Bangladesh University of

Engineering and
Technology

Term Paper on
LABSA Manufacturing
Industry
 BANGLADESH UNIVERSITY OF ENGINEERING AND TECHNOLOGY

Term Paper on
LABSA Manufacturing Industry
Course No.: ChE 308
Course Name: Chemical Process Analysis
Submitted by

1902056 - Prottasha Debnath

Title Page
1902057 - Umma Hany Nawrin

1902058 - Md. Mizanur Rahman

1902059 - Samiul Haque

1902060 - Swarnila Chakma

Level / Term : L-3 / T-1

Group : 06 (A2)

Submitted to

Dr. Md. Shahinoor Islam Kaniz Fatema

Professor Assistant Professor
Department of Chemical Engineering Department of Chemical Engineering
BUET BUET

Zarin Tasnim Juthi Tanzim Ur Rahman

Lecturer Lecturer
Department of Chemical Engineering Department of Chemical Engineering
BUET BUET
Hridoy Roy
Adjunct Lecturer
Department of Chemical Engineering
BUET

ii
Statement of Academic Integrity
We, the students of group 06, confirm that this report is entirely our own work, with no
unapproved help or resources used. Except for the bits that are completely documented
and directly drawn from theoretical notions, all the texts and pictures are our own effort.
We understand what plagiarism is and what the implications are. We further accept that
if any disobedience of the ethical norms demanded by BUET from its student body is
discovered in our work, our professor will pursue the academic dishonesty processes
established by the Department of Chemical Engineering, BUET.

1902056- Prottasha Debnath

1902057- Umma Hany Nawrin
1902058- Md. Mizanur Rahman
1902059- Samiul Haque
1902060- Swarnila Chakma
Department of Chemical Engineering
Bangladesh University of Engineering and Technology

iii
Abstract
Linear alkyl benzene sulphonic acid (LABSA) is a commonly used key component in
the production of different types of washing agents, emulsifiers, wetting agents, and
agricultural herbicides. LABSA is produced by sulfonating linear alkylbenzene (LAB)
with sulfuric acid, resulting in a highly soluble liquid that effectively emulsifies oil and
grease for cleaning purposes. The Asia-Pacific region, particularly China, is the largest
consumer and producer of LABSA, with increasing demand for household and
industrial cleaning products in emerging economies driving the global LABSA market
growth. However, concerns have been raised regarding the environmental impacts of
LABSA production and use, including highly acidic wastewater and foam formation in
water bodies that can harm aquatic life. Proper disposal and treatment of wastewater
are crucial to minimize these impacts. Moreover, LABSA poses health hazards if
ingested, inhaled, or comes in contact with skin or eyes, requiring proper handling
procedures and safety measures during manufacturing, storage, and transportation.
Despite its cost-effectiveness, versatility, and good detergent properties, careful
management of LABSA production and use is essential to minimize environmental and
health risks.

iv
Acknowledgement
The term paper is based on LABSA Manufacturing Industry as assigned to us by our
respected teachers, a group of five members. This work is associated with the sessional
course CHE308-Chemical Process Analysis. We would like to express our sincere
gratitude to our respected teachers Department of Chemical Engineering, BUET, Dr.
Md. Shahinoor Islam, Professor, Department of Chemical Engineering, BUET, Kaniz
Fatema, Assistant Professor, Department of Chemical Engineering, BUET, Zarin
Tasnim Juthi, Lecturer, Department of Chemical Engineering, BUET, Tanzim Ur
Rahman, Lecturer, Department of Chemical Engineering, BUET, Hridoy Roy, Adjunct
Lecturer, Department of Chemical Engineering, BUET, for their continuous guidance,
constructive suggestions, sincere co-operation, and constant encouragement. It was
their constructive instructions and discussions which made us able to write this term
paper.

We are also grateful to the industrial resources for their support throughout the research
process. These are the main foundation that made this project possible. Without the
contributions of these individuals and organizations, this report would not have been
possible.

1902056 - Prottasha Debnath

1902057 - Umma Hany Nawrin
1902058 - Md. Mizanur Rahman
1902059 - Samiul Haque
1902060 - Swarnila Chakma
Department of Chemical Engineering
Bangladesh University of Engineering and Technology

v
Table of Contents

Title Page .......................................................................................................................ii

Statement of Academic Integrity ................................................................................. iii
Abstract ......................................................................................................................... iv
Acknowledgement ......................................................................................................... v
Table of Contents .......................................................................................................... vi
List of Tables ............................................................................................................. viii
List of figures ................................................................................................................ ix
1. Introduction ................................................................................................................ 1
2. Importance of LABSA ............................................................................................... 2
3. Properties of LABSA ................................................................................................. 3
3.1. Physical Properties .............................................................................................. 3
3.2. Chemical Properties ............................................................................................ 3
4. Process description..................................................................................................... 5
4.1. Raw materials ...................................................................................................... 5
4.2. Process ................................................................................................................. 5
4.3. Process Block Diagram ....................................................................................... 8
5. Material Balances....................................................................................................... 9
6. Energy Balances....................................................................................................... 13
7. Market Analysis ....................................................................................................... 18
7.1. LABSA Industries in Bangladesh ......................................................................... 18
7.2. Production and Importation in Bangladesh ....................................................... 18
7.3. LABSA Production in the World ...................................................................... 18
7.4. Global Market ................................................................................................... 19
7.5. Market Segmentation ........................................................................................ 19
7.6. Product Diversification ..................................................................................... 20
8. Wastes and Waste Treatment of LABSA Industry .................................................. 22
8.1. Wastes of LABSA Industry............................................................................... 22
8.2. Waste Treatment Management.......................................................................... 23
8.2.1. Effluent Treatment Plant ............................................................................ 23
8.2.2. Solid Waste Management ........................................................................... 24
8.2.3. Recycling and Reuse .................................................................................. 24

