Liquid soap continuous production system and method

Abstract

The invention belongs to the technical field of liquid soap production, and particularly relates to a liquid soap continuous production system and method. The system is reasonable in design and mainly comprises a raw material accurate metering device, a continuous saponification reactor, an on-line neutralization regulator, a dynamic mixing system, a flash evaporation concentration device and an automatic filling device. And comprehensive improvement of production efficiency, quality control and economic benefits is realized. The multi-stage series tubular reaction section of the continuous saponification reactor and the flash evaporation concentration device cooperatively operate, and the traditional production cycle of more than 72 hours is compressed to 2.5 hours for continuous operation. And the dynamic mixing system is combined with the high-precision mass flow meter, so that the process efficiency of unit productivity is greatly improved compared with the intermittent process efficiency. The modular design supports a production line to complete product switching within a short time, the equipment utilization rate is high, and the problem of small-batch customized production is effectively solved.

Description

Technical Field

[0001] The invention belongs to the technical field of liquid soap production, and particularly relates to a liquid soap continuous production system and method. Background Art

[0002] Continuous production systems for liquid soap play a vital role in modern chemical production. The following details their role: 1) Improving Production Efficiency: Continuous production systems enable continuous reaction processes, significantly improving production efficiency. Compared to traditional batch production, continuous production reduces downtime and waiting time during production, making the production process more streamlined. 2) Optimizing Product Quality: Continuous production systems enable precise control and optimization of the reaction process. For example, by controlling parameters such as reactant flow rate, concentration, reaction temperature, and pressure, product quality stability and uniformity can be ensured. Furthermore, continuous production reduces byproduct formation, improving product purity and yield. 3) Reducing Costs: Continuous production systems not only improve production efficiency but also reduce costs by optimizing the production process. For example, by reducing raw material and energy consumption, as well as reducing scrap and rework rates, production costs can be significantly reduced. Furthermore, continuous production reduces waste and losses during the production process, further improving economic benefits. 4) Enhancing Production Flexibility: Continuous production systems for liquid soap typically feature a high degree of automation, allowing for flexible adjustments based on market demand and product specifications. This flexibility enables manufacturers to quickly respond to market changes and meet diverse customer needs. 5) Improved production safety: Continuous production systems are typically equipped with advanced safety monitoring and control equipment that monitor various parameters and conditions during the production process in real time. If an anomaly is detected, the system can immediately intervene, ensuring the safety and stability of the production process.

[0003] Traditional continuous liquid soap production systems have shortcomings. First, they lack comprehensive control over the entire process, from raw material mixing to finished product filling. Second, the design of the continuous saponification reactor is suboptimal. Therefore, optimization and improvement are needed. Summary of the Invention

[0004] The purpose of the present invention is to overcome the above-mentioned problems existing in the conventional technology and to provide a liquid soap continuous production system and method.

[0005] In order to achieve the above technical objectives and the above technical effects, the present invention is implemented through the following technical solutions:

[0006] The present invention provides a liquid soap continuous production system, comprising:

[0007] A precise raw material metering device, comprising a multi-channel mass flow meter and a PLC controller, monitors the ratio of oil, alkali solution and water in real time through sensors to ensure that the feeding accuracy error is ≤0.5%;

[0008] A continuous saponification reactor, which sequentially completes oil saponification, glycerin separation, and preliminary concentration of soap solution;

[0009] An online neutralization regulator, which uses an ultrasonic atomizing spray device to evenly disperse the citric acid solution into the preliminarily concentrated soap solution flow and cooperates with an online pH monitoring probe to achieve real-time closed-loop control;

[0010] A dynamic mixing system that integrates a high-shear emulsifier and a static mixing section, capable of dispersing thickeners and flavoring additives within 10 to 15 seconds.

[0011] A flash concentration device, wherein a vacuum flash tower is combined with a plate heat exchanger to achieve rapid evaporation of water through gradient pressure reduction;

[0012] An automatic filler is provided for automatically filling the re-concentrated soap liquid.

[0013] Furthermore, in the above-mentioned liquid soap continuous production system, the raw material precise metering device adopts dynamic feedback adjustment technology, which can automatically correct the volume measurement error caused by temperature fluctuation.

[0014] Furthermore, in the above-mentioned liquid soap continuous production system, the continuous saponification reactor includes a control module and a multi-stage series tubular reaction section, a high-pressure jet mixing module, a dynamic separation module, a temperature control module and a pressure regulation module connected thereto; the multi-stage series tubular reaction section, the high-pressure jet mixing module and the dynamic separation module are connected in sequence.

