bio diesel

TECHNICAL PROJECT REPORT

MANUFACTURE OF BIO-FUEL BY TRANS-ESTERIFICATION

PROSESS OF BIODEGRADABLE TBOs

AND OTHER SUCH FEED STOCKS.

CAPACITY: 60,000 KL/YR FEED STOCK

SANKLP BIOFULS ENGERY TECH

GAT NO 238, VIL- WADGAON ANAND JUNNAR, DIST-PUNE.

MAHARASHTRA-PIN CODE---412411 1. OBJECTIVE

To establish a process plant for the manufacture of Bio-diesel and specialty Fatty acid, Methyl ester, Glycerin and other specialty products as in Annex B, by Trans-esterification catalyzed process of wide cut petroleum base stock like Edible / Non edible oil, Animal fat, Tap grease etc. The proposed plant capacity is equivalent to 60,000 KL/year of final products. The process design is to continuous operation to make two basic process the plant can also take other hydrocarbon fractions from petrochemical, organic chemical, mineral and other process plant as well.

The proposed unit is named as SANKALP BIO -TECH and will be located at the Gat No 238, ViL: Wadgaon Anand on NH-No 222 Tal: Junnar Dist Pune Maharashtra. About Mumbai 150 Km, Raigad 150 km, Thane 125 km, Nasik 100 km, Pune 100 km, Ahmednagar 75 km, Aurangabad 150 km. This is industrially C zone and several attractive from state Govt. are available.

All the base stock will be available from the rural and urban aria of India and many processing plant in the word.

The products will be absorbed by large number of Truck, Tractor, Generator, Boiler, Foundry and other Industries in all over the word.

Bio-diesel has been produced for many years. In resent times it has become commercially viable for many producers and end users alike, mostly due to spiraling fuel prices, Government taxation and

dwindling crude oil supplies. Numerous production facilities have sprung up to reap the benefit of producing environmentally friendly fuels.

2. RAW MATERIAL

Wide Trans – estrification and process catalyzed base stock are the major raw materials. These include -

1 Light distillates from the tank bottoms of edible oil refinery sludge’s

2 Light distillates Fatty Acid from refineries.

3. Light distillates sludge’s from mat tan tallow.

4. Light distillates process from Animal Fats.

5. Middle distillates and Tap Grease from hotels.

6. Middle distillates and Soya / Pam / Atrophy

7. Middle distillates and residual stock from the petrochemical process plants.

Characteristics of some of the typical base stocks are given Annex - A The major objective of this project is to utilize the above raw materials to manufacture the Bio-Fuels, Methyl Ester, Fatty Acid & specialty Glycerin and other specialty products of higher value, and formulations, based on these.

3. PRODUCTS AND APPLICATION

Bio-diesel is an efficient clean, 100% natural energy alternative to petroleum diesel. Biodiesel fuel can make from new or used feedstock, which are non-toxic renewable resources. Fat and oil are chemically reacted with alcohol to produce chemical compounds known as fatty acid esters. Bio-diesel is the name given to these esters when they’re intended for use as fuel. Glycerin is produced as a co-product.

Bio-diesel is a cleaner-burring diesel replacement fuel made from natural, renewable sources as new and used vegetable oils and animal fats. Specifications for Bio-diesel (B100) provided by the National Bio-diesel Board. Specifications for Bio-diesel Fuel (B100) blend stock for distillate fuels provided by ASTM International. Pure Biodiesel (B100) needs to meet the requirements of ASTM D 6751 to avoid engine operational problems to obtain a copy of ASTM s

Standard Specification for Biodiesel fuel (B100) blend stock for distillate fuels visit the ASTM International web site.

Bio-diesel is non-toxic and biodegradable and is registered with Environmental Protection Agency as a fuel and fuel additive. The composition of the Committee responsible for formulation of this standard is given in Annex B.

These base stocks have boiling ranges form 50 to 60°C. Most reactors have boiling range from 40 to 130°C. IS –1560-2007. Bureau of Indian Standards (BIS) these are given in the Annex – B. All these products could further be subdivided from “Aromatic Free” grade to “High Aromatic” grade depending on user’s requirement.” Cosmetic Grade” is another special requirement for such products. However, most of the industrial users have their own specifications and acceptance norms. The plant will be equipped to take care of such requirements.

This standard is prepared keeping in view of the end us application, production and feed stock availability. Considerable assistance has been drawn from ASTM D 6751-02 and EN 14214 while preparing this standard. Biodiesel is a Fatty Acid alkyl ester for use as diesel fuel the requirement of I S 1460 “Automotive diesel fuel – Specification.

The Bio-diesel shall not conation any residuum oil. The material also comply with requirements prescribed when tested according to the appropriate methods prescribed in IS 1448{P} series and others as given in col 4 and 5 of table 1.

BUREAU OF INDIAN STANDARDS – BIO-DIESEL- IS -1560: 2005

NO CHARACTERISTIC R.MENT METHED OF TEST REF.

1 2 3 4 ISO / ASTMD / EN 5 IS1448 P 1 Density 15 oC. Kg/m3 860-900 ISO- 3675,12185 D 4052 P:16/ P:32 2 Kinematic viscosity at 40oC,cSt 2.5-6.0 ISO 3104 P: 25 3 Flash point (PMCC) o C, Min 120 - P: 21 4 Sulphur, mg/kg. Max 50.00 D 5453 P: 83 5 Carbon residue (R.bott.)1p. mass, Max 0.05 D 4530 ISO-10370, 6245 - 6 Sulfated ash, present by mass, Max 0.02 ISO 6245 P: 4 7 Water content mg/kg Max 500 D 7009 ISO-3733, 6296 P: 40 8 Total contamination. Mg/kg, Max 24 EN 12662 - 9 Copper corr0sion.3 h at 50oC, Max 1 ISO 2160 P: 15 10 Cetane No. Min 51 ISO 5156 P: 9 11 Acid value, mg KOH/g, Max 0.50 - P: 1/Sec 1 12 Methanol2, present by mass, Max 0.20 EN 14110 - 13 Ethanol3, present by mass, Max 0.20 - - 14 Ester content, present by mass, Max 96.50 EN 14103 -

15 Free Glycerol, present by mass Max 0.02 DN 6584 - 16 Total Glycerol, present by mass, Max 0.25 DN 6584 - 17 Phosphorous, mg/kg. Max 10.00 DN 4951 - 18 Sodium and Potassium, mg/kg. Max To report EN 14108 / 14109 - 19 Calcium and Magncsium, mg/kg. Max To report See4 - 20 Iodine value To report EN 14104 - 21 Oxidation stability at 110oC,h. Min 6 EN 14112 -

I- Carbon residue shall be run by 100 percent sample. II- Applicable for fatty acid methyl ester.

