Biodiesel production from Jatropha seed 2008

CHAPTER ONE

1.1 INTRODUCTION
Jatropha is a drought-resistant shrub or tree belonging to the family Euphorbiaceous, which is
cultivated in Central and South America, South–East Asia, India and Africa. It is a plant with
many attributes, multiple uses and considerable potential .In Ethiopia, the land area for jatropha
plantation is increasing because this plant can be used to reclaim land, prevent and/or control
erosion, plus it provides a new agricultural development mode with no competition between food
and non-food uses. The seed is the part of the jatropha plant with the highest potential for
utilization. It contains between 30% and 40% oil, and between 20% and 30% protein. The
jatropha seed is generally toxic to humans and animals.[1]
Jatropha seed oil is regarded as a potential alternative to diesel fuel and vegetable oils have
numerous advantages in this respect because they are safe to store and handle because of their
high flash points. The fact that jatropha oil cannot be used for nutritional purposes without
detoxification makes its use as an energy source for fuel production, very attractive .The use of
biodiesel from jatropha oil is a promising alternative because it is renewable, and
environmentally friendly, and it can also be produced locally. Cultivating jatropha plants on land
where noother crops can grow, and using its oil as an alternative energy source.[2]
Conventional industrial technology for the synthesis of biodiesel from vegetable oils involves
isolation of the oil from the seed refining, and then Tran’s esterification. Oil extraction from
oilseeds is usually done by mechanical pressing with a hydraulic or single expeller press,
followed by solvent extraction. The combination of these operations produces oil extraction
yields up to 98%, with residual oil content in cake meal between 0.5% and 1.5%.
The solvent extraction most commonly used today is by percolation with a countercurrent flow
using hexane as extracting solvent. Currently, twin-screw extrusion has been successfully carried
out to extract oil from oilseed, and to conduct mechanical pressing and solvent extraction of
sunflower oil in a single step. Highest oil extraction yield (98%) with best cake meal quality
(residual oil content lower than 3%) was obtained using a screw rotation speed of 185 rpm, feed
rate of 30 kg/h, and solvent-to-solid ratio.[2]

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The preparation of biodiesel from various vegetable oils using alkaline trans- esterification of
triglycerides with monohydric alcohol has been studied for several decades, and a large part of
industrial production has been achieved using this method, although it requires extra-steps during
the extraction and refining processes.
Recently, the preparation o
biodiesel usingtrans- esterification has been successfully carried out with various oilseeds. Trans-
esterification is a biodiesel production method that uses the original agricultural products as the
source of triglycerides, instead of purified oil, with direct trans- esterification. It reduces the
time-consuming pre-extracted oil production system, and maximizes ester yield.[3]
The conversion of jatropha seed to fatty acid methyl esters(FAME) by acid-catalyzed in trans
esterification has been successfully carried out using seed size lase than 0.335mm and n-hexane
as co-solvent under reaction conditions of 60 °C temperature. A systematic study should be
conducted to investigate and identify optimal reaction conditions for single step in alkaline trans-
esterification combined with solvent extraction of jatropha oil. [3]

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1,2Statement of the problem

In our study, we select jatropha as a raw material for biodiesel production because the poison
characteristics of jatropha oil which makes it have no compared to other edible oil. Besides, it is
easy to grow in tropical and sub-tropical climate.
We use batch reactor with mechanical stirrer for biodiesel production. But the suitable reactor for
biodiesel production still has been searching in order to obtain the maximum product yield and
reduce the biodiesel production cost.
In our country the demands for biodiesel keep increasing year by year this make we still
searching the optimum parameter to obtain high yield, high quality and comparable biodiesel
fuel with petroleum- based diesel.
Generally, the percentage of biodiesel yield from jatropha oil is still low due to the high free
fatty acid content in jatropha oil.

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1.3 OBJECTIVE
1.3.1 General Objective
The primary objective is to extracts oil and converts the oil found in Jatropha seeds into a usable
biodiesel.

1.3.2SPECIFIC OBJECTIVE
 Extraction of Jatropha oil from Jatropha seed using solvent extraction process.
 Production of biodiesel (Tran’sesterification process) of high quality that can be
used.
 To characterize the physico-chemical properties of the biodiesel produced.
 To determine the material and energy balance of the process.

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CHAPTER TWO

2 LITERATURE REVIEW
Jatropha is a genus of over 100 plants, shrubs and trees. It is native to Central America and has
become neutralized to many tropical and subtropical areas, including India, Africa, and North
America. Originating in the Caribbean, Jatropha was spread to Africa and Asia through trading
as a valuable hedge plant.[4]
Since Jatropha was introduced into the subcontinents over 500 years ago by Portuguese sailors,
hundreds of sub-species have developed through cross-fertilization and adaptation to the
subcontinents with varied climatic conditions. As a result, Jatropha oil yields and growing
characteristics vary from region to region. Research on the qualities and characteristics of
Jatropha varieties that flourish in different locations has been done as well as micro-propagating
for mass production of seedlings with necessary characteristics for each planting area.Jatropha
seed Life Cycle and Harvest. [4]
The nature Jatropha plant bears separate male and female flowers, and does not grow more than
5 meters tall. The size of the Jatropha plant kept less than 1 meter tall by hedging; this is
convenient for the collection of seeds, as farmers can harvest the seeds with little effort. Jatropha
plants are typically harvested between December and January and can produce seeds with high
oil content (30 - 40%). Plants are able to produce seeds between 1 and 5 years depending on soil
fertility and rainfall, and continue to produce seeds for more than 20 years. The Jatropha plant is
hardy, and can grow in harsh conditions on low fertility soils, in low and high rainfall areas.

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Figure below show a picture of developed Jatropha tree, approximately four years old.