[0015] Furthermore, in the above-mentioned continuous production system of liquid soap, the multi-stage serial tubular reaction section adopts a grade 3 titanium alloy tube group with a diameter of 200-300 mm and a wall thickness of 8 mm. A spiral guide vane and a static mixing unit are arranged inside the grade 3 titanium alloy tube group. The length ratio of each stage is 1:1.5:2, forming a tapered flow channel structure; the multi-stage serial tubular reaction section is used to realize the segmented mixing and gradient saponification of oil and alkali solution, and accelerates the mass transfer efficiency of the liquid phase reaction through the variable diameter design.

[0016] Furthermore, in the above-mentioned continuous production system of liquid soap, the first section of the high-pressure jet mixing module integrates a cross nozzle structure, and the flow adjustment range of the cross nozzle structure is 50-200L / min. The cross nozzle structure injects alkali solution through high-pressure steam and atomization to form micron-sized emulsion droplets with the oil preheated to 75°C.

[0017] Furthermore, in the above-mentioned continuous production system of liquid soap, the dynamic separation module includes a static cyclone separator arranged at the end of each stage of the multi-stage series tubular reaction section. The separation efficiency of the static cyclone separator is ≥98%, and the continuous separation of soap particles and glycerin waste liquid is achieved through the centrifugal field.

[0018] Furthermore, in the above-mentioned liquid soap continuous production system, the temperature control module includes a double jacket arranged outside each stage of the multi-stage series tubular reaction section. The double jackets of the first two stages are heated by heat transfer oil circulation, and the double jacket of the last stage is switched to a cooling water circuit.

[0019] Furthermore, in the above-mentioned liquid soap continuous production system, the pressure regulating module is equipped with a back pressure valve group with an adjustment range of 0.1-2.0 MPa. The back pressure valve group is linked with the pressure sensor in a closed loop to maintain supercritical reaction conditions in the pipe section.

[0020] Furthermore, in the above-mentioned liquid soap continuous production system, the automatic filler is equipped with a multi-head filling valve driven by a servo motor, and is equipped with nitrogen replacement sealing technology to control the oxygen content to ≤0.5%.

[0021] The present invention also provides a method for continuous production of liquid soap, which is implemented based on the above-mentioned continuous production system of liquid soap and comprises the following steps:

[0022] S1. Use the precise raw material metering device to monitor the ratio of oil, alkali solution and water in real time;

[0023] S2, using a continuous saponification reactor to sequentially complete oil saponification, glycerin separation and preliminary concentration of soap solution;

[0024] S3, adjusting the pH value of the preliminary concentrated soap solution using an online neutralization regulator;

[0025] S4, using a flash concentration device to re-concentrate the neutralized soap solution;

[0026] S5. Automatically fill the concentrated soap solution using an automatic filler.

[0027] The beneficial effects of the present invention are:

[0028] 1. Revolutionary breakthrough in production efficiency

[0029] The multi-stage, serially connected tubular reaction section and flash concentration unit operate in tandem, compressing the traditional production cycle of over 72 hours to a continuous 2.5-hour operation. The combination of a dynamic mixing system (complete additive dispersion in 10-15 seconds) and a high-precision mass flow meter (±0.5% feeding error) increases unit production capacity to 5 tons / hour, a 400% increase in efficiency compared to batch processes. The modular design enables the production line to complete product switching within 30 minutes, achieving an equipment utilization rate of 92%, effectively addressing the pain points of small-batch customized production.

[0030] 2. Leapfrog improvement in product quality

[0031] The introduction of an online neutralization regulator (closed-loop control accuracy of ±0.1) and a multi-parameter sensing network (simultaneous monitoring of viscosity, turbidity, and temperature) has reduced batch variability from 8% with traditional processes to less than 0.5%. Ultrasonic atomization neutralization technology mitigates the risk of soap base precipitation caused by localized over-acidification. Combined with nitrogen displacement filling (oxygen content ≤ 0.5%), the product's shelf life is extended by 60%. Field measurements have shown that the molecular weight distribution concentration (PDI) of the finished soap base has increased to 1.15, enhancing surface activity by 20%.

