CH 4202 COMPREHENSIVE DESIGN PROJECTDESIGN OF ASOY BEAN BASED PRINTING INKMANUFACTURING PLANT11IntroductionProcessEnvironment, Health and SafetyCost Analysis and ConclusionContents2INTRODUCTION3Varnish production (mixture of solvent, resins and additives) - bind the pigment to the printed surface and wet the pigment particles Mix with pigment - pigment particles tend to clump together which disperse using roll mills, Bead mills or Cavitation mixer

PRINTING INK MANUFACTURING PROCESS45COMPONENTS IN PRINTING INK

SolventResinsAdditivesPigment~80% Linseed oil - A cool humid climate with temperature ranging from 10C to 27C.

Castor oil North Parts of India and Russia China etc / A low temperature (less than 15C) in the seed bed prolongs the emergence of seedlings.

Soy bean oil - (21C -32C) /warm and moist climate,(Soybean is cultivated in Matale, Anuradhapura, Kurunegala, NuwaraEliya, Monaragala, Badulla,and Polonnaruwa disrtcts)

ALTERNATIVE VEGETABLE OILS FOR PETROLIUMIMPORTANT OF SOY BEAN INK7 Mechanical process Diffusion of a solvent into oil bearing cellsThe extraction of flavors and fragrances using supercritical CO2 Enzyme is used to degrade cell walls Sudden reduction of osmotic pressure by osmotic shock, can rupture the cells, and release oil off the surface Ultrasonic assisted process can generally accelerate extraction

Expellers/pressSolvent extractionSuper Critical Oil extractionEnzymatic ExtrusionsOsmotic shock

Ultra sonic assisted extractionSOY BEAN OIL EXTRACTION PROCESS8Expellers 16%Solvent Ex 75%Enzymatic Extrusions 80% but high cost8

ComponentPercentage %Triacylglycerol 94.4Phospholipids3.7Un-saponifable matter 1.3-1.6Sterols 0.23Tocopherols0.13Hydrocarbons 0.38Free fatty acids 0.3-0.7Trace metals iron1-3 ppmcopper0.03-0.05 ppmCOMPONENTS OF SOY BEAN OIL9SUGGESTED SOY BEAN INK PLANTParameterAmountAnnual demand of ink 2160 MTTarget market share 50% Average Soybean oil in ink (60%w/w) 648 MTOil yield(w/w) 15% Required Soybean 4322 MT/YearSoy bean yield 2 (MT/ha) Area required for cultivation 2161 (ha) Percentage of Cultivate60%Land required 1300 (ha)10Average Soybean oil in ink =2160.67*50%*60%10SITE SELECTIONClimate and cultivationAvailability of labor Transportation Availability of utilities Local community and wild life Political and other aspectsGalgamuwaInKurunagala district1112PROCESSSoy bean seeds Oil extracting plantCrude soy bean oil Refining plantRefined Bleached De-odorized Soy Bean OilInk manufacturing plantSoy bean oil based printing ink 13OVERALL PROCESS FLOW DIAGRAMMFD13CrusherSoy Bean Seeds Cracked Soy BeanOIL EXTRACTING PLANT14OIL EXTRACTION PLANTAspiratorDehulled Cracked Soy BeanCracked Soy BeanAirAir+HullsCyclone Separator HullsAir1515Conditioner Dehulled Cracked Soy Bean Cooked Soy BeanSteam Steam16OIL EXTRACTION PLANTRoll millCooked Soy BeanDrying Dried Soy Bean Flakes Moisture17Removal of Moisture from 13% to 8%OIL EXTRACTION PLANTFlakingRemove moisture from 13% -> 8%17Solvent extractor Water Distillation Make up hexaneDried Soy Bean Flakes Filtration Flash DistillationDe-solventizor Cyclone Separator FootsMealFootsCrude Soy Bean Oil Steam18OIL EXTRACTION PLANT18Hydrator Water Crude Soy Bean Oil Phosphoric acidNeutralization TankNaOH CentrifugerPrimary Centrifuged Soy Bean OilWater 19REFINING PLANTWashing Water Water Centrifuging Primary centrifuged soy bean oilSecondary Centrifuged Soy Bean Oil20REFINING PLANTBleaching by Activated Carbon Pigments Low boiling compoundsDe-odorizing by Vacuum Distillation Secondary Centrifuged Soy Bean OilRefined Bleached Deodorized Soy Bean OilSteam 21REFINING PLANTAlkyd Resin ReactorPurge Nitrogen RBD Soy Bean OilDibutilene Oxide Styrene Allyl Alcohol Alkyd Resin22INK MANUFACTURING PLANTFrom this point onwards process is divided according to the variation of the product.Letter press blackLetter press colorLithography blackGravure

