Chemical Engineering Project 2024-25

Hand Sanitizer Production

A Laboratory-Based Chemical Process Prototype Demonstrating Formulation, Mixing, and Production of Alcohol-Based Hand Sanitizer

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WHO Formula
Lab Verified
99.9% Effective
Laboratory Setup

Department

Chemical Engineering

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Project Overview

Understanding the Chemical Process

Hand sanitizers are essential antiseptic solutions used to eliminate harmful microorganisms. This project focuses on the laboratory-scale preparation of alcohol-based hand sanitizer using standard chemical engineering techniques.

Chemical Formulation

Precise measurement and mixing of active ingredients

Controlled Mixing

Systematic blending for uniform distribution

Reaction & Stabilization

Ensuring chemical stability and effectiveness

Project Objectives

  • Understand chemical formulation of sanitizer
  • Design a process flow system
  • Produce sanitizer in laboratory conditions
  • Ensure safety and quality standards

Project Scope

Laboratory Scale

Educational Use

Industry Process

WHO Recommended

Based on WHO-recommended formulations, this project ensures effectiveness, safety, and quality control.

Raw Materials

Materials & Chemicals Used

Each component plays a crucial role in the sanitizer formulation process, contributing specific properties to the final product.

Ethanol

80%

Main antimicrobial agent

Highly flammable

H₂O₂

0.125%

Kills bacterial spores

Ensures purity

Glycerol

1.45%

Moisturizer & humectant

Skin-friendly

Water

~18%

Distilled water dilution

Sterile grade

Optional Additives

Fragrance

Improves smell

Aloe Vera

Skin protection

Carbomer

Gel formation

Process Design

Process Flow Diagram

Interactive visualization of the chemical process from raw materials to final product

Ethanol H₂O₂ Glycerol Raw Materials Mix Mixer Reactor Raw Product + Fragrance SANITIZER Final Product
1

Measure ingredients

2

Initial mixing

3

Chemical reaction

4

Base formation

5

Additives

6

Quality check

Process Block Diagram

Block Diagram

System overview of sanitizer production

Process Parameters

Temperature Room Temp (25°C)
Mixing Time 15-20 minutes
Settling Period 72 hours
pH Range 6.5 - 7.5
Procedure

Steps of Preparation

Step-by-step process following WHO guidelines

Measure Ethanol

1

Measure 80% ethanol in a clean, dry container using a measuring cylinder

2

Add Hydrogen Peroxide

Carefully add 0.125% hydrogen peroxide to eliminate bacterial spores

Add Glycerol

3

Add 1.45% glycerol carefully as moisturizer to prevent skin dryness

4

Add Distilled Water

Add distilled water to reach the required final volume

Mix Thoroughly

5

Transfer to mixing unit and blend thoroughly for uniform distribution

6

Add Fragrance

Add fragrance (optional) and mix gently

Store & Quality Check

7

Store for 72 hours before use to ensure complete stabilization

Safety First

Experimental Setup & Safety

Proper equipment setup and safety measures are essential for successful sanitizer preparation. Ethanol is highly flammable and requires special precautions.

Equipment Used

Mixing Unit

For uniform blending

Reactor Vessel

Chemical reaction

Measuring Cylinders

Accurate volumes

Storage Containers

Product storage

Fire Hazard Warning

Ethanol is highly flammable. Keep away from open flames, sparks, and heat sources.

No smoking in laboratory area

Safety Measures

Use Gloves & Lab Coat

Chemical-resistant protection required

Ventilated Area

Work in well-ventilated space

Eye Protection

Safety goggles mandatory

Important Notes
  • • Never taste or directly smell chemicals
  • • Dispose of waste materials properly
  • • Report any spills immediately
  • • Keep fire extinguisher accessible
Lab Design

Laboratory Arrangement

Optimized workspace layout for safe and efficient production

Laboratory Layout

Laboratory Setup Overview

Complete arrangement showing chemical storage, mixing, reaction, and quality testing sections

Chemical Storage

Separate flammable storage with proper ventilation

Mixing Section

Primary blending and initial mixing operations

Reaction Area

Controlled environment for chemical reactions

Quality Testing

Analysis and verification of final product

Outcomes

Results & Applications

Analysis of the prepared sanitizer's properties and its potential applications

Appearance

Clear Liquid

Transparent, no particles

Efficacy

99.9%

Microbial reduction

Skin-Friendly

Non-Irritant

Glycerol enriched

Stability

6+ Months

Shelf life

Practical Applications

Hospitals

Medical-grade sanitation

Schools

Educational institutions

Public Places

High-traffic areas

Personal Use

Daily hygiene

Findings

Key Observations

Critical Parameters

Alcohol Concentration

Must be maintained between 60-80% for effective antimicrobial action

Glycerol Function

Effectively reduces skin dryness and prevents irritation

Hydrogen Peroxide

Ensures product purity by eliminating bacterial spores

Mixing Uniformity

Thorough mixing essential for consistent product quality

Quality Testing

Quality Testing in Progress

Verification of alcohol concentration

Technical Specifications

pH Level 6.5 - 7.5