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1
DEPARTMENT OF CHEMICAL ENGINEERING PROGRAM
PROCESS STREAM
Project title – Biodiesel production from Jatropha
SUBMITTED BY
GROUP MEMBERS ID NO
YALEMBRHAN DEBEBE 3020/03
SELOMON AREGAWI 2656/03
GODEFA TESFAY
SUBMITTED TO INSTRUCTOR GETU
2
ACKNOWLEDGEMENT
First and for most we thank our Almighty God for making all this happen. Our next
gratitude goes to our advisor INST G/ hiwot for his guidance on the project. We also thank to
our instructor Getu for his effective lectures. Our Last but not least gratitude goes to all friends
who contributed best up on completion of the project.
ABSTRACT The project mainly deals with the methods of production of biodiesel from a jatropha plant. It
also asses the material and energy balance of biodiesel with all the cost estimation. It describes
the different methods of producing biodiesel.
Contents ...................................................................................................................................................................... 1
ACKNOWLEDGEMENT ................................................................................................................................... 2
ABSTRACT ...................................................................................................................................................... 2
CHAPTER ONE ............................................................................................................................................... 4
3
INTRODUCTION ............................................................................................................................................. 4
1.2. Statements of the Problem ................................................................................................................ 5
1.3. Objectives of the Study ...................................................................................................................... 5
Chapter two .................................................................................................................................................. 5
2. LITERATURE REVIEW ................................................................................................................................. 5
2.1. Basic Concepts of Biofuel ................................................................................................................... 6
2.1.1. Biofuel ......................................................................................................................................... 6
2.2. Development Status of Biofuel .......................................................................................................... 6
2.2.1. Development status of biofuel in Africa ..................................................................................... 7
2.2.2. Development status of biofuel in Ethiopia ................................................................................. 7
2.3. Jatropha Cultivation, Processing and Uses ........................................................................................ 8
2.3.1. Description of Jatropha ............................................................................................................... 8
2.3.2. Jatropha cultivation .................................................................................................................... 8
2.3.3. Jatropha oil extraction ................................................................................................................ 8
2.4 Biodiesel production ........................................................................................................................... 9
2.4.1. Direct use and blending .............................................................................................................. 9
2.4.2. Micro emulsions .......................................................................................................................... 9
2.4.3. Thermal cracking (pyrolysis) ..................................................................................................... 10
2.4.4. Trans esterification (Alcoholysis) .............................................................................................. 10
2.5 Physical and chemical properties...................................................................................................... 11
2.5.1 Fats and oils ............................................................................................................................... 11
2.5.2 Treating High FFA Waste Vegetable Oil ..................................................................................... 12
CHAPTER THREE .......................................................................................................................................... 13
RESEARCH METHODOLOGY ........................................................................................................................ 13
3.1 Biodiesel reaction.............................................................................................................................. 13
3.2 Biodiesel process layout.................................................................................................................... 14
3.3 Supercritical methanol process of Biodiesel flow sheet ................................................................... 15
Chapter four ................................................................................................................................................ 15
Material balance and Energy balance calculations ..................................................................................... 15
4.1 Material balance ............................................................................................................................... 15
4.2. ENERGY BALANCE ............................................................................................................................ 21
4.2.1 CALCULATION FOR DISTLATION COLUMN I ............................................................................... 21
4
4.2.2CALCULATIONS ON DISTILATION COLUMN 𝑰𝑰 ............................................................................ 22
` ........................................................................................................................................................... 23
4.2.3 Energy balance of plug flow reactor .......................................................................................... 25
4.3 Equipment sizing ............................................................................................................................... 26
4.3.1VOLUME OF PFR (PLUG FLOW REACTOR) ................................................................................... 26
4.3.2 Volume of Flow tank .................................................................................................................. 27
4.4 COST ESTIMATION ............................................................................................................................ 28
4.5 COST INDEXES: .................................................................................................................................. 30
4.6 Safety and Environment .................................................................................................................... 35
4.7 Conclusion ......................................................................................................................................... 35
CHAPTER ONE
INTRODUCTION Biodiesel, a mixture of mono alkyl esters of long chain free fatty acids, has become
increasingly attractive worldwide because it is made from renewable resources and combine
high performance with environmental benefits. In commercial processes, highly refined
vegetable oils, primarily consisting of triglycerides (TGs) and typically used as feed stocks,
are Trans esterified with low molecular weight alcohols. e.g. methanol and ethanol, with no
catalysts .To be more economically viable, the use of virgin oils, which cost accounts for
88% of the total estimated production cost of biodiesel, could be replaced with a more
economical feedstock, such as waste fats and oils that contain a low to moderate amount of
free fatty acids (FFAs) in addition to moisture and other impurities. However, the synthesis
of biodiesel from these low quality oils is challenging due to undesirable side reactions as a
result of the presence of FFAs and water. The pretreatment stages, involving an acid
catalyzed pre-esterification integrated with water separation, are necessitated to reduce acid
concentrations and water to below threshold limits prior to being processed by standard
biodiesel manufacturing. Besides catalyzing esterification, acid catalysts are able to catalyze
TG transesterification, opening the door for the use of acid catalysts to perform simultaneous
FFA esterification and TG trans esterification. Moreover, in general industrial processes,
heterogeneous catalysts are more desirable because they are non-corrosive, separable, and
recyclable. The use of solid catalysts would also reduce the number of reaction and
separation steps required in the conversion of fats and oils to biodiesel, allowing for more
economical processing and yielding higher quality ester products and glycerol.
5
1.2. Statements of the Problem So far, in Ethiopia little work has been done on renewable source of energy development
in general and no work has been done on and of biodiesel production from Jatropha in
particular. On one hand, the oil price increase, which is the result of the mismatch between
demand and supply, is becoming the barrier for stable and sustainable economic development.
On the other hand, since it is believed that fossil fuels are the main cause for atmospheric air
pollution and global warming, effort is being exerted to minimize the use of fossil fuels
and to substitute it by renewable energy sources . The increasing demand of energy, the
associated price hikes and environmental concerns have hit the Ethiopian economy very hard. It
is therefore not surprising that the government places high priority on alternative energy sources
that partially or totally substitutes imported fuel.
unsustainable practice and this could in its turn hamper the exploration of the true
Jatropha potential risks and benefits.
However, Jatropha receives a lot of attention from project developers in the field of
biofuel production and clean development mechanism. As a pioneer species well
adapted to semi-arid climates, Jatropha is promising to simultaneously combat desertification,
provide biodiesel and enhance socio-economic development in degraded rural areas
. As such, biodiesel production and use from Jatropha
is believed to have better energy balance, low emission and a positive socioeconomic
impact, although no quantitative studies are available to confirm this in
Ethiopia. This study gives a detail analysis for environmental and economic impact of
Biodiesel production from Jatropha in comparison with fossil diesel.
1.3. Objectives of the Study The study has the following objectives:
To analyze and compare the energy balance and material balance of biodiesel from
jatropha.
To evaluate the financial and economic feasibility of large-scale Jatropha
plantation and Jatropha cultivation as a fence.
To assess the financial and economic viability of Jatropha biodiesel production as
compared to fossil diesel over the life cycle.
Chapter two
2. LITERATURE REVIEW In this chapter the study looked at the basic concepts of biofuel, Jatropha cultivation and
Processing and the environmental and economic aspects of biofuel production. The recent
findings on cultivation and processing, energy balance, GHG emission and economics of
Jatropha were also reviewed.
6
2.1. Basic Concepts of Biofuel
2.1.1. Biofuel
The development of biofuel has a benefit from the point of environmental protection and
rise of energy prices.