III- Applicable for fatty acid ethyl ester. IIII-European methed is under development. EN 14214 AND ASTM SPECIFICATION

No Specification Test method Units EUROPE EN14214

USA ASTM D 6751

1 Density @ 15oC EN ISO 12185 g /cm3 0.86-0.90 -

2 Vicosity 40oC EN ISO 3104 mm2/s 3.50-5.00 1.9 – 6.0

3 Distillation - % @ oC - 90%360oC

4 Flash Point ISO 2719 oC 120 min 130 min

5 Sulphur BS/EN/I20846 mg/kg 10 max 15 max

6 Carbon Residue IP13 % mass 0.03 max -

7 Sulphated Ash EN ISO 3987 % mass 0.02 max 0.02 max

8 Water EN ISO 12937 mg/kg 500 max 500 max

9 Total Contamination EN 12662 mg/kg 24 max *

10 Copper Strip Corrosion EN ISO 2160 3h/50oC 1 3

11 Oxidation Stability110o EN 14112 Hours 6 min -

12 Cetane Number EN ISO 5165 - 51 min 47 min

13 Acid Value EN 1404 mg/Koh/g 0.5 max 0.8 max

14 Methanol EN 14110 % mass 0.2 max -

15 Ester Content EN 14103 % mass 96.5 min -

16 Monoglyceride EN 14105 % mass 0.8 max -

17 Diglyceride EN 14105 % mass 0.2 max -

18 Triglyceride EN 14105 % mass 0.2 ma -

19 Free Glycerol EN 14105 % mass 0.2 max 0.2 max

20 Total Glycerol EN 14105 % mass 0.25 max -

21 Iodine Value EN 14111 - 120 max -

22 Linolenic Acid M. Ester EN 14111 % mass 12 max -

23 Polyunsaturated MEster - % mass 1 max -

24 Phosphorous EN 14107 mg/kg 10 max 10 max

25 Alkalinity EN 14108 mg/kg - -

26 Group I Metals {Na, K} - mg/kg 5 max -

27 Group2Metals{Ca, Mg} - mg/kg 5 max -

28 Cold Filter Plugging Po. EN 116 - - -

* Combined water and contamination test under ASTM D 6759

European Bio-diesel standard EN 14214 has been used to show the capabilities of Bio-diesel production equipment, which is impossible to achieve with just a Bio-diesel reactor alone. So as to pass the 27 sub-tests, which make up EN 14214, it is important to see Bio-diesel as having three main phases of production: 1- Pre-filtration, 2- Reaction, 3- Purification.

4.1 DEMAND

Specialty Bio-fuels industry is in primary stage in the country but long time running foreign country. A few bulk Biofuels like Bio-diesel & Ethanol, Fatty Acid, Methyl & Ethyl Ester, Pharmaceutical Glycerin, Cosmetic products etc are manufactured. There is no organized manufacture of low tonnage Biofuels Demand is largely met by crude approximate process products, not so specific to the demand, recently some MNC’s have started marketing import & export. Specific Bio-fuels are also being demand by actual users for a specialty Petroleum fuels is estimated to be well over 14, 00,00,000 tones per year.

Most major European vehicle manufactures now provide vehicle warranties covering the use of pure Bio-diesel though that might not be just any Bio-diesel. Some insist on ”RME” s. and want cover soy Bio-diesel in the US but this seems to be more a trade-related issue than a quality control one. Germany has more than 1,500 filling stations supplying Bio-diesel and it’s cheaper than ordinary diesel fuel. It’s widely used in France the words largest producer. Virtually all-fossil diesel fuel sold in France contains between 2% and 5% Bio-diesel. New Europe laws will soon require this Europe wide. Some states in the US are legislating similar requirements. There are a growing number of US suppliers. Bio-diesel is more expensive than ordinary diesel in the US but sales are rising very fast and prices will drop in time. In the UK Bio-diesel is taxed less than petroleum diesel and its available commercially.

4.2 PRODUCTION

In last few years several SSI manufactures have started manufacturing some of these Biofuels. Total capacity of these is estimated to 4 to 5 lack tons per year. Requirement of Biofuels is specific to the location

and industries the area. Considering large number of automobile, industries in country. The enough demand for the products and no difficulty are expected in marketing these. Bio-diesel production: There are three basic routes to Bio-diesel production from straight vegetable oil, animal fats / tallow, waste oil etc.

Almost all Bio-diesel is produced using base catalyzed transesterification as it is the most economical process requiring only low temperatures and pressures and producing a 98% conversion yield. For this reason only this process will be described in this project report.

The trans-esterification is the reaction of triglyceride with an alcohol to from esters and glycerol. During the estrification process the triglyceride is reacted with alcohol in the presence of a catalyst usually a strong alkaline like sodium hydroxide. The alcohol reacts with the fatty acid to from the mono-alkyl ester or Bio-diesel and crude glycerin. In most production methanol or ethanol is the used (methanol produces methyl esters & ethanol produces ethyl esters) and is base catalysed by either potassium or sodium hydroxide. Potassium hydroxide more suitable for Bio-diesel production.

The figure below shows the chemical process for methyl ester Bio-diesel. The reaction between the fat or oil and the alcohol is a reversible reaction and so the alcohol must be add in excess to drive the reaction towards the right and ensure complete conversion.

O ||

CH2O -- C -- R | O | || O

CH2OH CH—O—C --R + CH3OH OH || | | O === 3CH 3O – C-- R + CH-

OH | || | CH2O --- C –R

CH2OH

Glycerol Glyceride Alcohol Catalyst Esters

A successful trans-estrification reaction is signified by the separation of the ester and glycerol layers after the reaction time. The heaver co-product glycerol settles out and may be sold as is it is or it may be purified for use in other industries e.g. the pharmaceutical, cosmetics etc.