Developed Jatropha Curcas Tree3

Figure2-2. Developed Jatropha Seeds4

Jatropha Plantation has been identified as a thrust area for the initiation of projects to capitalize
on its vast potential. Emerging economies with unproductive lands and tropical climates have
looked towards Jatropha cultivation as a way to benefit greatly from the renewable energy

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resources it provides. Jatropha plantation has been focused on Ethiopia and several African
nations so far, and has the potential of growing in any tropical nation.[6]
Jatropha is a multi-purpose commercial crop with its major use in biodiesel production. Apart
from biodiesel production, Jatropha can be used to alleviate soil degradation, desertification
anddeforestation. Also, it can be used for climatic protection and carbon capture, and increasing
the income for agro-industries. Glycerin, a byproduct in the production of biodiesel from
Jatropha seed oil can be used in soap production and other glycerin based products.[6]
The production of the biodiesel from the Jatropha seeds has been broken down into two main
steps:
1. Extraction of seed oil
2. Conversion of the seed oil to biodiesel

2.1 Extraction of Jatropha seed oil

Extraction of oil from Jatropha seeds can be performed using three different methods:
mechanical extraction and solvent extraction.
A) Mechanical extraction
Common method used to extract the Jatropha oil from the seed, since this method is effective for
seed contain 30-40% oil. The mechanical extraction has several advantages compared to the
other methods, such as simple equipment and low investment, low operating cost, and the
oildoes not undergo solvent separation process, etc. Usually the quality and quantity of the oil
obtained by mechanical extraction process are affected by various operating conditions such as
pretreatment of the Jatropha seeds, extraction pressure, and storage condition. Effect of
extraction condition on quality of oil has been investigated in several studies for wide variations
of material, including conophor nut, olive, jojoba, and groundnut, and peanut kernel oil. [7]
The changes of oil quality during storage also have been investigated for numerous materials,
such as soybean, peanut kernel, sunflower, olive, and fish oil. Mechanical extraction of Jatropha
seeds was performed using hydraulic pressing equipment. Untreated seed particles were pressed
with various pressures to determine the optimum pressure. Pressure was started at 2000 psi as the
oil started to flow out of the seedbed, and stopped at 6000 psi since the oil yield relatively
constant at the pressure above 6000 psi. [8]

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Mechanical extraction was performed for 25 minutes when the oil has stopped flowing out. Oil
yield measurement was conducted using mass balance. Mechanical extraction is the most widely
used method to extract oil from Jatropha seed. However, the oil produced with this method
usually has a low price, since it’s turbid and contains a significant amount of water and metals
contents. [8]
B) Solvent Extraction
Solvent Extraction is a process which involves extracting oil from oil-bearing materials by
treating it with a low boiler solvent as opposed to extracting the oils by mechanical pressing
methods (such as expellers, hydraulic presses, etc.) The solvent extraction method recovers
almost all the oils and leaves behind only 0.5% to 0.7% residual oil in the raw material. In the
case of mechanical pressing the residual oil left in the oil cake may be anywhere from 6% to
14%.[7]
The solvent extraction method can be applied directly to any low oil content raw materials. It
can also be used to extract pre-pressed oil cakes obtained from high oil content materials.
Because of the high percentage of recovered oil, solvent extraction has become the most popular
method of extraction of oils and fats. The process solvent extraction is basically a process of
diffusion of a solvent into oil-bearing cells of the raw material resulting in a solution of the oil in
solvent.[8]
The extraction process consists of treating the raw material with hexane and recovering the oil by
distillation. Evaporation and condensation from the distillation recovers the n-hexane absorbed in
the material. The n-hexane thus recovered is reused for extraction. The low boiling point of
hexane (67°C / 152°F) and the high solubility of oils and fats in it are the properties exploited in
the solvent extraction process.[8]

2.2Trans esterification
The Trans esterification process has been chosen as the step to convert the Jatropha seed oil to
biodiesel.The chemicals used in the Trans esterification process a easily attainable and are used
widely in industry. The Trans esterification process is a standard method for converting natural
oils to biodiesel.[9]

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Preliminary analysis shows that this process will be able to successfully convert the seed oil from
Jatropha. In addition to this, others have used this process to convert Jatropha seed oil, and have
successfully yielded a biodiesel product. [9]
Nearly all natural plant oils are composed entirely of mono, di, and tri-glycerides, which through
the Trans esterification pathway can become biodiesel. Biodiesel is a combination of medium to
long chain esters that have very attractive properties as a renewable fuel. They are stable at
ambient temperature, burn cleanly, and usually have very low sulfur compared to petroleum
diesel. [9]
Most industrial applications of Tran’s esterification are carried out using a base catalyzed
reaction with NaOH and methanol. Base catalyzed reactions are preferred because the acid
catalyst mechanism requires high heat and long reaction times. Traditionally the NaOH is first
solvated in the methyl alcohol before being added to the process. There are two main reasons
why the NaOH is added first, one is because it deprotonates the alcohol prior to insertion into the
medium and secondly is because it simplifies the mixing of the base catalyst into the immiscible
source oil. Once the alcohol/catalyst mixture is added to the source oil the reaction proceeds as
follows:[9]

1) First the alcohol is deprotonated with the base:

2) Then the carbonyl is attracted by a slight positive charge on the triglyceride:

3) Next, the unstable tetrahedral intermediate breaks up into a di-glycerol and an ester.

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4) Finally, this process is repeated with two more RO groups to yield a glycerol and two
additional esters. The overall reaction is shown below.

