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.
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.
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.
EQUIPMENT DETAILS Sr No. Item MOC Capacity Qty 1 Drying - I 1.1 Circulation pump ejector CI 35 m 3 /hr @ 35m 2 1.2 Circulation pump for FFE SS 316 60 m 3 /hr @ 10m 2 1.3 Transfer pump for organic SS 316 20 m 3 /hr @ 30m 2 1.4 Ejector SS 316L - 2 1.5 Column with pckg support & packing SS 316L 900 Ø x 2.0m 1 1.6 Falling Film evaporator SS 316L 50 m 2 1 1.7 Secondary condenser SS 316L 16 m 2 1 1.8 Primary condenser SS 316L 60 m 2 1 1.9 Ejector tank MS 500 L 2 1.10 Barometric seal pot GLASS 100 L 1 1.11 Gravity separator SS 316L 0.45m 3 1 1.12 Distillation still SS-316L 5.0m3 1 1.13 Constant level feed tank SS-316 0.45m3 1 1.14 Day tank SS-316L 400m3 2 1.19 Field instruments Lot 2 Esterification 2.1 Reflux divertor 1 2.2 Reflux divertor 1 2.3 Reflux divertor 1 2.4 Static mixer SS-316L 250NB 1 2.5 Static mixer SS-316L 250NB 1 2.6 Static mixer SS-316L 250NB 1 2.7 Aq phase feed pump to soap splitting SS-316 5m3/hr @ 30m 2 2.8 Transfer pump for organic SS-316 20m3/hr @ 30m 2 2.9 Transfer pump for aqueous SS-316 5m3/hr @ 30m 2 2.10 Recirculation pump SS-316 550m3/hr @ 20m 2 2.11 Recirculation pump SS-316 550m3/hr @ 20m 2 2.12 Recirculation pump SS-316 550m3/hr @ 20m 2 2.13 Heat exchanger SS-316L 40m2 1 2.14 Heat exchanger SS-316L 40m2 1 2.15 Heat exchanger SS-316L 40m2 1 2.16 Heat exchanger SS-316L 40m2 1 2.17 Vent condenser SS-316L 6m2 1 2.18 Vent condenser SS-316L 6m2 1 2.19 Primary condenser SS-316L 16m2 1 2.20 Primary condenser SS-316L 16m2 1 2.21 Primary condenser SS-316L 16m2 1 2.22 Secondary condenser SS-316L 6m2 1 2.23 Separator-B SS-316L 3.8m3 1 2.24 Separator-A SS-316L 11m3 1 2.25 Separator-B SS-316L 3.8m3 1 2.26 Separator-A SS-316L 11m3 1 2.27 Separator-B SS-316L 3.8m3 1 2.28 Separator-A SS-316L 11m3 1 2.29 Syphon breaking valve with level adjustment GLASS 50NB 6 2.30 Esterification reactor SS-316L 11m3 1 2.31 Esterification reactor SS-316L 11m3 1
2.32 Esterification reactor SS-316L 11m3 1 2.33 Aq phase splitting tank SS-316L 0.45m3 1 2.34 Holding tank for aqueous PP 15m3 1 2.35 Constant level feed tank for Methanol MS 0.45m3 1 2.36 Constant level feed tank for H 2 SO 4 MS 0.45m3 1 2.37 Holding tank for organics PP 15m3 1 2.38 Nitrogen pot set GLASS 25L 3 2.39 Field instruments Lot 3 Saponification 3.1 Transfer pump for organics SS-316 20m3/hr @ 50m 2 3.2 Metering pump for organics SS-316 20m3/hr @ 50m 2 3.3 Rotopump(screw) SS-316 2 3.4 Transfer pump for aqueous SS-316 5m3/hr @ 30m 2 3.5 Transfer