Ppjatropha

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DEPARTMENT OF CHEMICAL ENGINEERING PROGRAM

PROCESS STREAM

Project title – Biodiesel production from Jatropha

SUBMITTED BY

GROUP MEMBERS ID NO

YALEMBRHAN DEBEBE 3020/03

SELOMON AREGAWI 2656/03

GODEFA TESFAY

SUBMITTED TO INSTRUCTOR GETU

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ACKNOWLEDGEMENT

First and for most we thank our Almighty God for making all this happen. Our next

gratitude goes to our advisor INST G/ hiwot for his guidance on the project. We also thank to

our instructor Getu for his effective lectures. Our Last but not least gratitude goes to all friends

who contributed best up on completion of the project.

ABSTRACT The project mainly deals with the methods of production of biodiesel from a jatropha plant. It

also asses the material and energy balance of biodiesel with all the cost estimation. It describes

the different methods of producing biodiesel.

Contents ...................................................................................................................................................................... 1

ACKNOWLEDGEMENT ................................................................................................................................... 2

ABSTRACT ...................................................................................................................................................... 2

CHAPTER ONE ............................................................................................................................................... 4

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INTRODUCTION ............................................................................................................................................. 4

1.2. Statements of the Problem ................................................................................................................ 5

1.3. Objectives of the Study ...................................................................................................................... 5

Chapter two .................................................................................................................................................. 5

2. LITERATURE REVIEW ................................................................................................................................. 5

2.1. Basic Concepts of Biofuel ................................................................................................................... 6

2.1.1. Biofuel ......................................................................................................................................... 6

2.2. Development Status of Biofuel .......................................................................................................... 6

2.2.1. Development status of biofuel in Africa ..................................................................................... 7

2.2.2. Development status of biofuel in Ethiopia ................................................................................. 7

2.3. Jatropha Cultivation, Processing and Uses ........................................................................................ 8

2.3.1. Description of Jatropha ............................................................................................................... 8

2.3.2. Jatropha cultivation .................................................................................................................... 8

2.3.3. Jatropha oil extraction ................................................................................................................ 8

2.4 Biodiesel production ........................................................................................................................... 9

2.4.1. Direct use and blending .............................................................................................................. 9

2.4.2. Micro emulsions .......................................................................................................................... 9

2.4.3. Thermal cracking (pyrolysis) ..................................................................................................... 10

2.4.4. Trans esterification (Alcoholysis) .............................................................................................. 10

2.5 Physical and chemical properties...................................................................................................... 11

2.5.1 Fats and oils ............................................................................................................................... 11

2.5.2 Treating High FFA Waste Vegetable Oil ..................................................................................... 12

CHAPTER THREE .......................................................................................................................................... 13

RESEARCH METHODOLOGY ........................................................................................................................ 13

3.1 Biodiesel reaction.............................................................................................................................. 13

3.2 Biodiesel process layout.................................................................................................................... 14

3.3 Supercritical methanol process of Biodiesel flow sheet ................................................................... 15

Chapter four ................................................................................................................................................ 15

Material balance and Energy balance calculations ..................................................................................... 15

4.1 Material balance ............................................................................................................................... 15

4.2. ENERGY BALANCE ............................................................................................................................ 21

4.2.1 CALCULATION FOR DISTLATION COLUMN I ............................................................................... 21

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4.2.2CALCULATIONS ON DISTILATION COLUMN 𝑰𝑰 ............................................................................ 22

` ........................................................................................................................................................... 23

4.2.3 Energy balance of plug flow reactor .......................................................................................... 25

4.3 Equipment sizing ............................................................................................................................... 26

4.3.1VOLUME OF PFR (PLUG FLOW REACTOR) ................................................................................... 26

4.3.2 Volume of Flow tank .................................................................................................................. 27

4.4 COST ESTIMATION ............................................................................................................................ 28

4.5 COST INDEXES: .................................................................................................................................. 30

4.6 Safety and Environment .................................................................................................................... 35

4.7 Conclusion ......................................................................................................................................... 35

CHAPTER ONE

INTRODUCTION Biodiesel, a mixture of mono alkyl esters of long chain free fatty acids, has become

increasingly attractive worldwide because it is made from renewable resources and combine

high performance with environmental benefits. In commercial processes, highly refined

vegetable oils, primarily consisting of triglycerides (TGs) and typically used as feed stocks,

are Trans esterified with low molecular weight alcohols. e.g. methanol and ethanol, with no

catalysts .To be more economically viable, the use of virgin oils, which cost accounts for

88% of the total estimated production cost of biodiesel, could be replaced with a more

economical feedstock, such as waste fats and oils that contain a low to moderate amount of

free fatty acids (FFAs) in addition to moisture and other impurities. However, the synthesis

of biodiesel from these low quality oils is challenging due to undesirable side reactions as a

result of the presence of FFAs and water. The pretreatment stages, involving an acid

catalyzed pre-esterification integrated with water separation, are necessitated to reduce acid

concentrations and water to below threshold limits prior to being processed by standard

biodiesel manufacturing. Besides catalyzing esterification, acid catalysts are able to catalyze

TG transesterification, opening the door for the use of acid catalysts to perform simultaneous

FFA esterification and TG trans esterification. Moreover, in general industrial processes,

heterogeneous catalysts are more desirable because they are non-corrosive, separable, and

recyclable. The use of solid catalysts would also reduce the number of reaction and

separation steps required in the conversion of fats and oils to biodiesel, allowing for more

economical processing and yielding higher quality ester products and glycerol.

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1.2. Statements of the Problem So far, in Ethiopia little work has been done on renewable source of energy development

in general and no work has been done on and of biodiesel production from Jatropha in

particular. On one hand, the oil price increase, which is the result of the mismatch between

demand and supply, is becoming the barrier for stable and sustainable economic development.

On the other hand, since it is believed that fossil fuels are the main cause for atmospheric air

pollution and global warming, effort is being exerted to minimize the use of fossil fuels

and to substitute it by renewable energy sources . The increasing demand of energy, the

associated price hikes and environmental concerns have hit the Ethiopian economy very hard. It

is therefore not surprising that the government places high priority on alternative energy sources

that partially or totally substitutes imported fuel.

unsustainable practice and this could in its turn hamper the exploration of the true

Jatropha potential risks and benefits.

However, Jatropha receives a lot of attention from project developers in the field of

biofuel production and clean development mechanism. As a pioneer species well

adapted to semi-arid climates, Jatropha is promising to simultaneously combat desertification,

provide biodiesel and enhance socio-economic development in degraded rural areas

. As such, biodiesel production and use from Jatropha

is believed to have better energy balance, low emission and a positive socioeconomic

impact, although no quantitative studies are available to confirm this in

Ethiopia. This study gives a detail analysis for environmental and economic impact of

Biodiesel production from Jatropha in comparison with fossil diesel.

1.3. Objectives of the Study The study has the following objectives:

To analyze and compare the energy balance and material balance of biodiesel from

jatropha.

To evaluate the financial and economic feasibility of large-scale Jatropha

plantation and Jatropha cultivation as a fence.

To assess the financial and economic viability of Jatropha biodiesel production as

compared to fossil diesel over the life cycle.

Chapter two

2. LITERATURE REVIEW In this chapter the study looked at the basic concepts of biofuel, Jatropha cultivation and

Processing and the environmental and economic aspects of biofuel production. The recent

findings on cultivation and processing, energy balance, GHG emission and economics of

Jatropha were also reviewed.

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2.1. Basic Concepts of Biofuel

2.1.1. Biofuel

The development of biofuel has a benefit from the point of environmental protection and

rise of energy prices.