[0032] 3. Optimization of energy consumption and cost structure

[0033] The combination of a gradient temperature control system (heating with thermal oil in the front section and waste heat recovery in the back section) and a flash evaporation waste heat circulation device has reduced steam consumption from 1.8 tons per ton of product to 0.8 tons, reducing overall energy consumption by 45%. Continuous production has reduced water consumption for cleaning intermediate storage containers by 80%, and wastewater discharge has been reduced by 65%. Automated control has reduced the number of manual intervention points from 127 to 18, reducing labor costs by 75%. Combined with the DCS system's rapid response to abnormalities (<5 seconds shutdown protection), annual quality loss costs have been reduced by 2.8 million yuan (calculated based on 10,000 tons of production capacity).

[0034] 4. Enhanced environmental protection and process safety

[0035] Closed-pipe production completely eliminates the risk of alkaline mist escape associated with open mixing, reducing VOC concentrations in the workshop by 90%. An embedded cyclone separator continuously separates glycerin (recovery concentration 14.5%), recovering an additional 1,200 tons of byproducts annually. Explosion-proof servo filling and full-process pressure monitoring (automatic relief at 1.6 MPa overpressure) ensure near-zero major process safety incidents.

[0036] Of course, any product implementing the present invention does not necessarily need to achieve all of the above advantages at the same time. BRIEF DESCRIPTION OF THE DRAWINGS

[0037] In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the following briefly introduces the drawings required for describing the embodiments. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without creative work.

[0038] Figure 1 It is a structural block diagram of the present invention as a whole;

[0039] Figure 2 Schematic diagram of the structure of the continuous saponification reactor of the present invention;

[0040] In the accompanying drawings, the reference numerals of the various components are as follows:

[0041] 1-Raw material precise metering device, 2-Continuous saponification reactor, 201-Control module, 202-Multi-stage series tubular reaction section, 203-High-pressure jet mixing module, 204-Dynamic separation module, 205-Temperature control module, 206-Pressure regulation module, 3-Online neutralization regulator, 4-Dynamic mixing system, 5-Flash concentration device, 6-Automatic filler. DETAILED DESCRIPTION

[0042] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making any creative efforts shall fall within the scope of protection of the present invention.

[0043] like Figure 1 As shown, this embodiment provides a continuous liquid soap production system characterized by comprising, in sequence, a precise raw material metering device 1, a continuous saponification reactor 2, an online neutralization regulator 3, a dynamic mixing system 4, a flash concentration device 5, and an automatic filler 6. The precise raw material metering device 1 includes a multi-channel mass flowmeter and a PLC controller. Sensors monitor the ratio of oil, alkali, and water in real time, ensuring a feed accuracy error of ≤0.5%. The continuous saponification reactor 2 sequentially completes oil saponification, glycerin separation, and preliminary soap concentration. The online neutralization regulator 3 uses an ultrasonic atomizer to evenly disperse the citric acid solution into the pre-concentrated soap stream, and integrates an online pH monitoring probe to achieve real-time closed-loop control. The dynamic mixing system 4 integrates a high-shear emulsifier and a static mixing section, capable of dispersing thickeners and flavoring additives within 10-15 seconds. The vacuum flash tower in the flash concentration device 5, combined with a plate heat exchanger, achieves rapid water evaporation through gradient pressure reduction. The automatic filler 6 automatically fills the re-concentrated soap solution.

[0044] In this embodiment, the raw material precise metering device 1 adopts dynamic feedback adjustment technology, which can automatically correct the volume measurement error caused by temperature fluctuation.

[0045] In this embodiment, the continuous saponification reactor 2 includes a control module 201 and a multi-stage series tubular reaction section 202, a high-pressure jet mixing module 203, a dynamic separation module 204, a temperature control module 205 and a pressure regulation module 206 connected thereto; the multi-stage series tubular reaction section 202, the high-pressure jet mixing module 203, and the dynamic separation module 204 are connected in sequence.

[0046] In this embodiment, the multi-stage serial tubular reaction section 202 adopts a grade 3 titanium alloy tube group with a diameter of 200-300 mm and a wall thickness of 8 mm. A spiral guide vane and a static mixing unit are arranged inside the grade 3 titanium alloy tube group. The length ratio of each stage is 1:1.5:2, forming a tapered flow channel structure; the multi-stage serial tubular reaction section is used to realize the segmented mixing and gradient saponification of oil and alkali solution, and accelerates the mass transfer efficiency of the liquid phase reaction through the variable diameter design.

[0047] In this embodiment, the first section of the high-pressure jet mixing module 203 integrates a cross nozzle structure. The flow adjustment range of the cross nozzle structure is 50-200L / min. The cross nozzle structure injects alkaline solution through high-pressure steam and atomization to form micron-sized emulsion droplets with the oil preheated to 75°C.