Tran’s esterification of a Triglyceride with Methanol

If water is present in the feed stock the reaction may emulsify and not proceed to completion.
The transestrefication reaction requires water content to be ≤ 1% by weight of vegetable oil.
Fortunately the water content of Jatropha oil is said to be ≤ .1% mass water. Although the initial
concentration of the water is not harmful, care must be taken that the methanol recycles are free
of water so that risks are minimized. Free Fatty Acids (FFA) are also a concern for this trans
esterification method as they will consume the base catalyst and form soap. Unfortunately FFA’s
are dependent on both the age and the location of Jatropha plant when it is grown. The trans
esterification process will takes place in the reactor and once the biodiesel has been created, it
will be passed through a series of processes to separate is from the byproducts and leftover
reactants

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2.3Biodiesel

Biodiesel refers to a vegetable oil- or animal fat-based diesel fuel consisting of long-chain
alkyl (methyl, propyl or ethyl) esters. It produced from transestrefication of vegetable oil or
animal fats with alcohol. Biodiesel can be used alone or mixed with petroleum-based diesel as an
alternative efficient fuel (Gerpen, 2005)and can be used in any diesel engine without
modification (Progress and recent trends in biodiesel fuels.,2009).
Biodiesel can be used as pure fuel or blended at any level with petroleum-based diesel for use by
diesel engines. The most common biodiesel blends are B2 (2%biodiesel and 98% petroleum
diesel). B5 (5% biodiesel and95%petroleum diesel, and B20 (20% biodiesel and 80% petroleum
biodiesel) (Balat, 2010).
Biodiesel have attractive characteristics compared to petroleum-based diesel because it is
biodegradable, nontoxic, and renewable and has reduced emission of CO, SO2, particulate
matter, volatile organic compound and unburned hydrocarbons as compared to conventional
diesel (Benjamin, 2008). But biodiesel also have several disadvantages such have high viscosity
of vegetable oils as compared to petroleum- based diesel at 40oC leads to unfavorable pumping
and spray characteristics (sinha, 2008).
As the result, it cause poor fuel atomization incomplete combustion and carbon deposition on the
injector and valve seats which give serious engine fouling (Kumar, 2010). Biodiesel offer safety
benefits over diesel fuel because it is much less combustible, with a flash point greater than 423
K compared to 350 K for petroleum-based diesel fuel (Balat, 2008).

2.3.1 Biodiesel Characteristic

Biodiesel is a light to dark yellow liquid. It is immiscible with water, has a high boiling point
and low vapor pressure. Typical methyl ester has flash point around 150 oC making it non-
flammable. Selected properties of biodiesel compared to biodiesel fuels are shown in table below

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Fuel property Diesel Biodiesel

Fuel standard ASTM D975 ASTM PS 121
Fuel composition C10-C21 HC C12-C22 FAME
Lower heating value (MJ/ 36.6 x 103 32.6 x 103
m3)
Kinematic viscosity at 40 1.3- 4.1 1.9-6.0
0
C (mm2/s)
Specific gravity at 15.5 0C 0.85 0.88
Density at 25 oC 848 880
Water(ppm by wt) 161 0.05% max
Carbon (wt %) 87 77
Hydrogen (wt %) 13 12
Oxygen (wt %) 0 11
Sulfur (wt %) 0.05 max 0.0-0.0024
Boiling point (oC) 188-343 182-338
Flash point (oC) 60-80 100-170
Cloud point (oC) -15 to 5 -3 to 12
Pour point (oC) -35 to -15 -15 to 10
Catani number 40-55 48-65
Stoichiometric air/fuel ratio 15 13.8
(wt/wt)
Table1:2.31 Specification of diesel and biodiesel fuel

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CHAPTER THREE

3METHODOLOGIES
3.1 Raw Material
 . Jatropha seed : as a raw material
 Sodium hydro oxide: - is also strong base but the main important of these chemical is to
neutralize the fatty acid.
 Water: used to dilute the ingredients and act as the reaction media.

3.2processing Methods
The Jatropha seed harvest from the local area.
The operations involved in extraction of Jatropha oil can be divided into two:
 Pre-treatment of the Jatropha seeds
 Solvent extraction of the Jatropha oil

3.2.1Pre-treatment of Jatropha seeds

The pre-treatment involves the preliminary preparations of the seeds in the following:
(a) Shelling: This involves the removal of the shells to obtain the seeds. It was done manually.
(b) Clearing: This involves the removal of foreign matter introduced during the sun drying and
any unshelled seed.
(c) Drying: The moisture content of the seed was reduced using the electric oven. The oven was
operated for 80°C about three hours.
(d) Crushing: used to reduce the sizes of the dry seeds so as to increase the interfacial area
between the solvent and the seeds. This helps to weaken the cell walls to release castor fat for
extraction

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3.2.2 Extraction of Jatropha oil

.Quality of oil depends on the type of extraction. Manufacturing of Jatropha seed oil includes the
Collection of raw materials for
the extraction and selection of extraction method
Some of the methods that are usually used for the extraction of jatropha oil are as follows.
1. Mechanical press
2 Solvent extractions
The common way of extracting the Jatropha seed oil is through a mechanical press, either
manually or electrically powered. This process is not very efficient, with only about 30-40% of
oil being extracted from the seed, and the rest being left in the seed residue. Also, the high heat
generated from pressing can damage the oil and reduce the overall yield. The solvent extraction
process utilizes a solvent to extract the oil out of the seed. There are many chemicals that can be
used as a solvent to extract oil, for example hydrocarbon solvents (hexane), halogenated solvents
(trichloroethylene) and supercritical solvents (supercritical CO2). Hexane has an extraction grade
of 40-98% with a narrow distillation range.. Hexane solvent extraction is the most feasible
extraction process for this project. The hexane solvent extraction method is practiced on a wide
scale and is used in general laboratory chemistry. Hexane is free of nitrogen and sulfur, and
sufficiently stable to be used indefinitely. In addition to this, hexane is the only solvent from this
list that is used in large scale operations.Hexane is also relatively cheap and easily attainable, and
will be used as the extraction method for the design. [9]
Hexane has been chosen as the method of extraction. Care has to be taken to prevent any
emission of hexane from the closed system because it is toxic. The hexane can be recovered and
reused again in the extraction process. Extraction will be done in a batch-wise operation for the
extraction process. The Jatropha seeds will be grinded up to increase the surface area that will
come into contact with the hexane solvent. The ground up Jatropha seeds will then be placed in a
batch reactor and hexane will be added into the reactor. The solvent will be allowed to contact
the seeds for about 20 minutes. Then, the liquid mixture will be removed from the batch reactor
and the solvent will be distilled out of the mixture. The seed cake left in the reactor will contain
some solvent that can be reused. [10]

