BIODIESEL Turn-Key Solution

Mr. Chetan B Sayankar Biodiesel Consultant

MISSION To develop & deliver cost effective reliable solutions with quick adaptability and customer centric approach through a standardized process and innovative thinking which would lead to achievement of common goal in an eco – friendly way.

VISION

To become a leading single point solution provider with the greatest value and developed strategies to exceed the expectations of our partners and clients by keeping quality and ethical dealing as priority.

VALUES To consistently explore the new horizons of the science and technology by preserving philanthropic cultural, social and environmental morals

Core Competencies

• Process

• Mechanical

• Piping

• Civil

• Electrical

• Instrumentation

• Molecular Seal

• Biodiesel Column

• Feed - Heat Exchanger

• Cooler – Heat Exchanger

• Reflux Drum

• IT sector

• Finance

• Oil & Gas

• Biodiesel Industries

• Infrastructure

• Petrochemical

ENGINEERING EPC SKILL DEVELOPMENT

We Serve…

Long

Lasting

Relationshi

p With

Customer

Cost

Optimizatio

n

Techniques

Global

Execution

Experienc

e

Customer

Centric

Approach

Quick

Adaptabilit

y

We Believe In

We are inspired by them

Our industry believes in them

Our clients

experience them

Our brand

reflects them

Our Values

Our values are operational. They have ensured our success to the present and will take us forward.

6

Proposal Engineerin

g Project

Initiating Project

Planning Project

Execution Project

Closeout

Complete Project Understanding

Focus On Project Requirement

Manpower Allocation

Meet Deadline and customer

satisfaction

Project Implementation Process

HSE – Quality System: Plan Procedures Control

Project Controls : Planning &

scheduling Work progress &

productivity control Cost estimates &

controls

Project Manager

Engineering Plan:

Design approach

Codes &

standards

Safety design

criteria

Group Senior Management

Control of Project Execution Project Manager:

single point of accountability for each project

Senior

Management: hands-on policy, supported by central expertise

What is Turn Key ?

A type of project that is constructed so that it can be sold to any buyer as a complete product

Complete Project Understanding

Manpower Allocation

Meet Deadline and customer satisfaction

Project Closeout

Project Execution

Project Initiating

Proposal

Project Planning

Engineering

Focus On Project Requirement

Turn-key Execution

Process

• Preparation Of Block Diagrams & PFDs

• Calculation of Material & Energy Balance

• Preparation of P&IDs

• Equipment List

• Equipment Data Sheets

• Instrument list

• Instrument Data Sheets • Line list

• Tie-in List

Mechanical

• Static Equipment

• Rotating Equipment

• Package Equipment

• Material Design Basis

• Equipment Fabrication Drawing

• RFQ for Equipment

• Material Standards

• Painting & Insulation Specification

• Quality Checking Protocol & Erection

Piping

• Piping 3D Modelling

• Developing Plot Plan

• Pipe Routing and Layout

• Pipe Sizing

• Isometrics

• Pipe Stress Analysis

• Pipe Support Design

• Piping MTO

3D MODEL OF 5MMGPY PLANT FOR BIODIESEL

Civil • Dimensional Catalogue for

all Structure Member

• Concrete Details

• Structural Drawing Detailed

Format

• Structural Load Details

• Foundation Drawing Format -

RCC

• Primary Support Detailing

• Pipe Rack Design

• Tank Farm Design Format

• Platform & Ladder Detail

Drawings Foundation Drawing of SRXC Column

Electrical

• Lighting Layout

• Single Line Diagram

• Detailed Electrical Load

List

• Earthing Details &

Layout

• Cable Tray Calculation

• Cable Schedule

• Junction Box Drawing &

Schedule

• Cable and Cable Tray

Layout

Instrumentation

• HMI Screen Development

• HMI Symbol

• Instrument mounting philosophy

• Ladder Logics

• Detailed Control & Logic details

• Preventive Maintenance &

HMI Live Screens

• I/O list

• Testing & Commissioning

• Activity Documents

What is Biodiesel ?