5. PROCESS

The most important variables that influence trans – esterification reaction time and conversion are:

1. Oil temperature.

2. Reaction temperature.

3. Ratio of alcohol.

4. Type of concentration of catalyst 5. Intensity of mixing. 6. Purity of reactants. 7.

The basic Bio-diesel production process steps: - 1 Methanol and Catalyst

2 Catalyst mixing 3 Veg Oils and Animal fats / UCO

4 Trans-esterification>>>Methanol recovery

5 Phase separation>>> Crude Methyl Ester

6 Crude Glycerin

7 Methyl Ester wash

8 Polish

9 Standard Bio-diesel

The process of Bio-diesels TBOs oil and animal fats are triglycerides containing glycerin. Process turns oils into esters, separating out the glycerin. The glycerin sinks to the bottom and Bio-diesel floats on top and can be siphoned off.

We make methanol to make methyl esters. We’d rather use ethanol because most methanols comes from fossil fuels (though it can also be made from biomass, such as wood) while ethanol is plant – based and you can distill it yourself but Biodiesel process is more complicated with ethanol.

Ethanol (or ethyl alcohol, grain alcohol – EtOH, C2H5OH) also goes by varies other well known names, such as whisky, vodka, gin, rum, brandy and so on but methanol is a deadly poison: first it blinds you then its kills you and it doesn’t take very much of it. It takes a couple of hours, and if you can get treatment fast enough you might survive.

Methanol is also called methyl alcohol, wood alcohol, wood naphtha, wood spirits, methyl hydrate (stove fuel), carbinol, colonial spirits, Columbian spirits, Manhattan spirits, methyl hydroxide, hydroxymethane, monohydroxymethane, pyroxylic spirit, or MeOH (CH3OH or CH4O) – all the same thing.

Major utilizes are

A) Tank Farm – Class A for inflammable materials

B) Tank Earm – Stainless steel

C) Water Circulation and Cooling Tower, and storage for civic, industrial

Use. And fire fighting.

D) Refrigeration – Chilled Water / Brine

E) Vent – System and Flare F) Power Supply and Distribution

G) Fire Protection and Safety

H) Nitrogen blanketing system.

The process units are indicated in the process flow sheet (Fig – 1)

CH2OCO CH2 R’ ‘’ COOR

CatalystCH2OCO + 3 ROH CH2O + R’ ‘’ COOR

CH2OCO CH2 R’ ‘’ COOR

10 Pounds 1 Pounds 1 Pounds 10 PoundsTriglycerides Alcohols Glycerin Bio-diesel

(Oil or fat) (Methanol) (Methyl esters)

5.1 REACTION

Refractionation is carried out in continuous trans-esterification process reactors provided seperator, product after centrifug pumps, then packed columns and product collection tanks. Two distillate and residual products will be produced as primary stocks; all other products will be prepared from these by appropriate process. Two distillation columns are with a heat recovery system of condensers and heat exchangers, whereby the heat is recovered and used for preheating and fresh feed. This results in an overall saving of 40 percent energy and fuel.

Refractionation is carried out in the following process steps -

5.1(A) FEED PREPARATION

Depending upon the products specifications a variety of feedstocks may be heated in appropriate proportion. This is established by prior laboratory evaluation of stock. The final stock is heated and held for 8-10 hrs to settle and remove water, dirt and other particulate matter it is passed through filters to remove fine particles, dirt and fibres etc, before taking to transetrification.

5.1(B) TRANS-ESTRIFICATIO/REACTION/REFRACTIONATIONThe prepared fed stock in 5.1 (A) is passed through a series of condensers and heat exchangers of column P2A / P2C and P2B / P2D and preheated and introduced in the column P2A & P2C. The top fraction is taken as Product – 1 Quality of the top product is controlled by control of reflux in the column – P2A / P2C. The bottom fraction of column – P2A / P2C is taken out from reboiler – HE4A / HE4C and pumped to column –P2B / P2D through a heater and hear recovery system. The fraction of column –P2B / P2D is taken product – 2. The quality is controlled by reflux to column P2B / P2D Bottom fraction of the column is withdrawn from reboiler – HE 4B / HE4D.

All the products are passed through a system of heat exchangers and coolers to cool down to 50-120° C and then taken to product storage tank.

5.2 WASH PROCESS / ADSORTION

By neutralising the free fatty acids with a catalyst the methanol is able to break down the linking bond in the triglycerides and result is the formulation of methanol esters and glycerol. Once purified, methyl esters become Bio-diesel. The above schematic shows the basic chemistry involved in Bio-diesel production. Once the methyl esters has been formulated, the following production residues are still present:

* Residual Methanol* Glycerol* Soap and Metals* Residual catalyst: Sodium or Potassium* Moisture* Free Fatty Acids

All of these can have potentially harmful impact on engine performance and component wear. Methyl esters are not classified as Bio-diesel until the proper specifications are met. Don’t clean and dry diesel what can happen.

* Corrosion of fuel injectors (water catalyst)* Fuel injector blockages (glycerin soaps etc) * Elastomeric seal failures (methanol) * Increased degradation of engine oil* Pump seizures due to high viscosity at low temperatures* Corrosion of fuel tanks (excess water, catalyst)* Bacterial growths and clogging of fuel lines/filters

Bio-diesel production is a game of infinite variables: base feed stocks, titrations, reaction efficiencies, viscosities and temperature all influence the process in different ways. Bio-diesel purification is a subject that is far to frequently overlook by many producers. Good upstream and in-house quality control procedures mark the difference between successful and unsuccessful procedures.

Products of Refractionation some times require adsorption treatment for – Improvement of color and texture, removal of moisture and removal of active sulfur and nitrogen compounds.

All the products do not required adsorption treatment.

Adsorption treatment is carried out by passing the product through the packed bed of adsorbent activated earth or activated bauxite Oil is allowed to percolate at a predetermined rate through the adsorbent bed Treated oil is collected as product.

The saturated bed is allowed the drain, and the drained oil is recycled or used as blending. About 30 to 50 times by volume oil could be treated before the bed gets saturated with impurities. After this the oil is drained out. After the drainage-superheated steam is passed through the bed to strip the oil held – up in the bed. Condensing the steam and hydrocarbon vapor and then separating the hydrocarbon solvent in the separator recover this. Passing hot air at about 600°C for 6-8 hrs reactivates stripped adsorbent bed. The bed is cooled and used again. Adsorbent bed is regenerated 20 to 30 times before the spent adsorbent is finally rejected. Alternatively the adsorbent could be discharged and bed is filled with fresh adsorbent. Alternatively, the oils, treated in a mixing tank with suspension of fine adsorbent (below 80 meshes) at about 50 to 70°C Slurry is filtered and treated oil recovered. Adsorbent is washed and rejected. Wash oil is recycled this process is more suitable for non-volatile products. Either of the above process could be used depending on situation. As most of the low boiling products do not required adsorption treatment this process is optional.