2.1.1.1. Definition of biofuel
Biofuel is defined as “solid, liquid or gaseous fuel obtained from relatively recently
lifeless or living biological materials and is different from fossil fuels, which are derived
from long dead biological material” . The two most widely used types of
biofuels are biodiesel and ethanol. Biodiesel fuels are oxygenated organic compounds methyl
Esters-derived from a range of renewable sources such as vegetable oil, animal fat,
and cooking oil and the process has several by-product benefits. The oxygen found in
biodiesel makes it unstable and needs stabilization to avoid storage problems. Biodiesel
fuels passes processes of crushing seeds to extract oils and catalytic in which oils are
reacted with an alcohol into alkyl esters. Ethanol is manufactured from microbial
conversion of biomass materials (e.g. sugar cane, sweet sorghum, maize, wheat, potato
etc.) through fermentation. Ethanol contains 35 percent oxygen. The production process
consists of conversion of biomass to fermentable sugars, fermentation of sugars to ethanol,
and the separation and purification of the ethanol fuel .
2.1.1.2. Generations of biofuel
Based on substances converted to biofuel, technology and crop requirements biofuel is
Categorized into three generations . For the production of first generation
biofuels the basic feed stocks are often seeds or grains such as wheat, which yields starch
that is fermented into bioethanol, or sunflower seeds, palm oil, soya been, which are
pressed to yield vegetable oil that can be used in biodiesel. These feed stocks could instead
enter the animal or human food chain, and as the global population has raised their use in
producing biofuels has been criticized for diverting foodstuff away from the human food
chain which leads to food shortages and price rises. Second generation biofuels supporters
claim that a more viable solution is to increase political and industrial support for, and
rapidity of, second generation biofuel implementation from a variety of non-food crops,
including cellulosic biofuels. These include waste biomass, the stalks of wheat, wood and
special-energy-or-biomass crops such as Jatropha etc..
The third generation biofuels, Algae fuel (Oilgae), is a biofuel from algae. Algae are low input,
high-yield feed stocks to produce biofuels. However, currently they are very
expensive and require high energy for processing. It produces 30 times more energy per
acre than land crops such as soya beans .
2.2. Development Status of Biofuel There has been growing worldwide interest in biofuels as renewable sources of energy to
substitute fossil fuel. They are more evenly diffused in every country, although in varying
quantities and at different costs. The few producers of crude oil and their market power
also make biofuels attractive as a means of enhancing security of energy supply and
combating environmental impacts. Targeting the transport sector biofuels will either
wholly or partially (by blending into the petroleum products) substitute for gasoline and
diesel. Developing countries are concerned to what extent biofuels can expand their own
7
energy supplies. The situation will change if biofuels from agricultural residues, energy
crops, wastes, and other feedstock’s become commercially viable .
2.2.1. Development status of biofuel in Africa
Renewable energy technologies and specifically biofuels offer developing countries a self-reliant
energy supplies at local and national levels, with potential economic,
environmental, social and security benefits. Regional institutions have playing roles in
developing rational energy policy and encouraging biofuel investment across the
continent. Information exchange and experience sharing have been encouraged among
institutions and practitioners who engaged in the sustainable energy development. The ongoing
African Roundtable on Sustainable Consumption and Production Program is a step
in the right direction towards overcoming the commercialization hurdles. Actions to
globalize the production and utilization of biofuel, including technology sharing between
African countries and others should be encouraged .
Strong tools are needed for estimating investment and operating costs of biomass to fuel
conversion plant in African countries, concentrating on parameters such as plant size, type
of feedstock, exchange rate, and other location-specific information, variables, to
investigate the applicability of the techniques developed, specifically (to demonstrate how
biofuel plant size optimization will benefit from availability of better capital and operating
cost-estimating techniques); to estimate the revenues that may be expected from avoided
carbon emissions. The greater the uncertainties of project cost such as capital cost, the
more cautious investors are likely to be .
2.2.2. Development status of biofuel in Ethiopia
The growing concern in Ethiopia is that an increase in feedstock cultivation will reduce
resources available for agricultural production that jeopardizes food security to the
growing human and livestock population. The energy system in the country is
characterized by the predominance of traditional fuels (firewood, crop residues, and
animal waste or dung etc.) which account nearly 94% of the total national energy
consumption. The demand for modern energy sources such as petroleum fuels is
increasing with increase in population and economic growth. Even though the share of
petroleum fuels is about 7% of the total consumption, the increasing demand for it and the
associated price hike have hit the national economy very hard. As a net importer of
petroleum, Ethiopia is highly vulnerable to price shocks and supply problems of oil in the
world market. This is the basis for the government to include large-scale commercial
production of biofuels as part of the range of other development programs (wind, biogas,
hydro-power, solar energy and natural gas and associated liquids) proposed to ensure
supply of modern energy services .
Ethiopian Ministry of Mines and Energy (MME) has prepared guidelines for the
implementation of projects to ensure the achievements of the objectives stated, while at
the same time avoiding unintended consequences. The strategy has addressed biofuel
development and use that are important elements to ensure social and environmental
sustainability. However, there are still some important elements that the strategy failed to
mention. At some points it lacks clarifications which open loop-holes that could
potentially lead to unintended consequences. One of the major worries is that the strategy
encourages large-scale production of biofuels at this early stage without even having a
proper land inventory which identifies the land available for various purposes.
8
Development in such large- scales, if proper mechanisms are not put in place, could likely
leave permanent damages to the environment .
Ethiopian MME is encouraging investors who are engaged in biofuel production.
Currently there are over 68 developers engaged in the cultivation of energy crops (Castor
bean, Palm oil and Jatropha) for biodiesel production of which 15 of them were
developing Jatropha plantations in the country. The cultivation of Jatropha is expanding
widely and created 140,000 job opportunities so far. For bio-ethanol,
however, there are only six projects in the country of which four of them are government
owned sugar estates. So far, over 300,000 ha of land have already been allocated for
investors. Over 80% of these developments are happening in arable lands, forest lands and
woodlands. Many of these companies are still requesting for more lands for expansion of
biofuel production. Several other national and foreign investors have obtained investment
licenses for the development of biofuels from the Federal Investment Commission. The
land requirement of these investors adds up to 1.65 million hectares. The requirements for
obtaining permits are minimal and it seems to have attracted many international investors
lately. Currently, only 5 of the 20 feedstock producing companies
operating in Ethiopia are done environmental assessment.
2.3. Jatropha Cultivation, Processing and Uses
2.3.1. Description of Jatropha
Jatropha (physic nut) is a large shrub or small tree up to 5m tall and has a life expectancy
of about 50 years. It is originated in Central and South America but now has spread around
the world. The plant develops a deep taproot and initially four shallow lateral roots.
Normally Jatropha flowers only once a year during the rainy season. Jatropha flowers
almost throughout the year in permanently humid regions or under irrigated conditions
. The seeds become mature when the capsule changes from green to yellow.
Jatropha has a deciduous nature, shedding its leaves during the dry season. The plant
components contain toxic elements, mainly phorbol esters.
2.3.2. Jatropha cultivation
The initial production step towards biodiesel production of Jatropha is cultivation of trees.
The main inputs are land, plantation establishment and management practices including
the production and use of all machineries, infrastructure and energy. The main outputs are
seeds, Jatropha oil and biodiesel among other by-products (husks, seed-cake, and
glycerin), and soot emissions.
2.3.3. Jatropha oil extraction
The main inputs of oil extraction stage are Jatropha seeds, machineries, infrastructure and
energy. The main output is Jatropha oil and seed-cake is an important by-product. The
emissions of wastewater have to be accounted for in the outputs of the process
as well . The two methods mainly used for the extraction of Jatropha
are: (i) mechanical extraction and (ii) chemical extraction The
Jatropha seeds have to be dried prior to oil extraction . The seed could be
dried up in the oven (105C) or sun dried (3 weeks). Mechanical expellers can be fed with
9
either whole seeds (common practice) or kernels or a mix of both. Only ground Jatropha
Kernels are used as feed for chemical extraction. The shells can be used directly as a
combustible by-product or gasification feedstock .
