Qazi Engineering Pvt. Ltd., as one of the one of the reputed manufacturers of Soap & Detergent Machinery in India, we take great pride in providing solutions for LABSA (Linear Alkyl Benzene Sulphonic Acid) production facilities.
LABSA, commercially known as Acid Slurry, is produced through a controlled reaction between SO3 (Sulphur Trioxide) and Linear Alkyl Benzene, maintaining concentration and temperature conditions.
Our expertise lies in offering end-to-end solutions for Acid Slurry manufacturing, ensuring efficient and high-quality production processes.
Manufacturing Process of Acid Slurry Plants
The manufacturing process, supported by Acid Slurry Plants by Qazi Engineering Pvt. Ltd., involves a series of carefully controlled steps to ensure efficient and high-quality production. Here is an overview of the Acid Slurry manufacturing process:
Sulphonation Reaction
The primary reaction involved in Acid Slurry production is sulphonation. Sulphuric Acid (H2SO4) is commonly used along with linear alkyl Benzene for sulphonation. This batch process offers the advantage of low capital equipment cost. The reaction between Sulphuric Acid and linear alkyl Benzene occurs under controlled conditions, including temperature and concentration.
Maintaining Reaction Conditions
Sulphonation is a challenging reaction to perform on an industrial scale due to its rapid and highly exothermic nature. It is crucial to control and maintain the required temperature within process limits to avoid darkening of the final product. Qazi Engineering’s Acid Slurry Plants are designed to ensure precise control over the reaction conditions, utilising advanced dispersion techniques and automation.
Viscosity Control
During the reaction, the viscosity of the reactants increases significantly, ranging from 15 to 300 times as the organic feedstock is converted to Sulphonic acid. This substantial increase in viscosity makes heat removal challenging. Qazi Engineering’s acid slurry manufacturing plants are equipped with efficient cooling systems to effectively manage heat transfer and control the viscosity of the reaction mass.
Cooling and Heat Transfer
Effective cooling of the reaction mass is essential because high temperatures promote side reactions that can produce undesirable byproducts. Qazi Engineering incorporates advanced cooling mechanisms in Acid Slurry manufacturing Plants to ensure efficient heat transfer and maintain optimal reaction conditions. These systems are designed to prevent overheating and minimise the formation of unwanted compounds.
Waste Acid Separation
After the completion of the sulphonation reaction, waste acid is separated from the reaction mixture. Qazi Engineering’s Acid Slurry making machines include provisions for the separation and disposal of waste acid, ensuring environmental compliance and safe handling of byproducts.
Automation and Control
Qazi Engineering’s Acid Slurry manufacturing plants are equipped with state-of-the-art automation and control systems. These systems enable precise monitoring and adjustment of process parameters, ensuring consistent product quality and efficient operation. Automation control, including PLC/SCADA systems, helps in maintaining optimal conditions, enhancing productivity, and minimising manual intervention.
Applications of LABSA
LABSA finds applications in various industries. Some of the main applications include:
1. Synthetic Detergent Industries
LABSA serves as a crucial intermediate raw material in synthetic detergents. It acts as a surfactant, providing excellent cleaning and foaming properties to the detergents. LABSA helps in removing dirt, grease, and stains effectively, making it an essential ingredient in laundry detergents, dishwashing liquids, and other cleaning products.
2. Anionic Specialty Formulations
LABSA is extensively used in the formulation of anionic specialty products. These products include industrial cleaners, degreasers, automotive shampoos, household cleaners, and personal care products. LABSA contributes to the excellent cleaning and emulsifying properties of these formulations.
3. Textile Industries
In the textile industry, LABSA finds applications as a mercerizing or washing agent. Mercerization is a process used to enhance the strength, lustre, and dye affinity of cotton fibres. LABSA is employed as a key ingredient in mercerizing agents, which improve the quality and appearance of cotton fabrics. Additionally, LABSA is used as a merchandising or washing agent in textile processing to remove impurities and enhance the fabric cleanliness.
4. Manufacturers of Alums & Superphosphate Fertilisers
LABSA generated a valuable byproduct called Spent sulphuric acid. This spent acid is utilised by manufacturers of alums and superphosphate fertilisers. Alums are used in water treatment processes, while superphosphate fertilisers are essential for agricultural purposes. The byproduct utilisation ensures sustainable production practices and reduces waste.
5. Other Industrial Applications
LABSA finds use in several other industries and applications. It is employed in the formulation of household cleaners, industrial degreasers, metal cleaners, and various specialty chemicals. LABSA’s ability to effectively remove dirt, oils, and stains makes it a preferred ingredient in such products.