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To recover the hexane, steam can be introduced to the seed cake, which will evaporate any
remaining solvent out of the cake. The steam and hexane mixture will then be condensed and
collected in a decanter where they will separate, due to their difference in densities. The hexane
can then be collected and recycled in the extraction process again

3.3PROCESS FLOWDIAGRAM

Jatropha seeds

Pre treatment

Oil extraction Cake

Hexane

Jatropha Seed oil

Distillation

Alcohol and Tran’s esterification

Catalyst reactor

Separator Crude glycerol

Biodiesel

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3.3.1Process description
1 Pre-treatment of Jatropha seeds
The pre-treatment involves the preliminary preparations of the seeds in the following:
(a) Shelling:| This involves the removal of the shells to obtain the seeds. It was done manually.
(b) Clearing: This involves the removal of foreign matter introduced during the sun drying and
any unshelled seed.
(c) Drying: The moisture content of the seed was reduced using the electric oven. The oven was
operated for 80°C about three hours.
(d) Crushing: used to reduce the sizes of the dry seeds so as to increase the interfacial area
between the solvent and the seeds. This helps to weaken the cell walls to release castor fat for
extractor
2Extractions.
Solvent Extraction is a process which involves extracting oil from oil-bearing materials by
treating it with a low boiler solvent as opposed to extracting the oils by mechanical pressing
methods (such as expellers, hydraulic presses, etc.).

3 Distillations
Distillation is the method used to separate two liquid based on their different boiling points.
However, to achieve high purification, several distillations are required. This is because all
materials have intermolecular interactions with each other, and two materials will co-distill
during distillation. This means that proportion between two materials, in this case oil and hexane
can be changed, and still, there are two materials in layers, the liquid and the vapor layer (Onuki,
2005).

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3Transestrefication.
The Trans esterification process has been chosen as the step to convert the Jatropha seed oil to
biodiesel.
Tran’s esterification is a chemical reaction used for the conversion of oil to methanol or ethanol
in presence of a catalyst like lye. After the chemical reaction, various components of oil break
down to form new compounds.
The triglycerides are converted in to methyl esters.thes compounds are biodiesel fuels with
different chemical combination.in the chemical reaction alcohol replaces glycerin. Glycerin that
has been separated during the Trans esterification process is released as byproduct of the
chemical reaction. Glycerin will either sink to the bottom of the reaction vessel or came to the
surface depending on its phase. It can be easily separated by centrifuges and this entire process is
known as Tran’s esterification.

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CHAPTER FOUR

4MATERIAL AND ENERGY BALANCE

4.1Material balance
Mass balance across each unit while we are producing biodiesel
Assumption:-produce 1000kg/day.
 The total working days per week are 6=300days/year.
 Density of oil = 920kg/m3
 Density of NaOH =2130Kg/m3
 Density of methanol=791kg/m3
Mass balance on the separator

Mixture.

Separator Glycerol 10%

Biodiesel 1000kg/day

Overall mass balance

M=MB+MG
MG=0.1(1000kg/day)
MG=100kg/day
M=100kg/day+1000kg/day
M=1100kg/day

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Mass balance on reactor

In put materials ratio are 10mlof oil and 1gmof NaOH
Mass of oil = 10ml*10-6m3 *920kg/m3*= 0.0092kg
Mass of NaOH =0.001Kg

NaOH 5%

Methanol
20%
OILMixture
75% 1100kg/day Reactor

Crude1100k
g/day

Mm+ MNaOH+MOIL=M.
M0IL=0.75(1100kg/day)
Moil=822kg/day
Mm=0.25(1100)kg/day=275kg/day

MNaOH=0.05(1100kg/day)
MNaOH=55kg/day
Material balance ondistillation

It is the equipment used for the separation of hexane from oil-hexane mixture. The mixture from
extractor enter in to the distillation with the mixture of 40% hexane and the rest oil, then with
two series distillation column the separation of hexane come to 95%.

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%, D Xh=95%
Distillation XOIL=5%
l
Feed
Xoil=60%
Xh=40%

B 822kg/day
XOIL=100Kg/day
Xh=0%
From hexane component balance
F*XF = B*Xhl +D*Xh
F=B*Xh+D*Xh=822kg/day*0+D*0.95
XF 0.4
F=D*0.95 ……..eq1
0.4
From oil component balance
F*Xoil=B*XOIL+D*0.05
F=822kg/day*1+D*0.05/0.6

F=822kg/day+D*0.05…….eq2
0.6

From equation 1 and 2

D=720kg/day
F=B+D
F=1710kg/day

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Material balance on extractor

Seed 60%

Hexane 40% Extractor

cake 55%
M=2090kg/day

M
1710kg/day
Overall mass balance

Mh+MS=Mo+Mc
MS=0.6(1710kg/day+2090kg/day)
MS=2280kg/day
Mh=0.4(3800kg/day)
Mh=1520kg/da

4. 2 Energy balance
Energy balance on the process

Crude
1100kg/day. Glycerol
Separator 100kg/day

Biodiesel=
1000kg/day.