2.4 Biodiesel production There are four primary options for making biodiesel from fats and oils.
2.4.1. Direct use and blending
The possibility of direct use of vegetable oils as fuel has been recognized since
the beginning of the diesel engine.
However, the straight use of vegetable oils to replace the conventional fuels encounters
the operational problems due to its high viscosity (11-to-17 times higher than diesel fuel).
Polymerization, as a result of reactivity of C-C double bonds that may be present, lower
its volatility which causes the formation of carbon deposits in engines due to incomplete
combustion, and oil ring sticking, thickening and gelling of the lubricating oils as a result
of contamination .
Due to the great advancement in petroleum industries, fossil fuels could be
produced at much cheaper cost than biomass alternatives, resulting in, for many years, the
near elimination of the biomass fuel production infrastructure. However, interest in the
use of vegetable oils for engine fuels has been reported periodically.
Vegetable oils can be used by blending with the diesel fuel, given rise to the
improvement in physicochemical properties of the former. Nevertheless, the long term
use of this blending in a modern diesel engine becomes impractical because of the
decrease in power output and thermal efficiency by carbon deposits.
2.4.2. Micro emulsions
A micro emulsion is technically defined as a stable dispersion of one liquid phase
In to another, which has the droplet diameter approximately 100 nm or less.
Micro emulsion process has been studied for biodiesel production as a means to improve
10
the viscosity of vegetable oils by blending with a simple alcohol i.e, methanol or ethanol
. However, the significant injector needle sticking, the carbon deposits, the
In complete combustion, and the increase in the viscosity of lubricating oils are reported
for utilizing the fuel produced from this process in long term run [7].
2.4.3. Thermal cracking (pyrolysis)
Pyrolysis is defined as the conversion of one substance into another by means of
heat in the absence of air or oxygen at temperatures range from 450 °C to 850 °C or by
heat with the aid of a Lewis acid catalyst. The Lewis acid catalysts used in this process
include zeolites, clay montmorrilite, aluminum chloride, aluminum bromide, ferrous
Chloride, and ferrous bromide. However, the removal of oxygen during thermal processing
also eliminates the environmental benefits associated with using an oxygenated fuel [5].
In addition, these fuels are produced more like gasoline rather than diesel.
2.4.4. Trans esterification (Alcoholysis)
Trans esterification reactions are a reversible reaction that involves the transformation of an ester
into a different ester. For manufacturing biodiesel, trans esterification is performed to lower the
viscosity of vegetable oils. Specifically, a triglyceride (TG) molecule (primary compound in
vegetable oils) reacts with a low molecular weight alcohol, yielding a mono alkyl ester and a
byproduct glycerin, which is used in pharmaceutical and cosmetic industries. The trans
esterification reaction for biodiesel synthesis is shown in Figure below:
Figure : Triglyceride trans esterification reaction.
11
2.5 Physical and chemical properties
2.5.1 Fats and oils
Fats and oils are members of the lipids family. Lipids may either be a solid or
liquid at room temperature, depending on their structure and composition. Normally,
“oil” refers to a lipid that is liquid at room temperature, while “fat” refers to a lipid that is
solid or semi-solid at room temperature. Fats and oils primarily consist of esters of
glycerol (mono-, di-, and triglycerides) and low to moderate contents of free fatty acids
(carboxylic acids). Other compounds such as phospholipids, polypeptides, sterols, water,
odorants and other impurities can be found in crude oils and fats. The structures of mono-
, di-, and triglycerides (MGs, DGs, and TGs) consists of glycerol (a backbone of carbon,
hydrogen, and oxygen) esterificed with fatty acids (chains of carbon and hydrogen atoms
with a carboxylic acid group at one end), as shown in Figure 2.1. Free fatty acids (FFAs)
can contain 4-24 carbon atoms with some degree of unsaturation (typically 1-3 C-C
double bonds). Fats have more saturated fatty acids, the compositional building blocks,
than oils, which give rise to a higher melting point and higher viscosity of the former.
Consequently, biodiesel produced from saturated fats have a higher cloud and gel points
than those made from unsaturated oils, making the former unsuitable to use in cold
climates.
12
2.5.2 Treating High FFA Waste Vegetable Oil
There are several methods to treat high FFA waste vegetable oils in small-scale systems. The
easiest is to mix the high FFA oil with low FFA oil. This will work for an occasional high FFA
batch. Other options require esterification (two-stage process) or intentionally make soap. These
options are:
- Add catalyst and water to change FFA to soap, and remove the soap
- Add acid and a large percentage of Methanol to covert FFA to usable product
- Add acid, heat and a smaller percentage of Methanol to covert FFA to a usable product
Adding catalyst and water to high FFA oil is the easiest solution, but it also has some
disadvantages. The percentage of feedstock that will be lost is higher then the percentage FFA.
100 gallons of waste vegetable oil will loose more than 10 gallons if it is 10% FFA. When this
procedure is carried out in the reaction tank, the resulting water and soap created will collect
above and below the oil. I found it time consuming to skim the soap off of the top of the oil.
Adding acid and large quantities of methanol to the oil is the most common method among
small-scale producers. The disadvantage to this method besides time is the cost of the methanol.
For 10% FFA, over seven gallons of methanol would be needed for the first stage to treat 40
gallons of oil. This is in addition to the eight gallons required for the second stage. A methanol
recovery system could return three gallons from the first stage and 1½ gallon from the second,
but this requires additional time and energy. This option requires an extra tank.
Adding acid with high heat (90 degree C) and smaller quantities of Methanol is not widely used.
13
CHAPTER THREE
RESEARCH METHODOLOGY
3.1 Biodiesel reaction
The basic biodiesel reaction is shown in Figure below. This reaction is known as
transesterification (do-it-yourselfers often call it the one-step process). The
triglyceride is vegetable oil. R1, R2 and R3 represent any of the fatty acids listed in
Table 1. Reacting one part Vegetable oil with three parts Methanol gives three
parts Methyl Esters (Biodiesel) and one part Glycerol. In practical terms, the
volume of Biodiesel will be equal to the input volume of vegetable oil.
14
3.2 Biodiesel process layout
Published literature about industrial plant design simulation of biodiesel production has been
scarce. Besides few studies evaluating simulation aspects of biodiesel production from several
vegetable oils, including canola, castor, rapeseed, soybean, sunflower, and waste cooking oil
have been conducted no work was found considering the conceptual design by using jatropha
curcas oil (JCO) as a feedstock in which JCO is converted via supercritical transesterification
with methanol to methyl esters (biodiesel) and glycerol as byproduct. Jatropha curcas oil (JCO)
is considered as the future feedstocks for biodiesel production because it is non-edible, easily
grown in a harsh environment and not compete with food resources. The main advantages using
supercritical methanol compared with conventional process include (i) no catalyst required; (ii)
not sensitive to both water and free fatty acid; and (iii) free fatty acids in the oil are esterified
simultaneously . The feedstock used in this process is jatropha curcas oil (JCO) since it is non-
edible, easily grown in a harsh environment, not compete with food resources and the price is
lower compared with edible oil.
Beginning at the left, jatropha oil was fed into the transesterification reactor simultaneously with
methanol and a recycled methanol. Before entering the reactor, jatropha and methanol were
pressurized to the reaction pressure (20 MPa) by P1 and P2. Then the pressurized stream flow
through heat exchanger H1 and brought to the desired temperature 340℃. A plug flow reactor
(PFR) was selected to carry out transesterification reaction. The transesterification products are
then fed to a flash tank (FT) where most of methanol evaporates whereas the other components
remain mostly in the liquid phase. V1 was used to depressurize stream from 20 to 0.2 MPa. Then
a distillation column (DC1) was used to further separate methanol. The recovered methanol was
then recycled and mixed with fresh methanol feed. After the PFR, FT and DC1, the bottom
stream was cooled down to 25 ℃ and was passed through a decanter (DEC) for separation of the
oil from the glycerol. Two liquid phases were formed: a glycerol rich phase and methyl oleate
rich phase. The oil stream leaving the final decanter was fed to a second distillation column
(DC2) to purify the biodiesel from other impurities where biodiesel is finally obtained as
distillate.
