Industry Overview
Oleochemicals are chemicals derived from plant and animal fats and are analogous to petrochemicals derived from petroleum. Basic oleochemical products such as fatty acids, fatty acid methyl esters (FAME), fatty alcohols, fatty amines, and glycerol are produced through various chemical and enzymatic reactions.
Fatty acids are fundamental oleochemicals produced by splitting vegetable oils and fats into fatty acids and glycerin. Refined fatty acids serve as raw materials for natural chemical products used in paper chemicals, lubricants, detergents, plastics, tires, candles, and other applications. They are generally characterized by the length of their carbon chains and the number of double bonds present in unsaturated acids.
In principle, fatty acids can be produced from virtually any oil or fat through hydrolytic or lipolytic splitting using water under high pressure and temperature or through enzymatic processes. In commercial production, a relatively limited number of fats and oils account for the bulk of raw-material utilization, with patterns varying by geography. Different oils produce fatty acids with different carbon-chain-length distributions, allowing products to be categorized according to their predominant chain lengths.
Cost Estimation
| Particulars | Value |
|---|---|
| Plant Capacity | 210 MT/Day |
| Land & Building (30,000 sq.mt.) | US$ 23.00 Lac |
| Plant & Machinery | US$ 11.79 Lac |
| Working Capital for 2 Months | US$ 1.77 Cr |
| Total Capital Investment | US$ 2.13 Cr |
| Rate of Return | 52% |
| Break Even Point | 24% |
Content Index
- INTRODUCTION
- OLEOCHEMICALS
- FATTY ACIDS
- SELECTING RAW MATERIALS FOR FATTY ACID PRODUCTION
- THE PRODUCTION PROCESS
- POST HYDROLYSIS PROCESSES
- USES OF FATTY ACIDS
- PROPERTIES
- COMPOSITION
- USES & APPLICATION
- B.I.S. SPECIFICATION
- MARKET POSITION
- MARKET HIGHLIGHTS
- COMPANIES PROFILED
- MANUFACTURING PROCESS
- OLEOCHEMICALS
- FATTY ACID/GLYCERINE & ACID OILS
- FATTY ACID PLANTS
- PROCESS DESCRIPTION
- A) DE-AERATION
- B) SPLITTING
- C) FATTY ACID DRYING
- D) GLYCERIN-WATER PRE-CONCENTRATION
- TO PRODUCE HIGH PURITY FATTY ACID FRACTIONS PROCESS DESCRIPTION
- A) DE-AERATION
- A) FRACTIONATION (2-COLUMN SYSTEM) FATTY
- REMOVAL OF LOW & HIGH BOILING COMPONENTS FROM FATTY ACIDS
- DISTILLATION
- GLYCERIN PLANTS
- GLYCERINE REFINING PROCESS
- GLYCERINE REFINING PROCESS INVOLVES THE FOLLOWING STEPS:
- PROCESS DESCRIPTION
- A) DEAERATION
- B) DISTILLATION
- C) CONDENSATION
- A) BLEACHING
- B) SALT REMOVAL
- ACID OIL PLANT
- PROCESS DESCRIPTION
- GLYCERIN REFINING PLANT
- DETAILED CONCEPTS OF GLYCERINE RECOVERY PLANT
- GLYCERINE RECOVERY PROCEDURE
- PURPOSE OF LYE TREATMENT
- METHOD OF LYE TREATMENT
- THE TESTS PERFORMED AT THIS STAGE ARE AS FOLLOWS:
- TREATMENT OF SWEET WATER
- FIRST TREATMENT
- SECOND TREATMENT
- EVAPORATION
- CONTINUOUS FINISHER
- PURIFICATION/REFINING OF CRUDE GLYCERINE
- THE IMPURITIES PRESENT IN THE CRUDE GLYCERINE INCLUDE:
- NOTE ON REFINING OF CRUDE GLYCERINE
- REFINING OF CRUDE GLYCERINE
- SOME PLANTS FOR REFINING CRUDE GLYCERINE ARE LISTED BELOW:
- MANUFACTURERS/SUPPLIERS/EXPORTERS
- RAW MATERIAL SUPPLIERS
- MANUFACTURERS OF FATTY ACID
- PLANT & MACHINERIES SUPPLIERS ADDRESS
- VACUUM DISTILLATION PLANT
- BOILER
- STORAGE TANK
- WEIGHING MACHINES
- PACKAGING MACHINE
- D.G. SET