2.1.1.1. Definition of biofuel

Biofuel is defined as “solid, liquid or gaseous fuel obtained from relatively recently

lifeless or living biological materials and is different from fossil fuels, which are derived

from long dead biological material” . The two most widely used types of

biofuels are biodiesel and ethanol. Biodiesel fuels are oxygenated organic compounds methyl

Esters-derived from a range of renewable sources such as vegetable oil, animal fat,

and cooking oil and the process has several by-product benefits. The oxygen found in

biodiesel makes it unstable and needs stabilization to avoid storage problems. Biodiesel

fuels passes processes of crushing seeds to extract oils and catalytic in which oils are

reacted with an alcohol into alkyl esters. Ethanol is manufactured from microbial

conversion of biomass materials (e.g. sugar cane, sweet sorghum, maize, wheat, potato

etc.) through fermentation. Ethanol contains 35 percent oxygen. The production process

consists of conversion of biomass to fermentable sugars, fermentation of sugars to ethanol,

and the separation and purification of the ethanol fuel .

2.1.1.2. Generations of biofuel

Based on substances converted to biofuel, technology and crop requirements biofuel is

Categorized into three generations . For the production of first generation

biofuels the basic feed stocks are often seeds or grains such as wheat, which yields starch

that is fermented into bioethanol, or sunflower seeds, palm oil, soya been, which are

pressed to yield vegetable oil that can be used in biodiesel. These feed stocks could instead

enter the animal or human food chain, and as the global population has raised their use in

producing biofuels has been criticized for diverting foodstuff away from the human food

chain which leads to food shortages and price rises. Second generation biofuels supporters

claim that a more viable solution is to increase political and industrial support for, and

rapidity of, second generation biofuel implementation from a variety of non-food crops,

including cellulosic biofuels. These include waste biomass, the stalks of wheat, wood and

special-energy-or-biomass crops such as Jatropha etc..

The third generation biofuels, Algae fuel (Oilgae), is a biofuel from algae. Algae are low input,

high-yield feed stocks to produce biofuels. However, currently they are very

expensive and require high energy for processing. It produces 30 times more energy per

acre than land crops such as soya beans .

2.2. Development Status of Biofuel There has been growing worldwide interest in biofuels as renewable sources of energy to

substitute fossil fuel. They are more evenly diffused in every country, although in varying

quantities and at different costs. The few producers of crude oil and their market power

also make biofuels attractive as a means of enhancing security of energy supply and

combating environmental impacts. Targeting the transport sector biofuels will either

wholly or partially (by blending into the petroleum products) substitute for gasoline and

diesel. Developing countries are concerned to what extent biofuels can expand their own

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energy supplies. The situation will change if biofuels from agricultural residues, energy

crops, wastes, and other feedstock’s become commercially viable .

2.2.1. Development status of biofuel in Africa

Renewable energy technologies and specifically biofuels offer developing countries a self-reliant

energy supplies at local and national levels, with potential economic,

environmental, social and security benefits. Regional institutions have playing roles in

developing rational energy policy and encouraging biofuel investment across the

continent. Information exchange and experience sharing have been encouraged among

institutions and practitioners who engaged in the sustainable energy development. The ongoing

African Roundtable on Sustainable Consumption and Production Program is a step

in the right direction towards overcoming the commercialization hurdles. Actions to

globalize the production and utilization of biofuel, including technology sharing between

African countries and others should be encouraged .

Strong tools are needed for estimating investment and operating costs of biomass to fuel

conversion plant in African countries, concentrating on parameters such as plant size, type

of feedstock, exchange rate, and other location-specific information, variables, to

investigate the applicability of the techniques developed, specifically (to demonstrate how

biofuel plant size optimization will benefit from availability of better capital and operating

cost-estimating techniques); to estimate the revenues that may be expected from avoided

carbon emissions. The greater the uncertainties of project cost such as capital cost, the

more cautious investors are likely to be .

2.2.2. Development status of biofuel in Ethiopia

The growing concern in Ethiopia is that an increase in feedstock cultivation will reduce

resources available for agricultural production that jeopardizes food security to the

growing human and livestock population. The energy system in the country is

characterized by the predominance of traditional fuels (firewood, crop residues, and

animal waste or dung etc.) which account nearly 94% of the total national energy

consumption. The demand for modern energy sources such as petroleum fuels is

increasing with increase in population and economic growth. Even though the share of

petroleum fuels is about 7% of the total consumption, the increasing demand for it and the

associated price hike have hit the national economy very hard. As a net importer of

petroleum, Ethiopia is highly vulnerable to price shocks and supply problems of oil in the

world market. This is the basis for the government to include large-scale commercial

production of biofuels as part of the range of other development programs (wind, biogas,

hydro-power, solar energy and natural gas and associated liquids) proposed to ensure

supply of modern energy services .

Ethiopian Ministry of Mines and Energy (MME) has prepared guidelines for the

implementation of projects to ensure the achievements of the objectives stated, while at

the same time avoiding unintended consequences. The strategy has addressed biofuel

development and use that are important elements to ensure social and environmental

sustainability. However, there are still some important elements that the strategy failed to

mention. At some points it lacks clarifications which open loop-holes that could

potentially lead to unintended consequences. One of the major worries is that the strategy

encourages large-scale production of biofuels at this early stage without even having a

proper land inventory which identifies the land available for various purposes.

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Development in such large- scales, if proper mechanisms are not put in place, could likely

leave permanent damages to the environment .

Ethiopian MME is encouraging investors who are engaged in biofuel production.

Currently there are over 68 developers engaged in the cultivation of energy crops (Castor

bean, Palm oil and Jatropha) for biodiesel production of which 15 of them were

developing Jatropha plantations in the country. The cultivation of Jatropha is expanding

widely and created 140,000 job opportunities so far. For bio-ethanol,

however, there are only six projects in the country of which four of them are government

owned sugar estates. So far, over 300,000 ha of land have already been allocated for

investors. Over 80% of these developments are happening in arable lands, forest lands and

woodlands. Many of these companies are still requesting for more lands for expansion of

biofuel production. Several other national and foreign investors have obtained investment

licenses for the development of biofuels from the Federal Investment Commission. The

land requirement of these investors adds up to 1.65 million hectares. The requirements for

obtaining permits are minimal and it seems to have attracted many international investors

lately. Currently, only 5 of the 20 feedstock producing companies

operating in Ethiopia are done environmental assessment.

2.3. Jatropha Cultivation, Processing and Uses

2.3.1. Description of Jatropha

Jatropha (physic nut) is a large shrub or small tree up to 5m tall and has a life expectancy

of about 50 years. It is originated in Central and South America but now has spread around

the world. The plant develops a deep taproot and initially four shallow lateral roots.

Normally Jatropha flowers only once a year during the rainy season. Jatropha flowers

almost throughout the year in permanently humid regions or under irrigated conditions

. The seeds become mature when the capsule changes from green to yellow.

Jatropha has a deciduous nature, shedding its leaves during the dry season. The plant

components contain toxic elements, mainly phorbol esters.

2.3.2. Jatropha cultivation

The initial production step towards biodiesel production of Jatropha is cultivation of trees.

The main inputs are land, plantation establishment and management practices including

the production and use of all machineries, infrastructure and energy. The main outputs are

seeds, Jatropha oil and biodiesel among other by-products (husks, seed-cake, and

glycerin), and soot emissions.

