 - - -
Total Gas 0.0 22128.5 0.0 0.0 0.0
Stream 27 Bag Filter Recycle Total Inlet 29543.3
Component kg/hr Composition Total Outlet 29543.3
LAS (s) 32.6 12.2%
Non-Ionic (s) 13.0 4.9%
Zeolite (s) 65.1 24.4%
CMC (s) 1.63 0.6%
Water (l) 16.1 6.0%
Total 266.8 100%
Inlets Outlets
Cyclone Stream 18 Stream 20 Stream 19
S-201 Cyclone Fines Cyclone
Dry Solids (s) 229.1 219.9 9.2
Water (l) - - -
Total Solids 229.1 219.9 9.2
Dry Air (g) 21445.6 - 21445.6
Water (v) 2450.8 - 2450.8
Total Gas 23896.4 0.0 23896.4
Total Inlet 24125.5
ty Sep. Top Outlet
hr Composition
9 12.2%
6 4.9%
9 24.4%
Inlets Outlets
8 2.4%
4 0.6% Air-Lift + Gravity Stream 21 Stream 24 Stream 22 Stream 29 Stream 26 Strea
1 11.0% Separator Blown Cool Air Rising in Recycle Gravity Grav
1 11.0% A-201 + S-203 Powder Inlet Air-Lift Stream Sep. Se
1 27.5% Dry Solids (s) 5091.2 - 5065.8 25.5 253.3 481
5 6.0% Water (l) 326.6 - 324.9 1.6 16.2 308
5 100% Total Solids 5417.8 0.0 5390.7 27.1 269.5 512
.7 76.3% Dry Air (g) - 11393.4 11393.4 - 11393.4 -
.8 23.2%
Water (v) - 53.6 53.6 - 53.6 -
3 0.5%
7.1 100% Total Gas 0.0 11447.1 11447.1 0.0 11447.1 0.
Total Inlet 16864.9
y Sep.Bottom Outlet
hr Composition
.0 12.2%
.0 4.9%
0.0 24.4%
.0 2.4%
25 0.6%
.5 11.0%
.5 11.0%
6.3 27.5%
.7 6.0%
1.2 100%
Inlets Outlets
Bag Filter Stream 26 Stream 27 Stream 28
S-202 Bag Filter Fines Bag Filter
Dry Solids (s) 253.3 250.8 2.5
Water (l) 16.2 16.1 0.2
Total Solids 269.5 266.8 2.7
Dry Air (g) 11393.4 - 11393.4
Water (v) 53.6 - 53.6
Total Gas 11447.1 0.0 11447.1
Total Inlet 11716.6
Stream 37 Perfume Oil
Perfume Oil (l) 31.25 100.0%
Water (l) 0.00 0.0%
Total 31.25 100%
Inlets
Stream 35 Stream 36 Stream 37 S
Drum Mixer
Stream 39 Detergent Powder Dosed Optical Perfume
Component kg/hr Composition M-301
Powder Brighteners Oil Su
LAS (s) 625.0 10.0% Dry Solids (s) 5843.8 - -
Non-Ionic (s) 250.0 4.0% Water (l) 312.5 - -
Zeolite (s) 1250.0 20.0% Total Solids 6156.3 0.0 0.0
Polyacrylate (s) 125.0 2.0% Liquids (l) - 31.25 31.25
CMC (s) 31.25 0.5% Water (l) - 0.0 0.0
Sodium Silicate (s) 562.5 9.0% Total Liquids 0.0 31.25 31.25
Sodium Carbonate (s) 562.5 9.0% Total Inlet 6250.0
Sodium Sulphate (s) 1406.3 22.5% Total Outlet 6250.0
erborate Monohydrate(s) 750.0 12.0%
Enzymes (s) 31.25 0.5%
Perfume Encapsulates (s) 62.50 1.0%
TAED (s) 187.5 3.0%
Perfume Oil (l) 31.25 0.5%
Brighteners (l) 31.25 0.5%
Sud-suppressor (l) 31.25 0.5%
Water (l) 312.5 5.0%
Total 6250.0 100%
Outlet Utility
Temperature Requirement
°C ∑Q
75.0 -12.50
85.0 -4.56
95.0 3.38
90.74 0.00
Inlets Outlets
ream 14 Stream 12 Stream 29 Stream 13 Stream 15
Liquids Solids Recycle Saturated Crutcher
Dosing Dosing Stream Steam Outlet
939.8 3253.6 25.5 - 4849.7
1279.4 242.4 1.6 141.6 2078.4
2219.2 3496.0 27.1 141.6 6928.1
Outlets
20 Stream 27 Stream 21 Stream 18
e Bag Filter Blown Gas Top
250.8 5091.2 229.1
16.1 326.6 -
266.8 5417.8 229.1
- - 21445.6
- - 2450.8
0.0 0.0 23896.4
20 Stream 27 Stream 21 Stream 18
e Bag Filter Blown Gas Top
250.8 5091.2 229.1
16.1 326.6 -
266.8 5417.8 229.1
- - 21445.6
- - 2450.8
0.0 0.0 23896.4
Outlets
am 29 Stream 26 Stream 30
ycle Gravity Gravity
eam Sep. Sep.
5.5 253.3 4812.5
.6 16.2 308.7
7.1 269.5 5121.2
- 11393.4 -
- 53.6 -
.0 11447.1 0.0
Inlets Outlets
Optical Perfume Sud- Detergent
Brighteners Oil Suppressors Powder
- - - 5843.8
- - - 312.5
0.0 0.0 0.0 6156.3
31.25 31.25 31.25 93.75
0.0 0.0 0.0 0.0
31.25 31.25 31.25 93.75
Air required for furnace/spray dryer Air requirement for spray dryer
Assumptions
- The furnace outlet air was Mols of
calculated and found to be 78.1% Water
N2, 18.8% O2, 1% CO2, 2% H2O, Lost 98.22 kmol/hr
therefore Cp of regular air used
Mass of
Steps Water
Energy supplied by air = (energy Lost 1767.95
to rid of water + Losses to the
atmosphere from surface area)
- From de Groot, it says that the Sensible 148115.27

ratio of TowerHeatLosses :
EnergyToEvaporateWater is 7:45
- Therefore, Energy supplied by
air = (energy to rid of water + Latent 3993219.18
Losses to the atmosphere from
surface area)
is the same as
Energy supplied by air = (energy
to rid of water + 0.16*energy to Sensible 115977.79
rid of water) = (1.16*energy to rid
of water)
Energy to
EnthalpyOfAir(kJ/kg)*Mair=Energy rid Water 4257312 kJ
Supplied by Air
EnthalpyOfAir(kJ/kg)=196 Energy
supplied
Per mol of fuel reacted, 99.16mols by 'Air'
Mass of 4257312
of gas leaves the furnace (excess 'Air'
air (88.9 mol) and combustion (Dryer) 21720.98 kg/hr
products (10.26 mol)) which has
been heated from 30 to 300
degrees celcius - 933.8% excess kmols Air
air was calculated Dryer 749.00 kmol/hr
Moles of
fuel
required 7.55 kmol/hr
Mass of
fuel
required 120.86 kg/hr
Furnace
air inlet
Actual
DRY air 21501.93 kg/hr
to make
N2
1 4257312.24
1182.5867342051 kW
SD -1200.1240261029 kW
- Non-reactive energy balance Heating the water for utility only:
- -Polyacrylate is stored in sealed silos
indoors, cool and dry area. Assumed
since its indoors, its temperature is
Steps 24
- °C and outdoor ambient temp is
27°C
-Check sodium sulphate storage
temp
-Neutralisation mixer outlet
Steps 24
27°C
temp
reference is taken at 60°C
- ASSUMING FOR THE RECYCLE
STREAM THE HEATS OF SOLUTION
ARE NEGLIGIBLE, this is justified
because the mass of the recyclye
stream accounts for 0.374% of the
total crutcher mixer mass
-Reference ALL taken as 25°C
Steps
-
Energy Balance around neutralisation mixer
Assumptions
-Water going into neutralisation Substance Mols In Enthalpy in Mols Out
mixer is process water readily (kmol/hr) (kJ/kmol) (kmol/hr)
available at the site
-Reactant and product species
were taken as references LABSA 1.80 2608.00 0.00
Steps
- We used Heat of Rxn method to
calculate the heat evolved around
the neutralisation mixer NaOH (inc water 5.99 400.14 0.00
-Calculate enthalpies for all in soln)
components entering the mixer,
using the specific heat to raise their
temperatures from 25 to inlet Water (from
0.00 0.00 4.13
conditions NaOH solution)
-Similarly, this was also done for
outlet stream
- overall duty was calculated by the
summation of the Heat of Rxn H2SO4 0.03 656.60 0.00
value (-104kj/mol) + enthalpic
change of components
- The heat of Rxn value (-104)
includes the heat of reaction for Water 16.97 -377.00 16.97
the side reaction of sulphuric acid,
this was taken from Sulphonation
Technology
Na2SO4 0.00 0.00 0.03
ADIABATIC REACTOR
LAS 0.00 0.00 1.80
Inlet Temp Outlet Temp
LABSA 30 LABSA -
NaOH 30 NaOH -
H2O (sol) 30 H2O (sol) 90.8035517
H2SO4 30 H2SO4 -
H2O 20 H2O 90.8035517
Na2SO4 - Na2SO4 90.8035517
LAS - LAS 90.8035517
Energy Balance around crutcher mixer
Temperature Temperature Mass In

Substance
in (°C) out (°C) (kg/hr)
LAS Salt 91 70 627

Neutralisation mixer outlet
Neutralisation mixer outlet Water 91 70 413
Na2SO4 91 70 4
Water 70 142
Non-ionic 63 70 251
Liquid streams Sodium 63 70 564
Silicate
Water 63 70 1092
Zeolite 24 70 1253
Water 24 70 238
Polyacrylate 63 70 125
Water 63 70 188
Sodium 24 70 1405
Solids Sulphate
except polyacry Water 24 70 0
Sodium 24 70 564
carbonate
Water 24 70 4
CMC 24 70 31
Water 24 70 0
LAS Salt 80 70 3
Non-ionic 80 70 1
Zeolite 80 70 7
CMC 80 70 0
Sodium 80 70 3
Recycle stream Silicate
Sodium 80 70 3
carbonate
Sodium 80 70 7
Sulphate
Water (in
powder) 80 70 2
Total 345896.17
96.0822680563
Enthalpy
Steam Bar Temp(°C) Saturated Water @ 70°C

Steam (kJ/kgK)
HP 42 253.2 2799.4
IP 15 198.3 2789.9 293.06
LP 7 165 2762
Mass Flow rate kg/hr 140
Enthalpy Out n∆H (out) n∆H (in)
(kJ/kmol)
0.00 0 4695.2926307
0.00 0 2398.5980509
4961.59 20513.76361249 0
0.00 0 19.760339589 Heat of Reaction
4961.59 84207.8087439 -6398.4242923 -104
30479.03 917.264764768 0 -104000
45799.27 82454.36512094 0 1.8
188093.2022421 715.22672889 -187200

188093.20 Total
187377.9755132 kJ/hr -52

∑Q
52.04943764256 kW
Outlet Utility
Ov. Energy Bal: °C ∑Q
177.9755132 75.0 -12.5
90.80 0.049437642556 0.0494376426 85.0 -4.6
95.0 3.4
90.8 0.0
xer
Enthalpy in Mass Out Enthalpy Out Heat Duty in Heat Duty out Total Heat Duty
(kJ/kg) (kg/hr) (kJ/kg) kJ/hr kJ/hr kJ/hr
132 627 90 82454 56387 -26068