- LABORATORY TESTING EQUIPMENTS
- PRINCIPLES OF PLANT LAYOUT
- PLANT LOCATION FACTORS
- PRIMARY FACTORS
- 1. RAW-MATERIAL SUPPLY:
- 2. MARKETS:
- 3. POWER AND FUEL SUPPLY:
- 4. WATER SUPPLY:
- 5. CLIMATE:
- SPECIFIC FACTORS
- 6. TRANSPORTATION:
- A. AVAILABILITY OF VARIOUS SERVICES AND PROJECTED RATES
- 7. WASTE DISPOSAL:
- 8. LABOR:
- 9. REGULATORY LAWS:
- 10. TAXES:
- 11. SITE CHARACTERISTICS:
- 12. COMMUNITY FACTORS:
- 13. VULNERABILITY TO WARTIME ATTACK:
- 14. FLOOD AND FIRE CONTROL:
- EXPLANATION OF TERMS USED IN THE PROJECT REPORT
- 1. DEPRECIATION:
- 2. FIXED ASSETS:
- 3. WORKING CAPITAL:
- 4. BREAK-EVEN POINT:
- 5. OTHER FIXED EXPENSES:
- 6. MARGIN MONEY:
- 7. TERM LOANS:
- 8. TOTAL LOAD:
- 9. LAND AREA/MAN POWER RATIO:
- UTILITIES
- WATER TREATMENT PLANT
- STEAM GENERATING SYSTEM
- POWER
- WORKING
- TOTAL MANPOWER AND PAYROLL
- UTILITIES
- WATER
- WATER QUALITY PARAMETERS FOR PROCESSED WATER:
- STEAM
- POWER
- EFFLUENT TREATMENT AND DISPOSAL
- THE WASTE FROM THE FOOD PROCESSING OPERATIONS MAY BE CLASSIFIED ON THE BASIS OF:
- STANDARDS
- TOLERANCE LIMITS FOR INDUSTRIAL EFFLUENT DISCHARGE
- WASTE TREATMENT
- PRIMARY TREATMENT
- ANAEROBIC TREATMENT
- ANAEROBIC TREATMENT HAS THE ADVANTAGES OF
- SECONDARY TREATMENT
- TERTIARY TREATMENT
- SOLIDS CONCENTRATION
- TYPICAL WASTE SOLIDS CHARACTERISTICS
- EQUIPMENT REQUIREMENTS
- LIST OF MAJOR FOREIGN INDUSTRIES FOR RAW MATERIALS
- PALM OIL:-
- CAUSTIC SODA:-
- SODIUM CARBONATE (SODA ASH):-
- PHOSPHORIC ACID:-
- HYDROCHLORIC ACID:-
- SULPHURIC ACID:-
- BLEACHING EARTH/ACTIVATED CARBON:-
- FERRIC CHLORIDE:-
- ALUMINIUM SULPHATE:-
- SODIUM CHLORIDE:-
- HYDROGEN PEROXIDE:-
- SODIUM CHLORIDE:-
- MAJOR INDIAN INDUSTRIES
- MACHINERY PHOTOGRTAPH
- QUALITY CONTROL
- PACKAGING TYPES
- DOCUMENTS REQUIRED FOR LICENSES
- LIST OF DOCUMENTS:
- ORGANIZATION CHART
- PLANT LAYOUT
- TURNKEY CONSULTANT
- SWOL ANALYSIS
- STRENGTHS
- OPPORTUNITIES
- WEAKNESS
- LIMITATIONS
- IMPLEMENTATION SCHEDULE
- PLANT LOCATION (AN OVERVIEW OF THAILAND)
- CAPITAL:
- AREA
- CLIMATE
Appendix
- APPENDIX – A:
- 01. PLANT ECONOMICS
- 02. LAND & BUILDING
- 03. PLANT AND MACHINERY
- 04. OTHER FIXED ASSESTS
- 05. FIXED CAPITAL
- 06. RAW MATERIAL
- 07. SALARY AND WAGES
- 08. UTILITIES AND OVERHEADS
- 09. TOTAL WORKING CAPITAL
- 10. TOTAL CAPITAL INVESTMENT
- 11. COST OF PRODUCTION
- 12. TURN OVER/ANNUM
- 13. BREAK EVEN POINT
- 14. RESOURCES FOR FINANCE
- 15. INSTALMENT PAYABLE IN 5 YEARS
- 16. DEPRECIATION CHART FOR 5 YEARS
- 17. PROFIT ANALYSIS FOR 5 YEARS
- 18. PROJECTED BALANCE SHEET FOR (5 YEARS)
Frequently Asked Questions
Oleochemicals are chemicals derived from natural fats and oils of plant or animal origin. They are broadly analogous to petrochemicals, but their carbon-based feedstocks are renewable or naturally occurring fats and oils. Important oleochemical products include fatty acids, fatty acid methyl esters, fatty alcohols, fatty amines, and glycerol. These products are used as intermediates or ingredients in industries such as detergents, lubricants, plastics, paper chemicals, candles, and other manufacturing applications.