2.3.3. Jatropha oil extraction

The main inputs of oil extraction stage are Jatropha seeds, machineries, infrastructure and

energy. The main output is Jatropha oil and seed-cake is an important by-product. The

emissions of wastewater have to be accounted for in the outputs of the process

as well . The two methods mainly used for the extraction of Jatropha

are: (i) mechanical extraction and (ii) chemical extraction The

Jatropha seeds have to be dried prior to oil extraction . The seed could be

dried up in the oven (105C) or sun dried (3 weeks). Mechanical expellers can be fed with

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either whole seeds (common practice) or kernels or a mix of both. Only ground Jatropha

Kernels are used as feed for chemical extraction. The shells can be used directly as a

combustible by-product or gasification feedstock .

2.4 Biodiesel production There are four primary options for making biodiesel from fats and oils.

2.4.1. Direct use and blending

The possibility of direct use of vegetable oils as fuel has been recognized since

the beginning of the diesel engine.

However, the straight use of vegetable oils to replace the conventional fuels encounters

the operational problems due to its high viscosity (11-to-17 times higher than diesel fuel).

Polymerization, as a result of reactivity of C-C double bonds that may be present, lower

its volatility which causes the formation of carbon deposits in engines due to incomplete

combustion, and oil ring sticking, thickening and gelling of the lubricating oils as a result

of contamination .

Due to the great advancement in petroleum industries, fossil fuels could be

produced at much cheaper cost than biomass alternatives, resulting in, for many years, the

near elimination of the biomass fuel production infrastructure. However, interest in the

use of vegetable oils for engine fuels has been reported periodically.

Vegetable oils can be used by blending with the diesel fuel, given rise to the

improvement in physicochemical properties of the former. Nevertheless, the long term

use of this blending in a modern diesel engine becomes impractical because of the

decrease in power output and thermal efficiency by carbon deposits.

2.4.2. Micro emulsions

A micro emulsion is technically defined as a stable dispersion of one liquid phase

In to another, which has the droplet diameter approximately 100 nm or less.

Micro emulsion process has been studied for biodiesel production as a means to improve

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the viscosity of vegetable oils by blending with a simple alcohol i.e, methanol or ethanol

. However, the significant injector needle sticking, the carbon deposits, the

In complete combustion, and the increase in the viscosity of lubricating oils are reported

for utilizing the fuel produced from this process in long term run [7].

2.4.3. Thermal cracking (pyrolysis)

Pyrolysis is defined as the conversion of one substance into another by means of

heat in the absence of air or oxygen at temperatures range from 450 °C to 850 °C or by

heat with the aid of a Lewis acid catalyst. The Lewis acid catalysts used in this process

include zeolites, clay montmorrilite, aluminum chloride, aluminum bromide, ferrous

Chloride, and ferrous bromide. However, the removal of oxygen during thermal processing

also eliminates the environmental benefits associated with using an oxygenated fuel [5].

In addition, these fuels are produced more like gasoline rather than diesel.

2.4.4. Trans esterification (Alcoholysis)

Trans esterification reactions are a reversible reaction that involves the transformation of an ester

into a different ester. For manufacturing biodiesel, trans esterification is performed to lower the

viscosity of vegetable oils. Specifically, a triglyceride (TG) molecule (primary compound in

vegetable oils) reacts with a low molecular weight alcohol, yielding a mono alkyl ester and a

byproduct glycerin, which is used in pharmaceutical and cosmetic industries. The trans

esterification reaction for biodiesel synthesis is shown in Figure below:

Figure : Triglyceride trans esterification reaction.

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2.5 Physical and chemical properties

2.5.1 Fats and oils

Fats and oils are members of the lipids family. Lipids may either be a solid or

liquid at room temperature, depending on their structure and composition. Normally,

“oil” refers to a lipid that is liquid at room temperature, while “fat” refers to a lipid that is

solid or semi-solid at room temperature. Fats and oils primarily consist of esters of

glycerol (mono-, di-, and triglycerides) and low to moderate contents of free fatty acids

(carboxylic acids). Other compounds such as phospholipids, polypeptides, sterols, water,

odorants and other impurities can be found in crude oils and fats. The structures of mono-

, di-, and triglycerides (MGs, DGs, and TGs) consists of glycerol (a backbone of carbon,

hydrogen, and oxygen) esterificed with fatty acids (chains of carbon and hydrogen atoms

with a carboxylic acid group at one end), as shown in Figure 2.1. Free fatty acids (FFAs)

can contain 4-24 carbon atoms with some degree of unsaturation (typically 1-3 C-C

double bonds). Fats have more saturated fatty acids, the compositional building blocks,

than oils, which give rise to a higher melting point and higher viscosity of the former.

Consequently, biodiesel produced from saturated fats have a higher cloud and gel points

than those made from unsaturated oils, making the former unsuitable to use in cold

climates.

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2.5.2 Treating High FFA Waste Vegetable Oil

There are several methods to treat high FFA waste vegetable oils in small-scale systems. The

easiest is to mix the high FFA oil with low FFA oil. This will work for an occasional high FFA

batch. Other options require esterification (two-stage process) or intentionally make soap. These

options are:

- Add catalyst and water to change FFA to soap, and remove the soap

- Add acid and a large percentage of Methanol to covert FFA to usable product

- Add acid, heat and a smaller percentage of Methanol to covert FFA to a usable product

Adding catalyst and water to high FFA oil is the easiest solution, but it also has some

disadvantages. The percentage of feedstock that will be lost is higher then the percentage FFA.

100 gallons of waste vegetable oil will loose more than 10 gallons if it is 10% FFA. When this

procedure is carried out in the reaction tank, the resulting water and soap created will collect

above and below the oil. I found it time consuming to skim the soap off of the top of the oil.

Adding acid and large quantities of methanol to the oil is the most common method among

small-scale producers. The disadvantage to this method besides time is the cost of the methanol.

For 10% FFA, over seven gallons of methanol would be needed for the first stage to treat 40

gallons of oil. This is in addition to the eight gallons required for the second stage. A methanol

recovery system could return three gallons from the first stage and 1½ gallon from the second,

but this requires additional time and energy. This option requires an extra tank.

Adding acid with high heat (90 degree C) and smaller quantities of Methanol is not widely used.

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CHAPTER THREE

RESEARCH METHODOLOGY

3.1 Biodiesel reaction

The basic biodiesel reaction is shown in Figure below. This reaction is known as

transesterification (do-it-yourselfers often call it the one-step process). The

triglyceride is vegetable oil. R1, R2 and R3 represent any of the fatty acids listed in

Table 1. Reacting one part Vegetable oil with three parts Methanol gives three

parts Methyl Esters (Biodiesel) and one part Glycerol. In practical terms, the

volume of Biodiesel will be equal to the input volume of vegetable oil.

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3.2 Biodiesel process layout

Published literature about industrial plant design simulation of biodiesel production has been

scarce. Besides few studies evaluating simulation aspects of biodiesel production from several

vegetable oils, including canola, castor, rapeseed, soybean, sunflower, and waste cooking oil

have been conducted no work was found considering the conceptual design by using jatropha

curcas oil (JCO) as a feedstock in which JCO is converted via supercritical transesterification

with methanol to methyl esters (biodiesel) and glycerol as byproduct. Jatropha curcas oil (JCO)

is considered as the future feedstocks for biodiesel production because it is non-edible, easily

grown in a harsh environment and not compete with food resources. The main advantages using

supercritical methanol compared with conventional process include (i) no catalyst required; (ii)

not sensitive to both water and free fatty acid; and (iii) free fatty acids in the oil are esterified

simultaneously . The feedstock used in this process is jatropha curcas oil (JCO) since it is non-

edible, easily grown in a harsh environment, not compete with food resources and the price is

lower compared with edible oil.