276 413 189 113953 77927 -36026
215 4 147 917 627 -290
142 0 0 0
75 251 88 18697 22177 3480
97 564 115 54547 64699 10152
159 1092 189 173529 205825 32297
-1 1253 41 -1128 50748 51876
-4 238 189 -997 44881 45878
4 125 5 528 627 98
159 188 189 29798 35344 5546
5 1405 155 6995 217868 210872
-4 0 189 0 0 0
-1 564 80 -590 45371 45960
-4 4 189 -17 743 760
-1 31 58 -41 1831 1872
-4 0 189 -1 60 61
110 3 90 364 298 -66
108 1 88 143 117 -26
50 7 41 327 268 -60
6 1 5 4 3 -1
71 0 58 12 10 -2
140 3 115 417 341 -76
58 3 47 171 140 -31
188 7 155 1396 1153 -243
230 2 189 376 308 -68
345896.2
kJ/hr MCp 593.2266211818
kW Ti 653.0759319493
Heat duty
Available Q kJ/hr Q kW
kJ/kg
2506.34 350887.6 97.46877777778
2496.84 349557.6 97.09933333333
2468.94 345651.6 96.01433333333
Energy Balance to bring raw materias from storage to process conditions
Assumptions
- Neutralisation mixer
Steps
-
Storage
Component Temperaure
(°C)
Water 20
(Process water)
LAS Acid 30
NaOH
Heat of Reaction (inc water in 30
soln)
kj/mol H2SO4 30
kj/kmol
kmol/hr
kj/hr
kW
Energy Balance around Airlift
Temperature
Substance
(°C)
Crutcher Blown
Temperature 70 Powder 80.0
Inlets
Mixer outlet Inlets
Temperature 90.803552 Air 3.0
Recycle Temp
Liq. Stream HX 80 Air 35.0
Ambient Outlets
Outlet Fines 35.0
Storage
Temp solids 24 Recycle 80.0
After HX liquids 62.938884
Blown powder: AIRLIFT
Cool Air
Mixer inlet
Mol. Flow rate Enthalpy Duty
Temperature
(kmol/hr) (kJ/kmol) (kW)
(°C)
20 16.97 0 0
30 1.80 0 0
30 5.99 0 0
30 0.03 0 0
Total 0
Energy
Mass Enthalpy
Exchanged
(kg/hr) (kJ/kg)
kJ/hr
5417.8 452656.9 -368503.8
11447.1 -253346.4
368503.8
11447.1 115157.5
5390.7 81889.7
27.1 2263.3
Air & Fines
AIRLIFT
Cool Air Powder recycle

Substance
Water
Non-ionic
Sodium
Silicate
Water
Polyacrylate
Water
Sodium Sulphate
(anhydrous, no water)
Reference: All species at

Assumptions 25°C, with water as liquid
- Powder leaving top has same
temperature as powder leaving
bottom
- airlift: assumed all energy lost
from powder heats up air, no losses Drop tank outlet (slurry)
Steps Inlets
-
bottom
from powder heats up air, no losses
Furnace Air
Steps Inlets
-
Recycle
Spray-Dryer Top
Outlets
Blown powder
Inlets
Spray Tower Stream 15 Stream 17 Stream 2
Inlets Slurry Hot Air Cyclone
D-201
Air-Lift + Gravity Stream 21 Stream Feed24 Stream
Inlet22 Stream
Recycle29
Separator Dry Solids (s)
Blown 4849.7
Cool Air - in Recycle
Rising 219.9
A-201 + S-203 WaterPowder (l) Inlet
2078.4 Air-Lift
- Stream-
Dry Solids (s) Total Solids
5091.2 - 5065.8 25.5
6928.1 0.0 219.9
Water (l) 326.6 - 324.9 1.6
Dry Air (g) - 21445.6 -
Total Solids 5417.8 0.0 5390.7 27.1
Dry Air (g)
Water (v) - 682.9 -
- 11393.4 11393.4 -
Water (v) Total Gas- 0.0
53.6 22128.5
53.6 -0.0
Total GasTotal Inlet 29543.3
0.0 11447.1 11447.1 0.0
Total Inlet Total Outlet 29543.3
16864.9
Liquid stream into crutcher HX - energy balance
Temperature Temperature Mass In Enthalpy in Mass Out Enthalpy Out

in (°C) out (°C) (kg/hr) (kJ/kg) (kg/hr) (kJ/kg)
20 0.00 141.62 -20.94 141.62 -104.72
30 0.00 250.61 9.83 250.61 -49.16
30 0.00 563.87 12.75 563.87 -63.75
30 0.00 1091.91 20.94 1091.91 -104.72
30 0.00 125.30 0.56 125.30 -2.78
30 0.00 187.50 20.94 187.50 -104.72
Sodium sulphate heated for the crutcher - energy balance
35 24 1405.39 10.97 1405.39 -1.097
Energy Balance around spray dryer
Energy
Temperature Mass Enthalpy
Substance Exchanged
(°C) (kg/hr) (kJ/hr)
kJ/hr
Slurry 70 6928.08 685929.8912 -4320446
Air 300 21445.582394 5932920.369 -1200.1240261 kW
Water (v) 300 682.87 366569.2795
Cyclone Fines 110 219.94 28399.47834
Bag Filter Fines 35 266.84 4053.542345
Air 110 21445.582394 1833811.751
Water (v) - Furnace 110 682.87 114863.7652
Water (v) - Evap. 110 1767.95 293794.3111
Fines 110 229.11 29582.78994
Powder 80 5091.25 425373.45
Inlets Outlets
am 15 Stream 17 Stream 20 Stream 27 Stream 21 Stream 18 0.979
urry Hot Air Cyclone Bag Filter
Outlets Blown Gas Top
eed Inlet22 Stream
am 24 Stream Recycle29 Recycle
Stream 26 Powder
Stream 30 Outlet
849.7
ol Air - in Recycle
Rising 219.9 250.8
Gravity Sep. 5091.2
Gravity 229.1
nlet
078.4 Air-Lift
- Stream- Top Outlet
16.1 326.6Sep. -
-
928.1 5065.8
0.0 25.5
219.9 266.8253.3 4812.5
5417.8 229.1
- 324.9 1.6 16.2 308.7
- 21445.6 - - - 21445.6
0.0 5390.7 27.1 269.5 5121.2
-
393.4
682.9
11393.4 -
- - 11393.4 - - 2450.8
0.0
53.6 22128.5
53.6 -0.0 0.0 53.6 0.0 - 23896.4
447.1 11447.1 0.0 11447.1 0.0
D
Heat Duty in Heat Duty out Total Heat Duty

Substance
kJ/hr kJ/hr kJ/hr
-2966.13 -14830.67 -11864.53

Dosed Powder
2464.09 -12320.47 -14784.57

Perfume Oil
7188.74 -35943.71 -43132.46

Sud-suppressors
22869.49 -114347.43 -137216.91

Optical Brigtheners
69.61 -348.07 -417.68
3927.08 -19635.42 -23562.50
-230978.6468
Total kJ/hr
-64.16073523
kW
15417.1778 -1541.71778 -16958.8955844 kJ/hr

-4.71080432899 kW
Blown powder Average Cp (Stream
Blown Powder
kg/hr
LAS 661.2
Non-Ionic 264.5
Zeolite 4A 1322.4
Polyacrylate 132.2
Sodium CMC 33.1
Sodium Silicate 595.1
Sodium Carbonate 595.1
Sodium Sulphate 1487.7
Water 326.6
Total 5417.80
Blown powder Average Cp (Stream 2
Blown Powder ࡯
Mass %
kg/hr kJ/k
LAS 661.2 12.20% 2.

Non-Ionic 264.5 4.88% 1.
Zeolite 4A 1322.4 24.41% 0.
Polyacrylate 132.2 2.44% 0.
Sodium CMC 33.1 0.61% 1.
Sodium Silicate 595.1 10.98% 2.
Sodium Carbonate 595.1 10.98% 1.
Sodium Sulphate 1487.7 27.46% 1.
Water 326.6 6.03% 4.
Total 5417.80 100%
Drum Mixer - energy balance
wder Average Cp (Stream 21) Cp of Fines leaving top of Spray Dryer (Stream 18)
𝑪_𝑷 Mixture𝑪_𝑷
. Fines Outlet 𝑪_𝑷
Mass % Mass %
kJ/kg K kJ/kg K kg/hr kJ/kg K
12.20% 2.00 0.244 LAS 29.8 12.99% 2.00

4.88% 1.97 0.096 Non-Ionic 11.9 5.19% 1.97
24.41% 0.90 0.220 Zeolite 4A 59.5 25.97% 0.90
2.44% 0.11 0.003 Polyacrylate 6.0 2.60% 0.11
0.61% 1.30 0.008 Sodium CMC 1.5 0.65% 1.30
10.98% 2.55 0.280 Sodium Silicate 26.8 11.69% 2.55
10.98% 1.05 0.115 Sodium Carbonate 26.8 11.69% 1.05
27.46% 1.10 0.301 Sodium Sulphate 66.9 29.22% 1.10
6.03% 4.19 0.252 Water 0.0 0.00% 4.19
100% 1.52 Total 229.11 100%
r Average Cp (Stream 21) Cp of Fines leaving top of Spray Dryer (Stream 18)
owder ࡯ࡼ Mixture ࡯ ࡼ. Fines Outlet ࡯ࡼ Mixture࡯ ࡼ.

Mass % Mass %
r kJ/kg K kJ/kg K kg/hr kJ/kg K kJ/kg K
2 12.20% 2.00 0.244 LAS 29.8 12.99% 2.00 0.260
5 4.88% 1.97 0.096 Non-Ionic 11.9 5.19% 1.97 0.102
.4 24.41% 0.90 0.220 Zeolite 4A 59.5 25.97% 0.90 0.234
2 2.44% 0.11 0.003 Polyacrylate 6.0 2.60% 0.11 0.003
1 0.61% 1.30 0.008 Sodium CMC 1.5 0.65% 1.30 0.008
1 10.98% 2.55 0.280 Sodium Silicate 26.8 11.69% 2.55 0.298
1 10.98% 1.05 0.115 Sodium Carbonate 26.8 11.69% 1.05 0.122
.7 27.46% 1.10 0.301 Sodium Sulphate 66.9 29.22% 1.10 0.321
6 6.03% 4.19 0.252 Water 0.0 0.00% 4.19 0.000
80 100% 1.52 Total 229.11 100% 1.35
yer (Stream 18) Avg.Cp of slurry entering the spray dryer (Stream 15)
Mixture𝑪_𝑷
. Crutcher Outlet 𝑪_𝑷 Mixture𝑪_𝑷
.
Mass %
kJ/kg K kg/hr kJ/kg K kJ/kg K
0.260 LAS 629.83 9.09% 2.00 0.182

0.102 Non-Ionic 251.93 3.64% 1.97 0.072
0.234 Zeolite 4A 1259.65 18.18% 0.90 0.164
0.003 Polyacrylate 125.97 1.82% 0.11 0.002
0.008 Sodium CMC 31.49 0.45% 1.30 0.006
0.298 Sodium Silicate 566.84 8.18% 2.55 0.209
0.122 Sodium Carbonate 566.84 8.18% 1.05 0.086
0.321 Sodium Sulphate 1417.11 20.45% 1.10 0.224
0.000 Water 2078.42 30.00% 4.19 1.257
1.35 Total 6928.08 100% 2.20
er (Stream 18)
Avg.Cp of slurry entering the spray dryer (Stream 15)
࡯ࡼ Mixture࡯ ࡼ.
kJ/kg K kJ/kg K Crutcher Outlet ࡯ࡼ Mixture ࡯ ࡼ.
Mass %
kg/hr kJ/kg K kJ/kg K
2.00 0.260
LAS 629.83 9.09% 2.00 0.182
1.97 0.102
Non-Ionic 251.93 3.64% 1.97 0.072
0.90 0.234
0.11 0.003 Zeolite 4A 1259.65 18.18% 0.90 0.164
Polyacrylate 125.97 1.82% 0.11 0.002
1.30 0.008
Sodium CMC 31.49 0.45% 1.30 0.006
2.55 0.298
Sodium Silicate 566.84 8.18% 2.55 0.209
1.05 0.122
Sodium Carbonate 566.84 8.18% 1.05 0.086
1.10 0.321
4.19 0.000 Sodium Sulphate 1417.11 20.45% 1.10 0.224
Water 2078.42 30.00% 4.19 1.257
1.35
Total 6928.08 100% 2.20
Pressure
Pressure Pressure Flowrate
Utility From To increase
before fan (Pa) after fan (Pa) (Pa) Air (kg/hr)
Atmosphere Furnace 101325 105000 3675 21501.93
Air-lift
2 Atmosphere 101325 155000 53675 11447.0629
Cooler
Pressure
Pressure Pressure Flowrate
Fan From To
before fan (Pa) after fan (Pa) increase Air (kg/hr)
(Pa)
Spray
1 dryer Cyclone 105000 106071 1071 21446
top
Gravity
2 Sep. Bag filter 155000 156493 1493 11447
top
Pressure Pressure Pressure Flowrate

Utility From To increase
before fan (Pa) after fan (Pa) Air (kg/hr)
(Pa)
F-201 AtmospherFurnace 101325 105000 3675 21501.931

F-202 Spray dryer
F-203 top
Gravity Sep.Cyclone 105000 106071 1071 21445.5824
F-204 top Bag filter 155000 156493.04 1493.04 11447.0629
Piping Length Pumping Power

Pump Code Stream Medium
m kW
P-101 5-5a 20 Polyacrylate 0.024
P-102 6-6a 10 Sodium Silicate 0.064
P-103 7-7a 10 Non-ionic 0.010
P-104 1-1a 20 LAS Acid 0.046
P-105 2-2a 20 Caustic Soda 0.012
P-106 3-3a 20 Water 0.024
P-107 14-14a 25 Liquids 0.230
P-108 4-4a 10 Paste 0.041
P-301 36-36a 15 Optical brightner 0.002
P-302 37-37a 15 Perfume oil 0.002
P-303 38-38a 15 Sud-suppresor 0.002
Vol
Fan Power Fan Power
Flowrate
Air (m3/s) (W) (kW)
5.0788764 26664.1009 26.66 Fan