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Q= MboidieselCP∆T+MGLYCERORCP∆T
=1000kg/day*0.88kJ/kg (323-298) +100kg/day*0.009kJ/kg*(323-298)
=22000KJ/day+22.5kJ/day
=22022.5kJ/day

Energy balance for reactor

Methanol
275kg/day NaOH
55kg/day

OIL 822kg/day Reactor

Crude
1100kg/day

Q=MCPavg∆T
CPoil=0.45kJ/kg k
cp=0.9*0.45+0.1*0.28=0.433kj/kg k
Methanol=0.28kJ/kg k
Q=1100*0.433(323-298)k=11907.5kJ/day

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Energy balance on distillation column

F = 350C
Distilla
40%hexane60 D = 95% hexane
% oil tion
5% oil

Xoil =100%
Xh = 0%

MF=1720kg/day
MD=720kg/day
MB=990kg/day
Energy balance
Basis 250c, 1hr
Heat capacity on top
CP, distillate = 0.95*1.675 + 0.05*0.45 = 1.6138kJ/kg k
Heat capacity on bottom
CP oil =0.45kj/kg k
Balance around the main condenser
Reflux ratio, R = 2.5
L
R= =2.5
D
L = 2.5*D
= 2.5* 720=1800kg
V= L + D
= 1800+720=2520kg

From vapor equilibrium data

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Boiling point of 95% hexane = 670C

Assuming complete condensation
Enthalpy of Vapor = Latent + Sensible heat
HV = MV λ V + MV CP∆T
=2520 *789 +2520 *1.675*(67 - 25)
= 2165562kJ/kg
QB = is determined from a balance over complete system.
Input = Out put
QB + HF = QC + HD + Hoil
QB = QC + HD + Hoil - HF
Heat capacity of feed
HF = mf .Cp. ∆T
=1720 *0.45*(35 - 25)
= 7740kJ/day
Heat capacity of bottom
Hoil = Moil .Cp. ∆T
= 990*0.45*(340-25)k
= 140332.5kJ/day
QB = QC + HD + Hoil - HF
=2165562kJ/kg + 0 +140332– 7740
= 2298154kj/day
QB = re-boiler heat input , QC = condenser cooling
QB is supplied by condensing steam
λV = 2174KJ/kg
Steam required
MS = QB/λV = 2298154KJ/kg/2174kg/day
MS=10571086KJ/day

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Energy balance for Extractor

Seed
2280kg/day

cake
Hexane Extractor 2090kg/day
1520kg/day

Oil
1710kg/day
Q=Moilcp∆T+Mccp∆T
Q=1710kg/day*1.8kJ/kg (323-298)k+2090kg/day*0.003(323-298)k
Q=40500KJ/day+82.5kJ/day
Q=40582.5KJ/day

4.3 Equipment selection and sizing

3.1 Selection
 Reactor
 Pump
 Separator
 Belt conveyer
 Storage tank
 Distillation column

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3.2Sizing
Storage tanks are sized depending on daily requirement: they can store and the assumption that
the plant works 3shiftswith 10% safety factor for the volume.
Oil storage tank= Mass/density
V=1720kg/day/920kg/m3
V=1.87m3/day

V=(1.87+1.87*0.1)
V=2.057m3
Distillation column=822kg/day/920kg/m3+720kg/day/654.8kg/m3
=0.893+1.0995
=1.9925m3+1.9925*0.1
V=2.19175m3

NaOH tank =mass/density

=55kg/day/2130kg/m3
=0.0516m3
=0.0516+0.0516*0.1
=0.05676m3

Methanol tank =275kg/day/791kg/m3

=0.347m3
=0.347+0.347m3*0.1
=0.3817m3
Glycerol storage tank=mass/density
= 110kg/day/1260kg/m3
V=0.0794+0.0794*0.1
V=0.08734m3
Biodiesel storage tank= 1000kg/day/880kg/m3
V=1.1364+1.1364*0.1
V=1.25004m3

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Reactor sizing
Density of oil (ρ’) = 920Kg/m3
Density of methanol= 791kg/m3
Mass of methanol=275kg/day
Mass of oil=822kg/day
Volumetric flow rate of each component enter to the reactor can be found as follows
•Vmethanol=M methanol/ ⍴ = 275kg/day / 791kg/m3
0.0516+0.0516*0.1*30day = 0.2064m3/day
•V oil= Moil/⍴oil = 822Kg/day./920Kg/m3 = 1.0761m3/day.+1.0761*0.1=1.18371m3/day
•Therefore V total= V methanol+ Voil=1.18371m3/day.
•This much size reactor is required to process the given prefer materials.

Separator=mas/density
=1000kg/day/880kg/m3+ 100kg/day/1260kg/m3
=1.136m3+0.079m3
=1.21536m3+1.21536*0.1
V=1.3368m3

4.3.3Design of Selected Equipment

Stirred tank reactor
Stirred tank reactor (agitated) is basic reactor type, it consists a tank fitted with mechanical
agitator and a cooling jacket. Stirred tank reactor is a reactor that divided into two:-
1. Continuous stirred tank reactor is more efficient than a batch stirred tank reactor but the
equipment is slightly more complicated.
2. Batch stirred tank reactor is the simplest type of reactor. It is composed of a reactor and a
mixer such as a stirrer, a turbine wing or a propeller.
This reactor is useful for substrate solutions of high viscosity and for immobilized enzymes with
relatively low activity. The batch system is generally suitable for the production of rather small
amounts of chemicals[12].
Sizing of stirred tank reactor

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Basic data needed to reactor design:

• Vessel function and selection
• Process material and service
• Operating and design temperature and pressure
• Material of construction
• Vessel dimension and orientation
• Type of vessel head to be used
• Opening and connection required
• Specification of heating and cooling jacket
• Type of agitator

Batch reactor
• Batch reactor consists of an agitator and a jacket around it for cooling purposes.
• Reactants are filled in and allowed to react for a certain period of time without them exiting.
• Jacket consists of agitation nozzles for providing higher turbulence and hence better heat
transfer
Among this type of reactor stirred tank reactor has the best performance for maximum
conversion and uniform homogeneity of products so we select it.

