Biodiesel Manufacturing Plant (Cap: 10,000 Ltr./Day)

BIODIESEL MANUFACTURING PLANT (CAP: 10,000 LTR./DAY)

[EIRI/EDPR/4717] J.C.: 2937XL

INTRODUCTION

Biodiesel refers to a non-petroleum-based diesel fuel consisting of short chain alkyl (methyl or ethyl) esters, made by Transesterfication of vegetable oil or animal fat (tallow), which can be used (alone, or blended with conventional petrodiesel) in unmodified diesel-engine vehicles. Biodiesel is distinguished from the straight vegetable oil (SVO) (sometimes referred to as "waste vegetable oil", "WVO", "used vegetable oil", "UVO", "pure plant oil", "PPO") used (alone, or blended) as fuels in some converted diesel vehicles. "Biodiesel" is standardized as mono-alkyl ester.

Biodiesel is a biofuel produced from various feedstocks’s including vegetable oils (such as oilseed, rapeseed and soya bean), animal fats or algae. Biodiesel can be blended with diesel for use in diesel engine vehicles. Biofuel – The term biofuel applies to any solid, liquid, or gaseous fuel produced from organic (once-living) matter. The word biofuel covers a wide range of products, some of which are commercially available today, and some of which are still in research and development. Biodiesel is a fuel made from plant oils that can be used in a conventional diesel engine.

Biodiesel is an environmentally safe, low polluting fuel for most diesel internal combustion and turbine engines. Can be mixed with petroleum diesel fuel and stored anywhere petroleum is. It is made from fresh or waste vegetable oils (triglycerides) that are a renewable energy source.

Bio-diesel is an eco-friendly, alternative diesel fuel prepared from domestic renewable resources that is vegetables oils (edible & non-edible oil) and animal fats. These natural oils & fats are made up mainly of try glycerides. These try glycerides when reacted chemically with lower alcohols in presence of catalyst result in fatty acid esters. These esters show striking similarity to petroleum derived diesel and are called “Bio-diesel”.

All plant oils and recycled cooking oils are esters of trivalent alcohol (Glycerin) and 3 fatty acid chains.

In a chemical process called tran-esterification the Glycerin in the oils is changed against a monovalent alcohol Methanol. The result is Fatty Acid Methyl Ester (FAME) and Glycerin.

COST ESTIMATION

Plant Capacity            10,000 Ltr./Day

Land & Building (1 Acre)    Rs. 80.00 Lac

Plant & Machinery                   Rs. 2.55 Cr

Working Capital for 1 Month    Rs. 84.19 Lac

Total Capital Investment         Rs. 4.35 Cr

Rate of Return                          55%

Break Even Point                     44%

CONTENTS

INTRODUCTION

FIGURE: TRANSESTERIFICATION OF TRIACYLGLYCEROLS TO YIELD FATTY ACID ALKYL ESTERS (BIODIESEL)

BIODIESEL A RENEWABLE SOURCE OF ENERGY

CHALLENGES WITH USING BIODIESEL

SPECIFICATION OF BIO DIESEL

SOURCE OF OIL

ADVANTAGES AND DISADVANTAGES OF BIODIESEL

FEED STOCK OF BIO DIESEL

APPLICATION AND ADVANTAGE OF BIO DIESEL

ADVANTAGES OF CONTINUOUS PROCESS:

OIL SEED CROPS FOR BIODIESEL

SOYBEANS

RAPESEED AND CANOLA

CAMELINA SEEDS (LEFT) AND CANOLA SEEDS

MUSTARD

CAMELINA

SAFFLOWER AND SUNFLOWER

WARM CLIMATE FEEDSTOCKS

JATROPHA

CASTOR BEAN

POTENTIAL OILSEED CROPS

IN ADDITION TO OIL SEED CROPS, BIODIESEL CAN BE PRODUCED FROM

USED AND WASTE OIL

ANIMAL FATS

ALGAE

USED AND WASTE OIL AND GREASE FOR BIODIESEL

USED COOKING OIL

TRAP GREASE

CONVERTING USED OIL AND TRAP GREASE TO BIODIESEL

ACID PRE-TREATMENT

GLYCEROLYSIS

SOLID ACID CATALYSTS

SUPERCRITICAL REACTORS

BIODIESEL IN INDIA

THE PROBLEM OF JATROPHA

B.I.S. SPECIFICATION

BIO-DIESEL (B L00) BLEND STOCK FOR DIESEL FUEL — SPECIFICATION

1 SCOPE

2 REFERENCES

3 REQUIREMENTS

4 PACKING AND MARKING

5 SAMPLING

LONG-TERM STORAGE OF BIO-DIESEL

A-1 SCOPE

A-2 TERMINOLOGY

A-3 FUEL SELECTION

A-4 FUEL ADDITIVES

A-5 TESTS FOR FUEL QUALITY

A-6 FUEL MONITORING

A-7 FUEL STORAGE CONDITIONS

PROPERTIES AND TEST OF BIODIESELS FROM MULTIPLE FEED STOCKS

FUEL PROPERTIES TESTS

TABLE: METHODS FOR TESTING PROPERTIES OF BIODIESELS

PROPERTIES OF BIODIESELS

TABLE: TEST RESULTS FOR ASTM D 86 — DISTILLATION OF PETROLEUM PRODUCTS

TABLE: TEST RESULTS FOR ASTM D 93 — FLASH-POINT BY PENSKY –MARTENS CLOSED CUP TESTER

TABLE: TEST RESULTS FOR ASTM D 97 — POUR POINT OF PETROLEUM

PRODUCTS

TABLE: TEST RESULTS FOR ASTM D 130 — DETECTION OF COPPER

CORROSION FROM PETROLEUM PRODUCTS BY THE COPPER STRIP TARNISH TEST

TABLE: TEST RESULTS FOR ASTM D 240 — HEAT OF COMBUSTION OF LIQUID HYDROCARBON FUELS BY BOMB CALORIMETER, BTU/LB

TABLE: TEST RESULTS FOR D 445 — KINEMATIC VISCOSITY OF TRANSPARENT AND OPAQUE LIQUIDS

TABLE: D 482 — ASH FROM PETROLEUM PRODUCTS

TABLE: TEST RESULTS FOR D 524 — RAMSBOTTOM CARBON RESIDUE OF PETROLEUM PRODUCTS

TABLE: TEST RESULTS FOR ASTM D 613 — CETANE NUMBER OF DIESEL

FUEL OIL (RESULTS FROM WILLIAMS LAB)

TABLE: TEST RESULTS FOR ASTM D 613 — CETANE NUMBER OF DIESEL

FUEL OIL (RESULTS FROM CSM)

TABLE: TEST RESULTS FOR ASTM D 664 — ACID NUMBER OF PETROLEUM PRODUCTS BY POTENTIOMETRIC TITRATION

TABLE: TEST RESULTS FOR ASTM D 971 — INTERFACIAL TENSION OF OIL AGAINST WATER BY THE RING METHOD

TABLE: TEST RESULTS FOR ASTM D 1091 — STANDARD TEST METHODS FOR PHOSPHORUS IN LUBRICATING OILS AND ADDITIVES, WEIGHT PERCENT

TABLE: TEST RESULTS FOR ASTM D 1094 — WATER REACTION OF AVIATION FUELS

TABLE: TEST RESULTS FOR ASTM D 1160 — DISTILLATION OF PETROLEUM PRODUCTS AT REDUCED PRESSURE

TABLE: TEST RESULTS FOR D 1298 — SPECIFIC GRAVITY – BY HYDROMETER METHOD

TABLE: TEST RESULTS FOR ASTM D 1322 — SMOKE POINT OF KEROSENE AND AVIATION TURBINE FUEL

TABLE: TEST RESULTS FOR ASTM D 1796 — WATER AND SEDIMENT IN FUEL OILS BY THE CENTRIFUGE METHOD (LABORATORY PROCEDURE)

