Detailed Project Report on essential oil extraction plant

ESSENTIAL OIL EXTRACTION PLANT [3632]

Essential oils extracted from a wide variety of plants and herbs have been traditionally employed in the manufacture of foodstuffs, cosmetics, cleaning products, fragrances, herbicides and insecticides. Further, several of these plants have been used in traditional medicine since ancient times as digestives, diuretics, expectorants, sedatives, etc., and are actually available in the market as infusions, tablets and/or extracts. Essential oils are also popular nowadays due to aromatherapy, a branch of alternative medicine that claims that essential oils and other aromatic compounds have curative effects. Moreover, in the last decades, scientific studies have related many biological properties (antioxidant, anti-inflammatory, antiviral, antibacterial, stimulators of central nervous system, etc.) of several plants and herbs, to some of the compounds present in the essential oil of the vegetal cells. For example, valerenic acid, a sesquiterpenoid compound, and its derivatives (acetoxyvalerenic acid, hydroxyvalerenic acid, valeranone, valerenal) of valerian extract are recognized as relaxant and sedative; lavender extract is used as antiseptic and anti-inflammatory for skin care; menthol is derived from mint and is used in inhalers, pills or ointments to treat nasal congestion; thymol, the major component of thyme essential oil is known for its antimicrobial activity; limonene and eucalyptol appear to be specifically involved in protecting the lung tissue. Therefore, essential oils have become a target for the recovery of natural bioactive substances. Essential oils are composed by lipophilic substances, containing the volatile aroma components of the vegetal matter, which are also involved in the defense mechanisms of the plants. The essential oil represent a small fraction of plant composition, and is comprised mainly by monoterpenes and sesquiterpenes, and their oxygenated derivatives such as alcohols, aldehydes, ketones, acids, phenols, ethers, esters, etc. The amount of a particular substance in the essential oil composition varies from really high proportions (e.g. around 80-90% w/w of d-limonene is present in orange essential oil) to traces. Nevertheless, components present in traces are also important, since all of them are responsible for the characteristic natural odor and flavor. Thus, it is important that the extraction procedure applied to recover essential oils from plant matrix can maintain the natural proportion of its original components. New effective technological approaches to extract and isolate these substances from raw materials are gaining much attention in the research and development field. Traditional approaches to recover essential oil from plant matrix include steam- and hydro-distillation and liquid-solvent extraction. One of the disadvantages of steam-distillation and hydro-distillation methods is related with the thermo ability of the essential oil constituents, which undergo chemical alteration due to the effect of the high temperatures applied (around the normal boiling temperature of water). Therefore, the quality of the essential oil extracted is extremely damaged. On the other side, the lipophilic character of essential oils requires solvents such as paraffinic fractions (pentane and hexane) to attain an adequate selectivity of the extraction. Further, liquid solvents should have low boiling points, in order to be easily separated from the extract and re-utilized. In this sense, the main drawback is the occurrence of organic toxic residues in the extracted product. Among innovative process technologies, supercritical fluid extraction (SFE) is indeed the most widely studied application. In practice, SFE is performed generally using carbon dioxide (CO2) for several practical reasons: CO2 has moderately low critical pressure (74 bar) and temperature (32oC), is non-toxic, non-flammable, available in high purity at relatively low cost, and is easily removed from the extract. Supercritical CO2 has a polarity similar to liquid pentane and thus, is suitable for extraction of lipophilic compounds. Thus, taking into account the lipophilic characteristic of plant essential oils, it is obvious that SFE using CO2 emerged as a suitable environmentally benign alternative to the manufacture of essential oil products. The commercial production of supercritical plant extracts has received increasing interest in recent decades and has brought a wide variety of products that are actually in the market. As mentioned before, supercritical plant extracts are being intensively investigated as potential sources of natural functional ingredients due to their favorable effects on diverse human diseases, with the consequent application in the production