Fatty acids can be produced by splitting fats or oils through hydrolytic or lipolytic processes. Hydrolytic splitting uses water under controlled pressure and temperature, while lipolytic processes may use enzymes. Industrial processing commonly involves separation and purification stages after splitting, including fatty acid drying, glycerin-water concentration, fractionation, and distillation where required. The selected process depends on the feedstock, desired fatty acid composition, product purity, plant configuration, and operating requirements.
Fatty acid production can use a wide range of natural fats and oils, although commercial production generally relies on a more limited group of major feedstocks. Examples discussed in the report include tallow, coconut and palm kernel oils, soya oil, and tall oil fatty acid sources. Feedstock selection is important because different oils and fats produce different carbon-chain-length distributions. Availability, quality, cost, geographical supply patterns, and the required product composition are important considerations when selecting raw materials.
Equipment requirements depend on the selected process and product specification, but a fatty acid plant may include splitting, de-aeration, drying, fractionation, distillation, storage, utility, and quality-control systems. The report also identifies equipment and supporting facilities such as vacuum distillation plants, boilers, storage tanks, weighing machines, packaging machines, D.G. sets, and laboratory testing equipment. Equipment selection should consider capacity, feedstock characteristics, product purity, energy requirements, safety, automation, maintenance, and applicable standards.
Glycerine recovery and refining convert glycerine-containing process streams into purified glycerine products. The report covers treatment of sweet water, lye treatment, evaporation, continuous finishing, purification, and refining of crude glycerine. Refining can involve operations such as deaeration, distillation, condensation, bleaching, and salt removal. The appropriate sequence depends on the characteristics of the crude glycerine and the required final quality. Effective recovery can improve resource utilization while providing an additional valuable product stream.
Plant location should be selected by evaluating raw-material supply, market access, power and fuel availability, water supply, climate, transportation, waste disposal, labor, regulatory requirements, taxes, site characteristics, community factors, and fire or flood risks. Proximity to major feedstock sources and customers can influence logistics costs and supply reliability. Adequate utilities, transportation infrastructure, environmental-management facilities, suitable land, and compliance with applicable regulations are also important for reliable and sustainable plant operation.
Oleochemical plants require utilities and environmental systems appropriate to their process configuration, including water treatment, steam generation, power supply, and effluent treatment and disposal. Water quality must be controlled according to process requirements, while steam and electrical systems must support production equipment and auxiliary operations. Wastewater and solids may require primary, anaerobic, secondary, or tertiary treatment depending on their characteristics. Environmental systems should be designed to meet applicable discharge standards and ensure safe handling and disposal of process wastes.
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