vi
 6.2.4. Pollution Prevention ................................................................................... 24
9. Environment Management during Construction ...................................................... 24
Conclusion ................................................................................................................... 27
References .................................................................................................................... 28
Nomenclature ............................................................................................................... 29
Workload Distribution ................................................................................................. 30

vii
List of Tables
Table 1 Specific heat capacities of the components involved ..................................... 13
Table 2 Table for enthalpies of inlet and outlet streams of oxidizer ........................... 14
Table 3 Table for enthalpies of inlet and outlet streams of catalytic convertor ........... 15
Table 4 Table for enthalpies of inlet and outlet streams of sulphonator ...................... 16
Table 5 Table for enthalpies of inlet and outlet streams of aging tank ........................ 17

viii
List of figures
Figure 1 Molecular structure of LABSA ....................................................................... 3
Figure 2 Process Block Diagram ................................................................................... 8
Figure 3 Estimation of worldwide production of LABSA........................................... 19
Figure 4 Effluent treatment plant ................................................................................. 23

ix
1. Introduction
Linear alkyl benzene sulfonic acid, also known as LABSA, is a synthetic chemical
surfactant, a widely used industrial detergent. It is one of the largest synthetic
surfactants by volume due to its low cost and high performance. This chemical is
biodegradable and environmentally friendly. It is an anionic surfactant with molecules
from a hydrophilic and hydrophobic group synthesized through sulphonation. The
chemical and physical properties of LABSA differ based on the length of the alkyl
chain. It is used as an emulsifier and as a wetting agent. It is a highly usable synthetic
surfactant due to its relatively low cost and good performance. Its straight chemical
chain makes it biodegradable, adding to the environmental consciousness factor.
Compared with some competitive surfactants with greater complex water tolerance and
better compatibility with enzymes, LABSA is usually preferred for its affordability and
favorable physical and chemical properties. Its main application lies in the production
of household detergents including laundry powders, laundry liquids, dishwashing
liquids and other household cleaners. Besides these, there are numerous industrial
applications like coupling agents and emulsifiers for agricultural herbicides and
emulsion polymerization exist.

1
2. Importance of LABSA
Linear alkylbenzene sulfonate, which includes the various salts of sulfonated
alkylbenzenes, is widely used in household detergents as well as in numerous industrial
applications. Linear alkylbenzene sulfonate was made as a biodegradable replacement
for nonlinear (branched) alkylbenzene sulfonate (BAS). It has mostly replaced BAS in
household detergents around the world.[1] Very small volumes are also used in personal
care applications. LABSA is chiefly used in the detergent industry to manufacture
washing powder, detergent powder, detergent cake, liquid soap, oil soap, scouring bars
and cleaning powder. This chemical finds applications in anionic specialty
formulations. The quality of pesticide sprays can be improved from it. Linear alkyl
benzene sulphonic acid is used as a washing and mercerizing agent in the textile
industry. LABSA is used to increase the surface area of distempers. Industrial,
institutional, and commercial cleaners account for most other applications. However,
LAS is also used as an emulsifier (e.g., for agricultural herbicides and in emulsions).
polymerization), and as a wetting agent in small quantities along with other surfactants
(e.g., for the formation of foam in toilet soaps). [2] Owing to its high active matter
content and miscibility with low salt content and water, LABSA is used in the
polymerization of emulsions and the production of coupling agents, emulsifiers,
agricultural herbicides, household and industrial cleaners.

2
3. Properties of LABSA
3.1. Physical Properties
LABSA is brownish liquid in physical state. Its melting point is 10˚C and boiling point
is 315˚C. Its specific gravity is 1.2.[3] Its IUPAC name is 4-dodecan-
3ylbenzenesulphonic acid. It is nonvolatile and viscous in nature. LABSA is an anionic
surfactant with molecules belonging to a hydrophilic and hydrophobic group,
synthesized through the process of sulphonation. It is a strong and highly corrosive
agent compared to other acids such as acetic acid and benzoic acid. As a non-oxidizing
agent, it dissolves easily in water. The substance is one of the most important substances
in detergents, which is used in polar and non-polar and has good properties in creating
foams, removing stains and cleaning. They are nonvolatile compounds produced by
sulfonation. Linear alkyl benzene sulfonic acid are complex mixtures of
homologues of different alkyl chain lengths (C10 to C13 or C14) and phen yl
positional isomers of 2 to 5-phenyl in proportions dictated by the starting
materials and reaction conditions, each containing an aromatic ring sulfonated at
the para position and attached to a linear alkyl chain at any position with the
exception of terminal one (1-phenyl). [4] LAS toxicity depends on the length of the
alkyl chain and the position of the aromatic ring in it. LAS with longer alkyl chain is
more toxic. Moreover, LASs become more toxic as the aromatic ring is positioned
further to the edge of the chain. [5]

Figure 1 Molecular structure of LABSA

3.2. Chemical Properties

LABSA is manufactured by reacting benzene with sulphonating agents like oleum, SO3
or sulphuric acid. First, the raw material linear alkyl benzene (LAB) is produced by the

3
reaction of benzene with alkyl halide in the presence of catalyst aluminum chloride
through the process of Friedel Crafts Alkylation.[6]

The next reactions involving the each of the manufacturing processes of LABSA from

LAB are given below in simpler terms:

The major chemical properties of LABSA are detergency, foaming, moistening and
emulsion. It is partially soluble in water but well solubilized in alcohol, glycol ether,
ester, ketone, aromatic and aliphatic hydrocarbons. It has strong absorbent capacity,
and it becomes an unclear viscous liquid after absorbing water. It is non-flammable in
nature. With increasing amount of acidity, it becomes a brown viscous fluid in
appearance. Its flash point is 149 ˚C. The range of its pH is 2-3. [7]

4
4. Process description
4.1. Raw materials
To produce liner alkyl benzene sulphonic acid, Sulfur tri oxide and LAB (Liner Alkyl
Benzene) are needed. Sulfur tri oxide is made up of Sulfur and Oxygen. So naturally
the sources which are rich in these elemental compositions are chosen for the task of
production of LABSA.