Efficiency 0.7
2.7038603 207328.144 207.33
Air Density 1.176 kg/m3 27°C
Vol
Fan Power Fan Power
Flowrate
(W) (kW)
Air (m3/s)
6.46 9885 9.89 Pressure

drop across
bag filter 6" WG 1493.04 Pa
2.77 5918 5.92 Pressure

drop across
Cyclone 4.3"WG 1071 Pa
Pressure
drop across
Airlift 0.5 bar
Vol Fan Power

Flowrate
(kW) Pressure
Air (m3/s)
drop across
Spray dryer negligble
Air Density 0.922 kg/m3 110°C

5.0788764 26.6641009 1.146 kg/m3 35°C
6.4610697 9.88543657
2.774642 5.9180735
To Do List
Table of Heat Capacities
Explaining how they were obtained
remember units
references
Need enthalpy tables
with stream number, temperature
Component
Inlet/Outlet Mass flow rates
Inlet/Outlet specific enthalpy
mols for
LAS, LABSA, NaOH,
Neutralisation (𝒏_𝒊𝒏 ) ̇

Component
kmol/hr
LABSA (30°C) 1.80
Caustic
Solution 5.99
(30°C)
Sulphuric Acid (30°C) 0.03
Water 16.97
(20°C)
( 〖∑𝒏〗 _𝒊
𝒏 ) ̇𝑯 ̂_𝒊𝒏
ሶ
࢔࢏࢔ ෡ࡴ࢏࢔ ሶࡴ
࢔࢏࢔ ෡࢏࢔
Component
kmol/hr kJ/mol kJ/hr
LABSA (30°C) 1.80 2608.0 4695.3
Caustic Solution (30°C) 5.99 400.1 2398.6
ሶ
࢔࢏࢔ ෡ࡴ࢏࢔ ሶࡴ
࢔࢏࢔ ෡࢏࢔
Component
LABSA (30°C) 1.80 2608.0 4695.3
Caustic Solution (30°C) 5.99 400.1 2398.6
Sulphuric Acid (30°C) 0.03 656.6 19.76
Water (20°C) 16.97 -377.0 -6398.4
σ ࢔ሶ࢔࢏ ෡
ࡴ࢔࢏ 715.2
Component
Crutcher
Neutralisati LAS
on
Water
Outlet
(Stream 4) Sodium Sulphate
Non-ionic
Liquid Sodium
Stream Silicate
(Stream 14) Polyacrylate
Water
Zeolite
Sodium Sulphate
Solids
Stream Sodium Carbonate
(Stream 12) Water
CMC
Water
LAS
Non-ionic
Zeolite
Polyacrylate
Recycle
Stream CMC
(Stream 29) Sodium
Silicate
Sodium Carbonate
Sodium Sulphate
Water
Added
Steam Water / Sat. Steam
(Stream 13)
Steam Comparison Pressure

Saturated
Steam Bar
HP 42.0
IP 15.0
LP 7.0
Substance
Neutralisatio LAS Salt
Water
Na2SO4
Liquid streamWater
Non-ionic
Sodium
Silicate
Water
Solids
except polyacry
Zeolite
Water
Polyacrylate
Water
Sodium Sulphate
Water
Sodium carbonate
Water
CMC
Water
Recycle stre LAS Salt
Non-ionic
Zeolite
Polyacrylate
CMC
Sodium
Silicate
Sodium carbonate
Sodium Sulphate
Water (in powder)
Temperature
HX Calculation Substance in (°C)
Water 20
Non-ionic 30
Sodium
Silicate 30
Water 30
Polyacrylate 30
Water 30
TOTAL H2O
Reference: Al
25°C, with wa
Spray Dryer Stream
Stream 15 (70°C)
Slurry Feed
Stream 17 (300°C)
Hot Air Inlet
Inlets
Stream 20 (110°C)
Cyclone Recycle
Stream 27 (35°C)
Bag Filter Recycle
Stream 18 (110°C)
Spray Tower
Outlets Top Outlet
Stream 21 (80°C)
Blown powder
Conveyor Code
C-202
C-302
C-301
C-201
Component
Inlets Stream 21 (80°C)

Stream
Blown 22 (35°C)
Powder
Air-Lifted Powder
Stream 29 (80°C)
Outlets
Recycle
= 102.4 kW
Fans F-201 F-202

Air
Fan
Compressor
30 27
1.05 2
pinch
Stream Description
22 Blown Powder
16 Furnace Outlet
19 Spray Dryer Exhaust
14 Liquids Heating
Heat Cold Stream (˚C)

Exchanger
𝑻_𝒊𝒏
HX1 30
HX2 27
H1 100
C1 -
C2 -
Component
Safety
Methane
Ethane
Propane
Iso-Butane
Normal-Butane
Iso-Pentane
Normal Pentane
Hexanes Plus
Nitrogen
Carbon Dioxide
Oxygen
Hydrogen
Key Ingredients
INTRODUCTION
Linear Alkylbenzene Sulphonate
Non-Ionic Surfactant
Zeolite
Perborate bleach
Additives / Minors
Sodium Carbonate
Sodium Silicate
Sulphate
Density (g/l)
Component Cp Units Reference
LABSA (l) 1.60 kJ/kg K (De Groot
521.6 kJ/kmol K
100% AM) 2.00 kJ/kg K (De Groot
696.0 kJ/kmol K
Water (l) 4.19 kJ/kg K (Felder a
75.40 kJ/kmol K
(v) 1.94 kJ/kg K (Engineer
w/w (aq) 3.22 kJ/kg K (O'Brien e
80.03 kJ/kmol K
c Acid (l) 1.34 kJ/kg K (Engineer
131.3 kJ/kmol K
Sodium Sulphate (s) 1.10 kJ/kg K (Yaws, 2004)
(aq) 463.2 kJ/kmol K (Kobe and Anderson, 1936)
Sodium Polyacrylate 0.11 kJ/kg K (Gaur and Lau, 1982)
CMC 1.30 kJ/kg K (Hurst an
Zeolite 4A 0.90 kJ/kg K (Qiu et al
Sodium Carbonate (s) 1.05 kJ/kg K (Chase, 1
(l) 1.79 kJ/kg K
Air (g) 1.006 kJ/kg K (Engineer
𝑯 ̂_𝒊𝒏 (𝒏_𝒊𝒏 ) ̇ (𝒏_𝒐𝒖𝒕 ) 𝑯 ̂_𝒐𝒖𝒕

𝑯 ̂_𝒊𝒏 Component ̇
kJ/mol kJ/hr kmol/hr kJ/mol
2608.0 4695.3 LAS (90.8°C) 1.80 45799.3
400.1 2398.6 Water (90.8°C) 21.11 4961.6
656.6 19.76 Sodium Sulphate (90.8°C) 0.03 30479.0
-377.0 -6398.4 ( 〖∑𝒏〗 _𝒐
𝒖𝒕 ) ̇𝑯 ̂_𝒐𝒖𝒕
715.2
ሶ
࢔࢚࢛࢕ ෡ࡴ࢚࢛࢕ ሶ෡
࢔࢚࢛࢕ ࡴ࢚࢛࢕
Component
෡
ࡴ࢏࢔ ሶࡴ
࢔࢏࢔ ෡࢏࢔
LAS (90.8°C) 1.80 45799.3 82454.4
kJ/mol kJ/hr
Water (90.8°C) 21.11 4961.6 104721.6
2608.0 4695.3
Sodium Sulphate (90.8°C) 0.03 30479.0 917.26
400.1 2398.6 ሶ ࡴ ෡࢚࢛࢕ 188093.2
σ ࢔࢚࢛࢕
ሶ
࢔࢚࢛࢕ ෡
ࡴ࢚࢛࢕ ሶ෡
࢔࢚࢛࢕ ࡴ࢚࢛࢕
Component
෡
ࡴ࢏࢔ ሶࡴ
࢔࢏࢔ ෡࢏࢔ LAS (90.8°C) 1.80 45799.3 82454.4
kJ/mol kJ/hr
Water (90.8°C) 21.11 4961.6 104721.6
2608.0 4695.3
Sodium Sulphate (90.8°C) 0.03 30479.0 917.26
400.1 2398.6 ሶ ࡴ ෡࢚࢛࢕ 188093.2
σ ࢔࢚࢛࢕
656.6 19.76
-377.0 -6398.4
σ ࢔ሶ࢔࢏ ෡
ࡴ࢔࢏ 715.2
(𝒎_𝒊𝒏 𝑯 ̂_𝒊𝒏 (𝒎_𝒊𝒏 ) ̇ 𝑯 ̂_𝒐𝒖𝒕 (𝒎_𝒐𝒖𝒕 ) ̇ (𝒎_𝒐𝒖𝒕 ) ̇𝑯 ̂_𝒐𝒖𝒕 ( 〖 −

(=) ̇(𝒎_𝒐𝒖𝒕)) ̇ 𝑯 ̂_𝒊𝒏 𝑯 ̂_𝒐𝒖𝒕
kg/hr kJ/kg kJ/kg kJ/kg kJ/hr 𝒎〗 _𝒊𝒏 ) ̇𝑯 ̂_𝒊𝒏
kJ/hr
627 132 82454 90.0 56387 -26068
413 276 113953 189 77927 -36026
4.3 215 917 147 627 -290
251 74.6 18697 88.5 22177 3480
564 96.7 54547 115 64699 10152
125 4.2 528 5.0 627 98.3
1279 159 203326 189 241169 37843
1253 -0.9 -1128 40.5 50748 51876
1405 5.0 6995 155 217868 210872

564 -1.0 -590 80.5 45371 45960
3.9 -4.2 -16.5 189 743 760
31.3 -1.3 -40.7 58.5 1831 1872
242 -4.2 -1015 189 45684 46699
3.3 110 364 90.0 298 -66.1
1.3 108 143 88.5 117 -26.0
6.6 49.5 327 40.5 268 -59.5
0.7 6.1 4.0 5.0 3.3 -0.7
0.2 71.4 11.8 58.5 9.7 -2.1
3.0 140 417 115 341 -75.9
3.0 58 171 47.1 140 -31.1
7.4 188 1396 155 1153 -243
1.6 230 376 189 308 -68.4
142 2762 391152 293 41503 -349649
Sat. Temp 𝑯 ̂_𝒊𝒏 𝑯 ̂_𝒐𝒖𝒕 𝑯 ̂_𝒐𝒖𝒕−𝑯 ̂ 𝒎 ̇(𝑯 ̂_𝒐𝒖𝒕−𝑯 ̂_

_𝒊𝒏 𝒊𝒏 )
°C kJ/kg kJ/kg kJ/kg kJ/hr kW
253.2 2799.4 293.1 2506.3 350888 97.5
198.3 2789.9 293.1 2496.8 349558 97.1
165.0 2762.0 293.1 2468.9 345652 96.0
Temperature Temperature
Mass In Enthalpy in Mass Out Enthalpy Out
91 70 627 132 627 90
91 70 413 276 413 189
91 70 4 215 4 147
20 70 142 -21 142 189
30 70 251 10 251 88
30 70 564 13 564 115
30 70 1092 21 1092 189
24 70 1253 -1 1253 41
24 70 238 -4 238 189
30 70 125 1 125 5
30 70 188 21 188 189
24 70 1405 5 1405 155
24 70 0 -4 0 189
24 70 564 -1 564 80
24 70 4 -4 4 189
24 70 31 -1 31 58
24 70 0 -4 0 189
80 70 3 110 3 90
80 70 1 108 1 88
80 70 7 50 7 41
80 70 1 6 1 5
80 70 0 71 0 58
80 70 3 140 3 115
80 70 3 58 3 47
80 70 7 188 7 155
80 70 2 230 2 189
Temperature Mass In Enthalpy in

Mass Out Enthalpy Out Heat Duty in
out (°C) (kg/hr) (kJ/kg) (kg/hr) (kJ/kg) kJ/hr
62.9388837414105 141.619 -20.9444 141.6190872848 158.921768561242 -2966.1
62.9388837414105 250.608 9.83248 250.6076434806 74.6066527455019 2464.09
62.9388837414105 563.867 12.749 563.8671978313 96.7365657638484 7188.74
62.9388837414105 1091.91 20.9444 1091.911764706 158.921768561242 22869
62.9388837414105 125.304 0.55556 125.3038217403 4.21543152682338 69.6132
62.9388837414105 187.5 20.9444 187.5 158.921768561242 3927.08
1279.41 20.9444 `
Reference: All species at