TABLE: TEST RESULTS FOR ASTM D 1959 — IODINE VALUE OF DRYING OILS AND FATTY ACIDS

TABLE: TEST RESULTS FOR ASTM D 2274 — STANDARD TEST METHOD FOR OXIDATION STABILITY OF DISTILLATE FUEL OIL (ACCELERATED METHOD), MG/100 ML

TABLE: TEST RESULTS FOR ASTM D 2500 — CLOUD POINT OF PETROLEUM PRODUCTS

TABLE: TEST RESULTS FOR D 2622 — TEST METHOD FOR SULFUR IN 

PETROLEUM PRODUCTS BY X-RAY SPECTROMETRY

TABLE: TEST RESULTS FOR ASTM D 2624 — ELECTRICAL CONDUCTIVITY

OF AVIATION AND DISTILLATE FUELS

TABLE: TEST RESULTS FOR ASTM D 3231 — STANDARD TEST METHOD

FOR PHOSPHORUS IN GASOLINE, PPM

TABLE: TEST RESULTS FOR ASTM D 3241 — THERMAL OXIDATION

STABILITY OF AVIATION TURBINE FUELS (JFTOT PROCEDURE)

TABLE: TEST RESULTS FOR ASTM D 3242 — ACIDITY IN AVIATION

TURBINE FUEL (TOTAL ACID NUMBER)

TABLE: TEST RESULTS FOR D 4539 — FILTERABILITY OF DIESEL FUELS

BY LOW-TEMPERATURE FLOW TEST (LTFT) (COLD FILTER PLUGGING POINT)

TABLE: TEST RESULTS FOR ASTM D 4629 — TRACE NITROGEN IN LIQUID

PETROLEUM HYDROCARBONS BY SYRINGE/INLET OXIDATIVE

COMBUSTION AND CHEMILUMINESCENCE DETECTION

TABLE: TEST RESULTS FOR ASTM D 5191 — VAPOR PRESSURE OF

PETROLEUM PRODUCTS (MINI METHOD)

TABLE: TEST RESULTS FOR ASTM D 5291 — INSTRUMENTAL

DETERMINATION OF CARBON, HYDROGEN, AND NITROGEN

IN PETROLEUM PRODUCTS AND LUBRICANTS

TABLE: TEST RESULTS FOR ASTM D 6078 — STANDARD TEST METHOD

FOR EVALUATING LUBRICITY OF DIESEL FUELS BY THE SCUFFING

LOAD BALL-ON-CYLINDER LUBRICITY EVALUATOR (SLBOCLE)

TABLE: TEST RESULTS FOR ASTM D 6217 — STANDARD TEST METHOD

FOR PARTICULATE CONTAMINATION IN MIDDLE DISTILLATE FUELS

BY LABORATORY FILTRATION

TABLE: TEST RESULTS FOR CHRISTINA PLANC METHOD

TABLE: TOTAL FATTY ACIDS, %

TABLE: CARBON, HYDROGEN, NITROGEN, OXYGEN ANALYSIS

TABLE: GAS CHROMATOGRAPHIC ANALYSIS OF FATTY ACIDS

BIODIESEL/DIESEL BLEND TESTING

TESTING METHODOLOGY

TABLE: CERTIFICATION DIESEL FUEL LOT D-434 PROPERTIES

TABLE: PHYSICAL AND CHEMICAL TESTS OF BIODIESEL BLENDS

BIODIESEL PRODUCTION AND PROBLEMS

TABLE: BIODIESEL SPECIFICATIONS (JULY 1996)

(FOR PURE MONO ALKYL ESTERS OF LONG CHAIN FATTY ACIDS DERIVED FROM RENEWABLE LIPID FEEDSTOCKS)

IN SUMMARY, THE BASIC PROBLEMS AND POTENTIAL SOLUTIONS ARE THE FOLLOWING:

TECHNOLOGY OF BIODIESEL

BIODIESEL FEEDSTOCKS ARE CLASSIFIED BASED ON THEIR FREE FATTY ACID CONTENT AS FOLLOWS:

COMMERCIAL BIODIESEL TECHNOLOGIES CAN BE GROUPED AS FOLLOWS:

A BRIEF OVERVIEW OF EACH MAJOR TECHNOLOGY FOLLOWS

A TYPICAL INPUT/OUTPUT STREAM IS SHOWN BELOW.