INK MANUFACTURING PLANT2324Letter Press BlackINK MANUFACTURING PLANTRBD soy bean oilAlkyd resinOil & resin reactorInline Injection3 role millBead millProductCarbon blackMagnesium Carbonate25Letter Press ColorINK MANUFACTURING PLANTPigments Pigment extendersMagnesium carbonateRBD soy bean oilAlkyd resinOil & resin reactorInline Injection3 role millBead millProduct26Lithography BlackINK MANUFACTURING PLANTPigments Polyethylene wax pasteAnti set off paintsManganese dries2800C-3200C petroleum distillateRBD soy bean oilAlkyd resinOil & resin reactorInline Injection3 role millBead millProduct27GravureINK MANUFACTURING PLANTPigments Alcohol Soluble NitrocelluloseDioctyl PhthalatePolyethylene WaxEthanolN- Propyl Acetate Magnesium CarbonateEthoxy PropanolRBD soy bean oilAlkyd resinOil & resin reactorInline Injection3 role millBead millProductSteam Requirement1bar steam- 1542.19 kg/hr3bar steam- 1695.35 kg/hr40bar steam- 140.82 kg/hrWater Requirement for 1 MT soy oil is 20.83 m3Staff RequirementManagerial Staff 10Operational Staff 90The average profit generated by 1 MT of soy oil based printing ink is about 196,048 LKRPLANT REQUIREMENTS2829ENVIRONMENT HEALTH & SAFETYENVIRONMENTNeed to consider following four aspectsAirWaterLandSound3031AIR32WATER33LAND34SOUNDHEALTH3536SAFETY37ACCIDENTS38FIRE PROTECTION39COST ANALYSIS& CONCLUSIONPRINTING INK IMPORTS40TARGET PRODUCTS AND THEIR ANNUAL QUANTITIES41ECONOMIC BENEFITS42WASTE TO ENERGY (WTE)43ANNUAL COST VARIATION OF HFO

Figure .: Possible Annual Saving on Steam using WTE Concept44Capital Cost ElementBillion LKR

Cost for 3300 acres to cultivate soy bean 2.640Plant for manufacturing printing ink 0.185

Plant for refined soy oil from soy seeds 0.313

Total capital investment

3.138

CAPITAL INVESTMENT COSTS4546CAPITAL INVESTMENT COST BREAK DOWNOPERATIONAL COSTSFixed costsVariable costsCost of maintenances (labor and materials)Cost of purchasing soy bean Cost of operating laborCost of purchasing other Additives Laboratory costsMiscellaneous operating material costSupervision costCost of Utilities (Services)Cost of plant overheadsHeating CostCost of capital chargesElectricity CostLocal TaxPacking and Shipping CostInsurance Cost of building, equipment, materials and employees etc.Process water costWater treatment cost47COMMISSIONING Commissioning year (2015) design capacity 38%Maximum operating capacity 81% reach 2035Excessive 19% design for case of excessive demand increase48INVESTMENT SUMMARYCapital investment cost3.1 Billion LKRPayback period8 yearsDiscount factor 8%IRR (Internal Rate of Return)9.83%NPV (Net Present Value)4.5 Billion LKR49Head of the Department Dr. P.G. RathnasiriGroup Supervisor Dr. B.A.J.K. PremachandraProject Coordinator Dr. Marliya IsmailAll members in lecture panelMrs. N. Candappa - technical director of Sithara Ink Industries, RathmalanaITI Staff (Industrial Technology Institute)Library Staff, University of Moratuwa

AKNOWLEDGEMENT50Thank You5152APPENDICES53COMPOSITION OF TRIACYLGLYCEROL ComponentWeigh percentageBoiling point (oC)-linolenic acid08.4%230Linoleic acid53.2%230-232Oleic acid23.4%360Stearic acid04.0%232Palmtic acid11.0%35154SEASONAL SOYBEAN CULTIVATION IN SRI LANKA