25°C, with water as liquid
Component 𝒎 ̇
𝑪_𝑷 ( 𝑻−𝑻_𝒓𝒆𝒇)
kg/hr kJ/hr
Slurry 6928 685930 Stream Component
Stream 15 (70°C)
Dry Air 21446 5932920 Slurry
Slurry Feed
Water Vap. 683 366569 Stream 17 (300°C) Dry Air
Hot Air Inlet
Fines 219.9 28399 Inlets Water Vap.
Stream 20 (110°C)
Fines
Fines 266.8 4054 Cyclone Recycle
Stream 27 (35°C)
Fines
Air 21446 1833812 Bag Filter Recycle
Fines 229.1 29583 Air
Stream 18 (110°C)
Fines
Water Vap. 2451 408658 Spray Tower
Outlets Top Outlet Water Vap.
Powder 5091 425373 Stream 21 (80°C)
Powder
Blown powder
= - 4320446 kJ/hr
𝑸 ̇ kW
= - 1200.1
Capacity Length Power

Stream
tonnes/hr m kW
21 5.42 30 6.34
29 0.03 100 10.44
30 6.16 60 8.53
12 3.25 - 3.50
𝒎 ̇ Component ࢓ሶ ࢓ሶ࡯ ࡼ ሺࢀ െ ࢀࢌࢋ࢘ ሻ
𝒎 ̇
𝑪_𝑷 ( 𝑻−𝑻_𝒓𝒆𝒇)
kg/hr kJ/hr
kg/hr kJ/hr
Stream 21 (80°C)
Inlets
Blown Powder 5418 452657
5418 452657 Stream 22 (35°C)
5391 81890
27.1 2263 Air-Lifted Powder 5391 81890
Outlets
𝑪𝒐𝒐𝒍𝒊𝒏𝒈 𝑫𝒖𝒕𝒚 = 368,504 kJ/hr Stream 29 (80°C)
= 102.4 kW Recycle 27.1 2263
ࢍ࢔࢏࢒࢕࢕࡯ ࢚࢛࢟ ࡰ = 368,504 kJ/hr
= 102.4 kW
F-203 F-204
Blower Blower
110 35
1.06 1.56
𝒎 ̇ 𝑻_𝒊𝒏 𝑻_𝒐𝒖𝒕 𝑭.𝑪_ 𝜟𝑯

Type 𝒑
kg/s ˚C ˚C kW/K kW
Hot 1.44 80 35 2.18 -98
Cold 6.07 27 300 6.22 1698
Hot 6.56 110 27 7.18 -597
Cold 0.616 30 63 2.03 67
Net requirement 1070kW
old Stream (˚C) Hot Stream (˚C) Heat Duty

𝑻_𝒐𝒖𝒕 (kW) Heat Cold Stream ( ˚C) Hot Stream (˚C) H
𝑻_𝒐𝒖𝒕 𝑻_𝒊𝒏
Exchanger ࢀ࢚࢛࢕ ࢀ࢔࢏ ࢀ࢚࢛࢕
ࢀ࢔࢏
63 80 49.4 66.8
HX1 30 63 80 49.4
100 110 46.84 454 HX2 27 100 110 46.84
300 - - 1243.8 H1 100 300 - -
C1 - - 49.4 35
C2 - - 46.84 27
Exchanger ࢀ࢚࢛࢕ ࢀ࢔࢏ ࢀ࢚࢛࢕
ࢀ࢔࢏
HX1 30 63 80 49.4
HX2 27 100 110 46.84
H1 100 300 - -
C1 - - 49.4 35
- 49.4 35 31.4
C2 - - 46.84 27
- 46.84 27 142.6
Typical Mol Percentage 𝑴_𝒓

% g/mol Typical Mol Percentage ࡹ࢘
Component
% g/mol
93.9 16
Methane 93.9 16
4.2 30
Ethane 4.2 30
0.3 44 Propane 0.3 44
0.03 - Iso-Butane 0.03 -
0.03 - Normal-Butane 0.03 -
0.01 - Iso-Pentane 0.01 -
0.01 - Normal Pentane 0.01 -
0.01 - Hexanes Plus 0.01 -

Nitrogen 1 14
1 14
Carbon Dioxide 0.5 44
0.5 44
Oxygen 0.01 -
0.01 - Hydrogen Trace -
Trace -
Weight Weight
Key Ingredients
%
%
Linear Alkylbenzene Sulphonate 10
10
Non-Ionic Surfactant 4
4 Zeolite 20
20 Perborate bleach 12
12 Additives / Minors 8.5
8.5 Sodium Carbonate 9
Sodium Silicate 9
9
Sulphate Balance
9
Density (g/l) 500
Balance
500
Mole Percentage 𝑴_𝒓

Component
% g/mol
Methane 93.9 16
Ethane 4.2 30
Propane 0.3 44
Iso-Butane 0.03 -
Butane 0.03 -
Iso-Pentane 0.01 -
Explanation
Contribution
Element
Element
J/mol K
Value was given for certain active matter concentrations and extrapolated HH 9.20
CC 13.08
O 16.00
O
averaged over ther operational temperature range and assumed constant
Average value for 50% solution in temperature range used, from graphical data, assumed constant over the range
Assumed constant over the temperature range
C12H26O4
(Yaws, 2004)
The mean heat capacity over the range 32.4° to 102.8°C. determined by graphical integration is 0.7796 cal. per gram (whic
(Gaur and Lau, 1982)
(Vail, 1952)
at 20 degrees (assumed constant in temp range)
problem finding value for solution so liquid was used

averaged over ther operational temperature range and assumed constant
𝑯 ̂_𝒐𝒖𝒕 (𝒏_𝒐𝒖𝒕 )
̇𝑯 ̂_𝒐𝒖𝒕
kJ/hr
82454.4
104721.6
917.26
188093.2
෡
ࡴ࢚࢛࢕ ሶ෡
࢔࢚࢛࢕ ࡴ࢚࢛࢕
r kJ/mol kJ/hr
45799.3 82454.4
4961.6 104721.6
30479.0 917.26
ሶ ࡴ
σ ࢔࢚࢛࢕ ෡࢚࢛࢕ 188093.2
෡
ࡴ࢚࢛࢕ ሶ෡
࢔࢚࢛࢕ ࡴ࢚࢛࢕
r kJ/mol kJ/hr
45799.3 82454.4
4961.6 104721.6
30479.0 917.26
ሶ ࡴ
σ ࢔࢚࢛࢕ ෡࢚࢛࢕ 188093.2
(𝒎_𝒐𝒖𝒕 ) ̇𝑯 ̂_𝒐𝒖𝒕 ( 〖 −
𝒎〗 _𝒊𝒏 ) ̇𝑯 ̂_𝒊𝒏
(𝒎_𝒊𝒏 𝑯 ̂_𝒊𝒏 (𝒎_𝒊𝒏 ) ̇ 𝑯 ̂_𝒐𝒖𝒕

Component (=) ̇(𝒎_𝒐𝒖𝒕)) ̇ 𝑯 ̂_𝒊𝒏
kg/hr kJ/kg kJ/kg
Liquid Non-ionic 251 74.6 18697
Stream Sodium
(Stream 564 96.7 54547
Silicate
14; Polyacrylate 125 4.2 528
63°C)
Added Water 1279 159 203326
Steam
(Stream
13; Sat. Steam / Water 142 2762 391152
165°C
) 𝑵𝒆𝒘 𝑶𝒗𝒆𝒓𝒂𝒍𝒍 𝑪𝒓𝒖
Saturated Pressure Sat. Temp ෡

ࡴ࢔࢏ ෡
ࡴ࢚࢛࢕ ෡
ࡴ࢚࢛࢕ െ෡
ࡴ࢔࢏ ࢓ሶሺ෡
ࡴ࢚࢛࢕ െ෡
ࡴ࢔࢏ )
Steam Bar °C kJ/kg kJ/kg kJ/kg kJ/hr kW
HP 42.0 253.2 2799.4 293.1 2506.3 350888 97.5
IP 15.0 198.3 2789.9 293.1 2496.8 349558 97.1
LP 7.0 165.0 2762.0 293.1 2468.9 345652 96.0
Saturated Pressure Sat. Temp
෡
ࡴ࢔࢏ ෡
ࡴ࢚࢛࢕ ෡
ࡴ࢚࢛࢕ െ෡
ࡴ࢔࢏ ࢓ሶሺ෡
ࡴ࢚࢛࢕ െ෡
ࡴ࢔࢏ )
Steam Bar °C kJ/kg kJ/kg kJ/kg kJ/hr kW
HP 42.0 253.2 2799.4 293.1 2506.3 350888 97.5
IP 15.0 198.3 2789.9 293.1 2496.8 349558 97.1
LP 7.0 165.0 2762.0 293.1 2468.9 345652 96.0
(𝒎_𝒊𝒏
Heat Duty in Heat Duty out Total Heat Duty Component(=) ̇(𝒎_𝒐𝒖𝒕)) ̇
kJ/hr kJ/hr kJ/hr kg/hr
Neutralisatio LAS Salt 627
82454 56387 -26068 n
113953 77927 -36026 Outlet Water 413
(Stream 4;
917 627 -290 90.8°C)Sodium Sulphate 4.3
-2966 26695 29661 Liquid Non-ionic 251
Stream Sodium
2464 22177 19713 (Stream 14; Silicate 564
PreliminaryPolyacrylate 125
7189 64699 57510 30°C)
22869 205825 182956 Water 1279
-1128 50748 51876 Added Water (20°C)
Water 142
-997 44881 45878 Zeolite 1253
70 627 557 Solids Sodium Sulphate1405
StreamSodium Carbonate564
3927 35344 31417 (Stream 12;
6995 217868 210872 24°C) CMC 31.3
0 0 0 Water 242
-590 45371 45960 LAS Salt 3.3
-17 743 760 Non-ionic 1.3
-41 1831 1872 Zeolite 6.6
-1 60 61 Recycle Polyacrylate 0.7
Stream
364 298 -66 CMC 0.2
(Stream 29;
80°C) Sodium
143 117 -26 3.0
Silicate
327 268 -60 Sodium Carbonate 3.0
4 3 -1 Sodium Sulphate 7.4
12 10 -2 Water 1.6
417 341 -76
171 140 -31
1396 1153 -243
376 308 -68
616137
171
Heat Duty out Total Heat Duty

kJ/hr kJ/hr
22506.355813326 25472.4889192349
18696.9974325227 16232.9031328643
54546.5762650808 47357.83335993
173528.548759885 150659.063465768
528.209680595435 458.59644629528
29797.8316052328 25870.7482718995
Stream Component ࢓ሶ ࢓ሶ࡯ ࡼ ሺࢀ െ ࢀࢌࢋ࢘ ሻ

kg/hr kJ/hr
Stream 15 (70°C)
Slurry 6928 685930
Slurry Feed
Stream 17 (300°C) Dry Air 21446 5932920
Hot Air Inlet
Water Vap. 683 366569
Stream 20 (110°C)
Fines 219.9 28399
Cyclone Recycle
Stream 27 (35°C)
Fines 266.8 4054
Bag Filter Recycle
Air 21446 1833812
Stream 18 (110°C)
Fines 229.1 29583
Spray Tower
Top Outlet Water Vap. 2451 408658
Stream 21 (80°C)
Powder 5091 425373
Blown powder
= - 4320446 kJ/hr
ࡽሶ = - 1200.1 kW
Data Inlet Outlet
Pressure bar 7.0 1.0
࢓ሶ ࢓ሶ࡯ ࡼ ሺࢀ െ ࢀࢌࢋ࢘ ሻ
kg/hr kJ/hr Temp. Data
Pressure bar
Temp.
ࡴ෡࢏
෡ࡴ࢚࢛࢕ െࡴ෡ ࢔࢏ kJ/kg
ሶ
࢓ ࡴ૛ࡻ
°C
kJ/kg
kg/hr
Inlet
7.0
165.0
2762
2552.7
94.2
Outlet
1.0
50.0
209 165.0 50.0
kJ/kg
ࡴ
෡
ࡴ࢏
෡࢚࢛࢕ െ
ሶ
Data
Pressure bar
Temp.
෡ࡴ࢔࢏ kJ/kg
࢓ࡴ૛ࡻ
°C
kJ/kg
kg/hr
Inlet
7.0
165.0
2762
2552.7
94.2
Outlet
1.0
50.0
209
2762 209
Data I nlet Outl et
kJ/kg 2552.7
Pres sure bar 7. 0 1.0
Temp. °C 165.0 50. 0
5418 452657
෡
ࡴ࢏ kJ /kg 2762 209
෡࢚࢛࢕ െ
ࡴ ෡
ࡴ࢔࢏ kJ /kg 2552. 7
࢓ ሶ
ࡴ૛ࡻ kg/hr 94.2
ሶ
࢓ ࡴ૛ࡻ kg/hr 94.2
r 5391 81890 Data Inlet
Pressure bar 7.0
27.1 2263 Temp. Data
Pressure bar
Temp. °C
෡ࡴ࢏ kJ/kg
Inlet
7.0
165.0
2762
Outlet
1.0
50.0
209 165.0
ࡴ෡࢚࢛࢕ െࡴ෡ ࢔࢏ kJ/kg 2552.7
ሶ kg/hr
࢓ ࡴ૛ࡻ 94.2
ࢍ࢔࢏࢒࢕࢕࡯ ࢚࢛࢟ ࡰ = 368,504 kJ/hr Data