pump for aqueous SS-316 5m3/hr @ 30m 2 3.6 Fine filters SS-316L 3 3.7 Vent condenser SS-316L 6m2 1 3.8 Separator-A MS 11m3 1 3.9 Separator-A SS-316L 11m3 1 3.10 Syphon breaking valve with level adjustment GLASS 50NB 2 3.11 Washing reactor SS-316L 1.5m3 1 3.12 Saponification reactor SS-316L 1.5m3 1 3.13 Holding tank for filtered organics MS 15m3 1 3.14 Holding tank for organics MS 5m3 1 3.15 Holding tank for aqueous MS 5m3 1 3.16 CLFT-Water MS 0.45m3 1 3.17 CLFT-KOH (aq phase from transesterification) MS 0.45m3 1 3.18 CLFT-Water MS 0.45m3 1 3.19 CLFT-Organics SS-316L 0.45m3 1 3.20 Nitrogen pot set GLASS 25L 1 3.21 Field instruments Lot 4 Soap splitting 4.1 CLFT - Aq phase of saponification MS 0.45m3 1 4.2 CLFT-Aq phase from esterification SS-316L 0.45m3 1 4.3 Soap splitting reactor SS-316L 1.5m3 1 4.4 Vent condenser SS-316L 6m2 1 4.5 Separator-B SS-316L 3.8m3 1 4.6 Syphon breaking valve with level adjustment GLASS 50NB 1 4.7 Holding tank for recovered FFA SS-316L 0.45m3 1 4.8 Metering pump for recovered FFA SS-316 1000 LPH 2 4.9 CLFT-methanol for salting MS 0.45m3 1 4.10 K2SO4 salting reactor SS-316L 1.5m3 1 4.11 Agitated neutsche filter cum dryer SS-304 5m2 2 4.12 Silo with rotary valve for K2SO4 SS-304 5.0m3 1 4.13 Methanol batch tank for washing MS 3m3 1 4.14 Primary condenser for ANF MS 16m2 1 4.15 Secondary condenser for ANF MS 6m2 1 4.16 Filtrate receiver cum feed tank to methanol recovery (transesterification) MS 5m3 1 4.17 Methanol receiver cum feed tank to salting reactor MS 5m3 1 4.18 Vent condenser for filtrate & methanol receivers MS 16m2 1 4.19 Feed pump for filtrate to metahnol recovery column SS-316 5m3/hr @ 30m 2 4.20 Feed pump for methanol to salting reactor SS-316 2m3/hr @ 20m 2 5 Drying - II 5.1 Circulation pump ejector CI 35 m 3 /hr @ 35m 2
5.2 Circulation pump for FFE CI/BRONZE 60 m 3 /hr @ 10m 2 5.3 Transfer pump for organic CI 20 m 3 /hr @ 30m 2 5.4 Ejector SS 316L - 2 5.5 Column with pckg support & packing MS 900 Ø x 2.0m 1 5.6 Falling film evaporator MS 50 m 2 1 5.7 Secondary condenser MS 16 m 2 1 5.8 Primary condenser MS 70 m 2 1 5.9 Ejector tank MS 500 L 2 5.10 Barometric seal pot GLASS 100 L 1 5.11 Gravity separator MS 0.45m 3 1 5.12 Distillation still MS 5.0m3 1 5.13 Constant level feed tank MS 0.45m3 1 5.14 Field instruments Lot 6 Transesterification 6.1 Tansfer pump for aqueous CI/BRONZE 5m3/hr @ 30m 1 6.2 Tansfer pump for organics CI/BRONZE 20m3/hr @ 30m 2 6.3 Tansfer pump for aqueous CI/BRONZE 5m3/hr @ 30m 2 6.4 Circulation pump CI/BRONZE 50m3/hr @80m 2 6.5 Recycle pump for aqueous CI/BRONZE 20m3/hr @ 30m 2 6.6 Circulation pump