of novel functional foods, nutraceuticals and pharmacy products. The reader is referred to several recent works in which is reviewed the supercritical extraction and fractionation of different type of natural matter to produce bioactive substances. The general agreement is that supercritical extracts proved to be of superior quality, i.e. better functional activity, in comparison with extracts produced by hydro-distillation or using liquid solvents using supercritical CO2 (50ºC and 45 MPa) and ethanol Soxhlet extraction. Extraction yields were, respectively, 3.8 and 9.1%. Nevertheless, the supercritical extract comprised 21% of essential oil, while the alcoholic extract contained only 9% of the volatile oil substances. Furthermore, studies related with the antibacterial and antifungal properties of the extract revealed better activity for the supercritical product. Another example of improved biological activity exhibit by supercritical extracts was reported by Glisic et al. demonstrating that supercritical carrot essential oil was much more effective against Bacillus cereus than that obtained by hydro-distillation. Indeed, numerous variables have singular effect on the supercritical extraction and fractionation process. Extraction conditions, such as pressure and temperature, type and amount of cosolvent, extraction time, plant location and harvesting time, part of the plant employed, pre-treatment, greatly affect not only yield but also the composition of the extracted material. Knowledge of the solubility of essential oil compounds in supercritical CO2 is of course necessary, in order to establish favorable extraction conditions. In this respect, several studies have been reported. Nevertheless, when the initial solute concentration in the plant is low, as is the case of essential oils, mass transfer resistance can avoid that equilibrium conditions are attained. Therefore, pretreatment of the plant become crucial to break cells, enhancing solvent contact, and facilitating the extraction. In fact, moderate pressures (9-12 MPa) and temperatures (35-50oC) are sufficient to solubilize the essential oil compounds. Yet, in some cases, higher pressures are applied to contribute to the rupture of the vegetal cells and the liberation of the essential oil. However, other substances such as cuticular waxes are co-extracted and thus, on-line fractionation can be applied to attain the separation of the essential oil from waxes and also other co-extracted substances. In this review, on the basis of data reported in the literature and own experience, a detailed and thorough analysis of the supercritical extraction and fractionation of plants and herbs to produce essential oils is presented. Furthermore, the supercritical CO2 extraction of several plants (oregano, sage, thyme, rosemary, basil, marjoram and marigold) from Lamiaceae family was accomplished in our supercritical pilot-plant at 30 MPa and 40oC. High CO2 density was applied in order to ensure a complete extraction of the essential oil compounds. Essential  oil  also  called etheral or  volatile  oils  are volatile  odoriferous bodies of an oily character derived  mostly form  vegetable  sources. They occur in small concentrations in special cells, glands or ducts, either in one particular organ of the plant or distributed over many part e.g.  Leaves, barks, roots, flowers or fruits. Occasionally, they are present in combination with sugars, as glycosides, e.g. amyodalin in bitter almonds and sinigrin in mustard seeds, and are liberated when the glycosides are hydrolyzed. Essential oils are insoluble in water, but freely soluble in alcohol, either, fatty oils and mineral oils. They are commonly liquid at ordinary temperature and some of them deposit solid matters on standing most of the essential oils are optically active, are lighter than water and possess high refractive index. They are composed of a number of chemical compounds:- Hydrocarbons, Alcohols, Ethers, Aldehydes Ketones, Oxides and lactones etc. M. Indica is found largely in the greater part of India upto an altitude of 1200 M. Its bark is dark colour and cracked.  Its leaves are clustered near the ouds of the branches. It is coriaceous, pubescent when young almost glabrous when mature the flowers of this tree are dense fasciles near ends of branches. They may be small, calyx, corolla tubular and fleshy. M. Indica is found in mixed deciduous forests, usually of  a somewhat  dry  type, often growing on rocky and sandy soil and turning on the deccan trap. It is common throughout central India, Mumbai and Andhra Pradesh. It is also common in the drier type of sal forests in Madhya Pradesh. It is much planted in the plains of northern India and Deccon peninsula when forest land is cleared for cultivation, mahua trees are carefully preserved.