Pressure bar
Temp. °C
ࡴ෡࢏ kJ/kg
෡ െ෡ࡴ kJ/kg
Inlet
7.0
165.0
2762
Outlet
1.0
50.0
209 kJ/kg 2762
ࡴ࢚࢛࢕ ࢔࢏ 2552.7
ሶ
࢓ ࡴ૛ࡻ kg/hr 94.2
= 102.4 kW ෡
෡
ࡴ
෡
Data
Pressure
Temp.
࢏
bar
°C
kJ/kg
kJ/kg
Inlet
7.0
165.0
2762
2552.7
Outlet
1.0
50. 0
209
kJ/kg 2552.7
ࡴ࢚࢛࢕ െࡴ࢔࢏
ሶ
࢓ ࡴ૛ࡻ kg/hr 94.2
(𝒎_𝑯 kg/hr 94.2

𝟐𝑶 ) ̇
࢓ሶ ࢀ࢔࢏ ࢀ࢚࢛࢕ ࡲǤ࡯࢖

Stream Description Type
kg/s ˚C ˚C kW/K
22 Blown Powder Hot 1.44 80 35 2.18
16 Furnace Outlet Cold 6.07 27 300 6.22
19 Spray Dryer Exhaust Hot 6.56 110 27 7.18
14 Liquids Heating Cold 0.616 30 63 2.03
Net requirement
Heat Cold Stream ( ˚C) Hot Stream (˚C) Heat Duty

changer ࢀ࢚࢛࢕ ࢀ࢔࢏ ࢀ࢚࢛࢕ (kW)
ࢀ࢔࢏
HX1 30 63 80 49.4 66.8
HX2 27 100 110 46.84 454
H1 100 300 - - 1243.8
C1 - - 49.4 35 31.4
C2 - - 46.84 27 142.6
changer ࢀ࢚࢛࢕ ࢀ࢔࢏ ࢀ࢚࢛࢕ (kW)
ࢀ࢔࢏
HX1 30 63 80 49.4 66.8
HX2 27 100 110 46.84 454
H1 100 300 - - 1243.8
C1 - - 49.4 35 31.4
C2 - - 46.84 27 142.6
Typical Mol Percentage ࡹ࢘ Typical Mol Percentage ࡹ࢘

nent Component
% g/mol % g/mol
ne 93.9 16 Methane 93.9 16
e 4.2 30 Ethane 4.2 30
ne 0.3 44 Propane 0.3 44
ane 0.03 - Iso-Butane 0.03 -
utane 0.03 - Normal-Butane 0.03 -
ane 0.01 - Iso-Pentane 0.01 -
ntane 0.01 - Normal Pentane 0.01 -
Plus 0.01 - Hexanes Plus 0.01 -
en 1 14 Nitrogen 1 14
oxide 0.5 44 Carbon Dioxide 0.5 44
en 0.01 - Oxygen 0.01 -
en Trace - Hydrogen Trace -
Weight Sodium Polyacrylate

% Sodium Silicate
Sodium Sulphate 11 Non
10
CMC 10
4 Sodium
Carbonate 9
20
Zeolite 8
12
Solids
8.5
9 12
9
Balance LABSA 1a M-101
500 Caustic Soda 2a Neutralisation 4a
Cr
Water 3a Mixer
Mole Percentage 𝑴_𝒓

Component
% g/mol
Pentane 0.01 -
Hexanes Plus 0.01 -
Nitrogen 1 14
Carbon Dioxide 0.5 44
Oxygen 0.01 -
Hydrogen Trace -
Mole Percentage ࡹ࢘ Mole Percentage ࡹ

Component Component
% g/mol % g/m
Methane 93.9 16 Pentane 0.01 -
Ethane 4.2 30 Hexanes Plus 0.01 -
Propane 0.3 44 Nitrogen 1 1
Iso-Butane 0.03 - Carbon Dioxide 0.5 4
Butane 0.03 - Oxygen 0.01 -
Iso-Pentane 0.01 - Hydrogen Trace -
Contribu
Contribution AtomAtom Total Contribution
Total Contribution
Element tion
J/molK KReccurence
Reccurence J/mol KJ/mol K
J/mol
H 9.20
9.20 26 26 239.2 239.2
C 13.08
13.08 12 12 156.96156.96
O 16.00 4 64.0
16.00 4 64.0
Total = 460.16 J/mol K
Total = 460.16 J/mol K kJ/kg K
= 1.97
= 1.97 kJ/kg K
nt over the range
.7796 cal. per gram (which we converted to kJ/kmol K for Na2SO4 solution)
𝑯 ̂_𝒐𝒖𝒕 (𝒎_𝒐𝒖𝒕 ) ̇ (𝒎_𝒐𝒖𝒕 ) ̇𝑯 ̂_𝒐𝒖𝒕 ( 〖 −
𝑯 ̂_𝒐𝒖𝒕
kJ/kg kJ/hr 𝒎〗 _𝒊𝒏kJ/hr
) ̇𝑯 ̂_𝒊𝒏
88.5 22177 3480
115 64699 10152
5.0 627 98.3
189 241169 37843
293 41503 -345652
𝑵𝒆𝒘 𝑶𝒗𝒆𝒓𝒂𝒍𝒍 𝑪𝒓𝒖𝒕𝒄𝒉𝒆𝒓 𝑸 ̇ = 0 kW

(𝒎_𝒊𝒏 𝑯 ̂_𝒊𝒏 (𝒎_𝒊𝒏 ) ̇ 𝑯 ̂_𝒐𝒖𝒕 (𝒎_𝒐𝒖𝒕 ) ̇ (𝒎_𝒐𝒖𝒕 ) ̇𝑯 ̂_𝒐𝒖𝒕 ( 〖 − Co
(=) ̇(𝒎_𝒐𝒖𝒕)) ̇ 𝑯 ̂_𝒊𝒏 𝑯 ̂_𝒐𝒖𝒕
kJ/kg kJ/kg kJ/kg kJ/hr 𝒎〗 _𝒊𝒏kJ/hr
) ̇𝑯 ̂_𝒊𝒏
Neutralisation
132 90.0 82454 56387 -26068 Outlet
276 189 113953 77927 -36026 (Stream 4; 90.8°C) Sodiu
215 147 917 627 -290 N
Liquid Stream
9.8 88.5 2464 22177 19713 Sodi
(Stream 14;
12.7 115 7189 64699 57510 Preliminary 30°C ) Po
0.6 5.0 69.6 627 557
20.9 189 26797 241169 214373 Added Water (20°C)
-20.9 189 -2966 26695 29661
-0.9 40.5 -1128 50748 51876 Sodiu
5.0 155 6995 217868 210872 Solids Stream
Sodiu
(Stream 12; 24°C)
-1.0 80.5 -590 45371 45960
-1.3 58.5 -40.7 1831 1872
-4.2 189 -1015 45684 46699
110 90.0 364 298 -66.1 N
108 88.5 143 117 -26.0
49.5 40.5 327 268 -59.5 Po
6.1 5.0 4.0 3.3 -0.7 Recycle Stream
(Stream 29; 80°C)
71.4 58.5 11.8 9.7 -2.1 Sodi
140 115 417 341 -75.9 Sodiu
57.5 47.1 171 140 -31.1 Sodiu
188 155 1396 1153 -243
230 189 376 308 -68.4
= 616137 kJ/hr
𝑸 ̇ = 171 kW
Inlet Outlet
7.0 1.0
165.0 50.0
2762 209
2552.7
94.2
Outlet
1.0
50.0
209
2552.7
94.2
ࢀ࢔࢏ ࢀ࢚࢛࢕ ࡲǤ࡯࢖ ࢤࡴ

˚C ˚C kW/K kW
80 35 2.18 -98
27 300 6.22 1698
110 27 7.18 -597
30 63 2.03 67
Net requirement 1070kW
Exhaust Gases
19 Air
28 Perborate
Sodium Polyacrylate 5 S-201 Air & Fines TAED
Sodium Silicate 6 Cyclone Perfume
hate
S-202 26
11 Non-ionic 7 Enzymes Encapsulate
MC 10 Bag S-203
ium Filter Gravity Separator
onate 9 Liquids
eolite 8
Fines & Gases Fines Fines
Solids 20
Steam 18 27 Air & Fines Powder 31 32 33 34
12 13 14b 22 30
M-101 D-201 A-201

M-102 C-301
Neutralisation 4a 15b Spray 21 Air-Lift
Crutcher Mixer Slurry Blown Powder Belt
Mixer Dryer Cooling
Conveyor 36a 37a 38a
29 24 35 M-301
17 Recycled Powder Drum
Cooled Solids-Dosed Powder Mixer
Hot Air Air
Mole Percentage ࡹ࢘
ent
% g/mol
e 0.01 -
Plus 0.01 -
n 1 14
xide 0.5 44
n 0.01 -
en Trace -
࢓࢏࢔ሶሺൌ ሶሻ ෡
࢓࢚࢛࢕ ࡴ࢔࢏ ሶ෡
࢓࢏࢔ ࡴ࢏࢔ ෡
ࡴ࢚࢛࢕ ሶ ෡
࢓࢚࢛࢕ ሶ ෡
ࡴ࢚࢛࢕ ࢓࢚࢛࢕ ࡴ࢚࢛࢕ െ࢓ ሶ࢔࢏ ෡
ࡴ࢔࢏
Component
kg/hr kJ/kg kJ/kg kJ/kg kJ/hr kJ/hr
Neutralisation LAS Salt 627 132 90.0 82454 56387 -26068
Outlet Water 413 276 189 113953 77927 -36026
(Stream 4; 90.8°C) Sodium Sulphate 4.3 215 147 917 627 -290
Liquid Stream Non-ionic 251 9.8 88.5 2464 22177 19713