Beginning at the left, jatropha oil was fed into the transesterification reactor simultaneously with

methanol and a recycled methanol. Before entering the reactor, jatropha and methanol were

pressurized to the reaction pressure (20 MPa) by P1 and P2. Then the pressurized stream flow

through heat exchanger H1 and brought to the desired temperature 340℃. A plug flow reactor

(PFR) was selected to carry out transesterification reaction. The transesterification products are

then fed to a flash tank (FT) where most of methanol evaporates whereas the other components

remain mostly in the liquid phase. V1 was used to depressurize stream from 20 to 0.2 MPa. Then

a distillation column (DC1) was used to further separate methanol. The recovered methanol was

then recycled and mixed with fresh methanol feed. After the PFR, FT and DC1, the bottom

stream was cooled down to 25 ℃ and was passed through a decanter (DEC) for separation of the

oil from the glycerol. Two liquid phases were formed: a glycerol rich phase and methyl oleate

rich phase. The oil stream leaving the final decanter was fed to a second distillation column

(DC2) to purify the biodiesel from other impurities where biodiesel is finally obtained as

distillate.

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3.3 Supercritical methanol process of Biodiesel flow sheet

Chapter four

Material balance and Energy balance calculations

4.1 Material balance There are 14 numbers of process streams in the system. The following paragraph will develop

the equations for the material balance in every unit.

The transesterification reaction involved in PFR is given by

The flow rate reactant is defined as

Let n1 =degree of the reaction 1 and αi = stoichiometric. It is defined as negative for feed and

positive for product.

The material balance of supercritical methanol process

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Figure .Flowchart shows the material balance of SCM process

The transesterification reaction involved in PFR reactor is given by Eq. above with a

94% conversion of triglyceride. The product for PFR is given by

The mass balance for methyl esters:

The mass balance for glycerol:

The mass balance for triglycerides:

Some approximations has been considered for vapor/liquid phase equilibrium. For our short cut

calculations, we assume ideal behavior which leads to the following assumptions:

𝜙𝑘 = 1, 𝛾𝑘 = 1, 𝑓𝑜𝑘 = 𝑃𝑜𝑘 (vapor pressure)

Antoine equation for vapor pressure: 𝑙𝑛 𝑃𝑜𝑘 = 𝐴𝑘 − 𝐵𝑘/(𝑇 + 𝐶𝑘) (10)

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These assumptions lead to Raoul’s Law:

𝑦𝑘/𝑥𝑘 = 𝑃𝑜𝑘/𝑃 = 𝐾𝑘 (11) with respect to the key components, a relative volatility can be defined

𝛼𝑘/𝑛 = 𝐾𝑘/𝐾𝑛 = 𝑃𝑜𝑘/𝑃𝑜𝑛 (12) The other split fraction for FT and DEC; and DC1 and DC2 can be calculated by using the

equation,

The product from PFR reactor will enter the FT and DC1 in order to recover the excess methanol

by distillation. Given the component list, the author choose methanol, M as a n component and

examine the relative volatilities of the component list at cooling water temperature. The split

fraction for ME, GLY and TG can be calculated by using above equation. The mass balances for

FT are given as below:

Table . The split fractions for FT, DC1, DEC and DC2



The mass balance for methanol:

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The mass balance for triglycerides

Here we would like to recover 99.99% of the M overhead, thus split fraction for the key

component, ξM= 0.999 and ξGLY=0.0001 while components ME and TG are heavier than heavy

key. The mass balance for DC1:





From DC1, the product will go to DEC for glycerol separation. The mass balance for DEC:





Finally, the last downstream purification for this process is the methyl ester purification by

distillation. The mass balance around the DC2 is given as:


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s

Figure Result of material balance

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From the overall mass balance, the product from PFR is determined (%Wt)- ME:41.64 %,

GLY:4.08 %, TG: 2.50% and M: 51.78% in which the molar ratio of methanol to oil used was

42. After the methanol recovery at FT and DC1, methanol is reduced to0.09(%mol). Glycerol is

an economically significant co-product that should be as fully refined as practicable. It is showed

that almost pure glycerol (96.49%) attained as by-product.

Finally, the biodiesel had a purity 99.96 % which passes the European biodiesel standard

EN 14214. It is observed that the results of this study is much better than the other studies and

jatropha curcas oil gives biodiesel yield higher than other oil feedstocks.

The properties of the biodiesel end-product stream

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4.2. ENERGY BALANCE

4.2.1 CALCULATION FOR DISTLATION COLUMN I

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1 2

Components at stage (1)

𝑀𝐸 = 43.28(.3896), = 16.9 𝐾𝑚𝑜𝑙/ℎ𝑟

𝐺𝐿𝑌 = 43.28(.1228) = 5.28 𝐾𝑚𝑜𝑙/ℎ𝑟

𝑇𝐺 = 43.28(.00783) = .338𝐾𝑚𝑜𝑙/ℎ𝑟

𝑀 = 43.28(.4791) = 20.761𝑘𝑚𝑜𝑙/ℎ𝑟

Components at stage (2) components at stage (3)

𝑀𝐸 = .748(22.54) = 16.859𝑘𝑚𝑜𝑙/ℎ𝑟 𝑀𝐸 = 0

𝐺𝐿𝑌 = .235(22.54) = 5.3𝑘𝑚𝑜𝑙/ℎ𝑟 𝑇𝐺 = 0

𝑀 = .009(22.54) = .02𝑘𝑚𝑜𝑙/ℎ𝑟 𝐺𝐿𝑌 = 0

𝑇𝐺 = .015(22.54) = .338𝑘𝑚𝑜𝑙/ℎ𝑟 𝑀 = 1(20.74)

= 20.74𝑘𝑚𝑜𝑙/ℎ𝑟

𝑃𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑜𝑛 𝑟𝑎𝑡𝑒 = 40000𝑡𝑜𝑛/ℎ𝑟, = 4566𝑘𝑔/ℎ𝑟

22

Q(1) =

= 𝑚𝑐𝑝( (𝑡2 − 𝑡1)𝑀 + 𝑚𝑐𝑝(𝑡2 − 𝑡1) 𝑇𝐺 + 𝑚𝑐𝑝(𝑡2 − 𝑡1)𝐺𝐿𝑌 + 𝑚𝑐𝑝(𝑡2 − 𝑡1)𝑀𝐸)

𝑄𝑀 = 𝑚𝑐𝑝(𝑡2 − 𝑡1) = 20.61 𝑐𝑝 = 3453.2𝐽

𝑄𝑇𝐺 = 𝑚𝑐𝑝(𝑡2 − 𝑡1) = .338𝑐𝑝 (105.3℃ − 104.3℃) = 1030.5𝐽

𝑄𝐺𝐿𝑌 = 𝑚𝑐𝑝(𝑡2 − 𝑡1) = 5.28𝑐𝑝 (105.3℃ − 104.3℃) = 1158.5𝐽

𝑄𝑀𝐸 = 𝑚𝑐𝑝(𝑡2 − 𝑡1) = 16.9𝑐𝑝 (105.3℃ − 104.3℃) = 2352𝐽

𝑄 (1) = ∑𝑄 = 7994𝐽

𝑄2 = 𝑚𝑐𝑝( (𝑡2 − 𝑡1)𝑀 + 𝑚𝑐𝑝(𝑡2 − 𝑡1) 𝑇𝐺 + 𝑚𝑐𝑝(𝑡2 − 𝑡1)𝐺𝐿𝑌 + 𝑚𝑐𝑝(𝑡2 − 𝑡1)𝑀𝐸)