COST ESTIMATION

Plant Capacity                          28 Kg/Day  
Land & Building (1500 sq.mt)     Rs. 2.02 Cr
Plant & Machinery                    Rs. 1.96 Cr
Working Capital for 2 Months   Rs. 62 Lac
Total Capital Investment          Rs. 4.71 Cr
Rate of Return                         25%
Break Even Point                     43%


INTRODUCTION    
ESSENTIAL OILS    
THERE ARE A NUMBER OF SPICES USED ALONG WITH FOOD, NAMELY    
MAJOR RAW MATERIALS USED IN EXTRACTION OF ESSENTIAL OIL    
ESSENTIAL OIL OF PLANT & HERBS    
USES AND APPLICATIONS OF ESSENTIAL OIL
ESSENTIAL OILS FOR HAIR    
DIFFERENT OILS ARE USED FOR DIFFERENT PROBLEMS FACED
   BY THE HAIR. SOME OF THEM ARE GIVEN BELOW:    
A. ESSENTIAL OILS FROM FLOWERS    
JASMINE OIL    
LAVENDER OIL    
B. ESSENTIAL OILS FROM HERBS SPIKENARD OIL (JATAMANSI OIL)    
C. CINNAMON OIL    
CINNAMON OIL    
ZEODOARY OIL    
ANISEED OIL    
BEST ESSENTIAL OILS IN INDIA    
ESSENTIAL OILS FROM SPICES    
USE OF CORINDER OIL    
USES OF ORANGE PEEL OIL (CITRUS PEEL OIL)    
PHARAMACOLOGICAL PROPERTIES OF ESSENTIAL OILS    
ANTISEPTICS:    
EXPECTORANTS AND DIURETICS:    
SPASMOLYTIC AND SEDATIVE:    
OTHERS:    31
CHEMICAL CONSTITUENTS OF ESSENTIAL OILS    
HYDROCARBON:    
TERPENES:    
MONOTERPENES [C10H16]    
B. SESQUITERPENES    
SESQUITERPENE LACTONES:    
C. DITERPENES    
ALCOHOLS    
ALDEHYDES    
ACIDS    
ESTERS    
KETONES:    
LACTONES    
ADVANTAGE OF SCF CO2 METHOD    
B.I.S. SPECIFICATION    
SOURCES OF NATURAL ESSENTIAL OILS    
ESSENTIAL OIL MARKET OVERVIEW    
INDIAN MARKET SHARE OF ESSENTIAL OIL    
BREAKUP OF INDIAN MARKET (2012-13)    
IMPORT OF ESSENTIAL OIL (2013-14)    
EXPORT OF ESSENTIAL OIL (2013-14)    
ESSENTIAL OIL MARKET OVERVIEW:    
DETAILED EXPORT DATA OF INDIA ESSENTIAL OILS    
GLOBAL MARKET POSITION OF ESSENTIAL OIL    
PRODUCT INSIGHTS    
APPLICATION INSIGHTS    
REGIONAL INSIGHTS    
COMPETITIVE INSIGHTS    
MAJOR PRODUCERS OF ESSENTIAL OILS    
MAJOR CONSUMER OF ESSENTIAL OILS    
LARGEST GLOBAL MARKET PLACES FOR ESSENTIAL OIL    
PRESENT MANUFACTURERS/SUPPLIERS/EXPORTERS OF ESSENTIAL OILS    
ANISEED ESSENTIAL OIL    
CAROM ESSENTIAL OIL    
CARBON DIOXIDE/CO2 EXTRACTION METHOD    
SOLVENTS OF SUPERCRITICAL FLUID EXTRACTION    
SUPERCRITICAL FLUID EXTRACTION (SFE) OF ESSENTIAL OIL    
EFFECT OF EXTRACTION CONDITIONS    76
DETAILS OF SUPERCRITICAL FLUID EXTRACTION    
PUMPS    
PRESSURE VESSELS    
PRESSURE MAINTENANCE    
COLLECTION    
HEATING AND COOLING    
PROCESS OUTLINE TO MANUFACTURE ESSENTIAL OIL    
FOR EXAMPLE    
PERCENTAGE EXTRACTED USING SUPER CRITICAL FLUID
   EXTRACTION SYSTEM    
PROCESS FLOW DIAGRAM    
MANUFACTURING PROCESS FOR EXTRACTION OF ESSENTIAL OILS FROM FLOWERS, HERBS, SPICES BY SUPER CRITICAL FLUID (CARBON DIOXIDE)   
A. EXTRACTION OF ESSENTIAL OIL FROM FLOWERS    
FROM FLOWERS    
B. FROM HERBS    
1. CLEANING    
2. WASHING    
3. DRYING    
4. DISINTEGRATION INTO SMALL CHIP    
C. FROM SPICES    
1. CLEANING    
2. DRYING    
3. CUTTING INTO PIECES    
EXTRACTION OF ROSE ESSENTIAL OIL    
ROSE ATTAR    
EXTRACTION OF VOLATILE OILS BY SUPER CRITICAL FLUID METHOD    
SFE FLOW DIAGRAM    
ANALYSIS OF ESSENTIAL OILS    
ANALYSIS OF CLOVE BUD OIL CO2 BY GCMS    
CHROMATOGRAPHIC DATA OF EUCALYPTUS OIL    
EXPERIMENTAL SETUP:    
A GAS CHROMATOGRAPH CONSISTS OF:    
ESSENTIAL OIL BY SOLVENT EXTRACTION    
STEP 1: MATERIALS AND APPARATUS    
STEP 2: LEAF DEHYDRATION    
STEP 3: LEAFE DISNITEGRATION    
STEP 4: SOLVENT EXTRACTION    
STEP 5: FILTRATION    
STEP 6: EVAPORATION    
STEP 7: BOTTLING & STORAGE    
COMPARE DISTILLED OILS AND SOLVENT EXTRACTED OILS (EX: ROSE)    
SOLVENT EXTRACTION METHOD FOR ESSENTIAL OIL    
MANUFACTURING PROCESS OF ESSENTIAL OIL BY SOLVENT EXTRACTION    
PROCESS FLOW CHART    
DETAILS OF HYPERCRITICAL CARBON DIOXIDE GAS CO2 EXTRACTION
   OF ESSENTIAL OILS    
CO2 HYPERCRITICAL EXTRACTION    
PLANT LAYOUT    
SUPPLIERS OF PLANT AND MACHINERIES    
ROTARY WASHER    
PULVERIZERS    
STRAINERS    
STORAGE VESSEL    
WEIGHING MACHINE    
MATERIAL HANDLING EQUIPMENTS    
POLLUTION CONTROL EQUIPMENTS    
D.G. SETS    
SUPPLIERS OF RAW MATERIALS    
FLOWERS    
GLASS BOTTLES    
SUPPLIERS OF PLANT AND MACHINERIES (GLOBAL)    

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)