(Stream 14; Sodium Silicate 564 12.7 115 7189 64699 57510
Preliminary 30°C ) Polyacrylate 125 0.6 5.0 69.6 627 557
Water 1279 20.9 189 26797 241169 214373
Added Water (20°C) Water 142 -20.9 189 -2966 26695 29661
Zeolite 1253 -0.9 40.5 -1128 50748 51876
Sodium Sulphate 1405 5.0 155 6995 217868 210872
Solids Stream
Sodium Carbonate 564 -1.0 80.5 -590 45371 45960
(Stream 12; 24°C)
CMC 31.3 -1.3 58.5 -40.7 1831 1872
Water 242 -4.2 189 -1015 45684 46699
LAS Salt 3.3 110 90.0 364 298 -66.1
Non-ionic 1.3 108 88.5 143 117 -26.0
Zeolite 6.6 49.5 40.5 327 268 -59.5
Polyacrylate 0.7 6.1 5.0 4.0 3.3 -0.7
Recycle Stream
CMC 0.2 71.4 58.5 11.8 9.7 -2.1
(Stream 29; 80°C)
Sodium Silicate 3.0 140 115 417 341 -75.9
Sodium Carbonate 3.0 57.5 47.1 171 140 -31.1
Sodium Sulphate 7.4 188 155 1396 1153 -243
Water 1.6 230 189 376 308 -68.4
= 616137 kJ/hr
ࡽሶ= 171 kW
Perborate
TAED
Perfume
Enzymes Encapsulates
arator
wder 31 32 33 34
30
Optical Brighteners
C-301 Perfume Oil
Belt Sud-Suppressor
Conveyor 36a 37a 38a
35 M-301
Drum 39 Detergent Powder
Solids-Dosed Powder
Mixer
࢕ ሶ ෡
࢓࢚࢛࢕ ሶ࢔࢏ ෡
ࡴ࢚࢛࢕ െ࢓ ࡴ࢔࢏
kJ/hr
-26068
-36026
-290
19713
57510
557
214373
29661
51876
210872
45960
1872
46699
-66.1
-26.0
-59.5
-0.7
-2.1
-75.9
-31.1
-243
-68.4
= 616137 kJ/hr
ࡽሶ= 171 kW
Specific Heat Capacities
Assumptions Component Cp Units
- assuming Cp of NaOH constant LABSA 1.60 kJ/kg K
https://link.springer.com/conten
t/pdf/bbm%3A978-0-306-48624- 521.60 kJ/kmol K
1%2F1.pdf LAS 100% active matter 2.00 kJ/kg K
- converted from kJ/kgK to 696.00 kJ/kmol K
kJ/kmolK by finding average
molecular weight of NaOH 50% LAS 60% active matter 2.80 kJ/kg K
solution as 24.83 g/mol Water Liq 75.40 kJ/kmol K
- cp taken for sodium carbonate NaOH 50% solution @50-60 degrees 3.22 kJ/kg K
soln is estimated using shomate
equation, NIST 80.03 kJ/kmol K
- Cp's for Non-ionic, sodium H2SO4 1.34 kJ/kg K
polycarboxylate, SCMC were Sodium Sulphate soln.
estimated using modified Kopps 0.78 cal/g K
Rule (Hurst & Harrison, 1992) 463.18 kJ/kmol K
GOT UNITS OF KOPPS WRONG, Non-Ionic (alkyl ethoxylate) 460.16 J/mol K
ITS ACTUALLY J/(MOL K)
-Repeating units for Zeolite 4A (hydrated) 0.9 kJ/kg K
Polycarboxylate: 1 unit mW=94 Sodium Polyacrylate 500 J/mol K
total mw= 4500 WRONG. , Sodium Carboxymethyl Cellulose 341.63 J/mol K
instead, used 500 as it was the
max value of Cp given in ATHAS Sodium Silicate 0.61 Kcal/kg K
data bank 2.5498 kJ/kg k
- SODIUM POLYACRYLATE - Ref: Sodium Carbonate (soln) 189.535 kJ/kmol
Gaur. U, Lau. S, 1982. Journal of
Physical Reference Data, Sodium Carbonate (solid) 110.9 j/mol K
Wunderlich B, table 11, pg 1085 1.04623 kJ/kg k
Sodium Sulphate solid 1.097 kJ/kg K
Non-Ionic (alkyl ethoxylate) 1.9665 kJ/kg K
Sodium Polyacrylate 0.11111 kJ/kg K
Sodium Carboxymethyl Cellulose 1.29897 kJ/kg K
H2SO4 131.32 kj/kmol/ K
Air 1.006 kJ/kg K
Water vapour
Avg 1.94 kJ/kg K
Heats of Formation
Reference MW Component
De Groot 326 LABSA
De Groot Extrap. 348 LAS salt
De Groot
Felder 18 Water
https://link.springer.com/content/pdf/bbm%3A978-0-306-48624-1%2F1.pdf
24.83 NaOH 50%
98
https://www.engineeringtoolbox.com/specific-heat-fluids-d_151.html
Sulphuric acid
https://pubs.acs.org/doi/abs/10.1021/j150373a001
142 Sodium Sulphate
solid
234 solution
Qiu @ 20 degrees 2190
4500
263 Heats of Solution
230 Component
estimated using shomate equation, NIST Sodium Carbonate
Sodium Sulphate
106
Stream Number
1
98
https://www.engineeringtoolbox.com/specific-heat-fluids-d_151.html
1.78806603773585 2
3
4
5
6
7
8
9
10
11
12
13
14
14a
14b
15
15a
16
17
18
19 - Fines
19 - Air
19 - Water (v)
20
21
22
23
24
25
26 - Air
26 - Fines
27
28
29
30
31
32
33
34
35
36
37
38
39
https://www.chemeo.com/cid/36-813-9/Benzenesulphonic%20acid%2C%204-%283-dodecyl%29-%2C%20me
Formation Units Units
-859.90 kj/mol -859900 kJ/kmol
-916.90 kj/mol -916900 kJ/kmol
-285.84 kj/mol -285840 kJ/kmol

-469.40 kj/mol -469400 kJ/kmol
-811.32 kj/mol -811320 kJ/kmol
-1384.50 kj/mol
1.17 kj/mol
-1383.33 kj/mol -1383330 kJ/kmol
Heat of vapourisation
Water 40.656 kJ/mol
23.40 kJ/mol 2258.667 kJ/kg
1.17 kJ/mol
8.24 kJ/kg
T (°C)
70
70
70
300
110
110
110
80
3
80
35
35
35
35
35
3-dodecyl%29-%2C%20methyl%20ester
Air required for furnace/spray dryer Air requirement for spray dryer
Assumptions
- The furnace outlet air was Mols of
calculated and found to be 78.1% Water
N2, 18.8% O2, 1% CO2, 2% H2O, Lost 98.22 kmol/hr
therefore Cp of regular air used
Mass of
Steps Water
Energy supplied by air = (energy Lost 1767.95
to rid of water + Losses to the
atmosphere from surface area)
- From de Groot, it says that the Sensible 148115.27

ratio of TowerHeatLosses :
EnergyToEvaporateWater is 7:45
- Therefore, Energy supplied by
air = (energy to rid of water + Latent 3993219.18
Losses to the atmosphere from
surface area)
is the same as
Energy supplied by air = (energy
to rid of water + 0.16*energy to Sensible 115977.79
rid of water) = (1.16*energy to rid
of water)
Energy to
EnthalpyOfAir(kJ/kg)*Mair=Energy rid Water 4257312 kJ
Supplied by Air
EnthalpyOfAir(kJ/kg)=196 Energy
supplied
Per mol of fuel reacted, 99.16mols by 'Air'
Mass of 4257312
of gas leaves the furnace (excess 'Air'
air (88.9 mol) and combustion (Dryer) 21720.98 kg/hr
products (10.26 mol)) which has
been heated from 30 to 300
degrees celcius - 933.8% excess kmols Air
air was calculated Dryer 749.00 kmol/hr
Moles of
fuel
required 7.55 kmol/hr
Mass of
fuel
required 120.86 kg/hr
Furnace
air inlet
Actual
DRY air 21501.93 kg/hr
to make
N2
1 4257312.24
1182.5867342051 kW
SD -1162.2370348974 kW
Steps 24
27°C
temp
Steps 24
27°C
temp
reference is taken at 60°C
- ASSUMING FOR THE RECYCLE
STREAM THE HEATS OF SOLUTION
ARE NEGLIGIBLE, this is justified
because the mass of the recyclye
stream accounts for 0.374% of the
total crutcher mixer mass
-Reference ALL taken as 25°C
Steps
-
Energy Balance around neutralisation mixer
Assumptions
-Water going into neutralisation Substance Mols In Enthalpy in Mols Out
mixer is process water readily (kmol/hr) (kJ/kmol) (kmol/hr)
available at the site
-Reactant and product species
were taken as references LABSA 1.80 2608.00 0.00
Steps
- We used Heat of Rxn method to
calculate the heat evolved around
the neutralisation mixer NaOH (inc water 5.99 400.14 0.00
-Calculate enthalpies for all in soln)
components entering the mixer,
using the specific heat to raise their
temperatures from 25 to inlet Water (from
0.00 0.00 4.13
conditions NaOH solution)
-Similarly, this was also done for
outlet stream
- overall duty was calculated by the
summation of the Heat of Rxn H2SO4 0.03 656.60 0.00
value (-104kj/mol) + enthalpic
change of components
- The heat of Rxn value (-104)
includes the heat of reaction for Water 16.97 -377.00 16.97
the side reaction of sulphuric acid,
this was taken from Sulphonation
Technology
Na2SO4 0.00 0.00 0.03
ADIABATIC REACTOR
LAS 0.00 0.00 1.80
Inlet Temp Outlet Temp
LABSA 30 LABSA -
NaOH 30 NaOH -
H2O (sol) 30 H2O (sol) 90.8035517
H2SO4 30 H2SO4 -
H2O 20 H2O 90.8035517
Na2SO4 - Na2SO4 90.8035517
LAS - LAS 90.8035517
Energy Balance around crutcher mixer
Temperature Temperature Mass In

Substance
in (°C) out (°C) (kg/hr)
LAS Salt 91 70 627
Neutralisation mixer outlet Water 91 70 413
Na2SO4 91 70 4
Water 20 70 142
Non-ionic 30 70 251
Liquid streams
Sodium 30 70 564
Silicate
Water 30 70 1092
Zeolite 24 70 1253
Water 24 70 238
Water 30 70 188
Sodium 24 70 1405
Solids
except polyacry Sulphate
Water 24 70 0
Sodium 24 70 564
carbonate
Water 24 70 4
CMC 24 70 31
Water 24 70 0
LAS Salt 80 70 3
Non-ionic 80 70 1
Zeolite 80 70 7
CMC 80 70 0
Sodium 80 70 3
Recycle stream Silicate
Sodium 80 70 3
carbonate
Sodium 80 70 7
Sulphate
Water (in
80 70 2
powder)
Total 616136.64
171.1490668718
Enthalpy
Steam Bar Temp(°C) Saturated Water @ 70°C

Steam (kJ/kgK)
HP 42 253.2 2799.4
293.06
IP 15 198.3 2789.9 293.06
LP 7 165 2762
Mass Flow rate kg/hr 140
Enthalpy Out n∆H (out) n∆H (in)
(kJ/kmol)
0.00 0 4695.2926307
0.00 0 2398.5980509
4961.59 20513.76361249 0
0.00 0 19.760339589 Heat of Reaction
4961.59 84207.8087439 -6398.4242923 -104
30479.03 917.264764768 0 -104000
45799.27 82454.36512094 0 1.8
188093.2022421 715.22672889 -187200

188093.20 Total
187377.9755132 kJ/hr -52

∑Q
52.04943764256 kW
Outlet Utility
Ov. Energy Bal: °C ∑Q
177.9755132 75.0 -12.5
90.80 0.049437642556 0.0494376426 85.0 -4.6
95.0 3.4
90.8 0.0
xer
Enthalpy in Mass Out Enthalpy Out Heat Duty in Heat Duty out Total Heat Duty
(kJ/kg) (kg/hr) (kJ/kg) kJ/hr kJ/hr kJ/hr
132 627 90 82454 56387 -26068
276 413 189 113953 77927 -36026
215 4 147 917 627 -290
-21 142 189 -2966 26695 29661
10 251 88 2464 22177 19713
13 564 115 7189 64699 57510
21 1092 189 22869 205825 182956

-1 1253 41 -1128 50748 51876
-4 238 189 -997 44881 45878
1 125 5 70 627 557
21 188 189 3927 35344 31417

5 1405 155 6995 217868 210872
-4 0 189 0 0 0
-1 564 80 -590 45371 45960
-4 4 189 -17 743 760
-1 31 58 -41 1831 1872
-4 0 189 -1 60 61
110 3 90 364 298 -66
108 1 88 143 117 -26
50 7 41 327 268 -60
6 1 5 4 3 -1
71 0 58 12 10 -2
140 3 115 417 341 -76
58 3 47 171 140 -31
188 7 155 1396 1153 -243
230 2 189 376 308 -68
616136.6
kJ/hr MCp 593.2266211818 171.1
kW Ti 1108.619338274
Heat duty
Available Q kJ/hr Q kW
kJ/kg
2506.34 350887.6 97.46877777778
2496.84 349557.6 97.09933333333
2468.94 345651.6 96.01433333333
Energy Balance to bring raw materias from storage to process conditions
Assumptions
- Neutralisation mixer
Steps
-
Storage
Component Temperaure
(°C)
Water 20
(Process water)
LAS Acid 30
NaOH
Heat of Reaction (inc water in 30
soln)
kj/mol H2SO4 30
kj/kmol
kmol/hr
kj/hr
kW
Temperature
Substance
(°C)
Crutcher Blown 80.0
Temperature 70 Powder
Inlets
Mixer outlet 3.0
Temperature 90.803552 Air
35.0
Recycle Temp 80 Air
Outlets
Liq. Stream HX 35.0
Outlet Fines
Ambient
Storage 80.0
Temp solids 24 Recycle
After HX liquids 30
Blown powder: AIRLIFT
Cool Air
Mixer inlet
Mol. Flow rate Enthalpy Duty
Temperature
(kmol/hr) (kJ/kmol) (kW)
(°C)
20 16.97 0 0
30 1.80 0 0
30 5.99 0 0
30 0.03 0 0
Total 0
Energy
Mass Enthalpy
Exchanged
(kg/hr) (kJ/kg)
kJ/hr
5417.8 452656.9 -368503.8
11447.1 -253346.4
368503.8
11447.1 115157.5
5390.7 81889.7
27.1 2263.3
Air & Fines
AIRLIFT
Cool Air Powder recycle

Substance
Water
Non-ionic
Sodium
Silicate
Water
Polyacrylate
Water
Sodium Sulphate
(anhydrous, no water)
Assumptions Reference: All species at

- Powder leaving top has same 25°C, with water as liquid
bottom
Steps
-
bottom
Drop tank outlet (slurry)

Steps
-
Furnace Air
Inlets
Recycle
Spray-Dryer Top
Outlets
Blown powder
Liquid stream into crutcher HX - energy balance
Temperature Temperature Mass In Enthalpy in Mass Out Enthalpy Out