15
3.3 Supercritical methanol process of Biodiesel flow sheet
Chapter four
Material balance and Energy balance calculations
4.1 Material balance There are 14 numbers of process streams in the system. The following paragraph will develop
the equations for the material balance in every unit.
The transesterification reaction involved in PFR is given by
The flow rate reactant is defined as
Let n1 =degree of the reaction 1 and αi = stoichiometric. It is defined as negative for feed and
positive for product.
The material balance of supercritical methanol process
16
Figure .Flowchart shows the material balance of SCM process
The transesterification reaction involved in PFR reactor is given by Eq. above with a
94% conversion of triglyceride. The product for PFR is given by
The mass balance for methyl esters:
The mass balance for glycerol:
The mass balance for triglycerides:
Some approximations has been considered for vapor/liquid phase equilibrium. For our short cut
calculations, we assume ideal behavior which leads to the following assumptions:
𝜙𝑘 = 1, 𝛾𝑘 = 1, 𝑓𝑜𝑘 = 𝑃𝑜𝑘 (vapor pressure)
Antoine equation for vapor pressure: 𝑙𝑛 𝑃𝑜𝑘 = 𝐴𝑘 − 𝐵𝑘/(𝑇 + 𝐶𝑘) (10)
17
These assumptions lead to Raoul’s Law:
𝑦𝑘/𝑥𝑘 = 𝑃𝑜𝑘/𝑃 = 𝐾𝑘 (11) with respect to the key components, a relative volatility can be defined
𝛼𝑘/𝑛 = 𝐾𝑘/𝐾𝑛 = 𝑃𝑜𝑘/𝑃𝑜𝑛 (12) The other split fraction for FT and DEC; and DC1 and DC2 can be calculated by using the
equation,
The product from PFR reactor will enter the FT and DC1 in order to recover the excess methanol
by distillation. Given the component list, the author choose methanol, M as a n component and
examine the relative volatilities of the component list at cooling water temperature. The split
fraction for ME, GLY and TG can be calculated by using above equation. The mass balances for
FT are given as below:
Table . The split fractions for FT, DC1, DEC and DC2
The mass balance for methyl esters:
The mass balance for glycerol:
The mass balance for methanol:
18
The mass balance for triglycerides
Here we would like to recover 99.99% of the M overhead, thus split fraction for the key
component, ξM= 0.999 and ξGLY=0.0001 while components ME and TG are heavier than heavy
key. The mass balance for DC1:
The mass balance for methyl esters:
The mass balance for glycerol:
The mass balance for methanol:
The mass balance for triglycerides:
From DC1, the product will go to DEC for glycerol separation. The mass balance for DEC:
The mass balance for methyl esters:
The mass balance for glycerol:
The mass balance for methanol:
The mass balance for triglycerides:
Finally, the last downstream purification for this process is the methyl ester purification by
distillation. The mass balance around the DC2 is given as:
The mass balance for methyl esters:
19
The mass balance for glycerol:
The mass balance for methanol:
The mass balance for triglycerides:
s
Figure Result of material balance
20
From the overall mass balance, the product from PFR is determined (%Wt)- ME:41.64 %,
GLY:4.08 %, TG: 2.50% and M: 51.78% in which the molar ratio of methanol to oil used was
42. After the methanol recovery at FT and DC1, methanol is reduced to0.09(%mol). Glycerol is
an economically significant co-product that should be as fully refined as practicable. It is showed
that almost pure glycerol (96.49%) attained as by-product.
Finally, the biodiesel had a purity 99.96 % which passes the European biodiesel standard
EN 14214. It is observed that the results of this study is much better than the other studies and
jatropha curcas oil gives biodiesel yield higher than other oil feedstocks.
The properties of the biodiesel end-product stream
21
4.2. ENERGY BALANCE
4.2.1 CALCULATION FOR DISTLATION COLUMN I
3
1 2
Components at stage (1)
𝑀𝐸 = 43.28(.3896), = 16.9 𝐾𝑚𝑜𝑙/ℎ𝑟
𝐺𝐿𝑌 = 43.28(.1228) = 5.28 𝐾𝑚𝑜𝑙/ℎ𝑟
𝑇𝐺 = 43.28(.00783) = .338𝐾𝑚𝑜𝑙/ℎ𝑟