Transestrefication reaction

Sizing of a batch reactor, the following rate equations have to be followed to calculate
theReaction time; let A be the triglycerides to biodiesel during transestrefication reaction.

Specification
rA=dNA/dt*v

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A=>product (biodiesel)
-rA=-dCA/dt=KCA
-lnCA/CA0=kt
DXA/dt=K (1-XA)
ln (1-XA) =kt
Calculate the Volume of reactor.
 Conversion= 75%.
 Reaction Time= 1hrs.
 Batch Time (tB)= 2.42hrs
 No. of reactor used = 1
 Working Pressure of Vessel (P) = 180 KPa
 Temperature of transestrefication Reaction = 60oC.
 Density of oil in (ρ’) = 920Kg/m3

 Now; tB = 2hrs.
 Density of Feed (ρ’) = 920 Kg/m3
Reactor volume, Vr = m* tB / ρ
Vr=1000kg*2/920=1.087m3.
Now; we allow 30% of volume of fluid as the free space in the reactor
Hence; with 30% allowance; VT= 0.3 x Vr + Vr
= 0.3 x 1.087 +1.087m3
= 1.4131m3
Mechanical design of stirred tank reactor
Vessel Dimension
Height to diameter ratio for our reactor is 2:1.[13]
H/D = 1:2
VT = 2Π (D2/4)*L
VT = 2 Π x (D2/4) x 2D
VT = Π x (D3)
14.52m3 = Π x (D3)
3.14D3 = 14.52m3 D = 1.6m

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Hence, putting in above equation;

H/D = 1:2
H =2D = 1.6/2 = 0.8m
Now; Height of Dished Bottom = 1 m from.
Therefore; Total Height = 0.8+ 1 = 1.8m
Design pressure
For the calculation of wall thickness we have to calculate the total pressure; which is the sum of
static pressure and operating pressure of the reactor. For vessel under internal pressure the design
pressure is normally taken as the pressure at which the relief device is set. The density of oil 920
kg/m3 [13]
Static Pressure (Ps) = ρ’ x g x H= (920x 9.81 x 1.8)/1000 = 16.245kPa
Total Pressure at base = Ps + P= 16.245+ 180 = 196.245KPa.
Maximum allowable pressure by taken, 30% of allowance = 0.3*Pt +Pt
Pd = (0.3*196.245 +196.245) = 235.5kPa.
Design Temperature
Strength of metal decrease with temperature increase so maximum allowable design stress will
depend on the material temperature. Therefore; by taking 30% of safety factor.[13]
Material of construction
Selection of a suitable material must take in to account the suitability of the material for
fabrication (particularly welding) as well as the compatibility of the material with the process
environment. In our case we select Carbon Steel b/c of minimum amount of financial investment.
[13 ]
T Design = Operating +Allowance.
= 0.3 *60+60 = 72 oc
Corrosion allowance
Additional thickness of metal added to allow for material lost by corrosion or scaling. For carbon
steel, a minimum allowance of 2mm should be used.
Wall thickness= CA+ Pi*Di/2⍴-P
Working Stress of Carbon Steel, @ T = (0 – 150)oC = 135N/mm2.
Tensile strength = 360 N/mm2
Internal diameter, Di = 1.6m =1600mm

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Corrosion allowance = 2mm.

Therefore wall thickness e =25580Pa*1.6 +0,002m
2*135000000N/m -2555580Pa
e = (437041.8/269744420) +0.002 =0.0016+0.002 = 0.0033m
e = 3.3mm
Therefore outside diameter = Di + 2t = 1.6m + 2*0.0033m.
Do = 2.55 m
Type of vessel head to be used
There are three types of heads:
• Ellipsoidal Head.
• Torispherical Head.
• Hemispherical Head.
Ellipsoidal head is used for pressure greater than 150psi and for less than that pressure we use
tori spherical head. That is why we have selected a Tori spherical head. [13]
Torispherical head
A tori spherical shape which is often used as the end closure of cylindrical vessel is formed from
part of a torus and part of a sphere. Torispherical ends are easier and cheaper to fabricate at low
Pressure (15bar).[13]
e (tH) = Pi*Rc*Cs/[2fJ + Pi(Cs – 0.2)]
Where; Rc = Di =1.71m and Rk = 6%Rc =0.1026m
Where RC =crown radius and Rk =knuckle radius.
J = 1(No joint in the head)
Cs = ¼[3+√ (Rc/Rk)] = ¼[3+√16.667]
Cs= (3+4.08)/4 =1.77
e = Pi*Rc*Cs/[2fJ + Pi(Cs – 0.2)]
e = 255580N/m2*1.71*1.77/[2*135000000N/m2 *1 +255580/m2 (1.77- 0.2)]
e =773563.986/(270000000+401260.6)
e = 0.0028m=28mm
Agitator design
Power requirements for agitation will depend on the degree of agitation required and will range
from about 0.2kw/m3 for moderate mixing to 2kw/m3 for intense mixing.[12]