20 0.00 141.62 -20.94 141.62 -104.72
30 0.00 250.61 9.83 250.61 -49.16
30 0.00 563.87 12.75 563.87 -63.75
30 0.00 1091.91 20.94 1091.91 -104.72
30 0.00 125.30 0.56 125.30 -2.78
30 0.00 187.50 20.94 187.50 -104.72
Sodium sulphate heated for the crutcher - energy balance
35 24 1405.39 10.97 1405.39 -1.097
Energy Balance around spray dryer
Energy
Temperature Mass Enthalpy
Substance Exchanged
(°C) (kg/hr) (kJ/kg)
kJ/hr
Slurry 70 6928.08 685929.8912
-4184053
Air 300 21264.840235 5882918.051
-1162.2370349 kW
Water (v) 300 434.42 234021.5321
Cyclone Fines 80 219.94 18376.13304
Bag Filter Fines 35 250.76 3809.219245
Air 110 21264.840235 1818356.488
Water (v) - Furnace 110 434.42 73894.46145

Water (v) - Evap. 110 1767.95 293794.3111
Fines 110 229.11 29582.78994
Powder 80 5091.25 425373.45

Heat Duty in Heat Duty out Total Heat Duty
Substance
kJ/hr kJ/hr kJ/hr
-2966.13 -14830.67 -11864.53

Dosed Powder
2464.09 -12320.47 -14784.57

Perfume Oil
7188.74 -35943.71 -43132.46

Sud-suppressors
22869.49 -114347.43 -137216.91

Optical Brigtheners
69.61 -348.07 -417.68
3927.08 -19635.42 -23562.50
-230978.6468
Total kJ/hr
-64.16073523
kW
15417.1778 -1541.71778 -16958.8955844 kJ/hr

-4.71080432899 kW
Blown powde
LAS
Non-Ionic
(alkyl-ethoxylate)
Zeolite 4A
(hydrated)
Sodium
Polycarboxylate
Sodium CMC
Sodium Silicate
Sodium Carbonate
Sodium Sulphate
Water
Total
Drum Mixer - energy balance
Blown powder Avg. Cp
Blown Powder CP Mixture

Mass %
(kg/hr) kJ/kg K Cp
661.2 12.20% 2.00 0.244
264.5 4.88% 1.97 0.096
1322.4 24.41% 0.90 0.220
132.2 2.44% 0.11 0.003
33.1 0.61% 1.30 0.008
595.1 10.98% 2.55 0.280
595.1 10.98% 1.05 0.115

1487.7 27.46% 1.10 0.301
326.6 6.03% 4.19 0.252
5417.80 1.00 1.52

Cp of Fines leaving top of Spray Dryer
Blown
CP
Powder Mass % Mixture Cp
kJ/kg K
(kg/hr)
LAS 29.8 12.99% 2.00 0.260
Non-Ionic
11.9 5.19% 1.97 0.102
(alkyl-ethoxylate)
Zeolite 4A
(hydrated) 59.5 25.97% 0.90 0.234
Sodium
6.0 2.60% 0.11 0.003
Polycarboxylate
Sodium CMC 1.5 0.65% 1.30 0.008
Sodium Silicate 26.8 11.69% 2.55 0.298

Sodium Sulphate 66.9 29.22% 1.10 0.321
Water 0.0 0.00% 4.19 0.000
Total 229.11 1.00 1.35

Avg.Cp of slurry entering the spray dryer
Crutcher CP
Mass % Mixture Cp
Outlet kJ/kg K
LAS 9.09% 2.00 0.182
629.83
Non-Ionic
3.64% 1.97 0.072
(alkyl-ethoxylate) 251.93
Zeolite 4A
(hydrated) 18.18% 0.90 0.164
1259.65
Sodium
1.82% 0.11 0.002
Polycarboxylate 125.97
Sodium CMC 0.45% 1.30 0.006

31.49
Sodium Silicate 8.18% 2.55 0.209
566.84
Sodium Sulphate 1417.11 20.45% 1.10 0.224
Water 2078.42 30.00% 4.19 1.257
Total 6928.08 1.00 2.20

Screw Conveyors: see pg 21-8 perrys
Belt Conveyors: 21-11
Bulk Mass Flow

Assumptions Species
Blown Powder Density Rate
- Liquids dont affect bulk density (Grav.Sep. Outlet) x 5121.17
- An average value of 1 g/ml was found
for the enzyme blend TAED 500 187.5
- TAED has a range of: 450-550. 500 Perborate Bleach 575 750
chosen
- Perborate has a range of: 500-650. Enzymes 1000 31.25
Value of 575 chosen Perfume Encapsulates 1500 62.5
500 6250
Final
Calculation 396
Unknown B.Density 483.2877 g/l
air lift cooler
and water
removed
Exit air
specific
4.707 g/kg of dry air
humidity
0.004707 kg/kg dry air
0.00468494795 kg/kg wet air

Wet air kg/hr
exiting 11447.06292201
Mass
Water 53.62889396998 kg/hr
In Air
Dry Air 11393.43402804 kg/hr
Water 258.5967721344
kg/hr
removed
Mass Fraction Furnace stuff

Ambient Relative
0.819387755102041 80%
Humidity
Ambient Air
0.03 15 27.7 °C
temp
0.12 69 18.88 g/kg dry air
0.005 5 Specific Humidity 0.0189 kg/kg dry air
0.01 15 0.0185 kg/kg wet air
1 500 kg dry air 21582.13 kg/hr
entering furnace
water from
407.471 kg/hr
ambient
Water fromair
275.398 kg/hr
combustion
kg water
entering 682.87 kg/hr
spray tower
Evaporated
1767.95 kg/hr
water
2450.82 kg/hr
water vapour
exiting spray
tower 2450823.18 g/hr
specific humidity
of air exiting 114.28 g H2O/kg dry air
spray tower
Dew Point of exit

54.88 °C
air @110°C
relative 80%
humidity
highest
Entry air av. temp 34.4 °C
specific
27.404 g/kg of dry air
humidity Mol composition 100 kmol Basis
0.027404 kg/kg dry air Nitrogen 79% 79
0.0266730517 kg/kg wet air Oxygen 21% 21

Dry Air kg/hr
entering 11393.434028
Water in
entry 312.2256661 kg/hr
Wet Air 11705.659694 kg/hr
uff Air Entering Spray Dryer (from furnace) EXCLUDING AMB.HUMIDITY

Component Air (kmols) Mol % 100 kmol Mass (kg)
basis
Nitrogen 77.28 78.15% 78.15 2188.13
g/kg dry air Oxygen 18.61 18.82% 18.82 602.20
kg/kg dry air CO2 1.00 1.01% 1.01 44.49
kg/kg wet air H2O 2.00 2.02% 2.02 36.40
98.89 1.00 100.00 2871.23
Air Entering Spray Dryer Including Ambient Hum

Air entering w/out
amb. humidity 21721 Composition of tower entry a
Moisture Entering 683 kg/hr
Combustion water 275 Nitrogen 16553.282
kg Dry air entering Oxygen
(and exiting) spray 21445.6 4555.702
tower
CO2
336.598
g H2O/kg dry air H2O
275.398
21720.981
Dry Air
kg mass%
2212 76.70% 8738.65328364 N2
2654.7807444
672 23.30% O2
11393.434028
dry air with products of combustion, excluding ambient humidity

LUDING AMB.HUMIDITY mol to mass conversion
Mass % Component Mol % Mass %
76.21% Nitrogen 78.1% 76.2% 16553.28
20.97% Oxygen 18.8% 21.0% 4555.702
1.55% CO2 1.0% 1.5% 336.5981
1.27% H2O 2.0% 1.3% 275.3984
100%
Dryer Including Ambient Humidity

Composition of tower entry air EXCLUDING AMBIENT HUMIDITY
76.21%
20.97%
1.55%
1.27%
100.00%
Cp
Water (v) 1.8615 kJ/kg K
Mass of
water 258.596772134394 kg/hr
Q1 -11553.0693918762 kJ/hr
Q2 -644888.630348751 kJ/hr
Energy Removed to
rid of water (v) -656441.699740627 kJ/hr
-182.344916594619 kW
Dry Air & Combustion Products (Excluding Ambient Humidity)
Component Mol % Mass % kg/hr
Nitrogen 78.1% 76.2% 16553
Dry Oxygen
Air & Combustion Products (Excluding
18.8% Ambient Humidity)
21.0% 4556
Carbon Dioxide
Component Mol % 1.0% Mass % 1.5% kg/hr 336.6
Water Vap.
Nitrogen 78.1% 2.0% 76.2% 1.3%16553 275.4
ambient humidity Oxygen 18.8%
Dry 21.0%
Air Exiting Furnace: 21445.64556 kg/hr
Carbon Dioxide 1.0% 1.5% 336.6
Water Vap. 2.0% 1.3% 275.4
Dry Air Exiting Furnace: 2 kg/hr
Highest Ambient 80 %
Relative Humidity
Ambient Dry Bulb Temp 27.7 °C
18.88 g/kg dry air
Specific Humidity
Dry Air Entering Furnace 21582.1 kg/hr
Water (v) from Ambient Air 407.5 kg/hr
Water (v) from Combustion 275.4 kg/hr
Total Water Vapour

682.9 kg/hr
Entering Spray Tower
Highest Ambient
80 %
Relative Humidity
18.88 g/kg dry air
Specific Humidity
Total Water Vapour
18.88 g/kg dry air
Specific Humidity
Total Water Vapour
682.9 kg/hr
Entering Spray Tower
Humidity)
% kg/hr
16553
4556
336.6
275.4
6 kg/hr
Assumptions
Sch. 40 1"
-The chosen pipe type was based on being one that can handle
Pipe Outer Diam. 33.401 mm pressure (40bar and 80bar)
Pipe Wall Thickness 3.378 mm - Approximated pipe diameter: Diam = sqrt(4 x vol. flow rate /
Pipe inside Diam 26.645 mm - The chosen pipe is then one that can accomodate the above
Please delete above later
Pipe inside Diam 0.026645 m -Pipe selected is the schedule for low pressure applications: Sc
Inside Area 0.000557598158 m^2 -Pipe selected is the schedule for low pressure applications: Sc
-Friction factor is estimated using f = 64/re because Re is so low
- No pressure changes due to elevation
Absolute roughness 0.046 mm - Ethyl formate debsity used for perfume oil
Sch. 80 1"
Pipe Outer Diam. 33.401 mm
Pipe Wall Thickness 4.547 mm
Pipe inside Diam 24.307 mm
Operating Pressures
Pipe inside Diam 0.024307 m (Pa)
Inside Area 0.000464036992 m^2 Neut. Mixer 105000.00
Crutcher Mixer 105000.00
Pi 3.14159265359 Liquid Mixer 105000.00
Drum mixer 105000.00
Velocity Calculated Diam Calculated Diam
Q (m3/s)
Slurry & Paste (m/s) (m) (mm)
Pump 4 0.000290055143 0.5 0.085380799065128 85.3807990651283
pump 11 0.00148035817 0.5 0.192887166024515 192.887166024515
Mass Flow
From To Pipe Length (m)
rate (kg/s)
Pump number NaOH Storage Neut. Mixer 20 0.04

Neutralisation
1 Water storage 20 0.08
mixer
LAS Acid Neutralisation
2 storage mixer
20 0.16
Neutralisation
3 Crutcher mixer 20 0.29
mixer
4 Polyacrylate
Liquid Mixer 20 0.09
De groot, pg 15 storage tank
5 Water Storage Liquid Mixer 10 0.04
6 Non-ionic Liquid Mixer 10 0.07

storage
Sodium Silicate
7 Liquid Mixer 10 0.46
storage
8 Liquid mixer Crutcher mixer 25 0.66

Low Pressure High Pressure
9 Pump Pump 20 1.92446562123483
11 High Pressure
Spray dryer 20 1.92446562123483
De groot, pg 15 Pump
Sud-suppressor
11a Drum mixer 15 0.01
storage
Optical B
12 Drum mixer 15 0.01
storage
Perfume Oil
13 drum mixer 15 0.01
storage
14
Mass Flow
From To Pipe Length (m)
rate (kg/s)
Low Pressure High Pressure

Pump number 20 1.92446562123483
Pump Pump
11 High Pressure
Spray dryer 20 1.92446562123483
De groot, pg 15 Pump
11a
d on being one that can handle a working pressure of 100 bar, sch 40 for low pressure and sch 80 for high
Diam = sqrt(4 x vol. flow rate / pi x velocity)

at can accomodate the above calculated pipe
r low pressure applications: Sch 40, NPS 1"

r low pressure applications: Sch 80, NPS 1"
g f = 64/re because Re is so low
evation
perfume oil
Vol Flowrate Density Viscosity Velocity ∆P ∆P

Re
(m3/s) (kg/m3) Pa.s (m/s) (Pa) (bar)
2.75634393E-05 1500 0.079 0.049432443 25.00874905 3520.364982561 0.0352036498