𝑀 = 43.28(.4791) = 20.761𝑘𝑚𝑜𝑙/ℎ𝑟
Components at stage (2) components at stage (3)
𝑀𝐸 = .748(22.54) = 16.859𝑘𝑚𝑜𝑙/ℎ𝑟 𝑀𝐸 = 0
𝐺𝐿𝑌 = .235(22.54) = 5.3𝑘𝑚𝑜𝑙/ℎ𝑟 𝑇𝐺 = 0
𝑀 = .009(22.54) = .02𝑘𝑚𝑜𝑙/ℎ𝑟 𝐺𝐿𝑌 = 0
𝑇𝐺 = .015(22.54) = .338𝑘𝑚𝑜𝑙/ℎ𝑟 𝑀 = 1(20.74)
= 20.74𝑘𝑚𝑜𝑙/ℎ𝑟
𝑃𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑜𝑛 𝑟𝑎𝑡𝑒 = 40000𝑡𝑜𝑛/ℎ𝑟, = 4566𝑘𝑔/ℎ𝑟
22
Q(1) =
= 𝑚𝑐𝑝( (𝑡2 − 𝑡1)𝑀 + 𝑚𝑐𝑝(𝑡2 − 𝑡1) 𝑇𝐺 + 𝑚𝑐𝑝(𝑡2 − 𝑡1)𝐺𝐿𝑌 + 𝑚𝑐𝑝(𝑡2 − 𝑡1)𝑀𝐸)
𝑄𝑀 = 𝑚𝑐𝑝(𝑡2 − 𝑡1) = 20.61 𝑐𝑝 = 3453.2𝐽
𝑄𝑇𝐺 = 𝑚𝑐𝑝(𝑡2 − 𝑡1) = .338𝑐𝑝 (105.3℃ − 104.3℃) = 1030.5𝐽
𝑄𝐺𝐿𝑌 = 𝑚𝑐𝑝(𝑡2 − 𝑡1) = 5.28𝑐𝑝 (105.3℃ − 104.3℃) = 1158.5𝐽
𝑄𝑀𝐸 = 𝑚𝑐𝑝(𝑡2 − 𝑡1) = 16.9𝑐𝑝 (105.3℃ − 104.3℃) = 2352𝐽
𝑄 (1) = ∑𝑄 = 7994𝐽
𝑄2 = 𝑚𝑐𝑝( (𝑡2 − 𝑡1)𝑀 + 𝑚𝑐𝑝(𝑡2 − 𝑡1) 𝑇𝐺 + 𝑚𝑐𝑝(𝑡2 − 𝑡1)𝐺𝐿𝑌 + 𝑚𝑐𝑝(𝑡2 − 𝑡1)𝑀𝐸)
𝑄𝑀 = 𝑚𝑐𝑝(𝑡2 − 𝑡1) + 𝑚𝜆
𝑄𝑀 = .02𝑐𝑝 (105.3℃ − 104.3℃) + 0.02𝜆 = 2246𝐽
𝑄𝐺𝐿𝑌 = 5.3𝑐𝑝(105.3℃ − 104.3℃) = 2340.5𝐽
𝑄𝑇𝐺 = 𝑚𝑐𝑝(𝑡2 − 𝑡1) = . 𝐺33802𝑐𝑝 (105.3℃ − 104.3℃) = 118.3𝐽
𝑄𝑀𝐸 = 𝑚𝑐𝑝(𝑡2 − 𝑡1) = 16.859 𝑐𝑝 (105.3℃ − 104.3℃) = 0.00
𝑄2 = ∑𝑄 = 4704.3𝐽
𝑄3 = 𝑚𝑐𝑝(𝑡2 − 𝑡1)𝑀 + 𝑚𝜆
𝑄3 = 20.74 𝑐𝑝 (105.3℃ − 104.3℃) + 20.74 𝜆
𝐻𝑒𝑎𝑡 𝑜𝑢𝑡 = 𝑄2 + 𝑄1 , 1170.5 𝐽 + 4704.3 𝐽 = 5874.8 𝐽
𝐻𝑒𝑎𝑡 𝑖𝑛 = 𝑄1 ,7994𝐽
𝐻𝑒𝑎𝑡 𝑝𝑟𝑜𝑣𝑖𝑑𝑒𝑑 𝑏𝑦 𝑡ℎ𝑒 𝑠𝑡𝑒𝑎𝑚 𝑖𝑛 𝑡ℎ𝑒 𝑟𝑒𝑏𝑜𝑖𝑙𝑒𝑟
𝑄𝑠 = 𝑄 𝑜𝑢𝑡 − 𝑄 𝑖𝑛 , 5874.8𝐽 – 7994𝐽 = −2120𝐽𝑠
4.2.2CALCULATIONS ON DISTILATION COLUMN 𝑰𝑰
𝟐
23
`
𝟏 3 𝟑
1. 𝐹 = 17.19𝑘𝑚𝑜𝑙/ℎ𝑟
0.9789𝑀𝐸, 0.0006𝐺𝐿𝑌, 0.0192 𝑇𝐺
0.0012𝑀, 𝑇𝑒𝑚𝑝 = 25℃
2. 𝐹 = 0.33𝑘𝑚𝑜𝑙/ℎ𝑟
0.0101𝑀𝐸, 0.00𝐺𝐿𝑌
0.9899𝑇𝐺, 0.00𝑀
𝑇𝑒𝑚𝑝 = 274℃, 3𝑘𝑝𝑎
3. 𝐹 = 16.86𝑘𝑚𝑜𝑙/ℎ𝑟
0.9981𝑀𝐸, 0.0006𝐺𝐿𝑌, 0.00𝑇𝐺
𝑇𝑒𝑚𝑝 = 274℃, 𝑝 = 3.5𝑘𝑝𝑎
ENERGY BALANCE OF COMPONENTS
STAGE ONE
𝑀𝐸 17.19(. 9789) = 16.83𝑘𝑚𝑜𝑙
ℎ𝑟
𝐹 = 17.19𝑘𝑚𝑜𝑙/ℎ𝑟
𝐺𝐿𝑌 = 0.0, 𝑇𝐺 = .0192(17.19) =0.3𝑚𝑜𝑙
ℎ𝑟
𝑀 = 0.0012(17.19) = 0 .02𝑘𝑚𝑜𝑙
ℎ𝑟
24
STAGE TWO
𝐹 = 0.33 𝑘𝑚𝑜𝑙/ℎ𝑟, 𝑀 = 0.00𝐹
𝑀𝐸 = 0.0101(0.33) = .00336 𝑘𝑚𝑜𝑙 /ℎ𝑟
𝑇𝐺 = 0.9899( 0.33) = 0.32 𝑘𝑚𝑜𝑙/ℎ𝑟
𝐺𝐿𝑌 = 0
STAGE THREE
𝐹 = 16.86 𝑘𝑚𝑜𝑙/ℎ𝑟
𝑀𝐸 = 0.9981(16.86) = 16.82 𝑘𝑚𝑜𝑙/ ℎ𝑟 , 𝑀 = 0.012(16.86) = 0.2 𝑘𝑚𝑜𝑙/ℎ𝑟
𝐺𝐿𝑌 = 0.0006(16.86) = 0.01 𝑘𝑚𝑜𝑙/ℎ𝑟 , 𝑇𝐺
= 0 ,
OVERALL ENERGY BALANCE
𝑄1 = (( 𝑚 𝑐𝑝 ∆𝑡)𝑀 + (𝑚𝑐𝑝∆𝑡)𝑇𝐺 + (𝑚𝑐𝑝∆𝑡)𝐺𝐿𝑌 + (𝑚𝑐𝑝∆𝑡)𝑀𝐸)1 𝑎𝑡 𝑡𝑒𝑚𝑝 = 25𝑜𝐶
𝑄𝑀 = (0.02 ∗ 𝑐𝑝 (274℃ − 25℃)) = 327.5𝐽
𝑄𝑇𝐺 = ( 0.33 𝑐𝑝 (274℃ − 25℃)) = 8626𝐽
𝑄𝐺𝐿𝑌 = ( 0.00 𝑐𝑝(274℃ − 25℃)𝑡) = 0.00
𝑄𝑀𝐸 = ( 16.83 𝑐𝑝 (274℃ − 25℃)) = 1970𝐽
𝑄1 = 𝛴𝑄 = 8626𝐽 + 0.00 + 1970𝐽 = 10923𝐽
𝑄2 = (( 𝑚 𝑐𝑝 ∆𝑡)𝑀 + (𝑚𝑐𝑝∆𝑡)𝑇𝐺 + (𝑚𝑐𝑝∆𝑡)𝐺𝐿𝑌 + (𝑚𝑐𝑝∆𝑡)𝑀𝐸)2 𝑎𝑡 𝑡𝑒𝑚𝑝, 274 𝑜𝐶
𝑄𝑀 = ( ( 0.0 ∗ 𝑐𝑝(274℃ − 25℃) + 𝜆𝑚 = 0.0 + 𝜆𝑚)2 = 0.0
𝑄𝑇𝐺 = ( 0.326 ∗ 𝑐𝑝 (274℃ − 25℃)) = 4058.7𝐽
𝑄𝐺𝐿𝑌 = ( 0.00 ∗ 𝑐𝑝(274℃ − 25℃)) = 0.00
𝑄𝑀𝐸 = (0.00336 ∗ 𝑐𝑝 (274℃ − 25℃)) = 33.46𝐽
𝑄2 = 𝛴𝑄 = 4058.7𝐽 + 33.46𝐽 + 0.00 + 0.00 = 4093𝐽
25
𝑄 3 = (( 𝑚 𝑐𝑝 ∆𝑡)𝑀 + (𝑚𝑐𝑝∆𝑡)𝑇𝐺 + (𝑚𝑐𝑝∆𝑡)𝐺𝐿𝑌 + (𝑚𝑐𝑝∆𝑡)𝑀𝐸)3 , 𝑎𝑡 𝑡𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒
= 170 𝑜𝐶
𝑄𝑀 = ( ( 16.82 ∗ 𝑐𝑝(274℃ − 170℃) ) + 𝜆𝑚)3 = 1715.6𝐽
𝑄𝑇𝐺 = ( 0.00 ∗ 𝑐𝑝 (274℃ − 25℃)) = 0.00
𝑄𝐺𝐿𝑌 = ( 0.01 𝑐𝑝 (274℃ − 25℃)) = 340𝐽
𝑄𝑀𝐸 = ( 0.2 ∗ 𝑐𝑝 ∗ (274℃ − 25℃)) = 1763𝐽
𝑄3 = 𝛴𝑄 2 = 1715.6𝐽 + 340𝐽 + 1763𝐽 + 0.00 = 3818𝐽
𝑇ℎ𝑒𝑛 , ℎ𝑒𝑎𝑡 𝑜𝑢𝑡 = 𝑄2 + 𝑄3 = 3818J + 4093J = 7911.5J
𝐻𝑒𝑎𝑡 𝑖𝑛 = 𝑄1 = 10923𝐽 , finally the heat provided by steam in the reboiler becomes,
Qs = Q out – Q in
Qs = 7911.5J – 10923𝐽 = −3011.5J
4.2.3 Energy balance of plug flow reactor
Heat of reaction calculations
|
∆𝐻𝑟 = ∆𝐻𝑓𝑝 − ∆𝐻𝑓𝑟
∆𝐻𝑓𝑝 = 3∆𝐻𝑀𝐸 + ∆𝐻𝐺𝐿𝑌
∆𝐻𝑓𝑝 = 3(−734.5𝑘𝑔
𝑚𝑜𝑙+ (−699.6)
𝑘𝑔
𝑚𝑜𝑙 =-2903
𝑘𝑔
𝑚𝑜𝑙
∆𝐻𝑓𝑟 = ∆𝐻𝑇𝐺 + 3∆𝐻𝑀
∆𝐻𝑓𝑟 = −2161𝑘𝐽
𝑚𝑜𝑙+ 3 ∗ (−239.2
𝑘𝐽
𝑚𝑜𝑙)=-2878.8
𝑘𝑔
𝑚𝑜𝑙
26
∆𝐻𝑟 = −2903𝑘𝐽
𝑚𝑜𝑙+ 2878.8
𝑘𝐽
𝑚𝑜𝑙= −24
𝑘𝐽
𝑚𝑜𝑙
∆𝑢 = 𝑄 + (𝑊𝑓 + 𝑊𝑠)
There is no work done by the shaft, so ∆𝑢 = 𝑄 + 𝑊𝑓
𝑊𝑓 = 𝑝∆𝑉 , 𝑠𝑜 , ∆𝑢 = 𝑄 + 𝑃𝑉
But ∆𝑢 + 𝑃𝑉 = ∆𝐻
∴ 𝑄 = 𝑛∆𝐻 , where, 𝑛 𝑖𝑠 𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑚𝑜𝑙𝑒𝑠
𝑛 =𝑚 ̇
�̇�𝑤𝐶𝐻3𝑂𝐻 =
6473.5 𝑘𝑔/ℎ𝑟
32𝑘𝑔/𝑘𝑚𝑜𝑙
n=203 kmol
𝑄 = 203 × (−24) = −4912.6𝑘𝐽/𝑘𝑚𝑜𝑙
4.3 Equipment sizing
4.3.1VOLUME OF PFR (PLUG FLOW REACTOR)
𝑃 = 20 𝑚𝑝𝑎 , 𝑋, 𝑇𝐺 = 0.94𝑠
𝑇𝑒𝑚𝑝 = 340℃
𝐹 = 215.66𝑘𝑚𝑜𝑙/ℎ𝑟 𝐹 = 216.57 𝑘𝑚𝑜𝑙/
ℎ𝑟
𝑀 = 0.338 𝑓 𝑀 = 0.896, 𝑀𝐸 = 0.0779
𝑇𝐺 = 0.0262 𝑇𝐺 = 0.0016 , 𝐺𝐿𝑌 = 0.0241
Considering without catalyst , 𝑇 = 340℃ , p = 20mpa