5.3 POLISHING THE FUEL / BLENDING

Final marketable products are prepared by polishing stocks and material from other sources in appropriate proportions. Boiling ranges are adjusted by polishing stock of different boiling range. Aromatic content could be adjusted by polishing dearomatised products. External and other hydrocarbon stocks could be used as polishing stocks .In some cases non – hydrocarbon like Alcohols, ethers and esters etc. are also required to be polished with the hydrocarbon after blending products are tested, an characterized.

5.4 STORAGE

An A, B, C class, bulk storage tank from with capacity to store 5 days requirement of base stock and 5 days requirement for finished products is provided. Similar capacities for ‘C’ class storage are also provided.

6. UTILITIES

Heat and cooling water also are the major utilities for this process. A brief description of utilities is as follows -

6.1 THERMIC FLUID HEATER

Thermic fluid heater and hot oil circulation system with heat capacity of 30 lakh Kcal / hr is required for the intended process capacity. Generally two units of equal thermal capacity are installed to take care of failure or maintenance shutdown of one unit. Maximum temperature of thermic fluid heater is 300°C that means maximum distillate temperature could be up to 260°C at atmospheric pressure. Vacuum is used to distill higher boiling fractions.

6.2 WATER CIRCULATIONS AND COOLING

Major part of distillation heat is discharged into cooling water. From the reservoir water is taken condensers after coolers. Where it may get heated up to 45°C, this is then passed through cooling tower / cooling pond, to about 35°C. Capacity of cooling tower 20,000 L/h Alternatively, a cooling pond with the same thermal capacity could be provided.

6.3 WATER STORAGE

Water will be required for the civic purpose and laboratory, cooling and fire fighting. Following water storage capacities are recommended.

1. Overhead storage for and civic purpose and laboratory 1, 00, 000 L.

2. Ground tank for cooling water 4, 00, 000 L.

3. Ground tank fire fighting 4, 00,000 L.

Two ground tanks are interconnected. There is separate pump for cooling water circulation a standalone diesel – cum. Power driven pump is provided for fire fighting.

6.4 POLLUTION TREATMENT

Trans-estrification is simple physical separation process and does not involve any reaction. All the products are the recovered and there is no waste. No water or air pollution is caused during the operation of the process at any stage. Similarly washing and other operation also do not produce any pollutant. Entire process is totally non – polluting. Therefore no provision is required to be made for treating liquid or gaseous effluents.

Thermic fluid heater flue gas may be a source of air pollution. These units will be purchased from approved vendors who meet air pollution requirements. Chimney height will be provided adequately to meet discharge norms of the location area.

6.5 SAFETY

Fire safety is most important as all the raw materials and products are highly inflammable (class- A) hydrocarbons. Following measures are taken to make the operation safe.

6.5(A) PROCESS DESIGN

Maximum care is taken in the process and equipment design and layout to make process plant fore safe by strictly following safety standards for storage of inflammable materials and battery limit operations.

6.5(B) VENTING AND FLARE

All the plant equipment and storage tanks are totally closed and are connected to a common vent line. The vent line is connected to a refrigerated vent condenser, where vent vapors are captured and recycled. Vent gas from condenser passes through a water seal, flame arrester and finally is discharged to atmosphere through a flare chimney.

6.5(C) NITROGEN BLANKETING

All the storage and process tanks and also some equipment is nitrogen blanketed and slight positive nitrogen pressure is kept. This ensures fire safety as well as lower vent losses.

6.5(D) FLAME PROOF ACCESSORIES

All the moving machinery, pumps, switches, lights, starters and other electrical installation are flame proof, Tools, flooring and all other gadgets are also flameproof.

6.5(E) FIRE FIGHTING EQUIPMENT

Extensive fire fighting equipment will be provided all over the plant these include: -

1. Hydrant head all over the plant and appropriate pipe installations are provided with separate hydrant pump to supply high-pressure water to hydrants. This pump is independent diesel – cum power driven to work even at the time of power failure. Also there is a separate 4,00,000 L ground reservoir for fighting. This is connected to cooling water reserve of 4,00,000 L to augment water supply at the time of emergency

2. Mobile and static, chemical and foam type fire extinguishers will be installed at all places, particularly within the buildings and near closed installations. 3. Fire sensors and alarms will be installed all over the plant particularly near pumps closed spaces and inside the buildings.

6.6 REFRIGRATION & CHILLED WATER CIRCULATION SYSTEM

Chilled water is required for condensers HE 2A / HE 2C at the time of distillation of light fractions boiling up to 60°C. It is also required to be circulated in the vent condenser. A refrigeration capacity of 60 tons is estimated and cold water temperature required is 10°C.

6.7 PRODUCTS PACKING AND DISPATCH

Generally products will be dispatched in tankers 20,000L or 12000L or 200 L barrels. Provision will also made to fill 50 L, 20 L, 5 L & 1 L container to take care of small and specially users.

7. RAW MATERIAL CONSUMPTION AND PRODUCT COSTS

The process can takes care of changes of raw materials and product specifications depending upon the market demand raw material availability. However for purpose of this report following assumptions have been made.

The process plant capacity is taken as 60,000 KL final stock as per year (300days) the additional 60,000 KL / Yr. Capacity for second stage could be added later. This report refers only to the first stage. However all the planning layout, and designs will be based on future capacity of 1,20,0000 tons feed stock/ Yr

1. Typical available base stocks and their characteristics are given in appendix A IOC naphtha (A.4). ANNEX.A/B TBOs oil & A.Fats is assumed as base stock for the report.

2. Two major primary distillate & trans-esterification fractions and

one residual fraction as given in table – 1, are assumed to be products. Characteristics of these products are given in appendix D & ANNEX-A

3. Overall evaporation and process losses are assumed to be 4 & 2percent.

Raw material consumption and product yield are given in table 2 (A) and table 2 (B) Raw material costs is Rs. 14328 lakhs and the product sales cost is Rs. 16482 lakhs, to date.