𝑄𝑀 = 𝑚𝑐𝑝(𝑡2 − 𝑡1) + 𝑚𝜆

𝑄𝑀 = .02𝑐𝑝 (105.3℃ − 104.3℃) + 0.02𝜆 = 2246𝐽

𝑄𝐺𝐿𝑌 = 5.3𝑐𝑝(105.3℃ − 104.3℃) = 2340.5𝐽

𝑄𝑇𝐺 = 𝑚𝑐𝑝(𝑡2 − 𝑡1) = . 𝐺33802𝑐𝑝 (105.3℃ − 104.3℃) = 118.3𝐽

𝑄𝑀𝐸 = 𝑚𝑐𝑝(𝑡2 − 𝑡1) = 16.859 𝑐𝑝 (105.3℃ − 104.3℃) = 0.00

𝑄2 = ∑𝑄 = 4704.3𝐽

𝑄3 = 𝑚𝑐𝑝(𝑡2 − 𝑡1)𝑀 + 𝑚𝜆

𝑄3 = 20.74 𝑐𝑝 (105.3℃ − 104.3℃) + 20.74 𝜆

𝐻𝑒𝑎𝑡 𝑜𝑢𝑡 = 𝑄2 + 𝑄1 , 1170.5 𝐽 + 4704.3 𝐽 = 5874.8 𝐽

𝐻𝑒𝑎𝑡 𝑖𝑛 = 𝑄1 ,7994𝐽

𝐻𝑒𝑎𝑡 𝑝𝑟𝑜𝑣𝑖𝑑𝑒𝑑 𝑏𝑦 𝑡ℎ𝑒 𝑠𝑡𝑒𝑎𝑚 𝑖𝑛 𝑡ℎ𝑒 𝑟𝑒𝑏𝑜𝑖𝑙𝑒𝑟

𝑄𝑠 = 𝑄 𝑜𝑢𝑡 − 𝑄 𝑖𝑛 , 5874.8𝐽 – 7994𝐽 = −2120𝐽𝑠

4.2.2CALCULATIONS ON DISTILATION COLUMN 𝑰𝑰

𝟐

23

`

𝟏 3 𝟑

1. 𝐹 = 17.19𝑘𝑚𝑜𝑙/ℎ𝑟

0.9789𝑀𝐸, 0.0006𝐺𝐿𝑌, 0.0192 𝑇𝐺

0.0012𝑀, 𝑇𝑒𝑚𝑝 = 25℃

2. 𝐹 = 0.33𝑘𝑚𝑜𝑙/ℎ𝑟

0.0101𝑀𝐸, 0.00𝐺𝐿𝑌

0.9899𝑇𝐺, 0.00𝑀

𝑇𝑒𝑚𝑝 = 274℃, 3𝑘𝑝𝑎

3. 𝐹 = 16.86𝑘𝑚𝑜𝑙/ℎ𝑟

0.9981𝑀𝐸, 0.0006𝐺𝐿𝑌, 0.00𝑇𝐺

𝑇𝑒𝑚𝑝 = 274℃, 𝑝 = 3.5𝑘𝑝𝑎

ENERGY BALANCE OF COMPONENTS

STAGE ONE

𝑀𝐸 17.19(. 9789) = 16.83𝑘𝑚𝑜𝑙

ℎ𝑟

𝐹 = 17.19𝑘𝑚𝑜𝑙/ℎ𝑟

𝐺𝐿𝑌 = 0.0, 𝑇𝐺 = .0192(17.19) =0.3𝑚𝑜𝑙

ℎ𝑟

𝑀 = 0.0012(17.19) = 0 .02𝑘𝑚𝑜𝑙

ℎ𝑟

24

STAGE TWO

𝐹 = 0.33 𝑘𝑚𝑜𝑙/ℎ𝑟, 𝑀 = 0.00𝐹

𝑀𝐸 = 0.0101(0.33) = .00336 𝑘𝑚𝑜𝑙 /ℎ𝑟

𝑇𝐺 = 0.9899( 0.33) = 0.32 𝑘𝑚𝑜𝑙/ℎ𝑟

𝐺𝐿𝑌 = 0

STAGE THREE

𝐹 = 16.86 𝑘𝑚𝑜𝑙/ℎ𝑟

𝑀𝐸 = 0.9981(16.86) = 16.82 𝑘𝑚𝑜𝑙/ ℎ𝑟 , 𝑀 = 0.012(16.86) = 0.2 𝑘𝑚𝑜𝑙/ℎ𝑟

𝐺𝐿𝑌 = 0.0006(16.86) = 0.01 𝑘𝑚𝑜𝑙/ℎ𝑟 , 𝑇𝐺

= 0 ,

OVERALL ENERGY BALANCE

𝑄1 = (( 𝑚 𝑐𝑝 ∆𝑡)𝑀 + (𝑚𝑐𝑝∆𝑡)𝑇𝐺 + (𝑚𝑐𝑝∆𝑡)𝐺𝐿𝑌 + (𝑚𝑐𝑝∆𝑡)𝑀𝐸)1 𝑎𝑡 𝑡𝑒𝑚𝑝 = 25𝑜𝐶

𝑄𝑀 = (0.02 ∗ 𝑐𝑝 (274℃ − 25℃)) = 327.5𝐽

𝑄𝑇𝐺 = ( 0.33 𝑐𝑝 (274℃ − 25℃)) = 8626𝐽

𝑄𝐺𝐿𝑌 = ( 0.00 𝑐𝑝(274℃ − 25℃)𝑡) = 0.00

𝑄𝑀𝐸 = ( 16.83 𝑐𝑝 (274℃ − 25℃)) = 1970𝐽

𝑄1 = 𝛴𝑄 = 8626𝐽 + 0.00 + 1970𝐽 = 10923𝐽

𝑄2 = (( 𝑚 𝑐𝑝 ∆𝑡)𝑀 + (𝑚𝑐𝑝∆𝑡)𝑇𝐺 + (𝑚𝑐𝑝∆𝑡)𝐺𝐿𝑌 + (𝑚𝑐𝑝∆𝑡)𝑀𝐸)2 𝑎𝑡 𝑡𝑒𝑚𝑝, 274 𝑜𝐶

𝑄𝑀 = ( ( 0.0 ∗ 𝑐𝑝(274℃ − 25℃) + 𝜆𝑚 = 0.0 + 𝜆𝑚)2 = 0.0

𝑄𝑇𝐺 = ( 0.326 ∗ 𝑐𝑝 (274℃ − 25℃)) = 4058.7𝐽

𝑄𝐺𝐿𝑌 = ( 0.00 ∗ 𝑐𝑝(274℃ − 25℃)) = 0.00

𝑄𝑀𝐸 = (0.00336 ∗ 𝑐𝑝 (274℃ − 25℃)) = 33.46𝐽

𝑄2 = 𝛴𝑄 = 4058.7𝐽 + 33.46𝐽 + 0.00 + 0.00 = 4093𝐽

25

𝑄 3 = (( 𝑚 𝑐𝑝 ∆𝑡)𝑀 + (𝑚𝑐𝑝∆𝑡)𝑇𝐺 + (𝑚𝑐𝑝∆𝑡)𝐺𝐿𝑌 + (𝑚𝑐𝑝∆𝑡)𝑀𝐸)3 , 𝑎𝑡 𝑡𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒

= 170 𝑜𝐶

𝑄𝑀 = ( ( 16.82 ∗ 𝑐𝑝(274℃ − 170℃) ) + 𝜆𝑚)3 = 1715.6𝐽

𝑄𝑇𝐺 = ( 0.00 ∗ 𝑐𝑝 (274℃ − 25℃)) = 0.00

𝑄𝐺𝐿𝑌 = ( 0.01 𝑐𝑝 (274℃ − 25℃)) = 340𝐽

𝑄𝑀𝐸 = ( 0.2 ∗ 𝑐𝑝 ∗ (274℃ − 25℃)) = 1763𝐽

𝑄3 = 𝛴𝑄 2 = 1715.6𝐽 + 340𝐽 + 1763𝐽 + 0.00 = 3818𝐽

𝑇ℎ𝑒𝑛 , ℎ𝑒𝑎𝑡 𝑜𝑢𝑡 = 𝑄2 + 𝑄3 = 3818J + 4093J = 7911.5J

𝐻𝑒𝑎𝑡 𝑖𝑛 = 𝑄1 = 10923𝐽 , finally the heat provided by steam in the reboiler becomes,