27
Assumptions
15% 𝑆𝐹
Volume =𝑚
𝜌
The reaction is
Calculating the mass flow rate of the reacting species ,
�̇� 𝑀 = 0.938(215.66) =202.3 kmol/hr
�̇� TG = 0.0262(215.66) = 5.65 kmol/hr
V total = 𝑚
𝜌1 + =
𝑚
𝜌2
V= 202.3 + 0.15(202.3)
𝜌1 +
5.65 + 0.15(5.65)
𝜌2
V = 232.65
𝜌1 +
6.5
𝜌2 , 𝑣 =
232.65 𝑘𝑔
0.7918𝑘𝑔/𝑚3=294𝑚3
If the reactor is 80% full on each cycle,
So volume of reactor 𝑣𝑟 =𝑣
0.8=
294𝑐
0.8= 367.5𝑚3
4.3.2 Volume of Flow tank
𝐹 = 216.57𝑘𝑚𝑜𝑙/ℎ𝑟
GLY= 0.0246, 𝑇𝐺 = 0.001
M= 0.896𝑇𝑒𝑚𝑝 = 340℃ , 𝑃 = 20 𝑚𝑝𝑎
Calculate mass flow rates of each component
28
�̇�𝑀𝐸 = 0.0779(216.57) = 16.9𝑘𝑚𝑜𝑙/ℎ𝑟 = 5002.4𝑘𝑔/ℎ𝑟
�̇�𝑇𝐺 = 0.0016(216.57) = 0.35𝑘𝑚𝑜𝑙/ℎ𝑟 = 309.4𝑘𝑔/ℎ𝑟
�̇�𝐺𝐿𝑌 = 0.0246(216.57) = 5.4𝑘𝑚𝑜𝑙/ℎ𝑟 = 469.8𝑘𝑔/ℎ𝑟̇
�̇�𝑀 = 0.896(216.57) = 194.046𝑘𝑚𝑜𝑙/ℎ𝑟 = 10282𝑘𝑔/ℎ𝑟
The volume of reactants with 15% SF, becomes
𝑣𝑡𝑜𝑡𝑎𝑙 =𝑚𝑀𝐸
𝜌+
𝑚𝑇𝐺
𝜌+
𝑚𝐺𝐿𝑌
𝜌+
𝑚𝑀
𝜌
𝑣𝑡𝑜𝑡𝑎𝑙 =5002.4𝑘𝑔/ℎ𝑟
0.88𝑘𝑔𝑙𝑡
+309.4𝑘𝑔/ℎ𝑟
0.523𝑘𝑔𝑙𝑡
+469.8𝑘𝑔/ℎ𝑟
1.260𝑘𝑔𝑙𝑡
+110282𝑘𝑔/ℎ𝑟
0.7918𝑘𝑔𝑙𝑡
𝑣𝑡𝑜𝑡𝑎𝑙 = 145929.11𝑙𝑡
𝑉𝑜𝑙𝑢𝑚𝑒 𝑜𝑓 𝑡ℎ𝑒 𝑓𝑙𝑜𝑤 𝑡𝑎𝑛𝑘 = 145.9 𝑚3
4.4 COST ESTIMATION An acceptable plant design must present a process that is capable of operating under conditions
which will yield a profit. Since, Net profit = Total income – All expenses It is essential that
Chemical engineer be aware of the many different types of cost involved in manufacturing
processes. Capital must be allocated for direct plant expenses, such as those for raw materials,
labor, and equipment. Besides direct expenses, many other indirect expenses are incurred, and
these must be included if a complete analysis of the total cost is to be obtained. Some examples
of these indirect expenses are administrative salaries, product distribution costs and cost
for interplant communication. A capital investment is required for any industrial process and
determination of the necessary investment is an important part of a plant design project. The total
investment for any process consists of fixed capital investments for physical \equipment and
facilities in the plant plus working capital which must be available to pay salaries, keep raw
materials and products on hand, and handle special items requiring a direct cost outlay. Thus in
an analysis of cost in industrial processes, capital investment cost, manufacturing cost, and
general expenses including income taxes must be taken into consideration.
CAPITAL INVESTMENT
29
Before an industrial plant can be put into operation, a large sum of money must be supplied to
purchase and install the necessary machinery and equipment. Land and service facilities must be
obtained and the plant must be erected complete with all piping, controls and service. In addition
it is necessary to have money available for the payment of expenses involved in the plant
operation. The total capital required for installation and working of a plant is called total capital
investment.
Total Capital Investment = Fixed Capital + Working Capital
Fixed Capital Investment: the capital needed to supply necessary manufacturing and plant
facilities is called fixed capital investment. The fixed capital is further subdivided into
manufacturing fixed capital investment and non-manufacturing fixed capital investment.
Working Capital: The capital required for the operation of the plant is known as
working capital.
FIXED CAPITAL INVESTMENT INCLUDE
A. DIRECT COST
1. Purchased Equipment Cost
2. Purchased Equipment Installation
3. Installation Cost
4. Instrumentation and Controls
5. Piping
6. Electrical Installation
7. Building including services
8. Yard improvement
9. Service facilities
10. Land
B. INDIRECT COST
1. Engineering and supervision
2. Construction expenses
3. Contractors fee
4. Contingencies
5. Startup expenseCost Estimation
WORKING CAPITAL INCLUDES:
1. Raw materials and supplies carried in stock
2. Finished product in stock and semi-finished products in the process of
being manufactured.