INPUT STREAMS:

OUTPUT STREAMS:

MARKET OVERVIEW OF BIODIESEL IN INDIA

OIL MINISTER ASSURES POLICY SUPPORT FOR STAKEHOLDERS

PRODUCTION

CONSUMPTION

TRADE

TABLE: INDIA: IMPORT DUTY ON BIODIESEL (PERCENT AD VALOREM ON CIF VALUE)

CONTINUOUS VERSES BATCH PROCESS FOR BIO DIESEL PRODUCTION

METHOD OF BIO DIESEL PRODUCTION

MANUFACTURERS/SUPPLIERS OF BIO-DIESEL

SCHEMATIC OF BIO DIESEL PRODUCTION

MANUFACTURING PROCESS OF BIO DIESEL

PROCESS IN DETAILS

PRETREATMENT

PROCESS FLOW DIAGRAM FOR TRANSESTERIFICATION

PROCESSING WITH ACID OIL FEED STOCK

PROCESSING WITH FATTY ACID FEED STOCK

PROCESSING WITH PLD OILS SUCH AS PALM STEARINE FEED STOCK

BIODIESEL FUEL QUALITY

SPECIFICATIONS DEMYSTIFIED

FLASH POINT

WATER AND SEDIMENT

KINEMATIC VISCOSITY

FIGURE 1: VELOCITY IS INDEPENDENT OF DENSITY WHEN KINEMATIC

VISCOSITY IS USED

SUBSTITUTING FOR µ IN ABOVE EQUATION, WE GET:

FIGURE 2: VISCOSITY TREND LINES FOR METHYL ESTER AND ETHYL

ESTER GC STANDARDS AT 40°C: (□) EES AND (O) MES. (SOURCE:

ALLEN ET AL. (1999))

SULFATED ASH

PISTON RING DEPOSITS FROM STRAIGHT VEGETABLE OIL PHOTO:

EXTENSION AG ENERGY

SULFUR

COPPER STRIP CORROSION

CETANE NUMBER

CLOUD POINT

CARBON RESIDUE

ACID NUMBER

FREE AND TOTAL GLYCERIN

CALCIUM AND MAGNESIUM

PHOSPHORUS CONTENT

SODIUM AND POTASSIUM

OXIDATIVE STABILITY

COLD SOAK FILTRATION

TRANSPORTATION AND STORAGE OF BIODIESEL

OXIDATION

CONTACT WITH WATER

MICROBIAL DEGRADATION

PREVENTING BIODIESEL FROM FREEZING

TRANSPORTING BIODIESEL

WASTE MANAGEMENT IN BIODIESEL PRODUCTION

WASTEWATER

ION EXCHANGE RESINS

MAGNESIUM SILICATE (MAGNESOL)

USED OIL SEDIMENT

GLYCERIN

COMPARISON OF BIODIESEL AND DIESEL SPECIFICATIONS

TABLE: COMPARISON OF BIODIESEL SPECIFICATIONS AND ASTM D 975 SPECIFICATIONS

CATALYSTS FOR BIODIESEL PRODUCTION

BIODIESEL BLENDS

SWOT ANALYSIS OF BIO DIESEL

STRENGTH

WEAKNESS

OPPORTUNITIES

THREATS

OPPORTUNITY

THREAT

SUPPLIER OF RAW MATERIAL

SUPPLIERS OF BIODIESEL PLANT

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)