Sulfur: Sulfur is one of the most common chemical elements found in nature. It is a
pale yellow, tasteless, and odorless brittle solid commonly found in volcanic regions
and hot springs. Nowadays very little sulfur is mined from nature, as most of the
production is recovered due to environmental reasons. Sulphur also can be obtained
from petroleum desulphurization. Byproduct elemental sulfur recovered from natural
gas and petroleum is the main source of sulfur worldwide.

LAB: Benzene + alkyl halides = Alkyl Benzene

LAB with appropriate chain length is predominantly used as a raw material in the
manufacture of Linear Alkyl Benzene Sulphonic Acid (LABSA) by reaction with sulfur
trioxide in the gaseous phase.

Industry by their own can produce LAB and then use it to produce LABSA or they can
purchase LAB as raw materials from outside. Some LAB supplier company in
Bangladesh are P.T. Consumer Product Industries, Linear International Ltd, Orange
Hub and so on.

4.2. Process
The steps of LABSA production are:
1. Air compression & drying
2. Sulphur melting
3. SO2 production
4. SO3 production
5. Ageing
6. Effluent treatment.
Air compression and drying section
The process air is sucked from the atmosphere and the air is filtered by using filter to
remove the dust particles present in the air. The entering temperature of the air will be

5
at room temperature and after filtering the temp of the air will reduce close to 27°C.
After filtering the air must be cooled. The air is cooled in the pre cooler. After cooling,
the cooled air is compressed in compressor. Due to the high pressure developed in the
compressor the temperature of the air will increase to 80°C and then the air is sent to
heat exchanger.

Heat Exchanger & Hydro cyclone

The compressed air is once again cooled by using the heat exchanger. In heat exchanger
the air is cooled by using water as cooling agent. Since the dew point of the air is 19°C
some fraction of water in the air gets condensed.

In hydro cyclone due to the centrifugal action most of the water from air get separated,
nearly 80%. The moisture collected can be drained at regular intervals. Drained water
will pump to cooling water for maximum utilization of chillness.

Adsorption Tower
The air is subjected adsorption tower, where actuated alumina is used as an adsorbing
agent. Here 99.5% of the remaining water in the air gets removed. The heated air is then
subjected to SO2 production.

Sulphur Melting
The Rhombic form or Sulphur is melted using steam in heating coils. The melting point
Sulphur is 116°C and so about 200°C of steam is subjected. This molten Sulphur is
subjected to the oven.

Oxidizer
The oxidizer used is lined with fire bricks. Once the molten sulfur and process air
subjected. The mixture is ignited. The molten sulfur burns as blue flame thereby
producing SO2. The reaction temperature maintained at the oven is about 720°C the
SO2 formed is cooled in the heat exchanger. About 92% conversion is achieved here
and it is an exothermic reaction.

S + O2 SO2

Fixed Bed Catalytic Convertor

The oxidation of sulfur dioxide is exothermic reaction. To maintain a considerable
forward reaction and high conversion of sulfur dioxide, temperature of 430º C to 550ºC
and 1atm-2atm pressure is maintained throughout the convertor.

6
 SO2 + 0.5O2 SO3

The SO3 production section, the fixed bed catalyst converter contains four beds of
vanadium pentoxide (V2O5) catalyst. Overall, almost 98% archives here.

Falling Film Sulphonating Reactor

The sulfonator for the production of LABSA from LAB and SO3 if of special type.
Falling film sulfonator which contains about 40 tubes is used, in which a thin film of
linear alkyl benzene (LAB) is subjected over which proportional amount of Barrier air
is subjected and then SO3- air mixture is subjected. The purpose of barrier air to stop
the reaction is to stop the reaction between the reactants for few seconds at the initial
stage. The reaction taking place is,

SO3 + C12H25 C18H29SO3H

In the sulfonator being the residence time of reactants is very low and so only 80%
conversion is achieved. The exit stream for sulfonator is directly subjected to ageing
tank.

Ageing Tank
Ageing tank is nothing but a jacketed vessel with agitator. Here unconverted LAB and
SO3 air mixture is reacted. Here about 10% conversions achieved. LABSA formed is
hydrolyzed in hydrolysis tank by water in hydrolysis tank by water to stop the reaction.

Effluent Treatment
The major effluent from the plant is Oleum and exhaust gas from the sulfonator. The
oleum from is sent to the scrubber where it is treated with NaOH for neutralization. The
neutralized product is sent into the solar pond and into the solar pond and allowed for
solar evaporation. The exhaust gas from the sulfonator is sent to the Electrostatic
Precipitator (ESP). Several electrodes relate to each electrode. The positively charged
ions are attracted by the anode and the negatively charged ions are attracted by the
cathode thereby the exhaust gas gets free from solids arc sent to the scrubber.

7
 4.3. Process Block Diagram

8
Figure 2 Process Block Diagram
5. Material Balances
Air Cooler and Hydro-cyclone
Air temperature is reduced from 80℃ to 10℃ through a heat exchanger using cooling
water.