8. UTILITY CONSUMPTION

Major utilities consumption is estimated as follows: -

8.1 THERMAL ENERGY

This is required for the distillation & trans-estrification mainly as reboiler heat. It is estimated is terms of fuel consumption with fuel calorific value 18,000 Kcal / Kg and fuel utilization of 70 percent. Energy consumption is estimated to be 2.1 x 109 Kcal / Yr. Equivalent to 5,000 tons fuel (LDO) per year. This will cost Rs. 1400.00 lakhs per year (Table – 3A and 3B)

8.2 WATER CONSUMPTION

Civic water requirement is assumed to be 40,000 L/day, and rate of cooling water circulation is 2,00,000 L/hr. Evaporation loss is assumed to be 5 percent on this basic civic water requirement is 40,000 L/day and cooling water requirement is 2, 40,000 L/day.

8.3 REFRIGERATION

Chilled water at 10°C will be required mainly to cool vent condenser and also for the condenser at the time of distillation of first fraction (40°C - 60°C) Refrigeration capacity, 60 tons is estimated to be adequate for these duties.

8.4 NITROGEN BLANKETING

Blanketing nitrogen is estimated on the basis of one percent by volume of the volumetric capacity. This is estimated to be 40m ³ / day. This will be provided by cylinder manifold.

8.5 POWER CONSUMPTION

Power is estimated for 50 KWH requirements for lighting and civic uses and 150 KWH for the industrial use. Power requirement in thus 200 KWH. This is estimated to cost Rs. 72.00 lakhs per year.

A diesel generation set of 100 KWH capacities is recommended to meet the power requirements during power failure.

Utility requirements and estimated cost is given in table – 3 (A) and table – 3 B The total utility cost is estimated to be Rs.1550.0 lakh per year table 2 B

9. PLANTS AND EQUIPMENT

Major process equipment is listed in table – 4 (A) Bare process equipment cost is Rs.213 lakhs. The cost of 1000 tons bulk storage tank and 1000 tons product storage tank in “A” class tank farm are estimated to be Rs.75 lakhs (table – 4b) The process pump cost is Rs. 45 lakhs (table – 4 C) Thus total process equipment cost is rounded to Rs.333 lakhs. The cost installation including civic work, structure, piping, insulation and instrumentation etc. is taken to be 100% for process equipment and 50% for bulk storage tanks. It is to be noted that process equipment cost for qualification to SSI unit Rs. 258 lakes as the cost of utility equipment, safety equipment and bulk storage that are not included.

Utility equipment is listed in table – 4 (D) this is estimated to be Rs.213 lakhs. The cost of installation for utility equipment is assumed at 50% giving in installed utility equipment cost Rs. 320 lakhs.

Laboratory apparatus, equipment is listed in table – 4 (E). A provision of Rs.40 lakhs is made for the laboratory development which includes general lab hardware, chemicals and consumable. A nominal amount Rs.20 lakhs us also remarked for laboratory furniture.

Installed equipment cost is given in table – 4 (F) Rs.900 lakhs. This includes Rs. 20 lakhs for office furniture and maintenance tools etc.

10. MANPOWER COST

This unit will provide direct employment to 50 semiskilled and skilled workers and 40 supervisory staff in addition, 20-40 casual workers will be required every day. Marketing of product will also generate additional manpower requirement. Manpower and its cost estimated in table – 5, at Rs. 160 lakhs per year.

11. LAND AND BUILDING

Area of the point acquired for the purpose 3.25 acre or 13000m². Estimated area breakup will be as follows:-

1. Total area of plot 13000m²2. Building area 1000 m² (stilt + 2 floors)3. Industrial shed - -high roof 500 m²

4. Industrial shed – low roof 150 m²5. Cabins 50 m²6. Open plant area 1000 m²7. Tank farm area 5000 m²8. Utilised area/ total area 3705 m² - 28.5 percent9. Built area / total area 416 m² - 3.2 percent10. Green patches area 2600 m²11. Future development area 2000 m²

Proper spread from the view point of operation and safety has been kept adequate roads are provided for easy approach to all parts of plant in an emergency. Green patches are provided for 2600 m² (20% of plot area) Land and building cost is estimated to be Rs. 91 lakhs (Table – 6)

12. COST PROJECTIONS

Approximate cost projections are given on the basis of the above basic data Fixed capital is estimated to be Rs.1171 lakhs (Table –7) Working capital Rs. 920 lakhs (table 8) and recurring cost Rs. 531 lakhs per year (Table –9) Ex worker production cost is Rs. 16169 lakhs / Yr and manufacturing cost is Rs. 2241 lakhs / yr (Table –10). This is Rs. 3886 and Rs. 5387 per ton of feed stock.

13. PROFITABILITY AND ECONOMIC INDICES

Some of the major economic indices are given in table – 11 Profit after corporatist tax is Rs. 381 lakhs. This is 50% of the fix capital and 5% of the total capital employed. The investment is likely to be recovered in 5 - 7 years.

Therefore, economics of the project as such is “EXCELLENT” This is on the basis of most conservative low values of the products. Price realization for specialty and formulated Bio-diesel is far greater and will give higher profitability further, no credits is taken for various types of subside and tax rebates available at the site. These will add to profitability and further improve the economic outlook.

Thus the project has excellent economics violability. However, market conditions and Govt., policies tax structure and international price fluctuations, seriously influence the economics of the process, and profitability.

1 - TABLE

MATERIAL BALANCE

PROCESS -- BIO – FUELS / BIO-DIESEL TRANS – ESTRIICATION

OF BIODEIGREBLE PROCESS REACTION.

CAPACITY- 60,000 KL / YR FIANAL STOCK PER YEAR

RAW MATERIAL – (DETAILS ANNEX –B)

N

O

PRODUCT BOILING

RANGE (°C)

YEILD % PRODUCT/YR.

55o TO 60oC WT VOL TONS KL

1. TBOs 0IL/ ANIMAL FATs 82.0 82 49200 54,600

2. METHANOL 16.2 16 9,600 12,000

Losses 1.8 2 1,200 1,400

Total

100 100 60,000 68,000

GLYCERIN 9.7 10 6,000 8,000

* BIO-DIESEL - * These names will be give-registered trade

names by Bureau of Indian Standards: 1560-2005.