Qs = Q out – Q in

Qs = 7911.5J – 10923𝐽 = −3011.5J

4.2.3 Energy balance of plug flow reactor

Heat of reaction calculations

|

∆𝐻𝑟 = ∆𝐻𝑓𝑝 − ∆𝐻𝑓𝑟

∆𝐻𝑓𝑝 = 3∆𝐻𝑀𝐸 + ∆𝐻𝐺𝐿𝑌

∆𝐻𝑓𝑝 = 3(−734.5𝑘𝑔

𝑚𝑜𝑙+ (−699.6)

𝑘𝑔

𝑚𝑜𝑙 =-2903

𝑘𝑔

𝑚𝑜𝑙

∆𝐻𝑓𝑟 = ∆𝐻𝑇𝐺 + 3∆𝐻𝑀

∆𝐻𝑓𝑟 = −2161𝑘𝐽

𝑚𝑜𝑙+ 3 ∗ (−239.2

𝑘𝐽

𝑚𝑜𝑙)=-2878.8

𝑘𝑔

𝑚𝑜𝑙

26

∆𝐻𝑟 = −2903𝑘𝐽

𝑚𝑜𝑙+ 2878.8

𝑘𝐽

𝑚𝑜𝑙= −24

𝑘𝐽

𝑚𝑜𝑙

∆𝑢 = 𝑄 + (𝑊𝑓 + 𝑊𝑠)

There is no work done by the shaft, so ∆𝑢 = 𝑄 + 𝑊𝑓

𝑊𝑓 = 𝑝∆𝑉 , 𝑠𝑜 , ∆𝑢 = 𝑄 + 𝑃𝑉

But ∆𝑢 + 𝑃𝑉 = ∆𝐻

∴ 𝑄 = 𝑛∆𝐻 , where, 𝑛 𝑖𝑠 𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑚𝑜𝑙𝑒𝑠

𝑛 =𝑚 ̇

�̇�𝑤𝐶𝐻3𝑂𝐻 =

6473.5 𝑘𝑔/ℎ𝑟

32𝑘𝑔/𝑘𝑚𝑜𝑙

n=203 kmol

𝑄 = 203 × (−24) = −4912.6𝑘𝐽/𝑘𝑚𝑜𝑙

4.3 Equipment sizing

4.3.1VOLUME OF PFR (PLUG FLOW REACTOR)

𝑃 = 20 𝑚𝑝𝑎 , 𝑋, 𝑇𝐺 = 0.94𝑠

𝑇𝑒𝑚𝑝 = 340℃

𝐹 = 215.66𝑘𝑚𝑜𝑙/ℎ𝑟 𝐹 = 216.57 𝑘𝑚𝑜𝑙/

ℎ𝑟

𝑀 = 0.338 𝑓 𝑀 = 0.896, 𝑀𝐸 = 0.0779

𝑇𝐺 = 0.0262 𝑇𝐺 = 0.0016 , 𝐺𝐿𝑌 = 0.0241

Considering without catalyst , 𝑇 = 340℃ , p = 20mpa

27

Assumptions

15% 𝑆𝐹

Volume =𝑚

𝜌

The reaction is

Calculating the mass flow rate of the reacting species ,

�̇� 𝑀 = 0.938(215.66) =202.3 kmol/hr

�̇� TG = 0.0262(215.66) = 5.65 kmol/hr

V total = 𝑚

𝜌1 + =

𝑚

𝜌2

V= 202.3 + 0.15(202.3)

𝜌1 +

5.65 + 0.15(5.65)

𝜌2

V = 232.65

𝜌1 +

6.5

𝜌2 , 𝑣 =

232.65 𝑘𝑔

0.7918𝑘𝑔/𝑚3=294𝑚3

If the reactor is 80% full on each cycle,

So volume of reactor 𝑣𝑟 =𝑣

0.8=

294𝑐

0.8= 367.5𝑚3

4.3.2 Volume of Flow tank

𝐹 = 216.57𝑘𝑚𝑜𝑙/ℎ𝑟

GLY= 0.0246, 𝑇𝐺 = 0.001

M= 0.896𝑇𝑒𝑚𝑝 = 340℃ , 𝑃 = 20 𝑚𝑝𝑎

Calculate mass flow rates of each component

28

�̇�𝑀𝐸 = 0.0779(216.57) = 16.9𝑘𝑚𝑜𝑙/ℎ𝑟 = 5002.4𝑘𝑔/ℎ𝑟

�̇�𝑇𝐺 = 0.0016(216.57) = 0.35𝑘𝑚𝑜𝑙/ℎ𝑟 = 309.4𝑘𝑔/ℎ𝑟

�̇�𝐺𝐿𝑌 = 0.0246(216.57) = 5.4𝑘𝑚𝑜𝑙/ℎ𝑟 = 469.8𝑘𝑔/ℎ𝑟̇

�̇�𝑀 = 0.896(216.57) = 194.046𝑘𝑚𝑜𝑙/ℎ𝑟 = 10282𝑘𝑔/ℎ𝑟

The volume of reactants with 15% SF, becomes

𝑣𝑡𝑜𝑡𝑎𝑙 =𝑚𝑀𝐸

𝜌+

𝑚𝑇𝐺

𝜌+

𝑚𝐺𝐿𝑌

𝜌+

𝑚𝑀

𝜌

𝑣𝑡𝑜𝑡𝑎𝑙 =5002.4𝑘𝑔/ℎ𝑟

0.88𝑘𝑔𝑙𝑡

+309.4𝑘𝑔/ℎ𝑟


+469.8𝑘𝑔/ℎ𝑟


+110282𝑘𝑔/ℎ𝑟


𝑣𝑡𝑜𝑡𝑎𝑙 = 145929.11𝑙𝑡

𝑉𝑜𝑙𝑢𝑚𝑒 𝑜𝑓 𝑡ℎ𝑒 𝑓𝑙𝑜𝑤 𝑡𝑎𝑛𝑘 = 145.9 𝑚3

4.4 COST ESTIMATION An acceptable plant design must present a process that is capable of operating under conditions

which will yield a profit. Since, Net profit = Total income – All expenses It is essential that

Chemical engineer be aware of the many different types of cost involved in manufacturing

processes. Capital must be allocated for direct plant expenses, such as those for raw materials,

labor, and equipment. Besides direct expenses, many other indirect expenses are incurred, and

these must be included if a complete analysis of the total cost is to be obtained. Some examples

of these indirect expenses are administrative salaries, product distribution costs and cost

for interplant communication. A capital investment is required for any industrial process and

determination of the necessary investment is an important part of a plant design project. The total

investment for any process consists of fixed capital investments for physical \equipment and

facilities in the plant plus working capital which must be available to pay salaries, keep raw

materials and products on hand, and handle special items requiring a direct cost outlay. Thus in

an analysis of cost in industrial processes, capital investment cost, manufacturing cost, and

general expenses including income taxes must be taken into consideration.

CAPITAL INVESTMENT

29

Before an industrial plant can be put into operation, a large sum of money must be supplied to

purchase and install the necessary machinery and equipment. Land and service facilities must be

obtained and the plant must be erected complete with all piping, controls and service. In addition

it is necessary to have money available for the payment of expenses involved in the plant

operation. The total capital required for installation and working of a plant is called total capital

investment.