35249.5 kg/day Wet Air

34799.85 kg/day Wet air
Air cooler &
499.46 kg/day H2O
Hydro-cyclone 34770.47 kg/day DA
29.38 kg/day H2O

449.51 kg/day H2O

As the dew point of wet air is 19℃, at 10℃ some of the water gets condensed. Here,
in the air cooler and hydro-cyclone at 10℃, 90% of the water in inlet gets condensed.
Abs. humidity at 80℃ dry bulb and 19℃ dew point = 0.014 kg H2 O/kg DA [8]
0.014
= 1+0.014 kg H2 O/kg wet air

Water content = 35249 × 0.0138 = 499.46 kg/day

Amount of air gets condensed = 499.46 × 0.9 = 449.51 kg/day
Amount of water in outlet = 499.46 − 470.08 = 29.38 kg/day
Air in outlet = 35249.50 − 449.51 = 34799.85 kg/day

Adsorber
34799.85 kg/day Wet air 34750.14 kg/day wet air
Adsorber
34770.47 kg/day DA 34749.89 kg/day DA
29.38 kg/day H2O 0.25 kg/day H2O

Here 99.5% of the remaining water gets adsorbed.

Amount of water adsorbed = 29.38 × 0.995 = 49.70 kg/day
Amount of wet air in outlet = 34799.85 − 49.70 = 34750.15 kg/day
Amount of water in outlet = 15.35 − 15.20 = 0.25 kg/day
0.25 kg/day of water is present in 34749.89 kg/day dry air.

9
Oxidizer

34750.14 kg/day wet

air
8052.2 kg/day O2
26505.1 kg/day N2
10009.6 kg/day SO2
0.25 kg/day H2O Oxidizer 435.2 kg/day S
(92% conversion of S)
3047.49 kg/day O2
26505.1 kg N2

5440 kg/day S 0.25 kg H2O

Amount of sulphur at inlet = 5440 kg/day = 170 kmoles/day

Moles of oxygen required = 170 kmoles/day
Assume 20% excess oxygen required = 170 × 1.2 × 32 = 6528 kg/day
100
Amount of air actually requires = 6528 × = 28382.61 kg/day
23

Amount of air at inlet = 34750.14 kg/day

Amount of sulphur in outlet = 0.08 × 170 × 32 = 435.2 kg/day
Amount of oxygen reacted = 0.92 × 170 × 32 = 126.89 kg/day
Amount of oxygen in outlet = 8052.2 − 5004.8 = 2940.38 kg/day
Amount of SO2 in outlet = 0.92 × 170 × 64 = 10009.6 kg/day

Fixed Bed Catalytic Converter

10009.60 kg/day SO2 (g) 12261.76 kg/day SO3

3047.49 kg/day O2 (g) 200.20 kg/day SO2 (g)

Catalytic Converter
(98% conversion of 595.14 kg/day O2 (g)
435.20 kg/day S(g)
SO3)
26506.10 kg/day N2 (g) 435.20 kg/day S(g)

0.25 kg/day H2O (v) 26506.10 kg/day N2 (g)

0.25 kg/day H2O (v)

Reaction: SO2 (l) + 1/2 O2 SO3 (g)

10
Amount SO2 in inlet = 10009.60 kg/day = 156.40 kmoles/day
Amount of SO2 reacted = 156.4 × 0.98 = 153.27 kmoles/day
= 9809.41 kg/day
Amount of oxygen reacted = 153.27 ∗ 0.5 kmoles⁄day = 76.64 kmoles⁄day
= 2452.32 kg/day
Amount of SO3 in outlet = 153.27 kmoles/day = 12261.76 kg/day
Amount of SO2 in outlet = 10009.60 − 9809.41 = 200.20 kg/day
Amount of oxygen in outlet = 3047.49 − 2452.32 = 595.14 kg/day

Seperator

12261.76 kg/day SO3 200.20 kg/day SO2

200.20 kg/day SO2 595.14 kg/day O2

Separator
595.14 kg/day O2 26506.10 kg/day N2

435.20 kg/day S 0.25 kg/day H2O

26506.10 kg/day N2

0.25 kg/day H2O

435.20 kg/day S 12261.76 kg/day SO3

Sulphonator

12261.76 kg/day SO3

Sulphonator
(80% conversion of SO3) 39973.34 kg/day LABSA
3292.07 kg/day LAB
33456 kg/day LAB 2452.35 SO3

11
Reaction: C18H30 + SO3 (g) C18H29SO3H
12261.76
Amount of SO3 in inlet = 12261.76 kg/day = kmoles/day
80

= 153.27 kmoles/day
33456
Amount of LAB in inlet = 33456 kg/day = kmoles/day
246

= 136 kmoles/day
Amount of SO3 reacted = 0.8 × 153.27 × 80 = 9809.41 kg/day
Amount of LAB reacted = 0.8 × 153.27 × 246 = 30163.54 kg/day
Amount of LABSA formed = 0.8 × 153.7 × 326 = 39973.34 kg/day
Amount of SO3 in outlet = 12261.76 − 9809.41 = 53.55 kg/day
Amount of LAB in outlet = 33456 − 30163.54 = 3292.07 kg/day

Aging Tank

Aging Tank
39973.34 kg/day LABSA (10% conversion of SO3) 40973 kg/day LABSA
2452.35 kg/day SO3 27.57 kg/day SO3
3292.07 kg/day LAB 2537 kg/day LAB