54,000 60,000

TABLE 2 (A)

RAW MATERIAL – RAW MATERIAL COST

PROCESS -- BIO – FUELS / BIO-DIESEL TRANS – ESTRIICATION



S.N MATERIAL CAPACITY TONS /YR

RATE RS/TONS

COST RS.LAKHS/YR

1. TBOs/ A. FAT 49,200 25100.00 12,995.00

2. METHANOL 9,600 25000.00 2400.00

3. LYE 300 25,000.00 75.00

Total Raw Material Cost (Rs. Lakhs) 13928.00

RAW MATERIAL COST PER YR (RS.LAKHS) 15470 13928.00

TABLE – 2 (B)

PROCESS - BIO – FUELS / BIO-DIESEL TRANS – ESTRIICATION

PRODUCT – PRODUCT COST (PRIMARY PRODUCT ONLY)

CAPACITY – 60,000 KL/YR BASE STOCK

SR. NO

PRODUCT CAPACITY(TONS/YR)

RATE(RS/TON)

COST(RS.LAKHS/YR)

1 BIO-DIESEL 54,000 33,000.00

17,820.00

2 GLYCERIN 6,000 10,000.00

600.00

Total Products Sales Cost (Rs. Lakhs /Yr.) 18,420.00

PRODUCT SALE COST PER YR. (RS. LAKHS) 18,420.00 16878

1542

TABLE 3 (A)

PROCESS - BIO – FUELS / BIO-DIESEL TRANS – ESTRIICATION



ENERGY AND FUEL REQUIREMENTS

CAPACITY – 60,000 KL / YR FIANAL STOCK

BASIS – 1 TON FEED BACK AR

ENERGY – KCAL / TON FUEL – KG / TON

S.NO ITEM HEAR REQUIRED(KCAL /TON)

FUEL (KG/TON)

1 Trans-esterification process 275775 39.4

2 Wet washing 32500 3.6

3 Dry washing 13000 1.5

4 Losses @ 10% 99250 11.0

Total 420525 55.5

Energy Consumption / Ton Feed = 420525 Kcal

Energy Consumption /Yr = 2.27 x 109 Kcal/ Yr.

Rounded = 2.3 x 109 Kcal / Yr.

Fuel Consumption / Ton Feed = 55.5 Kg.

Equivalent Fuel consumption = 2997 Tons/Yr.

Rounded = 3000 Tons/ Yr.

TABLE – 3 (B)

PROCESS- BIO – FUELS / BIO-DIESEL TRANS – ESTRIICATION



UTILITY CONSUMPTION

CAPACITY – 60,000 KL/YR. BIO -DIESEL STOCK

S.N

UTILITY UNIT CONSUMPTI-ON UNIT /YR

RATEUNIT/YR

COST RS.LAKHS/YR

1. Thermal energyFuel consumption

Kcal

2.3x 109

3000 28000 /- 840.002. Power KWH 288x 105 5 /- 144.00

3. Magnesium/Water Tons

72000/ 25/- 600.00

4. Nitrogen Tons

40 5000/- 2.00

5. Refrigeration Included in 2 -

6. Miscellaneous 58.00

TOTAL UTILITY (RS. LAKHS) 1550.00

TOTAL UTILITY COST (RS. LAKHS PER YEAR) 1550.00

TABLE – 4 (A)

PROCESS- BIO – FUELS / BIODIESEL TRANS – ESTRIICATION



1. PROCESS EQUIPMENT

S.N. ITEM CODE VOL COST

1 Feed Tank – 5 P 1A / P 1 C 20 KL

2 Heat Oil Tank – 2 P 1 B / P 1 D 20 KL

3 Filtration Unit -- 2 H E 1A / H E 1 C -

4 Feed Heater – 10 H E 1 B / H E 1 D -

5 Methanol Tank -- 1 P 2 A / P 2 C 10 KL-

6 Catalyst Storage P 2 B / P 2 D -

7 Catalyst Mixing Tank -2 H E 2 A / H E 2 C 10 KL-

8 Feed Oil Tank --2 H E 2 B / H E 2 D 20 KL-

9 Transesterification Tank P 3 A / P 3 C 20 KL-

10 React Heater -- 5 P 3 B / P3 D

11 Separator Tank -- 2 H E 3 A / H E 3 C 20 KL-

12 Recovery Methanol T- 2 H E 3 B / H E 3 D 10 KL-

13 Crude Glycerin Tank- 2 P 4 A / P 4 B 10 KL-

14 Crude Methyl Ester Tank- 5 P 4 B / P 4 D 20 KL-

15 Biodiesel Wash Tank- 5 H E 4 A / H E 4 C 25 KL-

16 Biodiesel Filtration Tank- 5 H E 4 B / H E 4 D

17 Bio-diesel Dry WashTank-5 P 5 A / P 5 C 20 KL

18 Bio. D. Washing Heater - 5 P 5 B / P 5 D

19 Biodiesel. Polishing Unit H E 5 A / H E 5 C -

20 Biodiesel Polish Tank - 5 P 6 A / P 6 C 20 KL

21 Biodiesel Storage Tank P 6 B / P 6 D 10 KL

22 P 6 A / P 6 C -

23 P 6 B / P 6 C -

24 P 7 A / P 7 C 10 KL

25 P 7 B / P 7 D 10 KL

26 P 8 A / P 8 C 10 KL

27 H E 4 A / H E 4 C -

28 H E 5 A / H E 5 C -

29 P 9 A / P 9 C -

30 P 10 A / P 10 C 5 KL

TOTAL (RS. LAKHS) 106.50

Process equipment cost (Rs. Lakhs) 106.50

Cost instruments, installation, insulation, piping etc @ 100% 213.00

Installed process equipment cost (Rs. Lakhs)213.00

TABLE –4 (B)

ROCESS- BIO – FUELS / BIODIESEL TRANS – ESTRIICATION

OF BIODEIGREBLE PROCES REACTION.

CAPACITY- 60,000 KL / YR FIANAL STOCK PER YEAR BULK STORAGE CAPACITY

SR NO.