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Agitator Dimensions from

 Impeller Height above Vessel floor E = Da = 0.57m
 Impeller Diameter Da = Dt/3 = 1.6m/3 = 0.533m
 Length of Impeller Blade L = Da /4 = 0.533/4 = 0.1333m
 Width of Baffle J = Dt/10 =1.6/10 = 0.16 m
 Width of Impeller Blade W = Da /5 = 0.533/5 =0.1066m
 Number of Impellers = 3
 Number of Impeller blades = 6
 Distance between two consecutive impellers = 0.57 m
 Tip Velocity = 3 to 6 m/sec select average value = 4 m/sec
.Tip Velocity = π x Da x N
 Speed of Impeller = N = [4/( π x 0.57)] x 60 = 167.61 RPM

CHAPTER FIVE
5 ECONOMIC FEASIBILITY OF THE PLAN
5.1Estimation of total capital investment cost

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Purchasing equipment cost estimation

Equipment Amount Size Unit cost(birr) Total cost(birr)

Reactor 1 1.18371m3 125270 250540
Pump 6 - 9500 57000
Separator 1 1.3368m3 15000 15000
Conveyer 1 - 12000 12000
Oil Storage tank1 1 2.057m3 10000 20000
Glycerol Storage 1 0.08734m3 5000 9000
tank2
Biodiesel storage 1 1.25m3 9000 15000
tank
Distillation 1 2.19175m3 284,539
NaOH tank 1 0.05675m3 9000 9000
Methanol tank 0.3817m3 12000 12000
Total 653079

Table5.1.1 purchasing equipment cost estimation

Fixed capital investment (FCI) estimation

A Direct cost
 Purchased equipment cost (PEC) =653079Br.
 Instrumentation and control (10% of PE) = 653307.9Br.
 Piping (5%PEC) =3265.95Br.
 Electricity (40% PEC) =261231.6Br.
 Building, process and auxiliary (10% of PEC) =653307.9Br.
 Service facilities (40 %of PEC) =261231.6Br.

Direct cost=1832344.05birr
B Indirect cost
 Eng.’s and supervision (20% of PEC) = 130615.8Br.

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 Construction expense and contractor fee (18%PEC) =117554.22Br.

INDIRECT COST (IC) =248170.02Br.
Fixed Capital Investment (FCI) = DC + IC
=1832344.05Br+248170.02Br.
=2780514.07Br
Working Capital investment (WCI) = 15% of TCI
TCI = FCI + WCI
WCI/0.15-WCI=FCI
5.667 WCI=2780514.07Br.
WCI=490650.09Br

5.2Total production cost (TPC) estimation

Raw material
 Total fresh fruit required: 2280 kg/day = 684000kg/yr.
 Price of fruit = 1.50 Br/kg=1026000Br
 Hexane =1520kg/day=456000kg/yr.=96395.846lt/yr.*30Br=1445938Br
 NaOH=55kg/day=33000kg/yr.=20*33000=660000Br
 Methanol =275kg/day=82500kg/yr.=1237500Br
Total production cost = Manufacturing cost + General expenses

No Work specification No.required Monthly Annually

1 Manager 1 4500.00 54000.00
2 Production head 1 4000.00 48000.00

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3 Quality head 1 3000.00 36000.00

4 Accountant 1 1500.00 18000.00
5 Sale man 1 1000.00 12000.00
6 Purchaser 2 2300.00 55200.00
7 Cleaner 2 600.00 14400.00
8 Operators 3 2000.00 72000.00
9 Guards 3 900.00 32400.00
10 Drivers 2 1500.00 36000.00
11 Store keeper 2 700.00 16800.00
12 Laboratory technician 2 1500.00 36000.00
Total 21 330800.00
Table 5.2.1Man power requirement and annually labor cost

Manufacturing cost
Direct production cost
1. Operating labor (OL)
OL =330800.00Br
2Raw material and inputs=2789938Br
3 Direct supervisor and clerical labor (20% of operating labor) =
330800*0.2
=66160Br

4. Utilities
 Electric =74512.5Kkj/day=22353750kw/yr
1kw=0.46br
22353750kw*0.46=10282725Br.
 Water=1000lt/day=3300000lt/yr.=3300000*0.26=78000Br.
Total utility=10360725Br

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5. Maintenance and repair (6% of FCI)

= 0.06*2080514Br.
=124830.8Br
6. Laboratory Charge (15% of operating labor)
= 0.15*330800Br =49620Br.
Therefore total direct production cost (DPC) will be:
=13391273Br
Indirect production cost
Indirect production cost (IDC) =fixed charge + plant over head cost
A Fixed Charges (FC)
1Depreciation = 13% of PEC
=0.13*653079Br.
=84900.27Br
2 Local taxes = 4% of FCI
= 0.04*2080514Br.
=83220.56Br.
3 Insurance = 0.01% of FCI
= 0.01*2080514Br.
=20805.14Br.
Fixed charge=188925.97Br
B Plant overhead cost (POC) (10% of TPC)
= 0.1*2205333.333Br
=220533.333Br
IDC= fixed charge (A) + plant overhead(B)
=409459.3033Br.
MANUFACTURING COST = DC+ID =13800732.3Br.

General expenses
A Administration cost (4% of TPC)
=0.04*2205333.33 Br
=88213.33Br.