Reaction: C18H30 + SO3 (g) C18H29SO3H

Amount of LABSA at inlet = 39973.34 kg/day

2452.35
Amount of SO3 at inlet = 2452.35 kg/day = kmoles/day
80

= 30.65 kmoles/day
Amount of LAB at inlet = 3292.07 kg/day
Amount of SO3 reacted = 0.1 × 30.65 × 80 = 245.24 kg/day
Amount of LAB reacted = 0.1 × 30.65 × 246 = 754.00 kg/day
Amount of LABSA formed = 0.1 × 30.65 × 326 = 999.60 kg/day
Amount of LABSA in outlet = 999.60 + 39973.34 = 40973 kg/day
Amount of SO3 in outlet = 2452.35 − 245.24 = 2207.11 kg/day
Amount of LAB in outlet = 3292.07 − 754 = 2538 kg/day

12
6. Energy Balances
Table 1 Specific heat capacities of the components involved [9]

Species Specific heat capacities, CP (kJ/kg℃)

O2 1.07

N2 1.04

S (l) 1.265

S (g) 0.672

SO2 (g) 1.695

SO3 (g) 0.62

SO3 (l) [3] 3.725

H2O (l) 4.2

H2O (v) 1.9

LAB 3.07

LABSA 4.2

Oxidizer

8052.2 kg/day O2 (g)

26505.10 kg/day N2 (g)
0.25 kg kg/day H2O (l)
@10℃ 10009.6 kg/day SO2 (g)
Oxidizer 435.2 kg/day S(g)
3047.49 kg/day O2 (g)

5440 kg/day S (l) 26505.1 kg N2 (g)

@ 700℃ 0.25 kg H2O (g)

@ 700℃

Reaction: S (l) + O2 (g) SO2 (g) ΔHro = -4640 kJ/kg [10]

Reference: At 25℃

13
Table 2 Table for enthalpies of inlet and outlet streams of oxidizer

min Tin Hin mout Tout Hout

Components
(kg/day) (℃) (kJ/kg) (kg/day) (℃) (kg/day)

S(l) 5440 200 221.38 - - -

S(g) - - - 435.20 700 453.60

O2 8052.20 10 -13.77 3047.49 700 619.65

N2 26505.10 10 -15.60 26505.10 700 650.00

SO2 - - - 10009.60 700 1059.37

H2O (l) 0.25 10 -63.00 - - -

H2O (v) - - - 0.25 700 1282.50

Σ min.Hin = 679933.10 kJ/day Σ mout.Hout = 29918287.47 kJ/day

Q = ξ. ΔHro + Σ mout . Hout − Σ min . Hin

= (5440 − 435.2) × (−4640) + 29918287.47 − 679933.10 kJ/day
= 6016083.19 kJ/day
= 69.63 kW
Q = 69.63 kW

Fixed Bed Catalytic Converter

10009.60 kg/day SO2 (g) 12261.76 kg/day SO3

3047.49 kg/day O2 (g) 200.20 kg/day SO2 (g)

Catalytic Bed
435.20 kg/day S(g) (98% conversion of S) 595.14 kg/day O2 (g)

26506.10 kg/day N2 (g) 435.20 kg/day S(g)

0.25 kg/day H2O (v) 26506.10 kg/day N2 (g)

@ 440 ℃ 0.25 kg/day H2O (v)

@ 600 ℃

Reaction: SO2 (l) + 1/2 O2 (g) SO3 (g) ΔHro = -1250 kJ/kg SO3

14
Reference: At 25℃
Table 3 Table for enthalpies of inlet and outlet streams of fixed bed catalytic convertor

Inlet (440 ℃) Outlet (470 ℃)

Components
min (kg/day) Hin (kJ/kg) mout (kg/day) Hout (kg/day)

SO2 (g) 10009.60 703.43 200.20 754

SO3 (g) - - 12261.76 275.90

O2 (g) 3047.49 278.88 595.14 299.04

S (g) 435.20 380.97 435.20 408.51

N2 (g) 26506.10 431.6 26506.10 462.80

H2O (v) 0.25 788.5 0.25 845.50

Σ min.Hin = 19752802.46 kJ/day Σ mout.Hout = 17132497.17 kJ/day

Q = ξ. ΔHro + Σ mout . Hout − Σ min . Hin

= 12261.76 × (−1250) + 17132497.17 − 19752802.46 kJ/day
= −17947505.29 kJ/day
= −207.73 kW
Q = −207.73 kW

Sulphonator

12261.76 kg/day SO3 (g)

@ 50℃ Sulphonator
(80% conversion SO3) 39973.34 kg/day LABSA
3292.07 kg/day LAB
2452.35 SO3

33456 kg/day @ 50℃

LAB
@ 50℃

Reaction: LAB+ SO3 LABSA ΔHro = 2092 kJ/kg SO3

(g)

15
Reference: At 25℃
Table 4 Table for enthalpies of inlet and outlet streams of sulphonator

Components Inlet (50℃) Outlet (50℃)

min (kg/day) Hin (kJ/kg) mout (kg/day) Hout (kg/day)

SO3 12261.76 15.5 3292.07 93.43

LAB 33456 76.75 39973.34 15.5

LABSA - - 2452.35 105

Σ min.Hin = 3087340.08 kJ/day Σ mout.Hout = 3633045.15 kJ/day

Q = ξ. ΔHro + Σ mout . Hout − Σ min . Hin

= (12261.76 − 3292.07) × 2092 + 3633045.15 − 3087340.08 kJ/day
= 19310296 kJ/day
= 223.50 kW
Q = 223.50 kW

Aging Tank

Aging Tank
39973.34 kg/day LABSA 40973 kg/day LABSA
(10% conversion of SO3
2452.35 kg/day SO3 (l) 2537 kg/day LAB
3292.07 LAB 27.57 kg/day SO3 (l)
@40℃ @30℃

