Gaseous effluents from a chemical company contain traces of sulphur dioxide, that result in the effluents exceeding the environmental limits. Directing the effluents to a catalytic conversion tower allow for oxidation of sulphur dioxide to SO3, which can be directed to the production. Nevertheless, the hot air from the effluents will be utilized for the reaction.
The drying tower of a detergent production company is running at 50% of its capacity, due to unoptimised operating parameters. Reviewing the operating parameters, particularly the air speed, and running a detailed mass/energy balance on the tower can provide a productivity gain of 20%, saving on material, energy and water.
This company’s production process is exothermic, with huge amount of heat generated during the chemical reaction. Directing this heat to run an absorption chiller can recover the heat into cooling capacity, while reducing the electricity consumption.
Although the slurry reactor is cleaned once a week, it was noted that significant fouling occurs after 2 days of operation, resulting is loss of production. Changing the configuration of the reactor, and the cleaning water setup eliminated the fouling, providing a gain in production.
This detergent production company enhanced the mixing tanks washing process with high pressure water nozzles. Results from this intervention drastically reduced their water consumption for cleaning purposes.
A detergent producing company used an old stretch wrapping machine to protect their products over pallets before storage. As the machine was of an outdated technology, the loss from stretch films was high, adding that a thickness of 23 microns was only suitable to use.
The company purchased and installed new machines equipped with a pre-stretching mechanism. This enabled better stretching before the film was applied on the products and reduced the losses of packaging material by using a 17 microns thickness film.
The company managed to reduce the weight of film per pallet by 40%, from 550g/pallet to 337 g/pallet.