Biodiesel Plant 30 Million Gal/Year

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1 Biodiesel Plant 30 Million Gal/Year Plant Capacity: 30 million gal/year (30,000,000 gal/year). The plant is large in size because it is built on gravity transfer basis, which saves energy resulting in a low cost of production. Start Up: 2008 Shut Down: 2010 Consumption Figures: 8,300MT Input of R/M & 9,000MT output of Biodiesel Highlights: Biodiesel Plant 100MT of Brown Grease gives 108MT of Bio diesel Includes Esterification, Transesterification and Distillation Sections to ensure feedstock use ranging from 0 100% FFA, vegetable oil range 0 5% and brown grease ranging from 40 80%. Any other feedstock with this range is also acceptable.

2 Process Description: I. Drying of Oil Oil has to be dried before the process of Esterification at 100 C for 1 hour to remove the moisture. Presence of moisture may interrupt the reaction by causing backward reaction or emulsion. II. Esterifications: There are (3) different reactions carried out to convert the Free Fatty Acid (FFA) into methyl ester by using methanol and sulphuric acid. The temperature of the reaction maintained throughout the process is 68 C- 70 C for 45 minutes. After the reaction, whole material is allowed for settling of 45 minutes in the separation funnel. Drain off the acid water before preceding to the next esterification. The 30% methanol was added based on mass of oil. * Add 8% of Con. H2SO4 by mass of FFA if the FFA value is above 70% or 7.3% of Con. H2SO4 by weight of oil if FFA value is below 70% Esterification I: Requirements: a) Methanol b) Sulphuric Acid OIL + METHANOL + SULPHURIC ACID METHYL ESTER + WATER During the process of esterification, the FFA is converted into methyl esters that are our biodiesel in the presence of methanol and acid. During this reaction, water is formed as a by-product. The water must be removed immediately form the oil once the reaction is completed. Presence of acidic water (water + acid) in the oil causes backward reaction (the biodiesel is again converted into FFA). Separation: After the reaction, whole material is allowed for settling of 45 minutes in the separation funnel. Drain off the bottom layer of water, methanol and acid, then the oil is take for second esterfication. Esterification II: Requirements: a) Methanol b) Sulphuric Acid OIL + METHANOL + SULPHURIC ACID METHYL ESTER + WATER During the process of esterification, the FFA is converted into methyl esters that are our biodiesel in the presence of methanol and acid. During this reaction, water is formed as a by-product. The water must be removed immediately form the oil once the reaction is completed. Presence of acidic water (water + acid) in the oil causes backward reaction (the biodiesel is again converted into FFA). Separation: After the reaction, whole material is allowed for settling of 45 minutes in the separation funnel. Drain off the bottom layer of water, methanol and acid, then the oil is taken for third esterfication.

3 Esterification III: Requirements: a) Methanol b) Sulphuric Acid OIL + METHANOL + SULPHURIC ACID METHYL ESTER + WATER During the process of esterification, the FFA is converted into methyl esters that are our biodiesel in the presence of methanol and acid. During this reaction, water is formed as a by-product. The water must be removed immediately form the oil once the reaction is completed. Presence of acidic water (water + acid) in the oil causes backward reaction (the biodiesel is again converted into FFA). Separation: After the reaction, whole material is allowed for settling of 45 minutes in the separation funnel. Drain off the bottom layer of water, methanol and acid. III. Saponification: Requirements: a) Caustic (sodium hydroxide, potassium hydroxide) b) Methanol METHYL ESTER + FFA SOAP + METHYL ESTER It is a process which can be used to remove soap. During this process the temperature of the reaction maintained is 65 C-70 C for 15 minutes. After the third esterification, the minimum FFA is to be reduced further here. The Alkali used for the reaction based on the FFA IV. Washing: After saponification, the whole materials are transferred to the separation funnel and is given the water wash up to neutralize. Before trans-esterification, the oil was dried to remove the moisture completely at 110 C for 30 minutes. V. Trans-Esterification Requirements: a) Caustic (sodium hydroxide, potassium hydroxide) b) Methanol Trans-esterification is a process which onverts the triglycerides into free glycerol. The methyl ester does not affect during the process. The temperature of the reaction maintained 65 C-70 C for 90 minutes. The alkali used for the reaction is 0.1% and 30% methanol based on mass of oil. VI. Washing: After trans-esterification, the whole material is transferred to the separation funnel and given a water wash up to neutralize. Before distillation the oil was dried to remove the moisture completely at 110 C for 60 minutes. VII. Distillation: Finally the oil was distilled out at 180 C-240 C less than 760mrn Hg. From this process, crude biodiesel converted to biodiesel and unsap was removed.