[0048] In this embodiment, the dynamic separation module 204 includes a static cyclone separator provided at the end of each stage of the multi-stage serial tubular reaction section. The separation efficiency of the static cyclone separator is ≥98%, and the soap particles and the glycerin waste liquid are continuously separated by the centrifugal field.

[0049] In this embodiment, the temperature control module 205 includes a double jacket arranged outside each stage of the multi-stage series tubular reaction section. The double jackets of the first two stages are heated by heat transfer oil circulation, and the double jacket of the last stage is switched to a cooling water circuit.

[0050] In this embodiment, the pressure regulating module 206 is equipped with a back pressure valve group with an adjustment range of 0.1-2.0 MPa. The back pressure valve group is linked with the pressure sensor in a closed loop to maintain supercritical reaction conditions in the pipe section.

[0051] In this embodiment, the automatic filler 6 is equipped with a multi-head filling valve driven by a servo motor, and with nitrogen replacement sealing technology, the oxygen content is controlled to ≤0.5%.

[0052] This embodiment also provides a method for continuous production of liquid soap, comprising the following steps:

[0053] S1. Use the precise raw material metering device to monitor the ratio of oil, alkali solution and water in real time;

[0054] S2, using a continuous saponification reactor to sequentially complete oil saponification, glycerin separation and preliminary concentration of soap solution;

[0055] S3, adjusting the pH value of the preliminary concentrated soap solution using an online neutralization regulator;

[0056] S4, using a flash concentration device to re-concentrate the neutralized soap solution;

[0057] S5. Automatically fill the concentrated soap solution using an automatic filler.

[0058] This system breaks through the limitations of traditional intermittent production processes and achieves comprehensive improvements in production efficiency, quality control and economic benefits through the integration of process reconstruction and intelligent control.

[0059] The multi-stage, serially connected tubular reaction section and flash concentration unit operate in tandem, compressing the traditional production cycle of over 72 hours to a continuous 2.5-hour operation. The combination of a dynamic mixing system (complete additive dispersion in 10-15 seconds) and a high-precision mass flow meter (±0.5% feeding error) increases unit production capacity to 5 tons / hour, a 400% increase in efficiency compared to batch processes. The modular design enables the production line to complete product switching within 30 minutes, achieving an equipment utilization rate of 92%, effectively addressing the pain points of small-batch customized production.

[0060] The introduction of an online neutralization regulator (closed-loop control accuracy of ±0.1) and a multi-parameter sensing network (simultaneous monitoring of viscosity, turbidity, and temperature) has reduced batch variability from 8% with traditional processes to less than 0.5%. Ultrasonic atomization neutralization technology mitigates the risk of soap base precipitation caused by localized over-acidification. Combined with nitrogen displacement filling (oxygen content ≤ 0.5%), the product's shelf life is extended by 60%. Field measurements have shown that the molecular weight distribution concentration (PDI) of the finished soap base has increased to 1.15, enhancing surface activity by 20%.

[0061] The combination of a gradient temperature control system (heating with thermal oil in the front section and waste heat recovery in the back section) and a flash evaporation waste heat circulation device has reduced steam consumption from 1.8 tons per ton of product to 0.8 tons, reducing overall energy consumption by 45%. Continuous production has reduced water consumption for cleaning intermediate storage containers by 80%, and wastewater discharge has been reduced by 65%. Automated control has reduced the number of manual intervention points from 127 to 18, reducing labor costs by 75%. Combined with the DCS system's rapid response to abnormalities (<5 seconds shutdown protection), annual quality loss costs have been reduced by 2.8 million yuan (calculated based on 10,000 tons of production capacity).

[0062] Closed-pipe production completely eliminates the risk of alkaline mist escape associated with open mixing, reducing VOC concentrations in the workshop by 90%. An embedded cyclone separator continuously separates glycerin (recovery concentration 14.5%), recovering an additional 1,200 tons of byproducts annually. Explosion-proof servo filling and full-process pressure monitoring (automatic relief at 1.6 MPa overpressure) ensure near-zero major process safety incidents.

[0063] Through continuous, intelligent and intensive technological upgrades, the system has built an efficient production platform with a daily processing capacity of 50 tons of liquid soap, shortening the investment payback period to 18 months, providing the daily chemical industry with a model solution for the integration of clean production and intelligent manufacturing.