ITEM CODE SPECI FICATION

COSTRS. LAC

1 Raw material bulk storage capacity 100 kl x 10

- 1000 KL 25.00

2. Product bulk storage capacity 100 kl x 10

- 1000 KL 25.00

TOTAL 50.00

Exact number of tanks and capacity of each tank will worked out when details of

Bulk storage cost (Rs. Lakhs) 50.00

Installation piping instrumentation cost @ 50% 25.00

Installed bulk storage cost (Rs. Lakhs) 75.00

TABLE – 4 (C)



CAPACITY - 60,000 KL / YR FIANAL STOCK PER YEAR

PROCESS PUMPS

S.N DESCRIPTION CODE SPECI FICATION

COST Rs THOUS.D

1. Bulk feed stock pump – 2 II 1 + II 3 FP/HP – 6 2.50

1. Heat Oil Tank pump – 2 II 2 + II 4 FP/HP – 3 2.50

2. Filtration Tank pump –2 II 3 A\ II 3 C FP/HP – 6 2.50

3. Methanol Tank pump – 2 II 3 B / II 3 D FP/HP – 6 5.00

4. Catalyst Mixing T- pump2 II 4 A / II 4 C FP/HP –6 2.50

5. Feed Oil Tank pump – 2 II 4 B / II 4 D FP/HP –6 5.00

6. Transesterification pump 2 II 5 A / II 5 C FP/HP – 6 2.50

7. Seperator Tank pump –2 II 5 B / II 5 D FP/HP – 6 5.00

8. Col – 2 reflux pump – 2 II 6 A / II 6 C FP/HP – 6 2.50

9. Col – 2 reflux pump – 4 II 6 B / II 6 D FP/HP – 6 5.00

10. Product transfer pump –2 II 7 A / II 7 C FP/HP – 3 2.50

11. Product transfer pump –4 II 7 B / II 7 D FP/HP – 3 5.00

12. Adsrober feed pump - 2 II 8 A / II 8 C FP/HP – 3 2.50

13. Treated oil transfer pump -2 II 9 A / II 9 C FP/HP – 3 2.50

14. Blending pump - 2 II 10 A / II 10 C

FP/HP – 3 2.50


Process pump cost Rs. Lakhs 45.00

Process equipment and pump cost (Rs. Lakhs) 258.00

Process equipment pumps and bulk storage tank cost (Rs. Lakhs) 333.00 Rounded (Re. Lakhs) 333.00 TABLE – 4 (D)




(B) UTILITY EQUIPMENT

S.NO ITEM –DESCRIPTION SPECIFICATION COST LAC

1. Thermic fluid unit –2 10 x 105 Kcal / hr 50.00

2. Thermic fluid unit – 4 10 x 105 Kcal / hr 40.00

3. Refrigeration unit 60 tons / hr. 25.00

4. Cooling pond 20 5 LPH 5.00

5. Ground water storage 8 x 10 5 L 7.00

6. Overhead water storage 40,000 L 5.00

7. Electrical installation 200 KVA 18.00

8. Provision for fire fig.and safety

- 43.00

9. Nitrogen blanket system 40 m ³ / day 7.00

10. Water circulation pump -2 30 HP 2.00

11. Hydrant diesel pump -2 30 HP 2.00

VENT SYSTEM

CODE

12. Vent header - 2 V1-X1 1 KL 3.00

13. Vent condenser - 2

HEV- - 3.00

14. Seal pot - 2 V2-X2 1KL 2.00

15. Chimney -2 V 3-X3 - 2.00

16. Vent collector - 2 V4-X4 1 KL 1.00

17. Vent Pump - 2 II V-IIX FP/HP – 3 1.00


Utility equipment cost (Rs. Lakhs) 213.00

Installation insulation and instrumentation and supporting equipment cost @ 50%

Re. Lakes 106.50

Installed utility cost (Rs. Lakhs) 320.00 TABLE 4 (E)




LIST OF LABORATORY APPARATUS AND EQUIPMENT

INSTALLED EQUIPMENT COST

NO ITEM NUMBER PROVISION

COST (RS)

1 ASTM Distillation 4 Sets 20,000

2 TBP Distillation 4 Sets 25,000

3 Vac. Distillation 2 Set 16,000

4 Distillation Pilot Plant 2 Set 3,00,000

5 Flash Point Apparatus 4 Set 15,000

6 Hydrometer Set 4 Set 20,000

7 ASTM Colorimeter 4 Set 30,000

8 Say bolt Viscometer Two 10,000

9 ASTM Viscometer (Oswald) w.vi.bath Two 2,00,000

10 Thermostatic Oven (200°C) Two 30,000

11 Muffle Furnace (1200°C) Two 75,000

12 Refract meter Two 75,000

13 Copper Corrosion Test Apparatus Two 25,000

14 Gas Chromatograph Two 5,00,000

15 Biocular Microscope Two

16 Vacuum Pump Two

17 Patch Test Kits Two

18 Bio-diesel Test Kits Two

19 Homebrew Safety Pack Kits Two

20

21

COST OF LABORATORY APPARATUS AND FURNITURE RS.LAKH 40.00 TABLE – 4 (F)

INSTALLED EQUIPMENT COST


OF BIODEIGREBLE PROCEES REACTITON.

CAPACITY – 60,000 KL / YR FINAL STOCK PER YEAR

SR.NO ITEM COST(RS. LAKH)

1. Installed process equipment cost with process pumps and bulk storage

333.00

2 Installed utility equipment cost 320.00

3 Cost of laboratory equipment 40.00

4 Provision for cost of installation of lab equipment25% of (5)

10.00

5 Provision for office equipment and furniture 20.00

6 Miscellaneous – unforeseen costs 77.00

TOTAL INSTALLED COST RS (LAKH) 900.00

INSTALLED EQUIPMENT COST (RS. LAKHS) 900.00

TABLE – 5

MANPOWER




SR.NO PERSONNEL CATEGORY ANNUAL COST * PER PERSON

NUMBER COST RSLAKHS /

YR 1 Directors

@ Rs. 15,00,000 / Yr2 30.00

2 Executives @ Rs. 5,00,000 / Yr

5 25.00

3 Supervisors – Plant, Lab, Office, Suptd, Marketing,Adn @ Rs 2,50,000

10 25.00

4 Skilled workers – Plant lab, Office staff. @ Rs.1, 00,000 / Yr

25 25.00

5 Unskilled workers plant, office staff@ Rs. 60,000/ Yr

30 18.00

6 Provision for contact and casual manpower (30%)

- 36.90

TOTAL

159.90

MANPOWER COST PER YEAR (RS.LAKH) 160.00

TABLE – 6

LAND AND BUILDING COST-



CAACITY- 60,000 KL / YR FIANAL STOCK PER YEAR

SR.NO ITEM COST RS. LAKHS

1. Land Cost – 13,000m² 5.20

2. Land Development Cost@ Rs. 52/ - per m²

6.80

3. Building Cost – Pucca – RCC Building – 1000m² @ Rs. 5000/- m ²

50.00

4. Industrial Shed – High Roof 500 m²@ Rs.2000 /- per m ²

10.00

5. Industrial Shed – Low Roof 150 m²@ Rs. 666/- Per m²

1.00

6 Provision For Miscellaneous Civil Work – 25% (1) To (5)

18.00

TOTAL LAND + BUILDING COST (RS. LAKHS)