4 EQUIPMENT DETAILS Sr No. Item MOC Capacity Qty 1 Drying - I 1.1 Circulation pump ejector CI 35 m 3 35m Circulation pump for FFE SS m 3 10m Transfer pump for organic SS m 3 30m Ejector SS 316L Column with pckg support & packing SS 316L 900 Ø x 2.0m Falling Film evaporator SS 316L 50 m Secondary condenser SS 316L 16 m Primary condenser SS 316L 60 m Ejector tank MS 500 L Barometric seal pot GLASS 100 L Gravity separator SS 316L 0.45m Distillation still SS-316L 5.0m Constant level feed tank SS m Day tank SS-316L 400m Field instruments Lot 2 Esterification 2.1 Reflux divertor Reflux divertor Reflux divertor Static mixer SS-316L 250NB Static mixer SS-316L 250NB Static mixer SS-316L 250NB Aq phase feed pump to soap splitting SS m Transfer pump for organic SS m Transfer pump for aqueous SS m Recirculation pump SS m Recirculation pump SS m Recirculation pump SS m Heat exchanger SS-316L 40m Heat exchanger SS-316L 40m Heat exchanger SS-316L 40m Heat exchanger SS-316L 40m Vent condenser SS-316L 6m Vent condenser SS-316L 6m Primary condenser SS-316L 16m Primary condenser SS-316L 16m Primary condenser SS-316L 16m Secondary condenser SS-316L 6m Separator-B SS-316L 3.8m Separator-A SS-316L 11m Separator-B SS-316L 3.8m Separator-A SS-316L 11m Separator-B SS-316L 3.8m Separator-A SS-316L 11m Syphon breaking valve with level adjustment GLASS 50NB Esterification reactor SS-316L 11m Esterification reactor SS-316L 11m3 1

5 2.32 Esterification reactor SS-316L 11m Aq phase splitting tank SS-316L 0.45m Holding tank for aqueous PP 15m Constant level feed tank for Methanol MS 0.45m Constant level feed tank for H 2 SO 4 MS 0.45m Holding tank for organics PP 15m Nitrogen pot set GLASS 25L Field instruments Lot 3 Saponification 3.1 Transfer pump for organics SS m Metering pump for organics SS m Rotopump(screw) SS Transfer pump for aqueous SS m Transfer pump for aqueous SS m Fine filters SS-316L Vent condenser SS-316L 6m Separator-A MS 11m Separator-A SS-316L 11m Syphon breaking valve with level adjustment GLASS 50NB Washing reactor SS-316L 1.5m Saponification reactor SS-316L 1.5m Holding tank for filtered organics MS 15m Holding tank for organics MS 5m Holding tank for aqueous MS 5m CLFT-Water MS 0.45m CLFT-KOH (aq phase from transesterification) MS 0.45m CLFT-Water MS 0.45m CLFT-Organics SS-316L 0.45m Nitrogen pot set GLASS 25L Field instruments Lot 4 Soap splitting 4.1 CLFT - Aq phase of saponification MS 0.45m CLFT-Aq phase from esterification SS-316L 0.45m Soap splitting reactor SS-316L 1.5m Vent condenser SS-316L 6m Separator-B SS-316L 3.8m Syphon breaking valve with level adjustment GLASS 50NB Holding tank for recovered FFA SS-316L 0.45m Metering pump for recovered FFA SS LPH CLFT-methanol for salting MS 0.45m K2SO4 salting reactor SS-316L 1.5m Agitated neutsche filter cum dryer SS-304 5m Silo with rotary valve for K2SO4 SS m Methanol batch tank for washing MS 3m Primary condenser for ANF MS 16m Secondary condenser for ANF MS 6m Filtrate receiver cum feed tank to methanol recovery (transesterification) MS 5m Methanol receiver cum feed tank to salting reactor MS 5m Vent condenser for filtrate & methanol receivers MS 16m Feed pump for filtrate to metahnol recovery column SS m Feed pump for methanol to salting reactor SS m 2 5 Drying - II 5.1 Circulation pump ejector CI 35 m 3 35m 2

