Detergent Powder Industry

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The raw material storage and delivery unit of detergent powder

The liquid raw materials mainly are straight-chain dodecyl benzene sulfonic acid [LABS], liquid caustic soda and sodium silicate, if using fuel oil as heat source, then there are four kinds of liquid materials.

In general, we need to set up storage tanks that can meet at least 3 to 5 days production dosage: sulfonic acid storage tank, liquid alkali storage tank, sodium silicate tanks, fuel oil tank. Then we will need to set up four kinds of material discharge pump, put the material pump of tank car into storage tank, at the same time also need four kinds of material delivery pump respectively send the sulfonic acid, liquid alkali, sodium silicate, fuel pump to sulfonic acid elevated tank, liquid elevated tank, sodium silicate elevated tank, fuel oil intermediate tank.

The solid raw materials of detergent powder mainly are sodium carbonate, penta-sodium, zeolite and Glauber’s salt, etc., solid raw materials need big enough raw materials warehouse for storage. Solid raw material transportation way usually are the manual conveying of elevator, manual conveying of electrical elevator, and pneumatic conveying of compressed air. The solid material transportation way depends on capacity and production way, adopt manual conveying for small capacity and manual control, adopt pneumatic conveying for large capacity and automatic control. This project quotation sets solid raw materials pneumatic conveying unit.

Measurement unit of detergent powder raw material

Measurement unit of liquid raw material

Liquid raw materials of detergent powder mainly are processed water, liquid alkali, sulfonic acid, sodium silicate, high-molecular polymer etc. Measurement methods of liquid raw materials are manual / Automatic measurement that use glass level gauge, manual measurement that using platform scale or weighing scale and automatic measurement that using weight sensor.

Liquid measurement method is decided by production capacity, production mode and the requirement of owner, automatic measurement method is used for large capacity, automatic control and the high requirement for measurement accuracy.

Measurement unit of solid raw material

Solid materials measurement methods usually are manual measurement and automatic measurement, manual measurement depends on the packaging specifications of solid raw materials

Slurry Preparation Unit

Slurry preparation unit including frontier blending process, filtering process and aging process.

Frontier blending process

Slurry preparation is to add required liquid raw material of detergent powder [such as process water, sodium hydroxide solution, sulfonic acid, sodium silicate, high-molecular polymers, etc.] and solid raw materials [such as sodium carbonate, Penta sodium, zeolite and Glauber’s salt, CMC, etc.] to post preparation tank according to the formula requirement and certain order, under the effect of stirring, mix and compound as detergent powder slurry with certain total solid content and certain temperature. Usually, the addition ingredient order is addition process water, liquid alkali [or solid alkali], sulfonic acid, sodium silicate, Glauber’s salt, sodium carbonate, penta-sodium, zeolite, CMC, etc

Slurry filtration process

Slurry is sent to filtering pot by batching pot through manual or automatic control method, slurry filtration is a very important process in the production process of washing powder, the slurry filtration effect directly affects the normal or abnormal production of detergent powder.

Due to spray tower slurry nozzle aperture is small, larger granule impurities in the slurry will block nozzle and make normal nozzle can’t atomize normally. Impurities that may appear in detergent powder raw materials and rework powder, packaging remaining raw material, and sundries such as iron pin on the wall of equipment can all be brought into the slurry in the pot, therefore the impurities in the slurry must be filtered before the preparation slurry entering the next procedure.

Slurry aging process

Slurry is sent to aging tank by filter sieve through manual or automatic control method, one function of aging slurry is further dissolving granules that are not dissolved in batching pot, mixing evenly to make slurry more delicate, the other function is making buffer time for batching to make production elastic, ensure production run continuously. Aging tank is mainly composed of shell and mixing plant.

Spray drying Unit

Spray drying units include slurry transportation, spray drying, gas stripping, sieve grading process.

The task of slurry transportation process is to grind slurry homogeneously, compress and transport it to slurry nozzle, the slurry transportation ability has a big impact on detergent powder production capacity. The main equipment’s of this process are slurry low pressure pump, magnetic filter, slurry homogeneity pump, high pressure pump, the surge tank. Slurry that comes from aging tank passes [with a strong magnet] magnetic filter and removes iron pin, enters homogeneous pump for homogenizing to make slurry more delicate, then compressed to a certain pressure by high pressure pump pressure to send to nozzle in the spray tower.

The equipment of spray drying processes is primary air fan, burner, secondary air fan, hot blast stove, spray tower, nozzle, tail wind dust extractor, tail gas fan, etc.

Air from primary fan in the hot blast stove burns with fuel to produce high temperature combustion gas, mixed with the cold air from secondary fan to lower the combustion gas temperature to reach a certain temperature, then enters spray tower.

Nozzles and tower sweepers are installed inside the spray tower, the high pressure slurry that comes from high pressure pump turns into small droplets through nozzle atomization, from top to bottom counter currently contacts with the hot air that from bottom to top from the hot blast stove, the water in the small droplets is evaporated, and dried into tiny hollow particles, falls to the bottom of the tower bottom under the effect of gravity, contacts with the cold air and is cooled to a definite temperature, leaves the outlet of tower bottom to the belt conveyor of tower bottom to convey to gas stripping process The tail gas of powder spray tower leaves outlet of tower top enters cyclone dust extractor and bag type dust extractor to remove dust and is discharged into the atmosphere through tail gas fan.

The equipment of gas stripping process usually is gas stripping hopper, sedimentation separator, gas stripping dust remover, gas stripping fan, screening equipment, etc.

The tower powder which comes from the bottom of the tower goes to gas stripping hopper, then is elevated to sedimentation separator by air that with certain flow velocity, the flow velocity of the mixture of air and detergent powder decreased rapidly to the sedimentation speed of detergent powder average granularity, detergent powder falls to the bottom of sedimentation separator under the action of gravity, sedimentation separator leaves top to realize air and detergent powder separation.

Post-blending Unit

To improve the comprehensive performance of detergent powder, we need to add other raw materials, such as perfume, color-enzyme, non-ionic, whitener, TAED, antifoam agent, etc. As these raw materials may vaporize [such as perfume, non-ionic, etc.] and decompose [such as enzyme, whitener, etc.] at high temperatures, can’t be added to slurry in frontier ingredients, can only be added to detergent powder in post blending.

In addition, certain amounts of other raw materials such as sodium carbonate, penta-sodium, Glauber’s salt and zeolite can be added to post blending, it also can improve the finished product production capacity and reduce the production cost of the finished product.

The working process of post blending unit includes qualified base powder storage and measurement, the unqualified base powder storage and measurement, solid raw material storage and measurement, liquid raw material storage and measurement, the mixture of base powder and post blending raw material.

The control method of post blending units are manual control and automatic control, manual control is suitable for small capacity and the not high measuring accuracy project

Finished product powder storage conveying unit

Finished product powder storage conveying unit including finished product warehouse and finished product conveying equipment, finished product conveyor equipment usually uses conveyor belt. To meet the packaging requirements, generally several finished product warehouses and belt conveyors are needed, in this way not only equipment investment becomes larger, but more plant areas are needed

Finished product packaging unit

Finished product small packaging usually adopt to use semi-automatic packaging machine and automatic packing machine, using semi-automatic packaging machine needs to configure the semiautomatic machine.

Due to the different packaging requirements of owners, automatic packaging machines of different brands vary considerably, so we offer a fully automatic packaging line including boxing machines starting from 100 gr up to 25 kg.