Detailed Project Report (DPR) on Crude Rice Bran Oil (Solvent Extraction Process)

CRUDE RICE BRAN OIL (SOLVENT EXTRACTION PROCESS)

[EIRI/EDPR/4405] J.C.: 2604XL

INTRODUCTION

Crude rice bran oil is extracted from the high-grade rice germ and of inner husk of brown rice, under the supervision of the highly skilled professionals, before human consumption. Crude rice bran oil may be the largest underutilized agricultural commodity in the world. Rice bran is the main source of production of rice oil. Though much of the rice bran continues to be used for animal feeds rather being extracted for the rice oil. RBO also finds applications in FMCG, chemical and pharmaceuticals industries for its high nutraceutical components.

CRBO is healthier, have a longer shelf life and a rich source of nutrition, it has much lower linolenic acid(polyunsaturated omega-6 fatty acid) which makes it edible.It is preferable for its very high smoking point of 490 F (254 C) and its mild flavour, which makes it suitable for high-temperature cooking such as for stir frying and deep frying. The high smoking point prevents fatty acid to breakdown at high temperatures thus making the oil usable even after multiple frying.But, the majority of rice bran oil produced in much of the world is only suitable for non-edible applications. Since crude rice bran oil with high free fatty acids (FFA)cannot be used as edible oil, it is considered as a potential source of non-edible type vegetable oil for utilization as a renewable low-cost feed stock for biodiesel production, for sustainable energy and environment. There has been an attempt for making ecological supportability through high FFA in CRBO which was subjected to esterification and trans esterification processes and the crude rice bran oil methyl ester thus obtained, was tested in a compression ignition (CI) engine to determine its ability to replace petroleum-based diesel and lead to less pollution.

MARKET ANALYSIS:

The global rice bran oil obtained from its crude form had a market size of USD 6.16 billion in 2020. The market is projected to grow from USD 6.67 billion in 2021 to USD 12.27 billion by 2028 at a steady CAGR of 9% during the 2021-2028 period. Though this oil is majorly used in Asian countries, demand for vegetable oil among consumers especially in Europe, Middle East& Africa and Latin &North America, is rising rapidly due to growing awareness regarding the nutrients it has, namely vitamins, antioxidants, and Trans free fat.Bran consists of 70 % of the rice kernel's nutrition, with the white rice part having just rest of the little value. After the outbreak of the coronavirus pandemic, people started inclining towards the immunity boosting foods for maximum health benefits and the companies thus thoughtfully adopted to make strong marketing and promotional activities for selling  their products.

SOLVENT EXTRACTION PROCESS FOR CRBO :

The CRBO can either be extracted by a mechanical process with oil presses or by a chemical process using a solvent. After preparation the bran is fully stabilized and sent to an extraction area where oil has to be separated from it, which yields two products, a high-grade crude rice bran oil and defatted rice bran. 

Solvent extraction method can be used  to recover oil  from  any  material with  low  oil content, or for pre-pressed oil cakes in order to obtainhigh oil content. Hexane is the most  commonly used solvent for this method, its cheap and excellent for oil extraction. Some short chain alcohols such as ethyl alcohol and isopropanol have also beenproposed as an alternative solvent for extraction. The yield of about 92% oil was obtained from hexane extraction of ohmic heating–stabilizedrice bran. Once it was reported about 42.7-99.9%  yield of oil from rice bran using ethanol to rice bran ratio of 2.5:1 and 4.5:1, and temperature of 60-90 C. Study have shown that increasing the extraction temperature from 40oC  to  60oC  and solvent (hexane and isopropanol) to bran ratios (w/w) of 2:1 and 3:1 increased the RBO yield. Extraction at 60o C for 10 min with 3:1  solvent to bran ratio using hexane yielded about 3.6%more oil, while extraction with isopropanol produces 6.4% more oil than at 40 C. The yield of liquid propane was found to yield about 22.4% of oil in 1 kg of rice bran at 0.76 MPa and ambient temperature. A RBO was also extracted with isopropanol and hexa neat 40 C for 15 min. The hexane extracted almost 40% more oil than the isopropanol, while increasing the temperature upto 120C, the yield of hexane did not increase but the isopropanol extracted 25% more RBO than hexane under similar conditions. About 99% oil was reported to be extracted by solvent extraction from oleiferous seed. A preliminary data suggested an optimum of 5:1 solvent-meal ratio. The CRBO obtained from this extraction process is further subjected to chemical or physical refining to meet the needful specifications of food grade vegetable oil. The organic solvent (usually hexane) used is however, flammable, volatile, toxic and pollutes the environment. Even though the use of hexane for extraction is considered efficient and most widely used, it has some undesirable effects.

FUTURE INSIGHTS:

The global Rice Bran Oil market size was seen to be worth USD 1289 million in 2021 and amid Ukraine – Russia crisis the market is forecasted to a readjusted size of USD 1589.2 million by 2028 with a CAGR of 3% during the forecast period 2022-2028.