CI/BRONZE 50m3/hr @80m 2 6.7 Static mixer SS-316L 80NB P=5bar 1 6.8 Static mixer SS-316L 80NB P=5bar 1 6.9 Holding tank for aqueous MS 5m3 1 6.10 CLFT-Water MS 0.45m3 1 6.11 Holding tank for aqueous MS 15m3 1 6.12 CLFT-H 2 SO 4 MS 0.45m3 1 6.13 CLFT-Organics MS 0.45m3 1 6.14 Holding tank for organics MS 15m3 1 6.15 Holding tank for aqueous MS 5m3 1 6.16 CLFT-Water MS 0.45m3 1 6.17 CLFT-KOH + MeOH MS 0.45m3 1 6.18 Holding tank for aqueous MS 3m3 1 6.19 Heat exchanger MS 16m2 1 6.20 Heat exchanger MS 16m2 1 6.21 Heat exchanger MS 16m2 1 6.22 Vent condenser MS 6m2 1 6.23 Primary condenser horizontal MS 16m2 1 6.24 Vent condenser vertical MS 6m2 1 6.25 Secondary condenser horizontal MS 6m2 1 6.26 Primary condenser horizontal MS 16m2 1 6.27 Separator-B MS 3.8m3 1 6.28 Separator-A MS 11m3 1 6.29 Separator-A MS 11m3 1 6.30 Separator-A MS 11m3 1 6.31 Separator-B MS 3.8m3 1 6.32 Separator-A MS 11m3 1 6.33 Washing reactor MS 1.5m3 1 6.34 Washing reactor MS 1.5m3 1 6.35 Washing reactor MS 1.5m3 1 6.36 Transesterification reactor MS 1.5m3 1 6.37 Transesterification reactor MS 1.5m3 1 7 Drying-III 7.1 Circulation pump ejector CI 35 m 3 /hr @ 35m 2
7.2 Circulation pump for FFE CI/BRONZE 60 m 3 /hr @ 10m 2 7.3 Transfer pump for organic CI 20 m 3 /hr @ 30m 2 7.4 Ejector SS 316L - 2 7.5 Column with pckg support & packing MS 900 Ø x 2.0m 1 7.6 Falling film evaporator MS 50 m 2 1 7.7 Secondary condenser MS 16 m 2 1 7.8 Primary condenser MS 60 m 2 1 7.9 Ejector tank MS 500 L 2 7.10 Barometric seal pot GLASS 100 L 1 7.11 Gravity separator MS 0.45m 3 1 7.12 Distillation still MS 5.0m3 1 7.13 Constant level feed tank MS 0.45m3 1 7.14 Field instruments Lot 8 KOH + MeOH Solution 8.1 Transfer pump CI/BRONZE 5m3/hr @ 30m 1 8.2 Transfer pump CI/BRONZE 5m3/hr @ 30m 1 8.3 Reflux divertor MS 1 8.4 Holding tank for KOH-MeOH MS 10m3 1 8.5 MeOH day tank MS 60m3 1 8.6 Batch tank for MeOH MS 5m3 1 8.7 Vent condenser MS 6m2 1 8.8 Vent condenser MS 6m2 1 8.9 Secondary condenser MS 6m2 1 8.10 Primary condenser MS 16m2 1 8.11 Reactor MS 5m3 1 9 Utilities 9.1 Chilled water plant with all accessories - 200TR @ 6ºc 1 9.2 Brine plant with all accessoroes - 25TR @ -5ºc 1 9.3 Cooling tower with basin - 1000m3/hr 1 9.4 Cooling tower pump CI 500m3/hr @ 40m 3 9.5 Cooling tower FRP 15m3/hr 1 9.6 Cooling tower pump CI 15m3/hr @ 15m 2 9.7 Air compressor with dryer & receiver - 250m3/hr @ 6.5Kg 1 9.8 PSA Nitrogen plant with receiver & PRS - 25Nm3/hr 1 9.9 Transformer & outdoor station - 3.5 MW 1 9.10 PCC & MCC panel - - Lot 9.11 Electrical fittings & cables - - Lot
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