• Made by chemically combining any natural oil or fat with an alcohol

• Most of the oils, edible & non-edible are suitable

Biodiesel Projects in Progress

Enzymatic Biodiesel Process

• We can use oil having 0-100% FFA in this technology & high quality glycerin in this technology is produced

• No need of Degumming and bleaching section in this technology & Safe process

• Methanol consumption is less & low quality methanol like aqueous methanol

• Low energy consumption & less than tenth of the energy is consumed in the chemical process.

• 1 kg enzyme can produce > 3000 kg of biodiesel

• A higher purity/higher value glycerol is derived from enzymatic biodiesel process compared to conventional production methods.

Single cylinder Diesel Engine Test Set up

IC Engine set up under test is Kirloskar TV1

Parameter Specification

Engine type

Four stroke , Constant Speed, Water

Cooled, Diesel Engine Valves per

cylinder Single Cylinder

Bore × Stroke 87.5 × 110 (mm)

Displacement Length 110.00 (mm)

Compression

ratio 17.5

Power 5.20 kW @ 1500 rpm

Torque 23.39 Nm @ 1506 rpm

Fuel Injection

system High Pressure Common Rail

Engine Details :

Components of Setup

Engine Setup Computer operated Test Rig Gas Analyser

Observation Hemp Biodiesel (B20)

SFC & Fuel Consumption vs Load

TORQUE, Mech % , Vol % vs Load

Observation Hemp Biodiesel (B50)

SFC & Fuel Consumption vs Load

TORQUE, Mech % , Vol % vs Load

Gas Emission Analyzer readings

Emission Results comparison between (B20) and (B50)

00.005

0.010.015

0.020.025

0.030.035

0 10 20

em

issio

n r

ate

( %

vo

l)

Load (kg)

Carbon Monoxide vs Load

CO (B20)

CO (B50)

0

2

4

6

8

10

0 10 20H

ex (

pp

m)

Load (kg)

Hydro Carbon vs Load

HC (B20)

HC (B50)

Biodiesel Technology Continuous Flow High FFA Conversion Processor

Continuous Flow Biodiesel Nano Reactor / Enzyme

High Purity Methanol Purification

Dry Washing (Biodiesel)

Glycerin Purification

Biodiesel Distillation

Modular Skid Components

(DCS) Plant Control System 3D MODEL OF DYCGR PROJECT

Commissioned Biodiesel Projects

Clinton County Bio Energy, USA

Biodiesel OF Las Vegas (BDLV), USA

Global Alternatives Fuels, USA

Menlo, Florida, USA

Biodiesel Plant Equipments

Methanol Plant

Biodiesel Plant

Potential in India

INDIA

• Abundance of Potential

Feedstock

• Talented researchers and

scientists

• Cheap Labor

• Available areas for utilization

of this Green fuel -Buses

• Companies following the

International standards

• Economical Production costs ?

India’s Initiative

Mr. Chetan Sayankar credentials

• Chemical professional with more than 13 years of experience • Business Development and handling of Turnkey projects of Oil

and Gas, Biofuels • Understanding the client requirement and process reactions taking

place, installing control systems, starting, running and upgrading the processes and bidding for domestic as well International clients

• Paper Published “Techno-Economic Analysis of an Alkali Catalyzed Biodiesel Production using Waste Palm Oil” © (2014) Trans Tech Publications, Switzerland

• “Training Simulator Development for Palm Oil Based Biodiesel Production” Proceedings of the 6th International Conference on Process Systems Engineering (PSE ASIA) 25 - 27 June 2013, Kuala Lumpur

• Worked on the innovation of Enzyme based technology of the Biodiesel and tried some good selectivity option for production of Biodiesel .Got successful Zero carbon (CO) emission on B20 and B50 Biodiesel Blend .

• Selected as a speaker National Advanced Biofuels conference & Expo 2016 Wisconsin Center topic Selective Biodiesel Production Process Using Specialized Liquid Lipase Enzyme to give Better Production Results.

• Patent file for selective enzyme based process for Biodiesel production

• Mobile: +919960400912 Email:-chetansay@gmail.com