6 5.2 Circulation pump for FFE CI/BRONZE 60 m 3 10m Transfer pump for organic CI 20 m 3 30m Ejector SS 316L Column with pckg support & packing MS 900 Ø x 2.0m Falling film evaporator MS 50 m Secondary condenser MS 16 m Primary condenser MS 70 m Ejector tank MS 500 L Barometric seal pot GLASS 100 L Gravity separator MS 0.45m Distillation still MS 5.0m Constant level feed tank MS 0.45m Field instruments Lot 6 Transesterification 6.1 Tansfer pump for aqueous CI/BRONZE 30m Tansfer pump for organics CI/BRONZE 30m Tansfer pump for aqueous CI/BRONZE 30m Circulation pump CI/BRONZE Recycle pump for aqueous CI/BRONZE 30m Circulation pump CI/BRONZE Static mixer SS-316L 80NB P=5bar Static mixer SS-316L 80NB P=5bar Holding tank for aqueous MS 5m CLFT-Water MS 0.45m Holding tank for aqueous MS 15m CLFT-H 2 SO 4 MS 0.45m CLFT-Organics MS 0.45m Holding tank for organics MS 15m Holding tank for aqueous MS 5m CLFT-Water MS 0.45m CLFT-KOH + MeOH MS 0.45m Holding tank for aqueous MS 3m Heat exchanger MS 16m Heat exchanger MS 16m Heat exchanger MS 16m Vent condenser MS 6m Primary condenser horizontal MS 16m Vent condenser vertical MS 6m Secondary condenser horizontal MS 6m Primary condenser horizontal MS 16m Separator-B MS 3.8m Separator-A MS 11m Separator-A MS 11m Separator-A MS 11m Separator-B MS 3.8m Separator-A MS 11m Washing reactor MS 1.5m Washing reactor MS 1.5m Washing reactor MS 1.5m Transesterification reactor MS 1.5m Transesterification reactor MS 1.5m3 1 7 Drying-III 7.1 Circulation pump ejector CI 35 m 3 35m 2

7 7.2 Circulation pump for FFE CI/BRONZE 60 m 3 10m Transfer pump for organic CI 20 m 3 30m Ejector SS 316L Column with pckg support & packing MS 900 Ø x 2.0m Falling film evaporator MS 50 m Secondary condenser MS 16 m Primary condenser MS 60 m Ejector tank MS 500 L Barometric seal pot GLASS 100 L Gravity separator MS 0.45m Distillation still MS 5.0m Constant level feed tank MS 0.45m Field instruments Lot 8 KOH + MeOH Solution 8.1 Transfer pump CI/BRONZE 30m Transfer pump CI/BRONZE 30m Reflux divertor MS Holding tank for KOH-MeOH MS 10m MeOH day tank MS 60m Batch tank for MeOH MS 5m Vent condenser MS 6m Vent condenser MS 6m Secondary condenser MS 6m Primary condenser MS 16m Reactor MS 5m3 1 9 Utilities 9.1 Chilled water plant with all accessories - 6ºc Brine plant with all accessoroes - -5ºc Cooling tower with basin m3/hr Cooling tower pump CI 40m Cooling tower FRP 15m3/hr Cooling tower pump CI 15m Air compressor with dryer & receiver - 6.5Kg PSA Nitrogen plant with receiver & PRS - 25Nm3/hr Transformer & outdoor station MW PCC & MCC panel - - Lot 9.11 Electrical fittings & cables - - Lot

8 BIO-DIESEL PROCESS FLOW DIAGRAM FEED H 2 SO 4 DRYING ESTERIFICATION RECYCLE CH 3 OH ALKALI SAPONIFICATION SOAP SPLITTING DRYING DISTILLATION MeOH STORAGE TRANSESTERIFICATION MeOH + KOH DRYING DISTILLATION ETP HIGH VACUUM BIO-DIESEL DISTILLATION BIO- DIESEL STORAGE ETP TO COAL YARD

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