Reaction: LAB + SO3 (g) LABSA ΔHro = 2092 kJ/kg SO3

Reference: At 25℃

16
Table 5 Table for enthalpies of inlet and outlet streams of aging tank

Components Inlet (40℃) Outlet (30℃)

min (kg/day) Hin (kJ/kg) mout (kg/day) Hout (kg/day)

SO3 2452.35 55.875 27.57 18.625

LAB 3292.07 16.05 2537.13 15.35

LABSA 39973.34 63.00 40973 21.00

Σ min.Hin = 2708183.20 kJ/day Σ mout.Hout = 899891.45 kJ/day

Q = ξ. ΔHro + Σ mout . Hout − Σ min . Hin

= (2452.35 − 27.57) × 2092 + 899891.45 − 2708183.20 kJ/day
= 3263615.81 kJ/day
= 37.77 kW
Q = 37.77 kW

17
7. Market Analysis
7.1. LABSA Industries in Bangladesh
The chemical industry in Bangladesh has been growing steadily in recent years, with a
focus on the production of basic chemicals. Bangladesh has some small manufacturers,
but the country mainly relies on imported LABSA for the production of detergents and
cleaning products. Demand for his LABSA is increasing in Bangladesh due to the
growth of the detergents and cleaners’ industry. There are a few small-scale producers
of LABSA in Bangladesh. These companies are some of the major LABSA
manufacturers in Bangladesh
● Bengal Fine Chemicals
● MHC Chem
● Sai Chemicals
● Silver Line Group
● Zaman Group

7.2. Production and Importation in Bangladesh

According to a report by the Bangladesh Tariff Commission, the estimated demand for
LABSA in Bangladesh was around 240,000 metric tons per year as of 2020. the
domestic production of LABSA in Bangladesh was estimated to be around 200,000
metric tons per year as of 2020.[11] Additionally, LABSA production in Bangladesh,
as in any other country, may be affected by various factors such as changes in demand,
raw material availability, and government regulations, among others. Based on the data
provided by the Bangladesh Tariff Commission, the import of Linear Alkylbenzene
Sulfonic Acid (LABSA) into Bangladesh was approximately 0.374 million metric tons
in the fiscal year 2020-2021.China and India are the two largest exporters of LABSA
to Bangladesh. Bangladesh exported only USD 24,000 worth of LABSA in the year
2020. This indicates that LABSA exports from Bangladesh are negligible compared to
its imports.

7.3. LABSA Production in the World

According to market research reports, the global production of LABSA was estimated
to be around 3.2 million metric tons in 2020, and it is expected to reach 3.8 million
metric tons by 2028, growing at a CAGR of 2.3% from 2021 to 2028. The production
of LABSA is concentrated in Asia Pacific, particularly in China and India, which are

18
 Figure 3 Estimation of worldwide production of LABSA [12]

the largest producers and consumers of LABSA in the world. Other regions such as
North America, Europe, and the Middle East and Africa also have significant
production capacities for LABSA, but they account for a smaller share of the global
production.

7.4. Global Market

The global LABSA market size was valued at USD 6.2 billion in 2020 and is expected
to reach USD 8.3 billion by 2028, growing at a CAGR of 3.6% from 2021 to 2028. The
increasing demand for detergents and cleaning agents, especially in developing
countries, is the primary driver of the LABSA market's growth.

7.5. Market Segmentation

The LABSA market can be segmented by application and geography.
By application, the market can be divided into:
1. Detergents
2. Emulsifiers
3. Personal Care Products
4. Others
In 2020, the detergents segment held the largest share of the market, accounting for
over 60% of the total revenue. This is attributed to the increasing demand for detergents,
especially in developing countries, due to rising disposable incomes, increasing
awareness about hygiene and cleanliness, and growing urbanization.

Geographically, the market can be segmented into:

1. North America
2. Europe

19
 3. Asia Pacific
4. Middle East and Africa
5. South America
In 2020, the Asia Pacific region dominated the LABSA market, accounting for over
50% of the total revenue. The region's dominance is attributed to the increasing demand
for detergents and cleaning agents in emerging economies such as India and China,
coupled with the presence of a large number of LABSA manufacturers in the region.
Here are some of the top LABSA producers globally based on market share and
production capacity:

1. Henkel AG & Co. KGaA

2. BASF SE
3. Clariant AG
4. Huntsman Corporation
5. Rhodia (Solvay Group)
6. Galaxy Surfactants Ltd.
7. TAYCA Corporation
8. The Dow Chemical Company
9. Kao Corporation
10. AK ChemTech Co. Ltd.

7.6. Product Diversification

Linear Alkyl Benzene Sulfonic Acid (LABSA) is primarily used as a raw material for
the production of detergent and cleaning products. However, there are several product
diversification opportunities for LABSA, including:

1. Textile Industry: LABSA can be used as an auxiliary in textile processing to

improve the penetration of dyes and enhance the dyeing quality of fabrics.
2. Agriculture Industry: LABSA can be used as a wetting agent and dispersant in
agricultural formulations, such as herbicides and insecticides, to improve their
efficacy and stability.
3. Oilfield Chemicals: LABSA can be used in the oil and gas industry as a wetting
agent and emulsifier in drilling muds, completion fluids, and production
chemicals.

20
4. Personal Care Products: LABSA can be used as an ingredient in the production
of personal care products, such as shampoos and body washes, to provide
foaming and cleansing properties.
5. Food Industry: LABSA can be used as a food additive, mainly as an emulsifier
and foaming agent in the production of baked goods and dairy products.
6. Paper and Pulp Industry: LABSA can be used as a wetting agent and dispersant
in the production of paper and pulp to improve their quality and efficiency.
7. Water Treatment: LABSA can be used as a coagulant aid and flocculating agent
in water treatment processes, especially for the removal of organic pollutants.