COST ESTIMATION

Plant Capacity                                     98.8 MT/Day

Land & Building (3885 sq.mt.)  Rs. 4.55  Cr

Plant & Machinery                               Rs. 5.03  Cr

Working Capital for 0.25 Months    Rs. 1.31  Cr

Total Capital Investment                   Rs. 11.40 Cr

Rate of Return                                      60%

Break Even Point                                 67%

CONTENTS

INTRODUCTION

USES/APPLICATIONS

HEALTH BENEFITS OF RICE BRAN OIL

HEART HEALTHY

REGULATES BLOOD SUGAR LEVELS

POTENT ANTI-INFLAMMATORY EFFECTS

PREVENTS CANCER

BOLSTERS IMMUNE HEALTH

COMBATS BAD BREATH

RICE BRAN OIL FOR ENHANCED SKIN HEALTH

MARKET OVERVIEW

ASIA-PACIFIC IS THE LARGEST MARKET

COMPOSITION AND PROPERTIES

FATTY ACID COMPOSITION

PHYSICAL PROPERTIES OF CRUDE AND REFINED RICE BRAN OIL

FORMULATION

RAW MATERIALS

RICE BRAN

HEXANE

SUPPLIERS OF RAW MATERIALS

MANUFACTURING PROCESS STEPS

PREPARATORY SECTION:

MAIN EXTRACTION

DESOLVENTISATION

DISTILLATION

PROCESS FLOW

ENGINEERING DESIGN CONSIDERATIONS

ETP FACILITY

ETP FLOW DIAGRAM (TYPICAL)

SEWAGE AND WASTE WATER EFFLUENT

STP FLOW DIAGRAM (TYPICAL)

WASTE GENERATION & MANAGEMENT/GREEN BELT

GREEN BELT

WATER (ESTIMATED)

WASTE (ESTIMATED)

FLUE GAS (ESTIMATED)

PLANT/MACHINERY (BROADLY)

SUPPLIERS OF PLANT & MACHINERIES/TURNKEY

COMPLETE PLANT SUPPLIERS ON TURNKEY BASIS

COOLING TOWER

MATERIAL HANDLING EQUIPMENTS

INSTRUMENTATION & PROCESS CONTROL EQUIPMENTS

LABORATORY EQUIPMENTS

POLLUTION CONTROL EQUIPMENTS

BOILERS

AIR COMPRESSORS

PROCESS EQUIPMENTS

STORAGE TANKS

D.G. SETS

POWER TRANSFORMERS

ETP PLANTS

PLATEFORM WEIGHING MACHINE

ELECTRICAL MEASURING INSTRUMENTS

SUBMERSIBLE WATER PUMP

UTILITIES PER MONTH (ESTIMATED)

PRINCIPLES OF PLANT LAYOUT

MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE:

PLANT LOCATION FACTORS

PRIMARY FACTORS

RAW-MATERIAL SUPPLY:

MARKETS:

POWER AND FUEL SUPPLY:

WATER SUPPLY:

CLIMATE:

SPECIFIC FACTORS

TRANSPORTATION:

WASTE DISPOSAL:

LABOR:

REGULATORY LAWS:

TAXES:

SITE CHARACTERISTICS:

COMMUNITY FACTORS:

VULNERABILITY TO WARTIME ATTACK:

FLOOD AND FIRE CONTROL:

HEALTH SAFETY AND ENVIRONMENT

ANTICIPATED ENVIRONMENTAL IMPACTS

CONSTRUCTION PHASE

OPERATION PHASE

MITIGATION MEASURES (PROPOSED)

HSE REQUIREMENT

SAFETY & OCCUPATIONAL MEASURE

POTENTIAL RISKS

PROPOSED IMPLEMENTATION SCHEDULE

PROJECT FINANCIALS

BASIS & PRESUMPTIONS (FOR PROFITABILITY WORKINGS)

PRELIMINARY LAYOUT

CONCLUSIONS

APPENDIX – A:

01. PLANT ECONOMICS

02. LAND & BUILDING

03. PLANT AND MACHINERY

04. OTHER FIXED ASSESTS

05. FIXED CAPITAL

06. RAW MATERIAL

07. SALARY AND WAGES

08. UTILITIES AND OVERHEADS

09. TOTAL WORKING CAPITAL

10. TOTAL CAPITAL INVESTMENT

11. COST OF PRODUCTION

12. TURN OVER/ANNUM

13. BREAK EVEN POINT

14. RESOURCES FOR FINANCE

15. INSTALMENT PAYABLE IN 5 YEARS

16. DEPRECIATION CHART FOR 5 YEARS

17. PROFIT ANALYSIS FOR 5 YEARS

18. PROJECTED BALANCE SHEET FOR (5 YEARS)