Advantages of Qazi Engineering Pvt. Ltd.'s Acid Slurry Plants
Qazi Engineering Pvt. Ltd. takes pride in offering Acid Slurry making machines that are designed and engineered with precision, incorporating advanced technologies and safety features. Here are the advantages of Qazi Engineering’s Acid Slurry Manufacturing Plants:
Efficient Production
Our LABSA Manufacturing Plants are highly efficient, ensuring optimal production processes. The plants are designed to maximise productivity, minimise downtime, and enhance overall operational efficiency. With our state-of-the-art engineering, these plants facilitate the smooth and continuous production of Acid Slurry.
Highest Safety Standards
Qazi Engineering prioritises safety in all aspects of plant design and operation. Our Acid Slurry making machines are equipped with the highest safety operating systems to ensure a secure working environment. The plants adhere to industry standards and regulations, minimising the risks associated with the production process. Safety measures are incorporated at every stage, from equipment design to automation control, to protect both the personnel and the surrounding environment.
Customised Solutions
Qazi Engineering understands that each customer’s requirements may vary. Therefore, Our LABSA Manufacturing Plants are designed to offer flexibility and customization options. The plants can be tailored to meet specific capacity needs, ranging from semi-automatic to fully automatic, with capacities ranging from 1 ton per hour to 10 tons per hour. This allows customers to choose the most suitable configuration that aligns with their production goals and resources.
Advanced Automation
Qazi’s LABSA Manufacturing Plants are equipped with advanced automation and control systems. These systems, such as PLC/SCADA, provide precise monitoring and control over process parameters. Automation ensures consistency in production, reduces manual intervention, and improves overall operational efficiency. Our plants are designed to optimise the manufacturing process by maintaining desired parameters, enhancing product quality, and minimising human errors.
Expertise and Training
Qazi Engineering offers expertise and training support to its customers. Our team of expert engineers provides comprehensive manufacturing training, assisting customers in setting up the production process with ease. This ensures a smooth transition and helps customers maximise the benefits of Qazi’s LABSA Manufacturing Plants.
Range of Plant Options
Qazi Engineering provides a range of Acid Slurry Manufacturing Plant options to suit different production needs. Customers can choose from a variety of plant types, including LABSA Manufacturing Plants, film sulfonation plants, and continuous sulfonation plants. This wide range allows customers to select the most suitable plant configuration based on their specific requirements.
Get to Know Our Team
Qazi Engineering Pvt. Ltd. believes that the strength of our company lies in the expertise and dedication of our team members. With over decades of experience in the engineering industry, our team members lead our Acid Slurry Manufacturing Plants division with their vast knowledge and technical expertise. They ensure that the production process meets the highest standards of efficiency and quality. Their attention to detail and commitment to continuous improvement drive our plants’ exceptional performance.
Frequently Asked Questions
LABSA, also known as Acid Slurry, is produced through a controlled reaction between Sulphur Trioxide (SO3) and Linear Alkyl Benzene, used in the production of synthetic detergents and various other applications.
The manufacturing process involves sulphonation, where Sulphuric Acid and Linear Alkyl Benzene react under controlled conditions of temperature and concentration to produce Acid Slurry.
Qazi Engineering’s Acid Slurry Plants are designed with advanced dispersion techniques and automation to control and maintain reaction conditions, ensuring efficient production processes.
Qazi Engineering’s LABSA manufacturing plants are equipped with efficient cooling systems to manage heat transfer and control the viscosity of the reaction mass.
Qazi Engineering incorporates advanced cooling mechanisms in Acid Slurry manufacturing plants to ensure efficient heat transfer and prevent overheating, minimizing the formation of unwanted compounds.
Qazi Engineering’s Acid Slurry making machines include provisions for the separation and disposal of waste acid, ensuring environmental compliance and safe handling of byproducts.
Qazi Engineering’s LABSA Manufacturing Plants offer efficient production, highest safety standards, customization options, advanced automation, expertise and training support, and a range of plant options to suit different production needs.
LABSA finds applications in synthetic detergent industries, anionic specialty formulations, textile industries, manufacturers of alums and superphosphate fertilisers, and various other industries.
LABSA acts as a surfactant in synthetic detergents, providing excellent cleaning and foaming properties, making it an essential ingredient in laundry detergents, dishwashing liquids, and other cleaning products.
Qazi Engineering’s team members have decades of experience in the engineering industry and lead the Acid Slurry Manufacturing Plants division, ensuring high standards of efficiency and quality in the production process.