Total Capital Investment = Fixed Capital + Working Capital

Fixed Capital Investment: the capital needed to supply necessary manufacturing and plant

facilities is called fixed capital investment. The fixed capital is further subdivided into

manufacturing fixed capital investment and non-manufacturing fixed capital investment.

Working Capital: The capital required for the operation of the plant is known as

working capital.

FIXED CAPITAL INVESTMENT INCLUDE

A. DIRECT COST

1. Purchased Equipment Cost

2. Purchased Equipment Installation

3. Installation Cost

4. Instrumentation and Controls

5. Piping

6. Electrical Installation

7. Building including services

8. Yard improvement

9. Service facilities

10. Land

B. INDIRECT COST

1. Engineering and supervision

2. Construction expenses

3. Contractors fee

4. Contingencies

5. Startup expenseCost Estimation

WORKING CAPITAL INCLUDES:

1. Raw materials and supplies carried in stock

2. Finished product in stock and semi-finished products in the process of

being manufactured.

3. Accounts receivable.

4. Cash kept on hand for monthly payment of operating expenses, such as

salaries, wages, and raw material purchased.

5. Accounts payable.

6. Taxes payable.

30

4.5 COST INDEXES: A cost index is merely an index value for a given point in time showing the cost that time

relative to certain base time. So, present cost is estimate from cost index as follows Present

Cost= Original Cost x (Index Value at Present Time/Index value at Time Original Cost was

Obtained) Cost index can be used to give a general estimate.

𝑷𝒍𝒖𝒈 𝒇𝒍𝒐𝒘 𝒓𝒆𝒂𝒄𝒕𝒐𝒓(𝑷𝑭𝑹)

𝐼𝑛𝑠𝑖𝑑𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 = 7.5𝑚

𝐻𝑒𝑖𝑔ℎ𝑡 = 14.35𝑚

𝑇𝑜𝑡𝑎𝑙 𝑐𝑎𝑝𝑎𝑐𝑖𝑡𝑦 = 367𝑚3

= 96,944.62𝑔𝑎𝑙𝑙𝑜𝑛

𝐶𝑜𝑠𝑡 𝑜𝑓 𝑃𝐹𝑅 = $82,000

15% 𝑐𝑜𝑠𝑡 𝑓𝑜𝑟 𝑐𝑜𝑜𝑙𝑖𝑛𝑔 𝑠/𝑚 = $7,500

𝑇𝑜𝑡𝑎𝑙 𝑐𝑜𝑠𝑡 = $89,500

𝐶𝑜𝑠𝑡 𝑖𝑛𝑑𝑒𝑥 1990 = 952

𝐶𝑜𝑠𝑡 𝑖𝑛𝑑𝑒𝑥 2014 = 1840

𝐶𝑜𝑠𝑡 𝑖𝑛 2014 = (82,000 ∗ 1840)/952

𝐶𝑜𝑠𝑡 𝑖𝑛 2014 = $15,8487.7

“𝑫𝒊𝒔𝒕𝒊𝒍𝒍𝒂𝒕𝒊𝒐𝒏 𝒄𝒐𝒍𝒖𝒎𝒏”(𝑰)

𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑜𝑓 𝑡ℎ𝑒 𝑐𝑜𝑙𝑢𝑚𝑛 = 13.4𝑓𝑡

𝐻𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝑐𝑜𝑙𝑢𝑚𝑛 = 68.5𝑓𝑡

𝑇𝑜𝑡𝑎𝑙 𝑝𝑢𝑟𝑐ℎ𝑎𝑠𝑒𝑑 𝑐𝑜𝑠𝑡 = $1526140

𝑃𝑢𝑟𝑐ℎ𝑎𝑠𝑒𝑑 𝑐𝑜𝑠𝑡 𝑖𝑛 2014 = (1526140 ∗ 1840)/952

= 2949682.5

𝑫𝒊𝒔𝒕𝒊𝒍𝒍𝒂𝒕𝒊𝒐𝒏 𝒄𝒐𝒍𝒖𝒎𝒏 (𝑰𝑰)

31


𝐻𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝑐𝑜𝑙𝑢𝑚𝑛 = 57𝑓𝑡



= $2367956.3

𝑫𝒆𝒄𝒂𝒏𝒕𝒆𝒓


𝐻𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝑐𝑜𝑙𝑢𝑚𝑛 = 28.4𝑓𝑡



= $4638.65

Flow tank

𝐼𝑛𝑠𝑖𝑑𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 = 4.2 𝑚

𝑇𝑜𝑡𝑎𝑙 ℎ𝑒𝑖𝑔ℎ𝑡 = 6.2 𝑚

𝐶𝑎𝑝𝑎𝑐𝑖𝑡𝑦 = 16.4 𝑚3

𝑃𝑢𝑟𝑐ℎ𝑎𝑠𝑒𝑑 𝑐𝑜𝑠𝑡 𝑖𝑛 1990 = 15 , 000

𝑃𝑢𝑟𝑐ℎ𝑎𝑠𝑒𝑑 𝑐𝑜𝑠𝑡 𝑖𝑛 2014 = (1500 × 1840)

952

32

= $ 28991.6

Table of purchased equipment cost

𝑪𝒐𝒔𝒕 𝒆𝒔𝒕𝒊𝒎𝒂𝒕𝒊𝒐𝒏 𝒇𝒐𝒓 𝒑𝒓𝒐𝒄𝒆𝒔𝒔𝒊𝒏𝒈 𝒑𝒍𝒂𝒏𝒕𝒔

𝐸 = $5509756

𝑃𝑢𝑟𝑐ℎ𝑎𝑠𝑒𝑑 𝑒𝑞𝑢𝑖𝑝𝑚𝑒𝑛𝑡 𝑖𝑛𝑠𝑡𝑎𝑙𝑙𝑎𝑡𝑖𝑜𝑛 47% 𝐸 = $2589585

𝐼𝑛𝑠𝑡𝑟𝑢𝑚𝑒𝑛𝑡𝑎𝑡𝑖𝑜𝑛 𝑎𝑛𝑑 𝑐𝑜𝑛𝑡𝑟𝑜𝑙 18% 𝐸 = $991356

𝐸𝑙𝑒𝑐𝑡𝑟𝑖𝑐𝑎𝑙 𝑖𝑛𝑠𝑡𝑎𝑙𝑙𝑒𝑑 11% 𝐸 = $606,073

𝐵𝑢𝑖𝑙𝑑𝑖𝑛𝑔𝑠 18% 𝐸 = $991756

𝑆𝑒𝑟𝑣𝑖𝑐𝑒𝑠 𝑓𝑎𝑐𝑖𝑙𝑖𝑡𝑦 70%𝐸 = $3816829

𝐿𝑎𝑛𝑑 6% 𝐸 = $330585

𝑇𝑜𝑡𝑎𝑙 𝑑𝑖𝑟𝑒𝑐𝑡 𝑎𝑛𝑑 𝑖𝑛𝑑𝑖𝑟𝑒𝑐𝑡 𝑝𝑙𝑎𝑛𝑡 𝑐𝑜𝑠𝑡 [𝐷 + 𝐼] = $1169449

𝐶𝑜𝑛𝑡𝑟𝑎𝑐𝑡𝑜𝑟’𝑠 𝑓𝑒𝑒𝑙, 20%𝐸 = $1157048.7

𝐶𝑜𝑛𝑡𝑖𝑛𝑔𝑒𝑛𝑐𝑦, 42%𝐸 = $2314097.5

𝐹𝑖𝑥𝑒𝑑 𝑐𝑎𝑝𝑖𝑡𝑎𝑙 𝑖𝑛𝑣𝑒𝑠𝑡𝑚𝑒𝑛𝑡 = $3471145

𝑊𝑜𝑟𝑘𝑖𝑛𝑔 𝑐𝑎𝑝𝑖𝑡𝑎𝑙 86%𝐸 $4738370

𝑇𝑜𝑡𝑎𝑙 𝑐𝑎𝑝𝑖𝑡𝑎𝑙 𝑖𝑛𝑣𝑒𝑠𝑡𝑚𝑒𝑛𝑡 = $820953

Equipment Cost in 1990($) Cost in 2014($)