YEARYalaMahaExtent (ha)Production (MT)Yield (MT/ha)Extent (ha)Production (MT)Yield (MT/ha)19983804101.083502800.8019994705201.113102300.7420003804101.082802200.7920013601800.501801500.8320021,0801,0100.943602900.8120032,1902,6701.221802401.3320041,1201,6501.473606101.6920052,7204,3801.614307201.6720062,6404,4601.692904901.6920072,5704,3101.682203101.4120081,0102,7202.694308001.8620091,2302,9902.437101,3501.9055SEASONAL CULTIVATION OF SOYBEAN IN SRI LANKA56Annual Cultivation of Soybean in Sri LankaYEARAnnualExtent (ha)Production (MT)Yield (MT/ha)19987306900.9519997807500.9620006606300.9520015403300.612002144013000.902003237029101.232004148022601.532005315051001.622006293049501.692007279046201.662008144035202.442009194043402.2457ANNUAL CULTIVATION OF SOYBEAN IN SRI LANKA58ANNUAL YIELD OF SOYBEAN (MT/ha)59VARIETIES OF SOYBEAN IN SRI LANKAN CONTEXTSoybean VarietyOil Content (w/w%)PB-0120%PM-1318%PM-2518%6061Year2015LKRRevenue1,989,709,886Fixed CostsMaintenance (labor and materials).156,899,992Operating labor.58,600,000 Laboratory costs.11,720,000 Supervision cost11,720,000 Cost of Plant overheads.11,720,000Cost of capital charges.313,799,985Cost of local Tax31,379,998 Insurance Cost31,379,998Waste water treatment cost6,000,000 (Less)Total Fixed Costs(633,219,974)Variable CostsCost of soybean seeds484,877,551Cost of other Additives283,737,305 Miscellaneous operating materials.47,069,998Heating Cost12,815,851Electricity cost4,186,771Process water cost3,931,232Transporting and packaging cost99,485,494(Less)Total Variable Costs(936,104,201)Operating Profit439,201,562(Less) Corporate tax 28%(122,976,437)Annual profit316,225,125

Alkyd Resin

64Componentkg/hrMyristic acid0.8080Palmitic acid39.6517Stearicacid13.0476Oleic acid68.0812Linoleic acid(LA)157.9484Alpha-linolenic acid(ALA)19.7211FFA0.0350Water5.7373Hexane38.3706Crude Soybean Oil Composition65If the investment is only made for the Soy bean oil extraction and ink manufacturing plant only, the pay back period will be 2 years.Provided that the continuous supply of the soy bean from local suppliers is guaranteed.

Pay Back time reduction66Oil Extraction Capacity1400 MT/ YearOverall Plant Capacity2600 MT/ YearThermal Energy Requirement7600 MJ/ TonElectricity Requirement2067 MWh67Hulls content in soybeans5.51%w/wMaterial waste in crushing2.00%De-hulling efficiency (removal of hulls)100.00%Loss of cracked bean while de-hulling5.00%Efficiency of cyclone separator 0198.00%Moisture content in soybeans & hulls10.00%w/wHeat transfer efficiency of conditioner 75.00%Percentage condensation of steam in conditioner25.00%Material waste in flacking2.00%Moisture removal in dryer13.73% to 8%w/wOil content in soybeans19.00%w/wSolvent : soybean meal ratio1w/wPercentage of Foots transferred to miscella5%w/wHexane : Dried soybean flakes ratio1.00Removal of foots by filtration100%Operating temperature for flash chamber115oCOperating pressure for flash chamber30kPaRecovery of hexane in hexane water distillation99%Recovery of water in hexane water distillation2%Residual oil in desolventized cake1.20%w/wHexane in desolventized cake1.00%w/wPercentage condensation of steam in de-solventizer25.00%Gum percentage in crude soybean oil3.00%w/wHydratable gum percentage in crude soybean oil2.70%w/wNon-hydratable gum percentage in crude soybean oil0.30%w/wWater used when hydration as a percentage to oil5.00%w/wPhosphoric acid used as a percentage to oil0.34%w/w68Extraction Plant 16.04%Refining Plant83.28%To produce 1MT of Printing Ink 4MT of Soybean seeds are neededConversion