21
8. Wastes and Waste Treatment of LABSA Industry
8.1. Wastes of LABSA Industry
Most of people might think all chemical compounds will make pollution while LABSA
is environment friendliness. Linear alkyl benzene sulphonic acid which we know as
LABSA doesn't have any side effects. If we want planet without types of contaminants,
we should do safety procedures. In recent years and even till now we are facing different
Causes so in case LABSA which is using in different fields like such as, textile industry,
leather industry, Produce industrial and more. We should choose product which has
good purity we will demand 97% which is safer, with good price. Acid slurry (LABSA
96%) LABSA has been the major surfactant used in detergents for more than thirty-
five years and continues to represent a substantial portion of the surfactants market
today. Because of LABSA's environmental safety, cleaning effectiveness and cost
competitiveness, LABSA has experienced 45 years of ever-increasing use around the
world. Linear alkyl benzene (LAB), the material used to produce LABSA, is derived
exclusively from petroleum bi-products-benzene and paraffin derived from kerosene.
LAB currently represents one-of the active ingredients in detergents worldwide.
Handling these chemical needs special pumps due to its sticky and acidic nature. it is
produced through an aboriginal system designed reaction system. The technology has
two major benefits over the existing alternative technologies. [13]

The Linear Alkylbenzene Sulfonic Acid (LABSA) industry generates several types of
wastes that can have adverse effects on the environment and human health if not
managed properly. Some of the major wastes of the LABSA industry include:

• Acid sludge: This is the major waste generated during the production of
LABSA. It contains a high concentration of sulfuric acid and organic
compounds, which can be harmful to the environment if not properly disposed
of.
• Spent acid: This is the sulfuric acid used in the LABSA production process that
has become spent and is no longer effective. It is highly corrosive and can cause
severe damage to soil and water resources if not disposed of correctly.
• Wastewater: The production process of LABSA generates a large amount of
wastewater that contains high levels of organic compounds, acids, and other

22
 pollutants. This wastewater must be treated before it can be safely discharged
into the environment.
• Solid waste: The LABSA industry also generates solid waste in the form of
filter cakes, spent catalysts, and other waste materials that can be hazardous to
human health and the environment.

8.2. Waste Treatment Management

The production of LABSA can result in the generation of various waste streams,
including wastewater and solid waste. Effective waste treatment management of
LABSA industry is crucial for minimizing the environmental impact of these waste
streams. Here are some potential strategies for managing waste in LABSA industry:

8.2.1. Effluent Treatment Plant

LABSA production generates significant amounts of wastewater, which typically

contains high levels of organic pollutants and surfactants. Treatment methods such as
biological treatment, chemical treatment, and physical treatment can be used to remove
these pollutants and ensure the wastewater meets the required discharge standards. De-
foaming agent is added to the effluent to prevent the foam or to break the foam already
formed. The effluent is sent aeration tank followed clarifier to remove and settle out the
organic sludge. The clarified effluent passes through the Pressurized Sand Filter (PSF)
to remove the fine particles. The treated water is used in soaps and detergents making.
There will not be any on land disposal of wastewater will be done. The schematic
diagram ETP is given below. [2]

Figure 4 Effluent treatment plant

23
8.2.2. Solid Waste Management
No major hazardous chemicals are used in the process. The production of LABSA can
also generate solid waste such as filter cake, spent catalysts, and spent acids. Proper
management of these wastes involves appropriate storage, transportation, and disposal
methods in compliance with local regulations.

From the material balance, it is observed that no process waste is generated. Some of
the solid waste generated through the whole process are waste oil (sent to authorized
recyclers for disposal purpose), used MS drums, used HDPE drums (after
detoxification, sent to authorized recyclers for disposal purpose), used HDPE cans
(after detoxification, sent to authorized recyclers for disposal purpose), domestic waste
(organic waste are composted, other wastes are sent to authorized recyclers for disposal
purpose). The generated waste should not be stored in the plant premises for more than
3 months and should be disposed as per the Hazardous and Other Wastes Rules.

8.2.3. Recycling and Reuse

Recycling and reusing waste streams can be an effective strategy for minimizing waste
generation and reducing the overall environmental impact of the LABSA industry. For
example, spent sulfuric acid can be regenerated and reused in the production process,
and LABSA-containing wastewater can be treated and reused for non-potable purposes.

6.2.4. Pollution Prevention

The LABSA industry can also implement pollution prevention measures to reduce the
generation of waste in the first place. These measures can include optimizing
production processes, minimizing raw material waste, and reducing water usage.

Overall, effective waste treatment management in the LABSA industry involves a

combination of strategies that target the different waste streams generated during
production. By implementing these strategies, the industry can minimize its
environmental impact and promote sustainable production practices.

9. Environment Management during Construction

The impacts during the construction phase on the environment are basically of transient
nature and are expected to reduce gradually on completion of the construction activities.