8.485973863E-05 1000 0.0010005 0.152187982 4053.022278 137.2606265756 0.0013726063
0.0001560478527 1050 1.3 0.279857188 6.022795785 327965.6379192 3.2796563792
0.0002900551429 1000 0.5 0.520186695 27.72074897 234464.8632908 2.3446486329
6.697970566E-05 1300 0.04315 0.12012182 96.42733874 4672.520646402 0.0467252065
3.933863536E-05 1000 0.0010005 0.070550153 1878.869391 31.81512119408 0.0003181512
7.289642505E-05 960 0.021 0.130732901 159.2401444 1237.435935052 0.0123743594
0.0003308910796 1390 0.2 0.593422117 109.8915396 53494.88443647 0.5349488444
0.0005903033854 1111.85 0.056369635731 1.058653758 556.3810913 67244.64568357 0.6724464568
0.0014803581702 1300
0.0014803581702 1300
9.04224537E-06 960 0.0192 0.016216419 21.60432422 210.506724806 0.0021050672
5.825876212E-06 1490 0.085 0.010448163 4.880035589 600.4386445808 0.0060043864
3.466675541E-06 2504 0.00149 0.006217157 278.391292 6.263079472063 6.263079E-05
Values for high pressure pump calculation
k 40
n 0.3
velocity 0.5
Diameter 0.192887166
Density 1300
Vol
flowrate 0.001480358
Efiiciency 0.5
Pressure
20
before pump
bar
100
Pressure
after pump bar
∆P required
for pressure
increase 80 bar
∆P due to
loss
47287.39067 pa
∆P total 8047287.391 Pa
Power 23825.73527 W
23.82573527 kW
Vol Vol Hydraulic

Pressure
Pump flowrate flowrate Power
(bar)
(m3/s) (l/min) (kW)
Low Presure 20 0.001480358 88.82149021084 2.9607163404
High Pressure 100 0.001480358 88.82149021084 14.803581702
Power
Efficiency Power W
(kW)
0.5 0.00019407 0.19406673

0.5 2.3296E-05 0.0232958
0.5 0.10235667 102.356667
0.5 0.13601548 136.015479
0.5 0.00062593 0.62592812
0.5 2.5031E-06 0.00250313
0.5 0.00018041 0.18040931
0.5 0.03540196 35.4019601
0.5 0.07938948 79.389484
0.5 0 0
0.5 0 0
0.5 3.8069E-06 0.00380691
0.5 6.9962E-06 0.00699616
Pump
0.5 4.3424E-08 4.3424E-05 From
number
1 NaOH
Storage
2 Water
Values for low pressure pump calculation storage
k 40 3 LAS Acid
storage
4 Neutralisa
n 0.3 De groot, tion
pg 15 mixer
velocity 0.5 5 Polyacryla

te storage
tank
Diameter 0 7 Non-ionic
storage
Sodium
Density 1300 8 Silicate
storage
Vol 9 Liquid
flowrate 0.00148036 mixer
11 Low
Efiiciency 0.5 De groot, Pressure
pg 15 Pump
Pressure High
1.05 Pressure
before pump
bar Pump
Sud-
20 12 suppresso
Pressure r
after pump bar storage
∆P required
for pressure 13 Optical B
increase 18.95 bar storage
∆P due to
14 Perfume
loss
Oil
47287.3907 pa storage
∆P total 1942287.39 Pa
Power 5750.56202 W
5.75056202 kW
Pump Power
(kW)
5.921432681
29.6071634
Density for Liq streams into crutcher
Component Mass kg/hr Mass fraction Density AVG
Non-ionic 251.93 0.11327028714 960 1111.8544086
Silicate 566.84 0.25485814607 1390
Water 1279.41 0.57523642321 1000
Polyacrylate 125.97 0.05663514357 1300
2224.15 1.00
Viscosity for Liq streams into crutcher

Component Mass kg/hr Mass fraction Viscosity AVG
Non-ionic 251.93 0.11327028714 0.021 0.0563696357
Silicate 566.84 0.25485814607 0.2
Water 1279.41 0.57523642321 0.001001

Polyacrylate 125.97 0.05663514357 0.04315
2224.15 1.00
Mass
Pump
Mass Flow Flow
To Pipe Length (m) Power
rate (kg/s) rate (Kw)
(kg/hr) Hydraulic
Power (kW)
20 0.04130588847
Neut. Mixer 148.7012 0.0081042153 0.011577
Neutralisatio
n 20 0.08477913711
mixer 305.2049 0.0166336667 0.023762
Neutralisatio
n 20 0.16369461703
mixer 589.3006 0.0321168839 0.045881
Crutcher 10 0.28977964261
mixer 1043.207 0.0284273829 0.040611
20 0.0870299291
Liquid Mixer 313.3077 0.0170752721 0.024393
10 0.06989319153
Liquid Mixer 251.6155 0.0068565221 0.009795
10 0.45977938298
Liquid Mixer 1655.206 0.0451043575 0.064435
Crutcher 25 0.65545484243
mixer 2359.637 0.1607503001 0.229643
High Pressure 10 1.92446562123

Pump 6928.076 0.1887900774 0.2697
10 1.92446562123
Spray dryer 6928.076 0.1887900774 0.2697
15 0.00868055556
Drum mixer 31.25 0.0012773438 0.001825
15 0.00868055556
Drum mixer 31.25 0.0012773438 0.001825
15 0.00868055556
drum mixer 31.25 0.0012773438 0.001825

𝒑_𝒉 (𝒌𝑾)=("Mg"
𝒉)/(𝟑.𝟔𝒙 〖𝟏𝟎〗 ^𝟔 )
Pump
Efficiency 0.7
Mixers
In-line Disintegrator Neutralisation
Vol 5.329289
flowrate m3/hr Crutcher
Chosen RI 12
Model Drop tank
Capacity 20 m3/hr Drum
Max power 55 Liquid (into

req kW crutcher)
Pre Spray-Drying Adds Temps
Involved
Sodium Sulphate 85
Sodium Carboxymethyl
Cellulose 85
Sodium Polycarboxylate 85
Non-Ionic (alkyl ethoxylate) 85
Zeolite 4A (hydrated) 85
Sodium Silicate 85
Sodium Carbonate 85
LAS 85
Water
Post Spray-Drying Adds
Sodium Perborate
Monohydrate <30
Enzymes <30
Perfume Oil <30
Perfume Encapsulates <30
Brighteners <30
TAED Bleach Activator <30
Sud-suppressor <30
Hydrates
below 32 degrees DECAhydrate forms, below 24 degrees 7.hydrate forms
WILL ABSORB moisture from the air and cake

-
-
HYDRATED
-
below 32 degrees DECAhydrate forms, 32-35 degrees 7.hydrate forms, 35-100 degrees 1.hydrate forms
-
below 40 degrees generally its tetrahydrate, but above 40 degrees its fully monohydrate
-
-
-
-
-
-
NEED 40% SOLUTION
100% pure Lauryl-alcohol Ethoxylate
-
-
-
-
2% free moisture
-
T-101 T-102 T-103 P-103 T-201 T-202 T-203 T-204
7a
7
5 6 6a
8 9 10 11
5a M-104
P-102
14
P-101 P-107 C-201
14a 12
T-104 T-105 T-106 Exhaust Gas

Steam 14b
13 19 A
1 2 3 P-106 F-203 18a S-201
3a M-102
18 20 S-202
P-105 4
2a 4a
27
1a P-108
M-101
P-104 15
M-103 T-201
15b
15a 21
D-201 P-201 P-202 C
17
Air 16 16a
2
F-201
H-201
F-202
Air 23
C-302
20
S-102
Cyclone
19
21 29
8 13
20
S-102
Cyclone
19
21 29
8 13
1 M-101 M-102 14 P-101 14a P-102 14b T-101

M-102 14
2 Neutralisation 4 Drop Low Pressure High Pressure Spray 22
Crutcher Mixer
3 Mixer Tank Pump Pump Dryer
25
18
S-101
P-102 H-101
15 15a 16 Coalescence 17
Fan Furnace
Filter
Air &
Emissions
S-103
S-101 Bag Fines
Cyclone Filter
S-102 Post-dryer
Neutralisation Liquids Solids
Exhaust Air
Gravity Adds
Reactants Dosing Dosing
& Fines Separator
Fines
Cooled Powder
M-101 M-102 M-102 T-101 A-101 M-

Slurry
Neutralisation Crutcher Drop Spray Blown Powder Air-Lift D
Mixer Mixer Tank Dryer Cooling M
Powder Lumps
Hot Air &

Air & H-101 Air
Combustion Gases
Fuel Furnace
T-202 T-203 T-204 T-301 T-302 T-303 T-304 T-305 T-306 T-307
9 10 11 36 37 38
P-301
31 32 33 34 36a
37a P-302
38a
C-201
P-303
Exhaust Gas
19 Air
18a S-201
28
18 20 S-202
26a
27
F-204 S-203
26
22
30
T-201
5b
35
C-301
21
M-301
C-202
17 Detergent
H-202 39 Powder
23a 24
H-201 25 Water
F-202
Air 23
29
20 28
S-104
S-102
Bag 27
Cyclone
Filter
S-103
Gravity Separator
19
21 29 Dry
30 Post-adds
26
20 28
S-104
S-102
Bag 27
Cyclone
Filter
S-103
Gravity Separator
19
21 29 Dry
30 Post-adds
26
14b T-101 A-101 Belt

Spray 22 Air-Lift Conveyor
Dryer Cooling 36 37
35
24
M-103
18 Air
39 Drum 38
Cooler
Mixer
S-101
23b
Coalescence 17
Filter Fan
23a
ines
-102 Post-dryer
ravity Adds
parator
Cooled Powder
A-101 M-103 Detergent Powder

Air-Lift Drum
Cooling Mixer
Air

Energy and Material Balance

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Final product x

Production Capacity Separator

Mass Mass flow Gravity

Sodium Carbonate (anhyd) 9.0 562.5 Sodium Silicate

Total 100.0 6250.0 Total

- same procedure can be applied Sodium

of Blown Powder Water (to make 60% AM 305.50

Total Exiting Neutraliser

1.190 0.329 Sodium Sulphate 4.27

0.48 0.13 Water 413.41

2.38 0.66 Total (kg/hr)

1.07 0.30 LABSA 586.91

2.68 0.74 H2SO4 2.95

9.16 2.53 NaOH (from H2SO4 reaction) 2.41

Component kg/hr Composition Component

LAS (s) 29.8 13.0% LAS (s)

Component kg/hr Composition Component

LAS (s) 32.9 12.20% LAS (s)

Component kg/hr Composition Component

Nitrogen (g) 8738.65 74.7% Nitrogen (g)

Component kg/hr Composition Component kg/hr

Nitrogen (g) 16553.28 75.3% Nitrogen (g) 16553.28

Coming out G.Sep

Stream Stream Stream

kg/hr Composition Component kg/hr Composition

28.6 13.0% LAS (s) 1.19 13.0%

kg/hr Composition Component kg/hr Composition

32.57 12.2% LAS (s) 0.33 12.2%

kg/hr Composition Component kg/hr Composition

8738.65 76.3% Water (l) 258.60 100.0%

Composition Component kg/hr Composition Component kg/hr Composition

10.15% Brighteners (l) 31.25 100.0% Sud-suppressor (l) 31.25 100.0%

125.00 31.25 562.50 562.50 1406.25

125.00 31.25 562.50 562.50 1406.25

6.58 1.64 29.61 29.61 74.01

131.58 32.89 592.11 592.11 1480.26

0.66 0.17 2.98 2.98 7.44

6.51 1.63 29.31 29.31 73.27

132.24 33.06 595.08 595.08 1487.70

5.95 1.49 26.78 26.78 66.95

0.24 0.06 1.07 1.07 2.68

5.71 1.43 25.71 25.71 64.27

125.30 31.33 563.87 563.87 1405.39

Sodium CMCSodium Silicate

0.61 10.98 10.98 27.46 6.03

Composition Component kg/hr Composition Component kg/hr

Component kg/hr Composition Component kg/hr Composition

Perfume Oil (l) 31.25 100.0% LAS (s) 625.0 10.0%

Perborate Monohydrate(s) 750.0 12.0%

Enzymes (s) 31.25 0.5%

Brighteners 31.3 Sodium Silicate 66% 1091.91

TAED Bleach Activator 187.5 Sodium Carbonate 0.70% 3.94

Free Moisture Mass flow

TAED Bleach Activator 2% 3.83

Composition Component kg/hr Composition

Gravity Separator Slurry (kg/hr)

Air-Lift Total Slurry Water

Recycle Stream Added Water (kg/hr) to

Bag Filter PMC (Powder

Bag Filter 16.08 Total Water Evaporated in

Drop Tank Outlet 1936.80

Additional Crutcher Water