PFR reactor 82,000 158487

Distillation column 1 1526140 2949682.6

Distillation column 2 1225160 2367956.3

Flow tank 15000 28991.6

Decanter 24000 4638.65

Total 2872300 5509756

33

1. 𝑅𝑎𝑤 𝑚𝑎𝑡𝑒𝑟𝑖𝑎𝑙

𝐶3𝑂𝐻 = 0.53𝑇𝑃𝐿 = 0.53[820953] = $4351053

𝐶57𝐻104𝑂6 = 0.3𝑇𝑃𝐿 = 0.3[ 820953] = $2462860

2. 𝑂𝑝𝑟𝑎𝑡𝑖𝑛𝑔 𝑙𝑎𝑏𝑜𝑟 [10 − 20% 𝑇𝑃𝐿]

= 0.15𝑇𝑃𝐿 = 0.15[820953] = $1231430

3. 𝑢𝑡𝑖𝑙𝑖𝑡𝑖𝑒𝑠[10 − 20%]𝑇𝑃𝐿

= 0.15𝑇𝑃𝐿 = 0.15[$820953] = $1231430

4. 𝑀𝑎𝑖𝑛𝑡𝑒𝑛𝑎𝑛𝑐𝑒 𝑎𝑛𝑑 𝑟𝑒𝑝𝑎𝑖𝑟 [2 − 10%𝐹𝐶𝐼]

(0.06)(34711453) = $208268.7

𝐹𝑖𝑥𝑒𝑑 𝑐𝑜𝑠𝑡

1, . 𝑑𝑒𝑝𝑟𝑒𝑐𝑖𝑎𝑡𝑖𝑜𝑛 [10%𝐹𝐶𝐼]

= 0.1[$3471145]

= $347114.5

2, 𝐿𝑂𝐶𝐴𝐿 𝑇𝐴𝑋 [1 − 4%]𝐹𝐶𝐼

0.025[$3471145]

= $86778.6

3, 𝐼𝑁𝑆𝑈𝑅𝐴𝑁𝐶𝐸 [0.5_1%]𝐹𝐶𝐼

= 0.0075[$3471145]

= $26033.5

𝑇𝑃𝐶 = 𝑉𝑎𝑟𝑖𝑎𝑏𝑙 𝑐𝑜𝑠𝑡 + 𝐹𝑖𝑥𝑒𝑑 𝑐𝑜𝑠𝑡

= 0.628𝑇𝑃𝐶 + $2252468

= $5139168 + $2252468

34

= $7391637

𝑃𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑜𝑛 𝑐𝑜𝑠𝑡 = 𝑎𝑛𝑛𝑢𝑎𝑙 𝑝𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑜𝑛 𝑐𝑜𝑠𝑡

𝑎𝑛𝑛𝑢𝑎𝑙 𝑝𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑜𝑛 𝑟𝑎𝑡𝑒

=7391637

40000 𝑡𝑜𝑛

= $184.7

𝑡𝑜𝑛

𝑃𝑎𝑦𝑏𝑎𝑐𝑘 𝑝𝑒𝑟𝑖𝑜𝑑

𝑆𝑒𝑙𝑙𝑖𝑛𝑔 𝑝𝑟𝑖𝑐𝑒 = $600

𝑡𝑜𝑛

𝑃𝑟𝑜𝑓𝑖𝑡/𝑦𝑒𝑎𝑟 = 𝑆𝑒𝑙𝑙𝑖𝑛𝑔 𝑝𝑟𝑖𝑐𝑒 – 𝑝𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑜𝑛 𝑐𝑜𝑠𝑡

= 600 − 184.7 = 415.3

𝑁𝑒𝑡 𝑝𝑟𝑜𝑓𝑖𝑡 𝑎𝑓𝑡𝑒𝑟 𝑡𝑎𝑥 = 0.65(415.3 × 40000) = $10797800

𝐷𝑒𝑝𝑟𝑒𝑐𝑖𝑎𝑡𝑖𝑜𝑛 = 𝑣 − 𝑣𝑠

𝑛

= $ 3471145

10 = $ 347114.5

𝑃𝑎𝑦𝑏𝑎𝑐𝑘 𝑝𝑒𝑟𝑖𝑜𝑑 = 𝐹𝑖𝑥𝑒𝑑 𝑐𝑎𝑝𝑖𝑡𝑎𝑙 𝑖𝑛𝑣𝑒𝑠𝑡𝑚𝑒𝑛𝑡

𝑝𝑟𝑜𝑓𝑖𝑡 + 𝑑𝑒𝑝𝑟𝑒𝑐𝑖𝑎𝑡𝑖𝑜𝑛

= 3471145

347114.5 + 1079800

35

= 2.43 𝑦𝑒𝑎𝑟𝑠

4.6 Safety and Environment Biodiesel producers are regulated by two entities: OSHA and the environmental protection agency.

OSHA’s concern is with the environment for the workers. It considers biodiesel production facilities

to be chemical plants. The handling/storage of class a flammable liquids (methanol) can be found

under section 29.1910.106. Some of the rules that may apply are: Methanol storage containers must be metal, grounded, use masonry supports and must not

spill contents if connectors burn through

Space required around tanks for fire fighting access

Explosion No other operations in the room with the equipment

proof electrical wiring The environmental protection agency (EPA) deals only with the protection of the environment. In the

case of biodiesel, most of the concern is about containment from spills of the various fluids.

4.7 Conclusion Nowadays, biodiesel is produced in great amount and its production continues to grow. The main

technology used in the industrial production is based on the transesterification of refined oils

with methanol using basic super critical methanol process (with no catalyst). However, the

problems related with this technology (mainly in product purification) have stimulated research

in the field of heterogeneous catalysis for biodiesel production. In particular, industry is making

great research efforts to find the right catalyst, and today, a plant based on super critical

methanol process. However, the research has not stopped there because several tasks still need to

be done.

36

References [1] Tovar, Líela y Téllez, Mauricio..

[2] Kann J., Rang H., , and Kriis J.. Advances in

biodiesel fuel research. Proc. Estonian Acad. Sci.

Chem., 51, 2, p.75–117 (2002).

[3]COLCIENCIAS. 2004. Agenda y Novedades.

http://www.colciencias.gov.co/agenda/pn113.html.

[4] Krung and Teixeira Mendes Y. Improving of

mamoneira, cited by Mazzani, Bruno. Oil plants.

Agronomic Research Center of Agricultural

Ministery. Central University of Venezuela.

Agronomy department. Barcelona . Salvat, 1963. p.

150.

[5] Yamane, K., Ueta, A. and Shimamoto, Y. Influence

of physical and chemical properties of biodiesel fuels

on injection, combustion and exhaust emission

characteristics in a direct injection compression

ignition engine. Int J Engine Research 2, 4, 249-

261.(2001).

[6] Ma, F., Hanna M.A. Biodiesel production: a review.

Bioresource Technology 70, 1-15.(1999).

[7] Kinast, J.A..Production of Biodiesels from Multiple

Feedstocks andProperties of Biodiesels and

Biodiesel/Diesel Blends.Final Report. National

Renewable Energy Laboratory. (2003).

37

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