3. Accounts receivable.
4. Cash kept on hand for monthly payment of operating expenses, such as
salaries, wages, and raw material purchased.
5. Accounts payable.
6. Taxes payable.
30
4.5 COST INDEXES: A cost index is merely an index value for a given point in time showing the cost that time
relative to certain base time. So, present cost is estimate from cost index as follows Present
Cost= Original Cost x (Index Value at Present Time/Index value at Time Original Cost was
Obtained) Cost index can be used to give a general estimate.
𝑷𝒍𝒖𝒈 𝒇𝒍𝒐𝒘 𝒓𝒆𝒂𝒄𝒕𝒐𝒓(𝑷𝑭𝑹)
𝐼𝑛𝑠𝑖𝑑𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 = 7.5𝑚
𝐻𝑒𝑖𝑔ℎ𝑡 = 14.35𝑚
𝑇𝑜𝑡𝑎𝑙 𝑐𝑎𝑝𝑎𝑐𝑖𝑡𝑦 = 367𝑚3
= 96,944.62𝑔𝑎𝑙𝑙𝑜𝑛
𝐶𝑜𝑠𝑡 𝑜𝑓 𝑃𝐹𝑅 = $82,000
15% 𝑐𝑜𝑠𝑡 𝑓𝑜𝑟 𝑐𝑜𝑜𝑙𝑖𝑛𝑔 𝑠/𝑚 = $7,500
𝑇𝑜𝑡𝑎𝑙 𝑐𝑜𝑠𝑡 = $89,500
𝐶𝑜𝑠𝑡 𝑖𝑛𝑑𝑒𝑥 1990 = 952
𝐶𝑜𝑠𝑡 𝑖𝑛𝑑𝑒𝑥 2014 = 1840
𝐶𝑜𝑠𝑡 𝑖𝑛 2014 = (82,000 ∗ 1840)/952
𝐶𝑜𝑠𝑡 𝑖𝑛 2014 = $15,8487.7
“𝑫𝒊𝒔𝒕𝒊𝒍𝒍𝒂𝒕𝒊𝒐𝒏 𝒄𝒐𝒍𝒖𝒎𝒏”(𝑰)
𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑜𝑓 𝑡ℎ𝑒 𝑐𝑜𝑙𝑢𝑚𝑛 = 13.4𝑓𝑡
𝐻𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝑐𝑜𝑙𝑢𝑚𝑛 = 68.5𝑓𝑡
𝑇𝑜𝑡𝑎𝑙 𝑝𝑢𝑟𝑐ℎ𝑎𝑠𝑒𝑑 𝑐𝑜𝑠𝑡 = $1526140
𝑃𝑢𝑟𝑐ℎ𝑎𝑠𝑒𝑑 𝑐𝑜𝑠𝑡 𝑖𝑛 2014 = (1526140 ∗ 1840)/952
= 2949682.5
𝑫𝒊𝒔𝒕𝒊𝒍𝒍𝒂𝒕𝒊𝒐𝒏 𝒄𝒐𝒍𝒖𝒎𝒏 (𝑰𝑰)
31
𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑜𝑓 𝑡ℎ𝑒 𝑐𝑜𝑙𝑢𝑚𝑛 = 9.5𝑓𝑡
𝐻𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝑐𝑜𝑙𝑢𝑚𝑛 = 57𝑓𝑡
𝑇𝑜𝑡𝑎𝑙 𝑝𝑢𝑟𝑐ℎ𝑎𝑠𝑒𝑑 𝑐𝑜𝑠𝑡 = $1225160
𝑃𝑢𝑟𝑐ℎ𝑎𝑠𝑒𝑑 𝑐𝑜𝑠𝑡 𝑖𝑛 2014 = (1225160 ∗ 1840)/952
= $2367956.3
𝑫𝒆𝒄𝒂𝒏𝒕𝒆𝒓
𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑜𝑓 𝑡ℎ𝑒 𝑐𝑜𝑙𝑢𝑚𝑛 = 3.5𝑓𝑡
𝐻𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝑐𝑜𝑙𝑢𝑚𝑛 = 28.4𝑓𝑡
𝑇𝑜𝑡𝑎𝑙 𝑝𝑢𝑟𝑐ℎ𝑎𝑠𝑒𝑑 𝑐𝑜𝑠𝑡 = $24000
𝑃𝑢𝑟𝑐ℎ𝑎𝑠𝑒𝑑 𝑐𝑜𝑠𝑡 𝑖𝑛 2014 = (24000 ∗ 1840)/952
= $4638.65
Flow tank
𝐼𝑛𝑠𝑖𝑑𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 = 4.2 𝑚
𝑇𝑜𝑡𝑎𝑙 ℎ𝑒𝑖𝑔ℎ𝑡 = 6.2 𝑚
𝐶𝑎𝑝𝑎𝑐𝑖𝑡𝑦 = 16.4 𝑚3
𝑃𝑢𝑟𝑐ℎ𝑎𝑠𝑒𝑑 𝑐𝑜𝑠𝑡 𝑖𝑛 1990 = 15 , 000
𝑃𝑢𝑟𝑐ℎ𝑎𝑠𝑒𝑑 𝑐𝑜𝑠𝑡 𝑖𝑛 2014 = (1500 × 1840)
952
32
= $ 28991.6
Table of purchased equipment cost
𝑪𝒐𝒔𝒕 𝒆𝒔𝒕𝒊𝒎𝒂𝒕𝒊𝒐𝒏 𝒇𝒐𝒓 𝒑𝒓𝒐𝒄𝒆𝒔𝒔𝒊𝒏𝒈 𝒑𝒍𝒂𝒏𝒕𝒔
𝐸 = $5509756
𝑃𝑢𝑟𝑐ℎ𝑎𝑠𝑒𝑑 𝑒𝑞𝑢𝑖𝑝𝑚𝑒𝑛𝑡 𝑖𝑛𝑠𝑡𝑎𝑙𝑙𝑎𝑡𝑖𝑜𝑛 47% 𝐸 = $2589585
𝐼𝑛𝑠𝑡𝑟𝑢𝑚𝑒𝑛𝑡𝑎𝑡𝑖𝑜𝑛 𝑎𝑛𝑑 𝑐𝑜𝑛𝑡𝑟𝑜𝑙 18% 𝐸 = $991356
𝐸𝑙𝑒𝑐𝑡𝑟𝑖𝑐𝑎𝑙 𝑖𝑛𝑠𝑡𝑎𝑙𝑙𝑒𝑑 11% 𝐸 = $606,073
𝐵𝑢𝑖𝑙𝑑𝑖𝑛𝑔𝑠 18% 𝐸 = $991756
𝑆𝑒𝑟𝑣𝑖𝑐𝑒𝑠 𝑓𝑎𝑐𝑖𝑙𝑖𝑡𝑦 70%𝐸 = $3816829
𝐿𝑎𝑛𝑑 6% 𝐸 = $330585
𝑇𝑜𝑡𝑎𝑙 𝑑𝑖𝑟𝑒𝑐𝑡 𝑎𝑛𝑑 𝑖𝑛𝑑𝑖𝑟𝑒𝑐𝑡 𝑝𝑙𝑎𝑛𝑡 𝑐𝑜𝑠𝑡 [𝐷 + 𝐼] = $1169449
𝐶𝑜𝑛𝑡𝑟𝑎𝑐𝑡𝑜𝑟’𝑠 𝑓𝑒𝑒𝑙, 20%𝐸 = $1157048.7
𝐶𝑜𝑛𝑡𝑖𝑛𝑔𝑒𝑛𝑐𝑦, 42%𝐸 = $2314097.5
𝐹𝑖𝑥𝑒𝑑 𝑐𝑎𝑝𝑖𝑡𝑎𝑙 𝑖𝑛𝑣𝑒𝑠𝑡𝑚𝑒𝑛𝑡 = $3471145
𝑊𝑜𝑟𝑘𝑖𝑛𝑔 𝑐𝑎𝑝𝑖𝑡𝑎𝑙 86%𝐸 $4738370
𝑇𝑜𝑡𝑎𝑙 𝑐𝑎𝑝𝑖𝑡𝑎𝑙 𝑖𝑛𝑣𝑒𝑠𝑡𝑚𝑒𝑛𝑡 = $820953
Equipment Cost in 1990($) Cost in 2014($)
PFR reactor 82,000 158487
Distillation column 1 1526140 2949682.6
Distillation column 2 1225160 2367956.3
Flow tank 15000 28991.6
Decanter 24000 4638.65
Total 2872300 5509756
33
1. 𝑅𝑎𝑤 𝑚𝑎𝑡𝑒𝑟𝑖𝑎𝑙
𝐶3𝑂𝐻 = 0.53𝑇𝑃𝐿 = 0.53[820953] = $4351053
𝐶57𝐻104𝑂6 = 0.3𝑇𝑃𝐿 = 0.3[ 820953] = $2462860
2. 𝑂𝑝𝑟𝑎𝑡𝑖𝑛𝑔 𝑙𝑎𝑏𝑜𝑟 [10 − 20% 𝑇𝑃𝐿]
= 0.15𝑇𝑃𝐿 = 0.15[820953] = $1231430
3. 𝑢𝑡𝑖𝑙𝑖𝑡𝑖𝑒𝑠[10 − 20%]𝑇𝑃𝐿
= 0.15𝑇𝑃𝐿 = 0.15[$820953] = $1231430
4. 𝑀𝑎𝑖𝑛𝑡𝑒𝑛𝑎𝑛𝑐𝑒 𝑎𝑛𝑑 𝑟𝑒𝑝𝑎𝑖𝑟 [2 − 10%𝐹𝐶𝐼]
(0.06)(34711453) = $208268.7
𝐹𝑖𝑥𝑒𝑑 𝑐𝑜𝑠𝑡
1, . 𝑑𝑒𝑝𝑟𝑒𝑐𝑖𝑎𝑡𝑖𝑜𝑛 [10%𝐹𝐶𝐼]
= 0.1[$3471145]
= $347114.5
2, 𝐿𝑂𝐶𝐴𝐿 𝑇𝐴𝑋 [1 − 4%]𝐹𝐶𝐼
0.025[$3471145]
= $86778.6
3, 𝐼𝑁𝑆𝑈𝑅𝐴𝑁𝐶𝐸 [0.5_1%]𝐹𝐶𝐼
= 0.0075[$3471145]
= $26033.5
𝑇𝑃𝐶 = 𝑉𝑎𝑟𝑖𝑎𝑏𝑙 𝑐𝑜𝑠𝑡 + 𝐹𝑖𝑥𝑒𝑑 𝑐𝑜𝑠𝑡
= 0.628𝑇𝑃𝐶 + $2252468
= $5139168 + $2252468
34
= $7391637