24
1) Site Preparation: Since the project site terrain is almost flat, leveling may not be
required. During dry weather conditions, dust may be generated by activities like
excavation and transportation through unmetalled roads. The dust will be suppressed
using water sprinkling.
2) Water Quality: During construction period water is used for domestic and civil
works. Local people are deployed for construction work hence there is no need of
arranging temporary sheds for the laborers. The construction site will be provided
with drinking water and suitable toilet facilities for workers to allow proper standards
of hygiene. These facilities would be connected to a septic tank and maintained to
ensure minimum environmental impact. In rainy season the water quality is likely to
be affected due to the construction work and loosening of topsoil. This is likely to
increase the suspended solids in the run-off during heavy precipitation. In order to
reduce the impact on water quality, temporary sedimentation tanks will be
constructed for the settlement of the suspended matter. Care shall be taken that there
will not any blockage in the existing drainage pattern.
3) Air Quality: No leveling operations are required. However, during dry weather
conditions, it is necessary to control the dust generated by excavation and
transportation activities. At the site such activity will be carried out after water
sprinkling. The PUC certified vehicles will be used minimize smoke in the exhaust.
All internal roads will be paved with Concrete to avoid dust emissions.
4) Noise Levels: The noise effect on the nearest inhabitants during the construction
activity are negligible. However, on site workers using high noise equipment will
adopt noise protection devices like earmuffs. Noise prone activities will be avoided
during night time in order to have minimum environmental impact.
5) Ecological Aspects: No major herbs or shrubs are observed at the plant site. Hence
there does not be any loss of biomass during construction period. Proper landscaping
and extensive plantation will be carried out simultaneously with the construction. A
comprehensive green belt program will improve the ecological condition of the
region.
6) Soil Quality Management: The entire chemical handling and storage area is
concreted in order to prevent the soil contamination due to accidental spillages.
7) Occupational Health and Safety: Occupational health surveillance is undertaken as
regular exercise for all the employees especially for those engaged in handling
hazardous substances.
25
• All the first aid facilities should be provided.
• The medical records of each employee should be maintained separately. Noise
levels at the critical areas will be monitored regularly and the workers at high
noise generating areas will undergo audiometric tests once in a year.
• Fire-fighting system should be provided inside the factory premises.
• Proper earthing should be done in all the electrical equipment.
• The unit makes the arrangements for protection of possible fire hazards during
manufacturing process in material handling.
• Training will be provided to all the employees on safety and health aspects of
chemical handling.
• Providing personnel protective equipment’s to all the employees in the stages
should be ensured.
• Good housekeeping practices should be carried out during the operational
activities of the proposed project.

26
Conclusion
In conclusion, our term paper on the LABSA manufacturing industry has been a
valuable learning experience. We were able to gain knowledge about the practical
aspects of establishing such a manufacturing industry, which cannot be fully understood
through theoretical learning alone. We had to conduct extensive research on various
sources to collect relevant information to make a comprehensive term paper. Our efforts
were focused on providing a clear and concise understanding of the basic method of
LABSA formation, including raw materials and reactions, process flow, and process
block diagram with material and energy balances. We also provided an overview of the
market outlook of the industry, highlighting its importance and potential for growth.
Additionally, we discussed the crucial aspect of waste management treatment,
emphasizing the need for proper disposal and treatment of wastewater to minimize
environmental impact. This experience has enhanced our conceptual knowledge and
provided us with a practical understanding of the complexities involved in establishing
and operating such an industry. Overall, we hope that our term paper has served as a
valuable resource for anyone seeking to gain insight into the LABSA manufacturing
industry.

27
References

[1] “Linear Alkylbenzene Sulfonic Acid (LABSA)”, S&P Global,

https://www.spglobal.com. [Accessed 18 February 2023]
[2] “Linear Alkyl Benzene Sulphonic Acid – LABSA”, World of Chemicals,
https://www.worldofchemicals.com. [Accessed 18 February 2023]
[3] Wedad H.A., Apr 2020, “Preparation and Production of High Grade Sulfonic”.
[4] ‘Linear Alkylbenzene Sulfonic Acid’, Chemical Land,
https://chemicalland21.com. [Accessed 18 February 2023]
[5] M.Y. Murray, 2011, Comprehensive Biotechnology, 2nd ed., Elsevier.
[6] Linear Alkylbenzene Sulfonic Acid, Fartak Chemicals, https://fartaklotus.com.
[Accessed 18 February 2023]
[7] Linear Alkyl Benzene Sulfonic Acid, Vidar Chemicals, https://www.vidar-
chemical.com. [Accessed 18 February 2023]
[8] R.M. Fedler and R.W. Rousseau, 2005, Elementary Principles of Chemical
Processes, 3rd ed., Wiley, New York, pp. 385.
[9] R.M. Fedler and R.W. Rousseau, 2005, Elementary Principles of Chemical
Processes, 3rd ed., Wiley, New York, pp. 634.
[10] J.M. Smith, H.C. Van Ness, M.M. Abbott and M.T. Swihart, 7th ed., 2005,
Chemical Engineering Thermodynamics, McGraw-Hill, New York, pp. 684.
[11] "Study on the LABSA Industry in Bangladesh" by Bangladesh Tariff
Commission.
[12] "Linear Alkyl Benzene Market.", Grand View Research,
https://www.grandviewresearch.com [Accessed 19 February 2023]

28
Nomenclature

Abbreviations Meaning

LABSA Linear Alkyl Benzene Sulphonic Acid

LAB Linear Alkyl Benzene

BAS Alkyl Benzene Sulfonate

International Union of Pure and Applied
IUPAC
Chemistry
LAS Linear Alkyl Sulfonate

ETP Effluent Treatment Plant

ESP Electrostatic Precipitator

USD U.S. Doller

CAGR Compound Annual Growth Rate

BASF Badische Anilin- und Sodafabrik

PUC Pollution Under Control

29
Workload Distribution

Student ID Contribution

Abstract, Introduction, Wastes and Waste

1902056
Treatment Management and Conclusion

Process description, Process Block

1902057 Diagram, Material balance and
Nomenclature

Material balance, Energy balance,

1902058
References, Merging and Illustrations

1902059 Market analysis

Introduction, Importance and Properties of

1902060
LABSA

30