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B. Distribution and selling cost (11% of TPC)

=0.11*2205333.33Br.
=242586.666Br.
CResearch and development cost (5% of TPC)
= 0.05*2205333.333Br.
=110266.6665Br.
D Interest (I) = TCI take 5% of TPC
= 0.05*2205333.33 Br.
=110266.666Br.
GENERAL EXPENSE = 5513332.65Br.
TOTAL PRODUCTION COST= Manufacturing cost + General expense
=13800732.3+551332.65Br.=14352064.95Br

5.3Profitability evaluation
Production capacity =1000kg/day
Annual Gross earning = sales – TPC
Density of biodiesel @ 25 oc = 880 kg/m3
Mass of biodiesel = density of biodiesel *volume of biodiesel
M=⍴ *v
Volumetric flow rate = mass flow rate/density
V=M/D =
V = 340909.09L/yr.
1 lit.biodiesel = 30 birr
340909.099 lit/yr. = X
X= Sales =17045454.5Br/year
Annual Gross earning =sale-TPC=17045454.5Br/yr. -14352064.95Br
=2693389.55Br
Net profit = Annual Gross earning – Annual income tax
Annual Income tax =g 35% of sales
= 0.35*2693389.55Br=942686.342Br
Net Profit =2693389.55Br-942686.3425Br=1750703.208.208Br

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TCI=3271164.162Br

Rate of Return on Investment (ROR)

ROI = (Net profit/total capital investment)*100%
=1750703.208.208 Br/3271164.162Br *100%
ROI = 53.5%
Payback period
Project life is assumed 5 years and we use straight line method
Depreciation=242586.666Br/5=48517.33Br
Payback period= Fixed capital investment/ (annual profit +depreciation)
Payback period =2780514.07Br
1750703.208Br+48517.33Br
= 1.55 year
The project’s initial investment will be fully recovered within 1.55 year.

5.4SITE SELECTION
It is obvious that biodiesel is a highly demandable and services in the whole part of Ethiopia .In
dire dawa consequently there is no biodiesel production plant and the demand is high and
Jatropha tree is easily cultivated in this tropical region .Due to that reason we wish to install a
biodiesel production plant.

CHAPTER 6
CONCLUSION

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This study showed that the application for simultaneous solvent extraction and in
transesterification of jatropha oil from seeds has been successfully carried out, and was a
promising alter-native technology for biodiesel processing from jatropha seeds. Most of the
quality of biodiesel produced from such conditions conformed to the Ethiopia Biodiesel
Standard.
The process flexibility would allow oilseeds to be treated and other co-solvents to be used.
Moreover, the process compactness, its flexibility, and the interdependence be-tween the oil
extraction from oilseeds and the transesterification of the extracted oil allow seed treatment
capacities which are greater than those of the conventional method. These greater capacities
could be adapted for treatment oilseed production, especially concerning specific varieties, to
increase the added value of the oilseeds.
Based on the rough economic analysis of solvent extraction method, the project is profitable
since the rate of return on investment was 53.5%, this show us the project returns its 53.5% of
the initial investment in 1.55 year and the payback period is around 1.55 year.

DE4

RECOMMENDATION

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To manufacture highly qualified and demandable biodiesel in the whole part of the world as well
as in our country Ethiopia with a minimum amount of initial financial investment is in the hand
of the person who is interested with. The selection of raw material is the first criterion, i.e.
Jatropha seed is as a source of oil. Extraction technology and removal of the toxic chemicals is
an excellent ways to meet these objectives.
In the first phase of the project, one should first design appropriately the production plant i.e.
which type of reactor is best for maximum conversion and which type of equipment is used for
the refining stage for biodiesel. In our case we are highly recommended that using stirred thank
reactor is best for maximum conversion of triglyceride in to biodiesel.

REFERENCE

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 Biodiesel production from Jatropha seed 2008

1. Gubiz GM, Mittelbach M, Tribe M. Exploitation of the tropical oil seed plant Jatropha
curcas L.Bioresour Technol 1999.
2. Open Shaw K. A review of Jatropha curcas: an oil plant of unfulfilled promise. Biomass
Bioenergy 2000
3. Kumar A, Sharma S. An evaluation of multipurpose oil seed crop for industrial uses
(Jatropha curcas L.): a review. Ind Crops Prod 2008.
4. http://worldisgreen.files.wordpress.com/2008/03/toil-jatropha-may2007.jpg
5. Lele Satish. Biodiesel and Jatropha Cultivation. India: Agrobios, 2006.
6. http://www.thewoodexplorer.com/maindata/Picts/Jatropha1.jpg
7. Adriaans. Suitability of solvent extraction for jatropha curcas. FACT Foundation, 2006.
20 Nov. <http://www.fact-fuels.org/media_en/FACT_(2006>
8. Thijis, Adriaans. Jatropha Handbook, Chapter 4 & 5. FACT Foundation, 2006. <
http://www.blt.bmlfuw.gv.at/vero/veroeff/0964_LIB_Forschungsbericht47.pdf>
9. http://worldisgreen.files.wordpress.com/2008/03/toil-jatropha-may2007.jpg><http://
www.thewoodexplorer.com/maindata/Picts/Jatropha1.jpg>
10. Asante FA, The chemistry of three indigenous seeds and their extraction, nutritional and
Industrial potentials of their Oils, MPhil Thesis, Department of Biochemistry, KNUST,
Kumasi,
11. Octave levnspiel; Chemical reaction engineering, third edition ,department of chemical
engineering, Oregon state university, John-Wiley and sons Neyork chic ester weinhein
Brisbane
12. sigaphore Toronto p; 13-26.
13. Coulson and Richardson’s Chemical; Butterworth Henimenemann,Rk SINNOTT ,
Elsevier
14. , Engineering Design, volume six, fourth edition, p; 811 -900.
15. Royce NBrown; Gulf professional publishing an inprint Butter worth Heinemann;
secondedition; compressor selection and sizing, 188-230.
16. Max S. Peters, Klaus D.Timmerhause, professor of chemical engineering University of
Colorado, Mc graw hill, inc.Plant Design and Economics for Chemical Engineers,
Fourthedition,p;150-211.

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17. Robert H.Perry(consultant)Chemical Engineering Hand book; Fifth Edition; prepared by

Astaff of specialists under the additional direction of Cecil Chilton(Senior advisor
Battelle
18. Memorial Institute, Mc Graw Hill Book Company.

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