𝑃𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑜𝑛 𝑐𝑜𝑠𝑡 = 𝑎𝑛𝑛𝑢𝑎𝑙 𝑝𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑜𝑛 𝑐𝑜𝑠𝑡
𝑎𝑛𝑛𝑢𝑎𝑙 𝑝𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑜𝑛 𝑟𝑎𝑡𝑒
=7391637
40000 𝑡𝑜𝑛
= $184.7
𝑡𝑜𝑛
𝑃𝑎𝑦𝑏𝑎𝑐𝑘 𝑝𝑒𝑟𝑖𝑜𝑑
𝑆𝑒𝑙𝑙𝑖𝑛𝑔 𝑝𝑟𝑖𝑐𝑒 = $600
𝑡𝑜𝑛
𝑃𝑟𝑜𝑓𝑖𝑡/𝑦𝑒𝑎𝑟 = 𝑆𝑒𝑙𝑙𝑖𝑛𝑔 𝑝𝑟𝑖𝑐𝑒 – 𝑝𝑟𝑜𝑑𝑢𝑐𝑡𝑖𝑜𝑛 𝑐𝑜𝑠𝑡
= 600 − 184.7 = 415.3
𝑁𝑒𝑡 𝑝𝑟𝑜𝑓𝑖𝑡 𝑎𝑓𝑡𝑒𝑟 𝑡𝑎𝑥 = 0.65(415.3 × 40000) = $10797800
𝐷𝑒𝑝𝑟𝑒𝑐𝑖𝑎𝑡𝑖𝑜𝑛 = 𝑣 − 𝑣𝑠
𝑛
= $ 3471145
10 = $ 347114.5
𝑃𝑎𝑦𝑏𝑎𝑐𝑘 𝑝𝑒𝑟𝑖𝑜𝑑 = 𝐹𝑖𝑥𝑒𝑑 𝑐𝑎𝑝𝑖𝑡𝑎𝑙 𝑖𝑛𝑣𝑒𝑠𝑡𝑚𝑒𝑛𝑡
𝑝𝑟𝑜𝑓𝑖𝑡 + 𝑑𝑒𝑝𝑟𝑒𝑐𝑖𝑎𝑡𝑖𝑜𝑛
= 3471145
347114.5 + 1079800
35
= 2.43 𝑦𝑒𝑎𝑟𝑠
4.6 Safety and Environment Biodiesel producers are regulated by two entities: OSHA and the environmental protection agency.
OSHA’s concern is with the environment for the workers. It considers biodiesel production facilities
to be chemical plants. The handling/storage of class a flammable liquids (methanol) can be found
under section 29.1910.106. Some of the rules that may apply are: Methanol storage containers must be metal, grounded, use masonry supports and must not
spill contents if connectors burn through
Space required around tanks for fire fighting access
Explosion No other operations in the room with the equipment
proof electrical wiring The environmental protection agency (EPA) deals only with the protection of the environment. In the
case of biodiesel, most of the concern is about containment from spills of the various fluids.
4.7 Conclusion Nowadays, biodiesel is produced in great amount and its production continues to grow. The main
technology used in the industrial production is based on the transesterification of refined oils
with methanol using basic super critical methanol process (with no catalyst). However, the
problems related with this technology (mainly in product purification) have stimulated research
in the field of heterogeneous catalysis for biodiesel production. In particular, industry is making
great research efforts to find the right catalyst, and today, a plant based on super critical
methanol process. However, the research has not stopped there because several tasks still need to
be done.
36
References [1] Tovar, Líela y Téllez, Mauricio..
[2] Kann J., Rang H., , and Kriis J.. Advances in
biodiesel fuel research. Proc. Estonian Acad. Sci.
Chem., 51, 2, p.75–117 (2002).
[3]COLCIENCIAS. 2004. Agenda y Novedades.
http://www.colciencias.gov.co/agenda/pn113.html.
[4] Krung and Teixeira Mendes Y. Improving of
mamoneira, cited by Mazzani, Bruno. Oil plants.
Agronomic Research Center of Agricultural
Ministery. Central University of Venezuela.
Agronomy department. Barcelona . Salvat, 1963. p.
150.
[5] Yamane, K., Ueta, A. and Shimamoto, Y. Influence
of physical and chemical properties of biodiesel fuels
on injection, combustion and exhaust emission
characteristics in a direct injection compression
ignition engine. Int J Engine Research 2, 4, 249-
261.(2001).
[6] Ma, F., Hanna M.A. Biodiesel production: a review.
Bioresource Technology 70, 1-15.(1999).
[7] Kinast, J.A..Production of Biodiesels from Multiple
Feedstocks andProperties of Biodiesels and
Biodiesel/Diesel Blends.Final Report. National
Renewable Energy Laboratory. (2003).
37