91.00

LAND AND BUILDING COST (RS. LAKHS) 91.00

TABLE NO – 7

FIXED CAPITAL-



CAACITY- 60,000 KL / YR FIANAL STOCK PER YEAR

S.NO ITEM COST (RS/LAKHS)

1. Land and Building Cost 91.00

2. Installed Plant Equipment Cost 900.00

3. Process and Engineering Cost 90.00

4. Pre-Project Costs 90.00

TOTAL 1171.00

FIXED CAPITAL (RS. LAKH) 1171.00

TABLE NO – 8

WORKING CAPITAL




S.NO ITEM COST (RS. LAKHS)

1. Raw Material Cost for 5 Days 232.13

2. Finished Product for 5 Days 281.13

3. Utility Cost for 30 days 187.3

4.

Manpower Cost for 30 Days 13.15

5. Recurring cost for 30 days 53.10

6. Miscellaneous Costs – 20% of Above (Aprox)

153.10

WORKING CAPITAL 920.00

WORKING CAPITAL (RS.LAKHS) 920 .00

TABLE NO – 9

RECURRING COST




S.NO ITEM COST RS. LAKHS /YR

1. Depreciation on Fixed Assets @ 10%

115.00

2. Interest on Fixed Assets @ 15 percent

172.50

3. Interest on working Capital @ 15 percent

139. 35

4. Insurance on Fixed Assets @ 1.0 Percent

11.50

5. Insurance on Stocks @ 2 percent

4.00

6. Municipal Taxes @ 1 percent on Land + Building

.50

7. Miscellaneous @ 20 percent of Above (Approx)

88.15

RECURRING COST 531.00

RECURRING COST (RS LAKHS PER YEAR) 531.00

TABLE NO – 10

MANUFACTURING COST



CAPACITY- 60,000 KL/YR FIANAL STOCK PER YEAR

NO ITEM COST RS/LAKHS

1.

Cost of Raw Material 13928.00

2. Cost of Utilities 1550.00

3. Cost of Manpower 160.00

4. Recurring Cost 531.00

5. Ex Works Cost Total (1) to (4) 16169.00

6. Manufacturing Cost Total (2) to (4) 2241.00

EX- WORKS PRODUCTION COST (RS LAKHS/YR)

16169.00

MANUFACTURE COST (RS. LAKHS/YR)

2241.00

EX WORKS COST PER KL FEED STOCK Rs.

26948/-

PER TON FEED STOCK Rs.

38867/-

MANUFACTUREING COST PER KL FEED STOCK Rs. 3735/-

PER TON FEED STOCK Rs. 5387/-

TABLE. 11

PROFITABILITY AND ECONOMIC INDICES



CAPACITY- 60,000 KL/YR FIANAL STOCK PER YEAR

S.N. ITEM UNIT FIGURE

1 Raw Material Cost Rs. Lakhs/Yr 13928.00

2 Utility Cost Rs. Lakhs/Yr 1550.00

3 Manpower Rs. Lakhs/Yr 160.00

4 Recurring Cost Rs. Lakhs/Yr 531.00

5 Ex- Works Product Cost Rs. Lakhs/Yr 16169 .00

6 Man. cost per KL Raw Material Rs. 3735.00

7 Sales Cost Rs. Lakhs/Yr 16878.00

8 Profit Before Tax Rs. Lakhs/Yr 709.00

9 Profit after tax Rs. Lakhs/Yr 381.00

10 Plant equipment cost Rs. Lakhs 900.00

11 Plant equip cost for SSI qualification Rs. Lakhs 258.00

12 Land and building cost Rs. Lakhs 91.00

13 Fixed Capital Rs. Lakhs 1171.00

14 Working Capital Rs. Lakhs 920.00

15 Total Capital Rs. Lakh 2091.00

16 Profit /Fixed Capital, Ratio Percent 25.00

17 Profit / Working Capital Ratio Percent 52.00

18 Profit /Total Capital, Ratio Percent 22.00

19 Capital Recovery Period Yrs 5-7

IS: 82-1973

DURATION OF OVEN HEATING FOR THE DETERMINATION OF RESUIDE ON EVAPORATION

Sr.No Material Duration in Minute

For Drying of Resuide in The

Oven

1 2 3

i) Turphine (See IS: 6646-1972*) 120

ii) White spirit thinners for paints and enamels 90Conforming to IS: 1872 – 1961 †

iii) Coal tar naptha light and thinner conforming 90To IS: 1873 – 1961‡ and IS: 5667-1970 §

iv) Benzol (see IS: 358 – 1964 ||) 60

v) Xylole (see IS: 359 – 1965 ¶) 60

vi) Ethylalcohol (see IS 321-1964**) 15

vii) Acetone (see IS: 170 – 1966††) 30

viii) Amyl acetate (see IS 231 – 1957 ‡‡) 60

ix) Amyl alcohol (see IS 360 – 1964 §§) 60

x) Trichloroethylene (See IS: 245 1971 ||||) 30

xi) Methylene chloride 30(See IS: 4566 – 1968 ¶¶)

* Specification for oil of turphine, solvent grade† Specification for thinner for synthetic paints and varnishes for aircrafts.‡ Specification for thinner, antichill for cellulose nitrate based paints dopes and lacquers For aircrafts. § Specification for thinner for cellulose nitrate based paints and lacquers.|| Specification for benzole, industrial (revised)¶ Specification xylole, industrial solvents grade (revised)** Specification for absolute alcohol (revised)†† Specification for acetone (first revision)‡‡ Specification for amyl acetate.§§ Specification for amyl alcohol (revised)|||| Specification for trichloroethylene, technical (second revision)¶¶ Specification for methylene chloride (dichloromethane), technical.

bio diesel

Design

light distillates process

application biodiesel

middle distillates

light distillates fatty

basic process

process design

petroleum diesel

light distillates sludges