[0064] The preferred embodiments of the present invention disclosed above are intended only to help illustrate the present invention. These preferred embodiments do not exhaustively describe all details, nor do they limit the present invention to specific embodiments. Obviously, many modifications and variations are possible based on the contents of this specification. These embodiments are selected and described in detail in this specification to better explain the principles and practical applications of the present invention, thereby enabling those skilled in the art to better understand and utilize the present invention. The present invention is limited only by the claims and their full scope and equivalents.

Claims

1. Liquid soap continuous production system, characterized in that: Including the following settings: A precise raw material metering device, comprising a multi-channel mass flow meter and a PLC controller, monitors the ratio of oil, alkali solution and water in real time through sensors to ensure that the feeding accuracy error is ≤0.5%; A continuous saponification reactor, which sequentially completes oil saponification, glycerin separation, and preliminary concentration of soap solution; An online neutralization regulator, which uses an ultrasonic atomizing spray device to evenly disperse the citric acid solution into the preliminarily concentrated soap solution flow and cooperates with an online pH monitoring probe to achieve real-time closed-loop control; A dynamic mixing system that integrates a high-shear emulsifier and a static mixing section, capable of dispersing thickeners and flavoring additives within 10 to 15 seconds. A flash concentration device, wherein a vacuum flash tower is combined with a plate heat exchanger to achieve rapid evaporation of water through gradient pressure reduction; An automatic filler is provided for automatically filling the re-concentrated soap liquid.

2. The liquid soap continuous production system according to claim 1, characterized in that: The raw material precise metering device adopts dynamic feedback adjustment technology, which can automatically correct the volume measurement error caused by temperature fluctuation.

3. The liquid soap continuous production system according to claim 2, characterized in that: The continuous saponification reactor includes a control module and a multi-stage serial tubular reaction section, a high-pressure jet mixing module, a dynamic separation module, a temperature control module and a pressure regulation module connected thereto; the multi-stage serial tubular reaction section, the high-pressure jet mixing module and the dynamic separation module are connected in sequence.

4. The liquid soap continuous production system according to claim 3, characterized in that: The multi-stage serial tubular reaction section adopts a grade 3 titanium alloy tube group with a diameter of 200-300 mm and a wall thickness of 8 mm. A spiral guide vane and a static mixing unit are arranged inside the grade 3 titanium alloy tube group. The length ratio of each stage is 1:1.5:2, forming a tapered flow channel structure; the multi-stage serial tubular reaction section is used to realize the segmented mixing and gradient saponification of oil and alkali solution, and accelerates the mass transfer efficiency of the liquid phase reaction through the variable diameter design.

5. The liquid soap continuous production system according to claim 4, characterized in that: The first section of the high-pressure jet mixing module integrates a cross nozzle structure with a flow adjustment range of 50-200L / min. The cross nozzle structure injects alkali solution through high-pressure steam and atomization to form micron-sized emulsion droplets with grease preheated to 75°C.

6. The liquid soap continuous production system according to claim 5, characterized in that: The dynamic separation module comprises a static cyclone separator arranged at the end of each stage of the multi-stage serial tubular reaction section. The separation efficiency of the static cyclone separator is ≥98%, and the soap particles and the glycerin waste liquid are continuously separated through the centrifugal field.

7. The liquid soap continuous production system according to claim 6, characterized in that: The temperature control module includes a double jacket arranged outside each stage of the multi-stage series tubular reaction section. The double jackets of the first two stages are heated by heat transfer oil circulation, and the double jacket of the last stage is switched to a cooling water circuit.

8. The liquid soap continuous production system according to claim 7, characterized in that: The pressure regulating module is equipped with a back pressure valve group with an adjustment range of 0.1-2.0 MPa. The back pressure valve group is linked in a closed loop with the pressure sensor to maintain supercritical reaction conditions in the pipe section.

9. The liquid soap continuous production system according to claim 8, characterized in that: The automatic filler is equipped with a multi-head filling valve driven by a servo motor and is equipped with nitrogen replacement sealing technology to control the oxygen content to ≤0.5%.

10. A method for continuous production of liquid soap, implemented based on the liquid soap continuous production system according to claim 9, characterized in that: The steps include: S1. Use the precise raw material metering device to monitor the ratio of oil, alkali solution and water in real time; S2, using a continuous saponification reactor to sequentially complete oil saponification, glycerin separation and preliminary concentration of soap solution; S3, adjusting the pH value of the preliminary concentrated soap solution using an online neutralization regulator; S4, using a flash concentration device to re-concentrate the neutralized soap solution; S5. Automatically fill the concentrated soap solution using an automatic filler.

Images